Hustler 103234 User Manual

Hustler TrimStar

Hydro Walkbehind

Parts Manual

103234 Rev. 8/06

•••••

P.O. Box 7000

•••

Hesston, Kansas

•

67062-2097

Chapter 1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Chapter 2 Contents

36" Deck Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

36" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

36" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

48" Deck Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

48" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

48" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Caster Wheel Assembly–788064 . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Spindle Assembly–350595K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Chapter 3 Contents

Tractor Frame Rivet Nut Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Hydro Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Steering Lower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

H-Bar Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Table of Contents

Chapter 4 Contents

Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

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

Electrical Schematic—792838 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Chapter 5 Contents

Drive Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

36" Belt Routing and Tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

48" Deck Belt Routing and Tensioning . . . . . . . . . . . . . . . . . . . . . . 5-4

Tractor Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

36" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

48" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1

103234 8/06 c-1

c-2 103234 8/06

Chapter 1

General Information

This Manual covers TrimStar (15/36) model 927400 & TrimStar (17/48) model 927426.

Frequently Ordered Parts

PART NO. DESCRIPTION

788711 Pump Drive Belt
788729 TS 48" Deck Drive Belt, B-Section (65.29 EL)
788745 TS 48" Deck Belt, B-Section (86.0 EL)
797514 TS 36" Deck Drive Belt, A-Section (66.0 EL)
788737 TS 36" Deck Belt, A-Section (49.8 EL)
068478 Fuel Filter
797852 Kawasaki KAI Air Filter Precleaner
797860 Kawasaki KAI Air Filter Cartridge
772079 Engine Oil Filter

Service Literature

PART NO. DESCRIPTION

104893 TrimStar Owner’s Manual
797787 Kawasaki KAI 15HP Engine Manual
797795 Kawasaki KAI 17/19HP Engine Manual

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

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 notification. If a change has been made to your machine which is not reflected in this parts manual, see
your Hustler dealer for current information and parts.

103234 8/06 1-1

Hardware Description Codes & Abbreviations

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

ABBREVIATION DESCRIPTION

CB Carriage Bolt
CE Clevis Pin
CP Cotter Pin
CS Cap Screw

CW Cup Washer

FDRW Fender Washer

FW Flat Washer

HX Hex Head
LW Lock Washer
MB Machine Bushing
MS Machine Screw
NT Nut
SC Self Tapping Cap Screw
SH Socket Head
SB Shoulder Bolt
SS Set Screw
OD Outside Diameter

ID Inside Diameter

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 NM SIZE FT-LBS NM

.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 M16 160 215
.875 420 565 M20 320 435

1.00 625 850 M24 555 750

NOTE:

Loctite® 592 to be used on all pipe threads.
Lubricate all grease zerks.

1-2 103234 8/06

Chapter 2 Contents

36" Deck Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

36" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

36" Deck Pulley Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

48" Deck Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

48" Deck Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

48" Deck Pulley Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Caster Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Spindle Assembly–350595K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

103234 8/06 2-1

36" Deck Carrier Assembly

12

2

3

4

3

4

6
7
8

1

9

7

8

10

1

9

13

11

13

1

9

14

6

5

4

10

1

9

11

1

3

4

3

15

36" DECK

16

18

24

25

14

17

15

13

23

19

20

21

23

22

16

18

13

24

12

17

23

19
20

21

23

22

25

2-2 103234 8/06

36" Deck Carrier Assembly

INDEX NO.

1 547596 381137 1 TRIMSTAR 36 FRAME

2

2 100883 100883 1 DECK MAIN COVER

3 778399 778399 8 FW .781 X 1.375 X .250 ZNY

4 778373 778373 4 .875 X 1 PLASTIC BUSHING

5 792002 792002 4 5/16-18 X 3/4" MALE KNOB

6 705954 705954 2 CS .500-13 X 1.25 HX G5 ZN

7 344267 344267 2 FW .510 X 2.15 X .187 SPL

8 712976 712976 2 FW .531 X 1.375 X .125 ZNY

9 784223 784223 4 BEARING

10 784603 784603 2 FASTRAK SPACER

11 339689 339689 2 CASTER FORK

12 042630 042630 2 CS .500-13 X 6.50 HX G5 ZNY

13 767962 767962 4 FW .531 X 1.063 X .090 SAE

14 781567 781567 2 NT .50-13 HXZY NL

15 788604 788604 2 WHEEL/TIRE ASSY 11 X 4-5

16 306969 306969 2 GAGE WHEEL SPACER

17 025593 025593 4 HP .177 X 3.25 WW# 206 ZN

18 102343 102343 2 FRONT DECK HEIGHT PIN

19 102350 102350 2 REAR DECK HEIGHT PIN

20 706176 706176 2 NT .375-24 HX JAM G5 ZN

21 778431 778431 2 .375-24 SPHERICAL ROD END

22 054502 054502 2 NT .375-16 HX GRD 5 ZNY

23 767954 767954 4 FW .406 X .812 X .060 SAE

24 005116 005116 2 CS .375-16X1.375 HX G5

25 758631 758631 2 RP .250X 1.375 HEAVY SPIRAL

SERVICE

PAR T NO.

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Assemble with extended inner race down.

2. Service part frame includes rivet nuts and decals see“Tractor Frame
Rivet Nut Assembly” on page 3-2 and “Tractor Decals” on page 5-6.

103234 8/06 2-3

36" Deck Assembly

3

1

2

3

5

3

4

6

8

5

3

10

7

10

11

3

9

2-4 103234 8/06

36" Deck Assembly

INDEX NO.

1 798918 798918 1 RUBBER DISCHARGE CHUTE

2 058776 058776 2 NT .312-18 HXZY NL

3 767954 767954 10 FW .406 X .812 X .060 SAE

4 063297 063297 2 SB .375 X .500 SH .312-18 TD ZN

5 054502 054502 4 NT .375-16 HX GRD 5 ZNY

6 102335 102335 1 DISCHARGE CHUTE MOUNT

7 011320 011320 2 CB .375-16 X .750 STD ZN

8 547612 100552 1 36" TRIMSTAR DECK

1

9 036244 036244 2 CS .375-16 X 1.00 HX G5

10 808485 808485 2 5/16-18 THREAD RIVET NUT

11 102996 102996 1 ANTI-BLOWOUT BAFFLE

SERVICE

PAR T NO.

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Service part frame includes rivet nuts and decals, see “36" Deck Decals”
on page 5-8.

103234 8/06 2-5

36" Deck Pulley Assembly

1

2

3

19

13

24

12

1

21

16

17

10

4

5

9

7

3

15

4

10

18

16

7

6

7

8

11

12

16

8

22

23

16

14

1

20

24

7

5

24

28

2

26

30

31

25

7

31

26

27

29

2

24

27

30

2-6 103234 8/06

36" Deck Pulley Assembly

INDEX NO.

1 797514 797514 1 BELT, A-SEC 66.0 EL

2 788737 788737 1 BELT, A-SECT 49.8 EL

3 781872 781872 2 CS .625-11 X 1.25 HX G5 ZN

4 028118 028118 2 FW .625 X 1.00 X .134 ZNYC

5 788364 788364 2 4.288" IDLER PULLEY

6 023317 023317 1 NT .500-13 UNT LK G5 ZN

7 767962 767962 11 FW .531 X 1.063 X .090 SAE

8 781153 781153 2 UHMW BUSHING

9 008193 008193 1 NT .500-13 HX G5 ZNYC

10 770867 770867 2 PLASTIC .75 X 1 BUSHING

11 382101 382101 1 IDLER ARM

12 036384 036384 2 SPRING 1/4 COIL PL 1.23

13 340885 059931 1 CHAIN (24 LINKS)

14 259812 059931 1 CHAIN (13 LINKS)

15 340158 340158 1 IDLER PIVOT BUSHING

16 016527 016527 9 CS .500-13 X 1.00 HX G5 Z

17 108059 108059 1 FW .515X1.500X.250 ZY

18 372730 372730 1 SLIDE IDLER

19 100875 100875 1 RIGHT PULLEY COVER

20 103002 103002 1 LEFT PULLEY COVER

21 796946 796946 1 5.75 OD JACKSHAFT PULLEY

22 078386 078386 1 FW .510 X 1.750 X .18 ZNYC

23 797043 797043 1 3.50 EOD DECK PULLEY

24 792002 792002 4 5/16-18 X 3/4" MALE KNOB

25 077859 077859 1 CS .500-13 X 3.25 HX G5

26 350595 350595 2 SPINDLE ASSEMBLY

4

27 212472 212472 2 KEY 1/4 SQ X 1.00 LONG

28 793794 793794 1 20.50"-L-F-CW BLADE

29 793802 793802 1 13.75"-L-F-CW BLADE

30 782474 782474 2 CW .631 2.250 X .187 PNT

31 029934 029934 2 CS .625-11 X 3.00 HX G5

32 705954 705954 1 CS .500-13X1.25 HX G5 Z

SERVICE

PAR T NO.

MFG. PART

NO.

QTY. DESCRIPTION

NOTES

1. Torque to 65-75 ft.-lbs.

2. Torque to 118 ft.-lbs.

3. See “36" Belt Routing and Tensioning” on page 5-3.

4. See “Spindle Assembly–350595K” on page 2-15.

103234 8/06 2-7

48" Deck Carrier Assembly

2

3

1

12

6

7

8

1

9

10

1

9

13

15

3

11

13

17

14

16

4

5

3

3

6

9

8

1

9

10

1

9

13

15

11

19

4

13

12

4

25

48" DECK

18

22

17

23

20

21

23

24

2-8 103234 8/06

18

22

23

17

19

20

21

25

23

24

48" Deck Carrier Assembly

INDEX NO.

1 547604 351353 1 TRIMSTAR 48 FRAME

2

2 381491 381491 1 DECK MAIN COVER

3 778399 778399 8 FW .781 X 1.375 X .250 ZNY

4 778373 778373 4 .875 X 1 PLASTIC BUSHING

5 792002 792002 4 5/16-18 X 3/4" MALE KNOB

6 705954 705954 2 CS .500-13 X 1.25 HX G5 ZN

7 344267 344267 2 FW .510 X 2.15 X .187 SPL

8 712976 712976 2 FW .531 X 1.375 X .125 ZNY

9 784223 784223 4 BEARING

10 784603 784603 2 FASTRAK SPACER

11 339689 339689 2 CASTER FORK

12 042630 042630 2 CS .500-13 X 6.50 HX G5 ZNY

13 767962 767962 4 FW .531 X 1.063 X .090 SAE

14 781567 781567 2 NT .50-13 HXZY NL

15 788604 788604 2 WHEEL/TIRE ASSY 11 X 4-5

16 306969 306969 2 GAGE WHEEL SPACER

17 025593 025593 4 HP .177 X 3.25 WW# 206 ZN

18 381582 381582 2 FRONT DECK HEIGHT PIN

19 381616 381616 2 REAR DECK HEIGHT PIN

20 706176 706176 2 NT .375-24 HX JAM G5 ZN

21 778431 778431 2 .375-24 SPHERICAL ROD END

22 054502 054502 2 NT .375-16 HX GRD 5 ZNY

23 767954 767954 4 FW .406 X .812 X .060 SAE

24 005116 005116 2 CS .375-16X1.375 HX G5

25 758631 758631 2 RP .250X 1.375 HEAVY SPIRAL

SERVICE

PAR T NO.

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Assemble with extended inner race down.

2. Service part frame includes rivet nuts and decals see“Tractor Frame
Rivet Nut Assembly” on page 3-2 and “Tractor Decals” on page 5-6.

103234 8/06 2-9

48" Deck Assembly

6

14

3

4

5

3

7

8

7

1

9

10

2

11

10

14

5

12

15

13

12

10

11

10

7

9

14

5

2-10 103234 8/06

48" Deck Assembly

INDEX NO.

1 798918 798918 1 RUBBER DISCHARGE CHUTE

2 058776 058776 2 NT .312-18 HXZY NL

3 767954 767954 6 FW .406 X .812 X .060 SAE

4 063297 063297 2 SB .375 X .500 SH .312-18

5 054502 054502 6 NT .375-16 HX GRD 5 ZNY

6 102335 102335 1 DISCHARGE CHUTE MOUNT BRACKET

7 808485 808485 3 RIVET NUT, 5/16-18 THREAD

8 547620 349993 1 48" TRIMSTAR DECK

2

9 781708 N/A 2 CS .500-13 X 4.25 HX G5 ZNY

10 767962 N/A 2 FW .531 X 1.063 X .090 SAE

11 031997 N/A 2 ANTI-SCALP WHEEL

12 053199 N/A 2 NT .500-13 HX JAM ZNYC

13 781567 781567 2 NT .50-13 HXZY NL

14 011320 011320 6 CB .375-16 X .750 STD ZN

15 352328 352328 2 AIRFLOW ANGLE

16 788166 788166 2 ANTI SCALP WHEEL ASSY

1

SERVICE

PAR T NO.

MFG. PART

NO.

1. Includes items 9 through 12.

QTY. DESCRIPTION

NOTES:

2. Service part frame includes rivet nuts and decals, see “48" Deck Decals”
on page 5-9.

103234 8/06 2-11

48" Deck Pulley Assembly

2

1

21

4

15

6

7

8

11

12

13

14

21

7

13

9

24

33

1

5

6

17

16

12

18

19

18

20

7

8

1

3

22

23

3

12

10

21

25

25

24

12

21

26

29

27

28

27

2

32

2-12 103234 8/06

30

31

48" Deck Pulley Assembly

INDEX NO.

1 788729 788729 1 B-SEC BELT, 65.29 EL

2 788745 788745 1 B-SEC BELT, 86.0 EL

3 016527 016527 14 CS .500-13 X 1.00 HX G5 ZNY

4 108059 108059 1 FW .515X1.500X.250 ZY

5 796482 796482 1 4.50 OD JACKSHAFT PULLEY

6 781872 781872 2 CS .625-11 X 1.25 HX G5 ZNY

7 028118 028118 3 FW .625 X 1.00 X .134 ZNYC

8 781856 781856 2 5.00" IDLER PULLEY

9 368985 368985 1 R.S. PULLEY COVER

10 368993 368993 1 L.S. PULLEY COVER

11 008193 008193 1 NT .500-13 HX G5 ZNYC

12 767962 767962 15 FW .531 X 1.063 X .090 SAE

13 770867 770867 2 .750 X 1 PLASTIC BUSHING

14 340158 340158 1 IDLER PIVOT BUSHING

15 372730 372730 1 IDLER

16 788364 788364 1 4.288" IDLER PULLEY

17 023317 023317 1 NT .500-13 UNT LK G5 ZN

18 781153 781153 2 BUSHING

19 382101 382101 1 IDLER ARM

20 016972 016972 1 NT .625-11 HX G5 ZNYC

21 792002 792002 4 5/16-18 X 3/4" MALE KNOB

22 078386 078386 2 FW .510 X 1.750 X .18 ZNYC

23 796474 796474 2 4.50 E.O.D PULLEY

24 036384 036384 2 SPRING 1/4 COIL PL 1.23

25 340885 055931 2 CHAIN (24 LINKS)

26 077859 077859 1 CS .500-13 X 3.250 HX G5

27 782474 782474 4 CW .631 2.250 X .187 PNT

28 783738 783738 1 CS .625-11 X 3.00 FULL HX

29 212472 212472 3 KEY 1/4 SQ X 1.00 LONG

30 350595 350595 3 SPINDLE ASSEMBLY

5

31 795757 795757 3 F16.50"-H-F-CW BLADE

32 029934 029934 3 CS .625-11 X 3.00 HX G5

33 705954 705954 1 CS .500-13X1.25 HX G5 Z

SERVICE

PAR T NO.

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Torque to 65-75 ft.-lbs.

2. Torque to 118 ft.-lbs.

3. See “48" Deck Belt Routing and Tensioning” on page 5-4.

4. See “Spindle Assembly–350595K” on page 2-15 for breakdown.

103234 8/06 2-13

Caster Wheel Assembly–788064

2

1

3

2

INDEX NO.

1 x N/A 1 WHEEL ASSEMBLY

2 772806 N/A 2 BEARING CAP

3 772814 N/A 1 3/4" ROLLER BEARING

SERVICE

PAR T NO.

MFG. PART

NO.

QTY. DESCRIPTION

2-14 103234 8/06

Spindle Assembly–350595K

4

1

2

3

1

5

6

INDEX NO.

1 077123 N/A 2 BEARING W/O COLLAR

2 766204 1 BLADE SPINDLE BUSHING

3 034843 1 CAST SPINDLE HOUSING

4 012005 1 GREASE FITTING

5 072272 1 FW 1.06 X 2.00 X.134 SAE ZN

6 788547 1 SADDLELESS SPINDLE SHAFT

SERVICE

PAR T NO.

MFG. PART

NO.

QTY. DESCRIPTION

103234 8/06 2-15

2-16 103234 8/06

Chapter 3 Contents

Tractor Frame Rivet Nut Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Hydro Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Steering Lower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

H-Bar Steering Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

103234 8/06 3-1

Tractor Frame Rivet Nut Assembly

TRACTOR
FRAME

1

2

2

48" FRAME SHOWN,
36" FRAME SIMILAR

2

3-2 103234 8/06

Tractor Frame Rivet Nut Assembly

INDEX NO.

1 044818 044818 3 CN ZN TIN-C7343-1420

2 N/A 808485 5 RIVET NUT, 5/16-18 THREAD

SERVICE

PAR T NO.

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

103234 8/06 3-3

Hydro Transmission Assembly

2

3 4

1

5

6

7

8

12

10

9

17

18

14

15

16

13

22

12

19

17

18

10

1

11

23

18

18

19

18

20

21

24

18

26

25

18

19

18

26

18

19

18

27

18

28

29

26

3-4 103234 8/06

25

Hydro Transmission Assembly

INDEX NO.

1 788711 788711 1 A-SEC BELT 47.4 EL

2 055947 055947 3 CS .250-20 X .500 HX G5

3 768515 768515 3 FW .281 X .625 X .051/.080 HD

4 302596 302596 1 REAR IZT BELT COVER

5 778746 778746 1 2" SPLIT RING

6 259812 059931 1 CHAIN (13 LINKS)

7 779272 779272 1 TINNERMAN CLIP

8 036384 036384 1 SPRING

9 025023 025023 1 CS .750-10 X 4.50 HX G5

10 025296 025296 2 FW .760 X 1.625 X .08 ZNYC

11 061101 061101 1 NT .750-10 HXZY NL

12 781153 781153 2 UHMW BUSHING

13 395756 395756 1 TRIMSTAR IDLER ARM

14 791566 791566 1 3.25" OD X .6" IDLER PULLEY

15 028118 028118 1 FW .625 X 1.00 X .134 ZNYC

16 781872 781872 1 CS .625-11 X 1.25 HX G5 ZN

17 036236 036236 4 CS .312-18 X 1.00 HX G5

18 768523 768523 30 FW .343 X .687 X .051/.080 HD

19 710087 710087 12 CS .312-18 X 2.50 HX G5

20 034280 034280 1 CS .312-18 X .75 HX G5

21 381863 381863 1 IZT FAN COVER

22 381087 381087 1 REAR CONTROL COVER

23 302604 302604 1 CENTER IZT MOUNT PLATE

24 788778 788778 1 RIGHT PUMP/MOTOR COMBO

25 788786 788786 1 LEFT PUMP/MOTOR COMBO

26 034272 034272 14 NT .312-18 HX G5 ZNYC

27 788588 788588 1 .312-18 X 13.5 STUD

28 367888 367888 1 STABILIZER BAR

29 396051 396051 1 BRAKE/TOW VALVE PIVOT PLATE

SERVICE

PAR T NO.

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Do not torque, Idler Arm must pivot freely.

103234 8/06 3-5

Steering Lower Assembly

1

2

26

28

11

22

17

24

10

30

4

3

6

3

4

9

7

4

3

6

5

11

4

12

27

26

4

12

3

4

31

32

25

1

24

29

13

17

4

3

33

11

22

19

21

6

5

8

3

4

14

15

17

18

16

20

22

17

23

16

3-6 103234 8/06

Steering Lower Assembly

INDEX NO.

1 307652 307652 1 PIVOT PIN

2 791053 791053 2 TURNBUCKLE ASSEMBLY

3 034272 034272 6 NT .312-18 HX G5 ZNYC

4 768523 768523 12 FW .343 X .687 X .051/.080 HD

5 788554 788554 2 .50 X 1.00 LOCK COLLAR

6 768259 768259 4 IGUS #MFI-0810-05 BUSHING

7 079186 079186 2 CS .312-18 X 1.25 HX G5

8 397489 397489 1 RH LOWER STEER CRANK

9 397471 397471 1 LH LOWER STEER CRANK

10 302604 N/A 1 CENTER IZT MOUNT PLATE

11 036236 036236 5 CS .312-18 X 1.00 HX G5

12 785774 785774 2 PUMP ROD ASSEMBLY

13 314856 314856 1 RIGHT DAMPER MOUNT

14 396101 396101 1 BRAKE/TOW VALVE ROD

15 043299 043299 1 1.31 RD .375-16 X .50 KNOB

16 086660 086660 2 NT .375-16 HXZY NL

17 767954 767954 5 FW .406 X .812 X .060 SAE

18 056036 056036 1 CS .375-16 X 2.25 HX G5

19 301978 301978 1 BRAKE/TOW LINK

20 395160 395160 1 SPRING

21 395699 395699 1 BRAKE/TOW LINK PLATE

22 054502 054502 5 NT .375-16 HX GRD 5 ZNY

23 396051 N/A 1 BRAKE/TOW VALVE PIVOT PLATE

24 725267 725267 4 FW .318 X .472 X .047 ZN

25 017236 017236 2 CP .093D X .750 LG HML Z

26 706143 706143 2 NT .312-18 HX JAM GR5 Z

27 036384 036384 1 1/4 COIL PL 1.23 SPRING

28 300319 300319 1 BRAKE ACTUATOR BRACKET

29 220129 059931 1 CHAIN (9 LINKS)

30 064014 064014 1 CS .312-18 X .875 HX G5

31 058776 058776 1 NT .312-18 HXZY NL

32 037788 037788 1 5/8 OD 4 IN SPRING

33 600967 600967 1 1.15" SPLIT RING

SERVICE

PAR T NO.

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Tension spring to 5.5" (measured outside to outside of hooks) when in
neutral.

103234 8/06 3-7

H-Bar Steering Assembly

22

29

28

23

21

30

2

1

48" MOWERS ONLY

SEE NOTE 2

25

24

19

7

35

34

38

36

44

32

33

8

31

45

38

8

}

40

42

37

48

48

39

37

40

41

30

8

46

47

7

6

3

5

8

31

22

48

37

36

9

11

8

43

27

9

10

15

18

22

28

4

2

1

16

39

37

40

30

14

15

17

8

38

7

8

13

5

23

26

24

20

41

12

22

30

38

29

8

35

}

40

42

8

36" MOWERS ONLY

SEE NOTE 1

46

47

48

48

48

49

3-8 103234 8/06

H-Bar Steering Assembly

INDEX NO.

1 771139 771139 2 GRIP

2 773556 773556 2 STEERING BEARING

3 365791 365791 1 STEERING COVER

4 779157 779157 2 CB .312-18X 1.750 SHTNK

5 769299 769299 6 SC #10 X .75 PHILLIPS

6 380295 380295 1 STEERING BAR

7 041152 041152 4 NT .312-24 HX ZNYC

8 768523 768523 16 FW .343 X .687 X .051/.080 HD

9 058776 058776 2 NT .312-18 HX ZNYC NL

10 077842 077842 4 MS # 6-32 X 1.00 RD SL

11 342378 342378 2 SWITCH SPACER

12 779165 779165 4 RP .078X .50 LONG ZN

13 792861 792861 1 OPERATOR PRESENCE SWITCH WIRE HARNESS

14 039693 039693 2 WN #6-32 X 1.00 TP 1116

15 341826 341826 2 OPC ARM

16 789669 789669 1 2" DIA X .375 THD KNOB

17 397216 397216 1 CRUISE HANDLE STEM

18 314567 314567 1 .500 X .049 W X 2.00 LG SPACER

19 041848 041848 1 CB .375-16 X 3.50 FUL ZN

20 397562 397562 1 UPPER CRUISE CRANK

21 397596 397596 1 LOWER CRUISECAM

22 364653 364653 4 .765 ID BEARING DISC

23 017160 017160 2 FW .810 X 2.000 X .156 SAE

24 791004 791004 2 CW .380 X 1.240 X .072 X .096

25 016428 016428 1 CS .375-16 X 2.50 HX GR5

26 086660 086660 1 NT .375-16 HXZY NL

27 314401 314401 1 .750 X .187 W X 1.62 LONG SPACER

28 045765 045765 3 FW 1.030 X 1.500 X .134 ZN

29 784223 784223 2 BEARING

30 034272 034272 4 NT .312-18 HX G5 ZNYC

31 781922 781922 2 DAMPER BALL STUD

32 792374 792374 1 PLUNGER SNAP MOUNT SWITCH

33 305086 305086 1 PIVOT PIN

34 788554 788554 1 .500X1.00 LOCK COLLAR

35 704916 704916 2 CS .250-20 X 1.25 HX G5

36 789446 789446 4 .250 X .625 X .196 T BEARING

37 024927 024927 4 NT .250-20 HX GR.5 ZNYC

38 768515 768515 4 FW .281 X .625 X .051/.080 HD

39 785766 785766 2 STEERING ROD ADJUSTER

40 768259 768259 4 IGUS #MFI-0810-05 BUSHING

41 397513 397513 2 CRUISE/SPEED ARM

42 079186 079186 2 CS .312-18 X 1.25 HX G5

43 314351 314351 1 DAMPER ARM

44 399998 399998 1 HBAR STEERING FRAME

45 788349 788349 1 CENTERING DAMPER

46 791053 N/A 2 TURNBUCKLE ASSEMBLY

47 705954 705954 4 CS .500-13 X 1.25 HX G5 Z

48 767962 767962 8 FW .531 X 1.063 X .090 SAE

49 008193 008193 4 NT .500-13 HX G5 ZNYC

SERVICE

PAR T NO.

MFG. PART

NO.

QTY. DESCRIPTION

103234 8/06 3-9

NOTES:

1. Steering rod adjuster assembly for 36” TrimStar.

2. Steering rod adjuster assembly for 48" TrimStar.

3-10 103234 8/06

Chapter 4 Contents

Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

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

Electrical Schematic—792838. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

103234 8/06 4-1

Engine Assembly

3

4

1

2

5

4

8

11

12

13

15

17

7

16

14

1

6

7

9

10

ENGINE
MOUNTING
HARDWARE

25

18

23

7

17

19

4-2 103234 8/06

21

22

20

24

6

7

Engine Assembly

INDEX NO.

1 791343 791343 1 KAWASAKI 15HP ENGINE (36" TRIMSTAR ONLY)

2 791368 791368 1 15 HP KAWASAKI MUFFLER

3 791558 791558 2 15 & 17HP EXHAUST GASKET

4 017004 017004 4 LW .312 MED SPRING ZNYC

5 782664 782664 4 NT M8-1.25 HX STAINLESS

6 034272 034272 5 NT .312-18 HX G5 ZNYC

7 768523 768523 8 FW .343 X .687 X .051/.080 HD

8 780775 780775 1 KAWASAKI OIL DRAIN O-RING

9 780767 780767 1 KAWASAKI OIL DRAIN ADAPTER

10 771378 771378 1 HOSE

11 787358 787358 1 ENGINE CRANKSHAFT SPACER

12 791541 791541 1 WARNER CLUTCH

13 212472 N/A 1 KEY 1/4 SQ X 1.00 LONG

14 799155 N/A 1 PULLEY

15 763417 763417 1 FW .454 X 1.50 X .250

16 763391 763391 1 CS .437-20 X 1.75 G5 ZNYC

17 034280 034280 3 CS .312-18 X .75 HX G5

18 788802 788802 2 ABS PLUG FOR 1.5 X 2.0 X .12W TUBING

19 103044 103044 1 CLUTCH ANCHOR

20 784918 784918 1 RUBBER BUMPER

21 029876 029876 4 LW .312 INT-EXT TOOTH ZN

22 052837 052837 4 CS .312-18 X 1.50 HX G5

23 035329 035329 1 3/8 NPT PIPE PLUG

24 053736 053736 1 OPEN TYPE J-CLIP

25 792838 792838 1 TRIMSTAR WIRE HARNESS

SERVICE

PAR T NO.

791350 791350 1 KAWASAKI 17HP ENGINE (48" TRIMSTAR ONLY)

791376 791376 1 17 HP KAWASAKI MUFFLER

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Torque to 45-48 ft-lb.

2. Engine speed 3400±50 RPM.

3. Engine oil capacity: 1.4 U.S. qts. (includes filter).

103234 8/06 4-3

Fuel System

1

2

3

4

5

6

7

8

4-4 103234 8/06

Fuel System

INDEX NO.

1 779306 779306 1 3.5" FUEL CAP

2 792044 792044 1 WALKBEHIND FUEL TANK

3 785295 N/A 1 GROMMET

1

4 783944 N/A 1 FUEL SHUT-OFF VALVE

1

5 015818 015818 1 FUEL LINE (3.5" LONG)

6 000323 000323. 2 CLIP

7 768523 768523 4 FW .343 X .687 X .051/.080 HD

8 034280 034280 4 CS .312-18 X .750 HX G5

SERVICE

PAR T NO.

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Valve and grommet included with new fuel tank.

103234 8/06 4-5

Instrument Panel

1

2

9

3

6

4

7

4

5

9

7

8

4-6 103234 8/06

Instrument Panel

INDEX NO.

1 769166 769166 1 HOUR METER

2 776476 776476. 1 PTO SWITCH 6201-321

3 083022 N/A 2 IGNITION KEY

3 785808 785808 1 INDAK COATED KEY

1

4 776518 776518 1 KEY SWITCH

5 786384 786384 1 THROTTLE CABLE ASSEMBLY

6 714998 714998 2 MS #10-24 X .625 HX ZN

7 704932 704932 4 FW .219 X .500 X .048 ZNYC

8 035626 035626 2 NT #10-24 HX ZN

9 785030 785030 1 CHOKE CABLE

SERVICE

PAR T NO.

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Assembled to ring supplied with ignition switch along with two (2) of

083022.

103234 8/06 4-7

Electrical Schematic—792838

4-8 103234 8/06

Chapter 5 Contents

Drive Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

36" Deck Belt Routing and Tensioning . . . . . . . . . . . . . . . . . . . . . . . 5-3

48" Deck Belt Routing and Tensioning . . . . . . . . . . . . . . . . . . . . . . . 5-4

Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

36" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

48" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

103234 8/06 5-1

Drive Wheel Assembly

1

2

4

3

1

INDEX NO.

2

1 785337 N/A TIRE 18 X 6.50-8 4 PLY

2 785303 N/A WHEEL, 5.35

3 019521 N/A TIRE VALVE

4 061077 061077. 8 WHEEL NUT

2

1 784272 TIRE 18 X 9.5-8

2 784280 WHEEL ASSY 8.00 X 6.32

3 019521 N/A TIRE VALVE

4 061077 061077. 8 WHEEL NUT

SERVICE

PAR T NO.

785345 785345 2 TIRE ASSEMBLY 18.00 X 6.50-8 (FOR 36" TRIMSTAR)

784264 784264 2 WHEEL/TIRE ASSY 18 X 9 (FOR 48" TRIMSTAR)

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Torque to 65–75 ft.-lbs.

2. Includes items 1–3.

5-2 103234 8/06

36" Belt Routing and Tensioning

1. Spring length after tensioning belt. Measure spring from outside of hook
to outside of hook.

2. Route belt as shown.

103234 8/06 5-3

48" Deck Belt Routing and Tensioning

1. Spring length after tensioning belt. Measure spring from outside of hook
to outside of hook.

1. Route belt as shown.

5-4 103234 8/06

This page intentionally left blank.

103234 8/06 5-5

Tractor Decals

2

7

3

8

5

4

1

6

10

9

5-6 103234 8/06

Tractor Decals

INDEX NO.

1 771030 771030 1 H-BAR STEERING DECAL

2 788844 788844 1 TRIMSTAR H-BAR CONTROL PANEL DECAL

3 788828 788828 1 TRIMSTAR ID DECAL

4 727172 727172 1 'MADE IN U.S.A.' DECAL

5 N/A 083279 1 TURF SERIAL NO PLATE

6 797662 797662 1 TRIMSTAR SERVICE DECAL

7 797647 797647 1 TRIMSTAR H-BAR IZT BELT DECAL

8 788893 788893 1 TRIMSTAR PARK BRAKE DECAL

9 793588 793588 1 HUSTLER NAME PLATE

10 794545 794545 1 DEFLECTOR SHIELD DECAL

SERVICE

PAR T NO.

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

103234 8/06 5-7

36" Deck Decals

1

2

3

4

5

5

7

6

INDEX NO.

1 727172 727172 1 'MADE IN U.S.A.' DECAL

2 793513 793513 1 36" DECK ID DECAL

3 727453 727453 1 BELT & PULLEY DECAL

4 794008 794008 1 TRIMSTAR DECK CUTTING HEIGHT DECAL

5 793570 793570 2 DECK WARNING DECAL

6 793984 793984 1 DECK DRIVE BELT ROUTING DECAL

7 797597 797597 1 TSH 36" DECK BELT ROUTING DECAL

SERVICE

PAR T NO.

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

5-8 103234 8/06

48" Deck Decals

1

2

3

4

5

6

6

78

INDEX NO.

1 727172 727172 1 'MADE IN U.S.A.' DECAL

2 793976 793976 1 48" DECK ID DECAL

3 727453 727453 1 BELT & PULLEY DECAL

4 760637 760637 1 MOWER DECK QUICK REFERENCE DECAL

5 794008 794008 1 TRIMSTAR DECK CUTTING HEIGHT DECAL

6 793570 793570 2 DECK WARNING DECAL

7 793984 793984 1 DECK DRIVE BELT ROUTING DECAL

8 797605 797605 1 TSH 48" DECK BELT ROUTING DECAL

SERVICE

PAR T NO.

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

103234 8/06 5-9

5-10 103234 8/06

Numerical Index

Part Page
No. No.

Index

Part Numbers

000323 4-5
005116 2-3
008193 2-7
011320 2-5
015818 4-5
016428 3-9
016527 2-7
016972 2-13
017004 4-3
017160 3-9
017236 3-7
019521 5-2
023317 2-7
024927 3-9
025023 3-5
025296 3-5
025593 2-3
028118 2-7
029876 4-3
029934 2-7
031997 2-11
034272 3-5
034280 3-5
035329 4-3
035626 4-7
036236 3-5
036244 2-5
036384 2-7
037788 3-7
039693 3-9
041152 3-9
041848 3-9
042630 2-3
043299 3-7
044818 3-3
045765 3-9
052837 4-3
053199 2-11
053736 4-3
054502 2-3

055931 2-13
055947 3-5
056036 3-7
058776 2-5
059931 2-7
061077 5-2
061101 3-5
063297 2-5
064014 3-7
068478 1-1

, 2-9
, 2-13, 3-9
, 2-11

, 2-13

, 2-13

, 2-9
, 2-13, 3-5

, 2-13

, 3-7, 3-9, 4-3
, 4-3, 4-5

, 3-7

, 2-13, 3-5, 3-7

, 2-9

, 2-5, 2-9, 2-11,

3-7

, 2-11, 3-7, 3-9
, 3-5, 3-7

, 2-11

Part Page
No. No.

077842 3-9
077859 2-7
078386 2-7
079186 3-7
083022 4-7
083279 5-7
086660 3-7
100552 2-5
100875 2-7
100883 2-3
102335 2-5
102343 2-3
102350 2-3
102996 2-5
103002 2-7
103044 4-3
104893 1-1
108059 2-7
212472 2-7
220129 3-7
259812 2-7
300319 3-7
301978 3-7
302596 3-5
302604 3-5
305086 3-9
306969 2-3
307652 3-7
314351 3-9
314401 3-9
314567 3-9
314856 3-7
339689 2-3
340158 2-7
340885 2-7
341826 3-9
342378 3-9
344267 2-3
349993 2-11
350595 2-7
351353 2-9
352328 2-11
364653 3-9
365791 3-9
367888 3-5
368985 2-13
368993 2-13
372730 2-7
380295 3-9
381087 3-5
381137 2-3
381491 2-9

, 2-13
, 2-13
, 3-9

, 3-9

, 2-11

, 2-13
, 2-13, 4-3

, 3-5

, 3-7

, 2-9

, 2-9
, 2-13
, 2-13

, 2-9

, 2-13

, 2-13

Part Page
No. No.

381582 2-9
381616 2-9
381863 3-5
382101 2-7
395160 3-7
395699 3-7
395756 3-5
396051 3-5
396101 3-7
397216 3-9
397471 3-7
397489 3-7
397513 3-9
397562 3-9
397596 3-9
399998 3-9
547596 2-3
547604 2-9
547612 2-5
547620 2-11
600967 3-7
704916 3-9
704932 4-7
705954 2-3

706143 3-7
706176 2-3
710087 3-5
712976 2-3
714998 4-7
725267 3-7
727172 5-7
727453 5-8
758631 2-3
760637 5-9
763391 4-3
763417 4-3
767954 2-3

767962 2-3

768259 3-7
768515 3-5
768523 3-5
769166 4-7
769299 3-9
770867 2-7
771030 5-7
771139 3-9
771378 4-3
772079 1-1
772806 2-14

, 2-13

, 3-7

, 2-7, 2-9, 2-13,

3-9

, 2-9

, 2-9

, 5-8, 5-9
, 5-9
, 2-9

, 2-5, 2-9, 2-11,

3-7

, 2-7, 2-9, 2-11,

2-13, 3-9

, 3-9
, 3-9
, 3-7, 3-9, 4-3, 4-5

, 2-13

103234 8/06 i-1

Part Page
No. No.

Part Page
No. No.

Part Page
No. No.

772814 2-14
773556 3-9
776476 4-7
776518 4-7
778373 2-3
778399 2-3
778431 2-3
778746 3-5
779157 3-9
779165 3-9
779272 3-5
779306 4-5
780767 4-3
780775 4-3
781153 2-7
781567 2-3
781708 2-11
781856 2-13
781872 2-7
781922 3-9
782474 2-7
782664 4-3
783738 2-13
783944 4-5
784223 2-3
784264 5-2
784272 5-2
784280 5-2
784603 2-3
784918 4-3
785030 4-7
785295 4-5
785303 5-2

, 2-9
, 2-9
, 2-9

, 2-13, 3-5
, 2-9, 2-11

, 2-13, 3-5

, 2-13

, 2-9, 3-9

, 2-9

785337 5-2
785345 5-2
785766 3-9
785774 3-7
785808 4-7
786384 4-7
787358 4-3
788166 2-11
788349 3-9
788364 2-7
788554 3-7
788588 3-5
788604 2-3
788711 1-1
788729 1-1
788737 1-1
788745 1-1
788778 3-5
788786 3-5
788802 4-3
788828 5-7
788844 5-7
788893 5-7
789446 3-9
789669 3-9
791004 3-9
791053 3-7
791343 4-3
791350 4-3
791368 4-3
791376 4-3
791541 4-3
791558 4-3

, 2-13
, 3-9

, 2-9
, 3-5
, 2-13
, 2-7
, 2-13

, 3-9

791566 3-5
792002 2-3
792044 4-5
792374 3-9
792838 4-3
792861 3-9
793513 5-8
793570 5-8
793588 5-7
793794 2-7
793802 2-7
793976 5-9
793984 5-8
794008 5-8
794545 5-7
795757 2-13
796474 2-13
796482 2-13
796946 2-7
797043 2-7
797514 1-1
797597 5-8
797647 5-7
797662 5-7
797787 1-1
797795 1-1
797852 1-1
797860 1-1
798918 2-5
799155 4-3
808485 2-5
927400 1-1
927426 1-1

, 2-7, 2-9, 2-13

, 4-8

, 5-9

, 5-9
, 5-9

, 2-7

, 2-11

, 2-11, 3-3

i-2 103234 8/06