Form No. Z2L Z Master with 2in SFS Side Discharge Mower Model No. 424 23000600 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 6, the tire by 6:, the valve by 6:2, and the wheel by 6:3. When you order the assembly identified by reference number 6, you receive all parts identified by reference numbers 6:, 6:2, and 6:3. 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 Cylinder/Crankcase Assembly Caster and Wheel Assembly................ 5 Kawasaki FD50D AS03................ 2 Main Frame Assembly..................... 6 Piston/Crankshaft Assembly Brake and Wheel Hub Assembly............ Kawasaki FD50D AS03................ 2 Steering Controls Assembly................ Valve/Camshaft Assembly Hydraulic System Assembly................ Kawasaki FD50D AS03................ 2 Seat Assembly............................ Lubrication Equipment Assembly Seat Assembly No. 522................ 2 Kawasaki FD50D AS03................ 30 Deck Connection Assembly................. 3 Cooling Equipment Assembly Drive Idler Assembly....................... 4 Kawasaki FD50D AS03................ 3 Z Stand Assembly........................ 5 Electric Equipment Assembly Engine, Clutch and Air Cleaner Assembly..... 6 Kawasaki FD50D AS03................ 32 Cooling System Assembly.................. Control Equipment Assembly Kawasaki FD50D AS03................ 33 Hood Assembly........................... Carburetor Assembly Cooling Mounting Frame Assembly.......... Kawasaki FD50D AS03................ 34 Fuel System Assembly..................... Air Filter/Muffler Assembly Electrical System Assembly................. 2 Kawasaki FD50D AS03................ 35 Deck and Wheel Gage Assembly............ 22 Fuel Tank/Fuel Valve Assembly Deck Assembly No. 5 6.............. 23 Kawasaki FD50D AS03................ 36 Spindle and Pulley Assembly............... 24 Starter Assembly Belt and Idler Arm Assembly................ 25 Kawasaki FD50D AS03................ 3 Electrical Schematic....................... 26 Accessories Model / Model / Striping Kit............................... 3063 Z Recycler Kit......................... 0 6 Hitch Kit............................... 25 ROPS............................ TORO Dealer Atomic Blade......................... 4 304 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 5 5 25 6 24 36 6 3:5 3:2 2 4 3: 3:6 3: 3 24 :4 25 3:4 :6 22 22 2 :2 24 2326 3:3 24 : :5 2 :3 35:4 35:2 35:3 35:3 35:6 35:5 35:3 Front Frame Assembly 4 533 Frame ASM :2 633 Decal Warning :3 2 Plug :4 302 5 Fitting Grease :5 4 2 2 Bushing Special :6 4 5 Decal Warning : 3 Bushing 3 6 65 Floorpan ASM 3:2 633553 2 Pad Antiskid 3:3 63366 Decal Check 3:4 554 Decal Missing, Cover 3:5 6333 Decal Z Master 3:6 6 65 Decal Danger, Slope 3: 6 652 2 Pad, Anti Skid 5 3 3 03 Lever Lift 6 63325 Grip Lever, Lift 3 64 03 Arm Lift, Deck 633325 Spring Compression 3256 24 Washer Flat 326 3 5 Nut Lock, NI 325 3 5 Ring Snap 2 63306 2 Arm Lift, Deck 4 323 2 2 Screw HH 5 633 0 Plate Lift, Deck 6 632 0 Plate Lift, Deck 63302 Bushing Lever, Lift Not serviced separately 35:4 35:3 35:5 35: 35 Sheet No.:2 63300 Bushing Lever, Lift 323 3 Screw HH 6330 Pin Hitch W/Lanyard 2 06005 Pin Hair 22 323 2 Screw HH 23 55 2 Washer Belleville 24 320 35 Nut HHF 25 323 6 3 Screw HH 26 323 2 Screw HH 2 3256 2 4 Washer Flat 35 2 Front Frame Spring ASM 35: 63306 Rod Lift, Deck 35:2 63344 2 Swivel Deck Mount, Rear 35:3 32 4 Nut Hex 35:4 32 6 2 Nut Jam 35:5 3256 2 Washer Flat 35:6 633064 Spring Support, Deck 36 63306 Decal Height, Deck 3 633345 Decal Height, Deck 4
2 3 4 5 5 4 22 2 4 : :2 :3 :5:3 :5: :5 :5:2 3 :4 Caster and Wheel Assembly 54353 2 Cap Grease 2 326 5 2 Nut Lock, NI 3 63350 6 Washer Bellville 4 254 4 4 Bearing Cone, Taper 5 254 2 4 Bearing Cup, Tapered 5435 2 Seal Grease 3 44 0 2 Fork Caster 64425 2 Caster Wheel ASM : 63350 2 Seal Bearing :2 6335 2 Spacer Bearing :3 63355 2 Bearing Cone, Taper :4 6335 Spacer Caster, Front :5 Wheel And Tire ASM :5: 52300 Tire :5:2 633 Wheel :5:3 63354 2 Bearing Cup 3 0 6530 0 Weight ASM 4 3244 0 4 Screw HH 0 4333 0 Lever Lift, Deck 6432 0 Strap 32 2 Screw 322 2 Nut HF 2 325 3 2 Screw HH 22 326 45 2 Nut Lock, NI Sheet No.:3 Not serviced separately 5
2 24 25 2 :2 2 26 3:2 3 4 44 2: 2:2 22 42 3:4 2 5 3:3 3:5 2 5 Main Frame Assembly 63364 03 Stop Brake, Park 4 322 3 6 Screw HH 5 323 6 2 Screw HH 63366 Cable Throttle 603336 Control Choke 5 364 Main Frame ASM :2 3 2433 Decal Console, Top 2 6330 2 Wheel And Tire ASM 2: 6333 Tire 2:2 6332 Wheel 3 6 654 Console ASM 3:2 6 650 Decal Control Panel 3:3 3 0262 Decal Valve, Fuel 3:4 43 Decal Protection, Ear 3:5 4 2 Decal Mobil 5 242 50 Nut Lug 326 2 2 Nut Lock 2 326 3 2 Nut Lock, NI 22 053 2 Bolt CARR 24 5362 Clip Loom 25 303335 Tie Plastic 26 5352 Knob Ball 2 32 4 Screw HH 2 322 33 Nut HF 2 5365 2 Bumper Catcher, Grass 42 4 Decal Z2l 44 3256 23 6 Washer Flat Sheet No.:4 6
5 3 24 2 23 3 23 y z y z y x 3 2 22 25 4:2 3 23 3 y 5: 5:2 5 4 4 26 2 26 23 2 6 30 Brake and Wheel Hub Assembly 5340 2 Bearing Control 2 633454 2 Spring Brake 3 6334 3 Rod Brake 4 634500 Brake Lever ASM 4:2 63326 Grip Lever, Brake 5 6322 03 Shaft Brake 6 3 0354 03 2 Bracket Brake 5235 2 Washer Spacer 3 0355 2 Band Brake 633060 4 Spacer Wheel, Short 633062 4 Spacer Wheel, Long 2 6332 2 Bearing Flange, Side 3 6333 4 Yoke Linkage, Brake 4 63344 2 Pin Trunion 5 3 050 2 Hub Wheel 5: 3 05 Hub Wheel 5:2 63326 4 Stud Wheel 323 4 4 Screw HH 3 23 4 Pin Spring, Clevis 325 Screw HH 2 302 2 Fitting Grease 22 3 03 Nut Square 23 32 3 Nut HH 24 320 35 4 Nut HHF 25 3253 Washer Lock 26 3256 4 4 Washer Flat 3 2 2 Sheet No.:5 2 322 Pin Cotter 2 0600 2 Pin Cotter 2 322 6 Screw HH 30 3 034 6 Spacer 3 3 034 2 Retainer Band, Brake
2 22 : RH 3: LH RH 3 LH y 23 :4 : :2 :3 :5 : 34 :6 :5 25 4 3 5 6 2 34 6 35 :5 3 34 :4 30 Steering Controls Assembly 3035 2 Yoke Adjustable 2 55 4 Washer Belleville 3 3 23 2 Damper Control, Motion 5 60335 2 Bushing Flanged 6 6033 2 Bolt Return, Neutral 6030 2 Spring Return, Neutral 4030 4 Screw HH LH Pump Linkage ASM : 5430 Balljoint RH :2 32 2 3 Nut Hex :3 3 3064 Link Rod, Tracking :4 04524 Nut :5 63352 Balljoint Thread, LH Tracking Rod ASM : 5430 Balljoint RH :2 32 2 Nut Hex :3 3 3060 Knob Tracking :4 04524 2 Nut :5 323245 2 Spring Compression :6 63352 Balljoint Thread, LH : 3 3064 Link Rod, Tracking 3 0632 RH Lever ASM : 63325 Grip Control, Motion Not serviced separately 3 34 34 32 :3 2 26 2 26 33 : 30 :2 2 24 34 Sheet No.:6 2 632 2 Arm Control, Pump 3 6423 Control Motion, LH 4 6423 Control Motion, RH 6 6332 4 Bearing Flange, Side 3 040 2 Arm Shaft, Control 322 6 4 Screw HH 2 323 4 Screw HH 22 323 6 4 Screw HH 23 323 6 Screw HH 24 03022 2 Screw Set 25 326 3 6 Nut Lock, NI 26 32 2 4 Nut Hex 2 32 2 2 Nut 2 3256 2 2 Washer Flat 30 3256 3 4 Washer Flat 32 322 5 2 Pin Cotter 33 020 2 Pin Clevis 34 322 6 Nut HF 35 320 35 Nut HHF 3 3 063 LH Lever ASM 3: 63325 Grip Control, Motion
24 : :2 4 5 2 4 4: 50 3 26 26: 6 22 40 46 2 4 6 : 25 2: 35 2 43 3 4 2:: 2::2 2:2 : 6 2 2 2:2 4 3 3 45 2 36 44 2 4 33: 34 33:3 42 33: 33 4 4 3 : 2: 5 : 6 40 46 3 30 22 4 2 32 Hydraulic System Assembly 3 334 2 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 523552 Decal Tank, HYD 3 4 36 Head Filter 6 63350 Filter HYD 6 63352 Filter HYD, Winter 3 2 Elbow 0 : 23 42 O Ring 6336 4 Fitting 0 : 23 0 O Ring :2 6032 O Ring 52332 2 Motor Wheel : 0036 Nut HH :2 325 42 Key Woodruff *: 3 24 Drive Link Kit *: 0003 Bearing Kit *: 0000 Seal Kit 2 60334 Bushing Pivot, Idler 3 3 3330 Spring Extension 4 3 2 Adapter Run, Tee 4: 23 42 O Ring 6 3 6 3 Clamp Hose 3 4 Clamp Hose Not serviced separately * Not illustrated :2 : 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 6030 4 Fitting Straight 2: 23 O Ring 2:2 6032 O Ring 22 3 63 2 Hose Lower 24 3 26 HYD Hose ASM 25 3 0 Hose HYD 26 3 0 Elbow 45 26: 23 42 O Ring 2 3 06 HYD Hose ASM 2 63356 2 Sheave 2 63356 Sheave 30 6334 Belt Drive, Pump 3 6336 Sheave Idler 32 3 2 HYD Hose ASM 33 6342 Bearing Arm ASM 33: 53034 2 Sleeve Bearing 33:3 302 40 Fitting Grease 34 32 6 2 Screw HH 35 323 Screw HH 36 323 Screw HH Sheet No.:
24 : :2 4 5 2 4 4: 50 3 26 26: 6 22 40 46 2 4 6 : 25 2: 35 2 43 3 4 2:: 2::2 2:2 : 6 2 2 2:2 4 3 3 45 2 36 44 2 4 33: 34 33:3 42 33: 33 4 4 3 : 2: 5 : 6 40 46 3 30 22 4 2 32 Hydraulic System Assembly (Continued) 3 0005 Screw HH 3 323 4 Screw HH 3 03022 2 Screw Set 40 30 2 Screw 4 03050 2 Screw Set 42 3256 22 2 Washer Flat 43 3256 3 Washer Flat 44 3256 4 Washer Flat 45 3 240 Key Square 46 022 2 Key 4 320 35 Nut HHF 4 322 33 2 Nut HF 4 05004 2 Washer Lock 50 32 3 2 Screw HH 5 3 265 2 Pump HYD *5: 3 2664 Input Shaft Kit *5:2 4 622 Bearing Thrust *5:3 3 2666 Cylinder Block Kit *5:4 5 65 Plate Valve *5:5 5 64 Seal Overhaul Kit *5: 6 53 Shock Valve Kit :2 : Sheet No.: * Not illustrated
3 32 2 30 33 6 4 23 2 4 6 Seat Assembly Sheet No.: C 304 2 522 Seat Suspension Kit 6 643255 Track Seat 4 632 03 Frame Seat 6 63323 Rod Holdup, Seat 322 5 Screw HH 323 3 2 Screw HH 326 2 Nut Lock, NI 2 326 3 2 Nut Lock, NI 23 322 4 Nut HF 30 242 33 2 R Clamp 3 3244 0 2 Screw HH 33 4 0 Tube Manual 4 6332 03 2 Stop Seat
3:2 34:3 3: 3:4 33 3:3 35:2 3: 34:2 34: 36: 3:2 35:4 35:3 35: 2 3 3:3 3: 3:4 3:3 3:2 36:2 35:2 4 (0 Series Only) 5 (0 Series Only) Seat Assembly No. 522 Sheet No.:A 2 3 22 Harness Wiring, Seat 3 303335 5 Tie Plastic 4 6332 03 2 Stop Seat 5 65322 03 2 Stop/Spacer Seat *30 6432 Switch Seat 3 6342 Armrest Pad Kit 3: Pad Arm 3:2 Capscrew 3:3 Capscrew 3:4 Flange Locknut * 3:5 2 Spacer 32 6343 Boot Kit * 32: Boot * 32:2 Wire Form, Upper * 32:3 2 Wire Form, Lower * 32:4 2 Tie Wrap 33 6344 Armrest Kit * 33: 2 Capscrew 33:2 Armrest ASM * 33:3 2 Washer 34 6345 Pan ASM 34: Pan 34:2 Seat Gray 34:3 Back Gray * 34:4 Adhesive Thermoset * 34:5 6 Nut Panel * 34:6 Staple 35 6346 Damper Kit 35: Damper 35:2 2 Locknut Hex 35:3 Washer 35:4 Spacer 36 634 Roller Kit 36: 4 Roller 36:2 2 Bumper * 36:4 2 Spacer 3 634 Spring And Cable Kit 3: 2 Spring 3:2 Cable ASM 3 634 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
5 6 3 4 2 2 3 2 Deck Connection Assembly 322 3 6 Nut HF 2 00 Screw Cap, HH 3 63344 4 Chain Lift, Deck 4 302 4 Fitting Grease 5 32 2 Nut Hex 6 3253 2 Washer Lock 32 2 Screw HH 63302 2 Balljoint Spherical 32 6 2 Nut Hex 3 2 0 2 Strut 632 0 2 Pin Strut 2 322 3 2 Screw HH 3 326 2 2 Nut Lock, NI 2 Sheet No.: 3
5 6 2 2 24 4: 4:3 4 6 2 2 5 y 24 23 22 2 24 5 2 Drive Idler Assembly 55 2 Washer Belleville 2 323 4 Screw HH 5 3 256 2 Spacer Idler 6 3 262 Bushing Idler 60334 Bushing Pivot, Idler 323 Screw HH 60346 Bushing Idler 463 Idler 603402 Spring Extension 2 63366 Pulley Idler 4 46 Idler Arm ASM 4: 53034 2 Sleeve Bearing 4:3 302 40 Fitting Grease 5 323 2 Screw HH 6 323 Screw HH 323 Screw HH 323 6 Screw HH 326 3 Nut Lock, NI 3256 24 3 Washer Flat 2 320 35 4 Nut HHF 22 3 326 Nut Coupling 23 32 3 Nut Jam 24 3256 4 3 Washer Flat Sheet No.: 4
4 5 3 5 2 3 6 2 6 4:2 4 Z Stand Assembly 323 Screw HH 2 0 6542 0 Bracket Cradle 3 326 3 2 Nut Lock, NI 4 0 6545 Leg ASM 4:2 4 5 Decal Z Stand 5 23 55 Pin Clevis 6 0 62 0 Pivot Pin ASM 323 Screw HH 0 66 0 Bracket Latch 3 6 2 Washer Thrust 23 Pin Lynch 320 355 Pin Hair 2 0 654 2 Cushion Rubber 4 5 64 Pin Hitch, Cotterless 5 0 35 Lanyard Nylon 6 32 4 Screw HH 326 42 Nut Lock, NI Sheet No.: 5
4 4 2 3 2 3 :5 :3 :4 :2 6 3 4 3 6 4 6 : 30 25 4 4 3 3 5 4 4 44 6 46 42 5 33 Engine, Clutch and Air Cleaner Assembly Sheet No.:4 63235 4 Washer 2 3 25 Muffler 4 633545 2 Spacer Grommet 5 633543 03 Strap Clutch, Brake 6 6036 2 Washer Spring 303334 6 Washer Spring 64300 Spacer Anchor, Clutch 3 364 Clutch : 303335 Tie Plastic Engine Kawasaki, Fd50d As03 2 3303 00 4 Nut Hex 3 05004 4 Washer Lock 4 3 052 Keeper Clutch 5 5 506 Bracket Mounting 6 3256 3 4 Washer Flat 5 505 Air Cleaner ASM :2 3 25 Filter :3 4 3652 Cover ASM :4 4 44 Valve Vacuator :5 25 Plug Pipe 64300 2 Clamp Hose 64304 Hose Inlet, Air 25 4 50 Screw HH 30 3256 3 Washer Flat Not serviced separately 3 322 2 Nut HF 33 335 025 4 Screw HH 3 335 0 2 Screw HH 3 322 6 3 Screw HH 4 633630 2 Grommet Brake 42 326 2 2 Nut Lock, NI 44 322 Screw HH 46 3 306 Valve Drain, Oil 4 3 04 Spacer Clutch 4 3 5 Arrestor Spark 4 3 52 Clamp Muffler 6
:2 2 4 5 :3 :2 3 3 2 4 5 6 6:2 3 35 34 2 23 24 25 4 22 36 3 33 32 3 2 2 30 26 2 6 5 5 Cooling System Assembly 4 43 Radiator Trim Plate ASM :2 65 260 2 Decal Surface, Hot :3 4 244 Decal Coolant, Havoline 2 6436 Cap Radiator 3 3 46 Radiator Mount, Horiz. 4 322 2 Screw HH 5 3256 23 4 Washer Flat 6 0 430 Fan Mounting Plate ASM 6:2 643253 2 Decal Fan, Radiator 0306 4 Screw 3256 6 Washer Flat 04254 4 Nut 6333 Fan 633 4 Clamp Hose 2 3 004 Hose Inlet, Radiator 3 3 005 Hose Outlet, Radiator 4 64364 Cap Tank, Overflow 5 64363 Tank Overflow 6 6433 Hose 64325 Fitting Elbow 53645 Bushing Valve, Fuel 3 2603 03 Bracket Bottle Sheet No.:5 32 2 2 Screw HH 2 3032 3 Tie Plastic 22 6432 Hose 23 6335 Extension Crankshaft 24 3255 3 Washer Lock 25 3304 00 3 Nut Hex 26 6336 Fan Pump, Cooling 2 3256 22 3 Washer Flat 2 005 3 Screw HSH 2 3 00 Shroud Fan, HYD 30 326 2 6 Nut Lock 3 3256 4 2 Washer Flat 32 320 500 6 Screw PPH 33 3 05 03 Shield LH 34 6334 03 Baffle Engine Shield, RH 35 32 4 6 Screw HH 36 322 33 6 Nut HF 3 3 320 Decal 350 Rpm
2 2 2 5 6 6 4 24 23 3 2 5 4 6 2 6 4 3 Hood Assembly 63364 03 Screen Radiator 2 0302 Rivet Bulbex 3 3256 4 2 Washer Flat 4 322 4 4 Screw HH 5 4 536 Hood 6 3256 23 Washer Flat 303435 5 Washer Spring 326 2 4 Nut Lock, NI 6335 03 2 Plate Hinge, Hood 6326 03 2 Shackle Hinge 322 25 Nut HF 2 322 3 6 Screw HH 3 025 2 Pin Clevis 4 3256 24 6 Washer Flat 5 06003 2 Pin Hair 6 6436 03 Angle Radiator, RH 643 03 Angle Radiator, Bottom 643 03 Angle Radiator, Top 6435 03 Angle Radiator, LH 643 2 Seal Trim 2 6436 2 Seal Trim 23 643 2 Latch Rubber 24 236 4 Rivet Pop 2 462 Decal Liquid Cooled, Z Master Sheet No.:6
5 5 34 34 25 26 2 34 25 35 :3 : 23 23 2 2 23 3 :2:3 :2:2 :2: 6 :2 32 4 2 2 6 33 32 30 2 3 24 34 32 36 33 35 33 4 32 22 LH 3 RH Cooling Mounting Frame Assembly 3256 24 6 Washer Flat 2 0305 4 Screw Truss Head 4 326 2 4 Nut Lock 5 633 03 Crossbar 6 322 4 4 Screw HH 322 2 Nut HF 322 3 Screw HH 326 42 6 Nut Lock, NI 322 33 2 Nut HF 5234 2 Bumper 2 32 2 Screw HH 3 64333 Decal Routing, Belt 4 3 0 03 Brace Radiator, LH 5 6325 03 Brace Radiator, RH 6 3 20 03 Deflector Air 326 3 4 Rivet Pop 4 40 2 Screw Tapping 3 0 03 Plenum Intake, Air 64426 Shield ASM : 633462 Decal Important :2 63430 Shield/Lift ASM :2: 3 30 Shield Engine :2:2 633300 03 Lift Shield :2:3 03035 3 Rivet Pop :3 3 036 Decal Devices, Rotating Sheet No.: 2 32 4 4 Screw HH 22 3 06 03 Plate Side, LH 23 3256 2 6 Washer Flat 24 236 4 Rivet Pop 25 322 5 Screw HH 26 6323 03 Mount Radiator, Rear 2 6336 03 Guard Bumper 2 633 03 2 Rib Top 2 633 03 2 Rib Bottom 30 633 03 2 Bar Hook, Latch 3 643 2 Keeper Latch, Rubber 32 320 35 Nut HHF 33 323 6 6 Screw HH 34 3256 23 Washer Flat 35 323 4 Screw HH 36 6336 03 2 Bar Mount Frame, Radiator 3 3 0 03 Plate Side, RH
23 24 2 2 6 25 26 4 5 2 4 22 5 5:3 :2 3 2 3 2 2 26 25 :2 FRONT Fuel System Assembly 3030 Clamp 2 46 03 Panel Control 3 3 25 Hose Fuel 4 3 335 Hose Fuel 5 30 2 Gas Cap ASM 5:3 40 Gasket Cap, Gas 543456 Hose Fuel 633023 6 Stud 5 362 LH Fuel Tank ASM :2 3 2605 Fitting Fuel, Bulkhead 5 362 RH Fuel Tank ASM :2 3 2605 Fitting Fuel, Bulkhead 2 63334 Valve Fuel 3 303426 Hose Line, Fuel 4 63334 6 Spring Tank, Fuel 5 32 4 2 Screw HH 6 322 3 2 Screw HH 326 4 6 Nut Lock, NI 3256 2 2 Washer Flat 05005 2 Washer Lock 3256 23 Washer Flat 2 462 Decal Panel, Control 22 440 Shield Panel, Control 23 030 4 Screw 24 303435 4 Washer Spring 25 32 3 2 Screw HH 26 05004 2 Washer Lock 2 64320 Hose Fuel 2 5362 Clip Loom 2 322 33 2 Nut HF Sheet No.:24
34 4 2 26 22 50 25 23 2 4 2 3 6 3 22 2 3 22 2 45:2 2 5 3 4 TO ENGINE 4 6 45 6 2 2 6 22 3 TO CLUTCH 2 3 24 24:2 24: 3 4 2 33 3 22 36: 36:2 43 44 Electrical System Assembly 4 5 Harness Wire 2 600 Fuse Type, Blade 3 6003 Fuse Blade Type, 30 Amp 4 64325 3 Relay 5 030 2 Screw 6 326 2 6 Nut Lock 54333 Insulator Solenoid 32 4 5 Screw HH 63336 3 Clip Loom 322 33 5 Nut HF 3304 00 Nut Hex 2 3256 23 2 Washer Flat 3 5 3646 Decal Warning, Battery 4 334 06 Screw HH 6 64345 Tab 3 023 Sender Temperature 64353 Washer Aluminum 5232 Wire Battery, Positive 63330 Wire Ground 2 5433 Insulator Battery 22 303335 Tie Plastic 23 3256 2 2 Washer Flat 24 5 62 Battery 24: 4 463 Decal Battery 4 36 35 Sheet No.:2 24:2 4 464 Decal Battery 25 3032 2 Tie Plastic 26 633652 03 Strap Holddown 2 5432 2 Wingnut 2 63365 2 Bolt Holddown 2 320 500 Screw PPH 3 633 3 Plate Tapped 33 633 Switch 34 5362 Clip Loom 35 63363 Switch Delta 36 30 Key Switch ASM 36: 3254 5 Washer Tooth 36:2 2 46 Nut HH 3 5334 Meter Hour 3 0 66 Module Delay, Seat 3 6435 Tie Plastic 4 63 360 2 Key Ignition 43 64303 Gauge Voltmeter 44 64302 Gauge Temperature 45 64442 Tilt Switch ASM 45:2 64340 Decal Switch, Mercury 4 5305 2 Switch Open, Normally 4 3 2 Decal Relay 50 3 22 Harness Wiring, Seat 2
2 2:2 25 23 3 3 6 40 24 Deck and Wheel Gage Assembly 5 6 Deck ASM 6 242 6 Spacer 6 230 6 Wheel Gage 33034 6 Washer 320 35 Nut HHF 2 2623 LH Cover ASM 2:2 6 5360 Decal Danger 23 24 2 4 Clamp Slotted 24 320 32 Screw HWH 25 322 Nut Lock, Flange 3 55 6 Washer Belleville 3 323 2 6 Screw HH 3 23 0 Skid 40 323 2 2 Screw CARR 3 Sheet No.: 22
4 5 :2 6 3 3:2 :3 2 :4 :2 :3 :6 : : :3 : :5 Deck Assembly No. 5 6 Deck ASM :2 4 56 Decal Warning :3 554 3 Decal Missing, Cover :4 466 Decal Routing, Belt :5 43 40 Decal Danger :6 3 Decal Torque, Blade Bolt : 3 Decal Wheel, Gage : 55 Decal Deck : 66 340 Decal Danger 2 322 50 Screw HH 3 5 3605 Deflector ASM 3:2 3 22 Decal Danger 4 5 4622 Spacer 5 4 554 Spring Torsion 6 326 2 Nut Lock, NI 0 652 RH Cover ASM :2 6 5360 Decal Danger 320 35 6 Nut HHF 323 2 6 Screw HH 322 Screw HH 322 Nut HF Sheet No.:A2 Not serviced separately 23
: :2 :3 :4 6 23 25 2 25 24 2 2 30 2: 2:2 2:3 2:4 2 26 : :5 :6 : : : : : 2:6 2:5 2: 2:6 2: 2 3 2: 2: 2: Spindle and Pulley Assembly 5 6 Spindle Housing ASM : 302 2 Fitting Grease :2 3246 Nut Jam :3 2 536 Washer :4 0 430 Pulley ASM :5 6 460 Housing :6 46 530 Bearing ASM : 253 3 2 Seal Oil : 2 050 Spacer : 5 66 Spindle Shaft ASM : 2 56 Bolt Blade : 53435 Washer Spring 2 4642 2 Outer Spindle ASM 2: 2 0 Shaft 2:2 3246 Nut Jam 2:3 450 Washer 2:4 465 Pulley And Hub ASM 2:5 6 460 Housing 2:6 253 3 2 Seal Oil 2: 2 050 Spacer 2: 46 530 Bearing ASM 2: 302 2 Fitting Grease 2: 53435 Washer Spring 2: 2 56 Bolt Blade 3 4 6 3 Blade 6 323 22 Screw CARR 322 2 Nut HF 3256 24 4 Washer Flat 23 323 42 Screw HH 24 653 Plate 25 55 2 Washer Belleville 26 430 Pulley Idler 2 465 Spacer Bracket 2 320 35 Nut HHF 2 323 Screw HH 30 6530 Spacer Sheet No.: 2 24
5 2 6 3 4 5:2 3 2 22 2 Belt and Idler Arm Assembly 65 540 Pulley Idler 2 00 Washer Flat 3 326 33 Nut Lock, NI 4 3256 2 Washer Flat 5 2 50 Idler Arm ASM 5:2 2 40 Bushing Rubber 6 65 550 Bushing Pulley 32 Screw HH 5 Key Square 320 35 2 Nut HHF 44 6300 Plate Idler 326 5 Nut Lock, NI 2 5 0240 V Belt 3 462 V Belt 556 03 Baffle Front, LH 3 325 03 Baffle Front, RH 2 3230 Screw CARR 22 322 Nut HF 22 2 Sheet No.: 3 25
Electrical Schematic 26
Cylinder/Crankcase Assembly Kawasaki FD50D AS03 04 04 242 2 Gasket Head 0 0 245 Head Comp Cylinder 0A 0 246 Head Comp Cylinder 22 22 2 Case Rocker 22A 22 3 Case Rocker 60 60 2466 Gasket, Breath 60A 60 240 2 Gasket, Rocker, Case 32 32 25 2 Plate 40 40 64 Cover, Breath 626 626 2225 2 Valve, Breath 405 405 6232 Cover Crankcase 4 4 62 Crankcase Comp 50 50 Joint 0 0 230 2 Screw 43 43 3 6 Pin 4 4 2242 Seal Oil 4A 4 2243 Seal Oil 3 3 6 Seal 24 24 2 Bearing Plane 24A 24 2 Bearing Plane 25 25 25 4 Bolt 25A 25 25 Bolt 20 20 02 2 Clamp 2 2 25 Tube 30 30G0630 Bolt Flanged 30A 30G030 4 Bolt Flanged 30B 30G045 4 Bolt Flanged 30C 3G060 4 Bolt Flanged 2 2G022 4 Bolt Stud 60 60B 2 O Ring Obtain Parts from Kawasaki 2
Piston/Crankshaft Assembly Kawasaki FD50D AS03 300 300 225 2 Piston Engine 3002 3002 6 2 Pin Piston 300 300 600 2 Ring Set Piston 325 325 5 2 Rod ASM Connecting 4 4 2 Crankshaft ASM 505 505 235 Gear Spur, 33T 36 36 00 4 Ring Snap 25 25 250 4 Bolt 5 5A50 Key Woodruff Obtain Parts from Kawasaki 2
Valve/Camshaft Assembly Kawasaki FD50D AS03 5 5 2 2 Bracket 4 4 23 2 Valve Intake 5 5 20 2 Valve Exhaust 60 4 Retainer Valve Spring 52 Collet 6 6 63 4 Arm Rocker 32 32 60 4 Tappet 36 36 4 4 Rod Push 600 600 52 4 Seat Spring 40 40 60 4 Spring Engine Valve 4 4 23 Camshaft 4 4 20 4 Seal Oil 245 245 5 Spring 25 25 234 4 Bolt 252 252 66 4 Collar 20 20 22 4 Washer 30 30G04 4 Bolt Flanged 3 3B0600 4 Nut Hex Obtain Parts from Kawasaki 2
Lubrication Equipment Assembly Kawasaki FD50D AS03 0 0 2566 2 Gasket, Drain Plug 3 3 22 Shaft, Oil Pump 320 320 6 Holder, Oil Pump 40 40 65 Cover, Oil Pump 65 65 226 Cap Oil Filler 654 654 5 Rotor Pump, Outer 654A 654 6 Rotor Pump, Inner 654B 654 Rotor Pump 3253 3253 6 H Pipe, Oil Gauge 4065 4065 Filter Oil 4065A 4065 2 Filter 505 505 232 Gauge, Oil 505 505 2354 Gear Spur, 33T 42 42 04 2 Pin 55 55 6 O Ring 66 66 2 Plug, Drain 244 244 53 Spring 30 30G066 3 Bolt Flanged 30A 30G0625 2 Bolt Flanged 600 600A300 Ball Steel 60 60B O Ring 60A 60B O Ring 60B 60B3025 O Ring Obtain Parts from Kawasaki 30
Cooling Equipment Assembly Kawasaki FD50D AS03 0 0 302 Gasket 60 60 245 Gasket Thermostat 3 3 Shaft Impeller 642 642 Cover Pump 660 660 22 Body Upper 660A 660 6002 Body Valve 3062 3062 0 Hose Cooling 3062A 3062 3 Hose Cooling 3062B 3062 4 Hose Cooling 4044 4044 63 Pump Water 4054 4054 5 Thermostat 4063 4063 54 Seal Mechanical 505 505 2355 Gear Spur, 25T 5256 5256 6 Impeller 5336 5336 Case Pump 3 20 24 2 Clamp 43 43 223 Pin 4 4 2 Seal Oil 2 2 56 4 Clamp 20 20 234 Washer 20A 20 235 Washer 30 30C02 Bolt Flanged 30A 30G0625 3 Bolt Flanged 30B 30G0635 2 Bolt Flanged 30C 30G030 2 Bolt Flanged 30D 30G045 Bolt Flanged 30E 30G060 2 Bolt Flanged 30F 30G00 4 Bolt Flanged G0 3 Bolt Stud 55 55A034 Pin Dowel 60 60B50 O Ring Obtain Parts from Kawasaki 3
Electric Equipment Assembly Kawasaki FD50D AS03 0 0 266 Gasket 52 52 5 Bracket 266 266 Regulator Voltage 22 22 0 Coil Ignition, No. 22A 22 Coil Ignition, No. 2 23 23 2 Flywheel ASM 26004 26004 3 Fuse ASM 26030 26030 23 Harness 20 20 00 Switch 503 503 22 Coil Charging 0 0 223 4 Scerw 3A 3 2 Clamp 66 66 Plug Drain 0 0 2 2 Plug Spark, BPR2ES 2 2 5 Band 25 25 Bolt 20 20 60 4 Clamp 2 2 60 Clamp 20 20 2 Washer 30 30G05 Bolt Flanged 30A 30G0630 2 Bolt Flanged 30B 30G02 3 Bolt Flanged 30C 30G06 2 Bolt Flanged 24 24B05 Screw Pan+ 5 5A50 Key Woodruff Obtain Parts from Kawasaki 32
Control Equipment Assembly Kawasaki FD50D AS03 5 5 23 Bracket 36 36 2466 Lever Throttle 36A 36 246 Lever Choke 66 66 242 Link Choke 6 6 Link 2 2 3 Arm ASM 3003 3003 Arm Pivot 32 32 Spring Governor 436 436 60 Sleeve 4 4 4 Governor ASM 43 43 20 Panel Comp Control 5226 5226 232 Panel Control 02 02 02 Bolt 02A 02 226 Bolt 0 0 23 2 Screw 5 5 5 2 Nut 22 02 232 Washer 2 2 46 Collar 3 3 2 2 Clamp 243 243 235 2 Collar 243A 243 24 Collar 244 244 52 Spring 245 245 5 Spring 245A 245 5 Spring 250 250 22 2 Bolt 20 20 35 Washer 20A 20 2 2 Washer 20B 20 2 Washer 20C 20 222 Washer 30 30B0630 2 Bolt Flanged 30A 30G064 2 Bolt Flanged 3 3B0600 2 Nut Hex 32 32G0500 2 Nut Hex 4 4B0600 Washer 42 42J000 Circlip Type E Obtain Parts from Kawasaki 33
Carburetor Assembly Kawasaki FD50D AS03 60 60 246 Gasket Intake 60A 60 246 Gasket Intake 60B 60 24 2 Gasket Intake Pipe 60C 60 243 Gasket Carburetor 5003 5003 26 Carburetor ASM 6060 6060 24 Pipe Intake 603 603 26 Insulator 646 646 222 Cover ASM 63 63 06 Float ASM 64 64 04 Float Chamber ASM 65 65 36 Throttle Valve ASM 66 66 36 Choke Valve ASM 2303 2303 5 Screw ASM 2303A 2303 60 Screw ASM 506 506 65 Manifold Intake 3 3 6 Clamp 63 63 2400 2 Jet Main 64 64 23 2 Jet Pilot 30 30G025 Bolt Flanged 30A 30T06 4 Bolt Flanged 0 0Q0600 Tube PVC Obtain Parts from Kawasaki 34
Air Filter/Muffler Assembly Kawasaki FD50D AS03 5 5 Bracket 60 60 246 2 Gasket Muffler 60A 60 244 2 Gasket Air Filter 403 403 5 Duct Lower 403A 403 6 Duct Upper 6060 6060 2 Pipe Intake 3 3 654 Clamp 3 3 2 Seal 20 20 5 Clamp 30 30G06 3 Bolt Flanged 3 3R000 Nut Hex 46 46F000 Washer Spring Obtain Parts from Kawasaki 35
Fuel Tank/Fuel Valve Assembly Kawasaki FD50D AS03 40 40 55 Filter Fuel 4040 4040 65 Pump Fuel 50 50 2 Joint 20 20 42 2 Clamp 20 20 5 Tube Obtain Parts from Kawasaki 36
Starter Assembly Kawasaki FD50D AS03 2 2 2226 Cap 30 30 2 Clutch ASM 30 30 6 Holder Brush 36 36 23 Lever Shift 4024 4024 25 Cover 603 603 Insulator 646 646 2 Cover ASM 646A 646 2225 Cover ASM 23 23 5 4 Brush 240 240 52 4 Spring Brush 20 20 54 Armature 263 263 2 Starter Electric 20 20 222 Switch 35 35 Stopper 02 02 22 2 Bolt 5 5 246 2 Nut 5A 5 24 Nut 33 33 Ring Snap 30 30G035 2 Bolt Flanged 3 3B000 2 Nut Hex 46 46F000 2 Washer Spring Obtain Parts from Kawasaki 3
Maintenance Record Date 3
Maintenance Record Date 3