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Sabre Lawn Tractor
38–Inch and 46–Inch (96 cm and 117 cm)
Models: 1338 Gear
1538 Gear
1538 Hydro
15538 Gear
15538 Hydro
1546 Gear
1638 Hydro
1646 Gear
1646 Hydro
Technical Manual
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John Deere Consumer Products Group
TM–GX10131 (Mar–97)
LITHO IN U.S.A. (New)
This technical manual is written for an experienced
technician and contains sections that are specifically for
this product. It is a part of a total product support
program.
The manual is organized so that all the information on a
particular system is kept together. The order of grouping
is as follows:
INTRODUCTION
Safety
Specifications and
Information
• Table of Contents
• Specifications
• Component Location
• System Schematic
• Theory of Operation
• Troubleshooting Chart
• Diagnostics
• Tests & Adjustments
• Repair
Note: Depending on the particular section or system
being covered, not all of the above groups may be
used.
Each section will be identified with a symbol rather than a
number. The groups and pages within a section will be
consecutively numbered.
We appreciate your input on this manual. If you find any
errors, or want to comment on the layout of the manual,
please mail your comments back to us.
Engine
Electrical
Gear Power Train
Hydrostatic Power Train
All information, illustrations and
specifications in this manual are based on
the latest information available at the time of
publication. The right is reserved to make
changes at any time without notice.
©
COPYRIGHT
Deere & Co.
John Deere Worldwide Lawn and
Grounds Care Division
Power Products Group
P.O. Box 7047
Charlotte, NC 28241
All rights reserved
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1997
Steering
Attachments
Miscellaneous
Service Information Bulletins
M
S
SAFETY
HANDLE FLUIDS SAFELY-AVOID
FIRES
• BE PREPARED FOR EMERGENCIES
HANDLE CHEMICAL PRODUCTS
SAFELY
TS1133
Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used
include such items as lubricants, coolants, paints, and
adhesives.
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques. Check the MSDS before you start any job
using a hazardous chemical. That way you will know
exactly what the risks are and how to do the job safely.
Then follow procedures and recommended equipment.
When you work around fuel, do not smoke or work near
heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and
debris.
Do not store oily rags; they can ignite and burn
spontaneously.
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department near your
telephone.
• DISPOSE OF WASTE PROPERLY
Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste
includes oil, fuel, coolant, brake fluid, filters, and
batteries. Use leakproof containers when draining
fluids. Do not use food or beverage containers that
may mislead someone into drinking from them. Do not
pour waste onto the ground, down a drain, or into any
water source. Inquire on the proper way to recycle or
dispose of waste from your local environmental or
recycling center.
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3/5/97
SAFETY
USE CARE IN HANDLING AND
SERVICING BATTERIES
• PREVENT BATTERY EXPLOSIONS
• Keep sparks, lighted matches, and open flame
away from the top of battery. Battery gas can
explode.
• Never check battery charge by placing a metal
object across the posts. Use a volt-meter or
hydrometer.
• Do not charge a frozen battery; it may explode.
Warm battery to 16°C (60°F).
• PREVENT ACID BURNS
• Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, eat holes in clothing,
and cause blindness if splashed into eyes.
• Avoid acid burns by:
1. Wearing eye protection and rubber gloves.
2. Avoiding breathing fumes from electrolyte.
3. Avoiding tipping battery.
4. Use proper jump start procedure.
USE SAFE SERVICE PROCEDURES
• WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment
appropriate to the job.
Prolonged exposure to loud noise can cause
impairment or loss of hearing. Wear a suitable hearing
protective device such as earmuffs or earplugs to
protect against objectionable or uncomfortable loud
noises.
Operating equipment safely requires the full attention
of the operator. Do not wear radio or music
headphones while operating machine.
• SERVICE MACHINES SAFELY
Tie long hair behind your head. Do not wear a necktie,
scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to
get caught, severe injury could result.
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
• If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda to help neutralize the acid.
3. Flush your eyes with water for 10–15 minutes.
4. Get medical attention immediately.
• If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.
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• USE PROPER TOOLS
Use tools appropriate to the work. Makeshift tools and
procedures can create safety hazards. Use power tools
only to loosen threaded parts and fasteners. For
loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
wrenches. Use only service parts meeting John Deere
specifications.
SAFETY
• PARK MACHINE SAFELY
1. Depress brake pedal fully.
2. Move park lever into lock position.
3. Check that shift lever has returned to neutral.
4. Make sure blade drive lever is pulled back fully.
5. Move throttle lever to SLOW IDLE position and
allow engine to idle for approximately 30 seconds
before turning key switch to OFF position. Remove
the ignition key to prevent accidental starting.
• Before working on the machine:
1. Lower all equipment to the ground.
2. Stop the engine and remove the key.
3. Disconnect the battery ground strap.
4. Hang a “DO NOT OPERATE” tag in operator
station.
• WORK IN CLEAN AREA
• Before starting a job
1. Clean work area and machine:
2. Have all the necessary tools to do your job
3. Have the right parts on hand.
4. Read all instructions thoroughly; do not attempt
shortcuts.
• ILLUMINATE WORK AREA SAFELY
Illuminate your work area adequately but safely. Use a
portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire
cage. The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
• WORK IN VENTILATED AREA
• SUPPORT MACHINE PROPERLY AND USE
PROPER LIFTING EQUIPMENT
TS229
If you must work on a lifted machine or attachment,
securely support the machine or attachment with jack
stands rated to support the lifted load.
Do not support the machine on cinder blocks, hollow
tiles, or props that may crumble under continuous load.
Do not work under a machine that is supported solely
by a jack. Follow recommended procedures in this
manual.
Lifting heavy components incorrectly can cause severe
personal injury or machine damage. Follow
recommended procedure for removal and installation
of components in the manual.
Engine exhaust fumes can cause sickness or death. If
it is necessary to run an engine in an enclosed area,
remove the exhaust fumes from the area with an
exhaust pipe extension.
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area.
WARNING: California Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
Gasoline engine exhaust from this product contains
chemicals known to the State Of California to cause
cancer, birth defects, or other reproductive harm.
• REMOVE PAINT BEFORE WELDING OR HEATING
Avoid potentially toxic fumes and dust. Hazardous
fumes can be generated when paint is heated by
welding, soldering, or using a torch. Do all work outside
or in a well ventilated area. Dispose of paint and
solvent properly. Remove paint before welding or
heating: If you sand or grind paint, avoid breathing the
dust. Wear an approved respirator. If you use solvent
or paint stripper, remove stripper with soap and water
before welding. Remove solvent or paint stripper
containers and other flammable material from area.
Allow fumes to disperse at least 15 minutes before
welding or heating.
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3/5/97
SAFETY
• AVOID HARMFUL ASBESTOS DUST
Avoid breathing dust that may be generated when
handling components containing asbestos fibers.
Inhaled asbestos fibers may cause lung cancer.
Components in products that may contain asbestos
fibers are brake pads and some gaskets. The asbestos
used in these components is usually found in a resin or
sealed in some way. Normal handling is not hazardous
as long as airborne dust containing asbestos is not
generated.
Avoid creating dust. Never use compressed air for
cleaning. Avoid brushing or grinding material
containing asbestos. When servicing, wear an
approved respirator. A special vacuum cleaner is
recommended to clean asbestos. If not available, apply
a mist of oil or water on the material containing
asbestos. Keep bystanders away from the area.
• SERVICE TIRES SAFELY
REPLACE DECALS
Replace missing or damaged Decals. See the machine
operator's manual for correct safety sign placement.
LIVE WITH SAFETY
Explosive separation of a tire and rim parts can cause
serious injury or death.
Do not attempt to mount a tire unless you have the
proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate
the tires above the recommended pressure. Never
weld or heat a wheel and tire assembly. The heat can
cause an increase in air pressure resulting in a tire
explosion. Welding can structurally weaken or deform
the wheel.
When inflating tires, use a clip-on chuck and extension
hose long enough to allow you to stand to one side and
NOT in front of or over the tire assembly. Use a safety
cage if available.
• Check wheels for low pressure, cuts, bubbles,
damaged rims or missing retaining hardware.
Before returning machine to customer, make sure
machine is functioning properly, especially the safety
systems. Install all guards and shields.
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SAFETY
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3/5/97
SPECIFICATIONS & INFORMATION CONTENTS
CONTENTS
Page
SPECIFICATIONS & INFORMATION
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
UNIFIED INCH TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
METRIC TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GASOLINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
GASOLINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ALTERNATIVE LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SYNTHETIC LUBRICANTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OIL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LUBRICANT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TRACTOR IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ENGINE SERIAL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
GEAR TRANSAXLE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HYDROSTATIC TRANSMISSION SERIAL NUMBER — K55. . . . . . . . . . . . . . . . . . 10
HYDROSTATIC TRANSMISSION SERIAL NUMBER — K51. . . . . . . . . . . . . . . . . . 10
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SPECIFICATIONS SPECIFICATIONS & INFORMATION
SPECIFICATIONS
Engine:
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs and Stratton
Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vertical Shaft
Models:
13 Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28M707
15 Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28N700
16 Horsepower (Cast Iron Sleeve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Q777
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline, Air Cooled, Single Cylinder, 4-Cycle
Crankcase Oil Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pints
Oil: Warm Climate (Above 40°F) . . . . . . . . . . . . . . . . . . . . . . . .SE, SF, SG, SAE 30W
Cold Climate (Below 40°F). . . . . . . . . . . . . . . . . . . . . . . .SE, SF, SG, SAE 10W30
Electrical:
®
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetron
Magneto Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 -0.35 mm (0.010 - 0.014 in.)
Charging System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Circuit (AC/DC)
Charging Capacity. . . . . . . . . . . . . . . . 2-4 amps, 14 volts DC@3600 rpm (Unregulated)
Spark Plugs
13 Hp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TY6129 (Champion RJ-19 LM)
15 & 16 Hp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M78543 (Champion RC-12 YC)
Spark Plug Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.)
Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BCI Group, U1
Battery Cranking Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 amps at 0° C (32° F)
Battery Cold Cranking Amps. . . . . . . . . . . . . . . . . . . . . . . . . . .190 amps at 0° C (32° F)
Battery Specific Gravity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Above 1.225 Points
Starter Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bendix Inertia Drive
Fuel Shut-Off Solenoid (16 H.P. Only). . . . . Replaceable (Below Carburetor Float Bowl)
Headlight Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 1156, 12 Volt
Magneto Ignition
Fuel/Air System:
Carburetor Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs & Stratton
Carburetor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Side Draft
Throttle/Choke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unitized Control Linkage
Carburetor Fuel Shut-Off Solenoid ( Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . .Electric
Fuel Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gravity Flow
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable Inline type
Fuel Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unleaded (87 Octane Minimum)
Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 L (1.25 gal)
Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper Element with Foam Pre-cleaner
Muffler Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-Backfire
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SPECIFICATIONS & INFORMATION SPECIFICATIONS
Power Train—K55 Transmission:
Gear Transaxle—
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dana
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spicer Heavy-Duty 4360 Transaxle
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Five-Speed/Linear Shift
Domestic Ground Speeds (at FAST idle—3350 rpm) and Gear Ratios:
1st Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 km/hr (1.5 mph)—61.67:1
2nd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 km/hr (2.0 mph)—46.67:1
3rd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 km/hr (3.1 mph)—30.00:1
4th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 km/hr (4.0 mph)—23.48:1
5th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 km/hr (5.0 mph)—18.46:1
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 km/hr (2.3 mph)—40.00:1
Brake Type . . . . . . . . . . . . . . . . . .Single, External Brake Disc With Dual Friction Pucks
Lubrication—Input Shaft Needle Bearings . . . . . . . . . . . . . . . . . . Multi-Purpose Grease
Lubrication—Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multi-Purpose Grease
Capacity—Transaxle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.64 kg (1.406 lbs)
Hydro Transaxle—
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kanzaki
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tuff Torq
®
K55 Transaxle
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic
Ground Speeds (at FAST idle—3350 rpm):
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0—8.66 km/hr (0—5.38 mph)
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0—4.24 km/hr (0—2.62 mph)
Brake Type . . . . . . . . . . . . . . . . . . . . . . Single, External Disc Brake With Friction Pucks
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10W30 Engine Oil, Class CD
Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 L (3.4 pt)
Power Train—K51 Transmission:
Gear Transaxle—
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dana
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spicer K51 Transaxle
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Five-Speed/Linear Shift
Domestic Ground Speeds (at FAST idle—2950 rpm) and Gear Ratios:
1st Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 km/hr (1.5 mph)
2nd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 km/hr (2.0 mph)
3rd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 km/hr (3.1 mph)
4th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.4 km/hr (4.0 mph)
5th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.0 km/hr (5.0 mph)
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 km/hr (2.3 mph)
Brake Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single, Internal Brake Disc
Lubrication—Input Shaft Needle Bearings . . . . . . . . . . . . . . . . . . Multi-Purpose Grease
Lubrication—Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multi-Purpose Grease
Capacity—Transaxle Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3 kg (5.07 lbs)
Hydro Transaxle—
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kanzaki
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tuff Torq
®
K51 Transaxle
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic
Ground Speeds (at FAST idle—2950 rpm):
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0—8.5 km/hr (0—5.3 mph)
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0—5.3 km/hr (0—3.3 mph)
Brake Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single, Internal Disc Brake
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10W30 Engine Oil, Class CD
Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 L (2.4 qt)
3/5/97 2 - 3
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SPECIFICATIONS SPECIFICATIONS & INFORMATION
Traction Drive Belt:
Gear—
New Belt Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2660±8 mm (104.7±0.3 in.)
Minimum Effective Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2631 mm (103.6 in.)
Maximum Effective Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2710 mm (106.7 in.)
Hydro—K55 Transmission
New Belt Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2485±8 mm (97.8±0.3 in.)
Minimum Effective Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2477 mm (97.5 in.)
Maximum Effective Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2530 mm (99.6 in.)
Hydro—K51 Transmission
New Belt Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2400±8 mm (94.5±0.3 in.)
Minimum Effective Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2392 mm (94.2 in.)
Maximum Effective Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2424 mm (94.9 in.)
Mower Deck Drive Belt
38-Inch Deck—
Actual effective length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2425±10 mm (95.5±0.4 in.)
46-Inch Deck—
Actual effective length . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3492±10 mm (137.5±0.4 in.)
Mower Deck:
38-Inch Mower Deck—
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotary—Dual Spindles (Non-Serviceable)
Material Type. . . . . . . . . . . . . . . . . . .Stamped 2.5 mm (0.098 in.) Nominal Gauge Steel
Cutting Blade. . . . . . . . . . . . . . . . . . . . . . . . . Two—76 x 5 x 496 mm (3 x 0.2 x 19.5 in.)
Blade Cutting Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30±5° Angle
Blade Wing Lift/Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40±3 mm (1.57±0.12 in.)
Overall Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 965 mm (38 in.)
Overall Width (w/o discharge chute) . . . . . . . . . . . . . . . . . . . . . . . . . 1026 mm (40.4 in.)
Drive Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Single V-Belt (With Spring Tension Idler)
Spindle Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . None—Sealed Bearings
Lift Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual—Operator’s Station
Cutting Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . Seven: 31.8—89 mm (1.25—3.5 in.)
46-Inch Mower Deck—
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rotary—Triple Spindles (Non-Serviceable)
Material Type. . . . . . . . . . . . . . . . . . .Stamped 2.5 mm (0.098 in.) Nominal Gauge Steel
Cutting Blade. . . . . . . . . . . . . . . . . . . . . . Three—50.8 x 5 x 407.4 mm (2 x 0.2 x 16 in.)
Blade Cutting Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30±5° Angle
Blade Wing Lift/Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.3±3 mm (0.8±0.12 in.)
Overall Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1168.4 mm (46 in.)
Overall Width (W/O Discharge Chute) . . . . . . . . . . . . . . . . . . . . . . . 1308 mm (51.5 in.)
Drive Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Single V-Belt (With Spring Tension Idler)
Spindle Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . None—Sealed Bearings
Lift Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual—Operator’s Station
Cutting Settings. . . . . . . . . . . . . . . . . . . . . . . Seven: 31.75 mm—89 mm (1.25—3.5 in.)
Chassis:
Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1135 mm (44.69 in.)
Overall Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1524 mm (60 in.)
Overall Width (W/O Mower Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . 908 mm (35.75 in.)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 980 mm (38.6 in.)
Average Overall Weight 38 inch (With Mower Deck, No Fuel) . . . . . 195.05 kg (430 lbs)
2 - 4 3/5/97
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SPECIFICATIONS & INFORMATION SPECIFICATIONS
Average Overall Weight 46 inch (With Mower Deck, No Fuel) . . . . . 204.12 kg (450 lbs)
Hitch Capacity—
Export:
Horizontal Pull Maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 kg (56 lbs)
Tongue Weight Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 kg (15 lbs)
Domestic:
Trailer Load Maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136 kg (300 lbs)
Trailer Tongue Weight Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.6 kg (50 lbs)
Steering:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual—Pinion/Sector
Axle Pivot Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shim Adjustable
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multipurpose Grease
Lubrication Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 hrs (Maximum)
Toe-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.24 in.) — Non-Adjustable
Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584 mm (23 in.)
Wheels:
Size—
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.0 x 4.50
Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.0 x 6.18
Tires:
Size—
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 x 6.50—6 NHS (2 Ply)
Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 x 9.50—8 NHS (2 Ply)
Pressure—
Front (with mower deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 kPa (14 psi)
Rear (with mower deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 kPa (10 psi)
3/5/97 2 - 5
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UNIFIED INCH TORQUE VALUES SPECIFICATIONS & INFORMATION
UNIFIED INCH TORQUE VALUES
SAE
Grade
and Head
Markings
SAE
Grade
and Nut
Markings
Size
1/4
5/16
3/8
7/16
1/2
Grade 1
LubricatedaDry
No Marks
No Marks
a
b
1 or 2
2
Grade 2
b
LubricatedaDry
5
5.1
5.2
5
Grade 5, 5.1 or 5.2 Grade 8 or 8.2
a
LubricatedaDry
a
8
8
LubricatedaDry
8.2
a
Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft
3.8 2.8 4.7 3.5 6 4.4 7.5 5.5 9.5 712913.5 10 17 12.5
7.7 5.7 9.8 7.2 12 9 15.5 11.5 19.5 14.5 25 18.5 28 20.5 35 26
13.5 10 17.5 13 22 16 27.5 20 35 26 44 32.5 49 36 63 46
22 16 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74
34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115
9/16
5/8
3/4
7/8
1
1-1/8
1-1/4
1-3/8
1-1/2
48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165
67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225
120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400
190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640
285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960
400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350
570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920
750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500
990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
DO NOT use these values if a different torque value or tightening procedure is given for a specific application.
Torque values listed are for general use only. Check tightness of fasteners periodically.
Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only
be tightened to the strength of the original.
Make sure fasteners threads are clean and that you properly start thread engagement. This will prevent them from
failing when tightening.
Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the
chart, applied to the nut, not to the bolt head.
Tighten toothed or serrated-type lock nuts to the full torque value.
a
“Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
“Dry” means plain or zinc plated without any lubrication.
b
Grade 2 applies for hex cap screws (not hex bolts) up to 152 mm (6 in.) long. Grade 1 applies for hex cap screws over
152 mm (6 in.) long, and for all other types of bolts and screws of any length.
2 - 6 3/5/97
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SPECIFICATIONS & INFORMATION METRIC TORQUE VALUES
METRIC TORQUE VALUES
Property
Class
and
Head
Markings
Property
Class
and
Nut
Markings
4.8
4.8
4.8
5
5
510
8.8
8.8
8.8
10
10
9.8
9.8
9.8
10.9
10.9
10.9
10
10
10
12.9
12.9
12
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
LubricatedaDry
Size
a
LubricatedaDry
a
LubricatedaDry
a
LubricatedaDry
Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft
M6
4.7 3.5 6 4.4 9 6.6 11.5 8.5 13 9.5 16.5 12.5 15.5 11.5 19.5 14.5
M8
11.5 8.5 14.5 10.7 22 16 28 20.5 32 23.5 40 29.5 37 27.5 47 35
M10
23 17 29 21 43 32 55 40 63 46 80 59 75 55 95 70
M12
40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120
12.9
12.9
12
12
a
M14
63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190
M16
100 74 125 92 190 140 240 175 275 200 350 225 320 235 400 300
M18
135 100 175 125 265 195 330 245 375 275 475 350 440 325 560 410
M20
190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580
M22
265 195 330 245 510 375 650 480 725 535 920 680 850 625 108 800
M24
330 245 425 315 650 480 820 600 920 680 115 850 108 800 135 100
M27
490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 200 1500
M30
660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1700 2700 2000
M33
900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730
M36
1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500
DO NOT use these values if a different torque value or tightening procedure is given for a specific application.
Torque values listed are for general use only. Check tightness of fasteners periodically.
Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property
class.
Fasteners should be replaced with the same or higher property class. If higher property class fasteners are used,
these should only be tightened to the strength of the original.
Make sure fasteners threads are clean and that you properly start thread engagement. This will prevent them from
failing when tightening.
Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the
chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value.
a
“Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
“Dry” means plain or zinc plated without any lubrication.
3/5/97 2 - 7
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GASOLINE SPECIFICATIONS SPECIFICATIONS & INFORMATION
GASOLINE SPECIFICATIONS
CAUTION
Handle fuel with care, it is highly flammable. DO
NOT refuel machine:
• Indoors. Always fill fuel tank outdoors.
• While you smoke.
• When machine is near and open flame or
sparks.
• When engine is running. STOP engine.
• When engine is hot. Allow it to cool.
Help prevent fires:
• Fill fuel tank only to bottom of filler neck.
• Clean oil, grease and dirt from machine.
• Clean up spilled fuel immediately.
• Do not store machine with fuel in tank in a
building where fumes may reach an open
flame or spark.
To prevent fire and explosion caused by static
electric discharge while you fill tank:
• Use approved, non-metal fuel container.
• When using a funnel, MAKE SURE it is
PLASTIC.
• Avoid using a funnel which has a metal screen
or filter.
LUBRICANT SPECIFICATIONS
ENGINE OIL
Use oil viscosity based on the expected air
temperature range during the period between oil
changes.
The following oil is preferred:
• 10W30
IMPORTANT: To avoid engine damage:
• DO NOT mix oil with gasoline
• Use only clean oil and fuel
• Use clean approved containers and funnels.
• Store oil and fuel in an area protected from dust,
moisture and other contamination.
Unleaded fuel is recommended because it burns
cleaner and leaves less unburned deposits in engine
combustion chamber. Regular unleaded gasoline with
an anti-knock index of 85 octane or higher may be
used. Use of gasohol is acceptable as long as the ethyl
alcohol blend does not exceed 11 percent. Do not use
gasoline that contains Methanol.
Fill fuel tank at end of each day's operation. Fill only to
bottom of filler neck.
GASOLINE STORAGE
Keep fuel in a clean container in a protected area. Do
not use deicers to remove water from fuel. Do not
depend on fuel filters to remove water.
If possible, install a water separator at the storage tank
outlet.
IMPORTANT: Keep all dirt, scale, water or other
foreign material out of fuel.
If mower is stored for the winter, add gasoline storage
stabilizer to the fuel. Follow directions on can.
Other oils may be used if they meet one of the
following:
• API Service Classification SG
• API Service Classification SF
• CCMC Specification G4
Oils meeting Military Specification MIL-L-46167B may
be used as arctic oils.
2 - 8 3/5/97
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SPECIFICATIONS & INFORMATION LUBRICANT SPECIFICATIONS
GREASE
Use grease based on the expected air temperature
range during the service interval.
The following greases are preferred:
• MOLY HIGH TEMPERATURE EP GREASE
• HIGH TEMPERATURE EP GREASE
• MULTI-PURPOSE GREASE
SYNTHETIC LUBRICANTS
Synthetic lubricants may be used in John Deere
equipment if they meet the applicable performance
requirements (industry classification and/or military
specification) as shown in this group.
The recommended temperature limits and service or oil
change intervals should be maintained as shown in the
operator’s manual.
Avoid mixing different brands, grades, or types of oil.
Oil manufacturers blend additive in their oils to meet
certain specifications and performance requirements.
Mixing different oils can interfere with the proper
functioning of these additives and degrade lubricant
performance.
OIL FILTERS
Filtration of oils is critical to proper lubrication. Always
change filters regularly.
Use filters meeting John Deere performance
specification.
LUBRICANT STORAGE
Other greases may be used if they meet one of the
following:
• SAE Multipurpose EP Grease with a maximum of
5% molybdenum disulfide.
• SAE Multipurpose EP Grease
Greases meeting Military Specification MIL-G-10924F
may be used as arctic grease.
ALTERNATIVE LUBRICANTS
Conditions in certain geographical areas outside the
United States and Canada may require different
lubricant recommendations than these printed in this
manual or the operator's manual. Consult with your
John Deere Dealer, or Sales Branch to obtain the
alternative lubricant recommendations.
This machine can operate at top efficiency only if clean
lubricants are used.
Use clean containers to handle all lubricants. Store
them in an area protected from dust, moisture, and
other contamination. Store drums on their sides.
3/5/97 2 - 9
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SERIAL NUMBER LOCATIONS SPECIFICATIONS & INFORMATION
SERIAL NUMBER LOCATIONS
When working on machines or components that are
covered by warranty, it is IMPORTANT that you include
the tractor identification number and
serial numbers on the warranty claim form.
The location of tractor identification number and
component serial numbers are shown below.
the component
TRACTOR IDENTIFICATION
NUMBER
A
GEAR TRANSAXLE SERIAL
NUMBER
C
Gear transaxle serial number sticker (C) is on rear of
housing.
HYDROSTATIC TRANSMISSION
SERIAL NUMBER — K55
A
Tractor identification number plate (A) is located on the
rear of frame or under seat.
ENGINE SERIAL NUMBER
D
Serial number (D) is stamped into top of upper case
half. It is only accessible with hydro removed.
HYDROSTATIC TRANSMISSION
SERIAL NUMBER — K51
B
Tractor engine serial number sticker (B) is located on
fan shroud.
2 - 10 3/5/97
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E
Serial number (E) is located on a bar coded label
located on the right rear side of the transaxle.
ENGINE CONTENTS
CONTENTS
Page
ENGINE
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE EQUIPMENT AND TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
The engines used on Sabre products are warranted by the
manufacturer - Briggs & Stratton Corporation.
Please refer to the Owners Manual supplied with your machine for
applicable Briggs & Stratton Owners Warranty Policy.
2/11/97 3 - 1
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CONTENTS CONTINUED ENGINE
Page
3 - 2 2/11/97
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SPECIFICATIONS ENGINE
SPECIFICATIONS
NOTE: Engine service specifications and procedures are available from
your local Briggs & Stratton dealer or by writing:
BRIGGS & STRATTON CORPORATION
Milwaukee, WI. 53201
For Parts Request:
13HP . . . . . . . . . .Illustrated Parts List Diamond Plus Model Series 28M700 to 28M799
15HP . . . . . . . . . . Illustrated Parts List Diamond Plus Model Series 28N700 to 28N788
16HP . . . . . . . . . . . . . Illustrated Parts List Vanguard Model Series 28Q700 to 28Q799
For Repair Manual Request:
13 Horsepower. . . . . . . . . . . . . REPAIR MANUAL For Single Cylinder 4-Cycle Engines
15 Horsepower. . . . . . . . . . . . . REPAIR MANUAL For Single Cylinder 4-Cycle Engines
16 Horsepower. . . . . . . . . . . . . REPAIR MANUAL For Single Cylinder 4-Cycle Engines
SERVICE EQUIPMENT AND TOOLS
Please refer to appropriate Briggs & Stratton Repair Manual, see above, for specific tools required to service the
particular engine in your mower.
OTHER MATERIALS
Name Use
RTV Silicone Sealant Seal valve cover.
Prussian Blue Compound Check valve seat contact.
Valve Lap Compound Lap valves.
SCOTCH-BRITE® Pad Clean cylinder head.
Zinc Oxide/Wood Alcohol Check block for cracks.
SCOTCH-BRITE® is a trademark of the 3M Company.
2/12/97 3 - 3
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ENGINE REPAIR
REPAIR
ENGINE REMOVAL
1. Turn all switches OFF and disconnect battery
negative ( - ) cable.
2. Raise hood. Disconnect light harness on right side
of hood. Lower hood to approximately 3/4 open
and slide off bracket.
Capscrews
And Nut
Heat Shield
Capscrews
CAUTION
Gasoline is explosive. Do not expose to flame or
spark. Serious injury can result. Store in a
properly marked, safe container. Wipe-up any
spills IMMEDIATELY.
7. Disconnect hose clamp (E) and slide fuel line off of
hose barb on carburetor.
H
G
F
8. Disconnect wires from starter terminal (F).
3. Remove two capscrews securing heat shield to
frame. Remove capscrew and nut on side of heat
shield. Remove heat shield.
B
E
A
C
4. Disconnect fuel shutoff solenoid wire (A)(16
horsepower only).
5. Turn fuel shutoff valve (B) (early models only) to
OFF position or pinch closed fuel hose to
carburetor.
6. Loosen clamp (C) to disconnect throttle cable (D).
D
NOTE: Ground terminal (G) will be disconnected when
engine mounting bolt is removed.
9. Disconnect two (2) harness connectors (H).
10. Remove traction drive belt and mower drive belt.
11. Remove capscrew securing pulley assembly to
engine output shaft. Remove pulley assembly.
3 - 4 2/12/97
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REPAIR ENGINE
Ground Wire
Capscrews
Nuts
12. Remove four cap screws. Remove engine.
ENGINE INSTALLATION
1. Install engine in mower frame.
Ground Wire
2. Put ground lead connector on top of front right hand
engine mounting flange, and insert capscrew
through connector, engine, and frame.
3. Install lower engine ground connector on capscrew
installed in step 2, and secure with washer and
nut.
4. Install other three capscrews, washers, and nuts.
Torque to 32 N•m (24 lb-ft).
5. If muffler was removed inspect muffler flange for
flatness. Install muffler with new gasket. Torque
mounting bolts to 24•m (18 lb-ft).
Capscrews
And Nut
Heat Shield
Capscrews
6. Install heat shield. Secure with two capscrews to
front frame mounting brackets. Install capscrew
and nut on side of heat shield.
2/12/97 3 - 5
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ENGINE REPAIR
B
E
N
C
Capscrew
10. Connect and adjust throttle cable (C) to obtain full
7. Install engine output shaft key and pulley assembly.
Secure with washer, lock washer and capscrew.
Torque to 75 N•m (55 lb-ft).
H
throttle and choke when lever is full forward, and
idle when lever is rearward.
11. Connect fuel solenoid wire (N) (16 horsepower
only), and fuel line and clamp (E).
12. Open fuel shutoff valve (B) (early models only), or
remove clamp from fuel line.
F
8. Connect wires to starter terminal (F).
9. Connect two (2) harness connectors (H).
3 - 6 2/12/97
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ELECTRICAL CONTENTS
CONTENTS
Page
ELECTRICAL
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSTIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
READING SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
WIRE COLOR ABBREVIATION CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
WIRE HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CRANKING & FUEL SHUTOFF SOLENOID CIRCUIT OPERATION . . . . . . . . . . . . . 9
CRANKING & FUEL SHUTOFF SOLENOID CIRCUIT DIAGNOSIS . . . . . . . . . . . . 10
IGNITION & SEAT SWITCH CIRCUIT OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 12
IGNITION CIRCUIT TEST POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHARGING & HEADLIGHT CIRCUIT OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 16
CHARGING CIRCUIT DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
HEADLIGHTS CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CHARGE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DC AMPERAGE OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
AC VOLTAGE OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
STARTER SOLENOID TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
STARTER AMP DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SEAT SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
BRAKE SWITCH / BLADE DRIVE SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . 24
BRAKE SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
IGNITION SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
GROUND CIRCUIT TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
IGNITION SWITCH REMOVAL & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SEAT SWITCH REMOVAL & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
STARTER SOLENOID REMOVAL & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 28
2/11/97 4 - 1
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CONTENTS CONTINUED ELECTRICAL
Page
4 - 2 2/11/97
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SPECIFICATIONS ELECTRICAL
SPECIFICATIONS
Battery:
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BCI group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .U-1
Cold Cranking Amps at 0
Reserve Capacity At 0
Specific Gravity (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.225 points
Electrolyte Quantity (Approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt)
Ignition:
Primary Coil Resistance
One direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 1000 Ohms
Other Direction (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 K Ohms
Secondary (Plug Wire And Core) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 - 10.85 K Ohms
Air gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.2 - 0.3 mm (0.008 - 0.012 in.)
Spark Plug:
Type:
13 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TY6129 (Champion RJ-19 LM)
15 and 16 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M78543 (Champion RC-12 YC)
Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.)
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (221 lb-in.)
°
C (32°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190 amps
°
C (32°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 amps
Starter:
Starter Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bendix Inertia Drive
Amp draw
Loaded (Engaging Engine) . . . . . . . . . . . . . . . . . . . . . . .180 amps at 225 engine rpm
Stator:
Stator size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 amp
Unregulated Output At 3600 Rpm (No Lamps Attached):
AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 volts AC
DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4 amps DC
Headlight Bulbs:
Headlight Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 1073, 12 Volt, 23 Watt
3/5/97 4 - 3
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ELECTRICAL THEORY OF OPERATION
THEORY OF OPERATION
GENERAL INFORMATION
The theory of operation stories divide the electrical
system into individual circuits by function. Each circuit
is isolated from the main wiring schematic and only
shows the components that are used in it. The story
contains information on function, operating conditions,
and theory of operation. The circuit schematics are
drawn with the components in the operating position,
with the power, or battery positive, into them across the
top and the ground, or battery negative, across the
bottom.
DIAGNOSTIC INFORMATION
The diagnostic procedures is used to test the complete
circuit regardless of the problem or complaint. Select a
symptom or system from the quick check or
troubleshooting chart and follow the test procedures
under that heading.
The diagnostic procedure lists:
• Test conditions
• Test sequence
• Test location
• Normal reading
• Check or test to perform if reading is not normal
When performing the test or check, be sure to set your
machine up to the test conditions listed and follow the
sequence carefully. The middle “NORMAL” column
gives the reading or condition that should be obtained
when performing the test or check. If the results of the
test or check are not normal, perform the test, check, or
adjustment listed in the third “IF NOT NORMAL”
column to repair the malfunction. The detailed tests or
adjustments referred to in the “IF NOT NORMAL”
column are located at the end of that group. The
system diagram that accompanies each test procedure
is drawn to resemble machine components. The key
number on the art matches the number in the “TEST
LOCATION” column and the leader line points to the
exact point the test is to be made.
WIRE COLOR ABBREVIATION
CHART
Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black
Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue
Brn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown
Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green
Gry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gray
Org . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange
Pnk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink
Pur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple
Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red
Tan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tan
Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .White
Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow
Blk/Wht. . . . . . . . . . . . . . . . . . . . . . . . . .Black/White
Blu/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . Blue/White
Brn/Wht . . . . . . . . . . . . . . . . . . . . . . . . Brown/White
Brn/Yel . . . . . . . . . . . . . . . . . . . . . . . . Brown/Yellow
Dk Blu. . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Blue
Dk Brn/Lt Grn . . . . . . . . . . Dark Brown/Light Green
Dk Brn/Red. . . . . . . . . . . . . . . . . . Dark Brown/Red
Dk Brn/Yel . . . . . . . . . . . . . . . . . Dark Brown/Yellow
Dk Grn . . . . . . . . . . . . . . . . . . . . . . . . . Dark Green
Lt Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Blue
Lt Grn . . . . . . . . . . . . . . . . . . . . . . . . . . Light Green
Org/Wht . . . . . . . . . . . . . . . . . . . . . . . Orange/White
Pnk/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . Pink/Black
READING SCHEMATICS
The schematic is made up of individual circuits laid out
in a sequence of related functions. Current flow is
generally from top to bottom through each circuit and
component. All components are shown in the OFF
position. The diagram does not list connector
information unless needed to avoid confusion.
Each component is shown by a symbol and name. The
identification code contains a device identifying letter
and number.
The circuit number and wire color of the wires are
shown directly next to the wire path.
4 - 4 3/5/97
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Pur/Wht . . . . . . . . . . . . . . . . . . . . . . . . Purple/White
Red/Blk. . . . . . . . . . . . . . . . . . . . . . . . . . . Red/Black
Red/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . Red/White
Wht/Blk. . . . . . . . . . . . . . . . . . . . . . . . . .White/Black
Wht/Red . . . . . . . . . . . . . . . . . . . . . . . . . . White/Red
Yel/Blk . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Black
Yel/Red. . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Red
Yel/Wht . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/White
ELECTRICAL SCHEMATIC ELECTRICAL
ELECTRICAL SCHEMATIC
120 BLK
ENGINE
CONNECTOR
SPARK
PLUG
HEADLAMP
HARNESS
HEADLIGHTS
CONNECTOR
940 WHT
0 = OFF
1 = ON
942 WHT
705 PUR/WHT
941 WHT
941A WHT
0 = OFF
1 = ON
SWITCH
IGNITION
10
SWITCH
BRAKE
IGNITION
MODULE
COIL
WHT/BLK
945 WHT/BLK
946A
0
1
BLADE
DRIVE
SWITCH
700 PUR
0 = OFF
1 = RUN02 = START
2 1
0,1
946 WHT/BLK
SEAT
1
0
710 PUR
0 = OFF SEAT
1 = ON SEAT
100 BLK
SWITCH
110 BLK
200 RED
451 YEL/WHT
220 RED/BLK
201 RED
RED/WHT
202
15A
FUSE
201 RED
START
SOLENOID
ENGINE
CONNECTOR
401 YEL
DIODE
RED
BATTERY
M
FUEL
SHUT-OFF
SOLENOID
G
STARTER
MOTOR
(16 HP ONLY)
STATOR
710 PUR
105 BLK
FRAME GROUND
3/5/97 4 - 5
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WIRE HARNESS ELECTRICAL
WIRE HARNESS
945 WHT
942 WHT/BLK
705 PUR
710 PUR/WHT
D
E
451 YEL/WHT
BLADE
DRIVE
SWITCH
R
1
0
2
ENGINE
220RED/BLK
BATTERY
GROUND
CONNECTOR
8mm (5/16") Eyelet
100
110
105
401YEL
FUEL SOLENOID
3
945
946
946A
940 WHT
0
2
1
941
941A
K
L
B
940
942
202RED/WHT
B
ENGINE GROUND
HEADLIGHTS
A
8mm (5/16") Eyelet
451YEL/WHT
B
A
201 RED
120 BLK
946A WHT/BLK
700 PUR
941A WHT
705PUR/WHT
BRAKE SWITCH
Eyelet
8mm (5/16")
BATTERY POSITIVE
SOLENOID
POSITIVE
1 2
R
U
P
0
1
7
220
202
200
100 BLK
401YEL
IGNITION SWITCH
5
10
SOLENOID
GROUND
K
BL
200 RED
15 AMP FUSE
& HOLDER
946 WHT/BLK
SEAT SWITCH
110 BLK
HEADLIGHT
WIRE HARNESS
4 - 6 3/5/97
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700 PUR
941 WHT
COMPONENT LOCATION ELECTRICAL
COMPONENT LOCATION
Headlights
Spark Plug
Starter Motor
Fuel Shut-Off
Solenoid
Seat Switch
Ignition Switch
Blade
Drive
Switch
Brake
Switch
Starter Solenoid
Battery
3/5/97 4 - 7
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