Hustler Super Z HyperDrive Parts Manual...This manual covers Hustler ® Super Z HyperDrive models...

200 South Ridge RoadHesston, Kansas

67062

Hustler® Super Z HyperDriveParts Manual

117589EX_0416 c-1

Table of Contents

General InformationService Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Options Available From Your Dealer. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Hardware Description Codes & Abbreviations . . . . . . . . . . . . . . . . . . . . 1-2Standard Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Section 2Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Engine Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Section 3Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Hydraulic Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Hydraulic Motor Service Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Oil Cooler Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Pump Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Steering—S/N 13034312 & Higher . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12Steering Assembly—S/N 13034312 & Higher. . . . . . . . . . . . . . . . . . . . 3-14Steering Cover Assembly—S/N 13034312 & Higher . . . . . . . . . . . . . . 3-16Steering—S/N Prior to 13034312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20LS Steering Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24RS Steering Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Section 4Wheel & Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Front Wheel Breakdown, Flex Forks®. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Drive Wheel Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Section 5Engine, Kawasaki FX1000V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Engine Service Parts, Kawasaki FX1000V . . . . . . . . . . . . . . . . . . . . . . . 5-4Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6Fuel Tank Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Section 6Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Section 760" Side Discharge Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-260" Side Discharge Deck Pulleys & Spindles . . . . . . . . . . . . . . . . . . . . . 7-460" Side Discharge Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-666" Side Discharge Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-866" Side Discharge Deck Pulleys & Spindles . . . . . . . . . . . . . . . . . . . . 7-1066" Side Discharge Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1272" Side Discharge Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

c-2 117589EX_0416

72" Side Discharge Deck Pulleys & Spindles. . . . . . . . . . . . . . . . . . . . 7-1672" Side Discharge Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18Side Discharge Deck Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20Side Discharge Deck Mounting Hardware . . . . . . . . . . . . . . . . . . . . . . 7-2260" Rear Discharge Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2460" Rear Discharge Deck Pulleys & Spindles . . . . . . . . . . . . . . . . . . . 7-2660" Rear Discharge Dust Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3060" Rear Discharge Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32Rear Discharge Deck Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36Rear Discharge Deck Mounting Hardware . . . . . . . . . . . . . . . . . . . . . . 7-38

Section 8Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2Seat Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4ROPS—S/N 15010001 & Higher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6ROPS—S/N Prior to 15010001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

117589EX_0416 1-1

General Information

This manual covers Hustler® Super Z HyperDrive models 932152EX, 932160EX, 932178EX, 932186EX, 932657EX, 934307EX, 934315EX, 934323EX, 934349EX & 934372EX.

Service Literature

PART NO.OPERATOR’S MANUAL (S/N 15010001 & HIGHER)OPERATOR’S MANUAL (S/N PRIOR TO 15010001)WARRANTY STATEMENTGENERAL SERVICE MANUAL

Options Available From Your Dealer

PART NO.60" ADAPTER KIT 60" SAND KIT66" ADAPTER KIT 66" SAND KIT72" ADAPTER KIT 72" SAND KITBAC-VAC CATCHER 60" MULCH KIT3 BAG CATCHER 72" MULCH KITFLEX FORK KIT ROLLER KIT (60" DECKS)HYDRO DECK LIFT KIT ROLLER KIT (72" DECKS)LIGHT KIT DUAL REAR ANTI-SCALP KIT (60" & 66" DECKS)SEMI-PNEUMATIC TIRE/WHEEL SINGLE REAR ANTI-SCALP KITSTEERING EXTENSION KIT DUAL REAR ANTI-SCALP KIT (72" DECKS)VX4 DECK HIGH VACUUM KIT 60"VX4 DECK HIGH VACUUM KIT 72"

Note: When ordering parts, you must use the part number as shown for each part, not the index number. Always give the model and serial number to your parts and service representative.

Note: Items sold in bulk such as seals and hoses are sold by the foot.

Using This Manual

This manual is part of a service package for the Hustler® mowers. Use of this manual in conjunction with other Hustler® mower and component manuals will provide the information necessary to service and maintain Hustler® mowers.

This Parts Manual provides a complete parts listing for the unit. Use this manual when ordering parts. Illustrations used were current at the time of printing, but subsequent production changes may cause your machine to vary slightly in detail. Excel Industries, Inc. reserves the right to redesign and change the machine as deemed necessary, without noti-fication. If a change has been made to your machine which is not reflected in this parts manual, see your authorized dealer for current information and parts.

The Service Manual is a service guide for use by Service Technicians. It provides the necessary information needed to perform normal maintenance requirements on these units.

The Operator's Manual provides fundamental operational information and operational safety that is needed when oper-ating the mower.

The component manuals are furnished by the various manufacturers to be used for the troubleshooting and servicing of their products.

DESCRIPTION605784604460117799117592

DESCRIPTION PART NO. DESCRIPTION113903 113679113904 113908113905 113909932103 113722932467 113724603167 116840113932 116842117147 113911789537 113910353961 113937116305116307

1-2 117589EX_0416

Hardware Description Codes & Abbreviations

The following codes are used throughout this parts manual. Refer to this list when ordering parts.

ABBREVIATIONCARRIAGE BOLT MACHINE BUSHINGCLEVIS PIN MACHINE SCREWCLIP NUT NUTCOTTER PIN SELF TAPPING CAP SCREWCAP SCREW SOCKET HEADCUP WASHER SHOULDER BOLTFENDER WASHER SET SCREWFLAT WASHER OUTSIDE DIAMETERHEX HEAD INSIDE DIAMETERLOCK WASHER WELD NUT

Standard Torques

The following chart lists the standard torque values for the threaded fasteners found in this manual. Torque all cap screws, nuts and set screws to these values unless a different torque is shown in the Notes section next to the fastener.

SIZE FT-LBS N•M SIZE FT-LBS N•M

DESCRIPTION ABBREVIATION DESCRIPTIONCB MBCE MSCN NTCP SCCS SHCW SB

FDRW SSFW ODHX IDLW WN

.250 8.2 11.1 M3 1 1.3

.312 17 23 M4 2.2 3

.375 30 40 M5 4.5 6.1

.438 48 65 M6 7.7 10.4

.500 73 99 M8 18.5 25

.562 105 143 M10 37 50

.625 145 200 M12 64 87

.750 260 350 M14 80 108.5

.875 420 565 M16 160 2151.00 625 850 M20 320 435

M24 555 750

117589EX_0416 2-1

Section 2

Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Engine Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2-2 117589EX_0416

Frame

1

3

4

5

6

6

6

7

7

89

5

5

1

8

2

10

117589EX_0416 2-3

Frame

INDEX NO. PART NO. QTY.

60" SD FRAME (WITH DECALS, RIVET NUTS, BUMPERS & GREASE FITTINGS)66" SD FRAME (WITH DECALS, RIVET NUTS, BUMPERS & GREASE FITTINGS)72" SD FRAME (WITH DECALS, RIVET NUTS, BUMPERS & GREASE FITTINGS)60" RD FRAME (WITH DECALS, RIVET NUTS, BUMPERS & GREASE FITTINGS)72" RD FRAME (WITH DECALS, RIVET NUTS, BUMPERS & GREASE FITTINGS)BUMPERDECK HEIGHT DECALSAFE OPERATION DECALSERIAL NUMBER / SPEC DECAL3/8-16 THREAD RIVET NUT1/2-13 THREAD RIVET NUTHOT DECALHUSTLER ID DECALGREASE FITTING STRAIGHT

NOTES:

1. Serial number decal. In the event the serial number decal becomes damaged or illegible, please contact your dealer to order a replacement.

DESCRIPTION

1 551763 1

551764 1

551765 1

551766 1

551767 1

2 781880 43 781427 14 601993 15 N/A 16 808493 47 600961 48 602041 29 602407 110 015495 4

2-4 117589EX_0416

Engine Guard

5

1

1

6

43

8

92

1

7

7

2

10

S/N PRIOR TO 15010001

117589EX_0416 2-5

Engine Guard


ENGINE GUARDCB .375-16 X 1.00 G5 ZNYCS .500-13 X 1.25 HX G5FW .531 X 1.063 X .175MUFFLER SHIELD (S/N 15010001 & HIGHER)HITCH PLATE (S/N 15010001 & HIGHER)NT .375-16 HX FLK G5SHIELDH LOGO DECALHITCH (S/N PRIOR TO 15010001)

NOTES:

1. See the Wheel & Tire section.

DESCRIPTION

1 118933 12 025395 43 705954 44 767962 45 121374 16 121375 17 016899 48 377994 29 604352 1

10 115905 1

2-6 117589EX_0416

117589EX_0416 3-1

Section 3

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Hydraulic Motor Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Oil Cooler Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Pump Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Steering—S/N 13034312 & Higher . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Steering Assembly—S/N 13034312 & Higher . . . . . . . . . . . . . . . . . 3-14

Steering Cover Assembly—S/N 13034312 & Higher. . . . . . . . . . . . 3-16

Steering—S/N Prior to 13034312 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

LS Steering Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

RS Steering Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3-2 117589EX_0416

Hydraulic System2

3 1

1343

5

18

3028

29323

22

4

233

31

3231

23

329

30

28

24

25

27

16

17

19

20

26

26

24

12

14

15

8

9

7

10

11

6

12

14

9

15

7 6

8

12

10

15

15

HYDRAULICRESERVOIR

21

29

117589EX_0416 3-3

Hydraulic System


HYDRAULIC OIL COOLERCS .375-16 X .625 HX G5FW .379 X .813 X .063CS .375-16 X 1.00 HX G5VIBRATION MOUNTCS M8-1.25 X 10 G10.9 SHBHFW .344 X 1.00 X .06 ZNYCNT .250-20 HX ZY NLPUMP ARMFW .281 X .625 X .066CS .250-20 X 1.50 HX G5FTG, -10MORB/-12BT 45°LS PUMPSEAL KITFTG, -8MORB/-8BT STRFTG, -10MORB/-10MORFS 90°TUBE, LP-BM LH LOOPTUBE, RP-TM LH LOOPRS PUMPSEAL KITTUBE, RP-TM RH LOOPTUBE, LP-BM RH LOOPNT .500-13 HX G5 ZNYCLOOP CLAMPNT .375-16 HX G5 ZNYFTG, -6MORB/-6MJIC STRRS CASE DRAIN HOSESPRING CLAMPLS CASE DRAIN HOSEWHEEL MOTORFW .531 X 1.063 X .175NT .500-13 UNT LK G8 ZNCS .500-13 X 2.50 SQ G5CB .500-13 X 1.50 FULL

NOTES:

DESCRIPTION

1 602709 12 056069 13 767954 104 036244 45 601571 16 603272 27 079210 28 068551 29 602732 2

10 768515 211 008581 212 774968 213 602556 1

603362 114 601523 215 602443 816 602873 117 602874 118 602964 1

603362 119 602876 120 602875 121 008193 422 043570 223 054502 524 779132 225 603044 126 601617 227 603043 128 602714 229 767962 1230 023317 831 602256 832 028274 4

3-4 117589EX_0416

Hydraulic Reservoir

1

23

2

35

4

47

9

10

1416

18

19

17

12

13

13

11

12

6

8

22

214

5

2018

4

15

24

24

26

27

25

25

TO LS WHEEL

TO RS WHEELMOTOR

MOTOR

117589EX_0416 3-5

Hydraulic Reservoir


BREATHER CAPSTRAINERHYDRAULIC RESERVOIRHOSE CLAMPPUMP SUCTION HOSEHOSE, TO COOLERFITTING, -12MORB/-12MJIC 90°HOSE, FROM COOLERFITTING, -12MORB/-12MORB STRCHECK VALVEFITTING, -8MORB HEX PLUGFITTING, -8MORB/-8MJIC, 90°HOSE, PUMP CASE DRAINCASE DRAIN MANIFOLDSPRING CLAMPSUPPORT BRACKETCS .312-18 X .75 HX G5FW .343 X .687 X .051/.080HCS .312-18 X .50 HX G8NT .312-18 HX G5FITTING, -8MORB HEX PLUGHYDRAULIC FILTERFITTING, -8MORB/-6BT 90°SPRING CLAMPFITTING, -6MORB/-6MJIC STRLS CASE DRAIN HOSERS CASE DRAIN HOSE

NOTES:

DESCRIPTION

1 032763 12 032771 13 602767 14 700484 65 603045 26 603046 17 603189 28 603047 19 603039 110 603053 111 603123 112 771311 213 603042 214 603000 115 601001 216 113623 117 034280 118 768523 319 068346 120 034272 121 781658 122 602768X 123 603190 224 601617 225 779132 226 603043 127 603044 1

3-6 117589EX_0416

Hydraulic Motor Service Parts

2

1


WOODRUFF KEYCASTLE NUTSEAL KIT (NOT SHOWN)

NOTES:

DESCRIPTION

1 064337 12 065516 13 748806 1

117589EX_0416 3-7

This page intentionally left blank.

3-8 117589EX_0416

Oil Cooler Mount

12

3

4

5

78

13

16

15

18

17

21

19

8 7

87

2

6

1723

24

2223

2526

14

20

910

7711

11

7

8

12

17

10 8

14

12

9

A

A

117589EX_0416 3-9

Oil Cooler Mount


AIR SCOOPLATCHCS .250-20 X 4.50 HX G5FAN 9"OIL COOLER COVERCOOLER MOUNT FIREWALLFW .343 X .687 X .051/.080HNT .312-18 HX G5HYPERDRIVE DECALCB .312-18 X .75 FUL ZNCOOLER MOUNT BRACKETCS .250-20 X 4.00 HX G5UPPER COOLER MOUNTWEATHERSTRIPFRONT SCREEN MOUNT BRACKETREAR SCREEN MOUNT BRACKETNT .250-20 HX ZY NLSCREEN1/4-20 THREAD RIVET NUTFW .281 X .625 X .066CS .250-20 X .75 HX G5NT .375-16 HX G5 ZNYFW .379 X .813 X .063CS .375-16 X 1.00 HX G5WIRE TIEWIRE TIE

NOTES:

DESCRIPTION

1 114038 12 791384 13 603229 44 603066 15 117407 16 114040 17 768523 168 034272 169 603290 2

10 016253 1611 117725 212 603228 213 114039 114 033035 15.5"15 114141 116 114142 117 068551 618 114165 119 808477 120 768515 121 055939 122 054502 423 767954 824 036244 425 000331 126 000430 2

WEATHERSTRIP LENGTH

7.75"A

3-10 117589EX_0416

Pump Drive

1

2

1

4

6

19

20

2122

14

25

23

1817

103

24

28

22

17

10 15

5

7

12

11

13

8

9

11

16

26

1514

27

3

117589EX_0416 3-11

Pump Drive


CS .500-13 X 5.00 HX G5FW .510 X 2.15 X .187 SPLKEY 1/4 SQ X 1.50 LGPULLEY 7.0 OD X 1.125 SHFTCLUTCH HARNESS PIGTAILCLUTCH KITFW .453 X 1.12 X .119 HRDCS .437-20 X 3.00 HX G5 P85NT .312-18 HX G5FW .343 X .687 X .051/.080HKEY 1/4 SQ X 1.12 LONGCS .312-18 X 1.00 HX G5CLUTCH ANCHORNT .375-16 HX G5 ZNYFW .379 X .813 X .063PULLEY 7.35 OP X 0.875 SHFTSS .312-18 X .75 SQ-HDCS .625-11 X 1.75 HX G5IDLER PIVOT BUSHINGTENSIONERIDLER PIVOT BUSHINGFW .531 X 1.063 X .175NT .500-13 HX G8 ZY NLGREASE FITTING STRAIGHTIDLER SPRINGEB, .375-16 X 3.00 FULL THD6" IDLER PULLEYBELT, 64.89" B B-SECTION

NOTES:

1. Torque to 45–48 ft-lbs. Replace (do not re-use) the fastener if it’s loosened or removed. Use only hand tools to install this fastener.

2. Torque to 12–15 ft-lbs.3. Torque to 71–75 ft-lbs. The tensioner should pivot freely.

DESCRIPTION

1 051151 12 344267 13 212076 14 602755 15 791251 16 601278K 17 602680 18 785048 19 034272 2

10 768523 411 210146 212 036236 213 113347 114 054502 215 767954 216 602754 217 083196 418 025007 119 602880 120 115536 121 602879 122 767962 123 781567 124 015495 125 601016 126 601486 127 603783 128 604208 1

3-12 117589EX_0416

Steering—S/N 13034312 & Higher

1

54

56

9

10

7

11

58

58

56

13

11

14

PUMPSUB-ASSEMBLY

2

3

1215

9

117589EX_0416 3-13

Steering—S/N 13034312 & Higher


STEERING COVER ASSEMBLYSUPER Z HD DECALHANDLE (WITH GRIP)GRIPCS .375-16 X 1.00 HX G5FW .379 X .813 X .063CS .375-16 X .75 HX G5SWITCHNT .375-16 HX G5 ZNYSTEERING DAMPERBALL STUDFW .343 X .687 X .051/.080HLW .325 INT-EXT TOOTHNT .312-18 HX FLK ZNYCNT .312-24 HX NL G5CAP LOCK

NOTES:

DESCRIPTION

1 N/A 12 605671 13 109839 2

781260 24 036244 45 767954 166 055822 67 601087 28 054502 69 603192 2

10 781922 211 768523 612 029876 213 016832 214 023655 215 601426 1

3-14 117589EX_0416

Steering Assembly—S/N 13034312 & Higher

3

3

5

64

1

7

7

5

4

2

64

4

8

117589EX_0416 3-15

Steering Assembly—S/N 13034312 & Higher


RS STEERING BOX ASSEMBLYLS STEERING BOX ASSEMBLYNT .312-24 HX NL G5FW .343 X .687 X .051/.080HNT .312-18 HX G5BALL STUDFW .344 X 1.00 X .12 HRD ZPUMP ROD ADJUSTER

NOTES:

DESCRIPTION

1 604295 12 604296 13 023655 24 768523 65 034272 26 781922 27 712927 28 781286 2

3-16 117589EX_0416

Steering Cover Assembly—S/N 13034312 & Higher

11

11

13

12

10

9

14

12

117589EX_0416 3-17



STEERING COVER (WITH DECAL)BUSHINGFW .750 X 1.50 X .156 ZNLOCK COLLAR .757 IDSTEER PIVOT TUBEGM .50 X 1.00 X .75 X .12

NOTES:

DESCRIPTION

9 550818 110 781153 211 603078 212 784439 213 113007 114 080358 1

3-18 117589EX_0416


15

16

15

16

17A

17

117589EX_0416 3-19



NT .500-13 HX JAM ZNYCSS .500-13 X 2.00 SHWEAR TAPE

NOTES:

DESCRIPTION

15 053199 216 797738 217 722199 11"

WEAR TAPE LENGTH

5.5" ± 0.3"A

3-20 117589EX_0416

Steering—S/N Prior to 13034312

12 3

45

6

8

7

10

21

19

13

14

54

6

5

5

11

1

1216

11

15

20

17

18

1718

19

LS PUMP ARM

13

14

20

21

15

16

9

RIGHT SIDE SHOWNLEFT SIDE SIMILAR

117589EX_0416 3-21



STEERING COVER (WITH DECALS)NT .500-13 HX JAM ZNYCSS 1/2-13 X 2.50 SH ZNYCCS .375-16 X .75 HX G5FW .379 X .813 X .063NT .375-16 HX G5 ZNYCS .375-16 X 1.00 HX G5STEERING BAR GRIPHANDLE (WITH GRIP)STEERING ARMWEAR TAPESUPER Z HD DECALCS .250-20 X 1.50 HX G5FW .281 X .625 X .066FW .343 X .687 X .051/.080HNT .312-24 HX NL G5CS M8-1.25 X 10 G10.9 SHBHFW .344 X 1.00 X .06 ZNYCPUMP ARMNT .250-20 HX ZY NLPUMP ROD ADJUSTER

NOTES:

DESCRIPTION

1 550818 12 053199 23 603055 24 055822 65 767954 286 054502 67 036244 48 781260 29 109839 2

10 113575 211 722199 11"12 604557 113 008581 214 768515 215 768523 1216 023655 417 603272 218 079210 219 602732 220 068551 221 781286 2

3-22 117589EX_0416


10

5

23

16

22

5

15

26

15

37

21

15

38

27

24

33

29

29

30

36

28

5

39

26

26

26

25

2334

32

31

26

27

22

35

RIGHT SIDE SHOWNLEFT SIDE SIMILAR

40

32

117589EX_0416 3-23



NT .375-16 HX G5 ZY NLCS .375-16 X 1.75 HX G5RS STEERING BOXFW .750 X 1.50 X .156 ZNBUSHINGBALL STUDSTEER PIVOT TUBELOCK COLLAR, 0.757 IDLS STEERING BOXNT .312-18 HX G5DAMPERSWITCHFW .344 X 1.00 X.12 HRD ZSTEERLEVER BUSHINGSS .500-13 X 2.00 SH ZYLW .325 INT-EXT TOOTHNT .312-18 HX FLK ZNYCGM .750 X .188 X 1.00 X .12CAP LOCK

NOTES:

DESCRIPTION

22 086660 623 705178 624 112898 125 603078 226 781153 627 781922 428 113007 129 784439 230 112899 131 034272 232 603192 233 601087 234 712927 235 348862 436 797738 237 029876 238 016832 239 047456 240 601426 1

3-24 117589EX_0416

LS Steering Box Assembly

1

3

43

2

6

6

9

8

5

4

3

2

7

3

7

117589EX_0416 3-25

LS Steering Box Assembly


STEERING ARMNT .375-16 HX G5 ZY NLFW .379 X .813 X .063CS .375-16 X 1.75 HX G5LS STEERING BOXBUSHINGSTEERLEVER BUSHINGGM .750 X .188 X 1.00 X .12SS .500-13 X 2.00 SH ZY

NOTES:

DESCRIPTION

1 113575 12 086660 33 767954 64 705178 35 112899 16 781153 27 348862 28 047456 19 797738 1

3-26 117589EX_0416

RS Steering Box Assembly

1

3

43

2

6

6

9

8

5

4

3

2

7

3

7

117589EX_0416 3-27

RS Steering Box Assembly


STEERING ARMNT .375-16 HX G5 ZY NLFW .379 X .813 X .063CS .375-16 X 1.75 HX G5RS STEERING BOXBUSHINGSTEERLEVER BUSHINGGM .750 X .188 X 1.00 X .12SS .500-13 X 2.00 SH ZY

NOTES:

DESCRIPTION

1 113575 12 086660 33 767954 64 705178 35 112898 16 781153 27 348862 28 047456 19 797738 1

3-28 117589EX_0416

Brake

1

2

3

53

4

4

8

6

2

10

7 8

2

119

12

4

13

2

1014

15

16

17

12

3

18

16

LEFT SIDE SHOWNRIGHT SIDE SIMILAR

117589EX_0416 3-29

Brake


NT .375-16 HX G5 ZY NLFW .379 X .813 X .063NT .312-24 HX NL G5FW .343 X .687 X .051/.080HBRAKE ROD ASSEMBLYLS BRAKE BELLCRANKRS BRAKE BELLCRANK (NOT SHOWN)BUSHINGNT .375-16 HX G5 ZNYBRAKE LINK TURNBUCKLECS .375-16 X 1.375 HX G5CS .375-16 X 4.50 HX G5NT .312-18 HX G5BRAKE ARMCB .312-18 X 1.00 FULL ZNCS .312-18 X .75 HX G8 FLKHUB ASSEMBLY (WITH STUDS)BRAKE ASSEMBLYWHEEL STUD LUG 1/2-20

NOTES:

1. Included with the wheel motor.2. Torque to 220–240 ft-lbs.3. Torque to 27 ft-lbs.

DESCRIPTION

1 086660 22 767954 123 023655 44 768523 125 781583 26 112907 1

112906 17 765339 48 054502 49 350397 2

10 005116 411 052514 212 034272 413 111309 214 037887 415 604461 816 602384 217 602383 218 601085 5

3-30 117589EX_0416

117589EX_0416 4-1

Section 4

Wheel & Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Front Wheel Breakdown, Flex Forks® . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Drive Wheel Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-2 117589EX_0416

Wheel & Tire

1

2345

6

5

7

8

9

1011

1114

111011

12 13

1

13

12

FRONT WHEELASSEMBLY

117589EX_0416 4-3

Wheel & Tire


CS .500-13 X 1.25 HX G5FW .515 X 1.65 X .125 HD ZYO-RING, SAE-14DUST CAPBEARINGSPACER 1.07 X 1.312 X 2.79DISC BEARINGTIRE/WHEEL ASSEMBLY 26 X 12 X 12 (USED WITH 60" DECK)TIRE/WHEEL ASSEMBLY 26 X 12-12 (USED WITH 66" & 72" DECKS)WHEEL NUTCS .500-13 X 4.50 HX G5FW .531 X 1.063 X .175SPACER 3.22 PLASTIC WHEELNT .500-13 HX G5 ZNYC

NOTES:

1. Torque to 65–75 ft-lbs.

DESCRIPTION

1 705954 22 798603 23 601375 24 603153 25 784223 46 387035 27 603164 28 604451 2

604455 29 061077 10

10 068239 211 767962 412 602345 213 602263 214 008193 2

4-4 117589EX_0416

Front Wheel Breakdown, Flex Forks®

3

3

4

1

2

3 2

3

4

5

5

10

7

8

6 9

6

LEFT SIDE

RIGHT SIDE

117589EX_0416 4-5

Front Wheel Breakdown, Flex Forks®


FLEX FORKS KIT (CONTAINS TWO FORKS)NT .750-10 HX ZY NLFW .760 X 1.625 X .08 ZNYCCS .750-10 X 9.50 HX ZYTIRE/WHEEL ASSEMBLY 13 X 6.50WHEEL BEARINGVALVE STEMBEARING SPACERTIRE, 13 X 6.50-6 SMOOTHTIRE, 13 X 6.50-6 RIBBEDWHEEL 6 X 4.50

NOTES:

1. The Flex Fork Kit contains two forks and is available for all models.

DESCRIPTION

1 603167 12 061101 23 025296 44 041475 25 604898 26 039677 27 019521 18 782771 19 604843 1

747741 110 747832 1

4-6 117589EX_0416

Drive Wheel Breakdown

1

2

3

604451 TIRE/WHEEL ASSEMBLY (60" DECKS)


TIRE 26 X 12-12WHEEL 12 X 8.50VALVE STEM

604455 TIRE/WHEEL ASSEMBLY (66" & 72" DECKS)

INDEX NO. PART NO. QTY

TIRE 26 X 12-12WHEEL 12 X 8.50VALVE STEM

NOTES:

DESCRIPTION

1 603775 12 796250 13 019521 1

DESCRIPTION

1 603775 12 784066 13 019521 1

117589EX_0416 5-1

Section 5

Engine, Kawasaki FX1000V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Engine Service Parts, Kawasaki FX1000V . . . . . . . . . . . . . . . . . . . . 5-4

Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Fuel Tank Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-2 117589EX_0416

Engine, Kawasaki FX1000V

2

1

4

13

5

915

16

21

21

23

109

11109

22

8

18

19

A

1

2

3

FUELVALVE

SEATSUPPORT

1

915

20 149

15

23

141

40AFUSE

BLK

512

8

11

9 10

17

6

7

PUR

BLK

RED/ 1BLK

15

24

117589EX_0416 5-3

Engine, Kawasaki FX1000V


KAWASAKI FX1000V ENGINEAIR FILTER INDICATORELBOW STREET FITTINGOIL DRAIN VALVECS M8 X 1.25 X 16 HX FL 10.9NEGATIVE BATTERY CABLEPOSITIVE BATTERY CABLENT .312-18 HX FLK ZNYCFW .343 X .687 X .051/.080HCS .312-18 X 1.00 HX G5LOOP CLAMPCABLE MOUNTMUFFLERCB .312-18 X .75 FUL ZNNT .312-18 HX G5HOSE CLAMPCB .312-18 X 1.25 ZNYCFW .379 X .813 X .063CS .375-16 X 1.25 HX G8 P85MUFFLER MOUNTHOSE CLAMPBRACE1/4" FUEL LINEWIRE TIE (NOT SHOWN)

NOTES:

1. Part of the wire harness.2. Supplied with the engine.3. Torque to 30 ft-lbs. Replace (do not reuse) the cap screw if it is removed

or loosened. Use only hand tools to install this fastener.4. Torque to 22 ft-lbs.

DESCRIPTION

1 N/A 12 788943 13 601216 14 796524 15 720516 36 605155 17 604029 18 016832 49 768523 10

10 036236 411 043570 212 115819 113 603708 114 016253 415 034272 616 045088 117 602827 118 767954 419 602580 420 115889 121 000323 222 114578 123 015818 14"24 000331 2

FUEL LINE LENGTH

14" VALVE TO ENGINEA

5-4 117589EX_0416

Engine Service Parts, Kawasaki FX1000V

4

1

23

5


MAIN AIR FILTERSAFETY AIR FILTERIN-LINE FUEL FILTEROIL FILTERVACUATOR VALVE

NOTES:

DESCRIPTION

1 785261 12 785279 13 068478 14 603138 15 763318 1

117589EX_0416 5-5


5-6 117589EX_0416

Fuel System

1

2

5

5

4

46

67

8

9

10

1112 7

8

10 99

12

11

7

8

1

3

B

1

1

1

A

4

4

117589EX_0416 5-7

Fuel System


FUEL CAP, 3.5"LS FENDER FUEL TANK ASSEMBLYRS FENDER FUEL TANK ASSEMBLYHOSE CLAMP1/4" FUEL LINEFUEL VALVE 3-WAYFW .406 X 1.00 X .12 HRD ZCS .375-16 X .75 HX G5CS .312-18 X 1.00 HX G5FW .343 X .687 X .051/.080HLOOP CLAMPNT .312-18 HX FLK ZNYC

NOTES:

1. Torque to 20 ft-lbs.

DESCRIPTION

1 779306 22 603979 13 603978 14 000323 45 015818 49"6 745059 17 712919 108 055822 109 036236 3

10 768523 311 043570 312 016832 3

FUEL LINE LENGTHS

13" LEFT TANK TO VALVE (FUEL)

36" RIGHT TANK TO VALVE (FUEL)

A

B

5-8 117589EX_0416

Fuel Tank Service Parts

2

1


SUCTION HOSE GROMMETSUCTION HOSE ASSY 33.5”

NOTES:

DESCRIPTION

1 785295 12 601530 1

117589EX_0416 6-1

Section 6

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-2 117589EX_0416

Battery

1

2

3

POSITIVEBATTERYCABLE

4

NEGATIVEBATTERYCABLE

117589EX_0416 6-3

Battery


CS .312-18 X 5.00 HX G5FW .343 X .687 X .051/.080HBATTERY STRAPCN .312-18 X .20 MAX THK

NOTES:

DESCRIPTION

1 050823 22 768523 23 113676 14 601069 2

6-4 117589EX_0416

Instrument Panel

1

1

4

5

2

63

7

11

12

10

3

14

12

13

15

16 17

8

18

16 15

1920

2021

22

24

BLKORGYEL/BLK

ORG

1

10A FUSE

9

25

20A FUSE

26 2

1

AUXILIARYCONNECTION

27

117589EX_0416 6-5

Instrument Panel


CHOKE CABLEKEY ASSEMBLYIGNITION SWITCHHOUR METERRED INDICATOR LIGHTPTO SWITCHCB 10-24 X .500 ZYNCINSTRUMENT PANEL (WITH DECAL)KNOBCS 10-24 X .75 HX FLK ZNRELAY CONTROL MODULENT #10-24 HX NL ZNTHROTTLE CABLEFW .219 X .500 X .048CS .250-20 X .50 HX G5FW .281 X .625 X .066INSTRUMENT PANEL DECALWIRE TIECS .312-18 X .75 HX G5FW .343 X .687 X .051/.080HLOOP CLAMPNT .312-18 HX G5WIRE TIE (NOT SHOWN)WIRE HARNESSCLUTCH CONNECTOR REPAIR KITSOLENOID JUMPERFUSE HOLDER

NOTES:

1. Part of the wire harness.2. Must order separately, as it is no longer part of the wire harness.

DESCRIPTION

1 603087 12 785808 13 045898 14 769166 15 712257 16 776476 17 601098 28 550856 19 603523 1

10 063198 211 604373 112 059832 413 603409 114 704932 215 055947 416 768515 417 603056 118 000430 119 034280 120 768523 221 043570 122 034272 123 000331 424 603810 125 114052 126 604430 127 601047 1

6-6 117589EX_0416

117589EX_0416 7-1

Section 7

60" Side Discharge Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

60" Side Discharge Deck Pulleys & Spindles . . . . . . . . . . . . . . . . . . 7-4

60" Side Discharge Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

66" Side Discharge Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

66" Side Discharge Deck Pulleys & Spindles . . . . . . . . . . . . . . . . . . 7-9

66" Side Discharge Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

72" Side Discharge Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

72" Side Discharge Deck Pulleys & Spindles . . . . . . . . . . . . . . . . . 7-16

72" Side Discharge Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Side Discharge Deck Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Side Discharge Deck Mounting Hardware. . . . . . . . . . . . . . . . . . . . 7-22

60" Rear Discharge Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

60" Rear Discharge Deck Pulleys & Spindles . . . . . . . . . . . . . . . . . 7-26

60" Rear Discharge Dust Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

60" Rear Discharge Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

Rear Discharge Deck Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

Rear Discharge Deck Mounting Hardware . . . . . . . . . . . . . . . . . . . 7-38

7-2 117589EX_0416

60" Side Discharge Service Deck

7

1

2

5

2

43

5

6

8

117589EX_0416 7-3



60" VX4 DECK (WITH DECALS & HARDWARE)CN .312-18 X .20 MAX THKBELT ROUTING DECALDISCHARGE CHUTE DECALDECK DANGERS DECALTHROWN OBJECTS DECAL60" SD DECK ID DECALVX4 TECHNOLOGY DECAL

NOTES:

DESCRIPTION

1 550739 12 601069 43 781419 14 601624 15 601837 26 601892 17 786277 18 603092 1

7-4 117589EX_0416

60" Side Discharge Deck Pulleys & Spindles

1

1

2

3

1920

17

28

3132

34

10

459

13

22

22

2423

26

25

26

27

2529

30

33

12

4

10

7 6

8

2

13

14

11

3

22

15

16

1718

21

1

117589EX_0416 7-5



CS .625-11 X 1.50 HX G5IDLER DUST SHIELD SMIDLER 6.0" RIVETEDFW .625 X 1.00 X .134DECK IDLER SLIDETENSION SPRINGCHAIN, 21 LINKUHMW IDLER SLIDEWN .312-18 ZNNT .625-11 HX G5 ZNYCIDLER DUST SHIELD LGIDLER 10.0" RIVETEDCS .500-13 X 1.25 HX G5CW .515 X 2.25 X .204 BLKPULLEY DRIVE 7.00 EFFFW 1.030 X 1.50 X .134GREASE FITTING STRAIGHTPUSHERFW .379 X .813 X .063NT .375-16 HX G5 ZY NLCS .312-18 X .625 BH ZN FW .531 X 1.063 X .175BLADE SPINDLE CWKEY 1/4 SQ X 1.00CW .631 X 2.25 X .187 PNTCS .625-11 X 3.00 FULL HX G5CB .375-16 X 1.25 G5 ZNCB .500-13 X 7.50 STD ZNPLASTIC WHEELSPACER 5.73 NT .500-13 HX G8 ZY NLPLASTIC WHEELSPACER 3.22 CB .500-13 X 5.00 ZNYC

NOTES:


DESCRIPTION

1 794446 12 602935 23 602821 24 028118 25 350884 16 781302 17 373191 18 602936 29 603023 4

10 016972 211 602963 112 602743 113 705954 1514 752386 315 602745 316 045765 317 015495 218 113340 119 767954 620 086660 621 603022 422 767962 1523 604255 324 212472 325 782474 226 783738 227 603113 628 602338 129 602341 130 602344 131 781567 332 602263 233 602345 234 603049 2

7-6 117589EX_0416

60" Side Discharge Deck1

12

1110

9

19

13

15

8

6

7

5

1

3

2

4

14

13 8

16

817

18

15

3

2

15813

117589EX_0416 7-7

60" Side Discharge Deck


RS PULLEY COVERLS PULLEY COVERKNOB 5/16-18 X 3/4"BELT, B-SEC 172" ELDISCHARGE CHUTE LGTORSION SPRINGCHUTE PINNT .375-16 HX G5 ZY NLBACKING PLATERUBBER BUMPERFW .344 X 1.00 X .06 ZNYCCS .312-18 X .875 HX G5FW .379 X .813 X .063RS INNER WALL ADJ.CB .375-16 X 1.00 G5 ZNYLS INNER WALL ADJ.BLADE, F20.50" EHN-F-CWBLADE, 20.50"-L-F-CWBLADE, 20.50"-MUL-F-CWBLADE, 20.50"-GAT-F-CWBLADE, F20.50"-H-F-CWCW .631 X 2.25 X .187 PNTCS .625-11 X 1.25 HX G5 Z

NOTES:

1. Torque to 118 ft-lbs.2. Torque to 10 ft-lbs.

DESCRIPTION

1 112933 12 112934 13 792002 44 604494 15 602891 16 602435 17 602432 18 086660 79 113563 1

10 602817 111 079210 212 064014 213 767954 614 113180 115 025395 616 113179 117 602771 3

793794 3794214 3794230 3794685 3

18 782474 319 781872 3

7-8 117589EX_0416


1

2

2

7

5

3

8

4

46

117589EX_0416 7-9



66" VX4 DECK (WITH DECALS & HARDWARE)CN .312-18 X .20 MAX THKDISCHARGE CHUTE DECALDECK DANGERS DECALBELT ROUTING DECAL66" DECK ID DECALVX4 TECHNOLOGY DECALTHROWN OBJECTS DECAL

NOTES:

DESCRIPTION

1 550750 12 601069 43 601624 14 601837 25 781419 16 799189 17 603092 18 601892 1

7-10 117589EX_0416


1

1

2

3

2019

18

28

3132

34

10

45 8

13

22

22

2423

2527

25

29

30

33

12

4

10

7 6

9

213

14

11

3

22

1516

18

17

21

26

1

117589EX_0416 7-11



CS .625-11 X 1.50 HX G5IDLER DUST SHIELD SMIDLER 6.0" RIVETEDFW .625 X 1.00 X .134DECK IDLER SLIDETENSION SPRINGCHAIN, 21 LINKWN .312-18 ZNUHMW IDLER SLIDENT .625-11 HX G5 ZNYCIDLER DUST SHIELD LGIDLER 10.0" RIVETEDCS .500-13 X 1.25 HX G5CW .515 X 2.25 X .204 BLKDRIVE PULLEY 7.85 EFFFW 1.030 X 1.50 X .134PUSHERGREASE FITTING STRAIGHTNT .375-16 HX G5 ZY NLFW .379 X .813 X .063CS .312-18 X .625 BH ZN FW .531 X 1.063 X .175BLADE SPINDLE CWKEY 1/4 SQ X 1.00CW .631 X 2.25 X .187 PNTCS .625-11 X 3.00 FULL HX G5CB .375-16 X 1.25 G5 ZNCB .500-13 X 7.50 STD ZNPLASTIC WHEELSPACER 5.73 NT .500-13 HX G8 ZY NLPLASTIC WHEELSPACER 3.22 CB .500-13 X 5.00 ZNYC

NOTES:


DESCRIPTION

1 794446 12 602935 23 602821 24 028118 25 350884 16 781302 17 373191 18 603023 49 602936 2

10 016972 211 602963 112 602743 113 705954 1514 752386 315 602859 316 045765 317 113340 118 015495 219 086660 620 767954 621 603022 422 767962 1523 604255 324 212472 325 782474 226 783738 227 603113 628 602338 129 602341 130 602344 131 781567 332 602263 233 602345 234 603049 2

7-12 117589EX_0416


1211

109

19

13

14

8

67

5

1

3

2

4

15

8

16

817

18

14

3

2

14

13

813

117589EX_0416 7-13



RS PULLEY COVERLS PULLEY COVERKNOB 5/16-18 X 3/4"BELT, B-SECDISCHARGE CHUTE LGTORSION SPRINGCHUTE PINNT .375-16 HX G5 ZY NLBACKING PLATERUBBER BUMPERFW .344 X 1.00 X .06 ZNYCCS .312-18 X .875 HX G5 ZNFW .379 X .813 X .063CB .375-16 X 1.00 G5 ZNYRS INNER WALL ADJ.LS INNER WALL ADJ.BLADE, F22.50" EHN-F-CWBLADE, F22.50" -H-F-CWBLADE, 22.50" -GAT-F-CWBLADE, 22.50" -MUL-F-CWCW .631 X 2.25 X .187 PNTCS .625-11 X 1.25 HX G5 Z

NOTES:


DESCRIPTION

1 113335 12 113336 13 792002 44 602854 15 602891 16 602435 17 602432 18 086660 79 113563 1

10 602817 111 079210 212 064014 213 767954 614 025395 615 113333 116 113334 117 602864 3

798496 3798512 3798504 3

18 782474 319 781872 3

7-14 117589EX_0416


1

2

6

5

7

8

34

4

2

117589EX_0416 7-15



72" VX4 DECK (WITH DECALS & HARDWARE)CN .312-18 X .20 MAX THKDISCHARGE CHUTE DECALDECK DANGERS DECALBELT ROUTING DECAL72" DECK ID DECALVX4 TECHNOLOGY DECALTHROWN OBJECTS DECAL

NOTES:

DESCRIPTION

1 550751 12 601069 43 601624 14 601837 25 781419 16 786285 17 603092 18 601892 1

7-16 117589EX_0416


1

1

2

3

1920

18

28

3132

34

10

458

13

22

22

242326

252627

2529

30

33

12

4

10

7 6

9

2

13

14

11

3

22

15

16

18

17

21

1

117589EX_0416 7-17



CS .625-11 X 1.50 HX G5IDLER DUST SHIELD SMIDLER 6.0" RIVETEDFW .625 X 1.00 X .134DECK IDLER SLIDETENSION SPRINGCHAIN, 21 LINKWN .312-18 ZNUHMW IDLER SLIDENT .625-11 HX G5 ZNYCIDLER DUST SHIELD LGIDLER 10.0" RIVETEDCS .500-13 X 1.25 HX G5CW .515 X 2.25 X .204 BLKDRIVE PULLEY 8.652 OPFW 1.030 X 1.50 X .134PUSHERGREASE FITTING STRAIGHTFW .379 X .813 X .063NT .375-16 HX G5 ZY NLCS .312-18 X .625 BH ZN FW .531 X 1.063 X .175BLADE SPINDLE CWKEY 1/4 SQ X 1.00CW .631 X 2.25 X .187 PNTCS .625-11 X 3.00 FULL HX G5CB .375-16 X 1.25 G5 ZNCB .500-13 X 7.50 STD ZNPLASTIC WHEELSPACER 5.73 NT .500-13 HX G8 ZY NLPLASTIC WHEELSPACER 3.22 CB .500-13 X 5.00 ZNYC

NOTES:


DESCRIPTION

1 794446 12 602935 23 602821 24 028118 25 350884 16 781302 17 373191 18 603023 49 602936 2

10 016972 211 602963 112 602743 113 705954 1514 752386 315 602746 316 045765 317 113340 118 015495 219 767954 620 086660 621 603022 422 767962 1523 604255 324 212472 325 782474 226 783738 227 603113 628 602338 129 602341 130 602344 131 781567 332 602263 233 602345 234 603049 2

7-18 117589EX_0416


1211

109

19

13

14

8

6

7

5

1

3

2

4

15

13

8

16

8

17

18

14

3

2

14

13

8

117589EX_0416 7-19



RS PULLEY COVERLS PULLEY COVERKNOB 5/16-18 X 3/4"BELT, B 195" ELDISCHARGE CHUTE LGTORSION SPRINGCHUTE PINNT .375-16 HX G5 ZY NLBACKING PLATERUBBER BUMPERFW .344 X 1.00 X .06 ZNYCCS .312-18 X .875 HX G5FW .379 X .813 X .063CB .375-16 X 1.00 G5 ZNYRS INNER WALL ADJ.LS INNER WALL ADJ.BLADE, F24.50" EHN-F-CWBLADE, F24.50"-H-F-CWBLADE, 24.50"-MUL-F-CWBLADE, 24.50"-GAT-F-CWCW .631 X 2.25 X .187 PNTCS .625-11 X 1.25 HX G5 Z

NOTES:


DESCRIPTION

1 112935 12 112936 13 792002 44 784207 15 602891 16 602435 17 602432 18 086660 79 113563 110 602817 111 079210 212 064014 213 767954 614 025395 615 112931 116 112932 117 602857 3

798702 3798710 3798728 3

18 782474 319 781872 3

7-20 117589EX_0416

Side Discharge Deck Lift

12

3

45

6

7

8

1312

11

6

7

7

14

6

5 49

10

8

157

8

7

8

7

117589EX_0416 7-21

Side Discharge Deck Lift


DECK HEIGHT PINSTOP HANDLEDECK LIFT INDICATORDECK LIFT SPRINGCS .437-14 X 1.75 HX G5DECK LIFT CHAINNT .437-14 HX FLG ZNE CLIP 1.00 X .625 X .05CS .625-11 X 1.25 HX G5 ZFW .625 X 1.50 X .105 ZNDECK LEVELER YOKENT .312-18 HX G5CS .312-18 X 1.50 HX G5CS .437-14 X 1.75 HX G5CE .750 X 2.25 X 1.75 HEAD

NOTES:

DESCRIPTION

1 600437 12 348318 13 602898 14 603184 25 055749 76 348391 47 704643 168 781294 69 781872 1

10 704783 111 348458 112 034272 113 756270 114 781831 115 781229 1

7-22 117589EX_0416

Side Discharge Deck Mounting Hardware

5

5

7

716

18

17

117589EX_0416 7-23

Side Discharge Deck Mounting Hardware


NT .750-10 HX ZY NLFW .760 X 1.625 X .08 ZNYCCS .750-10 X 3.00 HX G5

NOTES:

DESCRIPTION

16 061101 217 025296 418 051169 2

7-24 117589EX_0416

60" Rear Discharge Service Deck

4

1

2

2

3

4

6

5

7

56

8

2

117589EX_0416 7-25

60" Rear Discharge Service Deck


60" RD DECK (WITH DECALS & HARDWARE)CN .312-18 X .20 MAX THK2 BELT ROUTING DECALDECK DANGERS DECALTHROWN OBJECTS DECALRUBBER FLAP DECAL60" DECK ID DECAL5/16-18 THREAD HEX RIVET NUT

NOTES:

DESCRIPTION

1 550935 12 601069 43 603349 14 601837 25 601892 26 603391 27 786277 18 792887 1

7-26 117589EX_0416

60" Rear Discharge Deck Pulleys & Spindles

12

1

13

22

31

2

3

4

5

6

2

7

8

916

19

14

13

18

17

16

15

11

2

26

18

24

2021

22

2325

11

27

2

11

2

12

2

2829

21

2

5

6

2

29

28

30

26

10

117589EX_0416 7-27



CS .625-11 X 2.50 HX G5FW .625 X 1.00 X .134BELT GUIDEDECK IDLER SPACER 1/2" LGIDLER DUST SHIELD SMIDLER 6.0" RIVETEDRD DECK IDLER ARMCS .312-18 X 1.50 FLT SH ZYIDLER GUIDECS .625-11 X 1.50 HX G5DUST SHIELD WITH OFFSETPULLEY V-IDLER HBB 5.0"CHAIN, 21 LINKNT .500-13 HX G8 ZY NLFW .531 X 1.063 X .175PLASTIC BUSHING .750 X 1IDLER PIVOT BUSHINGTENSION SPRINGFW .500 X 1.25 X .075 ZNYCS .312-18 X 1.25 FLT SHNT .625-11 HX G5 ZNYCIDLER DUST SHIELD LGIDLER 8.0" RIVETEDIDLER SLIDE IDLER SLIDE UHMWCS .625-11 X 2.00 HX G5 Z6" HB IDLER PULLEYFW .343 X .687 X .051/.080HNT .312-18 HX G5 ZY NLCW .631 X 2.25 X .187 PNTCS .625-11 X 3.00 FULL HX G5

NOTES:

DESCRIPTION

1 025015 12 028118 123 113088 14 603256 15 602935 26 602821 27 114133 18 797910 29 601779 1

10 794446 111 603057 412 602672 213 373191 214 781567 115 767962 1316 770867 217 109549 118 781302 219 704759 120 784199 421 016972 222 602963 123 602838 124 114105 125 601619 226 016642 327 796714 228 768523 629 058776 630 782474 131 783738 1

7-28 117589EX_0416


34

42

38

41

321

37

36

35

35

40

39

15

133

117589EX_0416 7-29



CS .500-13 X 1.25 HX G5CS .500-13 X 1.75 HX G5CW .515 X 2.25 X .204 BLKPULLEY DRIVE 7.00 EFFPULLEYKEY 1/4 SQ X 1.00FW 1.030 X 1.50 X .134CS .500-13 X 1.00 HX G5 ZNSPACERBLADE SPINDLE CCWBLADE SPINDLE CW

NOTES:


DESCRIPTION

32 705954 133 017616 234 752386 335 602745 236 770388 137 212472 338 045765 239 016527 1240 114108 141 604256 142 604255 2

7-30 117589EX_0416

60" Rear Discharge Dust Shield

24

3

5

101

2

6

1

7

13

9

8

1

11

12

13

2

18

19

18

20

21

14515

16

17

117589EX_0416 7-31

60" Rear Discharge Dust Shield


NT .312-18 HX G5 ZYFW .343 X .687 X .051/.080HGREASE FITTING STRAIGHTCS .375-16 X 1.00 HX G5FW .379 X .813 X .063PUSHERFW .781 X 1.375 X .250 ZNYRS CHUTE BRACKETLS CHUTE BRACKETRS CLAMP ANGLE DUST SHIELDLS CLAMP ANGLERUBBER SIDE FLAPNT .375-16 HX G5 ZY NLDISCHARGE CHUTE ANGLERD REAR FLAPDECK STIFFENER ANGLECB .312-18 X 1.00 FULL ZNCB .312-18 X .75 FUL ZNREAR DECK STOPCB .375-16 X 1.50 STD G5

NOTES:

DESCRIPTION

1 058776 102 768523 103 015495 24 036244 65 767954 126 113340 17 778399 28 109482 19 109483 1

10 109487 111 114440 112 109486 113 601483 214 086660 615 106716 216 600254 217 351676 218 037887 619 016253 420 114522 121 710194 6

7-32 117589EX_0416

60" Rear Discharge Deck1

11

6

8

8

10

3

9

12

1211

1514

139

10

45

3

7

2

10

117589EX_0416 7-33

60" Rear Discharge Deck


RS PULLEY COVER (WITH DECALS)DECK DANGERS DECALKNOB 5/16-18 X 3/4"CENTER PULLEY COVERLS PULLEY COVERBELT, B 145.5" ELBELT, B 138" ELCB .500-13 X 5.00 ZNYCNT .500-13 HX G8 ZY NLFW .531 X 1.063 X .175SPACER 3.22 PLASTIC WHEELCB .500-13 X 7.50 STD ZNPLASTIC WHEELSPACER 5.73

NOTES:

DESCRIPTION

1 550939 12 601837 13 792002 54 550938 15 114210 16 777185 17 027284 18 603049 29 781567 3

10 767962 311 602345 212 602263 213 602338 114 602341 115 602344 1

7-34 117589EX_0416


20

17

18

21

22

242

1916

1716

21

23

1

1

117589EX_0416 7-35



CS .375-16 X .75 HX G5FW .379 X .813 X .063LS ADJUSTABLE BAFFLERS ADJUSTABLE BAFFLEBLADE, F20.50"-L-F-CCWBLADE, 20.50" GAT-F-CCWCW .631 X 2.25 X .187 PNT CS .625-11 X 1.25 HX G5 LH THREADBLADE, F20.50"-L-F-CWBLADE, 20.50" GAT-F-CWCS .625-11 X 1.25 HX G5 Z

NOTES:


DESCRIPTION

16 055822 617 767954 618 114205 119 114204 120 795633 1

601928 121 782474 322 604383 123 600901 2

794230 224 781872 2

7-36 117589EX_0416

Rear Discharge Deck Lift

1

2

3

7

16

7

10

4

56

8

10

5

9

10

7

89

911

12

8

10

9

9

1314

6

15

5

5

117589EX_0416 7-37

Rear Discharge Deck Lift


DECK HEIGHT PINSTOP HANDLEDECK LIFT INDICATORCE .750 X 2.25 X 1.75 HEADE CLIP 1.00 X .625 X .05DECK LIFT SPRINGCS .437-14 X 1.75 HX G5DECK LIFT CHAINNT .437-14 HX FLG ZNGREASE FITTING STRAIGHTCS .312-18 X 1.50 FLTHR HXNT .312-18 HX G5FW .625 X 1.50 X .105 ZNCS .625-11 X 1.25 HX G5 ZDECK LEVELER YOKECS .437-14 X 1.75 FULTH

NOTES:

DESCRIPTION

1 600437 12 348318 13 602898 14 781229 15 781294 66 603184 27 055749 78 348391 49 704643 16

10 015495 411 756270 112 034272 113 704783 114 781872 115 348458 116 781831 1

7-38 117589EX_0416

Rear Discharge Deck Mounting Hardware

18

19

17

97

9

117589EX_0416 7-39

Rear Discharge Deck Mounting Hardware


FW .760 X 1.625 X .08 ZNYCNT .750-10 HX ZY NLCS .750-10 X 3.50 HX G5

NOTES:

DESCRIPTION

17 025296 418 061101 219 789115 2

7-40 117589EX_0416

117589EX_0416 8-1

Section 8

Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Seat Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

ROPS—S/N 15010001 & Higher . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

ROPS—S/N Prior to 15010001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

8-2 117589EX_0416

Seat1

30

31

10

29

32

11

7

3 5

6

7 9

8

10

11

11

1213

1226

24

14

1517 18

19

1621

22

20

23

1024

2827

11

10

2

10

23

1

1

34

2

1018 24

COOLER MOUNTFIREWALL

33

36

10

11

36

10

435

117589EX_0416 8-3

Seat


SEATGM .50 X 1.00 X .75 X .12SEAT PAN (WITH DECALS)LEVEL FUEL FILL DECALARMREST WARNING DECALFW .344 X 1.00 X .12 HRD ZNT .312-18 HX ZY NLFIBER WASHERSEAT PAN STOP (PLATED)FW .379 X .813 X .063NT .375-16 HX G5 ZY NLCS .375-16 X 1.00 HX G5FW .406 X 1.00 X .12 HRD ZENGINE COMPARTMENT DECALHYDRAULIC PRESSURE DECALSEAT SUPPORT (WITH DECALS)HOT/SYN HYDRO OIL DECALVIBRATION MOUNTFUEL INDICATOR DECALLS STEERING DECALLS FRAME COVER (WITH DECALS)PUMP BELT WARNING DECALCN .312-18 X .20 MAX THKNT .375-16 HX G5 ZNYRS STEERING DECALRS FRAME COVER (WITH DECALS)FW .343 X .687 X .051/.080HCS .312-18 X 1.00 HX G5BATTERY WARNINGS DECALSEAT LATCHTORSION SPRINGSB .375 X .375 SH .312-18WIRE TIEFLOOR PANSEAT SWITCH PIGTAILCS .375-16 X 1.25 HX G5 ZN

NOTES:

1. Do not torque; the seat pan & seat pan stop must pivot freely.

DESCRIPTION

1 605696 12 080358 23 550815 14 605688 15 785188 16 712927 47 058776 58 724716 29 350421 210 767954 1411 086660 612 036244 613 712919 414 601967 115 601968 116 550816 117 601058 118 601650 319 791848 120 785139 121 550823 122 600899 123 601069 524 054502 325 785220 126 550824 127 768523 528 036236 529 601815 130 113157 131 783910 132 754358 133 000331 334 117323 135 604439 136 052860 3

8-4 117589EX_0416

Seat Service Parts

1

3

4

2

5


BACK CUSHIONRS ARMRESTLS ARMRESTSEAT BELTSEAT CUSHIONSEAT SWITCH (NOT SHOWN)SLIDE KIT (NOT SHOWN)ISOLATOR KIT (NOT SHOWN)

NOTES:

DESCRIPTION

1 604940 12 604938 13 604937 14 604941 15 604939 16 604973 17 119287 18 119288 1

117589EX_0416 8-5


8-6 117589EX_0416

ROPS—S/N 15010001 & Higher

1

45

5

6

3

3

2

1

117589EX_0416 8-7

ROPS—S/N 15010001 & Higher


ROPS KITPOLY STOP KITROPS HARDWARE KITCS .500-13 X 3.50 HX G5FW .531 X 1.063 X .175NT .500-13 UNT LK G8 ZN

NOTES:


DESCRIPTION

1 605741 12 605731 23 605638 14 061812 45 767962 86 023317 4

8-8 117589EX_0416

ROPS—S/N Prior to 15010001

2

4

4

32

5

5

47

1

1

8

3

5 6

117589EX_0416 8-9

ROPS—S/N Prior to 15010001


ROPS KIT (WITH DECALS, SEATBELT & HARDWARE)HAND KNOBLYNCH PIN W/ LANYARDCS .500-13 X 3.50 HX G5NT .500-13 UNT G8ROPS STOPFW .531 X 1.063 X .175ROPS DECAL

NOTES:


DESCRIPTION

1 603338 12 601470 23 601471 24 061812 65 023317 66 603099 17 767962 88 601635 2

8-10 117589EX_0416

Hustler® Super Z HyperDriveTable of ContentsGeneral InformationService LiteratureOptions Available From Your DealerUsing This ManualStandard Torques

Section 2FrameEngine Guard

Section 3Hydraulic SystemHydraulic ReservoirHydraulic Motor Service PartsOil Cooler MountPump DriveSteering—S/N 13034312 & HigherSteering Assembly—S/N 13034312 & HigherSteering Cover Assembly—S/N 13034312 & HigherSteering—S/N Prior to 13034312LS Steering Box AssemblyRS Steering Box AssemblyBrake

Section 4Wheel & TireFront Wheel Breakdown, Flex Forks®Drive Wheel Breakdown

Section 5Engine, Kawasaki FX1000VEngine Service Parts, Kawasaki FX1000VFuel SystemFuel Tank Service Parts

Section 6BatteryInstrument Panel

Section 760" Side Discharge Service Deck60" Side Discharge Deck Pulleys & Spindles60" Side Discharge Deck66" Side Discharge Service Deck66" Side Discharge Deck Pulleys & Spindles66" Side Discharge Deck72" Side Discharge Service Deck72" Side Discharge Deck Pulleys & Spindles72" Side Discharge DeckSide Discharge Deck LiftSide Discharge Deck Mounting Hardware60" Rear Discharge Service Deck60" Rear Discharge Deck Pulleys & Spindles60" Rear Discharge Dust Shield60" Rear Discharge DeckRear Discharge Deck LiftRear Discharge Deck Mounting Hardware

Section 8SeatSeat Service PartsROPS—S/N 15010001 & HigherROPS—S/N Prior to 15010001

Hustler Super Z HyperDrive Parts Manual...This manual covers Hustler ® Super Z HyperDrive models...

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Transcript of Hustler Super Z HyperDrive Parts Manual...This manual covers Hustler ® Super Z HyperDrive models...