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LAZERZ®
AirCooledModels
SetupInstructions
ForSerialNos.720,000&Higher
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.Partnumbersnotshownareavailableonthedealer
extranet.
DealerPack
Part#
DescriptionQty.Use
323-6
CapScrew,Hex3/8-16x1inch
8
98-5975
Washer,SpringDisc
8
3290-357
Nut,HexFlange3/8-16inch
8
InstallingtheRolloverProtection
System(RollBar).
32128-20
Nut,5/16-18inchWhizlock
4
1-303335Tie,Plastic2
Installingtheseat.
—
WarrantyRegistrationForm
1
103-2106
Key,ExmarkLogo
1
1-603511
Key,Standard
1
Filloutwarrantyregistrationformand
placekeysintoliteraturepack.
LiteraturePack
Part#
DescriptionQty.Use
—
Manual,Operator’s
1
—Manual,Parts1
Readbeforeoperatingthemachine.
—DVD,ExmarkSafetyVideo1Viewbeforeoperatingthemachine.
InstallingtheRolloverProtection
System(RollBar)
1.Removesidesandtopofcratefromthebase.
2.Removerollbarcomponentsfromthecrate.
3.Removerollbartubesfromsidesofcrate.
4.Removethetwobracketsusedtomountthebottom
oftheupperrollbartubetothecrate.
5.Removethe1/2-13x31/4inchcapscrewsand
1/2-13inchhexangelocknutsfromthetwo
bracketsateachendoftheupperrollbartubeand
retainforlateruse(Figure1).
6.Removethefour1/4inchlagscrewsholdingthe
wheelhubbracketstothecratebottomanddiscard.
Figure1
1.1/2-13x31/4inch
Capscrew
3.Upperrollbartube
2.1/2-13inchhexangelock
nuts
7.Raisetherearoftheunitapproximately10–12inches
andsupportitwithjackstandsorequivalentsupport.
©2004–2007—ExmarkMfg.Co.,Inc.
P .O.Box808
Beatrice,NE68310
PartNo.4500-290Rev.A
PrintedintheUSA.
AllRightsReserved
Caution
Raisingtherearoftheunitforassemblyrelying
solelyonmechanicalorhydraulicjackscouldbe
dangerous.Themechanicalorhydraulicjacks
maynotbeenoughsupportormaymalfunction
allowingtheunittofall,whichcouldcause
injury.
DoNotrelysolelyonmechanicalorhydraulic
jacksforsupport.Useadequatejackstandsor
equivalentsupport
8.Locatetheleftandrightlowerrollbartubes.
9.Alignlowerrollbartubesalongrearengineframe
(Figure2).
10.Looselyinstalllowerrollbarhardware(four3/8-16
x1inchcapscrews,fourspringdiscwashersand
four3/8-16inchwhizlocknuts)tothetubesoneach
side(Figure2).
Note:Besurethespringdiscwasherconeis
installedtowardstheheadofthecapscrew.
Figure2
1.3/8-16x1inchcapscrews
3.Wheelnuts
2.Springdiscwasher(cone
towardscapscrewhead)
4.3/8-16inchwhizlocknuts
Figure3
1.1/4-20inchnylocnut
5.Upperrollbartube
2.1/2-13inchhexangelock
nuts
6.Latchpinassembly
3.Applyoiltoinsidesurface
ofearshapedholes
7.1/2-13x31/4inch
capscrew
4.Bumper
11.Locatethelatchpinassemblies(pinandhairpin
connectedwithalanyard).
12.Inserta1/2-13x31/4inchcapscrew(removedin
step5)intothebenttabwasheronthelanyardof
eachpinassembly(Figure3).
Note:Makesurethebenttabinthewasheris
towardstheheadofthebolt.
13.Lightlyoiltheinsidesurfacesoftheear-shaped
platesattheupperendofthelowerrollbartubes
(Figure3).
14.Locatetheupperu-shapedsectionoftherollbar.
Installtheupperrollbarsectionusingthetwo1/2-13
x31/4inchcapscrewsandtwo1/2-13inchhex
angelocknuts(removedinstep5).Donotover
tighten.Makesureupperrollbarcanpivotfreely.
Note:Makesurethecapscrewandnutsareinstalled
withthenuttotheinsideoftherollbar.
Note:Makesurethetabonthelanyardwasheris
installedasshownandpointstowardthefrontof
theunit.
15.Raisetherollbarintotheuprightpositionandsecure
withthelatchpinassembliesoneachside.Install
2
latchpinfromoutersurfaceofrollbarassemblyand
securewiththehairpintotheinside.
16.Torquealllowerrollbarhardwareattachedtothe
machineframeto30-35ft-lb(41-47N-m).
InstallingtheDriveWheels
1.Removethe1/2-20inchdrivewheelnuts(installed
onstudsofdrivemotors;Figure2)andretainfor
wheelmounting.Removeanddiscardshipping
bracketsmountedonwheelhubs.
2.Mountdrivewheelswiththevalvestemtothe
outsideoftheunit.Secureusingfour1/2-20inch
wheelnutsremovedinstep1.
3.Torqueto95ft-lb(128N-m).
CheckingTirePressure
1.Checkthetirepressureinthedrivetires.Proper
inationfordrivetiresis13psi(90kPa).
2.Adjustifnecessary.
InstallingtheSeat
1.Removeseatassemblyfromthecrate.
2.Locatethefour5/16-18inchwhizlocknutspackaged
withtherollbarhardware.
3.27HPKohler&28HPKawasakiUnitsOnly:
SeeFigure4.Aligntheseattrackstudsonthe
bottomoftheseatwiththeholesintheseatframe.
Placeseatontopoftheframeandsecurewiththe
four5/16-18inchwhizlocknutsidentiedinstep2.
Figure4
1.Seatassembly3.5/16-18inchwhizlocknuts
2.Seattrackstuds
4.31HPBriggs&StrattonUnitsOnly:
A.Removethe5/16-18inchwhizlocknutsusedto
holdseatstopsonseatsforshipping.
B.Aligntheseattrackstudsonthebottomofthe
seatwiththeholesintheseatstops(slotstothe
front)andholesintheseatframeandsecurewith
thefour5/16-18inchwhizlocknuts.
C.Routetheswitchwirefromtheseatoverthetop
ofthefrontseatframecrossmember.
D.Usingoneofthetwowiretiesincludedsecure
thewirenearwheretheseatholduprodis
connectedtotheseatframe.
E.Usingthesecondwiretie,securethewireagainto
approximatelythemiddleoftheseatholduprod.
F.Connecttheseatwiretothemainwiringharness
lead.Slowlylowertheseatcheckingthatthewire
cannotcontactanymovingpartsorpinchpoints.
Readjustwiretiesifnecessary.
5.28HPKohlerEFIUnitsOnly:
A.Removethe5/16-18inchwhizlocknutsusedto
holdseatstopsonseatsforshipping.
B.Aligntheseattrackstudsonthebottomofthe
seatwiththeholesintheseatstops(slotsto
therear)andholesintheseatframeandsecure
withthefour5/16-18inchwhizlocknuts(see
Figure5).
Figure5
1.Seatassembly3.Seatstop
2.Seattrackstuds4.5/16-18inchwhizlocknuts
C.Routetheswitchwirefromtheseatoverthetop
ofthefrontseatframecrossmember.
3
D.Usingoneofthetwowiretiesincludedsecure
thewirenearwheretheseatholduprodis
connectedtotheseatframe.
E.Usingthesecondwiretie,securethewireagainto
approximatelythemiddleoftheseatholduprod.
F.Connecttheseatwiretothemainwiringharness
lead.Slowlylowertheseatcheckingthatthewire
cannotcontactanymovingpartsorpinchpoints.
Readjustwiretiesifnecessary.
ServicingtheBattery
Warning
CALIFORNIA
Proposition65Warning
Batteryposts,terminals,andrelated
accessoriescontainleadandleadcompounds,
chemicalsknowntotheStateofCalifornia
tocausecancerandreproductiveharm.
Washhandsafterhandling.
Note:Themachineisshippedwithalledleadacid
battery.
1.Unhookseatlatchandtiltseatuptogainaccessto
thebattery.
Danger
Chargingthebatterymayproduceexplosive
gasses.Batterygassescanexplodecausing
seriousinjury.
•Keepsparks,ames,orcigarettesawayfrom
battery.
•Ventilatewhenchargingorusingbatteryin
anenclosedspace.
•Makesureventingpathofbatteryisalways
openoncebatteryislledwithacid.
2.Checkthevoltageofthebatterywithadigital
voltmeter.Locatethevoltagereadingofthebattery
inthetablebelowandchargethebatteryforthe
recommendedtimeintervaltobringthechargeup
toafullchargeof12.6voltsorgreater.
Important:Makesurethenegativebattery
cablesaredisconnectedandthebatterycharger
usedforchargingthebatteryhasanoutputof
16voltsand7ampsorlesstoavoiddamaging
thebattery(seechartforrecommendedcharger
settings).
Voltage
Reading
Percent
Charge
Maximum
Charger
Settings
Charging
Interval
12.6or
greater
100%
16volts/7
amps
NoCharging
Required
12.4–12.675–100%
16volts/7
amps
30Minutes
12.2–12.450–75%
16volts/7
amps
1Hour
12.0–12.225–50%
14.4volts/4
amps
2Hours
11.7–12.00–25%
14.4volts/4
amps
3Hours
11.7orless
0%
14.4volts/2
amps
6Hoursor
More
Caution
Iftheignitionisinthe“ON”positionthere
ispotentialforsparksandengagementof
components.Sparkscouldcauseanexplosion
ormovingpartscouldaccidentallyengage
causingpersonalinjury
Besureignitionswitchisinthe“OFF”position
beforechargingthebattery.
3.Connectthenegativebatterycables.
Note:Ifthepositivecableisalsodisconnected,
connectthepositive(red)cabletothepositive
batteryterminalrst,thenthenegative(black)cable
tothenegativebatteryterminal.Slipinsulatorboot
overthepositiveterminal.
Note:Iftimedoesnotpermitchargingthebattery,
orifchargingequipmentisnotavailable,connect
thenegativebatterycablesandrunthevehicle
continuouslyfor20to30minutestosufciently
chargethebattery.
InstallingtheCanisterAirCleaner
Kohler
1.Removeaircleaner(withbracketattached)from
seatframe.Keepaircleanerandmountingbracket
together.
2.Removethetoptwovalvecovermountingscrews
frombothleftandrightsideenginevalvecovers.
Keepscrewsforre-attachingaircleaner.
3.Positiontheaircleanerassemblyovertheengine,
aligningaircleanerbracketholeswithtopholesin
4
thevalvecovers.Reinstallvalvecoverscrewsthrough
aircleanerbracketandtorqueto70in-lb(4.9N-m).
4.Removeplasticplugsfromairintakeelbowon
engineandaircleanerhose.Adjusttheaircleaner
andhoseasrequiredandconnectintakehosetoair
cleaneroutlet.Positionandtightenthetwohose
clampstosecurethehoseconnections.
5.Secureaircleanerbytighteningthetensioning
boltandspringassemblyuntilendsofclampare
approximately1/2inch(12.7mm)apart.
Kawasaki
1.Removeaircleaner(withbracketattached)andhose
clampfromthecartonlocatedontheoorpan.
Keepaircleanerandmountingbrackettogether.
2.Looselyassemblethehoseclampontotheaircleaner
intakehose.
3.Removetheprotectivetapefromthecarburetor
intake.Slidetheaircleanerintakehoseontothe
carburetorwhilealigningthefourbracketmounting
holeswiththeappropriatescrewsintheengine.
4.Removetheaircleanerassembly.Removeandretain
thefourscrewsfromtheengine(twotopcarburetor
screwsandtwoscrewstowardtherearoftheengine).
5.Re-assembletheaircleanerassemblytotheengine
re-usingthefourscrewsremovedinstep4.Tighten
therearscrewssecurely.Torquethetwocarburetor
boltsto52in-lb.(5.9N-m).
6.Checktobesuretheaircleanerintakehose
adequatelyengagesthecarburetorintake.Tighten
thehoseclamp.
7.Locatethefrontenginepanelandfourblackanged
screwsinabaginthecarton.Assemblethepanelto
thefrontoftheengineandsecurewithscrews.
8.Secureaircleanerbytighteningthetensioning
boltandspringassemblyuntilendsofclampare
approximately1/2inch(12.7mm)apart.
Briggs&Stratton
1.Removeaircleaner(withbracketandintakehose
attached)fromseatframe.Keepaircleanerand
mountingbrackettogether.
2.Settheaircleanerontopoftheenginewiththe
airintakehosetotherighthandside(fromthe
operator’sposition),roughlyaligningthemounting
holes.Notetheorientationoftheairinletontheair
cleaner.Thisshouldbepointingstraightup.Ifnot,
removethemetalbracket.Whileslightlyspreading
theaircleanermountingbase,rotatetheaircleaner
bodyaccordingly.Re-assemblethemetalbracketto
theaircleanerbase.Repeatifnecessary.
3.Oncetheinletisvertical,securetheaircleanertothe
engineusingthetwolongerM8screwslocatedina
baginthecubbyonthemower.(Discardtheshorter
screws.Theyarenotusedinthisapplication).
4.Rotatetheairintakehosetoalignwiththecarburetor
intake.Removeanddiscardtheplasticcapfromthe
carburetorintake.Locatethewirestylehoseclamp
inthecubby.Slideitontheairintakehose.Slidethe
airintakehoseontothecarburetorintake.Check
tobesuretheaircleanerintakehoseadequately
engagesthecarburetorintakeandtheaircleaner
elbow .Tightenbothwirestylehoseclampssecurely.
5.Locatetheinletraincapandatbandstyleclampin
thecubby.Installtheclamponthecap,andthecap
ontheaircleanerinlet.Tightentheclampjustsnug.
Overtighteningwilldamagethecapandpossibly
theaircleanerinlet.
InstallingtheMotionControl
Levers
1.Loosenandremovethetwo3/8x1inchboltsand
springdiscwasherswhichattachthemotioncontrol
leverstothecontrolarmshaftsforshippingandthe
two3/8x1inchboltsandspringdiscwasherswhich
arescrewedintothecontrolarmshafts.
2.Installtheleftmotioncontrolleverontothecontrol
armshaftontheleftsideoftheconsole(Figure6).
3.Placethelever(withthemountingplatetowardsthe
rear)ontheoutsideofthecontrolarmshaftand
securewiththeboltsandwashersremovedinstep1.
Note:Besurethespringdiscwasherconeis
installedtowardstheheadofthebolts.
4.Positiontheleversotheboltsareinthecenterof
theslotsonthelevermountingplateandtighten
untilsnug.
5.Repeatonoppositesideofunit.
Note:Therearetwoleverheightoptionsavailable.
Placetheleversinthetoptwoholestoincrease
heightofthelevers,orinthebottomtwoholesto
decreasetheheightofthelevers.
5
Figure6
1.Motioncontrollever
3.Springdiscwashers(cone
towardsbolthead)
2.3/8x1inchbolts4.Controlarmshaft
6.Aligntheleversfront/rearposition.Withthelevers
intheneutralposition,loosenthehardwareand
adjusttheleversslidingand/ortiltingthelever(s)
forwardorbackwarduntilproperlyalignedand
tightenhardware(Figure7).
7.Iftheendsofthelevershitagainsteachother,
whileinthedriveposition(leversrotatedinasfaras
possible),makeadjustmentsbymovingthelevers
outwardstotheneutrallockpositionandcarefully
bendingthemoutward.Movethembacktothedrive
positionandcheckforclearance.Repeatifnecessary.
Figure7
1.Leversinalignment
PositioningtheDischargeChute
Loosentwo5/16inchnylocnutsattachingdischarge
chute.Lowerthedischargechuteintoposition.
Retightennylocnutsuntilchuteissnugbutcanpivot
freely.
ServicingtheEngine
RefertoEngineOwner’sManual.
ServicingtheHydraulicOil
Themachineisshippedwithhydraulicoilinthe
reservoir.
1.Runthemachineforapproximately15minutesto
allowanyextraairtopurgeoutofthehydraulic
system.
2.Checkhydraulicreservoirandifnecessaryllthe
reservoirtotheappropriatelevelwithMobil1
15W-50syntheticmotoroil.
3.Replacehydraulicreservoircapandtightenuntil
snug.Donotovertighten.
Note:Thebafeislabeled“HOT”and“COLD”.
Theoillevelvarieswiththetemperatureoftheoil.
The“HOT”levelshowsthelevelofoilwhenitisat
225°F(107°C).The“COLD”levelshowsthelevelof
theoilwhenitisat75°F(24°C).Filltotheappropriate
leveldependinguponthetemperatureoftheoil.For
example:Iftheoilisabout150°F(65°C).Filltohalfway
betweenthe“HOT”and“COLD”levels.Iftheoilisat
roomtemperature(about75°F(24°C)),llonlytothe
“COLD”level.
FillingOuttheWarranty
RegistrationForm
Filloutwarrantyregistrationformandplacekeysinto
literaturepack.
6
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