Dixie Chopper XW2300, XW2400, XF/XW2500, XWK2501, XWK2503 Parts Manual

Serial Numbers

2037200

and Higher

Model #	____________________	Engine Model #	____________________
Serial #	____________________	Engine Serial #	____________________
Date Purchased	____________________	Engine Spec. #	____________________

XW,XF-60 PARTS MANUAL

700005

April, 2002

Congratulationson your purchase of a DIXIE CHOPPER lawn

mower. We believe you have exercised excellent judgement, and are most appreciative of your patronage.

Your DIXIE CHOPPER Dealer is your #1 SOURCE for DIXIE CHOPPER parts and service !

Please call or visit your nearest authorized Dixie Chopper Dealer for additional service information.

AUTHORIZED DEALER

Let us know how you are getting along with your new CHOPPER! www.dixiechopper.com

Dixie Chopper reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes to products previously manufactured. Neither Dixie Chopper, nor its dealers, accept responsiblility for variations which may be evident in the actual specifications of its products and the statements and descriptions contained in this publication.

CONTENTS

Quick Reference Parts	1
Decals	2
Decal Placement	5
Frame	6
Wheels & Tires	7
Foot Pedal	8
Deck Lift System	9
OCDC	10
Deck	11
Hubs & Belts	13
Transmission Frame	14
Transmission & Drive	17
Wheel Motor	18
Hydraulic Hose Diagram	19
Fuel System	20
Body	21
Throttle	23
Brake Assembly	24
Engine - Kohler 23Hp	26
Engine - Honda 24Hp	27
Engint - Kohler 25Hp	28
Engine - Kawasaki 25Hp	29
Engine - Kohler 26Hp EFI	30
Electrical Diagram - Honda	31
Electrical Diagram - Kohler	32
Electrical Diagram - Kawasaki	33
Electrical Diagram - Kohler EFI	34

XW MODEL

QUICK REFERENCE PARTS

MODEL	XW2300		XW2400	XF/XW2500	XWK2501	XWK2503	XW2600-EFI
Engine	Kohler 23 Hp		Honda 24Hp	Kohler 25Hp	Kawasaki 25Hp	Kawasaki 25Hp	Kohler 26Hp
Deck	60"		60"	60"	60"	60"	60"
Rear Tires	97200		97200	97200	97452	97200	97200
Rear Rims	400014		400014	400014	61238	400014	400014
Front Tires	97165		97165	97165	97165	97165	97165
Front Rims	10239		10239	10239	10239	10239	10239
Belts
Engine-Transmission	9907B41		9907B41	9907B41	9907B41	9907B41	9907B41
Engine-Deck	9907B85		9907B85	9907B85	9907B85	9907B85	9907B85
Deck	9907B130		9907B130	9907B130	9907B130	9907B130	9907B130
Filters
Fuel Filter	97392		97392	97392	97392	97392	97392
Nelson Air Filter				90122			90122
Amsoil Oil Filter				60119			60119
Zinga-Hydro Filter	68140		68140	68140	68140	68140	68140
Blades
Standard	30227-60H		30227-60H	30227-60H	30227-60H	30227-60H	30227-60H
Heavy-Duty	30227-60N		30227-60N	30227-60N	30227-60N	30227-60N	30227-60N
		Various Parts ALL MODELS
Fiber Washer	W-101
Spindle Bearing	30218
Deck Roller (Ctr)	30240-O
Choke Control	20248		Kawasaki & Honda ONLY		600002
Throttle Cable	68249		Kawasaki & Honda ONLY		364000668211
Brake Cable	65246 (Left)		65247 (Right)
Parking Brake Band	65244
Fuel Cap	40117-1
Control Lever Grip	20257

DECALS

REF #	PART #	DESCRIPTION	QTY.
1	97507	XW2300 Front Panel	1
2	65419	XW2400 Front Panel	1
3	65462	XFW2500 Front Panel	1
4	65428	XW2500 Front Panel	1
5	800006	XWK2501 Front Panel	1
6	800011	XWK2503 Front Panel	1
7	800016	XW2600 Front Panel	1
8	800003	Big Wheel Decal	1

REF # PART #		DESCRIPTION	QTY.
9	65413	Patent Pending	1
10	800014	Ignition	1
11	800015	Choke	1
12	65406	Parking Brake Caution	1
13	97013	VTC Only	1
14	30591	Warranty Notice	1
15	800010	Flex-Deck Ready Decal	1
16	97160	RPM Notice	1

DECALS (CONT’D)

REF #	PART #	DESCRIPTION	QTY.
17	30588	Hillside Danger	1
18	264000200210	VTC	1
19	30586	Tractor Buster	1
20	30590	USA Decal	1
21	65409	60 Inch Cut	2
22	40118	Fuel Caution	2

REF #	PART #	DESCRIPTION	QTY.
23	990765438	Belt Information	1
24	30585	Fender Caution	1
25	63401	Throttle	1
26	63402	Brake & Steering	1
27	97514	Horn Warning	1
28	97008	Cross Member Decal	1

DECALS (CONT’D)

REF #	PART #	DESCRIPTION	QTY.
28	30573	Floor Pan Decal	2
29	30571	Fender Decal	2
30	30229	Deck Danger Decal	2

REF # PART #		DESCRIPTION	QTY.
31	97072	OCDC Safety Decal	1
32	65430	Flatlander Decal	1
33	65422	Belt Route Decal	1

	DECAL PLACEMENT
	9	T-Box
	13 Oil Tank
		19 Rear Left
	20 Rear Right	Fender	17
		12
	Fender		26
	25
			27
					Side Left
					Fender
31			8	32
16	14			1	2	3	4	5	6	7
28	24 22
	29
	18
	10	11
			28
		23
		30
		21
	15
21
33

FRAME

4

			5
			6
		7	3
			8
34			9
13	14		10

	12	11
		2
		34
15		1

		22	16
			17
			18
27	24		19
28			20
	23		21
			25
		26

400000	XW2400

	XF2500
	XW2500
	XWK2501
	XWK2503
400027	XW2600 EFI

XW2300

70100-22

R E F # P A R T #				D E S C R I P T I O N	Q T Y .
1	1 0 0 0 0 0	W e ld m e n t - X W F r a m e			1
2	B - 2 0 4	3 /8 " - 1 6		U - B o lt	4
3	N - 1 6 0	3	/8 " - 1 6	C o u p lin g N u t	8
4	4 0 0 0 0 0	V S ty le R e a r G u a r d			1
	4 0 0 0 2 7	H S t y le		R e a r G u a r d	1
	7 0 1 0 0 - 2 2	2 2 / 2 3 H p R e a r G u a r d			1
5	4 0 0 0 2 6	W e ld m e n t - L o w R id e S e a t P a n
			w / H in g e
					1
6	1 0 0 0 0 7	W e ld m e n t - L o w R id e
			T r a n s m is s io n F r a m e		1
7	B - 2 2 9	3 /8 " - 1 6		x 5 " B o lt	2
8	N - 1 0 7	3 /8 " - 1 6		N y lo c N u t	2
9	N - 1 3 5	7 /1 6 " - 2 0 N y lo c N u t			4
1 0	W - 1 6 8	7 /1 6 " S t a n d a r d F la t W a s h e r			8
1 1	B - 1 9 9	7 /1 6 " - 2 0 x 2 " B o lt			4
1 2	1 0 1 0 0 - S T	B u m p e r - X W / X F			1
1 3	W - 1 6 0	1 0 m m F la t W a s h e r			2
1 4	B - 1 7 9	3 /8 - 1 6 X 2 1 / 2			2
1 5	N - 1 0 8	3 /8 " - 1 6		W h iz F la n g e N u t	2

R E F # P A R T #		D E S C R I P T I O N	Q T Y .
1 6	N - 1 0 3 - W	5 / 1 6 " - 1 8 W h iz F la n g e N u t	4
1 7	7 2 2 1 6	P u ll S t o p W e ld m e n t	1
1 8	N - 1 1 0	1 / 2 " - 1 3 N u t	1
1 9	4 0 2 2 1 - 6 0	B o lt 1 4 " x 1 / 2 "	1
2 0	W - 1 1 3	5 / 1 6 " S t a n d a r d F la t W a s h e r	4
2 1	B - 1 5 6	5 / 1 6 " - 1 8 x 2 " B o lt	4
2 2	W - 1 0 7	S h a r k - T o o t h B e lle v ille W a s h e r	1
2 3	7 2 2 2 0	B e lt G u id e A s s e m b ly	1
2 4	7 2 2 1 7	B e lt G u id e W e ld m e n t	2
2 5	7 2 2 2 2	A ll T h r e a d	1
2 6	N - 1 1 0	N u t	6
2 7	7 2 2 2 2	A ll T h r e a d	1
2 8	N - 1 1 0	N u t	6
2 9	B - 1 2 3	1 / 2 " - 1 3 x 1 1 / 2 " B o lt	4
3 0	W - 1 0 9	1 / 2 " F la t W a s h e r	4
3 1	9 7 1 2 4	C r o s s m e m b e r	1
3 2	N - 1 5 7	1 / 2 " - 1 3 W h iz F la n g e N u t	4
3 3	4 0 0 0 0 8	M o u n t - F lo o r P a n H in g e F r a m e	2
3 4	9 7 1 6 9	P la s t ic S q u a r e C a p	2
	6 7 2 5 5	R o u n d C a p	2

WHEELS & TIRES

	1A	1
		2
	3
	4
	5
	6
	7				9	11
				13
					10
						25
	8
		15				12
	16
17						27
			14			26
18
						24
						23
19						22
20					21

REF #	PART #	DESCRIPTION	QTY.
1	10220	Dust Cap	2
1A	P -108	Cotter Pin	2
2	N-142	1" Slotted Hex Nut	2
3	10207	Top Bearing	2
4	10206	Outer Bearing Race	4
5	97171	B ottom Bearing	2
6	10208	Oil Seal	2
7	97170	Front Fork W eldm ent	2
8	B -122	B olt - 5/8"-11x7" Hex Head	2
9	N-115	Nut - 5/8"-11 Nyloc	2
10	67205	Inner Front W heel B earing	2
11	10203	Outer Front W heel Spacer	2
12	10205	Outer Front W heel Bearing	2
13	97166	Front Tire A ssem bly	2
	N/A	Front Tire	2
	10239	Rim	2
	10127-S	Valve Stem	2
14	67205	Inner Front W heel B earing	2
15	67204	Inner Front W heel S pacer	2
16	10205	Outer Front W heel Bearing	2
17	10203	Outer Front W heel Spacer	2

REF #	PART #	DESCRIPTION	QTY.
18	97451	L/R Titan CTR Assem bly (X W K2501)	2
	97452	Titan CTR Tire	2
	61238	Rim	2
	10127-S	Valve Stem	2
	400019	Left Tire Assem bly (X F2400,2500,2600)
		(XW 2300, 2400, 2500, 2503, 2600)	1
	97200	Turf B oss III Tire	1
	400014	Rim	1
	10127-S	Valve Stem	1
	400020	Right Tire Assem bly (X F2400,2500,2600)
		(XW 2300, 2400, 2500, 2503, 2600)	1
	97200	Turf B oss III Tire	1
	400014	Rim	1
	10127-S	Valve Stem	1
19	N-113	Lug Nut	8
20	PB339303P	W heel M otor A xle Nut	2
21	67266	Brake Drum	2
22	67002	W heel Flange w/studs	2
23	B -183	W heel M otor B olt	8
24	W -138	W heel M otor S quare W asher	8
25	PW 72546	1/4" Key	2
26	67114	W heel M otor 14Cu.In.	2
		(XF2400,XW K2501,XF2500,XF2600)
	67118-W	W heel M otor 18Cu.In.
		(XW 2300, 2400, 2500, 2503,2600)	2
27	N-127	W heel M otor Nut	8

FOOT PEDAL ASSEMBLY

17

16

	15	19
		1
		18

7

4 5 6

8 9

	14	3
13		2

10

11 12

REF #	PART #	DESCRIPTION	QTY.
1	10107-1/2	Kit - Foot Pedal	1
2	10225-2	Weldment - #50 Foot Lift Arm	1
3	10224-1	Pawl	1
4	990735020	Foot Pedal Lock ( Incl. #5 - #6 )	1
5	W-164	Washer	1
6	N-144	Nut	1
7	300008	Deck Height Pointer	1
8	N-130	Coupling Nut	1
9	300007	Deck Height Indicator	1
10	10226-1	Lift Sprocket	1

REF # PART #		DESCRIPTION	QTY.
11	10228-1	Pin	1
12	F-100	Grease Fitting	1
13	B-131	Bolt	1
14	W-113	Washer	1
15	68219	#50 Chain	1
16	10233	#50 Half Link	1
17	10232	#50 Master Link	1
18	20217-25	Spring	1
19	30213	Cotter Pin	1

DECK LIFT SYSTEM

6

			2	3		5
		1	1				1
				4			7
			8
					11
			19				12
		10
	8			10	9		13
			9					14
								15
	20						8
								16
				8			18
					15
REF #	PART #		DESCRIPTION	QTY.			15
							17
1	68112		1" Bushing	3
2	68106		1.1875" Bushing	1
3	S-114		1/2"-13 Stud	4
4	N-157		1/2"-13 Whiz Flange Nut	4
5	68105		1/4" Bushing	1
6	68104		#50 Small Sprocket	1	REF # PART #		DESCRIPTION	QTY.
7	N-157		1/2"-13 Whiz Flange Nut	8	14	N-108	3/8"-16 Whiz Flange Nut	1
8	68103		Deck Lift Sprocket #50	7	15	W-154	3/4" Flat Washer	4
9	990710003		#50 Rear Deck Lift Chain	2	16	B-239	3/4"-10x10" Bolt	1
10	68217		#50 Front Deck Lift Chain	2	17	B-238	3/4"-10x8.5" Bolt	1
11	990710002		#50 Return Spring Chain	1	18	N-158	3/4"-10 Nyloc Nut	2
12	97455		200 lb. Return Spring	1	19	68113	3/4"x31.5" Rod	1
13	B-241		3/8"-16 Eye Bolt	1	20	10232	#50 Master Link	10