Copyright Shivers Mfg, Update Manual

Transcription

1 Copyright Shivers Mfg, Update Manual

2 2008 Update Manual Kohler Kawasaki Overly Aggressive Transmissions Boss SR1200 Belt Issues Joystick Construction Twinstick Construction Clutches Spindles Mufflers Boss 60 Inch Deck Adjusting Travel Dampeners Electrical Replacement Parts

3 2008 Country Clipper Update Manual Kohler

4 1 Kohler Engines 2 Remember the Basics Spark Fuel Compression Timing Air Keep a Troubleshooting Guide Nearby 3 Kohler Engines 4 Common Causes of Engine Troubles Smoking (Blue, Black, White) Leaking Oil Engine Will Not Crank Cranks But Will Not Start Excessive Engine Noise After-Bang Backfire While Running Runs Roughly Low Power Hunting/Surging Kohler Engines Smoking (Blue - Oil Consumption) Incorrect Oil Viscosity/Type Crankcase Overfilled Worn Engine Components Normal Wear Abuse Head Gasket Failure Smoking (Blue - Oil Consumption) Breather problem Crankcase Not Sealed Breather Reed Not Seating (Broken) Oil Return Plugged Assembled Wrong Oil Ring Failure Due to Overheating

5 5 Kohler Engines 6 Kohler Engines Smoking (Blue Fuel) Old/Seasonal Fuel Winter/Summer Blend Fuel Fuel Additives Aged Fuel Smoke Will Smell Like Fuel Smoking (White Rich Running) Normally at Start-Up Carburetor Malfunction Plugged Vent in Fuel Cap Oil in Combustion Chamber 7 Kohler Engines 8 Kohler Engines Leaking Oil Oil Level Too High Crankcase Pressure Gasket or Seal Leak Crack/Hole in Block Structural Failure Engine Will Not Crank Loose or Corroded Connections Safety Interlock Switch Dead/Weak Battery Wrong Key Switch

6 9 Kohler Engines 10 Kohler Engines Cranks But Will Not Start Fuel, Spark or Compression Choke Closed (All the Way) Cam Worn or Out of Time Fuel Cap Not Vented Cranks But Will Not Start Battery Connected Backwards Blown Diode in Harness 11 Kohler Engines 12 Kohler Engines Excessive Engine Noise Low or No Oil Incorrect or Inadequate Oil Low or No Oil Pressure Wrong Viscosity Oil Faulty Lifters Improper Valve Lash Failed Compression Release Smoking (Black Over Fueling) Choke Partially Closed or Misadjusted Carburetor Malfunction Float Set Too High Needle & Seat Not Sealing Air Jets Plugged Plugged Vent in Fuel Cap Weak Spark at Spark Plug Air Filter Plugged

7 13 Kohler Engines 14 After-Bang (Backfire) Improper Shutdown Governed Idle Not Set Correctly Plugged or Damaged Muffler Backfire While Running Plugged or Damaged Muffler Water in Fuel Cam Lobe Worn Valve Not Sealing Burned Sticking Lifter pumped 15 Kohler Engines 16 Low Power Governor Setting Intake Gasket Leak (Lean Running) Restricted or Damaged Exhaust System Worn Cam Lobe External Load Fuel Supply Issues Restricted Air Cleaner Kohler Engines Runs Rough - Will Not Accelerate Leaking Intake Carburetor Issue Float Set Too Low Build-Up or Obstructions in Jets Improper Fuel Mixture E85 Blends Fuel Additives Weak Spark or Ignition Timing Cam Timing or Worn Lobes Kohler Engines Hunting/Surging Governor Initial Adjustment Spring Location Binding or Friction Lean Condition Fuel Supply Issues

8 17 Tools and Aids 18 Tools and Aids Leakdown Tester S Purpose To determine if valves or rings are leaking by using pressurized air in the combustion chamber. Leakdown Tester S Instructions 1. Run Engine For 3-5 Minutes to Warm Up 2. Remove Spark Plug(s) and Air Filter 4. Rotate Crankshaft Until Piston is at TDC on Compression Stroke 5. Ensure Crankshaft is Locked in Position to Continue Testing 5. Install Adapter Hose into Spark Plug Hole. 6. Connect Air Source of at Least 50 psi to Tester 19 Tools and Aids 20 Tools and Aids Leakdown Tester S Instructions (cont.) 7. Adjust the regulator knob until the gauge needle is in the yellow set area at the low end of the scale. 8. Connect the tester to the adapter hose while firmly holding the engine at TDC. 9. Note the gauge reading and listen for escaping air from the carburetor, exhaust and breather hose. Leakdown Tester S The gauge reading indicates the severity of the leak. Air Escaping From: Crankcase Breather Exhaust Carburetor Cause Leak Past Rings or Head Gasket Internally Leaking Exhaust Valve Leaking Intake Valve

9 21 22 Tools and Aids Vacuum/Pressure Gauge S Purpose To identify the amount of either pressure or vacuum in the crankcase Tools and Aids Ignition Tester 18Kv S Purpose The 18Kv is used to test for strong, consistent spark output on CD ignition systems. Use when testing Courage and Command Twin ignition systems. Tools and Aids Vacuum/Pressure Gauge S Instructions 1. Insert the rubber stopper with gauge into the oil fill hole. Note: Make sure the gauge is at 0 reading. 2. Start the engine and run at no-load high idle speed ( RPM) 3. Observe the gauge reading. Movement to the left of 0 is vacuum, and movement to the right indicates pressure. 4. Correct crankcase vacuum should be a minimum of 4 Inches of Water Column Tools and Aids Ignition Tester 18Kv S The 18Kv is used to test spark on CD ignition systems. Use this tester when checking Courage and Command Twin.

10 25 26 Ignition Tester 18Kv S Instructions 1. Disconnect high tension lead of the ignition to be tested from the spark plug. 27 Tools and Aids 2. Install the lead onto the appropriate tester. 3. Connect the ground clip of the tester to a secure ground location on the block. 4. Engage the starter and observe the spark at the tester. You should find a good blue consistent spark. Tools and Aids Oil Pressure Test Kit S Instructions 1. With engine off, remove the oil filter and install test adapter with gauge. A two foot hose is supplied in the kit and can be installed between the gauge and adapter. 2. Some engines offer alternate locations to check oil pressure. If this is an option, remove the 1/8 pipe plug and install the test gauge. 3. Start the engine and observe the reading on the gauge. Minimum oil pressure is 3200 RPM and low idle. Tools and Aids Oil Pressure Test Kit S Purpose To check oil system pressure at the oil filter, or any location where a 1/8 pipe tap is accessible.

11 2008 Country Clipper Update Manual Kawasaki

12 1 2 Leak Down Tester Verify Combustion Chamber Condition Cylinder, rings, valves Necessary Diagnostic Tools Use this test when the engine has: Oil consumption Low power Hard starting Oil leaking from lower crank case seal (vertical engines only) Excessive oil from the carburetor air box 3 4 Compression Tester Coolant Pressure Tester Use this test when the engine has: Broken recoil studs Hard starting problems Electric starter failures Detonation Oil consumption Low power For engines with an ACR, typical compression measurements may not be greater than 95psi. Simulates Running Pressure No need to disassemble the engine Check system for its ability to hold pressure If system does not hold pressure, try to determine leak location with out disassembling the engine

13 5 6 Coolant Leak Detector ECU Adaptor Use Before Engine Disassembly Helps find hairline cracks Leaks that might go undetected Is it the head gasket or the cylinder head that is leaking? If necessary, disassemble the engine and inspect See what the ECU is seeing Used to measure circuit voltage or resistance 7 8 Multi-Meters Spark Testers Verify Circuits/Components See Service Manual for specifications Digital Meters Readings may very from Service Manual The adjustable gap spark tester Simulates combustion chamber conditions by loading the coil Running Gap Tester Can help detect intermittent spark Does not give an indication of the quality of the spark

14 9 Tachometer 10 Clear Fuel Line Engine speed is important for: Performance Safety Is determined by the OEM Verify Fuel Supply Benefits Saves time Readily available inexpensive 11 Auxiliary Fuel Supply 12 Isolates the engine from the fuel supply Gravity feed the carburetor directly

15 13 14 Fuel Troubleshooting Fuel and Carburetion First, engine must be mechanically sound Visual Inspection Fuel leaks Inlet Bowl gasket Porosity Check for air leaks at Gaskets Throttle / choke shaft 15 Surging 16 Manually control throttle shaft Carburetor or governor? Verify condition by applying the choke Does engine smooth out? Minor restrictions can cause this Could it be a leaking gasket? Contamination Small amounts of contamination in the idle circuitry can cause the engine to surge.

16 17 18 Governor Surge Rich Running Choke does not smooth out engine Governor preset Worn linkage Worn governor plates Worn bushing Correct air filter? Was a canister air filter installed? Were the high speed jets changed? Before cleaning or replacing the carburetor, check: Cylinder leak-down Valve lash Ignition coils Choke Oil condition Exhaust system Engine Electrical Systems Electrical Systems And Troubleshooting Troubleshooting electrical systems can be difficult. Make sure you have the Service Manual It is helpful to break the systems down - Charging system - Ignition system - Starting system Use a systematic approach

17 21 22 Break Systems Down Charging System Focus on what is needed Includes Charging system Battery Photo copy diagram Highlight suspect circuit Flywheel inside magnets Stator coil Regulator Fuses Key switch Machine harness Grounding circuit Does not include Any part of the ignition circuit Fuel injection circuit Amp Charging System Amp Charging System Most common 15 Amp system One long copper winding Insulated from the stator frame One wire Magnetic field rotates - AC voltage at ends Out to regulator C D Testing the 15 Amp system Check the Stator output AC Voltage Check the stator resistance Check for a short to ground on the stator Check for battery voltage at the regulator More than ½ volt difference indicates machine harness issue If all good then regulator is failed Stator good if output above 26v 3000 RPM

18 Amp Regulator Rectifier Charging System Test Harness Rectifies AC to DC Changes stator output to pulsating DC DC pulsations are smoothed by battery Regulates output Senses system voltage and system needs Excessive power is shorted to ground AC From Stator DC From and to battery Used to by pass machine harness 15 amp fuse, wire, connectors Remove harness connection at regulator output tab Attach by-pass harness to battery positive terminal then to regulator If system now works failure is in machine harness Amp Charging System 20 Amp Charging System System similar to 15 amp system Stator AC output Rectifies AC to DC Changes stator output to pulsating DC DC pulsations are smoothed by battery Regulates output Senses system voltage and system needs Excessive power is shorted to ground What do the wires do? Stator input two black wires Orange OEM optional charging light Gray engine ground Red regulator output Yellow system voltage sensor

19 29 20 Amp Battery Not 30 Charging 20 Amp Overcharge Before replacing regulator verify Battery and stator good With key switch on check: Record battery voltage Measure voltage at yellow and red terminals - use gray wire as ground Should match battery If similar voltage at both terminals and no system voltage increase then bad regulator Suppose the battery was overcharged Check for battery voltage at yellow terminal Bad connection in sensing circuit can add resistance Key switches Corrosion Fuse connections Clutch Coil Clutch Coil Clutch coil Two shorter windings Secured to stator frame at one end Magnetic field rotates - AC changed to DC with diodes Clutch coil testing TEST MACHINE FIRST!!! Testing open circuit voltage may yield 40 volts DC or more Electrical output is load dependent Voltage will vary with RPM and clutch load A To machine wire harness Winding 1 Winding 2 Full wave AC from Winding 1. Full wave AC from Winding 2. Half wave pulsating DC from Winding 1. Half wave pulsating DC from Winding 2. Full wave pulsating DC from Windings 1 & 2. A DC supply to machine wire harness

20 33 34 Stator Output Break Systems Down Power limited by... Number of windings Size of windings Magnetic field strength Speed of rotating magnetic field Caused by arcing from corrosion - NOT overcharging None of these can improve over time to increase Stator output!! Magneto Ignition Magneto Ignition system Includes Flywheel outer magnet Ignition coils/leads Plugs Stop circuit -Key switch -Wire harness -Operator safeties Magneto Ignition - normal operation Does not include Flywheel inside magnets Stator Regulator Fuses Battery Key Switch Machine Safety Interlocks RUN Key switch is open Flywheel rotates clockwise Plugs fire on every revolution Note: Diodes are shown externally for clarity. Key Switch

21 37 Magneto Ignition - 38 normal operation Magneto Ignition - normal operation RUN Key switch is open Flywheel rotates clockwise Plugs fire on every rotation RUN Key switch is open Flywheel rotates clockwise Plugs fire on every rotation Coil #2 trigger connects primary coil to ground causing spark plug to fire Diode on Coil #1 prevents accidental grounding of Coil #2 Key Switch Magneto Ignition normal operation Coil #1 trigger connects primary coil to ground causing spark plug to fire Diode on Coil #2 prevents accidental grounding of Coil #1 Magneto Ignition - normal operation Key Switch RUN Key switch is open Flywheel rotates clockwise Plugs fire on every rotation OFF Key switch is closed Coil voltage shorts to ground, preventing trigger operation Key Switch Key Switch

22 41 Magneto Ignition - 42 no spark one side Magneto Ignition - no spark one side RUN Key switch is open Flywheel rotates clockwise Diode on Coil #1 is shorted, grounding Coil #2 Coil #1 operates normally Coil #1 must be replaced to restore normal operation of Coil #2 Key Switch RUN 43 Review-Charging Systems 44 Key switch is open Flywheel rotates clockwise Diode on Coil #2 is shorted, grounding Coil #1 Coil #2 operates normally Coil #2 must be replaced to restore normal operation of Coil #1 Note: Diodes are shown externally for clarity. #2 #1 Key Switch Review-Ignition Systems Check system voltage Check stator Check harness Check regulator Know your system Check for spark Check harness Check air gap Check magnets

23 2008 Country Clipper Update Manual Overly Aggressive Transmissions

24 Boss Shift Linkage Inspection And Possible Reverse Shock Valve Replacement This procedure is for only Boss SR1200 or Boss SR1205 Series Mowers.

25 1 2 Remove side panels. Check all linkages; make sure all the ball joints are moving freely. Check for radial (up and down) slack in the cross shaft. 3 4 Brake Band Mounting Bolt Check the dampeners to make sure the mower has the correct ones. The joystick dampener (H-2467) has maroon writing and the part number. Check the wheel hubs to see if they are dragging against the wheel motor mounting bolts. At this time check the brakes to see if they are too tight.

26 5 6 Check the joystick. Test the dampeners in light and heavy position. Remove the fan covers for better accessibility. 7 8 Check the shift levers on the pump to see if they are broken. Replace any broken parts. Move the joystick forward or back to move the shift lever out of the way to expose the shock valve.

27 9 10 Old Shock Valve New Shock Valve 044 If necessary, replace the shock valve only on the reverse side of the pump. The reverse side is the outside or shift lever side of the pump Remove the old shock valve. The numbers will read New shock valve with spring and plug. The numbers will read

28 13 14 Insert shock valve and spring into plug. Place the valve in the pump Repeat this procedure on the reverse shock valve on the other transmission. Use a torque wrench to torque the shock valve. Torque the valve to inch pounds.

29 17 18 Replace the fan covers and side panels Test drive the mower. Check the oil level in the tank after driving. Fill with 20W-50 motor oil.

30 2008 Country Clipper Update Manual Boss SR1200 Belt Issue

31 1 2 Boss SR1200 Belt Issue Boss SR1200 Belt Issue The SR1200 Boss tractor has experienced some hydro belt issues. A mower that has had a belt issue has a tendency to have more. Country Clipper has attributed this to several possible causes: Check the tension spring to be sure it has the correct tension. Check the hydro pulley to make sure it is placed on the hydro pump properly. 3 4 Boss SR1200 Belt Issue Boss SR1200 Belt Issue Check the idler pulley to be sure the edges of the lip are not sharp and rough. Make sure the belt is not running against the idler pulley lip (upper or lower).

32 5 Boss SR1200 Belt Issue 6 Boss SR1200 Belt Issue Make sure the bushings are ok in the idler arm. Replace the belt with the new wrapped D-3777-W belt. 7 8 Boss SR1200 Belt Issue Boss SR1200 Belt Issue The hydro pulley can be placed on the pump upside down. Be sure to check to see if it is placed on the hydro correctly. The hydro belt should not run against the lip of the flat idler pulley. Also check the edge of the pulley for extremely sharp edges and rough spots.

33 9 10 Boss SR1200 Belt Issue Boss SR1200 Belt Issue The hydro spring extension has two holes in it for the belt that holds the spring. The bolt should be in the inside hole, as shown. The new idler arm ( A) comes as an assembly. The pin goes into the Teflon bushing very hard. 11 Boss SR1200 Belt Issue The old hydro idler arm ( A) has a smaller tube with 2 oil lite bushings pressed into it. The bushings sometimes wear out prematurely, allowing the arm to tip, throwing the belt off.

34 2008 Country Clipper Update Manual Joystick Construction

35 1 2 Joystick Construction A A Joystick Construction The A Joystick Assembly is the same as the A except for the safety switch. The old unit had an E-6074 switch. The new unit has an E Joystick Construction 4 Joystick Construction Teflon bushing

36 2008 Country Clipper Update Manual Twinstick Construction

37 1 2 Twin Stick Construction Twin Stick Construction A A 3 4 Twin Stick Construction Twin Stick Construction Forward handle stop (adjustment) Handle closeness adjustment Reverse handle stop (adjustment) Jam Nut Fiber Washer Cupped Washer Threaded Hole

38 2008 Country Clipper Update Manual Clutches

39 1 Clutches 2 Clutches The clutch used on mid-mounts up to the 1 ½ crank. This supersedes the older clutches. This is the clutch used on out fronts prior to the 03 series out fronts. 3 Clutches 4 Clutches The Magstop Clutch used on all 1 1/8 crankshafts starting with the 2001 series mid mounts, not including the 1205 series Boss. The magstop clutch used on all 1 crank engines.

40 5 6 The Magstop clutch used on the 1205 series Boss. 1 ½ shaft used on the grassbagger. 7 E-6276 Magstop clutch used on the 03 series out front mower. This clutch looks very much like the E-6247 but runs backward.

41 2008 Country Clipper Update Manual Spindles

42 1 Spindles 2 Spindles The difference between the two spindles are the tapered flange and the milled spots for spacer washers on the rear holes. The 609F-019A spindle does not work well with the A 3 Spindles 4 Note the milled circles for spacer washers on the 609F- 019A. Also a small amount is cut from the leading edge of the flange to allow it to set flat with the spacer washers. Note the thickness of the flange top and bottom on the 609F-019A spindle. Spindles The flange thickness is uniform all the way around on the A. The A comes with a metric grease zerk (H- 2546), but does not come with the Woodruff Keys.

43 5 6 Spindles Spindles The only serious problem so far with the A is that the flange holding the top bearing is too light. This problem is being addressed. If you have a mower with the 609G-019A spindles and spacer washers, use 609F-019A for replacement spindles. If it has a A, replace with A spindles.

44 2008 Country Clipper Update Manual Mufflers

45 1 2 Mufflers Mufflers H-2474 Country Clipper purchases mufflers for the Briggs and Stratton twin, the 25hp, 37hp, and 26hp Kawasaki. 3 4 Mufflers This muffler fits the 26 hp Kawasaki Liquid Cooled Engine. Mufflers H-2284 H-2544 This muffler fits the 19hp, 23hp, and 25hp Kawasaki engine. This muffler fits the big block 37hp and 30 hp Kawasaki.

46 5 Mufflers This muffler fits the twin cylinder Briggs and Stratton. Notice the brace welded to the barrel of the muffler. H-2464

47 2008 Country Clipper Update Manual Boss 60 Inch Deck

48 1 2 SR Deck SR Deck The new 60 deck for 1205 series Boss. 3 4 SR Deck Longer flexible Idler Larger Idler Pulley SR Deck Larger spindle pulleys Tapered pulley covers

49 5 SR Deck 6 SR Deck 7 Both the cross deck belt and the engine to deck belt on the 60 deck are the same. SR Deck The old deck has square pulley covers. The old deck has smaller pulleys and A section cross deck belt.

50 2008 Country Clipper Update Manual Adjusting Travel

51 1 Adjusting Travel 2 Adjusting Travel The twinstick JAZEE PRO and the new twinstick JAZEE are adjusted alike. The linkage goes from the twinstick lever to the transmission. The only adjustment is the little tracking adjustment cam on the Part # P. The cams can be loosened and rotated 360 degrees, moving the linkage either closer to or farther from the pivot point, speeding up or slowing down that side. 3 Adjusting Travel Adjusting Travel These are the the new 3/8 lower linkage on the Boss. Adjusting travel on a Boss is the same as adjusting travel on a Zeton. Part I Joystick

52 1 Preparing Mower 2 Locate Linkage Disk Assembly The tires are removed from this machine for easy visibility. Be sure mower is on a level, hard surface. Put mower on jack stands for safety. On a joystick machine, remove the side panel and locate the swivel disk assembly on the slow side. This will generally be the right side. 3 Locate Swivel Arm 4 Loosen Upper Control Arm Swivel Arm Swivel Disk Assembly Notice that the swivel disk assembly controls the right side and the swivel arm controls the left side. Loosen the upper control arm from the linkage disk. Do not remove bolt or linkage.

53 5 Reposition Upper Linkage Arm 6 Tighten Setscrew Using a 1/8 allen wrench, tighten the setscrew snug against the bolt. The setscrew is located in the end of the arm on the linkage disk. As this unit is slow on the right side, loosen the upper linkage arm and push it toward the pivot (toward the shaft). Tighten the bolt again. 7 Locate Swivel Arm 8 Locate the Hydro Pump Locate the swivel arm. Loosen the setscrew in the end of the swivel arm and the bolt that fastens the swivel arm to the linkage rod. Slide the linkage arm toward the end of the swivel arm. Tighten the bolt again and snug the set screw to the bolt. If you have adjusted the upper linkage as much as possible and the machine still runs faster on one side than the other, locate the linkage bolt on the shift lever next to the right hand hydro pump.

54 9 Remove Shift Arm Bolt 10 Align Shift Lever Have someone push the steering control stick forward and move the shift lever back as far as it will go. If the hole in the shift lever is farther back than the ball joint opening in the linkage rod, you must lengthen the linkage rod so that the two holes align properly. 11 Loosen Jam Nuts 12 Lengthen Linkage Rod Loosen the jam nut on the lower linkage rod. Lengthen the linkage rod until it matches the hole in the shift lever.

55 13 Replace Linkage Bolt 14 Setting Neutral Loosen Upper Linkage Rod Jam Nuts Replace the linkage bolt and secure the jam nut. Reset neutral. 15 Setting Neutral 16 Loosen Upper Linkage Rod Jam Nuts Loosen the jam nut on the ball joint that connects the linkage rod to the swivel linkage disk assembly. Setting Neutral Put the joystick control securely in the neutral position and start the engine. The drive wheel hub will begin to rotate forward. Adjust the upper linkage counterclockwise until the wheel stops. Continue turning the linkage arm until the wheel starts to rotate backward Turn it clockwise just until it stops. This will set neutral Loosen the upper jam nut on the ball joint that connects the linkage rod to the joystick assembly.

56 17 Tighten the Jam Nuts 18 Tighten the Jam Nuts Tighten the jam nuts. 19 Check Travel 20 Tighten the jam nuts. Locate Lower Linkage Ball Joint If the right side is still slower than the left you may have to repeat the process for adjusting lower linkage on the right side and reset neutral. If the machine is still slow on the right side, you must locate the lower linkage ball joint located on the left side of the left hand hydro pump. Remove shift arm bolt.

57 21 Lengthen Lower Linkage 22 Check Alignment on Linkage Arm Lengthen the lower linkage two turns to slow the left side down. Push the linkage arm all the way forward. The opening in the ball joint at the end of the shift arm should set farther back than the opening in the linkage arm. 23 Fasten Linkage Arm 24 Tighten Jam Nut Align the linkage arm with the shift arm and replace and tighten the bolt. Tighten the jam nut.

58 1 Locate Swivel Disk 2 Loosen Connecting Bolt Remove the right and left fender skirts. Locate the swivel disk assembly on the slow side. On the large majority of units, the right side will be the slow side. Loosen the bolt that connects the upper linkage. The steering dampener does not get in the way. Do not remove bolt or upper linkage. 3 Relocate the Upper Linkage 4 Tighten Bolt and Screw Push the upper linkage in toward the pivot point as much as possible. Tighten the bolt and tighten the set screw against the bolt.

59 5 Locate Swivel Disk Assembly 6 Locate Upper Linkage Bolt Locate the bolt that fastens the upper linkage. Loosen the bolt and set screw. Locate the swivel disk assembly on the fast side. This will generally be the left side. 7 Adjust Upper Linkage Position 8 Tighten Upper Linkage Bolt Slide the upper linkage back or away from the pivot to slow that side down. Tighten the bolt and setscrew.

60 9 Locate Lower Linkage 10 Remove Shift Arm Bolt If the slow side is still slower than the fast side, locate the lower linkage on the slow side. Remove the bolt that connects it to the shift lever. 11 Align Shift Lever 12 Loosen Jam Nuts Have someone push the right steering control stick forward and move the shift lever. If the hole in the shift lever is farther back than the ball joint opening in the linkage rod, you must lengthen the linkage rod so that the two holes align properly.

61 13 Lengthen Linkage Rod 14 Replace Linkage Arm Bolt Lengthen the linkage rod until it matches the hole in the shift lever. Replace and tighten linkage arm bolt and tighten jam nut. 15 Setting Neutral: 16 Loosen Upper Linkage Jam Nuts Setting Neutral: Loosen Upper Linkage Jam Nuts Loosen the jam nut on the ball joint that connects the linkage rod to the swivel linkage disk assembly. Loosen the upper jam nut on the ball joint that connects the linkage rod to the steering assembly.

62 17 Setting Neutral 18 Setting Neutral: Tighten Linkage Rod Jam Nuts Put the twinstick controls securely in the neutral position and start the engine. The drive wheel hub will begin to rotate forward. Adjust the upper linkage counterclockwise until the wheel stops. Continue turning the linkage arm until the wheel starts to rotate backward. Turn it clockwise just until it stops. This will set neutral. 19 Setting Neutral: 20 Tighten Linkage Rod Jam Nuts Tighten the lower jam nut. Check Travel If one side is still slow, you may have to repeat the process for adjusting the lower linkage and set neutral. Tighten the upper jam nut

63 21 Locate Lower Linkage Ball Joint 22 Lengthen Lower Linkage If the machine is still slow on the right side, you must locate the lower linkage ball joint located on the left side of the left hand hydro pump. Remove shift arm bolt. Lengthen the lower linkage two turns to slow the left side down. 23 Check Alignment on Linkage Arm 24 Fasten Linkage Arm Push the linkage arm all the way forward. The opening in the ball joint at the end of the shift arm should set farther back than the opening in the linkage arm. Align the linkage arm with the shift arm and replace and tighten the bolt.

64 2008 Country Clipper Update Manual Dampeners

65 1 2 Dampeners Dampeners The heavy duty dampener for the twin stick (H-2168) has white lettering. It is very hard to pull out the cylinder The light duty dampener for the joystick (H-2467) has maroon lettering and is easy to pull out the cylinder.

66 2008 Country Clipper Update Manual Electrical

67 1 Wiring Schematics Country Clipper has changed the wiring harness for simplification and to remove the auxiliary starter solenoid wherever possible. Instead of one harness with wiring and plugs for every mower, we have gone to separate harnesses.

68 2 E-6340 The E-6340 is the harness used in the recent past. It has all the extra wiring and plugs that make it so confusing. The E-6340 uses a starter relay on every unit. The starter circuit is controlled through the ground circuit. The same ground circuit is used for the starter and for the safety circuit.

69 3 E-6400 The E-6400 is the current Boss wiring harness. It is the same circuit as the E-6340 except the starter circuit is controlled by the power circuit instead of the ground to engage the starter. The seat switch cannot be bypassed on the E-6400 The joystick is equipped with a plunger switch and the clutch has been changed. The new clutch switch will work on older mowers, but the old switch will not work on the new mowers.

70 4 E-6405 The E-6405 harness is used on all joystick mowers with Briggs & Stratton engines.

71 5 E-6436 DELPHI (E-6308) SHRINK WRAP WIRES, SO WIRES DON'T CATCH ON MOWER DELPHI (E-6098) 1: MAGNETO 2: OIL PRESURE SWITCH 3: START SOLENOID 4: DC & FUEL SOLENOID 5: NOT USED DELPHI AMP WIRE TIE TOGETHER E " SHIVVERS #E : DC 2: MAGNETO 3: FUEL SOLENOID 4: DC (JUMPER WIRE TO #1) 5: OIL PRESSURE 6: NOT USED AMP SHIVVERS #E-5976 AMP The E-6436 adapter harness is used on any twinstick mower with a Briggs & Stratton engine.

72 6 E-6415 The E-6415 harness is used on all JAZEE PRO and Charger mowers with Kohler engines and joysticks. It can be identified by one red stripe on the harness.

73 7 E-6416 The E-6416 harness is used on all JAZEE PRO and Charger mowers with Kohler engines and twinsticks. It can be identified by two red stripes on the harness

74 8 E-6417 The E-6417 adapter harness is used with the E-6415 and E It adapts the harness to Kawasaki engines on JAZEE PRO and Chargers. The lighted fender kits now come with their own harness. The wires have been removed from all other harnesses.

75 9 E-6398 The E-6398 is the harness for the lighted fender kit. The wires have been removed from all other harnesses.

76 10 Quick Fix Start Adapter

77 11 Quick Fix Start Adapter It has come to our attention that the wires on the E 6447 Quick Fix Start Adapter kit are wired incorrectly. This could be a potential safety hazard and needs to be corrected immediately. The blue wire goes to the 87A terminal on the relay. (See attached schematic) Some have been found on the 87 terminal. If they are wired to the 87 terminal, the relay will work the opposite of the way it was intended. It shuts off the safety circuit in the run position.

78 12 Quick Fix Start Adapter E-6098 TerMinal (4) [-6308 Cover FrOM "'Ire 'WIrE> End E-5880 Terl"llnQI TerMinal (4) \ r ~~~ ~~~2~~,. ;Co... er \lire Cover End [-S075 E '=_ '0;;;_ ""= 16Go. 16GQ Red ;"-,... [-5976 E-5976 Terl'llnal Terl'llnQt (4)-' (4)-/

79 2008 Country Clipper Update Manual Replacement Parts

80 1 Replacement Parts 2 Replacement Parts The Boss lower linkage rod ( P) is basically the same as the Zeton lower linkage ( P). If a Zeton lower linkage rod needs to be replaced, it should be replaced with a P plus 2 H-2465 spacers. 3 Replacement Parts If an old style 3/8 bolt rear deck hanger needs replaced, it should be replaced with a new style ½ assembly. The parts needed are : A Rear Deck Hanger Assy F-1489 ½ Jam Nut P Hanger Pin F-1936 ½-13x3 ½, 2 thread If an old style 3/8 bolt front hanger assembly needs to be replaced, it should be replaced with the new style ½ assembly. The parts needed to do that are: P Adjustable Hanger End F-1489 ½ Jam Nut P Hanger Pin F-1936 ½-13x3 ½, 2 threaded

81 Country Clipper 613 W. English Corydon, IA (800)