Belt Kit

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Shut off the engine.

4. Disconnect the spark plug wire from the spark plug.

Note: Discard all removed parts unless indicated otherwise.

1. Remove the 2 bolts, 2 washers, and belt guard (Figure 1).

   

   Figure 1

   1. Belt guard
   2. Washer—0.38 x 0.75 x 0.08 inches (2)
   3. Bolt—3/8 x 1 inch (2)
   4. Belt

2. Loosen, or remove and retain, the 4 carriage bolts, 4 washers, and 4 locknuts securing the engine to the frame (Figure 2).

   

   Figure 2

   Front fasteners shown

   1. Jam nut
   2. Locknut—5/16 inch (4)
   3. Washer—0.38 x 0.73 x 0.07 inches (4)
   4. Carriage bolt—5/16 x 1-1/2 inches (4)

3. Loosen the jam nut on the tensioner bolt (Figure 2).

4. Remove the belt (Figure 1).

5. Remove the clutch pulley (Figure 3).

   Note: Remove and retain the square key for later installation.

   

   Figure 3

   1. Square key
   2. Clutch pulley
   3. Washer (0.81 x 2.00 x 0.15 inches)
   4. Washer (0.39 x 1.25 x 0.12 inches)
   5. Washer (0.31 x 0.75 x 0.08 inches)
   6. Bolt (5/16 x 3/4 inch)

6. Remove the front pulley (Figure 4).

   

   Figure 4

   1. Set screw
   2. Front pulley
   3. Square key

7. Remove the guard plate (Figure 5).

   

   Figure 5

   1. Flange bolt—5/16 x 3/4 inch (3)
   2. Locknut—5/16 inch (3)
   3. Guard plate

8. Remove the cutter wheel (Figure 6).

   

   Figure 6

   1. Bolt—3/8 x 1-1/2 inches (4)
   2. Washer—0.40 x 0.81 x 0.11 inches (8)
   3. Bearing assembly (2)
   4. Locknut—3/8 inch (4)
   5. Cutter wheel

Parts needed for this procedure:

Refer to the Installation Instructions for the kit to install the wheel teeth to the cutter wheel.

Parts needed for this procedure:

1. Slide a bearing assembly onto the shaft on both sides of the cutter wheel and follow the instructions provided with the bearing assemblies (Figure 7).

   

   Figure 7

   1. Bolt—3/8 x 1-1/2 inches (4)
   2. Washer—0.40 x 0.81 x 0.11 inches (8)
   3. Bearing assembly (2)
   4. Locknut—3/8 inch (4)
   5. Cutter wheel

2. Secure the bearings to the frame of the machine using 4 bolts (3/8 x 1-1/2 inches), 8 washers (0.40 x 0.81 x 0.11 inches), and 4 locknuts (3/8 inch) as shown in Figure 7. Torque to 60 to 76 N∙m (44 to 56 ft-lb).

3. Install the guard plate using 2 flange bolts (5/16 x 3/4 inch), 1 carriage bolt (5/16 x 3/4 inch) and 3 locknuts (5/16 inch) as shown in Figure 8.

   

   Figure 8

   1. Flange bolt—5/16 x 3/4 inch (2)
   2. Locknut—5/16 inch (3)
   3. Guard plate
   4. Carriage bolt (5/16 x 3/4 inch)

4. Apply thread-locking compound to the bolt (1/4 x 3/4 inch) and use the bolt, washer (0.27 x 0.89 x 0.09 inches), and square key to install the front pulley, with the pulley face flush with the end of the shaft (Figure 9). Torque the bolt to 13.6 N∙m (120 in-lb).

   

   Figure 9

   1. Set screw
   2. Square key
   3. Bolt (1/4 x 3/4 inch)
   4. Washer (0.27 x 0.89 x 0.09 inches)
   5. Front pulley

5. Apply thread-locking compound to the set screw, and secure the pulley with the set screw, washer (0.27 x 0.89 x 0.09 inches), and bolt (1/4 x 3/4 inch) as shown in Figure 9. Torque the setscrew to 14.9 to 17.6 N∙m (132 to 156 in-lb).

6. Apply thread-locking compound to the bolt (5/16 x 1-1/8 inch) and use the bolt, 2 washers (0.76 x 1.26 x 0.07 inches), 1 washer (0.32 x 1.12 x 0.18 inches), 1 washer (0.31 x 0.78 x 0.07 inches) and the square key to install the clutch pulley (Figure 10). Torque the bolt to 22.6 to 28.2 N∙m (200 to 250 in-lb).

   

   Figure 10

   1. Washer (0.76 x 1.26 x 0.07 inches)
   2. Clutch pulley
   3. Square key
   4. Washer (0.32 x 1.12 x 0.18 inches)
   5. Washer (0.31 x 0.78 x 0.07 inches)
   6. Bolt (5/16 x 1-1/8 inch)

7. Install the belt around the front pulley and clutch pulley (Figure 13).

8. Tighten the jam nut on the tensioner bolt (Figure 11).

   

   Figure 11

   Front fasteners shown

   1. Jam nut
   2. Locknut—5/16 inch (4)
   3. Washer—0.38 x 0.73 x 0.07 inches (4)
   4. Carriage bolt—5/16 x 1-1/2 inches (4)

9. Push down on the belt to check the tension (Figure 12). You should be able to push the belt down 5.6 mm (0.22 inch) using 3.4 kg (7.4 lb) of force. Adjust the tensioner bolt as necessary to tighten or loosen the belt.

   

   Figure 12

   1. Belt without force
   2. Belt with 3.4 kg (7.4 lb) of force

10. Install or tighten the fasteners securing the engine to the frame (Figure 11).

    Note: Ensure that the engine does not twist in the chassis and the clutch pulley is aligned with the belt.

11. Install the belt guard using 2 bolts (3/8 x 1 inch) and 2 washers (0.38 x 0.75 x 0.08 inches) as shown in Figure 13.

    

    Figure 13

    1. Belt guard
    2. Washer—0.38 x 0.75 x 0.08 inches (2)
    3. Bolt (3/8 x 1 inch)
    4. Belt

Parts needed for this procedure:

Install a new decal over the existing decal on the wing bracket as shown in Figure 14.

Figure 14

1. Decal