Country Clipper Boss XL 9000 Product Manual
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Country Clipper Boss XL 9000 Product Manual

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SERIAL RANGE: 20258001 - ________
PRODUCT MANUAL
Common Service Parts & Mower Information
Manuals
Country Clipper Safety Instructions and Operation
Country Clipper Repair Parts
Kawasaki Engine Owners
Warranty
Country Clipper Warranty
Kawasaki Engine Warranty
Hydro-Gear Warranty
Battery Warranty
Additional Information
Country Clipper Product Specifications
Notes/Service Records
P-13495 (12/20)

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Summary of Contents for Country Clipper Boss XL 9000

  • Page 1 SERIAL RANGE: 20258001 - ________ PRODUCT MANUAL Common Service Parts & Mower Information Manuals Country Clipper Safety Instructions and Operation Country Clipper Repair Parts Kawasaki Engine Owners Warranty Country Clipper Warranty Kawasaki Engine Warranty Hydro-Gear Warranty Battery Warranty Additional Information...
  • Page 2 Common Service Parts & Information 52” Blade  High Lift Fusion  High Lift  Gator  Low Lift    H‐2884 H‐2883  H‐2666  H‐2660  60” Blade  High Lift Fusion  High Lift  Gator  Low Lift  1  H‐2886 H‐2885  H‐2667  H‐2661  72” Blade  High Lift Fusion  High Lift  Gator  Low Lift    H‐2887 H‐2656  H‐2877  H‐2662    52” Deck Belt  D‐3658  Charger   60” Deck Belt ...
  • Page 3 Safety Instructions and Operation P-13495...

  • Page 4: Table Of Contents

    Table of Contents – Safety Instructions and Operation BASIC INFORMATION ..........................1.1 Warranty Registration ........................1.1 Model/Serial Number ........................1.1 Parts/Service ..........................1.1 MOWER SAFETY GUIDELINES ........................2.1 Slope Operation ..........................2.2 Children ............................2.2 Hauling ............................2.2 Towing ............................2.3 Service (Safe Handling of Gasoline) ....................

  • Page 5: Warranty Registration

    Safety Instructions and Operation Section 1… Basic Information Thank you for purchasing a new Country Clipper mower. This manual will assist the operator in the proper operation and maintenance of the mower. Following the information and instructions provided in the manual can help you attain years of performance from your Country Clipper mower.
  • Page 6 Safety Instructions and Operation Section 2… Mower Safety Guidelines At Country Clipper, we share your desire to protect your family, friends, neighbors, and yourself from accidental injury. Never allow untrained people to operate the mower. It’s the owner’s responsibility to receive proper training in the operation of the mower and any other individuals authorized to use the machine.

  • Page 7: Slope Operation

    Operation on slopes, hills, and/or embankments is a key factor that can cause loss of control or tip over accidents that can result in severe injury or death. Operation on all slopes requires extra caution. Country Clipper recommends the operator survey the slope and terrain conditions prior to operating on or near a slope. Prudent discretion and judgement should be exercised to ensure safe operation.

  • Page 8: Towing

    Safety Instructions and Operation Towing 2.43 Do not exceed recommendation for weight limits for towed equipment and towing on slopes. 2.44 Tow only with a machine designed with a hitch for towing. 2.45 Only use an approved hitch for the machine. 2.46 Keep children off the towed equipment.

  • Page 9: Safety Interlock System

    The engine will stop if the Park Brake is engaged and the Deck Engagement Switch is engaged. Do not operate mower if any of these test fail to produce the results indicated. Contact your Country Clipper dealer to troubleshoot and resolve the issue.

  • Page 10: Safety Decals

    Safety Instructions and Operation Warning …Denotes a hazard or unsafe practice which COULD result in severe personal injury or death. The following illustrations depict the various safety decals used on the equipment with a brief explanation for those requiring one. Safety Decals P-12706…...
  • Page 11 P-13480... ROPS Safety – If ROPS must be lowered for operation do not wear seat belt and drive with extra care. Replace Safety Decals when missing or illegible. Contact your Country Clipper Dealer or Country Clipper for free replacement of Safety Decals. P-13495...
  • Page 12 Safety Instructions and Operation Section 3… Controls Your Country Clipper mower has a variety of controls and switches that are used to operate and adjust key  operational parameters of the mower.  Make sure you become familiar and proficient in the use of these controls.  A proficient understanding of the function of these controls will assure the operator’s confidence and safety  during operation and servicing the mower.        Ignition Switch  Electronic Fuel Gage (If Equipped)  Blade Engagement Switch  Float Fuel Gage (If Equipped)  Throttle Control Lever  Joystick Drive Control Lever (If Equipped)  Choke Push‐Pull Control (If Equipped)  Twin Stick Drive Control Lever (If Equipped)  Hour Meter  3.10 EFI Engine Mil Light Diagnostic (If Equipped)         3.11 Parking Brake  3.13 Transport Latch  3.12 Cut Height Plate Pin  3.14 Cut Height Foot Pedal        P-13495 3.1 ...
  • Page 13 Safety Instructions and Operation     3.15 Seat Suspension Adjustment (Boss XL)  3.17 Lumbar Support  Selector (Boss XL)  3.16 Seat Slide Lever (Boss XL)        3.18 Seat Recline Knob (Boss XL)  3.19 Seat Suspension Adjustment (Charger)    3.20 Seat Slide Lever (Charger)      P-13495 3.2 ...

  • Page 14: Control Descriptions

    Safety Instructions and Operation     3.21 Seat Recline Lever (Charger)  3.22 Arm Rest Adjustment (Charger & Boss XL)  Control Descriptions Ignition Switch: A four position switch: “Off”, “Run + Accessory”, “Run”, and “Start”.  With key inserted,  rotate clockwise to the “Start” position, release key when engine starts.  The switch will automatically  return to the “Run” position.  If unit is equipped with a 12 volt accessory (i.e. Light Kit or similar)  connected to the key switch; turn the key counterclockwise to the “Run + Accessory” position to power  the accessory.  Turn switch to “Off” position to shutoff engine and any 12 volt accessory connected to  the key switch.  Blade Engagement Switch: This is a two position switch: pull switch up to engage the mower blades,  push switch down to disengage the mower blades.  Throttle Control Lever: Connected to the engine throttle control by a cable. Move the throttle lever  generally forward to increase engine rpm and rearward to decrease engine rpm.   Choke Push‐Pull Control: Connected to the engine choke control by a cable. Pull the choke knob up to  assist starting a cold engine.  Push knob down after engine has started.  Hour Meter: The hour meter records accumulative time while the engine is running.  Electronic Fuel Gage:  Indicates the fuel fill level.  Float Fuel Gage: Indicates the fuel fill level.  Joystick Drive Control Levers: Connected to the drive transaxles to translate the control lever movement  to forward, reverse, and turning motion of the mower.  Twin Stick Drive Control Lever: Connected to the respective drive transaxle for each side to translate the  control lever movement to forward, reverse, and turning motion of the mower.  3.10 EFI Engine Mil Light Diagnostic: The Mil light is used on fuel injected engines only.  During normal  operation the light will turn on when the ignition switch is turned to the “Run” position prior to starting  the engine. Then after the engine is started the light shuts off.  If the Mil light illuminates while the  engine is running a fault is currently happening, and dealer service is required.  3.11 Park Brake: When the lever is pulled up the brake is applied on both transaxles.  3.12 Cut Height Selector Plate & Pin: Used to set the height of cut of the deck.  3.13 Transport Release Latch: Used to bypass the deck transport position. ...

  • Page 15: Control Decals

    Safety Instructions and Operation 3.18 Seat Recline Knob (Boss XL): Used to adjust seat back recline level.  3.19 Seat Suspension Adjustment (Charger): Used adjust the seat suspension per the operator comfort.  3.20 Seat Slide Lever (Charger) Used to adjust the seat fore or aft for comfort.  3.21 Seat Recline Lever (Charger): Used to adjust the seat back recline level.  3.22 Arm Rest Adjustment (Charger & Boss XL): Used to adjust the arm rest up or down per operator  comfort.  Control Decals P-13437… Transport Latch – Lock position will   permit the deck to lock in transport when raised to that position. Un-lock P- 11382… Brake “ON” / “OFF” Position. position will not lock the deck in  ...
  • Page 16 Safety Instructions and Operation     P-13482… Throttle Control Position, Idle Rpm to P-13481… Malfunction Indicator Lamp, Used on Full Throttle. equipment equipped with Electronic Fuel Injection engine. Lamp will   illuminate if problems or faults detected while engine is running. Service  ...

  • Page 17: Pre-Operation Checklist

    Safety Instructions and Operation Section 4… Start Up & Operation Warning Never allow untrained people to operate the mower. Do not operate machine with faulty equipment. Clear area of debris and obstacles and stay alert to changing conditions that can impact the mower operation.

  • Page 18: Starting The Engine

    Safety Instructions and Operation Starting The Engine The mower’s Safety Interlock System is designed to protect the operator and bystanders from accidental  injury due to unintentional engine starting and/or the operator leaving the operator zone. The engine  starter will not engage until the operator satisfies the following conditions:  4.1.1 Steering Drive Control Lever(s) are in the neutral lock position.  4.1.2 Deck Blade Engagement Switch is in the “Off” position (Pushed Down).  Danger THE SAFETY INTERLOCK SYSTEM MUST NOT BE DISCONNECTED OR BYPASSED. UNEXPECTED OPERATION COULD OCCUR RESULTING IN PERSONAL INJURY OR DEATH. 4.1.3 NOTE: The operator’s seat has a safety switch integrated into the seat cushion.  The switch is  activated by the weight of the operator. Should the operator become unseated, for any reason,  when the Drive Control Lever(s) is/are in the drive position and/or the Blade Engagement Switch  is “ON” the engine will stop.  4.1.4 NOTE: The following steps are the correct procedure for starting the engine.  Contact your ...

  • Page 19: Roll Over Protection Structure (Rops)

    Safety Instructions and Operation Roll Over Protection Structure (ROPS) Proper use of the ROPS along with the seat belt is effective in reducing injuries in the event of an overturn  accident.  Overturning the unit with the ROPS lowered or removed can result in series injury or death. Warning This vehicle is equipped with a certified Roll Over Protection Structure (ROPS). The seat belt must be worn during vehicle operation. Failure to do so will reduce or eliminate protection for the operator in the event of a roll-over.
  • Page 20 Safety Instructions and Operation 4.3.1 The two‐post ROPS can be folded down by removing the Cotter Pins and pulling out the T‐Handle  Clevis Pins.  This should only be done to operate the mower under low hanging tree limbs or other  obstructions. Additionally, this may be required when loading the mower in an enclosed trailer.  Warning Use of the ROPS in the “folded” position should only be when absolutely necessary. Do not use the seat belt if the ROPS is not in the up position. NOTE: Minimize the chance of injury or death from a rollover incident by:  4.3.2 Keep ROPS in the locked upright position and wear the seat belt. ...

  • Page 21: Mower Driving Operation

    OR DEATH. Important Until the operator is familiar with their Country Clipper Zero Turning Radius Mower, they should follow these recommendations: Disengage the mower blades. Go very slowly (throttle engine rpm down to ½ throttle or less) until thoroughly familiar with the machine. Keep away from fences, buildings, and other obstructions.

  • Page 22: Deck Height Adjustment

    In case of steering control loss during operation of the mower; place the Steering Control Lever(s) in the neutral lock position, set the Park Brake, shut off the Blade Engagement Switch, and shut off the Ignition Switch. Inspect the machine and contact your Country Clipper dealer to resolve the issue before continuing operation.
  • Page 23 Safety Instructions and Operation Section 4, Figure 1 P-13495...
  • Page 24 Safety Instructions and Operation Section 4, Figure 2 P-13495...

  • Page 25: Blade Engagement

    Safety Instructions and Operation Blade Engagement Danger KEEP HANDS AND FEET AWAY FROM ROTATING PARTS OR UNDER THE MACHINE. KEEP CLEAR OF THE DECK DISCHARGE AREA AND/OR BLADES WHILE OPERATING. DISENGAGE BLADES AND SHUT THE ENGINE OFF IF ANYONE ENTERS THE AREA. Danger NEVER OPERATE THE MACHINE WITHOUT THE DISCHARGE CHUTE, GRASS CATCHER, OR OTHER SAFETY DEVICES IN PLACE AND FUNCTIONING PROPERLY.

  • Page 26: Transmission Free Wheel Release

    Safety Instructions and Operation 4.7.4 Travel Speed… Vary ground speed of mower to suite the turf conditions and terrain during the  year. (i.e. slowdown in tall thick grass, on slopes, wet conditions, rough terrain etc.)  4.7.5 Normal Mowing… It is recommended to cut off only 1/3 of the grass blade to maintain a healthy  lawn. When mowing an area for the first time it is recommended to cut the turf slightly higher to  avoid scalping uneven terrain and to avoid unseen obstacles in the lawn. If the grass is taller than  6 inches it may require mowing twice to get the desired quality of cut.  4.7.6 Turf Growth Rate… Turf grows at different rates during the seasonal growing period. Turf usually  experiences the greatest growth rate from early Spring to the start of Summer. During this period  the grass may require more frequent mowing to maintain the desired appearance. As you move  into Mid‐Summer, less frequent mowing may be required. If regular mowing intervals cannot be  maintained; mow at a higher cut height and then come back a couple days later and mow at the  desired cut height.  4.7.7 Alternate Cutting Direction… Always alternate the mowing pattern to keep grass blades growing  straight and to disperse grass clippings evenly throughout the lawn.  4.7.8 Keep Blades Sharp… Dull blades and improperly sharpened blades can cause cut quality issues.   See Mower Blade Service for information and details on the proper maintenance of blades.  Warning Never work with blades while engine is running and/or blade engagement switch is in the “on” position.

  • Page 27: Mower Transportation

    Safety Instructions and Operation move the tab to the center of the mower to lock in place via the notch in the tab. Both  transmissions must be bypassed to move the mower. Deactivate by moving the Bypass Actuator  tab outward and pushing forward back to the normal run position.     Mower Transportation When transporting the mower from one location to another via a transport vehicle, follow the proceeding  guidelines.  4.9.1 Raise Deck and Latch in Transport… Depress the deck lift pedal to raise the deck into transport  position and secure the deck latch into the lock position.  Warning Caution should be exercised when loading and unloading a mower on a trailer or transport vehicle. Depending on the trailer or transport vehicle; the ramp slope could cause loss of control or tip over.

  • Page 28: Preseason Mower Prep

    Safety Instructions and Operation 4.10.5 Service Mower… Thoroughly lubricate and service per maintenance schedule, Section 5.  4.10.6 Fuel… Drain fuel from fuel tank and run engine until it stops due to lack of fuel.  4.10.7 Battery… Remove battery from the mower, clean terminals, and cable connectors. Charge the  battery if necessary. Store the battery in a cool dry place. Keep the battery fully charged to  prevent battery damage when the temperature is below 32°F (0°C).  Warning Charge battery in a well ventilated area; away from ignition sources. When connecting and disconnecting the charger to the battery, unplug the charger from the outlet. 4.10.8 Storage… Store the mower in a clean dry place.  Preseason Mower Prep 4.11 When preparing the mower for a new season, reinstall the battery and perform the Pre‐Operation ...

  • Page 29: Maintenance

    Safety Instructions and Operation Section 5… Maintenance Warning Observe all common shop safety practices when inspecting, servicing, and repairing equipment. Use of the appropriate Personnel Protective Equipment (PPE) is required. Maintenance Schedule     Each  First 5  First  Every 50  Every 100  Every  Maintenance ...

  • Page 30: Maintenance Introduction

    Safety Instructions and Operation Maintenance Introduction Regular maintenance is the best method to avoid costly downtime, expenses, and premature repair. Following the  service recommendations and intervals, on a routine basis, will help maintain your mower at its optimum  performance.  When operating, remain alert for unusual noises which could signal a problem. Visually inspect the mower for any  abnormal wear, leaks, or damage. The best time to detect potential issues is while performing scheduled  maintenance service.   Keep the mower clear of heavy build‐up of grease, oil, and debris, especially in the engine compartment and  under the seat platform areas. Inspect daily for grass clippings, wire, and/or string tangles. The underside of the  mower deck will collect a build‐up of grass clippings and dirt, especially when grass is wet or has high moisture  content. This build‐up will harden, restricting blade and air movement and will probably show a poorer quality of  cutting. Routine removal of this build up is crucial for optimal mower performance. Some repairs will require  assistance from a trained service mechanic and should not be attempted by unskilled personnel. Contact your    Authorized Country Clipper Dealer when assistance is needed or to schedule maintenance at the dealership.   Engine Maintenance Check Engine Oil daily or after every 4 hours of use. Refer to the manufacture’s engine manual for the  maintenance schedule, oil recommendations, and capacity. IMPORTANT: Change engine oil and filter  within the first 5 hours of operation and thereafter per the engine manufacture’s recommendations.   Danger DISCONNECT AND GROUND SPARK PLUG LEADS AND DISCONNECT NEGATIVE BATTERY LEAD PRIOR TO CLEANING, INSPECTING, AND/OR SERVICING. ACCIDENTAL STARTS CAN CAUSE SEVERE INJURY.
  • Page 31 Safety Instructions and Operation   5.1.5 Close Drain & Install Filter… After the oil has drained, turn the drain valve clockwise to close the  valve. Install a new oil filter.  5.1.6 Clean Up… Clean up any spills or drips and remove the used oil container.  5.1.7 Refill Engine Crankcase… Refill per the manufacture’s recommendations.  5.1.8 Check Work… Make sure that the oil drain valve is shut completely and the oil filter and dipstick  are secure.  5.1.9 Air Filter… Check the engine air filter before each use.  Examine for dirt and debris build‐up on the  filter.  Replace as required.  Follow the engine manufacture’s recommendations. The mower is  equipped with a safety air filter. The main filter is installed over the safety filter.  The safety filter  does not need replaced unless it gets contaminated with dirt or moisture.    5.1.10 Remove Air Filter… Remove dust cap and filter from the canister. Inspect safety filter.  5.1.11 Install Filter… Install a new main filter into the canister and re‐install the dust cap.  Check to make  sure the dust cap sealed and is secure.  5.1.12 Check Air Cleaner Assembly… Check all fittings and clamps periodically for tightness and inspect  hoses for holes or cracks.  Make sure there is no path for dirt ingestion into the engine.   5.1.13 IMPORTANT… Do not operate engine without the air filter in place. Do not clean the filter  element, replace with a new filter only. Improper cleaning of used air filter elements can get dust  on the inside of the filter causing dirt ingestion and engine failure.  5.1.14 Fuel Filter… Refer to engine owner’s manual for schedule and procedure for replacing.  5.1.15 Spark Plugs…  Refer to engine owner’s manual for schedule and procedure for replacing.  5.1.16 Engine Cleaning… Proper engine cooling is essential. To prevent overheating, clean screens,  cooling fins, and other external surfaces of engine.  See engine owner’s manual for specific  requirements.  ...

  • Page 32: Grease Points

    Safety Instructions and Operation Grease Points Country Clipper has designed your mower to minimize the required grease points. Some components  utilize sealed bearings, others utilize self‐lubricating bushings. However there are a few locations that  require to be greased. These are shown below.  5.2.1 Caster Wheels… The grease zerk for the front  caster wheel is located on the tire rim hub.  There is a zerk located on each caster wheel.   Re‐lubrication should be at a rate of 10 pumps  of NLGI #2 grease every 50hrs or annually.              5.2.2 Caster Pivot… The caster pivot grease zerk is  located on the front axle caster pivot tube.  There is a zerk located on each front caster  pivot tube. Re‐lubrication should be at a rate of  5 pumps of NLGI #2 grease every 50hrs or  annually.            5.2.3 Deck Lift Jack… (If Equipped, Boss XL 72” Deck  Standard Equipment) Locate the grease zerk on  the jack cross shaft.  Re‐lubrication should be  at a rate of 5 pumps of NLGI #2 grease every 50  hours or annually.   ...

  • Page 33: Tires

    If this occurs while operating the mower, place the Drive Control Lever(s) in Neutral Lock position, set the Park Brake, and turn the engine off. Inspect machine for cause and contact your Country Clipper dealer to remedy the issue before continuing Electrical System Your Country Clipper mower is a 12 volt, negative ground system. ...

  • Page 34: Deck Service

    Safety Instructions and Operation 5.5.3 Electrical Fuse… Country Clipper uses two 30 Amp  Fuses to protect the electrical system. The fuses are  located behind the seat on the right hand inner  fender panel.  The fuses protect the electric system  from a direct short to ground.        Deck Service Your Country Clipper mower has been designed with a  Stand‐Up Deck feature to allow you access to the underside  of your deck for cleaning and routine maintenance. There are  two different procedures to stand up the deck depending on  how your mower is equipped; Manual Lift or Powered Lift.  All 52” & 60” decks models come standard with the Manual  Lift option. The 72” deck models come standard with the  Powered Lift option. The Powered Lift option can be installed  on the 52” & 60” deck models as an optional accessory.    Manual Deck Lift Procedure  5.6.1 Step 1. Position The Mower… Standing up the deck must be done on a hard level surface. When  positioning the mower on the hard surface, back up the mower so the Front Caster Tires swing  away from the deck. Turn the engine off, and remove the key.  5.6.2 Step 2. Transport Latch… Move Transport Latch forward to the lock position and push the Cut  Height Foot Pedal forward and lock the deck in the transport position.                 ...
  • Page 35 Safety Instructions and Operation Warning Never attempt to stand the deck up without the Cut Height Foot Pedal all the way rearward and locked in place with the Deck Height Pin. When properly done, the Rear Deck Hooks will be released from the deck hangers.
  • Page 36 Safety Instructions and Operation Warning Do not attempt to flip deck without releasing deck belt from clutch pulley on the engine or from the center spindle assembly pulley! Warning Manually lifting the deck can be very strenuous. Use proper lifting techniques, lift with hips and knees (not your back).
  • Page 37 Safety Instructions and Operation by the frame, transmission, or other mower components. Re‐install Foot Plate. Slowly rotate Deck  Belt Tension Lever and re‐apply spring tension to the belt.  5.6.12 Step 5. Lower Foot Step…  Pivot the Front Step back down for use.  5.6.13 Step 6. Cut Height Pin… Re‐insert the Cut Height Pin to the desired cut height.  5.6.14 Step 7. Lower Deck to Cut Height… Lower deck to desired cut height and position Transport Latch  to the desired position.    Powered Deck Lift Procedure  5.6.15 Step 1. Position The Mower… Standing up the deck must be done on a hard level surface. When  positioning the mower on the hard surface, back up the mower so the Front Caster Tires swing  away from the deck. Turn the engine off, and remove the key.  5.6.16 Step 2. Transport Latch… Move Transport Latch forward to the lock position and push the Cut  Height Foot Pedal forward and lock the deck in the transport position.                          5.6.17 Step 3. Lower Deck to Ground Surface… Remove the Cut Height Pin from the Cut Height Selector  plate. Push the Cut Height Foot Pedal Forward and move the Transport Latch to the unlock  position. Lower the deck so it is resting on the ground surface.  5.6.18 Step 4. Lock Deck in Lowest Position… Step off the mower platform. Push the Cut Height Foot  Pedal to the most rearward position and re‐insert the Cut Height Pin in the Cut Height Selector ...
  • Page 38 Safety Instructions and Operation 5.6.19 Step 5. Flip Up Front Step… Pivot the Front Step up and towards the operator platform.  5.6.20 Step 6. Release Deck Belt Tension & Disconnect Belt… Follow the appropriate procedure for your  mower series:  Charger… Locate the Deck Belt Tension Lever at the rear of the deck on the trim side. Release the  belt tension by slowly rotating the lever to remove the spring tension.  With the tension removed  on the belt, reach under the rear of the mower and remove the deck belt from the clutch pulley  on the engine crank shaft. Rest the belt on the ground.                          Boss XL… Locate the Engine to Deck Belt Tension Lever behind the rear left tire. Release the belt  tension by slowly rotating the lever to remove the spring tension. Remove the foot plate from the  operator platform and set aside. Access the engine to deck belt on the center spindle assembly  and remove from the top pulley. Hook the belt onto the bolt protruding from the lower lip of the  foot deck support.                       ...
  • Page 39 Safety Instructions and Operation 5.6.21 Step 7. Power Deck Lift Jack Tool… The following tools will be required to operate the Powered  Deck Lift Jack.    5.6.22 Step 8. Assemble Tools… Assemble the 5/8 Inch Socket to the 6 Inch Extension, the 6 Inch  Extension to the 3/8 Square Drive Jack, and then insert the 3/8 Square Drive into the Power Drill.  Set the Power Drill to rotate clockwise.  5.6.23 Step 9. Fit Assembled Tool To Pinion Gear… Fit the 5/8 Inch Socket onto the Pinion Gear Hex  Head.                        5.6.24  Step 10. Raise Deck To Service Position… Rest the drill on the Anti‐Rotation Stop; securely grip  the drill and slowly start turning the Pinion Gear clockwise. Continue operating the drill until the  jack stops rising. The Powered Deck Lift Jack will stop rising when the cycle is complete. Set the  Parking Brake.                     ...

  • Page 40: Mower Blade Service

    Safety Instructions and Operation Powered Deck Lowering (Mowing Position)  5.6.25 Step 1. Lower Deck… Fit the 5/8 Inch Socket onto the Pinion Gear Hex Head. Securely grip the drill  and slowly start turning the Pinion Gear counter clockwise. Continue operating the drill until the  jack is completely lowered and disengages the lift mechanism. The Pinion Gear Hex Head can and  should be rotated counter clockwise 2 to 3 cycles after the deck is lowered to the ground to make  sure it has completely disengaged from the lift mechanism.   5.6.26 Step 2. Un‐Lock Deck from Lowest Position… Push the Cut Height Foot Pedal to the most  rearward position and remove the Cut Height Pin in the Cut Height Selector plate. (Note: This  takes a fair amount of effort; a ½ inch breaker bar can be used in the Cut Height Foot Pedal to  reduce the effort required.)  5.6.27 Step 3. Transport Latch… Place Transport Latch in the lock position. Raise the deck up to the  transport position and let it lock into place. Make sure both Rear Deck Hangers re‐connect to the  Deck Hanger Clevis Pins.  5.6.28 Step 4. Reconnect Deck Drive Belt… Follow the appropriate procedure for your mower series:  Charger… Re‐install deck drive belt to the Electric Clutch Pulley. Check to make sure the belt  routing is not impeded by the frame, transmission, or other mower components. Additionally,  ensure the belt is properly installed on all the deck pulleys and idlers. Slowly rotate Deck Belt  Tension Lever and re‐apply the spring tension to the belt.  Boss XL… Re‐install the Engine to Deck belt. Unhook the belt from the bolt and re‐install on the  center spindle pulley Make sur the belt is properly installed on the Electric Clutch Pulley and  routed properly on the belt tensioner idlers. Check to make sure the belt routing is not impeded  by the frame, transmission, or other mower components. Re‐install Foot Plate. Slowly rotate Deck  Belt Tension Lever and re‐apply spring tension to the belt.  5.6.29 Step 5. Lower Foot Step…  Pivot the Front Step back down for use.  5.6.30 Step 6. Cut Height Pin… Re‐insert the Cut Height Pin to the desired cut height.  5.6.31 Step 7. Lower Deck to Cut Height… Lower deck to desired cut height and position Transport Latch  to the desired position.  Mower Blade Service Mower blade sharpness should be checked daily or prior to each usage. A sharp blade in good condition is ...
  • Page 41 Safety Instructions and Operation 5.7.3 Blade Sharpening… The blades can be sharpened with a grinder or touched up with a file. Note  the angle of the cutting edge and try to maintain when sharpening.      5.7.4 Blade Balance… Check the blade balance after sharpening. There are a variety of blade balancing  techniques and commercial blade balancing tools available through a majority of hardware supply  stores. If the blade is out of balance, true it up before re‐installing.   5.7.5 Blade Straightness… Lay the blade on a flat surface and check to make sure both cutting edges  are in the same cutting plane. Replace blade if warped or distorted.          5.7.6 Twisted Blade… Also check the blade for twisting when placed on the flat surface. Replace blade if  twisted or distorted.        P-13495 5.13...

  • Page 42: Hydraulic Drive Service

    Safety Instructions and Operation 5.7.7 Blade Wear… Blades should be discarded if excessive wear, cracks, and/or distortion are present.    5.7.8 Re‐Install Blades… Install blade, washer, and bolt to spindle assembly. Torque blade bolt to 100  ft‐lbs (136 Nm).  DANGER FAILURE TO CORRECTLY TORQUE THE BLADE BOLT MAY RESULT IN THE LOSS OF THE BLADE WHICH CAN CAUSE SERIOUS INJURY OR DEATH.   Hydraulic Drive Service Regular external maintenance of the Hydraulic Transaxle drives will ensure proper cooling of the hydraulic  system. Maintenance should include the following:  5.8.1 Oil Level… Inspect the oil level by locating the expansion tank for each transaxle behind the ...

  • Page 43: Standard Operation Adjustments

    Safety Instructions and Operation 5.8.5 Drain Oil… Place an oil drain pan (12 inch or more in diameter and 8 qt. capacity is optimal)  beneath the oil filter. Remove the oil filter cover from the transaxle to drain the oil. Remove the  O‐ring from the cover and discard the O‐ring.    5.8.6 Remove Filter… After the oil has drained from the transaxle, remove the oil filter from the  transaxle housing.  5.8.7 Install New Filter… Install a new filter and a new O‐ring onto the filter cover and install the filter  cover. Torque cover to 480‐580 in‐lbs (54‐65 Nm).  5.8.8 Fill Transaxle… Fill the transaxle with new 20W‐50 motor oil through the expansion tank until the  fluid level can be seen in the sight slot. There is a vent plug at the top of the transaxle that can be  opened to improve the new oil fill rate but it is not a requirement.  5.8.9 Purge Procedure… Trapped air must be removed from the hydrostatic drive system to achieve  optimum operation and longevity of the drive. Air creates inefficiency because its compression  and expansion rate is higher than that of the oil approved for use in hydrostatic drive system.  5.8.10 Drive Wheels Off Ground… Raise the rear drive wheels off the ground for the initial air purging.  5.8.11 Activate Bypass… Activate the Bypass to allow the drive tire to free wheel.  5.8.12 Start Engine… Start the engine and move throttle to ¾ to full throttle operation.  5.8.13 Activate Drive Lever(s)… Slowly operate the drive lever(s) in both forward and reverse directions  5 to 10 times.  5.8.14 Check Oil Level… Check oil level; add oil as required after stopping the engine.  5.8.15 Repeat As Necessary… Repeat steps as necessary until all air is purged from the system.  5.8.16 De‐Activate Bypass… De‐Activate the Bypass to allow normal drive wheel operation.  5.8.17 Drive Wheels On Ground… Lower the rear drive wheels to the ground.  5.8.18 Normal Operation… Operate the mower for 30 to 60 minutes under normal driving conditions ...
  • Page 44 Safety Instructions and Operation       Joystick Forward Tracking & Speed Adjustment  (Always confirm tire pressure setting before making adjustment, 12 psi)  5.9.4 Locate Mower on Hard Level Surface… Locate mower  on a hard level surface, engage Park Brake and shut the  engine off.  5.9.5 Remove Rear Drive Tire… Remove the Rear Drive Tires  to access the transmission linkages.  5.9.6 Disconnect Left Transmission Linkage… Disconnect the  Left Transmission Linkage from the Swivel Arm by  removing the bolt. Allow the linkage to swing away  from the Swivel Arm. (Left & Right orientation is as an  operator sits in the seat. Trim side of deck “Left”,  Discharge side of deck “Right”)        5.9.7 Set Right Transmission Linkage… On the right side Outer  Linkage; that connects to the right side transmission,  loosen the Jam Nuts on both ends of the Coupling Nut.  (The upper Jam Nut is a left‐hand thread.)  Note: Use two wrenches (one on the nut and one on the  Coupling Nut or rod end housing) when loosening or  tightening Jam Nuts to prevent damaging the rod end ball  joints!  5.9.8 Lengthen Outer Linkage… Rotate the Coupling Nut several  turns to lengthen it.  5.9.9 Joystick Full Forward… Lift the Joystick Drive Control Lever  out of the neutral position and hold it firmly in the full ...
  • Page 45 Safety Instructions and Operation 5.9.11 Set The Outer Linkage Length… Rotate the Coupling Nut exactly one full turn to lengthen the  Outer Linkage; retighten the Jam Nuts.  When retightening make sure that the ball joints on both  top and bottom are aligned so that they do not bind up when moving the Joystick Drive Control  Lever to the extremes of its travel.  5.9.12 Set Left Transmission Linkage… Reconnect the linkage to the left side transmission by reinserting  the bolt back into the Swivel Arm.  5.9.13 Loosen Jam Nuts On Left Linkage… Loosen the Jam Nuts on both ends of the Left Transmission  Linkage.  (One of these is a left‐hand thread.)  Note: Use two wrenches (one on the nut and one on the Coupling Nut or rod end housing) when  loosening or tightening Jam Nuts to prevent damaging the rod end ball joints!  5.9.14 Lengthen Left Transmission Linkage… Rotate the linkage rod a couple turns to lengthen it.  5.9.15 Joystick Full Forward… Lift the Joystick Drive Control Lever out of the neutral position and hold it  firmly in the full forward position.  5.9.16 Shorten Left Linkage… Rotate the left side transmission linkage rod to shorten the linkage until  resistance is felt from the transmission control bottoming out in the transmission.  Rotate the  linkage back and forth a couple times to confirm, and mark this position.  5.9.17 Set The Left Transmission Linkage… Rotate the linkage exactly one full turn longer and retighten  the jam nuts. Use two wrenches and make sure the ball joints on each end are aligned so that  they do not bind up when moving the joystick lever to the extremes of its travel.  5.9.18 Test Drive Mower… Operate mower at full forward travel; if mower drives straight no further  adjustment is required, if the mower veers to the left the right hand transmission needs to be  slowed down, if the mower veers to the right the left hand transmission needs to be slowed  down.  5.9.19 Adjust Full Forward Tracking… Determine which transmission needs to be slowed down to obtain  straight forward travel.  With the engine shut off, make small ¼ turn adjustments to lengthen the  linkage on the side that needs to be slowed down. Test drive and repeat adjustment until the  mower is traveling straight forward. (Caution – tracking adjustment could affect Neutral Lock  Adjustment.) ...
  • Page 46 Safety Instructions and Operation Joystick Control Lever Sensitivity Adjustment  5.9.27 Joystick Lever Turning Sensitivity… The rate  of turning response can be controlled by  moving the Control Linkage closer to or  further away from the attachment point to  the Joystick.  5.9.28 Remove Fender Skirt… Remove the Fender  Skirt on the Joystick side.  5.9.29 Adjust Sensitivity… Locate the Cross Bolt  and Lock Nut that attach the Control  Linkages to the Joystick. Carefully remove  the Cross Bolt and Lock Nut from the  Joystick; make sure to account for all  spacers. The sensitivity is determined by  which spacer is placed on the inside of the  Ball Joints:  Slower ‐ Short Gold Spacer  Faster – Long Silver Spacer  All spacers must be used during reassembly  5.9.30 Reassemble… Reinsert the Cross Bolt through the Spacers, Ball Joints, and Joystick. Secure with  the Lock Nut. All spacers must be used during reassembly.  (Caution – Adjusting the Joystick Control Level Sensitivity could affect Forward Tracking and/or  Neutral Lock Adjustment.)  Twin Stick Neutral Lock Adjustment  5.9.31 Set Neutral Lock Position… If the mower wants to  move or travel with the engine running and the Twin  Stick Drive Control Levers are in the Neutral Lock  Position; the Neutral Lock position needs adjusted.  Each Twin Stick Drive Control Lever is linked directly  to a Transmission Control Plate via an adjustable  length ball joint rod‐end linkage.   5.9.32 Remove Rear Drive Tire… Remove the Rear Drive ...
  • Page 47 Safety Instructions and Operation Twin Stick Forward Tracking Adjustment  5.9.37 Forward Tracking… In an open area, actuate the Twin Stick  Drive Control Levers into the full forward position at ¾ to  full engine throttle. If the mower veers either left or right,  some adjustment is required. If mower is veering to the  right, then the left transmission needs to be slowed down  or vice versa.  5.9.38 Position Mower… Stop the mower, engage Park Brake, and  shut the engine off.  5.9.39 Adjust Tracking… On the transmission that needs  adjustment; turn the Tracking Adjustment Screw in until it  contacts the stop, then turn screw at ½ turn (slowing  speed) increments, until the mower tracks straight.    Twin Stick Handle Adjustments  5.9.40 Twin Stick Handle Height Adjustment… The length or  height of the handles has two available positions.  Mount the handles in the upper set of holes or the  lower set of holes for maximum operator comfort.  5.9.41 Twin Stick Fore & Aft Adjustment… Adjust the handles  fore and aft position before tightening the handle  mounting bolts.  The fore/aft position of the handles  should be set such that they are aligned with each other  while in the neutral position.  5.9.42 Twin Stick Handle Gap Adjustment… Adjust the gap  between the handles by turning in or out the Gap  Adjustment Screw on the handle base.  There should be  about one inch gap between the ends of the operator  handles when they are “in” (driving positon).  Make the  height of the handles the same, or in line with each  other.  This may require adjusting both sides. ...
  • Page 48 Safety Instructions and Operation Deck Leveling Adjustment  (Note: The deck has been factory leveled. If leveling is required follow this procedure.)  5.9.43 Locate Mower on Hard Level Surface… Locate mower on a hard level surface, engage Park Brake  and shut the engine off.  5.9.44 Confirm Tire Pressure… Set the tire pressure on each of the four tires to 12psi (83kPa). (Make  sure all four tires are equal).  5.9.45 Set Cut Height To 3 Inches… Set the deck cutting height to 3 inches and rotate the two outside  blades by hand until one end of each outside blade points forward (toward the front of tractor).  5.9.46 Ground to Blade Tip Measurement… Measure from the ground to the front blade tip on each  outside blade of the deck.  These measurements should be within 1/8 inch 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).  (Important: Do not attempt to set the deck cut height higher or lower than specified. This could  cause failure of the deck drive system.  5.9.47 Front Deck Height Of Cut Adjustment… If adjustment is needed; turn the Height of Cut Adjusting  Bolt clock‐wise to raise the deck, turn the Height of Cut Adjusting Bolt counter clock‐wise to lower  the deck. Make sure the left and right side measure approximately 3 inches within 1/8 inch from  one side to the other.  5.9.48 Rear Blade Tip Measurement (Deck Rake)… Measure the rear blade tip height from the ground  on both sides of the deck. The rear blade tip height should be equal or greater than the front  blade tip height. Country Clipper recommends that the rear blade tip measure 1/8 to 1/4 inch  higher than the front blade tip measurement.  5.9.49 Rear Deck Height Of Cut Adjustment… If adjustment is needed; turn the Height of Cut Adjusting  Bolt clockwise to raise the deck, turn the Height of Cut Adjusting Bolt counter clockwise to lower  P-13495 5.20...
  • Page 49 Safety Instructions and Operation the deck. Make sure the left and right side measure approximately within 1/8 inch from one side  to the other.  5.9.50 Recheck Deck Blade Tip Measurements… Recheck all measurements. Make adjustments as  required.  (NOTE: Deck should be hanging equally on all 4 Deck Hangers when properly adjusted.)  5.9.51 Set Deck to Desired Cut Height… Set deck to the desired operation cut height position.  Deck Lift Assist Spring  5.9.52 Deck Lift Assist Spring… The Deck Lift Assist Springs are used to reduce the effort required to raise  and/or lower the deck.  Changing the length of the spring stretch will have a direct effect on this  effort. Reducing the gap between the Spring Anchor Tab and Deck Lift Assist Spring will decrease  the effort required to lift the deck. Increasing the gap will increase the effort.  (Note: Reducing the gap between the Spring Anchor Tab and Deck Lift Assist Spring beyond the  Factory Settings can cause cut quality issues. The deck can float up, especially when operating  over rough ground.)  5.9.53 Factory Settings… Country Clipper recommends the following measurements between the Spring  Anchor Tab and the Spring:  52” Deck = 1 1/8 inches  60” Deck = 1 inch  72” Deck = 3/4 inch    5.9.54 Adjust Spring Length… Turn  the bolt clockwise to reduce  the gap; counter clockwise to  increase the gap.  5.9.55 Adjust Both Springs… The  Left and Right Deck Lift Assist  Springs must be adjusted  equally.       ...
  • Page 50 Safety Instructions and Operation Section 6… Troubleshooting Problem Cause Remedy Mower blade engagement switch is in “On” position Press switch down to “Off” position Joystick… press control lever down to “Neutral Lock ” position Drive lever(s) not in “Neutral” position Twinstick…...
  • Page 51 Safety Instructions and Operation Other Consult Dealer Problem Cause Remedy Damaged seal, housing, or gaskets Replace damaged components Transaxle Leaks Oil Air trapped in hydraulic system Purge hydraulic system Other Consult Dealer Steering linkage out of adjustment Re-adjust drive linkage Mower Creeps when Steering Control Neutral Lock positon not adjusted properly...
  • Page 52 Safety Instructions and Operation Common Cut Quality Problems Problem: Streaking Problem: Stringers Streaking is when thin strips of uncut grass are left after mowing. Stringers are sparse patches of uncut grass left behind in the Streaking commonly occurs by operator error or poor blade lawn surface.

  • Page 53: Belt Routing

    Safety Instructions and Operation Section 7… Belt Routing Charger 52” Deck Belt Routing Charger 60” Deck Belt Routing P-13495...
  • Page 54 Safety Instructions and Operation Boss XL 60” Deck Belt Routing Boss XL 72” Deck Belt Routing P-13495...
  • Page 55 Safety Instructions and Operation Charger & Boss XL Hydro Belt Routing P-13495...
  • Page 56 Safety Instructions and Operation Section 8… Maintenance Record Date Hours Service Performed P-13495...
  • Page 57 Repair Parts SERIAL RANGE: 20258001 - ________ P-13495...
  • Page 58 HYDRO IDLER DOUBLE IDLER TIRES BATTERY ENGINES ENGINE & CLUTCH MOUNTING & RELATED PARTS WIRE HARNESS & RELATED PARTS WIRE HARNESS SCHEMATIC Country Clipper Division, Shivvers Manufacturing Inc. 613 W English St. Corydon, IA 50060-0467 Ph. 641-872-2544 Fax. 641-872-1593 P-13495...
  • Page 59 Repair Parts BOSS XL 60" DECK ASSEMBLY (9000) {730B-002A} SERIAL RANGE: 20258001 - ________ PARTS M ARKED ' *' INCL UDED IN DECK IDL ER ASS' Y ITEM S # 9 & # 1 2 (SEE PG 5 ) SPINDL E ASS' Y (SEE PG 4 ) TIGHTEN TOP NUT (ITEM # 2 4 ) TO ACHIEVE 2 -1 /2 "...
  • Page 60 Repair Parts BOSS XL 72" DECK ASSEMBLY (9000) {730A-001A} SERIAL RANGE: 20258001 - ________ PARTS M ARKED ' *' INCL UDED IN ITEM S # 9 & # 1 0 DECK IDL ER TIGHTEN TOP NUT (ITEM # 2 2 ) TO ACHIEVE 1 -1 /2 "...
  • Page 61 Repair Parts BOSS XL DISCHARGE CHUTE ASSEMBLY (9000) & RELATED PARTS SERIAL RANGE: 20258001 - ________ PART OF ITEM # 2 7 2 " DECK Item # Part # Description 643-110P CHUTE HINGE 660-120P OUTLET STIFFENER, SMALL F-1009-02 WASHER, FLAT F-1015-15 HHCS, 5/16-18 X 1", YZ, GR5 F-1671...
  • Page 62 Repair Parts BOSS XL DECK SPINDLE ASSEMBLY (9000) {629JY-001A} SERIAL RANGE: 20258001 - ________ PARTS M ARKED ' *' ARE PART OF FOR USE WITH FOR USE WITH COM PL ETE CENTER SPINDL E OUTER SPINDL ES ASSEM BL Y DECK B L A D E P A R T N U M B E R S 60"...
  • Page 63 Repair Parts BOSS XL DECK IDLER (9000) SERIAL RANGE: 20258001 - ________ DECK DECK Item # Part # Description 620-201P WASHER, BEARING CAP 621-103P MOUNTING PIN 643-078W SINGLE IDLER ARM LONG WLDT 668-045P SPACER, SPRING MTG D-3730 BUSHING, DU 5/8 DIA X 1/2 LG D-3904 PULLEY, FLAT IDLER, 5"...
  • Page 64 Repair Parts BOSS XL DECK LIFT ASSEMBLY (9000) & RELATED PARTS SERIAL RANGE: 20258001 - ________ 6 0 " DECK -USE BACK HOL E 7 2 " DECK -USE FRONT HOL E REAR DECK HANGER (SEE PG 1 OR 2 ) Item # Part # Description...
  • Page 65 Repair Parts BOSS XL DECK LIFT ASSEMBLY (9000) & RELATED PARTS (CON'T) SERIAL RANGE: 20258001 - ________ 7 2 0 -0 9 9 A (ITEM # 3 ) INSTAL L ITEM # 1 2 IN OUTER M OST GROOVES FUL L Y TIGHTEN ITEM # 1 6 THEN BACK OFF 1 /2 TO 1 TURN 7 2 0 -1 0 0 A...
  • Page 66 Repair Parts BOSS XL CUT HEIGHT ASSEMBLY (9000) & RELATED PARTS SERIAL RANGE: 20258001 - ________ CUT HEIGHT SUB-ASSEM BL Y (SEE DETAIL ) INSIDE VIEW OF CUT HEIGHT SUB-ASSEM BL Y, SHOWING DECAL S INCL UDES ITEM S 2 3 & 2 4 WITH DECK CONNECTED TIGHTEN UNTIL GAP HOOK SPRING WITH OPENING...
  • Page 67 Repair Parts BOSS XL JACK ASSEMBLY (9000) SERIAL RANGE: 20258001 - ________ STANDARD EQUIPM ENT ON 7 2 " M ODEL S ONL Y 1 2 1 9 DRIVE FUL L Y INTO CASTL E NUT, THEN JACK GEARBOX FOL D & PRESS INSERT STAM PED FINISHED SUB-ASSEMBLY FL AT ON END...
  • Page 68 Repair Parts BOSS XL PIVOTING FRONT AXLE (9000) SERIAL RANGE: 20258001 - ________ TORQUE TO 2 5 0 FT/L BS GREASE TORQUE TO 2 5 FT/L BS M AX ENSURE AXL E M OVES FREEL Y Item # Part # Description 606-303P WASHER, 10GA GALVANIZED...
  • Page 69 Repair Parts BOSS XL FRONT STEP & FOOT PAN (9000) SERIAL RANGE: 20258001 - ________ PARTS M ARKED ' *' STANDARD ON 7 2 " DECK M ODEL S ONL Y Item # Part # Description 629-958P JACK - DRILL ANTI ROTATION STOP 629-983P ANTI ROTATION PIVOT STOP 663-134P...
  • Page 70 Repair Parts BOSS XL FRONT PANEL (9000) SERIAL RANGE: 20258001 - ________ INCL UDES ITEM S 5 , 7 , 8 , 9 , 1 0 & 1 1 Item # Part # Description 629-971A FRONT PANEL W/ DECALS F-2063 NUT, 5/16-18, NYLOC, FLANGED, YZ F-2119 FHCS, 1/4-20 X 3/4", YZ, GR5, LOCK PATCH...
  • Page 71 Repair Parts BOSS XL RIGHT HAND FENDER (9000) & RELATED PARTS SERIAL RANGE: 20258001 - ________ PARTS M ARKED ' *' ARE PART OF ITEM # 1 SEAT M OUNT (SEE PG 1 8 ) PART OF ITEM # 1 1 FRONT PANEL (SEE PG 1 2 ) Item #...
  • Page 72 Repair Parts BOSS XL LEFT HAND FENDER (9000) & RELATED PARTS SERIAL RANGE: 20258001 - ________ PART OF ITEM # 1 BATTERY BOX (SEE PG 3 2 ) FRONT PANEL (SEE PG 1 2 ) SIDE M OUNT CHANNEL PART OF ITEM # 1 1 (SEE PG 2 2 ) Item # Part #...
  • Page 73 Repair Parts BOSS XL ENGINE GUARD (9000) SERIAL RANGE: 20258001 - ________ DO NOT OVERTIGHTEN FASTENERS Item # Part # Description 724-100P ENGINE GUARD 724-140W WLDT, MUFFLER GUARD W/ HITCH 724-149W WLDT, ENGINE GUARD RAIL F-2126 FHCS, 3/8-16 X 2",YZ, GR5 F-2141 FHCS, 3/8-16 X 1", YZ, GR5 F-2142...
  • Page 74 Repair Parts BOSS XL ROPS ASSEMBLY (9000) SERIAL RANGE: 20258001 - ________ PART OF ITEM # 1 0 Item # Part # Description 724-006W WLDT, FRAME 724-107P HINGE PLATE, ROPS F-1521 WASHER, 1/2" CUSTOM, YZ F-2151 NUT, 3/8-16 NYLOC, FLANGED, YZ F-2152 NUT, 1/2-13 NYLOC, FLANGED, YZ F-2163...
  • Page 75 Repair Parts BOSS XL SEAT & RELATED PARTS (9000) SERIAL RANGE: 20258001 - ________ PART OF ITEM # 1 4 J OYSTICK M ODEL S ONL Y Item # Part # Description 724-075P SECURITY GRIP MOUNT 724-105P ARM REST MOUNT 724-116P SEAT PAN 724-124W...
  • Page 76 Repair Parts BOSS XL SEAT BASE (9000) SERIAL RANGE: 20258001 - ________ INSTAL L AFTER BOL T IS SECURED Item # Part # Description 660-038P SPACER, 3/8" WIDE 724-043P SEAT MOUNT ANGLE, LH 724-109P SEAT MOUNT ANGLE, RH 724-153P STIFFENER, FENDER CAP F-1009-02 WASHER, FLAT F-1009-03...
  • Page 77 Repair Parts BOSS XL FUEL TANK ASSEMBLY (9000) SERIAL RANGE: 20258001 - ________ KAWASAKI - 4 8 " KAWASAKI 5 8 " IF A TANK IS REQUIRED, IT CAN ONLY BE PURCHASED AS A COMPLETE ASSEMBLY {H-3144} (PARTS M ARKED ' *' ARE INCL UDED IN ASS' Y) Item # Part # Description...
  • Page 78 Repair Parts BOSS XL JOYSTICK CONTROL (9000) & RELATED PARTS SERIAL RANGE: 20258001 - ________ PART OF ITEM # 1 0 SIDE M OUNT (SEE PG 2 2 ) SWIVEL ARM (SEE PG 2 2 ) TRANSM ISSION (SEE PG 2 7 ) Item # Qty Part # Description...
  • Page 79 Repair Parts BOSS XL JOYSTICK ASSEMBLY (9000) {724-115A} SERIAL RANGE: 20258001 - ________ TORQUE TO 1 0 FT/L BS PART OF # 7 PART OF # 7 DETAIL APPL Y SM AL L AM OUNT OF GREASE (ITEM # 3 0 ) TO 2 FACES ON BOTTOM YOKE, SWIVEL, ASS'Y...
  • Page 80 Repair Parts BOSS XL JOYSTICK ASSEMBLY MOUNTING (9000) & RELATED PARTS SERIAL RANGE: 20258001 - ________ FRAM E J OYSTICK CONTROL (SEE PG 2 0 ) TRANSM ISSION (SEE PG 2 7 ) Item # Qty Part # Description Item # Qty Part # Description 638-028P...
  • Page 81 Repair Parts BOSS XL TWIN LEVER CONTROL (9000) & RELATED PARTS SERIAL RANGE: 20258001 - ________ (RIGHT SIDE SHOWN) INSTAL L AFTER BOL TS ARE SECURED FRAM E TRANSM ISSION (SEE PG 2 7 ) Item # Qty Part # Description Item # Qty Part # Description...
  • Page 82 Repair Parts BOSS XL TWIN LEVER ASSEMBLY (9000) SERIAL RANGE: 20258001 - ________ {724-136A - RIGHT SIDE} {724-137A - LEFT SIDE} (RIGHT SIDE SHOWN) SIDE M OUNT (SEE PG 2 3 ) Item # Part # Description 714-074P PIN, PIVOT, TWIN LEVER 721-006P SPRING GUIDE, TS 721-090W...
  • Page 83 Repair Parts CONTROL PANEL BOSS XL (9000) SERIAL RANGE: 20258001 - ________ FENDER CAP (SEE PG 1 3 ) Item # Part # Description E-6403 PTO SWITCH E-6717 IGNITION SWITCH, 4-POSITION W/ PLASTIC KEYWAY E-6718 KEY ASSEMBLY E-6716 HOUR METER F-1022-26 MACHINE SCREW,RND, 10-32 X 5/8, SLOTTED, CZ F-1071...
  • Page 84 Repair Parts BOSS XL BRAKE ASSEMBLY (9000) SERIAL RANGE: 20258001 - ________ TIGHTEN FIRST (BEFORE ITEM S # 1 0 & # 1 1 ) Item # Part # Description 709-221P BRAKE LINK ANCHOR 724-034W WLDT,BRAKE ROD 724-040P BRAKE HANDLE MOUNT PLATE 724-054W WLDT, BRAKE HANDLE E-6474...
  • Page 85 Repair Parts BOSS XL TRANSMISSION (9000) & RELATED PARTS SERIAL RANGE: 20258001 - ________ (RIGHT SIDE SHOWN) FENDER CAP (SEE PG 1 3 - RH, PG 1 4 - L H) HYDRO BEL T ROUTING ENGINE PUL L EY HYDRO IDL ER L H TRANSM ISSION RH TRANSM ISSION Item #...
  • Page 86 Repair Parts BOSS XL HYDRO MOUNT (9000) SERIAL RANGE: 20258001 - ________ DOUBL E IDL ER ASS' Y (SEE PG 3 0 ) Item # Part # Description 724-015P HYDRO MOUNT PLATE 724-016P HYDRO MOUNT BRACE 724-046P DOUBLE IDLER TENSION ARM 724-048P DOUBLE IDLER MOUNTING BRACKET F-1011-02...
  • Page 87 Repair Parts BOSS XL HYDRO IDLER (9000) SERIAL RANGE: 20258001 - ________ (LOOKING AT BOTTOM) AFTER PRESSING IN BUSHINGS (ITEM # 5 ), ENSURE PIN (ITEM # 2 ) ROTATES FREEL Y Item # Part # Description 620-201P WASHER, BEARING CAP 709-077P MOUNTING PIN 709-123P...
  • Page 88 Repair Parts BOSS XL DOUBLE IDLER ASSEMBLY (9000) SERIAL RANGE: 20258001 - ________ AFTER PRESSING IN BUSHINGS (ITEM # 7 ), ENSURE PIN (ITEM # 4 ) ROTATES FREEL Y Item # Qty Part # Description Item # Qty Part # Description 620-201P WASHER, BEARING CAP...
  • Page 89 Repair Parts BOSS XL TIRES & RELATED PARTS (9000) SERIAL RANGE: 20258001 - ________ TORQUE TO 7 5 FT/L BS TORQUE TO GREASE 7 5 FT/L BS 9 8 7 PARTS M ARKED ' *' ARE INCL UDED IN ITEM # 1 1 FIL L CAVITY WITH GREASE Item #...
  • Page 90 Repair Parts BOSS XL BATTERY BOX (9000) SERIAL RANGE: 20258001 - ________ Item # Part # Description 724-147P BACK PLATE, BATTERY BOX 724-148P BATTERY BOX ----- 12 VOLT BATTERY YSP 40, 350 CCA F-2124 FHCS, 3/8-16 X 3/4", YZ, GR5 F-2132 NUT, 1/4-20 NYLOC, FLANGED, YZ F-2151...
  • Page 91 Repair Parts BOSS XL ENGINES (9000) SERIAL RANGE: 20258001 - ________ GROUND ENGINE STARTER KAWASAKI 31 HP - FX921V 35 HP - FX1000V (USE THROTTL E CABL E H-3 1 6 4 & CHOKE CABL E H-3 1 6 6 ) Item # Qty Part # Description 1 724-154P...
  • Page 92 Repair Parts BOSS XL ENGINE & CLUTCH MOUNTING (9000) SERIAL RANGE: 20258001 - ________ (L OOKING AT BOTTOM ) TORQUE TO 5 5 -6 0 FT/L BS ITEM # 1 0 TORQUE SPECS KAWASAKI = 3 0 -3 2 FT/L BS KOHL ER = 3 3 -3 5 FT/L BS ROUTE CL UTCH PIGTAIL &...
  • Page 93 Repair Parts P-13495...
  • Page 94 Repair Parts P-13495...
  • Page 95 Kawasaki Owner's Manual General-purpose Engine...
  • Page 96 Kawasaki Owner's Manual SAFETY AWARENESS Whenever you see the symbols shown below, heed their instructions! Always follow safe operat- ing and maintenance practices. WARNING This warning symbol identifies special in- structions or procedures which, if not cor- rectly followed, could result in personal injury, or loss of life.
  • Page 97 Kawasaki Owner's Manual EMISSION CONTROL INFORMATION Fuel Information THIS ENGINE IS CERTIFIED TO OPERATE ON UNLEADED REGULAR GRADE GASOLINE ONLY. A min- imum of 87 octane of the antiknock index is recommended. The antiknock index is posted on service station pumps in the U.S.A.
  • Page 98 Kawasaki Owner's Manual Tampering with Emission Control System Prohibited Federal law and California State law prohibit the following acts or the causing thereof: (1) the removal or Federal law prohibit the following acts or the causing thereof: (1) the removal or rendering inoperative rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any by any person other than for purposes of maintenance, repair, or replacement, of any device or element of device or element of design incorporated into any new engine for the purposes of emission control prior to its...
  • Page 99 Kawasaki Owner's Manual TABLE OF CONTENTS GENERAL INFORMATION......Choke Cable Installation, Adjustment ..Location of Safety Related Labels....Engine Speed Adjustment ......Location of Parts ........... MAINTENANCE ..........Engine Serial Number ........Periodic Maintenance Chart ......Tune-up Specifications ........Oil Level Check ..........Engine Oil Capacity........

  • Page 100: General Information

    Kawasaki Owner's Manual GENERAL INFORMATION GENERAL INFORMATION Location of Parts A. Oil Gauge Filler B. Oil Filter C. Oil Drain Plug D. Air Cleaner E. Carburetor F. Spark Plug Cap/Spark Plug G. Air Inlet Screen H. Fan Housing I. Electric Starter J.

  • Page 101: Engine Oil Capacity

    Kawasaki Owner's Manual GENERAL INFORMATION Engine Oil Capacity Engine Oil Capacity 1.7 L (1.8 US·qt) [when oil filter is not removed] FX921V FX1000V 1.9 L (2.0 US·qt) [when oil filter is removed] FUEL AND OIL RECOMMENDATIONS FUEL AND OIL RECOMMENDATIONS ETHANOL: (Ethyl or Grain Alcohol) Fuel You may use gasoline containing up to 10%...

  • Page 102: Engine Oil

    Kawasaki Owner's Manual FUEL AND OIL RECOMMENDATIONS Engine Oil The following engine oils are recommended. API Service Classification : SF, SG, SH, SJ or SL. Oil Viscosity Oil Viscosity Choose the viscosity according to the temperature Choose the viscosity according to the temperature as follows: as follows: -20ºC...

  • Page 103: Engine Oil

    Kawasaki Owner's Manual PREPARATION Engine Oil Check the engine oil daily before starting the en- gine otherwise shortage of the engine oil may cause serious damage to the engine such as seizure. Place the engine on level surface. Clean area around the oil gauge before removing it.
  • Page 104 Kawasaki Owner's Manual STARTING A. Fuel Valve A. Throttle Lever A. Throttle Lever STARTING CAUTION Put the switch key (A) into the engine switch. Turn the switch key to the START position on the Do not run the electric starter continuously equipment.

  • Page 105: Operating

    Kawasaki Owner's Manual OPERATING OPERATING CAUTION Warming Up Allow engine to warm up sufficiently (3 to 5 minutes at idle) before applying a load. This After the engine starts, move the throttle lever (A) will allow oil to reach all engine parts, and allow piston clearance to reach design spec- ifications.

  • Page 106: Stopping

    Kawasaki Owner's Manual STOPPING 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 the lever to its low speed end turns ignition off. Ordinary Stop Move throttle lever (A) to SLOW position.

  • Page 107: Engine Speed Adjustment

    Kawasaki Owner's Manual ADJUSTMENT Engine Speed Adjustment NOTE If any adjustment is necessary, see an authorized service facility to perform the adjustment. B. Control Lever (Throttle) H. Choke Valve Pivot Arm I. Throttle Valve Pivot Arm MAINTENANCE MAINTENANCE Maintenance, replacement, or repair of the emission control devices and systems may be performed by any nonroad engine repair establishment or individual.

  • Page 108: Oil Level Check

    Kawasaki Owner's Manual MAINTENANCE INTERVAL MAINTENANCE Every Every Every Every Every Every Daily 50 hr. 100 hr. 200 hr. 250 hr. 300 hr. 500 hr. Check cleanout cover. Clean dust and dirt from cylinder and Tighten nuts and screws. Change engine oil. Clean and regap spark plugs.

  • Page 109: Oil Change

    Kawasaki Owner's Manual MAINTENANCE Install the oil drain plug. Oil Change Remove the oil gauge and refill with fresh oil (See FUEL AND OIL RECOMMENDATIONS chapter). Change oil after first 8 hours of operation. There- Check the oil level (see PREPARATION chapter). Change oil every 100 hours.

  • Page 110: Air Cleaner Service

    Kawasaki Owner's Manual MAINTENANCE NOTE Air Cleaner Service CAUTION Primary Element Do not run the engine with the air cleaner Replace the primary element every 250 hrs. removed. Secondary Element Replace the secondary element with a new one, Air Cleaner if the secondary element is dirty when the primary This air cleaner elements are not recommended to element is checked.

  • Page 111: Fuel Filter And Fuel Pump Service

    Kawasaki Owner's Manual MAINTENANCE 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 sol- vents 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 ap- pliances with a pilot light.

  • Page 112: Cooling System Cleaning

    Kawasaki Owner's Manual MAINTENANCE [Bolts Size, Tightening Torque] Cooling System Cleaning Bolts Size Length Tightening torque Before each operation, check that the air inlet (ro- Before each operation, check that the air inlet (ro- 5.9 N·m (0.6 kgf·m, 4.3 12 mm tary) screen (C) is free from grass and debris.

  • Page 113: Storage

    Kawasaki Owner's Manual STORAGE STORAGE Install the sediment bowl. Fuel System Draining Put a pan under the carburetor and loosen the drain screw of the carburetor to drain the gasoline Engine to be stored over 30 days should be com- When not operating your Kawasaki engine more completely.

  • Page 114: Troubleshooting Guide

    Kawasaki Owner's Manual 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 troubleshooting. Remedy Symptom Probable Cause Insufficient Faulty pistons, cylinders, piston rings, start or output is compression and head gaskets Faulty valves...

  • Page 115: Environmental Protection

    Kawasaki Owner's Manual ENVIRONMENTAL PROTECTION ENVIRONMENTAL PROTECTION To protect our environment, properly dispose of used batteries, engine oil, gasoline, coolant, or other com- ponents that you might discard. Consult your authorized Kawasaki dealer or local environmental waste agency for the proper disposal pro- cedures.

  • Page 116: Wiring Diagram

    Kawasaki Owner's Manual WIRING DIAGRAM WIRING DIAGRAM Wiring Diagram (With 12 V - 15 A Charging Coil) WARNING For electrical safety, always remove cable tempting any repair or maintenance. Battery Capacity Recommended Model Battery Capacity Lawn Mower 12 V 550 CCA Class Snow Thrower 12 V 550 CCA Class NOTE...
  • Page 117 Effective October 1, 2020 Consumer Limited Warranty Country Clipper, a Division of Shivvers Mfg., Inc. will Warrant on the terms and conditions herein, that we will repair, adjust, or replace parts found by examination by the factory or by an authorized Country...
  • Page 118 Country Clipper. The servicing dealer will require a proof of purchase if the product has not been registered.
  • Page 119 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 120 Kawasaki Warranty 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 purchased in any of the following regions: North, Central or South America, Caribbean, Australia, New Zealand, and all territories of the United States of America (collectively, the "Purchase Area") that it will repair or replace, free of charge, any engine parts found to be defective, under normal use and proper maintenance, for a period of thirty-six (36) months, subject to the following conditions, exclusions, obligations and limitations.
  • Page 121 ' • " • · = = = • • ' • Kawasaki Warranty •u�+H ' ·,•· • ·:- : ·••-•' ..,,, ..,,:,-..·.:• "1o\111011•, ,,,- • :::;•-�•' \'It♦••, ' .:?.•• .. •I 4♦1♦• A ... ,', ❖:· . · ·:· ❖...
  • Page 122 Kawasaki Warranty...
  • Page 123 All Models Warranty Policies and Procedures BLN-50225_P18 Revision March, 2019...
  • Page 124 Hydro-Gear Warranty Policies and Procedures ® Limited Warranty BLN-50225_P18 March, 2019 Hydro-Gear Limited Partnership (hereinafter referred to as "Hydro-Gear") warrants to the original equipment manufacturer (OEM), authorized distributor, or authorized servicing dealer purchasing a Hydro-Gear product or replacement parts (such purchaser is hereinafter referred to as "Buyer") that the product or replacement parts will be free from defects in material and workmanship at the time of shipment from Hydro-Gear, and will conform to such drawings and specifica- tions as are applicable to the product or replacement parts under Hydro-Gear's sales agreement with Buyer.
  • Page 125 All Models Hydro-Gear Warranty Policies and Procedures ® Warranty Periods BLN-50225_P18 March, 2019 Note: Proof of purchase must be available if requested to assist in determining commencement of the warranty period. If proof of purchase is not available, the Hydro-Gear Serial Number will determine the commencement of the warranty period.
  • Page 126 Warranty Claims Procedure A. Claims submitted to Hydro-Gear will require a Hydro-Gear, OEM, Outdoor Power Equipment Institute (OPEI) or equivalent claim form from the servicing dealer. Dealer claims must provide all pertinent information typical on OPEI claim forms, i.e.., owner's name, servicing dealer, Hydro-Gear Serial Numbers, symptoms, repair date, and type of use, etc.
  • Page 127 Battery Warranty Terms The OE Interstate Battery will be covered under a free replacement warranty for 6 months. This warranty period will begin the date the lawnmower is purchased by the end user. Battery Warranty Process If you have a lawnmower that won’t start, please complete these steps before calling for a warranty replacement. Completion of these steps before calling will expedite the warranty process.
  • Page 128 SPECIFICATIONS BOSS XL - Joystick Steering 3560KAJ-9000 3572KAJ-9000 MODEL 3160KAJ-9000 35 H.P. Kawasaki 31 H.P. Kawasaki Engine FX1000V (999cc) FX921V (999cc) Hydrostatic Transmission Hydro-Gear ZT5400 Steering Control Single Joystick 10.25 Gallons Fuel Capacity 26x14-12 Tires, Rear 15x6-6 Tires, Front Zero-Turn Turning Radius 12-1/2 MPH Ground Speed Forward...
  • Page 129 PRODUCT MANUAL Country Clipper Division Shivvers Manufacturing, Inc. 613 W. English St. Corydon, IA 50060-0467 Ph. 641-872-2544 Fax. 641-872-1593 P-13495 (12/20)

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