John Deere Garden Tractors GX255 GX325 GX335 & GX345 Technical Manual – PDF DOWNLOAD

Description

John Deere Garden Tractors GX255 GX325 GX335 & GX345 Technical Manual – PDF DOWNLOAD

DESCRIPTION:

John Deere Garden Tractors GX255 GX325 GX335 & GX345 Technical Manual – PDF DOWNLOAD

INTRODUCTION:

Manual Description
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 and Information
• Identification Numbers
• Tools and Materials
• Component Location
• Schematics and Harnesses
• Theory of Operation
• Operation and Diagnostics
• Diagnostics
• Tests and Adjustments
• Repair
• Other

TABLE OF CONTENTS:

John Deere Garden Tractors GX255 GX325 GX335 & GX345 Technical Manual – PDF DOWNLOAD

TM1973 GX Garden Tractors………………………………………………………………………………. 1
Introduction………………………………………………………………………………………. 3
Safety……………………………………………………………………………………………. 5
Recognize Safety Information…………………………………………………………………….. 5
Understand Signal Words…………………………………………………………………………. 5
Replace Safety Signs……………………………………………………………………………. 5
Handle Fluids Safely – Avoid Fires……………………………………………………………….. 5
Use Care In Handling and Servicing Batteries………………………………………………………. 5
Prevent Battery Explosions………………………………………………………………………. 6
Prevent Acid Burns……………………………………………………………………………… 6
Wear Protective Clothing………………………………………………………………………… 6
Use Care Around High-Pressure Fluid Lines…………………………………………………………. 6
Service Machines Safely…………………………………………………………………………. 7
Use Proper Tools……………………………………………………………………………….. 7
Park Machine Safely…………………………………………………………………………….. 7
Using 120 Volt Electric Outlet System Safely………………………………………………………. 7
Support Machine Properly and Use Proper Lifting Equipment…………………………………………… 8
Work In Clean Area……………………………………………………………………………… 8
Using High Pressure Washers……………………………………………………………………… 8
Illuminate Work Area Safely……………………………………………………………………… 8
Work In Ventilated Area…………………………………………………………………………. 8
Warning: California Proposition 65 Warning………………………………………………………… 8
Remove Paint Before Welding or Heating……………………………………………………………. 8
Avoid Harmful Asbestos Dust……………………………………………………………………… 8
Service Tires Safely……………………………………………………………………………. 9
Avoid Injury From Rotating Blades, Augers and PTO Shafts……………………………………………. 9
Service Cooling System Safely……………………………………………………………………. 9
Handle Chemical Products Safely………………………………………………………………….. 10
Dispose of Waste Properly……………………………………………………………………….. 10
Live With Safety……………………………………………………………………………….. 10
Specifications & Information………………………………………………………………………… 11
Table of Contents………………………………………………………………………………. 11
Fastener Torques……………………………………………………………………………….. 13
Metric Fastener Torque Values………………………………………………………………… 13
Inch Fastener Torque Values………………………………………………………………….. 14
General Information…………………………………………………………………………….. 15
Gasoline…………………………………………………………………………………… 15
Gasoline Storage……………………………………………………………………………. 15
Engine Oil – North America…………………………………………………………………… 16
Engine Oil – Europe…………………………………………………………………………. 16
Engine Break – In Oil……………………………………………………………………….. 16
Hydrostatic Transmission Oil…………………………………………………………………. 17
Anti-Corrosion Grease……………………………………………………………………….. 17
Alternative Lubricants………………………………………………………………………. 17
Synthetic Lubricants………………………………………………………………………… 17
Lubricant Storage…………………………………………………………………………… 18
Mixing Of Lubricants………………………………………………………………………… 18
Chassis Grease……………………………………………………………………………… 18
Oil Filters………………………………………………………………………………… 18
Serial Number Locations…………………………………………………………………………. 19
Product Identification Number (PIN)…………………………………………………………… 19
Engine Identification Number – FH531V/ FH601V………………………………………………….. 19
Engine Identification Number – FD611V…………………………………………………………. 19
Carburetor Identification Number – FH531V……………………………………………………… 19
Carburetor Identification Number – FH601V……………………………………………………… 19
Carburetor Identification Number – FD611V……………………………………………………… 20
Hydrostatic Transaxle Identification Number……………………………………………………. 20
Engine – Kawasaki (FH531V)………………………………………………………………………….. 21
Table of Contents………………………………………………………………………………. 21
Specifications…………………………………………………………………………………. 23
General Specifications………………………………………………………………………. 23
Tests and Adjustment Specifications…………………………………………………………… 23
Repair Specifications……………………………………………………………………….. 24
Torque Specifications……………………………………………………………………….. 25
Tools and Materials…………………………………………………………………………….. 26
Tools……………………………………………………………………………………… 26
Other Materials…………………………………………………………………………….. 27
Service Parts Kits………………………………………………………………………….. 27
Component Location……………………………………………………………………………… 28
Engine Components…………………………………………………………………………… 28
Engine:Kawasaki (FH531V):Carburetor Component Location;Component Location:Engine:Kawasaki (FH531V) C…. 29
Diagnostics……………………………………………………………………………………. 30
Engine Troubleshooting Guide…………………………………………………………………. 30
Starting Motor Troubleshooting Guide………………………………………………………….. 31
Tests and Adjustments…………………………………………………………………………… 32
Throttle Cable Check and Adjustment…………………………………………………………… 32
Choke Plate Check and Adjustment……………………………………………………………… 32
Governor Static Adjustment…………………………………………………………………… 34
Slow Idle Speed Adjustment…………………………………………………………………… 34
Fast Idle Speed Adjustment…………………………………………………………………… 35
Valve Clearance Check and Adjustment………………………………………………………….. 36
Cylinder Compression Pressure Test……………………………………………………………. 36
Crankcase Vacuum Test……………………………………………………………………….. 37
Engine Oil Pressure Test…………………………………………………………………….. 38
Fuel Pump Test……………………………………………………………………………… 38
Spark Test…………………………………………………………………………………. 39
Spark Plug Gap Adjustment……………………………………………………………………. 40
Ignition Coil Air Gap Adjustment……………………………………………………………… 40
Repair………………………………………………………………………………………… 41
Throttle Control Lever and Cable……………………………………………………………… 41
Engine Removal and Installation………………………………………………………………. 41
Muffler Removal and Installation……………………………………………………………… 43
Air Cleaner Assembly………………………………………………………………………… 43
Carburetor Removal and Installation…………………………………………………………… 44
Carburetor Disassembly And Assembly…………………………………………………………… 45
Fuel Pump Replacement……………………………………………………………………….. 46
Blower Housing Removal and Installation……………………………………………………….. 46
Flywheel Removal and Installation…………………………………………………………….. 47
Breather Removal and Installation…………………………………………………………….. 47
Rocker Arm Removal and Installation…………………………………………………………… 48
Cylinder Head Removal and Installation………………………………………………………… 49
Cylinder Head Inspection…………………………………………………………………….. 50
Recondition Valve Seats……………………………………………………………………… 52
Lap Valves…………………………………………………………………………………. 52
Crankcase Cover Removal and Installation………………………………………………………. 53
Piston and Connecting Rod……………………………………………………………………. 53
Analyze Crankshaft and Connecting Rod Wear…………………………………………………….. 58
Camshaft and Tappets………………………………………………………………………… 58
Crankshaft and Main Bearings…………………………………………………………………. 59
Crankshaft Oil Seals………………………………………………………………………… 61
Deglaze Cylinder Bore……………………………………………………………………….. 61
Resize Cylinder Bore………………………………………………………………………… 61
Oil Pump Disassembly and Assembly…………………………………………………………….. 62
Oil Filter Manifold…………………………………………………………………………. 64
Governor Inspection and Replacement…………………………………………………………… 64
Governor Shaft Inspection and Replacement……………………………………………………… 64
Stator Removal and Installation………………………………………………………………. 65
Armature Removal and Installation…………………………………………………………….. 65
Starting Motor……………………………………………………………………………… 66
Starting Motor Disassembly and Assembly……………………………………………………….. 66
No-Load Amperage Draw and RPM Test……………………………………………………………. 68
Engine – Kawasaki (FH601V)………………………………………………………………………….. 69
Table of Contents………………………………………………………………………………. 69
Specifications…………………………………………………………………………………. 71
General Specifications………………………………………………………………………. 71
Test and Adjustment Specifications……………………………………………………………. 71
Repair Specifications……………………………………………………………………….. 72
Torque Specifications……………………………………………………………………….. 73
Tools and Materials…………………………………………………………………………….. 74
Tools……………………………………………………………………………………… 74
Other Materials…………………………………………………………………………….. 75
Service Parts Kits………………………………………………………………………….. 75
Component Location……………………………………………………………………………… 76
Engine Components…………………………………………………………………………… 76
Carburetor (Externally Vented)……………………………………………………………….. 77
Carburetor (Internally Vented)……………………………………………………………….. 78
Diagnostics……………………………………………………………………………………. 79
Engine Troubleshooting Guide…………………………………………………………………. 79
Starting Motor Troubleshooting Guide………………………………………………………….. 80
Tests and Adjustments…………………………………………………………………………… 81
Throttle Cable Check and Adjustment…………………………………………………………… 81
Choke Plate Check and Adjustment……………………………………………………………… 82
Governor Adjustment…………………………………………………………………………. 83
Slow Idle Speed Adjustment…………………………………………………………………… 83
Fast Idle Speed Adjustment…………………………………………………………………… 84
Valve Clearance Check and Adjustment………………………………………………………….. 85
Cylinder Compression Pressure Test……………………………………………………………. 85
Crankcase Vacuum Test……………………………………………………………………….. 86
Engine Oil Pressure Test…………………………………………………………………….. 87
Fuel Pump Test……………………………………………………………………………… 87
Spark Test…………………………………………………………………………………. 88
Spark Plug Gap Adjustment……………………………………………………………………. 89
Ignition Coil Air Gap Adjustment……………………………………………………………… 89
Repair………………………………………………………………………………………… 90
Throttle Control Lever and Cable……………………………………………………………… 90
Muffler Removal and Installation……………………………………………………………… 90
Air Cleaner Removal and Installation………………………………………………………….. 90
Carburetor (Externally Vented) Removal………………………………………………………… 91
Carburetor (Externally Vented) Repair…………………………………………………………. 93
Carburetor (Internally Vented) Removal………………………………………………………… 98
Carburetor (Internally Vented) Repair…………………………………………………………. 99
Fuel Pump Replacement………………………………………………………………………..104
Blower Housing Removal and Installation………………………………………………………..104
Flywheel Removal and Installation……………………………………………………………..105
Intake Manifold Removal and Installation……………………………………………………….106
Breather Removal and Installation……………………………………………………………..106
Engine Removal and Installation……………………………………………………………….107
Rocker Arm Removal and Installation……………………………………………………………109
Cylinder Head Removal and Installation…………………………………………………………110
Cylinder Head Inspection……………………………………………………………………..111
Recondition Valve Seats………………………………………………………………………113
Lap Valves………………………………………………………………………………….113
Crankcase Cover Removal and Installation……………………………………………………….114
Piston and Connecting Rod…………………………………………………………………….114
Analyze Crankshaft and Connecting Rod Wear……………………………………………………..119
Camshaft and Tappets…………………………………………………………………………119
Crankshaft and Main Bearings………………………………………………………………….120
Crankshaft Oil Seals…………………………………………………………………………121
Deglaze Cylinder Bore………………………………………………………………………..122
Resize Cylinder Bore…………………………………………………………………………122
Oil Pump Disassembly and Assembly……………………………………………………………..123
Oil Filter Manifold………………………………………………………………………….124
Governor Inspection and Replacement……………………………………………………………124
Governor Shaft Inspection and Replacement………………………………………………………125
Stator Removal and Installation……………………………………………………………….125
Armature Removal and Installation……………………………………………………………..125
Starting Motor Removal and Installation………………………………………………………..126
Starting Motor Disassembly and Assembly………………………………………………………..127
No-Load Amperage Draw and RPM Test…………………………………………………………….129
Engine – Kawasaki (FD611V)…………………………………………………………………………..131
Table of Contents……………………………………………………………………………….131
Specifications………………………………………………………………………………….133
General Specifications……………………………………………………………………….133
Tests and Adjustment Specifications……………………………………………………………133
Repair Specifications………………………………………………………………………..134
Tools and Materials……………………………………………………………………………..137
Tools………………………………………………………………………………………137
Dealer Fabricated Tools………………………………………………………………………137
Other Materials……………………………………………………………………………..138
Service Parts Kits…………………………………………………………………………..138
Component Location………………………………………………………………………………139
Internal Engine Components – Side View…………………………………………………………139
Internal Engine Components – Front View………………………………………………………..140
Carburetor Components………………………………………………………………………..141
Diagnostics…………………………………………………………………………………….142
Engine Troubleshooting Guide………………………………………………………………….142
Starting Motor Troubleshooting Guide…………………………………………………………..144
Tests and Adjustments……………………………………………………………………………145
Throttle Cable Check and Adjustment……………………………………………………………145
Choke Plate Check and Adjustment………………………………………………………………146
Governor Adjustment………………………………………………………………………….146
Fast Idle Speed Adjustment……………………………………………………………………147
Slow Idle Speed Adjustment……………………………………………………………………148
Valve Clearance Check and Adjustment…………………………………………………………..148
Cylinder Compression Pressure Test…………………………………………………………….149
Crankcase Vacuum Test………………………………………………………………………..150
Engine Oil Pressure Test……………………………………………………………………..150
Fuel Pump Test………………………………………………………………………………151
Fuel Pump Test – (FD611V – AS02 2004 Engines Only……………………………………………….152
Spark Test………………………………………………………………………………….153
Spark Plug Gap Adjustment…………………………………………………………………….153
Cylinder Leak-Down Test………………………………………………………………………154
Cooling System Pressure Test………………………………………………………………….155
Radiator Cap Pressure Test……………………………………………………………………155
Repair…………………………………………………………………………………………156
Throttle Control Lever and Cable………………………………………………………………156
Engine Removal and Installation……………………………………………………………….156
Muffler Removal and Installation………………………………………………………………157
Air Cleaner Assembly…………………………………………………………………………158
Carburetor Removal and Installation……………………………………………………………159
Carburetor Disassembly and Assembly……………………………………………………………159
Intake Manifold Removal and Installation……………………………………………………….160
Fuel Pump Removal and Installation…………………………………………………………….161
Fuel Pump Replacement – FD611V – AS02 2004 Engines Only………………………………………….161
Radiator Removal and Installation……………………………………………………………..162
Cooling Fan…………………………………………………………………………………163
Cooling Air Duct Removal and Installation………………………………………………………163
Thermostat………………………………………………………………………………….163
Thermostat Opening Test………………………………………………………………………164
Water Pump Removal and Installation……………………………………………………………164
Overflow Reservoir…………………………………………………………………………..166
Flywheel……………………………………………………………………………………166
Rocker Arm Assembly………………………………………………………………………….166
Cylinder Head and Valves……………………………………………………………………..167
Recondition Valve Seats………………………………………………………………………169
Lap Valves………………………………………………………………………………….170
Crankcase Cover……………………………………………………………………………..170
Piston and Connecting Rod…………………………………………………………………….170
Camshaft and Tappets…………………………………………………………………………175
Crankshaft and Main Bearings………………………………………………………………….176
Crankshaft Oil Seals…………………………………………………………………………177
Cylinder Block………………………………………………………………………………178
Oil Pump……………………………………………………………………………………180
Breather……………………………………………………………………………………181
Governor……………………………………………………………………………………182
Governor Shaft………………………………………………………………………………182
Governor Shaft Seal………………………………………………………………………….182
Stator……………………………………………………………………………………..183
Pulser Coils………………………………………………………………………………..183
Ignition Coils………………………………………………………………………………183
Ignition Module……………………………………………………………………………..183
Starting Motor Disassembly and Assembly………………………………………………………..184
No-Load Amperage Draw and RPM Test…………………………………………………………….186
Electrical…………………………………………………………………………………………189
Table of Contents……………………………………………………………………………….189
General Information……………………………………………………………………………..193
Reading Electrical Schematics…………………………………………………………………193
Theory of Operation Information……………………………………………………………….194
Diagnostic Information……………………………………………………………………….194
Wire Color Abbreviation Chart…………………………………………………………………194
Common Circuit Tests…………………………………………………………………………195
Conductors for 12 Volt Circuits……………………………………………………………….195
Specifications………………………………………………………………………………….196
General Specifications……………………………………………………………………….196
Special or Required Tools…………………………………………………………………….197
Component Location………………………………………………………………………………198
GX255, GX325, and GX335 Components…………………………………………………………….198
Schematics and Harnesses…………………………………………………………………………199
Schematic and Wiring Harness Legend – GX255, GX325, and GX335…………………………………….199
GX255, GX325, and GX335 Main Schematic…………………………………………………………200
GX255, GX325, and GX335 Main Wiring Harness…………………………………………………….203
GX255, GX325, and GX335 Main Wiring Harness Color Codes………………………………………….205
W2 Engine Wiring Harness……………………………………………………………………..205
W3 Engine Wiring Harness……………………………………………………………………..206
W4 PTO Clutch Wiring Harness………………………………………………………………….206
W5 Fuel Solenoid Power Wiring Harness………………………………………………………….206
W6 Fuel Solenoid Ground Wiring Harness…………………………………………………………206
W7 Stator Wiring Harness……………………………………………………………………..207
W8 Headlight Wiring Harness…………………………………………………………………..207
Operation and Diagnosis – GX255/325/335……………………………………………………………208
Unswitched Power Circuit Operation – GX255/ 325/335……………………………………………..208
Unswitched Power Circuit Schematic – GX255/325/335………………………………………………209
Unswitched Power Circuit Diagnosis – GX255/ 325/335……………………………………………..210
Switched Power Circuit Operation – GX255/ 325/335……………………………………………….211
Switched Power Circuit Schematic – GX255/325/335………………………………………………..212
Switched Power Circuit Diagnosis – GX255/ 325/335……………………………………………….213
Starting Circuit Operation – GX255/325/335……………………………………………………..216
Starting Circuit Schematic – GX255/325/335……………………………………………………..217
Starting Circuit Diagnosis – GX255/325/335……………………………………………………..218
Ignition Circuit Operation – GX255/325/335……………………………………………………..219
Ignition Circuit Operation Engine Shutting Off – GX255/325/335……………………………………219
Ignition Circuit Schematic – GX255/325/335……………………………………………………..220
Ignition Circuit Diagnosis – GX255/325/335……………………………………………………..221
Fuel Shutoff Solenoid Circuit Operation – GX255/325/335………………………………………….223
Fuel Shutoff Solenoid Circuit Schematic – GX255/325/335………………………………………….224
Fuel Shutoff Solenoid Circuit Diagnosis – GX255/325/335………………………………………….225
Charging Circuit Operation – GX255/325/335……………………………………………………..227
Charging Circuit Schematic – GX255/325/335……………………………………………………..228
Charging Circuit Diagnosis – GX255/325/335……………………………………………………..229
PTO Circuit Operation, PTO Off – GX255/325/ 335…………………………………………………231
PTO Circuit Schematic, PTO Off – GX255/325/335………………………………………………….232
PTO Circuit Operation, PTO On – GX255/325/ 335………………………………………………….233
PTO Circuit Schematic, PTO On – GX255/325/335…………………………………………………..234
PTO Circuit Diagnosis – GX255/325/335………………………………………………………….235
Reverse Implement Option (RIO) Circuit Operation – GX255/325/335………………………………….238
RIO Circuit Schematic – GX255/325/335………………………………………………………….239
RIO Circuit Diagnosis – GX255/325/335………………………………………………………….240
Low Oil Pressure Light Circuit Operation – GX255/325/335…………………………………………241
Low Oil Pressure Light Circuit Schematic – GX255/325/335…………………………………………242
Low Oil Pressure Light Circuit Diagnosis – GX255/325/335…………………………………………243
Low Fuel Light Circuit Operation – GX335 (Later Models)………………………………………….244
Low Fuel Light Circuit Schematic – GX335 (Later Models)………………………………………….245
Low Fuel Light Circuit Diagnosis – GX335 (Later Models)………………………………………….246
Hour Meter Circuit Operation – GX255/325/335……………………………………………………247
Hour Meter Circuit Schematic – GX255/325/335……………………………………………………248
Hour Meter Circuit Diagnosis – GX255/325/335……………………………………………………249
Headlight Circuit Operation – GX255/325/335…………………………………………………….250
Headlight Circuit Schematic – GX255/325/335…………………………………………………….251
Headlight Circuit Diagnosis – GX255/325/335…………………………………………………….252
Component Location………………………………………………………………………………253
GX345 Components…………………………………………………………………………….253
Schematics and Harnesses GX345……………………………………………………………………254
Schematic and Wiring Harness Legend – GX345…………………………………………………….254
GX345 Main Schematic…………………………………………………………………………255
GX345 Main Wiring Harness…………………………………………………………………….259
GX345 Main Wiring Harness Color Codes………………………………………………………….261
W2 Engine Wiring Harness……………………………………………………………………..261
W3 Engine Wiring Harness……………………………………………………………………..262
W4 Engine Wiring Harness……………………………………………………………………..262
W5 Engine Wiring Harness……………………………………………………………………..263
W6 PTO Clutch Wiring Harness………………………………………………………………….263
W7 Engine Wiring Harness……………………………………………………………………..264
W8 and W9 Engine Wiring Harnesses……………………………………………………………..264
W10 Headlight Wiring Harness………………………………………………………………….264
Operation and Diagnosis – GX345…………………………………………………………………..265
Unswitched Power Circuit Operation – GX345……………………………………………………..265
Unswitched Power Circuit Schematic – GX345……………………………………………………..266
Unswitched Power Circuit Diagnosis – GX345……………………………………………………..267
Switched Power Circuit #1 Operation – GX345…………………………………………………….268
Switched Power Circuit #1 Schematic – GX345…………………………………………………….269
Switched Power Circuit #1 Diagnosis – GX345…………………………………………………….270
Switched Power Circuit #2 – GX345……………………………………………………………..271
Switched Power Circuit #2 Schematic – GX345…………………………………………………….272
Switched Power Circuit #2 Diagnosis – GX345…………………………………………………….273
Starting Circuit Operation – GX345…………………………………………………………….275
Starting Circuit Schematic – GX345…………………………………………………………….276
Starting Circuit Diagnosis – GX345…………………………………………………………….277
Ignition Circuit Operation – GX345…………………………………………………………….278
Ignition Circuit Schematic – GX345…………………………………………………………….279
Ignition Circuit Diagnosis – GX345…………………………………………………………….280
Fuel Shut-Off Solenoid Circuit Operation – GX345………………………………………………..282
Fuel Shut-Off Solenoid Circuit Schematic – GX345………………………………………………..283
Fuel Shut-Off Solenoid Circuit Diagnosis – GX345………………………………………………..284
Charging Circuit Operation – GX345…………………………………………………………….285
Charging Circuit Schematic – GX345…………………………………………………………….286
Charging Circuit Diagnosis – GX345…………………………………………………………….287
PTO Circuit Operation – PTO Off – GX345………………………………………………………..289
PTO Circuit Schematic – PTO Off – GX345………………………………………………………..290
PTO Circuit Operation – PTO On – GX345…………………………………………………………291
PTO Circuit Schematic – PTO On – GX345…………………………………………………………292
PTO Circuit Diagnosis – GX345…………………………………………………………………293
Reverse Implement Option (RIO) Circuit Operation – GX345…………………………………………295
RIO Circuit Schematic – GX345…………………………………………………………………296
RIO Circuit Diagnosis – GX345…………………………………………………………………297
Low Oil Pressure Light Circuit Operation – GX345………………………………………………..299
Low Oil Pressure Light Circuit Schematic – GX345………………………………………………..300
Low Oil Pressure Light Circuit Diagnosis – GX345………………………………………………..301
Coolant Temperature Light Circuit Operation – GX345……………………………………………..302
Coolant Temperature Light Circuit Schematic – GX345……………………………………………..303
Coolant Temperature Light Circuit Diagnosis – GX345……………………………………………..304
Low Fuel Light Circuit Operation – GX345 (Later Models)………………………………………….305
Low Fuel Light Circuit Schematic – GX345 (Later Models)………………………………………….306
Low Fuel Light Circuit Diagnosis – GX345 (Later Models)………………………………………….307
Hour Meter Circuit Operation – GX345…………………………………………………………..308
Hour Meter Circuit Schematic – GX345…………………………………………………………..309
Hour Meter Circuit Diagnosis – GX345…………………………………………………………..310
Headlight Circuit Operation – GX345……………………………………………………………311
Headlight Circuit Schematic – GX345……………………………………………………………312
Headlight Circuit Diagnosis – GX345……………………………………………………………313
Tests and Adjustments……………………………………………………………………………314
Common Circuit Test………………………………………………………………………….314
Ground Circuit Test………………………………………………………………………….314
Battery Test………………………………………………………………………………..315
Charge Battery………………………………………………………………………………316
Battery Load Test……………………………………………………………………………316
Regulated Amperage Test………………………………………………………………………317
Regulated Voltage Test……………………………………………………………………….318
Unregulated Voltage Output Test – GX255/325/ 335………………………………………………..318
Unregulated Voltage Output Test – GX345………………………………………………………..319
Regulator/Rectifier Test……………………………………………………………………..319
Starter Solenoid Test………………………………………………………………………..320
Starter Loaded Amperage Draw Test – GX255/ 325/335………………………………………………320
Starter Loaded Amperage Draw Test – GX345………………………………………………………321
Ignition Module Test…………………………………………………………………………321
Flywheel Magnet Test…………………………………………………………………………322
Ignition Coil Test – GX255/325/335…………………………………………………………….322
Ignition Coil Test – GX345……………………………………………………………………322
Pulser Coil Test – GX345……………………………………………………………………..323
Spark Plug Cap Test – GX345…………………………………………………………………..324
Brake Switch Test……………………………………………………………………………324
PTO/RIP Switch Test………………………………………………………………………….325
PTO Clutch Test……………………………………………………………………………..325
Seat Switch Test…………………………………………………………………………….326
Headlight Switch Test………………………………………………………………………..326
Oil Pressure Switch Test……………………………………………………………………..327
Coolant Temperature Switch Test……………………………………………………………….327
Fuel Shutoff Solenoid Test……………………………………………………………………328
Low Fuel Switch Test…………………………………………………………………………328
Repair…………………………………………………………………………………………329
Connector Body – Blade Terminals………………………………………………………………329
METRIPACK® Connectors………………………………………………………………………..329
Power Train – Hydrostatic……………………………………………………………………………333
Table of Contents……………………………………………………………………………….333
Specifications………………………………………………………………………………….335
Hydrostatic Transaxle………………………………………………………………………..335
Adjustment Specifications…………………………………………………………………….335
Repair Specifications………………………………………………………………………..335
Torque Specifications………………………………………………………………………..336
Other Materials……………………………………………………………………………..336
Component Location………………………………………………………………………………337
Transaxle Case Halves………………………………………………………………………..337
Charge Pump…………………………………………………………………………………338
Piston Pump…………………………………………………………………………………339
Motor………………………………………………………………………………………340
Reduction Gears, Differential, and Axles……………………………………………………….341
Swash Plate and Neutral Centering Assembly……………………………………………………..343
Transaxle Brake……………………………………………………………………………..345
Center Case Assembly…………………………………………………………………………346
Belt Drive and Idlers – GX255…………………………………………………………………347
Belt Drive and Idlers – GX325, GX335, and GX345…………………………………………………348
Brake Pedal and Linkage………………………………………………………………………349
Forward and Reverse/Cruise Control Linkage – GX255………………………………………………351
Traction Assist Linkage (S/N 120001 -)…………………………………………………………352
Forward and Reverse Pedals and Linkage (Exploded View) – GX255……………………………………353
Cruise Control Lever and Linkage (Exploded View) – GX255…………………………………………355
Forward and Reverse Pedals and Linkage – GX325, GX335, and GX345………………………………….356
Theory of Operation……………………………………………………………………………..358
Controls and Linkage Operation – GX255…………………………………………………………358
Controls and Linkage Operation – GX325, GX335, and GX345…………………………………………363
Foot Controls – GX325, GX335, and GX345………………………………………………………..363
Brake Linkage – GX325, GX335, and GX345………………………………………………………..364
Hydrostatic System Operation………………………………………………………………….365
Gear Power Flow……………………………………………………………………………..367
Transaxle Brake……………………………………………………………………………..368
Diagnostics…………………………………………………………………………………….369
Machine Will Not Move Forward Or Reverse……………………………………………………….369
Noisy Operation……………………………………………………………………………..371
Machine Creeps………………………………………………………………………………372
Machine Moves In One Direction Only……………………………………………………………373
Erratic Speed……………………………………………………………………………….373
Machine Does Not Achieve Full Ground Speed……………………………………………………..374
Park Brake Does Not Hold Machine On Hill……………………………………………………….376
Brake Switch Will Not Engage………………………………………………………………….378
Traction Assist System……………………………………………………………………….379
Tests and Adjustments……………………………………………………………………………380
Hydrostatic Transaxle Bleeding Procedure……………………………………………………….380
Neutral Creep Adjustment……………………………………………………………………..380
Forward and Reverse Pedal Height Adjustment – GX255……………………………………………..381
Forward and Reverse Pedal Height Adjustment – GX325, GX335, and GX345……………………………..382
Brake Linkage Adjustment – GX255………………………………………………………………383
Brake Linkage Adjustment – GX325, GX335, and GX345………………………………………………383
Belt Tension Adjustment – GX325, GX335, and GX345……………………………………………….384
Hand Lever Rod Adjustment – GX255……………………………………………………………..384
Neutral Return Arm Bearing Adjustment – GX255…………………………………………………..385
Cruise/Hand Control Lever Tension Adjustment – GX255…………………………………………….385
Repair…………………………………………………………………………………………386
Traction Drive Belt Tensioner Assembly – GX255………………………………………………….386
Traction Drive Belt Removal and Installation – GX325, GX335, and GX345…………………………….386
Traction Drive Belt Tensioner Assembly – GX325, GX335, and GX345………………………………….388
Control Pedals and Linkage – GX255…………………………………………………………….389
Control Pedals and Linkage – GX325, GX335, and GX345…………………………………………….389
Intermediate Shaft – GX255……………………………………………………………………390
Intermediate Shaft – GX325, GX335, and GX345……………………………………………………391
Brake Pedal and Linkage – GX255……………………………………………………………….391
Brake Pedal and Linkage – GX325, GX335, and GX345……………………………………………….393
Brake Rod Removal and Installation – GX255……………………………………………………..394
Brake Rod Removal and Installation – GX325, GX335, and GX345……………………………………..394
Transaxle Removal and Installation (S/N 120001 -)……………………………………………….395
Transaxle Removal and Installation (S/N – 120000)……………………………………………….400
Neutral Return Arm – GX255……………………………………………………………………404
Cruise Control Lever – GX255………………………………………………………………….405
Transaxle Disassembly and Assembly………………………………………………………………..406
Case Disassembly…………………………………………………………………………….406
Differential Lock Shaft Removal and Installation (S/N 120001 -)…………………………………..407
Final Drive and Axle Removal………………………………………………………………….408
Brake Removal……………………………………………………………………………….410
Rotating Group Removal……………………………………………………………………….412
Control Shaft Removal………………………………………………………………………..417
Control Shaft Disassembly…………………………………………………………………….417
Oil Filler Tube Removal………………………………………………………………………418
Shock Absorber Removal……………………………………………………………………….419
Freewheeling Control Shaft Removal…………………………………………………………….419
Center Case Disassembly………………………………………………………………………420
Transaxle Assembly…………………………………………………………………………..421
Freewheeling Control Shaft Installation………………………………………………………..421
Shock Absorber Installation…………………………………………………………………..422
Oil Filler Tube Installation………………………………………………………………….423
Control Shaft Assembly……………………………………………………………………….423
Control Shaft Installation……………………………………………………………………424
Rotating Group Assembly………………………………………………………………………425
Brake Installation…………………………………………………………………………..430
Charge Pump Installation……………………………………………………………………..431
Final Drive and Axle Installation……………………………………………………………..432
Case Assembly……………………………………………………………………………….435
Hydraulics…………………………………………………………………………………………437
Table of Contents……………………………………………………………………………….437
Specifications………………………………………………………………………………….439
Tests and Adjustments Specifications…………………………………………………………..439
Repair Specifications………………………………………………………………………..439
Special Tools……………………………………………………………………………….439
Special Materials……………………………………………………………………………439
Component Location………………………………………………………………………………440
Hydraulic Lift System Components………………………………………………………………440
Lift Lever and Linkage……………………………………………………………………….441
Mower Deck Lift Linkage………………………………………………………………………442
Hydraulic Schematic………………………………………………………………………….443
Theory of Operation……………………………………………………………………………..445
Hydraulic Lift System Operation……………………………………………………………….445
Diagnostics…………………………………………………………………………………….446
Noise From Transmission When Using Hydraulics…………………………………………………..446
Excessive Attachment Drop With Control Valve In Neutral………………………………………….446
Hydraulic Lift Slow Or No Lift Capacity………………………………………………………..447
Hydraulic Lift Will Not Work………………………………………………………………….448
Tests and Adjustments……………………………………………………………………………449
Hydraulic Lift Oil Flow and Pressure Test………………………………………………………449
Repair…………………………………………………………………………………………449
Hydraulic Lift Control Valve………………………………………………………………….449
Hydraulic Lift Cylinder Removal and Installation………………………………………………..451
Lift Lever Removal And Installation……………………………………………………………452
Lift Linkage Inspection………………………………………………………………………452
Hydraulic In-Line Filter Removal and Installation……………………………………………….453
Steering…………………………………………………………………………………………..455
Table of Contents……………………………………………………………………………….455
Specifications………………………………………………………………………………….457
Tests and Adjustments Specifications…………………………………………………………..457
Torque Specifications………………………………………………………………………..457
Repair Specifications………………………………………………………………………..457
Special Tools……………………………………………………………………………….457
Service Parts Kits…………………………………………………………………………..457
Component Location………………………………………………………………………………458
Steering Wheel………………………………………………………………………………458
Front Axle………………………………………………………………………………….459
Steering Control Unit………………………………………………………………………..460
Theory of Operation……………………………………………………………………………..461
Steering System……………………………………………………………………………..461
Diagnostics…………………………………………………………………………………….462
Hydraulic System Checks………………………………………………………………………462
Steering Symptom Diagnosis……………………………………………………………………462
Tests and Adjustments……………………………………………………………………………464
Steering Wheel Centering……………………………………………………………………..464
Repair…………………………………………………………………………………………465
Steering Gear Removal and Installation…………………………………………………………465
Steering Control Unit and Column………………………………………………………………469
Steering Control Unit………………………………………………………………………..471
Steering GX325……………………………………………………………………………………..477
Table of Contents……………………………………………………………………………….477
Specifications………………………………………………………………………………….479
Adjustment Specifications…………………………………………………………………….479
Repair Specifications………………………………………………………………………..479
Special Tools……………………………………………………………………………….479
Other Materials……………………………………………………………………………..479
Theory of Operation……………………………………………………………………………..480
Steering System……………………………………………………………………………..480
Tilt Steering Operation………………………………………………………………………481
Steering Gearbox Operation……………………………………………………………………482
Diagnostics…………………………………………………………………………………….483
Steering System Diagnosis…………………………………………………………………….483
Steering Check………………………………………………………………………………485
Tests and Adjustments……………………………………………………………………………486
Drag Link Adjustment…………………………………………………………………………486
Toe-In Adjustment……………………………………………………………………………486
Repair…………………………………………………………………………………………487
Steering Tilt Assembly……………………………………………………………………….487
Steering Gearbox…………………………………………………………………………….487
Steering GX335 / GX345………………………………………………………………………………493
Table of Contents……………………………………………………………………………….493
Specifications………………………………………………………………………………….495
Tests and Adjustments Specifications…………………………………………………………..495
Torque Specifications………………………………………………………………………..495
Special Tools……………………………………………………………………………….495
Other Materials……………………………………………………………………………..495
Service Parts Kits…………………………………………………………………………..495
Component Location………………………………………………………………………………496
Steering System Components……………………………………………………………………496
Steering Valve Components…………………………………………………………………….497
Theory of Operation……………………………………………………………………………..498
Steering Valve and System Operation……………………………………………………………498
Tilt Steering Operation………………………………………………………………………499
Diagnostics…………………………………………………………………………………….500
Hydraulic System Checks………………………………………………………………………500
Steers Hard or No Steering In Both Directions…………………………………………………..500
Steers Hard or No Steering In One Direction…………………………………………………….501
Steering Pulls In One Direction……………………………………………………………….502
Steering Wheel Tilt Assembly Will Not Move……………………………………………………..502
Steering Wheel Creeps………………………………………………………………………..503
Steering Shimmy Or Vibration………………………………………………………………….503
Noise During Turn……………………………………………………………………………503
Slow Steering Responses………………………………………………………………………504
Tests and Adjustments……………………………………………………………………………505
Steering System Oil Flow and Pressure Tests…………………………………………………….505
Steering System Leakage Test………………………………………………………………….505
Steering Valve Leakage Test…………………………………………………………………..506
Steering Cylinder Leakage Test………………………………………………………………..507
Toe-In Adjustment……………………………………………………………………………508
Repair…………………………………………………………………………………………508
Steering Tilt Assembly……………………………………………………………………….508
Steering Valve and Column…………………………………………………………………….509
Steering Cylinder……………………………………………………………………………512
Steering Shaft Replacement……………………………………………………………………512
Brakes…………………………………………………………………………………………….515
Table of Contents……………………………………………………………………………….515
Component Location………………………………………………………………………………517
Brake Pedal and Linkage………………………………………………………………………517
Theory of Operation……………………………………………………………………………..519
External Brake Linkage……………………………………………………………………….519
Transaxle Brake Operation…………………………………………………………………….519
Diagnostics…………………………………………………………………………………….520
Machine Will Not Move In Forward Or Reverse…………………………………………………….520
Brakes Do Not Engage When Pedal Depressed………………………………………………………520
Parking Brake Does Not Hold Machine On Hill…………………………………………………….521
Noisy Operation……………………………………………………………………………..521
Erratic Speed……………………………………………………………………………….522
Machine Does Not Achieve Full Ground Speed……………………………………………………..522
Machine Will Not Move In Forward Direction Or Is Slow In Forward………………………………….523
Machine Is Slow In Reverse……………………………………………………………………523
Neutral Start Switch Does Not Engage When Pressing Brake Pedal……………………………………524
Engine Can Be Started Without Depressing Brake Pedal…………………………………………….524
Tests and Adjustments……………………………………………………………………………525
Brake Linkage Test and Adjustment……………………………………………………………..525
Repair…………………………………………………………………………………………525
Brake Assembly………………………………………………………………………………525
Attachments………………………………………………………………………………………..527
Table of Contents……………………………………………………………………………….527
Specifications………………………………………………………………………………….529
Mower Deck Adjustment Specifications…………………………………………………………..529
Mower Deck Repair Specifications………………………………………………………………529
Special Tools……………………………………………………………………………….529
Service Parts Kits…………………………………………………………………………..529
Component Location………………………………………………………………………………530
48 – Inch Convertible Mower Deck………………………………………………………………530
54 – Inch Convertible Mower Deck………………………………………………………………537
Diagnostics…………………………………………………………………………………….544
Mower Decks Troubleshooting Chart…………………………………………………………….544
Mower Drive Checks…………………………………………………………………………..545
PTO Clutch Diagnosis…………………………………………………………………………547
Tests and Adjustments……………………………………………………………………………548
Mower Level Side-to-Side……………………………………………………………………..548
Mower Level Front-To-Rear…………………………………………………………………….549
Electric PTO Clutch Adjustment………………………………………………………………..550
Repair…………………………………………………………………………………………551
Electric PTO Clutch Removal and Installation……………………………………………………551
PTO Clutch Break-In Procedure…………………………………………………………………551
48-Inch Deck……………………………………………………………………………………552
48-Inch Convertible Mower Deck Removal and Installation………………………………………….552
48-Inch Mower Drive Belt……………………………………………………………………..553
48-Inch Deck Mower Blades…………………………………………………………………….553
48-Inch Deck Spindles………………………………………………………………………..555
48-Inch Deck Jack Sheave……………………………………………………………………..557
Idlers……………………………………………………………………………………..558
54-Inch Convertible Deck…………………………………………………………………………558
54-Inch Mower Deck Removal and Installation…………………………………………………….558
54-Inch Convertible Mower Drive Belt…………………………………………………………..559
54-Inch Deck Mower Blades…………………………………………………………………….560
54-Inch Jack Sheave………………………………………………………………………….561
54-Inch Convertible Deck Spindles……………………………………………………………..562
Idlers……………………………………………………………………………………..564
Miscellaneous………………………………………………………………………………………565
Table of Contents……………………………………………………………………………….565
Specifications………………………………………………………………………………….567
Torque Specifications………………………………………………………………………..567
Component Location………………………………………………………………………………568
Lift Assist and Depth Stop……………………………………………………………………568
Tests and Adjustments……………………………………………………………………………569
Hood Latch Adjustment………………………………………………………………………..569
Lift Assist Spring Adjustment…………………………………………………………………569
Checking Wheel Bolt Torque……………………………………………………………………569
Repair…………………………………………………………………………………………570
Front Axle – GX255…………………………………………………………………………..570
Front Axle – GX325, GX335, and GX345…………………………………………………………..571
Steering Spindles……………………………………………………………………………572
Front Wheels………………………………………………………………………………..573
Rear Wheels…………………………………………………………………………………574
Engine Hood…………………………………………………………………………………574
Control / Dash Panel…………………………………………………………………………575
Seat and Support Removal and Installation………………………………………………………577
Fender Deck – GX255………………………………………………………………………….578
Fender Deck – GX325, GX335, and GX345………………………………………………………….580
Fuel Tank – GX255……………………………………………………………………………580
Fuel Tank – GX325, GX335, and GX345……………………………………………………………581
Attachment Lift (Foot Pedal)………………………………………………………………….581
Lift Assist Spring and Tension Adjuster Removal and Installation………………………………….584
Height Adjuster Assembly Removal and Installation……………………………………………….584
Index……………………………………………………………………………………………..585
Numerics……………………………………………………………………………………….585
A……………………………………………………………………………………………..585
B……………………………………………………………………………………………..585
C……………………………………………………………………………………………..585
D……………………………………………………………………………………………..586
E……………………………………………………………………………………………..586
Engine……………………………………………………………………………………..588
Kawasaki (FD611V)………………………………………………………………………..588
Kawasaki (FH531V)………………………………………………………………………..589
Kawasaki (FH601V)………………………………………………………………………..589
F……………………………………………………………………………………………..590
G……………………………………………………………………………………………..590
H……………………………………………………………………………………………..590
I……………………………………………………………………………………………..591
L……………………………………………………………………………………………..591
M……………………………………………………………………………………………..592
N……………………………………………………………………………………………..592
O……………………………………………………………………………………………..592
P……………………………………………………………………………………………..592
R……………………………………………………………………………………………..593
S……………………………………………………………………………………………..593
T……………………………………………………………………………………………..595
U……………………………………………………………………………………………..595
W……………………………………………………………………………………………..596

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