John Deere Sabre Yard & Graden Tractors Technical Manual TM1769 – PDF Download by www.heydownloads.com

SABRE LAWN TRACTORS

TECHNICAL MANUAL

John Deere Worldwide Commercial and Consumer Equipment Division TM1769 (03Mar00) Replaces TM1769 (25May99) Litho in U.S.A

M89683

Models: 1438GS, 1438HS, 1438G, 1538HS, 1542HS, 1542G, 1542H, 15.538G, 15.538H, 15.542G, 15.542H, 1642G, 1642H, 1642HS, 1642HV, 1646H, 1646HS, 1646HV, 1742GS, 1742HS, 1846HV, 1846HMS, 2046HV

INTRODUCTION This technical manual is written for an experienced technician and contains sections that are specifically for this product. It is a part of a total product support program.

Safety Specifications and Information

The manual is organized so that all the information on a particular system is kept together. The order of grouping is as follows:

Engine – Single Cylinder

• • • • • • • • •

Engine – V-Twin

Table of Contents Specifications Component Location System Schematic Theory of Operation Troubleshooting Chart Diagnostics Tests & Adjustments Repair

Note:

Depending on the particular section or system being covered, not all of the above groups may be used.

Engine – Intek™ V-Twin Electrical Electrical with RIO System Gear Power Train

Each section will be identified with a symbol rather than a number. The groups and pages within a section will be consecutively numbered.

Hydrostatic Power Train K51 Hydrostatic Power Train K55

We appreciate your input on this manual. If you find any errors, or want to comment on the layout of the manual, please mail your comments back to us.

All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.

Steering Attachments

Miscellaneous

2/29/00

1-1

SAFETY

HANDLE FLUIDS SAFELY-AVOID FIRES

RECOGNIZE SAFETY INFORMATION

Be Prepared For Emergencies

This is the safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe servicing practices.

Understand Signal Words A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards. DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.

REPLACE SAFETY SIGNS

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

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

1-2

2/29/00

SAFETY

USE CARE IN HANDLING AND SERVICING BATTERIES

USE CARE AROUND HIGHPRESSURE FLUID LINES Avoid High-pressure Fluids

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

Prevent Acid Burns • Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. • Avoid acid burns by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling or dripping electrolyte. 5. Use proper jump start procedure.

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

Avoid Heating Near Pressurized Fluid Lines

• If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 10_15 minutes. 4. Get medical attention immediately. • If acid is swallowed: 1. Drink large amounts of water or milk. 2. Then drink milk of magnesia, beaten eggs, or vegetable oil. 3. Get medical attention immediately.

2/29/00

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

1-3

SAFETY

USE SAFE SERVICE PROCEDURES

Park Machine Safely

Wear Protective Clothing

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

Before working on the machine: 1. Lower all equipment to the ground. 2. Stop the engine and remove the key. 3. Disconnect the battery ground strap. 4. Hang a â&#x20AC;&#x153;DO NOT OPERATEâ&#x20AC;? tag in operator station.

Support Machine Properly And Use Proper Lifting Equipment

Service Machines Safely

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

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

1-4

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

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

2/29/00

SAFETY

Using High Pressure Washers

Avoid Harmful Asbestos Dust

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

Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer.

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

Work In Ventilated Area

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

SERVICE TIRES SAFELY

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

WARNING: California Proposition 65 Warning: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Gasoline engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or 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, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. Remove paint before welding or heating: If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

2/29/00

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

1-5

SAFETY

AVOID INJURY FROM ROTATING BLADES, AUGERS AND PTO SHAFTS

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

HANDLE CHEMICAL PRODUCTS SAFELY

LIVE WITH SAFETY

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

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

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

1-6

2/29/00

CONTENTS

SPECIFICATIONS & INFORMATION

CONTENTS Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INCH TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 METRIC TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 GASOLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 GASOLINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ENGINE BREAKâ&#x20AC;&#x201C;IN OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ANTI-CORROSION GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ALTERNATIVE LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SYNTHETIC LUBRICANTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 LUBRICANT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 MIXING OF LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 CHASSIS GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 HYDROSTATIC TRANSMISSION OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 GEAR TRANSMISSION GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 TRACTOR IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ENGINE SERIAL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 GEAR TRANSAXLE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 HYDROSTATIC TRANSMISSION SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . 15

2/29/00

2-1

NOTES

2-2

SPECIFICATIONS & INFORMATION

2/29/00

SPECIFICATIONS & INFORMATION

SPECIFICATIONS

SPECIFICATIONS Engine (Single Cylinder): Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs and Stratton Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vertical Shaft Models: 14 Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287707 15 Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28N700 15.5 Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28N700 16 Horsepower (Cast Iron Sleeve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Q777 Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline, Air Cooled, Single Cylinder, 4-Cycle Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Splash type Crankcase Oil Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.42 L (1.5 qt) Oil: Warm Climate (Above 40°F) . . . . . . . . . . . . . . . . . . . . . . . .SE, SF, SG, SAE 30W Cold Climate (Below 40°F). . . . . . . . . . . . . . . . . . . . . . . .SE, SF, SG, SAE 10W30 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetron® Magneto Ignition Magneto Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.25 - 0.35 mm (0.010 - 0.014 in.) Charging System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Circuit (AC/DC) Charging Capacity. . . . . . . . . . . . . . . 2 - 4 amps, 14 volts DC@3600 rpm (Unregulated) Spark Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M78543 (Champion RC-12 YC) Spark Plug Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.) Starter Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bendix Inertia Drive Fuel Shut-Off Solenoid . . . . . . . . . . . . . . . . Replaceable (Below Carburetor Float Bowl) Engine (V-Twin Vanguard): Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs and Stratton Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vertical Shaft Models: 16 Horsepower (V-Twin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303777 18 Horsepower (V-Twin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350777 Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gasoline, Air Cooled, V-Twin Cylinder, 4-Cycle Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fully Pressurized Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Element, Full Flow, Spin-On Filter Crankcase Oil Capacity: without oil filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.42 L (1.5 qt) with oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.66 L (1.75 qt) Oil: Warm Climate (Above 40°F) . . . . . . . . . . . . . . . . . . . . . . . .SE, SF, SG, SAE 30W Cold Climate (Below 40°F). . . . . . . . . . . . . . . . . . . . . . . .SE, SF, SG, SAE 10W30 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetron® Magneto Ignition Magneto Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.20 - 0.30 mm (0.008 - 0.012 in.) Charging System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Circuit (AC/DC) Charging Capacity. . . . . . . . . . . . . . . 2 - 4 amps, 14 volts DC@3600 rpm (Unregulated) Spark Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M78543 (Champion RC-12 YC) Spark Plug Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.) Starter Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bendix Inertia Drive Fuel Shut-Off Solenoid . . . . . . . . . . . . . . . . Replaceable (Below Carburetor Float Bowl)

3/22/00

2-3

SPECIFICATIONS

SPECIFICATIONS & INFORMATION

Engine (V-Twin Intek™): Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs and Stratton Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vertical Shaft Model: 20 Horsepower (V-Twin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407777 Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gasoline, Air Cooled, V-Twin Cylinder, 4-Cycle Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fully Pressurized Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Element, Full Flow, Spin-On Filter Crankcase Oil Capacity: without oil filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 L (1.9 qt) with oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt) Oil: Warm Climate (Above 40°F) . . . . . . . . . . . . . . . . . . . . . . . .SE, SF, SG, SAE 30W Cold Climate (Below 40°F). . . . . . . . . . . . . . . . . . . . . . . .SE, SF, SG, SAE 10W30 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetron® Magneto Ignition Magneto Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.20 - 0.30 mm (0.008 - 0.012 in.) Charging System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Circuit (AC/DC) Charging Capacity. . . . . . . . . . . . . . . 2 - 4 amps, 14 volts DC@3350 rpm (Unregulated) Spark Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M78543 (Champion RC-12 YC) Spark Plug Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.) Starter Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bendix Inertia Drive Fuel Shut-Off Solenoid . . . . . . . . . . . . . . . . Replaceable (Below Carburetor Float Bowl) Electrical: Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BCI Group, U1 Battery Cranking Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 amps at 0° C (32° F) Battery Cold Cranking Amps. . . . . . . . . . . . . . . . . . . . . . . . . . .190 amps at 0° C (32° F) Battery Specific Gravity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Above 1.225 Points Headlight Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 1156, 12 Volt Fuel/Air System: Carburetor Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs & Stratton Carburetor Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Side Draft Throttle/Choke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unitized Control Linkage Carburetor Fuel Shut-Off Solenoid ( Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . .Electric Fuel Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gravity Flow Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable In-line type Fuel Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unleaded (87 Octane Minimum) Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 L (1.25 gal) Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper Element with Foam Pre-cleaner Muffler . . . . . . . . . . . . . . . . . . . . . . . . . Anti-Backfire Horizontal Discharge Below Frame Brakes Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transaxle Type: Gear Transaxle . . . . . . . . . . . . . Single, External Brake Disc With Dual Friction Pucks Hydrostatic Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single, Internal Brake Disc Traction Drive Belt: Gear New Belt Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2686 ± 8 mm (105.75 ± 0.3 in.) Minimum Effective Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2656 mm (104.57 in.) Maximum Effective Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2736 mm (107.72 in.)

2-4

3/22/00

SPECIFICATIONS & INFORMATION

SPECIFICATIONS

Hydro—K51 Transmission New Belt Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2435 ± 8 mm (95.87 ± 0.3 in.) Minimum Effective Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2427 mm (95.55 in.) Maximum Effective Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2443 mm (96.18 in.) Hydro—K55 Transmission New Belt Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2485 ± 8 mm (97.8 ± 0.3 in.) Minimum Effective Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2477 mm (97.5 in.) Maximum Effective Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2530 mm (99.6 in.) Gear Transaxle Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dana Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spicer H-D 4360 Transaxle Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Five-Speed/Linear Shift Domestic Ground Speeds (at FAST idle—2950 rpm) and Gear Ratios: 1st Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 km/hr (1.5 mph) 2nd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 km/hr (2.0 mph) 3rd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 km/hr (3.1 mph) 4th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 km/hr (4.0 mph) 5th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 km/hr (5.0 mph) Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 km/hr (2.3 mph) Lubrication—Input Shaft Needle Bearings . . . . . . Unirex® N3 Grease Only (M120263) Lubrication—Transaxle . . . . . . . . . . . . . . . . .Shell Darina® D Grease Only (AM119608) Capacity—Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.64 kg (1.406 lbs) Hydro Transaxle K51 Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kanzaki Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tuff Torq® K-51 Transaxle Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic Ground Speeds (at FAST idle—2950 rpm): Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0—8.5 km/hr (0—5.3 mph) Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0—5.3 km/hr (0—3.3 mph) Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10W30 Engine Oil, Class CD Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 L (2.4 qt) Hydro Transaxle K55 Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kanzaki Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tuff Torq® K-55 Transaxle Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic Ground Speeds (at FAST idle—2950 rpm): Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0—8.6 km/hr (0—5.3 mph) Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0—4.2 km/hr (0—2.6 mph) Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10W30 Engine Oil, Class CD Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 L (1.7 qt) Chassis: Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1178.2 mm (46.39 in.) Overall Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1524 mm (60 in.) Overall Width (W/O Mower Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . 908 mm (35.75 in.) Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 980 mm (38.6 in.) Average Overall Weight 38 inch (With Mower Deck, No Fuel) . . . . . 177.35 kg (391 lbs) Average Overall Weight 42 inch (With Mower Deck, No Fuel) . . . . . 185.52 kg (409 lbs)

3/22/00

2-5

SPECIFICATIONS

SPECIFICATIONS & INFORMATION

Average Overall Weight 46 inch (With Mower Deck, No Fuel) . . . . . 191.42 kg (422 lbs) Hitch Capacity— Export: Horizontal Pull Maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 kg (56 lbs) Tongue Weight Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 kg (15 lbs) Domestic: Trailer Load Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136 kg (300 lbs) Trailer Tongue Weight Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.6 kg (50 lbs) Steering: Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual - Pinion/Sector Axle Pivot Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shim Adjustable Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multipurpose Grease Lubrication Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 hrs (Maximum) Toe-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 mm (0.24 in.) - Non-Adjustable Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584 mm (23 in.) Wheels: Size— Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.0 x 4.50 Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.0 x 6.18 Tires: Size— Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 x 6.50—6 NHS (2 ply) Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 x 9.50—8 NHS (2 ply) Pressure— Front (with mower deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 kPa (14 psi) Rear (with mower deck). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 kPa (10 psi) PTO Drive Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-Belt Clutch Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Belt Tensioning Control Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lever on dash Mower Deck Drive Belt 38-Inch Deck— Actual effective length . . . . . . . . . . . . . . . . . . . . . . . . . . 2407 ± 10 mm (94.76 ± 0.4 in.) 42-Inch Deck (Single Cylinder Engine)— Actual effective length . . . . . . . . . . . . . . . . . . . . . . . . . 2930 ± 10 mm (115.03 ± 0.4 in.) 42-Inch Deck (V-Twin Engine)— Actual effective length . . . . . . . . . . . . . . . . . . . . . . . 2921.8 ± 10 mm (154.40 ± 0.4 in.) 46-Inch Deck (Single Cylinder Engine)— Actual effective length . . . . . . . . . . . . . . . . . . . . . . . . . 3665 ± 10 mm (144.29 ± 0.4 in.) 46-Inch Deck (V-Twin Engine)— Actual effective length . . . . . . . . . . . . . . . . . . . . . . . . . 3640 ± 10 mm (143.10 ± 0.4 in.)

2-6

3/22/00

SPECIFICATIONS & INFORMATION

SPECIFICATIONS

Mower Deck: 38-Inch Mower Deck— Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotary—Dual Spindles (Non-Serviceable) Material Type. . . . . . . . . . . . . . . . . . .Stamped 2.5 mm (0.098 in.) Nominal Gauge Steel Cutting Blade. . . . . . . . . . . . . . . . . . . . . . . . . .Two - 76 x 5 x 496 mm (3 x 0.2 x 19.5 in.) Blade Cutting Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 ± 5° Angle Blade Wing Lift/Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ± 3 mm (1.57 ± 0.12 in.) Overall Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 965 mm (38 in.) Overall Width (w/o discharge chute) . . . . . . . . . . . . . . . . . . . . . . . . . 1026 mm (40.4 in.) Drive Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Single V-Belt (With Spring Tension Idler) Spindle Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . None - Sealed Bearings Lift Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual - Operator’s Station Cutting Settings. . . . . . . . . . . . . . . . . . . . . . . . . . .Seven: 25.4 - 101.6 mm (1.0 - 4.0 in.) 42-Inch Mower Deck— Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotary—Dual Spindles (Non-Serviceable) Material Type. . . . . . . . . . . . . . . . . . .Stamped 2.5 mm (0.098 in.) Nominal Gauge Steel Cutting Blade. . . . . . . . . . . . . . . . . . . . . . Two - 57 x 4 x 545 mm (2.25 x 0.16 x 21.4 in.) Blade Cutting Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 ± 5° Angle Blade Wing Lift/Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ± 2 mm (0.87 ± 0.08 in.) Overall Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1066 mm (42 in.) Overall Width (w/o discharge chute) . . . . . . . . . . . . . . . . . . . . . . . . . 1118 mm (44.0 in.) Drive Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Single V-Belt (With Spring Tension Idler) Spindle Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . None—Sealed Bearings Lift Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual - Operator’s Station Cutting Settings. . . . . . . . . . . . . . . . . . . . . . . . . . .Seven: 25.4 - 101.6 mm (1.0 - 4.0 in.) 46-Inch Mower Deck— Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rotary—Triple Spindles (Non-Serviceable) Material Type. . . . . . . . . . . . . . . . . . .Stamped 2.5 mm (0.098 in.) Nominal Gauge Steel Cutting Blade. . . . . . . . . . . . . . . . . . . . . . Three - 50.8 x 5 x 407.4 mm (2 x 0.2 x 16 in.) Blade Cutting Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 ± 5° Angle Blade Wing Lift/Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.3 ± 3 mm (0.8 ± 0.12 in.) Overall Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1168.4 mm (46 in.) Overall Width (W/O Discharge Chute) . . . . . . . . . . . . . . . . . . . . . . . 1308 mm (51.5 in.) Drive Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Single V-Belt (With Spring Tension Idler) Spindle Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . None - Sealed Bearings Lift Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual - Operator’s Station Cutting Settings. . . . . . . . . . . . . . . . . . . . . . . . . . .Seven: 25.4 - 101.6 mm (1.0 - 4.0 in.) Implement Lift Lift System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual with Lift-Assist Spring Lift Lever Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front of Seat between Legs

3/22/00

2-7

INCH TORQUE VALUES

SPECIFICATIONS & INFORMATION

INCH TORQUE VALUES 1 or 2b

SAE Grade and Head Markings

5.1

8.2

No Marks

2 SAE Grade and Nut Markings

Size

5.2

No Marks

Grade 1

Grade 2b

Grade 5, 5.1 or 5.2

Grade 8 or 8.2

Lubricateda Drya

lb-ft

1/4

3.8

2.8

4.7

3.5

4.4

7.5

5.5

9.5

13.5

12.5

5/16

7.7

5.7

9.8

7.2

15.5

11.5

19.5

14.5

18.5

20.5

3/8

13.5

17.5

27.5

32.5

7/16

20.5

32.5

100

1/2

110

120

155

115

9/16

35.5

125

155

115

175

130

220

165

5/8

105

135

100

170

125

215

160

240

175

305

225

3/4

120

150

110

190

140

240

175

300

220

380

280

425

315

540

400

7/8

190

140

240

175

190

140

240

175

490

360

615

455

690

510

870

640

285

210

360

265

285

210

360

265

730

540

920

680

1030 760

1-1/8 400

300

510

375

400

300

510

375

910

670

1150 850

1-1/4 570

420

725

535

570

420

725

535

1280 945

1-3/8 750

550

950

700

750

550

950

700

1700 1250 2140 1580 2700 2000 3400 2500

1-1/2 990

730

1250 930

990

730

1250 930

2250 1650 2850 2100 3600 2650 4550 3350

DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original. Make sure fasteners threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.

1300 960

1450 1075 1850 1350

1630 1200 2050 1500 2600 1920

Tighten toothed or serrated-type lock nuts to the full torque value. a

“Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry” means plain or zinc plated without any lubrication. b Grade 2 applies for hex cap screws (not hex bolts) up to 152 mm (6 in.) long. Grade 1 applies for hex cap screws over 152 mm (6 in.) long, and for all other types of bolts and screws of any length.

Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head.

2-8

3/22/00

METRIC TORQUE VALUES

SPECIFICATIONS & INFORMATION

METRIC TORQUE VALUES 4.8

Size

9.8

10.9

4.8

8.8

9.8

10.9

12.9

4.8

8.8

9.8

10.9

12.9

5 5

12.9 12

Property Class and Nut Markings

12.9

8.8

Property Class and Head Markings

Class 4.8

Class 8.8 or 9.8

Class 10.9

Class 12.9

Lubricateda Drya

lb-ft

4.7

3.5

4.4

6.6

11.5

8.5

9.5

16.5

12.5

15.5

11.5

19.5

14.5

11.5

8.5

14.5

10.7

20.5

23.5

29.5

27.5

M10

M12

29.5

110

140

105

130

165

120

M14

120

150

110

175

130

220

165

205

150

260

190

M16

100

125

190

140

240

175

275

200

350

225

320

235

400

300

M18

135

100

175

125

265

195

330

245

375

275

475

350

440

325

560

410

M20

190

140

245

180

375

275

475

350

530

390

675

500

625

460

790

580

M22

265

195

330

245

510

375

650

480

725

535

920

680

850

625

108

800

M24

330

245

425

315

650

480

820

600

920

680

115

850

108

800

135

100

M27

490

360

625

460

950

700

1200 885

M30

660

490

850

625

1290 950

M33

900

665

1150 850

M36

1150 850

1350 1000 1700 1250 1580 1160 200

1500

1630 1200 1850 1350 2300 1700 2140 1700 2700 2000

1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730

1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500

DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class. Fasteners should be replaced with the same or higher property class. If higher property class fasteners are used, these should only be tightened to the strength of the original.

approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value. a

“Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry” means plain or zinc plated without any lubrication.

Make sure fasteners threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. Tighten plastic insert or crimped steel-type lock nuts to 3/22/00

2-9

METRIC TORQUE VALUES

SPECIFICATIONS & INFORMATION

GASOLINE

c CAUTION Gasoline is HIGHLY FLAMMABLE, handle it with care. DO NOT refuel machine while: • • • • •

indoors, always fill gas tank outdoors; machine is near an open flame or sparks; engine is running, STOP engine; engine is hot, allow it to cool sufficiently first; smoking.

STOP ENGINE

NO HOT ENGINE

NO SMOKING

Help prevent fires: • • • •

fill gas tank to bottom of filler neck only; NO STATIC ELECTRIC NO OPEN FLAME DISCHARGE OR SPARK be sure fill cap is tight after fueling; clean up any gas spills IMMEDIATELY; keep machine clean and in good repair–free of excess grease, oil, debris, and faulty or damaged parts; • any storage of machines with gas left in tank should be in an area that is well ventilated to prevent possible igniting of fumes by an open flame or spark, this includes any appliance with a pilot light. To prevent fire or explosion caused by STATIC ELECTRIC DISCHARGE during fueling: • ONLY use a clean, approved POLYETHYLENE PLASTIC fuel container and funnel WITHOUT any metal screen or filter.

To avoid engine damage: • DO NOT mix oil with gasoline; • ONLY use clean, fresh unleaded gasoline with an octane rating (anti-knock index) of 87 or higher; • fill gas tank at the end of each day's operation to help prevent condensation from forming inside a partially filled tank; • keep up with specified service intervals. Use of alternative oxygenated, gasohol blended, unleaded gasoline is acceptable as long as: • the ethyl or grain alcohol blends DO NOT exceed 10% by volume or • methyl tertiary butyl ether (MTBE) blends DO NOT exceed 15% by volume.

IMPORTANT: DO NOT use METHANOL gasoline because METHANOL is harmful to the environment and to your health.

2 - 10

c 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.

GASOLINE STORAGE IMPORTANT: Keep all dirt, scale, water or other foreign material out of gasoline. Keep gasoline stored in a safe, protected area. Storage of gasoline in a clean, properly marked (“UNLEADED GASOLINE”) POLYETHYLENE PLASTIC container WITHOUT any metal screen or filter is recommended. DO NOT use de-icers to attempt to remove water from gasoline or depend on fuel filters to remove water from gasoline. Use a water separator installed in the storage tank outlet. BE SURE to properly discard unstable or contaminated gasoline. When storing unit 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.

3/22/00

METRIC TORQUE VALUES

SPECIFICATIONS & INFORMATION

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 oil is PREFERRED: • TORQ-GARD SUPREME®—SAE 5W-30. • UNI–GARD™—SAE 5W-30. The following John Deere oils are also recommended, based on their specified temperature range: • TURF–GARD®—SAE 10W-30; • UNI–GARD™—SAE 10W-30; • PLUS–4®—SAE 10W-30; • TORQ–GARD SUPREME®—SAE 30. • UNI–GARD™—SAE 30.

Deere Merchandise Sales Guide; • Lubrication Sales Manual PI7032.

ENGINE BREAK–IN OIL IMPORTANT: 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 (North America); or oils meeting CCMC Specification G5 (Europe). These oils will not allow rebuilt or remanufactured engines to break-in properly. The following John Deere oil is PREFERRED: • BREAK–IN ENGINE OIL.

Other oils may be used if above John Deere oils are not available, provided they meet one of the following specifications: • SAE 5W-30—API Service Classification SG or higher; • SAE 10W-30—API Service Classification SG or higher; • SAE 30—API Service Classification SC or higher. • CCMC Specification G4 or higher.

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 and cast iron types. The following John Deere oil is also recommended as a break-in engine oil:

SAE 10W-30

SAE 5W-30

SAE 30

• TORQ–GARD SUPREME®—SAE 5W-30. If the above recommended John Deere oils are not available, use a break-in engine oil meeting the following specification during the first 5 hours (maximum) of operation: • SAE 5W-30—API Service Classification SE or higher. • SAE 5W-30—CCMC Specification G4 or higher. IMPORTANT: After the break-in period, use the John Deere oil that is recommended for this engine. PREFERRED AIR TEMPERATURE

M58275

John Deere Dealers: You may want to cross-reference the following publications to recommend the proper oil for your customers: • Module DX,ENOIL2 in JDS–G135; • Section 530, Lubricants & Hydraulics, of the John

3/22/00

2 - 11

METRIC TORQUE VALUES

SPECIFICATIONS & INFORMATION

ANTI-CORROSION GREASE This anti-corrosion grease is formulated to provide the best protection against absorbing moisture, which is one of the major causes of corrosion. This grease is also superior in its resistance to separation and migration. • DuBois MPG-2® Multi-Purpose Polymer Grease—M79292. Other greases may be used if they meet or exceed the following specifications:

SAE 5W-30

• John Deere Standard JDM J13A2, NLGI Grade 1.

PREFERRED AIR TEMPERATURE

M58275

JDM J13A2 NLGI Grade 1

BREAK-IN OIL

The following anti-corrosion grease is PREFERRED:

John Deere Dealers: You may want to cross-reference the following publications to recommend the proper oil for your customers: • Module DX,ENOIL4 in JDS–G135; • Section 530, Lubricants & Hydraulics, of the John Deere Merchandise Sales Guide; • Lubrication Sales Manual PI7032.

AIR TEMPERATURE

M58275

John Deere Dealers: You may want to cross-reference the following publications to recommend the proper grease for your customers: • Module DX,GREA1 in JDS–G135; • Section 530, Lubricants & Hydraulics, of the John Deere Merchandise Sales Guide; • Lubrication Sales Manual PI7032.

2 - 12

3/22/00

METRIC TORQUE VALUES

SPECIFICATIONS & INFORMATION

ALTERNATIVE LUBRICANTS

CHASSIS GREASE

Conditions in certain geographical areas outside the United States and Canada may require different lubricant recommendations than the ones printed in this technical manual or the operator's manual. Consult with your John Deere Dealer, or Sales Branch, to obtain the alternative lubricant recommendations.

Use the following grease based on the air temperature range. Operating outside of the recommended grease air temperature range may cause premature failures.

IMPORTANT: Use of alternative lubricants could cause reduced life of the component.

IMPORTANT: ONLY use a quality grease in this application. DO NOT mix any other greases in this application. DO NOT use any BIO–GREASE in this application. The following John Deere grease is PREFERRED:

If alternative lubricants are to be used, it is recommended that the factory fill be thoroughly removed before switching to any alternative lubricant.

SYNTHETIC LUBRICANTS Synthetic lubricants may be used in John Deere equipment if they meet the applicable performance requirements (industry classification and/or military specification) as shown in this manual.

• NON-CLAY HIGH-TEMPERATURE EP GREASE®—JDM J13E4, NLGI Grade 2. • GREASE–GARD™—JDM J13E4, NLGI Grade 2. Other greases may be used if above preferred John Deere grease is not available, provided they meet the following specification: • John Deere Standard JDM J13E4, NLGI Grade 2.

Avoid mixing different brands, grades, or types of oil. Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements. Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance.

JDM J13E4 NLGI Grade 2

The recommended air temperature limits and service or lubricant change intervals should be maintained as shown in the operator’s manual.

LUBRICANT STORAGE 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 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.

3/22/00

AIR TEMPERATURE

M58275

2 - 13

METRIC TORQUE VALUES

SPECIFICATIONS & INFORMATION

HYDROSTATIC TRANSMISSION OIL IMPORTANT: ONLY use a quality SAE 10W-30 SYNTHETIC engine oil in this transmission. Mixing of two viscosity grade oils is NOT RECOMENDED. DO NOT use BIO–HY–GARD® in this transmission. The following John Deere transmission and hydraulic oil is PREFERRED: • 10W-30 SYNTHETIC OIL. The following John Deere oil is also recommended if above preferred oil is not available: • John Deere Low Viscosity HY-GARD™ J20D. Other oils may be used if above recommended John Deere oils are not available. Use only oils that meet one of the following specifications: • John Deere Standard JDM J20D; • John Deere Standard JDM J20C. • CCMC Specifications G4 or higher.

• Module DX,ENOIL2 in JDS–G135; • Section 530, Lubricants & Hydraulics, of the John Deere Merchandise Sales Guide; • Lubrication Sales Manual PI7032. Use only oils that meet the following specifications: • API Service Classifications SG or higher.

GEAR TRANSMISSION GREASE Use the following grease viscosity based on the air temperature range. Operating outside of the recommended oil air temperature range may cause premature gear case failure. IMPORTANT: ONLY use a quality grease in this gear case. DO NOT mix any other oils in this gear case. DO NOT use BIO–HY–GARD® in this gear case. The following PREFERRED:

John

Deere

gear

case

oil

• AN102562 CORN HEAD GREASE.

SAE 5W-30

SAE 10W-30

SAE 80W-90

Use the appropriate oil viscosity based on these air temperature ranges. Operating outside of these recommended oil air temperature ranges may cause premature hydrostatic transmission failure.

AIR TEMPERATURE

M58275

John Deere Dealers: You may want to cross-reference the following publications to recommend the proper oil for your customers:

2 - 14

M58275

John Deere Dealers: You may want to cross-reference the following publications to recommend the proper oil for your customers: • Module DX,GEOIL in JDS–G135; • Section 530, Lubricants & Hydraulics, of the John Deere Merchandise Sales Guide; • Lubrication Sales Manual PI7032.

3/22/00

SERIAL NUMBER LOCATIONS

SPECIFICATIONS & INFORMATION

SERIAL NUMBER LOCATIONS When working on machines or components that are covered by warranty, it is IMPORTANT that you include the tractor identification number and the component serial numbers on the warranty claim form.

GEAR TRANSAXLE SERIAL NUMBER

The location of tractor identification number and component serial numbers are shown below.

TRACTOR IDENTIFICATION NUMBER

M55792a

Gear transaxle serial number sticker (C) is on rear of housing.

HYDROSTATIC TRANSMISSION SERIAL NUMBER

M87550

Tractor identification number plate (A) is located on the rear of frame or under seat.

ENGINE SERIAL NUMBER D M87551

M95201

M95200

Serial number (D) is located on a bar coded label located on the right rear of the transaxle.

M95202

Tractor engine serial number sticker (B) is located on fan shroud.

3/22/00

2 - 15

SERIAL NUMBER LOCATIONS

2 - 16

SPECIFICATIONS & INFORMATION

3/22/00

CONTENTS

ENGINES – SINGLE CYLINDER

CONTENTS Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL SPECIFICATIONS - 14—16 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL SPECIFICATIONS - 17 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TESTS AND ADJUSTMENTS SPECIFICATIONS - 14—16 HP . . . . . . . . . . . . . . . . . 3 TESTS & ADJUSTMENTS SPECIFICATIONS - 17 HP . . . . . . . . . . . . . . . . . . . . . . . 4 REPAIR SPECIFICATIONS - 14—16 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REPAIR SPECIFICATIONS - 17 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TORQUE SPECIFICATIONS (Alphabetical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ENGINE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 THROTTLE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 FUEL SHUTOFF SOLENOID TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 GOVERNOR ADJUSTMENT-STATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 GOVERNOR ADJUSTMENT - RUNNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 GOVERNOR IDLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SLOW IDLE CARBURETOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 IGNITION ARMATURE AIR GAP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 FUEL AND AIR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 UPPER BLOWER HOUSING REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . 16 AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 CARBURETOR REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 CARBURETOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 CARBURETOR INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 CARBURETOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 BREATHER VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 ENGINE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 CYLINDER HEAD REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23 CYLINDER HEAD INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 VALVES REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 VALVES REFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 VALVES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 GOVERNOR REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 OIL PUMP REMOVAL & INSTALLATION - 17 HP ONLY. . . . . . . . . . . . . . . . . . . . . . 28 PISTON REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 CONNECTING ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 CYLINDER BORE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 CYLINDER BORE HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 CYLINDER BORE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 RESIZING CYLINDER BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2/29/00

3-1

CONTENTS CONTINUED

ENGINES â&#x20AC;&#x201C; SINGLE CYLINDER

Page FLYWHEEL REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT AND CAM GEAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT AND CAM GEAR INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . MAGNETO BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAM GEAR BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PTO BEARING REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

36 36 38 39 40 40

2/29/00

ENGINES – SINGLE CYLINDER

SPECIFICATIONS

SPECIFICATIONS GENERAL SPECIFICATIONS - 14—16 HP Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs & Stratton Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diamond Plus Model 14 HP (10.44 kW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287707 15 HP (11.19 kW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28N707 15.5 HP (11.56 kW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28N707 16 HP (11.93 kW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Q707 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.30 mm (3.437 in.) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.78 mm (3.062 in.) Crankcase Oil Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.42 L (1.5 qt) Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper with outer foam element Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal discharge below frame Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Normal Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable (In-Line Type) Spark Plug Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.)

GENERAL SPECIFICATIONS - 17 HP Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs & Stratton Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intek™ Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1036-E1 Gasoline Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311777 Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.6 kW (17 hp) Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .508 cm3 (31.0 cu-in.) Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.6 mm (3.57 in.) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.8 mm (3.06 in.) Crankcase Oil Capacity without oil filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.42 L (1.5 qt) with oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.66 L (1.75 qt) Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper with outer foam element Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal discharge below frame Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Normal Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable (In-Line Type)

TESTS AND ADJUSTMENTS SPECIFICATIONS - 14—16 HP Valve Clearance Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13—0.18 mm (0.005—0.007 in.) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.23—0.28 mm (0.009—0.011 in.) Valve Guide Depth . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12—0.15 mm (0.005—0.006 in.) Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750 ±100 rpm Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3600 ±50 rpm

3/22/00

3-3

TESTS & ADJUSTMENTS SPECIFICATIONS - 17 HP

ENGINES – SINGLE CYLINDER

TESTS & ADJUSTMENTS SPECIFICATIONS - 17 HP Valve Clearance Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08—0.13 mm (0.003—0.005 in.) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13—0.18 mm (0.005—0.007 in.) Valve Guide Depth . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12—0.15 mm (0.005—0.006 in.) Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750 ± 100 rpm Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 ± 100 rpm Magneto Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.25 - 0.35 mm (0.010 - 0.014 in.) Spark Plug Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.)

REPAIR SPECIFICATIONS - 14—16 HP Cylinder Bore, Pistons and Rings: Cylinder Bore Standard Maximum Dimension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.31 mm (3.4375 in.) Minimum Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.29 mm (3.4365 in.) Cylinder Bore Out of Round (max) . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06mm (0.003 in.) Piston Pin (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.29 mm (0.799 in.) Piston Pin Bore (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.35 mm (0.801 in.) Ring End Gap Wear Limit Aluminum Bore: Compression Ring (Top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.89 mm (0.035 in.) Compression Ring (Center). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.89 mm (0.035 in.) Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 mm (0.045 in.) Cast Iron Bore: Compression Ring (Top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.) Compression Ring (Center). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.) Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.89 mm (0.035 in.) Compression and Oil Ring Groove Wear Limit (New Ring Installed) 0.18 mm (0.007 in.) Valves: Valve Guide (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.09 mm (0.240 in.) Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17 – 1.57 mm (0.046 – 0.062 in.) Valve Margin (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.) Valve Face Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Valve Seat Narrowing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Connecting Rod and Crankshaft: Connecting Rod Crankpin (Wear Limit). . . . . . . . . . . . . . . . . . . . . . 31.80 mm (1.252 in.) Connecting Rod Piston Pin Bearing (Wear Limit) . . . . . . . . . . . . . . 20.37 mm (0.802 in.) Crankshaft PTO Journal (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . 34.95 mm (1.1376 in.) Crankshaft Magneto Journal (Wear Limit). . . . . . . . . . . . . . . . . . . 34.95 mm (1.1376 in.) Magneto Bearing (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.13 mm (1.383 in.) PTO Bearing (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.13 mm (1.383 in.) Crankpin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.219mm (1.1291 in.) Crankshaft Crankpin Journal (Wear Limit) . . . . . . . . . . . . . . . . . . . 31.67 mm (1.247 in.) Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 – 0.58 mm (0.002 – 0.023 in.) Cam Gear PTO Journal (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . 12.65 mm (0.498 in.) Cam Gear Magneto Journal (Wear Limit) . . . . . . . . . . . . . . . . . . . . 12.65 mm (0.498 in.) Cam Lobe (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.07 mm (1.184 in.) Cam Gear Bearing (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.8 mm (0.504 in.)

3-4

3/22/00

ENGINES – SINGLE CYLINDER

REPAIR SPECIFICATIONS - 17 HP

REPAIR SPECIFICATIONS - 17 HP Cylinder Bore, Pistons and Rings: Cylinder Bore Standard Maximum Dimension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.75 mm (3.573 in.) Minimum Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.68 mm (3.570 in.) Cylinder Bore Out of Round (max) . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 mm (0.0015 in.) Piston Pin (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.29 mm (0.799 in.) Piston Pin Bore (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.35 mm (0.801 in.) Ring End Gap (Wear Limit) Cast Iron Bore: Compression Ring (Top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.) Compression Ring (Center). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.) Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.89 mm (0.035 in.) Compression and Oil Ring Groove Wear Limit (New Ring Installed) 0.15 mm (0.006 in.) Valves: Valve Guide (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.09 mm (0.240 in.) Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.79—1.98 mm (0.031—0.078 in.) Valve Margin (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.) Valve Face Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Valve Seat Narrowing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Connecting Rod and Crankshaft: Connecting Rod Crankpin (Wear Limit). . . . . . . . . . . . . . . . . . . . . . 31.80 mm (1.252 in.) Connecting Rod Piston Pin Bearing (Wear Limit) . . . . . . . . . . . . . . 20.37 mm (0.802 in.) Crankshaft PTO Journal (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . 34.95 mm (1.376 in.) Crankshaft Magneto Journal (Wear Limit). . . . . . . . . . . . . . . . . . . . 34.95 mm (1.376 in.) Magneto Bearing (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.13 mm (1.383 in.) PTO Bearing (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.13 mm (1.383 in.) Crankshaft Crankpin Journal (Wear Limit) . . . . . . . . . . . . . . . . . . . 31.67 mm (1.247 in.) Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . 0.05—0.58 mm (0.002—0.023 in.) Cam Gear PTO Journal (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . 12.65 mm (0.498 in.) Cam Gear Magneto Journal (Wear Limit) . . . . . . . . . . . . . . . . . . . . 12.65 mm (0.498 in.) Cam Lobe (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.07 mm (1.184 in.) Cam Gear Bearing (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.8 mm (0.504 in.)

3/22/00

3-5

TORQUE SPECIFICATIONS (Alphabetical)

ENGINES – SINGLE CYLINDER

TORQUE SPECIFICATIONS (Alphabetical) Alternator to Cylinder Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Nm (35 lb in.) Air Cleaner Base to Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 N•m (55 lb-in.) Blower Housing Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 N•m (55 lb-in.) Carburetor to Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 N•m (65 lb-in.) Carburetor Bowl Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 N•m (40 lb-in.) Connecting Rod Cap Screws 28N700 and 28Q700 (Small Screw) . . . . . . . . . . . . . . . . . . . . . . 18.1 N•m (160 lb-in.) 28N700 and 28Q700 (Large Screw) . . . . . . . . . . . . . . . . . . . . . . 23.4 N•m (260 lb-in.) 287700 (Both Screws are Same Size . . . . . . . . . . . . . . . . . . . . . 20.9 N•m (185 lb-in.) 311777 (Both Screws are Same Size . . . . . . . . . . . . . . . . . . . . . 20.9 N•m (185 lb-in.) Counterweight Bolt (311777) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 N•m (115 lb-in.) Crankcase Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.8 N•m (140 lb-in.) Cylinder Head Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.8 N•m (220 lb-in.) Cylinder Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 N•m (55 lb-in.) Drive Belt Idler Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6 N•m (85 lb-in.) Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 N•m (24 lb-ft) Engine Output Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 N•m (55 lb-ft) Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5 N•m (165 lb-in.) Flywheel Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115.6 N•m (85 lb-ft) Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 N•m (40 lb-in.) Governor Arm Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 N•m (40 lb-in.) Head Bolts (Final) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.9 N•m (220 lb-in.) Heat Shield Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 N•m (40 lb-in.) Ignition Armature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 N•m (25 lb-in.) Intake Manifold Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 N•m (100 lb-in.) Oil Breather Mounting Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 N•m (55 lb-in.) Oil Filter Adaptor Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 14.7 N•m (130 lb-in.) Oil Pump Cover Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 N•m (55 lb-in.) Rocker Arm Adjustment Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 N•m (60 lb-in.) Rocker Arm Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6 N•m (85 lb-in.) Starting Motor Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 N•m (140 lb-in.) Starting Motor Thru Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 N•m (50 lb-in.) Stator to Cylinder Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9 Nm (35 lb in.) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.) Sump Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.8 N•m (140 lb-in.) Throttle Valve Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 N•m (40 lb-in.) Valve Cover Nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 N•m (60 lb-in.)

3-6

3/22/00

TROUBLESHOOTING

ENGINES – SINGLE CYLINDER

Starting motor/solenoid defective

●

Improper switch position (See Electrical Section)

●

Engine seized

●

Fuel shutoff solenoid defective

●

Fuel filter/lines clogged

●

Fuel pump defective

●

Ignition coil air gap not adjusted properly

●

Carburetor not adjusted properly, dirty

●

Air cleaner dirty

●

Old/contaminated fuel

●

Spark plugs loose/dirty

●

Magneto kill circuit grounded/ shorted (See Electrical Section)

●

Valve tappets need adjustment

●

Lack of compression, check valves, pistons and rings

●

Magneto kill circuit open (See Electrical Section)

Fuel mixture too rich

●

Engine overheats

Fusible link (F1) open

Engine running on one cylinder

●

Low oil pressure

●

Excessive engine noise/vibration

Engine starts hard

●

Low compression

Engine cranks but will not start

Battery has low or no charge/ cables loose or dirty

Check or Solution

Loss of power

Engine will not crank

Problem or Symptom

Engine won’t shutoff

TROUBLESHOOTING

●

● ●

●

● ●

●

Mower deck binding or dragging

●

Grass build-up under deck

●

3/22/00

3-7

TROUBLESHOOTING

No lubrication in gear box or hydro transaxle

●

● ●

Deck spindles seized

●

Loose cylinder head bolts

●

Defective head gasket

●

Warped cylinder head

●

Worn bore and/or rings

●

Broken connecting rod

●

Cutter blade or other rotating part bent or out of balance

●

Mounting bolts loose

●

Camshaft worn

●

Internal bearings worn or excessive tolerance

●

Oil galleries/filter clogged

●

Oil pump defective

●

Low oil level or wrong viscosity

●

Exhaust system restricted

Fuel mixture too rich

●

Excessive drive belt tension

Burned valves, valve seats, and/or loose valve seats

Engine overheats

Engine running on one cylinder

Low oil pressure

Excessive engine noise/vibration

Low compression

Loss of power

Engine won’t shutoff

Engine starts hard

Check or Solution

Engine will not crank

Problem or Symptom

Engine cranks but will not start

ENGINES – SINGLE CYLINDER

●

● ●

Air/fuel mixture excessively lean

●

Cylinder cooling fins/blower housing filled with grass clippings

●

Overchoking

●

Float needle stuck open

●

3-8

3/22/00

ENGINE TROUBLESHOOTING

ENGINES – SINGLE CYLINDER

ENGINE TROUBLESHOOTING Engine Will Not Crank

NOTE: To test specific electrical components, see Electrical Section and refer to either Diagnostics or Tests and Adjustments for further guidance.

Check battery voltage. Is battery voltage 12.4 volts or higher?

CAUTION

BE AWARE! The engine may start to rotate at any time. Keep hands away from all moving parts when testing.

Charge battery and perform a no-load test. Is battery voltage 12.4 volts or higher?

• Battery defective

YES

Does starter solenoid click when ignition switch is turned to START position?

• Fuse open • Starting motor solenoid defective • Defective switches or wiring

YES

See Electrical Troubleshooting • Engine seized • Starting motor solenoid defective • Starting motor pinion gear sticking or damaged • Starting motor defective

Repair or replace

3/22/00

3-9

ENGINE TROUBLESHOOTING

ENGINES – SINGLE CYLINDER

Engine Cranks But Will Not Start

CAUTION

DO NOT rotate engine with starter if the spark plugs are removed. Gasoline spray from the open cylinders may be ignited by ignition spark and cause an explosion or fire.

Check battery voltage. Is battery voltage 12.4 volts or higher?

IMPORTANT: Perform a visual inspection first to determine if battery cables are tight and not corroded and if the battery is of sufficient size to turn the engine over at minimum cranking speed of 350 rpm.

NOTE: To test specific electrical components, see Electrical Section and refer to either Diagnostics or Tests and Adjustments for further guidance.

Charge battery and perform a no-load test. Is battery voltage 12.4 volts or higher?

YES

Does fuel shutoff solenoid click when ignition switch is turned to START/RUN position?

• Battery defective

• Defective fuel shutoff solenoid • Defective switches or wiring

See Electrical Troubleshooting Does engine have internal resistance?

YES

Does engine crank slow?

YES

NOTE: Remove spark plugs and turn engine over by hand. Engine should rotate freely with little resistance.

(less than 350rpm) NO

Is choke operating properly?

Adjust

YES

• Piston rings or other internal components binding

Repair or replace

• Starting motor defective

Do spark plugs have a strong blue spark?

YES

Are tappets adjusted properly?

YES YES

Adjust

• Defective spark plugs • Magneto kill circuit shorted to ground • Flywheel magnet weak • Ignition coil air gap not adjusted properly

• Air cleaner plugged • Excessively rich fuel mixture • Water in fuel • Float needle stuck open

See Electrical Troubleshooting

• Not enough compression

Is engine getting fuel?

3 - 10

• Fuel shutoff valve closed • Fuel lines/vent plugged • Fuel pump defective • Insufficient engine vacuum

See Tests and Adjustments

3/22/00

ENGINE TROUBLESHOOTING

ENGINES – SINGLE CYLINDER

Engine Runs Erratically/Loss Of Power

NOTE: To test specific electrical components, see Electrical Section and refer to either Diagnostics or Tests and Adjustments for further guidance.

IMPORTANT: Before proceeding, inspect the mower deck and belts for binding in the spindle assemblies or belts that are too tight/loose. A loose belt like a loose blade can cause a backlash effect that will counteract engine cranking effort. Excessive drive belt tension may cause premature bearing wear or result in bearing seizure. Grass clippings that build up near the cutting blades can cause excessive resistance and heat build-up that causes problems with the engine’s ability to turn the blades at a constant speed. Low lubricant levels in the spindles will build-up heat causing excessive resistance for the engine to deal with.

• Defective spark plug

• Carburetion • Crankcase vacuum • Ignition Timing • Governor operation • Camshaft

NOTE: A fouled spark plug may indicate that the carburetor is out of adjustment. • Faulty ignition wire/ignition system • Defective head gasket • Intake manifold leak • Valves/valve adjustment • Piston rings • Piston • Cylinder bore

3/22/00

See Tests and Adjustments

3 - 11

TESTS AND ADJUSTMENTS

ENGINES – SINGLE CYLINDER

TESTS AND ADJUSTMENTS

FUEL SHUTOFF SOLENOID TEST

THROTTLE CABLE ADJUSTMENT

Reason: To test proper operation of fuel shutoff solenoid.

Reason: To make sure the throttle cable moves the throttle through its full range of movement.

Required Tools:

Procedure:

1. Move throttle lever to FAST idle position.

• Jumper wire

1. Listen for an audible click when ignition switch is turned from OFF to ON. 2. If solenoid does not click, problem could be in equipment wiring.

B M95232

2. Hole in governor control lever must align with hole (A) in governor control plate. 3. Loosen throttle cable clamp (B). 4. Slide the throttle cable left or right to align holes. 5. Tighten throttle cable clamp.

A M95224

3. Disconnect wire from solenoid (A). 4. Momentarily place a jumper wire from solenoid wire to battery positive terminal. 5. If solenoid now clicks, the solenoid is working properly.

NOTE: If battery voltage drops below 9 volts when cranking engine or while engine is running, the solenoid will not function. Results: • Solenoid is operating properly if a click is heard when ignition switched from off to on

3 - 12

3/22/00

GOVERNOR ADJUSTMENT-STATIC

ENGINES – SINGLE CYLINDER

GOVERNOR ADJUSTMENT-STATIC

Specification: Lock nut . . . . . . . . . . . . . . . . . . . . 4.5 N•m (40 lb-in.)

(Engine OFF)

GOVERNOR ADJUSTMENT RUNNING

CAUTION

Before starting or running engine, static adjustment of the governor must be made. Failure to make static adjustments first, could result in engine overspeeding, and may result in engine or equipment damage causing personal injury and/or property damage.

(Full Throttle No Load) Reason: To verify the engine speed settings are within limits. Equipment:

NOTE: All linkage must be installed to make adjustment.

• JT07270 Pulse Tachometer

Reason: To set the initial engine speed limits.

CAUTION

Equipment: • JT07270 Pulse Tachometer Procedure:

NOTE: All linkage must be installed to make adjustment. Procedure: 1. With engine running move throttle lever to FAST idle position. 2. Measure engine rpm.

M95236

1. Loosen governor lever bolt and nut (A). 2. Move throttle lever to FAST idle position. 3. While holding throttle in fast position use a flat blade screwdriver to turn governor shaft clockwise until it stops.

Space between control box and engine block

IMPORTANT: Do not bend governor link or distort governor lever. 4. Hold lever and shaft in position and tighten governor lever bolt and nut to 4.5 N•m (40 lb-in.).

3/22/00

To Increase Speed M95237

3 - 13

GOVERNOR IDLE ADJUSTMENT

ENGINES – SINGLE CYLINDER

3. Bend the upper governor spring anchor (A) to adjust the top no load engine rpm. 4. Bend the anchor up to lengthen the spring to increase the rpm, or down to shorten the spring to reduce the engine rpm. 10 mm (0.375 in.) slot 6 mm (0.250 in.) deep both ends

57 mm (2.25 in.)

146 mm (5.75 in.)

M95239

M95238

IMPORTANT: Do not bend governor link or distort governor lever.

6. Bend tang (C) until it contacts remote control slide (D).

SLOW IDLE CARBURETOR ADJUSTMENT

GOVERNOR IDLE ADJUSTMENT Reason: Reason: To set the governed idle speed.

To set the carburetor mixture screws for proper operation of the carburetor.

Equipment:

Equipment: • JT07270 Pulse Tachometer

• JT07270 Pulse Tachometer Procedure: 1. Start engine and run at 1/2 throttle for 5 minutes to bring engine to operating temperature. 2. Move throttle to idle position.

IMPORTANT: In order to obtain correct operation of the carburetor, the adjustment procedure must be performed in the sequence shown. Procedure: 1. Start engine and run at 1/2 throttle for 5 minutes to bring engine to operating temperature. 2. Move throttle to idle position.

B A

M95222

3. Hold throttle shaft (A) in closed position with finger, adjust idle speed screw (B) to 1200 rpm. 4. Release throttle. 5. Set throttle to 1750 rpm.

3 - 14

M95222

3/22/00

VALVE CLEARANCE ADJUSTMENT

ENGINES – SINGLE CYLINDER 3. Turn idle speed screw (A) to obtain 1750 rpm minimum. 4. Then turn idle mixture screw (B) slowly clockwise until engine just begins to slow. Note position of slot on screw. 5. Now turn idle mixture screw (B) in counterclockwise direction until engine just begins to slow. Note position of slot on screw. 6. Turn screw to midpoint between speed changes.

3. Insert a screwdriver through the spark plug opening until it touches the top of the piston. 4. Continue to turn the crankshaft clockwise until the piston has moved down 6.35 mm (0.25 in.).

10 mm Open End Wrench M95246 M95231

7. Install limiter cap (C) with flat facing up. 8. Move throttle control from idle to high speed position. Engine should accelerate smoothly. If it does not, open idle mixture needle screw 1/8 turn. There should be no afterfire.

VALVE CLEARANCE ADJUSTMENT NOTE: Correct position of crankshaft is necessary to eliminate interference by the compression release mechanism on the cam gear when adjusting valve clearance. 1. Starting with a cold engine, remove valve cover. 2. Turn crankshaft until piston is at Top Dead Center, (TDC) on the compression stroke (Both Valves Closed).

5. Check valve clearance with a feeler gauge between valve stem and rocker arm. Valve clearance should be 0.13—0.18 mm (0.005—0.007 in.) for the intake valve, and 0.23—0.28 mm (0.009—0.011 in.) for the exhaust valve. 6. If not, adjust as necessary using a 13 mm open end wrench and a 5 mm hex wrench. Tighten lock nut to 7 N•m (60 lb-in.). 7. Recheck clearance and make adjustments if necessary. 8. Install valve cover. Specifications: Lock nut . . . . . . . . . . . . . . . . . . . . . . 7 N•m (60 lb-in.) Valve Clearance Intake. . . . . . . . . 0.13—0.18 mm (0.005—0.007 in.) Exhaust . . . . . . . 0.23—0.28 mm (0.009—0.011 in.)

Spark Plug Port

M95245

3/22/00

3 - 15

IGNITION ARMATURE AIR GAP ADJUSTMENT IGNITION ARMATURE AIR GAP ADJUSTMENT

ENGINES – SINGLE CYLINDER

FUEL AND AIR REPAIR UPPER BLOWER HOUSING REMOVAL AND INSTALLATION

Reason: To set the ignition air gap for proper operation and timing of the ignition system.

Procedure:

Equipment: • 30 mm (0.012 in.) Thickness Gauge

Procedure:

B A

M95221

1. Remove the screw holding the dipstick tube in place. 2. Remove the two screws holding the starting motor guard in place and remove guard. 3. Remove the four screws (A) holding the upper blower housing in place. 4. Lift upper blower housing up and off of engine. 5. Remove three screws (B) securing rotating screen. 6. Install in reverse order of removal.

C M95220

AIR CLEANER SERVICE 1. Rotate flywheel until magnet (A) is away from armature laminations. 2. Loosen the armature mounting screws (B) and slide armature away from flywheel as far as possible. 3. Tighten one screw enough to hold the armature in place. 4. Rotate flywheel until magnet is directly under armature laminations. 5. Place a 30 mm (0.012 in.) thickness gauge (C) between armature and magnet. 6. Loosen the mounting screw so magnet will pull armature against thickness gauge. 7. Tighten both mounting screws (B) to 2.8 N•m (25 lb-in.). 8. Rotate flywheel while pulling thickness gauge out from between the armature and the magnet.

Procedure: D A

E B C

M94907

3 - 16

3/22/00

CARBURETOR REMOVAL AND INSTALLATION

ENGINES â&#x20AC;&#x201C; SINGLE CYLINDER

IMPORTANT: DO NOT use petroleum solvents, such as kerosene, to clean paper cartridge. They may cause cartridge to deteriorate. DO NOT oil paper cartridge. DO NOT use pressurized air to clean or dry paper cartridge. 1. To service dual element, remove cover (A). 2. Slide foam pre-cleaner (B) off cartridge (C). 3. Wash it in liquid detergent and water. 4. Squeeze it dry in a clean cloth. 5. Saturate it in engine oil. Wrap it in clean absorbent cloth and squeeze to remove excess oil. 6. Remove cartridge and clean by tapping gently on a flat surface. If very dirty, replace. 7. Reinstall cartridge, pre-cleaner, cover and knobs (D) and (E).

1. Remove air cleaner cover (A) and air cleaner (B). 2. Remove the air cleaner base support bracket. 3. Remove air cleaner base (C) and breather tube. 4. Remove fuel line (D) and drain into a properly identified gasoline container. 5. Disconnect the plug connected to the fuel shutoff solenoid. 6. While supporting the carburetor in one hand, loosen and remove the two bolts (E) holding the carburetor to the intake manifold.

CARBURETOR REMOVAL AND INSTALLATION

Procedure:

M95224

7. Carefully pull the carburetor away from the intake manifold and rotate the carburetor to disengage the choke linkage (F), governor link (G) and governor link spring (H). 8. Remove carburetor and gasket. 9. Reassemble in reverse order. 10. Connect governor link and governor link spring to throttle lever.

A F

E D

M95230

M95223

3/22/00

11. Install choke link to outer hole (I) of choke lever on carburetor.

3 - 17

CARBURETOR DISASSEMBLY 12. Position gasket in place on the carburetor and slide choke link (F) into slot (J) in choke control bracket. 13. Making certain that the gasket is in place, install the carburetor bolts and tighten to 7 N•m (65 lb-in.). 14. Install the air cleaner base and breather tube. Tighten the base screw to 4.5 N•m (40 lb-in.) and the two nuts to 6 N•m (55 lb-in.). 15. Install air cleaner base support bracket and tighten to 4.5 N•m (40 lb-in.). 16. Install fuel line and fuel line clamp.

ENGINES – SINGLE CYLINDER

CAUTION

Static governor adjustment must be made whenever carburetor or manifold has been removed from engine. Failure to make static adjustments first could result in engine overspeeding and may result in engine or equipment damage causing personal injury or property damage.

M95230

3. Remove idle mixture needle limiter cap and idle mixture screw with spring (A). B E F

IMPORTANT: Be sure breather tube is not kinked and that it is installed onto nipple as far as possible. D

17. Install air cleaner cartridge, pre-cleaner and cover.

Specifications: Air cleaner base support bracket 4.5 N•m (40 lb-in.) Carburetor screws . . . . . . . . . . . . . . 7 N•m (65 lb-in.) Air cleaner base . . . . . . . . . . . . . . . . 6 N•m (55 lb-in.)

CARBURETOR DISASSEMBLY Procedure: 1. Remove fuel shutoff solenoid and fuel bowl washer. 2. With a small punch, drive the float hinge pin out of float hinge. Remove float and fuel inlet valve assembly.

M95229

4. Rotate throttle shaft and lever (B) to closed position and remove two throttle valve screws (C). 5. Remove throttle valve (D), throttle shaft with lever (B), and foam seal (E). 6. Remove throttle shaft seal or bushing from carburetor (F). G

I J H

M95228

3 - 18

3/22/00

CARBURETOR INSPECTION

ENGINES â&#x20AC;&#x201C; SINGLE CYLINDER 7. Rotate choke shaft (G) to wide open position. 8. Pull choke valve (H) out of choke shaft and lever. 9. Remove choke shaft and lever, return spring(I), and foam washer(J).

CARBURETOR INSPECTION IMPORTANT: A clean fuel system is necessary in order to maintain proper operation of the engine. Gummy or dirty fuel tanks and carburetors should be cleaned in a carburetor cleaner such as Bendix Carburetor cleaner or equivalent. DO NOT soak rubber, neoprene or plastic parts in cleaner. Procedure: 1. Check all moving parts for wear, nicks and burrs. Replace, if worn or damaged. 2. Check float for leaks or damage. Replace, if damaged or leaking. 3. Using dry compressed air, carefully blow through all passages. 4. Inspect idle mixture needle for bent or grooved point. Replace if grooved or bent.

M95225

10. Using 1/4-20 self-threading screw or tap (K), threaded into fuel inlet seat (L) 3-4 turns and remove screw or tap.

CARBURETOR ASSEMBLY IMPORTANT: When assembling the carburetor, use new seals and gaskets. Procedure:

M N

A L B

M95226 M95227

11. Place 1/4-20 nut and washer (M) on a 1/4-20x1in. screw to use as a puller. 12. Place the hex end of a 1/4 in. drive 3/8 in. socket (N) over fuel inlet seat (L). 13. Place the puller screw through the socket and thread it into the tapped inlet seat until the screw bottoms. 14. Thread nut down onto the washer and socket and continue turning nut until inlet seat is free from carburetor body.

3/22/00

1. Carefully press new fuel inlet seat (A) into carburetor body until seat is flush with fuel inlet boss (B).

3 - 19

BREATHER VALVE SERVICE

ENGINES – SINGLE CYLINDER 10. Insert inlet needle valve in slot on float. 11. Place float and needle in carburetor and install float hinge pin, centering hinge pin. 12. Place bowl gasket on carburetor body, 13. Place bowl on carburetor and install float bowl washer and fuel shutoff solenoid and tighten to 4.5 N•m (40 lb-in.).

D C

Specification: Solenoid torque . . . . . . . . . . . . . . 4.5 N•m (40 lb-in.) Throttle valve . . . . . . . . . . . . . . . . 4.5 N•m (40 lb-in.)

BREATHER VALVE SERVICE M95228

2. Insert spring inside large foam seal (C) and slide seal and spring onto choke shaft (D) with straight end of spring up toward choke shaft lever. 3. Insert choke shaft (D) into carburetor body until hook of spring hooks on spring anchor (E). 4. Lift choke shaft (D) up slightly and turn counterclockwise until stop on lever clears spring anchor and push shaft down. 5. Insert choke valve (F) into choke shaft (D) with dimples (G) toward fuel inlet (H) side of carburetor. Dimples help to hold and align choke valve on shaft. J

IMPORTANT: A leak at the seal between the tube and crankcase cover, or at the seal at the upper end of the dipstick, can result in a loss of crankcase vacuum and a discharge of oil or smoke through the muffler. 1. Remove breather tube from breather.

NOTE: The engine utilizes a breather valve to control and maintain a vacuum in the crankcase. The breather valve closes on the up stroke of the piston and opens on the down stroke of the piston to maintain a vacuum in the crankcase. This vacuum prevents oil leakage past piston rings, valve guides, oil seals, governor shaft and gaskets.

2. Remove two screws holding breather and remove breather gasket. Discard old gasket.

I L M

M95229

6. Install throttle shaft seal (I) with sealing lip down in carburetor body until top of seal is flush with top of carburetor. 7. Install throttle shaft (J) and small foam washer (K). Turn shaft until flat (L) is facing out. 8. Lay throttle valve (M) on shaft with numbers (N) toward idle mixture screw and dimples facing in resting on edge of shaft. 9. Install two screw (O) to secure throttle valve to shaft and tighten to 4.5 N•m (40 lb-in.).

3 - 20

M95247

3. The fiber disc valve (A) must move freely. If the valve is stuck or binding, the breather valve must be replaced. 4. Measure the clearance between the fiber disc valve and the body. A 1.14 mm (0.045 in.) wire gauge (B) should not enter the space between the fiber disc valve and the body. DO NOT FORCE GAUGE. 3/22/00

REPAIR

ENGINES – SINGLE CYLINDER 5. Install breather using a new gasket and tighten the two screws to 6.2 N•m (55 lb-in.).

NOTE: When installing breather, make sure breather gasket is located properly. 6. Install breather tube in breather.

REPAIR ENGINE REMOVAL 1. Turn all switches OFF and disconnect battery negative (–) cable. 2. Remove mower deck. 3. Raise hood. Disconnect light harness on right side of hood. Lower hood to approximately 3/4 open and slide off bracket.

Capscrews And Nut

Heat Shield

Capscrews M95203

4. Remove the capscrews securing heat shield to frame. Remove capscrew and nut on side of heat shield. Remove heat shield. 5. Remove two capscrews securing muffler to engine and the capscrew securing muffler to frame. Remove muffler.

A B

M95207

6. Disconnect fuel shut-off solenoid wire (A). 7. Loosen clamp (B) to disconnect throttle cable (C).

3/22/00

3 - 21

ENGINE INSTALLATION

ENGINES – SINGLE CYLINDER engine output shaft. Remove pulley assembly.

Capscrews

8. Disconnect hose clamp (D) and slide fuel line off hose barb on carburetor.

M55799

15. Remove four cap screws securing engine to frame. 16. Remove engine.

ENGINE INSTALLATION

1. Install engine in mower frame.

M95208

9. Disconnect wires from starter terminal (E). 10. Disconnect wires from stator and fuel shutoff solenoid (G).

Ground Wire

NOTE: Ground terminal (F) will be disconnected when engine mounting bolt is removed.

M95208

J H

2. Put ground lead connector on top of front right hand engine mounting flange, and insert capscrew through connector, engine, and frame. 3. Install other three capscrews, washers, and nuts. Tighten to 32 N•m (24 lb-ft). 4. If muffler was removed inspect muffler flange for flatness. Install muffler with new gasket. Tighten mounting bolts to 24•m (216 lb-in.).

I K

M95205

11. Remove two capscrews (H) securing belt guard bracket. Remove bracket and belt guard (I). 12. Remove traction drive belt idler pulley and belt guard. 13. Remove traction drive belt (J). 14. Remove capscrew (K) securing pulley assembly to

3 - 22

3/22/00

ENGINES – SINGLE CYLINDER

CYLINDER HEAD REMOVAL AND INSTALLATION 10. Connect wires to starter terminal (E). 11. Connect two (2) harness connectors (G).

Capscrews And Nut

Heat Shield

Capscrews

A C

M95203

M95207

5. Install heat shield. Secure with capscrews to front frame mounting brackets. Install capscrew and nut on side of heat shield.

12. Connect and adjust throttle cable (C), see “THROTTLE CABLE ADJUSTMENT” on page 12. 13. Connect fuel solenoid wire (A), and fuel line and clamp (D). 14. Connect battery negative (–) cable.

CYLINDER HEAD REMOVAL AND INSTALLATION IMPORTANT: Mark all parts when disassembling cylinder heads to prevent interchanging. Capscrew M95205

6. Install engine output shaft key and pulley assembly. Secure with washer, lock washer and capscrew. Tighten capscrew to 75 N•m (55 lb-ft). 7. Install traction drive belt. 8. Install traction drive belt idler pulley and belt guard and tighten to 32 N•m (24 lb-ft). 9. Install belt guard and guard bracket. Secure with two capscrews.

Procedure: 1. Disconnect spark plug leads and remove spark plugs. 2. Remove aircleaner assembly, carburetor and blower housing. 3. Remove intake manifold and governor control bracket and linkage.

Valve Cover

Capscrews

M95240 E

M95208

4. Remove four capscrews securing valve cover.

3/22/00

3 - 23

CYLINDER HEAD REMOVAL AND INSTALLATION

ENGINES â&#x20AC;&#x201C; SINGLE CYLINDER

Rocker Nuts

Rocker Arm Screws

Rocker Arms

7 3

M95244

5. Remove eight (8) cylinder head bolts.

Rocker Arm Studs

Push Rod Guide

M95241

7. Lay cylinder head flat and remove rocker studs, shaft, rocker arms and push rod guide.

Cylinder Head Gasket

M87024

Alignment Sleeves M87024

6. Remove cylinder head, cylinder head gasket and push rods.

8. Place new gaskets and cylinder head on cylinder. Align head with cylinder head alignment sleeves located in the cylinder. 9. Apply approved lubricant to bolts threads and install eight cylinder heads bolts. IMPORTANT: Do not use sealer of any kind on gaskets. 10. Tighten eight bolts down evenly by hand. Then, using torque wrench, tighten cylinder head bolts in sequence.

3 - 24

3/22/00

CYLINDER HEAD INSPECTION AND REPAIR

ENGINES – SINGLE CYLINDER

IMPORTANT: Do not tighten one bolt down completely before the others, as it may cause a warped cylinder head.

CYLINDER HEAD INSPECTION AND REPAIR

17. Install aircleaner assembly. 18. Install spark plug and plug wire.

4 Procedure: 1. Remove combustion chamber deposits from combustion chamber and around valves using a soft, hand wire brush or scraper. With piston at top dead center, remove combustion chamber deposits from top of piston.

7 3

M95244

11. Using the pattern shown above, tighten the cylinder head bolts in a three step process to a final torque of 24.9 N•m (220 lb-in.). • First step = 8.5 N•m (75 lb-in.) • Second step = 16.9 N•m (150 lb-in.) • Final step = 24.9 N•m (220 lb-in.) 1

IMPORTANT: Use care to prevent combustion chamber deposits from entering push rod or oil return cavity in cylinder. Take care not to damage cylinder, top of piston, cylinder head and cylinder head gasket surfaces. Remove only the combustion chamber deposits. It is not necessary to remove the discoloration marks on the piston, valves and cylinder head. These marks are normal and will not affect engine operation. 2. Inspect cylinder head for broken fins or cracks.

VALVES REMOVAL Procedure: 1. Remove the valves, place cylinder head on workbench with support to hold valves in place. 2. Remove valve cap from valve stem.

4 Valve Cover

Valve Cap

Retainer M95240

12. Install valve cover with new gasket and tighten using the crossing pattern shown. Tighten to 6.8 N•m (60 lb-in.). 13. Install intake manifold and tighten to 11.3 N•m (100 lb-in.). 14. Install blower housing. 15. Install governor control bracket and linkage. 16. Install carburetor and adjust governor linkage. See “GOVERNOR ADJUSTMENT-STATIC” on page 13.

3/22/00

Valve Spring M95242

3. With thumbs, press down on valve spring retainer and spring to compress spring until large end of slot in retainer can line up with end of valve stem.

3 - 25

VALVES REFACE

ENGINES – SINGLE CYLINDER

4. Release pressure and remove retaining washer and spring 5. Remove valve seal and washer. 6. Repeat procedure on other valve.

VALVES REFACE Procedure: Valve Stem Seal

4. If the valve is badly burned, it should be replaced. Replace valve if margin is 0.39 mm (0.0156 in.) or less or is badly burned or damaged, replace cylinder head. Valve seats are not replaceable. 5. Inspect valve springs and replace if broken or worn. 6. Inspect valve guides by inserting plug gauge into valve guide. If plug gauge inserts 6.35 mm (0.250 in.) or more, the guide must be replaced. If plug gauge is not available, the rejection dimension for both intake and exhaust valve guides is 6.09 mm (0.240 in.). Specification: Valve Seat Width . 0.17—1.57 mm (0.046—0.062 in.)

VALVES INSTALLATION Procedure:

M87026

1. To remove valve stem seals, grasp seal with pliers and pull up on seal while turning.

Rod Guide

IMPORTANT: Always replace valve stem seals whenever valves are removed for servicing. Rocker Arm Stud

1.17 mm—1.57 mm (0.046 in.—0.062 in.) 0.8 mm (0.030 in.) Fit For Use

Margin

45°

0.4 mm (0.0156 in.) Discard M87027

Faces on valves may be resurfaced with a valve grinder to 45°. Valve seats can be reconditioned using Valve Seat Cutter. Valves and seats should then be lapped with Valve Lapping Tool and Valve Lapping Compound. Remove grinding marks and assure a good seal between valve and seat. Thoroughly clean lapping compound from valve seat and valve face. 2. Valve seat width should be 1.17—1.57 mm (0.046—0.062 in.). 3. If seat is wider, it may be narrowed using Valve Seat Cutter. Use 30° side of cutter to narrow the seats.

3 - 26

M95243

1. Place push rod guide in cylinder head with the word “TOP” up and the mounting holes positioned over the mounting holes. 2. Coat rocker arm studs with hardening sealant. 3. Install rocker arm studs and tighten to 9.6 N•m (85 lb-in.). 4. Valve stems and guides must be free of foreign material and burrs or valve sticking will occur and valve stem seals will be damaged.

3/22/00

ENGINES – SINGLE CYLINDER

GOVERNOR REMOVAL AND INSTALLATION

Valve Stem Seal

GOVERNOR REMOVAL AND INSTALLATION Procedure: Throttle Governor Link Governor Lever Governor Spring

M87026

5. Oil inside diameter of valve stem seal with engine oil and install on valve stem. Press seal down over valve guide. 6. Lightly coat valve stems with a valve guide lubricant and install valve into valve guide.

Cam Gear

Carburetor

Governor Gear Governor Bracket

Paddle

NOTE: Be sure valve guide lubricant is not on valve face, valve seat, or exposed end of valve stem. Cup

M95233

1. Drain oil from sump. 2. Remove all rust, foreign material and burrs from crankshaft. 3. Remove sump screws and remove sump and sump gasket.

Retainer

Governor Cup

Crankshaft

Governor Crank

Valve Spring M95242

7. Place valve spring over valve stem. 8. Place retainer on spring and with thumbs on retainer press on retainer to compress spring. 9. Compress spring until valve stem extends through large end of retainer slot. 10. Continue to press until small end of slot can slide into groove on valve stem. Be sure retainer is fully engaged in valve stem groove. 11. Install cylinder head on engine block. See “CYLINDER HEAD REMOVAL AND INSTALLATION” on page 23. 12. Set valve clearance. See “VALVE CLEARANCE ADJUSTMENT” on page 15.

Governor Slinger

Cam Gear M95234

4. Inspect governor gear and bearing, flyweight pivots, and governor cup for wear or damage. 5. Before installing sump, be sure that governor cup is in line with governor shaft paddle.

Specifications: Rocker arm studs. . . . . . . . . . . . . 9.6 N•m (85 lb-in.)

3/22/00

3 - 27

OIL PUMP REMOVAL & INSTALLATION - 17 HP ONLY ENGINES – SINGLE CYLINDER

Sealant

9 7 5

4 10 6

B M95235

6. Install sump and gasket being sure screw #9 has nonhardening sealant on the threads. 7. Tighten all screws using the pattern indicated above to 15.8 N•m (140 lb-in.). 8. Complete installation of remaining governor linkage and carburetor. 9. Adjust governor. See “GOVERNOR ADJUSTMENTSTATIC” on page 13.

3. Remove the three screws (A) securing the oil pump cover (B) and o-ring to the sump.

OIL PUMP REMOVAL & INSTALLATION - 17 HP ONLY The pump is used to draw oil from the sump and pump it through the oil filter and back to the sump through a drain hole in the sump. The oil pump is driven by the lower end of the cam gear. This system does not supply oil under pressure to any of the bearings. This system only pumps oil to the oil filter and back to the crankcase for filtration purposes. Procedure: 1. Drain oil from sump and filter. 2. Remove all rust, foreign material and burrs from the bottom of the crankcase and the crankshaft.

3 - 28

4. Remove the inner and outer rotors. 5. Inspect surfaces of the rotors, pump housing, cover and shaft for wear and scoring. 6. Inspect pump housing for debris. Clean as needed. 7. Replace any worn or damaged components. 8. If debris as found the sump should be removed for cleaning and replacement of the oil screen.

3/22/00

ENGINES – SINGLE CYLINDER OIL

PUMP REMOVAL & INSTALLATION - 17 HP ONLY

Throttle

Governor Link

2 4

Governor Lever

Governor Spring

9 Cam Gear

7 1 5

Carburetor

3 M95235

9. Using the pattern shown, loosen the ten cap screws (C) securing the sump cover to the cylinder block ½ turn at a time until all ten cap screws are loosened, then remove the cap screws. This will prevent warping or breakage of the sump cover.

Governor Gear Governor Bracket

Paddle

Cup

M95233

12. Before installing sump, be sure that governor cup is in line with governor shaft paddle. 3

Sealant

9 7 5

2 4 10

10. Using a punch through the slots in the oil pump housing, press the oil screen out of the sump.

8 M95235

13. Install sump and gasket being sure screw #9 has nonhardening sealant on the threads. 14. Tighten all screws using the pattern indicated above to 15.8 N•m (140 lb-in.).

11. Press a new screen filter into the sump with the hole in the back of the screen oriented away from the governor shaft.

3/22/00

3 - 29

PISTON REMOVAL AND INSTALLATION 15. Lightly coat the rotors with clean motor oil and install the inner then the outer rotor. 16. Insert the o-ring into the o-ring groove in the sump and secure cover with the three screws. Tighten the screws to 9.0 N•m (80 lb-in.). 17. Complete installation of remaining governor linkage and carburetor. 18. Adjust governor. See “GOVERNOR ADJUSTMENT-STATIC” on page 13.

ENGINES – SINGLE CYLINDER pin and require the piston pin to be pressed out.

Specifications: Sump Cover . . . . . . . . . . . . . . . 15.8 N•m (140 lb-in.) Oil Pump Cover . . . . . . . . . . . . . . 9.0 N•m (80 lb-in.)

M86904

7. Remove top and center compression rings using ring expander.

PISTON REMOVAL AND INSTALLATION Procedure: 1. Remove air filter and bracket, upper blower housing, flywheel, alternator, carburetor and governor linkage. 2. Remove starter, cylinder heads and crankcase cover.

NOTE: Remove any carbon or ridge at the top of the cylinder bore. This will prevent breaking the rings when removing the piston and connecting rod from the engine. 3. Remove the connecting rod cap. Then push the piston and connecting rod out through the top of the cylinder.

IMPORTANT: New piston rings must be installed whenever the engine is disassembled for major servicing or overhaul, providing that cylinder bores are within specifications.

NOTE: Measure cylinder bores before checking pistons and rings. If cylinder bores require resizing it will not be necessary to check pistons and rings since a new oversized piston assembly will be used. 8. If cylinder bore is more than 0.08 mm (0.003 in.) oversize, or 0.06 mm (0.0025 in.) out of round, it must be resized. IMPORTANT: When servicing pistons, rings, piston pins or rods, each rod, piston, piston pin and ring set must be kept as a set for the cylinder that it was removed from. Mark each set before removing from the engine.

Notch Pin Retainer

M95249

4. To remove connecting rod from piston, rotate piston pin retainer until one end is exposed in notch in piston pin bore. 5. With a needle nose pliers, grasp end of piston pin retainer and pull in and up to remove. 6. From opposite side of piston, push piston pin out of piston and connecting rod. Piston pin is a push fit in piston and rod. Deposits may build up on piston

3 - 30

M87038

NOTE: Oil control ring is shown being spiraled into compression ring groove.

3/22/00

PISTON INSPECTION

ENGINES â&#x20AC;&#x201C; SINGLE CYLINDER 9. Spiral top oil control ring from oil ring groove into center compression ring groove. Repeat into top compression ring groove, and then off piston. Repeat for bottom oil control ring.

NOTE: If the cylinder is to be resized, there is no reason to check the piston, since a new oversized piston assembly will be used. If however, the cylinder is not to be resized and the piston shows no signs of wear or scoring, the piston rings must be replaced.

PISTON INSPECTION Procedure: 1. Clean carbon from top two ring grooves. 2. Place a new ring in each piston groove.

10. Insert old rings one at a time approximately 25.4 mm (1.0 in.) down into a cylinder bore. M86905

3. If a 0.18 mm (0.007 in.) or larger feeler gauge can be inserted in the compression ring or the oil ring grooves, the compression and ring grooves are worn and the piston should be replaced.

CONNECTING ROD INSPECTION M86906

11. Check end gap with feeler gauge. If ring gap is greater than 0.89 mm (0.035 in.) for compression ring and 1.14 mm (0.045 in.) for oil ring, the ring worn and should be replaced. 12. A worn ring will usually show scratches caused by abrasives and/or have a shiny appearance. Never reuse worn piston rings.

Procedure:

CAUTION

Wear gloves or cover rings with a rag. The top and bottom edges of the ring may be extremely sharp. Personal injury to hand could occur. Never reuse worn piston rings.

NOTE: Before installing new piston rings, the cylinder bore should be reconditioned using a rigid hone with finishing stones. This will restore the proper cross hatch angle in the cylinder bores. The correct cylinder cross hatch ensures proper lubrication and piston ring rotation.

M88925

1. If the crankpin bearing in the connecting rod is scored, the rod must be replaced. Reject size of crankpin bearing and piston pin bearing is as follows: Specifications: Crankpin bearing . . . . . . . . . . . 31.80 mm (1.252 in.) Piston pin bearing . . . . . . . . . . 20.37 mm (0.802 in.) 2. Replace connecting rod if either bore is worn.

3/22/00

3 - 31

CONNECTING ROD INSPECTION

ENGINES â&#x20AC;&#x201C; SINGLE CYLINDER

Top Compression Ring Center Compression Ring Oil Control Ring

M88926

Expander

3. If piston pin is worn 0.01 mm (0.005 in.) out of round or below reject size, it must be replaced. 4. Reject sizes for piston pin and piston pin bore are as follows: Specifications: Piston pin . . . . . . . . . . . . . . . . . 20.29 mm (0.799 in.) Piston pin bore . . . . . . . . . . . . . 20.35 mm (0.801 in.) Notch

M95250

9. The correct piston ring positions are shown above. The top and second compression rings are installed with "ID" mark toward top of piston. 10. Install oil ring expander coil spring first. Spiral oil control ring into top ring groove, then into second ring groove and into position over expander coil spring. 11. Position gap of oil ring expander coil spring approximately 180Â° from oil control ring. 12. Using ring expander, install center compression ring then, top compression ring as shown above. Projections Ring Compressor

M88927 M88929

5. The piston pin is a slip fit in both piston and connecting rod. 6. Use a thin nose pliers or screwdriver and install a piston pin lock in groove on one side of piston. 7. Piston must be installed with notch or arrow toward flywheel side of cylinder. Dot on piston can face either direction. 8. Insert piston pin from opposite side of piston until pin stops against piston pin lock. Then install other piston pin lock. Be sure both locks are seated in grooves. M88930

13. Apply oil to piston rings, piston skirt. 14. Place piston and ring compressor upside down on bench and push down until head of piston and edge of ring compressor are even. 15. Tighten ring compressor until rings are fully

3 - 32

3/22/00

CONNECTING ROD INSPECTION

ENGINES – SINGLE CYLINDER compressed. Then loosen ring compressor very slightly so that compressor can be rotated on piston skirt while holding connecting rod.

NOTE: The pistons have offset piston pin bores. Position the notch or arrow on piston is facing toward the flywheel side of engine.

20.9 N•m (185 lb-in.).

NOTE: Failure to use a torque wrench can result in loose connecting rods causing breakage, or tight connecting rods causing scoring. 22. Rotate crankshaft two (2) revolutions to check for binding. Rod should also be free to slide sideways on crankpin.

Flywheel Side

Specification: Connecting rod screws . . . . . . 20.9 N•m (185 lb-in.)

Circle Projections Down

M88932

16. Thoroughly clean and then oil cylinder bore. 17. Rotate crankshaft until crankpin journal is at bottom of stroke. This permits complete entry of compressed rings, piston and rod assembly, when pushed into cylinder.

Match Marks

M88933

18. Clean and oil crankshaft crankpin. 19. Pull connecting rod against crankpin. 20. Install rod cap with match marks aligned. 21. Install connecting rod screws and tighten to

3/22/00

3 - 33

CYLINDER BORE INSPECTION

ENGINES – SINGLE CYLINDER

CYLINDER BORE INSPECTION

CYLINDER BORE HONING

Procedure:

Top Center

Approximately 45°

45°

Bottom Measure At Six Points

M86885

Center Of Piston Ring Travel M86883

1. Always inspect cylinder after engine has been disassembled. Visual inspection will show if there are any cracks, stripped bolt holes, broken fins or if the cylinder walls are damaged. Use a telescoping gauge, and dial caliper, or an inside micrometer to determine the size of the cylinder bore. Measure at right angles. Specifications: Standard bore size (min.) . . 87.287 mm (3.4365 in.) Standard bore size (max.) . . 87.312 mm (3.4375 in.) 2. If the cylinder bore is more than 0.08 mm (0.003 in.) oversize, or 0.04 mm (0.0015 in.) out of round, it must be resized, or replaced. See “RESIZING CYLINDER BORE” on page 35. 3. If cylinder bores are within specification and show no signs of scoring or other damage, new pistons rings may be installed providing the cylinder bores are reconditioned using a rigid hone with finishing stones. This will restore the proper cross hatch angle in the cylinder bores. The proper cylinder cross hatch ensures proper lubrication and piston ring rotation.

3 - 34

1. The cylinder finish, (Cross Hatch) should be applied after cylinder bore has been resized to within 0.0015 in. of the desired size or when reconditioning a cylinder bore. The finishing stones will produce the correct cross hatch necessary for proper lubrication and piston ring rotation. The correct hatch angle is approximately 45°. 2. It is recommended that the cylinder bores be reconditioned to restore the cross hatch when new piston rings are to be installed in a cylinder that is within specification. Be careful not to hone oversize or it will be necessary to resize the cylinder.

NOTE: To produce the proper cross hatch finish use a drill speed of approximately 200 rpm and 40— 60 strokes per minute. Lubricate hone liberally to prevent build up on finishing stones.

CYLINDER BORE CLEANING IMPORTANT: Ensure that the entire cylinder and crankcase are thoroughly cleaned after honing. First wash the cylinder and crankcase carefully in a solvent such as kerosene or commercial solvent. Then thoroughly wash cylinder and crankcase using a stiff brush with soap and hot water, Rinse thoroughly with hot running water. Repeat washing and rinsing until all traces of honing grit are gone. Honing grit is highly abrasive and will cause rapid wear to all of the internal components of the engine unless it is completely removed.

3/22/00

RESIZING CYLINDER BORE

ENGINES – SINGLE CYLINDER Procedure: 1. When cylinder and crankcase have been thoroughly cleaned, use a clean white rag or napkin and wipe the cylinder bore. If honing grit is present it will appear as a gray residue on rag. If any honing grit is evident, re-wash and rinse entire cylinder and crankcase and check again. When there is no trace of honing grit on rag, the cylinder is properly cleaned. Then oil cylinder bore to prevent rusting.

RESIZING CYLINDER BORE Procedure:

Fixture

Mounting Screws Wear

Ring Travel Unworn Area

Bore

0.750 in. to 1.0 in.

Extreme Hone Travel At Finish

0.750 in. To 1.0 in.

2. If this is done accurately, the service oversize rings and pistons will fit perfectly and proper clearances will be maintained. IMPORTANT: If a boring bar is used, a hone must be used after the boring operation to produce the proper cylinder cross hatch. See “RESIZING CYLINDER BORE” on page 35. 3. If a hone is used to resize the cylinder bore, place hone in middle of cylinder bore. Tighten adjusting knob with finger until stones fit snugly against cylinder wall. DO NOT FORCE. 4. Connect drive shaft to hone. Be sure that cylinder and hone are centered and aligned with drive shaft and drill spindle. Lubricate hone as recommended by hone manufacturer. 5. The recommended drill speed is 300 to 700 rpm maximum and 40-60 strokes per minute. 6. Because cylinder bores normally wear only in the area of ring travel, the cylinder bore will be round above and below ring travel. 7. Start drill and, as hone spins, move it up and down at the bottom of the cylinder bore. 8. Gradually increase the length of the strokes until hone travels full length of cylinder bore. Do not travel more than 19.05 mm (0.750 in.) to 25.4 mm (1.0 in.) above cylinder bore. 9. Lubricate hone frequently to prevent build up on stones. 10. As cutting tension decreases, stop hone and tighten adjusting knob following hone manufacturer’s recommendations. 11. Check cylinder bore size frequently. 12. Check cylinder bores at top and bottom for burrs. Remove burrs. Cylinder head and crankcase cover surfaces must be free of burrs and gasket material. 13. After cylinder bore has been brought to proper resizing dimension, a cross hatch must be applied to bore. See “RESIZING CYLINDER BORE” on page 35.

Hone Travel At Start

M88942

3 - 35

FLYWHEEL REMOVAL AND INSTALLATION FLYWHEEL REMOVAL AND INSTALLATION

ENGINES – SINGLE CYLINDER

6. Flywheel should be inspected for cracks, broken flywheel fins, burrs on taper or keyway and distortion of keyway. Also check taper of crankshaft for burrs, rust or other damage. Replace crankshaft, if damaged. 7. Before installing flywheel, clean taper and crankshaft taper removing all oil, dirt or grease. 8. Install flywheel. 9. Install flywheel nut.

Procedure: 1. Remove blower housing. 2. Remove rotating screen.

Strap Wrench

24.0 mm Socket M88863 M88864

3. Place flywheel strap wrench around outer rim of flywheel. Insert 1/2 in. breaker bar into drive end of strap wrench and wind clockwise to remove slack in strap. While holding breaker bar, loosen flywheel nut using 24 mm socket and wrench.

10. Place Flywheel Strap Wrench around outer rim of flywheel. Insert 1/2 in. breaker bar into drive end of strap wrench and wind counterclockwise to remove slack in strap. While holding strap, tighten flywheel nut to 115.6 N•m (85 lb-in.). Specification:

Flywheel Puller

Flywheel nut . . . . . . . . . . . . . . . 115.6 N•m (85 lb-in.)

CRANKSHAFT AND CAM GEAR REMOVAL Procedure:

M87011

4. Install Flywheel puller turning puller screws into flywheel puller holes evenly. Tighten puller screws equally until flywheel loosens. IMPORTANT: Protect crankcase threads during flywheel removal.

NOTE: Before crankcase cover is removed, it is recommended that any rust, paint or burrs be removed from power take off end of crankshaft. This will eliminate or reduce chances of damaging the crankcase cover bearing. 1. Drain oil from crank case. 2. Remove flywheel. See “FLYWHEEL REMOVAL AND INSTALLATION” on page 36. 3. Remove crankcase cover. If crankcase cover sticks, tap lightly with soft hammer on alternate sides near dowel pins.

5. Remove flywheel.

3 - 36

3/22/00

CRANKSHAFT AND CAM GEAR REMOVAL

ENGINES â&#x20AC;&#x201C; SINGLE CYLINDER IMPORTANT: DO NOT remove dowel pins.

4. Tip engine over onto flywheel side of crankcase. 5. Support engine to prevent end of crankshaft from resting on workbench. 6. Rotate crankshaft until timing marks are aligned. With cam gear in this position, the valve tappets will remain clear of cam lobes.

10. Check timing gear for chipped or cracked teeth and keyway for wear. Replace timing gear, if damaged. If timing gear is chipped or cracked, also check cam gear for damage. 11. Replace crankshaft if worn or if journals are scored. Keyways should be checked to be sure they are not worn or spread. Remove burrs from keyway edges to prevent damaging the bearing or oil seal. Gear Teeth P.T.O. Journal

Timing Marks

Mag. Journal

M88934

7. Lift out cam gear and governor assembly. 8. Remove piston and connecting rod assemblies. 9. Remove crankshaft from crankcase. IMPORTANT: If engine is rotated from this position, tappets will fall out. Tappets must not be mixed.

Exhaust Intake

M88937

12. Inspect cam gear teeth, lobes and journals for wear and nicks. Cam gear journal and lobe reject sizes are as follows: Specifications:

Timing Gear Teeth Mag. Journal

Crankpin

PTO journal . . . . . . . . . . . . . . . . 12.65 mm (0.498 in.) MAG. journal . . . . . . . . . . . . . . . 12.65 mm (0.498 in.) Cam Lobes . . . . . . . . . . . . . . . . 30.07 mm (1.184 in.)

PTO Journal

M88935

IMPORTANT: The various wear points on the crankshaft must be measured. Specifications: PTO journal. . . . . . . . . . . . . . . . 34.95 mm (1.376 in.) MAG. journal. . . . . . . . . . . . . . . 34.95 mm (1.376 in.) Crankshaft crankpin . . . . . . . . 31.50 mm (1.247 In.) 3/22/00

3 - 37

CRANKSHAFT AND CAM GEAR INSTALLATION CRANKSHAFT AND CAM GEAR INSTALLATION

ENGINES – SINGLE CYLINDER

10. Place seal protector in magneto crankshaft seal.

Procedure: 1. Install intake and exhaust valve tappets. 2. Slide magneto side counterweight onto crankshaft. Tighten to

13 N•m (115 lb-in.)

PTO Side Counterweight Crankcase Link Pin Rounded Side Up

Link

M95258

Link Eccentric Dowel Pin

Mag Side Counterweight Vise with Brass Jaws

M95257

3. Place crankshaft and counterweight in a vise with soft vise jaws or shop rags to protect magneto journal. 4. Slip link over dowel pin with rounded edge of free end up. 5. Slide PTO side counterweight onto dowel pin and crankshaft eccentric. 6. Install screw and tighten to 13 N•m (115 lb-in.). 7. Rotate crankshaft to check for binding. If binding exist, loosen screw and re-tighten screw and check again. 8. If woodruff key was removed, install in crankshaft.

11. Place crankshaft and counterweight assembly into block and start magneto journal into magneto bearing. 12. Align link with crankcase link pin and push into place. 13. Install connecting rod on crankshaft. 14. Install cam gear, making sure tappets clear cam lobes. 15. Timing marks must be aligned. 16. Install governor and oil slinger assembly. See “GOVERNOR REMOVAL AND INSTALLATION” on page 27. 3

Sealant

9 7 5

2 4 10

8 M95235

Timing Gear

Woodruff Key

Timing Mark M95255

9. Slide timing gear onto crankshaft with chamfer toward eccentric.

3 - 38

17. Place new crankcase cover gasket on crankcase. 18. Take care to protect the oil seal while assembling crankcase cover. No force should be used. 19. Tighten cover bolts to 15.8 N•m (140 lb-in.) using the sequence shown. 20. Install cylinder heads. See “CYLINDER HEAD REMOVAL AND INSTALLATION” on page 23. 21. Install flywheel. See “FLYWHEEL REMOVAL AND INSTALLATION” on page 36.

3/22/00

MAGNETO BEARING INSPECTION

ENGINES – SINGLE CYLINDER 22. Install intake manifold and carburetor assembly. See “CARBURETOR REMOVAL AND INSTALLATION” on page 17. 23. Install governor lever and governor springs. See “GOVERNOR REMOVAL AND INSTALLATION” on page 27. 24. Install oil fill tube and dipstick assembly. 25. Perform static governor adjustment. See “GOVERNOR ADJUSTMENT-STATIC” on page 13. 26. Install engine shrouding. See “UPPER BLOWER HOUSING REMOVAL AND INSTALLATION” on page 16. 27. Install air filter assembly. See “AIR CLEANER SERVICE” on page 16.

3. Lubricate outside surface of bearing and place on inside of block. Split in Bearing

Stake Area

M95259

MAGNETO BEARING INSPECTION 1. When checking the main magneto bearing, it should be replaced if scored or if not within specification. Specification: Magneto bearing reject size . . 35.13 mm (1.383 in.)

4. Position bearing with split line away from stake grooves. 5. Using an arbor press and bushing driver, press in bearing until 2.78 mm (0.109 in.) below surface of block. Staked

M95261 M95251

2. Support cylinder block on arbor press and using bushing driver. Press out bearing toward inside of the block.

Bearing Driver Crankcase

6. Stack new bearing into bearing bushing. 7. Install new oil seal using a cylinder support. Press in seal until it is flush with mounting surface. 8. When installing new magneto side oil seal, properly support cylinder. Press in seal until it is 1.5 mm (0.0625 in.) below mounting surface. 9. The cylinder block must be replaced if the cam gear bearing dimensions exceed reject size.

Bearing

Support M95260

3/22/00

3 - 39

CAM GEAR BEARING INSPECTION

ENGINES â&#x20AC;&#x201C; SINGLE CYLINDER

CAM GEAR BEARING INSPECTION

Edge of Bearing

45 Degrees

Notch M95252 M95253

1. Measure cam gear bearing. 2. Bearing is worn more then 12.80 mm (0.504 in.) the cylinder, crankcase cover, or sump must be replaced.

PTO BEARING REMOVAL AND INSTALLATION

2. With a chisel or screwdriver and hammer, make a notch in bearing pocket opposite the split in bearing pocket. 3. Lubricate outside surface of bearing and place on inside of cover with 4. Using an arbor press and bushing driver, press in bearing until 3.18 mm (0.125 in.) below surface of cover.

Removal:

Bearing Driver Crankcase

Stake Bearing in Notch

Bearing M95254

Support M95260

1. Support crankcase cover on arbor press and using bushing driver. Press out bearing toward inside of the cover.

5. Stake new bearing into notch created earlier. 6. Install new oil seal using a cylinder support. Press in seal until it is flush with mounting surface. 7. When installing new PTO oil seal, properly support cylinder. Press in seal until it is 1.5 mm (0.0625 in.) below mounting surface. 8. The crankcase cover must be replaced if the cam gear bearing dimensions exceed reject size. Specifications: PTO bearing . . . . . . . . . . . . . . . 20.04 mm (0.789 in.)

NOTE: Always install new oil seals whenever engine is disassembled for major servicing or when repairing bearings. Always use the correct seal protector to prevent damaging oil seal.

3 - 40

3/22/00

CONTENTS

ENGINE – Briggs & Stratton V–TWIN

CONTENTS Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TESTS AND ADJUSTMENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TORQUE SPECIFICATIONS (Alphabetical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ENGINE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 THROTTLE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 CHOKE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 FUEL SHUTOFF SOLENOID TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 COMPRESSION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 GOVERNOR ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SLOW IDLE CARBURETOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 FAST IDLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 CYLINDER BALANCE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 ENGINE OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 UPPER BLOWER HOUSING REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . 18 AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 CARBURETOR REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 CARBURETOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 CARBURETOR INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 CARBURETOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ENGINE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 CYLINDER AIR GUIDES REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . 28 CYLINDER HEAD REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29 CYLINDER HEAD INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 VALVES REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 VALVES INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 VALVES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 PISTON REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 CONNECTING ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 CYLINDER BORE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 CYLINDER BORE HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 CYLINDER BORE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 RESIZING CYLINDER BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 FLYWHEEL REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 CRANKSHAFT REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 MAGNETO BEARING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 PTO BEARING REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 BREATHER VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2/29/00

4-1

CONTENTS CONTINUED

ENGINE – Briggs & Stratton V–TWIN

Page OIL PUMP REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4-2

2/29/00

ENGINE – Briggs & Stratton Briggs & Stratton V–TWIN

SPECIFICATIONS

SPECIFICATIONS GENERAL SPECIFICATIONS 16 Horsepower: Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs & Stratton Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vanguard V-Twin Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 916928 Gasoline Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303777 Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.93 kW (16.0 hp) Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480 cm3 (29.3 cu. in.) Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 mm (2.68 in.) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 mm (2.60 in.) Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurized 69 – 344 kPa (10 – 50 psi) Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Flow Filter (w/o By-Pass Valve) Crankcase Capacity w/o Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.42 L (1.5 U.S. qt) w/ Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.65 L (1.7 U.S. qt) Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper with outer foam element Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal discharge below frame Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Normal Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable (In-Line Type) 18 Horsepower: Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs & Stratton Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vanguard V-Twin Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 916928 Gasoline Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350777 Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.42 kW (18.0 hp) Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570 cm3 (34.7 cu. in.) Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 mm (2.83 in.) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 mm (2.76 in.) Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurized 69 – 344 kPa (10 – 50 psi) Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Flow Filter (w/o By-Pass Valve) Crankcase Capacity w/o Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.42 L (1.5 U.S. qt) w/ Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.65 L (1.7 U.S. qt) Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper with outer foam element Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal discharge below frame Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Normal Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable (In-Line Type)

3/22/00

4-3

TESTS AND ADJUSTMENTS SPECIFICATIONS

ENGINE – Briggs & Stratton V–TWIN

TESTS AND ADJUSTMENTS SPECIFICATIONS Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 – 0.16 mm (0.004 – 0.006 in.) Valve Guide Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 mm (0.281 in.) Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750 ±100 rpm Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 ±50 rpm Oil Pump Operating Pressure . . . . . . . . . . . . . . . . . . . . . . . . 69 – 344 kPa (10 – 50 psi) Spark Plug Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.) Armature Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 – 0.30 (0.008 – 0.012 in.)

REPAIR SPECIFICATIONS Valves: Valve Guide Standard Dimension . . . . . . . . . . . . . . . 6.01 – 6.02 mm (0.236 – 0.237 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.05 mm (0.238 in.) Valve Stem Standard Dimension Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.94 – 5.96 mm (0.234 – 0.235 in.) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.94 – 5.95 mm (0.234 – 0.235 in.) Valve stem Wear Limit Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.92mm (0.233 in.) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.91mm (2.328 in.) Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 1.6 mm (0.047 – 0.062 in.) Valve Margin (Min) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 mm (0.016 in.) Valve Face Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Valve Seat Narrowing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Cylinder Bore, Pistons and Rings: 16 HP Cylinder Bore Standard Dimension . . . . . . . 68 – 68.025 mm (2.677 – 2.678 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.065 mm (2.6795 in.) 18 HP Cylinder Bore Standard Dimension . . . . . . . 72 – 72.025 mm (2.834 – 2.835 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.065 mm (2.837 in.) Piston Pin Standard Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.07 mm (0.672 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.06 mm (0.671 in.) Piston Pin Bore Standard Dimension . . . . . . . . . . . . . . . . . . . . . . . 17.10 mm (0.673 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.12 mm (0.674 in.) Ring End Gap Standard Dimension . . . . . . . . . . . . . 0.20 – 0.40 mm (0.008 – 0.016 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.) Compression Ring Groove Wear Limit (New Ring Installed). . . . . . . 0.10 mm (0.004 in.) Oil Ring Groove Clearance Wear Limit (New Ring Installed) . . . . . . 0.20 mm (0.008 in.) Connecting Rod and Crankshaft: Connecting Rod Crankpin Standard Dimension . 37.06 – 37.08 mm (1.459 – 1.460 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.12 mm (1.461 in.) Connecting Rod Piston Pin Bearing Std. Dimension . . . . . . . . . . . 17.10 mm (0.673 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.12 mm (0.674 in.) Crankshaft PTO Journal Standard Dimension . . . 34.96 – 34.97 mm (1.376 – 1.377 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.92 mm (1.375 in.) Crankshaft Magneto Journal Standard Dimension 34.99 – 35.01 mm (1.377 – 1.378 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.95 mm (1.376 in.) Magneto Bearing Standard Dimension . . . . . . . . 35.02 – 35.06 mm (1.379 – 1.3805 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.12 mm (1.383 in.) PTO Bearing Standard Dimension . . . . . . . . . . . . 35.04 – 35.05 mm (1.379 – 1.380 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.07 mm (1.381 in.)

4-4

3/22/00

ENGINE – Briggs & Stratton V–TWIN

TORQUE SPECIFICATIONS (Alphabetical)

Crankpin Standard Dimension . . . . . . . . . . . . . . . . 37.0 – 37.02 mm (1.456 – 1.457 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.95 mm (1.455 in.) Crankshaft End Play. . . . . . . . . . . . . . . . . . . . . . . . . 0.08 – 0.40 mm (0.003 – 0.015 in.) Cam Gear PTO Journal Standard Dimension . . . 19.94 – 19.96 mm (0.785 – 0.786 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.92 mm (0.784 in.) Cam Gear Magneto Journal Standard Dimension 15.95 – 15.97 mm (0.628 – 0.629 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.93 mm (0.627 in.) Cam Lobe Standard Dimension . . . . . . . . . . . . . . 30.33 – 30.53 mm (1.194 – 1.202 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.25 mm (1.191 in.) Cam Bearing (Magneto Side) Standard Dimension16.0 – 16.025 mm (0.630 – 0.631 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.08 mm (0.633 in.) Cam Bearing (PTO Side) Standard Dimension . . . 20.0 – 20.02 mm (0.787 – 0.788 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.04 mm (0.789 in.)

TORQUE SPECIFICATIONS (Alphabetical) Alternator to Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Nm (20 lb in.) Air Cleaner Base to Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 N•m (65 lb-in.) Connecting Rod Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 N•m (115 lb-in.) Cooling Fan Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (150 lb-in.) Crankcase Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (150 lb-in.) Cylinder Head Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 N•m (165 lb-in.) Cylinder Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 N•m (65 lb-in.) Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (150 lb-in.) Flywheel Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 N•m (125 lb-ft) Fuel Shutoff Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 N•m (45 lb-in.) Governor Lever Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (70 lb-in.) Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 N•m (140 lb-in.) Oil Breather Mounting Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 N•m (30 lb-in.) Oil Filter Adaptor Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 N•m (65 lb-in.) Oil Pump Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 N•m (65 lb-in.) Rocker Arm Adjustment Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 N•m (65 lb-in.) Rocker Arm Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 N•m (140 lb-in.) Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.) Starting Motor Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 N•m (140 lb-in.) Valve Cover Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 N•m (25 lb-in.)

3/22/00

4-5

TROUBLESHOOTING

ENGINE – Briggs & Stratton V–TWIN

Starting motor/solenoid defective

●

Improper switch position (See Electrical Section)

●

Engine seized

●

Fuel shutoff solenoid defective

●

Fuel filter/lines clogged

●

Fuel pump defective

●

Ignition coil air gap not adjusted properly

●

Carburetor not adjusted properly, dirty

●

Air cleaner dirty

●

Old/contaminated fuel

●

Spark plugs loose/dirty

●

Magneto kill circuit grounded/ shorted (See Electrical Section)

●

Valve tappets need adjustment

●

Lack of compression, check valves, pistons and rings

●

Magneto kill circuit open (See Electrical Section)

Fuel mixture too rich

●

Engine overheats

Fusible link (F1) open

Engine running on one cylinder

●

Low oil pressure

●

Excessive engine noise/vibration

Engine starts hard

●

Low compression

Engine cranks but will not start

Battery has low or no charge/ cables loose or dirty

Check or Solution

Loss of power

Engine will not crank

Problem or Symptom

Engine won’t shutoff

TROUBLESHOOTING

●

● ●

●

● ●

●

Mower deck binding or dragging

●

Grass build-up under deck

●

4-6

3/22/00

No lubrication in gear box or hydro/transaxle

●

● ●

Deck spindles seized

●

Loose cylinder head bolts

●

Defective head gasket

●

Warped cylinder head

●

Worn bore and/or rings

●

Broken connecting rod

●

Cutter blade or other rotating part bent or out of balance

●

Mounting bolts loose

●

Camshaft worn

●

Internal bearings worn or excessive tolerance

●

Oil galleries/filter clogged

●

Oil pump defective

●

Low oil level or wrong viscosity

●

Exhaust system restricted

Fuel mixture too rich

●

Excessive drive belt tension

Burned valves, valve seats, and/or loose valve seats

Engine overheats

Engine running on one cylinder

Excessive engine noise/vibration

Low compression

Loss of power

Engine won’t shutoff

Engine starts hard

Engine cranks but will not start

Check or Solution

Engine will not crank

Problem or Symptom

Low oil pressure

TROUBLESHOOTING

ENGINE – Briggs & Stratton V–TWIN

●

● ●

Air/fuel mixture excessively lean

●

Cylinder cooling fins/blower housing filled with grass clippings

●

Overchoking

●

Float needle stuck open

●

3/22/00

4-7

ENGINE TROUBLESHOOTING

ENGINE – Briggs & Stratton V–TWIN

ENGINE TROUBLESHOOTING Engine Will Not Crank

NOTE: To test specific electrical components, see Electrical Section and refer to either Diagnostics or Tests and Adjustments for further guidance.

Check battery voltage. Is battery voltage 12.4 VDC or higher?

CAUTION

BE AWARE! The engine may start to rotate at any time. Keep hands away from all moving parts when testing.

Charge battery and perform a no-load test. Is battery voltage 12.4 VDC or higher?

• Battery defective

YES

Does starting motor solenoid click when ignition switch is turned to START position?

YES

• Fusible link open • Starting motor solenoid defective • Defective switches or wiring

See Electrical Troubleshooting

• Engine seized • Starting motor solenoid defective • Starting motor pinion gear sticking or damaged • Starting motor defective

Repair or replace

4-8

3/22/00

ENGINE TROUBLESHOOTING

ENGINE – Briggs & Stratton V–TWIN

Engine Cranks But Will Not Start

CAUTION

DO NOT rotate engine with starter if the spark plugs are removed. Gasoline spray from the open cylinders may be ignited by ignition spark and cause an explosion or fire.

Check battery voltage. Is battery voltage 12.4 VDC or higher?

NOTE: To test specific electrical components, see Electrical Section and refer to either Diagnostics or Tests and Adjustments for further guidance.

Charge battery and perform a no-load test. Is battery voltage 12.4 VDC or higher?

YES

Does fuel shutoff solenoid click when ignition switch is turned to START/RUN position?

• Battery defective

• Defective fuel shutoff solenoid • Defective switches or wiring

See Electrical Troubleshooting Does engine have internal resistance?

YES

Does engine crank slow?

YES

NOTE: Remove spark plugs and turn engine over by hand. Engine should rotate freely with little

(less than 350 rpm) NO

Is choke operating properly?

Adjust

• Piston rings or other internal components binding

Repair or replace YES

• Starting motor defective

Do spark plugs have a strong blue spark?

YES

Are tappets adjusted properly?

YES YES

Adjust

• Defective spark plugs • Magneto kill circuit shorted to ground • Flywheel magnet weak • Ignition coil air gap not adjusted properly

• Air cleaner plugged • Excessively rich fuel mixture • Water in fuel • Float needle stuck open

See Electrical Troubleshooting

• Not enough compression

Is engine getting fuel?

3/22/00

• Fuel shutoff valve closed • Fuel lines/vent plugged • Fuel pump defective • Insufficient engine vacuum

See Tests and Adjustments

4-9

ENGINE TROUBLESHOOTING Engine Runs Erratically/Loss Of Power IMPORTANT: Before proceeding, inspect the mower deck and belts for binding in the spindle assemblies or belts that are too tight/loose. A loose belt like a loose blade can cause a backlash effect that will counteract engine cranking effort. Excessive drive belt tension may cause premature bearing wear or result in bearing seizure. Grass clippings that build up near the cutting blades can cause excessive resistance and heat build-up that causes problems with the engine’s ability to turn the blades at a constant speed. Low lubricant levels in the spindles will build-up heat causing excessive resistance for the engine to deal with.

Perform a Cylinder Balance Test to determine if the problem is with one cylinder or both cylinders. Does the problem exist in just one cylinder?

ENGINE – Briggs & Stratton V–TWIN There is a diode in-line in the magneto kill wire coming from each ignition module. This diode prevents feedback from one module to the other. Without these diodes, one magneto could fire the coil for the other magneto. If a diode fails in one of the magneto kill wires, that coil, could be fired by the other module, the result may be similar to that of an erratic running engine. A twin cylinder engine may run adequately on one cylinder as long as the power required for the application does not exceed the power produced by the one cylinder.

NOTE: To test specific electrical components, see Electrical Section and refer to either Diagnostics or Tests and Adjustments for further guidance.

• Defective spark plug

YES

• Carburetion • Crankcase vacuum • Ignition Timing • Governor operation • Camshaft

4 - 10

See Tests and Adjustments

3/22/00

TESTS AND ADJUSTMENTS

ENGINE – Briggs & Stratton V–TWIN

TESTS AND ADJUSTMENTS THROTTLE CABLE ADJUSTMENT Reason: To make sure the throttle cable moves the throttle through its full range of movement. Choke Cable

Procedure: 1. Remove air cleaner assembly, and base. 2. Install nuts on carburetor studs. 3. Move throttle lever to FAST idle position.

M92400

2. Loosen choke cable clamp. 3. Move choke cable until choke is completely closed. 4. Tighten choke cable clamp.

FUEL SHUTOFF SOLENOID TEST Governor Control Swivel

Reason: To test proper operation of fuel shutoff solenoid. Required Tools: • Jumper wire Throttle Cable M92400

Procedure: 4. Loosen throttle cable clamp. 5. Move throttle cable until governor control swivel is at end of travel. 6. Tighten throttle cable clamp.

CHOKE CABLE ADJUSTMENT Reason: To make sure the choke cable moves the choke through its full range of movement. Procedure: 1. Move choke lever to full choke position.

1. Remove air cleaner assembly, and base. 2. Install nuts on carburetor studs. 3. Listen for an audible click when ignition switch is turned from OFF to ON. 4. If solenoid does not click, problem could be in equipment wiring. 5. Disconnect wire from solenoid. 6. Momentarily place a jumper wire from solenoid wire to battery positive terminal. 7. If solenoid now clicks, the solenoid is working properly.

3/22/00

4 - 11

COMPRESSION TEST

ENGINE – Briggs & Stratton V–TWIN

COMPRESSION TEST

6. Use the following example and insert the recorded readings to determine the percent of leakage between cylinders.

Reason: To determine the performance difference between cylinders. Required Tools:

Example: cyl #1

cyl #2

75 psi

55 psi

Formula:

55 ÷ 75 = 0.7333 x 100 = 73.333, 100 - 73.333 = 26.7%

• JDM59 Compression Gauge

NOTE: Briggs & Stratton does not publish any compression pressures, as it is extremely difficult to obtain an accurate reading without special equipment. What is recommended is to calculate the difference in compression readings between the two cylinders. Two methods are given in the following; one without a cylinder leak tester and one with a cylinder leak tester.

WITHOUT CYLINDER LEAK TESTER IMPORTANT: The battery must be fully charged for this test. Check and adjust the valves to ensure the valves have not been adjusted too tight. If either valve is off its seat the leak test will be invalid. 1. The engine should be run for at least 5 minutes to bring the engine to operating temperature. 2. Remove spark plugs and ground the magnetos by attaching a jumper wire from the magneto kill circuit connector to the engine to prevent a spark that could ignite anything combustible.

Highest Reading Lowest Reading

Results: • A difference of more than 25% indicates a loss of compression in the cylinder with the lowest reading.

WITH CYLINDER LEAK TESTER Required Tools: • JTO3502 Cylinder Leak Tester • Breaker Bar and 30 mm Socket

NOTE: If the directions that come with the tester being used are different than the following, use the directions that came with the tester. IMPORTANT: Check and adjust the valves to ensure the valves have not been adjusted too tight. If either valve is off its seat the leak test will be invalid. 1. The engine should be run for at least 5 minutes to bring the engine to operating temperature.

Compression Gauge

CAUTION

With spark plugs removed, the magnetos must be grounded to the engine to prevent a spark that could ignite anything combustible. M88958

3. Insert a compression gauge into either cylinder. 4. Turn engine over with the starter until the highest pressure reading is obtained and record reading. 5. Repeat steps 3 and 4 with the next cylinder and record reading.

4 - 12

2. Remove spark plugs and ground the magnetos by attaching a jumper wire from the magneto kill circuit connector to the engine to prevent a spark that could ignite anything combustible.

3/22/00

GOVERNOR ADJUSTMENT

ENGINE – Briggs & Stratton V–TWIN IMPORTANT: The piston must be positioned at Top Dead Center (TDC) to ensure that the intake valves are away from the compression relief balls. If not, the intake valve will be open and the leak test will be invalid. 3. Remove valve covers. 4. Remove the rotating screen. 5. Turn crankshaft until piston is at Top Dead Center (TDC), on the compression stroke (Both Valves Closed). 6. Screw the adaptor into the spark plug hole but do not attach it to the tester at this time.

Regulator Tester

Air Line M88974

7. Pull back the locking ring and rotate the regulator knob fully counterclockwise. Connect an air line to the tester. IMPORTANT: The air supply must have enough supply pressure to calibrate the tester (Usually 586 – 655 kPa (85 – 95 psi)). 8. Pull back the locking ring and rotate the regulator knob clockwise until the gauge needle rests in the SET range of the gauge. Push the locking ring towards the tester to lock it.

9. Connect the adaptor hose to the tester and record the needle position while holding the flywheel in position with a breaker bar.

NOTE: A small amount of air escaping from the crankcase breather is normal. Results: • Excessive air escaping from the crankcase breather indicates worn piston rings or cylinder wall • Air escaping from the carburetor indicates a worn intake valve or seat • Air escaping from the exhaust pipe indicates a worn exhaust valve or seat • Gauge reading in the Green (low) area indicates good compression. (Less Than 25% Is Considered Normal) • Gauge reading in the Yellow (Moderate) area indicates borderline compression. The engine is still usable but an overhaul or replacement should be considered • Gauge reading in the Red (High) area indicates excessive compression loss and engine reconditioning or replacement is necessary

GOVERNOR ADJUSTMENT

CAUTION

STATIC ADJUSTMENT (Engine OFF)

NOTE: All linkage must be installed to make adjustment. Tester

Procedure:

Breaker Bar

Hose M88957

3/22/00

4 - 13

SLOW IDLE CARBURETOR ADJUSTMENT

ENGINE – Briggs & Stratton V–TWIN

Throttle Restrictor Tang Governor Shaft

Lever Bolt Idle Tang

Governor Lever

Lever

M92396

M89124

1. Remove: • Hood • Top muffler shield • Air cleaner assembly 2. Loosen governor lever bolt and nut. 3. Push on governor lever until throttle is wide open. IMPORTANT: Do not bend governor link or distort governor lever.

2. Bend governor idle tang to obtain a slow idle of 1750 rpm. 3. With throttle lever in SLOW idle position and engine running at governed idle, bend throttle restrictor tang so that it just contacts the governor lever.

Fast Idle Tang

4. Hold lever in this position and rotate governor shaft counterclockwise as far as it will go. Hold lever and shaft in position and torque governor lever bolt and nut to 8 N•m (70 lb-in.). Specification: M92397

Lock nut . . . . . . . . . . . . . . . . . . . . . . 8 N•m (70 lb-in.) DYNAMIC ADJUSTMENT (Engine Running)

4. Move throttle lever to FAST idle position and bend fast idle tang to obtain top no load engine speed of 3300 rpm.

Equipment: • Pulse Tachometer JT07270

SLOW IDLE CARBURETOR ADJUSTMENT

NOTE: Carburetor mixture adjustments must be made before adjusting governed idle, throttle restrictor and top no load rpm adjustments.

Reason:

Procedure:

To set the carburetor mixture screws for proper operation of the carburetor.

1. Move throttle lever to SLOW idle position. Equipment: • JT07270 Pulse Tachometer IMPORTANT: In order to obtain correct operation of the carburetor, the adjustment procedure

4 - 14

3/22/00

SLOW IDLE CARBURETOR ADJUSTMENT

ENGINE – Briggs & Stratton V–TWIN must be performed in the sequence shown. INITIAL ADJUSTMENT

Idle Mixture Screw

Procedure: 1. Remove air cleaner assembly, and base. 2. Install nuts on carburetor studs. 3. Remove limiter cap. 4. Turn idle mixture screw clockwise until it just seats. DO NOT FORCE. 5. Turn screw 1 ¼ turns counter-clockwise. This setting will allow the engine to start. FINAL ADJUSTMENT

M92398

NOTE: All carburetor adjustments with engine running must be made with the air cleaner installed. 6. Install air cleaner base and air cleaner. 7. Start and run engine for 5 minutes to allow engine to reach operating temperature. 8. Move throttle lever to SLOW idle position. Idle Speed Screw

11. Turn idle mixture screw slowly clockwise until engine speed just starts to slow (Lean Mixture). 12. Turn idle mixture screw slowly counter-clockwise until engine speed just starts to slow (Rich Mixture). 13. Turn screw to the midpoint between rich and lean settings. 14. Hold throttle lever against idle speed adjustment screw and readjust idle speed to 1200 rpm. 15. Release throttle lever and note rpm.

Throttle Restrictor Tang

M92399

9. Install pulse tachometer 10. Hold throttle lever against idle speed screw and temporarily adjust idle speed to 1400 rpm.

Idle Tang

Governor Lever M92396

16. If necessary bend idle tang to obtain 1750 rpm. 17. Position limiter cap so that stops on limiter cap are at midpoint between stops on carburetor. 18. With throttle lever in the SLOW position and engine running at governed idle rpm, bend throttle restrictor tang so that it just contacts governor lever. 19. Move throttle lever to FAST position. 20. Engine should accelerate smoothly. If necessary, readjust idle mixture screw 1/8 turn counterclockwise (Richer Mixture). 3/22/00

4 - 15

FAST IDLE ADJUSTMENT

ENGINE – Briggs & Stratton V–TWIN

FAST IDLE ADJUSTMENT

VALVE CLEARANCE ADJUSTMENT

Equipment:

NOTE: Correct position of crankshaft is necessary to eliminate interference by the compression release mechanism on the cam gear when adjusting valve clearance.

• JT07270 Pulse Tachometer

NOTE: Carburetor mixture adjustments must be made before adjusting governed idle, throttle restrictor and top no load rpm adjustments. Procedure: 1. Move throttle lever to SLOW idle position.

1. Remove valve cover. 2. Turn crankshaft until piston is at Top Dead Center, (TDC) on the compression stroke (Both Valves Closed). 3. Insert a screwdriver through the spark plug opening until it touches the top of the piston. 4. Continue to turn the crankshaft clockwise until the piston has moved down 6.35 mm (0.25 in.).

Throttle Restrictor Tang 5 mm Hex Wrench

Idle Tang

Governor Lever

Feeler Gauge M92396

5. Check valve clearance with a feeler gauge between valve stem and rocker arm. Valve clearance should be 0.10 – 0.16 mm (0.004 – 0.006 in.). 6. If not, adjust as necessary using a 13 mm open end wrench and a 5 mm hex wrench. Tighten lock nut to 7 N•m (60 lb-in.). 7. Recheck clearance and make adjustments if necessary. 8. Install valve cover.

Fast Idle Tang

M92397

4. Move throttle lever to FAST idle position and bend fast idle tang to obtain top no load engine speed of 3300 rpm.

4 - 16

Specifications: Lock nut . . . . . . . . . . . . . . . . . . . . . . 7 N•m (60 lb-in.) Valve Clearance . 0.10 – 0.16 mm (0.004 – 0.006 in.)

3/22/00

CYLINDER BALANCE TEST

ENGINE – Briggs & Stratton V–TWIN

CYLINDER BALANCE TEST Reason: If engine is hard starting, runs rough, misses or lacks power, perform a cylinder balance test. To determine if both cylinders are operating to their full potential.

7. Ground out one cylinder with screw driver. Note rpm on tachometer. 8. Remove screw drive and allow engine to recover. 9. Ground second cylinder with screw driver. Note rpm on tachometer. Results: • If the difference between the two cylinders is less than 75 rpm, the cylinders should be considered equal • If the difference between the two cylinders is greater than 75 rpm, this indicates that the cylinder with the least rpm loss is weakest, and should be considered as the possible problem

Equipment: • D053515T Spark tester • JT07270 Engine tachometer • Screw driver with insulated handle Procedure:

ENGINE OIL PRESSURE TEST

High Tension Lead

Reason:

Spark Plug

To verify that the engine has enough oil pressure to lubricate the internal engine components. Equipment:

Spark Tester

M88975

1. Disconnect spark plug high tension lead. 2. Connect spark tester to spark plug and high tension lead. 3. Start engine and note spark at tester. Shut engine off. 4. Repeat steps 1 – 3 for second cylinder. 5. Connect engine tachometer. 6. Start engine and run at top no load speed. Note rpm on tachometer. . Ground Screw Driver

• JT07262 Oil Pressure Test Adapter w/ O-ring (required ONLY on engines without test ports) • JT05847 Connector • JT03017 Hose Assembly • JT03262 Coupler • JT07034 Gauge, 0 – 700 kPa(0 – 100 psi)

NOTE: The connector, hose assembly, coupler, and gauge are found in other SERVICEGARD™ test kits. The connector pipe thread (NPT) also matches the oil pressure switch port on early Kohler engines. Test Procedure At Oil Filter Base: 1. Perform test procedure with engine level. 2. Stop engine. 3. Disconnect spark plug wire and allow engine to cool. 4. Drain engine oil from oil filter. 5. Remove oil filter and wipe filter base clean. 6. Install pre-assembled adapter, connector, hose assembly, coupler, and gauge on to oil filter base. ONLY hand-tighten adapter to oil filter base. 7. Check crankcase oil level and adjust to full mark.

Spark Plug

M88976

3/22/00

4 - 17

REPAIR

ENGINE – Briggs & Stratton V–TWIN

REPAIR JTO7034 Gauge

JTO3262 Coupler

JTO3017 Hose Assembly

UPPER BLOWER HOUSING REMOVAL AND INSTALLATION JTO7262 Oil Pressure Adapter w/ O-ring

Procedure:

JTO5847 Connector Blower Housing

M91215

8. Monitor oil pressure during cranking, if oil pressure is below 28 kPa (4 psi) – STOP engine immediately and correct cause before continuing. 9. Connect spark plug wire. 10. Warm-up engine by running at MEDIUM idle for five minutes.

CAUTION

Engine components are HOT. DO NOT touch with bare skin. Wear protective eye glasses and clothing. 11. Record oil pressure readings at SLOW and FAST idle. 12. Stop engine and allow to cool. 13. Remove adapter, connector, hose assembly, coupler, and gauge. 14. Install new oil filter. 15. Run engine for 30 seconds and stop engine. 16. Check crankcase oil level and adjust to full mark.

M87009

1. Remove rotating screen. 2. Remove fuel pump and bracket. 3. Disconnect upper bolt on dipstick tube. 4. Remove top carburetor access plate. 5. Remove upper blower housing. 6. Install in reverse order of removal.

AIR CLEANER SERVICE Procedure:

Results: • If oil pressure readings are not within 69 – 517 kPa (10.0 – 75.0 psi) at FAST idle, inspect and/or replace the following: –Oil pump assembly. (See “OIL PUMP REMOVAL AND INSTALLATION” on page 45.) –Oil suction screen.

Cartridge Pre-Cleaner Plate

–Oil passages –Bearing wear

Knobs

–Oil Seals Cover M87006

4 - 18

3/22/00

ENGINE â&#x20AC;&#x201C; Briggs & Stratton Vâ&#x20AC;&#x201C;TWIN

CARBURETOR REMOVAL AND INSTALLATION

IMPORTANT: DO NOT use petroleum solvents, such as kerosene, to clean paper cartridge. They may cause cartridge to deteriorate. DO NOT oil paper cartridge. DO NOT use pressurized air to clean or dry paper cartridge. 1. To service pre-cleaner round dual element, remove cover assembly. 2. Slide foam pre-cleaner off cartridge. 3. Wash it in liquid detergent and water. 4. Squeeze it dry in a clean cloth. 5. Saturate it in engine oil. Wrap it in clean absorbent cloth and squeeze to remove excess oil. 6. Remove cartridge and clean by tapping gently on a flat surface. If very dirty, replace. 7. Reinstall cartridge, cover plate, knob and precleaner. 8. Reinstall air cleaner cover.

breather tube. 4. Remove upper blower housing.

NOTE: The engine is equipped with fuel shutoff solenoid. The blower housing should be removed so that the solenoid wire can be properly routed during reassembly. Disconnect fuel shutoff solenoid wire from equipment switch wire. 5. Remove air cleaner base and breather tube.

Choke Link

CARBURETOR REMOVAL AND INSTALLATION

Air Cleaner Bracket

CAUTION

Gasoline is extremely flammable. Do not smoke. Always work in a ventilated area away from open flame or spark producing equipment; including equipment that utilizes pilot lights. Wipe-up any spills IMMEDIATELY.

Procedure: 1. Remove carburetor access plate. 2. Remove air cleaner. Air Inlet Tube

Choke Control Bracket Screws M88870

6. Remove air cleaner bracket. 7. Remove two screws and choke control bracket. 8. Disconnect choke link from carburetor. 9. Remove fuel line clamp and fuel line from carburetor.

Nuts

Link Retainer Governor Link

Deflector Governor Link Spring

Gasket Breather Tube

M88871

M88900A

3. Remove air cleaner housing, air cleaner tube and

3/22/00

10. Disconnect governor link and spring.

4 - 19

CARBURETOR REMOVAL AND INSTALLATION 11. Remove carburetor, gaskets and spacer. 12. Install spacer, gaskets and carburetor. Tighten to 7 N•m (65 lb-in.). 13. Connect governor link to throttle lever and snap retainer over link.

ENGINE – Briggs & Stratton V–TWIN

IMPORTANT: Be sure breather tube is not kinked and that it is installed onto nipple as far as possible. Improper installation can cause engine damage. 19. Install air cleaner cartridge, pre-cleaner and cover.

Choke Link

Air Cleaner Bracket

Governor Link

Choke Control Bracket M88899

14. Install air cleaner bracket and tighten to 7 N•m (65 lb-in.). 15. Install choke link on choke lever on carburetor. Connect link to choke control lever and install choke control bracket. 16. Install fuel line and fuel line clamp. 17. Install blower housing. Air Inlet Tube

Retainer M88901

20. Connect governor link to throttle lever and snap retainer over link. Then install governor link spring in loop on retainer.

Nuts Choke Control Bracket Choke Link

Gasket Breather Tube

Screws

M88900A

18. Install air cleaner base.

CAUTION

4 - 20

M88902

21. Connect choke link to choke lever and install choke control bracket and tighten to 7 N•m (65 lb-in.). 22. Install blower housing and rotating screen. Install fuel pump and bracket and connect fuel line to carburetor. Rotate fuel line clamp so that it will not interfere with carburetor cover. DO NOT install carburetor cover at this time.

3/22/00

CARBURETOR DISASSEMBLY

ENGINE – Briggs & Stratton V–TWIN

1. Observe position of bowl drain screw to aid in reassembly. 2. Remove fuel shutoff solenoid and washer and bowl.

Air Inlet Tube

Nuts Float Hinge Pin

Gasket Breather Tube

Screws M88900A

23. Install new air cleaner mounting gasket with adhesive side toward air cleaner base. Guide breather tube onto nipple on breather and install air cleaner base on carburetor mounting studs. 24. Install carburetor shield. 25. Install nuts and screws finger tight.

M88873

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

Bowl Gasket

Specifications: Air cleaner bracket. . . . . . . . . . . . . . 7 N•m (65 lb-in.) Carburetor screws . . . . . . . . . . . . . . 7 N•m (65 lb-in.) Choke control bracket . . . . . . . . . . 7 N•m (65 lb-in.) M88874

NOTE: Make sure air inlet tube is installed correctly in air cleaner base.

4. Remove carburetor bowl gasket.

CARBURETOR DISASSEMBLY Procedure: Fixed Main Jet

M88875

Solenoid

5. Remove fixed main jet using a small bladed screwdriver.

Washer M88897

3/22/00

4 - 21

CARBURETOR DISASSEMBLY

ENGINE â&#x20AC;&#x201C; Briggs & Stratton Vâ&#x20AC;&#x201C;TWIN 8. The idle mixture valve is equipped with a adjustment limiter cap. Use pliers to remove the cap. 9. Remove the idle mixture valve.

Tube

High Speed Nozzle Screws

Top

Throat M88876

Fixed Main Jet

6. When the fixed main jet has been removed, the high speed nozzle can be removed. Reach into carburetor throat with a flat blade screw driver and push the high speed nozzle up through fixed main jet tube.

M88879

10. Remove two screws holding throttle valve to throttle shaft and remove throttle valve. Welch Plug

Idle Jet Plug

Idle Jet

M88880 M88877

7. Remove idle jet plug and idle jet.

11. To remove throttle shaft it is necessary to first remove welch plug from side of carburetor. Use a punch to pry plug out. . Snap Ring Washer

Idle Mixture Valve

Collar

Seal (Lip Out)

M88881

12. Remove external snap ring and throttle shaft washer. 13. Remove throttle shaft, throttle shaft collar and M88878

4 - 22

3/22/00

CARBURETOR INSPECTION

ENGINE â&#x20AC;&#x201C; Briggs & Stratton Vâ&#x20AC;&#x201C;TWIN throttle shaft seal.

3. Check all mating surfaces for nicks, burrs, foreign material, or cracks. Replace all damaged parts. Washer

E-Ring

Spring Ball Felt Seal

Felt Seal Washer

3.0 mm (0.125 in.) E-Ring

M88882

0.25

mm M88884

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

4. Inspect throttle and choke shaft and bushings for wear. Wear between throttle shaft and bushing should not exceed 0.25 mm (0.010 in.). 5. Check wear by placing carburetor on a flat surface. Measure the distance between the throttle lever and flat surface with a feeler gauge while moving shaft up and down.

Punch

Welch Plug Worn

M88883

15. Remove small welch plug from top of carburetor body.

M88885

6. If the difference is greater than 0.25 mm (0.010 in.), this indicates that the throttle shaft and/or bushings are worn. 7. Wear on the throttle shaft can be checked by comparing the worn and unworn portions of the shaft. 8. Choke shaft and bushings are checked in the same manner. 9. Throttle and choke shaft are replaceable. If throttle or choke shaft bushings are worn, replace carburetor.

Procedure: 1. Check all moving parts for wear, nicks and burrs. Replace, if worn or damaged. 2. Check float for leaks or damage. Replace, if damaged or leaking.

3/22/00

4 - 23

CARBURETOR ASSEMBLY

ENGINE – Briggs & Stratton V–TWIN

CARBURETOR ASSEMBLY IMPORTANT: When assembling the carburetor, use new seals and gaskets.

3. Install throttle valve on shaft with numbers down. With throttle valve in closed position, tighten screws securely. Then install new welch plug in side of carburetor body. Use a round punch and tap in plug until it is flat. Use a sealant on outside diameter of plug to prevent air leaks.

Procedure:

Washer E-Ring

Welch Plug

Round Punch

Ball

Spring Felt Seal

Felt Seal Washer

E-Ring

M88886 M88889

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

Collar

Seal (Lip Out)

Washer

Snap Ring

4. Install new E-ring, washer and felt seal onto choke shaft. 5. Insert spring and check ball in to spring pocket. Push choke shaft into hole until ball engages groove in choke shaft. 6. Place choke valve onto flat on choke shaft with flat edge of choke valve up and dimples down. 7. With choke valve in closed position, install and tighten screw securely.

Bowl Gasket M88887

2. Install throttle shaft seal with sealing lip out. Slide collar over throttle shaft and insert throttle shaft through carburetor body. Place washer over end of throttle shaft and install new snap ring. Numbers Down M88890

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

M88888

4 - 24

3/22/00

CARBURETOR ASSEMBLY

ENGINE â&#x20AC;&#x201C; Briggs & Stratton Vâ&#x20AC;&#x201C;TWIN

Fuel Inlet Retainer Valve Groove

Float Tang

Inlet Valve Retainer

Bend Here

M88891

9. Install fuel inlet valve retainer in fuel inlet valve groove.

Parallel M88894

Float Tang

12. Hold carburetor in vertical position, with float hinge up. The float should be parallel with carburetor bowl mounting surface. If not, bend tang. DO NOT press on float to adjust.

Inlet Valve Assembly

Idle Jet Plug

Gasket M88892

10. Slide fuel inlet valve assembly onto float tang and place assembly in carburetor. M88895

13. Install idle jet, plug and gasket. Tighten plug securely.

Float Hinge Pin

Idle Mixture Valve Spring

M88893

11. Install float hinge pin into place.

M88896

14. Install idle mixture valve and adjustment limiter cap.

3/22/00

4 - 25

ENGINE REMOVAL

ENGINE – Briggs & Stratton V–TWIN

NOTE: Special high altitude jets may be required in certain areas. Capscrews And Nut Fixed Main Jet

M88875

Heat Shield

Capscrews M95203

15. Install high speed nozzle and fixed main jet.

4. Remove two capscrews securing heat shield to frame. Remove capscrew and nut on side of heat shield. Remove heat shield.

Solenoid

Bowl

Choke Cable

Washer

Throttle Cable

M88897 M95206

16. Install bowl, washer and screw or fuel shutoff solenoid and washer. Position bowl drain. Specification:

5. Loosen throttle cable and choke cable clamps. Disconnect cable ends from engine.

Solenoid torque . . . . . . . . . . . . . . . . 5 N•m (45 lb-in.)

ENGINE REMOVAL 1. Turn all switches OFF and disconnect battery negative (–) cable. 2. Remove mower deck. 3. Raise hood. Disconnect light harness on right side of hood. Lower hood to approximately 3/4 open and slide off bracket.

c CAUTION Gasoline is extremely flammable. Do not smoke. Always work in a ventilated area away from open flame or spark producing equipment; including equipment that utilizes pilot lights. Wipe-up any spills IMMEDIATELY. 6. Disconnect hose clamp (A) and slide fuel line off hose barb on fuel filter. 7. Disconnect wires from starter terminal (B).

NOTE: Ground terminal (C) will be disconnected when engine mounting bolt is removed.

4 - 26

3/22/00

ENGINE INSTALLATION

ENGINE – Briggs & Stratton V–TWIN

ENGINE INSTALLATION D

1. Install engine in mower frame. 2. Put ground lead connector on top of front right hand engine mounting flange, and insert capscrew through connector, engine, and frame. 3. Install other three capscrews, washers, and nuts. Torque to 32 N•m (24 lb-ft). 4. If muffler was removed inspect muffler flange for flatness. Install muffler with new gasket. Torque mounting bolts to 24 N•m (216 lb-in.).

B C

M95204

Capscrews And Nut

8. Disconnect two (2) engine wiring harness connectors (D).

Heat Shield

Capscrews

G M95203 E

F H

M95205

5. Install heat shield. Secure with two capscrews to front frame mounting brackets. Install capscrew and nut on side of heat shield.

9. Remove two capscrews (E) securing belt guard bracket. Remove bracket and belt guard (F). 10. Remove traction drive belt (G). 11. Remove capscrew (H) securing pulley assembly to engine output shaft. Remove pulley assembly.

M95205

Capscrew

Capscrews

M55799

6. Install engine output shaft key and pulley assembly. Secure with washer, lock washer and capscrew. Torque capscrew to 75 N•m (55 lb-ft). 7. Install traction drive belt. 8. Install belt guard and guard bracket. Secure with two capscrews.

12. Remove four cap screws securing engine to frame. Remove engine.

3/22/00

4 - 27

CYLINDER AIR GUIDES REMOVAL AND INSTALLATIONENGINE – Briggs & Stratton V–TWIN

Cylinder Air Guide C

B M95204

Cylinder Air Guides M88980

9. Connect wires to starter terminal (B). 10. Connect two (2) harness connectors (C). 11. Connect fuel line and clamp (A).

6. Remove front and side cylinder air guides. 7. Install right, front and side cylinder air guides. 8. Install carburetor. 9. Install carburetor linkage. 10. Install air filter assembly. 11. Install upper blower housing.

Choke Cable

INTAKE MANIFOLD REMOVAL AND INSTALLATION

Procedure: M95206

12. Connect and adjust throttle cable (I) to obtain full throttle when lever is full forward, and idle when lever is rearward. 13. Connect and adjust choke cable to obtain full choke when choke knob is pulled out, and choke is fully open when choke knob is fully seated. 14. Connect battery negative (–) cable.

1. Remove upper blower housing. 2. Remove air filter assembly. 3. Remove cylinder air guides. 4. Disconnect carburetor linkage. 5. Remove carburetor. Intake Manifold Bolts

CYLINDER AIR GUIDES REMOVAL AND INSTALLATION Procedure: 1. Remove upper blower housing. 2. Remove air filter assembly. 3. Disconnect carburetor linkage. 4. Remove carburetor. 5. Remove intake manifold.

Intake Manifold M88979

6. Remove intake manifold.

NOTE: Replace used intake manifold and carburetor gaskets with new gaskets.

4 - 28

3/22/00

ENGINE â&#x20AC;&#x201C; Briggs & Stratton Vâ&#x20AC;&#x201C;TWIN CYLINDER

HEAD REMOVAL AND INSTALLATION rock the arm against spring pressure and allow push rod to drop out of the rocker arm socket. Push rod will move out of position, releasing valve spring pressure.

7. Install intake manifold. 8. Install carburetor. 9. Connect carburetor linkage. 10. Install cylinder air guides. 11. Install air filter assembly. 12. Install upper blower housing.

6. Release valve spring pressure.

CYLINDER HEAD REMOVAL AND INSTALLATION

IMPORTANT: Exhaust valve push rods are aluminum. Intake valve push rods are steel. Mark push rods for identification with tape or tags to prevent interchange.

IMPORTANT: Mark all parts when disassembling cylinder heads to prevent interchanging. 10 mm Wrench

Removal: 1. Disconnect spark plug leads and remove spark plugs. 2. Remove aircleaner assembly, support, choke bracket, carburetor and blower housing. 3. Remove intake manifold, valley cover, exhaust manifold, governor control bracket and linkage. 4. Remove cylinder air guides.

Seals

Rocker Studs

Valve Cover M87021

Nuts Rocker Arms Shaft

Studs M87033

5. Remove valve cover. Push Rods

Shaft Supports (Offset Holes Must Face Out) M87022

Rocker Arm

7. Remove rocker studs, shaft and rocker arm shaft supports. 8. Lift out push rods.

Valve Spring M87020

NOTE: To release spring pressure from rocker arms, 3/22/00

4 - 29

CYLINDER HEAD REMOVAL AND INSTALLATION ENGINE â&#x20AC;&#x201C; Briggs & Stratton Vâ&#x20AC;&#x201C;TWIN

Sealing Washers

Sealing Washers 1

Cylinder Head Bolts

Cylinder Head Bolts M87023 4

M87023

9. Remove cylinder head bolts and sealing washers.

Cylinder Head Gasket

3. Tighten four bolts down evenly by hand. Then, using torque wrench, torque cylinder head bolts in sequence. IMPORTANT: Do not tighten one bolt down completely before the others, as it may warp cylinder head. 4. Insert push rods into recess in tappets. IMPORTANT: Exhaust valve push rods are aluminum. Intake Valve push rods are steel. Mark push rods for identification with tape or tags to prevent interchange.

Alignment Sleeves M87024

Shaft

10. Remove cylinder head and gasket. Installation:

Studs

1. Place new gaskets and cylinder head on cylinder. Align head with cylinder head alignment sleeves located in the cylinder. 2. Apply approved lubricant to bolts threads and install four cylinder heads bolts and two sealing washers. Rocker Arm

IMPORTANT: Do not use sealer of any kind on gaskets.

Shaft Supports (Offset Holes Must Face Out)

M87022

5. The rocker shaft support holes are offset. Install with holes facing outward toward the ends of rocker shaft.

4 - 30

3/22/00

CYLINDER HEAD INSPECTION AND REPAIR

ENGINE – Briggs & Stratton V–TWIN

13. Install spark plug leads. Push Rods

CYLINDER HEAD INSPECTION AND REPAIR Procedure: Rocker Arm Valve Spring

M87020

6. Compress valve spring with rocker arm and insert push rod into rocker arm socket. Be sure push rods remain seated in recess in tappets.

Rocker Studs

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

M87031

VALVES REMOVAL 7. Assemble rocker arms, shaft, supports and studs and install on cylinder head. 8. Torque studs to 16 N•m (140 lb-in.). 9. Adjust valves. (See “VALVES INSTALLATION” on page 33.)

1. Remove the valves, place cylinder on workbench with support to hold valves in place. Rocker Studs Valve Spring Compressor

Seals

Nuts

M87033

10. Install gasket and valve cover. Place seal washers and nuts on studs. 11. Install intake and exhaust manifold, governor control bracket, cylinder air guides, valley cover, blower housing and air cleaner assembly. 12. Install and torque spark plugs to 20 N•m (180 lb-in.).

3/22/00

Split Retainer

M87025

2. Reinstall rocker studs into cylinder head. Do not tighten. Slip end of Valve Spring Compressor under stud of valve spring. Press down on tool handle to compress valve spring and remove split

4 - 31

VALVES INSPECTION AND REPAIR retainers. 3. Release pressure and remove retaining washer and spring. 4. Remove rocker studs. 5. Repeat procedure on other cylinder head.

VALVES INSPECTION AND REPAIR

Valve Stem Seal

ENGINE – Briggs & Stratton V–TWIN Specification: Valve seat width . . . . . . . . . . . . . 1.2 – 1.6 mm (0.0468 – 0.0625 in.) 4. If seat is wider, it may be narrowed using Valve Seat Cutter. Use 30° side of cutter to narrow the seats. If the valve is badly burned, it should be replaced. Replace valve if margin is badly burned or damaged, replace cylinder head. Valve seats are not replaceable. 5. Inspect valve springs and replace if broken or worn. 6. Inspect valve guides by inserting plug gauge into valve guide. If plug gauge inserts 6.4 mm (0.250 in.) or more, the guide must be replaced. If plug gauge is not available, the rejection dimension for both intake and exhaust valve guides is 6.05 mm (0.238 in.).

Bushing Driver Valve Guide Bushing

M87026

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

1.2 mm—1.6 mm (0.0468 in.—0.0625 in.) 0.8 mm (0.030 in.) Fit For Use

Margin

45°

0.4 mm (0.0156 in.) Discard

M87028

7. To remove valve guides, use Bushing Driver. Support cylinder head and press out valve guide. 7.0 mm (0.281 in.)

M87027

Bushing Driver

2. Faces on valves may be resurfaced with a valve grinder to 45°. Valve seats can be reconditioned using Valve Seat Cutter. Valves and seats should then be lapped with Valve Lapping Tool and Valve Lapping Compound. Remove grinding marks and assure a good seal between valve and seat. Thoroughly clean lapping compound from valve seat and valve face. 3. Valve seat width should be 1.2 – 1.6 mm (0.0468 – 0.0625 in.). Valve Guide Bushing

4 - 32

M87029

3/22/00

VALVES INSTALLATION

ENGINE – Briggs & Stratton V–TWIN

VALVES INSTALLATION 8. To install new valve guides, place new valve guide on Bushing Driver. Valve guide can be installed either way. Press in valve guide to dimension 7.0 mm (0.281 in.).

VALVES REAM

1. Install springs and valve spring retainers over valve stems. Temporarily install rocker studs in cylinder head. With Valve Spring Compressor, compress spring and install split retainers. Repeat procedure for other valves. Remove rocker studs.

Procedure: Pilot Guide

Adjusting Screw Reamer

13.0 mm Wrench

5.0 mm Hex Wrench

Feeler Gauge Nut Lock

M87032

M87030

1. To ream valve guides, use Finish Reamer and Reamer Pilot Guide to finish ream valve guide. Use oil, Stanisol or kerosene to lubricate reamer. Ream through entire guide. Keep turning reamer clockwise when removing reamer. Flush out all chips. 2. Install new seals over valve guides. Press down on seal until it bottoms. Valve stems must be free of foreign material and burrs or sticking will occur and valve stem seals will be damaged. Be sure valve guides are free of foreign materials and burrs. Lightly coat valve stems with Valve Guide Lubricant and insert valves into valve guides. IMPORTANT: Insure Valve Guide lubricant is not on valve face, seat or end of valve stem.

NOTE: In order to adjust valve clearance, correct position of the crankshaft is necessary to eliminate interference by the compression release mechanism on the cam gear when adjusting valve clearance. 2. Turn crankshaft until piston in cylinder you are checking is at top dead center, on the compression stroke (Both Valves Closed). Using a screwdriver or similar object inserted through spark plug hole and touching the top of the piston, continue turning crankshaft clockwise until piston has moved 6.35 mm (0.250 in.) past top dead center. 3. Check valve clearance with feeler gauge between valve stem and rocker arm. Valve clearance specifications are the same for both the intake and exhausts. 4. Torque lock nut to 7 N•m (60 lb-in.). 5. Recheck clearance. Readjust if required. 6. Rotate crankshaft several turns to check for proper operation. Specifications: Valve clearance0.10 – 0.16 mm (0.004 in. – 0.006 in.) Lock nut torque . . . . . . . . . . . . . . . . 7 N•m (60 lb-in.)

3/22/00

4 - 33

PISTON REMOVAL AND INSTALLATION PISTON REMOVAL AND INSTALLATION 1. Remove air filter and bracket, upper blower housing, flywheel, alternator, carburetor and governor linkage. 2. Remove starter, cylinder heads and crankcase cover.

NOTE: Remove any carbon or ridge at the top of the cylinder bore. This will prevent breaking the rings when removing the piston and connecting rod from the engine.

ENGINE â&#x20AC;&#x201C; Briggs & Stratton Vâ&#x20AC;&#x201C;TWIN

pistons and rings. If cylinder bores require resizing it will not be necessary to check pistons and rings since a new oversized piston assembly will be used. 5. If cylinder bore is more than 0.08 mm (0.003 in.) oversize, or 0.04 mm (0.0015 in.) out of round, it must be resized. IMPORTANT: When servicing pistons, rings, piston pins or rods, each rod, piston, piston pin and ring set must be kept as a set for the cylinder that it was removed from. Mark each set before removing from the engine.

3. Remove the connecting rod cap. Then push the piston and connecting rod out through the top of the cylinder. Oil Control Ring

M87038 M87036

4. To remove connecting rod from piston, remove piston pin locks with screwdriver. Piston pin is a push fit in piston and rod. Deposits may build up on piston pin and require the piston pin to be pressed out.

NOTE: Oil control ring is shown being spiraled into compression ring groove. 6. Spiral top oil control ring from oil ring groove into center compression ring groove. Repeat into top compression ring groove, and then off piston. Repeat for bottom oil control ring.

Piston

M86904

7. Insert old rings one at a time approximately 25.4 mm (1.0 in.) down into a cylinder bore.

IMPORTANT: Remove top and center compression rings using ring expander. New piston rings must be installed whenever the engine is disassembled for major servicing or overhaul, providing that cylinder bores are within specifications.

NOTE: Measure cylinder bores before checking

4 - 34

3/22/00

CONNECTING ROD INSPECTION

ENGINE â&#x20AC;&#x201C; Briggs & Stratton Vâ&#x20AC;&#x201C;TWIN

inserted in the oil ring grooves, the compression and ring grooves are worn and the piston should be replaced. 4. To check ring end gap, first clean all carbon from the end of the rings.

Feeler Gauge

Ring

CONNECTING ROD INSPECTION

Crankpin Bearing

M86906

8. Check end gap with feeler gauge. If ring gap is greater than 0.76 mm (0.030 in.) for compression and oil ring, the ring groove is worn and should be replaced. 9. A worn ring will usually show scratches caused by abrasives and/or have a shiny appearance. Never reuse worn piston rings.

CAUTION

Wear gloves or cover rings with a rag. The top and bottom edges of the ring may be extremely sharp. Personal injury to hand could occur. Never reuse worn piston rings.

Piston Pin Bearing

M88925

1. If the crankpin bearing in the connecting rod is scored, the rod must be replaced. Reject size of crankpin bearing and piston pin bearing is as follows: Specifications: Crankpin bearing . . . . . . . . . . 37.12 mm (1.4615 in.) Piston pin bearing . . . . . . . . . 17.10 mm (0.6735 in.)

2. Replace connecting rod if either bore is worn.

Piston Pin Bore

PISTON INSPECTION 1. Clean carbon from top two ring grooves. 2. Place a new ring in each piston groove. M88926

Feeler Gauge Piston

3. Reject sizes for piston pin and piston pin bore are as follows: Specifications: M86905

Piston pin . . . . . . . . . . . . . . . . 17.06 mm (0.6718 in.) Piston pin bore . . . . . . . . . . . . . 17.10 mm 0.6735 in.)

3. If a 0.10 mm (0.004 in.) or larger feeler gauge can be inserted in the compression ring grooves, or a 0.20 mm (0.008 in.) or larger feeler gauge can be

3/22/00

If piston pin is worn 0.01 mm (0.005 in.) out of round or below reject size, it must be replaced.

4 - 35

CONNECTING ROD INSPECTION

“Out 1” Cylinder #1 “Out 2” Cylinder #2

ENGINE – Briggs & Stratton V–TWIN

Projections

Notch Ring Compressor

M88929

M88927

4. The piston pin is a slip fit in both piston and connecting rod. Use a thin nose pliers or screwdriver and install a piston pin lock in groove on one side of piston. Refer to above drawing to determine correct location of rod in relation to notch on piston. Insert piston pin from opposite side of piston until pin stops against piston pin lock. Then install other piston pin lock. Be sure both locks are seated in grooves. Top Compression Ring (Barrel Face)

Second Compression Ring (Taper Face)

“ID” Mark Indicates Top Of Ring

Oil Ring Expander

M88930

8. Apply oil to piston rings, piston skirt and compress rings with ring compressor tool. Place piston and ring compressor upside down on bench and push down until head of piston and edge of ring compressor are even. Tighten ring compressor until rings are fully compressed. Then loosen ring compressor very slightly so that compressor can be rotated on piston skirt while holding connecting rod. Flywheel Side

PTO Side

Circle M88928

5. The correct piston ring positions are shown above. The oil ring is installed with the expander between the two oil control rings. The top and second compression rings are installed with "ID" mark toward top of piston. 6. Install expander first. Spiral bottom oil control ring into top ring groove, then into second ring groove and into position below expander. Repeat procedure for top oil control ring. 7. Using ring expander, install center compression ring then, top compression ring as shown above.

4 - 36

“Out 1” Cylinder #1 “Out 2” Cylinder #2

M88931

NOTE: The pistons have offset piston pin bores. When the Circle on piston is facing toward the flywheel side of engine, the words "OUT-1" on the side of the connecting rod for cylinder No. 1 and "OUT-2" on the side of the connecting rod for cylinder No. 2 should face toward the PTO side of the crankcase. 3/22/00

CYLINDER BORE INSPECTION

ENGINE – Briggs & Stratton V–TWIN

CYLINDER BORE INSPECTION Flywheel Side

Top Center Bottom Measure At Six Points

Circle Projections Down

M88932

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

Match Marks

Center Of Piston Ring Travel M86883

Connecting Rod Screws M88933

10. Clean and oil crankshaft crankpin. 11. Pull connecting rod against crankpin. 12. Install rod cap with match marks aligned. 13. Install connecting rod screws and torque to 13 N•m (115 lb-in.).

NOTE: Failure to use a torque wrench can result in loose connecting rods causing breakage, or tight connecting rods causing scoring. 14. Rotate crankshaft two (2) revolutions to check for binding. Rod should also be free to slide sideways on crankpin.

Standard bore size (min.) . . . . . 72.0 mm (2.835 in.) Standard bore size (max.) . . . 72.025 mm (2.836 in.) 2. If the cylinder bore is more than 0.08 mm (0.003 in.) oversize, or 0.04 mm (0.0015 in.) out of round, it must be resized, or replaced. (See “RESIZING CYLINDER BORE” on page 38.) 3. If cylinder bores are within specification and show no signs of scoring or other damage, new pistons rings may be installed providing the cylinder bores are reconditioned using a rigid hone with finishing stones. This will restore the proper cross hatch angle in the cylinder bores. The proper cylinder cross hatch ensures proper lubrication and piston ring rotation.

Specification: Connecting rod screws . . . . . . . . 13 N•m (115 lb-in.)

3/22/00

4 - 37

CYLINDER BORE HONING

ENGINE – Briggs & Stratton V–TWIN

CYLINDER BORE HONING

crankcase and check again. When there is no trace of honing grit on rag, the cylinder is properly cleaned. Then oil cylinder bore to prevent rusting.

RESIZING CYLINDER BORE Approximately 45°

45°

Fixture

M86885

1. The cylinder finish, (Cross Hatch) should be applied after cylinder bore has been resized to within 0.038 mm (0.0015 in.) of the desired size or when reconditioning a cylinder bore. The finishing stones will produce the correct cross hatch necessary for proper lubrication and piston ring rotation. The correct hatch angle is approximately 45°. 2. It is recommended that the cylinder bores be reconditioned to restore the cross hatch when new piston rings are to be installed in a cylinder that is within specification. Be careful not to hone oversize or it will be necessary to resize the cylinder.

NOTE: To produce the proper cross hatch finish use a drill speed of approximately 200 rpm and 40 – 60 strokes per minute. Lubricate hone liberally to prevent build up on finishing stones.

Mounting Screws Wear

Ring Travel Unworn Area

Bore

0.750 in. to 1.0 in.

Extreme Hone Travel At Finish

Hone Travel At Start

CYLINDER BORE CLEANING 0.750 in. To 1.0 in.

IMPORTANT: Ensure that the entire cylinder and crankcase are thoroughly cleaned after honing. Honing grit is highly abrasive and will cause rapid wear to all of the internal components of the engine unless it is completely removed. 1. Wash the cylinder and crankcase carefully in a solvent such as kerosene or commercial solvent. 2. Thoroughly wash cylinder and crankcase using a stiff brush with soap and hot water, Rinse thoroughly with hot running water. 3. Repeat washing and rinsing until all traces of honing grit are gone. 4. When cylinder and crankcase have been thoroughly cleaned, use a clean white rag or napkin and wipe the cylinder bore. If honing grit is present it will appear as a gray residue on rag. If any honing grit is evident, re-wash and rinse entire cylinder and

4 - 38

M88942

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 0.25 mm (0.010 in.), 0.51 mm (0.020 in.), or 0.76 mm (0.030 in.) over standard size. Specifications 16 hp: Standard bore size . . . . . . . Min. 68.0 mm (2.677 in.) Standard bore size . . . . . Max. 68.025 mm (2.678 in.) Specifications 18 hp: Standard bore size (min.) . . . . . 72.0 mm (2.835 in.) Standard bore size (max.) . . . 72.025 mm (2.836 in.) 2. If this is done accurately, the service oversize rings and pistons will fit perfectly and proper clearances will be maintained. 3/22/00

ENGINE – Briggs & Stratton V–TWIN

FLYWHEEL REMOVAL AND INSTALLATION

IMPORTANT: If a boring bar is used, a hone must be used after the boring operation to produce the proper cylinder cross hatch. (See “CYLINDER BORE HONING” on page 38.)

FLYWHEEL REMOVAL AND INSTALLATION Removal:

3. If a hone is used to resize the cylinder bore, place hone in middle of cylinder bore. Tighten adjusting knob with finger until stones fit snugly against cylinder wall. DO NOT FORCE. 4. Connect drive shaft to hone. Be sure that cylinder and hone are centered and aligned with drive shaft and drill spindle. Lubricate hone as recommended by hone manufacturer. 5. The recommended drill speed is 300 – 700 rpm maximum and 40 – 60 strokes per minute. 6. Because cylinder bores normally wear only in the area of ring travel, the cylinder bore will be round above and below ring travel. 7. Start drill and, as hone spins, move it up and down at the bottom of the cylinder bore. 8. Gradually increase the length of the strokes until hone travels full length of cylinder bore. Do not travel more than 19.05 mm (0.750 in.) to 25.4 mm (1.0 in.) above cylinder bore. 9. Lubricate hone frequently to prevent build up on stones. 10. As cutting tension decreases, stop hone and tighten adjusting knob following hone manufacturer’s recommendations. 11. Check cylinder bore size frequently. 12. Check cylinder bores at top and bottom for burrs. Remove burrs. Cylinder head and crankcase cover surfaces must be free of burrs and gasket material. 13. After cylinder bore has been brought to proper resizing dimension, a cross hatch must be applied to bore. (See “CYLINDER BORE HONING” on page 38.)

1. Remove rotating screen. 2. Remove blower housing.

Strap Wrench

30.0 mm Socket M88863

Flywheel Puller

M87011

3/22/00

4 - 39

CRANKSHAFT REMOVAL AND INSTALLATION 6. Flywheel should be inspected for cracks, broken flywheel fins, burrs on taper or keyway and distortion of keyway. Also check taper of crankshaft for burrs, rust or other damage. Replace crankshaft, if damaged.

ENGINE – Briggs & Stratton V–TWIN

CRANKSHAFT REMOVAL AND INSTALLATION Removal:

Installation: 1. Before installing flywheel, clean taper and crankshaft taper removing all oil, dirt or grease. 2. Install flywheel. 3. Install flywheel nut.

Dowel Pins

Crankcase Cover

M88864

4. Place Flywheel Strap Wrench around outer rim of flywheel. Insert 1/2 in. breaker bar into drive end of strap wrench and wind counterclockwise to remove slack in strap. While holding strap, tighten flywheel nut to 175 N•m (125 lb-ft). Specification:

M87035

NOTE: Before crankcase cover is removed, it is recommended that any rust, paint or burrs be removed from power take off end of crankshaft. This will eliminate or reduce chances of damaging the crankcase cover bearing. 1. Remove governor lever and disconnect governor link and springs. Remove governor control bracket. Remove oil fill tube and dipstick assembly. 2. Remove exhaust manifold, intake manifold and cylinder heads. 3. Remove crankcase cover. If crankcase cover sticks, tap lightly with soft hammer on alternate sides near dowel pins.

Flywheel nut torque . . . . . . . . . . . 175 N•m (125 lb-ft) IMPORTANT: DO NOT remove dowel pins.

Timing Marks

M88934

4. Tip engine over onto flywheel side of crankcase. 5. Support engine to prevent end of crankshaft from

4 - 40

3/22/00

ENGINE â&#x20AC;&#x201C; Briggs & Stratton Vâ&#x20AC;&#x201C;TWIN

CRANKSHAFT REMOVAL AND INSTALLATION

resting on workbench. 6. Rotate crankshaft until timing marks are aligned. With cam gear in this position, the valve tappets will remain clear of cam lobes. IMPORTANT: If engine is rotated from this position, tappets will fall out. Tappets must not be mixed.

Gear Teeth

Spring

PTO Journal

Cam Lobes Mag. Journal

7. Lift out cam gear and governor assembly. Timing Gear Teeth

Oil Galleries Crankpin Mag. Journal

Intake

Exhaust

PTO Journal

Threads And Keyway

Oil Galleries

Keyway M88935

8. Mark the connecting rods and caps to prevent interchanging when reassembling. 9. Remove piston and connecting rod assemblies. 10. Remove crankshaft from crankcase. IMPORTANT: The various wear points on the crankshaft must be measured.

Compression Release Balls M88937

12. Check timing gear teeth for chipped or cracked teeth. Replace if needed. 13. The compression release balls must be clean and free to move when the centrifugal weight is rotated counterclockwise. When the centrifugal weight is released, the balls should move up into the locked position. 14. Inspect cam gear teeth, lobes and journals for wear and nicks. Cam gear journal and lobe reject sizes are as follows: Minimum Specifications: PTO journal . . . . . . . . . . . . . . . 19.92 mm (0.7845 in.) MAG. journal . . . . . . . . . . . . . . 15.93 mm (0.6273 in.) Cam Lobes . . . . . . . . . . . . . . . . 30.25 mm (1.191 in.)

Minimum Specifications:

Governor Slider

PTO journal. . . . . . . . . . . . . . . . 34.92 mm (1.375 in.) MAG. journal. . . . . . . . . . . . . . . 29.94 mm (1.179 in.) Crankshaft crankpin . . . . . . . . 36.95 mm (1.455 In.) 11. Replace crankshaft if worn or if journals are scored. Keyways should be checked to be sure they are not worn or spread. Remove burrs from keyway edges to prevent damaging the bearing or oil seal. Check oil galleries for blockage or obstructions.

Flywheel Pivot

Locating Pin

Timing Marks Thrust Washer (If Required) M88938

15. Governor slider must move freely on PTO journal of cam gear. Flywheel must pivot freely. Make sure flyweight spring is not stretched. Governor weights must move freely on hinge pins. Make sure hinge pins are not loose. 3/22/00

4 - 41

MAGNETO BEARING INSPECTION

ENGINE – Briggs & Stratton V–TWIN

Installation: 1. Assemble governor slider onto PTO journal on cam gear making sure that slot on slider fits over locating pin on cam gear. Be sure the weights are in the proper location so that they will be able to move freely without binding. Tip engine to position crankshaft horizontally.

4 M88941

0-Ring M88939

2. Place new crankcase cover gasket on crankcase.

NOTE: Be sure O-ring is installed in crankcase.

5. Tighten cover bolts to 17 N•m (150 lb-in.) in the sequence shown above. 6. Install cylinder heads. 7. Install flywheel. 8. Install intake manifold and carburetor assembly. 9. Install governor lever and governor springs. 10. Install oil fill tube and dipstick assembly. Perform static governor adjustment. 11. Install engine shrouding. 12. Install air filter assembly.

MAGNETO BEARING INSPECTION

Boss Governor Shaft

M88943 M88940

1. When checking the main magneto bearing, it should be replaced if scored or if not within specification. 3. Rotate governor shaft against boss. 4. Take care to protect the oil seal while assembling crankcase cover. No force should be used.

4 - 42

Specification: Magneto bearing reject size . 30.08 mm (1.1845 in.)

3/22/00

MAGNETO BEARING INSPECTION

ENGINE â&#x20AC;&#x201C; Briggs & Stratton Vâ&#x20AC;&#x201C;TWIN

3.0 mm (0.125 in.)

Punch Roll Pin

Remove Taper

M88947 M88944

2. To remove the magneto bearing, first remove oil seal. The magneto bearing has a roll pin installed in the oil gallery to prevent the bearing from turning. Use a 4.8 mm (0.1875 in.) punch to drive roll pin into oil gallery.

4. Before installing the new roll pin, grind off the taper, approximately 3.0 mm (0.125 in.) from one end of new roll pin. Quench pin in water periodically to prevent loss of temper. Remove all burrs and clean thoroughly.

Brushing Driver

M88948 M88945

3. To install magneto bearing, place cylinder on a suitable cylinder support. Position new bushing against counterbore bearing in crankcase and carefully align oil holes in bushing with oil gallery holes in bearing. Press in new bushing with a suitable bushing driver tool.

5. Place tapered end of new roll pin in oil hole in bearing. Use roll pin driver, to install new roll pin. Drive in new roll pin until tool bottoms. Install new oil seal. Use a suitable cylinder support and press in new oil seal until it is flush with cylinder.

M88950

Oil Holes Must Align

M88946

NOTE: Be sure oil holes in bushing are aligned with oil gallery holes in bearing.

3/22/00

IMPORTANT: The crankcase cover must be replaced if PTO bearing is scored or if dimensions exceed reject size. Maximum Specification: PTO main bearing reject size . 35.07 mm (1.381 in.)

4 - 43

PTO BEARING REMOVAL AND INSTALLATION PTO BEARING REMOVAL AND INSTALLATION Removal: 1. Remove oil pump. 2. Remove oil seal. 3. Support crankcase cover on arbor press and using bushing driver. Press out bearing toward inside of the cover.

ENGINE – Briggs & Stratton V–TWIN

BREATHER VALVE SERVICE IMPORTANT: A leak at the seal between the tube and crankcase cover, or at the seal at the upper end of the dipstick, can result in a loss of crankcase vacuum and a discharge of oil or smoke through the muffler. Reed Valve

Breather Screw And “O” Ring

Installation:

Steel Plate

M88912

M88949

4. Lubricate outside surface of bearing and place on inside of cover. Using an arbor press and flat steel plate, press in bearing until flush with surface of cover. 5. Install new oil seal using a cylinder support. Press in seal until it is flush with mounting surface. 6. When installing new PTO oil seal, properly support cylinder. Press in seal until it is 1.5 mm (0.0625 in.) below mounting surface. 7. The crankcase cover must be replaced if the cam gear bearing dimensions exceed reject size.

Gasket

Maximum Specifications: Cam bearing gear bearing reject size Magneto bearing . . . . . . . . . . . 16.08 mm (0.633 in.) PTO bearing . . . . . . . . . . . . . . . 20.04 mm (0.789 in.)

NOTE: Always install new oil seals whenever engine is disassembled for major servicing or when repairing bearings. Always use the correct seal protector to prevent damaging oil seal.

4 - 44

Breather Valve Assembly

M88913

1. Before breather valve assembly can be removed for inspection, the air cleaner assembly and support bracket must be removed.

3/22/00

OIL PUMP REMOVAL AND INSTALLATION

ENGINE – Briggs & Stratton V–TWIN

Specification: Torque screw . . . . . . . . . . . . . . . . . . 3 N•m (30 lb-in.)

Breather Tube Reed Valve

M88914

2. Check to see that reed valve is not deformed. The reed valve is spring loaded and must make a complete seal around the vent hole in breather body.

M88917

IMPORTANT: Do not use force on reed valve. Gasket

NOTE: The breather is vented through the air cleaner to prevent dirt from entering the crankcase. 4. Check breather tube for cracks, holes or hardening. Replace if damaged.

OIL PUMP REMOVAL AND INSTALLATION Breather Assembly M88915

NOTE: When installing breather, make sure breather gasket is located properly.

M88919

“O” Ring

Breather Gasket M88916

3. Place breather on gasket. Slip large O-ring onto mounting screw and install screw and torque to 3 N•m (30 lb-in.). 3/22/00

This engine is equipped with a full pressure lubrication system with an oil filter.

4 - 45

OIL PUMP REMOVAL AND INSTALLATION

ENGINE – Briggs & Stratton V–TWIN

NOTE: The outer rotor of pump can be removed for inspection and cleaning. With pump removed, oil pick-up screen may be removed for cleaning.

Inner Rotor

Installation:

Outer Rotor Drive Gear

Pump Housing

Pressure Relief Valve

“O” Rings

M88918

The gear driven oil pump supplies lubrication to all bearing journals.

Boss Pickup Screens Bolts

M88921

Oil pressure . . . . . . . . . . . . . . . . . . . . . . . 10 – 50 psi

4. Slip oil pick-up screen into slots in crankcase cover. 5. Install oil pump and tighten screws to 7 N•m (65 lb-in.).

NOTE: Engine oil pressure will vary with oil viscosity, ambient air temperature differences, operating temperatures and engine load.

NOTE: Boss on oil pump body holds pick-up screen in proper position. Be sure in install new “O” rings on pump mounting screws.

Removal:

Torque Specification:

Specification:

Mounting screws . . . . . . . . . . . . . . . 7 N•m (65 lb-in.)

Note O-Rings Oil Pump Screws

M88920

NOTE: The oil pump is attached to the inside of the crankcase cover. 1. Remove oil fill dipstick assembly. 2. Remove crankcase cover. 3. Remove two screws attaching oil pump assembly to crankcase cover.

4 - 46

3/22/00

CONTENTS

ENGINE â&#x20AC;&#x201C; Briggs & Stratton INTEK V-TWIN

CONTENTS Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TESTS AND ADJUSTMENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ENGINE TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 THROTTLE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 CHOKE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 FUEL SHUTOFF SOLENOID TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 GOVERNOR ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 COMPRESSION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 IGNITION ARMATURE AIR GAP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 CYLINDER BALANCE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 UPPER BLOWER HOUSING REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . 17 AIR CLEANER REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 CARBURETOR REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 CARBURETOR DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 19 ENGINE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 CYLINDER AIR GUIDES REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . 25 CYLINDER HEAD REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26 CYLINDER HEAD INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 VALVE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 VALVE INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 VALVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 PISTON, RINGS AND ROD REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . 30 PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 CONNECTING ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 CYLINDER BORE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 CYLINDER BORE HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 CYLINDER BORE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 RESIZING CYLINDER BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 FLYWHEEL REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 CRANKSHAFT AND CAM GEAR REMOVAL AND INSTALLATION . . . . . . . . . . . . . 36 MAGNETO BEARING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 PTO AND CAM BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 BREATHER VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 OIL PUMP REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2/29/00

5-1

NOTES

5-2

ENGINE â&#x20AC;&#x201C; Briggs & Stratton V-TWIN

2/29/00

ENGINE – Briggs & Stratton INTEK V-TWIN

GENERAL SPECIFICATIONS

SPECIFICATIONS GENERAL SPECIFICATIONS Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs & Stratton Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intek™ V-Twin Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0137-E1 Gasoline Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407777 Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.9 kW (20.0 hp) Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .656 cm3 (40.0 cu-in.) Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.4 mm (2.97 in.) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.4 mm (2.89 in.) Valving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurized Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Flow Filter (w/o By-Pass Valve) Oil Capacity w/o oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.42 L (1.5 qt) w/ oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt) Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper with outer foam element Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal discharge below frame Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Normal Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable (In-Line Type)

TESTS AND ADJUSTMENTS SPECIFICATIONS Armature Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.20 - 0.30 mm (0.008 - 0.012 in.) Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750 ± 50 rpm Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3350 ± 50 rpm Oil Pump Operating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 50 psi Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.10 - 0.16 mm (0.004 - 0.006 in.) Valve Guide Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 mm (0.281 in.) Spark Plug Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.)

REPAIR SPECIFICATIONS Valves: Valve Guide Standard Dimension . . . . . . . . . . . . . . . .6.01 - 6.02 mm (0.236 - 0.237 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.05 mm (0.238 in.) Valve Stem Standard Dimension Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.97 - 5.98 mm (0.234 - 0.235 in.) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.97 - 5.98 mm (0.234 - 0.235 in.) Valve stem Wear Limit Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.92 mm (0.233 in.) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.92 mm (0.232 in.) Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2 - 1.6 mm (0.047 - 0.062 in.) Valve Margin (Min) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 mm (0.016 in.) Valve Face Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Valve Seat Narrowing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°

3/22/00

5-3

REPAIR SPECIFICATIONS

ENGINE â&#x20AC;&#x201C; Briggs & Stratton INTEK V-TWIN

Cylinder Bore, Pistons and Rings: Cylinder Bore Standard Dimension . . . . . . . . . . . .75.41 - 75.44 mm (2.968 - 2.969 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.48 mm (2.972 in.) Piston Pin Standard Dimension . . . . . . . . . . . . . . .17.07 - 17.08 mm (0.672 - 0.673 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.06 mm (0.672 in.) Piston Pin Bore Standard Dimension . . . . . . . . . . . .17.09 - 17.1 mm (0.673 - 0.674 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.13 mm (0.675 in.) Ring End Gap Standard Dimension Top. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.13 - 0.33 mm (0.005 - 0.013 in.) Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.35 - 0.56 mm (0.014 - 0.022 in.) Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.13 - 0.33 mm (0.005 - 0.013 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.) Ring Groove Wear Limit (New Ring Installed). . . . . . .0.05 - 0.07 mm (0.002 - 0.003 in.) Connecting Rod and Crankshaft: Connecting Rod Crankpin Standard Dimension . . 38.10 - 38.11 mm (1.500 - 1.501 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.12 mm (1.461 in.) Connecting Rod Piston Pin Bearing Std. Dimension17.08 - 17.09 mm (0.672 - 0.673 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.12 mm (0.674 in.) Crankshaft PTO Journal Standard Dimension . . . .41.25 - 41.27 mm (1.624 - 1.625 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.22 mm (1.623 in.) Crankshaft Magneto Journal Standard Dimension .34.99 - 35.01 mm (1.377 - 1.378 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.95 mm (1.376 in.) Magneto Bearing Standard Dimension . . . . . . . . .35.02 - 35.06 mm (1.379 - 1.3805 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.12 mm (1.383 in.) PTO Bearing Standard Dimension . . . . . . . . . . . . .41.32 - 41.34 mm (1.627 - 1.628 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.37 mm (1.629 in.) Crankshaft Crankpin Journal Standard Dimension .38.05 - 38.07 mm (1.498 - 1.499 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.01 mm (1.496 in.) Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . .0.05 - 0.76 mm (0.002 - 0.030 in.) Cam Gear PTO Journal Standard Dimension . . . . .15.85 - 15.87 mm (0.624 - 0.625 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.82 mm (0.623 in.) Cam Gear Magneto Journal Standard Dimension .15.85 - 15.87 mm (0.624 - 0.625 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.82 mm (0.623 in.) Cam Lobe Standard Dimension Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31.19 - 31.26 mm (1.228 - 1.231 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.15 mm (1.225 in.) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31.14 - 31.21 mm (1.226 - 1.229 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.06 mm (1.223 in.) Cam Bearing (Magneto Side) Standard Dimension 15.88 - 15.90 mm (0.625 - 0.626 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.93 mm (0.622 in.) Cam Bearing (PTO Side) Standard Dimension. . . .15.88 - 15.90 mm (0.625 - 0.626 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.93 mm (0.622 in.)

5-4

3/22/00

ENGINE – Briggs & Stratton INTEK V-TWIN

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS Alternator to Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 N•m (20 lb in.) Air Cleaner Base to Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 N•m (65 lb-in.) Armature Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 N•m (25 lb in.) Back Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 N•m (100 lb-in.) Blower Housing Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 N•m (30 lb-in.) Carburetor to Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4 N•m (55 lb-in.) Choke Cable Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 N•m (25 lb-in.) Connecting Rod Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 N•m (100 lb-in.) Crankcase Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.6 N•m (200 lb-in.) Cylinder Head Cap Screws (final) . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (220 lb-in.) Cylinder Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 N•m (65 lb-in.) Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 N•m (24 lb-ft) Engine Output Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 N•m (55 lb-ft) Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 N•m (140 lb-in.) Fan Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 N•m (140 lb-in.) Flywheel Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 N•m (150 lb-ft) Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 N•m (45 lb-in.) Governor Control Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Governor Lever Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6 N•m (130 lb-in.) Heat Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 N•m (65 lb-in.) Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Muffler to Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 N•m (65 lb-in.) Oil Filter Adaptor Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 N•m (65 lb-in.) Oil Pump Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 N•m (50 lb-in.) Rocker Arm Adjustment Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 N•m (60 lb-in.) Rocker Arm Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 N•m (100 lb-in.) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.) Starting Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.8 N•m (140 lb-in.) Starting Motor thru Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 N•m (50 lb-in.) Throttle Cable Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 N•m (25 lb-in.) Traction Drive Belt Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 N•m (65 lb-in.) Valve Cover Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 N•m (100 lb-in.)

3/22/00

5-5

TORQUE SPECIFICATIONS

ENGINE – Briggs & Stratton INTEK V-TWIN

Starting motor/solenoid defective

●

Improper switch position (See Electrical Section)

●

Engine seized

●

Fuel mixture too rich

●

Engine overheats

Fuse (F1) open

Engine running on one cylinder

●

Low oil pressure

●

Excessive engine noise/vibration

Engine starts hard

●

Low compression

Engine cranks but will not start

Battery has low or no charge/cables loose or dirty

Check or Solution

Loss of power

Engine will not crank

Problem or Symptom

Engine won’t shutoff

TROUBLESHOOTING

●

Fuel shutoff solenoid defective

●

Fuel filter/lines clogged

●

Fuel pump defective

●

Ignition coil air gap not adjusted properly

●

Carburetor not adjusted properly, dirty

●

Air cleaner dirty

●

Old/contaminated fuel

●

Spark plugs loose/dirty

●

Magneto kill circuit grounded/shorted (See Electrical Section)

●

Valve tappets need adjustment

●

Lack of compression, check valves, pistons and rings

●

● ●

Magneto kill circuit open (See Electrical Section)

●

● ●

●

Mower deck binding or dragging

●

Grass buildup under deck

●

No lubrication in gear box or hydro/transaxle

●

● ●

Excessive drive belt tension ●

Deck spindles seized

●

Loose cylinder head bolts

●

Defective head gasket

●

Burned valves, valve seats, and/or loose valve seats

5-6

●

3/22/00

●

Broken connecting rod

●

Cutter blade or other rotating part bent or out of balance

●

Mounting bolts loose

●

Camshaft worn

●

Internal bearings worn or excessive tolerance

●

Oil galleries/filter clogged

●

Oil pump defective

●

Low oil level or wrong viscosity

●

Exhaust system restricted

●

Fuel mixture too rich

Worn bore and/or rings

Engine overheats

●

Low oil pressure

●

Excessive engine noise/vibration

Low compression

●

Engine won’t shutoff

Warped cylinder head

Check or Solution

Engine will not crank

Loss of power

Engine starts hard

Engine cranks but will not start

Problem or Symptom

Engine running on one cylinder

TORQUE SPECIFICATIONS

ENGINE – Briggs & Stratton INTEK V-TWIN

● ●

Air/fuel mixture excessively lean

●

Cylinder cooling fins/blower housing filled with grass clippings

●

Overchoking

●

Float needle stuck open

●

3/22/00

5-7

ENGINE TROUBLESHOOTING GUIDE

ENGINE – Briggs & Stratton INTEK V-TWIN

ENGINE TROUBLESHOOTING GUIDE Engine Will Not Crank NOTE: To test specific electrical components, see Electrical Section and refer to either Diagnostics or Tests and Adjustments for further guidance.

c CAUTION BE AWARE! The engine may start to rotate at any time. Keep hands away from all moving parts when testing.

Check battery voltage. Is battery voltage 12.4 volts or higher?

Charge battery and perform a no-load test. Is battery voltage 12.4 volts or higher?

• Battery defective

YES

Does starting motor solenoid click when ignition switch is turned to START position?

YES

• Fusible link open • Starting motor solenoid defective • Defective switches or wiring See Electrical Troubleshooting • Starting motor solenoid defective • Starting motor pinion gear sticking or damaged • Starting motor defective • Engine seized

Repair or replace

5-8

3/22/00

ENGINE TROUBLESHOOTING GUIDE

ENGINE – Briggs & Stratton INTEK V-TWIN

Engine Cranks But Will Not Start

c CAUTION DO NOT rotate engine with starting motor if the spark plugs are removed. Gasoline spray from the open cylinders may be ignited by ignition spark and cause an explosion or fire.

Check battery voltage. Is battery voltage 12.4 volts or higher?

NOTE:

To test specific electrical components, see Electrical Section and refer to either Diagnostics or Tests and Adjustments for further guidance.

Charge battery and perform a no-load test. Is battery voltage 12.4 volts or higher?

• Battery defective

YES

• Defective fuel shutoff solenoid • Defective switches or wiring

Does fuel shutoff solenoid click when ignition switch is turned to START/RUN position?

See Electrical Troubleshooting Does engine have internal resistance?

YES

Does engine crank slow?

YES

NOTE: Remove spark plugs and turn engine over by hand. Engine should rotate freely with little resistance.

(less than 350rpm) NO

Is choke operating properly?

• Piston rings or other internal components binding

Adjust NO

Repair or replace YES

• Starting motor defective

Do spark plugs have a strong blue spark?

YES

Are tappets adjusted properly?

YES YES

Adjust

• Defective spark plugs • Magneto kill circuit shorted to ground Check RIO System Operation • Flywheel magnet weak • Ignition coil air gap not adjusted properly

• Air cleaner plugged • Excessively rich fuel mixture • Water in fuel • Float needle stuck open

See Electrical Troubleshooting

• Not enough compression

Is engine getting fuel?

3/22/00

• Fuel shutoff valve closed • Fuel lines/vent plugged • Fuel pump defective • Insufficient engine vacuum

See Tests And Adjustments

5-9

ENGINE TROUBLESHOOTING GUIDE

ENGINE – Briggs & Stratton INTEK V-TWIN

Engine Runs Erratically/Loss Of Power

There is a diode in-line in the magneto kill wire coming from each ignition module. This diode prevents feedback from one module to the other. Without these diodes, one magneto could fire the coil for the other magneto. If a diode fails in one of the magneto kill wires, that coil, could be fired by the other module, the result may be similar to that of an erratic running engine. A twin cylinder engine may run adequately on one cylinder as long as the power required for the application does not exceed the power produced by the one cylinder.

IMPORTANT: Before proceeding, inspect the mower deck and belts for binding in the spindle assemblies or belts that are too tight/loose. A loose belt like a loose blade can cause a backlash effect that will counteract engine cranking effort. Excessive drive belt tension may cause premature bearing wear or result in bearing seizure. Grass clippings that build up near the cutting blades can cause excessive resistance and heat buildup that causes problems with the engine’s ability to turn the blades at a constant speed. Low lubricant levels in the spindles will buildup heat causing excessive resistance for the engine to deal with.

Perform a Cylinder Balance Test to determine if the problem is with one cylinder or both cylinders. Does the problem exist in just one cylinder?

NOTE:

To test specific electrical components, see Electrical Section and refer to either Diagnostics or Tests and Adjustments for further guidance.

• Defective spark plug

YES

NOTE:

A fouled spark plug may indicate that the carburetor is out of adjustment.

• Faulty ignition wire/ignition system • Defective head gasket • Intake manifold leak • Valves/valve adjustment • Piston rings • Piston • Cylinder bore • Faulty diode in Magneto kill circuit • Camshaft

• Carburetion • Crankcase vacuum • Ignition Timing • Governor operation • Camshaft

5 - 10

See Tests And Adjustments

3/22/00

THROTTLE CABLE ADJUSTMENT

ENGINE – Briggs & Stratton INTEK V-TWIN

TESTS AND ADJUSTMENTS THROTTLE CABLE ADJUSTMENT Reason: To make sure the throttle cable moves the throttle through its full range of movement. Cable Clamp

Choke Cable

Procedure: 1. Move throttle lever to FAST idle position. M95494

2. Loosen choke cable clamp. 3. Move choke cable until choke is completely open. 4. Tighten choke cable clamp to 2.8 N•m (25 lb-in.). 5. Pull choke knob to full choke position and make sure choke is closing completely. Readjust if necessary.

Governor Control Swivel

Specification: Choke Cable Clamp . . . . . . . . . . . 2.8 N•m (25 lb-in.) Throttle Cable M95557

2. Loosen throttle cable clamp. 3. Move throttle cable until governor control swivel is at end of travel. 4. Tighten throttle cable clamp to 2.8 N•m (25 lb-in.).

FUEL SHUTOFF SOLENOID TEST Reason: To test proper operation of fuel shutoff solenoid. Required Tools:

Specification:

• Jumper wire

Throttle Cable Clamp . . . . . . . . . . 2.8 N•m (25 lb-in.) Procedure:

CHOKE CABLE ADJUSTMENT Reason:

1. Listen for an audible click when ignition switch is turned from OFF to ON. 2. If solenoid does not click, problem could be in equipment wiring.

To make sure the choke cable moves the choke through its full range of movement. Procedure: 1. Push choke knob in and make sure choke is completely open. Push choke knob in to fully open choke position.

Connector

M95558

3/22/00

5 - 11

GOVERNOR ADJUSTMENT

ENGINE – Briggs & Stratton INTEK V-TWIN

3. Disconnect wire connector to fuel solenoid. 4. Momentarily place a jumper wire from solenoid wire to battery positive terminal. 5. If solenoid now clicks, the solenoid is working properly.

NOTE: If battery voltage drops below 9 volts when cranking engine or while engine is running, the solenoid will not function.

IMPORTANT: Do not bend governor link or distort governor lever. 4. Hold lever in this position and rotate governor shaft clockwise as far as it will go. Hold lever and shaft in position and tighten governor lever bolt and nut to specification. Specification: Governor Lever Nut . . . . . . . . . 14.6 N•m (130 lb-in.)

Results: • Solenoid is operating properly if a click is heard when ignition switched from OFF to ON.

DYNAMIC ADJUSTMENT (Engine Running) Equipment:

GOVERNOR ADJUSTMENT

• JD07270 Pulse Tachometer; or, • JTO5719 Photo Tachometer

c CAUTION

Procedure:

1. Move throttle lever to SLOW idle position.

STATIC ADJUSTMENT (Engine OFF) Governor Idle Tang

NOTE:

All linkage must be installed to make adjustment.

Procedure:

M95560

2. Bend governor idle tang to obtain a slow idle of 1750 rpm. Lever

Governor Lever

Governor Shaft

Throttle Restrictor Tang

Lever Bolt

M95495

1. Remove hood and top muffler shield. 2. Loosen governor lever bolt and nut. 3. Push on governor lever until throttle is wide open.

5 - 12

M95559

3/22/00

COMPRESSION TEST

ENGINE – Briggs & Stratton INTEK V-TWIN

3. With throttle lever in SLOW idle position and engine running at governed idle, bend throttle restrictor tang so that it just contacts the governor lever.

Fast Idle Tang

Without Cylinder Leak Tester – IMPORTANT: The battery must be fully charged for this test. Check and adjust the valves to ensure the valves have not been adjusted too tight. If either valve is off its seat the leak test will be invalid.

c CAUTION

Fast Idle Spring

With spark plugs removed, the magnetos must be grounded to the engine to prevent a spark that could ignite anything combustible.

M95559

1. Remove spark plugs and ground the magnetos by attaching a jumper wire from the magneto kill circuit connector to the engine to prevent a spark that could ignite anything combustible.

4. Move throttle lever to FAST idle position and bend fast idle tang (lower end of fast idle spring) to obtain top no load engine speed of 3350 rpm.

Compression Gauge

Specification: Slow Idle rpm . . . . . . . . . . . . . . . . . . . 1750 ± 50 rpm Fast Idle rpm. . . . . . . . . . . . . . . . . . . . 3350 ± 50 rpm

COMPRESSION TEST Reason: To determine the performance difference between cylinders. Required Tools: • JDM59 Compression Gauge

NOTE:

Briggs & Stratton does not publish any compression pressures, as it is extremely difficult to obtain an accurate reading without special equipment. What is recommended is to calculate the difference in compression readings between the two cylinders. Two methods are given in the following; one without a cylinder leak tester and one with a cylinder leak tester.

Cylinder Port

M95556

2. Insert a compression gauge into either cylinder. 3. Turn engine over with the starting motor until the highest pressure reading is obtained and record reading. 4. Repeat steps 3 and 4 with the next cylinder and record reading. 5. Use the following example and insert the recorded readings to determine the percent of leakage between cylinders. Example: cyl #1 cyl #2 75 psi 55 psi Formula:

55 ÷ 75 = 0.7333 x 100 = 73.333, 100 - 73.333 = 26.7% Highest Reading Lowest Reading

3/22/00

5 - 13

COMPRESSION TEST

ENGINE – Briggs & Stratton INTEK V-TWIN

Results: • A difference of more than 25% indicates a loss of compression in the cylinder with the lowest reading.

Regulator Tester

With Cylinder Leak Tester – Required Tools: • JTO3502 Cylinder Leak Tester • Breaker Bar and 30 mm Socket Air Line

c CAUTION With spark plugs removed, the magnetos must be grounded to the engine to prevent a spark that could ignite anything combustible.

M88974

7. Pull back the locking ring and rotate the regulator knob fully counterclockwise. Connect an air line to the tester. IMPORTANT: The air supply must have enough supply pressure to calibrate the tester (Usually 85 - 95 psi). 8. Pull back the locking ring and rotate the regulator knob clockwise until the gauge needle rests in the SET range of the gauge. Push the locking ring towards the tester to lock it.

Tester Breaker Bar

2. Remove spark plugs and ground the magnetos by attaching a jumper wire from the magneto kill circuit connector to the engine to prevent a spark that could ignite anything combustible.

Hose

IMPORTANT: The piston must be positioned at Top Dead Center (TDC) to ensure that the intake valves are away from the compression relief balls. If not, the intake valve will be open and the leak test will be invalid. 3. Remove valve covers. 4. Remove the rotating screen. 5. Turn crankshaft until piston is at Top Dead Center (TDC), on the compression stroke (Both Valves Closed). 6. Screw the adaptor into the spark plug hole but do not attach it to the tester at this time.

M88957

9. Connect the adaptor hose to the tester and record the needle position while holding the flywheel in position with a breaker bar.

NOTE:

A small amount of air escaping from the crankcase breather is normal.

Results: • Excessive air escaping from the crankcase breather indicates worn piston rings or cylinder wall

5 - 14

3/22/00

ENGINE – Briggs & Stratton INTEK V-TWIN

IGNITION ARMATURE AIR GAP ADJUSTMENT

• Air escaping from the carburetor indicates a worn intake valve or seat • Air escaping from the exhaust pipe indicates a worn exhaust valve or seat • Gauge reading in the Green (low) area indicates good compression. (Less Than 25% Is Considered Normal) • Gauge reading in the Yellow (Moderate) area indicates borderline compression. The engine is still usable but an overhaul or replacement should be considered • Gauge reading in the Red (High) area indicates excessive compression loss and engine reconditioning or replacement is necessary

4. Rotate flywheel until magnet is directly under armature laminations. 5. Place a 25 mm (0.010 in.) thickness gauge (C) between armature and magnet. 6. Loosen the mounting screw so magnet will pull armature against thickness gauge. 7. Tighten both mounting screws (B) to 2.8 N•m (25 lb-in.). 8. Rotate flywheel while pulling thickness gauge out from between the armature and the magnet. 9. Repeat steps 1 - 8 for the remaining ignition armature. Specifications:

IGNITION ARMATURE AIR GAP ADJUSTMENT

Armature Air Gap . 0.20 - 0.30 mm (0.008 - 0.012 in.) Armature Mounting Screws . . . . 2.8 N•m (25 lb-in.)

VALVE CLEARANCE ADJUSTMENT

Reason: To set the ignition air gap for proper operation and timing of the ignition system. Equipment:

NOTE: Correct position of crankshaft is necessary to eliminate interference by the compression release mechanism on the cam gear when adjusting valve clearance.

• 25 mm (0.010 in.) Thickness Gauge 1. Remove valve cover. 2. Turn crankshaft until piston is at Top Dead Center, (TDC) on the compression stroke (Both Valves Closed). 3. Insert a screwdriver through the spark plug opening until it touches the top of the piston. 4. Continue to turn the crankshaft clockwise until the piston has moved down 6.35 mm (0.25 in.).

Procedure:

B A

13 mm Wrench Feeler Gauge

M95220

1. Rotate flywheel until magnet (A) is away from armature laminations. 2. Loosen the armature mounting screws (B) and slide armature away from flywheel as far as possible. 3. Tighten one screw enough to hold the armature in place.

3/22/00

5 mm Hex Wrench M95496

5. Check valve clearance with a feeler gauge between valve stem and rocker arm. Valve clearance should be 0.10 - 0.16 mm (0.004 - 0.006 in.).

5 - 15

CYLINDER BALANCE TEST

ENGINE – Briggs & Stratton INTEK V-TWIN

6. If not, adjust as necessary using a 13 mm open end wrench and a 5 mm hex wrench. Tighten lock nut to 6.8 N•m (60 lb-in.). 7. Recheck clearance and make adjustments if necessary. 8. Install valve cover. Screw Driver

Specifications: Lock nut . . . . . . . . . . . . . . . . . . . . 6.8 N•m (60 lb-in.) Valve Clearance . . 0.10 - 0.16 mm (0.004 - 0.006 in.)

CYLINDER BALANCE TEST Spark Plug

Reason: If engine is hard starting, runs rough, misses or lacks power, perform a cylinder balance test. To determine if both cylinders are operating to their full potential. Tools: • D053515T Spark Tester • JT07270 Engine Tachometer • Screwdriver with insulated handle

M88976

7. Ground out one cylinder with screwdriver. Note rpm on tachometer. 8. Remove screwdriver and allow engine to recover. 9. Ground second cylinder with screwdriver. Note rpm on tachometer. Results: • If the difference between the two cylinders is less than 75 rpm, the cylinders should be considered equal • If the difference between the two cylinders is greater than 75 rpm, this indicates that the cylinder with the least rpm loss is weakest, and should be considered as the possible problem.

Procedure:

High Tension Lead Spark Plug

Spark Tester

M95561

1. Disconnect spark plug high tension lead. 2. Connect spark tester to spark plug and high tension lead. 3. Start engine and note spark at tester. Shut engine off. 4. Repeat steps 1 - 3 for second cylinder. 5. Connect engine tachometer. 6. Start engine and run at top no load speed. Note rpm on tachometer.

5 - 16

3/22/00

UPPER BLOWER HOUSING REMOVAL AND

ENGINE – Briggs & Stratton INTEK V-TWIN

INSTALLATION

REPAIR

IMPORTANT: DO NOT use petroleum solvents, such as kerosene, to clean foam pre-cleaner. They may cause foam to deteriorate. DO NOT oil paper cartridge. DO NOT use pressurized air to clean or dry paper cartridge. If paper cartridge is excessively dirty replace with new cartridge.

UPPER BLOWER HOUSING REMOVAL AND INSTALLATION Procedure:

Blower Housing

1. Remove cover assembly. 2. Remove filter cartridge and clean by tapping gently on a flat surface. If very dirty, replace.

Foam Pre-Cleaner

M95497A

1. Remove the four screws (A) securing the rotating screen to the fan. 2. Remove the six screws (B) (three on each side) holding the upper blower housing to the engine block. 3. Remove upper blower housing. 4. Install in reverse order of removal. Specifications:

M95500

3. Remove foam pre-cleaner. 4. Wash it in liquid detergent and water. 5. Squeeze it dry in a clean cloth. 6. Saturate it in clean engine oil. Wrap it in clean absorbent cloth and squeeze to remove excess oil. 7. Installation is the reverse of removal.

Blower Housing Screws . . . . . . . 9.0 N•m (80 lb-in.)

AIR CLEANER REMOVAL AND INSTALLATION

Cover

Filter Cartridge

M95498

3/22/00

5 - 17

CARBURETOR REMOVAL AND INSTALLATION

ENGINE – Briggs & Stratton INTEK V-TWIN

CARBURETOR REMOVAL AND INSTALLATION Choke Link

c CAUTION

Thru Bolts

Removal: 7. Remove the four thru bolts holding the carburetor and gaskets to the intake manifold. 8. Disconnect choke link while removing carburetor with solenoid, gaskets and spacer.

1. Remove upper blower housing.

Fuel Line

Installation: Cap Screws

Cap Screws

Choke Cable

1. Reconnect choke link while assembling spacer, gaskets and carburetor to intake manifold. 2. Secure Carburetor to intake using mounting studs and tighten to 7 N•m (65 lb-in.). 3. Install air cleaner elbow and tighten the four nuts to 7 N•m (65 lb-in.). 4. Connect throttle link to throttle lever.

M95499

2. Remove and plug the fuel inlet line. 3. Remove the choke cable. 4. Remove the four cap screws holding the intake manifold to the cylinder block.

Fuel Line Cap Screws

Cap Screws

Choke Cable Throttle Lever

Throttle Link

M95499

5. Install intake manifold and carburetor assembly and secure to cylinder block with four cap screws. Tighten to 9 N•m (80 lb-in.). 6. Reconnect and adjust choke cable. See “CHOKE CABLE ADJUSTMENT” on page 11. 7. Reconnect fuel line. 8. Install blower housing.

M95501

5. Disconnect the throttle link from the throttle lever while carefully pulling the carburetor and manifold assembly away from the engine. 6. Remove the four nuts holding the air cleaner elbow to the carburetor.

5 - 18

Specifications: Carburetor to Intake Manifold . . . . . 7 N•m (65 lb-in.) Air Cleaner Elbow to Carburetor . . 7 N•m (65 lb-in.) Intake Manifold . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.)

3/22/00

CARBURETOR DISASSEMBLY AND ASSEMBLY

ENGINE â&#x20AC;&#x201C; Briggs & Stratton INTEK V-TWIN

CARBURETOR DISASSEMBLY AND ASSEMBLY Component Location: Top Plate Choke Shaft Choke Valve

Foam Seal

Top Plate Gasket

Fuel Bowl

Discharge Nozzle

Rubber Gasket

Main Jet

Emulsion Tube Body

Rubber Gasket

Carburetor Body

Foam Seal Inlet Valve

Fuel Shutoff Solenoid

Throttle Shaft

Float Throttle Valve Plates O-ring

M95543

C E

B D A

M95544

1. Remove the two screws (A) holding the fuel bowl to the carburetor body and remove fuel bowl and drain the remaining gasoline into a suitable container. 2. Remove fuel shutoff solenoid (B) with washer. 3/22/00

M95545

3. Mark choke valve so it can be installed in its original position. 4. Remove the two screws securing the choke valve (C) to the choke shaft (D). Pull choke shaft and foam seal (E) out of carburetor body.

5 - 19

CARBURETOR DISASSEMBLY AND ASSEMBLY

ENGINE â&#x20AC;&#x201C; Briggs & Stratton INTEK V-TWIN

M95549

9. With a small punch, push out float hinge pin (K). M95546

5. Mark the throttle valves so they can be installed in their original position. 6. Remove the four screws securing the throttle valves (F) to the throttle shaft (G). Pull throttle shaft and foam seal out of carburetor body. 7. Remove the three screws (H) securing the cover plate and gasket to the carburetor body.

M95550

10. Remove float (L) and fuel inlet valve (M) as an assembly.

M95547

8. Remove the cover plate (I) and gasket (J).

M95548

11. Remove the screw (N) holding the discharge nozzle (O) into the carburetor body. 12. Remove the discharge nozzle and the rubber gasket. 13. Remove the two screws (P) and the emulsion tube body (Q). 14. Clean all metal parts with carburetor cleaner.

5 - 20

3/22/00

ENGINE â&#x20AC;&#x201C; Briggs & Stratton INTEK V-TWIN

CARBURETOR DISASSEMBLY AND ASSEMBLY

15. Inspect all moving parts for wear, nicks and burrs. Inspect float for leaks or damage. Inspect all mating surfaces for nicks, burrs, foreign material, and cracks. Replace all parts that are worn or damaged.

.250 in. Plate M95548

0.25 mm 0.010 in.

M89909

16. Check throttle and choke shafts and bushings for wear. Wear between shafts and carburetor bushings should not exceed 0.25 mm (0.010 in.). 17. Check wear by placing carburetor on 6 mm (1/4 in.) 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.

1. Install the rubber gasket and discharge nozzle (O) into the carburetor body and tighten screw (N) securely. 2. Install the rubber gasket and emulsion tube body (Q) to the carburetor body and tighten securely with two screws (P).

Worn Area M95550

3. Hook the fuel inlet valve (M) into the float tang (L) and slip float over emulsion tube body watching to align fuel inlet valve into seat.

M89910

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

Assembly:

NOTE: When assembling carburetor always use new seals and gaskets.

3/22/00

M95549

4. Push float hinge pin (K) into place. Center pin so that it does not interfear with fuel bowl.

5 - 21

CARBURETOR DISASSEMBLY AND ASSEMBLY

ENGINE â&#x20AC;&#x201C; Briggs & Stratton INTEK V-TWIN

Parallel

M95551

5. Check to be sure that float is parallel to carburetor body. If needed bend tang slightly to bring float to a parallel position.

M95545

9. Slide foam seal (E) onto choke shaft and slide shaft (D) into carburetor body. 10. Using the marks created during disassembly, install the choke valve (C) in its original position. Tighten screws securely.

M95546

6. Slide foam seal onto throttle shaft and slide shaft (G) into carburetor body. 7. Using the marks created during disassembly, install the throttle valves (F) in their original position. Tighten screws securely. 8. Place the cover gasket and cover plate on top of the carburetor body and tighten securely with the three screws (H).

M95541

11. Install O-ring in groove on bottom of carburetor body.

B A

M95544

5 - 22

3/22/00

ENGINE REMOVAL

ENGINE – Briggs & Stratton INTEK V-TWIN

12. Place fuel bowl over the emulsion tube body and tighten screws (A) securely. 13. Install fuel shutoff solenoid (B) with washer. Tighten to 5 N•m (45 lb-in.).

Specifications: Fuel Shutoff Solenoid . . . . . . . . . . . 5 N•m (45 lb-in.) A

B M95494

7. Loosen retaining clamp (A) for the throttle (B) and choke (C) cables and disconnect both cables.

Oil Capacity Without Filter . . . . . 1.42 L (1.5 U.S. qt) Oil Capacity With Filter . . . . . . . . . 1.9 L (2.0 U.S. qt)

Top Heat Shield Cap Screws (3)

G H F M95503

Front Heat Shield Cap Screws (4)

M95502

5. Remove the top and front exhaust heat shields. 6. Remove four cap screws securing muffler to engine and the four cap screw securing muffler to frame. Remove muffler.

3/22/00

8. Disconnect hose clamp (D) and slide fuel line (E) off hose barb on fuel pump and plug fuel line. 9. Disconnect wires from starting motor terminal (F). 10. Unplug connectors from stator and fuel shutoff solenoid (G).

NOTE: Ground terminal (H) will be disconnected when engine mounting bolt is removed.

5 - 23

ENGINE INSTALLATION

ENGINE – Briggs & Stratton INTEK V-TWIN

2. Put ground lead connector (H) on top of rear right hand engine mounting flange, and insert cap screw through connector, engine, and frame. 3. Install other three cap screws, washers, and nuts. Tighten to 32 N•m (24 lb-ft). 4. Inspect muffler flange for flatness. Install muffler with new gasket. Tighten muffler mounting bolts to 7 N•m (65 lb-in.).

L I N J

K M

M95205

11. Remove two cap screws (I) securing belt guard bracket. Remove bracket and belt guard (J). 12. Remove traction drive belt tension spring (K). 13. Remove traction drive belt (L). 14. Remove cap screw (M) securing pulley assembly to engine output shaft. Remove pulley assembly (N).

L I N J M

M95205

5. Install engine output shaft key and pulley assembly (N). Secure with washer, lock washer and cap screw (M). Tighten cap screw to 75 N•m (55 lb-ft). 6. Install traction drive belt (L). 7. Install traction drive belt tension spring (K). 8. Install belt guard and guard bracket (J). Secure with two cap screws (I). Tighten cap screw to 7 N•m (65 lb-in.).

Cap Screws

M55799

15. Remove four cap screws securing engine to frame. 16. Remove engine. E

ENGINE INSTALLATION 1. Install engine in mower frame. G H F M95503

9. Connect wires to starting motor terminal (F). 10. Reconnect plug connectors from main wire harness to the stator and fuel shutoff solenoid (G). 11. Remove plug from fuel line hose (E) and connect to the fuel pump and secure with hose clamp (D).

M95503

5 - 24

3/22/00

CYLINDER AIR GUIDES REMOVAL AND

ENGINE – Briggs & Stratton INTEK V-TWIN

INSTALLATION

CYLINDER AIR GUIDES REMOVAL AND INSTALLATION Removal:

1. Remove upper blower housing. See “UPPER BLOWER HOUSING REMOVAL AND INSTALLATION” on page 17. 2. Remove carburetor. See “CARBURETOR REMOVAL AND INSTALLATION” on page 18.

Cylinder Air Guide

Fuel Pump

B M95494

12. Reconnect and adjust choke (C) and throttle (B) cables. See “CHOKE CABLE ADJUSTMENT” on page 11., See “THROTTLE CABLE ADJUSTMENT” on page 11. A

Top Heat Shield Cap Screws (3) M95528

3. Remove the two screws (A) holding the fuel pump to the cylinder block. 4. Disconnect the fuel line to the carburetor and the pulse line to the valve cover. 5. Remove the third screw from the bottom of the air guide and remove the air guide. Front Heat Shield Cap Screws (4)

M95502

13. Install the top and front heat shields and tighten to not more than 7 N•m (65 lb-in.). 14. Refill crankcase with engine oil. 15. Install hood and Reconnect headlight harness on right side of hood. 16. Connect battery negative (–) cable. 17. Install mower deck.

Specifications: Engine Mounting Bolts . . . . . . . . . . 32 N•m (24 lb-ft) Exhaust Manifold . . . . . . . . . . . . . 24 N•m (216 lb-in.) Muffler to Frame . . . . . . . . . . . . . . . . 7 N•m (65 lb-in.) Engine Output Pulley. . . . . . . . . . . . 75 N•m (55 lb-ft) Belt Guard. . . . . . . . . . . . . . . . . . . . . 7 N•m (65 lb-in.) Heat Shield . . . . . . . . . . . . . . . . . . . . 7 N•m (65 lb-in.) Oil Capacity Without Filter . . . . . . . . . . . . . . 1.42 L (1.5 U.S. qt) With Filter . . . . . . . . . . . . . . . . . . 1.9 L (2.0 U.S. qt) 3/22/00

M95531

6. Remove the three screws (B) holding the left side air guide to the cylinder block.

5 - 25

CYLINDER HEAD REMOVAL AND INSTALLATION

ENGINE – Briggs & Stratton INTEK V-TWIN

4. Remove valve cover. Push Rods

Rocker Arm Valve Spring M95530 M95534

7. Remove the two screws (C) holding the front air guide in place. 8. Install air guides in reverse order. 9. Install carburetor. 10. Install carburetor linkage. 11. Install air filter assembly. 12. Install upper blower housing.

NOTE: To release spring pressure from rocker arms, rock the arm against spring pressure and allow push rod to drop out of the rocker arm socket. Push rod will move out of position, releasing valve spring pressure. 5. Release valve spring pressure.

Specification: Air Guide Screws . . . . . . . . . . . . . 6.8 N•m (60 lb-in.)

CYLINDER HEAD REMOVAL AND INSTALLATION

IMPORTANT: Exhaust valve push rods are aluminum. Intake valve push rods are steel. Mark push rods for identification with tape or tags to prevent interchange.

IMPORTANT: Mark all parts when disassembling cylinder heads to prevent interchanging. Rocker Support

1. Disconnect spark plug leads and remove spark plugs. 2. Remove intake manifold. 3. Remove cylinder air guides. See “CYLINDER AIR GUIDES REMOVAL AND INSTALLATION” on page 25.

Rocker Stud

Valve Cover Rocker Arm

Cap Screws

M95533

Cap Screws

6. Remove rocker studs, rocker arm supports, and rocker arms. 7. Lift out push rods.

M95536

5 - 26

3/22/00

CYLINDER HEAD REMOVAL AND INSTALLATION

ENGINE – Briggs & Stratton INTEK V-TWIN

M95386

Cylinder Head Cap Screws

M95386

8. Remove cylinder head cap screws.

Cylinder Head

4. Tighten five bolts down evenly by hand. Then tighten cylinder head bolts in sequence shown, in 6 N•m (55 lb-in.) increments, to 25 N•m (220 lb-in.). IMPORTANT: Do not tighten one bolt down completely before the others, as it may cause a warped cylinder head.

Gasket

5. Insert push rods into recess in tappets. IMPORTANT: Exhaust valve push rods are aluminum. Intake Valve push rods are steel. Mark push rods for identification with tape or tags to prevent interchange.

Alignment Sleeves M87024

Rocker Support

9. Remove cylinder head and gasket. Rocker Stud

Installation: 1. Clean gasket surfaces. 2. Place new gasket and cylinder head on cylinder. Align head with cylinder head alignment sleeves located in the cylinder. 3. Apply approved lubricant to threads and install five cylinder head cap screws. IMPORTANT: gaskets.

Do not use sealer of any kind on

Rocker Arm

M95533

6. Assemble rocker arms, shaft, supports and studs and install on cylinder head. 7. Tighten studs to 11.2 N•m (100 lb-in.).

3/22/00

5 - 27

CYLINDER HEAD INSPECTION AND REPAIR

Push Rods

ENGINE – Briggs & Stratton INTEK V-TWIN

CYLINDER HEAD INSPECTION AND REPAIR Procedure: 1. Remove combustion chamber deposits from combustion chamber and around valves using a soft, hand wire brush or scraper. With piston at top dead center, remove combustion chamber deposits from top of piston.

Rocker Arm Valve Spring M95534

8. Compress valve spring with rocker arm and insert push rod into rocker arm socket. Be sure push rods remain seated in recess in tappets. 9. Adjust valves. See “VALVE CLEARANCE ADJUSTMENT” on page 15. Valve Cover Cap Screws

VALVE REMOVAL Cap Screws

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

M95536

10. Install gasket and valve cover and tighten to 2.8 N•m (25 lb-in.). 11. Install intake and exhaust manifold, governor control bracket, cylinder air guides, valley cover, blower housing and air cleaner assembly. 12. Install and tighten spark plugs to 20 N•m (180 lb-in.). 13. Install spark plug leads.

Rocker Studs

Valve Spring Compressor

Specification: Cylinder Head Bolts (final) . . . . . 25 N•m (220 lb-in.) Rocker Arm Studs . . . . . . . . . . 11.2 N•m (100 lb-in.) Valve Cover Screws . . . . . . . . . 11.2 N•m (100 lb-in.) Spark Plugs . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.)

Split Retainer

M95535

2. Reinstall rocker studs into cylinder head. Do not tighten. Slip end of Valve Spring Compressor under stud of valve spring. Press down on tool handle to compress valve spring and remove split retainers.

5 - 28

3/22/00

VALVE INSPECTION AND REPAIR

ENGINE – Briggs & Stratton INTEK V-TWIN

3. Release pressure and remove retaining washer and spring. 4. Remove rocker studs. 5. Repeat procedure on other cylinder head.

VALVE INSPECTION AND REPAIR Procedure:

5. Replace valve if margin is badly burned or damaged, replace cylinder head. Valve seats are not replaceable. 6. Inspect valve springs and replace if broken or worn. 7. Inspect valve guides by inserting plug gauge into valve guide. If plug gauge inserts 6.4 mm (0.250 in.) or more, the guide is worn and cylinder head must be replaced. If plug gauge is not available, the rejection dimension for both intake and exhaust valve guides is 6.05 mm (0.238 in.). Specifications:

Valve Stem Seal

M87026

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

Valve Guide Wear Limits . . . . . . 6.05 mm (0.238 in.) Valve Stem Wear Limits Intake. . . . . . . . . . . . . . . . . . . . 5.92 mm (0.233 in.) Exhaust . . . . . . . . . . . . . . . . . . 5.92 mm (0.233 in.) Valve Seat Width . . . . 1.2–1.6 mm (0.047–0.062 in.) Valve Margin (min) . . . . . . . . . . . . 0.4 mm (0.016 in.) Valve Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Valve Seat Narrowing Angle . . . . . . . . . . . . . . . . . 30°

VALVE INSTALLATION Procedure:

Rocker Studs

Valve Spring Compressor

1.2 mm—1.6 mm (0.0468 in.—0.0625 in.) 0.8 mm (0.030 in.) Fit For Use

Margin

45°

0.4 mm (0.0156 in.) Discard M87027

2. Faces on valves may be resurfaced with a valve grinder to 45°. Valve seats can be reconditioned using Valve Seat Cutter. Valves and seats should then be lapped with Valve Lapping Tool and Valve Lapping Compound. Remove grinding marks and assure a good seal between valve and seat. Thoroughly clean lapping compound from valve seat and valve face. 3. Valve seat width should be 1.2—1.6 mm (0.047—0.062 in.). 4. If seat is wider, it may be narrowed using Valve Seat Cutter. Use 30° side of cutter to narrow the seats. If the valve is badly burned, it should be replaced.

3/22/00

Split Retainer

M95535

1. Install springs and valve spring retainers over valve stems. Temporarily install rocker studs in cylinder head. 2. With Valve Spring Compressor, compress spring and install split retainers. Repeat procedure for other valves. 3. Remove rocker studs.

5 - 29

PISTON, RINGS AND ROD REMOVAL AND INSTALLATION ENGINE â&#x20AC;&#x201C; Briggs & Stratton INTEK V-TWIN

PISTON, RINGS AND ROD REMOVAL AND INSTALLATION

NOTE:

Procedure: 1. Remove upper blower housing, flywheel, alternator, intake and carburetor assembly and governor linkage. 2. Remove starting motor, cylinder heads and crankcase cover.

NOTE: Remove any carbon or ridge at the top of the cylinder bore. This will prevent breaking the rings when removing the piston and connecting rod from the engine.

Measure cylinder bores before checking pistons and rings. If cylinder bores require re-sizing it will not be necessary to check pistons and rings since a new oversized piston assembly will be used.

5. If cylinder bore is more than 0.05 mm (0.003 in.) oversize, or 0.035 mm (0.0015 in.) out of round, it must be resized. IMPORTANT: When servicing pistons, rings, piston pins or rods, each rod, piston, piston pin and ring set must be kept as a set for the cylinder that it was removed from. Mark each set before removing from the engine.

3. Remove the connecting rod cap. Then push the piston and connecting rod out through the top of the cylinder. Oil Control Ring

M87038

M87036

NOTE:

Piston

If the cylinder is to be resized, there is no reason to check the piston, since a new oversized piston assembly will be used. If however, the cylinder is not to be resized and the piston shows no signs of wear or scoring, the piston rings must be replaced.

Checking End Gap: M86904

1. Insert old rings one at a time approximately 25.4 mm (1.0 in.) down into a cylinder bore.

5 - 30

3/22/00

PISTON INSPECTION

ENGINE â&#x20AC;&#x201C; Briggs & Stratton INTEK V-TWIN

PISTON INSPECTION Feeler Gauge

Procedure: 1. Clean carbon from top two ring grooves. 2. Place a new ring in each piston groove.

Ring

Feeler Gauge Piston M86906

2. Check end gap with feeler gauge. If ring end gap is greater than 0.76 mm (0.030 in.) for compression and oil ring, the ring is worn and should be replaced. A worn ring will usually show scratches caused by abrasives and/or have a shiny appearance. Never reuse worn piston rings.

c CAUTION The top and bottom edges of the ring may be extremely sharp. Never reuse worn piston rings.

M86905

3. If a 0.12 mm (0.005 in.) or larger feeler gauge can be inserted in the compression ring grooves, or a 0.20 mm (0.008 in.) or larger feeler gauge can be inserted in the oil ring grooves, the compression and ring grooves are worn and the piston should be replaced. Specifications: Wear Limits: Ring Grooves . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)

Specifications: Wear Limits: Ring End Gap . . . . . . . . . . . . . . . 0.76 mm (0.030 in.) Cylinder Oversize . . . . . . . . . . . 0.08 mm (0.003 in.) Cylinder Out of Round. . . . . . . 0.04 mm (0.0015 in.)

3/22/00

5 - 31

CONNECTING ROD INSPECTION

ENGINE – Briggs & Stratton INTEK V-TWIN

CONNECTING ROD INSPECTION “Out 1” Cylinder #1 “Out 2” Cylinder #2

Procedure:

Crankpin Bearing Notch or Circle M88927

Piston Pin Bearing

M88925

1. If the crankpin bearing in the connecting rod is scored, the rod must be replaced. Reject size of crankpin bearing and piston pin bearing is as follows: Specifications: Wear Limits: Crankpin Bearing . . . . . . . . . . . 38.13 mm (1.502 in.) Piston Pin Bearing . . . . . . . . . 17.13 mm (0.676 in.) 2. Replace connecting rod if either bore is worn.

Piston Pin Bore

4. The piston pin is a slip fit in both piston and connecting rod. Use a thin nose pliers or screwdriver and install a piston pin lock in groove on one side of piston. Refer to above drawing to determine correct location of rod in relation to notch or circle on piston. 5. Insert piston pin from opposite side of piston until pin stops against piston pin lock. Then install other piston pin lock. Be sure both locks are seated in grooves.

Top Compression Ring (Barrel Face)

Second Compression Ring (Taper Face)

“I.D.” Mark Indicates Top Of Ring

Oil Ring Expander

M88928 M88926

3. Reject sizes for piston pin and piston pin bore are as follows: Specifications: Piston Pin . . . . . . . . . . . . . . . . 17.06 mm (0.6718 in.) Piston Pin Bore . . . . . . . . . . . . . 17.13 mm 0.675 in.)

6. The correct piston ring positions are shown above. The oil ring is installed with the expander between the two oil control rings. The top and second compression rings are installed with “I.D.” mark toward top of piston. 7. Install expander first. Spiral bottom oil control ring into top ring groove, then into second ring groove and into position below expander. Repeat procedure for top oil control ring. 8. Using ring expander, install center compression ring then, top compression ring as shown above.

If piston pin is worn 0.01 mm (0.005 in.) out of round or below reject size, it must be replaced.

5 - 32

3/22/00

CONNECTING ROD INSPECTION

ENGINE – Briggs & Stratton INTEK V-TWIN

Flywheel Side

Projections Ring Compressor

M88929

Circle Projections Down

M88932

10. Thoroughly clean and then oil cylinder bore. Rotate crankshaft until crankpin journal is at bottom of stroke. This permits complete entry of compressed rings, piston and rod assembly, when pushed into cylinder. If other piston and rod assembly was removed, repeat procedure for that cylinder. M88930

9. Apply oil to piston rings, piston skirt and compress rings with ring compressor tool. Place piston and ring compressor upside down on bench and push down until head of piston and edge of ring compressor are even. Tighten ring compressor until rings are fully compressed. Then loosen ring compressor very slightly so that compressor can be rotated on piston skirt while holding connecting rod. Flywheel Side

Match Marks

PTO Side

Circle

Connecting Rod Screws M88933

11. Clean and oil crankshaft crankpin. 12. Pull connecting rod against crankpin. 13. Install rod cap with match marks aligned. 14. Install connecting rod screws and tighten to specification.

“Out 1” Cylinder #1 “Out 2” Cylinder #2

M88931

NOTE: The pistons have offset piston pin bores. When the Circle on piston is facing toward the flywheel side of engine, the words “OUT-1” on the side of the connecting rod for cylinder No. 1 and “OUT-2” on the side of the connecting rod for cylinder No. 2 should face toward the PTO side of the crankcase. 3/22/00

NOTE: Failure to use a torque wrench can result in loose connecting rods causing breakage, or tight connecting rods causing scoring. 15. Rotate crankshaft two (2) revolutions to check for binding. Rod should also be free to slide sideways on crankpin. Specifications: Connecting Rod Screws . . . . . 11.2 N•m (100 lb-in.)

5 - 33

CYLINDER BORE INSPECTION

ENGINE – Briggs & Stratton INTEK V-TWIN

CYLINDER BORE INSPECTION

CYLINDER BORE HONING

Procedure:

Top Center Approximately 45°

45°

Bottom Measure At Six Points

M86885

Center Of Piston Ring Travel M86883

1. Always inspect cylinder after engine has been disassembled. Visual inspection will show if there are any cracks, stripped bolt holes, broken fins or if the cylinder walls are damaged. Use a telescoping gauge, and dial caliper, or an inside micrometer to determine the size of the cylinder bore. Measure at right angles. Specifications: Standard Bore Size (min.) . . . . 75.41 mm (2.969 in.) Standard Bore Size (max.). . . . 75.51 mm (2.973 in.) 2. If the cylinder bore is more than 0.08 mm (0.003 in.) oversize, or 0.04 mm (0.0015 in.) out of round, it must be resized, or replaced. See “RESIZING CYLINDER BORE” on page 35. 3. If cylinder bores are within specification and show no signs of scoring or other damage, new pistons rings may be installed providing the cylinder bores are reconditioned using a rigid hone with finishing stones. This will restore the proper cross hatch angle in the cylinder bores. The proper cylinder cross hatch ensures proper lubrication and piston ring rotation.

5 - 34

NOTE: To produce the proper cross hatch finish use a drill speed of approximately 200 rpm and 40 – 60 strokes per minute. Lubricate hone liberally to prevent build up on finishing stones.

3/22/00

ENGINE – Briggs & Stratton INTEK V-TWIN

Procedure: 1. When cylinder and crankcase have been thoroughly cleaned, use a clean white rag or napkin and wipe the cylinder bore. If honing grit is present it will appear as a gray residue on rag. If any honing grit is evident, re-wash and rinse entire cylinder and crankcase and check again. When there is no trace of honing grit on rag, the cylinder is properly cleaned. Then oil cylinder bore to prevent rusting.

RESIZING CYLINDER BORE Procedure:

Fixture

Mounting Screws Wear

Ring Travel Unworn Area

Bore

0.750 in. to 1.0 in.

Extreme Hone Travel At Finish

0.750 in. To 1.0 in.

RESIZING CYLINDER BORE 3. If this is done accurately, the service oversize rings and pistons will fit perfectly and proper clearances will be maintained. IMPORTANT: If a boring bar is used, a hone must be used after the boring operation to produce the proper cylinder cross hatch. See “CYLINDER BORE HONING” on page 34. 4. If a hone is used to resize the cylinder bore, place hone in middle of cylinder bore. Tighten adjusting knob with finger until stones fit snugly against cylinder wall. DO NOT FORCE. 5. 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. 6. The recommended drill speed is 300 - 700 rpm maximum and 40 - 60 strokes per minute. 7. Because cylinder bores normally wear only in the area of ring travel, the cylinder bore will be round above and below ring travel. 8. Start drill and, as hone spins, move it up and down at the bottom of the cylinder bore. 9. Gradually increase the length of the strokes until hone travels full length of cylinder bore. Do not travel more than 19.05 mm (0.750 in.) to 25.4 mm (1.0 in.) above cylinder bore. 10. Lubricate hone frequently to prevent build up on stones. 11. As cutting tension decreases, stop hone and tighten adjusting knob following hone manufacturer’s recommendations. 12. Check cylinder bore size frequently. 13. Check cylinder bores at top and bottom for burrs. Remove burrs. Cylinder head and crankcase cover surfaces must be free of burrs and gasket material. 14. After cylinder bore has been brought to proper resizing dimension, a cross hatch must be applied to bore. See “CYLINDER BORE HONING” on page 34.

Hone Travel At Start

M88942

2. If the cylinder bore is not within specifications, it will have to be resized using a boring bar or hone. Always resize to exactly 0.25 mm (0.010 in.), 0.51 mm (0.020 in.), or 0.76 mm (0.030 in.) over standard size. Specifications: Standard Bore Size (min.) . . . . 75.40 mm (2.968 in.) Standard Bore Size (max.). . . . 75.48 mm (2.971 in.)

3/22/00

5 - 35

FLYWHEEL REMOVAL AND INSTALLATION

ENGINE – Briggs & Stratton INTEK V-TWIN

7. Before installing flywheel, clean taper and crankshaft taper removing all oil, dirt or grease. 8. Install flywheel. 9. Install flywheel nut.

Procedure: 1. Remove rotating screen. 2. Remove blower housing.

Flywheel Holder

30.0 mm Socket 30.0 mm Socket M89926

3. Place flywheel holder on fan retainer with lugs of flywheel holder engaging slots on fan retainer. While flywheel holder, loosen flywheel nut using 30 mm socket and wrench.

M89927

10. Place flywheel holder on fan retainer with lugs of flywheel holder engaging the slots of the fan retainer. While holding flywheel holder, tighten flywheel nut to specification. Specification: Flywheel Nut . . . . . . . . . . . . . . . . . 203 N•m (150 lb-ft)

CRANKSHAFT AND CAM GEAR REMOVAL AND INSTALLATION

Flywheel Puller

Procedure:

M87011

4. Install Flywheel puller turning puller screws into flywheel puller holes evenly. Tighten puller screws equally until flywheel loosens. IMPORTANT: Protect crankcase threads during flywheel removal. 5. Remove flywheel. 6. Flywheel should be inspected for cracks, broken flywheel fins, burrs on taper or keyway and distortion of keyway. Also check taper of crankshaft for burrs, rust or other damage. Replace crankshaft, if damaged.

5 - 36

Governor Lever Governor Control Bracket

M95530

1. Remove governor lever and disconnect governor link and springs. Remove governor control bracket. Remove oil fill tube and dipstick assembly. 2. Remove exhaust manifold, intake manifold and cylinder heads. 3/22/00

CRANKSHAFT AND CAM GEAR REMOVAL AND

ENGINE â&#x20AC;&#x201C; Briggs & Stratton INTEK V-TWIN

INSTALLATION NOTE:

Before crankcase cover is removed, it is recommended that any rust, paint or burrs be removed from power take off end of crankshaft. This will eliminate or reduce chances of damaging the crankcase cover bearing.

7. Lift out cam gear and governor assembly. Timing Gear Teeth

Oil Galleries Crankpin Mag. Journal

PTO Journal

Crankcase Cover

Threads And Keyway

Oil Galleries

Keyway M88935

8. Mark the connecting rods and caps to prevent interchanging when reassembling. 9. Remove piston and connecting rod assemblies. 10. Remove crankshaft from crankcase. Dowel Pins

IMPORTANT: The various wear points on the crankshaft must be measured. M95527

Wear Limit Sizes: 3. Remove crankcase cover. If crankcase cover sticks, tap lightly with soft hammer on alternate sides near dowel pins. IMPORTANT: DO NOT remove dowel pins.

Timing Marks

PTO Journal . . . . . . . . . . . . . . . 34.92 mm (1.375 in.) MAG. Journal . . . . . . . . . . . . . . 34.95 mm (1.376 in.) Crankshaft Crankpin . . . . . . . . 36.95 mm (1.455 in.) 11. Replace crankshaft if worn or if journals are scored. Keyways should be checked to be sure they are not worn or spread. Remove burrs from keyway edges to prevent damaging the bearing or oil seal. Check oil galleries for blockage or obstructions. Gear Teeth PTO Journal

Cam Lobes M95552

Mag. Journal

Intake

Exhaust M95553

IMPORTANT: If engine is rotated from this position, tappets will fall out. Tappets must not be mixed. 3/22/00

5 - 37

MAGNETO BEARING INSPECTION

ENGINE â&#x20AC;&#x201C; Briggs & Stratton INTEK V-TWIN

12. Check timing gear teeth for chipped or cracked teeth. Replace if needed. 13. Inspect cam gear teeth, lobes and journals for wear and nicks. Cam gear journal and lobe reject sizes are as follows:

MAGNETO BEARING INSPECTION Procedure:

Specifications: PTO Journal . . . . . . . . . . . . . . . MAG. Journal . . . . . . . . . . . . . . Cam Lobes Internal . . . . . . . . . . . . . . . . . External . . . . . . . . . . . . . . . . .

15.82 mm (0.623 in.) 15.82 mm (0.623 in.) 31.15 mm (1.229 in.) 31.06 mm (1.223 in.)

14. Tip engine to position crankshaft horizontally. 15. Place new crankcase cover gasket on crankcase. 16. Rotate governor shaft against bottom of crankcase cover. 17. Take care to protect the oil seal while assembling crankcase cover. No force should be used.

M88943

1. When checking the main magneto bearing, it should be replaced if scored or if not within tolerance. Specification: Magneto bearing reject size . . 35.12 mm (1.383 in.)

9 6

Punch

Roll Pin

8 M95527

18. Tighten cover bolts to specification in the above sequence.

M88944

Torque Specification: Bolts . . . . . . . . . . . . . . . . . . . . . 22.6 Nâ&#x20AC;˘m (200 lb-in.) 19. Install cylinder heads. 20. Install flywheel. 21. Install intake manifold and carburetor assembly. 22. Install governor lever and governor springs. 23. Install oil fill tube and dipstick assembly. Perform static governor adjustment. 24. Install engine shrouding. 25. Install air filter assembly.

5 - 38

Brushing Driver

M88945

3/22/00

PTO AND CAM BEARING INSPECTION

ENGINE â&#x20AC;&#x201C; Briggs & Stratton INTEK V-TWIN

3. To remove magneto bearing, place cylinder on a suitable cylinder support. Press out old bushing with a suitable bushing driver tool. 4. To install magneto bearing, place cylinder on a suitable cylinder support. Position new bushing against counterbore bearing in crankcase and carefully align oil holes in bushing with oil gallery holes in bearing. Press in new bushing with a suitable bushing driver tool.

M88948

6. Place tapered end of new roll pin in oil hole in bearing. Use roll pin driver, to install new roll pin. Drive in new roll pin until tool bottoms. 7. Install new oil seal using a suitable cylinder support. Press in new oil seal until it is flush with cylinder.

Oil Holes Must Align

M88946

PTO AND CAM BEARING INSPECTION Procedure:

NOTE: Be sure oil holes in bushing are aligned with oil gallery holes in bearing.

3.0 mm (0.125 in.)

Remove Taper

M88950

M88947

5. Before installing the new roll pin, grind off the taper, approximately 3.0 mm (0.125 in.) from one end of new roll pin. Quench pin in water periodically to prevent loss of temper. Remove all burrs and clean thoroughly.

NOTE: Old roll pin was driven into oil gallery hole. Place new roll pin into second oil gallery, not into same gallery as old pin.

1. Remove oil pump. 2. Remove oil seal. 3. Inspect PTO bearing and cam bearing. The crankcase cover must be replaced if PTO bearing or cam bearing is scored or if dimensions exceed reject size. 4. Install new PTO oil seal using a cylinder support. Press in seal until it is flush with mounting surface. Specifications: PTO end bearing reject size . . 41.37 mm (1.628 in.) Cam Bearing reject size. . . . . . 15.93 mm (0.628 in.)

NOTE: Always install new oil seal whenever engine is disassembled for major servicing or when repairing bearings. Always use the correct seal protector to prevent damaging oil seal.

3/22/00

5 - 39

LUBRICATION

ENGINE â&#x20AC;&#x201C; Briggs & Stratton INTEK V-TWIN

LUBRICATION BREATHER VALVE SERVICE Reed Valve

NOTE:

A leak at the seal between the tube and crankcase cover, or at the seal at the upper end of the dipstick, can result in a loss of crankcase vacuum and a discharge of oil or smoke through the muffler. M95504

The reed valve is spring loaded and must make a complete seal around the vent hole in breather body. Check to see that reed valve is not deformed. Reed Valve

IMPORTANT: Do not use force on reed valve.

M95504

The engine utilizes a breather valve to control and maintain a vacuum in the crankcase. The breather valve closes on the up stroke of the piston and opens on the down stroke of the piston to maintain a vacuum in the crankcase. This vacuum prevents oil leakage past piston rings, valve guides, oil seals, governor shaft and gaskets.

1. When installing breather, make sure breather gasket is located properly. 2. Place gasket and breather on engine block and install screws. Tighten to specification. Torque Specification: Screw. . . . . . . . . . . . . . . . . . . . . . . 6.2 Nâ&#x20AC;˘m (55 lb-in.)

Breather Tube

M95532

3. The breather is vented through the air cleaner to prevent dirt from entering the crankcase. Check breather tube for cracks, holes or hardening. Replace if damaged.

Breather Valve Assembly M95532

Before breather valve assembly can be removed for inspection, the blower housing and intake manifold must be removed.

5 - 40

3/22/00

ENGINE â&#x20AC;&#x201C; Briggs & Stratton INTEK V-TWIN

OIL PUMP REMOVAL AND INSTALLATION

OIL PUMP REMOVAL AND INSTALLATION Cover O-ring Inner Rotor Outer Rotor O-ring Groove M95487 M88919

This engine is equipped with a full pressure lubrication system with an oil filter. The gear driven oil pump supplies lubrication to all bearing journals. The oil pump draws oil through a screened pick up in the engine base and pumps the oil through the oil filter. The filtered oil flows through oil galleries (passages) in the crankcase cover and cylinder where it is distributed to the main bearings and cam gear bearings.

A pressure relief valve located in the oil pump housing limits the maximum oil pressure in the system. An oil gallery in the crankshaft supplies oil from the magneto bearing to the crankpin, lubricating the connecting rods.

NOTE: Engine oil pressure will vary with oil viscosity, ambient air temperature differences, operating temperatures and engine load.

9 6

Specification: Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . 15 - 50 psi

8 M95527

Procedure: 1. Drain oil from sump and filter. 2. Remove all rust, foreign material and burrs from the bottom of the crankcase and the crankshaft. 3. Remove the three screws (A) securing the oil pump cover (B) and O-ring to the sump.

3/22/00

9. Using the pattern shown, loosen the ten cap screws (C) securing the sump cover to the cylinder block Â˝ turn at a time until all ten cap screws are loosened, then remove the cap screws. This will prevent warping or breakage of the sump cover.

5 - 41

OIL PUMP REMOVAL AND INSTALLATION

ENGINE – Briggs & Stratton INTEK V-TWIN

Cover O-ring Inner Rotor Outer Rotor O-ring Groove M95488

10. Using a punch through the slots in the oil pump housing, press the oil screen out of the sump.

M95487

15. Lightly coat the rotors with clean motor oil and install the inner then the outer rotor. 16. Insert the O-ring into the O-ring groove in the sump and secure cover with the three screws. Tighten the screws to 5.6 N•m (50 lb-in.). 17. Complete installation of remaining governor linkage and carburetor. 18. Adjust governor. Specifications:

M95489

Sump Cover . . . . . . . . . . . . . . . 22.6 N•m (200 lb-in.) Oil Pump Cove Screws . . . . . . . . 5.6 N•m (50 lb-in.) 19.

11. Press a new screen filter into the sump with the hole in the back of the screen oriented away from the governor shaft. 12. Before installing sump, be sure that governor cup is in line with governor shaft paddle. 13. Install sump and gasket.

9 6

8 M95527

14. Tighten all screws, using the pattern indicated above, to 22.6 N•m (200 lb-in.).

5 - 42

3/22/00

CONTENTS

ELECTRICAL

CONTENTS Page

READING ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . 3 THEORY AND DIAGNOSTIC INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 THEORY OF OPERATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DIAGNOSTIC INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 WIRE COLOR ABBREVIATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

COMMON CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CONDUCTORS FOR 12 VOLT CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SCHEMATIC AND WIRING HARNESS LEGEND . . . . . . . . . . . . . . . . . . 7 COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 WIRE HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 W2 ENGINE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 W3 HEADLIGHT WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 STATOR WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Y1 FUEL SHUTOFF SOLENOID (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 THEORY OF OPERATION AND DIAGNOSTICS . . . . . . . . . . . . . . . . . . 14 CRANKINGCIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 CRANKING AND FUEL SHUT-OFF CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . 15 CRANKING AND FUEL SHUTOFF SOLENOID CIRCUIT DIAGNOSIS . . . . . . . . . . 16 IGNITION AND SEAT SWITCH CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . 18 IGNITION AND SEAT SWITCH CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . 19 IGNITION AND SEAT SWITCH CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 20 CHARGING AND HEADLIGHT CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . 22 CHARGING AND HEADLIGHT CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . 23 CHARGING AND HEADLIGHT CIRCUIT DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . 24

TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 BATTERY TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 CHARGE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 ALTERNATOR DC OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 ALTERNATOR DIODE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 AC VOLTAGE OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 STARTING SOLENOID TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 STARTER AMP DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 STARTER NO-LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 IGNITION DIODE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 FLYWHEEL MAGNET TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 SEAT SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 BRAKE SWITCH / PTO SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 BRAKE SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 GROUND CIRCUIT TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 KEY SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2/29/00

6-1

CONTENTS CONTINUED

ELECTRICAL

Page

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 KEY SWITCH REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . SEAT SWITCH REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING MOTOR SOLENOID REMOVAL AND INSTALLATION . . . . . . . . . . . . . STATOR AND IGNITION MODULE REMOVAL AND INSTALLATION . . . . . . . . . . . STARTING MOTOR REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . STARTING MOTOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING MOTOR PINION GEAR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . .

6-2

36 36 37 37 38 39 40 42

2/29/00

READING ELECTRICAL SCHEMATICS

ELECTRICAL

READING ELECTRICAL SCHEMATICS

The identifying letter is always the same for a specific component, but the identifying numbers are numbered consecutively from upper left to lower right. The terminal designation (J) is placed directly outside the symbol next to the connecting wire path. Switch positions (K) are also placed directly outside the symbol. The solid line (L) shows the position the switch is currently in and dash lines (M) represent other switch positions.

The schematic is made up of individual circuits laid out in a sequence of related functions. It is formatted with all power wires (A) across the top and all ground wires (B) across the bottom. Current flow is generally from top to bottom through each circuit and component. All components are shown in the OFF position. The diagram does not list connector (C) information unless needed to avoid confusion. If the connector is shown, the number next to it is the terminal pin location (D) in the connector.

Each circuit is identified at the bottom of the drawing by a section number (N) and section name (O). The circuit number (P) and wire color (Q) of the wires are shown directly next to the wire path.

Each component is shown by a symbol (E), its name (F), and an identification code (G). The identification code contains a device identifying letter (H) and number (I).

The same component name and identification code are used consistently on all diagrams in this section. Components can be easily cross-referenced.

S1 Key Switch B

F2 15 Amp Fuse

Wht

Red

S2 Seat Switch

K2 Ignition Relay

Run Off

F3 15 Amp Fuse

K1 Start Relay

F1 Fusible Link

215 Org

X2 721 Pur/ Wht

Red

X3 G1 Battery

M1 Starting Motor

W2 Engine X4 Wiring Yel/ Harness T1 Wht Ignition X5 Yel/Wht Yel/Wht Coil

X3 T2 Ignition Coil P

E1 Spark Plug

SE1-Power and Starting Circuit

3/22/00

805 Pnk/Blk

W1 Shielded Ground

710 Pur

Blk

800 Pink

Start 210 Red

Off Seat

On Seat

414 Yel/ Blk

E2 Spark Plug

Yel/ Wht Wht

SE2-Ignition and Interlock Circuit

Blk/Yel

105 Blk

SE3-PTO and Interlock

6-3

THEORY AND DIAGNOSTIC INFORMATION

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

DIAGNOSTIC INFORMATION The diagnostic procedures is used to test the complete circuit regardless of the problem or complaint. Select a symptom or system from the quick check or troubleshooting chart and follow the test procedures under that heading. The diagnostic procedure lists: • Test conditions • Test sequence • Test location • Normal reading • Check or test to perform if reading is not normal When performing the test or check, be sure to set your machine up to the test conditions listed and follow the sequence carefully. The middle "NORMAL" column gives the reading or condition that should be obtained when performing the test or check. If the results of the test or check are not normal, perform the test, check, or adjustment listed in the third "IF NOT NORMAL" column to repair the malfunction. The detailed tests or adjustments referred to in the "IF NOT NORMAL" column are located at the end of that group. The system diagram that accompanies each test procedure is drawn to resemble machine components. The key number on the art matches the number in the "TEST LOCATION" column and the leader line points to the exact point the test is to be made.

6-4

ELECTRICAL

WIRE COLOR ABBREVIATION CHART Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue Brn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green Gry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gray Org . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange Pnk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink Pur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Tan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tan Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow Blk/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . Black/White Blu/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue/White Brn/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . Brown/White Brn/Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown/Yellow Dk Blu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Blue Dk Brn/Lt Grn . . . . . . . . . . . . . Dark Brown/Light Green Dk Brn/Red . . . . . . . . . . . . . . . . . . . . Dark Brown/Red Dk Brn/Yel . . . . . . . . . . . . . . . . . . . .Dark Brown/Yellow Dk Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Green Lt Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Blue Lt Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Green Org/Wht . . . . . . . . . . . . . . . . . . . . . . . . . Orange/White Pnk/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink/Black Pur/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . Purple/White Red/Blk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/Black Red/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/White Wht/Blk. . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Black Wht/Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Red Yel/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yellow/Black Yel/Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yellow/Red Yel/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/White

3/22/00

COMMON CIRCUIT TESTS

ELECTRICAL

COMMON CIRCUIT TESTS

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

Shorted Circuit: A shorted circuit may result in the wrong component operating (i.e. improper wire-to-wire contact). To test for a shorted or improperly wired circuit: 1. Turn component switch ON. 2. Start at the controlling switch of the component that should not be operating. 3. Follow the circuit and disconnect wires at connectors until component stops operating. 4. Shorted or improper connections will be the last two wires disconnected.

M85601

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

M85602

M85600

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

CONDUCTORS FOR 12 VOLT CIRCUITS

STRANDED CONDUCTORS FOR 12 VOLT CIRCUITS SAE WIRE SIZE (GAUGE)

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

3/22/00

6-5

SPECIFICATIONS

ELECTRICAL

SPECIFICATIONS For all Sabre Lawn Tractors 1998 Model Year and before: For Sabre Lawn Tractors with the Reverse Implement Option (RIO), see "ELECTRICAL WITH RIO SYSTEM" Electrical section. Battery: Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 BCI group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .U-1 Cold Cranking Amps at 0°C (32°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190 amps Reserve capacity at 0°C (32°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 amps Specific gravity (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.225 points Electrolyte required fill (Approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt) Ignition: Primary coil resistance One direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1000 ohms Other direction (Minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 K ohms Secondary (Plug wire and core) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 - 10.85 K ohms Air gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.2 - 0.3 mm (0.008 - 0.012 in.) Spark Plug: Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M78543 (Champion RC-12 YC) Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.) Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (221 lb-in.) Starter: Starter Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bendix Inertia Drive Amp draw Loaded (engaging engine) . . . . . . . . . . . . . . . . . . . . . . .180 amps at 225 engine rpm Stator: Stator size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 amp Unregulated output at 3600 rpm (no lamps attached): AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 volts AC DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4 amps DC Headlight Bulbs: Headlight Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 1073, 12 VDC, 23 Watt

6-6

3/22/00

ELECTRICAL

SCHEMATIC AND WIRING HARNESS LEGEND

SCHEMATIC AND WIRING HARNESS LEGEND E1—Spark Plug (SE3, W2) E2—RH Headlight (SE4, W3) E3—LH Headlight (SE4, W3) F1—Fuse 15 amp (SE2, W1) G1—Battery (SE1, W1) G2—Stator (SE2, W1) K1—Start Solenoid (SE3, W1) M1—Starting Motor (SE2, W1) S1—Key Switch (SE3, W1) S2—Seat Switch (SE3, W1) S3—PTO Switch (SE3, W1) S4—Brake Switch (SE3, W1) T1—Magneto Ignition (SE3, W2) V1—Diode (SE1, W1) V2—Diode (SE3, W2) W1—Shielded Ground (SE1, W1) Y1—Fuel Shutoff Solenoid (SE2, W2) CONNECTORS: X1—W1 Main Wiring Harness to Stator (SE1, W1) X2—W1 Main Wiring Harness to T1 Magneto and Y1 Fuel Shutoff Solenoid (SE2 and SE3, W1) X3—W1 Main Wiring Harness to Headlights (SE4, W1) WIRING HARNESSES: W1—Main Wiring Harness W2—Engine Wiring Harness W3—Headlight Wiring Harness

3/22/00

6-7

COMPONENT LOCATION

ELECTRICAL

COMPONENT LOCATION

S2 Seat Switch G1 Battery S3 PTO Switch

Key Switch S1

G2 Stator

T1 Magneto Ignition

K1 Starting Motor Solenoid

F1 Fuse 15 Amp

Y1 Fuel Shutoff Solenoid

S4 Brake Switch

6-8

M1 Starting Motor

3/22/00

W1 Frame Ground

110 Blk

100 Blk

105 Blk

G1 Battery

M1 Starting Motor

Red

201 Red

220 Red/Blk

K1 Start Solenoid

V1 Diode

220 Red/ Blk

SE 1 - CHARGING

201 Red

G2 Stator

451 Yel/ Blk

401 Yel

200 Red

Y1 Fuel Shut-off Solenoid (16 hp only)

W2 Engine Wiring Harness

710 Pur

700 Pur

SE 2 - STARTING

105 Blk

201 Red

F1 15A FUSE

202 Red/ Wht

200 Red

S1 Key Switch

1 0 0 = Off 1 = On

S3 PTO Switch

700 Pur

705 Pur/ Wht

V2 Diode

946 Wht/ Blk

945 Wht/Blk

946A Wht/Blk

941A Wht

942 Wht

940 Wht

SE 3 - ENGINE IGNITION

946 Wht/Blk 110 Blk

0 = Off Seat 1 = On Seat

0 = Off 1 = Run 2 = Start

S2 Seat Switch

0 1

100 Blk

2 1 0

0,1

941 Wht

451 Yel/Blk

710 Pur

1 0 0 = Off 1 = On

S4 Brake Switch

T1 Magneto Ignition

942 Wht

705 Pur/ Wht

120 Blk

SE 4 - HEADLIGHTS

E1 Spark Plug

W2 Engine Wiring Harness

940 Wht

W3 Headlight Wiring Harness

E2 and E3 Headlights

451 Yel/ Wht

ELECTRICAL

ELECTRICAL SCHEMATIC

6-9

401 Yel

100 Blk

110 Blk

S1 Key Switch

941 Wht

700 Pur

200 Red 200

S2 Seat Switch

946 Wht/Blk

K1 Start Solenoid Ground

Bl k

202

10 5

K1 Start Solenoid Positive

220

Red 201

946 945

120 Blk

201 Red

G1 Battery Ground 8mm (5/16") Eyelet

S3 PTO Switch

705 Pur

710 Pur/Wht

202 Red/Wht

946A

F1 Fuse 15 Amp

105

110

100

6 - 10 A

Pur 710

942

940

941A

705 Pur/Wht

700 Pur

12 0

W1 Frame Ground 8mm (5/16") Eyelet

941A Wht

401 Yel

940 Wht

X2 Engine Connector

X1 Engine Connector

451 Yel/Wht

946A Wht/Blk

220 Red/Blk

S4 Brake Switch

945 Wht

942 Wht/Blk

941

451 Yel/Wht

X3 Headlight Connector

A B

G1 Battery Positive 8mm (5/16") Eyelet

WIRE HARNESS ELECTRICAL

WIRE HARNESS

3/22/00

W2 ENGINE WIRING HARNESS

ELECTRICAL

W2 ENGINE WIRING HARNESS Wht

Magneto Stop

940 Wht

401 Yel

X2 to W1 Engine Wiring Harness

Gry

Fuel Shutoff Solenoid

W3 HEADLIGHT WIRING HARNESS E2 LH Headlight Blk

Yel Blk

E1 RH Headlight

X3 To W1 Main Wiring Harness

Yel

STATOR WIRING HARNESS

Gry Gry

X1 to W1 Main Wiring Harness

Y1 FUEL SHUTOFF SOLENOID (optional) To W2 Engine Wiring Harness

3/22/00

Gry

Y1 Fuel Solenoid

6 - 11

TROUBLESHOOTING

ELECTRICAL

Test battery and connections.

●

● ●

See Ignition Circuit Tests See Charging Circuit Tests

●

See Starter Solenoid Test

●

Headlights do not light or will not shut off.

Battery goes dead, discharges or overcharges.

Engine will not shut off.

Weak or no spark.

Engine misses or runs rough. ●

● ●

●

● ●

See Seat Switch Tests

●

See headlight circuit test points.

Engine dies when blade lever is engaged.

●

Engine dies when brake lever is released.

See Ground Circuit Tests

●

Fuel shut-off solenoid will not close (16 hp only)

●

Fuel shut-off solenoid will not open (16 hp only)

See Cranking Circuit Diagnosis

Engine starts hard or will not stay running.

Check or Solution

Engine will not crank.

Problem or Symptom

Engine cranks—will not start.

TROUBLESHOOTING

●

See fuel shut-off solenoid circuit test points (16 hp only)

●

Check for short circuit.

●

Check for high resistance or open circuit.

●

Check for correct spark plug and spark plug gap.

●

Check strength of flywheel ignition module magnet and/or flywheel stator magnets.

●

See fuel and air system tests and adjustments.

●

● ●

●

Check for stator shorted to ground Check seat switch connector is plugged in and interlock spring inside connector is good

6 - 12

3/22/00

ELECTRICAL

TROUBLESHOOTING

NOTES:

3/22/00

6 - 13

THEORY OF OPERATION AND DIAGNOSTICS

ELECTRICAL

THEORY OF OPERATION AND DIAGNOSTICS CRANKING CIRCUIT OPERATION (INCLUDES FUEL SHUT-OFF CIRCUIT) Function: The cranking system is used to energize the starting motor. Operating Conditions: In order to crank the engine; the PTO lever must be off (PTO switch plunger depressed), the park brake must be engaged (brake switch plunger depressed), and the key switch must be in the start position. The operator does not have to be on the seat to crank the engine if the above conditions are met. Theory of Operation: The starting motor has a separate starter solenoid, located under the operatorâ&#x20AC;&#x2122;s seat. Current flows from the battery positive terminal to the starter solenoid secondary terminal, plug in fuse, and key switch. With the key switch in the start position, current flows from the key switch, to the PTO switch, brake switch, and to the starter solenoid primary terminal, energizing the pull-in windings of the solenoid and engaging the starter. The 16 hp fuel shut-off solenoid is also energized by the ignition switch and allows fuel to flow to the carburetor. The PTO switch is located under the left side of the mower frame, at the end of the PTO drive lever shaft. It is used to prevent the engine from cranking if the PTO is engaged. With the PTO lever disengaged, (PTO switch plunger depressed), current flows through the 705 Pur/Wht wire to the brake switch. The brake switch is located under the right side of the mower frame, in front of the brake pedal bell crank. When the park brake is engaged, the bell crank depresses the brake switch plunger and the switch is closed, energizing the starter solenoid primary coil. The starter solenoid plunger is pulled in by the primary coil, closing the secondary terminals and supplying high battery current to the starter motor. The spinning of the starter motor extends the starter Bendix drive into the engine flywheel, turning over the engine until the ignition circuit fires. Once the engine starts, the operator releases the ignition switch to run position. The current flow to the starter solenoid primary coil is stopped, releasing the starter solenoid plunger, and cutting off the high battery current to the starter motor.

6 - 14

3/22/00

CRANKING AND FUEL SHUT-OFF CIRCUIT SCHEMATIC

ELECTRICAL

CRANKING AND FUEL SHUT-OFF CIRCUIT SCHEMATIC 200 Red

202 Red/ Wht

S3 PTO Switch

200 Red

F1 15A FUSE

2 1 0 401 Yel

941A Wht

S1 Key Switch 0,1

700 Pur

705 Pur/ Wht

100 Blk

0 = Off 1 = Run 2 = Start

1 0 0 = Off 1 = On

705 Pur/ Wht

700 Pur 942 Wht

S4 Brake Switch

201 Red 201 Red

201 Red

G1 Battery

710 Pur

K1 Start Solenoid Red

Red

M1 Starting Motor

105 Blk

710 Pur

105 Blk

W2 Engine Wiring Harness

1 0 0 = Off 1 = On

401 Yel

M Y1 Fuel Shut-off Solenoid (16 hp only)

100 Blk

W1 Frame Ground

3/22/00

6 - 15

CRANKING AND FUEL SHUTOFF SOLENOID CIRCUIT DIAGNOSIS

ELECTRICAL

CRANKING AND FUEL SHUTOFF SOLENOID CIRCUIT DIAGNOSIS Test Conditions: • Key switch in OFF position

Test/Check Point

• Meter negative (–) lead on battery negative (–) terminal • Meter positive (+) lead on numbered test point

Normal

If Not Normal

1. Battery positive terminal

11.8-13.2 volts

Test battery.

2. Starter solenoid

Battery voltage

Check positive battery cable.

3. Key switch

Battery voltage

Check F1 fuse and 201 Red and 202 Red/Wht wires and connections.

Test Conditions: • Key switch in START position • Transmission in neutral

• PTO OFF • Park brake engaged

NOTE: Perform the tests below one at a time, allowing the starter to cool between tests. Do not allow the starter to crank for more that 15 seconds, and allow 30 seconds for starter windings to cool. If starter mechanism is not turning, windings may still be conducting current and heating up. Disconnect starter cable from starter (and isolate cable terminal) if cranking circuit or fuel shutoff solenoid (and not starter) is being tested. Test/Check Point

Normal

If Not Normal

4. Key switch

Battery voltage

Replace key switch

5. PTO switch

Battery voltage

Check 700 Pur wire and connections.

6. Brake switch

Battery voltage

Check 705 Pur/Wht wire and connections. If OK, replace PTO switch.

7. Start solenoid

Battery voltage

Check 710 Pur wire and connections. If OK, replace brake switch.

8. Start solenoid ground terminal (black Greater than 0 volts Less than 0.2 volts wire)

Greater than 0.2 volts - check start solenoid ground circuit Blk wire. 0 volts - replace solenoid.

9. Start solenoid

Battery voltage

Clean battery terminals. Replace start solenoid.

10. Starting motor

Battery voltage

Check Red wire back to solenoid. Test starting motor. See “STARTER AMP DRAW TEST” on page 29.

Fuel Shutoff Solenoid Test: (16 hp only)

(Ignition Switch In Start Position)

11. Key switch

Battery voltage

Replace key switch

12. Fuel shut-off solenoid

Battery voltage

Check 401 Yel wire and connections.

13. Fuel shut-off solenoid

Greater than 0 volts Less than 0.2 volts

Greater than 0.2 volts: Check engine ground; 0 volts: Replace fuel shut-off solenoid.

6 - 16

3/22/00

CRANKING AND FUEL SHUTOFF SOLENOID CIRCUIT DIAGNOSIS

ELECTRICAL

Red Red

2 201 Red

W1 Shielded Ground

8 G1 Battery K1 Start Solenoid

105 Blk 7 710 Pur

13 11 Ground back to Battery

401 Yel

S1 Key Switch Y1 Fuel Shutoff Solenoid

700 Pur 4

3 200 Red

12 401 Yel

S3 PTO Switch 705 Pur/Wht 700 Pur

M1 Starting Motor

S4 Brake Switch

Red 10

705 Pur/Wht

3/22/00

710 Pur 6

6 - 17

IGNITION AND SEAT SWITCH CIRCUIT OPERATION

IGNITION AND SEAT SWITCH CIRCUIT OPERATION Function: To create a spark that ignites the fuel/air mixture in the engine. Operating Conditions: To produce a spark, the key switch must be in the START or RUN position. The operator can be ON or OFF the seat—seat switch; however, the PTO lever must be OFF and the brake switch must be ENGAGED (brake pedal applied) to start the engine. Once the engine is running, the operator must be ON the seat to release the brake pedal, or engage the PTO, or the ignition module will be grounded and the engine will stop.

ELECTRICAL

induction into the secondary coil which prevents the spark plug from firing, killing the engine. The PTO switch is in parallel with the brake switch, and will also ground the ignition module when the PTO is engaged with no operator on the machine, killing the engine. The PTO and brake switches are also used to prevent the engine from cranking if the PTO lever is ENGAGED or park Brake is NOT ENGAGED when key switch is moved to START. See “CRANKING CIRCUIT OPERATION” on page 14. The seat switch connector has an interlock built in which prevents the mower from being used with the seat switch disconnected. An internal spring will short the two cavity connectors together when disconnected from the seat switch. This has the effect of grounding the ignition module when the PTO lever is engaged or the brake pedal is released, stalling the engine.

Theory of Operation: The ignition system is an electronic magneto design. Ignition timing is controlled by the ignition module and is NOT ADJUSTABLE. Battery current is always present at key switch terminal "B". When the optional fuel shut-off solenoid is installed, it becomes energized when the key switch is in either START or RUN position, via key switch terminal "A", unseating the plunger and allowing fuel flow into the venturi of the carburetor. When the key switch is turned OFF, current flow is broken and internal spring force closes the solenoid plunger, stopping fuel flow. As the flywheel turns in the cranking circuit, a magnet in the flywheel produces current in the primary coil of the ignition module by electromagnetic induction. When the primary current builds to its highest level, the ignition module induces high voltage current into the secondary coil. This high voltage current then flows to the spark plug and jumps the spark plug gap and creates a spark that ignites the fuel/air mixture, causing the engine to start and run. When the key switch is in the START or RUN position, the key switch eliminates the path to ground for ignition current, allowing spark generation to continue. The engine is SHUT-OFF by grounding the ignition module in one of two ways: 1. Through the key switch when the key is moved to OFF position. 2. Through the brake switch, or PTO switch, if the operator tries to get OFF the seat with the PTO ENGAGED or the park brake NOT ENGAGED. When the brake pedal is RELEASED, the brake switch creates a path for the ignition module to the seat switch. When the operator is OFF the seat, the seat switch (normally closed) completes the path to ground for the ignition module current, preventing high current

6 - 18

3/22/00

IGNITION AND SEAT SWITCH CIRCUIT SCHEMATIC

ELECTRICAL

IGNITION AND SEAT SWITCH CIRCUIT SCHEMATIC 940 Wht 941 Wht

942 Wht

200 Red 200 Red

941 Wht

S1 Key Switch 0,1 2 1 0

700 Pur

401 Yel

0 = Off 1 = Run 2 = Start

100 Blk

S3 PTO Switch

202 Red/ Wht

1 0 0 = Off 1 = On

F1 15A FUSE

705 Pur/ Wht

941A Wht

705 Pur/ Wht

700 Pur 946A Wht/ Blk

942 Wht

S4 Brake Switch

710 Pur 201 Red

945 Wht/Blk

201 Red

710 Pur

K1 Start Solenoid G1 Battery Red

Red

M1 Starting Motor

105 Blk

W2 Engine Wiring Harness

401 Yel

0 1

Y1 Fuel Shut-off Solenoid (16 hp only)

0 = Off Seat 1 = On Seat 946 Wht/Blk 110 Blk

S2 Seat Switch

940 Wht

100 Blk

W1 Frame Ground

1 0 0 = Off 1 = On

W2 Engine Wiring Harness

V2 Diode

E1 Spark Plug T1 Magneto Ignition

3/22/00

6 - 19

IGNITION AND SEAT SWITCH CIRCUIT DIAGNOSIS

ELECTRICAL

IGNITION AND SEAT SWITCH CIRCUIT DIAGNOSIS When diagnosing an ignition problem, isolate magneto circuit from ground circuit by separating engine connector. If engine will not start check magneto circuit first and then check ground circuit. If engine will not shut off, check ground circuit. Remember engine is stopped by grounding ignition coil through either key switch, seat switch or the brake switch and PTO switch. Test Conditions: • Key switch in OFF position • Park Brake engaged Test/Check Point

• PTO disengaged • X2 Engine connector Disconnected Normal

If Not Normal

1. Key switch

Continuity to ground

Check 100 Blk wire and connections.

2. X2 engine connector

Continuity to ground

Check 940 and 941 Wht wires and connections. If OK, replace key switch.

Test Conditions: • Key switch in RUN position (engine not running) • Park Brake DISENGAGED 3. X2 engine connector

• PTO ENGAGED • X2 Engine connector Disconnected Infinite resistance

Check for any Wht and/or Wht/Blk wires shorted to chassis.

Test Conditions: • Key switch in RUN position (engine not running) • Park brake ENGAGED Test/Check Point

• PTO ENGAGED • Seat switch released Normal

If Not Normal

4. Seat switch

Continuity to ground

Check 110 Blk wire and connections.

5. PTO switch

Continuity to ground

Check 946A and 946 Wht/Blk wires and connections. If OK, replace seat switch.

6. X2 engine connector

Continuity to ground

Check 940 and 941A Wht wires and connections. If OK, replace PTO switch.

Test Conditions: • Key switch in RUN position (engine not running) • Park brake DISENGAGED Test/Check Point

• PTO DISENGAGED • Seat switch released Normal

If Not Normal

7. Brake switch

Continuity to ground

Check 945 and 946 Wht/Blk wires and connections.

8. X2 engine connector

Continuity to ground

Check 940 and 942 Wht wires and connections. If OK, replace brake switch.

6 - 20

3/22/00

IGNITION AND SEAT SWITCH CIRCUIT DIAGNOSIS

ELECTRICAL

Test Conditions:Test performed if engine will NOT shut off by key switch or when operator leaves seat with EITHER PTO ENGAGED or brake switch OFF. • Key switch in OFF position (Closes fuel valve to stop engine) • Allow engine to cool, and remove engine cover to access ignition coils • Disconnect diode(s) from ignition coil(s) • Operator OFF seat • PTO ON (ENGAGED); or, Park brake OFF 9. Ignition coil diode(s)

Continuity to ground with diode disconnected from ignition coil.

Faulty diode(s). Replace diode(s).

1 100 Blk 8 6 3 2

S1 Key Switch

940 Wht

941 Wht

X2 Engine Connector

110 Blk V1 or V2 Diode (Briggs & Stratton Engines) T1 or T2 Magneto 9 Ignition Coil (Briggs & Stratton Engines)

946 Wht/Blk

941A Wht

942 Wht

S4 Brake Switch 945 Wht/Blk 7

3/22/00

S2 Seat Switch

S3 PTO Switch 946A Wht/Blk 5

6 - 21

CHARGING AND HEADLIGHT CIRCUIT OPERATION

ELECTRICAL

CHARGING AND HEADLIGHT CIRCUIT OPERATION Function: To maintain battery voltage at 12.4 VDC or higher, and provide electrical power to light the headlights. Operating Conditions: The engine must be running for the charging system to operate. Headlights are on only when the engine is running. Theory of Operation: The charging system is of the permanent magnet and stator design. Magnets imbedded into the crankshaft flywheel pass a multi-pole stator mounted under the flywheel, inducing alternating current into the stator coils. Alternating current is routed to the headlamp bulbs anytime the engine is running through the 451 Yel/Wht wire. System Operation: The dual circuit stator provides DC current for charging the battery and an independent AC circuit for headlights. The battery is not used for lights, so lights are available even if the battery is disconnected or removed. Current for lights is available as long as the engine is running. Alternating current is routed to the headlamp bulbs anytime the engine is running through the 451 Yel/Wht wire. The output depends upon engine speed, so brightness of the lights changes with engine speed. Magnets mounted to the flywheel rotate around two coils of wire, (the stator), mounted underneath the flywheel. As the magnets rotate, current is generated in the coiled wire and is rectified by an in-line diode in the engine wire harness side to the 220 Red/Blk circuit, to DC current to charge the battery. This circuit is protected by the 15 amp plug-in fuse (F1) and the ground circuit is completed through the frame. The current from the DC side of the stator is unregulated and is rated at 3 amps. The output rises from 2 amps at 2400 RPM to 3 amps at 3600 RPM.

6 - 22

3/22/00

CHARGING AND HEADLIGHT CIRCUIT SCHEMATIC

ELECTRICAL

CHARGING AND HEADLIGHT CIRCUIT SCHEMATIC E1 and E2 Headlights W3 Headlight Wiring Harness

X3 451 Yel/Wht 220 Red/Blk

200 Red

X3 120 Blk

220 Red/ Blk

451 Yel/ Blk

202 Red/ Wht

V1 Diode

F1 15A FUSE

200 Red

S1 Key Switch 0,1

G 2 1 0 0 = Off 1 = Run 2 = Start

G2 Stator 201 Red 201 Red

201 Red

G1 Battery

710 Pur

K1 Start Solenoid Red

105 Blk

Red

M1 Starting Motor

105 Blk

W1 Frame Ground

3/22/00

6 - 23

CHARGING AND HEADLIGHT CIRCUIT DIAGNOSIS

ELECTRICAL

CHARGING AND HEADLIGHT CIRCUIT DIAGNOSIS Test Conditions: • Key switch RUN position, engine RUNNING at full throttle • Stator connector unplugged

• Park brake ON • PTO OFF • Be sure to set multimeter to read AC or DC voltage or amperage as test requires

Test/Check Point

Normal

If Not Normal

1. Stator connector, DC lead

2 - 4 amps

Check diode in DC wire.

2. Stator connector, AC lead

14 volts AC or higher

Replace stator.

Test Conditions: • Key switch OFF • Park Brake ON

• PTO OFF

3. Stator connector, Diode

Continuity with black test lead clipped to connector pin, and red test lead clipped to pin piercing wire behind diode.

Replace diode.

4. Stator connector, Diode

No continuity with black test lead clipped to pin piercing wire behind diode, and red test lead clipped to connector pin.

Replace diode.

Test Conditions: • Engine must be RUNNING at full throttle.

• PTO OFF • Park brake ENGAGED (ON)

5. Headlamps

Bulbs lit

Check for burned out bulb.

6. Headlight wiring harness connector X1

Battery voltage

Check 451 Yel wire and connections.

7. RH headlight

Battery voltage

Check headlight wiring harness and connector.

8. RH headlight

Greater than 0 volts - less than 0.2 volts.

0 volts: Replace headlight Greater than 0.2 volts: Check harness connector (X2) and 125, 110, 135 Blk wires and connections.

9. LH headlight

Battery voltage

Check Blk jumper wire and connections between headlights.

Greater than 0 volts - less than 0.2 volts.

0 volts: Replace headlight. Greater than 0.2 volts: Check Yel jumper wire and connections between headlights.

10. LH headlight

6 - 24

3/22/00

CHARGING AND HEADLIGHT CIRCUIT DIAGNOSIS

ELECTRICAL

G1 Stator Pin 3 4 220 Red/Blk

V1 Diode

2 X2 Connector 1 451 Yel/Blk

6 451 Yel/Blk

X1 Headlight Connector

7 Blk 8 Yel

W3 Headlight Wiring Harness 10

3/22/00

Yel

Blk

6 - 25

TESTS AND ADJUSTMENTS

TESTS AND ADJUSTMENTS BATTERY TEST Reason: To check condition of battery and determine battery voltage.

ELECTRICAL

• All cells less than 1.225 with less than 50 point variation, charge battery at 10 amp rate. • All cells more than 1.225 with less than 50 point variation, load test battery. • More than 50 point variation: replace battery.

CHARGE BATTERY Reason:

Equipment: • Hydrometer • Voltmeter or Battery Tester

To increase battery charge after battery has been discharged. Equipment: • Battery charger (variable rate)

Battery Charger and Booster

Procedure: Procedure: 1. Clean battery terminals and top of battery. 2. Inspect battery terminals and case for breakage or cracks. 3. Check electrolyte level in each battery cell. Add clean, soft water as needed. If water was added, charge battery for 20 minutes at 10 amps. 4. Remove surface charge by placing a small load on the battery for 15 seconds. 5. Check specific gravity of each cell with a hydrometer. 6. Check battery voltage with voltmeter or Battery Tester. Specifications: Minimum specific gravity . . . . . . . . . 1.225 with less than 50 point variation Minimum battery voltage. . . . . . . . . . . . . . .12.4 VDC Results: • Battery voltage less than 12.4 VDC, charge battery. • Battery voltage more than 12.4 VDC, test specific gravity. • All cells less than 1.175, charge battery at 10 amp rate.

6 - 26

NOTE:

See BATTERY TEST in this group before charging battery.

1. Connect variable rate charger to battery.

NOTE: Maximum charge time at boost setting is 10 minutes. Allow additional 5 minutes for each 10 degrees below 70 degrees F. 2. Start charger at slow rate. Increase charge rate one setting at a time. Check charger ammeter after 1 minute at each setting. Maintain 10 amp charge rate. Use boost setting as necessary. 3. Check if battery is accepting a 10 amp charge after 10 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 steps 6 and 7. Battery is accepting 10 amp charge after 10 minutes at boost setting, but battery did need water or all cells were below 1.175: go to steps 4 and 5. 4. Set charger at 15-25 amps.

3/22/00

BATTERY LOAD TEST

ELECTRICAL

IMPORTANT: Decrease charge rate if battery gases or bubbles excessively or becomes too warm to touch. 5. Check specific gravity after 30 minutes (60 minutes for maintenance-free battery). More than 50 point variation between cells: replace battery. Less than 50 point variation between cells: go to steps 6 and 7.

NOTE: If battery was discharged at slow or unknown rate, charge at 10–15 amps for 6–12 hours. (Maintenance-free battery: 12–24 hours.) If battery was discharged at fast rate, charge at 20–25 amps for 2–4 hours. (Maintenance-free battery: 4–8 hours.) 6. Continue charging battery until specific gravity is 1.230-1.265 points. 7. Load test battery.

Procedure: 1. Turn load knob of tester clockwise until amperage reading (A) is equal to: a. Cold cranking amperage rating (use blue scale). — OR — b. Three times ampere hour rating (use black scale). 2. Hold for 15 seconds and turn load knob of tester off. 3. Repeat procedure steps 1 and 2 from above and read condition of battery at DC Volts scale (B). Results: • If the battery does not pass the test and has not been charged, charge battery and retest. • If the battery does not pass the test and has been charged, replace the battery.

ALTERNATOR DC OUTPUT TEST Reason:

BATTERY LOAD TEST

To determine proper output of stator.

Reason:

Equipment:

To check condition of battery under load.

• Multimeter

Equipment:

Procedure:

• Battery Tester

1. Disconnect connector from stator. 2. Set multimeter for DC amps. A

D D.C. AMPS

D.C. VOLTS

C Red Lead To Pin

Black Lead To Battery +

Connections: 1. Turn load knob (C) of tester counter-clockwise to off. 2. Connect tester positive cable (D) to battery positive terminal. 3. Connect tester negative cable (E) to battery negative terminal.

3/22/00

Raised Rib On Connector Indicates DC Pin Side

AC Output DC Output M89148

3. Insert RED test lead into 10 A receptacle in meter. 4. Insert BLACK test lead into COM receptacle in meter.

6 - 27

ALTERNATOR DIODE TEST

ELECTRICAL

5. Attach RED test clip to DC output pin in connector 6. Attach BLACK test lead clip to positive (+) battery terminal. 7. Start engine and run at full throttle. 8. Check output. Specifications: DC output at full throttle . . . . . . . . . . . . . . 2–4 amps Results:

• If meter beeps once, diode is OK. • If meter makes a continuous tone, diode is defective (shorted). Replace diode. • If meter displays “OL”, proceed to step 6. 7. Reverse test leads. • If meter beeps once, diode is installed backwards. Replace diode. • If meter still displays OL, diode is defective (open). Replace diode.

AC VOLTAGE OUTPUT TEST

• Output will vary with battery voltage. If battery voltage is at its maximum, output will be approximately 2 amps • If no or low output is found, test diode

ALTERNATOR DIODE TEST

Reason: To measure engine alternating current voltage output to determine stator condition. Equipment: • Multimeter

Reason: To determine alternator diode is functioning correctly. Equipment: • Multimeter with diode test function.

Black Wire

Procedure: M95148

1. Disconnect connector from stator. 2. Set multimeter for Diode Test position.

Connections: 1. Disconnect engine connector (A). 2. Set multimeter to read AC voltage. 3. Connect red multimeter lead to black wire from engine connector at terminal (B). 4. Connect black multimeter lead to chassis ground. Procedure: 1. Start and run engine at 3600 rpm while watching multimeter.

Specifications: Red Wire

AC Voltage Output (3600 rpm): . . . . . . . . . . . 14 VAC M89153

Results: 3. Insert RED test lead into VOLTS receptacle in meter. 4. Insert BLACK test lead into COM receptacle in meter. 5. Attach RED test lead clip to point (A). (It may be necessary to pierce wire with a pin as shown) 6. Attach BLACK test lead clip to point (B). (DC output pin)

6 - 28

• If reading is less than specifications, see Briggs & Stratton service manual for electrical system repair.

3/22/00

STARTING SOLENOID TEST

ELECTRICAL

STARTING SOLENOID TEST

10. Connect VOM to negative (–) battery terminal (A) and terminal (D) (Pur wire) of starting motor solenoid. 11. Momentarily turn ignition key to START position and check for battery voltage.

Reason: To determine if starting solenoid is defective.

Results:

Equipment: • Volt Ohm Meter Procedure: 1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Raise hood. 6. Disconnect and ground spark plug lead.

• No battery voltage – Check Pur wire and connections. • Battery voltage – Check Blk wire and connections between starting motor solenoid and frame ground. If OK, starting motor solenoid is OK.

STARTER AMP DRAW TEST Reason: To determine the amperage required to crank the engine and check starter motor operation under load. Equipment: • Battery Tester • Photo Tachometer

B C v

D A

A M87617

7. Connect VOM to negative (–) battery terminal (A) and terminal (B) of starting motor solenoid. Check for battery voltage.

M55943a

Connections: Results: • No battery voltage – Check battery positive (+) terminal and starting motor solenoid terminal (B) for loose connections. Clean any corrosion. • Battery voltage – go to next step. 8. Connect VOM to negative (–) battery terminal (A) and terminal (C) of starting motor solenoid. 9. Momentarily turn ignition key to START position and check for battery voltage. Results • Battery voltage – starting motor solenoid is not defective. • No battery voltage – go to next step.

3/22/00

1. Put transaxle in neutral. Engage park brake. 2. Test system ground connections and battery. 3. Turn knob (A) of tester counter-clockwise to off. 4. Connect red clamp of battery tester to positive terminal of battery and black clamp of tester to negative terminal of battery. 5. Install tachometer reflective tape on flywheel screen. 6. Remove spark plug high tension lead and ground to engine. Procedure: 1. Crank engine and read voltage on DC voltage scale of battery tester and check engine rpm. 2. Turn key switch to off position.

6 - 29

STARTER NO-LOAD TEST IMPORTANT: Perform the following procedure within 15 seconds to prevent electrical damage to components. 3. Turn knob of battery tester clockwise until the DC voltage is the same as when cranking. 4. Read DC amperage on battery tester. 5. Turn load knob fully counterclockwise.

ELECTRICAL

STARTER NO-LOAD TEST Reason: To determine starting motor condition under no-load conditions. Required Tools:

Specifications: Maximum starter amp draw . . . . . . . . . . . . . . . . . . . . . . . . 180 amps at 225 rpm Results: • If amperage is above specification, or rpm is low, check starter for binding or damaged. • If starter is good, check internal engine, traction or PTO drive for binding or damage.

• JT05791 Multimeter • JT02153 Current Clamp • 12 Volt Battery • Jumper Cables Procedure: IMPORTANT: Do not clamp starting motor housing in vise or strike with a hammer. Clamp only on the mounting bracket. Starting motors contain two ceramic magnets that can be broken or cracked if the motor housing is hit, deformed or dented.

1. Clamp the starting motor mounting bracket in a vise. 2. Connect the NEG jumper cable to the battery NEG post and the frame of the starting motor. 3. Connect the POS jumper cable to the POS post of the battery.

JTO7270 Hand-Held Digital Tachometer

JTO2153 Current Clamp

JTO5791 Multitester

6 - 30

3/22/00

IGNITION DIODE TEST

ELECTRICAL

4. Connect current clamp RED lead to the VOLTS jack of the multimeter and the BLACK lead of the current clamp to the COM jack on the multimeter. 5. Clamp jaws of current clamp around the positive jumper cable. 6. Set the current clamp to 2000A and the multimeter to 300mV. 7. Adjust the DCA ZERO ADJUST dial on the current clamp for a zero reading on the multimeter.

NOTE: The core of the jaws may hold some magnetic force after the current clamp has been used for measurement. If you cannot zero adjust the display, open the jaws and snap them closed several times. 8. Momentarily touch the POS jumper cable lead to the starting motor POS post and read the starting motor amperage draw.

NOTE: If using a multimeter other than JT05791, use a meter that will read millivolts. Millivolts = current in amps; 1mV= 1 amp.

IGNITION DIODE TEST Reason: To verify correct function of diodes in engine stop circuit. If a diode fails "open", the cylinder with the open diode will continue to run when the engine is shut off. If a diode fails "short", the cylinder with the shorted diode will not run (no spark). Equipment: â&#x20AC;˘ Ohmmeter Procedure: 1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Place PTO switch in OFF position. 6. Remove engine blower housing. 7. Disconnect diode grounding wire from ignition coil.

Specifications: Maximum starting motor amp draw . . . . . . 35 amps Result: â&#x20AC;˘ If amperage is above specification, check starting motor for binding or damaged

8. Set meter to diode test range.

NOTE: The meter will measure and display voltage drop across diode when set to diode test range. 9. Place one meter lead on connector and second meter lead on opposite side of diode. 10. Reverse position of meter leads and retest.

NOTE: If using ohmmeter for test, resistance in one direction will be approximately 80,000 ohms, and reading will "fall" during testing. Ohmmeter reading in opposite direction will be between 4 and 5 mega-ohms and "rise" during testing.

3/22/00

6 - 31

FLYWHEEL MAGNET TEST Results: • Meter should "beep" once in one meter lead position only. • Meter has continuous tone in either position, diode is shorted, replace diode. • Meter displays "OL" in both positions, diode is "open", replace diode.

FLYWHEEL MAGNET TEST

ELECTRICAL

SEAT SWITCH TEST Reason: To ensure proper operation of seat switch. Equipment: • Ohmmeter Procedure:

Reason: To make sure flywheel magnet(s) have enough force to induce current into ignition coil.

1. Park machine on level surface and turn key switch OFF. 2. Shift lever in NEUTRAL and park brake LOCKED. 3. Disconnect harness connector from seat switch.

Equipment: • Screwdriver Procedure: 1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Raise hood. 6. Remove flywheel blower housing from engine. 7. Loosely hold screwdriver blade about 25 mm (1.0 in.) away from magnet. Results: • Magnet should attract blade to it. • If blade is NOT attracted to magnet, flywheel must be replaced.

B M55816a

4. Check continuity across switch terminals (A) and (B). Results: • There should BE continuity between terminals (A and B) when seat is RELEASED. • There should NOT BE continuity between terminals (A and B) when plunger is DEPRESSED. • If continuity is NOT correct, replace switch.

NOTE:

6 - 32

The seat switch connector has an interlock spring which shorts the 3 wires together when removed from seat switch terminals. Check that spring mechanism is releasing properly when center tab is depressed.

3/22/00

BRAKE SWITCH / PTO SWITCH TEST

ELECTRICAL

BRAKE SWITCH / PTO SWITCH TEST

BRAKE SWITCH ADJUSTMENT Reason:

Reason: To make sure the brake pedal switch and PTO switch operate properly.

To ensure that engine starts only when brake is fully applied. Procedure:

Equipment:

1. Depress brake pedal and set park brake. .

• Ohmmeter

Procedure: 1. Park machine on level surface and turn key switch OFF. 2. Shift lever in NEUTRAL and park brake LOCKED. 3. Blade drive DISENGAGED. 4. Locate switch being tested as follows: Brake switch is located under right side frame at brake pedal bellcrank. Blade drive switch is located under left side frame at bottom of blade drive lever actuating arm. 5. Disconnect harness connector from switch being tested.

B A C D

M56409

6. Check continuity as follows using terminals shown above. • There should BE continuity between terminals (B and C) when plunger is RELEASED, • There should NOT BE continuity between terminals (B and C) when plunger is DEPRESSED. • There should NOT BE continuity between terminals (A and D) when plunger is RELEASED, • There should BE continuity between terminals (A and D) when plunger is DEPRESSED.

M95149

2. Check condition of both mounting rivets. If not tight, damaged, or improperly installed, they could affect adjustment and function of start and safety circuits. If rivets are bad, go to Step 3; if rivets are good, go to Step 4. 3. Disconnect harness connector and remove switch assembly to bench vise. Remove rivets, as necessary, using a 4.76 mm (3/16 in.) drill bit and replace with 4.75 x 14.61 mm (0.187 x 0.575 in.) aluminum pop rivets (M67899). Loosely install switch and solidly connect harness connector. 4. Loosen switch bracket hardware. 5. Move switch until plunger (A) is about 3 mm (1/8 in.) from bottoming. 6. Check that switch does not bottom when brake pedal fully depressed. Increase clearance if needed. 7. Tighten bracket hardware. 8. Check switch operation. • Engine should NOT turn over or start when brake pedal is not depressed. • Engine should turn over and start when brake pedal is fully depressed. • If operation is not correct, test switch.

Results: • If continuity is NOT correct, replace switch.

3/22/00

6 - 33

GROUND CIRCUIT TESTS

ELECTRICAL

GROUND CIRCUIT TESTS

Procedure:

OHMMETER METHOD: 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

GROUND

M55642

Chassis Ground

1. Turn key switch to off position. Engage park brake. 2. Connect ohmmeter negative (black) lead to negative terminal of battery. Put meter positive (red) lead on negative terminal of battery and record reading. 3. Put meter red lead on ground terminal of circuit or component to be tested that is closest to the battery negative terminal. Resistance reading must be very close to or the same as the battery negative terminal reading. Work backwards from the battery on the ground side of the problem circuit until the resistance reading increases above 0.1 ohms. The problem is between the last two test points. If a problem is indicated, disconnect the wiring harness connector to isolate the wire or component and check resistance again. Maximum allowable resistance in the circuit is 0.1 ohms. Check both sides of connectors closely as disconnecting and connecting may temporarily solve problem. VOLTMETER METHOD: 1. Put transmission in neutral. Engage park brake. Put blade drive switch in disengaged position. Turn key switch to on position. 2. Connect voltmeter negative (black) lead to negative terminal of battery. 3. Put meter positive (red) lead on ground terminal of component to be tested. Be sure the component circuit is activated (key on, switches closed) so voltage will be present at the component. Record voltage. Voltage must be greater than 0 but less than 1 volt. Some components will have a very small voltage reading on the ground side and still be operating correctly. Results:

GROUND M95150

Engine Ground (Single Cylinder)

• If resistance is above 0.1 ohms, check for open wiring, loose terminal wire crimps, poor connections, or corrosion in the ground circuit. • If voltage is 0, the component is open. • If voltage is greater than 1 volt, the ground circuit is bad. Check for open wiring, loose terminal wire crimps, poor connections, or corrosion in the ground circuit.

GROUND

M95151

Engine Ground (V-Twin)

6 - 34

3/22/00

KEY SWITCH TEST

ELECTRICAL

KEY SWITCH TEST Reason: To verify key switch functions are operating properly. Equipment: • Ohmmeter or Continuity Tester Procedure: 1. Park machine on level surface and turn key switch OFF. 2. Shift lever in NEUTRAL and park brake LOCKED. 3. Remove key switch cover. See “KEY SWITCH REMOVAL AND INSTALLATION” on page 36. 4. Disconnect key switch connector. ST M

G A M58346

NOTE: Key switch terminals are identified to coincide with electrical schematic designations. 5. Use an ohmmeter to test key switch continuity in OFF, RUN, and START positions. Key Switch Continuity Switch Position

Terminal Continuity

OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (G and M) RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (A and B) START . . . . . . . . . . . . . . . . . . . . . . . (A and B and ST) Results: • If any continuity is NOT correct, replace key switch.

3/22/00

6 - 35

REPAIR

ELECTRICAL

REPAIR

DO NOT overtighten screws, they are threaded into plastic.

KEY SWITCH REMOVAL AND INSTALLATION

SEAT SWITCH REMOVAL AND INSTALLATION NOTE: Seat switch connector has an internal spring which will short cavities of connector together when it is disconnected from seat switch. This prevents operator from defeating seat switch by leaving connector disconnected.

B B

M55806

A M55846

1. Remove rear retaining screws (A) and Bracket (B).

NOTE: Front bracket (F) does not have to be removed.

1. Tilt seat forward. 2. Disconnect connector (A). 3. Rotate switch assembly (B) counterclockwise to remove switch from seat pan.

M55818 E

4. Depress tabs (D) of cover and remove. 5. Unsnap switch (C) from housing. 6. Assemble in reverse order of disassembly. M95152

2. Remove key switch connector (C). 3. Check and/or replace key switch as required. 4. Install new switch and replace cover by inserting lugs (D) into slots (E). Secure from underside of tractor fender with two screws (A) and bracket (B).

6 - 36

3/22/00

STARTING MOTOR SOLENOID REMOVAL AND INSTALLATION

ELECTRICAL

STARTING MOTOR SOLENOID REMOVAL AND INSTALLATION

STATOR AND IGNITION MODULE REMOVAL AND INSTALLATION

Procedure: 1. Park machine on level surface, engage parking brake, stop engine. 2. Lift seat and remove negative battery cable from battery terminal. 3. Remove positive battery cable from battery terminal. 4. Remove battery hold-down (rubber strap) from frame, and lift battery from tractor. 5. Starter solenoid is located under operatorâ&#x20AC;&#x2122;s seat in front of battery.

Stator

Ignition Modules Wire Hub

Starting Motor Bracket

105 Black To Ground

M44227 710 Purple To PTO Switch

Red To Starter

Red To Battery 201 Red To Fuse

6. Follow wiring above to remove and replace solenoid from frame. 7. When connecting battery, always connect positive cable to battery terminal first, and negative cable last.

1. Remove upper blower housing. 2. Turn flywheel magnet away from ignition module. 3. Disconnect wire from ignition module. 4. Remove cap screws and ignition module. 5. Remove flywheel nut and flywheel. 6. Inspect flywheel for damage, broken fins, damaged keyway, and damaged key. 7. Remove starting motor bracket. 8. Remove cap screws and stator. 9. Inspect for damage. 10. Install stator. Tighten cap screws to specification. 11. Route wires back to original position. 12. Install flywheel and tighten nut to specification. 13. Rotate magnet away from ignition module mount. Install ignition modules by pushing the module away from flywheel as far as possible and tighten one screw. Repeat for second module.

B A K

C D

M58360

14. Align flywheel magnet (B) with mounting posts for ignition module. 15. Place 0.25 mm (0.01 in.) feeler gauge blade (K) or shim stock across magnet face. 3/22/00

6 - 37

STARTING MOTOR REMOVAL AND INSTALLATION IMPORTANT: Ensure flywheel magnet (B) is centered on ignition module (A) so all three poles of the ignition module are properly gapped from the flywheel magnet. 16. Position ignition module (A) so all three poles mate with the feeler gauge blade (K) and its two mounting holes align with mounting posts. 17. Install and tighten cap screws to 5.1 ±1.1 N•m (45±10 lb-in.). 18. Repeat steps 13 - 16 for second module. 19. Connect ground wire on each module.

ELECTRICAL

STARTING MOTOR REMOVAL AND INSTALLATION 1. Disconnect negative (–) battery cable. 2. Disconnect red wires from the starting motor terminal. 3. Remove upper blower housing and starting motor gear cover plate.

Starting Motor Bolts

Specifications: Ignition module air gap . . . . . . . 0.25 mm (0.010 in.) Module cap screws . . . . 5.1 ±1.1 N•m (45 ±10 lb-in.) Stator cap screws . . . . . . . . . . . . . . 4 N•m (35 lb-in.) Flywheel nut . . . . . . . . . . . . . . . . . 175 N•m (125 lb-ft) 20. Install stator and tighten to 4 N•m (35 lb-in.). IMPORTANT: Ensure stator wires are routed behind stator wire hub to prevent interference with flywheel rotation. 21. Install starting motor and bracket. 22. Install flywheel and tighten flywheel nut to 175 N•m (125 lb-ft). 23. Install upper blower housing.

M88983

4. Remove starting motor bolts. 5. Install starting motor bolts and tighten to specification. Specification: Starting motor bolts. . . . . . . . . 15.8 N•m (140 lb-in.) 6. Install starting motor gear cover plate and upper blower housing.

6 - 38

3/22/00

STARTING MOTOR DISASSEMBLY

ELECTRICAL

STARTING MOTOR DISASSEMBLY C-Ring Bolts Retainer Spring

M86977

Drive Gear Helix (Starting Motor Clutch)

Wave Washer

2. Remove bolts and inspect bushing for wear. If worn, replace drive head end assembly.

Drive End Head

Armature Thru Bolt Housing

M86978

Brush Holder

End Cap

M86976

IMPORTANT: DO NOT clamp motor housing in a vise or strike with a steel hammer. Starting motors contain two powerful magnets that can be broken or cracked if the motor housing is deformed or dented.

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

Brush Holder

1. Remove pinion gear assembly. See “STARTING MOTOR PINION GEAR REPLACEMENT” on page 42. Armature

End Cap M86979

3/22/00

6 - 39

STARTING MOTOR ASSEMBLY

ELECTRICAL

4. While holding brush holder and armature, remove bearing end cap from armature.

Brush Holder

Brushes

Brushes Armature

Normal Length New

M86980

3 mm (0.125 in.)

5. Remove brush holder from armature commutator. IMPORTANT: DO NOT use emery cloth to clean the commutator. The particles from the cloth will become embedded in the commutator and cause rapid brush wear.

or less replace M86982

8. The brushes should be checked for proper seating, weak brush springs, dirt, oil or corrosion. 9. If brushes are worn to dimensions shown, replace brushes. When all parts have been thoroughly cleaned, lightly lubricate the bearings with #20 oil.

STARTING MOTOR ASSEMBLY

M86981

NOTE: The bearing housing and armature should not be soaked in a cleaning solution. Fine sandpaper, such as crocus cloth, can be used to clean the armature. The commutator may also be machined with the use of a diamond cutting tool to no less than 31.24 mm (1.23 in.) outside diameter. 6. Slots between the commutator bars should be cleaned as shown using a broken piece of hacksaw blade. 7. If it is suspected that the armature field coil, magnets or motor housing is defective, a new part should be tried in the motor. If proper testing equipment is available, check the suspected armature or field coil to determine if it is defective (opens or grounds).

6 - 40

Retainers Retainers

M86983

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

3/22/00

STARTING MOTOR ASSEMBLY

ELECTRICAL

M86985

2. Place armature commutator in brush holder and remove brush retainers. M86988

5. Place wave washer on armature shaft with concave side up. Then place flat washer on armature.

Mark

M86986

3. Install bearing end plate on armature commutator journal making sure plate indexes with brush holder. M86989

6. Place drive end cap on starting motor housing making sure that mark on cap lines up with housing seam.

Notch

M86987

4. Slide motor housing over armature with the notch toward brush holder.

3/22/00

M86977

6 - 41

STARTING MOTOR PINION GEAR REPLACEMENT

ELECTRICAL

7. Install bolts in starting motor, use starting motor clutch to check for binding of armature shaft and correct if it binds. 8. Install starting motor drive. 9. Install starting motor and tighten bolts to specification.

Plate

Specification:

Stator

Starting motor bolts. . . . . . . . . 15.8 N•m (140 lb-in.)

STARTING MOTOR PINION GEAR REPLACEMENT NOTE: If only the pinion gear is to be replaced, the starting motor does not have to be removed from the engine.

Intek V-Twin

M95529

The plate surrounding and below the stator does not have to be removed.

Required Tools: • JDG1087 C-Ring Remover • JDG1086 C-Ring Installer

Tool Handle

Procedure: 1. Disconnect negative (–) battery cable. 2. Remove upper blower housing and flywheel.

C-Ring

C-Ring Remover M88981

Starting Motor Pinion

3. Position C-ring using screw driver tip so C-ring removal tool can be aligned properly. Single Cylinder

M88982

To Prevent eye injury, always wear eye protection when removing C-ring.

Plate

V-Twin

6 - 42

c CAUTION

M88982

3/22/00

STARTING MOTOR PINION GEAR REPLACEMENT

ELECTRICAL

Drive Pins

C-Ring

7. Before installing starting motor clutch, apply a lithium based lubricant sparingly around base of helix.

NOTE: Do not use mineral spirit based lubricants to lubricate helix. Retainer

Tool #JDG1087 M88955

M86970 M88956

4. Install C-ring removal tool, JDG1087 over retainer and compress spring. IMPORTANT: removed.

8. Place starting motor clutch on starting motor shaft, rotate clutch until it drops into place.

The C-ring is not reusable once

5. Screw in handle until drive pins on tool forces off the C-ring from starting motor shaft.

Spring

Pinion Gear

Retainer

M88984

Flat Washer

9. Install pinion gear with beveled side of teeth up, then install return spring making sure spring is in recess of starting motor gear.

Helix Clutch

Spring

Wave Washer

Pinion Gear

M86969 M88985

6. Remove retainer, spring, flat washer, wave washer, pinion gear and starting motor clutch. 3/22/00

6 - 43

STARTING MOTOR PINION GEAR REPLACEMENT

ELECTRICAL

10. Place wave washer with concave side up on starting motor clutch spline.

C-Ring Installer

C-Ring Retainer

M88986

11. Place retainer and new C-ring on starting motor shaft. 12. Align one of the slots on the C-ring installer with open end of C-ring. 13. Use a hammer to drive snap ring down until it engages groove in starting motor shaft. Then make sure retainer is all the way up against the snap ring. 14. Install flywheel, upper blower housing and reconnect negative (â&#x20AC;&#x201C;) battery cable.

6 - 44

3/22/00

CONTENTS

ELECTRICAL WITH RIO SYSTEM

CONTENTS Page

COMMON CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CONDUCTORS FOR 12 VOLT CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SCHEMATIC AND WIRING HARNESS LEGEND . . . . . . . . . . . . . . . . . . 7 COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 WIRE HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 W2 HEADLIGHT WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 W3 ENGINE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 W4 ENGINE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Y1 FUEL SHUTOFF SOLENOID (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

THEORY OF OPERATION AND DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 14 POWER CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 POWER CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 POWER CIRCUIT DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 CRANKING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 CRANKING CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 CRANKING CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 IGNITION AND SHUTOFF CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 22 IGNITION AND SHUTOFF ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . 23 IGNITION AND SHUTOFF CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . 24 IGNITION AND SHUTOFF CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . 26 CHARGING AND HEADLIGHT CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . 28 CHARGING CIRCUIT ELECTRICAL SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . 29 CHARGING AND HEADLIGHT CIRCUIT DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . 30 PTO with RIO CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 PTO with RIO CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 PTO with RIO CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 PTO with RIO CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 BATTERY TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 CHARGE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 ALTERNATOR DC OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 ALTERNATOR DIODE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 AC VOLTAGE OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 STARTING SOLENOID TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 STARTER AMP DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2/29/00

7-1

CONTENTS CONTINUED

ELECTRICAL WITH RIO SYSTEM

Page STARTER NO-LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION DIODE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLYWHEEL MAGNET TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEAT SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE SWITCH / PTO SWITCH TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RIS SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RIO SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GROUND CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELAY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KEY SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIODE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 43 44 44 45 45 46 46 47 48 48 49

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 KEY SWITCH REMOVAL - FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KEY SWITCH REMOVAL - DASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEAT SWITCH REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER SOLENOID REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . STATOR AND IGNITION MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING MOTOR PINION GEAR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . .

7-2

49 50 50 50 51 52 55

2/29/00

ELECTRICAL WITH RIO SYSTEM

READING ELECTRICAL SCHEMATICS

Each circuit is identified at the bottom of the drawing by a section number (N) and section name (O). The circuit number (P) and wire color (Q) of the wires are shown directly next to the wire path.

Each component is shown by a symbol (E), its name (F), and an identification code (G). The identification code contains a device identifying letter (H) and number (I).

The same component name and identification code are used consistently on all diagrams in this section. Components can be easily cross-referenced.

S1 Key Switch B

F2 15 Amp Fuse

Wht

Red

S2 Seat Switch

K2 Ignition Relay

Run Off

F3 15 Amp Fuse

K1 Start Relay

F1 Fusible Link

215 Org

X2 721 Pur/ Wht

Red

X3 G1 Battery

M1 Starting Motor

W2 Engine X4 Wiring Yel/ Harness T1 Wht Ignition X5 Yel/Wht Yel/Wht Coil

X3 T2 Ignition Coil P

E1 Spark Plug

SE1-Power and Starting Circuit

3/22/00

805 Pnk/Blk

W1 Shielded Ground

710 Pur

Blk

800 Pink

Start 210 Red

Off Seat

On Seat

414 Yel/ Blk

E2 Spark Plug

Yel/ Wht Wht

SE2-Ignition and Interlock Circuit

Blk/Yel

105 Blk

SE3-PTO and Interlock

7-3

THEORY AND DIAGNOSTIC INFORMATION

ELECTRICAL WITH RIO SYSTEM

WIRE COLOR ABBREVIATION CHART Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black

THEORY OF OPERATION INFORMATION

Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue

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

Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green

Brn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown Gry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gray Org . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange Pnk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pink Pur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Tan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tan Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .White Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow Blk/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . Black/White Blu/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . Blue/White Brn/Wht . . . . . . . . . . . . . . . . . . . . . . . . Brown/White Brn/Yel . . . . . . . . . . . . . . . . . . . . . . . . .Brown/Yellow Dk Blu. . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Blue

• Test sequence

Dk Brn/Lt Grn . . . . . . . . . . Dark Brown/Light Green

• Test location

Dk Brn/Red . . . . . . . . . . . . . . . . . Dark Brown/Red

• Normal reading

Dk Brn/Yel . . . . . . . . . . . . . . . . . Dark Brown/Yellow

• Check or test to perform if reading is not normal

Dk Grn . . . . . . . . . . . . . . . . . . . . . . . . . Dark Green

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

Lt Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Blue Lt Grn . . . . . . . . . . . . . . . . . . . . . . . . . . Light Green Org/Wht . . . . . . . . . . . . . . . . . . . . . . . Orange/White Pnk/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . Pink/Black Pur/Wht . . . . . . . . . . . . . . . . . . . . . . . . Purple/White Red/Blk. . . . . . . . . . . . . . . . . . . . . . . . . . . Red/Black Red/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . Red/White Wht/Blk. . . . . . . . . . . . . . . . . . . . . . . . . . White/Black Wht/Red . . . . . . . . . . . . . . . . . . . . . . . . . . White/Red Yel/Blk . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Black Yel/Red. . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Red Yel/Wht . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/White

7-4

3/22/00

COMMON CIRCUIT TESTS

ELECTRICAL WITH RIO SYSTEM

COMMON CIRCUIT TESTS

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

M85601

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

M85602

M85600

CONDUCTORS FOR 12 VOLT CIRCUITS

STRANDED CONDUCTORS FOR 12 VOLT CIRCUITS SAE WIRE SIZE (GAUGE)

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

3/22/00

7-5

SPECIFICATIONS

ELECTRICAL WITH RIO SYSTEM

SPECIFICATIONS This Electrical section covers Sabre Lawn Tractors 1999 Model Year and above: Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Serial Number 1438GS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .GX1438A010001– GX1438F010001– GX1438C010001– 1438HS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .GX1438B010001– GX1438D010001– 1538HS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .GX1538B010001– GX1538J010001– 1542HS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .GX1542B010001– GX1542D010001– 1642HS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .GX1642B010001– 1646HS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .GX1646B010001– GX1646D010001– 1846HV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .GX1846B010001– 2046HV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .GX2046B010001– Battery: Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 BCI group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .U-1 Cold Cranking Amps at 0°C (32°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190 amps Reserve Capacity At 0°C (32°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 amps Specific Gravity (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.225 points Electrolyte Quantity (Approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt) Ignition: Primary Coil Resistance One direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1000 ohms Other Direction (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 K ohms Secondary (Plug Wire And Core) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 - 10.85 K ohms Air gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.2 - 0.3 mm (0.008 - 0.012 in.) Spark Plug: Type: All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M78543 (Champion RC-12 YC) Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.) Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (221 lb-in.) Starter: Starter Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bendix Inertia Drive Amp Draw Loaded (Engaging Engine) . . . . . . . . . . . . . . . .180 amps at 225 engine rpm Stator: Stator size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 amp Unregulated Output At 3600 Rpm (No Lamps Attached): AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 VAC DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4 amps DC Headlight Bulbs: Headlight Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 1156, 12 volt, 23 watt

7-6

3/22/00

ELECTRICAL WITH RIO SYSTEM

SCHEMATIC AND WIRING HARNESS LEGEND

SCHEMATIC AND WIRING HARNESS LEGEND E1—RH Headlight (SE1, W2) E2—LH Headlight (SE1, W2) E3—Spark Plug (SE5, W4) E4—Spark Plug (SE5, W4) F1—Fuse 15 amp (SE1, W1) G1—Stator (SE2, W3) G2—Battery (SE2, W1) K1—Starting Motor Solenoid (SE3, W1) K2—RIO Latch Relay (SE4, W1) M1—Starting Motor (SE3, W1) S1—Key Switch (SE3, W1) S2—Seat Switch (SE4, W1) S3—RIO Switch (SE4, W1) S4—PTO Switch (SE4, W1) S5—Brake Switch (SE4, W1) S6—RIS Switch (SE4, W1) T1—Magneto Ignition (SE5, W4) T2—Magneto Ignition (SE5, W4) V1—Diode (SE2, W3) V2—Diode (SE4, W1) V3—Diode (SE5, W4) V4—Diode (SE5, W4) W1—Shielded Ground (SE2, W1) Y1—Fuel Shutoff Solenoid (SE5, W4) CONNECTORS: X1—W1 Main Wiring Harness to Headlights (SE1, W1) X2—W1 Main Wiring Harness to Stator (SE2, W1) X3—W1 Main Wiring Harness to V2 Diode (SE4, W1) X4—W1 Main Wiring Harness to T1 Magneto and Y1 Fuel Shutoff Solenoid (SE5, W1) WIRING HARNESSES: W1—Main Wiring Harness W2—Headlight Wiring Harness W3—Engine Stator Wiring Harness W4—Engine Wiring Harness

3/22/00

7-7

COMPONENT LOCATION

ELECTRICAL WITH RIO SYSTEM

COMPONENT LOCATION

S2 Seat Switch

S6 RIS Switch G2 Battery S4 PTO Switch

Key Switch S1

G1 Stator

T1 Magneto Ignition

K2 RIO Latch Relay

K1 Starting Motor Solenoid

X1 Headlight Connector S3 RIO Switch Y1 Fuel Shutoff Solenoid

F1 Fuse 15 Amp

S5 Brake Switch

7-8

V2 Diode

M1 Starting Motor

3/22/00

W1 STANDARD ELECTRICAL SCHEMATIC

ELECTRICAL WITH RIO SYSTEM

W1 STANDARD ELECTRICAL SCHEMATIC

220 Red/ Blk

451 Yel/ Wht

402 Yel

941 Wht

X2 V1 Diode

W3 Engine Stator Wiring Harness

940 Wht

Gry

943 Wht 942 Wht 200 Red

451 Yel/ Wht

943 Wht

941 Wht

220 200 Red/ Red Blk

G1 Stator

(0) Off (1) Run (2) Start

705 Pur/ Wht

S1 Key Switch 0

0, 1

2 10 700 Pur

Yel

W2 Headlight Wiring Harness

401 Yel

949 Wht/ Blk

100 Blk

705 942 Pur/ Wht Wht

S4 PTO Switch

(1) (0) 700 (0) PTO Off Pur (1) PTO On

S5 Brake Switch

W4 Engine Wiring Harness

(1) (0) 945 (0) Brake Off Wht/ Blk (1) Brake On

710 Pur

V3 Diode

202 Red/ Wht

E1 and E2 Headlight

F1 Fuse 15 Amp

Blk

Red

951 Blk/ Wht

S2 Seat Switch

V2 Diode

110 Blk

940 Wht

K1 Starting Motor Solenoid 105

G2 Battery

Released Pushed 952 Wht/Blk 950 Wht/ Blk

M1 Starting Motor

S3 RIO Switch

105 Blk 100 Blk 110 Blk 130 Blk

130 Blk

Forward/ Neutral Reverse

K2 RIO Latch Relay 955 403 Wht Yel

T1 Magneto Ignition

954 Wht

E3 Spark Plug V4 Diode

T2 Magneto Ignition

957 Wht

E4 Spark Plug

W1 Shielded Ground

3/22/00

V3 Diode

953 Blk/ 956 Wht Blk

403 Yel

SE 2 - CHARGING

S6 RIS Switch

Blk

E3 Spark Plug

946 Wht/Blk

710 Pur

T1 Magneto Ignition

948 Wht/ Blk

Operator Off Operator On

201 Red

120 Blk

SE 1 - HEADLIGHTS

Y1 Fuel Shutoff Solenoid

SE 3 - STARTING

SE 4 - MAGNETO KILL & START INTERLOCK

7-9

SE 5 - ENGINE IGNITION

W1 STANDARD ELECTRICAL SCHEMATIC

ELECTRICAL WITH RIO SYSTEM

W1 STANDARD ELECTRICAL SCHEMATIC

220 Red/ Blk

451 Yel/ Wht

402 Yel

941 Wht

X2 V1 Diode

W3 Engine Stator Wiring Harness

940 Wht

Gry

943 Wht 942 Wht 200 Red

451 Yel/ Wht

943 Wht

941 Wht

220 200 Red/ Red Blk

G1 Stator

(0) Off (1) Run (2) Start

705 Pur/ Wht

S1 Key Switch 0

0, 1

2 10 700 Pur

Yel

W2 Headlight Wiring Harness

401 Yel

949 Wht/ Blk

100 Blk

705 942 Pur/ Wht Wht

S4 PTO Switch

(1) (0) 700 (0) PTO Off Pur (1) PTO On

S5 Brake Switch

W4 Engine Wiring Harness

(1) (0) 945 (0) Brake Off Wht/ Blk (1) Brake On

710 Pur

V3 Diode

202 Red/ Wht

E1 and E2 Headlight

F1 Fuse 15 Amp

Blk

Red

951 Blk/ Wht

S2 Seat Switch

V2 Diode

110 Blk

940 Wht

K1 Starting Motor Solenoid 105

G2 Battery

Released Pushed 952 Wht/Blk 950 Wht/ Blk

M1 Starting Motor

S3 RIO Switch

105 Blk 100 Blk 110 Blk 130 Blk

130 Blk

Forward/ Neutral Reverse

K2 RIO Latch Relay 955 403 Wht Yel

T1 Magneto Ignition

954 Wht

E3 Spark Plug V4 Diode

T2 Magneto Ignition

957 Wht

E4 Spark Plug

W1 Shielded Ground

3/22/00

V3 Diode

953 Blk/ 956 Wht Blk

403 Yel

SE 2 - CHARGING

S6 RIS Switch

Blk

E3 Spark Plug

946 Wht/Blk

710 Pur

T1 Magneto Ignition

948 Wht/ Blk

Operator Off Operator On

201 Red

120 Blk

SE 1 - HEADLIGHTS

Y1 Fuel Shutoff Solenoid

SE 3 - STARTING

SE 4 - MAGNETO KILL & START INTERLOCK

7-9

SE 5 - ENGINE IGNITION

W1 STANDARD ELECTRICAL SCHEMATIC

ELECTRICAL WITH RIO SYSTEM

W1 STANDARD ELECTRICAL SCHEMATIC

220 Red/ Blk

451 Yel/ Wht

402 Yel

941 Wht

X2 V1 Diode

W3 Engine Stator Wiring Harness

940 Wht

Gry

943 Wht 942 Wht 200 Red

451 Yel/ Wht

943 Wht

941 Wht

220 200 Red/ Red Blk

G1 Stator

(0) Off (1) Run (2) Start

705 Pur/ Wht

S1 Key Switch 0

0, 1

2 10 700 Pur

Yel

W2 Headlight Wiring Harness

401 Yel

949 Wht/ Blk

100 Blk

705 942 Pur/ Wht Wht

S4 PTO Switch

(1) (0) 700 (0) PTO Off Pur (1) PTO On

S5 Brake Switch

W4 Engine Wiring Harness

(1) (0) 945 (0) Brake Off Wht/ Blk (1) Brake On

710 Pur

V3 Diode

202 Red/ Wht

E1 and E2 Headlight

F1 Fuse 15 Amp

Blk

Red

951 Blk/ Wht

S2 Seat Switch

V2 Diode

110 Blk

940 Wht

K1 Starting Motor Solenoid 105

G2 Battery

Released Pushed 952 Wht/Blk 950 Wht/ Blk

M1 Starting Motor

S3 RIO Switch

105 Blk 100 Blk 110 Blk 130 Blk

130 Blk

Forward/ Neutral Reverse

K2 RIO Latch Relay 955 403 Wht Yel

T1 Magneto Ignition

954 Wht

E3 Spark Plug V4 Diode

T2 Magneto Ignition

957 Wht

E4 Spark Plug

W1 Shielded Ground

3/22/00

V3 Diode

953 Blk/ 956 Wht Blk

403 Yel

SE 2 - CHARGING

S6 RIS Switch

Blk

E3 Spark Plug

946 Wht/Blk

710 Pur

T1 Magneto Ignition

948 Wht/ Blk

Operator Off Operator On

201 Red

120 Blk

SE 1 - HEADLIGHTS

Y1 Fuel Shutoff Solenoid

SE 3 - STARTING

SE 4 - MAGNETO KILL & START INTERLOCK

7-9

SE 5 - ENGINE IGNITION

W1 WIRING HARNESS

ELECTRICAL WITH RIO SYSTEM

W1 WIRING HARNESS Circuit No.

Wire Size

Color

Connection Point

100

0.5

Blk

S1, W1

105

0.5

Blk

K1, W1

110

0.5

Blk

S2, W1

120

0.5

Blk

X1, Frame

130

0.5

Blk

S3, W1

200

0.5

Red

S1, splice

201

0.5

Red

S4 PTO Switch

950 Wht/Blk

0.5

Red

F1, splice

220

0.5

Yel

splice, X2

401

0.5

Yel

S1, splice

402

0.5

Yel

splice, X3

403

0.5

Yel

splice, K2

451

0.5

Yel/Blk

X2, X1

956 Blk

0.5

Pur

S1, S4

705

0.5

Pur/Wht

S5, S4

710

0.5

Pur

S5, K1

940

0.5

Wht

splice, X3

941

0.5

Wht

S1, splice

942

0.5

Wht

splice, S5

0.5

Wht

0.5

Wht/Blk

S5, splice

946

0.5

Wht/Blk

splice, S2

948

0.5

Wht/Blk

V2, splice

949

0.5

Wht/Blk

splice, S4

950

0.5

Wht/Blk

K2, splice

951

0.5

Blk/Wht

splice, V2

952

0.5

Wht/Blk

splice, S6

953

0.5

Blk/Wht

K2, splice

954

0.5

Wht

splice, S6

955

0.5

Wht

splice, K2

956

0.5

Blk

K2, splice

957

0.5

Wht

splice, S3

201 Red

943 Wht

705 Pur/Wht

949 Wht/Blk

952 Wht/Blk

105 Blk

Positive

954 Wht

700 Pur

V2 Diode X4 949 Wht/Blk 950 Wht/Blk 951 Blk/Wht

Frame Ground

700 Pur

401 Yel 402 Yel 403 Yel

S1 Key Switch

100 Blk 105 Blk 110 Blk 130 Blk

200 Red 202 Red/Wht 220 Red/Blk

451 Yel/Wht 220 Red/Blk

X2 to W3 Engine Wiring Harness

200 Red

401 Yel

948 Wht/Blk

951 Blk/Wht

Ground 952 Wht/Blk 953 Blk/Wht 956 Blk

402 Yel 940 Wht

100 Blk

945 Wht/Blk 946 Wht/Blk 948 Wht/Blk

954 Wht 955 Wht 957 Wht

X3 to W4 Engine Wiring Harness

940 Wht 941 Wht 942 Wht 943 Wht

S2 Seat Switch B

splice, S4

945

B+

403 Yel

953 Blk/Wht

943

955 Wht

K2 RIO Relay

941 Wht

700

S6 RIS Switch

710 Pur 952 Wht/ Blk

K1, F1

202

K1 Starting Motor Solenoid

946 Wht/Blk

F1 15 Amp Fuse

110 Blk

957 Wht

S3 RIO Switch

202 Red/Wht

201 Red

W1 120 Blk Engine Ground 451 Yel/Wht

120 Blk

X1 to W2 Headlight Wiring Harness

130 Blk

7 - 10

S5 Brake Switch 710 Pur

942 Wht

705 Pur/Wht

945 Wht/Blk

3/22/00

W1 WIRING HARNESS

ELECTRICAL WITH RIO SYSTEM

W1 WIRING HARNESS Circuit No.

Wire Size

Color

Connection Point

100

0.5

Blk

S1, W1

105

0.5

Blk

K1, W1

110

0.5

Blk

S2, W1

120

0.5

Blk

X1, Frame

130

0.5

Blk

S3, W1

200

0.5

Red

S1, splice

201

0.5

Red

S4 PTO Switch

950 Wht/Blk

0.5

Red

F1, splice

220

0.5

Yel

splice, X2

401

0.5

Yel

S1, splice

402

0.5

Yel

splice, X3

403

0.5

Yel

splice, K2

451

0.5

Yel/Blk

X2, X1

956 Blk

0.5

Pur

S1, S4

705

0.5

Pur/Wht

S5, S4

710

0.5

Pur

S5, K1

940

0.5

Wht

splice, X3

941

0.5

Wht

S1, splice

942

0.5

Wht

splice, S5

0.5

Wht

0.5

Wht/Blk

S5, splice

946

0.5

Wht/Blk

splice, S2

948

0.5

Wht/Blk

V2, splice

949

0.5

Wht/Blk

splice, S4

950

0.5

Wht/Blk

K2, splice

951

0.5

Blk/Wht

splice, V2

952

0.5

Wht/Blk

splice, S6

953

0.5

Blk/Wht

K2, splice

954

0.5

Wht

splice, S6

955

0.5

Wht

splice, K2

956

0.5

Blk

K2, splice

957

0.5

Wht

splice, S3

201 Red

943 Wht

705 Pur/Wht

949 Wht/Blk

952 Wht/Blk

105 Blk

Positive

954 Wht

700 Pur

V2 Diode X4 949 Wht/Blk 950 Wht/Blk 951 Blk/Wht

Frame Ground

700 Pur

401 Yel 402 Yel 403 Yel

S1 Key Switch

100 Blk 105 Blk 110 Blk 130 Blk

200 Red 202 Red/Wht 220 Red/Blk

451 Yel/Wht 220 Red/Blk

X2 to W3 Engine Wiring Harness

200 Red

401 Yel

948 Wht/Blk

951 Blk/Wht

Ground 952 Wht/Blk 953 Blk/Wht 956 Blk

402 Yel 940 Wht

100 Blk

945 Wht/Blk 946 Wht/Blk 948 Wht/Blk

954 Wht 955 Wht 957 Wht

X3 to W4 Engine Wiring Harness

940 Wht 941 Wht 942 Wht 943 Wht

S2 Seat Switch B

splice, S4

945

B+

403 Yel

953 Blk/Wht

943

955 Wht

K2 RIO Relay

941 Wht

700

S6 RIS Switch

710 Pur 952 Wht/ Blk

K1, F1

202

K1 Starting Motor Solenoid

946 Wht/Blk

F1 15 Amp Fuse

110 Blk

957 Wht

S3 RIO Switch

202 Red/Wht

201 Red

W1 120 Blk Engine Ground 451 Yel/Wht

120 Blk

X1 to W2 Headlight Wiring Harness

130 Blk

7 - 10

S5 Brake Switch 710 Pur

942 Wht

705 Pur/Wht

945 Wht/Blk

3/22/00

W1 WIRING HARNESS

ELECTRICAL WITH RIO SYSTEM

W1 WIRING HARNESS Circuit No.

Wire Size

Color

Connection Point

100

0.5

Blk

S1, W1

105

0.5

Blk

K1, W1

110

0.5

Blk

S2, W1

120

0.5

Blk

X1, Frame

130

0.5

Blk

S3, W1

200

0.5

Red

S1, splice

201

0.5

Red

S4 PTO Switch

950 Wht/Blk

0.5

Red

F1, splice

220

0.5

Yel

splice, X2

401

0.5

Yel

S1, splice

402

0.5

Yel

splice, X3

403

0.5

Yel

splice, K2

451

0.5

Yel/Blk

X2, X1

956 Blk

0.5

Pur

S1, S4

705

0.5

Pur/Wht

S5, S4

710

0.5

Pur

S5, K1

940

0.5

Wht

splice, X3

941

0.5

Wht

S1, splice

942

0.5

Wht

splice, S5

0.5

Wht

0.5

Wht/Blk

S5, splice

946

0.5

Wht/Blk

splice, S2

948

0.5

Wht/Blk

V2, splice

949

0.5

Wht/Blk

splice, S4

950

0.5

Wht/Blk

K2, splice

951

0.5

Blk/Wht

splice, V2

952

0.5

Wht/Blk

splice, S6

953

0.5

Blk/Wht

K2, splice

954

0.5

Wht

splice, S6

955

0.5

Wht

splice, K2

956

0.5

Blk

K2, splice

957

0.5

Wht

splice, S3

201 Red

943 Wht

705 Pur/Wht

949 Wht/Blk

952 Wht/Blk

105 Blk

Positive

954 Wht

700 Pur

V2 Diode X4 949 Wht/Blk 950 Wht/Blk 951 Blk/Wht

Frame Ground

700 Pur

401 Yel 402 Yel 403 Yel

S1 Key Switch

100 Blk 105 Blk 110 Blk 130 Blk

200 Red 202 Red/Wht 220 Red/Blk

451 Yel/Wht 220 Red/Blk

X2 to W3 Engine Wiring Harness

200 Red

401 Yel

948 Wht/Blk

951 Blk/Wht

Ground 952 Wht/Blk 953 Blk/Wht 956 Blk

402 Yel 940 Wht

100 Blk

945 Wht/Blk 946 Wht/Blk 948 Wht/Blk

954 Wht 955 Wht 957 Wht

X3 to W4 Engine Wiring Harness

940 Wht 941 Wht 942 Wht 943 Wht

S2 Seat Switch B

splice, S4

945

B+

403 Yel

953 Blk/Wht

943

955 Wht

K2 RIO Relay

941 Wht

700

S6 RIS Switch

710 Pur 952 Wht/ Blk

K1, F1

202

K1 Starting Motor Solenoid

946 Wht/Blk

F1 15 Amp Fuse

110 Blk

957 Wht

S3 RIO Switch

202 Red/Wht

201 Red

W1 120 Blk Engine Ground 451 Yel/Wht

120 Blk

X1 to W2 Headlight Wiring Harness

130 Blk

7 - 10

S5 Brake Switch 710 Pur

942 Wht

705 Pur/Wht

945 Wht/Blk

3/22/00

W2 HEADLIGHT WIRING HARNESS

ELECTRICAL WITH RIO SYSTEM

W2 HEADLIGHT WIRING HARNESS E2 LH Headlight Blk

Yel

X1 To W1 Main Wiring Harness

Blk

E1 RH Headlight

Yel

W3 ENGINE WIRING HARNESS

Gry Gry

X2 to W1 Engine Wiring Harness

W4 ENGINE WIRING HARNESS Wht

Magneto Stop

940

402

X4 to W1 Engine Wiring Harness

X3 to Y1 Fuel Shutoff Solenoid

Gry

Y1 FUEL SHUTOFF SOLENOID (optional) X4 To W4 Engine Wiring Harness

3/22/00

Gry

Y1 Fuel Solenoid

7 - 11

TROUBLESHOOTING

ELECTRICAL WITH RIO SYSTEM

Test battery and connections.

●

See Ignition Circuit Tests See Charging Circuit Tests

●

See Starter Solenoid Test

●

Headlights do not light or will not shut off.

Battery goes dead, discharges or overcharges.

Engine will not shut off.

Weak or no spark.

Engine misses or runs rough. ●

●

See Seat Switch Tests

●

See headlight circuit test points.

Engine dies when blade lever is engaged.

●

Engine dies when brake lever is released.

See Ground Circuit Tests

●

Fuel shut-off solenoid will not close (16 hp only)

●

Fuel shut-off solenoid will not open (16 hp only)

See Cranking Circuit Diagnosis

Engine starts hard or will not stay running.

Check or Solution

Engine will not crank.

Problem or Symptom

Engine cranks—will not start.

TROUBLESHOOTING

●

See fuel shut-off solenoid circuit test points (16 hp only)

●

Check for short circuit.

●

Check for high resistance or open circuit.

●

Check for correct spark plug and spark plug gap.

●

Check strength of flywheel ignition module magnet and/or flywheel stator magnets.

●

See fuel and air system tests and adjustments.

●

● ●

●

Check for stator shorted to ground Check seat switch connector is plugged in and interlock spring inside connector is good

7 - 12

3/22/00

ELECTRICAL WITH RIO SYSTEM

TROUBLESHOOTING

NOTES:

3/22/00

7 - 13

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL WITH RIO SYSTEM

THEORY OF OPERATION AND DIAGNOSIS POWER CIRCUIT OPERATION Function: Provides unswitched power to the primary components and switched power to secondary components whenever the battery is connected. Operating Conditions, Unswitched Circuits: Voltage must be present at the following components with the key switch in the OFF position: • Battery Positive Terminal • Starting Motor Solenoid Positive Contact Stud • Key Switch Red Wire • Red/Blk Wire at Engine Wiring Harness Connector The positive battery cable connects the battery to the starting motor relay bolt. The ground cable connection is equally important as the positive cable. Proper starting operation depends on these cables and connections to carry the high current for its operation. The 201 Red wire, 15 amp fuse (F1), 202 Red/Wht and 200 Red wires provide unswitched voltage to the key switch. The 201 Red wire, 15 amp fuse (F1), 202 Red/Wht and 220 Red/Blk wires provide unswitched voltage to the engine stator wiring harness connector (X2). Switched Circuits, Operating Conditions: Placing the key switch in the RUN position provides voltage from 200 Red wire through the key switch to the 401, 402 and 403 Yel wires. The 402 Yel wire provides current to the engine wire harness (W4) at connector (X3) to the fuel shutoff solenoid (Y1). The 403 Yel wire provides current to the RIO latch relay (K2).

7 - 14

3/22/00

POWER CIRCUIT SCHEMATIC

ELECTRICAL WITH RIO SYSTEM

POWER CIRCUIT SCHEMATIC

X2 W3 Engine Wiring Harness G

(1) Run (2) Start

S1 Key Switch

W4 Engine Wiring Harness

0, 1

X2 V1 Diode

(0) Off

200 Red

220 Red/ Blk

2 10

220 200 Red/ Red Blk

401 Yel

402 Yel

202 Red/ Wht

Gry

Y1 Fuel Shutoff Solenoid

G1 Stator F1 Fuse 15 Amp 201 Red

Red

K1 Starting Motor Solenoid

G2 Battery

K2 RIO Latch Relay 403 Yel

403 Yel

M1 Starting Motor

W1 Shielded Ground

3/22/00

7 - 15

POWER CIRCUIT DIAGNOSIS

ELECTRICAL WITH RIO SYSTEM

POWER CIRCUIT DIAGNOSIS Test Conditions: • Key switch in OFF position Test/Check Point

Normal

If Not Normal

1. Positive and negative battery post

12.4 VDC or above

Clean battery terminals and test battery.

2. Starting motor solenoid battery stud terminal

Battery voltage

Clean and check battery cable and tighten connections.

3. Key switch

Battery voltage

Check 200 and 201 Red wire and connections and 15 amp fuse (F1).

4. Engine connector (X2)

Battery voltage

Check 220 Red/Blk wire and connections.

5. Ground cable frame connection to negative battery terminal

Less than 0.1 ohm resistance

Check harness wires and negative cable connections to frame, removing any paint, rust or corrosion. Clean negative battery connection to battery post.

6. Key switch

Battery voltage

Replace key switch.

7. Engine connector (X4)

Battery voltage

Check 402 Yel wire and connections.

8. RIO Latch Relay

Battery voltage

Check 403 Yel wire and connections.

Test Conditions: • Key switch in RUN position • Engine OFF

7 - 16

3/22/00

POWER CIRCUIT DIAGNOSIS

ELECTRICAL WITH RIO SYSTEM

W1 Shielded Ground

G1 Battery K1 Starting Motor Solenoid

6 401 Yel

3 8

403 Yel

S1 Key Switch

K2 RIO Latch Relay

4 402 Yel

X4 To Engine Wiring Harness

3/22/00

200 Red

220 Red/Blk X2 To Engine Wiring Harness

7 - 17

CRANKING CIRCUIT OPERATION

CRANKING CIRCUIT OPERATION (INCLUDES FUEL SHUT-OFF CIRCUIT) Function:

ELECTRICAL WITH RIO SYSTEM

into the engine flywheel, turning over the engine until the ignition circuit fires. Once the engine starts, the operator releases the key switch to run position. The current flow to the starter solenoid primary coil is stopped, releasing the starter solenoid plunger, and cutting off the high battery current to the starter motor.

To energize the Starting Motor Solenoid and engage the starting motor which cranks the engine. Operating Conditions: In order to crank the engine; the PTO lever must be disengaged (PTO switch plunger depressed), the brake pedal must be depressed (brake switch plunger depressed), and the key switch must be in the start position. The operator does not have to be on the seat to crank the engine if the above conditions are met. Theory of Operation: The starting motor has a separate starter solenoid, located under the operatorâ&#x20AC;&#x2122;s seat. Current flows from the battery positive terminal to the starter solenoid (K1) secondary terminal, 15 amp plug in fuse (F1), and key switch (S1). With the key switch in the start position, current flows from the key switch (S1), 700 Pur wire, PTO switch (S4) (normally closed contacts), 705 Pur/ Wht wire, brake switch (S5) (normally open contacts), 710 Pur wire, and the starter solenoid (K1) primary terminal, energizing the pull-in windings of the solenoid and engaging the starting motor (M1). Ground for this function is provided by the 105 Blk wire and the frame ground. The fuel shut-off solenoid is also energized by the key switch and allows fuel to flow to the carburetor. The fuel shut-off solenoid becomes energized when the key switch is in either START or RUN position. Current is provided by 402 Yel wire to the fuel shutoff solenoid unseating the plunger and allowing fuel flow into the venturi of the carburetor. When the key switch is turned OFF, current flow is broken and internal spring force closes the solenoid plunger, stopping fuel flow. The PTO switch (S4) is located under the left side of the mower frame, at the end of the PTO lever shaft. It is used to prevent the engine from cranking if the PTO is engaged. With the PTO lever disengaged, (PTO switch plunger depressed), current flows through the 705 Pur/ Wht wire to the brake switch (S5). The brake switch (S5) is located under the right side of the mower frame, in front of the brake pedal bell crank. When the park brake is engaged, the bell crank depresses the brake switch plunger and the switch is closed. Current then flows through the 710 Pur wire to energize the starter solenoid (K1) primary coil. The starter solenoid plunger is pulled in by the primary coil, closing the secondary terminals and supplying high battery current to the starter motor. The spinning of the starter motor extends the starter bendix drive

7 - 18

3/22/00

CRANKING CIRCUIT SCHEMATIC

ELECTRICAL WITH RIO SYSTEM

CRANKING CIRCUIT SCHEMATIC

(0) Off

200 Red

(1) Run (2) Start

0, 1

2 10

200 Red

700 Pur

401 Yel

S1 Key Switch

705 Pur/ Wht

S4 PTO Switch

(1) (0) 700 (0) PTO Off Pur (1) PTO On

705 Pur/ Wht

S5 Brake Switch (1) (0) (0) Brake Off (1) Brake On

710 Pur

202 Red/ Wht

F1 Fuse 15 Amp 201 Red

W4 Engine Wiring Harness

710 Pur

K1 Starting Motor Solenoid

402 Yel

105 Blk

Red

M1 Starting Motor

Gry

Y1 Fuel Shutoff Solenoid

G2 Battery

105 Blk

W1 Shielded Ground

3/22/00

7 - 19

CRANKING CIRCUIT DIAGNOSIS

ELECTRICAL WITH RIO SYSTEM

CRANKING CIRCUIT DIAGNOSIS Test Conditions: • Key switch in OFF position • Park brake ON

• PTO OFF • Spark plug disconnected

Test/Check Point

Normal

1. Starting motor solenoid

12.4 VDC or higher

Check Red wire and connections from battery. Test battery.

2. Key switch

Battery voltage

Check 200 and 201 Red wires, 202 Red/ Wht wire, and 15 amp plug in fuse.

Test Conditions: • Key switch in RUN position • Park brake ON

If Not Normal

• PTO OFF • Spark plug disconnected

3. Fuel shutoff solenoid

Battery voltage

Check Gry wire, 402 Yel wire and connections. If OK replace key switch.

4. Fuel shutoff solenoid

Continuity to ground

Check engine frame ground. If OK, replace fuel shut-off solenoid.

Test Conditions: • Key switch in START position while preforming each test step • Park brake ON

• PTO OFF • Spark Plug disconnected

NOTE: Engine will turn over during this test. Allow time for starter to cool between each test. Test/Check Point

Normal

If Not Normal

5. PTO switch

Battery voltage

Check 700 Pur wire and connections. If OK, replace key switch.

6. Brake switch

Battery voltage

Check 705 Pur/Wht wire and connections. If OK, replace brake switch.

7. Starting motor solenoid

Battery voltage

Check 710 Pur wire and connections. If OK, replace PTO switch.

8. Starting motor

Battery voltage

Check Red starting motor cable. If OK, replace starting motor solenoid.

9. Starting motor

Continuity to ground

Check engine frame ground. If OK, replace starting motor.

7 - 20

3/22/00

CRANKING CIRCUIT DIAGNOSIS

ELECTRICAL WITH RIO SYSTEM

6 401 Yel

K1 Starting Motor Solenoid

710 Pur

S1 Key Switch

200 Red

M1 Starting Motor

Y1 Fuel Shutoff Solenoid 3 402 Yel

8 Red

S5 Brake Switch S4 PTO Switch 5

700 Pur

705 Pur/Wht

3/22/00

7 - 21

IGNITION AND SHUTOFF CIRCUIT OPERATION

IGNITION AND SHUTOFF CIRCUIT OPERATION Function: To create a spark at the correct time that ignites the fuel/air mixture in the cylinder. To ground the system to keep the engine from starting or to shut off the engine. Operating Conditions: To produce a spark, the key switch must be in the START or RUN position. The operator can be ON or OFF the seat; however, the PTO must be disengaged and the brake switch must be ENGAGED (brake pedal depressed or park brake on) to start the engine. Once the engine is running, the operator must be ON the seat to disengage the brake or engage the PTO. The engine will shutoff when the key switch is turned to the OFF position, the operator leaves the seat without locking the parking brake, and disengaging the PTO, or the operator places the tractor in reverse with the PTO engaged without pressing the reverse implement switch (RIS). Theory of Operation: The ignition system is a transistor-controlled magneto design. Ignition timing is controlled by the transistor and is not adjustable. The engine is shut off by grounding both sides of the ignition primary coil. With the ignition primary coil grounded, a spark cannot be produced. As the electric starter turns the flywheel, a magnet in the flywheel produces current in the primary coil of the ignition module by electromagnetic induction. When the primary current builds to its highest level, the ignition module induces high voltage current into the secondary coil. This high voltage current then flows to the spark plug and jumps the spark plug gap and creates a spark that ignites the fuel/air mixture, causing the engine to start and run.

ELECTRICAL WITH RIO SYSTEM

The second path to ground is eliminated if the operator is ON the seat (seat switch open), or the operator is OFF the seat (seat switch closed), and the brake switch is engaged and the PTO is disengaged. When the brake pedal is RELEASED, the brake switch (S5) connects 942 Wht wire from the 940 Wht wire and ignition, to the 945 Wht/Blk wire to the seat switch (S2). When the operator is OFF the seat, the seat switch (S2) (normally closed) completes the path to ground through the 110 Blk wire, preventing high current induction into the secondary coil which prevents the spark plug from firing, killing the engine. The PTO switch is in parallel with the brake switch, and will also ground the ignition module when the PTO is engaged with no operator on the seat, killing the engine. The PTO and brake switches are also used to prevent the engine from cranking if the PTO lever is ENGAGED or park Brake is NOT ENGAGED when key switch is moved to START. The operatorâ&#x20AC;&#x2122;s seat switch has an interlock built into itâ&#x20AC;&#x2122;s connector which prevents the mower from being used with the seat switch disconnected. An internal spring will short the two cavity connectors together when disconnected from the seat switch. This has the effect of grounding the ignition module when the PTO lever is engaged or the brake pedal is released, killing the engine. A third path to ground will be created with engine running, if the operator places the tractor in reverse while the PTO is engaged and the Reverse Implement Switch (RIS) is not pressed. With the PTO engaged the path to ground is created for the Wht wire from the engine magneto, 940 and 943 Wht wires, PTO switch (S4) contacts (normally open), 949 and 950 Wht/Blk wires, RIO latch relay (K2) (normally closed), 955 and 957 Wht wires, RIO switch(S3) (normally open), to the 130 Blk wire.

The ignition module will stop producing current to the spark plug if the 940 White wire from the coil is allowed to ground to the mower chassis. The engine is shut off by grounding the ignition module in one of three ways: 1. Through the key switch when key is moved to OFF position. 2. Through the seat switch, if the operator tries to get OFF the seat with the PTO ENGAGED or the park brake NOT ENGAGED. 3. Through the RIO switch and relay if the RIS switch is not pressed while starting to operate the tractor in reverse with the PTO ENGAGED. Placing the key switch in the START or RUN position eliminates the path to ground for the Wht wire from the engine magneto, 940 and 941 Wht wires, key switch (S1) contacts (normally closed), to the 100 Blk wire.

7 - 22

3/22/00

IGNITION AND SHUTOFF ELECTRICAL SCHEMATIC

ELECTRICAL WITH RIO SYSTEM

IGNITION AND SHUTOFF ELECTRICAL SCHEMATIC

941 Wht 943 Wht 940 Wht

942 Wht

943 Wht

S1 Key Switch 941 Wht

949 Wht/ Blk

(0) Off

S4 PTO Switch

942 Wht

(1) (0) (0) PTO Off (1) PTO On

S5 Brake Switch

X4 T1 Magneto Ignition

V3 Diode

(1) (0) (0) Brake Off (1) Brake On

945 Wht/ Blk

E3 Spark Plug

(1) Run (2) Start 0

0, 1

V4 Diode

2 10

T2 Magneto Ignition

100 Blk

E4 Spark Plug

S2 Seat Switch 110 Blk

Operator Off Operator On 946 Wht/Blk

948 Wht/ Blk

V2 Diode X3

951 Blk/ Wht

S6 RIS Switch Released Pushed 952 Wht/Blk

950 Wht/ Blk

G2 Battery

953 Blk/ 956 Wht Blk

954 Wht

K2 RIO Latch Relay

955 Wht

S3 RIO Switch 100 Blk 110 Blk 130 Blk

Forward/Neutral Reverse 130 Blk

957 Wht

W1 Shielded Ground

3/22/00

7 - 23

IGNITION AND SHUTOFF CIRCUIT DIAGNOSIS

ELECTRICAL WITH RIO SYSTEM

IGNITION AND SHUTOFF CIRCUIT DIAGNOSIS When diagnosing an ignition problem, isolate magneto circuit from ground circuit by separating engine connector. If engine will not start check magneto circuit first and then check ground circuit. If engine will not shut off, check ground circuit. Remember engine is stopped by grounding ignition coil through either key switch, seat switch or the brake switch and PTO switch. Test Conditions: • Key switch in OFF position • Park brake ON Test/Check Point

• PTO OFF (DISENGAGED) • Engine cool to avoid burns Normal

If Not Normal

1. Spark plug

Spark plug not fouled. Correct air gap.

Adjust air gap. Replace spark plug.

2. Diode V2

Continuity in one direction

Check diode. See “DIODE TEST” on page 49. Replace diode.

Test Conditions: • Key switch in START position • Park brake ON

• PTO OFF (DISENGAGED)

NOTE: Engine will turn over and can start during this test 3. Spark plug tester installed.

Spark present at tester

No spark: Check armature air gap. Check for grounded primary lead. Check for continuity between engine kill wire and ground (should be infinite). Check ignition coil. Weak Spark: Check spark plug(s).

Test Conditions: • Key switch in OFF position • Park brake ON

• PTO OFF (DISENGAGED) • Engine wiring harness disconnected from main wiring harness

4. Key switch

Continuity to ground.

Check 100 Blk wire and connections.

5. Engine connector X4

Continuity to ground

Check 940 and 941 Wht wires and connections. If OK, replace key switch.

Test Conditions: • Key switch in RUN position • Park brake OFF

• PTO OFF (DISENGAGED) • Engine wiring harness disconnected from main wiring harness

6. Seat switch

Continuity to ground

Check 110 Blk wire and connections.

7. Brake switch

Continuity to ground

Check 945 and 946 Wht/Blk wires and connections. If OK, replace seat switch.

8. Engine connector X4

Continuity to ground

Check 940 and 942 Wht wires and connections. If OK, replace brake switch.

7 - 24

3/22/00

IGNITION AND SHUTOFF CIRCUIT DIAGNOSIS

ELECTRICAL WITH RIO SYSTEM

Spark Plug Tester

2 V2 Diode 3 1

E3 or E4 Spark Plug

4 S1 Key Switch

200 Red

5 8

940 Wht

X4 To Engine Wiring Harness

S2 Seat Switch

110 Blk

S5 Brake Switch 7 945 Wht/Blk

3/22/00

7 - 25

IGNITION AND SHUTOFF CIRCUIT DIAGNOSIS

ELECTRICAL WITH RIO SYSTEM

IGNITION AND SHUTOFF CIRCUIT DIAGNOSIS Test Conditions: • Key switch in RUN position • Park brake OFF • Diode (V2) disconnected. Test/Check Point

• PTO ON (ENGAGED) • Shift lever in REVERSE • Engine wiring harness disconnected from main wiring harness Normal

If Not Normal

9. RIO switch

Continuity to ground

Check 130 Blk wire and connections.

10. RIS switch

Continuity to ground

Check 954 and 957 Wht wires and connections. If OK, replace RIO switch.

11. RIO latch relay

Continuity to ground

Check 956 Blk wire and 953 Blk/Wht wire and connections. If OK, replace RIS switch.

12. RIO latch relay

Continuity to ground

Check 955 and 957 Wht wires and connections. If OK, replace RIO switch.

13. PTO switch

Continuity to ground

Check 949 Wht/Blk wire and connections. If OK, replace RIO latch relay.

14. Engine connector X4

Continuity to ground

Check 940 and 943 Wht wires and connections. If OK, replace PTO switch.

7 - 26

Continuity to ground with diode disconnected from ignition coil

Faulty diode(s). Replace diode(s).

3/22/00

ELECTRICAL WITH RIO SYSTEM

IGNITION AND SHUTOFF CIRCUIT DIAGNOSIS

S6 RIS Switch

954 Wht

S3 RIO Switch 9 130 Blk

K2 RIO Latch Relay

V1 or V2 Diode (Briggs & Stratton Engines)

956 Blk Connecting to 953 Blk/Wht

955 Wht T1 or T2 Magneto 15 Ignition Coil (Briggs & Stratton Engines)

949 Wht/Blk S4 PTO Switch 14 940 Wht

X4 To Engine Wiring Harness

3/22/00

7 - 27

CHARGING AND HEADLIGHT CIRCUIT OPERATION

ELECTRICAL WITH RIO SYSTEM

CHARGING AND HEADLIGHT CIRCUIT OPERATION Function: To maintain battery voltage at 12.4 VDC or higher, and provide electrical power to light the headlights. Operating Conditions: The engine must be running for both the charging system to operate, and the headlights to be on. System Operation: The dual circuit stator provides DC current for charging the battery and an independent AC circuit for headlights. The battery is not used for lights, so lights are available even if the battery is disconnected or removed. Current for lights is available as long as the engine is running. Alternating current is routed to the headlamp bulbs anytime the engine is running through the 451 Yel/Wht wire. The output depends upon engine speed, so brightness of the lights changes with engine speed. Magnets mounted to the flywheel rotate around two coils of wire, (the stator), mounted underneath the flywheel. As the magnets rotate, current is generated in the coiled wire and is rectified by an in-line diode in the engine wire harness side to the 220 Red/Blk circuit, to DC current to charge the battery. This circuit is protected by the 15 amp plug-in fuse (F1) and the ground circuit is completed through the frame. The current from the DC side of the stator is unregulated and is rated at 3 amps. The output rises from 2 amps at 2400 rpm to 3amps at 3600 rpm.

7 - 28

3/22/00

CHARGING CIRCUIT ELECTRICAL SCHEMATIC

ELECTRICAL WITH RIO SYSTEM

CHARGING CIRCUIT ELECTRICAL SCHEMATIC

451 Yel/ Wht

220 Red/ Blk

X2 V1 Diode

W3 Engine Wiring Harness G

451 Yel/ Wht

(0) Off

200 Red 220 200 Red/ Red Blk

G1 Stator

(1) Run (2) Start

0, 1

S1 Key Switch

2 10

Yel

W2 Headlight Wiring Harness 202 Red/ Wht

E1 and E2 Headlight

F1 Fuse 15 Amp

Blk

201 Red Red

120 Blk

K1 Starting Motor Solenoid 105

G2 Battery

Blk

M1 Starting Motor

105 Blk

W1 Shielded Ground

3/22/00

7 - 29

CHARGING AND HEADLIGHT CIRCUIT DIAGNOSIS

ELECTRICAL WITH RIO SYSTEM

CHARGING AND HEADLIGHT CIRCUIT DIAGNOSIS Test Conditions: • Key switch RUN position, engine RUNNING at full throttle • Stator connector unplugged

• Park brake ON • PTO OFF • Be sure to set multimeter to read AC or DC voltage or amperage as test requires

Test/Check Point

Normal

If Not Normal

1. Stator connector, DC lead

2 - 4 amps

Check diode in DC wire.

2. Stator connector, AC lead

14 VAC or higher

Replace stator.

Test Conditions: • Key switch OFF

• PTO OFF • Park Brake ON

3. Stator connector, Diode

Continuity with black test lead clipped to connector pin, and red test lead clipped to pin piercing wire behind diode

Replace diode.

4. Stator connector, Diode

No continuity with black test lead clipped to pin piercing wire behind diode, and red test lead clipped to connector pin

Replace diode.

Test Conditions: • Engine must be RUNNING at full throttle.

• PTO OFF • Park brake ENGAGED (ON)

5. Headlamps

Bulbs lit

Check for burned out bulb.

6. Headlight wiring harness connector X1

Battery voltage

Check 451 Yel wire and connections.

7. RH headlight

Battery voltage

Check headlight wiring harness and connector.

8. RH headlight

Greater than 0 volts - less than 0.2 volts.

0 volts: Replace headlight. Greater than 0.2 volts: Check harness connector (X2) and 125, 110, 135 Blk wires and connections.

9. LH headlight

Battery voltage

Check Blk jumper wire and connections between headlights.

Greater than 0 volts - less than 0.2 volts.

0 volts: Replace headlight. Greater than 0.2 volts: Check Yel jumper wire and connections between headlights.

10. LH headlight

7 - 30

3/22/00

ELECTRICAL WITH RIO SYSTEM

CHARGING AND HEADLIGHT CIRCUIT DIAGNOSIS

G1 Stator Pin 3 4 V1 Diode 2 X2 Connector 1

6 451 Yel X1 Headlight Connector

9 7

Blk Blk E1 RH Headlight

E2 L. H. Headlight

Yel

Yel 10

To X1

3/22/00

7 - 31

PTO with RIO CIRCUIT OPERATION

PTO with RIO CIRCUIT OPERATION Function: To provide a safety interlock when the tractor is being operated in reverse while the PTO is engaged, by providing a ground path to be used by either the ignition coil to shutoff the engine, or the RIO latch relay to open its contacts (normally closed) used to provide the ignition ground path, and use it for its own ground path. An operator who deems it necessary, and chooses to keep the PTO engaged while backing up, must take a deliberate action to actuate the RIS switch, by pushing the button momentarily while shifting to reverse.

ELECTRICAL WITH RIO SYSTEM

PTO ON and operating in reverse while activating the RIO circuit During this condition, when the PTO is engaged and the tractor is operated in reverse, there is a ground path created for the RIO latch relay, both momentary and continuous. The momentary ground path allows the RIO latch relay to pull in, closing the contacts between the common and normally open contacts of the relay. Pushing the RIS switch button provides a ground across the relay from 956 Blk wire, 952 Wht/Blk wire, RIS switch contacts (normally open), 954 and 957 Wht wires, RIO switch contacts (normally open), and 130 Blk wire to ground, while the tractor is in reverse.

RIO Operating Conditions:

The momentary path is connected into the continuous path when the RIS switch is pushed and closes its contacts to connect wires 956 Blk, 953 Blk/Wht and 952 Wht/Blk wires to 954 and 957 Wht wires.

The key switch must be in the RUN position, engine running, the operator must be ON the seat, the PTO ENGAGED, and the RIS switch must be pushed (momentary) while starting operation in reverse.

The continuous path is through wire 130 Blk, RIO switch contacts (normally open), 957 and 954 Wht wires, RIO latch relay contacts (normally open), and 952 Wht/Blk and 956 Blk wires.

Theory of Operation: The Reverse Implement Option (RIO) is controlled by a relays and two switches wired in a circuit with the ignition coil. This combination of components provide for control of three different functional situations:

When the operator places the shift lever back to neutral or forward, the RIO switch is allowed to return to its normal (static) condition, breaking the ground path holding the latch relay in the ON condition. This allows the circuit to be self reset and ready for the next reverse operation with PTO engaged.

• PTO OFF with any drive function • PTO ON and operating in reverse without activating the RIO circuit • PTO ON and operating in reverse while activating the RIO circuit PTO OFF When the PTO is disengaged, the tractor will operate in both forward and reverse without activating any other switch(s). The PTO switch is pressed in and breaks (opens) the ground path interlock with the RIO circuit switches for the ignition coil and the engine will continue to run normally. PTO ON and operating in reverse without activating the RIO circuit During this condition when the PTO is engaged and the tractor is operated in reverse, there is a ground path created for the ignition coil through wire 130 Blk, RIO switch contacts (normally open), 957 and 955 Wht wires, RIO latch relay contacts (normally closed), 950 and 949 Wht/Blk wires, PTO switch contacts (normally open), 943 and 940 Wht wires, and the ignition coil. This will ground the ignition coil and cause the engine to shutoff. (See “IGNITION AND SHUTOFF CIRCUIT OPERATION” on page 22.)

7 - 32

3/22/00

PTO with RIO CIRCUIT OPERATION

ELECTRICAL WITH RIO SYSTEM

PTO with RIO CIRCUIT OPERATION

941 Wht 943 Wht 940 Wht

942 Wht

943 Wht

S1 Key Switch 941 Wht

949 Wht/ Blk

(0) Off

S4 PTO Switch

942 Wht

(1) (0) (0) PTO Off (1) PTO On

S5 Brake Switch

X4 T1 Magneto Ignition

V3 Diode

(1) (0) (0) Brake Off (1) Brake On

945 Wht/ Blk

E3 Spark Plug

(1) Run (2) Start 0

0, 1

V4 Diode

2 10

T2 Magneto Ignition

100 Blk

E4 Spark Plug

S2 Seat Switch 110 Blk

Operator Off Operator On 946 Wht/Blk

948 Wht/ Blk

V2 Diode X3 X3

951 Blk/ Wht

S6 RIS Switch Released Pushed 952 Wht/Blk

950 Wht/ Blk

954 Wht

953 Blk/ 956 Wht Blk

K2 RIO Latch Relay

G2 Battery

955 Wht

S3 RIO Switch 100 Blk 110 Blk 130 Blk

Forward/Neutral Reverse 130 Blk

957 Wht

W1 Shielded Ground

3/22/00

7 - 33

PTO with RIO CIRCUIT DIAGNOSIS

ELECTRICAL WITH RIO SYSTEM

PTO with RIO CIRCUIT DIAGNOSIS Test Conditions: • Key switch in OFF position • Park brake ON Test/Check Point

• PTO OFF (DISENGAGED) • Engine wiring harness disconnected from main wiring harness Normal

If Not Normal

1. Diode V2

“DIODE TEST” on page 49

Replace diode.

2. Key switch

Continuity to ground.

Check 100 Blk wire and connections.

3. Engine connector X4

Continuity to ground

Check 940 and 941 Wht wires and connections. If OK, replace key switch.

Test Conditions: • Key switch in RUN position • Park brake OFF

• PTO OFF (DISENGAGED) • Engine wiring harness disconnected from main wiring harness

4. Seat switch

Continuity to ground

Check 110 Blk wire and connections.

5. Brake switch

Continuity to ground

Check 945 Wht/Blk wire and connections. If OK, replace seat switch.

6. Engine connector X4

Continuity to ground

Check 940 and 942 Wht wires and connections. If OK, replace brake switch.

7 - 34

3/22/00

ELECTRICAL WITH RIO SYSTEM

PTO with RIO CIRCUIT DIAGNOSIS

1 V2 Diode 2 S1 Key Switch

200 Red

S2 Seat Switch

110 Blk

S5 Brake Switch 5 3 6

945 Wht/Blk 940 Wht

X4 To Engine Wiring Harness

3/22/00

7 - 35

PTO with RIO CIRCUIT DIAGNOSIS

ELECTRICAL WITH RIO SYSTEM

PTO with RIO CIRCUIT DIAGNOSIS Test Conditions: • Key switch in RUN position • Park brake OFF • Diode (V2) disconnected. Test/Check Point

• PTO ON (ENGAGED) • Shift lever in REVERSE • Engine wiring harness disconnected from main wiring harness Normal

If Not Normal

7. RIO switch

Continuity to ground

Check 130 Blk wire and connections.

8. RIS switch

Continuity to ground

Check 954 and 957 Wht wires and connections. If OK, replace RIO switch.

9. RIO latch relay

Continuity to ground

Check 956 Blk wire and 952 Wht/Blk wire and connections. If OK, replace RIS switch.

10. RIO latch relay

Continuity to ground

Check 955 and 957 Wht wires and connections. If OK, replace RIO switch.

11. PTO switch

Continuity to ground

Check 949 Wht/Blk wire and connections. If OK, replace RIO latch relay.

12. Engine connector X4

Continuity to ground

Check 940 and 943 Wht wires and connections. If OK, replace PTO switch.

Test Conditions: Test performed if engine will NOT shut off by key switch or when operator leaves seat with EITHER PTO ENGAGED or brake switch OFF. • Key switch in OFF position (Closes fuel valve to stop engine) • Allow engine to cool, and remove engine cover to access ignition coils • Disconnect diode(s) from ignition coil(s) • Operator OFF seat • PTO ON (ENGAGED); or, Park brake OFF 13. Ignition coil diode(s)

7 - 36

Continuity to ground with diode disconnected from ignition coil.

Faulty diode(s). Replace diode(s).

3/22/00

ELECTRICAL WITH RIO SYSTEM

PTO with RIO CIRCUIT DIAGNOSIS

S6 RIS Switch

954 Wht S3 RIO Switch 7 130 Blk

K2 RIO Latch Relay

V1 or V2 Diode (Briggs & Stratton Engines)

956 Blk Connecting to 952 Wht/Blk

955 Wht T1 or T2 Magneto 13 Ignition Coil (Briggs & Stratton Engines)

949 Wht/Blk S4 PTO Switch 12 940 Wht

X4 To Engine Wiring Harness

3/22/00

7 - 37

TESTS AND ADJUSTMENTS

TESTS AND ADJUSTMENTS BATTERY TEST Reason: To check condition of battery and determine battery voltage.

ELECTRICAL WITH RIO SYSTEM

CHARGE BATTERY Reason:

Equipment: • Hydrometer • Voltmeter or Battery Tester

To increase battery charge after battery has been discharged. Equipment: • Battery charger (variable rate)

Battery Charger and Booster

7 - 38

NOTE:

See BATTERY TEST in this group before charging battery.

1. Connect variable rate charger to battery.

NOTE: Maximum charge time at boost setting is 10 minutes. Allow additional 5 minutes for each 10 degrees below 21.1° C (70° F). 2. Start charger at slow rate. Increase charge rate one setting at a time. Check charger ammeter after 1 minute at each setting. Maintain 10 amp charge rate. Use boost setting as necessary. 3. Check if battery is accepting a 10 amp charge after 10 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 steps 6 and 7. Battery is accepting 10 amp charge after 10 minutes at boost setting, but battery did need water or all cells were below 1.175: go to steps 4 and 5. 4. Set charger at 15-25 amps.

3/22/00

BATTERY LOAD TEST

ELECTRICAL WITH RIO SYSTEM

ALTERNATOR DC OUTPUT TEST Reason:

BATTERY LOAD TEST

To determine proper output of stator.

Reason:

Equipment:

To check condition of battery under load.

• Multimeter

Equipment:

Procedure:

• Battery Tester

1. Disconnect connector from stator. 2. Set multimeter for DC amps. A

D D.C. AMPS

D.C. VOLTS

C Red Lead To Pin

Black Lead To Battery +

3/22/00

Raised Rib On Connector Indicates DC Pin Side

AC Output DC Output M89148

3. Insert RED test lead into 10 A receptacle in meter. 4. Insert BLACK test lead into COM receptacle in meter.

7 - 39

ALTERNATOR DIODE TEST

ELECTRICAL WITH RIO SYSTEM

• If meter beeps once, diode is OK • If meter makes a continuous tone, diode is defective (shorted). Replace diode • If meter displays “OL”, proceed to step 6 7. Reverse test leads. • If meter beeps once, diode is installed backwards. Replace diode • If meter still displays OL, diode is defective (open). Replace diode

AC VOLTAGE OUTPUT TEST

• Output will vary with battery voltage. If battery voltage is at its maximum, output will be approximately 2 amps • If no or low output is found, test diode

ALTERNATOR DIODE TEST

Reason: To measure engine alternating current voltage output to determine stator condition. Equipment: • Multimeter

Reason: To determine alternator diode is functioning correctly. Equipment: • Multimeter with diode test function.

Black Wire

Procedure: M95148

1. Disconnect connector from stator. 2. Set multimeter for Diode Test position.

Specifications: Red Wire

AC Voltage Output (3600 rpm): . . . . . . . . . . . 14 VAC M89153

7 - 40

• If reading is less than specifications, see Briggs & Stratton service manual for electrical system repair.

3/22/00

STARTING SOLENOID TEST

ELECTRICAL WITH RIO SYSTEM

STARTING SOLENOID TEST

10. Connect VOM to negative (–) battery terminal (A) and terminal (D) (Pur wire) of starting motor solenoid. 11. Momentarily turn ignition key to START position and check for battery voltage.

Reason: To determine if starting solenoid is defective.

Results:

STARTER AMP DRAW TEST Reason: To determine the amperage required to crank the engine and check starter motor operation under load. Equipment: • Battery Tester • Photo Tachometer

B C v

D A

A M87617

7. Connect VOM to negative (–) battery terminal (A) and terminal (B) of starting motor solenoid. Check for battery voltage.

M55943a

3/22/00

7 - 41

ELECTRICAL WITH RIO SYSTEM

STARTER NO-LOAD TEST Reason: To determine starting motor condition under no-load conditions. Required Tools:

JTO7270 Hand-Held Digital Tachometer

JTO2153 Current Clamp

JTO5791 Multitester

7 - 42

3/22/00

IGNITION DIODE TEST

ELECTRICAL WITH RIO SYSTEM

NOTE: If using a multimeter other than JT05791, use a meter that will read millivolts. Millivolts = current in amps; 1mV= 1 amp.

Specifications: Maximum starting motor amp draw . . . . . . 35 amps Result: â&#x20AC;˘ If amperage is above specification, check starting motor for binding or damaged

8. Set meter to diode test range.

3/22/00

7 - 43

FLYWHEEL MAGNET TEST

ELECTRICAL WITH RIO SYSTEM

SEAT SWITCH TEST Reason: To ensure proper operation of seat switch. Equipment: • Ohmmeter Procedure:

Reason: To make sure flywheel magnet(s) have enough force to induce current into ignition coil.

1. Park machine on level surface and turn key switch OFF. 2. Shift lever in NEUTRAL and park brake LOCKED. 3. Disconnect harness connector from seat switch.

Equipment: • Screwdriver. Procedure: 1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Raise hood. 6. Remove flywheel blower housing from engine. 7. Loosely hold screwdriver blade about 25 mm (1.0 in.) away from magnet. Results: • Magnet should attract blade to it. • If blade is NOT attracted to magnet, flywheel must be replaced.

B M55816a

4. Check continuity across switch terminals (A) and (B). Results: • There should BE continuity between terminals (A and B) when seat is RELEASED, • There should NOT BE continuity between terminals (A and B) when plunger is DEPRESSED. • If continuity is NOT correct, replace switch.

NOTE:

7 - 44

The seat switch connector has an interlock spring which shorts the three wires together when removed from seat switch terminals. Check that spring mechanism is releasing properly when center tab is depressed.

3/22/00

BRAKE SWITCH / PTO SWITCH TEST

ELECTRICAL WITH RIO SYSTEM

BRAKE SWITCH / PTO SWITCH TEST

BRAKE SWITCH ADJUSTMENT Reason:

Reason: To make sure the brake pedal switch and PTO switch operate properly.

To ensure that engine starts only when brake is fully applied. Procedure:

Equipment:

1. Depress brake pedal and set park brake. .

• Ohmmeter

Procedure: 1. Park machine on level surface and turn key switch OFF. 2. Shift lever in NEUTRAL and park brake LOCKED. 3. Blade drive DISENGAGED. 4. Locate switch being tested as follows: • Brake switch is located under right side frame at brake pedal bellcrank. • Blade drive switch is located under left side frame at bottom of blade drive lever actuating arm. 5. Disconnect harness connector from switch being tested.

B A C D

M56409

M95149

Results: • If continuity is NOT correct, replace switch.

3/22/00

7 - 45

RIS SWITCH TEST

ELECTRICAL WITH RIO SYSTEM

RIS SWITCH TEST

RIO SWITCH TEST

Reason:

To determine proper operation of RIS switch.

To determine proper operation of RIO switch.

Equipment:

• Ohmmeter

Test Connections:

• Set ohmmeter for 1X scale

NOTE: On analog (swing needle) Ohmmeters, set zero point before each test.

Procedure:

1. Remove connector from RIS switch.

1. Remove connector from RIO switch.

A B

2. Connect meter leads to pairs of switch posts and compare to specifications. 3. 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 RIS switch does not pass both tests, replace switch.

7 - 46

Results: • If RIO switch does not pass both tests, replace switch.

3/22/00

GROUND CIRCUIT TESTS

ELECTRICAL WITH RIO SYSTEM

GROUND CIRCUIT TESTS

Procedure:

GROUND

M55642

Chassis Ground

GROUND M95150

Engine Ground (Single Cylinder)

• If resistance is above 0.1 ohms, check for open wiring, loose terminal wire crimps, poor connections, or corrosion in the ground circuit. • If voltage is 0 volts, the component is open. • If voltage is greater than 1 volt, the ground circuit is bad. Check for open wiring, loose terminal wire crimps, poor connections, or corrosion in the ground circuit.

GROUND

M95151

Engine Ground (V-Twin)

3/22/00

7 - 47

RELAY TEST

ELECTRICAL WITH RIO SYSTEM

RELAY TEST

KEY SWITCH TEST

Reason:

To check relay terminal continuity in the energized and de-energized condition.

To verify key switch functions are operating properly. Equipment:

Equipment:

• Ohmmeter or Continuity Tester

• Ohmmeter or continuity tester Procedure: Procedure: 1. Park machine on level surface. 2. Engage park brake. 3. Turn key switch OFF. 4. Disconnect relay connector. 5. Check terminal continuity using an ohmmeter or continuity tester.

1. Park machine on level surface and turn key switch OFF. 2. Shift lever in NEUTRAL and park brake LOCKED. 3. Remove key switch cover. (See “KEY SWITCH REMOVAL - FENDER” on page 49.) 4. Disconnect key switch connector. ST

G A E

M58346

M56817 (D)86

(B)30

NOTE: Key switch terminals are identified to coincide with electrical schematic designations.

5. Use an ohmmeter to test key switch continuity in OFF, RUN, and START positions. Key Switch Continuity

Results: • There should be continuity between terminals (A) and (B), and between terminals (C) and (D). • There should NOT be continuity between terminals (E) and (B). 6. Connect a jumper wire from battery positive (+) terminal to relay terminal (C). Connect a jumper wire from relay terminal (D) and ground (–). Results:

Switch Position

Terminal Continuity

• There should be continuity between terminals (E) and (B). • If continuity is NOT correct, replace relay.

7 - 48

3/22/00

DIODE TEST

ELECTRICAL WITH RIO SYSTEM

DIODE TEST

REPAIR

Reason:

KEY SWITCH REMOVAL - FENDER

To verify that diode has proper continuity. F

Equipment: • Ohmmeter or continuity tester Procedure: 1. Remove diode from connector. Diode A

M55806

Test Lead (A)

Test Lead (B)

1. Remove rear retaining screws (A) and Bracket (B). 2. Connect ohmmeter red (+) lead to pin (A) of diode. Connect ohmmeter black (–) lead to pin (B) of diode. Check for continuity. 3. Reverse test leads. Check for continuity.

NOTE: Front bracket (F) does not have to be removed.

Results: • Diode must have continuity in one direction only. Replace defective diode.

D C

M95152

3/22/00

7 - 49

KEY SWITCH REMOVAL - DASH

ELECTRICAL WITH RIO SYSTEM

KEY SWITCH REMOVAL - DASH 1. Remove six screws and four bolts securing fuel tank. Move fuel tank aside.

C D

M55818

4. Depress tabs (D) of cover and remove. 5. Unsnap switch (C) from housing. 6. Assemble in reverse order of disassembly.

MX0968

2. Disconnect electrical wiring harness connector (A) from switch. 3. Squeeze clips (B)and slide switch out of dash. 4. Assemble in reverse order of disassembly.

STARTER SOLENOID REMOVAL AND INSTALLATION Procedure:

1. Park machine on level surface, engage parking brake, shut engine OFF. 2. Lift seat and remove negative battery cable from battery terminal. 3. Remove positive battery cable from battery terminal. 4. Remove battery hold-down (rubber strap) from frame, and lift battery from tractor. 5. Starter solenoid is located under operatorâ&#x20AC;&#x2122;s seat in front of battery.

105 Black To Ground

710 Purple To PTO Switch

A M55846 Red To Starter

1. Tilt seat forward. 2. Disconnect connector (A). 3. Rotate switch assembly (B) counterclockwise to remove switch from seat pan.

7 - 50

Red To Battery 201 Red To Fuse

6. Follow wiring above to remove and replace solenoid from frame. 7. When connecting battery, always connect positive cable to battery terminal first, and negative cable last.

3/22/00

STATOR AND IGNITION MODULE

ELECTRICAL WITH RIO SYSTEM

STATOR AND IGNITION MODULE Removal and Installation:

15. Place 0.25 mm (0.01 in.) feeler gauge blade (K) or shim stock across magnet face. IMPORTANT: Ensure flywheel magnet (B) is centered on ignition module (A) so all three poles of the ignition module are properly gapped from the flywheel magnet.

Stator

Ignition Modules Wire Hub

16. Position ignition module (A) so all three poles mate with the feeler gauge blade (K) and its two mounting holes align with mounting posts. 17. Install and tighten cap screws to 5.1 ±1.1 N•m (45±10 lb-in.). 18. Repeat steps 13 - 16 for second module. 19. Connect ground wire on each module.

Starting Motor Bracket

Specifications: M44227

Ignition module air gap . . . . . . . 0.25 mm (0.010 in.) Module cap screws . . . . 5.1 ±1.1 N•m (45 ±10 lb-in.) Stator cap screws . . . . . . . . . . . . . . 4 N•m (35 lb-in.) Flywheel nut . . . . . . . . . . . . . . . . . 175 N•m (125 lb-ft) 20. Install stator and tighten to 4 N•m (35 lb-in.). IMPORTANT: Ensure stator wires are routed behind stator wire hub to prevent interference with flywheel rotation. 21. Install starting motor and bracket. 22. Install flywheel and tighten flywheel nut to 175 N•m (125 lb-ft). 23. Install upper blower housing.

B A K

C D

M58360

14. Align flywheel magnet (B) with mounting posts for ignition module.

3/22/00

7 - 51

STARTING MOTOR

ELECTRICAL WITH RIO SYSTEM

STARTING MOTOR

Disassembly:

Removal and Installation: 1. Disconnect negative (–) battery cable. 2. Disconnect red wires from the starting motor terminal. 3. Remove upper blower housing and starting motor gear cover plate.

C-Ring Retainer Spring

Drive Gear Starting Motor Bolts

Helix (Starting Motor Clutch)

Wave Washer

Drive End Head

M88983

4. Remove starting motor bolts. 5. Install starting motor bolts and tighten to specification.

Armature Thru Bolt

Specification:

Housing

Starting motor bolts. . . . . . . . . 15.8 N•m (140 lb-in.) 6. Install starting motor gear cover plate and upper blower housing.

Brush Holder

End Cap

M86976

IMPORTANT: DO NOT clamp motor housing in a vise or strike with a steel hammer. Starting motors contain two powerful magnets that can be broken or cracked if the motor housing is deformed or dented. 1. Remove pinion gear assembly. (See “STARTING MOTOR PINION GEAR REPLACEMENT” on page 55.)

7 - 52

3/22/00

STARTING MOTOR

ELECTRICAL WITH RIO SYSTEM

4. While holding brush holder and armature, remove bearing end cap from armature.

Bolts Brush Holder

M86977

2. Remove bolts and inspect bushing for wear. If worn, replace drive head end assembly.

Armature

M86980

M86978

Brush Holder

Armature

End Cap M86979

3/22/00

M86981

7 - 53

STARTING MOTOR

ELECTRICAL WITH RIO SYSTEM

M86985

Brushes

2. Place armature commutator in brush holder and remove brush retainers. Normal Length New 3 mm (0.125 in.) or less replace M86982

Assembly:

3. Install bearing end plate on armature commutator journal making sure plate indexes with brush holder.

Retainers Retainers

M86983

Notch

7 - 54

M86987

4. Slide motor housing over armature with the notch toward brush holder.

3/22/00

STARTING MOTOR PINION GEAR REPLACEMENT

ELECTRICAL WITH RIO SYSTEM

STARTING MOTOR PINION GEAR REPLACEMENT NOTE: If only the pinion gear is to be replaced, the starting motor does not have to be removed from the engine.

M86988

5. Place wave washer on armature shaft with concave side up. Then place flat washer on armature.

Mark

Required Tools: • JDG1087 C-Ring Remover • JDG1086 C-Ring Installer Procedure: 1. Disconnect negative (–) battery cable. 2. Remove upper blower housing and flywheel.

Starting Motor Pinion M86989

6. Place drive end cap on starting motor housing making sure that mark on cap lines up with housing seam.

Single Cylinder

M88982

Plate

M86977

3/22/00

V-Twin

M88982

7 - 55

STARTING MOTOR PINION GEAR REPLACEMENT

ELECTRICAL WITH RIO SYSTEM

Drive Pins

C-Ring

Plate Retainer Stator Tool #JDG1087 M88955

Intek V-Twin

M95529

The plate surrounding and below the stator does not have to be removed.

Tool Handle

M88956

4. Install C-ring removal tool, JDG1087 over retainer and compress spring. C-Ring

IMPORTANT: removed.

C-Ring Remover M88981

3. Position C-ring using screw driver tip so C-ring removal tool can be aligned properly.

c CAUTION To Prevent eye injury, always wear eye protection when removing C-ring.

The C-ring is not reusable once

5. Screw in handle until drive pins on tool forces off the C-ring from starting motor shaft. Retainer Helix Clutch

Spring Flat Washer Wave Washer

Pinion Gear

M86969

6. Remove retainer, spring, flat washer, wave washer, pinion gear and starting motor clutch.

7 - 56

3/22/00

STARTING MOTOR PINION GEAR REPLACEMENT

ELECTRICAL WITH RIO SYSTEM

7. Before installing starting motor clutch, apply a lithium based lubricant sparingly around base of helix.

C-Ring Installer

NOTE: Do not use mineral spirit based lubricants to lubricate helix. C-Ring Retainer

M88986

M86970

8. Place starting motor clutch on starting motor shaft, rotate clutch until it drops into place.

Spring

Pinion Gear M88984

9. Install pinion gear with beveled side of teeth up, then install return spring making sure spring is in recess of starting motor gear. Wave Washer

M88985

10. Place wave washer with concave side up on starting motor clutch spline.

3/22/00

7 - 57

STARTING MOTOR PINION GEAR REPLACEMENT

7 - 58

ELECTRICAL WITH RIO SYSTEM

3/22/00

CONTENTS

GEAR POWER TRAIN

CONTENTS Page SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 OTHER MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SERVICE PART KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 TRANSAXLE COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TRACTION DRIVE SYSTEM COMPONENT LOCATION. . . . . . . . . . . . . . . . . . . . . . 8

THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 TRACTION DRIVE SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 TRANSAXLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 BRAKE SYSTEM OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 CLUTCH/BRAKE LINKAGE AND DRIVE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . 15 SHIFT LINKAGE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 TRACTION DRIVE BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 TRACTION DRIVE BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 TRACTION DRIVE BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 TRACTION DRIVE SYSTEM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 SHIFT LINKAGE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22 TRANSAXLE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 TRANSAXLE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 INTERMEDIATE SHAFT AND DRIVE SHAFT REPAIR . . . . . . . . . . . . . . . . . . . . . . 29 TRANSAXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2/29/00

8-1

NOTES

8-2

GEAR POWER TRAIN

2/29/00

GEAR POWER TRAIN

SPECIFICATIONS

SPECIFICATIONS Dimensions: Overall Axle Width (End-To-End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735.4 mm (29 in.) Overall Case Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432.5 mm (17. in.) Overall Case Length (Front-To-Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 mm (11 in.) Overall Height (Top Of Input Shaft-To-Bottom Case) . . . . . . . . . . . . . 183.4 mm (7.2 in.) Overall Case Height (Top Case-To-Bottom Case). . . . . . . . . . . . . . . . . 154.2 mm (6 in.) Gear Teeth: Bevel Pinion Gear (Input Shaft). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Drive Shaft: Bevel Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Drive Sprocket Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1st Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2nd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3rd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 4th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 5th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Spur Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Intermediate Shaft: Drive Sprocket Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 1st Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 2nd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 3rd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 4th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 5th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Combination Gear (Idler Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 and 35 Differential Spur Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Differential Miter Bevel Gears (Axle Shafts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Differential Miter Bevel Gears (Cross Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Drive Belt: Effective Length New Belt Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2686 ± 8 mm (105.75 ± 0.3 in.) Minimum Effective Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2656 mm (104.57 in.) Maximum Effective Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2736 mm (107.72 in.) Top Width New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.7 mm (0.500 in.) Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 mm (0.43 in.) Depth New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 mm (0.31 in.) Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 mm (0.28 in.) Lubrication: Grease Type, (Case) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multi-Purpose EP Capacity (Grease) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .638 gms (1.4 lbs) Overall Weight (With Grease) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.2 kg (31.3 lbs) Rear Axle Loading: Maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .450 lbs

3/22/00

8-3

TORQUE SPECIFICATIONS

GEAR POWER TRAIN

Gear Ratios: 1st Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2nd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3rd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61.67:1 46.67:1 30.00:1 23.48:1 15.71:1 40.00:1

Ground Speeds: 1st Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2nd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3rd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.20 km/h (1.37 mph) 2.91 km/h (1.81 mph) 4.54 km/h (2.82 mph) 5.79 km/h (3.60 mph) 8.66 km/h (5.38 mph) 3.40 km/h (2.11 mph)

TORQUE SPECIFICATIONS Brake Assembly Mounting Cap Screws . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.) Clutch Bellcrank Mounting Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . 34 N•m (25 lb-ft) Detent Ball and Spring Set Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flush Only Gear Shift Lever Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 N•m (84 lb-ft) Hanger Bracket to Frame Cap Screws (Front) . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) PTO Clutch to Crankshaft Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . 75 N•m (55 lb-ft) Front Hanger cap screws to frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) Front Transaxle Cap Screws To Hangers . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Rear Axle Cap Screws and Nuts To Frame. . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) Shift Linkage Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (132 lb-in.)

OTHER MATERIALS Form-In-Place Gasket Silicone Sealant Never-Seez®—PT506 or PT569

SERVICE PART KITS Brake Friction Puck Assembly Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119620 Clutch Keys Assembly Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119611 Combination Gear Assembly Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119607 Detent Assembly Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119619 Differential Miter Gear Assembly Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119612 Differential Ring Gear Assembly Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119879 Drive Chain and Sprocket Assembly Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119613 Drive Shaft Assembly Shim Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119610 Input Shaft Assembly Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119602 Input Shaft Assembly Shim Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119603 Pinion and Gear Assembly Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119606 Transaxle Assembly Kit (Complete) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM121563 Right Hand Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM122525 Left Hand Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM122524 Gear Set Assembly Kit 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119614 Gear Set Assembly Kit 2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119615 Gear Set Assembly Kit 3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119616 Gear Set Assembly Kit 4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119617 Gear Set Assembly Kit 5th . . . . . . . . . . . . . . . . . . Use Parts Manual For Specific Model

8-4

3/22/00

TROUBLESHOOTING

GEAR POWER TRAIN

Park brake will not hold ●

●

Belt worn, frayed, glazed, or stretched—replace belt

●

Clutch/brake pedal linkage out of adjustment

●

Clutch/brake components worn, bent, or broken— replace and adjust

●

Shift lever and linkage bent, worn, out of adjustment, or broken— replace or adjust properly Input sheave, input shaft, and axle keys or keyways worn or damaged— replace

●

Noisy operation

●

Shifts hard

●

Jumps out of gear or must hold into

●

Cannot get reverse gear

●

Cannot get all forward gears

Belt sheaves, idlers, and guides loose, out of adjustment, worn, or damaged

Check or Solution

Leaking grease

●

Jerky or aggressive engagement

●

Loses power under load, belt slips, or erratic drive

●

Lack of drive in one or both directions

●

Belt jumping off or slapping

Problem or Symptom

Brakes will not stop tractor

TROUBLESHOOTING

Internal transaxle components worn, stripped, or broken

●

Transaxle case halves worn or broken—replace

●

Incorrect type or volume of lubricant used—replace with correct type and volume

●

Intermediate shifter/brake shaft or axle seals worn or damaged—replace seals

●

Transaxle cap screws loose or case holes stripped

●

Poor application of sealant on transaxle case halves

●

Incorrect type sealant— replace with proper sealant

●

3/22/00

8-5

COMPONENT LOCATION

GEAR POWER TRAIN

COMPONENT LOCATION 1. Flange bearing

45. Spacer

2. Shim 3. Spur gear (14 teeth)

46. Drive chain drive sprocket (9 teeth) 47. Drive shaft bevel gear (42 teeth)

4. Shift collar 5. Shift key (4 used)

48. Shim 49. Drive shaft

6. Shifter Fork

50. Drive shaft 1st gear (12 teeth)

7. Intermediate shifter/brake shaft 8. Woodruff key

51. Drive shaft 2nd gear (15 teeth) 52. Drive shaft 3rd gear (20 teeth)

9. Upper case housing

53. Drive shaft 4th gear (23 teeth)

10. O-ring seal (2 used) 11. Screw (2 used)

54. Drive shaft 5th gear (28 teeth) 55. Spacer

12. Detent ball (2 used) 13. Detent spring (2 used)

56. Washer 57. Flange bearing

14. Set screw (2 used) Flush Only

58. Square-cut rubber ring

15. Shifter shaft rubber boot 16. Screw (14 used)

59. Left axle shaft 60. Washer (0.758x1.25x0.031 in.)

17. Retaining ring 18. Drive chain large sprocket /reverse gear (18 teeth)

61. Washer (0.758x1.25x0.031 in.) 62. Differential bevel gear (15 teeth)

19. Spacer

63. Retaining ring

20. Intermediate shaft 1st gear (37 teeth) 21. Intermediate shaft 2nd gear (35 teeth)

64. Differential ring gear (32 teeth 65. Differential bevel gear (15 teeth)

22. Intermediate shaft 3rd gear (30 teeth) 23. Intermediate shaft 4th gear (27 teeth)

66. Retaining ring 67. Differential bevel gear (15 teeth)

24. Intermediate shaft 5th gear (22 teeth)

68. Shim

25. Spacer w/internal keys 26. Washer

69. Shim 70. Right axle shaft

27. Flange bearing

71. Square-cut rubber ring

28. Square-cut rubber seal (open lip to inside) 29. Drive chain (24 pitches)

72. Differential cross shaft 73. Differential bevel gear (15 teeth)

30. Retaining ring 31. Shim

74. Lower case housing 75. Thin friction puck

32. Needle bearing (2 used)

76. Brake disc

33. Washer (2 used) 34. Input shaft

77. Thick friction puck 78. Friction puck striker plate

35. Bevel pinion gear (14 teeth) 36. Woodruff key

79. Brake housing 80. Brake lever

37. Retaining ring

81. Washer

38. Washer 39. Spacer

82. Lever stop bracket 83. Cap screw (5/16x1.44.)

40. Washer

84. Lock nut (5/16)

41. Idler gear (12 and 35 teeth) 42. Shim

85. Lever Stop bushing 86. Actuator dowel pin (2 used)

43. Idler shaft

87. Washer

44. Flange bearing

88. Cap screw (5/16x2.25)

8-6

3/22/00

TRANSAXLE COMPONENT LOCATION

GEAR POWER TRAIN

TRANSAXLE COMPONENT LOCATION 1

10 N•m (88 lb-in.) 4

Flush Only

10 N•m (88 lb-in.)

5 9

7 8 18 19

29 22

30 23

24 38

25 40

27 28

42 43

35 45

47 48

49 60

Shims (42 and 48) are critical when any gears or case halves are being replaced.

54 55 56

57 68 69

70 74

71 75

76 78 77 79

80 81

22 N•m (190 lb-in.)

82 83

Use Form-In-Place Gasket Silicone Sealant to seal housing halves.

22 N•m (190 lb-in.)

3/22/00

87 88

M42310

8-7

TRACTION DRIVE SYSTEM COMPONENT LOCATION TRACTION DRIVE SYSTEM COMPONENT LOCATION 1. Frame weldmentâ&#x20AC;&#x201D;idler adjustment 2. Carriage bolt (M8x45) 3. Clutch bellcrank bracket 4. Bushing 5. Cap screw 6. Clutch assist spring assembly 7. Carriage bolt (M8x45) 8. Clutch pedal cross shaft 9. Park lever 10. Idler 11. Carriage bolt (M8x50) 12. Clutch spring 13. Washer (2 used) 14. Belt guide 15. Flange nut (M8) 16. Crankshaft drive sheave 17. Foot pad 18. Drive belt 19. Cotter pin 20. Washer 21. Clutch sheave 22. Park locking rod tension spring 23. Flange nut (M6) 24. Park locking rod 25. Flange nut (M8) 26. Rolled pin (M4x20) 27. Safety wire 28. Washer 29. Brake rod compression spring 30. Brake compression spring strap 31. Flange nut (M8) 32. Adjustable idler 33. Belt guide 34. Flange nut (M8) 35. Cotter pin 36. Belt guide 37. Flange nut (M8) 38. Brake rod 39. Cotter pin 40. Washer 41. Brake lever 42. Brake rod return spring 43. Flange nut (M6) 44. Belt guide 45. Transaxle drive sheave 46. Snap ring 47. Lock nut (M8) 48. Cap screw (M8x30) 49. Special patch lock cap screw 50. Lock washer (1/4 in.)

8-8

GEAR POWER TRAIN

51. Washer 52. Cap screw (M8x30) 53. Shift knob 54. Shift lever 55. Right shift lever mounting bracket 56. Lock nut (M8) 57. Special square hole washer 58. Shift arm 59. Lock nut (M8) 60. Universal shift link 61. Lock nut (M8) 62. Left shift lever mounting bracket

3/22/00

TRACTION DRIVE SYSTEM COMPONENT LOCATION

GEAR POWER TRAIN

TRACTION DRIVE SYSTEM COMPONENT LOCATION 12

14 13

11 9

8 17

10 18

3 4

23 24

25 28

29 31

32 33 34 35

37 43

39 42

M55827b

SHIFT LINKAGE SYSTEM COMPONENT LOCATION 48 47

58 57

56 M55836

3/22/00

8-9

THEORY OF OPERATION

GEAR POWER TRAIN

THEORY OF OPERATION

As the bellcrank pivots rearward, belt tensioning spring (C) is stretched, building additional tension in the spring. As the operator begins to ease-up on the clutch/brake pedal (A), tensioning spring (C) pulls the bellcrank tensioning sheave (E) into the drive belt, causing the belt to tighten and seat in the grooves of the transaxle drive sheave (H) and the engine drive sheave (B). This interaction of components results in turning the transaxle drive sheave rapidly in a clockwise direction, transferring power from the engine to the 5-speed transaxle.

TRACTION DRIVE SYSTEM OPERATION

A. Clutch Pedal

E. Tensioning Sheave

B. Engine Drive Sheave F. Bellcrank Assembly C. Tensioning Spring

G. Actuating Spring Assembly

D. Clutch Shaft

H. Transaxle Drive Sheave

Function: The belt traction drive transfers power from the engine to the 5-speed transaxle. The clutch pedal controls the belt traction drive, and allows the transaxle to be shifted through itâ&#x20AC;&#x2122;s five speed range. With engine running and clutch engaged (clutch pedal (A) released), the engine drive sheave (B) pulls the drive belt and transmits power to the transaxle drive sheave (H). As clutch/brake pedal (A) is depressed by the operator, clutch shaft (D) pulls the clutch actuating spring assembly (G) forward. Initial movement of the pedal compresses the spring in the actuating spring assembly (G) and, once compressed, pivots the bellcrank assembly (F). As the bellcrank assembly pivots, the tensioning sheave (E) moves rearward, releasing drive belt tension. This allows the engine drive sheave to rotate without transferring any power through the slackened drive belt.

B A H

8 - 10

M76576

3/22/00

TRANSAXLE OPERATION

GEAR POWER TRAIN

TRANSAXLE OPERATION

cross shaft and bevel gears (E) to both drive axles (K) out to the wheels and tires. The keyed drive wheels are retained by an E-Ring.

Function: The transaxle transmits power from the engine to the drive axles and rear wheels, and provides gear selection of five forward speeds, one reverse, and neutral.

R S T U

M42318

H I

Reverse Gears:

With engine running and clutch engaged, the transaxle drive sheave, input shaft, and input pinion gear (A), are driven by the engine and traction drive belt.

N F

Power is transferred to the bevel drive gear (L), and drive shaft (C), which drives the small drive chain sprocket (U), the drive chain (T), and the large drive chain sprocket (S) on the intermediate shaft (J).

D K

L K M42318

A. Input Pinion Gear B. Intermediate Gears C. Drive Shaft D. Forward Drive Gears E. Cross Shaft Bevel Gears F. Idler Shaft G. Spur Gear H. Shift Fork

I. Shift Keys J. Intermediate Shaft K. Drive Axles L. Beveled Drive Gear M. Differential Ring Gear N. Idler Gear O. Shift Collar

Forward Gears: With engine running and clutch engaged, the transaxle drive sheave, input shaft, and input pinion gear (A), are driven by the engine and traction drive belt.

When the operator shifts into reverse, the shift fork (H), shift collar (O), and shift keys (I) become keyed to the large drive chain sprocket (S). The large drive chain sprocket (S) turns the intermediate shaft (J) and the spur gear (G). The idler shaft (F) and idler gear (N) are driven by the spur gear in reverse, which turn the differential, drive axles, and drive wheels in reverse. Neutral: When the operator moves the shift lever into neutral position, the shifter fork (H) places the shift keys (I) under the free-floating spacer (R), allowing no power to be transmitted into the intermediate shaft (D), which also allows neutral to be maintained with clutch pedal released and engine running.

The input pinion gear (A), which is splined to the input shaft and retained by a snap ring, drives the beveled drive gear (L). The beveled drive gear turns the drive shaft (C), and the five forward drive gears (D). A forward gear is selected when the operator moves the shift lever. The shift linkage moves the shift fork (H), shift collar (O), and shift keys (I) into one of the five intermediate gears (B). The selected gear is keyed to the intermediate shaft (J). Power is transferred by the intermediate gear (B) on the right side of the intermediate shaft, to the splined spur gear (G) on the left side of the shaft. The spur gear (G) drives the idler gear (N), splined to the idler shaft (F), which transfers power into the differential ring gear (M). Power is transferred by the 3/22/00

8 - 11

BRAKE SYSTEM OPERATION

GEAR POWER TRAIN

BRAKE SYSTEM OPERATION G

M76576

A. Clutch/Brake Pedal

E. Adjustable Idler Assembly

B. Clutch Cross Shaft and Bellcrank

F. Transaxle Drive (Input) Sheave

C. Clutch Actuating Spring Assembly

G. Brake Rod Assembly

D. Clutch Bellcrank and Tensioning Idler Assembly

H. Clutch Tensioning Spring

Function: The brake system allows the operator to slow down, stop, or lock the tractor into park position.

There is a small segment of pedal travel (P) that briefly allows the tractor to free-wheel so the operator can shift-on-the-go before the brake starts to engage. This segment can be adjusted to allow more overlap between clutch and brake functions, if desired.

Theory of Operation: R

NOTE: Clutch/brake pedal has approximately 127 mm (5 in.) of travel, and operates as follows:

N O

L K

Q Transaxle Brake Assembly

J I M42594

M55833a

The first movement of the clutch/brake pedal (N) is used for taking-up freeplay in the linkage and the beginning of compressing the clutch actuating spring assembly (C). The next segment of pedal travel (O) is fully compressing the clutch actuating spring assembly (C), and pulling the clutch bellcrank and idler assembly (D) fully rearward, overcoming the belt tensioning spring (H) and fully disengaging the traction drive system. As the pedal is released, belt tensioning spring (H) pulls the clutch bellcrank and tensioning idler assembly (D) forward into the belt, tensioning the belt and fully engaging the traction drive system.

8 - 12

The last segment of travel (Q) fully engages the brake system. The brake lever (S), with the bottom cam surface contour (I), pushes the two dowel pins (J) against the striker plate (K). The striker plate forces the thicker, outer friction puck (L) against the brake disc (H). The two friction pucks (L and M) become compressed against both sides of the brake disc (R). The brake disc is keyed to the end of the intermediate shifter/brake shaft (not shown). When the compression force of the friction pucks is great enough to stop the brake disc rotation, the transaxle and wheels stop turning. This works in conjunction with the clutching system. With the clutch/brake pedal (A) fully depressed and the traction drive system disengaged (fully clutched), the park brake lever assembly (not shown) can be engaged, locking the clutch/brake pedal linkage and the brake disc in the park position. 3/22/00

DIAGNOSIS

GEAR POWER TRAIN

DIAGNOSIS Test Conditions: • Mower on level surface • Mower deck removed • Engine OFF Test/Check Point

• Front wheels blocked • Rear wheels raised off ground with axle housings on jack stands. • Park brake ON Normal

If Not Normal

1. Inspect traction drive belt.

Belt in good condition, not glazed, split, unraveled, or stretched. Minimum width 11 mm (0.43 in.).

Replace traction drive belt See Repair section for removal/ installation instructions

2. Inspect engine and transaxle sheaves, idlers and idler bearings, and belt guides.

Sheaves, idlers and guides in good condition.

Replace any loose, worn, or damaged components. (See Repair section for removal/ installation instructions)

3. Test drive mower up 17° slope in first, second, third and reverse gears.

Mower pulls up slope with no clutch Adjust traction drive belt rear idler slippage (traction drive belt adjusted (See clutch actuating spring properly). adjustment)

4. Shift linkage adjustment.

Linkage shifts smoothly, obtains all gears Adjust linkage. (See shift linkage and neutral. (See Shift Linkage adjustment section for procedure) Adjustment section for test.)

5. Inspect exterior of transaxle housing.

No cracks, leaks, or loose hardware.

6. Perform brake test (See tests and adjustments)

Mower holds on 17° slope, and stops in Go to step 7 and 8 0.9-1.5 M (3-5 ft) or less.

7. Inspect brake pads and disk

Pads and disks not worn beyond Replace pad and disk as needed. specifications. Disc not rubbing on If disk is rubbing case, rebuild transaxle case. transaxle

8. Inspect brake linkage

Brake spring adjustment is 7.5-8 mm Adjust brakes (See Tests and (0.30-0.32 in.). (See Tests and Adjustments section) Adjustments section.)

9. Inspect rear tires

Tire pressures are equal

Adjust air pressure.

Tire outside diameters are equal

Match tires for same size.

10. Inspect rear wheels

Wheels not bent or out of round.

Replace wheels.

11. Remove rear wheels and inspect axles.

Keys, keyways and E-rings in good Repair or replace as needed. shape and seated correctly.

Guides installed, properly adjusted and tight.

Repair or replace as necessary. If case seal is leaking, reseal case

Test Conditions: • Mower on level surface • Front wheels blocked • Park brake OFF

• Rear wheels raised off ground with axle housings on jack stands. • Operator on seat, engine running at operating temperature.

1. Depress clutch pedal and shift into all 5 speeds and reverse

Rear wheels remain still with no axle Adjust clutch actuating spring. rotation (clutch pedal down).

2. Shift transaxle through gears, using clutch to shift

Shifts smoothly, and obtains all forward Adjust shift linkage and reverse gears (both rear wheels are If still no drive, check transaxle being driven). drive sheave shaft key, or remove transaxle for internal inspection.

3/22/00

8 - 13

DIAGNOSIS

GEAR POWER TRAIN

1 2

M55827b

M55836

M42312

8 - 14

M55832

3/22/00

TESTS AND ADJUSTMENTS

GEAR POWER TRAIN

TESTS AND ADJUSTMENTS CLUTCH/BRAKE LINKAGE AND DRIVE ADJUSTMENT

2. Look for a steady pull in all three lower gears up the slope. 3. If traction test fails in any or all of the three lower gears, the belt tension must be adjusted.

Reason: To ensure clutch/brake pedal linkage and traction drive system maintains traction in all three lower gears up a 17° slope. Also, to ensure it disengages traction drive belt, engages brake to slow down or stop tractor within a specified distance, and holds tractor stationary in PARK position on a 17° slope or less.

17°

Procedure:

NOTE:

M95095

This is a four part test and adjustment procedure: PARK BRAKE TEST

1. Test drive on 17° slope, 2. Brake spring adjustment, 3. Clutch spring adjustment, 4. Repeat test drive on 17° slope.

1. Drive or push tractor onto a 17° slope and lock clutch/brake pedal in PARK position. 2. Park brake must hold tractor stationary on slope and tractor must not roll downward once park brake is set.

TRACTION BELT DRIVE TEST BRAKE TEST

CAUTION

DO NOT engage clutch/brake pedal too aggressively or tractor may tip over backwards. It is recommended that you install the mower deck before performing the test drive on a 17° slope.

1. Drive tractor on dry pavement in a safe, open, and level area at fast idle in high gear. Apply a “panic stop” force (no more than 50 pounds of force) to brake pedal. Tractor must stop within 0.9 - 1.5 M (3 - 5 ft) and both wheels should lock-up, leaving skid marks on pavement. 2. Repeat Steps 4 - 6 for reverse. 3. If any test fails, the clutch and brake linkages must be adjusted or components replaced. IMPORTANT: Anytime the brake or clutch spring need to be adjusted, both must be examined to ensure desired results will be obtained.

NOTE:

These adjustment procedures can be performed with tractor on the floor; however, you may want to safely raise the tractor for easier access. If you do, remove the battery to avoid spilling any electrolyte solution.

17° M95095

1. Test drive tractor to see if traction drive system pulls tractor up a 17° slope in all three lower gears.

3/22/00

8 - 15

CLUTCH/BRAKE LINKAGE AND DRIVE ADJUSTMENT BRAKE ADJUSTMENT—

GEAR POWER TRAIN

If the shim slides freely:

• Before inspecting the brakes, depress the brake/ clutch pedal and lock park brake lever into park position. • Check for brake disc contacting the case and/or brake lever contacting its mounting bracket, top or bottom. If so, replace friction pucks and brake disc before making any adjustments.

6. Install the shim and tighten the lock nut until there is slight interference. 7. Remove the shim and cycle the brake pedal. Readjust if needed. 8. If adjustment can not be obtained, inspect brake assembly components, replace as necessary, and repeat all adjustment procedures and drive tests. CLUTCH ACTUATING SPRING ADJUSTMENT IMPORTANT: Anytime the brake or clutch spring need to be adjusted, both must be examined to ensure desired results will be obtained.

Contact Points

M58279

1. Place the tractor on a flat surface, block the front and rear wheels, and release the parking brake. B C

E D

C D

M95096

2. From the rear of the tractor, locate the brake disc, lock nut, and friction pucks. 3. Insert a 0.010 in. (0.25 mm) shim gauge (A) between the disc (B) and friction puck (C). The shim should slide with slight interference. If the shim will not fit: 4. Loosen the lock nut (D) until the shim slides in. Tighten the lock nut until the shim has slight interference. 5. Remove the shim and cycle the brake pedal. Readjust if needed.

8 - 16

M76582

1. Unlock park brake and release pedal (A). 2. Measure clutch actuating spring length (B). Measurement should be 42 - 45 mm (1.65 1.77in.). Clutch actuating spring length is adjusted by sliding rear idler sheave (C) on it’s slotted mounting bracket, as follows: 3. Depress brake/clutch pedal (A) and lock park brake. 4. Remove belt guide (D) to access idler sheave mounting nut (E). Loosen mounting nut and adjust idler as follows: • If spring length is less than 42 mm (1.65 in.), slide idler rearward. • If spring length is greater than 45 mm (1.77 in.), slide idler forward. 5. Tighten idler nut (E). 6. Cycle pedal in and out two or three times measuring clutch spring length each time. Measurement must fall within 42 - 45 mm (1.65 - 1.77 in.) each time. If not, continue to adjust rear idler slightly until it does.

3/22/00

SHIFT LINKAGE ADJUSTMENT

GEAR POWER TRAIN 7. Install belt guide (D). This clutch spring setting should provide proper belt tension to pull tractor up a 17° slope in all three lower gears. 8. Install battery, if removed.

3. Check that transaxle does not rotate while shift lever (D) is in neutral position (C), and clutch/brake pedal released.

REPEAT TEST DRIVE 1. Repeat test drive in at beginning of this section. 2. If tractor fails either brake test, inspect brake assembly components, replace as necessary, and repeat all adjustment procedures and drive tests. 3. If belt is not excessively worn, make small adjustments to idler sheave to obtain proper response in traction drive system as follows: • lengthening the clutch spring causes increased drive traction and aggressiveness • shortening the clutch spring causes decreased drive traction and aggressiveness.

SHIFT LINKAGE ADJUSTMENT

C D

M55808

4. If transaxle rotates, move shift lever (D) slightly until transaxle shift lever clicks firmly into it’s neutral detent. (This may occur while shift lever (D) is in the reverse or first gear range of shift gate). 5. Stop engine.

Reason: To ensure shift lever obtains all shift positions and that neutral position does not allow transaxle to rotate.

G E

Conditions: • Remove deck • Safely raise rear wheels 51 mm (2 in.) off ground and block front wheels (front and rear). • Shift lever in neutral. • Park brake off. Procedure:

M42535

6. Raise seat and loosen left side lock nut (E) holding shift linkage bracket to frame. (Left wheel removed for clarity purposes only.) Slide shift linkage bracket (F) forward or rearward in slots (G) until shift lever is centered in neutral shift gate. Tighten lock nut (E).

A B

M42590

1. Check that shift linkage hardware (A and B) is in good condition and tight. 2. Start and run engine at fast idle.

3/22/00

M55803

8 - 17

REPAIR

GEAR POWER TRAIN

7. If left side bracket adjustment (Step 6) does not allow enough shift lever movement to center shift lever in neutral gate, loosen three mounting brackets (I) holding shift quadrant (H) to fender. 8. Adjust quadrant forward or rearward until shift lever is centered in the neutral gate. 9. Tighten mounting brackets (I). Restart engine and move shift lever through all gears (using clutch to shift). Re-check for axle rotation in neutral (steps 2 through 4 this section). 10. Lower tractor to surface and remove blocks.

Steering Arm Steering Link

Spindle Shaft

Results: • Test drive tractor to ensure all forward and reverse gears are obtained and that tractor does not move when shifter is in neutral position. • If adjustments are not satisfactory, repeat procedure until proper results are obtained. • If adjustments are still not satisfactory, internal transaxle repair is needed.

M58338b

4. Remove cotter key and washer holding steering link to right front spindle shaft. 5. Rotate steering link to align tabs on link with slots in steering arm. Remove link from arm.

REPAIR TRACTION DRIVE BELT REMOVAL

NOTE: If drive belt is in good condition, it does not need to be removed when removing transaxle. Engage park brake and remove belt from transaxle drive sheave. 1. Park mower on level surface. 2. Remove mower deck. 3. Safely raise and block tractor to gain easy access to underside of frame.

NOTE: If mower is to be raised at an angle, remove battery from frame before jacking.

A M76582a

6. Depress and lock brake pedal (A) with park brake lever. 7. Remove front idler belt guide and sheave (B).

E D C

M76583

8. Remove clutch bellcrank belt guide (C).

8 - 18

3/22/00

TRACTION DRIVE BELT INSPECTION

GEAR POWER TRAIN 9. Remove adjustable idler belt guide (D). 10. Remove park lever (E).

16. Pull belt under belt guide and around steering arm (I).

CAUTION

Mower drive lever return spring is under tension and located inside frame. Use pliers or spring puller tool to remove spring. Protect your eyes and face from the possibility of spring being released at high speed. 11. Remove mower drive lever return spring (F)

K M95097

17. Rotate mower drive lever to allow belt to pass between lever (J) and switch (K). 18. Remove belt from clutch bellcrank and idler sheave, and remove belt from mower.

M42768

12. Remove belt from transaxle drive sheave, and pull through transaxle belt guide.

TRACTION DRIVE BELT INSPECTION 1. Examine belt to determine if it is worn, stretched, cracked, frayed, or damaged beyond the point of continued use. 2. Measure and compare removed belt to the following: New Belt Dimensions: Length . . . . . . . . . . . . 2686 Âą 8 mm (105.75 Âą 0.3 in.) Minimum length . . . . . . . . . . . 2656 mm (104.6 in.) Maximum length . . . . . . . . . . . 2736 mm (107.7 in.) Top width . . . . . . . . . . . . . . . . . . 12.7 mm (0.500 in.) Minimum top width. . . . . . . . . . . . 11 mm (0.43 in.) Depth . . . . . . . . . . . . . . . . . . . . . 7.874 mm (0.31 in.) Minimum depth. . . . . . . . . . . . . . . . 7 mm (0.28 in.)

3. Replace belt if any of above dimensions are not found.

H M95098

13. Pull belt from around engine drive sheave (G). 14. Pull LH side of front belt guide (H) down and rotate belt guide toward rear of tractor. 15. Pull traction drive belt forward and loop belt down and around engine drive sheave.

NOTE: If belt is stiff or will not clear engine sheave, remove cap screws securing front belt guide bracket to frame and remove bracket and belt guide assembly.

3/22/00

8 - 19

TRACTION DRIVE BELT INSTALLATION TRACTION DRIVE BELT INSTALLATION

GEAR POWER TRAIN 4. Route through clutch sheave (H) and adjustable idler (I) as shown.

A J B M95205

1. Install end of drive belt through belt guide bracket (A), and pull belt down between guide (A) and sheave (B). Pull belt over large sheave (B) and up into small sheave.

M42768

5. Install drive belt through rear belt guide (J) and over transaxle drive sheave (K). 6. Install belt guides on clutch sheave and adjustable idler. 7. Install park brake lever and mower drive lever return spring. 8. Release park brake and check that belt is seated in grooves of all sheaves and idlers. 9. Perform Clutch/Brake Pedal Linkage Adjustments, shown earlier in this section.

TRACTION DRIVE SYSTEM REMOVAL

M95097

1. Remove mower deck. 2. Block mower wheels securely at front and rear. 3. Engage park brake.

2. Route belt between mower drive lever (C) and switch (D), and around steering arm (E).

F G

M95205

4. Remove front belt guide bracket from tractor frame. 5. Remove traction drive belt from transaxle sheave. 6. Disengage park brake. M76583

3. Route drive belt over the top of clutch cross shaft (F) and park brake locking rod (G).

8 - 20

3/22/00

TRACTION DRIVE SYSTEM REMOVAL

GEAR POWER TRAIN

D H B E C

G M76586

M76582

CAUTION

Clutch tension spring is capable of causing extreme injury if allowed to be released quickly from mower frame. Protect your face, eyes and hands before releasing spring. 7. Thread one end of a three foot long piece of starter rope under the front hook of clutch tension spring (A). Pull rope half way through spring until ends meet, and wrap ends around a bar several times to make a temporary handle. Pull handle until spring hook is free from frame, and release tension from spring. Tension is now off traction drive system and it may be worked on safely. 8. Remove clutch actuating spring (B) from clutch bellcrank (C) and cross shaft (D).

3/22/00

9. Remove clutch/brake pedal by removing mounting nut (E) and pulling pedal through frame. 10. Remove brake bracket from bellcrank by removing cotter key and washer (F). 11. Remove bellcrank from clutch shaft by removing safety wire (G) securing roll pin, then driving out roll pin (H) and removing bellcrank. 12. Remove two bolts and nuts through retainer plate holding left end of clutch shaft, and remove shaft from frame. 13. Remove nut (I) holding parking brake lock lever to parking brake locking rod. 14. Remove spring from frame to parking brake locking rod and slide rod out of frame. 15. Bellcrank assembly is held to frame with one bolt and bushing.

8 - 21

SHIFT LINKAGE REMOVAL AND INSTALLATION SHIFT LINKAGE REMOVAL AND INSTALLATION

GEAR POWER TRAIN

5. Replace necessary components. 6. Install shift linkage in reverse order of removal. 7. Remove shift knob (G). 8. Remove lock nuts (M and O) to remove shift link (N). 9. Remove lock nuts (A and I) and cap screws (B and F). 10. Tighten shift lever cap screw and lock nuts to specifications shown.

1. Remove battery. 2. Block rear of tractor off ground. Remove left drive wheel. 3. Adjust mounting brackets (J and P) so shift rod (H) can be removed from the left side of the frame. You will have to "snake" the shift rod from the tractor. 4. Remove cap screw (C) to remove shift lever (L) and washers (D, E, and K).

C 16 N•m (12 lb-ft.) G

P D

O 15 N•m (132 lb-in.)

E F

M 15 N•m (132 lb-in.)

L K

H I 15 N•m (132 lb-in.) J

M55830

A–Lock Nut

G–Shifter Knob

M–Lock Nut

B–Cap Screw

H–Shift Rod

N–Shift Link

C–Shift Lever Cap Screw

I–Lock Nut

O–Lock Nut

D–Lock Washer

J–Right-Hand Bracket

P–LH Bracket

E–Washer

K–Special Square-Hole Washer

F–Cap Screw

L–Shift Lever

8 - 22

3/22/00

TRANSAXLE REMOVAL AND INSTALLATION

GEAR POWER TRAIN

TRANSAXLE REMOVAL AND INSTALLATION 1. Raise mower off ground and support with jackstands under frame and not transaxle case. 2. Remove rear wheels.

M42590

3. Disconnect shift linkage (B) from shift arm (C). 4. Remove traction drive belt (A). Hint: Lock park brake to loosen belt. Release park brake after removal.

7. Support transaxle with jack stands or have a helper hold transaxle in place while you remove hardware. 8. Remove front cap screws (F) and rear hardware (G). 9. Carefully remove transaxle to workbench. 10. Install transaxle in reverse order of removal. 11. Tighten mounting hardware to the following specifications: Front Hanger cap screws to frame . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) Front transaxle cap screws to hangers. . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Rear axle cap screws and nuts to frame . . . . . . . . . . . . . 30 N•m (22 lb-ft) Shift linkage lock nut . . . . . . . . . 15 N•m (132 lb-in.) 12. Install traction drive belt (A). 13. Install drive wheels. 14. Lower tractor to ground.

TRANSAXLE DISASSEMBLY IMPORTANT: Prevent damage to transaxle: Maintain absolute cleanliness when working on transaxle. The close tolerances in this unit will not tolerate ANY dirt. Use only clean fresh multipurpose EP grease during assembly. Pay close attention to the order and orientation of all components inside the transaxle. Tag and label parts, if necessary. This will aid assembly and prevent transaxle damage Remove Drive Sheave/Shift Arm:

D E

H I

M95099

5. Disconnect clutch/brake rod return spring (D). 6. Remove cotter pin (H) and disconnect clutch/brake rod (E) from brake lever (I).

M55825

G M42534

3/22/00

1. Remove drive sheave snap ring (C). 2. Remove drive sheave (B). 3. Remove shift arm lock nut (D), lock washer, and flat washer.

8 - 23

TRANSAXLE DISASSEMBLY

GEAR POWER TRAIN

4. Remove shift arm (A), and square-hole flat washer from transaxle shifter shaft. Remove Shifter Detent Assembly: A B H E

G F M42316

1. Remove shifter shaft rubber boot (E). 2. Remove both set screws (H) and detent springs (G). 3. Use a magnet or place a shop cloth over holes and turn transaxle upside-down to catch both detent balls (F) in cloth. DO NOT drop or lose detent balls. 4. Inspect detent balls and springs for wear or damage. Replace components as necessary. Do not install springs or detent balls until final assembly. Remove Brake Assembly:

M42317

1. Remove brake assembly by removing two outer cap screws (D) holding caliper to transaxle. 2. It is recommended that inside (thin) brake pad (A), and outside (thick) brake pad (C), and brake disc (B), all be replaced when transaxle is disassembled. 3. Inspect remaining components for wear or damage. Replace components as necessary, but do not install this assembly until transaxle has been completely assembled. Separate Transaxle Housing Case Halves: IMPORTANT: Maintain absolute cleanliness when working on transaxle. The close tolerances in this unit will not tolerate ANY dirt. Use only clean fresh multipurpose EP grease during assembly.

Contact Points

1 M58279

IMPORTANT: Before removal, inspect brake components for wear. Check that brake disc is not contacting transaxle case (1), brake lever is not contacting its mounting bracket (2) (top or bottom). If so, all worn components must be replaced.

8 - 24

3/22/00

TRANSAXLE DISASSEMBLY

GEAR POWER TRAIN

Input Shaft and Pinion Gear Inspection:

M42312

1. Remove brake assembly (A) (see previous procedure). Remove sixteen transaxle housing socket head screws (B).

D E

Lower Case Half

Upper Case Half

M42525a

1. Visually check overall condition of assembly, including the key and keyway, and the drive sheave hub keyway. 2. Check condition of pinion gear (D); look for wear, pitting, broken teeth, etc. 3. Grasp the input shaft and try to rock it left or right inside case housing. If movement is noticeable, replace needle bearing (B and C). 4. Use a feeler gauge to measure clearance between pinion gear (D) and snap ring (E): Clearance . . . . . . . . . . .0.127 mm (0.005 in.) or less. 5. If clearance is excessive, shim thickness (A) needs to be changed or worn components must be replaced. Input Shaft/Pinion Gear Disassembly:

M42318

2. Carefully separate transaxle housing case. Remove upper case from lower case assembly. 3. Inspect overall condition of transaxle without removing any components. Visually target worn or damaged parts for replacement. 4. Remove most of the grease without removing any components.

E K D

G M42320

1. Remove snap ring (E), bevel pinion gear (D), small washer (F), and large washer (G) from input shaft (K) inside upper case half.

3/22/00

8 - 25

TRANSAXLE DISASSEMBLY

GEAR POWER TRAIN Bearing Inside Diameter . . . . . 15.89â&#x20AC;&#x201C;15.92 mm (0.625â&#x20AC;&#x201C;0.627 in.) 6. Replace both bearings by carefully pressing them from case bore without damaging bore. 7. Pack area between bearing with Multi-Purpose EP Grease. 8. Clean and inspect bore. If scratched or deformed, replace upper case half.

J K I

Assemble Input Shaft/Pinion Gear Assembly: H M42313

2. Turn upper case half so input shaft is facing up. 3. Remove woodruff key (J), E-ring (I), shim washer (H), and input shaft (K).

A G B

J H I J K L

M42525a

M42497

IMPORTANT: DO NOT scratch or deform upper case half bore when installing needle bearings.

M42496

IMPORTANT: DO NOT scratch or deform upper case half bore when removing needle bearings.

1. Pack needle bearings (A and B) with Multi-Purpose EP Grease before installing. 2. Install lower needle bearing (B) with flat side of bearing (with lettering) toward inside of case. Press lower needle bearing in case bore with a maximum recess of 0.76 mm (0.030 in.) (H) from case surface. 3. Install upper needle bearing (A) with flat side of bearing (with lettering) toward outside of case. Press lower needle bearing flush with surface of case bore. A maximum recess of 0.76 mm (0.030 in.) from case surface is also acceptable. 4. Pack cavities (G and H) with Multi-Purpose EP grease before installing input shaft.

4. Visually inspect condition of needle bearings, upper bearing (J) and lower bearing (K). If needles are discolored, spalled, scratched, missing, broken, etc. replace bearings. 5. Measure inside diameters of each bearing:

8 - 26

3/22/00

TRANSAXLE DISASSEMBLY

GEAR POWER TRAIN

Shifter Disassembly:

E K

I M42320

5. Install input shaft (E) (with keyway on outside of case), large washer (I), small washer (J), bevel pinion gear (K), and snap ring (L).

D M42322

1. Lift shifter shaft (B) from lower case half mounting hole (C) and groove of shift collar (D). F E A

E M42313

6. Turn upper case half over. 7. Install a shim washer (C) (from Shim Kit) of the proper thickness that allows enough clearance for E-ring (D) to be installed. 8. Turn upper case half over and measure air gap between snap ring (L) and bevel pinion gear (K): Clearance . . . . . . . . . . .0.127 mm (0.005 in.) or less. 9. If clearance is excessive, shim thickness (C) needs to be changed. 10. Install woodruff key (F) in shaft keyway.

M42323

2. Clean shifter assembly and inspect condition of detent holes (A), shift pins (E), shaft (B), lower case mounting hole (C), and shift collar (D). 3. Replace any worn or damaged parts of shifter assembly, rubber boot, detent balls, detent springs, or set screws. 4. If lower case mounting hole (C) is worn or damaged, replace the case half. 5. If shift collar (D) is worn or damaged, replace it when intermediate shaft assembly is disassembled.

3/22/00

8 - 27

TRANSAXLE DISASSEMBLY

GEAR POWER TRAIN

Idler Gear Inspection: E B

M42325

M42523

1. Visually check overall condition of assembly, including shaft and bushings, gears for wear, pitting, broken teeth, etc. 2. Use a feeler gauge to measure clearance (A) between end surface of combination gear and side surface of case half: Clearance . . . . . . . 0.33 - 0.63 mm (0.013 - 0.025 in.), 3. If clearance is excessive worn and/or damaged components need to be replaced.

3. Separate and inspect idler components: • Washers (B and D) should be 0.632 x 1.00 x 0.026 in., not scored or discolored (burnt). • Spacer (C) should be 0.630 x 1.00 x 0.169 in., not scored or discolored (burnt). • Narrow combination gear (E) should have 35 good teeth and wide combination gear (F) should have 12 good teeth, not scored or discolored (burnt). • Idler shaft (G) should be smooth and not scored, pitted, or discolored (burnt). • Shim washer(s) (H) should be 0.632x1.00 and range in thickness from 0.010 to 0.082 in.

J I K

Idler Gear Disassembly:

M42326

• Inside bearing (I) and outside bearing (K), (which are press fit), should not be scored or discolored (burnt); A

NOTE: Replacement gear and needle bearings and a new shaft are also recommended whenever new gear is ordered.

L M42324

1. Lift idler gear assembly (A) from lower case half. 2. Clean components and disassemble. M42327

4. Inspect lower and upper case halves idler shaft bearing surfaces (L) for excessive scoring or wear. Replace case halves as necessary.

8 - 28

3/22/00

INTERMEDIATE SHAFT AND DRIVE SHAFT REPAIR

GEAR POWER TRAIN

INTERMEDIATE SHAFT AND DRIVE

SHAFT REPAIR

Exploded View

E B

Intermediate and Drive Shaft Inspection:

M42335

Intermediate and Drive Shaft Disassembly:

E C

I M42327

M42527

1. Inspect overall condition of intermediate shaft and drive shaft assemblies, including gears for wear, pitting, broken teeth, etc. 2. For the drive shaft assembly (I), use a feeler gauge to measure clearance (G) between side surface of small gear (F) and side surface of shim washer (H): 3. For the intermediate shaft assembly (E), use a feeler gauge to measure clearance (C) between end surface of flange bearing (D) and washer (B): Clearance (G) . . . . . . . . . . . . . . . . . . . . . .0 - 0.20 mm (0 - 0.008 in.) Clearance (C) . . . . . . . . . . . . . . . . . . . . . .0 - 0.25 mm (0 - 0.010 in.) 4. If either or both clearance measurements are in excess of specifications shim washers (A) or (H) need to be added or worn components need to be replaced.

3/22/00

1. Lift both drive (I) and intermediate (E) shaft assemblies from transaxle case together. 2. Carefully remove drive shaft assembly components (bottom row of exploded view) from drive shaft (I). Be sure to remember each components orientation to its neighbor and to the drive shaft. Mark the same side of each component to aid reassembly. 3. Clean components individually once disassembled. 4. Inspect each component closely for wear, scoring, cracks, chips, and broken teeth or splines. 5. Repeat steps 2 through 4 for the intermediate shaft (E) and its components (top two rows of exploded view). 6. Replace components as necessary. IMPORTANT: Remember gear sets are a matched set and both must be replaced, even if only one gear in the set is damaged.

8 - 29

TRANSAXLE ASSEMBLY

GEAR POWER TRAIN 2. Carefully remove axle shaft assembly components from ring gear (G). Be sure to remember each components orientation to its neighbor and to the ring gear (G). Mark the same side of each component to aid reassembly. 3. Clean components individually once disassembled, be sure to remove all sealant material from upper and lower case halves. 4. Inspect each component (especially both upper and lower case halves) closely for wear, scoring, cracks, chips, or discoloration (burnt). Replace components as necessary. 5. Replace seals (I and F) every time transaxle housing has been separated.

Differential/Axle Shaft Inspection:

A F

TRANSAXLE ASSEMBLY E

Left-Hand Short Axle

Right-Hand Long Axle M42826

1. Visually check overall condition of assembly. 2. Use a feeler gauge to measure clearance (A) between side surface of shim washer and side surface of lower case. Clearance . . . . . . . 0.18 - 0.38 mm (0.007 - 0.015 in.), 3. If clearance is excessive, worn or damaged components must be replaced.

IMPORTANT: Prevent damage to transaxle: Maintain absolute cleanliness when working on transaxle. The close tolerances in this unit will not tolerate ANY dirt. Use only clean fresh multipurpose EP grease during assembly. Coat all mating surfaces, except seal surfaces, with SAE 30 weight oil before assembly. Pay close attention to proper order and orientation of all components. Use a calliper to identify the correct shim, spacer, or washers are installed correctly. Differential/Axle Shaft Assembly:

Differential/Axle Shafts Disassembly: M42493

A B F

1. Put inward pressure on both axles (D and E) as you lift differential assembly (F) from lower case. M42493

G H

8 - 30

M42492

1. Assemble left-hand, short axle (A) as shown with splined, beveled gear facing the ring gear. 2. Assemble right-hand, long axle (D) as shown with splined, beveled gear facing the ring gear and shim washers (B) assembled in combination of thicknesses to obtain specified air gap (see Inspect Differential/Axle Shafts Assembly). 3. Assemble internal shaft (C) as shown with beveled gears facing each other. 4. Install internal shaft assembly in slots of ring gear and push beveled gears away from each other so they are ready to mesh with both axle beveled gears.

3/22/00

TRANSAXLE ASSEMBLY

GEAR POWER TRAIN

4. Install remaining intermediate shaft components in their proper order and orientation (reference top two rows of components in photo M42335, See “INTERMEDIATE SHAFT AND DRIVE SHAFT REPAIR” on page 29.) F

H M42492

5. Install axle shafts so beveled gears (E) mesh with differential internal shaft beveled gears. 6. Keep inward pressure on both axles as you install differential assembly in lower case housing. 7. Measure air gap between shim washers (F) and side of housing (H). If air gap meets specification (see Inspect Differential/Axle Shafts Assembly), go to next step. If air gap does not meet specification, remove right axle shaft and add other shim washer combinations until air gap in within specification. 8. Carefully install new axle shaft seals (G and I) and seat them in their lower case housing grooves. Assemble Drive/Intermediate Shaft Assemblies:

B A

M42526

1. Install retaining ring (C) in intermediate shaft groove. 2. Install four keys in grooves of intermediate shaft and hold them so internal shift collar anchors (A) will seat in internal groove of collar (B) as it is installed on the shaft. 3. Slide shift collar and keys against retaining ring (C) and compress locking ramps/lugs (D) to clear retaining ring.

I M42499

5. Install drive shaft components one at a time from left-to-right (reference bottom row of components in photo M42335, See “INTERMEDIATE SHAFT AND DRIVE SHAFT REPAIR” on page 29.) Long flange of small sprocket (J) faces bevel drive gear. 6. Shim washer(s) (E) for intermediate shaft (F) are found in Shim Kit. 7. Shim washer(s) (H) for drive shaft (I) are found in Shim Kit. 8. Install new intermediate shaft seal (G) with open lip facing inside.

K J

M N

M42498

3/22/00

M42327

9. Measure air gaps (K and N)—(see Inspect Drive/ Intermediate Shaft Assemblies). Make any changes in shim washer (M) thicknesses from Shim Kit and shim washer (J) thicknesses from Shim Kit to obtain proper air gaps. 10. When proper air gap is obtained, gears should drag slightly against feeler gauge.

8 - 31

TRANSAXLE ASSEMBLY

GEAR POWER TRAIN 2. Install idler combination gear assembly (H) into lower case half. 3. Measure air gap (J) between shim washer (I) and face of case (K) (see Inspect Idler Combination Gear Assembly). 4. When proper air gap is obtained, assembly should drag slightly against feeler gauge.

Assembly Transaxle Housing Case Halves:

Q M42322

11. Apply Never-Seez® to top surface (O) of shifter plate and contact portions of shifter shaft (P) and (Q) with upper and lower case halves. 12. Install shifter fork assembly. Upper Case Half

Assemble Idler Combination Gear Assembly:

D A

Lower Case Half E

M42325

1. Install components on idler shaft in order shown: • Washers (A and C) should be 0.632 x 1.00 x 0.026 in.; • Spacer (B) should be 0.630 x 1.00 x 0.169 in.; • Narrow combination gear (D) should have 35 good teeth and wide combination gear (E) should have 12 good teeth; • Idler shaft (F) should be smooth, not scored, worn, or pitted; • Shim washer(s) (G) are found in shim kit.

M42318

1. Pack upper case beveled pinion gear and lower case housing assembly with 638 g (1.406 lbs) of Multi-Purpose EP grease. 2. Apply Form-In-Place Gasket Silicone Sealant to lower case. 3. BE SURE sealant DOES NOT contact any gear, shaft, or bearing surfaces.

C A

H I J K

M42324

8 - 32

M42312

3/22/00

TRANSAXLE ASSEMBLY

GEAR POWER TRAIN 4. Align lower and upper case halves together, be sure shaft seals are seated correctly and you may have to turn input shaft (D) slightly to insure beveled pinon gear meshes with beveled drive gear. 5. Install 14 outside socket head screws (A) and two center socket head screws (B) with new rubber seals (C). 6. Tighten screws to 10 Nâ&#x20AC;˘m (88 lb-in.).

Install Brake Assembly:

A S B C D

Install Shifter Detent Assembly: R

E F

H B

O N

I C M42316

IMPORTANT: DO NOT drop or lose detent balls. 1. Install shifter shaft rubber boot (B). 2. Coat detent balls (C) and springs (D) with Never-Seez and install in case bores. 3. Install and tighten set screws (A) until they are flush with top of mounting hole surface.

3/22/00

J K

M42317

1. Install woodruff key (D) into shaft keyway (A). 2. Install thinner friction puck (B) in lower case puck recess (S). 3. Install brake disc (C) with hub outward. 4. Install spacer (O) over left lip (P) of mounting bracket. 5. Install long cap screw (M) and washer (N) in left mounting bracket hole. 6. Install brake lever (H), washer (I), bent bracket (J), and lock nut (L) on mounting bracket center stud. 7. Install short cap screw (K) in right mounting bracket hole (G). 8. Install dowel pins (F) inside two center mounting bracket holes (Q). 9. Install striker plate (R) and thick friction puck (E) in backside recess of mounting bracket.

8 - 33

TRANSAXLE ASSEMBLY

GEAR POWER TRAIN

L M42314

1. Install complete brake assembly to transaxle. 2. Tighten cap screws (K and M) to 20 N•m (160 lb-in.). 3. Tighten lock nut (L) to specification until there is a 10 mm (0.39 in.) clearance between thick friction puck and brake disc. Install Drive Sheave and Shift Arm:

B A D

C E

M55825

1. Install woodruff key (C) in input shaft (E). 2. Install drive sheave (D) and fasten with snap ring (F). 3. Install shift arm (A). Tighten cap screw (B) to 16 N•m (140 lb-in.).

NOTE: Be sure when installing that special square hole washer and shift arm are seated properly over square end of shifter shaft.

8 - 34

3/22/00

CONTENTS

HYDRO POWER TRAIN K51

CONTENTS Page SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 OTHER MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CRUISE CONTROL/SHIFT LINKAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 PEDAL COMPONENT LOCATION - 2046HV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 TRANSAXLE COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TRACTION DRIVE COMPONENT LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 PEDAL COMPONENT LOCATION - EXCEPT 2046HV . . . . . . . . . . . . . . . . . . . . . . . 9

THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 TRACTION DRIVE BELT SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 10 TRANSAXLE AND SHIFT LINKAGE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 10 BRAKE/NEUTRAL RETURN PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 TRANSPORT (FREE-WHEEL) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 DIAGNOSIS - DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 DIAGNOSIS - TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 TRACTION DRIVE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 DRIVE BELT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 SHIFT LINKAGE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 SPRING TENSION ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 BRAKE SPRING ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 TRACTION DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 TRACTION DRIVE BELT TENSIONING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 28 TRANSAXLE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 TRANSAXLE - EXTERNAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2/29/00

9-1

NOTES

9-2

HYDRO POWER TRAIN K51

2/29/00

HYDRO POWER TRAIN K51, K51E

SPECIFICATIONS

SPECIFICATIONS Transaxle: Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kanzaki Model (All except 2046HV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tuff Torq® K-51 Model (2046HV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tuff Torq® K-51E Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic Drive Belt: Effective Length New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2435 ± 8 mm (95.87 in.) Top Width New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.7 mm (0.50 in.) Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 mm (0.39 in.) Bottom Width New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.63 mm (0.30 in.) Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.24 in.) Depth New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.89 mm (0.35 in.) Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 mm (0.28 in.) Lubrication: Oil Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10W30 Engine Oil, Class CD Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36 L (2.5 qt) Gear Ratios: Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.2:1 Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.2:1 Ground Speeds: Domestic Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Export Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0 - 8.5 kph (0 - 5.3 mph) 0 - 5.3 kph (0 - 3.3 mph) 0 - 8.5 kph (0 - 5.3 mph) 0 - 5.3 kph (0 - 3.3 mph)

Output Torque Rating: Rated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 N•m (170.4 lb-ft) Maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805 N•m (594 lb-ft) Brake Torque Rating: Maximum. . . . . . . . . . . . . . . . . . .196 N•m (145 lb-ft) at 245 N (55 lbs) Brake Arm Force Rear Axle Loading: Maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240 kgs (528 lbs)

3/22/00

9-3

REPAIR SPECIFICATIONS

HYDRO POWER TRAIN K51, K51E

REPAIR SPECIFICATIONS Transaxle Components Wear Tolerances: Pump (Input) Shaft Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual Check Motor (Drive) Shaft Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual Check Axle Shaft Thrust Washers Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual Check Brake Components Wear Tolerances: Brake Puck (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 mm (0.1 in.) Brake Disc (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 mm (0.32 in.) Brake Lever Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 mm (1 in.) Degrees Forward from Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20° Travel Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Cruise Control Lever: Compression Spring Installed Dimension . . . . . . . . . . . . . . .17 - 18 mm (0.67 - 0.71 in.) TORQUE SPECIFICATIONS: Case Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.5 - 27.4 N•m (192 - 240 lb-in.) Center Block Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 N•m (40 lb-ft)

OTHER MATERIALS Transaxle Housing Case Half Sealant: Form-In-Place Silicone Gasket Sealant Pump Connector Pipe Plug Sealant: Pipe Sealant With Teflon® Approved Teflon® Sealant Tape Lubrication: Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10W30 Class-CD

9-4

3/22/00

COMPONENT LOCATION

HYDRO POWER TRAIN K51, K51E

COMPONENT LOCATION CRUISE CONTROL/SHIFT LINKAGE

3 2 1

5 6

7 8

6 21 22

23 24

11 9

13 15

10 14

19 16 18 17

1. Torsion Spring 2. Spring Pin (4 x 20 mm) 3. Lever 4. Knob 5. Carriage Bolt (2046HV) 6. Friction Washer (2 used, 2046HV) 7. Lock Nut 8. Strap, Return-to-Neutral (Reverse Orientation for 2046HV) 9. Roller

3/22/00

10. Rod (2046HV) 11. Ball Joint (except 2046HV) 12. Stud, Adjusting (except 2046HV) 13. Nut (5/16 inch, except 2046HV) 14. Ball Joint (except 2046HV) 15. Bushing (except 2046HV) 16. Bracket 17. Shoulder Bolt 18. Cap Screw (M10 x 25) 19. Cap Screw (M8 x 25)

MX0950

20. Nut (except 2046HV) 21. Washer (2 used, 2046HV) 22. Compression Spring (2046HV) 23. Lock Nut (2 used, except 2046HV) 24. Cotter Pin (2 used, 2046HV) 25. Washer (2 used, 2046HV) 26. Flange Nut (M8) 27. Flange Nut (M10) 28. Cruise Arm 29. Spring

9-5

PEDAL COMPONENT LOCATION - 2046HV

HYDRO POWER TRAIN K51, K51E

PEDAL COMPONENT LOCATION - 2046HV

19 7 3

6 9 7

2 1 13 12 7 6

18 17 6 16 15 14

1. Motion Control Rod 2. Motion Arm 3. Cruise Lever 4. Damper 5. Bracket 6. Cotter PIn (4 used)

9-6

7. Washer (5 used) 8. Brake Rod 9. Spring 10. Lock Nut 11. Brake Pedal 12. Pin

13. Bracket 14. Cotter Pin 15. Washer 16. Bracket 17. Washer 18. Hydro Pedal Assembly 19. Spring

3/22/00

TRANSAXLE COMPONENT LOCATION

HYDRO POWER TRAIN K51, K51E

TRANSAXLE COMPONENT LOCATION

7 8

6 4 1

2 3 5

11 11 12

13 11

16 14

M95101A 17 11

1. Knob (Except 2046HV) 2. Hex Jam Nut (Except 2046HV) 3. Tow Valve Rod (Except 2046HV) 4. Tow Valve Rod (2046HV) 5. Snap Ring 6. Cap Screw (M6 x 30, 2 used)

3/22/00

7. Snap Ring 8. Spacer (2 used) 9. Sheave 10. Fan 11. Lock Nut (2 used) 12. Flange Nut (8 used) 13. Screw (2 used)

14. Screw (2 used) 15. Strap (2 used) 16. Push Nut 17. Screw (RH, M8 x 70, 2 used) Screw (LH, Not Shown, M8 x 60, 2 used) 18. Transaxle Assembly

9-7

TRACTION DRIVE COMPONENT LOCATION

HYDRO POWER TRAIN K51, K51E

TRACTION DRIVE COMPONENT LOCATION 10

9 8 7 6

5 19 13

4 14

15 16

3 21

23 18 3 22

MX0962

1. Belt Guide (2046HV) 2. Belt 3. Flange Nut (M8, 4 used) 4. Sheave 5. Bolt (M8 X 60) 6. Cap Screw 7. Bushing 8. Arm

9-8

9. Bolt (M8 X 45, 2 used) 10. Spring 11. Belt Guide (2046HV) 12. Sheave, Engine 13. Lock Washer 14. Cap Screw (7/16 X 4 in.) 15. Lock Nut 16. Spring Washer

17. Guide (2046HV) 18. Guide (PTO, 2046HV) 19. Idler 20. Washer 21. Guide (2046HV) 22. Guide (2046HV) 23. Idler

3/22/00

HYDRO POWER TRAIN K51, K51EPEDAL

COMPONENT LOCATION - EXCEPT 2046HV

PEDAL COMPONENT LOCATION - EXCEPT 2046HV 8

7 6

1 2

11 12

7 6

13 15

18 17

16 19 20 21 6 7

M95103

1. Neutral Switch 2. Lock Nut (3/8 in.) 3. Pivot 4. Nut (3/8 in.) 5. Rod 6. Washer 7. Cotter Pin

3/22/00

8. Brake Rod Return Spring 9. Brake Spring Strap 10. Brake Compression Spring 11. Washer 12. Park Brake Lever 13. Extension Spring 14. Flange Nut

15. Rod, Parking Brake 16. Shaft, Brake 17. Pad 18. Strap, Return to Neutral 19. Screw (M8 x 20) 20. Bracket 21. Lock Nut (M8)

9-9

THEORY OF OPERATION

HYDRO POWER TRAIN K51, K51E

THEORY OF OPERATION In this group the Sabre hydrostatic power train is separated into the following systems: • Traction Drive Belt System • Transaxle and Shift Linkage System • Brake/Neutral Return Pedal System • Transport (Free-Wheeling) System

TRANSAXLE AND SHIFT LINKAGE OPERATION Function: The function of the transaxle is to transfer power from the traction drive belt system (driven by the engine), to the rear wheels, and allow the operator to select ground speed and direction.

TRACTION DRIVE BELT SYSTEM OPERATION Function: The traction drive belt transfers power from the engine to the input pulley of the hydrostatic transaxle. Major Components:

The drive belt turns the transaxle input pulley, and drives the transaxle’s hydrostatic pump. When the hydrostatic drive is in neutral, no pressure is built up in the pump. When the operator pushes the hydrostatic drive lever (cruise control lever, model 2046HV) or pedal forward, the shift linkage tilts the swash plate, inside the transaxle, off center, and the pump pistons build pressure which drives the hydrostatic motor. The motor drives the rear axle and wheels through the differential assembly. The transaxle provides infinite ground speed selections up to 5.5 mph (8.8 km/h) in forward and up to 3.3 mph (5.3 km/h) in reverse.

• Foot pedal and brake linkage • Engine drive sheave • Traction drive belt • Tensioning idler assembly • Tensioning spring • Adjusting idler assembly • Transaxle drive sheave

Major Components: • Transaxle input pulley and fan • Pump (input) shaft and cylinder block assembly • Shift linkage and pump swashplate assembly • Center block assembly • Motor cylinder block assembly and drive shaft • Differential assembly and axle shafts • Wheels and tires.

Theory of Operation: B A

Theory of Operation:

G E

H M55834

The traction drive belt (A) is driven by the upper pulley of the engine drive sheave (B). The traction belt then transmits engine power to the input pulley of the hydrostatic transaxle (C). An idler pulley (D) is used between the engine sheave and the transaxle. The traction drive belt is tensioned by the tension idler (E), which is mounted on a spring loaded bracket (F). The tension spring (G) runs forward and hooks to the frame. When the traction drive belt stretches beyond the range of the spring loaded tension idler, an adjustable idler (H) can be moved in slots on the frame, allowing the tension idler to move back into range.

9 - 10

M87470

Neutral: When the engine is running, the traction drive belt (A) turns the transaxle input pulley (C), cooling fan, and input shaft. The input shaft turns the hydrostatic pump input shaft and pump body, inside the transaxle.

3/22/00

TRANSAXLE AND SHIFT LINKAGE OPERATION

HYDRO POWER TRAIN K51, K51E

I Q

M95105

I K

M87433

When in neutral, the shift linkage holds the shifter shaft (N) and the variable-angle pump swashplate (O) in the neutral position. While in neutral (swashplate level) position, the pump cylinder block (P) rotates with the pump (input) shaft but does not pump any oil into the motor half of the center block (Q) because the pump pistons are not moving up and down as they rotate. Therefore, the motor cylinder block (R) does not turn nor do the motor (output) shaft (S), differential assembly (T), or drive axles (U and V). Forward:

M87566

When the shift lever is moved into forward position, the shift bracket pivots, pulling the link rearward. The transmission linkage turns the shifter shaft, and through it, the variable-angle pump swashplate into forward position.

When the hydrostatic drive lever (cruise control lever, model 2046HV) (I), is in the neutral position (J), the shift bracket (K) is centered and the link (L) is centered in the slot on the right side frame.

C B E

M87468

A D

M87407

Model K51 transaxle shown. Model K51E is similar. The link (L) moves the transaxle shift lever (M). The shift lever turns the transaxle shifter shaft (N, right side frame rail removed for clarity). 3/22/00

With the pump swashplate angled in forward position, the pump cylinder block pistons are pumping oil through one side of the center block (A) into the pistons (B) of the motor, forcing the pistons out against the fixed-angle swashplate (C). As the pistons slide down the swashplate surface, the motor cylinder (D), motor (output) shaft (E), differential assembly, and drive axles to turn in the forward direction. Reverse: When the shift lever is moved into reverse position, the shift bracket pivots in the opposite direction, pushing the link forward. The transmission linkage turns the shifter shaft, and through it, the variable-angle pump

9 - 11

BRAKE/NEUTRAL RETURN PEDAL swashplate into reverse position.

HYDRO POWER TRAIN K51, K51E Theory of Operation

With the pump swashplate angled in the opposite direction from the forward position, the pump cylinder block pistons are pumping oil through the other side of the center block (A) into the pistons (B) of the motor, forcing the pistons out (on the opposite side) against the fixed-angle swashplate (C) and causing the motor cylinder (D), motor (output) shaft (E), differential assembly, and drive axles to turn in the reverse direction.

B C

BRAKE/NEUTRAL RETURN PEDAL

COMPONENT LOCATION AND OPERATION

P Q

Function: The brake system allows the stop the tractor, return the pedals to neutral, and lock 2046HV tractors the pedal tension.

operator to slow down or shift linkage and hydro the brake into park. On also relieves drive belt G

Major Components: • Foot pedal • Frame cross rod and bellcrank • Brake rod, compress spring, and strap • Brake rod return spring • Brake rod adjustment coupler • Transaxle brake assembly and return spring • Shift linkage • Shift/return-to-neutral bracket • Shift bracket return-to-neutral strap and bushing • Shift bracket support strap • Park locking rod • Park locking lever • Park locking spring

F M87565

I M87567

LH Side L K N

M M87566

RH Side

9 - 12

3/22/00

TRANSPORT (FREE-WHEEL) SYSTEM

HYDRO POWER TRAIN K51, K51E When the brake pedal (A) is depressed, the frame rod (B) and frame rod arms (C) rotate forward. This motion causes the brake rod (D) and neutral return strap (E), to move forward at the same time. As the brake pedal is depressed further, spring strap (F) compresses the compression spring (G). The compression spring pulls the brake rod (D) forward. On the left hand side of the tractor, the brake lever (H) rotates forward forcing (by means of a cam) the brake shaft (I) into the transmission where it is pushed against the internal brake disc. As the brake pedal is depressed further, greater force is applied until the disc stops turning. This works in conjunction with the neutral return linkage, stopping the tractor. On the right hand side of the tractor, the neutral return strap (E) is pulled forward, forcing the cam roller (J) to roll up one of the ramp contours of shifter bracket (K). This action moves the shifter bracket and shifter lever (L) back towards the neutral position. At the same time, this returns the shift linkage (M) into neutral position and the internal, variable pump swashplate into its level (non-pumping) position. This works in conjunction with the brake linkage, stopping the tractor. As-soon-as the shift lever reaches either radius of the neutral slot, the return spring (N) snaps the shift lever back into neutral position. When the brake pedal is fully depressed, the brake can be locked into park position with the park lever (O) and locking rod (P). The locking spring (Q) holds the locking rod in place until the operator eases up on the pedal and the force of compression spring (G) locks the frame rod arm (C) against the locking rod (D). To release the park brake, the operator must again depress the brake pedal fully and pull the park lever and locking rod (P) into the disengaged position.

1. The first segment of travel (W) is taking-up freeplay in the brake and return-to-neutral linkages. 2. The next segment of travel (X) is returning the shift linkage to neutral and engaging the brake. IMPORTANT: Full brake engagement (drive wheels stop turning) must not occur until shift linkage has returned completely to neutral. If this is not the case, see Tests and Adjustments procedures later in this section. 3. The last segment of travel (Y) is locking and unlocking the brake linkage into park.

TRANSPORT (FREE-WHEEL) SYSTEM Function: The transport (free-wheel) system allows the operator to push the tractor while the engine is off, transmission in or out of either forward or reverse, and the brake released. Major Components: â&#x20AC;˘ Internal center block relief valve assembly â&#x20AC;˘ Internal actuating assembly â&#x20AC;˘ External over-center actuating lever assembly Theory of Operation:

Brake Pedal Travel

A X M87415

Oil bypass relief ports (A), located inside the center block of the transaxle pump, allow oil to flow freely without the pump being turned by the engine and traction drive system.

M58271a

NOTE: Brake pedal has approximately 127 mm (5 in.) of travel.

3/22/00

9 - 13

TRANSPORT (FREE-WHEEL) SYSTEM

HYDRO POWER TRAIN K51, K51E When the actuating shaft (D) rotates 35Â°, a flat side (E) (inside the motor pump housing assembly) moves in front of an oil bypass relief port. When the port is opened, oil is allowed to flow freely through the motor pump. By hydraulically disconnecting the wheel axles from the engine input shaft, the operator is allowed to push the tractor with the engine off and the brake released.

M87467

When the actuating rod (B) is pulled out to its locked position, the linkage assembly (C) rotates the actuating shaft (D) 35Â°.

C M87417

D M87407

M87413

9 - 14

3/22/00

TROUBLESHOOTING

HYDRO POWER TRAIN K51, K51E

Belt worn, frayed, glazed, or stretched - replace belt

●

Tensioning spring weak or broken - replace as necessary

●

Accumulation of grass and other debris in cooling fins or around moving parts of transmission

●

Brake pedal linkage out of adjustment - adjust properly

●

Brake system components worn, bent, or broken - replace and adjust properly

●

Shift lever linkage bent, worn, out of adjustment, or broken - replace or adjust properly

●

Neutral return linkage worn, bent, or broken replace as necessary

●

Input sheave, input shaft, and axle keys or keyways loose, worn, or damaged replace as necessary

3/22/00

●

Creeps in neutral

●

Transport mode pushes hard

●

Transaxle overheats

Input shaft /pulley will not turn

●

Park brake will not hold

Cannot get full forward or reverse speed

●

Brakes will not stop tractor

Jerky or aggressive engagement

●

Leaking lubricant

Loses power under load, belt slips, or erratic drive

●

Noisy operation

Lack of drive in one wheel or both

Belt sheaves and idlers loose, out of adjustment, worn, or damaged tighten, replace, or adjust properly

Shifts hard

Check or Solution

Belt jumping off or slapping

Problem or Symptom

Returns to neutral during operation or under load

TROUBLESHOOTING

●

9 - 15

TROUBLESHOOTING

Transaxle case and mountings loose, worn, or broken - replace transaxle as necessary

●

Fan and/or pulley loose or damaged - tighten or replace

●

Hydrostatic oil filter plugged

●

Incorrect type or volume of lubricant used - replace with correct type and volume. Note: Initial leakage may be result of excessive factory rust preventive. Clean case and verify source of leak

●

Bleed procedure overlooked or improperly done - repeat procedure correctly

●

Wheels and axle keys, key ways, or snap rings worn replace as necessary

●

9 - 16

●

Creeps in neutral

●

Transport mode pushes hard

●

Transaxle overheats

●

Park brake will not hold

●

Brakes will not stop tractor

●

Leaking lubricant

Internal hydro pump and/ or motor cylinder block and valve plate mating surfaces worn or scored replace transaxle as necessary

Noisy operation

●

Shifts hard

●

Returns to neutral during operation or under load

Jerky or aggressive engagement

●

Input shaft /pulley will not turn

Loses power under load, belt slips, or erratic drive

Internal transaxle components worn, stripped, or broken replace transaxle as necessary

Check or Solution

Belt jumping off or slapping

Lack of drive in one wheel or both

Problem or Symptom

Cannot get full forward or reverse speed

HYDRO POWER TRAIN K51, K51E

●

3/22/00

●

Poor application of transaxle case halves sealant - replace sealant properly

●

Incorrect type sealant replace with proper sealant

●

Transport (free-wheeling) valves and linkage out of adjustment or damaged readjust or replace as necessary

●

Engine performance problems - see Engine Section

●

3/22/00

●

Creeps in neutral

●

Park brake will not hold

●

Transport mode pushes hard

●

Transaxle overheats

Transaxle case halves cap screws loose or stripped tighten to 27 N•m (240 lb-in.) or replace screws

Leaking lubricant

Motor drive shaft or axle seals worn or damaged replace seals

Noisy operation

Shifts hard

Returns to neutral during operation or under load

Input shaft /pulley will not turn

Cannot get full forward or reverse speed

Jerky or aggressive engagement

Loses power under load, belt slips, or erratic drive

Lack of drive in one wheel or both

Check or Solution

Belt jumping off or slapping

Problem or Symptom

Brakes will not stop tractor

TROUBLESHOOTING

HYDRO POWER TRAIN K51, K51E

9 - 17

DIAGNOSIS - DRIVE BELT

HYDRO POWER TRAIN K51, K51E

DIAGNOSIS - DRIVE BELT Test Conditions: • Tractor on level surface

• Front wheels blocked

• Engine OFF

• Rear wheels raised off surface with axle housings on jack stands

Test/Check Point

Normal

If Not Normal

1. Fan

Fan tight and in good condition.

Tighten fan. Repair or replace as needed.

2. Drive belt

Belt in good condition, not glazed, split, unraveled, or stretched.

Replace belt as needed.

3. Tensioning spring

Tensioning spring installed and not damaged.

Install spring. Replace spring as needed.

4. Sheaves and idlers, belt traction drive system

Drive sheaves and idlers in good condition and adjusted properly.

Adjust idler assembly. Repair or replace as needed.

Drive belt not slipping, squealing, or vibrating excessively.

Check belt condition. Check adjustment and condition of idlers and guides. Adjust, repair or replace components as needed.

5. Transaxle housing exterior

No cracks, leaks, or loose hardware.

Tighten hardware. Check warranty. Replace transaxle.

6. Axles

Axles straight, undamaged.

Check that axles are straight. Check condition of keys and keyways. Repair or replace as needed.

7. Tires

Driving tires correctly inflated.

Adjust air pressure.

Driving tires have same circumference.

Match tires for circumference.

Tires in good shape

Check tires for tread wear.

Wheels not bent or out-of-round, attached to axle properly.

Check wheels for straightness. Check condition of keys, keyways, washers, and snap rings. Repair or replace components as needed.

8. Wheels

Test Conditions: • Engine ON 9. Engine performance.

9 - 18

• Rear wheels raised off surface with axle housings on jack stands Engine running smoothly throughout throttle range. See “TRACTION DRIVE SYSTEM” on page 22.

Adjust, tune, or repair engine.

3/22/00

DIAGNOSIS - DRIVE BELT

HYDRO POWER TRAIN K51, K51E

3 2

M55834

M87473a

M87495

M55892

3/22/00

9 - 19

DIAGNOSIS - TRANSAXLE

HYDRO POWER TRAIN K51, K51E

DIAGNOSIS - TRANSAXLE Test Conditions: • Tractor operated in test area

• Tests run at engine slow idle and fast idle

• Engine at operating temperature

• Hydro run through full range of speeds in both directions

Test/Check Point

Normal

If Not Normal

1. Shift linkage

Shift linkage adjusted properly and working smoothly.

Repair or replace as needed.

2. Brake linkage and assembly

Brake and brake linkage adjusted properly and working smoothly.

Adjust as needed. See “BRAKE SPRING ADJUSTMENT” on page 25. Repair or replace as needed.

Brake components not worn or damaged.

Repair or replace as needed.

Neutral return linkage adjusted properly and working smoothly.

Adjust as needed. Repair or replace as needed.

3. Neutral return linkage

Test Conditions: • Tractor on level surface.

• Front wheels blocked.

• Engine OFF

• Rear wheels raised off surface with axle housings on jack stands.

Test/Check Point

Normal

If Not Normal

4. Hydro housing exterior

No cracks, leaks, or loose hardware.

Tighten hardware. Replace transaxle.

5. Transport (free wheeling) valve and linkage

Transport linkage engaging and disengaging properly.

Repair or replace linkage as needed.

6. Internal hydro components

No worn, scored or scratched components.

Replace as needed. See “TRANSAXLE REMOVAL AND INSTALLATION” on page 29.

Correct type and quality of oil. Oil not dirty or burnt.

Fill with correct quantity of new oil, class CD or higher.

Retaining snap rings in good shape and seated correctly.

Replace as needed.

NOTE: If internal hydro component parts are suspected (after performing all external checks and adjustments) CALL SABRE SERVICE DEPARTMENT FOR AUTHORIZATION TO REPLACE TRANSAXLE ASSEMBLY.

9 - 20

3/22/00

DIAGNOSIS - TRANSAXLE

HYDRO POWER TRAIN K51, K51E

NOTE: K51 Transaxle is shown. K51E Transaxle is similar.

5 4 6

M87473

3/22/00

9 - 21

TESTS AND ADJUSTMENTS

HYDRO POWER TRAIN K51, K51E

TESTS AND ADJUSTMENTS TRACTION DRIVE SYSTEM Reason: To ensure shift, neutral return, and brake linkages and belt drive system maintain traction in lower 1/3 of forward speed range up a 17° slope. To ensure that transport (free-wheeling) valve assembly and linkage allow tractor to be pushed when engaged and to drive tractor when disengaged. Also, to ensure tractor returns to neutral, engages the brake, stops tractor within specification, and holds tractor stationary in PARK position on a 17° slope or less.

5. Shift lever and linkage must return-to-neutral, park brake must hold tractor stationary on slope, and tractor must not creep downward once park brake is locked into position. 6. Drive tractor on dry pavement in a safe, open, and level area at fast idle in full forward position. Apply a “panic stop” force (no more than 50 pounds of force) - tractor must stop within 0.9 - 1.5 m (3 - 5 ft) and both wheels should “lock-up”, leaving skid marks on pavement. 7. Repeat Steps 4 - 6 for reverse. 8. If any test fails, the brake linkage and return-to-neutral linkage must be adjusted or components replaced.

DRIVE BELT ADJUSTMENT

Procedure: • Test drive on 17° slope, • Drive belt adjustment, • Transport valve linkage adjustment, • Shift linkage adjustments, • Brake rod adjustment, • Repeat test drive on 17° slope.

B C A

Test Drive—

CAUTION

DO NOT accelerate or engage shift lever too aggressively or tractor may tip over backwards while performing the test drive on a 17° slope.

31.1 ± 0.64 cm (12.25 ± 0.25 in.)

M95100

1. Lock park brake.

CAUTION

Tensioning spring (A) is under high tension. Wear gloves and use a firm grip when stretching spring. 2. Measure length of tensioning spring (A). If measurement is to specification, belt tension is good. If tension spring length does not meet specification, proceed to step 3.

17° M95095

1. Test drive tractor to see if traction drive system pulls tractor up a 17° slope in lower 1/3 of forward range. 2. Look for a steady pull up the slope. 3. If test fails in any of the lower 1/3 range, the belt tension must be adjusted. 4. Drive or push tractor onto a 17° slope, depress the brake pedal and lock it in PARK position.

9 - 22

NOTE: If tractor does not pass traction drive tests and tensioning spring length meets specifications, replace belt. Specification: Spring Length (NOT including hooks) . . . . . . . . . . . . . . . 31.1 ± 0.64 cm (12.25 ± 0.25 in.)

3/22/00

SHIFT LINKAGE ADJUSTMENT

HYDRO POWER TRAIN K51, K51E 3. Carefully pull larger tensioning idler (B) rearward until belt can be removed from adjustable idler (C), then slowly release tensioning idler. 4. Loosen and move adjustable idler (C) rearward in slots (D). 5. Tighten adjustable idler (C) and carefully install belt in larger tensioning idler (B). 6. Repeat procedure until tensioning spring length meets specification.

NOTE: If a new belt is required, adjustable idler should be reset at front end of slot (D).

Adjust - All except Model 2046HV, K51E Transaxle 5. If transaxle creeps, loosen front and rear jam nuts (C) of turnbuckle assembly (D). 6. Use flats (E) to turn threaded link (use 1/4 turn increments) clockwise to shorten turnbuckle length or counterclockwise to extend turnbuckle length. 7. Adjust turnbuckle length until creep stops. Hold flats (E) stationary and tighten jam nuts (C). 8. As a last resort, if prior adjustment fails to stop creep motion with few threads of link left, adjust shift quadrant forward or rearward.

SHIFT LINKAGE ADJUSTMENT 1. Safely raise rear of tractor off the surface and block the front wheels. Remove rear wheels to gain access to transaxle shift linkage and to safely check for creep in transaxle (axles turning while shift linkage is in neutral position without brake engaged). 2. Check that all shift linkage hardware is in good condition and tight. Replace components as necessary.

M55850

M58277

9. Loosen shift quadrant three mounting brackets (F). 10. With engine at fast idle, move quadrant forward or rearward until creep motion stops with shift lever in return-to-neutral position (via brake pedal). 11. Holding quadrant in place, turn engine off and tighten three mounting brackets (F). 12. With engine running at fast idle, re-cycle shift lever and return-to-neutral linkage several times to ensure adjustment eliminates creep. Adjust - Model 2046HV, K51E Transaxle 1. Perform steps 1 through 4 as with the K-51 transaxle.

3. With park brake unlocked, cycle shift lever (A) into full forward and step on brake pedal to return shift lever into neutral position (B). DO NOT move shift lever by hand. A

D MX0964

M87468

Neutral adjustment eccentric shaft (A) and lock nut (B). Some components removed for clarity

4. Run engine at fast idle and check that transaxle does not creep while shift lever is in this position.

3/22/00

9 - 23

SPRING TENSION ADJUSTMENT

B C

HYDRO POWER TRAIN K51, K51E 9. Turn eccentric shaft (A) clockwise until the axle shaft stops turning. Mark the eccentric shaft and transaxle case. 10. Turn the eccentric shaft clockwise approximately 8° (F ) from forward stop position (E). 11. Hold eccentric shaft with wrench and tighten lock nut (B).

SPRING TENSION ADJUSTMENT Model K51 - Bellcrank Spring 1/3

1/3

E F

2. Loosen lock nut (B) and turn the eccentric shaft (A) clockwise until the axle shaft(s) rotates in reverse. Mark the eccentric shaft for position (C). 3. Turn the eccentric shaft slowly counterclockwise until the axle shaft(s) stops rotating. Mark the transaxle case at the reverse stop position (D). 4. Turn the eccentric shaft slowly counterclockwise until the axle shaft(s) rotates forward. 5. Turn the eccentric shaft clockwise until the axle shaft(s) stops rotating. Mark the transaxle case at the forward stop position (E). 6. Turn the eccentric shaft slowly clockwise until the mark is approximately 1/3 the distance between the forward and reverse stop positions. This is neutral position (F). 7. Hold eccentric shaft with wrench and tighten lock nut. If the axle shafts do not rotate in reverse although the eccentric shaft has been turned one full turn, adjust neutral as follows: 8. Turn eccentric shaft counterclockwise until axle shaft(s) rotate forward.

1. Make sure bellcrank assembly and transaxle right, front mounting bracket are oriented properly. (Shown from Top)

M87540

2. Check shift linkage bellcrank spring tension by measuring spring length distance (A) between flanged nut and top anchor washer and surface of friction disc. 3. Adjust to specification. This will ensure shift lever will remain stationary wherever operator lets go of lever anywhere in shift quadrant. Adjustment may vary from one operator’s preference to the next. Specification: Bellcrank spring length (maximum) production spring . . . . . 20 ± 1 mm (0.78 ± 0.04 in.) Model K51E - Cruise Arm Spring

MX0975

8°

E F

9 - 24

The K51E cruise arm tension spring (A) adjustment is the same as the K51 bellcrank spring adjustment. Individual operator’s preference may vary.

3/22/00

BRAKE SPRING ADJUSTMENT

HYDRO POWER TRAIN K51, K51E

BRAKE SPRING ADJUSTMENT

Specifications:

Model K51 1. Unlock park brake and release brake pedal. 2. Measure distance from inside of brake rod stop tabs (A) to outside of compression spring bracket (B) (located below foot tread area on LH side of transmission). Distance should be 2 - 10 mm (0.08 - 0.40 in.). A

CAUTION

M42596

(LH side of transaxle) 30° Max.

M87543

If distance is less than or equal to 2 mm (0.08 in.): 1. Gradually adjust jam nuts until specified measurement is obtained. 2. Depress pedal and park brake. 3. Measure the distance from inside of brake rod stop tabs (A) to outside of compression spring bracket (B). Gap should have a minimum distance of 2 mm (0.08 in.). 4. Check brake rod compression spring. It should not be completely compressed when park brake is locked. A slight air gap should be visible between the coils when proper adjustment is reached. 5. Recycle park brake a few times and remeasure distances each time until specified measurements are obtained. 6. Brake lever (C) travel should not exceed 30°. If it does, measure brake components individually.

3/22/00

Repeat Test Drive—

DO NOT accelerate or engage clutch/brake pedal too aggressively or tractor may tip over backwards. It is recommended that you attach the mower deck to the tractor before performing the test drive on a 17° slope.

B 2 - 10 mm (0.08 - 0.40 in.)

Spring bracket to stop tabs (minimum) . . . . . . . . . . . . . . . . . . . . 2 mm (0.08 in.) (maximum) . . . . . . . . . . . . . . . . . . 10 mm (0.40 in.) Brake lever travel (maximum) . . . . . . . . . . . . . . . . 30°

1. Attach mower deck to tractor - this will help stabilize the tractor. 2. Repeat test drive. See “TRACTION DRIVE SYSTEM” on page 22. 3. Look for a steady pull up the slope. If tractor fails traction test, inspect traction drive belt: • replace the belt if it is excessively worn, stretched, glazed, or unraveling. See “TRACTION DRIVE BELT” on page 27. • if belt is not excessively worn, make finite adjustments above or below specification to gain proper response in traction drive system. Remember: Lengthening the clutch spring increases traction and aggressiveness; shortening the clutch spring decreases traction and aggressiveness. 4. Drive tractor onto a 17° slope and lock clutch/brake pedal in park position. Check that park brake holds tractor stationary on slope and that tractor does not creep downward once park brake is set. 5. If tractor fails park brake test, adjust as necessary. 6. Return to work area and finish installing mower. Results: • Test drive tractor to ensure full forward and reverse speeds are obtained, and that transaxle does not creep in neutral position. • If adjustments are not satisfactory, repeat procedure until proper results are obtained. • If adjustments are still not satisfactory, internal transaxle repair is needed.

9 - 25

BRAKE SPRING ADJUSTMENT Model K51E 1. Unlock park brake and release brake pedal.

HYDRO POWER TRAIN K51, K51E 6. Recycle park brake a few times. Brake lever travel should not exceed 30°.

MX0976

2. Turn lock nut (A) to clockwise to remove slack from the brake rod compression spring (B) and brake linkage. .

MX0977

7. As the free play is taken up when the brake pedal is applied, bracket (F) pulls on the idler arm (E), relieving tension on the drive belt, allowing the belt to slip, reducing power into the transaxle. When the brake pedal linkage is correctly adjusted and the brake pedal is applied:

30° Max.

D C

• The brake rod actuates the transaxle brake, • The brake rod bracket pulls on the idler arm, reducing belt tension, • The return-to-neutral strap returns the transaxle motion arm, pedals, and cruise control lever to the neutral position.

M87543A

3. If the travel of the brake lever requires adjustment: loosen cap screw in front hole of brake cam (C). loosen cap screw in adjustment slot of brake cam (D).

NOTE: Only loosen the cap screws enough to perform the brake cam adjustment. Transaxle oil may leak from the cam opening in the transaxle housing. 4. Pivot the brake cam until the brake lever is correctly adjusted, and tighten the cap screws. 5. Check brake rod compression spring (A). It should not be completely compressed when park brake is locked. A slight air gap should be visible between the coils when proper adjustment is reached.

9 - 26

3/22/00

REPAIR

HYDRO POWER TRAIN K51, K51E

REPAIR

Installation:

TRACTION DRIVE BELT

Removal: 1. Park tractor on level surface and remove battery. 2. Remove mower deck. 3. Safely raise and block tractor to gain easy access to underside of frame.

CAUTION

Tensioning spring is under high tension. Wear gloves and use a firm grip when stretching spring.

M87469

1. Thread belt around belt guide on engine drive pulley assembly.

M87470

C B

M87469

4. Pull tensioning idler (A) rearward until belt (C) can be removed from adjustable idler (B). Release tensioning idler and remove belt from tensioning idler, and transaxle drive sheave. Inspection:

2. Place belt over pulley on input shaft (D) of gear box. 3. Place belt over adjustable idler pulley. 4. Extend tension pulley and slip belt over pulley. 5. Check belt tension. See “DRIVE BELT ADJUSTMENT” on page 22. 6. Remove blocking and return tractor to level. 7. Replace battery.

1. Inspect drive belt. Effective Length New . . . . . . . . . . . . . 2435 ± 8 mm (95.87 ± 0.3 in.) Top Width New . . . . . . . . . . . . . . . . . . . . . . 12.7 mm (0.50 in.) Minimum . . . . . . . . . . . . . . . . . . . . 10 mm (0.39 in.) Depth New . . . . . . . . . . . . . . . . . . . . . . 8.89 mm (0.35 in.) Minimum . . . . . . . . . . . . . . . . . . . . . 7 mm (0.28 in.) 2. Replace belt as necessary.

3/22/00

9 - 27

TRACTION DRIVE BELT TENSIONING SYSTEM TRACTION DRIVE BELT TENSIONING SYSTEM

HYDRO POWER TRAIN K51, K51E

A. Transaxle Drive Sheave B. Spacer C. Cap Screw

Removal/Inspection/Installation: 1. Remove traction drive belt. See “TRACTION DRIVE BELT” on page 27.

D. Cap Screw (M8 x 20) E. Bushing F. Bellcrank

G. Bolt (M8 x 45)

CAUTION

H. Tensioning Spring

Bellcrank tensioning spring is under high tension. Wear safety glasses and gloves when removing or installing spring from frame. 2. Mark the location of the spring to the bellcrank. 3. Thread one end of a three foot long piece of starter rope under the front hook of the bellcrank tension spring (H). Pull the rope half way through the front hook until the ends meet. 4. Wrap ends around a bar several times to make a temporary handle. Pull handle until spring hook is free from frame, and release tension from spring. Tension is now off traction drive system and it may be worked on safely. 5. Use this drawing for repair of system.

I. Engine Pulley J. Lock Washer K. Cap Screw L. Drive Belt M. Flange Nuts (M8)

NOTE: Model K51 transaxle shown. Transaxle model K51E (2046HV tractor) is similar.

C 20 N•m (168 lb-in.)

D 34 N•m (25 lb-ft)

L D

NOTE: To remove drive sheave and fan assembly (A), transaxle must be lowered or completely removed from tractor.

M M

M95106

9 - 28

3/22/00

HYDRO POWER TRAIN K51, K51E

TRANSAXLE REMOVAL AND INSTALLATION

4. Pull idler arm (C) towards transaxle and remove drive belt from idler pulley (D).

NOTE: Model K51 transaxle shown. Transaxle model K51E (2046HV tractor) is similar. Removal: 1. Remove mower deck. 2. Safely raise and block rear of tractor. E M87470

5. Remove drive belt from drive sheave and fan (E).

NOTE: Loosen the belt guide nuts on Model K51E Transaxles (2046HV) to slide the guide away from the transaxle before removing the belt. A M87467

6. Remove drive wheels, inspect keys and keyways, washers, and snap rings. Replace as necessary during assembly. F

3. Unscrew and remove free wheeling knob (A) and nut (not required on 2046HV). Push free wheeling rod in. H I

CAUTION

Large idler spring (B) is under high tension. Wear safety glasses and gloves when removing drive belt.

G G

M87468 B

NOTE: RH frame rail removed for clarity.

C M87469

3/22/00

7. Detach components from the motion control arm (shown above, all except 2046HV). 8. It is necessary to hold hidden nut (H) on opposite side with a 10 mm wrench while removing nut (I). Remove lock nut (I) from clutch linkage (F). 9. Model K51E Transaxles (2046HV) only: Detach the damper and cruise rod from the transaxle motion control rod. Detach the motion control rod from the pedals. 10. Loosen, but do not remove, three flange nuts (G) and cap screws securing transaxle to RH side of frame.

9 - 29

TRANSAXLE - EXTERNAL COMPONENTS

HYDRO POWER TRAIN K51, K51E

6. Install drive belt over transaxle drive sheave and fan. J

K J

CAUTION

Large idler spring is under high tension. Wear safety glasses and gloves when removing drive belt.

M87472

11. Remove cotter pin (K) and washers from brake linkage on LH side of transaxle. Remove brake rod from brake lever. 12. Loosen, but do not remove, three flange nuts (J) and cap screws securing transaxle to LH side of frame. 13. Being careful to not catch free wheeling rod on frame, remove six flange nuts (G) and (J) and cap screws holding transaxle to tractor frame.

NOTE: Safely support bottom of transaxle or have a helper hold transaxle in place while you remove final hardware. 14. Remove transaxle to workbench.

7. Pull idler arm towards transaxle and install drive belt onto idler pulley. 8. Install mower deck.

TRANSAXLE - EXTERNAL COMPONENTS Removal: Drive Sheave and Fan: 1. Thoroughly clean transaxle with approved solvent for aluminum castings and dry with compressed air.

Installation: 1. Being careful to insert free wheeling rod into frame hole, set transaxle into frame. 2. Insert six cap screws through transaxle and frame holes, and loosely place flange nuts on cap screws. Tighten cap screws to specification.

M87416

Specifications: Cap screw and flange nut to mounting brackets and frame . 30 Nâ&#x20AC;˘m (264 lb-in.) Turnbuckle lock nut . . . . . . . . . . . 15 Nâ&#x20AC;˘m (132 lb-in.) 3. Install brake linkage into transaxle brake lever using washers and new cotter pin. 4. Model K51 Transaxle (all except 2046HV): Attach the motion control arm to the transaxle. Hold the rear washer with a 10 mm wrench, install lock nut onto shift linkage turnbuckle. Tighten lock nut to specification. 5. Model K51E Transaxle (2046HV): Attach the motion control rod to the pedals. Attach the cruise control rod and the damper.

9 - 30

2. Remove c-clip (A) and upper fan retainer (B). 3. Remove drive sheave and fan assembly.

M87419

4. Remove fan lower retainer (C) and e-ring (D).

3/22/00

TRANSAXLE

HYDRO POWER TRAIN K51, K51E

1. Remove 20 transaxle housing cap screws (A).

Install Drive Sheave and Fan: 1. Install e-ring (D) in groove on input shaft, and fan lower retainer (C) with flat side towards fan. 2. Install drive sheave and fan, fan retainer (B) with flat side towards fan, and c-clip (A).

TRANSAXLE Disassembly:

NOTE: THE INSTRUCTIONS IN THIS MANUAL ARE FOR OUT-OF-WARRANTY REPAIRS ONLY. This transaxle is warranted for 2 years (residential - home owner application) or 90 days (commercial application). Should an internal defect result in a transaxle failure within the warranty period, the transaxle will be replaced as a complete assembly. If internal hydro components are suspected (after performing all external checks and adjustments) CALL THE SABRE SERVICE DEPARTMENT FOR AUTHORIZATION TO REPLACE THE TRANSAXLE ASSEMBLY. Model K51 transaxle is shown. Model K51E is similar.

M87433

2. Carefully separate transaxle housing into upper and lower case halves. 3. Remove any gasket residue from both case halves. 4. Inspect overall condition of components without removing any of them. Visually target worn, discolored or damaged parts. 5. Remove any remaining oil without removing any components. Remove and Inspect Idler Gears:

IMPORTANT: PAY CLOSE ATTENTION to the ORDER and ORIENTATION of ALL components to their neighboring components. Mark them, if necessary. This will be of great help during reassembly. 1. Remove the transaxle from the tractor. See “TRANSAXLE REMOVAL AND INSTALLATION” on page 29. 2. Remove the drive sheave and fan. See “TRANSAXLE - EXTERNAL COMPONENTS” on page 30. 3. Thoroughly clean transaxle with approved solvent for aluminum castings. Dry with compressed air. Separate Transaxle Housing Case Halves:

E C D M87427

1. Visually inspect assembly: • idler gear teeth (A) are all in good condition; • sides of idler gear (B) are not contacting adjacent parts; • internal idler gear (C) is in good condition and moves freely in idler gear; • axle shaft (D) is in good condition, not worn or discolored, and moves freely in internal idler gear; • washers (E) are not worn, cracked or discolored; • area is free of metal chips or shavings.

A M87434

3/22/00

9 - 31

TRANSAXLE

HYDRO POWER TRAIN K51, K51E Disassemble Differential Axle Assembly:

A C

E D E M87428

Inspect Differential Axle Assembly: M87400

Short Axle Side

1. Remove short axle side thrust washer (D).

C D H

I J

G E F M87399

1. Visually inspect assembly: • ring gear teeth (A) are all in good condition; • sides of ring gear (B) are not contacting walls of case half (C); • thrust plates (D) are holding assembly in proper alignment; • axle shafts and bevel gear splines (E) instantly and smoothly turn differential bevel gears; • bevel gears (F) are all in good condition; • axle shaft bushing (G) are both in good condition; • axle shafts (H) are both in good condition; • area is free of metal chips or shavings.

9 - 32

M87401

Short Axle Side 2. Turn C-ring (I) in its groove so gap faces down to keep C-ring from falling down inside case. 3. Carefully slide short axle outward slightly while holding axle bevel gear (J) stationary, just enough to expose C-ring (I). 4. Carefully lift C-ring (I) from axle. DO NOT remove axle, this will hold bevel gear (J) in place while long axle side is disassembled.

3/22/00

TRANSAXLE

HYDRO POWER TRAIN K51, K51E

J A

M87406

M87403

Long Axle Side 5. Repeat steps 1 - 4 for long axle side. 6. Grab entire differential gear assembly by both axle bevel gears (J) and slide each axle clear to remove gear assembly. 7. Remove both axles and axle bushings (M).

K M87404

11. Inspect thrust washers (D), c-rings (I), and bevel gear (J) recess surfaces for scoring, pitting or wear. 12. Inspect axle bevel gears (J) for wear, scoring, pitting, chipped or broken teeth, and worn, chipped or broken splines. Gears should have 16 teeth. 13. Inspect differential ring gear (A) for wear, scoring, pitting, chipped or broken teeth, and cross-shaft notch wear. Ring gear should have 53 teeth. 14. Inspect differential cross-shafts (N) and bevel gears (F) for wear, scoring, pitting, discoloration and chipped or broken teeth. Gears should have 10 teeth. Measure inside diameter of gears and outside diameter of cross-shafts. 15. Inspect axle shafts for scoring, pitting, discoloration, damaged c-ring and snap ring grooves, damaged keyways, and chipped or broken splines. Measure axle outside diameters. IMPORTANT: Axle shaft seals (K) must be replaced every time axles are removed. Protect new seals by wrapping tape over splines and C-ring grooves of axle shafts before assembly.

Long Axle Side 8. Remove and discard axle seals (K) from both sides. Replace with new seals every time axles are removed. 9. Inspect upper case half outer left and right axle bushings for scoring, pitting, wear or discoloration.

16. Inspect upper case journals and bushing seat grooves for excessive wear, scoring, pitting or discoloration. 17. If there are worn or damaged internal components, replace transaxle. Specifications:

M87405

10. Measure inside diameter of bushings (L) and inner left and right axle bushings (M). 3/22/00

Bushing ID (maximum) . . . . . . . 19.2 mm (0.756 in.) Bevel gears ID (maximum) . . . 14.95 mm (0.588 in.) Cross-shaft OD (minimum) . . . . 14.7 mm (0.579 in.) Axles OD (minimum) . . . . . . . . . . . 19 mm (0.748 in.) 18. Install axles, bushings, bevel gears, c-rings, and thrust washers in reverse order of disassembly. 19. Wrap tape around shaft splines to protect seals. 20. Apply grease to lip surfaces of seals before installing flush with transaxle case lip. 21. Install new axle shaft seals (K).

9 - 33

TRANSAXLE

HYDRO POWER TRAIN K51, K51E

Disassemble Pump, Motor, and Center Block Assembly:

3. Apply downward pressure on entire pump, motor and center block with one hand. Gradually remove three cap screws (A) with the other hand.

A M F

B C

M87407

IMPORTANT: READ THIS PROCEDURE COMPLETELY BEFORE PROCEEDING. Pump, motor, and center block assembly is under CONSIDERABLE PRESSURE. Do not allow assembly to FLY APART or damage may occur to many finely polished, machined components. PAY CLOSE ATTENTION to the ORDER and ORIENTATION of ALL components to their neighboring components. Mark them, if necessary. This will be of great help during reassembly. 1. Visually check overall condition of assembly, without removing any components. Look for scoring, pitting, discoloration, worn or broken teeth or splines, or other detectable damage.

H I

C M87409

4. Holding the motor cylinder block (C) in one hand and the drive shaft (H) and brake disc (F) in the other, carefully lift motor, swashplate (I) and drive shaft far enough from case to pull drive shaft and disc out from pump body. 5. Taking care to not scratch mating surfaces of motor cylinder block and pump cylinder block, remove motor, swashplate and drive shaft. 6. Carefully move motor and shaft assembly to a clean workbench area. Disassemble and Inspect Motor and Swashplate:

D E B

B E

NOTE:

M87408

Pistons are individually spring loaded and under compression.

NOTE:

M87411

Pistons and holes in cylinder block are matched sets. Remove, inspect and replace one cylinder at a time.

2. Gradually loosen three cap screws (A).

NOTE:

9 - 34

As cap screws are loosened, the pump assembly (B), swashplate (D), drive shaft, bearing (E), and brake disc (F) will push up from case due to piston spring pressure. 3/22/00

TRANSAXLE

HYDRO POWER TRAIN K51, K51E IMPORTANT: PAY CLOSE ATTENTION to the ORDER and ORIENTATION of ALL COMPONENTS to their neighboring components.

Remove Pump and Swashplate:

1. Carefully separate motor and swashplate components. 2. Clean and inspect components individually once disassembled: • swashplate (A) surfaces of ramps and bearing recess should not be scored, pitted, discolored or worn badly;

NOTE:

Larger inside diameter thrust washer seats closest to swashplate as compared to thrust washer closest to motor cylinder.

M87412

NOTE: • swashplate ball bearing and thrust washers (B) should not be scored, pitted, discolored, missing any ball bearings or have any broken ball bearing retainers; • motor cylinder block (C), pistons (D) and springs must have free movement and should not be scored, pitted, discolored, distorted or worn; • mating surface of motor cylinder block (C) should not be grooved, discolored or worn thin around ports; • drive shaft (E) should not be scored, pitted, discolored, distorted, worn, or have chipped or missing splines; • check gear (F) for wear, scoring, pitting, chipped or broken teeth; • brake disc (G) should not be scored, pitted, discolored, distorted, or worn.

If not already done, turn shift arm so swashplate is flat and parallel to pump assembly.

1. Holding pump cylinder (A) down, separate, lift pump body (B) off pump input shaft and remove. Place pump body on a clean workbench area.

C M87413

2. Reaching down to hold pistons in place, remove pump cylinder (A) and pistons as a unit. Carefully move pump to a clean workbench area.

3/22/00

M87414

9 - 35

TRANSAXLE

HYDRO POWER TRAIN K51, K51E

3. Remove swashplate (C) and thrust bearings (D). Place swashplate and thrust bearings on a clean workbench area.

• swashplate roller bearing and thrust washers (F) should not be scored, pitted, discolored, missing any ball bearings or have any broken ball bearing retainers;

Disassemble and Inspect Pump and Swashplate: Remove/Install Input Shaft Assembly: IMPORTANT: Carefully remove components so case bore is not damaged. F E

D C

A B A

NOTE:

M87415

Pistons and holes in cylinder block are matched sets. Remove, inspect and replace one piston at a time.

M87417

3. Remove input shaft seal (A) and discard.

IMPORTANT: PAY CLOSE ATTENTION to the ORDER and ORIENTATION of ALL COMPONENTS to their neighboring components. 1. Carefully separate pump and swashplate components. 2. Clean and inspect components individually once disassembled: • inspect pump body (A) for cracks, scoring, pitting and discoloration; • check valve ball bearings in pump body (A) should move freely in their housings; • mating surfaces of pump body (A) should not be grooved, discolored or worn thin around ports; • pump cylinder block (B), pistons (C) and springs must have free movement and should not be scored, pitted, discolored, distorted or worn; • mating surface of pump cylinder block (B) should not be grooved, discolored or worn thin around ports; • thrust bearings (D) should not be scored, pitted, distorted, or worn; • swashplate (E) surfaces of ramps and bearing recess should not be scored, pitted, discolored or worn badly;

NOTE:

9 - 36

Larger inside diameter thrust washer seats closest to swashplate as compared to thrust washer closest to pump cylinder.

M87418

4. Remove c-clip (B) and input shaft assembly. Do not remove e-ring (C) at this time.

Input Shaft Assembly

M87419

3/22/00

TRANSAXLE

HYDRO POWER TRAIN K51, K51E

4. Remove two cap screws (C). 5. Remove brake assembly from upper case half.

G H

F I D

M87420

5. Inspect ball bearing (D) for scoring, pitting, discoloration and other wear. 6. Inspect splines (F and G) for chipped or broken teeth, and machined surfaces (H and I) for scoring, pitting, discoloration and other wear. Wrap tape around shaft splines (F) to protect seal. 7. Apply grease to lip surfaces of seal before installing it flush with transaxle case lip. 8. Install new input shaft seal (A).

M87423

6. Remove and replace seal (D). 7. Inspect O-ring (E) for cracks and deterioration. Replace as necessary. 8. Inspect brake shaft (F) for wear. Replace as necessary. Specification:

Brake Assembly Removal/Installation:

Brake Component Wear Tolerance Brake shaft forward rotation (maximum) . . . . . . . 20Â° Remove Clutch Actuation Assembly: A C B

M87421

1. Remove and inspect brake friction shoe (A) and spacer (B). 2. Inspect for wear or discoloration. .

M87424 Seal

1. Remove nylock nut (A). 2. Remove washer, spring, spacer, metal disc, and composite friction disc. 3. Remove spring pin (B). 4. Visually inspect friction pads (C) for wear, cracks, grease or oil spots, or deterioration. Check pads for minimum thickness of 2.5 mm (0.1 in.).

M87422

3. Mark brake assembly and upper case half for proper alignment. This will assist in brake adjustment after transaxle reassembly.

3/22/00

9 - 37

TRANSAXLE

HYDRO POWER TRAIN K51, K51E Assembly: IMPORTANT: Coat all components lightly with fresh oil before assembly, especially any mating surfaces between components.

Install Swashplate and Pump: M87425

E G

M87429 D

M87426

1. Lightly coat both sides of swashplate thrust bearings (A) with oil and install in case half.

5. Inspect seal (D) for wear or leakage. Replace as necessary. To replace: • Remove input shaft (E). (See REMOVE INPUT SHAFT ASSEMBLY section.) • Slide shaft (F) and stop (G), as a unit, out of transaxle case half. • Remove and replace seal. • Lubricate shaft and seal and install. • Install input shaft assembly. 6. Reassemble clutch actuation assembly in reverse order.

M87414

2. Install swashplate (B).

C A

M87540

7. Tighten nylock nut (A) to specification. Specification: Bellcrank spring length (I) (maximum) production spring . . . . . 20 ± 1 mm (0.78 ± 0.04 in.) M87413

9 - 38

3/22/00

TRANSAXLE

HYDRO POWER TRAIN K51, K51E 3. Lightly coat pistons with oil. Install pump (C). Gently push pump down to ensure pistons are seated and moving freely. 4. Lightly coat top mating surface of pump with oil. E

11. Insert three cap screws and tighten finger tight. 12. Check alignment of brake disc, bearing and cap screws. 13. Align flat side of swashplate (side facing bearing H) vertically. Ensure swashplate seats squarely into upper case half.

H M87430

5. Lightly coat all mating surfaces with oil. 6. Assemble drive shaft assembly (D), swashplate assembly (E), motor assembly (F), and pump cover assembly (G).

M87407

14. Alternately tighten three cap screws to 55 N•m (40 lb-ft).

J D

G H

I M87432 M87408

15. Install idler gear assembly. 7. Holding brake disc (D) in one hand, and pump cover assembly (G) in the other; • Press all parts together ensuring pistons slide into motor body; • Set assembly gently in transaxle case half, seating swashplate (F) first.

IMPORTANT: Ensure flat surface of idler gear shaft lies flat on surface of transaxle case seat (K). Failure to do so will result in damage to transaxle case when assembling upper and lower transaxle case halves.

IMPORTANT: Do not scratch mating surfaces of pump body and pump cover assembly during this process. 8. Holding pump cover assembly in one hand, align brake disc pads with outside of brake disc. 9. Lower assembly farther into transaxle case half, aligning bearing (H) in bearing race. 10. Press pump cover assembly farther towards swashplate (compressing motor piston springs) until cap screw hole alignment sleeves (I) align with mating holes in transaxle case half. 3/22/00

9 - 39

TRANSAXLE

HYDRO POWER TRAIN K51, K51E

Assemble Transaxle Case Halves:

Fill Oil Reservoir: B

A C

M87463

C M87462

IMPORTANT: Make sure ALL mating surfaces of transaxle case halves are free off all oil, clean and dry before application of gasket material. 1. Apply a solid bead (A) of Form-In-Place Silicone Gasket Sealant around lower case half. Be sure to stay to the inside of the mounting bolt holes. 2. Continue application of sealant around inner holes (B).

1. Remove reservoir cover (A) by gently prying it straight up with two large screwdrivers. 2. Remove spring (B) and filter (C). 3. Fill reservoir with 2.4 L (2.5 U.S. qt) of 10W30 Class-CD engine oil. Oil should reach bottom of fill hole (D). 4. Install filter, spring, and reservoir cover.

IMPORTANT: When assembling case halves, make sure that bypass push pins (C) are fully seated in bore. 3. Allow sealant to cure according to manufacturerâ&#x20AC;&#x2122;s instructions before assembling case halves. 4. Align holes in case halves and place lower case half firmly onto upper case half.

D E M87434

5. Install 20 cap screws (D) finger tight initially, and then tighten from center-to-outside in a crossing pattern, beginning with two cap screws (E). 6. Tighten 20 cap screws to 27 Nâ&#x20AC;˘m (240 lb-in.).

9 - 40

3/22/00

CONTENTS

HYDROSTATIC POWER TRAIN K55

CONTENTS Page SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 OTHER MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 HYDROSTATIC TRANSAXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TRACTION DRIVE COMPONENT LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SHIFT LINKAGE COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 BELT TRACTION DRIVE SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 10 TRANSAXLE AND SHIFT LINKAGE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 10 BRAKE/NEUTRAL RETURN OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 TRANSPORT (FREE-WHEEL) OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 DIAGNOSIS CONTINUED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 TRACTION DRIVE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 TRACTION DRIVE BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 TRACTION DRIVE BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 TRACTION DRIVE BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 TRACTION DRIVE BELT TENSIONING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 31 POWER TRAIN LINKAGE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 TRANSAXLE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 TRANSAXLE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 TRANSAXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 INSTALL TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 TRANSAXLE BLEED PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2/29/00

10 - 1

NOTES

10 - 2

HYDROSTATIC POWER TRAIN K55

2/29/00

HYDROSTATIC POWER TRAIN K55

SPECIFICATIONS

SPECIFICATIONS Transaxle: Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kanzaki Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tuff Torq® K-55 Transaxle Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic Gear Teeth: Spur Gear (drive shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 teeth Differential Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 teeth Differential Bevel Pinion Gears (cross shaft). . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 teeth Differential Bevel Pinion Gears (axle shafts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 teeth Drive Belt: Effective Length New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2485 ± 8 mm (97.8 ± 0.3 in.) Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2477 mm (97.5 in.) Maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2530 mm (99.6 in.) Top Width New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.11 mm (0.52 in.) Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 mm (0.39 in.) Bottom Width New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.93 mm (0.31 in.) Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.24 in.) Depth New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.46 mm (0.37 in.) Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 mm (0.28 in.) Lubrication: Oil Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10W30 Engine Oil, Class CD Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 L (1.7 qt) Gear Ratios: Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3:1 Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3:1 Ground Speeds: Domestic Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 - 8.66 km/hr (0 - 5.38 mph) Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 - 4.24 km/hr (0 - 2.62 mph) Export Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 - 7.75 km/hr (0 - 4.82 mph) Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 - 3.80 km/hr (0 - 2.36 mph) Output Torque Rating: Rated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 N•m (145 lb-ft) Maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 680 N•m (506 lb-ft) Brake Torque Rating: Maximum. . . . . . . . . . . . . . . . . . .196 N•m (145 lb-ft) at 245 N (55 lbs) Brake Arm Force 3/22/00

10 - 3

REPAIR SPECIFICATIONS

HYDROSTATIC POWER TRAIN K55

Rear Axle Loading: Maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240 kgs (528 lbs)

REPAIR SPECIFICATIONS Transaxle Components Wear Tolerances: Pump (Input) Shaft Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual Check Motor (Drive) Shaft Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual Check Axle Shaft Thrust Washers Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual Check Pump Plate Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual Check Motor Plate Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual Check Pump Swashplate Upper Case Thrust Bushings Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 mm (0.051 in.) Pump Swashplate Bushing Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual Check Pump Swashplate-To- Shifter Blocks Maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Axle Shaft-To-Upper Case Bushing Maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 mm (0.02 in.) Differential Cross-Shaft-To-Bevel Pinion Gears Maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 mm (0.02 in.) Brake Components Wear Tolerances: Brake Disc (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 mm (0.1 in.) Brake Puck (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 mm (0.32 in.) Brake Lever (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 mm (1 in.) Brake Lever Forward Angle (Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°

TORQUE SPECIFICATIONS Brake Lever Bracket Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 N•m (40 lb-ft) Case Cap Screws New Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) Used Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (243 lb-in.) Center Block Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 N•m (40 lb-ft) Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 N•m (168 lb-in.) Pump Port Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (217 lb-in.) Pump Port Connector Pipe Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (72 lb-in.) Pump Port Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (217 lb-in.) Reservoir Cover Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 N•m (260 lb-in.)

10 - 4

3/22/00

HYDROSTATIC POWER TRAIN K55

OTHER MATERIALS

3/22/00

10 - 5

COMPONENT LOCATION

HYDROSTATIC POWER TRAIN K55

COMPONENT LOCATION 1. Axle Shaft/Wheel Key (2 used)

49. Spacer (M10 x 20 x 20)

2. Left Axle Shaft

50. Cap Screw (M10 x 60, 3 used)

3. Left Axle Shaft Seal

51. Pump Filter

4. Left Axle Shaft Bushing

52. Motor Plate Dowel Pin (2 used)

5. Upper Case Housing

53. Pump Plate

6. O-Ring

54. Rolled Pins (M12 x 22, 2 used)

7. Fill Cap

55. Pump and Motor Center Block

8. Snap Ring

56. Motor Plate

9. Input Shaft Seal

57. Motor Cylinder Block

10. Snap Ring

58. Motor Piston Spring (5 used)

11. Ball Bearing

59. Motor Piston Washer (5 used)

12. Snap Ring

60. Motor Piston (5 used)

13. Cap Screw (M8 x 20) (4 used)

61. Motor Swashplate Bearing

14. Vent Valve Cap

62. Motor Fixed Swashplate Housing

15. Vent Valve

63. Spring

16. Reservoir Cover

64. Snap Ring

17. Brake Friction Puck Shims

65. Ball Bearing

18. Brake Friction Puck

66. Motor Output Shaft (6 teeth)

19. Brake Disc (splined)

67. Ball Bearing

20. Brake Lever

68. Silicone Sealant

21. Cap Screw (M10 x 45, 2 used)

69. Debris Magnet

22. Brake Lever Mounting Bracket

70. Magnet Seal

23. Right Axle Shaft Bushing

71. Motor Output Shaft Seal

24. Right Axle Shaft Seal

72. RH Axle Bushing

25. Right Axle Shaft

73. LH Axle Bushing

26. Shifter Shaft O-Ring

74. Lower Case Housing

27. Shift Block (2 used)

75. O-Ring

28. Shifter Shaft

76. Drain Plug

29. Left Axle Shaft Thrust Washer

77. Cap Screw (Self-Tapping, M8 x30, 17 used)

30. Left Axle Shaft C-Ring Retainer

78. O-Ring

31. Left Axle Shaft Differential Bevel Pinion Gear (16 teeth)

79. Bleed Port Connector

32. Differential Ring Gear (98 teeth)

80. Pipe Plug

33. Differential Cross Shaft Block

81. O-Ring

34. Differential Cross Shaft Bevel Gear (10 teeth)

82. O-Ring

35. Right Axle Shaft Differential Bevel Pinion Gear (16 teeth)

83. Pump Port Plug

36. Right Axle Shaft C-Ring Retainer

84. O-Ring

37. Right Axle Shaft Thrust Washer

85. Transport Bypass Valve Actuating Pin

38. Differential Cross Shaft Bevel Gear (10 teeth)

86. Transport Bypass Valve Actuating Bracket

39. Pump Swashplate Upper Case Thrust Bushing (2 used)

87. E-Ring

40. Pump Swashplate

88. Transport Bypass Valve Push Pin (2 used)

41. Pump Swashplate Bushing

89. Transport Bypass Valve Spring (2 used)

42. Pump Swashplate Bearing

90. Transport Bypass Valve Push Pin Guide (2 used)

43. Pump Input Shaft

91. Transport Bypass Valve Body (2 used)

44. Pump Piston (5 used)

92. O-Ring (2 used)

45. Pump Piston Washer (5 used)

93. Ball (2 used)

46. Pump Piston Spring (5 used)

94. Ball Holder (2 used)

47. Pump Cylinder Block

95. Spring (2 used)

48. Pump Plate Dowel Pin (2 used)

96. Spring Holder (2 used)

10 - 6

3/22/00

HYDROSTATIC TRANSAXLE

HYDROSTATIC POWER TRAIN K55

HYDROSTATIC TRANSAXLE 27 N•m 1 9

13 (20 lb-ft)

11 12

13 16

26 39

21 20

57 N•m (42 lb-ft)

40 22 41

24 25

29 30

35 36

54 38 55

56 57

58 59

40 N•m 50 (30 lb-ft)

65 66

70 69

77 New Case: 31 N•m

(278 lb-in.) Used Case: 27 N•m (243 lb-in.)

68 72

73 74 75

19 N•m (168 lb-in.) 76

84 85 86

79 24 N•m (217 lb-in.)

88 89

80 8 N•m (72 lb-in.) 90 91

81 92 93 94

3/22/00

83 24 N•m (217 lb-in.)

96 95

10 - 7

TRACTION DRIVE COMPONENT LOCATION

HYDROSTATIC POWER TRAIN K55

TRACTION DRIVE COMPONENT LOCATION

14 9

10 12

11 6

16 5

18 7

8 17

4 19

20 21 25

22 23

27 1

29 31

36 35 37 38

1. Transaxle drive sheave 2. Brake Coupler 3. Carriage bolt (M8 x 35) 4. Park locking rod tension spring 5. Cap screw (M8 x 20) 6. Bushing 7. Tensioning strap 8. Park locking rod 9. Carriage bolt (M8 x 45) 10. Tensioning spring 11. Brake shaft 12. Park lever 13. Drive belt

10 - 8

14. Crankshaft drive sheave 15. Foot pad 16. Cap screw (M8 x 35) 17. Brake shaft bellcrank 18. Brake pedal 19. Idler sheave 20. Flange nut (M6) 21. Cotter pin 22. Rolled pin (M4 x 20) 23. Safety wire 24. Washer 25. Lock nut (M8) 26. Cotter pin

27. Washer 28. Brake compression spring strap 29. Brake rod compression spring 30. Brake rod 31. Flange nuts (M8) 32. Adjustable idler sheave 33. Return-to-neutral strap 34. Brake rod return spring 35. Nut (3/8 in.) 36. Cotter pin 37. Washer 38. Lock nut

3/22/00

SHIFT LINKAGE COMPONENT LOCATION

HYDROSTATIC POWER TRAIN K55

SHIFT LINKAGE COMPONENT LOCATION 7

6 5

9 33 32

31 30 11

25 14

23 26

19 15

16 20

18 17

1. Cap screw (M6 x 20) 2. Shift arm 3. Lock nut (M6) 4. Lock nut (M10) 5. Flange nut (M8) 6. Neutral return strap 7. Shift knob 8. Neutral return bushing 9. Rolled pin (M4 x 20) 10. Shift lever 11. Shift lever neutral return spring 12. Spacer

3/22/00

13. Support strap 14. Shoulder bolt 15. Cap screw (M10 x 25) 16. Cap screw (M8 x 25) 17. Spacer 18. Flange nut (M8) 19. Lock nut (5/16 - 24 UNF 3B) 20. Shift link ball joint assembly (5/ 16 - 24 UNF) 21. Flange nut (M8) 22. Mounting stud (M10 x 76.5 Top, M8 x 40 - Bottom)

23. Shift/return-to-neutral bracket 24. Flange nut (M8) 25. Lock nut (5/16 - 24 UNF 3B) 26. Woodruff Key (5/32 x 5/8 in.) 27. Anchored washer 28. Friction disc 29. Bellcrank 30. Friction disc 31. Anchored washer 32. Shift link 33. Tensioning spring 34. Snap ring

10 - 9

THEORY OF OPERATION

HYDROSTATIC POWER TRAIN K55

THEORY OF OPERATION In this group the Sabre hydrostatic power train is separated into the following systems: • Belt Traction Drive System • Transaxle and Shift Linkage System • Brake/Neutral Return System • Transport (Free-Wheeling) System

TRANSAXLE AND SHIFT LINKAGE OPERATION Function:

BELT TRACTION DRIVE SYSTEM OPERATION

The function of this system is to transfer power from the belt traction drive system, through the transaxle’s hydraulic pump and motor center block matrix into the differential assembly and out the drive axles to the rear wheels. The transaxle provides infinite ground speed selections up to 5 mph in forward and up to 2.6 mph in reverse.

Function:

It also provides the means to interrupt the flow of power when shifted into neutral.

The function of this system is to transfer power from the engine to the hydrostatic transaxle.

Major Components: • Transaxle drive sheave and fan • Pump (input) shaft and cylinder block assembly • Shift linkage and pump swashplate assembly • Center block assembly • Motor cylinder block assembly and drive shaft • Differential assembly and axle shafts • Wheels and tires.

Major Components: • Foot pedal and brake linkage • Engine drive sheave • Traction drive belt • Tensioning idler assembly • Tensioning spring • Adjusting idler assembly • Transaxle drive sheave

Theory of Operation:

Theory of Operation: B A F

G B

C H

M55834

The traction drive belt (A) is driven by the upper pulley of the engine drive sheave (B). The traction belt then transmits engine power to the input pulley of the hydrostatic transaxle (C). An additional idler pulley (D) is used between the engine sheave and the transaxle. The traction drive belt is tensioned by the tension idler (E), which is mounted on a spring loaded bracket (F). The tension spring (G) runs forward and hooks to the frame. When the traction drive belt stretches beyond the range of the spring loaded tension idler, an adjustable idler (H) can be moved in slots on the frame, allowing the tension idler to move back into range.

10 - 10

Neutral: As soon as the engine is running, the traction drive belt (A) turns the transaxle input sheave and fan (B) in a clockwise direction. The sheave hub is splined and retained by a flat washer and flanged cap screw onto the splined pump (input) shaft (C).

3/22/00

TRANSAXLE AND SHIFT LINKAGE OPERATION

HYDROSTATIC POWER TRAIN K55

M L K Q D

P O

When in neutral, the shift lever (D), shift bracket (F), turnbuckle link (E), bellcrank (G), link strap (H), and shifter shaft lever (I) hold the shifter shaft (J) and the variable-angle pump swashplate (O) in the neutral position. While in neutral (level) position, the pump cylinder block (N) rotates with the pump (input) shaft but does not pump any oil into the motor half of the center block (P) because the pump pistons are not moving up and down as they rotate. Therefore, the motor cylinder block (Q) does not turn nor do the motor (output) shaft (M), differential assembly (L), or drive axles (K and R).

Forward:

M L K Q P R

H G I

3/22/00

When the shift lever (D) is moved into forward position, the shift bracket (F) pivots, pulling the turnbuckle link (E) rearward, pivoting the bellcrank (G), link strap (H), shifter lever (I), shifter shaft (J), and variable-angle pump swashplate (O) into forward position. With the pump swashplate angled in forward position, the pump cylinder block pistons (N) are pumping oil through one side of the center block (P) into the motor half of the center block, turning the motor cylinder block (Q)

10 - 11

TRANSAXLE AND SHIFT LINKAGE OPERATION

HYDROSTATIC POWER TRAIN K55

against itâ&#x20AC;&#x2122;s fixed-angle swashplate and causing the motor (output) shaft (M), differential assembly (L), and drive axles (K and R) to turn in the forward direction. Reverse: E

H D

M L K Q P R

10 - 12

When the shift lever (D) is moved into reverse position, the shift bracket (F) pivots in the opposite direction, pushing the turnbuckle (E) forward, pivoting the bellcrank (G), link strap (H), shifter lever (I), shifter shaft (J), and variable-angle pump swashplate (O) into reverse position. With the pump swashplate angled in reverse position, the pump cylinder block pistons (N) are pumping oil through the other half of the center block (P) into the motor half of the center block causing the motor cylinder block (Q) to rotate against itâ&#x20AC;&#x2122;s fixed-angle swashplate, turning the motor (output) shaft (M), differential assembly (L), and drive axles (K and R) in the reverse direction.

3/22/00

BRAKE/NEUTRAL RETURN OPERATION

HYDROSTATIC POWER TRAIN K55

BRAKE/NEUTRAL RETURN OPERATION Function: The brake system allows the operator to slow down or stop the tractor, return the shift linkage to neutral, and lock the brake into park.

the brake lever (K) rotates forward forcing its friction surface (Q) against the brake disc (R). Continued force pushes the disc against the shimmed friction puck (P), captured in the housing. As the brake pedal is depressed further, more-and-more force is applied until the disc stops turning. This works in conjunction with the neutral return linkage, stopping the tractor.

Major Components:

• Foot pedal • Frame cross rod and bellcrank • Brake rod, compress spring, and strap • Brake rod return spring • Brake rod adjustment coupler • Transaxle brake assembly and return spring • Shift linkage • Shift/return-to-neutral bracket • Shift bracket return-to-neutral strap and bushing • Shift bracket support strap • Park locking rod • Park locking lever • Park locking spring

J O

P Q

Theory of Operation: L

G U T A

D H

N F

K E R

M G L

H I

K J

When the brake pedal (A) is depressed, the bellcrank (B) and frame rod (F) rotate forward. This motion causes the brake rod (H) and neutral return strap (G), connected at the same point on the bellcrank, to move forward at the same time. As the brake pedal is depressed further, spring strap (N) compresses the compression spring (M). As the spring is compressed,

3/22/00

As this is happening, the neutral return strap (G) is pulled forward, forcing the cam roller (U) to roll up one of the ramp contours of shifter bracket (L). This action moves the shifter bracket (L) and lever (D) back towards the neutral position. At the same time, this returns the shift linkage (I) into neutral position and the internal, variable pump swashplate into its level (non-pumping) position. This works in conjunction with the brake linkage, stopping the tractor. As-soon-as the shift lever reaches either of the radii of the neutral slot (V), the return spring (S) snaps the shift lever back into neutral position.

10 - 13

BRAKE/NEUTRAL RETURN OPERATION

HYDROSTATIC POWER TRAIN K55

B D

IMPORTANT: Full brake engagement (drive wheels stop turning) must not occur until shift linkage has returned to neutral completely. If this is not the case, see Tests and Adjustments procedures later in this section. 3. The last segment of travel (Y) is locking and unlocking the brake linkage into park.

When the brake pedal is fully depressed, the brake can be locked into park position with the park lever (C) and locking rod (D). The locking spring (E) holds the locking rod in place until the operator eases up on the pedal and the force of compression spring (M) locks the bellcrank (B) against the locking rod (D). To release the park brake, the operator must again depress the brake pedal fully and pull the park lever (C) and locking rod (D) into the disengaged position. The brake rod neutral spring (J), maintains just enough air gap between the brake lever friction surface (Q), friction puck (P), and the brake disc (R) when the brake linkage is disengaged.

NOTE: Brake pedal has approximately 127 mm (5 in.) of travel.

10 - 14

3/22/00

HYDROSTATIC POWER TRAIN K55

TRANSPORT (FREE-WHEEL) OPERATION

TRANSPORT (FREE-WHEEL) OPERATION Function: The transport (free-wheel) system allows the operator to push the tractor while the engine is off, transmission in or out of either forward or reverse, and the brake released.

F E

Major Components: • Internal center block relief valve assembly • Internal actuating assembly • External over-center actuating lever assembly Theory of Operation:

I F A

A pair of bypass relief valves (A), located inside the center block of the transaxle, allow for oil to flow freely without the pump being turned by the engine and traction drive system.

B C

3/22/00

When the actuating lever (I) is moved into its over-center locked position (H), the single chain link assembly (G) pushes the actuating pin (F) and bracket (E) against both valve pins (D). As the pins move inside their guides (B), the return springs (C) become compressed and the check balls of the relief valves (A) are unseated; allowing oil to flow freely. This allows the operator to push the tractor with the engine off and the brake released. When the actuating lever (I) is returned to its disengaged position, the return springs (C) force the valve pins (D) out, allowing the check balls to seat in the relief valves (A), stopping oil free flow and the wheels from turning freely.

10 - 15

TROUBLESHOOTING

HYDROSTATIC POWER TRAIN K55

Tensioning spring weak or broken—replace as necessary

●

Accumulation of grass and other debris in cooling fins or around moving parts of transmission

●

Brake pedal linkage out of adjustment—adjust properly

●

Brake system components worn, bent, or broken— replace and adjust properly

●

Neutral return linkage worn, bent, or broken—replace as necessary

●

Input sheave, input shaft, and axle keys or keyways loose, worn, or damaged— replace as necessary Internal transaxle components worn, stripped, or broken—replace as necessary

10 - 16

●

Oil on brake disk and/or shoes Shift lever linkage bent, worn, out of adjustment, or broken—replace or adjust properly

Creeps in neutral

●

Transport mode pushes hard

●

Transaxle overheats

●

Park brake will not hold

●

Brakes will not stop tractor

Belt worn, frayed, glazed, or stretched—replace belt

●

Leaking lubricant

●

Noisy operation

●

Shifts hard

●

Returns to neutral during operation or under load

●

Check or Solution

Cannot get full forward or reverse speed Input (Pump) shaft /pulley will not turn

Lack of drive in one or both directions

Belt sheaves and idlers loose, out of adjustment, worn, or damaged—tighten, replace, or adjust properly

Problem or Symptom

Loses power under load, belt slips, or erratic drive Jerky or aggressive engagement

Belt jumping off or slapping

TROUBLESHOOTING

●

3/22/00

Transaxle case and mountings loose, worn, or broken—replace halves or mountings

●

Fan and/or pulley loose or damaged—tighten or replace

●

Hydrostatic oil filter plugged

●

Incorrect type or volume of lubricant used—replace with correct type and volume. Note: Initial leakage may be result of excessive factory rust preventative. Clean case and verify source of leak

●

Bleed procedure overlooked or improperly done—repeat procedure correctly

●

Wheels and axle keys, key ways, or snap rings worn— replace as necessary

●

Transaxle case halves cap screws loose or stripped— tighten to 27 N•m (20 lb-ft) or replace screws Poor application of transaxle case halves sealant— replace sealant properly

3/22/00

●

Motor drive shaft or axle seals worn or damaged— replace seals

●

Creeps in neutral

●

Transport mode pushes hard

●

Transaxle overheats

●

Park brake will not hold

●

Brakes will not stop tractor

Returns to neutral during operation or under load

Cannot get full forward or reverse speed Input (Pump) shaft /pulley will not turn

Loses power under load, belt slips, or erratic drive Jerky or aggressive engagement ●

Noisy operation

●

Shifts hard

Internal hydro pump and/or motor cylinder block and valve plate mating surfaces worn or scored—replace as necessary

Lack of drive in one or both directions

Check or Solution

Belt jumping off or slapping

Problem or Symptom

Leaking lubricant

TROUBLESHOOTING

HYDROSTATIC POWER TRAIN K55

●

10 - 17

Check or Solution

10 - 18 Problem or Symptom

Transport (free-wheeling) valves and linkage out of adjustment or damaged— readjust or replace as necessary ● ●

Engine performance problems—see Engine Section ● ● ● ●

Drain Plug not tight or bad seal. Replace seal and Torque to15 N•m (11lb-ft) ●

Park brake will not hold

Brakes will not stop tractor

● ●

Creeps in neutral

Transport mode pushes hard

Incorrect type sealant— replace with proper sealant Transaxle overheats

●

Leaking lubricant

Noisy operation

Shifts hard

Returns to neutral during operation or under load

Cannot get full forward or reverse speed Input (Pump) shaft /pulley will not turn

Loses power under load, belt slips, or erratic drive Jerky or aggressive engagement

Lack of drive in one or both directions

Belt jumping off or slapping

TROUBLESHOOTING HYDROSTATIC POWER TRAIN K55

3/22/00

HYDROSTATIC POWER TRAIN K55

TROUBLESHOOTING

NOTES:

3/22/00

10 - 19

DIAGNOSIS

HYDROSTATIC POWER TRAIN K55

DIAGNOSIS Test Conditions: • Tractor on level surface.

• Front wheels blocked

• Engine OFF

• Rear wheels raised off surface with axle housings on jack stands

Test/Check Point

Normal

If Not Normal

1. Drive belt

Belt in good condition, not glazed, split, unraveled, or stretched

Replace drive belt as needed.

2. Fan

Fan in good condition and tight

Tighten fan. Repair or replace as needed.

3. Sheaves and idlers

Drive sheaves and idlers in good condition and adjusted properly

Adjust idler assembly. Repair or replace as needed.

4. Tensioning spring

Tensioning spring installed and not damaged

Install spring. Repair or replace as needed.

5. Shift linkage

Shift linkage adjusted properly and working smoothly

Adjust as needed. Repair or replace as needed.

6. Brake linkage and assembly

Brake and brake linkage adjusted properly and working smoothly.

Adjust as needed. Repair or replace as needed.

Brake components not worn or damaged

Repair or replace as needed.

7. Neutral return linkage

Neutral return linkage adjusted properly and working smoothly

Adjust as needed. Repair or replace as needed.

8. Hydro housing exterior

No cracks, leaks, or loose hardware

Tighten hardware. Repair or replace transaxle housing. Replace any damaged components.

9. Axles

Axles straight

Repair or replace as needed.

Keys and keyways all in good shape

Repair or replace as needed.

No worn, scored or scratched components

Repair or replace as needed.

Correct type and quantity of oil. Oil not dirty or burnt

Fill to proper level. Replace with correct or unburned oil.

Retaining snap rings in good shape and seated correctly

Repair or replace as needed.

11. Transport (free wheeling) valve and linkage

Transport linkage engaging and disengaging properly

Adjust. Repair or replace as needed.

12. Wheels and tires.

Air pressure equal in driving tires

Adjust air pressure.

Driving tires have same radius

Match tires for same radius.

Wheels not bent or out of round

Repair or replace wheels as necessary.

10. Internal hydro components

10 - 20

3/22/00

DIAGNOSIS

HYDROSTATIC POWER TRAIN K55

3 2

9 8

3/22/00

10 - 21

DIAGNOSIS CONTINUED

HYDROSTATIC POWER TRAIN K55

DIAGNOSIS CONTINUED Test Conditions: • Tractor operating in test area

• Tests run at engine slow idle and fast idle

• Engine at operating temperature

• Hydro run through full range of speeds in both directions

Test/Check Point 1. Engine performance

Normal Engine running throttle range

smoothly

If Not Normal throughout

Adjust, tune, or repair engine.

2. Belt traction drive system

Belt not slipping, squealing, or vibrating excessively

Check belt condition, check adjustment and condition of idlers and guides. Adjust, repair or replace components as needed.

3. Shift linkage operation

Shifting is smooth, full speed obtained, and constant speed is maintained (little or no movement in linkage when shift lever is released)

Check shift linkage condition. Check bellcrank friction discs and tensioning spring adjustment. Adjust, repair or replace components as needed.

4. Return-to-neutral/brake and park brake linkage operation

Brakes stop tractor and park brake holds tractor stationary on 17° slope. Return-to-neutral/brake linkage engages brake and returns shift lever linkage back into neutral

Check brake pedal, return-to-neutral, and park brake linkages. Check brake disc and friction pucks for wear. Adjust, repair or replace components as needed.

5. Transaxle performance

Transport (free-wheel) valve when engaged allows operator to push tractor with little effort. When disengaged, tractor moves only by starting engine and engaging transaxle. Transaxle operates smoothly throughout forward and reverse ranges

Check transport (free-wheel) valve and linkage adjustment and condition. Check hydro internal components and fluid level. Adjust, repair or replace components as needed.

6. Axles, wheels, and tires

Axles, wheels, and tires in good shape and functioning properly

Check axles and wheel for straitness, check condition of keys and keyways, washers, and snap rings. Check tires for tread wear and proper inflation. Repair or replace components as needed.

10 - 22

3/22/00

DIAGNOSIS CONTINUED

HYDROSTATIC POWER TRAIN K55

3/22/00

10 - 23

TESTS AND ADJUSTMENTS

HYDROSTATIC POWER TRAIN K55

TESTS AND ADJUSTMENTS TRACTION DRIVE SYSTEM Reason:

To ensure shift, neutral return, and brake linkages and belt drive system maintain traction in lower 1/3 of forward speed range up a 17° slope. To ensure that transport (free-wheeling) valve assembly and linkage allow tractor to be pushed when engaged and to drive tractor when disengaged. Also, to ensure tractor returns to neutral, engages the brake, stops tractor within specification, and holds tractor stationary in PARK position on a 17° slope or less. Procedure:

NOTE: This is a six part test and adjustment procedure: • Test drive on 17° slope, • Drive belt adjustment, • Transport valve linkage adjustment • Shift linkage adjustments, • Brake rod adjustment, • Repeat test drive on 17° slope. Test Drive:

CAUTION

DO NOT engage shift lever too aggressively or tractor may tip over backwards. while performing the test drive on a 17° slope.

4. Drive or push tractor onto a 17° slope, depress the brake pedal and lock it in PARK position. 5. Shift lever and linkage must return-to-neutral, park brake must hold tractor stationary on slope, and tractor must not creep downward once park brake is locked into position. 6. Drive tractor on dry pavement in a safe, open, and level area at fast idle in full forward position. Apply a “panic stop” force (no more than 50 pounds of force) – tractor must stop within 0.9 - 1.5 M (3 - 5 ft) and both wheels should “lock-up”, leaving skid marks on pavement. 7. Repeat Steps 4 - 6 for reverse. 8. If any test fails, the brake linkage and return-to-neutral linkage must be adjusted or components replaced. Drive Belt Adjustment:

C E D

10 - 24

3/22/00

TRACTION DRIVE SYSTEM

HYDROSTATIC POWER TRAIN K55 1. Lock park brake.

CAUTION

Tensioning spring (B) is under high tension. Wear gloves and use a firm grip when stretching spring. 2. Carefully pull larger tensioning idler (C) rearward until belt (A) can be removed from adjustable idler (E), then slowly release tensioning idler. 3. Loosen and move adjustable idler (E) rearward in slot (D) in increments of 10 mm (0.39 in.). 4. Tighten adjustable idler (E) and carefully install belt in larger tensioning idler (C). 5. Repeat procedure until belt tension is sufficient to overcome any slippage. 6. If adjustable idler is adjusted to rear end of slot (D) and belt tension is not sufficient to overcome any slippage, replace belt.

NOTE: If a new belt is required, adjustable idler (E) should be reset at front end of slot (D).

3. Watch closely that actuating pin (E) moves inward all-the-way and, as lever snaps into over-center position, does not move outward at all. 4. If actuating pin (E) does move outward, loosen mounting nuts (C). 5. Push and hold edge of mounting bracket (D) inward until actuating pin (E) bottoms out (internally). Hold edge of bracket (D) stationary while axle mounting nuts (C) are tightened to 15 N•m (132 lb-in.) Test Transport Valve Operation: 1. With engine off and shift lever in any position, put transport valve lever (A) in over-center position (B) and push tractor forward at least 3.05 M (10 ft) – tractor should push easily the entire distance. 2. Push tractor backward the same distance – tractor should push easily the entire distance. 3. If tractor pushes hard, repeat adjustment procedure above—be sure actuating pin (E) does not move outward once over-center position (B) is achieved and mounting nuts (C) are tightened. 4. Repeat test Steps 1 and 2. 5. If tractor still pushes hard, internal component are not assembled properly or are damaged. Remove transaxle and make necessary inspection and repairs (see Repair Group later in this section).

Transport (Free-Wheel) Valve Adjustment: Shift Linkage Adjustment:

1. Replace lever assembly (A) components as needed. D

C B

E C

E D

2. Slowly engage lever (A) into over-center position (B).

3/22/00

10 - 25

TRACTION DRIVE SYSTEM

HYDROSTATIC POWER TRAIN K55 Bellcrank Spring Tension Adjustment:

1. Safely raise rear of tractor off the surface and block the front wheels. Remove rear wheels to gain access to transaxle shift linkage and to safely check for creep in transaxle (axles turning while shift linkage is in neutral position without brake engaged). 2. Check that all shift linkage hardware is in good condition and tight. Replace components as necessary. 3. With park brake unlocked, cycle shift lever (A) into full forward and step on brake pedal to return shift lever into neutral position (B). DO NOT move shift lever by hand. 4. Run engine at fast idle and check that transaxle does not creep while shift lever is in this position. 5. If transaxle creeps, loosen front and rear jam nuts (C) of turnbuckle assembly (D). 6. Use flats (E) to turn threaded link (use 1/4 turn increments) clockwise to shorten turnbuckle length or counterclockwise to extend turnbuckle length. 7. Adjust turnbuckle length until creep stops. Hold flats (E) stationary and tighten jam nuts (C). 8. Only as a last resort, if prior adjustment fails to stop creep motion with few threads of link left, would you adjust shift quadrant forward or rearward. 9. Loosen shift quadrant three mounting brackets (F). 10. With engine at fast idle, move quadrant forward or rearward until creep motion stops with shift lever in return-to-neutral position (via brake pedal). 11. Holding quadrant in place, turn engine off and tighten three mounting brackets (F). 12. With engine running at fast idle, re-cycle shift lever and return-to-neutral linkage several times to ensure adjustment eliminates creep.

1. Make sure bellcrank assembly and transaxle right, front mounting bracket are oriented properly. Slot (C) should be aligned with transaxle housing rib (A) so that ear (D) of lower anchor washer is not wedged behind housing vertical rib (B).

10 - 26

3/22/00

TRACTION DRIVE SYSTEM

HYDROSTATIC POWER TRAIN K55 2. Check shift linkage bellcrank spring tension by measuring spring length distance (E) between flanged nut and top anchor washer and adjust to specification. This will ensure shift lever will remain stationary wherever operator lets go of lever anywhere in shift quadrant. This adjustment may vary from one operator’s preference to the next.

H I F

Specification: Bellcrank spring length (maximum) production spring. . . . 15 ± 1 mm (0.59 ± 0.04 in.) service spring . . . . . . . 21 ± 1 mm (0.83 ± 0.04 in.)

Brake Spring Adjustment:

2. Measure distance between centers of brake lever hole (G) and brake rod hole (I), distance should be 85 mm (3.35 in.). 3. If not, gradually adjust jam nuts (F and J) until specified measurement is obtained. 4. Depress pedal (A) and lock park brake (B). 5. Measure distance between end of compression spring bracket (C) and front edge of brake rod stop tabs (D), gap should have a minimum distance of 2 mm (0.08 in.). 6. Check brake rod compression spring (E), it should not be completely compressed, as shown, when park brake is locked. A slight air gap should be visible between the coils when proper adjustment is reached. 7. Recycle park brake a few times and remeasure distances each time until specified measurements are obtained. 8. Brake lever travel (H) should not exceed 30°, if it does measure brake components individually.

C D

1. Unlock park brake lever (B) and release brake pedal (A). C

3/22/00

Specifications: Brake lever hole-to-brake rod hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 mm (3.35 in.) Spring bracket-to-stop tabs (minimum). . . . . . . . . . . . . . . . . . . . 2 mm (0.08 in.) Brake lever travel (maximum) . . . . . . . . . . . . . . . . 30°

10 - 27

TRACTION DRIVE SYSTEM

HYDROSTATIC POWER TRAIN K55

3. Look for a steady pull in all three lower gears up the slope. If tractor fails traction test, inspect traction drive belt: • if belt is excessively worn, stretched, glazed, or unraveling—replace it (see Inspect, Remove, and Install Traction Drive Belt in the Repair Section), • if belt is not excessively worn, make finite adjustments above or below specification to gain proper response in traction drive system. Remember: to lengthen clutch spring causes increased traction and aggressiveness; to shorten clutch spring causes decreased traction and aggressiveness.

Specifications: Brake Components Wear Tolerances: (K) brake puck (minimum) . . . . . . . . 8 mm (0.3 in.) (L) brake lever (minimum) . . . . . . . 25 mm (1.0 in.) (M) brake disc (minimum) . . . . . 2.5 mm (.098 in.) 9. Replace components as necessary. 10. Install rear wheels, and lower tractor to surface. Repeat Test Drive:

CAUTION

DO NOT engage clutch/brake pedal too aggressively or tractor may tip over backwards. It is recommended that you hang the mower deck from the tractor before performing the test drive on a 17° slope. 1. Attach mower deck to tractor – this will help stabilize the tractor.

4. Drive tractor onto a 17° slope and lock clutch/brake pedal in park position. Check that park brake holds tractor stationary on slope and that tractor does not creep downward once park brake is set. 5. If tractor fails park brake test, inspect brake assembly components and replace as necessary. 6. Return to work area and finish installing mower. Results: • Test drive tractor to ensure full forward and reverse speeds are obtained and that transaxle does not creep in neutral position. • If adjustments are not satisfactory, repeat procedure until proper results are obtained. • If adjustments are still not satisfactory, internal transaxle repair is needed.

2. Carefully test drive tractor to see if traction drive system pulls tractor steadily up a 17° slope in lower 1/3 of forward range.

10 - 28

3/22/00

REPAIR

HYDROSTATIC POWER TRAIN K55

REPAIR TRACTION DRIVE BELT REMOVAL

Link Arm Cotter Pin

1. Park tractor on level surface and remove battery. 2. Disconnect spark plug. 3. Remove mower deck. 4. Safely raise and block tractor to gain easy access to underside of frame.

CAUTION

Tensioning spring (J) is under high tension. Wear gloves and use a firm grip when stretching spring.

7. Remove cotter pin and washer from end of steering link arm.

Belt Tension Idler Link Arm

Yoke Arm

Adjust. Idler

5. Pull tensioning idler rearward until belt can be removed from adjustable idler. Release tensioning idler and remove belt from tensioning idler, and transaxle drive sheave (Not Shown).

Park Brake Lever Link Arm

Locking Rod

6. Remove park brake lever from locking rod. Yoke Arm

3/22/00

10 - 29

TRACTION DRIVE BELT INSPECTION

HYDROSTATIC POWER TRAIN K55

TRACTION DRIVE BELT INSTALLATION Tension Idler

Belt

Engine Pulley

Yoke Arm Yoke Arm Link Arm

8. Remove link arm from steering yoke by rotating link arm until parallel with steering yoke arm.

Adjust. Idler

1. Thread belt around belt guide on engine drive pulley assembly. Install on smaller drive pulley, nearest engine. 2. Place belt over pulley on input shaft of gear box. 3. Place belt over idler pulley. 4. Extend tension pulley and slip belt over pulley. 5. Replace steering link arm in steering yoke. Place other end in tie rod and secure with washer and new cotter pin.

Park Brake Lever

9. Remove belt from engine drive sheave and remove belt from tractor.

TRACTION DRIVE BELT INSPECTION 1. Inspect drive belt. Effective Length: New. . . . . . . . . . . . . . . 2485 ± 8 mm (97.8 ± 0.3 in.) Minimum . . . . . . . . . . . . . . . . . . . 477 mm (97.5 in.) Maximum . . . . . . . . . . . . . . . . . . 2530 mm (99.6 in.) Top Width: New . . . . . . . . . . . . . . . . . . . . . 13.11 mm (0.52 in.) Minimum . . . . . . . . . . . . . . . . . . . . 10 mm (0.39 in.) Bottom Width: New . . . . . . . . . . . . . . . . . . . . . . 7.93 mm (0.31 in.) Minimum . . . . . . . . . . . . . . . . . . . . . 6 mm (0.24 in.) Depth: New . . . . . . . . . . . . . . . . . . . . . . 9.46 mm (0.37 in.) Minimum . . . . . . . . . . . . . . . . . . . . . 7 mm (0.28 in.) 2. Replace belt as necessary.

10 - 30

Locking Rod

6. Reassemble brake lock. 7. Check belt tension. (See “Drive Belt Adjustment:” on page 24.) 8. Remove blocking and return tractor to level. 9. Hook up battery and spark plug.

3/22/00

TRACTION DRIVE BELT TENSIONING SYSTEM

HYDROSTATIC POWER TRAIN K55

TRACTION DRIVE BELT TENSIONING SYSTEM REMOVAL/INSPECTION/INSTALLATION 1. Remove mower deck.

CAUTION

Bellcrank tensioning spring (J) is under high tension. Use locking pliers or spring puller tool. Wear safety glasses and gloves when removing or installing bellcrank tensioning spring.

A. Transaxle drive sheave B. Washer C. Cap screw (M6 x 25) D. Adjustable idler weldment bracket E. Carriage bolt (M8 x 35) F. Cap screw (M8 x 20) G. Bushing H. Bellcrank I. Carriage bolt (M8 x 45) J. Tensioning spring K. Adjustable idler L. Crankshaft drive sheave M. Drive belt N. Bellcrank idler O. Flange nuts (M8)

2. Remove traction drive belt. (See “TRACTION DRIVE BELT REMOVAL” on page 29.) 3. Install mower deck.

J L I H 34 N•m (25 lb-ft)

E M N

D 20 N•m (168 lb-in.) C

B K O

NOTE: To remove Transaxle drive sheave and fan assembly (A) transaxle must be lowered or completely removed from tractor.

3/22/00

10 - 31

POWER TRAIN LINKAGE SYSTEM

HYDROSTATIC POWER TRAIN K55

POWER TRAIN LINKAGE SYSTEM

1-Cap screw (M6 x 20) 33-Cotter pin (M3.2 x 20) 2-Shift arm 34-Compression spring 3-Lock nut (M6) 35-Washer 4-Lock nut (M10) 36-Cotter pin (M3.2 x 20) 5-Shift link 37-Washer 6-Snap ring 38-Brake pedal pad 7-Anchor washer 39-Brake pedal 8-Spring 40-Lock nut (M8) 9-Friction disc 41-Compression spring strap 10-Bellcrank 42-Brake rod 11-Friction disc 43-Shift bracket 12-Anchor washer 44-Bushing 13-Stud (M10 x 76.5/M8 x 40) 45-Support strap 14-Woodruff key (5/32 x 5/8 in.)46-Shoulder bolt 15-Lock nut (5/16 in.) 47-Cap screw (M10 x 25) 16-Turnbuckle 48-Cap screw (M8 x 25) 17-Return spring 49-Spacer 18-Rolled pin (M4 x 20) 50-Flange nut (M8) 19-Shift lever 51-Lock nut 20-Shift knob 52-Flange nut (M10) 21-Park brake rod 53-Flange nut 22-Brake cross-shaft 54-Friction puck and shims 23-Park brake lever 55-Nut 24-Safety wire 56-Return spring 25-Cap screw (M8 x 35) 57-Cotter pin (M3.2 x 20) 26-Rolled pin (M4 x 20) 58-Washer 27-Brake bellcrank 59-Brake lever bracket 28-Spring 60-Brake lever 29-Flange nut (M6) 61-Brake adapter 30-Neutral return strap 62-Lock nut 31-Flange nut (M10) 63-Brake disc 32-Bushing

REMOVAL/INSPECTION/INSTALLATION 1. Remove mower deck.

CAUTION

Large idler bellcrank spring is under high tension. Use locking pliers or spring puller tool and wear safety glasses and gloves when removing clutch bellcrank spring. 2. Remove traction drive belt. (See “TRACTION DRIVE BELT REMOVAL” on page 29.) 3. Use this drawing for complete repair of system. 4. Adjust the drive belt tension, shift linkage, bellcrank spring, and brake spring after installing transaxle. (See “TESTS AND ADJUSTMENTS” on page 24.) 5. Install mower deck.

24 26

23 4

1 18 6 8

16 10

36 33 34

12 37

13 43 14

52 51

46 47 50 53

54 55 57 58

10 - 32

61 60

3/22/00

TRANSAXLE REMOVAL AND INSTALLATION

HYDROSTATIC POWER TRAIN K55

TRANSAXLE REMOVAL AND INSTALLATION Removal: 1. Safely raise and block rear of tractor off surface. 2. Safely support bottom of transaxle or have a helper hold transaxle in place when you remove final hardware (Steps 13 - 14). 3. Remove drive wheels, inspect key and keyways, washers, and snap rings. Replace as necessary.

11. Pull transport lever (N) into over-center position to remove two LH mounting cap screws and flange nuts (M). 12. Remove transaxle to workbench. 13. Remove snap ring (E) to remove shift link (D). 14. Remove cap screw and lock nut (G) to remove shift arm (H). Inspect woodruff key and keyways of shift arm and pump variable swashplate shifter shaft. 15. Remove flange nut (I) slowly to remove bellcrank assembly (J). 16. Drain oil from transaxle. Installation:

C A

A E K J H

I F

O N B

4. Remove traction drive belt (C) from drive sheave. 5. Disconnect shift linkage turnbuckle (A) from bellcrank assembly (J). 6. Remove cotter pin and washer (K) to disconnect brake rod from brake lever. 7. Remove chain link (O) from left-side transport valve assembly. 8. Remove left-front mounting bracket lower cap screw and flange nut (F). 9. Remove flange nut (B) from right-front mounting bracket. 10. Remove two right-side mounting cap screws and flange nuts (L).

3/22/00

17. Make sure bellcrank assembly and transaxle right, front mounting bracket are oriented properly. Slot (C) should be aligned with transaxle housing rib (A) so that ear (D) of lower anchor washer is not wedged behind housing vertical rib (B). 18. Install transaxle in reverse order of removal. 19. Tighten mounting hardware to specifications.

10 - 33

TRANSAXLE DISASSEMBLY

HYDROSTATIC POWER TRAIN K55

20. Install traction drive belt. Specification: Flange nut to right-front mounting bracket . . . . . . . . . . . 15 N•m (132 lb-in.) Cap screw and nut to left-front mounting bracket . . . . . . . . . . . 15 N•m (132 lb-in.) Cap screws and nuts to frame . . . . . . . . . . . . . . 30 N•m (264 lb-in.) Shift arm cap screw and lock nut . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.) Turnbuckle lock nut . . . . . . . . . . . 15 N•m (132 lb-in.) Adjust Entire Traction Drive System: See Tests and Adjustments group earlier in this section.

5. Install an 19m8334 (M6 x1.0 x 30) socket head cap screw (D) from stock into end of pump (input) shaft – finger tight only. 6. Put puller on special screw and pull drive sheave from pump shaft.

TRANSAXLE DISASSEMBLY IMPORTANT: PAY CLOSE ATTENTION to the ORDER and ORIENTATION of ALL COMPONENTS to their neighboring components. Mark them, if necessary. This will help greatly when its assembly time. Remove Drive Sheave and Fan:

1. Thoroughly clean transaxle with approved solvent for aluminum castings and dry with compressed air. 2. Remove fan cap screws and flange nuts (A). 3. Remove cap screw and washer (B). 4. Reference transaxle serial number (C) whenever necessary.

10 - 34

7. Inspect drive sheave for damage, replace as necessary. 8. Remove fan and inspect for damage, replace as necessary. Remove Reservoir Cover:

NOTE: If there is no damage to cover or upper case housing, you need not remove cover because there are no components inside the reservoir.

3/22/00

TRANSAXLE DISASSEMBLY

HYDROSTATIC POWER TRAIN K55

Remove Brake Assembly: A 1

1. Remove four cap screws (A) to remove reservoir cover. 2. Inspect cover for cracks or holes, replace as necessary. 3. If cover is in good condition and to be reused, clean off all gasket residue and wipe clean, then set cover and four cap screws aside for final assembly.

1. First, inspect brake assembly for wear or damage: â&#x20AC;˘ Check for brake disc contact points at case points (1 and 2), â&#x20AC;˘ Check for brake lever contact point at mounting bracket edge (3). If contact is detected, replace lever, disc, and friction puck as a set.

Remove Breather Valve Assembly: A F

C D

1. Pull breather valve assembly from reservoir cover. 2. Inspect condition of breather valve assembly, replace as necessary.

3/22/00

2. Remove two cap screws to remove brake assembly. 3. Inspect intermediate shaft brake splines (A) and brake disc splines (B) for chips, rust, and broken teeth. Replace as necessary. 4. Inspect mating surfaces of brake lever shaft (C) and mounting hole (D) for scoring, pitting, and wear. Replace as necessary. 5. Inspect mating surfaces of case recess (F) and friction puck and shims (E) for rust. Clean or replace as necessary.

10 - 35

TRANSAXLE DISASSEMBLY

HYDROSTATIC POWER TRAIN K55

Upper Case Half

6. Measure brake components individually. 7. Replace components as necessary and as a set only. Set brake assembly components aside for final assembly.

Lower Case Half

Specifications: Brake Components Wear Tolerances: (G) brake puck (minimum). . . . . . . . 8 mm (0.3 in.) (H) brake lever (minimum). . . . . . . 25 mm (1.0 in.) (I) brake disc (minimum) . . . . . 2.5 mm (0.098 in.) Separate Transaxle Housing Case Halves:

2. Carefully separate transaxle housing into upper and lower case halves. 3. Remove any gasket residue from both case halves. 4. Inspect overall condition of components without removing any of them. Visually target worn or damaged parts for replacement. 5. Remove any remaining oil without removing any components. Disassemble Transport (Free-Wheeling) Assembly:

NOTE: 1. Remove seventeen transaxle housing cap screws (B).

10 - 36

Inspect transport actuating bracket and pin assembly (A) for wear or leakage to outside. If assembly is in good condition, just set lower case half aside for final assembly.

3/22/00

TRANSAXLE DISASSEMBLY

HYDROSTATIC POWER TRAIN K55

Disassemble Shifter Shaft Assembly:

Maximum Air Gap 0.15 mm (0.0059 in.)

E F

1. If wear or leakage is detected, remove E-ring (C), actuating bracket (D), and pin (F). 2. Remove and discard O-ring (E). Replace it with new O-ring every time assembly is removed or leaking. 3. Inspect pin (F) and lower case bore (B) for pitting, scoring, or rust. Replace as necessary. 4. Inspect E-ring (C) and bracket (D) for wear or deformity. Replace as necessary. 5. Remove and discard filter (G). Replace it with a new filter every time case halves are separated. 6. Remove and inspect push pins (J), springs (I), and push pin guides (H). Replace as necessary.

(Pump, motor, and center block removed for clarity) A B D C

H L

7. Inspect transport bypass relief valve body and balls (N) for pitting, scoring, discoloration, or damage. 8. If any detected, install brake disc on motor drive shaft splines and hold shop cloth over valve bores to catch valve bodies. 9. Turn brake disc clockwise to force one of valve assemblies (N) from center block (M), then turn brake disc counterclockwise to force other valve assembly from center block. 10. If valve assemblies do not dislodge, remove plug (L) and bleed port connector (K) and try using compressed air to dislodge valve assemblies. 11. If valve assemblies still remain lodged, depress check balls with extractor tool(s) to grab onto valve body and pull them from center block and discard valve bodies. 12. Check bores, if damaged â&#x20AC;&#x201C; replace center block.

3/22/00

G F

1. First, measure air gap between edge of swashplate slot (A) and shift blocks (D). If out of specification, replace shift blocks. 2. Lift shifter shaft assembly (E) and shift blocks (D) from upper case half mounting hole (B) and slot of swashplate (A). 3. Inspect mating surfaces of case hole (B) and end of shaft (H) for scoring or pitting. Replace as necessary. 4. Remove and discard O-ring (G). Replace O-ring every time shifter shaft is removed. 5. Inspect mating surfaces of shifter shaft ball joint (C) and shift blocks (D) for scoring or pitting. Replace as necessary. 6. Inspect shifter shaft keyway (E) for chips or wear. Replace shifter shaft as necessary.

10 - 37

TRANSAXLE DISASSEMBLY

HYDROSTATIC POWER TRAIN K55 Short Axle Side

Inspect Differential Axle Assembly:

2. Turn C-ring (D) in its groove so gap (C) faces down to keep C-ring from falling down inside case. 3. Carefully slide short axle outward slightly while holding axle bevel gear (B) stationary, just enough to expose C-ring (D). 4. Carefully lift C-ring (D) from axle. DO NOT remove axle, this will hold bevel gear (B) in place while long axle side is disassembled.

B A

C D H

I H F

1. Visually inspect assembly: • ring gear teeth (A) are all in good condition; • sides of ring gear (B) are not contacting walls of case half (C); • thrust plates (D) are holding assembly in proper alignment; • axle shafts and bevel gear splines (E) instantly and smoothly turn differential bevel gears; • bevel gears (F) are all in good condition; • axle shaft bushings (H) are both in good condition; • axle shafts (I) are both in good condition; • area is free of metal chips or shavings.

B C D

Disassemble Differential Axle Assembly:

5. Repeat Steps 1 - 4 for long axle side. 6. Grab entire differential gear assembly by both axle bevel gears (B) and slide each axle clear to remove gear assembly. 7. Remove both axles and axle bushings.

Short Axle Side

1. Remove short axle side thrust washer (A).

B C D

10 - 38

8. Remove and discard axle seals (E) from both sides. Replace with new seals every time axles are removed.

3/22/00

TRANSAXLE DISASSEMBLY

HYDROSTATIC POWER TRAIN K55

17. Replace components as necessary. IMPORTANT: Axle shaft seals (O) must be replaced every time axles are remove. Protect new seals by wrapping tape over splines and C-ring grooves of axle shafts before assembly.

18. Inspect upper case journals (K) and bushings seat grooves (R) for excessive wear, scoring, pitting, or discoloration. Replace as necessary. Specifications: Bushing ID (maximum) . . . . . . . . 19.2 mm (0.76 in.) Bevel gears ID (maximum) . . . . 15.11 mm (0.60 in.) Cross-shaft OD (minimum) . . . 14.96 mm (0.589 in.) Axles OD (minimum) . . . . . . . . . . . 19 mm (0.748 in.)

9. Inspect upper case half outer left and right axle bushings for scoring, pitting, wear, or discoloration. 10. Measure inside diameter of bushings (F) and K-55 inner left and right axle bushings (G). 11. If bushings exceed specification, replace upper case half (outer bushings are not serviced) and both inner axle bushings (G), replace as a set only.

Disassemble Pump, Motor, and Center Block Assembly:

A B

C D E

B C

F G

12. Inspect thrust washers (H), C-rings (I), and bevel gear (J) recess surfaces (N) for scoring, pitting, or wear. 13. Inspect axle bevel gears (J) for wear, scoring, pitting, chipped or broken teeth, and worn, chipped, or broken splines. Gears should have 16 teeth. 14. Inspect differential ring gear (L) for wear, scoring, pitting, chipped or broken teeth, and cross-shaft notch wear. Ring gear should have 98 teeth. 15. Inspect differential cross-shaft (Q) and bevel gears (P) for wear, scoring, pitting, discoloration, and chipped or broken teeth. Gears should have 10 teeth. Measure inside diameter of gears and outside diameter of cross-shaft. 16. Inspect axle shafts for scoring, pitting, discoloration, damaged C-ring and snap ring grooves, damaged keyways, and chipped or broken splines. Measure axles outside diameters.

3/22/00

IMPORTANT: READ THIS PROCEDURE COMPLETELY BEFORE PROCEEDING. Pump, motor, and center block assembly is under CONSIDERABLE PRESSURE. Do not allow assembly to FLY APART or damage may occur to many finely-polished, machined components. PAY CLOSE ATTENTION to the ORDER and ORIENTATION of ALL COMPONENTS to their neighboring components. Mark them, if necessary. This will help greatly when its assembly time. 1. Visually check overall condition of assembly, without removing any components. Look for scoring, pitting, discoloration, worn or broken teeth or splines, or other detectable damage. 2. Remove port plug (D) and connector (E). Remove and discard three O-rings (B. Replace O-rings every time port plug and connector are remove.

10 - 39

TRANSAXLE DISASSEMBLY

HYDROSTATIC POWER TRAIN K55

3. Hold downward on entire pump (F), motor (A), and center block (G) assembly with one hand as you gradually loosen three cap screws (C) with the other. 4. Keeping downward pressure steady, slowly remove three cap screws (C) and spacer (H). I

IMPORTANT: Carefully remove components so case bore is not damaged. 1. Remove and discard shaft seal (B). 2. Remove snap ring (C) and pump shaft assembly (A).

E Q P

F M G H

5. Without losing any pressure; reposition both hands, one over the motor portion (I) and one over pump and center block portion (K). 6. Now compress both portions together a little more to allow you to walk rolled pins (M) and entire assembly from upper case. Maintain pressure so you do not scratch mating surfaces of motor cylinder block (J) and finished-brass motor plate (N) and pump cylinder block and its plate (L). Also, do not scratch bearing races (O and P) on case grooves while walking assembly from upper case. 7. Carefully move and separate motor, pump, and center block assembly to workbench.

3. Inspect ball bearing (F) for scoring, pitting, discoloration, and other wear. 4. If damaged, remove two snap rings (D) to remove and replace bearing. 5. Inspect splines (E and I) for chipped or broken teeth and machined surfaces (G and H) for scoring, pitting, discoloration, and other wear. Replace shaft as necessary and assemble in reverse order. Disassemble and Inspect Pump and Swashplate:

G A

Remove Pump Input Shaft Assembly:

F I

H A C L

J K

10 - 40

IMPORTANT: PAY CLOSE ATTENTION to the ORDER and ORIENTATION of ALL COMPONENTS to their neighboring components. Mark them, if necessary. This will help greatly during assembly.

3/22/00

TRANSAXLE DISASSEMBLY

HYDROSTATIC POWER TRAIN K55 1. Carefully separate pump and swashplate components. 2. Clean and inspect components individually once disassembled: • Thrust bushings (A) should not be scored, pitted, or worn badly – measure thickness: Thrust bushings thickness: Minimum . . . . . . . . . . . . . . . . . . 1.3 mm (0.050 in.); • Swashplate (B) machine surfaces of ramps and bearing recess and bushing should not scored, pitted, discolored, or worn badly; • Swashplate roller bearing (C, D, and E) should not be scored, pitted, discolored, missing any rollers, or roller retainer broken; • Pump cylinder block (F), pistons (L), washers (K), and springs (M) must have free movement and should not be scored, pitted, discolored, distorted, or worn; • Bronze pump plate (J) and mating surface of cylinder block (F) should not be grooved, discolored, or worn thin around ports; • Center block machined surface (I) should not scored, pitted, or discolored; • Center block rolled pins (G) and dowel pins (H) should be in good condition, not missing or sheared off; • Upper case ramps and centering pins (N) should be in good condition. IMPORTANT: If thrust bushings and swashplate ramps are damaged, they must be replaced as a set. If swashplate recess machined surface or bushing are damaged, replace with new swashplate (bushing is not serviced separately). If bronze pump plate or center block are damaged, they both must be replaced. If any component of pump cylinder block is damaged, a complete new pump cylinder block must be ordered. Disassemble and Inspect Motor and Drive Shaft:

G E F

K M

R N

Q O P

3/22/00

IMPORTANT: Pay CLOSE attention to the ORDER and ORIENTATION of ALL COMPONENTS to their neighboring components. Mark them, if necessary. This will help greatly during assembly. 1. Carefully separate motor and drive shaft components. 2. Clean and inspect components individually once disassembled: • drive shaft seal must be replaced every time drive shaft is removed or case halves separated; • drive shaft splines (B and E) should be in good condition, not chipped, broken, or worn; • drive shaft ball bearings (C) should not be scored, pitted, loose, or discolored; • drive shaft snap ring (D) should be in good condition as should its groove; • drive shaft machined surface (R) should not be scored, pitted, or worn; • drive shaft spur gears (T) should have 6 teeth, not be scored, pitted, discolored, chipped or broken, nor worn thin; • drive shaft-to-cylinder block spring (F) should be in good condition, not weak, broken, nor distorted;

G E F

K M

R N

Q O P

• Motor fixed swashplate (G) should be in good condition, bearing recess machined surface should not be scored, pitted, discolored, nor worn badly; • Motor fixed swashplate ball bearing and thrust washers (H, I, and J) should not be scored, pitted, discolored, missing any balls, or ball retainer broken; • Motor cylinder block (K), pistons (Q), washers (O), and springs (P) must have free movement and should not be scored, pitted, discolored, distorted, or worn; • Bronze motor plate (N) and mating surface of cylinder block (K) should not be grooved, discolored, or worn thin around ports; • Center block machined surface (M) should not scored, pitted, or discolored; • Center block dowel pins (L) should be in good condition, not missing or sheared off;

10 - 41

TRANSAXLE ASSEMBLY

HYDROSTATIC POWER TRAIN K55

â&#x20AC;˘ Upper case drive shaft ball bearing grooves (S) should be in good condition, not scored, pitted, or discolored. IMPORTANT: If fixed swashplate bearing components are damaged, they must be replaced as a set. If bronze motor plate or center block are damaged, they both must be replaced. If any component of motor cylinder block is damaged, a complete new motor cylinder block must be ordered. If upper or lower case halves show wear or damage, they need not be ordered as a set unless wear or damage is severe enough.

Install Pump, Assemblies:

Swashplate,

and

Shifter

Shaft

IMPORTANT: Read the next four steps completely before proceeding.

TRANSAXLE ASSEMBLY IMPORTANT: Coat all components lightly with fresh oil before assembly, especially any mating surfaces between components.

C D

Assemble and Install Pump Shaft Assembly: E A

C B

I J

IMPORTANT: Carefully install pump assembly so case bore is not damaged.

shaft

1. Assemble pump (input) shaft and carefully install it into upper case with snap ring (C). 2. Wrap tape around shaft splines (A) to protect seal. 3. Apply grease to lip surfaces of seal (B) before installing it flush with case lip.

10 - 42

3/22/00

TRANSAXLE ASSEMBLY

HYDROSTATIC POWER TRAIN K55

C K

1. Install swashplate thrust plates (A). 2. Install new O-ring (E) on shifter shaft. 3. Install swashplate (F), shift blocks (D) (apply grease to help hold blocks in place), ball joint (C), and shifter shaft (B) together. 4. Install thin bearing thrust washer (G) first, ball bearing (H), and thick bearing thrust washer (I) on top (mates with pump pistons) into swashplate (J).

F G

IMPORTANT: Hold fingers tightly between all five pistons so pistons donâ&#x20AC;&#x2122;t drop out of cylinder block during assembly and spline alignment. 5. Install pump cylinder block assembly (K) over pump shaft, twisting left or right until splines of cylinder block align with shaft splines (L), and on top of swashplate bearing assembly. 6. Push on pump cylinder block a few times to ensure assembly is properly installed and has smooth movement and good spring tension. Install Motor and Drive Shaft Assembly:

3/22/00

J I

1. Assemble motor drive shaft. 2. Wrap tape over brake disc splines (A) before installing new seal with open lip to inside. Remove tape once seal is installed. 3. Install narrow thrust washer (C) into fixed swashplate recess (B) first, then ball bearing (D), and wide thrust washer (E) last (mates with motor pistons). 4. Install motor drive shaft assembly with longer cylinder block splines (G), spring (H), and snap ring (F) through fixed swashplate hole as shown. 5. Coat motor (I) and pump (J) machined surfaces of center block and backside of bronze motor (L) and pump (K) plates with grease to hold bronze plates in place. 6. Install motor (L) and pump (K) plates with bronze side facing away from center block.

10 - 43

TRANSAXLE ASSEMBLY

HYDROSTATIC POWER TRAIN K55

Install Pump, Motor, and Center Block Assembly:

D C A

7. Wrap tape around short (B) and long (E) axle shaft splines and C-ring grooves to protect new seals. 8. Install axle shafts tin lower transmission case. Install inner bushings (G) and slide axle shafts flush with inside edge of bushings.

M L K

IMPORTANT: DO NOT scratch surface of bronze plate (M) with machined surface of cylinder block or with end of drive shaft (L). 1. Assemble motor cylinder block and drive shaft assembly (C) to center block. 2. Watch to see that end of pump shaft (J) is aligned with bronze plate center hole (I) as you execute Step 3. 3. At a slight angle, align seal (A), ball bearings (B), and fixed swashplate body (N) (with thick portion down) with upper case grooves and, at the same time, align two center block rolled pins (K) with case mounting holes as you squeeze center block and motor assemblies together. 4. Once rolled pins (K) are started, install center two cap screws (D) into rolled pin holes and turn finger tight only. 5. Install spacer (G) and right (third) cap screw (D) and turn finger tight. 6. Check assembly closely to ensure everything is aligned properly then tighten three caps screws to 55 Nâ&#x20AC;˘m (40 lb-ft).

1. Apply grease to new axle seals (A) and install them, open side of seals to inside, over axle, taking care not to damage lip faces, so they are flush with outside case lip. . 2. Assemble and hold differential cross-shaft, bevel gears, and ring gear assembly (F) together as you align it with motor drive shaft spur gears (C) and axle shafts (B and E). 3. Slide axle shafts into their bevel gears and retain them with C-ring (D).

4. Install thrust washer (H).

Install Differential Axle Assembly:

10 - 44

5. Repeat C-ring (D) procedures for short axle side.

3/22/00

TRANSAXLE ASSEMBLY

HYDROSTATIC POWER TRAIN K55

D E

6. Repeat thrust washer procedures for short axle side. Install Filter, Magnet, (Free-Wheeling) Assembly:

and

Transport

2. Install new filter (C). 3. Install bypass valve push pin guides (D), springs (E), and push pins (F).

A G

H J

1. Carefully install new relief valve assemblies (B) to specification into center block bores (A).

4. Install new O-ring (J) on actuating pin and install in lower case half bore (G).

Specification: Transport relief valve assemblies . . . . . . . . . . . . . . . approximately 13 mm (0.51 in.) I K

6 H

5. Fasten actuating bracket (I) with E-ring (H). 6. Be sure assembly is pushed all the way out before assembling transaxle case halves. 7. Install clean or new magnet assembly (K).

3/22/00

10 - 45

TRANSAXLE ASSEMBLY

HYDROSTATIC POWER TRAIN K55

Assemble Transaxle Case Halves: Upper Case Half

Lower Case Half

5. Install 17 cap screws (E) finger tight initially and then tighten from center-to-outside in a crossing pattern, beginning with two cap screws (G). Tighten 17 cap screws to specifications. Specifications:

IMPORTANT: Make sure ALL mating surfaces of transaxle case halves are free off all oil, clean and dry before application of Gasket Material. 1. Apply a solid bead (B) of Form-In-Place Silicone Gasket Sealant around lower case half. Be sure to stay to the inside of the mounting holes. 2. Be sure to apply a solid bead around two inner holes (D). IMPORTANT: When assembling case halves make sure that bypass push pins are fully seated in bore and that actuating bracket and rod are fully withdrawn. Failure to do so will result in broken push pins.

New upper case . . . . . . . . . . . . . . 30 N•m (264 lb-in.) Used upper case . . . . . . . . . . . . . 27 N•m (240 lb-in.) 6. Install new O-ring on drain plug (F) and tighten it to 24 N•m (204 lb-in.). Install Brake Assembly:

3. Align hole (C) with bleed port stack (A) and firmly push lower case half onto upper case half. 4. Align all 17 case half holes.

10 - 46

3/22/00

TRANSAXLE ASSEMBLY

HYDROSTATIC POWER TRAIN K55

2. Install cover to reservoir and fasten with 4 cap screws (C). Tighten cap screws to specification. 3. Fill reservoir with 1.6 L (1.7 U.S. qt) of 10W30, Class-CD engine oil. Oil should reach bottom of fill hole (D). 4. Install breather valve assembly (E) and fill cap (B). Tighten cap screws to 24 N•m (204 lb-in.)

A B

Install Fan and Drive Sheave: C A

1. Install brake components to transaxle and, using friction puck shims (B), adjust air gap (C) between brake lever and brake disc to 0.8 – 1.3 mm (0.030 – 0.050 in.). 2. Tighten cap screws (A) to 55 N•m (40 lb-ft). Install Reservoir Cover and Assembly and Fill Reservoir:

Breather

B D

Valve

1. Assemble fan to transaxle drive sheave using two fan holes (C). Two washers and nuts (B) go under fan. Bottom fan lip (D) goes towards transaxle. A

1. If reservoir cover was removed or replaced, apply a solid bead (A) of Form-In-Place Silicone Gasket Sealant around the cover, staying to inside of holes.

2. Install sheave/fan assembly to pump input shaft with cap screw and washer (A). Tighten cap screw to specification 20 N•m (168 lb-in.)

3/22/00

10 - 47

INSTALL TRANSAXLE Quick Transaxle Bleed Procedure:

1. Turn transaxle over. 2. Remove recess plug (A) from bleed port stack. 3. While you pour new oil into hole, have a helper hold transaxle off bench and turn brake disc to rotate motor shaft and bleed internal pump, motor, and center block assembly. 4. Stop pouring oil when oil reaches bottom of hole. Apply Pipe Sealant with Teflon® or Teflon® tape to pipe plug. DO NOT allow any tape to enter internal portion of bleed port stack. Tighten plug to 8 N•m (72 lb-in.).

HYDROSTATIC POWER TRAIN K55 IMPORTANT: TURN OFF ENGINE. 5. Safely lower tractor to surface. 6. Recheck and top-off oil level. 7. Sit in seat, shift into forward, and, if necessary, have helper push tractor until transaxle drives tractor under its own power. 8. Move throttle lever to fast idle and alternate shift lever between forward and reverse several times until transaxle is responsive and obtains full forward speed of 8 km/hr (5 mph) and reverse speed of 4.2 km/hr (2.6 mph). 9. Recheck and top-off oil level. Test and Adjust Entire Traction Drive System For relevant procedures: See ADJUSTMENTS” on page 24.

“TESTS

AND

INSTALL TRANSAXLE See “TRANSAXLE REMOVAL AND INSTALLATION” on page 33.

TRANSAXLE BLEED PROCEDURE 1. With vehicle parked on a flat level surface, preferably outside and away from all obstructions, check transmission oil. Top of if required. 1. Safely raise and block frame so that rear wheels are a minimum of 51 mm (2.0 in.) off the surface. Chock front wheels.

CAUTION

Vehicle must be blocked and chocked in such a fashion that it will not move when engine is running. DO NOT park vehicle facing wall. Operator should be in seat during this procedure to prevent inadvertent run always if vehicle should come off blocks. 2. Run engine at SLOW idle. 3. CAREFULLY engage and disengage transport (free-wheel) lever while helper pushes shift lever into forward, neutral, and reverse. Repeat several times. 4. When drive wheels start to turn, shift to neutral and be sure transport lever is disengaged.

10 - 48

3/22/00

CONTENTS

STEERING

CONTENTS Page COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE EQUIPMENT AND TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 STEERING GEAR - ALL EXCEPT 2046HV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 STEERING GEAR - 2046HV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 REPLACE PEDESTAL BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ADJUST STEERING BACKLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2/29/00

11 - 1

NOTES

11 - 2

STEERING

2/29/00

COMPONENT LOCATION

STEERING

COMPONENT LOCATION STEERING 3 4

5 1

6 7 8 6 7 7 6 7 6 8

14 13

12 10 10 11 12 M95107

1. Steering Wheel 2. Bolt 3. Washer 4. Lock Nut 5. Cotter Pin (M4 X 32) 6. Washer (A/R)

3/22/00

7. Bushing (4 used) 8. Steering Gear 9. Pinion Shaft 10. Washer (3 used, except 2046HV) 11. Cotter Pin (3 used, except 2046HV)

12. Lock Nut (4 used, 2046HV only) 13. Tie Rod 14. Drag Link (2046HV) 15. Drag Link (except 2046HV)

11 - 3

SERVICE EQUIPMENT AND TOOLS

STEERING

SERVICE EQUIPMENT AND TOOLS C

NOTE:

Order tools from your SERVICE-GARD Catalog. Some tools may be available from a local supplier.

Name

Use

Inside Puller and Slide Hammer

Remove steering bushings.

M95110

4. Remove drag link (A) from steering gear yoke (C) by rotating until parallel with steering yoke arm.

REPAIR STEERING GEAR - ALL EXCEPT 2046HV

E F

Removal:

1. Remove battery and safely raise front of tractor. 2. Remove fuel tank and dash panel. (See “FUEL TANK AND DASH PANEL REMOVAL & INSTALLATION” on page 6 in MISCELLANEOUS Section.)

M51991 A

NOTE: Write down location and number of washers on pinion and steering gear shafts. If a new shaft is installed, number and placement of washers may need adjustment.

M95108

3. Remove cotter pin and washer (B) from end of drag link (A).

NOTE: Steering gear can not be removed from the steering shaft. There may be 0 - 3 washers installed above steering gear. These washers are not interchangeable with other washers on the shaft. They are needed to ensure proper pinion gear to steering gear backlash engagement for proper steering response.

M95109

11 - 4

5. Remove cotter pin and washer(s) (E) from pinion shaft (F). 6. Remove C-clip and washer(s) (G) from steering gear shaft (C). Remove steering gear (C) from bottom of tractor. 7. Inspect pinion shaft and steering gear assembly, replace as necessary.

8. Remove pedestal (D) and steering gear shaft (C) as an assembly 9. Remove snap ring and washer(s) (G). 10. Remove steering gear shaft (C). 11. Replace worn or damaged parts as necessary.

3/22/00

STEERING GEAR - 2046HV

STEERING 12. Adjust steering backlash. (See Adjust Steering Backlash later in this section).

H B A F MX0966

M95111

Installation: Install assembly in reverse order, making sure pinion shaft (F) and steering gear (C) alignment marks (H) are aligned as pinion shaft is installed.

STEERING GEAR - 2046HV

3. Hold jam nut (B) and remove lock nut (C) from end of drag link (A). 4. Separate the rod end from the steering yoke (E). 5. Replace the drag link assembly if inspection reveals wear or damage.

NOTE:

Removal:

NOTE: The repair procedures for the steering is the same for all tractors. The model 2046HV tractor uses a different drag link assembly. The differences are shown in the following steps.

The drag link assembly has no serviceable components. If any part of the assembly is worn or damaged, replace the entire assembly.

Installation: 1. Installation is the reverse of removal. 482.6 mm (19 in.)

MX0967 A

Link Arm

2. Correct alignment of the steering system requires that the drag link is the correct length. The drag link should measure 482.6 mm (19 in.) from endto-end.

Cotter Pin D B

F G

C M95108 MX0965

1. Hold jam nut (B) and remove lock nut (C) from end of drag link (A). 2. Separate the rod end from the steering arm (D). MX0968

3. Adjust the length by loosening the jam nut (G) and turning the rod end (F). Turn the rod end 3/22/00

11 - 5

REPLACE PEDESTAL BUSHINGS counterclockwise to lengthen, clockwise to shorten the overall length of the drag link. 4. When the drag link is the correct length, turn the rod end so that the threads are 180Â° from the threads on the opposite end of the tie rod (photo MX0967). 5. Secure the rod end in position with the jam nut (G).

STEERING

ADJUST STEERING BACKLASH

D C

REPLACE PEDESTAL BUSHINGS E B A

M51991

M51989

1. Inspect four bushings (A) installed in steering sleeves of pedestal. If worn or damaged, replace them individually or as a set. 2. Clamp pedestal to stationary bench. 3. Use a slide hammer puller set up with inside jaws to remove four bushings. 4. Install new bushings using a rubber hammer.

1. Install steering gear (B) with four bottom washers in pedestal. 2. Install washers and snap ring (A) on gear (B). 3. Install pedestal on tractor.

B F

D M95111

4. Align marks (F) on sector gear and pinion gear as steering pinion shaft (D) is installed from the bottom of the tractor. 5. Install washers (E) and cotter pin (C). 6. Install and fasten tie rods (Long leg of tie rod is installed in axle spindle). 7. Install steering wheel on top of steering shaft (D) and fasten with mounting hardware. 8. Turn steering left-to-right several times to test steering response and feel. 9. Repeat adjustment procedure until minimum backlash without binding is achieved.

11 - 6

3/22/00

CONTENTS

ATTACHMENTS

CONTENTS Page

COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 LIFT LINKAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 38 INCH DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 42 INCH DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 46 INCH DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SPINDLE BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 MOWER BELT TENSION ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DECK LEVELING (SIDE-TO-SIDE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 DECK LEVELING (FRONT-TO-REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ADJUSTING DECK SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 MOWER DECK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REPLACING MOWER DECK BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 MOWER DECK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 MOWER SPINDLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 GAGE WHEEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2/29/00

12 - 1

NOTES

12 - 2

ATTACHMENTS

2/29/00

COMPONENT LOCATION

ATTACHMENTS

COMPONENT LOCATION LIFT LINKAGE

Lift Lever Lift Assist Spring Cap Screw Lift Lever Lock

Lift Arm (RH) Lift Arm (LH)

Flange Nut

Cap Screw

Latch Springs Cap Screw Push Nut

Retaining Bracket

Bushing

Spacer Washer

Roller

Flange Nut

Latch Bar Flange Nut

Latch Quadrant Plate Cap Screw

Latch Slotted Holes

Flange Nut

3/22/00

M95112

12 - 3

38 INCH DECK

ATTACHMENTS

38 INCH DECK 3 4

63 60 58 49

62 61 23 60

59 58

50 53

15 15 2 5

45 48

16 57

55 56

44 43 58

18 19

20 21

22 41

46 47

23 39

36 37

3 25

28 15 33 34 35

1. Strap, PTO Spring 2. Cotter Pin 3. Washer 4. Compression Spring 5. Spring Locking Pin 6. Shield 7. Screw, M6 x 12 8. End, PTO Rod 9. Nut 10. Rod, LH Brake 11. Arm, Idler 12. Belt 13. Spindle Assembly 14. Bolt, M8x16 15. Flange Nut, M10 16. Guide 17. Idler

12 - 4

18. Spacer 19. Guide, Belt 20. Mower Deck 21. Label, Danger 22. Label, Mulcher 23. Flange Nut, M8 24. Rod, Front Draft 25. Ball, Leveling 26. Lock Nut, M10 27. Screw, M10 x 50 28. Deflector 29. Blade 30. Washer 31. Washer 32. Bolt 33. Spacer 34. Wheel, Gage

29 30 31 32 M95113

35. Screw, M10x70 36. Label, Danger 37. Screw, M8x20 38. Cap Screw, M8x80 39. Washer, 21/64x 1-15/32x7/64 in. 40. Pad, Brake (W/Spring) 41. Lock Nut, M6 42. Screw, M8x12 SelfTapping 43. Nut, Push On 44. Lock Nut, M8 45. Hinge 46. Torsion Spring 47. Chute 48. Pin, 8x226 mm

49. Rod, Adjusting 50. Bushing 51. Bracket, RH Draft 52. Pin 53. Bracket, LH Draft 54. Eye Bolt 55. Bushing 56. Rod, RH Brake 57. Carriage Bolt, M8x35 58. Washer, 6.4x12x1.600 mm 59. Washer, 8.4x24x2 mm 60. Cotter Pin, 2.5x20 mm 61. Sheave, Flat Idler 62. Rod 63. Pin, 10x22 mm

3/22/00

42 INCH DECK

ATTACHMENTS

42 INCH DECK 2 1

4 6

4 4

12 13 11

12 8 15

14 10

6 10 5 67

27 14 64

62 61

65 32

22 23 24

18 19 20 21

63 12

27 22 23

28 29

34 68

30 6

59 57

12 8

42 49 50

70 54

51 52 53

1. Bracket, RH Rear Draft 2. Bracket, LH Rear Draft 3. Bushing 4. Nut 5. Bolt, “J” 6. Nut, M10x1.5 Flange 7. Eye Bolt 8. Spring Locking Pin 9. Pin, Cylinder 10. Pin, Cotter, Extended 11. Pin, 10x22 mm 12. Washer 13. Spring, Compression 14. Rod-PTO Spring 42 in. 15. Nut 16. Rod, Deck Stop 17. Shield, Belt 18. Screw, Flanged 19. Nut, Metric Flanged 20. Guide, Belt-PTO 42 in.

21. Idler, 4.50 in. 22. Nut, Lock, M8x1.25-8 23. Washer 24. Rod, LH Brake 25. Locknut, M6x1 26. Brake Pad Assembly 27. Nut, M8x1,25 Hx Flg 28. Pulley, V-Idler 29. Spacer 30. Bolt, M8x1.25x35 31. Sheave, Deck Spindle 32. Bolt, Rd Hd Sq Short 33. Belt, Mower Drive 34. Deck, Welded 42 in. 35. Screw, Flanged 36. Wheel, Gage 37. Spacer, Split 38. Bolt, Front Draft Rod 39. Ball, Leveling 40. Lock Nut, M10

47 44 45 46

56 41

3/22/00

39 40

74 72

43 72

75 76 73 72

75 72 73

41. Screw, Hex Hd 42. Deflector, Lower 43. Blade, Mulch 44. Washer, Blade 45. Washer, Hardened 46. Bolt, Blade 47. Washer, 10.5x30x2.5 48. Bolt 49. Spring, Chute (Rear) 50. Spring, Chute (Front) 51. Chute, Inner 52. Retainer, Push On 53. Chute, Discharge (w/decals) 54. Pin, Chute Guard 55. Hinge, Discharge Chute 56. Bolt, Rd Hd Sq Short 57. Nut, Lock M8x1.25-8 58. Guide, Belt

76 M95114

59. Screw, Slftpg 60. Rod, RH Brake 61. Pin, Cotter, Extended Prongs 62. Bolt 63. Arm, Idler 64. Sheave, Flat Idler 65. Bushing, Idler Pivot 66. Washer 67. Washer 68. Label 69. Label 70. Label 71. Mulch Cover 72. Washer 73. Lock Nut 74. Screw 75. Strap 76. Hook

12 - 5

46 INCH DECK

ATTACHMENTS

46 INCH DECK 18

19 17

22 15 14 13

12 18

12 11

6 25

32 26

5 10

6 2

7 6

8 12 53 14 13

64 66

40 15

15 36

65 53

6 57

51 69

53 62

49 31

41 49

42 44

48 45 46

59 60

1. Shield, RH Belt 2. Bracket, RH Rear Draft 3. Bracket, LH Rear Draft 4. Bushing 5. Rod, Adjusting 6. Flange Nut, M10 7. Eye Bolt 8. Bushing, Idler Pivot 9. Bolt, Carriage M8 x 35 10. Rod 11. Arm, Idler 12. Washer, 6.4x12x1.6 13. Cotter Pin 14. Washer, 8.4x24x2 15. Flange Nut, M8 16. Pin 17. Strap, PTO Spring 18. Washer, 13/32 x 13/16 x 0.065 in.

12 - 6

19. Compression Spring 20. Rod, PTO Spring 21. Spring Locking Pin 22. End, PTO Rod (Blade Drive Arm) 23. Nut, M10 24. Rod, LH Brake 25. Pulley 26. Spacer 27. Pulley, 5 in. Flat Idler 28. Shield, LH Belt 29. Bumper 30. Screw, M6x12 31. Guide, Belt 32. Spindle 33. Bolt, Carriage M8x16 34. Guide, LH Belt 35. Mower Deck 1.17M

36. Bolt, Carriage M8x40 37. Guide, Belt 38. Screw, M8x12 39. Bolt, Carriage M10x45 40. Rod, Front Draft 41. Ball, Leveling 42. Lock Nut, M10 43. Deflector 44. Blade 45. Washer 46. Washer 47. Bolt 48. Cap Screw, M8x80 49. Washer, 11/3 x 1-3/8x0.134 in. 50. Screw, M8x20 51. Bushing, Bellcrank

M95115

52. Guide, Belt 53. Lock Nut, M8 54. Pad, Brake (W/Spring) 55. Lock Nut, M6 56. Spacer 57. Gage Wheel 58. Screw, M10x70 59. Nut, 7.925 Push On 60. Chute 61. Pin, 8x226 mm 62. Torsion Spring 63. Hinge 64. Rod, Brake 65. Pin 66. Bellcrank 67. Label, Danger 68. Label, Mulcher 69, Label, Danger

3/22/00

TESTS AND ADJUSTMENTS

ATTACHMENTS

TESTS AND ADJUSTMENTS BEFORE PERFORMING ADJUSTMENTS:

ANY

5. Measure distance from brake surface to pulley braking surface.

SERVICE

1. Depress clutch/brake pedal fully and set parking brake. 2. Place gearshift lever in neutral (N) position. 3. Place PTO lever in “DISENGAGED” position. 4. Turn ignition key “OFF” and remove key. 5. Make sure the blades and all moving parts have completely stopped. 6. Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug.

SPINDLE BRAKE ADJUSTMENT

Specifications: Brake to Pulley Distance ........................... 2 - 3 mm (0.08 - 0.12 in.) 6. If not to specification adjust nut on end of brake rod to set brake at proper distance from pulley. 7. Reinstall belt covers if removed. 8. Connect spark plug.

MOWER BELT TENSION ADJUSTMENT

CAUTION

Spindle brake adjustment must be checked every time the belt tension is adjusted. Perform brake adjustment after belt tension adjustment.

CAUTION

Spindle brake engagement must be checked and corrected every time the belt tension is adjusted. Belt tension should be adjusted, if required, before brakes are adjusted. 1. Park mower on a hard, smooth surface. Stop engine, remove key, wait for moving parts to stop and remove wire from spark plug to prevent accidental starting. 2. Place cutting unit in lowest setting. 3. Engage mow lever. 4. Remove belt guard if necessary.

1. Park mower on a hard, smooth surface. Stop engine, remove key, wait for moving parts to stop and remove wire from spark plug to prevent accidental starting. 2. Place cutting unit in lowest setting. 3. Engage mow lever. 20 - 25 mm (0.781 - 0.984 in.)

IMPORTANT: There are two (2) spindle brakes on the 38 inch deck and three (3) spindle brakes on the 46 inch deck. All brakes must be adjusted.

2-3 mm (0.078 - 0.118 in.) M95117

Adjustment Nut

Specifications: Bracket to Washer Distance . . . . . . . . . . . 20 - 25 mm (0.78 - 0.98 in.)

Brake

M95116

3/22/00

4. Measure distance from bracket to washer on tension rod.

5. If adjustment is required: • Disengage Mow lever. • Remove spring pin clip and washer from tension rod and remove rod from blade drive lever.

12 - 7

DECK LEVELING (SIDE-TO-SIDE) IMPORTANT: Do not attempt to loosen jam nut on tension rod without using a suitable wrench to support fitting.

Jam Nut

ATTACHMENTS

DECK LEVELING (SIDE-TO-SIDE) 1. Park tractor on a hard, level surface. 2. Stop engine and remove key. Disengage blade drive. 3. Check tire pressure. (14 psi - Front Tire; 10 psi - Rear Tire) 4. Adjust cutting height to middle position.

CAUTION

Blades are sharp and could cause personal injury. Wear gloves or wrap blades with shop cloths to remove and install blades. DO NOT hold blade with bare hand. Use a block of wood wedged between deck and blade to keep spindle from turning.

M95117

• Loosen jam nut. • Turn fitting on tension rod in proper direction to lengthen or shorten effective rod length.

Tension Rod Adjuster

Outside Blade Tip Outside Blade Tip

Jam Nut

Tension Rod

M95119

38 Inch Mower Deck 16 - 19 mm (0.63 - 0.75 in.) 42 Inch Mower Deck 21 - 24 mm (0.83 - 0.94 in.)

M95118

46 Inch Mower Deck 16.5 - 19.5 mm (0.65 - 0.77 in.)

• Tighten jam nut to 27 N•m (20 lb-ft) • Assemble tension rod to tractor blade drive arm. • Recheck dimension from bracket to washer. Readjust if necessary.

5. Turn left blade by hand parallel to mower axle. Hold left blade with glove and turn right blade parallel to axle. 6. Measure height from level surface to outside blade tip on left and right blades. Difference between measurements should not exceed 1/4 in. (6 mm). 7. Turn blades 180° and measure again to ensure blades are not bent.

NOTE: Adjusting “J” bolt on left-hand rear side of rear draft arm, shown below.

6. Check brake clearance. (See “SPINDLE BRAKE ADJUSTMENT” on page 7.) 7. Reconnect spark plug.

12 - 8

3/22/00

DECK LEVELING (FRONT-TO-REAR)

ATTACHMENTS

DECK LEVELING (FRONT-TO-REAR) Front Blade Tip

Rear Draft Arm

“J” Bolt

Lower Adjusting Nut

Rear Blade Tip

M76929 M95125

NOTE: Adjusting “J” bolts are on both left and right hand sides of rear draft arms. For minor sideto-side adjustments, do not alter factory preset of right hand side adjusting “J” bolt. Reset left hand side adjusting “J” bolt to obtain proper side-to-side adjustment. A deck leveling gauge (P/N TY15272) may be obtained through your local Sabre Service Center at nominal cost to aid in deck adjustment. 8. Using a 15 mm wrench, loosen top clamping nut on left hand side adjusting “J” bolt facing inside of mower approximately 1 turn. (See Fig. 44) 9. Loosen upper adjusting nut on adjusting “J” bolt. 10. Turn lower adjusting nut towards rear to raise left side of deck. 11. Turn nut towards front to lower left side of deck. 12. Tighten upper nut after adjustment. 13. Tighten clamping nut on adjusting “J” bolt.

1. Turn blades to point front to rear. 2. Measure height from level surface to front and rear blade tips. Turn blades 180° and measure again to ensure blades are not bent. • Height of rear blade tip should be 1/8 to 3/8 in. (3-10 mm) higher than front blade tip. M95124

Ball Front Draft Rod 8.37 in. 212.6 mm

Flange Nut

IMPORTANT: Make sure each front draft rod is equally tensioned. The installed rods should exhibit identical amounts of movement between left and right rods. If one rod moves more freely than the other, then the adjustment flange nut should be tightened until the movement of the assembly matches that of the other side.

Front Draft Rod

Adjustment Flange Nuts Front Draft Rod

3/22/00

M95126

12 - 9

ADJUSTING DECK SUSPENSION 3. Turn adjustment flange nuts on front draft rods equally until adjustment is correct. Turning nut clockwise will raise the front of the mower. Turning flange nut counterclockwise will lower the front of the mower.

ADJUSTING DECK SUSPENSION TO OBTAIN CUT HEIGHT NOTE: Normal settling of the deck suspension after years of use may cause cut height range to shift downward. This may be readjusted by resetting the right hand adjusting “J” bolt adjuster. Adjustments are easier to make in the lowest cutting position, while the 4.25 in. (110 mm) dimension should be measured in the highest cutting position.

ATTACHMENTS

REPAIR MOWER DECK REMOVAL 1. Stop engine, engage park brake, disengage blade drive. 2. Place 2 in. (50 mm) blocks under edges of mower deck.

CAUTION

Mower lift lever is under high tension. When mower deck is removed, always grasp lift lever securely before releasing lift lock lever. Do not place hands between lift lever and frame while adjusting.

• Loosen right hand side adjusting “J” bolt and move bolt downward in slot on right hand side of mower deck bracket so the right hand rear blade tip is about 4.25 in. (110 mm) from ground in the highest deck setting. Retighten right hand adjusting “J” bolt nuts securely in slot. • Repeat sequences described for minor adjustments detailed in DECK LEVELING (SIDE-TO-SIDE) and DECK LEVELING (FRONT-TO-BACK) sections. (Shown from right hand side of tractor)

Slot (Hidden) Mower Deck Lift Lever

“J” Bolt Mower Deck Bracket

M95127

Mower Deck Lift Lock Lever

M95128

3. Lower mower deck lift lever to lowest position, bringing deck down onto blocks. Engine Pulley

Mower Drive Belt

M95129

4. Pull down on LH side of belt guide and rotate away from pulley. Remove mower deck drive belt from tractor engine pulley.

12 - 10

3/22/00

REPLACING MOWER DECK BELT

ATTACHMENTS

REPLACING MOWER DECK BELT Spring Pin Clip Washer Blade Drive Arm

1. Remove mower deck from tractor. (See “MOWER DECK REMOVAL” on page 10.) 38 INCH MOWERS: Belt Guard

Tensioning Pulley

Tension Rod

M95130

5. Remove spring pin clip and washer holding tension rod to blade drive arm. 6. Remove spring pin clips and washers from two mower draft rods at front of deck. M95132

Guide Rod

42 INCH MOWERS: Tensioning Pulley Belt Guard

Rear Draft Pin

M95131

Rear Draft Arm

7. Remove two spring pin clips from two rear draft pins holding rear draft arms to mower frame. 8. Remove rear draft pins from draft arms. 9. Raise mower deck lift lever to highest position. Remove blocks from under deck. 10. Pull deck out from under side of mower, being careful to not catch rear draft arms on frame. 11. If mower is to be driven with deck removed, remove two draft rods from under mower to prevent damage.

3/22/00

M95133

2. Remove three cap screws and belt guard. 3. Remove belt from the mower deck spindles and idlers. 4. Installation of belt is in reverse order of removal. Use diagram above for belt routing. Be sure belt is not twisted. 5. Inspect spindle brake pads for wear. 6. Reinstall belt guard and tighten cap screws securely. 7. Install mower deck on tractor. (See “MOWER DECK INSTALLATION” on page 12.) 8. Adjust mower deck belt tension. (See “MOWER BELT TENSION ADJUSTMENT” on page 7.) 9. Adjust spindle brake. (See “SPINDLE BRAKE ADJUSTMENT” on page 7.)

12 - 11

MOWER DECK INSTALLATION

ATTACHMENTS

MOWER DECK INSTALLATION

46 INCH MOWER:

CAUTION

Mower lift lever is under high tension. When mower deck is removed, always grasp lift lever securely before releasing lift lock lever. Do not place hands between lift lever and frame while adjusting.

Tensioning Pulley M95134

46-in. Deck Belt Routing

1. Raise the mower deck lift lever to its highest point by pressing the lift lever lock and raising the lever up. 2. Slide deck under mower from side, being careful not to catch rear draft brackets on frame. 3. Place deck on 2 in. (50mm) blocks under edges of mower deck.

M95135

Guide Rod

Rear Draft Arm

1. Remove six cap screws holding left and right belt guards. 2. Remove mower drive belt from deck pulleys and idlers, and remove belt from mower deck. 3. Installation of belt is in reverse order of removal. Use diagram above for belt routing. Be sure belt is not twisted.

Center Draft Arm Between Guide Rod And Plate

CAUTION

M76929

Do not operate tractor without belt guard(s) installed. 4. Reinstall belt guards and tighten screws securely. 5. Install mower deck on tractor. (See “MOWER DECK INSTALLATION” on page 12.) 6. Adjust mower deck belt tension. (See “MOWER BELT TENSION ADJUSTMENT” on page 7.) 7. Adjust spindle brake. (See “SPINDLE BRAKE ADJUSTMENT” on page 7.)

4. Lower deck lift lever to lowest position, while centering rear draft arms between guide rods and plate on both sides of tractor.

Guide Rod Rear Draft Pin

Rear Draft Arm M95131

12 - 12

3/22/00

MOWER DECK INSTALLATION

ATTACHMENTS 5. Raise front of draft arms to align holes in end of draft arms with holes in mower frame. Install draft pins through rear draft arms and mower frame. Secure with spring pin clips.

View from Bottom of Tractor Front of Tractor Engine Pulley

42 in. with V-Twin engine

Front Draft Rods

Spring Pin Clip

M95126

6. Attach draft rods to front of deck with washers and spring pin clips.

Install Free End Install Threaded Of Belt Guide End of Belt Guide 38 & 42 in. with single On This End On This End cylinder engine Of Bracket Of Bracket M95136

Spring Pin Clip Washer

View from Bottom of Tractor Front of Tractor

Blade Drive Arm

Tension Rod

Engine Pulley

46 in. with single cylinder engine

M95130

7. Attach mower deck spring tension rod to blade drive arm with washer and spring pin clips. Engine Pulley

Install Free End Install Threaded 46 in. with End of Belt Guide V-Twin engine Of Belt Guide On This End On This End Of Bracket Of Bracket Mower Drive Belt

M95129

8. Install mower drive belt on engine pulley. 9. Install belt guide in proper hole(s) in belt guide bracket. See below.

3/22/00

M95137

10. Remove blocks from under mower. 11. Check mower deck belt tension. (See “MOWER BELT TENSION ADJUSTMENT” on page 7.)

12 - 13

MOWER SPINDLE ASSEMBLY

ATTACHMENTS

MOWER SPINDLE ASSEMBLY

46 INCH MOWER: A

REMOVAL

NOTE:

C B

Spindles are not serviceable. The spindle, complete with pulley, must be replaced as an assembly if any parts are needed.

1. Remove deck unit from machine. (See “MOWER DECK REMOVAL” on page 10.) 38 INCH MOWER:

M95134 A

4. Remove belt shields and belt (A).

IMPORTANT: DO NOT remove nuts (B) or sheaves (C) from spindles.

c D

M95132

CAUTION

42 INCH MOWER: A B

Blade

Belleville Washer D

Small Washer

M95133

Blade Cap Screw

M58340

2. Remove belt shield) (D) and belt (A). IMPORTANT: DO NOT remove nuts (B) or sheaves (C) from spindles.

5. Remove blade cap screw, small washer, and belleville washer to remove blade(s).

3. Proceed to Step 5.

12 - 14

3/22/00

GAGE WHEEL ADJUSTMENT

ATTACHMENTS

Specifications: Spindle Assembly Nuts . . . . . . . . 27 N•m (20 lb-ft) Blade Cap Screw . . . . . .46 - 65 N•m (34 - 48 lb-ft) 3. Install mower belt. (See “REPLACING MOWER DECK BELT” on page 11.) 4. Install shield(s) (D), as shown. 5. Install deck. (See “MOWER DECK INSTALLATION” on page 12.) 6. Adjust mower belt tension. (See “MOWER BELT TENSION ADJUSTMENT” on page 7.) 7. Adjust spindle brakes. (See “SPINDLE BRAKE ADJUSTMENT” on page 7.)

J I

K M55887

GAGE WHEEL ADJUSTMENT 6. Remove spindle bearing guard(s) (I) and mounting hardware (K) to remove spindle assembly (J). INSTALLATION

NOTE:

Spindles are not serviceable. The spindle, complete with pulley, must be replaced as an assembly if any parts are needed.

IMPORTANT: DO NOT add grease to spindle grease fitting. Grease fittings are for manufacturers use only. Adding grease may damage spindle seals.

This unit has been equipped with gage wheels to minimize scalping by the mower deck when mowing uneven terrain. To achieve best results follow these guidelines: 1. Set gage wheels so they ride about 1/4 in. (6 mm) higher than the desired cutting height. 2. All mowers: Make sure that all gage wheel mounting bolts are securely tightened after adjustment to prevent losing wheel parts while mowing.

NOTE: 46 Inch Mower Deck: Be sure that front and rear gauge wheels ride in the same hole sets front-to-back and side-to-side to provide optimum performance. 3. Do not run the gage wheels on the ground continuously while mowing or transporting. Doing this will result in accelerated wear of gage wheel components and may lead to early failure. The gage wheels are designed to handle occasional ground contact in uneven terrain situations to prevent scalping.

Blade

Belleville Washer (Concave side MUST face blade)

Deflector Cup

Small Lock Washer Blade Cap Screw M95138

IMPORTANT: Blade bolt is Grade 8 heat treated 1. Install each spindle assembly in reverse order. Tighten mounting hardware to specification. 2. Install spindle bearing guard(s) and blade(s) to specification. 3/22/00

12 - 15

GAGE WHEEL ADJUSTMENT

12 - 16

ATTACHMENTS

3/22/00

CONTENTS

MISCELLANEOUS

CONTENTS Page

COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 FUEL TANK AND DASH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FRONT WHEELS REMOVAL & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REAR WHEELS REMOVAL & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FRONT WHEEL BEARING REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FRONT AXLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FRONT AXLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FRONT AXLE REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FUEL TANK AND DASH PANEL REMOVAL & INSTALLATION . . . . . . . . . . . . . . . . . 6

2/29/00

13 - 1

NOTES

13 - 2

MISCELLANEOUS

2/29/00

COMPONENT LOCATION

MISCELLANEOUS

COMPONENT LOCATION FUEL TANK AND DASH PANEL

6 5

1 11

12 7 9 7

7 10 7

9 M95139

1. Fuel Tank 2. Filler Cap 3. Dash Panel 4. Clip Nut (2 used) 5. Screw (6 used)

3/22/00

6. Fastener Grommet (4 used) 7. Hose Clamps (6 used) 8. Screw 9. Fuel Delivery Hose (Typical)

10. Fuel Filter 11. Flange Screw 12. Nylock Nut

13 - 3

REPAIR

MISCELLANEOUS

REPAIR

REAR WHEELS REMOVAL & INSTALLATION

FRONT WHEELS REMOVAL & INSTALLATION

1. Safely lift and support tractor.

1. Safely lift and support tractor. 2. Remove plastic cap.

A B A

C M55832

M57056

3. Remove snap ring (A) and wheel. 4. Clean axle, washers, and bearings of old grease. 5. Inspect bearings for excessive wear. Replace if necessary.

NOTE: Front wheels are installed with valves to the inside. 6. Grease spindles with specified grease.

2. Remove plastic cap (A), E-ring (B) (gear) or snap ring (C) (hydro), and outer washer (D). 3. Remove wheel.

NOTE: Rear wheels are installed with valves to the outside. 4. Apply grease to axle shaft and key. 5. Install wheel on axle. 6. Install outer washer (D), E-ring (B) or snap ring (C), and plastic cap (A).

FRONT WHEEL BEARING REPAIR Two (2) Washer

1. Remove bearings (A) using slide hammer puller.

Bearings

Cap Washer M95141

Snap Ring

M95140

7. Install two washers on axle. 8. Install wheel on axle. 9. Place large washer on axle and install snap ring. 10. Install plastic cap.

13 - 4

2. Install new bearings using suitable driver on outside race of bearing.

3/22/00

FRONT AXLE REMOVAL

MISCELLANEOUS

FRONT AXLE REMOVAL

FRONT AXLE REPAIR

1. Safely support front of tractor. 2. Remove front wheels. (See “REAR WHEELS REMOVAL & INSTALLATION” on page 4.)

NOTE: If new axle is being installed, original bushing can be used if in good condition.

B A

3. Grease axle pivot ID and bushing OD and install. Tighten lock nut (B) to specification. 4. Grease spindle shafts (C) before installing rims.

1. Remove axle. (See “FRONT AXLE REMOVAL” on page 5.) 2. Remove bushings (A), you may need to use a driver and hammer or an hydraulic press.

Lock Nut (B) 54 N•m (40 lb-ft)

Washer Bushing (A)

M55893

C Tie Rod

3. Disconnect draft arms (D) from axle. 4. Remove tie rods (C) at spindle arms. 5. Remove muffler shield(s) and muffler (B).

Lock Nut

Grease Fitting

Bushing Washer C Bushing (A) Washer 4 Used Cap Screw

Washer M95142

Bushing

Cotter Pin

Bushing

Washer Bushing Vehicle Frame M95143

Pivot Cap Screw

6. Remove pivot cap screw (A). 7. Remove axle and replace parts as necessary.

FRONT AXLE INSTALLATION 1. Install axle. Tighten pivot cap screw to 54 N•m (40 lb-ft) 2. Install muffler. Tighten muffler cap screw(s) to 19 - 30 N•m (168 - 265 lb-in.) 3. Install muffler shield(s). 4. Connect tie rods to axle (long leg in axle spindle). 5. Connect draft arms to axle.

3/22/00

13 - 5

FUEL TANK AND DASH PANEL REMOVAL & INSTALLATION FUEL TANK AND DASH PANEL REMOVAL & INSTALLATION

MISCELLANEOUS

6. Remove spring rod from switch cam. 7. Remove socket head cap screw securing switch cam to rod.

1. Disconnect battery ground (â&#x20AC;&#x201C;) cable.

Plastic Grommet

Blade Drive Lever

D M95147

M95144

8. Remove screw (D) securing steering wheel to column and remove steering wheel and washer(s). 9. Remove mower deck blade drive lever through dash, retain plastic grommet. 10. Remove fuel tank/dash panel assembly to workbench. Cable Assembly

CAUTION

Gasoline is explosive. Do not expose to flame or spark. Serious injury can result. Catch or wipe up any spilled fuel immediately. 2. Remove fill cap. Disconnect fuel line at engine side of fuel filter (A) and drain any fuel into an approved container. 3. Disconnect throttle cable (B) at throttle plate. For v-twin engines, disconnect throttle and choke cables from engine. 4. Remove mounting screws on right and left side of gas tank (C). 5. Disconnect mower deck blade drive lever.

Spring Rod

Screws M95146

11. Remove lever from throttle cable assembly only if dash panel or throttle cable assembly are to be replaced. 12. Remove six screws to separate tank from dash panel and cable assembly. 13. Remove overflow tube and fuel line, replace as necessary.

Cap Screw

M95145

13 - 6

3/22/00

MISCELLANEOUS

FUEL TANK AND DASH PANEL REMOVAL & INSTALLATION

Cable Assembly E

M58323

M58322

17. Install fuel tank lip (E) in console notches (F) while aligning six mounting holes. Cable Assembly

14. Remove and replace throttle cable assembly as necessary. 15. Properly dispose of fuel tank and/or dash panel as necessary.

Fuel Tank Screws

M95146

18. Fasten fuel tank to dash panel with six screws. 19. Install lever on end of throttle cable assembly.

Cable Assembly

Overflow Hose M58320

16. Install overflow tube and fuel line to fuel tank spigots.

H J

M58306

3/22/00

13 - 7

FUEL TANK AND DASH PANEL REMOVAL & INSTALLATION

MISCELLANEOUS

20. Align fuel hose with slot (G), overflow tube with frame hole (H), throttle cable with hole (I), and dash panel steering shaft hole with steering shaft (J) as you install fuel tank/dash panel assembly onto steering pedestal.

Spring Rod

Cap Screw

M95145 C

M95144

29. Assemble spacer, switch cam, spring rod on tension lever end. Line up holes in shaft and cam and Secure with cap screw and nylock nut 30. Add fuel to tank and turn fuel shutoff valve (early models only) to ON position. 31. Check for and fix any leaks from fuel system.

21. Secure gas tank to pedestal with four (4) flanged screws (C). 22. Attach throttle cable (B) to carburetor. 23. Connect fuel line to fuel filter (A).

Plastic Grommet Blade Drive Lever

M95147

24. Place blade drive lever into hole in dash and frame. 25. Insert plastic grommet

NOTE:

Apply anti-seize lubricant to steering shaft before installing steering wheel.

26. Install washer(s) onto steering shaft. 27. Install steering wheel and fasten with cap screw and lock nut. 28. Connect throttle cable and choke cable (V-twins).

13 - 8

3/22/00

INDEX

Numerics 38 Inch Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 42 Inch Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5 46 Inch Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6

B Briggs & Stratton (Single Cylinder) Repair Specifications . . . . . . . . . . . . . . . . . . Specifications Connecting Rod and Crankshaft . . . . . . Cylinder Bore, Pistons and Rings . . . . . Valves . . . . . . . . . . . . . . . . . . . . . . . . . . Tests & Adjustments Specifications . . . . . . . . . . . . . . . . . . . . .

3-5 3-5 3-5 3-5 3-4

C Component Location 38 Inch Deck . . . . . . . . . . . . . . . . . . . . . . . . 12-4 42 Inch Deck . . . . . . . . . . . . . . . . . . . . . . . . 12-5 46 Inch Deck . . . . . . . . . . . . . . . . . . . . . . . . 12-6 Electrical Pre 1999 . . . . . . . . . . . . . . . . . . . . 6-8 Electrical w/Reverse Implement Option . . . . 7-8 Fuel Tank and Dash Panel . . . . . . . . . . . . . 13-3 Gear Transaxle . . . . . . . . . . . . . . . . . . . . . . . 8-6 Hydrostatic Transmission - K51 . . . . . . .9-5, 9-6 External . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Pedal Linkage Assembly . . . . . . . . . . . . 9-9 Traction Drive System . . . . . . . . . . . . . . 9-8 Hydrostatic Transmission - K55 . . . . . . . . . 10-6 Lift Linkage . . . . . . . . . . . . . . . . . . . . . . . . . 12-3 Steering . . . . . . . . . . . . . . . . . . . . . . .11-3, 11-6

E Electrical Key Switch Removal & Installation Dash . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50 Electrical Pre 1999 Charge Battery . . . . . . . . . . . . . . . . . . . . . . 6-26 Diagnosis Charging and Headlight Circuit . . . . . . 6-24 Cranking and Fuel Shutoff . . . . . . . . . . 6-16 Ignition and Seat Switch Circuit . . . . . . 6-20 Key Switch Removal & Installation . . . . . . . 6-36 Main electrical Schematic . . . . . . . . . . . . . . . 6-9 Main Wiring Harness . . . . . . . . . . . . . . . . . 6-10 Operation Charging and Headlight Circuit . . . . . . 6-22

2/29/00

Cranking and Fuel Shutoff . . . . . . . . . . 6-14 Ignition and Seat Switch Circuit . . . . . . 6-18 Schematic & Wiring Harness Legend . . . . . . 6-7 Seat Switch Removal & Installation . . . . . . 6-36 Specifications Headlight Bulbs . . . . . . . . . . . . . . . . . . . 6-6 Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Spark Plug . . . . . . . . . . . . . . . . . . . . . . . 6-6 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Starting Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . 6-40 Disassembly . . . . . . . . . . . . . . . . . . . . . 6-39 Pinion Gear Replacement . . . . . . . . . . 6-42 Removal & Installation . . . . . . . . . . . . . 6-38 Starting Motor Solenoid Removal & Installation . . . . . . . . . . . . . 6-37 Stator & Ignition Module Removal and Installation . . . . . . . . . . . 6-37 Stator Wiring Harness . . . . . . . . . . . . . . . . 6-11 Tests and Adjustments AC Voltage Output . . . . . . . . . . . . . . . . 6-28 Alternator DC Output . . . . . . . . . . . . . . 6-27 Alternator Diode . . . . . . . . . . . . . . . . . . 6-28 Battery Load . . . . . . . . . . . . . . . . . . . . . 6-27 Battery Test . . . . . . . . . . . . . . . . . . . . . 6-26 Brake Switch Adjustment . . . . . . . . . . . 6-33 Brake Switch/PTO Switch . . . . . . . . . . 6-33 Flywheel Magnet . . . . . . . . . . . . . . . . . 6-32 Ground Circuit . . . . . . . . . . . . . . . . . . . 6-34 Ignition Diode . . . . . . . . . . . . . . . . . . . . 6-31 Key Switch . . . . . . . . . . . . . . . . . . . . . . 6-35 Seat Switch . . . . . . . . . . . . . . . . . . . . . 6-32 Starting Motor Amp Draw . . . . . . . . . . . 6-29 Starting Motor No-Load . . . . . . . . . . . . 6-30 Starting Motor Solenoid . . . . . . . . . . . . 6-29 Troubleshooting . . . . . . . . . . . . . . . . . . . . . 6-12 W2 Engine Wiring Harness . . . . . . . . . . . . 6-11 W3 Headlight Wiring Harness . . . . . . . . . . 6-11 Y1 Fuel Shutoff Solenoid . . . . . . . . . . . . . . 6-11 Electrical w/Reverse Implement Option Component Location . . . . . . . . . . . . . . . . . . 7-8 Diagnosis Charging and Headlight Circuit . . . . . . 7-30 Cranking and Fuel Shut-off . . . . . . . . . 7-20 Ignition and Shutoff Circuit . . . . . . . . . . 7-24 Power Circuit . . . . . . . . . . . . . . . . . . . . 7-16 PTO with RIO Circuit . . . . . . . . . . . . . . 7-34 Key Switch Removal & Installation . . . . . . . 7-49

INDEX - 1

INDEX Main electrical Schematic . . . . . . . . . . . . . . . 7-9 Main wiring Harness . . . . . . . . . . . . . . . . . . 7-10 Operation Charging and Headlight Circuit . . . . . . 7-28 Cranking and Fuel Shut-off . . . . . . . . . 7-18 Ignition and Shutoff Circuit . . . . . . . . . . 7-22 Power Circuit . . . . . . . . . . . . . . . . . . . . 7-14 PTO with RIO Circuit . . . . . . . . . . . . . . 7-32 Schematic and Wiring Harness Legend . . . . 7-7 Seat Switch Removal & Installation . . . . . . 7-50 Specifications Headlight Bulbs . . . . . . . . . . . . . . . . . . . 7-6 Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Spark Plug . . . . . . . . . . . . . . . . . . . . . . . 7-6 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Starter Solenoid Removal & Installation . . . 7-50 Starting Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . 7-54 Disassembly . . . . . . . . . . . . . . . . . . . . . 7-52 Pinion Gear Replacement . . . . . . . . . . 7-55 Removal and Installation . . . . . . . . . . . 7-52 Stator and Ignition Module Removal and Installation . . . . . . . . . . . 7-51 Tests and Adjustments AC Voltage Output . . . . . . . . . . . . . . . . 7-40 Alternator DC Output . . . . . . . . . . . . . . 7-39 Alternator Diode . . . . . . . . . . . . . . . . . . 7-40 Battery Load . . . . . . . . . . . . . . . . . . . . . 7-39 Battery Test . . . . . . . . . . . . . . . . . . . . . 7-38 Brake Switch Adjustment . . . . . . . . . . . 7-45 Brake Switch/PTO Switch Test . . . . . . 7-45 Charge Battery . . . . . . . . . . . . . . . . . . . 7-38 Diode Test . . . . . . . . . . . . . . . . . . . . . . 7-49 Flywheel Magnet . . . . . . . . . . . . . . . . . 7-44 Ground Circuit Tests . . . . . . . . . . . . . . 7-47 Ignition Diode Test . . . . . . . . . . . . . . . . 7-43 Key Switch Test . . . . . . . . . . . . . . . . . . 7-48 Relay Test . . . . . . . . . . . . . . . . . . . . . . 7-48 RIO Switch Test . . . . . . . . . . . . . . . . . . 7-46 RIS Switch Test . . . . . . . . . . . . . . . . . . 7-46 Seat Switch Test . . . . . . . . . . . . . . . . . 7-44 Starting Motor Amp Draw . . . . . . . . . . . . . . . . . . . 7-41 No Load Amp Draw . . . . . . . . . . . . 7-42 Starting Solenoid . . . . . . . . . . . . . . . . . 7-41 Troubleshooting . . . . . . . . . . . . . . . . . . . . . 7-12 W2 Headlight Wiring Harness . . . . . . . . . . 7-11 W3 Engine Wiring Harness . . . . . . . . . . . . 7-11

INDEX - 2

W4 Engine Wiring Harness . . . . . . . . . . . . 7-11 Y1 Fuel Shutoff Solenoid . . . . . . . . . . . . . . 7-11 Engine Single Cylinder Air Cleaner Service . . . . . . . . . . . . . . . 3-16 Breather Valve Service . . . . . . . . . . . . 3-20 Cam Gear Bearing Inspection . . . . . . . 3-40 Carburetor Assembly . . . . . . . . . . . . . . . . . . . . 3-19 Disassembly . . . . . . . . . . . . . . . . . 3-18 Inspection . . . . . . . . . . . . . . . . . . . 3-19 Removal and Installation . . . . . . . . 3-17 Connecting Rod and Crankshaft . . . . . . 3-4 Connecting Rod Inspection . . . . . . . . . 3-31 Crankshaft and Cam Gear Installation . . . . . . . . . . . . . . . . . . . 3-38 Removal . . . . . . . . . . . . . . . . . . . . 3-36 Cylinder Bore Cleaning . . . . . . . . . . . . . . . . 3-34 Bore Honing . . . . . . . . . . . . . . . . . . 3-34 Bore Inspection . . . . . . . . . . . . . . . 3-34 Bore Resizing . . . . . . . . . . . . . . . . 3-35 Head Inspection and Repair . . . . . 3-25 Head Removal & Installation . . . . . 3-23 Cylinder Bore, Pistons and Rings . . . . . 3-4 Engine Installation . . . . . . . . . . . . . . . . 3-22 Engine Removal . . . . . . . . . . . . . . . . . . 3-21 Flywheel Removal & Installation . . . . . 3-36 Governor Removal & Installation . . . . . 3-27 Magneto Bearing Inspection . . . . . . . . 3-39 Piston Inspection . . . . . . . . . . . . . . . . . 3-31 Piston Removal and Installation . . . . . . 3-28 PTO Bearing Removal and Installation 3-40 Specifications General . . . . . . . . . . . . . . . . . . . . . . 3-3 Repair . . . . . . . . . . . . . . . . . . . . . . . 3-4 Starting Motor Removal and Installation . . . . . . . . 3-40 Tests and Adjustments Fuel Shut-off Solenoid . . . . . . . . . . 3-12 Governor - Running . . . . . . . . . . . . 3-13 Governor - Static . . . . . . . . . . . . . . 3-13 Governor Idle Adjustment . . . . . . . 3-14 Ignition Armature Air Gap . . . . . . . 3-16 Slow Idle . . . . . . . . . . . . . . . . . . . . 3-14 Specifications . . . . . . . . . . . . . . . . . 3-3 Throttle Cable Adjustment . . . . . . . 3-12 Valve Clearance . . . . . . . . . . . . . . 3-15 Torque Specifications . . . . . . . . . . . . . . . 3-6 Troubleshooting . . . . . . . . . . . . . . . . . . . 3-7 Upper Blower Housing . . . . . . . . . . . . . 3-16

2/29/00

INDEX Valves Installation . . . . . . . . . . . . . . . . . . . 3-26 Reface . . . . . . . . . . . . . . . . . . . . . . 3-26 Removal . . . . . . . . . . . . . . . . . . . . 3-25 Specifications . . . . . . . . . . . . . . . . . 3-4 V-Twin - Intek Blower Housing Removal/Installation . 5-17 Breather Valve Service . . . . . . . . . . . . 5-40 Cam Gear Removal/Installation . . . . . . 5-36 Carburetor Disassembly and Assembly . . . . . . 5-19 Removal/Installation . . . . . . . . . . . 5-18 Connecting Rod Inspection . . . . . . . . . . . . . . . . . . . 5-32 Removal/Installation . . . . . . . . . . . 5-30 Crankcase Cover . . . . . . . . . . . . . . . . . 5-38 Crankshaft Removal/Installation . . . . . 5-36 Cylinder Air Guides Removal/Installation 5-25 Cylinder Bore Cleaning . . . . . . . . . . . . . . . . . . . . 5-34 Honing . . . . . . . . . . . . . . . . . . . . . . 5-34 Inspection . . . . . . . . . . . . . . . . . . . 5-34 Pistons Specifications . . . . . . . . . . . 5-4 Resizing . . . . . . . . . . . . . . . . . . . . . 5-35 Cylinder Head Inspection & Repair . . . . . . . . . . . . 5-28 Removal/Installation . . . . . . . . . . . 5-26 Engine Removal/Installation . . . . . . . . 5-23 Flywheel Removal/Installation . . . . . . . 5-36 General Specifications . . . . . . . . . . . . . . 5-3 Installation . . . . . . . . . . . . . . . . . . . . . . 5-24 Lubrication . . . . . . . . . . . . . . . . . . . . . . 5-40 Magneto Bearing Inspection . . . . . . . . 5-38 Piston Inspection . . . . . . . . . . . . . . . . . 5-31 PTO & CAM Bearing Inspection . . . . . 5-39 Repair Specifications . . . . . . . . . . . . . . . 5-3 Resizing Cylinder Bore . . . . . . . . . . . . 5-35 Rings & Rod Removal/Installation . . . . 5-30 Tests & Adjustments . . . . . . . . . . . . . . 5-11 Choke Cable Adjustment . . . . . . . . 5-11 Compression Test . . . . . . . . . . . . . 5-13 Cylinder Balance Test . . . . . . . . . . 5-16 Cylinder Leak Test With Leak Tester . . . . . . . . . . 5-14 Without Leak Tester . . . . . . . 5-13 Fuel Shutoff Solenoid Test . . . . . . 5-11 Governor Running . . . . . . . . . . . . . . . . . 5-12 Static . . . . . . . . . . . . . . . . . . . 5-12 Ignition Armature Air Gap . . . . . . . 5-15 Specifications . . . . . . . . . . . . . . . . . 5-3 Throttle Cable Adjustment . . . . . . . 5-11 Valves Clearance Adjustment . . . . 5-15 2/29/00

Torque Specifications . . . . . . . . . . . . . . . 5-5 Troubleshooting . . . . . . . . . . . . . . . . . . . 5-6 Engine Cranks But Will Not Start . . . 5-9 Engine Runs Erratically/Loss of Power . 5-10 Engine Will Not Crank . . . . . . . . . . . 5-8 Valves Inspection & Repair . . . . . . . . . . . . 5-29 Installation . . . . . . . . . . . . . . . . . . . 5-29 Removal . . . . . . . . . . . . . . . . . . . . 5-28 Specifications . . . . . . . . . . . . . . . . . 5-3 V-Twin - Vanguard 16 Horsepower . . . . . . . . . . . . . . . . . . . . 4-3 18 Horsepower . . . . . . . . . . . . . . . . . . . . 4-3 Air Cleaner Service . . . . . . . . . . . . . . . 4-18 Breather Valve Service . . . . . . . . . . . . 4-44 Carburetor Assembly . . . . . . . . . . . . . . . . . . . . 4-24 Disassembly . . . . . . . . . . . . . . . . . 4-21 Inspection . . . . . . . . . . . . . . . . . . . 4-23 Removal and Installation . . . . . . . . 4-19 Connecting Rod Inspection . . . . . . . . . 4-35 Crankshaft Removal and Installation . . . . . . . . 4-40 Cylinder Air Guides . . . . . . . . . . . . . . . . . . . 4-28 Bore Honing . . . . . . . . . . . . . . . . . . 4-38 Bore Inspection . . . . . . . . . . . . . . . 4-37 Head Inspection and Repair . . . . . 4-31 Head Removal & Installation . . . . . 4-29 Engine Installation . . . . . . . . . . . . . . . . 4-27 Engine Removal . . . . . . . . . . . . . . . . . . 4-26 Flywheel Removal & Installation . . . . . 4-39 General Specifications . . . . . . . . . . . . . . 4-3 Intake Manifold . . . . . . . . . . . . . . . . . . . 4-28 Magneto Bearing Inspection . . . . . . . . 4-42 Oil Pump Removal & Installation . . . . . 4-45 Piston Inspection . . . . . . . . . . . . . . . . . . . 4-35 Removal and Installation . . . . . . . . 4-34 PTO Bearing Removal & Installation . . 4-44 Repair Specifications . . . . . . . . . . . . . . . 4-4 Specifications Connecting Rod and Crankshaft . . . 4-4 Cylinder Bore, Pistons and Rings . . 4-4 Valves . . . . . . . . . . . . . . . . . . . . . . . 4-4 Tests and Adjustments Choke Cable . . . . . . . . . . . . . . . . . 4-11 Compression . . . . . . . . . . . . . . . . . 4-12 Cylinder Balance . . . . . . . . . . . . . . 4-17 Fast Idle Adjustment . . . . . . . . . . . 4-16 Fuel Shut-off Solenoid . . . . . . . . . . 4-11

INDEX - 3

INDEX Governor . . . . . . . . . . . . . . . . . . . . 4-13 Oil Pressure Test . . . . . . . . . . . . . . 4-17 Slow Idle Adjustment . . . . . . . . . . . 4-14 Specifications . . . . . . . . . . . . . . . . . 4-4 Throttle Cable . . . . . . . . . . . . . . . . 4-11 Valve Clearance . . . . . . . . . . . . . . 4-16 Torque Specifications . . . . . . . . . . . . . . 4-5 Troubleshooting . . . . . . . . . . . . . . . . . . . 4-6 Upper Blower Housing . . . . . . . . . . . . . 4-18 Valves Inspection . . . . . . . . . . . . . . . . . . . 4-32 Installation . . . . . . . . . . . . . . . . . . . 4-33 Ream . . . . . . . . . . . . . . . . . . . . . . . 4-33 Removal . . . . . . . . . . . . . . . . . . . . 4-31 Engine Repair Specifications Briggs & Stratton (Single Cylinder) . . . . . . . . 3-5 Engine Serial Number Locations . . . . . . . . . . . 2-15

F Front Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . 13-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5 Front Wheels Bearing Repair . . . . . . . . . . . . . . . . . . . . . . 13-4 Removal and Installation . . . . . . . . . . . . . . 13-4 Fuel Tank and Dash Panel Removal and Installation . . . . . . . . . . . . . . 13-6

G Gage Wheel Adjustment . . . . . . . . . . . . . . . . . 12-15 Gasoline Specifications . . . . . . . . . . . . . . . . . . . . . . . 2-10 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Gear Transaxle Brake System Operation . . . . . . . . . . . . . . 8-12 Component Location . . . . . . . . . . . . . . . . . . 8-6 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . 8-29 Intermediate Shaft . . . . . . . . . . . . . . . . . . . 8-29 Serial Number Location . . . . . . . . . . . . . . . 2-15 Shift Linkage Removal & Installation . . . . . 8-22 Specifications Dimensions . . . . . . . . . . . . . . . . . . . . . . 8-3 Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Gear Ratios . . . . . . . . . . . . . . . . . . . . . . 8-4 Gear Teeth . . . . . . . . . . . . . . . . . . . . . . . 8-3 Ground Speeds . . . . . . . . . . . . . . . . . . . 8-4

INDEX - 4

Lubrication . . . . . . . . . . . . . . . . . . . . . . . 8-3 Rear Axle Loading . . . . . . . . . . . . . . . . . 8-3 Service Parts Kits . . . . . . . . . . . . . . . . . . 8-4 Torque Specifications . . . . . . . . . . . . . . . 8-4 Tests and Adjustments Brake Adjustment . . . . . . . . . . . . . . . . . 8-16 Brake Test . . . . . . . . . . . . . . . . . . . . . . 8-15 Clutch Actuating Spring . . . . . . . . . . . . 8-16 Clutch/Brake . . . . . . . . . . . . . . . . . . . . . 8-15 Shift Linkage Adjustment . . . . . . . . . . . 8-17 Traction Drive Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . 8-19 Installation . . . . . . . . . . . . . . . . . . . . . . 8-20 Removal . . . . . . . . . . . . . . . . . . . . . . . . 8-18 Traction Drive System Removal . . . . . . . . . 8-20 Transaxle Assembly . . . . . . . . . . . . . . . . . . . . . . . 8-30 Disassembly . . . . . . . . . . . . . . . . . . . . . 8-23 Removal and Installation . . . . . . . . . . . 8-23 Transaxle Operation Theory . . . . . . . . . . . . 8-11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 8-5 General Specifications Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Single Cylinder . . . . . . . . . . . . . . . . . Engine V-Twin . . . . . . . . . . . . . . . . . . . . . . . Fuel/Air System . . . . . . . . . . . . . . . . . . . . . . Gear Transaxle . . . . . . . . . . . . . . . . . . . . . . . Hydro Transaxle K51 . . . . . . . . . . . . . . . . . . Hydro Transaxle K55 . . . . . . . . . . . . . . . . . . Implement Lift . . . . . . . . . . . . . . . . . . . . . . . . Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . Mower Deck Drive Belt . . . . . . . . . . . . . . . . . PTO Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Traction Drive Belt . . . . . . . . . . . . . . . . . . . . Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4 2-5 2-4 2-3 2-3 2-4 2-5 2-5 2-5 2-7 2-7 2-6 2-6 2-6 2-6 2-4 2-6

H Hydrostatic Transmission - K51 Component Location . . . . . . . . . . . . . . .9-5, 9-6 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18 External Components Removal . . . . . . . . . 9-30 Free-Wheel System Operation . . . . . . . . . . 9-13 Specifications Brake Components Wear Tolerances . . 9-4 Brake Torque Rating . . . . . . . . . . . . . . . 9-3 2/29/00

INDEX Components Wear Tolerances . . . . . . . 9-4 Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Gear Ratios . . . . . . . . . . . . . . . . . . . . . . 9-3 Ground Speeds . . . . . . . . . . . . . . . . . . . 9-3 Lubrication . . . . . . . . . . . . . . . . . . . . . . . 9-3 Output Torque Rating . . . . . . . . . . . . . . 9-3 Rear Axle Loading . . . . . . . . . . . . . . . . . 9-3 Torque Specifications . . . . . . . . . . . . . . 9-4 Transaxle . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Tests and Adjustments Bellcrank Tension Adjustment . . . . . . . 9-24 Brake Spring Adjustment . . . . . . . . . . . 9-25 Drive Belt Adjustment . . . . . . . . . . . . . 9-22 Shift Linkage Adjustment . . . . . . . . . . . 9-23 Theory of Operation . . . . . . . . . . . . . . . . . . 9-10 Traction Drive Belt Installation . . . . . . . . . . . . . . . . . . . . . . 9-27 Removal . . . . . . . . . . . . . . . . . . . . . . . . 9-27 System Operation . . . . . . . . . . . . . . . . 9-10 Tension System . . . . . . . . . . . . . . . . . . 9-28 Traction Drive System . . . . . . . . . . . . . . . . 9-22 Transaxle Disassembly . . . . . . . . . . . . . . . 9-31 Transaxle Removal and Installation . . . . . . 9-29 Troubleshooting . . . . . . . . . . . . . . . . . . . . . 9-15 Hydrostatic Transmission - K55 Component Location Power Train Linkage . . . . . . . . . . . . . 10-32 Shift Linkage . . . . . . . . . . . . . . . . . . . . 10-9 Traction Drive . . . . . . . . . . . . . . . . . . . . 10-8 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 Specifications Brake Components Wear Tolerances . 10-4 Brake Torque Rating . . . . . . . . . . . . . . 10-3 Components Wear Tolerances . . . . . . 10-4 Drive Belt . . . . . . . . . . . . . . . . . . . . . . . 10-3 Gear Ratios . . . . . . . . . . . . . . . . . . . . . 10-3 Gear Teeth . . . . . . . . . . . . . . . . . . . . . . 10-3 Ground Speeds . . . . . . . . . . . . . . . . . . 10-3 Lubrication . . . . . . . . . . . . . . . . . . . . . . 10-3 Output Torque Rating . . . . . . . . . . . . . 10-3 Rear Axle Loading . . . . . . . . . . . . . . . . 10-4 Torque Specifications . . . . . . . . . . . . . 10-4 Transaxle . . . . . . . . . . . . . . . . . . . . . . . 10-3 Tests and Adjustments Brake Spring Adjustment . . . . . . . . . . 10-27 Drive Belt Adjustment . . . . . . . . . . . . 10-24 Shift Linkage Adjustment . . . . . . . . . . 10-25 Transport (Free-Wheel) Valve Adjustment . 10-25

2/29/00

Theory of Operation . . . . . . . . . . . . . . . . . Traction Drive Belt Belt Inspection . . . . . . . . . . . . . . . . . . Belt Installation . . . . . . . . . . . . . . . . . . Belt Removal . . . . . . . . . . . . . . . . . . . Tensioning System . . . . . . . . . . . . . . . Traction Drive System . . . . . . . . . . . . . . . Transaxle Assembly . . . . . . . . . . . . . . . . . Transaxle Bleed Procedure . . . . . . . . . . . Transaxle Disassembly . . . . . . . . . . . . . . Transaxle Installation . . . . . . . . . . . . . . . . Transaxle Removal and Installation . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . .

10-10 10-30 10-30 10-29 10-31 10-24 10-42 10-48 10-34 10-48 10-33 10-16

Hydrostatic Transmission Serial Number Location 2-15

L Lift Linkage Components . . . . . . . . . . . . . . . . . 12-3 Lubricants Alternative Lubricants . . . . . . . . . . . . . . . . . Anti-Corrosion Grease . . . . . . . . . . . . . . . . Engine Break-In Oil . . . . . . . . . . . . . . . . . . Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . Grease Chassis . . . . . . . . . . . . . . . . . . . . . . . . Gear Transmission . . . . . . . . . . . . . . . . Mixing of Lubricants . . . . . . . . . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . Synthetic Lubricants . . . . . . . . . . . . . . . . . .

2-13 2-12 2-11 2-11 2-13 2-14 2-13 2-13 2-13

M Mower Deck Adjusting Deck Suspension Cut Height . . 12-10 Belt Replacement . . . . . . . . . . . . . . . . . . . 12-11 Belt Tension Adjustment . . . . . . . . . . . . . . . 12-7 Installation . . . . . . . . . . . . . . . . . . . . . . . . 12-12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10 Spindle Assembly . . . . . . . . . . . . . . . . . . . 12-14 Spindle Brake Adjustment . . . . . . . . . . . . . 12-7 Mower Deck Leveling Front-to-Rear . . . . . . . . . . . . . . . . . . . . . . . 12-9 Side-to-Side . . . . . . . . . . . . . . . . . . . . . . . . 12-8

R Rear Wheels Removal and Installation . . . . . . . . . . . . . . 13-4

INDEX - 5

INDEX

S Safety Around High-Pressure Fluid Lines . . . . . . . . Avoid Injury From Augers and PTO Shafts . . . . . . . . . . . . . Rotating Blades . . . . . . . . . . . . . . . . . . . Handle Fluids Safely - Avoid Fires . . . . . . . . Handling and Servicing Batteries . . . . . . . . . Recognize Safety Information . . . . . . . . . . . Safe Service Procedures . . . . . . . . . . . . . . . Service Tires Safely . . . . . . . . . . . . . . . . . . .

1-3 1-6 1-6 1-2 1-3 1-2 1-4 1-5

Serial Number Locations . . . . . . . . . . . . . . . . . . 2-15 Spindle Brake Adjustment . . . . . . . . . . . . . . . . . 12-7 Steering Backlash Adjustment . . . . . . . . . . . . . . . . . Component Location . . . . . . . . . . . . .11-3, Gear Removal and Installation . . . . . . . . . . Pedestal Bushing Replacement . . . . . . . . .

11-6 11-6 11-4 11-6

T Torque Values Inch Torques Values . . . . . . . . . . . . . . . . . . . 2-8 Metric Torque Values . . . . . . . . . . . . . . . . . . 2-9 Tractor Identification Numbers . . . . . . . . . . . . . 2-15 Troubleshooting Electrical Pre 1999 . . . . . . . . . . . . . . . . . . . 6-12 Electrical w/Reverse Implement Option . . . 7-12 Engine V-Twin - Intek . . . . . . . . . . . . . . . . . . . . . 5-6 V-Twin - Vanguard . . . . . . . . . . . . . . . . . 4-6 Gear Transaxle . . . . . . . . . . . . . . . . . . . . . . . 8-5 Hydrostatic Transmission - K51 . . . . . . . . . 9-15 Hydrostatic Transmission - K55 . . . . . . . . 10-16

INDEX - 6

2/29/00