Caster Kit

1. Shut off the engine, wait for all moving parts to stop, and allow the machine to cool.

2. Disconnect the wire from the spark plug.

3. Lift the front of the machine using an appropriate lifting device or jack stands.

   Note: If using jack stands, use the front lip of the deck to hold the machine up. Place blocks behind the rear wheels to prevent the machine from moving.

Remove the wheel nuts securing the front wheels. Remove the wheels from the wheel bolts and retain the wheels.

Figure 1

1. Locknut (2)

1. Remove the engine shield and arms.

   1. Remove the engine shield. Retain it and the fasteners for later installation.

      

      Figure 2

      1. Engine shield
      2. Bolt
      3. Washer
      4. Locknut

   2. Remove the carriage bolts securing the engine shield arms to the height-of-cut brackets and the bumper assembly. Remove and discard the engine shield arms.

      Retain the height-of-cut bracket fasteners for later installation.

      

      Figure 3

      1. Locknut
      2. Carriage bolt
      3. Engine shield arm

2. Remove the fasteners securing the front bumper assembly to the deck.

   Retain the fasteners for later installation.

   

   Figure 4

   1. Locknut
   2. Carriage bolt
   3. Front bumper assembly

3. Remove the front bumper assembly.

   

   Figure 5

Remove the 4 flange-head bolts securing the belt cover. Remove the belt cover and retain the bolts for later installation.

Note: If your machine has a Kohler^® engine, a push-in fastener instead of a bolt will be in the rearmost hole of the belt cover.

Figure 6

Kawasaki® model shown

1. Belt cover
2. Flange-head bolt

Figure 7

Kawasaki® model shown

Parts needed for this procedure:

1. Install the right belt cover to the deck using the previously removed bolts or fasteners.

   

   Figure 8

   1. Right belt cover
   2. Previously removed bolts or fasteners
   3. Ensure that the tabs are inserted into the belt cover.
   4. Left belt cover

2. Slide the tabs of the left belt cover into the right belt cover. Secure the left belt cover using the remaining fasteners.

   Note: Ensure that the tabs are inserted into the belt cover, not over the top of the belt cover.

Parts needed for this procedure:

Install the previously removed wheels to the caster forks on the front caster assembly using 2 hex-head bolts (3/8 x 3-3/4 inches), 2 washers and spacers, and 2 locknuts (3/8 inch). Torque the locknuts to 37 to 44 N·m (27 to 33 ft-lb).

Figure 9

1. Hex-head bolt (3/8 x 3-3/4 inches)
2. Spacer
3. Wheel
4. Washer
5. Locknut (3/8 inch)
6. Front caster assembly

Note: If the bolt does not go through the holes in the caster fork, flex the wheel slightly so that the bolt and holes are aligned, then push the bolt through.

Parts needed for this procedure:

1. Drill 2 holes (8 mm or 5/16 inch) into the front of the deck as shown in Figure 10.

   

   Figure 10

   1. 12.4 cm (4-7/8 inches)
   2. 8 mm (5/16 inch) hole

2. Secure the height-of-cut plate to the holes in the deck using 2 hex-head bolts (5/16 x 7/8 inch) and 2 locknuts (5/16 inch). Torque the locknuts to 20 to 25 N·m (175 to 225 in-lb).

   

   Figure 11

   1. Hex-head bolt (5/16 x 7/8 inch)
   2. Height-of-cut plate
   3. Locknut (5/16 inch)

Parts needed for this procedure:

1. Install the assembled front caster assembly from Assembling the Front Caster Assembly to the front of the deck using carriage bolts (5/16 x 3/4 inch) and locknuts (5/16 inch) previously removed in step 2 of Removing the Bumper Assembly.

   

   Figure 12

2. Using the caster bracket tabs as a template, drill 2 holes (8 mm or 5/16 inch) into the top of the deck as shown in Figure 13.

   

   Figure 13

   1. 8 mm (5/16 inch) hole through caster tabs
   2. Top of deck

3. Insert 2 hex-head bolts (5/16 x 7/8 inch) through the top of the deck and secure with 2 locknuts (5/16 inch). Torque the locknuts to 20 to 25 N·m (175 to 225 in-lb).

   

   Figure 14

   1. Locknut (5/16 inch)
   2. Hex-head bolt (5/16 x 7/8 inch)

4. Install 2 engine guard brackets to the sets of holes at the front of the mower using the 4 carriage bolts and 4 locknuts previously removed in step 2 of Removing the Bumper Assembly.

   

   Figure 15

   1. Locknut
   2. Carriage bolt
   3. Engine guard bracket

5. Install 2 engine guard arms to the height-of-cut brackets using the 2 carriage bolts and 2 locknuts previously removed in step 2 of Removing the Bumper Assembly. Torque the locknuts to 20 to 25 N·m (175 to 225 in-lb).

   

   Figure 16

   1. Carriage bolt (5/16 x 3/4 inch)
   2. Locknut (5/16 inch)
   3. Engine guard arm
   4. Previously removed locknut
   5. Previously removed carriage bolt

6. Using 4 carriage bolts (5/16 x 3/4 inch) and locknuts (5/16 inch), secure the engine guard arms to the engine guard brackets. Torque the locknuts to 20 to 25 N·m (175 to 225 in-lb).

7. Install the engine shield to the engine guard arms using the 2 hex-head bolts, 2 washers, and 2 locknuts previously removed in step 1 of Removing the Bumper Assembly.

Figure 17

The cutting height is controlled by the front pin and the rear lever. The pin is at the front of the machine, and the lever is on the left side of the machine. To raise or lower the machine, remove the pin and engage the lever, raise or lower the machine, and lock the pin and disengage the lever.

1. Lift the caster lock pins.

2. Turn and insert the pins into the holes on the axle.

Reverse the process to lock the casters.

Note: Lock the casters when you want the front wheels to remain straight (for example, when mowing the side of a hill).

Figure 18