John Deere L100, L108, L110, L111, L118, L120, and L130 Lawn Tractors Technical Manual TM2026 01MAR05

A
Attachments
Diagnostics
Mower Deck Troubleshooting Chart . . . . . . . . 407
Mower Drive Check . . . . . . . . . . . . . . . . . . . . 408
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
Tests and Adjustments . . . . . . . . . . . . . . . . . . . . . 410
Avoid Harmful Asbestos Dust . . . . . . . . . . . . . . . . . . . . . 4
Avoid Injury
Rotating Blades, Augers And PTO Shafts . . . . . . . . 5
Axle Removal and Installation, Front . . . . . . . . . . . . . . 382
B
Battery
Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Voltage and Specific Gravity Tests . . . . . . . . . . . . 315
Blades
Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
Removal and Installation . . . . . . . . . . . . . . . . . . . 415
Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
Brake Pedal Removal/Installation
Gear Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
Hydrostatic Transaxle . . . . . . . . . . . . . . . . . . . . . . 395
Brakes
Adjustment
Gear Transaxle . . . . . . . . . . . . . . . . . . . . . . . . 390
Hydrostatic Transaxle . . . . . . . . . . . . . . . . . . . 391
Assembly Removal & Installation
Gear Transaxle . . . . . . . . . . . . . . . . . . . . . . . . 397
Component Location . . . . . . . . . . . . . . . . . . . . . . . 388
Linkage Removal/Installation
Gear Transaxle . . . . . . . . . . . . . . . . . . . . . . . . 392
Hydrostatic Transaxle . . . . . . . . . . . . . . . . . . . 392
Mower Deck Blade Brake (42 Inch Deck) . . . . . . . 415
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
System Operation
Gear Power Train . . . . . . . . . . . . . . . . . . . . . . 339
Hydrostatic Power Train . . . . . . . . . . . . . . . . . 360
Tests and Adjustments . . . . . . . . . . . . . . . . . . . . . 390
Break-in engine oil
4-cycle gasoline . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Briggs & Stratton Engine (Single Cylinder)
Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . 30
Balancer System Removal & Installation . . . . . . . . 49
Breather Valve Service . . . . . . . . . . . . . . . . . . . . . . 33
Cam Gear Bearing Inspection . . . . . . . . . . . . . . . . 52
Carburetor Assembly . . . . . . . . . . . . . . . . . . . . . . . 32
Carburetor Disassembly . . . . . . . . . . . . . . . . . . . . . 31
Carburetor Inspection . . . . . . . . . . . . . . . . . . . . . . . 32
Carburetor Removal & Installation . . . . . . . . . . . . . 30
Connecting Rod Inspection . . . . . . . . . . . . . . . . . . . 43
Crankshaft & Cam Gear Installation . . . . . . . . . . . . 50
Crankshaft & Cam Gear Removal . . . . . . . . . . . . . 48
Cylinder Bore
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Resizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Cylinder Head
Inspection and Repair . . . . . . . . . . . . . . . . . . . .38
Removal & Installation . . . . . . . . . . . . . . . . . . . .36
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . .35
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Flywheel Removal and Installation . . . . . . . . . . . . . .47
Governor Removal & Installation . . . . . . . . . . . . . . .40
Magnet to Bearing Inspection . . . . . . . . . . . . . . . . . .51
PTO Bearing Removal & Installation . . . . . . . . . . . .52
Piston Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Piston, Rings & Rod Removal and Installation . . . . .41
Repair Specifications . . . . . . . . . . . . . . . . . . . . . . . .20
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Starting Motor Assembly . . . . . . . . . . . . . . . . . . . . .55
Starting Motor Disassembly . . . . . . . . . . . . . . . . . . .53
Starting Motor Pinion Gear Replacement . . . . . . . . .57
Starting Motor Removal & Installation . . . . . . . . . . .53
Tests and Adjustments
Cylinder Leakdown Test . . . . . . . . . . . . . . . . . .27
Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . . . .23
Governor Dynamic Adjustment . . . . . . . . . . . . .24
Governor Idle Adjustment . . . . . . . . . . . . . . . . .25
Governor Static Adjustment . . . . . . . . . . . . . . . .23
Ignition Armature Air Gap . . . . . . . . . . . . . . . . .27
Slow Idle Carburetor . . . . . . . . . . . . . . . . . . . . .25
Throttle Cable Adjustment . . . . . . . . . . . . . . . . .23
Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . .26
Tests and Adjustments Specifications . . . . . . . . . . .19
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . .21
Upper Blower Housing Removal & Installation . . . . .29
Valves
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Reface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Briggs & Stratton Engine (V-Twin)
Air Cleaner Removal & Installation . . . . . . . . . . . . .128
Blower Housing Removal & Installation . . . . . . . . .128
Breather Valve Service . . . . . . . . . . . . . . . . . . . . . .160
Carburetor Disassembly and Assembly
Single Barrel . . . . . . . . . . . . . . . . . . . . . . . . . .130
Two Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Carburetor Removal/Installation
Single Barrel . . . . . . . . . . . . . . . . . . . . . . . . . .129
Two Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Connecting Rod Inspection . . . . . . . . . . . . . . . . . .149
Connecting Rod and Camshaft Specifications . . . .117
Crankshaft and Camshaft
Removal, Inspection and Installation . . . . . . . .156
Cylinder Air Guides Removal & Installation . . . . . .141
Cylinder Bore
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Resizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Cylinder Bore and Piston Specifications . . . . . . . . 116
Cylinder Head
Inspection and Repair . . . . . . . . . . . . . . . . . . 145
Removal and Installation . . . . . . . . . . . . . . . . 142
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . 140
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . 115
Flywheel Removal and Installation . . . . . . . . . . . . 154
Magneto Bearing Inspection . . . . . . . . . . . . . . . . . 158
Oil Pump Removal and Installation . . . . . . . . . . . . 161
PTO and Cam Bearing Inspection . . . . . . . . . . . . 159
Piston Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 149
Piston and Connecting Rod (Assembling) . . . . . . 150
Pistons, Rings, & Rods Removal & Installation . . 147
Repair Specifications . . . . . . . . . . . . . . . . . . . . . . 116
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Starting Motor Assembly . . . . . . . . . . . . . . . . . . . . 165
Starting Motor Disassembly . . . . . . . . . . . . . . . . . 163
Starting Motor Pinion Gear Replacement . . . . . . . 167
Starting Motor Removal & Installation . . . . . . . . . 163
Tests and Adjustments
Choke Cable Adjustment . . . . . . . . . . . . . . . . 120
Compression Test . . . . . . . . . . . . . . . . . . . . . 122
Cylinder Balance Test . . . . . . . . . . . . . . . . . . 124
Fuel Shutoff Solenoid Test . . . . . . . . . . . . . . . 121
Governor Adjustment-Dynamic . . . . . . . . . . . 122
Governor Adjustment-Static . . . . . . . . . . . . . . 121
Ignition Armature Air Gap . . . . . . . . . . . . . . . . 125
Oil Pressure Test . . . . . . . . . . . . . . . . . . . . . . 126
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 115
Throttle Cable Adjustment . . . . . . . . . . . . . . . 120
Valve Clearance Adjustment . . . . . . . . . . . . . 126
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . 118
Valves
Inspection and Repair . . . . . . . . . . . . . . . . . . 146
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 116
Valves Lap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Bushing, Front Wheel – Removal and Installation . . . . 427
C
California Proposition 65 Warning . . . . . . . . . . . . . . . . . . 4
Chain Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Component Location
42C Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . 405
48C Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . 406
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
Electrical – L120/L130 . . . . . . . . . . . . . . . . . . . . . . 227
Gear Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
Hydrostatic Transaxle . . . . . . . . . . . . . . . . . . . . . . .356
Mower Lift Linkage . . . . . . . . . . . . . . . . . . . . . . . . .404
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .376
D
Diagnostics
Attachments
Mower Deck Troubleshooting Chart . . . . . . . .407
Mower Drive Check . . . . . . . . . . . . . . . . . . . . .408
Briggs & Stratton Engine (Single Cylinder) . . . . . . .22
Briggs & Stratton Engine (V-Twin) . . . . . . . . . . . . .119
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262
Kohler Engine (Single Cylinder) . . . . . . . . . . . . . . . .68
Kohler Engine (V-Twin) . . . . . . . . . . . . . . . . . . . . .177
Transaxle
Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .344
Hydrostatic . . . . . . . . . . . . . . . . . . . . . . . 360, 361
Dispose of Waste Properly . . . . . . . . . . . . . . . . . . . . . . . .5
E
Electrical
Armature Air Gap Adjustment . . . . . . . . . . . . . . . .330
Battery
Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .316
Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .317
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .226
Voltage and Specific Gravity Tests . . . . . . . . .315
Brake Switch Test . . . . . . . . . . . . . . . . . . . . . . . . .325
Briggs & Stratton Engine (Single Cylinder)
Starting Motor Assembly . . . . . . . . . . . . . . . . . .55
Starting Motor Disassembly . . . . . . . . . . . . . . . .53
Starting Motor Pinion Gear Replacement . . . . .57
Briggs & Stratton Engine (V-Twin)
Starting Motor Assembly . . . . . . . . . . . . . . . . .165
Starting Motor Disassembly . . . . . . . . . . . . . . .163
Starting Motor Pinion Gear Replacement . . . .167
Starting Motor Removal/Installation . . . . . . . . .163
Charging Circuit Diagnosis – All Models . . . . . . . . .295
Charging Circuit Operation – All Models . . . . . . . . .292
Charging Circuit Wiring Schematic
L100/L108/L110/L111/L118 . . . . . . . . . . . . . . .293
L120/L130 . . . . . . . . . . . . . . . . . . . . . . . . . . . .294
Common Circuit Tests . . . . . . . . . . . . . . . . . . . . . .225
Component Location – L120/L130 . . . . . . . . . . . . .227
Conductors for 12 Volt Circuits . . . . . . . . . . . . . . . .225
Cranking Circuit Diagnosis – All Models . . . . . . . . .279
Cranking Circuit Operation – All Models . . . . . . . . .276
Cranking Circuit Wiring Schematic
L100/L108/L110/L111/L118/L120 . . . . . . . . . .277
L130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278
Diagnostic Information . . . . . . . . . . . . . . . . . . . . . .224
Diode Test – Ignition Coils L111/L118/L120 . . . . . .327
Flywheel Ignition Magnet Test . . . . . . . . . . . . . . . .320
Flywheel Stator Magnets Test . . . . . . . . . . . . . . . .320
Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . . . . . .261
Fuel Shutoff Solenoid Test . . . . . . . . . . . . . . . . . . .329
Ground Circuit Tests . . . . . . . . . . . . . . . . . . . . . . . 315
Headlight Circuit Diagnosis – All Models . . . . . . . . 311
Headlight Circuit Operation – All Models . . . . . . . . 308
Headlight Circuit Wiring Schematic
L100/L108/L110/L111/L118 . . . . . . . . . . . . . . 309
L120/L130 . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Hour Meter/Service Light Circuit Diagnosis –
L110/L111/L118/L120/L130 . . . . . . . . . . . . . . 314
Hour Meter/Service Light Circuit Operation –
L110/L111/L120/L130 . . . . . . . . . . . . . . . . . . 312
Hour Meter/Service Light Circuit Wiring Schematic
L110/L118/L120 – Late Models . . . . . . . . . . . . 313
L110/L120 Early Models . . . . . . . . . . . . . . . . . 312
L111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
L130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Ignition Module Diode Test – L110/L130 . . . . . . . . 328
Ignition Module Test – L110/L130 . . . . . . . . . . . . . 329
Ignition and Shutoff Circuit Diagnosis – All Models 288
Ignition and Shutoff Circuit Operation – All Models 281
Ignition and Shutoff Circuit Wiring Schematic
L100/L108/L110/L118 Late Models . . . . . . . . 283
L100/L110 Early Models . . . . . . . . . . . . . . . . . 282
L111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
L120 Early Models . . . . . . . . . . . . . . . . . . . . . 284
L120 Late Models . . . . . . . . . . . . . . . . . . . . . . 285
L130 Early Models . . . . . . . . . . . . . . . . . . . . . 286
L130 Late Models . . . . . . . . . . . . . . . . . . . . . . 287
Key Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . 324
Kohler Engine (Single Cylinder)
Starting Motor Brush Replacement . . . . . . . . 110
Starting Motor Drive Replacement . . . . . . . . . 109
Starting Motor Removal & Installation . . . . . . 109
Kohler Engine (V-Twin)
Starting Motor Armature Test . . . . . . . . . . . . . 218
Starting Motor Assembly . . . . . . . . . . . . . . . . 216
Starting Motor Disassembly . . . . . . . . . . . . . . 215
Starting Motor Removal and Installation . . . . 215
Starting Motor Repair and Brush Replacement 217
Main Wiring Schematic
L100/L108/L110/L118 Late Models . . . . . . . . 230
L100/L110 Early Models . . . . . . . . . . . . . . . . . 228
L111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
L120 Early Models . . . . . . . . . . . . . . . . . . . . . 242
L120 Late Models . . . . . . . . . . . . . . . . . . . . . . 244
L130 Early Models . . . . . . . . . . . . . . . . . . . . . 246
L130 Late Models . . . . . . . . . . . . . . . . . . . . . . 248
PTO Clutch – L120/L130 . . . . . . . . . . . . . . . . . . . . 261
PTO Clutch Circuit Diagnosis – L120/L130 . . . . . . 298
PTO Clutch Circuit Operation – L120/L130 . . . . . . 297
PTO Clutch Circuit Wiring Schematic – L120/L130 297
PTO Clutch Test – L120/L130 . . . . . . . . . . . . . . . . 330
PTO Switch Test – L120/L130 . . . . . . . . . . . . . . . . 325
PTO with RIO Circuit
Diagnosis – L100/L108/L110/L118 . . . . . . . . . 302
Diagnosis – L120/L130 . . . . . . . . . . . . . . . . . . 307
Operation – L100/L108/L110/L111/L118 . . . . 299
Operation – L120/L130 . . . . . . . . . . . . . . . . . . .304
Wiring Schematic – L100/L108/L110/L118
Late Models . . . . . . . . . . . . . . . . . . . .301
Wiring Schematic – L100/L110 Early Models . .300
Wiring Schematic – L111 . . . . . . . . . . . . . . . . .301
Wiring Schematic – L120/L130 Early Models . .305
Wiring Schematic – L120/L130 Late Models . .306
PTO/Brake Switch Test – All Models
(L120/L130 – Brake Switch Only) . . . . . . . . . . .325
Power Circuit Diagnosis
L100/L108/L110/L118 Late Models . . . . . . . . .268
L100/L110 Early Models . . . . . . . . . . . . . . . . .264
L111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268
L120/L130 . . . . . . . . . . . . . . . . . . . . . . . . . . . .274
Power Circuit Operation
L100/L108/L110/L111/L118 . . . . . . . . . . . . . . .262
L120/L130 . . . . . . . . . . . . . . . . . . . . . . . . . . . .271
Power Circuit Wiring Schematic
L100/L108/L110/L118 Late Models . . . . . . . . .267
L100/L110 Early Models . . . . . . . . . . . . . . . . .263
L111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267
L120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .272
L130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .273
RIO Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . .326
RIS Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . .326
Reading Electrical Schematics . . . . . . . . . . . . . . . .223
Regulated Amperage Test – All Models . . . . . . . . .322
Regulated Voltage Test – All Models . . . . . . . . . . .321
Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .324
Schematic and Wiring Harness Legend
L100/L110/L118 . . . . . . . . . . . . . . . . . . . . . . . .233
L120/L130 . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
Schematics and Harnesses . . . . . . . . . . . . . . . . . .228
Seat Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . .327
Spark Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .328
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
Starter Solenoid Test – All Models . . . . . . . . . . . . .317
Starting Motor Amperage Draw Test
Loaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .318
No-Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .319
Stator – L100/L108 . . . . . . . . . . . . . . . . . . . . . . . . .260
Stator – L110/L130 . . . . . . . . . . . . . . . . . . . . . . . . .260
Stator – L111/L118/L120 . . . . . . . . . . . . . . . . . . . . .260
Stator Output Test – All Models . . . . . . . . . . . . . . .321
Theory of Operation Information . . . . . . . . . . . . . .224
Voltage Regulator/Rectifier
All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . .261
Bench Test – L110/L130 . . . . . . . . . . . . . . . . . .322
W1 Front Wiring Harness Wire Color Codes
L100/L110 Early Models . . . . . . . . . . . . . . . . .240
L120/L130 Early Models . . . . . . . . . . . . . . . . .256
L120/L130 Late Models . . . . . . . . . . . . . . . . . .256
W1 Front Wiring Harness Wiring Color Codes
L100/L110/L118 Late Models . . . . . . . . . . . . .240
L111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
W1 and W2 Main Wiring Harness
L100/L108/L110/L118 – Late Models . . . . . . . 238
L100/L110 – Early Models . . . . . . . . . . . . . . . 234
L111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
L120/L130 – Early Models . . . . . . . . . . . . . . . 250
L120/L130 – Late Models . . . . . . . . . . . . . . . . 254
W1 and W2 Wiring Harness
L100/L110 – Early Models . . . . . . . . . . . . . . . 236
L120/L130 – Early Models . . . . . . . . . . . . . . . 252
W2 Rear Wiring Harness Wire Color Codes
L100/L110/L111/L118 All Models . . . . . . . . . . 241
L120/L130 Early and Late Models . . . . . . . . . 257
W3 and W4 Jumper Wiring Harness
L100/L108/L110/L111/L118/L120 . . . . . . . . . 258
W5 Headlight Wiring Harness – All Models . . . . . . 258
W6 Engine Wiring Harness – L100/L108 . . . . . . . 259
W6 Engine Wiring Harness – L110/L130 . . . . . . . 260
W6 Engine Wiring Harness – L111/L118/L120 . . . 259
W7 Positive Jumper Cable
L100/L108/L110/L111/L118/L120 . . . . . . . . . 258
Engine
Briggs & Stratton (Single Cylinder)
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fuel and Air Repair . . . . . . . . . . . . . . . . . . . . . 29
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Tests and Adjustments . . . . . . . . . . . . . . . . . . . 23
Briggs & Stratton (V-Twin)
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 115
Tests and Adjustments . . . . . . . . . . . . . . . . . . 120
Kohler (Single Cylinder)
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Fuel and Air Repair . . . . . . . . . . . . . . . . . . . . . 79
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Tests and Adjustments . . . . . . . . . . . . . . . . . . . 69
Kohler (V-Twin)
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 171
Tests and Adjustments . . . . . . . . . . . . . . . . . . 180
Engine oil specifications
4-cycle, gasoline . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F
Fender Deck Removal and Installation . . . . . . . . . . . . 429
Front Axle Removal and Installation . . . . . . . . . . . . . . 382
Front Axle Spindle Replacement . . . . . . . . . . . . . . . . . 382
Front Wheel Bushing Removal and Installation . . . . . 427
Front Wheel Removal and Installation . . . . . . . . . . . . 426
Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . 261
Fuel Tank Removal and Installation . . . . . . . . . . . . . . 430
G
Gasoline Specifications
4-Cycle Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Gasoline Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Gear Transaxle
Brake & Gear Assembly . . . . . . . . . . . . . . . . . . . . .350
Brake Assembly Installation . . . . . . . . . . . . . . . . . .350
Brake System Operation . . . . . . . . . . . . . . . . . . . .339
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .344
Drive Sheave/Shift Arm Installation . . . . . . . . . . . .351
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .338
Removal and Installation . . . . . . . . . . . . . . . . . . . .349
Shift Linkage Removal & Installation . . . . . . . . . . .348
Traction Drive Belt Removal and Installation . . . . .346
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
H
Handle Chemical Products Safely . . . . . . . . . . . . . . . . . .5
Handling And Servicing Batteries . . . . . . . . . . . . . . . . . . .1
Hood Removal and Installation . . . . . . . . . . . . . . . . . . .427
Hydrostatic Transaxle
Control Pedal Removal & Installation . . . . . . . . . . .369
Diagnostic Check . . . . . . . . . . . . . . . . . . . . . . . . . .360
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .361
Neutral Creep Adjustment . . . . . . . . . . . . . . . . . . .362
Removal & Installation . . . . . . . . . . . . . . . . . . . . . .367
Traction Drive Belt
Removal & Installation . . . . . . . . . . . . . . . . . . .364
Tensioner Removal and Installation . . . . . . . . .366
I
Ignition Module Test – L110/L130 . . . . . . . . . . . . . . . . .329
Illuminate Work Area Safely . . . . . . . . . . . . . . . . . . . . . . .3
Inch Fastener Torque Values . . . . . . . . . . . . . . . . . . . . .11
K
Kohler Engine (Single Cylinder)
Air Intake System Components . . . . . . . . . . . . . . . .80
Balancer Shaft
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Removal/Installation . . . . . . . . . . . . . . . . . . . . . .96
Repair Specifications . . . . . . . . . . . . . . . . . . . . .63
Blower Housing Removal & Installation . . . . . . . . . .79
Breather Inspection . . . . . . . . . . . . . . . . . . . . . . . . .92
Camshaft
End Play Measurement . . . . . . . . . . . . . . . . . . .94
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Removal/Installation . . . . . . . . . . . . . . . . . . . . . .93
Repair Specifications . . . . . . . . . . . . . . . . . . . . .63
Carburetor Disassembly & Inspection . . . . . . . . . . .83
Carburetor Removal & Installation . . . . . . . . . . . . . .81
Connecting Rod Measurement . . . . . . . . . . . . . . . .100
Connecting Rod Repair Specifications . . . . . . . . . . .64
Crankcase Oil Seal Removal/Installation . . . . . . . .105
Crankshaft
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Removal & Installation . . . . . . . . . . . . . . . . . . 102
Repair Specifications . . . . . . . . . . . . . . . . . . . . 62
Crankshaft & Main Bearing Inspection . . . . . . . . . 103
Cylinder Block Inspection . . . . . . . . . . . . . . . . . . . 107
Cylinder Bore Deglazing . . . . . . . . . . . . . . . . . . . . 107
Cylinder Bore, Piston & Rings
Repair Specifications . . . . . . . . . . . . . . . . . . . . 64
Cylinder Head Assembly
Repair Specifications . . . . . . . . . . . . . . . . . . . . 62
Cylinder Head Inspection . . . . . . . . . . . . . . . . . . . . 90
Cylinder Head Removal/Installation . . . . . . . . . . . . 88
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Engine Removal & Installation . . . . . . . . . . . . . . . . 85
Flywheel Removal & Installation . . . . . . . . . . . . . . . 92
Fuel Pump Removal & Installation . . . . . . . . . . . . . 85
General Specifications . . . . . . . . . . . . . . . . . . . . . . 61
Governor Inspection . . . . . . . . . . . . . . . . . . . . . . . . 97
Governor Removal/Installation . . . . . . . . . . . . . . . . 97
Governor Repair Specifications . . . . . . . . . . . . . . . 65
Hydraulic Valve Lifters Inspection . . . . . . . . . . . . . . 95
Hydraulic Valve Lifters Removal & Installation . . . . 95
Oil Pan Removal & Installation . . . . . . . . . . . . . . . 104
Oil Pan Seal Removal & Installation . . . . . . . . . . . 105
Oil Pickup Inspection . . . . . . . . . . . . . . . . . . . . . . 106
Oil Pump Relief Valve Inspection . . . . . . . . . . . . . 106
Oil Pump Removal and Installation . . . . . . . . . . . . 106
Piston Assembly Measurement . . . . . . . . . . . . . . 101
Piston Assembly Removal . . . . . . . . . . . . . . . . . . . 98
Piston Disassemble . . . . . . . . . . . . . . . . . . . . . . . . 98
Piston Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Piston Installation . . . . . . . . . . . . . . . . . . . . . . . . . 102
Piston Measurement . . . . . . . . . . . . . . . . . . . . . . . 100
Piston Ring End Gap Measurement . . . . . . . . . . . . 99
Piston Ring Side Clearance Measurement . . . . . . . 99
Repair Piston Pin Inspection . . . . . . . . . . . . . . . . . 100
Repair Specifications . . . . . . . . . . . . . . . . . . . . . . . 62
Rocker Arms Removal & Installation . . . . . . . . . . . 88
Rocker Arms Repair Specifications . . . . . . . . . . . . 62
Rocker Shaft Repair Specifications . . . . . . . . . . . . 62
Special or Required Tools . . . . . . . . . . . . . . . . . . . 67
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Starting Motor Brush Replacement . . . . . . . . . . . . 110
Starting Motor Drive Replacement . . . . . . . . . . . . 109
Starting Motor Removal & Installation . . . . . . . . . 109
Stator & Ignition Module Removal & Installation . . 108
Tests and Adjustments
Automatic Compression Release (ACR) . . . . . 73
Choke Adjustment . . . . . . . . . . . . . . . . . . . . . . 69
Crankcase Vacuum Test . . . . . . . . . . . . . . . . . 74
Cylinder Leak Test . . . . . . . . . . . . . . . . . . . . . . 72
Fast Idle Speed Adjustment . . . . . . . . . . . . . . . 70
Fuel Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . 76
Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . . . 76
Governor Adjustment . . . . . . . . . . . . . . . . . . . . 70
Ignition Armature Air Gap Adjustment . . . . . . . .78
Oil Pressure Test . . . . . . . . . . . . . . . . . . . . . . . .77
Slow Idle Speed Adjustment . . . . . . . . . . . . . . .71
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Starting Motor Armature Test . . . . . . . . . . . . . .110
Throttle Cable Adjustment . . . . . . . . . . . . . . . . .69
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . .66
Valve Cover Removal & Installation . . . . . . . . . . . . .88
Valve Guides Inspection . . . . . . . . . . . . . . . . . . . . . .91
Valve Seats Recondition . . . . . . . . . . . . . . . . . . . . .92
Valves & Valve Lifter Repair Specifications . . . . . . .62
Valves And Springs Removal & Installation . . . . . . .89
Valves Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Valves Lap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Voltage Regulator & Rectifier
Removal and Installation . . . . . . . . . . . . . . . . .109
Kohler Engine (V-Twin)
Camshaft
Repair Specifications . . . . . . . . . . . . . . . . . . . .172
Crankshaft
Repair Specifications . . . . . . . . . . . . . . . . . . . .172
Crankshaft Plain Bearings
Repair Specifications . . . . . . . . . . . . . . . . . . . .172
Cylinder Bore
Repair Specifications . . . . . . . . . . . . . . . . . . . .172
Cylinder Head
Repair Specifications . . . . . . . . . . . . . . . . . . . .173
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
General Specifications . . . . . . . . . . . . . . . . . . . . . .171
Governor
Repair Specifications . . . . . . . . . . . . . . . . . . . .173
Piston
Repair Specifications . . . . . . . . . . . . . . . . . . . .172
Repair
Air Cleaner Removal and Installation . . . . . . . .192
Block Inspection . . . . . . . . . . . . . . . . . . . . . . . .214
Camshaft End Play . . . . . . . . . . . . . . . . . . . . .204
Camshaft Inspection . . . . . . . . . . . . . . . . . . . .204
Camshaft Removal and Installation . . . . . . . . .203
Carburetor Removal and Installation . . . . . . . .193
Crankcase Reed Valve Inspection . . . . . . . . . .201
Crankshaft Oil Seal Removal and Installation .212
Crankshaft and Connecting Rod
Measurements . . . . . . . . . . . . . . . . . . . . . .209
Cylinder Bore Deglaze . . . . . . . . . . . . . . . . . . .214
Cylinder Head Inspection . . . . . . . . . . . . . . . . .200
Cylinder Head Removal and Installation . . . . .196
Engine Installation . . . . . . . . . . . . . . . . . . . . . .191
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . .189
Flywheel Removal and Installation . . . . . . . . .202
Fuel Pump, Removal and Installation . . . . . . .193
Governor Control Arm
Removal and Installation . . . . . . . . . . . . . .205
Governor Removal and Installation . . . . . . . . .205
Hydraulic Valve Lifters Inspection . . . . . . . . . .195
Lap Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
Oil Pan Crankshaft Seal
Removal and Installation . . . . . . . . . . . . . 212
Oil Pan Removal and Installation . . . . . . . . . . 211
Oil Pressure Switch Removal & Installation . . 213
Oil Pump Removal and Installation . . . . . . . . 213
Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . 210
Piston Disassembly . . . . . . . . . . . . . . . . . . . . 206
Piston Inspection . . . . . . . . . . . . . . . . . . . . . . 207
Piston Installation . . . . . . . . . . . . . . . . . . . . . . 211
Piston Pin Inspection . . . . . . . . . . . . . . . . . . . 207
Piston Removal . . . . . . . . . . . . . . . . . . . . . . . 206
Piston Ring End Gap . . . . . . . . . . . . . . . . . . . 207
Piston Ring Side Clearance . . . . . . . . . . . . . . 208
Piston to Bore Measurement . . . . . . . . . . . . . 20