Ransomes 898657, 898658, 898656 Cushman Turf-Truckster Gas Parts Manual

Part No. 2701234 Rev. 4
Always Think Safety!
Thank you for purchasing a Cushman product. You are one of our many customers who have voted
their confidence in our company by purchasing our products.
This is one of the best designed and built pieces of commercial industrial and turf equipment available.
Many safety features have been designed and built into this product. Please Do Not remove or defeat
any safety features as they were installed for your protection.
The useful life and good service you obtain from your vehicle depends to a large extent on the way
it is maintained and operated.
Treat your equipment properly, lubricate and adjust it as instructed in this manual and it will give you
many years of reliable service.
See your Cushman dealer for service and parts. She/he stocks genuine Cushman parts manufactured
with the same precision and skill as the original parts.
IMPORTANT!
This Manual Will Aid You In The Safe Operation And Proper Maintenance Of Your Equipment.
Read Manual Thoroughly Before Attempting Operation. If Any Portion Is Not Clearly Understood,
Contact An Authorized Dealer For Clarification.
GENERAL INFORMATION
!
This symbol is used throughout the manual to alert you to information about unsafe
actions or situations, and will be followed by the word DANGER, WARNING, or CAUTION.
DANGER indicates immediate hazards that may result in severe injury or death. WARNING
indicates unsafe actions or situations that may cause severe injury, death and/or major equipment or property damage. CAUTION indicates unsafe actions or situations that may cause
injury, and/or minor equipment or property damage.
NOTE: This symbol appears next to information or instructions which will help you operate
and maintain your equipment the right way.
!
WARNING
The information and instructions included in this manual alert you to
certain things you should do very carefully. If you do not, you could:
• hurt yourself or others
• hurt the next person who operates the equipment
• damage the equipment.
400-6-00-CU
2000 Textron Inc. All Rights Reserved.
Lincoln, NE. Printed in U.S.A.
VEHICLE IDENTIFICATION NUMBERS
Cushman, a Textron Company, reserves the right to make changes at any time, without notice, in specifications and
models and also to discontinue models and the accessories designed to be used on these models. The right is also
reserved to change specifications or parts at any time without incurring any obligation to equip same on models
manufactured prior to date of such change.
While the information contained in this parts manual is based on the latest product information available at the time
of publication, the continuing accuracy of this parts manual cannot be guaranteed. Cushman reserves the right to
make changes without notice.
Illustrations in this manual are a reference guide for parts identification only. Since these illustrations may not depict
actual positioning of component parts, they should not be used as an assembly diagram. Doing so may result in
improper assembly leading to sudden failure.
!
WARNING
• Altering this equipment in any manner which adversely affects the equipment operation,
performance, durability or use, may cause hazardous conditions.
• When replacement parts are required, use genuine Cushman parts or parts with equivalent characteristics including type, strength and material. Failure to do so may result in
product malfunction and possible injury to the operator and/or bystanders.
This unit is not a motor vehicle within the definition of
the national traffic motor vehicle safety act. It is not
designed or manufactured for use on roads, streets
or highways. It is not appropriate for such use.
This unit is not meant to be licensed as a motor
vehicle.
IMPORTANT!
SPARK ARRESTERS ARE REQUIRED BY CALIFORNIA
PUBLIC RESOURCES CODE, SECTIONS 4428–4442,
WHEN OPERATING ANY INTERNAL COMBUSTION
ENGINE ON HYDROCARBON FUELS, ON FOREST-,
BRUSH-, OR GRASS-COVERED LANDS.
MODIFICATIONS AND ACCESSORIES
Factory installed modifications and accessories are available for use on this vehicle.
An accessory parts manual (Part No. 2701052) is available and can be obtained by contacting your authorized
Cushman Dealer. In the USA and Canada call 1-888-922-8873 for Dealer information.
Read and understand all literature before attempting to operate this vehicle or any attached equipment.
IMPORTANT!
THIS EQUIPMENT SHOULD NOT BE MODIFIED OR ADDED
TO WITHOUT THE MANUFACTURER’S AUTHORIZATION.
NOTE: Some vehicles may be equipped with special options
that are not serviced by Cushman.
The addition of accessories not of manufacturer’s
design may result in erratic vehicle operation, improper battery charging and discharging, and failure
of vehicle components.
Direct any inquiries to:
Textron Turf Care and Specialty Products
Attn: Chief Engineer
P.O. Box 82409
Lincoln, NE 68501–2409 USA
1
OPERATION CONTROL SYMBOLS
AND DECALS
NOTICE
THIS UNIT IS NOT A MOTOR VEHICLE WITHIN THE
DEFINITION OF THE NATIONAL TRAFFIC MOTOR
VEHICLE SAFETY ACT. IT IS NOT DESIGNED
OR MANUFACTURED FOR USE ON ROADS, STREETS
OR HIGHWAYS, NOR IS IT APPROPRIATE FOR
SUCH USE. IT IS NOR MEANT TO BE LICENSED
AS A MOTOR VEHICLE.
821071
Park Brake Indicator Light
This light will come on when
the park brake is applied.
Motor Vehicle Compliance
This decal lets the operator know that the
vehicle is not defined as a motor vehicle and
therefore should not be driven on streets,
roads or highways
009034880
Battery (Voltmeter) Charging
This symbol appears on the voltmeter gauge. This gauge indicates the charging of the battery.
Electric Cooling Fan Warning
This decal warns the operator keep
hands away from the cooling fan, the
cooling fan can start at any time even
with the ignition key in the OFF position.
WARNING
OFF
DIM
BRIGHT
Headlight Switch Positions
These symbols appear on the light
switch. As indicated, each one represents the headlights functions.
844643
P.T.O. Warning
This decal warns the operator that
an uncovered P.T.O. can cause
entanglement of clothing and/or
body parts.
Engine Oil Pressure Light
This light will come on when the ignition key
is turned to the ON position and when the
engine is started (it will shut off once the
engine is running). Its main function is to
warn the operator if the oil pressure gets
to low. If this light comes on during normal vehicle operation, stop the vehicle
and check for problems
PARKING BRAKES ARE NOT AUTOMATICALLY APPLIED. VEHICLE MAY
MOVE CAUSING PERSONAL INJURY
AND/OR PROPERTY DAMAGE. ALWAYS
APPLY HAND OR FOOT BRAKES.
822819
Park Brake Warning
This decal warns the operator that the
park brake is not automatically applied.
Fuel Level Indicator
This symbol appears on the fuel
gauge. The fuel gauge indicates
the amount of fuel in the fuel tank
X 100
Engine RPM
This symbol indicates
engine rpm’s.
Water Temperature Gauge
This symbol appears on the water
temperature gauge. This gauge warns
the operator if the coolant system is
overheating.
840901
840748
Radiator Coolant Warning
This decal warns the operator not to remove the radiator cap
when the engine is hot. Refer to the Cooling System Section
in this manual for proper safety and operating instructions.
WARNING
FAILURE TO HEED THESE
WARNINGS MAY RESULT IN
SERIOUS INJURY OR DEATH
1.
2.
3.
4.
5.
READ AND UNDERSTAND ALL LABELS AND THE OPERATOR’S MANUAL.
DO NOT ALLOW UNTRAINED PERSONNEL TO OPERATE THIS VEHICLE.
DO NOT MODIFY THIS VEHICLE WITHOUT MANUFACTURER’S AUTHORIZATION.
PLACE LOADS FORWARD OF REAR AXLE.
TOP HEAVY LOADS CAN CAUSE UPSETTING. DO NOT EXCEED PAYLOAD
CAPACITY.
6. DO NOT OPERATE IF REPAIRS ARE REQUIRED.
7. KEEP ALL SHIELDS IN PLACE.
Read the Operator’s Manual
This decal informs the operator to read
and understand the Operator’s manual.
To prevent injury, they must be familiar
with the operation of this product and be
fully aware of safe operating procedures.
8. SHIFT INTO NEUTRAL OR PARK BEFORE STARTING ENGINE.
9. ONLY CARRY PASSENGERS IN SEATS PROVIDED.
10. WHEN PARKING (LEAVING) VEHICLE, FOLLOW ALL INSTRUCTIONS IN
OPERATOR’S MANUAL.
11. AVOID SUDDEN STARTS, STOPS AND SHARP TURNS ESPECIALLY ON SLOPES, OR
WITH HEAVY LOADS
12. KEEP ALL LABELS AND INSTRUCTIONAL LITERATURE LEGIBLE AND INTACT.
13. KEEP ARMS AND LEGS WITHIN VEHICLE BODY.
845038
Vehicle Operation
This decal informs the operator of proper procedures for safely
operating the vehicle. Read this manual completely to become
aware of other safety issues and operating procedures which will
help you operate this vehicle in a safe and responsible manner.
2
SERVICE and MAINTENANCE INDEX
Page
Page
A
I
Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . 11
Accessories, list of . . . . . . . . . . . . . . . . . . . . . . . . . 44
Accessory Power Plug (12volt) . . . . . . . . . . . . . . . . 8
Access Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Air Cleaner and Element . . . . . . . . . . . . . . . . 30-31
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
B
J
Jacks, Jacking Locations And Using A Hoist:
4-Wheel Models . . . . . . . . . . . . . . . . . . . . 34-35
Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . 32-33
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Bleeding the Brake System . . . . . . . . . . . . . . 37-38
Brake Lever, Parking . . . . . . . . . . . . . . . . . . . . . . . . 9
Brake Pedal, Service . . . . . . . . . . . . . . . . . . . . . . 11
Brake Fluid Indicator Light . . . . . . . . . . . . . . . . 8, 37
Brake Fluid Level & Bleeding . . . . . . . . . . . . 37-38
Bulbs and Bulb Replacement . . . . . . . . . . . . 27-28
L
C
O
Clutch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . 17-18
Oil Warning Light . . . . . . . . . . . . . . . . . . . . . . . . 8, 16
Oil Level (engine) . . . . . . . . . . . . . . . . . . . . . . 15-16
D
Park Brake Lever and Adjustment . . . . . . . . . 9, 39
Parts Illustrations . . . . . . . . . . . . . . . . . . . . . . 52-140
Power Steering Reservoir (4-wheel models) . . . 31
Pre-Starting Check List . . . . . . . . . . . . . . . . . . . . . 14
P.T.O. Operation . . . . . . . . . . . . . . . . . . . . . . . 47-49
Dash Panel Dipswitch Settings . . . . . . . . . . . . . . 29
Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Diagnostic Check . . . . . . . . . . . . . . . . . . . . . . . 24-25
Differential, 14.21:1 (2-speed) . . . . . . . . . . . . . . . 40
Differential, 2-Speed (operation) . . . . . . . . . . . . . 45
Driving the Vehicle . . . . . . . . . . . . . . . . . . . . . . 21-22
E
Engine:
Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-30
Break-in Period . . . . . . . . . . . . . . . . . . . . . . . . 14
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-18
Identification Numbers . . . . . . . . . . . . . . . . . . . 6
Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16
Pre-starting Check . . . . . . . . . . . . . . . . . . . . . 14
Starting:
Automatic Transmission . . . . . . . . . . . . . . . 20
Manual Transmission . . . . . . . . . . . . . . . 20-21
F
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 15
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . 15
Front Cowl Access and Release Lever . . . . . . . 24
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26, 28
G
Gasoline Containing Alcohol . . . . . . . . . . . . . . . . 15
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Gear Selector:
Automatic Transmission . . . . . . . . . . . . . . . . 12
Manual Transmission . . . . . . . . . . . . . . . . . . 11
General Information . . . . . . . . . . Inside Front Cover
Governor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . 39
Governor & Throttle Hand Control . . . . . . . . . . . 47
H
Headlight Replacement . . . . . . . . . . . . . . . . . . . . 27
Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic Lift System . . . . . . . . . . . . . . . . . . . . . . 45
Hydraulic P.T.O. . . . . . . . . . . . . . . . . . . . . . . . . 47-48
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . 50
Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Lubrication Recommendations . . . . . . . . . . . . 7, 44
M
Maintenance Guide . . . . . . . . . . . . . . . . . . . . . 42-43
Master Cylinder Reservoir . . . . . . . . . . . . . . . . . . 37
P
R
Radiator Coolant Level, Fill and Drain . . . . . 17-18
Remote Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . 46
Reservoir, Hydraulic . . . . . . . . . . . . . . . . . . . . . . . 50
S
Safety Instructions . . . . . Inside Front Cover, 12-14
Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Service and Maintenance . . . . . . . . . . . . . . . . 24-44
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Starting the engine:
Automatic Transmission . . . . . . . . . . . . . . . . 20
Manual Transmission . . . . . . . . . . . . . . . 20-21
Stopping, Parking the Vehicle . . . . . . . . . . . . 22-23
T
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Taillight Replacement . . . . . . . . . . . . . . . . . . . . . . 27
Tire Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Tire Removal and Replacement:
Front & Rear (4-wheel), Rear (3-wheel) . . . 36
3-wheel Front . . . . . . . . . . . . . . . . . . . . . . . . . 36
Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Towing a Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Towing The Vehicle:
Automatic Transmission . . . . . . . . . . . . . 33-34
Manual Transmission . . . . . . . . . . . . . . . . . . 34
Transmission, Automatic . . . . . . . . . . . . . . . . . . . 41
Transmission, Manual . . . . . . . . . . . . . . . . . . . . . . 40
V
Vehicle Identification Number . . . . . . . . . . . . . . . . 6
Vehicle Operation . . . . . . . . . . . . . . . . . . . . . . 12-23
Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
W
Water Temp. Gauge & Overheat Buzzer . . . . 8, 19
3
PARTS ILLUSTRATIONS
INDEX
PARTS
Page
Page
A
E
Accelerator pedal (foot throttle) . . . . . . . . . . . . . . . . . 83
Accessory power plug (12 volt) . . . . . . . . . . . . . . . . . 90
Access panels (front cowl) . . . . . . . . . . . 54, 56, 58, 60
Air cleaner, Bracket and Filter . . . . . . . . . . . . . . 63, 64
Alternator (break down of) . . . . . . . . . . . . . . . . . . . . 143
Automatic transmission . . . . . . . . . . . . . . . . . 123, 124
Axles, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Electrical components . . . . . . . . . . . . . . . . . . . . . . . . 90
Electrical connectors . . . . . . . . . . . . . . . . . . . . . . . . . 89
Emissions control (Suzuki 660 EFI) . . . . . . . . . . . . . 141
Engine Control Unit (ECU) . . . . . . . . . . . . . . 59, 61, 90
Cover (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . 59, 61
Engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Cover, left (screen panel) . . . . . . . . . . . . . . . . . . . . 52
Screen (right-side panel) . . . . . . . . . . . . . . . . 106, 108
Engine mounts . . . . . . . . . . . . . . . . . . . . . . . . . 111, 112
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
B
Belts, engine:
Alt., pwr. strng., wtr pump. . . . . . 70, 103, 104, 105
Gov., hyd. pump . . . . . . . . . . . . . . . . 103, 104, 105
Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Body, Hood, Headlights, 4-wheel . . . . . . . . . . . . . . . 54
Body, Hood, Headlights, 3-wheel . . . . . . . . . . . . . . . 56
Brake band (automatic transmission) . . . . . . . . . . . . 129
Brake lever (parking) . . . . . . . . . . . . . . . . . . . . . . . . . 62
Brake pedal (service) . . . . . . . . . . . . . . . . . . . . . . . . . 66
Brake cylinder (master) and Brake Lines . . . . . . . . . . 66
Brake fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . . . 66
Brakes, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Buzzer, over-heat . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
C
Cables:
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Governor hand control . . . . . . . . . . . . . . . . . . . . . 97
Hand throttle control . . . . . . . . . . . . . . . . . . . . . . . 97
Park brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Park brake to rear brakes . . . . . . . . . . . . . . . . . . 62
Shifter (automatic transmission) . . . . . . . . . . . . . . . 93
Shifter (manual transmission) . . . . . . . . . . . . . . . . 132
Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Two-speed differential control . . . . . . . . . . . . . . . 94
Camshaft & components . . . . . . . . . . . . . . . . . . . . 117
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . 52, 58, 60
Clutch cover & disc (manual transmission) . . . . . . . 138
Clutch assembly (automatic transmission) . . . . . . . . 127
Clutch pedal and linkage (manual transmission) . . 134
Cover, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Cylinder, hydraulic lift . . . . . . . . . . . . . . . . . . . . . . . . 86
Cylinder block, engine . . . . . . . . . . . . . . . . . . . . . . . 115
Cylinder head, engine . . . . . . . . . . . . . . . . . . . . . . . 114
D
Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Differential (14.21:1) . . . . . . . . . . . . . . . . . . . . . . . . . 94
Dipstick:
Oil, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Hydraulic reservoir . . . . . . . . . . . . . . . . . . . . . . . . 88
Transmission (automatic) . . . . . . . . . . . . . . . . . . . 125
Drawbar (trailer hitch) . . . . . . . . . . . . . . . . . . . . . . 58, 60
Driveshaft (auto. trans.) . . . . . . . . . . . . . . . . . . . . . . . . 123
Driveshaft (manual trans.) . . . . . . . . . . . . . . . . . . . . . . 138
Drum, brake (front) . . . . . . . . . . . . . . . . . . . . . 76, 78, 80
(front and rear) . . . . . . . . . . . . . . . . . . . . 98
4
F
Fan, radiator cooling . . . . . . . . . . . . . . . . . . . . 106, 108
Fenders (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . 58, 60
Filter:
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63, 64
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 70
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Oil (Suzuki 660 EFI) . . . . . . . . . . . . . . . . . . . . . . . . 115
Flywheel (Suzuki 660 EFI) . . . . . . . . . . . . . . . . . . . . . 116
Foot throttle, Cable and Linkage . . . . . . . . . . . . . . . 83
Fuel system: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 70
Filter, Suzuki 660 EFI . . . . . . . . . . . . . . . . . . . . . 68, 70
Pump, Suzuki 660 EFI . . . . . . . . . . . . . . . . . . . . 68, 70
Tank, Suzuki 660 EFI . . . . . . . . . . . . . . . . . . . . . 68, 70
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58, 60
Galvanized (frame) . . . . . . . . . . . . . . . . . . . . . . 58, 60
Front Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54, 56
Front fork (3-wheel) . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55, 57, 89
Fuse holder . . . . . . . . . . . . . . . . . . . . . . . . . . . 55, 57, 89
G
Gaskets, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Governor hand control . . . . . . . . . . . . . . . . . . . . . . . 97
Governor & throttle linkage . . . . . . . . . . . . . . 100, 101
H
Handhold (passenger side) . . . . . . . . . . . . . . . . . . . . . 52
Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54, 56, 90
Headlight switch . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54, 56, 90
Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Hood release latch . . . . . . . . . . . . . . . . . . . . . . . 54, 56
Housing, carrier w/gears . . . . . . . . . . . . . . . . . . 94, 96
Housing, rear axles . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Housing, transmission (auto) . . . . . . . . . . . . . . . . . 124
Hubs, wheel: front . . . . . . . . . . . . . . . . 76, 78, 80, 98
rear . . . . . . . . . . . . . . . . . . . . . . . . 94, 98
Hydraulics:
Control box cover . . . . . . . . . . . . . . . . . . . 85, 86, 88
Control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85, 88
Reservoir (tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Selector valve and valve system . . . . . . . . . . . . 85
Hydraulic reservoir guard . . . . . . . . . . . . . . . . . . 58, 60
Page
Page
I
S (con’t.)
Ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Input shaft & gears (automatic trans.) . . . . . . . . . . . 127
Input shaft & gears (manual trans.) . . . . . . . . . . . . . 136
Instrument panel w/tach . . . . . . . . . . . . . . . . . . . . . . 90
Intake manifold (Suzuki 660 EFI) . . . . . . . . . . . 119, 120
Solenoid (starter) . . . . . . . . . . . . . . . . . . . . . . . 55, 57, 90
Solenoid, oil pump (auto. transmission) . . . . . . . . . . 126
Spark plugs (Suzuki 660 EFI) . . . . . . . . . . . . . . . . . . 114
Starter (auto. trans.) . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Starter (manual trans.) . . . . . . . . . . . . . . . . . . . . . . . . 140
Steering gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72, 74
Steering wheel and shaft . . . . . . . . . . . . . . . . . . 72, 74
Struts, front (spring & shock) . . . . . . . . . . . . . . . . 76, 78
Suspension, front (4-wheel) . . . . . . . . . . . . . . . . . 76, 78
L
Leaf springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Lift cylinder (hydraulic) . . . . . . . . . . . . . . . . . . . . . . . . 86
Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Lower ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58, 60
M
Master cylinder reservoir (brake fluid) . . . . . . . . . . . 66
Mud flap (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . 54, 56
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Motor mounts . . . . . . . . . . . . . . . . . . . . . . . . . . 111, 112
O
Oil cooler (auto. trans.) . . . . . . . . . . . . . . . . . . . . . . . 106
Oil pan, Gasket and Dipstick:
Suzuki 660 EFI . . . . . . . . . . . . . . . . . . . . . . . . . 115
Oil pump (Suzuki 660 EFI) . . . . . . . . . . . . . . . . . . . . . 122
Output gears (auto. transmission) . . . . . . . . . . . . . . 128
Overheat buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
P
Park brake, Lever and Cable . . . . . . . . . . . . . . . . . . 62
PCV valve (Suzuki 660 EFI) . . . . . . . . . . . . . . . . . . . 121
Pistons (Suzuki 660 EFI) . . . . . . . . . . . . . . . . . . . . . . 116
Planetary gears (auto. transmission) . . . . . . . . . . . . 128
Power steering pump (4-wheel) . . . . . . . . . . . . . . . . 72
Pulleys (engine) . . . . . . . . . . . . . . . . . . . . 104, 105, 106
R
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106, 108
Rear platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58, 60
Galvanized (rear platform) . . . . . . . . . . . . . . . . 58, 60
Rear springs, shackles . . . . . . . . . . . . . . . . . . . . . . . 84
S
Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Shackles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Shift shaft (auto. transmission) . . . . . . . . . . . . . . . . . 129
Shifter & shifter linkage:
(automatic transmission) . . . . . . . . . . . . . . . . . . . . 93
(manual transmission) . . . . . . . . . . . . . . . . . . . . . 132
Shifter gear and forks (manual trans.) . . . . . . . . . . 135
Shift switch (auto. transmission) . . . . . . . . . . . . . . . . 126
Shock absorbers: rear . . . . . . . . . . . . . . . . . . . . . . . 84
front (strut assembly) . . . . . . 76, 78
T
Taillight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59, 61
Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Thermostat (Suzuki 660 EFI) . . . . . . . . . . . . . . 106, 142
Throttle body . . . . . . . . . . . . . . . . . . . . . . . . . . 119, 120
Throttle hand control . . . . . . . . . . . . . . . . . . . . . . . . . 97
Throttle linkage (engine) . . . . . . . . . . . . . . . . . 100, 101
Tie rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76, 78
Timing belts & cover (Suzuki 660 EFI) . . . . . . . . . . . 118
Tires, front and rear . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Torque chart and torque specifications . . . . . . . . . 51
Torque converter (auto. transmission) . . . . . . . . . . . 123
Transmission (auto. trans.) . . . . . . . . . . . . . . . . 123, 124
Transmission housing (manual trans.) . . . . . . . . . . 139
Transmission mounts . . . . . . . . . . . . . . . . . . . 111, 112
Transmission pan & gaskets . . . . . . . . . . . . . . . . . 125
Transmission tubes (auto. transmission) . . . . . . . . . 126
Transmission valve (auto. transmission) . . . . . . . . . 130
Two-speed differential, 14.21:1 . . . . . . . . . . . . . . . . 94
U
U-joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123, 138
W
Water pump (Suzuki 660 EFI) . . . . . . . . . . . . . . . . . . 142
Water temp. sender . . . . . . . . . . . . . 90, 106, 108, 142
Wire harness:
Suzuki engine . . . . . . . . . . . . . . . . . . . . . . . . 92, 141
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Taillight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Wiring Diagram
Model 898656 . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Model 898657 . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Model 898658 with Serial No’s up to REV1287 . . 148
Model 898658 with Serial No’s
beginning with 00002120 . . . . . . 152
Wiring Schematic
Model 898656 . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Model 898657 . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Model 898658 with Serial No’s up to REV1287 . . 150
Model 898658 with Serial No’s
beginning with 00002120 . . . . . . 154
After you identify a part by the reference number and the part number,
always read the description of the part to be sure it is what you want.
5
VEHICLE IDENTIFICATION NUMBERS
VEHICLE & ENGINE IDENTIFICATION NUMBERS
The Following Identification Numbers (Vehicle Identification Number, Model Number And Serial Number)
Must Appear On All Correspondence Concerning This Vehicle.
NOTE: Reference to the front, rear, left and right sides of the vehicle are
always determined by the operator’s seated position.
VEHICLE IDENTIFICATION NUMBERS
The Vehicle Identification Number (VIN), the model number, and the serial number are all printed on the Nameplate/Identification Decal attached to the crossmember under the dash (See Fig 1).
The serial number and model number are also stamped on the front left lower ROPS upright. It is located to the left
of the model and serial no. decals (See Fig 2).
VEHICLE,
MODEL AND SERIAL NO.
VEHICLE SERIAL NO.
STAMPED INTO LOWER ROPS
Figure 1
Nameplate / Identification Decal
Figure 2
Serial Number And Model Number
ENGINE IDENTIFICATION NUMBERS
Your Cushman Turf-Truckster is equipped with a
Suzuki 660 3-cylinder, 4-cycle, 12-valve, liquid-cooled
gasoline powered engine,
The Engine Serial No. for the Suzuki 660 engine is
stamped onto the upper engine block on the right side of
the engine and is partially hidden by the right side
engine mount, therefore it is also hand printed on the
cylinder (valve) cover on the left-hand side of the
engine.
We recommend you immediately record all vehicle
identification numbers and keep in a secure place for
ease of accessibility if ever you should need them.
6
Serial No. Also
Hand Printed on the
Cylinder Cover
Figure 3
Suzuki 660 Engine Serial Number
SPECIFICATIONS
SPECIFICATIONS
Specifications subject to change without notice.
All turf models are equipped with either a 4-wheel or 3-wheel hydraulic brake system, and a lever operated parking brake
integral to the rear brake drums.
Rear Axle:
Models 898656, 898657 & 898658 . . . . . . . . . . . . 14.21:1 2-speed hypoid differential
Transmission: Models 898657 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-speed automatic
Models 898658 & 898656 . . . . . . . . . . . . . . . . . . . . 4-speed manual with low-low (creeper) 1st gear.
Capacities
Battery
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 gal. (24.6 L)
Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BCI Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Size 24
Cold Cranking Amps (minimum) . . . . . . . . . . . . . . . . 420
Reserve Capacity Minutes (minimum) . . . . . . . . . . . . 70
Ground Terminal Polarity . . . . . . . . . . . . . . . . . Negative
Cooling System:
Suzuki 660 . . . . . . . . . . . . . . . . . . . . . . . 3.3 qts. (3.1 L)
Crankcase (including filter):
Suzuki 660 . . . . . . . . . . . . . . . . . . . . . . . . 3.3 qt. (3.1 L)
Transmission (automatic) . . . . . . . . . . . . . . 3.7 qt. (3.5 L)
(manual) . . . . . . . . . . . . . . . 1.05 qt. (1.0 L)
Differential . (14.21:1) . . . . . . . . . . . . . 5.2 Pints (2.46 L)
Hydraulic System
Standard hydraulics . . . . . . . . . . . . . . . . . 4 gal. (15.2 L)
With Hi-Lo hydraulic accessory . . . . . . 7.6 gal. (28.8 L)
ENGINE SPECIFICATIONS
!
WARNING
• The engine governor controls are preset to
Tires
Front . . . . . . . . . . . . . . . . . . . . . . . . 20 x 10.00-10 Multi-Rib
Rear . . . . . . . . . . . . . . . . . . . 24 x 13.00-12 Titan Ultra Trac
Brake Fluid
Use type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dot 3
Towing Capacity (trailer hitch only)
Trailer GVWR . . . . . . . . . . . . . . . . . . . . 1,500 lbs (680 kg)
Tongue Weight . . . . . . . . . . . . . . . . . . . . 200 lbs (90.7 kg)
Fuel
Gasoline Engines . . . . . . . . . . . . . . . Unleaded gasoline
87 Octane or higher
Lubrication Recommendations
Transmission Fluid (automatic) . . . . . . . Mercon/Dexron II
(manual) . SAE EP 80-90 Gear Lube
Hydraulic System . . . . . . . . . . . . . . . . Hyd Benz Bio 377
or GreensCare 68
Differential Oil . . . . . . . . . . . . SAE EP 80-90 Gear Lube
Pressure Gun Grease . . . . . . . . . . . . . . . . . . Lithium Base
Power Steering . . . . . . . . . . . . Power Steering Fluid (GM)
Steering
14.1 ratio Saginaw power steering and a 14 inch
(355.6 mm) steering wheel
control engine and ground speeds to design
limits. To prevent premature engine failure and
speeds greater than design limits, NEVER alter
the governor controls in any manner to
increase engine speed beyond recommended
maximum R.P.M.
Suzuki 660 EFI Engine
Horsepower (SAE hp) . . . . . . . . . . . . . . . . . . . . . . . . 31
Max. Engine Speed . . . . . . . . . . . . . . . . . . . 4450 RPM
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.60” (66mm)
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.56” (65mm)
Displacement . . . . . . . . . . . . . . . 40.1 cu in. (657 cm3)
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . 10.5:1
Cylinder Compression . . . . . . 178 PSI (1,228 kPa)
Engine Rotation
(viewed from flywheel) . . . . . . . . Counterclockwise
Valve Clearance (intake) .0031″ (0.08 mm) - cold
(intake) .0047″ (0.12 mm) - hot
(exhaust) .0039″ (0.10 mm) - cold
(exhaust) .0047″ (0.12 mm) - hot
Spark Plug Gap . . . . . . . . . . . .032-.035 (0.8-0.9 mm)
Spark Plug Number . . . . . . . . . . . Denso XU22EPR-U
Spark Plug Torque . . . . . 18.5-21.5 lb. ft. (25-30 N⋅m)
Ignition Timing . . . . . . . . . . . 4-5 BTDC @ 950 RPM
Idle Speed . . . . . . . . . . . . . . . . . . . . . . . 950 50 RPM
7
CONTROLS
GAUGES, WARNING LIGHTS and CONTROLS
The following pages contain information which will help you become more familiar with the different
gauges and controls used while operating this vehicle.
TACHOMETER (1)
Indicates the engine speed (x 100) in revolutions per
minute (See Fig. 4).
HOUR METER (2)
The hour meter (See Fig. 4) records the number of
hours the engine has run. The hour meter runs when the
key switch is “ON” even if the engine is not running.
FUEL GAUGE (3)
The fuel gauge (See Fig. 4) indicates the amount of fuel
remaining in the fuel tank.
BRAKE FLUID LEVEL WARNING LIGHT (6)
This light (See Fig. 5) indicates the brake fluid level is
low.
WATER TEMPERATURE GAUGE, AND
OVERHEAT WARNING BUZZER (7)
The purpose of this system is to warn the operator if the
engine temperature exceeds the normal operating
range.
If the water temperature gauge (See Fig. 5) raises above
the 230 F (110C) mark, a heat sensor is activated
causing the overheat warning buzzer to sound.
OIL PRESSURE WARNING LIGHT (4)
The red oil pressure light (See Fig. 4) indicates oil pressure is too low for engine operation.
7
1
4
5
3
2
Figure 4
Dash Panel Identification
VOLTMETER (5)
6
Figure 5
Dash Panel Identification
ACCESSORY POWER PLUG
A power port is available for plugging in laptop computers, cellular phones and other accessory items which
require a 12-volt plug-in (See Fig. 6).
The voltmeter (See Fig. 4) indicates the voltage level of
the battery. Under normal operation it will indicate 12 to
18 volts (meaning the battery is being properly
charged). A reading below 12 volts indicates the battery is being drained, this may indicate a malfunction
in the charging system which should be checked
immediately.
CHECK ENGINE LIGHT (6) Model 898656 Only
The “Check Engine Light” (See Fig. 5) is also the brake
fluid level warning light. If this light comes on and remains
on, check the brake fluid level, if the fluid level is correct (but
the light remains on) have the vehicle inspected by the
shop mechanic.
8
ACCESSORY
POWER PLUG
Figure 6
Accessory Power Plug
CONTROLS
IGNITION SWITCH
1. ACCESSORY POSITION – Allows use of various instruments and accessories without causing ignition
system damage.
2. OFF POSITION – Prevents function of all vehicle electrical power operated features except for the flasher (hazard) lights, and the radiator cooling fan. Switch must be
in OFF position for key removal.
3. ON POSITION – Key is placed in this position for normal
engine operation.
4. START POSITION – Hold key in start position to
engage engine starter. Upon release, key will return to
ON position automatically. Key must be returned to
the OFF position before the starter can be reactivated.
NOTE: Do Not turn key to START position with vehicle
engine running. Damage to flywheel teeth may
result.
!
IGNITION SWITCH POSITIONS
(SHOWN AS REFERENCE ONLY)
Figure 7
Four Position Ignition Switch
DANGER
• Never turn the key to the START position unless the gear selector is in “Park”, neutral or
if you have a manual transmission, unless the clutch pedal is depressed. If the clutch
pedal is not depressed and the vehicle is in any gear other than neutral (park or neutral
for automatic transmissions) and the engine is started, the vehicle may lurch forward or
backward depending which gear the vehicle is in. This lurching could cause serious
personal injury or death.
• If the engine will start without depressing the clutch pedal (or with the gear selector in
“R”, “D”, “2”, or “L” for automatic transmissions) DO NOT operate the vehicle. The
vehicle should be repaired immediately by your authorized Cushman dealer.
PARKING BRAKE LEVER
NOTE: Park brakes are not automatically applied. Make
sure to set the park brake when leaving the
vehicle.
The park brake lever is located to the left side of the drivers
seat. To engage the brake, pull up on the lever until park
brake is applied (the handle will not pull back any further).
To release, while slightly pulling up on the handle, push the
button at the end of the lever and, while holding the button
in, lower the lever to it’s original position (See Fig. 8).
PARK BRAKE
LEVER
Park Brake Lever
Shown in the
Released Position
Figure 8
Park Brake Lever
9
CONTROLS
HORN BUTTON
The horn button is located to the left of the steering
wheel, below the dash panel. Depress to sound horn.
Horn will not sound when the ignition switch is in the
OFF position.
LIGHT SWITCH
LIGHT SWITCH
The light switch is used to turn the headlights and taillights on. The switch has three detents, OFF, DIM, and
BRIGHT. Push switch up one detent for DIM or push
switch up two detents for BRIGHT.
HEADLIGHT OPERATION SYMBOLS
HORN BUTTON
Figure 9
Horn Button and Light Switch Location
OFF
DIM
(1st Detent)
BRIGHT
(2nd Detent)
FOOT CONTROL PEDALS
CLUTCH PEDAL (Manual Transmission Only)
The clutch pedal has to be depressed before shifting
into any of the gears. The clutch has a Safety Feature
called a “clutch interlock switch”. This switch prevents the starter from operating unless the clutch is disengaged (the clutch pedal is depressed).
CLUTCH PEDAL
If the engine will start without depressing the clutch
pedal:
• DO NOT operate the vehicle. The clutch interlock
system should be repaired immediately by your
authorized Cushman dealer.
The clutch pedal has to be depressed:
before starting the vehicle
before shifting into any of the gears
and
before coming to a complete stop
Figure 10
Clutch Pedal Location
(Manual Transmission Only)
!
DANGER
• Never start the engine unless the clutch pedal is depressed (pushed down). If the vehicle is in
any gear other than neutral, with the clutch pedal not depressed and the engine is started, the
vehicle will lurch forward or backward depending which gear the vehicle is in. This lurching
could cause serious personal injury or death.
10
CONTROLS
FOOT THROTTLE PEDAL
(ACCELERATOR PEDAL)
Push pedal down to open throttle (increase speed),
release the pedal to return throttle to idle position
(decrease speed).
ACCELERATOR
PEDAL
BRAKE
PEDAL
SERVICE BRAKE PEDAL
Depress the pedal to slow or stop the vehicle.
If the brakes DO NOT stop the vehicle properly, the
brakes must be adjusted or repaired.
Figure 11
Foot Control Pedals
(Clutch Pedal With Manual Trans. Only)
!
CAUTION
• Improper maintenance of brake system can result in the operator losing control of vehicle.
• Loads not properly secured can quickly shift causing personal injury or vehicle damage if
the brakes are applied too hard and fast.
GEAR SELECTOR
Manual Transmission
The gear selector has an “H” pattern as shown in Fig. 12.
There is also a shift-pattern design molded into the top of
the gear selector handle.
Refer to the section “Driving the Vehicle” for
information on the proper way to shift gears.
Remember, before shifting to any gear you have to
depress the clutch pedal before you shift to that particular gear.
!
1
3
N
2
4
R
Figure 12
Shift Pattern (Manual Transmission)
DANGER
• Never start the engine unless the clutch pedal is depressed (pushed down). If the vehicle is in
any gear other than neutral, with the clutch pedal not depressed and the engine is started, the
vehicle will lurch forward or backward depending which gear the vehicle is in. This lurching
could cause serious personal injury or death.
11
CONTROLS
Gear Selector (con’t.)
Automatic Transmission
The gear selector has the gear selections listed on the left
side of the shifter handle. Some units may have the
gear selections on the right side as shown in Fig. 13.
Push in the selector lever button when shifting in or out
of “P” Park , into “N” Neutral or when down shifting to
“2” Second or “L” Low from “D” Drive.
It is not necessary to use the button when shifting up
from Low, Second or Drive to Neutral, from Reverse
(R) to Neutral or from Neutral to Drive.
Refer to the section “Driving the Vehicle” for
information on the proper way to use the gear
selector.
!
Figure 13
Automatic Transmission Gear Selector
DANGER
• Never turn the key to the START position unless the gear selector is in “Park” or neutral.
If the vehicle is in any gear other than Park or neutral, and the engine is started, the
vehicle may lurch forward or backward depending which gear the vehicle is in. This
lurching could cause serious personal injury or death.
• If the engine will start when the gear selector is in “R”, “D”, “2”, or “L” DO NOT operate
the vehicle. The vehicle should be repaired immediately by your authorized Cushman
dealer.
VEHICLE OPERATION
!
WARNING
• This is heavy equipment that may cause serious injury or death to you the operator or
bystanders if improperly used or overturned.
• NEVER operate this vehicle until you have read and understand the operator’s manual.
• ONLY trained and authorized persons shall operate this vehicle.
• NEVER allow children to operate the vehicle.
Read this section carefully and thoroughly in order to become familiar with proper operating
procedures.
Be sure to obtain an operating demonstration from your Cushman dealer before attempting to drive the
vehicle.
12
CONTROLS
Vehicle Operation (con’t.)
!
WARNING
• This is heavy equipment that may cause serious injury or death to you the operator or
bystanders if improperly used or overturned.
• NEVER operate this vehicle until you have read and understand the operator’s manual.
• ONLY trained and authorized persons shall operate this vehicle.
• NEVER allow children to operate the vehicle.
1. BEFORE using the vehicle, always check all parts of unit and any attachments. If something is
wrong DO NOT use the vehicle. Fix the problem before using the vehicle to prevent possible
injury.
2. WHILE using the vehicle, if something is wrong, STOP using it. Fix the problem before using the
vehicle again.
3. ALWAYS make sure the area of operation is clear of litter, trash and other foreign objects.
4. NEVER carry any persons on the vehicle other than the operator and any passenger for which a
proper seat has been provided by the manufacturer (depending on model).
5. ALWAYS keep both hands on the steering wheel whenever possible. A passenger must ALWAYS
use handholds provided.
6. To avoid loss of steering control, NEVER hang or install anything of a foreign nature such as a
steering knob (spinner) on the steering wheel.
7. ALWAYS use extreme care when backing and make sure no one is behind you. To maintain vehicle
control, ALWAYS back the vehicle carefully at reasonable speed.
8. ALWAYS keep arms and legs inside of vehicle while it is moving. Sit only in seats provided by the
manufacturer. Any body parts that stick out past the side of vehicle could be hit by nearby
objects.
9. ALWAYS stay a safe distance away from pedestrians, ramp edges, platforms, other equipment,
etc.
10. ALWAYS watch for and avoid low overhang such as tree limbs, overhead walkways, etc. Make sure
there is enough room overhead for your vehicle and your head to clear easily.
11. ALWAYS drive straight up and down the face of an incline, ramp, grade, slope, NEVER across the face.
12. ALWAYS slow down:
Before you turn.
When driving in strange areas.
When crossing railroad tracks, chuck holes or other rough ground surfaces.
13. NEVER make sudden stops, turns or accelerations which may upset the vehicle.
14. ALWAYS use good judgement when operating on or near an incline, ramp, grade, slope or other surface.
15. ALWAYS adjust your speed to conditions (dry, moist, icy, etc.).
16. NEVER start or stop suddenly. You may unseat your passenger or cause unstable vehicle operating
conditions.
13
CONTROLS
Vehicle Operation (con’t.)
17. NEVER change direction of vehicle abruptly or make sharp turns on an incline, ramp, grade, slope or
other surface.
18. NEVER drive the vehicle with the engine speed increased by the hand throttle. Loss of vehicle control
could result.
19. ALWAYS keep your windows clean and unobstructed.
20. The addition of any accessory equipment and the carrying of any payload will make the vehicle
slightly less stable when turning or driving on slopes. A cab may make it hard for drivers to judge how
fast they are going. To prevent loss of control and possible upset, ALWAYS slow down before turning
and then turn corners slowly.
21. ALWAYS run vehicle where there is plenty of fresh air to prevent a buildup of carbon monoxide fumes.
Carbon monoxide is colorless, odorless and deadly. NEVER run vehicle in an enclosed space where
exhaust fumes will collect.
22. NEVER overload your vehicle. The nameplate (on cross-tube under dash) shows heaviest load you
can carry. ALWAYS position loads carefully so they can’t shift or tip over suddenly. ALWAYS keep
loads low (not top heavy) so vehicle does not get top heavy when driven. ALWAYS place loads on rear
deck (box) AHEAD of rear axle. If you place heavy loads behind the rear axle, the front wheel(s) will
begin to lift off the ground and vehicle may become unstable. Steering control may be lost.
23. ALWAYS fasten the seat belt (if so equipped) BEFORE starting the engine.
24. ALWAYS make sure the engine is stopped and cool before removing radiator pressure cap. To prevent scalding by hot water, NEVER remove the radiator cap while engine is hot.
25. NEVER use the vehicle in or near an area where there is dust or fumes in the air which are explosive.
The electrical and exhaust systems of this vehicle will make sparks which can ignite explosive materials.
26. ALWAYS signal that you are going to turn or stop so that other persons know what you plan to do.
Obey all traffic rules and regulations.
PRE–STARTING CHECKLIST
Before starting your engine for the first time; after a prolonged shutdown; and before each days use,
check the following:
Check the engine oil level.
Check tire pressure.
Check the radiator coolant level and radiator intake screen.
Check brake fluid level.
Check the fuel level.
ENGINE BREAK IN
The service life of your engine is dependent upon how
your engine is operated during the first 50 hours of
operation.
ALWAYS: Use care not to overload your engine
Maintain engine oil level
Maintain cooling system
14
!
WARNING
• To prevent premature engine failure and
speeds greater than design limits,
NEVER alter the governor controls in any
manner to increase engine speed beyond
recommended maximum R.P.M.
SERVICE & MAINTENANCE
FUEL LEVEL
1. Check fuel level in fuel tank. Turn the ignition switch to the ON position,
fuel level will be determined by how far the fuel gauge needle rises. The
illustration below shows the various levels for reading the fuel gauge.
2. Fuel tank capacity is 6.5 gal. (24.6 L). Fill if necessary using the
following fuel recommendations:
• Gasoline Engines - Unleaded gasoline with an 87 or higher
Octane reading.
The fuel tank is located on the right side of the vehicle in front of the
rear tire.
!
•
•
•
•
•
•
Fuel Tank Volume
WARNING
Remove fuel cap slowly. Fuel may be under pressure. Spray may cause serious injury.
Engine fuels are extremely flammable and highly explosive under certain conditions.
NEVER remove the fuel tank cap or attempt to refuel the unit while the engine is running.
NEVER refuel indoors. NEVER smoke while refueling.
ALWAYS wipe up spilled fuel immediately.
NEVER operate the unit without an approved cap on the fuel tank filler opening.
Gasoline Containing Alcohol
We DO NOT recommend the use of ALCOHOL bearing fuels in any of our products. The use of these fuels may
create a potential safety hazard.
!
WARNING
• Gasoline containing ALCOHOL can cause deterioration of some non–metallic materials in the
•
•
•
fuel system.
Fuel hoses must be inspected frequently and replaced if excessive stiffness, deterioration or fuel
leakage is found.
Gasoline containing ALCOHOL will attract and hold moisture inside fuel tanks. Moisture may
cause corrosion of metallic parts within the fuel system.
Fuel leakage from a fuel system can occur while the system is in use, in transit, or in storage. Such
leakage can contribute to an explosion or fire, causing serious bodily injury or death.
OIL LEVEL (Engine)
Always turn the engine off when checking the oil level. Oil level should be checked daily.
NOTE: Make sure vehicle is parked on a level surface with the park brake applied.
If the engine has recently been running, allow time (with the engine turned off) to let the oil settle to obtain a
correct level reading.
15
SERVICE & MAINTENANCE
Engine Oil Level (con’t.)
Remove the dipstick and wipe with a clean rag, reinsert
the dipstick until the small cap on the dipstick contacts the
oil tube, remove dipstick and read the oil level (dipstick is
located on the right side of the engine, to the right and
below the rear of the alternator).
OIL DIPSTICKS MAY
VARY IN APPEARANCE
OIL LEVEL MUST
BE BETWEEN THE MARKS
The oil level should always between the ADD and FULL
mark on the dipstick. DO NOT OVER FILL.
If the oil level is below the add mark, add an SAE 10W-30
oil to bring the level up between the marks.
Remove the oil fill cap and add the appropriate amount of
engine oil. Use the dip stick to check the level again, if oil
level is sufficient, replace oil fill cap.
DO NOT OVERFILL
DO NOT
OVERFILL
ADD OIL IF THE LEVEL
IS AT OR BELOW THIS MARK
Figure 16
Oil Level Reading
Engine Oil Capacity, Suzuki 660 . . . . . 3.3 qts. (3.1 L)
Engine Oil Replacement Filters:
Suzuki 660 . . . . . . . . . . Order Part No. 2701908
Engine Oil
Dipstick
OIL PRESSURE LIGHT
Figure 14
Dipstick Location
Figure 17
Oil Pressure Warning Light
Engine
Oil Fill Cap
Suzuki 660
SAE 10W-30 for all temperature ranges
°F
–20
°C –30
Figure 15
Oil Fill Cap
NOTE: If you notice the oil pressure warning light
coming on while driving the vehicle, Stop the
vehicle and check for problems.
16
0
–20
20 32 40
–10
0
10W-40
60 77 80
10
20 25 30
100
40
Temperature Range Anticipated Before Next Oil Change
Using multi grade oils (5W-20, 10W-30, and 10W-40) will
increase oil consumption. Check oil level more frequently
when using them.
SERVICE & MAINTENANCE
TIRE PRESSURE
1. Check all tires for proper inflation. Keep tires inflated to the specifications corresponding to that particular tire size.
Air pressure needed is determined by the payload carried. Adjust pressure as required. Lower pressure will help
avoid leaving tire marks in soft turf. Higher pressures may be required for heavy loads. NEVER exceed the maximum pressure indicated on the tire.
TIRE SIZE
TIRE PRESSURE
20-8.00 X 10 (4 PLY) . . . . . . . . . . . . 20 PSI (138 KPA)
20-10.00 X 10 . . . . . . . . . . . . . . . . . . 20 PSI (138 KPA)
24-13.00 X 12 . . . . . . . . . . . . . . . . . . 15 PSI (110 KPA)
NOTE: Improper inflation will shorten the life of your tires considerably. Fill tires with care. Use a pressure gauge
before connecting an air hose to a partly inflated tire. Due to the low air volume needed, over-inflation
may be reached in a matter of two or three seconds.
RADIATOR COOLANT LEVEL
The vehicle is equipped with a cooling radiator and an electric cooling fan.
!
WARNING
• The cooling fan is thermostatically controlled and may start at any time, even with the
ignition key in the OFF position, DO NOT attempt service without first disconnecting the
negative (–) battery cable or without first removing the fan fuse.
• The cooling system is under pressure, if a leak is present, be careful when raising the seat
or when opening the engine cover. Hot coolant can be sprayed causing personal injury.
To provide proper engine cooling it is important to keep
the cooling system properly maintained. Part of maintaining the system involves making sure the intake
screen, radiator fins and surrounding engine areas
remain free of debris.
• DO NOT obstruct or cover the intake screen in front
of the radiator. Keep the fins and radiator screens
clean.
RADIATOR AND RADIATOR FINS ARE
LOCATED BEHIND THE SCREEN
• If the radiator fins or intake screen become dirty, air
cannot circulate well enough to cool the engine sufficiently, therefore you risk the chance of the engine
overheating. Engines damaged due to overheating caused by plugged radiators WILL NOT be
warranted.
The cooling system level and the intake screen should
be checked every day before vehicle operation.
Figure 18
Intake Screen (Right Side of Vehicle)
Along with the daily pre-start list, you should also:
1. Check the radiator and coolant hoses for leaks and faulty connections, repair as necessary.
2. Inspect the engine belts for fraying or cracking and check the engine for loose hardware.
17
SERVICE & MAINTENANCE
Radiator Coolant Level (con’t.)
NOTE: Clean the radiator fins with compressed air. If water is used to clean the radiator, use compressed air to blow all
the water from the fins. Water left between the fins will collect dirt and plug the radiator, this will reduce the amount
of air flow to properly cool the engine. Engines damaged due to overheating caused by plugged radiators
WILL NOT be warranted.
DRAINNG & FILLING THE COOLING SYSTEM
The cooling system should be drained and refilled every 400 hours or nine (9) months.
Cooling System Capacity: Suzuki 660 Engine . . . . . . . . . 3.3 qts. (3.1 L)
Disconnect the negative (–) battery cable or remove the
electric fan fuse from the fuse panel under the front hood.
After the engine has cooled, remove the radiator cap, place
an approved container below the radiator and open the
drain cock at the bottom of the radiator (remove the bottom
radiator hose to completely drain the system). Also drain the
fluid from the coolant reservoir bottle.
Connect the lower radiator hose (if removed), close the
drain cock and make sure coolant reservoir is properly
secure.
!
WARNING
• ALWAYS make sure the engine is stopped
and cool before removing the radiator cap.
To prevent scalding by hot water, NEVER
remove cap while radiator is hot.
NOTE: Most communities have a disposal site for this type of refuse. Please dispose of fluids properly.
To Fill the Cooling System:
Make a 50/50 mixture of anti-freeze and water in a separate container before adding coolant to the radiator. Never
add straight anti-freeze to the radiator, the mixture must never be more than 50% anti-freeze.
Unless the radiator is very low, always add coolant to the overflow reservoir not to the radiator.
Fill radiator to the bottom of the filler neck with the anti-freeze/water mixture and fill the reservoir bottle to the full
mark.
Loosen the bleeder bolt on top of the thermostat housing (See Fig’s. 19 & 20 below) until coolant begins to come out
through the bleeder bolt port. Once coolant begins to leak from the hole, retighten the bolt.
Run the engine with the raditor cap removed until the upper radiator hose gets warm (this will tell you the thermostat
has opened allowing coolant to circulate through the whole system). The coolant level will drop as the coolant circulates, continue adding coolant until the level remains constant approximately 1/4” (6.3 mm) from the bottom of the
filler neck.
Cooling System
Bleeder Bolt
Figure 19
Bleeder Bolt on Models 898657 & 898658
18
Cooling System
Bleeder Bolt
Figure 20
Bleeder Bolt on Model 898656
SERVICE & MAINTENANCE
WATER TEMPERATURE GAUGE
and OVERHEAT WARNING BUZZER
The purpose of this system is to warn the operator if the engine temperature exceeds the normal operating range.
If the water temperature gauge raises above the 230 mark, a heat sensor is activated causing the overheat warning
buzzer to sound.
During operation (driving), if the water temperature
gauge shows 230° F (110° C) or over, and/or the overheat warning buzzer sounds, follow this procedure:
1. STOP the vehicle, DO NOT STOP THE ENGINE.
2. Immediately disengage any accessories that are
operating.
3. Slow the engine to a “fast idle”.
4. Remove any dirt , chaff, debris, etc. from the radiator
intake screen located on the right side of the engine
cover (the intake screen and surrounding area
will be hot, use caution when removing debris
from this area).
The temperature indicator on the gauge should go
down within approximately 30 seconds after the
intake screen is cleaned. If the temperature does
not go down, STOP THE ENGINE and check the
following areas:
WATER TEMP
GAUGE
Figure 21
Water Temperature Gauge
1. Raise vehicle seat and visually check to see if electric radiator fan is operating and check to determine if there
may be a leak in the cooling system (allow ample time for the engine and surrounding area to cool before
attempting to perform any service or maintenance).
!
WARNING
• Be careful when opening the engine cover, when raising the seat and when cleaning the
chaff from around the intake screen. Parts that are metal may be hot to the touch.
• The vehicle seat is a machinery guard. To avoid injury, use extreme caution and DO NOT
place hands or clothing near moving parts (belts, fan, etc.).
• ALWAYS make sure the engine is stopped and cool before removing the radiator cap or
before performing any service or maintenance on or around the engine area. To prevent
scalding by hot water, NEVER remove the radiator cap while radiator is hot.
• The cooling system is under pressure, if a leak is present, be careful when raising the seat
or when opening the engine cover. Hot coolant can be sprayed causing personal injury.
2. Check the radiator fins and screen. If they are dirty, they must be cleaned. Engines damaged due to
overheating caused by plugged radiators WILL NOT be warranted.
3. Check oil engine level.
4. Check radiator and coolant reservoir levels.
Failure to:
(1) heed the overheat warning and
(2) maintain cooling system, will cause permanent damage.
19
OPERATING THE VEHICLE
STARTING THE ENGINE (Gasoline Engines)
Automatic Transmission
1. Apply the park brake (the parking brake should have been applied when the vehicle was last parked).
2. Make sure the gear selector is in Park “P” (engine will not start if gear selector is in “R”, “D”, “2”, or “L”).
If the engine will start when the gear selector is in “R”, “D”, “2”, or “L” DO NOT operate the vehicle. The
vehicle should be repaired immediately by your authorized Cushman dealer.
3. Turn the ignition key to the ON position and observe the warning lights and gages (some of the warning lights
will remain on until the engine has started and is running).
!
DANGER
• Never turn the key to the START position unless the gear selector is in “Park” or neutral.
If the vehicle is in any gear other than Park or neutral, and the engine is started, the
vehicle may lurch forward or backward depending which gear the vehicle is in. This
lurching could cause serious personal injury or death.
• If the engine will start when the gear selector is in “R”, “D”, “2”, or “L” DO NOT operate
the vehicle. The vehicle should be repaired immediately by your authorized Cushman
dealer.
4. Turn and hold ignition key in the START position to engage engine starter, release key when engine starts
(upon release, the key will automatically return to the ON position).
• If the engine does not start after operating starter for 10 seconds, stop the starter. Wait for 30 seconds, then
try to start the engine again (turn key to Off before restarting).
• The starter motor should never be run for more than 30 seconds.
5. Allow engine to warm-up before driving the vehicle (always allow at least one minute for the engine to
warm-up).
Manual Transmission
1. Make sure the parking brake is applied (the parking brake should have been applied when the vehicle was last
parked).
2. Turn the ignition key to the ON position and observe the warning lights and gages (some of the warning lights
will remain on until the engine has started and is running).
3. Move the gear selector to “NEUTRAL”.
4. Push clutch pedal down (starter will not operate unless clutch pedal is pushed down). The clutch interlock switch prevents the starter from operating unless the clutch is disengaged (the clutch pedal is depressed).
If the engine will start without depressing the clutch pedal DO NOT operate the vehicle. The clutch interlock
system should be repaired immediately by your authorized Cushman dealer.
!
DANGER
• Never turn the key to the START position unless the clutch pedal is depressed
(pushed down) or the gear selector is in neutral. If the vehicle is in any gear other
than neutral, and the clutch pedal is not depressed when the engine is started, the
vehicle may lurch forward or backward depending which gear the vehicle is in.
This lurching could cause serious personal injury or death.
20
OPERATING THE VEHICLE
Starting The Engine, Gasoline Engines, Manual Transmission (con’t.)
5. Turn and hold ignition key in the START position to engage engine starter, release key when engine starts
(upon release, the key will automatically return to the ON position).
• If the engine does not start after operating starter for 10 seconds, stop the starter. Wait for 30 seconds, then
try to start the engine again (turn key to Off before restarting).
• The starter motor should never be run for more than 30 seconds.
6. Allow engine to warm-up before driving the vehicle (always idle and warm-up the engine for at least one minute)
DRIVING THE VEHICLE
Automatic Transmission
After the engine has been started:
Depress the brake pedal and move the gear selector to
either “D” Drive or “R” Reverse, depending on which
direction you want the vehicle to travel (you can select
“2” Second or “L” Low, but Drive is recommended for
normal driving).
Release the park brake, release the brake pedal and
slowly depress (push down) the accelerator pedal to
achieve the desired speed.
Vehicle engine speed should NEVER be faster than
idle speed when shifting from PARK or NEUTRAL
into REVERSE, DRIVE, SECOND or LOW, sudden
vehicle movement may occur.
Figure 22
Automatic Transmission Gear Selector
NOTE: Accelerating the engine speed with the transmission in gear (REVERSE, DRIVE, SECOND or LOW) while
holding the vehicle with the service brake or parking brake, may cause transmission damage.
MAKE SURE the vehicle is at a complete stop before moving the selector lever to PARK or when shifting
from DRIVE to REVERSE, or from REVERSE to DRIVE, if vehicle is not completely stopped, transmission
damage may occur.
When driving forward down a steep incline or long grade, the transmission may be shifted to a lower gear
(SECOND or LOW) to help slow the vehicle. Excessive or prolonged use of brakes can cause loss of braking
efficiently or loss of braking function due to overheating and can cause premature brake wear.
Manual Transmission
After the engine has been started, release the parking brake.
Determine which direction you need the vehicle to go and select a gear using the gear selector lever.
The gear selector has an “H” pattern as shown in Fig. 23 (there is also a shift-pattern design molded into the top of
the gear selector handle).
With the clutch pedal fully depressed, select the appropriate gear (forward or reverse), release the clutch pedal
slowly while depressing the throttle pedal.
21
OPERATING THE VEHICLE
Driving the Vehicle, Manual Transmission (con’t.)
As you release the clutch pedal you will notice after the
pedal has been partially released the vehicle begins to
move. When the vehicle begins to move, give the
throttle a little more gas and at the same time keep
releasing the clutch pedal.
1
3
N
When selecting the forward direction, begin with
1st or 2nd gear shifting to the next higher gear as the
vehicle gains speed.
2
4
R
NOTE: 1st gear is a “creeper” gear, high engine r.p.m.
can result in damage to engine if care is not
taken before shifting to 2nd gear.
Figure 23
Gear Shifting Pattern
When the vehicle gains enough speed, depress the
clutch pedal and shift to the next higher gear and so on.
When you shift gears remember that as you push in
the clutch you need to release the throttle pedal.
DO NOT drive with the clutch pedal partially depressed.
NOTE: Do Not push in the accelerator pedal at the same time you push in the clutch to shift the gears.
Only downshift if the vehicle is at a complete stop, or if the engine’s speed is decreasing.
Remember, before shifting to any gear you have to depress the clutch pedal before you shift to that gear.
You can down-shift from fourth to third, from third to second and so on while the vehicle is moving but only when the
engine’s speed is decreasing (even though the engine rpm’s and the vehicles’ speed is decreasing, some of the
lower gears may require the vehicle to come to a near or complete stop while down-shifting).
If the engine rpm and/or the vehicle speed is not decreased sufficiently and you try to down-shift, it is possible to
damage the transmission. Do Not force the gear selector to the next lower gear, slow the engine and vehicle speed
until the gear selector can be shifted properly.
STOPPING, PARKING (LEAVING) THE VEHICLE
Manual Transmission
Before you leave the operator’s seat, do the following things in the order shown below.
1. Bring the vehicle to a COMPLETE stop and hold in position with the service brake while depressing the clutch
pedal (when bringing the vehicle to a stop, apply the brakes until the vehicle has slowed then push the clutch in and
apply the brakes until the vehicle comes to a complete stop).
!
DANGER
• If the clutch pedal is not depressed (pushed down) or if the clutch pedal is released
before the engine has completely stopped and the gear selector is in any gear other
than neutral, the vehicle may lurch (jump) forward or backward, depending which
gear the vehicle is in. This lurching could cause serious personal injury or death.
22
OPERATING THE VEHICLE
Stopping, Parking (Leaving) the Vehicle (con’t.)
2. After the vehicle has come to a complete stop, turn
the key switch to the “OFF” position while holding
the clutch and the brake pedals down until the
engine is COMPLETELY STOPPED. Place the
vehicle in first gear, remove your foot from the brake
pedal and remove the ignition key to prevent unauthorized use of vehicle.
3. Apply the parking brake. The parking brake is
NOT automatically applied.
When parking the vehicle or starting the engine on
an incline, the front wheel should be “curbed”
whenever possible (See Fig 24).
Figure 24
Vehicle parked With Front Wheel(s) Curbed
Automatic Transmission
Before you leave the operator’s seat, do the following things in the order shown below.
1. Bring the vehicle to a COMPLETE stop and hold in position with the service brake. Move the gear selector to the
“P” Park position and apply the park brake, then remove your foot from the brake pedal.
2. Turn the ignition key to the “OFF” position. Remove the key to prevent unauthorized use of the vehicle.
When parking the vehicle or starting the engine on an incline, the front wheel should be “curbed”
whenever possible (See Fig 24).
TOWING A TRAILER (Trailer Hitch)
Trailer GVWR – 1,500 lbs. (680 kg)
Tongue Weight – 200 lbs. (90.7 kg)
This vehicle is capable of pulling trailers and other equipment of greater weight than the vehicle itself, so caution and
good judgment must be used to avoid losing control of the vehicle while braking or cornering.
Connect the equipment to be pulled to the trailer hitch on the rear of the vehicle. Secure using a tow pin or similar
object. Be sure to secure the tow pin (or similar object) so it cannot fall out of the mounting hole.
!
WARNING
• NEVER pull loads which may exceed the
braking capacity of the vehicle. The operator
must determine if the Cushman vehicle has
adequate braking capacity to stop either a
loaded or unloaded vehicle and the trailer on
the type(s) of surface(s) and grade(s) on
which the vehicle will be operated.
Trailer Hitch
• Position the load on the trailer so that the
tongue weight on the towing vehicle will not
cause instability or affect steering control.
• NEVER make sudden stops, turns or accelerations when towing a trailer or equipment.
Figure 25
Trailer Hitch
23
SERVICE & MAINTENANCE
SERVICE and MAINTENANCE
Think Ahead! Work Safely!
!
WARNING
• When replacement parts are required, use genuine Cushman parts or parts with equivalent characteristics
including type, strength and material. Failure to do so may result in product malfunction and possible injury
to the operator and/or bystanders.
• Never attempt to perform service or maintenance functions on this vehicle if you are UNAUTHORIZED or
UNTRAINED. Improper maintenance can cause hazardous conditions. See your authorized CUSHMAN
dealer for necessary maintenance and service.
• Note the Safety and Operation decals applied to various parts of the vehicle, replace any decals which may
become illegible, torn, or removed from the vehicle.
FRONT COWL ACCESS
The front cowl opens to gain access to the fuse panel, the
horn, the master cylinder reservoir as well as various access
panels which when removed, allow access to wiring for the
dash panel, shifting lever linkage and the upper part of the
front suspension.
To open the front cowl; while facing the front of the vehicle,
locate the release lever near the upper left corner of the left
side headlight.
Pull the lever to the right to release the front cowl latch and at
the same time pull up on the front cowl.
Pull Lever
To Release
Cowl Latch
FRONT COWL
RELEASE LEVER
Open the cowl allowing it to rest against the rops structure (if
equipped) or the steering wheel.
The front cowl will not “spring up” when the release lever is
pulled. The cowl will have to be raised when the latch is
released.
Figure 26
Release Lever For Front Cowl
DIAGNOSTIC CHECK (Electrical System)
The electrical system is equipped with a plug-in connector which, when used with the Diagnostic Jumper Accessory
(Part No. 2700920) will perform diagnostic checks on various electrical components.
Place the gear selector into park, apply the park brake and turn the ignition switch to the off position.
Open the front cowl (hood) and locate the plug-in connector coming from the small section of wire-harness below the brake
fluid reservoir (See Fig. 27).
Plug the diagnostic jumper into the plug-in connector.
Turn the ignition switch to the on position and note the brake fluid level warning light at the lower left corner of the instrument
panel (See Fig. 28).
The light will flash a code to let you know that everything is normal (Code 12) or to let you know which specific component
needs attention.
The light will first flash to correspond to the first digit of the code, then flash again to correspond with the second digit of the
code.
24
SERVICE & MAINTENANCE
Diagnostic Check, Electrical System (con’t.)
Brake Fluid Level Warning Light
(Also Used for Diagnostic Check)
Existing
Plug-in Connector
From Wire Harness
Diagnostic
Jumper
Figure 27
Diagnostic Jumper Shown Connected
Figure 28
This Light Will Flash For Diagnostic Check
A Code 14 would turn the light on for 0.3 seconds then off for one second (long pause), then on-off, on-off, on-off, on-off (the
last four flashes will be short quick flashes).
If a Code 43 were present the light would - flash then pause,... flash then pause,... flash then pause,... flash then pause, then
flash, flash, flash (four long pauses followed by three quick flashes).
The code will continue to repeat itself until the ignition switch is turned off (if there are multiple faults, each code will be
displayed three (3) times starting with the lowest numbered code).
Turn the ignition key to the off position, then back to the on position each time you want to take a reading.
The following list shows which code number corresponds to which component
and lists possible causes for each fault:
CODE
11 Pressure Sensor – Voltage at pin 25 (green/yellow wire) of the 34 pin ECU connector is either higher than 4.5 V or
lower than 0.19V.
12 Normal – System operating normally
13 Throttle Sensor – Voltage at pin 33 (gray/yellow wire) of the 34 pin ECU connector is either higher than 4.73V or lower
than 0.25V.
14 O2 Sensor – No signal for a length of time at pin 24 ot the 34 pin ECU connector.
15 Crank Angle Sensor – While in starting mode, no signal is seen at pin 16 (brown/red wire) of the 34 pin ECU connector.
16 Vehicle Speed Sensor – No signal for a length of time at pin 16 (orange wire) of the 26 pin ECU connector.
19 Water Temperature Sensor – Voltage at pin 32 (green/white wire) of the 34 pin ECU connector is either higher than
4.85V or lower than 0.15V.
41 Shift Solenoid No. 1 – Open or short circuit at pin 27 (blue/black wire) of the 34 pin ECU connector, should be “on” if
gear selector is in “L” (“on” meaning there should be 12 volts going through this wire).
42 Shift Solenoid No. 2 – Open or short circuit at pin 28 (blue/white wire) of the 34 pin ECU connector, should be on if gear
selector is in “L” or “2” (“on” meaning there should be 12 volts going through this wire).
43 Shift Solenoid No. 3 – Open or short circuit at pin 29 (blue/red wire) of the 34 pin ECU connector.
46 Shift Switch – No signal at pin 18 (green/pink wire) of the 26 pin ECU connector, and no signal at pin 19 (orange/blue
wire) of the 26 pin ECU connector, and no signal at pin 20 (orange/green wire) of the 26 pin ECU connector, and no
signal at pin 24 (green/blue wire) of the 26 pin ECU connector, and no signal at pin 25 (green wire) of the 26 pin ECU
connector, and no signal at pin 26 (red wire) of the 26 pin ECU connector.
or
signal present at more than one of pins 18, 19, 20, 24, 25 and 26 of the 26 pin ECU connector.
25
SERVICE & MAINTENANCE
FUSES
The fuse box is located under the front cowl (See Fig. 29).
The fuses protect the electrical lighting circuits and accessory circuits such as the windshield washers, turn signals
etc.
When replacing fuses, make sure the ignition key is
turned to the off position and all switches associated with
that fuse are also in the off position.
Be sure the replacement fuse is the same amp as the
fuse being replaced.
Pull straight out to remove a fuse. To install a fuse, push
the new fuse into the appropriate fuse slot.
FUSE
PANELS
You can troubleshoot most blown fuses using the process
of elimination, for instance; did the fuse blow when a specific accessory was turned on, when the headlights were
turned on, or perhaps the instrument panel lights flickered
then went dead while traveling on a bumpy road.
Some of the more common causes of electrical failure
are loose wires, loose ground wire(s), faulty connections,
broken or exposed wires and improper connections.
Figure 29
Fuse Block Located Under Front Cowl
If you replace a fuse and the replacement fuse blows when power is again supplied to that source and this continues to
happen each time you replace the fuse there may be a more serious problem than anticipated, please contact your
Cushman Service Representative for further assistance.
!
CAUTION
• Fuses continuously being “blown” when electrical power is supplied may indicate a more
serious problem, if the problem continues and you can’t pin-point a problem, please contact
your Cushman dealer for the service representative nearest you.
• Electrical failure and/or fire can result if the fuses are not the proper amperage.
Models 898656 and
Models 898658 Beginning With
Serial No’s. 00002120 Will Have a 20AMP Fuse
ACC
Power Port
Engine
Coils
ECU
15
Taillights
Trailer Lights
15
Headlights
Brake Lights
Fuel Relay
15
10
ECU
10
10
Wiper,
Dome light
ECU
Accy. Plug
Fuse panels shown left to right as they would appear mounted to the firewall.
26
Back-up
Alarm
Main Relay
10
Turn
Signals
Engine
Injectors
20
15
Accy. Plug
Accy. Plug
10
Instrument
Panel
10
Heater
5th Wheel Brake
Horn
Radiator
Fan
10
Shift
Switch
SERVICE & MAINTENANCE
BULB REPLACEMENT, DASH PANEL
Remove the four (4) screws securing the instrument
panel to the dash.
Pull the instrument panel out and tilt forward to gain
access to the rear of the panel (See Fig. 30).
Determine which bulb will be replaced. Rotate the bulb
holder 1/4 turn, pull up and remove holder and bulb.
Remove the bulb from the holder and replace with the
appropriate bulb. Reverse this sequence to install the
bulb and holder.
Use the number printed on the bulb to obtain the
correct replacement bulb, also refer to the chart on
Page 28 for bulb specifications.
BULB AND
HOLDER
ROTATE 1/4 TURN
Figure 30
Dash Panel Bulb Removal
HEADLIGHT REPLACEMENT
Remove the four (4) screws securing the headlight
bezel to the front cowl (See Fig. 31).
HEADLIGHT
BEZEL
Pull the headlight and bezel from the front cowl opening.
Disconnect the electrical connector from the rear of the
headlight and remove the headlight from the bezel.
Replace headlight and install in the reverse sequence
used for removal.
REMOVE THE FOUR (4) SCREWS
FOR HEADLIGHT REMOVAL
Figure 31
Headlight Removal
Headlight . . . . . . . . . . . Part No. 837303
Bezel . . . . . . . . . . . . . . . Part No. 841428
Mounting Screws . . . Part No. 800943
BULB REPLACEMENT, TAILLIGHT
Remove the two (2) screws securing the taillight lens to
the taillight.
Remove the bulb and replace with a No. 1157 bulb.
Replace the lens cover making sure the gasket is positioned correctly.
To remove the taillight from the vehicle, remove the two
(2) nuts and shakeproof washers securing the taillight to
the frame.
Taillight Assembly . . . . . . . . .
Bulb . . . . . . . . . . . . . . . . . . . . . . .
Lens Screws . . . . . . . . . . . . . . .
Lens and Gasket . . . . . . . . . . .
License Illuminator Lens . . .
Part No. 893602
Part No. 822049
Part No. 312288
Part No. 829099
Part No. 829099
REMOVE THE TWO (2)
SCREWS FOR BULB
OR LENS REPLACEMENT
Figure 32
Taillight Bulb Replacement
27
SERVICE & MAINTENANCE
BULBS, FUSES AND FLASHER
BULBS:
Voltmeter light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil pressure warning light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water temperature gauge light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel gauge light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hour Meter Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn signal(s), front (accessory) . . . . . . . . . . . . . . . . . . 32 CP . . . . . . . . .
Taillight(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-4 CP . . . . . . .
Headlight(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-45 Watt . . . . .
FUSES:
...............................................
...............................................
...............................................
...............................................
No. GE 658
No. C194
No. C161
No. GE 658
No. GE 658
No. GE 658
No. 1156 . . . . . . . . . Part No. 837670
No. 1157 . . . . . . . . . Part No. 822049
No. H6545 . . . . . . . Part No. 837303
10 AMP . . . . . . . . . . . . . . . . . . . . . . . . . .
15 AMP . . . . . . . . . . . . . . . . . . . . . . . . . .
20 AMP . . . . . . . . . . . . . . . . . . . . . . . . . .
30 AMP . . . . . . . . . . . . . . . . . . . . . . . . . .
Part No. 836892
Part No. 849983
Part No. 826000
Part No. 833038
FLASHER: Turn signal (accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part No. 825501
ACCESS PANELS
There are four access panels; two (2) located under the
front hood, one located in the middle of the floorboard
and one located on the fame behind the stopwall.
The panels under the front hood allow access to the
shifter linkage, some of the electrical wiring for the instrument panel and sections of the front suspension.
The panel on the floorboard allows access to the throttle
cable, linkage, electrical wire harness, as well as the
brake lines running to the master cylinder. It will be necessary to remove the accelerator pedal in order to
completely remove the center floorboard panel.
The panel behind the stopwall allows more access to the
engine and transmission areas
To remove any of the panels, simply remove the hardware securing the panel and remove panel.
Access Panel
Access Panel
Figure 34
Access Panels Under Front Hood
(3-Wheel Model Shown)
Remove This
Panel
Floorboard
Access Panel
Figure 33
Access Panel on Floorboard
28
Figure 35
Rear Platform Access Panel
SERVICE & MAINTENANCE
DASH PANEL DIPSWITCH SETTINGS
Remove the four (4) screws securing the instrument
panel to the dash.
Pull the instrument panel out and tilt forward to gain
access to the rear of the panel (See Fig. 36).
DIPSWITCH SETTINGS
LOCATION
Using a small blade screwdriver or similar tool, push the
switch levers either up or down using the following
sequence codes (the top of the dash panel will be referenced as “position 1”)
Figure 36
Dash Panel Dipswitch Location
SEQUENCE CODE 0 1 1 1 0 0 1 0
SEQUENCE CODE 0 0 0 1 0 1 1 0
MODEL: 898658 With
Serial No’s. Up To Rev1287
MODELS: 898656, 898657 &
Models 898658 Beginning With
Serial No’s. 00002120
ENGINE MAINTENANCE
Keep your engine clean.
If dirt has accumulated on the engine, it should be washed with a non-flammable solvent or strong detergent.
!
WARNING
• To reduce risk of fire, always keep the engine free of excessive grease.
• The engine cover is a machinery guard. Never remove or install the engine
cover while the engine is running. Moving parts can cause personal injury.
When washing becomes necessary, it can be carried out simultaneously when servicing the vehicle.
In order to maintain reliable service from your engine, a regular check-up and maintenance schedule should be
followed.
The following maintenance information covers basic engine service only.
For extensive service and repairs, we recommend contacting the authorized Cushman dealer nearest you.
Proper maintenance will prolong the engine’s life and avoid premature overhaul.
Access To Engine
Never remove or install the engine cover while the engine is running. The engine cover is a machinery guard and its
removal exposes you to moving parts. Keep hands, hair and clothing away from flywheel, radiator cooling fan, alternator fan, engine belts, pulleys and air intake.
To gain access to the engine, push the engine cover latch to the rear of the unit, tilt cover forward. The latch is located
on top of the engine cover (center-rear, between the seat cushion(s) and backwall).
29
SERVICE & MAINTENANCE
Access to Engine (con’t.)
When replacing the engine cover, make sure the retaining tabs, located at the front corners of the engine cover, are
inserted into the slots in the floorboard.
!
WARNING
• Failure to latch the seat properly can result in the engine cover tipping forward
causing loss of control of the vehicle and possible personal injury.
There is also a key-lock latch available. To gain access to the engine on models with a locking handle, insert the key
into the locking handle located at the side of the engine cover latch, turn the key to allow the latch to be pushed back
(the locking handle can also be used as an accessory on any of the other turf vehicles).
ENGINE COVER
LATCH
Figure 37
Engine Cover Latch
RETAINING TAB
IN SLOT ON
FLOORBOARD
Figure 38
Engine Cover Retaining Tab
AIR CLEANER ELEMENT
This is a large capacity dry type air cleaner with a replaceable element.
We recommend the filter element be replaced before
engine performance is effected. This may occur at 250
hours of service in very dirty operating conditions or at 500
hours in normal operating conditions.
Alternator
We DO NOT recommend cleaning the filter element
because of the possibility of damaging the element.
Checking and Installing the Element
Air
Cleaner
Tilt the engine cover forward and locate the air cleaner on
the right side of the engine (See Fig. 39).
To remove the air cleaner element release the latches
securing the cover to the air cleaner assembly. Remove
the filter element.
Figure 39
Air Cleaner Assembly
Check the element for damage, pin holes, etc. by placing a
light source such as a flashlight inside.
Air Cleaner Complete . . . . . . . . Part No. 892679
Air Cleaner Element . . . . . . . . . Part No. 840352
30
SERVICE & MAINTENANCE
Air Cleaner Element (con’t.)
Replace the element with a new one if it is damaged or is
excessively clogged with dirt and/or debris.
Clean dust from inside of housing with damp cloth, making
sure dust does NOT enter air intake.
Check all gaskets to be sure they are NOT damaged or
loose.
Insert element in housing open end first.
ELEMENT
Position the cover so that the collector is pointing down.
Clamp cover into position with collector pointing down.
DUST COVER
• DO NOT use bent or dented air cleaner assemblies.
• DO NOT use bent or damaged air cleaner element.
• The dust collector empties automatically when
properly installed with collector down.
!
DUST COLLECTOR
Figure 40
Air Cleaner Element and Dust Cover
(Shown Removed From the Housing)
WARNING
• Before servicing or doing any maintenance work around the engine area,
make sure the engine has had time to cool. Serious burns can result if the
engine or surrounding area is hot.
A dirty, clogged or damaged air filter will cause the engine to start hard as well as run rough and sluggish. Don’t forget
to check the air cleaner element if the engine does not run smoothly and other problems cannot be found.
POWER STEERING (4-WHEEL MODELS)
The power steering reservoir is located on the right side of
the engine, below and to the right of the alternator.
The level in the reservoir should be checked after the
first 35 hours and then again after another 35 hours,
after that the level should be checked every 100 hours.
Use GM power steering fluid to maintain the correct fluid
level.
Power Steering
Reservoir
Remove the power steering reservoir cap. When checking
the fluid level for the first time at the beginning of the day,
the fluid level should be at the “cold” mark on the dipstick.
When checking the fluid level after the engine has been
running and the fluid is warm, the level should read
between the “cold” and “hot” marks.
Figure 41
Power Steering Reservoir
31
SERVICE & MAINTENANCE
BATTERY
The battery is located on the left side of the vehicle, directly behind the stopwall behind the drivers seat.
The battery is negative ground and if connected in the opposite polarity, damage to the alternator will occur. The
same applies when connecting a booster battery to the system.
!
WARNING
• Untrained/Unauthorized persons should
NEVER attempt to service or recharge the
battery in this vehicle.
• Battery electrolyte is an acidic solution and
should be handled with care. If electrolyte is
spilled or splashed on any part of the body,
immediately flush the exposed area with liberal amounts of water and obtain medical aid
immediately.
Figure 42
Voltmeter (Battery Charging System)
The battery in this vehicle is “low maintenance”.
Add distilled water as required.
NOTE: Keep top of battery clean and free of corrosion
by washing with a solution of baking soda and
water or ammonia and water. Rinse with clean
water. Terminals with heavy corrosion should
be removed and cleaned with solution. For
best results clean both battery post and cable
terminals until shiny. Replace terminals and
tighten.
BATTERY
TURF VEHICLES
The voltmeter indicates the voltage level of the battery.
Under normal operation it will indicate 12 to 18 volts
(meaning the battery is being properly charged). A reading below 12 volts indicates the battery is being drained,
this may indicate a malfunction in the charging system which should be checked immediately.
Figure 43
Battery Location For Turf Vehicles
JUMP STARTING WITH A BOOSTER BATTERY
!
•
•
32
WARNING
DO NOT allow open flames or sparks near a battery when connecting for jump
starting or while recharging the battery with a charger.
Hydrogen gas is produced during the charging process and can be explosive.
Provide adequate ventilation to prevent possible explosion.
SERVICE & MAINTENANCE
Jump Starting With a Booster Battery (con’t.)
Both booster battery and discharged battery should be treated carefully when using jumper cables.
Follow exactly the procedure outlined, being careful not to cause sparks.
1. Apply parking brake, put transmission in neutral and turn off all electrical loads.
2. Attach one end of one jumper cable to the positive (+) terminal of the booster battery and the other end to the
positive (+) terminal of the discharged battery. DO NOT permit vehicles to touch each other.
(2) CONNECT CABLE TO
POSITIVE TERMINAL ON
DEAD BATTERY
(1)
CONNECT CABLE TO
POSITIVE TERMINAL ON
GOOD BATTERY
(+)
(4)
CONNECT CABLE TO
FRAME OR ENGINE BLOCK
OF DISABLED VEHICLE
(+)
(–)
(–)
(3)
CONNECT CABLE TO
NEGATIVE TERMINAL ON
GOOD BATTERY
BOOSTER (GOOD) BATTERY
DISCHARGED (DEAD) BATTERY
3. Attach one end of remaining cable to the negative (–) terminal of the booster battery and the other end to a
good ground on the vehicle or engine away from the discharged battery. DO NOT lean over the battery
when making this connection.
4. Reverse this sequence exactly when removing the jumper cables.
NOTE: This is a negative ground wiring system, reversing battery connection will
damage alternator rectifier.
Booster batteries used for starting must be connected with proper polarity.
Vehicle battery cables should be disconnected before using a “Fast
Charger.”
TOWING THE VEHICLE (automatic transmission)
When transporting the vehicle or when it is disabled, the BEST method of moving the vehicle is
on a trailer. If that is not possible, the driveshaft
MUST be removed before towing the vehicle.
If towing the vehicle with a tow-rope or a chain, an
operator is required to steer the vehicle and to
control the brakes.
!
WARNING
• NEVER tow the vehicle faster than 5 M.P.H. (8 km/h).
Towing at excessive speed could cause either
vehicle to lose proper steering control.
33
SERVICE & MAINTENANCE
Towing the Vehicle, Automatic Transmission (con’t.)
TOW LINE ATTACHMENT
Attach a tow line (tow line attaching locations are shown in Fig. 44)
only to the front vertical frame member of the vehicle.
Release the park brake and slowly move the towing vehicle forward until the tow line becomes tight.
Tow at a maximum speed of 5 m.p.h. (8 km/h).
While towing, try to keep the tow line taught at all times. Be cautious
going down inclines and while turning corners.
If in an EMERGENCY and the vehicle must be towed and the drive
shaft cannot be removed, attach a tow line to the front vertical frame
member ONLY. Make sure the transmission is in “N” Neutral and
the park brake is released. Tow at a maximum speed of 5 m.p.h.
(8 km/h).
Manual Transmission
If for any reason the vehicle needs to be towed, follow the guidelines below to properly tow the vehicle.
If towing the vehicle with a tow-rope or a chain, an operator is
required to steer the vehicle and to control the brakes.
Attach a tow line only to the front vertical frame member on either
side of vehicle as shown in Figure 44.
A Front Bumper Accessory (Part No. 894778)
is Available For Use With the Turf Truck. If a
Front Bumper is Mounted on Your Vehicle,
Make Sure to Follow the Instructions Included
With the Bumper For Proper Connection of the
Chain or Tow Rope.
Figure 44
Tow Line Attachment Location
Make sure the drive transmission is in “neutral” (out of gear) and
the park brake is released.
With the tow line attached, have the towing vehicle move forward until the tow line becomes tight.
!
WARNING
• NEVER tow the vehicle faster than 5 M.P.H. (8 km/h). Towing at excessive
speed could cause either vehicle to lose proper steering control.
While towing, try to keep the tow line taught at all times. Be cautious going down inclines and while turning corners.
JACKS, JACKING LOCATIONS AND USING A HOIST
A scissors type jack or a floor jack with a 1 1/2 ton (minimum) capacity that can be lowered to 3 3/8” (86mm) height
is required.
The jacking locations are shown In the chart illustration on the following page.
Put the gear selector in “P” Park (for automatic transmissions). Apply the park brake (for manual transmissions,
place gear selector in 1st gear and apply the park brake.
Place a jack in the appropriate location (See Fig. 45) and place a block behind (or in front) of the tire diagonally
opposite the side which is being raised (See Illustration on following page).
34
SERVICE & MAINTENANCE
Jacks, Jacking Locations and Using a Hoist (con’t.)
!
WARNING
• DO NOT rely solely on hydraulic or mechanical jacks for support. Use appropriate
jack stands or equivalent for supporting the vehicle.
• If using a hoist, raise vehicle to appropriate height and support using jack stands or
equivalent support.
• Never place feet, hands or any part of your body under the vehicle when raising it
with a hoist.
Jack the vehicle to the appropriate height and place jack
stands or equivalent support beneath the frame near the
jack. Lower the jack and allow the vehicle to rest on the jack
stands.
The illustration shows the frame without the body
in order to show the jacking locations more clearly.
NOTE: Raise the vehicle only enough to perform the
maintenance required.
When using a hoist to raise the vehicle, use the
same procedure for supporting the frame and
blocking the tires as you would when using a jack.
♦
♦
♦
To prevent damage to the vehicle or attached
accessory, NEVER use a hoist to raise only one
corner of the vehicle. ALWAYS raise BOTH front
or rear corners equally.
♦
♦ - JACKING LOCATION
When removing the front tire on the three-wheel vehicle,
place blocks behind both rear tires, then jack one side of the
vehicle to the appropriate height and place jack stands or
equivalent support beneath the frame. Lower the jack and
allow the vehicle to rest on the jack stands.
♦
♦
Raise the opposite side of the vehicle enough to allow the
front tire to clear the ground. Place supports under the frame
and lower the jack to allow the vehicle to rest on the jack
stands.
♦
♦
Figure 45
Jacking Locations
Block Tire Here
If Using Jack Here
Block Tire Here
♦
♦
♦
If Using
Jack Here
If Using Jack Here
♦
Block Tire Here
If Using Jack Here
♦
♦
Block Tire Here
35
SERVICE & MAINTENANCE
TIRE REMOVAL (Front and Rear)
With the vehicle on a flat level surface (if possible), put the gear selector in Park and apply the park brake.
Place a block in front of (or behind) the tire diagonally opposite the side which is being raised (Refer to the “Jacks,
Jacking Locations and Using a Hoist” section in this manual).
Raise the vehicle only enough to perform the maintenance required.
1. Remove the wheel retaining nuts and remove tire
and wheel assembly from hub.
2. Install the tire and wheel by reversing the above
sequence. Make sure valve stem is located toward
the outside.
VALVE
STEM
3. Tighten wheel retaining nuts to 70 to 100 ft. lbs.
(95 to 140 N·m) torque.
!
WHEEL
RETAINING NUTS
WARNING
• DO NOT rely solely on hydraulic or
mechanical jacks for support. Use
appropriate jack stands or equivalent for
supporting the vehicle. Never place feet,
hands or any part of your body under the
vehicle when raising it.
Figure 46
Wheel Retaining Nuts and Valve Stem
TIRE REMOVAL 3-Wheel Front
Put the gear selector in 1st gear (manual transmissions) or in “P” Park (for automatic transmissions). Apply the
park brake.
Place a block behind both rear wheels (Refer to the “Jacks, Jacking Locations and Using a Hoist” section in
this manual).
Raise the vehicle only enough to perform the maintenance required.
BRAKE LINK
ANCHOR BOLT
With the vehicle raised and properly supported, remove
the brake link anchor bolt and bushing. Retain hardBRAKE HOSE
ware.
CLAMP
Loosen the axle nuts on each side of the front tire,
loosen the nuts enough to allow the washer to slide out
of the retaining slot (the washers have a tab on them
which fits into a slot on the axle support).
Support the tire, slide the washers out and remove tire
and axle assembly (it may be necessary to remove the
brake hose clamp to allow the axle to clear the front
fork). Remove the wheel retaining nuts and remove the
tire from the axle.
Install the tire and wheel by reversing the above
sequence.
AXLE NUT AND
RETAINING WASHER
Figure 47
3-Wheel Front Tire Removal
Tighten the wheel retaining nuts to 70 to 100 ft. lbs. (95 to 140 N·m) torque.
36
SERVICE & MAINTENANCE
BRAKES
This vehicle is equipped with a three or four wheel hydraulic brake system and a hand operated park brake
lever.
!
WARNING
• Improper maintenance of the brake system may result in loss of vehicle control by
the operator. Losing control of the vehicle due to brake loss may cause vehicle
damage and/or injury to the operator or bystanders.
BRAKE FLUID
RESERVOIR
BRAKE FLUID LEVEL
INDICATOR LIGHT
Figure 48
Brake Fluid Reservoir
Figure 49
Brake Fluid Level Indicator Light
(Also “Check Engine” Light, Model 898656 Only)
If the brakes Do Not stop the vehicle properly, they must
be repaired before the vehicle is operated again.
The brake fluid master cylinder reservoir is located
under the front cowl.
If the brake fluid level indicator light (See Fig. 49) comes
on and remains on, check the brake fluid level in the reservoir.
The fluid level must be kept within the MIN (minimum)
and MAX (maximum) levels as shown in Figure 48. If you
notice continuous problems with the fluid level, check all
brake lines and hoses for leaks and/or tight connections.
When it is necessary to add fluid, use a DOT 3 type
brake fluid.
If the brakes do not hold properly, if they feel spongy or if
the brake fluid reservoir is allowed to “run-dry”, it may be
necessary to bleed the brake lines in order to get fluid
back into the system.
Bleeding a 4-Wheel Brake System
The brake fluid level indicator light also functions as the
“Check Engine” light on Models 898656. If the brake
fluid level is correct but the light remains on, have the
vehicle inspected by the shop mechanic.
FLUID LEVEL
Figure 50
Brake Fluid Level Reading
When bleeding the system with four wheel brakes, bleed the left rear brake first then the right rear, then the right
front and finally the left front.
Attach a hose to the bleeder screw on top of the left rear dust shield and place the other end of the hose in a container to catch the fluid run-off when bleeding the system (Most communities have a disposal system for this type of
refuse. Please dispose of fluids properly).
37
SERVICE & MAINTENANCE
Brakes, Bleeding a 4-Wheel Brake System (con’t.)
Loosen the bleeder screw. Have an assistant push down
on the brake pedal and hold pedal down. Tighten the
bleeder screw and release the brake pedal.
Loosen the bleeder screw again, press down on the brake
pedal, hold pedal down and tighten the bleeder screw,
release pedal.
Do Not release the brake pedal until the bleeder screw is
tightened otherwise air will be sucked back into the brake
lines.
Continue this procedure until all air bubbles are purged
from the system and a steady flow of fluid comes from the
brake line. Repeat the procedure on the right rear brake,
then the right front and finally the left front.
Do Not let the reservoir run dry when bleeding the system,
air can get back into the system meaning the whole bleeding process will have to be started over. Check the reservoir regularly when bleeding the system.
BLEEDER
SCREW
Figure 51
Bleeder Screw on Top of Dust Shield
(Front and Rear 4-Wheel, Rear 3-Wheel)
3-WHEEL BRAKES
Bleeding the 3-Wheel Brake System
For 3-wheel brakes, do the left rear, right rear, then the front.
Attach a hose to the bleeder screw (See Fig. 51) on top of the left rear dust shield and place the other end of the hose
in a container to catch the fluid run-off when bleeding the system. Most communities have a disposal system for this
type of refuse. Please dispose of fluids properly.
Loosen the bleeder screw. Have an assistant push down
on the brake pedal and hold pedal down. Tighten the
bleeder screw and release the brake pedal.
Loosen the bleeder screw again, press down on the brake
pedal, hold pedal down and tighten the bleeder screw,
release pedal.
Do Not release the brake pedal until the bleeder screw is
tightened otherwise air will be sucked back into the brake
lines.
Bleeder Screw
on 3-Wheel Front
Continue this procedure until all air bubbles are purged
from the system and a steady flow of fluid comes from the
brake line. Repeat the procedure on the right rear brake,
then the right front and finally the left front.
Do Not let the reservoir run dry when bleeding the system,
air can get back into the system meaning the whole bleeding process will have to be started over. Check the reservoir regularly when bleeding the system.
38
Figure 52
3-Wheel Front Bleeder Screw
SERVICE & MAINTENANCE
PARK BRAKE
The park brake applies the brakes to both rear wheels.
To engage the brake, pull up on the lever until park brake is applied (the park brake lever will be at an approximate 45
angle when applied).
To release, slightly pull up on the handle, push the button at the end of the lever and while holding the button in, lower
the lever to it’s original position.
Park Brake Adjustment
Raise the engine cover and locate the park brake cable and bracket beneath the console panel (See Fig. 54).
With the park brake released (brake lever down) tighten the adjustment nut a couple of turns and apply the park
brake, continue adjustment until the brake lever is at an approximate 45 when the brake is applied.
PARK BRAKE
LEVER
Park Brake Lever
Shown in the
Released Position
Figure 53
Park Brake Lever Location
PARK BRAKE
ADJUSTMENT NUT
Figure 54
Park Brake Adjustment Nut
GOVERNOR OIL LEVEL
Check the oil level in the governor after every 100 hours
of use. To check the level, remove the plug from the back
side of the governor. Oil should be up to the level of the
plug opening.
GOVERNOR OIL
FILL PLUG
Governor Oil Capacity . . . . . . . . 1.5 oz. (44 ml)
Oil Type . . . . . . . . . . . . . . . . SAE 20W engine oil
If fluid level is low, add the recommended oil type.
Remove the plug from the rear side of the governor,
remove the plug from the top of the governor and add an
SAE 20W motor oil until the oil begins to leak from the
rear port. Replace both plugs.
When replacing the plug, use Teflon tape or a Permatex
20 sealant (or equivalent pipe thread sealant) on the
threads of the plug.
GOVERNOR OIL
LEVEL CHECK PLUG
Figure 55
Governor Fill Plug (Suzuki Engines Only)
Torque the plugs to 95 ± 10 in.lb.
39
SERVICE & MAINTENANCE
TWO-SPEED DIFFERENTIAL (14.21:1)
The differential fluid should be checked every 100 hours (or 3 months) and changed after the first 100 hours.
After the first change at 100 hours the fluid should be changed every 600 hours (or 12 months).
Differential Fluid Capacity . 5.2 pints. (2.46 L)
Fluid Type . . . . . . . . SAE EP 80-90 Gear Lube
To check fluid level, remove the filler plug from the front of the differential.
Fluid should be level with the bottom of the filler hole. If level is low, add gear lube until the appropriate level is
reached (fluid will begin to leak from the filler hole when full level is reached). Replace filler plug.
To drain the differential fluid, remove the drain plug from the bottom rear of the differential and drain. Replace drain
plug and add fluid to the recommended level.
When draining and filling the differential, use a pipe thread sealant on the plug threads before replacing them.
LEVEL CHECK
AND FILL PLUG
DRAIN PLUG
Figure 56
Differential Filler and Level Check Plug
Figure 57
Differential Drain Plug
DRIVE TRANSMISSION
Manual Transmission (Suzuki 660 EFI Engine)
Maintaining proper lubrication level in the transmission is very important to the life of the gears and bearings.
Check transmission fluid level every 100 hours (or 3 months).
Change transmission fluid every 600 hours or (12 months).
Transmission Capacity: 1.05 qts. (0.9 L)
Recommended Lubricant: SAE EP 80-90 Gear Lube
The filler plug is located on the right side of the transmission. When removed, the filler plug opening is used to determine proper fluid level.
The fluid level must be level with the bottom of the filler plug hole.
If level is low, add fluid (through the filler hole) until it begins to flow from the filler hole. Reinstall the plug.
To drain the transmission fluid, remove the drain plug on the rear of the transmission.
When draining and filling the transmission, use a pipe thread sealant on the plug threads before replacing them.
40
SERVICE & MAINTENANCE
Drive Transmission, Manual (con’t.)
TRANSMISSION
DRAIN PLUG
TRANSMISSION
FILL PLUG
Figure 58
Transmission Drain Plug (Suzuki 660 EFI Engine)
Figure 59
Transmission Filler Plug (Suzuki 660 EFI Engine)
Automatic Transmission
Check transmission fluid level every 100 hours (or 3 months).
Change transmission fluid every 600 hours or (12 months).
Transmission Capacity: 3.7 qts. (4.2 L)
Recommended Lubricant: Mercon/Dexron II
To check the transmission fluid the engine must be running. Place the gear selector in “P” Park, apply the park brake
and start the engine.
With the engine running, remove the dipstick and wipe it with a clean rag. Insert the dipstick into the extension tube
until it contacts the tube. Remove the dipstick and read the fluid level.
Fluid must be kept between the two marks on the dipstick. If necessary, add fluid to obtain the proper level. Do Not
overfill. Add fluid using the extension tube as the fill tube.
To drain the transmission fluid, remove the drain plug located on the bottom left, rear corner of the transmission pan.
DRAIN PLUG
AUTOMATIC TRANSMISSION
TRANSMISSION
FLUID DIPSTICK
AND
FILL TUBE
Figure 60
Automatic Transmission Dip Stick
Figure 61
Automatic Transmission Drain Plug
NOTE: Most communities have special sites to dispose of used petroleum based products such as transmission fluid,
engine oil and differential fluid. Please use an appropriate container to catch any fluids and dispose of properly.
41
SERVICE & MAINTENANCE
MAINTENANCE GUIDE
The following maintenance charts have been compiled as a general
guideline for service intervals, based on hours of operation.
Maintenance Operation
Daily
Clean radiator intake screen
Check water separator, drain as required
(diesel only)
Check fuel level
Check engine oil level
Check cooling system coolant level
Check engine for loose parts, damage and leaks
Check exhaust color (diesel only)
Check for engine noise; vibration
Check tire pressure
First
35 Hrs
First
50 Hrs
Every
75 Hrs
or 2 months
Change engine oil and filter (Suzuki only)
*
Change engine oil (Perkins Diesel)
*
Change engine oil filter (Perkins)
*
Check valve clearance
(to be done by authorized dealer)
Check engine idle speed
Check power steering fluid
Change fuel filter
Lubricate chassis (see lube chart)
Check governor oil level (Suzuki engines)
Check differential oil level
Check transmission fluid level
Check hydraulic tank fluid level
Check brake fluid (BF)
Check brake adjustment
Check clutch adjustment
Every
100 Hrs
or 3 months
After first
100 hrs.
Change differential oil
* Depending on operating conditions, the engine oil and engine filter may need more frequent replacement.
If coolant level is low add a 50/50 mixture of water and anti-freeze, NEVER add straight anti-freeze to the coolant system
OIL FILTER:
Suzuki 660 EFI
(all models) - Part No. 2701908
AIR CLEANER ELEMENT:
(all models) - Part No. 840352
42
FUEL FILTER:
Suzuki 660 EFI
(all models) - Part No. 2701998
TIMING BELT
Suzuki 660 EFI
(all models) - Part No. 2701985
SERVICE & MAINTENANCE
Maintenance Guide (con’t.)
Maintenance Operation
Replace air cleaner element
Check valve clearance (See authorized dealer)
Check fan belt and tension
Inspect radiator hoses and clamps
Change coolant
Every
200 Hrs
or 6 months
Every
400 Hrs
or 9 months
Every
600 Hrs
or 12 months
Every
1500 Hrs
Replace hydraulic system filter
Change hydraulic system oil (tank only)
Clean battery and terminals.
Check alternator
Repack front and rear wheel bearings
Check starter motor brushes
Check brake linings
Change differential fluid
Drain and replace radiator coolant
Check engine idle speed
Check glow plugs (diesel only)
Check injection pump and timing (diesel only)
Check fuel hoses and clamps
Check all belts for tightness and cracking
Adjust front brakes
Replace timing belt (Suzuki engines)
Change transmission fluid
Check fuel hoses and clamps
Check spark plugs for fouling
(clean and gap as necessary)
* Depending on operating conditions, the engine oil and engine filter may need more frequent replacement.
Depending on operating conditions, the air filter element may require more frequent replacement.
SPARK PLUGS:
Suzuki 660:
Part No. 2701832 Denso XU22EPR-U
gap .032” - .035” (0.8 mm - 0.9 mm)
ENGINE BELTS, Suzuki 660:
4-Wheel (898657 & 898658)
Part No. 2700564 (gov, hyd pump)
53” (1346 mm)
Part No. 2700565 (alt., pwr strng.)
45” (1143 mm)
3-Wheel (898656)
Part No. 2700564 (gov, hyd pump)
53” (1346 mm)
Part No. 2701365 (alt., pwr strng.)
39” (991 mm)
43
SERVICE & MAINTENANCE
LUBRICATION RECOMMENDATIONS
Automatic Transmission Fluid . Mercon/Dexron II
Transmission Fluid (man) SAE EP 80–90 Gear Lube
Power Steering . . . . . Power Steering Fluid (GM)
Differential Fluid . . . . . SAE EP 80–90 Gear Lube
Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . Dot 3
Pressure Gun Grease . . . . . . . . . . . . . Lithium Base
Hydraulic Fluid . . . . . . Ransomes Turf Protector Biodegradable (Hyd Benz Bio 377) or
GreensCare 68 Biodegradable Hydraulic Oil
Lubricate all chassis fittings with lithium base pressure gun grease every 100 hours or 1000 miles.
4
4
2
4
2
Brake Fluid
Reservoir
Brake Fluid
Reservoir
3
3
Fuse Box
Fuse Box
1
Ref.
No. Lubrication Area
1.
2.
3.
4.
NOTE: Reference to item 1,
Too much grease can
damage the seals.
Number Of
Grease Fittings
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Ball Joints . . . . . . . . . . . . . . . . . . . . . .
Lower Ball Joint . . . . . . . . . . . . . . . . . . . . . . .
Tie Rod Ends, 4-wheel . . . . . . . . . . . . . . . . .
Tie Rod Ends, 3-wheel . . . . . . . . . . . . . . . . .
2
2
2
4
2
1
The biodegradable hydraulic fluidscan be ordered in the
following quantities:
Hyd Benz Bio 377
2 1/2 gal. (9.5 L) - Part No. 65363
5 gal. (19 L) - Part No. 65352
55 gal. (208 L) - Part No. 65354
GreensCare 68
5 gal. (19 L) - Part No. 5003103
55 gal. (208 L) - Part No. 5003102
ACCESSORIES, ATTACHMENTS and 5th WHEEL IMPLEMENTS
There are numerous accessories, attachments and implements available for your vehicle.
Some accessories and attachments include:
High/Low Hydraulics System; Steel Cab Sets; Steel Door Sets; Heater/Defroster; Dump Boxes; Platform Beds
also, the Quick Aerator, Core Harvester, TD 1500 & 2000 Top Dressers the Vicon Spreader,
Turf Master Sprayers, Seed & Fertilizer Spreaders......and more
For information and availability on these accessories and others, contact your local Cushman Dealer.
44
OPERATING REMOTE HYDRAULICS
EQUIPMENT
The following information will tell you about the different controls and functions used when operating
the P.T.O. and hydraulics system. These features are used when operating the accessories and
implements often used with this vehicle.
TWO–SPEED DIFFERENTIAL
844177
The two-speed differential has a high and low operating
range, as well as a neutral position.
TWO-SPEED
DIFFERENTIAL CONTROL
Shift the two–speed differential ONLY when the vehicle
is stopped . Pull the control handle all the way UP to
operate in the high range, push it all the way DOWN to
operate in the low range.
The two–speed differential control is located on the control panel to the left of the operator’s seat (See Fig 62).
Figure 62
Two-speed Differential Control Handle
POWER HYDRAULIC LIFT SYSTEM
The power hydraulic lift system is referred to as a “live” system. This means the hydraulic pump operates whenever
the engine is running.
The hydraulic lift control lever is located on the control
panel to the left of the driver’s seat (See Fig 63).
The hydraulic lift is used when the vehicle is equipped
with a dump box or similar accessory.
Push the lever forward and to the right to latch it in the
float position (the float position allows the accessory
being used to follow the contour of the land, the accessory, when in the lowered position, will “float” over the
ground even in undulating terrain).
HYDRAULIC LIFT
LEVER
844179
Decal Shows
Lever Positions
and Their Function
Figure 63
Hydraulic Lift Control Handle
Pull back on the lever to extend the hydraulic cylinder ram (raise the dump box) push forward on the lever to retract
the hydraulic cylinder ram (lower the dump box).
45
OPERATING REMOTE HYDRAULICS
REMOTE HYDRAULICS
The hydraulic system has a remote selector valve located at the front of the control panel, to operate accessories
such as the Core Harvester or Top Dresser.
844179
Decal Shows
Remote Hydraulic
Functions
MAKE SURE HOSE IS INSERTED
INTO THE QUICK COUPLER
WHEN AN ACCESSORY
IS NOT BEING USED.
NOTE: The “DOWN” position directs hydraulic oil to the
standard vehicle hydraulic lift system.
The “UP” position directs hydraulic oil to the left
side of the hydraulic panel for remote hydraulic
system use.
REMOTE
HYDRAULICS
CONTROL
Figure 65
Remote Hydraulics Closed Loop Shown
MOTOR DRIVEN
ACCESSORY
TRUCKSTER
CYLINDER
LIFT
VALVE
10
7
1
4
9
2
5
8
3
6
SELECTOR
VALVE
Figure 64
Remote Hydraulics Control Handle
FILTER
HYDRAULIC
TANK
HYDRAULIC
PUMP
When the remote hydraulics are not connected to equipment, the male and female quick connectors must be connected to form a closed loop (See Fig. 65).
It is extremely important that the hose nipple be inserted
into the quick connector to form a closed loop as shown.
This will prevent dirt from entering the system and prevent
the hydraulic system from over-heating, leading to system
failure if the remote selector knob is accidentally pulled up
with the accessory removed.
!
ACCESSORY
CYLINDER
PRESSURE
RETURN
SUCTION
PRESSURE OR RETURN
FOR MOTOR DRIVEN ACCESSORY AND
TRUCKSTER DUMP BOX OPERATION:
PLUG 1–4, 2–3, 8–9, 7–10.
FOR TRUCKSTER CYLINDER
OPERATION:
PLUG 1–4, 2–3, 7–8.
FOR MOTOR DRIVEN ACCESSORY AND
INOPERABLE TRUCKSTER CYLINDER:
PLUG 1–2, 3–4, 8–9, 7–10.
FOR ACCESSORY CYLINDER
OPERATION:
PLUG 1–5, 2–6, 4–3, 7–8.
Standard Hydraulic Hook-Up Shown
WARNING
• The vehicle is equipped with a hydraulic system to operate equipment. During operation,
ALWAYS stay clear of moving parts to prevent injury.
46
OPERATING REMOTE HYDRAULICS
GOVERNOR CONTROL AND HAND THROTTLE
A manually set, variable governor control is included with
the P.T.O. for regulation of P.T.O. or ground speed. The
control lever is attached to the panel to the left of the
instrument panel. The hand throttle lever is attached to
the same panel.
Hand Throttle
Governor Control
The engine governor is preset to control engine (vehicle)
ground speeds to design limits, to prevent speeds
greater than design limits, NEVER alter the governor
controls in any manner to increase speed beyond the
recommended maximum R.P.M.
Normal Operation Mode:
• Hand throttle control lever in “DOWN” position.
• Variable governor control in “UP” position.
Figure 66
Governor and Hand Throttle Controls
POWER TAKE OFF (Hydraulic P.T.O.)
The hydraulic P.T.O. transmits power from a hydraulic pump to a splined shaft at the rear of the vehicle for easy
hook-up and operation of optional equipment.
The control handle is located on the control panel to the left of the operator’s seat.
To activate the P.T.O., move the live hydraulic hose from the upper coupler on
the left side of the hydraulic panel to the lower coupler on the left side of the
panel as shown in Fig 68.
Make sure the hydraulic P.T.O. control handle is in the down position (if the control
handle is not down the P.T.O. shaft can start rotating).
NOTE: To engage P.T.O. ALWAYS STOP the vehicle, THEN pull the
P.T.O. control knob upward.
MOVE HOSE FROM UPPER
TO LOWER COUPLER
P.T.O.
CONTROL HANDLE
Figure 67
P.T.O. Control Handle Location
PULL UP to engage. – PUSH DOWN to disengage.
Figure 68
Moving Live Hydraulic Hose for Hydraulic P.T.O.
47
OPERATING REMOTE HYDRAULICS
Power Take Off, Hydraulic P.T.O. (con’t.)
For Use When The Vehicle Is Stationary
(Automatic & Manual Transmission)
Verify the accessory being used is properly attached and
all connection points are secure.
For automatic transmissions, put the gear selector in the
Park position, make sure the park brake is still applied
and start the engine. Continue with Step 1 shown below.
HI-Lo
Hydraulic Lever
For manual transmissions, put the gear selector in neutral
and engage the clutch (push the clutch pedal down),
make sure the park brake is still applied and start the
engine. Continue with Step 1 shown below.
1. Slide the hi-lo hydraulic lever to either the lo or hi position (See Fig. 69). Most applications will use the “lo”
hydraulic setting. Push the hand control throttle lever
to the up position (full throttle).
Figure 69
Governor and Hand Throttle Controls
2. Move the governor control lever to desired engine
R.P.M.
3. Lower the hand lever throttle to reduce engine speed
and pull up on the PTO control handle to engage the
PTO. Push hand lever throttle up to the full throttle
position
Governor Control
The PTO will not stop unless the PTO control
handle is pushed down.
!
WARNING
• When an attachment is not connected to the
P.T.O. shaft, disengage drive to the P.T.O. by
pushing the hydraulic control handle down
and replacing the live hydraulic hose in the
upper coupler.
Hand Throttle
Figure 70
Governor and Hand Throttle Controls
• The PTO runs when the control handle is up,
the control handle must be in the down
position for the PTO to stop.
• P.T.O. includes a spring loaded P.T.O. cover.
This cover must remain on the vehicle and
be used at all times. An uncovered rotating
spline can catch clothing and result in serious injury or death.
PTO
SHAFT
• ALWAYS disengage the P.T.O. before
attaching any equipment to the P.T.O. shaft.
• ALWAYS remain clear of the P.T.O. shaft and
all moving parts.
48
Figure 71
P.T.O. Shaft Location
OPERATING REMOTE HYDRAULICS
For Use While Vehicle Is Moving
(Automatic and Manual Transmissions)
1. Refer to the Power Take-Off R.P.M./Vehicle Speed decal to
select the proper P.T.O. and ground speed combination for the
accessory equipment being used. The decal representing the
P.T.O. and ground speed is located on the top of the engine
cover between the seats.
See Fig. 71 on the previous page for PTO rotation.
Make sure the accessory being used is properly connected and
ready for use.
898659/898657/898658
Automatic Transmissions
As you approach the work area, determine a starting point; stop the vehicle at the starting point; place the gear selector in Park and apply the park brake. Slide the hi-lo hydraulic lever to either the “lo” or “hi” position (See Fig. 69 on
the previous page) then continue with Step 2 below (although “lo” is the standard setting for operating accessories,
some accessories such as the Vicon Spreader, Top Dresser and Core Harvester will use the “hi” setting).
Manual Transmissions
As you approach the work area, determine a starting point; stop the vehicle at the starting point, with clutch pedal
depressed, place the gear selector in neutral and apply the park brake. Slide the hi-lo hydraulic lever to either the “lo”
or “hi” position (See Fig. 69 on the previous page) then continue with Step 2 below (although “lo” is the standard
setting for operating accessories, some accessories such as the Vicon Spreader, Top Dresser and Core Harvester will
use the “hi” setting).
2. Place the governor hand control to the full up position (See Figure 72). Push the foot throttle (accelerator)
pedal to the floorboard.
3. Move the governor control lever to adjust desired
engine R.P.M.
4. After desired r.p.m. has been set, release the accelerator pedal to allow the engine to return to idle.
Place foot on the brake pedal and release park brake.
Governor Control
Select desired gear, release brake pedal, press accelerator to the floorboard and pull up on the hydraulic
control handle to engage the PTO (the PTO can only
be stopped by pushing the control handle down.)
Begin driving the vehicle over the work area. Check
the accessory occasionally to ensure proper operation.
Even though the accelerator pedal is pushed all the
way down, the vehicle will only travel at the speed
allowed by the r.p.m. setting of the governor hand
control.
!
Figure 72
Governor Hand Control
WARNING
• NEVER attempt to drive the vehicle with the engine speed increased by the hand
throttle. The hand throttle also controls the foot throttle, so the foot throttle pedal
cannot be used to reduce engine and vehicle speed. FAILURE to obey this warning
may result in you, the operator, losing vehicle control.
49
OPERATING REMOTE HYDRAULICS
HYDRAULIC RESERVOIR
Normally the hydraulic system will not need additional fluid. Sometimes a leak may develop causing the system
to require repair and refilling.
!
WARNING
• Escaping hydraulic oil under pressure can have sufficient force to penetrate the skin,
causing serious injury. If injured by escaping fluid, see doctor at once. Serious infection
or reaction can develop if proper medical treatment is not administered immediately.
• After applying pressure to the system, use a piece of cardboard or wood, NOT your
hands, to check for leaks.
• Wear eye protection and use caution to stay clear of any moving parts.
If you notice hydraulic fluid escaping when the system is being used or if a leak is suspected, turn off all
hydraulic functions and stop the engine. Check the hoses and fittings to determine where the fluid may be
escaping from. If necessary, start the engine and using a piece of cardboard or similar material, check areas
where the leak is suspected. Repair as needed.
Periodically check the hydraulic fluid level (hydraulic level should be checked every 100 hours of operation).
Loss of fluid can signal a small leak before it becomes worse.
To check the hydraulic fluid level:
1. Place vehicle on level surface. Fully lower any
accessory attachment, including dump box. Stop
the vehicle engine.
2. Remove the dipstick/breather plug from the top of
the tank (See Figs. 73 and 74). Wipe the dipstick,
then place in tank with the threaded flange resting
on the tank (do not screw in). Fluid should show on
the knurled portion of the dipstick (See Fig 74).
Add fluid as required. Do Not overfill the hydraulic
system. Severe damage may result. Always
reinstall the dipstick/breather plug.
If additional fluid is needed, add either Ransomes
Turf Protector Biodegradable hydraulic fluid or
GreensCare 68 biodegradable hydraulic oil.
Hydraulic
Reservoir
Figure 73
Hydraulic Reservoir Tank
3. Screw the dipstick/breather plug securely in place.
Hydraulic System Capacity:
Standard Hydraulics . . . . . . 4 gal. (15.2 L)
Hi-Lo Hydraulics . . . . . . . . . 7.6 gal. (28.8 L)
Knurled Portion
on Dipstick
Ransomes Turf Protector Hyd Benz Bio 377
2 1/2 gal. (9.5 L) - Part No. 65363
5 gal. (19 L) - Part No. 65352
55 gal. (208 L) - Part No. 65354
GreensCare 68
5 gal. (19 L) - Part No. 5003103
55 gal. (208 L) - Part No. 5003102
50
Figure 74
Hydraulic Tank Dipstick
TORQUE SPECIFICATIONS
HEX HEAD CAP SCREWS
The torque values shown should be used as a general guideline when specific torque values are not given.
Note the minimum grade for the U.S. standard bolt is grade 5.
U.S. Standard Hardware
Shank Size (Diameter in inches, fine or coarse thread)
Grade
1/4 5/16 3/8 7/16 1/2 9/16 5/8
SAE
grade 5 **
SAE
grade 8 **
**
Flangelock
Screw w/
Flangelock
Nut
110
3/4 7/8
1
150 250 378 583
1 1/8
ft.-lbs.
9
18
31
50
75
782
N·m
12
24
42
68
102 150 203 339 513 790 1060
ft.-lbs.
13
28
46
75
115
N·m
18
38
62
108 156 224 305 502 801 1211 1912
ft.-lbs.
24
40
N·m
33
54
165 225 370 591 893 1410
Minimum commercial quality (Lower quality not recommended).
* Grade 5 marking –
** Grade 8 marking –
Metric Standard Hardware
Shank Size (Diameter in millimeters, fine or coarse thread)
Grade
Grade
8.8*
Grade
10.9**
Grade
12.9***
M4
M5
M6
M7
M8
ft.-lbs.
1.5
3
5.2
8.2
13.5
24
N·m
2
4
7
11
18
32
ft.-lbs.
2.2
4.5
7.5
12
N·m
3
6
10
16
ft.-lbs.
2.7
5.2
8.2
15
N·m
3.6
7
11
20
* Grade 8.8 marking –
8.8
M10 M12 M14 M16 M18 M20 M22 M24 M27
142 195 276
353 530
144
190 260 368
470 707
18.8 35.2 62.2 100 147
202 275 390
498 747
25
47
21.8 43.5
29
58
43.5 70.5 108
58
94
83
133 196
269 366 520
664 996
75
119
176
242 330 471
596 904
100 159 235
323 440 628
794 1205
** Grade 10.9 marking –
10.9
*** Grade 12.9 marking –
12.9
51
ENGINE COVER
SUZUKI 660 EFI TURF MODELS 898656, 898657 & 898658
17
7
15
5
16
7
9
25
13
3
20
8
9
Reference
Lower Rops
4
23
1
2
24
10
5
11
12
6
19
22
26
18
21
14
P893436
52
ENGINE COVER
SUZUKI 660 EFI TURF MODELS 898656, 898657 & 898658
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Part
No.
306328
308090
450452
450453
450454
800026
450541
452388
452398
523085
816401
830784
841789
841804
842030
No.
Req’d
Ref.
No.
Pin, cotter, .09 x .75 . . . . . . . . . . . 1
Washer, 1/4 . . . . . . . . . . . . . . . . . . 1
Nut, M6-1.00 (G10.9) . . . . . . . . . . . 2
Nut, M8-1.25 (G10.9) . . . . . . . . . . 2
Nut, M10-1.50 (G10.9) . . . . . . . . . . 5
Screw, 1/4-20 x 3/4 . . . . . . . . . . . . 7
Screw, M6-1.00 x 16 . . . . . . . . . . 10
Screw, M8-1.25 x 20 (8.8) . . . . . . 2
Screw, M10-1.50 x 20 . . . . . . . . . 5
Bracket . . . . . . . . . . . . . . . . . . . . . . 1
Spring, torsion . . . . . . . . . . . . . . . . 1
Pin, clevis, .25 x 1.88 . . . . . . . . . . 1
Catch, engine cover latch . . . . . . 1
Insulation, engine cover . . . . . . . . 3
Mount, backrest . . . . . . . . . . . . . . . 2
16
17
18
19
20
21
22
Description
*
*
*
23 24 25
26
Part
No.
893321
893322
2700789
845038
893541
894232
2700796
822819
844177
844179
840436
309488
2702725
450543
Description
No.
Req’d
Seat, base assembly . . . . . . . . .
Backrest assembly . . . . . . . . . . .
Cover, engine, w/decal . . . . . . .
Decal, Operation . . . . . . . . . . . . .
Handhold (right side) . . . . . . . . . .
Cover, left . . . . . . . . . . . . . . . . . . .
Panel, console (turf) . . . . . . . . . .
Decal, Warning, Park Brake . . . .
Decal, auxillary transmission . . . .
Decal, hydraulic controls . . . . . . .
Lock, handle . . . . . . . . . . . . . . . .
Washer . . . . . . . . . . . . . . . . . . . . .
Seal, seat base . . . . . . . . . . . . . .
Screw, M6-1.00 x 25 . . . . . . . . .
2
2
1
1
1
1
1
1
1
1
1
2
2
8
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
* Not Illustrated.
Although Item No’s. 23 & 24 (handle lock and washers) are used on EC Models, they may be obtained
for use on any turf vehicles.
53
BODY, HOOD, HEADLIGHTS
SUZUKI 660 TURF 4-WHEEL MODELS 898657 & 898658
16
Reference
Lower Rops
37
7
30
12
33
31
11
33
11
18
11
9
10
33
19
24
12
28
39
24
38 40
35
5
39
41
12
42
5
22
12
2
4
15
32
23
26
8
1
21
3
12
29
25
13
ÎÎ
ÎÎ
ÎÎ
17
27
36
14
20
6
11
6
11
13
12
34
Reference Front
Suspension Frame
(Part No. 893421)
54
P893332
BODY, HOOD, HEADLIGHTS
SUZUKI 660 TURF 4-WHEEL MODELS 898657 & 898658
Although Ref. No’s. 49, 50, 51
Keyswitch Plate and Associated Hardware
May Not be Installed on all Vehicles.
They Can be Ordered and Used on any Turf
Models Listed Above
35
51
50
49
43
13
45
48
8
44
Shown For
Reference Only
46
13
13
47
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
*
*
16
17
18
19
20
21
22
23
24
25
26
Part
No.
No.
Req’d
Ref.
No.
303952 Washer, #10 . . . . . . . . . . . . . . . . . . 1
894743 Nut ay., double 1/4-20 . . . . . . . . . 2
306419 Screw, 1/4-20 x 1/2 . . . . . . . . . . . . 2
306463 Pin, cotter . . . . . . . . . . . . . . . . . . . . 1
38061A Cap, vinyl . . . . . . . . . . . . . . . . . . . . 2
450400 Washer, M8 . . . . . . . . . . . . . . . . . . 2
450410 Lockwasher, M6 . . . . . . . . . . . . . . 2
450452 Nut, M6-1.00 . . . . . . . . . . . . . . . . . 3
450541 Screw, M6-1.00 x 16 (RPH) . . . . . 7
452695 Screw, M6-1.00 x 20, taptite . . . . 6
800930 Screw, M8-1.25 x 16 (8.8) . . . . . . 6
800934 Screw, M6-1.00 x 16 (8.8) . . . . . 25
800943 Screw, tap, #10-14 . . . . . . . . . . . 19
837303 Headlight, rectangular . . . . . . . . . 2
2700792 Clip, front (w/decals) . . . . . . . . . . 1
821071 Decal, notice not motor vehicle . . . 1
840901 Decal, Warning read ops. manual . 1
843854 Hood, Turf (green) . . . . . . . . . . . . . 1
841428 Bezel, headlamp . . . . . . . . . . . . . . 2
841477 HInge, hood . . . . . . . . . . . . . . . . . . 1
841637 Angle, front clip mount . . . . . . . . . 1
841715 Rod, hood release . . . . . . . . . . . . . 1
841753 Bracket, hood latch . . . . . . . . . . . . 1
2702198 Latch, hood . . . . . . . . . . . . . . . . . 1
841264 Panel, dash (left) . . . . . . . . . . . . . . 1
841913 Plate, access . . . . . . . . . . . . . . . . . 2
844430 Decal, CUSHMAN . . . . . . . . . . . . 1
844167 Bracket, horn/brake reservoir . . . 1
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
(45)
(45)
(45)
46
47
48
49
50
51
Description
Part
No.
Description
No.
Req’d
844426 Decal, Turf (left) . . . . . . . . . . . . . . . 1
844427 Decal, Turf (right) . . . . . . . . . . . . . . 1
886090 Horn . . . . . . . . . . . . . . . . . . . . . . . . 1
894030 Striker, hood . . . . . . . . . . . . . . . . . . 1
844669 Seal, weather . . . . . . . . . . As Req’d.
306488 Lockwasher, 1/4 shakeproof . . . . 2
548159 Washer, 5/16 (1 1/4” diameter) . . . 4
548175 Washer, 1/4 (1 1/4” diameter) . . . . . 8
800582 Screw, 1/4-20 x 3/4 . . . . . . . . . . . . 6
844049 Flap, mud . . . . . . . . . . . . . . . . . . . . 2
844293 Plug . . . . . . . . . . . . . . . . . . . . . . . . . 3
800344 Screw, tapping, #10 type AB . . . . 2
823549 Tie, cable, 15.5” (394 mm) . . . . . . . 2
840508 Mount, cable tie . . . . . . . . . . . . . . . 2
844116 Decal, left dash panel, turf . . . . . . 1
38541 Tube, document . . . . . . . . . . . . . . 1
452378 Screw, M6-1.00 x 20 . . . . . . . . . . . 2
825996 Fuse-holder . . . . . . . . . . . . . . . . . . 3
826000 Fuse, 20 amp . . . . . . . . . . As Req’d.
833038 Fuse, 30 amp . . . . . . . . . . As Req’d.
836892 Fuse, 10 amp . . . . . . . . . . As Req’d.
842983 Fuse, 15 amp . . . . . . . . . . As Req’d.
835480 Relay, 30 amp . . . . . . . . . . . . . . . . 1
843167 Relay, 12V 15A, DPST . . . . . . . . . . 2
2701465 Solenoid, 12V . . . . . . . . . . . . . . . 1
2702012 Strap, keyswitch mount . . . . . . . 1
2702014 Decal, keyswitch plate . . . . . . . . 1
2701850.7 Plate, keyswitch mount . . . . . . 1
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
* Not Illustrated.
55
BODY, HOOD, HEADLIGHTS
3-WHEEL SUZUKI 660 EFI TURF MODEL 898656
16
Reference
Lower Rops
6
7
30
12
35
33
11
35
11
18
11
9
10
35
19
12
25
24
28
31
39 32
37
40
2
12
5
22
1
40
31
15
4
23
12
26
8
34
3
21
29
13
ÎÎ
ÎÎ
17
12
14
41
27
20
38
Item No. 4 (Cotter Pin)
Install From Bottom,
Bend Legs Down
13
12
P893579
56
36
BODY, HOOD, HEADLIGHTS
3-WHEEL SUZUKI 660 EFI TURF MODEL 898656
Although Ref. No’s. 48, 49, 50
Keyswitch Plate and Associated Hardware
May Not be Installed on all Vehicles.
They Can be Ordered and Used on any Turf
Models Listed Above
37
50
48
49
42
13
8
44
47
43
45
13
Shown For
Reference Only
46
13
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
*
*
16
17
18
19
20
21
22
23
*
24
25
Part
No.
46
No.
Req’d
Ref.
No.
303952 Washer, #10 . . . . . . . . . . . . . . . . . . 1
894743 Nut ay., double 1/4-20 . . . . . . . . . 2
306419 Screw, 1/4-20 x 1/2 . . . . . . . . . . . . 2
306463 Pin, cotter . . . . . . . . . . . . . . . . . . . . 1
38541 Tube, document . . . . . . . . . . . . . . 1
844293 Plug . . . . . . . . . . . . . . . . . . . . . . . . . 3
450410 Lockwasher, M6 . . . . . . . . . . . . . . 2
450452 Nut, M6-1.00 . . . . . . . . . . . . . . . . . 3
450541 Screw, M6-1.00 x 16 (RPH) . . . . . 7
452695 Screw, M6-1.00 x 20, taptite . . . . 6
800930 Screw, M8-1.25 x 16 (8.8) . . . . . . 4
800934 Screw, M6-1.00 x 16 (8.8) . . . . . 25
800943 Screw, tap, #10-14 . . . . . . . . . . . 19
837303 Headlight, rectangular . . . . . . . . . 2
2700793 Clip, front w/decal (3-wheel) . . . . 1
821071 Decal, notice not motor vehicle . . 1
840901 Decal, Warning read ops. manual 1
843854 Hood, turf (green) . . . . . . . . . . . . . 1
841428 Bezel, headlamp . . . . . . . . . . . . . . 2
841477 HInge, hood . . . . . . . . . . . . . . . . . . 1
841637 Angle, front clip mount . . . . . . . . . 1
844653 Rod, hood release (3-wheel) . . . . 1
841753 Bracket, hood latch . . . . . . . . . . . . 1
2702198 Latch, hood . . . . . . . . . . . . . . . . . 1
841264 Panel, dash (left) . . . . . . . . . . . . . . 1
844116 Decal, left dash panel, turf . . . . . . 1
844645 Cover, steering gear (3-wheel) . . 2
844646 Cover, access (3-wheel) . . . . . . . . 1
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
(44)
(44)
(44)
45
46
47
48
49
50
Description
Part
No.
Description
No.
Req’d
844167 Bracket, horn/brake reservoir . . . 1
844422 Decal, turf, LH (3-wheel) . . . . . . . . 1
844423 Decal, turf, RH (3-wheel) . . . . . . . 1
886090 Horn . . . . . . . . . . . . . . . . . . . . . . . . 1
894030 Striker, hood . . . . . . . . . . . . . . . . . . 1
823549 Tie, cable, 15.5” (394 mm) . . . . . . 2
840508 Mount, cable tie . . . . . . . . . . . . . . . 2
844669 Seal, weather . . . . . . . . . . As Req’d.
306488 Lockwasher, 1/4 shakeproof . . . . 2
548159 Washer, 5/16 (1 1/4” diameter) . . . 4
548175 Washer, 1/4 (1 1/4” diameter) . . . . 8
800582 Screw, 1/4-20 x 3/4 . . . . . . . . . . . . 6
844049 Flap, mud . . . . . . . . . . . . . . . . . . . . 2
800344 Screw, tapping, #10 type AB . . . . 2
38061A Cap, vinyl . . . . . . . . . . . . . . . . . . . . 2
844783 Decal, 3-wheel (center) . . . . . . . . . 1
452378 Screw, M6-1.00 x 20 . . . . . . . . . . . 2
825996 Fuse-holder . . . . . . . . . . . . . . . . . . 3
826000 Fuse, 20 amp . . . . . . . . . . As Req’d.
833038 Fuse, 30 amp . . . . . . . . . . As Req’d.
836892 Fuse, 10 amp . . . . . . . . . . As Req’d.
842983 Fuse, 15 amp . . . . . . . . . . As Req’d.
835480 Relay, 30 amp . . . . . . . . . . . . . . . . 1
843167 Relay, 12V 15A, DPST . . . . . . . . . . 2
2701465 Solenoid, 12V . . . . . . . . . . . . . . . 1
2702012 Strap, keyswitch mount . . . . . . . 1
2702014 Decal, keyswitch plate . . . . . . . . 1
2701850.7 Plate, keyswitch mount . . . . . . 1
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
* Not Illustrated.
57
FRAME
4-WHEEL SUZUKI 660 TURF MODELS 898657 & 898658
6
Bolts To
Radiator Bracket
28
3
15
FRONT
OF
VEHICLE
10
4
6
12
3
2
25
14
37
16
4
30
45
10
3
3
10
10
8
27
13
4
7
6
3
24
23
6
19
4
6
6
35 18
1
19
17
4
6
6
3
Reference
Battery & Hydraulic
Tank
9
21
5
11
29
Reference
Motor Mounts
3
3
20
22
3
5
34
3
Reference
Ground Wire
(Part No. 894602)
2
3
33
29
2
6
1
26
3
4
32
32
58
31
9
5
10
6
36
2700542
FRAME
4-WHEEL SUZUKI 660 TURF MODELS 898657 & 898658
41
43
Some Newer 657 & 658 Models Will be Equipped
With the Hydraulic Tank, Mount Bracket,
Strap and Tank Guard Shown Below.
39
38
Reference
Hydraulic Tank
Battery Shown For
Reference Only
44
47
46
38
Shown For
Reference Only
40
Ref.
No.
42
(31)
No.
Req’d
Ref.
No.
309067 Lockwasher, 1/2 shakeproof . . . . 2
450453 Nut, M8-1.25 (G10.9) . . . . . . . . . . . 3
450454 Nut, M10-1.50 (10.9) . . . . . . . . . . 40
450455 Nut, M12-1.75 (10.9) . . . . . . . . . . 21
452389 Screw, M8-1.25 x 25 (G8.8) . . . . . 3
452398 Screw, M10-1.50 x 20 (8.8) . . . . 27
452402 Screw, M10-1.50 x 50 (8.8) . . . . . 6
452403 Screw, M10-1.50 x 60 (8.8) . . . . . 4
452405 Screw, M10-1.50 x 80 (8.8) . . . . . 5
452410 Screw, M12-1.75 x 30 (8.8) . . . . 17
548911 Nut, 5/16-18 . . . . . . . . . . . . . . . . . . 1
800177 Screw, 5/16-18 x 3/4 . . . . . . . . . . . 1
800279 Nut, speed, 1/4-20 . . . . . . . . . . . . 4
300646 Screw, 1/4-20 x 3/4 (G5) . . . . . . . . 4
800930 Screw, M8-1.25 x 16 (8.8) . . . . . . 1
841258 Bracket, drawbar . . . . . . . . . . . . . . 1
2700796 Panel, console, turf (w/decals) . . 1
822819 Decal, Warning Park Brake . . . . . 1
*
844177 Decal, auxillary transmission . . . . 1
*
844179 Decal, hydraulic controls . . . . . . . 1
*
18
810437 Clamp . . . . . . . . . . . . . . . . . . . . . . . 1
19
842870 Angle, support . . . . . . . . . . . . . . . . 2
20
844601 Bracket, battery clamp . . . . . . . . . 1
21
882971 Pin, disconnect . . . . . . . . . . . . . . . 2
22
809265 Pin, hair 25/32 x 2 11/16 . . . . . . 1
23
893145 ROPS, lower . . . . . . . . . . . . . . . . . 1
24
893199.7 Platform, turf . . . . . . . . . . . . . . . . 1
also 893199G Platform, turf (galvanized) . . . . . 1
25
893220 Drawbar, turf . . . . . . . . . . . . . . . . . 1
26
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part
No.
Ä
Ä
Ä
Description
Part
No.
Description
No.
Req’d
893235
893235G
893487
893488
893525
893527
2703294.7
452406
452415
844729
844647
821893
308090
450452
452378
548910
800881
893602
2702917
Frame, main (4-wheel) . . . . . . . 1
Frame, main (4-wheel galv.) . . . 1
Fender (left) . . . . . . . . . . . . . . . . 1
Fender (right) . . . . . . . . . . . . . . . 1
Support, platform . . . . . . . . . . . 2
Support, fuel tank . . . . . . . . . . 1
Guard, hydraulic tank . . . . . . . 1
Screw, M10-1.50 x 90 (8.8) . . . 4
Screw, M12-1.75 x 80 (8.8) . . . 8
Spacer, battery hold-down . . . 1
Angle, hold-down . . . . . . . . . . . 2
Trim, push-on . . . . . . . As Req’d.
Washer, 1/4 . . . . . . . . . . . . . . . 4
Nut, M6-1.00 (10.9) . . . . . . . . . 5
Screw, M6-1.00 x 20 . . . . . . . . 3
Nut, 1/4-20 . . . . . . . . . . . . . . . . 2
Screw, M6-1.00 x 35 (8.8) . . . . 2
Lamp ay., tail and stop . . . . . . 1
Engine control unit (ECU)
model ‘657 . . . . . . . . . . . . . . . . . 1
(43)
2702972
ECU model ‘658 w/serial no’s.
(43)
2702975
ECU model ‘658 w/serial no’s.
2700993.7
2701107.7
2702284.7
2702281.7
beginning with 00002120 . . . . .
Cover, ECU . . . . . . . . . . . . . . . .
Panel, access . . . . . . . . . . . . . .
Mount, tank (hydraulic) . . . . . . .
Strap, oil tank . . . . . . . . . . . . . .
also
27
28
29
30
31
32
33
34 35 36
37
38
39
40
41
42
43
up to Rev1287 . . . . . . . . . . . . . . 1
44
45
46
47
1
1
1
1
1
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
* Not Illustrated.
Item No. 34 (Battery Hold-down Spacer, Part No. 844729) may not be used on all vehicles. If the battery
clamp cannot be adjusted to properly secure the battery, this spacer will be required.
Only one (1) of Item No. 35 (Hold-down Angle, Part No. 844647) is used with Models 898658 beginning
with Serial No. 00002120. Models prior to this use two of these hold-down angles.
59
FRAME
3-WHEEL SUZUKI EFI TURF MODEL 898656
6
Bolts to
Radiator Bracket
28
FRONT
OF
VEHICLE
3
15
10
4
6
12
3
2
25
14
16
4
30
43
10
3
3
10
10
8
27
13
4
7
6
3
24
23
6
4
6
6
33 18
1
19
4
17
6
19
6
3
9
Reference
Battery &
Hydraulic Tank
21
22
29
11
5
Reference
Motor Mounts
Reference
Ground Wire
(Part No. 894602 )
3
3
3
5
5
20
34
2
2
3
3
29
26
10
6
31
9
3
1
32
32
60
6
893576
FRAME
3-WHEEL SUZUKI EFI TURF MODEL 898656
39
Some Newer 656 Models Will be Equipped
With the Hydraulic Tank, Mount Bracket,
Strap and Tank Guard Shown Below.
41
37
36
Battery Shown For
Reference Only
Reference
Hydraulic Tank
42
45
44
36
Shown For
Reference Only
38
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
*
*
*
18
19
20
21
22
Part
No.
ÄÄ
Ä
ÄÄ
40
(31)
No.
Req’d
Ref.
No.
309067 Lockwasher, 1/2 shakeproof . . . . 2
450453 Nut, M8-1.25 (G10.9) . . . . . . . . . . . 3
450454 Nut, M10-1.50 (G10.9) . . . . . . . . . 40
450455 Nut, M12-1.75 (G10.9) . . . . . . . . . 13
452389 Screw, M8-1.25 x 25 (8.8) . . . . . . 3
452398 Screw, M10-1.50 x 20 (8.8) . . . . 27
452402 Screw, M10-1.50 x 50 (8.8) . . . . . 6
452403 Screw, M10-1.50 x 60 (8.8) . . . . . 4
452405 Screw, M10-1.50 x 80 (8.8) . . . . . 5
452410 Screw, M12-1.75 x 30 (8.8) . . . . 17
548911 Nut, 5/16-18 . . . . . . . . . . . . . . . . . . 1
800177 Screw, 5/16-18 x 3/4 . . . . . . . . . . . 1
800279 Nut, speed, 1/4-20 . . . . . . . . . . . . 4
800582 Screw, 1/4-20 x 3/4 . . . . . . . . . . . . 4
800930 Screw, M8-1.25 x 16 (8.8) . . . . . . 1
841258 Bracket, drawbar . . . . . . . . . . . . . . 1
2700796 Panel, console, w/decals (turf) . 1
822819 Decal, Warning Park Brake . . . . . . 1
844177 Decal, auxillary transmission . . . . . 1
844179 Decal, hydraulic controls . . . . . . . . 1
810437 Clamp . . . . . . . . . . . . . . . . . . . . . . . 1
842870 Angle, support . . . . . . . . . . . . . . . . 2
844601 Bracket, battery clamp . . . . . . . . . 1
882971 Pin, disconnect . . . . . . . . . . . . . . . 2
809265 Pin, hair 25/32 x 2 11/16 . . . . . . 1
23
24
Description
also
25
26
also
27
28
29
30
31
32
33
34 35
36
37
38
39
40
41
42
43
44
45
Part
No.
Description
No.
Req’d
893145
ROPS, lower . . . . . . . . . . . . . .
893199.7 Platform, turf . . . . . . . . . . . . . . . .
893199G Platform, turf (galvanized) . . . . .
893220
Drawbar, turf . . . . . . . . . . . . . . .
897159
Frame, main (3-wheel) . . . . . . .
897159G Frame, main (3-wheel galv.) . . .
893487
Fender (left) . . . . . . . . . . . . . . . .
893488
Fender (right) . . . . . . . . . . . . . . .
893525
Support, platform . . . . . . . . . . .
893527
Support, fuel tank . . . . . . . . . .
2703294.7 Guard, hydraulic tank . . . . . . .
452406
Screw, M10-1.50 x 90 (8.8) . . .
844647
Angle, hold-down . . . . . . . . . . .
844729
Spacer, battery hold-down . . .
308090
Washer, 1/4 . . . . . . . . . . . . . . .
450452
Nut, M6-1.00 (10.9) . . . . . . . . .
452378
Screw, M6-1.00 x 20 . . . . . . . .
548910
Nut, 1/4-20 . . . . . . . . . . . . . . . .
800881
Screw, M6-1.00 x 35 (8.8) . . . .
893602
Lamp ay., tail and stop . . . . . .
2702975 Engine control unit (ECU) . . . .
2700993.7 Cover, ECU . . . . . . . . . . . . . . . .
2701107.7 Panel, access . . . . . . . . . . . . . .
2702284.7 Mount, tank (hydraulic) . . . . . . .
2702281.7 Strap, oil tank . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
2
1
1
4
2
1
4
5
3
2
2
1
1
1
1
1
1
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
* Not Illustrated.
Item No. 34 (Battery Hold-down Spacer, Part No. 844729) may not be used on all vehicles. If the battery
clamp cannot be adjusted to properly secure the battery, this spacer will be required.
61
PARK BRAKE LEVER AND CABLE
SUZUKI 660 EFI TURF MODELS 898656, 898657 & 898658
4
6
The Neoprene Cover, Pop Rivets and
Mounting Strips are Generally used on
Vehicles With Cab Sets but can also be
used on Vehicles Without Cabs.
Reference
Console Panel
(Part No. 2700796)
4
19
Reference
Lower Rops
(Part No. 893145)
17
18
1
2
3
2
15
11
7
12
16
Reference
Console Panel
2
2.85”
(72.4 mm)
8
13
10
Apply Loctite 592
To Bushing O.D.
.44”
(11.2 mm)
2
To Install Neoprene Cover and Hardware,
Use Neoprene Cover as a Template, Mark
and Drill Six (6) .140” (3.5 mm) Dia. Holes.
Position Neoprene Cover and Secure Using
Mounting Strips and Rivets as Shown.
4
14
5
9
8
P893446, P2701428
Ref.
No.
1
2
3
4
5
6
7
8
9
10
62
Part
No.
450377
450453
450454
452388
452391
452398
800446
809152
827182
845134
Description
No.
Req’d
Nut, staytite, M6-1.00 . . . . . . . . . .
Nut, M8-1.25 (G10.9) . . . . . . . . . .
Nut, M10-1.50 (10.9) . . . . . . . . . . .
Screw, M8-1.25 x 20 (G8.8) . . . . .
Screw, M8-1.25 x 40 (8.8) . . . . . .
Screw, M10-1.50 x 20 (8.8) . . . . .
Locknut, 5/16-24 . . . . . . . . . . . . . .
Washer, 5/16 x 1 3/16 . . . . . . . . .
Pulley, 3” dia. (76 mm dia.) . . . . . .
Bracket, park brake lever . . . . . . .
1
6
2
5
1
2
1
2
1
1
Ref.
No.
11
12
13
14
15
16
17
18
19
Part
No.
Description
No.
Req’d
843158 Bracket, park brake cable . . . . . .
843356 Equalizer, park brake . . . . . . . . . .
843359 Bushing, park brake . . . . . . . . . . .
845133 Cable, park brake . . . . . . . . . . . . .
894317 Lever, park brake . . . . . . . . . . . . .
893583 Cable, park brake (to rear brakes)
133741 Rivet, pop (.12 .5 clsd. end) . . . . . .
2701335 Mounting, park brake . . . . . . . . .
2701336 Cover, parking brake . . . . . . . . .
1
1
1
1
1
2
6
1
1
AIR CLEANER, BRACKET and FILTER
SUZUKI 660 EFI TURF MODELS 898657
and MODELS 898658 With Serial No’s. Up To REV1287
To Radiator
Mounting Frame
3
17
2
13
1
15
9
7
14
16
8
9
7
6
FRONT
OF
VEHICLE
12
4
10
18
11
5
Shown For
Reference Only
895016, 895114
Ref.
No.
1
2
3
4
5
6
7
8
9
Part
No.
300646
306396
308090
452378
450453
452388
825358
834217
825358
Description
No.
Req’d
Screw, 1/4-20 x 3/4 . . . . . . . . . . . .
Lockwasher, 1/4 . . . . . . . . . . . . . .
Washer, 1/4 . . . . . . . . . . . . . . . . . .
Screw, M6-1.00 x 20 . . . . . . . . . . .
Nut, M8-1.25 (G10.9) . . . . . . . . . . .
Screw, M8-1.25 x 20 (G8.8) . . . . .
Clamp, worm-drive . . . . . . . . . . . .
Hose, air cleaner . . . . . . . . . . . . . .
Clamp, worm-drive . . . . . . . . . . . .
2
2
2
2
2
2
4
1
2
Ref.
No.
10
11
12
13
14
15
16
17
18
Part
No.
Description
No.
Req’d
842915 Bracket, air filter . . . . . . . . . . . . . .
842997 Cap, 7/64 i.d. x 3x4 . . . . . . . . . . . .
450452 Nut, M6-1.00 (10.9) . . . . . . . . . . . .
893182 Filter complete, air . . . . . . . . . . . .
840352 Element, air cleaner . . . . . . . . . .
888549 Connector, hose (air cleaner) . . . .
2700162 Hose, air intake . . . . . . . . . . . . . .
2700333 Connector, hose 3/8 to 1/2 . . . .
2700329.7 Bracket, air cleaner . . . . . . . .
1
1
2
1
1
1
1
1
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
63
AIR CLEANER, BRACKET and FILTER
SUZUKI 660 EFI TURF MODEL 898656
and MODELS 898658 With Serial No’s. Beginning With 00002120
12
3
To Radiator
Mounting Frame
2
16
1
14
13
9
7
15
8
9
7
5
10
17
11
6
4
18
FRONT
OF
VEHICLE
Shown For
Reference Only
2701379
Ref.
No.
1
2
3
4
5
6
7
8
9
Part
No.
300646
306396
308090
800934
450453
452389
825358
834217
825358
Description
No.
Req’d
Screw, 1/4-20 x 3/4 . . . . . . . . . . . .
Lockwasher, 1/4 . . . . . . . . . . . . . .
Washer, 1/4 . . . . . . . . . . . . . . . . . .
Screw, M6-1.00 x 16 (8.8) . . . . . .
Nut, M8-1.25 (G10.9) . . . . . . . . . . .
Screw, M8-1.25 x 25 (G8.8) . . . . .
Clamp, worm-drive . . . . . . . . . . . .
Hose, air cleaner . . . . . . . . . . . . . .
Clamp, worm-drive . . . . . . . . . . . .
2
2
2
2
2
2
4
1
2
Ref.
No.
10
11
12
13
14
15
16
17
18
Part
No.
Description
No.
Req’d
842915 Bracket, air filter . . . . . . . . . . . . . .
842997 Cap, 7/64 i.d. x 3x4 . . . . . . . . . . . .
893182 Filter complete, air . . . . . . . . . . . .
840352 Element, air cleaner . . . . . . . . . .
888549 Connector, hose (air cleaner) . . . .
2701393 Hose, air intake . . . . . . . . . . . . . .
2700333 Connector, hose 3/8 to 1/2 . . . .
2701446.7 Bracket, air cleaner . . . . . . . .
2702431 Plug . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
64
EXHAUST SYSTEM
SUZUKI 660 EFI TURF MODELS 898656, 898657 & 898658
4
3
1
1
12
9
6
5
Mounts to
Transmission
10
8
FRONT
OF
VEHICLE
7
2
Engine Shown
For Reference Only
11
13
14
15
Reference
Exhaust Manifold
2700049
Ref.
No.
1
2
3
4
5
6
7
8
Part
No.
450193
450378
450454
452398
813688
833188
838295
841982
Description
No.
Req’d
Screw, M8-1.25 x 30 . . . . . . . . . . .
Locknut, M8-1.25 staytite . . . . . .
Nut, M10-1.50 (G10.9) . . . . . . . . .
Screw, M10-1.50 x 20 (8.8) . . . . .
Clamp, tubing (1 1/8”) . . . . . . . . . .
Tailpipe . . . . . . . . . . . . . . . . . . . . . .
Strap, muffler hanger . . . . . . . . . .
Clamp, exhaust tube (1 1/2”) . . . .
2
2
2
2
1
1
1
1
Ref.
No.
9
10
11
12
13
14
15
Part
No.
Description
No.
Req’d
843968 Support, muffler . . . . . . . . . . . . . . .
893381 Muffler . . . . . . . . . . . . . . . . . . . . . . .
894742.8 Tube, exhaust inlet . . . . . . . . . .
839946 Bracket, muffler . . . . . . . . . . . . . . .
2702500 Seal ring, muffler . . . . . . . . . . . . .
2702502 Bolt, muffler flange . . . . . . . . . . .
2702501 Spring, muffler flange . . . . . . . . .
1
1
1
1
1
2
2
65
HYDRAULIC BRAKE LINES
4-WHEEL SUZUKI 660 EFI TURF MODELS
898657 & 898658
8
19
33
21
18
35
11
36
8
11
7
17
23
Mounts To Front
Suspension Frame
31
24
30
5
Some Vehicles May Not Be
Equipped With Item No. 37,
Master Cylinder Bracket.
15
29
37
6
27
26
26
4
16
24
Reference
Frame
5
3
To Rear Brake Hose
Connection
22
12
9
1
2
13
10
5
28
20
3
14
25
28
26
66
P893441
HYDRAULIC BRAKE LINES
4-WHEEL SUZUKI 660 EFI TURF MODELS
898657 & 898658
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Part
No.
103867
306328
450453
450510
452388
452424
845380
800934
806714
810152
825624
840725
840726
842051
842103
842935
843022
843021
844167
Description
No.
Req’d
Washer, 5/16 . . . . . . . . . . . . . . . . . 1
Pin, cotter, 3/32 x 3/4 . . . . . . . . . . 1
Nut, M8-1.25 (G10.9) . . . . . . . . . . . 2
Screw, M3-.50 x 20 (G10.9) . . . . . 2
Screw, M8-1.25 x 20 (8.8) . . . . . . 4
Nut, M3-.50 . . . . . . . . . . . . . . . . . . 2
Hose, 5/16” brake . . . . . . As Req’d.
Screw, M6-1.00 x16 (8.8) . . . . . . . 4
Pin, clevis 5/16 x 15/16 . . . . . . . . 1
Cover, brake pedal . . . . . . . . . . . . 1
Clamp, hose . . . . . . . . . . . . . . . . . . 4
Pin, brake pivot . . . . . . . . . . . . . . . 1
Bearing, brake pivot . . . . . . . . . . . 1
Tube, brake line rear . . . . . . . . . . 1
Union, brake fitting (metric) . . . . . . 1
Tab, locking . . . . . . . . . . . . . . . . . . 1
Tube, rear brake . . . . . . . . . . . . . . 1
Tube, front brake . . . . . . . . . . . . . . 1
Bracket, reservoir mounting . . . . 1
Ref.
No.
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34 *
35
36
37
Part
No.
892921
895113
894167
452692
890808
450454
452398
809137
810435
800943
812445
841842
843418
894456
825886
826006
2702215
2701737.7
Description
No.
Req’d
Lever, brake . . . . . . . . . . . . . . .
Cylinder, brake (dual) . . . . . . . .
Rod, brake . . . . . . . . . . . . . . . . .
Screw, tap M6-1.00 x 12 . . . . .
Switch, micro . . . . . . . . . . . . . .
Nut, M10-1.50 (G10.9) . . . . . . .
Screw, M10-1.50 x 20 (8.8) . . .
Clip . . . . . . . . . . . . . . . . . . . . . . .
Clamp . . . . . . . . . . . . . . . . . . . . .
Screw, tap #10-14 x 5/8 . . . . .
Clamp, tube/wire . . . . . . . . . . .
Tee, M10-1.00 . . . . . . . . . . . . . .
Clamp, tee . . . . . . . . . . . . . . . . .
Reservoir, brake fluid . . . . . . . .
Terminal, 1/4 L male . . . . . . . .
Connector, 2-contact female .
Reservoir, brake fluid . . . . . . .
Bracket, master cylinder . . . . .
1
1
1
1
1
1
7
1
2
1
1
1
1
1
2
1
1
1
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
The brake hose (Part No. 845380) is serviced as a 6’ (1829 mm) length.
* Not Illustrated.
67
FUEL SYSTEM
SUZUKI 660 EFI TURF MODELS
898658 With Serial No’s. Up to REV1287
and MODELS 898657
8
1
17
14
8
1
18
14
FRONT
OF
VEHICLE
Use Cable Ties as Needed
to Keep Hoses Away From
Hot and/or Moving Parts
10
25
2
11
Shown For
Reference Only
7
9
23
21
20
22
13
21
12
12
19
13
36
40
26
27
5
To
Fender
To
Main Frame
31
15
29
13
12
24
39
30
28
34
12
6
41
12
12
16
12
15
4
12
13
16
12
33
Shown For
Reference Only
3
38
5
32
12
To
Fuel Injectors
40
35
13
37
3
4
2700045, 2701741
68
FUEL SYSTEM
SUZUKI 660 EFI TURF MODELS
898658 With Serial No’s. Up to REV1287
and MODELS 898657
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Part
No.
120052
320107
450452
452378
450453
800875
829954
800021
843343
843298
833851
825624
826590
829787
829997
800930
833953
894201
841969
836852
84310
Description
No.
Req’d
Lockwasher, #10 . . . . . . . . . . . . . . 5
Tie, cable, 7 1/2” (190.5 mm) . . . . 2
Nut, M6-1.00 (G10.9) . . . . . . . . . . . 2
Screw, M6-1.00 x 20 . . . . . . . . . . . 2
Nut, M8-1.25 (10.9) . . . . . . . . . . . . 4
Nut, M12-1.25 (8.8) . . . . . . . . . . . . 1
Gasket . . . . . . . . . . . . . . . . . . . . . . 1
Screw, #10-32 x 1/2 . . . . . . . . . . . 5
Cap fuel (unvented) . . . . . . . . . . . . 1
Sender, fuel . . . . . . . . . . . . . . . . . . 1
Seal, foam . . . . . . . . . . . . As Req’d.
Clamp, hose . . . . . . . . . . . . . . . . . 11
Hose, fuel, 5/16 i.d. . . . . . As Req’d.
Terminal, 45 1/4 male . . . . . . . . . 2
Grommet . . . . . . . . . . . . . . . . . . . . 1
Screw, M8-1.25 x 16 (8.8) . . . . . . 4
Cover, fuel sender . . . . . . . . . . . . . 1
Harness, fuel tank . . . . . . . . . . . . . 1
Tank, fuel . . . . . . . . . . . . . . . . . . . . 1
Breather . . . . . . . . . . . . . . . . . . . . 1
Grommet . . . . . . . . . . . . . . . . . . . 2
Ref.
No.
22
23
24
25
26
27
28
29
30
31
32 33
34
35
36
37
38
39
40
41
Part
No.
843727
843726
893527
893555
103867
800221
450454
452398
548911
800177
888487
Description
No.
Req’d
Elbow, 90 . . . . . . . . . . . . . . . . . . 1
Tube, fuel pick-up . . . . . . . . . . . . 1
Support, fuel tank . . . . . . . . . . . . .
Strap, fuel tank . . . . . . . . . . . . . . .
Washer, 5/16 . . . . . . . . . . . . . . . . .
Nut, crownlock, 5/16-24 . . . . . . . .
Nut, M10-1.50 (10.9) . . . . . . . . . . .
Screw, M10-1.50 x 20 (8.8) . . . . .
Nut, 5/16-18 . . . . . . . . . . . . . . . . . .
Screw, 5/16-18 x 3/4 . . . . . . . . . . .
Kit, hose
(7/16 i.d. x 18” hose & clamps) . .
2700159.7 Bracket, fuel (hi-p) . . . . . . . . . .
2700161 Connector, tee (5/16”) . . . . . . . . .
2700166 Clamp, fuel pump (hi-p) . . . . . . .
2700178 Connector, union (5/16-7/16) . . .
2701897 Pump, fuel (660 efi) . . . . . . . . . . .
2701898 Filter, fuel (660 efi) . . . . . . . . . . . .
2701899 Regulator, fuel (660 efi) . . . . . . . .
830930 Clamp, hose . . . . . . . . . . . . . . . . . .
309067 Washer, star . . . . . . . . . . . . . . . . . .
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
2
1
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY
Ref. No. 32 (888487, Hose Kit) is shipped with an 18” length of hose and two clamps.
Cut hose to appropriate length for your particular application.
69
FUEL SYSTEM
SUZUKI 660 EFI TURF MODELS 898656
and MODELS 898658 With Serial No’s. Beginning With 00002120
8
1
17
8
1
14
18
14
25
10
43
7
9
23
20
21
22
5
39
21
40
12
19
To
Fender
15
2
To
Main Frame
26
11
13
24
42
31
12
4
33
31
41
37
3
27
28
28
29
34
6
13
5
36
32
12
12
12
35
16
12
12
13
13
FRONT
OF
VEHICLE
Cut Section of Tubing to
Appropriate Length, Attach to Hose
(Protects Hose From Engine)
13
12
12
38
30
13
To Fuel
Injector Rail
70
12
P2701741
FUEL SYSTEM
SUZUKI 660 EFI TURF MODELS 898656
and MODELS 898658 With Serial No’s. Beginning With 00002120
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Part
No.
120052
320107
450452
452378
450453
800875
829954
800021
843343
843298
452398
825624
826590
829787
829997
800930
833953
894201
841969
836852
84310
843727
Description
No.
Req’d
Lockwasher, #10 . . . . . . . . . . . . . . 5
Tie, cable, 7 1/2” (190.5 mm) . . . . 2
Nut, M6-1.00 (G10.9) . . . . . . . . . . . 2
Screw, M6-1.00 x 20 . . . . . . . . . . . 2
Nut, M8-1.25 (10.9) . . . . . . . . . . . . 4
Nut, M12-1.25 (G8.8) . . . . . . . . . . . 1
Gasket . . . . . . . . . . . . . . . . . . . . . . 1
Screw, #10-32 x 1/2 . . . . . . . . . . . 5
Cap fuel (unvented) . . . . . . . . . . . . 1
Sender, fuel . . . . . . . . . . . . . . . . . . 1
Screw, M10-1.50 x 20 (8.8) . . . . . 2
Clamp, hose . . . . . . . . . . . . . . . . . 12
Hose, fuel, 5/16 i.d. . . . . . As Req’d.
Terminal, 45 1/4 male . . . . . . . . . 2
Grommet . . . . . . . . . . . . . . . . . . . . 1
Screw, M8-1.25 x 16 (8.8) . . . . . . 2
Cover, fuel sender . . . . . . . . . . . . . 1
Harness, fuel tank . . . . . . . . . . . . . 1
Tank, fuel . . . . . . . . . . . . . . . . . . . . 1
Breather . . . . . . . . . . . . . . . . . . . . 1
Grommet . . . . . . . . . . . . . . . . . . . 2
Elbow, 90 . . . . . . . . . . . . . . . . . . 1
Ref.
No.
23
24
25
26
27 28
29
30
31
32
33
34
35
36
37
38 39
40
41
42
43
Part
No.
Description
No.
Req’d
843726 Tube, fuel pick-up . . . . . . . . . . . . 1
843078 Support, fuel tank . . . . . . . . . . . . . 1
893555 Strap, fuel tank . . . . . . . . . . . . . . . 1
800177 Screw, 5/16-18 x 3/4 . . . . . . . . . . . 1
888487 Kit, hose (7/16 i.d. x 18” hose) . . . . 1
830930 Clamp, hose . . . . . . . . . . . . . . . . . 2
2701693.7 Bracket, fuel (hi-p) . . . . . . . . . . 1
2700161 Connector, tee (5/16”) . . . . . . . . . 1
2700166 Clamp, fuel pump (hi-p) . . . . . . . 2
2700178 Connector, union (5/16-7/16) . . . 1
2701897 Pump, fuel (660 efi) . . . . . . . . . . . 1
2701898 Filter, fuel (660 efi) . . . . . . . . . . . . 1
2701899 Regulator, fuel (660 efi) . . . . . . . . 1
309067 Washer, star . . . . . . . . . . . . . . . . . . 1
452389 Screw, M8-1.25 x 25 (8.8) . . . . . . 2
826191 Tubing, convoluted . . . . . As Req’d.
103867 Washer, 5/16 . . . . . . . . . . . . . . . . . 1
800221 Nut, crownlock 5/16-24 . . . . . . . . 1
450454 Nut, M10-1.50 (10.9) . . . . . . . . . . . 2
548911 Nut, 5/16-18 . . . . . . . . . . . . . . . . . . 1
833851 Seal, foam . . . . . . . . . . . . As Req’d.
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY
Ref. No. 27 (888487, Hose Kit) is shipped with an 18” length of hose and two clamps.
Cut hose to appropriate length for your particular application.
Ref.
No. 38 (826191, convoluted tubing) is shipped in a 25 ft (7.6 M) length.
Cut tubing to appropriate length for your particular application.
71
STEERING WHEEL, STEERING SHAFT, CONNECTING HOSES
POWER STEERING PUMP, AND STEERING GEAR
SUZUKI 660 TURF MODELS 898657 & 898658
14
13
15
10
29
9
2
9
1
Also Reference Pulleys,
Belts and Brackets
35
33
26
8
28
31 *
27 30
To
Engine
LOCTITE 242
* USE
ON THESE ITEMS
16
15
31
12
17
11
18
3
19
6
20
7
18
19
21
Reference
Front Clip
2
22
5
32
23
24
34
25
Included
With Ref. No. 25
4
Reference
Lower Rops
P893331
72
STEERING WHEEL, STEERING SHAFT, CONNECTING HOSES
POWER STEERING PUMP, AND STEERING GEAR
SUZUKI 660 TURF MODELS 898657 & 898658
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Part
No.
Description
No.
Req’d
320107 Tie, cable, 7 1/2” (190 mm) . . . . . .
450453 Nut, M8-1.25 (G10.9) . . . . . . . . . . .
450457 Nut, M16-2.00 . . . . . . . . . . . . . . . .
800930 Screw, M8-1.25 x 16 (G8.8) . . . . .
450739 Screw, M10-1.50 x 30 (G12.9) . . .
2700453 Cover . . . . . . . . . . . . . . . . . . . . . .
819923 Collar, foam . . . . . . . . . . . . . . . . . .
823549 Tie, cable, 15 1/2” (394 mm) . . . . .
830930 Clamp . . . . . . . . . . . . . . . . . . . . . . .
809092 Clamp, tube . . . . . . . . . . . . . . . . . .
892486 Cover, steering wheel center . . . .
839862 Decal, steering wheel . . . . . . . . .
840222 Hose, 3/8 i.d. x 90 elbow . . . . . .
843767 Hose, steering pressure . . . . . . . .
111838 ‘O’-Ring . . . . . . . . . . . . . . . . . . . . .
843768 Hose, steering return . . . . . . . . . .
111838 ‘O’-Ring . . . . . . . . . . . . . . . . . . . . .
808060 Bearing, needle . . . . . . . . . . . . . . .
828590 Housing, bearing . . . . . . . . . . . . . .
3
4
1
2
1
1
2
2
2
2
1
1
1
1
2
1
1
2
2
Ref.
No.
20
21
22
23
24
25
26
27 28
29
30
31
32 33
34
35
Part
No.
Description
No.
Req’d
892228 Wheel, steering (w/o horn) . . . . . .
893344 Shaft, steering . . . . . . . . . . . . . . . .
893571 Tube, steering mount . . . . . . . . . .
303269 Lockwasher, 7/16 . . . . . . . . . . . . .
311392 Screw, 7/16-14 x 2 . . . . . . . . . . . .
841336 Arm, pitman . . . . . . . . . . . . . . . . . .
2700565 V-belt, 45” (1143 mm) . . . . . . . . . .
892534 Pump, power steering . . . . . . . . .
839907 Pulley, steering pump . . . . . . . . .
2700573 Cap, steering reservoir . . . . . . .
452394 Screw, M8-1.25 x 70 (8.8) . . . . . .
452388 Screw, M8-1.25 x 20 (8.8) . . . . . .
841255 Gear, power steering . . . . . . . . . .
842988 Bracket, steering pump and
alt. mounting (Suzuki 660) . . . . . . .
306799 Lockwasher,
5/16 external, shakeproof . . . . . .
800943 Screw, tap, #10-24 x 5/8 . . . . . . .
1
1
1
3
3
1
1
1
1
1
2
4
1
1
2
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEEDING ASSEMBLY.
Service Parts for the pump are available at automotive centers. Refer to 1991-92 Buick Regal
with a 3.8L V6 engine (Saginaw Pump #26025515).
Also see Alternator, Engine Belts, Pulleys and Brackets.
73
STEERING WHEEL, STEERING SHAFT AND STEERING GEAR
3-WHEEL SUZUKI 660 EFI TURF MODEL 898656
Front of
Vehicle
The Link Arm Assembly Must Have Length
Adjusted so the Pitman Arm Points Straight
Back When the Fork Assembly is Pointing
Straight Forward. All Steering Components
Must Move Freely Through Entire Fork Travel
Link Arm
Assembly
Fork Assembly
13
15
12
6
16
Steering Gear
Travel
Pitman Arm
The Pitman Arm Must be Installed So That
When the Steering Gear is in Its Center of
Travel the Arm is Pointing Straight Back.
9
18
10
15
16
19
Reference
Front Fork
5
5
20
23
25
21
22
24
23
11
27
11
3
2
26
8
Reference
Lower Rops
Reference
Front Clip
17
Reference
Main Frame
1
14
4
2
28
74
P893578
STEERING WHEEL, STEERING SHAFT AND STEERING GEAR
3-WHEEL SUZUKI 660 EFI TURF MODEL 898656
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Part
No.
Description
No.
Req’d
303269 Lockwasher, 7/16 . . . . . . . . . . . . .
306825 Nut, castle, 7/16-20 . . . . . . . . . . .
306799 Lockwasher, 5/16 ext. shkprf. . . .
311392 Screw, 7/16-14 x 2 (G5) . . . . . . . .
450453 Nut, M8-1.25 (10.9) . . . . . . . . . . . .
450457 Nut, M16-2.00 (10.9) . . . . . . . . . . .
450739 Bolt, M10-1.50 x 30 sckthd (12.9)
800930 Screw, M8-1.25 x 16 ( 8.8) . . . . . .
2700453 Cover . . . . . . . . . . . . . . . . . . . . . .
819923 Collar, foam . . . . . . . . . . . . . . . . . .
816586 Retainer, grease . . . . . . . . . . . . . .
892486 Cover, steering wheel center . . . .
839862 Decal, steering wheel . . . . . . . . .
845225 Arm, pitman . . . . . . . . . . . . . . . . . .
808060 Bearing, needle . . . . . . . . . . . . . . .
3
2
2
3
2
1
1
2
1
2
2
1
1
1
2
Ref.
No.
Part
No.
16
17
18
19
20
21
22
23
24
25
26
828590
887597
892228
893564
893571
302944
800485
831405
841793
887512
306328
548224
887750
306328
548224
*
27
28
*
Description
No.
Req’d
Housing, bearing . . . . . . . . . . . . . .
Gear, steering . . . . . . . . . . . . . . . .
Wheel, steering 14” w/o horn . . .
Shaft, steering 3-wheel . . . . . . . .
Tube, steering mount . . . . . . . . . .
Nut, 9/16-18 jam . . . . . . . . . . . . . .
Nut, 9/16-18 jam (LH thread) . . . .
Fitting, grease 90 1/4-28 . . . . . .
Link, fork . . . . . . . . . . . . . . . . . . . . .
End assembly, tie rod (right) . . . .
Pin, cotter, 3/32 x 3/4 . . . . . . . . .
Fitting, lubrication . . . . . . . . . . . .
End assembly, tie rod (left) . . . . .
Pin, cotter, 3/32 x 3/4 . . . . . . . . .
Fitting, lubrication . . . . . . . . . . . .
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
* Not Illustrated. Although this lubrication fitting is the standard fitting that comes with this tie rod, it is not used in
this application. Use Ref. No. 23, Part No. 831405.
75
FRONT SUSPENSION (Left Side) and TIE RODS
4-WHEEL SUZUKI 660 TURF MODELS 898657 & 898658
Reference
Union Tee
(Part No. 841842)
With Differential
Reference Front
Suspension Frame
(Part No. 893421)
Reference
Pitman Arm
(Part No. 841336)
20
21
11
3
4
28
With
Item No. 26
19
27
7
When ordering Items
No. 35 or No. 26,
You Will Need to Also
Order Item No. 12
12
49
1
26
11
13
5
14
38
29
39
12
35
8
48
12
10
23
52
6
25
15
53
With
Item No. 35
11
36
33
37
34
50
22
13
34
33
24
16
Reference
Brake Assembly
4
2
30
9
51
12
31
43
42
32
46
FRONT
OF
VEHICLE
893329
76
44
47
40
45
17
41
18
FRONT SUSPENSION (Left Side) and TIE RODS
4-WHEEL SUZUKI 660 TURF MODELS 898657 & 898658
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
*
Part
No.
Description
No.
Req’d
302944 Nut, jam, 9/16-18 . . . . . . . . . . . . .
450077 Bolt, M16-2.00 x 90 . . . . . . . . . . .
450382 Nut, M16-2.00, locking insert . . .
450393 Washer, M16 . . . . . . . . . . . . . . . . .
450457 Nut, M16-2.00, flange (G10.9) . . .
452398 Screw, M10-1.5 x 20 (8.8) . . . . . .
800945 Bolt, M12-1.75 x 60 (G10.9) . . . . .
800485 Nut, 9/16-18, left-hand . . . . . . . . .
800919 Bolt, M10-1.5 x 30 (G10.9) . . . . . .
809137 Clip . . . . . . . . . . . . . . . . . . . . . . . . .
810437 Clamp . . . . . . . . . . . . . . . . . . . . . . .
831405 Fitting, grease, 1/4-28 (90) . . . .
841167 Bushing, silentbloc . . . . . . . . . . . .
841404 Rod, tie . . . . . . . . . . . . . . . . . . . . . .
844148 Ball joint, upper . . . . . . . . . . . . . . .
841429 Ball joint, lower . . . . . . . . . . . . . . .
817250 Cap, grease . . . . . . . . . . . . . . . . . .
304636 Pin, cotter 1/8 x 1 1/8” . . . . . . . . .
841630 Trunnion, control arm . . . . . . . . . .
841737 Shim, .060” . . . . . . . . . . . . . . . . . . .
841738 Shim, .024” . . . . . . . . . . . . . . . . . . .
2702217 Tube, brake (left) . . . . . . . . . . . . .
841841 Hose, brake . . . . . . . . . . . . . . . . . .
894573 Knuckle, steering (left) . . . . . . . . . .
842104 Bracket, brake tube . . . . . . . . . . .
887512 End, tie rod (RH thread) . . . . . . . . .
306328 Pin, cotter, 3/32 x 3/4 . . . . . . . . .
548224 Fitting, lubrication . . . . . . . . . . . .
1
2
2
4
2
1
2
1
4
1
4
4
4
1
1
1
1
1
1
4
2
1
1
1
1
1
1
1
Ref.
No.
28
29
30
31
32
33
34
35
36
*
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
Part
No.
2702247
816586
893233
841430
800909
306328
306825
887750
306328
548224
311537
816586
893266
311537
385174
815403
817928
270225.7
808088
814474
800908
450452
452378
450455
452413
894635
2703081
Description
No.
Req’d
Nut, castle 3/4-16 . . . . . . . . . . .
Retainer, grease . . . . . . . . . . . .
Arm assembly, lower control . .
Drum, brake . . . . . . . . . . . . . . . .
Nut, wheel retaining, M12-1.50
Pin, cotter, 3/32 x 3/4 . . . . . . . .
Nut, castle, 7/16-20 . . . . . . . . . .
End, tie rod (LH thread) . . . . . . .
Pin, cotter, 3/32 x 3/4 . . . . . . .
Fitting, lubrication . . . . . . . . . . .
Nut, castle 3/4-16 . . . . . . . . . . .
Retainer, grease . . . . . . . . . . . .
Arm assembly, upper control . .
Nut, castle 3/4-16 . . . . . . . . . . .
Bearing, cone (outer) . . . . . . . . .
Bearing, cone (inner) . . . . . . . . .
Seal, grease . . . . . . . . . . . . . . . .
Hub assembly . . . . . . . . . . . . . .
Cup, bearing (outer) . . . . . . . . .
Cup, bearing (inner) . . . . . . . . .
Screw, lug M12-1.50 x 42 . . . .
Nut, M6-1.00 (G10.9) . . . . . . . . .
Screw, M6-1.00 x 20 (G10.9) . .
Nut, M12-1.75 (G10.9) . . . . . . .
Screw, M12-1.75 x 60 . . . . . . . .
Strut ay, (shock & spring) . . . . . .
Protector, spring hose . . . . . . . .
1
1
1
1
5
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
5
1
1
4
4
1
1
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
* Not Illustrated. Although this lubrication fitting is the standard fitting used with this tie rod, it is not used in this
application. Use Ref. No. 12, Part No. 831405.
If ordering Ref. No’s. 26 (887512) or 35 (887750) you will also need to order Ref. No. 12 (831405).
77
FRONT SUSPENSION (Right Side) TIE RODS, and SKID PLATE
4-WHEEL SUZUKI 660 TURF MODELS 898657 & 898658
41
24
15
57
FRONT
OF
VEHICLE
23
50
40
7
59
54
56
17
49
53
55
21
13
48
51
42
58
28
52
10
43
Reference Brakes
And Brake Shoes
32
27
26
25
63
14
43
33
42
With
Item No. 34
8
36
35
18
29
64
2
48
22
3
60
38
15
19
11
61
16
4
62
46
15
34
30
17
6
39
45
With
Item No. 44
1
6
5
37
15
20
12
60
44
When ordering Items
No. 34 or No. 44,
You Will Need to Also
Order Item No. 15
47
31
9
78
893329
FRONT SUSPENSION (Right Side) TIE RODS, and SKID PLATE
4-WHEEL SUZUKI 660 TURF MODELS 898657 & 898658
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Part
No.
302944
303269
311392
450077
450382
450393
450457
452398
452408
800945
452692
800485
800919
809137
831405
843418
841167
841255
841336
841404
844148
841429
304636
817250
841630
841737
841738
841839
841841
841842
842033
894574
842104
Description
No.
Req’d
Nut, jam, 9/16-18 . . . . . . . . . . . . .
Lockwasher, 7/16 . . . . . . . . . . . . .
Screw, 7/16-14 x 2 . . . . . . . . . . . .
Bolt, M16-2.00 x 90 . . . . . . . . . . .
Nut, locking insert M16-2.00 . . . .
Washer, M16 . . . . . . . . . . . . . . . . .
Nut, M16-2.00, flange (G10.9) . . .
Screw, M10-1.5 x 20 (G8.8) . . . . .
Screw, M10-1.75 x 20 (10.9) . . . .
Bolt, M12-1.75 x 60 (10.9) . . . . . .
Screw, M6-1.00 x 12 . . . . . . . . . . .
Nut, 9/16-18, left-hand . . . . . . . . .
Bolt, M10-1.5 x 30 . . . . . . . . . . . . .
Clip . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting, grease 1/4-28 (90) . . . . .
Clamp, tee . . . . . . . . . . . . . . . . . . .
Bushing, silentbloc . . . . . . . . . . . .
Gear, power steering . . . . . . . . . .
Arm, pitman . . . . . . . . . . . . . . . . . .
Rod, tie . . . . . . . . . . . . . . . . . . . . . .
Ball joint, upper . . . . . . . . . . . . . . .
Ball joint, lower . . . . . . . . . . . . . . .
Pin, cotter 1/8 x 1 1/8 . . . . . . . . . .
Cap, grease . . . . . . . . . . . . . . . . . .
Trunnion, control arm . . . . . . . . . .
Shim, .060” . . . . . . . . . . . . . . . . . . .
Shim, .024” . . . . . . . . . . . . . . . . . . .
Tube, brake (right) . . . . . . . . . . . . .
Hose, brake . . . . . . . . . . . . . . . . . .
Tee, union, M10-1.00 flare . . . . . .
Plate, skid . . . . . . . . . . . . . . . . . . . .
Knuckle, steering (right) . . . . . . . .
Bracket, brake tube . . . . . . . . . . .
1
3
3
2
2
4
2
1
6
2
1
1
4
1
4
1
4
1
1
1
1
1
1
1
1
4
2
1
1
1
1
1
1
Ref.
No.
34
35
*
36
37
38
39
40
41
42
43
44
45
*
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
Part
No.
887512
306328
548224
306825
816586
893234
893421
841430
800909
306328
306825
887750
306328
548224
306825
816586
810437
893266
385174
815403
817928
2702257.7
808088
814474
800908
311537
450452
452378
450455
452413
452415
894635
2703081
Description
No.
Req’d
End, tie rod (RH thread) . . . . . . 1
Pin, cotter, 3/32 x 3/4 . . . . . . 1
Fitting, lubrication . . . . . . . . . . 1
Nut, castle, 7/16-20 . . . . . . . . . 1
Retainer, grease . . . . . . . . . . . 1
Arm assembly, lower control . 1
Frame assembly, front . . . . . . 1
Drum, brake . . . . . . . . . . . . . . . 1
Nut, wheel retaining, M12-1.50 5
Pin, cotter, 3/32 x 3/4 . . . . . . . 2
Nut, castle, 7/16-20 . . . . . . . . . 2
End, tie rod (LH thread) . . . . . . 1
Pin, cotter, 3/32 x 3/4 . . . . . . 1
Fitting, lubrication . . . . . . . . . . 1
Nut, castle, 7/16-20 . . . . . . . . . 1
Retainer, grease . . . . . . . . . . . 1
Clamp . . . . . . . . . . . . . . . . . . . . 4
Arm assembly, upper control . 1
Bearing, cone (outer) . . . . . . . . 1
Bearing, cone (inner) . . . . . . . . 1
Seal, grease . . . . . . . . . . . . . . . 1
Hub assembly . . . . . . . . . . . . . 1
Cup, bearing (outer) . . . . . . . . 1
Cup, bearing (inner) . . . . . . . . 1
Screw, lug M12-1.50 x 42 . . . 5
Nut, castle 3/4-16 . . . . . . . . . . 1
Nut, M6-1.00, flange (10.9) . . . 1
Screw, M6-1.00 x 20 . . . . . . . 1
Nut, M12-1.75 (10.9) . . . . . . . 12
Screw, M12-1.75 x 60 . . . . . . . 4
Screw, M12-1.75 x 80 (8.8) . . . 8
Strut ay. (shock & spring) . . . . . 2
Protector, spring hose . . . . . . . 1
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
* Not Illustrated. Although this lubrication fitting is the standard fitting used with this tie rod, it is not used in this
application. Use Ref. No. 15, Part No. 831405.
If ordering Ref. No’s. 34 (887512) or 44 (887750) you will also need to order Ref. No. 15 (831405).
79
FRONT FORK
3-WHEEL SUZUKI 660 EFI TURF MODEL 898656
Reference Hydraulic Brake Lines,
Turf 3-Wheel With Front Brakes
4
Reference
3-Wheel Frame
Hold the Nut Below From Turning and
Tighten This Nut to 100 9ft.-lbs. of
Torque. The Fork Must Turn Freely.
12
2
1
3
41
Tighten this Nut to 15 ft.-lbs. of
Torque. Hold This Nut While
Tightening the Top Nut.
16
45
2
4
46
Clamp Must be Applied Toward
End Of Protective Hose. This
Will Form a Loop Of Hose
Which Allows Wheel Removal.
44
7
8
10
18
6
19 33
11
25
These Items, as well
as the same items on
the opposite side of
the fork are included
with Ref. No. 17
7
13
25
5
9
14
33
19
41
50
48
43
8
18
49
47
FRONT
OF
VEHICLE
51
49
30
32
42
31
38
39
40
27
Reference
Brake Assembly
23
37
34
22
21
35
36
24
26
28
20
17
29
15
P893743
80
FRONT FORK
3-WHEEL SUZUKI 660 EFI TURF MODEL 898656
Reference
Front Brake Hose
Reference
Front Clip
52
Reference
Master Brake Cylinder
55
53
54
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Part
No.
307665
842646
844180
844190
450075
450382
450455
452413
813850
841167
894549
307665
894550
894636
800909
112050
894538
304104
306494
307665
385174
452398
452400
807630
809156
809229
827068
836719
841430
Description
No.
Req’d
Nut, 3/4-16 jam . . . . . . . . . . . . . . .
Cone, bearing . . . . . . . . . . . . . . . .
Retainer, spindle bearing . . . . . . .
Seal, oil . . . . . . . . . . . . . . . . . . . . . .
Bolt, M16-2.00 x 80 . . . . . . . . . . .
Nut, M16-2.00 locking insert . . . .
Nut, M12-1.75 (G10.9) . . . . . . . . . .
Bolt, M12-1.75 x 60 . . . . . . . . . . .
Bumper, rubber . . . . . . . . . . . . . . .
Bushing, silentbloc . . . . . . . . . . . .
Fork assembly . . . . . . . . . . . . . . . .
Nut, 3/4-16 jam . . . . . . . . . . . . . .
Yoke assembly . . . . . . . . . . . . . . .
Strut and shock, complete . . . . . .
Nut, wheel mount . . . . . . . . . . . . .
Screw, 1/4-20 x 5/8 (G5) . . . . . . . .
Axle, hub & brake assembly . . . .
Nut, 5/8-18 . . . . . . . . . . . . . . . . . .
Lockwashr, 5/8 . . . . . . . . . . . . . . .
Nut, 3/4-16 . . . . . . . . . . . . . . . . . .
Cone, tapered bearing . . . . . . . .
Screw, M10-1.50 x 20 (G8.8) . . .
Bolt, M10-1.50 x 30 (8.8) . . . . . .
Seal, oil . . . . . . . . . . . . . . . . . . . . .
Washer, 5/8 x 1.38 dia. . . . . . . . .
Washer, 3/4 x 1.6 dia. . . . . . . . . .
Cone, tapered bearing . . . . . . . .
Nut, bearing adjustment . . . . . . .
Drum, brake . . . . . . . . . . . . . . . . .
1
2
1
2
2
2
4
4
2
2
1
1
1
2
5
1
1
2
2
1
1
2
2
1
2
1
1
1
1
Ref.
No.
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
Part
No.
Description
No.
Req’d
Washer, oilite 1 x 1.5 x .125 . .
Seal, oil 1.5 id. x 2.5 od. . . . . . .
Spring, thrust . . . . . . . . . . . . . . .
Washer, keeper . . . . . . . . . . . . .
Hub, complete (3-wheel) . . . . . .
Bolt, lug M12-1.50 x 42 . . . . . .
Cup, tapered roller bearing
1.78 od. .48T . . . . . . . . . . . . . . . . .
827069 Cup, tapered roller bearing
2.44 od. .56T . . . . . . . . . . . . . . . . .
894537 Axle, complete . . . . . . . . . . . . . .
894539 Arm, complete, brake . . . . . . . .
844128 Bushing, oilite . . . . . . . . . . . . . .
809137 Clip . . . . . . . . . . . . . . . . . . . . . . . .
450454 Nut, M10-1.50 (10.9) . . . . . . . . . .
452398 Screw, M10-1.50 x 20 . . . . . . . .
450379 Nut, staytite, M10-1.50 . . . . . . . .
814924 Clamp . . . . . . . . . . . . . . . . . . . . . .
825477 Clip . . . . . . . . . . . . . . . . . . . . . . . .
841760 Link, brake anchor . . . . . . . . . . .
2702216 Hose, front brake . . . . . . . . . . . .
844486 Bushing . . . . . . . . . . . . . . . . . . . . .
844642 Bracket, brake hose support . . .
452399 Screw, M10-1.50 x 25 (8.8) . . . .
450453 Nut, M8-1.25 . . . . . . . . . . . . . . . .
452390 Screw, M8-1.25 x 30 (8.8) . . . . .
845378 Bracket, hose support . . . . . . . .
845391 Tube, brake line (3-wheel front) . .
844129
844197
844433
844508
2702258
800908
808088
1
1
1
2
1
5
1
1
1
1
1
2
2
1
1
1
1
1
1
2
1
1
2
2
1
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
81
WHEEL SIZE MEASUREMENT
Wheel size is determined by measuring the wheel at the bead seat.
The first number is the wheel diameter measured at the bead seat.
The second number is the wheel width measured at the bead seat.
The illustration below shows an example of how to measure the wheel to determine tire size.
BEAD SEAT
WHEEL
10.00”
Shown For
Reference Only
(First Number)
Wheel Diameter
7.50”
(Second Number)
Wheel Width
FRONT and REAR TIRES FOR TURF MODELS
5
WHEEL MOUNT NUTS ARE
THE SAME FOR ALL WHEELS
6
1
7
4
2
8
3
9
TIRES
20 x 10.00 - 10 Multi-Rib (front)
24 x 13.00 - 12 Titan Ultra Trac (rear)
or approved equal
(Obtain Locally if only replacing the tire)
P894262
Ref.
No.
Part
No.
1
2
3
4
5
894763
841433
886735
◊◊
800909
Description
No.
Req’d
Tire and wheel (front) 4-wheel . . . 2
Wheel, 10.00 x 7.50, five bolt . . 1
Stem, valve . . . . . . . . . . . . . . . . . 1
Tire, 20 x 10.00 - 10, multi–rib . . 1
Nut, wheel mount . . . . . . . . . . . . 20
Ref.
No.
6
7
8
9
Part
No.
Description
No.
Req’d
894762 Tire and wheel (rear) . . . . . . . . . . 2
◊◊
Tire, 24 x 13.00 - 12, Titan ultra trac
or approved equal (rear) . . . . . . . 1
841434 Wheel, 12.00 x 10.50 . . . . . . . . . 1
886735 Stem, valve . . . . . . . . . . . . . . . . . 1
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY
◊◊ Obtain locally
82
FOOT THROTTLE AND LINKAGE
SUZUKI 660 EFI TURF MODELS 898656, 898657 & 898658
10
FRONT
OF
VEHICLE
When attaching the throttle link to
the pedal, the pin (Item No. 11)
will be inserted in the second
hole from the top
4
5
20
4
1
19
16
12
17
1
3
11
18
6
13
8
1
12
4-Wheel
Panel Shown
1
18
2
14
15
11
3
11
9
7
To
Engine
21
P893675, P895114, P894659
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
Part
No.
306328
844224
450452
452378
452695
515268
524633
524643
548911
800943
806714
No.
Req’d
Ref.
No.
Part
No.
Pin, cotter, 3/32 x 3/4 . . . . . . . . . . 4
Pin, roll 3/16 x 1 3/4” . . . . . . . . . . 2
Nut, M6-1.00 (G10.9) . . . . . . . . . . 6
Screw, M6-1.00 x 20 . . . . . . . . . . . 6
Screw, M6-1.00 x 20, taptite . . . . 1
Bushing . . . . . . . . . . . . . . . . . . . . . . 2
Screw, shoulder 5/16-18 x 1 . . . . 2
Bearing, split . . . . . . . . . . . . . . . . . 2
Nut, 5/16-18 . . . . . . . . . . . . . . . . . . 2
Screw, tap, #10-14 x 5/8 . . . . . . 10
Pin, clevis, 5/16 x 3/4 . . . . . . . . . . 3
12
13
14
(14)
15
16
17
18
19
20
21
844223
830784
841663
844445
843360
843561
843562
843563
843997
894159
895119
Description
Description
No.
Req’d
Spring, torsion . . . . . . . . . . . . . . . .
Pin, clevis, 1/4 x 1 7/8 . . . . . . . . .
Panel, floor access (4-wheel) . . .
Panel, floor access (3-wheel) . . .
Channel, mount . . . . . . . . . . . . . . .
Link, throttle . . . . . . . . . . . . . . . . . .
Mount, channel . . . . . . . . . . . . . . .
Plate, pivot . . . . . . . . . . . . . . . . . . .
Bracket, stop . . . . . . . . . . . . . . . . .
Pedal, throttle . . . . . . . . . . . . . . . .
Cable, throttle (Suzuki Models) . .
2
1
1
1
1
1
1
2
1
1
1
83
REAR SPRING, SHACKLES, U–BOLTS
and REAR SHOCK ABSORBERS
SUZUKI 660 EFI TURF MODELS 898656, 898657 & 898658
2
8
FRONT
OF
VEHICLE
14
2
12
13
5
17
14
16
2
5
1
15
10
Reference
14.21:1
Differential
9
16
4
6
4
5
9
10
11
7
P894510
Ref.
No.
1
2
3
4
5
6
7
8
9
Part
No.
311396
311398
800198
800294
800602
807332
809180
813850
823621
3
Description
No.
Req’d
Screw, 7/16-14 x 2 1/4 . . . . . . . . .
Screw, 1/2-13 x 3 1/2 . . . . . . . . . .
Nut, 1/2-20 crownlock . . . . . . . . .
Nut, 7/16-14 crownlock . . . . . . . .
Nut, 1/2-13 . . . . . . . . . . . . . . . . . . .
Shock absorber . . . . . . . . . . . . . . .
Washer, 7/16 . . . . . . . . . . . . . . . . .
Bumper, rubber . . . . . . . . . . . . . . .
Bushing . . . . . . . . . . . . . . . . . . . . . .
2
6
1
4
6
2
1
2
4
Ref.
No.
Part
No.
10
11
12
13
14
15
16
17
825500
887187
548061
843238
843876
893862
843238
893613
Description
No.
Req’d
Washer, 3/8 . . . . . . . . . . . . . . . . . .
U-bolt, 2” . . . . . . . . . . . . . . . . . . . . .
Nut, 7/16-20 unitorq . . . . . . . . . .
Bushing, nylatron . . . . . . . . . . . . .
Shackle, rear spring . . . . . . . . . . .
Spring, leaf . . . . . . . . . . . . . . . . . . .
Bushing, nylatron . . . . . . . . . . . . .
Upstop . . . . . . . . . . . . . . . . . . . . . .
4
4
2
2
4
2
2
2
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEEDING ASSEMBLY.
84
HYDRAULIC CONTROL VALVE SYSTEM
8
Refer to the Hook-up Decal
on back of the hydraulic box
for hook-up options.
25
16
SEAL KIT
Part No. 887017
26
18
24
27
16
20
9
21
23
28
12
11
Reference
Hydraulic
Control Valve
27
17
5
26
2
13
14
4
19
15
6
7
1
3
10
22
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Part
No.
2700047, 895016
No.
Req’d
Ref.
No.
Nut, jam 3/8-16 . . . . . . . . . . . . . . . 1
Nut, jam 3/8-24 . . . . . . . . . . . . . . . 1
Nut, M8-1.25 (G10.9) . . . . . . . . . . . 2
Screw, M8-1.25 x 50 (G8.8) . . . . . 2
Knob . . . . . . . . . . . . . . . . . . . . . . . . 1
Washer, flat (1.62 dia.) . . . . . . . . . . 1
Elbow, 90 w/o-ring . . . . . . . . . . . 1
Coupler, half (male) . . . . . . . . . . . . 1
Fitting, hydraulic . . . . . . . . . . . . . . 1
Plate, stop . . . . . . . . . . . . . . . . . . . 1
Fitting, hydraulic 90 . . . . . . . . . . 1
Hose, hydraulic, .25 x 42” (1067 mm)
.44FJIC-.37MNPT . . . . . . . . . . . . . . 1
844019 Hose, hydraulic, 3/8 x 17” (432 mm)
9/19-18 UNF 2B JIC, 37 flare . . . . 2
844571 Adapter, 90 elbow . . . . . . . . . . . . 1
844582 Rod, handle extension . . . . . . . . . 1
16
17
304632
306388
450453
452392
548171
822419
826558
832408
844566
832798
835101
841892
Description
18
19
20 21
*
22
23
24
25
26
27
28 Part
No.
Description
No.
Req’d
844584 Bushing, flip-lok . . . . . . . . . . . . . . . 2
844600 Hose, hydraulic, .5 x 39” (991 mm)
8FJIC-.37MNPT . . . . . . . . . . . . . . . 1
2701291 Hose, hydraulic, .37 x 24” (610 mm)
8FJIC-8FJIC90 . . . . . . . . . . . . . . . 1
844652 Adapter, straight . . . . . . . . . . . . . . 1
888042 Pump, hydraulic . . . . . . . . . . . . . . 1
306560 Key, woodruff #5 . . . . . . . . . . . . . 1
887017 Kit, seal, hydraulic pump . . . . . . . 1
894696 Valve, hydraulic selector . . . . . . . 1
894702 Nipple, hydraulic, dry seal . . . . . . 1
2700800 Cover, hydraulics (w/decal) . . . . . 1
837270 Decal, hydraulic connections . . 1
320107 Tie, cable 7 1/2” (190 mm) . . . . . . . 2
840877 Sleeve, nylon . . . . . . . . . . . . . . . . . 2
844583 Fitting, 90 adapter . . . . . . . . . . . . 1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
* Not Illustrated.
Although Ref. No. 20 (hydraulic pump, Part No. 888042) is shipped with two hydraulic fittings, these
fittings are not used in this application. When ordering Ref. No. 20 you will also need to order
hydraulic fittings Ref. No’s 9 & 28. These fittings are the correct fittings to use in this application.
85
HYDRAULIC LIFT SYSTEM
5
8
5
5
7
8
6
13
1
5
1
18
2
15
18
19
20
2
4
11
9
4
14
15
11
17
11
10
12
10
16
3
11
12
Reference Hydraulic
Control Valve
2700047
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
Part
No.
452378
450452
450453
800930
809265
823119
882993
830810
832408
832409
832414
835101
Description
No.
Req’d
Screw, M6-1.00 x 20 . . . . . . . . . . .
Nut, M6-1.00 (G10.9) . . . . . . . . . .
Nut, M8-1.25 (10.9) . . . . . . . . . . . .
Screw, M8-1.25 x 16 (G8.8) . . . . .
Pin, hair . . . . . . . . . . . . . . . . . . . . .
Adapter, 90 . . . . . . . . . . . . . . . . .
Cylinder, lift . . . . . . . . . . . . . . . . . .
Pin, clevis . . . . . . . . . . . . . . . . . . . .
Coupler half, male . . . . . . . . . . . . .
Coupler half, female . . . . . . . . . . .
Ring, retaining . . . . . . . . . . . . . . . .
Fitting, hydraulic 90 . . . . . . . . . .
2
2
4
8
4
1
1
2
1
2
4
2
Ref.
No.
13
14
15
16
17
*
18
19
20
Part
No.
Description
No.
Req’d
832900 Hose, hydraulic, 1/4 x 38” (955 mm)
.25MNPT-.37MNPT . . . . . . . . . . . . . 2
844051 Plate, float latch . . . . . . . . . . . . . . . 1
821893 Trim, push-on . . . . . . . . . . As Req’d.
844598 Hose, hydraulic, 1/4 x 30” (762 mm)
4FJIC-6MNPT . . . . . . . . . . . . . . . . . 1
2700800 Cover, hydraulics (w/decal) . . . . . 1
837270 Decal, hydraulic connections . . 1
817320 Clamp, hose . . . . . . . . . . . . . . . . . . 2
320107 Tie, cable 7 1/2” (190 mm) . . . . . . 2
840877 Sleeve, nylon . . . . . . . . . . . . . . . . . 1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
* Not Illustrated.
86
HYDRAULIC CONTROL VALVE
2
1
20
11
10
18
5
17
21
14
13
16
8
6
15
19
7
9
4
15
3
894233
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
Part
No.
103867
306328
548910
886270
306463
308089
316907
450454
452404
521144
814079
Description
No.
Req’d
Washer, 5/16 . . . . . . . . . . . . . . . . .
Pin, cotter 3/32 x 3/4 . . . . . . . . . .
Nut, flange, 1/4-20 . . . . . . . . . . . .
Valve, hydraulic . . . . . . . . . . . . . . .
Pin, cotter 1/16 x 1/2 . . . . . . . . . .
Washer, #10 . . . . . . . . . . . . . . . . . .
Screw, 1/4-20 x 2 3/4 . . . . . . . . . .
Nut, M10-1.50 (G10.9) . . . . . . . . .
Screw, M10-1.50 x 70 (8.8) . . . . .
Cover, handle . . . . . . . . . . . . . . . .
Pin, clevis 5/16 x 1 1/8 . . . . . . . . .
1
1
4
1
1
1
4
1
1
1
1
Ref.
No.
Part
No.
12
13
14
15
16
17
18
19
20
21
823118
823225
825538
844454
828056
828057
839213
843355
843758
843759
Description
No.
Req’d
Fitting, hydraulic straight . . . . . . .
Pin, clevis 3/16 x 1 . . . . . . . . . . . .
Spring, compression . . . . . . . . . . .
Elbow, 90 w/o-ring . . . . . . . . . . .
Fitting . . . . . . . . . . . . . . . . . . . . . . .
Fitting . . . . . . . . . . . . . . . . . . . . . . .
Connector, valve . . . . . . . . . . . . . .
Mount, control valve . . . . . . . . . . .
Handle, control valve . . . . . . . . . .
Bushing, control valve . . . . . . . . .
1
1
1
2
1
1
1
1
1
1
87
HYDRAULIC FILTER AND RESERVOIR
25
28
17
Reference
Hydraulic Control Valve
And Control Panel
Seal Kit
Part No. 887017
29
3
15
27
26
5
6
13
2
5
1
20
19
7
7
4
10
12
8
23
14
16
18
11
Some Newer Models
are Equipped With the
Hydraulic Tank Shown Below
(Ref. No. 30)
24
22
7
9
21
7
24
30
2700047, 895016
Ref.
No.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
523768
548827
844583
827486
832414
835101
836206
844564
844565
844590
844600
12
13
844627
844630
14
15
885249
888042
Description
No.
Req’d
Adapter, 90 elbow . . . . . . . . . . . .
Screw, 1/4-20 x 1/2 . . . . . . . . . . . .
Fitting, 90 adapter . . . . . . . . . . . .
Valve, pressure relief . . . . . . . . . .
Ring, retaining . . . . . . . . . . . . . . . .
Fitting, hydraulic 90 . . . . . . . . . .
Clamp, hose . . . . . . . . . . . . . . . . . .
Hose, hydraulic, 1 x 26” . . . . . . . .
Hose, hydraulic, 3/4 x 16” . . . . . . .
Adapter, straight . . . . . . . . . . . . . .
Hose, hydraulic, 1/2 x 39 (990 mm)
8FJIC-.37MNPT . . . . . . . . . . . . . . .
Fitting, swivel tee . . . . . . . . . . . . .
Hose, hydraulic, 3/8 x 21 (533 mm)
6FJIC-8FJIC . . . . . . . . . . . . . . . . . .
Element, filter . . . . . . . . . . . . . . . . .
Pump, hydraulic . . . . . . . . . . . . . .
1
2
1
1
2
1
4
1
1
1
1
1
1
1
1
Ref.
No.
*
16
17
*
18
19
20
21
22
23
24
25
26
27
28
29
30
Part
No.
Description
No.
Req’d
887017 Kit, seal, hydraulic pump . . . . . . .
893539 Dipstick, hydraulic tank . . . . . . . .
2700800 Cover, hydraulics (w/decal) . . . . .
837270 Decal, hydraulic connections . .
894675 Tank, hydraulic . . . . . . . . . . . . . . .
894691 Head, filter . . . . . . . . . . . . . . . . . . .
894701 Coupler, hydraulic dryseal . . . . . .
450453 Nut, M8-1.25 (G10.9) . . . . . . . . . .
452388 Screw, M8-1.25 x 20 (G8.8) . . . . .
452399 Screw, M10-1.50 x 25 (8.8) . . . . .
800113 Plug . . . . . . . . . . . . . . . . . . . . . . . . .
450452 Nut, M6-1.00 (10.9) . . . . . . . . . . . .
452380 Screw, M6-1.00 x 30 (8.8) . . . . . .
844937 Plate, coupler retainer . . . . . . . . .
844973 Bushing . . . . . . . . . . . . . . . . . . . . . .
844566 Fitting, htdraulic . . . . . . . . . . . . . . .
2700273 Tank, hydraulic . . . . . . . . . . . . . .
1
1
1
1
1
1
1
2
2
2
2
2
2
1
1
1
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
* Not Illustrated.
Although Ref. No. 15 (hydraulic pump, Part No. 888042) is shipped with two hydraulic fittings, these
fittings are not used in this application. When ordering Ref. No. 15 you will also need to order
hydraulic fittings Ref. No’s 3 & 29. These fittings are the correct fittings to use in this application.
88
ELECTRICAL CONNECTORS
16
9
12
2
20
17
10
23
3
24
5
15
21
8
13
26
6
14
25
7
1
18
4
19
22
11
Ref.
No.
1
2
3
4
(4)
(4)
5
6
7
8
9
10
11
12
13
(13)
(13)
(13)
14
Part
No.
825880
825877
825894
825970
825970
844328
825996
825997
825998
825999
825973
826005
826726
829631
826000
833038
836892
842983
837296
Description
No.
Req’d.
Connector, female . . . . . As Req’d
Connector, female, 6-contact . . . 1
Connector, female, 3-contact . . . 1
Boot, terminal (solenoid) . . . . . . . . 2
Boot, terminal (alternator) . . . . . . . 3
Boot, terminal (alternator) . . . . . . . 1
Fuseholder . . . . . . . . . . . . . . . . . . . 1
Terminal,
fuse clip, 1-way 1 lead . . . . . . . . . 4
Terminal,
fuse clip, 1-way 2 lead . . . . . . . . . 6
Terminal,
fuse clip, 3-way 1 lead . . . . . . . . . 2
Connector, male, 6-contact . . . . . 3
Connector, male, 2-contact . . . . . 1
Connector, male, 1-contact . . . . . 1
Connector, female, 4-contact . . . 2
Fuse, 20 amp. . . . . . . . . . As Req’d
Fuse, 30 amp. . . . . . . . . . As Req’d
Fuse, 10 amp. . . . . . . . . . As Req’d
Fuse, 15 amp. . . . . . . . . . As Req’d
Connector . . . . . . . . . . . . . . . . . . . 1
Ref.
No.
15
16
17
18
(18)
(18)
19
(19)
20
21
22
23
24
25
26
Part
No.
Description
No.
Req’d.
841895 Cover, battery terminal . . . . . . . .
844013 Connector, 18-contact . . . . . . . . .
843550 Connector,
receptacle, 18-contact . . . . . . . . .
894596 Cable, battery, red
30” (762 mm) . . . . . . . . . . . . . . . . . .
894594 Cable, battery, red
46” (1168 mm) . . . . . . . . . . . . . . . . .
2701502 Cable, battery, red
38” (965 mm) . . . . . . . . . . . . . . . . .
894513 Cable, battery, black
46” (1168 mm) . . . . . . . . . . . . . . . . .
892811 Cable, battery, black
24” (607 mm) . . . . . . . . . . . . . . . . . .
829630 Connector, male, 4-contact . . . . .
837301 Connector, head lamp . . . . . . . . .
843598 Connector, rocker switch . . . . . . .
800943 Screw, #10-14 x 5/8 . . . . . . . . . . .
2700913 Jumper, tailight . . . . . . . . . . . . . .
839919 Plug, 40 pin . . . . . . . . . . . . . . . . . .
839920 Receptacle, 40 pin . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
2
1
2
1
1
1
89
ELECTRICAL COMPONENTS
and SECONDARY WIRING HARNESSES
2
9
1
15
8
6
14
13
12
11
1
23
10
3
5
6
21
ÎÎÎÎÎ
ÎÎÎÎÎ
ÎÎÎÎÎ
ÎÎÎÎÎ
ÎÎÎÎÎ
ÎÎÎÎÎ
ÎÎÎÎÎ
18
19
17
20
7
30
16
25
28
ÄÄ
ÄÄ
ÄÄ
ÄÄ
ÄÄ
27
4
26
29
33
24
31
32
22
Used With Model 898656 and
Models 898658 With Serial No’s. Beginning
With 00002120 Only.
The wiring harnesses are shown as a reference
only. Although the actual harness resembles the
illustrations shown, connections, terminals and
routing can change without notice.
893442, 893448, 893972
90
ELECTRICAL COMPONENTS
and SECONDARY WIRING HARNESSES
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
*
Part
No.
Description
No.
Req’d.
450452 Nut, M6-1.00 (G10.9) . . . . . . . . . .
452378 Screw, M6-1.00 x 20 . . . . . . . . . .
800934 Screw, M6-1.00 x 16 (G10.9) . . . .
830366 Switch, push (horn button) . . . . . .
2701658 Panel, instrument w/tach . . . . . .
800943 Screw, #10-14 x 5/8 . . . . . . . . . . .
837303 Headlight, rectangular . . . . . . . . .
843581 Switch, headlight . . . . . . . . . . . . .
843942 Socket, 12V acc. plug . . . . . . . . .
886090 Horn . . . . . . . . . . . . . . . . . . . . . . . .
889673 Solenoid . . . . . . . . . . . . . . . . . . . . .
120052 Lockwasher, #10 . . . . . . . . . . . . .
132520 Nut, #10-32 . . . . . . . . . . . . . . . . .
306325 Lockwasher, 5/16 . . . . . . . . . . . .
306932 Nut, 5/16-18 . . . . . . . . . . . . . . . . .
890000 Buzzer assembly . . . . . . . . . . . . .
890154 Switch, ignition, complete . . . . . .
837295 Switch, ignition . . . . . . . . . . . . . .
837296 Connector . . . . . . . . . . . . . . . . . .
3
2
1
1
1
4
2
1
1
1
1
2
2
2
2
1
1
1
1
Ref.
No.
19
20
21
22
23
24
25
26
27
28
29
30
31 32 (32) 33 (33) Part
No.
Description
No.
Req’d.
837299 Spacer . . . . . . . . . . . . . . . . . . . . .
837300 Spacer . . . . . . . . . . . . . . . . . . . . .
890158 Connector and wire . . . . . . . . . .
894201 Harness, wire, fuel tank . . . . . . . .
894308 Switch (normally open) . . . . . . . . . .
894313 Harness, wire, taillight . . . . . . . . .
893602 Taillight . . . . . . . . . . . . . . . . . . . . . .
843857 Sender, water temperature . . . . .
829787 Terminal, 45 1/4” male . . . . . . . .
835480 Relay, 30 amp (12V) . . . . . . . . . . .
843167 Relay, 12V, 15 amp DPST . . . . . . .
2702952 Wire, noise suppressor . . . . . . .
2701758 Harness, fan switch . . . . . . . . . .
17680-50F70 Switch, fan . . . . . . . . . . . . .
2703052 Switch, fan . . . . . . . . . . . . . . . . . .
2702917 Engine control unit (ECU) . . . . . .
2702975 Engine control unit (ECU) . . . . . .
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
INDENTED PARTS NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
* Not Illustrated
Models 898658 with Serial No’s. up to REV1287 and Models 898657.
Models 898658 with Serial No’s. beginning with 00002120 and Models 898656.
The convoluted tubing used on the wiring harnesses can be ordered in bulk length only. Cut off the
required amount for your particular application. Order the tubing as follows:
Part No. 826190 .350 i.d. sold in 50’ (15.2 m) lengths
Part No. 826191 .500 i.d. sold in 25’ (7.6 m) lengths
91
ENGINE & MAIN WIRE HARNESS
SUZUKI 660 EFI TURF MODELS 898656, 898657 & 898658
The wiring harness is shown as a reference
only. Although the actual harness resembles
the illustration shown, connections, terminals
and routing can change without notice.
ECU
TURN SIGNAL
SWITCH
KEY
SWITCH
FLASHER
TO
ENGINE HARNESS
TO
ENGINE
HARNESS
CAB
STOP LIGHT
POWER
POINT
TRAILER
BRAKES
FUEL
SENDER
TAIL
LIGHT
BRAKE
SWITCH
HORN
SWITCH
HEADLIGHT
SWITCH
ACCESSORY
PLUG
DIAGNOSTIC
PORT
FAN
RELAY
MAIN
RELAY
FUEL
RELAY
FUSE
BLOCK
TRAILER
BRAKES
CLUTCH
SWITCH
COOLANT
OVER TEMP
ALARM
BRAKE
FLUID
SENDER
SHIFTER
LIGHT
SPEEDO
SIGNAL
SHIFTER
LIGHT
TACH
SIGNAL
FUSE
BLOCK
TO
TACH/SPEEDO
SIGNAL
LEFT TURN
SIGNAL
INSTRUMENT
PANEL
GROUND
STANDOFF
LEFT
HEADLIGHT
HORN
FUSE
BLOCK
RIGHT
HEADLIGHT
RIGHT TURN
SIGNAL
Ref.
No.
1
*
*
Part
No.
Description
No.
Req’d
895052 Harness, main . . . . . . . . . . . . . . . . 1
895049 Harness, engine (all models) . . . . . 1
2700919 Harness, main . . . . . . . . . . . . . . . 1
Ref.
No.
Part
No.
Models 898658 with Serial No’s. up to REV1287 and Models 898657.
beginning with 00002120 and Models 898656.
Models 898658 with Serial No’s.
92
No.
Req’d
* 2702946 Harness, Suzuki engine . . . . . . . 1
* 2702947 Harness, Suzuki engine . . . . . . . 1
* Not Illustrated.
Description
AUTOMATIC TRANSMISSION SHIFTER
SUZUKI 660 TURF MODEL 898657
With Ref. No. 11,
Cable Hrdwr. Kit
Part No. 892164
12
5
9
Mounts to Transmission
Using Existing Hardware
1
13
6
7
1
6
3
4
Mounts to Transmission
Using Existing Hardware
2
With Ref. No. 11,
Cable Hrdwr. Kit
Part No. 892164
8
10
With Ref. No. 11,
Cable Hrdwr. Kit
Part No. 892164
Ref.
No.
1
2
3
4
5
6
7
Part
No.
103867
302030
306375
306396
800582
821164
842740
Description
No.
Req’d
Washer, 5/16 . . . . . . . . . . . . . . . . .
Screw, 1/4-20 x 1 1/4 . . . . . . . . . .
Nut, 1/4-20 . . . . . . . . . . . . . . . . . . .
Lockwasher, 1/4 . . . . . . . . . . . . . .
Screw, 1/4-20 x 3/4 . . . . . . . . . . . .
Pin, hair 1/4 x 1 1/8 . . . . . . . . . . . .
Lever, shifter . . . . . . . . . . . . . . . . .
2
1
1
1
4
2
1
Ref.
No.
8
9
10
11
12
13
Part
No.
2700046, 895016
Description
No.
Req’d
845345.7 Bracket, shifter cable mount . .
894584 Shifter ay. w/cable . . . . . . . . . . . . .
894508 Cable, shifter . . . . . . . . . . . . . . . .
892164 Kit, cable hardware . . . . . . . . . . .
894585 Shifter, ATM . . . . . . . . . . . . . . . . . .
894743 Nut, double (1/4-20) . . . . . . . . . . . .
1
1
1
1
1
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
93
TWO-SPEED HYPOID DIFFERENTIAL (14.21:1)
SUZUKI 660 EFI TURF MODELS 898656, 898657 & 898658
20
95
77
69
72
92
84
14
17
21
14
76
82
12
88
14
91
96
91
79
71
70
68
74
75
34
61
29
73
26
28
39
89
57
44
60
49
23
38
43
18
25
48
46
59
40
17
58
38
80
83
81
45
27
19
30
37
36
32
28 *
43
56
52
78
58
66
67
50
51
42
47
53
9
90
94
93
LOCTITE 515
BOTH SIDES
13
55
LOCTITE 242
TORQUE TO
50 ft. lbs.
85
86
22
54 41
35
63
6
62
87
33
26
11
15
10
4
22
3
7
8
14
17
1
65
2
64
5
16
RING EYES MUST BE POSITIONED WITH GAP
* RETAINING
CENTERED OVER THE CAST OIL DRAIN GROOVE.
894509
94
ALSO REFER TO PAGE 96
24
Also Included With
Ref. No’s. 50 & 51
31
TWO-SPEED HYPOID DIFFERENTIAL (14.21:1)
SUZUKI 660 EFI TURF MODELS898656, 898657 & 898658
Ref.
No.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
or
45
46
47
48
49
894826
112050
800909
841842
832584
832587
800944
841430
836959
841838
841837
836431
839948
893583
103867
111074
304636
306322
891089
306405
306423
306435
307776
548201
845356
548952
800559
800973
800737
844956
805837
800743
800695
810435
842359
809180
809254
842360
811992
811993
812009
812335
838539
836693
836420
844750
836421
836422
836426
845034
836429
Description
No.
Req’d
Differential, 14.21:1 . . . . . . . . . . . . . 1
•Screw, 1/4-20 x 5/8, tapping . . . . . 1
•Nut, wheel retaining . . . . . . . . . . . 10
•Fitting, hydraulic brake tee . . . . . . 1
•Clamp, tee mount bracket . . . . . . 1
•Hose, hydraulic brake . . . . . . . . . . 1
•Screw, M10-1.50 x 25 . . . . . . . . . . 8
•Drum, brake . . . . . . . . . . . . . . . . . . 2
•Bracket, tee mounting . . . . . . . . . . 1
•Tube, brake, (left) . . . . . . . . . . . . . . 1
•Tube, brake, (right) . . . . . . . . . . . . 1
•Cover, front . . . . . . . . . . . . . . . . . . . 1
•Tag, 14.21:1 ratio . . . . . . . . . . . . . . 1
•Cable, park brake . . . . . . . . . . . . . . 2
•Washer, 5/16 . . . . . . . . . . . . . . . . . 14
•Plug . . . . . . . . . . . . . . . . . . . . . . . . . 1
•Pin, cotter, 1/8 x 1 1/8 . . . . . . . . . . 2
•Screw, 5/16-18 x 7/8 . . . . . . . . . . 12
•Jackshaft . . . . . . . . . . . . . . . . . . . . . 1
•Washer, 3/8 . . . . . . . . . . . . . . . . . . 10
•Screw, 5/16-18 x 1 3/4 . . . . . . . . . 2
•Screw, 5/16-18 x 1 1/4 . . . . . . . . . 1
•Screw, 3/8-16 x 2 3/4 . . . . . . . . . . . 3
•Screw, set, 5/16-18 x 5/16 . . . . . . 1
•Washer . . . . . . . . . . . . . . . . . . . . . . 2
•Lockring . . . . . . . . . . . . . . . . . . . . . . 1
•Nut, 1/2-20, crownlock . . . . . . . . . 2
•Nut, 3/4-16, crownlock . . . . . . . . . 1
•Ring, retaining . . . . . . . . . . . . . . . . 2
•Bearing, bronze thrust . . . . . . . . . . 1
•Locknut, special . . . . . . . . . . . . . . 10
•Nut, 3/4-16, slotted . . . . . . . . . . . . 2
•Ring, retaining . . . . . . . . . . . . . . . . 1
•Clamp . . . . . . . . . . . . . . . . . . . . . . . 1
•Pinion, 15 tooth . . . . . . . . . . . . . . . 1
•Washer, special . . . . . . . . . . . . . . . 1
•Ring, retaining . . . . . . . . . . . . . . . . 1
•Gear, 52 tooth . . . . . . . . . . . . . . . . . 1
•Shim, cluster gear . . . . . . . . . . . . . 3
•Bearing, thrust . . . . . . . . . . . . . . . . 1
•Bearing, ball . . . . . . . . . . . . . . . . . . 1
•Seal, oil . . . . . . . . . . . . . . . . . . . . . . 1
•Seal, oil . . . . . . . . . . . . . . . . . . . . . . 2
•Bearing, ball . . . . . . . . . . . . . . . . . . 3
•Spacer, pinion, .625” (15.9 mm) . 1
•Spacer, pinion, .750” (19.0 mm) . 1
•Shaft, input . . . . . . . . . . . . . . . . . . . 1
•Shaft, main . . . . . . . . . . . . . . . . . . . 1
•Collar, axle bearing . . . . . . . . . . . . 2
•Collar, thrust . . . . . . . . . . . . . . . . . . 1
•Collar, engaging . . . . . . . . . . . . . . . 1
Ref.
No.
50 (50)
51 (51)
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
(89)
(89)
90
91
92
93
94
95
96
97
Part
No.
Description
No.
Req’d
2700530 •Shaft, assembly (left) . . . . . . . . . . . 1
2700514 ••Shaft, axle (left) 23.27” (591.05 mm) 1
2700531 •Shaft, assembly (right)
2700515 ••Shaft, axle (right) 29.21” (741.93 mm) 1
836694 •Seal, ’O’ ring . . . . . . . . . . . . . . . . . . 2
836695 •Bearing, tapered roller . . . . . . . . . . 2
836841 •Bracket . . . . . . . . . . . . . . . . . . . . . . 1
836852 •Breather . . . . . . . . . . . . . . . . . . . . . . 1
837020 •Baffle, vent . . . . . . . . . . . . . . . . . . . 1
836692 •Baffle, oil scoop . . . . . . . . . . . . . . . 1
894519 •Gear, cluster . . . . . . . . . . . . . . . . . . 1
844087 ••Bushing . . . . . . . . . . . . . . . . . . . . . 2
894886 •Gear, driven . . . . . . . . . . . . . . . . . . 1
812006 ••Bushing . . . . . . . . . . . . . . . . . . . . . 2
893519 •Retainer, complete w/seal . . . . . . 2
838539 ••Seal, bearing . . . . . . . . . . . . . . . . . 1
2701599 •Hub assembly . . . . . . . . . . . . . . . . . 2
800908 ••Screw, wheel retaining . . . . . . . . 5
893588 •Housing, axle (left) . . . . . . . . . . . . . 1
893590 •Housing, axle (right) . . . . . . . . . . . 1
889780 •Cover ay., shift . . . . . . . . . . . . . . . . 1
548204 ••Set screw, 3/8-16 x 3/8 . . . . . . . . 1
548937 ••Lockwasher . . . . . . . . . . . . . . . . . . 1
807366 ••Button, positioning . . . . . . . . . . . . 1
2700493 ••Spring . . . . . . . . . . . . . . . . . . . . . . . 1
831099 ••Seal . . . . . . . . . . . . . . . . . . . . . . . . 2
836657 ••Fork, shift . . . . . . . . . . . . . . . . . . . . 1
836658 ••Shaft, shift . . . . . . . . . . . . . . . . . . . 1
836662 ••Bushing, guide . . . . . . . . . . . . . . . 1
889925 ••Cover . . . . . . . . . . . . . . . . . . . . . . . 1
891829 •Housing, carrier w/gears . . . . . . . . 1
103867 ••Washer, 5/16 . . . . . . . . . . . . . . . . . 8
111074 ••Plug . . . . . . . . . . . . . . . . . . . . . . . . 1
111758 ••Stud . . . . . . . . . . . . . . . . . . . . . . . 10
306322 ••Screw, 5/16-18 x 7/8 . . . . . . . . . . 8
517226 ••Bushing . . . . . . . . . . . . . . . . . . . . . 2
836443 ••Cover, rear . . . . . . . . . . . . . . . . . . 1
•Brake, rear complete, (right) . . . . . 1
•Brake, rear complete, (left) . . . . . . 1
844813 •Ring, backing . . . . . . . . . . . . . . . . . 4
2702146 •Spacer, diff. cover (rear) . . . . . . . . 1
844951 •Shim, .003 . . . . . . . . . . . . . . . . . . . . 1
844952 •Shim, .005 . . . . . . . . . . . . . . . . . . . . 1
844953 •Shim, .010 . . . . . . . . . . . . . . . . . . . . 2
893067 Cable, control (2 speed hi-low) . . . 1
132520 Nut, #10-32 . . . . . . . . . . . . . . . . . . . . 2
306328 Pin, cotter, 3/32 x 3/4 . . . . . . . . . . . 1
450452 Nut, M6-1.00 (10.9) . . . . . . . . . . . . . 1
452378 Screw, M6-1.00 x 20 . . . . . . . . . . . . 1
806703 Pin, clevis, 5/16 x 29/32 . . . . . . . . . 1
837043 Bracket . . . . . . . . . . . . . . . . . . . . . . . 1
2701374 Washer (with Ref. No. 64) . . . . . . . . 1
• INDENTED PARTS NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
• Refer to the parts breakdown for the brakes.
Also includes Ref. No’s. 16, 24 & 31.
95
TWO-SPEED HYPOID DIFFERENTIAL 14.21:1 (con’t.)
TURF MODELS 898656, 898657 & 898658
Two (2) different pinion spacers (Reference No. 44 on Pages 94-95) have been used in the 14.21:1 differential Part
No. 894826. To determine which spacer is the correct one for your particular application, the 52-tooth gear, Part
No. 842360 (Item No. 37 on Pages 94-95) must be measured as shown.
DIMENSION “A”
Ref. No. 37
(Page 94-95)
If dimension “A” is .625” (15.9 mm)
use spacer Part No. 836420
If dimension “A” is .750” (19.0 mm)
use spacer Part No. 844750
52 TOOTH GEAR
Part No. 842360
HOUSING and GEAR ASSEMBLY FOR 14.21:1 DIFFERENTIALS,
SUZUKI 660 EFI TURF MODELS 898656, 898657 & 898658
9
11
4
8
7
4
1
5
WHEN ORDERING FOR THE
14.21:1 DIFFERENTIAL
YOU WILL ALSO NEED TO
ORDER THIS SPACER
(PART NO. 2702146)
2
3
10
6
Ref.
No.
1
2
3
4
5
6
7
*
8
*
*
*
*
*
Part
No.
891829
103867
111074
111758
306322
517226
800717
800718
814476
836443
836675
836676
836677
836678
836680
No.
Req’d
Ref.
No.
Housing and gear assembly . . . . 1
Washer, 5/16 . . . . . . . . . . . . . . . . 8
Plug . . . . . . . . . . . . . . . . . . . . . . . . 1
Stud . . . . . . . . . . . . . . . . . . . . . . . 10
Screw, 5/16-18 x 7/8 . . . . . . . . . . 9
Bushing . . . . . . . . . . . . . . . . . . . . . 2
Screw, 3/8-24 x 13/16 . . . . . . . . 10
Nut, 3/4-16 hex lock . . . . . . . . . . 1
Cup, bearing (2.53 o.d.) . . . . . . . 1
Cover, rear . . . . . . . . . . . . . . . . . . 1
Cup, bearing (2.89 o.d.) . . . . . . . 2
Cone, bearing (1.63 i.d.) . . . . . . 2
Cup, bearing (2.84 o.d.) . . . . . . . 1
Cone, bearing (1.375 i.d.) . . . . . 1
Cone, bearing (1.125 i.d.) . . . . . 1
9
10
Description
*
*
*
*
*
*
*
*
*
*
*
11
Part
No.
Description
No.
Req’d
836692 Baffle, oil . . . . . . . . . . . . . . . . . . . .
889870 Gear set . . . . . . . . . . . . . . . . . . . .
836681 Shim, .003 . . . . . . . . . . . . . . . . . .
836682 Shim, .005 . . . . . . . . . . . . . . . . . .
836683 Shim, .010 . . . . . . . . . . . . . . . . . .
836684 Shim, .030 . . . . . . . . . . . . . . . . . .
836685 Shim, .003 . . . . . . . . . . . . . . . . . .
836686 Shim, .005 . . . . . . . . . . . . . . . . . .
836687 Shim, .010 . . . . . . . . . . . . . . . . . .
836688 Shim, .003 . . . . . . . . . . . . . . . . . .
836689 Shim, .005 . . . . . . . . . . . . . . . . . .
836690 Shim, .010 . . . . . . . . . . . . . . . . . .
836691 Shim, .030 . . . . . . . . . . . . . . . . . .
2702146 Spacer, rear cover (14.21:1) . . .
1
1
2
2
2
3
1
2
4
1
1
2
2
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
* Not Illustrated.
96
HAND CONTROLS, GOVERNOR and THROTTLE
SUZUKI 660 EFI TURF MODELS 898656, 898657 & 898658
11
10
* Apply Loctite 242
14
17
12
20
16
3*
19
2
Reference
14.21:1 Differential
8
24
23
13
22
3*
5
15
2
4
1
6
Reference
Governor
21
Reference
Control Panel
7
2
6
Reference
Foot Throttle
9
1
Must Attach Control Cable to Park
Brake Cable W/Cable Tie to Avoid
Coming in Contact With the Muffler
5
18
13
893439, 894509
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
Part
No.
111898
120052
132520
306328
306514
306531
320107
450452
452378
800271
800582
806703
Description
No.
Req’d
Clamp, cable . . . . . . . . . . . . . . . . .
Lockwasher, #10 . . . . . . . . . . . . . .
Nut, #10-32 . . . . . . . . . . . . . . . . . .
Pin, cotter 29/32 x 3/4 . . . . . . . . .
Screw, #10-32 x 1/2 . . . . . . . . . . .
Nut, #10-24 . . . . . . . . . . . . . . . . . .
Tie, cable 7 1/2 ” (190.5 mm) . . . .
Nut, M6-1.00 (G10.9) . . . . . . . . . . .
Screw, M6-1.00 x 20 . . . . . . . . . . .
Screw, #10-24 x 1/2 (G5) . . . . . . .
Screw, 1/4-20 x 3/4 . . . . . . . . . . . .
Pin, clevis 5/16 x 31/32 . . . . . . . .
3
7
2
1
3
6
1
1
1
4
4
1
Ref.
No.
13
14
15
16
17
18
19
20
21
22
23
24
Part
No.
817104
827821
828049
837043
841264
843607
844116
844130
893067
894743
307776
836841
Description
No.
Req’d
Stop, wire . . . . . . . . . . . . . . . . . . . .
Knob . . . . . . . . . . . . . . . . . . . . . . . .
Cable, control (hand throttle) . . . . .
Bracket (cable to differential) . . . . . .
Panel, left hand (turf) . . . . . . . . . . .
Bushing, throttle cable . . . . . . . . .
Decal, left hand dash (turf) . . . . . .
Cable, governor control . . . . . . . .
Cable, control (hi-lo shift) . . . . . . . .
Nut, double . . . . . . . . . . . . . . . . . . .
Screw, 3/8-16 x 2 3/4 . . . . . . . . . .
Bracket, hi-lo shift cable mount .
2
2
1
1
1
1
1
1
1
2
2
1
97
FRONT and REAR BRAKES & HUBS
SUZUKI 660 EFI TURF MODELS 898656, 898657 & 898658
Shown For
Reference Only
17
For Rear
Parking Brake
17
16
15
16
4
17
17
17
18
18
17
17
16
17
17
14
19
13
All components shown with the brake
assembly are used on the front and
rear brakes unless otherwise noted.
12
20
2
With Rear
Wheels Only
3
9
FRONT
OF
VEHICLE
7
1
11
6
8
With Front
Wheels Only
98
10
5
894509, 894510
FRONT and REAR BRAKES & HUBS
SUZUKI 660 EFI TURF MODELS 898656, 898657 & 898658
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
*
*
*
*
Part
No.
No.
Req’d
Ref.
No.
304636 Pin, cotter 1/8 x 1 1/8 . . . . . . . . . . 2
306325 Lockwasher, 5/16 . . . . . . . . . . . . . 8
306932 Nut, M10-1.50 . . . . . . . . . . . . . . . . 8
800944 Screw, M10-1.50 x 25 (G10.9) . . . 8
800909 Nut, wheel retaining, M12-1.5 . . 10
805843 Nut, castle, 5/8-18 . . . . . . . . . . . . . 2
809156 Washer, special . . . . . . . . . . . . . . . 2
817250 Cap, grease . . . . . . . . . . . . . . . . . . 2
841430 Drum, brake . . . . . . . . . . . . . . . . . . 2
2701599 Hub assembly (rear, all models) . 2
800908 Screw, lug, M12-1.50 x 45 . . . . 10
2702257.7 Hub assembly (front)
Models 898657 & 898658 . . . . 2
808088 Cup, bearing (outer) . . . . . . . . . . . 1
814474 Cup, bearing (inner) . . . . . . . . . . . 1
800908 Screw, lug, M12-1.50 x 45 . . . . 10
*
Description
12
13
14 *
15
16
17
*
18
*
19 *
*
20
Part
No.
Description
No.
Req’d
2702258 Axle, hub & brake assembly (front)
Model 898656 only . . . . . . . . . . . . 1
893519 Seal and retainer . . . . . . . . . . . . . . 2
838539 Seal, bearing . . . . . . . . . . . . . . . . 1
893585 Brake, complete, front (LH) . . . . . 1
893586 Brake, complete, front (RH) . . . . . 1
894930 Cylinder, wheel . . . . . . . . . . . . . . 1
894932 Kit, brake shoe . . . . . . . . . . . . . . . 1
894933 Kit, spring (LH) . . . . . . . . . . . . . . . . 1
894934 Kit, spring (RH) . . . . . . . . . . . . . . . . 1
894935 Kit, adjuster repair (LH) . . . . . . . . . 1
894936 Kit, adjuster repair (RH) . . . . . . . . 1
893581 Brake, complete w/lever, rear (LH) 1
893582 Brake, complete w/lever, rear (RH) 1
894931 Kit, cylinder repair . . . . . . . . . . . . . 1
844813 Ring, retainer . . . . . . . . . . . . . . . . . 4
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
* Not Illustrated.
• When ordering the front or rear brake assemblies (Part No’s. 893585, 893586, 893581 & 893582) all
components shown in the illustration with items No. 14 & 19 are included with the assemblies. If replacement
parts are required, the individual parts will be grouped into kits as stated in the above parts list.
• For a breakdown of the 3-wheel front brakes, see the parts illustration for Front Fork, 3-wheel.
99
GOVERNOR AND THROTTLE LINKAGE
SUZUKI 660 TURF MODELS 898658 With Serial No’s. Up To REV1287 & MODELS 898657
33
To
Throttle Body
3
24
5
13
20
8
7
16
42
2
26
35
8
11
9
21
37
12
28
51
50
30
25 *
9
13
29
8
4
4
36
19
20
46
25 *
22
49
19
12
27
13
40
39
9
5
41
31
8
32
18
1
23
38
5
34
USE LOCTITE 242
ON THESE ITEMS
Reference
Govenor Bracket
Part No. 895014.7
6
To
Accelerator
Pedal
48 *
*
10
8
14
17
44
15 *
47 *
43
46
44
1
45
895016, 895114
Ref.
No.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
103867
111893
130728
132520
306320
306325
306372
306375
306396
306450
306487
306981
308090
450454
452378
452401
548190
553046
302288
800024
800927
806773
810722
813379
830140
831586
100
Description
No.
Req’d
Washer, 3/8 . . . . . . . . . . . . . . . . . . . .
Screw, special #10-32 . . . . . . . . . . .
Nut, 1/4-20 . . . . . . . . . . . . . . . . . . . .
Nut, jam #10-32 . . . . . . . . . . . . . . . .
Nut, 5/16-24 . . . . . . . . . . . . . . . . . . .
Lockwasher, 5/16 . . . . . . . . . . . . . . .
Pin, cotter 3/32 x 1/2” . . . . . . . . . . .
Nut, 1/4-20 . . . . . . . . . . . . . . . . . . . .
Lockwasher, 1/4 . . . . . . . . . . . . . . . .
Screw, 5/16-18 x 3/4 . . . . . . . . . . . .
Screw, 1/4-20 x 5/8 . . . . . . . . . . . . .
Washer, 3/8 . . . . . . . . . . . . . . . . . . . .
Washer, 1/4 . . . . . . . . . . . . . . . . . . . .
Nut, M10-1.50 (G10.9) . . . . . . . . . . .
Screw, M6-1.00 x 20 . . . . . . . . . . . .
Screw, M10-1.50 x 40 (G8.8) . . . . .
Pin, hair (11/16 x 1 7/8) . . . . . . . . . .
Key, woodruff 1/4 x 1/2 . . . . . . . . . .
Screw, 1/4-20 x 1 . . . . . . . . . . . . . . .
Screw, 1/4-20 x 1 1/2 . . . . . . . . . . .
Screw, shoulder, 1/4-20 x 5/8 . . . .
Pin, clevis (5/16 x 1 1/8) . . . . . . . . . .
Yoke . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin, clevis (1/4 x 3/8) . . . . . . . . . . . .
Bearing, ball . . . . . . . . . . . . . . . . . . .
Ball joint . . . . . . . . . . . . . . . . . . . . . . .
3
1
1
2
3
2
1
4
4
2
2
5
3
1
2
1
1
1
2
2
1
1
1
1
2
1
Ref.
No.
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
Part
No.
Description
No.
Req’d
833101 Spring, extension . . . . . . . . . . . . . . .
894434 Arm assembly, governor . . . . . . . . .
835271 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . .
2700334 Spring, extension . . . . . . . . . . . . . . .
843013 Pulley, governor . . . . . . . . . . . . . . . .
843536 Rod, governor arm . . . . . . . . . . . . . .
2700503 Cable, throttle body . . . . . . . . . . . . .
2700810 Governor, complete . . . . . . . . . . . . .
2701129 Arm, throttle . . . . . . . . . . . . . . . . . . .
2700859 Arm, governor . . . . . . . . . . . . . . . . . .
2700540 Lever, governor (Suzuki 660) . . . . . .
894464 Base, throttle (Suzuki 660) . . . . . . . .
895119 Cable, throttle . . . . . . . . . . . . . . . . . .
843866 Bushing, governor . . . . . . . . . . . . . .
894435 Bracket assembly, governor . . . . . .
2700335 Spring, governor . . . . . . . . . . . . . . .
2700502 Bracket, lower govnr. mount . . . . .
2700522 Bushing, standoff, 1” (25.4 mm) . . . .
2700523 Bushing, standoff, 1 3/4” (44.5 mm) .
450452 Nut, M6-1.00 (10.9) . . . . . . . . . . . . . .
452381 Screw, M6-1.00 x 40 (8.8) . . . . . . . .
452383 Screw, M6-1.00 x 60 (8.8) . . . . . . . .
452548 Bolt, carriage, M6-1.00 x 50 (G4.6)
450399 Washer, M6 . . . . . . . . . . . . . . . . . . . .
821164 Pin, hair (1/4 x 1 1/8) . . . . . . . . . . . .
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
3
1
1
1
1
1
GOVERNOR AND THROTTLE LINKAGE
SUZUKI 660 EFI TURF MODEL 898656 and MODELS 898658
With Serial No’s. Beginning With 00002120
To
Throttle Body
31
3
24
5
13
7
16
20
40
39
38
2
37
33
26
25 *
19
29
8
4
4
34
8
20
8
35
12
9
13
25 *
12
11
9
28
LOCTITE 242
* USE
ON THESE ITEMS
30
27
21
15 *
41
19
42
23
5
22
To
Accelerator
Pedal
36
18
5
1
32
10
6
1
43
14
17
1
8
Mounts
to Engine
Reference
Hydraulic Pump
Bracket
Mounts
to Engine
P2701379
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Part
No.
103867
111893
130728
132520
306320
306325
306372
306375
306396
306450
306487
306981
308090
450454
452388
452401
548190
553046
302288
800024
806773
843536
Description
No.
Req’d
Washer, 3/8 . . . . . . . . . . . . . . . . . .
Screw, special #10-32 . . . . . . . . .
Nut, 1/4-20 . . . . . . . . . . . . . . . . . . .
Nut, jam #10-32 . . . . . . . . . . . . . . .
Nut, 5/16-24 . . . . . . . . . . . . . . . . . .
Lockwasher, 5/16 . . . . . . . . . . . . .
Pin, cotter 3/32 x 1/2” . . . . . . . . . .
Nut, 1/4-20 . . . . . . . . . . . . . . . . . . .
Lockwasher, 1/4 . . . . . . . . . . . . . .
Screw, 5/16-18 x 3/4 . . . . . . . . . . .
Screw, 1/4-20 x 5/8 . . . . . . . . . . . .
Washer, 3/8 . . . . . . . . . . . . . . . . . .
Washer, 1/4 . . . . . . . . . . . . . . . . . .
Nut, M10-1.50 (G10.9) . . . . . . . . . .
Screw, M8-1.25 x 20 (8.8) . . . . . .
Screw, M10-1.50 x 40 (8.8) . . . . .
Pin, hair 11/16 x 1 7/8 . . . . . . . . .
Key, woodruff 1/4 x 1/2 . . . . . . . .
Screw, 1/4-20 x 1 . . . . . . . . . . . . .
Screw, 1/4-20 x 1 1/2 . . . . . . . . . .
Pin, clevis 5/16 x 1 1/8 . . . . . . . . .
Rod, governor arm . . . . . . . . . . . .
5
2
1
4
3
2
1
4
3
2
2
5
2
1
1
1
1
1
2
2
1
1
Ref.
No.
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
Part
No.
Description
No.
Req’d
810722 Yoke . . . . . . . . . . . . . . . . . . . . . . . .
813379 Pin, clevis 1/4 x 3/8 . . . . . . . . . . . .
830140 Bearing, ball . . . . . . . . . . . . . . . . . .
831586 Ball joint . . . . . . . . . . . . . . . . . . . . .
833101 Spring, extension . . . . . . . . . . . . .
894434 Arm assembly, governor . . . . . . .
835271 Nut . . . . . . . . . . . . . . . . . . . . . . . . . .
895119 Cable, throttle . . . . . . . . . . . . . . . .
2701543 Cable, throttle body . . . . . . . . . .
2700810 Governor, complete . . . . . . . . . .
2701129 Arm, throttle . . . . . . . . . . . . . . . . .
2700859 Arm, governor . . . . . . . . . . . . . . .
2700540 Lever, governor . . . . . . . . . . . . . .
2701609 Base, throttle . . . . . . . . . . . . . . . .
2700334 Spring, extension . . . . . . . . . . . .
2700335 Spring, governor . . . . . . . . . . . . .
450399 Washer, M6 . . . . . . . . . . . . . . . . . .
821164 Pin, hair (1/4 x 1 1/8) . . . . . . . . . . .
843866 Bushing, governor . . . . . . . . . . . . .
894435 Bracket, governor . . . . . . . . . . . . .
2701829 Bolt . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
101
GOVERNOR
SUZUKI 660 EFI TURF MODELS 898656, 898657 & 898658
Use Teflon Tape,
Permatex #2 Sealant
or Equivalent.
Torque to
95 10 in. lbs.
Jam Nut
6
19
Govenor Nut
15
20
Adjust Governor Nut and
Secure With Jam Nut
Allowing .006” (.152 mm)
Sideplay For Lever.
USE
LOC-TITE 271
29
24
1
12
7
11
23
21
15
2
10
5
18
Torque to
96 24 in. lbs.
9
3
4
8
22
16
17
13
30
27
28
25
26
After Setting Governor Spool Yoke
to .321/.319, Adjust Set Screw to
Maintain That Dimension, Then
Apply GM Ind. Silicone Sealant or
Equivalent
14
Set Screw
.321
.319
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Part
No.
Description
895016, 2700810
No.
Req’d
2700810 Governor, complete . . . . . . . . . .
111812 Yoke, spool . . . . . . . . . . . . . . . . . .
111814 Washer, thrust . . . . . . . . . . . . . . .
111816 Washer, thrust . . . . . . . . . . . . . . .
111817 Spool, governor . . . . . . . . . . . . . .
112840 Bearing, thrust . . . . . . . . . . . . . . .
130728 Nut, jam, 1/4-20 . . . . . . . . . . . . . .
158061-18 O-ring . . . . . . . . . . . . . . . . . . . .
160410 Carrier & weights . . . . . . . . . . . . .
302288 Screw, 1/4-20 x 1” . . . . . . . . . . . .
306396 Lockwasher, 1/4” . . . . . . . . . . . . .
306506 Lockwasher, #6 . . . . . . . . . . . . . .
306915 Screw, machine, #6-32 x 5/16” .
306966 Pin, roll, 1/8” x 3/4” . . . . . . . . . . .
548325 Ring, retaining . . . . . . . . . . . . . . .
800227 Plug, 1/8-27 . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
2
2
2
2
1
1
2
Ref.
No.
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Part
No.
Description
No.
Req’d
800558 Screw, set, 3/8-16 x 5/16” . . . . .
833056 Gasket, governor . . . . . . . . . . . . .
833102 Seal, oil . . . . . . . . . . . . . . . . . . . . .
835271 Nut, governor arm . . . . . . . . . . . .
843537 Bracket, governor knee . . . . . . .
843149 Bushing, steel . . . . . . . . . . . . . . .
843157 Head, governor . . . . . . . . . . . . . .
894471 Reservoir, governor . . . . . . . . . . .
833103 Bearing, needle . . . . . . . . . . . . .
888397 Shaft, governor, complete . . . . .
833066 Shaft, governor . . . . . . . . . . . . .
833104 Ring, retaining . . . . . . . . . . . . . .
833345 Bearing, ball . . . . . . . . . . . . . . . .
2700525 Lever, governor control . . . . . .
2702249 Key, woodruff .12 x .50 . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
102
ALTERNATOR, ENGINE BELTS, PULLEYS and BRACKETS
SUZUKI 660 EFI TURF MODEL 898656
5
6
GOV
ALT
Reference
Alternator
HYDR
PUMP
3
2
WATER
PUMP
18
To
Engine
16
CRNKSHFT
13 *
1
*
4
Engine Belt Diagram
3-Wheel Model 898656
Use Loctite 242
On These Items
7
Reference
Governor
9
10
27
12
Reference
Hyd. Pump
14
19
6
26
17
FRONT
OF
VEHICLE
24
25
11
13
15
Fan Switch
Harness
To
Engine
Crankshaft
G
G/B
4 1
W/R
Y
EXC
P
S
B
8
21
28
E
B
20
B
To
Water Pump
R
R
R
R/W
R
22
30
ALTERNATOR WIRING
Ref.
No.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
103867
120052
306531
306325
306375
306396
306416
306450
548804
306562
306837
450453
452388
306981
844035
Description
29
23
P2701379
No.
Req’d
Washer, 3/8 . . . . . . . . . . . . . . . . . . . .
Lockwasher, #10 . . . . . . . . . . . . . . .
Nut, #10-24 . . . . . . . . . . . . . . . . . . . .
Lockwasher, 5/16 . . . . . . . . . . . . . . .
Nut, 1/4-20 . . . . . . . . . . . . . . . . . . . .
Lockwasher, 1/4 . . . . . . . . . . . . . . . .
Screw, 5/16-18 x 1 . . . . . . . . . . . . . .
Screw, 5/16-18 x 3/4 . . . . . . . . . . . .
Nut, 3/8-16 . . . . . . . . . . . . . . . . . . . .
Nut, 3/8-16 . . . . . . . . . . . . . . . . . . . .
Screw, 3/8-16 x 3 1/4 . . . . . . . . . . .
Nut, M8-1.25 (G10.9) . . . . . . . . . . . .
Screw, M8-1.25 x 20 (8.8) . . . . . . . .
Washer, 3/8 . . . . . . . . . . . . . . . . . . . .
Pulley, 4.75” (governor) . . . . . . . . . . .
3
4
4
3
1
2
1
2
1
2
1
1
4
3
1
Ref.
No.
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Part
No.
Description
No.
Req’d
2700564 V-belt, 53” (1346 mm) . . . . . . . . . . .
2701657.7 Bracket, alternator mounting . . .
2701365 V-belt, 39” (991 mm) . . . . . . . . . . . .
2701691.7 Bracket, governor mounting . . . .
2701944 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . .
2701942 Pulley, crankshaft . . . . . . . . . . . . . .
2702537 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . .
2702525 Pulley, water pump . . . . . . . . . . . . .
450400 Washer, M8 . . . . . . . . . . . . . . . . . . . .
452378 Screw, M6-1.00 x 20 . . . . . . . . . . . .
2701688.7 Bracket, upper radiator hose . . .
120177 Lockwasher, 3/8 . . . . . . . . . . . . . . . .
306835 Screw, 3/8-16 x 1 3/4 . . . . . . . . . . .
800073 Bolt, carriage 3/8-16 x 1 1/4 . . . . . .
828100 Pulley, 5.50” (hydraulic pump) . . . .
1
1
1
1
1
1
4
1
1
1
1
2
1
1
1
103
ALTERNATOR, ENGINE BELTS, PULLEYS and BRACKETS
SUZUKI 660 EFI TURF MODELS 898658 With Serial No’s. Up To REV1287
and MODELS 898657
Reference
Power Steering Pump
Part No. 892534
GOV
ALT
Reference
Alternator
5
19
16
6
Part No. 893633
WATER
PUMP
PWR
STRNG
CRNKSHFT
HYDR
PUMP
12
*
Use Loctite 242
On These Items
ENGINE BELT DIAGRAM
MODELS 898657 & 898658
18
4
23
1
12
17
To
Engine
Reference
Governor
Part No. 2700810
7
To
Engine
13 *
10
11
30
20
FRONT
OF
VEHICLE
13
14
29
28
4 1
8
13
To
Engine
15
13 *
To
Water Pump
ALTERNATOR WIRING
G
9
G/B
27
W/R
P
EXC
S
To
Engine
Crankshaft
26
B
E
24
31
10
3
Reference
Hydraulic Pump
Part No. 888042
25
B
R
22
R
R
2
21
R/W
R
895016
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
104
Part
No.
Description
No.
Req’d
103867 Washer, 3/8 . . . . . . . . . . . . . . . . . . . .
120177 Lockwasher, 3/8 . . . . . . . . . . . . . . . .
306835 Screw, 3/8-16 x 1 3/4 . . . . . . . . . . .
306325 Lockwasher, 5/16 . . . . . . . . . . . . . . .
306375 Nut, 1/4-20 . . . . . . . . . . . . . . . . . . . .
306396 Lockwasher, 1/4 . . . . . . . . . . . . . . . .
306416 Screw, 5/16-18 x 1 . . . . . . . . . . . . . .
306450 Screw, 5/16-18 x 3/4 . . . . . . . . . . . .
306562 Nut, 3/8-16 . . . . . . . . . . . . . . . . . . . .
306981 Washer, 3/8 . . . . . . . . . . . . . . . . . . . .
311213 Screw, 3/8-16 x 3 . . . . . . . . . . . . . . .
450453 Nut, M8-1.25 (G10.9) . . . . . . . . . . . .
452388 Screw, M8-1.25 x 20 (8.8) . . . . . . . .
452394 Screw, M8-1.25 x 70 (8.8) . . . . . . . .
844035 Pulley, 4.75” (governor) . . . . . . . . . . .
2700564 V-belt, 53” (1346 mm) . . . . . . . . . . .
3
2
1
3
1
1
1
2
2
3
1
3
9
2
1
1
Ref.
No.
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Part
No.
Description
No.
Req’d
839907 Pulley, 5.50” (steering pump) . . . . . .
895010.7 Bracket, alternator mounting . . . .
2700565 V-belt, 45” (1143 mm) . . . . . . . . . . .
895014.7 Bracket, governor mounting . . . . .
800073 Bolt, carriage, 3/8-16 x 1 1/4 . . . . .
828100 Pulley, 5.50” (hydraulic pump) . . . . . .
548804 Nut, 3/8-16 . . . . . . . . . . . . . . . . . . . .
2701944 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . .
2701941 Pulley, crankshaft . . . . . . . . . . . . . .
2702537 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . .
2702524 Pulley, water pump . . . . . . . . . . . . .
450399 Washer, M6 . . . . . . . . . . . . . . . . . . . .
450432 Lockwasher, M6 . . . . . . . . . . . . . . . .
452378 Screw, M6-1.00 x 20 . . . . . . . . . . . .
845277.7 Bracket, hydraulic pump . . . . . . . .
2701110.7 Bracket, upper radiator hose . . . .
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
ALTERNATOR, ENGINE BELTS, PULLEYS and BRACKETS
SUZUKI 660 EFI TURF MODEL 898658
With Serial No’s. Beginning With 00002120
5
6
Reference
Power Steering Pump
GOV
ALT
Reference
Alternator
3
HYDR
PUMP
18
2
WATER
PUMP
14
To
Engine
PWR
STRNG
16
CRNKSHFT
13 *
1
*
4
Engine Belt Diagram
3-Wheel Model 898656
Use Loctite 242
On These Items
7
9
10
Reference
Governor
29
27
12
Reference
Hyd. Pump
30
19
12
6
13
26
17
FRONT
OF
VEHICLE
24
25
11
13
15
Fan Switch
Harness
To
Engine
Crankshaft
G
G/B
4 1
W/R
Y
EXC
P
S
B
20
B
To
Water Pump
R
R
R
R/W
R
32
22
Part
No.
Description
31
23
ALTERNATOR WIRING
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
28
E
B
Ref.
No.
8
21
P2701379
No.
Req’d
103867 Washer, 3/8 . . . . . . . . . . . . . . . . . . . .
120052 Lockwasher, #10 . . . . . . . . . . . . . . .
306531 Nut, #10-24 . . . . . . . . . . . . . . . . . . . .
306325 Lockwasher, 5/16 . . . . . . . . . . . . . . .
306375 Nut, 1/4-20 . . . . . . . . . . . . . . . . . . . .
306396 Lockwasher, 1/4 . . . . . . . . . . . . . . . .
306416 Screw, 5/16-18 x 1 . . . . . . . . . . . . . .
306450 Screw, 5/16-18 x 3/4 . . . . . . . . . . . .
548804 Nut, 3/8-16 . . . . . . . . . . . . . . . . . . . .
839907 Pulley, 5.50” (steering pump) . . . . . .
306837 Screw, 3/8-16 x 3 1/4 . . . . . . . . . . .
450453 Nut, M8-1.25 (G10.9) . . . . . . . . . . . .
452388 Screw, M8-1.25 x 20 (8.8) . . . . . . . .
452394 Screw, M8-1.25 x 70 (8.8) . . . . . . . .
844035 Pulley, 4.75” (governor) . . . . . . . . . . .
2700564 V-belt, 53” (1346 mm) . . . . . . . . . . .
3
4
4
3
1
2
1
2
1
1
1
3
5
2
1
1
Ref.
No.
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Part
No.
Description
No.
Req’d
2701657.7 Bracket, alternator mounting . . .
2701365 V-belt, 39” (991 mm) . . . . . . . . . . . .
2701691.7 Bracket, governor mounting . . . .
2701944 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . .
2701942 Pulley, crankshaft . . . . . . . . . . . . . .
2702537 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . .
2702525 Pulley, water pump . . . . . . . . . . . . .
450400 Washer, M8 . . . . . . . . . . . . . . . . . . . .
452378 Screw, M6-1.00 x 20 . . . . . . . . . . . .
2701688.7 Bracket, upper radiator hose . . .
120177 Lockwasher, 3/8 . . . . . . . . . . . . . . . .
306835 Screw, 3/8-16 x 1 3/4 . . . . . . . . . . .
306562 Nut, 3/8-16 . . . . . . . . . . . . . . . . . . . .
306981 Washer, 3/8 . . . . . . . . . . . . . . . . . . . .
800073 Bolt, carriage 3/8-16 x 1 1/4 . . . . . .
828100 Pulley, 5.50” (hydraulic pump) . . . .
1
1
1
1
1
4
1
1
1
1
2
1
2
3
1
1
105
RADIATOR and COOLING SYSTEM
SUZUKI 660 TURF MODELS 898658 With Serial No’s. Up To REV1287
and MODELS 898657
52
50
51
7
Reference
Platform Support
14
13
28
The Neoprene Cover and Mounting
Hardware are Used on Vehicles
Equipped with Seat Belts and/or
Cab Sets (See Following Page)
16
29
23
27
25
14
19
30
24
21
11
18
27
3
2
10
31
1
28
15
48
40
33
With Auto.
Tran. Only
49
27
22
20
31
37
44
46
32
15
12
41
Adhesive
This Side
39
45
35
Use
Loctite
592
9
15
53
Shown as
Reference Only
8
6
43
36
47
31
17
26
31
38
34
6
5
895016, 894615, P2701428
4
106
RADIATOR and COOLING SYSTEM
SUZUKI 660 TURF MODELS 898658 With Serial No’s. Up To REV1287 & MODELS 898657
Reference
Top View
Radiator Screen
The Neoprene Cover and Mounting Hardware (Ref. No’s. 50, 51 & 52)
are Used On Vehicles Which Are Equipped With Seat Belts.
Seat Belts Are Included With the Upper ROPS Accessory (Part No. 894761); the
Upper ROPS Mod (Part No. 53715) and the Cab Set Mod (Part No. 53721).
1.56”
(40 mm)
.44”
(11.2 mm)
Pop Rivet
(Ref No. 52)
Backing Plate
(Ref. No. 50)
.140”
(3.5 mm)
Neoprene Cover
(Ref. No. 51)
To Install the Neoprene Cover and Backing Plate, Place the Cover on Top of the Radiator
Screen and Position the Cover Using the Dimensions Shown in the Illustration above.
Radiator Screen and
Neoprene Cover Also
Shown on Previous Page
Using the Cover as a Template, Mark and Drill Four (4) .140” (3.5 mm) Dia. Holes.
Secure the Cover and Mount Plate Using the Rivets as Shown.
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12 13
14
15
16
17
18
19
20
21
22
23
24
25
26
Part
No.
No.
Req’d
Ref.
No.
Screw, 1/4-20 x 3/4 . . . . . . . . . . . . 2
Lockwasher, 1/4 . . . . . . . . . . . . . . 2
Washer, 1/4 . . . . . . . . . . . . . . . . . . 2
Nut, M6-1.00 . . . . . . . . . . . . . . . . . 4
Screw, M6-1.00 x 16 . . . . . . . . . . . 4
Screw, M6-1.00 x 20 . . . . . . . . . . . 5
Hose, radiator overflow . . As Req’d.
Clamp, tube . . . . . . . . . . . . . . . . . . 1
Grommet . . . . . . . . . . . . . . . . . . . . 2
Screw, 5/16-18 x 3/4 . . . . . . . . . . . 4
Nut, isolation . . . . . . . . . . . . . . . . . 4
Clamp, hose . . . . . . . . . . . . . . . . . . 4
Cap, coolant reservoir . . . . . . . . . 1
Foam . . . . . . . . . . . . . . . . . . . . . . . . 2
Kit, oil cooler mounting,
automatic transmission . . . . . . . . 1
840754 Decal, Warning Pressure . . . . . . . 1
843040 Bracket, fan mounting . . . . . . . . . 1
888549 Connector, hose (air cleaner) . . . . 1
894590 Radiator . . . . . . . . . . . . . . . . . . . . . 1
833443 Plug . . . . . . . . . . . . . . . . . . . . . . . . 1
889049 Cap, radiator . . . . . . . . . . . . . . . . 1
833442 O-ring . . . . . . . . . . . . . . . . . . . . . . 1
889050 Reservoir, coolant . . . . . . . . . . . . . 1
893388 Mount, radiator . . . . . . . . . . . . . . . 1
893554 Screen . . . . . . . . . . . . . . . . . . . . . . 1
2700799 Fan, radiator, cooling . . . . . . . . . 1
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42 *
43
44
45
46
47
48
49
50
51
52
53
300646
306396
308090
450452
450541
452378
835805
832033
809231
800177
831846
825624
889051
833512
800789
Description
Part
No.
Description
No.
Req’d
450453 Nut, M8-1.25 (G10.9) . . . . . . . . . . . 3
452388 Screw, M8-1.25 x 20 (G8.8) . . . . . 2
452395 Screw, M10-1.50 x 80 (8.8) . . . . . 1
452398 Screw, M10-1.50 x 20 (8.8) . . . . . 2
820889 Clamp, tubing . . . . . . . . . . . . . . . . 6
843857 Sender, water temperature . . . . . 1
2700160 Hose, radiator upper . . . . . . . . . 1
2700031 O-ring, 15/16” i.d. . . . . . . . . . . . . 1
2700050 Hose, radiator lower . . . . . . . . . . 1
833715 Plug . . . . . . . . . . . . . . . . . . . . . . . . . 1
845334 Outlet, water . . . . . . . . . . . . . . . . . 1
845365 Tube, water outlet . . . . . . . . . . . . . 1
829787 Terminal, 45 1/4” male . . . . . . . . 1
826590 Hose, 5/16 i.d. . . . . . . . . . As Req’d.
838340 Cooler, oil (auto. trans.) . . . . . . . . . 1
821893 Trim, push-on . . . . . . . . . . As Req’d.
009034880 Decal, fan . . . . . . . . . . . . . . . . 1
2702540 Bolt, bleed valve . . . . . . . . . . . . . 1
2702469 Bolt, water outlet mount . . . . . . . 2
2702541 Washer, bleed valve . . . . . . . . . . 1
845409 Bracket, u-water inlet . . . . . . . . . . 1
2701108 Clamp, 1.25 i.d. . . . . . . . . . . . . . . 1
2701110.7 Bracket, upper radiator hose . . . 1
2701421 Backing plate, cover . . . . . . . . . . 1
2701422 Cover, neoprene . . . . . . . . . . . . . 1
133741 Rivet, pop (.12 .50 clsd end) . . . . . 1
2702542 Thermostat . . . . . . . . . . . . . . . . . 1
Item No’s. 9, 12, 15, 40 & 41 are used with the automatic transmission vehicles only.
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
The parts illustration only shows two (2) of Item 12 (825624 Hose Clamps). The other two are used
to secure the cooler hoses to the transmission lines.
* Not Illustrated. Item 42 (821893 Push-on Trim) is used to protect the automatic transmission hoses
and is used on the right side motor mount and the right side frame rail.
107
RADIATOR and COOLING SYSTEM
SUZUKI 660 EFI TURF MODEL 898658 With Serial No’s. Beginning With 00002120
and MODEL 898656
15
50
51
7
Reference
Platform Support
14
13
28
The Neoprene Cover and Mounting
Hardware are Used on Vehicles
Equipped with Seat Belts and/or
Cab Sets (See Following Page)
16
29
23
27
25
14
18
19
11
30
24
21
27
3
2
10
31
1
33
9
28
48
53
12
40
31
44
46
22
45
41
39
20
37
52
49
27
27
32
42
28
Shown as
Reference Only
Use
Loctite 592
To Lower
Engine Block
43
8
35
6
36
47
31
17
26
31
38
34
6
5
P2701379, P893445
4
108
RADIATOR and COOLING SYSTEM
SUZUKI 660 EFI TURF MODEL 898658 With Serial No’s. Beginning With 00002120
and MODEL 898656
Reference
Top View
Radiator Screen
The Neoprene Cover and Mounting Hardware (Ref. No’s. 15, 50 & 51)
are Used On Vehicles Which Are Equipped With Seat Belts.
Seat Belts Are Included With the Upper ROPS Accessory (Part No. 894761); the
Upper ROPS Mod (Part No. 53715) and the Cab Set Mod (Part No. 53721).
1.56”
(40 mm)
.44”
(11.2 mm)
Backing Plate
(Ref. No. 50)
Pop Rivet
(Ref No. 15)
.140”
(3.5 mm)
Neoprene Cover
(Ref. No. 51)
To Install the Neoprene Cover and Backing Plate, Place the Cover on Top of the Radiator
Screen and Position the Cover Using the Dimensions Shown in the Illustration above.
Radiator Screen and
Neoprene Cover Also
Shown on Previous Page
Using the Cover as a Template, Mark and Drill Four (4) .140” (3.5 mm) Dia. Holes.
Secure the Cover and Mount Plate Using the Rivets as Shown.
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Part
No.
Description
No.
Req’d
300646 Screw, 1/4-20 x 3/4 . . . . . . . . . . . . 2
306396 Lockwasher, 1/4 . . . . . . . . . . . . . . 2
308090 Washer, 1/4 . . . . . . . . . . . . . . . . . . 2
450452 Nut, M6-1.00 . . . . . . . . . . . . . . . . . 4
450541 Screw, M6-1.00 x 16 . . . . . . . . . . . 4
452378 Screw, M6-1.00 x 20 . . . . . . . . . . . 5
835805 Hose, radiator overflow . . As Req’d.
832033 Clamp, tube . . . . . . . . . . . . . . . . . . 1
845224 Cap, .313 x 1 . . . . . . . . . . . . . . . . . . 1
800177 Screw, 5/16-18 x 3/4 . . . . . . . . . . . 4
831846 Nut, isolation . . . . . . . . . . . . . . . . . 4
825624 Clamp, hose . . . . . . . . . . . . . . . . . . 1
889051 Cap, coolant reservoir . . . . . . . . . 1
833512 Foam . . . . . . . . . . . . . . . . . . . . . . . . 2
133741 Rivet, pop (.12 .50 clsd end) . . . . . 4
840754 Decal, Warning Pressure . . . . . . . 1
843040 Bracket, fan mounting . . . . . . . . . 1
888549 Connector, hose (air cleaner) . . . . 1
894590 Radiator . . . . . . . . . . . . . . . . . . . . . 1
833443 Plug . . . . . . . . . . . . . . . . . . . . . . . . 1
889049 Cap, radiator . . . . . . . . . . . . . . . . 1
833442 O-ring . . . . . . . . . . . . . . . . . . . . . . 1
889050 Reservoir, coolant . . . . . . . . . . . . . 1
893388 Mount, radiator . . . . . . . . . . . . . . . 1
893554 Screen . . . . . . . . . . . . . . . . . . . . . . 1
2700799 Fan, radiator, cooling . . . . . . . . . 1
450453 Nut, M8-1.25 (G10.9) . . . . . . . . . . . 4
Ref.
No.
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
Part
No.
Description
No.
Req’d
452388 Screw, M8-1.25 x 20 (G8.8) . . . . .
452395 Screw, M10-1.50 x 80 (8.8) . . . . .
452398 Screw, M10-1.50 x 20 (8.8) . . . . .
820889 Clamp, tubing . . . . . . . . . . . . . . . .
843857 Sender, water temperature . . . . .
2701639 Hose, radiator upper . . . . . . . . .
2700031 O-ring, 15/16” i.d. . . . . . . . . . . . .
2700050 Hose, radiator lower . . . . . . . . . .
833715 Plug . . . . . . . . . . . . . . . . . . . . . . . . .
2701637 Housing, thermostat . . . . . . . . . .
845365 Tube, water outlet . . . . . . . . . . . . .
829787 Terminal, 45 1/4” male . . . . . . . .
452392 Screw, M8-1.25 x 50 (8.8) . . . . . .
2701638 Spacer, thermostat . . . . . . . . . . .
2701513 Gasket, thermostat spacer . . . .
009034880 Decal, fan . . . . . . . . . . . . . . . .
2702540 Bolt, bleed valve . . . . . . . . . . . . .
2702542 Thermostat . . . . . . . . . . . . . . . . .
2702541 Washer, bleed valve . . . . . . . . . .
845409 Bracket, u-water inlet . . . . . . . . . .
2701108 Clamp, 1.25 i.d. . . . . . . . . . . . . . .
2701688.7 Bracket, upper radiator hose . .
2701421 Backing plate, cover . . . . . . . . . .
2701422 Cover, neoprene . . . . . . . . . . . . .
2701757 Switch, fan (on-93C, off-88C) . .
2702539 Cap, thermostat . . . . . . . . . . . . .
3
1
2
4
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
109
DECALS, TURF MODELS
PREVENT HYDRAULIC SYSTEM DAMAGE
HOSE REMOVED FROM ACCESSORY 8 MUST
BE CLEANED AND PLUGGED INTO RETURN
PORT 7 TO PREVENT DAMAGE DUE TO ACC–
IDENTAL ENGAGEMENT OF SELECTOR VALVE.
MOTOR
DRIVEN
ACCESSORY
LIFT
VALVE
10
NOTICE
TRUCKSTER
CYLINDER
7
1
4
9
5
2
9
6
8
3
SELECTOR
VALVE
HYDRAULIC
TANK
4
1
THIS UNIT IS NOT A MOTOR VEHICLE WITHIN THE
DEFINITION OF THE NATIONAL TRAFFIC MOTOR
VEHICLE SAFETY ACT. IT IS NOT DESIGNED
OR MANUFACTURED FOR USE ON ROADS, STREETS
OR HIGHWAYS, NOR IS IT APPROPRIATE FOR
SUCH USE. IT IS NOR MEANT TO BE LICENSED
AS A MOTOR VEHICLE.
821071
840748
15
844643
ACCESSORY
CYLINDER
HYD
PUMP
PRESSURE
RETURN
SUCTION
PRESSUREOR RETURN
FILTER
FOR MOTOR DRIVEN ACCESSORY AND
TRUCKSTER DUMP BOX OPERATION:
PLUG 1–4, 2–3, 8–9, 7–10.
FOR TRUCKSTER CYLINDER
OPERATION:
PLUG 1–4, 2–3, 7–8.
FOR MOTOR DRIVEN ACCESSORY AND
INOPERABLE TRUCKSTER CYLINDER:
PLUG 1–2, 3–4, 8–9, 7–10.
FOR ACCESSORY CYLINDER
OPERATION:
PLUG 1–5, 2–6, 4–3, 7–8.
16
7
837270
3
898659/898657
844179
6
13
844116
840901
17
5
8
11
844177
10
TURF–TRUCKSTER
R
TURF–TRUCKSTER
WARNING
2
12
R
R
PARKING BRAKES ARE NOT AUTOMATICALLY APPLIED. VEHICLE MAY
MOVE CAUSING PERSONAL INJURY
AND/OR PROPERTY DAMAGE. ALWAYS
APPLY HAND OR FOOT BRAKES.
822819
14
WARNING
FAILURE TO HEED THESE
WARNINGS MAY RESULT IN
SERIOUS INJURY OR DEATH
Ref.
No.
1
2
3
4
5
6
7
8
9
110
Part
No.
821071
822819
837270
840754
845027
840901
844116
844177
844179
1.
2.
3.
4.
5.
READ AND UNDERSTAND ALL LABELS AND THE OPERATOR’S MANUAL.
DO NOT ALLOW UNTRAINED PERSONNEL TO OPERATE THIS VEHICLE.
DO NOT MODIFY THIS VEHICLE WITHOUT MANUFACTURER’S AUTHORIZATION.
PLACE LOADS FORWARD OF REAR AXLE.
TOP HEAVY LOADS CAN CAUSE UPSETTING. DO NOT EXCEED PAYLOAD
CAPACITY.
6. DO NOT OPERATE IF REPAIRS ARE REQUIRED.
7. KEEP ALL SHIELDS IN PLACE.
No.
Req’d
Ref.
No.
Decal, Notice not motor vehicle . 1
Decal, Warning, park brake . . . . . 1
Decal, remote hyd. connections . 1
Decal, Warning, pressure . . . . . . 1
Decal, Pinch point . . . . . . As Req’d.
Decal, Warning, read ops. man. . . 1
Decal, LH dash, turf . . . . . . . . . . . 1
Decal, aux. transmission . . . . . . . 1
Decal, hydraulic controls . . . . . . . 1
10
11
12
13
14
15
16
17
Description
8. SHIFT INTO NEUTRAL OR PARK BEFORE STARTING ENGINE.
9. ONLY CARRY PASSENGERS IN SEATS PROVIDED.
10. WHEN PARKING (LEAVING) VEHICLE, FOLLOW ALL INSTRUCTIONS IN
OPERATOR’S MANUAL.
11. AVOID SUDDEN STARTS, STOPS AND SHARP TURNS ESPECIALLY ON SLOPES, OR
WITH HEAVY LOADS
12. KEEP ALL LABELS AND INSTRUCTIONAL LITERATURE LEGIBLE AND INTACT.
13. KEEP ARMS AND LEGS WITHIN VEHICLE BODY.
845038
Part
No.
Description
No.
Req’d
844426 Decal, 4 wheel turf LH . . . . . . . . .
844427 Decal, 4 wheel turf RH . . . . . . . . .
844430 Decal, Cushman-Textron . . . . . . .
009034880 Decal, Warning, fan . . . . . . .
845038 Decal, Vehicle Operation . . . . . . .
844643 Decal, Warning, pto . . . . . . . . . . .
845232 Decal, ground speed . . . . . . . . . .
2701389 Decal, diamond C . . . . . . . . . . . .
1
1
1
1
1
1
1
1
ENGINE and TRANSMISSION MOUNTS
SUZUKI 660 TURF MODELS 898658 With Serial No’s. Up To REV1287
and MODELS 898657
9
5
8
4
2
16
7
4
20
11
5 2
FRONT
OF
VEHICLE
7
17 1
13
To
Engine
14
1
3
19
Reference
Frame
15
7
6
18
10
4
5
4
2
12
4
4
7
6
895114
Ref.
No.
1
2
3
4
5
6
7
8
9
10
Part
No.
Description
No.
Req’d
103867 Washer, 5/16 . . . . . . . . . . . . . . . . .
306982 Washer, 7/16 . . . . . . . . . . . . . . . . .
450453 Nut, M8-1.25 (G10.9) . . . . . . . . . . .
452454 Nut, M10-1.50 (10.9) . . . . . . . . . . .
450412 Lockwasher, M10 . . . . . . . . . . . . .
452398 Screw, M10-1.50 x 20 (8.8) . . . . .
452406 Screw, M10-1.50 x 90 (8.8) . . . . .
452389 Screw, M8-1.25 x 25 (8.8) . . . . . .
845206.7 Bracket, transmission to frame . .
894998.7 Mount, motor (left) . . . . . . . . . . .
2
3
4
9
3
2
7
4
1
1
Ref.
No.
11
12
13
14
15
16
17
18
19
20
Part
No.
Description
No.
Req’d
895000.7 Mount,motor (right) . . . . . . . . . .
893525 Support, platform . . . . . . . . . . . . .
839946 Bracket, muffler . . . . . . . . . . . . . . .
2702996 Mount, engine (right) . . . . . . . . .
2702999 Mount, engine (left) . . . . . . . . . .
2703001 Mount, rear . . . . . . . . . . . . . . . . .
2703002 Nut . . . . . . . . . . . . . . . . . . . . . . . .
2701827 Bolt . . . . . . . . . . . . . . . . . . . . . . . .
2702661 Bolt . . . . . . . . . . . . . . . . . . . . . . . .
2702998 Bolt . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
1
1
2
4
2
3
111
ENGINE and TRANSMISSION MOUNTS
SUZUKI 660 EFI TURF MODELS 898658 With Serial No’s. Beginning With 00002120
and MODELS 898656
9
7
4
FRONT
OF
VEHICLE
2
19
13
15
4
2
16 1
8
Mounts to
Engine
11
1
3
18
Reference
Frame
14
2
5
17
10
4
4
12
4
4
6
5
P2700567, P2701381
Ref.
No.
1
2
3
4
5
6
7
8
9
10
112
Part
No.
Description
No.
Req’d
103867 Washer, 5/16 . . . . . . . . . . . . . . . . .
452405 Screw, M10-1.50 x 80 (8.8) . . . . .
450453 Nut, M8-1.25 (G10.9) . . . . . . . . . . .
452454 Nut, M10-1.50 (10.9) . . . . . . . . . . .
452398 Screw, M10-1.50 x 20 (8.8) . . . . .
452406 Screw, M10-1.50 x 90 (8.8) . . . . .
452389 Screw, M8-1.25 x 25 (8.8) . . . . . .
839946 Bracket, muffler . . . . . . . . . . . . . . .
845206.7 Bracket, transmission to frame . .
894998.7 Mount, motor (left) . . . . . . . . . . .
2
3
4
9
2
4
4
1
1
1
Ref.
No.
11
12
13
14
15
16
17
18
19
Part
No.
Description
No.
Req’d
2701698 Mount,motor (right) . . . . . . . . . . .
893525 Support, platform . . . . . . . . . . . . .
2702997 Mount, engine (right) . . . . . . . . . .
2703000 Mount, engine (left) . . . . . . . . . .
2703001 Mount, rear . . . . . . . . . . . . . . . . .
2703002 Nut . . . . . . . . . . . . . . . . . . . . . . . .
2701827 Bolt . . . . . . . . . . . . . . . . . . . . . . . .
2702661 Bolt . . . . . . . . . . . . . . . . . . . . . . . .
2702998 Bolt . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
1
2
4
2
3
ENGINE GASKETS
SUZUKI 660 EFI TURF
MODELS 898656, 898657, 898658
6
2
FRONT
OF
VEHICLE
5
Shown For
Reference Only
4
1
7
11
Shown For
Reference Only
9
Shown For
Reference Only
8
10
3
All Items Shown are used with all Models
Unless Otherwise Indicated.
Ref.
No.
1
2
3
4
5
Part
No.
2701775
2701812
2701776
2701795
2701796
2701797
2701798
Description
No.
Req’d
Gasket set, complete . . . . . . . . . .
Gasket set, complete . . . . . . . . . .
Gasket, head . . . . . . . . . . . . . . .
Gasket, valve cover . . . . . . . . .
Gasket, intake manifold . . . . . . .
Gasket, exhaust manifold . . . .
Gasket, distributor drive . . . . . .
1
1
1
1
1
1
1
Ref.
No.
6
7
8
9
10 11
Part
No.
2701799
2701803
2701800
2701801
2701804
2701802
Description
Gasket,
Gasket,
Gasket,
Gasket,
Gasket,
Gasket,
No.
Req’d
cyl. plate . . . . . . . . . . . 1
throttle body . . . . . . . . . . 1
oil pump cover . . . . . .
water pump . . . . . . . . .
surge tank . . . . . . . . . . .
water inlet . . . . . . . . . .
1
1
1
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
Models 898658 with Serial No’s. up to REV1287 and Models 898657.
Models 898658 with Serial No’s. beginning with 00002120 and Models 898656.
113
CYLINDER HEAD & COMPONENTS
SUZUKI 660 EFI TURF MODELS 898656, 898657, 898658
26
25
20
21
19
17
16
24
2
18
22
15
4
23
8
12
13
3
7
11
5
FRONT
OF
VEHICLE
9
6
10
14
14
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Part
No.
2701776
2701795
2701798
2701799
2701813
2701814
2701815
2701816
2701819
2701820
2701821
2701822
2701823
2701824
1
No.
Req’d
Ref.
No.
Gasket, head . . . . . . . . . . . . . . . . 1
Gasket, valve cover . . . . . . . . . . 1
O-ring, distributor drive . . . . . . . 1
Gasket . . . . . . . . . . . . . . . . . . . . . 1
Head, cylinder . . . . . . . . . . . . . . . 1
Plug, oil venturi . . . . . . . . . . . . . 1
Guide, valve . . . . . . . . . . . . . . . 12
Seal . . . . . . . . . . . . . . . . . . . . . . . 2
Seal . . . . . . . . . . . . . . . . . . . . . . . 1
Plug . . . . . . . . . . . . . . . . . . . . . . . 4
Pin . . . . . . . . . . . . . . . . . . . . . . . 10
Bolt . . . . . . . . . . . . . . . . . . . . . . 11
Bolt . . . . . . . . . . . . . . . . . . . . . . 13
Pin . . . . . . . . . . . . . . . . . . . . . . . . . 2
15
16
17
18
19
20
21
22
2701825
2701826
2701827
2701828
2701829
2701830
2701831
2701832
23
24
25
26
2701833
2701834
2701835
2701836
Description
Part
No.
Description
No.
Req’d
Bolt, cylinder head . . . . . . . . . . .
Plate, cylinder head . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . . .
Cover, cylinder head . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Cap, oil filler . . . . . . . . . . . . . . . . .
O-ring, spark plug pipe . . . . . . .
Plug, spark
Nippon Denso XU22EPR-U . . . . .
Case, distributor . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Cover, cylinder . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
8
1
2
1
4
1
3
3
1
2
1
4
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
114
CYLINDER BLOCK, COMPONENTS, OIL DIPSTICK & FILTER
SUZUKI 660 EFI TURF MODELS 898656, 898657 & 898658
Item No. 21 (Oil Level Dipstick) is the Existing Dipstick on Models 898657
and on 898658 Models with Serial No’s. up to REV1287. An Extension
Tube Kit (Ref. No. 25) Has Been Designed to Allow Better Access to the
Dipstick and is Already Installed on Some of These Models. You can
Either Order the Extension Kit (if it has not been installed) or you can
Order Item 21 to Replace the Existing Suzuki Dipstick.
26
25
21
Models 898657 and
Models 898658 With
Serial No’s. Up To
REV1287.
29
19
28
FRONT
OF
VEHICLE
20
16
27
15
18
24
23
17
18
30
6
2
7
22
8
4
3
11
32
12
1
Models 898656 and
Models 898658 With
Serial No’s. Beginning
With 00002120
14
31
13
4
4
5
All Items are Used On All Models
Unless Otherwise Indicated
9
10
Ref.
No.
1
2
3
4
5
6
(6)
7
(7)
8
9
10
11
12
13
14
15 (15)
Part
No.
2701837
2701819
2701820
2701838
2701839
2701840
2701900
2701901
2701900
2702537
2701904
2701905
2701906
2701907
2701908
2701909
2701910
2701911
Description
No.
Req’d
Block, cylinder . . . . . . . . . . . . . . .
Seal . . . . . . . . . . . . . . . . . . . . . . .
Plug . . . . . . . . . . . . . . . . . . . . . . .
Plug . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . .
Plate, clutch hsng. upper . . . . . . . .
Plate, clutch hsng. upper (898657) .
Plate, clutch hsng. lower . . . . . . . .
Plate, clutch hsng. lower (898657) . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Sender, oil pressure . . . . . . . . . .
Wire, oil pressure . . . . . . . . . . . .
Clamp (898657) . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Filter, oil . . . . . . . . . . . . . . . . . . . .
Nipple . . . . . . . . . . . . . . . . . . . . . .
Pan, oil . . . . . . . . . . . . . . . . . . . . .
Pan, oil . . . . . . . . . . . . . . . . . . . . .
1
2
1
3
8
1
1
1
1
1
1
1
1
1
1
1
1
1
Ref.
No.
16
17
18
19
20
21
22
23
24
25 26 27 28 29 30
31
32 Part
No.
Description
No.
Req’d
2701912 Bolt . . . . . . . . . . . . . . . . . . . . . . . 14
2701913 Stud . . . . . . . . . . . . . . . . . . . . . . . 2
2701914 Nut . . . . . . . . . . . . . . . . . . . . . . . . 2
2701915 Plug, oil drain . . . . . . . . . . . . . . . . 1
2701916 Gasket, oil drain plug . . . . . . . . . 1
2701917 Dipstick, oil level . . . . . . . . . . . . . 1
2701919 Strainer, oil pump . . . . . . . . . . . . 1
2701920 O-ring . . . . . . . . . . . . . . . . . . . . . . 1
2701921 Bolt . . . . . . . . . . . . . . . . . . . . . . . . 2
2701606 Kit, dipstick extension . . . . . . . . 1
2701598 Dipstick, oil level . . . . . . . . . . . 1
2701605 O-ring, rubber . . . . . . . . . . . . . 1
2701559.7 Extension, dipstick . . . . . . . . . 1
800934
Screw, M6-1.00 x 16 (8.8) . . . . 1
2701598 Dipstick, oil level . . . . . . . . . . . . . 1
2701605 O-ring, rubber . . . . . . . . . . . . . . . 1
2701709.7 Extension, dipstick . . . . . . . . . . 1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
Models 898658 with Serial No’s. up to REV1287 and Models 898657.
Models 898658 with Serial No’s. beginning with 00002120 and Models 898656.
115
CRANKSHAFT, FLYWHEEL, PISTONS
SUZUKI 660 EFI TURF MODELS 898656, 898657 & 898658
1
4
2
23
3
4
18
5
FRONT
OF
VEHICLE
21
16
17
24
6
7
22
19
20
14
9
13
1
(1)
(1)
2
(2)
(2)
3
4
5
6
7
(7)
8
9
(9)
10
(10)
10
All Items are Used On All Models
Unless Otherwise Indicated
11
12
15
Ref.
No.
8
Part
No.
2701922
2701923
2701924
2701925
2701926
2701927
2701928
2701929
2701930
2701931
2701932
2701933
2701934
2701935
2701936
2701937
2701938
Description
No.
Req’d
Ring, piston (standard) . . . . . . .
Ring, piston . . . . . . . . . . . . . . . . .
Ring, piston . . . . . . . . . . . . . . . . .
Piston (standard) . . . . . . . . . . . .
Piston (OS:0.25) . . . . . . . . . . . . . .
Piston (OS:0.50) . . . . . . . . . . . . . .
Pin, piston . . . . . . . . . . . . . . . . . .
Ring, snap . . . . . . . . . . . . . . . . . .
Rod, connecting . . . . . . . . . . . . .
Nut, connecting rod . . . . . . . . . .
Bearing, cnnctng. rod . . . . . . . . .
Bearing, cnnctng. rod . . . . . . . . .
Crankshaft . . . . . . . . . . . . . . . . . .
Bearing set, crnkshft. . . . . . . . . .
Bearing set, crnkshft. . . . . . . . . .
Bearing set, crank thrust . . . . . .
Bearing set, thrst . . . . . . . . . . . .
3
3
3
3
3
3
3
6
3
2
6
6
1
1
1
1
1
Ref.
No.
11
12
13 (13) 14
15
16
17
18
19
20
21
(21)
22
23
24
Part
No.
2701939
2701940
2701941
2701942
2701943
2701944
2701945
2701946
2701834
2701948
2701949
2701953
2701954
2701950
2701951
2701952
Description
No.
Req’d
Seal, front . . . . . . . . . . . . . . . . . .
Pulley, timing belt . . . . . . . . . . . .
Pulley, crankshaft . . . . . . . . . . . .
Pulley, crnkshft (Model 656) . . . .
Key . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Seal, rear main . . . . . . . . . . . . . .
Plate, rear . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Pin . . . . . . . . . . . . . . . . . . . . . . . . .
Pin (manual trans.) . . . . . . . . . . . .
Pin (automatic trans.) . . . . . . . . . .
Flywheel (manual trans.) . . . . . . .
Bolt (manual trans.) . . . . . . . . . . . .
Bearing, input shaft (manual) . . .
1
1
1
1
1
1
1
1
4
2
2
1
1
1
6
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
Models 898658 with Serial No’s. up to REV1287 and Models 898657.
Models 898658 with Serial No’s. beginning with 00002120 and Models 898656.
116
CAMSHAFT & COMPONENTS
SUZUKI 660 EFI TURF
MODELS 898656, 898657 & 898658
10
5
4
8
6
11
1
5
3
16
15
7
19
16
14
2
15
9
14
18
17
18
12
FRONT
OF
VEHICLE
17
13
Ref.
No.
1
2
3
4
5
6
7
8
9
10
Part
No.
2701947
2701955
2701956
2701957
2701958
2701959
2701960
2701961
2701962
2701963
Description
No.
Req’d
Camshaft . . . . . . . . . . . . . . . . . . . 1
Seal, camshaft . . . . . . . . . . . . . . 1
Shaft, rocker arm (No. 1) . . . . . . 2
Shaft, rocker arm (No. 2) . . . . . . 2
Arm, valve rocker, intake No. 1 . . 3
Arm, valve rocker, intake No. 2 . . 3
Arm, rocker exhaust . . . . . . . . . . 6
Screw, adjusting . . . . . . . . . . . . . 6
Screw, valve adjusting . . . . . . . . 6
Nut, adjusting (intake) . . . . . . . . 12
Ref.
No.
11
12
13
14
15
16
17
18
19
Part
No.
2701965
2701966
2701967
2701968
2701969
2701970
2701971
2701972
2701964
Description
No.
Req’d
Washer, wavy . . . . . . . . . . . . . . . 4
Valve, intake . . . . . . . . . . . . . . . . 6
Valve, exhaust . . . . . . . . . . . . . . . 6
Spring, valve . . . . . . . . . . . . . . . 12
Retainer, valve spring . . . . . . . 12
Cotter, valve . . . . . . . . . . . . . . . 24
Seat, valve spring . . . . . . . . . . . 12
Seal, valve stem . . . . . . . . . . . . 12
Nut, adjusting (exhaust) . . . . . . . 6
117
TIMING BELT & TIMING COVER
SUZUKI 660 EFI TURF
MODELS 898656, 898657 & 898658
1
17
12
10
19
7
18
11
3
2
13
4
5
8
16
15
14
FRONT
OF
VEHICLE
9
13
6
Ref.
No.
1
2
3
4
5
6
7
8
9
10
118
Part
No.
2701973
2701974
2701975
2701976
2701977
2701978
2701834
2701980
2701981
2701979
Description
No.
Req’d
Cover, timing belt (inside) . . . . . .
Cover, timing belt (outside) . . . . .
Grommet . . . . . . . . . . . . . . . . . . .
Spacer . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
E-ring . . . . . . . . . . . . . . . . . . . . . .
Seal . . . . . . . . . . . . . . . . . . . . . . . .
Seal, cover outside . . . . . . . . . . .
1
1
4
4
4
5
3
1
1
1
Ref.
No.
11
12
13
14
15
16
17
18
19
Part
No.
2701982
2701983
2701984
2701985
2701986
2701987
2701988
2701989
2701990
Description
No.
Req’d
Seal . . . . . . . . . . . . . . . . . . . . . . . .
Seal set . . . . . . . . . . . . . . . . . . . .
Cap . . . . . . . . . . . . . . . . . . . . . . . .
Belt, timing . . . . . . . . . . . . . . . . . .
Tensioner assembly . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Pulley, cam shaft timing . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Pin . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
1
1
1
1
1
INTAKE MANIFOLD & THROTTLE BODY
SUZUKI 660 EFI TURF MODELS 898657 and
MODELS 898658 With Serial No’s. Up To REV1287
18
16
11
To
Water Inlet Pipe
10
7
20
21
15
21
17
23
13
9
8
1
12
14
22
4
2
21
4
5
19
25
FRONT
OF
VEHICLE
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
Part
No.
2701991
2701796
2701992
2701914
2701834
2701993
2701994
2701995
2701996
2701997
2701998
2701999
2702000
6
21
Description
26
3
24
No.
Req’d
Manifold, intake . . . . . . . . . . . . . .
Gasket, intake manifold . . . . . . .
Stud bolt . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Stud bolt . . . . . . . . . . . . . . . . . . . .
Body assy., throttle . . . . . . . . . . .
Sensor, throttle position . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . .
Sensor, pressure . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . .
Valve, ISC . . . . . . . . . . . . . . . . .
Gasket . . . . . . . . . . . . . . . . . . . .
1
1
2
3
6
1
1
1
2
1
2
1
1
Ref.
No.
14
15
16
17
18
19
20
21
22
23
24
25
26
Part
No.
Description
No.
Req’d
2701998 Screw . . . . . . . . . . . . . . . . . . . . .
2701803 Gasket . . . . . . . . . . . . . . . . . . . . .
2702001 Bolt . . . . . . . . . . . . . . . . . . . . . . . .
2702426 Stud bolt . . . . . . . . . . . . . . . . . . . .
2701914 Nut . . . . . . . . . . . . . . . . . . . . . . . .
2702427 Hose, water inlet . . . . . . . . . . . . .
2702428 Hose, water outlet . . . . . . . . . . . .
2702429 Clip . . . . . . . . . . . . . . . . . . . . . . . .
2702430 Sensor, water temp. . . . . . . . . . .
2702431 Plug . . . . . . . . . . . . . . . . . . . . . . . .
833715 Cap plug . . . . . . . . . . . . . . . . . . . . .
832033 Clamp, hose . . . . . . . . . . . . . . . . . .
842998 Cap, 5/16 i.d. x 1 . . . . . . . . . . . . . .
4
1
2
2
2
1
1
4
1
1
1
1
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
119
INTAKE MANIFOLD & THROTTLE BODY
SUZUKI 660 EFI TURF MODEL 898656 and
MODELS 898658 With Serial No’s. Beginning With 00002120
29
21
27
22
18
26
20
FRONT
OF
VEHICLE
24
23
25 19
28
32
11
31
To
Water Inlet Pipe
32
30
32
10
14
17
9
12
32
1
8
2
33
4
4
7
14
5
25
15
16
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Part
No.
2702467
2701796
2701992
2701914
2701834
2701993
2702468
2701804
2702469
2702470
2702471
2702472
2702473
2701827
2702474
2702475
2702431
2702476
2701995
24
13
Description
37
3
6
36
14
No.
Req’d
Manifold, intake . . . . . . . . . . . . . .
Gasket, intake manifold . . . . . . .
Stud bolt . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Stud bolt . . . . . . . . . . . . . . . . . . . .
Tank, surge . . . . . . . . . . . . . . . . .
Gasket . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, intake manf. No. 1 . . . . .
Bracket, intake manf. No. 2 . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, surge tank . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Plug . . . . . . . . . . . . . . . . . . . . . . . .
Body assy., throttle . . . . . . . . . . .
Sensor, throttle position . . . . . .
1
1
2
3
6
1
1
1
1
2
1
1
1
5
1
1
1
1
1
Ref.
No.
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Part
No.
Description
No.
Req’d
2701996 Screw . . . . . . . . . . . . . . . . . . . . .
2702477 Sensor, pressure . . . . . . . . . . . .
2701998 Screw . . . . . . . . . . . . . . . . . . . . .
2702478 Valve, ISC . . . . . . . . . . . . . . . . .
2702000 Gasket . . . . . . . . . . . . . . . . . . . .
2701998 Screw . . . . . . . . . . . . . . . . . . . . .
2701803 Gasket . . . . . . . . . . . . . . . . . . . . .
2702001 Bolt . . . . . . . . . . . . . . . . . . . . . . . .
2702426 Stud bolt . . . . . . . . . . . . . . . . . . . .
2701914 Nut . . . . . . . . . . . . . . . . . . . . . . . .
2702479 Hose, water inlet . . . . . . . . . . . . .
2702480 Hose, water outlet . . . . . . . . . . . .
2702429 Clip . . . . . . . . . . . . . . . . . . . . . . . .
2702481 Sensor, water temp. . . . . . . . . . .
833715 Cap plug . . . . . . . . . . . . . . . . . . . . .
832033 Clamp, hose . . . . . . . . . . . . . . . . . .
2702432 Hose, brake vacuum . . . . . . . . .
2702433 Clamp . . . . . . . . . . . . . . . . . . . . . .
2
1
2
1
1
4
1
2
2
2
1
1
4
1
1
1
1
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
120
PCV VALVE & COMPONENTS
SUZUKI 660 EFI
MODELS 898656, 898657 & 898658
Intake Manifold
Shown For Reference Only
All Items Shown are used with all Models
Unless Otherwise Indicated.
7
15
To
Air Cleaner
9
1
12
2
4
11
15
16
10
17
4
14
8
5
13
6
3
18
9
FRONT
OF
VEHICLE
Cylinder Head Cover
Shown For
Reference Only
Ref.
No.
1
(1) 2
3
4
5
6
7
8
(8) 9
Part
No.
2701991
2702467
2701796
2701992
2701914
2701834
2701993
2702431
2702482
2702483
2702484
Description
No.
Req’d
Manifold, intake . . . . . . . . . . . . . .
Manifold, intake . . . . . . . . . . . . . .
Gasket, intake manifold . . . . . . .
Stud bolt . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Stud bolt . . . . . . . . . . . . . . . . . . . .
Plug . . . . . . . . . . . . . . . . . . . . . . . .
Hose, breather . . . . . . . . . . . . . .
Hose, breather . . . . . . . . . . . . . .
Clip, hose . . . . . . . . . . . . . . . . . . .
1
1
1
2
4
6
1
1
1
1
2
Ref.
No.
10
11
12
(12)
13
14
15
16
17
18
Part
No.
Description
No.
Req’d
2702485 Clamp . . . . . . . . . . . . . . . . . . . . . .
2702486 Bolt . . . . . . . . . . . . . . . . . . . . . . . .
2702487 Hose, PVC . . . . . . . . . . . . . . . . . .
2702488 Hose, PVC . . . . . . . . . . . . . . . . . .
2702489 Seal . . . . . . . . . . . . . . . . . . . . . . . .
2702490 Valve, PCV . . . . . . . . . . . . . . . . . .
2702491 Clip . . . . . . . . . . . . . . . . . . . . . . . .
832033 Clamp, hose . . . . . . . . . . . . . . . . . .
833715 Plug . . . . . . . . . . . . . . . . . . . . . . . . .
842998 Cap, 5/16 i.d. x 1 . . . . . . . . . . . . . .
1
1
1
1
1
1
2
1
1
1
Models 898656 and Models 898658 with Serial No’s. beginning with 00002120.
121
OIL PUMP
SUZUKI 660 EFI TURF
MODELS 898656, 898657 & 898658
3
1
2
7
5
6
8
FRONT
OF
VEHICLE
4
Ref.
No.
1
2
3
4
Part
No.
2702515
2702516
2702517
2702518
Description
No.
Req’d
Pump, oil . . . . . . . . . . . . . . . . . . .
Rotor, oil pump . . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . .
Valve set, oil relief . . . . . . . . . .
1
1
5
1
Ref.
No.
5
6
7
8
Part
No.
2701800
2701949
2702519
2702520
Description
No.
Req’d
Gasket, oil pump cover . . . . . . .
Pin . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
1
2
4
4
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
122
DRIVESHAFT, TORQUE CONVERTER
and AUTOMATIC TRANSMISSION
SUZUKI 660 MODEL 898657
4
3
2
6
3
1
5
12
7
11
9
10
8
FRONT
OF
VEHICLE
13
Ref.
No.
1
2
3
4
5
6
Part
No.
Description
No.
Req’d
895112.7 Driveshaft, complete
(automatic transmission) . . . . .
548482 Plug, expansion . . . . . . . . . . . .
826284 Cross, u-joint . . . . . . . . . . . . . . .
826285 Yoke, universal . . . . . . . . . . . . .
895125 Yoke, front . . . . . . . . . . . . . . . . .
895126 Shaft, drive . . . . . . . . . . . . . . . .
1
3
2
1
1
1
Ref.
No.
7
8
9
10
11
12
13
Part
No.
2702697
2702698
2702699
2702700
2701951
2702701
2702702
Description
No.
Req’d
Transmission, complete . . . . . . .
Flange, drive plate . . . . . . . . . . .
Plate, drive (flywheel) . . . . . . . . .
Plate, drive rear . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Converter, torque . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
6
1
6
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
123
AUTOMATIC TRANSMISSION
and COMPONENTS
SUZUKI 660 MODEL 898657
10
22
5
6
8
21
20
9
13
2
7
11
11
18
14
16
19
17
1
4
3
FRONT
OF
VEHICLE
17
16
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
Part
No.
2702750
2702751
2702752
2702753
2702760
2702761
2702662
2702754
2702683
2702755
2702494
Description
12
15
No.
Req’d
Case, transmission . . . . . . . . . . .
Breather . . . . . . . . . . . . . . . . . . .
Housing, torque converter . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Plug, booster . . . . . . . . . . . . . . . .
O-ring . . . . . . . . . . . . . . . . . . . . .
Cap . . . . . . . . . . . . . . . . . . . . . . . .
Housing, extension . . . . . . . . . . .
Seal, extension case . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
6
1
1
1
1
1
5
2
Ref.
No.
12
13
14
15
16
17
18
19
20
21
22
Part
No.
Description
No.
Req’d
2702756 Bolt . . . . . . . . . . . . . . . . . . . . . . . .
2702686 Bolt . . . . . . . . . . . . . . . . . . . . . . . .
2702757 Stud . . . . . . . . . . . . . . . . . . . . . . .
2702758 Stud . . . . . . . . . . . . . . . . . . . . . . .
2702689 Nut . . . . . . . . . . . . . . . . . . . . . . . .
2702690 Collar . . . . . . . . . . . . . . . . . . . . . .
2702759 Hook, engine . . . . . . . . . . . . . . . .
2702762 Bolt, transmission case . . . . . . .
2702763 Bracket, connector clamp . . . . .
2702764 Bolt . . . . . . . . . . . . . . . . . . . . . . . .
2703051.7 Bracket, electrical (40 pin) . . .
1
1
1
1
2
2
1
2
1
1
1
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
124
AUTOMATIC TRANSMISSION PAN,
DIPSTICK & GASKETS
SUZUKI 660 MODEL 898657
14
6
10
9
7
8
11
12
13
5
FRONT
OF
VEHICLE
1
4
3
2
Ref.
No.
1
2
3
4
5
6
7
Part
No.
2702806
2702807
2702808
2702809
2702810
2702811
2702813
No.
Req’d
Ref.
No.
Pan, transmission . . . . . . . . . . . . 1
Bolt . . . . . . . . . . . . . . . . . . . . . . . 15
Plug, transmission drain . . . . . . . . 1
Gasket, plug . . . . . . . . . . . . . . . . 1
Magneto, fluid cleaner . . . . . . . . 1
Tube, transmission dipstick . . . . . . 1
O-ring . . . . . . . . . . . . . . . . . . . . . 1
8
9
10
11
12
13
14
Description
Part
No.
2702475
2702816
2701921
2702817
2702748
2702749
2702814
Description
No.
Req’d
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Harness, solenoid wire . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Plate, solenoid harness . . . . . . .
Set, transmission gasket . . . . . . . .
Gasket, transmission pan . . . . . .
Dipstick, transmission . . . . . . . .
1
1
1
1
1
1
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
125
TRANSMISSION TUBES, OIL PUMP,
SOLENOIDS & SHIFT SWITCH
(AUTOMATIC TRANSMISSION)
SUZUKI 660 MODEL 898657
8
2
1
4
7
3
4
21
6
5
22
To
Oil Cooler
15
14
FRONT
OF
VEHICLE
20
16
18
17
11
19
12
10
9
13
13
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
Part
No.
2702843
2702849
2702847
2702845
2702765
2702766
2702767
2702768
2702822
2702823
2702824
Description
No.
Req’d
Pipe assembly, oil . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Union bolt . . . . . . . . . . . . . . . . . . .
Gasket . . . . . . . . . . . . . . . . . . . . .
Pump, oil . . . . . . . . . . . . . . . . . . .
Seal, oil pump . . . . . . . . . . . . . .
Bolt, oil pump . . . . . . . . . . . . . . . .
Ring set, oil pump seal . . . . . . .
Solenoid, direct clutch . . . . . . . . .
O-ring . . . . . . . . . . . . . . . . . . . . .
Solenoid, 2nd brake . . . . . . . . . .
1
1
2
4
1
1
8
1
1
1
1
Ref.
No.
12
13
14
15
16
17
18
19
20
21
22
Part
No.
Description
No.
Req’d
2702823 O-ring . . . . . . . . . . . . . . . . . . . . . 1
2702764 Bolt . . . . . . . . . . . . . . . . . . . . . . . . 2
2702885 Switch, shift . . . . . . . . . . . . . . . . . 1
2702886 Bolt . . . . . . . . . . . . . . . . . . . . . . . . 1
2702881 Joint, transmission shifter . . . . . . 2
2702882 Bushing . . . . . . . . . . . . . . . . . . . . 1
2702883 Washer . . . . . . . . . . . . . . . . . . . . . 1
2702884 E-ring . . . . . . . . . . . . . . . . . . . . . . 1
842740 Lever, shifter . . . . . . . . . . . . . . . . . 1
825624 Clamp, hose . . . . . . . . . . . . . . . . . . 2
826590 Hose, 5/16 i.d. . . . . . . . . . As Req’d.
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
126
TRANSMISSION INPUT SHAFT & CLUTCH ASSEMBLY
(AUTOMATIC TRANSMISSION)
SUZUKI 660 MODEL 898657
3
2
1
FRONT
OF
VEHICLE
4
8
6
7
Ref.
No.
1
2
3
4
Part
No.
2702769
2702770
2702771
2702772
Description
5
No.
Req’d
Shaft set, input . . . . . . . . . . . . . .
Plate set, forward clutch . . . . .
O-ring set, forward clutch . . . .
Bearing set, thrust (No. 1) . . . . .
1
1
1
1
Ref.
No.
5
6
7
8
Part
No.
2702773
2702774
2702775
2702776
Description
No.
Req’d
Clutch assembly, direct . . . . . . .
Plate set, direct clutch . . . . . . .
O-ring set, direct clutch . . . . . .
Washer set, direct clutch . . . . . .
1
1
1
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
127
TRANSMISSION PLANETARY GEARS and OUTPUT SHAFT
(AUTOMATIC TRANSMISSION)
SUZUKI 660 MODEL 898657
13
11
12
8
10
9
7
17
2
6
5
16
4
3
1
FRONT
OF
VEHICLE
15
14
Ref.
No.
1
2
3
4
5
6
7
8
9
Part
No.
Description
No.
Req’d
2702778 Bearing set, thrust (No. 3) . . . . . .
2702777 Gear assembly,
forward planetary link . . . . . . . . .
2702780 Bearing set, thrust (No. 4) . . . . .
2702779 Gear assembly, front . . . . . . . . .
2702781 Bearing set, thrust (No. 5) . . . . .
2702782 Gear, planetary sun . . . . . . . . . .
2702783 Washer set, thrust . . . . . . . . . . .
2702785 Bearing set, thrust (No. 1) . . . . . .
2702784 Gear, rear planetary . . . . . . . . . .
1
1
1
1
1
1
1
1
1
Ref.
No.
10
11
12
13
14
15
16
17
18
Part
No.
2702786
2702787
2702788
2702789
2702790
2702792
2702793
2702794
2702795
18
Description
No.
Req’d
Clutch set, 1-way . . . . . . . . . . . .
Plate set, 1st/reverse . . . . . . . . .
Piston set, 1st/reverse . . . . . . . .
O-ring set, 1st/reverse . . . . . . .
Shaft, output . . . . . . . . . . . . . . . .
Ring, snap . . . . . . . . . . . . . . . . . .
Ring, speedometer exciter . . . . .
Cir-clip, exciter ring . . . . . . . . . . .
Bearing, thrust (Set No. 6) . . . . . .
1
1
1
1
1
1
1
1
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
128
BRAKE BAND & SHIFT SHAFT
(AUTOMATIC TRANSMISSION)
SUZUKI 660 MODEL 898657
3
FRONT
OF
VEHICLE
4
7
2
6
5
9
10
11
9
8
1
Ref.
No.
1
2
3
4
5
Part
No.
Description
No.
Req’d
2702800 Band set, second brake . . . . . . .
2702805 Spring, second brake
piston return . . . . . . . . . . . . . . . . .
2702803 Piston assembly,
second brake . . . . . . . . . . . . . . . .
2702804 Cover set, 2nd brake . . . . . . . . .
2702801 Ring set, 2nd brake seal . . . . . .
1
1
1
1
1
Ref.
No.
6
7
8
9
10
11
Part
No.
2702796
2701921
2702797
2702798
2702494
2702799
Description
No.
Req’d
Pole set, parking . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . .
Shaft set, lever . . . . . . . . . . . . . .
Seal . . . . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . .
Washer . . . . . . . . . . . . . . . . . . . . .
1
3
1
2
1
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
129
TRANSMISSION VALVE
(AUTOMATIC TRANSMISSION)
SUZUKI 660 MODEL 898657
17
2
11
14
1
10
12
5
19
13
15 5
5
5
6
7
18
3
8
16
3
FRONT
OF
VEHICLE
8
15
5
4
6
16
9
5
4
4
Ref.
No.
1
2
3
4
5
6
7
8
9
10
130
Part
No.
Description
No.
Req’d
2702821 Body assembly
transmission valve . . . . . . . . . . .
2702825 Strainer, transmission . . . . . . . .
2702826 Bolt, valve body, No. 5 . . . . . . . .
2702827 Bolt, valve body, No. 6 . . . . . . . .
2702836 Bolt, valve body, No. 1 . . . . . . . .
2702834 Bolt, valve body, No. 2 . . . . . . . .
2702835 Bolt, valve body, No. 3 . . . . . . . .
2702837 Bolt, valve body, No. 4 . . . . . . . .
2702838 Bolt, valve body, No. 6 . . . . . . . .
2702828 Piston set, C1 accumulator . . . . .
1
1
2
3
6
2
1
2
1
1
Ref.
No.
Part
No.
11
12
13
14
2702829
2702830
2702833
2702831
15
16
17
18
19
2702839
2702840
2702841
2702842
2702832
Description
No.
Req’d
Spring, forward piston . . . . . . . .
Piston set, B1 accumulator . . . . .
Seal ring set, accumulator . . . . . .
Spring, accumulator
2nd brake position . . . . . . . . . . .
Bolt, valve body, No. 1 . . . . . . . .
Bolt, valve body, No. 2 . . . . . . . .
Spring, 2nd brake No. 2 . . . . . . . .
Spring, 2nd brake No. 3 . . . . . . . .
Spring, accumulator
forward piston lower . . . . . . . . . .
1
1
1
1
2
2
1
1
1
STARTER
(AUTOMATIC TRANSMISSION)
SUZUKI 660 MODEL 898657
7
8
10
11
1
4
12
3
14
3
9
5
13
6
FRONT
OF
VEHICLE
2
Ref.
No.
1
2
3
4
5
6
7
Part
No.
2702906
2702907
2702895
2702896
2702897
2702898
2702899
Description
No.
Req’d
Motor assembly, starting . . . . . .
Yoke assembly . . . . . . . . . . . . .
Screw assembly . . . . . . . . . . . .
Bushing . . . . . . . . . . . . . . . . . . . .
Bushing . . . . . . . . . . . . . . . . . . . .
Holder assembly, brush . . . . . .
Lever assembly . . . . . . . . . . . . .
1
1
1
1
1
1
1
Ref.
No.
8
9
10
11
12
13
14
Part
No.
2702900
2702908
2702909
2702903
2702904
2702905
2702470
Description
No.
Req’d
Switch assembly . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . .
Armature . . . . . . . . . . . . . . . . . . .
Ring assembly . . . . . . . . . . . . . .
Clutch assembly . . . . . . . . . . . .
Washer . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
1
1
2
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
131
SHIFTER and SHIFTER LINKAGE
SUZUKI 660 EFI TURF MODELS 898656 & 898658
4
8
7
6
31
5
2
20
17
28
25
27
15
14
12
10
13
18
26
11
20
19
30
22
29
17
1
21
24
25
23
3
2
9
2
16
P893434
132
SHIFTER and SHIFTER LINKAGE
SUZUKI 660 EFI TURF MODELS 898656 & 898658
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Part
No.
Description
No.
Req’d
308090 Washer, 1/4 . . . . . . . . . . . . . . . . . .
452695 Screw, M6-1.00 x 20, taptite . . . .
548175 Washer, 1/4 x 1.25 . . . . . . . . . . . .
800582 Screw, 1/4-20 x 3/4 . . . . . . . . . . .
841265 Panel, dash (right hand) . . . . . . . .
843792 Plate, shifter boot . . . . . . . . . . . . .
2702696 Boot, shifter . . . . . . . . . . . . . . . . .
2702695 Knob, shifter . . . . . . . . . . . . . . . .
2701274 Shifter, complete . . . . . . . . . . . . .
300977 Screw, 1/4-28 x 5/8 . . . . . . . . . .
306396 Lockwasher, 1/4 . . . . . . . . . . . .
306397 Nut, 1/4-28 . . . . . . . . . . . . . . . . .
308090 Washer, 1/4 . . . . . . . . . . . . . . . .
308091 Washer, 1/2 . . . . . . . . . . . . . . . .
450454 Nut, M10-1.50 (G10.9) . . . . . . .
452400 Screw, M10-1.50 x 30 (8.8) . . .
5
6
3
4
1
1
1
1
1
1
1
1
1
1
1
1
Ref.
No.
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Part
No.
Description
No.
Req’d
452695 Screw, M6-1.00 x 20, taptite . .
548008 Screw, 1/2-20 x 1 . . . . . . . . . . .
842773 Rod end, 1/2” (female) . . . . . . .
842774 Ball joint, 1/4” . . . . . . . . . . . . . . .
843614 Spring, torsion . . . . . . . . . . . . . .
843679 Plate, wear . . . . . . . . . . . . . . . . .
843685 Bushing, spring . . . . . . . . . . . . .
843686 Tab, locating . . . . . . . . . . . . . . . .
843724 Clamp, cable . . . . . . . . . . . . . . .
893967 Selector, complete . . . . . . . . . .
893968 Mount, shifter . . . . . . . . . . . . . . .
2701273 Cable, shifter, 97” (2.5M) . . . . . .
2701328 Cable, shifter, 89” (2.3M) . . . . . .
452692 Screw, M6-1.00 x 12, taptite . . .
894793 Nut assembly, double 1/4-20 . . . .
4
1
1
2
1
1
1
1
2
1
1
1
1
2
2
INDENTED PARTS NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
133
CLUTCH LINKAGE
SUZUKI 660 EFI
TURF MODELS 898656 & 898658
5
1
10
4
14
2
15
11
7
3
8
6
9
13
12
P2701278
Ref.
No.
1
2
3
4
5
6
7
8
134
Part
No.
450453
450510
306328
452388
452424
806714
810152
840725
Description
No.
Req’d
Nut, M8-1.25 (G10.9) . . . . . . . . . .
Screw, M3-.50 x 20 . . . . . . . . . . . .
Pin, cotter, 3/32 x 3/4 . . . . . . . . . .
Screw, M8-1.25 x 20 (8.8) . . . . . .
Nut, flange M3-.50 . . . . . . . . . . . .
Pin, clevis, 5/16 x 15/16 . . . . . . . .
Cover, pedal . . . . . . . . . . . . . . . . . .
Pin, brake pivot . . . . . . . . . . . . . . .
1
2
1
1
2
1
1
1
Ref.
No.
Part
No.
9
10
11
12
13
14
15
840726
842935
892933
895013
844202
890808
844611
Description
No.
Req’d
Bearing, brake pivot . . . . . . . . . . .
Tab, locking . . . . . . . . . . . . . . . . . .
Lever, clutch . . . . . . . . . . . . . . . . . .
Cable, clutch . . . . . . . . . . . . . . . . .
Washer, slotted . . . . . . . . . . . . . . .
Switch, clutch interlock . . . . . . . . .
Spring, torsion . . . . . . . . . . . . . . . .
1
1
1
1
4
1
1
SHIFTER GEARS & FORK (MANUAL TRANSMISSION)
SUZUKI 660 EFI MODELS 898656 & 898658
13
Existing Bolt Must be
Removed In Order to
Remove Shift Mechanism
19
35
37
40
17
35
49
32
21
29
20
36
14
18
34
9
10
12
1
9
8 10
11
27
31
4
11
30
5
10
9
28
43
11
44
6
3
FRONT
OF
VEHICLE
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Part
No.
2702618
2702619
2702620
2702621
2702622
2702625
2702626
2702627
2702628
2702629
2702630
2702660
2702632
2702633
2702634
2702635
2702636
2702637
2702638
2702639
2702640
2702641
2701351
2702642
2702643
Description
7
No.
Req’d
Fork, low speed gear shift . . . . . . .
Fork, high speed gear shift . . . . . .
Fork, reverse gear shift . . . . . . . . .
Shaft, low speed . . . . . . . . . . . . . .
Shaft, high speed . . . . . . . . . . . . .
Shaft, reverse . . . . . . . . . . . . . . . .
Plug . . . . . . . . . . . . . . . . . . . . . . . .
Roller . . . . . . . . . . . . . . . . . . . . . .
Spring pin (4.5 x 18) . . . . . . . . . . .
Spring, gear shift locating . . . . . . .
Ball . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Bolt, gear shift stop . . . . . . . . . . . .
Lever, gear shift/select . . . . . . . . .
Bushing, select lever boss . . . . . .
Bushing, select lever shaft . . . . . .
Shaft, gear shift/select . . . . . . . . .
Case, gear shift guide . . . . . . . . . .
Spring, low select . . . . . . . . . . . . .
Cam, reverse gear shift . . . . . . . . .
Spring, cam guide return . . . . . . .
Lever, shift cable . . . . . . . . . . . . . .
Lever, gear selector cable . . . . . . .
Boot, select lever (inside) . . . . . . .
Boot, select lever (outside) . . . . . .
1
1
1
1
1
1
1
1
3
3
5
1
1
1
2
1
1
1
1
1
1
1
1
1
1
Ref.
No.
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
48
16
15
23
2
Part
No.
22
47
46
45
38
39
41
42
33
25
15
24
26
Description
No.
Req’d
2702644 Bracket, select lever . . . . . . . . . .
2702645 Boot, shaft oil . . . . . . . . . . . . . . .
2702647 Washer . . . . . . . . . . . . . . . . . . . . .
2702648 Spring pin (3.5 x 28) . . . . . . . . . . .
2702649 Spring pin (3 x 25) . . . . . . . . . . . .
2702650 Spring pin (3 x 20) . . . . . . . . . . . .
2702651 Spring pin (6 x 28) . . . . . . . . . . . .
2702652 Spring pin (6 x 25) . . . . . . . . . . . .
2702653 Seal, oil (14 x 22 x 6) . . . . . . . . . .
2702654 E-ring . . . . . . . . . . . . . . . . . . . . . .
2701827 Bolt . . . . . . . . . . . . . . . . . . . . . . . .
2702655 Washer . . . . . . . . . . . . . . . . . . . . .
2702494 Nut . . . . . . . . . . . . . . . . . . . . . . . .
2702656 Lock washer . . . . . . . . . . . . . . . .
2701111 Plate, reverse interlock . . . . . . . . .
452392 Bolt, M8-1.25 x 50 (8.8) . . . . . . . .
892811 Cable, battery (24” black) . . . . . . .
884513 Cable, battery (46” black) . . . . . . .
2701369.7 Bracket, shift mount . . . . . . . .
308090 Washer, 1/4 . . . . . . . . . . . . . . . . . .
450410 Washer, M6 . . . . . . . . . . . . . . . . . .
800934 Screw, M6-1.00 x 16 (8.8) . . . . . .
2701370 Nut, insert . . . . . . . . . . . . . . . . . .
2701366 Bushing . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
2
5
1
1
1
1
1
1
1
1
1
1
1
1
1
135
INPUT SHAFT & GEARS (Manual Transmission)
SUZUKI 660 EFI TURF MODELS 898656 & 898658
47
59
48
9
21
FRONT
OF
VEHICLE
20
42
58
22
46
45
11
49
10
8
18
18
56
37
19
13
34
44
57
36
38
35
34
12
35
14
15
33
37
17
50
7
16
40
40
41
43
39
41
6
1
4
5
31
2
29
3
27
26
23
55
25
32
24
30
136
28
53
51
54
52
INPUT SHAFT & GEARS (Manual Transmission)
SUZUKI 660 EFI TURF MODELS 898656 & 898658
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23 (23) 24
25
26
27
28
29
Part
No.
2702556
2702557
2702558
2702559
2702560
2702561
2702562
2702563
2702564
2702565
2702566
2702567
2702569
2702570
2702571
2702572
2702569
2702573
2702574
2702575
2702576
2702577
2702578
2702579
2702580
2702581
2702582
2702583
2702566
2702584
Description
No.
Req’d
Shaft, input . . . . . . . . . . . . . . . . .
Bearing . . . . . . . . . . . . . . . . . . . . .
C-ring . . . . . . . . . . . . . . . . . . . . . .
Ring, snap . . . . . . . . . . . . . . . . . .
Seal . . . . . . . . . . . . . . . . . . . . . . . .
Bearing (20 x 26 x 17) . . . . . . . . .
Shaft, main . . . . . . . . . . . . . . . . .
Bearing (27 x 55 x 13) . . . . . . . . .
Ring, snap . . . . . . . . . . . . . . . . . .
Ring, snap . . . . . . . . . . . . . . . . . .
Bearing (20 x 47 x 14) . . . . . . . . .
Gear, main shaft, low . . . . . . . . .
Bearing (30 x 35 x 21) . . . . . . . . .
Gear, main shaft, 2nd . . . . . . . . .
Bearing (35 x 40 x 21.8) . . . . . . . .
Gear, main shaft, 3rd . . . . . . . . .
Bearing (30 x 35 x 21) . . . . . . . . .
Washer, main shaft bearing . . . . .
C-ring (main shaft fr brng) . . . . . . .
Gear, main shaft, 5th . . . . . . . . .
Bearing (22 x 26 x 22.8) . . . . . . . .
Washer, main shaft, 5th . . . . . . . .
Shaft, counter . . . . . . . . . . . . . . .
Shaft, counter . . . . . . . . . . . . . . .
Gear, counter shaft drive . . . . . .
Ring, snap . . . . . . . . . . . . . . . . . .
Gear, cntr shft, 5th . . . . . . . . . . .
Bearing, counter shaft center . . . .
Bearing (20 x 47 x 14) . . . . . . . . .
Bearing . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
Ref.
No.
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
Part
No.
2702585
2702586
2702587
2702595
2702596
2702597
2702598
2702599
2702600
2702601
2702602
2702603
2702600
2702604
2702605
2702606
2702607
2702608
2702609
2702610
2702600
2702611
2702612
2702613
2702614
2701921
2702615
2702616
2702617
2702581
Description
No.
Req’d
Circlip . . . . . . . . . . . . . . . . . . . . . .
Ring, snap . . . . . . . . . . . . . . . . . .
Plug (od: 47) . . . . . . . . . . . . . . . . .
Hub, low speed sync . . . . . . . . .
Ring, synchronizer . . . . . . . . . . .
Spring, synchronizer . . . . . . . . .
Circlip, low speed sync hub . . . . .
Spring . . . . . . . . . . . . . . . . . . . . . .
Key, synchronizer . . . . . . . . . . . .
Hub, high speed sync . . . . . . . .
Ring, 2nd gear sync . . . . . . . . . .
Spring, low speed sync . . . . . . .
Key, synchronizer . . . . . . . . . . . .
Circlip, synchronizer . . . . . . . . . .
Hub, 5th speed sync . . . . . . . . .
Plate, 5th sync hub . . . . . . . . . . .
Ring, high speed sync . . . . . . . .
Spring, synchronizer ring . . . . . .
Spring, 5th sync . . . . . . . . . . . . .
Circlip, synchronizer . . . . . . . . . .
Key, synchronizer . . . . . . . . . . . .
Shaft, reverse idle gear . . . . . . .
Gear, reverse idle . . . . . . . . . . . .
Washer . . . . . . . . . . . . . . . . . . . . .
Plate, rev shft stop . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Gear, main shaft reverse . . . . . .
Bearing (27 x 32 x 23.8) . . . . . . . .
Ring, speedometer exciter . . . .
Ring, snap . . . . . . . . . . . . . . . . . .
1
1
1
1
2
2
1
2
3
1
2
2
3
1
1
1
1
1
1
1
3
1
1
1
1
2
1
1
1
1
Models 898658 with Serial No’s. up to REV1287.
Models 898658 with Serial No’s. beginning with 00002120 and Models 898656.
137
CLUTCH and DRIVESHAFT
SUZUKI 660 EFI TURF MODELS 898656 & 898658
4
3
2
6
3
1
5
17
15
16
12
7
11
9
10
14 13
FRONT
OF
VEHICLE
8
Ref.
No.
1
2
3
4
5
6
7
8
Part
No.
Description
No.
Req’d
2701321.7 Driveshaft, complete
(manual transmission) . . . . . .
548482
Plug, expansion . . . . . . . . . . .
826284
Cross, u-joint . . . . . . . . . . . . .
826285
Yoke, universal . . . . . . . . . . . .
894192
Yoke, front . . . . . . . . . . . . . . . .
895126
Shaft, drive . . . . . . . . . . . . . . .
2702546 Cover, clutch . . . . . . . . . . . . . . . .
2702547 Bolt (8 x 16) . . . . . . . . . . . . . . . . . .
1
3
2
1
1
1
1
6
Ref.
No.
9
10
11
12
13
14
15
16
17
Part
No.
2702548
2702549
2702550
2702551
2702552
2702553
2702554
2702555
2702470
Description
No.
Req’d
Disc, clutch . . . . . . . . . . . . . . . . .
Bearing, clutch release . . . . . . .
Clip, release bearing . . . . . . . . .
Fork, clutch release . . . . . . . . . .
Support, clutch release fork . . . . .
Clip, clutch release fork . . . . . . . . .
Cap, transmission case . . . . . . .
Bracket, clutch cable . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
138
TRANSMISSION CASE
SUZUKI 660 EFI TURF MODELS 898656 & 898658
5
22
3 3
5
23
24
View A
4
3
5
10
25
4
12
View C
View B
11
14
5
5
3
13
16
22
View A
6
20
15
9
19
21
18
2
17
21
1
7
8
3
13
10
9
13
13
3
20
19
13
13
13
13
12
FRONT
OF
VEHICLE
View C
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
Part
No.
2702657
2702658
2702659
2702660
2702661
2702662
2702663
2702664
2702658
2702665
2702470
2702659
2702660
Description
No.
Req’d
Case, transmission . . . . . . . . . . .
Pin . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . .
Cap (D:36) . . . . . . . . . . . . . . . . . . .
Case, extension No. 1 . . . . . . . . . .
Case, extension No. 2 . . . . . . . . . .
Pin . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt (8 x 120) . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
1
2
5
1
4
1
1
1
4
1
1
2
7
12
View B
Ref.
No.
14
15
16
17
18
19
20
21
22
23
24
25
Part
No.
2702683
2702684
2702685
2702686
2702687
2702758
2702689
2702690
2702691
2702692
2702693
2702694
Description
No.
Req’d
Seal, extension case . . . . . . . . .
Plug (L:15) . . . . . . . . . . . . . . . . . .
Switch, back-up lamp . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Stud bolt . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . .
Pin . . . . . . . . . . . . . . . . . . . . . . . . .
Hook, engine . . . . . . . . . . . . . . . .
Plug, breather . . . . . . . . . . . . . . .
Hose . . . . . . . . . . . . . . . . . . . . . . .
Plug . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
1
2
2
2
1
1
1
1
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
139
STARTER
(Manual Transmission)
SUZUKI 660 EFI MODELS 898656 & 898658
8
7
10
3
11
1
12
4
14
3
9
5
6
FRONT
OF
VEHICLE
Ref.
No.
1
2
3
4
5
6
7
Part
No.
2702893
2702894
2702895
2702896
2702897
2702898
2702899
13
2
Description
No.
Req’d
Starter, complete . . . . . . . . . . . .
Yoke assembly . . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . .
Bushing . . . . . . . . . . . . . . . . . . . .
Bushing . . . . . . . . . . . . . . . . . . . .
Holder assembly, brush . . . . .
Lever, pinion drive . . . . . . . . . . .
1
1
1
1
1
1
1
Ref.
No.
8
9
10
11
12
13
14
Part
No.
2702900
2702901
2702902
2702903
2702904
2702905
2702470
Description
No.
Req’d
Switch . . . . . . . . . . . . . . . . . . . . .
Bolt, housing . . . . . . . . . . . . . . .
Armature . . . . . . . . . . . . . . . . . . .
Ring assembly . . . . . . . . . . . . . .
Clutch assembly . . . . . . . . . . . .
Washer . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
1
1
2
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
140
EMISSION CONTROLS
SUZUKI 660 EFI TURF
MODELS 898656, 898657 & 898658
3
Delivery Pipe From
Models 898657 & 898658 With
Serial No’s. Up To REV1287 Shown
23
1
2
8
4
FRONT
OF
VEHICLE
6
5
11
22
12
7
19
All Items Shown are used with all Models
Unless Otherwise Indicated.
21
10
20
14
13
9
16
15
17
!
18
Ref.
No.
1
(1) 2
3
4
5
6
7
8
9
10
11
12
18
Part
No.
2702508
2702509
2702486
2701829
2702510
2702511
2702512
2702513
2702514
2702492
2701797
2702493
2702494
CAUTION
• Be careful when installing exhaust tube. The edges of
the shield are sharp and can cause personal injury.
Description
No.
Req’d
Pipe, delivery . . . . . . . . . . . . . . . .
Pipe, delivery . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Insulator . . . . . . . . . . . . . . . . . . . .
Injector, fuel . . . . . . . . . . . . . . . . .
Grommet set . . . . . . . . . . . . . . .
Cushion . . . . . . . . . . . . . . . . . . . .
Clamp . . . . . . . . . . . . . . . . . . . . . .
Maniflod, exhaust . . . . . . . . . . . .
Gasket . . . . . . . . . . . . . . . . . . . . .
Stud bolt . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
2
3
3
3
1
1
1
3
3
Ref.
No.
13
14
15
16
17
18
19
20
21
22
23 (23) Part
No.
2702495
2702496
2702497
2701913
2702498
2702499
2702500
2702501
2702502
2702503
2702946
2702947
Description
No.
Req’d
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Cover, manifold upper . . . . . . . .
Cover, manifold lower . . . . . . . .
Stud bolt . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . .
Bolt (6x10) . . . . . . . . . . . . . . . . . . .
Ring, seal . . . . . . . . . . . . . . . . . . .
Spring . . . . . . . . . . . . . . . . . . . . . .
Bolt (10x65) . . . . . . . . . . . . . . . . . .
Sensor, oxygen . . . . . . . . . . . . . .
Harness, Suzuki engine . . . . . . .
Harness, Suzuki engine . . . . . . .
1
1
1
2
2
5
1
2
2
1
1
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
Models 898658 with Serial No’s. up to REV1287 and Models 898657.
beginning with 00002120 and Models 898656.
Models 898658 with Serial No’s.
141
WATER PUMP, THERMOSTAT & WATER OUTLET
SUZUKI 660 EFI TURF MODELS 898656, 898657 & 898658
32
26
25
14
20
18
19
15
13
11
29
14
13
28
20
27
11
31
Model 898658 With Serial No’s.
Up To REV1287
and Model 898657
19
30
Model 898658 With Serial No’s.
Beginning With 00002120
and Model 898656
12
12
16
10
17
16
17
8
1
9
22
2
21
6
3
24
7
23
All Items Shown are used with all Models
Unless Otherwise Indicated.
Ref.
No.
1 2
(1) (2)
3
4 (4) 5
6
7 (7) 8
9
10
11
12
13
14
Part
No.
2702521
2701801
2702522
2701801
2702523
2702537
2702537
2701914
2702519
2702524
2702525
2702543
2701802
2701834
2702542
2702430
2702540
2702541
Description
5
4
No.
Req’d
Pump, water . . . . . . . . . . . . . . . .
Gasket, water pump . . . . . . . . .
Pump, water . . . . . . . . . . . . . . . .
Gasket, water pump . . . . . . . . .
Stud . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Pulley, water pump . . . . . . . . . . .
Pulley, water pump . . . . . . . . . . .
Case, water inlet . . . . . . . . . . . . .
Gasket . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat (82C) . . . . . . . . . . . .
Sensor, water temp. . . . . . . . . . .
Bolt, bleed valve . . . . . . . . . . . . .
Washer, bleed valve . . . . . . . . . .
1
1
1
1
2
4
3
2
3
1
1
1
1
2
1
1
1
1
Ref.
No.
15 16
17
18 19
20
21
22
23
24
25 26 27 28 29 30 31 32 Part
No.
Description
No.
Req’d
2702469 Bolt, water outlet mount . . . . . . .
832033 Clamp, hose . . . . . . . . . . . . . . . . . .
833715 Plug . . . . . . . . . . . . . . . . . . . . . . . . .
845334 Outlet, water . . . . . . . . . . . . . . . . .
843857 Sender, water temp. . . . . . . . . . . .
829787 Terminal, 45 1/4 male . . . . . . . . .
452378 Screw, M6-1.00 x 20 . . . . . . . . . . .
845409 Bracket, u-water inlet . . . . . . . . . .
845365 Tube, water inlet . . . . . . . . . . . . . .
2700031 O-ring . . . . . . . . . . . . . . . . . . . . . .
845224 Cap, .313 x 1 . . . . . . . . . . . . . . . . .
825624 Clamp, hose . . . . . . . . . . . . . . . . . .
2701637 Housing, thermostat . . . . . . . . . .
452392 Screw, M8-1.25 x 50 (8.8) . . . . . .
2701638 Spacer, thermostat . . . . . . . . . . .
2701513 Gasket, thermostat spacer . . . .
2703052 Switch, fan . . . . . . . . . . . . . . . . . .
2702539 Cap, thermostat . . . . . . . . . . . . .
2
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
Models 898658 with Serial No’s. up to REV1287 and Models 898657.
Models 898658 with Serial No’s. beginning with 00002120 and Models 898656.
142
ALTERNATOR
SUZUKI 660 EFI TURF
MODELS 898656, 898657 & 898658
A Service Manual is available for the
Mando Alternator.
Please order Part No. 845258
2
3
5
4
9
6
21
7
1
38
37
36
16
39
30
39
40
36
Ref.
No.
1
2
3
4
5
6
7
8*
9
10 *
11 *
12 *
13 *
14 *
15 *
16
17 *
18 *
19 *
20 *
21
Part
No.
893633
842558
842559
842560
842561
842562
842563
893849
842564
842565
842566
842567
893850
893851
893852
842568
893853
842569
842570
842571
893854
Description
No.
Req’d
Alternator . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . . .
Lockwasher . . . . . . . . . . . . . . . . .
Pulley . . . . . . . . . . . . . . . . . . . . . . .
Spacer . . . . . . . . . . . . . . . . . . . . . .
Fan . . . . . . . . . . . . . . . . . . . . . . . .
Spacer . . . . . . . . . . . . . . . . . . . . . .
Bracket assembly (front) . . . . . .
Bracket, front . . . . . . . . . . . . . . .
Screw, flange . . . . . . . . . . . . . . .
Bearing . . . . . . . . . . . . . . . . . . . .
Retainer . . . . . . . . . . . . . . . . . . . .
Rotor assembly . . . . . . . . . . . . . .
Stator assenbly . . . . . . . . . . . . .
Bracket assembly (rear) . . . . . . .
Bracket, rear . . . . . . . . . . . . . . . .
Rectifier assembly . . . . . . . . . . .
Screw set . . . . . . . . . . . . . . . . . .
Mold . . . . . . . . . . . . . . . . . . . . . . .
Nut, flange . . . . . . . . . . . . . . . . .
Condenser assembly . . . . . . . .
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
2
1
Ref.
No.
22 *
23 *
24 *
25 *
26 *
27 *
28 *
29 *
30
31 *
32 *
33 *
34 *
35 *
36
37
38
39
40
41
42
Part
No.
842572
842573
842574
893855
842575
842576
842577
842578
842579
842580
842581
842582
842571
842570
120052
306375
306396
306531
308089
825970
844328
42
Description
41
No.
Req’d
Mold-B . . . . . . . . . . . . . . . . . . . . .
Nut, flange . . . . . . . . . . . . . . . . .
Through bolt . . . . . . . . . . . . . . . .
Regulator assembly . . . . . . . . . .
Brush . . . . . . . . . . . . . . . . . . . . . .
Spring, brush . . . . . . . . . . . . . . .
Set, screw . . . . . . . . . . . . . . . . . . .
Terminal-L . . . . . . . . . . . . . . . . . . .
Cover . . . . . . . . . . . . . . . . . . . . . . .
Set, screw . . . . . . . . . . . . . . . . . . .
Wire, lead (A) . . . . . . . . . . . . . . . .
Wire, lead (B) . . . . . . . . . . . . . . . .
Nut, flange . . . . . . . . . . . . . . . . . .
Mold . . . . . . . . . . . . . . . . . . . . . . . .
Lockwasher, #10 . . . . . . . . . . . . . .
Nut, 1/4-20 . . . . . . . . . . . . . . . . . . .
Lockwasher, 1/4 . . . . . . . . . . . . . .
Nut, #10-24 . . . . . . . . . . . . . . . . . .
Washer, #10 . . . . . . . . . . . . . . . . . .
Boot, terminal . . . . . . . . . . . . . . . .
Boot, terminal . . . . . . . . . . . . . . . .
1
1
4
1
1
1
1
1
1
1
1
1
2
1
4
1
1
4
1
4
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
* Not Illustrated
143
WIRING DIAGRAM
SUZUKI 660 EFI
TURF TRUCKSTER, MODEL 898657 (automatic transmission)
R/BL
BL/Y
G/R
G/Y
BR
BL/B
B
Industrial
Taillight Harness
PIN 34
PIN 9
BL/B
PIN 1
PIN 27
PIN 21
PIN 1
PIN 7
PIN 26
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
11 BR
6W
7 B/G
21 R/W
15 BL/W
8 G/W
13 B/W
16 OR
1 B/R
18 G/PK
19 OR/BL
20 OR/G
24 G/BL
25 G
26 R
PIN
PIN
PIN
PIN
PIN
PIN
PIN
1 B/R
5 R/G
6 PK
16 BL/R
8 BL/B
12 BL/W
4 B/W
BR
BL/B
R/B
BL/B
B
BR
R/B
B/G
BL/B
OR
BL/W
B/W
OR
W
W/Y
R/OR
W/R
R/G
B
R
R
B
Temp
Sender
W/OR
OR
PK
W/PK
PK/BL
W/OR
PIN 10 B/G
PIN 16 B/R
PIN 11 W/OR
PIN 18 R/Y
PIN 17 W
PIN 3 B
PIN 4 B/Y
PIN 38 PK/B
PIN 13 Y
PIN 40 G/W
PIN 19 B/W
PIN 39 W/R
PIN 20 R/OR
PIN 37 W/Y
PIN 36 BL
W/OR
Not
Used
Brake
Switch
B/R
B
R/G
R
R
B
PIN 31
OR
PK/BL
W/PK
PK
W/OR
R/G
BL
R
B
BL
Oil Pressure
Sender
R
B
G/W
Y/B
P
S
B
B
PIN 1
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PK/B
B/R
EXC
Y
R
B
R
B/R
B
W/Y
R/G
R
B
B
Y
W/OR
W/R
R/OR
R
R
G/W
B/W
B/W
BL
PK/BL
BL/B
OR
B/R
R/Y
Y
G/W
W/R
Y
R
Y
G/W
PK/BL
BR/Y
BR/Y
OR/BL
PK
R
G/PK
G/BL
G
BL/R
BL/W
B
BL/B
OR
PK/B
B/W
B
B
B/Y
G/BL
BL/W
B
B/Y
R
B/R
PIN 10
OR/BL
G
BL/R
W/Y
PK/B
B
Y
W/PK
OR
B/R
B
W/R
B
B/R
BL/W
W
R/G
PIN 40
BR/Y
PK
G/PK
OR
B
B/Y
PK/B
W/R
B/R
Park Brake
Switch
OR/G
BL/B
Y
B/G
B/Y
R
B
R
W/OR
B
Fuel Pump
R/Y
R
B
B/R
W
W/OR
B
R
B
Back-up
Alarm
W/PK
B
B
Chassis
Ground
W/OR
R/Y
R
R
W
R
R
R
R/G
W/R
B
R
B
B/Y
R
G/PK
G/BL
BR/Y
OR/G
–
B
B
B/R
Back-up
Switch
W
G/W
PK/B
B
PIN 31
12 PK/BL
24 R
25 BR/Y
23 W/PK
31 PK
30 OR/BL
29 OR/G
28 G
27 G/BL
26 G/PK
35 BL/W
34 BL/B
33 BL/R
32 OR
W/PK
R
OR/G
B
G
BL/W
BL/B
B
BR/Y
OR/BL
PK
Shift
Solenoid
BL/R
B
BR/Y
Y
PIN 10 B/G
PIN 38 PK/B
PIN 39 W/R
PIN 4 B/Y
PIN 37 W/Y
PIN 36 BL
PIN 12 PK/BL
PIN 23 W/PK
PIN 11 W/OR
PIN 31 PK
PIN 25 BR/Y
PIN 17 W
PIN 40 G/W
PIN 13 Y
PIN 3 B
19 B/W
35 BL/W
34 BL/B
33 BL/R
24 R
28 G
27 G/BL
29 OR/G
30 OR/BL
26 G/PK
16 B/R
32 OR
18 R/Y
20 R/OR
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN 1
Shift
Switch
B
B/R
OR
+
Battery
Speed
Sensor
Start
Solenoid
Starter
Engine Ground
No. 2
B
W/OR
PK
W/Y
PIN 40
R/G
PK
W/R
PIN 10
OR
B
G/W
W/B
G/W
R/OR
B/R
PK
BR/Y
B
B/W
W/B
R/W
R/Y
B/R
B/BL
B/W
B
144
R/Y
B/W
W
B
R/G
B/W
BL
W
B
BR
BL/W
G/W
B/Y
W/R
B/W
B
Radiator Fan
2700799
B
G/W
R
G/BL
OR/G
G
R/G
BL/R
B/R
BL/W
PK
B/W
BL/B
B/Y
OR
R/G
B
B/W
BL/B
B/G
R/W
B/W
R/OR
Suzuki
Harness
B/W
Coil
B
No. 3
W/R
Coil
No. 1
W
B/G
BL/W
B
B/BL
B
Turf
Taillight
B
B/G
Engine Ground
No. 1
Coil
No. 2
B
BR
BR
W/PK
B/R
BR/R
B/R
B
OR
BR
PK/BL
W/B
Sensor
B
B
B
R/B
BR
BL/B
R/BL
B
Crank Angle BR/R
R/B
B
B
R/G
BR/B
Oxygen
Sensor
Main
Harness
R/B
R/B
B/W
B/R
BR/B
W/R
BR
BR
Not
Used
B/R
OR/BL
W
BR/W
B/R
W
Injector
No. 1
B/R
PIN 13
W/G
B/R
B/R
BR
PIN 10 B/Y
PK
BR/W
Injector
No. 2
PIN 1
PIN 4 B/W
Not
Used
Injector
No. 3
W/R
B/W
PIN 4
PIN 7 W/R
PIN 2 PK
PIN 1 B/R
BR
OR
R/B
BR
PIN 16
PIN 13
BR
BL/B
B
B
BR
PIN 16
PIN 4
PIN 1
W/G
W/R
B/W
3 Y/BL
15 W/G
5 R/G
6 PK/B
8 BL/B
16 BL/R
11 PK/G
12 BL/W
9 Y/W
Right Industrial
Taillight
G/PK
Not
Used
R/Y
BR/R
Not
Used
R/BL
R/B
R
B/R
B/R
B
R
B/R
R/B
Idle Speed R/Y
B/R
Controller R/BL
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
B
R
W
Turf Taillight
Harness
W
W/R
W/B
Left Industrial
Taillight
R
W
R/B
BR
B/R
G/Y
BL/Y
G/R
Pressure
Sensor
B
R
G/R
PIN 16 BR/R
PIN 17 B
PIN 9 B/BL
PIN 19 W/R
PIN 20 W
PIN 21 W/B
PIN 28 BL/W
PIN 7 PK/G
PIN 29 BL/R
PIN 27 BL/B
PIN 4 PK/B
PIN 3 R/G
PIN 8 W/G
PIN 18 Y/BL
BL/B
BR
BR
R
W
B
B
BR
W
B
B
R/Y
BL/Y
G/R
GY/Y
R/B
Throttle
Sensor
R
BL/Y
GY/Y
BR/W
BR/B
R/BL
BR/R
B/BL
G/W
B
B
B
R
ECU
R/B
BL/Y
Y/W
Water Temp Y/W
Sensor
22 G
34 BL/Y
32 G/W
26 G/R
33 GY/Y
25 G/Y
13 R/Y
14 R/BL
11 R/B
12 R
2 BR/W
10 BR
1 BR/B
24 R/BL
BR
BL/Y
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
G/W
R/W
G
BL/Y
B/R
G
BL/Y
Y/W
Ignition
Adjust
Resistor
B/W
R
B/R
R/Y
B/Y
W/R
R/G
Engine
Harness
W
PK/B
R/OR
B
Y
W/Y
B/R
COLOR CODE:
OR
G
Y/B
Y/B
Y/R
R
B
B
B
B/R
W/BL
Y/B
B
B/W
B
Y
B/W
R
Fuse Block
15
Fuse
15
Amperage 10
10
B/W
B/W
B/W
PK
B
B
B
R/B
R/B
PK/B
Brake Fluid
Reservoir
B/R
B/G
B/W
B/W
PK/B
PK
BL
W/R
BR/Y
R/OR
R/B
R/B
R
Y
R/B
B
BL/W
W
R
Diagnostic
Plug
Horn
Fuel
Relay
G/B
BL
G/W
BL
R/G
BL/W
W
B/G
W
BL/W
B
B/W
BL
BL
R
BL/W
B/G
B/R
B/G
R/G
Y
PK/B
W/R
R
R/OR
R/Y
G/B
B/W
G/W
W/G
W/R
B/R
Y
R
W/R
B/G
BL
B/R
B/R
B
B
B
W/BL
PK
R
Fuse Block
15
Fuse
10
Amperage 10
10
W/G
G/W
B/W
Y
Y/R
Y/R
R
R
BR/Y
W/R
G
Y
B/W
Y/R
R
W
R
Y
R
Y
W/OR
R
R
W/BL
Ground
Standoff
B/R
Y
R
R/G
BL
B/G
B/R
W/R
W/R
W/R
B
B
B/R
R
R/Y
B/W
Y/R
G/W
B/R
B/R
B
B
B/W
B/W
Fan
Relay
Main
Relay
Accessory Plug
B
B
R/B
BL
B
OR/B
B
B
Y
Y/R
W
PK/B
R
W/OR
W
Y
R
R
Y/R
R
W/R
R
R
Y/R
Trailer Brake
Receptacle
Accessory Plug
B
R/G
R
W/BL
W/R
W
R
R
W/R
W/R
B
W
B/W
W/G
R
R/G
B/R
R/OR
R/Y
G/B
B/W
G/W
BL/W
W
B/G
R/B
B
B
B
B
B
Y
B
B
PK
R
Accessory Plug
B
B
B
B/R
W/OR
R
R
OR/B
OR/B
R
BR
B
B/R
R/Y
R
B/R
Y/R
Trailer Brake
Controller
B
R
B
B/W
W/R
BL
BR
R
W
B
Y
W
Y
W/R
B
OR/B
OR/B
OR/B
G
R
W
BL
B
BR
OR/B
BL
G
PK
B/W
B/W
B/G
B/R
R/G
R/OR
G/B
G/W
BL/W
B/G
R/B
B
B
B
W/G
BR
BR
Dome
Light
B
W
R
B
B
B
BR
B
W/BL
Wiper
Motor
BL
OR/B
Brake Controller
Harness
G
BR/Y
W/R
Y/R
Y
B/G
G/W
B/R
R
R
Speedometer
Panel
OR
R
Y
B
Y
R
B
W/R
R
Tachometer
Panel
Y
R
B
W/R
B
Power Point
(ACC 12V Plug-in Port)
PIN 1
PIN 3
R
Y
BR
B/W
W/R
B
Heater
Fan
B
W/R
Y/R
OR
B
R
R
B
Wiper/Dome Light
Harness
BR
Speedometer
Signal
PIN 16
PIN 18
OR
B
Y/R
OR
W/OR
W/R
PIN 12 PK/BL
PIN 10 BL
PIN 8 W/Y
PIN 11 OR
PIN 9 W/OR
PIN 17 W/BL
PIN 3 BR
PIN 18 B/W
PIN 16 B
PIN 4 R/B
PIN 13 G/B
PIN 15 Y/B
PIN 14 W/R
R
W/R
R
B/Y
Tachometer
Signal
Y
R
R
R
W/OR
G
B/R
B
B
W/BL
R
B
W/R
R
B
W/R
R
R
B/R
W/OR
W/R
Y/R
R
B/G
PK/B
Y/R
BL
PK/BL
Y
PK/B
W/Y
W/R
W/R
G/W
OR/B
G/W
B/G
B/Y
BR/Y
W
PK
W
G
OR
B
B
Y/R
R
B/G
G/W
W
BR/Y
BR/Y
R/G
W/G
G
Heater
Switch
OR/B
W/G
B
B
B/R
PK
B
B
G/B
R/OR
R/Y
PK
BL/W
G/W
B/G
W
W/R
Heater
Harness
Shifter
Light
B/W
B
B
Headlight
Switch
W/OR
BR W
BR
BR
BR
B/W
R/B
W
B/W
G/B
R/OR
B/R
R/G
B/G
BR
BR
BR
W/OR
W/BL
BL
W/BL
W
B/R
R/G
W/OR
B
Y
B/W
R/B
BL/W
G/W
OR
R/Y
R/OR
B/R
PK
B
B/G
B/W
OR
R/Y
B
R/B
W
BL/W
B/W
W/BL
BR
Y
G/W
W/BL
BR
BR
BL
BR
PK/B
W
OR/B
OR/B
OR/B
Y
B/W
BL
BR
BR
OR/B
B/R
B/G
B
W
W/BL
G
R/G
Y
Y/B
R
B
B
Y
W/G
R
R/G
B/R
R/OR
R/Y
G/B
B/W
G/W
BL/W
W
B/G
R/B
B
B
B
B
B
OR/B
B
B/R
BR
W/OR
B
BL
BR
BR
R
W/BL
B
W
B
B
R/B
BR
OR
W
Horn
Switch
B
B
PK
B
R
B
B Y/B
BL
W
B
B
W
BL
BL
Y/B
OR/B
B
B
Y/B
PK/BL
BL/B
BR
Right
Headlight
BL
G/B
G/B
BL
B BL
B
W
B
W
R
G/B
B
Y/R
R/B
Y
Y
PK/BL
G
W/G
G/B
B
R/G
B
B
OR/B
Y/R
Left
Headlight
Y/B
B
B
OR/B
BL/B
Flasher
G
PK/BL
Cab, W/G
Stop Light
OR
G/B
R/G
OR
G/B
G/B
R/B
BL/B
Right
Coolant
Turn Signal Overtemp.
Alarm
B
OR
G/B
OR
B
Left Turn
Signal
OR/B
OR
R
Y
GY/B
OR
OR
OR
B
R
B
R/Y - Red w/Yellow Stripe
W/BR - White w/Brown Stripe
W/G - White w/Green Stripe
W/OR - White w/Orange Stripe
W/R - White w/Red Stripe
W/Y - White w/Yellow Stripe
W/B - White w/Black Stripe
W/BL - White w/Blue Stripe
W/PK - White w/Pink Stripe
Y/B - Yellow w/Black Stripe
Y/BL - Yellow w/Blue Stripe
Y/R - Yellow w/Red Stripe
Y/W - Yellow w/White Stripe
R
GY
Key
Switch
B
Taillight
Adapter
B
Fuel
Level
Sender
Harness
B
GY/B
Y/R
B
Y
OR
GY
R
G
G/W - Green w/White Stripe
G/Y - Green w/Yellow Stripe
GY/Y - Grey w/Yellow Stripe
OR/G - Orange w/Green Stripe
OR/B - Orange w/Black Stripe
OR/BL - Orange w/Blue Stripe
P/BL - Purple w/Blue Stripe
PK/B - Pink w/Black Stripe
PK/BL - Pink w/Blue Stripe
PK/G - Pink w/Green Stripe
R/B - Red w/Black Stripe
R/BL - Red w/Blue Stripe
R/G - Red w/Green Stripe
R/OR - Red w/Orange Stripe
B/G - Black w/Green Stripe
B/R - Black w/Red Stripe
B/W - Black w/White Stripe
B/Y - Black w/Yellow Stripe
BL/B - Blue w/Black Stripe
BL/R - Blue w/Red Stripe
BL/W - Black w/White Stripe
BL/Y - Black w/Yellow Stripe
BR/W - Black w/White Stripe
BR/Y - Black w/Yellow Stripe
G/B - Green w/Black Stripe
G/BL - Green w/Blue Stripe
G/PK - Green w/Pink Stripe
G/R - Green w/Red Stripe
B
Turn Signal
Switch
Fuel Level
Sender
B - Black
BL - Blue
BR - Brown
G - Green
GY - Grey
OR - Orange
PK - Pink
P - Purple
R - Red
W - White
Y - Yellow
G/W
Fuse Block
20
Fuse
15
Amperage 10
10
145
WIRING SCHEMATIC
SUZUKI 660 EFI
TURF TRUCKSTER, MODEL 898657 (automatic transmission)
Ignition
Switch
Starter
Solenoid
10A
20A
Fan
Relay
15A
Main
Relay
IGN
ST
ACC
20A
Radtr
Fan
10A
Fuel
Relay
+
Ignition
Coil #1
Shift
Switch
2
N
P
L
D
R
Fan
Switch
Spark
Plug
Spark
Plug
2
L
P
R
Alternator
Crank
Angle
Sensor
Injector
#2
D
Spark
Plug
Speed
Sensor
Injector
#1
N
Starter
Ignition
Coil #3
Shifter
Light
Fuel
Pump
Back–up
Alarm
–
Ignition
Coil #2
COM
Pressure
Sensor
Injector
#3
Shift
Solenoid
Wiper
Switch
Wiper
Motor
10A
Dome
Light
Throttle
Sensor
Idle
Speed
Controller
ACC
Port
10A
ACC
Port
1 2 3
Water Temp
Sensor
M
ACC
Port
P34–9
P34–17
P26–16
P34–21
P26–15
P26–21
P26–6
P26–11
P34–16
P34–20
P34–19
P34–26
P34–25
P34–33
P34–32
P34–22
P34–13
P34–14
P26–1
P34–3
P34–12
P26–8
P26–13
P26–7
P34–4
P34–1
P34–10
P34–2
P34–11
Heater
Fan
P34–27
P34–28
P34–29
Heater
Switch
P26–18
P26–19
P26–20
P26–24
P26–25
P26–26
10A
P34–24
P34–34
ECU
Ignition
Adjust
Resistor
Oxygen
Sensor
TURN SIGNAL SWITCH
SCHEMATIC
FLASHER
LH STOP RH
REAR SW REAR
FLASHER
LH
FRNT
RH
FRNT
LH STOP RH
REAR SW REAR
“NEUTRAL”
“LH TURN”
146
RH
FRNT
LH
FRNT
RH
FRNT
“HAZARD”
FLASHER
LH STOP RH
REAR SW REAR
LH
FRNT
FLASHER
LH
FRNT
RH
FRNT
LH STOP RH
REAR SW REAR
“RH TURN”
IGNITION SWITCH
SCHEMATIC
BAT
ST
ACC
BAT
IGN
ST
“OFF”
P18
P4
P8 P17
ST
ACC
BAT
IGN
ST
“ON”
ACC
IGN
“ACC”
POSITION
15A
10A
Flasher
Headlight
Switch
Panel Lights
Diesel Preheat
Voltmtr
P14
Park
Brake
Switch
Oil
Pressure
Switch
Fuel
Level
Sender
Water
Temp
Sender
15A
Brake
Switch
High Beam P9
Left Turn
P13
Power
Point
Horn
Right Turn
P15
P7
Front
Right
Turn
Lamp
Front
Left
Turn
Lamp
P16
Left
Tail Lamp
Service
Brake
Switch
10A
Trailer Brake
Controller
Turn Signal
Switch
P3
Speedmtr
Temp Buzzer
Temp Gauge
P11
IGN
Dash Panel
Tachmtr
P10
Fuel Gauge
Oil Pressure
P12
ACC
“START”
P14
Service Brakes
Diagnostics
Park Brake
Diagnostics
Port
BAT
Coolant
Overheat
Alarm
Left
Head Lamp
Right
Head Lamp
Trailer Brake
Receptacle
Horn
Switch
Right
Tail Lamp
Cab/Stop
Light
HEADLIGHT SWITCH
SCHEMATIC
B+
B+
LOW
BEAM
HIGH
BEAM
DASH
LOW
BEAM
B+
HIGH
BEAM
DASH
TAIL
“OFF”
LOW
BEAM
HIGH
BEAM
DASH
TAIL
TAIL
“LOW BEAM”
“HIGH BEAM”
147
WIRING DIAGRAM
SUZUKI 660 EFI
TURF TRUCKSTER, MODEL 898658 With Serial No’s. Up To REV1287
R/BL
BL/Y
G/R
G/Y
BR
BL/B
Industrial
Taillight Harness
PIN 34
PIN 9
BL/B
PIN 1
PIN 27
PIN 21
PIN 1
PIN 7
PIN 26
PIN
PIN
PIN
PIN
PIN
PIN
PIN
11 BR
7 B/G
6W
15 BL/W
8 G/W
13 B/W
16 OR
PIN
PIN
PIN
PIN
PIN
PIN
PIN
1 B/R
18 G/PK
19 OR/BL
20 OR/G
24 G/BL
25 G
26 R
PIN
PIN
PIN
PIN
PIN
PIN
PIN
1 B/R
6 R/G
7 PK
10 BL/R
9 BL/B
14 BL/W
4 B/W
BR
BL/B
R/B
BL/B
B
BL/W
BL/B
OR
B/G
R/B
BR
G/W
R
G/BL
OR/G
B/W
G
OR/BL
R/G
BL/R
B/R
BL/W
B/W
PK
B/G
OR
B/R
B/W
W
W/Y
R
R/G
R
Oil Pressure
Sender
W/OR
PK
W/PK
PK/BL
W/OR
OR
W/OR
Clutch
Switch
Brake
Switch
B/R
B
R/G
R
R
B
R/G
PIN 10 B/G
PIN 16 B/R
PIN 11 W/OR
PIN 18 R/Y
PIN 17 W
PIN 3 B
PIN 4 B/Y
PIN 38 PK/B
PIN 13 Y
PIN 40 G/W
PIN 19 B/W
PIN 39 W/R
PIN 20 R/OR
PIN 37 W/Y
PIN 36 BL
OR
PK/BL
W/PK
PK
W/OR
R/G
B
BL
R
B
BL
R
B/R
Temp
Sender
PIN 31
PIN 1
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
G/W
Y/B
P
B
R
B
PK/B
W/Y
EXC
S
PK/BL
BR/Y
B/R
B
W/R
R/OR
R
R
R
R/Y
B/W
R
BL/B
OR
W/OR
B
Y
G/W
W/R
BL
PK/BL
G/BL
BL/W
B/R
W/Y
G/W
Y
Y
G/W
Y
Radiator Fan
148
R
OR/BL
BR/Y
BL/B
PK
R
G/PK
G/BL
G
BL/R
BL/W
B
W/PK
OR
B/R
B
W/R
B
R/G
B/R
OR
PK/B
B/W
W/R
B
Y
R/Y
R
PK/B
B
B
Y
B
B
PIN 10
OR/BL
G
BL/R
OR
B/Y
R
B/R
PIN 40
BR/Y
PK
G/PK
BL/W
W
R/G
Park Brake
Switch
R
BL/B
B/Y
B/R
R
B
OR/G
B
B/Y
R/OR
B
Back-up
Alarm
W/PK
W/OR
B/W
B
B/R
W
W/OR
B
R
B
R
G/PK
G/BL
BR/Y
B
B/Y
B
Fuel Pump
B
B
B
Chassis
Ground
W/OR
R/Y
R
R
B
B
B/R
Back-up
Switch
PK/B
W/R
B
B
W
R
R
R
R/G
W/R
R
B
BL/B
OR/G
–
BL/R
BR/Y
OR/BL
PK
W/PK
R
OR/G
B
G
BL/W
12 PK/BL
24 R
25 BR/Y
23 W/PK
31 PK
30 OR/BL
29 OR/G
28 G
27 G/BL
26 G/PK
35 BL/W
34 BL/B
33 BL/R
32 OR
Not
Used
Y
B/G
B/Y
B
PIN 31
W
G/W
PK/B
PIN 10 B/G
PIN 38 PK/B
PIN 39 W/R
PIN 4 B/Y
PIN 37 W/Y
PIN 36 BL
PIN 12 PK/BL
PIN 23 W/PK
PIN 11 W/OR
PIN 31 PK
PIN 25 BR/Y
PIN 17 W
PIN 40 G/W
PIN 13 Y
PIN 3 B
19 B/W
35 BL/W
34 BL/B
33 BL/R
24 R
28 G
27 G/BL
29 OR/G
30 OR/BL
26 G/PK
16 B/R
32 OR
18 R/Y
20 R/OR
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN 1
Not
Used
B
B/R
OR
+
Battery
Speed
Sensor
Start
Solenoid
Starter
B
BR/Y
Y
W/Y
PIN 40
Engine Ground
No. 2
B
W/R
PIN 10
R/G
W/OR
G/W
W/B
OR
PK
PK
BR/Y
B
B/W
G/W
R/OR
B
B/W
W
W/B
W
B/R
PK
B/BL
B/W
B
R/G
B/W
BL
B
B
R/Y
B/Y
W
B
BR
BL/W
G/W
R/Y
R/G
B
B/W
BL/B
B/G
B/W
B
W/R
B/W
B
BR
W
BL/W
R/OR
Suzuki
Harness
B/W
Coil
B
No. 3
W/R
Turf
Taillight
B
B
B/G
B/BL
B
B
OR
BR
BR
W/B
B
B
PK/BL
W/PK
B/R
BR/R
R/B
B
B
B
R/B
BR
BL/B
R/BL
B/R
R/B
R/B
BL/B
B/Y
W/R
B
BR/B
Main
Harness
B/R
BR/B
Engine Ground
No. 1
Coil
No. 1
PIN 10
B/R
BR
BR
B
Crank Angle BR/R
Coil
No. 2
PIN 1
BR/W
B/R
Oxygen
Sensor
Sensor
PIN 10
PIN 4 B/W
W
Injector
No. 1
B/R
PIN 4
PIN 12 B/Y
B/R
B/R
PIN 14
PIN 15
BR
OR
R/B
BR
PIN 14
PIN 4
PIN 1
BR
BL/B
B
B
BR
PK
BR/W
Injector
No. 2
W
W/R
B/W
Not
Used
Injector
No. 3
BR
W/G
W/R
B/W
3 Y/BL
5 W/G
6 R/G
7 PK/B
9 BL/B
10 BL/R
13 PK/G
14 BL/W
11 Y/W
15 W/G
8 W/R
2 PK
1 B/R
Right Industrial
Taillight
G/PK
Not
Used
R/Y
BR/R
Not
Used
R/BL
R/B
R
B/R
B/R
B
R
B/R
R/B
Idle Speed R/Y
B/R
Controller R/BL
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
B
R
W
Turf Taillight
Harness
W
W/R
W/B
Left Industrial
Taillight
R
W
R/B
BR
B/R
G/Y
BL/Y
G/R
Pressure
Sensor
B
R
G/R
PIN 16 BR/R
PIN 17 B
PIN 9 B/BL
PIN 19 W/R
PIN 20 W
PIN 21 W/B
PIN 28 BL/W
PIN 7 PK/G
PIN 29 BL/R
PIN 27 BL/B
PIN 4 PK/B
PIN 3 R/G
PIN 8 W/G
PIN 18 Y/BL
BL/B
BR
BR
R
W
B
B
BR
W
B
B
R/Y
BL/Y
G/R
GY/Y
R/B
Throttle
Sensor
R
BL/Y
GY/Y
BR/W
BR/B
R/BL
BR/R
B/BL
G/W
B
B
B
R
ECU
B
BL/Y
Y/W
Water Temp Y/W
Sensor
22 G
34 BL/Y
32 G/W
26 G/R
33 GY/Y
25 G/Y
13 R/Y
14 R/BL
11 R/B
12 R
2 BR/W
10 BR
1 BR/B
24 R/BL
R/B
BL/Y
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
G/W
BR
G
BL/Y
B/R
G
BL/Y
Y/W
Ignition
Adjust
Resistor
B/W
R
B/R
R/Y
B/Y
W/R
R/G
Engine
Harness
W
PK/B
R/OR
B
Y
W/Y
B/R
COLOR CODE:
OR
G
Y/B
Y/B
Y/R
R
B
B
B
B/R
W/BL
Y/B
B
B/W
B
Y
B/W
R
Fuse Block
15
Fuse
15
Amperage 10
10
B/W
B/W
B/W
PK
B
B
B
R/B
R/B
PK/B
Brake Fluid
Reservoir
B/R
B/G
B/W
B/W
PK/B
PK
BL
W/R
BR/Y
R/OR
R/B
R/B
R
Y
R/B
B
BL/W
W
R
Diagnostic
Plug
Horn
Fuel
Relay
G/B
BL
G/W
BL
R/G
BL/W
W
B/G
W
BL/W
B
B/W
BL
BL
R
BL/W
B/G
B/R
B/G
R/G
Y
PK/B
W/R
R
R/OR
R/Y
G/B
B/W
G/W
W/G
W/R
B/R
Y
R
W/R
B/G
BL
B/R
B/R
B
B
B
W/BL
PK
R
Fuse Block
15
Fuse
10
Amperage 10
10
W/G
G/W
B/W
Y
Y/R
Y/R
R
R
BR/Y
W/R
G
Y
B/W
Y/R
R
W
R
Y
R
Y
W/OR
R
R
W/BL
Ground
Standoff
B/R
Y
R
R/G
BL
B/G
B/R
W/R
W/R
W/R
B
B
B/R
R
R/Y
B/W
Y/R
G/W
B/R
B/R
B
B
B/W
B/W
Fan
Relay
Main
Relay
Accessory Plug
B
B
R/B
BL
B
OR/B
B
B
Y
Y/R
W
PK/B
R
W/OR
W
Y
R
R
Y/R
R
W/R
R
R
Y/R
Trailer Brake
Receptacle
Accessory Plug
B
R/G
R
W/BL
W/R
W
R
R
W/R
W/R
B
W
B/W
W/G
R
R/G
B/R
R/OR
R/Y
G/B
B/W
G/W
BL/W
W
B/G
R/B
B
B
B
B
B
Y
B
B
PK
R
Accessory Plug
B
B
B
B/R
W/OR
R
R
OR/B
OR/B
R
BR
B
B/R
R/Y
R
B/R
Y/R
Trailer Brake
Controller
B
R
B
B/W
W/R
BL
BR
R
W
B
Y
W
Y
W/R
B
OR/B
OR/B
OR/B
G
R
W
BL
B
BR
OR/B
BL
G
PK
B/W
B/W
B/G
B/R
R/G
R/OR
G/B
G/W
BL/W
B/G
R/B
B
B
B
W/G
BR
BR
Dome
Light
B
W
R
B
B
B
BR
B
W/BL
Wiper
Motor
BL
OR/B
Brake Controller
Harness
G
BR/Y
W/R
Y/R
Y
B/G
G/W
B/R
R
R
Speedometer
Panel
OR
R
Y
B
Y
R
B
W/R
R
Tachometer
Panel
Y
R
B
W/R
B
Power Point
(ACC 12V Plug-in Port)
PIN 1
PIN 3
R
Y
BR
B/W
W/R
B
Heater
Fan
B
W/R
Y/R
OR
B
R
R
B
Wiper/Dome Light
Harness
BR
Speedometer
Signal
PIN 16
PIN 18
OR
B
Y/R
OR
W/OR
W/R
PIN 12 PK/BL
PIN 10 BL
PIN 8 W/Y
PIN 11 OR
PIN 9 W/OR
PIN 17 W/BL
PIN 3 BR
PIN 18 B/W
PIN 16 B
PIN 4 R/B
PIN 13 G/B
PIN 15 Y/B
PIN 14 W/R
R
W/R
R
B/Y
Tachometer
Signal
Y
R
R
R
W/OR
G
B/R
B
B
W/BL
R
B
W/R
R
B
W/R
R
R
B/R
W/OR
W/R
Y/R
R
B/G
PK/B
Y/R
BL
PK/BL
Y
PK/B
W/Y
W/R
W/R
G/W
OR/B
G/W
B/G
B/Y
BR/Y
W
PK
W
G
OR
B
B
Y/R
R
B/G
G/W
W
BR/Y
BR/Y
R/G
W/G
G
Heater
Switch
OR/B
W/G
B
B
B/R
PK
B
B
G/B
R/OR
R/Y
PK
BL/W
G/W
B/G
W
W/R
Heater
Harness
Shifter
Light
B/W
B
B
Headlight
Switch
W/OR
BR W
BR
BR
BR
B/W
R/B
W
B/W
G/B
R/OR
B/R
R/G
B/G
BR
BR
BR
W/OR
W/BL
BL
W/BL
W
B/R
R/G
W/OR
B
Y
B/W
R/B
BL/W
G/W
OR
R/Y
R/OR
B/R
PK
B
B/G
B/W
OR
R/Y
B
R/B
W
BL/W
B/W
W/BL
BR
Y
G/W
W/BL
BR
BR
BL
BR
PK/B
W
OR/B
OR/B
OR/B
Y
B/W
BL
BR
BR
OR/B
B/R
B/G
B
W
W/BL
G
R/G
Y
Y/B
R
B
B
Y
W/G
R
R/G
B/R
R/OR
R/Y
G/B
B/W
G/W
BL/W
W
B/G
R/B
B
B
B
B
B
OR/B
B
B/R
BR
W/OR
B
BL
BR
BR
R
W/BL
B
W
B
B
R/B
BR
OR
W
Horn
Switch
B
B
PK
B
R
B
B Y/B
BL
W
B
B
W
BL
BL
Y/B
OR/B
B
B
Y/B
PK/BL
BL/B
BR
Right
Headlight
BL
G/B
G/B
BL
B BL
B
W
B
W
R
G/B
B
Y/R
R/B
Y
Y
PK/BL
G
W/G
G/B
B
R/G
B
B
OR/B
Y/R
Left
Headlight
Y/B
B
B
OR/B
BL/B
Flasher
G
PK/BL
Cab, W/G
Stop Light
OR
G/B
R/G
OR
G/B
G/B
R/B
BL/B
Right
Coolant
Turn Signal Overtemp.
Alarm
B
OR
G/B
OR
B
Left Turn
Signal
OR/B
OR
R
Y
GY/B
OR
OR
OR
B
R
B
R/Y - Red w/Yellow Stripe
W/BR - White w/Brown Stripe
W/G - White w/Green Stripe
W/OR - White w/Orange Stripe
W/R - White w/Red Stripe
W/Y - White w/Yellow Stripe
W/B - White w/Black Stripe
W/BL - White w/Blue Stripe
W/PK - White w/Pink Stripe
Y/B - Yellow w/Black Stripe
Y/BL - Yellow w/Blue Stripe
Y/R - Yellow w/Red Stripe
Y/W - Yellow w/White Stripe
R
GY
Key
Switch
B
Taillight
Adapter
B
Fuel
Level
Sender
Harness
B
GY/B
Y/R
B
Y
OR
GY
R
G
G/W - Green w/White Stripe
G/Y - Green w/Yellow Stripe
GY/Y - Grey w/Yellow Stripe
OR/G - Orange w/Green Stripe
OR/B - Orange w/Black Stripe
OR/BL - Orange w/Blue Stripe
P/BL - Purple w/Blue Stripe
PK/B - Pink w/Black Stripe
PK/BL - Pink w/Blue Stripe
PK/G - Pink w/Green Stripe
R/B - Red w/Black Stripe
R/BL - Red w/Blue Stripe
R/G - Red w/Green Stripe
R/OR - Red w/Orange Stripe
B/G - Black w/Green Stripe
B/R - Black w/Red Stripe
B/W - Black w/White Stripe
B/Y - Black w/Yellow Stripe
BL/B - Blue w/Black Stripe
BL/R - Blue w/Red Stripe
BL/W - Black w/White Stripe
BL/Y - Black w/Yellow Stripe
BR/W - Black w/White Stripe
BR/Y - Black w/Yellow Stripe
G/B - Green w/Black Stripe
G/BL - Green w/Blue Stripe
G/PK - Green w/Pink Stripe
G/R - Green w/Red Stripe
B
Turn Signal
Switch
Fuel Level
Sender
B - Black
BL - Blue
BR - Brown
G - Green
GY - Grey
OR - Orange
PK - Pink
P - Purple
R - Red
W - White
Y - Yellow
G/W
Fuse Block
20
Fuse
15
Amperage 10
10
149
WIRING SCHEMATIC
SUZUKI 660 EFI
TURF TRUCKSTER, MODEL 898658 With Serial No’s. Up To REV1287
Ignition
Switch
Starter
Solenoid
10A
20A
Fan
Relay
15A
Main
Relay
IGN
ST
ACC
15A
Radtr
Fan
10A
Fuel
Relay
Ignition
Coil #1
Clutch
Switch
Ignition
Coil #2
Ignition
Coil #3
Spark
Plug
Spark
Plug
Shifter
Light
Fuel
Pump
Back-up
Alarm
Spark
Plug
Speed
Sensor
Injector
#1
Starter
Alternator
Crank
Angle
Sensor
Injector
#2
Pressure
Sensor
Injector
#3
Wiper
Switch
Wiper
Motor
10A
Throttle
Sensor
Dome
Light
Idle
Speed
Controller
ACC
Port
10A
ACC
Port
Water Temp
Sensor
M
ACC
Port
P34–9
P34–17
P26–15
P26–6
P26–11
P34–16
P34–20
P34–19
P34–26
P34–25
P34–33
P34–32
P34–22
P26–16
P34–21
P34–13
P34–14
P26–1
P34–3
Heater
Fan
P34–12
Heater
Switch
P26–8
P26–13
P26–7
P34–4
P34–1
P34–10
P34–2
P34–11
10A
P34–24
P34–34
ECU
Ignition
Adjust
Resistor
Oxygen
Sensor
TURN SIGNAL SWITCH
SCHEMATIC
FLASHER
LH STOP RH
REAR SW REAR
FLASHER
LH
FRNT
RH
FRNT
LH STOP RH
REAR SW REAR
“NEUTRAL”
“LH TURN”
150
RH
FRNT
LH
FRNT
RH
FRNT
“HAZARD”
FLASHER
LH STOP RH
REAR SW REAR
LH
FRNT
FLASHER
LH
FRNT
RH
FRNT
LH STOP RH
REAR SW REAR
“RH TURN”
IGNITION SWITCH
SCHEMATIC
BAT
ST
ACC
BAT
IGN
ST
“OFF”
P18
P4
P8 P17
ST
ACC
BAT
IGN
ST
“ON”
ACC
IGN
“ACC”
POSITION
15A
10A
Flasher
Headlight
Switch
Panel Lights
Diesel Preheat
Voltmtr
P14
Park
Brake
Switch
Oil
Pressure
Switch
Fuel
Level
Sender
Water
Temp
Sender
15A
Brake
Switch
High Beam P9
Left Turn
P13
Power
Point
Horn
Right Turn
P15
P7
Front
Right
Turn
Lamp
Front
Left
Turn
Lamp
P16
Left
Tail Lamp
Service
Brake
Switch
10A
Trailer Brake
Controller
Turn Signal
Switch
P3
Speedmtr
Temp Buzzer
Temp Gauge
P11
IGN
Dash Panel
Tachmtr
P10
Fuel Gauge
Oil Pressure
P12
ACC
“START”
P14
Service Brakes
Diagnostics
Park Brake
Diagnostics
Port
BAT
Coolant
Overheat
Alarm
Left
Head Lamp
Right
Head Lamp
Trailer Brake
Receptacle
Horn
Switch
Right
Tail Lamp
Cab/Stop
Light
HEADLIGHT SWITCH
SCHEMATIC
B+
LOW
BEAM
B+
HIGH
BEAM
DASH
LOW
BEAM
B+
HIGH
BEAM
DASH
TAIL
“OFF”
LOW
BEAM
HIGH
BEAM
DASH
TAIL
TAIL
“LOW BEAM”
“HIGH BEAM”
151
WIRING DIAGRAM
SUZUKI 660 EFI
TURF TRUCKSTER, MODEL 898656 and
MODELS 898658 With Serial No’s. Beginning With 00002120
R/BL
BL/Y
G/R
G/Y
BR
BL/B
B
Industrial
Taillight Harness
PIN 34
PIN 9
BL/B
PIN 1
PIN 27
PIN 21
PIN 1
PIN 7
PIN 26
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
11 BR
6W
7 B/G
21 R/W
15 BL/W
8 G/W
13 B/W
16 OR
1 B/R
18 G/PK
19 OR/BL
20 OR/G
24 G/BL
25 G
26 R
PIN
PIN
PIN
PIN
PIN
PIN
PIN
1 B/R
5 R/G
6 PK
16 BL/R
8 BL/B
12 BL/W
4 B/W
BR
BL/B
R/B
BL/B
B
B
BL/W
BL/B
OR
B/G
R/B
BR
G/W
R
G/BL
OR/G
B/W
G
R/G
BL/R
B/R
BL/W
PK
B/W
BL/B
B/Y
OR
W
Not
Used
R/G
Fan Switch
R
Temp
Sender
W/OR
OR
PK
B
W/PK
PK/BL
W/OR
OR
PK/BL
W/PK
PK
W/OR
W/OR
Clutch
Switch
Brake
Switch
B/R
B
R/G
R
R/G
B
BL
Oil Pressure
Sender
PIN 1
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
BL
R
B/R
R
B
B
R
B
G/W
Y/B
P
S
PK/BL
BR/Y
R
B/R
OR/BL
BR/Y
BL/B
PK
R
G/PK
G/BL
G
BL/R
BL/W
B
W/PK
OR
B/R
B
W/R
B
R/G
B/R
OR
R/OR
PK/B
W/Y
EXC
B
152
B
W/Y
Y
R
B
Y
Y
B
R
W/OR
W/R
R/OR
R
Y
W/R
R
B
Y
G/W
Y
R
BL/B
OR
B/R
R/Y
B/W
BL
G/BL
BL/W
B
Y
G/W
W/R
PIN 31
PIN 10
OR/BL
G
BL/R
OR
Y
G/W
B
B
PIN 40
BR/Y
PK
G/PK
BL/W
B/Y
R
B/R
Park Brake
Switch
R
BL/B
R/G
R
B
W/PK
W
PK/B
B/W
B/W
B
B
Radiator Fan
R/Y
R
PK/B
B
Back-up
Alarm
OR/G
B
B/Y
R
G/PK
G/BL
BR/Y
W/OR
Not
Used
Y
B/R
R
W
W/OR
B
B
B
Back-up
Switch
B
B
Fuel Pump
B
B
B/Y
Chassis
Ground
W/OR
R/Y
R
R
B
B
B/R
B
W/Y
PK/BL
B
B
W
R
R
R/G
R
R
B
W/R
BL/B
OR/G
–
BL/R
BR/Y
OR/BL
PK
W/PK
R
OR/G
B
G
BL/W
B/Y
B/R
PIN 10 B/G
PIN 16 B/R
PIN 11 W/OR
PIN 18 R/Y
PIN 17 W
PIN 3 B
PIN 4 B/Y
PIN 38 PK/B
PIN 13 Y
PIN 40 G/W
PIN 19 B/W
PIN 39 W/R
PIN 20 R/OR
PIN 37 W/Y
PIN 36 BL
Not
Used
12 PK/BL
24 R
25 BR/Y
23 W/PK
31 PK
30 OR/BL
29 OR/G
28 G
27 G/BL
26 G/PK
35 BL/W
34 BL/B
33 BL/R
32 OR
B
B/R
OR
+
Battery
Speed
Sensor
Start
Solenoid
PK/B
W/R
R
PIN 31
Y
B/G
B/Y
B
PIN 1
W
G/W
PK/B
PIN 10 B/G
PIN 38 PK/B
PIN 39 W/R
PIN 4 B/Y
PIN 37 W/Y
PIN 36 BL
PIN 12 PK/BL
PIN 23 W/PK
PIN 11 W/OR
PIN 31 PK
PIN 25 BR/Y
PIN 17 W
PIN 40 G/W
PIN 13 Y
PIN 3 B
19 B/W
35 BL/W
34 BL/B
33 BL/R
24 R
28 G
27 G/BL
29 OR/G
30 OR/BL
26 G/PK
16 B/R
32 OR
18 R/Y
20 R/OR
PIN 10
W/B
Starter
B
BR/Y
Y
W/Y
PIN 40
Engine Ground
No. 2
B
W/R
B
B/W
W/B
R/G
W/OR
PK
G/W
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
B/W
B
OR
PK
B/W
W
B
G/W
R/OR
B
BL
W
R/W
B/R
PK
B/BL
B/W
B
R/G
B/W
B/R
B/Y
W/R
B
R/Y
BR/Y
B
BR
BL/W
G/W
R/Y
R/G
B
B/W
BL/B
B/G
R/W
B/W
R/OR
Suzuki
Harness
B/W
Coil
B
No. 3
W/R
Coil
No. 1
W
B/G
BL/W
B
B/BL
B
Turf
Taillight
B
B/G
Engine Ground
No. 1
Coil
No. 2
B
BR
BR
W/PK
B/R
BR/R
B/R
B
OR
BR
PK/BL
W/B
Sensor
B
B
B
R/B
BR
BL/B
R/BL
B
Crank Angle BR/R
R/B
B
B
R/G
BR/B
Oxygen
Sensor
Main
Harness
R/B
R/B
B/W
B/R
BR/B
W/R
BR
BR
Not
Used
B/R
OR/BL
W
BR/W
B/R
W
Injector
No. 1
B/R
PIN 13
W/G
B/R
B/R
BR
PIN 10 B/Y
PK
BR/W
Injector
No. 2
PIN 1
PIN 4 B/W
Not
Used
Injector
No. 3
W/R
B/W
PIN 4
PIN 7 W/R
PIN 2 PK
PIN 1 B/R
BR
OR
R/B
BR
PIN 16
PIN 13
BR
BL/B
B
B
BR
PIN 16
PIN 4
PIN 1
W/G
W/R
B/W
3 Y/BL
15 W/G
5 R/G
6 PK/B
8 BL/B
16 BL/R
11 PK/G
12 BL/W
9 Y/W
Right Industrial
Taillight
G/PK
Not
Used
R/Y
BR/R
Not
Used
R/BL
R/B
R
B/R
B/R
B
R
B/R
R/B
Idle Speed R/Y
B/R
Controller R/BL
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
B
R
W
Turf Taillight
Harness
W
W/R
W/B
Left Industrial
Taillight
R
W
R/B
BR
B/R
G/Y
BL/Y
G/R
Pressure
Sensor
B
R
G/R
PIN 16 BR/R
PIN 17 B
PIN 9 B/BL
PIN 19 W/R
PIN 20 W
PIN 21 W/B
PIN 28 BL/W
PIN 7 PK/G
PIN 29 BL/R
PIN 27 BL/B
PIN 4 PK/B
PIN 3 R/G
PIN 8 W/G
PIN 18 Y/BL
BL/B
BR
BR
R
W
B
B
BR
W
B
B
R/Y
BL/Y
G/R
GY/Y
R/B
Throttle
Sensor
R
BL/Y
GY/Y
BR/W
BR/B
R/BL
BR/R
B/BL
G/W
B
B
B
R
ECU
R/B
BL/Y
Y/W
Water Temp Y/W
Sensor
22 G
34 BL/Y
32 G/W
26 G/R
33 GY/Y
25 G/Y
13 R/Y
14 R/BL
11 R/B
12 R
2 BR/W
10 BR
1 BR/B
24 R/BL
BR
BL/Y
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
G/W
R/W
G
BL/Y
B/R
G
BL/Y
Y/W
Ignition
Adjust
Resistor
B/W
R
B/R
R/Y
B/Y
W/R
R/G
Engine
Harness
W
PK/B
R/OR
B
Y
W/Y
B/R
COLOR CODE:
OR
G
Y/B
Y/B
Y/R
B
B
B
B/R
W/BL
Y/B
B
R
Fuse Block
15
Fuse
15
Amperage 10
10
B/W
R
B
B/G
B/W
B/W
PK
B
B
R/B
PK/B
W/R
BR/Y
R/OR
R/B
R/B
R
B/R
Y
R/B
Brake Fluid
Reservoir
B/R
B/G
B/W
B/W
PK/B
PK
B
BL/W
B
R/W
Diagnostic
Plug
Horn
Fuel
Relay
G/B
BL
R/Y
BL
R/G
B/R
W/R
W/R
R/W
BL/W
B
B/W
R/B
W/R
R
R/OR
R/Y
G/B
B/W
G/W
BL
Y
BL/W
B/G
B
R/B
B/G
R/G
R/W
B
B
W/R
B/R
BL/W
W/R
B/G
BL
B
B
B
Y
BL
B/W
B
Ground
Standoff
BL
Fuse Block
20
Fuse
10
Amperage 10
10
W/G
G/W
G/W
B/W
Y
Y/R
Y/R
R
R
BR/Y
W/R
G
Y
B/W
Y/R
R
W
W/R
B/R
PK/B
B/R
R
R
Y
B
R/G
BL
B/G
B/R
W/R
W/R
B
B
Not
Used
B/R
B/R
Accessory Plug
B
B/W
B/W
G/W
B/W
Y/R
R
R
W/BL
W/G
W
Y/R
Y
R
Y
W/OR
R
R
R
R
W/R
R
BL
B
OR/B
Main
Relay
B
W/BL
Y/R
PK
W
W/OR
PK/B
R
W/BL
R
W/R
W
Y/R
Trailer Brake
Receptacle
Accessory Plug
B
R/G
PK
R
R
R/W
B
B
B/W
R/W
G
Y
W/R
Y/R
Y
B/G
G/W
Y
BR/Y
R
B/R
B
B
B/R
W/OR
R
Y
B
R
Accessory Plug
B
B
B
B
B/W
W/R
R
OR/B
OR/B
R
BR
B
B
R
Y
B
Y
Y/R
Trailer Brake
Controller
B/R
OR/B
B/W
OR/B
B
B
W/BL
BL
BR
R
W
PK
B/W
B/W
B/G
B/R
Speedometer
Panel
W/R
B
BR
OR/B
OR/B
G
R
W
BL
B
B
BR
B
BR
BR
BR
BL
G
B
Y
W/G
R
R/G
B/R
R/OR
R/Y
G/B
B/W
G/W
BL/W
B/G
R/B
B
B
B
B
B
Tachometer
Panel
R
PIN 1
PIN 3
B
Dome
Light
B
W
R
Brake Controller
Harness
R
PIN 16
PIN 18
OR
Y
B/W
BR
B/R
R/Y
R
B/R
Power Point
(ACC 12V Plug-in Port)
Wiper
Motor
B
W/R
B
B
OR/B
R/Y
R/G
R/OR
G/B
G/W
BL/W
R/W
B/G
R/B
B
B
B
W/G
Y
G
Speedometer
Signal
OR
R
Y
B
Y
R
BL
OR/B
W/R
B
Y/R
Y
R
B
W/R
BR
Heater
Fan
B
OR/B
B
Y/R
W/OR
OR
W/R
PIN 12 PK/BL
PIN 10 BL
PIN 8 W/Y
PIN 11 OR
PIN 9 W/OR
PIN 17 W/BL
PIN 3 BR
PIN 18 B/W
PIN 16 B
PIN 4 R/B
PIN 13 G/B
PIN 15 Y/B
PIN 14 W/R
R
W/R
R
B/Y
Tachometer
Signal
W/BL
R
B/R
R
W/OR
Y/R
B/R
W/R
R
OR
B
R
R
B
W/R
B
PK
R
B/R
W/OR
B
Wiper/Dome Light
Harness
W/R
OR
B
B
W/R
R
B
B/G
PK/B
B/G
G/W
W
BR/Y
BL
PK/BL
Y
PK/B
W/Y
B/R
W/R
G/W
W/R
Y/R
R
B/R
G/W
B/G
B/Y
BR/Y
W
R/G
R/OR
G/B
B/W
G/W
BL/W
B/G
R/B
B
B
B
B
B
OR/B
W
Heater
Switch
B
Y/R
R
Y
BR/Y
R/G
G
W/R
Heater
Harness
Shifter
Light
B
B
W/G
G
B/G
Headlight
Switch
W/OR
BR W
BR
B/W
B
G/B
R/OR
B/R
PK
PK
BR
BR
B
R/W
BL/W
G/W
R/Y
R/OR
B/R
W/G
B
B
G/B
W/OR
W/BL
BL
W/BL
W
BR
BR
B/W
R/B
R/W
B/W
OR
R/G
B/G
BR
R
B/R
R/G
W/OR
B
Y
B/W
R/B
BL/W
G/W
R/Y
R/OR
B/R
PK
B
B/G
B/W
OR
R/Y
B
R/B
R/W
BL/W
B/W
W/BL
BR
R
G/W
W/BL
BL
BR
Y
W/G
R/W
OR/B
OR/B
OR/B
BR
BR
BL
BR
BR
OR/B
Y
B/W
W
B/G
B
W
W/BL
R/G
Y
Y/B
PK/B
B
B
G
W/OR
B
BL
BR
BR
R
W/BL
B
W
B
B
R/B
BR
OR
W
Horn
Switch
B
B
PK
B
R
B
B Y/B
BL
W
Y/B
OR/B
B
B
Y/B
PK/BL
BL/B
BR
Right
Headlight
BL
G/B
G/B
BL
B BL
B
W
B
W
R
G/B
B
Y/R
R/B
Y
Y
PK/BL
G
W/G
R/G
B
B
G/B
OR
B
OR/B
Y/R
Left
Headlight
Y/B
B
B
OR/B
BL/B
Flasher
G
PK/BL
Cab, W/G
Stop Light
OR
G/B
R/G
R
G/B
G/B
R/B
BL/B
B
OR
Right
Coolant
Turn Signal Overtemp.
Alarm
G/B
B
OR
B
Left Turn
Signal
OR/B
OR
R
Y
GY/B
OR
OR
OR
B
R
B
R/Y - Red w/Yellow Stripe
W/BR - White w/Brown Stripe
W/G - White w/Green Stripe
W/OR - White w/Orange Stripe
W/R - White w/Red Stripe
W/Y - White w/Yellow Stripe
W/B - White w/Black Stripe
W/BL - White w/Blue Stripe
W/PK - White w/Pink Stripe
Y/B - Yellow w/Black Stripe
Y/BL - Yellow w/Blue Stripe
Y/R - Yellow w/Red Stripe
Y/W - Yellow w/White Stripe
R
GY
Key
Switch
B
Taillight
Adapter
B
B
W
BL
BL
Fuel
Level
Sender
Harness
B
GY/B
Y/R
B
Y
OR
GY
R
G
G/W - Green w/White Stripe
G/Y - Green w/Yellow Stripe
GY/Y - Grey w/Yellow Stripe
OR/G - Orange w/Green Stripe
OR/B - Orange w/Black Stripe
OR/BL - Orange w/Blue Stripe
P/BL - Purple w/Blue Stripe
PK/B - Pink w/Black Stripe
PK/BL - Pink w/Blue Stripe
PK/G - Pink w/Green Stripe
R/B - Red w/Black Stripe
R/BL - Red w/Blue Stripe
R/G - Red w/Green Stripe
R/OR - Red w/Orange Stripe
B/G - Black w/Green Stripe
B/R - Black w/Red Stripe
B/W - Black w/White Stripe
B/Y - Black w/Yellow Stripe
BL/B - Blue w/Black Stripe
BL/R - Blue w/Red Stripe
BL/W - Black w/White Stripe
BL/Y - Black w/Yellow Stripe
BR/W - Black w/White Stripe
BR/Y - Black w/Yellow Stripe
G/B - Green w/Black Stripe
G/BL - Green w/Blue Stripe
G/PK - Green w/Pink Stripe
G/R - Green w/Red Stripe
B
Turn Signal
Switch
Fuel Level
Sender
B - Black
BL - Blue
BR - Brown
G - Green
GY - Grey
OR - Orange
PK - Pink
P - Purple
R - Red
W - White
Y - Yellow
G/W
Fuse Block
20
Fuse
15
Amperage 10
10
153
WIRING SCHEMATIC
SUZUKI 660 EFI
TURF TRUCKSTER, MODEL 898656 and
MODELS 898658 With Serial No’s. Beginning With 00002120
Ignition
Switch
Starter
Solenoid
10A
20A
Fan
Relay
15A
Main
Relay
IGN
ST
ACC
20A
Radtr
Fan
10A
Fuel
Relay
Ignition
Coil #1
Clutch
Switch
Ignition
Coil #3
Spark
Plug
Spark
Plug
Shifter
Light
Fuel
Pump
Fan
Switch
Back-up
Alarm
Spark
Plug
Speed
Sensor
Injector
#1
Starter
Ignition
Coil #2
Alternator
Crank
Angle
Sensor
Injector
#2
Pressure
Sensor
Injector
#3
Wiper
Switch
Wiper
Motor
10A
Throttle
Sensor
Dome
Light
Idle
Speed
Controller
ACC
Port
10A
ACC
Port
Water Temp
Sensor
M
ACC
Port
P34–9
P34–17
P26–16
P34–21
P26–15
P26–21
P26–6
P26–11
P34–16
P34–20
P34–19
P34–26
P34–25
P34–33
P34–32
P34–22
P34–13
P34–14
P26–1
P34–3
Heater
Fan
P26–8
P26–13
P26–7
P34–4
P34–1
P34–10
P34–2
P34–11
Heater
Switch
P34–12
10A
P34–24
P34–34
ECU
Ignition
Adjust
Resistor
Oxygen
Sensor
TURN SIGNAL SWITCH
SCHEMATIC
FLASHER
LH STOP RH
REAR SW REAR
FLASHER
LH
FRNT
RH
FRNT
LH STOP RH
REAR SW REAR
“NEUTRAL”
“LH TURN”
154
RH
FRNT
LH
FRNT
RH
FRNT
“HAZARD”
FLASHER
LH STOP RH
REAR SW REAR
LH
FRNT
FLASHER
LH
FRNT
RH
FRNT
LH STOP RH
REAR SW REAR
“RH TURN”
IGNITION SWITCH
SCHEMATIC
BAT
ST
ACC
BAT
IGN
ST
“OFF”
P18
P4
P8 P17
ST
ACC
BAT
IGN
ST
“ON”
ACC
IGN
“ACC”
POSITION
15A
10A
Flasher
Headlight
Switch
Panel Lights
Diesel Preheat
Voltmtr
P14
Park
Brake
Switch
Oil
Pressure
Switch
Fuel
Level
Sender
Water
Temp
Sender
15A
Brake
Switch
High Beam P9
Left Turn
P13
Power
Point
Horn
Right Turn
P15
P7
Front
Right
Turn
Lamp
Front
Left
Turn
Lamp
P16
Left
Tail Lamp
Service
Brake
Switch
10A
Trailer Brake
Controller
Turn Signal
Switch
P3
Speedmtr
Temp Buzzer
Temp Gauge
P11
IGN
Dash Panel
Tachmtr
P10
Fuel Gauge
Oil Pressure
P12
ACC
“START”
P14
Service Brakes
Diagnostics
Park Brake
Diagnostics
Port
BAT
Coolant
Overheat
Alarm
Left
Head Lamp
Right
Head Lamp
Trailer Brake
Receptacle
Horn
Switch
Right
Tail Lamp
Cab/Stop
Light
HEADLIGHT SWITCH
SCHEMATIC
B+
B+
LOW
BEAM
HIGH
BEAM
DASH
LOW
BEAM
B+
HIGH
BEAM
DASH
TAIL
“OFF”
LOW
BEAM
HIGH
BEAM
DASH
TAIL
TAIL
“LOW BEAM”
“HIGH BEAM”
155
Notes
156