Repair Parts Manual COUNTRY

Transcription

1 Repair Parts Manual COUNTRY ZERO TURN MOWER CHARG:..R TM Congratulations for buying a Country Clipper product. Your Country Clipper Zero Turn Radius Riding Mower was designed and built to provide long and trouble free service. Keep in mind that it, like any other mechanical device, can be potentially dangerous if used improperly, and hazard control and accident prevention are dependent upon the awareness, concern, prudence, and proper training of personnel involved in the operation, transport, maintenance, and storage of the equipment. Study this manual and pay special attention to the important Safety Precautions on pages 3-5. Following these instructions will help you continue to enjoy the trouble-free performance expected of the Country Clipper product.

2

3 SECTION - COUNTRY CLIPPER CHARGER 040 ZERO TURN RADIUS MOWER TABLE OF CONTENTS MOWER DECKS AND RELATED S. 5" DECK ASSEMBLY. 5" TRI-PORT DECK ASS EMBLY 3. 60" DECK ASSEMBLY 4. DECK SPINDLE ASSEMBLY 5. DOUBLE IDLER & RELATED S- 5" DECK 6. DOUBLE IDLER & RELATED S-5" TRI-PORT DECK 7. DOUBLE IDLER & RELATED S- 60" DECK 8. LIFT HANDLE ASSEMBLY & RELATED S 9. LIFT ASSEMBLY & RELATED S 0. TRANSMISSION IDLERS & RELATED S SECTION - TRACTOR FRAME AND RELATED S. CASTER WHEEL ASSEMBLY. FRAME SIDES & RELATED S 3. FENDER ASSEMBLY 4. SEAT, FOOT DECK ASSEMBLY & RELATED S 5. FRONT STEP ASSEMBLY 6. R.O.P.S. ASSEMBLY (ROLL OVER PROTECTION SYSTEM) & RELATED S SECTION 3 - TRACTOR DRIVE AND RELATED S 7. FUEL TANKASSEMBLY 8. JOYSTICK STEERING CONTROL & RELATED S 9. JOYSTICK STEERING CONTROL & RELATED S (CON'T) 0. JOYSTICK STEERING CONTROL & RELATED S (CON'T). TWIN STICK STEERING CONTROL & RELATED. PARKING BRAKE ASSEMBLY & RELATED S 3. GEAR MOTOR WHEEL ASSEMBLY 4. MOTOR ASSEMBLY & RELATED S FOR 5.5HP KAWASAKI 5. MOTOR ASSEMBLY & RELATED S FOR 6HP EFI KOHLER 6. HIGH PRESSURE LINES & FITTINGS 7. OIL RETURN LINES & COOLER ASSEMBLY 8. E-645 WIRE HARNESS ASSEMBLY & RELATED S 9. E-646 WIRE HARNESS ASSEMBLY & RELATED S 30. E-647 WIRE HARNESS ADAPTER & RELATED S 3. E-6547 WIRE HARNESS ADAPTER & RELATED S Country Clipper Division Shiwers Manufacturing Inc. 63 W. English St. Corydon, IA Ph Fax

4 5" HE AVY DECK ASS EMBLY ~6 68V- 00A~ q QTY P W W P P A A A W 0 D-387 F F F F F F F-83 8 F F F F F F-4 4 F-3 5 F-48 3 BUSHING DUST BAFFLE, 5" Hanger Weldment CHUTE HINGE BUSHING OUTLET STIFFENER w/decal PULLEY COVER w/decals 5" HEAVY DECK w/decals SPLITTER BAFFLE BELT, B-84 /4" Flat Washer 5/6" Flat Washer 5/6-8 x " Capscrew 3/8-6 x " Capscrew /" WASHER, CUSTOM 3/8-6 x -/4" Carraige Bolt Carriage Bolt, /4 X 3/4" / x -5/8" Clevis Pin CARRIAGE BOLT, /4 X -/" Nut, 5/6-8 Nyloc, Flanged 5/6-8 x " CARRIAGE BOLT, FHCS, /4-0 x 0.75, YZ, LOCK PATCH, GRS FHCS, 3/8-6 x 0.75, YZ, GR5 NUT, /4-0 NYLOC, FLANGED FHCS, 5/6-8 x.00, YZ, GR5 QTY. 6 F-5 8 Nut,3/8-6 Nyloc, Flanged 7 F-60 FHCS, 3/8-6x4/", YZ, GR5 8 F-6 4 FHCS, 3/8-6 x 6", YZ, GR5 9 F-6 FHCS, /4-0 x 3/4", GR5, YZ 30 F-575 SPRING, COMP.656 X.05 X.97 3 H Roller, 3-3/4 DIA. x 4-3/6L 3 H-39 4 /" Rue Ring 33 H-40 /" x 4-/" Clevis Pin 34 H-73 Chute, Discharge, Small 643-A CHUTE ASSEMBLY 35 H-77 Roller, 3-3/4 DIA. x 3 /4"L 36 H-787 GRIP, DECK HANDLE 37 P-0935 Decal, WARNING 38 P-094 DECAL "DANGER ROTATING BLADES" 39 P-43 DECAL, HOIST POINT 40 P-93 DECAL, JAZEE DECK BELT ROUTING 4 P-95 DECAL, DECK SIZE, 5 4 P-496 DECAL, MISSING CHUTE 43 P-706 WARNING DECAL, DISCHARGE CHUTE A DECK PROP ASS'Y, EDGE XL T 45 3 SPINDLE ASS'Y (SEE pg.4) 46 DOUBLE IDLER ASS'Y (SEE pg.5) 47 REAR IDLER ASS'Y (SEE pg.5) 48 FRONT IDLER ASS'Y (SEE pg.5)

5 5" TRI- PORT DECK ASSEMBLY ~686K- 00A~ Q QTY P W P P A A A W W W A D F F F F F F F F-09-0 F F-5 3 F-58 0 BUSHING Hanger Weldment SCALPER BRACKET ROLLER, " OUTLET STIFFENER w/decal RUBBER CHUTE ASS'Y, SM. PULLEY COVER w/decals SPLITTER BAFFLE BAFFLE, DISCHARGE WLDT 8" TUBE WLDT. 5" TRIPORT DECK w/decals BELT, B-84 5/6-8 Nyloc Nut 3/8-6 Stover Nut /4" Flat Washer 5/6" Flat Washer 5/6-8 x 7/8" Capscrew 5/6-8 x " Capscrew /4" LockWasher 5/6" LockWasher 3/8" LOCKWASHER 5/6-8 Stover Nut /4-0 Stover Nut QTY. 4 F-5 6 /" WASHER, CUSTOM 5 F /4-0 x 3/4" Capscrew 6 F /8-6 x 7/8" Capscrew 7 F /6-8 x 3/4" CARRIAGE BOLT 8 F /8-6 x -/4" Carraige Bolt 9 F /8-6 x 6" Capscrew 30 F-889 / x -5/8" Clevis Pin 3 H Roller, 3-3/4 DIA. x 4-3/6L 3 H-39 4 /" Rue Ring 33 H-40 /" x 4-/" Clevis Pin 34 H-575 SPRING, COMP.656 X.05 X H-78 /" x 5-/" Clevis Pin 36 P-0935 Decal, WARNING 37 P-094 DECAL "DANGER ROTATING BLADES" 38 P-43 DECAL, HOIST POINT 39 P-93 DECAL, JAZEE DECK BELT ROUTING 40 P-95 DECAL, DECK SIZE, 5 4 P-496 DECAL, MISSING CHUTE A DECK PROP ASS'Y, EDGE XL T 43 3 SPINDLE ASS'Y (SEE pg.4) 44 DOUBLE IDLER ASS'Y (SEE pg.6) 45 REAR IDLER ASS'Y (SEE pg.6) 46 FRONT IDLER ASS'Y (SEE pg.6)

6 60" HE AVY DECK ASS EMBLY ~668U- 00A~ Q / 4 QTY P W W P P A A A W 0 D-387 F F F-74 4 F F F F-83 8 F F F F-9 4 F-3 3 F F-5 4 BUSHING Hanger Weldment 60" DUST BAFFLE WELDMENT CHUTE HINGE BUSHING OUTLET STIFFENER w/decal PULLEY COVER w/decals 60" DECK WLD w/decals SPLITTER BAFFLE BELT, B-84 5/6" Flat Washer 5/6-8 x " Capscrew 3/8-6 X " CARRIAGE BOLT /" WASHER, CUSTOM 5/6-8 x 3/4" Capscrew 3/8-6 x -/4" Carraige Bolt Carriage Bolt, /4 X 3/4" / x -5/8" Clevis Pin Nut, 5/6-8 Nyloc, Flanged 5/6-8 x " CARRIAGE BOLT, FHCS, /4-0 x 0.75, YZ, LOCK PATCH, GRS NUT, /4-0 NYLOC, FLANGED FHCS, 5/6-8 x.00, YZ, GR5 Nut,3/8-6 Nyloc, Flanged 3 QTY. 5 F-57 CARRIAGE BOLT, /4 X -/4" 6 F-60 FHCS, 3/8-6x4/", YZ, GR5 7 F-6 4 FHCS, 3/8-6 x 6", YZ, GR5 8 F-575 SPRING, COMP.656 X.05 X.97 9 H Roller, 3-3/4 DIA. x 4-3/6L 30 H-39 4 /" Rue Ring 3 H-40 /" x 4-/" Clevis Pin 3 H-78 /" x 5-/" Clevis Pin 33 H-73 Chute, Discharge, Small 643-A CHUTE ASSEMBLY 34 H-77 Roller, 3-3/4 DIA. x 3 /4"L 35 H-787 GRIP, DECK HANDLE 36 P-0935 Decal, WARNING 37 P-094 DECAL "DANGER ROTATING BLADES" 38 P-43 DECAL, HOIST POINT 39 P-93 DECAL, JAZEE DECK BELT ROUTING 40 P-95 DECAL, DECK SIZE, 60 4 P-496 DECAL, MISSING CHUTE 4 P-706 WARNING DECAL, DISCHARGE CHUTE A DECK PROP ASS'Y, EDGE XL T 44 3 SPINDLE ASS'Y (SEE pg.4) 45 DOUBLE IDLER ASS'Y (SEE pg.7) 46 REAR IDLER ASS'Y (SEE pg.7) 47 FRONT IDLER ASS'Y (SEE pg.7) P-3 59

7 TORQUE TO 40 ft-lb PULLEY NOT INCLUDED * IN ASSEMBLY - DECK SPINDLE ASSEMBLY 69FN-00A (APPLY THIN LAYER OF CHEVRON RYKOTAC GREASE TO THE TOP SURFACES OF THE BEARING AND HOUSING PRIOR TO INSTALLING ITEM #3 (BEARING CAP). 5 8 NEW MOWERS ARE SHIPPED WITH 3 to 4 oz OF CHEVRON SRI NLGI GREASE INSIDE EACH SPINDLE HOUSING. BLADE NOT INCLUDED IN ASSEMBLY ~ 0 TORQUE TO 00 ft-lb QTY. QTY. F-078 3/4-6 TOP LOCK NUT F /8-4 X.5 CAP SCREW P * 5" DECK CENTER PU LLEY 3 F /8 LOCK WASHER * P * 60" DECK CENTER PULLEY 4 F /8-4 LOCK NUT P CAP, BEARING 5 H- 707 GREASE PACKET 4 H-639 O'RING, RUBBER 6 H- 884 FUSION, HIGH LIFT 8 3/8" CUT 5" 5 D-3867 BEARING, #606 H-886 FUSION, HIGH LIFT, " CUT 60" P SHAFT, SPIND LE P HOUSING, SPINDLE OPTIONAL BLADES P BLADE DRIVER H- 660 BLADE, LOW LIFT, 8 3/8" CUT, 5" P BLADE WASHER H- 66 BLADE, LOW LIFT, " CUT, 60" 0 F-073 5/8- X.5 HHCS GR. 8 H-666 BLADE, GATOR, 8 3/8" CUT 5" P 4 SPINDLE SPACER WASHER H-667 BLADE, GATOR, " CUT 60" 4

8 DOUBLE IDLER DRIVE BELT IDLER & RELATED S 5" DECK REAR STATIONARY IDLER ASSEMBLY 6 FRONT STATIONARY IDLER ASSEMBLY '4 7 QTY. 60-0P P P P P P P P P P 668-0P P 3 D D D D F F F WASHER, BEARING CAP Mounting Pin Belt Tightner Ann Idler Ann Double Idler Mount EXTENSION FOR SPRING SPACER BELT KEEPER BELT KEEPER, SINGLE END HANDLE, BELT TENSIONER SPACER, BELT GUARD BELT GUARD Flanged Bushing 5/8" Bore PULLEY,FLATIDLER,6"(NTN) PULLEY, V-IDLER, 4.59 OD, AB, NTN PULLEY, FLAT IDLER, NTN, DBL INSERT 3/8-6 Stover Nut /-3 Stover Nut 3/8" Flat Washer 5 QTY. 0 F F F F F F-56 6 F F F-8 9 F F F F F-4 34 F F-5 36 H H-69 3/8" LOCKWASHER 3/8-6 x " Capscrew /" LOCKWASHER /-3 Hex Jam Nut /" WASHER, CUSTOM /-3 x-/" Capscrew 3/8-6 x 7/8" Capscrew /4" x /" DRIVE SCREW /-3X-/4" CARRIAGE BOLT 3/8-6 x -/" Carraige Bolt /-3 THIN NYLOC NUT 3/8-6 x " Carraige Bolt /-3 X 3" CARRIAGE BOLT FHCS, 3/8-6 x 0.75, YZ, GR5 Nut,3/8-6 Nyloc, Flanged Nut, /-3 Nyloc, Flanged BALL, -/4" SPRING,5 X -/,TAPERED ENDS

9 DOUBLE IDLER DRIVE BELT IDLER & RELATED S 5" TRI-PORT DECK 3 I RIGHT REAR STATIONARY IDLER ASSEMBLY FRONT STATIONARY IDLER ASSEMBLY..7 QTY P EXTENSION FOR SPRING P HANDLE, BELT TIGHTENER P BELT TENSIONER 4 F-083 WASHER, 3/8 FENDER 5 D-393 "V'' IDLER PULLEY 6 D-394 IDLER PULLEY 7 F /8 LOCK NUT 8 F /8 FLAT WASHER BSP MOUNTING PIN P IDLER ARM F-5 4 /" FLAT WASHER 60-0 P 4 BEARING CAP 3 F /" LOCK NUT 4 F-8 /-3 X -/4" GR. 5 5 H-69 SPRING, 5x - /, TAPPERED ENDS P BELT KEEPER P SPACER 8 D-3730 BUSHING, TEFLON COATED 9 F-976 3/8-6 X -3/4" CARRIAGE BOLT 0 F-733 /4" DRIVE STUD F-865 3/8-6 X -/" CARRIAGE BOLT 6 QTY P 3 F F P P 7 D P 9 F P 3 F F F P MOUNT, DOUBLE IDLER 3/8-6 X " GR. 5 /-3 X -/" GR. 5 BELT GUARD SPACER, BELT GUARD 6" IDLER PULLEY SHACKLE /" THIN NYLOC NUT BELT KEEPER, SINGLE END /" LOCK WASHER /" THIN NUT /" -3 X 3" CARRIAGE BOLT 3/8" SPACER

10 DOUBLE IDLER DRIVE BELT IDLER & RELATED s S 60" DECK REAR STATIONARY IDLER ASSEMBLY 35 FRONT STATIONARY IDLER ASSEMBLY QTY. QTY. 60-0P P P P P P P P P P P 66-05P P P 5 D D D D F F WASHER, BEARING CAP Mounting Pin Idler Arm 3/8" Spacer Double Idler Mount EXTENSION FOR SPRING SPACER BELT KEEPER BELT KEEPER, SINGLE END BELT TIGHTENER ARM HANDLE, BELT TENSIONER SHACKLE SPACER, BELT GUARD BELT GUARD Flanged Bushing 5/8" Bore PULLEY, FLAT IDLER, 6" (NTN) PULLEY, V-IDLER, 4.59 OD, AB, NTN PULLEY, FLAT IDLER, NTN, DBL INSERT 3/8-6 Stover Nut 3/8" Flat Washer 7 F F F F F F F-8 8 F F F F F-4 33 F F-4 35 F F-5 37 F H H-69 3/8" LOCKWASHER /" LOCKWASHER /-3 Hex Jam Nut /" WASHER, CUSTOM 3/8-6 x 7/8" Capscrew /4" x /" DRIVE SCREW /-3X-/4" CARRIAGE BOLT 3/8-6 x - /" Cerraige Bolt /-3 THIN NYLOC NUT 3/8-6 x " Carraige Bolt /-3 X 3" CARRIAGE BOLT FHCS, 3/8-6 x 0.75, YZ, GR5 FHCS, 3/8-6 x.5, YZ, GR5 FHCS, 3/8-6 x ", VZ, GR5 Nut,3/8-6 Nyloc, Flanged Nut, /-3 Nyloc, Flanged FHCS, /-3 x-3/4", YZ, GR5 BALL, -/4" SPRING,5 X -/,TAPERED ENDS

11 LIFT HANDLE ASSEMBLY & RELATED S 8 \ QTY P LIFT HANDLE, LOWER 659-0W FRAME WELDMENT, LH. 3 F-6 3/8-6 X " CAPSCREW P HANDLE LINK P HANDLE PIVOT BRACKET P TOP PEG LATCH PLATE P LIFY HANDLE, UPPER 8 H-60 SPRING, /" OD. X 8" P PLT, SPRING MOUNT 0 F-67 CARRIAGE BOLT, 3/8-6 X /4" P SPRING ANCHOR PLATE F-5 NUT, /-3, NYLOC FLANGED 3 F-5 4 FHCS, /-3 X /4", YZ GR5 4 F-439 /-3 X 3" GR. 5 QTY P HANDLE PIVOT PIN 6 F-5 7 NUT, 3/8-6, NYLOC FLANGED 7 F-889 CLEVIS PIN, / X 5/8" 8 F-5 /" FLAT WASHER 9 H-39 RUE RING, /" 0 H-34 VINYL GRIP, 3/8 X /" 663-0BOP BAR, SPRING EXT. F-8 FHCS, /-3 X ", YZ GR5 3 F HEX NUT, / SEE PAGE 9 8

12 LIFT ASSEMBLY & RELATED S ---~ 659-7A RELEASE HANDLE ASSEMBLY QTY. QTY P DRAG BAR TAB P DECK HOOK P 4 DRAG LINK BAR W RELEASE HANDLE WELDMENT P LIFT BAR P HOOK KEEPER P LIFT SLEEVE, FRONT 3 H-547 SPRING, TORSION P LIFT SLEEVE, REAR 4 F-5 NUT, 3/8-6, NYLOC FLANGED 6 F-879 5/6-8 X /4" GR.5 5 F WASHER, FLAT, 3/8" 7 F-5 5/6-8 STOVER NUT 6 F-87 PIN, GROOVED, "C", /4 X.50" P DECK LIFT PEDAL 7 F-6 FHCS, 3/8-6 X, YZ, GR P 4 HANGER PIN 8 H-40 TREAD PAD 0 F-85 CLEVIS PIN, / X /" 9 H-96 /4"x" HANDLE GRIP F NUT. /" JAM W FRONT AXLE WELDMENT F /-3 X 3 /, " THREAD P LATCH PLATE 3 F-5 7 WASHER, / NARROW P PLATE, CATCH 4 H-39 7 RUE RING, /" 33 F-3 NUT, /4-0, NYLOC FLANGED 5 F-890 CLEVIS PIN, / X 3 /" 34 F-83 CARRIAGE BOLT, /4-0 X 3/4" 6 F CLEVIS PIN, / X 3/4" 35 F-5 NUT, /-3, NYLOC FLANGED 7 F /6-4 x " HHCS 36 F /6-4 JAM NUT P ADJUSTABLE HANGER END 37 F-88 /-3 x 3- /" CAPSCREW A RELEASE HANDLE ASSEMBLY 9

13 TRANSMISSION IDLERS & RELATED S 5-(x) OF IDLER ARM ASS'Y # 5 QTY SSP Mounting Pin A Hydro Idler Arm Assembly P PLATE, PUMP ADAPTER 4 D-3904 PULLEY, FLAT IDLER, 5" 5 F /8" Flat Washer 6 F /" FLAT WASHER 7 F /8-6 x -/" capscrew 8 F-073 3/8-6 x" capscrew QTY. 9 F /-3 x 3-/" capscrew 0 F Nut, 5/6-8 Nyloc, Flanged F-48 0 FHCS, 5/6-8 x.00, Y, GRS F-5 5 Nut,3/8-6 Nyloc, Flanged 3 F-5 3 Nut,/-3 Nyloc, Flanged 4 H-69 SPRING,5 X -/,TAPERED ENDS 5 D-3730 FLANGED BUSHING 0

14 0 CASTER WHEEL ASSEMBLY NOTCH TO REAR OF MOWER 9 4 NUT TO INSIDE OF MOWER VALVE STEM TO 6 OUTSIDE OF MOWER NO P QTY. Bearing cap P W Stop Tab WLDT,AXLE,FRONT W D WLD'T, CASTER YOKE Bearing SF-6-3 D-3936 TIRE PSS'Y, WHITE, SMOOTH, 3X F /6" LockWasher QTY. F-855 F F- 0 F-94 F P 3/6 x l" Roll Pin (Heavy Duty) /4 x 5/8 Self Tapping capscrew FHCS, 5/6-8><.00, Yl., LOCK PATQ-, G HHCS, 3/4-0 X 9-/, VZ, G NUT, FLANGE NYLOC, Y CAP FOR BEARINGS

15 FRAME SIDES & RELATED S 7 QTY W FRAME SIDE RH W FRAME SIDE LH W AXLE MOUNTING WLDT W MOTOR MOUNT WLDT P SIDE PANEL RH. (JOYSTICK) P SIDE PANEL RH. (TWINSTICK) P SIDE PANEL LH. (JOYSTICK) P SIDE PANEL LH. (TWINSTICK) 7 F-386 /-3 X -/4" GR A ENGINE GUARD w/decal 9 F-40 4 FHCS, /-3 x -/" GR P DRAG BAR TAB H-773 BEARING, FLG-SPHERICAL, IGUS F-5 0 NUT, 3/8-6, NYLOC FLANGED 3 F-8 FHCS, /-3 x GR.5 4 F-7 5 FHCS, /-3 X -/4" GR.5 5 F-5 8 NUT -3 NYLOC FLANGED QTY. 6 F-4 4 FHCS, X 3 4 GR.5 7 F-8 FHCS, /-3 X ", GR.5 8 H-8 SEAL SHAFT 9 D-385 BEARING, TAPARED SET W FRONT AXLE WELDMENT P-986 DECAL, NEW CC, CHROME, LG F-6 FHCS, 3/8-6 x " GR.5 3 D-386 BEARING, TAPARED SET P " WASHER 5 F-78 3/6 X " COTTER PIN 6 F-74-4 SLOTTED NUT 7 H-94 GREASE CAP 8 F-5 4 FHCS, 3/8-6 x -/4", YZ, GR P GUARD, BUMPER P PLATE, SPRING MOUNT 3 F-0-05 HEX NUT, /-3

16 FENDER ASSEMBLY & RELATED S QTY A FENDER CAP w /DECAL, RH, (JS) 69-89A FENDER CAP w /DECAL, EFI, RH, (JS A FENDER CAP w /DECAL, RH, {TS) A FENDER CAP w/decal, EFI, RH, (TS 5 P-95 DECAL, CONTROL PANEL 6 P-37 DECAL, CONTROL PANEL, EFI A FENDER CAP w/decal, LH (JS) A FENDER CAP w/decal, LH (TS) 9 4 P-38 DECAL, PARK BRAKE A FENDER SKIRT w/decal, RH A FENDER SKIRT w/decal, LH 7 P-99 DECAL, NEW CC, SM, CHROME A LATCH PLATE RH W/DECAL P LATCH PLATE LH SEE PAGE SEE PAGE 7 3 TWINSTICK FENDER ASSY QTY. F-9 8 FHCS, /4-0x3/4", GR.5 w/patch F-5 3 5/6-8 LOCK NUT A LOCK PIN, DECK HEIGHT, ASS'Y F- 8 FHCS, 5/6- Bxl" GR.5 w/patch F-0 5 FHCS, 5/6-8 X 3/4" GR A FRONT PANEL w/decals F / 6-8 "U"-NUT F /4-0 "U"-NUT H-8 CUP HOLDER P-034 DECAL, "CUT HEIGHT" P-3000 DECAL, "USA" P-557 DECAL, "CAUTION" P-370 DECAL, WARNING H-66 U CHANNEL TRIM 659-6P NEUTRAL PLATE P-986 DECAL, NEW CC, LG, CHROME

17 SEAT, FOOTDECK & RELATED S UNDERSIDE OF SEAT MOUNTING BASE "#" - LATCH S 5 \~4 \ 3 7~ 4 Qi 3 / / _ 6-8,. u.owerside PLATE I QTY P PLATE, SEAT P PLT, REAR SEAT FI LLER P PLATE, ARM REST RH P PLATE, ARM REST LH (JOYSTICK) P PLATE, ARM REST LH (TWINSTICK) 5 H-763 PAD, ARM REST A FOOT DECK w /DECAL, CHARGER P PIN, SEAT HINGE P LIFT BAR 9 H- 755 SEAT H- 90 COVER FOR SEAT H P PLATE, LATCH SLIDE LONG P-34 SERIAL TAG F /8-6 LOCK NUT 3 P-473 SERIAL TAG LAMINATION DECAL 4 F-486 3/8-6 JAM NUT 5 F- 0 4 FHCS, 5/6-8x3/4" GR5 6 F /6 FLAT WASHER 7 H-764 HANDLE, JOYSTICK 8 F- 4 FHCS, 3/8-6 X ", YZ, GR5 9 F-48 FHCS, 5/6-8 X " YZ GR P SPACER, SEAT PAN F- 5 FHCS, 5/6-8x - /4" GR5 F /8-6 NYLOC NUT, FLANGED 3 F- 6 FHCS 5/6-8x" w/patch QTY. F-6 FHCS, 4-0 X 3 4, GR5, YZ F /4" FLAT WASHER F-06 /"x3/8 SHOULDER BOLT, SOCKET F- FHCS, 5/6-8 X -/4 YZ, GR5 F-0 0 FH CS, 5/6-8x3/4" GR5 F NUT, 5/6-8, NYLOC FALNGED P SHELF, REAR, FUEL TANK P BAR, REINFORCEMENT, SEAT H- 460 CABLE F-5 4 /" WASHER E-6347 SEAT SWITCH H-635 3/4x4" EXTENSION SPRING F-3 NUT, /4-0, NYLOC FLANGED F- 858 /4-0 "U" NUT H- 96 HANDLE, GRIP F-06 /"x /" SHOULDER BOLT H-608 SPRING, ASSIST F-785 SCREW,HX WASHER HD #4 X 3/4" H-636 SPRING, CMPR, SEAT CHARGER P BATTERY HOLD DOWN F-09-0 / 4" LOCK WASHER W WLDT, BRAKE HANDLE P-98 DECAL, CHARGER, CHROME H-46 3 RUBBER BUMPER H- 80 PLASTIC PLUG

18 FRONT STEP ASSEMBLY ~ QTY P FRONT STEP F-4 FHCS, 3/8-6 X 4" GR.5 3 F-5 4 NUT, 3/8-6, NYLOC FLANGED P BRACKET, STEP MOUNT, RH P BRACKET, STEP MOUNT, LH 6 H-46 RUBBER BUMPER BUTTON 7 F-4 FHCS, 3/8-6 X 3/4" GR.5 5

19 ROPS ASSEMBLY (H-68) AND RELATED S ' _ MOWER LEFT SIDE PANEL --- QTY F-088 F-089 F-090 F-093 H-70 H-700 F-09 F HHCS /-3 x /4" FLAT WASHER /"<t, TOP LOCK NUT /",p PULL PIN-/ W/COTTER KEY SPRING POLYURETHANE CHANNEL HHCS /-3 x /" NLN /-3 GR 8 6

20 FUEL TANK ASSEMBLY H-75 (INCLUDES ALL S EXCEPT #) r~ 3 6 ~ (J I QTY GALLON TANK, VENTED H-743 GAS CAP, RATCHET 3 H ft FUEL LINE 4 H-74 PICK UP TUBE 5 H-74 GROMMET, PICK UP TUBE 6 H-687 HOSE CLAMP, /" 7 H-678 REMOTE VENT 8 H-679 REMOTE VENT GROMMET 9 H ft VENT LINE 0 H-698 VENT LINE CLAMP 7

21 JOYSTICK STEERING CONTROL AND RELATED S QTY. 65-A JOYSTICK ASSEMBLY F-03 BUTTON SHCS, /4-0x" 65-9P PIN, PIVOT, JS, LONG F-5 /" WASHER 65-6P SPACER, JOYSTICK PANEL F NUT, 5/6-8, NYLOC FLANGED F-3 NUT, / 4-0, NYLOC FLANGED F-00-0 /4-0 x 3-/" CAPSCREW 65-6P BUSHING,.375 ROD END, SHORT 8 QTY P LINKAGE, INNER, JOYSTICK 65-07P BUSHING,.375 ROD END 65-lOOP TUBE, PIVOT, JOYSTICK P, OUTER, LINKAGE, JOYSTICK 4 F-0 3 FHCS, 5/6-8 x 3/4" GR5 5 H-99 BOOT 6 H-765 NUT, JOYSTICK 7 H-764 HANDLE, JOYSTICK

22 JOYSTICK ASSEMBLY 65-A 9 / TORQUE TO: 0 FT-LBS - YOKE, SWIVEL ASSEMBLY!65-9AI ITEM QTY A ROD ASSEMBLY, SHORT H-947 GASKET. FOAM, JOYSTICK P HOUSING, JOYSTICK P PIN, PIVOT, JOYSTICK 5 F-03 BUTTON SHCS, /4-0 x ", CZ W NEUTERAL PLATE, WLDT 7 E-6474 SWITCH, SNAP MOUNT P MOUNT, SWITCH 9 F /4-0 LOCK NUT P TUBE, GUIDE, CONTROL ROD P YOKE, SWIVEL, JOYSTICK H-705 RING, DETENT,.75 EXT. 3 F-37 NUT, #-4, NYLOCK P SPACER, CAM DETENT ITEM 5 F H P P 9 F-36 0 F-35 F-93 F D P 5 D F-5 7 H F QTY. 3/6 x " SPIRAL PIN SPRING, DETENT, JOYSTICK TAB, CAM DETENT TUBE-SPACER, DETENT CAM WASHER, FLAT, # PLAIN SCR, PANHD, PHLPS, #-4x-3/4" /-3 x " CAPSCREW /" FLAT WASHER THRUST BEARING PIVOT, JOYSTICK ( OF 65-8A) BUSHING, FLANGED ( OF 65-8A) /" WASHER, CUSTOM SPRING, BELLEVILLE,.50x x.073 /-3 STOVER NUT 9

23 JOYSTICK STEERING CONTROL AND RELATED S (CON'T) 8 "" QTY P HYDRO SHIFT ROD F-063 NUT, 5/ 6", NYLOC FLANGED 3 F /6" FLAT WASHER 4 F-75 5MM x 6MM ROLL PIN 5 H-467 DUAL ACTION DAM PER, LITE DUTY 6 H-468 LINKAGE, JOYSTICK P OUTER, LIN KAGE, JS P LINKAGE, INNER, JS 9 F /8" LOCK WAS HER 0 SEE PAG E 4 F /4-0 X " BOLT GR P LEVER, CONTROL QTY P DAMPNER BOLT, FEMALE 4 F-60 4 E-RING P 4 5/6-8 X 3/4" DAMPNER BOLT P SWIVEL ARM 7 F-394 3/8-6 X " CAPSCREW BUSHI NG 9 F-09-0 / 4" LOC K WASHER 0 F- 539 /4-0 X /4" CAPSCREW F- 58 /4-0 STOVER NUT F /4" FLAT WASHER 3 F-06 SHCS, -4 X -/4, ZIN C 0

24 TWINSTICK STEERING CONTROL & RELATED S (RIGHTHAND SHOWN, LEFTHAND OPPOSITE) _ 3 TRANSMISSION/ 5 QTY P LINK ROD ASSEMBLY H-739 GRIP, 5", CLOSED END W DUAL LEVER CONTROL 4 F NUT, 5/6-8, NYLOC FLANGED 5 F-9 FHCS, 5/6-8 X /" w/patch 6 H-465 ADAPTER, ROD END, LONG P 3 TUBE SPACER P LOWER SHIFT BLOCK 9 F-5 WASHER 0 F-060 /-3 NUT, FLANGE LOCK 606-5P WASHER, NYLON / ID x /8" F-93 HHCS, /-3 X ", YZ GR5 3 F-5 NUT, 3/8-6, NYLOC FLANGED P SHIFTING YOKE 5 F-8 FHCS, /4-0 X -/4", YZ GRS QTY. F-486 3/8-6 JAM NUT F /4" LOCK WASHER F-60 E-RING FOR /4" SHAFT F-307 3/8-6 X /4" CAPSCREW D-3730 FLANGED BUSHING 5/8" BORE F /6-8 x 3 /" CAPSCREW E-6474 SWITCH, SNAP MOUNT 647-4P MOUNTING BRACKET (RH) P MOUNTING BRACKET (LH) F-3 NUT, /4-0, NYLOC FLANGED F-045 SPACER F / 4" FLAT WASHER P DAMPER BOLT, /4-0 H-843 DUAL ACTION DAMPNER, 750N P DAMPER BOLT, 5/6-8 X 3/4"

25 PARKING BRAKE ASSEMBLY & RELATED S SEE PAGE 3 FOR SEAT HINGE S QTY P F W W F P W F-73 F-438 F W W 663-P LINK, ADJUSTABLE, BRAKE 3 NUT, /" FLANGED, NYLOC 4 WLDT, CAM LEVER 5 BRAKE ROD WLDT 6 5/6-8 x " CAPSCREW 7 PIN, PIVOT 8 BRAKE ARM WLDT 9 SHOULDER BOLT,.37x.37, SOCKET 0 3/8 X 3/4" CLEVIS PIN ROLL PIN, 3/6 X " HVY. DUTY SHORT BRAKE ARM (LH) 3 SHORT BRAKE ARM (RH) 4 ROD, BRAKE LINK QTY P 4 BRAKE ANCHOR LINK F-49 8 /8 X " COTTER PIN D-3668 BRAKE BAND 6" X " WIDE F /8 X 5/6" CLEVIS PIN H-96 GRIP HANDLE W WLDT, BRAKE HANDLE D /8x - /8. FLG BALL BEARING F-77 3/8-6 x -/" CARRAIGE BOLT F-47 FHCS, 3/8-6 x - /", YZ, GR5 F-5 NUT, 3/8", FLANGED, NYLOC F-53 FHCS, 5/6-8 X -3/4", YZ, GR5 F WASHER, 5/6"

26 GEAR MOTOR,WHEEL ASSEMBLY 3 I 8 TORQUE TO: 00 FT-LBS I QTY W P 4 3 F D F F A 8 F H H-798 D-3669 F D P MOTOR MOUNT BRAKE MOUNT NUT, /-3, NYLOC FLANGED 5.9 CIR PARKER WHEEL MOTOR /-3 X 3/4" BOLT GR. 5 WHEEL STUD (REPLACEMENT) WHEEL HUB 3/4-6 CASTLE NUT /8 X /" COTTER PIN GREASE CAP TIRE/WHEEL ASSEMBLY LUG NUT /-0 X 60 DEG. / 4 X " WOODRUFF KEY WHEEL BACKING PLATE 3

27 MOTOR ASSEMBLY & RELATED S FOR 5.5HP KAWASAKI 9 3,,-! ~!"' --J 5 -.-$. '-.~ 6 30~ ~ : 8 ::: ~-- - ~ TORQUE TO : 55FT-LBS QTY. M-5384 P H-87 4 H-60 5 H E H D W 0 F-737 F-738 F D P 5 F-5 4 ENGINE, KAWASAKI, 5.5HP DECAL, "CLEAN" CHOKE CABLE THROTTLE CABLE OIL DRAIN OIL PRESSURE SWITCH MUFFLER (KAWASAKI) V-BELT A-7 KEVLAR MOTOR MOUNT 6mm X 6mm BOLT GR. 5 6mm SPRING WASHER WASHER,.840 X.46 X.5 KEY - 5mm x 0mm HYDRO PUMP PULLEY FHCS, 3/8-6 X /4" GR5 NO. NO. QTY. 6 F-0 7 F F F P F-063 D D F F P 7 F-3 8 E P 30 F-043 FHCS, X 3 4 GR5 FHCS, 3/8-6x-/4", YZ, GR5 /4-0 NYLOC SETSCREW 3/8" LOCK WASHER CLUTCH STOP NUT, 5/6-8, NYLOC FLANGED PUMP, cc, RH PUMP, cc LH 3/8" FLAT WASHER NUT, 3/8-6, NYLOC FLANGED KEY, /4" SQ. X /4" 7/6-0x-/" CAPSCREW, GR8 /8" CLUTCH BRAKE MOTOR PULLEY SPACER

28 MOTOR ASS EMBLY & RELATED S FOR 6HP EFI KOHLER,/ 9 3 ~ 5 I 0 30 QTY. M-5396 ENGINE KOHLER, 6.5HP EFI P-0077 DECAL, "CLEAN " 3 H-589 OIL DRAIN ( KOHLER) 4 H-60 THROTTLE CABLE P PLATE, DEFLECTOR EFI P PLATE, DEFLECTOR COVER 7 H-85 MUFFLER 8 D-354 V-BELT A-7 KEVLAR W MOTOR MOUNT 0 F-737 6mm X 6mm BOLT GR. 5 F-738 6mm SPRING WASHER F-736 WASHER,.840 X.46 X.5 3 D-354 KEY - 5mm x 0mm P HYDRO PUMP PULLEY 5 F-5 4 FHCS, 3/8-6 X /4" GR5 6-0 FHCS, 5/6-8 X 3/4" GR5 5 7 F F-8 9 F P F-063 D D F F P 7 F-3 8 E P 30 F F-00 3 F-448 QTY. 4 HFCS, 3 8-6x-, THRO FORM 3 /4-0 NYLOC SETSCREW 4 3/8" LOC K WASHER CLUTCH STOP NUT, 5/6-8, NYLOC FLANGED PUMP, cc, RH PUMP, cc LH 8 3/8" FLAT WASHER 4 NUT, 3/8-6, NYLOC FLANGED KEY, /4" SQ. X /4" 7/6-0x-/" CAPSCREW, GR8 /8" CLUTCH BRAKE MOTOR PULLEY SPACER (KAWASAKI) 3 HEX M/S (ZINC) 0-3 X 7 /8 3 LOCKNUT, 0-3 NYLOC YELLOW PLTD P-3 59

29 PLUMBING KIT HIGH PRESSURE LINES & FITTINGS ih-846~ TORQUE TO: 3 35FT- LBS ~ TORQUE TO: 4FT- LBS 4 TORQUE TO: 4FT-LBS 8 TORQUE TO: 4FT-LBS TORQUE TO: 35FT-LBS / I\-.~ 5 \ TORQUE TO: 4FT-LBS 3 TORQ UE TO: 4FT-LBS \ 7 VIEWED FROM FRONT RIGHT D-3908 H H-49 4 H F F- 3 8 H QTY. 4 4 WHEEL MOTOR FITTING, STR IGHT, 7 /8-4 TUBE ASS 'Y, LH. FORWARD TUBE ASS'Y, LH. REVERSE SEE PAGE 4 /4-0 X " BOLT GR. 5 NUT, /4-0, NYLOC FLANGED FITTING, STRAIGHT, 3/ 4" X /"

30 PLUMBING KIT OIL RETURN LINES & COOLER ASSEMBLY ih-846~ / 9 TORQUE TO: 6FT-LBS - -8 TORQUE TO: 6FT-LBS 8 TORQUE TO: 6FT- LBS 5 QTY. H-908 OI L COOLER 3 F /4" WAS HER 4 3 F-6 6 FHCS, /4-0x3/4", YZ, GR5 5 4 F- 0 FHCS, 5/6-8x3/4", YZ, GR5 6 5 F- 3 4 NUT, /4-0, FLANGED NYLOC 7 6 H-8 3 HOSE CLAMP 8 7 H-438 4" HOSE, 3/8" ID. HI TEMP. 9 8 H /6" ADAPTER SEE PAGE 4 0 H-97 CAP,.5" THREAD VENTED F-5 5/6-8 STOVER NUT 3 H-805 OI L TANK 4 7 H-847 H-859 H-858 H- 860 F H-849 H-848 F P P F-063 H- 535 QTY " HOSE, 3/8 id. HI TEMP. OIL FILTER FILTER BASE HOSE BARB 90 DEG. ELBOW / 4" LOCK WASHER RETURN HOSE TEE ASSEMBLY SUCTION HOSE TEE ASS EMBLY 5/6-8 x " CAPSCREW BRACKET, COOLER BRACE, COOLER NUT,5/6-8, FLANGED NYLOC 7 8" CLAMP

31 E-645 WIRE HARNESS & RELATED S (JOYSTICK) / TO SEAT SWITCH BLUE 4---fiBLUE #A ~-0 Seat SW Clutch BLK. YEL RED () BLUE"""~ 6 ~RED YEL ~ 5:f ~ lgolt;oo 0NCLUDES #6) REC -----n BU<.~ () RED ~ \ () BLUE~ED ~ ~BU<. \ () RED 8 QTY * E-67 E E- 648 E E E- 647 E P E-6369 E-697 F-858 F-09-0 E- 607 F F-58 F E-6445 E-646 E-6374 BATTERY HOUR METER CABLE, BATTERY TO SOLENOID START SWITCH CLUTCH SWITCH WIRE HARNESS ADAPTER (KAWASAKI) WIRE HARNESS ADAPTER (KOHLER) BATTERY HOLD DOWN RETAINER CLIP BRAKE SWITCH /4-0 U-NUT / 4" LOCK WASHER FUSE, #ATC- 30 /4-0 X 3/4" GR. 5 /4-0 LOCK NUT / 4" FLAT WASHER KEY, SET CLUTCH SPIKE SUPPRESSOR (KOHLER) SEAT SWITCH (NOT SHOWN) 8

32 E-646 WIRE HARNESS & RELATED S {TWINSTICK) / ~-0 ro SEAT SWITCH BLUE 4 --fiblue #A Seat SW Clutch ()BLUE BU<. YEL. RED 0 ~~ ~RED 6 ~ YEL. ~ ~ I t 3 lj) gn i ion ( IN CLUDES #8) ~ \ () BLUE----A--ED ~ ~BLK. \ () RED * NO. QTY. E-67 BATTERY E-5878 HOUR METER E-5873 START SWITCH E-6403 CLUTCH SWITCH E-648 CABLE, BATTERY TO SOLENOID E- 647 WIRE HARNESS ADAPTER (KAWASAKI) E WIRE HARNESS ADAPTER (KOHLER) P BATTERY HOLD DOWN E RETAINER CLIP E BRAKE SWITCH F- 858 /4-0 U- NUT F /4" LOC K WASHER E-607 FUSE, #ATC-30 F /4-0 X 3/4" GR. 5 F- 58 /4-0 LOCK NUT F /4" FLAT WASHER F #0 SCREW, 5/8" LONG 647- A SWITCH ARM ASSEMBLY E-6445 KEY, SET E-646 CLUTCH SPIKE SUPPRESSOR (KOHLER) E-6374 SEAT SWITCH (NOT SHOWN) 9

33 E-647 KAWASAKI ADAPTER HARNESS & RELATED S TO OIL PRESSURE SWITCH GREEN - GRN/WHT.,,-/TO ENGINE ~~~<======c..j... RED TO FUEL SHUT- OFF RED TO BATTERY + YEL. / TO STARTER I TO ENGINE STARTER QTY. E-645 E- 646 E- 648 WIRE HARNESS (JOYSTICK) WIRE HARNESS (TWINSTICK) CABLE. BATTERY TO SOLENOID 30

34 E KOHLER E.F.I. HARNESS ADAPTER & RELATED S INDICATOR LIGHT RED RED TO BATTERY + I TO ENGINE STARTER QTY. 3 E-645 E- 646 E- 648 E WIRE HARNESS (J OYSTICK) WI RE HARNESS (TWI NSTICK) CABLE. BATTERY TO SOLENOID INDICATOR LIGHT 3

35

36 Repair Parts Manual TM Country Clipper Division Shivvers Manufacturing Inc. 63 W. English St. Corydon, IA Ph Fax