LX172, LX173, LX176,
LX178, LX186 & LX188
Lawn Tractors



TECHNICAL
MANUAL






John Deere
Lawn & Grounds Care Division

TM1492 (31MAY96)

Litho in U.S.A
INTRODUCTION
6/4/96
1 - 1
This technical manual is written for an experienced
technician and contains sections that are specifically for
this product. It is a part of a total product support
program.
The manual is organized so that all the information on a
particular system is kept together. The order of grouping
is as follows:

Table of Contents

Specifications

Component Location

System Schematic

Theory of Operation

Troubleshooting Chart

Diagnostics

Tests & Adjustments

Repair
Note: Depending on the particular section or system
being covered, not all of the above groups may
be used.
Each section will be identified with a tab symbol rather
than a number. The groups and pages within a section
will be consecutively numbered.
All information, illustrations and specifications in this
manual are based on the latest information available at
the time of publication. The right is reserved to make
changes at any time without notice.
We appreciate your input on this manual. To help, there
are postage paid post cards included at the back. If you
find any errors or want to comment on the layout of the
manual please fill out one of the cards and mail it back to
us.
COPYRIGHT 1996
JOHN DEERE HORICON WORKS
Horicon, Wisconsin
All rights reserved
Information
Specifications and
EngineKawasaki
Electrical
Power Train (Hydrostatic)
Steering
Brakes
EngineKohler
Safety
Miscellaneous
Power Train (Gear)
Attachments
www.servicemanualall.com
SAFETY
1 - 2
6/4/96
RECOGNIZE SAFETY INFORMATION
This is the safety-alert symbol. When you see this
symbol on your machine or in this manual, be alert to
the potential for personal injury.
Follow recommended precautions and safe servicing
practices.
Understand Signal Words
A signal wordDANGER, WARNING, or CAUTION
is used with the safety-alert symbol. DANGER
identifies the most serious hazards.
DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention
to safety messages in this manual.
REPLACE SAFETY SIGNS
Replace missing or damaged safety signs. See the
machine operator's manual for correct safety sign
placement.
HANDLE FLUIDS SAFELY-AVOID
FIRES
Be Prepared For Emergencies
When you work around fuel, do not smoke or work near
heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and
debris.
Do not store oily rags; they can ignite and burn
spontaneously.
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department near your
telephone.
www.servicemanualall.com
SAFETY
6/4/96
1 - 3
USE CARE IN HANDLING AND
SERVICING BATTERIES
Prevent Battery Explosions
Keep sparks, lighted matches, and open flame
away from the top of battery. Battery gas can
explode.
Never check battery charge by placing a metal
object across the posts. Use a volt-meter or
hydrometer.
Do not charge a frozen battery; it may explode.
Warm battery to 16C (60F).
Prevent Acid Burns
Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, eat holes in clothing,
and cause blindness if splashed into eyes.
Avoid acid burns by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the
acid.
3. Flush your eyes with water for 10-15 minutes.
4. Get medical attention immediately.
If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.
USE SAFE SERVICE PROCEDURES
Wear Protective Clothing
Wear close fitting clothing and safety equipment
appropriate to the job.
Prolonged exposure
to
loud noise can cause
impairment or loss of hearing. Wear a suitable hearing
protective device such as earmuffs or earplugs to
protect against objectionable or uncomfortable loud
noises.
Operating equipment safely requires the full attention
of the operator. Do not wear radio or music
headphones while operating machine.
Service Machines Safely
Tie long hair behind your head. Do not wear a necktie,
scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to
get caught, severe injury could result.
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
Use Proper Tools
Use tools appropriate to the work. Makeshift tools and
procedures can create safety hazards. Use power tools
only to loosen threaded parts and fasteners. For
loosening and tightening hardware, use the correct size
tools. DO NOT use U.S. measurement tools on metric
fasteners. Avoid bodily injury caused by slipping
wrenches. Use only service parts meeting John Deere
specifications.
www.servicemanualall.com
SAFETY
1 - 4
6/4/96
Park Machine Safely
Before working on the machine:
1. Lower all equipment to the ground.
2. Stop the engine and remove the key.
3. Disconnect the battery ground strap.
4. Hang a "DO NOT OPERATE" tag in operator
station.
Support Machine Properly And Use
Proper Lifting Equipment
If you must work on a lifted machine or attachment,
securely support the machine or attachment.
Do not support the machine on cinder blocks, hollow
tiles, or props that may crumble under continuous load.
Do not work under a machine that is supported solely
by a jack. Follow recommended procedures in this
manual.
Lifting heavy components incorrectly can cause severe
injury or machine damage. Follow recommended
procedure for removal and installation of components
in the manual.
Work In Clean Area
Before starting a job:
1. Clean work area and machine.
2. Make sure you have all necessary tools to do your
job.
3. Have the right parts on hand.
4. Read all instructions thoroughly; do not attempt
shortcuts.
Using High Pressure Washers
Directing pressurized water at electronic/electrical
components or connectors, bearings, hydraulic seals,
fuel injection pumps or other sensitive parts and
components may cause product malfunctions. Reduce
pressure and spray at a 45 to 90 degree angle.
Illuminate Work Area Safely
Illuminate your work area adequately but safely. Use a
portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire
cage. The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
Work In Ventilated Area
Engine exhaust fumes can cause sickness or death. If
it is necessary to run an engine in an enclosed area,
remove the exhaust fumes from the area with an
exhaust pipe extension.
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area.
WARNING: California Proposition
65 Warning
Gasoline engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
Remove Paint Before Welding Or
Heating
Avoid potentially toxic fumes and dust. Hazardous
fumes can be generated when paint is heated by
welding, soldering, or using a torch. Do all work outside
or in a well ventilated area. Dispose of paint and
solvent properly. Remove paint before welding or
heating: If you sand or grind paint, avoid breathing the
dust. Wear an approved respirator. If you use solvent or
paint stripper, remove stripper with soap and water
before welding. Remove solvent or paint stripper
containers and other flammable material from area.
Allow fumes to disperse at least 15 minutes before
welding or heating.
www.servicemanualall.com
SAFETY
6/4/96
1 - 5
Avoid Harmful Asbestos Dust
Avoid breathing dust that may be generated when
handling components containing asbestos fibers.
Inhaled asbestos fibers may cause lung cancer.
Components in products that may contain asbestos
fibers are brake pads, brake band and lining
assemblies, clutch plates, and some gaskets. The
asbestos used in these components is usually found in
a resin or sealed in some way. Normal handling is not
hazardous as long as airborne dust containing
asbestos is not generated.
Avoid creating dust. Never use compressed air for
cleaning. Avoid brushing or grinding material
containing asbestos. When servicing, wear an
approved respirator. A special vacuum cleaner is
recommended to clean asbestos. If not available, apply
a mist of oil or water on the material containing
asbestos. Keep bystanders away from the area.
SERVICE TIRES SAFELY
Explosive separation of a tire and rim parts can cause
serious injury or death.
Do not attempt to mount a tire unless you have the
proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate
the tires above the recommended pressure. Never weld
or heat a wheel and tire assembly. The heat can cause
an increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and extension
hose long enough to allow you to stand to one side and
NOT in front of or over the tire assembly. Use a safety
cage if available.
Check wheels for
low pressure, cuts, bubbles,
damaged rims or missing lug bolts and nuts.
AVOID INJURY FROM ROTATING
BLADES, AUGERS AND PTO
SHAFTS
Keep hands and feet away while machine is running.
Shut off power to service, lubricate or remove mower
blades, augers or PTO shafts.
SERVICE COOLING SYSTEM
SAFELY
Explosive release of fluids from pressurized cooling
system can cause serious burns.
Shut off machine. Only remove filler cap when cool
enough to touch with bare hands. Slowly loosen cap to
first stop to relieve pressure before removing
completely.
www.servicemanualall.com
SAFETY
1 - 6
6/4/96
HANDLE CHEMICAL PRODUCTS
SAFELY
Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used
with John Deere equipment include such items as
lubricants, coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques. Check the MSDS before you start any job
using a hazardous chemical. That way you will know
exactly what the risks are and how to do the job safely.
Then follow procedures and recommended equipment.
Dispose of Waste Properly
Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste
used with John Deere equipment include such items as
oil, fuel, coolant, brake fluid, filters, and batteries. Use
leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead
someone into drinking from them. Do not pour waste
onto the ground, down a drain, or into any water
source. Inquire on the proper way to recycle or dispose
of waste from your local environmental or recycling
center, or from your John Deere dealer.
LIVE WITH SAFETY
Before returning machine to customer, make sure
machine is functioning properly, especially the safety
systems. Install all guards and shields.
www.servicemanualall.com
SPECIFICATIONS AND GENERAL INFORMATION
CONTENTS
Page
CONTENTS
6/3/96
2 - 1
SPECIFICATIONS AND GENERAL INFORMATION
GENERAL VEHICLE SPECIFICATIONS
VEHICLE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
METRIC FASTENER TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . .2-7
INCH FASTENER TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
GASOLINE
4-CYCLE ENGINESNORTH AMERICA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
GASOLINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
4-CYCLE ENGINESEUROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
GASOLINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
OILS AND LUBRICANTS
KAWASAKI 4-CYCLE GASOLINE ENGINE OILNORTH AMERICA . . . . . . . . . 2-11
KAWASAKI 4-CYCLE GASOLINE ENGINE OILEUROPE . . . . . . . . . . . . . . . . 2-12
KOHLER 4-CYCLE GASOLINE ENGINE OILNORTH AMERICA . . . . . . . . . . . 2-13
KOHLER 4-CYCLE GASOLINE ENGINE OILEUROPE . . . . . . . . . . . . . . . . . . 2-13
BREAK-IN 4-CYCLE GASOLINE ENGINE OILNORTH AMERICA. . . . . . . . . . 2-14
BREAK-IN 4-CYCLE GASOLINE ENGINE OILEUROPE . . . . . . . . . . . . . . . . . 2-15
HYDROSTATIC TRANSMISSION OILNORTH AMERICA. . . . . . . . . . . . . . . . . 2-16
HYDROSTATIC TRANSMISSION OILEUROPE . . . . . . . . . . . . . . . . . . . . . . . . 2-16
GEAR TRANSMISSION GREASE NORTH AMERICA . . . . . . . . . . . . . . . . . . . 2-17
GEAR TRANSMISSION GREASEEUROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
GREASENORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
GREASEEUROPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
ANTI-CORROSION GREASENORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . 2-19
ANTI-CORROSION GREASEEUROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
ALTERNATIVE LUBRICANTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
SYNTHETIC LUBRICANTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
LUBRICANT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
MIXING OF LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
OIL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
GASOLINE ENGINE COOLANTNORTH AMERICA . . . . . . . . . . . . . . . . . . . . . 2-21
GASOLINE ENGINE COOLANT DRAIN INTERVALNORTH AMERICA . . . . . . 2-21
GASOLINE ENGINE COOLANTEUROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
GASOLINE ENGINE COOLANT DRAIN INTERVALEUROPE . . . . . . . . . . . . . 2-22
SERIAL NUMBER LOCATIONS
MACHINE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
ENGINE SERIAL NUMBERLX172, LX176 AND LX186 . . . . . . . . . . . . . . . . . . 2-23
ENGINE SERIAL NUMBERLX173. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
ENGINE SERIAL NUMBERLX178 AND LX188. . . . . . . . . . . . . . . . . . . . . . . . . 2-23
CARBURETOR SERIAL NUMBERLX172, LX176 AND LX186. . . . . . . . . . . . . 2-23
CARBURETOR PART NUMBERLX173 (ONLY) . . . . . . . . . . . . . . . . . . . . . . . . 2-23
CARBURETOR SERIAL NUMBERLX178 AND LX188 . . . . . . . . . . . . . . . . . . . 2-24
GEAR TRANSAXLE SERIAL NUMBERLX172 AND LX173 . . . . . . . . . . . . . . . 2-24
HYDROSTATIC TRANSAXLE SERIAL NUMBER
LX176, LX178, LX186 AND LX188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
MOWER DECK SERIAL NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
www.servicemanualall.com
2 - 2
6/5/96
GENERAL VEHICLE SPECIFICATIONS
SPECIFICATIONS & INFORMATION
GENERAL VEHICLE SPECIFICATIONS
ENGINELX172 AND LX176
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .John Deere "K" Series
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FC420V
Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Natural
Horsepower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4 kW (14 hp)
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423 mL (25.8 cu. in.)
Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle
Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 mm (3.500 in.)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 mm (2.68 in.)
Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1550 75 rpm
Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3350 50 rpm
Valving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurized
Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Flow Filter
Engine Oil Capacity (with filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 L (3.2 U.S. pt)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . Two-stage with replaceable filter element
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal discharge below frame
ENGINELX173
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kohler
Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Command LT
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CV15S
Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Natural
Horsepower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.19 kW (15.0 hp)
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426 cc (26.0 cu. in.)
Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle
Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 mm (3.60 in.)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 mm (2.64 in.)
Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1650 75 rpm
Fast Idle (Domestic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3350 50 rpm
Valving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurized
Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Flow Filter (w/o By-Pass Valve)
Engine Oil Capacity (with filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 L (1.9 U.S. qt)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper with outer foam element
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal discharge below frame
Compression Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic/Centrifugal
Compression Ratio (Cranking) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2:1
Compression Ratio (Running). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5:1
www.servicemanualall.com
6/5/96
2 - 3
SPECIFICATIONS & INFORMATION
GENERAL VEHICLE SPECIFICATIONS
ENGINELX178
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .John Deere "K" Series
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD440V
Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Natural
Horsepower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 kW (15 hp)
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 (V-twin)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437 mL (26.7 cu. in.)
Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle
Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 mm (2.34 in.)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 mm (2.44 in.)
Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1550 75 rpm
Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3400 75 rpm
Valving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurized
Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Flow Filter
Engine Oil Capacity (with filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 L (3.2 U.S. pt)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . Two-stage with replaceable filter element
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal discharge below frame
ENGINELX186
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .John Deere "K" Series
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FC540V
Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Natural
Horsepower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4 kW (14 hp)
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423 mL (25.8 cu. in.)
Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle
Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 mm (3.50 in.)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 mm (2.680 in.)
Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1550 75 rpm
Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3350 50 rpm
Valving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurized
Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Flow Filter
Engine Oil Capacity (with filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.80 L (3.8 U.S. pt.)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . Two-stage with replaceable filter element
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal discharge below frame
www.servicemanualall.com
2 - 4
6/5/96
GENERAL VEHICLE SPECIFICATIONS
SPECIFICATIONS & INFORMATION
ENGINELX188
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .John Deere "K" Series
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD501V
Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Natural
Horsepower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.6 kW (17 hp)
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 (V-twin)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437 mL (26.7 cu. in.)
Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle
Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 mm (2.34 in.)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 mm (2.44 in.)
Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1550 75 rpm
Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3550 75 rpm
Valving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurized
Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Flow Filter
Engine Oil Capacity (with filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 L (3.2 U.S. pt)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . Two-stage with replaceable filter element
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal discharge below frame
FUEL SYSTEM
Fuel Tank Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear
Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 L (2.5 U.S. gal)
Fuel (minimum octane) . . . . . . . . . . . . . . . . . . . . . . . . . . Unleaded Gasoline, 87 Octane
Fuel Pump Location
LX172, LX173, LX176 and LX186 . . . . . . . . . . . . . . . . . On left-hand side of engine
LX178 and LX188. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On front of engine
Fuel Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Float-Type Side Draft Carburetor
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable In-Line
ELECTRICAL
Ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . .Electronic Capacitor Discharge Ignition (CDI)
Type of Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Shift
Charging System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel Alternator
Charging Capacity
LX172/LX173/LX176/LX186 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 amp, Regulated
LX178/LX188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 amp, Regulated
Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BCI Group, U1
Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V
Battery Reserve Capacity at 25 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 minutes
Battery Cold Cranking Amps at -18C (0F) . . . . . . . . . . . . . . . . . . . . . . . . . . .295 amps
Ignition Interlock Switches. . . . . . . . . . . . . . . . . . . . . . . . . .Neutral StartLX172/LX173
BrakeLX176/LX178/ LX186/LX188
PTO DRIVE
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V-Belt
Clutch Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine-Mounted, Electric
Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch on dash
www.servicemanualall.com
6/5/96
2 - 5
SPECIFICATIONS & INFORMATION
GENERAL VEHICLE SPECIFICATIONS
POWER TRAIN
Drive Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear
Transaxle Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt
Gear TransaxleLX172/ LX173
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Transaxle
Number of Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Forward, 1 Reverse
Travel Speeds at Full RPM
1st Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 km/h (1.6 mph)
2nd Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 km/h (2.5 mph)
3rd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 km/h (3.8 mph)
4th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 km/h (4.8 mph)
5th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 km/h (5.7 mph)
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 km/h (2.7 mph)
Transaxle Lubricant Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 L (2.5 qt)
Lubricant Type. . . . . . . . . . . . . . . . John Deere Non-Clay High-Temperature EP Grease
Hydrostatic TransaxleLX176/ LX178/LX186/LX188
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydrostatic, Piston-Type Transaxle
Transaxle Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable, Internal
Travel Speeds at Full RPM
Forward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08.8 km/h (05.5 mph)
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04.0 km/h (02.5 mph)
Transaxle Lubricant Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 L (7.2 U.S. qt)
Lubricant Type. . . . . . . . . . . . . . . . . . . . John Deere TURFGARD 10W-30 Engine Oil
STEERING
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sector and Pinion
BRAKES
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transaxle
Type
LX172/LX173 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Disk, Single Pedal
LX176/LX178/LX186/LX188 . . . . . . . . . . . . . . . . . . . . . External Band, Single Pedal
Park Brake
LX172/LX173 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Pedal, Clutch Interlock
LX176/LX178/LX186/LX188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Pedal
IMPLEMENT LIFT
Lift System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual with Lift-Assist Spring
Lift Lever Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Left-hand side of hood
Cutting Heights . . . . . . . . . . . . . . . . . . . . . . . . . . 12.788.9 mm (12.7 mm increments)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.53.5 in. (0.50 in. increments)
www.servicemanualall.com
2 - 6
6/5/96
GENERAL VEHICLE SPECIFICATIONS
SPECIFICATIONS & INFORMATION
WEIGHTS AND DIMENSIONS
Net Weight (no fuel) (estimated)
LX172/LX173
With 38-Inch Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 kg (525 lb)
With 44-Inch Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 kg (540 lb)
With 48-Inch Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 kg (560 lb)
LX176
With 38-Inch Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 kg (535 lb)
With 48-Inch Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 kg (570 lb)
LX178
With 38-Inch Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 kg (540 lb)
With 44-Inch Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 kg (575 lb)
LX186/LX188
With 48-Inch Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268 kg (590 lb)
Mower Deck Weight (estimated)
38-Inch Mower Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 kg (95 lb)
44-Inch Mower Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 kg (108 lb)
48-Inch Mower Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 kg (125 lb)
Overall Width (less mower deck)
LX172/LX173/LX176/LX178. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.262 m (49.7 in.)
LX186/LX188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.504 m (59.2 in.)
Overall Width (with mower deck, discharge chute down)
With 38-Inch Mower Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32 m (52 in.)
With Rear Bagger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26 m (49.5 in.)
With 44-Inch Mower Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.163 m (45.7 in.)
With 48-Inch Mower Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.54 m (60.5 in.)
With Power Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.56 m (61.5 in.)
Overall Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.02 m (40.2 in.)
Overall Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.68 m (66.1 in.)
Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.165 m (45.9 in.)
Turning Radius
Inside Rear Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.508 m (20 in.)
Outside Front Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.88 m (74 in.)
WHEELS AND TIRES
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 x 6.00-6 in.
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 x 10.00-8 in.
www.servicemanualall.com
6/5/96
2 - 7
SPECIFICATIONS & INFORMATION
METRIC FASTENER TORQUE VALUES
METRIC FASTENER TORQUE VALUES
Class 4.8
Class 8.8 or 9.8
Class 10.9
Class 12.9
Lubricateda
Drya
Lubricateda
Drya
Lubricateda
Drya
Lubricateda
Drya
SIZE
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
M6
48
3.5
6
4.5
9
6.5
11
8.5
13
9.5
17
12
15
11.5
19
14.5
M8
12
8.5
15
11
22
16
28
20
32
24
40
30
37
28
47
35
M10
23
17
29
21
43
32
55
40
63
47
80
60
75
55
95
70
M12
40
29
50
37
75
55
95
70
110
80
140
105
130
95
165
120
M14
63
47
80
60
120
88
150
110
175
130
225
165
205
150
260
109
M16
100
73
125
92
190
140
240
175
275
200
350
225
320
240
400
300
M18
135
100
175
125
260
195
330
250
375
275
475
350
440
325
560
410
M20
190
140
240
180
375
275
475
350
530
400
675
500
625
460
800
580
M22
260
190
330
250
510
375
650
475
725
540
925
675
850
625
1075
800
M24
330
250
425
310
650
475
825
600
925
675
1150
850
1075
800
1350
1000
M27
490
360
625
450
950
700
1200
875
1350
1000
1700
1250
1600
1150
2000
1500
M30
675
490
850
625
1300
950
1650
1200
1850
1350
2300
1700
2150
1600
2700
2000
M33
900
675
1150
850
1750
1300
2200
1650
2500
1850
3150
2350
2900
2150
3700
2750
M36
1150
850
1450
1075
2250
1650
2850
2100
3200
2350
4050
3000
3750
2750
4750
3500
TS1163
4.8
8.8
9.8
10.9
12.9
5
10
12Property
Class
and
Head
Markings
Property
Class
and
Nut
Markings
4.8
4.8
55
8.8
8.8
9.8
9.8
10.9
10.9
12.9
12.9
12.9
12
12
10
10
10
1010DO NOT use these hand torque values if a different
torque value or tightening procedure is given for a
specific application. Torque values listed are for general
use only and include a 10% variance factor. Check
tightness of fasteners periodically. DO NOT use air
powered wrenches.
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same grade.
Make sure fastener threads are clean and that you
properly start thread engagement. This will prevent
them from failing when tightening.
When bolt and nut combination fasteners are used,
torque values should be applied to the NUT instead of
the bolt head.
Tighten toothed or serrated-type lock nuts to the full
torque value.
a "Lubricated" means coated with a lubricant such
as engine oil, or fasteners with phosphate and oil
coatings. "Dry" means plain or zinc plated (yellow
dichromate - Specification JDS117) without any
lubrication.
Reference: JDSG200.
www.servicemanualall.com
2 - 8
6/5/96
INCH FASTENER TORQUE VALUES
SPECIFICATIONS & INFORMATION
INCH FASTENER TORQUE VALUES
Grade 1
Grade 2b
Grade 5, 5.1 or 5.2
Grade 8 or 8.2
Lubricateda
Drya
Lubricateda
Drya
Lubricateda
Drya
Lubricateda
Drya
SIZE
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
1/4
3.7
2.8
4.7
3.5
6
4.5
7.5
5.5
9.5
7
12
9
13.5
10
17
12.5
5/16
7.7
5.5
10
7
12
9
15
11
20
15
25
18
28
21
35
26
3/8
14
10
17
13
22
16
27
20
35
26
44
33
50
36
63
46
7/16
22
16
28
20
35
26
44
32
55
41
70
52
80
58
100
75
1/2
33
25
42
31
53
39
67
50
85
63
110
80
120
90
150
115
9/16
48
36
60
45
75
56
95
70
125
90
155
115
175
130
225
160
5/8
67
50
85
62
105
78
135
100
170
125
215
160
215
160
300
225
3/4
120
87
150
110
190
140
240
175
300
225
375
280
425
310
550
400
7/8
190
140
240
175
190
140
240
175
490
360
625
450
700
500
875
650
1
290
210
360
270
290
210
360
270
725
540
925
675
1050
750
1300
975
1-1/8
470
300
510
375
470
300
510
375
900
675
1150
850
1450
1075
1850
1350
1-1/4
570
425
725
530
570
425
725
530
1300
950
1650
1200
2050
1500
2600
1950
1-3/8
750
550
950
700
750
550
950
700
1700
1250
2150
1550
2700
2000
3400
2550
1-1/2
1000
725
1250
925
990
725
1250
930
2250
1650
2850
2100
3600
2650
4550
3350
TS1162
1 or 2b
2
5
5.1
5.2
5
8
8.2
8
No Marks
No Marks
SAE
Grade
and Nut
Markings
SAE
Grade
and Head
Markings
DO NOT use these hand torque values if a different
torque value or tightening procedure is given for a
specific application. Torque values listed are for general
use only and include a 10% variance factor. Check
tightness of fasteners periodically. DO NOT use air
powered wrenches.
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same grade.
Make sure fastener threads are clean and that you
properly start thread engagement. This will prevent
them from failing when tightening.
When bolt and nut combination fasteners are used,
torque values should be applied to the NUT instead of
the bolt head.
Tighten toothed or serrated-type lock nuts to the full
torque value.
a "Lubricated" means coated with a lubricant such
as engine oil, or fasteners with phosphate and oil
coatings. "Dry" means plain or zinc plated (yellow
dichromate - Specification JDS117) without any
lubrication.
b "Grade 2" applies for hex cap screws (not hex
bolts) up to 152 mm (6-in.) long. "Grade 1"
applies for hex cap screws over 152 mm (6-in.)
long, and for all other types of bolts and screws
of any length.
Reference: JDSG200.
www.servicemanualall.com
6/5/96
2 - 9
SPECIFICATIONS & INFORMATION
GASOLINE
GASOLINE
4-CYCLE ENGINESNORTH AMERICA

c CAUTION
Gasoline is HIGHLY FLAMMABLE, handle it with care.
DO NOT refuel machine while:
indoors, always fill gas tank outdoors;
machine is near an open flame or sparks;
engine is running, STOP engine;
engine is hot, allow it to cool sufficiently first;
smoking.
Help prevent fires:
fill gas tank to bottom of filler neck only;
be sure fill cap is tight after fueling;
clean up any gas spills IMMEDIATELY;
keep machine clean and in good repairfree of excess grease, oil, debris, and faulty or damaged
parts;
any storage of machines with gas left in tank should be in an area that is well ventilated to prevent
possible igniting of fumes by an open flame or spark, this includes any appliance with a pilot light.
To prevent fire or explosion caused by STATIC ELECTRIC DISCHARGE during fueling:
ONLY use a clean, approved POLYETHYLENE PLASTIC fuel container and funnel WITHOUT any metal
screen or filter.
To avoid engine damage:
DO NOT mix oil with gasoline;
ONLY use clean, fresh unleaded gasoline with
an octane rating (anti-knock index) of 87 or
higher;
fill gas tank at the end of each day's operation to
help prevent condensation from forming inside a
partially filled tank;
keep up with specified service intervals.
Use of alternative oxygenated, gasohol blended,
unleaded gasoline is acceptable as long as:
the ethyl or grain alcohol blends DO NOT exceed
10% by volume or
methyl tertiary butyl ether (MTBE) blends DO NOT
exceed 15% by volume.
IMPORTANT: DO NOT use METHANOL gasolines
because METHANOL
is harmful
to
the
environment and to your health.
GASOLINE STORAGE
IMPORTANT: Keep all dirt, scale, water or other
foreign material out of gasoline.
Keep gasoline stored in a safe, protected area. Storage
of gasoline in a clean, properly marked ("UNLEADED
GASOLINE") POLYETHYLENE PLASTIC container
WITHOUT any metal screen or filter is recommended.
DO NOT use de-icers to attempt to remove water from
gasoline or depend on fuel filters to remove water from
gasoline. Use a water separator installed in the storage
tank outlet. BE SURE to properly discard unstable or
contaminated gasoline. When storing unit or gasoline,
it is recommended that you add John Deere Gasoline
Conditioner and Stabilizer
(TY15977) or an
equivalent to the gasoline. BE SURE to follow
directions on container and to properly discard empty
container.

c WARNING
California Proposition 65 Warning: Gasoline
engine exhaust from this product contains
chemicals known to the State of California to
cause
cancer,
birth
defects,
or
other
reproductive harm.
NO STATIC ELECTRIC
DISCHARGE
NO SMOKING
NO HOT ENGINE
STOP ENGINE
NO OPEN FLAME
OR SPARK
www.servicemanualall.com
2 - 10
6/5/96
GASOLINE
SPECIFICATIONS & INFORMATION
4CYCLE ENGINESEUROPE

c CAUTION
Gasoline is HIGHLY FLAMMABLE, handle it with care.
DO NOT refuel machine while:
indoors, always fill gas tank outdoors;
machine is near an open flame or sparks;
engine is running, STOP engine;
engine is hot, allow it to cool sufficiently first;
smoking.
Help prevent fires:
fill gas tank to bottom of filler neck only;
be sure fill cap is tight after fueling;
clean up any gas spills IMMEDIATELY;
keep machine clean and in good repairfree of excess grease, oil, debris, and faulty or damaged
parts;
any storage of machines with gas left in tank should be in an area that is well ventilated to prevent
possible igniting of fumes by an open flame or spark, this includes any appliance with a pilot light.
To prevent fire or explosion caused by STATIC ELECTRIC DISCHARGE during fueling:
ONLY use a clean, approved POLYETHYLENE PLASTIC fuel container and funnel WITHOUT any metal
screen or filter.
To avoid engine damage:
DO NOT mix oil with gasoline;
ONLY use clean, fresh unleaded gasoline with
an octane rating (anti-knock index) of 87 or
higher;
fill gas tank at the end of each day's operation to
help prevent condensation from forming inside a
partially filled tank;
keep up with specified service intervals.
Use of alternative oxygenated, gasohol blended,
unleaded gasoline is acceptable as long as:
the ethyl or grain alcohol blends DO NOT exceed
10% by volume or
methyl tertiary butyl ether (MTBE) blends DO NOT
exceed 15% by volume.
IMPORTANT: DO NOT use METHANOL gasolines
because METHANOL
is harmful
to
the
environment and to your health.
GASOLINE STORAGE
IMPORTANT: Keep all dirt, scale, water or other
foreign material out of gasoline.
Keep gasoline stored in a safe, protected area. Storage
of gasoline in a clean, properly marked ("UNLEADED
GASOLINE") POLYETHYLENE PLASTIC container
WITHOUT any metal screen or filter is recommended.
DO NOT use de-icers to attempt to remove water from
gasoline or depend on fuel filters to remove water from
gasoline. Use a water separator installed in the storage
tank outlet. BE SURE to properly discard unstable or
contaminated gasoline. When storing unit or gasoline,
it is recommended that you add John Deere Gasoline
Conditioner and Stabilizer
(TY15977) or an
equivalent to the gasoline. BE SURE to follow
directions on container and to properly discard empty
container.
NO STATIC ELECTRIC
DISCHARGE
NO SMOKING
NO HOT ENGINE
STOP ENGINE
NO OPEN FLAME
OR SPARK
www.servicemanualall.com
6/5/96
2 - 11
SPECIFICATIONS & INFORMATION
OILS AND LUBRICANTS
OILS AND LUBRICANTS
KAWASAKI 4-CYCLE GASOLINE
ENGINE OILNORTH AMERICA
Use the appropriate oil viscosity based on the expected
air temperature range during the period between
recommended oil changes. Operating outside of these
recommended oil air temperature ranges may cause
premature engine failure.
The following John Deere oils are PREFERRED:
PLUS4SAE 10W-40;
TORQGARD SUPREMESAE 5W-30.
The following John Deere oils are also recommended,
based on their specified temperature range:
TURFGARDSAE 10W-30;
PLUS4SAE 10W-30;
TORQGARD SUPREMESAE 30.
Other oils may be used if above John Deere oils are not
available, provided they meet one of the following
specifications:
SAE 10W-40API Service Classifications SG or
higher;
SAE 5W-30API Service Classification SG or
higher;
SAE 10W-30API Service Classifications SG or
higher;
SAE 30API Service Classification SC or higher.
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper oil
for your customers:
Module DX,ENOIL2 in JDSG135;
Section 530, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide;
Lubrication Sales Manual PI7032.
AIR TEMPERATURE
SAE 10W-40M58275
SAE 5W-30PREFERRED
SAE 10W-30SAE 30www.servicemanualall.com
2 - 12
6/5/96
OILS AND LUBRICANTS
SPECIFICATIONS & INFORMATION
KAWASAKI 4-CYCLE GASOLINE
ENGINE OILEUROPE
Use the appropriate oil viscosity based on the expected
air temperature range during the period between
recommended oil changes. Operating outside of these
recommended oil air temperature ranges may cause
premature engine failure.
The following John Deere oils are PREFERRED:
TORQGARD SUPREMESAE 10W-40;
UNIGARDSAE 10W-40;
TORQGARD SUPREMESAE 5W-30;
UNIGARDSAE 5W-30.
The following John Deere oils are also recommended,
based on their specified temperature range:
TORQGARD SUPREMESAE 10W-30;
UNIGARDSAE 10W-30;
TORQGARD SUPREMESAE 30;
UNIGARDSAE 30.
Other oils may be used if above John Deere oils are not
available, provided they meet one of the following
specifications:
CCMC Specifications G4 or higher.
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper oil
for your customers:
Module DX,ENOIL2 in JDSG135;
Section 530, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide.
AIR TEMPERATURE
SAE 10W-40M58275
SAE 5W-30PREFERRED
SAE 10W-30SAE 30www.servicemanualall.com
6/5/96
2 - 13
SPECIFICATIONS & INFORMATION
OILS AND LUBRICANTS
KOHLER 4-CYCLE GASOLINE
ENGINE OILNORTH AMERICA
Use the appropriate oil viscosity based on the expected
air temperature range during the period between
recommended oil changes. Operating outside of these
recommended oil air temperature ranges may cause
premature engine failure.
The following John Deere oils are PREFERRED:
PLUS4SAE 10W-40;
TURFGARDSAE 10W-30;
PLUS4SAE 10W-30;
The following John Deere oil is also recommended,
based on their specified temperature range:
TORQGARD SUPREMESAE 5W-30.
Other oils may be used if above John Deere oils are not
available, provided they meet one of the following
specifications:
SAE 10W-40, 10W-30, or 5W-30API Service
Classifications SG or higher;
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper oil
for your customers:
Module DX,ENOIL2 in JDSG135;
Section 530, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide;
Lubrication Sales Manual PI7032.
AIR TEMPERATURE
SAE 10W-40M58275
SAE 5W-30PREFERRED
SAE 10W-30KOHLER 4-CYCLE GASOLINE
ENGINE OILEUROPE
Use the appropriate oil viscosity based on the expected
air temperature range during the period between
recommended oil changes. Operating outside of these
recommended oil air temperature ranges may cause
premature engine failure.
The following John Deere oils are PREFERRED:
TORQGARD SUPREMESAE 10W-40;
UNIGARDSAE 10W-40;
TORQGARD SUPREMESAE 10W-30;
UNIGARDSAE 10W-30.
The following John Deere oil is also recommended,
based on their specified temperature range:
TORQGARD SUPREMESAE 5W-30;
UNIGARDSAE 5W-30.
Other oils may be used if above John Deere oils are not
available, provided they meet one of the following
specifications:
CCMC Specifications G4 or higher.
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper oil
for your customers:
Module DX,ENOIL2 in JDSG135;
Section 530, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide.
AIR TEMPERATURE
SAE 10W-40M58275
SAE 5W-30PREFERRED
SAE 10W-30www.servicemanualall.com
2 - 14
6/5/96
OILS AND LUBRICANTS
SPECIFICATIONS & INFORMATION
BREAK-IN 4-CYCLE GASOLINE
ENGINE OILNORTH AMERICA
IMPORTANT: ONLY use a quality break-in oil in
rebuilt or remanufactured engines for the first 5
hours (maximum) of operation. DO NOT use oils
with heavier viscosity weights than SAE 5W-30
or oils meeting specifications API SG or SH,
these
oils will
not
allow
rebuilt
or
remanufactured engines to break-in properly.
The following John Deere oil is PREFERRED:
BREAKIN ENGINE OIL.
John Deere BREAKIN ENGINE OIL is formulated
with special additives for aluminum and cast iron type
engines to allow the power cylinder components
(pistons, rings, and liners as well) to "wear-in" while
protecting other engine components, valve train and
gears, from abnormal wear. Engine rebuild instructions
should be followed closely to determine if special
requirements are necessary.
John Deere BREAKIN ENGINE OIL
is also
recommended for non-John Deere engines, both
aluminum and cast iron types.
The following John Deere oil is also recommended:
TORQGARD SUPREMESAE 5W-30.
If the above recommended John Deere oils are not
available, use a break-in engine oil meeting the
following specification during the first 5 hours
(maximum) of operation:
SAE 5W-30API Service Classification SE or
higher.
IMPORTANT: After the break-in period, use the
John Deere oil that is recommended for this
engine.
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper oil
for your customers:
Module DX,ENOIL4 in JDSG135;
Section 530, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide;
Lubrication Sales Manual PI7032.
M58275
BREAK-IN OILAIR TEMPERATURE
PREFERRED
SAE 5W-30www.servicemanualall.com
6/5/96
2 - 15
SPECIFICATIONS & INFORMATION
OILS AND LUBRICANTS
BREAK-IN 4-CYCLE GASOLINE
ENGINE OILEUROPE
IMPORTANT: ONLY use a quality break-in oil in
rebuilt or remanufactured engines for the first 5
hours (maximum) of operation. DO NOT use oils
with heavier viscosity weights than SAE 5W-30
or oils meeting CCMC Specification G5these
oils will not allow rebuilt or remanufactured
engines to break-in properly.
The following John Deere oil is PREFERRED:
BREAKIN ENGINE OIL.
John Deere BREAKIN ENGINE OIL is formulated
with special additives for aluminum and cast iron type
engines to allow the power cylinder components
(pistons, rings, and liners as well) to "wear-in" while
protecting other engine components, valve train and
gears, from abnormal wear. Engine rebuild instructions
should be followed closely to determine if special
requirements are necessary.
John Deere BREAKIN ENGINE OIL
is also
recommended for non-John Deere engines, both
aluminum and cast iron types.
The following John Deere oil is also recommended:
TORQGARD SUPREMESAE 5W-30.
If the above recommended John Deere oils are not
available, use a break-in engine oil meeting the
following specification during the first 5 hours
(maximum) of operation:
SAE 5W-30CCMC Specification G4 or higher.
IMPORTANT: After the break-in period, use the
John Deere oil that is specified for this engine.
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper oil
for your customers:
Module DX,ENOIL4 in JDSG135;
Section 530, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide.
M58275
BREAK-IN OILAIR TEMPERATURE
PREFERRED
SAE 5W-30www.servicemanualall.com
2 - 16
6/5/96
OILS AND LUBRICANTS
SPECIFICATIONS & INFORMATION
HYDROSTATIC TRANSMISSION OIL
NORTH AMERICA
Use the appropriate oil viscosity based on these air
temperature ranges. Operating outside of these
recommended oil air temperature ranges may cause
premature hydrostatic transmission failure.
IMPORTANT: ONLY use a quality SAE 10W-30 or
SAE 5W-30 engine oil in this transmission.
Mixing of these two viscosity grade oils is
permitted. DO NOT use BIOHYGARD in this
transmission.
The following John Deere oils are PREFERRED:
TURF-GARDSAE 10W-30;
PLUS-4SAE 10W-30.
TORQ-GARD SUPREMESAE 5W-30.
Other oils may be used if above recommended John
Deere oils are not available, provided they meet one of
the following specifications:
API Service Classifications SG or higher.
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper oil
for your customers:
Module DX,ENOIL2 in JDSG135;
Section 530, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide;
Lubrication Sales Manual PI7032.
M58275
SAE 10W-30AIR TEMPERATURE
SAE 5W-30HYDROSTATIC TRANSMISSION
OILEUROPE
Use the appropriate oil viscosity based on these air
temperature ranges. Operating outside of these
recommended oil air temperature ranges may cause
premature hydrostatic transmission failure.
IMPORTANT: ONLY use a quality SAE 10W-30 or
SAE 5W-30 engine oil in this transmission.
Mixing of these two viscosity grade oils is
permitted. DO NOT use BIOHYGARD in this
transmission.
The following John Deere oils are PREFERRED:
TORQ-GARD SUPREMESAE 10W-30;
TORQ-GARD SUPREMESAE 5W-30.
Other oils may be used if above recommended John
Deere oils are not available, provided they meet one of
the following specifications:
CCMC Specifications G4 or higher.
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper oil
for your customers:
Module DX,ENOIL2 in JDSG135;
Section 530, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide.
M58275
AIR TEMPERATURE
SAE 10W-30SAE 5W-30www.servicemanualall.com
6/5/96
2 - 17
SPECIFICATIONS & INFORMATION
GEAR TRANSMISSION GREASENORTH AMERICA
GEAR TRANSMISSION GREASE
NORTH AMERICA
Use the following gear grease based on the air
temperature
range. Operating outside of
the
recommended grease air temperature range may
cause premature gear transmission failure.
IMPORTANT: ONLY use a quality gear grease in
this transmission. DO NOT mix any other
greases in this transmission. DO NOT use any
BIOGREASE in this transmission.
The
following
John Deere gear
grease
is
PREFERRED:
NON-CLAY HIGH-TEMPERATURE EP GREASE
JDM J13E4, NLGI Grade 2.
Other gear greases may be used
if above
recommended John Deere gear grease is not
available, provided they meet one of the following
specification:
John Deere Standard JDM J13E4,
NLGI Grade 2.
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper
grease for your customers:
Module DX,GREA1 in JDSG135;
Section 530, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide;
Lubrication Sales Manual PI7032.
JDM J13E4M58275
AIR TEMPERATURE
NLGI Grade 2GEAR TRANSMISSION GREASE
EUROPE
Use the following gear grease based on the air
temperature
range. Operating outside of
the
recommended grease air temperature range may
cause premature gear transmission failure.
IMPORTANT: ONLY use a quality gear grease in
this transmission. DO NOT mix any other
greases in this transmission. DO NOT use any
BIOGREASE in this transmission.
The
following
John Deere gear
grease
is
PREFERRED:
GREASEGARDJDM J13E4, NLGI Grade 2.
Other gear greases may be used
if above
recommended John Deere gear grease is not
available,
provided
they meet
the
following
specification:
John Deere Standard JDM J13E4,
NLGI Grade 2.
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper
grease for your customers:
Module DX,GREA1 in JDSG135;
Section 530, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide.
JDM J13E4NLGI Grade 2M58275
AIR TEMPERATURE
www.servicemanualall.com
2 - 18
6/5/96
GREASENORTH AMERICA
SPECIFICATIONS & INFORMATION
GREASENORTH AMERICA
Use the following grease based on the air temperature
range. Operating outside of the recommended grease
air temperature range may cause premature failures.
IMPORTANT: ONLY use a quality grease in this
application. DO NOT mix any other greases in
this application. DO NOT use any BIOGREASE
in this application.
The following John Deere grease is PREFERRED:

NON-CLAY
HIGH-TEMPERATURE
EP
GREASEJDM J13E4, NLGI Grade 2.
Other greases may be used if above preferred John
Deere grease is not available, provided they meet the
following specification:
John Deere Standard JDM J13E4, NLGI Grade 2.
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper
grease for your customers:
Module DX,GREA1 in JDSG135;
Section 530, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide;
the Lubrication Sales Manual PI7032.
JDM J13E4M58275
AIR TEMPERATURE
NLGI Grade 2GREASEEUROPE
Use the following grease based on the air temperature
range. Operating outside of the recommended grease
air temperature range may cause premature failures.
IMPORTANT: ONLY use a quality grease in this
application. DO NOT mix any other greases in
this application. DO NOT use any BIOGREASE
in this application.
The following John Deere grease is PREFERRED:
GREASEGARDJDM J13E4, NLGI Grade 2.
Other greases may be used if above preferred John
Deere grease is not available, provided they meet the
following specification:
John Deere Standard JDM J13E4, NLGI Grade 2.
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper
grease for your customers:
Module DX,GREA1 in JDSG135;
Section 530, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide.
JDM J13E4M58275
AIR TEMPERATURE
NLGI Grade 2www.servicemanualall.com
6/5/96
2 - 19
SPECIFICATIONS & INFORMATION
ANTI-CORROSION GREASENORTH AMERICA
ANTI-CORROSION GREASE
NORTH AMERICA
This anti-corrosion grease is formulated to provide the
best protection against absorbing moisture, which is
one of the major causes of corrosion. This grease is
also superior in its resistance to separation and
migration.
The following anti-corrosion grease is PREFERRED:
DuBois MPG-2 Multi-Purpose Polymer
GreaseM79292.
Other greases may be used if they meet or exceed the
following specifications:
John Deere Standard JDM J13A2, NLGI Grade 1.
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper
grease for your customers:
Module DX,GREA1 in JDSG135;
Section 530, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide;
the Lubrication Sales Manual PI7032.
JDM J13A2NLGI Grade 1M58275
AIR TEMPERATURE
ANTI-CORROSION GREASE
EUROPE
This anti-corrosion grease is formulated to provide the
best protection against absorbing moisture, which is
one of the major causes of corrosion. This grease is
also superior in its resistance to separation and
migration.
The following anti-corrosion grease is PREFERRED:
DuBois MPG-2 Multi-Purpose Polymer
GreaseM79292.
Other greases may be used if they meet or exceed the
following specifications:
John Deere Standard JDM J13A2, NLGI Grade 1.
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper
grease for your customers:
Module DX,GREA1 in JDSG135;
Section 530, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide.
JDM J13A2NLGI Grade 1M58275
AIR TEMPERATURE
www.servicemanualall.com
2 - 20
6/5/96
ALTERNATIVE LUBRICANTS
SPECIFICATIONS & INFORMATION
ALTERNATIVE LUBRICANTS
Conditions in certain geographical areas outside the
United States and Canada may require different
lubricant recommendations than the ones printed in
this technical manual or the operator's manual. Consult
with your John Deere Dealer, or Sales Branch, to
obtain the alternative lubricant recommendations.
IMPORTANT: Use of alternative lubricants could
cause reduced life of the component.
If alternative
lubricants are to be used,
it
is
recommended that the factory fill be thoroughly
removed before switching to any alternative lubricant.
SYNTHETIC LUBRICANTS
Synthetic lubricants may be used in John Deere
equipment if they meet the applicable performance
requirements (industry classification and/or military
specification) as shown in this manual.
The recommended air temperature limits and service
or lubricant change intervals should be maintained as
shown in the operator's manual.
Avoid mixing different brands, grades, or types of oil.
Oil manufacturers blend additives in their oils to meet
certain specifications and performance requirements.
Mixing different oils can interfere with the proper
functioning of these additives and degrade lubricant
performance.
LUBRICANT STORAGE
All machines operate at top efficiency only when clean
lubricants are used. Use clean storage containers to
handle all lubricants. Store them in an area protected
from dust, moisture, and other contamination. Store
drums on their sides. Make sure all containers are
properly marked as to their contents. Dispose of all old,
used containers and their contents properly.
MIXING OF LUBRICANTS
In general, avoid mixing different brands or types of
lubricants. Manufacturers blend additives in their
lubricants
to meet
certain specifications and
performance requirements. Mixing different lubricants
can interfere with the proper functioning of these
additives and lubricant properties which will downgrade
their intended specified performance.
OIL FILTERS
IMPORTANT: Filtration of oils is critical to proper
lubrication performance. Always change filters
regularly.
The following John Deere oil filters are PREFERRED:
AUTOMOTIVE AND LIGHT TRUCK ENGINE OIL
FILTERS.
Most John Deere filters contain pressure relief and
anti-drainback valves for better engine protection.
Other oil filters may be used if above recommended
John Deere oil filters are not available, provided they
meet the following specification:
ASTB Tested In Accordance With SAE J806.
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper oil
filter for your customers:
Module DX,FILT in JDSG135;
Section 540, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide;
Lawn & Grounds Care Tune-Up Guide PI672.
www.servicemanualall.com
6/5/96
2 - 21
SPECIFICATIONS & INFORMATION
GASOLINE ENGINE COOLANTNORTH AMERICA
GASOLINE ENGINE COOLANT
NORTH AMERICA
The engine cooling system when filled with a proper
dilution mixture of anti-freeze and deionized or distilled
water provides year-round protection against corrosion,
cylinder or liner pitting, and winter freeze protection
down to 37C (34F).
The following John Deere coolant is PREFERRED:
PRE-DILUTED DIESEL ENGINE ANTI-FREEZE/
SUMMER COOLANT (TY16036).
This coolant satisfies specifications for "Automobile
and Light Duty Engine Service" and is safe for use in
John Deere Lawn and Grounds Care/Golf and Turf
Division equipment, including aluminum block gasoline
engines and cooling systems.
The above preferred pre-diluted anti-freeze provides:
adequate heat transfer
corrosion-resistant chemicals for the cooling
system
compatibility with cooling system hose and seal
material
protection during extreme cold and extreme hot
weather operations
chemically pure water for better service life
compliance with ASTM D4656 (JDM H24C2)
specifications
If above preferred pre-diluted coolant is not available,
the
following
John
Deere
concentrate
is
recommended:
DIESEL ENGINE ANTI-FREEZE/SUMMER
COOLANT CONCENTRATE (TY16034).
If either of above recommended engine coolants are
available use any Automobile and Light Duty Engine
Service ethylene glycol base coolant, meeting the
following specification:
ASTM D3306 (JDM H24C1).
Read container label completely before using and
follow instructions as stated.
IMPORTANT: To prevent engine damage, DO NOT
use pure anti-freeze or less than a 50% anti-
freeze mixture in the cooling system. DO NOT
mix or add any additives/conditioners to the
cooling system in Lawn and Grounds Care/Golf
and Turf Division equipment. Water used to
dilute engine coolant concentrate must be of
high qualityclean, clear, potable water (low in
chloride and hardnessTable 1) is generally
acceptable. DO NOT use salt water. Deionized or
distilled water is ideal to use. Coolant that is not
mixed to these specified levels and water purity
can cause excessive scale, sludge deposits,
and increased corrosion potential.
Mix 50 percent anti-freeze concentrate with 50 percent
distilled or deionized water. This mixture and the pre-
diluted mixture (TY16036) will protect the cooling
system down to -37C(-34F) and up to 108C (226F).
Certain geographical areas may require lower air
temperature protection. See the label on your anti-
freeze container or consult your John Deere dealer to
obtain the latest information and recommendations.
GASOLINE ENGINE COOLANT
DRAIN INTERVALNORTH
AMERICA
When using John Deere Pre-Diluted (TY16036)
Automobile and Light Duty Engine Service coolants,
drain and flush the cooling system and refill with fresh
coolant mixture every 36 months or 3,000 hours of
operation, whichever comes first.
When using John Deere Concentrate (TY16034)
Automobile and Light Duty Engine Service coolants,
drain and flush the cooling system and refill with fresh
coolant mixture every 24 months or 2,000 hours of
operation, whichever comes first.
If above John Deere Automobile and Light Duty Engine
Service coolants are not being used; drain, flush, and
refill the cooling system according to instructions found
on product container or in equipment operator's manual
or technical manual.
Water Quality
Property
Requirements
Total Solids, Maximum
340 ppm (20 grns/gal)
Total Hardness, Max.
170 ppm (10 grns/gal)
Chloride (as Cl), Max.
40 ppm (2.5 grns/gal)
Sulfate (as SO4), Max.
100 ppm (5.8 grns/gal)
www.servicemanualall.com
2 - 22
6/5/96
GASOLINE ENGINE COOLANTEUROPE
SPECIFICATIONS & INFORMATION
GASOLINE ENGINE COOLANT
EUROPE
The engine cooling system when filled with a proper
dilution mixture of anti-freeze and deionized or distilled
water provides year-round protection against corrosion,
cylinder or liner pitting, and winter freeze protection
down to 37C (34F).
ONLY use a quality Automobile and Light Duty Engine
Service ethylene glycol base coolant, meeting the
following specification:
ASTM D3306 (JDM H24C1).
Read container label completely before using and
follow instructions as stated.
IMPORTANT: To prevent engine damage, DO NOT
use pure anti-freeze or less than a 50% anti-
freeze mixture in the cooling system. DO NOT
mix or add any additives/conditioners to the
cooling system in Lawn and Grounds Care/Golf
and Turf Division equipment. Water used to
dilute engine coolant concentrate must be of
high qualityclean, clear, potable water (low in
chloride and hardnessTable 1) is generally
acceptable. DO NOT use salt water. Deionized or
distilled water is best to use. Coolant that is not
mixed to these specified levels and water purity
can cause excessive scale, sludge deposits,
and increased corrosion potential.
Mix 50 percent anti-freeze concentrate with 50 percent
distilled or deionized water. This mixture will protect the
cooling system down to -37C(-34F) and up to 108C
(226F).
Certain geographical areas may require lower air
temperature protection. See the label on your anti-
freeze container or consult your John Deere dealer to
obtain the latest information and recommendations.
Water Quality
Property
Requirements
Total Solids, Maximum
340 ppm (20 grns/gal)
Total Hardness, Max.
170 ppm (10 grns/gal)
Chloride (as Cl), Max.
40 ppm (2.5 grns/gal)
Sulfate (as SO4), Max.
100 ppm (5.8 grns/gal)
GASOLINE ENGINE COOLANT
DRAIN INTERVALEUROPE
If a quality Automobile and Light Duty Engine Service
ethylene glycol base coolant is being used, drain and
flush the cooling system and refill with fresh coolant
mixture every 24 months or 2,000 hours of operation,
whichever comes first.
If a quality Automobile and Light Duty Engine Service
coolant is not being used; drain, flush, and refill the
cooling system according to instructions found on
product container or in equipment operator's manual or
technical manual.
www.servicemanualall.com
6/5/96
2 - 23
SPECIFICATIONS & INFORMATION
SERIAL NUMBER LOCATION
SERIAL NUMBER LOCATION
When ordering parts or submitting a warranty claim, it
is IMPORTANT that the machine product identification
number and component serial numbers are included.
The location of the machine identification number and
component serial numbers are shown.
MACHINE IDENTIFICATION
NUMBER
ENGINE SERIAL NUMBERLX172,
LX176 AND LX186
ENGINE SERIAL NUMBERLX173
M83520
M80810
M83620
ENGINE SERIAL NUMBERLX178
AND LX188
CARBURETOR SERIAL NUMBER
LX172, LX176 AND LX186
CARBURETOR PART NUMBER
LX173 (ONLY)
M45979
M82830
M82830
3672
To Head
Part #
www.servicemanualall.com
2 - 24
6/5/96
SERIAL NUMBER LOCATION
SPECIFICATIONS & INFORMATION
CARBURETOR SERIAL NUMBER
LX178 AND LX188
GEAR TRANSAXLE SERIAL
NUMBERLX172 AND LX173
HYDROSTATIC TRANSAXLE SERIAL
NUMBERLX176, LX178, LX186
AND LX188
M53957
M54761
M54762
MOWER DECK SERIAL NUMBER
LOCATION
38 and 48-Inch Mower Decks
44-Inch Rear Discharge Mower Deck
M82828
M82827
www.servicemanualall.com
ENGINEKAWASAKI FC420V(LX172/LX176) / FC540V(LX186)
CONTENTS
Page
CONTENTS
5/31/96
3 - 1
ENGINEKAWASAKI FC420V(LX172/LX176) / FC540V(LX186)
SPECIFICATIONS
ENGINE DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
TEST AND ADJUSTMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
REPAIR SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
SPECIAL OR ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
SERVICE PARTS KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
COMPONENT LOCATION
EXTERNAL ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
INTERNAL ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
OIL PUMP, BREATHER AND
COMPRESSION RELEASE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
FUEL/AIR SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
THEORY OF OPERATION
LUBRICATION SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
COOLING SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
TROUBLESHOOTING
TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
ENGINE TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
STARTER MOTOR TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . 3-28
TESTS AND ADJUSTMENTS
THROTTLE CABLE TEST AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
CHOKE PLATE TEST AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
GOVERNOR ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
FAST IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
SLOW IDLE SPEED ADJUSTMENTNON CARB/EPA ENGINES . . . . . . . . . . . 3-32
SLOW IDLE SPEED ADJUSTMENTCARB/EPA ENGINES . . . . . . . . . . . . . . . 3-32
CYLINDER COMPRESSION PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
VALVE CLEARANCE TEST AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . 3-35
AUTOMATIC COMPRESSION RELEASE (ACR) TEST . . . . . . . . . . . . . . . . . . . . 3-35
CRANKCASE VACUUM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
ENGINE OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
FUEL PUMP TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
SPARK TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
SPARK PLUG GAP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
MAGNETO IGNITION COIL RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . 3-39
IGNITOR MODULE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
MAGNETO IGNITION COIL WITH IGNITION MODULE RESISTANCE TEST. . . 3-40
REPAIR
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
THROTTLE CONTROL LEVER AND CABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
www.servicemanualall.com
CONTENTS
ENGINEKAWASAKI FC420V(LX172/LX176) / FC540V(LX186)
3 - 2
5/31/96
Page
REPAIR, continued
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
CARBURETOR
Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Clean/Inspect/Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
BLOWER HOUSING
Inspection/Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Flywheel Screen Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
FLYWHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
ROCKER ARM ASSEMBLY
Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
CYLINDER HEAD AND VALVES
Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Valve Guide Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
ANALYZE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
RECONDITION VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
LAP VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
CRANKCASE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
PISTON AND CONNECTING ROD
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Check Piston Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
ANALYZE PISTON RING WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
ANALYZE PISTON WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
CAMSHAFT AND TAPPETS
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
RECIPROCATING BALANCER
Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Bearing Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
crankshaft end play test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
CRANKSHAFT AND MAIN BEARINGS
Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
End Play Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
www.servicemanualall.com
5/31/96
3 - 3
ENGINEKAWASAKI FC420V(LX172/LX176) / FC540V(LX186)
CONTENTS
Page
REPAIR, continued
CRANKSHAFT OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
ANALYZE CRANKSHAFT AND CONNECTING ROD WEAR. . . . . . . . . . . . . . . . 3-67
CYLINDER BLOCK
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Deglaze Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Rebore Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
OIL PUMP
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
OIL FILTER MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
GOVERNOR SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
STATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
MAGNETO IGNITION COIL
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
Air Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
IGNITOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
MAGNETO IGNITION COIL WITH IGNITOR MODULE
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
Air Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
STARTER
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
Analyze Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
Starter No-Load Amperage Draw and RPM Bench Tests . . . . . . . . . . . . . . . . 3-74
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
Inspection/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
www.servicemanualall.com
CONTENTS
ENGINEKAWASAKI FD440V(LX178) / FD501V(LX188)
3 - 4
5/31/96
Page
ENGINEKAWASAKI FD440V(LX178) / FD501V(LX188)
SPECIFICATIONS
ENGINE DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
TEST AND ADJUSTMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
SPECIAL OR ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
SERVICE PARTS KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
COMPONENT LOCATION
EXTERIOR ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
INTERNAL ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
FUEL/AIR SYSTEM COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
THEORY OF OPERATION
LUBRICATION SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
COOLING SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92
TROUBLESHOOTING
TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
ENGINE TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
STARTER MOTOR TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . 3-100
TESTS AND ADJUSTMENTS
THROTTLE CABLE TEST AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 3-101
CHOKE PLATE TEST AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-101
GOVERNOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102
FAST IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103
SLOW IDLE SPEED ADJUSTMENT NON CARB/EPA ENGINES. . . . . . . . . . . . 3-103
SLOW IDLE SPEED ADJUSTMENT CARB/EPA ENGINES . . . . . . . . . . . . . . . . 3-104
CYLINDER COMPRESSION PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . 3-105
VALVE CLEARANCE TEST AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 3-106
CRANKCASE VACUUM TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107
ENGINE OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108
FUEL PUMP TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108
SPARK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110
SPARK PLUG GAP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110
COOLING SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110
RADIATOR CAP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111
REPAIR
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112
THROTTLE CONTROL LEVER AND CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114
www.servicemanualall.com
5/31/96
3 - 5
ENGINEKAWASAKI FD440V(LX178) / FD501V(LX188)
CONTENTS
Page
REPAIR, continued
CARBURETOR
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115
Clean/Inspect/Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-118
Float Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-118
INTAKE MANIFOLD
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-118
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119
FUEL PUMP
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119
RADIATOR
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120
COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
COOLING AIR DUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
THERMOSTAT
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
Opening Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122
COOLANT PUMP
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122
Disassembly/Inspection/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122
OVERFLOW RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123
ROCKER ARM ASSEMBLY
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124
CYLINDER HEAD AND VALVES
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
Inspection/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
ANALYZE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-127
RECONDITION VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128
LAP VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128
CRANKCASE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129
PISTON AND CONNECTING ROD
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131
Check Piston Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133
ANALYZE PISTON RING WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133
ANALYZE PISTON WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134
www.servicemanualall.com
CONTENTS
ENGINEKAWASAKI FD440V(LX178) / FD501V(LX188)
3 - 6
5/31/96
Page
REPAIR, continued
CAMSHAFT AND TAPPETS
Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136
CRANKSHAFT AND MAIN BEARINGS
Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-137
CRANKSHAFT OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-137
ANALYZE CRANKSHAFT AND CONNECTING ROD WEAR . . . . . . . . . . . . . . . 3-137
CYLINDER BLOCK
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138
Deglaze Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138
Rebore Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138
OIL PUMP
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-139
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-140
BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-141
GOVERNOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-141
GOVERNOR SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142
GOVERNOR SHAFT SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142
STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142
PULSER COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142
IGNITION COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143
IGNITION MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143
STARTER
Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143
Analyze Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143
No-Load Amperage Draw and RPM Bench Tests . . . . . . . . . . . . . . . . . . . . . 3-144
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-145
Inspection/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-146
www.servicemanualall.com
6/5/96
3 - 7
ENGINEKAWASAKI FC420V(LX172/LX176) / FC540V(LX186)
SPECIFICATIONS
TEST AND ADJUSTMENT SPECIFICATIONS
SLOW Idle
Carburetor SLOW Idle Stop Screw Setting . . . . . . . . . . . . . . . . . . . . . . 1450 75 rpm
Throttle Control Arm
SLOW Idle Stop Screw Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1550 75 rpm
FAST Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3350 100 rpm
Cylinder Compression Pressure (Minimum) . . . . . . . . . . . . . . . . . . . . . 483 kPa (71 psi)
Valve Clearance (Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Jam Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm (180 lb-in.)
Valve Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm (53 lb-in.)
Exhaust Valve ACR Movement (Minimum) . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Crankcase Vacuum (Minimum) . . . . . . . . . . . . . . . . . . .15 cm (6 in.) of water movement
Engine Oil Pressure (Minimum)
FAST Idle (3350 100 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 kPa (35 psi)
SLOW Idle (1550 75 rpm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.68 kPa (3 psi)
Fuel Pump Pressure (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12 kPa (0.90 psi)
Fuel Pump Flow (Minimum)
FC420V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 mL/15 seconds (1.8 oz/15 seconds)
FC540V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 mL/15 seconds (2.2 oz/15 seconds)
Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . 0.090.22 mm (0.0040.009 in.)
Spark Plug Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.)
Spark Plug Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm (177 lb-in.)
REPAIR SPECIFICATIONS
Rock Arm Assembly
Shaft O.D. (Minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.94 mm (0.509 in.)
Bearing I.D. (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.07 mm (0.515 in.)
Push Rod Bend (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.)
SPECIFICATIONS
ENGINE DESIGNATION
NOTE: LX172 and LX176 tractors use engine model number FC420V, LX186 tractor uses engine model number
FC540V.
F C 5 4 0 V
Four Cycle
Model Designation/
Variation A, B, C, D, etc.
Displacement
V -
G -
R -
D -
Vertical
Gear Drive off Camshaft
Gear Box Drive
Direct Drive
www.servicemanualall.com
3 - 8
6/5/96
SPECIFICATIONS
ENGINEKAWASAKI FC420V(LX172/LX176) / FC540V(LX186)
REPAIR SPECIFICATIONS (Continued)
Cylinder Head and Valves
Rocker Arm Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm (89 lb-in.)
Valve Adjustment Screw Jam Nut Torque. . . . . . . . . . . . . . . . . . . . 20 Nm (180 lb-in.)
Valve Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm (53 lb-in.)
Cap Screw Torque in Sequence (Lubricated)
at 7 Nm (62 lb-in.) Increments
Initial Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Nm (288 lb-in.)
Final Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Nm (456 lb-in.)
Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm (177 lb-in.)
Cylinder Head Distortion (Maximum) . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Valve Guide I.D. (Maximum)
FC420V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.015 mm (0.2762 in.)
FC540V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.07 mm (0.2780 in.)
Valve Seating Surface . . . . . . . . . . . . . . . . . . . . . . 1.101.46 mm (0.0430.057 in.)
Valve Spring Free Length (Minimum)
Early Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.50 mm (1.476 in.)
Late Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.50 mm (1.398 in.)
Valve Margin (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 mm (0.024 in.)
Valve Stem Bend (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.)
Valve Guide Installation Depth
FC420V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 0.1 mm (0.472 0.004 in.)
FC540V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 0.1 mm (0.370 0.004 in.)
Finished Valve Guide I.D. (Reamed) . . . . . . . . . . . 7.007.02 mm (0.2750.276 in.)
Valve Seat and Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Valve Narrow Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Breather Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm (0.0400.080 in.)
Crankcase Cover
Oil Capacity (w/Filter) FC420V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 L (3.4 U.S. pt)
Oil Capacity (w/Filter) FC540V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (4.0 U.S. pt)
Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (230 lb-in.)
Piston Assembly
Piston Ring Groove Side Clearance (Maximum)
Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.17 mm (0.007 in.)
Second Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Pin O.D. (Minimum)
Early Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.98 mm (0.865 in.)
Late Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.975 mm (0.747 in.)
Pin Bore I.D. (Maximum)
Early Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.04 mm (0.868 in.)
Late Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.042 mm (0.7497 in.)
Piston O.D.
Standard Piston. . . . . . . . . . . . . . . . . . . . . 88.8388.864 mm (3.48853.4984 in.)
Oversize Piston 0.50 mm (0.020 in.) . . . . . . 89.33089.364 mm (3.5173.518 in.)
Cylinder Bore I.D.
Standard Size Bore
Standard. . . . . . . . . . . . . . . . . . . . . . . . . . 88.9889.00 mm (3.50313.5039 in.)
Wear Limit (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.076 mm (3.5069 in.)
Oversize Bore0.50 mm (0.020 in.)
Standard. . . . . . . . . . . . . . . . . . . . . . . . . . 89.4889.50 mm (3.52283.5236 in.)
Wear Limit (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.576 mm (3.5266 in.)
www.servicemanualall.com
6/5/96
3 - 9
ENGINEKAWASAKI FC420V(LX172/LX176) / FC540V(LX186)
SPECIFICATIONS
REPAIR SPECIFICATIONS (Continued)
Piston Assembly (Continued)
Piston-To-Cylinder Bore Clearance . . . . . . . . 0.0110.151 mm (0.00430.0059 in.)
Connecting Rod
Connecting Rod Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . 20 Nm (177 lb-in.)
Crankshaft Bearing I.D. (Maximum)
Standard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.07 mm (1.617 in.)
Undersized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.56 mm (1.597 in.)
Piston Pin Bearing I.D. (Maximum)
Early Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.06 mm (0.869 in.)
Late Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.051 mm (0.750 in.)
Piston Rings
Ring ThicknessTop and Second Rings (Minimum) . . . . . . . . . 1.94 mm (0.076 in.)
Ring End Gap (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Ring End Gap (Maximum)
Compression RingsTop and Second
Early Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.90 mm (0.035 in.)
Late Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.059 in.)
Oil Ring Side Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30 mm (0.051 in.)
Camshaft
End Journal O.D.Cylinder Block (Minimum)
FC420V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.912 mm (0.7839 in.)
FC540V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.912 mm (0.8233 in.)
End Journal O.D.Crankcase Cover (Minimum)
FC420V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.912 mm (0.8233 in.)
FC540V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.912 mm (0.8233 in.)
Lobe Height (Minimum)
FC420V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.75 mm (1.446 in.)
FC540V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.10 mm (1.461 in.)
Bearing I.D.Cylinder Block (Maximum)
FC420V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.076 mm (0.7904 in.)
FC540V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.076 mm (0.8298 in.)
Bearing I.D.Crankcase Cover (Maximum)
FC420V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.076 mm (0.8298 in.)
FC540V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.076 mm (0.8298 in.)
ACR Tappet Lift (Minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 mm (0.024 in.)
ACR Disengagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600900 rpm
Reciprocating Balancer
Support Shaft Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Nm (65 lb-in.)
Link Rod
Journal O.D.On Crankshaft (Minimum)
FC420V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.950 mm (2.1240 in.)
FC540V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.941 mm (2.2811 in.)
Small End I.D. (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . 12.601 mm (0.4961 in.)
Large End I.D. (Maximum)
FC420V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.121 mm (2.1307 in.)
FC540V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.153 mm (2.2895 in.)
Bearing Installation Depth Below Surface (Both Ends) . . . . . . . . 1.0 mm (0.0394 in.)
Balancer Weight
Bearing I.D. (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.097 mm (1.0274 in.)
Bearing Installation Depth (Below Surface). . . . . . . . . . . . . . . . 0.50 mm (0.0197 in.)
Support Shaft
Shaft O.D. (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.927 (1.0208 in.)
www.servicemanualall.com
3 - 10
6/5/96
SPECIFICATIONS
ENGINEKAWASAKI FC420V(LX172/LX176) / FC540V(LX186)
REPAIR SPECIFICATIONS (Continued)
Crankshaft
Total Indicated Runout (TIR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Main Bearing Journal O.D.Crankcase Cover Side (Minimum)
FC420V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.919 mm (1.3747 in.)
FC540V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.904 mm (1.4923 in.)
Main Bearing Journal O.D.Cylinder Block Side (Minimum)
Both Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.945 mm (1.3757 in.)
Connecting Rod Journal O.D. (Minimum)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.928 mm (1.6113 in.)
Undersized . . . . . . . . . . . . . . . . . . . . . . . . . 40.4740.48 mm (1.59321.5937 in.)
Crankcase Cover Crankshaft Bearing I.D. (Maximum)
FC420V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.069 mm (1.3807 in.)
FC540V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.056 mm (1.4983 in.)
Oil Seal Installation Depth
Both Sides/Both Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .flush with surface
Oil Pump
Rotor Shaft O.D. (Minimum)
FC420V (Large O.D.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.627 mm (0.4971 in.)
FC420V (Small O.D.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.935 mm (0.3125 in.)
FC540V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.627 mm (0.4971 in.)
Rotor Shaft Bearing I.D. (Maximum)
FC420V (Oil Pump Cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.76 mm (0.5024 in.)
FC420V (Crankcase Cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.07 mm (0.3177 in.)
FC540V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.76 mm (0.5023 in.)
Outer Rotor
FC420V
Minimum Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.92 mm (0.4692 in.)
Minimum O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.95 mm (1.1397 in.)
FC540V
Minimum Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.92 mm (0.3905 in.)
Minimum O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.47 mm (1.5933 in.)
Outer Rotor Bearing Housing
FC420V
Maximum Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.14 mm (0.4779 in.)
Maximum I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.20 mm (1.1496 in.)
FC540V
Maximum Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17 mm (0.4003 in.)
Maximum I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.77 mm (1.6051 in.)
Relief Valve Spring Free Length (Minimum) . . . . . . . . . . . . . . . . 19.00 mm (0.7480 in.)
Governor
Governor Mounting Shaft Height . . . . . . . . . . . . . . 32.232.8 mm (1.2671.291 in.)
Governor Lever Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 Nm (69 lb-in.)
Engine Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . 34 Nm (300 lb-in.)
Blower Housing To Flywheel Screen Gap (Minimum). . . . . . . . . . . . . 1.5 mm (0.059 in.)
Flywheel Screen To Cooling Fan Cap Screw Torque . . . . . . . . . . . . . . 6 Nm (53 lb-in.)
Cooling Fan To Flywheel Cap Screw Torque . . . . . . . . . . . . . . . . . . . 10 Nm (89 lb-in.)
Flywheel Mounting Nut Torque
FC420V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Nm (101 lb-ft)
FC540V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Nm (127 lb-ft)
Oil Drain Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm (200 lb-in.)
www.servicemanualall.com
6/5/96
3 - 11
ENGINEKAWASAKI FC420V(LX172/LX176) / FC540V(LX186)
SPECIFICATIONS
REPAIR SPECIFICATIONS (Continued)
Stator
Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm (53 lb-in.)
Ignitor Module
FC420V-DS15 (FC420V FC420VB50632)
FC540V-DS15 (FC540V FC540VA00384)
No Specifications. . . . . . . . . . . . . . . . . . . . . replace with known good ignitor module
Magneto Ignition Coil
FC420V-DS10 (FC420V FC420VB50632)
FC540V-DS15 (FC540V FC540VA00384)
Resistance Between Primary Lead and Core . . . . . . . . . . . . . . . . . 0.480.72 ohms
Resistance Between Plug Cap and Core . . . . . . . . . . . . . . . . . . 10.916.3 K ohms
Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.)
Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm (53 lb-in.)
Magneto Ignition Coil With Ignitor Module
FC420V-DS10 (FC420VB50633 )
FC540V-DS15 (FC540VA00385 )
Resistance Between Primary Lead and Core . . . . . . . . . . . . . . . . . 0.480.72 ohms
Resistance Between Plug Cap and Core . . . . . . . . . . . . . . . . . . . 8.713.1 K ohms
Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.)
Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm (53 lb-in.)
Starter
Maximum Amperage (No Load) . . . . . . . . . . . . . . . . . . . . . . . . . 50 amps at 6000 rpm
Minimum Starter Brush Length
FC420V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.240 in.)
FC540V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 mm (0.413 in.)
Starter-To-Engine Mounting Cap Screw Torque . . . . . . . . . . . . . . . 16 Nm (140 lb-in.)
www.servicemanualall.com
3 - 12
6/5/96
SPECIFICATIONS
ENGINEKAWASAKI FC420V(LX172/LX176) / FC540V(LX186)
SPECIAL OR ESSENTIAL TOOLS
NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or in the
European Microfiche Tool Catalog (MTC).
JT07270 Digital PulseTachometer
Used to check SLOW and FAST idle speeds and starter performance.
JDM59 Compression Gauge
Used to check engine compression.
JT05697 Manometer Kit
Contains #5 plug and the following:
JT05703 Barb Fitting
Used to connect U-tube manometer to engine for Crankcase Vacuum Test.
JT05699 Line
Used to connect U-tube manometer to engine for Crankcase Vacuum Test.
JT05698 U-Tube Manometer
Used to check crankshaft vacuum.
JT03503 Crankcase Vacuum Test Kit
Used to check crankcase vacuum.
JT05698 90 Elbow Fitting
Used to connect pressure gauge to engine when performing Engine Oil Pressure Test.
JT03344 Pressure Gauge Assembly
Used to read engine oil pressure when performing Engine Oil Pressure Test.
JT03017 Hose Assembly
Used to connect pressure gauge to engine when performing Engine Oil Pressure Test.
JDG356 Pressure Gauge
Used to check fuel pump performance.
D-05351ST Spark Tester
Used to check overall condition of ignition system.
JDM70 Valve Spring Compressor
Used to remove and install valve springs.
JDG504 Valve Guide Driver Tool
Used to replace valve guide bushings.
JT05712 Current Gun
Used to check starter performance.
www.servicemanualall.com
6/5/96
3 - 13
ENGINEKAWASAKI FC420V(LX172/LX176) / FC540V(LX186)
SPECIFICATIONS
OTHER MATERIALS
Number
Name
Use
M79292
MPG-2 Multipurpose Polymer Grease
Apply to engine crankshaft.
SCOTCH-BRITE Abrasive
Sheets/Pads
Clean cylinder head.
Valve Guide Cleaner
Clean valve guides.
Stanisol (or Kerosene)
Finish ream valve guides.
Prussian Blue Compound
Check valve seat contact.
Lithium Base Grease
Pack oil seals.
Zinc Oxide/Wood Alcohol
Check block for cracks.
Mineral Spirits
Clean armature.
LOCTITE PRODUCTS
U.S./
Canadian/
LOCTITE No.
TY9375/TY9480/592
Pipe Sealant with TEFLON
Apply to threads of oil
pressure switch.
MPG-2 is a registered trademark of DuBois USA.
LOCTITE is a registered trademark of the Loctite Corp.
SCOTCH-BRITE is a registered trademark of the 3M Co.
SERVICE PARTS KITS
The following kits are available through your parts
catalog:
Fuel Pump Gasket Kit
Carburetor
Gasket Kit
Vent Kit
Jet Kit
Choke Shaft Kit
Throttle Shaft Kit
Breather Valve Kit
Air Cleaner Assembly
Blower Housing Engine Cover Kit
Flywheel Screen and Spacer Kit
Dipstick Tube Kit
Rocker Arm and Shaft Kit
Intake Valve Kit
Exhaust Valve Kit
Camshaft and Tappet Kit
Camshaft Axial Play Shim Kit
Piston Ring Kit
Oversized Piston
Oversized Piston Ring Kit
Undersized Connecting Rod
Crankshaft End Play Shim Kit
Cylinder Block
Overhaul Gasket Kit
Short Block Kit
Oil Pump Kit
Governor and Shaft Kit
www.servicemanualall.com
3 - 14
5/31/96
COMPONENT LOCATION
ENGINEKAWASAKI FC420V(LX172/LX176) / FC540VLX186)
COMPONENT LOCATION
EXTERNAL ENGINE COMPONENTS
Oil Pressure SwitchDipstickOil FilterDrain PlugSpark PlugRocker Arm CoverThrottle Control PanelAir Cleaner CoverStarterSolenoidCarburetorBlower HousingFlywheel ScreenCrankcase CoverCrankcaseVacuum HoseFuel PumpThrottle andGovernor LinkageCarburetorFuel ShutoffAir Cleaner HousingRIGHT FRONT VIEWLEFT REAR VIEWSolenoidChoke LinkageInlet HoseIgnition ModuleM45627
www.servicemanualall.com
5/31/96
3 - 15
ENGINEKAWASAKI FC420V(LX172/LX176) / FC540VLX186)
COMPONENT LOCATION
INTERNAL ENGINE COMPONENTS
M45811
Intake Valve
Valve Spring
Valve Guide
Exhaust Valve
Camshaft
Governor Shaft
Crankshaft Gear
Flywheel
Flywheel Nut
Stem Seal
Piston Pin
Cylinder Head
Main Bearing
Support Shaft
Balancer
Link Rod
Oil Seal
Spacer
Valve
Spring Retainer
Collets
Rocker Shaft
Rocker Arm
Adjusting Screw
Push Rod
Piston
Connecting Rod
Tappet
Rotator
Crankshaft
Ignition Coil
TOP VIEW
LEFT SIDE VIEW
www.servicemanualall.com
3 - 16
5/31/96
COMPONENT LOCATION
ENGINEKAWASAKI FC420V(LX172/LX176) / FC540VLX186)
OIL PUMP BREATHER AND COMPRESSION RELEASE COMPONENTS
M45812
BreatherBreatherMazeGovernorGovernor GearCamshaftShaftReliefOil PressureOuter RotorRelief Valve PlateOil Pump GearCoverScreenInner RotorAutomaticFly-WeightsFly-WeightsValveSpringRelief ValveCompressionRelease TabValveHoseTOP VIEWLEFT SIDE VIEWwww.servicemanualall.com
5/31/96
3 - 17
ENGINEKAWASAKI FC420V(LX172/LX176) / FC540VLX186)
COMPONENT LOCATION
FUEL/AIR SYSTEM COMPONENTS
M45665
Fuel Pump
Carburetor
Air Cleaner Cover
Paper Element
Blower Housing
Flywheel Screen
Flywheel Fan
Fuel Pump Outlet Hose
Vacuum Hose
Throttle Control Panel
Choke Linkage
Throttle Linkage
Governor Arm
Air Cleaner Base
Air Cleaner Housing
Foam Element
Fuel Filter
Fuel Pump Inlet Hose
LEFT REAR VIEW
www.servicemanualall.com
3 - 18
5/31/96
THEORY OF OPERATION
ENGINEKAWASAKI FC420V(LX172/LX176) / FC540VLX186)
THEORY OF OPERATION
LUBRICATION SYSTEM OPERATION
Function:
To provide pressurized oil to lubricate internal engine
components.
Theory of Operation:
A positive displacement gerotor pump is used to
pressurize the lubrication system. The oil pump is
driven directly off the crankshaft gear. The lubrication
system is protected by an oil pressure relief valve, low
oil pressure switch, and an oil filter with bypass.
The oil pump draws oil from the sump through the pick-
up screen. Pressure oil from the pump flows through
the pump outlet passage past the oil pressure relief
valve. The oil pressure relief valve limits the oil
pressure to approximately 296 kPa (43 psi) and
protects the oil pump from damage if an oil passage
becomes blocked. If oil pressure exceeds 296 kPa (43
psi), the relief valve opens allowing oil to return to
sump. Relief valve is not adjustable.
Pressure oil from the relief valve flows to the oil filter.
The filter contains a bypass valve which opens if the
element becomes plugged
to ensure engine
lubrication.
An oil pressure switch mounted in the oil filter manifold
turns on a warning light if oil pressure is below 28 kPa
(4 psi). Filtered pressure oil flows through a passage in
the oil sump to the crankshaft main bearing (PTO side)
and then to the camshaft bearing. Drilled passages in
the crankshaft distribute oil from the main bearings to
the lower balancer link, connecting rod journal, upper
balancer link, and crankshaft ball bearing (flywheel
side). A drilled passage in the connecting rods allow oil
from the connecting rod journal to lubricate the piston
and cylinder walls.
Pressure-free oil flowing out of the crankshaft ball
bearing or upper balancer link also lubricates the
balancer. A drilled passage in the top of the balancer
allows oil to flow to the support shaft and balancer
bushing.
The rocker arms, valves, and pushrods are lubricated
by an oil/air mixture and carried to the rocker arm cover
through the breather passage. The breather passage is
located directly above the upper pushrod. The oil from
the oil/air mixture is separated from the air through the
breather maze and flows to the bottom of the cylinder
head. This oil drains back to the sump through an oil
return passage located in the bottom of the cylinder
block directly under the lower pushrod.
www.servicemanualall.com
5/31/96
3 - 19
ENGINEKAWASAKI FC420V(LX172/LX176) / FC540V(LX186)



@
@
@






y
y
y
M48880
Connecting
Connecting
Crankshaft
Pick-Up Screen
Oil Pump
Oil Pressure
Oil Filter
Oil
Camshaft
Crankshaft
Breather
Oil Return
Upper
Balancer
Lower
Oil Pump Gear
Relief
Upper
Passage
Ball Bearing
Balancer
Link
Passage
Balancer
Link
Balancer
Link
Valve
Spring
Relief Valve
Oil/Air Mixture
Pressure-Free Oil
Pressure Oil
Pressure
Switch
Main Bearing
Bearing
Rod Passage
Rod Journal
Connecting
Rod Journal
Crankshaft
Main Bearing
Lower
Balancer
Link
Oil Pump Gear
Oil Pressure
Relief Valve
Oil Pump
Pick-Up Screen
Balancer
Camshaft
Bearing
Crankshaft
Ball Bearing
www.servicemanualall.com



Thank you very much
for your reading.
Please Click Here
Then
Get
More
Information.