Dixon KODIAK Operation and maintenance manual

Model Year 2005
Safety Instructions & Operator’s Manual

2
IMPORTANT - READ CAREFULLY
The Dixon® ZTR® mower is both easy and
fun to operate. However, any power mower
must be operated properly to be safe. It is
not a toy or a recreational vehicle. Before
you start to use the mower, read this
Operator’s Manual carefully. It contains
valuable information that is necessary for
the safe operation of the machine. Observe
all safety rules and become completely
familiar with the controls.
The information contained in this manual
applies to all Dixon® Kodiak™ ZTR®
mowers.
See your authorized Dixon® dealer for
warranty service, parts and repairs or to
answer any questions you may have about
your new Dixon® ZTR®.

3
TABLE OF CONTENTS
Page
SAFETY&WARNING....................................4-15
WARRANTY...................................................16-17
SPECIFICATIONS........................................18-19
SEATADJUSTMENT.........................................20
CONTROLS..................................................21-24
OPERATIONINSTRUCTIONS....................25-35
CARE&MAINTENANCE............................36-48
STANDARDSERVICEPARTS LIST.........49-50
TROUBLESHOOTING..................................51-52
KODIAK™
PartNumber18124-0804

SAFETY
4
Blade Contact
Tip Over
Run Over
Back Over
RIDING LAWN MOWERS,
IF IMPROPERLY OPERATED
CAN CAUSE SERIOUS INJURY OR DEATH
Picturedbelow arethemost commoncauses ofinjuryto
theoperator orbystander. Please readandunderstand
thismanualto preventinjuries.

SAFETY
5
Safety Alert Symbol
When you see this symbol, BE ALERT
to the potential for injury.
Follow the recommended safety precautions and
safe operating practices.
DANGER
(highlightedinred)
indicatesan imminently hazardous
situation which, if not avoided, will result
in death or serious injury.
WARNING
(highlightedinorange)
indicates a potentially
hazardoussituation which, if not
avoided,could result in deathor
seriousinjury.
CAUTION
(highlightedinyellow)
indicates a potentially
hazardoussituationwhich,
ifnot avoided, may result in minor
or moderate injury. It may also
be used to alert against
unsafepractices.

WARNING
6
Failure to observe the following safety instructions
could result in serious injury or death.
GENERAL OPERATION:
Read,understand,andfollowall instructionsin this
manualand onthe mowerbefore starting.
Onlyallow responsibleadults,whoarefamiliarwiththe
instructions,to operatethemower.
Clearthe area ofobjects such asrocks, toys, wire,etc.,
whichcould bepickedup andthrown bytheblade.
Be sure the area is clear of other people before mowing.
Stopmower ifanyoneenters thearea.
Be aware of the mower discharge direction and do not
pointit at anyone. Mowerblades canthrowrocks orother
debris.
Donot operatethemower withouteither theentiregrass
catcheror the deflectorin place. Thiswilldecrease the
possibilityof injuryfrom objectsbeing thrownby the
mowerblades.
Never carrypassengers. Theymayfall offand become
seriouslyinjured orinterfere withsafeoperation ofthe
mower.
Mowing in reverse is not recommended because it is
difficultto maintainaclear visionof themowingpath.
However, shouldit becomenecessaryto backup,
rememberto look downand behind beforeandwhile
backing.

WARNING
7
GENERAL OPERATION (continued):
Neverleavearunningmower unattended. Alwaysturn off
blades,set parking brake,stopengine and removekey
beforedismounting.
Turnoffbladeswhen notmowing. Injurycould occurfrom
contactwithmovingparts.
Underno circumstancesshould youplace handsor feet
underthe mowerdeckor inthe chutewhileblades or
impellerarestillrunning.
Toavoid personalinjuryfromaccidentalclutchengage-
ment,stop engine beforeremoving grasscatcheror
uncloggingchute.
Mowonly indaylightor goodartificial light.
Donot operatethe mowerwhile underthe influenceof
alcoholor drugs.
Slowdown beforeturningto reducethe riskoftip-over.
Watchfor trafficwhen operatingnearor crossingroad-
ways.
Useextra carewhen loadingorunloading themower into
atrailer ortruck. Push,do notride themowerwhen
loadingand unloading.
Failure to observe the following safety instructions
could result in serious injury or death.

WARNING
8
Protectyour eyes.Always wearsafetygoggles orsafety
glasseswith side shieldswhen operatingmower.
Data indicates that operators, age 60 years and above,
areinvolved in alargepercentage of ridingmower-
relatedinjuries. Theseoperators shouldevaluate their
abilityto operate theriding mowersafelyenough to
protectthemselves andothersfromseriousinjury.
Toprotectagainst possibletip-over, followthe
manufacturer’s recommendationfor wheelweights and
counterweights.
Maintainor replace safety& instruction labelsas
needed.
GENERAL OPERATION (continued):
The engine exhaust from this product contains chemicals known to the State of
California to cause cancer , birth defects or other reproductive harm.
Failure to observe the following safety instructions
could result in serious injury or death.

WARNING
9
SLOPE OPERATION:
Slopes are a major factor related to loss-of-control
and tip-over accidents, which can result in
severe injury or death.
All slopes require extra caution. If you feel uneasy
on a slope, do not mow it!
DO
Mowacross theslope withyourDixon® ZTR®--
neverup or down.This will decreasethe risk of
tip-over.
Removeobstacles such asrocks,tree limbs, wires
andother foreignobjects thatcanbe thrownby
mowerblades.
Watchfor holes,ruts,rootsandbumps. Uneven
terraincouldoverturnthemower. Tallgrasscan
hidesuch obstacles.
Useslow speed. Tires maylosetraction on slopes
eventhoughthebrakesare functioningproperly.
Avoid starting or stopping on a slope. If tires lose
traction,disengage the bladesand proceed slowly
downthe slope.
Failure to observe the following safety instructions
could result in serious injury or death.

WARNING
10
Keepall movementonthe slopesslow and
gradual. Donotmake sudden changes in speed
ordirection.
Useextreme cautionwhen operatingthe mower
withattachmentsto preventtip-overorroll-over.
Iffrontwheelsliftoff theground, pullleversbackto
stabilizethe mower. Discontinuemowing the
slope!
SLOPE OPERATION (continued):
DO (continued):
Failure to observe the following safety instructions
could result in serious injury or death.

WARNING
11
SLOPE OPERATION (continued):
DO NOT
Donot turnonslopesunlessnecessary,and then,
turnslowly andgradually downhill,if possible. Rapid
uphillturnsmay causetip-over.
Donot mow neardrop-offs, ditches, orembank-
ments.Themowercouldsuddenly turnover ifa
wheel is over the edge of a cliff or ditch or if an
edge caves in.
Donot mow onwet grass.Reducedtraction could
causesliding.
Donot tryto stabilizethe mowerby puttingyourfoot
ontheground.
Donot usegrasscatcher orother attachmentson
steepslopes. The added weightmay change the
stabilityof themower thuscreating thepotential for
tip-over.
Failure to observe the following safety instructions
could result in serious injury or death.

WARNING
12
FIRE HAZARDS:
Useextra carewhen handlinggasoline andother
fuels.They areflammable andvapors areexplosive.
Storeall fuel inapproved containersspecifically
designedfor that purpose.
Allowengine tocool beforerefueling.Never remove
fuelcap oradd fuelwith enginerunning.
Donot smoke whilerefueling oroperatingthe mower.
Toreducefire hazard, keepmower free ofgrass,
leavesand otherdebrisbuild-up.
Ifgasoline is spilled,donot attempt tostart the
engine. Movemower away fromthe areaofthe spill.
Donot create anysource of ignitionuntil gas vapors
have dissipated. Wipe up spilled fuel and dispose of
wasteproperly.
Iffuelisspilled onclothing,changeclothingimmediately.
Beforestoring, allow mowerto cool. Cleanfueland
oil spillage.
Neverstore the moweror fuelcontainerinside a
buildingwhere thereisan openflame.
Failure to observe the following safety instructions
could result in serious injury or death.

WARNING
13
FIRE HAZARDS (continued):
To prevent fire or explosion, keep sparks and open flames
away from battery.
Keep electrical connections clean and tight. Inspect them
often. Loose connections and corrosion increase fire risk.
Before disconnecting the negative ground cable, make sure
all switches are off. This decreases the chance of sparking
and fire.
Usecare when backingto avoid pushingthe grass
bagsinto theframeor“hot”exhaustmufflerof the
engine. Firecould result.
To prevent fire and explosion caused by static electricity:
Never fill containers inside a vehicle or on a truck or
trailer bed with a plastic liner. Always place containers
on the ground away from your vehicle before filling.
When practical, remove fuel powered equipment from
the truck or trailer and refuel it on the ground. If this is
not possible, refuel such equipment on a trailer with a
portable container, rather than from a fuel dispenser
nozzle.
If a fuel dispenser nozzle must be used, keep the
nozzle in contact with the rim of the fuel tank or
container opening at all times until fueling is complete.
Do not use a nozzle lock-open device.
Failure to observe the following safety instructions
could result in serious injury or death.

WARNING
14
CHILDREN:
Tragic accidents can occur if the operator is not
alert to the presence of children.
Children are attracted to lawn mowers and the
mowingactivity.
NEVER assume children will stay where they
were last seen.
Be alert to avoid accidents.
Keepchildren outofthe mowingarea andunderthe
watchfulcareofanotherresponsible adult.
Bealert and turnmower offifa childentersthe area.
Beforeand during backinglookBEHIND and DOWN
forsmallchildren.
Nevercarrychildren.Theymay falloff andbeseriously
injuredor interferewith safemoweroperation.
Neverallow childrento operatethe mower.
Useextra carewhen approachingblind corners,shrubs,
trees,or otherobjects thatmayobscure vision.
Failure to observe the following safety instructions
could result in serious injury or death.

WARNING
15
SERVICE:
Never run a mower inside a closed area or without proper
ventilation.
Keep nuts and bolts tight, especially blade attachment
bolts, and keep equipment in good condition.
Never tamper with safety devices. Check their proper
operationregularly.
Stop and inspect the equipment if you strike an object.
Repair, if necessary, before restarting.
Never make adjustments or repairs with the engine running
unless otherwise specified.
Grass catcher components are subject to wear, damage
and deterioration which could expose moving parts or allow
objects to be thrown. Frequently check components.
Replace with original equipment parts when necessary.
Mower blades are sharp and can cut. Wrap blades or wear
gloves, and use extra caution when servicing them.
Batteries contain sulfuric acid. To prevent burns, avoid
contact with skin, eyes and clothing.
Failure to observe the following safety instructions
could result in serious injury or death.

16
DIXON® ZTR® PRO SERIES COMMERCIAL/RESIDENTIAL WARRANTY POLICY
Kodiak™,Grizzly™&SilverTip™ Mowers
DIXON® WARRANTS ITS ZTR® MOWERS AGAINST DEFECTS IN MATERIAL AND WORKMANSHIP
FOR THE PERIODS SET FORTH BELOW. THE SOLE REMEDY UNDER THIS WARRANTY IS
REPLACEMENT OR REPAIR OF PARTS INCLUDING LABOR COSTS.
THIS WARRANTY IS SUBJECT TO THE FOLLOWING CONDITIONS AND LIMITATIONS:
1. COMMERCIAL WARRANTY (use other than, or in addition to, mowing at owner’s primary place of
residence):
a. First two years - 100% parts and labor subject to the conditions and limitations described herein
with the exception of non-covered items specified below.
b. Third year - limited to 100% parts cost as shown in the current Dixon® Parts Price List and
subject to the conditions and limitations as described herein.
c. Attachments marketed through or approved by Dixon Industries, Inc. are warranted for one year
parts and labor in commercial use applications.
d. Pro Series Models are not subject to hour meter restrictions.
e. Warranty applies to new and unused mowers and is not transferable.
2. RESIDENTIAL WARRANTY (used only at owner’s primary place of residence):
a. Three years - 100% parts and labor subject to the conditions and limitations described herein for
a period of three years from date of purchase by the original owner.
b. Attachments marketed through or approved by Dixon Industries, Inc., are warranted for two
years parts and labor in residential use applications.
c. Warranty applies to new and unused mowers and is transferable.
3. All Dixon® warranty must be accomplished by authorized Dixon® dealers and in accordance with
Dixon® warranty policy and allowances. All warranty claims must be submitted to Dixon Industries
for approval.
4. Warranty labor reimbursement to dealers based on published Dixon® flat rate schedule.
5. Warranty does not apply to damage in transit or incidents of misuse, negligence, accidents,
or alteration. The use of parts or components other than those supplied by Dixon Industries
VOIDS ALL WARRANTY.
6. Battery warranty is limited to 90 days from date of purchase.
7. The following items are not covered by this warranty policy:
(a) Routine maintenance or adjustments to include any oils, filters or other fluids used.
(b) Belts, blades and tires.
(c) Pick up and delivery charges for transportation of mower to and from an authorized
Dixon® dealer’s place of business.
(d) Engines. These are covered under a separate warranty by each individual engine
manufacturer. Consult engine manual for warranty details.
(e) Any costs or expense of providing substitute equipment while repair work is being
performed on a warranted mower.
8. THERE IS NO OTHER EXPRESS WARRANTY. TO THE EXTENT PERMITTED BY LAW, ALL
IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE ARE EXCLUDED; OTHERWISE, ALL SUCH IMPLIED WARRANTIES ARE
LIMITED TO THE SAME DURATION AND REMEDIES AS THE EXPRESS WARRANTY. ALL
LIABILITIES FOR CONSEQUENTIAL DAMAGES UNDER ANY EXPRESS OR IMPLIED WARRANTY
ARE EXCLUDED.

SPECIFICATIONS
17
SPECIFICATIONS SUBJECT TOCHANGE WITHOUT NOTICE
Additional information may be provided elsewhere in this manual.
KODIAK
CHASSIS: 11 GA - rectangular tube
SEAT: Designed for operator comfort by use of high-density closed cell
foam padded back and arm rests, upholstered with CorduraTM
water-repellent fabric. Seat is adjustable fore and aft. Mounted
on operator suspension system.
MOWER DECK: Made of 11 GA fabricated welded construction with external
reinforcement ribs. Three blades combine for a 50 cut width.
Cut height approximately 1.5 to 5 via 8 position lift handle.
BLADE DRIVE: Electric clutch
DRIVE SYSTEM: Each rear wheel is independently driven by a Parker 10cc pump
and TE0230 wheel motor.
ENGINE: Each mower is powered with either a 19HP Kawasaki, 20HP
Honda, 20HP Kohler, or a 21 HP Briggs & Stratton Vanguard
twin cylinder engine, overhead valve, air cooled, gasoline, full
pressure lubrication with oil filter.
STARTING SYSTEM: Electric by key switch operation with safety interlocks on parking
brake and blade drive clutch.
TIRES: Front 13 x 5 x 6 smooth tread (16-21 lbs)
Rear 20 X 10 X 10 Turf Master (8-14 lbs)
CAPACITIES: Fuel - 11 gallon (approximately)
Hydrostat Oil tank - 4 quart with in-line 25 micron filter
Engine - 2 qts. SAE 10W30 (with filter)
DIMENSIONS: Width 60
Height 46.5
Length 75
Weight 760 lbs.

18
SEAT ADJUSTMENT INSTRUCTIONS
1. Grasp seat slide adjuster and move it
into adjustment position.
2. Slide seat forward or backward.
3. Release seat slide adjuster.
Seat Slide Adjuster

CONTROLS
19
CONTROL LEVERS
Note: For access to the seat, move control levers to neutral
positionandswing them outward.
TOGO FORWARD
•Fromneutralposition,gentlypush controllevers for-
ward.
•Toincrease speed,move leversfurther forward.
TO GO BACKWARDS
•Fromneutralposition,gentlypull controllevers toward
you.
TURNING
•Turningiscontrolledbymoving onecontrollever slightly
forwardor rearwardof theother.
•Toturn left,moveleftleverrearward oftherightlever.
•Toturn right,moverightleverrearward oftheleftlever.
•Toturn onmower’sownaxis (zeroturning radius),stop
andmove oneleverto reverseposition andtheother to
forwardposition.
BRAKING
•Tobrakemower, moveboth levers indirectionopposite
of travel.
Note:The pressurerequired tooperatethe moweris verylight.
LEFT TURN OPPOSITE

CONTROLS
20
CAUTION
MOWER DECK CUT HEIGHT LIFT LEVER:
•Locatedtothe rightand front ofthe operator.
•Controlsthecutting height.
•Eight positionsof adjustment
•Depresstriggerand move leverforward to lowerdeck.
•Depress trigger and pull lever back to raise deck.
Note: Alwaysuse highposition fortransport.
PARKING BRAKE:
The parking brake is designed to hold
the mowerfrom moving andis not
intendedfor use instopping the
mowerwhileit is in motion. The
engine will stop if the parking brake is
engagedwhile thecontrol leversarein
thedrive position.
Engageparkingbrake
beforestartingengine.
TO SET PARKING BRAKE:
Thehandoperated parking brakeis located on the left
handside of themower.
•Toengage brake,pulllever up(to therear).
•Torelease brake, movelever forward(down).
Note: Alwaysset parking brake before dismounting.
Releaseparking brake before moving mower.