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TM1680 - 220A Walk-Behind Greensmower

TECHNICAL

MANUAL

Litho in U.S.A

John Deere

Lawn & Grounds Care Division

220A Walk-Behind

Greensmower

Serial No. (030001— )

TM1680 (01/Dec/96)

M83741

INTRODUCTION

11/14/96 1 - 1

This technical manual is written for an experienced

technician and contains sections that are specifically for

this product. It is a part of a total product support

program.

The manual is organized so that all the information on a

particular system is kept together. The order of grouping

is as follows:

• Table of Contents

• Specifications

• Component Location

• System Schematic

• Theory of Operation

• Troubleshooting Chart

• Diagnostics

• Tests & Adjustments

• Repair

Note: Depending on the particular section or system

being covered, not all of the above groups may

be used.

Each section will be identified with a symbol rather than a

number. The groups and pages within a section will be

consecutively numbered.

All information, illustrations and specifications in this

manual are based on the latest information available at

the time of publication. The right is reserved to make

changes at any time without notice.

We appreciate your input on this manual. To help, there

are postage paid post cards included at the back. If you

find any errors or want to comment on the layout of the

manual please fill out one of the cards and mail it back to

us.

JOHN DEERE LAWN AND

GROUNDS CARE DIVISION

Horicon, Wisconsin

General Information

Specifications and

Engine (Honda GX120)

Electrical

Handlebars and Controls

Brakes

Safety

Miscellaneous

Power Train

Cutting Unit

SAFETY

1 - 2 12/6/96

RECOGNIZE SAFETY INFORMATION

This is the safety-alert symbol. When you see this

symbol on your machine or in this manual, be alert to

the potential for personal injury.

Follow recommended precautions and safe servicing

practices.

Understand Signal Words

A signal word—DANGER, WARNING, or CAUTION—is

used with the safety-alert symbol. DANGER identifies

the most serious hazards.

DANGER or WARNING safety signs are located near

specific hazards. General precautions are listed on

CAUTION safety signs. CAUTION also calls attention

to safety messages in this manual.

REPLACE SAFETY SIGNS

Replace missing or damaged safety signs. See the

machine operator’s manual for correct safety sign

placement.

HANDLE FLUIDS SAFELY-AVOID

FIRES

Be Prepared For Emergencies

When you work around fuel, do not smoke or work near

heaters or other fire hazards.

Store flammable fluids away from fire hazards. Do not

incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and

debris.

Do not store oily rags; they can ignite and burn

spontaneously.

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance

service, hospital, and fire department near your

telephone.

SAFETY

12/6/96 1 - 3

USE SAFE SERVICE PROCEDURES

Wear Protective Clothing

Wear close fitting clothing and safety equipment

appropriate to the job.

Prolonged exposure to loud noise can cause

impairment or loss of hearing. Wear a suitable hearing

protective device such as earmuffs or earplugs to

protect against objectionable or uncomfortable loud

noises.

Operating equipment safely requires the full attention

of the operator. Do not wear radio or music

headphones while operating machine.

Service Machines Safely

Tie long hair behind your head. Do not wear a necktie,

scarf, loose clothing, or necklace when you work near

machine tools or moving parts. If these items were to

get caught, severe injury could result.

Remove rings and other jewelry to prevent electrical

shorts and entanglement in moving parts.

Use Proper Tools

Use tools appropriate to the work. Makeshift tools and

procedures can create safety hazards. Use power tools

only to loosen threaded parts and fasteners. For

loosening and tightening hardware, use the correct size

tools. DO NOT use U.S. measurement tools on metric

fasteners. Avoid bodily injury caused by slipping

wrenches. Use only service parts meeting John Deere

specifications.

Park Machine Safely

Before working on the machine:

1. Lower all equipment to the ground.

2. Stop the engine and remove the key.

3. Disconnect the battery ground strap.

4. Hang a “DO NOT OPERATE” tag in operator

station.

Support Machine Properly And Use

Proper Lifting Equipment

If you must work on a lifted machine or attachment,

securely support the machine or attachment.

Do not support the machine on cinder blocks, hollow

tiles, or props that may crumble under continuous load.

Do not work under a machine that is supported solely

by a jack. Follow recommended procedures in this

manual.

Lifting heavy components incorrectly can cause severe

injury or machine damage. Follow recommended

procedure for removal and installation of components

in the manual.

Work In Clean Area

Before starting a job:

1. Clean work area and machine.

2. Make sure you have all necessary tools to do your

job.

3. Have the right parts on hand.

4. Read all instructions thoroughly; do not attempt

shortcuts.

SAFETY

1 - 4 12/6/96

Illuminate Work Area Safely

Illuminate your work area adequately but safely. Use a

portable safety light for working inside or under the

machine. Make sure the bulb is enclosed by a wire

cage. The hot filament of an accidentally broken bulb

can ignite spilled fuel or oil.

Work In Ventilated Area

Engine exhaust fumes can cause sickness or death. If

it is necessary to run an engine in an enclosed area,

remove the exhaust fumes from the area with an

exhaust pipe extension.

If you do not have an exhaust pipe extension, open the

doors and get outside air into the area.

WARNING: California Proposition

65 Warning

Gasoline engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects, or other reproductive harm.

Remove Paint Before Welding Or

Heating

Avoid potentially toxic fumes and dust. Hazardous

fumes can be generated when paint is heated by

welding, soldering, or using a torch. Do all work outside

or in a well ventilated area. Dispose of paint and

solvent properly. Remove paint before welding or

heating: If you sand or grind paint, avoid breathing the

dust. Wear an approved respirator. If you use solvent or

paint stripper, remove stripper with soap and water

before welding. Remove solvent or paint stripper

containers and other flammable material from area.

Allow fumes to disperse at least 15 minutes before

welding or heating.

Avoid Harmful Asbestos Dust

Avoid breathing dust that may be generated when

handling components containing asbestos fibers.

Inhaled asbestos fibers may cause lung cancer.

Components in products that may contain asbestos

fibers are brake pads, brake band and lining

assemblies, clutch plates, and some gaskets. The

asbestos used in these components is usually found in

a resin or sealed in some way. Normal handling is not

hazardous as long as airborne dust containing

asbestos is not generated.

Avoid creating dust. Never use compressed air for

cleaning. Avoid brushing or grinding material

containing asbestos. When servicing, wear an

approved respirator. A special vacuum cleaner is

recommended to clean asbestos. If not available, apply

a mist of oil or water on the material containing

asbestos. Keep bystanders away from the area.

SERVICE TIRES SAFELY

Explosive separation of a tire and rim parts can cause

serious injury or death.

Do not attempt to mount a tire unless you have the

proper equipment and experience to perform the job.

Always maintain the correct tire pressure. Do not inflate

the tires above the recommended pressure. Never weld

or heat a wheel and tire assembly. The heat can cause

an increase in air pressure resulting in a tire explosion.

Welding can structurally weaken or deform the wheel.

When inflating tires, use a clip-on chuck and extension

hose long enough to allow you to stand to one side and

NOT in front of or over the tire assembly. Use a safety

cage if available.

Check wheels for low pressure, cuts, bubbles,

damaged rims or missing lug bolts and nuts.

SAFETY

12/6/96 1 - 5

AVOID INJURY FROM ROTATING

BLADES, AUGERS AND PTO

SHAFTS

Keep hands and feet away while machine is running.

Shut off power to service, lubricate or remove mower

blades, augers or PTO shafts.

HANDLE CHEMICAL PRODUCTS

SAFELY

Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used

with John Deere equipment include such items as

lubricants, coolants, paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides specific

details on chemical products: physical and health

hazards, safety procedures, and emergency response

techniques. Check the MSDS before you start any job

using a hazardous chemical. That way you will know

exactly what the risks are and how to do the job safely.

Then follow procedures and recommended equipment.

Dispose of Waste Properly

Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste

used with John Deere equipment include such items as

oil, fuel, coolant, brake fluid, filters, and batteries. Use

leakproof containers when draining fluids. Do not use

food or beverage containers that may mislead

someone into drinking from them. Do not pour waste

onto the ground, down a drain, or into any water

source. Inquire on the proper way to recycle or dispose

of waste from your local environmental or recycling

center, or from your John Deere dealer.

LIVE WITH SAFETY

Before returning machine to customer, make sure

machine is functioning properly, especially the safety

systems. Install all guards and shields.

SAFETY

1 - 6 12/6/96

This page intentionally left blank.

SPECIFICATIONS AND GENERAL INFORMATION CONTENTS

Page

CONTENTS

12/9/96 2 - 1

SPECIFICATIONS AND GENERAL INFORMATION

GENERAL SPECIFICATIONS

VEHICLE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

REPAIR INFORMATION

METRIC FASTENER TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

INCH FASTENER TORQUE VALUES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

GASOLINE

4-CYCLE ENGINES—NORTH AMERICA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

GASOLINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

4-CYCLE ENGINES—EUROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

GASOLINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

OILS AND LUBRICANTS

4-CYCLE GASOLINE ENGINE OIL—NORTH AMERICA. . . . . . . . . . . . . . . . . . . . 2-8

4-CYCLE GASOLINE ENGINE OIL—EUROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

SPEED REDUCER OIL—NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

SPEED REDUCER OIL—EUROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

REEL SUPPORT GREASE—NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

REEL SUPPORT GREASE—EUROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

ANTI-CORROSION GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

GREASE—NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

GREASE—EUROPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

ALTERNATIVE LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

SYNTHETIC LUBRICANTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

LUBRICANT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

MIXING OF LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

SERIAL NUMBER LOCATIONS

SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

MACHINE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

ENGINE SERIAL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

CARBURETOR IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

OPERATIONAL CHECKOUT PROCEDURES

ENGINE OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

SPEED REDUCER OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

THROTTLE LEVER CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

OPERATOR PRESENCE BAIL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

PARK BRAKE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

TRAVEL CLUTCH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

REEL CLUTCH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2 - 2 12/9/96

GENERAL SPECIFICATIONS SPECIFICATIONS AND INFORMATION

GENERAL SPECIFICATIONS

VEHICLE SPECIFICATIONS

ENGINE

Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Honda

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline, 25° Incline

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GX120 K1LJD2

Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Natural

Horsepower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 kW (4.0 hp)

Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 cm3 (7.2 cu in.)

Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle

Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 mm (2.4 in.)

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 mm (1.7 in.)

Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5:1

Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 +220/-150 rpm

Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3450 ±150 rpm

Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25° BTDC

Valving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves

Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Splash

Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forced Air

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual-Element (Silent) Type

Carburetor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Externally Vented

Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .In-line

Engine Oil Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.56 L (0.59 qt)

Type of Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recoil

Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5 kg. (34.2 lb)

FUEL SYSTEM

Fuel Tank Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On Engine

Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 L (0.66 gal)

Fuel (minimum octane) . . . . . . . . . . . . . . . . . . . . . . . . . . Unleaded Gasoline, 87 Octane

Fuel Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gravity

Carburetor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Float-type Side Draft

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Screen

ELECTRICAL

Ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transistorized Magneto

DRIVE TRAIN/TRAVELING DEVICE

Traction Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Smooth Surface, Dual Aluminium

Traveling Speed

Forward Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 km/h (5.5 mph)

Mow Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 km/h (5.5 mph)

Front Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Machined Steel, Solid or Grooved

BRAKES

Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Band Type, lever Activated

12/9/96 2 - 3

SPECIFICATIONS AND INFORMATION GENERAL SPECIFICATIONS

CUTTING UNIT

Cutting Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559 mm (22 in.)

Cutting Height (minimum)

Standard—3.0 mm Bedknife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 mm (1/8 in.)

Optional—2.5 mm Bedknife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 mm (7/64 in.)

Cutting Height (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2 mm (7/8 in.)

Frequency of Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm (0.195 in.)

Reel

Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 mm (5 in.)

Number of Blades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heat Treated Special Alloy Steel

Grass Catcher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotational Moulded Poly Propylene

WEIGHTS AND DIMENSIONS

Weight (less GTC and Wheels, with Grass Catcher) . . . . . . . . . . . . . . . 99.5 kg (219 lb)

Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 946 mm (37.25 in.)

Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 940 mm (37.00 in.)

Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.119 m (46.8 in.)

WHEELS AND TIRES

Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1-6 (2 pr) Tubeless

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125—140 kPa (18—20 psi)

(Specifications and design subject to change without notice.)

2 - 4 12/9/96

METRIC FASTENER TORQUE VALUES SPECIFICATIONS AND INFORMATION

METRIC FASTENER TORQUE VALUES

Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

LubricatedaDryaLubricatedaDryaLubricatedaDryaLubricatedaDrya

SIZE N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft

M6 4.8 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5

M8 12 8.5 15 11 22 16 28 20 32 24 40 30 37 28 47 35

M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70

M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120

M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 109

M16 100 73 125 92 190 140 240 175 275 200 350 225 320 240 400 300

M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410

M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580

M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800

M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000

M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500

M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000

M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750

M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500

TS1163

4.8

8.8 9.8

10.9

12.9

510

Property

Class

and

Head

Markings

Property

Class

and

Nut

Markings

4.8

8.8

9.8

10.9

10.9 12.9

12.9

10 10

DO NOT use these hand torque values if a different

torque value or tightening procedure is given for a

specific application. Torque values listed are for general

use only and include a ±10% variance factor. Check

tightness of fasteners periodically. DO NOT use air

powered wrenches.

Shear bolts are designed to fail under predetermined

loads. Always replace shear bolts with identical grade.

Fasteners should be replaced with the same class.

Make sure fastener threads are clean and that you

properly start thread engagement. This will prevent

them from failing when tightening.

When bolt and nut combination fasteners are used,

torque values should be applied to the NUT instead of

the bolt head.

Tighten toothed or serrated-type lock nuts to the full

torque value.

“Lubricated” means coated with a lubricant such

as engine oil, or fasteners with phosphate and oil

coatings. “Dry” means plain or zinc plated (yellow

dichromate - Specification JDS117) without any

lubrication

Reference: JDS—G200.

12/9/96 2 - 5

SPECIFICATIONS AND INFORMATION INCH FASTENER TORQUE VALUES

INCH FASTENER TORQUE VALUES

Grade 1 Grade 2bGrade 5, 5.1 or 5.2 Grade 8 or 8.2

LubricatedaDryaLubricatedaDryaLubricatedaDryaLubricatedaDrya

SIZE N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft

1/4 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 712913.5 10 17 12.5

5/16 7.7 5.5 10 7 12 9151120 15 25 18 28 21 35 26

3/8 14 10 17 13 22 16 27 20 35 26 44 33 50 36 63 46

7/16 22 16 28 20 35 26 44 32 55 41 70 52 80 58 100 75

1/2 33 25 42 31 53 39 67 50 85 63 110 80 120 90 150 115

9/16 48 36 60 45 75 56 95 70 125 90 155 115 175 130 225 160

5/8 67 50 85 62 105 78 135 100 170 125 215 160 215 160 300 225

3/4 120 87 150 110 190 140 240 175 300 225 375 280 425 310 550 400

7/8 190 140 240 175 190 140 240 175 490 360 625 450 700 500 875 650

1290 210 360 270 290 210 360 270 725 540 925 675 1050 750 1300 975

1-1/8 470 300 510 375 470 300 510 375 900 675 1150 850 1450 1075 1850 1350

1-1/4 570 425 725 530 570 425 725 530 1300 950 1650 1200 2050 1500 2600 1950

1-3/8 750 550 950 700 750 550 950 700 1700 1250 2150 1550 2700 2000 3400 2550

1-1/2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350

TS1162

1 or 2b

55.1 5.2

88.2

No Marks

SAE

Grade

and Nut

Markings

SAE

Grade

and Head

Markings

DO NOT use these hand torque values if a different

torque value or tightening procedure is given for a

specific application. Torque values listed are for general

use only and include a ±10% variance factor. Check

tightness of fasteners periodically. DO NOT use air

powered wrenches.

Shear bolts are designed to fail under predetermined

loads. Always replace shear bolts with identical grade.

Fasteners should be replaced with the same grade.

Make sure fastener threads are clean and that you

properly start thread engagement. This will prevent

them from failing when tightening.

When bolt and nut combination fasteners are used,

torque values should be applied to the NUT instead of

the bolt head.

Tighten toothed or serrated-type lock nuts to the full

torque value.

“Lubricated” means coated with a lubricant such

as engine oil, or fasteners with phosphate and oil

coatings. “Dry” means plain or zinc plated (yellow

dichromate - Specification JDS117) without any

lubrication

“Grade 2” applies for hex cap screws (not hex

bolts) up to 152 mm (6-in.) long. “Grade 1”

applies for hex cap screws over 152 mm (6-in.)

long, and for all other types of bolts and screws

of any length.

Reference: JDS—G200.

2 - 6 12/9/96

GASOLINE SPECIFICATIONS AND INFORMATION

GASOLINE

4–CYCLE ENGINES—NORTH AMERICA

cCAUTION

Gasoline is HIGHLY FLAMMABLE, handle it with care.

DO NOT refuel machine while:

• indoors, always fill gas tank outdoors;

• machine is near an open flame or sparks;

• engine is running, STOP engine;

• engine is hot, allow it to cool sufficiently first;

• smoking.

Help prevent fires:

• fill gas tank to bottom of filler neck only;

• be sure fill cap is tight after fueling;

• clean up any gas spills IMMEDIATELY;

• keep machine clean and in good repair–free of excess grease, oil, debris, and faulty or damaged

parts;

• any storage of machines with gas left in tank should be in an area that is well ventilated to prevent

possible igniting of fumes by an open flame or spark, this includes any appliance with a pilot light.

To prevent fire or explosion caused by STATIC ELECTRIC DISCHARGE during fueling:

• ONLY use a clean, approved POLYETHYLENE PLASTIC fuel container and funnel WITHOUT any metal

screen or filter.

To avoid engine damage:

• DO NOT mix oil with gasoline;

• ONLY use clean, fresh unleaded gasoline with

an octane rating (anti-knock index) of 87 or

higher;

• fill gas tank at the end of each day's operation to

help prevent condensation from forming inside a

partially filled tank;

• keep up with specified service intervals.

Use of alternative oxygenated, gasohol blended,

unleaded gasoline is acceptable as long as:

• the ethyl or grain alcohol blends DO NOT exceed

10% by volume or

• methyl tertiary butyl ether (MTBE) blends DO NOT

exceed 15% by volume.

IMPORTANT: DO NOT use METHANOL gasolines

because METHANOL is harmful to the

environment and to your health.

GASOLINE STORAGE

IMPORTANT: Keep all dirt, scale, water or other

foreign material out of gasoline.

Keep gasoline stored in a safe, protected area. Storage

of gasoline in a clean, properly marked (“UNLEADED

GASOLINE”) POLYETHYLENE PLASTIC container

WITHOUT any metal screen or filter is recommended.

DO NOT use de-icers to attempt to remove water from

gasoline or depend on fuel filters to remove water from

gasoline. Use a water separator installed in the storage

tank outlet. BE SURE to properly discard unstable or

contaminated gasoline. When storing unit or gasoline,

it is recommended that you add John Deere Gasoline

Conditioner and Stabilizer (TY15977) or an

equivalent to the gasoline. BE SURE to follow

directions on container and to properly discard empty

container.

cWARNING

California Proposition 65 Warning: Gasoline

engine exhaust from this product contains

chemicals known to the State of California to

cause cancer, birth defects, or other

reproductive harm.

NO STATIC ELECTRIC

DISCHARGE

NO SMOKING

NO HOT ENGINE

STOP ENGINE

NO OPEN FLAME

OR SPARK

12/9/96 2 - 7

SPECIFICATIONS AND INFORMATION GASOLINE

4–CYCLE ENGINES—EUROPE

cCAUTION

Gasoline is HIGHLY FLAMMABLE, handle it with care.

DO NOT refuel machine while:

• indoors, always fill gas tank outdoors;

• machine is near an open flame or sparks;

• engine is running, STOP engine;

• engine is hot, allow it to cool sufficiently first;

• smoking.

Help prevent fires:

• fill gas tank to bottom of filler neck only;

• be sure fill cap is tight after fueling;

• clean up any gas spills IMMEDIATELY;

• keep machine clean and in good repair–free of excess grease, oil, debris, and faulty or damaged

parts;

• any storage of machines with gas left in tank should be in an area that is well ventilated to prevent

possible igniting of fumes by an open flame or spark, this includes any appliance with a pilot light.

To prevent fire or explosion caused by STATIC ELECTRIC DISCHARGE during fueling:

• ONLY use a clean, approved POLYETHYLENE PLASTIC fuel container and funnel WITHOUT any metal

screen or filter.

To avoid engine damage:

• DO NOT mix oil with gasoline;

• ONLY use clean, fresh unleaded gasoline with

an octane rating (anti-knock index) of 87 or

higher;

• fill gas tank at the end of each day's operation to

help prevent condensation from forming inside a

partially filled tank;

• keep up with specified service intervals.

Use of alternative oxygenated, gasohol blended,

unleaded gasoline is acceptable as long as:

• the ethyl or grain alcohol blends DO NOT exceed

10% by volume or

• methyl tertiary butyl ether (MTBE) blends DO NOT

exceed 15% by volume.

IMPORTANT: DO NOT use METHANOL gasolines

because METHANOL is harmful to the

environment and to your health.

GASOLINE STORAGE

IMPORTANT: Keep all dirt, scale, water or other

foreign material out of gasoline.

Keep gasoline stored in a safe, protected area. Storage

of gasoline in a clean, properly marked (“UNLEADED

GASOLINE”) POLYETHYLENE PLASTIC container

WITHOUT any metal screen or filter is recommended.

DO NOT use de-icers to attempt to remove water from

gasoline or depend on fuel filters to remove water from

gasoline. Use a water separator installed in the storage

tank outlet. BE SURE to properly discard unstable or

contaminated gasoline. When storing unit or gasoline,

it is recommended that you add John Deere Gasoline

Conditioner and Stabilizer (TY15977) or an

equivalent to the gasoline. BE SURE to follow

directions on container and to properly discard empty

container.

NO STATIC ELECTRIC

DISCHARGE

NO SMOKING

NO HOT ENGINE

STOP ENGINE

NO OPEN FLAME

OR SPARK

2 - 8 12/9/96

OILS AND LUBRICANTS SPECIFICATIONS AND INFORMATION

OILS AND LUBRICANTS

4–CYCLE GASOLINE ENGINE OIL—

NORTH AMERICA

Use the appropriate oil viscosity based on the expected

air temperature range during the period between

recommended oil changes. Operating outside of these

recommended oil air temperature ranges may cause

premature engine failure.

NOTE: For a new or rebuilt engine, the oil should be

changed after first 20 hours of use.

The following John Deere oils are PREFERRED:

• PLUS–4®—SAE 10W-30;

• TORQ–GARD SUPREME®—SAE 5W-30.

The following John Deere oils are also recommended,

based on their specified temperature range:

• TURF–GARD®—SAE 10W-30;

• PLUS–4®—SAE 10W-40;

• TORQ–GARD SUPREME®—SAE 30.

Other oils may be used if above John Deere oils are not

available, provided they meet one of the following

specifications:

• SAE 5W-30—API Service Classification SG or

higher;

• SAE 10W-30—API Service Classification SG or

higher;

• SAE 30—API Service Classification SC or higher.

John Deere Distributors: You may want to cross-

reference the following publications to recommend the

proper oil for your customers:

• Module DX,ENOIL2 in JDS–G135;

• Section 530, Lubricants & Hydraulics, of the John

Deere Merchandise Sales Guide;

• Lubrication Sales Manual PI7032.

AIR TEMPERATURE M58275

SAE 5W-30

PREFERRED

SAE 10W-30

SAE 30

SAE 10W-40

12/9/96 2 - 9

SPECIFICATIONS AND INFORMATION OILS AND LUBRICANTS

4–CYCLE GASOLINE ENGINE OIL—

EUROPE

Use the appropriate oil viscosity based on the expected

air temperature range during the period between

recommended oil changes. Operating outside of these

recommended oil air temperature ranges may cause

premature engine failure.

NOTE: For a new or rebuilt engine, the oil should be

changed after first 20 hours of use.

The following John Deere oils are PREFERRED:

• UNI–GARD™—SAE 10W-30;

• TORQ–GARD SUPREME®—SAE 5W-30;

• UNI–GARD™—SAE 5W-30.

The following John Deere oils are also recommended,

based on their specified temperature range:

• TORQ–GARD SUPREME®—SAE 10W-30;

• UNI–GARD™—SAE 10W-40;

• TORQ–GARD SUPREME®—SAE 30;

• UNI–GARD™—SAE 30.

Other oils may be used if above John Deere oils are not

available, provided they meet one of the following

specifications:

• CCMC Specification G4 or higher.

John Deere Distributors: You may want to cross-

reference the following publications to recommend the

proper oil for your customers:

• Module DX,ENOIL2 in JDS–G135;

• Section 530, Lubricants & Hydraulics, of the John

Deere Merchandise Sales Guide.

AIR TEMPERATURE M58275

SAE 5W-30

PREFERRED

SAE 10W-30

SAE 30

SAE 10W-40

2 - 10 12/9/96

OILS AND LUBRICANTS SPECIFICATIONS AND INFORMATION

SPEED REDUCER OIL—NORTH

AMERICA

Use the appropriate oil viscosity based on the air

temperature ranges. Operating outside of these

recommended oil air temperature ranges may cause

premature gear case failure.

IMPORTANT: ONLY use a quality oil in this gear

case. DO NOT mix any other oils in this gear

case. DO NOT use BIO–HY–GARD® in this gear

case.

The following John Deere gear case oil is

PREFERRED:

• GL-5 GEAR LUBRICANT®—SAE 80W-90.

The following John Deere gear case oil is also

recommended if above preferred oil is not available:

• GL-5 GEAR LUBRICANT®—SAE 85W-140.

Other gear case oils may be used if above

recommended John Deere gear case oils are not

available, provided they meet the following

specification:

• API Service Classification GL–5.

John Deere Distributors: You may want to cross-

reference the following publications to recommend the

proper oil for your customers:

• Module DX,GEOIL in JDS–G135;

• Section 530, Lubricants & Hydraulics, of the John

Deere Merchandise Sales Guide;

• Lubrication Sales Manual PI7032.

M58275

SAE 80W-90

AIR TEMPERATURE

SAE 85W-140

PREFERRED

SPEED REDUCER OIL—EUROPE

Use the appropriate oil viscosity based on the air

temperature ranges. Operating outside of these

recommended oil air temperature ranges may cause

premature gear case failure.

IMPORTANT: ONLY use a quality oil in this gear

case. DO NOT mix any other oils in this gear

case. DO NOT use BIO–HY–GARD® in this gear

case.

The following John Deere gear case oil is

PREFERRED:

• EXTREME–GARD™—SAE 80W-90.

The following John Deere gear case oil is also

recommended if above preferred oil is not available:

• EXTREME–GARD™—SAE 85W-140.

Other gear case oils may be used if above

recommended John Deere gear case oils are not

available, provided they meet the following

specification:

• API Service Classification GL–5.

John Deere Distributors: You may want to cross-

reference the following publications to recommend the

proper oil for your customers:

• Module DX,GEOIL in JDS–G135;

• Section 530, Lubricants & Hydraulics, of the John

Deere Merchandise Sales Guide.

M58275

SAE 80W-90

AIR TEMPERATURE

SAE 85W-140

PREFERRED

12/9/96 2 - 11

SPECIFICATIONS AND INFORMATION OILS AND LUBRICANTS

REEL SUPPORT GREASE—NORTH

AMERICA

Use the following reel support greases based on the air

temperature range. Operating outside of the

recommended grease air temperature range may

cause premature reel support failure.

The following John Deere grease is PREFERRED:

• CORN HEAD GREASE—JDM J13E6, NLGI

Grade 0 (Polyurea Grease).

Other greases may be used if above John Deere

greases are not available, provided they meet the

following compatibility specifications only:

• Polyurea Grease—NLGI Grade 0;

• Calcium Complex Grease—NLGI Grade 0.

IMPORTANT: DO NOT mix any other greases

(including calcium, lithium, lithium complex,

and lithium 12-hydroxy based greases) with

above recommended greases, they are NOT

COMPATIBLE. For best results, completely

remove all non-compatible grease from housing

and fill with above preferred grease or one of

the other greases, which are compatible with

each other. DO NOT use any BIO–GREASE.

John Deere Distributors: You may want to cross-

reference the following publications to recommend the

proper grease for your customers:

• Module DX,CORN in JDS–G135;

• Section 530, Lubricants & Hydraulics, of the John

Deere Merchandise Sales Guide;

• Lubrication Sales Manual PI7032.

JDM J13E6

NLGI Grade 0

M58275

AIR TEMPERATURE

REEL SUPPORT GREASE—

EUROPE

Use the following reel support greases based on the air

temperature range. Operating outside of the

recommended grease air temperature range may

cause premature reel support failure.

The following John Deere grease is PREFERRED:

• GREASE–GARD®—JDM J13E6, NLGI Grade 0.

Other greases may be used if above preferred John

Deere grease is not available, provided they meet the

following compatibility specifications only:

• Polyurea Grease—NLGI Grade 0;

• Calcium Complex Grease—NLGI Grade 0.

IMPORTANT: DO NOT mix any other greases

(including calcium, lithium, lithium complex,

and lithium 12-hydroxy based greases) with

above recommended greases, they are NOT

COMPATIBLE. For best results, completely

remove all non-compatible grease from housing

and fill with above preferred grease or one of

the other greases, which are compatible with

each other. DO NOT use any BIO–GREASE.

John Deere Distributors: You may want to cross-

reference the following publications to recommend the

proper grease for your customers:

• Module DX,CORN in JDS–G135;

• Section 530, Lubricants & Hydraulics, of the John

Deere Merchandise Sales Guide.

M58275

JDM J13E6

NLGI Grade 0

AIR TEMPERATURE

2 - 12 12/9/96

OILS AND LUBRICANTS SPECIFICATIONS AND INFORMATION

ANTI-CORROSION GREASE

SPECIFICATIONS

This anti-corrosion grease is formulated to provide the

best protection against absorbing moisture, which is

one of the major causes of corrosion. This grease is

also superior in its resistance to separation and

migration.

The following anti-corrosion grease is PREFERRED:

• DuBois MPG-2® Multi-Purpose Polymer

Grease—M79292.

Other greases may be used if they meet or exceed the

following specifications:

• John Deere Standard JDM J13A2, NLGI Grade 1.

John Deere Distributors: You may want to cross-

reference the following publications to recommend the

proper grease for your customers:

• Module DX,GREA1 in JDS–G135;

• Section 530, Lubricants & Hydraulics, of the John

Deere Merchandise Sales Guide;

• Lubrication Sales Manual PI7032.

JDM J13A2

NLGI Grade 1

M58275

AIR TEMPERATURE

12/9/96 2 - 13

SPECIFICATIONS AND INFORMATION OILS AND LUBRICANTS

GREASE—NORTH AMERICA

Use the following grease based on the air temperature

range. Operating outside of the recommended grease

air temperature range may cause premature failures.

IMPORTANT: ONLY use a quality grease in this

application. DO NOT mix any other greases in

this application. DO NOT use any BIO–GREASE

in this application.

The following John Deere grease is PREFERRED:

• NON-CLAY HIGH-TEMPERATURE EP

GREASE®—JDM J13E4, NLGI Grade 2.

Other greases may be used if above preferred John

Deere grease is not available, provided they meet the

following specification:

• John Deere Standard JDM J13E4, NLGI Grade 2.

John Deere Distributors: You may want to cross-

reference the following publications to recommend the

proper grease for your customers:

• Module DX,GREA1 in JDS–G135;

• Section 530, Lubricants & Hydraulics, of the John

Deere Merchandise Sales Guide;

• Lubrication Sales Manual PI7032.

JDM J13E4

M58275

AIR TEMPERATURE

NLGI Grade 2

GREASE—EUROPE

Use the following grease based on the air temperature

range. Operating outside of the recommended grease

air temperature range may cause premature failures.

IMPORTANT: ONLY use a quality grease in this

application. DO NOT mix any other greases in

this application. DO NOT use any BIO–GREASE

in this application.

The following John Deere grease is PREFERRED:

• GREASE–GARD™—JDM J13E4, NLGI Grade 2.

Other greases may be used if above preferred John

Deere grease is not available, provided they meet the

following specification:

• John Deere Standard JDM J13E4, NLGI Grade 2.

John Deere Distributors: You may want to cross-

reference the following publications to recommend the

proper grease for your customers:

• Module DX,GREA1 in JDS–G135;

• Section 530, Lubricants & Hydraulics, of the John

Deere Merchandise Sales Guide.

JDM J13E4

M58275

AIR TEMPERATURE

NLGI Grade 2

2 - 14 12/9/96

OILS AND LUBRICANTS SPECIFICATIONS AND INFORMATION

ALTERNATIVE LUBRICANTS

Conditions in certain geographical areas outside the

United States and Canada may require different

lubricant recommendations than the ones printed in

this technical manual or the operator's manual. Consult

with your John Deere Dealer, or Sales Branch, to

obtain the alternative lubricant recommendations.

IMPORTANT: Use of alternative lubricants could

cause reduced life of the component.

If alternative lubricants are to be used, it is

recommended that the factory fill be thoroughly

removed before switching to any alternative lubricant.

SYNTHETIC LUBRICANTS

Synthetic lubricants may be used in John Deere

equipment if they meet the applicable performance

requirements (industry classification and/or military

specification) as shown in this manual.

The recommended air temperature limits and service

or lubricant change intervals should be maintained as

shown in the operator’s manual.

Avoid mixing different brands, grades, or types of oil.

Oil manufacturers blend additives in their oils to meet

certain specifications and performance requirements.

Mixing different oils can interfere with the proper

functioning of these additives and degrade lubricant

performance.

LUBRICANT STORAGE

All machines operate at top efficiency only when clean

lubricants are used. Use clean storage containers to

handle all lubricants. Store them in an area protected

from dust, moisture, and other contamination. Store

drums on their sides. Make sure all containers are

properly marked as to their contents. Dispose of all old,

used containers and their contents properly.

MIXING OF LUBRICANTS

In general, avoid mixing different brands or types of

lubricants. Manufacturers blend additives in their

lubricants to meet certain specifications and

performance requirements. Mixing different lubricants

can interfere with the proper functioning of these

additives and lubricant properties which will downgrade

their intended specified performance.

12/9/96 2 - 15

SPECIFICATIONS AND INFORMATION SERIAL NUMBER LOCATION

SERIAL NUMBER LOCATION

When ordering parts or submitting a warranty claim, it

is IMPORTANT that the machine product identification

and component serial numbers are included.

The location of the machine identification number and

component serial numbers are shown.

MACHINE IDENTIFICATION

NUMBER

ENGINE SERIAL NUMBER

CARBURETOR IDENTIFICATION

NUMBER

M83740

M83819

M83820

2 - 16 12/9/96

OPERATIONAL CHECKOUT PROCEDURES SPECIFICATIONS AND INFORMATION

OPERATIONAL CHECKOUT

PROCEDURES

The procedures covered in this group are used to give

a quick checkout of all the systems and components on

the unit. These checkouts should be run to insure

proper operation after any extended storage, when the

unit comes in for service and after repairs have been

made on the unit. They can also be helpful in

determining the value of the unit at trade-in time. The

unit should be placed on a level surface to run

checkout. All checkouts should be done and all the

steps of each checkout should be followed.

Each checkout list:

• Conditions—How the unit should be set up for the

checkout.

• Procedure—The specific action to be done.

• Normal—What should happen, or be heard, or

seen.

• If Not Normal—Where to go if other tests or

adjustments are needed.

When performing the checkout, be sure to set your

machine up to the test conditions listed and follow the

sequence carefully. The “NORMAL” paragraph gives

the result that should happen when performing the

checkout. If the results are not normal, follow the

instructions listed in the “IF NOT NORMAL” paragraph

to determine the cause and repair the malfunction.

ENGINE OIL LEVEL CHECK

Conditions:

• Engine stopped.

• Machine parked on level surface.

• RUN/OFF switch in OFF position.

• Engine oil cold

• Block placed under front roller to level machine/

engine

Procedure:

1. Before removing dipstick, clean around dipstick.

2. Remove dipstick and check oil level.

M83863

Normal:

• Oil level is to the outer edge of the oil filler neck.

If Not Normal:

• Oil level is below outer edge of oil filler neck, add

oil. (See 4-CYCLE GASOLINE ENGINE OIL—

NORTH AMERICA on page 2-8, or 4-CYCLE

GASOLINE ENGINE OIL—EUROPE on page 2-

9.)

SPEED REDUCER OIL LEVEL

CHECK

Conditions:

• Engine stopped.

• Machine parked on level surface.

• RUN/OFF switch in OFF position.

• Engine oil cold

• Block placed under front roller to level machine/

speed reducer.

Procedure:

3. Remove cap screw and drive belt cover.

M83901

Oil Level

M83755

Drive Belt Cover

Cap Screw

12/9/96 2 - 17

SPECIFICATIONS AND INFORMATION OPERATIONAL CHECKOUT PROCEDURES

1. Before removing dipstick, clean around dipstick.

2. Wipe dipstick with a clean rag.

3. Thread dipstick into case.

4. Remove dipstick and check oil level.

Normal:

• Oil level is between is between bottom of dipstick

and first mark.

If Not Normal:

• Oil level is below bottom of dipstick, add oil. (See

SPEED REDUCER OIL—NORTH AMERICA on

page 2-10, or SPEED REDUCER OIL—EUROPE

on page 2-10.)

• Oil level is above first mark, drain excess oil unit

level is between bottom of dipstick and first mark.

M83861

Dipstick

M83862

First Mark

THROTTLE LEVER CHECK

Conditions:

• Machine parked on level surface.

• Operator presence bail engaged.

• Travel clutch disengaged.

• Park brake engaged.

Procedure:

1. Start engine and run at slow idle (1400 +220/-150

rpm).

2. Move throttle from SLOW to FAST to SLOW

positions.

Normal:

• Engine must accelerate and decelerate

SMOOTHLY without hesitation.

• Throttle lever should move freely, yet hold desired

position.

If Not Normal:

• Adjust throttle cable. (See THROTTLE CABLE

CHECK AND ADJUSTMENT on page 3-22.)

• Adjust throttle lever tension. (See THROTTLE

LEVER TENSION ADJUSTMENT on page 6-3.)

M83782

Throttle Lever

2 - 18 12/9/96

OPERATIONAL CHECKOUT PROCEDURES SPECIFICATIONS AND INFORMATION

OPERATOR PRESENCE BAIL

CHECK

Conditions:

• Engine running.

• Reel clutch in MOW position.

• Park brake disengaged.

Procedure:

1. Hold operator presence bail against handlebar.

2. Engage travel clutch lever.

Normal:

• Transport drive (traction roller/transport wheels)

should engage.

• Reel drive should engage.

If Not Normal:

• Adjust operator presence bail. (See OPERATOR

PRESENCE BAIL ADJUSTMENT on page 6-3.)

• Adjust drive belt tension. (See DRIVE BELT

TENSION CHECK AND ADJUSTMENT on page

5-10.)

• Repair power train as necessary. (See POWER

TRAIN—REPAIR.)

Procedure:

3. Release operator presence bail.

cCAUTION

Perform this check in a large, flat and open area

away from people and/or stationary objects or

structures.

M83782

Travel Clutch Lever

Normal:

• Transport drive (traction roller/transport wheels)

should stop.

• Reel drive should stop.

If Not Normal:

• Adjust belt guide. (See BELT GUIDE

ADJUSTMENT on page 5-11.)

PARK BRAKE CHECK

Conditions:

• Engine running.

• Reel clutch in OFF position.

• Travel clutch disengaged.

Procedure:

1. Move park brake lever to ENGAGED position.

Normal:

• Engine should remain running.

• Machine should not move when pushed or pulled.

• Cutting reel should not move.

If Not Normal:

• Adjust park brake. (See PARK BRAKE CHECK

AND ADJUSTMENT on page 7-7.)

M83870

Park Brake Lever

(ENGAGED Position)

12/9/96 2 - 19

SPECIFICATIONS AND INFORMATION OPERATIONAL CHECKOUT PROCEDURES

TRAVEL CLUTCH CHECK

Conditions:

• Engine running.

• Reel clutch in OFF position.

• Park brake disengaged.

• Operator presence bail engaged.

Procedure:

1. Engage travel clutch lever.

Normal:

• Transport drive (traction roller/transport wheels)

should engage.

If Not Normal:

• Adjust drive belt tension. (See DRIVE BELT

TENSION CHECK AND ADJUSTMENT on page

5-10.)

• Repair power train as necessary. (See POWER

TRAIN—REPAIR.)

REEL CLUTCH CHECK

Conditions:

• Engine stopped.

• Machine parked on level surface.

• Park brake disengaged.

cCAUTION

Perform this check in a large, flat and open area

away from people and/or stationary objects or

structures.

M83782

Travel Clutch Lever

Procedure:

1. Place reel clutch lever in MOW position.

2. Start engine and run at slow idle (1400 +220/-150

rpm).

3. Hold operator presence bail against handlebar.

4. Engage travel clutch lever.

Normal:

• Transport drive (traction roller/transport wheels)

should engage.

• Reel drive should engage.

If Not Normal:

• Adjust drive belt tension. (See DRIVE BELT

TENSION CHECK AND ADJUSTMENT on page

5-10.)

• Repair power train as necessary. (See POWER

TRAIN—REPAIR.)

cCAUTION

Perform this check in a large, flat and open area

away from people and/or stationary objects or

structures.

M83859

M83782

Travel Clutch Lever

Operator Presence Bail

2 - 20 12/9/96

OPERATIONAL CHECKOUT PROCEDURES SPECIFICATIONS AND INFORMATION

Procedure:

5. Release operator presence bail.

6. Place reel clutch lever in MOW position.

7. Hold operator presence bail against handlebar.

8. Engage travel clutch lever.

Normal:

• Transport drive (traction roller/transport wheels)

should engage.

• Reel drive should not engage.

If Not Normal:

• Adjust drive belt tension. (See DRIVE BELT

TENSION CHECK AND ADJUSTMENT on page

5-10.)

• Repair power train as necessary. (See POWER

TRAIN—REPAIR.)

M83859

M83782

Travel Clutch Lever

Operator Presence Bail

ENGINE (HONDA GX120) CONTENTS

Page

CONTENTS

12/9/96 3 - 1

ENGINE (HONDA GX120)

SPECIFICATIONS

TEST AND ADJUSTMENT SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

REPAIR SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

SPECIAL OR ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

OTHER MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

SERVICE PARTS KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

COMPONENT LOCATION AND OPERATION

EXTERIOR ENGINE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

INTERNAL ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

LUBRICATION SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

COOLING SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

TROUBLESHOOTING

ENGINE AND FUEL SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . 3-16

ENGINE TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

CHECKS, TESTS AND ADJUSTMENTS

THROTTLE CABLE CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 3-22

SLOW IDLE SPEED ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

GOVERNOR/FAST IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 3-23

CYLINDER COMPRESSION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

VALVE CLEARANCE, CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 3-24

SPARK TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

SPARK PLUG GAP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

REPAIR

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

THROTTLE CABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

AIR CLEANER ASSEMBLY

Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

THROTTLE PLATE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

CARBURETOR

Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Disassembly/Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Clean/Inspect/Rebuild. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Pilot Screw and Limiter Cap Replacement . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Float Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

BLOWER HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

RECOIL STARTER

Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Disassembly/Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

CONTENTS ENGINE (HONDA GX120)

3 - 2 12/9/96

Page

REPAIR (Continued)

IGNITION COIL

Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Air Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

FLYWHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

ROCKER ARM COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

CYLINDER HEAD AND VALVES

Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Valve Guide Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

ANALYZE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

RECONDITION VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

LAP VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

REDUCTION ASSEMBLY

Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

Bearing/Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

CRANKCASE COVER

Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

Bearing/Inspection Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

CAMSHAFT AND TAPPETS

Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

PISTON AND CONNECTING ROD

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

Check Connecting Rod Side Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

Check Connecting Rod-to-Crankshaft Clearance . . . . . . . . . . . . . . . . . . . 3-55

Check Piston Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

ANALYZE PISTON RING WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

ANALYZE PISTON WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

CRANKSHAFT

Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Timing/Governor Drive Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . 3-58

ANALYZE CRANKSHAFT AND CONNECTING ROD WEAR . . . . . . . . . . . . . . . . 3-59

CYLINDER BLOCK

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

Bearing Inspection/Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

Deglaze Cylinder Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

Rebore Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

GOVERNOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

12/6/96 3 - 3

ENGINE (HONDA GX120) SPECIFICATIONS

SPECIFICATIONS

TEST AND ADJUSTMENT SPECIFICATIONS

Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3450 ±150 rpm

Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 +200/-150 rpm

Cylinder Compression. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586—834 kPa (85—121 psi)

Valve Clearance

Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.15 ±0.02 mm (0.006 ±0.001 in.)

Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.20 ±0.02 mm (0.008 ±0.001 in.)

Pivot Lock Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (7 lb-ft)

Spark Plug Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7—0.8 mm (0.028—0.031 in.)

REPAIR SPECIFICATIONS

Engine

Engine Oil Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 L (0.63 qt)

Oil Drain Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 N•m (13 lb-ft)

Fuel Tank

Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 L (0.66 gal)

Cap Screw Mounting Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (7 lb-ft)

Flange Nut Mounting Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (7 lb-ft)

Fuel Filter Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (1.4 lb-ft)

Muffler

Mounting Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (17 lb-ft)

Air Cleaner Assembly

Air Cleaner Wing Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (6.5 lb-ft)

Mounting Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 N•m (6.1 lb-ft)

Carburetor

Float Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.7 mm (0.54 in.)

Sediment Cup Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (3 lb-ft)

Ignition Coil

Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 ±0.2 mm (0.016 ±0.008 in.)

Resistance (Primary Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.8—1.0 ohm

Resistance (Secondary Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9—7.1 K ohm

Flywheel

Flange Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 N•m (54 lb-ft)

3 - 4 12/6/96

SPECIFICATIONS ENGINE (HONDA GX120)

REPAIR SPECIFICATIONS, continued

Cylinder Head

Cap Screw Torque in Sequence

Initial Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 N•m (8.5 lb-ft)

Final Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (17 lb-ft)

Maximum Cylinder Head Distortion. . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)

Rocker Arm

Pivot Bolt Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (17 lb-ft)

Pivot Lock Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (7 lb-ft)

Valve Guide

Standard ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50 mm (0.217 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.572 mm (0.2194 in.)

Valve Seats:

Standard Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 mm (0.03 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm (0.08 in.)

Valve Spring

Free Length

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.5 mm (1.20 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.5 mm (1.16 in.)

Intake Valve

Stem O.D.

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.48 mm (0.216 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.318 mm (0.2094 in.)

Maximum Valve Stem Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Head Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 mm (0.87 in.)

Exhaust Valve

Stem O.D.

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.44 mm (0.214 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.275 mm (0.2077 in.)

Maximum Valve Stem Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Head Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 mm (0.75 in.)

Crankcase Cover

Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 N•m (9 lb-ft)

Camshaft Holder I.D.

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.0 mm (0.55 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.048 mm (0.5531 in.)

12/6/96 3 - 5

ENGINE (HONDA GX120) SPECIFICATIONS

REPAIR SPECIFICATIONS, continued

Piston

Connecting Rod Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 N•m (9 lb-ft)

Piston Skirt O.D.—Standard Piston

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.985 mm (2.3616 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.845 mm (2.3561 in.)

Piston Skirt O.D.— 0.25 mm (0.010 in.) Oversize Piston

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.235 mm (2.3716 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.095 mm (2.3661 in.)

Piston Skirt O.D.—0.50 mm (0.020 in.) Oversize Piston

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.485 mm (2.38 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.345 mm (2.3761 in.)

Piston-to-Cylinder Clearance

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015—0.050 mm (0.0006—0.0020 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)

Piston Ring Thickness—1st and 2nd Compression

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 mm (0.06 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.37 mm (0.054 in.)

Piston Ring Thickness—Oil Control

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 mm (0.10 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37 mm (0.093 in.)

Piston Ring Groove Side Clearance

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015—0.045 mm (0.0006—0.0018 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)

Piston Ring End Gap—Top and Second

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2—0.4 mm (0.008—0.016 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.04 in.)

Piston Ring End Gap—Oil Control

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15—0.35 mm (0.006—0.014 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.04 in.)

Piston Pin O.D.

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.0 mm (0.51 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.954 mm (0.510 in.)

Piston Pin Bore I.D.

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.002 mm (0.5119 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.048 mm (0.5137 in.)

Piston-to-Piston Pin Bore Clearance

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002—0.014 mm (0.0001—0.0006 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 mm (0.003 in.)

3 - 6 12/6/96

SPECIFICATIONS ENGINE (HONDA GX120)

REPAIR SPECIFICATIONS, continued

Connecting Rod

Piston Pin Bushing I.D.

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.005 mm (0.512 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.07 mm (0.515 in.)

Crankshaft Bearing I.D.—Standard Crankshaft

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.02 mm (1.024 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.066 mm (1.0262 in.)

Crankshaft Bearing I.D.—0.25 mm (0.010 in.) Undersize Crankshaft

Standard . . . . . . . . . . . . . . . . . . . . . . . . . 25.770—25.783 mm (1.0146—1.0151 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.816 mm (1.0164 in.)

Connecting Rod-to-Crankshaft Journal Clearance

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040—0.063 mm (0.0016—0.0025 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)

Connecting Rod-to-Crankshaft Side Clearance

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1—0.7 mm (0.004—0.028 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 mm (0.043 in.)

Camshaft

Cam Lobe Height—Intake

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.7 mm (1.09 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.45 mm (1.081 in.)

Cam Lobe Height—Exhaust

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.75 mm (1.093 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.50 mm (1.083 in.)

Journal O.D.

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.984 mm (0.5506 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.916 mm (0.5479 in.)

Crankshaft

Connecting Rod Journal O.D.

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.98 mm (1.023 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.92 mm (1.020 in.)

Cylinder Block

Cylinder Bore I.D.— Standard Piston

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.0 mm (2.36 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.165 mm (2.3687 in.)

Cylinder Bore I.D.— 0.25 mm (0.010 in.) Oversize Piston

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.25 mm (2.37 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.415 mm (2.3787 in.)

Cylinder Bore I.D.—0.50 mm (0.020 in.) Oversize Piston

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.5 mm (2.41 in.)

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.665 mm (2.3887 in.)

12/6/96 3 - 7

ENGINE (HONDA GX120) SPECIFICATIONS

SPECIAL OR ESSENTIAL TOOLS

NOTE: Order tools according to information given in the U.S. SERVICEGARD

™

Catalog or in the

European Microfiche Tool Catalog (MTC).

JT07270 Digital Pulse Tachometer

Used to check/adjust engine slow and fast idle rpm.

JDM-59 Compression Gauge

Used to check engine compression.

D-05351ST Spark Tester

Used to check overall condition of ignition system.

JDG504 Valve Guide Driver Tool

Used to replace valve guide bushings.

JDG1023 5.5 mm Valve Guide Reamer

Used to ream valve guide bushings.

OTHER MATERIALS

Number Name Use

M79292 MPG-2 Polymer Multipurpose Grease Prevents parts from seizing.

Apply to engine crankshaft.

SCOTCH-BRITE Abrasive Sheet/Pad Clean cylinder head.

Stanisol (or Kerosene) Finish ream valve guides.

Prussian Blue Compound Check valve seat contact.

Lapping compound Lap valves into valve seats.

Lithium Base Grease Pack oil seals.

Zinc Oxide/Wood Alcohol Check block for cracks.

Plastigauge®Used to check connecting

rod-to-crankshaft clearance.

Plastigauge® is a registered trademark of DANA corporation.

SCOTCH-BRITE is a registered trademark of 3M Co.

3 - 8 12/6/96

SPECIFICATIONS ENGINE (HONDA GX120)

SERVICE PARTS KITS

The following kits are available through your parts catalog:

• Carburetor Assembly

• Carburetor Float Valve Kit

• Carburetor Float Kit

• Carburetor Drain Screw Kit

• Carburetor Float Chamber Screw Kit

• Carburetor Float Chamber Kit

• Carburetor Pilot Screw and Limiter Cap Kit

• Carburetor Pilot Jet Kit

• Carburetor Gasket Kit

• Engine Gasket Kit

• Piston Ring Kit (Standard)

• Piston Ring Kit (0.25 mm [0.010 in. oversize])

• Piston Ring Kit (0.50 mm [0.020 in. oversize])

• Piston (0.25 mm [0.010 in. oversize])

• Piston (0.50 mm [0.020 in. oversize])

• Connecting Rod (Standard)

• Connecting Rod (0.25 mm [0.010 in.] undersize)

• Governor Kit

• Cylinder Block

12/6/96 3 - 9

ENGINE (HONDA GX120) COMPONENT LOCATION AND OPERATION

COMPONENT LOCATION AND OPERATION

EXTERNAL ENGINE COMPONENTS

M83756

Recoil Starter

Fuel Tank

Oil Drain Plug

Muffler

Carburetor

Blower Housing

Oil Dipstick

Choke Lever

Fuel Shutoff Lever

Air Cleaner

3 - 10 12/6/96

COMPONENT LOCATION AND OPERATION ENGINE (HONDA GX120)

EXTERNAL ENGINE COMPONENTS, continued

M83757

Oil Drain Plug

Muffler

Carburetor

Rocker Arm Cover

Cylinder Head

Reduction Assembly Cover

Spark Plug

Breather Hose

Air Cleaner

Fuel Tank

Lead

PTO Output Shaft

Crankcase Cover

12/6/96 3 - 11

ENGINE (HONDA GX120) COMPONENT LOCATION AND OPERATION

INTERNAL ENGINE COMPONENTS

M83928

Piston Valve Spring

Governor Shaft

Camshaft

Connecting Rod

Rocker Arm

Valve Guide

Valve Rotator

Piston Pin

Tappet

Push Rod

Push Rod Guide

Governor Drive Gear

Governor Gear

Connecting Rod Oil Dipper

(Exhaust Valve Only)

3 - 12 12/6/96

COMPONENT LOCATION AND OPERATION ENGINE (HONDA GX120)

LUBRICATION SYSTEM OPERATION

Function:

To provide oil to lubricate internal engine components.

Theory of Operation:

The Honda GX120 uses a “Splash” lubrication system,

and does not use an oil pump.

As the crankshaft turns, a dipper located on the

connecting rod cap is immersed into the oil supply in

the crankcase and “splashes” oil onto internal engine

components including camshaft lobes, cylinder walls,

tappets, piston pin and crankshaft ball bearings.

Oil for the connecting rod journal is supplied by a small

passage on the underside of the connecting rod. Oil for

the camshaft and PTO shaft journals are collected in

“wells” located on the top of holders in the cylinder

block and crankcase covers and routed to the journals

by small passages.

Oil is supplied to the rocker arms, valves and pushrods

by a passage in the cylinder block and head. Oil returns

to the crankcase through a passage located between

the tappets.

12/6/96 3 - 13

ENGINE (HONDA GX120) COMPONENT LOCATION AND OPERATION

M83837

Oil Dipper

Camshaft

Crankshaft

Oil Return Passage

Oil Supply Passage

Connecting Rod Journal

Oil Supply Passage

Well

Oil Dipper

Well

Crankshaft

Oil Supply Passage

3 - 14 12/6/96

COMPONENT LOCATION AND OPERATION ENGINE (HONDA GX120)

COOLING SYSTEM OPERATION

Function:

To remove heat from the engine.

Theory of Operation:

The engine is air-cooled with air flow provided by a fan

mounted on the flywheel. When the engine is running,

the fan draws air through the openings in the recoil

starter cover. The blower housings then direct the air

flow past the cooling fin on the cylinder head and block.

Most of the cooling air flows directly over the valve

area. This increased cooling capacity in the valve area

helps to minimize valve sticking and seat wear due to

overheating. The cooling fins are cast into the engine

block and cylinder head to increase their surface area

to allow more of the heat generated by the engine to be

transferred to the cooling air.

It is important that the intake openings on the recoil

starter and cooling fins on the cylinder block and

cylinder head remain free of debris to ensure proper air

flow. The engine covers should not be removed or

altered, as cooling capacity will be reduced. Cylinder

block and head cooling fins must remain clean to

properly dissipate heat.

12/6/96 3 - 15

ENGINE (HONDA GX120) COMPONENT LOCATION AND OPERATION

M83836

Flywheel Fan

Blower Housing

Cylinder Head

Cooling Fins

3 - 16 12/6/96

COMPONENT LOCATION AND OPERATION ENGINE (HONDA GX120)

TROUBLESHOOTING

ENGINE AND FUEL SYSTEM TROUBLESHOOTING CHART

Problem Or

Symptom

Check

Solution

Engine cranks but will not

start or starts hard.

Engine will not stay running,

runs rough, or irregularly.

Engine stalls frequently.

Engine backfires.

Engine surges, or has uneven

or uncontrolled rpm.

Engine misses.

Engine has low power.

Engine has no spark.

Lack of fuel in carburetor.

Engine floods.

Exhaust smoke black or uses

too much fuel.

Exhaust smoke blue or has

excessive oil consumption.

Fuel in oil.

Engine overheats.

Excessive engine noise or

vibration.

Spark plug fouled, defective,

or gap not correct. Incorrect

spark plug.

ll lll l ll

Defective ignition

components. llll llll l l

Fuel filter or line restricted.

Fuel stale, contains water, or

wrong type.

llll lll l ll

Air filter element(s) plugged,

oil soaked, or restricted. lll lll l l

Choke, throttle, or governor

linkage misadjusted.

Carburetor misadjusted.

llll lll ll l

Carburetor worn,

contaminated with debris or

varnish. Passages plugged.

Wrong jets.

llll lll l

Carburetor, intake manifold,

or cylinder head gaskets

leaking or damaged.

llll lll ll

Low compression from worn

piston, rings, cylinder, valves

or warped head.

lll lll l l

Valve clearance incorrect.

Burned or warped valves and

seats. Defective springs.

llll lll

12/6/96 3 - 17

ENGINE (HONDA GX120) COMPONENT LOCATION AND OPERATION

ENGINE AND FUEL SYSTEM TROUBLESHOOTING CHART, continued

Problem Or

Symptom

Check

Solution

Engine cranks but will not

start or starts hard.

Engine will not stay running,

runs rough, or irregularly.

Engine stalls frequently.

Engine backfires.

Engine surges, or has uneven

or uncontrolled rpm.

Engine misses.

Engine has low power.

Engine has no spark.

Lack of fuel in carburetor.

Engine floods.

Exhaust smoke black or uses

too much fuel.

Exhaust smoke blue or has

excessive oil consumption.

Fuel in oil.

Engine overheats.

Excessive engine noise or

vibration.

Engine oil viscosity or level

incorrect. l l l l l

Engine gaskets or seals

leaking. llll lll

Crankcase breather

restricted or drain hole

plugged.

lll l l l l

Valve guides or seals worn or

leaking. Valve stems worn. llll lll l

Worn, stuck, or broken piston

rings. Cylinder bore worn.

Check compression and

vacuum.

ll l l l

Connecting rod or crankshaft

bearings worn. Internal wear

limits out of specification.

l l l

3 - 18 12/6/96

COMPONENT LOCATION AND OPERATION ENGINE (HONDA GX120)

ENGINE TROUBLESHOOTING GUIDE

Engine Hard to Start

Remove spark plug and

check spark by cranking

engine while having the

plug grounded against

engine block. Install

spare plug to plug hole

to avoid fuel spitting from

the hole.

cCAUTION:

To avoid electric

shock, DO NOT hold

plug. Make sure to

hold plug cap.

Are sparks produced when spark plug

is replaced?

Are sparks produced between high

tension lead and engine block with

plug cap removed?

Are sparks produced between high

tension lead and engine block when

ignition coil is replaced?

• Faulty spark plug.

• Faulty contact of plug

cap terminal to lead.

• Faulty ignition coil.

• Incorrect ignition coil

air gap.

• Demagnetized

flywheel.

Replace

Correct

Replace

Correct

YES

Is compression

sufficient? Crank engine several times, then

remove spark plug and observe

electrode.

Are they wet?

• No fuel in the tank.

• Clogged fuel filter.

• Plugged air hole in

tank cap.

• Plugged fuel line.

• Excessive use of

choke.

• Clogged air cleaner.

• Fuel level too high in

float bowl.

Add

Clean

Open choke

Adjust

Clean

Check carburetor. • Check for plugged fuel passage.

• Check for plugged air passage.

• Check float level.

• Check carburetor setting.

• Worn piston/piston

rings.

• Stuck piston rings.

• Worn cylinder bore.

• Insufficient cylinder

head tightening.

• Faulty contact of valve

seat.

• Tight valve.

• Warped cylinder

head.

• Broken valve spring.

• Stuck valve.

• Burned head gasket.

YES

Replace

Clean or replace

Bore or replace

Retighten

Lap

Adjust

Repair or replace

Replace

Clean or grind

Replace

YES

12/6/96 3 - 19

ENGINE (HONDA GX120) COMPONENT LOCATION AND OPERATION

Engine Malfunctions at Low Speed

Remove spark plug and

check spark by cranking

engine while having the

plug grounded against

engine block. Install

spare plug to plug hole

to avoid fuel spitting from

the hole.

cCAUTION:

To avoid electric

shock, DO NOT hold

plug. Make sure to

hold plug cap.

• Faulty plug insulation.

• Fouled electrode.

• Faulty high tension

cord.

• Incorrect ignition coil

air gap.

Is unusual smoke emitted out of

muffler?

Gradually open throttle valve by

hand. Does engine speed drop or

does engine stall at a certain

position?

Is air drawn through carburetor

flange?

Is valve clearance normal?

Is alignment of timing gear marks

correct?

• Overrich fuel in

carburetor slow

system.

• Passages in

carburetor plugged.

• Loose flange nuts.

• Damaged gasket.

• Compression

leak through

valve.

• Largely deviated valve

timing.

WEAK

STRONG

YES

Replace

Correct

Clean

Replace

Adjust

Clean

Tighten

Replace

Adjust

Correct

3 - 20 12/6/96

COMPONENT LOCATION AND OPERATION ENGINE (HONDA GX120)

Engine Runs Erratically

Oil Consumption Is Excessive

• Dust or water in fuel line or fuel filter.

• Air or vapor lock in fuel line.

• Plugged air vent in fuel tank cap.

• Plugged air/fuel passages in carburetor.

• Too little opening of carburetor pilot air-screw.

• Incorrect governor linkage adjustment.

• Faulty governor spring.

• Governor gear assembly malfunction.

• Stale fuel.

• Excessive carbon deposit in engine.

• Excessive engine load.

• Engine overheating.

Problem in fuel system (lack of fuel).

Problem in governor system.

Engine knocks.

Check

Replace

Clean

Remove

Correct

Clean

Correct

Change

Clean

Adjust

See Has

Low Power

• Plugged oil ring groove.

• High oil level.

• Worn valve stems and valve guides.

• Oil leakage along governor shaft.

• Oil seals leaking.

• Head gasket leaking.

• Drain plug leaking.

• Breather tube clogged.

• Drain-back hole in tappet chamber plugged.

• Incorrect oil viscosity.

• Same as Hard To Start.

Is compression sufficient? Clean

Adjust

Replace

YES

Replace

Change

Clean

Replace

Retighten or

replace

12/6/96 3 - 21

ENGINE (HONDA GX120) COMPONENT LOCATION AND OPERATION

Engine Has Low Power

Fuel Consumption Is Excessive

Is engine overheated?

Is lubricating condition normal?

Is unusual smoke emitted out of

muffler?

Is compression sufficient?

• Excessive engine load.

• Carburetor not properly adjusted.

• Dirty or clogged air intake screens, shroud and

engine fins.

• Carbon deposit in combustion chamber.

• Wrong spark plug.

• Too much or too little oil in crankcase.

• Excessively contaminated lubricating oil.

• Air cleaner clogged.

• Carbon deposit in exhaust hole and muffler.

• Carburetor not properly adjusted.

• Too much oil in crankcase.

• Same as Hard To Start.

Change

Correct

Adjust load

Adjust

Replace

Clean

Adjust

Correct

YES

• Carburetor not properly adjusted.

• Air cleaner clogged.

• High idling RPM

• Choke valve not fully open.

• Same as Hard To Start.

Is compression sufficient? Adjust

Clean

Adjust

Open

YES

3 - 22 12/6/96

CHECKS, TESTS AND ADJUSTMENTS ENGINE (HONDA GX120)

CHECKS, TESTS AND

ADJUSTMENTS

THROTTLE CABLE CHECK AND

ADJUSTMENT

Reason:

To make sure the throttle control lever allows full range

of engine speeds.

Procedure:

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position.

3. Move Travel Clutch Lever to NEUTRAL position.

4. Engage park brake.

5. Move throttle lever to FAST idle position.

NOTE: Air cleaner removed for photo clarity only.

6. Loosen screw and move cable until throttle arm

rests against fast idle stop.

7. Tighten screw.

8. Start engine and move throttle lever from SLOW to

FAST to SLOW positions to verify operation.

M83917

Screw

Fast Idle Stop

Throttle Arm

SLOW IDLE SPEED ADJUSTMENT

Reason:

To ensure that the engine is running at proper SLOW

idle rpm.

Equipment:

• JT07270 Digital Pulse Tachometer

Procedure:

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position.

3. Move Travel Clutch Lever to NEUTRAL position.

4. Engage park brake.

5. Start and run engine for five minutes to bring to

operating temperature.

6. Move throttle to SLOW idle position.

7. Hold a JT07270 Digital Pulse Tachometer at spark

plug lead.

8. Adjust slow idle adjustment screw until the engine is

running at a slow idle speed of 1400 +200/-150

rpm.

ATTENTION!

DO NOT attempt to adjust the carburetor unless

you are a factory trained technician with

authorization to service CARB/EPA Certified

Emissions Carburetors.

M83912

Slow Idle

Adjustment Screw

Spark Plug Lead

12/6/96 3 - 23

ENGINE (HONDA GX120) CHECKS, TESTS AND ADJUSTMENTS

GOVERNOR/FAST IDLE SPEED

ADJUSTMENT

Reason:

To ensure that the engine is running at proper FAST

idle rpm.

Equipment:

• JT07270 Digital Pulse Tachometer

Procedure:

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position.

3. Move Travel Clutch Lever to NEUTRAL position.

4. Engage park brake.

5. Remove fuel tank. (See FUEL TANK—Removal/

Installation on page 3-27.)

6. Loosen governor arm nut and move governor arm

to allow the throttle to open fully.

7. Rotate governor shaft as far as it will go in the same

direction. Tighten nut to secure arm on shaft.

8. Install fuel tank.

9. Start and run engine for five minutes to bring to

operating temperature.

10. Move throttle to FAST idle position.

11. Hold a JT07270 Digital Pulse Tachometer at spark

plug lead.

M83765

Nut

Shaft

Governor Arm

Limiting Screw

12. Adjust fast idle adjustment screw until the engine is

running at a fast idle speed of 3450 ±150 rpm.

CYLINDER COMPRESSION

PRESSURE TEST

Reason:

To determine the condition of the piston, rings, cylinder

walls and valves.

Equipment:

• JDM59 Compression Gauge

Procedure:

1. Run engine for five minutes to bring to operating

temperature.

2. Park machine on a level surface.

3. Move RUN/OFF switch to OFF position.

4. Move Travel Clutch Lever to NEUTRAL position.

5. Engage park brake.

6. Remove spark plug.

cCAUTION

Engine components are HOT. Be careful not to

touch, especially the muffler while making

adjustments. Wear protective eye glasses and

clothing.

M83911

Fast Idle Adjustment Screw

3 - 24 12/6/96

CHECKS, TESTS AND ADJUSTMENTS ENGINE (HONDA GX120)

7. Install JDM59 Compression Gauge in spark plug

hole.

8. Ground high tension lead.

9. Move throttle control lever to FAST idle position.

10. Pull recoil starter (full strokes) several times and

record highest gauge reading. Compression

should read from 586—834 kPa (85—121 psi).

Results:

NOTE: Specification listed is for an engine that has

had sufficient time to allow rings to fully seat.

Compression that is lower than specifications

on low hour machines probably does not

indicate a problem.

• If above specifications, adjust valves and check fuel

and air intake systems. Check exhaust for

restriction.

• If below specifications, squirt clean engine oil into

cylinder and repeat test (one sprint from oil can).

• If compression pressure DOES NOT increase after

retest, check for leaking intake or exhaust valves,

valve seats or cylinder head gasket. Replace parts

as necessary.

• If compression pressure INCREASES after retest,

check rings, piston and cylinder bore for broken

rings, scoring, wear or damage. Replace parts as

necessary.

M83878

JDM59 Compression Gauge VALVE CLEARANCE CHECK AND

ADJUSTMENT

Reason:

To ensure proper opening and closing of the intake and

exhaust valves.

Equipment:

• Feeler Gauge (Blade Type)

Check Procedure:

IMPORTANT: Perform adjustment when engine is

cold.

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position. Allow

engine to cool.

3. Move Travel Clutch Lever to NEUTRAL position.

4. Engage park brake.

5. Remove spark plug.

6. Remove rocker arm cover. (See ROCKER ARM

COVER—Removal/Installation on page 3-41.)

7. Slowly pull recoil starter until piston is at Top Dead

Center (TDC) of compression stroke (both intake

and exhaust valves will be closed). The triangular

mark on the starter pulley will align with the top

hole on the Top Dead Center of the compression

or exhaust stroke.

M83908

Triangular Mark

Hole

12/6/96 3 - 25

ENGINE (HONDA GX120) CHECKS, TESTS AND ADJUSTMENTS

8. Use a blade-type feeler gauge to measure valve

clearance.

Specifications:

Intake. . . . . . . . . . . 0.15 ±0.05 mm (0.006 ±0.001 in.)

Exhaust. . . . . .0.20 mm ±0.02 mm (0.008 ±0.001 in.)

Results:

• If valve clearance does not meet the specifications,

adjust as follows:

Adjustment Procedure:

1. Hold rocker arm pivot and loosen rocker arm lock

nut.

2. Turn the rocker arm pivot to obtain specified

clearance.

3. Retighten rocker arm pivot lock nut to 10 N•m (7 lb-

ft) while holding the rocker arm pivot.

4. Recheck clearance after tightening lock nut.

M83877

M83876

Rocker Arm Lock Nut

SPARK TEST

Reason:

To test the overall condition of the ignition system.

Equipment:

• D-05351ST Spark Tester

Procedure:

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position.

3. Move Travel Clutch Lever to NEUTRAL position.

4. Engage park brake.

5. Remove high tension lead from spark plug.

6. Connect D-05351ST Spark Tester to spark plug.

7. Connect high tension lead to Spark Tester.

IMPORTANT: DO NOT adjust spark tester gap

beyond 5.0 mm (0.200 in.) (5 turns), as damage

to ignition system could occur.

8. Adjust Spark Tester gap to 4.2 mm (0.166 in.) (4

turns) with screw.

9. Pull recoil starter (full strokes) several times and

watch spark at spark tester. If engine will start,

watch spark with engine running. A steady, strong,

blue spark should be observed.

Results:

• If spark is weak, or no spark is present, install a

new spark plug and repeat test.

• If spark is still weak, or no spark is present, run

tests on individual components to find the cause of

the malfunction.

M83875

D-05351ST Spark Tester

3 - 26 12/6/96

CHECKS, TESTS AND ADJUSTMENTS ENGINE (HONDA GX120)

SPARK PLUG GAP ADJUSTMENT

Reason:

To ensure correct spark plug gap for maximum

performance.

Equipment:

• Feeler Gauge

Procedure:

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position. Allow

engine to cool.

3. Move Travel Clutch Lever to NEUTRAL position.

4. Engage park brake.

5. Remove spark plug.

IMPORTANT: DO NOT clean spark plug with sand

paper or abrasives. Engine scoring can result.

6. Scrape or wire brush deposits from spark plug.

7. Inspect plug for:

• Cracked porcelain

• Pitted or damaged electrodes

8. Check spark plug gap using a feeler gauge. Set gap

to 0.7—0.8 mm (0.028—0.031 in.).

9. Inspect sealing washer. Replace spark plug if

necessary.

10. Install plug finger-tight until washer is seated. Using

a spark plug wrench, tighten plug an additional 1/2

turn if a new plug (or 1/8—1/4 turn for a used plug)

to compress washer.

cCAUTION

Engine components are HOT. Be careful not to

touch, especially the muffler while making

adjustments. Wear protective eye glasses and

clothing.

M48365

12/6/96 3 - 27

ENGINE (HONDA GX120) REPAIR

REPAIR

FUEL TANK

Removal/Installation

1. Remove air cleaner assembly. (See AIR CLEANER

ASSEMBLY—Removal/Installation on page 3-30.)

NOTE: Fuel tank capacity is approximately 2.5 L (0.66

U.S. gal).

2. Remove drain plug and drain fuel into a properly

marked container.

3. Disconnect fuel line at carburetor.

4. Remove cap screw.

cCAUTION

Gasoline vapor is explosive. DO NOT expose to

spark or flame. Serious personal injury can

result.

M83747

Drain Plug

M83750

Fuel Line

M83751

Cap Screw

10 N•m (7 lb-ft)

5. Remove two flange nuts and ground wire.

6. Remove fuel tank.

7. Inspect fuel tank for signs of wear or damage.

Replace if necessary.

8. Inspect fuel filter. Clean and/or replace if necessary.

(See Fuel Filter.)

Installation is done in the reverse order of removal.

• Attach ground wire to the fuel tank stud (recoil

starter side).

• Tighten cap screw and flange nuts to 10 N•m (7 lb-

ft).

• Inspect for leaks. Repair leaks and wipe-up spilled

fuel before starting engine.

FUEL FILTER

1. Remove fuel tank. (See FUEL TANK—Removal/

Installation.)

2. Remove fuel line.

3. Remove fuel filter.

4. Clean and inspect fuel filter. Replace if necessary.

Installation is done in the reverse order of removal.

• Tighten fuel filter to 2 N•m (1.4 lb-ft).

M83752

Ground Wire

Flange Nuts

10 N•m (7 lb-ft)

M83753

O-Ring

Fuel Filter

2 N•m (1.4 lb-ft)

3 - 28 12/6/96

REPAIR ENGINE (HONDA GX120)

THROTTLE CABLE

Removal/Installation

1. Remove handlebar cover. (See HANDLEBAR

COVER—Removal/Installation on page 6-5.)

2. Remove air cleaner cover and element. (See AIR

CLEANER ASSEMBLY—Removal/Installation on

page 3-30.)

3. Loosen clamp and disconnect throttle cable at

throttle plate assembly.

4. Loosen clamp and disconnect throttle cable at

throttle lever.

Installation is done in the reverse order of removal.

• Adjust throttle cable. (See THROTTLE CABLE

CHECK AND ADJUSTMENT on page 3-22.)

M83754

Throttle CableClamp

Throttle Plate

M83759

Throttle Cable

Clamp

Throttle Lever

MUFFLER

Removal/Installation

1. Remove nuts and washers.

2. Remove muffler and gasket.

Installation is done in the reverse order of removal.

• Use new gasket for installation.

• Tighten mounting nuts to 24 N•m (17 lb-ft).

cCAUTION

To prevent possible burns, allow engine to cool

before removing muffler.

M86165

Nuts and Washers

24 N•m (17 lb-ft)

12/6/96 3 - 29

ENGINE (HONDA GX120) REPAIR

ENGINE

Removal/Installation

1. Remove air cleaner cover and element. (See AIR

CLEANER ASSEMBLY—Removal/Installation on

page 3-30.)

2. Loosen clamp and disconnect throttle cable at

throttle plate assembly.

3. Remove nut and RUN/OFF switch ground wire.

4. Disconnect RUN/OFF switch wiring lead.

5. Remove cap screw and drive belt cover.

M83754

Clamp Throttle Cable

Throttle Plate

M83752

Ground Wire

Nut

RUN/OFF Switch Lead

M83755

Drive Belt Cover

Cap Screw

6. Remove front and rear engine mounting bolts and

nuts.

7. Slide engine forward and remove drive belts.

8. Remove engine.

M83760

Mounting Bolts and Nuts

Front of Engine

M83761

Rear of Engine

Mounting Bolts and Nuts

M83762

Drive Belts

3 - 30 12/6/96

REPAIR ENGINE (HONDA GX120)

9. If engine is to be repaired, remove:

• Cap screw, washer, drive sheave and key.

• Cap screws and belt cover bracket

• Cap screws and brackets.

NOTE: Crankcase capacity is approximately 0.6 L

(0.63 qt).

10. If engine is to be repaired, remove drain plug and

drain crankcase.

Installation is done in the reverse order of removal.

NOTE: If the engine has been rebuilt (cylinder rebored

or deglazed, etc.), the oil should changed after

the first 20 hours (maximum) of operation.

• Fill engine to proper level with oil of correct

specifications. (See 4-CYCLE GASOLINE

ENGINE OIL—NORTH AMERICA on page 2-8, or

4-CYCLE GASOLINE ENGINE OIL—EUROPE on

page 2-9.)

• Adjust drive belt tension. (See DRIVE BELT

TENSION CHECK AND ADJUSTMENT on page

5-10.)

• Adjust drive belt guide. (See DRIVE BELT GUIDE

ADJUSTMENT on page 5-11.)

• Adjust throttle cable. (See THROTTLE CABLE

CHECK AND ADJUSTMENT on page 3- 22.)

M83763

Cap Screw

Belt Guide Bracket

Belt Cover Bracket

Drive Sheave

Cap Screws Cap Screws

AIR CLEANER ASSEMBLY

Removal/Installation

1. Remove wing nut and cover.

2. Remove wing nut and air cleaner.

3. Move fuel shutoff valve to OFF position.

4. Move choke lever to FULL CHOKE position.

M83749

Wing Nut

9 N•m (6.5 lb-ft)

Cover

Wing Nut

9 N•m (6.5 lb-ft)

Air Cleaner Element

Seal

Housing

M83775

Fuel Shutoff Lever

(ON Position)

Choke Lever

(ON Position)

12/6/96 3 - 31

ENGINE (HONDA GX120) REPAIR

5. Remove two flange nuts.

6. Remove cap screw.

7. Remove air cleaner housing and gasket.

8. Inspect and clean air filter element. Replace if

necessary. (See Service procedure.)

9. Inspect gasket for damage. Replace if necessary.

Installation is done in the reverse order of removal.

• Install gasket as shown.

• Connect breather tube to air cleaner housing.

• Tighten air cleaner element and cover wing nuts to

9 N•m (6.5 lb-ft).

• Tighten housing flange nuts to 8.5 N•m (6 lb-ft).

M83748

Flange Nuts

8.5 N•m (6 lb-ft)

M83944

Breather Tube

Gasket

Service

IMPORTANT: Carefully remove air cleaner cover

and elements. Inspect inside paper element and

intake passage for signs of dust. If present,

replace elements and test engine compression

or inspect for damage.

Any time the air cleaner is removed, check for

free choke plate operation during reassembly.

1. Remove air cleaner cover and element. (See AIR

CLEANER ASSEMBLY—Removal/Installation on

page 3-30.)

2. Remove foam element from paper element.

3. Wash foam element in warm soapy water, rinse and

allow to dry throughly.

4. Apply 12—15 drops of clean engine oil to foam

element. Squeeze out excess oil.

IMPORTANT: DO NOT clean paper element with

solvent or compressed air.

5. Gently tap paper element to remove dust.

6. Inspect paper element:

• Element is still usable if you can see light through it

and element appears clean.

• Replace element if oily, dirty or damaged in any

way.

7. Inspect cover and housing for damage. Replace

parts as necessary.

8. Assemble and install air cleaner assembly.

M83884

Foam Element

Paper Element

3 - 32 12/6/96

REPAIR ENGINE (HONDA GX120)

THROTTLE PLATE ASSEMBLY

Removal/Installation

1. Remove air cleaner assembly. (See AIR CLEANER

ASSEMBLY—Removal/Installation on page 3-30.)

2. Loosen clamp and disconnect throttle cable at

throttle plate assembly.

3. Disconnect governor spring.

4. Remove two cap screws.

5. Remove throttle plate assembly.

Installation is done in the reverse order of removal.

• Adjust throttle cable. (See THROTTLE CABLE

CHECK AND ADJUSTMENT on page 3-22.)

M83754

Clamp Throttle Cable

Throttle Plate

M83764

Cap Screws Governor Spring

CARBURETOR

Removal/Installation

1. Remove air cleaner assembly. (See AIR CLEANER

ASSEMBLY—Removal/Installation on page 3-30.)

NOTE: Fuel tank capacity is approximately 3.6 L (0.95

qt).

2. Remove drain plug and drain fuel into a properly

marked container.

3. Disconnect fuel line at carburetor.

cCAUTION

Gasoline is extremely flammable. DO NOT

smoke. Always work in a ventilated area away

from open flame or spark producing equipment,

this includes equipment that utilizes pilot lights.

M83747

Drain Plug

M83750

Fuel Line

12/6/96 3 - 33

ENGINE (HONDA GX120) REPAIR

4. Slide carburetor forward (away from engine) until

slot aligns with governor linkage. Disconnect

linkage and spring.

5. Remove carburetor.

NOTE: Throttle plate assembly removed for photo

clarity only.

6. Remove spark plug lead from insulator.

7. Remove insulator and gaskets.

Installation is done in the reverse order of removal.

• Use new gaskets for Installation.

• Tighten air cleaner housing flange nuts to 8.5 N•m

(6 lb-ft).

• Adjust engine slow idle speed. (See SLOW IDLE

SPEED ADJUSTMENT on page 3-22.)

• Adjust engine fast idle speed. (See GOVERNOR/

FAST IDLE SPEED ADJUSTMENT on page 3-23.)

M83776

Governor Linkage

Spring

M83777

Spark Plug Lead

Carburetor Gasket

Insulator Gasket

Insulator

3 - 34 12/6/96

REPAIR ENGINE (HONDA GX120)

Disassembly/Assembly

ATTENTION!

DO NOT attempt to repair, replace jets, or adjust

the engine emissions carburetor unless you are

a factory trained technician with authorization

to service CARB/EPA Certified Emissions

Carburetors.

cCAUTION

Gasoline is extremely flammable. DO NOT

smoke. Always work in a ventilated area away

from open flame or spark producing equipment,

this includes equipment that utilizes pilot lights.

M83879

Carburetor Body

Float

Pilot Screw

Main Nozzle

Fuel Valve

Choke Lever

Main Jet

Float Pin

Choke Plate

Sediment Cup

Float Chamber

Float Valve

Gasket

Limiter Cap

Spring

Throttle Stop Screw

Plate

Screw

(2 used)

Spring

Pilot Jet

Packing

Screw

Washer

Drain Screw

12/6/96 3 - 35

ENGINE (HONDA GX120) REPAIR

Clean/Inspect/Rebuild

IMPORTANT: DO NOT clean holes or passages

with small drill bits or wire.

NOTE: If all rubber or plastic parts cannot be removed

for cleaning, use a cleaning solvent with a high

flash point that will not damage these parts

when cleaning.

Leave pilot screw and limiter cap in place

during cleaning. Removal of limiter cap

requires breaking the pilot screw. Remove only

if replacement of screw is required. If

replacement is required, see Pilot Screw and

Limiter Cap Replacement.

1. Remove rubber and plastic parts from carburetor.

Soak all carburetor metal parts in a carburetor

cleaning solution for 1/2 hour maximum.

IMPORTANT: Rinse carburetor parts in warm water

to neutralize corrosive action of cleaner on

aluminum.

2. Rinse carburetor parts in warm water and dry with

compressed air. DO NOT use rag or paper to dry

parts; lint can plug holes and passages in

carburetor.

3. Inspect all parts for wear or damage:

• Inspect the carburetor body for wear or damage.

Verify all sealing surfaces and flanges are smooth

and free of nicks and burrs. Replace as necessary.

cCAUTION

Reduce compressed air to less than 210 kPa (2

bar) (30 psi) when using for cleaning purposes.

Clear area of bystanders, guard against flying

chips, and wear personal protection equipment

including eye protection.

• Inspect inlet needle for wear or damage. The tip

should be smooth, without any grooves, scratches

or tears. If worn or damaged, replace the float

assembly and carburetor body as a set.

• Check float level height. (See Float Level

Adjustment procedure on page 3-36.)

Pilot Screw and Limiter Cap

Replacement

NOTE: Removal of limiter cap requires breaking the

pilot screw. Remove only if replacement of

screw is required.

1. Remove broken pilot screw.

2. Place spring on pilot screw and install screw in

carburetor.

3. Turn pilot crew in (clockwise) until lightly seated,

then turn out (counterclockwise) 1-5/8 turns.

M83880

Good Worn (Replace)

Float Valve

Valve Seat

M83881

Limiter Cap

Pilot Screw

Shear Point

M83882

Limiter Cap

Pilot Screw

Spring

3 - 36 12/6/96

REPAIR ENGINE (HONDA GX120)

IMPORTANT: DO NOT allow the pilot screw to turn

while installing limiter cap.

4. Apply Loctite 660 to inside of limiter cap.

5. Install limiter cap on pilot screw.

Float Level Adjustment

1. Assemble carburetor (minus the float chamber).

2. Place carburetor with engine-side mounting flange

down on a flat, level surface.

3. Measure the distance between the top of the float

and carburetor body with the float valve resting

against the seat as shown. DO NOT compress the

spring. The float height should measure 13.7 mm

(0.54 in.).

4. Replace the float and/or float valve if the

measurement is out of specification.

BLOWER HOUSING ASSEMBLY

Removal/Installation

1. Removal air cleaner assembly. (See AIR CLEANER

ASSEMBLY—Removal/Installation on page 3-30.)

cCAUTION

Gasoline vapor is explosive. DO NOT expose to

spark or flame. Serious personal injury can

result.

M83883

Limiter Cap Stop

M83910

NOTE: Fuel tank capacity is approximately 3.6 L (0.95

qt).

2. Remove drain plug and drain fuel into a properly

marked container.

3. Disconnect fuel line at carburetor.

4. Remove four cap screws.

5. Remove blower housing.

M83747

Drain Plug

M83750

Fuel Line

M83766

Cap Screws

Blower

Housing

12/6/96 3 - 37

ENGINE (HONDA GX120) REPAIR

6. Remove two cap screws.

7. Remove shield.

Installation is done in the reverse order of removal.

RECOIL STARTER

Removal/Installation

1. Remove three cap screws.

2. Remove recoil starter.

Installation is done in the reverse order of removal.

• Remove dirt and debris before installation.

• Position recoil starter for best starter grip location.

Disassembly/Inspection

cCAUTION

Recoil spring is wound under tension. DO NOT

let spring fly loose. Hold spring firmly in place

while replacing. Wear safety glasses and gloves

to protect yourself from possible injury.

M83767

Shield

Cap Screws

M83768

Cap Screws

Cap Screw

1. Hold reel and carefully feed starter rope out until

there is enough slack to untie knot.

2. Remove starter grip.

3. Hold reel and slowly allow the spring to relieve

tension.

4. Loosen reel cover screw and remove reel cover.

5. Remove ratchets and springs.

6. Remove the starter reel and spring from the starter

case.

7. Inspect all parts for wear or damage. Replace parts

as necessary.

M83942

Starter Grip

Knot

Reel

M83943

Reel Cover

Reel Cover Screw

Snap Ring Ratchet (2 used)

Spring (2 used)

M83841

Starter Reel Inner Hook

Starter Case Case Tab

3 - 38 12/6/96

REPAIR ENGINE (HONDA GX120)

Assembly

1. Insert hook on outer side of spring into groove on

inside of reel.

NOTE: Leave approximately 30 cm (12 in.) of rope

outside starter reel.

2. Route starter rope through starter reel and tie as

shown. Wind starter rope around reel in direction

of arrow. Leave approximately 30 cm (12 in.) of

rope outside starter reel.

3. Install starter reel on starter case with spring inner

hook anchored to case tab.

cCAUTION

Recoil spring is wound under tension. DO NOT

let spring fly loose. Hold spring firmly in place

while replacing. Wear safety glasses and gloves

to protect yourself from possible injury.

M83843

Groove Hook

Starter Reel

Recoil Starter Spring

M83842

Starter Rope

Knot

M83841

Starter Reel Inner Hook

Starter Case Case Tab

4. Hold starter case and rotate starter reel two

revolutions in direction of arrow for preliminary

winding.

5. Route starter rope through starter case rope guide

and pull outward.

6. Route starter rope through starter grip and tie as

shown.

7. Install ratchets, springs and reel cover. Install and

tighten reel cover bolt.

8. Check operation of the ratchet by pulling the starter

rope several times.

M83840

M83839

Starter Grip

M83838

Reel Cover

Reel Cover Screw

Snap Ring Ratchet (2 used)

Spring (2 used)

12/6/96 3 - 39

ENGINE (HONDA GX120) REPAIR

IGNITION COIL

Removal/Installation

1. Remove fuel tank. (See FUEL TANK—Removal/

Installation on page 3-27.)

2. Remove blower housing. (See BLOWER

HOUSING—Removal/Installation on page 3-36.)

3. Remove throttle plate assembly. (See THROTTLE

PLATE ASSEMBLY—Removal/Installation on

page 3-32.)

4. Disconnect spark plug lead from spark plug and

remove lead from retainer.

5. Disconnect ground wire.

6. Remove cap screws and ignition coil.

Installation is done in the reverse order of removal.

M83769

Spark Plug Lead

Retainer

M83770

Ignition Coil

Ground Wire

Cap Screws

• Secure ignition wire into ribs on crankcase and

through grommet.

• Adjust air gap. (See Air Gap Adjustment

procedure.)

Air Gap Adjustment

1. Turn flywheel magnet away from ignition coil.

2. Loosen ignition coil mounting cap screws.

3. Insert an 0.4 mm (0.016 in.) feeler gauge between

flywheel and ignition coil.

4. Push ignition coil against flywheel and tighten

mounting cap screws.

5. Turn flywheel to remove feeler gauge.

M83905

Ribs

M83771

0.4 mm (0.016 in.) Gap

Cap Screws

3 - 40 12/6/96

REPAIR ENGINE (HONDA GX120)

Test

Primary Side:

Measure resistance between ignition coil primary

(black) lead and iron coil. Replace ignition coil if

resistance is not within 0.8—1.0 ohms.

Secondary Side:

NOTE: A false reading will be obtained if the spark

plug cap is not removed.

1. Remove spark plug cap.

2. Measure resistance between the end of the spark

plug lead and iron coil. Replace ignition coil if

resistance is not within 5.9—7.1 K ohms.

M83885

Core

Primary (Black) Lead

M83886

Spark Plug Lead

Core

FLYWHEEL

Removal/Installation

1. Remove ignition coil. (See IGNITION COIL—

Removal/Installation on page 3-39.)

2. Remove cap screw and shield.

3. Remove flywheel nut.

4. Remove starter pulley and cooling fan.

IMPORTANT: Use a puller to remove flywheel.

Avoid attaching puller to the magnet sections.

To avoid possible damage, DO NOT hit the

flywheel with a hammer to loosen.

5. Using a puller, remove flywheel and key.

Installation is done in the reverse order of removal.

M83903

Cap Screw

Shield

Cooling Fan

Starter Pulley

Nut

75 N•m (54 lb-ft)

M83906

Flywheel Puller

Magnet Sections

12/6/96 3 - 41

ENGINE (HONDA GX120) REPAIR

• Align lug on starter pulley with hole on flywheel.

• Tighten flywheel nut to 75 N•m (54 lb-ft).

ROCKER ARM COVER

Removal/Installation

1. Remove four cap screws.

2. Disconnect breather tube at air cleaner assembly.

3. Remove rocker arm cover and gasket.

Installation is done in the reverse order of removal.

• Remove gasket material for mating surfaces of

head and rocker arm cover before installation.

• Use new gasket for installation.

M83904

Lug

Hole

M83758

Breather Tube

Cap Screws

Cap Screws Breather Tube

CYLINDER HEAD AND VALVES

Removal/Installation

1. Remove carburetor. (See CARBURETOR—

Removal/Installation on page 3-32.)

2. Remove throttle plate assembly. (See THROTTLE

PLATE ASSEMBLY—Removal/Installation on

page 3-32.)

3. Remove muffler. (See MUFFLER—Removal/

Installation on page 3-28.)

4. Remove blower housing. (See BLOWER

HOUSING—Removal/Installation on page 3-36.)

5. Remove rocker arm cover. (See ROCKER ARM

COVER—Removal/Installation on page 3-41.)

6. Disconnect spark plug lead.

7. Remove rocker arm pivot locknuts and remove

rocker arm pivots and rocker arms.

8. Remove push rods.

IMPORTANT: Loosen cylinder head bolts 1/4 turn

at a time in the sequence shown to avoid

warping the cylinder head.

9. Loosen head bolts in the sequence shown .

10. Remove head bolts, cylinder head and gasket.

11. Disassemble and inspect cylinder head and valves.

(See Inspection procedures on page 3-43.)

M83778

Pivot Lock Nuts

10 N•m (7 lb-ft)

M83780

3 - 42 12/6/96

REPAIR ENGINE (HONDA GX120)

Installation is done in the reverse order of removal.

• Use new gaskets for installation.

IMPORTANT: Torque should be applied in the

sequence shown in increments.

• Tighten cap screws in sequence shown to initial

torque of 12 N•m 8.5 lb-ft). Finish tightening

cylinder head to final torque of 24 N•m (17 lb-ft).

• Adjust valve clearance. (See VALVE CLEARANCE

CHECK AND ADJUSTMENT on page 3-24.)

M83780

Cap Screws

Initial Torque: 12 N•m (8.5 lb-ft)

Final Torque: 24 N•m (17 lb-ft)

Disassembly/Assembly

• Inspect all parts for wear or damage. (See

Inspection procedures.)

IMPORTANT: If valve rotator is not installed,

exhaust valve may drop into cylinder when

engine is started.

• Apply a light coat of clean engine oil to intake and

exhaust valve stems during assembly.

• Tighten rocker arm pivot bolts to 24 N•m (17 lb-ft)

M83844

Valve Rotator

(Exhaust Valve Only)

Valve

Exhaust Valve

Intake Valve

Valve Guide

Cylinder Head

Rocker Arm Pivot Bolt

Spring

(2 used)

24 N•m (17 lb-ft)

Push Rod Guide (2 used)

Retainer

(Exhaust)

Retainer

(Intake)

(2 used)

12/6/96 3 - 43

ENGINE (HONDA GX120) REPAIR

Inspection

Cylinder Head:

1. Remove carbon deposits from combustion chamber

using SCOTCH-BRITE® abrasive pads or an

equivalent.

2. Clean head with a suitable solvent and dry with

compressed air.

3. Inspect head for cracks or broken cooling fins.

4. Inspect gasket surface for burrs and nicks.

5. Use a straight-edge and feeler gauge to check head

for distortion at several points around head.

Replace head if distortion is greater than 0.10 mm

(0.004 in.).

cCAUTION

Reduce compressed air to less than 210 kPa (2

bar) (30 psi) when using for cleaning purposes.

Clear area of bystanders, guard against flying

chips, and wear personal protection equipment

including eye protection.

M83845

Feeler Gauge

Valve Guides:

1. Clean inside of valve guides with a valve guide

cleaner.

2. Measure inside diameter of valve guides. Valve

guides should measure 5.50 mm (0.217 in.).

Replace valve guides if inside diameter is greater

than 5.572 mm (0.2194 in.). (See Valve Guide

Replacement on page 3-44.)

3. Subtract the outside diameter of the valve stems

from inside diameter of valve guides to determine

guide-to-stem clearance.

Intake Guide-to-Stem Clearance

Standard . . . . . 0.02—0.044 mm (0.0008—0.0017 in.)

Wear Limit. . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)

Exhaust Guide-to-Stem Clearance

Standard . . . . . 0.06—0.087 mm (0.0024—0.0034 in.)

Wear Limit. . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)

4. If guide-to-stem clearance exceeds wear limit,

determine if new guides would bring clearance

within specifications. If so, replace guides. (See

Valve Guide Replacement on page 3-44.) If guide-

to-stem clearance would still exceed wear limit,

replace both guides and valves.

Valve Seats:

1. Measure valve seat width. Recondition valve seat if

measurement is less than 0.8 mm (0.03 in.) or

greater than 2.0 mm (0.08 in.).

M83846

M83847

3 - 44 12/6/96

REPAIR ENGINE (HONDA GX120)

Valve Springs:

1. Inspect springs for pitting, rust and burrs. Replace if

necessary.

2. Measure spring free length. Replace spring if

measurement is less than 29.5 mm (1.16 in.).

Intake and Exhaust Valves:

1. Remove carbon from valve head, face and stem

with a power-operated wire brush. Be sure carbon

is removed, not merely burnished.

2. Inspect valve head, face and stem for defects.

Replace if necessary.

3. Measure outside diameter of intake valve stem.

Replace if diameter is less than 5.318 mm (0.2094

in.).

4. Measure outside diameter of exhaust valve stem.

Replace if diameter is less than 5.275 mm (0.2077

in.).

5. Replace warped valves or valves with less than

0.60 mm (0.024 in.) margin. Valve stem ends

should be ground square before checking valve-to-

tappet clearance.

M50036

M53961

M38087

Valve

Face

Margin

Valve Stem End

6. Check valve stem for bends using V-blocks and a

dial indicator. Turn valve slowly and read variation

on indicator. Replace valve if variation is greater

than 0.03 mm (0.001 in.).

Valve Guide Replacement

1. Disassemble and throughly clean the cylinder head.

(See Disassembly/Assembly procedures on page

3-42.)

2. Chill the replacement valve guides in a freezer for

about one hour prior to installation.

IMPORTANT: DO NOT heat cylinder head over

150°C (300°F). Excessive heat may loosen valve

seats.

3. Using an oven, heat cylinder head to 150° C

(300° F).

4. Remove cylinder head from oven and place on

wood blocks with combustion chamber side up.

5. Using a JDG504 5.5 mm Valve Guide Driver, drive

valve guides out from combustion chamber side.

cCAUTION

To prevent possible burns, use heavy gloves

when handling hot cylinder head.

M51753

M83931

JDG504

5.5 mm Valve

Guide Driver

12/6/96 3 - 45

ENGINE (HONDA GX120) REPAIR

6. Flip the cylinder head over (combustion chamber

side down) and place on a flat, firm surface.

7. Remove valve guides from freezer as needed.

8. Install valve guides using a JDG504 Valve Guide

Driver:

• Exhaust guide is correctly installed when clip is fully

seated against cylinder head casting.

• Intake guide is correctly installed when the top of

valve guide is 3.0 mm (0.12 in.) from the cylinder

head casting.

IMPORTANT: Allow the cylinder head to cool to

room temperature before reaming valve guides.

9. Coat JDG1023 5.5 mm Valve Guide Reamer and

valve guides with Stanisol or kerosene lubricant.

10. Rotate reamer clockwise through the valve guide.

Continue rotating reamer while removing it from

the valve guide.

M83929

JDG504

Exhaust

Clip

Valve Guide Driver

Intake

3.0 mm (0.12 in.)

M83930

JDG1023

5.5 mm Valve Guide Reamer

11. Thoroughly clean cylinder head to remove any

cutting residue.

12. Inspect valve guide bore; it should be straight,

round and centered in the valve guide.

13. Insert valve and check operation. Valve should

move smoothly in guide. If valve does not move

smoothly, the guide may have been damaged

during installation. Replace valve guide if

necessary.

14. Recheck valve-to-guide clearance. (See

CYLINDER HEAD—Inspection on page 3-43.)

ANALYZE VALVES

Lead deposits on the intake valve are caused by

exhaust gas leakage past the valve. This indicates that

the valve is not seating properly.

IMPORTANT: DO NOT grind the exhaust valve or

life will be shortened.

Lap the valves after resurfacing the seat to correct this

condition.

NOTE: Be sure to reset valve-to-tappet clearance after

grinding valve seats.

M83914

Not Acceptable

Acceptable

M29934

Lead Deposits

3 - 46 12/6/96

REPAIR ENGINE (HONDA GX120)

Valve stem corrosion is caused by moisture in the

engine. Moisture in the fuel/air mixture can condense

inside the engine when the engine is stopped and

cools down.

Valve corrosion can also occur during storage. Fogging

or pouring oil in the combustion chamber before storing

helps prevent valve corrosion.

Corroded or pitted valves collect deposits and may

cause sticking valves. Replace badly corroded or pitted

valves.

Exhaust valves are designed to function in temperature

exceeding 2760°C (5000°F). However, when operating

at high temperatures for long periods of time, valve

burning may occur. Valves running too hot will show a

dark discoloration of the valve stem into the area

protected by the valve guide. Another indication is

distortion of the valve margin and valve face. Valve seat

inserts may also begin to burn away.

Other causes for valves running hot are worn valve

guides or valve springs, incorrect valve clearance, lean

fuel-air mixture, and incorrect or overheated spark

plug.

M5563

Valve Stem

Corrosion

M30024

Valve Margin

Valve Face

Using old or stale gasoline is a common cause for

sticky valves.

This gummy deposit can be seen on the valve. When

this condition exists, the carburetor may also contain

gummy deposits and will require cleaning.

Always use fresh gasoline and drain fuel tank, lines and

carburetor before storing machine.

RECONDITION VALVE SEATS

1. Throughly clean the combustion chamber and valve

seats to remove carbon deposits.

2. Inspect valve seats for damage. If seats are loose,

warped or distorted beyond reconditioning,

replace cylinder head. Pitted or worn seats can be

refaced using a seat cutter.

3. Apply a light coat of Prussian Blue or erasable felt-

tipped marker ink to valve face.

4. Insert valve, and snap it closed against seat several

times, DO NOT rotate valve. Transferred marking

compound will show any area that is not

concentric.

IMPORTANT: Turn cutter clockwise, DO NOT turn

counterclockwise. Continue to turn cutter as

you lift it off the valve seat.

5. To recondition seat, cut at a 45° angle to clean up

seat.

M29936

Gummy (Sticky)

Deposits

M83849

12/6/96 3 - 47

ENGINE (HONDA GX120) REPAIR

6. Use 30° or 60° cutters to narrow and adjust valve

seats so that valve makes contact with the middle

of the valve face.

• Use 30° cutter to remove material from top edge of

seat (contact too high).

• Use 60° cutter to remove material from bottom

edge of seat (contact too low).

7. Check valve seat width. If necessary, use a 45°

cutter to adjust seat width.

LAP VALVES

If valve seat does not make proper contact, lap the

valve into the seat:

1. Apply a small amount of fine lapping compound to

face of valve.

2. Grip head of valve with a vacuum cup tool and turn

valve to lap valve to seat.

3. Lift valve from seat every 8 to 10 strokes. Lap until a

uniform ring appears around the surface of the

valve face.

4. Wash all parts in solvent to remove lapping

compound. Dry parts.

5. Check position of lap mark on valve face. Lap mark

must be on or near the center of valve face.

M83916

Contact Too High

Contact Too Low

M83848

Valve Lapping Tool

REDUCTION ASSEMBLY

Removal/Installation

NOTE: Crankcase capacity is approximately 0.6 L

(0.63 qt).

1. Remove drain plug and drain crankcase.

2. Remove caps screws, cover and gasket.

NOTE: Thrust washer may stick to cover.

3. Remove thrust washer from PTO shaft. Note

orientation for assembly.

4. Hold flywheel with a strap wrench and remove cap

screw and washer.

5. Remove drive sprocket, PTO shaft and chain as a

unit.

NOTE: If chain is worn or damaged and must be

replaced, replace drive sprocket, PTO shaft

and chain as a set.

6. Inspect all parts for wear or damage. Replace as

necessary.

M83779

Cap Screws

M83781

Cap Screw

3 - 48 12/6/96

REPAIR ENGINE (HONDA GX120)

7. Inspect ball bearing. Replace as necessary. (See

Bearing/Oil Seal Replacement procedure.)

8. Replace seal. (See Bearing/Oil Seal Replacement

procedure.)

Installation is done in the reverse order of removal.

• Remove gasket material from mating surfaces

before installation.

• Use new gaskets for installation.

• Install thrust washer on PTO shaft with bevel facing

ball bearing.

Bearing/Oil Seal Replacement

1. Remove reduction assembly cover. (See

REDUCTION ASSEMBLY—Removal/Installation

on page 3-47.)

Bearing:

1. Spin bearing by hand and check for axial and/or

radial free play. Replace bearing if it has excessive

play or is noisy.

NOTE: Remove bearing only if replacement is

required.

2. Remove oil seal.

M83907

Cover

Seal

Ball Bearing

M38073

Radial

Axial

Free

Play

Free

Play

3. Remove bearing using a driver set.

4. Apply a light coat of clean engine oil to bearing

outer race.

5. Install bearing using a driver set until fully seated

against housing.

6. Install new oil seal.

Oil Seal:

7. Remove worn or damaged seal using a screwdriver.

8. Pack lithium-based grease inside lips of seal.

9. Install seal with lip toward inside of cover using a

seal driver set.

CRANKCASE COVER

Removal/Installation

NOTE: Crankcase capacity is approximately 0.6 L

(0.63 qt).

1. Remove drain plug and drain crankcase.

2. Remove reduction assembly. (See REDUCTION

ASSEMBLY—Removal/Installation on page 3-47.)

3. Remove alignment pins.

4. Remove seven cap screws.

Installation is done in the reverse order of removal.

• Remove gasket material from mating surfaces

before installation.

• Use new gaskets for installation.

• Tighten cap screws to 12 N•m (9 lb-ft).

M83783

Cap Screws

Alignment Pins

12/6/96 3 - 49

ENGINE (HONDA GX120) REPAIR

Bearing Inspection/Replacement

1. Spin bearing by hand and check for axial and/or

radial free play. Replace bearing if it has excessive

play or is noisy.

NOTE: Remove bearing only if replacement is

required.

2. Drive bearing out from reduction cover side using a

driver set.

3. Apply a light coat of clean engine oil to bearing

outer race.

4. Install bearing using driver set until fully seated

against housing.

CAMSHAFT AND TAPPETS

Removal/Installation

1. Remove cylinder head. (See CYLINDER HEAD—

Removal/Installation on page 3-41.)

2. Remove crankcase cover. (See CRANKCASE

COVER—Removal/Installation on page 3-48.)

M38073

Radial

Axial

Free

Play

Free

Play

M83918

Bearing

3. Rotate camshaft until timing marks align.

4. Remove and inspect camshaft. (See Inspection

procedures.)

IMPORTANT: Tappets must be install in the same

bores from which they were removed.

5. Mark each tappet to aid in installation.

6. Remove and inspect tappets for wear or damage.

Replace if necessary.

Installation is done in the reverse order of removal.

• Apply a light coat of clean engine oil to tappets and

bores and install tappets in original bores.

• Apply a light coat of clean engine oil to camshaft

lobes and journals.

• Align timing marks when installing camshaft.

M83821

Timing Marks

M83822

Tappets

3 - 50 12/6/96

REPAIR ENGINE (HONDA GX120)

Inspection

1. Inspect camshaft for wear or damage. Replace if

necessary.

2. Measure cam intake lobe height. Replace camshaft

if lobe height is less than 27.45 mm (1.081 in.).

3. Measure cam exhaust lobe height. Replace

camshaft if lobe height is less than 27.75 mm

(1.083 in.).

4. Measure flywheel side journal and PTO side journal

diameter. Replace camshaft if either journal

diameter is less than 13.916 mm (0.5479 in.).

5. Measure inside diameter of camshaft holder in

crankcase cover. Replace crankcase cover if

diameter is greater than 14.048 mm (0.5531 in.).

M83887

M83888

M83889

6. Measure inside diameter of camshaft holder in

block. Replace block if diameter is greater than

14.048 mm (0.5531 in.).

PISTON AND CONNECTING ROD

Removal

1. Remove camshaft and tappets. (See CAMSHAFT

AND TAPPETS—Removal/Installation on page 3-

49.)

2. Check cylinder bore for carbon and varnish ridges.

These ridges can cause piston damage if not

removed.

3. If necessary, remove ridge from top of cylinder bore

using a ridge reamer.

4. Turn crankshaft to expose connecting rod end cap.

5. Remove cap screws and connecting rod cap.

6. Push piston and connecting rod assembly from

cylinder bore.

7. Disassemble and inspect all parts for wear or

damage. (See Disassembly and Inspection

procedures on page 3-51.)

M83825

Camshaft Holder

M83823

Cap Screws

12/6/96 3 - 51

ENGINE (HONDA GX120) REPAIR

Installation

1. Deglaze cylinder bore. (See CYLINDER BLOCK—

Deglaze Cylinder Bore on page 3-60.)

2. Stagger piston ring end gaps 180° apart, but do not

align with oil ring side rail end gaps.

3. Apply a light coat of clean engine oil to piston and

rings. Compress rings with a ring compressor.

4. Apply a light coat of clean engine oil to cylinder

bore, connecting rod bearing surface and ring

compressor.

5. Install piston and connecting rod assembly in

cylinder bore with triangle mark on piston facing

the push rod opening.

6. Install connecting rod cap with dipper toward

camshaft and ribs on cap and connecting rod

aligned. Tighten cap screws to 12 N•m (9 lb-ft).

7. Install camshaft and tappets, crankcase cover and

cylinder head.

M83824

Push Rod Opening

Triangle Mark

M83823

Cap Screws

12 N•m (9 lb-ft)

Disassembly

• Analyze piston and piston ring wear. (See

ANALYZE PISTON RING WEAR on page 3-55 and

ANALYZE PISTON WEAR on page 3-57.)

• Remove piston rings using a piston ring expander.

IMPORTANT: DO NOT reuse piston pin retaining

rings. Always use new retaining rings for

assembly.

• Inspect all parts for wear or damage. (See

Inspection procedures.)

M83890

1st Compression Ring

2nd Compression Ring

Oil Control Ring

Piston

Piston Pin

Retaining Ring Connecting

(2 used) Rod

3 - 52 12/6/96

REPAIR ENGINE (HONDA GX120)

Assembly

IMPORTANT: DO NOT reuse piston pin retaining

rings.

1. Install connecting rod to piston with long end of

connecting rod toward triangle mark on piston.

2. Apply a light coat of clean engine oil to piston pin

and connecting rod bearing.

3. Install piston pin.

IMPORTANT: DO NOT align retaining ring gap with

cutout in piston pin bore.

4. Install retaining rings by inserting one end in

groove, and holding other end with a needle-nosed

pliers, rotate the ring into place.

M83830

Triangle Mark

Piston

Connecting Rod

Piston Pin

M83891

Retaining Ring

Cutout

5. Before installing rings on piston, check ring end gap

in cylinder bore. (See Check Piston Ring End Gap

on page 3-55.)

IMPORTANT: Install all rings with marking facing

up.

Be sure that top and second compression rings

are not interchanged.

DO NOT align any piston ring end gaps with

piston pin bore.

NOTE: Rings should rotate freely in grooves after

installation.

M83892

M83850

1st Compression Ring

Oil Control Ring

2nd

(Chrome Plated)

Compression

Ring

12/6/96 3 - 53

ENGINE (HONDA GX120) REPAIR

6. Install oil control and compression rings:

• Install oil control ring in bottom groove with mark

facing up. Position end gap approximately 45°

away from triangle mark.

• Install 2nd compression ring in middle grove with

mark facing up. Position end gap approximately

120° away from end gap of oil control ring.

• Install 1st compression ring in top grove with mark

facing up. Position end gap approximately 120°

away from end gap of 2nd compression ring.

Inspection

Piston:

IMPORTANT: DO NOT use a caustic cleaning

solution or a wire brush to clean piston.

1. Remove all deposits from piston.

2. Clean carbon deposits from piston ring grooves with

a ring groove cleaner. If cleaning tool is not

available, break an old ring and use it to carefully

clean groove.

3. Check that all oil return passages in grooves are

open.

4. Inspect piston for scoring or fractures. Replace

piston if damaged.

5. Measure 1st and 2nd compression ring thickness.

Replace rings if measurement is less than 1.37

mm (0.054 in.).

M29946

Ring Groove Cleaner

M83893

6. Measure oil control ring thickness. Replace ring if

measurement is less than 2.37 mm (0.093 in.).

7. Using new rings, check piston ring-to-groove

clearance at several points around piston. Replace

piston if any clearance is greater than 0.15 mm

(0.006 in.).

8. Measure piston outside diameter at a point 10 mm

(0.4 in.) from the bottom of the skirt and 90° to the

piston pin bore. Replace piston if outside diameter

measures less than specifications.

NOTE: If the engine has had a previous major

overhaul, an oversized piston may have been

installed. Pistons and rings are available in

0.25 mm (0.010 in.) and 0.50 mm (0.020 in.)

oversize.

Piston O.D. Specifications (Wear Limit):

Standard Piston . . . . . . . . . . 59.845 mm (2.3561 in.)

0.25 mm (0.010 in.)

Oversize Piston . . . . . . . . . . 60.095 mm (2.3661 in.)

0.50 mm (0.020 in.)

Oversize Piston . . . . . . . . . . 60.345 mm (2.3761 in.)

9. Measure cylinder bore diameter. (See CYLINDER

BLOCK—Inspection on page 3-59.)

10. Subtract piston outside diameter measurement

from cylinder bore measurement to determine

piston-to-cylinder bore clearance.

11. Replace piston and/or rebore cylinder block if

clearance is greater than 0.12 mm (0.005 in.).

(See CYLINDER BLOCK—Rebore Cylinder Bore

on page 3-60.)

M83894

M83895

10 mm (0.4 in.)

3 - 54 12/6/96

REPAIR ENGINE (HONDA GX120)

12. Measure piston pin bore diameter in piston.

Replace piston if measurement is greater than

13.048 mm (0.5137 in.).

13. Measure piston pin diameter at six places. Replace

pin if any measurement is less than 12.954 mm

(0.5100 in.).

14. Subtract piston pin outside diameter measurement

from piston pin bore measurement to determine

piston pin-to-bore clearance. Replace piston pin

and/or piston if clearance is greater than 0.08 mm

(0.003 in.).

Connecting Rod:

1. Analyze crankshaft and connecting rod wear. (See

ANALYZE CRANKSHAFT AND CONNECTING

ROD WEAR on page 3-59.)

2. Clean and inspect connecting rod. Replace if

scored or damaged.

M80427

M82050A

Measuring Positions

3. Measure connecting rod piston pin bore. Replace

connecting rod if measurement is greater than

13.07 mm (0.515 in.).

NOTE: If the engine has had a previous major

overhaul, an undersized connecting rod may

have been installed. A 0.25 mm (0.010 in.)

undersize connecting rod is available.

4. Install connecting rod cap. Tighten cap screws to 12

N•m (9 lb-ft).

5. Measure connecting rod crankshaft bearing.

Replace connecting rod if measurement is greater

than specifications.

Crankshaft Bearing Diameter

Specifications (Wear Limit):

Standard Crankshaft . . . . . . 26.066 mm (1.0262 in.)

0.25 mm (0.010 mm)

Undersize Crankshaft . . . . . 25.816 mm (1.0164 in.)

M83896

M83897

12/6/96 3 - 55

ENGINE (HONDA GX120) REPAIR

Check Connecting Rod Side Play

1. Remove crankshaft from cylinder block. (See

CRANKSHAFT—Removal/Installation on page 3-

58.)

2. Install connecting rod on crankshaft. Tighten

connecting rod cap screws to 12 N•m (9 lb-ft).

3. Measure connecting rod side clearance. Replace

connecting rod and/or crankshaft if clearance is

greater than 1.1 mm (0.043 in.).

Check Connecting Rod-to-

Crankshaft Clearance

1. Remove crankshaft from cylinder block. (See

CRANKSHAFT—Removal/Installation on page 3-

58.)

2. Clean all oil from crankshaft journal and connecting

rod bearing surfaces.

NOTE: DO NOT rotate crankshaft while Plastigauge is

in place.

3. Place a piece of Plastigauge® on the crankshaft

journal, and install connecting rod and cap.

Tighten connecting rod cap screws to 12 N•m (9

lb-ft).

M83898

M83899

Cap Screws

12 N•m (9 lb-ft)

NOTE: If the engine has had a previous major

overhaul, an undersized connecting rod may

have been installed. A 0.25 mm (0.010 in.)

undersize connecting rod is available.

4. Remove cap and measure Plastigauge®. If

clearance is greater than 0.12 mm (0.005 in.),

replace connecting rod and recheck clearance.

5. If after replacing connecting rod clearance is still

beyond specifications, replace crankshaft.

Check Piston Ring End Gap

1. Install each ring squarely in bore approximately

25.4 (1.00 in.) down from top of cylinder.

2. Measure end gap. Replace rings if end gap is

greater than 1.0 mm (0.04 in.).

ANALYZE PISTON RING WEAR

Rings of the wrong size or rings having improper end

gaps will not conform to the shape of the cylinder. This

results in high oil consumption and excessive blow-by.

Ring end gaps should be staggered on the piston

during installation. (See PISTON AND CONNECTING

ROD on page 3-50.) End gaps in alignment can also

cause oil consumption and blow-by.

M83900

Plastigauge

Scale

M83892

3 - 56 12/6/96

REPAIR ENGINE (HONDA GX120)

Light scuffing or scoring of both rings and piston occurs

when unusually high friction and combustion

temperatures approach the melting point of the piston.

When this condition exists, it is due to one or more of

the following probable causes:

• Dirty cooling shroud and cylinder head.

• Lack of cylinder lubrication.

• Improper combustion.

• Wrong bearing or piston clearance.

• Too much oil in crankcase causing fluid friction.

The engine operating at abnormally high temperature

may cause varnish, lacquer or carbon deposits to form

in the piston ring grooves making the piston rings stick.

When this happens, excessive oil consumption and

blow-by will occur.

Engine overheating and ring sticking is usually caused

by one or more of the following:

• Overloading.

• Incorrect ignition timing.

• Lean fuel mixture.

• Dirty cooling fins.

• Incorrect oil.

• Low oil supply.

• Stale fuel.

M29943

Scuffing/Scoring

M29944

Carbon Deposits

Vertical scratches across the piston rings are due to an

abrasive in the engine. Abrasives may be airborne, may

have been left in the engine during overhaul, or may be

loose lead or carbon deposits.

When this condition exists, check for one or more of the

following:

• Damaged, collapsed or improperly installed air

filter.

• Loose connection or damaged basket between air

cleaner and carburetor.

• Air leak around carburetor-to-cylinder head gasket.

• Air leak around throttle shaft.

• Failure to properly clean cylinder bore after

reconditioning engine.

Abrasive particles in engine oil cause scratches on side

rails of oil control ring. Inner spacer wear or distortion

may cause:

• High oil consumption.

• Increased deposits in combustion chamber.

• Sticking compression rings.

Increased oil consumption may be caused by:

• Worn side rails with low tension.

• Worn or distorted inner spacer.

M29945

Vertical Scratches

M38101

Spacer Side Rails

12/6/96 3 - 57

ENGINE (HONDA GX120) REPAIR

ANALYZE PISTON WEAR

Detonation is abnormal combustion causing excessive

temperature and pressure in the combustion chamber.

Commonly called knock, spark knock or timing knock,

detonation occurs as the compressed fuel-air mixture

ignites spontaneously to interrupt the normal ignition.

The following is a list of possible causes for detonation.

• Pre-ignition.

• Lean fuel mixture.

• Low octane fuel.

• Advanced ignition timing.

• Engine lugging.

• Build-up of carbon deposits on piston or cylinder

head, causing excessive compression.

• Wrong cylinder head or milling of head increasing

compression ratio.

Pre-ignition is the igniting of the fuel-air mixture prior to

regular ignition spark. Pre-ignition causes shock,

resulting in pings, vibration, detonation and power loss.

Severe damage to piston, rings and valves results from

pre-ignition.

Check the following for causes of pre-ignition:

• Internal carbon deposits.

• Incorrect spark plug (high heat range).

• Broken ceramic in spark plug.

• Sharp edges on valves.

• Sharp edges in combustion chamber.

M29947

M30039

Pre-Ignition Damage

Check rod and piston alignment when piston shows a

diagonal wear pattern extending across the skirt of the

piston. Contact with the cylinder wall show on the

bottom of the skirt at left and at the ring lands at the

right.

A cylinder bored at an angle to the crankshaft can also

cause improper ring contact with the cylinder.

This condition causes:

• Rapid piston wear.

• Uneven piston wear.

• Excess oil consumption.

A broken retaining ring caused the damage shown.

Retaining rings loosen or break due to:

• Rod misalignment.

• Excessive crankshaft end play.

• Crankshaft journal taper.

• Weak retaining rings.

• Incorrectly installed retaining rings.

Inertia can cause a broken retaining ring to beat out the

piston and cylinder, causing extensive damage.

M29948

Diagonal

Wear Pattern

M29949

Retaining Ring

Failure Damage

3 - 58 12/6/96

REPAIR ENGINE (HONDA GX120)

CRANKSHAFT

Removal/Installation

1. Remove flywheel. (See FLYWHEEL—Removal/

Installation on page 3-40.)

1. Remove camshaft. (See CAMSHAFT AND

TAPPETS—Removal/Installation on page 3-49.)

2. Remove piston and connecting rod. (See PISTON

AND CONNECTING ROD—Removal on page 3-

50.)

3. Remove crankshaft.

4. Inspect ball bearing in cylinder block. (See

CYLINDER BLOCK—Bearing Inspection/

Replacement on page 3-60.)

5. Inspect crankshaft for wear or damage. (See

Inspection procedure.)

Inspection

1. Analyze crankshaft and connecting rod wear. (See

ANALYZE CRANKSHAFT AND CONNECTING

ROD WEAR on page 3-59).

2. Measure connecting rod journal. Replace

crankshaft if journal diameter is less than 25.92

mm (1.020 in.)

3. Check Connecting Rod-to-Crankshaft Clearance.

(See Check Connecting Rod-to-Crankshaft

Clearance on page 3-55.)

4. Check Connecting Rod Side Play. (See Check

Connecting Rod Side Play on page 3-55.)

M83919

Crankshaft

M83920

5. Inspect timing and governor drive gears for wear or

damage. Replace if necessary. (See Timing/

Governor Gear Replacement procedure.)

Timing/Governor Gear Replacement

NOTE: The removal/installation procedure is identical

for both the timing and governor gears.

1. Mark a reference line on the timing/governor gear

and crankshaft.

2. Using a knife-edged puller, press the gear off the

crankshaft.

3. Using the old gear as a reference, mark the new

gear in the same position as the old gear.

4. Support the crankshaft as shown.

5. Place the gear on the crankshaft and align the

marks on the gear and crankshaft.

6. Using driver, press gear on crankshaft until fully

seated.

M83921

Knife-Edge Puller

M83922

Crankshaft

Gear

12/6/96 3 - 59

ENGINE (HONDA GX120) REPAIR

ANALYZE CRANKSHAFT AND

CONNECTING ROD WEAR

Check connecting rod and cap for damage or unusual

wear patterns.

Lack of lubrication or improper lubrication can cause

the connecting rod and cap to seize the crankshaft, the

connecting rod and piston may both break causing

other internal damage. Inspect block carefully before

rebuilding engine.

Crankshaft and connecting rod damage can also result

from:

• Engine run low on oil or without oil.

• Oil not changed regularly.

• Bearing cap installed incorrectly.

CYLINDER BLOCK

Inspection

1. Clean block and check for cracks.

NOTE: Cracks not visible to the eye may be detected

by coating the suspected area with a mixture of

25% kerosene and 75% light engine oil. Wipe

area dry and immediately apply coating of zinc

oxide dissolved in wood alcohol. If crack is

present, coating becomes discolored at the

defective area. Replace block if any cracks are

found.

A bare block is available for service.

2. Measure cylinder bore diameter at three positions;

top, middle and bottom. At these three positions,

measure in both directions; along the crankshaft

centerline and in the direction of crankshaft

rotation.

NOTE: If the engine has had a previous major

overhaul, oversize pistons and rings may have

been installed. Pistons are available in 0.25

mm (0.010 in.) and 0.50 mm (0.020 in.)

oversize.

Cylinder Bore I.D.:

Standard Piston

Standard . . . . . . . . . . . . . . . . . . . . 60.0 mm (2.36 in.)

Wear Limit. . . . . . . . . . . . . . . 60.165 mm (2.3687 in.)

0.25 mm (0.010 in.) Oversize Piston

Standard . . . . . . . . . . . . . . . . . . . 60.25 mm (2.37 in.)

Wear Limit. . . . . . . . . . . . . . . 60.415 mm (2.3787 in.)

0.50 mm (0.020 in.) Oversize Piston

Standard . . . . . . . . . . . . . . . . . . . . 60.5 mm (2.41 in.)

Wear Limit. . . . . . . . . . . . . . . . 60.665 mm (2.3887 in)

M82411A

Top

Middle

Bottom

Crankshaft

Rotation

Crankshaft

Centerline

3 - 60 12/6/96

REPAIR ENGINE (HONDA GX120)

Bearing Inspection/Replacement

1. Spin bearing by hand and check for axial and/or

radial free play. Replace bearing if it has excessive

play or is noisy.

NOTE: Remove bearing only if replacement is

required.

2. Remove oil seal.

3. Remove bearing using a driver set.

4. Apply a light coat of clean engine oil to bearing

outer race.

5. Install bearing using driver set until fully seated

against crankcase casting.

6. Install new oil seal

M83865

Ball Bearing

M38073

Radial

Axial

Free

Play

Free

Play

Oil Seal Replacement

7. Remove worn or damaged oil seal using a

screwdriver.

8. Pack lithium-based grease inside lips of seal.

9. Install seal with lip toward inside of crankcase using

a seal driver set.

Deglaze Cylinder Bore

1. Deglaze cylinder bore using a rigid hone with a 220

to 300 grit stone.

2. Use hone as instructed by manufacturer to obtain a

45° crosshatch pattern.

IMPORTANT: DO NOT use gasoline, kerosene or

commercial solvents to clean cylinder bore.

Solvents will not remove all abrasives from

cylinder walls.

3. Clean cylinder walls using clean white rags and

warm soapy water. Continue to clean cylinder until

white rags show no discoloration.

4. Dry cylinder and apply a light coat of clean engine

oil.

Rebore Cylinder Block

IMPORTANT: Check stone for wear or damage. Use

correct stone for the job.

NOTE: The cylinder can be rebored to use 0.25 mm

(0.010 in.), and 0.50 mm (0.020 in.) oversize

piston and rings. Have a reliable repair shop

rebore the block, or use a drill press and

honing tool.

Rebore cylinder with a honing tool to initial and

final bore specifications.

M83864

Oil Seal

12/6/96 3 - 61

ENGINE (HONDA GX120) REPAIR

1. Align center of bore to drill press center.

2. Lower and raise hone until end extends 20—25 mm

(0.75—1.0 in.) past end of cylinder.

3. Adjust hone stones until they contact the narrowest

point of the cylinder walls.

4. Coat the inside of cylinder with honing oil. Turn

hone by hand. Adjust if too tight.

5. Run drill press between 200—250 rpm. Move hone

up and down in cylinder approximately 20 times

per minute.

NOTE: Measure bore when cylinder is cool.

6. Stop press and check cylinder diameter.

NOTE: Finish should not be smooth. It should have a

°—

cross-hatch pattern.

7. Check bore for size, taper and out of round.

8. If cylinder bore exceeds wear limit, rebore cylinder

or replace block.

9. Hone the cylinder an additional 0.007—0.009 mm

(0.0003—0.0004 in.) for final bore specifications.

This allows for 0.020 mm (0.0008 in.) shrinkage

when cylinder cools.

IMPORTANT: DO NOT use gasoline, kerosene or

commercial solvents to clean cylinder bore.

Solvents will not remove all abrasives from

cylinder walls.

10. Clean cylinder walls using clean white rags and

warm soapy water. Continue to clean cylinder until

white rags show no discoloration.

11. Dry cylinder and apply a light coat of clean engine

oil.

M82412A

40°—60°

GOVERNOR

Removal/Installation

1. Remove crankshaft. (See CRANKSHAFT—

Removal/Installation on page 3-58.)

2. Remove governor return spring.

3. Remove linkage and spring.

4. Remove nut and screw.

5. Remove governor arm and washer.

6. Remove clip, governor arm shaft and washer.

M83902

Governor Return Spring

Spring

Linkage

M83826

Cap Screw

Washer

Cap Screw

Arm

Nut

M83829

Clip

Shaft

Washer

3 - 62 12/6/96

REPAIR ENGINE (HONDA GX120)

7. Spread governor weights and remove slider.

8. Remove washer.

9. Remove clip and governor weight holder.

10. Remove washer.

11. Remove pins and weights if necessary.

12. Inspect all parts for wear or damage. Replace parts

as needed.

Installation is done in the reverse order of removal.

• Check to make sure governor weights move freely.

• Insert clip firmly into shaft groove.

• Check to make sure slider moves freely

• Position shaft over governor slider, and install clip

with straight side of clip against the groove in shaft.

M83828

Slider

Weight Pin

Clip

Washer

Weights

Weight

Holder (2 used)

(2 used)

M83827

Clip

• Install governor spring in hole marked “1”.

• Adjust governor. (See GOVERNOR/FAST IDLE

SPEED ADJUSTMENT on page 3-23.)

M83902

Governor Return Spring

Spring

Linkage

ELECTRICAL CONTENTS

Page

CONTENTS

12/9/96 4 - 1

ELECTRICAL

THEORY AND DIAGNOSTIC INFORMATION

THEORY OF OPERATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

DIAGNOSISTIC INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

WIRE COLOR ABBREVIATION CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

READING ELECTRICAL SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

WIRING HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

TROUBLESHOOTING CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

CIRCUIT OPERATION AND DIAGNOSIS

IGNITION CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

IGNITION CIRCUIT OPERATION—ENGINE SHUTTING OFF . . . . . . . . . . . . . . 4-10

IGNITION CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

TESTS

COMMON CIRTCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

FLYWHEEL MAGNET TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

RUN/OFF SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4 - 2 12/9/96

THEORY AND DIAGNOSTIC INFORMATION ELECTRICAL

THEORY AND DIAGNOSTIC

INFORMATION

THEORY OF OPERATION

INFORMATION

The theory of operation stories divide the electrical

system into individual circuits by function. Each circuit

is isolated from the main wiring schematic and only

shows the components that are used in it. The story

contains information on function, operating conditions,

and theory of operation. The circuit schematics are

drawn with the components in the operating position,

with the power, or battery positive, into them across the

top and the ground, or battery negative, across the

bottom.

DIAGNOSTIC INFORMATION

The diagnostic procedures is used to test the complete

circuit regardless of the problem or complaint. Select a

symptom or system from the quick check or

troubleshooting chart and follow the test procedures

under that heading.

The diagnostic procedure lists:

• Test conditions

• Test sequence

• Test location

• Normal reading

• Check or test to perform if reading is not normal

When performing the test or check, be sure to set your

machine up to the test conditions listed and follow the

sequence carefully. The middle “NORMAL” column

gives the reading or condition that should be obtained

when performing the test or check. If the results of the

test or check are not normal, perform the test, check, or

adjustment listed in the third “IF NOT NORMAL”

column to repair the malfunction. The detailed tests or

adjustments referred to in the “IF NOT NORMAL”

column are located at the end of that group. The

system diagram that accompanies each test procedure

is drawn to resemble machine components. The key

number on the art matches the number in the “TEST

LOCATION” column and the leader line points to the

exact point the test is to be made.

WIRE COLOR ABBREVIATION

CHART

Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Black

Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue

Brn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown

Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green

Gry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gray

Org . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange

Pnk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pink

Pur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple

Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red

Tan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tan

Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .White

Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow

Blk/Wht. . . . . . . . . . . . . . . . . . . . . . . . . .Black/White

Blu/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . Blue/White

Brn/Wht . . . . . . . . . . . . . . . . . . . . . . . . Brown/White

Brn/Yel . . . . . . . . . . . . . . . . . . . . . . . . Brown/Yellow

Dk Blu. . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Blue

Dk Brn/Lt Grn . . . . . . . . . . Dark Brown/Light Green

Dk Brn/Red. . . . . . . . . . . . . . . . . . Dark Brown/Red

Dk Brn/Yel . . . . . . . . . . . . . . . . . Dark Brown/Yellow

Dk Grn . . . . . . . . . . . . . . . . . . . . . . . . . Dark Green

Lt Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Blue

Lt Grn . . . . . . . . . . . . . . . . . . . . . . . . . . Light Green

Org/Wht . . . . . . . . . . . . . . . . . . . . . . . Orange/White

Pnk/Blk. . . . . . . . . . . . . . . . . . . . . . . . . . Pink/Black

Pur/Wht . . . . . . . . . . . . . . . . . . . . . . . . Purple/White

Red/Blk. . . . . . . . . . . . . . . . . . . . . . . . . . . Red/Black

Red/Wht . . . . . . . . . . . . . . . . . . . . . . . . . .Red/White

Wht/Blk. . . . . . . . . . . . . . . . . . . . . . . . . .White/Black

Wht/Red . . . . . . . . . . . . . . . . . . . . . . . . . .White/Red

Yel/Blk . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Black

Yel/Red. . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Red

Yel/Wht. . . . . . . . . . . . . . . . . . . . . . . . . Yellow/White

12/9/96 4 - 3

ELECTRICAL READING ELECTRICAL SCHEMATICS

READING ELECTRICAL

SCHEMATICS

The schematic is made up of individual circuits laid out

in a sequence of related functions. It is formatted with

all power wires (A) across the top and all ground wires

(B) across the bottom. Current flow is generally from

top to bottom through each circuit and component. All

components are shown in the OFF position. The

diagram does not list connector (C) information unless

needed to avoid confusion. If the connector is shown,

the number next to it is the terminal pin location (D) in

the connector.

Each component is shown by a symbol (E), its name

(F), and an identification code (G). The identification

code contains a device identifying letter (H) and

number (I).

The identifying letter is always the same for a specific

component, but the identifying numbers are numbered

consecutively from upper left to lower right. The

terminal designation (J) is placed directly outside the

symbol next to the connecting wire path. Switch

positions (K) are also placed directly outside the

symbol. The solid line (L) shows the position the switch

is currently in and dash lines (M) represent other switch

positions.

Each circuit is identified at the bottom of the drawing by

a section number (N) and section name (O).

The circuit number (P) and wire color (Q) of the wires

are shown directly next to the wire path.

The same component name and identification code are

used consistently on all diagrams in this section.

Components can be easily cross-referenced

Link

Fusible

Starting

Motor

Shielded

Ground

Battery

Start

Relay

S1 Key

Switch

Off

Run

Start

210

Red

721

Red

Blk

215

Org

Fuse

15 Amp

Fuse

15 Amp

Red

414

Yel/

800

Pink

Spark

Plug

Ignition

Coil

Ignition

Coil

Ignition

Seat

Switch

Relay

X3 710

805 Pnk/Blk

Pur/

Red

Seat

Off

Seat

Yel/Wht

Yel/

Wht

Blk/Yel

Wht

Yel/Wht

Wht

BWht

105 Blk

Blk

SE1-Power and Starting Circuit SE2-Ignition and Interlock Circuit SE3-Pto and Interlock

Pur

Engine

Spark

Plug

Yel/

Wht

Harness

Wiring

Wht

4 - 4 12/9/96

COMPONENT LOCATION ELECTRICAL

COMPONENT LOCATION

JOHNDEERE

M83948

RUN/OFF

Switch

Ignition Coil

Spark Plug

12/9/96 4 - 5

ELECTRICAL ELECTRICAL SCHEMATIC

ELECTRICAL SCHEMATIC

M83932

Run/Off

Ignition

Spark

Switch

Coil

Plug

200 Yel/Red

100 Blk

Harness

Ground

0 = RUN

1 = OFF

4 - 6 12/9/96

WIRING HARNESS ELECTRICAL

WIRING HARNESS

M83915

Run/Off

Switch

Engine

Harness

200 200

100 100

Harness

Ground

12/9/96 4 - 7

ELECTRICAL TROUBLESHOOTING

TROUBLESHOOTING

Problem or

Symptom

No spark.

Engine will not

shut off.

Check or

Solution

Check ground circuit. l

See Ignition circuit diagnosis. l

4 - 8 12/9/96

CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

CIRCUIT OPERATION AND

DIAGNOSIS

IGNITION CIRCUIT OPERATION

Function:

To create a spark that ignites that fuel/air mixture in the

engine.

Operating Conditions:

• RUN/OFF switch in RUN position.

Theory of Operation

The ignition system is a transistor-controlled magneto

design. There are no moving parts and there is no

need for an external power source (battery). The power

and triggering signal are both generated by a

permanent magnet on the outside edge of the flywheel,

is therefore not adjustable. The engine is shut off by

grounding the ignition coil through the RUN/OFF

switch.

The ignition coil consists of an iron core with two sets of

wires wound around it. The primary winding is

connected to As the flywheel turns, the permanent

magnet on the flywheel aligns with the ignition coil and

produces current in the primary coil by electro-

magnetic induction.

In the initial stage low voltage current is produced. The

low voltage current flows through resistor “A” to the

base of transistor “A”, causing it to open and allows

current to build in the primary coil windings (primary

coil current flow). Resistor “B” has high resistance, so

current will be prevented from flowing to the base of

transistor “B”.

In the second stage (spark produced), the flywheel

current flow is increased. The current can now flow

through the resistor “B” to the base of transistor “B”.

Transistor “B” is now energized which causes transistor

“A” to open. Current then flows through transistor “B”

(Primary coil secondary current flow). A voltage of

several hundred volts is then produced in the primary

coil windings by electromagnetic induction.

The high voltage current flows through the coil wire to

the spark plug. The voltage is now high enough to jump

the spark plug gap and a spark is produced, igniting

the fuel/air mixture in the cylinder.

12/6/96 4 - 9

ELECTRICAL CIRCUIT OPERATION AND DIAGNOSIS

M83935

RUN/OFF

Ignition

Switch

Coil

200 Yel/Red

100 Blk

Low Voltage Primary Circuit

Low Voltage Secondary Circuit

High-Voltage Coil Circuit

Flywheel

Resistor

Transistor “A”

Ground Circuit

Transistor “B”

Harness

Ground

Harness

Ground

100 Blk

RUN/OFF

Switch

Flywheel

200 Yel/Red

Transistor “B”

Ignition

Coil

0 = RUN

1 = OFF

0 = RUN

1 = OFF

Spark

Plug

Spark

Plug

Coil

“A”

Resistor

“C”

Resistor

“B”

Resistor

“A”

Resistor

“C”

Resistor

“B”

Engine Ground

Transistor “A”

Primary Coil Current Flow

Primary Coil Secondary Current Flow

4 - 10 12/9/96

CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

IGNITION CIRCUIT OPERATION—

ENGINE SHUTTING OFF

Function:

To shut the engine off by grounding the ignition coil

through the RUN/OFF switch.

Operating Conditions:

• RUN/OFF switch in OFF position.

Theory of Operation

When the RUN/OFF switch is moved to the OFF

position, a path to ground is provided through the

switch. This prevents voltage from building up in the

coil primary windings, preventing a spark from being

generated.

12/9/96 4 - 11

ELECTRICAL CIRCUIT OPERATION AND DIAGNOSIS

M83936

Ground Circuit

RUN/OFF

Ignition

Spark

Switch

Coil

Plug

200 Yel/Red

100 Blk

Harness

Ground

0 = RUN

1 = OFF

Flywheel

Transistor “A”

Transistor “B”

Coil

4 - 12 12/9/96

CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

IGNITION CIRCUIT DIAGNOSIS

When diagnosing an ignition problem, isolate the magneto circuit from the ground circuit by disconnecting the RUN/

OFF switch connectors. If the engine will not start, check the magneto circuit first a then the ground circuit. If the

engine will not shut off, check the ground circuit first. Remember the engine is stopped by grounding the ignition

coil through the RUN/OFF switch.

Test Conditions:

• RUN/OFF switch in RUN position.

• Travel clutch in NEUTRAL position.

• Check connection(s) for corrosion and looseness when checking/testing.

Test Conditions:

• RUN/OFF switch in OFF position.

• Ohmmeter (or continuity tester) lead connected to Yel/Red wire No. 200 at engine connector.

Test Conditions:

• RUN/OFF switch in RUN position.

Test/Check Point Normal If Not Normal

1. Spark plug/spark tester (See

SPARK TEST on page 3-25.) Spark test indicates hot, blue spark. No Spark present:

Test ignition coil. (See IGNITION

COIL—Test on page 3-40.)

Check armature air gap. (See

IGNITION COIL—Air Gap

Adjustment on page 3-39.)

Check flywheel magnet. (See

FLYWHEEL MAGNET TEST on

page 4-14.)

Spark present:

Check spark plug condition and

gap. (See SPARK PLUG GAP

ADJUSTMENT on page 3-26.) If

plug is good, continue checking

ground circuit.

Test/Check Point Normal If Not Normal

2. RUN/OFF switch—Terminal

No. 2. Maximum 0.1 ohms resistance. Replace wire harness.

3. RUN/OFF switch—Terminal

No. 3. Maximum 0.1 ohms resistance. Test RUN/OFF switch. (See RUN/

OFF SWITCH TEST on page 4-15.)

4. Engine ground. Maximum 0.1 ohms resistance. Replace wire harness.

Test/Check Point Normal If Not Normal

5. RUN/OFF switch—Terminal

No. 3. No continuity. (High resistance.) Test RUN/OFF switch. (See RUN/

OFF SWITCH TEST on page 4-15.)

12/9/96 4 - 13

ELECTRICAL CIRCUIT OPERATION AND DIAGNOSIS

132

4 - 14 12/9/96

TESTS ELECTRICAL

TESTS

COMMON CIRCUIT TESTS

Shorted Circuit:

A shorted circuit may result in the wrong component

operating (i.e. improper wire-to-wire contact). To test for

a shorted or improperly wired circuit:

1. Turn component switch ON.

2. Start at the controlling switch of the component that

should not be operating.

3. Follow the circuit and disconnect wires at

connectors until component stops operating.

4. Shorted or improper connections will be the last two

wires disconnected.

High Resistance or Open Circuit:

High resistance or open circuits usually result in slow,

dim or no component operation (i.e. poor, corroded, or

disconnected connections). Voltage at the component

will be low when the component is in operation. To test

for high resistance and open circuits:

1. Check all terminals and grounds of the circuit for

corrosion.

2. If terminals are not corroded or loose, the problem

is in the component or wiring.

Grounded Circuit:

Grounded circuits usually result in no component

operation or a blown fuse.

M85600

M85601

FLYWHEEL MAGNET TEST

Reason:

To make sure the flywheel magnet has enough force to

induce current in the ignition coil.

Procedure:

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position.

3. Engage park brake.

4. Remove blower housing. (See BLOWER HOUSING

ASSEMBLY—Removal/Installation on page 3-36.)

5. Hold a steel tool about 25 mm (1.0 in.) from

flywheel magnet. The tool should be attracted by

the magnet.

Result:

• Replace the flywheel if the magnet does not attract

tool.

M85602

M83945

Magnet

12/9/96 4 - 15

ELECTRICAL TESTS

RUN/OFF SWITCH TEST

Reason:

To make sure the RUN/OFF switch is operating

properly.

Test Equipment:

• Ohmmeter or continuity tester.

Procedure:

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position.

3. Engage park brake.

4. Disconnect wires from switch.

5. Move switch to RUN position.

6. Check continuity across terminals 2 and 3. There

should be no continuity.

7. Move switch to OFF position.

8. Check continuity across terminals 2 and 3. There

should be continuity.

Results:

• If continuity is not correct, replace switch.

M83946

Terminal 2

Terminal 3

4 - 16 12/9/96

TESTS ELECTRICAL

This page intentionally left blank.

POWER TRAIN CONTENTS

Page

CONTENTS

11/19/96 5 - 1

POWER TRAIN

SPECIFICATIONS

ADJUSTMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

REPAIR SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

COMPONENT LOCATION AND OPERATION

DRIVE BELT/SPEED REDUCTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

TROUBLESHOOTING

POWER TRAIN TROUBLESHOOTING CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

DIAGNOSIS

MACHINE WILL NOT DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

NOISY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

MACHINE DOES NOT REACH FULL GROUND SPEED. . . . . . . . . . . . . . . . . . . . 5-7

ERRATIC SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

PARK BRAKE DOES NOT HOLD MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

TRACTION DRIVE PULLS TO ONE SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

CHECKS AND ADJUSTMENTS

DRIVE BELT TENSION CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 5-10

BELT GUIDE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

TRACTION ROLLER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

TRANSPORT ROLLER DRIVE CHAIN TENSION ADJUSTMENT. . . . . . . . . . . . 5-13

REPAIR

CLUTCH CONTROL CABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

DRIVE BELT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

SPEED REDUCER ASSEMBLY

Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Disassembly/Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

TRACTION ROLLER ASSEMBLY

Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Disassembly/Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

DRIVE CHAIN TENSIONERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

DRIVE BELT IDLER BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

5 - 2 12/9/96

SPECIFICATIONS POWER TRAIN

SPECIFICATIONS

ADJUSTMENT SPECIFICATIONS

Drive Belt-to-Guide Clearance (Clutch ENGAGED) . . . . . . . . . . . . . . . 1 mm (0.040 in.)

Transport Roller Drive Chain-Maximum Deflection . . . . . . . . . . . . . . . . .11 mm (7/16 in.)

REPAIR SPECIFICATIONS

Speed Reducer Oil Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 L (0.5 qt)

Traction Roller Eccentric Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (16 lb-ft)

12/9/96 5 - 3

POWER TRAIN COMPONENT LOCATION AND OPERATION

COMPONENT LOCATION AND OPERATION

DRIVE BELT/SPEED REDUCER SYSTEM

JOHN DEERE

M83834

Drive Belts

Traction Roller Speed

Clutch

Traction

Reel Drive Chain

Tension Idler

Drive Chain

Reducer

Assembly

Control Cable

Assembly

Traction

Drive Chain

Reel Drive

Clutch Lever

Output (Traction)

Shaft (2 used)

Output (Reel)

Shaft

Function:

To transmit power to the reel and transport roller

assembly. The speed reducer assembly also features a

differential assembly to assist in turning.

Theory of Operation:

The speed reducer is connected to the engine by two

V-belts. When the travel clutch lever is moved to the

ENGAGED position, the cable pulls the tension idler

down against the belts, applying tension to the drive

belts.

As tension is applied to the belts, the speed reducer

input sheave/shaft turns and power is transferred to the

differential assembly by way of a chain.

Output (traction) shafts connected to the differential

transfer power to the transport roller assembly by way

of chain drives on each side of the mower.

The transport roller assembly consists of two

independently-driven aluminum rollers. As the mower

is turned, the speed reducer differential allows the

rollers to turn at different speeds, allowing the mower to

turn smoothly.

The speed reducer also drives the cutting unit reel. The

reel drive can be disengaged when transporting the

mower, by placing the reel drive clutch in the STOP

position.

When the reel drive clutch is moved to the MOW

position, a ramped clutch is engaged with the input

shaft assembly, transferring power to the cutting reel by

a chain drive.

5 - 4 12/9/96

TROUBLESHOOTING POWER TRAIN

TROUBLESHOOTING

POWER TRAIN TROUBLESHOOTING CHART

Problem or

Symptom

Machine will not drive.

Drive train noisy.

Machine does not

achieve full ground

speed.

Erratic speed

Park brake does not

hold machine.

Traction drive pulls to

one side.

Check or

Solution

Engine drive sheave and/or key

damaged or missing. l

Wrong oil in speed reducer. l

Drive belts broken, worn or out of

adjustment. lll

Clutch cable out of adjustment or

damaged. l l

Speed reducer input shaft

assembly damaged. l l

Speed reducer input shaft key

damaged or missing. l l

Speed reducer chain broken and/or

input shaft/differential sprockets

damaged.

ll l

Differential gears damaged. ll ll

Speed reducer bearing(s)

worn, binding or damaged. l l l

Traction drive chain(s) loose. l l l

Traction drive chain(s) broken. lll

Speed reducer output shaft drive

sprocket(s) and/or key(s) damaged

or missing.

lll

Speed reducer output shaft

(frame) bearing(s) worn,

binding or damaged.

l l l

Park brake engaged. l l

Traction drive roller key(s) and/

or sprocket(s) damaged or

missing.

lll

Traction drive roller bearing(s)

worn, binding or damaged. l l l

12/9/96 5 - 5

POWER TRAIN DIAGNOSIS

DIAGNOSIS

MACHINE WILL NOT DRIVE

Test Conditions:

• Machine parked on level surface.

• RUN/OFF switch in OFF position.

• Park brake disengaged.

• Travel clutch disengaged.

Test Location Normal If Not Normal

1. Park brake. Brake not engaged. Release park brake.

2. Engine drive sheave. No damage to drive key or keyway,

sheave intact with no evidence of wear. Replace sheave and/or key.

3. Drive belts. Not broken, worn, frayed, glazed or

stretched. Replace drive belts. (See DRIVE BELT

REPLACEMENT on page 5-14.)

Properly tensioned. Adjust drive belt tension. (See DRIVE

BELT TENSION CHECK AND

ADJUSTMENT on page 5-10.)

4. Speed reducer input

shaft assembly. Key not missing or damaged. Replace key. (See SPEED REDUCER—

Disassembly/Inspection on page 5-17.)

Shaft not damaged. Replace input shaft. (See SPEED

REDUCER—Disassembly/Inspection

on page 5-17.)

Sprocket not damaged. Replace sprocket. (See SPEED

REDUCER—Disassembly/Inspection

on page 5-17.)

5. Speed reducer chain. Not broken. Replace chain. (See SPEED

REDUCER—Disassembly/Inspection

on page 5-17.)

6. Differential Assembly Gears not damaged. Replace differential gears. (See SPEED

REDUCER—Disassembly/Inspection

on page 5-17.)

7. Speed reducer output

shafts. Shafts not damaged. Replace output shaft(s). (See SPEED

REDUCER—Disassembly/Inspection

on page 5-17.)

Sprocket keys not damaged or missing. Replace keys.

8. Traction drive chains Not broken. Replace chain(s).

9. Traction drive roller

assembly Keys not missing or damaged. Replace keys. (See TRACTION

ROLLER ASSEMBLY—Disassembly/

Assembly on page 5-25.)

Sprockets not damaged. Replace sprockets. (See TRACTION

ROLLER ASSEMBLY— Disassembly/

Assembly on page 5-25.)

5 - 6 12/9/96

DIAGNOSIS POWER TRAIN

NOISY OPERATION

Test Conditions:

• Machine parked on level surface.

• RUN/OFF switch in OFF position.

• Park brake disengaged.

• Travel clutch disengaged.

Test Location Normal If Not Normal

1. Speed reducer

dipstick cap. (Check

cold.)

Oil between bottom of dipstick and first

mark with cap completely turned into

threads.

Fill to correct level with oil meeting

specifications. (See SPEED REDUCER

OIL—NORTH AMERICA or SPEED

REDUCER OIL—EUROPE on page 2-

10.)

2. Differential Assembly Gears not damaged. Replace differential gears. (See SPEED

REDUCER—Disassembly/Inspection

on page 5-17.)

3. Speed reducer

assembly bearings

(Input and output

shafts).

Bearings not worn or damaged. Replace bearings. (See SPEED

REDUCER—Disassembly/Inspection

on page 5-17.)

4. Speed reducer output

shaft (frame)

bearings.

Bearings not worn or damaged. Replace bearings. (See FRAME AND

DRIVE COVERS on page 9-4.)

5. Traction drive chains. Chains not loose. Tighten drive chains. (See TRANSPORT

ROLLER DRIVE CHAIN TENSION

ADJUSTMENT on page 5-13.)

Chains properly lubricated. Apply grease to chains. (See

GREASE—NORTH AMERICA or

GREASE—EUROPE on page 2-13.)

6. Traction roller

assembly. Bearings not worn or damaged. Replace bearings (See TRACTION

ROLLER ASSEMBLY—Disassembly/

Assembly on page 5-25.)

12/9/96 5 - 7

POWER TRAIN DIAGNOSIS

MACHINE DOES NOT REACH FULL GROUND SPEED

Test Conditions:

• Machine parked on level surface.

• RUN/OFF switch in OFF position.

• Park brake disengaged.

• Travel clutch disengaged.

ERRATIC SPEED

Test Conditions:

• Machine parked on level surface.

• RUN/OFF switch in OFF position.

• Park brake disengaged.

• Travel clutch disengaged.

Test Location Normal If Not Normal

1. Park brake. Brake not engaged. Release park brake.

2. Drive belts. Not worn, frayed, glazed or stretched. Replace drive belts. (See DRIVE BELT

REPLACEMENT on page 5-14.)

Properly tensioned. Adjust drive belt tension. (See DRIVE

BELT TENSION CHECK AND

ADJUSTMENT on page 5-10.)

3. Speed reducer

assembly bearings

(Input and output

shafts).

Bearings not worn, damaged or binding. Replace bearings. (See SPEED

REDUCER—Disassembly/Inspection

on page 5-17.)

4. Speed reducer output

shaft (frame)

bearings.

Bearings not worn, damaged or binding. Replace bearings. (See FRAME AND

DRIVE COVERS on page 9-4.)

5. Traction roller

assembly. Bearings not worn or damaged. Replace bearings (See TRACTION

ROLLER ASSEMBLY—Disassembly/

Assembly on page 5-25.)

Test Location Normal If Not Normal

1. Drive belts. Not worn, frayed, glazed or stretched. Replace drive belts. (See DRIVE BELT

REPLACEMENT on page 5-14.)

2. Traction drive chains. Chains not loose. Tighten drive chains. (See TRANSPORT

ROLLER DRIVE CHAIN TENSION

ADJUSTMENT on page 5-13.)

5 - 8 12/9/96

DIAGNOSIS POWER TRAIN

PARK BRAKE DOES NOT HOLD MACHINE

Test Conditions:

• Machine parked on level surface.

• RUN/OFF switch in OFF position.

• Park brake disengaged.

• Travel clutch disengaged.

Test Location Normal If Not Normal

1. Speed reducer input

shaft assembly. Key not missing or damaged. Replace key. (See SPEED REDUCER—

Disassembly/Inspection on page 5-17.)

Shaft not damaged. Replace input shaft. (See SPEED

REDUCER—Disassembly/Inspection

on page 5-17.)

Sprocket not damaged. Replace sprocket. (See SPEED

REDUCER—Disassembly/Inspection

on page 5-17.)

2. Speed reducer chain. Not broken. Replace chain. (See SPEED

REDUCER—Disassembly/Inspection

on page 5-17.)

3. Differential Assembly Gears not damaged. Replace differential gears. (See SPEED

REDUCER—Disassembly/Inspection

on page 5-17.)

4. Speed reducer output

shafts. Shafts not damaged. Replace output shaft(s). (See SPEED

REDUCER—Disassembly/Inspection

on page 5-17.)

Sprocket keys not damaged or missing. Replace keys.

5. Traction drive chains Not broken. Replace chain(s).

6. Traction drive roller

assembly Keys not missing or damaged. Replace keys. (See TRACTION

ROLLER ASSEMBLY—Disassembly/

Assembly on page 5-25.)

Sprockets not damaged. Replace sprockets. (See TRACTION

ROLLER ASSEMBLY—Disassembly/

Assembly on page 5-25.)

12/9/96 5 - 9

POWER TRAIN DIAGNOSIS

TRACTION DRIVE PULLS TO ONE SIDE

Test Conditions:

• Machine parked on level surface.

• RUN/OFF switch in OFF position.

• Park brake disengaged.

• Travel clutch disengaged.

Test Location Normal If Not Normal

1. Differential Assembly Gears not damaged. Replace differential gears. (See SPEED

REDUCER—Disassembly/Inspection

on page 5-17.)

2. Speed reducer

assembly bearings

(output shafts).

Bearings not worn, damaged or binding. Replace bearings. (See SPEED

REDUCER—Disassembly/Inspection

on page 5-17.)

3. Speed reducer output

shaft (frame)

bearings.

Bearings not worn, damaged or binding. Replace bearings. (See FRAME AND

DRIVE COVERS on page 9-4.)

4. Speed reducer output

shaft sprocket(s)

and/or key(s).

Sprockets not damaged. Replace sprockets.

Keys not damaged or missing. Replace keys.

5. Traction drive chains. Chains not loose. Tighten drive chains. G1(See

TRANSPORT ROLLER DRIVE CHAIN

TENSION ADJUSTMENT on page 5-

13.)

Chains not broken. Replace drive chain(s).

6. Traction roller

assembly. Bearings not worn or damaged. Replace bearings (See TRACTION

ROLLER ASSEMBLY—Disassembly/

Assembly on page 5-25.)

Sprockets not damaged. Replace sprockets. (See TRACTION

ROLLER ASSEMBLY—Disassembly/

Assembly on page 5-25.)

Keys not damaged or missing. Replace keys. (See TRACTION

ROLLER ASSEMBLY—Disassembly/

Assembly on page 5-25.)

5 - 10 12/9/96

CHECKS AND ADJUSTMENTS POWER TRAIN

CHECKS AND ADJUSTMENTS

DRIVE BELT TENSION CHECK AND

ADJUSTMENT

Reason:

When properly adjusted, with engine OFF and clutch in

NEUTRAL, machine should move freely. With clutch

ENGAGED, transport roller should not move.

Check Procedure:

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position.

3. Move Travel Clutch Lever to NEUTRAL position.

4. Pull the machine backwards, transport wheels/roller

turn should turn freely.

• If transport wheels/roller turn freely, proceed to next

step.

• If transport wheels/roller do not turn, adjust belt

tension.

5. Move clutch lever to ENGAGED position.

6. Pull the machine backwards, if transport wheels/

roller should not turn.

• If transport wheels/roller turns, or excessive force is

required to engage clutch, adjust belt tension.

• If transport wheels/roller does not turn, proceed to

next step.

7. Move clutch lever to DISENGAGED position.

8. Start engine, the machine should not move forward.

If it does, adjust belt tension.

Adjustment Procedure:

NOTE: The drive belt tension should be adjusted just

tight enough so that the transport roller does

not move when the clutch is engaged. DO NOT

over-tighten belt tension.

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position.

3. Move Travel Clutch Lever to NEUTRAL position.

4. Loosen jam nuts (one on each side of bracket).

5. Lengthen or shorten ferrule length to change belt

idler tension:

• Shorten ferrule length to INCREASE tension.

• Lengthen ferrule length to DECREASE tension.

6. Repeat CHECK procedure. If additional adjustment

is required, go to step 7.

7. Remove cap screw and drive belt cover.

8. Loosen jam nut (one on each side of bracket).

9. Lengthen or shorten ferrule length to change belt

idler tension:

• Shorten ferrule length to INCREASE tension.

• Lengthen ferrule length to DECREASE tension.

10. Repeat CHECK procedure. If additional adjustment

is required, go to step 11.

M83871

Jam Nuts

M83755

Drive Belt Cover

Cap Screw

M83786

Jam Nuts

12/9/96 5 - 11

POWER TRAIN CHECKS AND ADJUSTMENTS

IMPORTANT: Engine PTO sheave and speed

reducer input sheave MUST align.

11. Loosen engine mounting bolts.

12. Slide engine forward (loosen) or rearward (tighten)

to adjust belt tension.

13. Tighten engine mounting bolts.

14. Replace drive belt cover.

DRIVE BELT GUIDE ADJUSTMENT

Reason:

When properly adjusted, the belt guide prevents

movement when the clutch is disengaged.

Procedure:

NOTE: The drive belt tension should be properly

adjusted before adjusting belt guides. (See

DRIVE BELT TENSION CHECK AND

ADJUSTMENT on page 5-10.)

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position.

3. Move Travel Clutch Lever to ENGAGED position.

4. Engage park brake.

5. Remove cap screw and drive belt cover.

M83873

Speed Reducer

Input Sheave

Engine PTO Sheave

M83755

Drive Belt Cover

Cap Screw

6. Loosen two cap screws, and adjust bracket until

there is a 1 mm (0.040 in.) clearance between belt

and guide.

7. Tighten guide mounting bolts.

8. Replace drive belt cover.

TRACTION ROLLER ADJUSTMENT

Reason:

In order to ensure an even, level cut, the transport roller

must be parallel to the reel.

Equipment:

• #006 Flat Bench Plate

• Feeler Gauge Set (Blade Type)

Procedure:

NOTE: The cutting height adjustment MUST be

performed before adjusting transport roller.

(See CUTTING HEIGHT ADJUSTMENT on

page 8-17.)

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position.

3. Move Travel Clutch Lever to NEUTRAL position.

4. Engage park brake.

5. Remove grass catcher.

6. Remove transport wheels and and right drive collar

(if equipped). (See TRANSPORT WHEELS on

page 9-3.)

M83858

Cap Screws

5 - 12 12/9/96

CHECKS AND ADJUSTMENTS POWER TRAIN

7. Place the machine on a #006 flat bench plate so

that the bed knife contacts the rear edge of the

support bar.

8. Support the handlebars so that they are centered in

the grommets. DO NOT lift the transport roller off

bench plate.

9. Check gap at each end of front roller. If gap is 0.1

mm (0.004 in.) or less, no adjustment is

necessary. If adjustment is require, proceed to

step 10.

M85584

Bed Knife

Support Bar

M85587

Handle

Grommet

M85585

10. Loosen four bearing housing cap screws.

11. Remove three acorn nuts, washers and shoulder

bolts, and remove right drive cover.

12. Rotate roller until holes in sprocket align with

bearing holder cap screws. Loosen two cap

screws.

13. Loosen nut attached to eccentric screw.

14. Position eccentric dot at position as shown. Rotate

eccentric until gap at ends of front roller is less

than 0.1 mm (0.004 in.).

M83791

Acorn Nuts

Cap Screws

M83874

Cap Screws

Nut

M83913

Dot

12/9/96 5 - 13

POWER TRAIN CHECKS AND ADJUSTMENTS

15. Tighten eccentric screw and nut and bearing holder

cap screws and eccentric screw and nut to 22 N•m

(16 lb-ft).

16. Install drive cover.

17. Install transport wheels and drive collars (if

equipped). (See TRANSPORT WHEELS on page

9-3.)

TRANSPORT ROLLER DRIVE CHAIN

TENSION ADJUSTMENT

Reason:

To maintain proper chain tension.

Procedure:

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position.

3. Move Travel Clutch Lever to NEUTRAL position.

4. Engage park brake

5. Remove transport wheels and left side drive collar

(if equipped). (See TRANSPORT WHEELS on

page 9-3.)

cCAUTION

Block machine securely before servicing or

repairing.

M83874

Cap Screws

Nut

6. Loosen four bearing housing cap screws.

7. Remove five acorn nuts, washers and shoulder

bolts, and remove left drive cover.

8. Loosen cap screw and reposition idler roller/bracket

until chain deflects 11 mm (7/16 in.) at mid span

opposite idler.

9. Tighten cap screw.

10. Install cover and transport wheels (if equipped).

11. Repeat procedure for opposite side.

M60559

Cap Screws

Acorn Nuts

M60567

Cap Screw

Drive Chain

Idler Roller

5 - 14 12/9/96

REPAIR POWER TRAIN

REPAIR

CLUTCH CONTROL CABLE

Removal/Installation

1. Remove handlebar cover. (See HANDLEBAR

COVER—Removal/Installation on page 6-5.)

2. Remove cotter pin and pin.

3. Slide cap off cable housing.

4. Remove top nut.

5. Pull cable back until cable housing clears slot.

6. Route cable through slotted hole in lower handlebar

bracket.

M83851

Cotter Pin Pin

M83872

Cap

Nut

M60584

Bracket

7. Compress spring, disconnect clutch cable end from

bracket.

8. Remove spring.

9. Remove jam nut and slide cable end from bracket.

Installation is done in the reverse order of removal.

• Adjust drive belt tension. (See DRIVE BELT

TENSION CHECK AND ADJUSTMENT on page

5-10.)

DRIVE BELT REPLACEMENT

1. Remove engine and belts. (See ENGINE—

Removal/Installation on page 3-29.)

2. Install new belts on gear case sheaves.

NOTE: Belts must be routed UNDER tension idler.

3. Install engine on support and install belts on engine

PTO sheaves. DO NOT tighten engine mounting

bolts at this time.

IMPORTANT: Engine PTO sheaves MUST align with

gear case sheaves.

4. Move engine rearward to tighten belts.

M83786

Cable End

Spring

Jam Nut

M83873

Tension Idler

Speed Reducer

Input Sheave

Engine PTO Sheave

12/9/96 5 - 15

POWER TRAIN REPAIR

5. Tighten engine mounting bolts.

6. Align belt guide. (See DRIVE BELT GUIDE

ADJUSTMENT on page 5-11.)

7. Adjust throttle cable. (See THROTTLE CABLE

CHECK AND ADJUSTMENT on page 3-22.)

SPEED REDUCER ASSEMBLY

Removal/Installation

1. Remove transport wheels and drive collars (if

equipped). (See TRANSPORT WHEELS on page

9-3.)

2. Remove engine and belts. (See ENGINE—

Removal/Installation on page 3-29.)

3. Remove clutch cable. (See CLUTCH CONTROL

CABLE—Removal/Installation on page 5-14.)

4. Remove park brake cable. (See PARK BRAKE

CABLE REPLACEMENT on page 7-8.

5. Remove cap screws, washer and nuts.

6. Remove brake band.

7. Loosen four bearing housing cap screws.

8. Remove five acorn nuts, washers and shoulder

bolts, and remove left drive cover.

M83788

Brake Band

Cap Screws Washer

M60559

Cap Screws

Acorn Nuts

9. Loosen cap screw to release chain tension.

10. Disconnect master link and remove transport roller

drive chain.

11. Remove nut.

12. Remove sprocket and key.

13. Loosen cap screw to release chain tension.

14. Disconnect master link and remove reel drive

chain.

M83789

Cap Screw

Drive Chain

M83790

Nut

Sprocket

M83794

Cap Screw

Drive Chain

5 - 16 12/9/96

REPAIR POWER TRAIN

15. Remove nut.

16. Remove sprocket and key.

17. Loosen four bearing housing cap screws.

18. Remove three acorn nuts, washers and shoulder

bolts, and remove right drive cover.

19. Loosen cap screw to release chain tension.

20. Disconnect master link and remove transport roller

drive chain.

M83795

Nut

Sprocket

M83791

Acorn Nuts

Cap Screws

Acorn Nut

M83792

Cap Screw

Drive Chain

21. Remove nut.

22. Remove sprocket and key.

23. Remove three allen screws.

24. Rotate bearing housing until grease fitting aligns

with notch in frame. Remove right bearing housing

assembly.

25. Remove front speed reducer mounting cap screws

and washers.

M83793

Sprocket

Nut

M83798

Notch

Allen Screws

Allen Screw

Grease Fitting

M83796

Cap Screws

and Washers

12/9/96 5 - 17

POWER TRAIN REPAIR

26. Remove rear speed reducer cap screws and

washers.

27. Slide speed reducer assembly to the right and

remove.

Installation is done in the reverse order of removal.

IMPORTANT: To aid in installation and prevent

damage to bearings and seals, remove left side

bearing housing assemblies and install onto

shafts before sliding speed reducer assembly

into place.

• Fill speed reducer assembly with oil meeting

specifications. (See SPEED REDUCER OIL—

NORTH AMERICA or SPEED REDUCER OIL—

EUROPE on page 2-10.)

• Adjust drive chain tension. (See TRANSPORT

ROLLER DRIVE CHAIN TENSION ADJUSTMENT

on page 5-13.)

• Adjust drive belt tension. (See DRIVE BELT

TENSION CHECK AND ADJUSTMENT on page

5-10.)

• Align belt guide. (See drive DRIVE BELT GUIDE

ADJUSTMENT on page 5-11.)

• Adjust throttle cable. (See THROTTLE CABLE

CHECK AND ADJUSTMENT on page 3-22.)

• Adjust park brake. (See PARK BRAKE CHECK

AND ADJUSTMENT on page 7-7.)

M83797

Cap Screws

and Washers

M83818

Bearing

Housings

Disassembly/Inspection

NOTE: Speed reducer oil capacity is approximately

0.5 L (0.5 qt).

1. Remove drain plug and drain oil into properly

marked container.

2. Remove nut and washer, cap screw and idler

bracket.

3. Remove nut, sheave and key.

M83801

Drain Plug

M83799

Idler Bracket

Nut

Cap Screw

and Washer

M83816

Nut

Sheave

5 - 18 12/9/96

REPAIR POWER TRAIN

4. Remove 11 allen head cap screws.

5. Remove cover.

6. Remove seals.

7. Remove shaft.

8. Inspect bearing. Replace bearing if worn or

damaged.

M83800

Allen Head Cap Screws (11 used)

M83814

Seals

M83802

Shaft

M83815

Bearing

9. Remove differential assembly, chain and input shaft

assembly as a unit.

10. Remove chain.

11. Inspect chain for worn or loose links.

Input Shaft Assembly:

12. Remove four cap screws.

13. Remove clutch and bearing.

14. Remove snap ring.

15. Remove chain sprocket, spacer, bearing and key

from shaft.

M83806

Chain

Differential Assembly

Input Shaft Assembly

M83809

Chain

M83812

Shaft

Key

Bearing

Sprocket

Snap Ring

Bearing

Clutch

Cap Screw

(4 used)

Spacer

12/9/96 5 - 19

POWER TRAIN REPAIR

Differential Assembly:

16. Remove four cap screws.

17. Remove chain sprocket and cover from gear case.

18. Remove gears from gear case.

19. Remove snap ring and remove spur gears and

spacers from pins.

20. Remove shaft, washer, bearing and seal.

M83813

Cap Screw

Spur Gear Pin (2 used)

Snap Ring

Gear Case

Chain

Cover

(2 used)

Gear

(2 used)

Spacer

(2 used)

Sprocket

(4 used)

(2 used)

M83803

Shaft

Washer

Bearing

Seal

21. Remove cap screw, washer, retainer and reel clutch

handle.

22. Inspect O-ring and eccentric on reel clutch handle.

23. Remove shaft, shift collar, bearing and seal.

24. Remove cap screw, bearing and spacer. Inspect

bearing and replace if necessary.

25. Remove gasket material from mating surfaces.

M83804

Cap Screw Retainer

Reel Clutch Handle

M83808

O-Ring

Eccentric

M83805

Shaft Bearing

Seal

Shift Collar

M83807

Bearing

Cap Screw

Spacer

5 - 20 12/9/96

REPAIR POWER TRAIN

26. Clean all metal parts with solvent and blow dry with

compressed air.

27. Inspect all parts for damage, nicks or unusual wear.

Replace parts as necessary.

Assembly

IMPORTANT: Always use new seal and O-rings.

Damaged or used parts will leak.

NOTE: Lubricate all seals and O-rings with multi-

purpose grease during installation.

Apply clean oil to all internal parts during

assembly. (See SPEED REDUCER OIL—

NORTH AMERICA or SPEED REDUCER

OIL—EUROPE on page 2-10.)

1. Install idler bearing, spacer and cap screw.

2. Install new seal

cCAUTION

Reduce compressed air to less than 210 kPa (2

bar) (30 psi) when using for cleaning purposes.

Clear area of bystanders, guard against flying

chips, and wear personal protection equipment

including eye protection.

M83807

Bearing

Cap Screw

Spacer

M83805

Shaft Bearing

Seal

Shift Collar

NOTE: Make sure bearing is full seated in housing.

3. Install bearing in housing.

4. Install shaft and shift collar.

NOTE: Align pin on reel clutch handle with groove in

shift collar.

5. Install reel clutch handle.

6. Install cap screw, washer and retainer.

7. Check for full movement of reel clutch handle from

STOP to MOW position.

M83817

Reel Clutch Handle

Groove

M83804

Cap Screw Retainer

Reel Clutch Handle

M83810 M83811

MOW Position

STOP Position

12/9/96 5 - 21

POWER TRAIN REPAIR

8. Install new seal.

NOTE: Make sure bearing is full seated in housing.

9. Install bearing in housing.

10. Install shaft and washer.

Differential Assembly:

11. Install gears in gear case with gear teeth facing

inside of gear case.

12. Install spur gears and spacers on pins. Secure with

snap ring.

NOTE: Install spur gear shaft assemblies with one

spur gear against chain sprocket and other

spur gear against cover.

13. Assemble spur gear assemblies, gear case, cover

and chain sprocket, using four cap screws.

M83803

Shaft

Washer

Bearing

Seal

M83813

Cap Screw

Spur Gear Pin (2 used)

Snap Ring

Gear Case

Chain

Cover

(2 used)

Gear

(2 used)

Spacer

(2 used)

Sprocket

(4 used)

(2 used)

Input Shaft Assembly:

14. Install bearing, spacer, key and sprocket on shaft.

Secure with snap ring.

15. Install bearing in clutch.

16. Install clutch on sprocket using four cap screws.

17. Install chain around differential assembly and input

shaft assembly and install as a unit.

18. Install shaft in differential assembly.

M83812

Shaft

Key

Bearing

Sprocket

Snap Ring

Bearing

Clutch

Cap Screw

(4 used)

Spacer

M83806

Chain

Differential Assembly

Input Shaft Assembly

M83802

Shaft

5 - 22 12/9/96

REPAIR POWER TRAIN

19. Install new seals in cover.

IMPORTANT: Apply multipurpose grease to lips of

seals and wrap ends of shafts with tape to

prevent damage to seal when installing cover.

20. Install cover with new gasket.

21. Install cap screws.

22. Install key, sheave and nut.

M83814

Seals

M83800

Allen Head Cap Screws (11 used)

M83816

Sheave

Nut

23. Install idler bracket, nut and cap screw and washer.

24. Fill speed reducer to proper level with oil meeting

specifications. (See SPEED REDUCER OIL—

NORTH AMERICA or SPEED REDUCER OIL—

EUROPE on page 2-10.)

TRACTION ROLLER ASSEMBLY

Removal/Installation

1. Remove transport wheels and drive collars (if

equipped). (See TRANSPORT WHEELS on page

9-3.)

2. Loosen four bearing housing cap screws.

3. Remove five acorn nuts, washers and shoulder

bolts, and remove left drive cover.

M83799

Idler Bracket

Nut

Cap Screw

and Washer

M60559

Cap Screws

Acorn Nuts

12/9/96 5 - 23

POWER TRAIN REPAIR

4. Loosen cap screw to release chain tension.

5. Disconnect master link and remove transport roller

drive chain.

6. Loosen four bearing housing cap screws.

7. Remove three acorn nuts, washers and shoulder

bolts, and remove right drive cover.

8. Loosen cap screw to release chain tension.

9. Disconnect master link and remove transport roller

drive chain.

M83789

Cap Screw

M83791

Acorn Nuts

Cap Screws

Acorn Nut

M83792

Cap Screw

Drive Chain

10. Loosen allen head cap screw on both sides of

mower.

11. Remove adjustment handles, bolts and springs

from both sides of mower.

12. Remove cap screws from both sides of mower.

13. Remove bed knife support.

M83831

Allen Head

Cap Screw

Adjustment Handle

M83832

Spring

Bolt

M83833

Cap Screw

Bed Knife Support

5 - 24 12/9/96

REPAIR POWER TRAIN

14. Left Side: Rotate roller until holes in sprocket align

with bearing holder cap screws. Remove three cap

screws.

15. Right Side: Rotate roller until holes in sprocket

align with bearing holder cap screws. Remove two

cap screws.

16. Remove bearing holder eccentric screw and nut.

17. Lift mower and remove traction roller assembly.

Installation is done in the reverse order of removal.

• Adjust bed knife-to-reel clearance. (See BED

KNIFE-TO-REEL ADJUSTMENT on page 8-15.)

• Adjust traction roller. (See TRACTION ROLLER

ADJUSTMENT on page 5-11.)

• Adjust drive chain tension. (See TRANSPORT

ROLLER DRIVE CHAIN TENSION ADJUSTMENT

on page 5-13.)

• Backlap reel. (See BACKLAPPING PROCEDURE

on page 8-16.)

M83835

Sprocket

Cap Screws

M83834

Eccentric Screw and Nut

Cap Screws

12/9/96 5 - 25

POWER TRAIN REPAIR

Disassembly/Assembly

M83909

Cotter PinNut

Spacer

Seal (2 used)

Ball Bearing

(2 used)

Tube

Key (2 used)

Shaft (2 used)

Roller (2 used)

Spindle

Cap Screw (4 used)

Cap Screw

(8 used)

Nut (2 used)

Chain Sprocket

(2 used)

Snap Ring

(2 used)

Ball Bearing

(2 used)

Seal (2 used)

Cover

Cap Screw

(6 used)

Lubrication Fitting

(2 used)

Cover

Bearing Housing

Eccentric

Nut

• Inspect all parts for wear or damage. Replace parts

as necessary.

• Apply Non-Clay High Temperature EP Grease

(North America) or Grease-Gard (Europe) to

lubrication fittings and pack inside of tube.

5 - 26 12/9/96

REPAIR POWER TRAIN

DRIVE CHAIN TENSIONERS

M83938

Screw

Tensioner Arm

Flange Nut

Cap Screw

Screw

Bushing

Idler

Bearing

Snap Ring

Screw

Tensioner Arm

Cap Screw

Flange Nut

Screw

Flange Nut

(2 used)

Bushing

• Inspect all parts for wear or damage. Replace parts

as necessary.

• Adjust tension arms to remove slack in chains. (See

TRANSPORT ROLLER DRIVE CHAIN TENSION

ADJUSTMENT on page 5-13 and REEL DRIVE

CHAIN TENSION ADJUSTMENT on page 8-17.)

12/9/96 5 - 27

POWER TRAIN REPAIR

DRIVE BELT IDLER BRACKET ASSEMBLY

M83937

Idler Bracket

Idler Ar m

Washer

Nut

Washer

Cap Screw

Arm

Cap Screw

Cap Screw Idler

• Inspect all parts for wear or damage. Replace parts

as necessary.

5 - 28 12/9/96

REPAIR POWER TRAIN

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HANDLEBAR AND CONTROLS CONTENTS

Page

CONTENTS

12/9/96 6 - 1

HANDLEBAR AND CONTROLS

COMPONENT LOCATION AND OPERATION

COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

ADJUSTMENTS

THROTTLE LEVER TENSION ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

OPERATOR PRESENCE BAIL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

HANDLEBAR HEIGHT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

REPAIR

HANDLEBAR COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

HANDLEBAR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

CLUTCH CONTROL/OPERATOR PRESENCE BAIL . . . . . . . . . . . . . . . . . . . . . . . 6-7

BRAKE CONTROL/THROTTLE LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6 - 2 12/6/96

COMPONENT LOCATION AND OPERATION HANDLEBAR AND CONTROLS

COMPONENT LOCATION AND OPERATION

COMPONENT LOCATION

JOHN DEERE

M83933

Throttle Lever Operator Presence Bail

Park Brake Lever

Handlebar

Clutch Control Lever

Handlebar Cover

12/6/96 6 - 3

HANDLEBAR AND CONTROLS ADJUSTMENTS

ADJUSTMENTS

THROTTLE LEVER TENSION

ADJUSTMENT

Reason:

To apply enough tension to hold throttle position, yet

allow easy throttle movement.

Procedure:

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position.

3. Move Travel Clutch Lever to NEUTRAL position.

4. Engage park brake.

5. Remove handlebar cover. (See HANDLEBAR

COVER—Removal/Installation on page 6-5.)

6. Using two wrenches, tighten or loosen the lock on

throttle pivot bolt. At proper tension, the throttle

should hold desired throttle setting during

operation, yet allow easy movement.

7. Install handlebar cover.

OPERATOR PRESENCE BAIL

ADJUSTMENT

Reason:

To ensure that all moving parts are disengaged when

bail is released.

Procedure:

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position.

3. Move Travel Clutch Lever to NEUTRAL position.

4. Engage park brake.

M83759

Throttle Lever

Pivot Bolt

5. Loosen two nuts.

6. Secure bail against handlebar loop.

7. Rotate engagement arm upward as far as possible.

8. Tighten nuts

9. Release operator presence bail.

M83855

Nuts

M83856

Operator Presence Bail

M83857

Engagement Arm

6 - 4 12/6/96

ADJUSTMENTS HANDLEBAR AND CONTROLS

HANDLEBAR HEIGHT

ADJUSTMENT

Reason:

To allow the operator to choose a comfortable

handlebar height.

Procedure:

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position.

3. Move Travel Clutch Lever to NEUTRAL position.

4. Engage park brake.

5. Loosen cap screw on each side of mower.

NOTE:

Brackets

MUST be straight up and down.

6. Adjust bracket up or down as desired and tighten

cap screws.

M83740

Cap Screw

Bracket

12/6/96 6 - 5

HANDLEBAR AND CONTROLS REPAIR

REPAIR

HANDLEBAR COVER

Removal/Installation

1. Move throttle lever to FAST idle position.

2. Remove two cap screws and washer.

3. Remove cover.

Installation is done in the reverse order of removal.

HANDLEBAR ASSEMBLY

Removal/Installation

1. Remove handlebar cover. (See HANDLEBAR

COVER—Removal/Installation.)

2. Disconnect RUN/OFF harness at engine.

3. Remove nut and ground wire.

M83782

Cap Screw

and Washer

Cap Screw

Throttle Lever

M83752

Ground Wire

Nut

RUN/OFF Switch Lead

4. Loosen clamp and disconnect throttle cable at

throttle lever.

5. Remove nut and carriage bolt

6. Rotate brake lever down.

7. Disconnect cable end from lever.

8. Slide cap off cable housing.

9. Remove top nut.

10. Pull cable back until brake cable housing clears

slot.

M83759

Throttle Cable

Clamp

Throttle Lever

M83866

Carriage Bolt

and Nut

Cable End

M83867

Cap

Nut

Cap

6 - 6 12/6/96

REPAIR HANDLEBAR AND CONTROLS

11. Remove cotter pin and pin from clutch control

cable.

12. Slide cap off cable housing.

13. Remove top nut.

14. Pull cable back until clutch control cable housing

clears slot.

15. Route cables through slotted hole in lower

handlebar bracket.

16. Remove cap screw and washer and bracket from

each side of mower.

M83868

Cotter Pin

M83869

Nut

Cap

M60584

Bracket

M83740

Cap Screw

and Washer

Bracket

17. Slide handlebar free of pegs.

18. Remove handlebar assembly.

Installation is done in the reverse order of removal.

• Adjust handlebar brackets straight up and down

before tightening.

IMPORTANT: Hooked end of brake cable end MUST

swing freely.

• Apply Multi-Purpose grease to hooked end of brake

cable.

• Adjust park brake. (See PARK BRAKE CHECK

AND ADJUSTMENT on page 7-7.)

• Adjust throttle cable. (See THROTTLE CABLE

CHECK AND ADJUSTMENT on page 3-22.)

• Adjust clutch control cable. (See DRIVE BELT

TENSION CHECK AND ADJUSTMENT on page

5-10.)

M83740

Bracket

M83866

Cable End

12/6/96 6 - 7

HANDLEBAR AND CONTROLS REPAIR

CLUTCH CONTROL/ OPERATOR PRESENCE BAIL

M83785

Bail

Knob

Lubrication

Pawl

Torsion Spring Arm

Nut (2 used)

Bolt

Stud

Nut

Cable

Arm

Lever

Fitting (2 used)

Cotter Pin

Cap Screw

Flange Nut

(3 used)

Bolt

(2 used)

1. Remove handlebar cover. (See HANDLEBAR

COVER—Removal/Installation on page 6-5.)

2. Inspect all parts for wear or damage. Replace parts

as necessary.

Installation is done in the reverse order of removal.

• Apply Multi-purpose grease to lubrication fittings.

• Adjust clutch control cable. (See DRIVE BELT

TENSION CHECK AND ADJUSTMENT on page

5-10.)

• Adjust operator presence bail. (See OPERATOR

PRESENCE BAIL ADJUSTMENT on page 6-3.)

6 - 8 12/6/96

REPAIR HANDLEBAR AND CONTROLS

BRAKE CONTROL/THROTTLE LEVER

M83784

Knob

Washer (2 used)

Throttle Lever

Spring Washer

Nut

Throttle

Clamp

Plate Lock Nut

Brake Cable

Wiring Harness

Lever

RUN/OFF Switch

Lock Plate

Fiber

Cap

Bolt (3 used)

Lock Washer

Arm

Nut

Flange

Nut

Flange

Nut

Screw

Cable

(2 used)

Bolt

Knob

Cap Screw

Washer

1. Remove handlebar cover. (See HANDLEBAR

COVER—Removal/Installation on page 6-5.)

2. Inspect all parts for wear or damage. Replace parts

as necessary.

Installation is done in the reverse order of removal.

• Adjust park brake. (See PARK BRAKE CHECK

AND ADJUSTMENT on page 7-7.)

• Adjust throttle cable. (See THROTTLE CABLE

CHECK AND ADJUSTMENT on page 3-22.)

• Adjust throttle lever. (See THROTTLE LEVER

TENSION ADJUSTMENT on page 6-3.)

BRAKES CONTENTS

Page

CONTENTS

12/9/96 7 - 1

BRAKES

COMPONENT LOCATION AND OPERATION

BRAKE SYSTEM OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

TROUBLESHOOTING CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3

DIAGNOSIS

MACHINE WILL NOT MOVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

BRAKE DOES NOT ENGAGE WHEN LEVER ENGAGED. . . . . . . . . . . . . . . . . . . 7-4

BRAKE DOES NOT HOLD MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

EXCESSIVE BRAKE WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

ADJUSTMENTS

PARK BRAKE CHECK AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

REPAIR

PARK BRAKE CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

BRAKE BAND REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7 - 2 12/6/96

COMPONENT LOCATION AND OPERATION BRAKES

COMPONENT LOCATION AND OPERATION

BRAKE SYSTEM OPERATION

JOHN DEERE

M83939

Brake Band Actuator Arm

Brake Cable

Drive Belt Idler

Return Spring

Speed Reducer

Input Sheave

Bracket Assembly

Function:

To provide a means of preventing the machine from

moving when not in operation.

Theory of Operation:

The 220A uses a band-type park brake mounted on the

speed reducer input sheave.

When the park brake is engaged, the cable causes the

brake band around the speed reducer input sheave to

tighten and apply drag, preventing the power train from

turning.

12/6/96 7 - 3

BRAKES TROUBLESHOOTING CHART

TROUBLESHOOTING CHART

Problem or

Symptom

Machine will not

move.

Brake does not

engage when lever

engagd.

Brake does not hold

machine.

Excessive brake

wear.

Check or

Solution

Cable not adjusted properly. llll

Cable broken or binding. l

Brake band/lining worn or

contaminated. l l

Return spring broken or

missing. l l

Speed reducer/drive chain/

traction roller damaged l

Park brake locked. l

7 - 4 12/6/96

DIAGNOSIS BRAKES

DIAGNOSIS

MACHINE WILL NOT MOVE

Test Conditions:

• Machine parked on a level surface.

• RUN/OFF switch OFF position.

• Travel clutch disengaged.

• Reel clutch in STOP position.

• Park brake released.

BRAKE DOES NOT ENGAGE WHEN LEVER ENGAGED

Test Conditions:

• Machine parked on a level surface.

• RUN/OFF switch OFF position.

• Travel clutch disengaged.

• Reel clutch in STOP position.

• Park brake released.

Test/Check Point Normal If Not Normal

1. Park brake lever. Brake lever not engaged. Release park brake.

2. Brake cable. Brake cable properly adjusted. Adjust cable. (See PARK BRAKE

CHECK AND ADJUSTMENT on page

7-7.)

3. Brake cable return spring. Spring not broken or missing. Replace return spring.

Test/Check Point Normal If Not Normal

1. Brake cable. Brake cable properly adjusted. Adjust cable. (See PARK BRAKE

CHECK AND ADJUSTMENT on page

7-7.)

Cable not broken or binding. Replace brake cable. (See PARK

BRAKE CABLE REPLACEMENT on

page 7-8.)

2. Brake band/lining. Brake band lining not worn. Adjust cable, see PARK BRAKE

CHECK AND ADJUSTMENT on page

7-7. If brake will still not engage after

the adjustment has been preformed,

replace brake band.(See BRAKE

BAND REPLACEMENT on page 7-9.)

Brake band lining not contaminated. Clean brake drum and/or replace

brake band. (See BRAKE BAND

REPLACEMENT on page 7-9.)

Brake band mounting hardware not

loose or missing. Tighten and/or replace mounting

hardware.

3. Actuator arm. Actutor arm not damaged. Replace actuator arm. (See DRIVE

BELT IDLER BRACKET ASSEMBLY

on page 5-27.)

12/6/96 7 - 5

BRAKES DIAGNOSIS

BRAKE DOES NOT HOLD MACHINE

Test Conditions:

• Machine parked on a level surface.

• RUN/OFF switch OFF position.

• Travel clutch disengaged.

• Reel clutch in STOP position.

• Park brake released.

Test/Check Point Normal If Not Normal

1. Brake cable. Brake cable properly adjusted. Adjust cable. (See PARK BRAKE

CHECK AND ADJUSTMENT on page

7-7.)

2. Brake band/lining. Brake band lining not excessively

worn. Adjust cable, see PARK BRAKE

CHECK AND ADJUSTMENT on page

7-7. If brake will still not engage after

the adjustment has been preformed,

replace brake band.(See BRAKE

BAND REPLACEMENT on page 7-9.)

Brake band lining not contaminated. Clean brake drum and/or replace

brake band. (See BRAKE BAND

REPLACEMENT on page 7-9.)

3. Speed reducer assembly. No internal damage. Repair speed reducer as necessary.

(See SPEED REDUCER

ASSEMBLY—Disassembly/

Inspection on page 5-17.)

4. Speed reducer output shaft

sprocket keys. Sprocket keys not damaged or

missing. Replace keys.

5. Traction drive chains Chains not broken. Replace drive chain(s).

6. Traction roller assembly. Sprockets not damaged. Replace sprockets. (See TRACTION

ROLLER ASSEMBLY— Disassembly/

Assembly on page 5-25.)

Keys not damaged or missing. Replace keys. (See TRACTION

ROLLER ASSEMBLY— Disassembly/

Assembly on page 5-25.)

7 - 6 12/6/96

DIAGNOSIS BRAKES

EXCESSIVE BRAKE WEAR

Test Conditions:

• Machine parked on a level surface.

• RUN/OFF switch OFF position.

• Travel clutch disengaged.

• Reel clutch in STOP position.

• Park brake released.

Test/Check Point Normal If Not Normal

1. Brake cable return spring. Spring not broken or missing. Replace return spring.

2. Brake cable. Brake cable properly adjusted. Adjust cable. (See PARK BRAKE

CHECK AND ADJUSTMENT on page

7-7.)

12/6/96 7 - 7

BRAKES CHECKS AND ADJUSTMENTS

CHECKS AND ADJUSTMENTS

PARK BRAKE CHECK AND

ADJUSTMENT

Reason:

To ensure that the park brake holds the machine when

engaged.

Check Procedure:

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position.

3. Move Travel Clutch Lever to NEUTRAL position.

4. Engage park brake.

5. Pull the machine backwards, if the transport

wheels/transport roller drag, the brake is adjusted

properly. If transport wheels turn, adjust brakes.

Adjustment Procedure:

6. Loosen jam nuts (one each side of bracket).

7. Shorten ferrule length.

8. Tighten jam nuts.

9. Repeat CHECK procedure. If additional adjustment

is required, go to step 10.

10. Remove cap screw and drive belt cover.

M83871

Jam Nuts

Ferrule Length

M83755

Drive Belt Cover

Cap Screw

11. Compress spring.

12. Loosen jam nuts holding brake cable at bracket.

13. Shorten ferrule length.

14. Tighten jam nuts.

15. Repeat CHECK procedure. If still not properly

adjusted, repeat adjustment procedure.

M83853

Jam Nuts

Ferrule Length

Spring

7 - 8 12/6/96

REPAIR BRAKES

REPAIR

PARK BRAKE CABLE

REPLACEMENT

1. Remove handlebar cover. (See HANDLEBAR

COVER—Removal/Installation on page 6-5.)

2. Remove carriage bolt and rotate brake lever down.

3. Disconnect cable end from lever.

4. Slide cap off cable housing.

5. Remove top nut.

6. Pull cable back until cable housing clears slot.

7. Route cable through slotted hole in lower handlebar

bracket.

M83851

Carriage Bolt

M83852

Nut

Cap

M60584

Bracket

8. Remove cap screw and drive belt cover.

9. Compress spring and disconnect brake cable end

from bracket.

10. Remove spring.

11. Remove jam nut and slide cable from bracket.

Installation is done in the reverse order of removal.

IMPORTANT: Hooked end of brake cable end

MUST swing freely.

• Apply Multi-Purpose grease to hooked end of brake

cable.

• Adjust park brake. (See PARK BRAKE CHECK

AND ADJUSTMENT on page 7-7.)

M83755

Drive Belt Cover

Cap Screw

M83853

Spring

M83854

Jam Nut

Cable End

12/6/96 7 - 9

BRAKES REPAIR

BRAKE BAND REPLACEMENT

1. Remove engine and belts. (See ENGINE—

Removal/Installation on page 3-29.)

2. Compress spring and disconnect brake cable end

from bracket.

3. Remove spring.

4. Remove jam nut and slide cable from bracket.

5. Remove caps screws, washer and nuts.

6. Remove brake band.

Installation is done in the reverse order of removal.

M83787

Spring

Jam Nut

Cable End

M83788

Washer

Cap Screws

Brake Band

7 - 10 12/6/96

REPAIR BRAKES

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CUTTING UNIT CONTENTS

Page

CONTENTS

12/6/96 8 - 1

CUTTING UNIT

SPECIFICATIONS

GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

ADJUSTMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

REPAIR SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

SPECIAL OR ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

DEALER FABRICATED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

OTHER MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

SERVICE PARTS KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

COMPONENT LOCATION

22-INCH REEL MOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

TROUBLESHOOTING

TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

DIAGNOSIS

MARCELLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

STREAKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

CUTTING HEIGHT CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

POOR QUALITY OF CUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

REEL DOES NOT ROTATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

UNIT NOT CUTTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

INFORMATION

BED KNIFE AND REEL RELATIONSHIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

REEL/BED KNIFE GRINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

RELIEF GRINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

BACKLAPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

GREENS TENDER CONDITIONER (GTC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

SMOOTH ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

GROOVED ROLLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

PERFORMANCE VARIABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

CHECKS AND ADJUSTMENTS

FRAME ALIGNMENT CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

BACKLAPPING AND BED KNIFE-TO-REEL ADJUSTMENT. . . . . . . . . . . . . . . . 8-14

REEL AND BED KNIFE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

BED KNIFE-TO-REEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

BACKLAPPING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

REEL DRIVE CHAIN TENSION ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

CUTTING HEIGHT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

OPTIONAL GREENS TENDER CONDITIONER (GTC)/

ROTARY BRUSH ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

CONTENTS CUTTING UNIT

8 - 2 12/6/96

Page

REPAIR

BED KNIFE

Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

REEL ASSEMBLY

Removal—Without Greens Tender Conditioner (GTC) . . . . . . . . . . . . . . . . . . 8-20

Installation—Without Greens Tender Conditioner (GTC). . . . . . . . . . . . . . . . . 8-22

Removal—With Greens Tender Conditioner (GTC). . . . . . . . . . . . . . . . . . . . . 8-23

Installation—With Greens Tender Conditioner (GTC) . . . . . . . . . . . . . . . . . . . 8-25

Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27

Disassembly/Inspection/Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28

FRONT ROLLER

Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29

Bearing Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30

AET10558 GROOVED ROLLER

Bearing Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31

12/6/96 8 - 3

CUTTING UNIT SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Cutting Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 cm (22 in.)

Cutting Height (Minimum)

Standard - 3.0 mm bedknife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 mm (1/8 in.)

Optional - 2.5 mm bedknife. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 mm (7/64 in.)

Cutting Height (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2 mm (7/8 in.)

Frequency of Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm (0.195 in.)

Reel

Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 mm (5 in.)

Number of Blades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heat Treated Special Alloy Steel

Grass Catcher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotational Moulded Poly Ethylene

Clip Ratio

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.195

Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.155

Front Roller

Machine Grooved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard

Smooth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Optional

Bed Knife Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bed Knife-to-Reel

Options:

Greens Tender Conditioner . . . . . . . . . . . . . . . . . . . . Standard spacing 6.5 mm (1/4 in.)

Rotary Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional

Transport Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Optional

ADJUSTMENT SPECIFICATIONS

Bed Knife-to-Reel Clearance . . . . . . . . . . . . . . . . . . . . . . . 0—0.025 mm (0—0.001 in.)

Greens Tender Conditioner (GTC)/Rotary Brush Height

Rotary Brush. . . . . . . . . . . . . . . . . . . . . . . . . 1 mm (1/32 in.) ABOVE Cutting Height

Greens Tender Conditioner. . . . . . . . . . . . . 1 mm (1/32 in.) BELOW Cutting Height

REPAIR SPECIFICATIONS

22-Inch Reel Mowers

Bed Knife Top surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5° Relief Angle

Front Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5° Relief Angle

Reel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spin Grind 20° Relief Grind

Bed Knife Support

Mounting Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 N•m (53 lb-in.)

8 - 4 12/6/96

REPAIR SPECIFICATIONS CUTTING UNIT

SPECIAL OR ESSENTIAL TOOLS

NOTE: Order tools according to information given in

the U.S. SERVICEGARD



Catalog or in the

European Microfiche Tool Catalog (MTC).

JDG795 Roller Bearing Puller

Used to remove bearings from rollers.

JDG243 or JDG506 Bearing Installer

Used to install bearings.

Two Bolt Gage Bar

Used to perform Height-of-Cut, Rear Roller/Bed Knife

and Greens Tender Conditioner Adjustments.

DEALER FABRICATED TOOLS

• 2-in. or 4-in. Paint brush, attach a piece of rubber

hose to the handle to extend its length. This will be

used to apply backlapping compound.

E32285

OTHER MATERIALS

Number Name Use

M79292 MPG-2 Multipurpose Polymer Grease Apply to engine crankshaft.

Lapping Compound Used in backlapping Procedure.

SERVICE PARTS KITS

The following kits are available through your parts catalog:

• Smooth Roller Kit

• Grooved Roller Kit

• Rotary Brush or Vertical Cutter Drive Kit

• Vertical Cutter Kit

• Rotary Brush Kit

12/6/96 8 - 5

CUTTING UNIT COMPONENT LOCATION

COMPONENT LOCATION

JOHN DEERE

M83941

Reel

Front Roller

T-Handle

(Bed Knife-to-Reel Adjustment)

Bed Knife

Front Roller Height

Adjustment Knob

8 - 6 12/6/96

TROUBLESHOOTING CUTTING UNIT

TROUBLESHOOTING

TROUBLESHOOTING CHART

Problem or

Symptom

Marcelling

Streaking

Cutting Height

Changes

Poor Cut Quality

Reels Do Not Rotate

Unit Not Cutting

Check or

Solution

Reel is dull ll

Incorrect number of blades for

conditions l l

Incorrect or inconsistent reel/

bed knife clearance l l ll

Damaged reel or bed knife l

Roller clamp bolt loose l

Roller bearing worn l

Roller out-of-round l

Reel/bed knife dull l l

Reel bearings worn or seized l

Machine speed too slow l

Grass too wet l

Changing soil conditions l

Cut grass collecting on roller l

Excessive grass growth l l

Chain broken l

12/6/96 8 - 7

CUTTING UNIT DIAGNOSIS

DIAGNOSIS

MARCELLING

Test Conditions:

• Machine parked on a level surface.

• RUN/OFF switch OFF position.

• Travel clutch disengaged.

STREAKING

Test Conditions:

• Machine parked on a level surface.

• RUN/OFF switch OFF position.

• Travel clutch disengaged.

Test/Check Point Normal If Not Normal

1. Reel Properly sharpened and backlapped See BACKLAPPING PROCEDURE

on page 8-16.)

Correct number of blades for applica-

tion See PERFORMANCE VARIABLES

on page 8-13.

Test/Check Point Normal If Not Normal

1. Reel/bed knife Properly sharpened and backlapped See BACKLAPPING PROCEDURE

on page 8-16 .)

2. Reel/bed knife Clearance properly adjusted across

bed knife Adjust clearance. (See BED KNIFE-

TO-REEL ADJUSTMENT on page 8-

15.)

3. Reel Reel not damaged or nicked Replace reel or perform backlapping

procedure. (See REEL ASSEM-

BLYRemovalWithout Greens Ten-

der Conditioner (GTC) on page 8-

20),REEL ASSEMBLYRemov-

alWith Greens Tender Conditioner

(GTC) on page 8-23 or (See BACK-

LAPPING PROCEDURE on page 8-

16.)

4. Bed knife Bed knife not damaged or nicked Grind or replace bed knife. (See BED

KNIFERemoval/Installation on page

8-20.)

8 - 8 12/6/96

DIAGNOSIS CUTTING UNIT

CUTTING HEIGHT CHANGESa

Test Conditions:

• Machine parked on a level surface.

• RUN/OFF switch in OFF position.

• Travel clutch disengaged.

POOR QUALITY OF CUTa

Test Conditions:

• Machine parked on a level surface.

• RUN/OFF switch in OFF position.

• Travel clutch disengaged.

aMay have causes related to conditions, see Operator’s Manual for more information.

Test/Check Point Normal If Not Normal

1. Roller clamp bolts Properly tightened Adjust cutting height. (See CUTTING

HEIGHT ADJUSTMENT on page 8-

17.)

2. Roller bearings Not worn Replace bearings. (See FRONT

ROLLER—Bearing Replacement on

page 8-30.)

3. Roller Not damaged or out-of-round Replace roller. (See FRONT

ROLLER—Removal/Installation on

page 8-29.)

4. Roller Clean, no grass collecting on roller Install scraper or Power Brush on

roller.

Test/Check Point Normal If Not Normal

1. Reel/bed knife Clearance properly adjusted across

bed knife Adjust clearance. (See BED KNIFE-

TO-REEL ADJUSTMENT on page 8-

15.)

2. Reel/bed knife Properly sharpened and backlapped Sharpen and backlap reel/bed knife

(See RELIEF GRINDING on page 8-

11 and BACKLAPPING PROCE-

DURE on page 8-16.)

12/6/96 8 - 9

CUTTING UNIT DIAGNOSIS

REEL DOES NOT ROTATE

Test Conditions:

• Machine parked on a level surface.

• Key switch OFF position.

• Travel clutch disengaged.

UNIT NOT CUTTINGa

Test Conditions:

• Machine parked on a level surface.

• RUN/OFF switch in OFF position.

• Travel clutch disengaged.

aMay have causes related to conditions, see Operator’s Manual for more information.

Test/Check Point Normal If Not Normal

1. Reel/bed knife Clearance properly adjusted across

bed knife Adjust clearance. (See BED KNIFE-

TO- REEL ADJUSTMENT on page 8-

15.)

2. Reel bearings Not worn or seized Replace bearings. (See REEL—Dis-

assembly/Inspection/Assembly on

page 8-28.)

3. Reel drive chain Not broken Replace reel drive chain.

4. Speed reducer reel clutch Not damaged Repair clutch. (See SPEED

REDUCER—Disassembly/Inspection

on page 5-17.)

Test/Check Point Normal If Not Normal

1. Reel/bed knife Clearance properly adjusted across

bed knife Adjust clearance. (See BED KNIFE-

TO-REEL ADJUSTMENT on page 8-

15.)

2. Reel Correct number of blades for applica-

tion Replace reel with reel having correct

number of blades for application. (See

PERFORMANCE VARIABLES on

page 8-13.)

3. Reel/bed knife Properly sharpened and backlapped See BACKLAPPING PROCEDURE

on page 8-16 .)

8 - 10 12/6/96

INFORMATION CUTTING UNIT

INFORMATION

REEL AND BED KNIFE

RELATIONSHIP

Reel Mowers are precision machines requiring daily

maintenance to maintain the well-groomed appearance

of turfgrass. The scissor-like shearing action, that only

a reel mower is capable of achieving, is only possible if

the reel and bed knife are sharp and the bed knife-to-

reel clearance is maintained.

Close examination of the bed knife-to-reel relationship

reveals two square edges passing one another with

approximately 0.05 mm (0.002 in.) clearance.

There are several reasons why this clearance is

necessary.

When the reel is allowed to contact the bed knife, the

square (sharp) edges of the reel and bed knife will

rollover, becoming dull.

Contact between the reel and bed knife generates

heat. Heat generated through this contact will distort

the shape of the bed knife. Distortion causes the bed

knife to draw closer to the reel, resulting in more

rollover of the cutting surfaces and more heat

generated in the bed knife.

Drag produced by an improperly adjusted cutting unit

may result in an unacceptable clip ratio, undue strain

on drive mechanisms and premature wear of the

cutting unit.

REEL/BED KNIFE GRINDING

Reasons for grinding:

To restore the cylindrical shape of a reel that has

become cone-shaped due to improper adjustment of

the bed knife-to-reel clearance or worn reel bearings.

To restore the edge when the grass is not being cut

across the entire length of the bed knife, evidenced by

streaks of grass left after the mower has passed.

Usually the result of nicked blades caused by hitting

foreign objects in the grass.

To restore the edge when the lack of frequent

backlapping allowed the edge to be rounded beyond

the capability of the backlapping procedure to restore

the edge.

To restore the edge when the bed knife-to-reel

clearance has been improperly adjusted (Reel

contacting bed knife).

Cutting action begins as the bed knife positions the

grass to be cut at the cutting edge. The reel then pulls

the grass towards the bed knife where it is sheared by

the cutting edges as they pass one another.

In order for the grass to be cut at the proper height, it

must contact the bed knife at the cutting edge. This is

accomplished by grinding a 5° relief angle on the front

face of the bed knife. Without a relief angle, the blade

of grass will contact the lower edge of the bed knife and

be bent over at too much of an angle prior to being cut.

In the case of mowing greens, where very small cuts

are being taken, the reel may not capture the grass at

all, and no grass will be cut.

Although some spingrinding machine manufacturers

say backlapping is not necessary, John Deere

recommends backlapping after spingrinding to remove

burrs and rough edges left from the spingrinding

procedure. Backlapping produces a honed edge that

will cut the grass evenly and leave the tops of the grass

with clean, straight edges.

It is important to note, dull cutting edges will tear rather

than shear the grass drawn into the bed knife. This will

shock the grass plant and retard its growth.

12/6/96 8 - 11

CUTTING UNIT INFORMATION

RELIEF GRINDING

John Deere recommends Relief Grinding the reel and bed knife for these reasons:

• Reduced blade contact area, results in less friction, requiring less horsepower to drive the reel.

• Ensures longer wear life.

• Less time is required to backlap.

• Reduces pulling and tearing of the grass as the unit gets dull by use.

• Provides an area for backlapping compound to be trapped to more effectively backlap reels.

• Relief grinding removes metal from the trailing edge of the blade forming an angle (Relief Angle) to reduce the

contact.

• Area of the cutting edges.

• Because of the relief grind it is possible, with backlapping, to true a reel (make it round) if a blade is 0.025—

0.05 mm (0.001—0.002 in.) too high.

CORRECT INCORRECT

Cutting Edge Cutting Edge

No Relief

20°

5° Relief

20°

Double

Relief Grind Relief

Grind Flat

Ground

Secondary Relief

Excessive

Relief

BACKLAPPING

This procedure is used to maintain a sharp cutting

edge between grindings. See Reel/Bed Knife Grinding,

in this section, to determine if grinding is necessary.

Backlapping, when compared to grinding, removes a

very small amount of metal, requires less time and will

effect a smooth, clean cut.

The backlapping procedure is accomplished by

spinning the reel backwards while applying special

abrasive compounds to the reel.

Usually, course compounds are used initially, followed

by a fine abrasive "tournament grade" for final honing.

Recommended grits for greens and tees when using

the 22-in. cutting units are 120, 180 and 220.

Recommended compounds for fairways are 60, 80 and

100 grit. Reel sharpening compounds should not be

toxic, oily or greasy.

The cutting unit should be inspected, lightly

backlapped, adjusted and checked every 20 hours. of

operation for a uniform cut along the complete length of

the bed knife.

It is important that the adjustment allows the reel to

turn freely without dragging against the bed knife.

Metal-to-metal contact will generate heat, causing the

reel to expand and intensifying the dragging that

produces more heat.

8 - 12 12/6/96

INFORMATION CUTTING UNIT

GREENS TENDER CONDITIONER

(GTC)

The conditioning process involves shallow vertical

cutting. The blades are adjusted to cut runners and lift

horizontal leaf material. It is important not to use a GTC

for three days following Top Dressing. It is also

important that frequent and thorough observations be

performed or stress to the plants may occur. Stress has

occurred when a yellow or brown tint is observed in the

color of the grass.

Grass is conditioned initially with the blades set 0.8 mm

(1/32 in.) below height-of-cut.

The green is then examined closely for inconsistencies

or appearance of over-aggressiveness. GTC

penetration should be decreased if indications are

present.

After 1 to 2 hours the green is checked for stress. If

visible stress is observed, GTC penetration is

decreased to 0.25 mm (1/64 in.) below height-of-cut.

Conditioning is continued at this setting for three to five

days checking frequently for signs of stress. If no stress

is observed, GTC penetration is increased by 0.25 mm

(0.010 in.) while observing every two to three days for

signs of stress.

Stress is a cumulative result of many factors such as

irrigation, temperature, humidity, chemical application

etc. Conditioning aggressiveness will require

adjustment and monitoring as these factors vary.

Conditioning frequency may also need to be reduced in

some cases.

SMOOTH ROLLER

The roller is used as a ground sensing device to detect

changes in the contour of the turf as the mower moves

forward.

A smooth roller is always used on the rear of a cutting

unit to establish the cutting height range. A front roller

used in conjunction with a rear roller is needed to

achieve more exact cutting heights.

GROOVED ROLLER

The grooved roller is used as a ground sensing device

to detect changes in the contour of the turf as the

mower moves forward. The main advantage in using a

grooved roller rather than a smooth one comes when

cutting long grass that is very wet. Grass that is wet will

tend to stay down rather than spring up after the roller

passes. Grooved rollers will not bend the grass over,

allowing it to be cut rather than passed over.

Along with advantages come disadvantages. Because

of the reduced contact area, inherent with a grooved

roller, the roller may penetrate deeper into the soil,

(especially in wet conditions) lowering the effective

cutting height and possibly scalping the turf. Serious

consideration should be given to mowing Greens with a

smooth roller attached, especially when the turf is very

wet.

12/6/96 8 - 13

CUTTING UNIT INFORMATION

PERFORMANCE VARIABLES

Three performance variables that affect the quality of

cut are:

• Number of reel blades (9 or 11)

• Reel rpm (sprockets)

• Ground speed of machine (sprockets)

NOTE: When discussing performance variables, we

must assume that other factors such as rate of

growth, mowing frequency, soil fertility and

equipment condition have been considered

and are not affecting the quality of cut.

Terms to help understand Performance Variables:

Shear point - A single point of cutting contact between

the cutting unit and the turf. Due to the Reel mower

design, there are an infinite number of shear points

across the bed knife.

Clip Ratio (CR) - The forward distance traveled

between successive cutting contacts at any one shear

point.

Cutting Height (CH) - The distance above the soil line

that grasses are clipped.

Since reel speed is directly coupled to ground speed

the Clip Ratio (CR) is fixed at 4.93 mm (0.195 in.).

When cutting greens, marcelling will be noticeable if

the Clip Ratio is greater than 6.35 mm (0.25 in.).

Between 6.35 mm (0.25 in.) and 5.08 mm (0.2 in.),

marcelling is seldom a problem. The 220A comes with

a standard Clip Ratio of 4.93 mm (0.195 in.). We feel

that this is the optimum Clip Ratio. Above 5.08 mm (0.2

in.), marcelling may become noticeable. The reel speed

can be increased to reduce the Clip Ratio to 3.94 mm

(0.155 in.). However, reel and bedknife life will be

reduced. Even more importantly, under certain

environmental conditions, the lower Clip Ratio can

result in turf damage. This damage will appear as a

brown strip where the mower overlaps on each pass.

NOTE: To calculate MPH, multiply 0.68148 x ft.

traveled/second. Another way to calculate

speed is to measure off an 88 ft. distance,

record the length of time, in seconds, it takes to

travel that distance and divide 60 by that time.

8 - 14 12/6/96

CHECKS AND ADJUSTMENTS CUTTING UNIT

CHECKS AND ADJUSTMENTS

FRAME ALIGNMENT CHECK

Reason:

To detect an eliminate non-parallelism which can result

in step cutting.

Equipment:

• Feeler Gauge Set (Blade Type)

• Flat Plate

Procedure:

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position.

3. Move travel clutch Lever to NEUTRAL position.

4. Engage park brake.

5. Release operator presence bail to disengage reel

drive.

6. Remove transport wheels (if equipped). (See

TRANSPORT WHEELS on page 9-3.)

7. Install new bed knife and adjust reel to zero

clearance. (See BED KNIFE-TO-REEL

ADJUSTMENT on page 8-15).

8. Set mower on a flat surface plate. The mower

should sit on drive rollers and bed knife with front

roller hanging over the edge of plate.

9. With one end of bed knife touching the surface

plate, check for gap between reel and surface

plate at each end using a feeler gauge. If gap

exceeds 0.13 mm (0.005 in.), adjust traction roller.

(See TRACTION ROLLER ADJUSTMENT on

page 5-11.)

BACKLAPPING AND BED KNIFE-TO-

REEL ADJUSTMENT

It is best to think of backlapping and bed knife-to-reel

adjustments as one procedure. Although backlapping

removes only a small amount of metal, the clearance

between the reel and bed knife increases due to

backlapping and must be readjusted.

Another very important point to remember is that

adjustments can only be successful if the frame

integrity (straitness and strength) is maintained.

Attaching bolts must be secure and bearings must be

well lubricated and not worn.

REEL AND BED KNIFE INSPECTION

1. Visually inspect cutting unit for damage. Chipped

paint, dents or gouges may indicate the need for a

closer look at the frame for distortion, broken

weldments or other damage that could prevent

proper adjustment. Repair or replace parts as

necessary.

2. Inspect for vertical or lateral movement in the reel or

bearings supporting the reel, repair or replace as

necessary.

3. While rotating the reel in the reverse direction by

hand, inspect each blade cutting edge for nicks,

gouges or distortion. Ensure the cutting edge land

does not exceed more than 3/4 of the blade

thickness. See REEL/BED KNIFE GRINDING on

page 8-10 to restore the relief angle and cutting

edge before continuing with this procedure.

4. Inspect the bed knife cutting edge for nicks, gouges

or distortion. Inspect leading edge of bed knife for

relief to prevent catching of knife. A small relief or

dub needs to be added after several backlappings.

5. Inspect the bed knife for uneven wear (indicated by

uneven land width across the length of the bed

knife). Ensure the cutting edge land does not

exceed 3/4 of the cutting edge. Replace the bed

knife if the cutting edge starts curling upward.

cCAUTION

Always wear protective gloves when working on

or near the reel or bed knife. Severe personal

injury can result from contact with the sharp

cutting edges.

Never allow more than one person at a time, to

work on any one cutting unit. Never allow work

to be accomplished on more than one cutting

unit at the same time. Serious personal injury

could result.

M83925

Cutting Edge

12/6/96 8 - 15

CUTTING UNIT CHECKS AND ADJUSTMENTS

BED KNIFE-TO-REEL ADJUSTMENT

Reason:

To ensure correct contact between bed and reel knife.

Equipment:

• Feeler Gauge Set (Blade Type)

Procedure:

NOTE: Reel must be free to turn by hand.

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position.

3. Move Travel Clutch Lever to NEUTRAL position.

4. Engage park brake.

5. Disengage reel clutch.

6. Remove grass catcher.

7. Loosen clamp screw on both sides of mower.

8. To adjust bed knife-to-reel clearance turn adjusting

handle:

• CLOCKWISE to decrease clearance.

• COUNTERCLOCKWISE to increase clearance.

cCAUTION

Always wear protective gloves when working on

or near the reel or bed knife. Severe personal

injury can result from contact with the sharp

cutting edges.

M60556

Clamp Screw

Adjusting Handle

IMPORTANT: Always rotate reel in the reverse

direction to avoid damaging or dulling the

cutting edges or the reel or bed knife.

9. Inspect gap along the entire length of the bed knife

using a 0.002-in feeler gauge:

• If the reel contacts the bed knife at any point, go to

step 11.

• If the gap is large enough to allow the feeler gauge

to pass between reel and bed knife, go to steps

12—13.

10. Slowly rotate the reel backwards and watch for

contact between the reel and bed knife at the

center of the bed knife. If contact is made, backlap

the reel and bed knife to eliminate “FROWN” in

bed knife or out-of-round condition of reel. (See

BACKLAPPING PROCEDURE on page 8-16.)

11. Measure the clearance at the center of bed knife. If

clearance exceeds 0.05 mm (0.002 in.), backlap

the reel and bed knife to eliminate “SMILE” in bed

knife or out-of-round condition of reel. (See

BACKLAPPING PROCEDURE on page 8-16.)

12. When properly adjusted and sharpened, each reel

blade should cut a piece of paper held at 90° to the

top surface of the bed knife along the entire length

of the bed knife with 0—0.025 mm (0—0.001 in.)

clearance

M72977

M83925

Center of Bed Knife

8 - 16 12/6/96

CHECKS AND ADJUSTMENTS CUTTING UNIT

IMPORTANT: DO NOT overtighten knife to reel.

Overtightening can cause damage to knife or

cutting edges.

13. Tighten clamp screw on both sides of mower.

BACKLAPPING PROCEDURE

Reason:

To ensure consistent cutting action.

Equipment:

• Long-Handled Brush (Dealer Fabricated)

• Backlapping Unit

• 3/8-in. Backlapping Bolt

Procedure:

IMPORTANT: Backlap cutting reel routinely to

prolong life of reel.

NOTE: The bed knife-to-reel contact should be

adjusted before performing backlapping

procedure. (See BED KNIFE-TO-REEL

ADJUSTMENT on page 8-15.)

cCAUTION

Disengage GREENS TENDER CONDITIONER

before backlapping. Severe personal injury may

result from rotating knives.

M60556

Clamp Screw

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position.

3. Move Travel Clutch Lever to NEUTRAL position.

4. Engage park brake.

5. Release operator presence bail to disengage reel

drive.

6. Remove reel shaft cover.

7. Screw 3/8-in. backlapping bolt into reel shaft.

8. Install socket extension on backlapping bolt.

9. Connect extension to backlapping unit.

10. Turn on backlapping motor. Make sure reel is

running in reverse.

cCAUTION

Avoid injury from rotating blades. keep hands

and feet away from blades while machine is

running.

Always wear protective gloves when working on

or near the reel or bed knife. Severe personal

injury can result from contact with the sharp

cutting edges.

Never allow more than one person at a time, to

work on any one cutting unit.

Never allow work to be accomplished on more

than one cutting unit at the same time. Serious

personal injury could result.

M60606

Backlapping Unit

Socket Extension

Cover

M56482

12/6/96 8 - 17

CUTTING UNIT CHECKS AND ADJUSTMENTS

IMPORTANT: Never operate cutting unit in the

Forward direction until abrasive compounds are

removed from the cutting unit. The abrasive

compound will dull the cutting edges

11. Apply 120 grit compound to the rotating reel evenly

from one side to the other and back again with a

long handled brush. (See DEALER FABRICATED

TOOLS on page 8-4 for instructions for making this

tool.)

12. Allow the reel to spin until quiet. If desired, follow

with a 220 grit compound to achieve a

“Tournament Grade" finish.

13. Rinse the lapping compound off the cutting unit

with water and repeat the Adjustment Procedure

before returning the unit to service. (See BED

KNIFE-TO-REEL ADJUSTMENT on page 8-15.)

14. Add a relief if needed, to the leading edge of the

knife, to prevent the edge from "catching" the reel

and curling it up.

REEL DRIVE CHAIN TENSION

ADJUSTMENT

Reason:

To maintain proper chain tension.

Procedure:

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position.

3. Move Travel Clutch Lever to NEUTRAL position.

4. Engage park brake.

5. Disengage reel clutch.

6. Remove transport wheels and left side drive collar

(if equipped). (See TRANSPORT WHEELS on

page 9-3.)

cCAUTION

Never use pressure washers or steam cleaners

to rinse the abrasives from the cutting unit. The

abrasives may be forced past the seals and

damage the bearings.

cCAUTION

Block machine securely before servicing or

repairing.

7. Loosen four bearing housing cap screws.

8. Remove five acorn nuts, washers and shoulder

bolts, and remove left drive cover.

9. Loosen cap screw and reposition idler roller/bracket

until chain deflects 6 mm (0.225 in.) at mid span

opposite idler.

10. Tighten cap screw.

11. Install cover and transport wheels (if equipped).

CUTTING HEIGHT ADJUSTMENT

Reason:

To set desired cutting height.

Procedure:

NOTE: The bed knife-to-reel adjustment MUST be

performed before adjusting cutting height. (See

BED KNIFE-TO-REEL ADJUSTMENT on page

8-15.)

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position.

3. Move Travel Clutch Lever to NEUTRAL position.

4. Engage park brake.

5. Disengage reel clutch.

M60559

Cap Screws

Acorn Nuts

M60567

Cap Screw

Reel Drive Chain

Idler Roller

8 - 18 12/6/96

CHECKS AND ADJUSTMENTS CUTTING UNIT

6. Loosen T-handle on both sides of mower until

adjusting bracket slides easily.

7. Loosen wing nut and set gauge to desired cutting

height.

8. Place gauge against bottom of front and transport

rollers and bed knife cutting surface.

M83772

T-Handle

Adjusting Bracket

E29234

Wing Nut

Gauge

M72976

Front Roller

Transport Roller

Screw Head

Gauge

9. Adjust height front roller up or down using adjusting

knob.

10. Adjust height to gauge by adjusting front roller until

knife make firm contact with underside of screw

head.

11. Repeat steps 8—10 for other side.

12. Recheck cutting height on both sides with gauge.

Re-adjust if necessary.

13. Tighten T-handles.

OPTIONAL GREENS TENDER

CONDITIONER (GTC)/ROTARY

BRUSH ADJUSTMENT

Reason:

To endure that the the machine drives evenly when the

Rotary Brush or Greens Tender Conditioner (GTC) is

engaged.

Procedure:

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position.

3. Move Travel Clutch Lever to NEUTRAL position.

4. Move reel clutch to STOP position.

5. Engage park brake.

6. Disengage Greens Tender Conditioner (GTC).

7. Remove grass catcher.

M83772

Adjusting Knob

12/6/96 8 - 19

CUTTING UNIT CHECKS AND ADJUSTMENTS

8. Loosen T-handle.

9. Loosen jam knob.

10. Set adjusting knob on lower step of sliding block.

11. Repeat procedure for other side.

12. Measure from the top of screw head to the top of

the gauge. Set to desired cutting height.

13. Loosen wing nut and adjust the screw as follows:

• Rotary Brush: 1 mm (1/32 in.) ABOVE cutting

height.

• Greens Tender Conditioner: 1 mm (1/32 in.)

BELOW cutting height.

14. Place gauge against bottom of front and rear rollers

and bed knife cutting surface.

M60623

T-Handle

Jam Knob

Adjusting Knob

Sliding Block

E29234

Wing Nut

M72976

Front Roller

Transport Roller

Screw Head

Gauge

15. Use adjusting knob to set height on each side.

16. Tighten jam knob.

17. Repeat for other side.

M60623

T-Handle

Jam Knob

Adjusting Knob

8 - 20 12/6/96

REPAIR CUTTING UNIT

REPAIR

BED KNIFE

Removal/Installation

1. Remove 13 screws and bed knife.

IMPORTANT: DO NOT reuse screws if bed knife is

removed.

2. Remove debris and corrosion from bottom surface

of shoe. Check the bed knife mounting surface

with a straight edge for distortion, straighten or

replace as necessary.

Installation is done in the reverse order of removal.

• Install bed knife using new screws. Starting at the

center screw, alternate tightening bed screws

working toward the ends of the knife. Tighten

screws to 6.5 N•m (58 lb-in.).

cCAUTION

Block machine securely before servicing or

repairing.

cCAUTION

Always wear protective gloves when working on

or near the reel or bed knife. Severe personal

injury can result from contact with the sharp

cutting edges.

M83925

Bed Knife Screws (13 Used)

REEL ASSEMBLY

Removal—Without Greens Tender

Conditioner (GTC)

1. Remove transport wheels and drive collars (if

equipped). (See TRANSPORT WHEELS on page

9-3.)

2. Loosen four bearing housing cap screws.

3. Remove five acorn nuts, washers and shoulder

bolts, and remove left drive cover.

4. Loosen cap screw to release chain tension.

5. Disconnect master link and remove reel drive chain.

cCAUTION

Block machine securely before servicing or

repairing.

M60559

Cap Screws

Acorn Nuts

M60567

Cap Screw

Reel Drive Chain

12/6/96 8 - 21

CUTTING UNIT REPAIR

6. Loosen cap screws and remove shield.

7. Remove cap

8. Remove shoulder bolt, spring, spacer and collar.

9. Loosen clamp screw and remove bed knife

adjusting handles from both sides of mower.

M83774

Cap Screws

Shield

M60528

Cap

M83926

Shoulder Bolt

M60628

Clamp Screw

Adjusting Handle

10. Remove spring and T-bolt from both sides of

mower.

11. Rotate bed knife support downward.

12. Remove three cap screws and shield from left

bearing housing. Left end of reel will lower.

13. Remove three bolts from right bearing housing.

14. Remove reel assembly.

15. Inspect all parts for wear or damage. Replace parts

as necessary. (See Disassembly/Inspection/

Assembly procedure on page 8-28.).

cCAUTION

Always wear protective gloves when working on

or near the reel or bed knife. Severe personal

injury can result from contact with the sharp

cutting edges.

M60629

Spring

M83773

Shield

Cap Screws

M83927

Cap Screws

8 - 22 12/6/96

REPAIR CUTTING UNIT

Installation—Without Greens Tender

Conditioner (GTC)

1. Install reel assembly and shield with three cap

screws.

2. Install bearing housing using three cap screws.

3. Install spring and T-bolt on both sides of mower.

cCAUTION

Always wear protective gloves when working on

or near the reel or bed knife. Severe personal

injury can result from contact with the sharp

cutting edges.

M83773

Shield

Cap Screws

M83927

Cap Screws

M60629

Spring

4. Install adjusting handles.

5. Adjust handles until bed knife just clears reel.

6. Tighten clamp screws.

7. Install collar, spring and shoulder bolt.

8. Install cap.

9. Pry right-hand end of reel to left side to check for

end play. Reel must slide easily.

10. Lubricate both sides of reel.

11. Adjust reel drive chain tension. (See REEL DRIVE

CHAIN TENSION ADJUSTMENT on page 8-17.)

12. Lubricate drive chains. (See GREASE—NORTH

AMERICA or GREASE—EUROPE on page 2-13.)

M60628

Adjusting Handle

Clamp Screw

M83926

Shoulder Bolt

Spacer

Spring

M60567

12/6/96 8 - 23

CUTTING UNIT REPAIR

13. Install left drive cover.

14. Tighten four bearing housing cap screws.

NOTE: Place three washers between shield bracket

and engine mount.

15. Slide shield under cap screws. Tighten caps

screws.

16. Adjust bed knife-to-reel clearance. (See BED

KNIFE-TO-REEL ADJUSTMENT on page 8-15).

17. Backlap reel. (See BACKLAPPING PROCEDURE

on page 8-16.)

Removal—With Greens Tender

Conditioner (GTC)

1. Remove transport wheels and drive collars (if

equipped). (See TRANSPORT WHEELS on page

9-3.)

M60559

Cap Screws

Acorn Nuts

M83774

3 Washers

Shield

2. Loosen four bearing housing cap screws.

3. Remove five acorn nuts, washers and shoulder

bolts, and remove left drive cover.

4. Loosen cap screw to release chain tension.

5. Disconnect master link and remove reel drive chain.

6. Loosen cap screws and remove shield.

M60559

Cap Screws

Acorn Nuts

M60567

Reel Drive Chain

Cap Screw

M83774

Cap Screws

Shield

8 - 24 12/6/96

REPAIR CUTTING UNIT

7. Turn knob counterclockwise past detent position.

8. Remove two cap screws and washers.

9. Remove gear case cover.

10. Remove shoulder bolt, spring and gear.

11. Remove key and collar.

M60622

Cap Screws

Gear Case Cover

Knob

M60615

Shoulder Bolt

Gear

Spring

M60609

Collar

Key

12. Remove adjuster T-handle, lock washer and bolt

from both sides of mower.

13. Remove nut, gear and key.

14. Remove vertical cutter or rotary brush.

15. Remove snap ring, gear case and collar.

cCAUTION

Always wear protective gloves when working on

or near a reel or GTC. Serious personal injury

can result from contact with sharp cutting

edges.

M60618

T-Handle

M60615

Gear

Nut Rotary Brush

M60611

Snap Ring

Collar Gear Case

12/6/96 8 - 25

CUTTING UNIT REPAIR

16. Loosen clamp screw and remove bed knife

adjusting handles from both sides of mower.

17. Remove spring and T-bolt from both sides of

mower.

18. Rotate bed knife support downward.

19. Remove three cap screws and shield from left

bearing housing. Left end of reel will lower.

cCAUTION

Always wear protective gloves when working on

or near the reel or bed knife. Severe personal

injury can result from contact with the sharp

cutting edges.

M60628

Adjusting Handle

Clamp Screw

M60629

Spring

M60567

Shield

Cap Screws

20. Remove three bolts from right bearing housing.

21. Remove reel assembly.

22. Inspect all parts for wear or damage. Replace parts

as necessary. (See Disassembly/Inspection/

Assembly procedure on page 8-28.).

Installation—With Greens Tender

Conditioner (GTC)

1. Install reel assembly and shield with three cap

screws.

cCAUTION

Always wear protective gloves when working on

or near a reel or GTC. Serious personal injury

can result from contact with sharp cutting

edges.

M83927

Cap Screws

M83773

Shield

Cap Screws

8 - 26 12/6/96

REPAIR CUTTING UNIT

2. Install bearing housing using three cap screws.

3. Install spring and T-bolt on both sides of mower.

4. Install adjusting handles.

5. Adjust handles until bed knife just clears reel.

6. Tighten clamp screws.

7. Install collar, gear case and snap ring

M83927

Cap Screws

M60629

Spring

M60628

Adjusting Handle

Clamp Screw

M60611

Snap Ring

Collar Gear Case

8. Install vertical cutter or rotary brush.

9. Install adjuster T-handle, lockwasher and bolt on

both sides of mower.

10. Install key and gear and nut.

11. Pry right-hand end of reel to left side to check for

end play. Reel must slide easily.

12. Lubricate both sides of reel.

13. Install reel drive chain.

14. Adjust reel drive chain tension. (See REEL DRIVE

CHAIN TENSION ADJUSTMENT on page 8-17.)

15. Lubricate drive chains. (See GREASE—NORTH

AMERICA or GREASE—EUROPE on page 2-13.)

M60618

T-Handle

Rotary Brush

M60615

Gear

Nut

M60567

Reel Drive Chain

12/6/96 8 - 27

CUTTING UNIT REPAIR

16. Install left drive cover.

NOTE: Place three washers between shield bracket

and engine mount.

17. Slide shield under cap screws. Tighten caps

screws.

18. Adjust bed knife-to-reel clearance. (See BED

KNIFE-TO-REEL ADJUSTMENT on page 8-15).

19. Backlap reel. (See BACKLAPPING PROCEDURE

on page 8-16.)

M60559

Cap Screws

Acorn Nuts

M83774

3 Washers

Shield

Bearing Inspection

NOTE: If one bearing and seal is being replaced,

replace other side also.

Rotate reel and inspect bearing for roughness and

ease of rotation. If reel binds or rotates rough, replace

bearing and seal. (See Disassembly/Inspection/

Assembly procedure on page 8-28.)

cCAUTION

Always wear protective gloves when working on

or near the reel or bed knife. Severe personal

injury can result from contact with the sharp

cutting edges.

E32305

Reel Bearing

8 - 28 12/6/96

REPAIR CUTTING UNIT

Disassembly/Inspection/Assembly

M83940

Reel

O-Ring

Bearing Cup

Bearing Cone

Lubrication Fitting

Housing

Key

Housing

Shoe

Bed Knife

Screw (13 used)

Nut

Washer

(2 used)

Sprocket

Snap Ring

Seal

(3 used)

Bushing

(2 used)

Shoulder Bolt

Spacer

Bearing

Cup

Bearing

Cone Seal

Shoulder Bolt

Spring

Spacer (No GTC)

Gear (GTC)

6.5 N•m (58 lb-in.)

12/6/96 8 - 29

CUTTING UNIT REPAIR

NOTE: If bearings and seal are to replaced, replace

both sides at the same time.

1. Inspect all parts for wear or damage. Replace parts

as necessary.

2. Apply reel support grease to lubrication fittings.

(See REEL SUPPORT GREASE—NORTH

AMERICA or REEL SUPPORT GREASE—

EUROPE on page 2-11.)

FRONT ROLLER

Removal/Installation

1. Loosen jam nut and set screw at both ends of the

roller.

2. Remove T-handle, lock washers, flat washer and

round head cap screw at both ends of the roller.

3. Remove roller and brackets.

4. Remove brackets from roller.

Installation is done in the reverse order of removal.

cCAUTION

Always wear protective gloves when working on

or near the reel or bed knife. Severe personal

injury can result from contact with the sharp

cutting edges.

M60576

T-Handle

Set Screw Jam Nut

Adjuster Knob

NOTE: DO NOT install set screws into holes in roller

shaft.

• Tighten T-handles.

• Center roller between brackets, install set screws

and tighten jam nuts.

NOTE: DO NOT over-lubricate. Excess grease could

fall from the mower during operation.

• Apply multi-purpose grease to grease fittings.

• Adjust cutting height. (See CUTTING HEIGHT

ADJUSTMENT on page 8-17.)

M60576

Jam Nut

Set Screw

Brackets

8 - 30 12/6/96

REPAIR CUTTING UNIT

Bearing Replacement

NOTE: This procedure applies to both smooth and

grooved rollers, except for AET10558 Grooved

Rollers. (See AET10558 GROOVED

ROLLER

—

Bearing Replacement on page

8-30.)

1. Attach threaded puller to the bearing by inserting

the pin through the hole in the bearing shaft and

puller. Slide the O-ring over the pin to keep it in

position.

2. Slide roller sleeve over the threaded puller with the

concave end of the roller sleeve against the end of

the roller. Install flat washer and nut on threaded

puller.

3. Clamp the hex end of the threaded puller in a vice

or hold it with a wrench. Turn nut counterclockwise

until the bearing is removed from the roller.

cCAUTION

Wear approved eye protection when using

JDG795 Roller Bearing Puller.

M83583

O-Ring

Roller

Flat Washer

Threaded Puller

Nut

Roller Sleeve

M83584

IMPORTANT: DO NOT press on center shaft of

bearing when installing bearing. Bearings will

set and become tight. Bearings must only be

installed by pressing on outside race of bearing.

4. Position roller in a press using the roller sleeve to

hold the roller while installing the bearing in the

other end.

5. Position JD243 or JD506 Bearing Installer over the

new bearing in the top end of the roller.

6. Smooth Rollers: Place a 0.89-mm (0.035-in.)

feeler gauge in the slot where the grease fitting

was located. Press the bearing into the roller until

the top of the outside bearing race is flush with the

top of the feeler gauge. Install the grease fitting.

7. Grooved Rollers: Press bearing into roller until the

top of the outside bearing is flush with end of the

roller.

M83586

M83585

M83587

12/6/96 8 - 31

CUTTING UNIT REPAIR

AET10558 GROOVED ROLLER

Bearing Replacement

1. Secure roller in a vice. Remove grease fittings.

2. Use a hammer and a block of wood to knock out the

opposite end bearing.

3. Remove bearing from shaft and repeat step 2 to

knock out the other end bearing.

4. Clean roller end cap and bearing shaft with crocus

cloth. Pack bearings with grease.

5. Install bearing shaft and bearings (sealed end of

bearing towards inside). Apply grease to lip of seal

and install with seal lip facing the bearing.

6. Install opposite seal.

7. Install grease fittings and lubricate (Do not over-

lubricate, a shot of grease is fine).

M4904

M46857

8 - 32 12/6/96

REPAIR CUTTING UNIT

This page intentionally left blank.

MISCELLANEOUS CONTENTS

Page

CONTENTS

11/18/96 9 - 1

MISCELLANEOUS

SPECIFICATIONS

REPAIR SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

SERVICE PARTS KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

REPAIR

TRANSPORT WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

FRAME AND DRIVE COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

9 - 2 12/6/96

SPECIFICATIONS MISCELLANEOUS

SPECIFICATIONS

REPAIR SPECIFICATIONS

Drive Collar Installation dimesion (from groove to face of collar) . . . . . 60 mm (2.40 in.)

SERVICE PARTS KITS

The following kits are available through your parts catalog:

• Transport Wheel and Parking Stand Kit

12/6/96 9 - 3

MISCELLANEOUS REPAIR

REPAIR

TRANSPORT WHEELS

Removal/Installation

1. Place machine on stand.

2. Release latch and slide wheel from shaft. Repeat

procedure for other side.

NOTE: Remove drive collars only if necessary to

perform further service.

M83742

M83743

Latch

3. Loosen allen head screw, and remove drive collar

and key. Repeat procedure for other side.

Installation is done in the reverse order of removal.

• Install drive collar with flat side facing machine.

• Install drive collar 60 mm (2.40 in.) from groove on

shaft to face of drive collar.

M83744

Stop Collar

Allen Head Screw

M83744

60 mm

(2.40 in.)

Flat Side

9 - 4 12/6/96

REPAIR MISCELLANEOUS

FRAME AND DRIVE COVERS

M83924

Grease

Seal

Cover

Cap Screw

Bearing

Housing

Cap Screw

(4 used)

Ball Bearing

(2 used)

Nut

(8 used) Washer

(8 used) Cover

(3 used)

Frame

Bearing

Housing

(3 used)

Engine

Support

Fittings

(3 used)

Shield

Bracket

Washer

(8 used)

Cap Screw

(2 used)

Spacer

(2 used)

Ball Bearing

(3 used)

Rod

Brace

Frame

(9 used)

Nut (2 used)

Screw (2 used)

Cap Screw

(3 used)

Washer

(3 used) Housing Cap

Cap Screw

(8 used)

Washer

(8 used)

Nut

(8 used)

• Inspect all parts for wear or damage. Replace parts

as necessary.

• Apply Non-Clay High-Temperature EP Grease

(North America) or Grease-Gard (Europe) to

grease fittings.

INDEX

12/9/96 INDEX - 1

AET10558 Grooved Roller

Bearing Replacement . . . . . . . . . . . . . . . . 8-31

Air Cleaner

Removal/Installation . . . . . . . . . . . . . . . . . 3-30

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Alternative Lubricants . . . . . . . . . . . . . . . . . . . 2-14

Anti-Corrosion Grease . . . . . . . . . . . . . . . . . . 2-12

Backlapping Information . . . . . . . . . . . . . . . . . 8-11

Bed Knife, Removal/Installation . . . . . . . . . . .8-20

Bed Knife-to-Reel Adjustment . . . . . . . . . . . . . 8-15

Blower Housing, Removal/Installation . . . . . . 3-36

Brake

Band Replacement . . . . . . . . . . . . . . . . . . 7-9

Cable Replacement . . . . . . . . . . . . . . . . . 7-8

Check and Adjustment . . . . . . . . . . . . . . . 7-7

Control Lever . . . . . . . . . . . . . . . . . . . . . . 6-8

Brake System

Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Operation . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Troubleshooting Chart . . . . . . . . . . . . . . . 7-3

Camshaft and Tappets

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

Removal/Installation . . . . . . . . . . . . . . . . . 3-49

Carburetor

Clean/Inspect/Rebuild . . . . . . . . . . . . . . . 3-35

Float Level Adjustment . . . . . . . . . . . . . . . 3-36

Identification Number . . . . . . . . . . . . . . . . 2-15

Pilot Screw and Limiter Cap Replacement 3-35

Removal/Installation . . . . . . . . . . . . . . . . . 3-32

Clutch Control . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Clutch Control Cable . . . . . . . . . . . . . . . . . . . . 5-14

Controls, Component Location . . . . . . . . . . . . 6-2

Cooling System Operation . . . . . . . . . . . . . . . 3-14

Crankcase Cover

Bearing Inspection/Replacement . . . . . . . 3-49

Removal/Installation . . . . . . . . . . . . . . . . . 3-48

Crankshaft

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Removal/Installation . . . . . . . . . . . . . . . . . 3-58

Timing/Governor Gear Replacement . . . . 3-58

Crankshaft and Connecting Rod

Analyze Wear . . . . . . . . . . . . . . . . . . . . . . 3-59

Cutting Height Adjustment . . . . . . . . . . . . . . . 8-17

Cutting Unit

Adjustment Specifications . . . . . . . . . . . . 8-3

Backlapping Information . . . . . . . . . . . . . . 8-11

Backlapping Procedure . . . . . . . . . . . . . . 8-16

Component Location . . . . . . . . . . . . . . . . 8-5

Dealer Fabricated Tools . . . . . . . . . . . . . . 8-4

Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Frame Alignment Check . . . . . . . . . . . . . . 8-14

General Specifications . . . . . . . . . . . . . . . 8-3

Greens Tender Conditioner Information . . 8-12

Height Adjustment . . . . . . . . . . . . . . . . . . 8-17

Performance Variables . . . . . . . . . . . . . . . 8-13

Relief Grinding . . . . . . . . . . . . . . . . . . . . . 8-11

Repair Specifications . . . . . . . . . . . . . . . . 8-3

Troubleshooting Chart . . . . . . . . . . . . . . . 8-6

Cylinder Block

Bearing Inspection/Replacement . . . . . . . 3-60

Deglaze Bore . . . . . . . . . . . . . . . . . . . . . . 3-60

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

Oil Seal Replacement . . . . . . . . . . . . . . . . 3-60

Rebore Cylinder . . . . . . . . . . . . . . . . . . . . 3-60

Cylinder Compression Pressure Test . . . . . . . 3-23

Cylinder Head and Valves

Analyze Valves . . . . . . . . . . . . . . . . . . . . . 3-45

Disassembly/Assembly . . . . . . . . . . . . . . . 3-42

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Lap Valves . . . . . . . . . . . . . . . . . . . . . . . . 3-47

Recondition Valve Seats . . . . . . . . . . . . . 3-46

Removal/Installation . . . . . . . . . . . . . . . . . 3-41

Valve Guide Replacement . . . . . . . . . . . . 3-44

Drive Belt

Guide Adjustment . . . . . . . . . . . . . . . . . . . 5-11

Idler Bracket Assembly . . . . . . . . . . . . . . . 5-27

Replacement . . . . . . . . . . . . . . . . . . . . . . 5-14

Tension Check and Adjustment . . . . . . . . 5-10

Drive Chain Tensioners . . . . . . . . . . . . . . . . . . 5-26

Drive Covers . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Electrical Schematic . . . . . . . . . . . . . . . . . . . . 4-5

Electrical System

Wire Color Abbreviation Chart . . . . . . . . . 4-2

Engine

External Component Location . . . . . . . . . 3-9

Internal Component Location . . . . . . . . . . 3-11

Oil Level Check . . . . . . . . . . . . . . . . . . . . 2-16

Removal/Installation . . . . . . . . . . . . . . . . . 3-29

Repair Specifications . . . . . . . . . . . . . . . . 3-3

Serial Number . . . . . . . . . . . . . . . . . . . . . . 2-15

Service Parts Kits . . . . . . . . . . . . . . . . . . . 3-8

Test and Adjustment Specifications . . . . . 3-3

Troubleshooting Chart . . . . . . . . . . . . . . . 3-16

Troubleshooting Guide . . . . . . . . . . . . . . . 3-18

INDEX

INDEX - 2 12/9/96

Flywheel, Removal/Installation . . . . . . . . . . . . 3-40

Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Front Roller

Bearing Replacement . . . . . . . . . . . . . . . . 8-30

Removal/Installation . . . . . . . . . . . . . . . . . 8-29

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Fuel System

Troubleshooting Chart . . . . . . . . . . . . . . . 3-16

Fuel Tank, Removal/Installation . . . . . . . . . . . 3-27

Gasoline Engine Oil

4-Cycle—Europe . . . . . . . . . . . . . . . . . . . 2-9

4-Cycle—North America . . . . . . . . . . . . . . 2-8

Gasoline Specifications

4-Cycle Engines—Europe . . . . . . . . . . . . 2-7

4-Cycle Engines—North America . . . . . . . 2-6

Gasoline Storage

Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

North America . . . . . . . . . . . . . . . . . . . . . . 2-6

Governor

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Removal/Installation . . . . . . . . . . . . . . . . . 3-61

Grease

Anti-Corrosion . . . . . . . . . . . . . . . . . . . . . . 2-12

Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

North America . . . . . . . . . . . . . . . . . . . . . . 2-13

Reel Support—Europe . . . . . . . . . . . . . . . 2-11

Reel Support—North America . . . . . . . . . 2-11

Greens Tender Conditioner (GTC)

Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . 8-18

Information . . . . . . . . . . . . . . . . . . . . . . . . 8-12

Grooved Roller

Information . . . . . . . . . . . . . . . . . . . . . . . . 8-12

Handlebar

Height Adjustment . . . . . . . . . . . . . . . . . . 6-4

Removal/Installation . . . . . . . . . . . . . . . . . 6-5

Handlebar Cover . . . . . . . . . . . . . . . . . . . . . . . 6-5

Idle Speed Adjustment

Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Ignition Coil

Air Gap Adjustment . . . . . . . . . . . . . . . . . 3-39

Removal/Installation . . . . . . . . . . . . . . . . . 3-39

Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Inch Fastener Torque Values . . . . . . . . . . . . . 2-5

Lubricants

Alternative . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Synthetic . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Lubrication System Operation . . . . . . . . . . . . . 3-12

Machine Identification Number . . . . . . . . . . . . 2-15

Metric Fastener Torque Values . . . . . . . . . . . . 2-4

Muffler, Removal/Installation . . . . . . . . . . . . . . 3-28

Oil Speed Reducer—Europe . . . . . . . . . . . . . 2-10

Speed Reducer—North America . . . . . . . 2-10

Oil, 4-Cycle Engine

Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

North America . . . . . . . . . . . . . . . . . . . . . . 2-8

Operational Checkout Procedures . . . . . . . . . 2-16

Operator Presence Bail

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Operator Presence Bail Check . . . . . . . . . . . . 2-18

Park Brake Check . . . . . . . . . . . . . . . . . . . . . . 2-18

Piston and Connecting Rod

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

Connecting Rod Side Play . . . . . . . . . . . . 3-55

Connecting Rod-to-Crankshaft Clearance 3-55

Disassembly . . . . . . . . . . . . . . . . . . . . . . . 3-51

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

Installation . . . . . . . . . . . . . . . . . . . . . . . . 3-51

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

Piston Rings

Analyze Wear . . . . . . . . . . . . . . . . . . . . . . 3-55

Check End Gap . . . . . . . . . . . . . . . . . . . . 3-55

Piston, Analyze Wear . . . . . . . . . . . . . . . . . . . 3-57

Power Train

Adjustment Specifications . . . . . . . . . . . . 5-2

Component Location and Operation . . . . . 5-3

Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Repair Specifications . . . . . . . . . . . . . . . . 5-2

Troubleshooting Chart . . . . . . . . . . . . . . . 5-4

Recoil Starter

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Disassembly/Inspection . . . . . . . . . . . . . . 3-37

Removal/Installation . . . . . . . . . . . . . . . . . 3-37

Reduction Assembly

Bearing/Oil Seal Replacement . . . . . . . . . 3-48

Removal/Installation . . . . . . . . . . . . . . . . . 3-47

Reel and Bed Knife Inspection . . . . . . . . . . . . 8-14

Reel Assembly

Bearing Inspection . . . . . . . . . . . . . . . . . . 8-27

Disassembly/Inspection/Assembly . . . . . . 8-28

Installation—With GTC . . . . . . . . . . . . . . . 8-25

Installation—Without GTC . . . . . . . . . . . . 8-22

Removal—With GTC . . . . . . . . . . . . . . . . 8-23

Removal—Without GTC . . . . . . . . . . . . . . 8-20

Reel Clutch Check . . . . . . . . . . . . . . . . . . . . . 2-19

Reel Support Grease

Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

North America . . . . . . . . . . . . . . . . . . . . . . 2-11

Reel/Bed Knife Grinding . . . . . . . . . . . . . . . . . 8-10

Relief Grinding . . . . . . . . . . . . . . . . . . . . . . . . 8-11

Rocker Arm Cover, Removal/Installation . . . . 3-41

Rotary Brush Adjustment . . . . . . . . . . . . . . . . 8-18

INDEX

12/9/96 INDEX - 3

Smooth Roller, Information . . . . . . . . . . . . . . . 8-12

Spark Plug Gap Adjustment . . . . . . . . . . . . . . 3-26

Spark Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Speed Reducer

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Disassembly . . . . . . . . . . . . . . . . . . . . . . . 5-17

Oil Level Check . . . . . . . . . . . . . . . . . . . . 2-16

Oil—Europe . . . . . . . . . . . . . . . . . . . . . . . 2-10

Oil—North America . . . . . . . . . . . . . . . . . . 2-10

Removal/Installation . . . . . . . . . . . . . . . . . 5-15

Synthetic Lubricants . . . . . . . . . . . . . . . . . . . . 2-14

Throttle Cable

Check and Adjustment . . . . . . . . . . . . . . . 3-22

Removal/Installation . . . . . . . . . . . . . . . . . 3-28

Throttle Lever

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Tension Adjustment . . . . . . . . . . . . . . . . . 6-3

Throttle Plate, Removal/Installation . . . . . . . . 3-32

Torque Values

Inch Fastener . . . . . . . . . . . . . . . . . . . . . . 2-5

Metric Fastener . . . . . . . . . . . . . . . . . . . . . 2-4

Traction Roller

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Disassembly/Assembly . . . . . . . . . . . . . . . 5-25

Removal/Installation . . . . . . . . . . . . . . . . . 5-22

Drive Chain Tension Adjustment . . . . . . . 5-13

Transport Wheels . . . . . . . . . . . . . . . . . . . . . . 9-3

Travel Clutch Check . . . . . . . . . . . . . . . . . . . . 2-19

Valve Clearance Check and Adjustment . . . . 3-24

Valves

Analyze Condition . . . . . . . . . . . . . . . . . . . 3-45

Lap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

Vehicle Specifications . . . . . . . . . . . . . . . . . . . 2-2

INDEX

INDEX - 4 12/9/96

This page intentionally left blank.

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