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•••••
200 South Ridge Road
•••Hesston, Kansas
•67062
BigDog® MowersR Diablo®
Parts Manual
Inspect spark arrester daily; replace every 500 hours or as needed.
The Engine Owner’s Manual provides information regarding the U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty.
Keep Engine Owner’s Manual with your unit. Should the Engine Owner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered per the information found in the Product Information section of the owner’s manual.
Federal law and California State law prohibit the following acts or the causing thereof:1. The removal or rendering inoperative by any person other than for purposes of maintenance,
repair, replacement, of any device or element of design incorporated into any equipment for the purposes of emissions control prior to or after its sales or delivery to the ultimate purchaser or while it is in use, or
2. The use of the equipment after such device or element of design has been removed or rendered inoperative by any person.
WARNING
The engine exhaust from this product contains chemicals known to the state
of California to cause cancer, birth defects or other reproductive harm.
NOTICE OF REQUIREMENT OF SPARK ARRESTER MUFFLER
This equipment may create sparks that can start fires around dry vegetation. California Public Resources Code Section 4442.6 provides that it is unlawful to use or operate an internal combustion engine on any forest-covered, brush-covered, or grass-covered land unless the engine is equipped with a spark arrester maintained in effective working order. A spark arrester is a device constructed of nonflammable materials specifically for the purpose of removing and retaining carbon and other flammable particles over 0.0232 of an inch in size from the exhaust flow of an internal combustion engine that uses hydrocarbon fuels or which is qualified and rated by the United States Forest Service. Other states or federal areas may have similar laws. The Operator Should Contact Local Fire Agencies For Laws or Regulations Relating to Fire Prevention Requirements. THIS EQUIPMENT DOES NOT HAVE A SPARK ARRESTER AND YOU SHOULD CONTACT YOUR AUTHORIZED DEALER FOR THE PURCHASE OF A SPARK ARRESTER.
115599_1113 c-1
Table of ContentsGeneral Information
Service Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Options Available From Your Dealer. . . . . . . . . . . . . . . . . . . . . . . . 1-1Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Hardware Description Codes & Abbreviations . . . . . . . . . . . . . . . . 1-2Standard Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Section 2Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Footrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Engine Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Section 3Hydraulic Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Transmission Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Steering Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Section 4Wheel & Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Front Tire Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Drive Wheel Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Section 5Engine, Kawasaki FX691V & FX730V . . . . . . . . . . . . . . . . . . . . . . 5-2Engine Service Parts, Kawasaki FX691V & FX730V . . . . . . . . . . . 5-6Fuel System—S/N 12080978 & Higher. . . . . . . . . . . . . . . . . . . . . . 5-8Fuel System—S/N Prior to 12080978. . . . . . . . . . . . . . . . . . . . . . . 5-10Fuel System Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Section 6Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Section 754" Service Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-254" Deck Pulleys & Spindles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-454" Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-660" Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-860" Deck Pulleys & Spindles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1060" Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12Spindle Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14Deck Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16Deck Mounting Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Section 8Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2Seat Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4ROPS—Foldable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
c-2 115599_1113
115599_1113 1-1
General Information
This manual covers BigDog® Mowers models 931378 & 931386.
Service Literature
PART NO.
OPERATOR’S MANUALWARRANTY STATEMENTGENERAL SERVICE MANUAL
Options Available From Your Dealer
PART NO.
54" 2-BAG CATCHER54" DECK MULCH KIT54" DECK CONTAINMENT KIT60" 2-BAG CATCHER60" DECK MULCH KIT60" DECK CONTAINMENT KITHOUR METER KITSTEERING EXTENSION KITLIGHT KITFLEX FORKS®
SEAT SPRING KIT
Note: When ordering parts, you must use the part number as shown for each part, not the index number. Always give the model and serial number to your parts and service representative.
Note: Items sold in bulk such as seals and hoses are sold by the foot.
Using This Manual
This manual is part of a service package for the BigDog® mowers. Use of this manual in conjunction with other Big-Dog® mower and component manuals will provide the information necessary to service and maintain BigDog® mowers.
This Parts Manual provides a complete parts listing for the unit. Use this manual when ordering parts. Illustrations used were current at the time of printing, but subsequent production changes may cause your machine to vary slightly in detail. Excel Industries, Inc. reserves the right to redesign and change the machine as deemed necessary, without noti-fication. If a change has been made to your machine which is not reflected in this parts manual, see your authorized dealer for current information and parts.
The Service Manual is a service guide for use by Service Technicians. It provides the necessary information needed to perform normal maintenance requirements on these units.
The Operator's Manual provides fundamental operational information and operational safety that is needed when oper-ating the mower.
The component manuals are furnished by the various manufacturers to be used for the troubleshooting and servicing of their products.
DESCRIPTION
603743115620115619
DESCRIPTION
929687112611112615930834113934113933367656333724112418603717108743
1-2 115599_1113
Hardware Description Codes & Abbreviations
The following codes are used throughout this parts manual. Refer to this list when ordering parts.
ABBREVIATION
CARRIAGE BOLT MACHINE BUSHINGCLEVIS PIN MACHINE SCREWCLIP NUT NUTCOTTER PIN SELF TAPPING CAP SCREWCAP SCREW SOCKET HEADCUP WASHER SHOULDER BOLTFENDER WASHER SET SCREWFLAT WASHER OUTSIDE DIAMETERHEX HEAD INSIDE DIAMETERLOCK WASHER
Standard Torques
The following chart lists the standard torque values for the threaded fasteners found in this manual. Torque all cap screws, nuts and set screws to these values unless a different torque is shown in the Notes section next to the fastener.
SIZE FT-LBS N-M SIZE FT-LBS N-M
DESCRIPTION ABBREVIATION DESCRIPTION
CB MBCE MSCN NTCP SCCS SHCW SB
FDRW SSFW ODHX IDLW
.250 8.2 11.1 M3 1 1.3
.312 17 23 M4 2.2 3
.375 30 40 M5 4.5 6.1
.438 48 65 M6 7.7 10.4
.500 73 99 M8 18.5 25
.562 105 143 M10 37 50
.625 145 200 M12 64 87
.750 260 350 M14 80 108.5
.875 420 565 M16 160 2151.00 625 850 M20 320 435
M24 555 750
115599_1113 2-1
Section 2
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Footrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Engine Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-2 115599_1113
Frame
7
12
10
2
17
14
2
1
65
23
4
8
9
13
11 10
10
16
15
1
2
3
18
115599_1113 2-3
Frame
INDEX NO. PART NO. QTY.
54" FRAME (WITH DECALS & HARDWARE)
60" FRAME (WITH DECALS & HARDWARE)
3/8-16 THREAD RIVET NUT
CN .312-18 X .20 MAX THK
FUEL INDICATOR DECAL
ENGINE COMPARTMENT DECAL
HOT DECAL
PUMP BELT WARNING DECAL
RS STEERING DECAL
DECK HEIGHT DECAL
SERIAL NUMBER / SPEC DECAL
LS STEERING DECAL
BIG DOG R LOGO DECAL
MADE IN USA DECAL
SAFE OPERATION DECAL
3/8-16 THREAD HEX RIVET NUT
5/16-18 THREAD RIVET NUT
TOW VALVE DECAL
STEP TREAD
NOTES:
1. In the event the serial number tag becomes damaged or illegible, please contact your dealer to order a replacement.
2. Patent numbers plate.
3. EPA compliance plate.
DESCRIPTION
1 551192 1
551193 1
2 808493 8
3 601069 2
4 791848 1
5 601967 1
6 602041 1
7 600899 1
8 785220 1
9 603407 1
10 N/A 3
11 785139 1
12 603724 1
13 727172 1
14 601993 1
15 600994 2
16 808485 1
17 601099 1
18 601987 1
2-4 115599_1113
Footrest
1
2
34
4
6
5
7
8
115599_1113 2-5
Footrest
INDEX NO. PART NO. QTY.
FLOOR PAN
CB .375-16 X .75 STD ZN
NT .375-16 HX ZY NL
FW .406 X .812 X .060 SAE
CB .375-16 X 1.00 G5 ZNY
NT .375-16 HX G5 ZNY
R754 DECAL
R760 DECAL
STEP TREAD
NOTES:
DESCRIPTION
1 190023 1
2 011320 2
3 086660 2
4 767954 4
5 025395 2
6 054502 2
7 603725 1
603726 1
8 602323 3
2-6 115599_1113
Engine Guard
12
3
5
5
6
4
7
10
8
89
6
INDEX NO. PART NO. QTY
REAR ENGINE PLATE GUARD
FW .406 X .812 X .060 SAE
CS .375-16 X 1.25 HX G5 ZN
NT .500-13 HX G8 ZY NL
FW .510 X 2.15 X .187 SPL
PLASTIC WHEEL ASSEMBLY
CS .500-13 X 4.25 HX G5
FW .531 X 1.063 X .090 SAE
PLASTIC WHEEL
NT .500-13 HX JAM ZNYC
NOTES:
DESCRIPTION
1 190002 1
2 767954 6
3 052860 6
4 781567 2
5 344267 4
6 788166 2
7 781708 2
8 767962 4
9 031997 2
10 053199 2
115599_1113 3-1
Section 3
Hydraulic Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Transmission Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Transmission Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Steering Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-2 115599_1113
Hydraulic Transmissions
2021
16
19
6
18
17
7
5
8
12
4
1
2
2
3
4
9
10
9
11
13
2
15
215
14
17
2
1
115599_1113 3-3
Hydraulic Transmissions
INDEX NO. PART NO. QTY.
CS .312-18 X 2.25 HX G5
FW .343 X .687 X .051/.080H
CS .312-18 X 2.50 HX G5
WIRE TIE
CS .625-11 X 1.75 HX G5
IDLER PULLEY 4.00" OD
SPRING 1/4 COIL PL 1.23
FW .781 X 1.25 X .024 ZN
BUSHING
PUMP TENSIONER
FW .760 X 1.625 X .08 ZNYC
SB .750 X 2.00 SH .625-11
BELT, A SEC, 67.6 EL
TRANSMISSION ASSEMBLY
NT .312-18 HX G5 ZNYC
OVERFLOW TANK (WITH CAP)
OVERFLOW TANK CAP
FW .281 X .625 X .051/.080 HD ZN/YL
NT .250-20 HX ZY NL
CS .250-20 X .75 HX G5
TOW LINK ROD
CP .062D X 1.00 LG HML Z
NOTES:
1. Torque to 100 ft-lbs.
2. Torque to 17 ft-lbs.
DESCRIPTION
1 038828 4
2 768523 16
3 710087 4
4 000331 3
5 025007 1
6 784827 1
7 036384 1
8 704791 1
9 770867 2
10 111771 1
11 025296 1
12 601084 1
13 602253 1
14 N/A 1
15 034272 8
16 600759 1
600767 1
17 768515 4
18 068551 2
19 055939 2
20 601088 2
21 048553 2
3-4 115599_1113
Transmission Assembly
1 67
117
3
10
5
4
4
8
9
12
11
8
7
613
13
14
14
15
2
1
1
7
12
115599_1113 3-5
Transmission Assembly
INDEX NO. PART NO. QTY.
LS TRANSMISSION
RS TRANSMISSION
HYDRAULIC FITTING, 45 DEG
SPRING CLAMP
OVERFLOW HOSE
NT .312-18 HX G5 ZNYC
FW .343 X .687 X .051/.080H
SPRING CLAMP
OVERFLOW HOSE
FITTING, 90 - 9/16 SAE
BALL STUD
STEERING DAMPER
CS .375-16 X 2.00 G5 ZNYC
FW .406 X 1.00 X .12 HRD Z
SPACER TUBE
NOTES:
1. Torque to 30 ft-lbs.
DESCRIPTION
1 603741 1
2 603740 1
3 600880 1
4 601001 2
5 601018 1
6 034272 2
7 768523 4
8 601474 2
9 601055 1
10 601219 1
11 781922 2
12 600221 2
13 016410 2
14 712919 2
15 600987 1
3-6 115599_1113
Transmission Service Parts
7 6
1
5
4
23
8
INDEX NO. PART NO. QTY.
FAN/PULLEY KIT
RETAINING CLIP
BRAKE ARM
CHARGE COVER KIT
O-RING
LS FILTER GUARD
RS FILTER GUARD (NOT SHOWN)
OIL FILTER
4 BOLT HUB KIT
NOTES:
DESCRIPTION
1 603866 1
2 600972 1
3 601221 1
4 603572 1
5 603223 1
6 600975 1
600974 1
7 600976 1
8 601433 1
115599_1113 3-7
This page intentionally left blank.
3-8 115599_1113
Steering
2
STEERINGSUB-ASSEMBLY
3
3
3
3
3
4
14
8
8
13
17
7
9
10
11
12
56
15
1
16
3
1
1
115599_1113 3-9
Steering
INDEX NO. PART NO. QTY
LOCK COLLAR 0.757 ID
NT .312-24 HX NL ZN
FW .343 X .687 X .051/.080H
PUMP ROD
CS .375-16 X 1.375 HX G5
NT .375-16 HX JAM G5 Z
CS .250-20 X .75 HX G5
FW .281 X .625 X .051/.080H
STEER TUBE SUPPORT
CS .312-18 X 1.00 HX G5
PLATED PIVOT TUBE
LW .312 INT-EXT TOOTH
NT .312-18 HX G5 ZNYC
BALL STUD
NT .250-20 HX G5 ZNYC
SPACER
NT .312-24 HX ZNYC
NOTES:
1. Part of the Transmission Assembly.
DESCRIPTION
1 784439 2
2 023655 2
3 768523 13
4 600981 2
5 005116 2
6 706168 2
7 055939 4
8 768515 8
9 108968 2
10 036236 1
11 361295 1
12 029876 2
13 034272 2
14 781922 2
15 024927 4
16 604456 2
17 041152 2
3-10 115599_1113
Steering Sub-Assembly1
2
5
4
3
3
3
3
6
5
3
7
7
34
8
INDEX NO. PART NO. QTY.
STEERING BAR GRIP
STEERING BAR (WITH GRIP)
FW .406 X .812 X .060 SAE
CS .375-16 X 1.75 HX G5
NT .375-16 NL G5
LEFT STEERING ARM (SHOWN)
RIGHT STEERING ARM
BUSHING
LS STEER PIVOT (SHOWN)
RS STEER PIVOT
NOTES:
DESCRIPTION
1 781260 2
2 360487 2
3 767954 12
4 705178 6
5 086660 6
6 107843 1
107842 1
7 770867 4
8 107848 1
107847 1
115599_1113 3-11
This page intentionally left blank.
3-12 115599_1113
Brake
1
4
2
3
7
13
2
12
9
8
9
26
2
10
5
214
18
21
17
15
16
MOWERFRAME
HYDRAULICTRANSMISSION
11125
8
87
STEERINGARM
115599_1113 3-13
Brake
INDEX NO. PART NO. QTY.
NT .375-16 NL G5
FW .406 X .812 X .060 SAE
SWITCH
CS .375-16 X 3.50 HX G5 Z
BRAKE ROD ASSEMBLY
NT .375-16 HX G5 ZNY
NT .312-24 HX NL ZN
FW .343 X .687 X .051/.080H
BUSHING
LS BRAKE BELL CRANK
RS BRAKE BELL CRANK
CS .375-16 X 1.50 HX G5
SHORT BRAKE LINK ROD
SPRING
LS BRAKE SPRING LINK
RS BRAKE SPRING LINK (NOT SHOWN)
CS .250-20 X .75 HX G5
NT .250-20 HX FL LK ZNY
OVERTRAVEL SPRING
NOTES:
DESCRIPTION
1 086660 4
2 767954 12
3 601087 2
4 005108 2
5 601410 2
6 054502 2
7 023655 4
8 768523 8
9 765339 4
10 107893 1
11 107892 1
12 080655 2
13 600991 2
14 601131 2
15 109203 1
109202 1
16 055939 2
17 016816 2
18 601051 2
3-14 115599_1113
115599_1113 4-1
Section 4
Wheel & Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Front Tire Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Drive Wheel Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-2 115599_1113
Wheel & Tire
1 3
12
4
5
6
7
8
9
115599_1113 4-3
Wheel & Tire
INDEX NO. PART NO. QTY.
TIRE/WHEEL ASSEMBLY 22 X 11-10
WHEEL BACKUP PLATE
WHEEL NUT
CS .500-13 X 1.25 HX G5 ZN
FW .510 X 2.15 X .187 SPL
FW .531 X 1.375 X .125 ZNY
BEARING
SPACER
FRONT TIRE S/A LEFT
FRONT TIRE S/A RIGHT (NOT SHOWN)
NOTES:
1. Torque to 65–75 ft-lbs.
DESCRIPTION
1 603749 2
2 111875 2
3 061077 8
4 705954 2
5 344267 2
6 712976 2
7 784223 4
8 784603 2
9 604570 1
10 604569 1
4-4 115599_1113
Front Tire Breakdown
4
5
21
3
3
7
7
6
89
10
115599_1113 4-5
Front Tire Breakdown
INDEX NO. PART NO. QTY.
FORK
CS .750-10 X 9.50 HX ZY
FW .760 X 1.625 X .08 ZNYC
NT .750-10 HX ZY NL
TIRE/WHEEL 13 X 6.5
TIRE 13 X 6.50
WHEEL BEARING
BEARING SPACER
WHEEL 6 X 4.5
TIRE VALVE
NOTES:
DESCRIPTION
1 190112 1
2 041475 1
3 025296 2
4 061101 1
5 603755 1
6 747741 1
7 039677 2
8 782771 1
9 603756 1
10 019521 1
4-6 115599_1113
Drive Wheel Breakdown
NOTES:
INDEX NO. PART NO. QTY. DESCRIPTION
1 603738 1 TIRE 22 X 11-10
2 603737 1 WHEEL 10X 8.5
3 019521 1 VALVE STEM
1
2
3
115599_1113 5-1
Section 5
Engine, Kawasaki FX691V & FX730V. . . . . . . . . . . . . . . . . . . . . . . . 5-2
Engine Service Parts, Kawasaki FX691V & FX730V . . . . . . . . . . . . 5-6
Fuel System—S/N 12080978 & Higher . . . . . . . . . . . . . . . . . . . . . . . 5-8
Fuel System—S/N Prior to 12080978 . . . . . . . . . . . . . . . . . . . . . . . 5-10
Fuel System Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-2 115599_1113
Engine, Kawasaki FX691V & FX730V
914
15
7
1
2
1
5
64
4 3
19
12
20
17
1812
11
10
13
84
6
3
2
316
115599_1113 5-3
Engine, Kawasaki FX691V & FX730V
INDEX NO. PART NO. QTY.
KAWASAKI FX691V & FX730V ENGINE
MUFFLER
CS .312-18 X 1.000 HX G5
FW .343 X .687 X .051/.080H
CLUTCH ANCHOR
NT .312-18 HX G5 ZNYC
OIL DRAIN VALVE
CB .312-18 X .750 FUL ZN
MUFFLER SHIELD
GROUND STRAP
LW .375 INT-EXT TOOTH
CS .375-16 X 1.25 HXG5 P85
KEY 1/4 SQ X 0.66 LG
PULLEY
FW .406 X .812 X .060 SAE
CLUTCH KIT
WIRE TIE, SMALL/SHORT
CLUTCH HARNESS PIGTAIL
FW .453 X 1.12 X .119 HRD
CS .437-20 X 2.50 HXG5 P85
NOTES:
1. Supplied with the engine.
2. Torque the bolt to 45–48 ft-lbs. Replace (do not reuse) the cap screw if it’s removed or loosened. Use only hand tools to install this fastener.
3. Torque the bolt to 30–35 ft-lbs. Replace (do not reuse) the cap screw if it’s removed or loosened. Use only hand tools to install this fastener.
DESCRIPTION
1 N/A 1
2 603150 1
3 036236 2
4 768523 8
5 113946 1
6 034272 6
7 796524 1
8 016253 2
9 108969 1
10 111894 1
11 793885 1
12 602580 4
13 712372 1
14 603255 1
15 767954 3
16 601785K 1
17 000331 3
18 791251 1
19 602680 1
20 785659 1
5-4 115599_1113
Engine, Kawasaki FX691V & FX730V
25
23
30A FUSE
1
17
22
6
12
10
11
21
4
4
6
26
25
24
24
A
B
4
4
4
115599_1113 5-5
Engine, Kawasaki FX691V & FX730V
INDEX NO. PART NO. QTY.
NEGATIVE BATTERY CABLE
POSITIVE BATTERY CABLE
1/4" FUEL LINE
CLAMP, 3/16"
HOSE CLAMP
3/16" VAPOR LINE
NOTES:
4. Part of the wire harness.
DESCRIPTION
21 601063 1
22 744276 1
23 015818 18"
24 603112 2
25 000323 2
26 603326 33"
FUEL & VAPOR LINE LENGTHS
18" FILTER TO FUEL VALVE (FUEL)
33" ENGINE PORT TO TEE (VAPOR)
A
B
5-6 115599_1113
Engine Service Parts, Kawasaki FX691V & FX730V
4
3
1
2
5
INDEX NO. PART NO. QTY.
MAIN AIR FILTER
SAFETY AIR FILTER
OIL FILTER
IN-LINE FUEL FILTER
VACUATOR VALVE
NOTES:
DESCRIPTION
1 785261 1
2 785279 1
3 602581 1
4 068478 1
5 763318 1
115599_1113 5-7
This page intentionally left blank.
5-8 115599_1113
Fuel System—S/N 12080978 & Higher
3
2
1
4
4
11
415
15
14 16
12
16
5
6
7
8
9
10
135
6
9
10
7
8
11
1
C
13
4
16
A
B
D E
115599_1113 5-9
Fuel System—S/N 12080978 & Higher
INDEX NO. PART NO. QTY.
RS FUEL TANK ASSEMBLY
LS FUEL TANK ASSEMBLY
RATCHETING GAS CAP 3.5"
HOSE CLAMP
CS .312-18 X 1.00 HX G5
FW .343 X .687 X .051/.080H
FW .406 X 1.00 X.12 HRD Z
CS .375-16 X .75 HX G5
LOOP CLAMP
NT .312-18 HX FLK ZNYC
FUEL VALVE 3-WAY
PLASTIC TEE, 3/16"
WIRE TIE
VACUUM BREAKER
1/4" FUEL LINE
3/16" VAPOR LINE
FUEL LINE LENGTHS
RIGHT TANK TO VALVE (FUEL)
LEFT TANK TO VALVE (FUEL)
RIGHT TANK TO TEE (VAPOR)
TEE TO VACUUM BREAKER (VAPOR)
LEFT TANK TO VACUUM BREAKER (VAPOR)
NOTES:
1. Torque to 7 ft-lbs.
DESCRIPTION
1 604058 1
2 604059 1
3 602916 2
4 000323 4
5 036236 2
6 768523 2
7 712919 6
8 055822 6
9 043570 2
10 016832 2
11 745059 1
12 604281 1
13 000331 1
14 604305 1
15 015818 36"
16 603326 46"
12"
24"
25"
5"
16"
A
B
C
D
E
5-10 115599_1113
Fuel System—S/N Prior to 12080978
3
2
1
4
4
4
11
415
15
14 154
12
15
5
6
7
8
9
10
135
6
9
10
7
8
411
1
C
1
3
4
4
15
A
B
D E
4
115599_1113 5-11
Fuel System—S/N Prior to 12080978
INDEX NO. PART NO. QTY.
RS FUEL TANK ASSEMBLY
LS FUEL TANK ASSEMBLY
RATCHETING GAS CAP 3.5"
HOSE CLAMP
CS .312-18 X 1.00 HX G5
FW .343 X .687 X .051/.080H
FW .406 X 1.00 X.12 HRD Z
CS .375-16 X .75 HX G5
LOOP CLAMP
NT .312-18 HX FLK ZNYC
FUEL VALVE 3-WAY
PLASTIC TEE 1/4" X 1/4" X 3/16"
WIRE TIE
VACUUM BREAKER
1/4" FUEL LINE
FUEL LINE LENGTHS
RIGHT TANK TO VALVE (FUEL)
LEFT TANK TO VALVE (FUEL)
RIGHT TANK TO TEE (VAPOR)
TEE TO VACUUM BREAKER (VAPOR)
LEFT TANK TO VACUUM BREAKER (VAPOR)
NOTES:
1. Torque to 7 ft-lbs.
DESCRIPTION
1 603032 1
2 603031 1
3 602916 2
4 000323 10
5 036236 2
6 768523 2
7 712919 6
8 055822 6
9 043570 2
10 016832 2
11 745059 1
12 603025 1
13 000331 1
14 603024 1
15 015818 82"
12"
24"
25"
5"
16"
A
B
C
D
E
5-12 115599_1113
Fuel System Service Parts
7
4
5
23
S/N 11090186-12080977
1
23
S/N PRIOR TO 11090186
6
5
S/N 12080978 & HIGHER
23
INDEX NO. PART NO. QTY.
VENT FITTING KIT
SUCTION HOSE GROMMET
SUCTION HOSE ASSEMBLY 19.5"
FUEL VENT VALVE
GROMMET
VENT FITTING
VACUUM BREAKER FILTER
NOTES:
DESCRIPTION
1 117118 1
2 785295 1
3 601527 1
4 604199 1
5 604200 1
6 604287 1
7 603161 1
115599_1113 6-1
Section 6
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-2 115599_1113
Battery
1
2
3
5
45
5
6
6
7
8
115599_1113 6-3
Battery
INDEX NO. PART NO. QTY.
CS .312-18 X 4.00 HX G5
FW .343 X .687 X .051/.080H
BATTERY CLAMP STRAP
CS .250-20 X .75 HX G5
LW .250 INT-EXT TOOTH Z
NT .250-20 HX G5 ZNYC
RED BATTERY CABLE BOOT
GM 1.50 X 2.12 X 1.75
WIRE TIE (NOT SHOWN)
NOTES:
DESCRIPTION
1 714618 2
2 768523 2
3 348417 1
4 055939 2
5 029868 4
6 024927 2
7 771428 1
8 794644 2
9 000331 1
6-4 115599_1113
Instrument Panel
13
2
3
7
7
1
10
6
6
14
5
5
9
8
11
12
16
171
18
1
15
1110
4
10A FUSE
15A FUSE
115599_1113 6-5
Instrument Panel
INDEX NO. PART NO. QTY.
CHOKE CABLE
PTO SWITCH
RED INDICATOR LIGHT
KEY ASSEMBLY
CB 10-24 X .500 ZYNC
NT #10-24 HX NL ZN
IGNITION SWITCH
FW .219 X .500 X .048 ZNYC
THROTTLE CABLE
CS .250-20 X .500 HX G5
FW .281 X .625 X .051/.080 HD ZN/YL
INSTRUMENT PANEL DECAL
INSTRUMENT PANEL (WITH DECAL)
WIRE TIE
HOUR METER
WIRE HARNESS
SEALED RELAY (WITH BRACKET)
CLUTCH CONNECTOR REPAIR KIT
NOTES:
1. Part of the wire harness.
DESCRIPTION
1 601097 1
2 776476 1
3 712257 1
4 785808 1
5 601098 4
6 059832 4
7 045898 1
8 704932 2
9 601096 1
10 055947 3
11 768515 3
12 602468 1
13 550446 1
14 000331 7
15 769166 1
16 603790 1
17 601053 3
18 114052 1
6-6 115599_1113
115599_1113 7-1
Section 7
54" Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
54" Deck Pulleys & Spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
54" Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
60" Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
60" Deck Pulleys & Spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
60" Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Spindle Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Deck Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Deck Mounting Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7-2 115599_1113
54" Service Deck
1
2
3
4
45
63
115599_1113 7-3
54" Service Deck
INDEX NO. PART NO. QTY
54" DECK (WITH DECALS & HARDWARE)
BELT ROUTING DECAL
DECK DANGERS DECAL
CN .312-18 X .20 MAX THK
DISCHARGE CHUTE DECAL
THROWN OBJECTS DECAL
NOTES:
DESCRIPTION
1 550424 1
2 781419 1
3 601837 2
4 601069 4
5 601624 1
6 601892 1
7-4 115599_1113
54" Deck Pulleys & Spindles1
2
3
4
6 57
8
9
1
10
11
1
12
13
14
15
14
16
18
21
20
2317
17
2
3
4
19
17
24
22
25
27
21
21 26
20
115599_1113 7-5
54" Deck Pulleys & Spindles
INDEX NO. PART NO. QTY.
CS .625-11 X 1.50 HX G5
FW .625 X 1.00 X .134 ZNYC
DUST SHIELD WITH OFFSET
IDLER PULLEY, NHI 5.0"
IDLER SLIDE
TENSION SPRING
CHAIN
CS .312-18 X 1.25 FLT SH
IDLER SLIDE
CS .625-11 X 1.25 HX G5 Z
FW .680 X 1.750 X .14 SAE
DRIVE PULLEY 5.68 OP
NT .375-16 HX G5 ZNY
FW .406 X .812 X .060 SAE
CS .375-16 X 1.375 HX G5
BLADE SPINDLE
FW .343 X .687 X .051/.080H
NT .312-18 HXZY NL
NT .500-13 HX G8 ZY NL
PLASTIC WHEEL ASSEMBLY (WITH HARDWARE)
FW .531 X 1.063 X .090 SAE
CS .312-18 X .75 HX G5
HEAVY DUTY PULLER
NT .312-18 HX G5 ZNYC
CS .500-13 X 4.25 HX G5
PLASTIC WHEEL
NT .500-13 HX JAM ZNYC
NOTES:
1. Torque to 67–75 ft-lbs.
DESCRIPTION
1 794446 3
2 028118 3
3 603057 3
4 781856 3
5 109770 1
6 781302 1
7 259812 1
8 784199 4
9 601619 2
10 781872 3
11 017152 3
12 786889 3
13 054502 12
14 767954 24
15 005116 12
16 783506 3
17 768523 8
18 058776 4
19 781567 2
20 788166 2
21 767962 6
22 034280 2
23 109444 2
24 034272 2
25 781708 2
26 031997 2
27 053199 2
7-6 115599_1113
54" Deck
1
14
15
16 1
4
5
3
8
7
6
10
11
9
13
12
11
12
17
20
18
19
FRONT WALL
DISCHARGECHUTE
134
5
122
2
115599_1113 7-7
54" Deck
INDEX NO. PART NO. QTY.
BELT, B 152" EL
LS PULLEY COVER
RS PULLEY COVER
CS .312-18 X .75 HX G5
FW .344 X 1.00 X.12 HRD Z
DISCHARGE CHUTE
TORSION SPRING
CHUTE PIN
CHUTE BRACKET
CHUTE ADAPTER PLATE
CB .375-16 X 1.00 STD CD
NT .375-16 HXZY NL
FW .406 X .812 X .060 SAE
BLADE, 18.50"-L-F-CW
BLADE, F18.50"-H-F-CW
BLADE, 18.50"-MUL-F-CW
BLADE, 18.50"-GAT-F-CW
CW .631 2.25 X .187 PNT
CS .625-11 X 1.25 HX G5 Z
NT .312-18 HXZY NL
"A" BLOWOUT BAFFLE
CB .312-18 X .75 FUL ZN
FW .343 X .687 X .051/.080H
NOTES:
1. Torque to 118 ft-lbs.
2. Do not torque the nut; the discharge chute must pivot freely.
DESCRIPTION
1 789388 1
2 602749 1
3 602748 1
4 034280 4
5 712927 4
6 601806 1
7 601824 1
8 601843 1
9 111067 1
10 190037 1
11 025395 4
12 086660 5
13 767954 4
14 601124 3
797696 3
797704 3
797712 3
15 782474 3
16 781872 3
17 058776 2
18 111999 1
19 016253 2
20 768523 2
7-8 115599_1113
60" Service Deck
3
1
6
3
4
52
115599_1113 7-9
60" Service Deck
INDEX NO. PART NO. QTY.
60" DECK (WITH DECALS & HARDWARE)
BELT ROUTING DECAL
DECK DANGERS DECAL
CN .312-18 X .20 MAX THK
DISCHARGE CHUTE DECAL
THROWN OBJECTS DECAL
NOTES:
DESCRIPTION
1 550961 1
2 781419 1
3 601837 2
4 601069 4
5 601624 1
6 601892 1
7-10 115599_1113
60" Deck Pulleys & Spindles1
2
7
8
9
1
10 1
12
13
14
1520
21
19
17
24
23
20
22
6 5
4
3
11
14
2
4
3
16
18
25
27
18
18 26
17
20
115599_1113 7-11
60" Deck Pulleys & Spindles
INDEX NO. PART NO. QTY.
CS .625-11 X 1.50 HX G5
FW .625 X 1.00 X .134 ZNYC
DUST SHIELD WITH OFFSET
IDLER PULLEY, NHI 5.0"
IDLER SLIDE
TENSION SPRING
CHAIN, 21 LINK
CS .312-18 X 1.25 FLT SH
IDLER SLIDE UHMW
CS .625-11 X 1.25 HX G5 Z
FW .680 X 1.75 X .14 SAE
DECK DRIVE PULLEY
NT .375-16 HX G5 ZNY
FW .406 X .812 X .060 SAE
BLADE SPINDLE
CS .375-16 X 1.375 HX G5
PLASTIC WHEEL ASSEMBLY (WITH HARDWARE)
FW .531 X 1.063 X .090 SAE
NT .500-13 HX G8 ZY NL
FW .343 X .687 X .051/.080H
NT .312-18 HX ZY NL
HEAVY DUTY PULLER
NT .312-18 HX G5 ZNYC
CS .312-18 X .75 HX G5
CS .500-13 X 4.25 HX G5
PLASTIC WHEEL
NT .500-13 HX JAM ZNYC
NOTES:
1. Torque to 67–75 ft-lbs.
DESCRIPTION
1 794446 3
2 028118 3
3 603057 3
4 781856 3
5 109770 1
6 781302 1
7 373191 1
8 784199 4
9 601619 2
10 781872 3
11 017152 3
12 601447 3
13 054502 12
14 767954 24
15 783506 3
16 005116 12
17 788166 2
18 767962 6
19 781567 2
20 768523 8
21 058776 4
22 109444 2
23 034272 2
24 034280 2
25 781708 2
26 031997 2
27 053199 2
7-12 115599_1113
60" Deck
2
12
9
1
11
4
4
7
13
18
10
16
19
1
3
9
10
10
5
4
5
8
6
8
15
14
17
FRONT WALL
DISCHARGECHUTE
2
115599_1113 7-13
60" Deck
INDEX NO. PART NO. QTY.
DISCHARGE CHUTE
TORSION SPRING
CHUTE PIN
NT .375-16 HXZY NL
FW .406 X .812 X .060 SAE
CHUTE BRACKET
CHUTE ADAPTOR PLATE
CB .375-16 X 1.00 G5 ZNY
CS .312-18 X .75 HX G5
FW .343 X .687 X .051/.080H
RS PULLEY COVER
LS PULLEY COVER
BELT, B 162
BLADE, 20.50"-L-F-CW
BLADE, 20.50"-MUL-F-CW
BLADE, 20.50"-GAT-F-CW
BLADE, F20.50"-H-F-CW
CW .631 X 2.25 X .187 PNT
CS .625-11 X 1.25 HX G5 Z
CB .312-18 X .75 FUL ZN
NT .312-18 HXZY NL
BLOWOUT BAFFLE
NOTES:
1. Torque to 118 ft-lbs.
2. Do not torque the nut; the discharge chute must pivot freely.
DESCRIPTION
1 601806 1
2 601824 1
3 601843 1
4 086660 5
5 767954 4
6 111067 1
7 190052 1
8 025395 4
9 034280 4
10 768523 6
11 113882 1
12 113883 1
13 601715 1
14 793794 3
794214 3
794230 3
794685 3
15 782474 3
16 781872 3
17 016253 2
18 058776 2
19 113835 1
7-14 115599_1113
Spindle Service Parts
2
5
4
1
3
2
INDEX NO. PART NO. QTY.
BLADE SPINDLE RETAINER RING
BLADE SPINDLE BEARING
BLADE SPINDLE SPACER
BLADE SPINDLE HOUSING
BLADE SPINDLE SHAFT
NOTES:
DESCRIPTION
1 783548 1
2 783555 2
3 783530 1
4 783514 1
5 783522 1
115599_1113 7-15
This page intentionally left blank.
7-16 115599_1113
Deck Lift
1
2
3
4
5
6
7
56
7
7
89
10
10
8
9
9
87
7
11
12
13
10
14
8
9
89
15
16
7
65
17
115599_1113 7-17
Deck Lift
INDEX NO. PART NO. QTY
STOP HANDLE
HEIGHT ADJ STOP
DECK LIFT INDICATOR
DECK LIFT ROD
CS .437-14 X 1.75 HX G5 ZN
DECK LIFT CHAIN
NT .437-14 HX FL ZN
FW .781 X 1.50 X .120 ZN
E-CLIP 1.00 X .625 X .050
GREASE FITTING STRAIGHT
CS .312-18 X 1.50 FUL THD ZN
NT .312-18 HX G5 ZN
DECK LEVELER YOKE
FW .531 X 1.063 X .09 SAE HRD ZN
CE .750 X 2.12 X 1.75 HEADLESS
DECK LIFT SPRING
CS .437-14 X 1.75 FUL THD G5 ZN
NOTES:
DESCRIPTION
1 348318 1
2 348284 1
3 784488 1
4 601942 1
5 055749 7
6 360131 4
7 704643 16
8 601681 6
9 781294 7
10 015495 4
11 756270 1
12 034272 1
13 348458 1
14 767962 6
15 781229 1
16 782995 1
17 781831 1
7-18 115599_1113
Deck Mounting Hardware
5
14
14
7
7
18
19
115599_1113 7-19
Deck Mounting Hardware
INDEX NO. PART NO. QTY
CS .500-13 X 2.00 GR ZN
NT .500-13 HX G5 ZN
NOTES:
DESCRIPTION
18 078949 2
19 008193 2
7-20 115599_1113
115599_1113 8-1
Section 8
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Seat Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
ROPS—Foldable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8-2 115599_1113
Seat
6
45
5
1
32
6
6
4
5
5
5
5
11
8
9
12
13
14
10
7
1
1
115599_1113 8-3
Seat
INDEX NO. PART NO. QTY.
SEAT WITH REMOVABLE BACK
BATTERY WARNINGS DECAL
SEAT PAN STOP
CS .312-18 X .875 HX G5 ZN
FW .343 X .687 X .051/.080H
NT .312-18 HX NL
CS .312-18 X .75 HX G5
SEAT LATCH ASSEMBLY
WIRE TIE
SEAT PAN (WITH DECAL)
NT .312-18 HX G5 ZNYC
CS .375-16 X 1.25 HX G5 ZN
FW .406 X .812 X .060 SAE
SEAT SPRING 150 LB/IN
NOTES:
1. Do not torque; the seat pan and seat pan stop must pivot freely.
DESCRIPTION
1 604575 1
2 601815 1
3 109240 1
4 064014 3
5 768523 16
6 058776 7
7 034280 3
8 603884 1
9 000331 2
10 550988 1
11 034272 3
12 052860 2
13 767954 2
14 601450 2
8-4 115599_1113
Seat Service Parts
2
7
6
1
3
4
5
INDEX NO. PART NO. QTY.
ARM PADS (WITH HARDWARE)
SEAT BACK
SEAT BACK COVER
SEAT BOTTOM
SEAT BOTTOM COVER
ARM REST BRACKETS (WITH HARDWARE)
SEAT BELT
STANDARD SEAT TRACK
SEAT SWITCH
NOTES:
DESCRIPTION
1 603809 1
2 605135 1
603894 1
3 605136 1
603893 1
4 603808 1
5 601444 1
6 603146 1
7 603148 1
115599_1113 8-5
This page intentionally left blank.
8-6 115599_1113
ROPS—Foldable
1
1
2
34
5
6
7
4
4
78
8
9
1
115599_1113 8-7
ROPS—Foldable
INDEX NO. PART NO. QTY.
ROPS KIT (WITH DECALS, SEAT BELT & HARDWARE)
CS .500-13 X 3.50 HX G5
ROPS STOP
NT .500-13 UNT LK G8 ZN
HAND KNOB
LYNCH PIN W/ LANYARD
CS .500-13 X 3.25 HX G5
FW .531 X 1.063 X .090 SAE
ROPS DECAL
NOTES:
1. Torque to 55 ft-lbs.
DESCRIPTION
1 601439 1
2 061812 1
3 601472 1
4 023317 6
5 601470 2
6 601471 2
7 077859 5
8 767962 8
9 601635 2
8-8 115599_1113
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