Muffler and Spark Arrester Kit

Z Master® Series Riding Mowers

Model No. 105-1678-Serial No. and Up

Model No. 105-1679-Serial No. and Up

Model No. 105-3633-Serial No. and Up

Important: When you finish installing the spark arrester, store these Installation Instructions with your Operator’s Manual for future reference.

Installation

Preparing the Machine

  1. Park the machine on a level surface.

  2. Move the motion-control levers to the NEUTRAL-LOCK position.

  3. Engage the parking brake.

  4. Shut off the engine and remove the key.

  5. Allow the machine and engine to cool completely.

Removing the Muffler

  1. Remove the muffler heat shield.

  2. Remove the 4 nuts and lock washers securing the muffler to the studs on the engine.

  3. Remove the old muffler and gaskets from the engine and ensure that you clean all the pieces of the gaskets off the engine exhaust manifold.

Installing the Cable Heat Shield

For Models 74240 and 74241

Parts needed for this procedure:

Cable heat shield1
Bolt (1/4 x 3/4 inch)1
Locknut (1/4 inch)1

  1. Remove the bolt below the cable bracket that is installed to the engine (Figure 1).

  2. Install the cable heat shield below the cable bracket using the bolt removed in step 1 (Figure 1).

    Ensure that you install the cable heat shield between the muffler and cable bracket.

  3. Install the bolt (1/4 x 3/4 inch) in the top of the cable bracket and into the cable heat shield (Figure 1).

  4. Secure the bolt (1/4 x 3/4 inch) using the locknut (1/4 inch) as shown in Figure 1.

    g006626

    Figure 1

    1. Cable heat shield (installed)
    2. Cable bracket
    3. Cable
    4. Bolt below the cable bracket
    5. Bolt (1/4 x 3/4 inch)
    6. Locknut (1/4 inch)
    7. Engine

Installing the Muffler

Parts needed for this procedure:

Muffler1
Gasket2

  1. Slide the 2 new gaskets over the studs on the engine.

  2. Install the new muffler to the studs on the engine, securing it tightly using the previously removed lock washers and nut (Figure 2).

  3. Install the muffler heat shield (Figure 2).

    g006627

    Figure 2

    1. Muffler
    2. Gaskets
    3. Nut
    4. Washer
    5. Cable heat shield (installed)
    6. Cable

Installing the Spark Arrester

Parts needed for this procedure:

Spark arrester1
Self-threading screw (#8 x 1/2 inch)2

Warning

Hot exhaust system components may ignite fuel vapors even after shutting off the engine. Hot particles exhausted during engine operation may ignite flammable materials. Fire may result in personal injury or property damage.

Do not refuel or run the engine unless the spark arrester is installed.

  1. Install the screw hole end of the spark arrester on the exhaust outlet as far as possible by hand.

    Important: Do not use a hammer; otherwise, you will damage the spark arrester.

  2. Secure the spark arrester to the muffler using the 2 self-threading screws (#8 x 1/2 inch) as shown in Figure 3.

    g355094

    Figure 3

    1. Spark arrester
    2. Self-threading screw (#8 x 1/2 inch)

Maintenance

Maintaining the Spark Arrester

Keep this Sheet with the Operator’s Manual for Future Reference
Maintenance Service IntervalMaintenance Procedure
Every 50 hours
  • Inspect the spark arrester for damage or build-up on the screen.
    		•

    1. Park the machine on a level surface.

    2. Move the motion-control levers to the NEUTRAL-LOCK position.

    3. Engage the parking brake.

    4. Shut off the engine and remove the key.

    5. Wait for the muffler to cool completely.

    6. If you observe any breaks in the screen or welds, replace the spark arrester.

    7. If the screen is plugged, remove the spark arrester and remove the loose particles from the spark arrester and clean the screen using a wire brush (soak in solvent, if necessary).

      Install the spark arrester to the exhaust outlet.