Exmark VH3615KA, Vh4815ka User Manual
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects,
or other reproductive harm.
WARNING
IMPORTANT
When the mower is used or oper ated on any California forest, brush or g rass covered land, a working
spark arrester must be at t ached t o the muffler. If not, the operator is violating state law, Section 442
Public Resource Code. To acquire a spark ar r ester for your unit, see your Engine Service Dealer.
POTENTIAL HAZARD
♦ This product is a piece of power equipment.
WHAT CAN HAPPEN
♦ Failure to follow safe operating pr actices can result in serious
operator injury or even death.
HOW TO AVOID THE HAZARD
♦ Keep all shields, guards and safety devices (especially the grass
discharge system) in place and in proper working condit ion.
♦ Stop engine and remove spark plug wire(s) or r emove key and
wait for all moving parts to stop before adjusting, servicing, or
performing maintenance.
♦ If mower deck becomes clogged, stop engine and remove spark
plug wire(s) or remove key and wait for all m oving par ts to stop
before cleaning blockage.
♦ Keep hands, feet and clothing away from power driven parts.
♦ Keep off mower unless seat platform is provided.
♦ Keep others off mower.
WARNING
WARNING
POTENTIAL HAZARD
♦ Gasoline is harmful or f at a l if swallowed. Long-term exposure to
vapors has caused cancer in laboratory animals.
WHAT CAN HAPPEN
♦ Failure to use caution may cause serious injury or illness.
HOW TO AVOID THE HAZARD
♦ Avoid prolonged breathing of vapors.
♦ Keep face away from nozzle and gas tank/container opening.
♦ Keep away from eyes and skin.
♦ Never siphon by mouth.
Exmark 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 manufactured previously. Exmark, or its distributors and
dealers, accept no responsibility for variations which may be evident in the actual specifications of its products
and the statements and descriptions contained in this publication.
ii
EXMARK PARTS PLUS
PROGRAM
EFFECTIVE DATE: September 1, 1995
Program
If your Exmark dealer does not have the Exmark part in stock,
Exmark will get the parts to the dealer the next business day or the
part will be FREE* Guaranteed!!
How the Program Works
1. If dealer does not have part in stock for a "down" unit at
the time of request by customer, the dealer contacts his
distributor by 1:00 p.m., local time, and requests Exmark
Parts Plus
shipment of six (6) line items or less.
2. Distributor ships part(s) to dealer or customer, as
requested by dealer, same day, overnight UPS Distributor
bills dealer for part and freight charges where applicable.
3. If distributor does not have the part(s) in stock to satisfy
Exmark Parts Plus
p.m., central time, with an Exmark Parts Plus
order, he contacts Exmark by 3:00
order of six (6) line items or less.
4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by
distributor, same day, overnight UPS Exmark bills the distributor for parts and shipping charges, where applicable.
5. The customer pays for the part and freight
if it is shipped under the Exmark Parts Plus
and if it arrives in accordance
to the program.
6. Who pays for the part and freight
if it fails to arrive overnight in accordance to the program?
A. Under any circumstance the customer does not pay.
B. If the part does not arrive overnight due to:
1. The dealer not submitting the Exmark Parts Plus
order to his Exmark distributor by 1:00 p.m., the dealer
pays for the part and freight.
2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus
order
to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.
3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,
Exmark pays for the part and freight.
4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark
pays for the part.
The following restrictions apply
-- The Exmark Parts Plus
Program is available only through participating Exmark
Dealers and applies only to orders submitted on this program Monday through Thursday. Part Plus service is available only in
the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental United
States and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air charge, plus the
Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no responsibility for Saturday
delivery shipments. To qualify, all Exmark Parts Plus
must be six (6) line items or less. Exclusions from the Exmark Parts Plus
orders must be received by Exmark by 3:00 p.m., central time. Orders
Program are: Any wholegood or accessory in its
entirety, engines and engine replacement parts, 5-speed Peerless transmissions and 5-speed transaxles, hydraulic or
hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United Parcel Service size and weight
restrictions.
Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day or
Second Day Air.
Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be ordered
for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.
iii
CONGRATULATIONS
designed and manufactured to give you a maximum amount of dependability and years of
trouble-free operation.
on the purchase of your Exmark Mower. This product has been car ef ully
OPERATOR'S MANUAL
This manual contains assembly, operating, m aint enance, adjustment and safety
instructions for your Exmark m ower.
BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS
ENTIRETY.
By following the operating, maintenance and safety instructions, you will prolong the life
of your mower, maintain its maximum ef ficiency and promote safe operation.
If additional information is needed, or should you require trained mechanic service,
contact your authorized Exmark equipment dealer or distributor.
All Exmark equipment dealers and distribut or s are kept informed of the latest methods
of servicing and are equipped to provide prompt and efficient service in the field or at their
service stations. They carry ample stock of ser vice parts or can secur e t hem promptly for you
from the factor y.
All Exmark parts are thoroug hly test ed and inspect ed before leaving the factory,
however, attention is required on your part if you are t o obt ain the fullest measure of
satisfaction and performance.
iv
TABLE OF CONTENTS
1. SAFETY ...................................................................................................PAGE
1.1 Safety Alert Symbol......................................................................................1
1.2 Training ........................................................................................................1
1.3 Preparation..............................................................................................1 - 3
1.4 Operation.................................................................................................3 - 4
1.5 Maintenance & Storage........................................................................... 4 - 5
1.6 Riding Attachments....................................................................................... 5
1.7 Safety Signs ....................................................................................... ....5 - 7
2. SPECIFICATIONS
2.1 Model Number..............................................................................................7
2.2 Engine..........................................................................................................7
2.3 Fuel System..................................................................................................7
2.4 Safety Interlock System................................................................................7
2.5 Steering/Brake Control .................................................................................7
2.6 Transmission.............................................................................................7-8
2.7 Wheel Drive System.....................................................................................8
2.8 Tires .............................................................................................................8
2.9 Deck.............................................................................................................8
2.10 Dimensions..................................................................................................8
2.11 Torque Requirements..................................................................................9
3. ASSEMBLY INSTRUCTIONS
3.1 to 3.23 Assembly...................................................................................9 - 11
4. OPERATION INSTRUCTIONS
4.1 Controls...............................................................................................12 - 13
4.2 Pre-Start..............................................................................................13 - 14
4.3 Operation Instructions..........................................................................14 - 17
4.4 Transporting ...............................................................................................17
5. MAINTENANCE & ADJUSTMENTS
5.1 Periodic Maintenance ..........................................................................18 - 24
5.2 Adjustments.........................................................................................24 - 32
6. TROUBLE SHOOTING
6.1 Mower Tacks Left or Right..........................................................................32
6.2 Mower Cuts Unevenly.................................................................................32
6.3 Blades Do Not Stop When Disengaged......................................................32
6.4 Engine Will Not Start ...........................................................................32 - 33
7. BELT ROUTING (MOWER DECKS)
8. WIRING DIAGRAM
........................................................................................34
.......................................................
33
9. HYDRAULIC DIAGRAM
10. WARRANTY
...........................................................................................36 - 37
................................................................................35
v
1. SAFETY
1.1 SAFETY ALERT SYMBOL
THIS SAFETY ALERT S YMBOL
THE MACHINE TO IDENTIFY IMPORTANT SAFETY MESSAGES WHICH MUST BE
FOLLOWED TO AVOID ACCIDENTS. THIS SYMBOL MEANS:
IS USED BOTH IN THIS MANUAL AND ON
ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
The safety alert symbol appears above informat ion which alerts you of unsaf e act ions or
situations and will be followed by the word
When used with t he word DANGER: IT DENOTES THAT AN EXTREME HAZARD
EXISTS WHICH WOULD RESULT IN HIGH PROBABILITY OF DEATH OR
IRREPARABLE INJURY IF PROPER PRECAUTIONS ARE NOT TAKEN.
When used with t he word WARNING: IT DENOTES THAT A HAZARD EXISTS
WHICH CAN RESULT IN INJURY OR DEATH IF PROPER PRECAUTIONS ARE NOT
TAKEN.
When used with t he word CAUTION: IT DENOTES A REMINDER OF SAFETY
PRACTICES OR DIRECTS ATTENTION TO UNSAFE PRACTICES WHICH COULD
RESULT IN PERSONAL INJURY IF PROPER PRECAUTIONS ARE NOT TAKEN.
DANGER, WARNING
1.2 TRAINING
1.2.1 Regard the Exmark mower as a piece of power equipm ent and teach this
regard to all who operate this unit.
1.2.2 Read the instructions carefully. Familiarize yourself with the cont r ols and the
proper use of the equipment.
1.2.3 Never allow children, teenagers, or people unfamiliar with these inst r uctions to
use the mower.
1.2.4 Avoid mowing while people, especially children, or pets, are nearby. Keep in
mind that the operator or user is responsible for accidents or hazards occurring
to other people or their property.
CAUTION.
, or
1.3 PREPARATION
1.3.1 The use of personal protective equipment, such as (but not limited to)
protection for the eyes, ears, feet and head is recommended.
1.3.2 While mowing, always wear substantial footwear and long trousers. Do not
operate equipment when barefoot or when wearing open sandals.
1.3.3 Thoroughly inspect the area where the equipment is to be used and remove all
stones, sticks, wires, bones and other f or eign objects which may damage the
equipment or cause personal injury to the operat or or bystander s.
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POTENTIAL HAZARD
♦ Engine exhaust contains carbon monoxide, which is
an odorless deadly poison.
WHAT CAN HAPPEN
♦ Carbon monoxide can kill you and is also known to the
State of California t o cause birth defects.
HOW TO AVOID THE HAZARD
♦ Do not run engine indoors or in a small confined area
where dangerous carbon monoxide fumes can collect.
WARNING
POTENTIAL HAZARD
♦ In certain conditions gasoline is extremely flammable
and highly explosive.
WHAT CAN HAPPEN
♦ A fire or explosion from gasoline can bur n you, ot hers,
and cause property damage.
HOW TO AVOID THE HAZARD
♦ DO NOT smoke while refueling , and stay away from
an open flame or where gasoline fumes m ay be ignited
by spark.
♦ Refuel only in a well ventilated area, or refuel
outdoors.
♦ Store gasoline in an approved container and keep it
out of the reach of children.
♦ Add fuel before start ing the engine. Never remove the
cap of the fuel tank or add fuel when engine is running
or when the engine is hot.
♦ Never fill the fuel tank so that the gasoline level rises
above a level that is 1/2” below the bottom of the filler
neck to allow for gasoline expansion and prevent fuel
spillage.
♦ If fuel is spilled, DO NOT attempt to start the engine.
Move away from the area of the spill and avoid
creating any source of ignition unt il fuel vapors have
dissipated.
DANGER
- 2 -
POTENTIAL HAZARD
♦ In certain conditions gasoline is extremely flammable
and highly explosive.
WHAT CAN HAPPEN
♦ A static charge can ignite g asoline vapors. A fire or
explosion from gasoline can burn you, others, and
cause property damage.
HOW TO AVOID THE HAZARD
♦ Purchase and store gasoline only in an approved
container.
♦ Always place gasoline containers on the ground away
from your vehicle before f illing.
♦ Do not fill gasoline containers inside a vehicle or on a
truck or trailer bed because inter ior car pets or plastic
truck bed liners may insulate the container and slow
the loss of any static charge.
♦ When practical, r emove gas-powered equipment from
the truck or trailer and refuel the equipment with its
wheels on the ground.
♦ If this is not possible, then refuel such equipment on a
truck or trailer from a portable container, rather t han
from a gasoline dispenser nozzle.
♦ If a gasoline dispenser nozzle must be used, keep the
nozzle in contact with the rim of the fuel tank or
container opening at all times until fueling is complete.
DANGER
1.4 OPERATION
Although hazard control and accident prevention are partially dependent upon the design
and configuration of the equipment, these factors are also dependent upon the awareness,
concern, prudence and proper training of the personnel involved in the opera tion,
transport, maintenance and storage of the equipment. It is essential that all Operator
Safety Mechanisms be connected and in operating condition prior to use for mowing.
1.4.1 Give complete, undivided attent ion t o t he job at hand.
1.4.2 Mow only in daylight or good artificial light.
children or others are in the area!
1.4.3 When feasible, avoid operating the eq uipm ent in wet grass.
1.4.4 Use
traction and/or control could occur. Mow
mowers, never up and down. Loss of control and/or loss of oper at or ’s footing
could result in a fall with an arm or leg getting under the mower or engine deck
and sustaining serious injury. Drive slower on slopes.
slopes greater than 20 degrees. Watch for dit ches, holes, rocks, dips, and
rises which can cause erratic handlebar movement and loss of footing. Keep
away from drop-offs and steep banks. Avoid sudden starts. Look down and
behind you before and while moving backwards.
grass is wet - slippery conditions create hazardous footing, affect steering, and
reduce traction and braking. The operator is responsible for safe operation on
slopes. See inside back cover to determine the approximate slope angle of the
area to be mowed.
EXTREME
Do Not
caution when mowing and/or turning on slopes as loss of
across
operate the mower when
slopes with walk behind
DO NOT
DO NOT
operate on
mow slopes when
- 3 -
1.4.5 Stop the blades when crossing surfaces other than g r ass; and when
transporting the mower to and fr om the area to be mowed.
1.4.6 Never operate the mower with defective guards, shields, or covers. Always
have safety shields, guards, switches, and other devices in place and in proper
working condition.
1.4.7
Do Not
change the engine governor setting s or over speed the engine.
Operating an engine at excessive speed may increase the hazard of personal
injury.
1.4.8 Place transmission in neutra l, disengage blade drive before starting engine
1.4.9 Start the engine carefully with feet well away from the blades.
1.4.10 Keep hands, feet and clothing away from r otating parts while the mower is
being operated.
1.4.11 Stop the engine and r e m ove plug wire(s) or ignition key:
• Before checking, cleaning or work ing on the mower.
• After striking a foreign object (inspect the mower f or damage and
make repairs before r est ar ting and operating the mower).
1.4.12 Stop the engine:
• Before clearing blockages.
• Whenever you leave the mower.
• Before removing the grass catcher.
• Before refueling.
• Before making height adjustments.
1.4.13 Before stopping the eng ine, return the throttle control to the idle position for 30
seconds to allow the engine to cool down.
1.4.14 The fuel system is provided with a shut-off valve. The fuel shut-off valve is
used to shut off the fuel when:
• The machine will not be used for a few days.
• During transport to and f r om the job.
• When parking inside a building.
1.4.15 This mower was designed for one operator only. Keep all others away fr om
mower during operation.
1.4.16
Do Not
mow without the grass deflector or entire grass collection system in
place and in proper working condition.
1.5 MAINTENANCE AND STORAGE
1.5.1 For engine maint enance, follow the engine manufacture’s recom m endations
precisely as stated in the engine manual.
1.5.2 When mak ing adjustments while the engine is running, such as carburetor and
motion control linkage adjust m ent s, stand to one side and keep clear of
moving/rotating components, such as engine screen, drive belts and sheaves.
Do Not
moving/rotating components.
1.5.3 Keep engine and engine area free from accumulation of grass, leaves,
excessive grease or oil and other debris which can accumulate in these areas.
These materials can become combustible and may result in a fire.
1.5.4 Store f uel in a container specifically designed for this purpose in a cool, dry
place.
wear loose fitting clothing or jewelry that could get tangled in
- 4 -
1.5.5 Keep the mower and fuel container in locked storage to prevent children f r om
playing or tampering with them.
1.5.6 Gasoline powered equipment or fuel containers should not be stored in a
basement or any enclosed area, where open pilot lights or heat appliances are
present.
1.5.7 Maximum mowing results and safet y can only be achieved if the m ower is
properly maintained and operated correctly.
1.5.8. Check all bolts frequently to maintain proper tightness.
1.5.9. Keep all guards, shields and all safety devices in place and in safe working
condition.
1.5.10 Frequently check for worn or deteriorating components that could cr eate a
hazard.
1.5.11 All replacement parts must be the same as or equivalent to the parts supplied
as original equipment.
POTENTIAL HAZARD
♦ Hydraulic fluid escaping under pressure can penetrat e
skin and cause injury.
WHAT CAN HAPPEN
♦ Fluid accidentally injected into the skin must be
surgically removed within a few hours by a doctor
familiar with this form of injury or gangrene ma y result .
HOW TO AVOID THE HAZARD
♦ Make sure all hydraulic fluid hoses and lines are in good
condition and all hydraulic connections and fittings are
tight before applying pressure to hydraulic system.
♦ Keep body and hands away from pinhole leaks or
nozzles that eject high pressure hydraulic fluid.
♦ Use cardboard or paper to find hydraulic leaks.
♦ Safely relieve all pressure in the hydraulic system
before performing any work on t he hydraulic system.
1.6 RIDING ATTACHMENTS
1.6.1 Use only
attachments may create a hazardous condition resulting in injury.
Exmark
riding attachments. The use of other than Exmark riding
WARNING
1.7 SAFETY SIGNS
1.7.1 Keep all safety signs legible. Remove all grease, dirt and debris from saf et y
signs.
1.7.2 Safety signs must be replaced if t hey are m issing or illegible.
1.7.3 When new components are installed, be sur e that current safety signs are
affixed to the replaced components.
1.7.4 New safety signs may be obtained from your authorized Exmark equipment
dealer or distributor or fr om Exmar k Mfg. Co. Inc.
1.7.5 Safety signs may be affixed by peeling of f the backing to expose the adhesive
surface. Apply only to a clean, dry surface. Smooth to remove any air bubbles.
1.7.6 Familiarize yourself with the following safety signs and inst r uct ion labels. They
are critical to the safe operation of your Exmark commercial mower.
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PART NO. 323741
LOCATION: Console
PART NO. 323691
LOCATION: RH Side
of Console
PART NO. 303517
LOCATION: Left Side of Rear
Surface on Engine Deck
PART NO. 403170
LOCATION: 48” Deck
PART NO. 403143
LOCATION: Right Side of Rear
Surface on Engine Deck
PART NO. 323427
LOCATION: 36” Deck
PART NO. 413214
LOCATION: Right Side of Hydro
Control Crank Arm
PART NO. 603845
LOCATION: Rear Center of Top
Surface of Engine Deck
- 6 -
PART NO. 403005
LOCATION: Front Corners of
Mower Deck
PART NO. 303508
LOCATION: On Top Rear Right Hand
Surface of Mower Deck
PART NO. 303102
LOCATION: Upper
Handle
PART NO. 513746
LOCATION: On Engine Blower
Housing Next to Muffler
2. SPECIFICATIONS
2.1 MODEL NUMBER:
Serial Nos. 220,000 & Higher:
2.2 ENGINE
2.2.1 Engine Specifications: See your Engine Owner's Manual.
2.2.2 3600 RPM (No Load).
2.3 FUEL SYSTEM
2.3.1 Capacity: 5.0 gal. ( 18. 9 L.)
2.3.2 Type of Fuel: Regular
using the research method, it should be a 90 oct ane minimum.
2.3.3 Fuel Filter: Replaceable in- line
2.3.4 Fuel Shut-Off Valve: 1/4 turn
2.4 SAFETY INTERLOCK SYSTEM
Operator must have transmission in neutral and blade clut ch disengaged to start
engine. Release of OPC levers will cause the engine to st op if hydro transmission is
not
in neutral and/or blade clutch is
PART NO. 303293
LOCATION: On Top Right
Side of Fuel Tank
VH3615KA; VH4815KA
unleaded
gasoline, 87 octane or higher. I n count r ies
engaged
.
PART NO. 513890
LOCATION: On Top of
Hydraulic Tank
2.5 STEERING/BRAKE CONTROL:
Fingertip drive control levers provide independent speed control, br aking and neutral
to each drive wheel for moving forward or reverse, st opping and power turning.
2.6 TRANSMISSION:
Twin Hydrostatic Drive
2.6.1 Two Hydro Gear BDP-10L series variable displacement pumps independently
coupled to two high efficiency Parker / Ross wheel drive motors .
- 7 -
2.6.2 Hydraulic Filter is replaceable cart r idge type.
F)
F)
P/N 513211: 10 microns, 18 psi bypass (Summer use above 32°
P/N 523541: 40 microns, 18 psi bypass (Winter use below 32°
2.6.3 Speed Range: Forward 0 - 6.2 m ph ( 10.0 km/h)
Reverse 0 - 2.2 mph (3.5 km/h)
2.7 WHEEL DRIVE SYSTEM:
Drive wheels are direct coupled to Parker/Ross wheel drive motors with 1.0" (25. 4
mm) tapered shaft.
2.8 TIRES
Drive Front Caster
Size .........................16 x 6.50-8 ........................9 x 3.50-4
Quantity.............................2........................................ 2
Tread.......................Turf Master............................ Smooth
Ply Rating..........................4........................................ 4
Pressure...............14 psi (97 kPa).................22 psi (152 kPa)
2.9 DECK
2.9.1 Cutting Width:
Model 36 in..............................................35.38 in. (89.9 cm)
Model 48 in..............................................47.24 in. (120.0 cm)
2.9.2 Discharge: Right Side
2.9.3 Blade Size:
Model 36 in....................18.00 in. (45.7 cm).............. Qty. 2
Model 48 in....................16.25 in. (41.3 cm).............. Qty. 3
2.9.4 Type of Drive: Manual engagement of belt with over-center lock. Belt tension
is adjustable via turnbuckle.
2.9.5 Blade Brake: W hen t he blade engagement control is move to the disengaged
position a friction brake pad stops the rotation of the blades.
2.9.6 Deck Mounting: Bolted directly to the engine deck.
2.9.7 Cutting Height: Adjusts in 1/4” ( . 63 cm ) increments from 1” (2.5 cm) t o 4 1/ 4”
(10.8 cm).
2.10 DIMENSIONS
2.10.1 Overall Width: 36” 48”
Discharge chute down
Discharge chute up
(Transport only)
2.10.2 Overall Length: 36” 48”
Overall Length
2.10.3 Curb Weight: 36” 48”
Curb Weight
∗
∗ Weights will vary slightly depending on engine option.
2.10.4 Overall Heig ht : 43.2”(109.7 cm)(all units)
2.10.5 Tread Width (to outside of tires):
36” Model....................35.6” (90.4 cm)
48” Model....................39.6” (100.6 cm
46.1” 58.2”
(117.1 cm) (148.0 cm)
36.4” 48.1”
(92.5 cm) (122.2 cm)
78.0” 73.0”
(198.1 cm) (185.4 cm)
433 lbs. 486 lbs.
(196 kg) (220 kg)
- 8 -
2.11 TORQUE REQUIREMENTS
BOLT LOCATION TORQUE
Blade/Cutter Housing Spindle Bolt.................................75-80 ft-lbs.
Caster Bracket Mounts..................................................30-35 ft-lbs.
Cutter Deck/Engine Deck Mount....................................30-35 ft-lbs.
Engine Mounting Bolts (Kohler & Kawasaki)..................25-30 ft-lbs.
3. ASSEMBLY INSTRUCTIONS
3.1 Uncrate unit, leaving it on the pallet , place upper handle assembly, fuel tank, and
drive linkages at the rear of the machine. Place casters at the front of unit.
3.2 Place a length of 4" x 4" block bet ween the front of the cutter deck and the pallet.
3.3 Remove the bolt bag from t he top of the fuel tank support .
3.4 Loosen the 5/16" hardware at the two (2) discharg e deflector hinge point s so that
the deflector is snug, but can be m oved up and down freely.
3.5 Refer to Parts Manual to help you identif y and locate par ts and their proper position.
3.6 Install casters to f ront of deck using appropriate har dware from the bolt bag
(eight 3/8 x 3/4" bolts and eight 3/8" whizlock nuts); tightening the lower f our
bolts first, then the top four.
3.7 Apply retaining adhesive “Fel-Pro Prolock Retaining I or Retaining II” or “Loctite
RC 609 or 680” on the two threaded studs from the bolt bag and inst all into the
two left holes underneath fuel tank. Install the fuel tank on top of the fuel tank
support with the studs going throug h t he slot s in the support. Install two 5/16 x
3/4 screws with a 5/16 SAE flatwasher and 5/16 lockwasher into the threaded
holes in the right side of the fuel tank.
flatwasher, then a spring, over each of t he studs and fasten with a 5/16 nyloc
nut. Tighten the 5/16 nylock nut fully than back off a 1/ 2 t urn. This is to allow for
normal fuel expansion and contraction with changes in temperature and fuel
levels.
3.8 Attach the fuel tank hose to the tank fitting and secur e with the clamp provided.
Make sure that fuel hose is not between engine and throttle plate on engine.
3.9 Position the lower end of the handle assembly on the outsideof the upper rear
section of the fuel tank & handle support.
Install four 3/8-16 x 1" bolts ( with four spring disk washers against the head of each
bolt) from the outside in. Secur e using four 3/8" whizlock nuts on the inside of each
handle support and tighten until the spring disk washers are flat (See Figure 1).
Do not over-tighten
Do not over-tighten
.
. Place a 5/16” SAE
FIG. 1
UPPER HANDLE MOUNTING
3.10 Route the throttle cable along the right side of the upper handle, under the fuel
tank support, and position the cable on the
Attach throttle cable to engine:
a) Position the throttle control lever (on console) in the full throttle (but not
choke) position. You will feel a detent when the thr ottle lever is
approximately 3/4”from the upper end of the slot (this is full thr ot tle position).
- 9 -
left
side of the engine.
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