Form No. Z2L Z Master with 2in SFS Side Discharge Mower Model No. 423 2300000 and Up Model No. 423 2300000 and Up Parts Catalog Ordering Replacement Parts To order replacement parts, please supply: the part number, the quantity, and the description of each part desired. Understanding Reference Numbers Each identified part in an illustration has a reference number. The reference number for a part also appears in the parts list, along with other information about the part. This catalog uses two special reference number formats, one to indicate parts in a service assembly and another to indicate the quantity of a given part in an illustration. Service Assembly Reference Numbers Parts in service assemblies have reference numbers in the form a:b. The a represents the reference number of the entire service assembly and the b represents a sequential number unique to each part within the service assembly. For example, a wheel assembly might be identified by reference number, the tire by :, the valve by :2, and the wheel by :3. When you order the assembly identified by reference number, you receive all parts identified by reference numbers :, :2, and :3. However, you may also order any part individually. Reference numbers of this type appear in illustrations and in part lists. Reference Numbers Indicating Quantity In an illustration, if a reference number indicates more than one part, the reference number has the form nx y. The n represents the quantity of the part, the X is the multiplication symbol, and the y represents the reference number. For example, in an illustration, the reference number 2X 3 means that two of the parts identified by reference number 3 are indicated. The TORO Company 03 All Rights Reserved
Contents Page Page Front Frame Assembly..................... 4 Electrical Schematic....................... 2 Caster and Wheel Assembly................ Cylinder/Crankcase Assembly Main Frame Assembly..................... Kawasaki FD0D AS03................ 2 Brake and Wheel Hub Assembly............ Piston/Crankshaft Assembly Steering Controls Assembly................ Kawasaki FD0D AS03................ 30 Hydraulic System Assembly................ Valve/Camshaft Assembly Seat Assembly............................ Kawasaki FD0D AS03................ 3 Seat Assembly No. (only on: 423). 2 Lubrication Equipment Assembly Seat Assembly No. 330 (only on: 423) 3 Kawasaki FD0D AS03................ 32 Deck Connection Assembly................. 4 Cooling Equipment Assembly Drive Idler Assembly....................... Kawasaki FD0D AS03................ 33 Z Stand Assembly........................ Electric Equipment Assembly Engine, Clutch and Air Cleaner Assembly..... Kawasaki FD0D AS03................ 34 Cooling System Assembly.................. Control Equipment Assembly Kawasaki FD0D AS03................ 3 Hood Assembly........................... Carburetor Assembly Cooling Mounting Frame Assembly.......... Kawasaki FD0D AS03................ 3 Fuel System Assembly..................... 2 Air Filter/Muffler Assembly Electrical System Assembly................. Kawasaki FD0D AS03................ 3 Deck and Wheel Gage Assembly............ 24 Fuel Tank/Fuel Valve Assembly Deck Assembly No. 4.............. 2 Kawasaki FD0D AS03................ 3 Spindle and Pulley Assembly............... 2 Starter Assembly Belt and Idler Arm Assembly................ 2 Kawasaki FD0D AS03................ 3 Accessories Model / Model / Striping Kit............................... 303 Seat Suspension Kit (For 423)......... Hitch Kit............................... 2 DFS Bagger.............................. 4 Atomic Blade......................... 4 303 Boot and Tube Kit (For DFS Bagger)......... 4 Z Recycler Kit (2in)................... 0 00 ROPS............................ TORO Dealer 2
Part Abbreviations Part descriptions in this catalog may include the following abbreviations. Abbreviation Meaning Abbreviation Meaning AR................. as required HYD................ hydraulic ASM................ assembly INC................. incorporated CARR.............. carriage LH................. left hand DEG................ degrees NI.................. nylon insert FH................. flat head PPH................ Phillips pan head GA................. gauge PTH................ Phillips truss head HF................. hex flange PTO................ power take off HH................. hex head RH................. right hand HHF................ hex head flange SFH................ slotted fillister head HLH................ hex lag head HJ.................. hex jam HOC................ height-of-cut SHH................ slotted hex head SQH................ square head SHWH.............. slotted hex washer head HS................. hex socket SPH................ slotted pan head HSBH.............. hex socket button head SRH................ slotted round head HSFH............... hex socket flat head STD................ standard HSH................ hex socket head TAP................ self tapping HWH............... hex washer head TTH................ Torx truss head HWHTF............. hex washer head WH................. wing head thread forming 3
3 2 24 3 3: 3:2 2 4 3: 3: 3: 3 24 :4 2 3:4 : 2 :2 24 232 3:3 24 : : 2 :3 3:4 3:2 3:3 3:3 3: 3: 3:3 Front Frame Assembly 4 32 Frame ASM :2 33 Decal Warning :3 2 Plug :4 302 Fitting Grease : 4 2 2 Bushing Special : 4 Decal Warning : 3 Bushing 3 Floorpan ASM 3:2 333 2 Pad Antiskid 3:3 33 Decal Check 3:4 4 Decal Missing, Cover 3: 333 Decal Z Master 3: Decal Danger, Slope 3: 2 2 Pad, Anti Skid 3 3 03 Lever Lift 332 Grip Lever, Lift 3 4 03 Arm Lift, Deck 3332 Spring Compression 32 24 Washer Flat 32 3 Nut Lock, NI 32 3 Ring Snap 2 330 2 Arm Lift, Deck 4 323 2 2 Screw HH 33 0 Plate Lift, Deck 32 0 Plate Lift, Deck 3302 Bushing Lever, Lift Not serviced separately 3:4 3:3 3: 3: 3 Sheet No.:2 3300 Bushing Lever, Lift 323 3 Screw HH 330 Pin Hitch W/Lanyard 2 000 Pin Hair 323 2 Screw HH 23 2 Washer Belleville 24 320 3 Nut HHF 2 323 3 Screw HH 2 323 2 Screw HH 2 32 2 4 Washer Flat 3 2 Front Frame Spring ASM 3: 330 Rod Lift, Deck 3:2 3344 2 Swivel Deck Mount, Rear 3:3 32 4 Nut Hex 3:4 32 2 Nut Jam 3: 32 2 Washer Flat 3: 3304 Spring Support, Deck 3 330 Decal Height, Deck 3 3334 Decal Height, Deck 4
2 3 4 4 2 : :2 :3 ::3 :: : ::2 2 :4 Caster and Wheel Assembly 433 2 Cap Grease 2 32 2 Nut Lock, NI 3 330 Washer Bellville 4 24 4 4 Bearing Cone, Taper 24 2 4 Bearing Cup, Tapered 43 2 Seal Grease 3 44 0 2 Fork Caster 0 233 2 U Bolt 0 2333 0 Bar Weight 442 2 Caster Wheel ASM : 330 2 Seal Bearing :2 33 2 Spacer Bearing :3 33 2 Bearing Cone, Taper :4 33 Spacer Caster, Front : Wheel And Tire ASM :: 2300 Tire ::2 33 Wheel ::3 334 2 Bearing Cup 2 32 3 4 Nut Lock, NI 44 0 3 Weight Bar ASM 32 4 4 Washer Flat 0 4333 0 Lever Lift, Deck 432 0 Strap 32 2 Screw 322 2 Nut HF 2 32 3 2 Screw HH 32 4 2 Nut Lock, NI Sheet No.:3 Not serviced separately
2 24 2 2 :2 2 2 3:2 3 4 44 2: 2:2 42 3:4 2 3:3 3: 2 Main Frame Assembly 334 03 Stop Brake, Park 4 3 3 Screw HH 323 2 Screw HH 33 Cable Throttle 0333 Control Choke 34 Main Frame ASM :2 3 2433 Decal Console, Top 2 330 2 Wheel And Tire ASM 2: 333 Tire 2:2 332 Wheel 3 4 Console ASM 3:2 0 Decal Control Panel 3:3 3 0 Decal Valve, Fuel 3:4 43 Decal Protection, Ear 3: 4 2 Decal Mobil 242 0 Nut Lug 32 2 2 Nut Lock 2 32 3 2 Nut Lock, NI 03 2 Bolt CARR 24 32 Clip Loom 2 30333 Tie Plastic 2 32 Knob Ball 2 32 4 Screw HH 2 322 33 Nut HF 2 3 2 Bumper Catcher, Grass 42 4 Decal Z2l 44 32 23 Washer Flat Sheet No.:4
3 24 2 23 3 23 y z y z y x 3 2 2 4:2 3 23 3 y : :2 4 4 2 2 2 23 2 30 Brake and Wheel Hub Assembly 340 2 Bearing Control 2 3344 2 Spring Brake 3 334 3 Rod Brake 4 3400 Brake Lever ASM 4:2 332 Grip Lever, Brake 3 03 Shaft Brake 3 032 03 2 Bracket Brake 23 2 Washer Spacer 3 03 2 Band Brake 3330 4 Spacer Wheel, Short 3332 4 Spacer Wheel, Long 2 332 2 Bearing Flange, Side 3 333 4 Yoke Linkage, Brake 4 3344 2 Pin Trunion 3 00 2 Hub Wheel : 3 0 Hub Wheel :2 332 4 Stud Wheel 323 4 4 Screw HH 3 23 4 Pin Spring, Clevis 32 Screw HH 2 4 2 Fitting Grease 3 03 Nut Square 23 32 3 Nut HH 24 320 3 4 Nut HHF 2 323 Washer Lock 2 32 4 4 Washer Flat 3 2 2 Sheet No.: 2 3 Pin Cotter 2 000 2 Pin Cotter 2 3 Screw HH 30 3 034 Spacer 3 3 034 2 Retainer Band, Brake
2 : RH 3: LH RH 3 LH y 23 :4 : :2 :3 : : 34 : : 2 4 3 2 34 3 : 3 34 :4 30 Steering Controls Assembly 303 2 Yoke Adjustable 2 4 Washer Belleville 3 3 23 2 Damper Control, Motion 033 2 Bushing Flanged 033 2 Bolt Return, Neutral 030 2 Spring Return, Neutral 4030 4 Screw HH LH Pump Linkage ASM : 430 Balljoint RH :2 32 2 3 Nut Hex :3 3 304 Link Rod, Tracking :4 0424 Nut : 332 Balljoint Thread, LH Tracking Rod ASM : 430 Balljoint RH :2 32 2 Nut Hex :3 3 300 Knob Tracking :4 0424 2 Nut : 32324 2 Spring Compression : 332 Balljoint Thread, LH : 3 304 Link Rod, Tracking 3 032 RH Lever ASM : 332 Grip Control, Motion Not serviced separately 3 34 34 32 :3 2 2 2 2 33 : 30 2 :2 34 24 Sheet No.: 2 32 2 Arm Control, Pump 3 423 Control Motion, LH 4 423 Control Motion, RH 332 4 Bearing Flange, Side 3 040 2 Arm Shaft, Control 3 4 Screw HH 2 323 4 Screw HH 323 4 Screw HH 23 323 Screw HH 24 030 2 Screw Set 2 32 3 Nut Lock, NI 2 32 2 4 Nut Hex 2 32 2 2 Nut 2 32 2 2 Washer Flat 30 32 3 4 Washer Flat 32 3 2 Pin Cotter 33 020 2 Pin Clevis 34 322 Nut HF 3 320 3 Nut HHF 3 3 03 LH Lever ASM 3: 332 Grip Control, Motion
24 : :2 4 2 4 4: 0 3 2 2: 40 4 2 4 : 2 2: 3 2 43 3 4 2:: 2::2 2:2 : 2 2 2:2 4 3 3 4 2 3 44 2 4 33: 34 33:3 42 33: 33 4 4 3 : 2: : 40 4 3 30 23 4 4 2 32 Hydraulic System Assembly 3 33 HYD Hose ASM 2 3 4 HYD Reservoir ASM 2: Reservoir HYD 2:: 3 4 Cap Reservoir, HYD 2::2 3 4 Gasket Cap 2:2 232 Decal Tank, HYD 3 4 3 Head Filter 4 3 333 HYD Hose ASM 330 Filter HYD 332 Filter HYD, Winter 3 2 Elbow 0 : 23 42 O Ring 03 4 Fitting Straight : 23 0 O Ring :2 032 O Ring 2332 2 Motor Wheel : 003 Nut HH :2 32 42 Key Woodruff *: 0000 Seal Kit *: 0003 Bearing Kit *: 3 24 Drive Link Kit 2 0334 Bushing Pivot, Idler 3 3 3330 Spring Extension 4 3 2 Adapter Run, Tee 4: 23 42 O Ring 3 3 Clamp Hose Not serviced separately * Not illustrated :2 : 3 4 Clamp Hose 3 0 Adapter Straight : 23 42 O Ring 3 2 Adapter Straight : 23 42 O Ring 3 02 2 Fitting HYD, 0 : 23 42 O Ring 2 030 4 Fitting Straight 2: 23 O Ring 2:2 032 O Ring 3 33 HYD Hose ASM 23 3 33 HYD Hose ASM 24 3 2 HYD Hose ASM 2 3 0 Hose HYD 2 3 0 Elbow 4 2: 23 42 O Ring 2 3 0 HYD Hose ASM 2 33 2 Sheave 2 33 Sheave 30 334 Belt Drive, Pump 3 33 Sheave Idler 32 3 2 HYD Hose ASM 33 342 Bearing Arm ASM 33: 3034 2 Sleeve Bearing 33:3 302 40 Fitting Grease 34 32 2 Screw HH Sheet No.:
24 : :2 4 2 4 4: 0 3 2 2: 40 4 2 4 : 2 2: 3 2 43 3 4 2:: 2::2 2:2 : 2 2 2:2 4 3 3 4 2 3 44 2 4 33: 34 33:3 42 33: 33 4 4 3 : 2: : 40 4 3 30 23 4 4 2 32 Hydraulic System Assembly (Continued) 3 323 Screw HH 3 323 Screw HH 3 000 Screw HH 3 323 4 Screw HH 3 030 2 Screw Set 40 30 2 Screw 4 0300 2 Screw Set 42 32 2 Washer Flat 43 32 3 Washer Flat 44 32 4 Washer Flat 4 3 240 Key Square 4 0 2 Key 4 320 3 Nut HHF 4 322 33 2 Nut HF 4 0004 2 Washer Lock 0 32 3 2 Screw HH 3 2 2 Pump HYD *: 3 24 Input Shaft Kit *:2 4 Bearing Thrust *:3 3 2 Cylinder Block Kit *:4 Plate Valve *: 4 Seal Overhaul Kit *: 3 Shock Valve Kit :2 : Sheet No.: * Not illustrated
3 32 2 30 33 4 23 2 4 Seat Assembly Sheet No.: C 304 2 330 Seat ASM (only on: 423) 2 Seat Suspension Kit (only on: 423) 432 Track Seat (only on: 423) 4 32 03 Frame Seat 3323 Rod Holdup, Seat 3 Screw HH 323 3 2 Screw HH 32 2 Nut Lock, NI 2 32 3 2 Nut Lock, NI 23 322 4 Nut HF 30 242 33 2 R Clamp 3 3244 0 2 Screw HH (only on: 423) 3 324 2 Screw (only on: 423) 32 32 2 Washer Flat (only on: 423) 33 4 0 Tube Manual 4 332 03 2 Stop Seat
3:2 34:3 3: 3:4 33 3:3 3:2 3: 34:2 34: 3: 3:2 3:4 3:3 3: 2 3 3:3 3: 3:4 3:3 3:2 3:2 3:2 4 (0 Series Only) (0 Series Only) Seat Assembly No. (only on: 423) Sheet No.:A 2 3 Harness Wiring, Seat 3 30333 Tie Plastic 4 332 03 2 Stop Seat 3 03 2 Stop/Spacer Seat *30 432 Switch Seat 3 342 Armrest Pad Kit 3: Pad Arm 3:2 Capscrew 3:3 Capscrew 3:4 Flange Locknut * 3: 2 Spacer 32 343 Boot Kit * 32: Boot * 32:2 Wire Form, Upper * 32:3 2 Wire Form, Lower * 32:4 2 Tie Wrap 33 344 Armrest Kit * 33: 2 Capscrew 33:2 Armrest ASM * 33:3 2 Washer 34 34 Pan ASM 34: Pan 34:2 Seat Gray 34:3 Back Gray * 34:4 Adhesive Thermoset * 34: Nut Panel * 34: Staple 3 34 Damper Kit 3: Damper 3:2 2 Locknut Hex 3:3 Washer 3:4 Spacer 3 34 Roller Kit 3: 4 Roller 3:2 2 Bumper * 3:4 2 Spacer 3 34 Spring And Cable Kit 3: 2 Spring 3:2 Cable ASM 3 34 Knob And Shaft Kit 3: Knob Tension, Adjust 3:2 Shaft Tension Adjust 3:3 2 Pin Spring 3:4 Spring Hanger * Not illustrated Not serviced separately 2
2 : : :4 : : 3 :3 : : Seat Assembly No. 330 (only on: 423) 3 020 Cushion Seat, Bottom 2 4 4 Cushion Seat, Back 4340 4 Spacer Track 432 Track Seat 33 Frame Seat 32 4 Screw HH 322 4 Nut HF 3 32 23 4 Washer Flat 32 Washer Flat 3 Armrest Kit : 33 2 Cushion Armrest :3 3 2 Screw HH :4 323 2 Channel, Armrest : 323 3 2 Nut Lock : 32 Bracket Armrest, RH : 3 Bracket Armrest, LH : 32 30 Screw HH : 32 42 2 Nut Lock, NI : 32 2 2 Screw HH : 323 2 Nut Lock : : : Sheet No.:A3 C 303 3
3 4 2 2 3 2 Deck Connection Assembly 322 3 Nut HF 2 00 Screw Cap, HH 3 3344 4 Chain Lift, Deck 4 302 4 Fitting Grease 32 2 Nut Hex 323 2 Washer Lock 32 2 Screw HH 3302 2 Balljoint Spherical 32 2 Nut Hex 3 2 0 2 Strut 32 0 2 Pin Strut 2 3 3 2 Screw HH 3 32 2 2 Nut Lock, NI 2 Sheet No.: 4
2 2 24 4: 4:3 4 2 2 y 24 23 2 24 2 Drive Idler Assembly 2 Washer Belleville 2 323 4 Screw HH 3 2 2 Spacer Idler 0300 Spacer (only on: 423) 3 Bushing Idler (only on: 423) 0334 Bushing Pivot, Idler 323 Screw HH 034 2 Bushing Idler (only on: 423) 034 Bushing Idler (only on: 423) 43 Idler 03402 Spring Extension 2 33 Pulley Idler 4 4 Idler Arm ASM 4: 3034 2 Sleeve Bearing 4:3 302 40 Fitting Grease 323 2 Screw HH 323 Screw HH 323 Screw HH 323 Screw HH 32 3 Nut Lock, NI 32 24 3 Washer Flat 2 320 3 4 Nut HHF 3 32 Nut Coupling 23 32 3 Nut Jam 24 32 4 3 Washer Flat Sheet No.:
4 3 2 3 2 4:2 4 Z Stand Assembly 323 Screw HH 2 0 42 0 Bracket Cradle 3 32 3 2 Nut Lock, NI 4 0 4 Leg ASM 4:2 4 Decal Z Stand 23 Pin Clevis 0 2 0 Pivot Pin ASM 323 Screw HH 0 0 Bracket Latch 3 2 Washer Thrust 23 Pin Lynch 320 3 Pin Hair 2 0 4 2 Cushion Rubber 4 4 Pin Hitch, Cotterless 0 3 Lanyard Nylon 32 4 Screw HH 32 42 Nut Lock, NI Sheet No.:
4 4 2 3 2 3 : :3 :4 :2 3 4 3 4 : 30 2 4 4 3 3 4 4 44 4 42 33 Engine, Clutch and Air Cleaner Assembly Sheet No.:4 323 4 Washer 2 3 2 Muffler 4 334 2 Spacer Grommet 3343 03 Strap Clutch, Brake 03 2 Washer Spring 303334 Washer Spring 4300 Spacer Anchor, Clutch 3 34 Clutch : 30333 Tie Plastic Engine Kawasaki, Fd0d As03 2 3303 00 4 Nut Hex 3 0004 4 Washer Lock 4 3 02 Keeper Clutch 0 Bracket Mounting 32 3 4 Washer Flat 0 Air Cleaner ASM :2 3 2 Filter :3 4 32 Cover ASM :4 4 44 Valve Vacuator : 2 Plug Pipe 4300 2 Clamp Hose 4304 Hose Inlet, Air 2 4 0 Screw HH 30 32 3 Washer Flat Not serviced separately 3 322 2 Nut HF 33 33 02 4 Screw HH 3 33 0 2 Screw HH 3 3 3 Screw HH 4 3330 2 Grommet Brake 42 32 2 2 Nut Lock, NI 44 3 Screw HH 4 3 30 Valve Drain, Oil 4 3 04 Spacer Clutch 4 3 Arrestor Spark 4 3 2 Clamp Muffler
:2 2 4 :3 :2 3 3 2 4 :2 3 3 34 2 23 24 2 4 3 3 33 32 3 2 2 30 2 2 Cooling System Assembly 4 43 Radiator Trim Plate ASM :2 20 2 Decal Surface, Hot :3 4 244 Decal Coolant, Havoline 2 43 Cap Radiator 3 3 4 Radiator Mount, Horiz. 4 3 2 Screw HH 32 23 4 Washer Flat 0 430 Fan Mounting Plate ASM :2 4323 2 Decal Fan, Radiator 030 4 Screw 32 Washer Flat 0424 4 Nut 333 Fan 33 4 Clamp Hose 2 3 004 Hose Inlet, Radiator 3 3 00 Hose Outlet, Radiator 4 434 Cap Tank, Overflow 433 Tank Overflow 433 Hose 432 Fitting Elbow 34 Bushing Valve, Fuel 3 203 03 Bracket Bottle Sheet No.: 32 2 2 Screw HH 2 3032 3 Tie Plastic 432 Hose 23 33 Extension Crankshaft 24 32 3 Washer Lock 2 3304 00 3 Nut Hex 2 33 Fan Pump, Cooling 2 32 3 Washer Flat 2 00 3 Screw HSH 2 3 00 Shroud Fan, HYD 30 32 2 Nut Lock 3 32 4 2 Washer Flat 32 320 00 Screw PPH 33 3 0 03 Shield LH 34 334 03 Baffle Engine Shield, RH 3 32 4 Screw HH 3 322 33 Nut HF 3 3 320 Decal 30 Rpm
2 2 2 4 24 23 3 2 4 2 4 3 Hood Assembly 334 03 Screen Radiator 2 0302 Rivet Bulbex 3 32 4 2 Washer Flat 4 3 4 4 Screw HH 4 3 Hood 32 23 Washer Flat 30343 Washer Spring 32 2 4 Nut Lock, NI 33 03 2 Plate Hinge, Hood 32 03 2 Shackle Hinge 322 2 Nut HF 2 3 3 Screw HH 3 02 2 Pin Clevis 4 32 24 Washer Flat 0003 2 Pin Hair 43 03 Angle Radiator, RH 43 03 Angle Radiator, Bottom 43 03 Angle Radiator, Top 43 03 Angle Radiator, LH 43 2 Seal Trim 2 43 2 Seal Trim 23 43 2 Latch Rubber 24 23 4 Rivet Pop 2 42 Decal Liquid Cooled, Z Master Sheet No.:
:3 : 23 23 2 23 2 3 :2:3 :2:2 :2: :2 4 33 32 2 2 30 34 2 2 3 24 34 2 2 34 2 34 2 3 33 3 33 32 3 32 4 32 LH 3 RH Cooling Mounting Frame Assembly 32 24 Washer Flat 2 030 4 Screw Truss Head 4 32 2 4 Nut Lock 33 03 Crossbar 3 4 4 Screw HH 322 2 Nut HF 3 3 Screw HH 32 42 Nut Lock, NI 322 33 2 Nut HF 234 2 Bumper 2 32 2 Screw HH 3 4333 Decal Routing, Belt 4 3 0 03 Brace Radiator, LH 32 03 Brace Radiator, RH 3 20 03 Deflector Air 32 3 4 Rivet Pop 4 40 2 Screw Tapping 3 0 03 Plenum Intake, Air 442 Shield ASM : 3342 Decal Important :2 3430 Shield/Lift ASM :2: 3 30 Shield Engine :2:2 33300 03 Lift Shield :2:3 0303 3 Rivet Pop :3 3 03 Decal Devices, Rotating Sheet No.: 2 32 4 4 Screw HH 3 0 03 Plate Side, LH 23 32 2 Washer Flat 24 23 4 Rivet Pop 2 3 Screw HH 2 323 03 Mount Radiator, Rear 2 33 03 Guard Bumper 2 33 03 2 Rib Top 2 33 03 2 Rib Bottom 30 33 03 2 Bar Hook, Latch 3 43 2 Keeper Latch, Rubber 32 320 3 Nut HHF 33 323 Screw HH 34 32 23 Washer Flat 3 323 4 Screw HH 3 33 03 2 Bar Mount Frame, Radiator 3 3 0 03 Plate Side, RH
23 24 2 2 2 2 4 2 4 :3 :2 3 2 3 2 2 2 2 :2 FRONT Fuel System Assembly 3030 Clamp 2 4 03 Panel Control 3 3 2 Hose Fuel 4 3 33 Hose Fuel 30 2 Gas Cap ASM :3 40 Gasket Cap, Gas 434 Hose Fuel 33023 Stud 32 LH Fuel Tank ASM :2 3 20 Fitting Fuel, Bulkhead 32 RH Fuel Tank ASM :2 3 20 Fitting Fuel, Bulkhead 2 3334 Valve Fuel 3 30342 Hose Line, Fuel 4 3334 Spring Tank, Fuel 32 4 2 Screw HH 3 3 2 Screw HH 32 4 Nut Lock, NI 32 2 2 Washer Flat 000 2 Washer Lock 32 23 Washer Flat 2 42 Decal Panel, Control 440 Shield Panel, Control 23 030 4 Screw 24 30343 4 Washer Spring 2 32 3 2 Screw HH 2 0004 2 Washer Lock 2 4320 Hose Fuel 2 32 Clip Loom 2 322 33 2 Nut HF Sheet No.:24 2
4 2 3 2 2 2 3 TO SEAT 2 23 3 0 2 2 4 2 3 2 3 4:2 2 34 2 3 4 TO ENGINE 4 4 2 2 4 3 TO CLUTCH 2 3 24 24:2 24: 3 4 2 33 3 3: 3:2 43 44 Electrical System Assembly 4 Harness Wire 2 00 Fuse Type, Blade 3 003 Fuse Blade Type, 30 Amp 4 432 3 Relay 030 2 Screw 32 2 Nut Lock 4333 Insulator Solenoid 32 4 Screw HH (only on: 423) 32 4 Screw HH (only on: 423) 333 3 Clip Loom 322 33 Nut HF (only on: 423) 322 33 Nut HF (only on: 423) 3304 00 Nut Hex 2 32 23 2 Washer Flat 3 34 Decal Warning, Battery 4 334 0 Screw HH 434 Tab 3 023 Sender Temperature 433 Washer Aluminum 232 Wire Battery, Positive 4 3 3 Sheet No.:2 3330 Wire Ground 2 433 Insulator Battery 30333 Tie Plastic (only on: 423) 30333 Tie Plastic (only on: 423) 23 32 2 2 Washer Flat 24 2 Battery 24: 4 43 Decal Battery 24:2 4 44 Decal Battery 2 3032 2 Tie Plastic 2 332 03 Strap Holddown 2 432 2 Wingnut 2 33 2 Bolt Holddown 2 320 00 Screw PPH (only on: 423) 2 320 00 2 Screw PPH (only on: 423) 3 33 3 Plate Tapped (only on: 423) 3 33 4 Plate Tapped (only on: 423) 33 33 Switch 34 32 Clip Loom 3 333 Switch Delta 3 30 Key Switch ASM
4 2 3 2 2 2 3 TO SEAT 2 23 3 0 2 2 4 2 3 2 3 4:2 2 34 2 3 4 TO ENGINE 4 4 2 2 4 3 TO CLUTCH 2 3 24 24:2 24: 3 4 2 33 3 3: 3:2 43 44 Electrical System Assembly (Continued) 3: 324 Washer Tooth 3:2 2 4 Nut HH 3 334 Meter Hour 3 0 Module Delay, Seat 3 43 Tie Plastic 4 3 30 2 Key Ignition 43 4303 Gauge Voltmeter 44 4302 Gauge Temperature 4 4442 Tilt Switch ASM 4:2 4340 Decal Switch, Mercury 4 30 2 Switch Open, Normally 4 3 2 Decal Relay 0 3 Harness Wiring, Seat (only on: 423) 32 Switch Closed, Normally (only on: 423) 2 322 2 Nut HF (only on: 423) 3 30 Plate Switch, Seat (only on: 423) 4 424 03 Mount Spring, Seat (only on: 423) 4 3 3 Sheet No.:2 234 Spring Switch, Seat (only on: 423) 00 Screw HH (only on: 423) 23
:2 :2 3 Deck and Wheel Gage Assembly 4 Deck ASM *2 3230 Screw CARR 230 Wheel Gage 242 Spacer 33034 Washer 320 3 Nut HHF LH Cover ASM :2 30 Decal Danger RH Cover ASM :2 30 Decal Danger 3 323 2 Screw HH Washer Belleville 3 Sheet No.: * Not illustrated 24
4 3 3:2 : : : 2 : :4 : : : : :3 :2 Deck Assembly No. 4 Deck ASM :2 43 40 Decal Danger :3 3 Decal Wheel, Gage :4 340 Decal Danger : 4 Decal Warning : 4 Decal Routing, Belt : 4 Decal Sfs : 4 3 Decal Missing, Cover : 3 Decal Torque, Blade Bolt : 4 Decal Deck 2 3 0 Screw HH 3 30 Deflector ASM 3:2 3 Decal Danger 4 4 Spacer 4 4 Spring Torsion 32 2 Nut Lock, NI 320 3 Nut HHF 323 2 Screw HH 3 2 Screw HH 322 2 Nut HF Sheet No.:A2 Not serviced separately 2
:2 2 4 4 : :2 :3 :4 3 23 2:2 2: 2: 2: 2 3 : : : : : : 2: 2: 2:4 2: 2: 2: 2: 2:2 2 : : Spindle and Pulley Assembly 3 3 0 Screw HH 4 4 4 Spring Torsion 33 Guide Belt 30 Deflector ASM :2 3 Decal Danger 32 2 Nut Lock, NI 323 Screw HH 32 3 Washer Flat 322 Nut Lock, Flange 3 320 32 Screw HWH 4 24 2 4 Clamp Slotted 44 3 Blade 32 24 Washer Flat 322 2 Nut HF 2 440 2 Outer Spindle ASM 2: 2 0 Shaft 2:2 302 2 Fitting Grease 2:4 4 30 Bearing ASM 2: 2 00 Spacer 2: 23 3 2 Seal Oil 2: 40 Housing 2: 44 Pulley And Hub ASM 2: 324 Nut Jam 2: 4 Washer 2: 343 Washer Spring 2:2 2 Bolt Blade Sheet No.: 2 Spindle Housing ASM : 302 2 Fitting Grease :2 324 Nut Jam :3 2 3 Washer :4 0 430 Pulley/Hub ASM : 40 Housing : 4 30 Bearing ASM : 23 3 2 Seal Oil : 2 00 Spacer : Spindle Shaft ASM : 2 Bolt Blade : 343 Washer Spring 23 323 Screw CARR 2 4 Spacer 2
2 2 :2 3 4 3 4 2 23 2 24 2 2 2 2 Belt and Idler Arm Assembly 40 Pulley Idler 2 00 Washer Flat 3 32 Nut Lock NI 4 32 2 Washer Flat 2 0 Idler Arm ASM :2 2 40 Bushing Rubber 0 Bushing Pulley 32 Screw HH Key Square 320 3 3 Nut HHF 44 30 Plate Idler, LH 32 Nut Lock, NI 2 44 20 V Belt 3 44 V Belt Drive, Deck 4 4 Spacer Bracket 3 Plate 2 Washer Belleville 323 42 Screw HH 430 Pulley Idler 233 03 Baffle Front, LH 234 03 Baffle Front, RH 2 322 Nut HF 3 3 4 Screw HH 23 30 Spacer 24 44 0 Bracket Pulley 2 323 Screw HH 2 3230 Screw CARR Sheet No.: 3 2
Electrical Schematic 2
Cylinder/Crankcase Assembly Kawasaki FD0D AS03 04 04 242 2 Gasket Head 0 0 24 Head Comp Cylinder 0A 0 24 Head Comp Cylinder 2 Case Rocker A 3 Case Rocker 0 0 24 Gasket, Breath 0A 0 240 2 Gasket, Rocker, Case 32 32 2 2 Plate 40 40 4 Cover, Breath 2 2 2 2 Valve, Breath 40 40 232 Cover Crankcase 4 4 2 Crankcase Comp 0 0 Joint 0 0 230 2 Screw 43 43 3 Pin 4 4 42 Seal Oil 4A 4 43 Seal Oil 3 3 Seal 24 24 2 Bearing Plane 24A 24 2 Bearing Plane 2 2 2 4 Bolt 2A 2 2 Bolt 20 20 02 2 Clamp 2 2 2 Tube 30 30G030 Bolt Flanged 30A 30G030 4 Bolt Flanged 30B 30G04 4 Bolt Flanged 30C 3G00 4 Bolt Flanged 2 2G0 4 Bolt Stud 0 0B 2 O Ring Obtain Parts from Kawasaki 2
Piston/Crankshaft Assembly Kawasaki FD0D AS03 300 300 22 2 Piston Engine 3002 3002 2 Pin Piston 300 300 00 2 Ring Set Piston 32 32 2 Rod ASM Connecting 4 4 2 Crankshaft ASM 0 0 23 Gear Spur, 33T 3 3 00 4 Ring Snap 2 2 2 4 Bolt A0 Key Woodruff Obtain Parts from Kawasaki 30
Valve/Camshaft Assembly Kawasaki FD0D AS03 2 2 Bracket 4 4 23 2 Valve Intake 20 2 Valve Exhaust 0 4 Retainer Valve Spring 2 Collet 3 4 Arm Rocker 32 32 0 4 Tappet 3 3 4 4 Rod Push 00 00 2 4 Seat Spring 40 40 0 4 Spring Engine Valve 4 4 23 Camshaft 4 4 20 4 Seal Oil 24 24 Spring 2 2 234 4 Bolt 22 22 4 Collar 20 20 22 4 Washer 30 30G04 4 Bolt Flanged 3 3B000 4 Nut Hex Obtain Parts from Kawasaki 3
Lubrication Equipment Assembly Kawasaki FD0D AS03 0 0 2 2 Gasket, Drain Plug 3 3 Shaft, Oil Pump 320 320 Holder, Oil Pump 40 40 Cover, Oil Pump 22 Cap Oil Filler 4 4 Rotor Pump, Outer 4A 4 Rotor Pump, Inner 4B 4 Rotor Pump 323 323 H Pipe, Oil Gauge 40 40 Filter Oil 40A 40 2 Filter 0 0 232 Gauge, Oil 0 0 234 Gear Spur, 33T 42 42 04 2 Pin O Ring 2 Plug, Drain 244 244 3 Spring 30 30G0 3 Bolt Flanged 30A 30G02 2 Bolt Flanged 00 00A300 Ball Steel 0 0B O Ring 0A 0B O Ring 0B 0B302 O Ring Obtain Parts from Kawasaki 32
Cooling Equipment Assembly Kawasaki FD0D AS03 0 0 302 Gasket 0 0 24 Gasket Thermostat 3 3 Shaft Impeller 42 42 Cover Pump 0 0 22 Body Upper 0A 0 002 Body Valve 302 302 0 Hose Cooling 302A 302 3 Hose Cooling 302B 302 4 Hose Cooling 4044 4044 3 Pump Water 404 404 Thermostat 403 403 4 Seal Mechanical 0 0 23 Gear Spur, 2T 2 2 Impeller 33 33 Case Pump 3 20 24 2 Clamp 43 43 3 Pin 4 4 2 Seal Oil 2 2 4 Clamp 20 20 234 Washer 20A 20 23 Washer 30 30C02 Bolt Flanged 30A 30G02 3 Bolt Flanged 30B 30G03 2 Bolt Flanged 30C 30G030 2 Bolt Flanged 30D 30G04 Bolt Flanged 30E 30G00 2 Bolt Flanged 30F 30G00 4 Bolt Flanged G0 3 Bolt Stud A034 Pin Dowel 0 0B O Ring Obtain Parts from Kawasaki 33
Electric Equipment Assembly Kawasaki FD0D AS03 0 0 2 Gasket 2 2 Bracket 2 2 Regulator Voltage 0 Coil Ignition, No. A Coil Ignition, No. 2 23 23 2 Flywheel ASM 2004 2004 3 Fuse ASM 2030 2030 23 Harness 20 20 00 Switch 03 03 22 Coil Charging 0 0 3 4 Scerw 3A 3 2 Clamp Plug Drain 0 0 2 2 Plug Spark, BPR2ES 2 2 Band 2 2 Bolt 20 20 0 4 Clamp 2 2 0 Clamp 20 20 2 Washer 30 30G0 Bolt Flanged 30A 30G030 2 Bolt Flanged 30B 30G02 3 Bolt Flanged 30C 30G0 2 Bolt Flanged 24 24B0 Screw Pan+ A0 Key Woodruff Obtain Parts from Kawasaki 34
Control Equipment Assembly Kawasaki FD0D AS03 23 Bracket 3 3 24 Lever Throttle 3A 3 24 Lever Choke 242 Link Choke Link 2 2 3 Arm ASM 3003 3003 Arm Pivot 32 32 Spring Governor 43 43 0 Sleeve 4 4 4 Governor ASM 43 43 20 Panel Comp Control 232 Panel Control 02 02 02 Bolt 02A 02 Bolt 0 0 23 2 Screw 2 Nut 02 232 Washer 2 2 4 Collar 3 3 2 2 Clamp 243 243 23 2 Collar 243A 243 24 Collar 244 244 2 Spring 24 24 Spring 24A 24 Spring 2 2 22 2 Bolt 20 20 3 Washer 20A 20 2 2 Washer 20B 20 2 Washer 20C 20 2 Washer 30 30B030 2 Bolt Flanged 30A 30G04 2 Bolt Flanged 3 3B000 2 Nut Hex 32 32G000 2 Nut Hex 4 4B000 Washer 42 42J000 Circlip Type E Obtain Parts from Kawasaki 3
Carburetor Assembly Kawasaki FD0D AS03 0 0 24 Gasket Intake 0A 0 24 Gasket Intake 0B 0 24 2 Gasket Intake Pipe 0C 0 243 Gasket Carburetor 03 03 2 Carburetor ASM 00 00 24 Pipe Intake 03 03 2 Insulator 4 4 2 Cover ASM 3 3 0 Float ASM 4 4 04 Float Chamber ASM 3 Throttle Valve ASM 3 Choke Valve ASM 2303 2303 Screw ASM 2303A 2303 0 Screw ASM 0 0 Manifold Intake 3 3 Clamp 3 3 2400 2 Jet Main 4 4 23 2 Jet Pilot 30 30G02 Bolt Flanged 30A 30T0 4 Bolt Flanged 0 0Q000 Tube PVC Obtain Parts from Kawasaki 3
Air Filter/Muffler Assembly Kawasaki FD0D AS03 Bracket 0 0 24 2 Gasket Muffler 0A 0 244 2 Gasket Air Filter 403 403 Duct Lower 403A 403 Duct Upper 00 00 2 Pipe Intake 3 3 4 Clamp 3 3 2 Seal 20 20 Clamp 30 30G0 3 Bolt Flanged 3 3R000 Nut Hex 4 4F000 Washer Spring Obtain Parts from Kawasaki 3
Fuel Tank/Fuel Valve Assembly Kawasaki FD0D AS03 40 40 Filter Fuel 4040 4040 Pump Fuel 0 0 2 Joint 20 20 42 2 Clamp 20 20 Tube Obtain Parts from Kawasaki 3
Starter Assembly Kawasaki FD0D AS03 2 2 2 Cap 30 30 2 Clutch ASM 30 30 Holder Brush 3 3 23 Lever Shift 4024 4024 2 Cover 03 03 Insulator 4 4 2 Cover ASM 4A 4 2 Cover ASM 23 23 4 Brush 240 240 2 4 Spring Brush 20 20 4 Armature 23 23 2 Starter Electric 20 20 2 Switch 3 3 Stopper 02 02 2 Bolt 24 2 Nut A 24 Nut 33 33 Ring Snap 30 30G03 2 Bolt Flanged 3 3B000 2 Nut Hex 4 4F000 2 Washer Spring Obtain Parts from Kawasaki 3