Country Clipper CHARGER 1050 Operator's Manual
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Country Clipper CHARGER 1050 Operator's Manual

Zero turn mower
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2017 Product Support Documents
Manuals
Country Clipper Operators Manual
Country Clipper Parts Manual
Kawasaki Engine Owner's Manual
Kohler Engine Owner's Manual
ROPS Safety Information
Warranty
Country Clipper Warranty
Kawasaki Engine Warranty
Kohler Engine Warranty
Hydro-Gear Warranty
Battery Warranty
Additional Information
Country Clipper Product Specifications

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  • Page 1 2017 Product Support Documents Manuals Country Clipper Operators Manual Country Clipper Parts Manual Kawasaki Engine Owner’s Manual Kohler Engine Owner’s Manual ROPS Safety Information Warranty Country Clipper Warranty Kawasaki Engine Warranty Kohler Engine Warranty Hydro-Gear Warranty Battery Warranty Additional Information...
  • Page 2 Safety Instructions & Operators Manual Congratulations for buying a Country Clipper product. Your Country Clipper Zero Turn Radius Riding Mower was designed and built to provide long and trouble free service. Keep in mind that it, like any other mechanical device, can be potentially dangerous if used improperly, and hazard control and accident prevention are dependent upon the awareness, concern, prudence, and proper training of personnel involved in the operation, transport, maintenance, and storage of the equipment.
  • Page 3   HOME...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS MODEL NUMBER’S & SERIAL NUMBER’S ................2 SAFETY ............................3 ACCIDENT PATTERNS TO AVOID ....................... 3 SAFETY INSTRUCTIONS AND RECOMMENDATIONS ................3 SAFETY INTERLOCK SYSTEM ........................5 START UP AND OPERATION ....................6 CHECKLIST BEFORE OPERATION ......................6 CONTROL LOCATIONS JOYSTICK MODELS ...................

  • Page 5: Model Number's & Serial Number's

    MODEL NUMBER’S & SERIAL NUMBER’S Date of Purchase: ____________________________________________ Mower Model Number: ____________________________________________ Mower Serial Number: ____________________________________________ Engine Spec Number: ____________________________________________ Hydro Serial Number (RH): ____________________________________________ Hydro Serial Number (LH): ____________________________________________ HOME...

  • Page 6: Safety

    BLADE -- This accident usually happens OR ARE OTHERWISE ASSOCIATED when the operator is clearing the with the Country Clipper Zero Turn discharge chute of grass, (especially Radius Mower should be trained in its when the grass is wet), or when the proper use and warned of its dangers.
  • Page 7 DO NOT MOVE CONTROL LEVER(S) NEVER REMOVE THE FUEL CAP or from forward position to reverse position add gasoline to a running or hot engine rapidly. The speed and/or direction of that has not been allowed to cool for travel is affected instantly by movement several minutes after running.

  • Page 8: Safety Interlock System

    APPROVED ACCESSORIES. SAFETY INTERLOCK SYSTEM DO NOT CHANGE THE ENGINE GOVERNOR SETTING or over speed Your Country Clipper Zero Turn Radius Mower the engine. is equipped with switches interlocked for your safety. BEWARE OF MOWER DISCHARGE...

  • Page 9: Start Up And Operation

    5. The engine will stop if the brake is “SET” IMPORTANT: Before cutting grass, clutch must and the mower blade clutch is engaged. be broken-in as follows: With engine at full RPM engage deck until blades come to full speed and then disengage until DO NOT OPERATE MOWER IF SAFETY blades come to a complete stop.

  • Page 10: Operation Joystick Models

    Reinsert the Cut Height Stop Pin. IMPORTANT: Until the operator is familiar with the 12. ENGAGE MOWER BLADE CLUTCH: Set Country Clipper Zero Turn Radius engine throttle to 1/2–3/4 throttle, engage the Blade Clutch Switch to the “ON” position, Mower, he/she should follow these...

  • Page 11: Control Locations Twinstick Models

    Left Hand Cut Height CAUTION Steering Adjustment Lever Parking Brake Control Lever Lever AVOID HILLS AND SLOPES. USE EXTREME CAUTION WHEN MOWING UP OR DOWN SLOPES. NEVER MOW ACROSS THE FACE OF A SLOPE. IF A SLOPE MUST BE ASCENDED, BACK UP THE SLOPE; DRIVE FORWARD WHEN DESCENDING.
  • Page 12 Cut Height Adjustment Lever Until the operator is familiar with the with enough hand pressure to freely move Country Clipper Zero Turn Radius the Cut Height Pin, rotate the Cut Height Mower, he/she should follow these Stop Pin so the key on the pin aligns with the...

  • Page 13: Operation Free Wheel

    CAUTION CAUTION WHEN LEAVING THE MOWER NEVER OPERATE MOWER WITHOUT UNATTENDED, ALWAYS REMOVE THE KEY DISCHARGE CHUTE IN PLACE. AND SET THE PARKING BRAKE, EVEN IF JUST FOR A FEW MOMENTS. HELP MOWING RECOMMENDATIONS PROTECT CHILDREN AND OTHER UNAUTHORIZED PERSONS FROM 1.

  • Page 14: Maintenance

    MAINTENANCE CAUTION BEFORE PERFORMING ANY MAINTENANCE, TURN OFF ENGINE REMOVE KEY AND DISCONNECT SPARK PLUGS. USE EXTREME CARE WHEN WORKING ON MACHINERY. DO NOT WEAR WATCHES OR JEWELRY. DO NOT WEAR LOOSE FITTING CLOTHES, AND OBSERVE ALL COMMON SAFETY PRACTICES WITH TOOLS. MAINTENANCE SCHEDULE Maintenance Service Interval Maintenance Procedure...
  • Page 15 This page intentionally left blank. HOME...

  • Page 16: Maintenance Instructions

    Model Front tires Rear tires included in your Country Clipper Zero 12-15 psi 12-15 psi Turn Radius Mower information packet. Models 83-103 kPa 83-103 kPa...

  • Page 17: Joystick Adjustment

    5. V-BELTS: JOYSTICK ADJUSTMENT All belts should be checked every 50 1. SETTING TRACKING AND FORWARD hours. Replace any belts found to be in SPEED: poor condition. All belts are equipped with spring loaded belt tighteners and do A. The initial setting is done with the engine not require tightening adjustments.
  • Page 18 G. Now set the LH transmission speed. Reconnect the linkage to the left side transmission. (see left side transmission illustration on previous page). H. Loosen the jam nuts on both ends of the Inside left side transmission linkage. One of Linkage these is a left-hand thread.

  • Page 19: Twinstick Adjustment

    Long silver spacer Neutral Cross Bolt Plate Long silver spacer Short gold spacer Neutral Plate Nuts Short gold spacer B. Start the engine. With the joystick still down, position the handle so both wheels are stationary. C. Tighten the two nuts on the bottom of TWINSTICK ADJUSTMENT the neutral plate, being careful not to shift it out of position.

  • Page 20: Hydrostatic Transmission

    C. After all the oil is drained out, replace the Lock Nut filter (use part # H-2026 when ordering from Country Clipper).Wipe off the filter base surface, apply a film of new oil to the gasket of the new filter and hand HYDROSTATIC TRANSMISSION tighten ¾...

  • Page 21: Seat Hold Down Latch

    SEAT HOLD DOWN LATCH D. Position the front caster wheels so they are away from the deck (such as the tractor would be traveling in reverse). To release the seat hold down latch, pull E. Lift the nose of the deck until the deck the latch handle to the right.
  • Page 22 MOWER SHOWN IN OPERATING POSITION. Cut Height Adjustment Lever Cut Height Adjustment Flip Front Step Up Foot Deck Front Caster Pivot Grease Zerk Front Caster Wheels Latch Plate Release positioned out of the way. Handle Hook Release Keeper Handle Deck Hook MOWER SHOWN IN SERVICING POSITION.

  • Page 23: Securing The Deck Prop

    SECURING THE DECK PROP Deck Prop shown in the “Stowed” position. Deck Prop being placed against the Deck lift casting. Deck Prop securely in place against Deck lift casting. HOME...

  • Page 24: Leveling The Deck

    4. Measure from the ground to the front blade tip of each outside blade. These measurements should be within 1/8” of each other. (NOTE: To simplify this measuring, an optional Blade Measuring tool, part Number 629-374A is available from your local “Country Clipper” Dealer). Deck hanger bolt Part # F-1936 1/2"...

  • Page 25: Adjusting The Latch Plate

    ADJUSTING THE LATCH PLATE 1. Level the deck before proceeding to adjust the latch plate. (Follow instructions on previous page.) Pin the deck in the lowest position before proceeding to adjust the latch plate. 2. Lift up on the hook keeper, while pulling up on the release handle. This will disconnect the rear of the deck.

  • Page 26: Trouble Shooting Check List

    TROUBLE SHOOTING CHECK LIST ENGINE WON’T TURN OVER: Mower blades engaged ---------------------------------------------------------------- disengage blades Drive not in neutral ---------------------------------------- move Control Lever(s) to neutral position Blown fuse ---------------------------------------------------------------------------------------- replace fuse Dead battery ------------------------------------------------------------------------------ charge or replace Solenoid ---------------------------------------------------------------------------------------- consult dealer Ignition switch --------------------------------------------------------------------------------- consult dealer Starter ------------------------------------------------------------------------------------------- consult dealer ENGINE WILL TURN OVER BUT WON’T START:...
  • Page 27 ENGINE SOMETIMES SKIPS AT HIGHER SPEEDS: Incorrect Ignition Timing -------------------------------------------------------------------- consult dealer Carburetor maladjusted --------------------------------------------------------------- readjust carburetor Faulty spark plugs ------------------------------------------------------------------------ check spark plug condition and reset gap* Bouncing off seat safety switch ------------------------------------------ slow down on rough terrain ENGINE OVER HEATED: Air intake screen or fins clogged --------------------------------------- clean intake screen and fins Fuel mixture too lean ----------------------------------------------------------------- readjust carburetor* Oil level too low or too high ---------------------------------------------------------------- adjust oil level...

  • Page 28: Belt Routings

    BELT ROUTINGS Hydrostatic Transmission Drive Belt (Viewed from ground looking up) Release tension from Hydrostat Drive Belt Left Hand Hydrostatic Right Hand Hydrostatic Transmission Pulley Transmission Pulley Idler Pulley Belt P/N D-3524 Motor Pulley Deck Drive Belt 60” DECK BELT Clutch 52”...

  • Page 29: Wiring Schematic For Kawasaki Joystick (E-6415)

    WIRING SCHEMATIC FOR KAWASAKI JOYSTICK (E-6415) PLUS (E-6417) ADAPTER HOME...

  • Page 30: Wiring Schematic For Kawasaki Twinstick (E-6416)

    WIRING SCHEMATIC FOR KAWASAKI TWINSTICK (E-6416) PLUS (E-6417) ADAPTER HOME...

  • Page 31: Wiring Schematic For Kohler Joystick (E-6415)

    WIRING SCHEMATIC FOR KOHLER JOYSTICK (E-6415) PLUS (E-6547) ADAPTER HOME...

  • Page 32: Wiring Schematic For Kohler Twinstick (E-6416)

    WIRING SCHEMATIC FOR KOHLER TWINSTICK (E-6416) PLUS (E-6547) ADAPTER HOME...

  • Page 33: Hydraulic Schematic

    HYDRAULIC SCHEMATIC: OIL COOLER OIL TANK CASE DRAIN CHARGE PUMP INLET HIGH PRESSURE RIGHT-HAND LEFT-HAND HYDROSTATIC HYDROSTATIC TRANSMISSION TRANSMISSION HIGH PRESSURE - REVERSE LEFT-HAND WHEEL MOTOR RIGHT-HAND WHEEL MOTOR HOME...

  • Page 34: Notes / Service Records

    NOTES / SERVICE RECORDS: DATE SERVICE WORK COMPLETED HOME...

  • Page 35: Notes / Service Records

    NOTES / SERVICE RECORDS: DATE SERVICE WORK COMPLETED HOME...
  • Page 36   HOME...
  • Page 37 Safety Instructions & Operators Manual Country Clipper Division Shivvers Manufacturing Inc. 613 W. English St. Corydon, IA 50060-0467 Ph. 641-872-2544 Fax. 641-872-1593 P-13333 HOME...
  • Page 38 Repair Parts Manual P-13332 HOME...
  • Page 39 HOME...
  • Page 40 E-6415 WIRE HARNESS ASSEMBLY & RELATED PARTS E-6416 WIRE HARNESS ASSEMBLY & RELATED PARTS E-6417 WIRE HARNESS ADAPTER & RELATED PARTS E-6547 WIRE HARNESS ADAPTER & RELATED PARTS Country Clipper Division Shiwers Manufacturing Inc. 613 W. English St. Corydon, IA50060-0437 Ph. 641-872-2544 Fax. 641-872-1593 P-13332 HOME...

  • Page 41: Deck Assembly

    52" HEAVY DECK ASSEMBLY j668V-002A} DRAG BAR (SEE PG. 7) PART PART QTY. QTY. DESCRIPTION DESCRIPTION 609-183P BUSHING F-2160 FHCS, 3/8-16 x 4 1/2", YZ, GR5 629-229W DUST BAFFLE, 52" F-2161 FHCS, 3/8-16 x 6", Y2, GR5 643-016W Hanger Weldment F-2162 FHCS, 1/4-20 x 3/4", GR5, YZ 643-110P...
  • Page 42 60" HEAVY DECK ASSEMBLY i668U-002Ai DRAG BAR (SEE PG. 7) PART PART QTY. DESCRIPTION QTY. DESCRIPTION 609-183P BUSHING F-2160 FHCS, 3/8-16 x 4 1/2", YZ, GR5 643-016W Hanger Weldment F-2161 FHCS, 3/8-16 x 6", VZ, GR5 643-104W 60" DUST BAFFLE WELDMENT F-2575 SPRING, COMP .656 X .052 X 1.97 643-110P...

  • Page 43: Deck Spindle Assembly

    DECK SPINDLE ASSEMBLY 629FN-001A TORQUE TO 250 ft-lb 1 PULLEY NOT INCLUDED *2 IN ASSEMBLY -------- 12 (APPLY THIN LAYER OF CHEVRON RYKOTAC GREASE TO THE TOP SURFACES OF THE BEARING AND HOUSING PRIOR TO INSTALLING ITEM #3 (BEARING CAP). NEW MOWERS ARE SHIPPED WITH 3 to 4 oz OF CHEVRON SRI NLGI 2 GREASE INSIDE EACH SPINDLE...
  • Page 44 DOUBLE IDLER DRIVE BELT IDLER & RELATED PARTS 52" DECK REAR STATIONARY IDLER ASSEMBLY FRONT STATIONARY IDLER ASSEMBLY PART PART QTY. DESCRIPTION QTY. DESCRIPTION 620-201P WASHER, BEARING CAP F-1019-03 3/8" LOCKWASHER 6 59-D85P Mounting Pin F-1394 3/8-16 x 1" Capscrew 660 - D31P F - 1464 Belt Tightner Arm...
  • Page 45 DOUBLE IDLER DRIVE BELT IDLER & RELATED PARTS 60" DECK REAR STATIONARY IDLER ASSEMBLY FRONT STATIONARY IDLER ASSEMBLY PART PART QTY. DESCRIPTION QTY. DESCRIPTION F-1019- 03 620-201P WASHER, BEARING CAP 3/8" LOCKWASHER 659-085P Mounting Pin F-1464 1/2" LOCKWASHER 660-D36P Idler Arm F-1489 1/2-13 Hex Jam Nut 660 -038P...

  • Page 46: Molded Chute Assembly

    MOLDED CHUTE ASSEMBLY l643-1 11Ai PART DESCRIPTION 643-llOP CHUTE HINGE H-2723 CHUTE, DISCHARGE, SMALL F-2066 5/16-18 l" CARRIAGE BOLT, F-2063 NUT 5 16-18 NYLOC FLANGED P-13332 HOME...
  • Page 47 LIFT HANDLE AS SEMEL Y & RELATED PARTS !1) -- 16 PART PART QTY. DESCRIPTION QTY. DESCRIPTION 709-102P LIFT HANDLE, LOWER F-2125 FHCS, 1/2-13 X 1 1/4", YZ GR5 659-022W FRAME WELDMENT, LH. F-1439 1/2-13 X 3" GR. 5 F-2126 3/8-16 X 2"...

  • Page 48: Lift Assembly & Related Parts

    LIFT ASSEMBLY & RELATED PARTS __ � 659-171A RELEASE HANDLE ASSEMBLY PART PART QTY. DESCRIPTION QTY. DESCRIPTION 659-140P DECK HOOK 642-063P DRAG BAR TAB 659-299P DRAG LINK BAR 659-148W RELEASE HANDLE WELDMENT 659-372P 620-051P LIFT BAR HOOK KEEPER H-3011 642-081P LIFT SLEEVE, FRONT SPRING, TORSION F-2151...

  • Page 49: Transmission Idlers & Related Parts

    TRANSMISSION IDLERS & RELATED PARTS 15-(x2) PART OF IDLER ARM ASS'Y #2 PART PART QTY. DESCRIPTION QTY. DESCRIPTION 659-085P Mounting Pin F-1936 1 /2-13 x 3-1 /2" Capscrew 663-057A Hydro Idler Arm Assembly F-2063 Nut, 5/16-18 Nyloc, Flanged PLATE, PUMP ADAPTER 663-146P F-2148 FHCS, 5/16-18 x 1.00, YZ, GR5...

  • Page 50: Caster Wheel Assembly

    CASTER WHEEL ASSEMBLY NOTCH TO REAR OF MOWER NUT TO INSIDE OF MOWER VALVE STEM TO Side) OUTSIDE OF MOWER PART PART QTY. DESCRIPTION QTY. DESCRIPTION 636-176P Bearing Cap F-1855 3/16 x 1" Roll Pin (Heavy Duty) 659-185P Stop Tab F-2030 1 / 4 x 5/8 Self Tapping Capscrew Fl-KS, 5/16-1&1.00, Yl, LOO<...

  • Page 51: Frame Sides & Related Parts

    FRAME SIDES & RELATED PARTS PART PART QTY. DESCRIPTION QTY. DESCRIPTION F-2124 FHCS, 3 8-1 6 X 3 4 GR.5 663-185W FRAME SIDE RH. 663-187W FRAME SIDE LH. F-2128 FHCS, 1 /2-13 X 2", GR.5 709-157W AXLE MOUNTING WLDT. H-2812 SEAL SHAFT 663-176W MOTOR MOUNT WLDT.

  • Page 52: Fender Assembly

    FENDER ASSEMBLY & RELATED PARTS TWINSTICK FENDER ASSY PART PART QTY. DESCRIPTION QTY. DESCRIPTION 629-840A FENDER CAP w/DECAL, RH, (J S ) F-2119 FHCS, 1/4-20x3/4", GR.5 w/PATCH 629-892A FENDER CAP w/DECAL, EFI, RH, (JS F-1125 5/16-18 LOCK NUT 629-842A FENDER CAP w/DECAL, RH, (TS) H-3013 DECK HEIGHT PIN 629-893A...
  • Page 53 SEAT, FOOTDECK & RELATED PARTS UNDERSIDE OF SEAT MOUNTING BASE "#1" - LATCH PARTS 1� 17 � 28..U.owrn SIDE PLATE •• 2912 3 0 37 PART PART QTY. DESCRIPTION QTY. DESCRIPTION F - 2162 FHCS, 1 4 - 20 X 3 4, GR5, YZ 663-194P PLATE, SEAT...

  • Page 54: Front Step Assembly

    FRONT STEP ASSEMBLY � PART QTY. DESCRIPTION 663-134P FRONT STEP F-2142 FHCS, 3/8-16 X 4" GR.5 F-2151 NUT, 3/8-16, NYLOC FLANGED 659-241 P BRACKET, STEP MOUNT, RH 659-242P BRACKET, STEP MOUNT, LH H - 2461 RUBBER BUMPER BUTION F-2124 FHCS, 3/8-16 X 3/ 4" GR.5 P-13332 HOME...
  • Page 55 ROPS ASSEMBLY (H-2682) AND RELATED PARTS MOWER LEFT SIDE PANEL PART QTY. DESCRIPTION F-2088 HHCS 1/2-13 x 1 1/4" F-2089 FLAT WASHER 1 /2""1 F-2090 TOP LOCK NUT 1 /2""1 F - 2093 PULL PIN-1/2 W/COTTER KEY H-2701 SPRING H-2700 POLYURETHANE CHANNEL F-2091 HHCS 1/2-13 x 1 1/2"...

  • Page 56: Fuel Tank Assembly

    FUEL TANK ASSEMBLY H-2944 (INCLUDES ALL PARTS EXCEPT #6-10) ,� � {J PART QTY. DESCRIPTION ----- 7 GALLON TANK, VENTED H-2678 REMOTE VENT H-2679 REMOTE VENT GROMMET H-2742 PICK UP TUBE H-2741 GROMMET, PICK UP TUBE H-1687 HOSE CLAMP, 1 /2" H-2698 VENT LINE CLAMP H-1648...
  • Page 57 JOYSTICK STEERING CONTROL AND RELATED PARTS ..1 PART PART QTY. DESCRIPTION QTY. DESCRIPTION JOYSTICK ASSEMBLY 625-172A 707-082P LINKAGE, INNER, JOYSTICK BUTTON SHCS, 1/4-20x1" F-2103 625-107P BUSHING, .375 ROD END PIN, PIVOT, JS, LONG 625-119P TUBE, PIVOT, JOYSTICK 625-100P 1/2" WASHER F-1521 OUTER, LINKAGE, JOYSTICK 707-083P...
  • Page 58 JOYSTICK ASSEMBLY 625-172A / TORQUE TO: 10 FT-LBS YOKE, SWIVEL ASSEMBLY 1625-169A! ITEM PART QTY. DESCRIPTION ITEM PART# QTY. DESCRIPTION 709-169A ROD ASSEMBLY, SHORT F-1503 3/16 x 1" SPIRAL PIN H-1947 GASKET, FOAM, JOYSTICK H-2710 SPRING, DETENT, JOYSTICK 625-095P HOUSING, JOYSTICK 625-103P TAB, CAM DETENT 625-106P...
  • Page 59 JOYSTICK STEERING CONTROL AND RELATED PARTS (CON'T) TORQUE TO: 10 FT-LBS PART PART QTY. DESCRIPTION QTY. DESCRIPTION 700-150P HYDRO SHIFT ROD 663-051P DAMPNER BOLT, FEMALE F-2063 NUT, 5/1 6", NYLOC FLANGED F-1610 E-RING F-1009-02 5/16" FLAT WASHER 638 - 028P 5/16 - 18 X 3/4"...
  • Page 60 TWINSTICK STEERING CONTROL & RELATED PARTS (RIGHTHAND SHOWN, LEFTHAND OPPOSITE) TRANSMISSION/ PART PART QTY. DESCRIPTION QTY. DESCRIPTION 663-050P LINK ROD ASSEMBLY F-1486 3/8-16 JAM NUT H-2739 GRIP, 15", CLOSED END F-1019-01 1/4" LOCK WASHER 659-364W DUAL LEVER CONTROL F-1610 E-RING FOR 1/4" SHAFT F-2063 NUT, 5/16-18, NYLOC FLANGED F-1307...
  • Page 61 PARKING BRAKE ASSEMBLY & RELATED PARTS SEE PAGE 13 FOR SEAT HINGE PARTS PART PART QTY. DESCRIPTION QTY. DESCRIPTION 663-165P LINK, ADJUSTABLE, BRAKE 647-010P BRAKE ANCHOR LINK F-2063 NUT, 1 /2" FLANGED, NYLOC F-1491 1 /8 X 1" COTIER PIN WLDT, CAM LEVER 663-166W D-3668...
  • Page 62 GEAR MOTOR,WHEEL ASSEMBLY ITEM #4 INCLUDES ITEMS #8 & #13 TORQUE TO: 200 FT-LBS PART QTY. DESCRIPTION 663-176W MOTOR MOUNT 647-017P BRAKE MOUNT F-2152 NUT, 1/2-13, NYLOC FLANGED D-3908 15.9 CIR PARKER WHEEL MOTOR F-1668 1/2-13 X 2 3/4" BOLT GR. 5 F-1654 WHEEL STUD (REPLACEMENT) 663-207A...
  • Page 63 MOTOR ASSEMBLY & RELATED PARTS FOR 25.5HP KAWASAKI 29 - � " '-.;, � ""28 � - - 2 7 TORQUE TO: 60FT-LBS PART PART QTY. DESCRIPTION QTY. DESCRIPTION F-2120 FHCS, 5 1 6-18 X M-5384 ENGINE, KAWASAKI, 25.5HP F-2125 FHCS, 3/8-16x1-1/4", Y2, GR5 P-10077 DECAL, "CLEAN"...
  • Page 64 MOTOR ASSEMBLY & RELATED PARTS FOR 26.5HP EFI KOHLER EFI FILLER & 02 SENSOR """"'-�F---1 (SEE ENGINE MANUAL) ""28 - - 2 7 TORQUE TO: 60FT-LBS PART PART QTY. QTY. DESCRIPTION DESCRIPTION M-5396 ENGINE KOHLER, 26.5HP EFI F-1228 1/4-20 NYLOC SETSCREW F-1019-03 3/8"...
  • Page 65 PLUMBING KIT HIGH PRESSURE LINES & FITTINGS iH-2846� � � TORQUE TO: 35FT-LBS ::----- TORQUE TO: 24FT-LBS TORQUE TO: 24FT-LBS TORQUE TO: 24FT-LBS /"'"' � " TORQUE TO: 35FT-LBS TORQUE TO: TORQUE TO: 24FT-LBS 24FT-L8S VIEWED FROM FRONT RIGHT PART QTY.
  • Page 66 PLUMBING KIT OIL RETURN LINES & COOLER ASSEMBLY iH-2846� TORQUE TO: 16FT-LBS TORQUE TO: 16FT - LBS TORQUE TO: 16FT-LBS PART PART QTY. DESCRIPTION QTY. DESCRIPTION OIL COOLER H-2908 H-2847 HOSE, 1 /2"rt, X 6", HI-TEMP F-1009-01 1/4" WASHER H-2859 OIL FILTER F-2162 FHCS, 1/4-20 X 3/4", Yl, GR5...
  • Page 67 E-6415 WIRE HARNESS & RELATED PARTS (JOYSTICK) TO SEAT SWITCH 7�- BLUE #14--fiBLUE #2A � Seat SW Clutch BLK�RED (2} BLUE� � lgo; t;o, 0NC LUD E5 #16 ) \:\l � � \ (2) BLUE__z_ED � TOCL.IITCH ?1--BLJ(. RED----0 � (2) RED BU( .�...
  • Page 68 E-6416 WIRE HARNESS & RELATED PARTS ( TWINS TI CK) TO SEAT SWITCH BWE #14 --fiBWE f2A � Seat SW Clutch •• YEL. (2) BLUE � YEL. #18) (2) RED PART QTY. DESCRIPTION BATIERY E - 6271 HOUR METER E-5878 START SWITCH E-5873 CLUTCH SWITCH...
  • Page 69 E-6417 KAWASAKI ADAPTER HARNESS RELATED PARTS & TO OIL PRESSURE SWITCH GREEN GRN/WHT TO ENGINE ,..= =L-' ����= -..TO FUEL SHUT-OFF TO BATIERY + YEL. / TO STARTER TO ENGINE STARTER PART QTY. DESCRIPTION E-6415 WIRE HARNESS (JOYSTICK) E-6416 WIRE HARNESS (TWINSTICK) E-6418...

  • Page 70: Harness Adapter

    E-6547 KOHLER E.F.I. HARNESS ADAPTER & RELATED PARTS INDICATOR LIGHT TO BATTERY + TO ENGINE TO ENGINE STARTER PART QTY. DESCRIPTION E-6415 WIRE HARNESS (JOYSTICK) E-6416 WIRE HARNESS (TWINSTICK) E-6418 CABLE, BATTERY TO SOLENOID E-6314 INDICATOR LIGHT P-13332 HOME...
  • Page 71 NOTES / SERVICE RECORDS: DATE SERVICE WORK COMPLETED HOME...
  • Page 72 HOME...
  • Page 73 Repair Parts Manual Country Clipper Division Shivvers Manufacturing Inc. 613 W. English St. Corydon, IA 50060-0467 Ph. 641-872-2544 Fax. 641-872-1593 P-13332 HOME...
  • Page 74 FX801V, FX751V 4 stroke air-cooled V-twin gasoline engine OWNER’S MANUAL HOME...
  • Page 75 HOME...
  • Page 76 SAFETY AWARENESS Whenever you see the symbols shown below, NOTICE heed their instructions! Always follow safe operating and maintenance practices. NOTICE is used to address practices not related to personal injury. DANGER DANGER indicates a hazardous situation NOTE which, if not avoided, will result in death or ○...
  • Page 77 READ THIS FIRST For your safety, read this Owner’s Manual and understand it thoroughly before operating this ENGINE. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death. DO NOT run the engine in enclosed areas. Operate only in a well-ventilated area. Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns.
  • Page 78 EMISSION CONTROL INFORMATION Fuel Information THIS ENGINE IS CERTIFIED TO OPERATE ON UNLEADED REGULAR GRADE GASOLINE ONLY. A minimum of 87 octane of the antiknock index is recommended. The antiknock index is posted on service station pumps in the U.S.A. Emission Control Information To protect the environment in which we all live, Kawasaki has incorporated an exhaust emission control system in compliance with applicable regulations of the United States Environmental Protection Agency and the...
  • Page 79 High Altitude Performance Adjustment Information To improve the EMISSIONS CONTROL PERFORMANCE of engines operated above 1000 meters (3300 feet), Kawasaki requires the following Environmental Protection Agency (EPA) and California Air Resources Board (CARB) approved modifications. High altitude adjustment requires replacement of carburetor main jets.
  • Page 80 Tampering with Emission Control System Prohibited Federal law and California State law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new engine for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the engine after such device or element of design has been removed or rendered inoperative by any person.
  • Page 81 FOREWORD We wish to thank you for purchasing this Kawasaki engine. Please read this Owner’s Manual carefully before starting your new engine so that you will be thoroughly familiar with the proper operation of your engine’s control, its features, capabilities and limitations. Also read the manual of the equipment to which this engine is attached.
  • Page 82 TABLE OF CONTENTS GENERAL INFORMATION ....... MAINTENANCE ..........24 Location of Safety Related Labels ....Periodic Maintenance Chart ......24 Location of Parts ..........Oil Level Check ..........26 Engine Serial Number ........10 Oil Cooler Service ........... 26 Tune-up Specifications ........10 Oil Change ............

  • Page 83: General Information

    8 GENERAL INFORMATION GENERAL INFORMATION Location of Safety Related Labels A. Warning Label B. Engine Maintenance HOME...

  • Page 84: Location Of Parts

    GENERAL INFORMATION 9 Location of Parts A. Oil Gauge Filler I. Electric Starter B. Oil Filter J. Voltage Regulator C. Oil Drain Plug K. Fuel Tube D. Air Cleaner L. Fuel Filter E. Carburetor M. Oil Cooler F. Spark Plug Cap/ N.

  • Page 85: Engine Serial Number

    10 GENERAL INFORMATION Engine Serial Number Tune-up Specifications The engine serial number is your only means of ITEM Specifications identifying your particular engine from others of the Ignition Timing Unadjustable same model type. Spark Plugs: NGK BPR4ES This engine serial number is needed by your 0.75 mm (0.030 in) dealer when ordering parts.

  • Page 86: Engine Oil Capacity

    GENERAL INFORMATION 11 Engine Oil Capacity Engine Oil Capacity 2.1 L (2.2 US·qt) [when oil filter is not removed] FX801V FX751V 2.3 L (2.4 US·qt) [when oil filter is removed] HOME...

  • Page 87: Fuel And Oil Recommendations

    12 FUEL AND OIL RECOMMENDATIONS FUEL AND OIL RECOMMENDATIONS Oxygenated Fuel Fuel Oxygenates (either ethanol or MTBE) are added to the gasoline. If you use the oxygenates, be sure it Use only clean, fresh, unleaded regular grade is unleaded and meets the minimum octane rating gasoline.

  • Page 88: Engine Oil

    FUEL AND OIL RECOMMENDATIONS 13 Engine Oil The following engine oils are recommended. API Service Classification: SF, SG, SH, SJ or SL. Oil Viscosity Choose the viscosity according to the temperature as follows: -20ºC -10ºC 0ºC 10ºC 20ºC 30ºC 40ºC SAE40 SAE30 SAE20W-50...

  • Page 89: Preparation

    14 PREPARATION PREPARATION ● Place the engine on level surface before fueling. Fuel ● Remove the fuel tank cap. ● Slowly pour fuel into the tank through the fuel WARNING strainer. ● Close the tank cap securely. Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns.

  • Page 90: Engine Oil

    PREPARATION 15 Engine Oil Check the engine oil daily before starting the engine otherwise shortage of the engine oil may cause serious damage to the engine such as seizure. ● Place the engine on level surface. Clean are a around the oil gauge before removing it. ●...

  • Page 91: Starting

    16 STARTING STARTING ○ Use proper oil for expected temperature (See Start Engine FUEL AND OIL RECOMMENDATIONS chapter). Use fresh gasoline. DANGER ○ Protect the engine or the equipment from direct exposure to weather when not in operation. Exhaust gas contains carbon monoxide, a ○...
  • Page 92 STARTING 17 A. Fuel Valve A. Throttle Lever A. Throttle Lever HOME...
  • Page 93 18 STARTING ● Put the switch key into the engine switch. NOTICE ● Turn the switch key to the START position on the equipment. Normally the engine will start within Do not run the electric starter continuously 3 seconds. for more than 5 seconds, otherwise the battery may discharge quickly.

  • Page 94: Operating

    OPERATING 19 OPERATING NOTICE Warming Up Allow engine to warm up sufficiently (3 to 5 After the engine starts, move the throttle lever on minutes at idle) before applying a load. This the equipment to halfway between “FAST” and will allow oil to reach all engine parts, and “SLOW”.

  • Page 95: Engine Inclination

    20 OPERATING Engine Inclination This engine will operate continuously at angles up to 25° in any direction. Refer to the operating instructions of the equipment this engine powers. Because equipment design or application, there may be more stringent restrictions regarding angle operation.

  • Page 96: Stopping

    STOPPING 21 STOPPING ● Close the fuel valve on the equipment. Stopping the Engine For Control Panel Switch Type, move the throttle lever on the equipment to its low speed end. Moving Ordinary Stop the lever to its low speed end turns ignition off. ●...

  • Page 97: Adjustment

    22 ADJUSTMENT ADJUSTMENT ● Move the equipment choke control to “CHOKE” Separate Choke Type position. Make sure that the carburetor choke valve (pivot arm) is completely closed. Throttle Cable Installation, Adjustment ● Make sure that the choke valve turns from fully ●...

  • Page 98: Engine Speed Adjustment

    ADJUSTMENT 23 Engine Speed Adjustment NOTE ○ Do not tamper with the governor setting or the carburetor setting to increase the engine speed. Every carburetor is adjusted at the factory and cap or stop plate is installed on each mixture screw.

  • Page 99: Maintenance

    24 MAINTENANCE MAINTENANCE Maintenance, replacement, or repair of the emission control devices and systems may be performed by any nonroad engine repair establishment or individual. Periodic Maintenance Chart WARNING Prevent accidental starting during engine service by removing the spark plug caps. NOTE ○...
  • Page 100 MAINTENANCE 25 INTERVAL MAINTENANCE Every Every Every Every Every Every Daily 50 hr. 100 hr. 200 hr. 250 hr. 300 hr. 500 hr. ● Check and add engine oil. ● Check for loose or lost nuts and screws. ● Check for fuel and oil leakage. ●...

  • Page 101: Oil Level Check

    26 MAINTENANCE Oil Level Check Oil Cooler Service Check the oil level daily and before each time of Check and clean oil cooler fins every 100 hours. ● operation. Be sure the oil level is maintained. See Clean dirt off the outside fins with a brush or PREPARATION chapter.

  • Page 102: Oil Change

    MAINTENANCE 27 ● Install the oil drain plug. Oil Change ● Remove the oil gauge and refill with fresh oil (See FUEL AND OIL RECOMMENDATIONS chapter). Change oil every 100 hours. ● ● Check the oil level (see PREPARATION chapter). Run the engine to warm oil.

  • Page 103: Oil Filter Change

    28 MAINTENANCE Oil Filter Change ● Change the oil filter every 200 hours of operation. WARNING Hot engine oil can cause severe burns. Allow engine temperature to drop from hot to warm level before attempting to remove oil filter. ● Drain the engine oil into a suitable container.

  • Page 104: Air Cleaner Service

    MAINTENANCE 29 NOTE Air Cleaner Service ○ Operating in dusty condition may require more frequent maintenance. NOTICE Primary Element Do not run the engine with the air cleaner Replace the primary element every 250 hrs. removed. Secondary Element Air Cleaner ●...
  • Page 105 30 MAINTENANCE ● Install the new air cleaner elements into the air cleaner body. ● Reinstall the case and the cap then securely fasten the two retaining clamps. D. Primary Element E. Secondary Element A. Retaining Clamps B. Case C. Air Cleaner Body F.

  • Page 106: Fuel Filter And Fuel Pump Service

    MAINTENANCE 31 Fuel Filter and Fuel Pump Service WARNING Improper use of solvents can result in fire or an explosion. Do not use gasoline or low flash-point solvents to clean the fuel filter and/or the fuel pump. Clean only in a well ventilated area away from sources of sparks or flame, including any appliances with a pilot light.

  • Page 107: Spark Plug Service

    32 MAINTENANCE RECOMMENDED SPARK PLUG Spark Plug Service NGK........BPR4ES WARNING Engines can become extremely hot during normal operation. Hot engine components can cause severe burns. Stop the engine and allow it to cool before checking spark plugs. Clean or replace the spark plugs and reset the gap every 100 hours of operation.

  • Page 108: Cooling System Cleaning

    MAINTENANCE 33 Cooling System Cleaning Before each operation, check that the air inlet (rotary) screen is free from grass and debris. Clean the screen if necessary. Every 50 hours of operation, check the inside fan housing from the cleanout covers. To inspect the inside, loosen bolts of the cleanout covers and remove them.

  • Page 109: Storage

    34 STORAGE STORAGE the gasoline from fuel tank completely. Engine Storage Procedure ● Install the sediment bowl. ● Put a pan under the carburetor and loosen the When not operating your Kawasaki engine more drain screw of the carburetor to drain the gasoline than 30 days, add fuel stabilizer to fuel tank and run completely.
  • Page 110 STORAGE 35 ● Remove the spark plugs and pour approx 1-2 mL (0.06-0.1 cu in.) of engine oil through the spark plug holes then screw the spark plugs in after turning the engine a few times. Slowly turn the engine until you feel the compression then leave it there.

  • Page 111: Troubleshooting Guide

    36 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE If the engine malfunctions, carefully examine the symptoms and the operating conditions, and use the table below as a guide to trouble shooting. Symptom Probable Cause Remedy Engine Insufficient Faulty pistons, cylinders, piston rings, and head gaskets won’t start compression Faulty valves...

  • Page 112: Environmental Protection

    ENVIRONMENTAL PROTECTION 37 ENVIRONMENTAL PROTECTION To help preserve the environment, properly discard used batteries, oils and fluids, or other engine components that you might dispose of in the future. Consult your authorized Kawasaki engine dealer or equally qualified service facility or local environmental waste agency for their proper disposal procedure.

  • Page 113: Specifications

    38 SPECIFICATIONS SPECIFICATIONS FX801V, FX751V Type Air-cooled, 4-stroke OHV 4Valves, V-twin cylinder, gasoline engine Bore × Stroke 84.5 × 76 mm (3.33 × 2.99 in.) Displacement 852 mL (52 cu.in.) Ignition System Solid-state ignition Direction of rotation Counterclockwise facing the PTO Shaft Starting system Electric starter Dry weight : kg (lbs)

  • Page 114: Wiring Diagram

    WIRING DIAGRAM 39 WIRING DIAGRAM Wiring Diagram (With 12 V - 15 A Charging Coil) WARNING For electrical safety, always remove cable from negative (–) side of battery before attempting any repair or maintenance. Battery Capacity Recommended Minimum Recommended Battery Capacity 12 V 550 CCA Class NOTE ○...
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  • Page 117 Part No. 99920-2231-07 WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. For repair / warranty assistance please contact your local Kawasaki Authorized Dealer, email: kawpower-website@kmc-usa.com or call toll-free 1-877-364-6404 HOME Printed in Japan...
  • Page 118 ECH630-ECH749, CH735/CH26, CH745 ECV630-ECV749, CV735, CV745 Owner's Manual IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating instruction of equipment that this engine powers. Ensure engine is stopped and level before performing any maintenance or service. Warranty coverage as outlined in the warranty card and on KohlerEngines.com.
  • Page 119 Safety Precautions WARNING: A hazard that could result in death, serious injury, or substantial property damage. CAUTION: A hazard that could result in minor personal injury or property damage. NOTE: is used to notify people of important installation, operation, or maintenance information. WARNING WARNING WARNING...
  • Page 120 Air Cleaner Dust Ejector Inner Element Retaining Clip Housing Valve Heavy-Duty Air End Cap Element Inlet Screen Cleaner Oil Fill/Dipstick Filter Minder Oil Cooler Oil Filter Low-Profi le Air Air Cleaner Fuel Filter Oil Fill Cleaner Base Paper Element Precleaner Rubber Seal Element Cover Air Cleaner...
  • Page 121 1. Place throttle control midway between slow Pre-Start Checklist and fast positions. 1. Check oil level. Add oil if low. Do not overfi ll. 2. Turn key switch to START position Release switch as soon as engine starts. If starter 2.
  • Page 122 Maintenance Instructions WARNING Before working on engine or equipment, disable Accidental Starts can cause engine as follows: 1) Disconnect spark plug severe injury or death. lead(s). 2) Disconnect negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) before servicing. Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or individual;...
  • Page 123 Fuel must meet these requirements: Change Oil and Filter ● Clean, fresh, unleaded gasoline. Change oil while engine is warm. ● Octane rating of 87 (R+M)/2 or higher. 1. Clean area around oil fi ll cap/dipstick and drain plug. Remove drain plug and oil fi ll cap/ ●...
  • Page 124 6. Reinstall end cap(s) with dust ejector valve/ Fuse Replacement screen down; secure with retaining clips. This engine has three (3) blade type automotive fuses. Replacement fuses must have same Breather Tube rating as blown fuse. Use fuse chart below to Ensure both ends of breather tube are properly determine correct fuse.
  • Page 125 Troubleshooting Do not attempt to service or replace major engine components, or any items that require special timing or adjustment procedures. This work should be performed by a Kohler authorized dealer. Possible Cause Broken Dirty Faulty Problem Improper Dirt In Fusible Debris Incorrect...
  • Page 126 P-13256 HOME...
  • Page 127 Clipper dealer to be defective in material, workmanship, or both, and operated and maintained as shown by Country Clipper's instructions and manuals for a period of 5 years of Residential use* from the date of original purchase. The first two years will include parts and labor. The third year will be parts only. The fourth and fifth year will be parts only on the mower deck weldment and frame weldment due to structural defect.
  • Page 128 Country Clipper. The servicing dealer will require a proof of purchase if the product has not been registered. The owner is responsible for delivery of the mower to the Country Clipper approved servicing dealer, within the Warranty period, and its return after Warranty work is completed.
  • Page 129 General Conditions Country Clipper may change the design of its products from time to time. Nothing contained in this Warranty shall be construed as obligating Country Clipper to incorporate said design changes into previously manufactured products, nor shall said changes be construed as an admission that previous designs were defective.
  • Page 130 KAWASAKI LIMITED WARRANTY FOUR-CYCLE ENGINE Kawasaki Motors Corp., U.S.A., P.O. Box 888285, Grand Rapids, MI 49588-8285 (hereinafter “Kawasaki”) warrants to the initial purchaser of each new Kawasaki four-cycle engine that such product shall be free, under normal use and maintenance, from any defect in material and workmanship for a period of thirty-six (36) months, subject to the following conditions, exclusions, obligations and limitations: COVERAGE.
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  • Page 133 Command PRO EFI Warranty Information The following warranty policies are current for Kohler engines. To determine the warranty and length of coverage associated with your Kohler engine, please refer to the Equipment Owner’s Manual and/or Kohler Warranty Card provided with the engine during sale as some engines may be covered by a warranty policy different than what is listed.
  • Page 134 have other rights which vary from country to country, or state to state within U.S.A. TO OBTAIN WARRANTY SERVICE: Original retail consumer must bring the engine to an authorized Kohler dealer found by visiting www.KohlerEngines.com or telephone 1-800-544-2444 (U.S.A. and Canada). Warranty Conditions-Australia The benefits given to you under this warranty are in addition to other rights and remedies that you have under Australian law in relation to the goods.
  • Page 135 MANUFACTURER’S WARRANTY COVERAGE: The 1995 and later SORE and evaporative emission control system is warranted for three years. If any exhaust or evaporative emission-related part on your SORE or engine powered equipment is defective, the part will be repaired or replaced by Kohler Co. OWNER’S WARRANTY RESPONSIBILITIES: As the SORE or engine powered equipment owner, you are responsible for the performance of the required maintenance listed in your owner’s manual.
  • Page 136 for disallowing a warranty claim. The manufacturer will not be liable to warrant failures of warranted parts caused by the use of a non-exempted add-on or modified part. PARTS COVERED BY WARRANTY Listed below are the parts (if equipped) covered by the Federal and California Emission Control Systems Warranty.
  • Page 137 Kohler Co. warrants to the original retail consumer that each new engine will be free from manufacturing defects in materials or workmanship for the applicable coverage period as set forth below, beginning on date of purchase; provided the engine is operated and maintained in accordance with Kohler Co.’s instructions and manuals.
  • Page 138 you have under Australian law in relation to the goods. All costs associated with claiming under this warranty must be borne by the consumer, including transport costs incurred in the repair or replacement of any defective part. Our goods come with guarantees that cannot be excluded under the Australian Consumer Law.
  • Page 139 purchaser. Kohler Co. warrants to the ultimate purchaser and each subsequent purchaser that the engine is: Designed, built, and equipped so as to conform with all applicable regulations adopted by the Air Resources Board and US EPA; and Free from defects in materials and workmanship that cause the failure of a warranted part to be identical in all material respects to the part as described in the engine manufacturer’s application for certification.
  • Page 140 Limitations This Emission Control Systems Warranty shall not cover any of the following: (a) Consequential damages such as loss of time, inconvenience, loss of use of the engine or equipment, etc. (b) Diagnosis and inspection fees that do not result in eligible warranty service being performed. ENGINE DIVISION, Kohler Co., Kohler Wisconsin HOME...
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  • Page 146 Interstate Batteries’ Limited Warranty (effective on batteries purchased May 1, 2012, or later) This limited warranty applies unless you return your battery within 30 days of purchase. Important: Keep this Limited Warranty and sales receipt in glove compartment. READ CAREFULLY: This limited warranty contains mandatory and binding individual arbitration and class-action waiver provisions, and other provisions that limit your legal rights.
  • Page 147 SPECIFICATIONS CHARGER – Joystick Steering MODEL 25552KAJ-1050 25560KAJ-1050 26560KOEJ-1050 Engine 25.5 H.P. Kawasaki 25.5 H.P. Kawasaki 26.5 H.P. Kohler FX801 (852cc) FX801 (852cc) ECV749 (747cc) Hydrostatic 12CC Hydro Gear Pumps Transmissions 15.9 CIR Parker Wheel Motors Steering Control Single Joystick Fuel Capacity 7 Gallons Tires, Rear...

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