Service Engine

Engine Warranty Maintenance Statement

Maintenance, repair, or replacement of the emission control devices and systems on this engine, which are being done at the customer’s expense, may be performed by any non-road engine repair establishment or individual. Warranty repairs must be performed by an authorized John Deere dealer.

Avoid Fumes

c CAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death. • Move the machine to an outside area before running the engine. • Do not run an engine in an enclosed area without adequate ventilation. • Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area. • Allow fresh outside air into the work area to clear the exhaust fumes out.

Engine Oil

MIF

Use oil viscosity based on the expected air temperature range during the period between oil changes.

The following oils are preferred:

• John Deere TURF-GARD®

• John Deere PLUS-4®

Other oils may be used if above John Deere oils are not available, provided they meet one of the following specifications:

• API Service Classification SF, SG, SH or SJ

Checking Engine Oil Level

NOTE: Check oil twice a day if you run engine over 4 hours in a day.

Make sure engine is cold when checking engine oil level.

1. Park machine safely. (See Parking Safely in the SAFETY Section.)

2. Allow engine to cool.

3. Clean area around dipstick prior to removing it.

MX25122

Picture Note: Dipstick in similar location on all models.

4. Remove dipstick (A) from tube by unscrewing it. Wipe it clean.

5. Install dipstick in tube, but do not screw on to threads.

6. Remove dipstick. Check oil level on dipstick; oil level should be between the ADD and FULL marks.

• If oil is low, add oil to bring oil level no higher than the FULL mark on dipstick.

• If oil level is above the FULL mark, drain to proper level.

7. Install dipstick and tighten.

Changing Engine Oil and Filter

c CAUTION: Avoid injury! Touching hot surfaces can burn skin. The engine, components, and fluids will be hot if the engine has been running. Keep hands and body away from hot surfaces when servicing or working near the engine and components.

1. Run engine to warm oil.

2. Park machine safely on a level surface. (See Parking Safely in the SAFETY section.)

3. Put container under oil drain area.

MX25968

4. Remove plug (A) and allow oil to drain.

5. After oil drains, remove oil filter and discard.

6. Install plug.

7. Apply a film of clean engine oil on gasket of new filter.

8. Install filter. Turn filter clockwise until gasket makes contact with mounting surface. Tighten 1/2 to 3/4 turn after gasket contact.

9. Clean area around the oil dipstick.

10. Unscrew and remove the dipstick.

11. Add oil.

12. Install and tighten dipstick.

13. Start engine and run at slow throttle for approximately two minutes. Check for leaks around filter and drain plug.

14. Stop engine.

15. Check oil level:

• Remove and wipe dipstick clean with a rag.

• Install dipstick but do not screw onto threads.

• Remove dipstick. Check oil level on dipstick; oil level should be between the ADD and FULL marks. Add oil if needed.

16. Install dipstick and tighten.

Checking and Replacing Air Cleaner Element

1. Park the machine safely. (See Parking Safely in the SAFETY section.)

MX25118

Picture Note: Your model may be different from the model shown.

2. Unhook latches (A) and remove cover (B).

MX25119

Picture Note: Your model may be different from the model shown.

3. Remove primary element (C) and secondary element (D).

NOTE: The air cleaner elements are not recommended to be cleaned.

• Do not wash air cleaner elements.

• Do not oil air cleaner elements.

• Do not use pressurized air to clean air cleaner elements.

4. Inspect air cleaner elements and replace if dirty or at specified intervals

• Replace the secondary element if dirty when the primary element is checked and replaced.

5. Clean the housing (E) with detergent and water. Dry thoroughly with a clean cloth.

NOTE: If the housing is damaged, it must be replaced.

6. Check the housing for deformation or other damage. The housing must seal well and permit only filtered air to reach the carburetor.

7. Check that no foreign material is obstructing the air passage.

8. Install new element(s).

9. Replace cover with the “up” mark on the cover at the twelve o’clock position and secure latches.

Checking Spark Plugs

c CAUTION: Avoid injury! Touching hot surfaces can burn skin. The engine, components, and fluids will be hot if the engine has been running. Allow the engine to cool before servicing or working near the engine and components.

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Clean area around both spark plugs.

MX43960

3. Disconnect the spark plug wire (A) from each plug.

4. Remove and inspect spark plugs:

• Clean each plug and check for damage, replace if necessary.

• If plugs are in good condition, check gap.

M85200

5. Check and adjust spark plug gap (B) to 0.76 mm (0.030 in.).

6. Install spark plugs.

• Tighten to 22 N•m (16 ft-lb).

7. Install both spark plug wires.

Cleaning Debris From Engine

c CAUTION: Avoid injury! Compressed air can cause debris to fly a long distance. • Clear work area of bystanders. • Wear eye protection when using compressed air for cleaning purposes. • Reduce compressed air pressure to 210 kPa (30 psi).

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Allow engine to cool.

MX43961

3. Loosen and remove five socket head bolts (A) and remove fan screen guard (B).

4. Remove four hex head bolts (C), fan screen and metal ring below fan screen.

5. Remove air cleaner canister bolt (D) and spread straps. Bend air intake hose (E), lift canister away from strap and move air filter housing away from engine shroud.

MX43962

6. Remove two air cleaner bracket bolts (F).

7. Remove two fuel pump bolts (G).

8. Remove two shroud/lift bracket bolts (H).

MX43963

9. Remove dip stick mounting bolt (I) and dipstick housing (J) from engine.

10. Remove four shroud bolts (K). Install dipstick housing (J) on engine and secure with one bolt (I).

MX43964

11. Remove wiring harness connector (L) from voltage regulator.

12. If engine is equipped with an oil cooler, remove mounting bolts.

13. Remove two shroud bolts (M). Lift shroud (N) upward and remove from engine.

14. Clean debris from engine area and all engine cooling fins.

15. Reverse steps to install shroud and tighten all hardware securely.

Replacing Fuel Filter

c CAUTION: Avoid injury! Fuel vapors are explosive and flammable: • Do not smoke while handling fuel. • Keep fuel away from flames or sparks. • Shut off engine before servicing. • Cool engine before servicing. • Work in a well-ventilated area. • Clean up spilled fuel immediately.

NOTE: Change fuel filter when fuel is low.

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Allow engine to cool.

3. Place a drain pan under hoses to catch any fuel that may be left in the hoses.

MX25125

4. Disconnect fuel hose (A) from the outlet side of the fuel filter (B), and drain gasoline into a properly marked container.

5. Remove the fuel filter from the inlet fuel hose (C). Discard filter.

6. Install new fuel filter.

• Make sure fuel filter is installed with arrow pointing in direction of fuel flow.

7. Connect hoses to new fuel filter.

Adjusting Carburetor

NOTE: Carburetor is calibrated by the engine manufacturer and is not adjustable.

If engine is operated at altitudes above 1829 m (6,000 ft), some carburetors may require a special high altitude main jet. See your authorized dealer.

If engine is hard to start or runs rough, check the TROUBLESHOOTING section of this manual.

Possible engine surging will occur at high throttle with transmission in N neutral and mower engagement lever disengaged. This is a normal condition due to the emission control system.

After performing the checks in the troubleshooting section and your engine is still not performing correctly, contact your authorized dealer.