Cushman SUZUKI 660 K6A User manual

Engine Parts
Manual
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1-INCLUDESITEMS3 - 16
By Jacobsen
®
GB
Suzuki 660 K6A
Turf Truckster
Haulster
4140631

Copyright 2005, Textron Inc.
“All rights reserved, including the right to reproduce this material or portions thereof in any form.”
To Order Parts
1. Write your full name and complete address on the
order.
2. Explain where and how to make shipment.
3. Give product number, name and serial number that is
stamped on the name plate or serial plate of your prod-
uct.
4. Order by the quantity desired, the part number, paint
code, and description of the part as given in the parts list.
5. Send or bring the order to an authorized Jacobsen
Dealer.
6. Inspect all shipments on receipt. If any parts are dam-
aged or missing, file a claim with the carrier before
accepting.
7. Do not return material without a letter of explanation, list-
ing the parts being returned. Transportation charges
must be prepaid.
Use of other than Jacobsen authorized parts will void the warranty.
Table of Contents
1.1 .........Engine Gaskets ................................................... 4
2.1 .........Cylinder Head ...................................................... 6
3.1 .........Cylinder Block ..................................................... 8
4.1 .........Oil Pan................................................................ 10
5.1 .........Engine Mounts .................................................. 12
6.1 .........Crankshafts ....................................................... 14
7.1 .........Camshafts.......................................................... 16
7.1 .........Camshafts (Continued)..................................... 18
8.1 .........Cam Chain ......................................................... 20
9.1 .........Intake Manifold & Throttle Body ...................... 22
10.1 .......Breather Hose.................................................... 24
11.1 .......Exhaust Manifold .............................................. 26
12.1 .......Fuel Components.............................................. 28
13.1 .......Fuel Rail ............................................................. 30
14.1 .......Oil Pump ............................................................ 32
15.1 .......Water Pump ....................................................... 34
16.1 .......Cooling Tubes ................................................... 36
17.1 .......Engine Electrical ............................................... 38
18.1 .......Alternator ........................................................... 40
19.1 .......Manual Transmission Starter ........................... 42
20.1 .......Automatic Transmission Starter...................... 44
21.1 .......Clutch ................................................................. 46
22.1 .......Gear Shafts ........................................................ 48
22.1 .......Gear Shafts (Continued)................................... 50
23.1 .......Shift Fork ........................................................... 52
24.1 .......Transmission Case ........................................... 54
25.1 .......Shift Brackets .................................................... 56
26.1 .......Torque Converter & Flex Plate......................... 58
27.1 .......Case Gaskets..................................................... 60
28.1 .......Transmission Case ........................................... 62
29.1 .......Oil Pump ............................................................ 64
30.1 .......Input Shaft & Clutch.......................................... 66
31.1 .......Planetary Gears................................................. 68
32.1 .......Output Shafts .................................................... 70
33.1 .......Parking Brake .................................................... 72
34.1 .......Brake Band ........................................................ 74
35.1 .......Oil Pan................................................................ 76
36.1 .......Valve................................................................... 78
37.1 .......Cooling Tubes ................................................... 80
38.1 .......Shift Switch........................................................ 82
1.1 .........Emission Control System................................. 84
Litho in U.S.A. 1-2006

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Suggested Stocking Guide
To Keep your Equipment fully operational and productive, maintain a stock of the more commonly used maintenance
items. We have included part numbers for additional support materials and training aids. A more complete listing of
accessories and attachments can be found in the Specifications Section.
How To Use This Manual
Abbreviations
N/S - Not serviced seperately, can only be obtained by ordering main component or kit.
AR -Variable quantity or measurement is required to obtain correct adjustment.
Symbols such as ▲, next to the item number, indicate that a note exists which contain additional information
important in ordering that part.
Indented Items
Bulleted items indicate component parts that are included as part of an assembly or another component. These parts
can be ordered separetely or as part of the main component.
Item Part No. Qty Description Serial Numbers/Notes
▲1 123456 1 Mount, Valve Indicates a piece part
2 789012 1 Valve, Lift Includes Items 2 and 3
3 345678 1 • Handle Serviced part included with Item 2
4 N/S 1 • Seal Kit Non serviced part included with Item 2
5 901234.6 1 Screw, 1/4-20 x 2” Hex Head Indicates part 901234 painted Orange
5 901234.2 1 Screw, 1/4-20 x 2” Hex Head Indicates part 901234 painted Green
Service Parts
Part No. Description Part No. Description
2701908 Engine Oil Filter 11400-67864 Engine Gasket Set
2701898 Engine Fuel Filter Element 17521-71J10 Water Pump - Alternator Belt
4120056 PCV Valve

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1.1 Engine Gaskets Serial No. All

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Item Part No. Qty. Description Serial Numbers/Notes
4140889 1 Gasket Set, Engine
14140890 1 • Gasket, Cylinder Head
2 4140891 1 • Gasket, Cylinder Head Cover
3 4119959 1 • Gasket, Intake Manifold
4 2701803 1 • Gasket, Throttle Body
5 4140981 1 • Gasket, Exh Manf
6 4119965 1 • O Ring, Water Pump
7 4119967 1 • Gasket, Thermostat Case
8 4119609 1 • O Ring, Water Inlet Pipe
9 4140893 1 • Gasket, Tens Adjuster

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2.1 Cylinder Head Serial No. All

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Item Part No. Qty. Description Serial Numbers/Notes
14140894 1 Head Assy, Cylinder
2 4140895 12 • Guide, Valve
3 2701816 2 • Plug (Od:20)
4 4119964 17 • Bolt
5 2701821 14 • Pin
6 4119956 8 Bolt, Cylinder Head
7 4119966 2 Pin
8 4140890 1 Gasket, Cylinder Head
9 4140896 1 Cover, Cylinder Head
10 4140891 1 Gasket, Head Upper Cover
11 4119970 5 Bolt
12 4119971 1 Bolt
13 4117892 4 Bolt (6x16)
14 4119973 1 Cap, Oil Filler
15 4119606 3 Spark Plug (Ngk,dcpr7e)
15 2701832 3 Spark Plug (Denso,xu22epr-u)
16 4140897 1 Cover, Cyl Head Upper
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3.1 Cylinder Block Serial No. All

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Item Part No. Qty. Description Serial Numbers/Notes
14140898 1 Block Assy, Cylinder
2 4119956 8 • Bolt, Crankcase
3 4120006 8 • Bolt, Crankcase No.2
4 4119607 1 • Plug, Oil Venturi
5 4120007 1 • Plug, Oil Gallery No.2
6 4120008 1 • Gasket, Oil Gallery Plug
7 4119604 1 • Plug, Oil Gallery
8 2701824 4 Pin
9 4120009 1 Stand, Oil Filter
10 2701908 1 Filter Assy, Oil
11 4140899 1 Plate, Clutch Housing Upper Manual Transmission
11 4140900 1 Plate, Clutch Housing Upper Automatic Transmission
12 4140901 1 Sensor Assy, Knock

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4.1 Oil Pan Serial No. All

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Item Part No. Qty. Description Serial Numbers/Notes
14139968 1 Pan, Oil
2 4120012 12 Bolt (6x16)
3 4120013 3 Stud Bolt
4 2701904 3 Nut
5 2701915 1 Plug, Drain
6 2701916 1 Gasket, Drain Plug
7 4140902 1 Plate, Oil Pan Baffle
8 2701809 1 Bolt
9 4140903 1 Strainer, Oil Pump
10 2701920 1 O Ring
11 2702523 1 Stud Bolt
12 2701914 1 Nut
13 2701921 2 Bolt
14 4140904 1 Gauge, Oil Level
15 4119977 1 Guide, Gauge
16 4119605 1 O Ring
17 4120015 1 Stud Bolt
18 2701914 1 Nut

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5.1 Engine Mounts Serial No. All

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Item Part No. Qty. Description Serial Numbers/Notes
1NS 1 Bush, Fr Mtg Part of 2701697
2 4120017 1 Bracket, Fr Mtg Rh
3 4120018 1 Mounting, Fr Lh
4 2701827 4 Bolt, Mtg Brkt Lh & Eng
5 4140905 3 Bolt, Mtg Brkt Rh & Eng
6 2703001 1 Mounting, Rear
7 2702661 2 Bolt, Rr Mtg & T/m
8 2703002 2 Nut, Rear Mtg Brkt

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6.1 Crankshafts Serial No. All

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Item Part No. Qty. Description Serial Numbers/Notes
14119978 3 Ring Set, Piston (Std)
1 4119979 3 Ring Set, Piston (Os:0.50)
2 4119980 3 Piston (Std,mark 1)
2 4119981 3 Piston (Std,mark 2)
2 4119982 3 Piston (Os:0.50)
3 4119983 3 Pin, Piston
4 4119984 6 Circlip
5 4140906 3 Connrod Assy
6 2701931 6 • Nut
7 4140907 6 Bearing Set, Connrod T:1.5
8 4119986 1 Crankshaft
9 4140908 3 Bearing Set, Crankshaft T:1.2,#1,#2, (Color:green)
9 4140909 3 Bearing Set, Crankshaft T:1.2,#1,#2, (Color:black)
9 4140910 3 Bearing Set, Crankshaft T:1.2,#1,#2, (Non Color)
9 4140911 3 Bearing Set, Crankshaft T:1.2,#1,#2, (Color:yellow)
9 4140912 3 Bearing Set, Crankshaft T:1.2,#1,#2, (Color:brown)
9 4140913 1 Bearing Set, Crankshaft T:1.2,#3 (Color:brown)
9 4140914 1 Bearing Set, Crankshaft T:1.2,#3 (Color:green)
9 4140915 1 Bearing Set, Crankshaft T:1.2,#3 (Color:black)
9 4140916 1 Bearing Set, Crankshaft T:1.2,#3 (Color:non)
9 4140917 1 Bearing Set, Crankshaft T:1.2,#3 (Color:yellow)
10 2701937 1 Bearing Set, Crank Thrust STD,T:2.5
10 2701938 1 Bearing Set, Crank Thrust OS,T:2.563
11 2701955 1 Seal, Crankshaft Front Oil
12 4140918 1 Sprocket, Crank Timing
13 4120020 1 Pulley, Crankshaft
14 4120021 1 Key
15 4120022 1 Bolt
16 4120023 1 Seal, Oil
17 4120024 1 Flywheel Manual Transmission Only
18 4119955 6 Bolt (10x18.5) Manual Transmission Only
19 2701952 1 Bearing, Input Shaft Manual Transmission Only
20 4140919 1 Belt, Water Pump (4pk870)
21 4120027 1 Tensioner Assy
22 4120028 2 Bolt
23 4120029 1 Pin

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7.1 Camshafts Serial No. All

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Item Part No. Qty. Description Serial Numbers/Notes
14120030 1 Camshaft, Intake
2 4120031 1 Camshaft, Exhaust
3 4140920 6 Valve, Intake
4 4120033 6 Valve, Exhaust
5 4120034 12 Spring, Valve
6 4120035 12 Retainer, Spring
7 2701970 24 Cotter, Valve
8 2701972 12 Seal, Valve Stem Oil
9 2701971 12 Seat, Spring
10 4140965 12 Tappet
11 4119912 AR Shim, Tappet (T:2.18)
11 4119913 AR Shim, Tappet (T:2.20)
11 4119914 AR Shim, Tappet (T:2.22)
11 4119915 AR Shim, Tappet (T:2.24)
11 4119916 AR Shim, Tappet (T:2.26)
11 4119917 AR Shim, Tappet (T:2.28)
11 4119918 AR Shim, Tappet (T:2.30)
11 4119919 AR Shim, Tappet (T:2.32)
11 4119920 AR Shim, Tappet (T:2.34)
11 4119921 AR Shim, Tappet (T:2.36)
11 4119922 AR Shim, Tappet (T:2.38)
11 4119923 AR Shim, Tappet (T:2.40)
11 4119924 AR Shim, Tappet (T:2.42)
11 4119925 AR Shim, Tappet (T:2.44)
11 4119926 AR Shim, Tappet (T:2.46)
11 4119927 AR Shim, Tappet (T:2.48)
11 4119928 AR Shim, Tappet (T:2.50)
11 4119929 AR Shim, Tappet (T:2.52)
11 4119930 AR Shim, Tappet (T:2.54)
11 4119931 AR Shim, Tappet (T:2.56)
11 4119932 AR Shim, Tappet (T:2.58)
11 4119933 AR Shim, Tappet (T:2.60)
11 4119934 AR Shim, Tappet (T:2.62)
11 4119935 AR Shim, Tappet (T:2.64)
11 4119936 AR Shim, Tappet (T:2.66)
11 4119937 AR Shim, Tappet (T:2.68)
11 4119938 AR Shim, Tappet (T:2.70)
11 4119939 AR Shim, Tappet (T:2.72)
11 4119940 AR Shim, Tappet (T:2.74)
11 4119941 AR Shim, Tappet (T:2.76)
11 4119942 AR Shim, Tappet (T:2.78)
11 4119943 AR Shim, Tappet (T:2.80)
11 4119944 AR Shim, Tappet (T:2.82)
11 4119945 AR Shim, Tappet (T:2.84)
11 4119946 AR Shim, Tappet (T:2.86)

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7.1 Camshafts (Continued)

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11 4119947 AR Shim, Tappet (T:2.88)
11 4119948 AR Shim, Tappet (T:2.90)
11 4119949 AR Shim, Tappet (T:2.92)
11 4119950 AR Shim, Tappet (T:2.94)
11 4119951 AR Shim, Tappet (T:2.96)
11 4119952 AR Shim, Tappet (T:2.98)
11 4119953 AR Shim, Tappet (T:3.00)
Item Part No. Qty. Description Serial Numbers/Notes

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SUZUKI 660 K6A
8.1 Cam Chain Serial No. All