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200 South Ridge Road Hesston, Kansas 67062 Hustler ® Super Z HyperDrive Parts Manual

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200 South Ridge RoadHesston, Kansas

67062

Hustler® Super Z HyperDriveParts Manual

Inspect spark arrester daily; replace every 500 hours or as needed.

The Engine Owner’s Manual provides information regarding the U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty.Keep Engine Owner’s Manual with your unit. Should the Engine Owner’s Manual become damaged or illegi-ble, replace immediately. Replacements may be ordered per the information found in the Product Informa-tion section of the owner’s manual.Federal law and California State law prohibit the following acts or the causing thereof:

1. The removal or rendering inoperative by any person other than for purposes of maintenance, repair, replacement, of any device or element of design incorporated into any equipment for the purposes of emissions control prior to or after its sales or delivery to the ultimate purchaser or while it is in use, or

2. The use of the equipment after such device or element of design has been removed or rendered inoperative by any person.

WARNING

The engine exhaust from this product contains chemicals known to the state

of California to cause cancer, birth defects or other reproductive harm.

NOTICE OF REQUIREMENT OF SPARK ARRESTER MUFFLER

This equipment may create sparks that can start fires around dry vegetation. California Public Resources Code Section 4442.6 provides that it is unlawful to use or operate an internal combustion engine on any forest-covered, brush-covered, or grass-covered land unless the engine is equipped with a spark arrester maintained in effective working order. A spark arrester is a device constructed of nonflammable materials specifically for the purpose of removing and retaining carbon and other flammable particles over 0.0232 of an inch in size from the exhaust flow of an internal combustion engine that uses hydrocarbon fuels or which is qualified and rated by the United States Forest Service. Other states or federal areas may have similar laws. The Operator Should Contact Local Fire Agencies For Laws or Regulations Relating to Fire Prevention Requirements. THIS EQUIPMENT DOES NOT HAVE A SPARK ARRESTER AND YOU SHOULD CONTACT YOUR AUTHORIZED DEALER FOR THE PURCHASE OF A SPARK ARRESTER.

117589_0416 c-1

Table of Contents

General InformationService Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Options Available From Your Dealer. . . . . . . . . . . . . . . . . . . . . . . . 1-1Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Hardware Description Codes & Abbreviations . . . . . . . . . . . . . . . . 1-2Standard Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Section 2Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Engine Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Engine Guard—Kawasaki DFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6Decals—Models ending in “US” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Section 3Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Hydraulic Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Hydraulic Motor Service Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Oil Cooler Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Pump Drive—Kawasaki . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Pump Drive—Vanguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12Steering—S/N 13034312 & Higher . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14Steering Assembly—S/N 13034312 & Higher. . . . . . . . . . . . . . . . . . . . 3-16Steering Cover Assembly—S/N 13034312 & Higher . . . . . . . . . . . . . . 3-18Steering—S/N Prior to 13034312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22LS Steering Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26RS Steering Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Section 4Wheel & Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Drive Wheel Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Section 5Engine, Kawasaki FX850V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Engine Service Parts, Kawasaki FX850V . . . . . . . . . . . . . . . . . . . . . . . . 5-5Engine, Kawasaki FX1000V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7Engine Service Parts, Kawasaki FX1000V . . . . . . . . . . . . . . . . . . . . . . . 5-9Engine, Kawasaki FX1000V DFI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11Engine Service Parts—Kawasaki FX1000V DFI. . . . . . . . . . . . . . . . . . 5-13Fuel System, Kawasaki/Vanguard—W/O Carbon Canister . . . . . . . . . 5-15Fuel System, Kawasaki—DFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18Engine, Vanguard—With Carbon Canister . . . . . . . . . . . . . . . . . . . . . . 5-20Engine, Vanguard—Without Carbon Canister . . . . . . . . . . . . . . . . . . . 5-22Engine Service Parts, Vanguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24Fuel System, Vanguard—With Carbon Canister. . . . . . . . . . . . . . . . . . 5-26Fuel Tank Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

c-2 117589_0416

Section 6Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Section 760" Side Discharge Service Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-260" Side Discharge Deck Pulleys & Spindles. . . . . . . . . . . . . . . . . . . . . 7-460" Side Discharge Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-666" Side Discharge Service Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-866" Side Discharge Deck Pulleys & Spindles. . . . . . . . . . . . . . . . . . . . 7-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1266" Side Discharge Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1372" Side Discharge Service Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1572" Side Discharge Deck Pulleys & Spindles. . . . . . . . . . . . . . . . . . . . 7-1772" Side Discharge Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19Side Discharge Deck Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21Side Discharge Deck Mounting Hardware . . . . . . . . . . . . . . . . . . . . . . 7-2360" Rear Discharge Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2560" Rear Discharge Deck Pulleys & Spindles . . . . . . . . . . . . . . . . . . . 7-2760" Rear Discharge Dust Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3160" Rear Discharge Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33Rear Discharge Deck Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37Rear Discharge Deck Mounting Hardware . . . . . . . . . . . . . . . . . . . . . . 7-39

Section 8Seat, Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2Seat Service Parts, Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4Seat, Grammer—S/N 15100849 & Higher . . . . . . . . . . . . . . . . . . . . . . . 8-6Seat, Grammer—S/N Prior to 15100849 . . . . . . . . . . . . . . . . . . . . . . . . 8-8Seat Service Parts, Grammer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10ROPS—S/N 15010001 & Higher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12ROPS—S/N Prior to 15010001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

117589_0416 1-1

General Information

This manual covers Hustler® Super Z HyperDrive models 932145, 932152, 932160, 932178, 932186, 932384US, 932392US, 932996, 933002, 934307, 934315, 934323, 934331, 934349, 934356, 934687, 934695, 934703 & 934711.

Service Literature

PART NO.OPERATOR’S MANUAL (S/N 15010001 & HIGHER)OPERATOR’S MANUAL (S/N PRIOR TO 15010001)WARRANTY STATEMENTGENERAL SERVICE MANUAL

Options Available From Your Dealer

PART NO.60" ADAPTER KIT 60" SAND KIT72" ADAPTER KIT 72" SAND KITBAC-VAC CATCHER 60" MULCH KIT3 BAG CATCHER 72" MULCH KITFLEX FORK KIT ROLLER KIT (60" DECKS)HYDRO DECK LIFT KIT ROLLER KIT (72" DECKS)LIGHT KIT DUAL REAR ANTI-SCALP KIT (60" DECKS)SEMI-PNEUMATIC TIRE/WHEEL SINGLE REAR ANTI-SCALP KITSTEERING EXTENSION KIT DUAL REAR ANTI-SCALP KIT (72" DECKS)VX4 DECK HIGH VACUUM KIT 60"VX4 DECK HIGH VACUUM KIT 72"

Note: When ordering parts, you must use the part number as shown for each part, not the index number. Always give the model and serial number to your parts and service representative.

Note: Items sold in bulk such as seals and hoses are sold by the foot.

Using This Manual

This manual is part of a service package for the Hustler® mowers. Use of this manual in conjunction with other Hustler® mower and component manuals will provide the information necessary to service and maintain Hustler® mowers.

This Parts Manual provides a complete parts listing for the unit. Use this manual when ordering parts. Illustrations used were current at the time of printing, but subsequent production changes may cause your machine to vary slightly in detail. Excel Industries, Inc. reserves the right to redesign and change the machine as deemed necessary, without noti-fication. If a change has been made to your machine which is not reflected in this parts manual, see your authorized dealer for current information and parts.

The Service Manual is a service guide for use by Service Technicians. It provides the necessary information needed to perform normal maintenance requirements on these units.

The Operator's Manual provides fundamental operational information and operational safety that is needed when oper-ating the mower.

The component manuals are furnished by the various manufacturers to be used for the troubleshooting and servicing of their products.

DESCRIPTION605784604460117590117592

DESCRIPTION PART NO. DESCRIPTION113903 113679113905 113909932103 113722932467 113724603167 116840113932 116842117147 113911789537 113910353961 113937116305116307

1-2 117589_0416

Hardware Description Codes & Abbreviations

The following codes are used throughout this parts manual. Refer to this list when ordering parts.

ABBREVIATIONCARRIAGE BOLT MACHINE BUSHINGCLEVIS PIN MACHINE SCREWCLIP NUT NUTCOTTER PIN SELF TAPPING CAP SCREWCAP SCREW SOCKET HEADCUP WASHER SHOULDER BOLTFENDER WASHER SET SCREWFLAT WASHER OUTSIDE DIAMETERHEX HEAD INSIDE DIAMETERLOCK WASHER WELD NUT

Standard Torques

The following chart lists the standard torque values for the threaded fasteners found in this manual. Torque all cap screws, nuts and set screws to these values unless a different torque is shown in the Notes section next to the fastener.

SIZE FT-LBS N•M SIZE FT-LBS N•M

DESCRIPTION ABBREVIATION DESCRIPTIONCB MBCE MSCN NTCP SCCS SHCW SB

FDRW SSFW ODHX IDLW WN

.250 8.2 11.1 M3 1 1.3

.312 17 23 M4 2.2 3

.375 30 40 M5 4.5 6.1

.438 48 65 M6 7.7 10.4

.500 73 99 M8 18.5 25

.562 105 143 M10 37 50

.625 145 200 M12 64 87

.750 260 350 M14 80 108.5

.875 420 565 M16 160 2151.00 625 850 M20 320 435

M24 555 750

117589_0416 2-1

Section 2

Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Engine Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Engine Guard—Kawasaki DFI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Decals—Models ending in “US”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-2 117589_0416

Frame

1

3

4

5

6

6

6

7

7

89

5

5

1

8

2

10

2

3

117589_0416 2-3

Frame

INDEX NO. PART NO. QTY.

54" SD FRAME (WITH DECALS, RIVET NUTS, BUMPERS & GREASE FITTINGS)60" SD FRAME (WITH DECALS, RIVET NUTS, BUMPERS & GREASE FITTINGS)72" SD FRAME (WITH DECALS, RIVET NUTS, BUMPERS & GREASE FITTINGS)60" RD FRAME (WITH DECALS, RIVET NUTS, BUMPERS & GREASE FITTINGS)72" RD FRAME (WITH DECALS, RIVET NUTS, BUMPERS & GREASE FITTINGS)BUMPERDECK HEIGHT DECALSAFE OPERATION DECALSERIAL NUMBER / SPEC DECAL3/8-16 THREAD RIVET NUT1/2-13 THREAD RIVET NUTHOT DECALHUSTLER ID DECALGREASE FITTING STRAIGHT

NOTES:

1. Serial number decal. In the event the serial number decal becomes damaged or illegible, please contact your dealer to order a replacement.

2. EPA compliance decal.3. Patent numbers decal.

DESCRIPTION

1 553135 1

551763 1

551765 1

551766 1

551767 1

2 781880 43 781427 14 601993 15 N/A 36 808493 47 600961 48 602041 29 602407 110 015495 4

2-4 117589_0416

Engine Guard

5

1

1

6

43

8

92

1

7

7

2

10

S/N PRIOR TO 15010001

117589_0416 2-5

Engine Guard

INDEX NO. PART NO. QTY.

ENGINE GUARDCB .375-16 X 1.00 G5 ZNYCS .500-13 X 1.25 HX G5FW .531 X 1.063 X .175MUFFLER SHIELD (S/N 15010001 & HIGHER)HITCH PLATE (S/N 15010001 & HIGHER)NT .375-16 HX FLK G5SHIELDH LOGO DECALHITCH (S/N PRIOR TO 15010001)

NOTES:

1. See the Wheel & Tire section.

DESCRIPTION

1 118933 12 025395 43 705954 44 767962 45 121374 16 121375 17 016899 48 377994 29 604352 1

10 115905 1

2-6 117589_0416

Engine Guard—Kawasaki DFI

5

1

1

2

43

6

7

8

2

9

10

S/N PRIOR TO 15010001

1

117589_0416 2-7

Engine Guard—Kawasaki DFI

INDEX NO. PART NO. QTY.

ENGINE GUARDCB .375-16 X 1.00 G5 ZNYCS .500-13 X 1.25 HX G5FW .531 X 1.063 X .175MUFFLER SHIELD (S/N 15010001 & HIGHER)NT .375-16 HX FLK G5SHIELDH LOGO DECALHITCH PLATE (S/N 15010001 & HIGHER)HITCH (S/N PRIOR TO 15010001)

NOTES:

1. See the Wheel & Tire section.

DESCRIPTION

1 552775 12 025395 43 705954 44 767962 45 121374 16 016899 47 377994 28 604352 19 121375 110 115905 1

2-8 117589_0416

Decals—Models ending in “US”

2

1

INDEX NO. PART NO. QTY.

ANSI COMPLIANCE DECALSPARK ARRESTER DECAL

NOTES:

DESCRIPTION

1 603363 12 601908 1

117589_0416 3-1

Section 3

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Hydraulic Motor Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Oil Cooler Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Pump Drive—Kawasaki . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Pump Drive—Vanguard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Steering—S/N 13034312 & Higher . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Steering Assembly—S/N 13034312 & Higher . . . . . . . . . . . . . . . . . 3-16

Steering Cover Assembly—S/N 13034312 & Higher. . . . . . . . . . . . 3-18

Steering—S/N Prior to 13034312 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

LS Steering Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

RS Steering Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3-2 117589_0416

Hydraulic System2

3 1

1343

5

18

3028

29323

22

4

233

31

3231

23

329

30

28

24

25

27

16

17

19

20

26

26

24

12

14

15

8

9

7

10

11

6

12

14

9

15

7 6

8

12

10

15

15

HYDRAULICRESERVOIR

21

29

117589_0416 3-3

Hydraulic System

INDEX NO. PART NO. QTY.

HYDRAULIC OIL COOLERCS .375-16 X .625 HX G5FW .379 X .813 X .063CS .375-16 X 1.00 HX G5VIBRATION MOUNTCS M8-1.25 X 10 G10.9 SHBHFW .344 X 1.00 X .06 ZNYCNT .250-20 HX ZY NLPUMP ARMFW .281 X .625 X .066CS .250-20 X 1.50 HX G5FTG, -10MORB/-12BT 45°LS PUMPSEAL KITFTG, -8MORB/-8BT STRFTG, -10MORB/-10MORFS 90°TUBE, LP-BM LH LOOPTUBE, RP-TM LH LOOPRS PUMPSEAL KITTUBE, RP-TM RH LOOPTUBE, LP-BM RH LOOPNT .500-13 HX G5 ZNYCLOOP CLAMPNT .375-16 HX G5 ZNYFTG, -6MORB/-6MJIC STRRS CASE DRAIN HOSESPRING CLAMPLS CASE DRAIN HOSEWHEEL MOTORFW .531 X 1.063 X .175NT .500-13 UNT LK G8 ZNCS .500-13 X 2.50 SQ G5CB .500-13 X 1.50 FULL

NOTES:

DESCRIPTION

1 602709 12 056069 13 767954 104 036244 45 601571 16 603272 27 079210 28 068551 29 602732 2

10 768515 211 008581 212 774968 213 602556 1

603362 114 601523 215 602443 816 602873 117 602874 118 602964 1

603362 119 602876 120 602875 121 008193 422 043570 223 054502 524 779132 225 603044 126 601617 227 603043 128 602714 229 767962 1230 023317 831 602256 832 028274 4

3-4 117589_0416

Hydraulic Reservoir

1

23

2

35

4

47

9

10

1416

18

19

17

12

13

13

11

12

6

8

22

214

5

2018

4

15

24

24

26

27

25

25

TO LS WHEEL

TO RS WHEELMOTOR

MOTOR

117589_0416 3-5

Hydraulic Reservoir

INDEX NO. PART NO. QTY.

BREATHER CAPSTRAINERHYDRAULIC RESERVOIRHOSE CLAMPPUMP SUCTION HOSEHOSE, TO COOLERFITTING, -12MORB/-12MJIC 90°HOSE, FROM COOLERFITTING, -12MORB/-12MORB STRCHECK VALVEFITTING, -8MORB HEX PLUGFITTING, -8MORB/-8MJIC, 90°HOSE, PUMP CASE DRAINCASE DRAIN MANIFOLDSPRING CLAMPSUPPORT BRACKETCS .312-18 X .75 HX G5FW .343 X .687 X .051/.080HCS .312-18 X .50 HX G8NT .312-18 HX G5FITTING, -8MORB HEX PLUGHYDRAULIC FILTERFITTING, -8MORB/-6BT 90°SPRING CLAMPFITTING, -6MORB/-6MJIC STRLS CASE DRAIN HOSERS CASE DRAIN HOSE

NOTES:

DESCRIPTION

1 032763 12 032771 13 602767 14 700484 65 603045 26 603046 17 603189 28 603047 19 603039 110 603053 111 603123 112 771311 213 603042 214 603000 115 601001 216 113623 117 034280 118 768523 319 068346 120 034272 121 781658 122 602768X 123 603190 224 601617 225 779132 226 603043 127 603044 1

3-6 117589_0416

Hydraulic Motor Service Parts

2

1

INDEX NO. PART NO. QTY.

WOODRUFF KEYCASTLE NUTSEAL KIT (NOT SHOWN)

NOTES:

DESCRIPTION

1 064337 12 065516 13 748806 1

117589_0416 3-7

This page intentionally left blank.

3-8 117589_0416

Oil Cooler Mount1

2

3

4

5

78

15

18

17

20

19

23

21

87

87

2

6

19

2526

2425

2728

16

22

9

11

11

11

10

8 78

7

12

13

7

8

14

19A

FRONT OFMOWER

FRONT OFMOWER

117589_0416 3-9

Oil Cooler Mount

INDEX NO. PART NO. QTY.

AIR SCOOPLATCHCS .250-20 X 4.50 HX G5FAN 9"OIL COOLER COVERCOOLER MOUNT FIREWALLFW .343 X .687 X .051/.080HNT .312-18 HX G5HYPERDRIVE DECALGM 1.12 X 1.75 X 1.37 X .12CB .312-18 X .75 FUL ZNRS COOLER MOUNTLS COOLER MOUNTCS .250-20 X 4.00 HX G5UPPER COOLER MOUNTWEATHERSTRIPFRONT SCREEN MOUNT BRACKETREAR SCREEN MOUNT BRACKETNT .250-20 HX ZY NLSCREEN1/4-20 THREAD RIVET NUTFW .281 X .625 X .066CS .250-20 X .75 HX G5NT .375-16 HX G5 ZNYFW .379 X .813 X .063CS .375-16 X 1.00 HX G5WIRE TIEWIRE TIE

NOTES:

DESCRIPTION

1 114038 12 791384 13 603229 44 603066 15 117407 16 114040 17 768523 168 034272 169 603290 2

10 706531 211 016253 1612 117408 113 117409 114 603228 215 114039 116 033035 15.5"17 114141 118 114142 119 068551 620 114165 121 808477 122 768515 123 055939 124 054502 425 767954 826 036244 427 000331 128 000430 2

WEATHERSTRIP LENGTH

7.75"A

3-10 117589_0416

Pump Drive—Kawasaki

1

2

1

4

6

19

20

2122

14

25

23

1817

103

24

28

22

17

10 15

5

7

12

11

13

8

9

11

16

26

1514

27

3

117589_0416 3-11

Pump Drive—Kawasaki

INDEX NO. PART NO. QTY.

CS .500-13 X 5.00 HX G5FW .510 X 2.15 X .187 SPLKEY 1/4 SQ X 1.50 LGPULLEY 7.0 OD X 1.125 SHFTCLUTCH HARNESS PIGTAILCLUTCH KITFW .453 X 1.12 X .119 HRDCS .437-20 X 3.00 HX G5 P85NT .312-18 HX G5FW .343 X .687 X .051/.080HKEY 1/4 SQ X 1.12 LONGCS .312-18 X 1.00 HX G5CLUTCH ANCHORNT .375-16 HX G5 ZNYFW .379 X .813 X .063PULLEY 7.35 OP X 0.875 SHFTSS .312-18 X .75 SQ-HDCS .625-11 X 1.75 HX G5IDLER PIVOT BUSHINGTENSIONERIDLER PIVOT BUSHINGFW .531 X 1.063 X .175NT .500-13 HX G8 ZY NLGREASE FITTING STRAIGHTIDLER SPRINGEB, .375-16 X 3.00 FULL THD6" IDLER PULLEYBELT, 64.89" B B-SECTION

NOTES:

1. Torque to 45–48 ft-lbs. Replace (do not re-use) the fastener if it’s loosened or removed. Use only hand tools to install this fastener.

2. Torque to 12–15 ft-lbs.3. Torque to 71–75 ft-lbs. The tensioner should pivot freely.

DESCRIPTION

1 051151 12 344267 13 212076 14 602755 15 791251 16 601278K 17 602680 18 785048 19 034272 2

10 768523 411 210146 212 036236 213 113347 114 054502 215 767954 216 602754 217 083196 418 025007 119 602880 120 115536 121 602879 122 767962 123 781567 124 015495 125 601016 126 601486 127 603783 128 604208 1

3-12 117589_0416

Pump Drive—Vanguard

1

2

1

4

6

19

20

21

22

14

25

23

18

10

3

24

28

217

10

15

5

7

12

13

8

9

11

16

26

1514

27

3

117589_0416 3-13

Pump Drive—Vanguard

INDEX NO. PART NO. QTY.

CS .500-13 X 5.00 HX G5FW .510 X 2.15 X .187 SPLKEY 1/4 SQ X 1.50 LGPULLEY 7.0 OD X 1.125 SHFTCLUTCH HARNESS PIGTAILCLUTCH KITFW .453 X 1.12 X .119 HRDCS .437-20 X 3.00 HX G5 P85NT .312-18 HX G5FW .343 X .687 X .051/.080HKEY 1/4 SQ X 1.12 LONGCS .312-18 X 1.00 HX G5CLUTCH ANCHORNT .375-16 HX G5 ZNYFW .379 X .813 X .063PULLEY 7.35 OP X 0.875 SHFTSS .312-18 X .75 SQ-HDCS .625-11 X 1.75 HX G5IDLER PIVOT BUSHINGTENSIONERIDLER PIVOT BUSHINGFW .531 X 1.063 X .175NT .500-13 HX G8 ZY NLGREASE FITTING STRAIGHTIDLER SPRINGEB, .375-16 X 3.00 FULL THD6" IDLER PULLEYBELT, 64.89" B B-SECTION

NOTES:

1. Torque to 45–48 ft-lbs. Replace (do not re-use) the fastener if it’s loosened or removed. Use only hand tools to install this fastener.

2. Torque to 12–15 ft-lbs.3. Torque to 71–75 ft-lbs. The tensioner should pivot freely.

DESCRIPTION

1 051151 12 344267 13 212076 14 602755 15 791251 16 601278K 17 602680 18 785048 19 034272 2

10 768523 411 210146 212 036236 213 113347 114 054502 215 767954 216 602754 217 083196 418 025007 119 602880 120 115536 121 602879 122 767962 123 781567 124 015495 125 601016 126 601486 127 603783 128 604208 1

3-14 117589_0416

Steering—S/N 13034312 & Higher

1

54

56

9

10

7

11

58

58

56

13

11

14

PUMPSUB-ASSEMBLY

2

3

1215

9

117589_0416 3-15

Steering—S/N 13034312 & Higher

INDEX NO. PART NO. QTY.

STEERING COVER ASSEMBLYSUPER Z HD DECALHANDLE (WITH GRIP)GRIPCS .375-16 X 1.00 HX G5FW .379 X .813 X .063CS .375-16 X .75 HX G5SWITCHNT .375-16 HX G5 ZNYSTEERING DAMPERBALL STUDFW .343 X .687 X .051/.080HLW .325 INT-EXT TOOTHNT .312-18 HX FLK ZNYCNT .312-24 HX NL G5CAP LOCK

NOTES:

DESCRIPTION

1 N/A 12 605671 13 109839 2

781260 24 036244 45 767954 166 055822 67 601087 28 054502 69 603192 2

10 781922 211 768523 612 029876 213 016832 214 023655 215 601426 1

3-16 117589_0416

Steering Assembly—S/N 13034312 & Higher

3

3

5

64

1

7

7

5

4

2

64

4

8

117589_0416 3-17

Steering Assembly—S/N 13034312 & Higher

INDEX NO. PART NO. QTY.

RS STEERING BOX ASSEMBLYLS STEERING BOX ASSEMBLYNT .312-24 HX NL G5FW .343 X .687 X .051/.080HNT .312-18 HX G5BALL STUDFW .344 X 1.00 X .12 HRD ZPUMP ROD ADJUSTER

NOTES:

DESCRIPTION

1 604295 12 604296 13 023655 24 768523 65 034272 26 781922 27 712927 28 781286 2

3-18 117589_0416

Steering Cover Assembly—S/N 13034312 & Higher

11

11

13

12

10

9

14

12

117589_0416 3-19

Steering Cover Assembly—S/N 13034312 & Higher

INDEX NO. PART NO. QTY.

STEERING COVER (WITH DECAL)BUSHINGFW .750 X 1.50 X .156 ZNLOCK COLLAR .757 IDSTEER PIVOT TUBEGM .50 X 1.00 X .75 X .12

NOTES:

DESCRIPTION

9 550818 110 781153 211 603078 212 784439 213 113007 114 080358 1

3-20 117589_0416

Steering Cover Assembly—S/N 13034312 & Higher

15

16

15

16

17A

17

117589_0416 3-21

Steering Cover Assembly—S/N 13034312 & Higher

INDEX NO. PART NO. QTY.

NT .500-13 HX JAM ZNYCSS .500-13 X 2.00 SHWEAR TAPE

NOTES:

DESCRIPTION

15 053199 216 797738 217 722199 11"

WEAR TAPE LENGTH

5.5" ± 0.3"A

3-22 117589_0416

Steering—S/N Prior to 13034312

12 3

45

6

8

7

10

21

19

13

14

54

6

5

5

11

1

1216

11

15

20

17

18

1718

19

LS PUMP ARM

13

14

20

21

15

16

9

RIGHT SIDE SHOWNLEFT SIDE SIMILAR

117589_0416 3-23

Steering—S/N Prior to 13034312

INDEX NO. PART NO. QTY.

STEERING COVER (WITH DECALS)NT .500-13 HX JAM ZNYCSS 1/2-13 X 2.50 SH ZNYCCS .375-16 X .75 HX G5FW .379 X .813 X .063NT .375-16 HX G5 ZNYCS .375-16 X 1.00 HX G5STEERING BAR GRIPHANDLE (WITH GRIP)STEERING ARMWEAR TAPESUPER Z HD DECALCS .250-20 X 1.50 HX G5FW .281 X .625 X .066FW .343 X .687 X .051/.080HNT .312-24 HX NL G5CS M8-1.25 X 10 G10.9 SHBHFW .344 X 1.00 X .06 ZNYCPUMP ARMNT .250-20 HX ZY NLPUMP ROD ADJUSTER

NOTES:

DESCRIPTION

1 550818 12 053199 23 603055 24 055822 65 767954 286 054502 67 036244 48 781260 29 109839 2

10 113575 211 722199 11"12 604557 113 008581 214 768515 215 768523 1216 023655 417 603272 218 079210 219 602732 220 068551 221 781286 2

3-24 117589_0416

Steering—S/N Prior to 13034312

10

5

23

16

22

5

15

26

15

37

21

15

38

27

24

33

29

29

30

36

28

5

39

26

26

26

25

2334

32

31

26

27

22

35

RIGHT SIDE SHOWNLEFT SIDE SIMILAR

40

32

117589_0416 3-25

Steering—S/N Prior to 13034312

INDEX NO. PART NO. QTY.

NT .375-16 HX G5 ZY NLCS .375-16 X 1.75 HX G5RS STEERING BOXFW .750 X 1.50 X .156 ZNBUSHINGBALL STUDSTEER PIVOT TUBELOCK COLLAR, 0.757 IDLS STEERING BOXNT .312-18 HX G5DAMPERSWITCHFW .344 X 1.00 X.12 HRD ZSTEERLEVER BUSHINGSS .500-13 X 2.00 SH ZYLW .325 INT-EXT TOOTHNT .312-18 HX FLK ZNYCGM .750 X .188 X 1.00 X .12CAP LOCK

NOTES:

DESCRIPTION

22 086660 623 705178 624 112898 125 603078 226 781153 627 781922 428 113007 129 784439 230 112899 131 034272 232 603192 233 601087 234 712927 235 348862 436 797738 237 029876 238 016832 239 047456 240 601426 1

3-26 117589_0416

LS Steering Box Assembly

1

3

43

2

6

6

9

8

5

4

3

2

7

3

7

117589_0416 3-27

LS Steering Box Assembly

INDEX NO. PART NO. QTY.

STEERING ARMNT .375-16 HX G5 ZY NLFW .379 X .813 X .063CS .375-16 X 1.75 HX G5LS STEERING BOXBUSHINGSTEERLEVER BUSHINGGM .750 X .188 X 1.00 X .12SS .500-13 X 2.00 SH ZY

NOTES:

DESCRIPTION

1 113575 12 086660 33 767954 64 705178 35 112899 16 781153 27 348862 28 047456 19 797738 1

3-28 117589_0416

RS Steering Box Assembly

1

3

43

2

6

6

9

8

5

4

3

2

7

3

7

117589_0416 3-29

RS Steering Box Assembly

INDEX NO. PART NO. QTY.

STEERING ARMNT .375-16 HX G5 ZY NLFW .379 X .813 X .063CS .375-16 X 1.75 HX G5RS STEERING BOXBUSHINGSTEERLEVER BUSHINGGM .750 X .188 X 1.00 X .12SS .500-13 X 2.00 SH ZY

NOTES:

DESCRIPTION

1 113575 12 086660 33 767954 64 705178 35 112898 16 781153 27 348862 28 047456 19 797738 1

3-30 117589_0416

Brake

1

2

3

53

4

4

8

6

2

10

7 8

2

119

12

4

13

2

1014

15

16

17

12

3

18

16

LEFT SIDE SHOWNRIGHT SIDE SIMILAR

117589_0416 3-31

Brake

INDEX NO. PART NO. QTY.

NT .375-16 HX G5 ZY NLFW .379 X .813 X .063NT .312-24 HX NL G5FW .343 X .687 X .051/.080HBRAKE ROD ASSEMBLYLS BRAKE BELLCRANKRS BRAKE BELLCRANK (NOT SHOWN)BUSHINGNT .375-16 HX G5 ZNYBRAKE LINK TURNBUCKLECS .375-16 X 1.375 HX G5CS .375-16 X 4.50 HX G5NT .312-18 HX G5BRAKE ARMCB .312-18 X 1.00 FULL ZNCS .312-18 X .75 HX G8 FLKHUB ASSEMBLY (WITH STUDS)BRAKE ASSEMBLYWHEEL STUD LUG 1/2-20

NOTES:

1. Included with the wheel motor.2. Torque to 220–240 ft-lbs.3. Torque to 27 ft-lbs.

DESCRIPTION

1 086660 22 767954 123 023655 44 768523 125 781583 26 112907 1

112906 17 765339 48 054502 49 350397 2

10 005116 411 052514 212 034272 413 111309 214 037887 415 604461 816 602384 217 602383 218 601085 5

3-32 117589_0416

117589_0416 4-1

Section 4

Wheel & Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Front Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Drive Wheel Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-2 117589_0416

Wheel & Tire

1 11

10

1

2

34

5

6

5

7

8

1213

14

1513

16

13

15

1413

12

117589_0416 4-3

Wheel & Tire

INDEX NO. PART NO. QTY.

CS .500-13 X 1.25 HX G5 ZNFW .515 X 1.65 X .125 HD ZYO-RING, SAE-14DUST CAPBEARINGSPACER 1.07 X 1.312 X 2.79DISC BEARINGFRONT WHEEL ASSEMBLYTIRE/WHEEL ASSEMBLY 26 X 12 X 12 (60" MOWER)TIRE/WHEEL ASSEMBLY 26 X 12 X 12 (72" MOWER)WHEEL NUTCS .500-13 X 4.50 HX G5FW .531 X 1.063 X .175SPACER 3.22 PLASTIC WHEELNT .500-13 HX G5 ZNYC

NOTES:

1. Torque to 65–75 ft-lbs.

DESCRIPTION

1 705954 22 798603 23 601375 24 603153 25 784223 46 387035 27 603164 28 N/A 2

10 604451 2604455 2

11 061077 1012 068239 213 767962 414 602345 215 602263 216 008193 2

4-4 117589_0416

Front Wheel Assembly

2

3

5

1

3

4

10

7

8

69

6

5

RS SHOWNLS SIMILAR

117589_0416 4-5

Front Wheel Assembly

INDEX NO. PART NO. QTY.

FORK, HEAVY DUTYFORKNT .750-10 HX ZY NLFW .760 X 1.625 X .08 ZNYCCS .750-10 X 9.50 HX ZYTIRE/WHEEL ASSEMBLY 13 X 6.50BEARINGVALVE STEMBEARING SPACERTIRE WHEEL

NOTES:

DESCRIPTION

1 116890 1113621 1

2 061101 13 025296 24 041475 15 604898 16 039677 27 019521 18 782771 19 604843 110 747832 1

4-6 117589_0416

Drive Wheel Breakdown

1

2

3

604451 TIRE/WHEEL ASSEMBLY (60" DECKS)

INDEX NO. PART NO. QTY.

TIRE 26 X 12-12WHEEL 12 X 8.50VALVE STEM

604455 TIRE/WHEEL ASSEMBLY (72" DECKS)

INDEX NO. PART NO. QTY

TIRE 26 X 12-12WHEEL 12 X 8.50VALVE STEM

NOTES:

DESCRIPTION

1 603775 12 796250 13 019521 1

DESCRIPTION

1 603775 12 784066 13 019521 1

117589_0416 5-1

Section 5

Engine, Kawasaki FX850V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Engine Service Parts, Kawasaki FX850V . . . . . . . . . . . . . . . . . . . . . 5-5

Engine, Kawasaki FX1000V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Engine Service Parts, Kawasaki FX1000V . . . . . . . . . . . . . . . . . . . . 5-9

Engine, Kawasaki FX1000V DFI . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Engine Service Parts—Kawasaki FX1000V DFI . . . . . . . . . . . . . . . 5-13

Fuel System, Kawasaki/Vanguard—W/O Carbon Canister. . . . . . . 5-15

Fuel System, Kawasaki—DFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Engine, Vanguard—With Carbon Canister . . . . . . . . . . . . . . . . . . . 5-20

Engine, Vanguard—Without Carbon Canister . . . . . . . . . . . . . . . . . 5-22

Engine Service Parts, Vanguard . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

Fuel System, Vanguard—With Carbon Canister . . . . . . . . . . . . . . . 5-26

Fuel Tank Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

5-2 117589_0416

Engine, Kawasaki FX850V

2

1

2

58

7

9

14

10

1112

2

3

4

1

3

4

1 40AFUSE1

1 BLK

6

BLK

RED/BLK

1YEL/BLK

2

8

13

PUR

117589_0416 5-3

Engine, Kawasaki FX850V

INDEX NO. PART NO. QTY.

KAWASAKI FX850V ENGINEAIR FILTER INDICATORELBOW STREET FITTINGCS M8 X 1.25 X 16 HX FL 10.9NEGATIVE BATTERY CABLEPOSITIVE BATTERY CABLENT .312-18 HX G5FW .343 X .687 X .051/.080HHOSE CLAMPFW .379 X .813 X .063CS .375-16 X 1.25 HX G8 P85CB .312-18 X 1.25 ZNYCMUFFLEROIL DRAIN VALVE

NOTES:

1. Part of the wire harness.2. Supplied with the engine.3. Torque to 12 ft-lbs plus 60° rotation of the cap screw head. Replace (do

not reuse) the cap screw if it is removed or loosened. Use only hand tools to install this fastener.

4. Torque to 22 ft-lbs.

DESCRIPTION

1 N/A 12 788943 13 601216 14 720516 15 605155 16 604029 17 034272 28 768523 59 045088 1

10 767954 411 602580 412 602827 113 603012 114 796524 1

5-4 117589_0416

Engine, Kawasaki FX850V

FUELVALVE

VAPORTEE

SEATSUPPORT

16

176

21

1918

16

23

20

176

A

B

15

19

22

INDEX NO. PART NO. QTY.

3/16" HOSE CLAMPHOSE CLAMPCS .312-18 X 1.00 HX G53/16" VAPOR LINEWIRE TIELOOP CLAMPBRACENT .312-18 HX FLK ZNYC1/4" FUEL LINE

NOTES:

DESCRIPTION

15 603112 116 000323 217 036236 318 603326 34"19 000331 420 043570 121 114578 122 016832 323 015818 17"

FUEL & VAPOR LINE LENGTHS

17" VALVE TO ENGINE (FUEL)

34" TEE TO ENGINE (VAPOR)

A

B

117589_0416 5-5

Engine Service Parts, Kawasaki FX850V

3

4

1

2

5

INDEX NO. PART NO. QTY.

MAIN AIR FILTERSAFETY AIR FILTERIN-LINE FUEL FILTEROIL FILTERVACUATOR VALVE

DESCRIPTION

1 785261 12 785279 13 068478 14 603138 15 763318 1

5-6 117589_0416

This page intentionally left blank.

117589_0416 5-7

Engine, Kawasaki FX1000V

1

4

12

7

1314

21

25

26

21

24

23

87

687

22

5

1920

A

1

B

2

3

FUELVALVE

VAPORTEE

SEATSUPPORT

1

713

17

11

713

2

3

11

BLK

140A FUSE

5 6 7

89

10YEL/BLK

18

2 1

1PUR

PUR

107

13

BLK

1516RED/

BLK

4

2

5-8 117589_0416

Engine, Kawasaki FX1000V

INDEX NO. PART NO. QTY.

KAWASAKI FX1000V ENGINEAIR FILTER INDICATORELBOW STREET FITTINGOIL DRAIN VALVENT .312-18 HX FLK ZNYCLOOP CLAMPFW .343 X .687 X .051/.080HCS .312-18 X 1.00 HX G5CABLE MOUNTCS M8 X 1.25 X 16 HX FL 10.9CB .312-18 X .75 FUL ZNMUFFLERNT .312-18 HX G5HOSE CLAMPNEGATIVE BATTERY CABLEPOSITIVE BATTERY CABLEMUFFLER MOUNTFW .379 X .813 X .063CS .375-16 X 1.25 HX G8 P85CB .312-18 X 1.25 ZNYCHOSE CLAMPBRACE1/4" FUEL LINEWIRE TIE3/16" VAPOR LINE3/16" HOSE CLAMP

NOTES:

1. Part of the wire harness.2. Supplied with the engine.3. Torque to 12 ft-lbs plus 60° rotation of the cap screw head. Replace (do

not reuse) the cap screw if it is removed or loosened. Use only hand tools to install this fastener.

4. Torque to 22 ft-lbs.

DESCRIPTION

1 N/A 12 788943 13 601216 14 796524 15 016832 46 043570 27 768523 108 036236 49 115819 1

10 720516 311 016253 412 603708 113 034272 614 045088 115 605155 116 604029 117 115889 118 767954 419 602580 420 602827 121 000323 222 114578 123 015818 14"24 000331 525 603326 34"26 603112 1

FUEL & VAPOR LINE LENGTHS

14" VALVE TO ENGINE (FUEL)

34" TEE TO ENGINE (VAPOR)

A

B

117589_0416 5-9

Engine Service Parts, Kawasaki FX1000V

4

1

23

5

INDEX NO. PART NO. QTY.

MAIN AIR FILTERSAFETY AIR FILTERIN-LINE FUEL FILTEROIL FILTERVACUATOR VALVE

NOTES:

DESCRIPTION

1 785261 12 785279 13 068478 14 603138 15 763318 1

5-10 117589_0416

This page intentionally left blank.

117589_0416 5-11

Engine, Kawasaki FX1000V DFI

2

1

5

12

10

9

11

17

22

17

21

25

1810

2418

10

19

23

1615

A

B

2

3

FUELVALVE

VAPORTEE

SEATSUPPORT

109

13

8

109

2

3

8140A

14

2

1

10

9

BLK

6

7

4FUSE

4

20

DFI TOENGINE

DFI TOHARNESS

C

5-12 117589_0416

Engine, Kawasaki FX1000V DFI

INDEX NO. PART NO. QTY.

KAWASAKI FX1000V DFI ENGINEAIR FILTER INDICATORELBOW STREET FITTINGCS M8 X 1.25 X 16 HX FL 10.9OIL DRAIN VALVENEGATIVE BATTERY CABLEPOSITIVE BATTERY CABLECB .312-18 X .75 FUL ZNNT .312-18 HX G5FW .343 X .687 X .051/.080HHOSE CLAMPFX 1000V DFI MUFFLERMUFFLER MOUNTFW .379 X .813 X .063CB .312-18 X 1.25 ZNYCCS .375-16 X 1.25 HX G8 P85HOSE CLAMPCS .312-18 X 1.00 HX G5BRACEFUEL LINE THERMAL SHIELDWIRE TIE3/16" VAPOR LINENT .312-18 HX FLK ZNYCLOOP CLAMP1/4" FUEL LINE

NOTES:

1. Part of the wire harness.2. Supplied with the engine.3. Torque to 30 ft-lbs. Replace (do not reuse) the cap screw if it is removed

or loosened. Use only hand tools to install this fastener.4. Torque to 22 ft-lbs.

DESCRIPTION

1 N/A 12 788943 13 601216 14 720516 15 796524 16 605155 17 604029 18 016253 49 034272 610 768523 911 045088 112 605223 113 115889 114 767954 415 602827 116 602580 417 000323 218 036236 319 114578 120 605215 11"21 000331 522 603326 23"23 016832 324 043570 125 015818 13"

FUEL & VAPOR LINE LENGTHS

13" VALVE TO ENGINE (FUEL)

23" TEE TO ENGINE (VAPOR)

11" VALVE TO ENGINE (FUEL LINE THERMAL SHIELD)

A

B

C

117589_0416 5-13

Engine Service Parts—Kawasaki FX1000V DFI

4

1

2

3

5

INDEX NO. PART NO. QTY.

MAIN AIR FILTERSAFETY AIR FILTERIN-LINE FUEL FILTEROIL FILTERVACUATOR VALVE

NOTES:

DESCRIPTION

1 785261 12 785279 13 068478 14 603138 15 763318 1

5-14 117589_0416

This page intentionally left blank.

117589_0416 5-15

Fuel System, Kawasaki/Vanguard—W/O Carbon Canister

A

1

2

47

5

6

56

5

5

97

4

48

8

11

121314

15 1011

13 1212

15

14

1011

1

3

1716

18

19

1716

1617

B

CF

E

1

1

1

2

D

4

10

5-16 117589_0416

Fuel System, Kawasaki/Vanguard—W/O Carbon Canister

INDEX NO. PART NO. QTY.

RATCHETING GAS CAP 3.5"LS FUEL TANK (S/N 14044000 & HIGHER)LS FUEL TANK (S/N PRIOR TO 14044000)RS FUEL TANK (S/N 14044000 & HIGHER)RS FUEL TANK (S/N PRIOR TO 14044000)HOSE CLAMP3/16" VAPOR LINEPLASTIC TEE, 3/16"1/4" FUEL LINEFUEL VALVE 3-WAYVAPOR SYSTEM FILTERFW .406 X 1.00 X .12 HRD ZCS .375-16 X .75 HX G5CS .312-18 X 1.00 HX G5FW .343 X .687 X .051/.080HLOOP CLAMPNT .312-18 HX FLK ZNYCCS .250-20 X .500 HX G5FW .281 X .625 X .066TANK COVERTANK COVERWIRE TIE (NOT SHOWN)

NOTES:

1. Torque to 20 ft-lbs.2. Part of the wire harness.

DESCRIPTION

1 603807 22 605102 1

604443 13 605101 1

604442 14 000323 45 603326 74"6 604281 27 015818 66"8 745059 19 604323 110 712919 1011 055822 1012 036236 313 768523 314 043570 315 016832 316 055947 417 768515 418 115998 119 115999 120 000331 1

FUEL & VAPOR LINE LENGTHS

17" LEFT TANK TO TEE (VAPOR)

24" TEE TO TEE (VAPOR)

24" RIGHT TANK TO TEE (VAPOR)

9" TEE TO FILTER (VAPOR)

44" RIGHT TANK TO VALVE (FUEL)

22" LEFT TANK TO VALVE (FUEL)

A

BCD

E

F

117589_0416 5-17

This page intentionally left blank.

5-18 117589_0416

Fuel System, Kawasaki—DFI

A

1

2

47

5

6

56

5

5

97

4

48

810

11

121314

15 1011

13 1212

15

14

1011

1

3

1716

18

19

1716

1617

B

CF

E

1

1

1

2

D

4

21 H

21G

117589_0416 5-19

Fuel System, Kawasaki—DFI

INDEX NO. PART NO. QTY.

RATCHETING GAS CAP, 3.5"LS FUEL TANK (S/N 14061079 & HIGHER)LS FUEL TANK (S/N PRIOR TO 14061079)RS FUEL TANK (S/N 14061079& HIGHER)RS FUEL TANK (S/N PRIOR TO 14061079)HOSE CLAMP3/16" VAPOR LINEPLASTIC TEE, 3/16"1/4" FUEL LINEFUEL VALVE 3-WAYVAPOR SYSTEM FILTERFW .344 X 1.00 X .12 HRD ZCS .375-16 X .75 HX G5CS .312-18 X 1.00 HX G5FW .343 X .687 X .051/.080HLOOP CLAMPNT .312-18 HX FLK ZNYCCS .250-20 X .50 HX G5FW .281 X .625 X .066TANK COVERTANK COVERWIRE TIE (NOT SHOWN)FUEL LINE THERMAL SHIELD

NOTES:

1. Torque to 20 ft-lbs.2. Part of the wire harness.

DESCRIPTION

1 603807 22 605102 1

604443 13 605101 1

604442 14 000323 45 603326 74"6 604281 27 015818 66"8 745059 19 604323 1

10 712927 1011 055822 1012 036236 313 768523 314 043570 315 016832 316 055947 417 768515 418 115998 119 115999 120 000331 121 605215 62"

FUEL LINE LENGTHS

17" LEFT TANK TO TEE (VAPOR)

24" TEE TO TEE (VAPOR)

24" RIGHT TANK TO TEE (VAPOR)

9" TEE TO FILTER (VAPOR)

44" RIGHT TANK TO VALVE (FUEL)

22" LEFT TANK TO VALVE (FUEL)

42" RIGHT TANK TO VALVE (THERMAL SHIELD)

20" LEFT TANK TO VALVE (THERMAL SHIELD)

A

BCD

E

F

GH

5-20 117589_0416

Engine, Vanguard—With Carbon Canister

2

1

17

7

2

18

19

34

4

3 5

24

24

22

234

27234

25

26

10

11

1615

9 B

12

3

FUELVALVE

SEATSUPPORT

1

43

126

43

1413

6

1

40AFUSE

BLK

2

TEE 21 A

20

28

8

4

153

4

15 24

117589_0416 5-21

Engine, Vanguard—With Carbon Canister

INDEX NO. PART NO. QTY.

VANGUARD M61 ENGINEPOSITIVE BATTERY CABLENT .312-18 HX G5FW .343 X .687 X .051/.080HHOSE CLAMPCB .312-18 X .75 FUL ZNMUFFLERSPARK ARRESTERCB .312-18 X 1.25 ZNYCFW .379 X .813 X .063SC .375-16 X 1.0 HX FL STPMUFFLER MOUNTELBOW STREET FITTINGAIR FILTER INDICATORWIRE TIEADAPTER3/8-18 OIL DRAIN VALVELW .375 INT-EXT TOOTHNEGATIVE BATTERY CABLECS .312-18 X 2.25 HX G51/4" FUEL LINE3/16" VAPOR LINECS .312-18 X 1.00 HX G5HOSE CLAMPBRACENT .312-18 HX FLK ZNYCLOOP CLAMPCLAMP, 3/16"

NOTES:

1. Part of the wire harness.2. Supplied with the engine.3. Torque to 30 ft-lbs.4. Torque to 17 ft-lbs.

DESCRIPTION

1 N/A 12 604029 13 034272 74 768523 115 045088 16 016253 47 604660 18 602281 19 602827 1

10 767954 411 792788 412 115889 113 601216 114 788943 115 000331 316 604799 117 796516 118 793885 119 604026 120 038828 121 015818 14"22 603326 30"23 036236 324 000323 225 114578 126 016832 327 043570 128 603112 1

FUEL & VAPOR LINE LENGTHS

14" VALVE TO ENGINE (FUEL)

30" TEE TO ENGINE (VAPOR)

A

B

5-22 117589_0416

Engine, Vanguard—Without Carbon Canister

2

1

16

7

2

17

18

34

4

3 5

23

23

21

224

26224

24

25

10

15

14

9

B

12

3

FUELVALVE

SEATSUPPORT

1

43

116

43

1312

6

1

40AFUSE

BLK

2

TEE

20 A

19

27

4

143

4

1424

8

117589_0416 5-23

Engine, Vanguard—Without Carbon Canister

INDEX NO. PART NO. QTY.

VANGUARD M61 ENGINEPOSITIVE BATTERY CABLENT .312-18 HX G5FW .343 X .687 X .051/.080HHOSE CLAMPCB .312-18 X .75 FUL ZNMUFFLERSPARK ARRESTERCB .312-18 X 1.25 ZNYCSC .375-16 X 1.25 FLGMUFFLER MOUNTELBOW STREET FITTINGAIR FILTER INDICATORWIRE TIEADAPTER3/8-18 OIL DRAIN VALVELW .375 INT-EXT TOOTHNEGATIVE BATTERY CABLECS .312-18 X 2.25 HX G51/4" FUEL LINE3/16" VAPOR LINECS .312-18 X 1.00 HX G5HOSE CLAMPBRACENT .312-18 HX FLK ZNYCLOOP CLAMP3/16" HOSE CLAMP

NOTES:

1. Part of the wire harness.2. Supplied with the engine.3. Torque to 44 ft-lbs.4. Torque to 17 ft-lbs.

DESCRIPTION

1 N/A 12 604029 13 034272 74 768523 115 045088 16 016253 47 604660 18 602281 19 602827 110 605814 811 115889 112 601216 113 788943 114 000331 315 604799 116 796516 117 793885 118 604026 119 038828 120 015818 14"21 603326 20"22 036236 323 000323 224 114578 125 016832 326 043570 127 603112 1

FUEL & VAPOR LINE LENGTHS

14" VALVE TO ENGINE (FUEL)

20" TEE TO ENGINE (VAPOR)

A

B

5-24 117589_0416

Engine Service Parts, Vanguard

21

3

5

4

NOTES:

INDEX NO. PART NO. QTY. DESCRIPTION

1 785261 1 MAIN AIR FILTER2 785279 1 SAFETY AIR FILTER3 604807 1 VAPOR FITTING4 068478 1 IN-LINE FUEL FILTER5 603196 1 OIL FILTER

117589_0416 5-25

This page intentionally left blank.

5-26 117589_0416

Fuel System, Vanguard—With Carbon Canister

2

1

3

1

5

5

12

13

10

9

1213 1

1

131

7

8

10

8

11

B

A

11

9

16

4

4

6

7

12

15

15

14

14

14

172

11

6

1213 1

13 112

4

117589_0416 5-27

Fuel System, Vanguard—With Carbon Canister

INDEX NO. PART NO. QTY.

RATCHETING GAS CAP, 3.5"RS FUEL TANK ASSEMBLY (S/N14044000 & HIGHER)RS FUEL TANK ASSEMBLY (PRIOR TO S/N 14044000)LS FUEL TANK ASSEMBLY (S/N 14044000 & HIGHER)LS FUEL TANK ASSEMBLY (PRIOR TO S/N 14044000)HOSE CLAMP1/4" FUEL LINEWIRE TIEFUEL VALVE 3-WAYCS .312-18 X 1.00 HX G5FW .343 X .687 X .051/.080HLOOP CLAMPNT .312-18 HX FLK ZNYCFW .379 X .813 X .063CS .375-16 X .75 HX G5CS .250-20 X .500 HX G5FW .281 X .625 X .066TANK COVERTANK COVER

NOTES:

1. Torque to 20 ft-lbs.2. Part of the wire harness.

DESCRIPTION

1 603807 22 605101 1

604442 13 605102 1

604443 14 000323 45 015818 68"6 000331 37 745059 18 036236 59 768523 510 043570 311 016832 712 767954 1013 055822 1014 055947 415 768515 416 115998 117 115999 1

FUEL LINE LENGTHS

47" RIGHT TANK TO VALVE (FUEL)

21" LEFT TANK TO VALVE (FUEL)

A

B

5-28 117589_0416

Evap System, Vanguard—With Carbon Canister

22

20

20

18

18

8

11

C

D

9

11

2119

20E

20F

23

23

117589_0416 5-29

Evap System, Vanguard—With Carbon Canister

INDEX NO. PART NO. QTY.

CARBON CANISTER3.0" CUSHIONED CLAMP3/16" VAPOR LINECB .312-18 X .75 FUL ZNPLASTIC TEE, 3/16"VACUUM BREAKER FILTER

NOTES:

DESCRIPTION

18 604314 219 602980 220 603326 90"21 016253 222 604281 123 603161 2

FUEL LINE LENGTHS

47" RIGHT TANK TO CANISTER (VAPOR)

20" LEFT TANK TO CANISTER (VAPOR)

17" CANISTER TO TEE (VAPOR)

6" CANISTER TO TEE (VAPOR)

C

DE

F

5-30 117589_0416

Fuel Tank Service Parts

56

3

4

1

2

INDEX NO. PART NO. QTY.

FUEL GAUGEGASKETVENT FITTINGGROMMETFUEL SHUTOFF GROMMETSUCTION HOSE ASSEMBLY 22"

NOTES:

DESCRIPTION

1 603888 12 603889 13 604287 14 604200 15 785295 16 601805 1

117589EX_0416 6-1

Section 6

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-2 117589EX_0416

Battery

1

2

3

POSITIVEBATTERYCABLE

4

NEGATIVEBATTERYCABLE

117589EX_0416 6-3

Battery

INDEX NO. PART NO. QTY.

CS .312-18 X 5.00 HX G5FW .343 X .687 X .051/.080HBATTERY STRAPCN .312-18 X .20 MAX THK

NOTES:

DESCRIPTION

1 050823 22 768523 23 113676 14 601069 2

6-4 117589EX_0416

Instrument Panel

1

1

4

5

2

63

7

11

12

10

3

14

12

13

15

16 17

8

18

16 15

1920

2021

22

24

BLKORGYEL/BLK

ORG

1

10A FUSE

9

25

20A FUSE

26 2

1

AUXILIARYCONNECTION

27

117589EX_0416 6-5

Instrument Panel

INDEX NO. PART NO. QTY.

CHOKE CABLEKEY ASSEMBLYIGNITION SWITCHHOUR METERRED INDICATOR LIGHTPTO SWITCHCB 10-24 X .500 ZYNCINSTRUMENT PANEL (WITH DECAL)KNOBCS 10-24 X .75 HX FLK ZNRELAY CONTROL MODULENT #10-24 HX NL ZNTHROTTLE CABLEFW .219 X .500 X .048CS .250-20 X .50 HX G5FW .281 X .625 X .066INSTRUMENT PANEL DECALWIRE TIECS .312-18 X .75 HX G5FW .343 X .687 X .051/.080HLOOP CLAMPNT .312-18 HX G5WIRE TIE (NOT SHOWN)WIRE HARNESSCLUTCH CONNECTOR REPAIR KITSOLENOID JUMPERFUSE HOLDER

NOTES:

1. Part of the wire harness.2. Must order separately, as it is no longer part of the wire harness.

DESCRIPTION

1 603087 12 785808 13 045898 14 769166 15 712257 16 776476 17 601098 28 550856 19 603523 1

10 063198 211 604373 112 059832 413 603409 114 704932 215 055947 416 768515 417 603056 118 000430 119 034280 120 768523 221 043570 122 034272 123 000331 424 603810 125 114052 126 604430 127 601047 1

6-6 117589EX_0416

117589EX_0416 7-1

Section 7

60" Side Discharge Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

60" Side Discharge Deck Pulleys & Spindles . . . . . . . . . . . . . . . . . . 7-4

60" Side Discharge Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

66" Side Discharge Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

66" Side Discharge Deck Pulleys & Spindles . . . . . . . . . . . . . . . . . 7-10

66" Side Discharge Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

72" Side Discharge Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

72" Side Discharge Deck Pulleys & Spindles . . . . . . . . . . . . . . . . . 7-16

72" Side Discharge Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Side Discharge Deck Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Side Discharge Deck Mounting Hardware. . . . . . . . . . . . . . . . . . . . 7-22

60" Rear Discharge Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

60" Rear Discharge Deck Pulleys & Spindles . . . . . . . . . . . . . . . . . 7-26

60" Rear Discharge Dust Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

60" Rear Discharge Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

Rear Discharge Deck Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

Rear Discharge Deck Mounting Hardware . . . . . . . . . . . . . . . . . . . 7-38

7-2 117589EX_0416

60" Side Discharge Service Deck

7

1

2

5

2

43

5

6

8

117589EX_0416 7-3

60" Side Discharge Service Deck

INDEX NO. PART NO. QTY.

60" VX4 DECK (WITH DECALS & HARDWARE)CN .312-18 X .20 MAX THKBELT ROUTING DECALDISCHARGE CHUTE DECALDECK DANGERS DECALTHROWN OBJECTS DECAL60" SD DECK ID DECALVX4 TECHNOLOGY DECAL

NOTES:

DESCRIPTION

1 550739 12 601069 43 781419 14 601624 15 601837 26 601892 17 786277 18 603092 1

7-4 117589EX_0416

60" Side Discharge Deck Pulleys & Spindles

1

1

2

3

1920

17

28

3132

34

10

459

13

22

22

2423

26

25

26

27

2529

30

33

12

4

10

7 6

8

2

13

14

11

3

22

15

16

1718

21

1

117589EX_0416 7-5

60" Side Discharge Deck Pulleys & Spindles

INDEX NO. PART NO. QTY.

CS .625-11 X 1.50 HX G5IDLER DUST SHIELD SMIDLER 6.0" RIVETEDFW .625 X 1.00 X .134DECK IDLER SLIDETENSION SPRINGCHAIN, 21 LINKUHMW IDLER SLIDEWN .312-18 ZNNT .625-11 HX G5 ZNYCIDLER DUST SHIELD LGIDLER 10.0" RIVETEDCS .500-13 X 1.25 HX G5CW .515 X 2.25 X .204 BLKPULLEY DRIVE 7.00 EFFFW 1.030 X 1.50 X .134GREASE FITTING STRAIGHTPUSHERFW .379 X .813 X .063NT .375-16 HX G5 ZY NLCS .312-18 X .625 BH ZN FW .531 X 1.063 X .175BLADE SPINDLE CWKEY 1/4 SQ X 1.00CW .631 X 2.25 X .187 PNTCS .625-11 X 3.00 FULL HX G5CB .375-16 X 1.25 G5 ZNCB .500-13 X 7.50 STD ZNPLASTIC WHEELSPACER 5.73 NT .500-13 HX G8 ZY NLPLASTIC WHEELSPACER 3.22 CB .500-13 X 5.00 ZNYC

NOTES:

1. Torque to 67–75 ft-lbs.

DESCRIPTION

1 794446 12 602935 23 602821 24 028118 25 350884 16 781302 17 373191 18 602936 29 603023 4

10 016972 211 602963 112 602743 113 705954 1514 752386 315 602745 316 045765 317 015495 218 113340 119 767954 620 086660 621 603022 422 767962 1523 604255 324 212472 325 782474 226 783738 227 603113 628 602338 129 602341 130 602344 131 781567 332 602263 233 602345 234 603049 2

7-6 117589EX_0416

60" Side Discharge Deck1

12

1110

9

19

13

15

8

6

7

5

1

3

2

4

14

13 8

16

817

18

15

3

2

15813

117589EX_0416 7-7

60" Side Discharge Deck

INDEX NO. PART NO. QTY.

RS PULLEY COVERLS PULLEY COVERKNOB 5/16-18 X 3/4"BELT, B-SEC 172" ELDISCHARGE CHUTE LGTORSION SPRINGCHUTE PINNT .375-16 HX G5 ZY NLBACKING PLATERUBBER BUMPERFW .344 X 1.00 X .06 ZNYCCS .312-18 X .875 HX G5FW .379 X .813 X .063RS INNER WALL ADJ.CB .375-16 X 1.00 G5 ZNYLS INNER WALL ADJ.BLADE, F20.50" EHN-F-CWBLADE, 20.50"-L-F-CWBLADE, 20.50"-MUL-F-CWBLADE, 20.50"-GAT-F-CWBLADE, F20.50"-H-F-CWCW .631 X 2.25 X .187 PNTCS .625-11 X 1.25 HX G5 Z

NOTES:

1. Torque to 118 ft-lbs.2. Torque to 10 ft-lbs.

DESCRIPTION

1 112933 12 112934 13 792002 44 604494 15 602891 16 602435 17 602432 18 086660 79 113563 1

10 602817 111 079210 212 064014 213 767954 614 113180 115 025395 616 113179 117 602771 3

793794 3794214 3794230 3794685 3

18 782474 319 781872 3

7-8 117589EX_0416

66" Side Discharge Service Deck

1

2

2

7

5

3

8

4

46

117589EX_0416 7-9

66" Side Discharge Service Deck

INDEX NO. PART NO. QTY.

66" VX4 DECK (WITH DECALS & HARDWARE)CN .312-18 X .20 MAX THKDISCHARGE CHUTE DECALDECK DANGERS DECALBELT ROUTING DECAL66" DECK ID DECALVX4 TECHNOLOGY DECALTHROWN OBJECTS DECAL

NOTES:

DESCRIPTION

1 550750 12 601069 43 601624 14 601837 25 781419 16 799189 17 603092 18 601892 1

7-10 117589EX_0416

66" Side Discharge Deck Pulleys & Spindles

1

1

2

3

2019

18

28

3132

34

10

458

13

22

22

2423

2527

25

29

30

33

12

4

10

7 6

9

213

14

11

3

22

1516

18

17

21

26

1

117589EX_0416 7-11

66" Side Discharge Deck Pulleys & Spindles

INDEX NO. PART NO. QTY.

CS .625-11 X 1.50 HX G5IDLER DUST SHIELD SMIDLER 6.0" RIVETEDFW .625 X 1.00 X .134DECK IDLER SLIDETENSION SPRINGCHAIN, 21 LINKWN .312-18 ZNUHMW IDLER SLIDENT .625-11 HX G5 ZNYCIDLER DUST SHIELD LGIDLER 10.0" RIVETEDCS .500-13 X 1.25 HX G5CW .515 X 2.25 X .204 BLKDRIVE PULLEY 7.85 EFFFW 1.030 X 1.50 X .134PUSHERGREASE FITTING STRAIGHTNT .375-16 HX G5 ZY NLFW .379 X .813 X .063CS .312-18 X .625 BH ZN FW .531 X 1.063 X .175BLADE SPINDLE CWKEY 1/4 SQ X 1.00CW .631 X 2.25 X .187 PNTCS .625-11 X 3.00 FULL HX G5CB .375-16 X 1.25 G5 ZNCB .500-13 X 7.50 STD ZNPLASTIC WHEELSPACER 5.73 NT .500-13 HX G8 ZY NLPLASTIC WHEELSPACER 3.22 CB .500-13 X 5.00 ZNYC

NOTES:

1. Torque to 67–75 ft-lbs.

DESCRIPTION

1 794446 12 602935 23 602821 24 028118 25 350884 16 781302 17 373191 18 603023 49 602936 2

10 016972 211 602963 112 602743 113 705954 1514 752386 315 602859 316 045765 317 113340 118 015495 219 086660 620 767954 621 603022 422 767962 1523 604255 324 212472 325 782474 226 783738 227 603113 628 602338 129 602341 130 602344 131 781567 332 602263 233 602345 234 603049 2

7-12 117589EX_0416

117589EX_0416 7-13

66" Side Discharge Deck1

1211

109

19

13

14

8

67

5

1

3

2

4

15

8

16

817

18

14

3

2

14

13

813

7-14 117589EX_0416

66" Side Discharge Deck

INDEX NO. PART NO. QTY.

RS PULLEY COVERLS PULLEY COVERKNOB 5/16-18 X 3/4"BELT, B-SECDISCHARGE CHUTE LGTORSION SPRINGCHUTE PINNT .375-16 HX G5 ZY NLBACKING PLATERUBBER BUMPERFW .344 X 1.00 X .06 ZNYCCS .312-18 X .875 HX G5 ZNFW .379 X .813 X .063CB .375-16 X 1.00 G5 ZNYRS INNER WALL ADJ.LS INNER WALL ADJ.BLADE, F22.50" EHN-F-CWBLADE, F22.50" -H-F-CWBLADE, 22.50" -GAT-F-CWBLADE, 22.50" -MUL-F-CWCW .631 X 2.25 X .187 PNTCS .625-11 X 1.25 HX G5 Z

NOTES:

1. Torque to 118 ft-lbs.2. Torque to 10 ft-lbs.

DESCRIPTION

1 113335 12 113336 13 792002 44 602854 15 602891 16 602435 17 602432 18 086660 79 113563 1

10 602817 111 079210 212 064014 213 767954 614 025395 615 113333 116 113334 117 602864 3

798496 3798512 3798504 3

18 782474 319 781872 3

117589EX_0416 7-15

72" Side Discharge Service Deck

1

2

6

5

7

8

34

4

2

7-16 117589EX_0416

72" Side Discharge Service Deck

INDEX NO. PART NO. QTY.

72" VX4 DECK (WITH DECALS & HARDWARE)CN .312-18 X .20 MAX THKDISCHARGE CHUTE DECALDECK DANGERS DECALBELT ROUTING DECAL72" DECK ID DECALVX4 TECHNOLOGY DECALTHROWN OBJECTS DECAL

NOTES:

DESCRIPTION

1 550751 12 601069 43 601624 14 601837 25 781419 16 786285 17 603092 18 601892 1

117589EX_0416 7-17

72" Side Discharge Deck Pulleys & Spindles

1

1

2

3

1920

18

28

3132

34

10

458

13

22

22

242326

252627

2529

30

33

12

4

10

7 6

9

2

13

14

11

3

22

15

16

18

17

21

1

7-18 117589EX_0416

72" Side Discharge Deck Pulleys & Spindles

INDEX NO. PART NO. QTY.

CS .625-11 X 1.50 HX G5IDLER DUST SHIELD SMIDLER 6.0" RIVETEDFW .625 X 1.00 X .134DECK IDLER SLIDETENSION SPRINGCHAIN, 21 LINKWN .312-18 ZNUHMW IDLER SLIDENT .625-11 HX G5 ZNYCIDLER DUST SHIELD LGIDLER 10.0" RIVETEDCS .500-13 X 1.25 HX G5CW .515 X 2.25 X .204 BLKDRIVE PULLEY 8.652 OPFW 1.030 X 1.50 X .134PUSHERGREASE FITTING STRAIGHTFW .379 X .813 X .063NT .375-16 HX G5 ZY NLCS .312-18 X .625 BH ZN FW .531 X 1.063 X .175BLADE SPINDLE CWKEY 1/4 SQ X 1.00CW .631 X 2.25 X .187 PNTCS .625-11 X 3.00 FULL HX G5CB .375-16 X 1.25 G5 ZNCB .500-13 X 7.50 STD ZNPLASTIC WHEELSPACER 5.73 NT .500-13 HX G8 ZY NLPLASTIC WHEELSPACER 3.22 CB .500-13 X 5.00 ZNYC

NOTES:

1. Torque to 67–75 ft-lbs.

DESCRIPTION

1 794446 12 602935 23 602821 24 028118 25 350884 16 781302 17 373191 18 603023 49 602936 2

10 016972 211 602963 112 602743 113 705954 1514 752386 315 602746 316 045765 317 113340 118 015495 219 767954 620 086660 621 603022 422 767962 1523 604255 324 212472 325 782474 226 783738 227 603113 628 602338 129 602341 130 602344 131 781567 332 602263 233 602345 234 603049 2

117589EX_0416 7-19

72" Side Discharge Deck1

1211

109

19

13

14

8

6

7

5

1

3

2

4

15

13

8

16

8

17

18

14

3

2

14

13

8

7-20 117589EX_0416

72" Side Discharge Deck

INDEX NO. PART NO. QTY.

RS PULLEY COVERLS PULLEY COVERKNOB 5/16-18 X 3/4"BELT, B 195" ELDISCHARGE CHUTE LGTORSION SPRINGCHUTE PINNT .375-16 HX G5 ZY NLBACKING PLATERUBBER BUMPERFW .344 X 1.00 X .06 ZNYCCS .312-18 X .875 HX G5FW .379 X .813 X .063CB .375-16 X 1.00 G5 ZNYRS INNER WALL ADJ.LS INNER WALL ADJ.BLADE, F24.50" EHN-F-CWBLADE, F24.50"-H-F-CWBLADE, 24.50"-MUL-F-CWBLADE, 24.50"-GAT-F-CWCW .631 X 2.25 X .187 PNTCS .625-11 X 1.25 HX G5 Z

NOTES:

1. Torque to 118 ft-lbs.2. Torque to 10 ft-lbs.

DESCRIPTION

1 112935 12 112936 13 792002 44 784207 15 602891 16 602435 17 602432 18 086660 79 113563 110 602817 111 079210 212 064014 213 767954 614 025395 615 112931 116 112932 117 602857 3

798702 3798710 3798728 3

18 782474 319 781872 3

117589EX_0416 7-21

Side Discharge Deck Lift

12

3

45

6

7

8

1312

11

6

7

7

14

6

5 49

10

8

157

8

7

8

7

7-22 117589EX_0416

Side Discharge Deck Lift

INDEX NO. PART NO. QTY.

DECK HEIGHT PINSTOP HANDLEDECK LIFT INDICATORDECK LIFT SPRINGCS .437-14 X 1.75 HX G5DECK LIFT CHAINNT .437-14 HX FLG ZNE CLIP 1.00 X .625 X .05CS .625-11 X 1.25 HX G5 ZFW .625 X 1.50 X .105 ZNDECK LEVELER YOKENT .312-18 HX G5CS .312-18 X 1.50 HX G5CS .437-14 X 1.75 HX G5CE .750 X 2.25 X 1.75 HEAD

NOTES:

DESCRIPTION

1 600437 12 348318 13 602898 14 603184 25 055749 76 348391 47 704643 168 781294 69 781872 1

10 704783 111 348458 112 034272 113 756270 114 781831 115 781229 1

117589EX_0416 7-23

Side Discharge Deck Mounting Hardware

5

5

7

716

18

17

7-24 117589EX_0416

Side Discharge Deck Mounting Hardware

INDEX NO. PART NO. QTY.

NT .750-10 HX ZY NLFW .760 X 1.625 X .08 ZNYCCS .750-10 X 3.00 HX G5

NOTES:

DESCRIPTION

16 061101 217 025296 418 051169 2

117589EX_0416 7-25

60" Rear Discharge Service Deck

4

1

2

2

3

4

6

5

7

56

8

2

7-26 117589EX_0416

60" Rear Discharge Service Deck

INDEX NO. PART NO. QTY.

60" RD DECK (WITH DECALS & HARDWARE)CN .312-18 X .20 MAX THK2 BELT ROUTING DECALDECK DANGERS DECALTHROWN OBJECTS DECALRUBBER FLAP DECAL60" DECK ID DECAL5/16-18 THREAD HEX RIVET NUT

NOTES:

DESCRIPTION

1 550935 12 601069 43 603349 14 601837 25 601892 26 603391 27 786277 18 792887 1

117589EX_0416 7-27

60" Rear Discharge Deck Pulleys & Spindles

12

1

13

22

31

2

3

4

5

6

2

7

8

916

19

14

13

18

17

16

15

11

2

26

18

24

2021

22

2325

11

27

2

11

2

12

2

2829

21

2

5

6

2

29

28

30

26

10

7-28 117589EX_0416

60" Rear Discharge Deck Pulleys & Spindles

INDEX NO. PART NO. QTY.

CS .625-11 X 2.50 HX G5FW .625 X 1.00 X .134BELT GUIDEDECK IDLER SPACER 1/2" LGIDLER DUST SHIELD SMIDLER 6.0" RIVETEDRD DECK IDLER ARMCS .312-18 X 1.50 FLT SH ZYIDLER GUIDECS .625-11 X 1.50 HX G5DUST SHIELD WITH OFFSETPULLEY V-IDLER HBB 5.0"CHAIN, 21 LINKNT .500-13 HX G8 ZY NLFW .531 X 1.063 X .175PLASTIC BUSHING .750 X 1IDLER PIVOT BUSHINGTENSION SPRINGFW .500 X 1.25 X .075 ZNYCS .312-18 X 1.25 FLT SHNT .625-11 HX G5 ZNYCIDLER DUST SHIELD LGIDLER 8.0" RIVETEDIDLER SLIDE IDLER SLIDE UHMWCS .625-11 X 2.00 HX G5 Z6" HB IDLER PULLEYFW .343 X .687 X .051/.080HNT .312-18 HX G5 ZY NLCW .631 X 2.25 X .187 PNTCS .625-11 X 3.00 FULL HX G5

NOTES:

DESCRIPTION

1 025015 12 028118 123 113088 14 603256 15 602935 26 602821 27 114133 18 797910 29 601779 1

10 794446 111 603057 412 602672 213 373191 214 781567 115 767962 1316 770867 217 109549 118 781302 219 704759 120 784199 421 016972 222 602963 123 602838 124 114105 125 601619 226 016642 327 796714 228 768523 629 058776 630 782474 131 783738 1

117589EX_0416 7-29

60" Rear Discharge Deck Pulleys & Spindles

34

42

38

41

321

37

36

35

35

40

39

15

133

7-30 117589EX_0416

60" Rear Discharge Deck Pulleys & Spindles

INDEX NO. PART NO. QTY.

CS .500-13 X 1.25 HX G5CS .500-13 X 1.75 HX G5CW .515 X 2.25 X .204 BLKPULLEY DRIVE 7.00 EFFPULLEYKEY 1/4 SQ X 1.00FW 1.030 X 1.50 X .134CS .500-13 X 1.00 HX G5 ZNSPACERBLADE SPINDLE CCWBLADE SPINDLE CW

NOTES:

1. Torque to 65–75 ft-lbs.

DESCRIPTION

32 705954 133 017616 234 752386 335 602745 236 770388 137 212472 338 045765 239 016527 1240 114108 141 604256 142 604255 2

117589EX_0416 7-31

60" Rear Discharge Dust Shield

24

3

5

101

2

6

1

7

13

9

8

1

11

12

13

2

18

19

18

20

21

14515

16

17

7-32 117589EX_0416

60" Rear Discharge Dust Shield

INDEX NO. PART NO. QTY.

NT .312-18 HX G5 ZYFW .343 X .687 X .051/.080HGREASE FITTING STRAIGHTCS .375-16 X 1.00 HX G5FW .379 X .813 X .063PUSHERFW .781 X 1.375 X .250 ZNYRS CHUTE BRACKETLS CHUTE BRACKETRS CLAMP ANGLE DUST SHIELDLS CLAMP ANGLERUBBER SIDE FLAPNT .375-16 HX G5 ZY NLDISCHARGE CHUTE ANGLERD REAR FLAPDECK STIFFENER ANGLECB .312-18 X 1.00 FULL ZNCB .312-18 X .75 FUL ZNREAR DECK STOPCB .375-16 X 1.50 STD G5

NOTES:

DESCRIPTION

1 058776 102 768523 103 015495 24 036244 65 767954 126 113340 17 778399 28 109482 19 109483 1

10 109487 111 114440 112 109486 113 601483 214 086660 615 106716 216 600254 217 351676 218 037887 619 016253 420 114522 121 710194 6

117589EX_0416 7-33

60" Rear Discharge Deck1

11

6

8

8

10

3

9

12

1211

1514

139

10

45

3

7

2

10

7-34 117589EX_0416

60" Rear Discharge Deck

INDEX NO. PART NO. QTY.

RS PULLEY COVER (WITH DECALS)DECK DANGERS DECALKNOB 5/16-18 X 3/4"CENTER PULLEY COVERLS PULLEY COVERBELT, B 145.5" ELBELT, B 138" ELCB .500-13 X 5.00 ZNYCNT .500-13 HX G8 ZY NLFW .531 X 1.063 X .175SPACER 3.22 PLASTIC WHEELCB .500-13 X 7.50 STD ZNPLASTIC WHEELSPACER 5.73

NOTES:

DESCRIPTION

1 550939 12 601837 13 792002 54 550938 15 114210 16 777185 17 027284 18 603049 29 781567 3

10 767962 311 602345 212 602263 213 602338 114 602341 115 602344 1

117589EX_0416 7-35

60" Rear Discharge Deck

20

17

18

21

22

242

1916

1716

21

23

1

1

7-36 117589EX_0416

60" Rear Discharge Deck

INDEX NO. PART NO. QTY.

CS .375-16 X .75 HX G5FW .379 X .813 X .063LS ADJUSTABLE BAFFLERS ADJUSTABLE BAFFLEBLADE, F20.50"-L-F-CCWBLADE, 20.50" GAT-F-CCWCW .631 X 2.25 X .187 PNT CS .625-11 X 1.25 HX G5 LH THREADBLADE, F20.50"-L-F-CWBLADE, 20.50" GAT-F-CWCS .625-11 X 1.25 HX G5 Z

NOTES:

1. Torque to 118 ft-lbs.

DESCRIPTION

16 055822 617 767954 618 114205 119 114204 120 795633 1

601928 121 782474 322 604383 123 600901 2

794230 224 781872 2

117589EX_0416 7-37

Rear Discharge Deck Lift

1

2

3

7

16

7

10

4

56

8

10

5

9

10

7

89

911

12

8

10

9

9

1314

6

15

5

5

7-38 117589EX_0416

Rear Discharge Deck Lift

INDEX NO. PART NO. QTY.

DECK HEIGHT PINSTOP HANDLEDECK LIFT INDICATORCE .750 X 2.25 X 1.75 HEADE CLIP 1.00 X .625 X .05DECK LIFT SPRINGCS .437-14 X 1.75 HX G5DECK LIFT CHAINNT .437-14 HX FLG ZNGREASE FITTING STRAIGHTCS .312-18 X 1.50 FLTHR HXNT .312-18 HX G5FW .625 X 1.50 X .105 ZNCS .625-11 X 1.25 HX G5 ZDECK LEVELER YOKECS .437-14 X 1.75 FULTH

NOTES:

DESCRIPTION

1 600437 12 348318 13 602898 14 781229 15 781294 66 603184 27 055749 78 348391 49 704643 16

10 015495 411 756270 112 034272 113 704783 114 781872 115 348458 116 781831 1

117589EX_0416 7-39

Rear Discharge Deck Mounting Hardware

18

19

17

97

9

7-40 117589EX_0416

Rear Discharge Deck Mounting Hardware

INDEX NO. PART NO. QTY.

FW .760 X 1.625 X .08 ZNYCNT .750-10 HX ZY NLCS .750-10 X 3.50 HX G5

NOTES:

DESCRIPTION

17 025296 418 061101 219 789115 2

117589_0416 8-1

Section 8

Seat, Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Seat Service Parts, Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Seat, Grammer—S/N 15100849 & Higher. . . . . . . . . . . . . . . . . . . . . 8-6

Seat, Grammer—S/N Prior to 15100849 . . . . . . . . . . . . . . . . . . . . . . 8-8

Seat Service Parts, Grammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

ROPS—S/N 15010001 & Higher . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

ROPS—S/N Prior to 15010001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

8-2 117589_0416

Seat, Suspension

1

2

34

6

10

8

13

1112

15

14 1613

1711

18

37

11

19

201932

33

2122 23

24

2625 27

28

29

30

1131

373612

11

5

7

35

10

30

2

34

1

1

34

19

1112

3811

9

117589_0416 8-3

Seat, Suspension

INDEX NO. PART NO. QTY.

SUSPENSION SEATSEAT BELTFW .440 X 1.00 X .083 ZNYCS .437-20 X 1.00 HX G8 ZNYCSEAT LATCHTORSION SPRINGSEAT PAN W/A (WITH DECALS & INSTALLATION KIT)BATTERY WARNINGS DECALLEVEL FUEL FILL DECALARMREST WARNING DECALFW .379 X .813 X .063NT .375-16 HX ZY NLNT .312-18 HX ZY NLSB .375 X .375 SH .312-18WIRE TIEFW .344 X 1.00 X .12 HRD ZFIBER WASHERSEAT PAN STOPCS .375-16 X 1.00 HX G5FW .406 X 1.00 X .12 HRD ZENGINE COMPARTMENT DECALHYDRAULIC PRESSURE DECALHOT/SYN HYDRO OIL DECALVIBRATION MOUNTSEAT SUPPORT (WITH DECALS)FUEL INDICATOR DECALLS FRAME COVER (WITH DECALS)PUMP BELT WARNING DECALLS STEERING DECALCN .312-18 X .20 MAX THKNT .375-16 HX G5 ZNYRS FRAME COVER (WITH DECAL)RS STEERING DECALFLOOR PANGM .50 X 1.00 X .75 X .12FW .343 X .687 X .051/.080HCS .312-18 X 1.00 HX G5CS .375-16 X 1.25 HX G5 ZN

NOTES:

1. Do not torque; the seat pan & seat pan stop must pivot freely.

DESCRIPTION

1 792051 12 601444 13 017129 24 797076 25 113157 16 783910 17 550815 18 601815 19 605688 1

10 785188 111 767954 1312 086660 613 058776 514 754358 115 000331 216 712927 417 724716 218 350421 219 036244 620 712919 421 601967 122 601968 123 601058 124 601650 225 550816 126 791848 127 550823 128 600899 129 785139 130 601069 531 054502 232 550824 133 785220 134 117323 135 080358 136 768523 537 036236 538 052860 3

8-4 117589_0416

Seat Service Parts, Suspension

12

8

10

5

9

3

6

413

1

2

7

14

11

INDEX NO. PART NO. QTY.

SLIDE KITKNOB KITBACK CUSHION KITBOTTOM CUSHION KITSEAT BACK PANEL KITSEAT SWITCHMOLDED ROUND ARMRESTARMREST STOP ASSEMBLYSEAT WEIGHT ADJUSTMENT KITSEAT DRAIN REPLACEMENTSPRING SADDLE KITRS ROUND ARMREST ASSEMBLY (WITH BRACKET)LS ROUND ARMREST ASSEMBLY (WITH BRACKET)SHOCK ABSORBER KIT

DESCRIPTION

1 793307 12 793323 13 793281 14 793299 15 797571 16 793315 17 797480 18 793273 19 601458 110 602076 111 603040 112 601533 113 601534 114 603152 1

117589_0416 8-5

This page intentionally left blank.

8-6 117589_0416

Seat, Grammer—S/N 15100849 & Higher1

31

29

34

35

6

7 98

1012

11

12

131226

2514

1517 18

19

16

2122

20

23

1024

1110

2

10

23

1

1

36

2

1018 24

COOLER MOUNTFIREWALL

33

35

10

11

35

10

4

27

32

30

2728

117589_0416 8-7

Seat, Grammer—S/N 15100849 & Higher

INDEX NO. PART NO. QTY.

SEATGM .50 X 1.00 X .75 X .12SEAT PAN (WITH DECALS)LEVEL FUEL FILL DECALARMREST WARNING DECALFW .344 X 1.00 X .12 HRD ZNT .312-18 HX ZY NLFIBER WASHERSEAT PAN STOP (PLATED)FW .379 X .813 X .063NT .375-16 HX ZY NLCS .375-16 X 1.00 HX G5FW .406 X 1.00 X .12 HRD ZENGINE COMPARTMENT DECALHYDRAULIC PRESSURE DECALSEAT SUPPORT (WITH DECALS)HOT/SYN HYDRO OIL DECALVIBRATION MOUNTFUEL INDICATOR DECALLS STEERING DECALLS FRAME COVER (WITH DECALS)PUMP BELT WARNING DECALCN .312-18 X .20 MAX THKNT .375-16 HX G5 ZNYRS STEERING DECALRS FRAME COVER (WITH DECAL)FW .343 X .687 X .051/.080HCS .312-18 X 1.00 HX G5BATTERY WARNINGS DECALCB .312-18 X .750 FUL ZNLATCH ASSEMBLYNT .312-18 HX G5WIRE TIESEAT SWITCH PIGTAILCS .375-16 X 1.25 HX G5 ZNFLOOR PAN

NOTES:

1. Do not torque; the seat pan and seat pan stop must pivot freely.

DESCRIPTION

1 605696 12 080358 23 550815 14 605688 15 785188 16 712927 47 058776 48 724716 29 350421 210 767954 1311 086660 512 036244 613 712919 414 601967 115 601968 116 550816 117 601058 118 601650 319 791848 120 785139 121 550823 122 600899 123 601069 524 054502 325 785220 126 550824 127 768523 728 036236 529 601815 130 016253 231 605907 132 034272 233 000331 334 604439 135 052860 336 117323 1

8-8 117589_0416

Seat, Grammer—S/N Prior to 151008491

30

31

10

29

32

11

7

3 5

6

7 9

8

10

11

11

1213

1226

24

14

1517 18

19

1621

22

20

23

1024

2827

11

10

2

10

23

1

1

34

2

1018 24

COOLER MOUNTFIREWALL

33

36

10

11

36

10

435

117589_0416 8-9

Seat, Grammer—S/N Prior to 15100849

INDEX NO. PART NO. QTY.

SEATGM .50 X 1.00 X .75 X .12SEAT PAN (WITH DECALS)LEVEL FUEL FILL DECALARMREST WARNING DECALFW .344 X 1.00 X .12 HRD ZNT .312-18 HX ZY NLFIBER WASHERSEAT PAN STOP (PLATED)FW .379 X .813 X .063NT .375-16 HX G5 ZY NLCS .375-16 X 1.00 HX G5FW .406 X 1.00 X .12 HRD ZENGINE COMPARTMENT DECALHYDRAULIC PRESSURE DECALSEAT SUPPORT (WITH DECALS)HOT/SYN HYDRO OIL DECALVIBRATION MOUNTFUEL INDICATOR DECALLS STEERING DECALLS FRAME COVER (WITH DECALS)PUMP BELT WARNING DECALCN .312-18 X .20 MAX THKNT .375-16 HX G5 ZNYRS STEERING DECALRS FRAME COVER (WITH DECALS)FW .343 X .687 X .051/.080HCS .312-18 X 1.00 HX G5BATTERY WARNINGS DECALSEAT LATCHTORSION SPRINGSB .375 X .375 SH .312-18WIRE TIEFLOOR PANSEAT SWITCH PIGTAILCS .375-16 X 1.25 HX G5 ZN

NOTES:

1. Do not torque; the seat pan & seat pan stop must pivot freely.

DESCRIPTION

1 605696 12 080358 23 550815 14 605688 15 785188 16 712927 47 058776 58 724716 29 350421 210 767954 1411 086660 612 036244 613 712919 414 601967 115 601968 116 550816 117 601058 118 601650 319 791848 120 785139 121 550823 122 600899 123 601069 524 054502 325 785220 126 550824 127 768523 528 036236 529 601815 130 113157 131 783910 132 754358 133 000331 334 117323 135 604439 136 052860 3

8-10 117589_0416

Seat Service Parts, Grammer

1

3

4

2

5

INDEX NO. PART NO. QTY.

BACK CUSHIONRS ARMRESTLS ARMRESTSEAT BELTSEAT CUSHIONSEAT SWITCH (NOT SHOWN)SLIDE KIT (NOT SHOWN)ISOLATOR KIT (NOT SHOWN)

NOTES:

DESCRIPTION

1 604940 12 604938 13 604937 14 604941 15 604939 16 604973 17 119287 18 119288 1

117589_0416 8-11

This page intentionally left blank.

8-12 117589_0416

ROPS—S/N 15010001 & Higher

1

45

5

6

3

3

2

1

117589_0416 8-13

ROPS—S/N 15010001 & Higher

INDEX NO. PART NO. QTY.

ROPS KITPOLY STOP KITROPS HARDWARE KITCS .500-13 X 3.50 HX G5FW .531 X 1.063 X .175NT .500-13 UNT LK G8 ZN

NOTES:

1. Torque to 73 ft-lbs.

DESCRIPTION

1 605741 12 605731 23 605638 14 061812 45 767962 86 023317 4

8-14 117589_0416

ROPS—S/N Prior to 15010001

2

4

4

32

5

5

47

1

1

8

3

5 6

117589_0416 8-15

ROPS—S/N Prior to 15010001

INDEX NO. PART NO. QTY.

ROPS KIT (WITH DECALS, SEATBELT & HARDWARE)HAND KNOBLYNCH PIN W/ LANYARDCS .500-13 X 3.50 HX G5NT .500-13 UNT G8ROPS STOPFW .531 X 1.063 X .175ROPS DECAL

NOTES:

1. Torque to 73 ft-lbs.

DESCRIPTION

1 603338 12 601470 23 601471 24 061812 65 023317 66 603099 17 767962 88 601635 2

8-16 117589_0416