BigDog Mowers C Series Parts Manual

Transcription

1 BigDog Mowers C Series Parts Manual 00 South Ridge Road Hesston, Kansas 6706

2 WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. NOTICE OF REQUIREMENT OF SPARK ARRESTER MUFFLER This equipment may create sparks that can start fires around dry vegetation. California Public Resources Code Section.6 provides that it is unlawful to use or operate an internal combustion engine on any forest-covered, brush-covered, or grass-covered land unless the engine is equipped with a spark arrester maintained in effective working order. A spark arrester is a device constructed of nonflammable materials specifically for the purpose of removing and retaining carbon and other flammable particles over 0.0 of an inch in size from the exhaust flow of an internal combustion engine that uses hydrocarbon fuels or which is qualified and rated by the United States Forest Service. Other states or federal areas may have similar laws. The Operator Should Contact Local Fire Agencies For Laws or Regulations Relating to Fire Prevention Requirements. THIS EQUIPMENT DOES NOT HAVE A SPARK ARRESTER AND YOU SHOULD CONTACT YOUR AUTHORIZED DEALER FOR THE PURCHASE OF A SPARK ARRESTER. Inspect spark arrester daily; replace every 500 hours or as needed. The Engine Owner s Manual provides information regarding the U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty. Keep Engine Owner s Manual with your unit. Should the Engine Owner s Manual become damaged or illegible, replace immediately. Replacements may be ordered per the information found in the Product Information section of the owner s manual. Federal law and California State law prohibit the following acts or the causing thereof:. The removal or rendering inoperative by any person other than for purposes of maintenance, repair, replacement, of any device or element of design incorporated into any equipment for the purposes of emissions control prior to or after its sales or delivery to the ultimate purchaser or while it is in use, or. The use of the equipment after such device or element of design has been removed or rendered inoperative by any person.

3 Table of Contents General Information Service Literature Available From Your Dealer Using This Manual Hardware Description Codes & Abbreviations Standard Torques Section Frame S/N 0507 & Higher Frame S/N Prior to Engine Guard Section Hydraulic System Pump Belt Transmission Assembly Transmission Service Parts Steering Steering Sub-Assembly Park Brake Section Wheel & Tire Front Wheel Breakdown Drive Wheel Breakdown Black Rim Drive Wheel Breakdown Chrome Rim Section 5 Engine, Briggs & Stratton 7.5/ HP S/N 0000 & Higher Fuel System, Briggs & Stratton 7.5/ HP S/N 0000 & Higher Engine, Briggs & Stratton 7.5/ HP S/N Prior to Fuel System, Briggs & Stratton 7.5/ HP S/N Prior to Engine Service Parts, Briggs 7.5 HP & HP Engine, Briggs & Stratton 6 HP S/N 0000 & Higher Fuel System, Briggs & Stratton 6 HP S/N 0000 & Higher Engine, Briggs & Stratton 6 HP S/N Prior to Fuel System, Briggs & Stratton 6 HP S/N Prior to Engine Service Parts, Briggs 6 HP Engine, Kaw FR5V & FR600V S/N 0000 & Higher Fuel System, Kaw FR5V & FR600V S/N 0000 & Higher Engine, Kaw FR5V & FR600V S/N Prior to Fuel System, Kaw FR5V & FR600V S/N Prior to Engine Service Parts, Kawasaki FR5V & FR600V Engine, Kaw FR65V S/N 0000 & Higher Fuel System, Kaw FR65V S/N 0000 & Higher Engine, Kaw FR65V S/N Prior to Fuel System, Kaw FR65V S/N Prior to _07 c-

4 Engine Service Parts, Kawasaki FR65V Fuel Tank & Fender S/N 0000 & Higher Fuel Tank & Fender S/N Prior to Fuel Tank Service Parts S/N Prior to Section 6 Battery Instrument Panel, 7 HP & HP Briggs & Stratton Instrument Panel, 6 HP Briggs & Stratton Instrument Panel, Kawasaki Section 7 " Service Deck " Deck Pulleys & Spindles " Deck " Service Deck " Deck Pulleys & Spindles " Deck " Service Deck " Deck Pulleys & Spindles " Deck Deck Lift Deck Mounting Hardware Section 8 Seat c- 56_07

5 General Information This Manual covers BigDog C-Series models 9055, 906, 907, 90669, & Service Literature PART NO. DESCRIPTION 60 OPERATOR S MANUAL 95 WARRANTY STATEMENT 089BD SERVICE MANUAL Available From Your Dealer PART NO. DESCRIPTION PART NO. DESCRIPTION 609 " MULCH KIT 9965 CATCHER, -BAG " & 6" 60 6" MULCH KIT 9986 CATCHER, -BAG 5" 6 5" MULCH KIT 077 LED LIGHT KIT 67 HOUR METER KIT 7 STEERING ARM EXTENSION KIT 65 5 CONTAINMENT KIT 606 ARM REST KIT Note: When ordering parts, you must use the part number as shown for each part, not the index number. Always give the model and serial number to your parts and service representative. Note: Items sold in bulk such as seals and hoses are sold by the foot. Using This Manual This manual is part of a service package for the BigDog mowers. Use of this manual in conjunction with other Big- Dog mower and component manuals will provide the information necessary to service and maintain BigDog mowers. This Parts Manual provides a complete parts listing for the unit. Use this manual when ordering parts. Illustrations used were current at the time of printing, but subsequent production changes may cause your machine to vary slightly in detail. Excel Industries, Inc. reserves the right to redesign and change the machine as deemed necessary, without notification. If a change has been made to your machine which is not reflected in this parts manual, see your BigDog dealer for current information and parts. The Service Manual is a service guide for use by Service Technicians. It provides the necessary information needed to perform normal maintenance requirements on these units. The Operator's Manual provides fundamental operational information and operational safety that is needed when operating the mower. The component manuals are furnished by the various manufacturers to be used for the troubleshooting and servicing of their products. 56_07 -

6 Hardware Description Codes & Abbreviations The following codes are used throughout this parts manual. Refer to this list when ordering parts. ABBREVIATION DESCRIPTION ABBREVIATION DESCRIPTION CB CARRIAGE BOLT MB MACHINE BUSHING CE CLEVIS PIN MS MACHINE SCREW CN CLIP NUT NT NUT CP COTTER PIN SC SELF TAPPING CAP SCREW CS CAP SCREW SH SOCKET HEAD CW CUP WASHER SB SHOULDER BOLT FDRW FENDER WASHER SS SET SCREW FW FLAT WASHER OD OUTSIDE DIAMETER HX HEX HEAD ID INSIDE DIAMETER LW LOCK WASHER Standard Torques The following chart lists the standard torque values for the threaded fasteners found in this manual. Torque all cap screws, nuts and set screws to these values unless a different torque is shown in the Notes section next to the fastener. SIZE FT-LBS N-M SIZE FT-LBS N-M M.. 7 M M M M M M M M M0 0 5 M _07

7 Section Frame S/N 0507 & Higher Frame S/N Prior to Engine Guard _07 -

8 Frame S/N 0507 & Higher _07

9 Frame S/N 0507 & Higher INDEX NO. PART NO. QTY. DESCRIPTION " MOWER FRAME (WITH DECALS & RIVET NUTS) " MOWER FRAME (WITH DECALS & RIVET NUTS) " MOWER FRAME (WITH DECALS & RIVET NUTS) 60 BIG DOG LOGO DECAL 777 MADE IN USA DECAL 0879 SERIAL NUMBER / SPEC DECAL HOT DECAL ENGINE COMPARTMENT DECAL LS STEERING DECAL SAFE OPERATION DECAL PUMP BELT WARNING DECAL RS STEERING DECAL /6-8 THREAD RIVET NUT 60 C DECAL BUMPER (WITH DECAL) CS.75-6 X.5 HX G NT.75-6 HX FLK ZNYC NOTES:. Serial Number plate. In the event the serial number tag becomes damaged or illegible, please contact your dealer to order a replacement.. EPA compliance plate.. Patent numbers plate. 56_07 -

10 Frame S/N Prior to _07

11 Frame S/N Prior to 0507 INDEX NO. PART NO. QTY. DESCRIPTION " FRAME (WITH DECALS & RIVET NUTS) " FRAME (WITH DECALS & RIVET NUTS) " FRAME(WITH DECALS & RIVET NUTS) STEP TREAD /6-8 THREAD RIVET NUT 7850 RS STEERING DECAL PUMP BELT WARNING DECAL HOT DECAL ENGINE COMPARTMENT DECAL 8 N/A SERIAL NUMBER / SPEC DECAL LS STEERING DECAL MADE IN USA DECAL 60 BIG DOG LOGO DECAL 6099 SAFE OPERATION DECAL 60 C DECAL 60 C6 DECAL 6075 C5 DECAL 60 STEP TREAD NOTES:. In the event the serial number tag becomes damaged or illegible, please contact your dealer to order a replacement.. EPA compliance plate.. Patent numbers plate. 56_07-5

12 Engine Guard INDEX NO. PART NO. QTY DESCRIPTION 9000 BUMPER GUARD PLATE 068 CS.75-6 X.50 HX G FW.06 X.8 X.060 SAE NT.75-6 HXZY NL NOTES: -6 56_07

13 Section Hydraulic System Pump Belt Transmission Assembly Transmission Service Parts Steering Steering Sub-Assembly Park Brake _07 -

14 Hydraulic System _07

15 Hydraulic System INDEX NO. PART NO. QTY. DESCRIPTION CS.-8 X.50 HX G CS.-8 X.00 HX G5 Z FW. X.687 X.05/.080H 797 TOWLINK ROD CP.06D X.00 LG HML Z 6 N/A TRANSMISSION ASSEMBLY NT 0.-8 HX G5. Torque to 7 ft-lbs. NOTES: 56_07 -

16 Pump Belt _07

17 Pump Belt INDEX NO. PART NO. QTY. DESCRIPTION CS.500- X.75 HX G CS.65- X.5 HX G5 ZY FW.65 X.00 X. ZNYC 068 SPRING / COIL PL. 079 PUMP IDLER 6006 BEARING DISC 6005 BUSHING NT.500- HX G8 ZY NL IDLER SPACER IDLER PULLEY.00" OD NT.65- HX G5 ZNYC BELT. Torque to 00 ft-lbs. NOTES: 56_07-5

18 Transmission Assembly _07

19 Transmission Assembly INDEX NO. PART NO. QTY. DESCRIPTION CS.75-6 X.5 HX G5 00 HYDROSTAT CROSS BRACE FW.06 X.8 X.060 SAE 0550 NT.75-6 HX G5 ZNY RS TRANSMISSION LS TRANSMISSION BRAKE ACTUATOR ROD NT.50-0 HX ZY NL FW.8 X.65 X.05/.080H 0 60 SPRING NOTES: 56_07-7

20 Transmission Service Parts 5 6 INDEX NO. PART NO. QTY. DESCRIPTION 609 FAN/PULLEY KIT 60 BOLT HUB KIT (INCLUDES NUT) HUB NUT 7987 RETAINING RING PARK BRAKE GEAR PARKING PAWL KIT NOTES: -8 56_07

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22 Steering STEERING SUB-ASSEMBLY _07

23 Steering INDEX NO. PART NO. QTY. DESCRIPTION 600 STEERING DAMPER 789 BALL STUD FW. X.687 X.05/.080H 0655 NT.- HX ZY NL LOCK COLLAR ID PUMP ROD 7 07 NT.-8 HX G5 ZNYC CS.-8 X.75 HX G PIVOT TUBE LW. INT-EXT TOOTH 606 CAP LOCK NOTES: 56_07 -

24 Steering Sub-Assembly LEFT SIDE SHOWN RIGHT SIDE SIMILAR _07

25 Steering Sub-Assembly INDEX NO. PART NO. QTY. DESCRIPTION 7860 STEERING BAR GRIP 070 STEERING BAR (WITH GRIP) 0550 NT.75-6 HX G5 ZNY FW.79 X.8 X.06 SAE CONTROL LEVER CS.75-6 X.50 BH BO BALL JOINT LINK NT.- HX NL ZN BUSHING CS.75-6 X.75 HX G FW. X.687 X.05/.080H NT.75-6 HX NL G LS STEERING BOX 0007 RS STEERING BOX (NOT SHOWN) NOTES: 56_07 -

26 Park Brake 0 RIGHT SIDE SHOWN LEFT SIDE SIMILAR 6 BALL JOINT LINK _07

27 Park Brake INDEX NO. PART NO. QTY. DESCRIPTION 000 LS BRAKE ACTUATOR 0000 RS BRAKE ACTUATOR 7659 BUSHING 608 NUT PLATE.0 CENTERS 5 78 PUSH BUTTON SWITCH NT.75-6 HX ZY NL FW.06 X.8 X.060 SAE CS.75-6 X.00 HX G8 Z CS 0- X.75 HXFLK ZN CP.06D X.00 LG HML Z FW. X.687 X.05/.080H 0655 NT.- HX ZY NL 0009 BRAKE ACTUATOR ROD NT.50-0 HXZY NL FW.8 X.65 X.05/.080H 6 60 SPRING. Part of the wire harness. NOTES: 56_07-5

28 -6 56_07

29 Section Wheel & Tire Front Wheel Breakdown Drive Wheel Breakdown Black Rim Drive Wheel Breakdown Chrome Rim _07 -

30 Wheel & Tire _07

31 Wheel & Tire INDEX NO. PART NO. QTY. DESCRIPTION PLASTIC WHEEL ASSEMBLY (WITH HARDWARE) 67 6 FW.50 X.5 X.87 SPL NT.500- NL G TIRE/WHEEL 8 X (BLACK RIMS " & 6" DECKS) 6080 TIRE/WHEEL 8 X (CHROME RIMS " & 6" DECKS) 6055 TIRE/WHEEL 8 X (BLACK RIMS 5" DECKS) 786 TIRE/WHEEL 8 X (CHROME RIMS 5" DECKS) WHEEL NUT CS.500- X.5 HS G FW.5 X.75 X BEARING SPACER 0 N/A FRONT WHEEL SUB-ASSEMBLY CS.500- X.5 HX G FW.5 X.06 X.090 SAE 0997 PLASTIC WHEEL 0599 NT.500- HX JAM ZNYC. Torque to ft-lbs. NOTES: 56_07 -

32 Front Wheel Breakdown _07

33 Front Wheel Breakdown INDEX NO. PART NO. QTY. DESCRIPTION 9006 CASTER FORK NT.500- HX G8 ZY NL FW.5 X.06 X.090 SAE 060 CS.500- X 6.50 HX G5 Z GAUGE WHEEL SPACER TIRE/WHEEL X -5 (SMOOTH) 7680 TIRE/WHEEL X -5 (RIBBED) BEARING CAP /" ROLLER BEARING NOTES: 56_07-5

34 Drive Wheel Breakdown Black Rim 6096 TIRE/WHEEL ASSEMBLY (" & 6" DECKS) INDEX NO. PART NO. QTY. DESCRIPTION 6067 TIRE 8 X WHEEL 8 X TIRE VALVE 6055 TIRE/WHEEL ASSEMBLY (5" DECKS) INDEX NO. PART NO. QTY DESCRIPTION 787 TIRE 8 X WHEEL 8.00 X TIRE VALVE NOTES: -6 56_07

35 Drive Wheel Breakdown Chrome Rim 6080 TIRE/WHEEL ASSEMBLY (" & 6" DECKS) INDEX NO. PART NO. QTY. DESCRIPTION 608 TIRE 8 X WHEEL 8 X TIRE VALVE 786 TIRE/WHEEL ASSEMBLY (5" DECKS) INDEX NO. PART NO. QTY DESCRIPTION 787 TIRE 8 X WHEEL 8.00 X TIRE VALVE NOTES: 56_07-7

36 -8 56_07

37 Section 5 Engine, Briggs & Stratton 7.5/ HP Fuel System, Briggs & Stratton 7.5/ HP S/N 0000 & Higher Fuel System, Briggs & Stratton 7.5/ HP S/N Prior to Engine Service Parts, Briggs 7.5 HP & HP Engine, Briggs & Stratton 6 HP Fuel System, Briggs & Stratton 6 HP S/N 0000 & Higher Fuel System, Briggs & Stratton 6 HP S/N Prior to Engine Service Parts, Briggs 6 HP Engine, Kaw FR5V & FR600V Fuel System, Kaw FR5V & FR600V S/N 0000 & Higher Fuel System, Kaw FR5V & FR600V S/N Prior to Engine Service Parts, Kawasaki FR5V & FR600V Engine, Kaw FR65V Fuel System, Kaw FR65V S/N 0000 & Higher Fuel System, Kaw FR65V S/N Prior to Engine Service Parts, Kawasaki FR65V Fuel Tank & Fender S/N 0000 & Higher Fuel Tank & Fender S/N Prior to Fuel Tank Service Parts S/N & Higher Fuel Tank Service Parts S/N Prior to _07 5-

38 Engine, Briggs & Stratton 7.5/ HP 8 RED BLK 9 0 RED TO BATTERY 6 9 5A FUSE _07

39 Engine, Briggs & Stratton 7.5/ HP INDEX NO. PART NO. QTY. DESCRIPTION N/A BRIGGS & STRATTON 7.5/ HP ENGINE 6006 SC # 8 X.00 PHCR BO 608 BRIGGS CONTACT COVER 07 NT.-8 HX G5 ZNYC FW. X.687 X.05/.080H NEGATIVE BATTERY CABLE LW. INT-EXT TOOTH RED BATTERY CABLE BOOT NT.50-0 HX G5 ZNYC FW.8 X.65 X.05/.080H 6006 POSITIVE BATTERY CABLE 6080 POSITIVE BATTERY CABLE 055 NT #0- HX ZN CS.50-0 X.75 HX G STARTER SOLENOID OIL DRAIN - /8-8 NPTF " OIL DRAIN HOSE CN.50-0 X.5 MAX THK CS.-8 X.75 HX G KEY / SQ X 0.66 LG ENGINE PULLEY 6080K CLUTCH KIT (WITH PIGTAIL) 795 CLUTCH HARNESS PIGTAIL FW.5 X. X.9 HRD CS.7-0 X.5 HX G5 P85 NOTES:. Part of the wire harness.. The pigtail is supplied with the clutch.. Torque the bolt to 5 8 ft-lbs. Replace (do not reuse) the cap screw if it s removed or loosened. Use only hand tools to install this fastener. 56_07 5-

40 Fuel System, Briggs & Stratton 7.5/ HP S/N 0000 & Higher B 7 9 FUEL FILTER A D C 7 E _07

41 Fuel System, Briggs & Stratton 7.5/ HP S/N 0000 & Higher INDEX NO. PART NO. QTY. DESCRIPTION 6 60 CLAMP, /6" " /6" VAPOR LINE PLASTIC TEE, /6" HOSE CLAMP 0 06 CS.75-6 X.00 HX G LOOP CLAMP 6057 VACUUM BREAKER WIRE TIE 0588 " /" FUEL LINE NT.75-6 HX FLK ZNYC FW.06 X.8 X.060 SAE VACUUM BREAKER FILTER NOTES: FUEL & VAPOR LINE LENGTHS A 9" TANK TO FUEL FILTER (FUEL) B " TANK TO TEE (VAPOR) C " TEE TO VACUUM BREAKER (VAPOR) D " FUEL FILTER TO ENGINE (FUEL) E " ENGINE TO TEE (VAPOR) 56_07 5-5

42 Fuel System, Briggs & Stratton 7.5/ HP S/N Prior to 0000 B 9 9 FUEL FILTER A D C 6 9 E _07

43 Fuel System, Briggs & Stratton 7.5/ HP S/N Prior to 0000 INDEX NO. PART NO. QTY. DESCRIPTION 6 60 CLAMP, /6" " /6" VAPOR LINE PLASTIC TEE /" X /" X /6" HOSE CLAMP 0 06 CS.75-6 X.00 HX G LOOP CLAMP 608 VACUUM BREAKER WIRE TIE " /" FUEL LINE NT.75-6 HX FLK ZNYC FW.06 X.8 X.060 SAE VACUUM BREAKER FILTER NOTES: FUEL & VAPOR LINE LENGTHS A 9" TANK TO FUEL FILTER (FUEL) B " TANK TO TEE (VAPOR) C " TEE TO VACUUM BREAKER (VAPOR) D " FUEL FILTER TO ENGINE (FUEL) E " ENGINE TO TEE (VAPOR) 56_07 5-7

44 Engine Service Parts, Briggs 7.5 HP & HP INDEX NO. PART NO. QTY. DESCRIPTION IN-LINE FUEL FILTER 6086 AIR PRECLEANER FILTER, FLAT PANEL (7.5 HP) 6088 AIR PRECLEANER FILTER ( HP) 6087 AIR FILTER, FLAT PANEL (7.5 HP) 6089 AIR FILTER, CARTRIDGE ( HP) 6085 OIL FILTER NOTES: _07

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46 Engine, Briggs & Stratton 6 HP _07

47 Engine, Briggs & Stratton 6 HP INDEX NO. PART NO. QTY. DESCRIPTION N/A BRIGGS & STRATTON 6 HP ELS ENGINE 6006 SC # 8 X.00 PHCR BO 60 STATIC COVER ASSEMBLY 6088 OIL DRAIN - /8-8 NPTF OIL DRAIN HOSE MUFFLER SC.75-6 X.0 HX FL STP WIRE TIE CLUTCH HARNESS PIGTAIL 0 77 KEY / SQ X 0.66 LG ENGINE PULLEY 6078K CLUTCH KIT (WITH PIGTAIL) FW.5 X. X.9 HRD 608 CS.7-0 X.5 HX G5 P85 NOTES:. Torque to 5 8 ft-lbs. Replace (do not reuse) the cap screw if it s removed or loosened. Use only hand tools to install this fastener.. Torque to 0 ft-lbs.. Supplied with the engine.. Torque to 7.5 ft-lbs. 56_07 5-

48 Engine, Briggs & Stratton 6 HP 5 5A FUSE RED BLK _07

49 Engine, Briggs & Stratton 6 HP INDEX NO. PART NO. QTY. DESCRIPTION RED BATTERY CABLE BOOT NT.50-0 HX G5 ZNYC FW.8 X.65 X.05/.080H POSITIVE BATTERY CABLE STARTER SOLENOID POSITIVE BATTERY CABLE 055 NT #0- HX ZN CS.50-0 X.75 HX G5 07 NT.-8 HX G5 ZNYC 7685 FW. X.687 X.05/.080H LW. INT-EXT TOOTH NEGATIVE BATTERY CABLE CN.50-0 X.5 MAX THK CS.-8 X.75 HX G5 5. Part of the wire harness. NOTES: 56_07 5-

50 Fuel System, Briggs & Stratton 6 HP S/N 0000 & Higher A C 0 D 8 B _07

51 Fuel System, Briggs & Stratton 6 HP S/N 0000 & Higher INDEX NO. PART NO. QTY. DESCRIPTION " /" FUEL LINE HOSE CLAMP LOOP CLAMP 6057 VACUUM BREAKER 608 PLASTIC TEE, /6" " /6" VAPOR LINE 5 06 CS.75-6 X.00 HX G CLAMP, /6" NT.75-6 HX FLK ZNYC FW.06 X.8 X.060 SAE VACUUM BREAKER FILTER NOTES: FUEL LINE LENGTHS A " TANK TO TEE (VAPOR) B " TEE TO VACUUM BREAKER (VAPOR) C 8" TANK TO ENGINE (FUEL) D 0" TEE TO ENGINE (VAPOR) 56_07 5-5

52 Fuel System, Briggs & Stratton 6 HP S/N Prior to 0000 A B C 0 7 D _07

53 Fuel System, Briggs & Stratton 6 HP S/N Prior to 0000 INDEX NO. PART NO. QTY. DESCRIPTION " /" FUEL LINE HOSE CLAMP LOOP CLAMP 608 VACUUM BREAKER 6005 PLASTIC TEE /" X /" X /6" 606 0" /6" VAPOR LINE 5 06 CS.75-6 X.00 HX G CLAMP, /6" NT.75-6 HX FLK ZNYC FW.06 X.8 X.060 SAE VACUUM BREAKER FILTER NOTES: FUEL LINE LENGTHS A " TANK TO TEE (VAPOR) B " TEE TO VACUUM BREAKER (VAPOR) C 8" TANK TO ENGINE (FUEL) D 0" TEE TO ENGINE (VAPOR) 56_07 5-7

54 Engine Service Parts, Briggs 6 HP INDEX NO. PART NO. QTY. DESCRIPTION 6057 AIR PRECLEANER FILTER AIR FILTER, CARTRIDGE IN-LINE FUEL FILTER 6057 OIL FILTER NOTES: _07

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56 Engine, Kaw FR5V & FR600V RED/BLK 6 5A FUSE RED BLK _07

57 Engine, Kaw FR5V & FR600V INDEX NO. PART NO. QTY. DESCRIPTION N/A KAWASAKI FR5V & FR600V ENGINE 970 CABLE GUIDE LOOP CLAMP 06 CS.75-6 X.00 HX G FW. X.687 X.05/.080H NT.75-6 HX FLK ZNYC CS M8 X.5 X 6 HX G MUFFLER LW. INT-EXT TOOTH NEGATIVE BATTERY CABLE 778 RED BATTERY CABLE BOOT 097 NT.50-0 HX G5 ZNYC FW.8 X.65 X.05/.080H 6006 POSITIVE BATTERY CABLE CS.50-0 X.75 HX G NT #0- HX ZN STARTER SOLENOID POSITIVE BATTERY CABLE WIRE TIE CN.50-0 X.5 MAX THK FW.06 X.8 X.060 SAE CS.75-6 X.5 HX G5 P ENGINE PULLEY 77 KEY / SQ X 0.66 LG K CLUTCH KIT (WITH PIGTAIL) CLUTCH HARNESS PIGTAIL FW.5 X. X.9 HRD CS.7-0 X.5 HX G5 P OIL DRAIN VALVE " OIL DRAIN HOSE NOTES:. Part of the wire harness.. Supplied with the engine.. Torque to 5 8 ft-lbs. Replace (do not reuse) the cap screw if it s removed or loosened. Use only hand tools to install this fastener.. Torque to 0 5 ft-lbs. Replace (do not reuse) the cap screw if it s removed or loosened. Use only hand tools to install this fastener. 5. Torque to ft-lbs. 56_07 5-

58 Fuel System, Kaw FR5V & FR600V S/N 0000 & Higher A B 5 C D _07

59 Fuel System, Kaw FR5V & FR600V S/N 0000 & Higher INDEX NO. PART NO. QTY. DESCRIPTION 000 HOSE CLAMP 60 CLAMP, /6" " /" FUEL LINE " /6" VAPOR LINE PLASTIC TEE, /6" VACUUM BREAKER VACUUM BREAKER FILTER NOTES: FUEL & VAPOR LINE LENGTHS A 5" TANK TO FUEL FILTER (FUEL) B " TANK TO TEE (VAPOR) C " TEE TO VACUUM BREAKER (VAPOR) D " TEE TO ENGINE PURGE PORT (VAPOR) 56_07 5-

60 Fuel System, Kaw FR5V & FR600V S/N Prior to 0000 A B 5 C D _07

61 Fuel System, Kaw FR5V & FR600V S/N Prior to 0000 INDEX NO. PART NO. QTY. DESCRIPTION HOSE CLAMP 60 CLAMP, /6" " /" FUEL LINE 606 " /6" VAPOR LINE PLASTIC TEE /" X /" X /6" VACUUM BREAKER VACUUM BREAKER FILTER NOTES: FUEL & VAPOR LINE LENGTHS A 5" TANK TO FUEL FILTER (FUEL) B " TANK TO TEE (VAPOR) C " TEE TO VACUUM BREAKER (VAPOR) D " TEE TO ENGINE PURGE PORT (VAPOR) 56_07 5-5

62 Engine Service Parts, Kawasaki FR5V & FR600V INDEX NO. PART NO. QTY. DESCRIPTION 600 AIR FILTER IN-LINE FUEL FILTER 6058 ENGINE OIL FILTER NOTES: _07

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64 Engine, Kaw FR65V 8 5A FUSE 5 RED/BLK RED BLK _07

65 Engine, Kaw FR65V INDEX NO. PART NO. QTY. DESCRIPTION N/A KAWASAKI FR65V ENGINE 970 CABLE GUIDE LOOP CLAMP 06 CS.75-6 X.00 HX G FW. X.687 X.05/.080H NT.75-6 HX FLK ZNYC CS M8 X.5 X 6 HX G MUFFLER LW. INT-EXT TOOTH NEGATIVE BATTERY CABLE 778 RED BATTERY CABLE BOOT 097 NT.50-0 HX G5 ZNYC FW.8 X.65 X.05/.080H 6006 POSITIVE BATTERY CABLE CS.50-0 X.75 HX G NT #0- HX ZN STARTER SOLENOID POSITIVE BATTERY CABLE CN.50-0 X.5 MAX THK FW.06 X.8 X.060 SAE CS.75-6 X.5 HX G5 P ENGINE PULLEY 77 KEY / SQ X 0.66 LG 6078K CLUTCHKIT (WITH PIGTAIL) CLUTCH HARNESS PIGTAIL FW.5 X. X.9 HRD CS.7-0 X.5 HX G5 P OIL DRAIN VALVE " OIL DRAIN HOSE WIRE TIE NOTES:. Part of the wire harness.. Supplied with the engine.. Torque to 5 8 ft-lbs. Replace (do not reuse) the cap screw if it s removed or loosened. Use only hand tools to install this fastener.. Torque to 0 5 ft-lbs. Replace (do not reuse) the cap screw if it s removed or loosened. Use only hand tools to install this fastener. 5. Torque to ft-lbs. 56_07 5-9

66 Fuel System, Kaw FR65V S/N 0000 & Higher A 6 7 B D 7 0 C _07

67 Fuel System, Kaw FR65V S/N 0000 & Higher INDEX NO. PART NO. QTY. DESCRIPTION 000 HOSE CLAMP 60 CLAMP, /6" 608 PLASTIC TEE, /6" LOOP CLAMP VACUUM BREAKER " /" FUEL LINE " /6" VAPOR LINE VACUUM BREAKER FILTER NOTES: FUEL & VAPOR LINE LENGTHS A 5" TANK TO ENGINE (FUEL) B " TANK TO TEE (VAPOR) C " TEE TO VACUUM BREAKER (VAPOR) D " TEE TO ENGINE (VAPOR) 56_07 5-

68 Fuel System, Kaw FR65V S/N Prior to 0000 A B 0 D 7 0 C _07

69 Fuel System, Kaw FR65V S/N Prior to 0000 INDEX NO. PART NO. QTY. DESCRIPTION HOSE CLAMP 60 CLAMP, /6" 6005 PLASTIC TEE /" X /" X /6" 0570 LOOP CLAMP VACUUM BREAKER " /" FUEL LINE " /6" VAPOR LINE VACUUM BREAKER FILTER NOTES: FUEL & VAPOR LINE LENGTHS A 5" TANK TO ENGINE (FUEL) B " TANK TO TEE (VAPOR) C " TEE TO VACUUM BREAKER (VAPOR) D " TEE TO ENGINE (VAPOR) 56_07 5-

70 Engine Service Parts, Kawasaki FR65V INDEX NO. PART NO. QTY. DESCRIPTION AIR FILTER IN-LINE FUEL FILTER 6058 ENGINE OIL FILTER NOTES: 5-56_07

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72 Fuel Tank & Fender S/N 0000 & Higher _07

73 Fuel Tank & Fender S/N 0000 & Higher INDEX NO. PART NO. QTY. DESCRIPTION 6076 RS FENDER 6050 LS FENDER FUEL TANK ASSEMBLY (S/N & HIGHER) 6059 LS FENDER FUEL TANK ASSEMBLY (S/N ) 6050 LS FENDER FUEL TANK ASSEMBLY (S/N ) RATCHETING GAS CAP,.5" FW. X.687 X.05/.080H CS.-8 X.750 HX G5. Torque to 7 ft-lbs. NOTES: 56_07 5-7

74 Fuel Tank & Fender S/N Prior to _07

75 Fuel Tank & Fender S/N Prior to 0000 INDEX NO. PART NO. QTY. DESCRIPTION 6076 RS FENDER 6050 LS TANK FENDER ASSEMBLY RATCHETING GAS CAP,.5" FW. X.687 X.05/.080H CS.-8 X.750 HX G5. Torque to 7 ft-lbs. NOTES: 56_07 5-9

76 Fuel Tank Service Parts S/N & Higher INDEX NO. PART NO. QTY. DESCRIPTION 6087 VENT FITTING SUCTION HOSE ASSEMBLY 6000 GROMMET NOTES: _07

77 Fuel Tank Service Parts S/N Prior to S/N PRIOR TO 066 S/N S/N INDEX NO. PART NO. QTY. DESCRIPTION 78 VENT FITTING KIT 6099 FUEL VENT VALVE 6000 GROMMET SUCTION HOSE ASSEMBLY 0.5" GROMMET VENT FITTING NOTES: 56_07 5-

78 5-56_07

79 Section 6 Battery Instrument Panel, 7 HP & HP Briggs & Stratton Instrument Panel, 6 HP Briggs & Stratton Instrument Panel, Kawasaki _07 6-

80 Battery 7 5 POSITIVE CABLE (RED) NEGATIVE CABLE (BLACK) _07

81 Battery INDEX NO. PART NO. QTY. DESCRIPTION 6090 CS.50-0 X 6.50 HX G FW.8 X.65 X.05/.080H 87 BATTERY CLAMP STRAP CS.50-0 X.75 HX G5 ZN LW.50 INT-EXT TOOTH Z NT.50-0 HX G5 ZNYC RED BATTERY CABLE BOOT CN.50-0 X.5 MAX THK GROMMET WIRE TIE NOTES: 56_07 6-

82 Instrument Panel, 7 HP & HP Briggs & Stratton _07

83 Instrument Panel, 7 HP & HP Briggs & Stratton INDEX NO. PART NO. QTY. DESCRIPTION PTO SWITCH KEY ASSEMBLY IGNITION SWITCH 6005 SEALED RELAY (WITH BRACKET) CB 0- X.50 ZYNC WIRE TIE THROTTLE/CHOKE CABLE FW.9 X.50 X.08 ZNYC NT #0- HX NL ZN FW.8 X.65 X.05/.080H CS.50-0 X.50 HX G5 550 INSTRUMENT PANEL (WITH DECAL) 608 INSTRUMENT PANEL DECAL WIRE HARNESS 5 05 CLUTCH CONNECTOR REPAIR KIT. Part of the wire harness. NOTES: 56_07 6-5

84 Instrument Panel, 6 HP Briggs & Stratton _07

85 Instrument Panel, 6 HP Briggs & Stratton INDEX NO. PART NO. QTY. DESCRIPTION PTO SWITCH KEY ASSEMBLY IGNITION SWITCH CB 0- X.50 ZYNC WIRE TIE " THROTTLE/CHOKE CABLE FW.9 X.50 X.08 ZNYC NT #0- HX NL ZN FW.8 X.65 X.05/.080H CS.50-0 X.50 HX G5 550 INSTRUMENT PANEL (WITH DECAL) 608 INSTRUMENT PANEL DECAL WIRE HARNESS 6005 SEALED RELAY (WITH BRACKET) 5 05 CLUTCH CONNECTOR REPAIR KIT. Part of the wire harness. NOTES: 56_07 6-7

86 Instrument Panel, Kawasaki _07

87 Instrument Panel, Kawasaki INDEX NO. PART NO. QTY. DESCRIPTION CHOKE CABLE PTO SWITCH KEY ASSEMBLY IGNITION SWITCH SEALED RELAY (WITH BRACKET) CB 0- X.50 ZYNC WIRE TIE THROTTLE CABLE FW.9 X.50 X.08 ZNYC NT #0- HX NL ZN CS.50-0 X.50 HX G FW.8 X.65 X.05/.080H 6009 INSTRUMENT PANEL DECAL INSTRUMENT PANEL (WITH DECAL) WIRE HARNESS 6 05 CLUTCH CONNECTOR REPAIR KIT. Part of the wire harness. NOTES: 56_07 6-9

88 6-0 56_07

89 Section 7 " Service Deck " Deck Pulleys & Spindles " Deck " Service Deck " Deck Pulleys & Spindles " Deck " Service Deck " Deck Pulleys & Spindles " Deck Deck Lift Deck Mounting Hardware _07 7-

90 " Service Deck _07

91 " Service Deck INDEX NO. PART NO. QTY DESCRIPTION 5509 " DECK (WITH DECALS & HARDWARE) CN.-8 X.00 MAX THK 606 DISCHARGE CHUTE DECAL 6087 DECK DANGERS DECAL THROWN OBJECTS DECAL 6 60 BELT ROUTING DECAL NOTES: 56_07 7-

92 " Deck Pulleys & Spindles _07

93 " Deck Pulleys & Spindles INDEX NO. PART NO. QTY DESCRIPTION 796 CS.65- X.50 HX G5 068 FW.656 X.00 X.078 ZNYC 7979 FW.650 X.5 X.8 ZNYC G IDLER PULLEY 5.0" OD IDLER SLIDE SPRING / COIL PL CHAIN, LINK CS.-8 X.5 FLT SH IDLER SLIDE UHMW CS.500- X.5 HS G CS.65- X.5 HX G5 Z FW.55 X.65 X.5 HD ZY 787 CW.6 X.5 X.87 PNT DECK SPINDLE PULLEY NT.75-6 HX G5 ZNY FW.79 X.8 X.06 SAE SPINDLE ASSEMBLY BLADE SPINDLE CS.75-6 X.75 HX G FW.00 X.50 X NT.-8 HX ZY NL FW. X.687 X.05/.080H NT.500- NL G PLASTIC WHEEL ASSEMBLY (WITH HARDWARE) CS.500- X.5 HX G FW.5 X.06 X.090 SAE 0997 PLASTIC WHEEL NT.500- HX JAM ZNYC NOTES:. Used on mowers with serial numbers prior to 060 and higher than 070; Torque to ft-lbs.. Used on mowers with serial numbers between 060 and 070. Torque the spindle bolt to 8 ft-lbs. 56_07 7-5

94 " Deck _07

95 " Deck INDEX NO. PART NO. QTY DESCRIPTION DISCHARGE CHUTE 608 DISCHARGE CHUTE PIN 608 TORSION SPRING 067 CHUTE BRACKET NT.75-6 HXZY NL FW.06 X.8 X.060 SAE HRD ZN DISCHARGE CHUTE ADAPTOR CB.75-6 X.000 STD CD RS PULLEY COVER LS PULLEY COVER BELT A-SECTION." 080 CS.-8 X.750 HX G5 ZN 797 FW. X.00 X. HRD Z 7979 BLADE, 0.50"-L-F-CW BLADE, F0.50"-L-F-CW 7995 BLADE, 0.50"-CAT-F-CW 79 BLADE, 0.50"-MUL-F-CW 790 BLADE, 0.50"-GAT-F-CW CW.6 X.50 X.87 PNT CS.65- X.50 HX G5 ZN NOTES:. Torque to 8 ft-lbs.. Do not torque; the discharge chute must pivot freely. 56_07 7-7

96 6" Service Deck 6 5 INDEX NO. PART NO. QTY. DESCRIPTION " DECK (WITH DECALS & HARDWARE) CN.-8 X.00 MAX THK 6087 DECK DANGERS NO ROPS DECAL 606 DISCHARGE CHUTE DECAL 5 60 DECK BELT ROUTING DECAL THROWN OBJECTS DECAL NOTES: _07

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98 6" Deck Pulleys & Spindles _07

99 6" Deck Pulleys & Spindles INDEX NO. PART NO. QTY DESCRIPTION 796 CS.65- X.500 HX G5 ZNYC 068 FW.656 X.00 X.078 ZNYC 7979 FW.650 X.5 X.8 ZNYCG PULLEY, 5.00" OD IDLER IDLER SLIDE CHAIN DECK LIFT SPRING TENSION SPRING CS.-8X.50 FLT SH ZNYC IDLER SLIDE CS.500- X.50 HX G5 ZN FW.55 X.65 X.5 HD ZY 609 PULLEY, 6.OO" OD FW.00 X.500 X. ZN NT.75-6 HX G5 ZN FW.06 X.8 X.060 SAE HRD ZN FW. X.687 X.05/.080 HD ZN/YL NT.-8 HX NL ZN CS.75-6 X.75 HX G5 ZN BLADE SPINDLE ASSEMBLY NT.500- HX G8 ZN NY PLASTIC WHEEL ASSEMBLY (WITH HARDWARE) 059 NT.500- HX JAM ZNYC FW.5 X.06 X.090 SAE 0997 PLASTIC WHEEL CS.500- X.50 HX G5. Torque to ft-lbs. NOTES: 56_07 7-

100 6" Deck _07

101 6" Deck INDEX NO. PART NO. QTY DESCRIPTION 778 BELT, A 7" EL 608 CHUTE PIN 608 TORSION SPRING DISCHARGE CHUTE NT.75-6 HX G5 ZN NY FW.06 X.8 X.060 SAE CHUTE BRACKET DISCHARGE CHUTE ADAPTER CB.75-6 X.000 STD ZN RS PULLEY COVER 6075 LS PULLEY COVER 080 CS.-8 X.750 HX G5 ZN 797 FW. X.00 X. HRD Z 605 BLADE,.50"-L-F-CW BLADE,.50"-MUL-F-CW 7985 BLADE,.50"-GAT-F-CW 60 BLADE,.50"-CAT-F-CW CW.6 X.50 X.87 PNT CS.65- X.50 HX G5 ZN NOTES:. Torque to 8 ft-lbs.. Do not torque; the discharge chute must pivot freely. 56_07 7-

102 5" Service Deck INDEX NO. PART NO. QTY DESCRIPTION " DECK (WITH DECALS & HARDWARE) 789 BELT ROUTING DECAL 6087 DECK DANGERS DECAL CN.-8 X.00 MAX THK DISCHARGE CHUTE DECAL THROWN OBJECTS DECAL STEP TREAD NOTES: 7-56_07

103 This page intentionally left blank. 56_07 7-5

104 5" Deck Pulleys & Spindles _07

105 5" Deck Pulleys & Spindles INDEX NO. PART NO. QTY. DESCRIPTION 796 CS.65- X.50 HX G5 068 FW.656 X.00 X.078 ZNYC 7979 FW.650 X.5 X.8 ZNYC G PULLEY IDLER 5.00" OD IDLER SLIDE TENSION SPRING CHAIN, LINK CS.-8 X.5 FLT SH IDLER SLIDE UHMW CS.500- X.5 HX G5 ZN FW.55 X.65 X.5 HD ZY DRIVE PULLEY 5.68 OP 0550 NT.75-6 HX G5 ZNY FW.06 X.8 X.060 SAE CS.75-6 X.75 HX G SPINDLE ASSEMBLY FW. X.687 X.05/.080H NT.-8 HX ZY NL NT.500- HX G8 ZY NL PLASTIC WHEEL ASSEMBLY (WITH HARDWARE) FW.5 X.06 X.090 SAE CS.500- X.5 HX G PLASTIC WHEEL 0599 NT.500- HX JAM ZNYC. Torque to ft-lbs. NOTES: 56_07 7-7

106 5" Deck _07

107 5" Deck INDEX NO. PART NO. QTY. DESCRIPTION BELT, B 5.5" EL 6079 LS PULLEY COVER 6078 RS PULLEY COVER 080 CS.-8 X.750 HX G FW. X.00 X. HRD Z DISCHARGE CHUTE TORSION SPRING CHUTE PIN CHUTE BRACKET CHUTE ADAPTER PLATE 0595 CB.75-6 X.00 STD CD NT.75-6 HXZY NL FW.06 X.8 X.060 SAE 60 BLADE, 8.50"-L-F-CW BLADE, F8.50"-H-F-CW BLADE, 8.50"-MUL-F-CW 7977 BLADE, 8.50"-GAT-F-CW CW.6.50 X.87 PNT CS.65- X.5 HX G5 Z NT.-8 HXZY NL "A" BLOWOUT BAFFLE CB.-8 X.750 FUL ZN FW. X.687 X.05/.080H NOTES:. Torque to 8 ft-lbs.. Do not torque; the discharge chute must pivot freely. 56_07 7-9

108 Deck Lift DETAIL VIEW _07

109 Deck Lift INDEX NO. PART NO. QTY. DESCRIPTION 0550 NT.75-6 HX GRD 5 ZNY FW.06 X.8 X.060 SAE FW.656 X.50 X.50 ZNY 089 HANDLE, DECK HT LOCK STEERLEVER BUSHING CS.75-6 X.500 HX G PIN, DECK HEIGHT STOP NT.7- HX FLG ZN DECK LIFT LINK, NON-SLOT CS.7-X.750 HX G GREASE FITTING STRAIGHT PIVOT SPACER BUSHING 06 CS.75-6 X.000 HX G5 088 LIFT PEDAL LINK DECK LIFT LINK PULLER STRAP DECK ADJUST PLATE LS (WITH DECAL) 8 60 DECK HEIGHT DECAL CS.75-6 X.5 HX G5 ZN NT.75-6 HX ZY NL NOTES: 56_07 7-

110 Deck Mounting Hardware _07

111 Section 8 Seat ROPS _07 8-

112 Seat VIEWED FROM UNDERNEATH _07

113 Seat INDEX NO. PART NO. QTY. DESCRIPTION SEAT 750 CS.7-0 X.50 G5 ZNY 079 FW.0 X.000 X.08 ZNY 60 SEAT BELT NT.7-0 HX GR5 ZNYC FW.5 X. X.9 HRD SEAT BELT CROSS BAR SEAT PAN (WITH DECAL) FW. X.687 X.05/.080H CS.-8 X.5 HX G NT.75-6 HXZY NL FW.06 X.8 X.060 SAE CS.75-6 X.5 HX G5 ZN 7985 COMPRESSION SPRING.5 X.00 X NT.75-6 HX GRD 5 ZNY 6 06 CS.75-6 X.000 HX G SB.75 X.75 SH NT.-8 HX G5 ZNYC CS.75-6 X.50 HX G5 Z BATTERY WARNINGS DECAL 600 SEAT LATCH 7890 TORSION SPRING 795 SEAT SWITCH NOTES:. Do not torque; the seat pan and latch must pivot freely. 56_07 8-

114 ROPS _07

115 ROPS INDEX NO. PART NO. QTY. DESCRIPTION 6079 ROPS KIT (WITH DECALS, SEATBELT & HARDWARE) 0776 CS.7-0 X.00 HX G8 ZNYC 707 FW.5 X.8 X.060 ZNYC 07 NT.500- UNT LK G8 ZN FW.5 X.06 X.090 SAE CS.500- X.75 HX G5 Z ROPS DECAL. Torque to 55 ft-lbs. NOTES: 56_07 8-5

116 8-6 56_07