HUSTLER Sport General Service Manual
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HUSTLER Sport General Service Manual

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108934
Hustler
General Service Manual
®
Sport
•••••
200 South Ridge Road
•••
Hesston, Kansas
•
67062-2097
REV E

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Summary of Contents for HUSTLER Sport

  • Page 1 Hustler ® Sport General Service Manual ••••• 200 South Ridge Road ••• Hesston, Kansas • 67062-2097 108934 REV E...
  • Page 2 WARNING WARNING WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. NOTICE OF REQUIREMENT OF SPARK ARRESTER MUFFLER This equipment may create sparks that can start fires around dry vegetation. California Public Resources Code Section 4442.6 provides that it is unlawful to use or operate an internal combustion engine on any forest-covered, brush-covered, or grass-covered land unless the engine is equipped with a spark arrester maintained in effective working order.

  • Page 3: Table Of Contents

    General Information ........1-1 ® Hustler Service Program ......1-1 Maintenance Introduction .
  • Page 4 Electrical ..........7-1 Electrical Schematic —...

  • Page 5: General Information

    Service Program assemblies. ® Daily inspect mower for grass clippings and wire and string This manual is part of a service package for the Hustler Sport ® mowers. Use of this manual in conjunction with other Hustler tangles. The underside of the mower deck will collect a build-up...
  • Page 6 REV E 108934...

  • Page 7: Safety

    SAFETY • Refuel outdoors. Never refuel or drain the fuel from the machine indoors. • Never attempt to start engine when there is a strong odor of gasoline or diesel fuel fumes present. Locate and correct cause. This safety alert symbol is used to call attention to a message •...

  • Page 8: Operation Precautions

     Never attempt to start engine when there is a strong odor  Use only genuine Hustler ® replacement parts to ensure of gasoline fumes present. Locate and correct cause.
  • Page 9  Shorts caused by battery terminals or metal tools touch- Prepare For Emergencies  Be prepared if a fire starts. ing metal mower components can cause sparks. Sparks  Keep a first aid kit and fire extinguishers available. can cause a battery gas explosion which will result in per- ...
  • Page 10 REV E 108934...

  • Page 11: Torque

    TORQUE Standard Torques The following chart lists the standard torque values for the threaded fasteners found in this manual. Torque all cap screws, nuts and set screws to these values unless a different torque is shown in the Special Torques section. 32.4 IN.-LBS.
  • Page 12 REV E 108934...

  • Page 13: Power Unit Maintenance

    POWER UNIT MAINTENANCE Steering Adjustments 3. Raise the seat platform and disconnect the mower harness from the seat switch. Bypass the seat switch by connecting the two mower harness female spades Steering control lever neutral adjustment together. Figure 4-1 The mower’s steering has been factory adjusted to eliminate creeping when the steering control levers are in the neutral posi- tion.
  • Page 14 engage the brake (neutral) slot and hold it in that position 14. Once both sides are properly adjusted, check them (Do not engage the steering control lever far enough to together to make sure everything is working properly. engage the brakes in the brake slot) (Figure 4-3). 15.

  • Page 15: Park Brake Spring Adjustment

    Align handles ± .125” Figure 4-4 Steering control lever Steering damper Steering stud damper Slot Steering control Figure 4-5 5. Release the damper spring housing and allow the internal the following method: spring to bring the housing back to the neutral position. 1.

  • Page 16: Belts

    ® If you wish to use non-pneumatic tires on your Hustler tom of the groove. Replace the pulley when this is the case, oth- mower the tires must be an approved tire purchased from Hus- erwise, the belt will lose power and slip excessively.

  • Page 17: Engine Maintenance

    ENGINE MAINTENANCE General Engine Maintenance Detailed instructions and recommendations for break-in and regular maintenance are specified in the Engine Owner’s man- ual. Please refer to this manual for engine servicing, lubricating oil levels with quality and viscosity recommendations, bolt torques, etc. The engine warranty is backed by the manufacturer. Engine Oil and Filter Oil drain valve WARNING...

  • Page 18: Carbon Canister

    Carbon Canister Fuel evaporation system filter Some Hustler Sport mowers produced after serial number 11010000 will have a carbon canister incorporated into the fuel Fuel tank system. Figure 5-3 This is a mandatory feature that is required on all mowers using gasoline engines that are put into operation in California.

  • Page 19: Engine Rpm Settings

    Engine RPM Settings The engine rpm’s are set at the factory for maximum mowing efficiency. Occasionally it may be necessary to check and adjust the settings. The idle speeds should be set as follows: B&S 17.5/21 hp ENGINE SPEED MODEL NO. ENDING WITH: HIGH IDLE MODEL NO.
  • Page 20 NOTE: Model numbers may or may not end with an extension after the number. There are several different extensions that may be shown; i.e. EX or CE. Example: 922222 (no extension) 922222 EX 922222 CE 922222 US REV E 108934...

  • Page 21: Deck Adjustments

    DECK ADJUSTMENTS Deck Leveling Block Block 1. Park the mower on a hard, flat surface. 2. Check tire pressures (8 – 12 psi) to make certain the tires are properly inflated before starting to level deck. WARNING Stop engine. Make sure deck clutch switch is in the down (OFF) position.
  • Page 22 Deck link Deck link Figure 6-4 REV E 108934...

  • Page 23: Blades

    Use a 15/16” wrench to remove the 5/8” cap screw holding the blade to the spindle shaft from underneath. NOTE: A blade ® holding tool (part number 381442) is available from Hustler Turf Equipment. It is designed to prevent the blades from rotat- Original edge ing when they are being removed or installed on the spindle.

  • Page 24: Belts

    Cutting edge Spring chain Twisted Blade Edge Spring chain (replace) anchor point Cutting Plane Cutting edge Straight Blade Edge End view of blades, comparing twisted and straightened blades Figure 6-7 Belts Idler spring Inspect belts frequently for wear and serviceability. Replace a belt that shows signs of severe cuts, tears, separation, weather Figure 6-8 checking and cracking, or burns caused by slipping.

  • Page 25: 42" Deck Belt Routing & Tensioning

    NOTE: The following notes are the same for the different decks shown. 1. Spring length after tensioning new belt. Measured from outside of hook to outside of hook with deck set at 3¼" cut height. 2. Route belt as shown. 42"...

  • Page 26: 54" Deck Belt Routing & Tensioning

    54" Deck Belt Routing & Tensioning 8.3” – 9.3” Figure 6-13 REV E 108934...

  • Page 27: 36" Rd Deck Belt Routing & Tensioning

    36" RD Deck Belt Routing & Tensioning 4.5” – 5.5” Figure 6-14 108934 REV E...
  • Page 28 REV E 108934...

  • Page 29: Electrical

    ELECTRICAL Electrical Schematic — Briggs & Stratton & Kawasaki 108934 REV E...

  • Page 30: Electrical Schematic - Honda Gxv 530

    Electrical Schematic — Honda GXV 530 NOTE: Honda engines are not available on CE or Export mowers. REV E 108934...

  • Page 31: Electrical Schematic - Kohler

    Electrical Schematic — Kohler NOTE: Kohler engines are not available on domestic mowers. 108934 REV E...
  • Page 32 REV E 108934...

  • Page 33: Maintenance

    MAINTENANCE Maintenance Schedule Refer to Figure 8-1, Figure 8-2, Figure 8-3, Figure 8-4, Figure 8-5, Figure 8-6 & Figure 8-7 WEEKLY ANNUALLY SERVICE AT OR 40 OR 100 INTERVALS INDICATED HOURS HOURS Verify safety start interlock system Prior to each use Visually inspect unit for loose hardware and/or damaged parts Prior to each use Visually inspect tires...

  • Page 34: Maintenance Locator Chart

    Maintenance Locator Chart Figure 8-1 1. Engine Oil Fill & Dipstick 2. Fuel Filter 3. Engine Air Cleaner 4. Engine Oil Drain Valve 5. Battery 6. Fuel Tank 7. Engine Oil Filter 8. Deck Lift Pivot Zerks (4) 9. Park Brake Switch (2) 10.

  • Page 35: Troubleshooting

    TROUBLESHOOTING The majority of operating problems that occur with a system can be traced to improper adjustments or delayed service. A consistently applied preventative maintenance program will prevent many problems. The following chart is designed to help you locate a problem by suggesting probable causes and the recommended solutions. PROBABLE SUGGESTED SYMPTOMS...
  • Page 36 REV E 108934...
  • Page 37 Standard torques ............ 3-1 General engine maintenance .........5-1 Steering adjustments ..........4-1 General maintenance precautions ......2-2 Steering control lever neutral adjustment .... 4-1 Hustler service program .........1-1 Steering damper ............. 4-2 Hydraulic pump belt adjustment ......4-4 Tires ................ 4-4 Maintenance introduction ........1-1 Warranty ..............

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