Husqvarna M105-85F Instruction manual

Workshop Manual
English
M 105/125-85F
G 125-85F

Contents
CONTENTS
Contents ....................................................................... 2
SAFETY INSTRUCTIONS
General Instructions....................................................... 3
Special Instructions ....................................................... 3
TECHNICAL DATA
Technical Data ............................................................... 4
MAINTENANCE
Maintenance Schedule .................................................. 5
DESIGN AND FUNCTION
General ......................................................................... 6
Serial Number ............................................................... 6
Engine ........................................................................... 6
Steering ........................................................................ 6
Drive Unit ...................................................................... 6
Cutting Deck ................................................................. 7
REPAIR INSTRUCTIONS
Dismantling the Engine.................................................. 8
Assembling the Engine .................................................. 9
Fuel Tank ....................................................................... 9
Changing the Engine Oil ................................................ 10
Checking and Adjusting the Steering Cable................... 11
Replacing the Steering Cable ........................................ 11
Assembling the Steering Shaft....................................... 12
Dismantling/Assembling the Cable Pulley...................... 12
Checking and Adjusting the Brake ................................. 13
Adjusting the Throttle Cable........................................... 13
Dismantling the Swing Axle............................................ 14
Dismantling/Assembling the Drive Chain ....................... 14
Adjusting the Drive Chain............................................... 14
Dismantling the Gearbox ............................................... 14
Dismantling/Assembling the Hydrostatic Transmission .. 15
Replacing the Belts........................................................ 16
Checking and Adjusting the Cutting Deck Ground Pressure 16
Removing the Cutting Deck ........................................... 16
ELECTRICAL SYSTEM
Checking the Safety System .......................................... 18
Seat Microswitch............................................................ 18
Blades Microswitch ........................................................ 18
Parking Brake Microswitch............................................. 18
Pedal Microswitch .......................................................... 18
Main Fuse...................................................................... 18
Troubleshooting Schedule
Troubleshooting Schedule ............................................. 19
Electrical schedulec 20
CONTENTS
2 – English

General Instructions
This workshop manual is written for personnel with a general
knowledge of repairing and servicing ride-on mowers.
The workshop where the ride-on mower is to be repaired
must be equipped with safety devices in accordance with
local bylaws.
No one may repair the ride-on mower without first reading
and understanding the content of this workshop manual.
The machine is tested and approved only with the equipment
originally provided or recommended by the manufacturer.
This workshop manual contains the following warning boxes
in relevant places.
WARNING! The warning box warns of the
risk of personal injury if the instructions are
not followed.
IMPORTANT!
This box warns of material damage if the instructions are
not followed.
Special Instructions
The fuel used in the ride-on mower has the following
hazardous properties:
• The fluid and its vapor are toxic.
• Can cause eye and skin irritation.
• Can cause breathing problems.
• Is highly flammable.
When using compressed air, do not direct the jet toward your
body. Air can penetrate into the blood circulation, which can
be fatal.
Use eye protection when working with tensioned springs.
Use hearing protection during testing.
During testing, do not touch the muffler before it has cooled
down. Risk of burns.This is especially true if the ride-on
mower is equipped with a catalytic converter. The coatings on
and in the catalytic converter element are hazardous to
ingest. Use protective gloves when working with the
converter/muffler.
The blades are sharp and can cause cuts and gashes. Use
protective gloves when handling the blades.
Use eye protection when working with the cutting unit.The
belt tensioning spring can break, fly off and could cause
personal injury.
Use eye protection when working with the battery with the
plugs removed. Be especially careful when handling battery
acid. Acid on the skin can cause serious corrosive injuries. In
the event of spillage on the skin, wash immediately with
water. Acid in the eyes can cause blindness; contact a doctor
immediately.
Be careful when servicing the battery. Explosive gases form
in the battery. Never perform maintenance on the battery
while smoking or in the vicinity of open flames or sparks.This
can cause the battery to explode and cause serious injuries.
IMPORTANT!
Waste oil and used oil filters shall be handled as
environmentally hazardous waste.
SAFETY INSTRUCTIONS
English – 3

Technical Data
M125-85F M125-85FH G125-85F
Dimensions
Length without cutting deck, mm/ft 1446 / 4.74 1446 / 4.74 1446 / 4.74
Length with cutting deck, mm/ft 2057.5 / 6.75 2057.5 / 6.75 2057.5 / 6.75
Width without cutting deck, mm/ft 805 / 2.56 805 / 2.56 805 / 2.56
Width with cutting deck, mm/ft 883 / 2,90 883 / 2,90 883 / 2,90
Height, mm/ft 1065 / 3.49 1065 / 3.49 1075 / 3,53
Operating weight with cutting deck, kg/lb 190 / 419 190 / 419 190 / 419
Wheelbase, mm/ft 799 / 2.62 799 / 2.62 799 / 2.62
Tire size, front 16 x 6.00 - 10 16 x 6.00 - 10 16 x 7.50 - 8
Tire size, back 13 x 5.00 - 8 13 x 5.00 - 8 13 x 5.00 - 8
Air pressure front - rear, kPa/bar/PSI 100 / 1.0 /14.5 100 / 1.0 /14.5 80 / 0.8 / 11.6
Engine
Brand/Model Briggs & Stratton/3125 Briggs & Stratton/3125 Briggs & Stratton/3125
Nominal engine output, kW (see note 1) 6.5 6.5 6.5
Stroke, cm3/cu.in 344 / 21 344 / 21 344 / 21
Max. engine speed, rpm 2900 ± 100 2900 ± 100 2900 ± 100
Fuel, minimum octane rating unleaded 85 85 85
Fuel tank capacity, liters 3.3 3.3 3.3
Oil, grade SJ-CF SAE 5W/30 or SAE
10W/30
SAE 5W/30 or SAE
10W/30
SAE 5W/30 or SAE
10W/30
Oil tank capacity, liters/USqt 1.4 / 1.5 1.4 / 1.5 1.4 / 1.5
Start Electric starter Electric starter Electric starter
Electrical System
Type 12 V, negative grounded 12 V, negative grounded 12 V, negative grounded
Battery 12 V, 18 Ah 12 V, 18 Ah 12 V, 18 Ah
Spark plug Champion QC12YC Champion QC12YC Champion QC12YC
Electrode gap, mm/inch 0.75 / 0.030 0.75 / 0.030 0.75 / 0.030
Main fuse Flat pin, 15 A. Flat pin, 15 A. Flat pin, 15 A
Noise Emissions and Cutting Width (see note 2)
Sound power level, measured dB(A) 98 99 98
Sound power level, guaranteed dB(A) 99 99 99
Cutting width, cm/inch 85 / 33,5 85 / 33,5 85 / 33,5
Noise Levels (see note 3)
Noise pressure level at the operator's ear, dB(A) 84 85 84
Vibration Levels (see note 4)
Vibration level in steering wheel, m/s2. 4.3 4,3 4.3
Vibration level in seat, m/s21.3 1.3 1.3
Transmission
Manufacturer Topec T7000 Tuff Torq T36N Topec T7000
Oil, grade SF-CC SAE 80W/90 SAE 10W/30 SAE 80W/90
Number of forward gears 3 - 3
Number of reverse gears 1 - 1
Forward speed, km/h 0-8 0-7.5 0-8
Reverse speed, km/h 0-4 0-7.5 0-4
Cutting Deck
Type Mulching unit Mulching unit Mulching unit
Cutting heights, 5 positions, mm/inch 25-70 / 1-2 3/4 25-70 / 1-2 3/4 25-70 / 1-2 3/4
Blade diameter, mm/inch 430 / 17 430 / 17 430 / 17
Note. 1: The power rating of the engine is the average net output (at the specified rpm) of a typical production engine of the model, measured to SAE standard J1349/
ISO1585. Mass production engines may differ from this value. Actual power output for the engine installed on the final machine will depend on the operating speed,
environmental conditions and other values.
Note. 2: Noise emissions in the environment measured as noise power (LWA) in conformity with EC directive 2000/14/EC.
Note. 3: Noise pressure level according to EN 836. Reported data for the noise pressure level has a typical dispersion (standard deviation) of 1.2 dB(A).
Note 4: Vibration level according to EN 836. Reported data for the vibration level has a typical dispersion (standard deviation) of 0.2 m/s2(steering wheel) and 0.8 m/s2
(seat).
TECHNICAL DATA
4 – English

Maintenance Schedule
The following is a list of maintenance procedures that must be performed on the ride-on mower. For points not described in this
workshop manual, refer to the operator’s manual.
Maintenance Daily maintenance
before starting
At least once
a year Maintenance interval in hours
25 50 100 200
Cleaning t
Check engine oil level t
Check the engine cooling air intake t
Check the steering wires l
Check the brakes l
Check the battery t
Lubricate the drive chain, manual gearbox. t
Check the safety system l
Check nuts and screws m
Check for fuel and oil leakages m
Clean around the muffler m
Change engine oil 1)l l
Change the air filter 2)t
Check the cutting deck t
Check the air pressure in the tires t
Lubricate joints and shafts 3)t
Check the V-belts l
Check and adjust the throttle cable l
Change the fuel filter m
Change the spark plug t
Check the fuel hose. Change if necessary 4)m
1)First change after 8 hours.When operating with a heavy load or at high ambient temperatures, change every 25 hours. 2)
Maintenance and changes are required more often in dusty conditions. 3)The ride-on mower should be lubricated twice a week
when used on a daily basis. 4)Performed by an authorized servicing dealer.
l= Described in this workshop manual
m= Not described in this workshop manual
t= Described in the operator’s manual
WARNING! Service procedures must not be conducted on
the engine or cutting deck unless:
The engine has been stopped.
The ignition key has been removed.
The ignition cable has been removed from the spark plug.
The parking brake is engaged.
The cutting deck is disengaged.
MAINTENANCE
English – 5

1 Service tools
The following special tools are used when working on the rider: Special tools for engine and transmission can be
found in the respective workshop manual.
1Battery charger (EU) 580 35 52-01
1Battery charger (UK) 580 35 52-02
2Tachometer 502 71 14-01
1
2

General
This manual covers the M105-85F , M125-85FH and G125-85F
mowers.They have front-mounted cutting decks for controlled
mowing and the best possible cutting results.
This riders have mulching units with rear discharge option.
M105-97F and M125-97FH can also be equipped with various
accessories such as a lawn rake and spreader.
M105-95F and G105-85F is delivered with a manual gearbox.
M125-95FH is only delivered with hydrostatic transmission.
Serial Number
The machine's serial number can be found on the printed
plate attached to the right side under the seat. Stated on the
plate, from the top, are:
• The machine's type designation.
• Manufacturer's product number.
• The machine’s serial number.
Please provide the type designation and serial number when
ordering spare parts.
The engine's serial number is given on a bar code decal.This is
placed on the left side of the crankcase, in front of the starter.
The text states:
• Model.
• Type.
• Code.
Please provide these when ordering parts.
The transmission’s serial number on hydrostatic machines is
stated on the bar code decal located on the front of the housing
for the left-hand drive shaft:
• Thetype designation is stated above the bar code and starts
with the letter "K".
• The serial number is stated above the bar code and has the
prefix "s/n".
• Themanufacturer’stypenumberisstatedunderthebarcode
and has the prefix "p/n".
Please provide the type designation and serial number when
ordering spare parts.
Engine
These ride-on mowers have single cylinder, air-cooled
engines from Briggs & Stratton.
Major engine repairs are not described in this workshop
manual.This information can be found in Briggs & Stratton’s
own manuals, which include detailed information about
engine adjustments and repairs.These manuals can be
ordered from an authorized servicing dealer.
It is important that only original spare parts are used to repair
the engines. If other parts are used, the guarantee is
invalidated.
Steering
The ride-on mowers have rear-wheel steering. Steering
forces from the steering wheel are transferred to the rear
wheel via a wire.
Drive Unit
M105-85F and G105-85F has a manual gearbox with three
forward gears, neutral and one reverse gear.
DESIGN AND FUNCTION
7 – English

M125-85FH is equipped with a hydrostatic transmission.The
speed is controlled variably using the pedals forward or reverse.
Cutting Deck
The M105-85F, M125-95FH and G105-85F have mulching
units with a rear discharge option.
The cutting deck is raised and lowered with the lifting pedal.
Depressing the pedal will lift the cutting deck to the transport
position.
In order to activate the transport position, the lock button on
the steering column is then pressed and held in while the lift
pedal is released.
If the lift pedal is released without pressing the lock button,
the cutting deck will be lowered (cutting position).
To activate the cutting position, press the pedal and then
release it.
The cutting height is adjusted using the lever, which has a catch
for each cutting height position.
DESIGN AND FUNCTION
English – 8

Dismantling the Engine
Pull up the lever for engaging the blades.
Remove the bonnet.
IMPORTANT!
Hold the battery cable screws in place so that the
electrodes are not strained.
Loosen the battery strap and detach the cable connections.
Remove the cable connecting the starter relay to the starter.
Separate the connector.
Remove the side plates.
Loosen the screws.Twist out the back of the plate 45°.Remove
the front edge of the plate.
Loosen the cable bracket from the engine.
Remove the fuel tank, see "Fuel Tank".
Remove the clip holding the throttle and choke cables.Release
the cable from its mounting.
Removetheplateovertheenginebylooseningthefourscrewsin
theframe,two on each side.The engine can be removedwithout
lifting off the plate.
REPAIR INSTRUCTIONS
9 – English

Remove the seat switch.
Remove the lower belt from the engine belt pulley.
Remove the belt guide by the engine belt pulley.
Remove the engine mounting screws.
Note where the battery's negative cable is connected.
Disconnect it from the engine if necessary.
Lift the engine away from the machine.
Assembling the Engine
Assemble in reverse order.
Fuel Tank
Dismantling
WARNING! Petrol is highly flammable and
environmentally hazardous. Exercise
caution to avoid fire and spillage.
Use a suitable vessel to collect the petrol.
Empty the petrol tank by removing the hose from the
connector under the tank. If you do not wish to empty the
tank, you can pinch the hose with lockable welding pliers and
then remove the hose and hose clip from the fuel filter’s lower
connector.You must then be sure to keep the hose opening
higher than the fuel level in the tank.
REPAIR INSTRUCTIONS
2
2
1
3
English – 10

Remove the screw holding the tank on the bracket. Lower the
tank and pull out the hose through the frame of the machine
(if it has been loosened by the fuel filter).
Assembling
It is easier to work if you empty the tank before assembly. Put
the hose in position. Connect it to the fuel filter with the hose
clip. Make sure the hose does not chafe.
Fit the fuel hose and the hose clip to the connector under the
tankasrequired.Fillwithpetrolandcheckthattherearenoleaks.
Screw on the fuel tank.
Changing the Engine Oil
The engine oil should be changed for the first time after
running for 8 hours; see Service Schedule. It should then be
changed after every 50 running hours.
WARNING! Engine oil can be very hot if it is
drained directly after stopping the engine.
Allow the engine to cool down first.
IMPORTANT!
Used engine oil is a health hazard and must not be
disposed of on the ground or in the environment; it should
always be disposed of at an appropriate disposal site.
Avoid contact with skin.Wash with soap and water in case
of spills.
Place a container under the engine drain plug on the left side of
the engine.
Remove the dipstick and drain plug. Let the oil run out into the
container.
Fit the drain plug and tighten it.
Fill with oil up to the top mark on the dipstick. Oil is filled using
thesamehole asthedipstick.Use thetypeofengineoilspecified
in "Specifications".
Warmtheengine.Thencheckthatthereisnoleakagefromtheoil
plug.
REPAIR INSTRUCTIONS
11 – English

Checking and Adjusting the
Steering Cable
Check the tension by squeezing the cables together (at the
arrows).Without applying too much force, it should be
possible to move the wires ± 5 mm from center position.
Tension the cables by tightening the adjuster nuts (one on each
sideoftheride-onmower).Adjust bothcablesequallyso that the
steering wheel position does not change.
Check the wire tension after adjusting by pinching together the
wires, see earlier in this section.
Replacing the Steering Cable
Dismantling
Loosen both ends of the steering cable from the rear steering
disc by loosening the outer nuts (M8).
Remove the retaining rings and lift off the plastic sprockets and
the washer between them from the two pulley brackets.
Remove the plastic cover over the steering column.
If the cable is intact, note how it is wound around the steering
column.Also note how the cable is routed before pulling it out of
the machine.
REPAIR INSTRUCTIONS
± 5 mm.
English – 12

Assembling
Attach the cable by first turning the steering wheel so that the
hole in the steering column guide roller points forward on the
machine.
Place the center nipple of the cable in the hole with the
marked part of the cable to the right in the direction of travel.
Wind the right end of the cable one turn clockwise under the
nipple and turn the left end counterclockwise above the
nipple so that both ends point towards the rear.
The cable is correctly fitted if it exits at the top on the left side and
the bottom on the right side.
At this stage, the cable can be fixed in position with a cable tie
or tape, for example.
Pull back the ends of the cable and place in the correct
tensioner. Do not forget to screw a nut (M8) onto each
tensioner that is used to secure the cable.
The marked (right) side of the cable is placed at the bottom of
both pulley brackets and connected to the rear steering disc
on the right side of the machine.
Note that the wire must be placed in the groove in the plastic
sprocket before it is all run back to the top of the shaft. If the
machine has hydrostatic transmission (M125-97FH), the right
cable must be routed under the parking brake arm on the
hydrostatic box and the left cable must be routed over the
parking brake arm.
Place the washers between the pulleys and lay the left end of
the wire at the top and connect it to the left attachment of the
steering disc.
Stretch the ends of both cables equally so that the steering
wheel position does not change. Hold the cable with pliers or
a wrench so that it does not twist. Secure the wire with the
inner nuts (M8).
Assembling the Steering Shaft
Fit the steering wheel/control rod on the control rod shaft and
knock the tension pin in all the way through the steering rod.
Dismantling/Assembling the Cable
Pulley
See "Replacing the Steering Cable".
1
2
1
REPAIR INSTRUCTIONS
2
1
13 – English

Checking and Adjusting the Brake
Check that the brakes are correctly adjusted by placing the
ride-on mower on a slight downhill slope with the clutch
disengaged and activating the brake.
M105-55F and G105-85F
Adjust the brake by lightly tightening the adjustment screw.
Check the brake and repeat if necessary. Tightening the
adjustment screw too much will prevent the machine from
moving.
WARNING! A poorly adjusted brake can
result in reduced braking ability.
M125-95FH
Check that the brakes are correctly adjusted by placing the
ride-on mower on a slight downhill slope with the clutch
disengaged and activating the brake.
Adjusting the Throttle Cable
The throttle cable may need to be adjusted, if the engine does
not respond as it should when accelerating, i.e. if it produces
black smoke or maximum revs are not reached.
Remove the bonnet.
Loosentheclampingscrewforthecable’soutercasingandmove
the choke control to the full choke position.
Pull the choke cable’s outer casing as far to the right as possible
and tighten the clamping screw.
Pull back the throttle to the full throttle position and check that
the choke is no longer actuated.
REPAIR INSTRUCTIONS
English – 14

Dismantling the Swing Axle
Remove the cables from the battery terminals and remove
the battery.
Remove the battery shelf.
Remove the fastening bolts and control rods for the axle.
Remove the swing axle.
Dismantling/Assembling the Drive
Chain
M105-97F and G105-85F
Remove the foot plate.
Cut the drive chain.
Fit a new drive chain with a master link.
Adjusting the Drive Chain
Loosen the four screws and slide the plate forward by hand to
tighten the chain.
Tighten the chain.
REPAIR INSTRUCTIONS
15 – English

Loosen the split pin, unhook the connection rod and pry the
belt from the gearbox pulley.
Dismantle the drive chain, see "Dismantling/Assembling the
Drive Chain".
Loosen the plate to which the gearbox is fastened.
Loosen the gearbox retaining screws.
The nit must be tightened 50 ±2 Nm when changing the shift
lever.
Dismantling/Assembling the
Hydrostatic Transmission
M125-85FH
Loosen the cutting deck belt.
Loosen the idler spring.
Pry off the drive belt.
Remove the lock washer and unhook the throttle stay.
Remove the five screws holding the hydrostatic transmission.
REPAIR INSTRUCTIONS
English – 16

Replacing the Belts
Starting position for removing the belt:
• No unit is attached to the machine.
• The front part of the belt is loose.
Loosen the belt tensioner. Pry off the belts downward.
Change the belts after 2 years or 100 hours running time.
Checking and Adjusting the Cutting
Deck Ground Pressure
Check the tire pressure, 0,8 bar.
Place bathroom scales under the cutting deck frame (on the
front edge) so that the cutting deck rests on the scales.
Adjust the cutting deck ground pressure with the adjuster nut
located inside the ride-on mower front wheel. Ground
pressure should be between 12 and 15 kg / 26.5-33 lb.
Removing the Cutting Deck
The cutting deck can be removed in order to facilitate
cleaning and servicing.
To remove the cutting deck proceed as follows:
• Position the machine on flat ground.
• Apply and secure the parking brake.
M105-95F and G105-85F:
• Depress the parking brake pedal (1).
• Press in the lock button (2) on the steering column.
• Releasethebrakepedalwhilekeepingthebuttonpressedin
McCulloch M125-85FH:
• Slide the parking brake lever forward.
• Hook the lever in place.
Place the cutting deck in the mowing position.
REPAIR INSTRUCTIONS
1
2
17 – English

Check that the adjustment lever for the cutting height is in the S
position.
Loosen the snap lock and lift off the front cover.
Loosen the spring for the drive belt tensioning wheel.
Lift off the drive belt.
Release the adjustment screw.
Loosen the split pin from the equipment frame.Grasp the upper
pipe construction of the deck and pull it out.
REPAIR INSTRUCTIONS
English – 18

Checking the Safety System
The ride-on mower is equipped with a safety system that
prevents starting or driving in the following conditions.
It must only be possible to start the engine when the following
conditions are met:
• Blades shut off, blade drive not engaged.
• Parking brake applied.
The driver does not need to be seated in the driver’s seat.
Check daily to ensure that the safety system works by
attempting to start the engine when one of the conditions is
not met. Change the conditions and try again.
Check that the engine stops if you temporarily move out of
the driver’s seat while the mower blades are engaged.
Seat Microswitch
Disconnect the cable connections from the microswitch.
Press in the fasteners and remove the microswitch from the
holder.
Blades Microswitch
Loosen the left side cover.
Disconnect the connector from the microswitch.
Parking Brake Microswitch
Remove the right side cover.
Disconnect the connector from the microswitch. There are
two microswitches, one on each side.
Pedal Microswitch
Disconnect the connector from the microswitch.
Main Fuse
The main fuse is placed in a detachable holder by the battery
under the engine cover.
Type: Flat pin, 15 A.
Do not use any other type of fuse when replacing.
A blown fuse is indicated by a burnt link. Pull the fuse from the
holder when replacing it.
The fuse is there to protect the electrical system. If it blows
again shortly after replacement, it is due to a short circuit,
which must be fixed before the machine can be put into
operation again.
ELECTRICAL SYSTEM
19 – English

Troubleshooting Schedule
Problem Cause
Engine will not start See the "Checking the Safety System" section if the controls are in the wrong position
There is no fuel in the fuel tank
Spark plug defective
Dirt in the carburetor or fuel line
Starter does not turn over the engine
Bad or old fuel in the fuel tank
Incorrect fuel in the fuel tank
Starter does not turn over the engine Battery flat
Main fuse blown.The fuse is found in front of the battery, under the engine cover
Bad contact between the cable and battery terminal
Ignition lock faulty
Faulty starter
Engine does not run smoothly Throttle in the choke position
Clogged air filter
Fuel tank vent blocked
Faulty spark plug
Dirt in the carburetor or fuel line
Carburetor incorrectly set
Incorrect ignition setting
Engine lacks power Throttle in the choke position
Clogged air filter
Faulty spark plug
Dirt in the carburetor or fuel line
Carburetor incorrectly set
Engine overheats Engine overloaded
Air intake or cooling fins clogged
Fan damaged
Too little or no oil in the engine
Faulty spark plug
Battery does not charge One or more battery cells faulty
Poor contact on the battery terminal cable connectors
The ride-on mower vibrates Blades are loose
One or more blades unbalanced, caused by damage or poor balancing after sharpening
Uneven mowing Blades blunt
Tall or wet grass
Grass build-up under the cover
Different tire pressures on right and left sides
Driving speed too high
Engine speed too low
Cutting deck rear drive belt slips
TROUBLESHOOTING CHART
English – 20