CONVERSION KIT INSTRUCTIONSJOHN DEERE GATOR 4X2

HONDA ENGINE CONVERSION KIT

SMALL ENGINE WAREHOUSE, INC.800-321-6725 TOLL FREEwww.SmallEngineWarehouse.com

INSTALLATION & SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1. VERIFY THAT YOU RECIEVED ALL LOOSE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2. LABEL WIRING AND REMOVE YOUR OLD ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3. INSTALL NEW ENGINE IN YOUR GATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4. ENGINE WIRING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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WRITE YOUR ENGINE INFO HERE

UNIT MODEL: (E.G. JD#)

ENGINE MODEL: (GX270)

SERIAL # :

SERIAL # :

These numbers are very difficult to obtain after the engine is installed and are required for warranty.

WRITE YOUR SALES INVOICE NUMBER HERE

This number is required for technical assistance. If you are in need of installation assistance, call us Toll Free at 800-321-6725

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INSTALLATION & SAFETYBefore you start, please read all of the provided details and written instructions on how to properly remove your old engine and install this engine kit.

We have designed our kits and instructions to allow for the easiest installation and assembly as possible, but assistance from a qualified technician may be necessary. There are occasional details that vary from machine to machine, so following the process will help ensure that your new engine is installed quickly and safely. Installing our engine kits into your equipment often require different skills including troubleshooting your wiring setup and even modifying your original equipment to allow space for installation and operation. We have tried to minimize the need for modifications to be made to the original design of the equipment, but this is sometimes unavoidable. Most engine swaps are not “plug & play” because it is very uncommon for your original engine (model and type) to be available for purchase today. We expect there to be some translation required from your old equipment to your newly repowered equipment. We have made every reasonable attempt to make this installation a clean and beneficial process for you.

If you feel like you need help, please contact us. We will assist you with regards to the engine kit purchased from us, and we may offer some suggestions regarding operation as well. We cannot claim to know the specifics of your machine, although we will try to help. Our design technicians and customer support staff are certified and authorized by the engine brands we sell and service. Because we cannot see firsthand your machine setup, it is difficult to diagnose problems over the phone and we will ask that you provide pictures when necessary. Give us a call or email us, and we will start working through the issues with you. Most of the time, the solution is simple and we can walk you through it. Your feedback is welcome and we want to hear about your installation.

For your own safety, please be careful when working around gasoline engines. There are many hazards to watch out for:

• Gasoline is both flammable and explosive.

• Carbon monoxide in an enclosed garage is just as lethal with a lawnmower as it would be with a car.

• Many steel engine parts are sharp enough to cause deep cuts.

• Rotating engines can cause injury by catching hands or clothing.

• Mufflers and surrounding areas take only seconds to get hot enough for severe burns.

• Voltage generated from the battery or the engine coil can cause electrical shock.

CAUTION!

THANK YOU FOR YOUR PURCHASE!

1. VERIFY THAT YOU'VE RECEIVED ALL LOOSE PARTS

Most parts required for the conversion are already mounted to the engine. The parts shipped loose are normally on top of the engine when packed, secured to the engine with cable ties, or inside a plastic bag.

A. 56.5" Choke Cable (1)B. 3/8" Flat Washers (3)C. 5/16-18x1" Bolt (1)

D. 5/16-18" Flange Nut (1)E. Muffler (1)F. Shock Absorber Bracket (1)

A B C D E F

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2. LABEL WIRING AND REMOVE YOUR OLD ENGINE

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Please label the wiring between your Gator and old engine before removing anything.

Most installation problems occur because of modified or unidentified tractor wiring.

Your old wiring CANNOT be identified over the phone.

STOP!1. Disconnect the battery cables from your battery.

2. Unplug the wiring harness and starter leads.

3. Disconnect the fuel line, throttle, and choke cables.

4. Unhook the shifter linkage.

5. Remove the belt guard and air intake hose.

6. Remove the support bar from the engine and transaxle.

7. Remove the old muffler.

8. Unbolt the (4) engine bolts.

9. Remove your old engine.

NOTE: It may be necessary to slot the (4) engine mounting holes 1/4" towards the front of the unit, allowing room between the transaxle and the engine.

3. INSTALL NEW ENGINE IN YOUR GATOR

1. Set the new engine down into place and install the belt onto the clutch before bolting down the engine.

2. Plug in the wiring harness and hook up the positive wires to the starter solenoid, shown in Figure 4.1 and Figure 4.2.

3. Connect the fuel lines to the fuel filter and the vacuum line to the port on the fuel pump, as shown in Figure 4.3 and Figure 5.2.

4. Install the support bar from the engine to the transaxle, as shown in Figure 4.3.

5. Connect the throttle cable to the throttle lever and throttle bracket on the top of the engine, shown in Figure 4.3.

6. Install the new choke cable assembly (A) in the gator and connect the choke cable to the choke lever and the bracket by the carburetor. (Figure 4.3 and Figure 5.4)

7. Connect the ground cables to the engine boss by the starter with the 5/16-18x1” bolt (C), 3/8” flat washers (B), and 5/16-18” flange nut (D), as shown in Figure 5.1.

8. Reconnect the shifter linkage to the shifter arm with the spring on top of the transmission shift arm.

FIGURE 4.1

FIGURE 4.2FIGURE 4.3CHOKE

THROTTLE

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DO NOT reuse the gasoline. Gasoline that contains ethanol starts to expire after a few weeks unless you use a stabilizer. Aged fuel may cause rough starts and poor running conditions.

Be sure to remove the old fuel from the gas lines before reconnecting so that any debris can be removed and not introduced into the new fuel system. If you are using the engine heavily, you will need to change the oil more frequently. Make sure to check your engine manual for the recommended service frequency.

STOP

FIGURE 5.1

FIGURE 5.2

FIGURE 5.4 FIGURE 5.3

9. Install the muffler (E) and shock absorber bracket (F) between the frame mount and the muffler bracket, shown in Figure 5.3.

10. Install the factory air cleaner hose to the new engine air intake tube.

11. Fill the engine with oil, as specified in the engine manual.

12. Make sure all of the battery and belt connections are tight.

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5. ENGINE WIRING INFORMATION

This kit was designed so that the new engine wiring should plug into your existing plug. If your plug does not match, then your Gator may have been modified from its original configuration or is a variation in design from the unit we originally designed from. As previously mentioned, we cannot determine the function of your wiring over the phone, so marking wires during engine removal is important. Requesting help from a mechanic may be required.

WARNINGPlease check to make sure that no voltage gets

to the white wire at any key position. MAGNETO DAMAGE WILL OCCUR

WHITE WIRE: Connects to existing tractor plugORANGE WIRE: Engine alternator