John-deere stx38 User Manual

TECHNICAL MANUALLitho in U.S.AJohn DeereWorldwide Commercial andConsumer Equipment DivisionSTX30, STX38, and STX46Lawn TractorsTM1561 (15Mar97)Replace

NOTESSPECIFICATIONS & INFORMATION2 - 23/12/97

4 - 163/21/97WIRING HARNESS DIAGRAMSELECTRICALSTX38 (SN 210001— )STX46 (SN 240001— )S5HeadlightSwitch945SeatSwitchS41 2450451100700200400942110K

3/21/974 - 17ELECTRICALWIRING HARNESS DIAGRAMS3750451120940 A1 Ignition ModuleEngineW2GroundPTOY1ClutchHeadlightsE21251201254220 N1 Regulator/rectifie

4 - 183/21/97WIRING SCHEMATICSELECTRICALWIRING SCHEMATICSSTX30 (SN 010001—135159) (SN 595001—750000)STX38 (SN 010001—139615) (SN 595001—750000)Y2Fuel

3/21/974 - 19ELECTRICALWIRING SCHEMATICSS2PTOSwitchS3Neutral StartSwitch(1)(0)(off)S5HeadlightSwitch(1)(0)(open)E2(Optional)HeadLight120 450 Yel/WhtSE

4 - 203/21/97WIRING SCHEMATICSELECTRICALSTX30 (SN 135160—160000)STX38 (SN 139616—160000) Y2Fuel ShutoffSolenoidG1 BatteryOffRunStartM1Starting MotorMK

3/21/974 - 21ELECTRICALWIRING SCHEMATICSS2PTOSwitchS3Neutral StartSwitch(1)(0)(off)S5HeadlightSwitch(1)(0)(open)E2(Optional)HeadLight120 450 Yel/WhtSE

4 - 223/21/97WIRING SCHEMATICSELECTRICALSTX38 (SN 160001—210000)Y2Fuel ShutoffSolenoidG1 BatteryOffRunStartM1Starting MotorMKey SwitchS1W1 Frame SE2-

3/21/974 - 23ELECTRICALWIRING SCHEMATICSS2PTOSwitchS3Neutral StartSwitch(1)(0)(off)S5HeadlightSwitch(1)(0)(open)E2(Optional)HeadLight120 450 Yel/WhtSE

4 - 243/21/97WIRING SCHEMATICSELECTRICALSTX38 (SN 210001— ) STX46 (SN 240001— )Y2Fuel ShutoffSolenoidY1PTO ClutchG2StatorGG1 BatteryN1Regulator/

3/21/974 - 25ELECTRICALWIRING SCHEMATICSS2PTOSwitch(0)(1)(off)S3BrakeSwitch(0)(1)(off)(1)(0)(closed)S5HeadlightSwitch(0)(1)(open)S4SeatSwitchE1SparkPl

3/20/972 - 3SPECIFICATIONS AND INFORMATIONGENERAL VEHICLE SPECIFICATIONSGENERAL VEHICLE SPECIFICATIONSEngine:Make . . . . . . . . . . . . . . . . . .

4 - 263/21/97CIRCUIT OPERATION AND DIAGNOSISELECTRICALCIRCUIT OPERATION AND DIAGNOSISCRANKING CIRCUIT OPERATIONSTX30 & STX38 (SN —210000)Functi

3/21/974 - 27ELECTRICALCIRCUIT OPERATION AND DIAGNOSISM1Starting MotorMW1 Frame GroundK1StarterSolenoid700 RedBlkOffRunStartM1Starting MotorMKey Switc

4 - 283/21/97CIRCUIT OPERATION AND DIAGNOSISELECTRICALCRANKING CIRCUIT DIAGNOSISSTX30 & STX38 (SN —210000)Test Conditions:• Transaxle in neutra

3/21/974 - 29ELECTRICALCIRCUIT OPERATION AND DIAGNOSISCRANKING CIRCUIT TEST POINTS STX30 & STX38 (SN —210000)19882546101211Red200710Purple720Pu

4 - 303/21/97CIRCUIT OPERATION AND DIAGNOSISELECTRICALCRANKING CIRCUIT OPERATIONSTX38 (SN 210001— ) & STX46 Function:The cranking system is used

3/21/974 - 31ELECTRICALCIRCUIT OPERATION AND DIAGNOSISY2Fuel ShutoffSolenoidG1 BatteryOffRunStartM1Starting MotorMKey SwitchS1W1 Frame (Optional)Groun

4 - 323/21/97CIRCUIT OPERATION AND DIAGNOSISELECTRICALCRANKING CIRCUIT DIAGNOSIS STX38 (SN 210001— ) & STX46Test Conditions:• Transaxle/hydro in

3/21/974 - 33ELECTRICALCIRCUIT OPERATION AND DIAGNOSISCRANKING CIRCUIT TEST POINTS STX38 (SN 210001— ) & STX46 198324561012711Red200700Purple700

4 - 343/21/97CIRCUIT OPERATION AND DIAGNOSISELECTRICALIGNITION CIRCUIT OPERATION STX30 & STX38 (SN —210000)Function:To create a spark that igni

3/21/974 - 35ELECTRICALCIRCUIT OPERATION AND DIAGNOSISY2Fuel ShutoffSolenoidG1 BatteryOffRunStartM1Starting MotorMKey SwitchS1W1 Frame SE2- Ignition C

2 - 43/20/97GENERAL VEHICLE SPECIFICATIONSSPECIFICATIONS AND INFORMATIONPower Train: (Continued)Lubrication—Input Shaft Needle Bearings . . . . . . .

4 - 363/21/97CIRCUIT OPERATION AND DIAGNOSISELECTRICALIGNITION CIRCUIT DIAGNOSIS STX30 & STX38 (SN —210000)When diagnosing an ignition problem,

3/21/974 - 37ELECTRICALCIRCUIT OPERATION AND DIAGNOSISIGNITION CIRCUIT TEST POINTS STX30 & STX38 (SN —210000)1E1293657Red200710Purple720PurpleR

4 - 383/21/97CIRCUIT OPERATION AND DIAGNOSISELECTRICALIGNITION CIRCUIT DIAGNOSIS STX30 & STX38 (SN —210000)Test Conditions:• Park brake engaged

3/21/974 - 39ELECTRICALCIRCUIT OPERATION AND DIAGNOSISIGNITION CIRCUIT TEST POINTS STX30 & STX38 (SN —210000)S121Blk100Key SwitchK2Start RelayD

4 - 403/21/97CIRCUIT OPERATION AND DIAGNOSISELECTRICALIGNITION CIRCUIT OPERATION STX38 (SN 210001— ) & STX46Function:To create a spark that igni

3/21/974 - 41ELECTRICALCIRCUIT OPERATION AND DIAGNOSISY2Fuel ShutoffSolenoidG1 BatteryOffRunStartKey SwitchS1W1 Frame (Optional)Ground401 YelK1Starter

4 - 423/21/97CIRCUIT OPERATION AND DIAGNOSISELECTRICALIGNITION CIRCUIT DIAGNOSIS STX38 (SN 210001— ) & STX46When diagnosing an ignition problem,

3/21/974 - 43ELECTRICALCIRCUIT OPERATION AND DIAGNOSISIGNITION CIRCUIT TEST POINTS STX38 (SN 210001— ) & STX46411A1 Ignition Module110Black945Wh

4 - 443/21/97CIRCUIT OPERATION AND DIAGNOSISELECTRICALCHARGING CIRCUIT OPERATION STX30 & STX38 (SN —210000)Function:To maintain battery voltage

3/21/974 - 45ELECTRICALCIRCUIT OPERATION AND DIAGNOSISG2StatorGUBlkBlkBrn/590YelBrn/595Wht210 RedSE3 - Charging CircuitM1Starting MotorMW1 Frame Groun

3/20/972 - 5SPECIFICATIONS AND INFORMATIONGENERAL VEHICLE SPECIFICATIONSMower Deck: (Continued)46-Inch Mower Deck—Type . . . . . . . . . . . . . . . .

4 - 463/21/97CIRCUIT OPERATION AND DIAGNOSISELECTRICALCHARGING CIRCUIT DIAGNOSIS STX30 & STX38 (SN —210000)Test Conditions:• Park brake engaged

3/21/974 - 47ELECTRICALCIRCUIT OPERATION AND DIAGNOSISCHARGING CIRCUIT TEST POINTS STX30 & STX38 (SN —210000)13G2N1G12595BatteryStatorRegulator

4 - 483/21/97CIRCUIT OPERATION AND DIAGNOSISELECTRICALCHARGING CIRCUIT OPERATIONSTX38 (SN 210001— ) & STX46Function:To maintain battery voltage

3/21/974 - 49ELECTRICALCIRCUIT OPERATION AND DIAGNOSISG2StatorGG1 BatteryN1Regulator/RectifierUOffRunStartM1Starting MotorMKey SwitchS1W1 Frame SE2- C

ELECTRICALCIRCUIT OPERATION AND DIAGNOSIS4 - 503/21/97CHARGING CIRCUIT DIAGNOSIS STX38 (SN 210001— ) & STX46Test Conditions:• Brake engaged • En

3/21/974 - 51ELECTRICALCIRCUIT OPERATION AND DIAGNOSISCIRCUIT OPERATION AND DIAGNOSISCHARGING CIRCUIT TEST POINTS STX38 (SN 210001— ) & STX4613X

4 - 523/21/97CIRCUIT OPERATION AND DIAGNOSISELECTRICALPTO CIRCUIT OPERATIONSTX30 & STX38 (SN —210000)Function:To provide power to energize the

3/21/974 - 53ELECTRICALCIRCUIT OPERATION AND DIAGNOSISG1 BatteryOffRunStartM1Starting MotorMKey SwitchS1W1 Frame GroundRedBlk200RedF1CircuitBreakerS2B

4 - 543/21/97CIRCUIT OPERATION AND DIAGNOSISELECTRICALPTO CIRCUIT DIAGNOSIS POINTSSTX30 & STX38 (SN —210000)Test Conditions:• Transaxle in neut

3/21/974 - 55ELECTRICALCIRCUIT OPERATION AND DIAGNOSISPTO CIRCUIT TEST POINTS STX30 & STX38 (SN —210000)46157Red510Yellow750Blue750Blue120Black

2 - 63/20/97METRIC FASTENER TORQUE VALUESSPECIFICATIONS AND INFORMATIONMETRIC FASTENER TORQUE VALUESClass 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9Lu

4 - 563/21/97CIRCUIT OPERATION AND DIAGNOSISELECTRICALPTO AND HEADLIGHTS CIRCUITS OPERATION STX38 (SN 210001— ) & STX46Function:To provide power

3/21/974 - 57ELECTRICALCIRCUIT OPERATION AND DIAGNOSISG1 BatteryOffRunStartKey SwitchS1W1 Frame GroundK1StarterSolenoid750 201OrgRedBlk(Splice)200RedS

ELECTRICALCIRCUIT OPERATION AND DIAGNOSIS4 - 583/21/97PTO CIRCUIT DIAGNOSIS STX38 (SN 210001— ) & STX46NOTE: If there excessive vibration in PTO

3/21/974 - 59ELECTRICALCIRCUIT OPERATION AND DIAGNOSISPTO CIRCUIT TEST POINTS STX38 (SN 210001— ) & STX4634621572RedRed200Red200400Yellow400Yell

ELECTRICALCIRCUIT OPERATION AND DIAGNOSIS4 - 603/21/97HEADLIGHTS CIRCUIT DIAGNOSIS STX38 (SN 210001— ) & STX46 NOTE: Fusible link (F1) 201 orang

3/21/974 - 61ELECTRICALCIRCUIT OPERATION AND DIAGNOSISHEADLIGHTS CIRCUIT TEST POINTS STX38 (SN 210001— ) & STX46G1K1S1S2S51Red2200Red2200Red3400

4 - 623/21/97TESTS AND ADJUSTMENTSELECTRICALTESTS AND ADJUSTMENTSGROUND CIRCUIT TESTSReason:To check for opens, loose terminal wire crimps, poorconnec

3/21/974 - 63ELECTRICALTESTS AND ADJUSTMENTSBATTERY TESTReason:To check condition of battery and determine batteryvoltage.Equipment:• Hydrometer• Volt

4 - 643/21/97TESTS AND ADJUSTMENTSELECTRICAL3. Check if battery is accepting a 10 amp charge after 10 minutes at boost setting.Battery will not accept

3/21/974 - 65ELECTRICALTESTS AND ADJUSTMENTSREGULATED VOLTAGE OUTPUT TESTReason:To determine regulated voltage output of the regulator/rectifier.Equip

3/20/972 - 7SPECIFICATIONS AND INFORMATIONMETRIC FASTENER TORQUE VALUESMETRIC FASTENER TORQUE VALUE - GRADE 7SizeSteel or Gray Iron TorqueAluminum Tor

4 - 663/21/97TESTS AND ADJUSTMENTSELECTRICALSTARTER SOLENOID TESTReason:To determine if starter solenoid or starter is defective.IMPORTANT: STX38 Ser

3/21/974 - 67ELECTRICALTESTS AND ADJUSTMENTSIGNITION SPARK TESTReason:To determine condition of ignition system.Equipment:• D-05351ST Spark TesterConn

4 - 683/21/97TESTS AND ADJUSTMENTSELECTRICALIGNITION MODULE TEST Reason:To determine condition of ignition module windings.Equipment:• OhmmeterProcedu

3/21/974 - 69ELECTRICALTESTS AND ADJUSTMENTSBRAKE PEDAL/PARK BRAKE SWITCH TESTSReason:To make sure the brake pedal switch operatesproperly.Equipment:•

4 - 703/21/97TESTS AND ADJUSTMENTSELECTRICALHEADLIGHT SWITCH TEST (OPTIONAL)Reason:To make sure the headlight switch terminals havecontinuity when the

3/21/974 - 71ELECTRICALTESTS AND ADJUSTMENTSPTO SWITCH TESTSIMPORTANT: PTO switch can fail from prolongedexposure to moisture. Original switch has se

4 - 723/21/97TESTS AND ADJUSTMENTSELECTRICALPTO CLUTCH AIR GAPSTX30 & STX38 (SN —210000)Reason:To set the PTO clutch air gap at a specific dime

3/21/974 - 73ELECTRICALTESTS AND ADJUSTMENTSTRANSMISSION NEUTRAL SWITCHSTX30 & STX38 ( —210000)Reason:To make sure tractor cannot be started wh

4 - 743/21/97REPAIRELECTRICALREPAIRREMOVE AND INSTALL KEY SWITCH AND PTO SWITCH1. Remove retaining screws (A) and Bracket (B).2. Remove key switch con

3/21/974 - 75ELECTRICALREPAIRREMOVE AND INSTALL STARTER SOLENOIDNOTE: Relay in located at the right-hand front cornerof battery compartment.1. Remove

2 - 83/20/97INCH FASTENER TORQUE VALUESSPECIFICATIONS AND INFORMATIONINCH FASTENER TORQUE VALUESGrade 1 Grade 2bGrade 5, 5.1 or 5.2 Grade 8 or 8.2Lubr

4 - 763/21/97REPAIRELECTRICAL16. Install and tighten cap screws to specification.17. Remove feeler gauge and connect wire (D) to terminal.Specificatio

3/21/974 - 77ELECTRICALREPAIRREMOVE AND INSTALL STARTERNOTE: Some starters may have a relay located at theright-hand rear corner of battery compartmen

4 - 783/21/97REPAIRELECTRICAL4. Clean stud terminal (F), replace if threads are stripped or if it is corroded.5. Replace insulator (E) if cracked.6. C

3/21/974 - 79ELECTRICALREPAIRREMOVE AND INSTALL TRANSMISSION NEUTRAL SWITCHSTX30 & STX38 (SN —210000)1. Early Models—Clean off debris from arou

4 - 803/21/97REPAIRELECTRICALNOTES

POWER TRAINCONTENTSPageCONTENTS3/20/975 - 1POWER TRAINSPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTENTSPOWER TRAIN5 -23/20/97TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28DIAGNOSIS . . . . . . .

3/21/975 - 3POWER TRAINSPECIFICATIONSSPECIFICATIONSGENERAL SPECIFICATIONSDimensions:Overall Axle Width (end-to-end). . . . . . . . . . . . . . . . . .

5 - 43/21/97SPECIFICATIONSPOWER TRAINGear Teeth—STX38 (SN 210001— ) & STX46:Bevel Pinion Gear (input shaft) . . . . . . . . . . . . . . . . . .

3/21/975 - 5POWER TRAINSPECIFICATIONSREPAIR SPECIFICATIONSWear Tolerances:Input Shaft—Shim:Standard . . . . . . . . . . . . . . . . . . . . . . . . .

3/20/972 - 9SPECIFICATIONS AND INFORMATIONO-RING SEAL SERVICE RECOMMENDATIONSO-RING SEAL SERVICE RECOMMENDATIONSFACE SEAL FITTINGS WITH INCH STUD ENDS

5 - 63/21/97SPECIFICATIONSPOWER TRAINWear Tolerances—continued:Differential Assembly—Bevel Gear Cross Shaft:Wear Limit . . . . . . . . . . . . . . . .

3/21/975 - 7POWER TRAINSPECIFICATIONSOTHER MATERIALSInput Shaft Needle Bearings Grease . . . . . . . . . . . . . . . . . . . . . . . .Unirex® N3 Grea

5 - 83/21/97SPECIFICATIONSPOWER TRAINNOTES

3/21/975 - 9POWER TRAINCOMPONENT LOCATIONCOMPONENT LOCATIONTRANSAXLE—PEERLESS MODEL 920-017STX30 (SN —135158) (SN 160759— )STX38 (SN —139614)

5 - 103/21/97COMPONENT LOCATIONPOWER TRAINTRANSAXLE—PEERLESS MODEL 930-004 & 930-004A STX30 (SN —135158) (SN 160759— ) STX38 (SN —139614)

3/21/975 - 11POWER TRAINCOMPONENT LOCATIONTRANSAXLE—PEERLESS MODEL 915-012A & 915-012B STX30 (SN 135159—160758)STX38 (SN 139615—185586) M83622Rein

5 - 123/21/97COMPONENT LOCATIONPOWER TRAINTRANSAXLE—DANA 5-SPEED STX38 (SN 210001—301382) STX46 1. Flange bearing2. Shim (0.632x1.00x0.010–0.082 in.)3

3/21/975 - 13POWER TRAINCOMPONENT LOCATION910111213141516303132333435366372925262728464748495051525354555657717069686766657576777978808183828488878685

5 - 143/21/97COMPONENT LOCATIONPOWER TRAINTRANSAXLE—DANA 5-SPEED STX38 (SN 301383— )1. Flange bearing2. Shim3. Spur gear (12 teeth)4. Shift collar5

3/21/975 - 15POWER TRAINCOMPONENT LOCATION910121314929352826274344454748515253545566657273747675798381787069716261603740394124232221201716763118 – 22.

2 - 103/20/97O-RING SEAL SERVICE RECOMMENDATIONSSPECIFICATIONS AND INFORMATIONFACE SEAL FITTINGS WITH METRIC STUD ENDS TORQUENOTE: Torque tolerance is

5 - 163/21/97COMPONENT LOCATIONPOWER TRAINTRACTION DRIVE SYSTEM STX30 & STX38 (SN —210000)M85808BoltSpacerWasherShaft SheaveHubBoltGuideClampEx

3/21/975 - 17POWER TRAINCOMPONENT LOCATIONCLUTCH AND BRAKE PEDAL STX30 & STX38 (SN —210000)M85810PadPedalScrewFlange WasherShaftLeverSnap Cotte

5 - 183/21/97COMPONENT LOCATIONPOWER TRAINTRACTION DRIVE SYSTEM STX38 (SN 210001— ) & STX46 1. Frame weldment—idler adjustment2. Carriage bolt (

3/21/975 - 19POWER TRAINCOMPONENT LOCATIONTRACTION DRIVE SYSTEM SHIFT LINKAGE SYSTEMM55827123456783635374140912111013141519222324343230282726253839474

5 - 203/21/97THEORY OF OPERATIONPOWER TRAINTHEORY OF OPERATIONCLUTCH PEDAL AND BELT TRACTION DRIVE SYSTEM OPERATION STX30 & STX38 (SN —210000)F

3/21/975 - 21POWER TRAINTHEORY OF OPERATIONCLUTCH PEDAL AND BELT TRACTION DRIVE SYSTEM OPERATION STX38 (SN 210001— ) & STX46Function:The functio

5 - 223/21/97THEORY OF OPERATIONPOWER TRAINTRANSAXLE OPERATION PEERLESS MODEL 920-017, 930-004 & 930-004A STX30 (SN —135158) (SN 160759— )

3/21/975 - 23POWER TRAINTHEORY OF OPERATIONTRANSAXLE OPERATION PEERLESS MODELS 915-012A/915-012B STX30 (SN 135159—160758) & STX38 (SN 139615—18558

5 - 243/21/97THEORY OF OPERATIONPOWER TRAINTRANSAXLE OPERATION STX38 (SN 210001— ) & STX46Function:The transaxle transmits power from the engine

3/21/975 - 25POWER TRAINTHEORY OF OPERATIONReverse:As in forward—likewise in reverse, with engine runningand clutch engaged, the transaxle input sheav

3/20/972 - 11SPECIFICATIONS AND INFORMATIONO-RING SEAL SERVICE RECOMMENDATIONSO-RING FACE SEAL FITTINGS1. Inspect the fitting sealing surfaces. They m

5 - 263/21/97THEORY OF OPERATIONPOWER TRAINBRAKE SYSTEM COMPONENT LOCATION AND OPERATIONIMPORTANT: Early Model STX30 & STX38 (SN —210000) brak

3/21/975 - 27POWER TRAINTHEORY OF OPERATIONM42586AFGCDEM42594FGJKMHLIM55833NOQBP

5 - 283/21/97TROUBLESHOOTINGPOWER TRAINTROUBLESHOOTINGProblem orSymptomBelt jumping off or slappingLack of drive in one or both directionsLoses power

3/21/975 - 29POWER TRAINTROUBLESHOOTINGNOTES

5 - 303/21/97DIAGNOSISPOWER TRAINDIAGNOSISContinued on page 5-32Test Conditions:• Tractor on level surface • Front wheels blocked• Engine OFF • Rear w

3/21/975 - 31POWER TRAINDIAGNOSISM55827321M558364M42312M558325786

5 - 323/21/97DIAGNOSISPOWER TRAINTest Conditions:• Tractor operating in test area • Tests run at engine slow idle and fast idle• Engine at operating t

3/21/975 - 33POWER TRAINDIAGNOSISM558271M558361M42312M558321

5 - 343/21/97TESTS AND ADJUSTMENTSPOWER TRAINTESTS AND ADJUSTMENTSCLUTCH/BRAKE PEDAL LINKAGE AND TRACTION DRIVE SYSTEMReason:To ensure clutch/brake pe

3/21/975 - 35POWER TRAINTESTS AND ADJUSTMENTSNOTE: These adjustment procedures can beperformed with tractor on the floor; however,you may want to safe

M55912M55913M58333M58333M58332STX38 Gear DriveSTX38 Hydrostatic DriveSTX46 Hydrostatic DriveSTX46 Gear DriveSTX38 Motorsport EditionM85680

2 - 123/20/97GASOLINE SPECIFICATIONSSPECIFICATIONS AND INFORMATIONGASOLINE SPECIFICATIONS4–CYCLE ENGINES - NORTH AMERICAcCAUTIONGasoline is HIGHLY FLA

5 - 363/21/97TESTS AND ADJUSTMENTSPOWER TRAINCLUTCH SPRING ADJUSTMENTIMPORTANT: Anytime the brake or clutch springneed to be adjusted, both must be e

3/21/975 - 37POWER TRAINTESTS AND ADJUSTMENTSSHIFT LINKAGE ADJUSTMENTReason:To ensure shift lever obtains all shift positions and thatneutral position

5 - 383/21/97REPAIRPOWER TRAINREPAIRBRAKES STX30 & STX38 (SN —210000) REMOVAL/INSTALLATIONNOTE: When the brake pedal is depressed, the setcompre

3/21/975 - 39POWER TRAINREPAIRTRACTION DRIVE BELT REMOVAL/ INSPECTION/INSTALLATION—STX30 & STX38 (SN —210000)Removal1. Remove ignition key and

5 - 403/21/97REPAIRPOWER TRAIN3. Install belt on guide (B) and idler (C).NOTE: Apply NEVER-SEEZ® lubricant to crankshaftbefore installing sheave.4. In

3/21/975 - 41POWER TRAINREPAIRCLUTCH ARM REMOVAL/INSTALLATION— STX30 & STX38 (SN —210000)Removal1. Engage park brake.2. Remove guide and sheave

5 - 423/21/97REPAIRPOWER TRAIN10. Disconnect linkage (C), unplug neutral start switch (D) and remove cap screw (B) from left side of transaxle.11. Rem

3/21/975 - 43POWER TRAINREPAIRTRANSAXLE CASE—DISASSEMBLYSTX30 (SN —135158) (SN 160759— ) & STX38 (SN —139614) (SN 185587—210000) PEERLESS

5 - 443/21/97REPAIRPOWER TRAINCounter Shaft—Disassemble1. Remove shifter fork from brake shaft assembly.2. Remove brake shaft and counter shaft assemb

3/21/975 - 45POWER TRAINREPAIRDifferential—Disassemble1. Remove differential assembly from lower case.M52019CFIEDABDGGICJAEH2. Remove blocks (G).3. Re

3/20/972 - 13SPECIFICATIONS AND INFORMATIONGASOLINE SPECIFICATIONS4–CYCLE ENGINES - EUROPEcCAUTIONGasoline is HIGHLY FLAMMABLE, handle it with care.DO

5 - 463/21/97REPAIRPOWER TRAINCounter Shaft—AssembleM52022OABCDBAEFGHIJLKNPQRFKMESS1. Put LUBRIPLATE lubricant in keyways of shaft (G).2. Position key

3/21/975 - 47POWER TRAINREPAIRInput Shaft—Assemble1. If new bearings (C) are used, press top bearing flush with cover. Press lower bearing to depth of

5 - 483/21/97REPAIRPOWER TRAINTRANSAXLE—REMOVAL/ INSTALLATION STX30 (SN 135159—160758) & STX38 (SN 139615—185586) (PEERLESS MODELS 915-012A &9

3/21/975 - 49POWER TRAINREPAIRTRANSAXLE CASE—DISASSEMBLY STX30 (SN 135159—160758) & STX38 (SN 139615—185586)NOTE: When separating transaxle cover,

5 - 503/21/97REPAIRPOWER TRAINDifferential1. Remove snap rings (C), thrust washers (A) and bevel side gears (B).2. Remove pinion gears (D) from pinion

3/21/975 - 51POWER TRAINREPAIRCounter ShaftNOTE: The shaft bushing area is longer on one end.Note the direction in which the shaft wasremoved and the

5 - 523/20/97REPAIRPOWER TRAINREPAIRTRANSAXLE CASE—ASSEMBLY STX30 (SN 135159—160758) & STX38 (SN 139615—185586)NOTE: Do NOT put grease between sli

3/20/975 - 53POWER TRAINREPAIRTRACTION DRIVE BELT REMOVAL/ INSPECTION/INSTALLATION— STX38 & STX46 LATE MODELNOTE: If drive belt is in good conditi

5 - 543/20/97REPAIRPOWER TRAIN2. Pull drive belt over the top of park rod (C), down and around steering arms (D), up through forward belt guide (E), o

3/20/975 - 55POWER TRAINREPAIRTRACTION DRIVE SYSTEM REMOVAL/INSPECTION/INSTALLATION— STX38 (SN 210001— ) & STX46 Removal/Inspection/Installation

2 - 143/20/974–CYCLE GASOLINE ENGINE OILSPECIFICATIONS AND INFORMATION4–CYCLE GASOLINE ENGINE OIL4–CYCLE GASOLINE ENGINE OIL - NORTH AMERICAIMPORTANT:

5 - 563/20/97REPAIRPOWER TRAINSHIFT LINKAGE REMOVAL/INSTALLATION STX38 (SN 210001— ) & STX46 M55830ABCDEONMLKFIHGP13.5—17.6 N•m(120—156 lb-in.)1

3/20/975 - 57POWER TRAINREPAIRTRANSAXLE—REMOVAL/ INSTALLATION STX38 (SN 210001— ) & STX46 IMPORTANT: STX38 (SN 301383— ) transaxlediffers sl

5 - 583/20/97REPAIRPOWER TRAINRemove Shifter Detent Assembly STX38 (SN 210001—301382) and STX46 Transaxle1. Remove shifter shaft rubber boot (E).2. Re

3/20/975 - 59POWER TRAINREPAIRSeparate Transaxle Housing Case Halves:1. Remove all sixteen transaxle housing socket head screws (B)—brake assembly (A)

5 - 603/20/97REPAIRPOWER TRAINDisassemble Input Shaft/Pinion Gear Assembly:1. Remove snap ring (B), bevel pinion gear (C), small washer (E), and large

3/20/975 - 61POWER TRAINREPAIRInspect Idler Combination Gear Assembly:1. Visually check overall condition of assembly, including shaft and bushings, g

5 - 623/20/97REPAIRPOWER TRAIN• inside bearing (I) and outside (K), which are pressfit, should not be scored nor discolored (burnt)• gear bore (J) sho

3/20/975 - 63POWER TRAINREPAIR—Exploded View—Intermediate and Drive Shaft Components. Shim washers (A) and (H) are found in Shim Kit.M42335EIHAInspect

5 - 643/20/97REPAIRPOWER TRAINTRANSAXLE ASSEMBLY—STX38 (SN 210001— ) & STX46 NOTE: STX38 (SN 301383— ) transaxle differsslightly from STX38 (

3/20/975 - 65POWER TRAINREPAIR—Exploded View of Intermediate and Drive Shaft Components—M42335FIHEG9. Measure air gaps (K and N)—(see Inspect Drive/In

3/20/972 - 15SPECIFICATIONS AND INFORMATION4–CYCLE GASOLINE ENGINE OIL4–CYCLE GASOLINE ENGINE OIL - EUROPEIMPORTANT: Kohler command engines weredesig

5 - 663/20/97REPAIRPOWER TRAIN.3. Install idler combination gear assembly (H) into lower case half.4. Measure air gap (J) between shim washer (I) and

3/20/975 - 67POWER TRAINREPAIR6. Turn upper case half over.7. Install a shim washer (C) (from Shim Kit) of the proper thickness that allows enough cle

5 - 683/20/97REPAIRPOWER TRAINSTX38 (SN 301383— ) Transaxle1. Install shifter shaft rubber boot (B).2. Coat detent balls (C) and springs (D) with J

HYDROSTATIC POWER TRAINCONTENTSPageCONTENTS3/12/976- 1HYDROSTATIC POWER TRAINSPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NOTESHYDROSTATIC POWER TRAIN6 - 23/12/97

3/21/976 - 3HYDROSTATIC POWER TRAINSPECIFICATIONSSPECIFICATIONSGENERAL SPECIFICATIONSGear Teeth:Spur Gear (drive shaft) . . . . . . . . . . . . . . .

6 - 43/21/97SPECIFICATIONSHYDROSTATIC POWER TRAINREPAIR SPECIFICATIONSTransaxle Components Wear Tolerances:Pump (Input) ShaftWear Limit . . . . . . .

3/21/976 - 5HYDROSTATIC POWER TRAINSPECIFICATIONSOTHER MATERIALSTransaxle Housing Case Half Sealant: . . . . . . . . . . . . . . . . . . . . . . . . .

6 - 63/21/97COMPONENT LOCATIONHYDROSTATIC POWER TRAINCOMPONENT LOCATION1. Axle Shaft/Wheel Key (2 used) 49. Spacer (M10x20x20)2. Left Axle Shaft 50. C

3/21/976 - 7HYDROSTATIC POWER TRAINCOMPONENT LOCATIONHYDROSTATIC TRANSAXLE1234567891012111314151617181920212223242526273940414243444546474849505153545

2 - 163/20/974–CYCLE GASOLINE ENGINE OILSPECIFICATIONS AND INFORMATIONBREAK–IN 4-CYCLE GASOLINE ENGINE OIL - NORTH AMERICAIMPORTANT: ONLY use a quali

6 - 83/21/97COMPONENT LOCATIONHYDROSTATIC POWER TRAINTRACTION DRIVE SYSTEM COMPONENT LOCATION124193231303435363738414039567891011121314162021222324291

3/21/976 - 9HYDROSTATIC POWER TRAINCOMPONENT LOCATIONSHIFT LINKAGE SYSTEM COMPONENT LOCATIONM558317109865111213141516171820212223242527282930313233134

6 - 103/21/97THEORY OF OPERATIONHYDROSTATIC POWER TRAINTHEORY OF OPERATIONIn this group the STX hydrostatic power train is separated into the followin

3/21/976 - 11HYDROSTATIC POWER TRAINTHEORY OF OPERATIONK50 Version ShownWhen in neutral, the shift lever (D), shift bracket (F), turnbuckle link (E),

6 - 123/21/97THEORY OF OPERATIONHYDROSTATIC POWER TRAINReverse:K50 Version ShownWhen the shift lever (D) is moved into reverse position,the shift brac

3/21/976 - 13HYDROSTATIC POWER TRAINTHEORY OF OPERATIONTheory of Operation:When the brake pedal (A) is depressed, the bellcrank(B) and frame rod (F) r

6 - 143/21/97THEORY OF OPERATIONHYDROSTATIC POWER TRAINM58271WXYNOTE: Brake pedal has approximately 127 mm (5 in.) of travel.1. The first segment of t

3/21/976 - 15HYDROSTATIC POWER TRAINTHEORY OF OPERATIONTRANSPORT (FREE-WHEEL) SYSTEM OPERATIONFunction:The transport (free-wheel) system allows the op

6 - 163/21/97TROUBLESHOOTINGHYDROSTATIC POWER TRAINTROUBLESHOOTINGProblem orSymptomDrive belt jumping off or Lack of drive in one or both directionsLo

3/21/976 - 17HYDROSTATIC POWER TRAINTROUBLESHOOTINGProblem orSymptomDrive belt jumping off or Lack of drive in one or both directionsLoses power under

3/20/972 - 17SPECIFICATIONS AND INFORMATION4–CYCLE GASOLINE ENGINE OILBREAK–IN 4-CYCLE GASOLINE ENGINE OIL - EUROPEIMPORTANT: ONLY use a quality brea

6 - 183/21/97DIAGNOSISHYDROSTATIC POWER TRAINDIAGNOSISTest Conditions:• Tractor on level surface. • Front wheels blocked.• Engine OFF.• Rear wheels ra

3/21/976 - 19HYDROSTATIC POWER TRAINDIAGNOSISM58272M55834M55892M582378129675234110119

6 - 203/21/97DIAGNOSISHYDROSTATIC POWER TRAINDIAGNOSIS CONTINUEDTest Conditions:• Tractor operating in test area. • Tests run at engine slow idle and

3/21/976 - 21HYDROSTATIC POWER TRAINDIAGNOSISM58272M55834M55892M58237M55927123564

6 - 223/21/97TESTS AND ADJUSTMENTSHYDROSTATIC POWER TRAINTESTS AND ADJUSTMENTSTRACTION DRIVE SYSTEMReason:To ensure shift, neutral return, and brake l

3/21/976 - 23HYDROSTATIC POWER TRAINTESTS AND ADJUSTMENTSDRIVE BELT ADJUSTMENT1. Lock park brake.2. Carefully pull larger tensioning idler (C) rearwar

6 - 243/21/97TESTS AND ADJUSTMENTSHYDROSTATIC POWER TRAINSHIFT LINKAGE ADJUSTMENT1. Safely raise rear of tractor off the surface and block the front w

3/21/976 - 25HYDROSTATIC POWER TRAINTESTS AND ADJUSTMENTS2. Check shift linkage bellcrank spring tension by measuring spring length distance (E) betwe

6 - 263/21/97TESTS AND ADJUSTMENTSHYDROSTATIC POWER TRAINSpecifications:Brake Components Wear Tolerances—(K) brake puck (minimum). . . . . . . . 8 mm

3/21/976 - 27HYDROSTATIC POWER TRAINREPAIRREPAIRTRACTION DRIVE BELT REMOVAL/INSPECTION/INSTALLATIONNOTE: If drive belt is in good condition, it doesn’

2 - 183/20/97HYDROSTATIC TRANSMISSION OILSPECIFICATIONS AND INFORMATIONHYDROSTATIC TRANSMISSION OILHYDROSTATIC TRANSMISSION OIL - NORTH AMERICAUse the

6 - 283/21/97REPAIRHYDROSTATIC POWER TRAINTRACTION DRIVE BELT TENSIONING SYSTEM REMOVAL/INSPECTION/INSTALLATION1. Remove mower deck.2. Use this drawin

3/21/976 - 29HYDROSTATIC POWER TRAINREPAIRPOWER TRAIN LINKAGE SYSTEM REMOVAL/INSPECTION/INSTALLATION1. Remove mower deck.2. Use this drawing for compl

6 - 303/21/97REPAIRHYDROSTATIC POWER TRAINTRANSAXLE REMOVAL AND INSTALLATIONRemoval1. Safely raise and block rear of tractor off surface.2. Safely sup

3/21/976 - 31HYDROSTATIC POWER TRAINREPAIRSpecification:Flange nut to right-front mounting bracket. . . . . . . . . . . . . . . . . . . . . . . . . .

6 - 323/21/97REPAIRHYDROSTATIC POWER TRAINRemove Reservoir Cover—NOTE: If there is no damage to cover or upper casehousing, you need not remove cover

3/21/976 - 33HYDROSTATIC POWER TRAINREPAIR6. Measure brake components individually.7. Replace components as necessary and as a set only. Set brake ass

6 - 343/21/97REPAIRHYDROSTATIC POWER TRAINDisassemble Transport (Free-Wheeling)Assembly–NOTE: Inspect transport actuating bracket and pinassembly (A)

3/21/976 - 35HYDROSTATIC POWER TRAINREPAIR1. First, measure air gap between edge of swashplate slot (A) and shift blocks (D). If out-of-specification,

6 - 363/21/97REPAIRHYDROSTATIC POWER TRAINDIFFERENTIAL AXLE—DISASSEMBLY K-50 Short Axle SideK-55 Short Axle Side1. Remove short axle side thrust washe

3/21/976 - 37HYDROSTATIC POWER TRAINREPAIR8. Remove and discard axle seals (E) from both sides. Replace with new seals every time axles are removed.K-

3/20/972 - 19SPECIFICATIONS AND INFORMATIONHYDROSTATIC TRANSMISSION OILHYDROSTATIC TRANSMISSION OIL - EUROPEUse the following oil viscosity based on t

6 - 383/21/97REPAIRHYDROSTATIC POWER TRAINPUMP, MOTOR, AND CENTER BLOCK—DISASSEMBLYIMPORTANT: Loss of Hydro Power—STX38 (M00STXC210001—270000)STX38 (

3/21/976 - 39HYDROSTATIC POWER TRAINREPAIRRemove Pump Input Shaft Assembly—K-50 VersionK-50 VersionK-55 VersionK-55 VersionIMPORTANT: Carefully remov

6 - 403/21/97REPAIRHYDROSTATIC POWER TRAINDisassemble and Inspect Pump and Swashplate—IMPORTANT: PAY CLOSE ATTENTION to the ORDER and ORIENTATION of

3/21/976 - 41HYDROSTATIC POWER TRAINREPAIR• motor fixed swashplate (G) should be in good condition, bearing recess machined surface should not be scor

6 - 423/21/97REPAIRHYDROSTATIC POWER TRAINInstall Pump, Swashplate, and Shifter ShaftAssemblies—IMPORTANT: Read these next four procedurescompletely

3/21/976 - 43HYDROSTATIC POWER TRAINREPAIR4. Install motor drive shaft assembly with longer cylinder block splines (G), spring (H), and snap ring (F)

6 - 443/21/97REPAIRHYDROSTATIC POWER TRAINInstall Differential Axle Assembly—1. Apply grease to new axle seals (A) and install them into each end so t

3/21/976 - 45HYDROSTATIC POWER TRAINREPAIRK-50 Short Axle SideK-55 Short Axle Side8. Repeat thrust washer procedures for short axle side.Install Filte

6 - 463/21/97REPAIRHYDROSTATIC POWER TRAINTRANSAXLE CASE HALVES—ASSEMBLY K-50 Version Shown1. Make sure mating surfaces of transaxle case halves are c

3/21/976 - 47HYDROSTATIC POWER TRAINREPAIRRESERVOIR COVER AND BREATHER VALVE—ASSEMBLY 1. If reservoir cover was removed or replaced, apply a solid bea

2 - 203/20/97ALTERNATIVE LUBRICANTSSPECIFICATIONS AND INFORMATIONALTERNATIVE LUBRICANTSConditions in certain geographical areas outside theUnited Stat

6 - 483/21/97REPAIRHYDROSTATIC POWER TRAINTRANSAXLE BLEED PROCEDURENOTE: This procedure is used before the transaxle isinstalled. If the transaxle is

STEERINGCONTENTSPageCONTENTS3/12/977 - 1STEERINGSPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

NOTESSTEERING7 - 23/12/97

3/12/977 - 3STEERINGSPECIFICATIONSSPECIFICATIONSTEST AND ADJUSTMENT SPECIFICATIONSSteering Backlash . . . . . . . . . . . . . . . . . . . . . . . . .

7 - 43/12/97TESTS AND ADJUSTMENTSSTEERINGTESTS AND ADJUSTMENTSSTEERING BACKLASHNOTE: To adjust steering backlash, put four washerson bottom of sector

3/12/977 - 5STEERINGREPAIRREPAIRSTEERING GEAR ASSEMBLY— REMOVAL 1. Remove battery and safely raise front of tractor.2. Remove fuel tank and dash panel

7 - 63/12/97REPAIRSTEERINGPEDESTAL BUSHINGS—REPLACEMENT1. Inspect four bushings (A) installed in steering sleeves of pedestal. If worn or damaged, rep

MISCELLANEOUSCONTENTSPageCONTENTS3/12/978 - 1MISCELLANEOUSSPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTENTSMISCELLANEOUS8 - 23/12/97

3/21/978 - 3MISCELLANEOUSSPECIFICATIONSSPECIFICATIONSSERVICE EQUIPMENT & TOOLSNOTE: Order tools from your SERVICEGARD catalog. Some tools may be a

3/20/972 - 21SPECIFICATIONS AND INFORMATIONGEAR TRANSMISSION GREASEGEAR TRANSMISSION GREASEUse the following gear grease based on the airtemperature r

8 - 43/21/97WHEELSMISCELLANEOUSWHEELSFRONT WHEELS—REMOVAL & INSTALLATION1. Safely lift and support tractor.2. Remove plastic cap.3. Remove snap ri

3/21/978 - 5MISCELLANEOUSWHEELSFRONT WHEELS—TOE-IN & CAMBERReason:To insure tractor toe-in is within specification.Procedure:Measure toe-in using

8 - 63/21/97FRONT AXLEMISCELLANEOUSFRONT AXLE REMOVAL & INSTALLATION1. Safely support front of tractor.2. Remove front wheels.3. Disconnect draft

3/21/978 - 7MISCELLANEOUSMOWER DECKSMOWER DECKSDIAGNOSISIMPORTANT: During hot weather the mower deckmay become covered with a soot like materialthat

8 - 83/21/97MOWER DECKSMISCELLANEOUS7. Install LH Bracket (M116689) on the right side of tractor. Fasten lower end of bracket (A) with nut removed in

3/21/978 - 9MISCELLANEOUSMOWER DECKSLIFT LINKAGE REPAIR—STX30 & STX38 (SN —210000) Adjustment Left Bracket HalfSpacerRatchetLift Assist SpringC

8 - 103/21/97MOWER DECKSMISCELLANEOUSSTX38 (SN 210001— ) & STX46 (SN 240001— )1. Remove battery and mower.2. Check for worn or damaged compo

3/21/978 - 11MISCELLANEOUSMOWER DECKS30-INCH MOWER DECKM85804Cap ScrewBushingBushingIdlerWasherFlange SpacerNutLock ExtensionBracketNutSpringWheelCap

8 - 123/21/97MOWER DECKSMISCELLANEOUS38-INCH MOWER DECK (SN —210000)M85805Lock WasherBushingWasherBushing(SN —100000)(SN 100001— )BracketSpringL

3/21/978 - 13MISCELLANEOUSMOWER DECKS38-INCH MOWER DECK (SN 210001—270000)M55930Cap ScrewBushingPin (2 Used)RH Draft ArmSpring Pin LH Draft ArmAdjusta

INTRODUCTION3/12/971 - 1This technical manual is written for an experiencedtechnician and contains sections that are specifically forthis product. It

2 - 223/20/97ANTI-CORROSION GREASE SPECIFICATIONSSPECIFICATIONS AND INFORMATIONANTI-CORROSION GREASE SPECIFICATIONSThis anti-corrosion grease is formu

8 - 143/21/97MOWER DECKSMISCELLANEOUS38-INCH MOWER DECK (SN 270001—595000)M58397Pin (2 Used)RH Draft ArmSpring Pin LH Draft ArmAdjustable BushingEyeId

3/21/978 - 15MISCELLANEOUSMOWER DECKS46-INCH MOWER DECK (SN 240001—270000)M58337Pin (2 Used)RH ShieldSpring Pin LH Draft ArmAdjustable BushingEyeIdler

8 - 163/21/97MOWER DECKSMISCELLANEOUS46-INCH MOWER DECK (SN 270001—595000)M58398Pin (2 Used)RH ShieldSpring Pin LH Draft ArmAdjustable BushingEyeIdler

3/21/978 - 17MISCELLANEOUSMOWER DECKSSPINDLES—STX30 & STX38 (SN —210000)NOTE: STX30 spindle is shown, STX38 is similar.Late model spindles (SN

8 - 183/21/97MOWER DECKSMISCELLANEOUS1. Remove shield(s) (D) and belt (A). DO NOT remove nuts (B) or sheaves (C) from spindles.2. Remove cap screw (H)

3/21/978 - 19MISCELLANEOUSMOWER DECKSMOWER BLADE ADJUSTMENTReason:To insure mower deck blades cut evenly.Procedure:1. Check blade alignment by measur

8 - 203/21/97MOWER DECKSMISCELLANEOUSBLADE DRIVE BELT REMOVAL/INSTALLATION—STX301. Remove ignition key and disconnect spark plug wire.2. Lower mower.3

3/21/978 - 21MISCELLANEOUSMOWER DECKSMOWER DECK BLOWOUT—STX46M85812InsertBladeLock NutRetainerPlateBoltBoltLock NutBoltWing NutNOTE: Blowout reduction

8 - 223/21/97SEAT REMOVAL & INSTALLATIONMISCELLANEOUSSEAT REMOVAL & INSTALLATIONMOUNTING PLATERemoval1. Lift operator’s seat forward to allow

INDEX3/20/97INDEX - 1AAir Intake System Components . . . . . . . . . . .3 - 29Alternative Lubricants . . . . . . . . . . . . . . . . . .2 - 20Analyz

3/20/972 - 23SPECIFICATIONS AND INFORMATIONGREASE SPECIFICATIONSGREASE SPECIFICATIONSGREASE - NORTH AMERICAUse the following grease based on the air t

INDEXINDEX - 23/20/97Gear Power Train Other Materials . . . . . . . . .5 - 7Gear Power Train Repair Specifications . . . . .5 - 5Gear Power Train Se

INDEX3/20/97INDEX - 3Hydrostatic Transaxle Brake Assembly Installation . . . . . . . . . . . . . . . . . . . .6 - 46Hydrostatic Transaxle Brake Compo

INDEXINDEX - 43/20/97LLap Valves . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 36Lift Linkage Repair. . . . . . . . . . . . . . . . . . . .

INDEX3/20/97INDEX - 5VValves & Valve Lifter Repair Specifications . . .3 - 4Valves— Lap. . . . . . . . . . . . . . . . . . . . . . . . .3 - 36Valv

INDEXINDEX - 63/20/97NOTES

2 - 243/20/97SERIAL NUMBER LOCATIONSSPECIFICATIONS AND INFORMATIONSERIAL NUMBER LOCATIONSENGINE SERIAL NUMBER SUFFUXDomestic Australia ExportSTX38/Gea

ENGINECONTENTSPageCONTENTS3/20/973 - 1ENGINESPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3GENE

CONTENTSENGINE3 - 23/20/97RECONDITION VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35LAP VALVES. . . .

4/23/973 - 3ENGINESPECIFICATIONSSPECIFICATIONSGENERAL SPECIFICATIONSMake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 - 44/23/97SPECIFICATIONSENGINETEST AND ADJUSTMENT SPECIFICATIONSEngine:Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4/23/973 - 5ENGINESPECIFICATIONSREPAIR SPECIFICATIONS (Continued)Rocker Arms:Rocker Arm I.D.New . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 - 64/23/97SPECIFICATIONSENGINEREPAIR SPECIFICATIONS (Continued)Camshaft:End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0

4/23/973 - 7ENGINESPECIFICATIONSREPAIR SPECIFICATIONS (Continued)Piston Thrust Face OD:New:12.5, 13, 14 hp . . . . . . . . . . . . . . . . . . . . 86.

SAFETY1 - 23/12/97RECOGNIZE SAFETY INFORMATIONThis is the safety-alert symbol. When you see thissymbol on your machine or in this manual, be alert tot

3 - 84/23/97SPECIFICATIONSENGINETORQUE SPECIFICATIONS (Alphabetical Order)Air Cleaner Base Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4/23/973 - 9ENGINESPECIFICATIONSSERVICE EQUIPMENT AND TOOLSOrder tools from your SERVICEGARD Catalog. Some tools may be available from a local supplie

3 - 104/23/97TROUBLESHOOTINGENGINETROUBLESHOOTINGProblem orSymptomEngine cranks but will not start or starts hardEngine will not stay running or runs

4/23/973 - 11ENGINETROUBLESHOOTINGContinued on next pageEngine oil viscosity or level incorrect. Engine oil filter restricted. Oil pump worn or passag

3 - 124/23/97TROUBLESHOOTINGENGINEProblem orSymptomFuel overflows carburetor ventEngine stops when hotEngine races or runs one speedEngine clattersEng

4/23/973 - 13ENGINETROUBLESHOOTINGNOTES

3 - 144/23/97DIAGNOSISENGINEDIAGNOSISMAIN COMPONENTSTest Conditions:• Machine PARKED on level surface.• Park brake LOCKED.• Key switch OFF.• Transaxle

4/23/973 - 15ENGINEDIAGNOSISM558141236M5590926M55927457

3 - 164/23/97DIAGNOSISENGINEENGINE HARD TO START AND/OR ENGINE STARTER KICKS OUTNOTE: Use correct starting procedure as listed inoperator’s manual. Th

4/23/973 - 17ENGINEDIAGNOSIS6. Cylinder compression. 40—90 psi Low compression (below 40 psi) can be the result of a stuck valve or automatic compress

SAFETY3/12/971 - 3USE CARE IN HANDLING AND SERVICING BATTERIESPrevent Battery Explosions• Keep sparks, lighted matches, and open flameaway from the to

3 - 184/23/97TESTS AND ADJUSTMENTSENGINETESTS AND ADJUSTMENTSTHROTTLE CABLE ADJUSTMENTReason:To make sure the throttle cable moves the throttle andcho

4/23/973 - 19ENGINETESTS AND ADJUSTMENTSGOVERNOR ADJUSTMENTReason:To make sure the governor shaft contacts the fly-weight plunger when the engine is s

3 - 204/23/97TESTS AND ADJUSTMENTSENGINESLOW IDLE SPEED ADJUSTMENTNON CARB/EPA (EARLY MODELS)Reason:To set engine slow idle mixture and rpm.Equipment:

4/23/973 - 21ENGINETESTS AND ADJUSTMENTSSLOW IDLE SPEED ADJUSTMENT—CARB/EPA STX38 (SN 210001— )& STX46 Reason:To set engine slow idle mixture an

3 - 224/23/97TESTS AND ADJUSTMENTSENGINECYLINDER COMPRESSION TESTReason:To check pressure capacity of piston rings and cylinderbore for efficient engi

4/4/97 3 - 23ENGINETESTS AND ADJUSTMENTSCRANKCASE VACUUM TESTReason:To measure the amount of crankcase vacuum, whichensures the crankcase is not press

3 - 244/23/97TESTS AND ADJUSTMENTSENGINEFUEL FLOW TESTReason:To determine fuel availability to the carburetor.Equipment:• Proper Fuel ContainerConnect

4/23/973 - 25ENGINEFUEL AND AIR SYSTEM REPAIRFUEL AND AIR SYSTEM REPAIRFUEL TANK AND DASH PANEL COMPONENTSM58321Filler Cap With Gauge (Optional)Filler

3 - 264/23/97FUEL AND AIR SYSTEM REPAIRENGINEREMOVE AND INSTALL FUEL TANK AND DASH PANEL ASSEMBLY1. Disconnect battery ground (-) cable.2. Squeeze fue

4/23/973 - 27ENGINEFUEL AND AIR SYSTEM REPAIR14. Install overflow tube and fuel line to fuel tank spigots (H) and (J), respectively.15. Install end of

SAFETY1 - 43/12/97USE SAFE SERVICE PROCEDURESWear Protective ClothingWear close fitting clothing and safety equipmentappropriate to the job. Prolonged

3 - 284/23/97FUEL AND AIR SYSTEM REPAIRENGINE20. Install left and right side hood latch brackets (E) removed earlier.21. Connect fuel line (C) to filt

4/23/973 - 29ENGINEFUEL AND AIR SYSTEM REPAIRAIR INTAKE SYSTEM COMPONENTSIMPORTANT: Grommet must be in place to prevent dirt ingestion. Late model t

3 - 304/23/97FUEL AND AIR SYSTEM REPAIRENGINEINSPECT CARBURETOR1. Disassemble bowl, float, inlet needle, low idle mixture screw and spring.IMPORTANT:

4/23/973 - 31ENGINEREPAIRREPAIRREMOVE AND INSTALL ENGINE1. Turn all switches OFF and disconnect battery negative (-) cable.2. Raise hood to disconnect

3 - 324/23/97REPAIRENGINEREMOVE AND INSTALL ROCKER ARMS1. Remove valve cover.IMPORTANT: Mark push rods for assembly inoriginal locations.2. Remove ca

4/23/973 - 33ENGINEREPAIRREMOVE AND INSTALL VALVES AND SPRINGSIMPORTANT: Make sure keepers are seated invalve stem groove (D). 1. Compress intake and

3 - 344/23/97REPAIRENGINEANALYZE VALVESLead deposits on the intake valve are caused byexhaust gas leakage past the valve when using leadedgasoline. Gr

4/23/973 - 35ENGINEREPAIRINSPECT VALVE GUIDES1. Clean inside of valve guide. Standard valve guide reamer (D20020WI) can be used.2. Measure inside diam

3 - 364/23/97REPAIRENGINELAP VALVESIMPORTANT: Valves and seats should be lapped ifthey do not make good contact.1. Apply light coat of lapping compou

4/23/973 - 37ENGINEREPAIRREMOVE AND INSTALL CAMSHAFT1. Rotate crankshaft to align two sets of marks (A).2. Remove camshaft (B).3. Inspect camshaft clo

SAFETY3/12/971 - 5Using High Pressure WashersDirecting pressurized water at electronic/electricalcomponents or connectors, bearings, hydraulic seals,f

3 - 384/23/97REPAIRENGINEMEASURE CAMSHAFT END PLAY1. Check that camshaft is seated in crankcase bore.2. Measure play (A) between camshaft and straight

4/23/973 - 39ENGINEREPAIR5. Measure inside diameter of crankcase lifter bore (D).6. Subtract lifter OD. from bore ID. to determine if clearance is not

3 - 404/23/97REPAIRENGINEBALANCER SHAFT INSPECTION 1. Inspect shaft for cracks and broken teeth. Replace shaft if cracked or damaged.2. Measure journa

4/23/973 - 41ENGINEREPAIRGOVERNOR INSPECTION 1. Measure outside diameter of control arm shaft. Replace if not within specification.Governor Control Ar

3 - 424/23/97REPAIRENGINEANALYZE PISTON RING WEARRings of the wrong size or rings having improper endgap will not conform to the shape of the cylinder

4/23/973 - 43ENGINEREPAIRThis detonation shockwave (“hammering”) of the pistoninside the cylinder causes damage to piston crown (C),top ring and groov

3 - 444/23/97REPAIRENGINEPISTON ASSEMBLY—DISASSEMBLE 1. Remove compression rings (C) from piston (B) using ring expander.2. Remove rails (A).3. Remove

4/23/973 - 45ENGINEREPAIRMiddle Compression Ring(12.5, 13, 14 hp). . . . . . . . . . . . 0.040—0.072 mm (0.0016—0.0028 in.)(15 hp) . . . . . . 0.040—0

3 - 464/23/97REPAIRENGINEPISTON ASSEMBLY IMPORTANT: Side of ring marked TOP faces top ofpiston with Dykem stripe to left of end gap. Topcompression r

4/23/973 - 47ENGINEREPAIRINSTALL CONNECTING ROD5. Fasten connecting rod (D) and cap (C) to crankshaft.6. Tighten cap screws (B) to specification.7. Ch

SAFETY1 - 63/12/97AVOID INJURY FROM ROTATING BLADES, AUGERS AND PTO SHAFTSKeep hands and feet away while machine is running.Shut off power to service,

3 - 484/23/97REPAIRENGINE5. Measure inside diameter of crankshaft main bearing bore (E) in crankcase.6. Subtract journal OD. from bore ID. to determin

4/23/973 - 49ENGINEREPAIR8. Install oil pan onto crankcase.9. In sequence shown, tighten oil pan cap screws to specification.Specification:Oil Pan Cap

3 - 504/23/97REPAIRENGINESpecification:Crankcase Seal Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 mm (0.157 in.)or until its top

4/23/973 - 51ENGINEREPAIRCYLINDER BLOCK REMOVE & INSTALL All components must be removed from block beforeinspection or machine work can be perform

3 - 524/23/97REPAIRENGINEREBORE CYLINDER BLOCKIMPORTANT: Check stone for wear or damage.Use correct stone.NOTE: The cylinder block can only be rebore

ELECTRICALCONTENTSPageCONTENTS3/12/974 - 1ELECTRICALSPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTENTSELECTRICAL4 - 23/12/97PTO CIRCUIT OPERATION STX30 & STX38 (SN —210000) . . . . . . . . . . . . . . . 52PTO CIRCUIT DIAGNOSIS POINTS STX

3/21/974 - 3ELECTRICALSPECIFICATIONSSPECIFICATIONSGENERAL SPECIFICATIONSBattery:Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 - 43/21/97THEORY AND DIAGNOSTIC INFORMATIONELECTRICALTHEORY AND DIAGNOSTIC INFORMATIONTHEORY OF OPERATION INFORMATIONThe theory of operation stories

3/21/974 - 5ELECTRICALTHEORY AND DIAGNOSTIC INFORMATIONREADING ELECTRICAL SCHEMATICSThe schematic is made up of individual circuits laid outin a seque

SPECIFICATIONS & INFORMATIONCONTENTSPageCONTENTS3/12/972 - 1SPECIFICATIONS & INFORMATIONGENERAL VEHICLE SPECIFICATIONS . . . . . . . . . . . .

4 - 63/21/97THEORY AND DIAGNOSTIC INFORMATIONELECTRICALCOMMON CIRCUIT TESTSShorted Circuit:A shorted circuit may result in the wrong componentoperatin

3/21/974 - 7ELECTRICALTHEORY AND DIAGNOSTIC INFORMATIONNOTES

ELECTRICALCOMPONENT LOCATION4 - 83/21/97COMPONENT LOCATIONM55829E2 HeadlightsStarter Solenoid(Optional)Fuel Shut-Off Solenoid(Optional)Regulator/Recti

3/21/974 - 9ELECTRICALTROUBLESHOOTINGTROUBLESHOOTINGProblem or SymptomCheck or SolutionEngine will not crank.Engine cranks but will not start.Engine s

4 - 103/21/97WIRING HARNESS DIAGRAMSELECTRICALWIRING HARNESS DIAGRAMSSTX30 (SN 010001—135159) (SN 595001—750000)STX38 (SN 010001—139615) (SN 595001—75

3/21/974 - 11ELECTRICALWIRING HARNESS DIAGRAMSEngineX1534Neutral StartS3SwitchFuel Shut-offY2650710720940210 N1 Regulator/rectifier450125750120Solenoi

4 - 123/21/97WIRING HARNESS DIAGRAMSELECTRICALSTX30 (SN 135160—160000)STX38 (SN 139616—160000)S5HeadlightSwitch500SeatSwitch800S41 2750720510520520450

3/21/974 - 13ELECTRICALWIRING HARNESS DIAGRAMSEngineX1645Neutral Start S3SwitchFuel Shut-offY2650710720940 A1 Ignition Module210 N1 Regulator/rectifie

4 - 143/21/97WIRING HARNESS DIAGRAMSELECTRICALSTX38 (SN 160001—210000)S5HeadlightSwitch500SeatSwitch800S41 2 37158001107507205105205204505205107157145

3/21/974 - 15ELECTRICALWIRING HARNESS DIAGRAMSEngineX171304 56Neutral StartS3SwitchFuel Shut-offY2650710720940 A1 Ignition Module210 N1 Regulator/rect