Tilton Yard Shark YSH2051Z, Yard Shark YSH2460Z, Yard Shark YSK2560Z, Yard Shark YSK2151Z Operator's Manual

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Operator’s Manual

Covers Models:

YSH2051Z, YSH2460Z YSK2151Z, YSK2560Z

Your Authorized Yard Shark Dealer:

Congratulations on the purchase of

your new Yard Shark commercial mower!

Before operating the mower read and understand

this operator’s manual!

Part # YZ2007

Rev 2007-03-26

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Proudly Distributed by:

Tilton Equipment Company P.O. Box 68 Rye, New Hampshire 03870-0068

1 About This Manual..........................................................................................................................................6

2 Delivery Checklist............................................................................................................................................7

3 Safety Instructions...........................................................................................................................................8

3.1 Training .....................................................................................................................................................8

3.2 Preparation................................................................................................................................................8

3.3 Maintenance and Storage..........................................................................................................................9

3.4 Serial Number and Model Identification..................................................................................................10

4 Machine Operation........................................................................................................................................11

4.1 Filling The Fuel Tank ..............................................................................................................................11

4.2 Motion Control Levers.............................................................................................................................12

4.3 Parking Brake..........................................................................................................................................12

4.4 PTO Engagement Switch .........................................................................................................................13

4.5 Choke Control..........................................................................................................................................13

4.6 Throttle Control.......................................................................................................................................13

4.7 Ignition Switch.........................................................................................................................................13

4.8 Fuel Gauge / Hour Meter.........................................................................................................................13

4.9 Seat and Armrests....................................................................................................................................14

4.10 Setting Mower Deck Cutting Height........................................................................................................15

4.11 Cold Engine Starting Procedure.............................................................................................................. 16

4.12 Warm Engine Starting Procedure............................................................................................................16

4.13 PTO / Blades............................................................................................................................................16

4.14 Deck Deflector.........................................................................................................................................16

4.15 Stopping PTO...........................................................................................................................................16

4.16 Shutting Down Engine .............................................................................................................................16

5 Service and Maintenance Procedures..........................................................................................................17

5.1 Clean Dust and Dirt From Engine Clean Air Intake Screen & Cooling Fins – Check Daily..................18

5.2 Check Seat Safety Switch Operation – Check Daily ................................................................................18

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5.3

Check Engine Oil Level – Check Daily....................................................................................................18

5.4 Check Mower Blades – Check Daily........................................................................................................18

5.5 Clean Underside of Deck – Check Daily .................................................................................................18

5.6 Air Filter Inspect / Clean.........................................................................................................................19

5.7 Engine Oil / Filter Change.......................................................................................................................19

5.8 Check Hydraulic Oil Level.......................................................................................................................19

5.9 Check Tire Pressure.................................................................................................................................19

5.10 Check / Adjust Deck Drive Belt Tension..................................................................................................20

5.11 Lubricate Control Levers........................................................................................................................21

5.12 Grease Deck Lift Pivots ...........................................................................................................................21

5.13 Grease Front Wheel Axle Bearings..........................................................................................................22

5.14 Check Pump Drive Belt............................................................................................................................22

5.15 Spark Plugs Check/Adjust/Replace..........................................................................................................23

5.16 Air Filter Replace ....................................................................................................................................23

5.17 Check / Adjust Valve Clearances.............................................................................................................23

5.18 Fuel Filter Change...................................................................................................................................23

5.19 Change Hydraulic Filter..........................................................................................................................23

5.20 Change Hydraulic Oil and Filter.............................................................................................................23

6 Service & Adjustments Perform as Needed.................................................................................................24

6.1 Adjusting Throttle Cable..........................................................................................................................24

6.2 Adjusting Choke Cable.............................................................................................................................25

6.3 Deck Adjustments.....................................................................................................................................25

6.4 Transmission Neutral Setting...................................................................................................................26

6.5 Deck Belt Replacement............................................................................................................................28

7 Fuel & Lubricant Recommendations...........................................................................................................28

7.1 Oxygenated Fuels.....................................................................................................................................28

7.2 Fuel Stabilizer / Conditioner....................................................................................................................29

7.3 Engine Oil Recommendation....................................................................................................................29

7.4 Hydraulic Oil Recommendation...............................................................................................................29

7.5 Engine Specifications...............................................................................................................................29

7.6 Hydrostatic System Specs.........................................................................................................................30

7.7 Fuel Tank Capacity............................................................................................................. .....................30

8 Service Record................................................................................................................................................31

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Parts lists and drawings.................................................................................................................................33

9.1 Aftermarket Replacement Parts NOT SHOWN in Drawings...................................................................33

9.2 Decals ......................................................................................................................................................34

9.3 Wiring Assemblies....................................................................................................................................36

9.4 Rear Wheel and Wheel Motor Group.......................................................................................................37

9.5 51′′ Deck Group.......................................................................................................................................38

9.6 60′′ Deck Group.......................................................................................................................................40

9.7 Deck Spindle Hub Detail..........................................................................................................................41

9.8 Deck Deflector Detail ..............................................................................................................................42

9.9 Deck Lift Group .......................................................................................................................................43

9.10 Front Caster Group .................................................................................................................................44

9.11 Honda 20hp Engine & Pump Drive Group..............................................................................................45

9.12 Kaw 21,25 & Honda 24 Engine & Pump Drive Group ...........................................................................46

9.13 Seat Group...............................................................................................................................................47

9.14 Fuel Tank Group......................................................................................................................................48

9.15 Hydraulic Pump & Lines Group..............................................................................................................49

9.16 Control Lever Group................................................................................................................................50

9.17 Control Panel Group ...............................................................................................................................51

9.18 Frame Parts Group..................................................................................................................................52

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Congratulations On The Purchase Of Your New Yard Shark Mower.

When you purchase a Yard Shark you are part of a family of satisfied customers – people who appreciate a mower that will provide you with years of excellent performance, durability, and trouble free service when operated and maintained as directed in this manual.

Read and understand this operator’s and parts manual and follow all instructions and warnings before operating this machine.

If you did not sign and receive your copy of your warranty registration, contact your Yard Shark dealer to do so immediately! Before any warranty service can be authorized you must register this product with Tilton Equipment Company.

1 About This Manual

This Yard Shark operator’s manual is considered a permanent part of the mower. It must be available to all operator’s and/or person(s) servicing the mower. Should the mower be resold , this manual must remain with the mower.

Should you ever have any questions regarding the operation, maintenance, or safety of your mower, please contact your authorized Yard Shark mower dealer who h as been trained on operation and service of this mower.

All information, illustrations, and specifications contained in this manual were in effect at the time of publication. The manufacturer reserves the right to change, modify, and/or discontinue specifications and/or design without notice. If you notice that a change has been made to your mower which is not shown or reflected in this manual, please see your authorized Yard Shark mower dealer before operating or servicing the mower.

This manual identifies potential hazards and has safety messages identified by the safety alert example symbols shown below, which signal a hazard that may cause serious injury or death if you do not follow the recommended precautions.

DANGER

WARNING

CAUTION

Failure to follow instructions WILL result in SERIOUS INJURY or DEATH!

Failure to follow instructions CAN result in SERIOUS INJURY or DEATH!

Failure to follow instructions can result in personal injury.

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2 Delivery Checklist

Before you, the owner or primary operator uses this machine, go through this check list so that you understand the safe and proper operating procedures for your new Yard Shark machine.

________ Read and understand this operator’s manual before ope rating your Yard Shark mower.

________ Understand the “Safety Instructions” section of manual.

________ Record engine and mower serial numbers in space provided.

________ Checking Engine Oil

________ Checking Hydro Oil

________ Filling Fuel Tank

________ Seat and Armrest Adjustments

________ Motion Control Levers and Parking Brake Operation

________ Engine Controls – Throttle/Choke/Ignition Switch

________ Fuel Gauge / Hour Meter

________ Setting Deck Height

________ Cold Engine Start Procedure

________ Warm Engine Start Procedure

________ Deck Deflector

________ PTO / Starting and Stopping Blades

________ Shutting Down Engine

________ Fill Out the Warranty Registration Form through your Yard Shark Dealer.

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3 Safety Instructions

3.1 Training

WARNING

o Read the operator’s manual and other training material. If the operator(s) or mechanic(s)

cannot read English it is the owner’s responsibility to explain this material to them.

o Become familiar with the safe operation of the equipment, operator controls, and

safety signs.

o All operators and mechanics should be trained. The owner is responsible for training

the users.

o NEVER let children or untrained people operate or service the equipment.

Local regulations may restrict the age of the operator.

o The owner/user can prevent and is responsible for accidents or injuries occurring to

themselves, other people or property.

3.2 Preparation

WARNING

o ALWAYS evaluate the terrain to determine what accessories and attachments are needed

to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer.

o ALWAYS wear appropriate clothing including safety glasses an d hearing protection. o ALWAYS inspect the area where the equipment is to be used and remove all objects such

as rocks, toys and wire which can be thrown by the machine

o ALWAYS use extra care when handling gasoline and other fuels. They are flam mable and

vapors are explosive.

o ALWAYS use only an approved safety fuel container. o ALWAYS check that operator’s presence controls, safety switches and shields are

attached and functioning properly.

o ALWAYS be sure all drives are in neutral and parking brake is engaged before starting

engine. Only start engine from the operator’s position.

o ALWAYS slow down and use extra care on hillsides. Be sure to travel in a safe direction

on hillsides. Turf conditions can affect the machine’s stability. Use caution while operating near drop-offs.

o ALWAYS turn uphill when changing directions while mowing left to right and right to left

on hill sides.

o ALWAYS use care when approaching blind corners, shrubs, trees, or other objects that

may obscure vision.

o ALWAYS stop on level ground, lower implements, disengage drives, engage parking

brake, shut off engine before leaving the operator’s position for any reason including emptying the catchers or unclogging the chute.

o ALWAYS stop equipment, shut off the engine, set parking brakes and inspect blades after

striking objects or if an abnormal vibration occurs. Make necessary sharpening repairs o r replace all blades before resuming operations.

o ALWAYS keep hands and feet away from the cutting units.

Failure to follow instructions CAN result

in SERIOUS INJURY or DEATH!

Failure to follow instructions CAN result

in SERIOUS INJURY or DEATH!

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o ALWAYS look behind and down before backing up to be sure of a clear path. o ALWAYS be aware of the mower discharge direction and do not point it at anyone. o ALWAYS slow down and use caution when making turn s and crossing roads

and sidewalks.

o ALWAYS stop blades if not mowing. o ALWAYS use care when loading or unloading the machine into a trailer or tru ck. o ALWAYS operate in good light, keeping away from holes and hidden hazards. o NEVER operate with long hair, loose clothing or jewelry that may get tangled in

moving parts.

o NEVER remove gas cap or add fuel when engine is running. o NEVER smoke while fueling the machine or near any fuels or fuel fumes. o NEVER refuel or drain the machine indoors. o NEVER raise deck with the blades running. o NEVER operate with guards not securely in place. o NEVER operate with the discharge deflector raised, removed or altered, unless using

a grass catcher.

o NEVER run an engine in an enclosed area. o NEVER change the engine governor setting or over speed the engine. o NEVER carry passengers and keep pets and bystanders clear of the work area. o NEVER operate the mower under the influence of alcohol or drugs.

3.3 Maintenance and Storage

o Disengage drives, lower implement, set parking brakes, stop engine, remove key and

disconnect spark plug wires. Wait for all movement to stop before adjusting, cleaning or repairing.

o Clean grass and debris from cutting units, drives, mufflers, and engine to help

prevent fires. Clean up oil or fuel spillage.

o Let engine cool before storing and do not store near flame. o Do not store fuel near flames or drain indoors. o Park machine on level ground. Never allow untrained personnel to service machine. o Use jack stands to support components when required. o Carefully release pressure from components with stored energy

(example, hydraulic components).

o Disconnect battery and remove spark plug wires before making any repairs. Disconnect

the negative terminal first and the positive last. Reconnect positive first and negative last.

o Use care when checking blades. Wrap the blade with a heavy rag or towel or wear gloves,

and use caution when servicing them. If blades are bent or damaged, replace all of the blades. Never straighten or weld them.

o Keep hands and feet away from moving parts. Do not make adjustments with the

engine running.

o Charge batteries in an open well ventilated area, away from spark and flames. o Charge battery with a 2 amp charger and disconnect the battery ground cable before

storing the machine for 30 days or more. Improper battery care will void battery warranty.

o Unplug charger before connecting or disconnecting from battery. Wear protective clothing

and use insulated tools.

o Keep all parts in good working condition and all hardware tightened. Replace all worn or

damaged decals.

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3.4 Serial Number and Model Identification

The serial number/model number tag can be found at the RH side of the mower under the seat in front of the engine compartment.

The engine serial number can be found on the Front LH side of the engine as shown below.

Record serial numbers here for future reference.

Mower Model Number____________________________

Mower Serial Number____________________________

Engine Serial Number____________________________

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4 Machine Operation

Left Side of machine is determined by sitting in the seat in the operating position.

4.1 Filling The Fuel Tank

WARNING

o Fill fuel tank outside in a well ventilated area o Shut the engine off and set parking brakes. o Allow engine to cool to ambient temperatures.

Gasoline is extremely flammable and gasoline vapor can explode. Failure to follow proper procedures can result in personal injury or death.

Do not add fuel while the engine is running or hot. Keep open flames, sparks and heat away from fuels and store fuel in

containers specifically designed for that purpose.

o Unlatch seat and tip forward to access the fuel tank.

o Use a funnel and be careful to not spill fuel. o Wipe up possible fuel spills and allow to completely dry before re-starting engine

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4.2 Motion Control Levers

Motion Control Levers in Operating Position

Motion control levers are in the operating position when they are as shown above. Left hand lever controls the speed and direction of the LH drive wheel. Right hand lever controls the speed and direction of the RH drive wheel. Moving both levers forward together causes mower to travel forward in a straight line. Moving both levers rearward together causes the mower to travel in reverse in a straight line. To turn left while moving forward, pull back slightly on the LH lever. To turn right while moving forward, pull back slightly on the RH lever. To make a zero radius turn, move one lever slightly ahead of neutral and the other lever slightly behind neutral center position.

4.3 Parking Brake

The parking brake system on the Yard Shark mower is not really a brake, but is actually a pin and cog system that is activated every time the control levers are moved out into the neutral locked position as shown below. It is an automatic system that sets itself when you move the levers out to get off the mower and releases itself when you move the levers back in to start moving. If the mower will not move or sounds like it is straining, simply move the control levers slightly forward or backwards to release the pin.

Motion Control Levers in Non-Operating Position – Parking Brakes On

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4.4 PTO Engagement Switch

Located on RH control panel. Switch is pulled UP (“ON” position) to engage the blades. Switch must be in the DOWN or OFF position in order to start the engine.

4.5 Choke Control

Pull choke knob UP or OUT to the choke “ON” position. Push choke knob DOWN or IN the choke “OFF” position.

4.6 Throttle Control

Move lever forward to increase engine speed. Move lever to the rear to idle position. When mowing the throttle should be in the full forward (fastest) position.

4.7 Ignition Switch

Three (3) position switch. The first position is OFF, second position is ON or RUN. The third position is the start position.

4.8 Fuel Gauge / Hour Meter

Digital display indicates amount of fuel remaining. When red light flashes, unit is very low on fuel and should be refueled. Refer to all items in filling the tank (Section 4.1).

The hour meter records time the key is on. Use hour meter to reco rd service intervals.

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4.9 Seat and Armrests

There are two adjustments at the front of the seat. The knob controls the stiffness of the suspension seat. This should be adjusted to fit the operator weight. The lever, shown above left with an arrow, allows for fore and aft adjustment. While seated, pull lever to the left to release seat and move seat into desired position. Make sure the latch is fully locked so that seat is secure. The armrest height can be adjusted with the small knobs, above right, screw out to raise armrests. Setting the armrests at the proper height will assist you in maintaining better control of the machine.

The other settings are located on either side of the seat backrest. The knob on the RH side adj usts the angle of the backrest. The knob on the LH side adjusts the lumbar support. Adjust these for your personal preference.

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4.10 Setting Mower Deck Cutting Height

While seated on the seat, push on foot lever to raise deck. The deck can now be locked in the upper position by using the deck latch lever located on the LH side of the mower (shown below). Move the lever to the rear to engage the deck lock. Remove pin and move to the desired position. The decal next to the foot lever indicates the cutting height. Moving the pin one hole adjusts the cutting height by 1/4′′.

To release deck lock, push forward on the deck latch lever while pushing forward with the foot pedal.

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4.11 Cold Engine Starting Procedure

o Be sure engine has oil to the proper level and gas in the fuel tank. o Pull up on Choke to “ON”. o Move throttle control about 1/3 of the way forward. o Turn key to “START” position and hold until engine starts. o If engine fails to start within 5 seconds, release the key, wait at least 10 seconds. o Note: Using the starter for more than 5 seconds at a time can overheat and damage

the starter.

o Gradually push choke knob in as engine warms up.

4.12 Warm Engine Starting Procedure

Same as above but leave choke in the “OFF” position.

4.13 PTO / Blades

DANGER

The PTO switch engages the cutting blades. Be certain everyone including pets are clear of the mower deck and the RH discharge area before engaging the PTO. Operator must be seated before the PTO can be engaged. The motor will kill if the seat switch is not depressed. Move throttle to halfway position. Pull up on PTO switch to the “ON” position. Then move throttle to full forward “FAST” position.

4.14 Deck Deflector

DANGER

Deck is equipped with a rubber deck discharge deflector. Deflector can be pivoted upwards for clearance, for storing or transporting. NEVER mow with the deflector in the UP position unless using an approved grass catcher/collector.

Operating PTO creates a thrown object hazard. NEVER operate with deflector or guards missing. Make sure discharge chute is not pointed toward pets or bystanders.

4.15 Stopping PTO

In an emergency, deck blades can be stopped anytime by pushing down on the PTO switch, also by turning the ignition key switch to “OFF”. Normal operation - move throttle to halfway position. Push down on PTO switch to “OFF” position.

4.16 Shutting Down Engine

In an emergency simply turn the ignition key switch to “OFF”. For normal shutdown, stop machine, turn off PTO, move throttle all the way to SLOW. Turn ignition key switch to OFF.

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5 Service and Maintenance Procedures

Service and Maintenance Procedures

Clean Dust and Dirt From Engine Clean Air Intake Screen and Cooling Fins Check Seat Switch Interlock X Check Engine Oil Level X Check Mower Blades X Clean Underside of Deck X Air Filter Inspect/Clean X Engine Oil / Filter Change X X Check Hydraulic Oil Level X X Check Tire Pressure X X Check/Adjust Deck Belt Tension X X Lubricate Control Levers X Grease Deck Lift Pivots X Grease Front Wheel Bearings X Check Pump Drive Belt X Spark Plugs Check / Adjust X Clean Oil Cooler Fins X Air Filter Replace (Both) X Spark Plugs / Replace X Valve Clearance X Fuel Filter / Change X Change Hydraulic Filter X X Change Hydraulic Oil & Filter X

Daily

After First

10 Hours

Every 25

Hours

Every 50

Hours

Every100

Hours

Every 300

Hours

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5.1 Clean Dust and Dirt From Engine Clean Air Intake Screen & Cooling Fins – Check Daily

Check for accumulations of dust, grass clippings, dirt, etc. Check around the fresh air intake screen on top of the engine. Also check cooling fins on engine and oil coolers and clean with compressed air. Be careful on the Honda 24 so the cooling fins on the separate oil cooler are not damaged. Remove excess accumulations around the base of the engine, under the se at, around hydro pumps and the top of the deck. Keeping the machine clean will guarantee a cooler and safer operating environment.

5.2 Check Seat Safety Switch Operation – Check Daily

WARNING

o When raised off the seat, turn key switch to start. o Engine should not crank. o If engine cranks, contact your dealer to resolve this problem before using mower. o While seated on mower, start engine, then engage PTO. o With the control levers moved outward to the locked/parking brake position, raise yourself

off the seat.

o Engine should shut off immediately. o If engine does not shut off, contact your dealer to resolve this problem before

using mower.

5.3 Check Engine Oil Level – Check Daily

At rear right of mower, unscrew dipstick. Wipe clean. Then, reinsert without screwing it in. Add oil, if needed to bring up to the full mark.

Safety interlock is designed to prevent PTO/blades operating unless operator is seated. Failure to maintain proper operation of system can result in injury or death.

5.4 Check Mower Blades – Check Daily

Raise front of mower and check condition of mower blades. If blades are not sharp they must be sharpened or replaced. If blades are bent or damaged replace all of the deck blades. Don’t attempt to straighten bent blades. It is dangerous to straighten because it could cause the blades to crack/break in operation.

5.5 Clean Underside of Deck – Check Daily

While checking conditions of blades, scrape out any accumulated grass clipping from under the mower deck. Mower performance will deteriorate if blades are not in good condition and grass builds up under deck.

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5.6 Air Filter Inspect / Clean

Follow instructions in the respective Honda or Kawasaki owner’s manual for details.

5.7 Engine Oil / Filter Change

o Drain used oil while the engine is warm. Warm oil drains quickly and more completely.

Replace oil filter at each oil change.

o Place a suitable container under the engine to catch used oil. o Remove the oil filler cap / dipstick, drain plug and oil filter. Allow used oil to

drain completely.

o Reinstall drain bolt and tighten securely. o Clean the filter mounting base and coat the rubber seal on the new filter with new

engine oil.

o Screw on the new filter by hand until seal contacts filter base, then tighten another

3/4 - 7/8 turn, alternatively tighten to 16 lbf-ft (22Nm).

o Refill crankcase with new oil (See engine operator’s manual for proper oil selection). o Start engine and check for leaks. Stop engine then check oil level. Add oil if needed to

bring oil to top of safe mark.

o Dispose of used oil and filter at local recycling center and obey all local and federal laws

for these products.

5.8 Check Hydraulic Oil Level

o Be extremely careful with dirt and contamination when you are servicing the

hydrostatic system.

o Contamination is the worst enemy of the hydrostatic system. o Clean around dipstick and filters BEFORE removing. o Only add oil from a sealed container. o Thoroughly clean funnels and anything that will come into contact with the oil. o Contamination in the system will void the warranty on the hydrostatic system. o Check level when oil is cold. o Unscrew dipstick and wipe clean. Insert into oil tank without screwing it in. If oil shows

on the dipstick (approximately 1/4″-1/2″ up from the bottom), then the oil level is adequate. If no oil shows on dipstick, then add oil to bring up to the dipstick. The upper mark is a high level mark for when the oil is hot. If oil tank is overfilled, oil will expand and come out of the dipstick / vent when the oil gets hot.

o See Section 7.4 for proper oil recommendation.

5.9 Check Tire Pressure

Inflate all 4 tires to 12 psi. A special low pressure air gauge (available at most auto parts stores) should be used to accurately check the pressure.

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5.10 Check / Adjust Deck Drive Belt Tension

o Spring for deck belt tension can be found by looking under the RH side of the mower.

To check belt tension, measure the length of the spring. The body of the spring should measure 3-1/2′′ to 3-3/4′′.

o An alternative method is to use a U.S quarter, to use as a feeler gauge between the coils.

Spring tension is correct when quarter will just fit between coils with minimal resistance.

If belt tension needs adjusting remove hair pin and unhook the deck belt tension arm from its stud at the front of the deck (photo above).There are 2 holes for the arm to hook into. Use the front hole for normal operation. If belt becomes stretched enough that you can’t get the proper tension then use the second hole.

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Go to left side of mower. Loosen the flat idler pulley (use a 9/16′′ wrench) and move slightly to the rear. Retighten pulley, rehook spring tension arm and recheck spring length. Adjust until body of spring measures 3-1/2′′ to 3-3/4′′ or a quarter fits snugly between the coils.

5.11 Lubricate Control Levers

o Raise seat. Use a grease gun with multipurpose grease.

o Grease zerks at the control arm pivots (2). o Use a light “dry lube” type spray lubricant (use a dry lube containing Teflon or “moly” )to

lube the brake linkage and the control arms.

o Lubricate the pivot for the park lock position, where the side plates of the handle mount to

the control arm block.

o Applying a small amount of multipurpose grease to the tab that actuates the parking lock

will make the entire park lock system work more smoothly.

o Use (2) 3/4′′ wrenches to adjust the amount of tension on control lever arm mounts so the

levers have the proper amount of resistance. (This is a personal preference on how stiff to make the arms to move back and forth from the locked position to the travel position).

5.12 Grease Deck Lift Pivots

Use a grease gun with multipurpose grease. Grease zerks at the rear deck lift pivots (2).

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5.13 Grease Front Wheel Axle Bearings

Use a grease gun with multipurpose grease. Grease the zerks on e ach the front wheels. One zerk per wheel.

5.14 Check Pump Drive Belt

Raise rear of mower to access pump drive belt. Use blocks as necessary to support mower safely. Pump belt idler arm should be free to move with firm hand force. If arm is sticky or stiff, remove arm and coat the mounting surfaces with anti-seize lubricate. Reassemble and adjust tension at pivot bolt. Proper tension can be achieved by tightening ½′′ nut on pivot bolt until spring washers are compressed, then back off ¼ turn. Arm should be free to move with firm hand force. Install the lock nut and tighten making sure that the adjustment is not changed. Measure length of the spring – Proper length is 4-1/4′′ inside spring hooks, OR length of coils should measure 3-1/4′′. Another method to check tension – A quarter ($.25 US coin) should just fit in between the coils in the spring.

Adjust position of idler to achieve proper belt tension. Use (2) 9/16′′ wrenches to move the idler in its adjustment slot.

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5.15 Spark Plugs Check/Adjust/Replace

Disconnect spark plug caps. Remove dirt from around spark plug areas. Remove the spark plugs with a 13/16 spark plug wrench. Replace plugs if the electrodes are worn or if insulator is cracked or chi pped. Regap spark plugs to .030′′ (.75 mm). Reinstall plugs by hand, be careful to avoid cross threading. To reinstall used plugs, tighten 1/8-1/4 turn after the spark plug seats lightly. To install new spark plugs, remove old plugs and gap new plugs. Thread new spark plugs into engine by hand, then use a 13/16′′ spark plug wrench and tighten 1/2 turn after the spark plug seats. (or tighten to 16 ft lb.)

5.16 Air Filter Replace

Each year or 300 hours replace primary (paper) air filter elements. Follow instructions in resp ective engine owner’s manual. Secondary filter should be replaced according to engin e owner’s manual.

5.17 Check / Adjust Valve Clearances

Both Kawasaki and Honda recommend valve clearance be checked every year or 300 hours. This should be performed by your servicing dealer unless you have the proper t ools and are mechanically adept. Refer to Honda or Kawasaki shop manual for procedure s.

5.18 Fuel Filter Change

Replace every year or 300 hrs, replace sooner if it becomes clogged. Consult engine owner’s manual for instructions.

5.19 Change Hydraulic Filter

o Place a pan under the hydrostatic oil filter, unscrew oil filter enough so the oil can drain

into the oil pan. It is possible to get a little oil on the drive belt at this point. It is recommended to place a small shield over the belt to prevent it from coming into contact with the oil.

o Allow oil to drain completely o Apply a thin film of clean oil to oil filter seal. o Screw filter on by hand until seal contacts base, then tighten an additional 3/4 turn. o Add proper oil to bring up to proper level – See section 5.8 in this manual. o See Section 7.4 for proper oil recommendation. o Dispose of used oil and filter at local recycling center and obey all local and federal laws

for these products.

5.20 Change Hydraulic Oil and Filter

o Be extremely careful with dirt and contamination when you are servicing the

hydrostatic system.

o Contamination is the worst enemy of the hydrostatic system. o Clean around dipstick and filter BEFORE removing. o Only add oil from a sealed container. o Thoroughly clean funnels and anything that will come into contact with the oil. o Contamination in the system will void the warranty on the hydrostatic system. o Place a pan under the oil tank, remove magnetic oil plug and drain the oil.

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o Place a pan under the hydrostatic oil filter, unscrew oil filter enough so the oil can drain

into the oil pan. It is possible to get a little oil on the drive belt at this point. It is recommended to place a small shield over the belt to prevent it from coming into contact with the oil.

o Allow oil to drain completely o Thoroughly clean the drain plug and replace. o Apply a thin film of clean oil to oil filter seal. o Screw filter on by hand until seal contacts base, then tighten an additional 3/4 turn. o Add oil to hydraulic reservoir until oil shows on the dipstick, approximately 7 quarts. o See Section 7.4 for proper oil recommendation. o To prime system – raise the rear of mower so that the rear wheels can spin freely. o Secure machine with jack stands. o Start engine and run at idle. o Immediately push both levers full forward and hold for 10 seconds. Then pull both levers

fully rearward and hold for ten seconds. Repeat this procedures several times until all air is purged from the system.

o Lower mower to the ground and check oil level. The oil level should be approximately 1/2′′

on the dipstick without the cap screwed in. Add oil to bring to proper level.

o Screw dipstick / cap onto hydraulic reservoir. o Dispose of used oil and filter at local recycling center and obey all local and federal laws

for these products.

6 Service & Adjustments Perform as Needed

6.1 Adjusting Throttle Cable

o If the throttle cable is not properly adjusted, the engine may not be operating at full speed

or the throttle may not stay in the fast position.

o Procedure should be done on a cold engine to prevent any chance of burns from the

hot engine.

o Shut down mower, set parking brakes and remove the key. o Move throttle lever full forward until it reaches its limiting stop and then back off about

1/8′′ - 1/4′′.

o Go to rear of mower. Throttle linkage should be fully opened (fast position).

o Loosen the clamp on the throttle cable and pull cable tight so the throttle is fully open. o Retighten clamp. o If throttle doesn’t hold its position while mowing, then the friction discs on the throttle lever

need to be tightened.

o Remove the cover on the control panel. Use a 7/16′′ combination wrench and a 7/16′′

socket to adjust the tension on the throttle pivot.

o Adjust pinch bolt so that it is tight enough to hold throttle in position.

Page 25

6.2 Adjusting Choke Cable

If choke cable is not properly adjusted, it is possible that either the choke won’t fully close or fully open. This will cause either hard starting, rough running or poo r fuel economy. When the choke control is pushed all the way in (off), the knob should not contact the base of the choke mounting. There should be about a 1/8′′ - 1/4′′ gap as shown below.

If adjustment is needed, go to back of mower. Loosen the clamp holding the choke cable. Now position choke knob 1/4′′ up. Go to rear of mower and gently push choke cable to the right (opens choke) and tighten screw on cable when the choke is fully opened.

6.3 Deck Adjustments

To level the cutting deck, proceed as follows. Set mower deck at 3″ cutting height. Measure from top of frame rail to top of deck as shown below.

Page 26

The front left and front right measurements should be within 1/16′′ of each other. If adjustment is needed at the front, adjust the front rockshaft hangers (as shown below).

The hangers at the front rockshaft (shown above) provide vertical adjustment. Normally these hangers are adjusted all the way UP. If one side of the deck is higher that the other, loosen the bolts at the higher side of the deck and move hanger slightly lower so that equal measurement is achieved at both sides. When equal measurements are achieved, proceed with the rear adjustment.

Measure from the top rear of the frame rail to the deck top on both sides of the machine (as shown above). These measurements should be within 1/16” of each other and should also be 1-3/4″ – 1-7/8″ less than the measurement at the front of the deck to the top of the rail. This will make the rear of the blades cut slightly higher than the front of the blades.

If adjustment is needed, remove cotter pin and clevis pin at the front of the lift linkage rods. Shorten or lengthen linkage rod to achieve the proper height.

When adjustment is complete, all 4 carrier links should have equal pressure on them.

6.4 Transmission Neutral Setting

If mower creeps when levers are in the neutral position (not the locked position) then the neutral position needs to be adjusted. Do the adjustments in this order only.

o Raise rear of mower slightly off the ground so the rear wheels can turn freely. o Secure machine with jack stands. o Control levers should be in the operating position (handles together). o With engine at a fast idle, wheels should not be turning.

Page 27

o Proceed with adjustment as follows. o Adjust centering on pumps first. To adjust pump neutral – use a 17mm open end wrench

and an 8mm open end wrench.

o Use the 17mm wrench to loosen the locknut (loosen just enough to turn eccentric with the

8mm wrench). Turn eccentric back and forth to see which way it needs to be adjusted. Adjust so wheel stops turning. When wheel stops turning move the lever forward and backward and let return to neutral. If necessary, readjust until neutral is achieved then retighten locknut with the 17mm wrench.

Picture above shows location of adjustments.

o Shut down engine and lower mower to the ground. o When the pumps’ neutral positions have been readjusted, the linkage rods will have to be

adjusted, also.

o With engine off, and control handles in the operating position, check linkage adjustment.

As you move the levers into the parking lock position the tab at the lower end of the control levers should enter the square hole perfectly centered. Neither side of the tab should touch the sides as the lever is moved into its locked position. The locations are shown in the figures below.

Page 28

Loosen 5/16′′ locknuts on the linkage rod. Keep in mind that the nuts at the rear of the rods are left hand thread and the nuts at the front are right hand thread. Turn linkage rod to lengthen or shorten as needed so correct alignment is achieved. Retighten locknuts, then recheck alignment. Readjust or fine tune as nece ssary.

6.5 Deck Belt Replacement

Lower deck to its lowest position. At front of mower deck, remove hairpin clip and lift spring tensioning arm off of its stud. Flip up the deck pulley covers with the step plates on them on the LH and RH sides of the deck. Covers can be locked in an open position by opening up 90 degrees and inserting a pin, bolt or screwdriver in the hole. Belt can now be removed. Replace worn belt with the new belt. Reattach the spring tensioning arm onto its stud, replace hairpin clip. Follow directions in previous section to adjust to proper tension. Recheck tension after first few hours as it is normal to have to adjust the belt tension until the belt becomes “broken in”; see belt tensioning in Section 5.10.

7 Fuel & Lubricant Recommendations

WARNING

Use unleaded gasoline with a pump octane rating of 89 or higher. These engines are designed to run on unleaded gasoline. Unleade d gas produces fewer engine and spark plug deposits and extends exhaust system life. Never use old or stale gasoline or an oil/gas mixture. Avoid getting dirt or water in the tank.

Gasoline is extremely flammable and gasoline vapor can explode. Failure to follow proper procedures can result in personal injury or death.

7.1 Oxygenated Fuels

To meet clean air standards, some area of the United States and Canada use oxygenated fuels to reduce emissions. If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating of 89. Ethanol – (ethyl or grain alcohol) 10% by volume. You may use gasoline containing up to 10% ethanol by volume. Ethanol blends may be marketed under the name “Gasohol”.

Page 29

If you notice any undesirable operating symptoms, try another source of gasoline. Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates listed above are not covered under warranty.

7.2 Fuel Stabilizer / Conditioner

Use a fuel stabilizer / conditioner to keep gasoline fresh if mower is to be stored longer than 30 days. Fuel stabilizers are most effective when mixed with fresh fuel. Fuel stabilizers will NOT make old gasoline fresh.

7.3 Engine Oil Recommendation

See engine owner’s manual for proper oil recommendations for the engine on your mo wer.

7.4 Hydraulic Oil Recommendation

We recommend the use of a Universal Tractor Hydraulic Oil. Viscosity – 60 SUS (10cSt) at no more than 212deg F (100 deg C) Some acceptable choices are as follows:

o John Deere: J20A, JD20C, Hy-Gard o Case-IH: Hy-Tran, Hy-Tran Plus, Hy-Tran Ultra o AGCO: Power Fluid 821, 821XL o Cenex: Qwiklift HTB, Maxtron THF+

7.5 Engine Specifications

7.5.1 Model YSH2051Z – Honda 20 hp w/ 51′′ Deck

o Make / Model Honda GXV-620 o Engine Type 4-stroke, Overhead Valve, 2 cylinder, 90° V-Twin o Displacement 37.5 in³ (614 cm³) o Bore x Stroke 3.03′′ x 2.60′′ (77mm x 66mm) o Maximum Output 20 bhp (14.9kW) at 3600 rpm o Maximum Torque 32.5 lbf-ft (44.13 N-m) at 2500 rpm o Cooling System Forced Air o Ignition System Transistorized Magneto o Spark Plug Gap 0.028′′ – 0.031′′ (0.70 mm – 0.80 mm) o Spark Plug Denso - J16CR-U o Engine Oil Cap. 2.3 US quarts w/ oil filter change, 1.8 qts. w/o filter change o Engine Speeds Idle 1,400 ±150 rpm; Fast 3,600 rpm.

7.5.2 Model YSH2460Z – Honda 24 hp w/ 60′′ Deck

o Make / Model Honda GXV-670 o Engine Type 4-stroke, Overhead Valve, 2 cylinder, 90° V-Twin o Displacement 40.9 in³ (670 cm³) o Bore x Stroke 3.03′′ x 2.83′′ (77mm x 72mm) o Maximum Output 24 bhp (17.9kW) at 3600 rpm o Maximum Torque 37.5 lbf-ft (50.8 N-m) at 2500 rpm o Cooling System Forced Air o Ignition System Transistorized Magneto o Spark Plug Gap 0.028′′ – 0.031′′ (0.70 mm – 0.80 mm) o Spark Plug Denso - J16CR-U o Engine Oil Cap. 2.6 US quarts with oil filter change, 2.1 qts w/o filter change o Engine Speeds Idle 1,400 ±150 rpm; Fast 3,600 rpm.

Page 30

7.5.3 Model YSK2151Z – Kawasaki 21 hp w/ 51′′ Deck

o Make / Model Kawasaki FH641V o Engine Type 4-stroke, Overhead Valve, 2 cylinder, 90° V-Twin o Displacement 41.19 in³ (675 cm³) o Bore x Stroke 2.96′′ x 2.99′′ (75.2mm x 76mm) o Maximum Output 21 bhp (15.7 kW) at 3600 rpm o Maximum Torque 38.4 lbf-ft (52.1 N-m) at 2400 rpm o Cooling System Forced Air o Ignition System Solid State Ignition o Spark Plug Gap 0.030′′ (0.75 mm) o Spark Plug Denso W16EPR-U o Engine Oil Cap. 1.8 US quarts with oil filter change, 1.6 qts w/o filter change o Engine Speeds Idle 1,550 rpm; Fast 3,600 rpm.

7.5.4 Model YSK2560Z – Kawasaki 25 hp w/ 60′′ Deck

o Make / Model Kawasaki FH721V o Engine Type 4-stroke, Overhead Valve, 2 cylinder, 90° V-Twin o Displacement 41.19 in³ (675 cm³) o Bore x Stroke 2.96′′ x 2.99′′ (75.2mm x 76mm) o Maximum Output 25 bhp (18.6 kW) at 3600 rpm o Maximum Torque 41.3 lbf-ft (56.0 N-m) at 2400 rpm o Cooling System Forced Air o Ignition System Solid State Ignition o Spark Plug Gap 0.030′′ (0.75 mm) o Spark Plug Denso W14EPR-U o Engine Oil Cap. 1.9 US quarts with oil filter change, 1.6 qts w/o filter change o Engine Speeds Idle 1,550 rpm; Fast 3,600 rpm.

7.6 Hydrostatic System Specs

Hydrostatic Pumps (2) White KP Series; Displacement – 10cc / revolution; Variable displacement, axial piston pump. Wheel Motors (2) White RG Series; 12.2 in³ (200cc) Component Manufacturer White Hydraulics, Inc., PO Box 1127 Hopkinsville, KY. USA 42241 System Capacity 2.1 US gallons (8.0 litres)

7.7 Fuel Tank Capacity

7.0 US gallons (26.5 litres)

Page 31

8 Service Record

Record all service and repairs here for future reference.

Performed

Date

Hours

Description of Service Performed

Page 32

Page 33

9 Parts lists and drawings.

9.1 Aftermarket Replacement Parts NOT SHOWN in Drawings

Spare Ignition Key Y3887

Pin Spanner Tool for Spindle Repair Y4259

Orange Touchup Paint

(1 can Rim Orange)

Air Filter – Primary

(Outer)

Air Filter – Secondary

(Inner)

Fuel Filter

Oil Filter

Spark Plug

YET-4381

Honda 20 hp Honda 24 hp Kawasaki 21 Kawasaki 25

Tilton Part No. Y4849 Y3974 Y3375 Y3375

OEM Part No. 17210-Z J 1-842 17210-7 59-013 11013-7020 11013-7020

Tilton Part No. N/A N/A Y3376 Y3376

OEM Part No. N/A N/A 11013-7019 11013-7019

Tilton Part No. Y4195 Y4195 Y3378 Y3378

OEM Part No. 16910-ZE8-015 16910-ZE8-015 49019-7001 49019-7001

Tilton Part No. Y4168 Y4168 Y3374 Y3374

OEM Part No. 15400-PLM-A01PE 15400-PLM-A01PE 49065-2078 49065-2078

Tilton Part

No.(Denso)

Denso

J16CR-U

Denso

J16CR-U

Denso

W16EPR-U

Denso

W14EPR-U

Page 34

Decal Y3351 – Qty (1) – Placement as shown above.

Decal Y3356 – Qty(1) - Place underneath seat plate next to battery compartment.

Decal Y3361 – Qty (2) – Place under deck pulley covers on LH and RH sides of deck.

Decal Y3365 – Qty(2) – Place one on each side of rear “YardShark” guard, close to the rear in vicinity of muffler.

Decal Y3366 – Qty(1) – Place on inside of LH fender, next to seat.

Page 35

Decal Y3362 – Qty(1) – Place on top of LH fender.

Decal Y3359 – Qty(1) - Place on RH side of deck near discharge chute.

Decal Y3363 – Qty(1) – Place on top of RH fender.

Decal Y3352 – Qty(1) – Place by adjustment holes by deck lift pedal.

Decal Y3360 – Qty(1) - Place on LH side of deck.

Page 36

Y3746 – Qty(1) - Seat switch wire harness

Y3748 – Qty(1) – Main engine/clutch wire harness

Y3747 – Qty(1) – Wire assy, main power

Y3750 – Qty(1) – Fuel gauge plug assy.

Y3751 – Qty(1) – Deck switch wiring assy.

Y4481 – 8” Battery Cable Qty(1) for Hondas Qty(2) for Kawasakis

Y4482 – Qty(1) - 40” Battery Cable

Y3749 – Qty(1) – Wire assy, key switch

Y3752 – Qty(1) – Relay wiring assy

Y7611 – Qty(1) – 30 amp bladetype fuse

Y3784 – Qty(2) Relay

Electrical & Wiring Group

Y3753 – Qty(1) – Ground wire

Page 37

Itm Qty Part No. Description

Page 37

2 Y1006 1/4−20 Top Lock Nut 2 8 Y1007 NUT, 1/2" UNC TOP LOCK 3 4 4 5 6 2 Y196314 1/8 x 2 Cotter Pin 7 8 2 Y30111 5 Bolt Wheel Hub 9 4 Y3458

Y1594

2 Y191246 1/4 x 1−1/4 UNC Bolt

10 Y193093 1/2−20 UNF Lug Nut

2 Y2692 White CE−14 Wheel Motor

8 Y3972 Hex Cap 1−2x2_3−4 UNC GR5 ZN

3/16 x 1 Roll Pin

1/2" SAE Flat Washer

Itm Qty Part No. Description

2 Y4250 3/32 x 1/2 Cotter Pin 12 1 Y4251 Brake Pin Rocker − RH 13 1 Y4258 Brake Pin Rocker − LH 14

2 Y4308 Compression Spring, Brake Pin 15 2 Y4426 16 2 Y4626 Brake Disc 17

2 Y4627 Brake Rod Support at Wheel Motor

18 19 2 Y4637 Brake Pin

Y4630

Y4680 Hex Cap 1−2x2_3−4 UNF

1/4" SAE FLAT WASHER

Brake Disc Spacer

Rear Wheel for 60" Mowers − (2) Y3991 − 23x9.50−12−Zero Offset Rear Wheel for 51" Mowers − (2) Y3989 − 23x9.50−12−1.25" Inset

Rear Axle and Wheel Motor Group

Page 38

Itm Qty Part No. Description

Page 38

1 3 9 3 Y190063 11 1

13 4 15 4 Y2928 Rubber Bumper 16 2 17 4 19 3 Y30207 DECK ROLLER, 3" x 5"

20 6 Y3458

Y1002 1/2−13 Hex Nut

HAIR PIN, #3 FOR 3/8" PINS Y191332 Hex Cap 3−8x1_1−4 UNC Y196304 1/8 X 3/4 COTTER PIN

Y2988 Y30064 Torsion Spring − Mower

5/32 x 3/4 Cotter Pin

1/2" SAE Flat Washer

Itm Qty Part No. Description

21 22 1 Y3765 24 2 Y4002 Hex Cap 1−2x3_1−2 UNC 28 29 1 Y4313 RH Pulley Cover 30 2 Y4314 Pulley Cover Hinge 31 1 Y4333 Belt Tensioner 32 1 Y4334 Pulley Cover Tread Plate LH 33 1 Y4335 Pulley Cover Tread Plate RH

Y3637

1 Y4311

Deck Roller Pin V−Belt 51" YardShark

LH Pulley Cover

Itm Qty Part No. Description

16 Y4349 3/8 SAE FLAT WASHER

35 2 Y4350

1 Y4372

8 Y4376 3/16 X .250 Std Pop Rivet 42 4 Y4377 44 1 Y4660 51 Deck Weldment − Tilton

1 Y4745

46 47 2 Y6916 DECK WHEEL 48 1

Y7790 1/4 X 3/4 Tapping Screw

3/8 X .056 BELLEVILLE WASHER 3/8 Std NC Nylock Nut

NUT, 8−32 UNC KEPS

Rubber Discharge Deflector Assy

FRONT VIEW

YardShark 51" Deck Group

Page 39

Itm Qty Part No. Description

Page 39

1 3 2 2 Y1006 1/4−20 Top Lock Nut 3 12 Y1018 Hex Cap 3−8x1 UNC 4 1 Y1045 5 6 1 Y1658 Hex Cap 3−8x2 UNC 7 8 14 Y1827 3/8" Lock Washer 9 3 Y190063

11 3

Y1002 1/2−13 Hex Nut

1/2−13 UNC Jam Nut

3 Y1053 1/2" Lock Washer

2 Y1826 3/8−16 UNC Hex Nut

HAIR PIN, #3 FOR 3/8" PINS

2 Y191242 Hex Cap 1−4x_3−4 UNC

Y191422

1/2 x 1−1/2 UNF Hex Cap Screw

Itm Qty Part No. Description

12 2 Y198119 1/2 X .070 BELLEVILLE WASHER 13 1 Y30065 14 3 Y30207 DECK ROLLER, 3" x 5" 15

6 Y3458 1/2" SAE Flat Washer 16 3 Y3637 Deck Roller Pin 17 3 Y3862

3 Y4145

18 19 3 Y4203 Deck Idler Pulley Assy − Flat

20 2 Y4225 3/8 x 2.25 Carr Bolt

1 Y4333 Belt Tensioner

22 16 Y4349

Deck Belt Tightening Spring

Spindle Assy Mowers 2006− 18" Blade − Std.

3/8 SAE FLAT WASHER

25.2

Itm Qty Part No. Description

23 24 1 Y4371 1/2−13 X 1−3/4 Carr Bolt 25 3 Y4374 BK57 X 1" Pulley Assy w/ 2 set

25.1 1 Y7187 BK57−1" Pulley

25.2 1 Y4123

25.3 1 Y192575

26 27 28 1 Y4660 51 Deck Weldment − Tilton 29

25.1

25.3

Y4358 Belt Tensioner Arm

screws

SetScrew 5_16−18 UNCx0.25 Knurled SetScrew 5_16−18 UNCx0.375 −

Knurled 3 Y4375 1/4 x 1 Key 3

Y4466

2 Y4674 Rear Deck Lift Pin

BLADE SPINDLE WASHER

REAR VIEW

YardShark 51" Deck Group

Page 40

Itm Qty Part No. Description

Page 40

1 3

2.1 1 Y3946 BK62−1" BORE PULLEY

2.2 1 Y4123

2.3 3 1 Y3973 4 1 Y4640 60" Deck Weldment

Y2978 20−1/2" Blade − Std.

Y3947 BK62 Pulley Assy w/ 2 Set Screws

SetScrew 5_16−18 UNCx0.25 Knurled

Y192575 5/16−18 SET SCREW X 3/8

Belt for 60" YardShark

2.1

Parts unique to 60" deck. All other parts same as 51" deck.

Yard Shark 60" Deck Group

Page 41

Complete Spindle Assy − # Y3862.

Page 41

Itm

Qty Part No.

1 1 Y1074 2 2 Y2755 3 1

4 1 Y3863 5 1 6

Y2959M Machined Hub for Mower Spindle

Y3864 Spindle Nut for Bottom of #3862 Assy

Y3865 Ext Ret Ring MSR−30

Internal Retaining Ring/MHO−62/ANSI Metric 6206 SEALED BEARING

Spindle Shaft for #3862 Assy

Description

Blade Side

Pulley Side

SECTION A-A

SCALE 3 / 4

Spindle Assembly

Page 42

Itm

Page 42

Qty Part No.

1 2 Y198046 1/4" Fender Washer 2 2 Y3624 3

6 Y4060 1/4 x 1 Carr Bolt 4 8 Y4062 5 1 Y4730

6 7 1 Y4734 Rubber Deflector−Tilton

Y4732

1/4 x 1 Hex Cap Screw

1/4 Std NC Nylock Nut Deflector Bottom Clamp Strap Deflector Mount Weldment

Description

Rubber Discharge Deflector Assy

Page 43

Itm Qty Part No. Description

Page 43

1 1 2 3 1 Y1053 1/2" Lock Washer

4 2

6 4 Y3458

7 4 Y4153 1/2−13 UNC Clevis RH 8

9 2 Y4170

Y1019

4 Y1045

Y2952

8 Y2988 5/32 x 3/4 Cotter Pin

Y4159 O−Ring

Hex Cap 1−2x1_1−4 UNC 1/2−13 UNC Jam Nut

5/32 X Cotter Pin

1/2" SAE Flat Washer

CLEVIS PIN, 5/8 x 1 1/4

Itm Qty Part No. Description

10 1 Y4274

2 Y4276 DECK PUSH ARM 12 4 Y4348 13 1 14 1 15 4 Y4362 DECK LIFT LINK

16 2 Y4453 DECK LIFT ROD

17 1

Y4359 Y4360 FOOT PEG

Y4672 REAR LH DECK LIFT w/ LATCH HOOK

Deck Lift Rock Shaft Weldment

CLEVIS PIN, 1/2" DIA. x 1 27/64" LENGTH REAR DECK LIFT RH

Deck Lift Group

Page 44

Itm Qty Part No. Description

1 1 2 1 Y130083 Dust Cap − Zinc 3 1 Y150001 4 1 Y1500031 5 1 Y1500041 6 1 7 1 8 1 Y3064 5/8 Thin NC Nylock Nut 9

10 1

Y1029 Hex Cap 5−8x7 UNC

Grease Seal Bearing−Cup&Cone 1" Bore

Bearing−Cup&Cone 1.0625" Bore Y193185 1" Slotted Nut − Thin Y196314 1/8 x 2 Cotter Pin

Y3990 Y4629 FRONT CASTER FORK WELDMNT

13X5 Wheel Assy

Front Wheel Group

Page 45

Itm Qty Part No. Description

1 2 Y1006 1/4−20 Top Lock Nut

4 Y1047

2 3 1 4 1 Y1658 Hex Cap 3−8x2 UNC 5 7 6 7 2 Y191240 Hex Cap 1−4x_1−2 UNC 8

9 2 Y198042

10 2 Y198064 5/16" Lock Washer

11 2 Y3625 1/4−20 HEX NUT 12 13 2 Y4060 1/4 x 1 Carr Bolt 14 1 Y4136 Engine, Honda GXV20 15 1 Y4140 16 2 Y4172 5mm x 25mm Key 17 1 18 19 1 Y4216

20 2 Y4217

22 1 Y4267 23 1 Y4268 24 25 1 Y4275 26 2 Y4349 27 28 29 1 Y4354 3/8 X 1−1/2 Carriage Bolt 30 2 Y4462 Loom Clamp 1/2 Dia − 1/4" Mount

31 1

32 1 Y4852 1/4 key x 3/4 long 33 4 34

Y1052 7/16" Lock Washer

Y1826 3/8−16 UNC Hex Nut

Y1827 3/8" Lock Washer

Y191282

Y3781 Loom Clamp 1/2 Dia − 3/8 Mount

Y4199 Belt 5mm pitch x 51.181 x 15mm wide

Y4202 2.75" idler Pulley

Y4266 Sprocket, 5mm PITCH, 60 GROOVE, SH Bore

Y4273

3 Y4350

Y4353

Y4474 Pump Drive Idler Arm

Y7194 Hex Cap 3−8x1_3−4 UNC

2 Y8230 5/16−18NC SERR FLANGE ZP

3/8 USS FLAT WASHER

5−16x1 UNC Hex Cap 1/4" Lock Washer

Warner Clutch # I−5218−52 B

Bushing−Engine, SH 1" bore Bushing−Pumps, SH 15mm

Clutch Spacer − 1" ID 7/16 x 2−1/2 Hex Cap Screw Muffler−Honda Clutch Stop 3/8 SAE FLAT WASHER 3/8 X .056 BELLEVILLE WASHER Pump Drive Idler Spring

Honda 20hp Power Group

Page 46

Important!

Page 46

See Note Below

Itm

Qty Part No.

1 2 Y1012 NUT WHIZ 1/4−20NC ZP 2 4 Y1047 3 1 4 1 Y1658 Hex Cap 3−8x2 UNC 5 7 6 7 2 Y191242 Hex Cap 1−4x_3−4 UNC 8 9 2 Y198042

10 2 Y198064 5/16" Lock Washer

Used on Kaw’s Only

11 1 Y3313

12 13 1 Y3944 Clutch − 1−1/8" bore 14 1 15 1 16 2 Y4172 5mm x 25mm Key 17 1 Y4199 Belt 5mm pitch x 51.181 x 15mm wide 18 19 2 Y4217

20 3 Y4266

21 1 Y4275 22 2 Y4349 3/8 SAE FLAT WASHER 23 3 Y4350 24 1 Y4353 25 26 1 Y4474 Pump Drive Idler Arm 27 1 Y4652 Muffler−Kawasaki 28 29 1 Y4668 1−1/8" x .050" Narrow Rim Mach Bushing 30 1

31 1 32 4 Y7194 Hex Cap 3−8x1_3−4 UNC 33 2

Y1052 7/16" Lock Washer

Y1826 3/8−16 UNC Hex Nut

Y1827 3/8" Lock Washer

Y191282

Y3326 7/16 X 2 Hex − UNF

Y3948 Bushing−Engine, SH 1−1/8" bore Y3966 Kawasaki 21 hp

Y4202 2.75" idler Pulley

Y4354 3/8 X 1−1/2 Carriage Bolt

Y4667 Clutch Mount Bushing − 1−1/8"

Y4669 Clutch Spacer − 1−1/8" ID Y4852

Y8230 5/16−18NC SERR FLANGE ZP

3/8 USS FLAT WASHER

5−16x1 UNC Hex Cap 1/4" Lock Washer

12V Solenoid

Bushing−Pumps, SH 15mm Sprocket, 5mm PITCH, 60 GROOVE, SH Bore Clutch Stop

3/8 X .056 BELLEVILLE WASHER Pump Drive Idler Spring

1/4 key x 3/4 long

Description

Important Note − Part #Y4668 (Item 29) is used only on Kawasaki Engines. It is used to compensate for a slightly longer crankshaft than the Honda 24hp. DO NOT USE ON HONDA’s !!

28 12

Kawasaki 25 hp Engine Part #Y3965 Honda 24 hp Engine Part #Y3960

Kaw21/25 & Honda24 Engine Group

Page 47

Itm

Page 47

1 2 1 Y140016 3 1 Y1623 5/16 x 3/4 Bolt 4 5 1 Y198064 5/16" Lock Washer 6 1 7 8 1 Y4236 9

10 1

11 2 Y4426

12 1 Y4625 13 14 4 Y8230

Part No. Description

Qty

4 Y1006 1/4−20 Top Lock Nut

Seat Cable − 1/8" x 18"

2 Y191240 Hex Cap 1−4x_1−2 UNC

Y3919 Michigan Suspension Seat

2 Y4060 1/4 x 1 Carr Bolt

Seat Latch Pin

Y4238 Seat Hinge Pin − Zinc Y4250 3/32 x 1/2 Cotter Pin

1/4" SAE FLAT WASHER Seat Plate Weldment

2 Y4691 Seat Support Bumper

5/16−18NC SERR FLANGE ZP

Seat Group

Page 48

Itm Qty Part No. Description

Page 48

1 5 2 3 Y191240 Hex Cap 1−4x_1−2 UNC 3 2

4 7 5 2 Y198046 1/4" Fender Washer 6 2 7 1 8 2 Y3787 9

10 1

11 1 Y4341

12 1 Y4342 Gas Cap 13 14 1 Y4344 Battery Terminal Cover 15 1 Y4345 Gas Tank Fitting 16 17 1 Y4347 Elbow, 1/4 pipe, 1/4 Hose barb 18 2 Y4426 19 2 Y4462 Loom Clamp 1/2 Dia − 1/4" Mount

Y191211 10−32 UNF x 1−2 Phillips Pan Head Zinc

Y191246 Y198042

Y3783 Loom Clamp 3/8 Dia − 1/4" Mount Y3786 Gas Line 1/4" SAE 30R7 − 43"

Y3789 1/4−20 UNC x 1−1/4" Stud Y4255

Y4343

Y4346 Gas Tank Draw Tube

1/4 x 1−1/4 UNC Bolt 1/4" Lock Washer

Clamp. Tension Spring 1/2"

Fuel Tank, Molded Plastic Fuel Sender

Wing Nut 1/4−20

1/4" SAE FLAT WASHER

Fuel Tank Group

Page 49

Itm Qty Part No. Description

Page 49

1 4 Y1001 7/16 Hex Nut UNC 2 6 3 4 Y1052 7/16" Lock Washer 4 2 5

6 2 Y198042 1/4" Lock Washer

7 2 Y3624 8

9 1 Y4232

10 1

11 1 12 1 Y4487 13 4 Y4488 14 1 15 1 16 1 Y4491 17 1 18

Y1047

Y1826 3/8−16 UNC Hex Nut

2 Y1827 3/8" Lock Washer

Y4231

Y4393 Y4486 Parker Triple−Lok 45° Straight Thread Elbow, 8−6 V5OX−S

Y4489 Parker Triple−Lok Straight Thread Connector, 8−6 F5OX−S Y4490

Y4492

Y4493

3/8 USS FLAT WASHER

1/4 x 1 Hex Cap Screw White LH Pump (Our RH) White RH Pump (Our LH) Hydraulic Oil Reservoir

Parker Triple−Lok 45° Straight Thread Elbow, 8 V5OX−S Parker Triple−Lok Straight Thread Elbow, 8−10 C5OX−S

6801−08−08 Jic(−8) to Male O−ring (−8), 90 degrees Parker Triple−Lok Swivel Nut Branch Tee, 8 S6X−S 6 C5OX−S (St Thd El.−3/8 JIC x 9/16 ORB) Parker Triple−Lok Straight Thread Branch Tee, 6 S5OX−S

Itm Qty Part No. Description

19 20 21 1 Y4496 Oil Filter 10 Micron 22 1 23 24 1 Y4503

25 1 Y4504 Hyd Line−Filter to RH Pump 26 27 1 Y4508 3/8" NPT Magnetic Drain Plug 28 1 Y4631 LH Top Oil Line 29 30 1 Y4633 RH Top Oil Line

31 1 Y4634 RH Bottom Oil Line 32 33 1 34 4 Y7654 7/16 X 1−1/2 Carr Bolt 35 4

Y4494

Y4495

Y4497 Oil Filter Head SAE 8 ports

Y4498 Oil Reservoir Dipstick

1 Y4505 Hyd Line−Pump to Pump

Y4632 LH Bottom Oil Line

Y4685 Oil Line−Return−Center Y4686 Oil Return Line−To Tank

Y7944 Str Thrd Conn, 8 F5OX−S,1/2 JIC x 3/4−16 ORB

8 GTX−S − (Female Adapter,3/8 Pipe x 1/2"JIC) 8 GTX−S − (Female Adapter,1/4 Pipe x 3/8"JIC)

Hyd Oil Suction Line to Filter

REAR VIEW

FRONT VIEW

Oil Filter/Reservoir Group

Page 50

Itm Qty Part No. Description

1 2

2 4 Y1018 Hex Cap 3−8x1 UNC

3 4 Y1073 1/4 X 1−1/8 ROLL PIN 4 2 5 4 6 2 Y191282 5−16x1 UNC Hex Cap 7 2 8 2 Y198064 5/16" Lock Washer 9 4 Y198119 1/2 X .070 BELLEVILLE

11 6 Y4064 5/16 x 3/4 Carr Bolt

12 2 Y4151

13 4 Y4193 5/16−24 UNF Hex Nut 14 2 15 16 2 Y4226 Foam Grip,.875" x 17" 17 2 Y4250 3/32 x 1/2 Cotter Pin 18 2 Y4260 Control Shaft Weldment 19 2 Y4263 Control Arm Block

20 2 Y4271 5/16−18 x 1.75 Carr Bolt

21 2 Y4286 5/16−24 LH/RH Adjustment

22 2 Y4287 23

24 1 Y4292 LH BRAKE ACTUATOR

25 2 Y4294 Control Lever Mount 26 2 Y4297 CONTROL WELDMENT 27 2 Y4301 CONTROL HANDLE WELDMENT 28 2 Y4304 29 2 Y4305 BEARING BLOCK FOR BRAKE

31 6 Y4349 32 2 Y4353 33 34 6 Y7731 35 6

Y1008 1/2 Std NC Nylock Nut

Y1279 Y1827 3/8" Lock Washer

Y196304 1/8 X 3/4 COTTER PIN

Y3050

Y4194

2 Y4208 5/16−18 UNC X 1−1/2 CARR BOLT

Y4289 RH BRAKE ACTUATOR

Y4331

2 Y4426 1/4" SAE FLAT WASHER

Y8230 5/16−18NC SERR FLANGE ZP

1/2 x 2−1/2 Hex Cap

WASHER ZERK, 1/4−28 90 DEG.

5/16−24 NF Rod End W/ Stud, LH Thd Inside Rod End

5/16−24 UNF LH Hex Nut

Rod − 12.50" OAL 5/16−24 RH Spherical Rod End

WELDMENT

Brake Linkage

ROD 3/16 x 1.75 Roll Pin 3/8 SAE FLAT WASHER Pump Drive Idler Spring

5/16 Std NC Nylock Nut

Control Group

Page 51

Itm Qty Part No. Description

Page 51

1 7 Y1012 NUT WHIZ 1/4−20NC ZP

2 3 2 Y1623 5/16 x 3/4 Bolt 4 2 5 3 6 4 Y191242 Hex Cap 1−4x_3−4 UNC 7 2 8 9 1 Y3350 Cup Holder Insert − Black Plastic

10 1 Y3772 Wire Loom − 3/8 ID − 44"− Not Pictured−Use to route

11 2 Y3778 Jumper, Hole Mount

12 1

Y140012−6FT Throttle Cable Assy

Y191211 Y191240 Hex Cap 1−4x_1−2 UNC

Y193004 10−32 NF Serr. Flange nut

Y198042

Y3779 Barrier Strip − 10 Terminal

10−32 UNF x 1−2 Phillips Pan Head Zinc

1/4" Lock Washer

throttle & choke cables

Itm Qty Part No. Description

13 1 14 1 Y4144 15 1 Y4160 16 1 Y4213 BATTERY 12 V 17 1 18 2 Y4245 19

21 7 Y4426 22 6 Y4485 23 24 1 Y4623 Control Box Weldment 25 1 Y4670 Control Panel Overlay 26 27 2 Y8230

Y3970

Y4243 Barrier Strip Mount − SS

2 Y4377

Y4383 Fuel Gauge

Y4622 Control Box Cover

Y4671 Cup Holder

Choke Cable − 61−1/2" Key Switch PTO Switch

8−32 x 1/2 Pan Hd Mach Screw NUT, 8−32 UNC KEPS

1/4" SAE FLAT WASHER #10−24 x 1/2" Washer Head Screw − ZP

5/16−18NC SERR FLANGE ZP

Control Box Group

Page 52

Itm Qty Part No. Description

1 1 2 2 Y1012 NUT WHIZ 1/4−20NC ZP

3 4 7 5 2 Y1058 6 3 Y1624 7 1 8 11 Y1827 3/8" Lock Washer 9

10 5

11 4 Y191282 5−16x1 UNC Hex Cap

12 12 13 14 6 Y198064 5/16" Lock Washer 15 1 Y3354 1/2" x 1" Ball Lock Pin − Zinc Clr

Y1010 3/8"−16 CNTRLOCK HEX NUT

Y1013

Y1018 Hex Cap 3−8x1 UNC

Y1826 3/8−16 UNC Hex Nut

Y191240 Y191242 Hex Cap 1−4x_3−4 UNC

Y198042

2 Y198062 Type A Plain Washer

NUT SERR FLANGE 3/8−16NC ZP

ZERK, 1/4−28 STRAIGHT 5/16−18 Hex nut UNC

Hex Cap 1−4x_1−2 UNC

1/4" Lock Washer

Itm Qty Part No. Description

16 2 Y3624 1/4 x 1 Hex Cap Screw 17 2 Y3625 1/4−20 HEX NUT

18 19 2 Y4059 5/16 x 1 Carriage Bolt

20 2 Y4063 1/4−20 x 3/4 Carr.Bolt

21 1 22 23 1 Y4285 FOOT PAN 24 6 25 2 26 10 Y4426 27 1 Y4454 Deck Ht Adjustment Plate, Bolt On 28 29 2 Y4456 Rockshaft Hanger 30 2 Y4457

31 1 32 1 Y4524 33 1 Y4601 Mower Frame Wldmnt 34 1 35 36 1 Y4683 Front Frame Plate 37 1 38 39 1 Y4740 Deck Latch Handle 40 1 Y4743 Eye Bolt

41 1 42 2 Y7194 Hex Cap 3−8x1_3−4 UNC 43 44 4

Y3867

Y4196 Seat Latch

Y4206 Hex Cap 3−8x1_1−2 UNC

Y4349 3/8 SAE FLAT WASHER Y4350

3 Y4455

Y4469 Seat Latch Mounting Bracket

Y4657 REAR GUARD−YS

2 Y4675 Hex Cap 3−8x_3−4 UNC

Y4684

Y4693 Rear Shield Weldment

Y4746 Gas Tank Gaurd

8 Y7790 1/4 X 3/4 Tapping Screw

Y8230 5/16−18NC SERR FLANGE ZP

Loom Clamp 1/2 Dia − 1/4" Mount

3/8 X .056 BELLEVILLE WASHER 1/4" SAE FLAT WASHER

SPACER

external retaining ring SH−75

Muffler Heat Shield

Rear Bumper

Detail drawings on next page.

Frame Group

Page 53

DETAIL A

Page 53

DETAIL B

DETAIL C

DETAIL D

Frame Group