Repair Parts

SERIAL RANGE: 19274001 - ________

COUNTRY CLIPPER XLT-C305 & CHALLENGER-D505

SERIAL RANGE 19274001 - ________ ZERO TURN RADIUS MOWER

TABLE OF CONTENTS SECTION 1 – MOWER DECKS AND RELATED PARTS

1. 48” DECK ASSEMBLY 2. 52” DECK ASSEMBLY 3. 60” DECK ASSEMBLY 4. DISCHARGE CHUTE ASSEMBLY 5. DECK SPINDLE ASSEMBLY 6. DOUBLE IDLER DRIVE BELT IDLER 7. BELT TENSION LEVER 8. FIXED IDLERS & RELATED PARTS 9. DECK LIFT ASSEMBLY & RELATED PARTS 10. DECK LIFT ASSEMBLY & RELATED PARTS (CON’T) 11. CUT HEIGHT ASSEMBLY & RELATED PARTS

SECTION 2 – TRACTOR FRAME AND RELATED PARTS 12. PIVOTING FRONT AXLE & FLOOR PAN 13. TIRES AND FRONT STEP 14. FRONT PANEL ASSEMBLY & RELATED PARTS 15. FRONT PANEL ASSEMBLY & RELATED PARTS (CON’T) 16. BATTERY BOX 17. BRAKE ASSEMBLY

SECTION 3 – TRACTOR DRIVE AND RELATED PARTS 18. FUEL TANK ASSEMBLY 19. JOYSTICK CONTROL & RELATED PARTS 20. JOYSTICK ASSEMBLY 21. JOYSTICK ASSEMBLY MOUNTING & RELATED PARTS 22. TWIN LEVER CONTROL & RELATED PARTS 23. TWIN LEVER ASSEMBLY 24. CONTROL PANEL 25. FENDER ASSEMBLY & RELATED PARTS 26. TRANSMISSION ASSEMBLY & RELATED PARTS 27. TRANSMISSION ASSEMBLY & RELATED PARTS (CON’T) 28. SEAT BASE & RELATED PARTS 29. SEAT BASE & RELATED PARTS (CON’T) 30. ENGINES 31. ENGINE & CLUTCH MOUNTING & RELATED PARTS 32. WIRE HARNESS & RELATED PARTS – JOYSTICK 33. WIRE HARNESS & RELATED PARTS – TWIN LEVER 34. WIRE HARNESS SCHEMATIC – JOYSTICK 35. WIRE HARNESS SCHEMATIC – TWIN LEVER

Country Clipper Division Shivvers Manufacturing Inc. 613 W English St. Corydon, IA 50060-0467 Ph. 641-872-2544 Fax. 641-872-1593

19122

20

8

14

12

5

BELT TENSIONLEVER(SEE PG 7)

16

7

15

28

11 23

24

26

SPINDLE ASS’Y(SEE PG 5)

16

DOUBLE IDLER ASS’Y(SEE PG 6)

9

18

12

FIXED IDLERASS’Y, FRONT(SEE PG 8)

13

2

FIXED IDLERASS’Y, REAR(SEE PG 8)

29

10

10

17

17

19

15

30

3

27

4 15

6

1212

19

15

15

25

21

20221CHUTE ASS’Y

(SEE PG 4)

48" DECK ASSEMBLY{722F-002A}

ITEM # QTY PART # DESCRIPTION1 5 609-183P BUSHING2 4 651-009W DECK HANGER, WIDE BASE3 1 686-080W SPLITTER, DISCHARGE4 1 722-034P DECK STOP5 1 722-041P DEFLECTOR PLATE6 1 722-045A 48" DECK W/ DECALS7 2 722-048A PULLEY COVER W/ DECALS8 1 D-3775-W BELT B-158" KEVLAR WRAPPED9 1 F-1009-01 FLAT WASHER, 1/4", YZ10 3 F-1009-02 WASHER, FLAT11 4 F-1521 WASHER, 1/2" CUSTOM, YZ12 6 F-1671 CARRIAGE BOLT,5/16-18 X 3/4", YZ, GR513 8 F-1672 BOLT, CARRIAGE, 3/8-16 X 1-1/4", YZ, GR514 1 F-1823 BOLT, CARRIAGE, 1/4-20 X 3/415 9 F-2063 NUT, 5/16-18, NYLOC, FLANGED, YZ16 4 F-2119 FHCS, 1/4-20 X 3/4", YZ, GR5, LOCK PATCH

ITEM # QTY PART # DESCRIPTION17 3 F-2120 FHCS, 5/16-18 X 3/4", YZ, GR518 1 F-2132 NUT, 1/4-20 NYLOC, FLANGED, YZ19 13 F-2151 NUT, 3/8-16 NYLOC, FLANGED, YZ20 5 F-2161 FHCS, 3/18-16 X 6" YZ, GR521 2 F-2250 CLIP, FIR TREE, 1/4" X 1", BLACK NYLON22 5 H-1948 ROLLER, 3-3/4 DIA23 4 H-2239 1/2" RUE RING24 4 H-2240 1/2" X 4-1/2" CLEVIS PIN25 2 H-3091 WEAR PAD26 2 P-10935 DECAL, "WARNING ROTATING DRIVE"27 1 P-10941 DECAL, DANGER28 1 P-11950 DECAL, DECK SIZE, 4829 1 P-12706 WARNING DECAL, DISCHARGE CHUTE30 1 P-12837 DECAL, DECK BELT ROUTING

1

18122

209

12

815

12

14

1123

1826

BELT TENSIONLEVER(SEE PG 7)

28

6

19

24

DOUBLE IDLER ASS’Y(SEE PG 6)

SPINDLE ASS’Y(SEE PG 5)

15

1710

FIXED IDLERASS’Y, FRONT(SEE PG 8)

1327

FIXED IDLERASS’Y, REAR(SEE PG 8)

10

16

1416

2

30

4

14

21 1429

7

1212

18

5

325

1014

20 221CHUTE ASS’Y(SEE PG 4)

52" DECK ASSEMBLY{722E-002A}

ITEM # QTY PART # DESCRIPTION1 5 609-183P BUSHING2 2 643-016W DECK HANGER, NARROW BASE3 2 651-009W DECK HANGER, WIDE BASE4 1 686-080W SPLITTER, DISCHARGE5 1 722-034P DECK STOP6 1 722-041P DEFLECTOR PLATE7 1 722-046A 52" DECK W/ DECALS8 2 722-048A PULLEY COVER W/ DECALS9 1 D-3951 BANDL BELT B-16610 4 F-1009-02 WASHER, FLAT11 4 F-1521 WASHER, 1/2" CUSTOM, YZ12 6 F-1671 CARRIAGE BOLT,5/16-18 X 3/4", YZ, GR513 8 F-1672 BOLT, CARRIAGE, 3/8-16 X 1-1/4", YZ, GR514 9 F-2063 NUT, 5/16-18, NYLOC, FLANGED, YZ15 4 F-2119 FHCS, 1/4-20 X 3/4", YZ, GR5, LOCK PATCH16 3 F-2120 FHCS, 5/16-18 X 3/4", YZ, GR5

ITEM # QTY PART # DESCRIPTION17 1 F-2132 NUT, 1/4-20 NYLOC, FLANGED, YZ18 13 F-2151 NUT, 3/8-16 NYLOC, FLANGED, YZ19 1 F-2155 BOLT, CARRIAGE, 1/4-20 X 5/8", YZ, GR520 5 F-2161 FHCS, 3/18-16 X 6" YZ, GR521 2 F-2250 CLIP, FIR TREE, 1/4" X 1", BLACK NYLON22 5 H-1948 ROLLER, 3-3/4 DIA23 4 H-2239 1/2" RUE RING24 4 H-2240 1/2" X 4-1/2" CLEVIS PIN25 2 H-3091 WEAR PAD26 2 P-10935 DECAL, "WARNING ROTATING DRIVE"27 1 P-10941 DECAL, DANGER28 1 P-11951 DECAL, DECK SIZE, 5229 1 P-12706 WARNING DECAL, DISCHARGE CHUTE30 1 P-12837 DECAL, DECK BELT ROUTING

2

17120

18

BELT TENSIONLEVER(SEE PG 7)

11 218

26

7

1624

SPINDLE ASS’Y(SEE PG 5)DOUBLE IDLER ASS’Y

(SEE PG 6)

22

16

5

13

15

FIXED IDLERASS’Y, FRONT(SEE PG 8)

1425

13

FIXED IDLERASS’Y, REAR(SEE PG 8)

2

10

283

12

13

15

15

1327

17

6

23

1915

9

1820

1715

CHUTE ASS’Y(SEE PG 4) 1

60" DECK ASSEMBLY{722D-002A}

ITEM # QTY PART # DESCRIPTION1 5 609-183P BUSHING2 4 643-016W DECK HANGER, NARROW BASE3 1 686-006W SPLITTER WELDMENT4 1 722-034P DECK STOP5 1 722-041P DEFLECTOR PLATE6 1 722-047A 60" DECK W/ DECALS7 2 722-048A PULLEY COVER W/ DECALS8 1 D-3776-W BELT B-180"9 2 F-1009-02 WASHER, FLAT10 1 F-2148 FHCS, 5/16-18 X 1", YZ, GR511 4 F-1521 WASHER, 1/2" CUSTOM, YZ12 1 F-2120 FHCS, 5/16-18 X 3/4"13 6 F-1671 CARRIAGE BOLT,5/16-18 X 3/4", YZ, GR514 8 F-1672 BOLT, CARRIAGE, 3/8-16 X 1-1/4", YZ, GR515 8 F-2063 NUT, 5/16-18, NYLOC, FLANGED, YZ

ITEM # QTY PART # DESCRIPTION16 4 F-2119 FHCS, 1/4-20 X 3/4", YZ, GR5, LOCK PATCH17 13 F-2151 NUT, 3/8-16 NYLOC, FLANGED, YZ18 5 F-2161 FHCS, 3/18-16 X 6" YZ, GR519 2 F-2250 CLIP, FIR TREE, 1/4" X 1", BLACK NYLON20 5 H-1948 ROLLER, 3-3/4 DIA21 4 H-2239 1/2" RUE RING22 4 H-2240 1/2" X 4-1/2" CLEVIS PIN23 2 H-3091 WEAR PAD24 2 P-10935 DECAL, "WARNING ROTATING DRIVE"25 1 P-10941 DECAL, DANGER26 1 P-11952 DECAL, DECK SIZE, 6027 1 P-12706 WARNING DECAL, DISCHARGE CHUTE28 1 P-12837 DECAL, DECK BELT ROUTING

3

4

5

63 4

6

71

5

8

3

6

2

4

4

DISCHARGECHUTE ASS’Y& RELATED PARTS

PART OF ITEM #2

ITEM # QTY PART # DESCRIPTION1 1 643-110P CHUTE HINGE2 1 643-135A OUTLET STIFFENER W/DECALS, SMALL3 2 F-1009-02 WASHER, FLAT4 11 F-2063 NUT, 5/16-18, NYLOC, FLANGED, YZ5 8 F-2066 BOLT, CARRIAGE, 5/16-18 X 1", YZ, GR56 3 F-2148 FHCS, 5/16-18 X 1", YZ, GR57 1 H-2723 CHUTE, DISCHARGE, SMALL8 1 P-12496 DECAL, CHUTE MISSING

4

1

14

2

3

9

10

8

15

13

17

7

12

8

1112 USE ITEM

#4 - 60" DECK#5 - 48" DECK#6 - 52" DECK

16

DECK SPINDLE ASSEMBLY{D-4020}

BLADE PART NUMBERS

48" DECK

52" DECK

60" DECK

H-2882 HIGH LIFT W/O FUSION (STANDARD)H-2659 LOW LIFTH-2665 GATOR

H-2883 HIGH LIFT W/O FUSION (STANDARD)H-2884 HIGH LIFT W/ FUSIONH-2660 LOW LIFTH-2666 GATOR

H-2885 HIGH LIFT W/O FUSION (STANDARD)H-2886 HIGH LIFT W/ FUSIONH-2661 LOW LIFTH-2667 GATOR

TORQUE TO 75 FT/LBS

***

*

*

*

*

*

*

*

PARTS MARKED "*" ARE PARTOF COMPLETE ASSEMBLY D-4020

ITEM # QTY PART # DESCRIPTION1 1 (SEE LIST) BLADE2 1 660-099P WASHER, BLADE, 5/83 1 660-206P SPINDLE SPACER4 1 D-3918 PULLEY, 5.195, A-B, DECK5 1 D-3919 PULLEY, 4.039, A-B, DECK6 1 D-3920 PULLEY, 4.513, A-B, DECK7 1 ---- SPINDLE HOUSING, MEDIUM DUTY8 2 D-4020-2 BEARING, HCH 6305-2RS19 1 D-4020-3 SPINDLE SHAFT, MEDIUM DUTY10 1 ---- SPINDLE SPACER11 1 D-4020-5 SPINDLE HARD WASHER12 2 D-4020-6 PULLEY ALIGNMENT SPACER13 1 D-3991 RETAINING RING14 1 F-1650 HHCS, 5/8-11 X 2", GR5, YZ15 4 F-2125 FHCS, 3/8-16 X 1-1/4", YZ, GR516 1 F-2143 FHCS, 1/2-13 X 1", YZ, GR517 4 F-2151 NUT, 3/8-16 NYLOC, FLANGED, YZ

5

TORQUE TO 100-120 FT/LBS

25

26

14

9

9

7

252

22

10

DECK

24

14

5

20

19

8 22

13

23

15

3

25

12

6

25

1

11

18214

1716

BELT TENSION LEVER(SEE PG 7)

DOUBLE IDLERDRIVE BELT IDLER

ITEM # QTY PART # DESCRIPTION1 2 620-201P WASHER, BEARING CAP2 1 660-039P MOUNT, DOUBLE IDLER3 1 660-081P EXTENSION, SPRING4 1 660-107P BELT KEEPER, A BELT5 1 668-021P SPACER, BELT GUARD6 1 714-183P BELT GUARD, 54’’7 1 722-031P MOUNTING PIN8 1 722-032P IDLER ARM9 2 D-3730 BUSHING, DU 5/8 DIA X 1/2 LG10 1 D-3923 PULLEY, V-IDLER, 4.59OD, AB, NTN11 1 D-3924 PULLEY, FLAT IDLER, 4.25 OD, NTN, DBL INSERT12 1 F-1005-03 NUT, 3/8-16, CENTERLOCK, YZ, GR513 4 F-1009-03 WASHER, FLAT, 3/8, YZ14 2 F-1009-05 WASHER, FLAT STD, 1/2" NOMINAL, YZ15 1 F-1394 HHCS, 3/8-16 X 1", YZ, GR516 1 F-1464 LOCKWASHER, 1/2"17 1 F-1489 NUT, HEX, JAM, 1/2-13, YZ18 1 F-1521 WASHER, 1/2" CUSTOM, YZ19 1 F-1733 DRIVE SCREW, 1/4" X 1/2", RND HD20 1 F-1822 BOLT, CARRIAGE, 1/2-13 X 2-1/4", YZ, GR521 1 F-1966 NUT, THIN, 1/2-13, NYLOC, YZ22 2 F-1976 BOLT,CARRIAGE, 3/8-16 X 2", YZ, GR523 1 F-1927 CARRIAGE BOLT, 1/2-13 X 2-3/4" ZINC/YELLOW DICHROMATE FULL THREAD24 2 F-2125 FHCS, 3/8-16 X 1-1/4", YZ, GR525 5 F-2151 NUT, 3/8-16 NYLOC, FLANGED, YZ26 1 F-2152 NUT, 1/2-13 NYLOC, FLANGED, YZ

6

16

13

14

9

3

8

4

211

15

12

1217

12

13

15

7

USE ITEM#1 - 48" DECK#5 - 52" DECK#6 - 60" DECK

8 8

4

13

2

10

3

14

13

11

916

BELT TENSION LEVER

ORIENTATION FOR 52" DECK

ITEM # QTY PART # DESCRIPTION1 1 660-031P BELT TIGHTENER ARM2 1 660-038P SPACER, 3/8" WIDE3 1 660-184P HANDLE, BELT TENSIONER4 1 661-015P SHACKLE5 1 722-040P BELT TIGHTENER ARM6 1 722-044P BELT TIGHTENER ARM7 1 F-1005-03 NUT, 3/8-16, CENTERLOCK, YZ, GR58 2 F-1009-03 WASHER, FLAT, 3/8, YZ9 1 F-1019-03 LOCKWASHER, HVY, 3/8, YZ10 1 F-1394 HHCS,3/8-16NC X 1",GR.5, YELLOW PLATED11 1 F-2124 FHCS, 3/8-16 X 3/4", YZ, GR512 2 F-2141 FHCS, 3/8-16 X 1", YZ, GR513 3 F-2151 NUT, 3/8-16 NYLOC, FLANGED, YZ14 1 F-2152 NUT, 1/2-13 NYLOC, FLANGED, YZ15 1 F-2154 FHCS, 1/2-13 x 1-3/4", YZ, GR516 1 H-2405 BALL, 1-1/4"17 1 H-2619 SPRING, 5 X 1-1/2, TAPERED ENDS

7

15

DECK

11

DECK4

7

14

USE ITEM#2 - 48" & 52" DECKS#3 - 60" DECKS

112

DECK

10

4

13

6

7

9

8

5

1

16

FIXED IDLER ASSEMBLIES

REAR FRONT

ITEM # QTY PART # DESCRIPTION1 2 620-201P WASHER, BEARING CAP2 1 660-112P BELT KEEPER3 1 660-114P BELT KEEPER, SINGLE END4 2 660-206P SPINDLE SPACER5 1 D-3903 PULLEY, FLAT IDLER, 6" (NTN)6 1 D-3904 PULLEY, FLAT IDLER, 5"7 2 F-1009-05 WASHER, FLAT STD, 1/2" NOMINAL, YZ8 1 F-1464 LOCKWASHER, 1/2"9 1 F-1489 NUT, HEX, JAM, 1/2-13, YZ10 1 F-1521 WASHER, 1/2" CUSTOM, YZ11 1 F-1707 CARRIAGE BOLT, 5/16-18 X 2-1/4 ZINC PLATED12 1 F-1966 NUT, THIN, 1/2-13, NYLOC, YZ13 1 F-1927 CARRIAGE BOLT, 1/2-13 X 2-3/4"14 1 F-2063 NUT, 5/16-18, NYLOC, FLANGED, YZ15 1 F-2047 CARRIAGE BOLT, 1/2-13 X 3" , YZ16 1 F-2152 NUT, 1/2-13 NYLOC, FLANGED, YZ

8

5

14

15

715

3

1

141418

16

2

7

4

11

6

15

5

12

18

17 9

ONLY PARTIALLYTIGHTEN UNTILCOMPLETE ASS’YIS INSTALLED(PAGES 9-11)

1

9

11

10

14

8

13

DECK LIFT ASSEMBLY& RELATED PARTS

ITEM # QTY PART # DESCRIPTION1 2 720-010P CLAMP EXTENSION2 1 720-079W WLDT, DECK LIFT, REAR3 1 720-084W WLDT, DECK LIFT, FRONT4 1 720-090P DECK LIFT LINK5 2 720-093P DRAG BAR6 2 720-094P FLOOR PAN SUPPORT7 2 724-032P DECK PIVOT MOUNT PLATE8 2 724-033P DECK SUSPENSION FRONT PLATE9 3 F-1521 WASHER, 1/2" CUSTOM, YZ10 2 F-1896 CLEVIS PIN, 1/2 X 1-3/4", YZ

ITEM # QTY PART # DESCRIPTION11 2 F-1966 NUT, THIN, 1/2-13, NYLOC, YZ12 1 F-2127 FHCS, 1/2-13 X 1-1/4", YZ, GR513 4 F-2147 FHCS, 3/8-16 X 1-1/2", YZ, GR514 9 F-2151 NUT, 3/8-16 NYLOC, FLANGED, YZ15 5 F-2180 FHCS, 3/8-16 x 3", YZ, GR516 1 F-2278 BUTTON SHCS, 1/2-13 X 1-1/2, YZ17 2 H-2239 1/2" RUE RING18 4 H-2461 RUBBER BUMPER

9

18

13

14

2014 9

USE ITEM#7 - RIGHT SIDE#8 - LEFT SIDE

4 11

FULLYTIGHTENTHENBACK OFF1/2 TO 1 TURN

12

15

20

19

10

22

5

6

17

10

21

315

13

3

16

152

3

16

720-099A

720-100A

DECK LIFT ASSEMBLY& RELATED PARTS (CON’T)

TIGHTEN BOLT ANDFIRST NUT TOWELDMENT, THENINSTALL SPRING, WASHER,AND SECOND NUT (DO NOTOVERTIGHTEN)

CONNECTION TO DECKREAR HANGER

CONNECTION TO DECKFRONT HANGER

(ITEM #4)

(ITEM #5)

USE SLOT CLOSEST TO MIDDLE OF DECK WITH CLAMP EXTENSION (#22) ON INNER MOST SIDE

ATTACH HOOK IN OUTER SLOT

ITEM # QTY PART # DESCRIPTION1 2 720-115P DECK HANGER, REAR2 2 720-097P DECK HANGER, FRONT3 8 720-098P NUT RETAINER4 2 720-099A ASS’Y, DECK HANGER, REAR5 2 720-100A ASS’Y, DECK HANGER, FRONT6 2 724-052P HANGER PIN, FRONT7 1 724-091W HANGER PIN WLDT, REAR LH8 1 724-092W HANGER PIN WLDT, REAR RH9 2 F-2097 WASHER, FENDER, 1/4" X 7/8"10 8 F-1158 NUT, CENTERLOCK, 1/4-20, YZ, GR511 2 F-1443 CLEVIS PIN, 5/16 X 7/8"12 2 F-1492 RUE RING, 5/16

ITEM # QTY PART # DESCRIPTION13 4 F-1998 SPIROL RING 1"14 4 F-2132 NUT, 1/4-20 NYLOC, FLANGED, YZ15 6 F-2152 NUT, 1/2-13 NYLOC, FLANGED, YZ16 8 F-2162 FHCS, 1/4-20 X 3/4", YZ, GR517 2 F-2181 FHCS, 1/2-13 X 4.50, YZ, GR818 2 F-2182 FHCS, 1/4-20 X 1-1/4", YZ, GR519 2 F-2277 FHCS 1/2-13 X 3-1/2, GR5, YZ, FULL THREAD20 2 H-1635 SPRING, EXT, 3/4" OD X 4" OAL21 4 F-2290 WASHER, 1" FLAT22 2 720-010P CLAMP EXTENSION

10

*

*ITEM # 21 ONLY USED WITH SERIAL NUMBERS PRIOR TO 20090016

20

1918 12

17

161

12

8

143

55

152

4 36

10

10

HOOK SPRING(WITH HOOK ON TOP) INBOTTOM HOLE - 48" DECKTOP HOLE - 52" & 60" DECKS

5

5

21

11

13

CUT HEIGHT SUB-ASSEMBLY(SEE DETAIL)

7

9

ATTACH SPRING TOHANDLE FIRST,THEN SPACER

CUT HEIGHT SUB-ASSEMBLY

CUT HEIGHT ASSEMBLY& RELATED PARTS

WITH DECK CONNECTED,TIGHTEN UNTIL GAP BETWEENTAB ON FRAME AND SPRING ISAPPROXIMATELY1" - 48" & 52" DECKS0.5" - 60" DECK

PARTIALLY TIGHTENUNTIL INSTALLEDONTO FRAME,THEN ENSURELATCH MECHANISMMOVES FREELY

INSIDE VIEW OF CUT HEIGHTSUB-ASSEMBLY, SHOWING DECALS

ITEM # QTY PART # DESCRIPTION1 1 720-104P PLATE, CUT HEIGHT - INNER2 1 720-105P PLATE, CUT HEIGHT - OUTER3 2 724-042P CATCH PLATE4 1 724-079P SPACER, CATCH PLATE5 4 724-080P SPACER, CUT HEIGHT PLATE6 1 F-1005-03 NUT, 3/8-16, CENTERLOCK, YZ, GR57 1 F-1009-03 WASHER, FLAT, 3/8, YZ8 1 F-1080 SNAP RING TRUARC #5144-37 3/8 HEAVY E-RING9 1 F-1329 SCREW,3/8-16 X 3 GR5 FULL THREADED, PLATED10 4 F-2151 NUT, 3/8-16 NYLOC, FLANGED, YZ11 2 F-2160 FHCS, 3/8-16 X 4-1/2", YZ, GR512 2 F-2218 FHCS, 3/8-16 X 2-1/4", YZ, GR513 1 F-2219 HFCS, 3/8-16 X 3/4", CZ, THD FORMING14 1 F-2260 HHCS, 3/8-16 X 1-3/4, YZ, GR815 1 H-1635 SPRING, EXT, 3/4" OD X 4" OAL16 1 H-2327 3/8 DIA X 1"LONG END CAP17 1 H-3013 DECK HEIGHT PIN18 1 H-3120 TRANSPORT LATCH RELEASE HANDLE19 1 P-13421 DECAL, CUT HEIGHT20 1 P-13437 DECAL, TRANSPORT LATCH21 1 H-3117 EXTENSION SPRING, 1.585 O.D. x (9.8) LONG, W/THREADED PLUG

11

4

11

9

2

10

7

13

3

6

5

10

1

812

GREASE

GREASE

TORQUE TO 25 FT/LBS MAXENSURE AXLE MOVES FREELY

PIVOTING FRONT AXLE& FLOOR PAN

TORQUE TO 250 FT/LBS

ITEM # QTY PART # DESCRIPTION1 1 606-303P WASHER, 10GA GALVANIZED2 1 720-052W WLDT, PIVOT SHAFT3 1 720-077W WLDT, FRONT AXLE4 1 720-095P FLOOR PAN5 1 D-3825 BRG, TAPERED, SET, L68149-L681106 1 D-3826 BRG, TAPERED, SET, L44643-L446107 1 F-1724 NUT, HEX, SLOTTED, 1-14, YZ8 1 F-1728 COTTER PIN, 3/16 X 2", YZ9 1 F-2078 NUT, 3/4-16, TOP LOCK, GR-GT, YZ10 4 F-2141 FHCS, 3/8-16 X 1", YZ, GR511 4 F-2151 NUT, 3/8-16 NYLOC, FLANGED, YZ12 1 H-1924 GREASE CAP PLATED13 1 H-2812 SEAL, SHAFT, 1.75, 2.38, 0.313

12

1

18

3

1210 11

USE ITEM#13 - 52" & 60" DECKS#14 - 48" DECKS

15

16

21

9

FILL CAVITYWITH GREASE

1012

23

11

3

6

16

20

7

4

23

18

5

82

227

19

17

TIRES & FRONT STEP

TORQUE TO75 FT/LBS

TORQUE TO75 FT/LBS

GREASE

PARTS MARKED "*" AREINCLUDED IN ITEM # 9

*

**

**

**

ITEM # QTY PART # DESCRIPTION1 2 659-092P WHEEL BACKING PLATE2 1 663-134P STEP, EXTENDED3 4 663-221P CAP, WHEEL BEARING4 2 720-047P DRAG RING5 2 721-021P SPACER, CASTER6 2 721-022W WLDT, CASTER YOKE7 4 D-2008-02 BEARING, SPD, SF-16-328 2 D-3969 O-RING, -224, 70 DURO NITRILE9 2 D-4021 TIRE ASS’Y, FLAT BLACK, SMOOTH, 13X 6.5-610 2 D-4021-4 TAPER ROLLER BEARING, LM11949/1191011 2 D-4021-5 GREASE SEAL, S1782800112 2 D-4021-6 SPACER, SPCR00513 2 D-4033 TIRE ASS’Y, 22 X 11-10, TURF, FLAT BLACK14 2 D-4034 TIRE ASS’Y, 22 X 9.5-10, FLAT BLACK15 8 F-1499 LUG NUT, 1/2-20, YZ16 2 F-2124 FHCS, 3/8-16 X 3/4", YZ, GR517 2 F-2143 FHCS, 1/2-13 X 1", YZ, GR518 2 F-2151 NUT, 3/8-16 NYLOC, FLANGED, YZ19 2 F-2179 WASHER, CASTER, .531 ID X 2.25 OD X .25THK, YZ20 2 F-2194 HHCS, 3/4-10 X 9-1/2",YZ, GR521 2 F-2195 NUT, FLANGE NYLOC, YZ22 2 H-1056 1/4" GREASE FITTING23 2 H-2461 RUBBER BUMPER

13

612TWIN LEVER

MODELS ONLY

11

11

USE ITEM#4 - XLT JOYSTICK#5 - XLT TWIN LEVER#7 - CHALLENGERJOYSTICK#8 - CHALLENGERTWIN LEVER

15

18

11

12

15

20

11

USE ITEM#21 - CHALLENGER#22 - XLT

12

19

BRAKE HANDLE ASSEMBLY(SEE DETAIL)

15

15

12

TWIN LEVERMODELS ONLY

314

1612

14

9

13

9

1 13

3 1011

14

12 913

1011

172

BRAKE HANDLE ASS’Y

FRONT PANEL ASS’Y& RELATED PARTS

ITEM # QTY PART # DESCRIPTION1 1 714-345P CRANK PLATE, PARK BRAKE2 1 714-346P HANDLE, PARK BRAKE3 2 714-349P BAR, LINK, PARK BRAKE4 1 720-110A FRONT PANEL W/ DECALS, XLT, JS5 1 720-111A FRONT PANEL W/ DECALS, XLT, TS6 1 720-113P BASE PLATE, SEAT MOUNT7 1 721-112A FRONT PANEL W/ DECALS, CHALLENGER, JS8 1 721-113A FRONT PANEL W/ DECALS, CHALLENGER, TS9 3 F-1009-01 FLAT WASHER, 1/4", YZ10 2 F-1009-02 WASHER, FLAT11 8 F-2063 NUT, 5/16-18, NYLOC, FLANGED, YZ12 8 F-2120 FHCS, 5/16-18 X 3/4", YZ, GR513 3 F-2132 NUT, 1/4-20 NYLOC, FLANGED, YZ14 3 F-2162 FHCS, 1/4-20 X 3/4", YZ, GR515 8 F-2229 NUT, RIVET, 1/4-20, OPEN END, .027-.165 MAT’L THK16 1 H-2934 PIVOT, BRAKE CRANK17 1 H-2935 PLATE, BRAKE HANDLE18 1 P-12557 DECAL, "CAUTION FUEL"19 1 P-13000 DECAL, MADE IN THE USA20 1 P-13312 DECAL, LOGO, CHROME w/BLK, LG21 1 P-13316 DECAL, CHALLENGER22 1 P-13365 DECAL, XLT

14

11

14

ROUTE WIRE HARNESSE-6600 (JOYSTICK)E-6649 (TWIN LEVER)UNDER FLANGE AND SECUREWITH E-5842

16

17

6FUEL TANKASS’Y(SEE PG 18)

TWIN LEVER ASS’Y(SEE PG 23)ORJOYSTICK ASS’Y(SEE PG 20)

FRONT PANEL ASS’Y(SEE PG 14)

16

13 20

12

8

1

92

419

75

BRAKE HANDLE ASS’Y(SEE PG 14)

3

10

15

18

FRONT PANEL ASS’Y& RELATED PARTS (CON’T)

SPACERSHOULDROLL FREELY

ITEM # QTY PART # DESCRIPTION1 2 707-073P STAND-OFF, LINKAGE MOUNT2 1 714-351P BRACE, FRONT PANEL3 1 720-073W WLDT, FRAME4 2 724-028P DISCONNECT BRACKET5 2 F-1011-03 NUT, 3/8-16, UNC-2B6 3 F-1009-01 FLAT WASHER, 1/4", YZ7 2 F-1009-03 WASHER, FLAT, 3/8, YZ8 1 F-2063 NUT, 5/16-18, NYLOC, FLANGED, YZ9 1 F-2120 FHCS, 5/16-18 X 3/4", YZ, GR510 2 F-2126 FHCS, 3/8-16 X 2",YZ, GR511 3 F-2132 NUT, 1/4-20 NYLOC, FLANGED, YZ

ITEM # QTY PART # DESCRIPTION12 1 F-2219 HFCS, 3/8-16 X 3/4", THR FORMING, YZ GR513 4 F-2151 NUT, 3/8-16 NYLOC, FLANGED, YZ14 3 F-2162 FHCS, 1/4-20 X 3/4", YZ, GR515 4 F-2180 FHCS, 3/8-16 x 3", YZ, GR516 2 F-2219 HFCS, 3/8-16 X 3/4", CZ, THD FORMING17 3 H-1920 SPRING, SEAT18 1 H-1926 1/4" X 1" HANDLE GRIP19 2 H-3039 WASHER, SPECIAL, 1/2" X 1-1/4" X 8GA20 2 F-1005-03 NUT, 3/8-16, CENTERLOCK, YZ, GR5

15

16

4

13 6

8

5

11

15

5

7

9

7

3

10

BRAKE HANDLE ASSEMBLY(SEE PG 14)

12

2

1

7

14

BRAKE ASSEMBLY

ITEM # QTY PART # DESCRIPTION1 2 659-159P BRAKE LINK2 1 E-6692 PLUNGER SWITCH, RAIL MOUNT3 1 F-1009-01 FLAT WASHER, 1/4", YZ4 2 F-1492 RUE RING, 5/165 4 F-2063 NUT, 5/16-18, NYLOC, FLANGED, YZ6 1 F-2122 FHCS, 5/16-18 X 1-1/4", YZ, GR5, FULL THD7 5 F-2132 NUT, 1/4-20 NYLOC, FLANGED, YZ8 4 F-2134 HFCS, 1/4-20 X 0.625", YZ, SELF TAPPING9 2 F-2148 FHCS, 5/16-18 X 1", YZ, GR510 1 F-2162 FHCS, 1/4-20 X 3/4", YZ, GR511 1 H-1635 SPRING, EXT, 3/4" OD X 4" OAL12 2 H-1637 COMPRESSION SPRING, .045 X .420 X 1.2513 2 H-2921 FLANGE BEARING-0.500"14 2 H-2924 BRAKE LINK ROD15 1 H-2953 WLDT, PARK BRAKE

17

9

2

131

15

14

1012

11

44

3

6

85

7

FUEL TANK ASSEMBLYKOHLER - 23"KAWASAKI - 32" KOHLER - 44"

KAWASAKI - 46"

FOR USE WITHCHALLENGER MODELS

FOR USE WITHXLT MODELS

XLT ONLY

CHALLENGER ONLY

CHALLENGERONLY

IF A TANK IS REQUIRED,IT CAN ONLY BEPURCHASED AS ACOMPLETE ASSEMBLYH-2724 - XLTH-3081 - CHALLENGER

(PARTS MARKED "*" AREINCLUDED IN ASS’Y)

*

*

*

*

*

*

*

ITEM # QTY PART # DESCRIPTION1 1 721-019P PLT, TANK SUPPORT2 2 F-2219 HFCS, 3/8-16 X 3/4", CZ, THD FORMING3 1 H-1648 FUEL LINE, 1/2" O.D., 1/4" I.D.4 2 H-1687 1/2 O.D. HOSE SPRING CLAMP5 1 H-2678 KELCH REMOTE VENT6 1 H-2679 KELCH REMOTE VENT GROMMET7 1 H-2697 HOSE, FUEL LINE .188 ID X .406 OD8 1 H-2698 CLAMP, .406 OD FUEL LINE9 1 H-2724 ASSEMBLY, FUEL TANK, SMALL10 1 H-2741 GROMMET, PICK UP TUBE (DAPCO #12240)11 1 H-2742 PICK UP TUBE (DAPCO INDUSTRIES)12 1 H-2743 RATCHET CAP, W/TETHER, 3.5 DIA13 2 H-2990 WEATHER-RESISTANT NEOPRENE FOAM (ADHESIVE) 1/2"14 1 H-3081 FUEL TANK ASSEMBLY15 1 P-12922 VENDOR SUPPLIED EPA CERT. LABEL

18

14

14

11

6

8

19

15

3

23

7

2

20

12

21

9 312

164

23

5 13

1717

10

22

14

14

18

JOYSTICK CONTROL& RELATED PARTS

PART OF # 6

INSTALL AFTER BOLTS(ITEM # 17) ARE SECUREDTO PANEL

ITEM # QTY PART # DESCRIPTION1 1 625-100P TUBE, PIVOT, JOYSTICK2 2 625-107P BUSHING, .375 ROD END3 2 625-116P BUSHING, .375 ROD END, SHORT4 1 625-119P PIN, PIVOT, JS, LONG5 1 625-126P SPACER, JOYSTICK PANEL6 1 625-171A JOYSTICK ASS’Y, SHORT7 1 720-038P PLT, BOOT RETAINER8 2 F-1011-01 NUT,HEX, 1/4-20 UNC-2B YELLOW PLATED9 1 F-1020-01 CAPSCREW, 1/4-20 X 3-1/2", YZ, GR510 1 F-1158 NUT, CENTERLOCK, 1/4-20, YZ, GR511 2 F-1448 LOCKNUT, 10-32 NYLOC YELLOW PLTD12 1 F-1462 JAM NUT, 1/2-20, RH, YZ13 1 F-1521 WASHER, 1/2" CUSTOM, YZ14 5 F-2063 NUT, 5/16-18, NYLOC, FLANGED, YZ15 2 F-2100 HHMS, 10-32 X 7/8", CZ16 1 F-2103 SHCS, BUTTON HD, 1/4-20 X 1", CZ17 3 F-2120 FHCS, 5/16-18 X 3/4", YZ, GR518 1 F-2122 FHCS, 5/16-18 X 1-1/4", YZ, GR5, FULL THD19 1 F-2132 NUT, 1/4-20 NYLOC, FLANGED, YZ20 1 H-1991 JOY STICK BOOT21 1 H-2964 HANDLE, JOYSTICK22 1 H-2990 WEATHER-RESISTANT NEOPRENE FOAM (ADHESIVE) 1/2"23 2 H-3025 LINKAGE: UPPER: 1/4-28 X 5

19

1726

2114

23

8

13

245 3

14

6

28

13 25

20

1

16

27

11

15

9 2

18

16

12

7

422

10

19

JOYSTICK ASSEMBLY{625-171A}

PART OF #8

PART OF #8

SEE DETAIL

YOKE, SWIVEL, ASS’Y(625-169A)

ITEM # QTY PART # DESCRIPTION1 1 625-096P YOKE, SWIVEL, JOYSTICK2 1 625-099P TUBE, GUIDE, CONTROL ROD3 1 625-103P TAB, CAM DETENT4 1 625-106P PIN, PIVOT, JS5 1 625-124P TUBE-SPACER, DETENT CAM6 1 625-125P SPACER, CAM DETENT7 1 625-127W NEUTRAL PLATE WELDMENT8 1 625-128A PIVOT ASSEMBLY9 1 625-154P HOUSING, JOYSTICK10 1 625-169A YOKE, SWIVEL ASSEMBLY11 1 659-285P MOUNT, SWITCH12 1 709-169A ROD ASSEMBLY, SHORT, 1/2"13 2 D-3784 BUSHING, DU 1/2 DIA X 3/8 WIDE14 2 D-3931 THRUST BEARING15 1 E-6474 SWITCH, SNAP MOUNT

ITEM # QTY PART # DESCRIPTION16 3 F-1005-01 NUT, 1/4-20 w/NYLOC, YZ17 1 F-1005-05 NUT, 1/2-13, CENTERLOCK, YZ, GR518 1 F-1293 HHCS, 1/2-13 X 2", YZ, GR519 1 F-1462 JAM NUT, 1/2-20, RH, YZ20 1 F-1503 PIN,SPIROL 3/16 DIA X 1 X .010 THK21 1 F-1521 WASHER, 1/2" CUSTOM, YZ22 1 F-2103 SHCS, BUTTON HD, 1/4-20 X 1", CZ23 1 F-2135 SCREW, PANHEAD, PHILLIPS #12-24 X 1.75 CZ24 1 F-2136 WASHER, FLAT, #12 PLAIN, CZ25 1 F-2137 NUT, #12-24, NYLOCK26 1 H-2704 SPRING, BELLEVILLE, .50 X 1 X .07327 2 H-2705 RING, RETAINING, .75 EXT.28 1 H-2710 SPRING, DETENT, JOYSTICK

20

3

JOYSTICK ASS’Y(SEE PG 20)

53

6

1

12

FRONT PANEL ASS’Y(SEE PG 14)

10

4

8 6

2

15

6

11

7

9

CONNECT TO TRANSMISSION

810

8

JOYSTICK ASSEMBLY MOUNTING& RELATED PARTS

ITEM # QTY PART # DESCRIPTION1 2 625-107P BUSHING, .375 ROD END2 1 714-084A ASSEMBLY, PIVOT PLATE3 2 F-1019-01 WASHER, LOCK, 1/4, YZ4 1 F-1521 WASHER, 1/2" CUSTOM, YZ5 2 F-1539 HHCS, 1/4-20 X 1-1/4", YZ, GR56 6 F-2132 NUT, 1/4-20 NYLOC, FLANGED, YZ7 4 F-2162 FHCS, 1/4-20 X 3/4", YZ, GR58 4 F-2202 NUT, 1/4-20, NYLOC, YZ9 1 H-2954 WLDT, JS PIVOT SHAFT10 2 H-3021 LINKAGE, CONTROL LOWER11 2 H-3031 SIDE FLANGE BRG., 0.500, BRONZE12 1 F-1009-01 FLAT WASHER, 1/4", YZ

21

13

17

7 6 1

INSTALL AFTER BOLT (ITEM #10)IS SECURED TO PANEL

17 8

FRONT PANEL ASS’Y(SEE PG 14)

5

7

8

16

6 1 10

BRAKE ASS’Y(SEE PG 17)

TRANSMISSION(SEE PG 26)

11

10

8144

13

8

8

3

9

12

2

15

TWIN LEVER CONTROL& RELATED PARTS

ITEM # QTY PART # DESCRIPTION1 4 625-116P BUSHING, .375 ROD END, SHORT2 2 659-375W WLDT, DUAL LEVER3 2 720-053P PLT, TWIN LEVER SUPPORT4 1 721-086A ASSY, TS CONTROL, R5 1 721-087A ASSY, TS CONTROL, L6 4 F-1019-01 WASHER, LOCK, 1/4, YZ7 4 F-1539 HHCS, 1/4-20 X 1-1/4", YZ, GR58 12 F-2063 NUT, 5/16-18, NYLOC, FLANGED, YZ9 6 F-2119 FHCS, 1/4-20 X 3/4", YZ, GR5, LOCK PATCH10 6 F-2120 FHCS, 5/16-18 X 3/4", YZ, GR511 1 F-2122 FHCS, 5/16-18 X 1-1/4", YZ, GR5, FULL THD12 4 F-2129 FHCS, 5/16-18 X 1-1/2", YZ, GR513 4 F-2132 NUT, 1/4-20 NYLOC, FLANGED, YZ14 2 F-2229 NUT, RIVET, 1/4-20, OPEN END, .027-.165 MAT’L THK15 2 H-2739 GRIP, 15", CLOSED END16 2 H-3037 LINKAGE, OUTER, JS17 2 H-2990 WEATHER-RESISTANT NEOPRENE FOAM (ADHESIVE) 1/2"

22

14

22

19

26

9

4

121

25

21

1617

15

USE ITEM#5 - RIGHT HAND#6 - LEFT HAND

7

19

12

25

18

13

8

23

USE ITEM#2 - RIGHT HAND#3 - LEFT HAND

20

19

20

USE ITEM#10 - RIGHT HAND#11 - LEFT HAND

19

24

TWIN LEVER ASSEMBLY{721-086A - RIGHT SIDE}{721-087A - LEFT SIDE}(RIGHT HAND SHOWN, LEFT HAND OPPOSITE)

ITEM # QTY PART # DESCRIPTION1 1 714-074P PIN, PIVOT, TWIN LEVER2 1 714-266P HOUSING, TWIN LEVER, R3 1 714-269P HOUSING, TWIN LEVER, L4 1 721-006P SPRING GUIDE, TS5 1 721-088W WLDT, TWIN LEVER PIVOT, R6 1 721-089W PIVOT WELDMENT FOR OVER-CENTER7 1 721-090W WLDT, HANDLE BASE8 1 721-093P PIN, SPRING OVER-CENTER9 1 721-094P SPRING GUIDE, TS OVER-CENTER10 1 721-103P PLT, TS HOUSING, R11 1 721-104P PLT, TS HOUSING, L12 2 D-3730 BUSHING, DU 5/8 DIA X 1/2 LG13 1 E-6692 PLUNGER SWITCH, RAIL MOUNT14 1 F-1011-02 NUT, HEX 5/16-18

ITEM # QTY PART # DESCRIPTION15 1 F-1125 NUT, CENTERLOCK, 5/16-18, YZ, GR516 1 F-1306 HHCS, 3/8-16 X 1-1/2", FULL THRD, CZ, GR517 1 F-1486 NUT, JAM, 3/8-16, YZ18 1 F-1903 SETSCREW, 3/8-16 X 3/4" W/ NYLON19 5 F-2063 NUT, 5/16-18, NYLOC, FLANGED, YZ20 2 F-2120 FHCS, 5/16-18 X 3/4", YZ, GR521 1 F-2122 FHCS, 5/16-18 X 1-1/4", YZ, GR5, FULL THD22 1 F-2145 HHCS, 5/16-18 X 6", YZ, GR823 1 F-2151 NUT, 3/8-16 NYLOC, FLANGED, YZ24 1 F-2160 FHCS, 3/8-16 X 4-1/2", YZ, GR525 2 H-3009 BUSHING, 0.313, NYLON, FLANGED26 1 H-3079 SPRING, TS OVER CENTER

23

2

89

1

USE ITEM#10 - KAWASAKI ENGINE#11 - KOHLER ENGINE

12

3

4

PART OF #2

7

5

6

CONTROL PANEL714-248A - KAWASAKI714-024A - KOHLER

PART OF #1

ITEM # QTY PART # DESCRIPTION1 1 714-031A CONTROL PLATE W/ DECAL2 1 E-5873 KEY ASSEMBLY, 3 POSITION3 1 E-5878 HOUR METER4 1 E-6403 PTO SWITCH5 1 E-6445 KEY SET OF TWO6 2 F-1022-26 MACHINE SCREW,RND, 10-32 X 5/8, SLOTTED, CZ7 2 F-1071 WASHER, FLAT #10, ZINC PLATED #10 SAE FLAT WASHER8 2 F-1448 LOCKNUT, 10-32 NYLOC YELLOW PLTD9 1 H-2287 CHOKE CABLE, 43-1/2"10 1 H-2610 THROTTLE CABLE, 38"11 1 H-2611 THROTTLE CABLE, 57"12 1 P-13195 DECAL, CONTROL PANEL, AVE & BLVD

24

8

13

1

858

10

10

8

CONTROL PANEL(SEE PG 24)

REMOVE KNOCKOUTSON PLASTIC FENDERSFOR TWIN LEVER MODELS(BOTH FENDERS)FOR CHALLENGER JOYSTICK MODELS(RIGHT HAND FENDER ONLY)

USE ITEM#3 - XLT#4 - CHALLENGER

USE ITEM#9 - CHALLENGER RIGHT SIDEXLT BOTH SIDES#11 - CHALLENGER LEFT SIDE

10

7

10

7

CHALLENGERBATTERY BOX(SEE PG 16)

12

10

2

8

USE ITEM#3 - XLT#6 - CHALLENGER

10

714

FENDER ASSEMBLY & RELATED PARTS

SECURE TO FRAMEON XLT MODELS

*

*

*

ITEMS MARKED "*"USED ON CHALLENGERMODELS ONLY

PART OF #1 PART OF #2

ITEM # QTY PART # DESCRIPTION1 1 714-037A FENDER w/DECALS, RH2 1 714-038A FENDER w/DECALS, LH3 4 714-323P TAB, FENDER MOUNT4 2 721-046P BRACKET, FENDER, REAR5 2 721-047P BRACKET, FENDER6 2 721-048P BRACKET, FENDER, MID7 4 F-2119 FHCS, 1/4-20 X 3/4", YZ, GR5, LOCK PATCH8 11 F-2132 NUT, 1/4-20 NYLOC, FLANGED, YZ9 2 F-2134 HFCS, 1/4-20 X 0.625", YZ, SELF TAPPING10 11 F-2162 FHCS, 1/4-20 X 3/4", YZ, GR511 1 F-2219 HFCS, 3/8-16 X 3/4", CZ, THD FORMING12 1 P-11370 DECAL, WARNING13 1 P-13188 DECAL, INSTRUCTIONS14 2 P-13366 DECAL, C/C LOGO, SM, VINYL

25

24

28 1334

1314 30

3 15

USE ITEM#7 - XLT#9 - CHALLENGER

USE ITEM#29 - JOYSTICK#33 - TWIN LEVER

19

41912 20

24

27

22

22

19

USE BOTTOM SLOT,TEETH TO INSIDE(ITEM #3)

25

USE ITEM#8 - XLT#10 - CHALLENGER

1

19

11

18

1726

531

356

16

3223 2152

TRANSMISSION ASSEMBLY& RELATED PARTS(LOOKING AT BOTTOM)

IDLER ARM ASS’Y(714-256A)

DAMPER CONNECTIONTO FRAME

DAMPER CONNECTIONTO TRANSMISSION

ITEM # QTY PART # DESCRIPTION1 1 659-173P HYDRO BRACE ZT28002 1 714-058P PIN, IDLER PIVOT3 2 714-098P TAB, DUMP VALVE4 1 714-256A ASS’Y, IDLER ARM5 2 D-3730 BUSHING, DU 5/8 DIA X 1/2 LG6 1 D-3924 PULLEY, FLAT IDLER, 4.25 OD, NTN, DBL INSERT7 1 D-3968-01 TRANSAXLE,ZT-3100 w/RTN, RH8 1 D-3968-02 TRANSAXLE, ZT-3100 w/RTN, LH9 1 D-3992-01 TRANSAXLE, ZT-3400, RH10 1 D-3992-02 TRANSAXLE, ZT-3400, LH11 2 F-1009-03 WASHER, FLAT, 3/8, YZ12 2 F-1011-02 NUT, HEX 5/16-1813 4 F-1071 WASHER, FLAT #10, ZINC PLATED #10 SAE FLAT WASHER14 2 F-1448 LOCKNUT, 10-32 NYLOC YELLOW PLTD15 2 F-1492 RUE RING, 5/1616 2 F-1521 WASHER, 1/2" CUSTOM, YZ17 1 F-1664 HHCS, 1/2-13 X 2-1/4", YZ, GR518 1 F-2007 HHCS 3/8-16 X 12.50 GR5 Z&Y

ITEM # QTY PART # DESCRIPTION19 10 F-2063 NUT, 5/16-18, NYLOC, FLANGED, YZ20 2 F-2129 FHCS, 5/16-18 X 1-1/2", YZ, GR521 1 F-2132 NUT, 1/4-20 NYLOC, FLANGED, YZ22 2 F-2151 NUT, 3/8-16 NYLOC, FLANGED, YZ23 1 F-2152 NUT, 1/2-13 NYLOC, FLANGED, YZ24 4 F-2177 FHCS, 5/16-18 X 2-1/2, YZ, GR525 4 F-2178 FHCS, 5/16-18 X 3", YZ, GR526 1 F-2216 FHCS, 1/4-20 X 1-3/4, YZ, GR527 1 F-2218 FHCS, 3/8-16 X 2-1/4", YZ, GR528 2 F-2221 HHMS, 10-32 X 1-1/4"29 2 H-2896 DAMPER, NC30030 1 H-2907 SPRING,5.43 X 1-1/2", TAPERED ENDS31 1 H-2942 PLT, IDLER ARM, TOP32 1 H-2943 PLT, IDLER ARM, BOTTOM33 2 H-2958 DAMPER, NC60034 2 H-2961 BUSHING, DAMPLER MOUNT35 1 H-2962 SPACER, IDLER

26

5

3

6

9

2

8

10

1

2

9

4

7

3

9

8

TRANSMISSION ASSEMBLY& RELATED PARTS CONT’

ROUTE HOSE THROUGH MOTOR MOUNT

ITEM # QTY PART # DESCRIPTION1 1 721-029P PLT, TANK MOUNT2 4 F-2132 NUT, 1/4-20 NYLOC, FLANGED, YZ3 4 F-2162 FHCS, 1/4-20 X 3/4", YZ, GR54 1 H-2517 VENT TUBE ADAPTER5 2 H-2567 TRANSAXLE OIL FILTER6 1 H-2762 VENT TUBE ADAPTER

ITEM # QTY PART # DESCRIPTION7 1 H-3033 HYDRO TANK ASSEMBLY8 2 H-3084 HOSE, 1/2" DIA X 16-1/2"9 4 H-3089 HOSE CLAMP, 0.78" HOSE O.D.- 4 H-3155 HOSE CLAMP, 0.88" HOSE O.D.

27

10 1 -P 11052 DECAL, "TRANSMISSION OIL..."

CHALLENGER ONLY

SECURE SPRINGEXTENSION CABLE(ITEM #8)

3

8

3

1

6

6

3

3

2

4 3

7

5

SEAT BASE& RELATED PARTS

ITEM # QTY PART # DESCRIPTION1 1 721-013P PLT, SEAT MOUNT, LOW2 2 F-1009-03 WASHER, FLAT, 3/8, YZ3 6 F-2063 NUT, 5/16-18, NYLOC, FLANGED, YZ4 1 F-2129 FHCS, 5/16-18 X 1-1/2", YZ, GR55 2 F-2141 FHCS, 3/8-16 X 1", YZ, GR56 2 F-2148 FHCS, 5/16-18 X 1", YZ, GR57 2 F-2151 NUT, 3/8-16 NYLOC, FLANGED, YZ8 1 H-2460 SPRING EXTENSION CABLE

28

CHALLENGER ONLY

JOYSTICKMODELS ONLY

10

7

7

USE ITEM#9 - CHALLENGER#11 - XLT

4

USE ITEM#15 - CHALLENGER#16 - XLT

5 14

1

12

78

USE ITEM#2 - TWIN LEVER#3 - JOYSTICK

7613

SEAT BASE& RELATED PARTS (CON’T)

CHALLENGER ONLY

ITEM # QTY PART # DESCRIPTION1 1 720-017P MOUNT PLATE, ARM REST, R2 1 720-018P MOUNT PLT, ARM REST, L3 1 720-071P PLT, ARM REST, LH, JS4 4 721-061P PLATE, SPACER5 4 F-1015-15 HHCS, 5/16-18 X 1", YZ, GR56 1 F-1486 NUT, JAM, 3/8-16, YZ7 8 F-2063 NUT, 5/16-18, NYLOC, FLANGED, YZ8 4 F-2121 FHCS, 5/16-18 X 1", LOCK PATCH, YZ, GR59 4 F-2129 FHCS, 5/16-18 X 1-1/2", YZ, GR510 1 F-2141 FHCS, 3/8-16 X 1", YZ, GR511 4 F-2148 FHCS, 5/16-18 X 1", YZ, GR512 1 H-2760 TRACK KIT, HD, 6" TRAVEL13 1 H-2764 HANDLE, JOYSTICK14 2 H-2799 PAD, ARM REST15 1 H-3087 SEAT ASS,Y, w/N.C. SWITCH, 121116 1 H-3129 SEAT ASS’Y, XLT

29

30

4

6

13

APPLY LIGHT COATOF NEVERSIEZE

2

USE ITEM#7 - XLT#8 - CHALLENGER

5

9

ENGINES

KOHLERXLT - 26 HP KT745

CHALLENGER - 25 HP ZT740(USE THROTTLE CABLE H-2611

& CHOKE CABLE H-2287)

GROUND

ITEM # QTY PART # DESCRIPTION1 1 621-113P SQUARE KEY 1/4 X 1/4 X 1-1/42 1 D-3974 MOTOR, PULLEY, 4.51 W/ 1-1/8’’ SHAFT3 1 F-1228 SET SCREW, SOCKET, 1/4-20 X 1/4", W/NYLOC4 1 F-2049 M6-1 X 20 H.F. FORM SCREW5 1 H-2589 OIL DRAIN VALVE (KOHLER)6 1 H-3034 MUFFLER, KOHLER ZT7407 1 M-5417 ENGINE, KOH, 26HP KT745, 3400RPM8 1 M-5418 ENGINE, KOH, 25HP ZT740, 3400RPM9 1 P-10077-11 DECAL, "PERIODIACALLY CLEAN"

7

5

1

4 2

APPLY LIGHT COATOF NEVERSIEZE

USE ITEM#8 - XLT#9 - CHALLENGER

10

6

3

KAWASAKIXLT - 24 HP FR730

CHALLENGER - 24 HP FS730(USE THROTTLE CABLE H-2610

& CHOKE CABLE H-2287)

GROUND

APPLY TEFLON TAPE

ITEM # QTY PART # DESCRIPTION1 1 621-113P SQUARE KEY 1/4 X 1/4 X 1-1/42 1 D-3974 MOTOR, PULLEY, 4.51 W/ 1-1/8’’ SHAFT3 1 E-6307 OIL PRESSURE SWITCH4 1 F-1228 SET SCREW, SOCKET, 1/4-20 X 1/4", W/NYLOC5 1 F-2243 HHCS, M8-1.25 X 12, YZ, GR86 1 H-2590 OIL DRAIN VALVE (KAWASAKI)7 1 H-3020 MUFFLER. KAWASAKI FR7308 1 M-5419 ENGINE, KAW, 24HP FR730, 3400RPM9 1 M-5420 ENGINE, KAW, 24HP FS730, 3400RPM10 1 P-10077-11 DECAL, "PERIODIACALLY CLEAN"

14

3

11

10

2

4

8

12

5

8

8

6

7

1

7

7

ENGINE & CLUTCH MOUNTING& RELATED PARTS(LOOKING AT BOTTOM)

USE ITEM#9 - KAWASAKITORQUE SPEC = 32 FT/LBS#13 - KOHLERTORQUE SPEC = 42 FT/LBS

ROUTE CLUTCH PIGTAIL& SECURE

TORQUE SPEC = 55-60 FT/LBS

ITEM # QTY PART # DESCRIPTION1 1 714-398P GUARD, MUFFLER2 1 721-075P GUARD, REAR ENGINE, LIGHT3 1 D-3769 V BELT A-67 KEVLAR4 2 E-5842 WIRE TIE5 1 E-6660 CLUTCH, 175 FT/LBS, 1-1/8" BORE, EXT PULLEY6 1 F-1766 HHCS, 7/16-20 X 3-1/4", YZ, GR87 4 F-2063 NUT, 5/16-18, NYLOC, FLANGED, YZ8 4 F-2120 FHCS, 5/16-18 X 3/4", YZ, GR59 4 F-2125 FHCS, 3/8-16 X 1-1/4", YZ, GR510 2 F-2151 NUT, 3/8-16 NYLOC, FLANGED, YZ11 2 F-2180 FHCS, 3/8-16 x 3", YZ, GR512 2 F-2219 HFCS, 3/8-16 X 3/4", CZ, THD FORMING13 4 F-2238 HFCS, 3/8-16 X 1-1/4", CZ, THD FORMING14 1 P-12918 DECAL, HYDRO BELT ROUTING

31

32

33

34

35