2008 update manual - boettcher supply, inc · 2008 update manual kohler kawasaki overly aggressive...

2008 Update Manual

Copyright Shivers Mfg, 2008

2008 Update ManualKohler

KawasakiOverly Aggressive Transmissions

Boss SR1200 Belt IssuesJoystick Construction

Twinstick ConstructionClutchesSpindlesMufflers

Boss 60 Inch DeckAdjusting Travel

DampenersElectrical

Replacement Parts

2008 Country Clipper Update Manual

Kohler

1 2

3 4

Remember the BasicsSparkFuelCompressionTimingAirKeep a Troubleshooting Guide Nearby

Kohler Engines

Kohler Engines Kohler Engines

Smoking (Blue, Black, White)Leaking OilEngine Will Not CrankCranks But Will Not StartExcessive Engine NoiseAfter-BangBackfire While RunningRuns RoughlyLow PowerHunting/Surging

Common Causes of Engine Troubles

Smoking (Blue - Oil Consumption)Incorrect Oil Viscosity/TypeCrankcase OverfilledWorn Engine ComponentsNormal WearAbuseHead Gasket Failure

Smoking (Blue - Oil Consumption)Breather problemCrankcase Not SealedBreather Reed Not Seating(Broken)Oil Return PluggedAssembled WrongOil Ring Failure Due to Overheating

5 6

7 8

Smoking (Blue – Fuel)Old/Seasonal FuelWinter/Summer Blend FuelFuel AdditivesAged FuelSmoke Will Smell Like Fuel



Smoking (White – Rich Running)Normally at Start-UpCarburetor MalfunctionPlugged Vent in Fuel CapOil in Combustion Chamber

Leaking OilOil Level Too HighCrankcase PressureGasket or Seal LeakCrack/Hole in BlockStructural Failure

Engine Will Not CrankLoose or Corroded ConnectionsSafety Interlock SwitchDead/Weak BatteryWrong Key Switch

9 10

11 12



Cranks But Will Not StartFuel, Spark or CompressionChoke Closed (All the Way)Cam Worn or Out of TimeFuel Cap Not VentedCranks But Will Not StartBattery Connected BackwardsBlown Diode in Harness

Excessive Engine NoiseLow or No OilIncorrect or Inadequate OilLow or No Oil PressureWrong Viscosity OilFaulty LiftersImproper Valve LashFailed Compression Release

Smoking (Black – Over Fueling)Choke Partially Closed or MisadjustedCarburetor MalfunctionFloat Set Too HighNeedle & Seat Not SealingAir Jets PluggedPlugged Vent in Fuel CapWeak Spark at Spark PlugAir Filter Plugged

13 14

15 16

After-Bang (Backfire)Improper ShutdownGoverned Idle Not Set CorrectlyPlugged or Damaged MufflerBackfire While RunningPlugged or Damaged MufflerWater in FuelCam Lobe WornValve Not SealingBurnedStickingLifter pumped



Runs Rough - Will Not AccelerateLeaking IntakeCarburetor IssueFloat Set Too LowBuild-Up or Obstructions in JetsImproper Fuel MixtureE85 BlendsFuel AdditivesWeak Spark or Ignition TimingCam Timing or Worn LobesLow PowerGovernor SettingIntake Gasket Leak (Lean Running)Restricted or Damaged Exhaust SystemWorn Cam LobeExternal LoadFuel Supply IssuesRestricted Air Cleaner

Hunting/SurgingGovernorInitial Adjustment Spring LocationBinding or FrictionLean ConditionFuel Supply Issues

17

19

18

20

Leakdown Tester - 25 761 05-SPurposeTo determine if valves or rings are leaking by using pressurized air in the combustion chamber.

Leakdown Tester - 25 761 05-SInstructions (cont.)7. Adjust the regulator knob until the gauge needle is in the yellow “set” area at the low end of the scale.8. Connect the tester to the adapter hose while firmly holding the engine at TDC.9. Note the gauge reading and listen for escaping air from the carburetor, exhaust and breather hose.

Leakdown Tester - 25 761 05-S

The gauge reading indicates the severity of the leak.Air Escaping From: Cause

Crankcase Breather Leak Past Rings or Head Gasket Internally

Exhaust Leaking Exhaust Valve

Carburetor Leaking Intake Valve

Tools and Aids Tools and AidsLeakdown Tester - 25 761 05-S

Instructions1. Run Engine For 3-5 Minutes to Warm Up2. Remove Spark Plug(s) and Air Filter4. Rotate Crankshaft Until Piston is at TDC on Compression Stroke5. Ensure Crankshaft is Locked in Position to Continue Testing5. Install Adapter Hose into Spark Plug Hole.6. Connect Air Source of at Least 50 psi to TesterTools and Aids Tools and Aids

21 22

23 24

Vacuum/Pressure Gauge - 25 761 22-SPurposeTo identify the amount of either pressure or vacuum in the crankcase.

Vacuum/Pressure Gauge - 25 761 22-SInstructions1. Insert the rubber stopper with gauge into the oil fill hole. Note: Make sure the gauge is at “0” reading.2. Start the engine and run at no-load high idle speed (3200-3750 RPM)3. Observe the gauge reading. Movement to the left of “0” is vacuum, and movement to the right indicates pressure.4. Correct crankcase vacuum should be a minimum of 4 Inches of Water Column

Ignition Tester 18Kv - 24 455 02-SPurposeThe 18Kv is used to test for strong, consistent spark output on CD ignition systems.Use when testing Courage and Command Twinignition systems.

Ignition Tester 18Kv - 24 455 02-SThe 18Kv is used to test sparkon CD ignition systems.Use this tester whenchecking Courage and Command Twin.

Tools and Aids Tools and Aids


25 26

27

Ignition Tester 18Kv - 24 455 02-SInstructions1. Disconnect high tension lead of the ignition to be tested from the spark plug.2. Install the lead onto the appropriate tester.3. Connect the ground clip of the tester to a secure ground location on the block. 4. Engage the starter and observe the spark at the tester. You should find a good blue consistent spark.

Oil Pressure Test Kit - 25 761 06-SPurposeTo check oil system pressure at the oil filter, or any location where a 1/8” pipe tap is accessible.

Oil Pressure Test Kit - 25 761 06-S

Instructions1. With engine off, remove the oil filter and install test adapter with gauge. A two foot hose is supplied in the kit and can be installed between the gauge and adapter.2. Some engines offer alternate locations to check oil pressure. If this is an option, remove the 1/8” pipe plug and install the test gauge.3. Start the engine and observe the reading on the gauge. Minimum oil pressure is 20psi @ 3200 RPM and 6psi @ low idle.


Tools and Aids


Kawasaki

1 2

3 4

Necessary Diagnostic Tools

Verify Combustion Chamber ConditionCylinder, rings, valvesUse this test when the engine has:Oil consumptionLow powerHard startingOil leaking from lower crank case seal(vertical engines only)Excessive oil from the carburetor air box

Leak Down Tester

Use this test when the engine has:Broken recoil studsHard starting problemsElectric starter failuresDetonationOil consumptionLow powerFor engines with an ACR, typical compression measurements may not be greater than 95psi.

Compression Tester Simulates Running PressureNo need to disassemble the engineCheck system for its ability to hold pressureIf system does not hold pressure, try to determine leak location with out disassembling the engine

Coolant Pressure Tester

5 6

7 8

Use Before Engine Disassembly Helps find hairline cracksLeaks that might go undetectedIs it the head gasket or the cylinder head that is leaking?If necessary, disassemble the engine and inspect

Coolant Leak Detector

See what the ECU is seeing Used to measure circuit voltage or resistance

ECU Adaptor

Verify Circuits/ComponentsSee Service Manual for specificationsDigital MetersReadings may very from Service Manual

Multi-Meters

The adjustable gap spark testerSimulates combustion chamber conditions by loading the coil

Running Gap TesterCan help detect intermittent sparkDoes not give an indication of the quality of the spark

Spark Testers

9 10

11 12

Clear Fuel LineTachometer

Auxiliary Fuel Supply

Isolates the engine from the fuel supplyGravity feed the carburetor directly

Verify Fuel SupplyBenefitsSaves timeReadily availableinexpensive

Engine speed is important for:PerformanceSafetyIs determined by the OEM

13 14

15 16

Fuel and CarburetionFirst, engine must be mechanically soundVisual InspectionFuel leaks InletBowl gasketPorosity Check for air leaks atGasketsThrottle / choke shaft

Fuel Troubleshooting

Manually control throttle shaftCarburetor or governor? Verify condition by applying the chokeDoes engine smooth out?Minor restrictions can cause thisCould it be a leaking gasket?

Surging

• Small amounts of contamination in the idle circuitry can cause the engine to surge.

Contamination

17 18

19 20

Choke does not smooth out engineGovernor presetWorn linkageWorn governor platesWorn bushing

Governor Surge

Correct air filter ? Was a canister air filter installed?Were the high speed jets changed?Before cleaning or replacing the carburetor, check:Cylinder leak-down Valve lashIgnition coilsChokeOil conditionExhaust system

Rich Running

Electrical Systems And Troubleshooting

Troubleshooting electrical systems can be difficult.

• Make sure you have the Service Manual

• It is helpful to break the systems down

- Charging system

- Ignition system

- Starting system

• Use a systematic approach

Engine Electrical Systems

21 22

23 24

Focus on what is needed

•Photo copy diagram

•Highlight suspect circuit

Charging systemIncludes

•Flywheel inside magnets

•Stator coil

•Regulator

•Fuses

•Key switch

•Battery

•Machine harness

•Grounding circuit

Does not include

•Any part of the ignition circuit

•Fuel injection circuit

Most common15 Amp systemOne long copper windingInsulated from the stator frameOne wire Magnetic field rotates - AC voltage at ends

Out to regulator

C D

15 Amp Charging System

Charging SystemBreak Systems Down

Testing the 15 Amp systemCheck the Stator output AC VoltageCheck the stator resistanceCheck for a short to ground on the statorCheck for battery voltage at the regulatorMore than ½ volt difference indicates machine harness issueIf all good then regulator is failed Stator good if

output above 26v AC @ 3000 RPM


25 26

27 28

Rectifies AC to DCChanges stator output to pulsating DCDC pulsations are smoothed by batteryRegulates outputSenses system voltage and system needsExcessive power is shorted to groundAC

From Stator

DCFrom and to battery

15 Amp Regulator Rectifier

Used to by pass machine harness15 amp fuse, wire, connectorsRemove harness connection at regulator output tabAttach by-pass harness to battery positive terminal then to regulatorIf system now works failure is in machine harness+-

Charging System Test Harness

System similar to 15 amp systemStator AC outputRectifies AC to DCChanges stator output to pulsating DCDC pulsations are smoothed by batteryRegulates outputSenses system voltage and system needsExcessive power is shorted to ground


•What do the wires do?– Stator input two black

wires– Orange OEM optional

charging light– Gray engine ground– Red regulator output– Yellow system voltage

sensor


29 30

31 32

Before replacing regulator verifyBattery and stator goodWith key switch on check:Record battery voltageMeasure voltage at yellow and red terminals - use gray wire as groundShould match batteryIf similar voltage at both terminals and no system voltage increase then bad regulator

20 Amp Battery Not Charging

Suppose the battery was overchargedCheck for battery voltage at yellow terminalBad connection in sensing circuit can add resistanceKey switchesCorrosionFuse connections

20 Amp Overcharge

Clutch coilTwo shorter windingsSecured to stator frame at one endMagnetic field rotates - AC changed to DC with diodesClutch coil testingTEST MACHINE FIRST!!!Testing open circuit voltage may yield 40 volts DC or more Electrical output is load dependentVoltage will vary with RPM and clutch load To machine wire harness

A

Clutch Coil

Winding 1

Winding 2

DC supply to machine wire harness

A

Full wave AC from Winding 2.

Full wave AC from Winding 1.

Half wave pulsating DC from Winding 1.

Half wave pulsating DC from Winding 2.

Full wave pulsating DC from Windings 1 & 2.

Clutch Coil

33 34

35 36

Power limited by...Number of windingsSize of windingsMagnetic field strengthSpeed of rotating magnetic fieldCaused by arcing from

corrosion - NOT overcharging

None of these can improve over time to increase Stator output!!

Magneto Ignition systemIncludes

•Flywheel outer magnet

•Ignition coils/Leads

•Plugs

•Stop circuit

-Key switch

-Wire harness

-Operator safeties

Does not include

•Flywheel inside magnets

•Stator

•Regulator

•Fuses

•Battery

Stator Output Break Systems Down

Key Switch

Machine Safety

Interlocks

Magneto Ignition

Key Switch

Note:

Diodes are shown externally for clarity.

RUN•Key switch is open

•Flywheel rotates clockwise

•Plugs fire on every revolution

Magneto Ignition -normal operation

37 38

39 40

Key Switch



•Plugs fire on every rotation

•Coil #2 trigger connects primary coil to ground causing spark plug to fire

•Diode on Coil #1 prevents accidental grounding of Coil #2


Key Switch




•Coil #1 trigger connects primary coil to ground causing spark plug to fire

•Diode on Coil #2 prevents accidental grounding of Coil #1

Key Switch




Key Switch

OFF•Key switch is closed

•Coil voltage shorts to ground, preventing trigger operation




41 42

43 44

Key Switch



Diode on Coil #1 is shorted, grounding Coil #2

•Coil #1 operates normally

•Coil #1 must be replaced to restore normal operation of Coil #2

Magneto Ignition -no spark one side



Diode on Coil #2 is shorted, grounding Coil #1

•Coil #2 operates normally

•Coil #2 must be replaced to restore normal operation of Coil #1

Key Switch

#2 #1

Note:

Diodes are shown externally for clarity.

Magneto Ignition -no spark one side

Check system voltageCheck statorCheck harnessCheck regulator

Review-Charging Systems

Know your systemCheck for sparkCheck harnessCheck air gapCheck magnets

Review-Ignition Systems


Overly Aggressive Transmissions

Boss Shift Linkage Inspection And

Possible Reverse Shock Valve Replacement

This procedure is for only Boss SR1200 or Boss SR1205 Series Mowers.

Remove side panels.

Check the dampeners to make sure the mower has the correct ones. The joystick dampener (H-2467) has maroon writing and the part number.

Check all linkages; make sure all the ball joints are moving freely. Check for radial (up and down) slack in the cross shaft.

Check the whemotor mountintoo tight.

2 1

4 3

Brake Band

Mounting Bolt

el hubs to see if they are dragging against the wheel g bolts. At this time check the brakes to see if they are

Check the joystick. Test the dampeners in light and heavy position.

Check the shift levers on the pump to see if they are broken. Replace any broken parts.

Remove the fan covers for better accessibility.

Move the joystick forward or back to move the shift lever out of the way to expose the shock valve.

5 6

7 8

10

If necessary, replace the shock valve only on the reverse side of the pump. The reverse side is the outside or shift lever side of the pump.

Remove the old shock valve. The numbers will read

New shock valve with The numbers will read

9

Old Shock Valve - 031

New Shock Valve – 044

11 12

200 031

spring and plug.

200 044

14

Insert shock valve and spring into plug.

Use a torque wrench to torque the shock valve. Torque the valve to 180-240 inch pounds.

Place the valve in the pump

Repeat this procedure on the reverse shock valve on the other transmission.

13

15 16

Replace the fan covers and side panels

Test drive the mower. Check the oil level in the tank after driving. Fill with 20W-50 motor oil.

18 17


Boss SR1200 Belt Issue

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3 4

The SR1200 Boss tractor has experienced some hydro belt issues. A mower that has had a belt issue has a tendency to have more.Country Clipper has attributed this to several possible causes:Check the hydro pulley to make sure it is placed on the hydro pump properly.

Boss SR1200 Belt Issue Boss SR1200 Belt Issue


Check the tension spring to be sure it has the correct tension.

Check the idler pulley to be sure the edges of the lip are not sharp and rough. Make sure the belt is not running against the idler pulley lip (upper or lower).

5 6

7 8

Make sure the bushings are ok in the idler arm. Replace the belt with the new wrapped D-3777-W belt.

The hydro pulley can be placed on the pump upside down. Be sure to check to see if it is placed on the hydro correctly.

The hydro belt should not run against the lip of the flat idler pulley. Also check the edge of the pulley for extremely sharp edges and rough spots.



9 10

11

The hydro spring extension has two holes in it for the belt that holds the spring. The bolt should be in the inside hole, as shown. The new idler arm (622-306A) comes as an assembly. The pin goes into the Teflon bushing very hard.

The old hydro idler arm (622-167A) has a smaller tube with 2 oil lite bushings pressed into it. The bushings sometimes wear out prematurely, allowing the arm to tip, throwing the belt off.


Boss SR1200 Belt Issue


Joystick Construction

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3 4

Joystick Construction Joystick Construction

Joystick Construction Joystick Construction

647-122A 647-110A

The 647-122A Joystick Assembly is the same as the 636-141A except for the safety switch. The old unit had an E-6074 switch. The new unit has an E-6297.

Teflon bushing


Twinstick Construction

1 2

3 4

Twin Stick Construction Twin Stick Construction

Twin Stick Construction Twin Stick Construction

636-169A 636-168A

Forward handle stop (adjustment)

Handle closeness adjustment

Reverse handle stop (adjustment)

Jam Nut

Fiber Washer Cupped

Washer

Threaded Hole


Clutches

1 2

3 4

The clutch used on mid-mounts up to the 1 ½” crank. This supersedes the older clutches.

Clutches Clutches

Clutches Clutches

This is the clutch used on out fronts prior to the 03 series out fronts.

The Magstop Clutch used on all 1 1/8” crankshafts starting with the 2001 series mid mounts, not including the 1205 series Boss.The magstop clutch used on all 1” crank engines.

5 6

7

The Magstop clutch used on the 1205 series Boss. 1 ½” shaft used on the grassbagger.

Magstop clutch used on the 03 series out front mower. This clutch looks very much like the E-6247 but runs backward.E-6276


Spindles

1 2

3 4

Spindles Spindles

Spindles Spindles

The difference between the two spindles are the tapered flange and the milled spots for spacer washers on the rear holes. The 609F-019A spindle does not work well with the 660-045A Note the thickness of the flange top and bottom on the 609F-019A spindle.Note the milled circles for spacer washers on the 609F-019A. Also a small amount is cut from the leading edge of the flange to allow it to set flat with the spacer washers. The flange thickness is uniform all the way around on the 660-045A.The 660-045A comes with a metric grease zerk (H-2546), but does not come with the Woodruff Keys.

5 6Spindles Spindles

The only serious problem so far with the 660-045A is that the flange holding the top bearing is too light. This problem is being addressed. If you have a mower with the 609G-019A spindles and spacer washers, use 609F-019A for replacement spindles. If it has a 660-045A, replace with 660-045A spindles.


Mufflers

1 2

3 4

Mufflers Mufflers

Mufflers Mufflers

Country Clipper purchases mufflers for the Briggs and Stratton twin, the 25hp, 37hp, and 26hp Kawasaki.This muffler fits the 26 hp Kawasaki Liquid Cooled Engine.

H-2474

This muffler fits the 19hp, 23hp, and 25hp Kawasaki engine.

H-2284 H-2544

This muffler fits the big block 37hp and 30 hp Kawasaki.

5 Mufflers

This muffler fits the twin cylinder Briggs and Stratton. Notice the brace welded to the barrel of the muffler.H-2464


Boss 60 Inch Deck

1 2

3 4

The new 60” deck for 1205 series Boss.

SR1205 60” Deck SR1205 60” Deck

SR1205 60” Deck SR1205 60” Deck

Longer flexible IdlerLarger Idler Pulley

Larger spindle pulleys Tapered pulley covers

5 6

7

Both the cross deck belt and the engine to deck belt on the 60” deck are the same.

SR1205 60” Deck SR1205 60” Deck

SR1205 60” Deck

The old deck has square pulley covers.

The old deck has smaller pulleys and A section cross deck belt.


Adjusting Travel

1 2

3

The twinstick JAZEE PROand the new twinstickJAZEE are adjusted alike.

The linkage goes from the twinstick lever to the transmission. The only adjustment is the little tracking adjustment cam on the Part # 659‐180P.

Adjusting Travel

The cams can be loosened and rotated 360 degrees, moving the linkage either closer to or farther from the pivot point, speeding up or slowing down that side.

Adjusting Travel

Adjusting Travel Adjusting Travel

These are the the new 3/8” lower linkage on the Boss.

Adjusting travel on a Boss is the same as adjusting travel on a Zeton.

Part I

Joystick

1 2

3 4

The tires are removed from this machine for easy visibility.

Be sure mower is on a level, hard surface. Put mower on jack stands for safety.

Preparing Mower

On a joystick machine, remove the side panel and locate the swivel disk assembly on the slow side. This will generally be the right side.

Locate Linkage Disk Assembly

Notice that the swivel disk assembly controls the right side and the swivel arm controls the left side.

Swivel ArmSwivel Disk Assembly

Locate Swivel Arm

Loosen the upper control arm from the linkage disk. Do not remove bolt or linkage.

Loosen Upper Control Arm

5 6

7 8

As this unit is slow on the right side, loosen the upper linkage arm and push it toward the pivot (toward the shaft). Tighten the bolt again.

Reposition Upper Linkage Arm

Using a 1/8” allen wrench, tighten the setscrew snug against the bolt. The setscrew is located in the end of the arm on the linkage disk.

Tighten Setscrew

Locate the swivel arm. Loosen the setscrew in the end of the swivel arm and the bolt that fastens the swivel arm to the linkage rod. Slide the linkage arm toward the end of the swivel arm. Tighten the bolt again and snug the set screw to the bolt.

Locate Swivel Arm

If you have adjusted the upper linkage as much as possible and the machine still runs faster on one side than the other, locate the linkage bolt on the shift lever next to the right hand hydro pump.

Locate the Hydro Pump

9 10

11 12

Remove Shift Arm Bolt

Have someone push the steering control stick forward and move the shift lever back as far as it will go. If the hole in the shift lever is farther back than the ball joint opening in the linkage rod, you must lengthen the linkage rod so that the two holes align properly.

Align Shift Lever

Loosen the jam nut on the lower linkage rod.

Loosen Jam Nuts

Lengthen the linkage rod until it matches the hole in the shift lever.

Lengthen Linkage Rod

13 14

15 16

Replace the linkage bolt and secure the jam nut. Reset neutral.

Replace Linkage Bolt

Loosen the jam nut on the ball joint that connects the linkage rod to the swivel linkage disk assembly.

Loosen the upper jam nut on the ball joint that connects the linkage rod to the joystick assembly.

Setting NeutralLoosen Upper Linkage Rod Jam Nuts

Setting NeutralLoosen Upper Linkage Rod Jam Nuts

Put the joystick control securely in the neutral position and start the engine. The drive wheel hub will begin to rotate forward. Adjust the upper linkage counterclockwise until the wheel stops. Continue turning the linkage arm until the wheel starts to rotate backward Turn it clockwise just until it stops. This will set neutral

Setting Neutral

17 18

19 20Tighten the jam nuts. Tighten the jam nuts.

Tighten the Jam Nuts Tighten the Jam Nuts

If the right side is still slower than the left you may have to repeat the process for adjusting lower linkage on the right side and reset neutral.

Check Travel

If the machine is still slow on the right side, you must locate the lower linkage ball joint located on the left side of the left hand hydro pump. Remove shift arm bolt.

Locate Lower Linkage Ball Joint

21 22

23 24

Lengthen the lower linkage two turns to slow the left side down.

Lengthen Lower Linkage

Push the linkage arm all the way forward. The opening in the ball joint at the end of the shift arm should set farther back than the opening in the linkage arm.

Check Alignment on Linkage Arm

Align the linkage arm with the shift arm and replace and tighten the bolt.

Fasten Linkage Arm

Tighten the jam nut.

Tighten Jam Nut

1 2

3 4

Remove the right and left fender skirts. Locate the swivel disk assembly on the slow side. On the large majority of units, the right side will be the slow side.

Locate Swivel Disk

Loosen the bolt that connects the upper linkage. The steering dampener does not get in the way.

Do not remove bolt or upper linkage.

Loosen Connecting Bolt

Push the upper linkage in toward the pivot point as much as possible.

Relocate the Upper Linkage

Tighten the bolt and tighten the set screw against the bolt.

Tighten Bolt and Screw

5 6

7 8

Locate the swivel disk assembly on the fast side. This will generally be the left side.

Locate Swivel Disk Assembly

Locate the bolt that fastens the upper linkage. Loosen the bolt and set screw.

Locate Upper Linkage Bolt

Slide the upper linkage back or away from the pivot to slow that side down.

Adjust Upper Linkage Position

Tighten the bolt and setscrew.

Tighten Upper Linkage Bolt

9 10

11 12

If the slow side is still slower than the fast side, locate the lower linkage on the slow side.

Locate Lower Linkage

Loosen Jam Nuts

Remove the bolt that connects it to the shift lever.

Remove Shift Arm Bolt

Have someone push the right steering control stick forward and move the shift lever. If the hole in the shift lever is farther back than the ball joint opening in the linkage rod, you must lengthen the linkage rod so that the two holes align properly.

Align Shift Lever

13 14

15 16

Lengthen the linkage rod until it matches the hole in the shift lever.

Lengthen Linkage Rod

Replace and tighten linkage arm bolt and tighten jam nut.

Replace Linkage Arm Bolt

Loosen the jam nut on the ball joint that connects the linkage rod to the swivel linkage disk assembly.

Setting Neutral:Loosen Upper Linkage Jam Nuts

Setting Neutral:Loosen Upper Linkage Jam Nuts

Loosen the upper jam nut on the ball joint that connects the linkage rod to the steering assembly.

Put the twinstick controls securely in the neutral position and start the engine. The drive wheel hub will begin to rotate forward. Adjust the upper linkage counterclockwise until the wheel stops. Continue turning the linkage arm until the wheel starts to rotate backward. Turn it clockwise just until it stops. This will set neutral.

Setting Neutral17 18

19 20Tighten the lower jam nut.

Setting Neutral:Tighten Linkage Rod Jam Nuts

Setting Neutral:Tighten Linkage Rod Jam Nuts

Tighten the upper jam nut

If one side is still slow, you may have to repeat the process for adjusting the lower linkage and set neutral.

Check Travel

21 22

23 24

If the machine is still slow on the right side, you must locate the lower linkage ball joint located on the left side of the left hand hydro pump. Remove shift arm bolt.

Locate Lower Linkage Ball Joint

Lengthen the lower linkage two turns to slow the left side down.

Lengthen Lower Linkage

Push the linkage arm all the way forward. The opening in the ball joint at the end of the shift arm should set farther back than the opening in the linkage arm.

Check Alignment on Linkage Arm

Align the linkage arm with the shift arm and replace and tighten the bolt.

Fasten Linkage Arm


Dampeners

1 2

The heavy duty dampener for the twin stick (H-2168) has white lettering. It is very hard to pull out the cylinder The light duty dampener for the joystick (H-2467) has maroon lettering and is easy to pull out the cylinder.

Dampeners Dampeners


Electrical

1

Country Clipper has changed the wiring harness for simplification and to remove the auxiliary starter solenoid wherever possible. Instead of one harness with wiring and plugs for every mower, we have gone to separate harnesses.

Wiring Schematics

2 E-6340

The E-6340 is the harness used in the recent past. It has all the extra wiring and plugs that make it so confusing.

The E-6340 uses a starter relay on every unit.

The starter circuit is controlled through the ground circuit. The same ground circuit is used for the starter and for the safety circuit.

3

The E-6400 is the current Boss wiring harness.

It is the same circuit as the E-6340 except the starter circuit is controlled by the power circuit instead of the ground to engage the starter.

The seat switch cannot be bypassed on the E-6400

The joystick is equipped with a plunger switch and the clutch has been changed. The new clutch switch will work on older mowers, but the old switch will not work on the new mowers.

E-6400

4 E-6405

The E-6405 harness is used on all joystick mowers with Briggs & Stratton engines.

5 E-6436

The E-6436 adapter harness is used on any twinstick mower with a Briggs & Stratton engine.

1: MAGNETO2: OIL PRESURE SWITCH3: START SOLENOID4: DC & FUEL SOLENOID5: NOT USED

1: DC2: MAGNETO3: FUEL SOLENOID4: DC (JUMPER WIRE TO #1)5: OIL PRESSURE 6: NOT USED

DELPHI 02962894

AMP 1-480704-0

456

3 2 1

3

4

5

1

2

DELPHI 02962894(E-6308)

DELPHI 02962874(E-6098)

AMP 770145-1

AMP 1-480704-0

SHRINK WRAP WIRES,SO WIRES DON'T

CATCH ON MOWER

2"

WIRE TIETOGETHER

E-5137

SHIVVERS#E-5865

SHIVVERS#E-5976

6

The E-6415 harness is used on all JAZEE PRO and Charger mowers with Kohler engines and joysticks.

It can be identified by one red stripe on the harness.

E-6415

7

The E-6416 harness is used on all JAZEE PRO and Charger mowers with Kohler engines and twinsticks.

It can be identified by two red stripes on the harness

E-6416

8 E-6417

The E-6417 adapter harness is used with the E-6415 and E-6416. It adapts the harness to Kawasaki engines on JAZEE PRO and Chargers.

The lighted fender kits now come with their own harness. The wires have been removed from all other harnesses.

9

The E-6398 is the harness for the lighted fender kit. The wires have been removed from all other harnesses.

E-6398

10 Quick Fix Start Adapter

11

It has come to our attention that the wires on the E‐6447 Quick Fix Start Adapter kit are wired incorrectly. This could be a potential safety hazard and needs to be corrected immediately.

The blue wire goes to the 87A terminal on the relay. (See attached schematic)

Some have been found on the 87 terminal. If they are wired to the 87 terminal, the relay will work the opposite of the way it was intended. It shuts off the safety circuit in the run position.

Quick Fix Start Adapter

12 Quick Fix Start Adapter

E-6098 TerMinal (4) [-6308 Cover

FrOM "'Ire End

E-5880 Terl"llnQI (4) \

[-S075

E - 5058 '0;;;_ ""= 16Go. Red ,....

[-5976 Terl'llnal (4)-/

r~~~ Cover \lIre End

E-6098 TerMinal (4) [-6308 Cover

FrOM 'WIrE> End

E-5880 TerMinal (4) \

E -5058 '=_ ""= 16GQ Red ;"-

E-5976 Terl'llnQt (4)-'

r~~~2~~,.;Co .... er End


Replacement Parts

1 2

3

Replacement Parts Replacement Parts

Replacement Parts

The Boss lower linkage rod (647-083P) is basically the same as the Zeton lower linkage (647-024P). If a Zetonlower linkage rod needs to be replaced, it should be replaced with a 647-083P plus 2 H-2465 spacers.

If an old style 3/8” bolt rear deck hanger needs replaced, it should be replaced with a new style ½” assembly. The parts needed are :624-183A Rear Deck Hanger AssyF-1489 ½” Jam Nut642-177 P Hanger PinF-1936 ½-13x3 ½, 2” thread

If an old style 3/8” bolt front hanger assembly needs to be replaced, it should be replaced with the new style ½” assembly. The parts needed to do that are:642-175P Adjustable Hanger EndF-1489 ½” Jam Nut642-177P Hanger PinF-1936 ½-13x3 ½”, 2” threaded

Country Clipper613 W. English

Corydon, IA 50060(800)344-8237

www.countryclipper.com

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