Hustler 302612 User Manual
Hustler Mini Z
Parts Manual
302612 Rev. 5/05
•••••••
Hustler Turf Equipment
•••••
P.O. Box 7000
•••
Hesston, Kansas
•
67062-2097
WARNING:
The engine exhaust from this p rod uct
contains chemicals known to the State
of Cal if orn ia to c au se c an cer, bir t h
defects or other reproductive harm.
IMPORTANT: This engine is not equipped with a spark arrest er muffler. It is a v io lation o f California Public Resourc e Code
Section 4442 to use or operate t his engi n e on any f orest-covered, b r ush-c overe d, or grass-co ve red u nimproved land . Other
states or federal areas may have similar laws.
This spark ignition system complies with Canadian ICES-002.
The Engine Owner’s Manual provides information regarding the U.S. Environmental Protection Agency (EPA) and the
California Emission Control Regulation of emission systems, maintenan ce and warranty.
Keep E ngine Owner’ s Ma nual with your unit. Should the Engine Owner’s Ma nual beco me damaged or i l legible, replace immedia tely. Re pl acements may be orde red per the information found in the Product Informati on sec tion of t he
owne r ’ s manual.
Chapter 1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Chapter 2 Contents
Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Chapter 3 Contents
Hydraulic System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Chapter 4 Contents
Battery Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Steering and Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Pump Belt and Pulley Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Chapter 5 Contents
Kawasaki Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Honda Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Kohler Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Instrument Panel Installation/Assembly . . . . . . . . . . . . . . . . . . . . . 5-16
Electrical Schematic–Kawasaki Engines (783894). . . . . . . . . . . . . 5-18
Electrical Schematic–Honda Engines (787200) . . . . . . . . . . . . . . . 5-20
Electrical Schematic–Kohler Engines (788000) . . . . . . . . . . . . . . . 5-22
Table of Contents
Chapter 6 Contents
Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Front Wheel Breakdown - 786061 . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Drive Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Anti-Rollover Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Chapter 7 Contents
Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Deck Pulley Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Blade Spindle Assembly Breakdown . . . . . . . . . . . . . . . . . . . . . . . 7-7
Chapter 8 Contents
Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Deck Belt Routing and Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Chapter 9 Contents
Tractor Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
52" Deck Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
44" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Chapter 10 Contents
Seat Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
302612 5/05 c-1
Chapter 11 Contents
Maintenance & Adjustments Safety Precautions. . . . . . . . . . . . . . 11-3
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-7
Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1
c-2 302612 5/05
Chapter 1
General Information
This Manual covers Hustler Mini Z 19/44 model 927228, Mini Z 19/52 model 927236, Mini Z 23/52
model 927244, Mini Z 24/52 model 927251, Mini Z 20/44 model 927483, Mini Z 20/52 model
927491, & Mini Z 27/52 model 927525.
Frequently Ordered Parts
PART NO. DESCRIPTON
027912
027920
768341
786533
791335
789388
785626
068478
785261
785279
785634
772079
747303
784256
783753
Service Literature
PAR T NO. DESCRIPTION
302638
778423
785642
742684
Lubrizol 7 oz. Bottle
Lubrizol 10 oz. Bottle
Hydraulic Oil Filter
Pump Drive Belt
44" Deck Belt
52" Deck Belt
Honda Fuel Filter
Kawasaki & Kohler Fuel Filter
Main Air Filter
Safety Air Filter Element
Honda 20/24HP Engine Oil Filter
Kawasaki Engine Oil Filter
Kohler Engine Oil Filter
16" X 2.5" X 0.204 .631 Dia. Hole Blade
18" X 2.5" X 0.204 .631 Dia. Hole Blade
Hustler Mini Z Owner’s Manual
Kawasaki 19/23HP Engine Manual
Honda 18/20/24HP Engine Manual
Kohler 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 neces
sary, 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.
302612 5/05 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
CE
CP
CS
CW
FDRW
FW
HX
LW
MB
MS
NT
SC
SH
SB
SS
OD
ID
Carriage Bolt
Clevis Pin
Cotter Pin
Cap Screw
Cup Washer
Fender Washer
Flat Washer
Hex Head
Lock Washer
Machine Bushing
Machine Screw
Nut
Self Tapping Cap Screw
Socket Head
Shoulder Bolt
Set Screw
Outside Diameter
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 302612 5/05
Chapter 2 Contents
Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Footrest Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
302612 5/05 2-1
Rivet Nut Installation
1
2
INDEX
NO.
SERVICE
PART NO.
1 546630 387936 1 52" MINI Z FRAME
546648 392449 1 44" MINI Z FRAME
2 N/A 808493 2 3/8-16 THREAD RIVET NUT
MFG. PART
NO.
QTY. DESCRIPTION
NOTES:
2-2 302612 5/05
Footrest Assembly
1
3
4
2
5
6
5
1
7
INDEX
NO.
SERVICE
PART NO.
1 388884 388884 1 MINI Z FLOOR PLATE
2 785485 785485 2 UPPER STEP TREAD
3 785493 785493 1 LOWER STEP TREAD
4 086660 086660 2 NT .375-16 HX LK NY
5 767954 767954 4 FW .406 X .812 X .060 SAE HD ZN
6 781880 781880 2 RUBBER BUMPER
7 052860 052860 2 CS .375-16 X 1.25 HX G5 ZNYC
MFG. PART
NO.
QTY. DESCRIPTION
NOTES:
1. Do not tighten, Item 1 ( 388884 Mini Z Floor Plate) must be able to pivot
on these bolts.
302612 5/05 2-3
2-4 302612 5/05
Chapter 3 Contents
Hydraulic System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
302612 5/05 3-1
Hydraulic System Installation
1
2
3
6
9
10
11
15
31
32
11
12
3
8
15
16
14
17
16
5
4
7
12
8
17
13
23
18
20
24
19
22
21
19
18
20
25
21
30
34
33
26
16
27
28
29
3-2 302612 5/05
Hydraulic System Installation
INDEX
NO.
10 768523 768523 3 FW .343 X .687 X .051/.080 HD ZNYC
11 787648 N/A 2 FILTER TO PUMP HOSE ASSEMBLY
12 779132 N/A 2 FITTING, STR-6MORB/-6JIC
13 781062 781062 1 HYDRO-GEAR BDP-10A-300 PUMP
14 781047 781047 1 HYDRO-GEAR BDP-10A-400 PUMP
15 041707 041707 4 NT .437-14 HX G5 ZNYC
16 704742 704742 8 FW .453 X .812 X .060 ZNYC
17 781559 N/A 4 FITTING, 45-8MORB/-8MSL
18 791152 791152 2 WHITE MOTOR CE14
19 008573 008573 8 CS .500-13 X 2.500 HX G5 ZNYC
20 767962 767962 8 FW .531 X 1.063 X .090 SAE HD ZN
21 781526 N/A 3 FITTING, 90-10MORB/-8MSL
22 787440 N/A 1 FITTING, 45-10MORB/-8MSL
23 79 1111 N/A 1 HYDRO TUBE, MINI-Z RLOOP/RP-BM
24 791129 N/A 1 HYDRO TUBE, MINI-Z RLOOP/LP-TM
25 791145 N/A 1 HYDRO TUBE, MINI-Z LLOOP/LP-TM
26 791137 N/A 1 HYDRO TUBE, MINI-Z LLOOP/RP-BM
27 705186 705186 4 CS .437-14 X 1.375 HX G5 ZNYC
28 787630 N/A 1 RESERVOIR TO FILTER HOSE ASSEMBLY
29 779447 N/A 1 ADAPTER T,-6JIC/-60RB/-6JIC
30 763946 N/A 1 FITTING 90, -6 O-RING/-6 JIC
31 055947 055947 2 CS .250-20 X .500 HX G5 ZNYC
32 768515 768515 2 FW .281 X .625 X .051/.080 HD ZNYC
33 768341 768341 1 FILTER ELEMENT
34 768333 768333 1 ZINGA BF SERIES FILTER HEAD
SERVICE
PART NO.
1 032763 032763 1 BREATHER CAP
2 032771 032771 1 STRAINER
3 368803 368803 1 HYDRAULIC OIL RESERVOIR
4 787614 N/A 1 FITTING, -12MORB/-6FORB
5 787473 N/A 1 FITTING, -6MORB/-6 BEADED TUBE
6 781658 N/A 1 FITTING, STR-8MORB/HEX PLUG
7 787655 N/A 2 CASE DRAIN HOSE ASSEMBLY
8 787465 787465 2 FITTING, 90-6MORB/-6BEADEDTUBE
9 034272 034272 3 NT .312-18 HX G5 ZNYC
MFG. PART
NO.
QTY. DESCRIPTION
NOTES:
1. Add 3.5 oz. Lubrizol® (027912) to new system or when hydraulic oil is
changed (see Owner’s Manual).
2. Hydraulic system capacity is 5 US quarts. Fill reservoir to within 1" of top
of Item 2 (032771 Strainer).
Note:
Seal Kit for hydraulic pump; 780718 (BDP10 Overhaul Seal Kit)
302612 5/05 3-3
3-4 302612 5/05
Chapter 4 Contents
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Steering and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Pump Belt and Pulley Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
302612 5/05 4-1
Battery Installation
1
2
3
5
8
7
6
4
7
6
12
9
10
1
11
2
13
7
8
14
4-2 302612 5/05
Battery Installation
INDEX
NO.
10 034272 034272 2 NT .312-18 HX G5 ZNYC
11 768820 768820 1 BATTERY GROUND CABLE
12 034280 034280 1 CS .312-18 X .750 HX G5 ZNYC
13 029876 029876 1 LW .312 INT-EXT TOOTH ZNYC
14 779850 779850 2 CB .312-18 X 3.00 FUL ZN
SERVICE
PART NO.
1 058776 058776 2 NT .312-18 HX NL ZNYC
2 768523 768523 3 FW .343 X .687 X .051/.080 HD ZNYC
3 348417 348417 1 BATTERY CLAMP STRAP
4 785063 785063 1 POSITIVE BATTERY CABLE
5 771428 771428 1 RED BATTERY CABLE BOOT
6 055939 055939 2 CS .250-20 X .750 HX G5 ZNYC
7 029868 029868 4 LW .250 INT-EXT TOOTH ZNYC
8 024927 024927 2 NT .250-20 HX GR.5 ZNYC
9 740696 740696 1 BATTERY
MFG. PART
NO.
QTY. DESCRIPTION
NOTES:
1. When perfoming service, disconnect battery ground cable and black
wire of harness,and do not reconnect them until engine is ready to be
started (See owners manual).
302612 5/05 4-3
Deck Lift Assembly
1
3
2
4
6
4
6
10
15
11
4
13
1
14
6
5
7
8
9
12
4
6
7
6
8
11
4
14
14
1
5
4
6
1
14
7
6
8
8
4-4 302612 5/05
Deck Lift Assembly
INDEX
NO.
10 756270 756270 1 CS .312-18 X 1.50 FLTHR GR5 ZNYC
11 034272 034272 1 NT .312-18 HX G5 ZNYC
12 348458 348458 1 DECK LEVELER YOKE
13 781229 781229 1 CE .750X2.25 X1.75 HEADLESS
14 015495 015495 4 STRAIGHT GREASE FITTING
15 784686 784686 1 FW .812 X 1.469 X .134 THK ZNYC
SERVICE
PART NO.
1 348318 348318 1 STOP HANDLE
2 784488 784488 1 DECK LIFT INDICATOR
3 348284 348284 1 HEIGHT ADJUSTMENT STOP
4 781294 781294 7 CLIP E, 1.00 X.625X .050
5 782995 782995 2 DECK LIFT SPRING
6 704643 704643 8 NT .437-14 HX FLG ZN
7 055749 055749 3 CS .437-14 X 1.750 HX G5 ZNYC
8 348391 348391 4 DECK LIFT CHAIN
9 781831 781831 1 CS .437-14 X 1.750 FULTH G5 ZNYC
MFG. PART
NO.
QTY. DESCRIPTION
NOTES:
1. Apply grease at zerks (see owner’s manual).
302612 5/05 4-5
Steering and Brake Assembly
1
2
4
7
8
6
9
14
10
12
13
11
6
31
12
2728
6
29
5
6
13
15
26
17
16
7
30
3
24
12
25
24
12
18
20
12
23
19
12
13
21
12
22
20
15
6
5
32
26
40
21
37
42
43
2
41
44
1
45
47
12
26
46
13
12
38
12
21
33
34
6
26
33
39
3536
4-6 302612 5/05
Steering and Brake Assembly
INDEX
NO.
10 781583 781583 2 BRAKE ROD ASSEMBLY
11 705178 705178 6 CS .375-16 X1.75 HX G5 ZNYC
12 768523 768523 26 FW .343 X .687 X .051/.080 HD ZNYC
13 041152 041152 8 NT .312-24 HX ZNYC
14 348862 348862 4 STEERLEVER BUSHING
15 781153 781153 4 .750 X 1.00 X .50 PLASTIC BUSHING
16 784439 784439 2 LOCK COLLAR
17 368910 368910 1 STEERING CENTER PIVOT TUBE
18 781286 781286 2 PUMP ROD ADJUSTER ASSEMBLY
19 704163 704163 2 CS .250-20 X 2.00 HX G5 ZNYC
20 768515 768515 4 FW .281X.625X.051/.080HD ZNYC
21 034272 034272 8 NT .312-18 HX G5 ZNYC
22 367557 367557 2 PUMP ARM
23 068551 068551 2 NT .250-20 HX NL ZNYC
24 781922 781922 4 DAMPER BALL STUD
25 783696 783696 2 CENTERING DAMPENER
26 086660 086660 12 NT .375-16 HX LK NY
27 367573 367573 1 LH STEERLEVER SUPPORT
28 367565 367565 1 RH STEERLEVER SUPPORT (NOT SHOWN)
29 063198 063198 4 CS 10-24 X .750 HXFLK ZNYC
30 782979 782979 2 CS .375-16 X 4.75 HX G5 ZNYC
31 781211 781211 2 PUSH BUTTON SWITCH
32 059832 059832 4 NT #10-24 HX NL ZN
33 060541 060541 4 SB .500 X .625 SH .375-16 ZN
34 765339 765339 4 INGUS#MFI-0608_05 BUSHING
35 302943 302943 1 LEFT BRAKE PIVOT ARM
36 302935 302935 1 RIGHT BRAKE PIVOT ARM (NOT SHOWN)
37 367169 367169 2 BRAKE LEVER EXTENSION
38 783852 N/A 2 KEY
39 791327 791327 2 BRAKE LINKAGE ASSEMBLYY
40 017004 017004 4 LW .312 MED SPRING ZNYC
41 048876 048876 8 CS .312-18 X .75 HX G8 ZNYC
42 783118 783118 1 BRAKE ASSEMBLY
3
43 783126 783126 1 BRAKE ASSEMBLY (NOT SHOWN)
4
44 782953 782953 2 HUB ASSEMBLY
45 783845 N/A 2 NUT
46 064014 064014 4 CS .312-18 X .875 HX G5 ZNYC
47 712927 712927 8 FW .344 X 1.00 X .12 HRD ZNYC
SERVICE
PART NO.
1 781260 781260 2 STEERING BAR GRIP
2 368704 368704 2 STEERING BAR
3 367128 367128 1 CONTROL PANEL
4 368670 368670 2 STEERING ARM MOUNT
5 055822 055822 6 CS .375-16 X .750 HX G5 ZNYC
6 767954 767954 26 FW .406 X .812 X .060 SAE HD ZN
7 781716 781716 4 SS .500-13 X 1.75 SH ZN
8 053199 053199 2 NT .500-13 HX JAM ZNYC
9 036244 036244 4 CS .375-16 X 1.00 HX G5 ZNYC
MFG. PART
NO.
QTY. DESCRIPTION
302612 5/05 4-7
NOTES:
1. Torque to 280-310 ft.-lbs. Included with wheel motor.
2. Torque brake assembly mounting bolts to 24 ft.-lbs.
3. 783118 used on left wheel.
4. 783126 used on right wheel.
4-8 302612 5/05
This page intentionally left blank.
302612 5/05 4-9
Pump Belt and Pulley Installation
For mowers with serial
numbers prior to
04040580
35
1
1
14
LOCATION FOR
RUBBER BUMPER
2
25
5
2
26
28
29
27
28
34
30
33
32
31
12
1
12
12
9
2
8
9
17
2
8
2
3
4
10
5
13
14
15
6
1
7
16
4
20
21
22
23
24
4-10 302612 5/05
18
19
3
Pump Belt and Pulley Installation
INDEX
NO.
1 779876 779876 1 ENGINE SC SINGLE PULLEY
2 212076 212076 1 KEY 1/4 SQ X 1.50 LONG
3 797654 797654 1 FW 1.156 X 1.750 X .250 ZY
5
4 791251 791251 1 CLUTCH PIGTAIL HARNESS (DIODE)
5 787366 787366 1 WARNER Z CLUTCH
6 783829 783829 1 FW .460X 1.750X .250 ZNYC
7 785048 785048 1 CS .437-20 X 3.00 HX G5 ZNYC
5
6
8 083196 083196 4 SS .312-18 X .750 SQ-HD ZN
9 325308 325308 2 PULLEY & FAN
10 768127 768127 2 KEY 5MM X 30MM RADIUS ENDS
11 366765 366765 1 CLUTCH ANCHOR ANGLE
12 016527 016527 2 CS .500-13 X 1.00 HX G5 ZNYC
13 767962 767962 4 FW .531 X 1.063 X .090 SAE HD ZN
14 008193 008193 2 NT .500-13 HX G5 ZNYC
15 784918 784918 1 RUBBER BUMPER
16 015495 015495 1 STRAIGHT GREASE FITTING
17 368860 368860 1 PUMP IDLER ARM
18 025296 025296 1 FW .760 X 1.625 X .08 ZN
19 061101 061101 1 NT .750-10 HX NL ZN
20 786848 786848 1 IDLER PULLEY
21 028118 028118 1 FW .62 X 1.00 X.134 ZN
22 781872 781872 1 CS .625-11 X 1.25 HX G5 ZN
23 781302 781302 1 IDLER SPRING
24 786533 786533 1 A-SEC PUMP IDLER BELT
25 787408 N/A 1 CLUTCH
26 778217 N/A 1 CS .437-20 X 2.25 G5 ZNYC
27 036244 N/A 1 CS .375-16 X 1.000 HX G5 ZN
28 767954 N/A 2 FW .406 X .812 X .060 SAE HD ZN
29 054502 N/A 1 NT .375-16 HX GRD 5 ZN
30 055939 N/A 1 CS .250-20 X .750 HX G5 ZN
31 362392 N/A 1 CLUTCH ANCHOR BRACKET
32 778738 N/A 1 .312 WIRING CLAMP
33 768515 N/A 1 FW .281 X .625 X .051/.080 HD ZN/YL
34 024927 N/A 1 NT .250-20 HX GR.5 ZN
SERVICE
PART NO.
785659 N/A 1 CS .437-20 X 2.50 HX G5 ZNYC
748681 N/A 1 GM .75 X 1.35 X 1.06 X .18 GROMMET
MFG.
PART NO.
QTY DESCRIPTION
NOTES:
1. Torque to 45-48 ft.-lbs.
2. Torque to 12-15 ft.-lbs.
3. Do not torque Item 18 (NT .750-10 HX NL ZN), Item 17 (368860 Pump Idler
Arm) should pivot freely.
4. Apply grease at zerks (see owner’s manual).
5. Used on mowers with serial number 05040948 and higher.
6. Used on mower with serial number prior to 05040948.
302612 5/05 4-11
7. Electric clutch burnishing procedure: After installing a new clutch, it is
important to burnish the clutch to insure maximum deck clutch life. In an
open area with no bystanders, set the engine speed to half throttle. Cycle
the deck clutch on for 15 seconds, and then off for 15 seconds. Repeat this
operation 10 times - it will require about 5 minutes to complete.
4-12 302612 5/05
Chapter 5 Contents
Kawasaki Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Honda Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Kohler Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Fuel System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Instrument Panel Installation/Assembly. . . . . . . . . . . . . . . . . . . . . . 5-16
Electrical Schematic–Kawasaki Engines (783894) . . . . . . . . . . . . . 5-18
Electrical Schematic–Honda Engines (787200) . . . . . . . . . . . . . . . 5-20
Electrical Schematic–Kohler Engines (788000). . . . . . . . . . . . . . . . 5-22
302612 5/05 5-1
Kawasaki Engine Installation
2
1
2
13
12
PART OF
WIRE HARNESS
41
15
1
14
16
11
7
17
18
19
3
4
5
8
7
9
6
7
3
10
3
6
7
YEL
6
7
TO BULLET
3
TERMINALS
(MALE-BRN)
(FEMALE-ORG)
21
22
24
22
TO SPADE
3
TERMINAL
PUR
23
3
21
25
31
32
33
43
30
27
21
29
20
7
36
37
P/O ENGINE
3
RED/BLK
34
28
35
40
42
3
PUR
22
26
POSITIVE
BATTERY
CABLE
38
39
5-2 302612 5/05
40
7
Kawasaki Engine Installation
INDEX
NO.
10 786038 786038 1 REMOTE AIR FILTER HOSE
11 779611 779611 1 KAWASAKI 19 HP ENGINE (FH601V, 3600 RPM) (USED ON 927228& 927236)
12 786863 786863 1 19/23/25 KAWASAKI MUFFLER
13 720177 720177 2 CS M 8-1.25 X 20 10.9 HXFLZNYC
14 786566 786566 1 1.375" MUFFLER CLAMP
15 780841 780841 2 KAW (23) MUFFLER GASKET
16 786871 786871 1 KAWASAKI MUFFLER MANIFOLD
17 360693 360693 1 HEAT SHIELD
18 017004 017004 4 LW .312 MED SPRING ZNYC
19 782664 782664 4 NT M8-1.25 HX STAINLESS STEEL
20 796524 796524 1 M20 X 2.5 OIL DRAIN VALVE
8
21 768515 768515 5 FW .281 X .625 X .051/.080HD ZNYC
22 024927 024927 3 NT .250-20 HX GR.5 ZNYC
23 768820 768820 1 BATTERY CABLE
24 783894 783894 1 TRACTOR WIRE HARNESS
25 044255 044255 1 NT #10-32 HX ZN
26 771428 771428 1 RED BATTERY CABLE BOOT
27 030817 030817 1 STARTER SOLENOID
28 055947 055947 2 CS .250-20 X .50 HX G5 ZNYC
29 769166 769166 1 HOUR METER
30 388892 388892 1 SEAT SUPPORT CROSSMEMBER
31 055822 055822 8 CS .375-16 X .750 HX G5 ZNYC
32 767954 767954 8 FW .406 X .812 X .060 SAE HD ZN
33 034280 034280 4 CS .312-18 X .75 HX G5 ZNYC
34 369132 369132 1 MUFFLER GUARD
35 300053 300053 1 ENGINE GUARD
36 029876 029876 4 LW .312 INT-EXT TOOTH ZNYC
37 052837 052837 4 CS .312-18 X1.50 HX G5 ZNYC
38 016527 016527 6 CS .500-13 X1.00 HX G5 ZNYC
39 767962 767962 6 FW .531 X 1.063 X.090 SAE HD ZN
40 064006 064006 2 CS .312-18 X .625 HX G5 ZNYC
41 789131 789131 1 HUSTLER Z FAN CONNECTION CAP
42 792192 792192 1 STARTER RELAY GROUND WIRE
43 808493 808493 10 RIVET NUT, 3/8-16 THREAD
44
SERVICE
PART NO.
1 786673 786673 1 DONALDSON AIR CLEANER CAP
2 785741 785741 1 MOUNTING BAND
3 057661 057661 2 HOSE CLAMP
4 788943 788943 1 AIR FILTER INDICATOR
5 782763 782763 1 AIR CLEANER
6 034272 034272 10 NT .312-18 HX G5 ZNYC
7 768523 768523 18 FW .343 X .687 X .051/.080HD ZNYC
8 370288 370288 1 MINI Z REMOTE AIR CLEANER BRACKET
9 036236 036236 2 CS .312-18 X 1.00 HX G5 ZNYC
777656 777656 1 KAWASAKI 23 HP ENGINE (FH680V, 3600 RPM) (USED ON 927244)
MFG. PART
NO.
QTY. DESCRIPTION
NOTES:
1. Includes mounting hardware.
2. Includes one (1) of Item 3 (057661 Hose Clamp).
302612 5/05 5-3
3. Part of Item 24 (783894 Tractor Wire Harness).
4. Engine oil capacity; 2 US quarts.
5. Engine RPM to be set at 3600±50.
6. When installing lower hose clamp on air cleaner hose, install as low as
possible (against carburetor inlet).
7. This connector used for optional hydraulic oil cooler fan.
8. Used on mowers with serial numbers 05031839 and higher. This part
replaces “O” ring , drain extension, and drain plug, on mowers with serial
numbers prior to 05031839,
9. Air filter service parts:
785261 MAIN AIR FILTER ELEMENT
763318 VACUATOR VALVE
5-4 302612 5/05
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