Description
Specifications and Information
Table of Contents
Fastener Torques9
Metric Fastener Torque Values9
Inch Fastener Torque Values10
General Information11
Gasoline 11
Gasoline Storage11
Engine Oil – North America12
Engine Oil – Europe 12
Engine Break – In Oil 12
Hydrostatic Transmission Oil13
Anti-Corrosion Grease 13
Alternative Lubricants13
Synthetic Lubricants 13
Lubricant Storage14
Mixing Of Lubricants14
Chassis Grease14
Oil Filters 14
Serial Number Locations 15
Product Identification Number (PIN)15
Engine Identification Number – Kohler15
Engine Identification Number – Kawasaki15
Engine Identification Number –
Briggs & Stratton 15
Hydrostatic Transaxle
Identification Number 15
Engine – Kohler
Specifications 19
General Specifications 19
Tests and Adjustments Specifications19
Repair Specifications20
Torque Specifications (Alphabetical)23
Special or Required Tools24
Other Materials24
Diagnostics 25
Engine Will Start25
Tests and Adjustments 26
Throttle Cable Adjustment26
Choke Cable Adjustment26
Governor Adjustment 27
Fast Idle Speed Adjustment 27
Slow Idle Screw Adjustment27
Cylinder Leak Test 28
Automatic Compression Release
(ACR) Check 30
Crankcase Vacuum Test31
Fuel Flow Tests32
Oil Pressure Test33
Fuel and Air Repair35
Air Intake System Components35
Carburetor Removal and Installation35
Carburetor Inspection36
Fuel Pump Removal and Installation37
Engine Repair38
Engine Removal and Installation38
Flywheel Removal and Installation40
Stator Removal and Installation 41
Rocker Arms Removal and Installation 42
Inspect Push Rod42
Cylinder Head Removal and Installation 42
Valves and Springs
Removal and Installation 43
Cylinder Head Inspection 43
Valves Inspection 45
Valve Seats Recondition 45
Lap Valves 46
Breather Inspection 46
Oil Pan Removal and Installation 46
Oil Pan Seal Removal and Installation 47
Crankcase Oil Seal
Removal and Installation 47
Power Train – Hydrostatic
Specifications 357
Hydrostatic Transaxle357
Adjustment Specifications 357
Repair Specifications357
Torque Specifications357
Other Materials358
Component Location359
Transaxle Case Halves 359
Charge Pump 360
Piston Pump361
Motor 362
Reduction Gears, Differential, and Axles 363
Swash Plate and
Neutral Centering Assembly364
Transaxle Brake 366
Center Case Assembly367
Belt Drive and Idlers 368
Brake Pedal and Linkage 369
Forward and Reverse/Cruise
Control Linkage 370
Forward and Reverse Pedals and
Linkage (Exploded View)371
Cruise Control Lever and
Linkage (Exploded View)373
Theory of Operation 374
Controls and Linkage Operation374
Foot Control – Neutral Position374
Foot Control – Forward (Maximum) 374
Foot Control – Neutral375
Foot Control – Forward (Maximum) 375
Foot Control – Reverse (Maximum) 376
Foot Control – Reverse (Maximum) 376
Brake Depressed – Maximum376
Brake Depressed – Maximum377
Brake Linkage 378
Cruise Control 378
Cruise Control – Off Position379
Cruise Control –
Maximum Speed Position380
Hand Control 380
Hand Control – Neutral 381
Hand Control – Neutral 381
Hand Control – Forward382
Hand Control – Reverse382
Hydrostatic System Operation 383
Hydrostatic System Operation 384
Gear Power Flow 385
Transaxle Brake 386
Diagnostics 387
Machine Will Not Move
Forward or Reverse 387
Noisy Operation 391
Machine Creeps 393
Machine Moves In One Direction Only 395
Erratic Speed 396
Machine Does Not Achieve
Full Ground Speed 397
Park Brake Does Not Hold
Machine On Hill 400
Brake Switch Will Not Engage 402
Cruise Control Does Not
Maintain Ground Speed 404
Transaxle Whines When
Brake Is Used 405
Tests and Adjustments 405
Hydrostatic Transaxle Bleeding Procedure 405
Neutral Creep Adjustment 405
Forward and Reverse Pedal
Height Adjustment 407
Hand Lever Rod Adjustment 407
Brake Linkage Adjustment 408
Neutral Return Arm Bearing Adjustment 408
Cruise/Hand Control Lever
Tension Adjustment 409
Repair 409
Transaxle Removal and Installation 409
Transaxle Disassembly 414
Transaxle Assembly 428
Traction Drive Belt
Tensioner Assembly 444
Control Pedals and Linkage 445
Intermediate Shaft 445
Neutral Return Arm 446
Cruise Control Lever 447
Hand Control Lever (Optional) 448
Brake Pedal and Linkage 449
Brake Rod Removal and Installation 450
STEERING
Specifications 453
Tests and Adjustments Specifications453
Torque Specifications453
Repair Specifications453
Service Equipment and Tools 453
Component Location454
Steering Wheel454
Front Axle455
Theory of Operation 456
Steering System 456
Diagnostics 457
Steering System 457
Steering Symptom Diagnosis 457
Tests and Adjustments 458
Steering Wheel Centering 458
Repair459
Steering Gear Removal and Installation459
Front Axle Removal,
Disassembly and Inspection464
Front Axle Assembly and Installation 467
Front Wheel Spindle Lubrication 470
Front Wheel Removal and Installation 470
Front Wheel Bearing
Removal and Installation 471
Safety
Attachments
Specifications 475
Adjustment Specifications 475
Repair Specifications475
Rotary Mower Use476
Tools and Materials 476
Tools476
Component Location477
38 – Inch Mower Deck 477
42 – Inch Mower Deck 481
44 – Inch Piranha Mower Deck 486
48 – Inch Mower Deck 491
54 – Inch Mower Deck 497
54 – Inch Convertible Mower Deck 504
Diagnostics 511
Mower Decks Troubleshooting Chart511
Mower Drive Checks 512
Tests and Adjustments 514
Mower Level Side-to-side514
Mower Level Front-To-Rear 515
Repair516
38-Inch Mower Deck
Removal and Installation 516
42-Inch Convertible Mower Deck
Removal and Installation 517
44-Inch Mower Deck
Removal and Installation 518
48-Inch Convertible Mower Deck
Removal and Installation 519
54-Inch Mower Deck Removal and Installation
520
54-Inch Convertible Mower Deck
Removal and Installation 521
38-Inch Drive Belt522
42-Inch Drive Belt523
44-Inch Piranha Mower Drive Belt523
48-Inch Mower Drive Belt 524
54-Inch Mower Drive Belt 524
54-Inch Convertible Mower Drive Belt525
38-Inch Deck Mower Blades 525
42-Inch Deck Mower Blades 526
44-Inch Deck Mower Blades 528
48-Inch Deck Mower Blades 529
54-Inch Deck Mower Blades 530
54-Inch Convertible Deck Mower Blades 532
38-Inch Deck Spindles 533
42-Inch Deck Spindles 534
44-Inch Deck Spindles 537
48-Inch Deck Spindles 540
54-Inch Deck Spindles 543
54-Inch Convertible Deck Spindles 546
Jack Sheave 549
Idlers 549
Electrical
General Information23
Reading Electrical Schematics231
Theory of Operation Information 232
Diagnostic Information232
Wire Color Abbreviation Chart232
Common Circuit Tests233
Conductors For 12 Volt Circuit 233
Specifications 234
General Specifications 23
Schematics and Harnesses 237
Schematic and Wiring Harness Legend –
GT225 237
Schematic and Wiring Harness Legend –
GT235 and GT2353E238
Schematic and Wiring Harness Legend –
GT245 239
Electrical Components Location –
GT225 240
Electrical Components Location –
GT235, GT235E and GT245 241
Main Electrical Schematic – GT225 24
Main Wiring Schematic –
GT235 and GT235E246
Main Wiring Schematic – GT235
(SN 060001-090000) and GT235E 25
Main Wiring Schematic – GT235
(SN 090001-) and GT245 (1 of 4) 251
W1 Main Wiring Harness (1 of 2) 25
W2 Engine Wiring Harness – GT225 25
W3 Engine Wiring Harness – GT225 25
W4 Engine Wiring Harness – GT225 25
W5 Engine Wiring Harness – GT225 25
W6 Headlight Wiring Harness 258
W2 Engine Wiring Harness –
GT235 (SN -060000)258
W2 Engine Wiring Harness – GT235
(SN 060001-090000) and 235E 25
W3 Engine Wiring Harness – GT235
(SN -090000) and 235E 259
W7 Stator Wiring Harness – GT235
(SN -090000)259
W8 Stator Wiring Harness – GT235E 259
W9 Inverter Wiring Harness –
GT235E259
W10 Inductor/GFCI Wiring Harness –
GT235E 259
W2 Engine Wiring Harness – GT235
(SN 090001-) and GT245 260
W3 Engine Wiring Harness – GT235
(SN 090001-) and GT245 260
W4 Engine Wiring Harness – GT235
(SN 090001-) and GT245 260
W5 Engine Wiring Harness – GT245 260
W11 Stator Wiring Harness – GT235
(SN 090001-) and GT245 260
A2 Discharge Module – GT225 261
Y1 PTO Clutch 261
Y2 Fuel Shutoff Solenoid – GT225 261
Y2 Fuel Shutoff Solenoid – GT235
(SN -090000) and GT235E 261
Y2 Fuel Shutoff Solenoid – GT235
(SN 090001-) and GT245 261
N1 Voltage Regulator/Rectifier – GT225 261
N1 Voltage Regulator/Rectifier –
GT235 (SN -060000) 261
N1 Voltage Regulator/Rectifier – GT235
(SN 060001-090000) and GT235E 261
N1 Voltage Regulator/Rectifier –
GT245 262
W1 Main Wiring Harness
Color Code Chart 262
W2 Engine Wiring Harness
Color Code Chart – GT225 262
W3 Engine Wiring Harness
Color Code Chart – GT225 263
W2 Engine Wiring Harness Color Code
Chart – GT235 (SN -090000) and 235E 263
W3 Engine Wiring Harness Color Code
Chart – GT235 and 235E 263
W2 Engine Wiring Harness Color Code Chart –
GT235 (SN 090001-) and GT245 263
W3 Engine Wiring Harness Color Code Chart –
GT235 (SN 090001-) and GT245 263
W6 Headlight Wiring Harness
Color Code Chart 263
Operation and Diagnostics 264
Power Circuit Operation 264
Power Circuit Electrical Schematic 265
Power Circuit Diagnosis 266
Cranking Circuit Operation 269
Cranking Circuit Electrical Schematic 270
Cranking Circuit Diagnosis 271
Ignition Circuit Operation274
Engine Shutting Off 274
Ignition Circuit Electrical Schematic 275
Ignition Circuit Diagnosis276
Charging Circuit Operation –
GT225 and GT235 (SN -060000)279
Charging Circuit Electrical Schematic –
GT225 and GT235 (SN -060000)280
Charging Circuit Diagnosis –
GT225 and GT235 (SN -060000)281
Charging Circuit Operation – GT235
(SN 060001-090000) and GT235E 284
Charging Circuit Electrical Schematic – GT235
(SN 060001- 090000) and GT235E 285
Charging Circuit Diagnosis – GT235
(SN 060001- 090000) and GT235E 286
Charging Circuit Operation – GT235
(SN 090001-) and GT245289
Charging Circuit Electrical Schematic –
GT235 (SN 090001-) and GT245290
Charging Circuit Diagnosis – GT235
(SN 090001-) and GT245291
120 Volt Circuit Operation – GT235E294
120 Volt Circuit Electrical Schematic –
GT235E295
120 Volt Circuit Diagnosis – GT235E296
PTO Circuit Operation – PTO Off298
PTO Circuit Electrical Schematic –
PTO Off 299
PTO Circuit Operation – PTO On300
PTO Circuit Electrical Schematic –
PTO On 301
PTO Circuit Diagnosis 302
Reverse Implement Option (RIO)
Circuit Operation 306
RIO Circuit Electrical Schematic 307
RIO Circuit Diagnosis308
Low Oil Pressure Light
Circuit Operation 312
Low Oil Pressure Light
Circuit Electrical Schematic313
Low Oil Pressure Circuit Diagnosis314
Headlight Circuit Operation 316
Headlight Circuit Electrical Schematic317
Headlight Circuit Diagnosis 318
Fuel Shutoff Solenoid Circuit Operation320
Fuel Shutoff Solenoid
Circuit Electrical Schematic321
Fuel Shutoff Solenoid Circuit Diagnosis 322
Hourmeter Circuit Operation 325
Hourmeter Circuit Electrical Schematic 326
Hourmeter Circuit Diagnosis 327
Tests and Adjustments 329
Common Circuit Test 329
Ground Circuit Test 329
Battery Test 330
Charge Battery 331
Battery Load Test 331
Regulated Amperage Test 332
Regulated Voltage Test 332
Stator Output Test (B&S Engine) 333
Stator Output Test (Kohler Engine) 333
Stator Output Test (Kawasaki Engine) 334
Regulator/Rectifier Test
(Kawasaki Engine) 334
Flywheel Magnet Test 335
Starter Loaded Amperage Draw Test 335
Starting Motor Solenoid Test 335
Starting Motor No-load
Amperage and RPM Tests 336
Armature Air Gap Adjustment 337
Spark Test 338
Light Switch Test 338
PTO/RIO Switch Test 339
Seat Switch Test 340
Brake/Neutral Start Switch Test 340
Oil Pressure Switch Test 341
Fuel Shutoff Solenoid Test 341
RIO Switch Test 342
RIO Switch Adjustment 342
Electric PTO Clutch Test 343
Ground Fault Circuit Interrupt
(GFCI) Test 344
Park Brake Interlock Circuit Test 345
Inverter Ground Continuity Test 345
Reset (On-Off) Switch Test 345
120 Volt Stator AC Output Test 346
Inductor Test 346
Repair 348
Electric Clutch
Removal and Installation 348
Connector Body – Blade Terminals 348
Metripack® Connector 349
Starting Motor 351
Steering
Miscellaneous
Specifications 553
Torque Specifications553
Other Materials553
Component Location554
Mower Deck Handle Lift 554
Mower Deck Foot Pedal Lift 555
Theory of Operation 556
Mower Deck Lift and Depth Stop
Theory of Operation 556
Tests and Adjustments 556
Hood Latch Adjustment556
Lift Assist Spring Adjustment –
Early Models556
Lift Assist Spring Adjustment –
Later Models557
Checking Wheel Bolt Torque557
Repair558
Hood Removal and Installation –
Models GT225, GT235558
Hood Removal and Installation –
Models GT235E, GT245 558
Seat and Support
Removal and Installation 559
Fender Deck Removal and Installation 559
Fuel Tank Removal and Installation 561
Mower Deck Lift (Handle)561
Mower Deck Lift (Foot Pedal)566
Spring and Adjuster
Removal and Installation 570
Height Adjuster Assembly
Removal and Installation 570
Engine – Briggs & Stratton
Engine
Specifications 67
General Specifications 67
Tests and Adjustments Specifications67
Repair Specifications67
Torque Specifications69
Special or Essential Tools69
Diagnostics 70
Engine Diagnostics70
Tests and Adjustments 76
Throttle Cable Adjustment76
Choke Cable Adjustment76
Fuel Shutoff Solenoid Test77
Compression Test 77
Without Cylinder Leak Tester77
With Cylinder Leak Tester78
Carburetor Adjustment 79
Governor Adjustment 80
Valve Clearance Adjustment 81
Engine Oil Pressure Test 81
Ignition Armature Air Gap Adjustment82
Repair82
Upper Blower Housing
Removal and Installation 82
Air Cleaner Removal and Installation 83
Carburetor Removal and Installation83
Carburetor Disassembly85
Carburetor Inspection87
Carburetor Assembly88
Engine Removal and Installation90
Cylinder Air Guides
Removal and Installation 92
Intake Manifold Removal and Installation92
Cylinder Head Removal and Installation 92
Cylinder Head Inspection and Repair95
Valve Removal 95
Valve Inspection and Repair 95
Valve Guide Ream 96
Valve Installation 96
Piston, Rings and Rod
Removal and Installation 97
Piston Inspection98
Connecting Rod Inspection 98
Cylinder Bore Inspection 101
Cylinder Bore Honing 101
Cylinder Bore Cleaning 101
Resizing Cylinder Bore 102
Flywheel Removal and Installation 103
Crankshaft Removal and Installation 105
Magneto Bearing Inspection 108
PTO and Cam Bearing Inspection 109
Lubrication 109
Oil Pump Removal 110
Starting Motor Removal and Installation 111
Starting Motor
Disassembly and Inspection 112
Starting Motor Assembly 113
Engine – Kawasaki (FH580V)
Specifications 117
General Specifications 117
Test and Adjustment Specifications 117
Repair Specifications118
Torque Specifications120
Tools and Materials 120
Tools120
Other Materials121
Service Parts Kits121
Component Location122
Engine Components122
Carburetor Component Location123
Engine Oil Flow Chart 124
Theory of Operation 125
Lubrication System Operation125
Diagnostics 126
Engine Troubleshooting Guide126
Starting Motor Troubleshooting Guide 127
Tests and Adjustments 128
Throttle Cable Adjustment128
Choke Cable Adjustment128
Choke Plate Check and Adjustment 129
Governor Adjustment 130
Slow Idle Speed Adjustment 130
Fast Idle Speed Adjustment 131
Valve Clearance Check and Adjustment132
Cylinder Compression Pressure Test133
Crankcase Vacuum Test133
Engine Oil Pressure Test 135
Fuel Pump Test135
Spark Test136
Spark Plug Gap Adjustment 137
Ignition Coil Air Gap Adjustment 137
Repair138
Throttle Control Lever and Cable 138
Muffler Removal and Installation138
Air Cleaner Assembly Removal139
Carburetor Removal and Installation139
Carburetor Disassembly and Assembly 140
Fuel Pump Replacement141
Blower Housing
Removal and Installation 142
Flywheel Removal and Installation142
Breather Removal and Installation 143
Engine Removal and Installation 143
Rocker Arm Removal and Installation 146
Cylinder Head Removal and Installation 147
Cylinder Head Inspection 148
Recondition Valve Seats 149
Lap Valves 150
Crankcase Cover
Removal and Installation 150
Piston and Connecting Rod 151
Analyze Crankshaft and
Connecting Rod Wear 155
Camshaft and Tappets 155
Crankshaft and Main Bearings 157
Crankshaft Oil Seals 158
Deglaze Cylinder Bore 158
Resize Cylinder Bore 159
Oil Pump Disassembly and Assembly 159
Oil Filter Manifold 161
Governor Inspection and Replacement 161
Governor Shaft
Inspection and Replacement 161
Stator Removal and Installation 162
Armature Removal and Installation 162
Starting Motor Removal and Installation 163
Starting Motor
Disassembly and Assembly 163
No-Load Amperage Draw and RPM Test 166
Engine – Kawasaki (FH601V)
Specifications 169
General Specifications 169
Test and Adjustment Specifications 169
Repair Specifications170
Torque Specifications172
Tools and Materials 172
Tools172
Other Materials173
Service Parts Kits173
Component Location174
Engine Components174
Carburetor (Externally Vented)175
Carburetor (Internally Vented)176
Diagnostics 177
Engine Troubleshooting Guide177
Starting Motor Troubleshooting Guide 178
Tests and Adjustments 179
Throttle Cable Check and Adjustment179
Choke Plate Check and Adjustment 180
Governor Adjustment 180
Slow Idle Speed Adjustment 181
Fast Idle Speed Adjustment 181
Valve Clearance Check and Adjustment182
Cylinder Compression Pressure Test183
Crankcase Vacuum Test184
Engine Oil Pressure Test 184
Fuel Pump Test185
Spark Test186
Spark Plug Gap Adjustment 186
Ignition Coil Air Gap Adjustment 187
Repair187
Throttle Control Lever and Cable 187
Muffler Removal and Installation187
Air Cleaner Removal and Installation188
Carburetor (Externally Vented) Removal 189
Carburetor (Externally Vented) Repair191
Carburetor (Internally Vented) Removal196
Carburetor (Internally Vented) Repair 197
Fuel Pump Replacement202
Blower Housing
Removal and Installation 202
Flywheel Removal and Installation203
Intake Manifold
Removal and Installation 204
Breather Removal and Installation 204
Engine Removal and Installation 205
Rocker Arm Removal and Installation 208
Cylinder Head Removal and Installation 209
Cylinder Head Inspection 210
Recondition Valve Seats 211
Lap Valves 212
Crankcase Cover
Removal and Installation 212
Piston and Connecting Rod 213
Analyze Crankshaft and
Connecting Rod Wear 217
Camshaft and Tappets 217
Crankshaft and Main Bearings 219
Crankshaft Oil Seals 220
Deglaze Cylinder Bore 220
Resize Cylinder Bore 221
Oil Pump Disassembly and Assembly 221
Oil Filter Manifold 223
Governor Inspection and Replacement 223
Governor Shaft
Inspection and Replacement 223
Stator Removal and Installation 224
Armature Removal and Installation 224
Starting Motor Removal and Installation 225
Starting Motor
Disassembly and Assembly 225
No-Load Amperage Draw and RPM Test 228
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