OPERATORS MANUAL, PART 2
Contents
1. Item Part Part Description Item Part Part Description No No No No 1 1187 Tank strap 2 off 18 1136 Platform assembly 2 1329 Tank cap 19 2087 Hydro support bracket 3 1393 Fuel tank including inlet fitting 20 1064 Subframe 4 1399 Hose clamp 21 1191 Bearing cap 5 1364 Tank outlet hose 22 1198 Circlip 6 1311 Bumper bar plug 2 off 23 1199 Bearing 6205 2RS 7 1370 Roll over protection bar assy 24 1192 Kingpin assembly RH optional extra 25 1193 Kingpin assembly LH 8 1129 Bumper bar assembly 26 1356 Outside rim front wheel 9 1120 Battery clamp 27 1357 Inside rim front wheel 10 1119 Battery box 28 1201 Bearing spacer 11 1004 Engine cover RH 29 1200 Front wheel bearing 6203 2RS 12 1003 Engine cover LH Two per wheel 13 1308 Toolbox 30 1202 Wheel nut 14 1376 Chassis assembly 31 1353 Tube front wheel 15 1145 Plastic knob 32 1354 Tyre front wheel 16 1140 Footrest plate 1760 Complete front wheel including 17 1143 Coach bolt tyre and tube 33 1231 Wheel bearing cap was R100 HEIGHT ADJUSTING MECHANISM Item Part Part Description Item Part Part Description No No No No 1 1358 Cable height adjusting pin 13 1159 Lift lever rear deck 2 1276 Height adjusting pin 14 1183 Pedal pin 3 1153 Self tapping screw 15 1178 Pedal assembly 4 1378 Washer 3 16 16 1379 Bolt 3 8 Whit x 3 5 1059 Plain washer 3 8 ID 17 1174 Height adjusting rod 62. 6 Pull out one of the R clips on the main deck pin at the front of the deck and remove the pin Lift the V frame off the deck and place a short piece of pipe or plastic tube over the front height adjusting system torsion bar and onto the belt tensioning bolt This will hold the V frame off the deck 7 Remove the four pins at the bottom of the chains which support the deck 8 Release the handbrake on the mower and the 2 freewheeling levers at the rear of the mower Grasp the front cross beam of the mower lift the beam and walk the mower backwards over the deck Replacement Replacing the deck is the reverse of the above sequence Engine Clutch Removal Removal 1 The clutch cannot be removed from the engine when it is in the in the mower so to service the clutch or the engine remove the engine and clutch as an assembly The engine mounts have been cut away so this can be accomplished relatively easily 2 Use only an approved crane or engine lifting device to lift the engine form the mower 3 Turn off the ignition key or disconnect the battery Release the power lead to the clutch by unplugging it on the inside of the firewall then loosening the cable clamp Remove all other wires leading to the engine being careful to tag them for ease of replacement before they are removed 4 Remove the covers on either side of the engine 5 Remove the blade drive belt as described in Deck removal and Replacement 6 Release the tens
3. mechanism to lift the deck A large spring attached to the mechanism reduces the force required for the lift The deck will descend to its lowest height by gravity once the pedal is pushed slightly and a pin is removed from the long height adjusting rod A lid under the operator s seat allows easy access to the battery and the fuses The mower is fitted with a toolbox on the left mudguard but this can be replaced with a fuel tank as an optional extra This will double the fuel capacity Lastly the mower has many safety features as mentioned in Part 1 These include an interlock which prevents the mower being started when the handbrake is off an interlock which stops blade rotation when the handbrake is applied a seat switch which turns off the engine if you dismount and a switch under the battery lid which prevents the engine being started when the lid is raised The handbrake is incorporated in the right hand control lever so when the lever is moved aside to exit the seat the handbrake is automatically applied Service Schedule Component Frequency Type of Maintenance Engine cooling air 100hrs Brush clean screen Cooling Fins engine 100hrs Clean with air hose if available USE SAFETY GLASSES otherwise by hand Engine air cleaner 25 hrs Shake out dirt dry type Wash sponge type pre cleaner When not serviceable replace Spark plugs 100hrs Service or replace Fuel filter 100hrs Re
4. 16 FS 110 blue FS 17 FS 110 red FR Wires 1 17 are pvc coated 2 2mm diameter End fittings FS 1 4 female spade MS 1 4 male spade O 4 round hole FR 4mm female round socket MP 4mm male round pin B bare end 15mm wire WIRING DIAGRAM HONDA ENGINE Wire No end fitting length mms colour end fitting 1 FS 870 yellow MS 50 yel B diode B 100 yellow O FS 510 yellow FS FS 300 blue FS FS 770 blue FS Blade FS 630 red FS Switch FS 820 red FS x FS 280 green O 8 O 500 green FS 80 green FS 9 O 110 green MS 10 FS 600 grey FS 160 yellow FS 430 yellow FS 540 red B 11 FS 300 black B 12 FS 490 green O 13 FS 650 black FS 760 black MP 14 FS 120 grey FR 15 FS 50 red FS 300 red O ee 16 FS 300 blue FS i 17 FS 110 red FR E RED I BLACK ee i ne i Wires 17 are pvc coated 2 2mm 3 diameter PARTS LISTS SEAT and LID Ll X vi Ss Ss RY 8 Ss X X SS s RX NN KS yh R S SSS SY Y KS x OP Item Part Part Description Item Part Part Description No No No No 1 1394 Seat spring was T535 15 1818 Seat hinge bracket 2 1072 Nut 8mm 16 1063 Bush seat pivot 3 1407 Plastic cap spring was T536 17 1062 Nut 3 8 UNC nyloc 4 1019 Washer 8 x 20 18 1054 Seat lid assembly 5 1018 Spring
5. and to tension the belts as described in the Adjustments section Ensure no contamination gets into the fuel line as this will end up in the carburettor Hydrostatic Transmission Removal Replacement Removal 1 This task is a lot easier with the engine clutch assembly removed the seat removed and the battery box removed IT IS IMPERATIVE THAT THE MOWER IS ON A LEVEL SURFACE 2 To remove the seat disconnect the wiring under the seat but carefully tag the wiring first Then remove the bolt hinge pin on the left front corner of the seat Slide the seat panel to the left and it will come off the right hand hinge pin 3 To remove the battery box first take off the battery strap then remove the battery Next undo the bolts on either side of the battery box and remove the box 4 Using a jack mount the rear of the machine on 2 car stands positioned near the two rear corners and under the side plates 5 Remove the two rear wheels 6 Disconnect the pin across the rear of the machine underneath the clutch pulley which is connected to the handbrake levers on the rear of the hydro units Remove the spring which is connected to the handbrake rod on top of the chassis Slide the handbrake rod forward 7 Remove the springs from the ends of the freewheeling levers then remove the levers from the hydro units Withdraw the levers from their guides and place them aside 8 Remove the frame chassis from underneath the hydro unit
6. Clutch strap 23 1271 Clutch strap spacer 24 1335 14 key x 29 25 1336 Pulley 4 26 1337 Collar crankshaft top 27 1400 Muffler B amp S 27A 1380 Muffler Honda 28 1384 Cap screw 5 16 x20 UNC 29 1381 Muffler gasket 16 MOWING DECK ASSEMBLY Mowing Deck Parts List Item Part Part Description Item Part Part Description No No No No 1 1228 Belt cover RH 30 1105 Roll pin 3mm x 20 2 1274 V belt deck drive 31 1314 Split pin 3mm x 25 3 1227 Belt cover LH 32 1282 Axle deck roller 4 1316 Bolt 12 x 3 HT UNF 33 1279 Deck roller 5 1046 V frame pivot bush 34 1211 Deck frame Welded to item 55 6 1049 Nut 2 UNF on later models 7 1015 Plain washer 1 2 35 1248 Deck retaining pin 8 1245 Spring washer 1 2 36 1171 R clip 9 1203 V frame assembly 37 1207 V frame coupling 10 1210 Nut 3 4 UNC 38 1319 Nut 1 UNF 11 1247 Spring washer 3 4 39 1325 Centre pulley assembly 12 1275 V belt deck outer 40 1296 Key 4 x 80 13 1014 Idler pulley 3 41 1323 Double pulley 1 off 14 1428 Nut 5 16 UNF 42 1320 Outer pulley deck 2 off 15 1018 Spring washer 8mm 43 1385 Spindle assembly outer 16 1019 Plain washer 8mm 44 1388 Spindle assembly Centre 17 1241 Blade belt tensioner Left hand 45 1294 Spindle housing 18 1243 Blade belt tensioner Right 46 1406 Spindle bearing 6206 2NSE 19 1233 Sway brace 47 H651 Blades only x 2 20 1237 Wash
7. nuts by hand 6 Deck Tilt and Minimum Deck Height If the deck is scraping on the ground at its lowest height it can be raised at the front by relocating the pins holding the chains on the front of the deck further rearward in the multi holed brackets the multi holed brackets are welded to the top of the deck To raise the rear of the deck remove the platform see para 2 page 6 and then tighten the nuts on the long height adjusting rods The nuts are on the left and right side of the mower roughly near the height adjusting pedal and the foot support As you tighten periodically measure the gap between the top of the deck at the front and the rear and the side rails The gap should be the same front to rear or say 10mm narrower at the rear A slight downward slope of the blades can produce a better cut Finally check that the four chains are tight If one of the chains is loose tighten the nut on the long rod on the same side as the loose chain 7 Removal of the Large Deck Spring Remove the deck as described above and the platform as described in para 2 page 6 Slide the pedal well forward on the height adjusting rod i e the rod with the multiple holes Grasp the height adjusting rod firmly and pull it towards the rear of the machine at the same time removing the pin you placed behind the bracket at the right front corner of the seat Now allow the rod to move forward slowly until it stops Use a strong wire hook
8. release assembly 18 1116 Pop rivet HANDBRAKE COMPONENTS Item Part Part Description Item Part Part Description No No No No 1 1082 Top plate handbrake pivot 10 1352 Tension spring 2 1017 Bolt M8 x 20 11 1345 Handbrake lever assembly 3 1099 Nyloc nut M8 12 1015 Washer 1 2 4 1029 Hydro lever handbrake 5 1030 Roller tube 6 1019 Washer 8 x 20 7 1350 Split pin 8 1031 Handbrake tie rod 9 1028 Rod assembly handbrake ENGINE and REAR WHEEL DRIVE Part No 1331 1386 1016 1015 1014 1017 1018 1019 1013 1011 1272 1024 1020 1267 1268 1340 Q ane GO 0o OO os xe Q Q O re KX N P OO S 4 es WY e i S 4 os S We o 4 ox 4 X A 4 GO OG 4 Xs xs S OO ess RX ote XT gt A SLS Part Description Engine B amp S Engine Honda Nyloc nut M12 Washer 2 x 1 Idler pulley 1 2 x 3 was T618 Bolt M8 x 20 Spring washer 8mm Plain washer 8 x 20 Bolt M12 x 45 Idler arm Drive belt Spring Latch assembly Hydrogear transmission LH Hydrogear transmission RH Rear tyre 20 Item Part Part Description No No 16 1341 Wheel nuts 17 1383 Rear wheel rim 18 1339 Crankshaft bolt 7 16 x 3 UNF 19 2064 Spring washer 7 16 20 1338 Stepped collar 21 1333 Clutch 22 1270
9. 1436 Bolt 3 8 Whit x 1 18 1359 Plastic plug 7 1167 Chain 5 links 19 1166 Spring deck lift 8 1171 R clip 20 1175 Height adjusting swivel 9 1062 Nyloc nut 3 8 UNC 21 1062 Nyloc nut 3 8 UNC 10 1172 Deck pin 22 1053 Stepped bolt 11 1173 Height adjusting tube 23 1160 Torsion tube assembly 12 1437 Bolt 3 8 Whit x 2 13 OPERATOR S CONTROLS Item Part Part Description Item Part Part Description No No No No 1 1106 Control lever assembly L amp RH 19 1118 Bolt M8 x 40 Includes items 2 3 4 17 amp 18 20 1117 Nylon roller 2 1114 Handgrip set 21 1404 Over travel device assembly 3 1109 Release assembly 22 1428 Nut 5 16 UNF 4 1112 Plastic knob 23 1073 Pivot block assembly 5 1098 Bolt M8 x 30 24 1085 Nylon bearing half 2 each side 6 1103 Rose joint 5 16 UNF 25 1076 RH control assembly 7 1091 Vertical rod hydro control 26 1314 Split pin 8 1099 Nyloc nut M8 27 1132 Spring RH control 9 1417 Nut 10 mm 28 1344 5 8 x 1 washer 10 1059 Washer 3 8 x 1 29 1133 Spring LH control 11 1416 Bolt M10 x 40 30 1096 LH control assembly 12 1072 Nut M8 31 1342 Bolt M8 x 25 13 1019 Washer 8 x 20 32 1088 Right angled lever 2 off 14 1328 Bolt M8 x 50 5002 Bronze bush not shown fits 15 1097 Support RH control in lever No 32 16 1081 Support LH control 33 1093 14 W threaded rod 17 1113 Spring
10. Deutscher Mowers Pty Ltd OPERATORS MANUAL PART 2 1400 ZTR Zero Turn Ride On Mower Table of Contents Page No Topic 1 2 Table of Contents and Outline of Machine Functions 2 Service Schedule 3 Adjustments belt tensions control levers 4 Adjustments handbrake 5 Trouble Shooting Guide and Electrical System 6 Removal replacement of the mower deck 7 Removal replacement of the engine clutch assembly 8 Removal replacement of the hydrostatic transmission units 9 Wiring diagram 10 18 Exploded view drawings and parts lists 10 Seat and lid 11 Electrical components 12 Chassis 13 Height adjusting mechanism 14 Operators controls 15 Handbrake components 16 Engine and rear wheel drive 17 Deck assembly drawing 18 Deck assembly parts list 19 Rear discharge version component parts Outline of Machine Functions The Deutscher 1400ZTR ride on mower is fitted with a Briggs amp Stratton engine or a Honda engine Both engines use a 12v starter system with its own charging system A key switch is used to start the engine on the control panel A single V belt is used to drive the transmissions from the engine The hydrostatic transmission units have an output shaft whose speed and direction of rotation can be varied independently of the input shaft speed and rotation direction The output shaft of the left hand hydrostatic transmission is attached to the left rear wheel and the output shaft of the right hand hydrostat
11. an open circuit in the earth wire from the engine to turning off the ignition key the switch or from the switch to the chassis earth Poor grass discharge from e Blades badly worn chute e Belts slipping e Mower deck set too low for the conditions e Driving too fast for the conditions e Grass very wet Mower turning to the left or right with the control levers held opposite each other Control levers need adjusting See Adjustments Hydro belt slipping To check see Adjustments One or both hydro units faulty See your mower dealer Mower not climbing up hills Tyres slipping on grass Hydro belt slipping Faulty hydro units Electrical System_ Ref Wiring Diagrams on Page 9 1 The diode in the clutch circuit is installed to prolong switch life FAILURE TO CONNECT THE DIODE CORRECTLY WILL CAUSE A SHORT CIRCUIT 2 The switch connected to the right hand control lever has a second function it prevents the mower being started unless the control lever is in the out position This ensures the handbrake is engaged when the mower is started 3 See page 6 Part 1 The buzzer is installed to warn operators that the battery will go flat if they leave the seat and do not turn off the ignition switch Deck Removal and Replacement Removal 1 Position the mower on a level area where you wish to remove the deck stop the engine engage the handbrake and lower the deck to its lowest height 2 Loosen the l
12. arge 34 UNC nut at the front of the deck in the centre under the front cross beam Then loosen a similar nut at the rear of the same bracket so the blade drive belt from the engine becomes slack Removing the foot platform will make access to these nuts easier To remove the platform pull the pin out of the height adjusting pedal and slide the pedal rearwards until it touches the control panel Remove the four screws retaining the platform Remove the platform by standing at the front with your left hand in the slot through which the height adjusting mechanism protrudes and your right hand under the right edge then lift it aside 3 Remove the long blade drive belt from the pulley on the deck 4 Pull out the pin securing the deck sway brace to the mower The pin is located at the base of the chassis just in front of the left hand wheel Pull the sway brace bar off its support pin but leave it connected to the deck 5 If you removed the pin from the height adjusting pedal slide the pedal forward so it is at least 300 mm away from the control panel Grasp the height adjusting rod the long square tube with the pedal on it firmly and pull it towards the rear of the machine until the chains supporting the deck are loose Place a bolt or the pedal pin in one of the height adjusting holes just behind the guide bracket at the front right hand side of the seat then slowly release your grip on the rod The four deck chains should remain loose
13. er 12 x 7 8 50 H650 Blade bolt nut washer x 2 21 1171 R clip H652 Bolt nut washer set x 2 22 1239 Split pin 3 16 x 1 51 G36 Disc retaining bolt 23 1094 Spring sway brace 52 1060 Spring washer 3 8 24 1238 Washer 1 2 x 1 x 1 8 53 R32 Blade plate assembly 25 1000 Plastic discharge chute 54 1382 Deck welded assembly 26 1286 Hinge plate assembly 27 1292 Hinge pin flap 28 1291 Starlock clip 8mm 29 1273 Flap spring 18 Rear Discharge Version Components Item Part No Part Description 1 1769 Rear discharge deck assembly 2 1957 Honda muffler VSM3 3 1762 Self threading screw 4 1775 Chassis plate 5 1062 Nut nyloc 3 8 6 1058 Bolt 3 8 x 1 7 1776 Bumper bar assembly rear discharge 8 1799 Air cleaner Honda No 9 1804 Air cleaner hose 10 1785 Air intake extension adaptor 11 1791 Hose Clamp 25 40 mm 2off 12 1792 Hose clamp 40 60 mm 1 off 19
14. evers If the two control levers are not opposite each other or you wish their neutral position to be further forward or backward simply loosen the 8mm bolt 18mm spanner at the base of each lever facing inwards relocate the levers and retighten the bolts The length of the hydro control rods inside the mower are factory set and should not need adjusting 5 Handbrake To test the handbrake park the mower on a smooth level surface and put the right hand control lever in its OUT position Try to push the mower with the freewheeling levers engaged If the mower moves adjust the handbrake as follows With the right lever in the IN position the free play on the handbrake lever where it joins the control lever rod should be approximately 1 2mm See diagram 1 If the free play is greater tighten the nut on the handbrake rod at the base of the machine under the front of the battery until the required free play is achieved Recheck the handbrake operation by trying to push the mower with the brake engaged MEASURE FREE PLAY Figure 1 Handbrake Adjustment If the method listed above fails to improve the handbrake function the two castellated nuts on the sides of the hydro units at the rear may need tightening Please note there should still be a small amount of free play in the levers under these nuts when the handbrake is off Remove the split pins to turn the castellated nuts and replace the pins after winding in the
15. ic transmission is attached to the right rear wheel A single fixed position idler pulley adjacent to the engine is used to keep the drive belt tight The two hydrostatic transmission units are controlled by levers as described in Part 1 of this manual and do not turn the wheels when the levers are in their neutral position The front wheels of the mower are castors and free to pivot in any direction An electric clutch on the engine is used to engage the cutters via a B section belt The clutch is switched on and off by a switch on the operators panel The fully floating side discharge 1400mm cut width mower deck is suspended on four chains below the frame of the mower and is held forward by a V shaped frame which is adjustable in length To tighten the deck drive belt This ensures that the deck drive belt remains tight when the deck is raised and lowered The mower deck is fitted with three disc blades and the central blade is driven by the long belt from the engine The two outer blades are driven by separate belts from pulleys on the central blade shaft These outer belts can be separately tensioned The mower deck is braced sideways with a long steel rod which can move up and down as the deck height is changed The rod is spring loaded at the end to absorb minor collisions by allowing the deck to swivel slightly Raising the mower deck is accomplished by the operator pushing on a foot pedal which in turn moves a
16. ioner for the hydro drive belt and pull the tensioner fully backward in its slot If this does not enable you to remove the hydro drive belt easily remove the tensioner completely Remove the hydro drive belt 7 Drain the engine oil See engine booklet 8 Disconnect the fuel line from the engine being careful not to spill fuel DO NOT SMOKE OR PERFORM THIS TASK ANYWHERE NEAR A NAKED FLAME TURN OFF MOBILE PHONES 9 Remove the four engine bolts and the spacer above the strap to the clutch Note carefully the position of the clutch strap i e on the right side with the spacer ABOVE the strap The strap must be in tension with the engine running and blades driving 10 Loosen the other end of the clutch strap and turn it in towards the crankshaft 11 Place strong straps around the engine and using a winch rated for the purpose carefully raise the engine and clutch assembly Never position yourself under the assembly once it is raised and keep bystanders away Lift the engine just above the rear of the mower and lock the lifting device 12 Release the freewheeling levers on the back of the mower and slowly draw the mower away from the engine 13 Lower the engine carefully to the ground or bench and sit it on blocks Replacement Replacement of the engine clutch assembly is the reverse of the installation Great care must be taken to avoid damaging the clutch pulley during this operation Don t forget to reconnect the clutch strap
17. or sturdy rope connected to the front of the spring to pull the spring forward and then down off the torsion bar bracket Trouble shooting Chart Problem Possible Cause Mower will not start when the e Right hand lever in IN position key is turned e Blown fuse in starter solenoid circuit e Driver not sitting in the seat e Engine starter motor fault e Flat battery Especially if the starter solenoid clicks but the engine does not turn over e Circuit fault Follow circuit diagram page 9 Battery will not charge e Corroded or loose battery terminals e Defective battery e _Inoperative diode or rectifier regulator Battery discharges rapidly e Low water level e Defective battery Engine cranks slowly e Weak or discharged battery e Corroded or loose electrical connections on the solenoid or the battery Blades will not turn when e Right hand control in the OUT position switched on at the panel e Clutch fault Check power is getting to the clutch before removing the clutch e Belt missing or slipping See adjustments e Circuit fault Follow circuit diagram page 9 Engine will not turn off when e Faulty ignition switch the key is turned off e Open circuit in engine earthing lead either between the engine and key switch or between the key switch and earth Engine will not turn off when e The switch under the seat is not operating when the seat lifts leaving the seat without e There is
18. place Battery daily Check water level top up if necessary Hydrostatic units 10hrs or daily Externally clean assists cooling Belts 50hrs Check for wear and adjust Tyres 30hrs Check for damage and air pressure Handbrake As required Adjust linkage If the mower can be pushed with the handbrake engaged 10 hrs Lubricate mechanism pivot points with light oil Hydro L shaped 10hrs Lubricate pivot bolt with light oil control lever More often under extreme conditions Adustments 1 Deck drive belt_ From engine to mower deck To check the belt tension reach in to the centre of the belt at the rear of the mowing deck and grasp the two sides of the belt in one hand i e With your thumb around one side of the belt and your little finger s around the other side Squeeze your grip to test the belt tension You should have about 15 mm movement inwards on each side Do not over tighten the belt This may reduce bearing life etc To tighten the belt loosen the front 34 UNC nut on the large thread at the front of the mower deck by a few turns Turn the second nut on the same thread clockwise facing forward and with each half turn recheck the belt tension as described above Retighten the front nut 2 Short blade belts On mower deck It is easier to tension these belts if you have the deck removed but it can be done with the deck on the mower and even with the belt guards in place To tighten these belts sim
19. ply loose the 3 8 UNC nuts on the belt idler pulleys push the pulleys inwards by hand and retighten the nuts It may be useful to place a piece of wood behind the idler bracket when pushing it in Once tightened the belt should deflect about 12 15 mm in the centre opposite the idler pulley when forced inwards by hand Important The idler pulley runs on the outside of the belt Using incorrect belts can cause premature belt failure as not all belts are designed for this arrangement 3 Hydrostatic transmission belt Under the engine Remove the left rear cover situated above the bumper bar To tension the belt loosen the 8mm tensioner clamping bolt on the left of the left engine mounting plate by one to two turns Push the belt idler inwards with a force of approximately 5 8 kg and while holding this force retighten the 8mm bolt OVERTIGHTENING THE BELT COULD CAUSE PREMATURE FAILURE OF THE HYDRO BEARINGS THE 5 8 kg FORCE IS ABOUT THE MAXIMUM MOST PEOPLE CAN ACHIEVE WHEN PUSHING ON THE TENSIONER WITH THEIR THUMB IF UNSURE OF THE FORCE REQUIRED USE A PIECE OF FLAT WOOD AND A SPRING BALANCE DO NOT USE A LEVER TO TIGHTEN THE BELT TENSIONER YOU WILL VOID YOUR WARRANTY You can check the belt tension by pushing the belt sideways at a point halfway between the right hydro pulley and the engine pulley The belt should deflect about 12mm when pushed sideways forcefully with your thumb 4 Hydrostatic Transmission control l
20. s IF YOU PUT YOUR ARM UNDER THE MACHINE ENSURE THE MOWER IS VERY SECURE ON THE CAR STANDS A security block or drum under the centre of the machine is recommended 9 The hydro units can now be removed by disconnecting and removing the bolts which hold them to the chassis side plates If you do not have sealing plugs for the hydro units keep the plastic tubular vent facing upwards at all times even during removal Replacement Replacement of the hydro units is the reverse of the installation Ensure the wheel bolts are tensioned to 40ft lb 54 Nm and the engine bolt through the clutch is tightened to 50ft lbs 68 Nm Use new nyloc nuts on the hydro bolts if they have been removed more than once before DO NOT FORGET TO RE INSTATE THE VENT PIPES IN THE HYDRO UNITS Tension the blade belt and the hydro belt as specified in the Adjustments section WIRING DIAGRAM BRIGGS and STRATTON ENGINE Wire No end fitting length mms Handbrake switch colour end fitting 1 FS 870 yellow MS 50 yel B diode B 100 yellow O 2 FS 510 yellow FS FS 300 blue FS 3 ee 4 FS 770 blue FS E 5 ES i FS 6 FS 820 red FS gt 8 9 Y FS 280 green O O 500 green FS 80 green FS O 110 green MS 10 FS 600 grey FS 160 yellow FS 430 yellow FS 540 red B Key Switch 11 FS 300 black B 12 FS 490 green O 13 FS 650 black FS 760 black MP 14 FS 120 grey FR 15 FS 50 red FS 300 red O
21. washer 8mm 19 1019 Washer 8 x 20 6 1017 Bolt M8 x 20 20 1099 Nut 8mm nyloc 7 1040 Seat switch stud 21 1816 Earthing strap 8 1817 Microswitch bracket 22 1821 Washer 50 Dia 9 1330 Standard seat KAB P2 23 1815 Engine cutout spacer 10 1371 Delux seat KAB U2 24 1945 Nylon insulator 11 1372 Back rest KAB P2 seat 25 1946 Nylon washer 12 1819 Seat base plate 26 R87 Spring Standard seat 13 1058 Bolt3 8 UNC x 1 1132 Spring delux seat 14 1059 Washer 3 8 x 1 27 1814 Engine cutout plate 10 ELECTRICAL COMPONENTS Item Part Part Description Item Part Part Description No No No No 1 1263 Lid amp handbrake switch 14 1255 Starter solenoid B amp S only 2 1373 Battery cable 245mm 15 1135 Control panel 3 1374 Battery was T315 16 1261 Key switch 4 1395 Engine earth lead 180mm 17 1262 Blade switch 5 1396 Throttle plate assembly B amp S 18 1256 Hour meter 6 1397 Choke cable assembly B amp S 19 1333 Electric clutch 1810 Choke cable assembly Honda 20 1947 Micro switch 7 1398 Throttle cable assembly B amp S 21 1250 Wiring loom incl buzzer 1811 Throttle cable assembly Honda 22 1712 Buzzer 8 1154 Cable clamp 23 3063 Battery cable Honda 560mm 9 1259 Screw 5mm x 15 10 1260 Nut 5mm nyloc 11 1254 Fuse 10 amp 2 off 12 1253 Fuse 20 amp 2 off 13 1252 Fuse box 11 CHASSIS
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