Gravely Rapid XZ 27hp Kohler User manual

Rapid XZ
Sevice Manual
03291700 7/08
Printed in USA
Models
990100 - Rapid XZ 27hp Kohler
990102 - Rapid XZ 30hp Kohler

1
TABLE OF CONTENTS
Section 1 - Introduction . . . . . . . . . . . . . . . . . . . . .1-2
1.1 The Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Model and Serial Numbers . . . . . . . . . . . . . . . . . 1-2
1.4 Product Registration . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Unauthorized Replacement Parts . . . . . . . . . . . 1-2
1.6 Delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.7 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.8 Service Position . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.9 Moving Unit Manually . . . . . . . . . . . . . . . . . . . . . 1-3
1.10 Rear Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Section 2 - Safety . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.1 Safety Alert System . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2 Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3 Notations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Safety Decals and Locations . . . . . . . . . . . . . . . 2-4
2.5 Practices and Laws. . . . . . . . . . . . . . . . . . . . . . . 2-4
2.6 Required Operator Training . . . . . . . . . . . . . . . . 2-4
2.7 Emission Control System Certification Label . . . 2-4
2.8 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Section 3 - Specifications . . . . . . . . . . . . . . . . . . .3-9
Section 4 - Controls and Features. . . . . . . . . . . .4-10
Section 5 - Maintenance . . . . . . . . . . . . . . . . . . .5-11
5.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . 5-11
5.2 Lubricating Unit . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.3 Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . 5-13
5.4 Checking Mower Gearbox Oil . . . . . . . . . . . . . 5-13
5.5 Servicing the Battery . . . . . . . . . . . . . . . . . . . . 5-13
Section 6 - Adjustments . . . . . . . . . . . . . . . . . . . 6-15
6.1 Adjusting Unit to Track Straight. . . . . . . . . . . . . 6-15
6.2 Steering Control Neutral Adjustment. . . . . . . . . 6-15
6.3 Steering Lever Height Adjustment . . . . . . . . . . 6-16
6.4 Parking Brake Adjustment . . . . . . . . . . . . . . . . 6-16
6.5 Parking Brake Interlock Adjustment . . . . . . . . . 6-17
Section 7 - Engine. . . . . . . . . . . . . . . . . . . . . . . . .7-18
7.1 Engine Troubleshooting . . . . . . . . . . . . . . . . . . 7-18
7.2 Changing Engine Oil. . . . . . . . . . . . . . . . . . . . . 7-21
7.3 Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . 7-22
7.4 Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7.5 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7.6 Muffler/Spark Arrestor . . . . . . . . . . . . . . . . . . . 7-22
7.7 Spark Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7.8 Remove Engine . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7.9 Install Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Section 8 - Attachments . . . . . . . . . . . . . . . . . . . .8-25
8.1 Attachment Installation and Removal . . . . . . . . 8-25
8.2 Raising Attachment into Service Position . . . . 8-27
8.3 PTO Belt Replacement . . . . . . . . . . . . . . . . . . 8-29
8.4 Mower Attachment . . . . . . . . . . . . . . . . . . . . . . 8-30
Replacing Mower Blades . . . . . . . . . . . . . . . . . 8-30
Sharpening Mower Blade . . . . . . . . . . . . . . . . . 8-31
Anti-Scalp Roller Adjustment . . . . . . . . . . . . . . 8-31
Mower Belt Replacement . . . . . . . . . . . . . . . . . 8-32
Adjust Mower Deck Level and Pitch . . . . . . . . . 8-32
Adjust Blade Height. . . . . . . . . . . . . . . . . . . . . . 8-33
Section 9 - Lift System . . . . . . . . . . . . . . . . . . . . 9-35
9.1 Principles of Operation . . . . . . . . . . . . . . . . . . . 9-35
9.2 Replace Lift Cylinder . . . . . . . . . . . . . . . . . . . . 9-35
9.3 Replace Lift Arm . . . . . . . . . . . . . . . . . . . . . . . . 9-37
9.4 Replace Pivot Shaft . . . . . . . . . . . . . . . . . . . . . 9-37
9.5 Replace Limit Switch. . . . . . . . . . . . . . . . . . . . . 9-37
Section 10 - Weight Transfer System . . . . . . . . 10-38
10.1 Principles of Operation . . . . . . . . . . . . . . . . . . 10-38
10.2 Replace Weight Transfer Cylinder . . . . . . . . . 10-38
10.3 Replace Weight Transfer Bar . . . . . . . . . . . . . 10-39
10.4 Replace Lift Arm . . . . . . . . . . . . . . . . . . . . . . . 10-40
10.5 Replace Pivot Shaft. . . . . . . . . . . . . . . . . . . . . 10-40
10.6 Replace Weight Transfer Sensor . . . . . . . . . . 10-40
Section 11 - Hydraulic System . . . . . . . . . . . . . 11-41
11.1 Basic Hydraulics . . . . . . . . . . . . . . . . . . . . . . . 11-41
11.2 Hydraulic Fluid Recommendations . . . . . . . . 11-41
11.3 Checking Hydraulic Oil Level . . . . . . . . . . . . . 11-41
11.4 Changing Hydraulic Oil and Filter . . . . . . . . . 11-41
11.5 Purging Procedure . . . . . . . . . . . . . . . . . . . . . 11-42
11.6 Pump Replacement . . . . . . . . . . . . . . . . . . . . 11-42
11.7 Valve Block Replacement . . . . . . . . . . . . . . . 11-42
Section 12 - Transmission. . . . . . . . . . . . . . . . . 12-45
12.1 Principles of Operation . . . . . . . . . . . . . . . . . . 12-45
12.2 Transmission Troubleshooting Guide . . . . . . . 12-45
12.3 Transmission Belt Replacement . . . . . . . . . . . 12-48
12.4 Hydrostatic Pump Replacement . . . . . . . . . . . 12-49
Section 13 - Fuel System . . . . . . . . . . . . . . . . . 13-50
13.1 Fuel System Troubleshooting . . . . . . . . . . . . . 13-50
13.2 Fuel Recommendations . . . . . . . . . . . . . . . . . 13-52
13.3 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-52
13.4 Fuel System Contamination . . . . . . . . . . . . . . 13-52
13.5 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-52
13.6 Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . 13-52
13.7 Fuel Tank Replacement . . . . . . . . . . . . . . . . . 13-53
Section 14 - Electrical System . . . . . . . . . . . . . 14-54
14.1 Electrical System Repairs . . . . . . . . . . . . . . . 14-54
14.2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-54
14.3 Electrical Measurements . . . . . . . . . . . . . . . . 14-54
14.4 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-55
14.5 Solenoids And Relays . . . . . . . . . . . . . . . . . . 14-56
14.6 Lighting Circuits . . . . . . . . . . . . . . . . . . . . . . . 14-57
14.7 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-57
14.8 Diodes And Rectifiers . . . . . . . . . . . . . . . . . . . 14-57
14.9 Electric Clutch . . . . . . . . . . . . . . . . . . . . . . . . 14-58
14.10 Engine Electrical Components . . . . . . . . . . . . 14-58
14.11 Safety Interlock System Electrical Tests . . . . 14-58
14.12 Wiring and Circuit Diagrams . . . . . . . . . . . . . 14-62
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Service Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

2
1.1 THE MANUAL
Before operating the unit, read all manuals carefully and
completely. They will provide you with an understanding
of safety instructions and machine controls during normal
operation and maintenance.
1.2 ORIENTATION
All reference to left, right, front, or rear are given from the
viewpoint of the operator seated in the operation position
and facing the direction of forward travel.
1.3 MODEL AND SERIAL NUMBERS
You should know the Model and Serial Numbers of your
machine when you order replacement parts or make
service inquiries.
These numbers are on the product registration form in
the unit’s literature package. They are also printed on a
serial number label on the frame of the unit.
• Record Unit Model and Serial numbers here.
• Record Engine Model and Serial numbers here.
1.4 PRODUCT REGISTRATION
The dealer is responsible for registering the unit at the
time of purchase. Registering will help the company
process warranty claims or contact you with the latest
service information. All claims meeting requirements
during the limited warranty period will be honored,
whether or not the product registration card is returned.
Keep a proof of purchase if you do not register your unit.
Customer Note: If the dealer does not register your
product, please fill out, sign, and return the product
registration card to the Ariens Company.
1.5 UNAUTHORIZED REPLACEMENT
PARTS
Use only Gravely replacement parts. Replacing any part
on this unit with anything other than a Gravely authorized
replacement part may adversely affect this unit’s
performance, durability, or safety and may void the
warranty. Gravely disclaims liability for any claims or
damages, whether warranty, property damage, personal
injury, or death arising out of the use of unauthorized
replacement parts.
1.6 DELIVERY
Customer Note: If you have purchased this product
without complete assembly and instruction by your
retailer, it is your responsibility to read and
understand all assembly instructions in this manual.
If you do not understand or have difficulty following
the instructions, contact your nearest Gravely Dealer
for assistance.
To locate your nearest Gravely dealer, go to
www.gravely.com on the Internet.
Before Attempting to Operate This Unit:
1. Make sure all assembly has been properly
completed.
2. Understand all Safety Precautions provided in the
manuals.
3. Review control functions and operation of the unit.
Do not operate the unit, unless all controls function
as described in this manual.
4. Review recommended lubrication, maintenance and
adjustments.
5. Review Limited Warranty Policy.
6. Fill out a product registration card and return the card
to the Ariens Company or go to www.gravely.com.
1.7 DISCLAIMER
Gravely reserves the right to discontinue, change, and
improve its products at any time without notice or
obligation to the purchaser. The descriptions and
specifications contained in this manual were in effect at
printing. Equipment described within this manual may be
optional. Some illustrations may not be applicable to your
unit.
SECTION 1 - INTRODUCTION
Figure 1
1.Unit Serial Number Label
1

3
1.8 SERVICE POSITION
IMPORTANT: Make sure unit is secure and will not tip
over. When a lift is used, strap and clamp unit to the lift.
1. Place steering levers in neutral position and engage
the parking brake.
2. Unlatch the seat and hood latches.
3. Slowly tip the seat forward until seat cable is taut and
is supporting the weight of the seat.
4. Tip the hood back to access the engine.
1.9 MOVING UNIT MANUALLY
IMPORTANT: Never tow unit.
1. Place unit in the service position.
2. Turn right and left bypass valves counterclockwise 1/
2 turn (Figure 3).
3. Disengage parking brake.
4. Push unit to desired location.
5. Engage parking brake.
6. Turn right and left bypass valves clockwise 1/2 turn.
1.10 REAR WEIGHTS
Some procedures will require removing the rear weights.
1. Remove the two locking nuts (under the weight
bracket).
2. Remove the bolts and washers.
3. Remove the weights.
4. If necessary, remove the weight bracket by taking out
the tapping screws.
Check parts for wear or deterioration.
Assemble in reverse order.
WARNING: Personal injury can occur if
safety precautions are not followed before
and after servicing.
• Place unit on a flat surface.
• Stop engine, set parking brake, and
remove ignition key.
• Wait until all moving parts have
completely stopped before servicing
unit.
Figure 2
3
1
2
4
1. Hood
2. Hood Latch (typical) 3. Steering Levers 4. Seat Cable
WARNING: Do not bypass transmission
when unit is on a slope.
Figure 3
WARNING: Weights are heavy and can
cause crushing injuries if dropped, Grasp
weights securely. Wear steel-toed shoes.
1. Left Bypass Valve 2. Right Bypass Valve
1
2

2 - 4
2.1 SAFETY ALERT SYSTEM
These are safety alert symbols. They mean:
•ATTENTION!
• YOUR SAFETY IS INVOLVED!
When you see this symbol:
• BECOME ALERT!
• OBEY THE MESSAGE!
2.2 SIGNAL WORDS
The safety alert symbols above and signal words below
are used on decals and in this manual.
Read and understand all safety messages.
2.3 NOTATIONS
NOTE: General reference information for proper opera-
tion and maintenance practices.
IMPORTANT: Specific procedures or information
required to prevent damage to unit or attachment.
2.4 SAFETY DECALS AND LOCATIONS
Always replace missing or damaged safety decals. See
Figure 4 for safety decal locations
2.5 PRACTICES AND LAWS
Practice usual and customary safe working precautions,
for the benefit of yourself and others. Understand and
follow all safety messages. Be alert to unsafe conditions
and the possibility of minor, moderate, or serious injury or
death. Learn applicable rules and laws in your area,
including those that may restrict the age of the operator.
2.6 REQUIRED OPERATOR TRAINING
The original purchaser of this unit was instructed by the
seller on safe and proper operation. If this unit is to be
used by someone other than original purchaser (loaned,
rented or sold), ALWAYS provide this manual and any
needed safety training before operation.
2.7 EMISSION CONTROL SYSTEM
CERTIFICATION LABEL
Tampering with emission controls and components by
unauthorized personnel may result in severe fines or
penalties. Emission controls and components can only
be adjusted by EPA and/or CARB authorized service
centers. Contact your Gravely Equipment Retailer
concerning emission controls and component questions.
SECTION 2 - SAFETY
WARNING: This cutting machine can
amputate hands and feet and throw
objects. Failure to observe the safety
instructions in the manuals and on decals
could result in serious injury or death.
Slopes are a major factor related to loss-
of-control and tip-over accidents.
Operation on all slopes requires extra
caution.
Tragic accidents can occur if the operator
is not alert to the presence of children.
Never assume that children will remain
where you last saw them.
Gasoline is extremely flammable and its
vapors are explosive. Handle with care!
Disengage attachment, stop unit and
engine, remove key, engage parking
brake, and allow moving parts to stop
before leaving operator’s position.
DANGER: IMMINENTLY HAZARDOUS
SITUATION! If not avoided, WILL RESULT
in death or serious injury.
WARNING: POTENTIALLYHAZARDOUS
SITUATION! If not avoided, COULD
RESULT in death or serious injury.
CAUTION: POTENTIALLY HAZARDOUS
SITUATION! If not avoided, MAY RESULT
in minor or moderate injury. It may also be
used to alert against unsafe practices.

2 - 5
Figure 4
07757600C
05363100
07757500B
ON
OFF
UP
DOWN
ATTACHMENT
LIFT WEIGHT
TRANSFER
UP
DOWN
05363000A
A
Item Part No. Qty Decal Description Item Part No. Qty Decal Description
1 05363100 1 Service Instructions Rapid XZ 6 05363000 1 Control Panel Rapid XZ
2 07757600 1 Steering Instruction 7 07754100 2 Hot Surface
3 05231800 1 Gravely Logo 8 05363300 2 Gravely Rapid XZ Hood
4 07735200 2 Danger Decal 9 05305100 1 American Flag
5 07757500 1 Parking Brake Lever
1
3
2
4
5
6
7
8
9
Mower Shown Without Deck
PD3285

2 - 6
2.8 SAFETY RULES
Read, understand, and follow all safety practices in
Owner/Operator Manual before beginning assembly.
Failure to follow instructions could result in personal
injury and/or damage to unit.
ALWAYS remove key and wire from spark plug before
assembly. Unintentional engine start up can cause death
or serious injury.
Complete a walk around inspection of unit and work area
to understand:
• Work area • Your unit • All safety decals
Determine which attachments are needed and can be
used safely.
Inspect unit before each use for: missing or damaged
decals and shields, correctly operating safety interlock
system, and deterioration of grass catchers. Replace or
repair as needed.
ALWAYS check overhead and side clearances carefully
before operation. ALWAYS be aware of traffic when
operating along streets or curbs.
Keep children and people away.
Keep children out of work area and under watchful care
of a responsible adult.
Keep area of operation clear of all toys, pets, and debris.
Thrown objects can cause injury.
Check for weak spots on docks, ramps or floors. Avoid
uneven work areas and rough terrain. Stay alert for
hidden hazards or traffic.
DO NOT operate near drop-offs, ditches, or
embankments. Unit can suddenly turn over if a wheel is
over the edge of a cliff or ditch, or if an edge caves in.
Data indicates that operators, age 60 and above, are
involved in a larger percentage of riding mower related
injuries. These operators should evaluate their ability to
operate the riding mower safely enough to protect
themselves and others from serious injury.
Read the entire Owner/Operator manual and other
training material. If the operator or the mechanic cannot
read the manual, it is the owner’s responsibility to explain
it to them. Only the user can prevent and is responsible
for accidents or injuries occurring to themselves, other
people or property.
Only trained adults may operate or service unit. Training
includes actual operation.
Local regulations may restrict the age of the operator.
NEVER allow children to operate or play on or near unit.
Be alert and shut off unit if children enter area.
NEVER operate unit after or during the use of
medication, drugs or alcohol. Safe operation requires
your complete and unimpaired attention at all times.
DO NOT wear loose clothing or jewelry and tie back hair
that may get caught in rotating parts.
Wear adequate outer garments.
NEVER wear open sandals or canvas shoes during
operation. Wear adequate safety gear, protective gloves
and footwear.
Wear proper footwear to improve footing on slippery
surfaces.
Always wear safety goggles or safety glasses with side
shields when operating mower.
Use ear plugs to protect hearing.
Moving parts can cut or amputate fingers or a hand.
Wrap blade(s) or wear gloves to service. On multiblade
mowers, rotation of one blade will cause all blades to
rotate.
NEVER place your hands or any part of your body or
clothing inside or near any moving part while unit is
running.
ALWAYS keep hands and feet away from all rotating
parts during operation. Rotating parts can cut off body
parts.
ALWAYS keep body and hands away from pin holes or
nozzles which eject hydraulic fluid under pressure.
DO NOT touch parts which are hot. Allow parts to cool.
ALWAYS keep hands and feet away from all pinch points.
Fumes from the engine exhaust can cause death or
serious injury. DO NOT run engine in an enclosed area.
Always provide good ventilation.
Read, understand, and follow all instructions in the
manual and on the machine before starting.
Understand:
• How to operate all controls
• The functions of all controls
• How to STOP in an Emergency
• Braking and steering characteristics
• Turning radius and clearances
Keep safety devices or guards in place and functioning
properly. NEVER modify or remove safety devices.
Do not operate without either entire grass catcher or the
discharge guard in place.
Stop engine before removing grass catcher or unclogging
chute.
Ensure Safety Interlock System is functioning properly.
DO NOT operate unit if safety interlock is damaged or
disabled.
Start and operate unit only when seated in operator’s
position. Steering control levers must be in neutral, power
takeoff (PTO) disengaged and parking brake set when
starting engine.
Use care when approaching blind corners, shrubs, trees
or other objects that may obscure vision.
Dust, smoke, fog, etc. can reduce vision and cause an
accident. Mow only in daylight or good artificial light.
Avoid slippery surfaces. Always be sure of your footing.

2 - 7
DO NOT mow on wet grass. Reduced traction could
cause sliding and affect the machine’s stability.
Watch for traffic when operating near or crossing
roadways.
Never carry passengers.
DO NOT try to stabilize the machine by putting your foot
on the ground.
Never direct discharge towards persons or property that
may be injured or damaged by thrown objects. Use
extreme caution on gravel surfaces.
Always stand clear of the discharge area.
ALWAYS disengage PTO, stop unit and engine, remove
key, engage parking brake and allow moving parts to stop
before leaving operator’s position.
Never engage PTO while raising attachment or when
attachment is in raised position.
DO NOT operate at too fast a rate. DO NOT change
engine governor settings or over-speed engine. Slow
down before turning.
DO NOT operate in reverse unless absolutely necessary.
ALWAYS look down and behind before and while
backing.
Stop and inspect equipment if you strike an object or if
there is an unusual vibration. Repair, if necessary, before
restarting. Never make adjustments or repairs with the
engine running.
Mower blades are sharp and can cut you. Wrap the
blade(s) or wear gloves, and use extra caution when
servicing them. NEVER weld or straighten mower blades.
Rotation of one blade may cause rotation of the other
blades.
Take all possible precautions when leaving unit
unattended. Shut off engine. Remove wire from spark
plug and secure it away from spark plug.
ALWAYS remove key to prevent unauthorized use.
Know the weight of loads. Limit loads to those you can
safely control and the unit can safely handle.
Disengage PTO when attachment is not in use. ALWAYS
turn off power to attachment when travelling, crossing
driveways, etc.
Mow up and down slopes, not across them.
DO NOT operate on slopes of more than 17 degrees.
Use of a Rollover Protection System (ROPS) is
recommended for slope operation. See “Accessories” on
page 75.
Always wear a seat belt when operating unit using a
Rollover Protection System (ROPS).
Keep all movements on the slope slow and gradual. Do
not make sudden changes in speed or direction.
Avoid starting or stopping on the slope. If tires lose
traction, disengage the blades and proceed slowly
straight down the slope.
If you cannot back up a slope or you feel uneasy on it, do
not mow it.
DO NOT park on slopes unless necessary. When parking
on slope always chock or block wheels. Always set
parking brake.
Use a slow speed. Tires may lose traction on slopes even
though the brakes are functioning properly.
Do not bypass transmission when on a slope.
Tow only with a machine that has a hitch designed for
towing. Do not attach towed equipment except at the
hitch point.
Follow the manufacturer’s recommendations for weight
limits for towed equipment and towing on slopes.
NEVER allow children or others in or on towed
equipment.
On slopes, the weight of the towed equipment may cause
loss of control. Travel slowly and allow extra distance to
stop.
Use extra care when loading or unloading unit onto trailer
or truck.
Secure unit chassis to transport vehicle. NEVER secure
from rods or linkages that could be damaged.
DO NOT transport machine while engine is running.
ALWAYS turn off power to attachment when transporting
unit.
Keep unit free of debris. Clean up oil or fuel spills.
This product is equipped with an internal combustion
type engine. DO NOT use unit on or near any
unimproved, forest-covered or brush covered land unless
exhaust system is equipped with a spark arrester
meeting applicable local, state or federal laws. A spark
arrester, if it is used, must be maintained in effective
working order by operator.
Fuel is highly flammable and its vapors are explosive.
Handle with care. Use an approved fuel container.
NO smoking, NO sparks, NO flames. ALWAYS allow
engine to cool before servicing.
NEVER fill fuel tank when engine is running or hot from
operation.
NEVER fill or drain fuel tank indoors.
Replace fuel cap securely and clean up spilled fuel.
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 gas-powered equipment from
the truck or trailer and refuel it on the ground. If this is not
possible, then refuel such equipment on a trailer with a
portable container, rather than from a gasoline dispenser
nozzle.
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.

2 - 8
If fuel is spilled on clothing, change clothing immediately.
Avoid Electric Shock. Objects contacting both battery
terminals at the same time may result in injury and unit
damage. DO NOT reverse battery connections.
Reverse connections may result in sparks which can
cause serious injury. Always connect positive (+) lead of
charger to positive (+) terminal, and negative (-) lead to
negative (-) terminal.
ALWAYS disconnect negative (-) cable FIRST and
positive (+) cable SECOND. ALWAYS connect positive
(+) cable FIRST, and negative (-) cable SECOND.
Explosive gases from battery can cause death or serious
injury. Poisonous battery fluid contains sulfuric acid and
its contact with skin, eyes or clothing can cause severe
chemical burns.
No flames, No sparks, No smoking near battery.
ALWAYS wear safety glasses and protective gear near
battery. Use insulated tools.
DO NOT TIP battery beyond a 45° angle in any direction.
ALWAYS keep batteries out of reach of children.
Battery posts, terminals and related accessories contain
lead and lead compounds, chemicals known to the State
of California to cause cancer and reproductive harm.
Wash hands after handling.
ALWAYS block wheels and know all jack stands are
strong and secure and will hold weight of unit during
maintenance.
Release pressure slowly from components with stored
energy.
NEVER attempt to make any adjustments to unit while
engine is running (except where specifically
recommended). Stop engine, remove key or spark plug
wires and wait for all moving parts to stop before
servicing or cleaning.
Check parking brake operation frequently. Adjust and
service as required.
ALWAYS maintain unit in safe operating condition.
Damaged or worn out muffler can cause fire or explosion.
Maintain or replace safety and instruction labels, as
necessary.
NEVER store unit with fuel in fuel tank, inside a building
where any ignition sources are present.
Shut off fuel and allow engine to cool completely before
storing in closed area or covering unit.
Clean grass and debris from unit, especially from around
muffler and engine, to help prevent fires.
For extended storage, lubricate and clean the unit
thoroughly. See engine manual for additional storage
requirements.
Lower cutting deck unless a positive mechanical lock is
used.
Use only attachments or accessories designed for your
unit.
Check all hardware at regular intervals, especially blade
attachment bolts. Keep all hardware properly tightened.
Check attachment components frequently. If worn or
damaged, replace with manufacturer’s recommended
parts.

3 - 9
SECTION 3 - SPECIFICATIONS
Model Number 990100 990102
Model Rapid XZ Rapid XZ
Engine Kohler Kohler
Engine Model Number CH740S CH750S
Engine Power – hp (kW) at Maximum RPM 27 (20.1) 30 (22.3)
Governed RPM (May be different from maximum RPM) 3750 ±50 3750 ±50
Cooling Air Cooled Air Cooled
Speed
Forward Max. – m.p.h (km/h) 13.0 (20.8) 13.0 (20.8)
Reverse Max. – m.p.h (km/h) 6.0 (9.6) 6.0 (9.6)
Turning Radius Zero Zero
Brakes Hydro/Dynamic Drum Parking
Electrical
Starter Electric Electric
Battery 12V Maintenance Free 12V Maintenance Free
PTO (Power Take-Off) ElectricPTO Clutch/Brake ElectricPTOClutch/Brake
Fuel
Fuel Type Refer to Engine Manual Refer to Engine Manual
Fuel Tank Capacity – gal. (L) 7.5 (28.4) 7.5 (28.4)
Transmission Hydrostatic Drive Hydrostatic Drive
Transmission Oil Mobil 1 Extended Performance 15w50 Synthetic
Hydraulic System Capacity 6.5 (6.2) 6.5 (6.2)
Hydraulic Oil Filter Yes Yes
Size and Weight
Length (without attachments) – in. (cm) 75.4 (192.0) 75.4 (192.0)
Width (without attachments) – in. (cm) 48.0 (122.0) 48.0 (122.0)
Height (seat back) – in. (cm) 45.6 (116.0) 45.6 (116.0)
Height with rollover protection system (ROPS) – in. (cm)
Extended
Folded 70.9 (180.0) 53.7 (136.4) 70.9 (180.0) 53.7 (136.4)
Weight – lb (kg) 1650 (750) 1650 (750)
Tires
Front Tire Size – in. (cm) Turf 24-12 x 12 BAR 24-12 x 12
Rear Tire Size – in. (cm) 5.25 x 13 5.25 x 13
Front Tire Pressure – psi (kPa) 12 – 15 (83 – 103) 12 – 15 (83 – 103)
Rear Tire Pressure – psi (kPa) 20 – 25 (138 – 172 20 – 25 (138 – 172

4 - 10
1. Lift Arm Up/Down Switch
2. Weight Transfer On/Off Switch
3. Attachment Lift Switch
4. Ignition Switch
5. PTO (Power Take-Off) Switch
6. Throttle Lever
7. Parking Brake Lever
8. Steering Levers
9. Fuel Tank
10.Seat Suspension Adjustment Knob
11.Seat Adjustment Lever
12.Lower Plated Lock Latch
13.Front Attachment Lock Latch
14.Footrest
15.Attachment Drive Cover
16.Attachment Lift Arms
17.Tie-Down Lugs
18.Counterweights
19.Hood
20.Choke Control
21.Oil Pressure Light
22.Hour Meter
SECTION 4 - CONTROLS AND FEATURES
Figure 5
OF4115
7
9
10
12
8
19
17
18
11
15
13
16
14
13
12
Unit Shown with 60 in.
Mower Deck Attachment Installed
6
13
22
4
21
2
20
5
092906

5 - 11
Proper maintenance can prolong the life of the unit. The
following chart shows the recommended service
schedule.
The intervals listed in this chart are for average operating
conditions. Severe operating conditions such as heavy
loads, high ambient temperatures, dusty conditions, or
airborne debris may require more frequent service.
Follow the intervals given in this Lubrication Guide until
experience dictates establishing intervals appropriate for
your operating conditions.
See the maintenance instructions in the Engine Manual
for information about maintaining the engine.
5.1 MAINTENANCE SCHEDULE
SECTION 5 - MAINTENANCE
WARNING: Personal injury can occur if
safety precautions are not followed before
and after servicing.
• Stop engine and wait until all moving
parts have completely stopped before
servicing unit.
• Do not operate unit until all safety
guards and covers have been
securely reinstalled and all
maintenance equipment has been
removed.
Interval Task Action
Each Use Check Safety Interlock System WARNING: Safety interlock system failure and improper
operation of unit can result in death or serious injury.
Test this system each time the unit is operated. If this system
does not function as described, do not operate unit until system
is repaired. See “” on page 58.
Check Parking Brake Engage parking brake. Push unit. If unit rolls, adjust parking
brake. See “Parking Brake Adjustment” on page 16.
Check Hydraulic Oil Level See “Checking Hydraulic Oil Level” on page 41.
Check Tires Examine for excessive wear, cuts, and flaws. Check tire
pressure. See “Specifications” on page 9 for correct tire
pressure.
Clean Unit Clean engine, battery, seat, attachments, etc. of dirt and debris.
Do not use solvents, hard cleaners, or abrasives.
IMPORTANT: Clean all grass, dirt, and debris from the
attachment drive shaft and the unit’s PTO shaft after each use.
NOTE: Protect painted surfaces with automotive wax.
Follow Engine Maintenance Schedule Perform scheduled engine maintenance. Refer to Engine
Manual for instructions.
Check Attachment Fasteners Make sure all hardware is tightenedto proper torque, especially
guards and shields. Check mower blades if applicable.
Lubricate Attachment Apply grease to lube fittings, wheel bearings, caster pivots, etc.
Apply oil to pin connections, pivot points and sliding parts.
Every 25
Hours Service Air Cleaning System Precleaner See Engine Manual for instructions.
Check Mower Blades (if applicable) Make sure mower blade hardware is tightened to 115–125
lbf-ft (156 to 159 N·m). Check blades for wear. Sharpen
or replace if necessary (see "Sharpening Mower Blade" on
page 31).

5 - 12
Every 50
Hours Lubricate Rear Axle and Pivot Points Apply grease to rear axle grease zerk. See “Lubricating Unit” on page 13. Grease drive shaft spline, drive shaft (zerk), and U-
joint (zerk)
Oil all pivot points and pin connections.
Every 100
Hours Clean Battery Keep battery and battery terminals clean. See “Cleaning the Battery” on page 14.
Change Engine Oil See “Changing Engine Oil” on page 21.
Service Engine Cooling System See Engine Manual for instructions.
Replace Air Cleaner Element See Engine Manual for instructions.
Check Fasteners Check mower blade mounting hardware and all other fasteners.
Replace missing or damaged fasteners. Tighten all nuts and
bolts to the correct torque value.
Check All Belts Check PTO belt. Replace if worn or deteriorated. See “PTO Belt
Replacement” on page 29.
Check transmission belt. Replace if worn or deteriorated. See
“Transmission Belt Replacement” on page 48.
Check attachment belts if applicable. See "Mower Belt
Replacement" on page 31 for mower attachment belts.
Every 200
Hours Change Oil Filter See “Changing Oil Filter” on page 22
Check Mower Gear Box Oil Level if
applicable Add SAE 90 oil as needed.
Every 400
Hours Repack Front and Rear Axle Pivots See “Lubricating Unit” on page 13.
Every 500
Hours Change Hydraulic Oil and Filter See Changing Hydraulic Oil on page 22
Interval Task Action

5 - 13
5.2 LUBRICATING UNIT
IMPORTANT: Wipe rear axle grease zerk and two front
axle pivots clean before and after lubrication.
NOTE: Use Ariens Hi-Temp Grease or equivalent (Part
No. 00036700).
5.3 CHECKING ENGINE OIL
The importance of checking and maintaining the proper
oil level in the crankcase cannot be overemphasized.
Check oil BEFORE EACH USE.
1. Make sure the engine is stopped, level, and is cool
so the oil has had time to drain into the sump.
2. To keep dirt, debris, etc., out of the engine, clean the
area around the dipstick before removing it.
3. Remove the dipstick; wipe oil off. Reinsert the
dipstick into the tube and press all the way down.
4. Remove the dipstick and check the oil level.
The oil level should be up to, but not over, the “F”
mark on the dipstick.
5.4 CHECKING MOWER GEARBOX OIL
Check the mower gearbox oil level once a year or every
200 hours of operation.
Check the level by parking the unit on a flat, level
surface. Remove the oil plug on the side of the gearbox
(accessible through the service hole underneath the
deck).
If no oil runs out, add SAE 90 oil until oil seeps from the
plug hole, and then replace the oil plug.
5.5 SERVICING THE BATTERY
NOTE: Unit comes equipped with a maintenance-free
battery that requires no regular maintenance except
cleaning the terminals.
Figure 6
Item Lubrication Location Interval
1 Repack Rear Axle Caster
Pivot 400 Hours
2 Grease Rear Axle Grease
Zerk 50 Hours
Oil All Pivot Points
and Pin
Connections
50
Hours
Figure 7
WARNING: AVOID INJURY! Read and
understand the entire Safety section
before proceeding.
WARNING: Battery posts, terminals, and
related accessories contain lead and lead
compounds, chemicals known to the State
of California to cause cancer and
reproductive harm. Wash hands after
handling.
View underneath
deck to the rear.
1
2
1. Oil Fill Plug 2. Service Opening

5 - 14
Battery Removal and Installation.
Remove Battery
1. Place unit in the service position (see “Service
Position” on page 3).
2. Disconnect negative (–) cable first, then positive (+)
cable (Figure 8).
3. Remove battery hold-down bracket and battery from
unit.
Install Battery
1. Install battery on unit with battery hold-down bracket.
2. Connect positive (+) cable first, then negative (–)
cable (Figure 8).
3. Coat terminals with dielectric grease or petroleum
jelly.
4. Close hood (see “Service Position” on page 3).
Cleaning the Battery
See Figure 8.
1. Disconnect negative (–) cable first, then positive (+)
cable.
2. Clean battery cable ends and terminals with wire
brush. Rinse with a weak baking soda solution.
3. Connect positive (+) cable first, then negative (–)
cable.
4. Coat terminals with dielectric grease or petroleum
jelly.
Charging the Battery
Follow First Aid directions for contact with battery fluid.
•External Contact: Flush with water.
•Eyes: Flush with water for at least 15 minutes and
get medical attention immediately!
•Internal Contact: Drink large quantities of water.
Follow with Milk of Magnesia, beaten egg or
vegetable oil. Get medical attention immediately!
• In case of internal contact, DO NOT induce vomiting!
IMPORTANT: DO NOT fast charge. Charging at a higher
rate will damage or destroy battery. ALWAYS follow
information provided on battery and battery charger.
Contact battery manufacturer and battery charger
manufacturer for detailed instructions.
1. Remove battery from unit (see “Battery Removal and
Installation.” on page 14).
2. Place battery on bench or other well-ventilated area.
3. Connect positive (+) lead of charger to positive (+)
terminal, and negative (–) lead to negative (–)
terminal (Figure 8).
4. Charge battery according to the instructions from
battery charger manufacturer and battery
manufacturer.
5. Install battery on unit (see “Battery Removal and
Installation.” on page 14).
Jump-Starting
Gravely does not recommend jump-starting the engine.
Jump-starting can damage engine and electrical system
components. See Engine Manual for more detailed
information.
Figure 8
1Battery
2 Negative (–) Terminal
3 Negative (–) Cable
4 Positive (+) Terminal
5 Positive (+) Cable
1
2
3
4
5
WARNING: FROZEN BATTERIES CAN
EXPLODE and result in death or serious
injury. DO NOT charge a frozen battery. Let
battery thaw before charging.

6 - 15
6.1 ADJUSTING UNIT TO TRACK STRAIGHT
Check and adjust tire pressure. Increase pressure on the
side to which the unit tracks. DO NOT exceed maximum
recommended tire pressure. See “Specifications” on
page 9 for correct tire pressure.
If adjusting the tire pressure does not solve the tracking
problem, adjust the limiter bolts on the stop bracket
(Figure 9). Front bolts adjust forward and rear bolts
adjust reverse. Lengthen the limiter bolt (move closer to
lever) on side which is too fast.
6.2 STEERING CONTROL NEUTRAL
ADJUSTMENT
If the steering levers do not line up (match) or the unit
has excessive creeping when the steering levers are in
neutral, adjust as follows.
Adjusting the Steering Levers to Line Up
(Match)
See Figure 10.
NOTE: The left side steering lever has no alignment
adjustment. Adjust the right steering lever to align the
steering levers.
1. Shut off engine. Engage parking brake. Remove the
ignition key.
2. Place unit in the service position (see “Service
Position” on page 3).
3. Loosen the three nuts holding the right steering lever
flange bushing to the unit frame.
4. Pivot the flange bushing until the right and left
steering levers align and then tighten the three bolts.
5. Check and adjust tracking (see “Adjusting Unit to
Track Straight“).
Eliminating Excessive Unit Creeping
See Figure 11.
1. If hydraulic system is cold, run unit for a minimum of
five minutes, then shut off engine.
SECTION 6 - ADJUSTMENTS
WARNING: Before adjusting tracking,
shut off engine, engage parking brake,
and remove ignition key.
Figure 9
1. Limiter
Bolt 2. Jam
Nut
3. Steering Lever
12
3
1
4
2
2
Figure 10
WARNING: This adjustment requires
operating the engine and opening the
hood.
• Be sure the unit is well-supported and
secure before starting the engine.
• Use extreme care to avoid contact
with moving parts and hot surfaces.
1. Right Steering Lever
Flange Bushing 2. Nuts
3. Right Steering Lever
1
2
Pivot flange bearing
on this axis.
3
OF3570

6 - 16
2. With the unit up to and facing a wall, jack the unit up
so that both drive wheels are off the ground.
3. Start the engine and release the parking brake.
4. Move the steering levers back and forth (from
forward to reverse) several times to make sure
controls are free. Then return steering levers to
neutral position.
NOTE: To find the neutral position, pull the steering
levers back to reverse, and then release them. The
levers will return to the neutral position.
5. Check wheel(s) for movement.
6. Shut off engine.
NOTE: The right and left steering levers are adjusted the
same way. To access the tie-rod, place unit in the service
position and engage the parking brake.
7. Adjust tie-rod(s):
a.Loosen the jam nut on each end of the tie-rod.
b. Start the engine.
c. Turn the tie-rod clockwise or counterclockwise
until the wheel does not move when the steering
levers are in neutral.
d. Move steering levers from forward to reverse
several times. Then return steering levers to
neutral position.
e. Shut off engine.
f. If wheel is not moving, tighten jam nuts on tie-rod.
The adjustment is complete.
8. If wheel is still moving, repeat step 7.
NOTE: If this tie-rod adjustment cannot set the steering
levers to neutral, the pump(s) need to be adjusted. Take
the unit to your Gravely Dealer for service or repair.
6.3 STEERING LEVER HEIGHT
ADJUSTMENT
The handles have three height positions ((Figure 12).
1. Remove spacer, handle, and eccentric spacer from
steering lever.
NOTE: Position the right and left handles at the same
height.
2. Install spacer, handle, and eccentric spacer in the
appropriate height position. Do not tighten nut
holding eccentric spacer.
3. Turn eccentric spacer until the right and left handles
are the same height. Tighten nut.
6.4 PARKING BRAKE ADJUSTMENT
The parking brake may need adjustment over time or
after new brake assemblies have been installed.
NOTE: After installing new brake assemblies, burnish the
pads by driving for a short distance (about 100 feet) with
the brake on. To do this, bring parking brake lever part-
way up while driving normally in a straight line.
See Figure 13.
IMPORTANT: When adjusting the parking brake, be sure
to check the parking brake on both sides of unit. Measure
the length of the spring between the washers above the
trunnion. The spring length should be 1-5/8 in. (41 mm).
Figure 11
1. Jam Nut 2. Tie-Rod
2
1
12
OF4155
Figure 12
Position 1
Position 2
Position 3
3
1
2
1. Eccentric Spacer
2. Handle
3. Steering Lever
OF3570

6 - 17
Adjusting the Parking Brake
NOTE: Steering levers must be in neutral to engage the
parking brake. Removing the wheel will make the adjust-
ment easier.
1. Engage the parking brake.
2. Turn the upper return nuts clockwise or
counterclockwise until the spring compresses or
extends to 1-5/8 in. (41 mm) when measured
between the two washers.
The wheel hub will turn slightly when the parking
brake is disengaged and the spring is set to the
correct length.
3. Disengage the parking brake.
4. Turn the lower return nut clockwise or
counterclockwise until there is 1/16–1/8 in. (1.59–
3.18 mm) between return nut and trunnion.
5. Tighten the jam nuts to hold the adjustment.
6.5 PARKING BRAKE INTERLOCK
ADJUSTMENT
The parking brake interlock needs adjustment:
• When engaging the parking brake does not lock the
steering levers in neutral,
• When the hydraulic pumps have been readjusted for
neutral.
1. Set the steering levers in neutral and engage the
parking brake.
2. Disconnect the interlock link rod from the parking
brake cross-shaft.
3. Turn the threaded rod to secure the lock lever on the
steering lever.
4. Connect the interlock link rod to the parking brake
cross-shaft with a cotter pin.
5. Engage and disengage the parking brake to check
the adjustment.
6. Repeat steps 2 – 5 until the parking brake interlock
engages and disengages properly. The steering
levers will lock solidly.
WARNING: ALWAYS block wheels.Be sure
all jack stands are strong and secure and will
hold weight of unit during maintenance.
Figure 13
6. Parking Brake Lever
7. Brake Rod
8. Lower Return Nut
9. Trunnion
10. Spring
11. Jam Nuts
12. Brake Arm
13. Front Washer
6
7
8
11
9
10
11 1-5/8 in. (41 mm)
12
13
1/16 – 1/8-in.
(1.59 – 3.18 mm)
OF4145
Wheel Removed for Clarity
Figure 14
1. Parking Brake Cross
Shaft
2. Interlock Lock Lever
3. Steering Lever
4. Trunnion
5. Interlock Link Rod
123
4
5
OF4105

7 - 18
Refer to the Engine Manual for specific instructions about
engine service and maintenance, oil spcifications, oil filter
part numbers, and other information.
Refer engine servicing and repair to the engine
manufacturer’s local service center. It has the service
information and parts available to properly service the
engine.
NOTE: Gravely dealers should be able to test engines
and engine components to pinpoint troubles and narrow
them down to properly advise the engine service techni-
cian.
7.1 ENGINE TROUBLESHOOTING
The following troubleshooting chart is to be used to
isolate engine problems and give possible causes and
corrective action responses.
The troubleshooting guide is generic and can be used for
several types of engines. Use only those possible causes
and corrective actions that apply to the engine supplied.
SECTION 7 - ENGINE
ENGINE TROUBLESHOOTING
PROBLEM PROBABLE CAUSE CORRECTION
Black Exhaust Restriction in air cleaner Remove obstruction
Poor compression Repair per instructions in manufacturer’s manual
Blocked fuel tank vent Remove obstruction
Incorrect grade of fuel Use fuel recommended in manufacturer’s manual
Leaking cylinder head gasket Replace per instructions in manufacturer’s manual
Sticking valves Repair per instructions in manufacturer’s manual
Worn cylinder bores Repair per instructions in manufacturer’s manual
Broken, worn, or sticking piston rings Repair per instructions in manufacturer’s manual
Blue/White Exhaust Incorrect grade of lubricating oil Use oil recommended in manufacturer’s manual
Poor compression Repair per instructions in manufacturer’s manual
Leaking cylinder head gasket Replace per instructions in manufacturer’s manual
Worn cylinder bores Repair per instructions in manufacturer’s manual
Worn valve stem guides Repair per instructions in manufacturer’s manual
Broken, worn, or sticking piston rings Repair per instructions in manufacturer’s manual
Difficult Starting Restriction in air cleaner Remove obstruction
Low cranking speed Check battery (see “Servicing the Battery” on page 13)
Check electrical system (see “Electrical System” on
page 54)
Cold engine oil Warm engine oil or disconnect transmission drive belt to
increase cranking speed
Controls not in correct operating position Reset controls (see (see "" on page 58)
Blocked fuel feed line Remove obstruction
Faulty fuel lift pump Replace pump
Choked fuel filter Clean or replace filter
Poor compression Repair per instructions in manufacturer’s manual
Blocked fuel tank vent Remove obstruction
Incorrect grade of fuel Use fuel recommended in manufacturer’s manual
Sticking valves Repair per instructions in manufacturer’s manual
Worn cylinder bores Repair per instructions in manufacturer’s manual
Pitted valve stems and seats Repair per instructions in manufacturer’s manual
Broken, worn, or sticking piston rings Repair per instructions in manufacturer’s manual
Engine Cranks But Does
Not Start Fuel tank empty Fill fuel tank
Defective spark plug Replace spark plug (refer to Engine Manual)
Plugged or dirty air cleaner Clean or replace air cleaner (refer to Engine Manual)
Plugged or dirty fuel filter Clean or replace fuel filter (refer to Engine Manual)

7 - 19
Engine Cranks But Does
Not Start (cont.) Defective fuel pump Replace fuel pump (refer to Engine Manual)
Faulty engine Repair or replace engine (refer to Engine Manual)
Engine Does Not Crank PTO engaged Disengage PTO
Parking brake disengaged Engage parking brake
Loose or corroded battery cables Clean and tighten battery cables (see "Servicing
the Battery" on page 13)
Discharged battery Charge battery (see "Charging the Battery" on
page 14)
Defective starter Replace starter
Erratic Running Restriction in air cleaner Remove obstruction
Controls not in correct operating position Reset controls (see "" on page 58)
Blocked fuel feed line Remove obstruction
Faulty fuel lift pump Replace pump
Choked fuel filter Clean or replace filter
Poor compression Repair per instructions in manufacturer’s manual
Blocked fuel tank vent Remove obstruction
Sticking throttle/restricted movement Lubricate or replace
Overheating Allow to cool; determine cause (see "Overheating" on
page 20)
Sticking valves Repair per instructions in manufacturer’s manual
Broken, worn, or sticking piston rings Repair per instructions in manufacturer’s manual
Restriction in air cleaner Remove obstruction
Excessive Fuel
Consumption Restriction in air cleaner Remove obstruction
Poor compression Repair per instructions in manufacturer’s manual
Blocked fuel tank vent Remove obstruction
Sticking throttle/restricted movement Lubricate or replace
Leaking cylinder head gasket Replace per instructions in manufacturer’s manual
Sticking valves Repair per instructions in manufacturer’s manual
Worn cylinder bores Repair per instructions in manufacturer’s manual
Pitted valve stems and seats Repair per instructions in manufacturer’s manual
Broken, worn, or sticking piston rings Repair per instructions in manufacturer’s manual
Excessive Crankcase
Pressure Leaking cylinder head gasket Replace per instructions in manufacturer’s manual
Worn cylinder bores Repair per instructions in manufacturer’s manual
Broken, worn, or sticking piston rings Repair per instructions in manufacturer’s manual
Pitted valve stems and seats Repair per instructions in manufacturer’s manual
Worn valve stems or guides Repair per instructions in manufacturer’s manual
Bad solenoid switch Replace switch
Choked breather pipe Remove obstruction
High Oil Pressure Incorrect grade of lubricating oil Use oil recommended in manufacturer’s manual
Pressure relief valve sticking closed Repair or replace spring
Ignition Off But Engine
Continues To Run Defective ignition switch Replace switch
Ignition ground wire disconnected Connect ground wire to clean metal surface
ENGINE TROUBLESHOOTING
PROBLEM PROBABLE CAUSE CORRECTION