Toro 71140, 71180, 71181, 71182, 71184 Service Manual
...
TORO XL LAWN TRACTOR SERVICE MANUAL
Table of Contents – Page 1 of 3
SPECIFICATIONS
DIMENSIONS
HYDRO-GEAR HYDROSTATIC TRANSAXLE USAGE
TURNING RADIUS
ELECTRICAL SYSTEM
TECUMSEH PEERLESS TRANSAXLES
1993 - 1995
1996 - PRESENT
TORQUE SPECIFICATIONS
FASTENER IDENTIFICATION
STANDARD TORQUE FOR DRY, ZINC PLATED, AND STEEL FASTENERS (INCH SERIES)
STANDARD TORQUE FOR DRY, ZINC, AND STEEL FASTENERS (METRIC FASTENERS)
OTHER TORQUE SPECIFICATIONS
SAE GRADE 8 STEEL SET SCREWS
THREAD CUTTING SCREWS (ZINC PLATED STEEL)
CONVERSION FACTORS
WHEEL BOLTS AND LUG NUTS
THREAD CUTTING SCREWS (ZINC PLATED STEEL)
EQUIVALENTS AND CONVERSIONS
DECIMAL AND MILLIMETER EQUIVALENTS
U.S. TO METRIC CONVERSIONS
XL GEAR DRIVE
XL GEAR DRIVE TRANSAXLE REMOVAL - 915 TRANSAXLE
XL GEAR DRIVE TRANSAXLE INSTALLATION - 915 TRANSAXLE
XL GEAR DRIVE TRACTION DRIVE BELT REPLACEMENT PROCEDURE - 915 TRANSAXLE
XL GEAR DRIVE SHIFT LEVER ADJUSTMENT - 915 TRANSAXLE
XL GEAR DRIVE BRAKE ADJUST MENT -915 TRANSAXLE
XL GEAR DRIVE MST-205 TRANSAXLE REMOVAL
XL GEAR DRIVE MST-205 TRANSAXLE INSTALLATION
XL GEAR DRIVE SHIFT LEVER ADJUSTMENTS, MST-205 TRANSAXLE
XL GEAR DRIVE BRAKE ADJUST MENT, MST-205 TRANSAXLE
CHECKING THE BRAK E
ADJUSTING THE BRAKE
XL GEAR DRIVE TRACTION DRIVE BELT REPLACEMENT PROCEDURE, MST-205 TRANSAXLE
CABLE ADJUSTMENT, SHIFT-ON-THE-GO, 915 AND MST-205 TRANSAXLE
XL HYDROSTATIC TRANSAXLES
IDENTIFICATION
HYDRO-GEAR 0500/0750 TRANSAXLE
HYDRO-GEAR 0510 TRANSAXLE
INTERNAL SERVICE
TROUBLESHOOTING CHART
PURGING PROCEDURES
FLUID CHANGE
HXL HYDRO TRANSAXLE REMOVAL - 2000 AND PRIOR
NEUTRAL ADJUSTMENT - HXL HYDRO- 2000 AND PRIOR
BRAKE ADJUSTMENT - HXL HYDRO - 2000 AND PRIOR
TRACTION DRIVE BELT REPLACEMENT ON HXL HYDRO - 2000 AND PRIOR
HXL HYDRO TRANSAXLE REMOVAL - 2001 AND LATER
HXL HYDRO TRANSAXLE INSTALLATION - 2001 AND LATER
TORO XL LAWN TRACTOR SERVICE MANUAL
Table of Contents – Page 2 of 3
XL HYDROSTATIC TRANSAXLES -CONTINUED
NEUTRAL ADJUSTMENT - HXL HYDRO - 2001 AND LATER
BRAKE ADJUSTMENT - HXL HYDRO - 2001 AND LATER
TRACTION DRIVE BELT REPLACEMENT - HXL HYDRO - 2001 AND LATER
CHASSIS
FRONT AXLE REMOVAL
UPPER STEERING SHAFT REMOVAL (NO TILT STEERING)
STEERING RACK REMOVAL
STEERING ASSEMBL Y
TILT STEERING
STEERING SHAFT REMOVAL (TILT STEERING)
STEERING TOWER REMOVAL
STEERING TOWER INSTALLATION
REAR BODY/FENDER ASSEMBLY REMOVAL
INSTALLATION OF THE REAR BODY
ELECTRICAL SYSTEM
RELAY
PURPOSE
LOCATION
HOW IT WORKS
TESTING
SOLENOID
PURPOSE
HOW IT WORKS
TESTING
LOCATION
NEUTRAL SWITCH (USED ON 1999 AND PRIOR LAW N TRACTORS)
PURPOSE
LOCATION
HOW IT WORKS
TESTING
PTO SWITCH
PURPOSE
LOCATION
HOW IT WORKS
TESTING
NEUTRAL SWITCH (USED ON 2000 AND LATER LAWN TRACTORS)
PURPOSE
LOCATION
HOW IT WORKS
TESTING
SEAT SWITCH
PURPOSE
LOCATION
HOW IT WORKS
TEST
KEYCHOICE™ REVERSE OPERATING SYSTEM – USED ON 1999 AND LATER XL LAWN TRACTORS
TESTING THE KEY CHOICE™ REVERSE OPERATING SYSTEM
CHECKING THE KEYCHOICE™ SYSTEM
TORO XL LAWN TRACTOR SERVICE MANUAL
Table of Contents – Page 3 of 3
ELECTRICAL SYSTEM - CONTINUED
KEYCHOICE™ REVERSE OPERATING SYSTEM SWITCH
PURPOSE
HOW IT WORKS
TESTING
REVERSE SWITCH
PURPOSE
LOCATION
HOW IT WORKS
TESTING
KEYCHOICE™ REVERSE OPERATING SYSTEM MODULE
PURPOSE
LOCATION
HOW IT WORKS
TESTING
MOWER
32" MOWER
REMOVING 32" MOWER
INSTALLING 32" MOW ER
BLADE DRIVE BELT
REMOVING THE BLADE DRIVE BELT
INSTALLING THE BLADE DRIVE BELT
SIDE-TO-SIDE MOWER LEVELING
FRONT-TO-REAR BLA DE SLOPE
38" MOWER
REMOVING 38" MOWER
INSTALLING 38" MOW ER
BLADE DRIVE BELT
REMOVING THE BLADE DRIVE BELT
INSTALLING THE BLADE DRIVE BELT
SIDE-TO-SIDE MOWER LEVELING
FRONT-TO-REAR BLA DE SLOPE
44" MOWER
REMOVING 44" MOWER
INSTALLING 44" MOW ER
INSTALLING 44" RECYCLER BAFFLE
REMOVING 44" RECYCLER BAFFLE
BLADE DRIVE BELT
REMOVING THE BLADE DRIVE BELT
INSTALLING THE BLADE DRIVE BELT
ADJUSTING BLADE BRAKES
SIDE-TO-SIDE MOWER LEVELING
FRONT-TO-REAR BLA DE SLOPE
XL Lawn Tractor
PREFACE
This service manual was written expressly for Toro service technicians. The Toro Company has made every effort
to make the information in this manual complete and correct.
Basic mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics
covered in this manual.
For additional information on the electrical system, please refer to the Toro Electrical Demystification Guide (492-
4404). For information specific to the engines used on this unit, refer to the appropriate engine manufacturer’s
service and repair instructions.
We are hopeful that you will find this manual a valuable addition to your service shop. If you have any questions or
comments regarding this manual, please contact us at the following address:
The Toro Company
Consumer Service Training Department
8111 Lyndale Avenue South
Bloomington, MN 55420
The Toro Company reserves the right to change product specifications or this manual without notice.
The hydrostatic transaxle is a sophisticated piece of machinery. Maintain strict cleanliness control during all stages
of service and repair. Cover or cap all hose ends and fittings whenever they are exposed. Even a small amount of
dirt or other contamination can severely damage the system.
Copyright© All Rights Reserved
©2001 The Toro Company
TABLE OF CONTENTS
SPECIFICATIONS
Specifi cations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydro-Gear Hydrostatic Transaxle Usage . . . . . . . . . . . . . . . . . . . . . . . . .
Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tecumseh Peerless Transaxles . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1993 - 1995 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1996 - Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifi cations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Identifi cation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) . . . . . . . . . . . . .
Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) . . . . . . . . . . . . . .
Other Torque Specifi cations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAE Grade 8 Steel Set Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thread Cutting Screws (Zinc Plated Steel) . . . . . . . . . . . . . . . . . . . . . . .
Wheel Bolts and Lug Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thread Cutting Screws (Zinc Plated Steel) . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Decimal and Millimeter Equivalents . . . . . . . . . . . . . . . . . . . . . . . . . .
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-1
1-1
1-2
1-2
1-2
1-2
1-2
1-3
1-3
1-4
1-5
1-6
1-6
1-6
1-6
1-6
1-7
1-7
1-7
XL GEAR DRIVE
XL Gear Drive Transaxle Removal - 915 Transaxle . . . . . . . . . . . . . . . . . . . . .
XL Gear Drive Transaxle Installation - 915 Transaxle . . . . . . . . . . . . . . . . . . . . .
XL Gear Drive Traction Drive Belt Replacement Procedure - 915 Transaxle . . . . . . . . . . . .
XL Gear Drive Shift Lever Adjustment - 915 Transaxle . . . . . . . . . . . . . . . . . . . .
XL Gear Drive Brake Adjustment - 915 Transaxle . . . . . . . . . . . . . . . . . . . . . .
XL Gear Drive MST-205 Transaxle Removal . . . . . . . . . . . . . . . . . . . . . . . .
XL Gear Drive MST-205 Transaxle Installation . . . . . . . . . . . . . . . . . . . . . . .
XL Gear Drive Shift Lever Adjustment, MST-205 Transaxle . . . . . . . . . . . . . . . . . .
XL Gear Drive Brake Adjustment, MST-205 Transaxle . . . . . . . . . . . . . . . . . . . .
Checking the Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XL Gear Drive Traction Drive Belt Replacement Procedure, MST-205 Transaxle . . . . . . . . . .
Cable Adjustment, Shift-On-The-Go, 915 and MST-205 Transaxle . . . . . . . . . . . . . . . .
XL HYDROSTATIC TRANSAXLES
Identifi cation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydro-Gear 0500/0750 Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydro-Gear 0510 Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purging Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2-4
2-6
2-9
2-11
2-12
2-13
2-14
2-15
2-15
2-15
2-16
2-19
3-1
3-1
3-1
3-2
3-2
3-3
3-3
iXL Lawn Tractor Service Manual
TABLE OF CONTENTS
XL HYDROSTATIC TRANSAXLES cont.
HXL Hydro Transaxle Removal - 2000 and Prior . . . . . . . . . . . . . . . . . . . . . .
Neutral Adjustmnet - HXL Hydro - 2000 and Prior . . . . . . . . . . . . . . . . . . . . . .
Brake Adjustment - HXL Hydro - 2000 and Prior . . . . . . . . . . . . . . . . . . . . . .
Traction Drive Belt Replacement on HXL Hydro - 2000 and Prior . . . . . . . . . . . . . . . .
HXL Hydro Transaxle Removal - 2001 and Later . . . . . . . . . . . . . . . . . . . . . .
HXL Hydro Transaxle Installation - 2001 and Later . . . . . . . . . . . . . . . . . . . . . .
Neutral Adjustment - HXL Hydro - 2001 and Later . . . . . . . . . . . . . . . . . . . . . .
Brake Adjustment - HXL Hydro - 2001 and Later . . . . . . . . . . . . . . . . . . . . . . .
Traction Drive Belt Replacement - HXL Hydro - 2001 and Later . . . . . . . . . . . . . . . . .
CHASSIS
Front Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Steering Shaft Removal (No Tilt Steering) . . . . . . . . . . . . . . . . . . . . . .
Steering Rack Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tilt Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Shaft Removal (Tilt Steering) . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Tower Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Tower Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Body/Fender Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation of the Rear Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric PTO Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric PTO Clutch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3
3-10
3-11
3-13
3-16
3-18
3-20
3-21
3-22
4-1
4-1
4-1
4-2
4-3
4-4
4-4
4-5
4-6
4-8
A4-1
A4-2
ELECTRICAL SYSTEM
Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Neutral Switch (Used on 1999 and Prior Lawn Tractors) . . . . . . . . . . . . . . . . . . .
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-1
5-1
5-1
5-2
5-2
5-2
5-3
5-3
5-3
5-4
5-4
5-4
5-4
5-4
5-4
5-4
5-5
5-5
5-5
ii XL Lawn Tractor Service Manual
TABLE OF CONTENTS
ELECTRICAL SYSTEM cont.
Neutral Switch (Used on 2000 and Later Lawn Tractors) . . . . . . . . . . . . . . . . . . .
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KeyChoice™ Reverse Operating System - Used on 1999 and Later XL Lawn Tractors . . . . . . . .
Testing The KeyChoice™ Reverse Operating System . . . . . . . . . . . . . . . . . . . .
Checking the KeyChoice™ System . . . . . . . . . . . . . . . . . . . . . . . . . .
KeyChoice™ Reverse Operating System Switch . . . . . . . . . . . . . . . . . . . . . .
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KeyChoice™ Reverse Operating System Module . . . . . . . . . . . . . . . . . . . . . .
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric PTO Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coil Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring Clutch Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5
5-5
5-5
5-6
5-6
5-6
5-6
5-6
5-6
5-6
5-7
5-7
5-7
5-8
5-8
5-8
5-8
5-8
5-8
5-9
5-9
5-9
5-9
5-9
5-10
5-10
5-10
A5-1
A5-1
A5-1
A5-1
A5-1
A5-2
A5-2
A5-2
A5-2
A5-2
A5-2
A5-3
MOWER
32” Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing 32” Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing 32” Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blade Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Blade Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Blade Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side-to-Side Mower Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front-to-Rear Blade Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6-1
6-2
6-4
6-4
6-4
6-5
6-5
iiiXL Lawn Tractor Service Manual
TABLE OF CONTENTS
MOWER cont.
38” Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing 38” Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing 38” Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blade Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Blade Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Blade Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side-to-Side Mower Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front-to-Rear Blade Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44” Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing 44” Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing 44” Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing 44” Recycler Baffl e . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing 44” Recycler Baffl e . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blade Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Blade Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Blade Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Blade Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side-to-Side Mower Levleing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front-to-Rear Blade Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32” Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32” Mower Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38” Mower with Manual PTO Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . .
38” Mower Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44” Mower with Manual PTO Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . .
44” Mower Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38” Mower with Electric PTO Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing 38” Mower with Electric PTO Clutch . . . . . . . . . . . . . . . . . . . . .
Installing 38” Mower with Electric PTO Clutch . . . . . . . . . . . . . . . . . . . . . .
Replacing the Blade Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Blade Drive Belt, 38” Mower with Electric PTO Clutch . . . . . . . . . . . . .
Installing the Blade Drive Belt, 38” Mower with Electric PTO Clutch . . . . . . . . . . . . . .
Leveling 38” Mower from Side-to-Side . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting 38” Mower Front-to-Rear Blade Slope . . . . . . . . . . . . . . . . . . . . . . .
44” Mower with Electric PTO Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing 44” Mower with Electric PTO Clutch . . . . . . . . . . . . . . . . . . . . .
Installing 44” Mower with Electric PTO Clutch . . . . . . . . . . . . . . . . . . . . . .
Replacing the Blade Drive Belt, 44” Mower with Electric PTO Clutch . . . . . . . . . . . . . . .
Removing the Blade Drive Belt, 44” Mower with Electric PTO Clutch . . . . . . . . . . . . .
Installing the Blade Drive Belt, 44” Mower with Electric PTO Clutch . . . . . . . . . . . . . .
Leveling 44” Mower from Side-to-Side . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting 44” Mower Front-to-Rear Blade Slope . . . . . . . . . . . . . . . . . . . . . . .
6-7
6-7
6-10
6-12
6-12
6-12
6-12
6-13
6-15
6-15
6-17
6-20
6-21
6-21
6-21
6-21
6-22
6-22
6-23
A6-1
A6-1
A6-1
A6-1
A6-2
A6-2
A6-2
A6-2
A6-4
A6-7
A6-7
A6-7
A6-7
A6-9
A6-10
A6-10
A6-12
A6-15
A6-15
A6-16
A6-16
A6-17
iv XL Lawn Tractor Service Manual
Specifications
SPECIFICATIONS
Engines
All tractors since 1993 were manufactured with Briggs & Stratton engines
ranging from 10 to 17 Horsepower. For more information on servicing the
engines, please contact Briggs & Stratton.
Dimensions
32” (81.3cm) XL
Lawn Tractors
Wheel Base:
Length:
Height:
Width (includes mower):
Weight:
48.5” (123.2cm) 47” (119.4cm) 47.5” (120.7cm)
66.5” (168.9cm) 66.5” (168.9cm) 68” (172.7cm)
39.3” (99.8cm) 40” (101.6cm) 42” (106.7cm)
39.3” (99.8cm) 45” (114.3cm) 55” (139.7cm)
375 lbs. Net (168.9kg) 412 lbs. Net (185.6kg) 468 lbs. Net (210.8kg)
Hydro-Gear Hydrostatic Transaxle
38” (96.5cm) XL and HXL
Lawn Tractors
Usage
Fuel
Capacity
7 qts (6.65l) Sector and Pinion
44” (111.8c m) HXL
Steering
Lawn Tractors
Year 12-38 XHL - 16-38 HXL
1993
1994
1995
1996
1997
1998
1999
2000
2001
316-0500
316-0500
321-0500 316-0750
323-0500 316-0750
323-0500 326-0750
323-0500 326-0750
323-0500 326-0750
323-0500 326-0750
15-44 XHL, 16-44HXL,
and 17-44 HXL
16-38 HXL and 17-44 HXL
318-0510
XL Lawn Tractor Service Manual 1 - 1
SPECIFICATIONS
Turning Radius
Model Turning Radius
32” (81.3cm) XL 21.5” (54.6cm) - Left
22” (55.8cm) - Right
38” (96.5cm) HXL and XL 20” (50.8cm) - Left
22” (55.8cm)- Right
44” (111.8cm) HXL 20” (50.8cm) - Left
22” (55.8cm) - Right
Electrical System
Engine Battery
3 amp unregulated / 80 watt A.C. Alternator 12 volt - 160 CCA
Tecumseh Peerless Transaxles
1993 - 1995
mvc-667
Tecumseh Peerless
Model: 915-020
Lubrication: Bentonite grease (available through
Tecumseh)
NOTE: Tractor may have been converted to current MST-205 transaxle.
Tecumseh Peerless
Model: MST-205
Lubrication: 80W90 gear lube
1996 - Present
mvc-668
For further information on servicing Peerless transaxles, contact Tecumseh Products.
1 - 2 XL Lawn Tractor Service Manual
SPECIFICATIONS
Torque Specifications
Recommended fastener torque values are listed in the
following tables. For critical applications, as
determined by Toro, either the recommended torque or
a torque that is unique to the application is clearly
identified and specified in the service manual.
These torque specifications for the installation and
tightening of fasteners shall apply to all fasteners which
do not have a specific requirement identified in the
service manual. The following factors shall be
considered when applying torque: cleanliness of the
fastener, use of a thread sealant (Loctite), degree of
lubrication on the fastener, presence of a prevailing
torque feature, hardness of the surface underneath of
the fastener’s head, or similar condition which affects
the installation.
As noted in the following tables, torque values should
be reduced by 25% for lubricated fasteners to
achieve the similar stress as a dry fastener. Torque
values may also have to be reduced when the fastener
is threaded into aluminum or brass. The specific
torque value should be determined based on the
aluminum or brass material strength, fastener size,
length of thread engagement, etc.
Fastener Identification
Inch Series Bolts and Screws
(A) Grade 1
(B) Grade 5
Figure 1
(C) Grade 8
The standard method of verifying torque shall be
performed by marking a line on the fastener (head or
nut) and mating part, then back off fastener 1/4 of a
turn. Measure the torque required to tighten the
fastener until the lines match up.
Figure 2
Metric Bolts and Screws
(A) Class 8.8 (B) Class 10.9
XL Lawn Tractor Service Manual 1 - 3
SPECIFICATIONS
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
Grade 1, 5, &
Thread Size
# 6 - 32 UNC
# 6 - 40 UNF 17 ± 2 190 ± 20 25 ± 2 280 ± 20
# 8 - 32 UNC
# 8 - 36 UNF 31 ± 3 350 ± 30 43 ± 4 31 ± 3
# 10 - 24 UNC
#10 - 32 UNF 48 ± 4 540 ± 45 68 ± 6 765 ± 70
1/4 - 20 UNC 48 ± 7 53 ± 7 599 ± 79 100 ± 10 1125 ± 100 140 ± 15 1580 ± 170
1/4 - 28 UNF 53 ± 7 65 ± 10 734 ± 113 115 ± 10 1300 ± 100 160 ± 15 1800 ± 170
5/16 - 18 UNC 115 ± 15 105 ± 17 1186 ± 169 200 ± 25 2250 ± 280 300 ± 30 3390 ± 340
5/16 - 24 UNF 138 ± 17 128 ± 17 1446 ± 192 225 ± 25 2540 ± 280 325 ± 30 3670 ± 340
3/8 - 16 UNC 16 ± 2 16 ± 2 22 ± 3 30 ± 3 41 ± 4 43 ± 4 58 ± 5
3/8 - 24 UNF 17 ± 2 18 ± 2 24 ± 3 35 ± 3 47 ± 4 50 ± 4 68 ± 5
7/16 - 14 UNC 27 ± 3 27 ± 3 37 ± 4 50 ± 5 68 ± 7 70 ± 7 68 ± 9
7/16 - 20 UNF 29 ± 3 29 ± 3 39 ± 4 55 ± 5 75 ± 7 77 ± 7 104 ± 9
1/2 - 13 UNC 30 ± 3 48 ± 7 65 ± 9 75 ± 8 102 ± 11 105 ± 10 142 ± 14
1/2 - 20 UNF 32 ± 3 53 ± 7 72 ± 9 85 ± 8 115 ± 11 120 ± 10 163 ± 14
5/8 - 11 UNC 65 ± 10 88 ± 12 119 ± 16 150 ± 15 203 ± 20 210 ± 20 285 ± 27
5/8 - 18 UNF 75 ± 10 95 ± 15 129 ± 20 170 ± 15 230 ± 20 240 ± 20 325 ± 27
3/4 - 10 UNC 93 ± 12 140 ± 20 190 ± 27 265 ± 25 359 ± 34 374 ± 35 508 ± 47
3/4 - 16 UNF 115 ± 15 165 ± 25 224 ± 34 300 ± 25 407 ± 34 420 ± 35 569 ± 47
7/8 - 9 UNC 140 ± 20 225 ± 25 305 ± 34 430 ± 45 583 ± 61 600 ± 60 813 ± 81
7/8 - 14 UNF 155 ± 25 260 ± 30 353 ± 41 475 ± 45 644 ± 61 660 ± 60 895 ± 81
8 with Thin
Height Nuts
In-lb In-lb N-cm In-lb N-cm In-lb N-cm
10 ± 2 13 ± 2 147 ± 23
13 ± 2 25 ± 5 282 ± 30
18 ± 2 30 ± 5 339 ± 56
ft-lb ft-lb N-m ft-lb N-m ft-lb N-m
SAE Grade 1 Bolts, Screws,
Studs, & Sems with Regular
Height Nuts (SAE J995 Grade
2 or Stronger Nuts)
SAE Grade 5 Bolts, Screws,
Studs, & Sems with Regular
Height Nuts (SAE J995 Grade
2 or Stronger Nuts)
15 ± 2 170 ± 20 23 ± 2 260 ± 20
29 ± 3 330 ± 30 41 ± 4 460 ± 45
42 ± 4 475 ± 45 60 ± 6 674 ± 70
SAE Grade 8 Bolts, Screws,
Studs, & Sems with Regular
Height Nuts (SAE J995 Grade
2 or Stronger Nuts)
Note: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
Note: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the
minimum proof load specified in SAE J429. The
tolerance is approximately
value. Thin height nuts include jam nuts.
± 10% of the nominal torque
Note: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
1 - 4 XL Lawn Tractor Service Manual
SPECIFICATIONS
Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners)
Class 8.8 Bolts, Screws, and Studs with
Thread Size
M5 X 0.8 57 ± 5 in-lb 640 ± 60 N-cm 78 ± 7 in-lb 885 ± 80 N-cm
M6 X 1.0 96 ± 9 in-lb 1018 ± 100 N-cm 133 ± 13 in-lb 1500 ± 150 N-cm
M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N-m 27 ± 2 ft-lb 36 ± 3 N-m
M10 X 1.5 38 ± 4 ft-lb 52 ± 5 N-m 53 ± 5 ft-lb 72 ± 7 N-m
M12 X 1.75 66 ± 7 ft-lb 90 ± 10 N-m 92 ± 9 ft-lb 125 ± 12 N-m
M16 X 2.0 166 ± 15 ft-lb 225 ± 20 N-m 229 ± 22 ft-lb 310 ± 30 N-m
M20 X 2.5 325 ± 33 ft-lb 440 ± 45 N-m 450 ± 37 ft-lb 610 ± 50 N-m
Note: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
Note: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Regular Height Nuts
(Class 8 or Strong Nuts)
Note: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately
the nominal torque value. Thin height nuts include jam nuts.
Class 10.9 Bolts, Screws, and Studs with
Regular Height Nuts (
Class 10 or Strong Nuts)
± 10% of
XL Lawn Tractor Service Manual 1 - 5
SPECIFICATIONS
Other Torque Specifications
SAE Grade 8 Steel Set Screws
Recommended Torque
Thread Size
Square Head Hex Socket
1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb
5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb
3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb
1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23, or Type F
Thread Size Baseline Torque*
No. 6 - 32 UNC 20 ± 5 in-lb
Wheel Bolts and Lug Nuts
Thread Size Recommended Torque**
7/16 - 20 UNF
Grade 5
1/2 - 20 UNF
Grade 5
M12 X 1.25
Class 8.8
M12 X 1.5
Class 8.8
** For steel wheels and non-lubricated fasteners.
Thread
Size
No. 6 18 20 20 ± 5 in-lb
Threads per Inch
Type A Type B
65 ± 10 ft-lb 88 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
Thread Cutting Screws
(Zinc Plated Steel)
Baseline Torque*
No. 8 - 32 UNC 30 ± 5 in-lb
No.10 - 24 UNC 38 ± 7 in-lb
1/4 - 20 UNC 85 ± 15 in-lb
5/16 - 18 UNC 110 ± 20 in-lb
3/8 - 16 UNC 200 ± 100 in-lb
Conversion Factors
in-lb X 11.2985 - N-cm
ft-lb X 1.3558 = N-m
No. 8 15 18 30 ± 5 in-lb
No. 10 12 16 38 ± 7 in-lb
No. 12 11 14 85 ± 15 in-lb
* Hole size, material strength, material thickness and
finish must be considered when determining specific
torque values. All torque values are based on nonlubricated fasteners.
N-cm X - 0.08851 = in-lb
N-cm X 0.73776 - ft-lb
1 - 6 XL Lawn Tractor Service Manual
Equivalents and Conversions
SPECIFICATIONS
XL Lawn Tractor Service Manual 1 - 7
THIS PAGE INTENTIONALLY LEFT BLANK
1 - 8 XL Lawn Tractor Service Manual
XL GEAR DRIVE
XL Gear Drive Transaxle Removal -
915 Transaxle
1. Disconnect battery cables and remove the battery
and battery tray. Remove the mower deck (refer
to “Mower” section on page 6 - 1).
2. Raise the rear of the tractor and remove the right
and left rear tires. Put jack-stands under the
frame, just in front of the transaxle (Figure 3).
4. Loosen the left transaxle belt guide and move it
away from the belt. The right transaxle belt guide
needs to be removed (Figure 5).
Figure 5
5. Unhook the idler spring from the idler assembly
(Figure 6).
mvc-796
Figure 3
3. Remove the rear hitch panel. There are 2 bolts
and nuts holding the seat springs and 2 bolts and
nuts on each side of the rear panel (Figure 4).
Figure 4
mvc-794
mvc-795
Figure 6
mvc-798
XL Lawn Tractor Service Manual 2 - 1
XL GEAR DRIVE
6. Remove the nut on the shift tie rod (Figure 7).
Figure 7
mvc-800
7. Remove the bolt and nut on the left side shift pivot
clamp and slide the shift pivot rod so you can
remove the shift tie rod (Figure 8).
8. Remove the nut and washer holding the left side
torque strap leaving the torque strap bolted to the
frame (Figure 9).
Figure 9
mvc-803
9. Remove both the top and bottom washer and nut
from the right side torque strap (Figure 10).
Figure 8
mvc-802
Figure 10
mvc-806
2 - 2 XL Lawn Tractor Service Manual
XL GEAR DRIVE
10. Remove the brake return spring (Figure 11).
Figure 11
11. Unhook the brake spring from the clutch/brake rod
(Figure 12).
mvc-808
A
12. Before removing the 4 transaxle bolts, put a floor
jack under the transaxle so you can lower it from
the frame. Remove the 4 bolts, washers, and nuts
(Figure 13).
Figure 13
13. Lower the transaxle slightly so you can free it from
the two front torque straps. Unhook the brake
spring from the transaxle brake arm (Figure 14).
mvc-810
B
Figure 12
(A) Spring (B) Clutch/brake rod
XL Lawn Tractor Service Manual 2 - 3
iso3
Figure 14
mvc-811
XL GEAR DRIVE
14. The transaxle should be free from the frame now
(Figure 15).
Figure 15
mvc-813
XL Gear Drive Transaxle Installation
- 915 Transaxle
1. Raise the transaxle to the frame making sure the
brake lever fits through the slot in the frame.
Reinstall the brake spring on the brake lever
(Figure 14 and Figure 16).
2. Install the right and left torque straps to the frame
and the transaxle, do not tighten. Install the 4 axle
bolts, washers, and nuts and tighten first. Then
tighten the torque straps (Figure 17).
Figure 17
3. Install the left side shift pivot clamp on the shift
pivot rod before securing the clamp to the frame.
Make sure the shift tie rod is reinstalled in the hole
in the shift pivot rod. Tighten the shift pivot clamp
and the shift tie rod (Figure 18).
mvc-816
Figure 18
Figure 16
2 - 4 XL Lawn Tractor Service Manual
mvc-814
mvc-817
XL GEAR DRIVE
4. Install brake spring to the clutch/brake rod (Figure
19).
A
B
Figure 19
(A) Spring (B) Clutch/brake rod
5. Install belt around the transaxle pulley. Reinstall
the idler spring to the idler assembly (Figure 20).
iso3
6. Install the right and left belt guides and adjust so
they are within 1/8” (3mm) of the transaxle pulley
and drive belt (Figure 21). Note direction of belt
guide installation, right hand points forward, left
hand points rearward.
1/8” (3mm)
1/8” (3mm)
Figure 21
7. Connect the brake return spring to the brake lever
(Figure 22).
mvc-818
Figure 20
XL Lawn Tractor Service Manual 2 - 5
mvc-798
Figure 22
mvc-819
XL GEAR DRIVE
8. Install the rear hitch panel. There are two bolts,
washers, and nuts on each side of the plate and 2
bolts, washers, and nuts for the seat springs
(Figure 23).
Figure 23
9. Install the right and left rear tires. Install the
battery and battery box. Note: Make sure the
battery drain tube is installed through the rear hole
of the frame (Figure 24; rear hitch panel removed
for clarity).
mvc-795
10. Check the following items:
A. The Shift-On-The-Go for proper adjustment. If
adjustment is needed, (refer to “Cable
Adjustment, Shift-On-The-Go, 915 and MST205 Transaxle” on page 2 - 19).
B. Brake Adjustment. If adjustment is needed,
(refer to “XL Gear Drive Brake Adjustment -915
Transaxle” on page 2 - 11).
C. Shift Lever Adjustment. If adjustment is
needed, (Refer to “XL Gear Drive Shift Lever
Adjustment - 915 Transaxle” on page 2 - 9).
11. Install mower deck; see instructions in the Mower
section.
12. Check all safety switches to make sure they are
operating properly.
XL Gear Drive Traction Drive Belt
Replacement Procedure - 915
Transaxle
1. Disconnect battery and remove battery and
battery tray. Remove mower deck. (Refer to
Mower section.)
Figure 24
mvc-639
2. Remove the rear hitch panel. There are 2 bolts
and nuts holding the seat springs and 2 bolts and
nuts on each side of the rear panel (Figure 25).
Figure 25
mvc-795
2 - 6 XL Lawn Tractor Service Manual
XL GEAR DRIVE
3. Loosen and move the right and left engine belt
guides (Figure 26).
Figure 26
mvc-821
4. Loosen the left side transaxle belt guide. Remove
the right side transaxle belt guide (Figure 27).
5. Remove the idler spring on the idler assembly.
Remove the idler pulley and belt guide (Figure
28). Remove the drive belt.
Figure 28
mvc-824
6. Install new belt around the engine drive pulley
(Figure 29).
Figure 27
mvc-796
Figure 29
mvc-825
XL Lawn Tractor Service Manual 2 - 7
XL GEAR DRIVE
7. Route belt back over the pedal pivot rod, the idler
pivot bracket, and around the transaxle pulley
(Figure 30).
Figure 30
8. Install the idler pulley to the idler bracket. Note
the correct hole location of the bolt and nut
retaining the pulley and belt guide bracket (Figure
31).
mvc-826
9. Hook the idler spring to the idler bracket (Figure
32).
Figure 32
10. Install the right side belt guide and adjust to within
1/8” (3mm) of the transaxle pulley and belt. Adjust
and tighten the left belt guide so it is within 1/8”
(3mm) of the transaxle pulley and belt (Figure 21
and Figure 33).
mvc-829
1/8” (3mm)
Figure 31
2 - 8 XL Lawn Tractor Service Manual
mvc-828
Figure 33
mvc-796
XL GEAR DRIVE
11. Recheck the routing of the belt (Figure 34).
Figure 34
12. Install the mower deck. (Refer to Mower Deck
section). Make sure the engine belt guides are
adjusted so they are within 1/8” (3mm) of both the
engine and mower drive pulley.
13. Install battery and battery tray making sure the
battery drain tube is installed in the rear hole of
the frame (Figure 35). Install the rear hitch panel
(Figure 25).
mvc-833
14. Check the following:
A. The Shift-On-The-Go for proper adjustment. If
adjustment is needed, (refer to “Cable
Adjustment, Shift-On-The-Go, 915 and MST205 Transaxle” on page 2 - 19).
B. Brake Adjustment. If adjustment is needed,
(refer to “XL Gear Drive Brake Adjustment -915
Transaxle” on page 2 - 11).
C. Shift Lever Adjustment. If adjustment is
needed, (refer to “XL Gear Drive Shift Lever
Adjustment - 915 Transaxle” on page 2 - 9).
15. Check all safety switches to make sure they are
operating properly.
XL Gear Drive Shift Lever
Adjustment - 915 Transaxle
It is VERY important the shift lever is properly aligned
with the shift gates.
If the gear shift lever and shift gates do not properly
align, you may encounter the following symptoms:
1. No reverse.
2. No fifth gear.
3. Jumping out of gear.
Figure 35
If the misalignment is ignored for a period of time,
severe transaxle damage will result.
Adjust using the following procedure:
1. Disconnect the battery cables and remove the
battery and battery tray.
mvc-639
XL Lawn Tractor Service Manual 2 - 9
XL GEAR DRIVE
2. Remove the rear hitch panel by removing the two
bolts and nuts holding the seat springs and two
bolts and nuts located on each side of the hitch
panel. Loosen the fastener securing the front
cable guide to remove tension from the shift cable
(Figure 36).
Figure 36
mvc-834
3. Remove the rubber shift gate cover (Figure 37).
4. Shift the transaxle through each gear to verify the
gear shift lever centers in each gate as the internal
transaxle detents are felt. The lever should also
“detent” into 5th gear and reverse (Figure 38).
That is, the shift lever should not contact the side
of the metal “fingers” of each gate as the lever
enters the gate.
Figure 38
mvc-836
5. If the shifter does not align with the gates, loosen
the bolt and nut between the shift pivot and the
shift pivot lever and adjust (Figure 39).
Figure 37
mvc-835
Figure 39
mvc-840
2 - 10 XL Lawn Tractor Service Manual
XL GEAR DRIVE
6. If the shifter still does not go into 5th gear, loosen
the jam nut on the tie rod end of the shift arm and
remove the nut. Rotate the tie rod end until the
gear shift lever is centered in the 5th gear gate.
Place the shift arm on the gear selector shaft and
verify that neutral, reverse, and fifth gears properly
align. Reinstall the shift arm fastener and tighten
the jam nut (Figure 40).
Figure 40
(1) Jam Nut
(2) Fastener
7. Reassembly:
A. Ensure the transaxle and engine pulley belt
guides are positioned 1/8” (3mm) away from
the drive belt.
B. Adjust the transaxle shift cable (refer to “Cable
Adjustment, Shift-On-The-Go, 915 and MST205 Transaxle” on page 2 - 19.)
C. Reinstall the shift gate cover, rear hitch panel,
battery, and battery tray. Note: Make sure the
battery drain tube is installed in rear hole of the
frame (Figure 35). Reconnect the battery
cables.
D. Test drive the tractor and verify all adjustments
and safety switches are operating properly.
(3) Shift Arm
HL11014
XL Gear Drive Brake Adjustment 915 Transaxle
The brake is located on the right side of the rear axle,
inside the rear tire. If the brake does not hold securely
or stopping power is insufficient, an adjustment is
required (Figure 41).
Figure 41
1. Park the machine on a level surface, disengage
the blade control (PTO), shift into neutral, set the
parking brake, and turn the ignition key to “OFF” to
stop the engine.
2. If the rear wheels lock and skid when you push the
tractor forward, no adjustment is required. An
adjustment is required if the wheels turn and do
not lock.
3. To increase braking resistance, tighten the brake
adjusting nut (Figure 41) 1/8 turn clockwise; then
check the brake again. Continue this adjusting
and checking process until the brake is set
properly.
If the brake system does not respond to
adjustment, the brake pads and possibly the brake
disc, require replacement.
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4. Push down on the clutch/brake pedal to release
the parking brake.
IMPORTANT: With the parking brake released,
the rear wheels must rotate freely when you push
the tractor. If the brake seems to “drag”, loosen
the adjusting nut slightly until the wheels rotate
freely.
XL Lawn Tractor Service Manual 2 - 11
XL GEAR DRIVE
XL Gear Drive MST-205 Transaxle
Removal
1. Disconnect battery cables and remove battery and
battery tray. Remove mower deck (refer to
“Mower” section on page 6 - 1). Lift the rear of the
tractor and remove both the right and left rear tires
(Figure 42).
Figure 42
2. Remove the rear hitch panel, removing the two
bolts and nuts holding the seat springs and two
bolts and nuts located on each side of the hitch
panel (Figure 43).
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3. Remove the right and left transaxle belt guides.
Put the park brake on and then slip the traction
drive belt off the transaxle pulley (Figure 44).
A
Figure 44
(A) Belt Guides
4. Release the park brake and disconnect the brake
spring (A) at the idler arm assembly. Remove the
brake return spring (B) (Figure 45).
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A
B
Figure 45
(A) Brake Spring (B) Brake Return Spring
Figure 43
2 - 12 XL Lawn Tractor Service Manual
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mvc-0005
XL GEAR DRIVE
5. Disconnect the shift link at the transaxle shift lever
(Figure 46).
Figure 46
6. Use a floor jack to support and lower the transaxle
from the frame. Unbolt and remove the two torque
strap bolts located in the front of the transaxle.
Remove the 4 axle bolts holding the transaxle to
the frame (Figure 47).
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XL Gear Drive MST-205 Transaxle
Installation
1. Raise the transaxle up to the frame and install the
4 axle bolts and 2 torque strap bolts. Tighten all 6
bolts (Figure 48).
A
Figure 48
(A) Torque Straps
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Figure 47
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2. Connect the brake spring between the clutch/
brake rod and the transaxle brake lever. Install
the brake return spring, located between the
transaxle brake lever and the axle frame bracket.
A
B
Figure 49
(A) Brake Spring (B) Brake Return Spring
mvc-0005
XL Lawn Tractor Service Manual 2 - 13
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