Hustler Turf Z XR7 User Manual

Hustler Z XR7

Parts Manual

•••••••

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 Calif orn ia to cau se c an cer, birt h

defects or other reproductive harm.

IMPORTANT: This engine is not equipped with a spark arr ester muffler. It is a violation of California Public Resource Code
Section 4442 to use o r operate this eng i ne on any fo rest-co vered, brush-cover ed, or grass-co ver ed unimproved land . Other
states or federal areas may have similar laws.

This spark ign i tion sy stem c ompli es with Can adian ICES -002.

The Eng ine Owne r’s Ma nual provide s info rma tion regarding the U.S. E nvironmenta l Protection Agency (EP A) a nd the
California Emission Control Regulation of emission systems, maintenance and warranty.

Keep E ng ine Owner’s Manual with your unit. Sho uld the E ngine Owner’s Manual become damaged or illeg ible, re­place i mmediately. Re pl acements may be o rd ered per the information found in th e Produc t In f ormation section of th e

owner’s manual.

Chapter 1

Chapter 2

Chapter 3

Chapter 4

Chapter 5

Table of Contents

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

Rivet Nut Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Hydraulic System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Battery Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Steering and Park Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Pump Belt and Pulleys Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Kawasaki Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Honda Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Kohler Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Instrument Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Electrical Schematic (799320) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Chapter 6

Chapter 7

Chapter 8

Chapter 9

Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Front Wheel Breakdown—747782 . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Optional Semi-Pneumatic Tire/Wheel—789537 . . . . . . . . . . . . . . . 6-5

Drive Wheel Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Anti-Rollover Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

66" Deck Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

66" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

60" Side Discharge Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . 7-6

60" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

54" Deck Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

54" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Spindle Assembly–796235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Deck Belt Routing and Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Seat Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Tractor Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

66" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

60" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

54" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

106567 4/07 c-1

Chapter 10

Maintenance & Adjustment Safety . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

Safe Maintenance & Adjustment Practices . . . . . . . . . . . . . . . . . . 10-4

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25

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

c-2 106567 4/07

Chapter 1

General Information

This Manual covers Hustler XR7 Z models 927723, 927731, 927749, 927756, 927772, 927798,
927806, 927814 with serial numbers prior to 07020000.

Frequently Ordered Parts

PART NO. DESCRIPTION

027912 Lubrizol 7 oz. Bottle
027920 Lubrizol 10 oz. Bottle
768341 Hydraulic Oil Filter
781443 Pump Drive Belt
797696 Blade, F18.50"-H-F-CW (54" Deck)
794685 Blade, F20.50"-H-F-CW (60" Deck)
798496 Blade, F22.50"-H-F-CW (66" Deck)
797928 Belt, B-Section (54" Deck)
797720 Belt, B-Section (60" Deck)
797936 Belt, B-Section (66" Deck)
068478 Fuel Filter
785261 Main Air Filter Element
785279 Safety Air Filter Element
772079 Kawasaki Engine Oil Filter
785634 Honda Engine Oil Filter
747303 Kohler Engine Oil Filter

Service Literature

PART NO. DESCRIPTION

600876 Owner’s Manual
785642 Honda 18/20/24 Engine Owner’s Manual
778423 Kawasaki 19–25 hp Engine Owner’s Manual
742684 Kohler Engine Owner’s Manual

Note: When ordering parts, yo u 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 represen tative.

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 nece s­sary, without notification. If a change has been made to your machine which is not reflected in this parts manual, see

106567 4/07 1-1

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 va lues 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 se ction 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 M14 80 108.5
.875 420 565 M16 160 215

1.00 625 850 M20 320 435
M24 555 750

NOTE:

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

1-2 106567 4/07

Chapter 2 Contents

Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Footrest Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

106567 4/07 2-1

Rivet Nut Installation

2

1

2

2

3

5

2

3

4

INDEX NO.

1 548032 107701 1 TRACTOR FRAME (54")

2 N/A 808493 15 3/8-16 THREAD RIVET NUT
3 N/A 600961 8 1/2-13 THREAD RIVET NUT
4 N/A 808477 2 1/4-20 THREAD RIVET NUT (KAW ONLY)
5 547950 106732 1 XR7 MMZ SEAT SUPPORT

1

SERVICE

PART NO.

547760 106211 1 TRACTOR FRAME (60")
547752 106039 1 TRACTOR FRAME (66")

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Seat support 547950 includes rivet nuts.

2-2 106567 4/07

Footrest Assembly

1

2

4

5

6

3

5

1

7

INDEX

NO.

1 359547 359547 2 STEP TREAD
2 395533 395533 1 FLOOR
3 305615 305615 2 PLATFORM 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 1.250 HX G5 ZN

SERVICE

PART NO.

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Do not tighten, Item 2 (348276 Floor) must be able to pivot on these
bolts.

106567 4/07 2-3

2-4 106567 4/07

Chapter 3 Contents

Hydraulic System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

106567 4/07 3-1

Hydraulic System Installation

2

1

16

15

31

4

3

17

19

5

20

18

17

FRONT

30

18

17
10

11

6

10

14

20

29

9

28

23

11

7

21

8

22

12

24

26

25

12

11

27

13

24

3-2 106567 4/07

Hydraulic System Installation

ITEM

NO.

1 768515 768515 2 FW .281 X .625 X .051/.080 HD ZN/YL
2 055947 055947 2 CS .250-20 X .500 HX G5 ZN
3 032771 032771 1 STRAINER
4 032763 032763 1 BREATHER CAP
5 349860 349860 1 RESERVOIR
6 034272 034272 4 NT .312-18 HX G5 ZN
7 768523 768523 4 FW .343 X .687 X .051/.080 HD ZN/YL
8 781062 781062 1 HYDRO-GEAR PUMP, BDP-10A-300

9 781047 781047 1 HYDRO-GEAR PUMP BDP-10A-400
10 041707 041707 4 NT .437-14 HX G5 ZN
11 704742 704742 8 FW .453 X .812 X .060 ZN
12 781054 781054 2 ROSS/PARKER WHEEL MOTOR, MB-15
13 705186 705186 4 CS .437-14 X 1.375 HX G5 ZN
14 768341 768341 1 FILTER ELEMENT
15 768333 768333 1 FILTER HEAD
16 781575 N/A 1 -6STR -6 90°, PUSHLOC HOSE 4.75"
17 763946 N/A 3 90°, -6 O-RING/-6 JIC FITTING
18 778985 N/A 2 -6STR -6 90°, PUSHLOC HOSE, 13.00"
19 781591 N/A 1 -6STR -6 90°, PUSHLOC HOSE, 15.00"
20 779132 N/A 2 STR-6MORB/-6JIC FITTING
21 781559 N/A 1 45°, -8MORB/-8MSL FITTING
22 781542 N/A 1 90°,-8MORB/-8MSL FITTING
23 781658 N/A 1 STR-8-MORB/HEX PLUG
24 781526 N/A 4 90°, -10MORB/-8MSL FITTING
25 781500 N/A 1 RIGHT LOOP/RP-BM HYDRO TUBE
26 781492 N/A 1 RIGHT LOOP/LP-TM HYDRO TUBE
27 781484 N/A 1 LEFT LOOP/RP-BM HYDRO TUBE
28 781476 N/A 1 LEFT LOOP/LP-TM HYDRO TUBE
29 781534 N/A 2 STR-8MORB/-8MSL FITTING
30 781518 N/A 1 -6STR -6STR PUSHLOC HOSE, 9.00"
31 763953 N/A 1 -6 O-RING/-6JIC/6JIC T FITTING

SERVICE

PART NO.

N/A 781469 1 MMZ HYDRAULIC KIT (INCLUDES 16-31)

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Add 3.5 oz. Lubrizol® (027912) 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 3 (032771 Strainer)

106567 4/07 3-3

Note:

HYDRAULIC SYSTEM CHARGING PROCEDURE

1. Set handles in the neutral position.

2. Start engine at idle.

3. Let run for a minimum of 30 seconds.

4. Stroke handles to forward position.

5. If motors do not turn in 15 seconds return handles to neutral and
repeat step 3 and 4 (one time).

6. If motors do not turn after second attempt, shut off the engine
and check for oil at the pump.

7. Increase throttle to half speed and work handles through forward
and reverse position until the motor operates smoothly
throughout the entire speed range.

Seal Kit for hydraulic pump; 727756 (BDP10 Overhaul Seal Kit)

3-4 106567 4/07

Chapter 4 Contents

Battery Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Steering and Park Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Pump Belt and Pulleys Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

106567 4/07 4-1

Battery Installation

TRACTOR
FRAME

1

2

1

4

3

5

1

9

8

11

6

5

7

8

9

10

11

12

4-2 106567 4/07

Battery Installation

INDEX

NO.

1 024927 024927 2 NT .250-20 HX GR.5 ZN
2 771428 771428 1 RED BATTERY CABLE BOOT
3 796219 796219 1 36" NEGATIVE BATTERY CABLE
4 744276 744276 1 POSITIVE BATTERY CABLE
5 768523 768523 3 FW .343 X .687 X .051/.080 HD ZN/YL
6 058776 058776 2 NT .312-18 HX NL ZN
7 348417 348417 1 BATTERY CLAMP STRAP
8 055939 055939 2 CS .250-20 X .750 HX G5 ZN

9 029868 029868 4 LW .250 INT-EXT TOOTH ZN
10 740696 740696 1 BATTERY
11 034272 034272 2 NT .312-18 HX G5 ZN
12 779850 779850 2 CB .312-18 X 3.00 FUL ZN

SERVICE

PART NO.

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. When performing service on mower, disconnect battery ground cable
and do not reconnect to battery until engine is ready to be started. See
Owners Manual.

1065674/07 4-3

Deck Lift Assembly

1

2

4

5

TRACTOR
FRAME

5

6

5

7

10

4

3

12

11

4

5

1

13

5

6

4

10

4

5

1

8

1

10

4

9

8

1

10

4

14

8

4

9

4-4 106567 4/07

9

Deck Lift Assembly

ITEM

NO.

1 348318 348318 1 STOP HANDLE
2 600437 600437 1 DECK HEIGHT 1/2" PIN W/A

2

{

3 783001 783001 1 DECK LIFT INDICATOR SUBASSEMBLY
4 704643 704643 8 NT .437-14 HX FLG ZN
5 781294 781294 7 CLIP E, 1.00 X .625 X .050
6 782995 782995 2 DECK LIFT SPRING SUBASSEMBLY
7 781229 781229 1 CE .750 X 2.25 X 1.75 HEADLESS
8 055749 055749 3 CS .437-14 X 1.750 HX G5 ZN

9 348391 018846 4 DECK LIFT CHAIN
10 015495 015495 4 STRAIGHT GREASE FITTING
11 034272 034272 1 NT .312-18 HX G5 ZN
12 756270 756270 1 CS .312-18 X 1.50 FUL THR GR5 ZN
13 348458 348458 1 DECK LEVELER YOKE
14 781831 781831 1 CS .437-14 X 1.750 FUL THD G5 ZN

SERVICE

PART NO.

348284 N/A 1 HEIGHT ADJUSTMENT STOP 3/8"

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Apply grease to zerks (see owner’s manual).

2. Verify pin diameter prior to ordering replacement part. For mowers with
3/8" diameter pins, order 348284; for mowers with 1/2" pins, order

600437. Item 3 includes 600437 (1/2" pin).

1065674/07 4-5

Steering and Park Brake Assembly

1

10

2

3

4

8

6

7

5

3

3

5

9

3

14

3

6

7

3

11

15

16

11

12

17

18

13

4

20

21

7

30

38

19

7

6

21

22

23

7

25

24

3

26

27

3

10

36

35

28

40

31

1

39

30

29

3

28

36

7

33

3

34

29

37

6

7

30

3

15

41

TRACTOR
FRAME

32

2

4-6 106567 4/07

Steering and Park Brake Assembly

ITEM

NO.

1 781260 N/A 2 STEERING BAR GRIP
2 348755 348755 2 STEERING BAR
3 767954 767954 48 FW .406 X .812 X .060 SAE HD ZN
4 036244 036244 10 CS .375-16 X 1.000 HX G5 ZN
5 705178 705178 6 CS .375-16 X 1.750 HX G5 ZN
6 041152 041152 8 NT .312-24 HX ZN
7 768523 768523 18 FW .343X .687 X .051/.080 HD ZN/YL
8 348946 348946 2 STEERING ARM MOUNT
9 348888 348888 1 STEERLEVER SUPPORT LH

10 055822 055822 8 CS .375-16 X .750 HX G5 ZN
11 781716 781716 4 SS .500-13 X 1.75 SH ZN
12 053199 053199 2 NT .500-13 HX JAM ZN
13 348987 348987 1 STEERING CONTROL PANEL
14 348862 348862 4 STEERLEVER BUSHING
15 086660 086660 8 NT .375-16 HX LK NY
16 781583 781583 2 BRAKE ROD ASSEMBLY
17 063198 063198 4 CS 10-24 X .750 HXFLK ZN
18 781211 781211 2 PUSH BUTTON SWITCH
19 781286 781286 2 PUMP ROD ADJUSTER ASSEMBLY
20 600221 600221 2 CENTERING DAMPER

6

21 781922 781922 4 DAMPER BALL STUD
22 704163 704163 2 CS .250-20 X 2.00 HX G5 ZN
23 768515 768515 4 FW .281 X .625 X .051/.080 HD ZN/YL
24 068551 068551 2 NT .250-20 HX NL ZN
25 367557 367557 2 PUMP ARM
26 348797 348797 2 ADJUSTABLE PIVOT
27 781153 781153 4 BUSHING
28 005116 005116 4 CS .375-16 X 1.375 HX G5 ZN
29 054502 054502 4 NT .375-16 HX GRD 5 ZN
30 034272 034272 8 NT .312-18 HX G5 ZN
31 781765 781765 2 BRAKE DRUM-HUB ASSEMBLY
32 781112 781112 1 BRAKE ASSEMBLY

3
4

33 036236 036236 4 CS .312-18 X 1.000 HX G5 ZN
34 350272 350272 2 BRAKE ARM EXTENSION
35 350330 350330 1 L.S. BRAKE PIVOT ARM

36 765339 765339 4 BUSHING
37 059832 059832 4 NT #10-24 HX NL ZN
38 782979 782979 2 CS .375-16 X 4.75 HX G5 ZN
39 065516 N/A 2 ROSS CASTLE NUT
40 350397 350397 2 BRAKE LINK TURNBUCKLE
41 064337 N/A 2 ROSS KEY

SERVICE

PART NO.

348714 348714 1 STEERLEVER SUPPORT RH

783696 783696 2 CENTERING DAMPER

781351 781351 1 BRAKE ASSEMBLY

350264 350264 1 R.S. BRAKE PIVOT ARM

MFG.

PART NO.

QTY DESCRIPTION

1065674/07 4-7

NOTES:

1. Torque to 350-375 ft.-lbs. Included with wheel motor.

2. Torque brake assembly mounting bolts to 100 ft.-lbs.

3. 781112 used on left wheel.

4. 781351 used on right wheel.

5. Includes Item 1 (781260 Steering Bar Grip).

6. Use 783696 on mowers with serial numbers prior to 06071499.

4-8 106567 4/07

This page intentionally left blank.

1065674/07 4-9

Pump Belt and Pulleys Installation

TRACTOR
FRAME

24

25
26

2

6

2

6

8

7

10

1

5

2

9

2

8

10

11

7

6

10

13

15

12

14

16

17

21

22

3

9

13

23

4

1

5

18

19

10

3

20

4-10 106567 4/07

Pump Belt and Pulleys Installation

INDEX

NO.

1 779876 779876 1 ENGINE SC SINGLE PULLEY
2 212076 212076 1 KEY 1/4 SQ X 1.50 LONG
3 787366 787366 1 WARNER CLUTCH
4 783829 783829 1 FW .460 X 1.750 X .250 ZNYC
5 785659 785659 1 CS .437-20 X 2.50 HX G5 ZNYC
6 083196 083196 4 SS .312-18 X .750 SQ-HD ZN
7 768127 768127 2 KEY 5MM X 30MM RADIUS ENDS
8 325308 325308 2 PULLEY & FAN

9 008193 008193 2 NT .500-13 HX G5 ZNYC
10 767962 767962 4 FW .531 X 1.063 X .090 SAE HD ZN
11 016527 016527 2 CS .500-13 X 1.00 HX G5 ZNYC
12 366765 366765 1 CLUTCH ANCHOR ANGLE
13 784918 784918 2 RUBBER BUMPER
14 349761 349761 1 PUMP IDLER ARM
15 015495 015495 1 STRAIGHT GREASE FITTING
16 025296 025296 1 FW .760 X 1.625 X .08 ZN
17 061101 061101 1 NT .750-10 HX NL ZN
18 781856 781856 1 IDLER PULLEY
19 028118 028118 1 FW .62 X 1.00 X.134 ZN
20 794446 794446 1 CS .625-11 X 1.50 HX G5 ZN
21 781302 781302 1 IDLER SPRING
22 781443 781443 1 A-SEC PUMP IDLER BELT
23 791251 791251 1 HARNESS, CLUTCH PIGTAIL(DIODE)
24 036236 036236 1 CS .312-18X1.000 HX G5 ZNYC
25 768523 768523 1 FW .343 X .687 X .051/.080 HD ZNYC
26 034272 034272 1 NT .312-18 HX G5 ZNYC

SERVICE

PART NO.

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Torque to 45-48 ft-lbs.

2. Torque to 12-15 ft-lbs.

3. Apply grease at zerk (see owner’s manual).

4. Included with Honda 24 HP engine (785014).

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. 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.

1065674/07 4-11

4-12 106567 4/07

Chapter 5 Contents

Kawasaki Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Honda Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Kohler Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Fuel System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Instrument Panel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Electrical Schematic (799320). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

106657 4/07 5-1

Kawasaki Engine Installation

Y

TO ENGINE
SENSOR

2

ELLOW

5

6

7

TO SPADE

2

TERMINAL

TO BULLET

2

TERMINALS

2

RED/BLK

7

10

6

11

PART OF
ENGINE

7

6

17

16

19

20

3

22

3

23

1

18

21

9

STARTER
SOLENOID
GROUND

2

3

NEGATIVE
BATTERY
CABLE

8

4

17

3

20

24

17

2

3

12

13

6

POSITIVE
BATTERY
CABLE

32

14

31

PURPLE

3

15

TRACTOR
FRAME

2

38

37

23

25

26

3

27

3

15

28

29

3

30

PART OF COMMON
WIRE HARNESS

9

33

34

36

39

35

1

5-2 106567 4/07

Kawasaki Engine Installation

ITEM

NO.

1 777656 777656 1 KAWASAKI 23 HP ENGINE

5
6

2 058776 058776 4 NT .312-18 HXZY NL
3 768523 768523 22 FW .343 X .687 X .051/.080 HD ZN/YL
4 029876 029876 1 LW .312 INT-EXT TOOTH ZN
5 792762 792762 1 BATTERY CABLE
6 768515 768515 5 FW .281 X .625 X .051/.080 HD ZN/YL
7 024927 024927 3 NT .250-20 HX GR.5 ZN
8 799312 799312 1 WIRE HARNESS ADAPTER

9 799320 799320 1 COMMON WIRE HARNESS
10 044255 044255 1 NT #10-32 HX ZN
11 030817 030817 1 STARTER SOLENOID
12 055947 055947 2 CS .250-20 X .500 HX G5 ZN
13 792192 792192 1 STARTER RELAY GROUND WIRE
14 771428 771428 1 RED BATTERY CABLE BOOT
15 050161 050161 4 CS .312-18 X 1.75 HX G5
16 786673 786673 1 DONALDSON AIR CLEANER CAP

7

17 057661 057661 3 HOSE CLAMP
18 788943 788943 1 AIR FILTER INDICATOR
19 785741 785741 1 MOUNTING BAND
20 034272 034272 6 NT .312-18 HX G5 ZN
21 782763 782763 1 AIR CLEANER
22 366443 366443 1 REMOTE AIR CLEAN MOUNT BRACKET
23 036236 036236 6 CS .312-18 X 1.00 HX G5 ZNYC
24 786038 786038 1 REMOTE AIR FILTER HOSE
25 796524 796524 1 OIL DRAIN M20 X 2.5 VALVE
26 350371 350371 1 MUFFLER GUARD
27 349704 349704 1 ENGINE CAGE MOUNT PLATE
28 767962 767962 6 FW .531 X 1.063 X .090 SAE HD ZN
29 016527 016527 6 CS .500-13 X 1.00 HX G5 ZN
30 064006 064006 2 CS .312-18 X .625 HX G5 ZN
31 781732 781732 1 MUFFLER MANIFOLD
32 781724 781724 1 MUFFLER
33 720177 720177 2 CS M 8-1.25 X 20 10.9 HXFL ZN
34 782649 782649 1 KAW (23) EXHAUST PIPE CLAMP
35 782664 782664 4 NT M8-1.25 HX STAINLESS STEEL
36 017004 017004 4 LW .312 MED SPRING ZN
37 360693 360693 1 HEAT SHIELD
38 780841 780841 2 KAW (23) MUFFLER GASKET
39 789131 789131 1 HUSTLER Z FAN CONNECTOR CAP

SERVICE

PART NO.

782318 782318 1 KAWASAKI 25 HP ENGINE (FH721V, 3600 RMP)

MFG.

PART NO.

QTY DESCRIPTION

106567 4/07 5-3

NOTES:

1. Includes mounting hardware.

2. Part of Item 8 (799312 Wire Harness Adapter).

3. Engine oil capacity; 2 US quarts (w/filter).

4. Engine RPM to be set at 3600± 50.

5. 23 HP engine used in 927723 and 927731 only.

6. 25 HP engine used in 927772 and 927798 only.

7. Includes one (1) of Item 17 (057661 Hose Clamp).

8. When installing lower hose clamp on air cleaner hose, install as low as
possible (against carburetor inlet).

9. This connector used for optional hydraulic oil cooler fan.

10. Air filter service parts:

785261 MAIN AIR FILTER ELEMENT
763318 VACUATOR VALVE

5-4 106567 4/07