HUSTLER FlipUp-54 User manual

200 South Ridge Road
Hesston, Kansas
67062
®
Hustler®Parts Manual

Inspect spark arrester daily; replace every 500 hours or as needed.
The Engine Owner’s Manual provides information regarding the U.S. Environmental Protection Agency
(EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty.
Keep Engine Owner’s Manual with your unit. Should the Engine Owner’s Manual become damaged or
illegible, replace immediately. Replacements may be ordered per the information found in the Product
Information section of the owner’s manual.
Federal law and California State law prohibit the following acts or the causing thereof:
1. The removal or rendering inoperative by any person other than for purposes of maintenance,
repair, replacement, of any device or element of design incorporated into any equipment for
the purposes of emissions control prior to or after its sales or delivery to the ultimate
purchaser or while it is in use, or
2. The use of the equipment after such device or element of design has been removed or
rendered inoperative by any person.
WARNING
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
NOTICE OF REQUIREMENT OF SPARK ARRESTER MUFFLER
This equipment may create sparks that can start fires around dry vegetation. California Public Resources Code
Section 4442.6 provides that it is unlawful to use or operate an internal combustion engine on any forest-covered,
brush-covered, or grass-covered land unless the engine is equipped with a spark arrester maintained in effective
working order. A spark arrester is a device constructed of nonflammable materials specifically for the purpose of
removing and retaining carbon and other flammable particles over 0.0232 of an inch in size from the exhaust flow of
an internal combustion engine that uses hydrocarbon fuels or which is qualified and rated by the United States
Forest Service. Other states or federal areas may have similar laws. The Operator Should Contact Local Fire
Agencies For Laws or Regulations Relating to Fire Prevention Requirements. THIS EQUIPMENT DOES NOT HAVE
A SPARK ARRESTER AND YOU SHOULD CONTACT YOUR AUTHORIZED DEALER FOR THE PURCHASE OF
A SPARK ARRESTER.

General Information 1
Frame, Fenders, Instrument Panel & Engine Guard
Frame 3-1
Fenders & Instrument Panel (Multi-Page) 3-2
Engine Guard 3-3
Transmissions, Drive Belt, Steering & Brake
Drive System, Transmissions & Drive Belt 4-1
Transmission Service Parts - 604708 4-2
Transmission Service Parts - 604709 4-3
Steering, Brake & Deck Lift Controls (Multi-Page) 4-4
Steering & Deck Lift Controls Sub-Assembly 4-5
Wheels & Tires
Wheels & Tires 5-1
Front Wheel Assembly 5-2
Drive Wheel Breakdown 5-3
Engine, Muffler, Clutch & Fuel System
Engine, Muffler & Clutch (Multi-Page) 6-1
Engine Service Parts - FR691V 6-2
Fuel System 6-3
Fuel Tank Service Parts - 607668 6-4
Battery
Battery 7-1
Deck, Deck Belt, Blades & Deck Lift
Service Deck 8-1
Deck Belt, Deck Pulleys & Spindles (Multi-Page) 8-2
Spindle Service Parts - 607418 8-3
Discharge Chute, Pulley Covers, & Blades 8-4
Deck Carrier, Deck Height, Floorpan & Footrest (Multi-Page) 8-5
Seat
Seat 9-1
Seat Service Parts - 608027 9-2

General Information
Note: When ordering parts, you must use the part number as shown for each part, not the index number. Always give
the model and serial number to your parts and service representative.
Note: Items sold in bulk such as seals and hoses are sold by the foot.
Using This Manual
This manual is part of a service package for the Hustler®mowers. Use of this manual in conjunction with other Hustler®
mower and component manuals will provide the information necessary to service and maintain Hustler®mowers.
This Parts Manual provides a complete parts listing for the unit. Use this manual when ordering parts. Illustrations used
were current at the time of printing, but subsequent production changes may cause your machine to vary slightly in
detail. Excel Industries, Inc. reserves the right to redesign and change the machine as deemed necessary, without noti-
fication. If a change has been made to your machine which is not reflected in this parts manual, see your authorized
dealer for current information and parts.
The Service Manual is a service guide for use by Service Technicians. It provides the necessary information needed to
perform normal maintenance requirements on these units.
The Operator's Manual provides fundamental operational information and operational safety that is needed when oper-
ating the mower.
The component manuals are furnished by the various manufacturers to be used for the troubleshooting and servicing
of their products.
Hardware Description Codes & Abbreviations
The following codes are used throughout this parts manual. Refer to this list when ordering parts.
ABBREVIATION CARRIAGE BOLT MACHINE BUSHING
CLEVIS PIN MACHINE SCREW
CLIP NUT NUT
COTTER PIN SELF TAPPING CAP SCREW
CAP SCREW SOCKET HEAD
CUP WASHER SHOULDER BOLT
FENDER WASHER SET SCREW
FLAT WASHER OUTSIDE DIAMETER
HEX HEAD INSIDE DIAMETER
LOCK WASHER WELD NUT
Standard Torques
The following chart lists the standard torque values for the threaded fasteners found in this manual. Torque all cap
screws, nuts and set screws to these values unless a different torque is shown in the Notes section next to the fastener.
SIZE FT-LBS N•M SIZE FT-LBS N•M
DESCRIPTION ABBREVIATION DESCRIPTION
CB MB
CE MS
CN NT
CP SC
CS SH
CW SB
FDRW SS
FW OD
HX ID
LW WN
.250 8.2 11.1 M3 1 1.3
.312 17 23 M4 2.2 3
.375 30 40 M5 4.5 6.1
.438 48 65 M6 7.7 10.4
.500 73 99 M8 18.5 25
.562 105 143 M10 37 50
.625 145 200 M12 64 87
.750 260 350 M14 80 108.5
.875 420 565 M16 160 215
1.00 625 850 M20 320 435
M24 555 750

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Frame 54" Raptor Flip-Up Parts Manual - 940320 - HTHFUL054KAWFR691VA
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Frame, Fenders, Instrument Panel & Engine Guard
Frame 54" Raptor Flip-Up Parts Manual - 940320 - HTHFUL054KAWFR691VA
Wed Nov 10 16:31:32 UTC 2021 3-1

Comments for Page: Frame
1. The frame includes the decal (605650).
2. The bumper (552922) includes the decal (602041).
Item Part No. Qty Name
1 552930 1 SVC, FRAME RFU
2 604307 3 MOUNT, PUSH BUTTON
3 000331 4 WIRE TIE, SMALL/SHORT
4 034272 4 NT .312-18HXG5
5 768523 4 FW 0.343SAE
6 015495 10 GREASE FITTING STRAIGHT
7 797910 4 CS .312-18x1.50FLT SH ZN
8 604888 2 GUIDE BLOCK, CARRIER
9 808493 6 RIVET NUT, 3/8-16 THREA
10 016899 6 NT .375-16 FLKG5
11 029629 8 CS .375-16X0.75 HXF G5ZN
12 054502 2 NT .375-16HXG5
13 767954 2 FW 0.379X.82X.06 HD ZN
14 121430 1 MUFFLER SHIELD
15 552922 1 SVC, BUMPER RFU
16 602041 1 DECAL, HOT
17 025395 2 CB .375-16 X 1.00 G5 ZN
18 605299 1 HAND GRIP, 7/8 I.D.
19 120370 1 W/A, FRAME LATCH
20 121108 1 SUPPORT, FUEL TANK W/A
21 605650 1 DECAL, TIP OVER DANGER
Not Shown 605547 1 WIRE HARNESS, KAWASAKI
Not Shown 602725 1 WIRE TIE,
Frame 54" Raptor Flip-Up Parts Manual - 940320 - HTHFUL054KAWFR691VA
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Frame, Fenders, Instrument Panel & Engine Guard
Fenders & Instrument Panel (Multi-Page) 54" Raptor Flip-Up Parts Manual - 940320 - HTHFUL054KAWFR691VA
Wed Nov 10 16:31:33 UTC 2021 3-2

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Fenders & Instrument Panel (Multi-Page) 54" Raptor Flip-Up Parts Manual - 940320 - HTHFUL054KAWFR691VA
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Fenders & Instrument Panel (Multi-Page) 54" Raptor Flip-Up Parts Manual - 940320 - HTHFUL054KAWFR691VA
Wed Nov 10 16:31:33 UTC 2021 3-2

Item Part No. Qty Name
1 601097 1 CABLE, CHOKE
2 776476 1 SWITCH, PTO 6201-321
3 607452 1 GAUGE, SING NEEDLE 12V
Not Shown 608044 1 FUEL GAUGE & SENDER KIT
4 785808 1 KEY ASSEMBLY
5 045898 1 IGNITION SWITCH
6 797308 1 SWITCH, ROCKER SPDT
7 601098 6 CB 10-24 X .500 ZYNC
8 606225 1 DECAL INST PANEL FU
9 552925 1 SVC, INSTRUMENT PANEL
10 055939 4 CS .250-20X0.75 HX G5 ZN
11 768515 12 FW 0.281SAE
12 601096 1 CABLE, THROTTLE
13 704932 6 FW 0.219X.50X.05 ZN
14 059832 6 NT #10-24 HX NL ZN
15 068551 4 NT .250-20 HXZY NL
16 605553 1 CONTROLLER
17 120673 1 FENDER BRACKET, RH
18 794784 4 CB .250-20 X .75 FUL ZN
19 000331 2 WIRE TIE, SMALL/SHORT
20 121258 1 FUSE BRKT
21 029629 2 CS .375-16X0.75 HXF G5ZN
22 024927 4 NT .250-20HXG5
23 016899 2 NT .375-16 FLKG5
24 608127 1 DECAL, USA, F&D
25 608103 1 DECAL, FLIP-UP
26 601981 1 DECAL, SAFE OPERATE-GRAY
27 605473 4 CS .250-20X0.75 BH TX BZ
28 605628 4 FW 0.281X.63X.07 ZB
29 604324 5 CS .250-20 X .75 HX FLG
30 605525 1 RH FENDER
31 808477 4 RIVET NUT, 1/4-20 THREA
32 605526 1 LH FENDER
33 120785 1 RESERVOIR MOUNT
34 601982 1 CN .250-20X .150 MAX THK
35 120674 1 FENDER BRACKET, LH
Fenders & Instrument Panel (Multi-Page) 54" Raptor Flip-Up Parts Manual - 940320 - HTHFUL054KAWFR691VA
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Fenders & Instrument Panel (Multi-Page) 54" Raptor Flip-Up Parts Manual - 940320 - HTHFUL054KAWFR691VA
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Comments for Page: Fenders & Instrument Panel (Multi-Page)
1. Part of the wire harness.
2. 607454 is used on mowers S/N 20062966 & HIGHER.
608044 is used on mowers S/N PRIOR TO 20062966.
3. The instrument panel includes the decal.
4. The sealed relay includes a bracket.
Item Part No. Qty Name
36 114052 1 KIT, CLUTCH CONN. REP.
37 601047 1 HOLDER, FUSE
38 601053 2 RELAY, SEALED W/BRACKET
39 605547 1 WIRE HARNESS, KAWASAKI
Fenders & Instrument Panel (Multi-Page) 54" Raptor Flip-Up Parts Manual - 940320 - HTHFUL054KAWFR691VA
Wed Nov 10 16:31:33 UTC 2021 3-2

Frame, Fenders, Instrument Panel & Engine Guard
Engine Guard 54" Raptor Flip-Up Parts Manual - 940320 - HTHFUL054KAWFR691VA
Wed Nov 10 16:31:34 UTC 2021 3-3

Comments for Page: Engine Guard
1. Part of the Frame Assembly.
Item Part No. Qty Name
1 016899 4 NT .375-16 FLKG5
2 029629 4 CS .375-16X0.75 HXF G5ZN
3 121696 1 KIT, ENGINE GUARD RFU
Comments for Part Num. 121696
Engine Guard Kit is not compatible when 2-Bag Catcher is installed.
4 604745 1 DECAL, H LOGO, MFSD 36/4
Engine Guard 54" Raptor Flip-Up Parts Manual - 940320 - HTHFUL054KAWFR691VA
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Transmissions, Drive Belt, Steering & Brake
Drive System, Transmissions & Drive Belt 54" Raptor Flip-Up Parts Manual - 940320 - HTHFUL054KAWFR691VA
Wed Nov 10 16:31:35 UTC 2021 4-1

Item Part No. Qty Name
1 786533 1 DRIVE BELT
Not Shown 786533X 1 20PK, DRIVE BELT
2 601983 1 CS .625-11 X 2.25 HXG5ZN
3 606949 2 IDLER, 3.25 FLAT
4 121319 1 IDLER SPACER
5 121728 1 TENSION ARM W/A
6 086660 1 NT .375-16 G8 NL
7 605481 1 BUSHING
8 605655 1 SPRING, PUMP IDLER
9 704718 1 FW .406X .688X.060 ZN
10 052860 1 CS .375-16X1.25 HX G5 ZN
11 028118 1 FW 0.625X1.00X.13 ZN
12 016972 1 NT .625-11 HX G5 ZN
13 781872 1 CS .625-11X1.250HXG5
14 704791 1 FW .781X1.25X.02 ZN
15 781153 2 BUSHING, UHMW
16 025296 1 FW .760X1.63X0.08 ZN
17 601084 1 SB .750X 2.000 SH.625-11
18 710087 4 CS .312-18X2.500HXG5
19 043067 4 CS .312-18X3.000HXG5
20 768523 16 FW 0.343SAE
21 034272 8 NT .312-18HXG5
22 604708 1 ZT2800, 20.69:1 TRANS
23 604709 1 ZT2800, 20.69:1 TRANS
24 016410 2 CS .375-16X2.000HXG5
25 767954 2 FW 0.379X.82X.06 HD ZN
26 605539 1 SPACER TUBE
27 768515 2 FW 0.281SAE
28 068551 2 NT .250-20 HXZY NL
29 601996 1 EXPANSION TANK, ZT2800
Not Shown 600767 1 CAP, OVERFLOW TANK
30 000331 1 WIRE TIE, SMALL/SHORT
31 603289 1 GM, 2.25IDX 3.0ODX 2.5GD
32 601503 2 CB .250-20 X .625 ZN
33 029629 1 CS .375-16X0.75 HXF G5ZN
34 601001 6 SPRING CLAMP, .75" DIA
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Drive System, Transmissions & Drive Belt 54" Raptor Flip-Up Parts Manual - 940320 - HTHFUL054KAWFR691VA
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Comments for Page: Drive System, Transmissions & Drive Belt
1. Torque to 17 ft-lbs.
2. Torque to 100 ft-lbs.
3. Torque to 30 ft-lbs.
4. Left side transmission.
5. Right side transmission.
6. The overflow tank includes the cap.
Item Part No. Qty Name
35 605744 1 OVERFLOW HOSE, 6"
36 605562 1 FTG, -8MBT/-8MBT, 90
37 706549 2 HP0.080X1.190
38 118310 2 LINK, TOW VALVE
39 605730 1 FTG, -6MORB/-8MBT STR
40 016899 1 NT .375-16 FLKG5
41 605745 1 OVERFLOW HOSE, 7"
42 045088 1 HOSE CLAMP 1" (FS)
43 605746 1 OVERFLOW HOSE, 19"
44 601219 1 FTG, 90 - 9/16 SAE
Drive System, Transmissions & Drive Belt 54" Raptor Flip-Up Parts Manual - 940320 - HTHFUL054KAWFR691VA
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