Hustler Turf Super Mini Z User Manual
Hustler Super Mini Z
Parts Manual
302620 Rev. 8/06
•••••••
Hustler Turf Equipment
•••••
P.O. Box 7000
•••
Hesston, Kansas
•
67062-2097
WARNING:
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
IMPORTANT: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code
Section 4442 to use or operate this engine on any fores t-covered, brush-covered, or grass-covered unimproved 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, maintenance and warranty.
Keep Engine Owner’s Manual with your unit. Should the Engine Owner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered pe r the information found in the Produc t Information sec tion of the
owner’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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Instrument Panel Installation/Assembly . . . . . . . . . . . . . . . . . . . . . 5-15
Electrical Schematic - Kawasaki Engines (783894) . . . . . . . . . . . . 5-17
Electrical Schematic - Honda Engines (787200). . . . . . . . . . . . . . . 5-19
Electrical Schematic—Kohler (788000) . . . . . . . . . . . . . . . . . . . . . 5-21
Table of Contents
Chapter 6 Contents
Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Front Wheel Breakdown - 786061 . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Drive Wheel Assembly/Installation . . . . . . . . . . . . . . . . . . . . . . . . . 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
302620 8/06
Chapter 11 Contents
Maintenance & Adjustments Safety Precautions . . . . . . . . . . . . . . 11-2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-15
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1
302620 8/06
Chapter 1
General Information
This Manual covers Hustler Super Mini Z 23/44 model 927269, Super Mini Z 25/52 model 927277,
Super Mini Z 24/52 model 927285, and Super Mini Z 27/52 model 927533.
Frequently Ordered Parts
PART NO. DESCRIPTION
027912 Lubrizol 7 oz. Bottle
027920 Lubrizol 10 oz. Bottle
783936 Hydraulic Oil Filter
786533 Pump Drive Belt
791335 44" Deck Belt
789388 52" Deck Belt
785626 Honda Fuel Filter
068478 Kawasaki Fuel Filter
785261 Main Air Filter
785279 Safety Air Filter Element
785634 Honda Engine Oil Filter
772079 Kawasaki Engine Oil Filter
747303 Kohler Engine Oil Filter
784256 16" X 2.5" X 0.204 .631 Dia. Hole Blade
783753 18" X 2.5" X 0.204 .631 Dia. Hole Blade
Service Literature
PART NO. DESCRIPTION
302638 Hustler Mini Z Owner’s Manual
778423 Kawasaki 19/23HP Engine Manual
785642 Honda 18/20/24HP Engine Manual
742684 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-
302620 8/06 1-1
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.
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 302620 8/06
Chapter 2 Contents
Rivet-nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
302620 8/06 2-1
Rivet-nut Installation
1
2
INDEX
NO.
SERVICE
PAR T NO.
1 546630 387936 1 52" MINI Z FRAME
546648 392449 44" MINI Z FRAME
2 N/A 808493 2 3/8-16 THREAD NUTSERT
MFG. PART
NO.
QTY. DESCRIPTION
NOTES:
2-2 302620 8/06
Footrest Assembly
2
3
1
4
5
6
5
1
7
INDEX
NO.
SERVICE
PAR T 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.
302620 8/06 2-3
2-4 302620 8/06
Chapter 3 Contents
Hydraulic System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
302620 8/06 3-1
Hydraulic System Installation
9
13
3
7
8
10
6
14
15
16
2
4
5
11
2
3
1
18
21
26
27
12
19
24
22
25
26
21
27
20
29
19
28
22
30
31
35
36
39
27
44
17
2
27
37
38
41
42
23
33
34
28
29
30
32
31
43
40
3-2 302620 8/06
Hydraulic System Installation
INDEX
NO.
10 783985 N/A 1 FITTING, STR ORB-BEADED TUBE
3
11 787564 N/A 1 MINI-Z CASE DRAIN HOSE ASSEMBLY
3
12 787572 N/A 1 MINI-Z CASE DRAIN HOSE ASSEMBLY
3
13 781658 N/A 1 FITTING, STR-8MORB/HEX PLUG
3
14 700484 700484 1 HOSE CLAMP
15 034272 034272 3 NT .312-18 HX G5 ZNYC
16 768523 768523 3 FW .343 X .687 X .051/.080 HD ZNYC
17 055947 055947 2 CS .250-20 X .500 HX G5 ZNYC
18 787580 N/A 1 HOSE ASSEMBLY, PUMP TO COOLER SMZ
3
19 784108 N/A 2 FITTING, 6 BEADED TUBE-ORB 45
3
20 787598 N/A 1 HOSE ASSEMBLY, PUMP TO COOLER SMZ
3
21 784082 N/A 2 FITTING, 8 BEADED TUBE-ORB 90
3
22 781559 N/A 3 FITTING, 45-8MORB/-8MSL
23 781542 N/A 1 FITTING, 90-8MORB/-8MSL
3
24 786368 786368 1 PUMP, HYDRO-GEAR BDP16A-306
25 786350 786350 1 PUMP, HYDRO-GEAR BDP16A-409
26 041707 041707 4 NT .437-14 HX G5 ZNYC
27 704742 704742 8 FW .453 X .812 X .060 ZNYC
28 791152 791152 2 WHITE MOTOR CE14
29 008573 008573 8 CS .500-13 X 2.500 HX G5 ZNYC
30 767962 767962 8 FW .531 X 1.063 X .090 SAE HD ZN
31 781526 N/A 3 FITTING, 90-10MORB/-8MSL
3
32 787440 N/A 1 FITTING, 45-10MORB/-8MSL
3
33 791061 N/A 1 HYDRO TUBE, SMZ-RH SIDE-RP/BM
3
34 795278 N/A 1 HYDRO TUBE, SMZ RH SIDE LP/TM
3
35 791103 N/A 1 HYDRO TUBE SMZ LH SIDE- LP/TM
3
36 791087 N/A 1 HYDRO TUBE SMZ LH SIDE-RP/BM
3
37 705186 705186 4 CS .437-14 X 1.375 HX G5 ZNYC
38 787622 N/A 1 HOSE ASSEMBLY, RESERVOIR TO FILTER SMZ
3
39 787457 N/A 1 FITTING, 90-12MORB/-12MJIC
3
40 791814 N/A 1 HOSE ASSY FILTR TO RH PUMP SMZ
3
41 787606 N/A 1 HOSE ASSEMBLY, FILTER TO PUMP SMZ
3
42 788174 N/A 1 FITTING, T -8MJIC/8MJIC/12MORB
3
43 783936 783936 1 FILTER ELEMENT
44 783928 783928 1 FILTER HEAD ZAF SERIES
SERVICE
PAR T NO.
1 068551 068551 2 NT .250-20 HX NL ZNYC
2 768515 768515 8 FW .281 X .625 X .051/.080 HD ZNYC
3 055939 055939 4 CS .250-20 X .750 HX G5 ZNYC
4 713198 713198 2 SEAL 3/8 X 3/4 X 7¾" LONG
5 713198 713198 2 SEAL 3/8 X 3/4 X 1½" LONG
6 787192 787192 1 HYDRAULIC OIL COOLER
7 032763 032763 1 BREATHER CAP
8 032771 032771 1 STRAINER
9 368803 368803 1 HYDRAULIC OIL RESERVOIR
MFG. PART
NO.
QTY. DESCRIPTION
302620 8/06 3-3
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 8 (032771 Strainer).
3. Included in Hydro Kit (791160).
Note:
Seal Kit for hydraulic pump; 788133 (BDP16 Overhaul Seal Kit)
3-4 302620 8/06
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
302620 8/06 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 302620 8/06
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
PAR T 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 performing maintenance, disconnect battery ground cable and
black wire of harness and do not reconnect to battery until engine is
ready to be started (See owners manual).
302620 8/06 4-3
Deck Lift Assembly
1
2
3
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 302620 8/06
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
PAR T NO.
1 348318 348318 1 STOP HANDLE
2 348284 348284 1 HEIGHT ADJUSTMENT STOP
3 784488 784488 1 DECK LIFT INDICATOR
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).
302620 8/06 4-5
Steering and Brake Assembly
1
2
4
7
8
6
9
14
10
12
13
11
6
2728
6
29
31
5
6
13
12
15
17
3
19
12
20
18
24
16
7
25
26
30
24
12
12
23
12
13
21
12
22
20
15
6
5
32
26
21
40
37
42
43
2
44
1
45
41
47
12
3536
26
46
12
13
33
26
34
12
38
21
6
33
39
4-6 302620 8/06
Steering and Brake Assembly
INDEX
NO.
5
10 781583 781583 2 BRAKE ROD ASSEMBLY
11 705178 705178 6 CS .375-16 X1.75 HX G5 ZNYC
12 768523 768523 34 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 369660 369660 2 PUMP ARM
23 068551 068551 2 NT .250-20 HX NL ZNYC
24 781922 781922 4 DAMPER BALL STUD
25 600221 600221 2 CENTERING DAMPENER
6
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 .750 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 ZN
SERVICE
PAR T NO.
1 781260 781260 2 STEERING BAR GRIP
2 368704 N/A 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
783696 783696 2 CENTERING DAMPENER
MFG. PART
NO.
QTY. DESCRIPTION
302620 8/06 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.
5. Includes Item 1 (781260 Steering Bar Grip).
6. Used on mowers with serial numbers prior to 06071186.
4-8 302620 8/06
This page intentionally left blank.
302620 8/06 4-9
Pump Belt and Pulley Installation
For mowers with serial
numbers prior to
04040580
35
1
27
28
30
31
32
33
34
14
LOCATION FOR
RUBBER BUMPER
2
25
2
5
26
28
29
13
1
2
8
2
3
9
12
2
8
4
10
5
9
13
14
16
15
4
6
1
7
20
21
22
23
24
11
17
18
19
3
4-10 302620 8/06
Pump Belt and Pulley Installation
INDEX
NO.
1 783761 783761 1 SUPER Z 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
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 785659 785659 1 CS .437-20 X 2.50 HX G5 ZNYC
8 083196 083196 4 SS .312-18 X .750 SQ-HD ZN
9 782466 782466 2 PULLEY & FAN BDP-21
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.
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 16 (368860 Pump
Idler Arm) should pivot freely.
4. Apply grease at zerks (see owner’s manual).
5. 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.
302620 8/06 4-11
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 302620 8/06
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 (787200). . . . . . . . . . . . . . . . . . . . . . 5-20
Electrical Schematic—Kohler (788000) . . . . . . . . . . . . . . . . . . . . . . 5-22
302620 8/06 5-1
Kawasaki Engine Installation
2
1
3
4
10
11
13
12
2
5
6
7
8
7
9
10
11
14
20
19
1
21
25
26
18
24
22
23
37
16
3
17
15
6
7
TO SPADE
TERMINAL
PUR
3
36
6
7
33
11
34
3
YEL
P/O ENGINE
27
11
28
31
28
11
29
TO BULLET
TERMINALS
3
(MALE-BRN)
(FEMALE-ORG)
3
11
30
38
39
40
35
3
RED/BLK
7
43
44
45
46
47
5-2 302620 8/06
32
POSITIVE
41
BATTERY
CABLE
7
47
42
3
PUR
Kawasaki Engine Installation
INDEX
NO.
10 055939 055939 6 CS .250-20 X .75 HX G5 ZNYC
11 768515 768515 11 FW .281 X .625 X .051/.080HD ZNYC
12 783837 783837 1 ELECTRIC COOLER FAN
13 047654 047654 2 CLIP
14 369470 369470 1 SUPER MINI Z HOOD
15 044818 044818 4 CN ZN TIN-C7343-1420
16 045088 045088 1 HOSE CLAMP 1"
17 786038 786038 1 REMOTE AIR FILTER HOSE
18 777656 777656 1 KAWASAKI 23 HP ENGINE (FH680V, 3600 RPM) (USED ON 927269)
19 786863 786863 1 19/23/25 KAWASAKI MUFFLER
20 720177 720177 2 CS M 8-1.25 X 20 10.9 HXFLZNYC
21 786566 786566 1 1.375" MUFFLER CLAMP
22 780841 780841 2 KAW (23) MUFFLER GASKET
23 786871 786871 1 KAWASAKI MUFFLER MANIFOLD
24 360693 360693 1 HEAT SHIELD
25 017004 017004 4 LW .312 MED SPRING ZNYC
26 782664 782664 4 NT M8-1.25 HX STAINLESS STEEL
27 796524 796524 1 M20 X 2.5 OIL DRAIN VALVE
7
28 024927 024927 3 NT .250-20 HX GR.5 ZNYC
29 768820 768820 1 BATTERY CABLE
30 783894 783894 1 TRACTOR WIRE HARNESS
31 044255 044255 1 NT #10-32 HX ZN
32 771428 771428 1 RED BATTERY CABLE BOOT
33 030817 030817 1 STARTER SOLENOID
34 055947 055947 2 CS .250-20 X .50 HX G5 ZNYC
35 792192 792192 1 STARTER RELAY GROUND WIRE
36 769166 769166 1 HOUR METER
37 388892 388892 1 SEAT SUPPORT CROSSMEMBER
38 055822 055822 8 CS .375-16 X .750 HX G5 ZNYC
39 767954 767954 8 FW .406 X .812 X .060 SAE HD ZN
40 034280 034280 4 CS .312-18 X .75 HX G5 ZNYC
41 369132 369132 1 MUFFLER GUARD
42 300061 300061 1 ENGINE GUARD
43 029876 029876 4 LW .312 INT-EXT TOOTH ZNYC
44 052837 052837 4 CS .312-18 X1.50 HX G5 ZNYC
45 016527 016527 6 CS .500-13 X1.00 HX G5 ZNYC
46 767962 767962 6 FW .531 X 1.063 X.090 SAE HD ZN
47 064006 064006 2 CS .312-18 X .625 HX G5 ZNYC
SERVICE
PAR T 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 370270 370270 1 MINI Z DEFLECTOR SCOOP
9 036236 036236 2 CS .312-18 X 1.00 HX G5 ZNYC
782318 782318 1 KAWASAKI 25 HP ENGINE (FH601V, 3600 RPM) (USED ON 927277)
MFG. PART
NO.
QTY. DESCRIPTION
302620 8/06 5-3
NOTES:
1. Includes mounting hardware.
2. Includes one (1) of Item 3 (057661 Hose Clamp).
3. Part of Item 30 (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. 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,
8. Air filter service parts:
785261 MAIN AIR FILTER ELEMENT
763318 VACUATOR VALVE
5-4 302620 8/06
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