Toro 30435 Operator's Manual
Form No. 3327–408
Mid–Size Mower
ProLine Hydro 17 HP with 44 inch Side
Discharge Mower
Model No. 30435—Serial No. 230000001 and Up
Operator’s Manual
Register your product at www.Toro.com
Original Instructions (EN)
Warning
CALIFORNIA
Proposition 65 Warning
The engine exhaust from this product contains
chemicals known to the State of California to
cause cancer, birth defects, or other reproductive
harm.
Important This engine is not equipped with a spark
arrester muffler. It is a violation of California Public
Resource Code Section 4442 to use or operate this engine
on any forest–covered, brush–covered or grass–covered
land. Other states or federal areas may have similar laws.
This spark ignition system complies with Canadian
ICES-002.
Ce système d’allumage par étincelle de véhicule est
conforme à la norme NMB-002 du Canada.
The enclosed Engine Owner ’s Manual is supplied for
information regarding The U.S. Environmental
Protection Agency (EPA) and the California Emission
Control Regulation of emission systems, maintenance
and warranty.
Keep this engine Owner ’s Manual with your unit.
Should this engine Owner’s Manual become damaged
or illegible, replace immediately. Replacements may be
ordered through the engine manufacturer.
Contents
Page
Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices 4. . . . . . . . . . . . . . . . . . .
Toro Mower Safety 5. . . . . . . . . . . . . . . . . . . . . . .
Slope Chart 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 9. . . . . . . . . . . . . . .
Gasoline and Oil 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Gasoline 13. . . . . . . . . . . . . . . . . . .
Using Stabilizer/Conditioner 13. . . . . . . . . . . . . . . .
Filling the Fuel Tank 13. . . . . . . . . . . . . . . . . . . . . .
Check Engine Oil Level 13. . . . . . . . . . . . . . . . . . . .
Setup 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Handle Assembly 15. . . . . . . . . . . . . .
Installing the Fuel Tank 16. . . . . . . . . . . . . . . . . . . .
Installing the Control Rods 17. . . . . . . . . . . . . . . . .
Installing the Speed Control Rod 17. . . . . . . . . . . . .
Installing the Hairpin Cotter Pins and Washers 18. .
2003 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Checking the Tire Pressure 18. . . . . . . . . . . . . . . . .
Activating the Battery 18. . . . . . . . . . . . . . . . . . . . .
Checking the Hydraulic Fluid and Engine Oil 19. .
Setting Up the Hydro Linkage 20. . . . . . . . . . . . . . .
Operation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Think Safety First 21. . . . . . . . . . . . . . . . . . . . . . . .
Controls 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Stopping the Engine 22. . . . . . . . . . . .
Operating Neutral Locks 22. . . . . . . . . . . . . . . . . . .
Operating the Parking Brake 23. . . . . . . . . . . . . . . .
Operating Mower Blade Control (PTO) 23. . . . . . .
The Safety Interlock System 23. . . . . . . . . . . . . . . .
Driving Forward or Backward 24. . . . . . . . . . . . . . .
Bringing Machine to Neutral Position 24. . . . . . . . .
Stopping the Machine 24. . . . . . . . . . . . . . . . . . . . .
Pushing the Machine by Hand 25. . . . . . . . . . . . . . .
Transporting Machines 25. . . . . . . . . . . . . . . . . . . .
Side Discharge or Mulch Grass 25. . . . . . . . . . . . . .
Adjusting the Height-of-Cut 26. . . . . . . . . . . . . . . .
Adjusting the Gage Wheels 26. . . . . . . . . . . . . . . . .
Adjusting the Handle Height 27. . . . . . . . . . . . . . . .
Using the Mid–Size Weight Kit 28. . . . . . . . . . . . . .
Maintenance 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 29. . . . . . . .
Servicing the Air Cleaner 30. . . . . . . . . . . . . . . . . .
Servicing the Engine Oil 31. . . . . . . . . . . . . . . . . . .
Servicing the Spark Plug 32. . . . . . . . . . . . . . . . . . .
Fuse Service 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Service 33. . . . . . . . . . . . . . . . . . . . . . . . . . .
Greasing and Lubrication 35. . . . . . . . . . . . . . . . . . .
Cleaning the Cooling System 36. . . . . . . . . . . . . . .
Checking the Tire Pressure 36. . . . . . . . . . . . . . . . .
Adjusting the Electric Clutch 37. . . . . . . . . . . . . . .
Servicing the Fuel Tank 37. . . . . . . . . . . . . . . . . . . .
Servicing the Fuel Filter 38. . . . . . . . . . . . . . . . . . .
Servicing the Hydraulic System 38. . . . . . . . . . . . .
Hydro Linkage Adjustments 40. . . . . . . . . . . . . . . .
Adjusting the Speed Control Linkage 40. . . . . . . . .
Temporary Neutral Stud Adjustment 41. . . . . . . . . .
Adjusting the Hydro Control Linkages 41. . . . . . . .
Adjusting the Neutral Stud 43. . . . . . . . . . . . . . . . .
Adjusting the Control Rod 44. . . . . . . . . . . . . . . . . .
Tracking Adjustment 45. . . . . . . . . . . . . . . . . . . . . .
Servicing the Brake 45. . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Electric Clutch 46. . . . . . . . . . . . . . .
Servicing the Cutting Blades 46. . . . . . . . . . . . . . . .
Correcting the Mower Quality of Cut 48. . . . . . . . .
Frame Set Up 48. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Deck Front-to-Rear Pitch 50. . . . . . .
Contact us at www.Toro.com
All Rights Reserved
2
Printed in the USA
Page
Changing the Deck Front-to-Rear Pitch 50. . . . . . .
Checking the Deck Side-to-Side Leveling 50. . . . .
Changing the Side-to-Side Leveling 51. . . . . . . . . .
Matching the Height of Cut 51. . . . . . . . . . . . . . . . .
Replacing the Mower Belt 51. . . . . . . . . . . . . . . . . .
Replacing the PTO Drive Belt 52. . . . . . . . . . . . . . .
Replacing the Caster Wheel Fork Bushings 52. . . .
Caster Wheel and Bearings Service 53. . . . . . . . . . .
Replacing the Grass Deflector 54. . . . . . . . . . . . . . .
Wiring Diagram 55. . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Diagram 56. . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Storage 57. . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Toro Total Coverage Guarantee 60. . . . . . . . . . . . .
Introduction
Page
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard.
However, regardless of the hazard, be extremely careful.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
Caution signals a hazard that may cause minor or
moderate injury if you do not follow the recommended
precautions.
This manual uses two other words to highlight
information. Important calls attention to special
mechanical information and Note: emphasizes general
information worthy of special attention.
Read this manual carefully to learn how to operate and
maintain your product properly. The information in this
manual can help you and others avoid injury and product
damage. Although Toro designs and produces safe
products, you are responsible for operating the product
properly and safely.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model and
serial numbers of your product ready. Figure 1 illustrates
the location of the model and serial numbers on the
product.
m–6612
1. Location o f the model and serial numbers
Write the product model and serial numbers in the space
below:
1
Figure 1
Safety
Note: The addition of attachments made by other
manufacturers that do not meet American National
Standards Institute certification will cause noncompliance
of this machine.
Improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
attention to the safety alert symbol, which means
CAUTION, WARNING, or DANGER—“personal
safety instruction.” Failure to comply with the
instruction may result in personal injury or death.
Safe Operating Practices
The following instructions are from ANSI standard
B71.4—1999.
Training
• Read the Operator ’s Manual and other training
material. If the operator(s) or mechanic(s) can not read
English it is the owner’s responsibility to explain this
material to them.
• Become familiar with the safe operation of the
equipment, operator controls, and safety signs.
• All operators and mechanics should be trained. The
owner is responsible for training the users.
Model No.
Serial No.
• Never let children or untrained people operate or
service the equipment. Local regulations may restrict
the age of the operator.
3
• The owner/user can prevent and is responsible for
accidents or injuries occurring to himself or herself,
other people or property.
Preparation
• 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.
• Wear appropriate clothing including hard hat, safety
glasses and hearing protection. Long hair, loose
clothing or jewelry may get tangled in moving parts.
• 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.
• Use extra care when handling gasoline and other fuels.
They are flammable and vapors are explosive.
• Use only an approved container
• Never remove gas cap or add fuel with engine
running. Allow engine to cool before refueling.
Do not smoke.
• Never refuel or drain the machine indoors.
• Check that operator ’s presence controls, safety
switches and shields are attached and functioning
properly. Do not operate unless they are functioning
properly.
Operation
• Never operate with the discharge deflector raised,
removed or altered, unless using a grass catcher.
• Do not change the engine governor setting or
overspeed the engine.
• Stop on level ground, disengage drives, engage
parking brake (if provided), shut off engine before
leaving the operator ’s position for any reason
including emptying the catchers or unclogging the
chute.
• Stop equipment and inspect blades after striking
objects or if an abnormal vibration occurs. Make
necessary repairs before resuming operations.
• Keep hands and feet away from the cutting unit.
• Look behind and down before backing up to be sure of
a clear path.
• Keep pets and bystanders away.
• Slow down and use caution when making turns and
crossing roads and sidewalks. Stop blades if not
mowing.
• Be aware of the mower discharge direction and do not
point it at anyone.
• Do not operate the mower under the influence of
alcohol or drugs.
• Use care when loading or unloading the machine into
or from a trailer or truck.
• Use care when approaching blind corners, shrubs,
trees, or other objects that may obscure vision.
• Never run an engine in an enclosed area.
• Only operate in good light, keeping away from holes
and hidden hazards.
• Be sure all drives are in neutral and parking brake is
engaged before starting engine. Only start engine from
the operator’s position.
• Be sure of your footing while using this machine,
especially when backing up. Walk, don’t run. Never
operate on wet grass. Reduced footing could cause
slipping.
• Slow down and use extra care on hillsides. Be sure to
travel side to side on hillsides. Turf conditions can
affect the machine’s stability. Use caution while
operating near drop-offs.
• Slow down and use caution when making turns and
when changing directions on slopes.
• Never raise deck with the blades running.
• Never operate with the PTO shield, or other guards not
securely in place. Be sure all interlocks are attached,
adjusted properly, and functioning properly.
Maintenance and storage
• Disengage drives, set parking brake, stop engine and
remove key or disconnect spark plug wire. Wait for all
movement to stop before adjusting, cleaning or
repairing.
• Clean grass and debris from cutting unit, drives,
mufflers, and engine to help prevent fires. Clean up oil
or fuel spillage.
• Let engine cool before storing and do not store near
flame.
• Shut off fuel while storing or transporting. Do not store
fuel near flames or drain indoors.
• Park machine on level ground. Set parking brake.
Never allow untrained personnel to service machine.
• Use jack stands to support components when required.
• Carefully release pressure from components with
stored energy.
4
• Disconnect battery or remove spark plug wire before
making any repairs. Disconnect the negative terminal
first and the positive last. Reconnect positive first and
negative last.
• Use care when checking blades. Wrap the blade(s) or
wear gloves, and use caution when servicing them.
Only replace blades. Never straighten or weld them.
• Keep hands and feet away from moving parts. If
possible, do not make adjustments with the engine
running.
• Charge batteries in an open well ventilated area, away
from spark and flames. Unplug charger before
connecting or disconnecting from battery. Wear
protective clothing and use insulated tools.
• Keep all parts in good working condition and all
hardware tightened. Replace all worn or damaged
decals.
Toro Mower Safety
The following list contains safety information specific to
Toro products and other safety information you must
know.
This product is capable of amputating hands and feet and
throwing objects. Always follow all safety instructions to
avoid serious injury or death.
This product is designed for cutting and recycling grass or,
when equipped with a grass bagger, for catching cut grass.
Any use for purposes other than these could prove
dangerous to user and bystanders.
General Operation
• Allow only responsible adults who are familiar with
the instructions to operate the machine.
• Be sure the area is clear of other people before
mowing. Stop the machine if anyone enters the area.
• Do not mow in reverse unless absolutely necessary.
Always look down and behind before and while
backing.
• Be aware of the mower discharge direction and do not
point it at anyone. Do not operate the mower without
either the entire grass catcher or the guard in place.
• Slow down before turning. Sharp turns on any terrain
may cause loss of control.
• Turn off blades when not mowing.
• Keep hands, feet, hair and loose clothing away from
attachment discharge area, underside of mower and
any moving parts while engine is running.
• Stop the engine before removing the grass catcher or
unclogging the chute.
• Mow only in daylight or good artificial light.
• Watch for traffic when operating near or crossing
roadways.
• Do not touch equipment or attachment parts which
may be hot from operation. Allow to cool before
attempting to maintain, adjust or service.
• Use only Toro-approved attachments. Warranty may
be voided if used with unapproved attachments.
Slope Operation
Slopes and ramps are a major factor related to
loss-of-control and accidents, which can result in severe
injury or death. All slopes and ramps require extra
caution. If you feel uneasy on a slope, do not mow it.
DO
• Remove obstacles such as rocks, tree limbs, etc. from
the mowing area.
• Watch for holes, ruts or bumps. Tall grass can hide
obstacles.
• Use slow speed so that you will not have to stop while
on the slope.
• Use extra care with grass catchers or other
attachments. These can change the stability of the
machine.
• Keep all movement on slopes slow and gradual. Do
not make sudden changes in speed or direction.
• Avoid starting or stopping on a slope. If tires lose
traction, disengage the blades.
• Check carefully for overhead clearances (i.e. branches,
doorways, electrical wires) before driving under any
objects and do not contact them.
• Mow slopes side to side.
DO NOT
• Do not mow slopes greater than 15 degrees.
• Avoid turning on slopes. If you must turn, turn slowly
and gradually downhill, if possible.
• Do not mow near drop-offs, ditches, or embankments.
The machine could suddenly turn over if a wheel goes
over the edge of a cliff or ditch, or if an edge caves in.
• Do not mow on wet grass. Reduced traction could
cause sliding.
• Do not use a grass catcher on steep slopes. Heavy
grass bags could cause loss of control of the machine.
5
• Do not mow up and down slopes.
Service
• Never store the machine or fuel container inside where
there is an open flame, such as near a water heater or
furnace.
• Keep nuts and bolts tight, especially the blade
attachment bolts. Keep equipment in good condition.
• Never tamper with safety devices. Check safety
systems for proper operation before each use.
• Use only genuine replacement parts to ensure that
original standards are maintained.
• Check brake operation frequently. Adjust and service
as required.
• Hydraulic fluid escaping under pressure can penetrate
the skin and cause injury. Use cardboard or paper to
find hydraulic leaks. Never use your hands.
6
Slope Chart
7
8
Safety and Instruction Decals
Safety decals and instructions are easily visible to the operator and are located near any
area of potential danger. Replace any decal that is damaged or lost.
1-523552
68-8340
82-4590
43-8480
66-1340
67-5360
93-1122
95-2814
9
98-0776
98-4387
1. Warning—wear hearing protection.
105-4110
106-5532
106-0699
104-8186
104-2838
104-8569
106-5513
105-4109
10
1. Keep bystanders a safe
distance from the machine.
2. Do not allow bystanders to
be hit by thrown objects.
3. Do not operate the mower
with the deflector up or
removed.
4. Stop the engine and pick up
debris before operating.
5. Cutting of hand or foot,
mower.
6. Engine—stop
7. Engine—run
8. Engine—ignition
9. Hour meter
106-0635
106-5516
10. To drive forward, move the
controls as illustrated.
11. To place the machine in
neutral, move the controls as
illustrated.
12. To drive in reverse, move the
controls as illustrated.
13. Power take-off (PTO)
14. Fast
15. Continuous variable setting
16. Slow
17. Neutral
106-5501
1. Choke 2. Fast 3. Continuous variable setting 4. Slow
11
1. Contains lead; do not
discard.
2. Recycle
1. Explosion hazard
2. No fire, open flames, or
smoking.
3. Caustic liquid/chemical
burn hazard
3. Wear eye protection;
4. No sparks, flame, or smoking
104-4163
4. Wear eye protection
5. Read the
6. Keep bystanders a safe
explosive gases can cause
blindness and other injuries
Operator’s
Manual.
distance from the battery.
104-4164
5. Sulfuric acid can cause
blindness or severe burns.
6. Flush eyes immediately with
water and get medical help
fast.
7. Maximum fill line
8. Minimum fill line
9. Instructions for activating the
battery
12
Gasoline and Oil
Recommended Gasoline
Use UNLEADED Regular Gasoline suitable for
automotive use (85 pump octane minimum). Leaded
regular gasoline may be used if unleaded regular is not
available.
Important Never use methanol, gasoline containing
methanol, or gasohol containing more than 10% ethanol
because the fuel system could be damaged. Do not mix oil
with gasoline.
Danger
In certain conditions, gasoline is extremely
flammable and highly explosive. A fire or
explosion from gasoline can burn you and others
and can damage property.
• Fill the fuel tank outdoors, in an open area,
when the engine is cold. Wipe up any gasoline
that spills.
• Never fill the fuel tank inside an enclosed
trailer.
• Do not fill the fuel tank completely full. Add
gasoline to the fuel tank until the level is 1/4 to
1/2 inch (6 to 13 mm) below the bottom of the
filler neck. This empty space in the tank allows
gasoline to expand.
• Never smoke when handling gasoline, and stay
away from an open flame or where gasoline
fumes may be ignited by a spark.
• Store gasoline in an approved container and
keep it out of the reach of children. Never buy
more than a 30-day supply of gasoline.
• Always place gasoline containers on the ground
away from your vehicle before filling.
• Do not fill gasoline containers inside a vehicle
or on a truck or trailer bed because interior
carpets or plastic truck bed liners may insulate
the container and slow the loss of any static
charge.
• When practical, remove gas–powered
equipment from the truck or trailer and refuel
the equipment with its wheels on the ground.
• If this is not possible, then refuel such
equipment on a truck or trailer from a portable
container, rather than from a gasoline
dispenser nozzle.
• If a gasoline dispenser nozzle must be used,
keep the nozzle in contact with the rim of the
fuel tank or container opening at all times until
fueling is complete.
Warning
Gasoline is harmful or fatal if swallowed.
Long–term exposure to vapors can cause serious
injury and illness.
• Avoid prolonged breathing of vapors.
• Keep face away from nozzle and gas tank or
conditioner opening.
• Keep gas away from eyes and skin.
Using Stabilizer/Conditioner
Use a fuel stabilizer/conditioner in the machine to provide
the following benefits:
• Keeps gasoline fresh during storage of 90 days or less.
For longer storage it is recommended that the fuel tank
be drained.
• Cleans the engine while it runs
• Eliminates gum-like varnish buildup in the fuel
system, which causes hard starting
Important Do not use fuel additives containing
methanol or ethanol.
Add the correct amount of gas stabilizer/conditioner to the
gas.
Note: A fuel stabilizer/conditioner is most effective when
mixed with fresh gasoline. To minimize the chance of
varnish deposits in the fuel system, use fuel stabilizer at
all times.
Filling the Fuel Tank
1. Shut the engine off and set the parking brake.
2. Clean around fuel tank cap and remove the cap. Add
unleaded regular gasoline to fuel tank, until the level is
1/4 to 1/2 inch below the bottom of the filler neck.
This space in the tank allows gasoline to expand. Do
not fill the fuel tank completely full.
3. Install fuel tank cap securely. Wipe up any gasoline
that may have spilled.
Check Engine Oil Level
Before you start the engine and use the machine, check
the oil level in the engine crankcase; refer to Checking the
Engine Oil Level, page 31.
13
Setup
Note: Determine the left and right sides of the machine
from the normal operating position.
Loose Parts
Note: Use the chart below to verify all parts have been shipped.
Step Description Qty. Use
1
2
3
4
5
Handle assembly
Flanged bolt 3/8 x 1 inch
Flanged bolt 3/8 x 1–1/4 inch
Flange nut 3/8 inch
Fuel tank with studs installed
Bolt, 5/16 x 7/8 inch
Lock washer, 5/16 inch
Washer, 5/16 inch
Spring
Hose clamp
E–ring 2 Installing the control rods
Cotter pin
Washer
Hairpin cotter pin 2
1
2
2
4
1
2
2
4
2
1
1
1
Installing the handle assembly
Installing the fuel tank
Installing the speed control rod
Installing the hairpin cotter pins and
washers
6
7
8
No parts needed Checking the tire pressure
No parts needed Activating the battery
No parts needed
14
Checking the hydraulic fluid and engine
oil
Step UseQty.Description
9
10
No parts needed Setting up the hydro control linkage
Oil drain hose
Operator’s Manual
Engine Operator’s Manual
Parts Catalog
Registration card
Step
1
Parts needed for this step:
• 1 Handle assembly
• 2 Flange bolts, 3/8 x 1 inch
• 2 Flange bolts, 3/8 x 1–1/4 inch
• 4 Flange nuts, 3/8 inch
Installing the Handle Assembly
1. Align handle with upper mounting holes in rear frame
(Fig. 2).
1
1
1
1
1
1. Handle assembly
2. Rear frame
3. Flange nut, 3/8 inch
4. Flange bolt, 3/8 x 1 inch
5. Upper mounting hole
Use for draining engine oil
Read before operating machine
Read before operating machine
Fill out and return to Toro
7
8
9
4
2
6
5
1
3
m–6600
Figure 2
6. Lower mounting holes
7. Low position
8. High position
9. Flange bolt, 3/8 x
1–1/4 inch
2. Secure the handle at each upper mounting hole with a
flange bolt (3/8 x 1–1/4 inch) and flange nut (Fig. 2).
3. Select the low position for the lower mounting hole
(Fig. 2).
4. Secure the handle at each lower mounting hole with a
flange bolt (3/8 x 1 inch) and flange nut (Fig. 2).
Note: The handle position can be adjusted to match the
operator ’s height preference.
Note: Handle assembly must be installed before fuel tank
is installed.
15
Step
Note: Tighten left side of shift lever plate until it is
completely tight and then unscrew the locknut one full
turn. This will allow the spring to work.
2
Parts needed for this step:
• 1 Fuel tank with studs installed
• 2 Bolts, 5/16 x 7/8 inch
• 2 Lock washers, 5/16 inch
• 2 Flat washers, 5/16 inch
• 2 Springs
• 1 Hose clamp
Installing the Fuel Tank
1. Align the fuel tank with the top of the rear frame
(Fig. 4).
2. Push the fuel line through the grommet and hole in the
hydraulic oil filter bracket (Fig. 4).
3. Push the fuel line onto the fuel tank connection and
secure it with the hose clamp that is on the fuel line
(Fig. 3).
7
3
4
5
1. Bolt, 5/8 x 7/8 inch
2. Lock washer, 5/16 inch
3. Washer, 5/16 inch
4. Spring
Figure 4
6
3
2
1
5. Locknut
6. Hose clamp
7. Fuel tank connection
m–6583
Note: To ease assembly of the fuel line to fuel tank
connection, apply a light lubricant, such as WD 40, to the
end of the fuel line.
Note: Make sure the fuel line and clamp are on as shown
in Figure 3.
2
3
Figure 3
1. Fuel line
2. Clamp
4. Secure the right side of the fuel tank to the rear frame
(Fig. 4) with 2 bolts (5/16 x 7/8 inch), lock washers
(5/16 inch) and washers (5/16 inch) (Fig. 4).
5. Secure the left side of the fuel tank to the rear frame
(Fig. 4) with washers (5/16 inch), springs and locknuts
(5/16 inch) (Fig. 4).
3. Fuel tank connection
1
m–6504
16
Step
Step
3
Parts needed for this step:
• 2 E–clips
Installing the Control Rods
1. For a starting point, make sure the rod fittings are
threaded approximately 2–1/2 inches (63 mm) onto the
control rods (Fig. 5).
2. Install the rod fittings into the and secure them with
E–rings (Fig. 5).
1
4
2
4
Parts needed for this step:
• 1 Cotter pin
• 1 Washer
Installing the Speed Control
Rod
1. Install the swivel into the speed control crank and
secure it with a washer and cotter pin (Fig. 6).
Note: If necessary move the speed control lever until the
swivel will go into the speed control crank.
1
1. Control ro d
2. Rod fitting
3
Figure 5
m–6601
3. 2–1/2 inch (63.5 mm) from
bottom
4. E–ring
4
5
6
1. Speed control rod
2. Swivel
3. Nut
3
2
3
m–6602
Figure 6
4. Speed control crank
5. Cotter pin
6. Washer
17
Step
Step
5
Parts needed for this step:
• 2 Hairpin cotter pins
Installing the Hairpin Cotter
Pins and Washers
Unused height–of–cut spacers may be stored on posts and
retained by a hairpin cotter.
1. On the opposite side of the muffler, install unused
washers and hairpin cotter pins into front and rear
height–of–cut pins (Fig. 7).
3
2
1
7
No parts needed for this step.
Activating the Battery
Bulk electrolyte with 1.265 specific gravity must be
purchased from a local battery supply outlet.
Warning
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals, and related accessories
contain lead and lead compounds, chemicals
known to the State of California to cause cancer
and reproductive harm. Wash hands after
handling.
Figure 7
1. Hairpin cotter
2. Unused spacers
3. Height–of–cut post
Step
6
No parts needed for this step.
Checking the Tire Pressure
Refer to Page 36 for the correct correct tire pressure.
Danger
m-6505
Battery electrolyte contains sulfuric acid which is
a deadly poison and causes severe burns.
• Do not drink electrolyte and avoid contact with
skin, eyes or clothing. Wear safety glasses to
shield your eyes and robber gloves to protect
your hands.
• Fill the battery where clean water is always
available for flushing the skin.
• Follow all instructions and comply with all
safety messages on the electrolyte container.
1. Remove the battery from the machine. Refer to
Removing the Battery on page 34.
2. Clean the top of the battery with a paper towel.
Note: Never fill the battery with electrolyte while the
battery installed in the machine. Electrolyte can be spilled
on other parts and cause corrosion.
3. Remove the vent caps from the battery (Fig. 35).
4. Slowly pour electrolyte into each battery cell until the
level is up to the “UPPER” line (Fig. 35) on the
battery case.
18
Loading...