HUSTLER Honda Engine Z User manual

•••••••

Hustler Turf Equipment

•••••

P.O. Box 7000

•••

Hesston, Kansas

•

67062-2097

Hustler Z

Parts Manual

t-2 108602 10/08

IMPORTANT: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code

Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered unimproved land. Other

states or federal areas may have similar laws.

This spark ignition system complies with Canadian ICES-002.

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, re-

place immediately. Replacements may be ordered per the information found in the Product Information section of the

owner’s manual.

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects or other reproductive harm.

WARNING:

108602 10/08 c-1

Table of Contents

Chapter 1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Chapter 2

Rivet Nut Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Chapter 3

Hydraulic System Installation—S/N 07120009 and higher . . . . . . . 3-2

Hydraulic System Installation—S/N prior to 07120009. . . . . . . . . . 3-6

Chapter 4

Battery Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Steering and Park Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Steering Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Pump Belt and Pulleys Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Chapter 5

Kawasaki Engine Installation (Remote Air Cleaner) . . . . . . . . . . . . 5-2

Kawasaki 25 HP Engine Installation (With HD Air Cleaner) . . . . . . 5-6

Kawasaki 26 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Kawasaki 29 HP Engine Installation (With HD Air Cleaner) . . . . . . 5-10

Honda Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Kohler Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Fuel System Installation (Air Cooled Engines) . . . . . . . . . . . . . . . . 5-18

Fuel System Installation (Liquid Cooled Engines). . . . . . . . . . . . . . 5-20

Instrument Panel Assembly (Air Cooled) . . . . . . . . . . . . . . . . . . . . 5-22

Instrument Panel Assembly (Liquid Cooled). . . . . . . . . . . . . . . . . . 5-24

Electrical Schematic (799320) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

Electrical Schematic—Kawasaki LC (799338) . . . . . . . . . . . . . . . . 5-27

Chapter 6

Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Front Wheel Breakdown—747782 . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Optional Semi-Pneumatic Tire/Wheel—789537 . . . . . . . . . . . . . . . 6-5

Drive Wheel Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Anti-Rollover Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Chapter 7

66" Side Discharge XR7 Deck Assembly . . . . . . . . . . . . . . . . . . . . 7-2

66" Side Discharge XR7 Deck Pulley Assembly. . . . . . . . . . . . . . . 7-4

60" Side Discharge XR7 Deck Assembly . . . . . . . . . . . . . . . . . . . . 7-6

60" Side Discharge XR7 Deck Pulley Assembly. . . . . . . . . . . . . . . 7-8

54" Side Discharge XR7 Deck Assembly . . . . . . . . . . . . . . . . . . . . 7-10

54" Side Discharge XR7 Deck Pulley Assembly. . . . . . . . . . . . . . . 7-12

Side Discharge Deck—"A" Adaptors. . . . . . . . . . . . . . . . . . . . . . . . 7-14

Side Discharge Deck—"B" Adaptors. . . . . . . . . . . . . . . . . . . . . . . . 7-16

54" Rear Discharge Deck Assy—S/N 08100000 & Higher . . . . . . . 7-18

c-2 108602 10/08

54" Rear Discharge Deck Assy—S/N 08010000—08100000 . . . . 7-20

54" Rear Discharge Deck Assy–S/N Prior to 08010000. . . . . . . . . 7-22

54" Rear Discharge Deck Pulley Assy—S/N 08100000 & Higher . 7-24

54" Rear Discharge Deck Pulley Assy—S/N Prior to 08100000 . . 7-26

Spindle Assembly–796235. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

Spindle Assembly–796680. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

Chapter 8

Deck Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

66" & 54" Side Discharge Deck Belt Routing and Tensioning . . . . 8-4

60" Side Discharge Deck Belt Routing and Tensioning . . . . . . . . . 8-5

54" Rear Discharge Deck Belt Routing and Tensioning. . . . . . . . . 8-6

Seat Installation—S/N 08010000 & Higher . . . . . . . . . . . . . . . . . . 8-8

Seat Installation—S/N Prior to 08010000. . . . . . . . . . . . . . . . . . . . 8-10

ROPS Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

Chapter 9

Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

66" Side Discharge XR7 Deck Decals . . . . . . . . . . . . . . . . . . . . . . 9-4

60" Side Discharge XR7 Deck Decals . . . . . . . . . . . . . . . . . . . . . . 9-5

54" Side Discharge XR7 Deck Decals . . . . . . . . . . . . . . . . . . . . . . 9-6

54" Rear Discharge Deck Decals. . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

Chapter 10

Assembly Pictures and Aids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

Maintenance & Adjustment Safety . . . . . . . . . . . . . . . . . . . . . . . . 10-13

Safe Maintenance & Adjustment Practices . . . . . . . . . . . . . . . . . . 10-14

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34

Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1

108602 10/08 1-1

Chapter 1

General Information

This Manual covers Hustler Z models 927723A/B, 927749A/B, 927756A/B, 927772A/B, 927798A/

B, 927806A/B, 927814A/B, 928432, 928853A/B, and 928861A/B, with serial numbers higher than

07020000.

Frequently Ordered Parts

Service Literature

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.

PART NO. DESCRIPTION

027912 Lubrizol 7 oz. Bottle

027920 Lubrizol 10 oz. Bottle

768341 Hydraulic Oil Filter

781443 Pump Drive Belt

797696 Blade, F18.50"-H-F-CW (54" Side Discharge Deck)

794685 Blade, F20.50"-H-F-CW (60" Side Discharge Deck)

798496 Blade, F22.50"-H-F-CW (66" Side Discharge Deck)

601012 Blade, F18.50"-L-F-CW (54" Rear Discharge Deck)

601013 Blade, F18.50-L-F-CCW (54" Rear Discharge Deck)

797928 Belt, B-Section (54" Side Discharge Deck)

797720 Belt, B-Section (60" Side Discharge Deck)

797936 Belt, B-Section (66" Side Discharge Deck)

601015 Belt, B-Section (54" Rear Discharge Deck)

068478 Fuel Filter

785261 Main Air Filter Element (Except 29 HP Kawasaki)

785279 Safety Air Filter Element (Kawasaki 25 HP w HD)

601652 Main Filter Element (Kawasaki 29 HP)

601653 Safety Filter Element (Kawasaki 29 HP)

772079 Kawasaki Engine Oil Filter

785634 Honda Engine Oil Filter

747303 Kohler Engine Oil Filter

PART NO. DESCRIPTION

601656 Owner’s Manual

785642 Honda 18/20/24 Engine Owner’s Manual

778423 Kawasaki 19–25 hp Engine Owner’s Manual

796805 Kawasaki FD731V (26 HP) Engine Manual

601637 Kawasaki 29 HP Engine Manual

742684 Kohler Engine Owner’s Manual

1-2 108602 10/08

Using this manual

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 neces-

sary, without notification. If a change has been made to your machine which is not reflected in this parts manual, see

your Hustler dealer for current information and parts.

Options Available From Your Dealer

Hardware Description Codes & Abbreviations

The following codes are used throughout this parts manual. Refer to this list when ordering parts.

PART NO. DESCRIPTION

108556 "A" Baffles Kit XR7 (66" Side Discharge Deck)

108555 "A" Baffles Kit XR7 (60" Side Discharge Deck)

108554 "A" Baffles Kit XR7 (54" Side Discharge Deck)

108551 "B" Baffles Kit XR7 (66" Side Discharge Deck)

108550 "B" Baffles Kit XR7 (60" Side Discharge Deck)

108549 "B" Baffles Kit XR7 (54" Side Discharge Deck)

108561 Containment Baffles Kit (66" Side Discharge Deck)

108560 Containment Baffles Kit (60" Side Discharge Deck)

108559 Containment Baffles Kit (54" Side Discharge Deck)

108565 Mulch Kit (66" Side Discharge Deck)

108563 Mulch Kit (54/60" Side Discharge Deck)

106880 Stripe Kit (66" Side Discharge Deck)

107359 Stripe Kit (54/60" Side Discharge Deck)

798512 Gator Blade, 22.50"-GAT-F-CW (66" Side Discharge Deck)

794230 Gator Blade, 20.50"-GAT-F-CW (60" Side Discharge Deck)

797712 Gator Blade, 18.50"-GAT-F-CW (54" Side Discharge Deck)

798504 Mulch Blade, 22.50"-MUL-F-CW (66" Side Discharge Deck)

794214 Mulch Blade, 20.50"-MUL-F-CW (60" Side Discharge Deck)

797704 Mulch Blade, 18.50"-MUL-F-CW (54" Side Discharge Deck)

102186 Deck Lift Kit MMZ

353961 Steering Extension Kit

357897 Hitch Kit MMZ

799270 Flex Fork Kit

789537 Semi-Pneumatic Tire/Wheel Assy 13x6.50-6

927582 Snow Blade

928218 Bac-Vac Catcher Assy (Requires additional kits for installation, see dealer)

381475 Z Light Kit

ABBREVIATION DESCRIPTION ABBREVIATION DESCRIPTION

CB Carriage Bolt MB Machine Bushing

CE Clevis Pin MS Machine Screw

CP Cotter Pin NT Nut

CS Cap Screw SC Self Tapping Cap Screw

CW Cup Washer SH Socket Head

FDRW Fender Washer SB Shoulder Bolt

FW Flat Washer SS Set Screw

HX Hex Head OD Outside Diameter

LW Lock Washer ID Inside Diameter

108602 10/08 1-3

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.

NOTE:

Loctite® 592 to be used on all pipe threads.

Lubricate all grease zerks.

SIZE FT-LBS NM SIZE FT-LBS NM

.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 160 215

1.00 625 850 M20 320 435

M24 555 750

1-4 108602 10/08

108602 10/08 2-1

Chapter 2 Contents

Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Footrest Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2-2 108602 10/08

Rivet Nut Installation

NOTES:

1. Seat supports 547950 and 549303 include rivet nuts.

2. Mowers with serial numbers prior to 08010000 require (2) of 808493

(Rivet Nut 3/8-16 thread).

ITEM NO. SERVICE

PART NO. MFG. PART

NO. QTY. DESCRIPTION

1 548032 107701 1 TRACTOR FRAME (54" SIDE DISCHARGE)

547760 106211 1 TRACTOR FRAME (60" SIDE DISCHARGE)

547752 106039 1 TRACTOR FRAME (66" SIDE DISCHARGE)

548545 108093 1 TRACTOR FRAME (54" REAR DISCHARGE)

2 808493 808493 13 3/8-16 THREAD RIVET NUT

3 600961 600961 8 1/2-13 THREAD RIVET NUT

4 808477 808477 2 1/4-20 THREAD RIVET NUT (KAW AIR COOLED ONLY)

4 808477 808477 3 1/4-20 THREAD RIVET NUT (KAW LIQUID COOLED ONLY)

5 547950 106732 1 XR7 MMZ SEAT SUPPORT

6 549303 109678 1 SEAT SUPPORT

FOR KAWASAKI

26 HP LIQUID

COOLED ONLY

FOR ALL MOWERS

EXCEPT 26 HP

LIQUID COOLED

This manual suits for next models

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