Hustler® Sport General Service Manual
Contents
1. 81 NY9 980 22 jyjzy a CH 2 810418 62 3NI9N3 713979 I E Ge GE p gt SIINYG 02 o 910418 Le _ 81 9NO ZI 39EVHD de 11134 9N3 81 N48 61 YILIN TOS 130415 91 NN9 980 12 ab I94VHITSE CU C SSJHd 11040 810W18 13A 81 SEN A 913918 92 110 Sg n i x QION310S YAY 91 980 0I uj YILYYIS Ka T D 81 A3Y NVL LI telywid BE 81 19 0434 S v 2 810N49 940 91 8IONVI SI QIONVL VI ee j gt HOLIMS KEE HOLIMS HOLIMS D ASILLVB IVYLNIN TYYLNIN 4 812980 8 N 813478 Sc AY134 T pc V LYVIS 910078 v2 Rap 91 034 940 910980 L 7 03Y HOLIMS v HOLMI H91079 SAIS 810918 Z EN Plod d c CFI2038 1 12038 ISNI HJLSYW HOLIMS VS NOILINOI 91 419 03H y o a o z o E 9 o o E o o 6 ORG 14 REVE 7 3 108934 REV E 7 4 108934 MAINTENANCE Maintenance Schedule Refer to Figure 8 1 Figure 8 2 Figure 8 3 Figure 8 4 Figure 8 5 Figure 8 6 amp Figure 8 7 SERVICE AT pue rn INTERVALS INDICATED HOURS HOURS Verify safety start interlock system Prior to each use Visually inspect unit for loose hardware and or damaged parts Prior to each use Visually inspect tires Prior to each use Check oil level engine 1 Prior to each use or every 4 hours Clean air intake s2. Figure 5 5 NOTE Mowers produced after serial number 12023522 and with an EX or CE extension after the model number do not have a fuel evaporation system filter Fuel amp Evaporative System Line Routings On mowers that have a fuel evaporative system installed pro duced after serial number 11010000 there are two rubber hoses that are connected to the fuel tank One is the fuel hose that is part of the fuel system The other is the vapor line that is part of the fuel evaporative system The fuel hose is connected to the port on the side wall of the fuel tank It connects the fuel tank to the engine Figure 5 6 The vapor line is connected to the port in the top of the fuel tank It connects the fuel tank to the engine s vapor port Figure 5 5 E Figure 5 6 NOTE Mowers produced after serial number 12023522 and with an EX or CE extension after the model number do not have a fuel evaporation system 108934 Engine RPM Settings The engine rpm s are set at the factory for maximum mowing efficiency Occasionally it may be necessary to check and adjust the settings The idle speeds should be set as follows B amp S 17 5 21 hp E
3. 9 3 6 OE LEA NIS NA Figure 6 12 108934 6 5 REVE 54 Deck Belt Routing amp Tensioning D Figure 6 13 108934 REV E 36 RD Deck Belt Routing amp Tensioning Figure 6 14 REVE 6 7 108934 REV E 6 8 108934 ELECTRICAL Av 138 NY HERE 8T1T GZ 818 Pa E e e o e 8NIB LI 81 NUS 91 2 a ALE YILIN il 3N19N3 3 810419 EZ YNOH 81 980 6 E E ale E oT 018 22 o 99808 A HITIN 8111187038 7 Y 8138 92 t 4 800NI 81 A 813980 L S Y po 81 G34 NVL El P 8DNVI ZI P DNI TI EN J EM HOLIMS LV3S x HOLIMS TYULN3N HOLINS WULNIN HUNT c 81018 la 2 8980 9 O Z DER A z LUVIS L i U x 91478 02 Su 9110347940 01 91 940 Cd 81318 6179 o AUILIVS HITI y o N N HOL UIS 8 o wg 0 O C naa NG GO I NOILINOI o ISNA WJISYW i Sg Mm 81 18 038 rund o m de G o Ka A a o A o 0 m H REV E 7 1 108934 Electrical Sch
4. can cause a battery gas explosion which will result in per sonal injury Prevent the battery terminals from touching any metal mower parts when removing or installing the battery Do not allow metal tools to short between the battery terminals and metal mower parts A Incorrect battery cable routing could cause damage to the mower and battery cables This can cause sparks which can cause a battery gas explosion which will result in per sonal injury Always disconnect the negative black bat tery cable s before disconnecting the positive red cable s Always connect the positive red battery cable s before connecting the negative black cable s Avoid Acid Burns A Sulfuric acid in battery electrolyte is poisonous It is strong enough to burn skin eat holes in clothing and cause blindness if splashed in eyes Avoid the hazard by Filling batteries in a well ventilated area Wearing eye protection and rubber gloves Avoiding breathing fumes when electrolyte is added Avoiding spilling or dripped electrolyte If you spill acid on yourself Flush your skin with water Apply baking soda or lime to help neutralize the acid Flush your eyes with water for 10 15 minutes Get medical attention immediately If acid is swallowed Drink large amounts of water or milk Then drink milk of magnesia beaten eggs or vegetable oil Get medical attention immediately REVE REV E 2 4 108934 TORQ
5. Figure 6 3 Figure 6 1 108934 6 1 REVE Deck link Deck link Figure 6 4 REV E 6 2 108934 Blades Mower blade maintenance Check the mower blades daily they are the key to power effi ciency and well groomed turf Keep the blades sharp A dull blade will tear rather than cut the grass leaving a brown ragged top on the grass within a few hours A dull blade also requires more power from the engine Replace any blade which is bent cracked or broken A A Never attempt to straighten a bent blade by heating or weld a cracked or broken blade as the blade may break and cause serious injury Replace worn or damaged blades Never work with blades while engine is running or deck clutch switch is engaged on Always place deck clutch switch in the disengaged position place steering control levers in the park brake position and turn engine off and disconnect negative battery cable Block up mower when you must work under it Wear gloves when handling blades Always check for blade damage if mower strikes a rock branch or other foreign object during mow ing Always wear adequate eye protection when grinding mower blades WARNING WARNING WARNING A Mower blade removal Use a 15 16 wrench to remove the 5 8 cap screw holding the blade to the spindle shaft from underneath NOTE A blade ho
6. Fuel evaporation system filter 5 2 General engine maintenance 5 1 General maintenance precautions 2 2 Hustler service program eseeeeeees 1 1 Hydraulic pump belt adjustment 4 4 Maintenance introduction msa 1 1 108934 i 1 PAGE Maintenance locator chart ssssesss 8 2 Maintenance precautions eessssss 2 2 Mower blade maintenance _ 2 21111122 11 6 3 Mower blade removal eene 6 3 Operate machine safely ooooncococcnnnnccccccnonoccncnnnnnns 2 2 Operation Precautions ssssssees 2 2 Park brake spring adjustment 4 3 Pre operation precautions uususss 2 1 Safe servicing practices oomoncccnnnnncnnncccccconnnannccc n 2 1 Service Program sss 1 1 Special Torques essent 3 1 Standard torques ssssssss 3 1 Steering adjustments sssssssssss 4 1 Steering control lever neutral adjustment 4 1 Steering damper sse 4 2 ECC E A E 4 4 Warranty Uu 1 1 REV E
7. Repeat for other side Reconnect the negative battery cable Close seat platform and re install seat platform hardware REVE Steering damper 40 s w N Rear damper ball stud Nylock nut spring Figure 4 7 Belts Inspect belts frequently for wear and serviceability Replace a belt that shows signs of severe cuts tears separation weather checking and cracking or burns caused by slipping Slight rav eling of belt covering does not indicate failure trim ravelings with a sharp knife Inspect the belt pulley grooves and flanges for wear A new belt or one in good condition should never run against the bot tom of the groove Replace the pulley when this is the case oth erwise the belt will lose power and slip excessively Never pry a belt to get it on a pulley as this will cut or damage the fibers of the belt covering Keep oil and grease away from belts and never use belt dress ings Any of these will destroy the belt composition in a very short time REVE 4 4 Hydraulic Pump Belt Adjustment The transmission drive belt tension remains constant by means of a tension idler and spring There is no tension adjust ment of this belt Figure 4 8 NOTE Inspect the belt every 100 hours and replace as needed Replace the belt every 200 hours or every two 2 years whichever comes first WARNING A If the transmission belt fails loss of control will occur especially when operating on a s
8. Electrical connections are corroded or loose Check the electrical con nections 15 amp fuse is blown For additional causes Replace the 15 amp fuse See engine manual Mower circles or veers in one direction Steering linkage needs adjustment Adjust linkage Loose steering linkage Tighten linkage Tires improperly inflated Adjust air pressure to 8 12 psi 55 83 KPa Transaxle component faulty Contact your Dealer The engine will not start starts hard or fails to keep running No fuel or line plugged Fill tank or replace line See Fuel System section for more details Mower creeps when park ing brake engaged Steering linkage out of adjustment Adjust steering linkage Brakes need adjustment Adjust parking brakes There is incorrect fuel in the fuel system Drain the tank and replace the fuel with the proper type There is dirt in the fuel filter Replace the fuel filter Dirt water or stale fuel in the fuel system The choke is not on Numerous Contact your Dealer Move the choke lever to ON See engine manual Engine Runs with continuous mis firing or engine runs unevenly or erratically Numerous See engine manual There is abnormal vibra tion he engine mounting bolts are loose Tighten the engine mount ing bolts he engine pulley idler pul ey or blade pulley is loose Tighten the appropriate pul ley
9. Once the valve is closed carefully remove the oil drain hose and clean up any spilled oil IMPORTANT All oil drips or spills must be cleaned off of the exhaust system before operating the machine 9 Re install the dust cap on the oil drain valve nipple 10 Clean the oil drain hose and store it appropriately Draining the engine oil units equipped with oil drain valve as shown in Figure 5 2 1 Locate the oil drain valve on the engine Figure 5 2 108934 5 1 Figure 5 1 2 Locate the oil drain hose that was supplied with the machine Be sure to clean and clear it of debris that might block the flow of the engine oil 3 Attach one end of the hose onto the oil drain valve nipple Make sure the hose is pushed all the way onto the valve 4 Position the loose end of the hose out thru the slot cut in the engine base plate so that it can drain into a suitable oil drain container 5 With the hose in position twist the valve counterclockwise to open the valve Allow 10 minutes for engine oil to adequately drain 6 After oil is drained close the valve by twisting it clockwise 7 Once the valve is closed carefully remove the oil drain hose and clean up any spilled oil IMPORTANT All oil drips or spills must be cleaned off of the exhaust system before operating the machine 8 Clean the oil drain hose and store it appropriately MAS um mu Oil drain hose Ra Oil drain valve Figure 5 2 Engine Air Filter
10. The engine pulley is dam aged Contact your Dealer The cutting blade s is are bent or unbalanced Install new cutting blade s A blade mounting bolt is loose Spindle bearing is worn or loose A blade spindle is bent Tighten the blade mounting bolt Replace or tighten spindle bearing Contact your Dealer Loss of power or system will not operate in either direction Restrictions in air cleaner Service air cleaner Poor compression Contact your Dealer Steering linkage needs adjustment Tow valve open Adjust linkage Close tow valve The traction drive belt is worn loose or broken Install a new traction drive belt Blades do not rotate The deck drive belt is worn loose or broken Install a new deck drive belt The deck drive belt is off the pulley Install the deck drive belt and check for a reason Electric clutch is not engag ing Check and or replace 10 amp fuse Contact your Dealer Air in system Check filter and fittings For additional causes See engine manual Air cooled engine over heating Air intake screen or clean ing fins clogged Clean screen and fin For additional causes See engine manual Low engine oil pressure Low oil level Add oil Oil diluted or too light Change oil and check for source of contamination Failed oil pump Contact your Dealer High oil consumption Numer
11. gear to avoid being burned or exposed to engine oil Check engine oil daily and after every 4 hours of operation Mower must be on a level surface when checking oil Refer to engine manual and maintenance schedule for oil recommenda tion and capacities Change the engine oil and filter after the first 5 hours of oper ation and then per the engine manufacturer s recommendations after that If mower is being operated in extremely dirty condi tions then it is recommended oil be changed more frequently IMPORTANT When removing the oil filter take precautions to minimize oil spillage on the exhaust system Draining the engine oil units equipped with oil drain valve as shown in Figure 5 1 1 Locate the oil drain valve on the lower left side of the engine 2 Remove the dust cap 3 Locate the oil drain hose that was supplied with the machine Be sure to clean and clear it of debris that might block the flow of the engine oil Figure 5 1 4 Attach one end of the hose onto the oil drain valve nipple Make sure the hose is pushed all the way onto the valve 5 Position the loose end of the hose out to the left side of the mower so that it can drain into a suitable oil drain container 6 With the hose in position twist the valve counterclockwise and pull out to open the valve Allow 10 minutes for engine oil to adequately drain 7 After oil is drained close the valve by pushing in on the valve body and twisting it clockwise 8
12. property damage use extreme care in handling fuel Fuel is extremely flamma ble and the vapors are explosive A Observe usual fuel handling precautions Do not smoke while refueling Extinguish all ciga rettes cigars pipes and other sources of ignition Do not remove fuel cap or fill tank with engine run ning or while engine is hot Clean up any fuel spills Allow engine to cool before storing machine inside a building Keep fuel away from open flame or spark and store machine away from open flame or spark or pilot light such as on a water heater or appliances Use extreme care when handling gasoline and other fuels They are extremely flammable and vapors are explosive A fire or explosion from fuel can burn you and others and can damage property 108934 24 Refuel outdoors Never refuel or drain the fuel from the machine indoors Never attempt to start engine when there is a strong odor of gasoline or diesel fuel fumes present Locate and correct cause Store fuel in an approved container and keep it out of the reach of children Never buy more than a 30 day supply of fuel Do not fill fuel containers inside a vehicle or on a truck or trailer bed with interior carpets or plastic truck bed liners Always place fuel containers on the ground away from your vehicle before filling When practical remove gas or diesel fuel powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground
13. tightened to 3 Loosen the steering damper s rear ball stud Figure 4 6 the correct torque specifications 4 Pullthe damper spring housing to the rear past the point 13 REVE Repeat steps 4 thru 12 for the left side 4 2 that the internal spring is engaged 108934 Figure 4 4 Steering control lever Steering Steering damper damper stud n Park Figure 4 5 Release the damper spring housing and allow the internal spring to bring the housing back to the neutral position Tighten the nut on the steering damper s rear ball stud Reconnect the negative battery cable To check move the steering control lever to the reverse position and release The steering control lever should return to the neutral position If not repeat steps 1 through 7 Brake Spring Adjustment Occasionally check the park brake spring adjustment using 108934 4 3 the following method 1 Shut engine off place steering control levers in the park brake position disengage deck clutch remove ignition switch key and disconnect negative battery cable before doing any adjustments On one side measure the park brake spring It should be compressed to 1 00 If it is not adjust the nylock nut until the proper spring compression is achieved Figure 4 7
14. Hustler Sport General Service Manual HUSTLE TURF EQUIPMENT 200 South Ridge Road Hesston Kansas 67062 2097 108934 REV E A WARNING A 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 4442 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 0232 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 th
15. If this is not possible then refuel such equipment on the truck or trailer using a portable container and not a fuel dis penser nozzle If a fuel dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is com plete Do not use a nozzle lock open device Never use gasoline or diesel fuel for cleaning parts Read and observe safety precautions elsewhere in this manual A Gasoline and diesel fuel is harmful or fatal if swallowed Long term exposure to vapors can cause serious injury and illness Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank or fuel con tainer opening Keep fuel away from eyes and skin If fuel is spilled on clothing change clothing immedi ately Understand Machine Operation A Only qualified and trained personnel should operate the equipment A Carefully read the operator s manual and all manuals fur nished with the attachments Learn the location and pur pose of all controls instruments indicators and labels Wear Protective Clothing A Do not operate or service the equipment while wearing sandals tennis shoes sneakers shorts or any type of loose fitting clothing Long hair loose clothing or jew elry may get tangled in moving parts Always wear long pants safety glasses ear protection and safety shoes when operating or servicing this machine A Always wear adequate eye protection
16. NGINE SPEED MODEL NO ENDING WITH HIGH IDLE MODEL NO WITHOUT EXTENSION MODEL NO WITH EX EXTENSION 3600 50 RPM B amp S 26 hp ENGINE SPEED MODEL NO ENDING WITH HIGH IDLE MODEL NO WITHOUT EXTENSION MODEL NO WITH EX EXTENSION 3600 50 RPM Kawasaki FR541 FR600 FR651 ENGINE SPEED MODEL NO ENDING WITH HIGH IDLE MODEL NO WITHOUT EXTENSION MODEL NO WITH US EXTENSION MODEL NO WITH EX EXTENSION 3600 50 RPM Honda GXV530 ENGINE SPEED MODEL NO ENDING WITH HIGH IDLE MODEL NO WITHOUT EXTENSION MODEL NO WITH EX EXTENSION 3600 50 RPM Kohler SV590 ENGINE SPEED MODEL NO ENDING WITH LOW IDLE HIGH IDLE MODEL NO WITH EX EXTENSION 1900 100 RPM 3600 50 RPM MODEL NO WITH CE EXTENSION 1900 100 RPM 2900 50 RPM Kohler SV715 ENGINE SPEED MODEL NO ENDING WITH LOW IDLE HIGH IDLE MODEL NO WITH EX EXTENSION 1900 50 RPM 3600 50 RPM MODEL NO WITH CE EXTENSION 1900 50 RPM 2900 50 RPM 108934 5 3 REVE NOTE Model numbers may or may not end with an extension after the number There are several different extensions that may be shown i e EX or CE Example 922222 no extension 922222 EX 922222 CE 922222 US REV E 5 4 108934 DECK ADJUSTMENTS Deck Leveling 1 Park the mower on a hard flat s
17. Perform engine air filter maintenance per the engine s owner s manual REVE Carbon Canister Some Hustler Sport mowers produced after serial number 11010000 will have a carbon canister incorporated into the fuel system Figure 5 3 This is a mandatory feature that is required on all mowers using gasoline engines that are put into operation in California These canisters should be replaced every 5 years or if they become damaged Fuel evaporation system filter 3 EA Figure 5 3 Fuel Evaporation System Filter Some Hustler Sport mowers produced after serial number 11010000 have a fuel evaporation system filter This filter must be checked and replaced every 100 hours or annually whichever comes first Figure 5 4 and Figure 5 5 Fuel evaporation system filter Carbon canister equipped machines Figure 5 4 REVE 5 2 Fuel evaporation system filter Vapor line 7
18. UE 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 Special Torques section SIZE FT LBS N M SIZE FT LBS N M 10 32 4 IN LBS 3 6 M3 12 IN LBS 1 3 250 98 4 IN LBS 11 1 M4 26 4 IN LBS 3 312 204 IN LBS 23 M5 54 IN LBS 6 1 375 30 40 M6 92 4 IN LBS 10 4 438 48 65 M8 222 IN LBS 25 500 73 99 M10 37 50 562 105 143 M12 64 87 625 145 200 M14 103 140 750 260 350 M16 160 215 875 420 565 M20 320 435 Special Torques DESCRIPTION FT LBS N M Wheel lug nuts 70 95 Blade spindle bolt top 73 99 Blade spindle bolt bottom 118 160 01 Electric clutch mounting bolt 3 47 63 Front wheel axle bolt 76 88 Transaxle hub nut 200 271 2 Transaxle pump pulley bolt 45 55 61 74 6 Engine torques N A N A NOTE 1 Lug nuts only It is recommended that these be checked after the first 2 hours of operation and every 50 hours and following removal for repair or replacement A WARNING 2 Engine torque values Refer to the respective engine owner s manual Particular attention must be given to tightening the drive 3 If clutch mounting bolt is loosened or removed do not wheel lug nuts and blade spindle bolts Failure to cor re use Replace with a n
19. ant part of the safety start interlock system Serious injury can result if the seat switch is not plugged into the mower s wiring harness the opposite direction to the point when the wheel stops rotating From that point turn the steering rod back again Y turn This ensures that the steering rod is adjusted so that the transmission control arm is centered in the neutral band of the transmission Figure 4 5 A A Never operate the mower with a non functioning seat switch Always reconnect the seat switch to the mower harness WARNING Steering control levers in neutral position 16 The steering control levers should be adjusted so that they align vertically with each other when in the neutral position Figure 4 4 Space between ends of steering control handles to be 50 25 Figure 4 4 17 Check to make sure all tools or obstructions are removed from under the mower 18 Raise the rear of the mower and remove the jack stands Lower the mower 19 Re attach the negative battery cable 20 Close the seat platform and re install the seat platform hardware Torque the lock down nut to 17 ft Ibs A Make sure the seat platform is securely bolted down by tightening the seat platform lock down nut prior to each use Figure 4 3 WARNING 9 Move the steering control lever forward and backward making sure that the wheel rotates forward and backward correctly Return the steering control lever to neutral and re c
20. at the brakes do not fight the transmissions since they have not yet been adjusted Steering control levers in park brake position Figure 4 2 Loosen the nuts on the rear steering damper ball studs The dampers must be allowed to slide in the slots in the mower frame Figure 4 5 7 Start the engine Move the steering control lever to barely REVE A engage the brake neutral slot and hold it in that position Do not engage the steering control lever far enough to engage the brakes in the brake slot Figure 4 3 WARNING Once both sides are properly adjusted check them together to make sure everything is working properly IMPORTANT With the engine off disconnect the two female spade connectors from each other from step 3 and reconnect them to the seat switch This must be completed so that the safety circuit is functioning This operation is extremely dangerous Pay close atten tion when adjusting the transmission control rod so you do not get your fingers tools or anything else close to the transmission s cooling fans 8 Beginning with the right side of the mower adjust the steering control rod so that the right side wheel starts rotating forward while holding the steering control lever in the neutral position Now adjust the steering rod back properly Figure 4 1 WARNING A Do not operate the mower without plugging the mower s wiring harness into the seat switch This switch is an import
21. comes first 6 Check fuel system for any crack or leaks including but not limit to fuel line hoses fuel valve vent line hoses vent valve vapor valve carbon canister and grommets Repair as needed 7 More often under dusty or dirty conditions and during hot weather 8 Inspect ROPS after the first 20 hours of operation and then after every 100 hours of operation or yearly whichever comes first REFERENCES A Referto engine owner s manual for engine service information NOTE After completing maintenance cycle 100 hours repeat cycle 108934 8 1 REVE Maintenance Locator Chart Figure 8 1 14 NP d OST Figure 8 2 Top View 11 48 54 Deck Figure 8 3 M 15 40 00 11 mos INS Engine Oil Fill amp Dipstick Fuel Filter Engine Air Cleaner Engine Oil Drain Valve Battery Fuel Tank Engine Oil Filter Deck Lift Pivot Zerks 4 Park Brake Switch 2 Drive Tire Pump Belt Engine Air Intake Screen Front Wheel Tires Front Wheel Zerks 2 Deck Belt Blades Fuel Evaporati
22. creen 4 Prior to each use or every 4 hours Clean foam element if equipped 4 Prior to each use Check fuel level Prior to each use Blades sharpen amp securely fastened Prior to each use Discharge chute securely in place amp in lowest position Prior to each use Clean engine and transaxle compartment Daily Grease deck height pivots X Grease front wheel bearings X Grease deck lift pedal pivot X Change engine oil amp filter 1 3 X Check battery connections X Check tire pressure with a gauge X Clean engine exterior a x Replace air cleaner paper element if equipped 4 X Check pump amp deck belt tension and condition 5 X Check fuel lines 6 x Check fuel tank grommet 6 x Tighten lug nuts on wheels 2 x Change fuel filter 6 x Check ROPS mounting hardware 8 x Replace fuel evaporation system filter 7 x NOTES 1 Initial oil change is after 5 hours of operation Thereafter change oil after every 40 hours operation Change more often under dusty or dirty conditions and dur ing hot weather periods 2 Torque initially and after first 2 hours of operation 3 Change engine oil filter per the engine manufacturer s recommendations Refer to Engine Owner s Manual for recommendations and other maintenance items 4 Service more often under dusty or dirty conditions 5 Pump drive belt only Inspect every 6 months or 100 hours and replace if worn or cracking is noticed Otherwise replace every 200 hours or 2 years whichever
23. ct the Customer Service Department at Hustler Turf Equip ment for additional information Warranty Warranty repair must be performed by a Hustler Turf Equip ment Authorized Dealer before warranty credit can be allowed Work performed by anyone other than an Authorized Dealer will invalidate the warranty claim and warranty credit will not be approved REVE REV E 1 2 108934 SAFETY This safety alert symbol is used to call attention to a message intended to provide a reasonable degree of PERSONAL SAFETY for operators and other persons during the normal operation and servicing of this equipment denotes immediate hazards which WILL result in severe personal injury or death denotes a hazard or unsafe practice which COULD result in severe personal injury or death A DANGER WARNING Safe Servicing Practices This product is capable of amputating hands and feet and throwing objects Always follow all safety instructions to avoid serious injury or death Understand correct service A Be sure you understand a service procedure before you work on the machine A Unauthorized modifications to the machine may impair the function and or safety and affect machine life A If it is necessary to make checks with the engine running always use two people with the operator at the controls able to see the person doing the checking Pre Operation Precautions Fuel Handling A To avoid personal injury or
24. d time to detect potential problems is while per forming scheduled maintenance service Correcting the problem as quickly as possible is the best insurance Clear away heavy build up of grease oil and dirt especially in the engine and under the seat platform areas minute dust par 108934 1 1 ticles are abrasive to close tolerance engine and hydraulic assemblies Daily inspect mower for grass clippings and wire and string tangles The underside of the mower deck will collect a build up of grass clippings and dirt especially when grass is wet or has high moisture content This build up will harden restricting blade and air movement and will probably show a poorer quality of cutting Therefore it should be removed routinely To do this it will be necessary to raise and block the deck using jack stands or blocks in the full up position and scrape the build up from underneath Some repairs require the assistance of a trained service mechanic and should not be attempted by unskilled personnel Consult your Hustler Turf Equipment service center when assistance is needed Information included in this manual was current at the time of printing but subsequent production changes may cause your machine to vary slightly in detail Hustler Turf Equipment 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 service manual con ta
25. e 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 1 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 2 The use of the equipment after such device or element of design has been removed or rendered inoperative by any person REVE 108934 108934 Table of Contents General Information cru mero sooo RE ar 1 1 Hustler Service Program 0 1 1 Maintenance Introduction 31 2a a Re Ee EEE 1 1 UE e EE 1 1 DAN we b exo So AL Nec av ce ieee E eB ah ran LER te 2 1 Safe Servicing Practices 2 1 Pre Operation Precautions 22222220 2 1 Operation Precautions 22523 act rasen ERA 2 2 Operate Machine Safely 2 2 General Maintenance Precautions 2 2 Mainteriatrice PIecautloris cs mex mr d
26. e will destroy the belt composition in a very short time Deck Belt Adjustment The spindle belt tension remains constant by means of a ten sion idler and spring The spring tension should be such that the belt does not slip under normal operating load conditions assuming the belt is not excessively worn or damaged As the belt stretches and wears in adjustment may become necessary To increase belt tension move the spring chain one or more link s at the anchor point on the deck frame Figure 6 8 Figure 6 9 Figure 6 10 Figure 6 11 Figure 6 12 Figure 6 13 amp Fig ure 6 14 IMPORTANT Do not over tension the spring to compensate for a badly worn belt or pulley REV E 6 4 Spring chain Spring chain anchor point A oh La L e ID 8 B ZIS L Idler spring Figure 6 8 Spring chain Spring chain anchor point Figure 6 9 Spring chain anchor point spring Figure 6 10 108934 NOTE The following notes are the same for the different decks shown 1 Spring length after tensioning new belt Measured from outside of hook to outside of hook with deck set at 314 cut height 2 Route belt as shown 42 Deck Belt Routing amp Tensioning Figure 6 11 48 Deck Belt Routing amp Tensioning 8 3
27. ematic Honda GXV 530 o D oo Ec ano 0 S25 u23 GO gt FF gt w rc 960209 SSINYYH Li 5 o JO 14Vd LON 349 SLINIYID 4S3HL A INO Ke c 139N 343334 804 NMOHS SLINDUII oo 310N 2 o 81 N89 980 ZZ AY TAU P 11194 81 918 62 x Dr ER celow 1g ez 711418 0 391148 rd annoys E gt 81 NN8 02 3NI9N3 es TC YILIN o 358vH5 810318 12 UNOH 810980 ZI JOYVHI 111 9N3 108 3304 81 NU8 61 ss3yd 110 wis 5 810 T8 13A 81 77815940 11 ss34d m _ x110 3 T 911318 92 3 o 913980 01 a xnv lt z W SEEMS a 818 4338 S u o a x a 81 038 NVI LI re 811940 6 x HOLTMS LYTS J cenaze nvl 9 em oi 2 Te DNI y 2 HOLIMS TVULNIN HOLIMS TYHLNAN Fea Tq 813318 Ge LV AYILLYO a R va T O ELLIS 91 118 ra E El D 91 980 L PX HOLIMS a e H210 12 HILNII T o 813918 ca 013038 Z SNR 711038 asn4 YILSYN YSI 81 418 038 v 108934 1 2 REVE Electrical Schematic Kohler 301 ld GNNOY ines Kohler engi NOTE are not available on
28. ew bolt Use only hand tools to rectly torque these items may result in the loss of a wheel install this fastener or blade which can cause serious damage or personal 4 If using pin locknut 250 ft lbs injury 108934 3 1 REVE REV E 3 2 108934 POWER UNIT MAINTENANCE Steering Adjustments Steering control lever neutral adjustment The mower s steering has been factory adjusted to eliminate creeping when the steering control levers are in the neutral posi tion However should the mower begin to creep the steering control lever linkage can be adjusted Before considering any adjustment check the tire air pressure Unequal tire pressure will cause the mower to drift to one side Refer to tire pressure information in the Tire section for detailed information NOTE Proper park brake adjustment must be completed before the steering control lever neutral adjustment can be done Refer to the Park Brake Spring Adjustment section for detailed information Fine adjustment to the unit s steering is made with the trans mission s control rod Neutral is properly adjusted when the steering control levers are in the park brake position and the transmissions do not whine If this occurs the steering control linkage may be adjusted as follows WARNING A This procedure will require that the unit to be raised and blocked up off of the ground It is necessary for the wheels to rotate without coming in contact with the floor or any ob
29. heck to make sure the wheel has stopped in the neutral position Place the steering control lever in the park brake position NOTE If neutral is set properly you should not hear the transmission whine 10 Turn the engine off 11 With the engine off move the right side steering control lever into the neutral position and pull the lever to the full reverse position Now slowly bring the steering control lever back to the neutral position and then place it in the park brake position This sets the steering damper in the correct neutral position 1 Steering damper The steering damper is spring loaded to return the steering control levers to the neutral position from the reverse position This gives the operator a sense of neutral during operation If the mower does not return to neutral from reverse then adjust as follows To set the steering dampers in the correct operating position follow these steps Shut engine off place steering control levers in the park Tighten the nut on the damper s rear ball stud Once this nut is tightened when the steering control lever is in the reverse position and then released the steering control brake position disengage deck clutch remove ignition switch key and disconnect negative battery cable before doing any adjustments lever should return to the neutral position Figure 4 5 2 Place the steering control lever in the neutral position 12 Check to make sure you have all fasteners
30. ject that would permit the unit to propel itself Stay clear and exercise caution when rotating wheels to prevent injury Use only appropriate vehicle stands with a minimum weight rating of 2000 pounds to block the unit up Use in pairs only Follow the instructions sup plied with the vehicle stands Keep hands hair clothing etc clear of the cooling fans on top of the transmissions Exercise extreme caution A A Untrained maintenance personnel should never attempt to make any adjustments or repairs to the mower s drive system while the engine is running The following proce dures should be performed by trained maintenance personnel only WARNING A WARNING 1 Raise the rear of the mower and block with certified jack stands The rear wheels need to be able to rotate freely and clear of all obstructions 2 Chock the front tires 108934 4 1 4 5 Raise the seat platform and disconnect the mower harness from the seat switch Bypass the seat switch by connecting the two mower harness female spades together Figure 4 1 harness Figure 4 1 Loosen the jam nuts on each end of the steering control rod assemblies Figure 4 5 Set both steering control levers in the park brake position Figure 4 2 NOTE Both steering control levers need to be in the park brake position when starting the engine but need to be moved rapidly out of the park brake position once engine is started so th
31. key and disconnect negative bat tery cable for maximum safety A Except when changing or checking belt always keep belt covers on mower deck for safety as well as cleanliness A Use a stick or similar instrument to clean under the mower making sure that no part of the body especially arms and hands are under mower A Keep your machine clean and remove any deposits of trash and clippings which can cause engine fires and hydraulic overheating as well as excessive belt wear Clean up oil or fuel spillage Allow machine to cool before storing A Always wear adequate eye protection when servicing the hydraulic system and battery or when grinding mower blades and removing accumulated debris A Never attempt to make any adjustments or repairs to the mower drive system mower deck or any attachment while the engine is running or deck clutch is engaged A Never work under the machine or attachment unless it is safely supported with jack stands Make certain machine is secure when it is raised and placed on the jack stands The jack stands should not allow the machine to move when the engine is running and the drive wheels are rotating Use only certified jack stands Use only appro priate jack stands with a minimum weight rating of 2000 pounds to block the unit up Use in pairs only Follow the instructions supplied with the vehicle stands A Keep nuts and bolts tight especially the blade attachment bolts Keep equipment in good working condi
32. lding tool part number 381442 is available from Hustler Turf Equipment It is designed to prevent the blades from rotat ing when they are being removed or installed on the spindle Contact your Hustler dealer for more information Sharpen the blades on a grinder following pattern as shown Figure 6 5 Touch up sharpening can be done with a file Check the blades for balance following grinding A commer cial balancing tool is available through most hardware supply stores or balancing can be done by placing the blade on an inverted line punch or 5 8 bolt Blade should not lean or tilt Spin the blade slowly blade should not wobble If blade is out of balance true it up before reinstalling Lay the blade on a flat surface and check for distortion Fig ure 6 6 amp Figure 6 7 Replace any distorted blade Do not re use spindle bolts which have stripped worn or undercut threads Torque bolts on spindles to 118 foot pounds 160 0 N m when reinstalling blades Properly compressed cup washers maintain the correct com 108934 6 3 pression load on the blades Replace the cup washers if they are cracked or flattened IMPORTANT The blade sail curved part must be point ing upward toward the inside of the deck to ensure proper cut ting IMPORTANT When mounting blades rotate them after installation to ensure blade tips do not touch each other or sides of the mower Failure to correctly torque the bolt may result i
33. lectrical Schematic Honda GXV 530 7 2 Electrical Schematic Kohler 7 3 Maintenance 8 1 Maintenance Locator Chart 00 8 2 Troubleshooting EE 9 1 toc 2 108934 GENERAL INFORMATION Hustler Service Program This manual is part of a service package for the Hustler Sport mowers Use of this manual in conjunction with other Hustler mower and component manuals will provide the information necessary to service and maintain Hustler Sport mowers This General 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 Parts Manual provides a complete parts listing for the unit Use this manual when ordering parts The Operators Manual provides fundamental operational information and operational safety that is needed when operat ing the mower The component manuals are furnished by the various manu facturers to be used for the troubleshooting and servicing of their products Maintenance Introduction Regular maintenance is the best prevention for costly down time or expensive premature repair The following pages con tain suggested maintenance information and schedules which the operator mechanic should follow on a routine basis Remain alert for unusual noises they could be signaling a problem Visually inspect the machine for any abnormal wear or damage A goo
34. lope If you lose steering control while operating the machine place the steering control levers in the park brake position immediately Inspect the machine and involve your dealer to resolve the problem Top View Hydraulic pump belt Tension idler Figure 4 8 Tires It is important for level mowing that the tires have the same amount of air pressure The recommended pressures are Drive wheels 8 12 psi 55 83 KPa Front wheels 8 12 psi 55 83 KPa If you wish to use non pneumatic tires on your Hustler mower the tires must be an approved tire purchased from Hus tler Turf Eguipment Warranty claims will be denied on any mower eguipped with unapproved non pneumatic tires 108934 ENGINE MAINTENANCE General Engine Maintenance Detailed instructions and recommendations for break in and regular maintenance are specified in the Engine Owner s man ual Please refer to this manual for engine servicing lubricating oil levels with quality and viscosity recommendations bolt torques etc The engine warranty is backed by the manufacturer Engine Oil and Filter A WARNING A If the engine has been running and is up to operating tem perature allow the engine to cool before changing the oil Engine and engine oil will be very hot so be very careful when changing oil and wear the appropriate protective
35. n lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Charge batteries in an open well ventilated area away from sparks and flames Unplug charger before connect ing or disconnecting from battery Wear protective cloth ing and use insulated tools Avoid skin and clothing contact with battery acid Always wear eye protection when checking the battery acid can cause serious injury to skin and eyes If con tact occurs flush area with clean water and call physi cian immediately Acid will also damage clothing Do not drink the battery electrolyte Do not allow open flame near the battery when charg ing Hydrogen gas forms inside the battery This gas is both toxic and flammable and may cause an explosion if exposed to flame Always disconnect the negative black battery cable s before disconnecting the posi tive red cable s Always connect the positive red battery cable s before connecting the negative black cable s Do not overfill battery Electrolyte may overflow and damage paint wiring or structure When cleaning the battery use soap and water Be careful not to get soap and water into the bat tery Clean the battery terminals with a solution of four parts water and one part baking soda when they become corroded 2 3 A Shorts caused by battery terminals or metal tools touch ing metal mower components can cause sparks Sparks
36. n the loss of the blade which can cause serious injury A Mower blades are sharp and can cut Wrap the blade s or wear gloves and use extra caution when servicing them WARNING A WARNING Resharpening pattern Do not sharpen to original pattern below It is easier to get a straight cutting edge following the resharpening pattern shown above Original edge Figure 6 5 Warped Blade Replace Cutting plane GE A Straight Blade Comparison of Warped and Straight Blades Figure 6 6 REVE Cutting edge Twisted Blade Edge replace Cutting Plane Cutting edge Pa Straight Blade Edge End view of blades comparing twisted and straightened blades Figure 6 7 Belts Inspect belts freguently for wear and serviceability Replace a belt that shows signs of severe cuts tears separation weather checking and cracking or burns caused by slipping Slight rav eling of belt covering does not indicate failure trim ravelings with a sharp knife Inspect the belt pulley grooves and flanges for wear A new belt or one in good condition should never run against the bot tom of the groove Replace the pulley when this is the case oth erwise the belt will lose power and slip excessively Never pry a belt to get it on a pulley as this will cut or damage the fibers of the belt covering Keep oil and grease away from belts and never use belt dress ings Any of thes
37. on System Filter Carbon Canister Figure 8 4 2 Deck Figure 8 6 36 Rear Discharge Deck Carbon canister equipped machines REV E 8 2 Figure 8 7 108934 TROUBLESHOOTING The majority of operating problems that occur with a system can be traced to improper adjustments or delayed service A consistently applied preventative maintenance program will prevent many problems The following chart is designed to help you locate a problem by suggesting probable causes and the recommended solutions SYMPTOMS PROBABLE CAUSES SUGGESTED REMEDIES SYMPTOMS PROBABLE CAUSES SUGGESTED REMEDIES Starting motor does not crank Steering control levers not in park brake position or Switch not adjusted Place steering control levers in park brake posi tion or re adjust switch Mower creeps when steering control levers are in neutral Steering linkage needs adjustment Adjust linkage Deck clutch switch engaged Disengage clutch switch Weak or dead battery Recharge or replace
38. ous Contact your Dealer Uneven cutting height The blade s are not sharp A cutting blade s is are bent Sharpen the blades Install new cutting blade s The deck is not level Level the deck per the Deck leveling and height adjustment section of the General Service Manual An anti scalp wheel is not set correctly Adjust the height of the anti scalp wheel The underside of the deck is dirty Clean the underside of the deck Tires improperly inflated Adjust air pressure to 8 12 psi 55 83 KPa A blade spindle is bent Contact your Dealer Mower jerky when starting or operates in one direc tion only Steering control linkage needs adjustment Loose steering linkage Adjust linkage Tighten linkage Transaxle component faulty Contact your Dealer 108934 REVE REV E 9 2 108934 PAGE Belts iut illa 4 4 6 4 Blades ea ETE 6 3 Carbon Canister tnnmmenennennnanaenannena 5 2 Deck Belt adjustment 0 0 0 ene naa annan 6 4 Deck Belt Routing 8 Tensioning 6 5 Deck leveling eeeeeeeeeeeeeeeeeeeee 6 1 Electrical Schematic sssssssssss 7 1 Engine air Til caca tenete eene than anna 5 1 Engine oil and filter seeeeeeees 5 1 Engine RPM settings eee eerie 5 3 Fuel amp Evaporative System Line Routings 5 2
39. tion A Never tamper with safety devices Check their proper operation regularly A Exercise caution when working under the deck as the mower blades are extremely sharp Wrap the blade s or wear gloves and use extra caution when servicing them A Use only genuine Hustler replacement parts to ensure that original standards are maintained Maintenance Precautions Avoid Fire Hazards A Be prepared if an accident or fire should occur Know where the first aid kit and the fire extinguishers are located and how to use them A Provide adequate ventilation when charging batteries A Do not smoke near battery A Never check fuel level with an open flame A Never use an open flame to look for leaks anywhere on the equipment A Never use an open flame as light anywhere on or around the equipment A When preparing engine for storage remember that fuel stabilizer is volatile and therefore dangerous Seal and tape openings after adding the inhibitor Keep container tightly closed when not in use A Inspect electrical wiring for worn or frayed insulation Install new wiring if wires are damaged 108934 Prepare For Emergencies A A A Be prepared if a fire starts Keep a first aid kit and fire extinguishers available Keep emergency numbers for doctor ambulance service hospital and fire department near the telephone Prevent Battery Explosions A A A 108934 Battery posts terminals and related accessories contai
40. u e ute asd PoE XE 2 2 Totale et os Aris ee RP LEM E DEED MUI REL 3 1 Standard Torguesa 10302 mei me hb Oe bg ien Fon eae Healt 3 1 Special T Orale ua o a ome SaaS rper AA a i aaa 3 1 Power Unit Maintenance 4 1 Steering Adjustments 104 20 2A nd ALANO NANG La ar 4 1 Park Brake Spring Adjustment 4 3 Bells at os n ue de ae ENTER a 4 4 Hydraulic Pump Belt Adjustment 22222220 4 4 TOSA cal cate tlc eee es PARC ARTS EN 4 4 Engine Maintenance soie eue aa Hirn 5 1 General Engine Maintenance 5 1 Engine Oil and Filter i4 v ex dess re Game DEP p 5 1 Engine Air o e sure dei AA 5 1 Carbon Gallis telo zu en ana 5 2 Fuel Evaporation System Filter 5 2 Fuel amp Evaporative System Line Routings 5 2 Engine RPM SEHMGS2 4 230023 ihres PIDE AO ERE 5 3 Deck AdIUSImaelllss sus yt tn x HE Een tenebo dx der RE 6 1 Deck Leveling oo rore A Ne gus des 6 1 Blades p 6 3 O nek 25203 aa Aba REPRE E Re 6 4 Deck Belt Adjustment e 6 4 42 Deck Belt Routing Tensioning 7 7 6 5 48 Deck Belt Routing 8 Tensioning 6 5 54 Deck Belt Routing 8 Tensioning 6 6 36 RD Deck Belt Routing amp Tensioning 6 7 toc 1 REV E REV E Electrical LER Mna EMI MER fee een 7 1 Electrical Schematic Briggs 8 Stratton amp Kawasaki 7 1 E
41. urface 2 Check tire pressures 8 12 psi to make certain the tires are properly inflated before starting to level deck A WARNING A Stop engine Make sure deck clutch switch is in the down OFF position Remove ignition key Place steering con trol levers in the park brake position Make sure blades are stopped before leaving seat 3 Raise and lock deck into transport position 4 Place 3 high deck support blocks two stacked 2 x 4 i Figure 6 2 blocks can be used to create a 3 high support at the four corners of the deck as indicated Figure 6 1 Figure 6 2 Block amp Figure 6 3 5 Remove the deck stop pin and lower the deck until it rests on the support blocks 6 Loosen the three bolts attaching the three deck links to the deck 7 Push the lift pedal forward place the deck stop pin in the indicator hole marked 3 25 and release the pedal 8 Pull the pedal rearward so that the crank lever is held firmly against the stop pin and play in the pivot joint is removed secure the pedal in this position a bungee cord may be used 9 Tighten the three deck links to the deck with the flanged nuts clamping on either side of the slot with 48 ft Ibs of torque Release the lift pedal and ensure that the deck can be raised and locked into the transport position Figure 6 4 Block Block
42. when servicing the hydraulic system and battery or when grinding mower blades and removing accumulated debris A Prolonged exposure to loud noise can cause impairment or loss of hearing Always wear adequate ear protection such as earplugs when operating this equipment as prolonged exposure to uncomfortable or loud noises can cause impairment or loss of hearing REVE Do not wear radios or music headphones while operat ing the machinery Safe operation requires your full attention Operation Precautions Avoid Fire Hazards A Clean flammable material from machine Prevent fires by keeping engine compartment top of deck exhaust area battery hydraulic lines fuel line fuel tank and operator s station clean of accumulated trash grass clippings and other debris Always clean up spilled fuel and oil Start Engine Safely A Avoid possible injury or death from machine runaway A Do not start engine by shorting across starter terminals A Before you start the engine Sit on the operator s seat Move control levers to the neutral brake position Operate Machine Safely A Refer to the unit s operator s manual for complete safety information on safe machine operation A Always maintain a safe distance from people and pets when mowing A Always be aware of what is behind the machine before backing up A Never leave machine unattended with ignition key in switch especially with children present A Follow daily and weekl
43. y checklists making sure hoses are tightly secured and bolts are tightened A Always keep engine and machine clean removing accu mulated dirt trash and other material from machine A Never put hands or feet under any part of the machine while it is running A Never attempt to start engine when there is a strong odor of gasoline fumes present Locate and correct cause A Keep all safety shields and covers in place except for servicing A Do not touch hot parts of machine General Maintenance Precautions A Repairs or maintenance requiring engine power should be performed by trained maintenance person nel only A Never run the engine in an enclosed area unless exhaust is vented to the outside Exhaust gases contain carbon monoxide which is an odorless and deadly poison A Unless specifically required DO NOT have engine run ning when servicing or making adjustments to mower Park the machine on level ground Place steering control levers in the park brake position disengage deck clutch lower deck remove ignition switch key and disconnect negative battery cable before doing any maintenance Wait for all movement to stop before adjusting cleaning or repairing To prevent carbon monoxide poisoning be sure proper ventilation is available when engine must be operated in an enclosed area REV E 2 2 A Before working on or under the deck make certain engine cannot be accidentally started Shut engine off remove ignition switch
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