MODELS:


MODELS:
898704
898706
898718
898720
898726
898727
& 898704LP (Manual Transmission)
& 898706LP (3-Wheel Manual)
& 898718LP (Manual Transmission)
& 898720LP (Auto Transmission)
(Perkins Diesel 1/2-ton)
(Perkins Diesel 1-ton)
Part No. 2701245 Rev. D
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 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. Genuine Cushman parts are 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.
150-1-02-CU
2002 Textron Inc. All Rights Reserved.
Lincoln, NE. Printed in U.S.A.
VEHICLE IDENTIFICATION NUMBERS
!
CALIFORNIA
Proposition 65 Warning
!
Engine exhaust, some of its constituents, and certain
vehicle components contain or emit chemicals known to the
State of California to cause cancer, birth defects or other
reproductive harm.
!
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.
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.
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 Golf, Turf and Specialty Products
Attn: Chief Engineer
P.O. Box 82409
Lincoln, NE 68501–2409 USA
SPECIFICATION INFORMATION
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.
1
OPERATION CONTROL SYMBOLS AND DECALS
WARNING
THE PROTECTION OFFERED BY THIS ROPS WILL BE IMPAIRED
IF IT HAS BEEN SUBJECTED TO ANY MODIFICATION OR
STRUCTURAL DAMAGE. THIS ROPS MUST BE REPLACED AFTER
844356
A ROLLOVER. SEAT BELTS MUST BE WORN AT ALL TIMES.
2702014
840901
Operator’s Manual/Key Switch
This decal instructs the operator to read and understand the Operator’s Manual before operating this
vehicle and also shows the ignition key positions
(some vehicles may have the Operator’s Manual
decal shown on the right).
ROPS & Seat Belt Warning
These decals are found on the upper rops frame.
They inform the operator to wear seat belts at all
times when operating a ROPS equipped vehicle. It
also informs the operator a ROPS structure is suitable for this vehicle application.
WARNING
PARKING BRAKES ARE NOT AUTOMATICALLY APPLIED. VEHICLE MAY
MOVE CAUSING PERSONAL INJURY
AND/OR PROPERTY DAMAGE. ALWAYS
APPLY HAND OR FOOT BRAKES.
822819
845027
Pinch Point Warning
This decal is used with the tailgate & box
sides and dump box. It warns of areas
which are capable of pinching the fingers
or other body parts.
Park Brake Warning
This decal warns the operator that the
park brake is not automatically applied.
840748
009034880
Electric Cooling Fan Warning
This decal warns the operator that the
cooling fan may start at any time even
with the ignition key in the OFF position.
WARNING
FAILURE TO HEED THESE
WARNINGS MAY RESULT IN
SERIOUS INJURY OR DEATH
1.
2.
3.
4.
5.
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.
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.
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
and understand 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
VEHICLE
OPERATION CONTROL SYMBOLS
ANDIDENTIFICATION
DECALS
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 too low. If this light comes on
during normal vehicle operation, stop the
vehicle and check for problems
Water Temperature Gauge
This symbol appears on the water temperature
gauge. This gauge warns the operator if the
coolant system is overheating.
X 100
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
840845
Engine RPM
This symbol appears on
the tachometer. It indicates
engine rpm’s.
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
This symbol indicates
diesel fuel only
NUMBERS
Fuel Level Indicator
This symbol appears on the fuel
gauge. The fuel gauge indicates
the amount of fuel in the fuel tank
Glow Plug Indicator
(Diesel Models Only)
This symbol will illuminate when first
starting a diesel engine. This symbol lets
the operator know when the glow plugs
are being heated and when the vehicle is
ready to start.
Park Brake Indicator Light
This light will come on when the park
brake is applied.
OFF
DIM
BRIGHT
Headlight Switch Positions
These symbols appear on the light switch.
As indicated, each one represents the headlights functions.
Battery (Voltmeter) Charging
This symbol appears on the voltmeter
gauge. This gauge indicates the charging
of the battery.
3
INDEX, SERVICE AND MAINTENANCE PAGES
Page
Page
A
Access panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Accessories and Modifications . . . . . . . . . . . . . . . . . 58
Accessories power plug . . . . . . . . . . . . . . . . . . . . . . . 11
Air cleaner and servicing . . . . . . . . . . . . . . . . . . . 43-44
Air intake screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
I
Identification numbers . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Intake screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
J
Jacks, Jacking Locations
and Using a Hoist . . . . . . . . . . . . . . . . . . . . . . . . 47-48
Jump starting (battery) . . . . . . . . . . . . . . . . . . . . . . 45-46
B
Battery , specifications & jump starting . . . . . 7, 45-46
Bleeding the brake systems . . . . . . . . . . . . . . . . . . . 50
Brake fluid, warning light, reservoir . . . . . . . . . 11, 49
Brake pedal, service . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Bulbs, replacement dash panel . . . . . . . . . . . . . . . . . 40
C
Capacities . . . . . . . . . . . . . . . . 7, 20, 22, 51, 52, 53, 54
Check engine light . . . . . . . . . . . . . . . . . . . . . . . . 10, 11
Clutch pedal & interlock switch . . . . . . . . . . . . . . . . . 13
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-24
D
Dash panel bulb replacement . . . . . . . . . . . . . . . . . . 40
Dash panel dipswitch settings . . . . . . . . . . . . . . . . . . 41
Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Diagnostic check . . . . . . . . . . . . . . . . . . . . . . . . . . 36-37
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53-54
Driving the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
E
Electric fan fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Engine:
Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Break–in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-24
Identification (serial) number . . . . . . . . . . . . . . . . . 9
Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-20
Pre-start check list . . . . . . . . . . . . . . . . . . . . . . . . 17
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Starting
Automatic transmission . . . . . . . . . . . . . . . 25-26
Manual transmission . . . . . . . . . . . . . . . . . 25, 27
Manual transmission (diesel) . . . . . . . . . . . . . 28
F
Front cowl access . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . 10, 18-19
Fuel specifications . . . . . . . . . . . . . . . . . . . . . . . 7, 18-19
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
G
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Gear selector, manual and automatic . . . . . . . . 14-15
Glow plug indicator (diesel onlly) . . . . . . . . . . . 11, 28
Governor oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
H
Headlight switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight replacement . . . . . . . . . . . . . . . . . . . . . . . .
Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hour meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
13
40
13
10
L
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Lubrication recommendations . . . . . . . . . . . . . . . 7, 59
M
Maintenance Guide . . . . . . . . . . . . . . . . . . . . . . . . 60-61
O
Oil warning light . . . . . . . . . . . . . . . . . . . . . . . . . . 10, 20
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Overheat warning buzzer . . . . . . . . . . . . . . . . . . 11, 24
P
Parking brake lever . . . . . . . . . . . . . . . . . . . . . . . 12, 51
Parking brake adjustment . . . . . . . . . . . . . . . . . . . . . 51
Parking and stopping the vehicle . . . . . . . . . . . . . . . 32
Power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Pre-start check list . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Propane cylinders, care and storage . . . . . . . . . . . . 56
Purging diesel fuel system . . . . . . . . . . . . . . . . . . . . . 29
R
Refueling the vehicle . . . . . . . . . . . . . . . . . . . . . . 18-19
ROPS (Roll Over Protection System) . . . . . . . . . . . . . 55
S
Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Serial number, engine . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Serial number, vehicle . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service and Maintenance . . . . . . . . . . . . . . . . . . 36-61
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Stopping the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . 25-29
T
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Taillight replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Throttle, foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Tire air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Tire removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-34
Torque chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Towing a trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Towing the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Transmission
Automatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
V
Vehicle identification numbers . . . . . . . . . . . . . . . . 9-10
Vehicle operation . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17
Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
W
Warning lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Water temperature gauge and buzzer . . . . . . . 11, 24
PARTS INDEX
Page
Page
A
F
Accelerator pedal (foot throttle) . . . . . . . . . . . . . . . . . . 98
Accessory power plug (12 volt) . . . . . . . . . . . . . . . . 150
Air cleaner, bracket (Suzuki models) . . . . . . . 109, 110
Air cleaner, bracket (Diesel models) . . . . . . . . . . . . . 196
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Alternator pulleys & brackets . . . . 122, 124, 126, 128
Axles, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140-142
Fan, radiator cooling . . . . . . . . . . . 134, 136, 138, 194
Filters:
Air cleaner element . . . . . . . . . . . . . . . 109, 110, 196
Fuel (Suzuki models) . . . . . . . . . . . . . . . . . . . . . 80, 82
Oil (engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Fuel (diesel models) . . . . . . . . . . . . . . . . . . . . . . . . . 186
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Fuel system (gasoline models) . . . . . . . . . . . . . . 80, 82
Fuel system (diesel models) . . . . . . . . . . . . . . . . . . . 186
Fuel system (LPG models) . . . . . . . . . . . . . . . . . . . . . . 84
Frame,4-wheel 1-ton & 1/2 ton . . . . . . . . . . . . . . . . . 70
3-wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Fork, front (3-wheel) . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Fuel injectors . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 173
Fuses and fuse holder . . . . . . . . . . . . . . . . 66, 67, 152
B
Belts, engine:
Alternator/power steering . 100, 122, 124, 126, 128
Alternator (3-wheel) . . . . . . . . . . . . . . . . . . . . . . . . . 126
Governor . . . . . . . . . . . . . . . . . . . 122, 124, 126, 128
Timing (engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Body, Hood, Headlights (4-wheel) . . . . . . . . . . . . 64-66
Body, Hood, Headlights (3-wheel) . . . . . . . . . . . . 67-69
Brake band (automatic trans.) . . . . . . . . . . . . . . . . . . 182
Brake pedal (service) . . . . . . . . . . . . . . . . . . . 104, 106
Brake lines and master cylinder . . . . . . . . . . 104, 106
Brake fluid reservoir and bracket . . . . . . . . . 104, 106
Brakes, front and rear . . . . . . . . . . . . . . . . . . . . . . . . 144
C
Cables:
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 152, 188, 190
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Park brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Shifter (manual trans) . . . . . . . . . . . . . . . . . . . . . 90, 92
Shifter (automatic trans) . . . . . . . . . . . . . . . . . . . . . . . 94
Camshaft & components . . . . . . . . . . . . . . . . . . . . . 158
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . 62, 70, 72
Clutch assembly (automatic trans.) . . . . . . . . . . . . . . 180
Clutch cover, disc . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Clutch cover, disc (diesel) . . . . . . . . . . . . . . . . . 188-190
Clutch pedal and cable . . . . . . . . . . . . . . 108, 193,195
Cover, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Cooling System . . . . . . . . . . . . . . . . . . . . 134, 136, 138
Cooling System (diesel) . . . . . . . . . . . . . . . . . . . . . . . 194
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Cylinder block, engine . . . . . . . . . . . . . . . . . . . . . . . 156
Cylinder head, engine . . . . . . . . . . . . . . . . . . . . . . . . 155
D
Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Differential, 10.25:1 . . . . . . . . . . . . . . . . . . . . . . 140-142
Differential, 11.16:1 . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Dipstick (engine oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Dipstick (automatic trans.) . . . . . . . . . . . . . . . . . . . . . 178
Driveshaft . . . . . . . . . . . . . . . . . . . . 146, 148, 188, 190
E
Electrical connectors; components . . . . . . . 150, 152
Emissions control . . . . . . . . . . . . . . . . . . . . . . 172, 173
Engine Control Unit (ECU) . . . . . . . . . . . . . . . . 62, 150
Engine mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 96
Engine mounts (diesel) . . . . . . . . . . . . . . . . . . . . . . . 185
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Exhaust system (diesel) . . . . . . . . . . . . . . . . . . . . . . 192
G
Gaskets, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Governor (breakdown of) . . . . . . . . . . . . . . . . . . . . . . 130
Governor & throttle linkage . . . . . . . . . . . . . . 118, 120
H
Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . 64, 68, 150
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64, 68, 150
Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Hood release latch . . . . . . . . . . . . . . . . . . . . . . . 64, 68
Housing, carrier w/gears (differential) . . . . . . . 140-142
Housing, rear axles . . . . . . . . . . . . . . . . . . . . . . 140-142
Hubs, wheel: front (4-wheel) . . . 74, 78, 112, 114, 144
rear (all models) . . . . . . . . . . . . . . . . . 144
front (3-wheel) . . . . . . . . . . . . . . . . . . . 116
I
Ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Input shaft & gears: manual transmission . . . . . . . 166
Input shaft & gears: diesel . . . . . . . . . . . . . . . . . . . . 168
Input shaft & gears: automatic transmission . . . . 180
Instrument panel w/tach . . . . . . . . . . . . . . . . . . . . . . 150
Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . 160, 161
L
Leaf springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Lower ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 72
LPG fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
M
Master cylinder reservoir . . . . . . . . . . . . . . . . 104, 106
Mud flap: front . . . . . . . . . . . . . . . . . . . . . . . . . . . 64, 68
rear . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 72
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86, 192
O
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60, 156
Oil pan and dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Oil pump (engine, Suzuki models) . . . . . . . . . . . . . . . 163
Oil pump (for automatic trans) . . . . . . . . . . . . . . . . . . 179
Oil pump strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Overheat buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5
PARTS INDEX (con’t.)
Page
Page
P
Park brake, Lever and Cable . . . . . . . . . . . . . . . . . . . 88
PCV valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Planetary gears (automatic trans) . . . . . . . . . . . . . . . 181
Power steering pump . . . . . . . . . . . . . . . . . . . . . . . . 100
Pulleys, engine . . . . . . . . . . . . . . . 122, 124, 126, 128
R
Radiator . . . . . . . . . . . . . . . . . . . . . 134, 136, 138, 194
Rear platform: 1-ton & 1/2 ton (4-wheel) . . . . . . . . . . 70
3-wheel . . . . . . . . . . . . . . . . . . . . . . . . 72
Rear springs, shackles . . . . . . . . . . . . . . . . . . . . . . . . 97
S
Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Shift switch (automatic trans) . . . . . . . . . . . . . . . . . . . 179
Shifter, linkage and cables (manual trans) . . . . . 90, 92
Shifter, linkage and cables (diesel) . . . . . . . . . 188-190
Shifter, linkage and cables (automatic trans) . . . . . . . 94
Shifter gears and forks . . . . . . . . . . . . . . . . . . . . . . . 164
Shifter forks (diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Shock absorbers: rear . . . . . . . . . . . . . . . . . . . . . . . . 97
front (strut assembly) . . . . . . 74, 78
3-wheel front (strut ay.) . . . . . . . 116
Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66, 67, 150
Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Starter (manual trans) . . . . . . . . . . . . . . . . . . . . . . . . . 174
Starter (automatic trans) . . . . . . . . . . . . . . . . . . . . . . . 184
Steering wheel, Shaft & Pump (4-wheel) . . . . . . . . 100
Steering wheel, steering gear (3-wheel) . . . . . . . . . 102
Suspension, front (4-wheel w/front brakes) . . 74, 76, 78
Suspension, front (4-wheel w/o front brakes) . . . . . . 112
T
Taillight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86, 192
Thermostat . . . . . . . . . . . . . . . 134, 136, 138, 170, 171
Throttle body . . . . . . . . . . . . . . . . . . . . . . . . . . 160, 161
Throttle linkage . . . . . . . . . . . . . . . . . . . . . . . . 118, 120
Tie rods . . . . . . . . . . . . . . . . . . . . . . . . . 74, 78, 112, 114
Timing belts & cover . . . . . . . . . . . . . . . . . . . . . . . . . 159
Tires, front and rear . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Torque chart (torque specifications) . . . . . . . . . . . . . . 200
Torque converter (automatic trans) . . . . . . . . . . . . . . 148
Transmission housing (manual trans) . . . . . . . . . . . 175
Transmission housing, diesel (manual trans) . . . . . 176
Transmission housing (automatic trans) . . . . . . . . . . 177
Transmission mounts . . . . . . . . . . . . . . . . . . . . . 95, 96
Transmission mounts (diesel) . . . . . . . . . . . . . . . . . . 185
Transmission valve (automatic trans) . . . . . . . . . . . . 183
W
Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 170, 171
Water temp. sender . . 134, 136, 138, 170, 171, 194
Wire harness:
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Fan switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Fuel tank . . . . . . . . . . . . . . . . . . . . . 80, 82, 150, 186
Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Suzuki engine . . . . . . . . . . . . . . . . . . . . . . . 149, 173
Taillight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Wiring diagram (704, 706, 718) . . . . . . . . . . . . . . . . . . 202
Wiring diagram (720) . . . . . . . . . . . . . . . . . . . . . . . . . 210
Wiring diagram (726 & 727 diesels) . . . . . . . . . . . . . . . 218
Wiring schematic (704, 706, 718) . . . . . . . . . . . . . . . . 204
Wiring schematic (720) . . . . . . . . . . . . . . . . . . . . . . . . 212
Wiring schematic (726 & 727 diesels) . . . . . . . . . . . . . . 220
Wiring diagram (704LP, 706LP, 718LP) . . . . . . . . . . . . . 206
Wiring schematic (704LP, 706LP, 718LP) . . . . . . . . . . . 208
Wiring diagram (720LP) . . . . . . . . . . . . . . . . . . . . . . . 214
Wiring schematic (720LP) . . . . . . . . . . . . . . . . . . . . . . 216
While the information contained in this parts manual is based on the latest product information available at
the time of printing, the continuing accuracy of this parts manual cannot be guaranteed. Cushman, a Textron
Company, reserves the right to make changes at any time without notice.
After you identify a part by the reference number and the six digit part number (some items may have five
digits, seven digits, nine digits or some may have ten or more) always read the description of the part to
make sure it is the part you need.
When ordering parts for your vehicle, you will need to include the vehicle serial and model numbers.
!
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 operator and/or bystanders.
• 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.
6
SPECIFICATIONS
SPECIFICATIONS
Specifications subject to change without notice.
All Haulster models are equipped with either two or four wheel hydraulic service brakes, and a lever operated parking
brake integral to the rear brake drums. Three wheel brakes are available for 3-wheeled models as a factory modification only.
Some models are equipped with a 3-speed automatic transmission and some have 4-speed manual transmissions (the
manual transmissions have a low-low [creeper] 1st gear).
Wheelbase
Vehicle Weight (with fuel and battery)
Model 898704: . . . . . . . . . . . . . . . . . . . . . . . .
Model 898706: . . . . . . . . . . . . . . . . . . . . . . . .
Model 898718: . . . . . . . . . . . . . . . . . . . . . . . .
Model 898720: . . . . . . . . . . . . . . . . . . . . . . . .
Model 898704LP: . . . . . . . . . . . . . . . . . . . . . .
Model 898706LP: . . . . . . . . . . . . . . . . . . . . . .
Model 898718LP: . . . . . . . . . . . . . . . . . . . . . .
Model 898720LP: . . . . . . . . . . . . . . . . . . . . . .
Model 898726: . . . . . . . . . . . . . . . . . . . . . . . .
Model 898727: . . . . . . . . . . . . . . . . . . . . . . . .
1385 lbs (628 kg)
1582 lbs (718 kg)
1443 lbs (665 kg)
1490 lbs (687 kg)
1460 lbs (662 kg)
1620 lbs (735 kg)
1530 lbs (694 kg)
1540 lbs (699 kg)
1498 lbs (679 kg)
1572 lbs (713 kg)
Rated Load Capacity
Includes 200 lbs. (91 kg) each for the operator and passenger.
Models 704, 704LP, 706 & 706LP . . . . . . . . 1900 lbs (862 kg)
Models 718, 718LP, 720 & 720LP . . . . . . . 2400 lbs (1089 kg)
Models 898726 . . . . . . . . . . . . . . . . . . . . . . . . 1900 lbs (862 kg)
Models 898727 . . . . . . . . . . . . . . . . . . . . . . . 2400 lbs (1089 kg)
Overall Height
With Optional Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 74” (1.9m)
Without Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51” (1.3m)
Models 704, 704LP, 718, 718LP,
720, 726, 727 . . . . . . . . . . . . . . . . . . . 88.2” (2.2m)
Models 706 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.0” (2.3m)
Wheel Tread
Front: all models (except 706, 706LP) . . . . . . 42” (1.06 m)
Rear: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44” (1.1 m)
Steering
4-Wheel Models:
Automotive style 14.1 ratio Saginaw power steering and a
14 inch (355.6 mm) steering wheel.
3-Wheel Models:
Automotive style 24.1 ratio manual steering and a 14 inch
(355.6 mm) steering wheel.
Fuel
Gasoline Engines . . . . . . . . . . . . . . . . . Unleaded gasoline
87 Octane or higher
Diesel Engines . . . . . . . . . . . . . . . . . No. 2-D (ASTM D975)
(See Fuel Recommendation Section)
Battery
Models 704, 704LP, 706, 706LP, & 726 . . . . . . . . . 118.5” (3m)
Models 718, 718LP, 720, 720LP & 727 . . . . . . . . . 136” (3.5m)
Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BCI Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Size 24
Cold Cranking Amps (minimum) . . . . . . . . . . . . . . . . . 420
Reserve Capacity Minutes (minimum) . . . . . . . . . . . . . 70
Ground Terminal Polarity . . . . . . . . . . . . . . . . . . . Negative
Overall Width
Tires
All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53” (1.3m)
Front and Rear . . . . . . . . . . . . . . . . . . 20.0 x 8.50-10 4-ply
Overall Length
Cargo Area
Models 704, 706 . . . . . . . . . . . . . 47.4” x 54.5” (1.2m x 1.4m)
Models 718, 720 . . . . . . . . . . . . . . . . 47.4 x 72” (1.2m x 1.8m)
Model 726 . . . . . . . . . . . . . . . . . . . 47.4” x 54.5” (1.2m x 1.4m)
Model 727 . . . . . . . . . . . . . . . . . . . . . . 47.4 x 72” (1.2m x 1.8m)
Outside Clearance Circle
Models 704, 704LP, 718, 718LP,
720, 720LP, 726, 727 . . . . . . . . . . . . . . . . . . 20.2’ (5m)
Models 706, 706LP . . . . . . . . . . . . . . . . . . . . . . . . 18.8’ (4.8m)
Capacities
Fuel Tank (gasoline & diesel) . . . . . . . . . . 6.5 gal. (24.6 L)
Fuel Tank LPG (not included) . . . . . . 34/44 lbs. (15/20 kg)
Cooling System: Suzuki 660 . . . . . . . . . . . 3.3 qts. (3.1 L)
Perkins Diesel . . . . . . . . . . 5 qts. (4.7 L)
Crankcase (including filter): Suzuki 660 . . . 3.3 qt. (3.1 L)
Perkins Diesel 3.7 qt. (3.5 L)
Differential, Worm Gear (10.25:1) . . . . . . . . 12 oz. (0.4 L)
Differential, Hypoid (11.16:1) . . . . . . . . . . . 5.2 pt. (2.46 L)
Transmission (automatic) . . . . . . . . . . . . . . . 3.7 qt. (3.5 L)
(manual) . . . . . . . . . . . . . . . . 1.05 qt. (1.0 L)
(manual, diesel) . . . . . . . . . 1.35 qt. (1.28 L)
7
SPECIFICATIONS
SPECIFICATIONS
Specifications subject to change without notice.
ENGINE SPECIFICATIONS
Brake Fluid
Use type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dot 3
Lubrication Recommendations
Transmission Fluid (automatic) . . . . . . . . . . Mercon/Dexron II
(manual) . . . . SAE EP 80-90 Gear Lube
Differential Oil . . . . . . . . . . . . . . . . . SAE EP 80-90 Gear Lube
Pressure Gun Grease . . . . . . . . . . . . . . . . . . . . . Lithium Base
Power Steering . . . . . . . . . . . . . . . . Power Steering Fluid (GM)
Gear Ratios
Worm Gear Differential . . . . . . . . . . . . . . . . . . . . . . . . 10.25:1
Hypoid Differential (optional) . . . . . . . . . . . . . . . . . . . 11.16:1
Manual Transmission (Suzuki)
4th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3rd gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2nd gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1st gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.000:1
1.469:1
2.361:1
4.063:1
3.750:1
Manual Transmission (Diesel)
4th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3rd gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2nd gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1st gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.000:1
1.423:1
1.947:1
3.652:1
3.468:1
Automatic Transmission
3rd gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2nd gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1st gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.008:1
1.536:1
2.727:1
2.222:1
Suspension
Front:
All models (except 706 & 706LP): Independent front suspension with coil over shocks.
Models 706 & 706LP: Front suspension, automotive type
suspension pivots, two coil over shocks.
Rear:
All models: two heavy-duty muliple leaf type springs.
Suzuki 660 Engine
Horsepower (SAE hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Max. Engine Speed . . . . . . . . . . . . . . . . . . . . . . 3600 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″ cold (0.08 mm)
(intake) . . . . . . . .0047″ hot (0.12 mm)
(exhaust) . . . . .0039″ cold (0.10 mm)
(exhaust) . . . . . .0047″ hot (0.12 mm)
Spark Plug Gap . . . . . . . . . . . . . . .032-.035 (0.8-0.9 mm)
Spark Plug Number . . . . . . . . . . . . . . . . . . NGK DCPR7E
OR 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
NOTE: The engine governor controls are preset to control
engine and ground speeds to design limits.
Perkins Diesel Engine (Model 103.10 - Spec. KD70377
Horsepower (SAE hp) . . . . . . . . . . . . . . . . . . . . . . . . . 22.3
Max. Engine Speed . . . . . . . . . . . . . . . . . . . . . . 3200 RPM
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.83” (72mm)
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9” (75mm)
Displacement . . . . . . . . . . . . . . . . . . 58.2 cu in. (954 cm3)
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . 23:1
Cylinder Compression . . . . . . . . . . . 425 PSI (2,932 kPa)
Engine Rotation
(viewed from flywheel) . . . . . . . . . . . . . . Counterclockwise
Valve Clearance (intake) . . . . . . . . . .008″ cold (0.2 mm)
(intake) . . . . . . . . . . .010″ hot (.25 mm)
(exhaust) . . . . . . . .008″ cold (0.2 mm)
(exhaust) . . . . . . . . .012″ hot (.30 mm)
Ignition Timing . . . . . . . . . . . . . 22 BTDC @ 1,000 RPM
Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 950 50 RPM
Electrical
12-volt gear drive starting motor; interlock prevents starter from
operating unless clutch is depressed (manual transmissions)
or unless in Park or Neutral (on automatic transmissions).
Heavy duty 55 amp alternator; dash mounted 12-volt power
accessory plug.
8
Brakes
1/2 ton models 704, 704LP, 706, 706LP & 726 have rear
brakes only as standard, front brakes are optional.
1 ton models 718, 718LP, 720, 720LP & 727 have four
wheel brakes as standard.
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 Decals attached to the crossmember under the left-hand side of the dash (See Fig 1).
The serial number and model number are also stamped on the front-left lower ROPS (See Fig 2).
Vehicle
Identification Decals
Model and Serial No’s.
Stamped in Lower ROPS
Figure 1
Nameplate / Identification Decals
Figure 2
Serial Number And Model Number
The Nameplate/Identification Decals also give a rated load capcity. This rated capcity is the total amount of weight the
vehicle can safely handle, Never carry loads heavier than the given load capacity.
Load capacities vary depending on the vehicle model and include 200 lbs (91 kg) each for the operator and the passenger (this means if the rated load capcity is 1,900 lbs [862 kg] you can carry a 1,500 lb [680 kg] pay-load).
ENGINE IDENTIFICATION NUMBERS
Your Cushman Haulster is equipped with either a:
Suzuki 660 electronic fuel injected (EFI), 3-cylinder,
4-cycle, liquid-cooled gasoline powered engine,
Suzuki 660 electronic fuel injected (EFI), 3-cylinder,
4-cycle, liquid-cooled LPG powered engine with an
electronic fuel management system,
Serial No. Also
Hand Printed on the
Cylinder Cover
or a Perkins 3-cylinder, 4-cycle liquid-cooled diesel
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.
Figure 3
Suzuki 660 Engine Serial Number
9
VEHICLE IDENTIFICATION NUMBERS
Vehicle & Engine Identification Numbers (con’t.)
The Engine Serial No. for the Perkins diesel engine is
stamped onto a metal plate on the upper engine block
on the left side of the engine (See Fig. 4).
We recommend you immediately record all vehicle
identification numbers and keep them in a secure place
for ease of accessibility. These numbers will be used
with all correspondence concerning the vehicle.
Engine Serial No.
Perkins Diesel
Figure 4
Perkins Diesel Engine Serial Number
GAUGES, WARNING LIGHTS and CONTROLS
TACHOMETER (1)
Indicates the engine speed (x 100) in revolutions per minute (See Fig. 5).
HOUR METER (2)
The hour meter (See Fig. 5) 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. 5) indicates the amount of fuel remaining in the fuel tank.
OIL PRESSURE WARNING LIGHT (4)
The RED oil pressure light (See Fig. 5) when illuminated, indicates oil pressure is too low for engine operation.
VOLTMETER (5)
The voltmeter (See Fig. 5) 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.
1
4
5
CHECK ENGINE LIGHT (6)
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.
6
2
Figure 5
Dash Panel Identification
10
3
CONTROLS
Gauges, Warning Lights And Controls (Con’t.)
BRAKE FLUID LEVEL WARNING LIGHT (6)
This light (See Fig. 6) indicates the brake fluid level is low (the brake fluid level warning light is also used when performing
the electrical diagnostic test).
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. 6) raises above the 230F (110C) mark, a heat sensor is activated causing the
overheat warning buzzer to sound.
GLOW PLUG INDICATOR (8)
(Diesel Only)
The glow plugs must be preheated before the engine can
be started. The glow plug indicator (See Fig. 6) is wired in
the glow plug circuit and indicates when the glow plugs
are being heated and when the engine is ready to start.
Turn ignition switch to the on position, observe the glow
plug indicator (Item 8, Fig. 6). The glow plug indicator light
should go out within approximately 20 seconds. When
the light goes out, turn the ignition switch to the start position and start engine.
7
8
6
Figure 6
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. 7).
CHECK ENGINE LIGHT
(LPG Models Only)
On LPG models, the Check Engine Light (See Fig. 8) indicates when the carburation system needs adjustment. The
light, located to the left of the drivers seat, will illuminate for approximately 10 seconds when the engine is first started,
and then turn off. If the light remains on, servicing is required.
Check Engine
Light
Accessory
Power Plug
Figure 7
Accessory Power Plug
Figure 8
Check Engine Light (LPG Models)
11
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.
2. Off
3. On
1. Acc.
4. Start
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.
!
Figure 9
Four Position Ignition Switch
WARNING
• 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.
Park Brake
Lever
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. 10).
Park Brake
Lever Shown In Its
Released Position
Figure 10
Park Brake Lever
12
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.
Horn Button
HEADLIGHT OPERATION SYMBOLS
Figure 11
Horn Button and Light Switch Location
OFF
DIM
(1st Detent)
BRIGHT
(2nd Detent)
FOOT CONTROL PEDALS
CLUTCH PEDAL (Manual Transmission Only)
The clutch pedal must 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 12
Clutch Pedal Location
(Manual Transmission Only)
!
WARNING
• 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.
13
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 13
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. 14.
There is also a shift-pattern design molded into the top of
the gear selector handle.
1
N
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.
!
3
2
4
R
Figure 14
Shift Pattern (Manual Transmission)
WARNING
• 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.
14
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. 15.
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 15
Automatic Transmission Gear Selector
WARNING
• 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
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.
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
!
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.
15
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.
16
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. ALWAYS keep your windows clean and unobstructed.
19. 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.
20. 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.
21. 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.
22. ALWAYS fasten the seat belt (if equipped with ROPS) BEFORE starting the engine. Never use seatbelts unless the vehicle is equipped with a ROPS (Roll Over Protection Structure).
23. 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.
24. 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.
25. 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 headlights & brake lights
Check the radiator coolant level and radiator intake screen
Check brake fluid level.
Check the fuel level
Insure shut-off valve on LPG tank is open
Check clutch interlock (manual transmissions)
Check disable switch (automatic transmissions)
17
SERVICE & MAINTENANCE
FUEL LEVEL (Gasoline & Diesel Models)
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.
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.
• Diesel Engines - Diesel Fuel No. 2-D (ASTM D975)
Do Not use Aviation Fuel JP4
Fuel Tank Volume
The fuel tank is located on the right side of the vehicle in front of the
rear tire.
For vehicles using diesel fuel, use #1 diesel fuel (ASTM No. 1D) when temperature is 20° F (-7° C) or below; use
#2 diesel fuel (ASTM No. 2D) when temperature is above 20° F (-7° C).
If No. 1D is not available, a winterized blend of No. 1D and No. 2D may be available. This blended fuel is usually
called No. 2D and may be used in colder climates.
Never use No. 2D at temperatures below 20° F (-7° C) unless you are sure it has been winterized . Cold temperatures may cause it to thicken, which will keep your vehicle from running.
!
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. ALWAYS
wipe up spilled fuel immediately.
NEVER remove the fuel tank cap or attempt to refuel the unit while the engine is running.
NEVER refuel indoors. NEVER smoke while refueling.
NEVER operate the unit without an approved cap on the fuel tank filler opening.
Fuel hoses must be inspected frequently and replaced if excessive stiffness, deterioration or
fuel leakage is found.
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.
•
•
•
•
•
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. Gasoline containing ALCOHOL will also attract and hold moisture inside fuel tanks.
Moisture may cause corrosion of metallic parts within the fuel system.
18
SERVICE & MAINTENANCE
FUEL LEVEL (LPG Models)
The fuel gauge in the dash panel does not register LPG
fuel capacity. LPG fuel capacity is registered on a gauge
mounted on the LPG tank. Make sure to read the side of
the gauge labeled for vertically mounted tanks.
LPG Fuel Gauge
Always use UL listed industrial truck LPG fuel tank
assemblies with the following markings:
• Tank type: Universal/Vertical
• Disconnect couplings: Rego 7141M
• Capacity: 34/44 lbs.
• Fuel withdrawl: Liquid
LPG Liquid
Service Valve
Insure LPG tank is secure and installed properly.
Open the LPG tank valve all the way (counter-clockwise)
prior to starting the engine.
Figure 16
LPG Fuel Guage and Service Valve
For prolonged or long term storage, turn the tank shut off
valve all the way off (clockwise).
!
WARNING
• LPG fuel is extremely flammable and highly explosive under certain conditions.
• LPG is pressurized in the tank. Use extreme caution when handling LPG tanks.
• NEVER vent an LPG tank to the atmosphere. The sudden expansion of gas will cause frosting at
•
•
•
•
•
•
the outlet, which can cause injury.
ALWAYS turn the engine off to refuel.
ALWAYS refuel in a well ventilated area. NEVER allow open flames near the tank.
NEVER smoke while refueling.
NEVER operate the unit without the LPG tank properly secured.
LPG is heavier than air and will settle in low areas and on clothing causing potentially dangerous conditions. Avoid open flames, which can cause flash fires.
When changing the tank, check all connection for damage and leaks.
OIL LEVEL (Engine)
Make sure vehicle is parked on a level surface with the park brake applied. Always turn the engine off when checking
the oil level. Oil level should be checked daily.
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.
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).
19
SERVICE & MAINTENANCE
Engine Oil Level (con’t.)
NOTE: If you notice the oil pressure warning light
coming on while driving the vehicle, Stop the
vehicle and check for problems.
Engine
Oil Fill Cap
Oil Pressure Light
Figure 19
Oil Fill Cap (Suzuki Engine)
Figure 17
Oil Pressure Warning Light
The oil level should always be between the ADD and
FULL mark on the dipstick. DO NOT OVER FILL.
Engine Oil
Dipstick
If the oil level is below the add mark, add an SAE 10W-30
oil to bring the level up between the marks.
OIL DIPSTICKS MAY
VARY IN APPEARANCE
OIL LEVEL MUST
BE BETWEEN THE MARKS
Figure 20
Dipstick Location (Suzuki Engine)
ADD OIL IF THE LEVEL
IS AT OR BELOW THIS MARK
DO NOT
OVERFILL
Figure 18
Oil Level Reading
Engine
Oil Fill Cap
Dipstick
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
Engine Oil Capacity, Suzuki 660 . . . . . 3.3 qts. (3.1 L)
Engine Oil Capacity, Perkins Diesel . 3.8 qts. (3.6 L)
20
Figure 21
Dipstick & Oil Fill Location (Perkins Diesel)
SERVICE & MAINTENANCE
Engine Oil Level (con’t.)
Engine oil and filter changed as follows:
Suzuki 660
Suzuki 660 . . . . . . . . . after first 50 hours (or 500 miles)
then every 100 hours* (or 3 months) thereafter
Perkins Diesel . . . . . after first 35 hours (or 350 miles)
then every 75 hours* (or 2 months) thereafter
* Depending on operating conditions the oil and filter may
require more frequent changing.
SAE 10W-30 for all temperature ranges
°F
–20
°C –30
0
–20
20 32 40
–10
0
10W-40
60 77 80
10
20 25 30
100
40
Temperature Range Anticipated Before Next Recommended Oil Viscosity Change
Engine Oil Replacement Filters:
Suzuki 660 . . . . . . . . . . Order Part No. 2701908
Perkins Diesel . . . . . . . Order Part No. 842553
RADIATOR COOLANT LEVEL
The vehicle is equipped with a cooling radiator, electric cooling fan and a water temperature gauge with overheat
buzzer. Unlatch the engine cover and tilt forward to gain access to the radiator.
!
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.
Radiator And Radiator Fins Are
Located Behind The Screen
• DO NOT obstruct or cover the intake screen in front
of the radiator. Keep the fins and radiator screens
clean.
• 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.
Figure 22
Intake Screen (Right Side of Vehicle)
The cooling system level and the intake screen should be checked every day before vehicle operation.
21
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.
ADDING ANTI-FREEZE TO THE COOLING SYSTEM
Remove the radiator cap and check the coolant level in the
radiator, the coolant should be at, or with-in a 1/4” (6 mm)
from the neck of the filler port (if coolant is needed, add a
50/50 anti-freeze/water mixture using the procedures
stated below).
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.
!
WARNING
• ALWAYS make sure the engine is stopped
and cool before removing the radiator cap.
To prevent scalding by hot coolant, NEVER
remove cap while radiator is hot.
Unless the radiator is very low, always add coolant to the overflow reservoir not to the radiator.
With the park brake applied and the gear selector in park (automatic transmissions) or neutral (manual transmissions) start the engine and let idle.
Remove the overflow reservoir cap, add the anti-freeze mixture to the overflow bottle until the coolant level reaches
approximately 4” (102 mm) in the bottle, replace reservoir cap.
If the radiator level is very low, add the anti-freeze mixture directly to the radiator until it reaches approximately 1/4”
(6 mm) from the bottom of the filler neck, then start the engine and add mixture to the overflow reservoir until proper
level is reached.
DRAINING & REFILLING THE COOLING SYSTEM
Cooling system should be drained and refilled every 12 months or 600 Hrs.
Capacity Suzuki Cooling Systems: 3.3 qts. (3.1 L)
Capacity Diesel Cooling Systems:
5 qts. (4.7 L)
To Drain The Cooling System:
Disconnect the negative (–) battery cable or remove the electric cooling fan fuse (See Figs. 23 & 24).
Cooling Fan
Fuse (25 amp.)
Figure 23
Electric Cooling Fan Fuse (Diesel Models)
22
Radiator Fan
Fuse
(25 amp Fuse)
Figure 24
Electric Cooling Fan Fuse (Suzuki Models)
SERVICE & MAINTENANCE
Radiator Coolant Level (con’t.)
1. After the engine has cooled, remove the radiator cap and open the drain cock at the bottom of the radiator.
2. Remove the lower radiator hose to completely drain the engine block.
NOTE: Most communities have disposal and/or recycling sites for products such as these. Please drain
coolant into an approved container and dispose of properly.
!
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 cooling fan fuse.
3. Drain the coolant from the reservoir bottle. Remove the overflow hose from the bottom of the bottle to drain
coolant from reservoir or remove the overflow hose connected to the neck of the radiator fill port.
4. After radiator and engine block have drained, connect the lower radiator hose to the radiator and any other
hoses you may have removed.
Check all radiator hoses and connections for leakage, cracking and brittleness. Replace if necessary.
To Refill The Cooling System
(Suzuki Models)
1. Fill radiator to the bottom of the filler neck with a
50/50 mixture of antifreeze and water.
Bleeder Bolt For
Model 720 Will Be
Located on This Side
2. Fill reservoir bottle to the FULL mark with the antifreeze/water mixture.
3. Loosen the air bleeding bolt (See Fig. 25) until coolant
begins to come out through the hole in the bleeder
bolt. Once coolant begins to leak from the hole,
retighten the bolt.
Cooling System
Bleeder Bolt
4. Run the engine with the radiator cap removed until
the upper radiator hose becomes warm.
5. Add coolant until it stays level with the bottom of the
filler neck. Install radiator cap.
Figure 25
Loosen Air Bleeder Bolt (Suzuki Models Shown)
To Refill The Cooling System
(Diesel Models)
1. Fill radiator to the bottom of the filler neck with a 50/50 mixture of antifreeze and water.
2. Fill reservoir bottle to the FULL mark with the antifreeze/water mixture.
3. Run the engine with the radiator cap removed until the upper radiator hose becomes warm.
4. Add coolant until it stays level with the bottom of the filler neck. Install radiator and reservoir caps.
NOTE: Never add straight anti-freeze to the radiator. Make a 50/50 mixture of anti-freeze and water in a separate
container before adding coolant to the system. The mixture must never be more than 50% anti-freeze.
Always recycle or dispose of used antifreeze in a responsible manner. Used antifreeze can be harmful to the
environment.
23
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, procede with the following
procedures:
WATER TEMP
GAUGE
1. STOP the vehicle, DO NOT STOP THE ENGINE.
2. Immediately disengage any accessories that are
operating.
Figure 26
Water Temperature Gauge
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:
5. 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).
6. 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.
7. Check oil engine level.
8. Check radiator and coolant reservoir levels.
Failure to: (1) heed the overheat warning and
(2) maintain cooling system, can cause permanent damage.
!
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 coolant,
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.
24
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).
!
WARNING
• 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.
!
WARNING
• 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 unexpected vehicle movement could cause serious personal
injury or death.
25
OPERATING THE VEHICLE
Starting The Engine, Gasoline Engines (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)
STARTING THE ENGINE (LPG 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 tank fitting is tightened securely.
Open the LPG service valve by turning the knob
counter-clockwise. Check for odors or frost on the
tank, near the vent and around the fitting (frost could
indicate a LPG leak).
LPG Fuel Gauge
3. 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.
4. 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).
!
LPG Liquid
Service Valve
Figure 27
LPG Fuel Guage and Service Valve
WARNING
• 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 unexpected vehicle movement
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.
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.
26
OPERATING THE VEHICLE
Starting The Engine, LPG Engines, Automatic Transmission (con’t.)
NOTE: The “Service Engine Soon” light (located on left side control panel) will come on and remain illuminated for
approximately 10 seconds after starting the engine. This is normal opertaion.
If the light does not illuminate during engine startup, or remains on longer than 10 seconds, the LPG
system requires service. Contact your authorized Cushman dealer for service.
6. 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. Make sure the tank fitting is tightened securely.
Open the LPG service valve by turning the knob
counter-clockwise. Check for odors or frost on the
tank, near the vent and around the fitting (frost could
indicate a LPG leak).
LPG Fuel Gauge
3. Move the gear selector to “NEUTRAL”.
4. 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).
5. 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).
LPG Liquid
Service Valve
Figure 28
LPG Fuel Guage and Service Valve
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.
!
WARNING
• 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 unexpected vehicle movement could cause serious personal
injury or death.
6. 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.
27
OPERATING THE VEHICLE
Starting The Engine, LPG Engines, Manual Transmission (con’t.)
NOTE: The “Service Engine Soon” light (located on left side control panel) will come on and remain illuminated for
approximately 10 seconds after starting the engine. This is normal opertaion.
If the light does not illuminate during engine startup, or remains on longer than 10 seconds, the LPG
system requires service. Contact your authorized Cushman dealer for service.
7. Allow engine to warm-up before driving the vehicle (always idle and warm-up the engine for at least one minute)
STARTING THE ENGINE (Diesel Engines)
Manual Transmission
The diesel engine uses glow plugs to pre-heat the combustion chamber and makes cold engines start easier. Do Not
use ether or starting fluid with diesel engines. Severe engine damage can occur.
When starting a new diesel engine for the first time, or after prolonged storage, or if the fuel tank is allowed to
run dry, the fuel system must be purged before attempting to start the engine (refer to Purging the Diesel Fuel
System).
When starting the vehicle for the first time during the day or when the engine has cooled, you will need to preheat the glow plugs in order to start the engine.
If the engine has been running and is still hot, it is not necessary to pre-heat the glow plugs before starting the
engine.
1. Apply the park brake (the parking brake should have been applied when the vehicle was last parked).
2. Move the gear selector to “NEUTRAL”.
3. 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.
!
WARNING
• 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.
4. Turn the ignition key to the ON position. Note the pre-heat light at the lower left of the instrument panel.
The light will come on when the ignition switch is turned to the “ON” position. When the pre-heat light goes off,
turn the ignition key to the “START” position.
Proper pre-heating time required is approximately 15 seconds. Pre-heating will take longer (approximately
30 seconds) when outside temperature falls below 32° F (0° C).
Preheating time should never last more than 2 minutes or the life of the glow plugs will be shortened.
28
OPERATING THE VEHICLE
Starting the Diesel Engine (manual transmission con’t.)
5. 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.
• The starter motor should never be run for more than 30 seconds.
• After the engine has started, make sure the oil pressure warning and service brake warning lights go off.
6. Allow engine to warm-up before driving the vehicle (always idle and warm-up the engine for at least one minute)
Check for abnormal noises such as knocking and excessive vibration
Knocking sounds will be heard while the engine is cold, during quick acceleration and while idling.
Knocking sounds will not be heard during normal operation.
Confirm the exhaust smoke is seen as follows:
While engine is cold: White smoke
When engine is warm and during normal operation: Almost smokeless
When engine is heavily loaded: Some black smoke
Starting under sub-freezing conditions:
•Make sure correct weight engine oil is used.
•Make sure the battery is fully charged.
•Pre-heat glow plugs for the correct length of time.
•Make sure cooling system is tested safe for the ambient temperature.
PURGING THE DIESEL FUEL SYSTEM
The fuel system must be purged when:
• Starting a new diesel engine for the first time
• The fuel tank is allowed to run dry
• After prolonged storage
• The fuel filter and/or fuel lines have been loosened, removed or replaced
Purge the fuel system using one of the procedures
as follows:
Purging Fuel System Using A Jumper Wire
1. Turn the ignition key to the off position.
2. Disconnect the white/red wire form the starter coil.
!
Disconnect Red/White Wire
From Starter Coil
WARNING
• Failure to remove this wire may result in the
starter engaging causing the vehicle to move.
This movement could result in personal injury
and/or property damage.
Figure 29
Purging Diesel Fuel System
29
OPERATING THE VEHICLE
Purging the Diesel Fuel System (con’t.)
3. Clip one end of a jumper wire to the EXC terminal on the back of the alternator as shown in Figures 30 & 31
(this terminal will have a green wire connected to it).
4. Clip the other end of the jumper wire to the “I” terminal on the starter solenoid (See Figs. 30 & 31).
“i” Terminal On The
Starter Solenoid
Connect To
“exc” Terminal
Connect Jumper Wire
To “i” Terminal
“exc” Terminal
On The
Alternator
Figure 30
Connect Jumper Wire to Alternator & Solenoid
Figure 31
Terminal Locations
5. Open the bleeder port located on top of the fuel injector (See Fig. 32).
Bleeder
Port
6. Turn the ignition key to the “ON” position (the fuel
pump will begin to pump).
When the fuel pump is pumping fuel only, the “thumping” sound will become more of a “purring” sound,
when this occurs tighten the bleeder port.
Turn the ignition key to the “OFF” position, remove the
jumper wire and reconnect the white w/red wire onto
the starter coil.
Figure 32
Bleeder Port Location
PURGING FUEL SYSTEM WITHOUT THE USE OF A JUMPER WIRE
Fuel system bleed may be accomplished using the glow plug timer if no jumper wire is available.
The fuel pump will energize for approximately 20 seconds during start-up from the glow plug pre-heat timer.
1. Open the bleeder port on top of the fuel injector (See Fig. 32).
Turn the ignition key to the “ON” position. The fuel pump will be activated for about 20 seconds until the glow plug
timer stops.
When the timer stops, turn the key to the “Off” position then turn it back to the “ON” position, the fuel pump will run
again for approximately 20 seconds, when the glow plug timer stops, turn the key off again. Continue with this
procedure until the system is purged. When the fuel pump is pumping fuel only, the “thumping” sound will be
more of a “purring” sound, when this occurs, tighten the bleeder port.
30
OPERATING THE VEHICLE
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 33
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 the appropriate gear using the gear selector lever.
The gear selector has an “H” pattern as shown in Fig. 34 (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 gently depressing the throttle pedal.
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
2
4
R
When selecting the forward direction, begin with 1st or
2nd gear shifting to the next higher gear as the vehicle
gains speed.
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 34
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.
31
OPERATING THE VEHICLE
Driving the Vehicle, Manual Transmission (con’t.)
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).
!
WARNING
• 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.
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 35).
32
Figure 35
Vehicle parked With Front Wheel(s) Curbed
OPERATING THE VEHICLE
Stopping, Parking (Leaving) the Vehicle (con’t.)
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 35).
TOWING A TRAILER (Using the Trailer Hitch)
A rear bumper and a tow hitch accessory are available for use with this vehicle. If the rear bumper and tow hitch
accessories have been installed, 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 object) so it cannot fall out of the mounting hole.
Remember, use caution and good judgement when towing a trailer or equipment. Adjust vehicle speed according
to surface conditions and terrain, ie. wet, hilly, etc. Never use excessive speed when towing an object.
!
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.
• 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.
TIRE REMOVAL 4-Wheel Front & Rear and 3-Wheel Rear
With the vehicle on a flat level surface (if possible), put the gear selector in first gear 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.
33
OPERATING THE VEHICLE
Tire Removal, 4-Wheel Front & Rear and 3-Wheel Rear (con’t.)
2. Install the tire and wheel by reversing the above
sequence. Make sure valve stem is located
toward the outside.
3. Tighten wheel retaining nuts to 70 to 100 ft. lbs.
(95 to 140 N·m) torque.
Wheel
Retaining Nut
Valve Stem
!
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 36
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.
With the vehicle raised and properly supported, remove
the brake link anchor bolt and bushing. Retain hardware.
BRAKE LINK
ANCHOR BOLT
BRAKE HOSE
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.
AXLE NUT AND
RETAINING WASHER
Figure 37
3-Wheel Front Tire Removal
Install the tire and wheel by reversing the above sequence.
Tighten the wheel retaining nuts to 70 to 100 ft. lbs. (95 to 140 N·m) torque.
34
OPERATING THE VEHICLE
TIRE REPLACEMENT
When tire replacement is neccessary, you can either obtain a tire from a local retailer and have it mounted to the rim
or, you can order the complete wheel assembly through your Cushman dealer.
If acquiring the wheel assembly through your Cushman dealer, order Part No. 894785.
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
20.5-8.00 X 10 (4 PLY) . . . . . . . . . . 50 PSI (345 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.
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 release the front cowl latch:
4-Wheel Models
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
3-Wheel Models
While facing the front of the vehicle, locate the release
lever near the upper center 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.
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.
Open the cowl allowing it to rest against the rops structure
(if equipped) or the steering wheel.
Front Cowl
Release Lever
Figure 38
Release Lever For Front Cowl
(4-Wheel Model Shown)
35
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.
DIAGNOSTIC CHECK (Electrical System)
Suzuki 660 EFI Models Only
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. 39).
NOTE: Some models may have two (2) connectors leading from the wire harness and
some may have one. Please follow the instructions with the Diagnostic Jumper
Accessory (Part No. 2700920) for your appropriate application.
To run the diagnostic test, 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. 40).
Diagnostic Check Light
(Also Brake Fluid Level Warning)
Existing
Plug-in Connector
From Wire Harness
Diagnostic
Jumper
Models With One
Connector Shown
Figure 39
Diagnostic Jumper Shown Connected
36
Figure 40
This Light Will Flash For Diagnostic Check
SERVICE & MAINTENANCE
Diagnostic Check, Electrical System (con’t.)
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.
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.
37
SERVICE & MAINTENANCE
FUSES
The fuses protect the electrical lighting circuits and accessory circuits such as the windshield washers, turn signals
etc.
The main fuse panels are located under the front cowl as shown in Figures 41 and 42 (Suzuki models have three fuse
panels; diesel models have two ).
!
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.
To Remove and Install Fuses:
Pull straight out to remove a fuse. To install a fuse, push the new fuse into the appropriate fuse slot.
Fuse Panels
Suzuki 660 Models
Figure 41
Fuse Block (Suzuki Models)
Fuse Panels
Diesel Models
Figure 42
Fuse Block (Diesel Models)
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.
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 connection, broken
wire, improper connections and so on.
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.
38
SERVICE & MAINTENANCE
Fuses (con’t.)
Diesel models also have a couple of other locations which fuses can be found. One is for the engine wire harness and
one is for the radiator cooling fan. These fuses are located in the lower right of the engine compartment, near the
lower portion of the air cleaner (See Fig. 43).
There are also a couple of relays used for the diesel models. Some vehicles may have a relay mounted to the top right
of the cooling fan (See Fig. 44), and some vehicles will have one mounted to each side of the lower portion of the cooling
fan (similar to the location shown in Figure 44 but only on the bottom side of the cooling fan).
Relay
Fan Relay
Fuse (25 amp.)
Engine Harness
Fuse (40 amp.)
Some Relays are Located on the
Lower Portion of the Cooling Fan
Figure 44
Relay Location (Some Diesel Models)
Figure 43
Engine Harness and Fan Relay Fuses (Diesel Models)
Fuse panels shown left to right as they would
appear mounted to the firewall (viewed from the
front of the vehicle).
Fuel Relay
Glow Plugs
Diesel Models Shown
ACC
Power Port
Shift
Switch
15
Instrument
Panel
10
Accy. Plug
Heater
20
Turn
Signals
10
Accy. Plug
15
10
Headlights
10
Wiper,
Dome light
Horn
10
Taillights
Trailer Lights
Accy. Plug
Suzuki Models Shown
ACC
Power Port
Taillights
Trailer Lights
Engine
Coils
15
ECU
15
15
Fuel Relay
10
Headlights
Brake Lights
Heater
10
Turn
Signals
10
Engine
Injectors
20
ECU
15
Accy. Plug
Accy. Plug
10
Instrument
Panel
Back-up
Alarm
Main Relay
10
5th Wheel Brake
Horn
Radiator
Fan
10
Wiper,
Dome light
ECU
10
Shift
Switch
Accy. Plug
39
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. 45).
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 41 for bulb specifications.
Bulb And
Holder
Rotate 1/4 Turn
Figure 45
Dash Panel Bulb Removal
HEADLIGHT REPLACEMENT
Remove the four (4) screws securing the headlight
bezel to the front cowl (See Fig. 46).
Headlight
Bezel
Remove The Four (4) Screws For
Headlight Removal
Figure 46
Headlight Removal
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.
Headlight . . . . . . . . . . . Part No. 837303
Bezel . . . . . . . . . . . . . . . Part No. 841428
Mounting Screws . . . Part No. 800943
TAILLIGHT REMOVAL and
BULB REPLACEMENT
To replace the taillight:
Remove the taillights from the platform frame by pushing
on the back side of the light assembly. Push near the
corners of the light, not the center. The taillight will
come out as one assembly (there is no hardware securing the taillight assembly to the platform).
With the taillight removed, disconnect the electrical connectors and install the new taillight. When installing the
assembly back onto the platform frame, make sure the
metal edges of the frame are properly seated into the
grooves on the rubber seal.
Taillight Assembly . . Part No. 892676
40
Figure 47
Taillight Removed From Platform Frame
(Shown With Lens Cover Removed)
SERVICE & MAINTENANCE
Taillight Removal And Bulb Replacement (con’t.)
To replace only the taillight bulb:
The taillight does not have to be removed in order to change the bulb. Push back the rubber seal along the edges of the
lens cover beginning near one of the corners. Continue working the rubber seal until the lens cover can be removed.
If necessary, when the rubber seal is pried away far enough to expose the edge of the lens cover, insert a small wood
wedge or similar device, between the lens cover and seal, then continue working around the seal until the cover can be
removed. Do Not use a screwdriver or other metal objects to pry the lens cover out, damage to the lens cover can
occur.
Remove the bulb and replace with a new No. 1157 bulb. Install the lens cover.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . Part No. 836892
15 AMP . . . . . . . . . . . . . . . . . . . . . . . . . . Part No. 849983
20 AMP . . . . . . . . . . . . . . . . . . . . . . . . . . Part No. 826000
25 AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part No.
30 AMP . . . . . . . . . . . . . . . . . . . . . . . . . . Part No. 833038
FLASHER: Turn signal (accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part No. 825501
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. 48).
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 48
Dash Panel Dipswitch Location
SEQUENCE CODE 0 0 0 1 0 1 1 0
SEQUENCE CODE 0 1 0 1 0 1 1 0
MODELS: All 700 Series Suzuki’s
MODELS: 898726 & 898727
41
SERVICE & MAINTENANCE
ACCESS PANELS
There are three access panels; two (2) located under the
front hood and one located in the middle of the floorboard.
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.
To remove any of the panels, simply remove the hardware
securing the panel and remove panel.
Access Panel
Access Panel
3-Wheel
Model Shown
Figure 50
Access Panels Under Front Hood (3-Wheel)
Floorboard
Access Panel
Access Panel
Access Panel
4-Wheel
Model Shown
Figure 49
Access Panel on Floorboard
Figure 51
Access Panels Under Front Hood (4-Wheel)
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. When washing becomes necessary, it can be carried out simultaneously when servicing the vehicle.
!
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.
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.
42
SERVICE & MAINTENANCE
Access To Engine
Checking and Installing the Element
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).
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 52
Engine Cover Latch
RETAINING TAB
IN SLOT ON
FLOORBOARD
Figure 53
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.
We DO NOT recommend cleaning the filter element because of the possibility of damaging the element.
Air Cleaner Complete . . . . . . . . . Part No. 892679
Air Cleaner Element . . . . . . . . . . Part No. 840352
Tilt the engine cover forward and locate the air cleaner on the right rear of the engine (See Fig. 54).
To remove the air cleaner element release the latches securing the cover to the air cleaner assembly. Remove the
filter element.
Check the element for damage, pin holes, etc. by placing a light source such as a flashlight inside.
43
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.
ELEMENT
Insert element in housing open end first.
Position the cover so that the collector is pointing down.
Clamp cover into position with collector pointing down (the
dust collector empties automatically when properly
installed with collector down).
DUST COVER
• DO NOT use bent or dented air cleaner assemblies.
DUST COLLECTOR
• DO NOT use bent or damaged air cleaner element.
Figure 55
Air Cleaner Element and Dust Cover
(Shown Removed From the Housing)
Alternator
!
Air
Cleaner
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
has not cooled.
Figure 54
Air Cleaner Assembly (Suzuki Models Shown)
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.
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.
44
Power Steering
Reservoir
Figure 56
Power Steering Reservoir (Suzuki Model Shown)
SERVICE & MAINTENANCE
BATTERY
!
WARNING
• California Proposition 65 Warning: Engine exhaust, some of its constituents, and certain vehicle
components contain or emit chemicals known to the State of California to cause cancer, birth
defects or other reproductive harm.
• Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands
after handling.
• 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.
The battery is located behind the engine cover screen on the left side of the vehicle.
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.
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 Location
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.
The voltmeter is located on the dash panel as shown in
Figure 5 on Page 10.
Figure 57
Battery Location For Industrial Vehicles
(Side Screen Removed))
JUMP STARTING WITH A BOOSTER BATTERY
!
•
•
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.
45
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.
46
!
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.
SERVICE & MAINTENANCE
Towing the Vehicle, Automatic Transmission (con’t.)
Attach a tow line (tow line attaching locations are shown in Fig. 58)
only to the front vertical frame member of the vehicle.
TOW LINE ATTACHMENT
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 58.
Make sure the drive transmission is in “neutral” (out of gear) and
the park brake is released.
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 58
Tow Line Attachment Location
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. 59) and place a block behind (or in front) of the tire diagonally
opposite the side which is being raised (See Illustration on following page).
47
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 59
Jacking Locations
Block Tire Here
If Using Jack Here
Block Tire Here
♦
♦
♦
If Using
Jack Here
If Using Jack Here
♦
Block Tire Here
48
If Using Jack Here
♦
Block Tire Here
♦
SERVICE & MAINTENANCE
BRAKES
Service Brakes
This vehicle is equipped with hydraulic brakes and a hand operated park brake lever.
Keep your brake system clean and properly maintained.
If the brakes Do Not stop the vehicle properly, they must be repaired before the vehicle is operated again.
!
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.
The brake fluid master cylinder reservoir is located under the front cowl.
If the brake fluid level indicator light (See Fig. 61) comes on and remains on, check the brake fluid level in the reservoir.
This light also functions as the “Check Engine” light, if the brake fluid level is correct but the light remains
on, run an engine diagnostic test to help determine the cause of the problem.
Brake Fluid
Reservoir
Brake Fluid Level
Indicator Light
Figure 60
Brake Fluid Reservoir
Figure 61
Brake Fluid Level Indicator Light
The fluid level must be kept within the MIN (minimum)
and MAX (maximum) levels as shown in Figure 62. 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.
Fluid Level
Figure 62
Brake Fluid Level Reading
The following instructions will assist with bleeding the brake system.
49
SERVICE & MAINTENANCE
Brakes, Service Brakes (con’t.)
Bleeding a 4-Wheel Brake System
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.
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
Figure 63
Bleeder Screw on Top of Dust Shield
(4-Wheel Front & Rear; 3-Wheel Rear)
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.
Bleeding the 3-Wheel Brake System
For 3-wheel brakes, do the left rear, right rear, then the front (if vehicle is equipped with front brakes)
Attach a hose to the bleeder screw (See Fig. 64) 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
and finally the 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.
50
Figure 64
3-Wheel Front Bleeder Screw
SERVICE & MAINTENANCE
PARK BRAKE
Park Brake Adjustment
Raise the engine cover and locate the park brake cable and bracket beneath the console panel (See Fig. 66).
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 fully applied.
Park Brake
Lever
Park Brake
Adjustment Nut
Park Brake Lever
Shown In
Released Position
Figure 65
Park Brake Lever Location
Figure 66
Park Brake Adjustment Nut
DRIVE TRANSMISSION
Manual Transmission
Check transmission fluid level every 100 hours (or 3 months).
Change transmission fluid every 600 hours or (12 months).
Transmission Capacity: Suzuki Engine Models
Diesel Engine Models
1.05 qts. (0.9 L)
1.35 qts. (1.28 L)
Recommended Lubricant: SAE EP 80-90 Gear Lube
The filler plug is located on the left rear side of the transmission. When removed, the filler plug opening is used to
determine proper fluid level.
!
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.
• 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.
51
SERVICE & MAINTENANCE
Drive Transmission, Manual (con’t.)
The fluid level must be level with the bottom of the filler plug hole.
If level is low, add the appropriate lubricant (through the filler hole) until it begins to flow from the filler hole.
To drain the transmission fluid, remove the drain plug on the rear of the transmission.
Use a pipe thread sealant on the drain and filler plug threads before reinstalling.
Fill Plug
Drain Plug
Fill Plug
Drain
Plug
Figure 67
Transmission Drain and Fill Plug
Figure 68
Transmission Drain and Fill Plug
(Suzuki 660 EFI Engine)
(Perkins Diesel Engine)
Automatic Transmission (Suzuki 660 Engine)
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.
Transmission Fluid
Dipstick
And Fill Tube
Figure 69
Automatic Transmission Dip Stick
52
Drain Plug
Automatic Transmission
Figure 70
Automatic Transmission Drain Plug
SERVICE & MAINTENANCE
DIFFERENTIAL (10.25:1)
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 . . . . . 12 oz (0.4 L)
Fluid Type . . . . . . . . SAE EP 80-90 Gear Lube
IMPORTANT!
TO AVOID EXPENSIVE REPAIR, DIFFERENTIAL LUBRICANT SHOULD BE
CHANGED ACCORDING TO THE MAINTENANCE GUIDE SCHEDULE.
!
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.
• 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.
To check fluid level, remove the filler plug from the rear 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).
Use a pipe thread sealant on the threads of the filler plug
and replace plug.
To drain the differential fluid, remove the drain plug from
the bottom of the differential and drain. Use a pipe
thread sealant on the threads of the plug, replace plug
and add fluid to the recommended level.
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.
10.25:1
Differential
Filler Plug
Drain Plug
Figure 71
Differential Filler and Drain Plug
DIFFERENTIAL 11.16:1 (Optional)
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).
53
SERVICE & MAINTENANCE
Differential 11.16:1 (con’t.)
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.
Drain Plug
Level Check
And Fill Plug
Figure 72
Figure 73
11.16:1 Differential Fill and Level Check Plug
11.16:1 Differential Drain Plug
GOVERNOR OIL LEVEL (Suzuki Engine Models)
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 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.
Torque the plugs to 95 ± 10 in.lb.
54
Governor Oil
Fill Plug
Governor Oil
Level Check Plug
Figure 74
Governor Fill and Level Check Plugs
SERVICE & MAINTENANCE
ROPS (Roll Over Protection System)
A roll over protection system (ROPS) with seatbelts is an
available option for this vehicle. A ROPS is advisable
when vehicle height clearance is not a concern. ROPS
can provide protection in the event of vehicle rollover,
provided the operator is wearing a properly fitted seatbelt.
See your authorized Cushman Dealer to order this
option. Part No. 894761, (ROPS) Roll Over Protection
System (includes seatbelts).
Figure 75
Roll Over Protection System (ROPS)
!
WARNING
A ROPS can help provide protection against bodily injury in the event of a vehicle rollover,
provided the seatbelts are properly used.
Seatbelts MUST BE installed with the ROPS upper frame.
Seatbelts MUST BE worn at all times when operating a vehicle with the ROPS accessory.
DO NOT use seatbelts unless vehicle is equipped with a ROPS.
If the vehicle is equipped with a ROPS accessory, the seatbelts must always be worn to avoid being thrown from the
vehicle in case of rollover.
The seatbelt and ROPS warning decals are located on the inside, upper left of the ROPS frame (See Fig. 76).
Seatbelts should be worn snuggly on the lower hips as shown in Figure 77.
Figure 76
Seat Belt & ROPS Warning Decals
Figure 77
Seat Belt (Included With ROPS)
55
SERVICE & MAINTENANCE
CHANGING PROPANE CYLINDERS
Always use UL listed industrial truck LPG fuel tank assemblies with
the following markings:
•
•
•
•
Tank type: Universal/Vertical
Disconnect couplings: Rego 7141M
Capacity: 34/44 lbs.
Fuel withdrawl: Liquid
!
WARNING
LPG fuel is extremely flammable and highly explosive under certain conditions.
LPG is pressurized in the tank. Use extreme caution when handling LPG tanks.
Never vent an LPG tank to the atmosphere. The sudden expansion of gas will cause frosting
at the outlet, which can cause personal injury.
Always turn the engine off to refuel. Always refuel in a well ventilated area.
Never allow open flames near the tank. Never smoke while refueling.
Never operate the unit without the LPG tank properly secured.
!
WARNING
LPG is heavier than air and may settle on clothing and on the ground near the unit. Avoid
open flames, which can cause flash fires.
When changing the tank, check all connections for damage and leaks.
Disconnecting Propane Cylinders
Always wear proper eye protection and use gloves that will not absorb propane to protect your hands from the
possible effects of escaping liquid propane.
Close the service valve on the tank and allow the engine to run until it stops to evacuate all fuel from the lines.
Turn off the ignition.
Unfasten the quick-connect coupler slowly. Be aware that there may be a momentary escape of gas.
NOTE: If gas continues to escape after the couplings have been disconnected, and
the connector cannot be retightened, close the valve and immediately leave
the area. Call emergency response personnel immediately.
Unlatch the cylinder mounting strap.
Put the empty cylinder in the proper location. Be careful lifting. Remember to move your feet, don’t twist your
body. Never drop, throw or otherwise mishandle propane cylinders, regardless of whether they are full or empty.
If you discover any problems with a cylinder, make sure that the cylinder is immediately taken out of service and
tagged with the defective cylinder tag, stating the nature of the defect.
56
SERVICE & MAINTENANCE
Connecting Propane Cylinders
Always use gloves that will not absorb propane liquid. This will help protect your hands from the possible effects of
escaping liquid propane.
Obtain a full cylinder from the storage area and move it to another area, away from the rest of the cylinders.
!
WARNING
LPG fuel is extremely flammable and highly explosive under certain conditions.
LPG is pressurized in the tank. Use extreme caution when handling LPG tanks.
Never vent an LPG tank to the atmosphere. The sudden expansion of gas will cause frosting
at the outlet, which can cause personal injury.
Always turn the engine off to refuel. Always refuel in a well ventilated area.
Never allow open flames near the tank. Never smoke while refueling.
Never operate the unit without the LPG tank properly secured.
!
WARNING
LPG is heavier than air and may settle on clothing and on the ground near the unit. Avoid
open flames, which can cause flash fires.
When changing the tank, check all connections for damage and leaks.
In a well lit area, look into the male quick connector at an angle to make sure that the washer and o-ring are in place and
that they are not scarred, cut, gouged or work-hardened. Keep your hands away from the service valve while performing this inspection. If the washer is missing, or the o-ring damaged or missing, they may be replaced. If a cylinder fails
this check, be sure to immediately take the cylinder out of service and tag it as to its defect.
Outdoors and with the valve opening pointing away from any person or source of ignition, perform a safety check of the
valve by quickly opening and closing the liquid service valve. Do not use the cylinder if there is a burst of gas from the
valve during the safety check. If a cylinder fails this check, be sure to immediately take the cylinder out of service and
tag it as to its defect. Do Not attempt this indoors!
Never look into a valve or have the valve pointed at any body part, person or source of ignition when doing a safety
check as noted above.
NO SMOKING!
Make sure the ignition key is in the off position before disconnecting or connecting cylinders.
Latch the cylinder mounting strap.
Inspect the visible part of the fuel line for cuts, abrasions, kinks and leaks.
Using non-absorbant gloves, fasten the quick-connect coupler. Tighten the coupler with quick strokes, Do Not overtighten. Do not use tools to tighten. Be aware that there may be a brief escape (”hiss”) of gas during the tightening
process, continue to tighten the connection until snug.
Slowly open the liquid service valve one-quarter of a turn, listening and looking for leaks. If no leaks are noted, open the
valve completely. Start the engine.
57
SERVICE & MAINTENANCE
Connecting Propane Cylinders (con’t.)
If the engine starts but will not accelerate or loses power, the excess flow valve inside the service valve may have
closed. Shut off the engine. Close the service valve. Wait 30 seconds and reopen the valve handle slowly, allowing
the pressure inside the tank and the line to equalize. If you continue to experience difficulties, contact your Cushman
dealer for service information.
Using a leak detector solution, that does not contain ammonia or other chemicals that will have an adverse effect on
brass, spray all connections, valves and fittings to determine if any leaks are present. Any sign of the formation of
bubbles is cause to take the cylinder out of service.
STORING PROPANE CYLINDERS
Store propane cylinders in a well ventilated area.
Cylinders should be stored horizontally to keep rain, snow and ice away from the valves.
Propane valves stored horizontally must be positioned so that the relief valve is in the 12 o’clock position.
Stored cylinders or cylinders not otherwise in use should have the service valves in the off position.
Do Not store cylinders near stairs or building exits. No more than 300 pounds of propane may be stored in one area.
A fire extinguisher of at least 18-pounds dry chemical with a BC rating should be located within 50 feet of and in sight of
the storage location.
Never leave empty cylinders lying around the facility. Always return them immediately to the designated storage
areas.
Gloves that will not absorb propane should be at the cylinder storage site and used during cylinder handling and
changeout.
Do Not store cylinders near areas that would trap escaping propane vapors such as pits, low areas or air intakes into
ventilating or heating equipment.
NFPA (National Fire Protection Association) 58 requires empty cylinders be considered full when you are determining
the amount of propane being stored. Refer to NFPA 58 or your local authority to determine the maximum number of
cylinders allowed in one location.
Cylinders must be stored at least 5 feet from electrical equipment or other sources of ignition.
Cylinders with leaks or that are defective should be taken out of service immediately and tagged with a Defective
Cylinder Tag, indicating the defect.
Leaking or defective cylinders should be stored in designated, well ventilated areas outdoors, away from possible
ignition sources or access by unknowing personnel. A defective cylinder tag should be attached to the cylinder collar,
indicating the defect.
VEHICLE MODS & ACCESSORIES
There are numerous mods and accessories available for your vehicle.
Some of the mods available are:
the Upper ROPS - Mod No. 53715; the Steel Cab Set - Mod No. 53721 and a Dome Light - Mod No. 53728
Other accessories include:
Left Cab Door - Part No. 894784; Right Cab Door - Part No. 894783; Windshield w/Wiper - Part No. 894757;
Rear Window - Part No. 894758; ROPS (4-wheel) - Part No. 894761; Spare Tire (20.0) - Part No. 894785;
Turn Signals - 894764; Outside Mirror - Part No. 894768; Roof Bracket - Part No. 894777;
Front Bumper - Part No. 894778 and a Back-up Alarm - Part No. 894811
For information and availability on these accessories, contact your local Cushman Dealer.
58
SERVICE & MAINTENANCE
LUBRICATION RECOMMENDATIONS
Automatic Transmission Fluid . . . . .
Mercon/Dexron II
Power Steering . . . . . . . . . . . . Power Steering Fluid (GM)
Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dot 3
Transmission Fluid (manual) SAE EP 80–90 Gear Lube
Differential Fluid . . . . . . . . . . . SAE EP 80–90 Gear Lube
Pressure Gun Grease . . . . . . . . . . . . . . . . . . . Lithium Base
Lubricate all chassis fittings with lithium base pressure gun grease every 100 hours or 1000 miles.
NOTE: Reference to item 1,
Too much grease can
damage the seals.
4
4
2
4
2
Brake Fluid
Reservoir
Brake Fluid
Reservoir
3
3
Fuse Box
Fuse Box
1
1
Ref.
No.
1
2
3
Lubrication Area
Number Of
Grease Fittings
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . 2
Upper Ball Joints . . . . . . . . . . . . . . . . . . . . 2
Lower Ball Joint . . . . . . . . . . . . . . . . . . . . . 2
Ref.
No.
4
(4)
Lubrication Area
Number Of
Grease Fittings
Tie Rod Ends, 4-wheel . . . . . . . . . . . . . . . 4
Tie Rod Ends, 3-wheel . . . . . . . . . . . . . . . 2
59
SERVICE & MAINTENANCE
MAINTENANCE GUIDE
The following maintenance charts have been compiled as a general guideline for service intervals, based on hours of operation.
These charts pertain to all models unless otherwise noted (includes models other than the Suzuki 660 EFI).
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 Diesel)
*
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)
Every
100 Hrs
or 3 months
Check brake adjustment
Check clutch adjustment
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
ENGINE OIL FILTER:
Suzuki 660 - Part No. 2701908
Perkins Diesel - Part No. 842553
60
BATTERY CABLES:
46” (1168 mm) red - Part No. 894594
46” (1168 mm) black - Part No. 884513
24” (607 mm) black - Part No. 892811
30” (762 mm) red - Part No. 894596
38” (965 mm) red - Part No. 2701502
FUEL FILTER:
Suzuki 660 - Part No. 2701998
Perkins Diesel - Part No. 2208175
SERVICE & MAINTENANCE
Maintenance Guide (con’t.)
Every
200 Hrs
or 6 months
Maintenance Operation
Every
400 Hrs
or 9 months
Every
600 Hrs
or 12 months
Every
1500 Hrs
Replace air cleaner element
Check valve clearance (See authorized dealer)
Check fan belt and tension
Inspect radiator hoses and clamps
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 EFI:
Part No. 2701832 Denso XU22EPR-U
gap .032” - .035” (0.8 mm - 0.9 mm)
ENGINE BELTS:
Diesel Models 898726 & 898727
Part No. 2703764, 48” (1219 mm)
ENGINE BELTS:
Suzuki Models 898704, 898718, 898720
898704LP, 898718LP, 898720LP
Part No. 2700565 (alt.) 45” (1143 mm)
Suzuki Models 898704, 898718, 898720
898704LP, 898718LP, 898720LP
Part No. 836854 (gov.) 42” (1067 mm)
TIMING BELT:
Suzuki 660: Part No. 2701985
AIR CLEANER ELEMENT:
All Models - Part No. 840352
Suzuki 3-Wheel Models 898706, 898706LP
Part No. 2701365 (alt.) 39” (991 mm)
Part No. 836854 (gov.) 42” (1067 mm)
61
ENGINE COVER
SUZUKI 660 HAULSTER MODELS
898704, 898704LP, 898706, 898706LP, 898718, 898718LP, 898720 & 898720LP
and
DIESEL MODELS 898726 & 898727
18
7
16
5
Reference
Lower Rops
(Part No. 893145)
17
7
10
33
26
3
19
With
LP Models
10
31
9
14
6
32
4
21
8
1
2
22
11
5
14
12
13
27
3
29
6
35
30
34
6
3
30
3
23
25
898720 Model
Mounts to Panel
As Shown
28
Pre-Cut
Knockouts
20
62
24
23
15
P893436, P2700600, P2701037, P2700628
34
ENGINE COVER
SUZUKI 660 HAULSTER MODELS
898704, 898704LP, 898706, 898706LP, 898718, 898718LP, 898720 & 898720LP
and
DIESEL MODELS 898726 & 898727
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
28
29
30
306328
308090
450452
450453
450454
800026
450541
452378
452388
452398
523085
816401
830784
825939
841804
842030
893321
893322
893541
894232
840436
309488
450544
548910
450543
2702199
2701221
822819
2701224
845038
2702975
Pin, cotter, .09 x .75 . . . . . . . . . . . . . . . . . . . . . . . . 1
Washer, 1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nut, M6-1.00 (G10.9) . . . . . . . . . . . . . . . . . . . . . . . 4
Nut, M8-1.25 (10.9) . . . . . . . . . . . . . . . . . . . . . . . . 2
Nut, M10-1.50 (10.9) . . . . . . . . . . . . . . . . . . . . . . . . 5
Screw, 1/4-20 x 3/4 . . . . . . . . . . . . . . . . . . . . . . . 11
Screw, M6-1.00 x 16 . . . . . . . . . . . . . . . . . . . . . . 10
Screw, M6-1.00 x 20 . . . . . . . . . . . . . . . . . . . . . . . 3
Screw, M8-1.25 x 20 (G8.8) . . . . . . . . . . . . . . . . . . 2
Screw, M10-1.50 x 20 . . . . . . . . . . . . . . . . . . . . . . 5
Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Spring, torsion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Pin, clevis, .25 x 1.88 . . . . . . . . . . . . . . . . . . . . . . . 1
Light, indicator (red) . . . . . . . . . . . . . . . . . . . . . . . . 1
Insulation, engine cover . . . . . . . . . . . . . . . . . . . . 3
Mount, backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Seat, base assembly . . . . . . . . . . . . . . . . . . . . . . . 2
Backrest assembly . . . . . . . . . . . . . . . . . . . . . . . . . 2
Handhold (right side) . . . . . . . . . . . . . . . . . . . . . . . . 1
Cover, left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Lock, handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Screw, M6-1.00 x 30 . . . . . . . . . . . . . . . . . . . . . . . 2
Nut, flange, 1/4-20 . . . . . . . . . . . . . . . . . . . . . . . . . 2
Screw, M6-1.00 x 25 . . . . . . . . . . . . . . . . . . . . . . . 8
Catch, engine cover latch . . . . . . . . . . . . . . . . . . . 1
Panel, console (haulster) . . . . . . . . . . . . . . . . . . . . 1
•Decal, Warning, Park Brake . . . . . . . . . . . . . . . . . . 1
Cover, engine, w/decal . . . . . . . . . . . . . . . . . . . . . 1
•Decal, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Engine control unit (ECU) . . . . . . . . . . . . . . . . . . . . 1
(30)
(30)
2702917
2702973
Engine control unit (ECU) . . . . . . . . . . . . . . . . . . . . 1
Engine control unit (ECU) . . . . . . . . . . . . . . . . . . . . 1
31
32
33
34
35
2704063
2704064
2702725
2701105.7
2701817.7
Decal, Service Engine Soon . . . . . . . . . . . . . . . . . . .
Decal, Light Indicates . . . . . . . . . . . . . . . . . . . . . . . .
Seal, seat base . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover, ECU (engine control unit) . . . . . . . . . . . . . . .
Bracket, ECU, . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*
1
1
2
1
1
Notes
Models 898720 & 898720LP
LP Models Only
* Not Illustrated.
Models 898704, 704LP,
898706, 706LP, 898718 & 718LP
Models 898720 Prior to 8-9-00
Models 898720 After 8-9-00
and Models 898720LP
LP Models Only
LP Models Only
Models 704, 704LP, 706, 706LP,
718 & 718LP
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
Although Item No’s. 21 & 22 (handle lock and washers) are used on EC Turf Models, they may be obtained
for use on any Cushman vehicle.
63
BODY, HOOD, HEADLIGHTS
SUZUKI 660 HAULSTER 4-WHEEL MODELS 898704, 898704LP,
898718, 898718LP, 898720, 898720LP and
DIESEL MODELS 898726 & 898727
16
Reference
Lower Rops
(Part No. 893145)
37
7
30
12
31
33
11
33
11
18
11
9
10
33
19
12
24
28
39
Not Used
On All Vehicles
24
38 40
35
5
2
39
42
12
41
5
22
43
12
Not Used
On All Vehicles
4
15
32
23
26
8
1
21
3
12
29
25
27
13
ÎÎÎ
ÎÎÎ
ÎÎÎ
17
36
14
20
6
11
6
11
13
12
34
Reference Front
Suspension Frame
(Part No. 893421)
64
P893442
BODY, HOOD, HEADLIGHTS
SUZUKI 660 HAULSTER 4-WHEEL MODELS 898704, 898704LP,
898718, 898718LP, 898720, 898720LP and
DIESEL MODELS 898726 & 898727
Ref.
No.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
303952
894743
306419
306463
38061A
450400
450410
450452
450541
452695
800930
800934
800943
837303
2700792
821071
840901
841263
841428
841477
841637
841715
841753
841787
841866
841913
844430
844167
844428
844429
886090
894030
844669
306488
548159
548175
800582
844049
844293
800344
823549
840508
38541
2700275
2700496
*
*
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
Description
No.
Req’d
Washer, #10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nut ay., double 1/4-20 . . . . . . . . . . . . . . . . . . . . . . 2
Screw, 1/4-20 x 1/2 . . . . . . . . . . . . . . . . . . . . . . . . 2
Pin, cotter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cap, vinyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Washer, M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Lockwasher, M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Nut, M6-1.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Screw, M6-1.00 x 16 (RPH) . . . . . . . . . . . . . . . . . . 7
Screw, M6-1.00 x 20, taptite . . . . . . . . . . . . . . . . . 6
Screw, M8-1.25 x 16 (8.8) . . . . . . . . . . . . . . . . . . . 6
Screw, M6-1.00 x 16 (8.8) . . . . . . . . . . . . . . . . . . 25
Screw, tap, #10-14 . . . . . . . . . . . . . . . . . . . . . . . . 10
Headlight, rectangular . . . . . . . . . . . . . . . . . . . . . . 2
Clip, front (w/decals) . . . . . . . . . . . . . . . . . . . . . . . . 1
Decal, notice, not motor vehicle . . . . . . . . . . . . . . . 1
Decal, Warning read ops. manual . . . . . . . . . . . . . . 1
Hood, Haulster (yellow) . . . . . . . . . . . . . . . . . . . . . . 1
Bezel, headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HInge, hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Angle, front clip mount . . . . . . . . . . . . . . . . . . . . . . 1
Rod, hood release . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bracket, hood latch . . . . . . . . . . . . . . . . . . . . . . . . 1
Latch, hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Panel, dash (left) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Plate, access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Decal, CUSHMAN/TEXTRON . . . . . . . . . . . . . . . . . . . 1
Bracket, horn/brake reservoir . . . . . . . . . . . . . . . . 1
Decal, Haulster (left) . . . . . . . . . . . . . . . . . . . . . . . . 1
Decal, Haulster (right) . . . . . . . . . . . . . . . . . . . . . . . 1
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Striker, hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Seal, weather . . . . . . . . . . . . . . . . . . . . . . As Req’d.
Lockwasher, 1/4 shakeproof . . . . . . . . . . . . . . . . . 2
Washer, 5/16 (1 1/4” dia.) . . . . . . . . . . . . . . . . . . . . 4
Washer, 1/4 (1 1/4” dia.) . . . . . . . . . . . . . . . . . . . . . 8
Screw, 1/4-20 x 3/4 . . . . . . . . . . . . . . . . . . . . . . . . 4
Flap, mud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Screw, tapping, #10 type AB . . . . . . . . . . . . . . . . . 2
Tie, cable, 15.5” (394 mm) . . . . . . . . . . . . . . . . . . . 2
Mount, cable tie . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tube, document . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Decal, LH dash . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Insert, dash (1/4-20 x .19 -.38) . . . . . . . . . . . . . . . . 4
Notes
Not used on all vehicles
* Not Illustrated.
* Not Illustrated.
Not used on all vehicles
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
65
BODY, HOOD, HEADLIGHTS
SUZUKI 660 HAULSTER 4-WHEEL MODELS 898704, 898704LP,
898718, 898718LP, 898720, 898720LP and
DIESEL MODELS 898726 & 898727
Ref. No’s. 52 & 53
Keyswitch Plate and Associated Hardware
May Not be Installed on all Vehicles.
54
50
53
51
55
52
45
47
46
44
48
56
Shown For
Reference Only
55
55
49
Ref.
No.
Part
No.
44
45
46
47
(47)
(47)
(47)
48
49
50
51
52
53
54
55
56
2701465
452378
825996
826000
833038
836892
842983
2700867
843167
2703150
2702012
2702014
2701850.7
800582
800943
450452
2701091
*
66
Description
No.
Req’d
Solenoid, 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Screw, M6-1.00 x 20 . . . . . . . . . . . . . . . . . . . . . . . 2
Fuse-holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuse, 20 amp . . . . . . . . . . . . . . . . . . . . . . As Req’d.
Fuse, 30 amp . . . . . . . . . . . . . . . . . . . . . . As Req’d.
Fuse, 10 amp . . . . . . . . . . . . . . . . . . . . . . As Req’d.
Fuse, 15 amp . . . . . . . . . . . . . . . . . . . . . . As Req’d.
Relay, 70 amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Relay, 12V 15A, DPST . . . . . . . . . . . . . . . . . . . . . . 2
Decal, fuse panel (Suzuki only) . . . . . . . . . . . . . . . 1
Strap, keyswitch mount . . . . . . . . . . . . . . . . . . . . . 1
Decal, keyswitch plate . . . . . . . . . . . . . . . . . . . . . . 1
Plate, keyswitch mount . . . . . . . . . . . . . . . . . . . . . 1
Screw, 1/4-20 x 3/4 . . . . . . . . . . . . . . . . . . . . . . . . 2
Screw, tap #10-14 . . . . . . . . . . . . . . . . . . . . . . . . 10
Nut, M6-1.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Kit, clip inserts (6mm & 8mm) . . . . . . . . . . . . . . . . . 1
Notes
Not used on all vehicles
Not used on all vehicles
Not used on all vehicles
Not used on all vehicles
Not used on all vehicles
* Not Illustrated.
BODY, HOOD, HEADLIGHTS
3-WHEEL SUZUKI 660 HAULSTER MODEL 898706 & 898706LP
Ref. No’s. 9 & 10
Keyswitch Plate and Associated Hardware
May Not be Installed on all Vehicles.
11
7
10
8
12
9
2
4
13
3
1
5
12
6
12
Ref.
No.
1
2
3
4
(4)
(4)
(4)
5
6
7
8
9
10
11
12
13
*
Part
No.
2701465
452378
825996
826000
833038
836892
842983
2700867
843167
2703150
2702012
2702014
2701850.7
800582
800943
450452
2701091
Shown For
Reference Only
Description
6
No.
Req’d
Solenoid, 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Screw, M6-1.00 x 20 . . . . . . . . . . . . . . . . . . . . . . . 2
Fuse-holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuse, 20 amp . . . . . . . . . . . . . . . . . . . . . . As Req’d.
Fuse, 30 amp . . . . . . . . . . . . . . . . . . . . . . As Req’d.
Fuse, 10 amp . . . . . . . . . . . . . . . . . . . . . . As Req’d.
Fuse, 15 amp . . . . . . . . . . . . . . . . . . . . . . As Req’d.
Relay, 70 amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Relay, 12V 15A, DPST . . . . . . . . . . . . . . . . . . . . . . 2
Decal, fuse panel . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Strap, keyswitch mount . . . . . . . . . . . . . . . . . . . . . 1
Decal, keyswitch plate . . . . . . . . . . . . . . . . . . . . . . 1
Plate, keyswitch mount . . . . . . . . . . . . . . . . . . . . . 1
Screw, 1/4-20 x 3/4 . . . . . . . . . . . . . . . . . . . . . . . . 2
Screw, tap #10-14 . . . . . . . . . . . . . . . . . . . . . . . . 10
Nut, M6-1.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Kit, clip inserts (6mm & 8mm) . . . . . . . . . . . . . . . . . 1
Notes
Not used on all vehicles
Not used on all vehicles
Not used on all vehicles
Not used on all vehicles
Not used on all vehicles
* Not Illustrated.
67
BODY, HOOD, HEADLIGHTS
3-WHEEL SUZUKI 660 HAULSTER MODEL 898706 & 898706LP
29
Reference
Lower Rops
50
20
43
25
46
44
24
46
24
31
24
22
23
46
32
25
38
37
41
52
Not Used
On All Vehicles
51 53
48
18
15
25
54
18
52
55
35
14
17
56
25
39
21
19
28
16
36
Not Used
On All Vehicles
34
42
26
ÎÎ
ÎÎ
30
25
27
45
40
33
49
Item No. 17 (Cotter Pin)
Install From Bottom,
Bend Legs Down
26
25
P893977
68
47
BODY, HOOD, HEADLIGHTS
3-WHEEL SUZUKI 660 HAULSTER MODEL 898706 & 898706LP
Ref.
No.
Part
No.
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
303952
894743
306419
306463
38061A
306488
450410
450452
450541
112050
800930
800934
800943
837303
2700793
821071
840901
841263
841428
841477
841637
844653
841753
2702198
841866
844645
844646
844167
844428
844429
886090
894030
844669
844430
548159
548175
800582
844049
844293
800344
823549
840508
38541
2700275
2700496
*
*
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
54
55
56
Description
No.
Req’d
Washer, #10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nut, double (1/4-20) . . . . . . . . . . . . . . . . . . . . . . . . 2
Screw, 1/4-20 x 1/2 . . . . . . . . . . . . . . . . . . . . . . . . 2
Pin, cotter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cap, vinyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Lockwasher, 1/4 shakeproof . . . . . . . . . . . . . . . . . 2
Lockwasher, M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Nut, M6-1.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Screw, M6-1.00 x 16 (RPH) . . . . . . . . . . . . . . . . . . 7
Screw, taptite 1/4-20 x 5/8 . . . . . . . . . . . . . . . . . . . 6
Screw, M8-1.25 x 16 (8.8) . . . . . . . . . . . . . . . . . . . 6
Screw, M6-1.00 x 16 (8.8) . . . . . . . . . . . . . . . . . . 25
Screw, tap, #10-14 . . . . . . . . . . . . . . . . . . . . . . . . 10
Headlight, rectangular . . . . . . . . . . . . . . . . . . . . . . 2
Clip, front (w/decals) . . . . . . . . . . . . . . . . . . . . . . . . 1
Decal, notice, not motor vehicle . . . . . . . . . . . . . . . 1
Decal, Warning read ops. manual . . . . . . . . . . . . . . 1
Hood, Haulster (yellow) . . . . . . . . . . . . . . . . . . . . . . 1
Bezel, headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hinge, hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Angle, front clip mount . . . . . . . . . . . . . . . . . . . . . . 1
Rod, hood release . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bracket, hood latch . . . . . . . . . . . . . . . . . . . . . . . . 1
Latch, hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Panel, dash (left) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cover, steering gear (3-wheel) . . . . . . . . . . . . . . . 1
Cover, access (3-wheel) . . . . . . . . . . . . . . . . . . . . . 1
Bracket, horn/brake reservoir . . . . . . . . . . . . . . . . 1
Decal, Haulster (left) . . . . . . . . . . . . . . . . . . . . . . . . 1
Decal, Haulster (right) . . . . . . . . . . . . . . . . . . . . . . . 1
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Striker, hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Seal, weather . . . . . . . . . . . . . . . . . . . . . . As Req’d.
Decal, center (3-wheel) . . . . . . . . . . . . . . . . . . . . . 1
Washer, 5/16 (1 1/4” dia.) . . . . . . . . . . . . . . . . . . . . 4
Washer, 1/4 (1 1/4” dia.) . . . . . . . . . . . . . . . . . . . . . 8
Screw, 1/4-20 x 3/4 . . . . . . . . . . . . . . . . . . . . . . . . 4
Flap, mud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Screw, tapping, #10 type AB . . . . . . . . . . . . . . . . . 2
Tie, cable, 15.5” (394 mm) . . . . . . . . . . . . . . . . . . . 2
Mount, cable tie . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tube, document . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Decal, LH dash . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Insert, dash (1/4-20 x .19 - .38) . . . . . . . . . . . . . . . . 4
Notes
Not used on all vehicles
* Not Illustrated.
* Not Illustrated.
Not used on all vehicles
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
69
FRAME, 4-WHEEL 1/2-TON AND 1-TON
SUZUKI 660 HAULSTERS MODELS 898704, 898704LP, 898718, 898718LP, 898720
& 898720LP and DIESEL MODELS 898726 & 898727
34
LPG Models Only
7
34
36
21
25
33
11
34
8
38
2
7
13
16
10
37
15
12
13
4
5
7
26
7
23
32
14
28
30
12
13
29
35
5
17
27
7
14 7
4
22
18
7
19
4
1
24
20
4
5
Reference
Motor Mounts
(704 & 718 Shown)
Reference
Ground Wire
4
6
3
4
20
31
10
10
9
23
5
70
P2700599, P2700600, P2703997, P2703998
FRAME, 4-WHEEL 1/2-TON AND 1-TON
SUZUKI 660 HAULSTERS MODELS 898704, 898704LP, 898718, 898718LP, 898720
& 898720LP and DIESEL MODELS 898726 & 898727
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
(21)
(21)
(21)
22
23
24
25
26
27
28
29
30
31
32
33
(33)
34
35
36
(36)
37
38
450391
450452
450453
450454
450455
452388
452398
452402
452406
452410
452399
548175
800934
842870
844049
844156
2701221
822819
893145
893235
893525
893404
893404G
894024
894024G
894890
309067
809156
452414
800315
806954
809152
815847
818303
452415
844647
894922
894922G
800930
810437
2703417.7
2703417G
828382
2704066.7
Description
No.
Req’d
Washer, M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Nut, M6-1.00 (G10.9) . . . . . . . . . . . . . . . . . . . . . . 14
Nut, M8-1.25 (10.9) . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nut, M10-1.50 (10.9) . . . . . . . . . . . . . . . . . . . . . . . 19
Nut, M12-1.75 (10.9) . . . . . . . . . . . . . . . . . . . . . . . 18
Screw, M8-1.25 x 20 (G8.8) . . . . . . . . . . . . . . . . . . 1
Screw, M10-1.50 x 20 (8.8) . . . . . . . . . . . . . . . . . 16
Screw, M10-1.50 x 50 (8.8) . . . . . . . . . . . . . . . . . . 4
Screw, M10-1.50 x 90 (8.8) . . . . . . . . . . . . . . . . . . 4
Screw, M12-1.75 x 30 (8.8) . . . . . . . . . . . . . . . . . 12
Screw, M10-1.50 x 25 . . . . . . . . . . . . . . . . . . . . . . 5
Washer, 1/4 x 1.25 dia. . . . . . . . . . . . . . . . . . . . . 10
Screw, M6-1.00 x 16 (8.8) . . . . . . . . . . . . . . . . . . 14
Angle, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Flap, mud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Plate, flap mount . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Panel, console (haulster) . . . . . . . . . . . . . . . . . . . . 1
Decal, park brake warning . . . . . . . . . . . . . . . . . . 1
ROPS, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Frame, main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Support, platform . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Platform, 1-ton . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Platform, galvanized (1-ton) . . . . . . . . . . . . . . . . . . 1
Platform, 1/2-ton . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Platform, galvanized (1/2-ton) . . . . . . . . . . . . . . . . 1
Support, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Lockwasher, 1/2 shakeproof . . . . . . . . . . . . . . . . . 2
Washer, 5/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Screw, M12-1.75 x 70 (8.8) . . . . . . . . . . . . . . . . . . 2
Nut, wing, 5/16-18 . . . . . . . . . . . . . . . . . . . . . . . . . 2
Bolt, battery hook . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Washer, 5/16 x 1 1/8” dia. . . . . . . . . . . . . . . . . . . . 2
Hold-down, battery . . . . . . . . . . . . . . . . . . . . . . . . . 1
Spacer, rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Screw, M12-1.75 x 80 (8.8) . . . . . . . . . . . . . . . . . . 8
Angle, hold-down . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Panel, fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Panel, fuel tank galvanized . . . . . . . . . . . . . . . . . . 1
Screw, M8-1.25 x 16 (8.8) . . . . . . . . . . . . . . . . . . . 1
Clamp, tube/wire . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Panel, fuel tank (LPG) . . . . . . . . . . . . . . . . . . . . . . 1
Panel, fuel tank (LPG) galvenized . . . . . . . . . . . . . 1
Sealer, sponge rubber . . . . . . . . . . . . . . . As Req’d.
Bracket, vaporizer (LPG) . . . . . . . . . . . . . . . . . . . . 1
Notes
1-Ton Models Only
* Not Illustrated.
LPG Models Only
LPG Models Only
LPG Models Only
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
71
FRAME, 3-WHEEL
SUZUKI 660 HAULSTER MODELS 898706 & 898706LP
31
34
LPG Models Only
21
33
34
36
30
7
4
11
29
32
34
38
2
7
16
13
8
10
7
37
15
12
13
12
13
4
5
7
24
7
23
26
28
27
35
14
7
5
17
7
14
25
4
18
7
22
19
4
1
20
4
Reference
Motor Mounts
Reference
Ground Wire
4
6
3
4
20
9
10
10
72
23
P2700602
FRAME, 3-WHEEL
SUZUKI 660 HAULSTER MODELS 898706 & 898706LP
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
(21)
22
23
24
25
26
27
28
29
30
31
32
33
(33)
34
35
36
(36)
37
38
450391
450452
450453
450454
450455
452388
452398
452402
452406
452410
452399
548175
800934
842870
844049
844156
2701221
822819
893145
897159
893525
893990
893990G
894890
309067
800315
806954
809152
815847
818303
844921
844922
800236
800698
894922
894922G
800930
810437
2703417.7
2703417G
828382
2704066.7
Description
No.
Req’d
Washer, M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Nut, M6-1.00 (G10.9) . . . . . . . . . . . . . . . . . . . . . . 14
Nut, M8-1.25 (10.9) . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nut, M10-1.50 (10.9) . . . . . . . . . . . . . . . . . . . . . . . 19
Nut, M12-1.75 (10.9) . . . . . . . . . . . . . . . . . . . . . . . 18
Screw, M8-1.25 x 20 (G8.8) . . . . . . . . . . . . . . . . . . 1
Screw, M10-1.50 x 20 (8.8) . . . . . . . . . . . . . . . . . 16
Screw, M10-1.50 x 50 (8.8) . . . . . . . . . . . . . . . . . . 4
Screw, M10-1.50 x 90 (8.8) . . . . . . . . . . . . . . . . . . 4
Screw, M12-1.75 x 30 (8.8) . . . . . . . . . . . . . . . . . 12
Screw, M10-1.50 x 25 . . . . . . . . . . . . . . . . . . . . . . 5
Washer, 1/4 x 1.25 dia. . . . . . . . . . . . . . . . . . . . . 10
Screw, M6-1.00 x 16 (8.8) . . . . . . . . . . . . . . . . . . 14
Angle, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Flap, mud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Plate, flap mount . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Panel, console (haulster) . . . . . . . . . . . . . . . . . . . . 1
Decal, park brake warning . . . . . . . . . . . . . . . . . . 1
ROPS, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Frame, main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Support, platform . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Platform, 3-wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Platform, galvanized (3-wheel) . . . . . . . . . . . . . . . 1
Support, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Lockwasher, 1/2 shakeproof . . . . . . . . . . . . . . . . . 2
Nut, wing, 5/16-18 . . . . . . . . . . . . . . . . . . . . . . . . . 2
Bolt, battery hook . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Washer, 5/16 x 1 1/8” dia. . . . . . . . . . . . . . . . . . . . 2
Hold-down, battery . . . . . . . . . . . . . . . . . . . . . . . . . 1
Spacer, rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Brace, rear bumper . . . . . . . . . . . . . . . . . . . . . . . . 1
Bumper, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bolt, carriage 3/8-16 x 3/4 . . . . . . . . . . . . . . . . . . . 6
Nut, 3/8-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Panel, fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Panel, fuel tank galvanized . . . . . . . . . . . . . . . . . . 1
Screw, M8-1.25 x 16 (8.8) . . . . . . . . . . . . . . . . . . . 1
Clamp, tube/wire . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Panel, fuel tank (LPG) . . . . . . . . . . . . . . . . . . . . . . 1
Panel, fuel tank (LPG) galvenized . . . . . . . . . . . . . 1
Sealer, sponge rubber . . . . . . . . . . . . . . . As Req’d.
Bracket, vaporizer (LPG) . . . . . . . . . . . . . . . . . . . . 1
Notes
* Not Illustrated.
LPG Models Only
LPG Models Only
LPG Models Only
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
73
FRONT SUSPENSION WITH FRONT BRAKES (Right Side)
TIE RODS, AND SKID PLATE
4-WHEEL MODELS 898718, 898718LP, 898720, 898720LP & 898727
39
24
Before Installing
Apply E.P.2
Wheel Grease
2
23
15
3
40
44
46
Loctite 242
Torque to
32 ft. lbs. (43.5 N⋅m)
13
5
17
18
43
Before Installing
Apply E.P.2
Wheel Grease
6
11
6
45
Not on all
Vehicles
21
8
Torque to
80 ft. lbs. (109 N⋅m)
31
16
9
30
10
60
Reference Brakes
And Brake Shoes
30
28
27
26
32
19
14
60
31
With
Item No. 34
Torque to
80 ft. lbs. (109 N⋅m)
33
25
8
36
35
50
29
6
49
30
22
59
55
54
38
15
47
52
7
53
4
6
56
36
15
34
57
17
58
42
With
Item No. 41
1
6
5
37
15
20
12
54
41
37
51
When ordering Items No. 34 or No. 41 (tie rod ends)
You Will Need to Also Order Item No. 15
48
893523
74
FRONT SUSPENSION WITH FRONT BRAKES (Right Side)
TIE RODS, AND SKID PLATE
4-WHEEL MODELS 898718, 898718LP, 898720, 898720LP & 898727
Ref.
No.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
302944
2702247
385174
450077
450382
450393
452413
452398
450452
800945
452378
800485
815403
809137
831405
Nut, jam, 9/16-18 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nut, castle 3/4-16 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bearing, cone (outer) . . . . . . . . . . . . . . . . . . . . . . . 1
Bolt, M16-2.00 x 90 . . . . . . . . . . . . . . . . . . . . . . . . 2
Nut, locking insert M16-2.00 . . . . . . . . . . . . . . . . . 4
Washer, M16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Screw, M12-1.75 x 60 . . . . . . . . . . . . . . . . . . . . . . 4
Screw, M10-1.5 x 20 (8.8) . . . . . . . . . . . . . . . . . . 10
Nut, M6-1.00, flange (G10.9) . . . . . . . . . . . . . . . . 1
Bolt, M12-1.75 x 60 (G10.9) . . . . . . . . . . . . . . . . . 2
Screw, M6-1.00 x 20 . . . . . . . . . . . . . . . . . . . . . . . 1
Nut, 9/16-18, left-hand . . . . . . . . . . . . . . . . . . . . . . 1
Bearing, cone (inner) . . . . . . . . . . . . . . . . . . . . . . . . 1
Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fitting, grease 1/4-28 (90) . . . . . . . . . . . . . . . . . . 4
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
817928
841167
893266
894635
841404
844148
841429
304636
817250
841630
841737
841738
841839
841841
810437
306328
894574
842104
887512
306328
548224
306825
816586
893234
800909
841430
887750
306328
548224
2702257.7
808088
814474
800908
Seal, grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushing, silentbloc . . . . . . . . . . . . . . . . . . . . . . . . .
Arm assembly, upper control . . . . . . . . . . . . . . . .
Strut ay. (shock & spring) . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin, cotter, 3/32 x 3/4 . . . . . . . . . . . . . . . . . . . . . . .
Knuckle, steering (right) . . . . . . . . . . . . . . . . . . . . .
Bracket, brake tube . . . . . . . . . . . . . . . . . . . . . . . .
End, tie rod (RH thread) . . . . . . . . . . . . . . . . . . . . .
Pin, cotter, 3/32 x 3/4 . . . . . . . . . . . . . . . . . . . . . .
Fitting, lubrication . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, castle, 7/16-20 . . . . . . . . . . . . . . . . . . . . . . . .
Retainer, grease . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arm assembly, lower control . . . . . . . . . . . . . . . . .
Nut, wheel retaining, M12-1.50 . . . . . . . . . . . . . .
Drum, brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End, tie rod (LH thread) . . . . . . . . . . . . . . . . . . . . . .
Pin, cotter, 3/32 x 3/4 . . . . . . . . . . . . . . . . . . . . . .
Fitting, lubrication . . . . . . . . . . . . . . . . . . . . . . . . .
Hub assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cup, bearing (outer) . . . . . . . . . . . . . . . . . . . . . . . .
Cup, bearing (inner) . . . . . . . . . . . . . . . . . . . . . . . .
Screw, lug M12-1.50 x 42 . . . . . . . . . . . . . . . . . .
*
36
37
38
39
40
41
42
*
43
44
45
46
Description
No.
Req’d
1
4
1
2
1
1
1
1
1
1
4
2
1
1
2
2
1
1
1
1
1
1
1
1
5
1
1
1
1
1
1
1
5
Notes
Order this fitting when ordering
Ref. No’s. 34 & 41
Not illustrated (see note below)
Not illustrated (see note below)
• 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.
75
FRONT SUSPENSION WITH FRONT BRAKES (Right Side)
TIE RODS, AND SKID PLATE
4-WHEEL MODELS 898718, 898718LP, 898720, 898720LP & 898727
50
49
55
59
29
52
53
47
57
With
Item No. 50
56
58
54
51
48
893523
Ref.
No.
Part
No.
47
48
49
50
51
52
53
54
55
56
57
58
59
60
841336
452408
303269
841255
842033
452692
843418
450455
311392
452415
841842
893421
2703081
306941
76
Description
No.
Req’d
Arm, pitman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Screw, M10-1.75 x 20 (G10.9) . . . . . . . . . . . . . . . 6
Lockwasher, 7/16 . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Gear, power steering . . . . . . . . . . . . . . . . . . . . . . . 1
Plate, skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Screw, M6-1.00 x 12 . . . . . . . . . . . . . . . . . . . . . . . 1
Clamp, tee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nut, M12-1.75 (G10.9) . . . . . . . . . . . . . . . . . . . . . 12
Screw, 7/16-14 x 2 . . . . . . . . . . . . . . . . . . . . . . . . . 3
Screw, M12-1.75 x 80 (8.8) . . . . . . . . . . . . . . . . . . 8
Tee, union, M10-1.00 flare . . . . . . . . . . . . . . . . . . 1
Frame assembly, front . . . . . . . . . . . . . . . . . . . . . . 1
Protector, spring hose . . . . . . . . . . . . . . . . . . . . . . 1
Nut, castle 1/2-20 . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Notes
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.
Bead Seat
The illustration shows an example of how to
measure the wheel to determine tire size.
Wheel
Shown For
Reference Only
10.00”
(First Number)
Wheel Diameter
7.50”
(Second Number)
Wheel Width
FRONT and REAR TIRES and WHEEL ASSEMBLY
MODELS 898704, 898704LP, 898706, 898706LP, 898718, 898718LP,
898720, 898720LP, 898726 & 898727
1
TIRE
20.5 x 8.0 - 10 sport trax,
sawtooth tread, Load Range C
(Obtain Locally)
2
4
The Wheel (Rim) is
5 Bolt on a
100mm Bolt Circle
3
5
P894263, P894600
Ref.
No.
Part
No.
1
894785
2
3
4
841433
886735
◊◊
5
800909
Description
No.
Req’d
Tire and wheel (4-wheel) . . . . . . . . . . . . . . . . . . . . 4
Tire and wheel (3-wheel) . . . . . . . . . . . . . . . . . . . . 3
Wheel, 10.00 x 7.50, five bolt . . . . . . . . . . . . . . . 1
Stem, valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tire, 20.5 x 8.0 -10, Load Range C
sport trax, sawtooth tread . . . . . . . . . . . . . . . . . . . . 1
Nut, wheel mount (4-wheel) . . . . . . . . . . . . . . . . 20
Nut, wheel mount (3-wheel) . . . . . . . . . . . . . . . . 15
Notes
Obtain locally
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY
77
FRONT SUSPENSION WITH FRONT BRAKES (Left Side)
TIE RODS, AND SKID PLATE
4-WHEEL MODELS 898718, 898718LP, 898720, 898720LP & 898727
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
34
With
Item No. 26
19
27
When ordering Items No. 26
or No. 35 (tie rod ends)
You Will Need to Also Order
Item No. 12
12
49
1
26
7
Torque to
80 ft. lbs. (109 N⋅m)
11
Not on all
Vehicles
3
4
13
14
38
29
39
12
35
8
12
48
23
5
10
6
25
37
With
Item No. 35
11
36
15
33
34
28
50
22
13
28
24
16
33
Loctite 242
Torque to
32 ft. lbs. (43.5 N⋅m)
4
2
30
9
51
Torque to
80 ft. lbs. (109 N⋅m)
12
31
43
42
32
Before Installing
Apply E.P.2
Wheel Grease
46
44
47
40
45
17
41
P893523
78
Before Installing
Apply E.P.2
Wheel Grease
18
FRONT SUSPENSION WITH FRONT BRAKES (Left Side)
TIE RODS, AND SKID PLATE
4-WHEEL MODELS 898718, 898718LP, 898720 , 898720LP & 898727
Ref.
No.
Part
No.
Description
No.
Req’d
1
2
3
4
5
6
7
8
9
10
11
12
302944
450077
450382
450393
894635
452398
800945
800485
800919
809137
810437
831405
Nut, jam, 9/16-18 . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt, M16-2.00 x 90 . . . . . . . . . . . . . . . . . . . . . . . .
Nut, M16-2.00, locking insert . . . . . . . . . . . . . . . .
Washer, M16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strut ay, (shock & spring) . . . . . . . . . . . . . . . . . . . . .
Screw, M10-1.5 x 20 (8.8) . . . . . . . . . . . . . . . . . . .
Bolt, M12-1.75 x 60 (G10.9) . . . . . . . . . . . . . . . . .
Nut, 9/16-18, left-hand . . . . . . . . . . . . . . . . . . . . . .
Bolt, M10-1.5 x 30 (G10.9) . . . . . . . . . . . . . . . . . .
Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting, grease, 1/4-28 (90) . . . . . . . . . . . . . . . . .
1
2
4
6
1
1
2
1
4
1
2
4
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
841167
841404
844148
841429
817250
304636
841630
841737
841738
2702217
841841
894573
842104
887512
306328
548224
306941
816586
893233
841430
800909
306328
306825
887750
306328
548224
2703081
816586
893266
2702247
385174
815403
817928
2702257.7
808088
814474
800908
450452
452378
450455
452413
Bushing, silentbloc . . . . . . . . . . . . . . . . . . . . . . . . .
Rod, tie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ball joint, upper . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ball joint, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cap, grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin, cotter 1/8 x 1 1/8” . . . . . . . . . . . . . . . . . . . . . .
Trunnion, control arm . . . . . . . . . . . . . . . . . . . . . . .
Shim, .060” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shim, .024” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tube, brake (left) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knuckle, steering (left) . . . . . . . . . . . . . . . . . . . . . .
Bracket, brake tube . . . . . . . . . . . . . . . . . . . . . . . .
End, tie rod (RH thread) . . . . . . . . . . . . . . . . . . . . . .
Pin, cotter, 3/32 x 3/4 . . . . . . . . . . . . . . . . . . . . . .
Fitting, lubrication . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, castle 1/2-20 . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . .
Protector, spring hose . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . .
4
1
1
1
1
1
1
4
2
1
1
1
1
1
1
1
2
1
1
1
5
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
5
1
1
4
4
*
28
29
30
31
32
33
34
35
36
*
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
Notes
Order this fitting when ordering
Ref. No’s. 26 or 35
• 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.
79
FUEL SYSTEM
SUZUKI 660 EFI HAULSTER MODELS 898720 Built After 8-9-2000
and MODELS 898704, 898706, 898718
8
1
17
14
8
1
18
25
14
26
10
26
Shown For
Reference Only
39
7
9
23
21
20
39
22
12
5
21
12
19
15
24
2
13
31
12
11
4
33
31
37
3
27
28
13
29
34
6
5
28
42
41
13
40
16
12
44
35
12
41
12
43
36
32
12
12
13
12
13
43
Cut Section of Tubing to
Appropriate Length, Attach to Hose
(Protects Hose From Engine)
38
30
12
To Rear Facing
Vacuum Port on
Intake Manifold
13
To Fuel
Injector Rail
80
12
P2700857, P2700600
FUEL SYSTEM
SUZUKI 660 EFI HAULSTER MODELS 898720 Built After 8-9-2000
and MODELS 898704, 898706, 898718
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
34
35
36
37
38 39
40
41
42
43
44
Part
No.
120052
320107
450452
452378
450453
800875
829954
800021
843343
843298
452398
4113022
826590
829787
829997
800930
833953
894201
841969
836852
84310
843727
843726
843078
894922
800930
832505
4113021
2701693.7
4115904
2700166
4113019
2701897
2701898
2701899
309067
452389
826191
821893
4113018
4113023
830245
825624
831039
Description
No.
Req’d
Notes
Lockwasher, #10 . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tie, cable, 7 1/2” (190.5 mm) . . . . . . . . . . . . . . . . . 2
Nut, M6-1.00 (G10.9) . . . . . . . . . . . . . . . . . . . . . . . 4
Screw, M6-1.00 x 20 . . . . . . . . . . . . . . . . . . . . . . . 4
Nut, M8-1.25 (10.9) . . . . . . . . . . . . . . . . . . . . . . . . . 8
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) . . . . . . . . . . . . . . . . . . 4
Clamp, 5/16 clutch-type 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) . . . . . . . . . . . . . . . . . . . 6
Cover, fuel sender . . . . . . . . . . . . . . . . . . . . . . . . . 1
Harness, fuel tank wire . . . . . . . . . . . . . . . . . . . . . 1
Tank, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Elbow, 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tube, fuel pick-up . . . . . . . . . . . . . . . . . . . . . . . . . 1
Support, fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Panel, fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Screw, M8-1.25 x 16 (8.8) . . . . . . . . . . . . . . . . . . . 4
Hose, fuel (7/16 i.d.) . . . . . . . . . . . . . . . . . As Req’d
Clamp, hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Bracket, fuel pump (hi-p) . . . . . . . . . . . . . . . . . . . . 1
Connector, tee (1/4” hose) . . . . . . . . . . . . . . . . . . . 1
Clamp, fuel pump (hi-p) . . . . . . . . . . . . . . . . . . . . . 1
Adapter (1/2 hose-5/16 hose) . . . . . . . . . . . . . . . . . 1
Pump, fuel (660 efi) . . . . . . . . . . . . . . . . . . . . . . . . . 1
Filter, fuel (660 efi) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Regulator, fuel (660 efi) . . . . . . . . . . . . . . . . . . . . . . 1
Washer, star . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Screw, M8-1.25 x 25 (8.8) . . . . . . . . . . . . . . . . . . . 2
Tubing, convoluted . . . . . . . . . . . . . . . . . . As Req’d.
Trim, push-on . . . . . . . . . . . . . . . . . . . . . . As Req’d.
Adapter (5/16 hose-1/4 hose) . . . . . . . . . . . . . . . . . 1
Clamp, 1/4 clutch-type hose . . . . . . . . . . . . . . . . . 2
Hose, fuel (1/4 i.d.) . . . . . . . . . . . . . . . . . . As Req’d
Clamp, hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hose, fuel (5/32 i.d.) . . . . . . . . . . . . . . . . . As Req’d
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY
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.
81
FUEL SYSTEM
SUZUKI 660 EFI HAULSTER, MODEL 898720 Prior to 8-9-2000
8
1
17
8
1
14
18
25
14
26
10
26
Shown For
Reference Only
35
7
9
20
5
35
23
21
22
12
21
12
19
13
13
To Rear Facing
Vacuum Port on
Intake Manifold
15
24
13
2
12
41
30
12
36
13
36
39
12
38
11
33
12
12
44
44
12
37
34
6
16
28
13
15
4
16
27
Shown For
Reference Only
3
32
5
42
12 13
12
41
3
4
31
13
Cut Section of Tubing to
Appropriate Length, Attach to Hose
(Protects Hose From Engine)
82
12
12
29
40
To Fuel
Injector Rail
FUEL SYSTEM
SUZUKI 660 EFI HAULSTER, MODEL 898720 Prior to 8-9-2000
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
34
35
36
37
38
39
40
41
42
43
Part
No.
120052
320107
450452
452378
450453
800875
829954
800021
843343
843298
452398
4113022
826590
829787
829997
800930
833953
894201
841969
836852
84310
843727
843726
843078
894922
800930
2700159.7
2700161
2700166
4113019
2701897
2701898
2701899
309067
821893
825624
830245
4113018
831039
826191
4113021
832505
4113023
Description
No.
Req’d
Notes
Lockwasher, #10 . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tie, cable, 7 1/2” (190.5 mm) . . . . . . . . . . . . . . . . . 2
Nut, M6-1.00 (G10.9) . . . . . . . . . . . . . . . . . . . . . . . 4
Screw, M6-1.00 x 20 . . . . . . . . . . . . . . . . . . . . . . . 4
Nut, M8-1.25 (10.9) . . . . . . . . . . . . . . . . . . . . . . . . . 8
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) . . . . . . . . . . . . . . . . . . 4
Clamp, hose (clutch-type) . . . . . . . . . . . . . . . . . . . 12
Hose, fuel, 5/16 i.d. . . . . . . . . . . . . . . . . . . As Req’d.
Terminal, 45 1/4 male . . . . . . . . . . . . . . . . . . . . . 2
Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Screw, M8-1.25 x 16 (8.8) . . . . . . . . . . . . . . . . . . . 6
Cover, fuel sender . . . . . . . . . . . . . . . . . . . . . . . . . 1
Harness, fuel tank wire . . . . . . . . . . . . . . . . . . . . . 1
Tank, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Elbow, 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tube, fuel pick-up . . . . . . . . . . . . . . . . . . . . . . . . . 1
Support, fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Panel, fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Screw, M8-1.25 x 16 (8.8) . . . . . . . . . . . . . . . . . . . 4
Bracket, fuel (hi-p) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Connector, tee (5/16”) . . . . . . . . . . . . . . . . . . . . . . . 1
Clamp, fuel pump (hi-p) . . . . . . . . . . . . . . . . . . . . . 1
Connector (1/2” hose to 5/16” hose) . . . . . . . . . . . . 1
Pump, fuel (660 efi) . . . . . . . . . . . . . . . . . . . . . . . . . 1
Filter, fuel (660 efi) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Regulator, fuel (660 efi) . . . . . . . . . . . . . . . . . . . . . . 1
Washer, star . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trim, push-on . . . . . . . . . . . . . . . . . . . . . . As Req’d.
Clamp, hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hose, fuel (1/4 i.d.) . . . . . . . . . . . . . . . . . . . As Req’d.
Adapter (1/2” hose to 5/16” hose) . . . . . . . . . . . . . . 1
Hose, fuel, 5/32 i.d. . . . . . . . . . . . . . . . . . . As Req’d.
Tubing, convoluted . . . . . . . . . . . . . . . . . . As Req’d.
Clamp, hose (clutch-type) . . . . . . . . . . . . . . . . . . . . 2
Hose, fuel, 7/16 i.d. . . . . . . . . . . . . . . . . . . As Req’d.
Clamp, hose (1/4” clutch-type) . . . . . . . . . . . . . . . . 2
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY
Ref.
No. 40 (826191, convoluted tubing) is shipped in a 25 ft. (7.6 M) length.
Cut tubing to appropriate length for your particular application.
83
FUEL SYSTEM
SUZUKI 660 HAULSTER MODELS 898704LP,
898706 LP, 898718LP & 898720LP
2
Connects to
LP Bottle
16
25
24
26
31
9
28
29
27
43
25
20
22
5
4
3
Shown For
Reference Only
Splice “Y” into Bottom Radiator Hose.
If Installing “Y” for the First Time,
Remove 1” (25.4 mm) from Hose
14
42
23
21
23
30
17
23
7
21
23
23
19
17
23
11
33
34
41
15
39
13
10
12
1
38
6
36
40
18
P2703998
84
37
35
42
8
32
FUEL SYSTEM
SUZUKI 660 HAULSTER MODELS 898704LP,
898706 LP, 898718LP & 898720LP
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
34
35
36
37
38
39
40
41
42
43
Part
No.
Description
133079
4111020
2703988.7
2704063
2704064
2704066.7
888856
320107
2704082
303916
303952
306531
306991
450454
452398
452399
845126
800178
800271
800390
820889
825939
832033
4111022
4111023
4111024
4111025
4111026
4111027
4111021
4111029
4111030
4111031
4111032
4111033
4111034
4111035
4111036
4111037
4111038
4111041
4111042
4111043
4111044
No.
Req’d
Nut, #8-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Support, LPG tank . . . . . . . . . . . . . . . . . . . . . . . . . 1
Guard, tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Decal, Service Engine Soon . . . . . . . . . . . . . . . . . . 1
Decal, Light Indicates . . . . . . . . . . . . . . . . . . . . . . . 1
Bracket, vaporizer . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tube, “Y” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tie, cable, 7.5” (190.5 mm) . . . . . . . . . . . . . . . . . . . 1
Placard, LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Lockwasher, #10 shakeproof, external . . . . . . . . 3
Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Nut, #10-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lockwasher, #8 shakeproof, external . . . . . . . . . 2
Nut, M10-1.50 (G10.9) . . . . . . . . . . . . . . . . . . . . . . . 4
Screw, M10-1.50 x 20 (G8.8) . . . . . . . . . . . . . . . . . 4
Screw, M10-1.50 x 25 (G8.8) . . . . . . . . . . . . . . . . . 4
Hose, (.61 i.d. x .94 o.d.) . . . . . . . . . . . . . . As Req’d
Screw, #8-32 x 1/2 . . . . . . . . . . . . . . . . . . . . . . . . . 2
Screw, #10-24 x 1/2 . . . . . . . . . . . . . . . . . . . . . . . . 3
Rivet, .125 x .390 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clamp, tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Light, indicator (red) . . . . . . . . . . . . . . . . . . . . . . . . 1
Clamp, hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Coupler, quick disconnect . . . . . . . . . . . . . . . . . . . 1
Elbow, 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hose assembly, LPG . . . . . . . . . . . . . . . . . . . . . . . 1
Elbow, 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Filter, inline LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Valve, relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hose, LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Harness, wire (fuel controller) . . . . . . . . . . . . . . . . 1
Vaporizer, LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Kit, repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Valve, fuel sut-off . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Elbow, 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Elbow, 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Elbow, 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Valve, 3 port, fuel control . . . . . . . . . . . . . . . . . . . . 1
Controller, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hose, LPG vapor (5/8” dia.) . . . . . . . . . . . As Req’d.
Harness, wire LED . . . . . . . . . . . . . . . . . . . . . . . . . 1
Notes
-6 SAE 45 x 1/4 NPT-Brass
-6 SAE 45 x 1/4 NPT-Brass
* Not illustrated
-6 SAE 45 x 1/4 NPT-Brass
1/4 NPT-Brass
3/8 NPT x 5/8 Beaded-Brass
3/8 NPT x 5/8 Beaded-Brass
1/2 NPT x 5/8 Beaded-Nylon
1/8 NPT x 3/16 Beaded-Nylon
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
• Obtain propane tanks locally. Propane tanks should be of the following specifications:
Tank Type: Universal/Vertical
Capacity: 34/44 lbs.
Fuel Withdrawl: Liquid
Disconnect Coupling: Rego 7141M
85
EXHAUST SYSTEM
SUZUKI 660 HAULSTER MODELS
898704, 898704LP, 898706, 898706LP, 898718, 898718LP, 898720 & 898720LP
Some early model Haulsters are equipped with the exhaust system shown below (Ref. No’s 1 thru 15).
The muffler (Ref. No. 10) and exhaust inlet tube (Ref. No. 11) have been discontinued and replaced with the muffler/tailpipe
assembly shown at the lower right of the page.
The tailpipe (Ref. No. 6) and support bracket (Ref. No. 9) can still be ordered as replacement parts for your existing muffler,
however, when replacing the existing muffler (Ref. No. 10) with the new muffler/tailpipe, you will also need to replace the
exhaust inlet tube (Ref. No. 11) as well as the existing support bracket (Ref. No. 9).
4
3
1
12
1
6
9
5
Mounts to
Transmission
10
8
7
11
Engine Shown
For Reference Only
2
14
13
15
Reference
Exhaust Manifold
17
If replacing the existing muffler (Ref. No. 10)
you will also need to replace the exhaust
inlet tube as well as the support bracket with
Ref. No’s. 17 & 18
16
18
The support bracket, exhaust inlet tube and
muffler/tailpipe will mount the same as the existing items with the exception of the tailpipe and
tailpipe clamp.
86
EXHAUST SYSTEM
SUZUKI 660 HAULSTER MODELS
898704, 898704LP, 898706, 898706LP, 898718, 898718LP, 898720 & 898720LP
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Part
No.
450193
450378
450454
452398
813688
833188
838295
841982
843968
893381
894742.8
839946
2702500
2702502
2702501
2703794.8
2703836.8
2703796.8
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”) . . . . . . . . . . . . . . . . .
Support, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . .
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tube, exhaust inlet . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal ring, muffler . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt, muffler flange . . . . . . . . . . . . . . . . . . . . . . . . .
Spring, muffler flange . . . . . . . . . . . . . . . . . . . . . . .
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tube, exhaust inlet . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
2
2
1
1
1
1
1
1
1
1
1
2
2
1
1
1
Notes
Discontinued (use 2703794.8)
Discontinued (use 2703796.8)
When
replacing the existing muffler (Ref. No. 10) with the muffler/tailpipe assembly, it will also be necessary to
replace the existing support bracket (Ref. No. 9) with the new bracket (Ref. No. 17)
87
PARK BRAKE LEVER AND CABLE
SUZUKI 660 HAULSTER MODELS
898704, 898704LP, 898706, 898706LP, 898718, 898718LP, 898720 & 898720LP
and DIESEL MODELS 898726 & 898727
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.
4
6
Reference
Console Panel
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”
2
(11.2 mm)
4
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.
P893446, P2701428, P2700600
88
5
14
9
8
PARK BRAKE LEVER AND CABLE
SUZUKI 660 HAULSTER MODELS
898704, 898704LP, 898706, 898706LP, 898718, 898718LP, 898720 & 898720LP
and DIESEL MODELS 898726 & 898727
Ref.
No.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
450377
450453
450454
452388
452391
452398
800446
809152
827182
845134
843158
843356
843359
845133
894317
893583
133741
2701335
2701336
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 . . . . . . . . . . . . . . . . . . .
Bracket, park brake cable . . . . . . . . . . . . . . . . . . .
Equalizer, park brake . . . . . . . . . . . . . . . . . . . . . . .
Bushing, park brake . . . . . . . . . . . . . . . . . . . . . . . .
Cable, park brake . . . . . . . . . . . . . . . . . . . . . . . . . .
Lever, park brake . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable, park brake (to rear brakes) . . . . . . . . . . . . .
Rivet, pop (.12 .5 clsd. end) . . . . . . . . . . . . . . . . . .
Mounting, park brake . . . . . . . . . . . . . . . . . . . . . . .
Cover, parking brake . . . . . . . . . . . . . . . . . . . . . . .
Notes
1
6
2
5
1
2
1
2
1
1
1
1
1
1
1
2
6
1
1
89
SHIFTER and SHIFTER LINKAGE
SUZUKI 660 EFI HAULSTER MODELS
898704, 898706 & 898718 Built Prior To 5-21-01
4
8
7
5
9
6
2
20
17
28
25
27
15
14
10
18
12
13
26
11
20
19
30
22
29
17
1
21
24
25
23
3
2
2
16
P2701277
90
SHIFTER and SHIFTER LINKAGE
SUZUKI 660 EFI HAULSTER MODELS
898704, 898706 & 898718 Built Prior To 5-21-01
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
308090
452695
548175
800582
843792
841265
2702696
2702695
894743
300977
306396
306397
308090
308091
450454
452400
452695
311763
842773
842774
843614
843679
843685
843686
843724
893967
893968
2701273
2701328
452692
Description
No.
Req’d
Washer, 1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M6-1.00 x 20, taptite . . . . . . . . . . . . . . . . .
Washer, 1/4 x 1.25 . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, 1/4-20 x 3/4 . . . . . . . . . . . . . . . . . . . . . . . .
Plate, shifter boot . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, dash (right hand) . . . . . . . . . . . . . . . . . . . . .
Boot, shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut assembly, double (1/4-20) . . . . . . . . . . . . . . . .
Screw, 1/4-28 x 5/8 . . . . . . . . . . . . . . . . . . . . . . . .
Lockwasher, 1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, 1/4-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, 1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, 1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, M10-1.50 (G10.9) . . . . . . . . . . . . . . . . . . . . . .
Screw, M10-1.50 x 30 (8.8) . . . . . . . . . . . . . . . . . .
Screw, M6-1.00 x 20, taptite . . . . . . . . . . . . . . . . .
Screw, 1/2-20 x 1 1/4” . . . . . . . . . . . . . . . . . . . . . .
Rod end, 1/2” (female) . . . . . . . . . . . . . . . . . . . . . .
Ball joint, 1/4” . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring, torsion . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plate, wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushing, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab, locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamp, cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selector, complete . . . . . . . . . . . . . . . . . . . . . . . . .
Mount, shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable, shifter, 97” (2.5M) . . . . . . . . . . . . . . . . . . . . .
Cable, shifter, 89” (2.3M) . . . . . . . . . . . . . . . . . . . . .
Screw, M6-1.00 x 12, taptite . . . . . . . . . . . . . . . . .
Notes
5
6
3
4
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
2
1
1
1
1
2
1
1
1
1
2
91
SHIFTER and LINKAGE
SUZUKI 660 HAULSTER MODELS
898704, 898704LP, 898706, 898706LP, 898718 & 898718LP Built After 5-21-01
and DIESEL MODELS 898726 & 898727
4
8
7
5
30
9
6
31
20
2
28
25
27
15
14
12
10
13
18
26
11
17
20
19
30
2
22
29
1
21
24
25
23
3
2
2
16
P2701277
92
SHIFTER and LINKAGE
SUZUKI 660 HAULSTER MODELS
898704, 898704LP, 898706, 898706LP, 898718 & 898718LP Built After 5-21-01
and DIESEL MODELS 898726 & 898727
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
308090
452695
548175
800582
843792
2703964.7
2702696
2702695
2700496
300977
306396
306397
308090
308091
450454
452400
816307
311763
842773
842774
843614
843679
843685
2703951
843724
893967
2703958.7
2701273
2701328
452692
2703931.7
Description
No.
Req’d
Washer, 1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M6-1.00 x 20, taptite . . . . . . . . . . . . . . . . .
Washer, 1/4 x 1.25 . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, 1/4-20 x 3/4 . . . . . . . . . . . . . . . . . . . . . . . .
Plate, shifter boot . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, dash (right hand) . . . . . . . . . . . . . . . . . . . . .
Boot, shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insert, 1/4-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, 1/4-28 x 5/8 . . . . . . . . . . . . . . . . . . . . . . . .
Lockwasher, 1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, 1/4-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, 1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, 1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, M10-1.50 (G10.9) . . . . . . . . . . . . . . . . . . . . . .
Screw, M10-1.50 x 30 (8.8) . . . . . . . . . . . . . . . . . .
Washer, flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, 1/2-20 x 1 1/4” . . . . . . . . . . . . . . . . . . . . . .
Rod end, 1/2” (female) . . . . . . . . . . . . . . . . . . . . . .
Ball joint, 1/4” . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring, torsion . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plate, wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushing, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab, locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamp, cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selector, complete . . . . . . . . . . . . . . . . . . . . . . . . .
Mount, shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable, shifter, 97” (2.5M) . . . . . . . . . . . . . . . . . . . . .
Cable, shifter, 89” (2.3M) . . . . . . . . . . . . . . . . . . . . .
Screw, M6-1.00 x 12, taptite . . . . . . . . . . . . . . . . .
Ring, shifter boot hold-down . . . . . . . . . . . . . . . . .
Notes
5
8
3
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1
1
4
1
93
AUTOMATIC TRANSMISSION SHIFTER
SUZUKI 660 HAULSTER MODEL 898720 & 898720LP
11
Some Earlier Models Were Equipped
With a Double-Nut Ay. (Ref. No. 13). You
Can Still Order this Nut Ay. or You Can
Order the Insert (Ref. No. 12)
5
9
Mounts to Transmission
Using Existing Hardware
12
1
6
13
1
6
3
7
8
4
11
2
11
10
11
11
Mounts to Transmission
Using Existing Hardware
11
2700046, 895016
Ref.
No.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
103867
302030
306375
306396
800582
821164
842740
845345.7
894584
894508
892164
2700496
894743
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, shifter cable mount . . . . . . . . . . . . . . . . .
Shifter ay. w/cable . . . . . . . . . . . . . . . . . . . . . . . . .
Cable, shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kit, cable hardware . . . . . . . . . . . . . . . . . . . . . . . .
Insert, 1/4-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, double (1/4-20) . . . . . . . . . . . . . . . . . . . . . . . . .
Notes
2
1
1
1
4
2
1
1
1
1
1
4
2
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
94
ENGINE and TRANSMISSION MOUNTS
SUZUKI 660 HAULSTER MODELS 898720 (Built After 8-9-00)
and
MODELS 898704, 898704LP, 898706, 898706LP, 898718, 898718LP & 898720LP
9
3
4
2
19
15
4
2
16 1
8
Mounts to
Engine
11
7
1
Reference
Frame
18
14
2
5
17
10
4
4
12
4
4
6
5
P2700567, P2702007
Ref.
No.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
103867
452405
450453
452454
452398
452406
452389
839946
845206.7
894998.7
2701698
893525
2702997
2703000
2703001
2703002
2701827
2702661
2702998
Description
No.
Req’d
Washer, 5/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M10-1.50 x 80 (G8.8) . . . . . . . . . . . . . . . . .
Nut, M8-1.25 (G10.9) . . . . . . . . . . . . . . . . . . . . . . .
Nut, M10-1.50 (10.9) . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M10-1.50 x 20 (8.8) . . . . . . . . . . . . . . . . . .
Screw, M10-1.50 x 90 (8.8) . . . . . . . . . . . . . . . . . .
Screw, M8-1.25 x 25 (8.8) . . . . . . . . . . . . . . . . . . .
Bracket, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, transmission to frame . . . . . . . . . . . . . . . . .
Mount, motor (left) . . . . . . . . . . . . . . . . . . . . . . . . . .
Mount,motor (right) . . . . . . . . . . . . . . . . . . . . . . . . .
Support, platform . . . . . . . . . . . . . . . . . . . . . . . . . .
Mount, engine (right) . . . . . . . . . . . . . . . . . . . . . . . .
Mount, engine (left) . . . . . . . . . . . . . . . . . . . . . . . .
Mount, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes
2
3
4
9
2
4
4
1
1
1
1
2
1
1
1
2
4
2
3
95
ENGINE and TRANSMISSION MOUNTS
SUZUKI 660 HAULSTER MODEL 898720 (Built Before 8-9-00)
9
5
8
4
2
16
7
4
20
11
5 2
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
P2700566
Ref.
No.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
103867
306982
450453
452454
450412
452398
452406
452389
845206.7
894998.7
895000.7
893525
839946
2702996
2702999
2703001
2703002
2701827
2702661
2702998
96
Description
No.
Req’d
Washer, 5/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, 7/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, M8-1.25 (G10.9) . . . . . . . . . . . . . . . . . . . . . . .
Nut, M10-1.50 (10.9) . . . . . . . . . . . . . . . . . . . . . . . .
Lockwasher, M10 . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M10-1.50 x 20 (8.8) . . . . . . . . . . . . . . . . . .
Screw, M10-1.50 x 90 (8.8) . . . . . . . . . . . . . . . . . .
Screw, M8-1.25 x 25 (8.8) . . . . . . . . . . . . . . . . . . .
Bracket, transmission to frame . . . . . . . . . . . . . . . . .
Mount, motor (left) . . . . . . . . . . . . . . . . . . . . . . . . . .
Mount,motor (right) . . . . . . . . . . . . . . . . . . . . . . . . .
Support, platform . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mount, engine (right) . . . . . . . . . . . . . . . . . . . . . . .
Mount, engine (left) . . . . . . . . . . . . . . . . . . . . . . . .
Mount, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
3
4
9
3
2
7
4
1
1
1
2
1
1
1
1
2
4
2
3
Notes
REAR SPRING, SHACKLES & U–BOLTS
SUZUKI 660 HAULSTER MODELS
898704, 898704LP, 898706, 898706LP, 898718, 898718LP, 898720 & 898720LP
and DIESEL MODELS 898726 & 898727
1
Torque to 25-35 ft. lbs.
(34-48 N⋅m)
11
5
10
9
With
Ref. No. 8
3
7
With
Ref. No. 6
14
11
1
13
3
12
13
Reference
10.25:1 Differential
(Part No. 2701142)
3
8
6
4
2
P893978, P893401
Torque to 64-74 ft. lbs. (87-101 N⋅m)
Approximate by Hand Torque Only.
Cannot be Measured by Torque Wrench.
Ref.
No.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
12
(12)
13
14
311398
800198
800602
809180
813850
887187
548061
887188
548061
843238
843876
893355
893862
843238
893613
Description
No.
Req’d
Screw, 1/2-13 x 3 1/2 . . . . . . . . . . . . . . . . . . . . . . .
Nut, 1/2-20 crownlock . . . . . . . . . . . . . . . . . . . . . .
Nut, 1/2-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, 7/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bumper, rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . .
U-bolt, 2” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, 7/16-20 unitorq . . . . . . . . . . . . . . . . . . . . . . .
U-bolt, 2 1/2” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, 7/16-20 unitorq . . . . . . . . . . . . . . . . . . . . . . .
Bushing, nylatron . . . . . . . . . . . . . . . . . . . . . . . . . .
Shackle, rear spring . . . . . . . . . . . . . . . . . . . . . . . .
Spring, leaf (1/2 ton) . . . . . . . . . . . . . . . . . . . . . . . .
Spring, leaf (1 ton) . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushing, nylatron . . . . . . . . . . . . . . . . . . . . . . . . .
Upstop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
1
6
1
2
2
2
2
2
2
4
2
2
2
2
Notes
704, 704LP, 706, 706LP, 726
718, 718LP, 720, 720LP, 727
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
97
FOOT THROTTLE AND LINKAGE
SUZUKI 660 HAULSTER MODELS 898704, 898704LP, 898706, 898706LP,
898718, 898718LP, 898720 & 898720LP
and
DIESEL MODELS 898726 & 898727
10
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
(15)
11
7
9
Used on
Later models
(21)
Used on
Earlier Models
22
(22)
21
P893675, P895114, 2700566
98
Used on
Later Models
FOOT THROTTLE AND LINKAGE
SUZUKI 660 HAULSTER MODELS 898704, 898704LP, 898706, 898706LP,
898718, 898718LP, 898720 & 898720LP
and
DIESEL MODELS 898726 & 898727
Ref.
No.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
(14)
15
(15)
16
17
18
19
20
21 306328
844224
450452
452378
452695
515268
524633
524643
548911
800943
806714
844223
830784
841663
844445
843360
2703257.7
843561
843562
843563
843997
894159
895119
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
Spring, torsion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Pin, clevis, 1/4 x 1 7/8 . . . . . . . . . . . . . . . . . . . . . . 1
Panel, floor access (4-wheel) . . . . . . . . . . . . . . . . 1
Panel, floor access (3-wheel) . . . . . . . . . . . . . . . . 1
Channel, mount . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Channel, mount . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Link, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Mount, channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Plate, pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Bracket, stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Pedal, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cable, throttle (Suzuki 660) (discontinued) . . . . . . . 1
(21)
22 2703684
894618
Cable, throttle (Suzuki 660 models) . . . . . . . . . . . . 1
Cable, throttle (Perkins) (discontinued) . . . . . . . . . . 1
(22)
2703683
Cable, throttle (Perkins) . . . . . . . . . . . . . . . . . . . . . 1
Description
No.
Req’d
Notes
Earlier Models
Later Models
Earlier Models
(Use 2703833 Replacement Kit)
Later Models
Earlier Diesel Models
(Use 2703834 Replacement Kit)
Later Diesel Models
Throttle cable Ref. No. 21 (895119) has been discontinued. When replacing the 895119 throttle cable,
use Part No. 2703833, Throttle Cable Replacement Kit. This kit includes one (1) 2703684 throttle
cable and one (1) 2703257.7 channel mount.
The diesel throttle cable Ref. No. 22 (894618) has been discontinued. When replacing the 894618
throttle cable, use Part No. 2703834, Throttle Replacement Kit. This kit includes one (1) 2703683
throttle cable and one (1) 2703257.7 channel mount.
99
STEERING WHEEL, STEERING SHAFT,
POWER STEERING PUMP and STEERING GEAR
SUZUKI 660 4-WHEEL HAULSTER MODELS 898704, 898704LP, 898718, 898718LP,
898720 & 898720LP and DIESEL MODELS 898726 & 898727
14
13
15
10
1
29
9
9
32
8
26
28
27 16
15
18
17
12
19
11
3
6
21
20
7
18
19
Reference
Front Clip
2
22
5
30
23
24
25
4
Included
With Ref. No. 25
31
P893331
Reference
Lower Rops
100
STEERING WHEEL, STEERING SHAFT,
POWER STEERING PUMP and STEERING GEAR
SUZUKI 660 4-WHEEL HAULSTER MODELS 898704, 898704LP, 898718, 898718LP,
898720 & 898720LP and DIESEL MODELS 898726 & 898727
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
(26)
27 28
29
30
31
32
320107
450453
450457
800930
450739
2700453
819923
823549
830930
809092
892486
839862
840222
843767
111838
843768
111838
808060
828590
892228
893344
893571
303269
311392
841336
2700565
2703764
892534
839907
2700573
841255
306799
800943
Description
No.
Req’d
Tie, cable, 7 1/2” (190 mm) . . . . . . . . . . . . . . . . . . .
Nut, M8-1.25 (G10.9) . . . . . . . . . . . . . . . . . . . . . . .
Nut, M16-2.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M8-1.25 x 16 (G8.8) . . . . . . . . . . . . . . . . . .
Screw, M10-1.50 x 30 (G12.9) . . . . . . . . . . . . . . . .
Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Collar, foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tie, cable, 15 1/2” (394 mm) . . . . . . . . . . . . . . . . .
Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamp, tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover, steering wheel center . . . . . . . . . . . . . . . .
Decal, steering wheel . . . . . . . . . . . . . . . . . . . . . .
Hose, 3/8 i.d. x 90 elbow . . . . . . . . . . . . . . . . . . .
Hose, steering pressure . . . . . . . . . . . . . . . . . . . .
‘O’-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, steering return . . . . . . . . . . . . . . . . . . . . . . .
‘O’-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing, needle . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing, bearing . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel, steering (w/o horn) . . . . . . . . . . . . . . . . . . .
Shaft, steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tube, steering mount . . . . . . . . . . . . . . . . . . . . . . .
Lockwasher, 7/16 . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, 7/16-14 x 2 . . . . . . . . . . . . . . . . . . . . . . . . .
Arm, pitman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V-belt, 45” (1143 mm) . . . . . . . . . . . . . . . . . . . . . . . .
V-belt, 48” (1219 mm) . . . . . . . . . . . . . . . . . . . . . . .
Pump, power steering . . . . . . . . . . . . . . . . . . . . . .
Pulley, steering pump . . . . . . . . . . . . . . . . . . . . . .
Cap, steering reservoir . . . . . . . . . . . . . . . . . . . . .
Gear, power steering . . . . . . . . . . . . . . . . . . . . . . .
Lockwasher,5/16 external, shakeproof . . . . . . . . .
Screw, tap, #10-24 x 5/8 . . . . . . . . . . . . . . . . . . . .
3
1
1
2
1
1
2
2
2
2
1
1
1
1
2
1
1
2
2
1
1
1
3
3
1
1
1
1
1
1
1
2
1
Notes
Suzuki 660 Models
Diesel Models
See Note Below
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING 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).
101
STEERING WHEEL, STEERING SHAFT AND STEERING GEAR
3-WHEEL SUZUKI 660 HAULSTER MODELS 898706 & 898706LP
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
7
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
102
P893578
STEERING WHEEL, STEERING SHAFT AND STEERING GEAR
3-WHEEL SUZUKI 660 HAULSTER MODELS 898706 & 898706LP
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
303269
306825
306799
311392
450453
450457
450739
800930
2700453
819923
816586
892486
839862
845225
808060
828590
887597
892228
893564
893571
302944
800485
831405
2702200
887512
306328
548224
887750
306328
548224
*
27
28
*
Description
No.
Req’d
Lockwasher, 7/16 . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, castle, 7/16-20 . . . . . . . . . . . . . . . . . . . . . . . .
Lockwasher, 5/16 ext. shkprf. . . . . . . . . . . . . . . . .
Screw, 7/16-14 x 2 (G5) . . . . . . . . . . . . . . . . . . . . .
Nut, M8-1.25 (10.9) . . . . . . . . . . . . . . . . . . . . . . . .
Nut, M16-2.00 (10.9) . . . . . . . . . . . . . . . . . . . . . . .
Bolt, M10-1.50 x 30 sckthd (12.9) . . . . . . . . . . . . .
Screw, M8-1.25 x 16 (8.8) . . . . . . . . . . . . . . . . . . .
Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Collar, foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retainer, grease . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover, steering wheel center . . . . . . . . . . . . . . . .
Decal, steering wheel . . . . . . . . . . . . . . . . . . . . . .
Arm, pitman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing, needle . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . .
3
2
2
3
2
1
1
2
1
2
2
1
1
1
2
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
Notes
Not Illustrated. See Note Below
Not Illustrated. See Note Below
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
* 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.
103
HYDRAULIC BRAKES WITHOUT FRONT BRAKES
4-WHEEL SUZUKI 660 MODELS 898704 & 898704LP
3-WHEEL SUZUKI 660 MODELS 898706 & 898706LP
and DIESEL MODELS 898726
8
17
19
30
21
18
33
31
8
11
11
7
15
34
5
Some Vehicles May Not Be
Equipped With Item No. 34,
Master Cylinder Bracket.
29
6
25
28
26
25
4
16
23
Reference
Frame
5
3
22
12
To Rear Brake Hose
Connection
9
1
2
13
10
5
27
20
3
14
24
27
25
104
P894381
HYDRAULIC BRAKES WITHOUT FRONT BRAKES
4-WHEEL SUZUKI 660 MODELS 898704 & 898704LP
3-WHEEL SUZUKI 660 MODELS 898706 & 898706LP
and DIESEL MODELS 898726
Ref.
No.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
(17)
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32 *
33
34
103867
306328
450453
450510
452388
452424
845380
800934
806714
810152
825624
840725
840726
842051
842103
842935
843022
844057
843858
844167
892921
895113
894167
890808
450454
452398
809137
810435
800943
812445
894456
2702215
825886
826006
2701737.7
Description
No.
Req’d
Washer, 5/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Pin, cotter, 3/32 x 3/4 . . . . . . . . . . . . . . . . . . . . . . . 1
Nut, M8-1.25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Screw, M3-.50 x 20 (RPH) . . . . . . . . . . . . . . . . . . . 2
Screw, M8-1.25 x 20 . . . . . . . . . . . . . . . . . . . . . . . 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 (4-wheel) . . . . . . . . . . . . . . . . . . . 1
Tube, rear brake (3-wheel) . . . . . . . . . . . . . . . . . . . 1
Plug, M10 . . . . . . . . . . . . . . . . . . . . . . . . . As Req’d.
Bracket, reservoir mounting . . . . . . . . . . . . . . . . . 1
Lever, brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cylinder, brake (dual) . . . . . . . . . . . . . . . . . . . . . . . 1
Rod, brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Switch, micro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nut, M10-1.50 (G10.9) . . . . . . . . . . . . . . . . . . . . . . 1
Screw, M10-1.50 x 20 (8.8) . . . . . . . . . . . . . . . . . . 7
Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Screw, tap #10-14 x 5/8 . . . . . . . . . . . . . . . . . . . . 1
Clamp, tube/wire . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Reservoir ay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Reservoir, brake fluid . . . . . . . . . . . . . . . . . . . . . . 1
Terminal, 1/4 L male . . . . . . . . . . . . . . . . . . . . . . . . 2
Connector, 2 contact female . . . . . . . . . . . . . . . . . 1
Bracket, master cylinder . . . . . . . . . . . . . . . . . . . . 1
Notes
Hose is Serviced as a 6’ Length
Not Illustrated
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
105
HYDRAULIC BRAKES WITH FRONT BRAKES
4-WHEEL SUZUKI 660 HAULSTER MODELS
898718, 898718LP, 898720 & 898720LP
and DIESEL MODELS 898727
8
19
33
21
18
35
11
36
8
11
7
17
23
Mounts To Front
Suspension Frame
31
24
15
37
5
Some Vehicles May Not Be
Equipped With Item No. 37,
Master Cylinder Bracket.
30
6
27
29
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
106
P893441
HYDRAULIC BRAKES WITH FRONT BRAKES
4-WHEEL SUZUKI 660 HAULSTER MODELS
898718, 898718LP, 898720 & 898720LP
and DIESEL MODELS 898727
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
103867
306328
450453
450510
452388
452424
845380
800934
806714
810152
825624
840725
840726
842051
842103
842935
843022
843021
844167
892921
895113
894167
452692
890808
450454
452398
809137
810435
800943
812445
841842
843418
894456
825886
826006
2702215
2701737.7
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
Lever, brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cylinder, brake (dual) . . . . . . . . . . . . . . . . . . . . . . . 1
Rod, brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Screw, tap M6-1.00 x 12 . . . . . . . . . . . . . . . . . . . . 1
Switch, micro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nut, M10-1.50 (G10.9) . . . . . . . . . . . . . . . . . . . . . . 1
Screw, M10-1.50 x 20 (8.8) . . . . . . . . . . . . . . . . . . 7
Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Screw, tap #10-14 x 5/8 . . . . . . . . . . . . . . . . . . . . 1
Clamp, tube/wire . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tee, M10-1.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Clamp, tee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Reservoir, brake fluid . . . . . . . . . . . . . . . . . . . . . . . 1
Terminal, 1/4 L male . . . . . . . . . . . . . . . . . . . . . . . 2
Connector, 2-contact female . . . . . . . . . . . . . . . . 1
Reservoir, brake fluid . . . . . . . . . . . . . . . . . . . . . . 1
Bracket, master cylinder . . . . . . . . . . . . . . . . . . . . 1
Notes
Hose is Serviced as a 6’ Length
Not Illustrated
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
107
CLUTCH PEDAL & CABLE
SUZUKI 660 HAULSTER
MODELS 898704, 898704LP, 898706, 898706LP, 898718 & 898718LP
5
1
10
4
14
2
15
11
7
3
8
6
9
13
12
P2701278
Ref.
No.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
450453
450510
306328
452388
452424
806714
810152
840725
840726
842935
892933
895013
844202
890808
844611
108
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing, brake pivot . . . . . . . . . . . . . . . . . . . . . . . .
Tab, locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lever, clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable, clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, slotted . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, clutch interlock . . . . . . . . . . . . . . . . . . . . .
Spring, torsion . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
2
1
1
1
1
1
1
1
4
1
1
Notes
AIR CLEANER, BRACKET and FILTER
SUZUKI 660 EFI HAULSTER MODEL 898720 Built Before 8–9–00
To Radiator
Mounting Frame
3
17
2
13
1
15
9
7
14
16
8
9
7
6
12
4
10
18
11
5
Shown For
Reference Only
2700566, 2702006
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Part
No.
300646
306396
308090
452378
450453
452388
825358
834217
825358
842915
842997
450452
893182
840352
888549
2700162
2700333
2700329.7
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 . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, air filter . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cap, 7/64 i.d. x 3x4 . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, M6-1.00 (10.9) . . . . . . . . . . . . . . . . . . . . . . . . .
Filter complete, air . . . . . . . . . . . . . . . . . . . . . . . . .
Element, air cleaner . . . . . . . . . . . . . . . . . . . . . . .
Connector, hose (air cleaner) . . . . . . . . . . . . . . . . .
Hose, air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector, hose 3/8 to 1/2 . . . . . . . . . . . . . . . . . .
Bracket, air cleaner . . . . . . . . . . . . . . . . . . . . . . . .
Notes
2
2
2
2
2
2
4
1
2
1
1
2
1
1
1
1
1
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
109
AIR CLEANER, BRACKET and FILTER
SUZUKI 660 EFI HAULSTER MODELS 898704, 898706, 898718
HAULSTER MODEL 898720 Built After 8–9–00
and
SUZUKI 660 HAULSTER MODELS 898704LP, 898706LP, 898718LP & 898720LP
3
To Radiator
Mounting Frame
Used on Some Earlier
704, 706, 718 & 720 Models
2
1
14
12
20
16
With LPG Models
704LP, 706LP,
718LP & 720LP
7
22
8
9
19
13
7
15
9
5
10
17, (17)
6
4
11
18
23
Shown For
Reference Only
P2700567, 2701395
110
AIR CLEANER, BRACKET and FILTER
SUZUKI 660 EFI HAULSTER MODELS 898704, 898706, 898718
HAULSTER MODEL 898720 Built After 8–9–00
and
SUZUKI 660 HAULSTER MODELS 898704LP, 898706LP, 898718LP & 898720LP
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
(17)
18
19
20
21
22
Part
No.
300646
306396
308090
800934
450453
452389
825358
834217
825358
842915
842997
893182
840352
888549
2701393
841230
2701446.7
2704065.7
2702431
2703985
2700333
450452
830930
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 . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, air filter . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cap, 7/64 i.d. x 3x4 . . . . . . . . . . . . . . . . . . . . . . . . .
Filter complete, air . . . . . . . . . . . . . . . . . . . . . . . . .
Element, air cleaner . . . . . . . . . . . . . . . . . . . . . . .
Connector, hose (air cleaner) . . . . . . . . . . . . . . . . .
Hose, air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector, hose 3/8T to 1/8MP . . . . . . . . . . . . . .
Bracket, air cleaner . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, air cleaner . . . . . . . . . . . . . . . . . . . . . . . .
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector, hose 3/8 to 1/2 . . . . . . . . . . . . . . . . . .
Nut, M6-1.00 (10.9) . . . . . . . . . . . . . . . . . . . . . . . . .
Clamp, worm drive, .87 dia. . . . . . . . . . . . . . . . . .
2
2
2
2
2
2
4
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
1
Notes
LPG Models Only
LPG Models Only
Used on some earlier Haulster models
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
111
FRONT SUSPENSION Without FRONT BRAKES (Right Side)
TIE RODS, STEERING GEAR AND SKID PLATE
4-WHEEL HAULSTER MODELS 898704, 898704LP & 898726
11
15
46
34
8
7
17
13
41
43
45
14
42
44
21
16
10
35
36
25
23
24
27
50
30
36
29
With
Ref. No. 28
18
35
22
2
3
47
32
19
15
With
Ref. No. 18
48
6
17
4
39
38
15
28
33
49
1
With
Ref. No. 37
31
6
5
15
20
12
37
47
40
When Ordering Items No.
28 or 37, You Will Also
Need To Order Item No. 15.
26
9
112
P894382, 894378
FRONT SUSPENSION Without FRONT BRAKES (Right Side)
TIE RODS, STEERING GEAR AND SKID PLATE
4-WHEEL HAULSTER MODELS 898704, 898704LP & 898726
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
34
35
36
37
38
*
39
40
41
42
43
44
45
46
47
48
49
50
Part
No.
302944
303269
311392
450077
450382
450393
450457
304636
452408
800945
817250
800485
385174
815403
831405
817928
841167
841255
841336
841404
844148
841429
841630
841737
841738
842033
894574
887512
306328
548224
306825
816586
893234
893421
800909
306328
306825
887750
306328
548224
306825
816586
893266
893206
808088
814474
800908
311537
450455
452413
452415
894635
Description
No.
Req’d
Notes
Nut, jam, 9/16-18 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Lockwasher, 7/16 . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Screw, 7/16-14 x 2 . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bolt, M16-2.00 x 90 . . . . . . . . . . . . . . . . . . . . . . . . 2
Nut, M16-2.00 locking insert . . . . . . . . . . . . . . . . . 2
Washer, M16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Nut, M16-2.00, flange (G10.9) . . . . . . . . . . . . . . . . 2
Pin, cotter 1/8 x 1 1/8 . . . . . . . . . . . . . . . . . . . . . . . 1
Screw, M10-1.75 x 20 . . . . . . . . . . . . . . . . . . . . . . 6
Screw, M12-1.75 x 60 (G10.9) . . . . . . . . . . . . . . . . 2
Cap, grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nut, 9/16-18, left-hand . . . . . . . . . . . . . . . . . . . . . . 1
Bearing, cone (outer) . . . . . . . . . . . . . . . . . . . . . . . . 4
Bearing cone (inner) . . . . . . . . . . . . . . . . . . . . . . . . 1
Fitting, grease, 1/4-28 (90) . . . . . . . . . . . . . . . . . 4
Seal, grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bushing, silentbloc . . . . . . . . . . . . . . . . . . . . . . . . . 4
Gear, power steering . . . . . . . . . . . . . . . . . . . . . . . 1
Arm, pitman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Rod, tie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Ball joint, upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Ball joint, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trunnion, control arm . . . . . . . . . . . . . . . . . . . . . . . 1
Shim, .060” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Shim, .024” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Plate, skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Knuckle, steering, (right) . . . . . . . . . . . . . . . . . . . . . 1
End assembly, tie rod (right) . . . . . . . . . . . . . . . . . 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
Nut, wheel retaining, M12-1.50 . . . . . . . . . . . . . . 5
Pin, cotter, 3/32 x 3/4 . . . . . . . . . . . . . . . . . . . . . . . 2
Nut, castle, 7/16-20 . . . . . . . . . . . . . . . . . . . . . . . . 2
End assembly, tie rod (left) . . . . . . . . . . . . . . . . . . 1
Pin, cotter, 3/32 x 3/4 . . . . . . . . . . . . . . . . . . . . . . 1
Fitting, lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nut, castle, 7/16-20 . . . . . . . . . . . . . . . . . . . . . . . . 1
Retainer, grease . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Arm assembly, upper control . . . . . . . . . . . . . . . . 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, M12-1.75 (G10.9) . . . . . . . . . . . . . . . . . . . . . 12
Screw, M12-1.75 x 60 . . . . . . . . . . . . . . . . . . . . . 4
Screw, M12-1.75 x 80 (8.8) . . . . . . . . . . . . . . . . . 8
Strut ay. (shock & spring) . . . . . . . . . . . . . . . . . . . . 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.
113
FRONT SUSPENSION Without FRONT BRAKES (Left Side)
TIE RODS, STEERING GEAR AND SKID PLATE
4-WHEEL HAULSTER MODELS 898704, 898704LP & 898726
Reference
Front Frame
(Part No. 893421)
Reference
Pitman Arm
(Part No. 841336)
3
25
24
With
Ref. No. 23
12
20
When Ordering Items No.
23 or 31, You Will Also
Need To Order Item No. 12.
1
23
21
4
7
19
14
26
13
34
8
31
5
12
35
12
42
With
Ref. No. 31
32
33
29
15
30
40
13
16
30
22
29
4
2
27
18
41
10
12
28
6
17
38
36
P894382, 894378
114
39
37
9
11
FRONT SUSPENSION Without FRONT BRAKES (Left Side)
TIE RODS, STEERING GEAR AND SKID PLATE
4-WHEEL HAULSTER MODELS 898704, 898704LP & 898726
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
34
35
36
37
38
39
40
41
42
Part
No.
302944
450077
450382
450393
450457
311537
800945
800485
385174
815403
304636
831405
841167
841404
844148
841429
817250
817928
841630
841738
841738
894573
887512
306328
548224
306825
816586
893233
800909
306328
306825
887750
306328
548224
306825
816586
893266
893206
808088
814474
800908
450455
450413
894635
Description
No.
Req’d
Notes
Nut, jam, 9/16-18 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bolt, M16-2.00 x 90 . . . . . . . . . . . . . . . . . . . . . . . . 2
Nut, M16-2.00 locking insert . . . . . . . . . . . . . . . . . 2
Washer, M16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Nut, M16-2.00, flange (G10.9) . . . . . . . . . . . . . . . . 2
Nut, castle 3/4-16 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bolt, M12-1.75 x 60 (10.9) . . . . . . . . . . . . . . . . . . . 2
Nut, 9/16-18, left-hand . . . . . . . . . . . . . . . . . . . . . . 1
Bearing, cone (outer) . . . . . . . . . . . . . . . . . . . . . . . 1
Bearing, cone (inner) . . . . . . . . . . . . . . . . . . . . . . . . 1
Pin, cotter 1/8 x 1 1/8 . . . . . . . . . . . . . . . . . . . . . . . 1
Fitting, grease, 1/4-28 (90) . . . . . . . . . . . . . . . . . . 4
Bushing, silentbloc . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rod, tie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Ball joint, upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Ball joint, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cap, grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Seal, grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trunnion, control arm . . . . . . . . . . . . . . . . . . . . . . . 1
Shim, .060” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Shim, .024” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Knuckle, steering (left) . . . . . . . . . . . . . . . . . . . . . . 1
End assembly, tie rod (right) . . . . . . . . . . . . . . . . . 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
Nut, wheel retaining, M12-1.50 . . . . . . . . . . . . . . 5
Pin, cotter, 3/32 x 3/4 . . . . . . . . . . . . . . . . . . . . . . . 1
Nut, castle, 7/16-20 . . . . . . . . . . . . . . . . . . . . . . . . 1
End assembly, tie rod (left) . . . . . . . . . . . . . . . . . . 1
Pin, cotter, 3/32 x 3/4 . . . . . . . . . . . . . . . . . . . . . . 1
Fitting, lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nut, castle, 7/16-20 . . . . . . . . . . . . . . . . . . . . . . . . 1
Retainer, grease . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Arm assembly, upper control . . . . . . . . . . . . . . . . 1
Hub assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cup, bearing (outer) . . . . . . . . . . . . . . . . . . . . . . . . 1
Cup, bearing (inner) . . . . . . . . . . . . . . . . . . . . . . . . 1
Screw, lug M12-1.50 x 42 . . . . . . . . . . . . . . . . . . 5
Nut, M12-1.75 (G10.9) . . . . . . . . . . . . . . . . . . . . . 12
Screw, M12-1.75 x 60 (8.8) . . . . . . . . . . . . . . . . . . 4
Strur ay. (shock & spring) . . . . . . . . . . . . . . . . . . . 2
• 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.
115
FRONT FORK
SUZUKI 660 3-WHEEL HAULSTER
MODELS 898706 & 898706LP
4
12
2
Hold the Nut Below From Turning and
Tighten This Nut to 100 9ft.-lbs. of
Torque. The Fork Must Turn Freely.
1
3
Reference
3-Wheel Frame
Tighten this Nut to 15 ft.-lbs. of
Torque. Hold This Nut While
Tightening the Top Nut.
2
4
11
7
8
10
18
6
22
17
7
13
20
5
9
14
25
23
8
24
21
22
19
20
16
16
15
17
18
P893577
116
FRONT FORK
SUZUKI 660 3-WHEEL HAULSTER
MODELS 898706 & 898706LP
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.
307665
842646
844180
844190
450075
450382
450455
452413
813850
841167
894549
307665
894550
894636
823621
825500
304104
306494
307665
809156
836719
844508
385174
809229
836621
894535
800908
808088
809268
894561
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 . . . . . . . . . . . . . . . . . .
Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, 5/8-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lockwasher, 5/8 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, 3/4-16, jam . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, 5/8 x 1 3/8 dia. . . . . . . . . . . . . . . . . . . . . .
Nut, bearing adjustment . . . . . . . . . . . . . . . . . . . .
Washer, keeper . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cone, tapered roller bearing . . . . . . . . . . . . . . . . .
Washer, 3/4 x 1.6 dia. . . . . . . . . . . . . . . . . . . . . . .
Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hub, complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt, lug M12-1.50 x 42 . . . . . . . . . . . . . . . . . . . .
Cup, tapered bearing . . . . . . . . . . . . . . . . . . . . . .
Ring, bearing backing . . . . . . . . . . . . . . . . . . . . .
Axle, complete . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes
1
2
1
2
2
2
4
4
2
2
1
1
1
1
1
1
2
2
1
2
1
2
2
2
2
1
5
2
2
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
* Not Illustrated
117
GOVERNOR AND THROTTLE LINKAGE
SUZUKI 660 EFI HAULSTER MODEL 898720 Built Before 8–9–00
33
To
Carburetor
24
5
13
7
16
4
3
20
36
4
26
25 *
29
51
50
8
42
2
30
12
35
20
8
8
37
19
25 *
9
13
12
11
9
28
LOCTITE 242
* USE
ON THESE ITEMS
22
27
40
5
41
32
18
21
1
34
23
5
Reference
Govenor Bracket
Part No. 895014.7
10
6
46
17
49
19
13
31
39
9
8
1
38
8
14
To
Accelerator
Pedal
48 *
44
15 *
47 *
43
46
44
45
2700901
118
GOVERNOR AND THROTTLE LINKAGE
SUZUKI 660 EFI HAULSTER MODEL 898720 Built Before 8–9–00
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
45
46
47
48
49
50
51
103867
111893
130728
2702244
306320
306325
306372
306375
306396
306450
306487
306981
308090
450454
452378
452401
548190
2702249
302288
800024
800927
806773
810722
813379
830140
831586
833101
894434
835271
2700334
843013
843536
2700503
2700810
2701129
2700859
2700540
894464
895119
843866
894435
2700335
2700502
2700522
2700523
450452
452381
452383
452548
450399
821164
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring, extension . . . . . . . . . . . . . . . . . . . . . . . . . .
Arm assembly, governor . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring, extension . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulley, governor . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rod, governor arm . . . . . . . . . . . . . . . . . . . . . . . . .
Cable, carburetor . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor, complete . . . . . . . . . . . . . . . . . . . . . . . .
Arm, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arm, governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lever, governor (Suzuki 660) . . . . . . . . . . . . . . . . . .
Base, throttle (Suzuki 660) . . . . . . . . . . . . . . . . . . . .
Cable, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushing, governor . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket assembly, governor . . . . . . . . . . . . . . . . .
Spring, governor . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, lower govnr. mount . . . . . . . . . . . . . . . . .
Bushing, standoff, 1” (25.4 mm) . . . . . . . . . . . . . . .
Bushing, standoff, 1 3/4” (44.5 mm) . . . . . . . . . . . . .
Nut, M6-1.00 (10.9) . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M6-1.00 x 40 (8.8) . . . . . . . . . . . . . . . . . . .
Screw, M6-1.00 x 60 (8.8) . . . . . . . . . . . . . . . . . . .
Bolt, carriage, M6-1.00 x 50 (G4.6) . . . . . . . . . . . .
Washer, M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin, hair (1/4 x 1 1/8) . . . . . . . . . . . . . . . . . . . . . . . .
Notes
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
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
119
GOVERNOR AND THROTTLE LINKAGE
SUZUKI 660 EFI HAULSTER MODELS 898704, 898706, 898718
and
MODELS 898720 Built After 8–9–00
To
Throttle Body
31
3
24
5
13
7
16
20
4
4
29
40
39
8
38
2
37
34
33
26
25 *
8
35
12
25 *
12
LOCTITE 242
* USE
ON THESE ITEMS
11
9
4
28
21
27
23
4
5
22
2
18
32
30
5
1
15 *
17
19
To
Accelerator
Pedal
36
Reference
Governor Bracket
10
6
1
41
14
8
P2701395
120
Mounts
to Engine
Mounts
to Engine
GOVERNOR AND THROTTLE LINKAGE
SUZUKI 660 EFI HAULSTER MODELS 898704, 898706, 898718
and
MODELS 898720 Built After 8–9–00
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
103867
111893
130728
2702244
306320
306325
306372
306375
306396
306450
306487
306981
308090
450454
452388
452401
548190
2702249
302288
800024
806773
843536
810722
813379
830140
831586
833101
833366
835271
895119
2700503
2700810
2701129
2700859
2700540
2701609
2700334
2700335
450399
821164
2701829
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 . . . . . . . . . . . . . . . . . . . . . . . . .
Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin, clevis 1/4 x 3/8 . . . . . . . . . . . . . . . . . . . . . . . .
Bearing, ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ball joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring, extension . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable, throttle body . . . . . . . . . . . . . . . . . . . . . . . .
Governor, complete . . . . . . . . . . . . . . . . . . . . . . . .
Arm, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arm, governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lever, governor . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring, extension . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring, governor . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin, hair (1/4 x 1 1/8) . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes
6
2
1
4
3
2
1
3
2
2
2
5
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
1
1
1
1
121
ALTERNATOR, ENGINE BELTS, PULLEYS and BRACKETS
SUZUKI 660 EFI HAULSTER MODELS
898720 Built Before 8-9-00
5
6
Reference
Power Steering Pump
Part No. 892534
GOV
ALT
Reference
Alternator
19
Part No. 893633
16
WATER
PUMP
PWR
STRNG
CRNKSHFT
12
ENGINE BELT DIAGRAM
MODEL 898720
18
2
1
4
12
17
Reference
Governor
Part No. 2700810
To
Engine
26
7
To
Engine
13 *
10
11
20
13
14
21
9
4 1
3
8
13
15
ALTERNATOR WIRING
To
Water Pump
G
G/B
W/R
EXC
P
S
B
25
24
E
22
B
R
R
*
Use Loctite 242
On These Items
23
R
R/W
R
122
To
Engine
Crankshaft
2700901
ALTERNATOR, ENGINE BELTS, PULLEYS and BRACKETS
SUZUKI 660 EFI HAULSTER MODELS
898720 Built Before 8-9-00
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
548804
450399
306325
306375
306396
306416
306450
450432
306981
311213
450453
452388
452394
844035
836854
839907
895010.7
2700565
895014.7
452378
2701944
2701941
2702537
2702524
2701110.7
Description
No.
Req’d
Washer, 3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, 3/8-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lockwasher, 5/16 . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, 1/4-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lockwasher, 1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, 5/16-18 x 1 . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, 5/16-18 x 3/4 . . . . . . . . . . . . . . . . . . . . . . .
Lockwasher, M6 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, 3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, 3/8-16 x 3 . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, M8-1.25 (G10.9) . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M8-1.25 x 20 (8.8) . . . . . . . . . . . . . . . . . . .
Screw, M8-1.25 x 70 (8.8) . . . . . . . . . . . . . . . . . . .
Pulley, 4.75” (governor) . . . . . . . . . . . . . . . . . . . . . .
V-belt, 42” (1067 mm) . . . . . . . . . . . . . . . . . . . . . . . .
Pulley, 5.50” (steering pump) . . . . . . . . . . . . . . . . . .
Bracket, alternator mounting . . . . . . . . . . . . . . . .
V-belt, 45” (1143 mm) . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, governor mounting . . . . . . . . . . . . . . . . .
Screw, M6-1.00 x 20 . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulley, crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulley, water pump . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, upper radiator hose . . . . . . . . . . . . . . . .
Notes
3
1
1
3
1
1
1
2
1
1
1
3
6
2
1
1
1
1
1
1
1
1
1
4
1
1
123
ALTERNATOR, ENGINE BELTS, PULLEYS and BRACKETS
SUZUKI 660 HAULSTER MODELS
898704, 898704LP, 898718 & 898718LP
and
SUZUKI 660 HAULSTER MODELS 898720 Built After 8-9-00
GOV
ALT
Reference
Power Steering Pump
18
5
6
Reference
Alternator
16
WATER
PUMP
3
PWR
STRNG
2
CRNKSHFT
14
To
Engine
ENGINE BELT DIAGRAM
MODELS 898704 & 898718
13 *
4
1
*
Use Loctite 242
On These Items
7
9
Reference Governor
10
12
12
17
19
13
To
Engine
25
11
6
26
13
24
28
To
Engine
Crankshaft
27
15
21
20
G
W/R
P
S
B
4 1
8
22
G/B
EXC
To
Water Pump
23
E
B
R
R
R
R/W
R
ALTERNATOR WIRING
124
P2701395
ALTERNATOR, ENGINE BELTS, PULLEYS and BRACKETS
SUZUKI 660 HAULSTER MODELS
898704, 898704LP, 898718 & 898718LP
and
SUZUKI 660 HAULSTER MODELS 898720 Built After 8-9-00
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
Part
No.
103867
120052
306531
306325
306375
306396
306416
306450
548804
839907
306837
450453
452388
452394
844035
2701109
2701657.7
2700565
2701691.7
2701944
2701941
2702537
2702524
450400
452378
2701688.7
452692
2703732.7
Description
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulley, 5.50” (steering pump) . . . . . . . . . . . . . . . . . .
Screw, 3/8-16 x 3 1/4 . . . . . . . . . . . . . . . . . . . . . . .
Nut, M8-1.25 (G10.9) . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M8-1.25 x 20 (8.8) . . . . . . . . . . . . . . . . . . .
Screw, M8-1.25 x 70 (8.8) . . . . . . . . . . . . . . . . . . .
Pulley, 4.75” (governor) . . . . . . . . . . . . . . . . . . . . . .
V-belt, 41” (1041 mm) . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, alternator mounting . . . . . . . . . . . . . . . .
V-belt, 45” (1143 mm) . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, governor mounting . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulley, crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulley, water pump . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M6-1.00 x 20 . . . . . . . . . . . . . . . . . . . . . . .
Bracket, upper radiator hose . . . . . . . . . . . . . . . .
Screw, M6-1.00 x 12, taptite . . . . . . . . . . . . . . . . .
Guard, hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes
3
4
4
3
1
2
1
2
1
1
1
3
5
2
1
1
1
1
1
1
1
4
1
1
1
1
2
1
125
ALTERNATOR, ENGINE BELTS, PULLEYS and BRACKETS
SUZUKI 660 HAULSTER MODELS 898706 & 898706LP
GOV
ALT
5
6
Reference
Alternator
18
16
WATER
PUMP
Part No. 893633
3
2
CRNKSHFT
To
Engine
ENGINE BELT DIAGRAM
MODEL 898706
13 *
1
*
4
Use Loctite 242
On These Items
7
Reference Governor
Part No. 2700810
9
12
19
17
To
Engine
10
11
6
14
13
24
26
To
Engine
Crankshaft
25
21
15
20
4 1
8
To
Water Pump
G
G/B
W/R
EXC
P
S
B
22
23
E
B
R
R
R
R/W
R
ALTERNATOR WIRING
126
P2701740
ALTERNATOR, ENGINE BELTS, PULLEYS and BRACKETS
SUZUKI 660 HAULSTER MODELS 898706 & 898706LP
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
120052
306531
306325
306375
306396
306416
306450
548804
452378
306837
450453
452388
2701688.7
844035
2701109
2701657.7
2701365
2701691.7
2701944
2701941
2702537
2702524
450400
452692
2703732.7
Description
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M6-1.00 x 20 . . . . . . . . . . . . . . . . . . . . . . .
Screw, 3/8-16 x 3 1/4 . . . . . . . . . . . . . . . . . . . . . . .
Nut, M8-1.25 (G10.9) . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M8-1.25 x 20 (8.8) . . . . . . . . . . . . . . . . . . .
Bracket, upper radiator hose . . . . . . . . . . . . . . . .
Pulley, 4.75” (governor) . . . . . . . . . . . . . . . . . . . . . .
V-belt, 41” (1041 mm) . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, alternator mounting . . . . . . . . . . . . . . . .
V-belt, 39” (990 mm) . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, governor mounting . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulley, crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulley, water pump . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M6-1.00 x 12, taptite . . . . . . . . . . . . . . . . .
Guard, hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes
3
4
4
3
1
2
1
2
1
1
1
1
4
1
1
1
1
1
1
1
1
4
1
1
2
1
127
ALTERNATOR, ENGINE BELTS, PULLEYS and BRACKETS
DIESEL MODELS 898726 & 898727
G
ALT
W/G
W/R
EXC
S
WTR
PUMP
15
R
G
MODELS
898726 & 898727
B
POWER
STRNG
B
R
CRNKSHFT
R
Reference
Fan Switch Tube
(With Radiator)
9
17
6
8
4
Reference
Throttle Bracket
9
Reference
Alternator
3
8
Shown For
Reference Only
1
Existing
Hardware
13
18
Reference
Pwr Strng Pump
8
19
16
7
8
9
2
20
14
5
5
10
6
14
12
2
11
22
6
21
Existing
Hardware
9
23
P2704009
128
ALTERNATOR, ENGINE BELTS, PULLEYS and BRACKETS
DIESEL MODELS 898726 & 898727
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
103867
120166
306325
306416
306836
306981
311213
450453
452388
452394
452390
452395
548804
800921
2703764
839907
2704062.7
844271
844268
844270
844272
843760
821893
Description
No.
Req’d
Notes
Washer, 3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Lockwasher, 1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Lockwasher, 5/16 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Screw, 5/16-18 x 1 . . . . . . . . . . . . . . . . . . . . . . . . . 1
Screw, 3/8-16 x 2 1/4 . . . . . . . . . . . . . . . . . . . . . . . 2
Washer, 3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Screw, 3/8-16 x 3 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nut, M8-1.25 (G10.9) . . . . . . . . . . . . . . . . . . . . . . . 8
Screw, M8-1.25 x 20 (8.8) . . . . . . . . . . . . . . . . . . . 5
Screw, M8-1.25 x 70 (8.8) . . . . . . . . . . . . . . . . . . . 2
Screw, M8-1.25 x 30 (8.8) . . . . . . . . . . . . . . . . . . . 3
Screw, M8-1.25 x 80 (8.8) . . . . . . . . . . . . . . . . . . . 2
Nut, flange 3/8-16 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Screw, M12-1.25 x 20 (8.8) . . . . . . . . . . . . . . . . . 2
V-belt, 48” (1219 mm) . . . . . . . . . . . . . . . . . . . . . . 1
Pulley, 5.50” (steering pump) . . . . . . . . . . . . . . . . 1
Bracket, alternator adjusment . . . . . . . . . . . . . . . 1
Bracket, alternator rear . . . . . . . . . . . . . . . . . . . . . 1
Bracket, power steering, rear . . . . . . . . . . . . . . . . 1
Bracket, alternator, front . . . . . . . . . . . . . . . . . . . . 1
Mount, engine (right) . . . . . . . . . . . . . . . . . . . . . . . 1
Bracket, hydraulic pump . . . . . . . . . . . . . . . . . . . . 1
Trim, push-on . . . . . . . . . . . . . . . . . . . . . . As Req’d.
129
GOVERNOR
SUZUKI 660 HAULSTER MODELS
898704, 898704LP, 898706, 898706LP, 898718, 898718LP, 898720 & 898720LP
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
21
23
15
2
10
5
18
Torque to
96 24 in. lbs.
9
3
4
8
22
16
17
13
27
28
25
After Setting Governor Spool Yoke
to .321/.319, Adujust Set Screw to
Maintain That Dimension, Then
Apply GM Ind. Silicone Sealant or
Equivalent
Set Screw
.321
.319
130
26
14
GOVERNOR
SUZUKI 660 HAULSTER MODELS
898704, 898704LP, 898706, 898706LP, 898718, 898718LP, 898720 & 898720LP
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.
Description
No.
Req’d
Notes
2700810 Governor, complete . . . . . . . . . . . . . . . . . . . . . . . . . 1
111812
Yoke, spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
111814
Washer, thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
111816
Washer, thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
111817
Spool, governor . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
112840
Bearing, thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
130728
Nut, jam, 1/4-20 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
158061-18
O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
160410
Carrier & weights . . . . . . . . . . . . . . . . . . . . . . . . . 1
302288
Screw, 1/4-20 x 1” . . . . . . . . . . . . . . . . . . . . . . . . . 2
306396
Lockwasher, 1/4” . . . . . . . . . . . . . . . . . . . . . . . . . . 2
306506
Lockwasher, #6 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
306915
Screw, machine, #6-32 x 5/16” . . . . . . . . . . . . . . 2
306966
Pin, roll, 1/8” x 3/4” . . . . . . . . . . . . . . . . . . . . . . . . 1
548325
Ring, retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
800227
Plug, 1/8-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
800558
Screw, set, 3/8-16 x 5/16” . . . . . . . . . . . . . . . . . . 1
833056
Gasket, governor . . . . . . . . . . . . . . . . . . . . . . . . . 1
833102
Seal, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
835271
Nut, governor arm . . . . . . . . . . . . . . . . . . . . . . . . . 1
843537
Bracket, governor knee . . . . . . . . . . . . . . . . . . . . 1
843149
Bushing, steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
843157
Head, governor . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
894471
Reservoir, governor . . . . . . . . . . . . . . . . . . . . . . . 1
833103
Bearing, needle . . . . . . . . . . . . . . . . . . . . . . . . . . 1
888397
Shaft, governor, complete . . . . . . . . . . . . . . . . . . 1
833066
Shaft, governor . . . . . . . . . . . . . . . . . . . . . . . . . . 1
833104
Ring, retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
833345
Bearing, ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2700525
Lever, governor control . . . . . . . . . . . . . . . . . . . . 1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
131
ALTERNATOR
SUZUKI 660 HAULSTER MODELS
898704, 898704LP, 898706, 898706LP, 898718, 898718LP,
898720 & 898720LP
2
3
A Service Manual is available
for the Mando Alternator, Please order:
Service Manual Part No. 845258
5
4
6
7
9
21
1
38
37
36
16
39
30
39
40
36
132
41
42
ALTERNATOR
SUZUKI 660 HAULSTER MODELS
898704, 898704LP, 898706, 898706LP, 898718, 898718LP,
898720 & 898720LP
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 *
34 *
35 *
36
37
38
39
40
41
42
Part
No.
893633
842558
842559
842560
842561
842562
842563
893849
842564
842565
842566
842567
893850
893851
893852
842568
893853
842569
842570
842571
893854
842572
842573
842574
893855
842575
842576
842577
842578
842579
842580
842581
842582
842571
842570
120052
306375
306396
306531
308089
825970
844328
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 . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
2
1
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
133
RADIATOR and COOLING SYSTEM
SUZUKI 660 HAULSTER MODELS 898704, 898704LP,
898706, 898706LP, 898718 & 898718LP
15
50
51
7
Reference
Platform Support
13
14
28
Although the neoprene cover and mounting
hardware are used on vehicles equipped
with seat belts and/or cab sets, they can be
used on any vehicle
16
29
23
27
25
14
18
19
21
11
30
24
27
3
2
10
31
1
33
28
49
22
9
53
12
40
31
44
27
28
46
20
45
41
39
48
37
27
52
32
42
Shown as
Reference Only
Use
Loctite 592
With LPG
Models Only
36
8
8
35
6
8
34
31
17
26
38
6
To Lower
Engine Block
5
P2701740, P893445, P2703990
4
134
43
56
47
31
54
9
55
RADIATOR and COOLING SYSTEM
SUZUKI 660 HAULSTER MODELS 898704, 898704LP,
898706, 898706LP, 898718 & 898718LP
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
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
Part
No.
300646
306396
308090
450452
450541
452378
835805
832033
845224
800177
831846
825624
889051
833512
133741
840754
843040
888549
894590
833443
889049
833442
889050
893388
893554
2700799
450453
452388
452395
452398
820889
843857
2701639
2700031
2700050
833715
2701637
845365
829787
452392
2701638
2701513
009034880
2702540
2702542
2702541
845409
2701108
2701688.7
2701421
2701422
2701757
2702539
320107
844895
844911
Description
No.
Req’d
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cap, .313 i.d. x 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Screw, 5/16-18 x 3/4 . . . . . . . . . . . . . . . . . . . . . . . 4
Nut, isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clamp, hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cap, coolant reservoir . . . . . . . . . . . . . . . . . . . . . . 1
Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rivet, pop (.12 .50 clsd end) . . . . . . . . . . . . . . . . . . 4
Decal, Warning Pressure . . . . . . . . . . . . . . . . . . . 1
Bracket, fan mounting . . . . . . . . . . . . . . . . . . . . . . 1
Connector, hose (air cleaner) . . . . . . . . . . . . . . . . . 1
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cap, radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Reservoir, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Mount, radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fan, radiator, cooling . . . . . . . . . . . . . . . . . . . . . . . 1
Nut, M8-1.25 (G10.9) . . . . . . . . . . . . . . . . . . . . . . . 4
Screw, M8-1.25 x 20 (G8.8) . . . . . . . . . . . . . . . . . . 3
Screw, M10-1.50 x 80 (8.8) . . . . . . . . . . . . . . . . . . 1
Screw, M10-1.50 x 20 (8.8) . . . . . . . . . . . . . . . . . . 2
Clamp, tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sender, water temperature . . . . . . . . . . . . . . . . . . 1
Hose, radiator upper . . . . . . . . . . . . . . . . . . . . . . . 1
O-ring, 15/16” i.d. . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hose, radiator lower . . . . . . . . . . . . . . . . . . . . . . . . 1
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Housing, thermostat . . . . . . . . . . . . . . . . . . . . . . . . 1
Tube, water outlet . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Terminal, 45 1/4” male . . . . . . . . . . . . . . . . . . . . . 1
Screw, M8-1.25 x 50 (8.8) . . . . . . . . . . . . . . . . . . . 3
Spacer, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 1
Gasket, thermostat spacer . . . . . . . . . . . . . . . . . . 1
Decal, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bolt, bleed valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Washer, bleed valve . . . . . . . . . . . . . . . . . . . . . . . . 1
Bracket, u-water inlet . . . . . . . . . . . . . . . . . . . . . . . 1
Clamp, 1.25 i.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bracket, upper radiator hose . . . . . . . . . . . . . . . . . 1
Backing plate, cover . . . . . . . . . . . . . . . . . . . . . . . . 1
Cover, neoprene . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Switch, fan (on-93C, off-88C) . . . . . . . . . . . . . . . . 1
Cap, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tie, cable 7.5” (190 mm) . . . . . . . . . . . . . . . . . . . . . 1
Hose, water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Reducer, hose, 5/8 to 1/2 . . . . . . . . . . . . . . . . . . . . 1
Notes
LPG Models only
LPG Models only
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
135
RADIATOR and COOLING SYSTEM
SUZUKI 660 EFI HAULSTER MODEL 898720
52
50
51
7
Reference
Platform Support
14
13
28
Although the neoprene cover and mounting
hardware are used on vehicles equipped
with seat belts and/or cab sets, they can be
used on any vehicle
16
29
23
27
25
14
19
30
24
21
11
18
27
3
2
10
31
1
28
15
48
40
33
9
49
27
22
20
15
35
31
37
44
46
45
Use
Loctite
592
32
12
41
Adhesive
This Side
39
Shown as
Reference Only
8
6
15
43
36
47
31
17
26
31
38
34
6
5
2701220, 2700901
4
136
RADIATOR and COOLING SYSTEM
SUZUKI 660 EFI HAULSTER MODEL 898720
Ref.
No.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
12 13
14
15
300646
306396
308090
450452
450541
452378
835805
832033
809231
800177
831846
825624
889051
833512
800789
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
45
46
47
48
49
50
51
52
840754
843040
888549
894590
833443
889049
833442
889050
893388
893554
2700799
450453
452388
452395
452398
820889
843857
2700160
2700031
2700050
833715
845334
845365
829787
826590
838340
821893
009034880
2702540
2702469
2702541
845409
2701108
2701110.7
2701421
2701422
133741
Description
No.
Req’d
Notes
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
Decal, Warning Pressure . . . . . . . . . . . . . . . . . . . 1
Bracket, fan mounting . . . . . . . . . . . . . . . . . . . . . . 1
Connector, hose (air cleaner) . . . . . . . . . . . . . . . . . 1
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cap, radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Reservoir, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Mount, radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fan, radiator, cooling . . . . . . . . . . . . . . . . . . . . . . . 1
Nut, M8-1.25 (G10.9) . . . . . . . . . . . . . . . . . . . . . . . 3
Screw, M8-1.25 x 20 (G8.8) . . . . . . . . . . . . . . . . . . 2
Screw, M10-1.50 x 80 (8.8) . . . . . . . . . . . . . . . . . . 1
Screw, M10-1.50 x 20 (8.8) . . . . . . . . . . . . . . . . . . 2
Clamp, tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Sender, water temperature . . . . . . . . . . . . . . . . . . 1
Hose, radiator upper . . . . . . . . . . . . . . . . . . . . . . . 1
O-ring, 15/16” i.d. . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hose, radiator lower . . . . . . . . . . . . . . . . . . . . . . . . 1
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Outlet, water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tube, water outlet . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Terminal, 45 1/4” male . . . . . . . . . . . . . . . . . . . . . 1
Hose, 5/16 i.d. . . . . . . . . . . . . . . . . . . . . . . As Req’d.
Cooler, oil (auto. trans.) . . . . . . . . . . . . . . . . . . . . . . 1
Trim, push-on . . . . . . . . . . . . . . . . . . . . . . As Req’d.
Decal, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bolt, bleed valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bolt, water outlet mount . . . . . . . . . . . . . . . . . . . . 2
Washer, bleed valve . . . . . . . . . . . . . . . . . . . . . . . . 1
Bracket, u-water inlet . . . . . . . . . . . . . . . . . . . . . . . 1
Clamp, 1.25 i.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bracket, upper radiator hose . . . . . . . . . . . . . . . . . . 1
Backing plate, cover . . . . . . . . . . . . . . . . . . . . . . . . 1
Cover, neoprene . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Rivet, pop (.12 .50 clsd end) . . . . . . . . . . . . . . . . . . 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.
137
RADIATOR and COOLING SYSTEM
SUZUKI 660 HAULSTER MODELS 898720LP
15
50
51
Reference
Platform Support
14
13
28
Although the neoprene cover and mounting
hardware are used on vehicles equipped
with seat belts and/or cab sets, they can be
used on any vehicle
16
29
23
27
14
25
18
11
30
24
27
19
21
3
2
1
10
31
33
58
28
59
49
31
57
27
28
22
With Auto.
Tran. Only
12
53
48
20
40
12
27
60
Adhesive
This Side
44
9
58
39
58
46
45
41
37
Use
Loctite 592
52
32
42
Shown as
Reference Only
With LPG
Models Only
17
43
8
56
36
55
8
6
9
35
6
26
34
31
138
5
47
31
P2701740, P893445, P2703990
54
38
To Lower
Engine Block
4
RADIATOR and COOLING SYSTEM
SUZUKI 660 HAULSTER MODELS 898720LP
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
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
300646
306396
308090
450452
450541
452378
835805
832033
845224
800177
831846
825624
889051
833512
133741
840754
843040
888549
894590
833443
889049
833442
889050
893388
893554
2700799
450453
452388
452395
452398
820889
843857
2701639
2700031
2700050
833715
2701637
845365
829787
452392
2701638
2701513
009034880
2702540
2702542
2702541
845409
2701108
2701688.7
2701421
2701422
2701757
2702539
320107
844895
844911
809231
800789
826590
838340
Description
No.
Req’d
Notes
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cap, .313 i.d. x 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Screw, 5/16-18 x 3/4 . . . . . . . . . . . . . . . . . . . . . . . . . 4
Nut, isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clamp, hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cap, coolant reservoir . . . . . . . . . . . . . . . . . . . . . . . . 1
Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rivet, pop (.12 .50 clsd end) . . . . . . . . . . . . . . . . . . . . 4
Decal, Warning Pressure . . . . . . . . . . . . . . . . . . . . . 1
Bracket, fan mounting . . . . . . . . . . . . . . . . . . . . . . . . 1
Connector, hose (air cleaner) . . . . . . . . . . . . . . . . . . 1
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cap, radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Reservoir, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Mount, radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fan, radiator, cooling . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nut, M8-1.25 (G10.9) . . . . . . . . . . . . . . . . . . . . . . . . . 4
Screw, M8-1.25 x 20 (G8.8) . . . . . . . . . . . . . . . . . . . . 3
Screw, M10-1.50 x 80 (8.8) . . . . . . . . . . . . . . . . . . . . 1
Screw, M10-1.50 x 20 (8.8) . . . . . . . . . . . . . . . . . . . . 2
Clamp, tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sender, water temperature . . . . . . . . . . . . . . . . . . . . 1
Hose, radiator upper . . . . . . . . . . . . . . . . . . . . . . . . . 1
O-ring, 15/16” i.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hose, radiator lower . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Housing, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tube, water outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Terminal, 45 1/4” male . . . . . . . . . . . . . . . . . . . . . . . 1
Screw, M8-1.25 x 50 (8.8) . . . . . . . . . . . . . . . . . . . . . 3
Spacer, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Gasket, thermostat spacer . . . . . . . . . . . . . . . . . . . . 1
Decal, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bolt, bleed valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Washer, bleed valve . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bracket, u-water inlet . . . . . . . . . . . . . . . . . . . . . . . . . 1
Clamp, 1.25 i.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bracket, upper radiator hose . . . . . . . . . . . . . . . . . . . 1
Backing plate, cover . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cover, neoprene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Switch, fan (on-93C, off-88C) . . . . . . . . . . . . . . . . . 1
Cap, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tie, cable 7.5” (190 mm) . . . . . . . . . . . . . . . . . . . . . . 1
Hose, water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Reducer, hose, 5/8 to 1/2 . . . . . . . . . . . . . . . . . . . . . 1
Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Kit, oil cooler mounting (auto. transmission) . . . . . 1
Hose, 5/16 i.d. . . . . . . . . . . . . . . . . . . . . . . . . As Req’d.
Cooler, oil (automatic transmission) . . . . . . . . . . . . . 1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
139
10.25:1 DIFFERENTIAL
SUZUKI 660 HAULSTER MODELS 898704, 898704LP, 898706, 898706LP,
898718, 898718LP, 898720 & 898720LP
25
26
27
9
61
68
59
52
64
53
60
63
62
62
65
68
69
60
30
59
67
61
17
61
40
58
66
57
51
9
25
26
27
4
37
1
11
33
2
38
4
31
13
34
73
36
11
32
10
72
14
20
49
29
75
39
74
50
48
14
10
49
15
35
22
23
24
54
21
30
47
28
46
45
41
44
7
77
76
140
56
12
3
71
42
43
18
19
70
6
8
16
5
893493
55
10.25:1 DIFFERENTIAL
SUZUKI 660 HAULSTER MODELS 898704, 898704LP, 898706, 898706LP,
898718, 898718LP, 898720 & 898720LP
Ref.
No.
Part
No.
ƒ
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
45
46
47
48
49
50
2701142
103867
112050
120177
304055
304636
306325
306405
306932
320122
450453
452389
551094
800290
800356
800944
805843
805875
842077
809156
810437
814465
814466
814467
814468
814469
814470
814471
814474
814476
814477
841842
841844
814924
815490
816515
818226
832584
832585
842071
842072
842074
842075
842076
879471
812335
814226
814476
879961
814475
886706
Description
No.
Req’d
Notes
Differential (10.25:1 ratio) . . . . . . . . . . . . . . . . . . . . 1
•Washer, 5/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
•Screw, 1/4-20 x 5/8 . . . . . . . . . . . . . . . . . . . . . . . 1
•Lockwasher, 3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . 4
•Screw, 5/16-18 x 1 3/8 . . . . . . . . . . . . . . . . . . . . . 6
•Pin, cotter, 1/8 x 1 1/8 . . . . . . . . . . . . . . . . . . . . . 2
•Lockwasher, 5/16 . . . . . . . . . . . . . . . . . . . . . . . . . 8
•Washer, 3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
•Nut, 5/16-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
•Cup, roller bearing . . . . . . . . . . . . . . . . . . . . . . . . 2
•Nut, M8-1.25 (G10.9) . . . . . . . . . . . . . . . . . . . . . . 1
•Screw, M8-1.25 x 25 (8.8) . . . . . . . . . . . . . . . . . . 1
•Screw, 3/8-16 x 1 3/4 . . . . . . . . . . . . . . . . . . . . . . 4
•Nut, 5/16-18, lock . . . . . . . . . . . . . . . . . . . . . . . . . 6
•Plug, filler drain . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
•Screw, M10-1.50 x 25 (10.9) . . . . . . . . . . . . . . . 8
•Nut, 5/8-18, castle . . . . . . . . . . . . . . . . . . . . . . . . 2
•Key, hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
•Plate, bearing adapter . . . . . . . . . . . . . . . . . . . . . 2
•Washer, special . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
•Clamp, 1/2” (park brake cable) . . . . . . . . . . . . . . 1
•Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
•Shim, .005 . . . . . . . . . . . . . . . . . . . . . . . . As Req’d
•Shim, .010 . . . . . . . . . . . . . . . . . . . . . . . . As Req’d
•Shim, .030 . . . . . . . . . . . . . . . . . . . . . . . . As Req’d
•Shim, .003 . . . . . . . . . . . . . . . . . . . . . . . . As Req’d
•Shim, .005 . . . . . . . . . . . . . . . . . . . . . . . . As Req’d
•Shim, .010 . . . . . . . . . . . . . . . . . . . . . . . . As Req’d
•Cup, roller bearing . . . . . . . . . . . . . . . . . . . . . . . . 2
•Cup, roller bearing . . . . . . . . . . . . . . . . . . . . . . . . 1
•Seal, rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
•Tee, union, flare M10-1.00 . . . . . . . . . . . . . . . . . 1
•Hose, brake 18” (457 mm) . . . . . . . . . . . . . . . . . 1
•Clamp (park brake cable) . . . . . . . . . . . . . . . . . . 1
•Tag, ratio (10.25:1) . . . . . . . . . . . . . . . . . . . . . . . . 1
•Shim .003 . . . . . . . . . . . . . . . . . . . . . . . . . As Req’d
•Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
•Clamp, tee mount . . . . . . . . . . . . . . . . . . . . . . . . . 1
•Bracket, tee mount . . . . . . . . . . . . . . . . . . . . . . . . 1
•Tube, brake (left) . . . . . . . . . . . . . . . . . . . . . . . . . 1
•Tube, brake (right) . . . . . . . . . . . . . . . . . . . . . . . . 1
•Shim, .005 . . . . . . . . . . . . . . . . . . . . . . . . As Req’d
•Shim, .010 . . . . . . . . . . . . . . . . . . . . . . . . As Req’d
•Shim, .030 . . . . . . . . . . . . . . . . . . . . . . . . As Req’d
•Retainer complete, bearing . . . . . . . . . . . . . . . . . 1
••Seal, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
••Retainer, bearing . . . . . . . . . . . . . . . . . . . . . . . . . 1
••Cup, bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
•Gear, worm, w/bearings & slinger (10.25:1 ratio)1
••Bearing, cone, roller . . . . . . . . . . . . . . . . . . . . . . 2
••Slinger set, oil, complete . . . . . . . . . . . . . . . . . . 1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
141
10.25:1 DIFFERENTIAL
SUZUKI 660 HAULSTER MODELS 898704, 898704LP, 898706, 898706LP,
898718, 898718LP, 898720 & 898720LP
25
26
27
9
61
68
59
52
64
53
60
63
62
62
65
68
69
60
30
59
67
61
17
61
40
58
66
57
51
9
25
26
27
4
37
1
11
33
2
38
4
31
13
34
73
36
11
32
10
72
14
20
49
29
75
39
74
50
48
14
10
49
15
35
22
23
24
54
21
30
47
28
46
45
41
44
7
77
76
142
56
12
3
71
42
43
18
19
70
6
8
16
5
893493
55
10.25:1 DIFFERENTIAL
SUZUKI 660 HAULSTER MODELS 898704, 898704LP, 898706, 898706LP,
898718, 898718LP, 898720 & 898720LP
Ref.
No.
Part
No.
51
52
53
54
55
56
57
885033
815403
827018
885034
815403
827018
879962
◊
306555
386767
842093
842094
814483
814484
815794
816812
816823
816824
816825
814204
893519
838539
893583
2701143
2701144
827486
841430
893553
800908
893581
893582
800198
809180
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
*
*
*
*
*
76
77
Description
No.
Req’d
•Axle (right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
••Bearing cone, roller . . . . . . . . . . . . . . . . . . . . . .
••Ring, backing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
•Axle, (left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
••Bearing cone, roller . . . . . . . . . . . . . . . . . . . . . .
••Ring, backing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
•Gear, carrier (10.25:1 ratio) . . . . . . . . . . . . . . . .
••Housing, carrier . . . . . . . . . . . . . . . . . . . . . . . . . .
••Screw, 5/16-18 x 3/4 . . . . . . . . . . . . . . . . . . . . .
••Bearing cone, carrier . . . . . . . . . . . . . . . . . . . . .
••Gear, axle shaft . . . . . . . . . . . . . . . . . . . . . . . . . .
••Gear, differential planet . . . . . . . . . . . . . . . . . . .
••Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
••Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
••Plate, locking . . . . . . . . . . . . . . . . . . . . . . . . . . . .
••Screw, special . . . . . . . . . . . . . . . . . . . . . . . . . . .
••Plate, retainer . . . . . . . . . . . . . . . . . . . . . . . . . . .
••Plate, locking . . . . . . . . . . . . . . . . . . . . . . . . . . . .
••Shaft, differential gear . . . . . . . . . . . . . . . . . . . .
••Gear, worm (10.25:1 ratio) . . . . . . . . . . . . . . . .
•Seal and retainer . . . . . . . . . . . . . . . . . . . . . . . . .
••Seal, bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
•Cable, park brake . . . . . . . . . . . . . . . . . . . . . . . . .
•Housing, axle (right) . . . . . . . . . . . . . . . . . . . . . . .
•Housing, differential (left) . . . . . . . . . . . . . . . . . .
••Valve, breather . . . . . . . . . . . . . . . . . . . . . . . . . .
•Drum, brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
•Hub, wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
••Nut, lug M12-1.50 x 42 . . . . . . . . . . . . . . . . . . .
•Brake, complete (left) . . . . . . . . . . . . . . . . . . . . . .
•Brake, complete (right) . . . . . . . . . . . . . . . . . . . .
Nut, 1/2-20, crownlock . . . . . . . . . . . . . . . . . . . . . .
Washer, special . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes
1
1
1
1
1
1
1
1
2
2
2
4
4
1
3
6
2
2
4
1
2
1
2
1
1
1
2
2
5
1
1
1
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
ƒ Differential assembly does not include Ref No’s. 76 & 77.
◊ Not Offered Separately.
* Not illustrated. Refer to the parts illustration pages referencing the front and rear brakes.
143
FRONT and REAR BRAKES & HUBS
SUZUKI 660 HAULSTER MODELS 898704, 898704LP, 898706, 898706LP,
898718, 898718LP, 898720, 898720LP
Shown As
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
With Rear
Wheels Only
3
2
With Rear
Wheels Only
9
Rear Hub
Shown
FRONT
OF
VEHICLE
7
1
11
6
10
8
5
Front Wheels
P893978, 2701142
144
FRONT and REAR BRAKES & HUBS
SUZUKI 660 HAULSTER MODELS 898704, 898704LP, 898706, 898706LP,
898718, 898718LP, 898720, 898720LP
Ref.
No.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
(10)
(10)
12
13
14
304636
306325
306932
800944
800909
805843
809156
817250
841430
893553
800908
893206
808088
814474
800908
894535
893519
838539
893585
*
893586
15
16
17
19
894930
894932
894933
894934
894935
894936
893581
*
893582
*
894931
844813
*
*
*
*
18
*
20
Description
No.
Req’d
Notes
Pin, cotter 1/8 x 1 1/8 . . . . . . . . . . . . . . . . . . . . . . . 2
Lockwasher, 5/16 . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Nut, M10-1.50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Screw, M10-1.50 x 25 (10.9) . . . . . . . . . . . . . . . . . 8
Nut, wheel retaining, M12-1.5 . . . . . . . . . . . . . . 10
Nut, castle, 5/8-18 . . . . . . . . . . . . . . . . . . . . . . . . . 2
Washer, special . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cap, grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Drum, brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hub, rear (all models) . . . . . . . . . . . . . . . . . . . . . . . . 2
Screw, lug, M12-1.50 x 45 . . . . . . . . . . . . . . . . . 10
Hub, front (all 4-wheel models) . . . . . . . . . . . . . . . . 2
Cup, bearing (outer) . . . . . . . . . . . . . . . . . . . . . . . . 1
Cup, bearing (inner) . . . . . . . . . . . . . . . . . . . . . . . . 1
Screw, lug, M12-1.50 x 45 . . . . . . . . . . . . . . . . . 10
Hub, front (3-wheel) . . . . . . . . . . . . . . . . . . . . . . . . . 1
Seal and retainer (rear) . . . . . . . . . . . . . . . . . . . . . . 2
Seal, bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Brake, complete, front (LH)
Models 718, 718LP, 720, 720LP . . . . . . . . . . . . . . . . . 1
Brake, complete, front (RH)
Models 718, 718LP, 720, 720LP . . . . . . . . . . . . . . . . . 1
Cylinder, wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Kit, brake shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Kit, spring (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Kit, spring (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Kit, adjuster repair (LH) . . . . . . . . . . . . . . . . . . . . . 1
Kit, adjuster repair (RH) . . . . . . . . . . . . . . . . . . . . . 1
Brake, complete w/lever,
rear (LH) all models . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Brake, complete w/lever,
rear (RH) all models . . . . . . . . . . . . . . . . . . . . . . . . . 1
Kit, cylinder repair . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Ring, retainer (rear) . . . . . . . . . . . . . . . . . . . . . . . . . 2
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
* Not Illustrated.
• All components shown with Ref. No’s. 14 & 19 are included with these assemblies. If replacement parts
are required, the individual parts shown in the assembly will be grouped into kits as stated in the above
parts list.
Also refer to the parts illustrations for the Differential, Front Suspension and Front Fork (3-wheel).
145
CLUTCH and DRIVESHAFT
SUZUKI 660 HAULSTERS MODELS 898704, 898704LP,
898706, 898706LP, 898718 & 898718LP
4
3
2
6
3
1
5
21
23
15
16
23 20
17
20
12
19
7
11
14
9
146
13
22
10
8
(P2700567)
18
The Two (2) Tubing Clamps
(Ref. No. 19) Are Used To Help
Secure the Shifter Cables
CLUTCH and DRIVESHAFT
SUZUKI 660 HAULSTERS MODELS 898704, 898704LP,
898706, 898706LP, 898718 & 898718LP
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
Part
No.
2701321.7
548482
826284
826285
894192
895126
2702546
2702547
2702548
2702549
2702550
2702551
2702552
2702553
2702554
2702555
2702470
800943
809092
821164
2701273
2701328
2701371
Description
No.
Req’d
Driveshaft, complete (manual transmission) . . .
Plug, expansion . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cross, u-joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yoke, universal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yoke, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft, drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover, clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt (8 x 16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, #10-14 taptite (plastic) . . . . . . . . . . . . . . . . .
Clamp, tube/wire . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin, hair .25 x 1.12 x .06 . . . . . . . . . . . . . . . . . . . . . .
Cable, shifter 97” (2464 mm) . . . . . . . . . . . . . . . . . .
Cable, shifter 89” (2261 mm) . . . . . . . . . . . . . . . . . .
Connector, shift lever . . . . . . . . . . . . . . . . . . . . . . .
Notes
1
3
2
1
1
1
1
6
1
1
1
1
1
1
1
1
1
2
2
2
1
1
2
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
147
DRIVESHAFT, TORQUE CONVERTER
and AUTOMATIC TRANSMISSION
SUZUKI 660 HAULSTER MODELS 898720 & 898720LP
4
3
2
6
3
1
5
12
7
11
9
10
8
13
Ref.
No.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
895112.7
548482
826284
826285
895125
895126
2702697
2702698
2702699
2702700
2701951
2702701
2702702
Description
No.
Req’d
Driveshaft, complete (automatic transmission) .
Plug, expansion . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cross, u-joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yoke, universal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yoke, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft, drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission, complete . . . . . . . . . . . . . . . . . . . . .
Flange, drive plate . . . . . . . . . . . . . . . . . . . . . . . . .
Plate, drive (flywheel) . . . . . . . . . . . . . . . . . . . . . . .
Plate, drive rear . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Converter, torque . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes
1
3
2
1
1
1
1
1
1
1
6
1
6
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
148
ENGINE & MAIN WIRE HARNESSES
SUZUKI 660 EFI HAULSTER MODELS 898704, 898704LP, 898706, 898706LP, 898718,
898718 LP, 898720 & 898720LP
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
Suzuki Main Wire Harness Shown
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
CLUTCH
SWITCH
COOLANT
OVER
TEMP
ALARM
FUSE
BLOCK
TRAILER
BRAKES
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.
Part
No.
Description
No.
Req’d
1
2700919
Harness, main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2*
3*
4*
5*
6
894266
895052
895049
2702947
2703162
Harness, main . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Harness, main . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Harness, engine . . . . . . . . . . . . . . . . . . . . . . . . . . .
Harness, Suzuki engine . . . . . . . . . . . . . . . . . . . .
Harness, engine (all diesel models) . . . . . . . . . . .
1
1
1
1
1
Notes
Models 704, 704LP, 706, 706LP
718, 718LP
all diesel models
Models 720 & 720LP
all Suzuki models
all diesel models
* Not Illustrated.
149
ELECTRICAL COMPONENTS
and SECONDARY WIRING HARNESSES
SUZUKI 660 HAULSTER MODELS 898704, 898704LP, 898706, 898706LP, 898718,
898718 LP, 898720 & 898720LP
and DIESEL HAULSTER MODELS 898726 & 898727
9
2
8
1
15
1
14
13
10
23
6
12
11
21
3
29, 36
ÎÎÎÎÎ
ÎÎÎÎÎ
ÎÎÎÎÎ
ÎÎÎÎÎ
ÎÎÎÎÎ
ÎÎÎÎÎ
ÄÄÄÄ
ÄÄÄÄ
ÄÄÄÄ
ÄÄÄÄ
ÄÄÄÄ
18
19
17
20
7
5
6
35
25
16
27
33
26
4
Used on Some
Older 720 Models
38
37
30
34
RIGHT
TAILLIGHT
28
24
TO
MAIN HARNESS
22
32
LEFT
TAILLIGHT
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.
31
P893442, P893977, P2701037
150
ELECTRICAL COMPONENTS
and SECONDARY WIRING HARNESSES
SUZUKI 660 HAULSTER MODELS 898704, 898704LP, 898706, 898706LP, 898718,
898718 LP, 898720 & 898720LP
and DIESEL HAULSTER MODELS 898726 & 898727
Ref.
No.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
450452
452378
800934
830366
841636
800943
837303
843581
843942
886090
2701465
120052
132520
306325
306932
890000
890154
837295
837296
837299
837300
890158
894201
894308
894314
892676
843857
829787
835480
843167
2702481
2701758
884398
2701757
2702975
822867
2700867
2702430
2702916
*
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
Description
No.
Req’d
Nut, M6-1.00 (G10.9) . . . . . . . . . . . . . . . . . . . . . . .
Screw, M6-1.00 x 20 . . . . . . . . . . . . . . . . . . . . . . .
Screw, M6-1.00 x 16 (G10.9) . . . . . . . . . . . . . . . . .
Switch, push (horn button) . . . . . . . . . . . . . . . . . . .
Panel, instrument w/tach . . . . . . . . . . . . . . . . . . . .
Screw, #10-14 x 5/8 . . . . . . . . . . . . . . . . . . . . . . . .
Headlight, rectangular . . . . . . . . . . . . . . . . . . . . . .
Switch, headlight . . . . . . . . . . . . . . . . . . . . . . . . . .
Socket, 12V acc. plug . . . . . . . . . . . . . . . . . . . . . .
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lockwasher, #10 . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, #10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lockwasher, 5/16 . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, 5/16-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Buzzer assembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, ignition, complete . . . . . . . . . . . . . . . . . . .
Switch, ignition . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector and wire . . . . . . . . . . . . . . . . . . . . . . .
Harness, wire, fuel tank . . . . . . . . . . . . . . . . . . . . .
Switch (normally open) . . . . . . . . . . . . . . . . . . . . . . .
Harness, wire, taillight . . . . . . . . . . . . . . . . . . . . . .
Taillight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sender, water temperature . . . . . . . . . . . . . . . . . .
Terminal, 45 1/4” male . . . . . . . . . . . . . . . . . . . . .
Relay, 30 amp (12V) . . . . . . . . . . . . . . . . . . . . . . . .
Relay, 12V, 15 amp DPST . . . . . . . . . . . . . . . . . . .
Sensor, water temperature . . . . . . . . . . . . . . . . . .
Harness, fan switch . . . . . . . . . . . . . . . . . . . . . . . .
Diode assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine control unit (ECU) . . . . . . . . . . . . . . . . . . . .
Flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay, 70 amp. SPST (12V) . . . . . . . . . . . . . . . . . .
Sensor, water temperature . . . . . . . . . . . . . . . . . .
Coil, ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
2
1
1
1
4
2
1
1
1
1
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
3
Notes
Not illustrated
Not on all vehicles
Used on some older 720 models
INDENTED PARTS NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
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
151
ELECTRICAL CONNECTORS
SUZUKI 660 HAULSTER MODELS 898704, 898704LP,
898706, 898706LP, 898718, 898718LP, 898720 & 898720LP
and DIESEL HAULSTER MODELS 898726 & 898727
15
12
17
20
16
10
4
11
23
21
6
5
13
3
8
26
7
25
1
24
28
9
2
22
19
14
18
30
27
31
29
152
ELECTRICAL CONNECTORS
SUZUKI 660 HAULSTER MODELS 898704, 898704LP,
898706, 898706LP, 898718, 898718LP, 898720 & 898720LP
and DIESEL HAULSTER MODELS 898726 & 898727
Ref.
No.
Part
No.
1
2
3
4
(4)
(4)
5
6
7
8
9
10
11
12
13
(13)
(13)
(13)
(13)
14
15
16
17
18
(18)
(18)
19
(19)
20
21
22
23
24
25
26
27
28
29
30
31
825880
825877
825894
825970
825970
844328
825996
825997
825998
825999
825973
826005
826726
829631
826000
833038
836892
842983
4113261
837296
841895
844013
843550
894594
894596
2701502
884513
892811
829630
837301
843598
800943
2700913
839919
839920
2702952
826006
884398
2700912
838770
Description
No.
Req’d
Notes
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
Fuse, 25 amp. . . . . . . . . . . . . . . . . . . . . . . As Req’d
Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cover, battery terminal . . . . . . . . . . . . . . . . . . . . . 1
Connector, 18-contact . . . . . . . . . . . . . . . . . . . . . . 1
Connector, receptacle, 18-contact . . . . . . . . . . . . 1
Cable, battery, red, 46” (1168 mm) . . . . . . . . . . . . 1
Cable, battery, red, 30” (762 mm) . . . . . . . . . . . . . 1
Cable, battery, red, 38” (965 mm) . . . . . . . . . . . . . 1
Cable, battery, black, 46” (1168 mm) . . . . . . . . . . . 1
Cable, battery, black, 24” (607 mm) . . . . . . . . . . . 1
Connector, male, 4-contact . . . . . . . . . . . . . . . . . . 1
Connector, head lamp . . . . . . . . . . . . . . . . . . . . . . 2
Connector, rocker switch . . . . . . . . . . . . . . . . . . . . 1
Screw, #10-14 x 5/8 . . . . . . . . . . . . . . . . . . . . . . . . 2
Jumper, tailight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Plug, 40 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Receptacle, 40 pin . . . . . . . . . . . . . . . . . . . . . . . . . 1
Wire, noise suppressor . . . . . . . . . . . . . . . . . . . . . 1
Connector, female, 2-contact . . . . . . . . . . . . . . . . 1
Diode assembly . . . . . . . . . . . . . . . . . . . . As Req’d
Jumper, diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . 1
Connector, socket 4-pin . . . . . . . . . . . . . . . . . . . . . 1
153
ENGINE GASKETS
SUZUKI 660 HAULSTER
MODELS 898704, 898704LP, 898706, 898706LP, 898718,
898718 LP, 898720 & 898720LP
4
1
11
Shown For
Reference Only
9
8
6
7
2
Shown For
Reference Only
5
Shown For
Reference Only
10
3
All Items Shown are used with all Models
Unless Otherwise Indicated.
Ref.
No.
Part
No.
Description
No.
Req’d
2701775 Gasket set, complete
(898704, 898706, 898718) . . . . . . 1
2701812 Gasket set, complete
(Model 898720) . . . . . . . . . . . . . . . 1
1
2
3
4
2701776
2701795
2701796
2701797
Gasket, head . . . . . . . . . . . . . . .
Gasket, valve cover . . . . . . . . .
Gasket, intake manifold . . . . . . .
Gasket, exhaust manifold . . . .
1
1
1
1
Ref.
No.
Part
No.
Description
Gasket,
Gasket,
Gasket,
Gasket,
Gasket,
Gasket,
No.
Req’d
5
6
7
8
9
10
2701798
2701799
2701803
2701800
2701801
2701804
distributor drive . . . . . .
cyl. plate . . . . . . . . . . .
throttle body . . . . . . . . .
oil pump cover . . . . . .
water pump . . . . . . . . .
surge tank . . . . . . . . . . .
1
1
1
1
1
1
11
2701802 Gasket, water inlet . . . . . . . . . . 1
(898704, 898706, 898718)
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
154
CYLINDER HEAD & COMPONENTS
SUZUKI 660 HAULSTER MODELS 898704, 898704LP, 898706, 898706LP,
898718, 898718LP, 898720 & 898720LP
28
25
26
27
20
21
17
16
19
24
4
22
18
23
8
15
12
2
13
3
7
11
5
9
6
10
14
14
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Part
No.
2701776
2701795
2701798
2701799
2701813
2701814
2701815
2701816
2701819
2701820
2701821
2701822
2701823
2701824
2701825
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
Bolt, cylinder head . . . . . . . . . . . 8
16
17
18
19
20
21
22
2701826
2701827
2701828
2701829
2701830
2701831
2701832
23
24
25
26
27
28
2701833
2701834
2701835
2701836
2702916
2701978
Description
Part
No.
Description
No.
Req’d
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 . . . . . . . . . . . . . . . . . . . . . . . .
Coil, ignition . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
4
1
3
3
1
2
1
4
3
3
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
155
CYLINDER BLOCK, COMPONENTS, OIL DIPSTICK & FILTER
SUZUKI 660 HAULSTER
MODELS 898704, 898704LP, 898706, 898706LP,
898718, 898718LP, 898720 & 898720LP
25
19
24
23
28
22
20
16
27
21
15
18
26
17
18
2
6
4
3
7
8
1
14
13
4
4
11
5
12
9
10
Ref.
No.
1
2
3
4
5
6
(6)
7
(7)
8
9
10
11
12
13
Part
No.
2701837
2701819
2701820
2701838
2701839
2701840
2701900
Description
No.
Req’d
Block, cylinder . . . . . . . . . . . . . . .
Seal . . . . . . . . . . . . . . . . . . . . . . .
Plug . . . . . . . . . . . . . . . . . . . . . . .
Plug . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . .
Plate, clutch hsng. upper . . . . . . .
1
2
1
3
8
1
Plate, clutch hsng. upper
(model 898720) . . . . . . . . . . . . . . .
2701901 Plate, clutch hsng. lower . . . . . . . .
2701902 Plate, clutch hsng. lower
(model 898720) . . . . . . . . . . . . . . .
2702537 Bolt . . . . . . . . . . . . . . . . . . . . . . . .
2701904 Sender, oil pressure . . . . . . . . . .
2701905 Wire, oil pressure . . . . . . . . . . . .
2701906 Clamp . . . . . . . . . . . . . . . . . . . . . .
2701907 Bolt . . . . . . . . . . . . . . . . . . . . . . . .
2701908 Filter, oil . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
Ref.
No.
14
15
(15)
16
17
18
19
20
21
22
23
24
25
26
27
28
Part
No.
Description
No.
Req’d
2701909 Nipple . . . . . . . . . . . . . . . . . . . . . . 1
2701911 Pan, oil . . . . . . . . . . . . . . . . . . . . . 1
2701910 Pan, oil (model 898720) . . . . . . . . 1
2701912 Bolt . . . . . . . . . . . . . . . . . . . . . . . 14
2701913 Stud . . . . . . . . . . . . . . . . . . . . . . . 2
2701914 Nut . . . . . . . . . . . . . . . . . . . . . . . . 2
2701915 Plug, oil drain . . . . . . . . . . . . . . . 1
2701916 Gasket, oil drain plug . . . . . . . . . 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
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
156
CRANKSHAFT, FLYWHEEL, PISTONS
SUZUKI 660 HAULSTER MODELS 898704, 898704LP, 898706, 898706LP,
898718, 898718LP, 898720 & 898720LP
1
4
2
23
3
4
18
5
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
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 (OS:0.25) . . . . . . . . .
Ring, piston (OS:0.50) . . . . . . . . .
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,
thrust (OS:0.125) . . . . . . . . . . . . .
3
3
3
3
3
3
3
6
3
2
6
6
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
2701942
2701941
2701943
2701944
2701945
2701946
2701834
2701948
2701949
2701953
2701954
2701950
2701951
2701952
Description
No.
Req’d
Seal, front . . . . . . . . . . . . . . . . . .
Pulley, timing belt . . . . . . . . . . . .
Pulley, crnkshft . . . . . . . . . . . . . .
Pulley, crnkshft (898720) . . . . . .
Key . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Seal, rear main . . . . . . . . . . . . . .
Plate, rear . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Pin . . . . . . . . . . . . . . . . . . . . . . . . .
Pin . . . . . . . . . . . . . . . . . . . . . . . . .
Pin (model 898720) . . . . . . . . . . . .
Flywheel (manual trans.) . . . . . . .
Bolt (manual trans.) . . . . . . . . . . . .
Bearing, input shaft . . . . . . . . . . .
1
1
1
1
1
1
1
1
4
2
2
1
1
1
6
1
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
157
CAMSHAFT & COMPONENTS
SUZUKI 660 HAULSTER
MODELS 898704, 898704LP, 898706, 898706LP,
898718, 898718LP, 898720 & 898720LP
10
5
4
8
6
11
1
5
3
16
15
7
19
16
14
2
15
9
14
18
17
18
12
17
13
Ref.
No.
158
Part
No.
1
2
3
4
5
2701947
2701955
2701956
2701957
2701958
6
2701959
7
8
9
2701960
2701961
2701962
Description
No.
Req’d
Camshaft . . . . . . . . . . . . . . . . . . .
Seal, camshaft . . . . . . . . . . . . . .
Shaft, rocker arm (No. 1) . . . . . .
Shaft, rocker arm (No. 2) . . . . . .
Arm, valve rocker
intake No. 1 . . . . . . . . . . . . . . . . .
Arm, valve rocker
intake No. 2 . . . . . . . . . . . . . . . . .
Arm, rocker exhaust . . . . . . . . . .
Screw, adjusting . . . . . . . . . . . . .
Screw, valve adjusting . . . . . . . .
1
1
2
2
3
3
6
6
6
Ref.
No.
10
11
12
13
14
15
16
17
18
19
Part
No.
2701963
2701965
2701966
2701967
2701968
2701969
2701970
2701971
2701972
2701964
Description
No.
Req’d
Nut, adjusting (intake) . . . . . . . . . 6
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
TIMING BELT & TIMING COVER
SUZUKI 660 EFI HAULSTER
MODELS 898704, 898704LP, 898706, 898706LP,
898718, 898718LP, 898720 & 898720LP
1
17
12
10
19
7
18
11
3
2
13
4
5
8
16
15
14
9
13
6
Ref.
No.
1
2
3
4
5
6
7
8
9
10
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
159
INTAKE MANIFOLD & THROTTLE BODY
SUZUKI 660 HAULSTER MODELS 898704, 898704LP, 898706, 898706LP, 898718 & 898718LP
29
21
27
22
18
26
20
24
23
25 19
28
32
11
31
To
Water Inlet Pipe
32
30
32
10
14
17
9
33
12
32
1
8
2
4
7
4
14
5
15
35
16
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Part
No.
2701991
2701796
2701992
2701914
2701834
2701993
2702468
2701804
2702469
2702470
2702471
2702472
2702473
2701827
2702474
2702475
2702431
2702476
2701995
13
Description
36
3
6
34
14
37
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.
2701996
2702477
2701998
2702478
2702000
2701998
2701803
2702001
2702426
2701914
2702479
2702480
2702429
2702481
833715
832033
320107
845224
Description
No.
Req’d
Screw . . . . . . . . . . . . . . . . . . . . .
Sensor, pressure . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . .
Valve, ISC . . . . . . . . . . . . . . . . .
Gasket . . . . . . . . . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . .
Gasket . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Stud bolt . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . .
Hose, water inlet . . . . . . . . . . . . .
Hose, water outlet . . . . . . . . . . .
Clip . . . . . . . . . . . . . . . . . . . . . . . .
Sensor, water temp. . . . . . . . . . .
Cap plug . . . . . . . . . . . . . . . . . . . .
Clamp, hose . . . . . . . . . . . . . . . .
Tie, cable . . . . . . . . . . . . . . . . . . .
Cap, .313 i.d. x 1.00 . . . . . . . . . . .
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
160
INTAKE MANIFOLD & THROTTLE BODY
SUZUKI 660 HAULSTER
MODELS 898720 & 898720LP
18
16
Used on Some
Older 720 Models
11
To
Water Inlet Pipe
10
7
20
28
22
21
15
21
17
23
13
9
8
1
12
14
4
2
21
4
5
19
25
26
3
24
6
21
27
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Part
No.
Description
No.
Req’d
2702467 Manifold, intake . . . . . . . . . . . . . .
2701796 Gasket, intake manifold . . . . . . .
2701992 Stud bolt . . . . . . . . . . . . . . . . . . . .
2701914 Nut . . . . . . . . . . . . . . . . . . . . . . . .
2701834 Bolt . . . . . . . . . . . . . . . . . . . . . . . .
2701993 Stud bolt . . . . . . . . . . . . . . . . . . . .
2701994 Body assy., throttle . . . . . . . . . . .
2701995 Sensor, throttle position . . . . . .
2701996 Screw . . . . . . . . . . . . . . . . . . . . .
2701997 Sensor, pressure . . . . . . . . . . . .
2701998 Screw . . . . . . . . . . . . . . . . . . . . .
2701999 Valve, ISC . . . . . . . . . . . . . . . . .
2702000 Gasket . . . . . . . . . . . . . . . . . . . .
12701998 Screw . . . . . . . . . . . . . . . . . . . . .
1
1
2
3
6
1
1
1
2
1
2
1
1
4
Ref.
No.
15
16
17
18
19
20
21
22 23
24
25
26
27
28
Part
No.
2701803
2702001
2702426
2701914
2702427
2702428
2702429
2702430
2702431
833715
832033
842998
320107
2702481
Description
No.
Req’d
Gasket . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Stud bolt . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . .
Hose, water inlet . . . . . . . . . . . . .
Hose, water outlet . . . . . . . . . . .
Clip . . . . . . . . . . . . . . . . . . . . . . . .
Sensor, water temp. . . . . . . . . . .
Plug . . . . . . . . . . . . . . . . . . . . . . .
Cap plug . . . . . . . . . . . . . . . . . . . .
Clamp, hose . . . . . . . . . . . . . . . .
Cap, 5/16 i.d. x 1 . . . . . . . . . . . .
Tie, cable . . . . . . . . . . . . . . . . . . .
Sensor, water temp. . . . . . . . . . .
1
2
2
2
1
1
4
1
1
1
1
1
1
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
Item No. 22 (water temp. sensor) was used on some of the older 720 models.
161
PCV VALVE & COMPONENTS
SUZUKI 660 HAULSTER
MODELS 898704, 898704LP, 898706, 898706LP,
898718, 898718LP, 898720 & 898720LP
7
1
To
Air Cleaner
15
2
4
12
11
15
10
4
16
17
5
3
14
8
6
13
9
19
18
Cylinder Head Cover
Shown For
Reference Only
Ref.
No.
1
2
3
4
5
6
7
8
9
162
Part
No.
2702467
2701991
2701796
2701992
2701914
2701834
2701993
2702431
2702483
2702482
2702484
Description
No.
Req’d
Manifold, intake . . . . . . . . . . . . . .
Manifold, intake (898720) . . . . . .
Gasket, intake manifold . . . . . . .
Stud bolt . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Stud bolt . . . . . . . . . . . . . . . . . . . .
Plug . . . . . . . . . . . . . . . . . . . . . . .
Hose, breather . . . . . . . . . . . . . .
Hose, breather (898720) . . . . . . .
Clip, hose . . . . . . . . . . . . . . . . . . .
1
1
1
2
4
6
1
1
1
1
2
Ref.
No.
10
11
12
13
14
15
16
17
18
19
Part
No.
2702485
2702486
2702488
2702487
2702489
2702490
2702491
832033
833715
845224
320107
Description
No.
Req’d
Clamp . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Hose, PCV . . . . . . . . . . . . . . . . . .
Hose, PCV (898720) . . . . . . . . . .
Seal . . . . . . . . . . . . . . . . . . . . . . .
Valve, PCV . . . . . . . . . . . . . . . . . .
Clip . . . . . . . . . . . . . . . . . . . . . . . .
Clamp, hose . . . . . . . . . . . . . . . .
Plug . . . . . . . . . . . . . . . . . . . . . . .
Cap, .313 i.d. x 1.00 . . . . . . . . . .
Tie, cable . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
2
1
1
1
1
OIL PUMP
SUZUKI 660 HAULSTER
MODELS 898704, 898704LP, 898706, 898706LP,
898718, 898718LP, 898720 & 898720LP
3
1
2
11
9
10
12
4
Ref.
No.
1
2
3
4
Part
No.
2702515
2702516
2702517
2702518
Description
No.
Req’d
Pump, oil . . . . . . . . . . . . . . . . . . .
Rotor, oil pump . . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . .
Valve, 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
163
SHIFTER GEARS & FORK (INITIAL UPPER MANUAL TRANSMISSION)
SUZUKI 660 MODELS 898704, 898704LP, 898706, 898706LP, 898718 & 898718LP
Existing Bolt Must be
Removed In Order to
Remove Shift Mechanism
13
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
7
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
164
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
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
GEAR SHIFT FORK
PERKINS DIESEL MODELS 898726 & 898727
23
9
22
21
13
12
11
20
4
10
1
5
3
19
2
14
29
31
Part
No.
25121-85051
04221-06129
01550-08553
01550-08403
25520-85203
09284-17004
25530-79501
09286-09001
25536-84200
25535-85412
09162-08008
08322-01083
08310-00083
25541-85201
25576-70D00
09160-17035
25545-85055
18
17
33
31
24
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
16
30
33
Ref.
No.
7
15
27
33
25
8
6
28
32
31
34
Description
26
No.
Req’d
Case, gear shift lever . . . . .
Pin . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . .
Shaft, gear shift lever . . . . .
Seal, oil . . . . . . . . . . . . . . . .
Shaft, gear select . . . . . . . .
Seal. oil . . . . . . . . . . . . . . . .
Boot, gear select shaft . . . .
Arm, gear select . . . . . . . . .
Washer . . . . . . . . . . . . . . . . .
Washer . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . .
Lever, gear select . . . . . . . .
Spring . . . . . . . . . . . . . . . . . .
Washer (17 x 32 x 1.2) . . . .
Dog, rerverse shift limit . . .
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
Ref.
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Part
No.
25546-60C01
09135-08005
06111-10003
25547-70D00
09168-10007
09128-10002
25211-85201
25221-85202
25221-83002
25411-85201
25420-85201
25451-85261
09261-03017
09205-05012
25415-83000
06111-12004
24821-09001
Description
No.
Req’d
Spring . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . .
Ball . . . . . . . . . . . . . . . . . . . .
Spring . . . . . . . . . . . . . . . . . .
Gasket . . . . . . . . . . . . . . . . .
Bolt (10 x 9) . . . . . . . . . . . . .
Fork, low speed gear shift .
Fork, high speed gear shift .
Fork, reverse gear shift . . .
Shaft, low speed fork . . . . .
Shaft, high speed fork . . . .
Shaft, reverse fork . . . . . . .
Roller . . . . . . . . . . . . . . . . . .
Spring, pin . . . . . . . . . . . . . .
Spring . . . . . . . . . . . . . . . . . .
Ball . . . . . . . . . . . . . . . . . . . .
Plug, breather . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
3
3
5
1
165
INPUT SHAFT & GEARS (INITIAL UPPER MANUAL TRANSMISSION)
SUZUKI 660 HAULSTER MODELS 898704, 898704LP, 898706, 898706LP,
898718 & 898718LP
47
59
48
9
21
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
166
28
53
51
54
52
INPUT SHAFT & GEARS (INITIAL UPPER MANUAL TRANSMISSION)
SUZUKI 660 HAULSTER MODELS 898704, 898704LP, 898706, 898706LP,
898718 & 898718LP
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
167
INPUT SHAFT & GEARS (MANUAL TRANSMISSION)
PERKINS DIESEL MODELS 898727 & 898727
2
8
1
8
3
5
7
6
4
9
45
20
38
15
9
16
35
12
11
34
35
21
33
38
5
10
12
34
11
32
14
46
47
31
23
41
53
29
32
40
42
43
23
30
51
31
30
48
5
13
18
39
22
49
52
50
28
17
19
54
34
44
36
27
37
36
24
5
26
168
25
INPUT SHAFT & GEARS (MANUAL TRANSMISSION)
PERKINS DIESEL MODELS 898726 & 898727
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.
24110-80410
09263-20056
09262-28005
09390-68002
09380-28007
09283-25088
24121-85252
06111-06003
09166-30007
24211-83011
09300-30003
09263-35015
24220-60A01
09263-35015
24230-83001
09263-30031
24250-83020
24255-60A00
24801-60810
09262-30086
09390-62010
09262-25073
09380-25011
24131-83002
24351-60A10
09262-28019
09262-28020
Description
No.
Req’d
Shaft, input . . . . . . . . . . . . .
Bearing . . . . . . . . . . . . . . . . .
Bearing . . . . . . . . . . . . . . . . .
C-ring . . . . . . . . . . . . . . . . . .
Circlip . . . . . . . . . . . . . . . . . .
Seal,oil . . . . . . . . . . . . . . . . .
Shaft, main . . . . . . . . . . . . .
Ball . . . . . . . . . . . . . . . . . . . .
Washer . . . . . . . . . . . . . . . . .
Gear, main shaft, low . . . . .
Bushing . . . . . . . . . . . . . . . .
Bearing . . . . . . . . . . . . . . . . .
Gear, main shaft 2nd . . . . .
Bearing . . . . . . . . . . . . . . . . .
Gear, main shaft 3rd . . . . .
Bearing . . . . . . . . . . . . . . . . .
Gear, main shaft 5th . . . . . .
Washer . . . . . . . . . . . . . . . . .
Bearing . . . . . . . . . . . . . . . . .
Bearing . . . . . . . . . . . . . . . . .
C-ring . . . . . . . . . . . . . . . . . .
Bearing . . . . . . . . . . . . . . . . .
Circlip . . . . . . . . . . . . . . . . . .
Shaft, counter . . . . . . . . . . .
Gear, counter shaft 5th . . .
Bearing, front . . . . . . . . . . .
Bearing, center . . . . . . . . . .
1
1
1
1
4
1
1
3
2
1
2
2
1
1
1
1
1
1
1
1
1
1
3
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
54
Part
No.
09262-20073
24400-83000
24431-83001
24436-83000
24441-85F41
24410-83000
24432-83001
24442-81A20
09388-00019
24420-83000
24471-60A00
24473-70D10
24551-83010
09261-06003
24560-83001
09166-16014
24671-83000
24681-83000
09380-17008
26121-85202
26131-85201
29431-85400
09280-19001
09280-21014
09282-08001
09128-06032
09164-20008
Description
No.
Req’d
Bearing, rear . . . . . . . . . . . .
Hub, synchronizer low . . . .
Ring, synchronizer low . . .
Spring, low/2nd . . . . . . . . . .
Spring, low . . . . . . . . . . . . . .
Hub, synchronizer high . . .
Ring, synchronizer high . . .
Spring, high . . . . . . . . . . . . .
Spring, 5th speed . . . . . . . .
Hub, reverse drive . . . . . . .
Key . . . . . . . . . . . . . . . . . . . .
Key . . . . . . . . . . . . . . . . . . . .
Shaft, reverse idle gear . . .
Pin . . . . . . . . . . . . . . . . . . . . .
Gear, reverse idle (NT:33) .
Washer . . . . . . . . . . . . . . . . .
Gear, countershaft (rev.) . .
Gear, mainshaft (rev.) . . . .
Circlip . . . . . . . . . . . . . . . . . .
Gear, speedometer drive . .
Gear, speedometer driven .
Case, speedometer gear . .
O-ring . . . . . . . . . . . . . . . . . .
O-ring . . . . . . . . . . . . . . . . . .
Seal, oil . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . .
Washer . . . . . . . . . . . . . . . . .
1
1
2
2
2
1
3
2
2
1
6
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
169
WATER PUMP, THERMOSTAT & WATER OUTLET
SUZUKI 660 HAULSTER
MODELS 898704, 898704LP, 898706, 898706LP, 898718, 898718LP & 898720 LP
25
32
26
28
14
13
11
29
20
27
31
19
30
16
10
1
17
2
6
8
3
9
22
7
21
24
4
23
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Part
No.
Description
No.
Req’d
2702522 Pump, water . . . . . . . . . . . . . . . .
2701801 Gasket, water pump . . . . . . . . .
2702523 Stud . . . . . . . . . . . . . . . . . . . . . . .
2702537 Bolt . . . . . . . . . . . . . . . . . . . . . . . .
2701914 Nut . . . . . . . . . . . . . . . . . . . . . . . .
2702519 Bolt . . . . . . . . . . . . . . . . . . . . . . . .
2702525 Pulley, water pump . . . . . . . . . . .
2702543 Case, water inlet . . . . . . . . . . . . .
2701802 Gasket . . . . . . . . . . . . . . . . . . . . .
2701834 Bolt . . . . . . . . . . . . . . . . . . . . . . . .
2702542 Thermostat (82C) . . . . . . . . . . . .
2702430 Sensor, water temp. . . . . . . . . . .
2702540 Bolt, bleed valve . . . . . . . . . . . . .
2702541 Washer, bleed valve . . . . . . . . . .
2702469 Bolt, water outlet mount . . . . . .
832033 Clamp, hose . . . . . . . . . . . . . . . . . .
1
1
2
3
2
3
1
1
1
2
1
1
1
1
2
1
Ref.
No.
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Part
No.
5
Description
No.
Req’d
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 . . . .
2701757 Switch, fan . . . . . . . . . . . . . . . . . .
2702539 Cap, thermostat . . . . . . . . . . . . .
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.
170
WATER PUMP, THERMOSTAT & WATER OUTLET
SUZUKI 660 EFI HAULSTER
MODEL 898720
14
13
18
19
15
20
11
12
16
17
1
10
2
6
8
22
3
9
7
21
24
5
4
23
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
Part
No.
2702521
2701801
2702523
2702537
2701914
2702519
2702524
2702543
2701802
2701834
2702542
2702430
Description
No.
Req’d
Pump, water . . . . . . . . . . . . . . . .
Gasket, water pump . . . . . . . . .
Stud . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Pulley, water pump . . . . . . . . . . .
Case, water inlet . . . . . . . . . . . . .
Gasket . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat (82C) . . . . . . . . . . . .
Sensor, water temp. . . . . . . . . . .
1
1
2
4
2
3
1
1
1
2
1
1
Ref.
No.
13
14
15
16
17
18
19
20
21
22
23
24
Part
No.
Description
No.
Req’d
2702540 Bolt, bleed valve . . . . . . . . . . . . .
2702541 Washer, bleed valve . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
1
1
1
1
1
1
1
1
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
171
EMISSION CONTROLS, FUEL INJECTORS & SUZUKI ENGINE WIRE HARNESS
SUZUKI 660 HAULSTER
MODELS 898704, 898704LP, 898706, 898706LP, 898718, 898718LP & 898720 LP
3
1
2
8
4
6
5
23
7
11
22
12
19
21
10
20
14
13
9
16
15
18
17
!
18
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
Part
No.
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 may cause personal injury.
Description
No.
Req’d
Pipe, delivery . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Insulator . . . . . . . . . . . . . . . . . . . .
Injector, fuel . . . . . . . . . . . . . . . . .
Grommet set . . . . . . . . . . . . . . .
Cushion . . . . . . . . . . . . . . . . . . . .
Clamp . . . . . . . . . . . . . . . . . . . . . .
Maniflod, exhaust . . . . . . . . . . . .
Gasket . . . . . . . . . . . . . . . . . . . . .
Stud bolt . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
2
3
3
3
1
1
1
3
3
Ref.
No.
13
14
15
16
17
18
19
20
21
22
(22)
23
Part
No.
2702495
2702496
2702497
2701913
2702498
2702499
2702500
2702501
2702502
2702503
4111001
2702947
Description
No.
Req’d
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Cover, manifold upper . . . . . . . .
Cover, manifold lower . . . . . . . .
Stud bolt . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . .
Bolt (6x10) . . . . . . . . . . . . . . . . . .
Ring, seal . . . . . . . . . . . . . . . . . . .
Spring . . . . . . . . . . . . . . . . . . . . . .
Bolt (10x65) . . . . . . . . . . . . . . . . .
Sensor, oxygen (Gas Models) . .
Sensor, oxygen (LPG Models) . .
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
172
EMISSION CONTROLS, FUEL INJECTORS & SUZUKI ENGINE WIRE HARNESS
SUZUKI 660 HAULSTER MODEL 898720
3
1
2
8
4
6
23
5
7
11
22
12
19
21
10
20
14
13
9
16
15
18
17
!
18
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
Part
No.
2702508
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 may cause personal injury.
Description
No.
Req’d
Pipe, delivery . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
Insulator . . . . . . . . . . . . . . . . . . . .
Injector, fuel . . . . . . . . . . . . . . . . .
Grommet set . . . . . . . . . . . . . . .
Cushion . . . . . . . . . . . . . . . . . . . .
Clamp . . . . . . . . . . . . . . . . . . . . . .
Maniflod, exhaust . . . . . . . . . . . .
Gasket . . . . . . . . . . . . . . . . . . . . .
Stud bolt . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . .
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
Part
No.
2702495
2702496
2702497
2701913
2702498
2702499
2702500
2702501
2702502
2702503
2702946
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 . . . . . . .
1
1
1
2
2
5
1
2
2
1
1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
173
STARTER
(MANUAL TRANSMISSION)
SUZUKI 660 HAULSTER MODELS 898704, 898704LP,
898706, 898706LP, 898718 & 898718LP
8
7
10
3
11
1
12
4
14
3
9
5
6
13
2
Ref.
No.
1
2
*
3
4
5
6
*
Part
No.
Description
No.
Req’d
2702893 Starter, complete . . . . . . . . . . . .
2702894 Yoke assembly . . . . . . . . . . . . .
31131-80090 Brush (+) . . . . . . . . . . . . .
2702895 Screw . . . . . . . . . . . . . . . . . . . . .
2702896 Bushing . . . . . . . . . . . . . . . . . . .
2702897 Bushing . . . . . . . . . . . . . . . . . . .
2702898 Holder assembly, brush . . . . .
31132-80090 Brush (–) . . . . . . . . . . . . .
1
1
2
1
1
1
1
1
Ref.
No.
7
8
9
10
11
12
13
14
Part
No.
2702899
2702900
2702901
2702902
2702903
2702904
2702905
2702470
Description
No.
Req’d
Lever, pinion drive . . . . . . . . . . .
Switch . . . . . . . . . . . . . . . . . . . . .
Bolt, housing . . . . . . . . . . . . . . .
Armature . . . . . . . . . . . . . . . . . .
Ring assembly . . . . . . . . . . . . . .
Clutch assembly . . . . . . . . . . . .
Washer . . . . . . . . . . . . . . . . . . . .
Bolt . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
1
1
1
2
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
* Not Illustrated
174
TRANSMISSION CASE
(MANUAL TRANSMISSION)
SUZUKI 660 HAULSTER MODELS 898704, 898704LP,
898706, 898706LP, 898718 & 898718LP
5
22
3 3
5
23
24
View A
4
5
10
25
4
12
View C
View B
11
14
3
5
5
13
16
22
3
6
View A
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
12
View C
View B
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
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
175
TRANSMISSION CASE
PERKINS DIESEL MODELS 898726 & 898727
5
3
4
6
3
3
3
4
4
10
11
6
19
18
9
16
20
12
17
1
21
2
14
15
13
7
8
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
Part
No.
24700-85200
04211-13149
09103-08131
01550-08303
01550-08403
01550-08803
24741-83001
09103-08152
09250-30003
37610-80023
09280-11002
Description
No.
Req’d
Case, transmission . . . . . . .
Pin . . . . . . . . . . . . . . . . . . . .
Bolt, No. 1 (8 x 120) . . . . . .
Bolt, No. 2 . . . . . . . . . . . . . .
Bolt, No. 3 . . . . . . . . . . . . . .
Bolt, No. 4 . . . . . . . . . . . . . .
Retainer, input shaft brng. .
Bolt (8 x 25) . . . . . . . . . . . . .
Cap, inspection timing . . . .
Switch, back-up lamp . . . . .
O-ring . . . . . . . . . . . . . . . . .
1
2
4
3
1
2
1
8
1
1
1
Ref.
No.
12
13
14
15
16
17
18
19
20
21
Part
No.
09250-10006
24770-85252
04211-13149
09103-08132
01550-08403
01550-08353
01421-08303
08316-10083
24780-83010
09246-16010
Description
No.
Req’d
Plug, locating . . . . . . . . . . . .
Case, extension . . . . . . . . .
Pin . . . . . . . . . . . . . . . . . . . . .
Bolt, No. 1 (8 x 100) . . . . . .
Bolt, No. 2 . . . . . . . . . . . . . .
Bolt, No. 3 . . . . . . . . . . . . . .
Stud bolt . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . .
Seal, extension case . . . . .
Plug, oil filler . . . . . . . . . . . .
1
1
2
3
1
5
1
1
1
2
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
176
AUTOMATIC TRANSMISSION
and COMPONENTS
SUZUKI 660 HAULSTER MODELS 898720 & 898720LP
10
5
22
6
8
21
20
9
13
2
7
11
11
18
14
16
19
17
1
4
3
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 . . . . . . . . . . . . . . . . . . . . . . . .
2700336.7 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
177
AUTOMATIC TRANSMISSION PAN,
DIPSTICK & GASKETS
SUZUKI 660 HAULSTER MODEL 898720 & 898720LP
14
6
10
9
7
8
11
12
13
5
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
178
TRANSMISSION TUBES, OIL PUMP,
SOLENOIDS & SHIFT SWITCH
(Automatic Transmission)
SUZUKI 660 HAULSTER MODEL 898720 & 898720LP
8
2
1
4
7
3
4
21
6
5
22
15
14
20
To
Oil Cooler
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
179
TRANSMISSION INPUT SHAFT & CLUTCH ASSEMBLY
(Automatic Transmission)
SUZUKI 660 HAULSTER MODEL 898720 & 898720LP
3
2
1
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
180
TRANSMISSION PLANETARY GEARS and OUTPUT SHAFT
(Automatic Transmission)
SUZUKI 660 HAULSTER MODEL 898720 & 898720LP
13
11
12
8
10
9
7
17
2
6
5
16
4
3
1
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
181
BRAKE BAND & SHIFT SHAFT
(Automatic Transmission)
SUZUKI 660 HAULSTER MODEL 898720 & 898720LP
3
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 . . . . . . . . . . . . . . . .
2702801 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
182
TRANSMISSION VALVE
(Automatic Transmission)
SUZUKI 660 HAULSTER MODEL 898720 & 898720LP
17
2
11
14
1
10
12
5
19
13
15 5
5
5
6
7
18
3
8
16
3
8
15
5
4
6
16
9
5
4
4
Ref.
No.
1
2
3
4
5
6
7
8
9
10
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
183
STARTER
(Automatic Transmission)
SUZUKI 660 HAULSTER MODEL 898720 & 898720LP
7
8
10
11
1
4
12
3
14
3
9
5
13
6
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
184
ENGINE and TRANSMISSION MOUNTS
PERKINS DIESEL MODELS 898726 & 898727
USE
LOC-TITE 242
11
7
8
13
23
11
22
24
7
25
3
4
15
USE
LOC-TITE 242
8
14
21
21
16
9
3
4
5
12
2
16
1
5
20
12
5
18
2
1
6
17
5
19
6
6
9
10
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.
120177
306562
306836
306981
450453
452454
450412
452389
452398
452406
800571
809174
843568
843760
844272
841885
894581
894582
893525
894580
452388
2702475
11741-85200
11710-77100
08310-00103
Description
No.
Req’d
Notes
Lockwasher, 3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Nut, 3/8-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Screw, 3/8-16 x 2 1/4 . . . . . . . . . . . . . . . . . . . . . 2
Washer, 3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Nut, M8-1.25 (G10.9) . . . . . . . . . . . . . . . . . . . . . 16
Nut, M10-1.50 (10.9) . . . . . . . . . . . . . . . . . . . . . . 6
Lockwasher, M10 . . . . . . . . . . . . . . . . . . . . . . . . . 2
Screw, M8-1.25 x 25 (8.8) . . . . . . . . . . . . . . . . 12
Screw, M10-1.50 x 20 (8.8) . . . . . . . . . . . . . . . . 2
Screw, M10-1.50 x 90 (8.8) . . . . . . . . . . . . . . . . 4
Nut, M10-1.25 (8.8) . . . . . . . . . . . . . . . . . . . . . . . 1
Washer, 3/8 (1.94” dia.) . . . . . . . . . . . . . . . . . . . 1
Mount, transmission . . . . . . . . . . . . . . . . . . . . . . 1
Mount, hydraulic pump . . . . . . . . . . . . . . . . . . . . 1
Mount, engine (right, 4-wheel) . . . . . . . . . . . . . . 1
Mount, isolation . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Mount, motor (left) . . . . . . . . . . . . . . . . . . . . . . . . 1
Mount, motor (right) . . . . . . . . . . . . . . . . . . . . . . . 1
Support, platform . . . . . . . . . . . . . . . . . . . . . . . . . 2
Frame, engine mount . . . . . . . . . . . . . . . . . . . . . 1
Screw, M8-1.25 x 20 (8.8) . . . . . . . . . . . . . . . . . 4
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Support, transmission . . . . . . . . . . . . . . . . . . . . . 1
Bracket, rear mount . . . . . . . . . . . . . . . . . . . . . . 1
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
185
FUEL SYSTEM
HAULSTER DIESEL MODELS 898726 & 898727
8
1
17
14
8
1
18
25
14
26
10
26
Shown For
Reference Only
35
7
9
20
3
35
23
21
22
21
12
19
36
13
24
15
2
12
11
32
33
5 37
13
38
12
12
12
16
5
4
28
5
27
12
12
12
31
6
29
34
To
Engine Harness
12
13
To Engine
Fuel Return
13
32
12
12
Reference
Air Cleaner Bracket
To Engine
Fuel Inlet
2704010
186
FUEL SYSTEM
HAULSTER DIESEL MODELS 898726 & 898727
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
34
35
36
37
38
Part
No.
120052
320107
450452
452378
450453
452389
829954
800021
843343
843298
452398
825624
826590
829787
829997
452390
833953
894201
841969
836852
84310
843727
843726
843078
894922
800930
838154
894638
2208175
2700178
452394
809231
834036
130306180
821893
830425
843534
831039
Description
No.
Req’d
Lockwasher, #10 . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tie, cable, 7 1/2” (190.5 mm) . . . . . . . . . . . . . . . . . 2
Nut, M6-1.00 (G10.9) . . . . . . . . . . . . . . . . . . . . . . . 4
Screw, M6-1.00 x 20 . . . . . . . . . . . . . . . . . . . . . . . 4
Nut, M8-1.25 (10.9) . . . . . . . . . . . . . . . . . . . . . . . . . 8
Screw, M8-1.25 x 25 (8.8) . . . . . . . . . . . . . . . . . . . 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) . . . . . . . . . . . . . . . . . . 4
Clamp, hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hose, fuel, 5/16” i.d. . . . . . . . . . . . . . . . . . As Req’d.
Terminal, 45 1/4 male . . . . . . . . . . . . . . . . . . . . . 2
Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Screw, M8-1.25 x 30 (8.8) . . . . . . . . . . . . . . . . . . . 2
Cover, fuel sender . . . . . . . . . . . . . . . . . . . . . . . . . 1
Harness, fuel tank wire . . . . . . . . . . . . . . . . . . . . . 1
Tank, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Elbow, 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tube, fuel pick-up . . . . . . . . . . . . . . . . . . . . . . . . . 1
Support, fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Panel, fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Screw, M8-1.25 x 16 (8.8) . . . . . . . . . . . . . . . . . . . 4
Bracket, fuel pump mounting . . . . . . . . . . . . . . . . 1
Pump, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Filter, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Connector, union (5/16-7/16) . . . . . . . . . . . . . . . . . 1
Screw, M8-1.25 x 70 (8.8) . . . . . . . . . . . . . . . . . . . 1
Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Connector, hose . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Pre-filter, fuel (ZZ7B901) . . . . . . . . . . . . . . . . . . . . . 1
Trim, push-on . . . . . . . . . . . . . . . . . . . . . . As Req’d.
Hose, fuel 1/4” i.d. . . . . . . . . . . . . . . . . . . . As Req’d.
Bracket, fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hose, fuel 5/32” i.d. . . . . . . . . . . . . . . . . . . As Req’d.
Notes
Order directly from Perkins
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY
When ordering from Perkin’s be sure to include the Engine Model and Spec No’s.
The model and specification numbers for the Perkins engine are as follows:
Model 103.10 - Spec. KD70377.
To locate the Perkin’s Dealer nearest to you, please call: 1-888-737-5364
187
DRIVE SHAFT, CLUTCH & TRANSMISSION SHIFTER LINKAGE
DIESEL HAULSTER MODELS 898726 & 898727
32
5
1
15
35
32
55
33
58
5 1
16
19
Reference
Shift Lever Case
56
48
34
50
Apply
Loc-tite 222
21
29
51
28
31
49
21
13
4
17
6
57
14
40
39
41
18
Apply
Loc-tite 242
27
52
Reference
Air Cleaner Brckt.
47
46
3
44
43
38
53
54
Reference
Transmission
52
47
45
37
42
36
41
9
3
2
1
30
25
11
8
24
22
Reference
Diesel Engine
20
3
24
26
10
25
9
23
8
12
7
3
8
894198, 893594
188
DRIVE SHAFT, CLUTCH & TRANSMISSION SHIFTER LINKAGE
DIESEL HAULSTER MODELS 898726 & 898727
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
Part
No.
103867
306325
452389
450377
548190
800934
894272
548482
826284
826285
894432
894433
833273
842010
843830
843778
894299
844202
892811
452392
548222
800948
800949
839752
842961
843323
843754
844228
894179
894645
Description
No.
Req’d
Notes
Washer, 5/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lockwasher, 5/16 . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Screw, M8-1.25 x 25 (8.8) . . . . . . . . . . . . . . . . . . 11
Nut, nylock M6-1.00 (8.8) . . . . . . . . . . . . . . . . . . . 1
Hairpin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Screw, M6-1.00 x 16 (8.8) . . . . . . . . . . . . . . . . . . . 1
Driveshaft, complete . . . . . . . . . . . . . . . . . . . . . . . 1
Plug, expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cross, u-joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Yoke, universal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Yoke, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Shaft, drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bushing, clutch arm . . . . . . . . . . . . . . . . . . . . . . . . 1
Connector, shift cable . . . . . . . . . . . . . . . . . . . . . . 1
Connector, shift cable . . . . . . . . . . . . . . . . . . . . . . 1
Cable, clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Washer, slotted . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Wire, ground, black 24” (610 mm) . . . . . . . . . . . . 1
Screw, M8-1.25 x 50 (8.8) . . . . . . . . . . . . . . . . . . . 2
Set screw, #8-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Screw, M10-1.25 x 35 (12.9) . . . . . . . . . . . . . . . . 1
Screw, M10-1.25 x 50 (12.9) . . . . . . . . . . . . . . . . 1
Pin, dowel, 8 mm x 18 mm . . . . . . . . . . . . . . . . . . 3
Sleeve, alignment . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Adapter, transmission (Perkins) . . . . . . . . . . . . . . 1
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Stop, 5th gear lockout . . . . . . . . . . . . . . . . . . . . . . 1
Cable, shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Ring, pressure plate (Perkins) . . . . . . . . . . . . . . . 1
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
189
DRIVE SHAFT, CLUTCH & TRANSMISSION SHIFTER LINKAGE
DIESEL HAULSTER MODELS 898726 & 898727
32
5
1
15
35
32
55
33
58
5 1
16
19
Reference
Shift Lever Case
56
48
34
50
Apply
Loc-tite 222
21
29
51
28
31
49
21
13
4
17
6
57
14
40
39
41
18
Apply
Loc-tite 242
27
52
Reference
Air Cleaner Brckt.
47
46
3
44
43
38
53
54
Reference
Transmission
52
47
45
37
42
36
41
9
3
2
1
30
25
11
8
24
22
Reference
Diesel Engine
20
3
24
26
10
25
9
23
8
12
7
3
8
894198, 893594
190
DRIVE SHAFT, CLUTCH & TRANSMISSION SHIFTER LINKAGE
DIESEL HAULSTER MODELS 898726 & 898727
Ref.
No.
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
Part
No.
01550-08803
01550-08403
01550-08553
09103-08131
39312-50F01
08321-01083
09111-08035
09117-08096
28391-85202
01421-10403
08316-10103
01421-10503
09205-03019
23260-85203
23265-85200
09448-20007
09300-14017
845223
23266-85002
08316-10083
01550-08353
04211-13149
22100-85200
22400-85141
37610-80023
09280-11002
09250-30003
894602
Description
No.
Req’d
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire, noise suppressor . . . . . . . . . . . . . . . . . . . .
Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, shift cables . . . . . . . . . . . . . . . . . . . . . .
Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin, roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft, clutch release . . . . . . . . . . . . . . . . . . . . . .
Bearing, clutch release . . . . . . . . . . . . . . . . . . . .
Spring, clutch release . . . . . . . . . . . . . . . . . . . . .
Bushing, clutch release . . . . . . . . . . . . . . . . . . .
Gasket, shifter case . . . . . . . . . . . . . . . . . . . . . .
Arm, clutch release . . . . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sleeve, alignment . . . . . . . . . . . . . . . . . . . . . . . .
Cover assembly, clutch . . . . . . . . . . . . . . . . . . . .
Disc, compression clutch . . . . . . . . . . . . . . . . . .
Switch, backup lamp . . . . . . . . . . . . . . . . . . . . . .
O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plug, transmission inspection timing . . . . . . . .
Wire, ground, black 32” (813 mm) . . . . . . . . . . .
Notes
1
4
1
1
2
2
2
4
1
1
2
1
1
1
1
1
2
1
1
1
1
2
1
1
1
1
1
1
• INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.
191
EXHAUST SYSTEM
DIESEL MODELS 898726 & 898727
Existing Transmission
Hardware
3
5
8
12
10
11
13
With Item 8
Below
9
2
7
1
4
6
8
P893566
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
192
Part
No.
103867
450193
450378
452389
2703794.8
2703800.8
838295
841982
842555
120177
306981
548849
844198
2703835.8
Description
No.
Req’d
Washer, flat, 5/16 . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M8-1.25 x 30 . . . . . . . . . . . . . . . . . . . . . . .
Locknut, M8-1.25 staytite . . . . . . . . . . . . . . . . . . .
Screw, M8-1.25 x 25 (8.8) . . . . . . . . . . . . . . . . . . .
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tube, exhaust inlet . . . . . . . . . . . . . . . . . . . . . . . . .
Strap, muffler hanger . . . . . . . . . . . . . . . . . . . . . . .
Clamp, exhaust tube (1 1/2”) . . . . . . . . . . . . . . . . .
Gasket, exhaust inlet . . . . . . . . . . . . . . . . . . . . . . .
Lockwasher, 3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, flat, .41 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, 3/8-16 x 4 3/4 . . . . . . . . . . . . . . . . . . . . . . .
Cover, starter hole . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
2
2
1
1
1
1
1
2
2
2
1
1
Notes
CLUTCH LINKAGE
DIESEL HAULSTER MODELS 898726 & 898727
9
12
1
6
2
13
5
17
3
16
18
14
8
4
10
7
11
16
15
P893668
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Part
No.
450377
450453
450510
306328
452388
452424
806714
810152
833273
840725
840726
842010
842935
892933
894299
844202
890808
844611
Description
No.
Req’d
Nut, M6-1.00, staytite . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin, brake pivot . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing, brake pivot . . . . . . . . . . . . . . . . . . . . . .
Bushing, clutch arm . . . . . . . . . . . . . . . . . . . . . . .
Tab, locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lever, clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable, clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, slotted . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, clutch interlock . . . . . . . . . . . . . . . . . . . .
Spring, torsion . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes
1
1
2
1
1
2
1
1
1
1
1
1
1
1
1
4
1
1
193
RADIATOR and COOLING SYSTEM
DIESEL HAULSTER MODELS 898726 & 898727
40
38
39
7
Reference
Platform Support
Although the neoprene cover and mounting
hardware are used on vehicles equipped with
seat belts and/or cab sets, they can be used
on any vehicle without cabsets or seatbelts
14
13
28
16
29
23
25
27
14
19
30
24
21
11
18
27
3
10
2
1
31
37
31 36
USE
LOCTITE 592
22
9
20
32
USE
LOCTITE 592
34
35
31
15
31
17
33
31
6
8
31
4
4
12
6
8
5
26
6
4
8
6
P2704009, P2704006
194
4
RADIATOR and COOLING SYSTEM
DIESEL HAULSTER MODELS 898726 & 898727
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
34
35
36
37
38
39
40
Part
No.
300646
306396
308090
450452
450541
452378
835805
825884
829787
800177
831846
844391
889051
833512
844390
840754
843040
888549
894590
833443
889049
833442
889050
893388
893554
2700799
450453
452388
452395
452398
820889
843857
009034880
2701757
2700031
894348
4410540
2701421
2701422
133741
Description
No.
Req’d
Notes
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Terminal, 45 1/4” male . . . . . . . . . . . . . . . . . . . . . 1
Screw, 5/16-18 x 3/4 . . . . . . . . . . . . . . . . . . . . . . . 4
Nut, isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hose, radiator lower . . . . . . . . . . . . . . . . . . . . . . . . 1
Cap, coolant reservoir . . . . . . . . . . . . . . . . . . . . . . 1
Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hose, radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Decal, Warning Pressure . . . . . . . . . . . . . . . . . . . 1
Bracket, fan mounting . . . . . . . . . . . . . . . . . . . . . . 1
Connector, hose (air cleaner) . . . . . . . . . . . . . . . . 1
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cap, radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Reservoir, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Mount, radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fan, radiator, cooling . . . . . . . . . . . . . . . . . . . . . . . 1
Nut, M8-1.25 (G10.9) . . . . . . . . . . . . . . . . . . . . . . . 4
Screw, M8-1.25 x 20 (G8.8) . . . . . . . . . . . . . . . . . 3
Screw, M10-1.50 x 80 (8.8) . . . . . . . . . . . . . . . . . 1
Screw, M10-1.50 x 20 (8.8) . . . . . . . . . . . . . . . . . 2
Clamp, tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sender, water temperature . . . . . . . . . . . . . . . . . . 1
Decal, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Switch, fan (on-93C, off-88C) . . . . . . . . . . . . . . 1
O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tube, fan switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hose, radiator upper . . . . . . . . . . . . . . . . . . . . . . . 1
Backing, plate cover . . . . . . . . . . . . . . . . . . . . . . . . 1
Cover, neoprene . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Rivet, pop (.12 .50, closed end) . . . . . . . . . . . . . . . 1
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
195
AIR CLEANER, BRACKET and FILTER
PERKINS DIESEL MODELS 898726 & 898727
To Radiator
Mounting Frame
3
2
13
Items 9, 11 & 12
Shown Assembled.
1
11, 12 *
7
7
6
9
8
7
14
7
17
15
16
5
10
4
894197, 894198
Ref.
No.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
12 *
13
14
15
16
17
300646
306396
308090
452389
450453
452390
825358
842993
842915
844311
893182
840352
888549
844313
841943
842235
452378
Description
No.
Req’d
Screw, 1/4-20 x 3/4 . . . . . . . . . . . . . . . . . . . . . . . .
Lockwasher, 1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, 1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M8-1.25 x 25 (8.8) . . . . . . . . . . . . . . . . . . .
Nut, M8-1.25 (8.8) . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M8-1.25 x 30 (8.8) . . . . . . . . . . . . . . . . . . .
Clamp, worm-drive . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, air filter . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, air cleaner . . . . . . . . . . . . . . . . . . . . . . . .
Filter complete, air . . . . . . . . . . . . . . . . . . . . . . . . .
Element, air cleaner . . . . . . . . . . . . . . . . . . . . . . .
Connector, hose (air cleaner) . . . . . . . . . . . . . . . . .
Hose, intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gasket, air inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M6-1.00 x 20 . . . . . . . . . . . . . . . . . . . . . . .
2
2
2
2
2
2
4
1
1
1
1
1
1
1
1
1
2
Notes
Not illustrated
INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
196
DECALS, HAULSTER MODELS
NOTICE
8
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
009034880
3
1
840748
844847
17
11
16
SERVICE
ENGINE SOON
LIGHT INDICATES
CARBURETION SYSTEM
REQUIRES ADJUSTMENT
15
6
HAULSTER 10
840845
844429
5
12
HAULSTER 4
844428
13
14
840901
844783
2
WARNING
7
R
PARKING BRAKES ARE NOT AUTOMATICALLY APPLIED. VEHICLE MAY
MOVE CAUSING PERSONAL INJURY
AND/OR PROPERTY DAMAGE. ALWAYS
APPLY HAND OR FOOT BRAKES. 822819
9
WARNING
FAILURE TO HEED THESE
WARNINGS MAY RESULT IN
SERIOUS INJURY OR DEATH
Ref.
No.
1
2
3
4
5
(5)
6
(6)
7
8
Part
No.
844430
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.
Description
No.
Req’d
821071 Decal, Notice not motor vehicle .
822819 Decal, Warning, park brake . . . . .
840754 Decal, Warning, pressure . . . . . .
840901 Decal, Warning, read ops. man. .
844428 Decal, 4-wheel Haulster (LH) . . .
844424 Decal, 3-wheel Haulster (LH) . . .
844429 Decal, 4 wheel Haulster (RH) . . .
844425 Decal, 3-wheel Haulster (RH) . . .
844430 Decal, Cushman-Textron . . . . . . .
009034880 Decal, Warning, fan . . . . . . .
1
1
1
1
1
1
1
1
1
1
Ref.
No.
9
10
11
12
13
14
15
16
17
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
845038 Decal, Vehicle Operation . . . . . . .
838427 Decal, Cushman . . . . . . . . . . . . . .
844847 Decal, Textron . . . . . . . . . . . . . . . .
2701389 Decal, Diamond “C” . . . . . . . . . .
844783 Decal, center (3-wheel) . . . . . . . .
2703150 Decal, fuse panel . . . . . . . . . . . .
840845 Decal, diesel fuel only . . . . . . . .
2704063 Decal, Service Engine Soon (LP)
2704064 Decal, Light Indicates... (LP) . . . .
1
2
1
1
1
1
1
1
1
197
ONE-SPEED HYPOID DIFFERENTIAL (11.16:1)
17
14
58
56
12
63
53
64
29
22
24
62
45
32
36
35
21
38
65
54
57
55
23
18
25
31
41
52
27
24 *
35
44
50
51
66
39
40
34
37
42
9
43
67
LOCTITE 515
BOTH SIDES
13
LOCTITE 242
TORQUE TO
50 ft. lbs.
59
60
19
33
61
30
47
6
46
28
22
61
11
15
10
4
19
3
7
8
14
49
17
1
5
2
48
16
893491
198
RING EYES MUST BE POSITIONED WITH GAP
* RETAINING
CENTERED OVER THE CAST OIL DRAIN GROOVE.
20
Also Included With
Ref. No’s. 50 & 51
26
ONE-SPEED HYPOID DIFFERENTIAL (11.16:1)
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
2701165
112050
800909
841842
832584
841844
800944
841430
836959
841838
841837
836431
836439
893583
103867
111074
304636
306322
306405
307776
845356
548952
800559
800973
800737
805837
800743
800695
810435
836440
809180
836441
811993
812335
838539
836693
Description
No.
Req’d
Differential, 11.16:1 . . . . . . . . . . . . . 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, 11.16:1 ratio . . . . . . . . . . . . . . 1
•Cable, park brake . . . . . . . . . . . . . . 2
•Washer, 5/16 . . . . . . . . . . . . . . . . . . 8
•Plug . . . . . . . . . . . . . . . . . . . . . . . . . 1
•Pin, cotter, 1/8 x 1 1/8 . . . . . . . . . . 2
•Screw, 5/16-18 x 7/8 . . . . . . . . . . 12
•Washer, 3/8 . . . . . . . . . . . . . . . . . . 10
•Screw, 3/8-16 x 2 3/4 . . . . . . . . . . . 3
•Washer . . . . . . . . . . . . . . . . . . . . . . 2
•Lockring . . . . . . . . . . . . . . . . . . . . . . 1
•Nut, 1/2-20, crownlock . . . . . . . . . 2
•Nut, 3/4-16, crownlock . . . . . . . . . 1
•Ring, retaining . . . . . . . . . . . . . . . . 2
•Locknut, special . . . . . . . . . . . . . . 10
•Nut, 3/4-16, slotted . . . . . . . . . . . . 2
•Ring, retaining . . . . . . . . . . . . . . . . 1
•Clamp . . . . . . . . . . . . . . . . . . . . . . . 1
•Pinion, 18 tooth . . . . . . . . . . . . . . . 1
•Washer, special . . . . . . . . . . . . . . . 1
•Gear, 49 tooth . . . . . . . . . . . . . . . . . 1
•Bearing, thrust . . . . . . . . . . . . . . . . 1
•Seal, oil . . . . . . . . . . . . . . . . . . . . . . 1
•Seal, oil . . . . . . . . . . . . . . . . . . . . . . 2
•Bearing, ball . . . . . . . . . . . . . . . . . . 3
Ref.
No.
Part
No.
Description
No.
Req’d
36 836420 •Spacer, pinion . . . . . . . . . . . . . . . . . 1
37
836426 •Collar, axle bearing . . . . . . . . . . . . 2
38 845034 •Collar, thrust . . . . . . . . . . . . . . . . . . 1
39
2700530 •Shaft assembly (left) . . . . . . . . . . . 1
(39) 2700514 ••Shaft, axle (left) 23.27” (591.05 mm) 1
40
2700531 •Shaft assembly (right) . . . . . . . . . . 1
(40)
2700515 ••Shaft, axle (right) 29.21” (741.93 mm) 1
41
836694 •Seal, ’O’ ring . . . . . . . . . . . . . . . . . . 2
42
836695 •Bearing, tapered roller . . . . . . . . . . 2
43
836852 •Breather . . . . . . . . . . . . . . . . . . . . . . 1
44
837020 •Baffle, vent . . . . . . . . . . . . . . . . . . . 1
45
809180 •Washer . . . . . . . . . . . . . . . . . . . . . . 1
46
893519 •Retainer, complete w/seal . . . . . . 2
47
838539 ••Seal, bearing . . . . . . . . . . . . . . . . . 1
48
893552 •Hub . . . . . . . . . . . . . . . . . . . . . . . . . . 2
49
800908 ••Screw, wheel retaining . . . . . . . . 5
50 2703506.7•Housing, axle (left) . . . . . . . . . . . . . 1
51 2703507.7•Housing, axle (right) . . . . . . . . . . . 1
52
891829 •Housing, carrier w/gears . . . . . . . . 1
53
103867 ••Washer, 5/16 . . . . . . . . . . . . . . . . 14
54
111074 ••Plug . . . . . . . . . . . . . . . . . . . . . . . . 1
55
111758 ••Stud . . . . . . . . . . . . . . . . . . . . . . . 10
56
306322 ••Screw, 5/16-18 x 7/8 . . . . . . . . . 14
57
517226 ••Bushing . . . . . . . . . . . . . . . . . . . . . 2
58
836443 ••Cover, rear . . . . . . . . . . . . . . . . . . 1
59
•Brake, rear complete, (right) . . . . . 1
60
•Brake, rear complete, (left) . . . . . . 1
61
844813 •Ring, backing . . . . . . . . . . . . . . . . . 4
62
844951 Shim, .003 . . . . . . . . . . . . . . . . . . . . . 1
844952 Shim, .005 . . . . . . . . . . . . . . . . . . . . . 1
844953 Shim, .010 . . . . . . . . . . . . . . . . . . . . . 1
63
836665 •Cover . . . . . . . . . . . . . . . . . . . . . . . . 1
64
836671 •Gasket . . . . . . . . . . . . . . . . . . . . . . . 1
65
836423 •Shaft . . . . . . . . . . . . . . . . . . . . . . . . . 1
66
2703481 •O ring . . . . . . . . . . . . . . . . . . . . . . . . 1
67
810437 •Clip . . . . . . . . . . . . . . . . . . . . . . . . . . 2
• INDENTED PARTS NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
• Refer to the parts breakdown for the brakes on Page 144.
Also includes Ref. No’s. 16, 20 & 26.
199
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 –
200
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
Notes
201
WIRING DIAGRAM
SUZUKI 660 EFI
HAULSTER MODELS 898704, 898706, 898718
BR
BL/B
B
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
BR
R/B
B/G
BL/W
BL/B
OR
R/G
BL/R
B/R
BL/W
PK
B/W
BL/B
B/Y
B
G/W
R
G/BL
OR/G
G
B/W
B/R
W
PIN 31
Not
Used
B/R
B
R/G
R
R
W/OR
OR
PK
W/PK
B
B/R
R/G
PIN 1
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
B
R
PK/BL
BR/Y
BR/Y
OR
PK/BL
W/PK
PK
W/OR
W/OR
Clutch
Switch
Brake
Switch
B/R
B
R/G
R
B/R
OR/BL
PK
R
G/PK
G/BL
G
BL/R
BL/W
B
W/PK
OR
B/R
B
W/R
B
BL/B
R/OR
B
B/W
R
Engine
Harness
895049
B/R
R/Y
B/Y
W/R
R/G
W
PK/B
R/OR
B
Y
W/Y
B/R
BL
R
B
BL
R
B/R
Y/B
B
B
Y
G/W
W/Y
R/G
B
Y
B
B
PK/B
W/Y
R
Y
R
W/OR
W/R
R/OR
R
Y
W/R
R
Y
Y
W/R
R
BL/B
OR
B/R
B
B/W
BL
G/BL
BL/W
R/Y
Y
G/W
Y
G/W
B
B/W
B
Y
Y
G/W
PIN 31
PIN 10
OR/BL
G
BL/R
OR
B/Y
PK/B
B/W
B
B
PIN 40
BR/Y
PK
G/PK
BL/W
W
R
B/R
Park Brake
Switch
R
BL/B
R/G
R
B
W/PK
OR
B
Back-up
Alarm
OR/G
B
B/Y
PK/B
B
R
G/PK
G/BL
BR/Y
W/OR
B
Fuel Pump
Radiator Fan
R/Y
R
B
B/R
W
W/OR
B
R
B
Back-up
Switch
B
B
Chassis
Ground
W/OR
R/Y
R
B
B/Y
B
R
B
B
B/R
W/Y
PK/BL
B/R
R/G
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
B/Y
B
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
Starter
PK/B
W/R
B/Y
B
PIN 1
PIN 40
Engine Ground
No. 2
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
PIN 10
Y
B/G
BL
W/B
W
G/W
PK/B
W/Y
B
B/W
W/B
BR/Y
Y
B/W
W
B
W
B/W
B
B
W/OR
PK
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
B/W
B
R/G
PK
W/R
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
W/R
OR
B
G/W
B
B/W
G/W
R/OR
B/R
PK
BR/Y
Suzuki
Harness
2702947
R/W
B/W
R/Y
R/G
B/Y
R/G
BL/W
G/W
R/Y
R/OR
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
B/W
Coil
B
No. 3
W/R
Coil
No. 1
OR
B
B/BL
B
B
B/G
R/W
B/W
B/G
Engine Ground
No. 1
Coil
No. 2
W
B/G
BL/W
B
BR
B
B/BL
B
BL/B
BR
BR
W/PK
B/R
BR/R
B/R
Turf
Taillight
B
PK/BL
W/B
Sensor
B
OR
BR
B
B
R/B
BR
BL/B
R/BL
B
Crank Angle BR/R
B
PK/BL
B
BR/B
Oxygen
Sensor
Main
Harness
2700919
R/B
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
PIN 4
PIN 7 W/R
PIN 2 PK
PIN 1 B/R
W/R
B/W
PIN 16
PIN 13
BR
OR
R/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
R/B
B
BR
BR
BL/B
B
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
Right Industrial
Taillight
Turf Taillight
Harness
W
W/R
W/B
Industrial
Taillight Harness
PIN 34
PIN 9
B
R
W
W/OR
BL/Y
G/R
G/Y
Left Industrial
Taillight
R
W
R/B
BR
R
G/Y
BL/Y
G/R
Pressure
Sensor
B
R
R/BL
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
EXC
P
Temp
Sender
S
B
B
Fan
Switch
Oil Pressure
Sender
Not Used on
All Vehicles
2703077
202
COLOR CODE:
OR
G
Y/B
Y/B
Y/R
B
B
B
B/R
W/BL
Y/B
B
OR/B
Y
R
Fuse Block
15
Fuse
15
Amperage 10
10
B
B/W
B/W
B/W
PK
B
B
R/B
R/B
PK/B
BL/W
B/G
B/W
Y
R/W
BL/W
B
B
R/G
BL
Y
BL/W
B/G
B
W/R
R
R/OR
R/Y
G/B
B/W
G/W
W/G
B/G
R/G
R/W
B
R/B
W/R
B/R
B/R
B
Y
R/W
B/W
B
Ground
Standoff
BL
W/R
W/R
B/G
B
R/G
BL
B/G
B/R
W/R
W/R
B
B
B
B/W
R/W
Y
G
W/BL
Y/R
PK
W
R
R/B
Brake Fluid
Reservoir
B/R
B/G
B/W
B/W
PK/B
PK
BL
Fuse Block
20
Fuse
10
Amperage 10
10
R/Y
BL
BL
BR/Y
G/W
G/W
B/W
Y
Y/R
Y/R
R
R
W/G
G
Y
B/W
Y/R
R
R
W/R
W/R
BR/Y
R/OR
R/B
R/B
G/B
B/W
Y/R
R
W
B
BL
Not
Used
B/R
B/R
B/R
PK/B
B/R
R
R
Y
W/OR
R
R
W/BL
Main
Relay
B
B
BL
B
OR/B
Accessory Plug
B/W
B/W
G/W
Trailer Brake
Receptacle
Accessory Plug
B
R
R
B
R/Y
R
B/R
W/BL
W/R
Y/R
Y
B/G
G/W
Y
BR/Y
R
B/R
PK/B
W/OR
W
Y/R
R
W/R
R
R
Y
Y
B
R/G
R
W/BL
R
W/R
W
Y/R
R
BR
B
Accessory Plug
B
B
B
B
B
PK
R
R
OR/B
OR/B
Trailer Brake
Controller
B
R
B/R
W/OR
R
Y/R
B
B
B
B/W
W/R
BR
R
W
B
Y
Y
B
Y
BL
BR
OR/B
OR/B
B
W/BL
W/R
B
B/R
R/W
R/G
R/OR
G/B
G/W
BL/W
B/G
R/B
B
B
B
W/G
Y
G
BR
BR
G
R
W
BL
B
Brake Controller
Harness
BR
BL
G
B/R
Speedometer
Panel
B
OR/B
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
R
W/R
B
B
Dome
Light
B
W
B
BL
OR/B
W/R
B
R
PIN 16
PIN 18
Wiper
Motor
W/R
W/R
Y/R
Y/R
Power Point
(ACC 12V Plug-in Port)
R
Y
BR
B/W
W/R
BR
OR
R
Y
B
Y
R
B
W/R
Y/R
Speedometer
Signal
OR
B
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/R
R
B/R
R
W/OR
PK
B/R
Heater
Fan
B
Wiper/Dome Light
Harness
B
Y
R
R
R
B
B
W/R
B/G
G/W
W
BR/Y
R
W/R
R
B
B/G
PK/B
R
B/R
W/OR
Y
W/Y
BL
PK/BL
G/W
PK/B
Y/R
R
B
OR
B
PK
B/W
B/W
B/G
B/R
W/R
W/R
B
B/G
B/Y
G
OR
B
B
Y/R
R
BR/Y
W
G/W
R/G
W/G
G
Heater
Switch
OR/B
W/G
B
W
B/R
PK
PK
B
B
G/B
R/OR
R/Y
R/OR
B/R
BL/W
G/W
B/W
G/B
B/G
R/W
W/R
Heater
Harness
Shifter
Light
B/W
B
B
Headlight
Switch
W/OR
BR W
BR
BR
BR
B/W
R/B
R/W
BL/W
G/W
OR
R/G
B/G
BR
W/OR
W/BL
B/W
R/G
B
BR/Y
B/G
R/Y
R/OR
B/R
PK
B
B
Y
B/W
R/B
BR
BR
OR/B
R/Y
B
B/W
OR
W/OR
BL
W/BL
W
B/R
BL/W
B/W
W/BL
BR
Y
G/W
W/BL
R/B
R/W
OR/B
OR/B
OR/B
BR
BR
BL
BR
B/R
R/W
BL
BR
BR
OR/B
Y
B/W
W
B/G
B
W
W/BL
G
R/G
Y
Y/B
PK/B
B
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
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
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
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
R
Horn
Fuel
Relay
B
BL/W
B
R/W
Diagnostic Timing
Plug
Plug
G/W
Fuse Block
20
Fuse
15
Amperage 10
10
203
WIRING SCHEMATIC
SUZUKI 660 EFI
HAULSTER MODELS 898704, 898706, 898718
Ignition
Switch
Starter
Solenoid
10A
25A
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”
204
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
P10
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
P12
Fuel Gauge
Timing
Port
ACC
“START”
P14
Service Brakes
Diagnostics
Oil Pressure
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”
205
WIRING DIAGRAM
SUZUKI 660 EFI
HAULSTER MODELS 898704LP, 898706LP, 898718LP
PIN 1
PIN 27
PIN 21
PIN 1
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
B
BR
BL/B
R/B
BL/B
Coil
No. 1
B
BL/W
BL/B
OR
B/G
R/B
BR
G/W
R
G/BL
OR/G
OR/BL
B/W
G
BL/R
B/R
BL/W
PK
B/W
OR
B/W
PK
B/W
B
B/W
W/B
B
BR/Y
W
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
B/Y
W/Y
BL
PK/BL
R
R/G
R
B/R
B
B
W/OR
OR
PK
B/R
B
PIN 31
W/PK
B/R
PIN 1
PIN 40
PK/B
W/R
B/Y
R/G
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
Y
B/G
PK/B
BL
B
W
G/W
Y
W/Y
W/B
R/G
W/OR
PK
B/W
W
B
W
OR
PK
B
B/W
B
G/W
R/OR
B
W/R
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
W/R
R/W
B/R
G/W
B
B/W
R/G
B/W
B/R
BR/Y
Suzuki
Harness
2702947
B
R/Y
R/G
B
BR
BL/W
G/W
R/Y
R/OR
B/Y
BL/B
B/G
R/W
B/W
B/BL
B/W
Coil
B
No. 3
W/R
Coil
No. 2
W
B/G
BL/W
B
B/BL
B
BR
B
B/G
Engine Ground
No. 1
Turf
Taillight
B
BR
W/B
B
B
OR
BR
PK/BL
W/PK
B/R
BR/R
B/R
B
B
B
R/B
BR
BL/B
R/BL
B
Crank Angle BR/R
R/B
B
G/PK
W
B
Not
Used
Main
Harness
2700919
B/Y
W/R
B/R
BR/B
BR/B
Not
Used
B/R
B/R
BR
BR
Sensor
PIN 13
R/B
R/B
BL/B
BR/W
W
Injector
No. 1
B/R
BR
PIN 10 B/Y
W/G
B/R
B/R
PIN 1
PK
BR/W
Injector
No. 2
PIN 4
PIN 4 B/W
Not
Used
Injector
No. 3
PIN 16
PIN 13
PIN 7 W/R
PIN 2 PK
PIN 1 B/R
W/R
B/W
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
BR
OR
R/B
BR
R/G
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
BR
BL/B
B
B
BR
W
PIN 7
PIN 26
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
Right Industrial
Taillight
Turf Taillight
Harness
BL/B
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
W/R
W/B
Industrial
Taillight Harness
PIN 34
PIN 9
B
R
W
PK/BL
BL/Y
G/R
G/Y
Left Industrial
Taillight
R
W
R/B
BR
R
G/Y
BL/Y
G/R
Pressure
Sensor
B
W/OR
R/BL
G/R
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
OR
PK/BL
W/PK
PK
W/OR
W/OR
Clutch
Switch
Brake
Switch
Oxygen
Sensor
Chassis
Ground
B/Y
Fuel Pump
B
Y
206
Y
R/OR
W/R
G/W
B
B/R
R
P
Temp
Sender
Oil Pressure
Sender
R
R
B/R
W
B/Y
W/R
R/G
PK/B
Y
R/OR
B
EXC
B
B
R/G
R/G
BL
R
B/W
B/R
R/Y
Y/B
S
B/R
B
G/W
W/Y
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
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
R
PK/B
W/R
R/G
R
Y
PK/BL
B
R
BR/Y
BR/Y
R
OR/BL
PK
W/PK
G/PK
G/BL
G
BL/R
B
B/W
R/OR
R
B
Y
G/W
W/R
R
B
R
B
B
Y
B/W
R
B
R
Radiator Fan
2700799
G/W
B/W
R
Y
W/OR
B
B/Y
PK/B
BL/B
OR
B/R
W/Y
B/R
BL
PK/B
G/BL
BL/W
BL/R
W/Y
B
OR/BL
G
R/Y
W
B
PIN 1
BR/Y
PK
G/PK
BL/W
W/OR
Fuel
Shut-Off
Valve
R
BL/W
B/R
B
BL/B
R/G
B/R
OR
B
B
R
R
OR
B
PIN 31
PIN 10
Park Brake
Switch
OR/G
BL/B
PIN 40
R
B
OR
B
W/R
R
B
B
W/OR
R
R/Y
R
R/G
W
B
R
B
B/R
B
Back-up
Alarm
W/PK
B
B/Y
R
G/PK
G/BL
BR/Y
B
R
LPG
Ground
B
B/R
W/OR
Engine
Ground
No. 2
R/Y
B
B
B
B R
W/R
R
B
BL
BL
P
R
OR
W
Fuel
Control
Module
R
OR
R
B
BL/B
Back-up
Switch
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
BL/R
BR/Y
OR/BL
PK
W/PK
R
OR/G
B
G
BL/W
OR/G
–
G
R
Not
Used
Fuel
Control
Valve
Service
Engine
Light
Not
Used
B
B/R
OR
+
Battery
Speed
Sensor
Start
Solenoid
Starter
2704004
Engine
Harness
895049
COLOR CODE:
GY
Taillight
Adapter
OR
G
Y/B
Y/B
Y/R
Y/B
B
B
B/R
B
OR/B
Y
R
Fuse Block
15
Fuse
15
Amperage 10
10
B
B/W
B
B/G
B/W
B/W
PK
B
B
R/B
Y
R/G
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
PK/B
BL/W
W/R
B/G
BL
B/R
B
B/R
Y
B
B
Ground
Standoff
BL
W/R
R/B
Brake Fluid
Reservoir
B/R
B/G
B/W
B/W
PK/B
PK
BL
Fuse Block
20
Fuse
10
Amperage 10
10
W/R
BR/Y
R/OR
R/B
R/B
G/B
R/Y
BL
BL
G/W
W/G
G/W
B/W
Y
Y/R
Y/R
R
R
BR/Y
W/R
G
Y
B/W
Y/R
R
R
B
R/G
BL
B/G
B/R
W/R
W/R
R/W
B/W
B
Not
Used
B/R
B/R
B
PK/B
B/R
R
W
Main
Relay
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
B
B
B
B/W
R/W
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
Y
B
R
R
B/R
R/Y
R
B/R
G
Y
W/R
Y/R
Y
B/G
G/W
Y
BR/Y
R
B/R
B
B
B/R
W/OR
R
R
OR/B
OR/B
R
BR
B
Accessory Plug
B
B
B
B
B/W
W/R
Y/R
Trailer Brake
Controller
B
R
Y
B
Y
BR
B
Y
B
W/BL
BL
BR
OR/B
OR/B
G
R
W
BL
R
W
B/R
Speedometer
Panel
W/R
B
W/R
W/R
R/W
R/G
R/OR
G/B
G/W
BL/W
B/G
R/B
B
B
B
W/G
Y
G
BR
BR
BR
BL
G
B
Brake Controller
Harness
OR/B
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
R
B
B
B
Dome
Light
B
W
B
W/R
R
PIN 16
PIN 18
Wiper
Motor
BL
OR/B
W/R
B
B
OR
R
Y
B
Y
R
PK
B/W
B/W
B/G
B/R
Y/R
Power Point
(ACC 12V Plug-in Port)
R
Y
BR
B/W
W/R
BR
Y
R
B
W/R
Y/R
Speedometer
Signal
OR
B
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
Heater
Fan
B
Wiper/Dome Light
Harness
B
OR
B
R
R
B
B
W/R
W/R
R
B
W/R
R
B
B/G
PK/B
R
B/R
W/OR
Y
W/Y
BL
PK/BL
G/W
PK/B
Y/R
R
B
W/R
W/R
B/W
G/W
B/G
B/Y
BR/Y
W
PK
Y
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
PK
B
B
G/B
R/OR
R/Y
R/OR
B/R
R/G
BL/W
G/W
B/G
R/W
W/R
Heater
Harness
Shifter
Light
B/W
B
B
Headlight
Switch
W/OR
BR W
BR
BR
BR
B/W
R/B
R/W
B/W
G/B
BR
W/OR
W/BL
OR/B
R/G
B/G
BL/W
G/W
OR
R/Y
R/OR
B/R
PK
B
B/G
B/W
OR
R/Y
B
B
Y
B/W
R/B
BR
B/R
BL/W
B/W
W/BL
BR
Y
G/W
W/BL
R/B
R/W
W/OR
BL
W/BL
W
BR
B/R
R/W
OR/B
OR/B
OR/B
BR
BR
BL
BR
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
OR/B
B
B/R
BR
W
B/G
BR
OR/B
Y
B/W
BL
BR
W/BL
G
R/G
B
W
PK/B
B
B
Y/B
PK
W/OR
B
BL
BR
BR
R
W/BL
W/BL
W
B
B
R/B
BR
OR
W
Horn
Switch
B
B
B
B
B
R
B
B Y/B
BL
W
Y/B
OR/B
B
B
BL
G/B
G/B
BL
B BL
B
W
B
W
R
G/B
Y/B
PK/BL
BL/B
BR
Right
Headlight
B
B
Left
Headlight
Y/B
Y/R
R/B
Y
Y
PK/BL
G
W/G
R/G
B
B
G/B
OR
B
OR/B
Y/R
Y/R
B
B
OR/B
BL/B
Flasher
G
PK/BL
Cab, W/G
Stop Light
OR
G/B
R/G
Right
Coolant
Turn Signal Overtemp.
Alarm
R
G/B
G/B
R/B
BL/B
G/B
Not
Used
Left Turn
Signal
OR/B
OR
R
Y
GY/B
Key
Switch
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
B
B
W
BL
BL
Y
B
GY/B
B
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
B - Black
BL - Blue
BR - Brown
G - Green
GY - Grey
OR - Orange
PK - Pink
P - Purple
R - Red
W - White
Y - Yellow
R
Horn
Fuel
Relay
B
BL/W
B
R/W
Diagnostic Timing
Plug
Plug
G/W
Fuse Block
20
Fuse
15
Amperage 10
10
207
WIRING SCHEMATIC
SUZUKI 660 EFI
HAULSTER MODELS 898704LP, 898706LP, 898718LP
Ignition
Switch
Starter
Solenoid
Clutch
Switch
10A
Main
Relay
IGN
ST
25A
Fan
Relay
15A
ACC
20A
Fuel
Relay
10A
Radtr
Fan
Ignition
Coil #1
Oxygen Sensor
Service Engine
Light
Fuel
Control
Module
Spark
Plug
Spark
Plug
Fuel
Pump
Fan
Switch
Spark
Plug
Speed
Sensor
Injector
#1
Starter
Ignition
Coil #3
Shifter
Light
Fuel
Control
Valve
Back-up
Alarm
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
Water Temp
Sensor
10A
ACC
Port
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
P34–1
P34–10
P34–2
Heater
Fan
P26–8
P26–13
P26–7
P34–4
Heater
Switch
P34–11
10A
Ignition
Adjust
Resistor
P34–24
P34–34
ECU
TURN SIGNAL SWITCH
SCHEMATIC
FLASHER
FLASHER
LH STOP RH
REAR SW REAR
LH
FRNT
RH
FRNT
LH STOP RH
REAR SW REAR
“NEUTRAL”
“LH TURN”
208
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
P10
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
P12
Fuel Gauge
Timing
Port
ACC
“START”
P14
Service Brakes
Diagnostics
Oil Pressure
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”
209
WIRING DIAGRAM
SUZUKI 660 EFI
HAULSTER MODEL 898720 (automatic transmission)
BR
BL/B
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
BR
R/B
B/G
BL/B
OR
BL/W
OR/G
B/W
G
OR/BL
R/G
BL/R
B/R
BL/W
PK
B/G
B/W
B/W
OR
B/W
B
W/B
W
PIN 31
Shift
Switch
R
W/OR
OR
PK
W/PK
PK/BL
B
B/R
R/G
PIN 31
PIN 1
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
OR
PK/BL
W/PK
PK
W/OR
W/OR
Not
Used
Brake
Switch
B/R
B
R/G
R
R/G
G/W
W/Y
R/G
BL
R
B
B/R
B/W
R
B/R
Engine
Harness
895049
B/R
R/Y
B/Y
W/R
R/G
W
PK/B
R/OR
B
Y
W/Y
B/R
BL
R
R
B
OR
B
PK/B
W/Y
R
R
R/OR
R
W/OR
W/R
R
Y
Radiator Fan
2700799
PK/BL
BR/Y
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
R/G
B/R
B
R/Y
R
Y
G/W
Y
W/R
B/W
BL
BL/B
OR
B/R
B
Y
G/W
R
B
W/R
B
Y
Y
G/W
W/Y
PK/BL
G/BL
BL/W
R/Y
B/Y
PK/B
B/W
B
B
PIN 10
OR/BL
G
BL/R
OR
B
B/Y
PK/B
B
R/OR
B
R
B/R
PIN 40
BR/Y
PK
G/PK
BL/W
W
R/G
Park Brake
Switch
OR/G
BL/B
B/Y
B/R
R
B
R
W/OR
B/W
B
B/R
W
W/OR
B
R
B
Back-up
Alarm
W/PK
B
B/Y
B
Fuel Pump
B
B
B
Chassis
Ground
W/OR
R/Y
R
R
W
R
R
R
R/G
W/R
B
R
B
B
B/R
R
G/PK
G/BL
BR/Y
OR/G
–
BL/B
Back-up
Switch
PK/B
W/R
B
W/PK
R
OR/G
B
G
BL/W
BL/R
B
BR/Y
OR/BL
PK
Shift
Solenoid
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
Y
B/G
B/Y
B
PIN 1
PIN 40
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
G/W
PK/B
BL
W/B
Starter
BR/Y
Y
W/Y
B
B/W
W/B
Engine Ground
No. 2
B
B/W
W
B
W
R/G
W/OR
PK
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
B/W
B
OR
PK
W/R
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
W/R
G/W
R/OR
B
G/W
B
B/W
W
B/R
PK
BR/Y
Suzuki
Harness
2702947
R/G
R/Y
R/G
B/Y
B
B/W
B/R
B/BL
B/W
Coil
B
No. 3
W/R
B
BR
BL/W
G/W
R/Y
R/OR
B
B/BL
B
BL/B
B/G
W
BL/W
B/G
Engine Ground
No. 1
BR
B
B/W
B
B
Turf
Taillight
B
BR
W/PK
B/R
BR/R
B
OR
BR
PK/BL
R/BL
B/R
B
R/B
BL/B
Main
Harness
895052
R/B
B
B
B
R/B
BR
BL/B
G/W
R
G/BL
PIN 10
B/Y
W/R
B/R
BR/B
B
Crank Angle BR/R
Coil
No. 1
PIN 1
B/R
BR
BR
BR/B
Coil
No. 2
PIN 10
BR/W
B/R
Oxygen
Sensor
Sensor
PIN 4
PIN 4 B/W
W
Injector
No. 1
B/R
PIN 14
PIN 15
PIN 12 B/Y
B/R
B/R
PIN 14
PIN 4
PIN 1
BR
OR
R/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
R/B
B
BR
BR
BL/B
B
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
Right Industrial
Taillight
Turf Taillight
Harness
W
W/R
W/B
Industrial
Taillight Harness
PIN 34
PIN 9
B
R
W
W/OR
BL/Y
G/R
G/Y
Left Industrial
Taillight
R
W
R/B
BR
R
G/Y
BL/Y
G/R
Pressure
Sensor
B
R
R/BL
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
Y/B
EXC
P
S
B
Temp
Sender
Oil Pressure
Sender
2702967
210
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
Y
R
Fuse Block
15
Fuse
15
Amperage 10
10
B/W
B/W
PK
B
B
B
R/B
R/B
Y
R/G
BL/W
B/W
PK/B
R/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/R
B/R
B
W/R
B/G
BL
Y
B/R
B/R
B
B
B
W/BL
R
R/B
Brake Fluid
Reservoir
B/R
B/G
B/W
B/W
PK/B
PK
BL
Fuse Block
15
Fuse
10
Amperage 10
10
R/Y
BL
BL
BR/Y
G/W
G/W
B/W
Y
Y/R
Y/R
R
R
W/G
G
W/R
W/R
BR/Y
R/OR
R/B
R/B
G/B
B/W
Y/R
W
Y
B/W
Y/R
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
R
Y
W/OR
R
W/R
W/G
W
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
PK
W
PK/B
R
W/OR
R
W/BL
Y/R
Y
Trailer Brake
Receptacle
Accessory Plug
B
R/G
R
R
Y/R
R
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
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
Y
W/R
Y/R
BR/Y
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
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
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
R
Horn
Fuel
Relay
B
BL/W
B
R/W
Diagnostic Timing
Plug
Plug
G/W
Fuse Block
20
Fuse
15
Amperage 10
10
211
WIRING SCHEMATIC
SUZUKI 660 EFI
HAULSTER MODEL 898720 (automatic transmission)
Ignition
Switch
Starter
Solenoid
10A
25A
Fan
Relay
15A
Main
Relay
IGN
ST
ACC
15A
Radtr
Fan
10A
Fuel
Relay
+
Ignition
Coil #1
Shift
Switch
2
N
P
L
D
R
Spark
Plug
Spark
Plug
Spark
Plug
Speed
Sensor
Injector
#1
N
Starter
Ignition
Coil #3
Shifter
Light
Fuel
Pump
Back–up
Alarm
–
Ignition
Coil #2
COM
2
L
P
R
D
Alternator
Crank
Angle
Sensor
Injector
#2
Pressure
Sensor
Injector
#3
Shift
Solenoid
Wiper
Switch
Wiper
Motor
10A
Dome
Light
Throttle
Sensor
Idle
Speed
Controller
ACC
Port
10A
ACC
Port
Water Temp
Sensor
1 2 3
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”
212
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
P10
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 Gauge
P11
Temp Buzzer
Fuel Gauge
P4
IGN
Dash Panel
Tachmtr
P12
ACC
“START”
P14
Service Brakes
Diagnostics
Oil Pressure
Park Brake
Diagnostics
Port
Timing
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”
213
WIRING DIAGRAM
SUZUKI 660 EFI
HAULSTER MODELS 898720LP (automatic transmission)
PIN 1
PIN 27
PIN 21
PIN 1
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
B
BR
BL/B
R/B
BL/B
Coil
No. 1
B
BL/W
BL/B
OR
B/G
R/B
BR
G/W
R
G/BL
OR/G
OR/BL
B/W
G
BL/R
B/R
BL/W
PK
B/W
OR
B/W
PK
B/W
B
B/W
W/B
B
BR/Y
W
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
B/Y
W/Y
BL
PK/BL
R
R/G
R
B/R
B
B
W/OR
OR
PK
B/R
B
PIN 31
W/PK
B/R
PIN 1
PIN 40
PK/B
W/R
B/Y
R/G
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
Y
B/G
PK/B
BL
B
W
G/W
Y
W/Y
W/B
R/G
W/OR
PK
B/W
W
B
W
OR
PK
B
B/W
B
G/W
R/OR
B
W/R
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
W/R
R/W
B/R
G/W
B
B/W
R/G
B/W
B/R
BR/Y
Suzuki
Harness
2702947
B
R/Y
R/G
B
BR
BL/W
G/W
R/Y
R/OR
B/Y
BL/B
B/G
R/W
B/W
B/BL
B/W
Coil
B
No. 3
W/R
Coil
No. 2
W
B/G
BL/W
B
B/BL
B
BR
B
B/G
Engine Ground
No. 1
Turf
Taillight
B
BR
W/B
B
B
OR
BR
PK/BL
W/PK
B/R
BR/R
B/R
B
B
B
R/B
BR
BL/B
R/BL
B
Crank Angle BR/R
R/B
B
G/PK
W
B
Not
Used
Main
Harness
895052
B/Y
W/R
B/R
BR/B
BR/B
Not
Used
B/R
B/R
BR
BR
Sensor
PIN 13
R/B
R/B
BL/B
BR/W
W
Injector
No. 1
B/R
BR
PIN 10 B/Y
W/G
B/R
B/R
PIN 1
PK
BR/W
Injector
No. 2
PIN 4
PIN 4 B/W
Not
Used
Injector
No. 3
PIN 16
PIN 13
PIN 7 W/R
PIN 2 PK
PIN 1 B/R
W/R
B/W
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
BR
OR
R/B
BR
R/G
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
BR
BL/B
B
B
BR
W
PIN 7
PIN 26
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
Right Industrial
Taillight
Turf Taillight
Harness
BL/B
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
W/R
W/B
Industrial
Taillight Harness
PIN 34
PIN 9
B
R
W
PK/BL
BL/Y
G/R
G/Y
Left Industrial
Taillight
R
W
R/B
BR
R
G/Y
BL/Y
G/R
Pressure
Sensor
B
W/OR
R/BL
G/R
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
OR
PK/BL
W/PK
PK
W/OR
W/OR
Clutch
Switch
Brake
Switch
Oxygen
Sensor
Y
R/OR
W/R
R
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
BL
R
B
B/R
B/W
P
Temp
Sender
Oil Pressure
Sender
R
R
B/R
W/R
R/G
W
PK/B
R/OR
B
Y
W/Y
B/R
BL
R
B/Y
EXC
B
B
R/G
R/G
G/W
B/R
R/Y
Y/B
S
B/R
B
PK/B
W/Y
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
PK/BL
B
R
BR/Y
BR/Y
R
OR/BL
PK
R
W/OR
W/R
R
Y
BL/B
OR
B/R
W/Y
G/W
B/W
R/OR
R
B
Y
214
R
B
B
Y
BL/R
B
Y
G/W
W/R
R
R
B/W
R
B
R
Radiator Fan
2700799
G/W
B/W
B
G/PK
G/BL
G
BL/R
B
BL/B
Fuel Pump
Y
G/BL
BL/W
B
B/Y
PK/B
OR/BL
G
R/Y
W
B
B/Y
PK/B
Fuel
Shut-Off
Valve
R
BL/W
B/R
B
B/R
R/G
B/R
W/OR
B
B
R
W/PK
OR
B
W/R
R
OR
B
PIN 1
BR/Y
PK
G/PK
BL/W
OR
B
PIN 31
PIN 10
Park Brake
Switch
R
BL/B
PIN 40
R
B
OR/G
B
Chassis
Ground
R/Y
B
B
W/OR
R
R/Y
R
R/G
W
B
R
B
Back-up
Alarm
W/PK
W/OR
B
R
G/PK
G/BL
BR/Y
B
B/Y
R
B
R
B
B
B/R
W
Engine
Ground
No. 2
R
LPG
Ground
R
R
B
BL
B
B R
R
OR
BL
P
W/R
BL/B
Back-up
Switch
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
BL/R
B
OR
W/PK
R
OR/G
B
G
BL/W
OR/G
–
Fuel
Control
Module
G
BR/Y
OR/BL
PK
Shift
Solenoid
Fuel
Control
Valve
Service
Engine
Light
Shift
Switch
B
B/R
OR
+
Battery
Speed
Sensor
Start
Solenoid
Starter
2704005
Engine
Harness
895049
COLOR CODE:
GY
Taillight
Adapter
OR
G
Y/B
Y/B
Y/R
Y/B
B
B
B/R
B
OR/B
Y
R
Fuse Block
15
Fuse
15
Amperage 10
10
B
B/W
B
B/G
B/W
B/W
PK
B
B
R/B
Y
R/G
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
PK/B
BL/W
W/R
B/G
BL
B/R
B
B/R
Y
B
B
Ground
Standoff
BL
W/R
R/B
Brake Fluid
Reservoir
B/R
B/G
B/W
B/W
PK/B
PK
BL
Fuse Block
20
Fuse
10
Amperage 10
10
W/R
BR/Y
R/OR
R/B
R/B
G/B
R/Y
BL
BL
G/W
W/G
G/W
B/W
Y
Y/R
Y/R
R
R
BR/Y
W/R
G
Y
B/W
Y/R
R
R
B
R/G
BL
B/G
B/R
W/R
W/R
R/W
B/W
B
Not
Used
B/R
B/R
B
PK/B
B/R
R
W
Main
Relay
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
B
B
B
B/W
R/W
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
Y
B
R
R
B/R
R/Y
R
B/R
G
Y
W/R
Y/R
Y
B/G
G/W
Y
BR/Y
R
B/R
B
B
B/R
W/OR
R
R
OR/B
OR/B
R
BR
B
Accessory Plug
B
B
B
B
B/W
W/R
Y/R
Trailer Brake
Controller
B
R
Y
B
Y
BR
B
Y
B
W/BL
BL
BR
OR/B
OR/B
G
R
W
BL
R
W
B/R
Speedometer
Panel
W/R
B
W/R
W/R
R/W
R/G
R/OR
G/B
G/W
BL/W
B/G
R/B
B
B
B
W/G
Y
G
BR
BR
BR
BL
G
B
Brake Controller
Harness
OR/B
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
R
B
B
B
Dome
Light
B
W
B
W/R
R
PIN 16
PIN 18
Wiper
Motor
BL
OR/B
W/R
B
B
OR
R
Y
B
Y
R
PK
B/W
B/W
B/G
B/R
Y/R
Power Point
(ACC 12V Plug-in Port)
R
Y
BR
B/W
W/R
BR
Y
R
B
W/R
Y/R
Speedometer
Signal
OR
B
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
Heater
Fan
B
Wiper/Dome Light
Harness
B
OR
B
R
R
B
B
W/R
W/R
R
B
W/R
R
B
B/G
PK/B
R
B/R
W/OR
Y
W/Y
BL
PK/BL
G/W
PK/B
Y/R
R
B
W/R
W/R
B/W
G/W
B/G
B/Y
BR/Y
W
PK
Y
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
PK
B
B
G/B
R/OR
R/Y
R/OR
B/R
R/G
BL/W
G/W
B/G
R/W
W/R
Heater
Harness
Shifter
Light
B/W
B
B
Headlight
Switch
W/OR
BR W
BR
BR
BR
B/W
R/B
R/W
B/W
G/B
BR
W/OR
W/BL
OR/B
R/G
B/G
BL/W
G/W
OR
R/Y
R/OR
B/R
PK
B
B/G
B/W
OR
R/Y
B
B
Y
B/W
R/B
BR
B/R
BL/W
B/W
W/BL
BR
Y
G/W
W/BL
R/B
R/W
W/OR
BL
W/BL
W
BR
B/R
R/W
OR/B
OR/B
OR/B
BR
BR
BL
BR
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
OR/B
B
B/R
BR
W
B/G
BR
OR/B
Y
B/W
BL
BR
W/BL
G
R/G
B
W
PK/B
B
B
Y/B
PK
W/OR
B
BL
BR
BR
R
W/BL
W/BL
W
B
B
R/B
BR
OR
W
Horn
Switch
B
B
B
B
B
R
B
B Y/B
BL
W
Y/B
OR/B
B
B
BL
G/B
G/B
BL
B BL
B
W
B
W
R
G/B
Y/B
PK/BL
BL/B
BR
Right
Headlight
B
B
Left
Headlight
Y/B
Y/R
R/B
Y
Y
PK/BL
G
W/G
R/G
B
B
G/B
OR
B
OR/B
Y/R
Y/R
B
B
OR/B
BL/B
Flasher
G
PK/BL
Cab, W/G
Stop Light
OR
G/B
R/G
Right
Coolant
Turn Signal Overtemp.
Alarm
R
G/B
G/B
R/B
BL/B
G/B
Not
Used
Left Turn
Signal
OR/B
OR
R
Y
GY/B
Key
Switch
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
B
B
W
BL
BL
Y
B
GY/B
B
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
B - Black
BL - Blue
BR - Brown
G - Green
GY - Grey
OR - Orange
PK - Pink
P - Purple
R - Red
W - White
Y - Yellow
R
Horn
Fuel
Relay
B
BL/W
B
R/W
Diagnostic Timing
Plug
Plug
G/W
Fuse Block
20
Fuse
15
Amperage 10
10
215
WIRING SCHEMATIC
SUZUKI 660 EFI
HAULSTER MODELS 898720LP (automatic transmission)
10A
ST
25A
Fan
Relay
15A
Main
Relay
IGN
ACC
20A
Fuel
Relay
10A
Radtr
Fan
Ignition
Coil #1
Oxygen Sensor
+
2
N
P
L
D
Service Engine
Light
R
Fuel
Control
Module
Back–up
Alarm
–
COM
N
L
P
Fan
Switch
Spark
Plug
Spark
Plug
Speed
Sensor
Alternator
Crank
Angle
Sensor
Injector
#2
R
Spark
Plug
Fuel
Pump
Fuel
Control
Valve
D
Ignition
Coil #3
Shifter
Light
Injector
#1
2
Ignition
Coil #2
Pressure
Sensor
Injector
#3
Wiper
Switch
Wiper
Motor
10A
Throttle
Sensor
Shift
Solenoid
Dome
Light
ACC
Port
10A
Idle
Speed
Controller
ACC
Port
Water Temp
Sensor
M
ACC
Port
1 2 3
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
P34–11
P34–1
P34–10
P34–2
P26–8
P26–13
P26–7
P34–4
Heater
Fan
P34–27
P34–28
P34–29
Heater
Switch
P26–18
P26–19
P26–20
P26–24
P26–25
P26–26
10A
Ignition
Adjust
Resistor
P34–24
P34–34
ECU
TURN SIGNAL SWITCH
SCHEMATIC
FLASHER
FLASHER
LH STOP RH
REAR SW REAR
LH
FRNT
RH
FRNT
LH STOP RH
REAR SW REAR
“NEUTRAL”
“LH TURN”
216
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
P10
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
P12
Fuel Gauge
Timing
Port
ACC
“START”
P14
Service Brakes
Diagnostics
Oil Pressure
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”
217
WIRING DIAGRAM
PERKINS DIESEL MODELS 898726 & 898727
B
FAN
LEFT INDUSTRIAL
TAILLIGHT 892676
Y
Y
25 AMP
FUSE
BR
Y
R
BR
W/B
B
W/B
BL/B
R
W
Y
R
FAN
RELAY
2700867
B
BR
BR
BR
RIGHT INDUSTRIAL
TAILLIGHT 892676
Y
B
Y
BL/B
B
Not Used on
All Vehicles
BR
W/B
INDUSTRIAL TAILLIGHT
HARNESS 894314
B
B
B
ENGINE
HARNESS
2703162
W/G
G
B
B
B
R/B
ALTERNATOR
W/B
893633
Y
R
R/B
R
W/R
EXC P
S
BL/B
R/B
W
BR
BR
B
B
B
B
B
R/B
Y
R
W/B
R
R
B
OR
BR
R
B B
R
R
BL/B
BR
TURF TAILLIGHT
R
25 AMP
FUSE
B
R
Y
R
W/G
W/R
W/B
TEMP SENDER
PRE-HEAT RELAY
(VIEW SHOWN FROM
BACK OF CONNECTOR)
Y
B
BL
BR
R
PARK
BRAKE
W/G
G
R
B
OR/B
843857
W/B
START
SOLENOID
2701465
BR
R
BR
R
B
FAN
SWITCH
2703052
BL/B
TURF TAILLIGHT
HARNESS 894313
893602
40 AMP
FUSE
R
W/B
R/B
B
BL
TRAILER BRAKE
RECEPTACLE
R
W/Y
P/BL
W/R
OR/B
R
P
G
W/Y
R/B
W/Y
R/B
W/B
P/BL
W/B
W/Y
P/BL
W/B
P/BL
R/B
B
W/R
B
P/BL
B
R
B
W/R
B
R
B
+
W/BR
W/R
B
B
–
R
W
P
R
G
B
B
B
B
P
B
R
R
B
G
P
OR
B
OR
R
W
G
G
R
R
R
R
R/B
W
W/R
W/G
B
W/G
OR
B
W/G
B
BR
B
OR
B
OR
G
Y
G
Y
BL
W/G
W/G
W/G
W/G
W/G
G
HARNESS
DIODES
884398
894201
FUEL PUMP
894638
BL
W
FUEL
SOLENOID
GLOW
PLUGS
B
G
G
G
G
OR
B
B
OIL
PRESSURE
GGG
W/G
STARTER
W
BL
W/G
Y
DIODE
884398
FUEL
SHUTOFF
RELAY
843167
FUEL LEVEL
SENDER
843298
COLOR CODE:
B - BLACK
BL - BLUE
BR - BROWN
G - GREEN
GY - GREY
OR - ORANGE
PK - PINK
P - PURPLE
R - RED
218
W - WHITE
Y - YELLOW
BL/B - BLUE w/BLACK STRIPE
G/B - GREEN w/BLACK STRIPE
OR/B - ORANGE w/BLACK STRIPE
P/BL - PURPLE w/BLUE STRIPE
R/B - RED w/BLACK STRIPE
W/B - WHITE w/BLACK STRIPE
W/BL - WHITE w/BLUE STRIPE
W/B
W/R
W
OR
OR
R/B
W/BR
B
B
R
10 GAUGE
B
10 GAUGE
B
W/Y
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
Y/B - YELLOW w/BLACK STRIPE
Y/R - YELLOW w/RED STRIPE
B
W
G
P
WIRING DIAGRAM (con’t.)
MODELS
898726 & 898727
TURN SIGNAL
SWITCH 894288
TAILLIGHT
ADAPTER
FLASHER
822867
OR
R
GY
OR
B
Y
G
OR
OR
G/B
G/B
Y/R
G/B
GY/B
Y
Y/R
R/B
OR
OR/B
BL/B
Y/B
Y/B
BL
BL
837303
W
W
BL
W
W
OR
BL
W/BL
BL
RIGHT HEADLIGHT
B
W/OR
B
B
HEADLIGHT SWITCH
BR
837303
B
B
B
Y/B
B
B
843581
B
B
Y/B
Y/B
BR
OR/B
BR
OR/B
OR/B
G/B
BR
PIN 1 NOT USED
PIN 2 W 49–W/BR
PIN 3 W 21–BR
PIN 4 W 42–R/B
PIN 5 NOT USED
PIN 6 NOT USED
PIN 7 W 48–W/B
PIN 8 W 31–W/Y
PIN 9 W 53–W/OR
PIN 10 W 4–W
PIN 11 W 2–OR
PIN 12 W 11–P/BL
PIN 13 W 33–GR/B
PIN 14 W 34–W/R
PIN 15 W 36–Y/B
PIN 16 W 54–B
PIN 17 W 30–W/BL
PIN 18 W 28–G
DASH PANEL
2701658
Y/B
W/Y
W/BR
R/B
BR
W/OR
W/B
P/BL
W/Y
R/B
W/BR
W/BR
W/B
W/B
W/R
W/R
OR
W/Y
W
W/R
G
B
B
OR
P/BL
Y/B
G
W
G/B
B
P/BL
R/B
R
B
W/BL
W/OR
HARNESS 894597
B
BR
OR/B
BR
TRAILER BRAKE
CONTROLLER
2703219
CAB
STOP LIGHT
B
0R/B
BL
B
BR
RIGHT TURN
SIGNAL
R
R
B
B
B
BL
LEFT TURN
SIGNAL
R
W
G/B
BL/B
B
LEFT HEADLIGHT
Y/B
R/B
BL/B
BR
B
B
Y/R
G/B
OR/B
B
B
B
W
B
R/B
R
BL
Y/R Y
B
B
G/B
B
B
OR/B
OR/B
OR/B
OR/B
OR/B
OR/B
OR/B
BR
TRAILER
BRAKES
BR
BR
W/R
BR
B
B
W/R
B
BL
OR/B
G
BL
W/R
OR/B
B
W/R
B
B
W/R
R/B
R/B
BL
BR
B
B
B
B
R/B
BRAKE FLUID
RESERVOIR 894456
B
W/BL
W/BL
COOLANT
OVERHEAT ALARM
R
B
W/BL
WIPER MOTOR
890000
B
886497
B
W
R
B
G
B
R
R
OR
P
R
G
G
AUTO TRAN
CONTROLLER
R
W/G
G
MAIN
HARNESS
894266
G
Y
Y/R
B
R
R
R
R
B
Y
ACC POWER
B
R
W
B
B
DOME LIGHT
182399
B
B
B
B
GROUND STANDOFF
828231
B
R
B
Y
R
W/R
R/B
W/BL
B
B
HEATER SWITCH
B
894801
W/OR
OR
BLC
R
M
Y/R
Y/R
W/OR
OR
B
Y
Y/R
W/OR
P
Y/R
20
10 Fuse
10 Amperage
10
R
B
B
B
R
B
W/R
B
B
15
10
10
15
HEATER FAN
ACC POWER
B
Fuse Blocks
OR
WIPER, DOME LIGHT
HARNESS 894804
B
ACC POWER
Y/R
825996
R
P
B
R
B
Y
FUSE HOLDER
P
B
B
G
B
P
R
B
B
B
G
POWER POINT
R
W
R/B
B
B
R
B
Y
R
Y
R
OR
R
W/R
HEATER HARNESS
894805
OR
B
B
OR
Y
894806
B
HORN BUTTON
830366
CLUTCH
SWITCH
BAT
BRAKE LIGHT
SWITCH 894308
R
894308
P
ACC
POWER
POINT
843942
W/G
G
ST
HORN
886090
IGN
KEY SWITCH
837295
219
WIRING SCHEMATIC
PERKINS DIESEL MODELS 898726 & 898727
15A
2EA
STARTER
SOLENOID
IGNITION
SWITCH
CLUTCH
SWITCH
40A
20A
ACC
ST
IGN
FUEL SHUTOFF
RELAY
FAN
POWER
POINT
10A
ALT.
10A
10A
ACC
POWER
WIPER
MOTOR
FAN
SWITCH
ACC
POWER
COOLANT
OVERHEAT
ALARM
HEATER
SWITCH
FUEL
SENDER
ACC
POWER
DOME
LIGHT
STARTER
SERVICE
BRAKE
RESV.
TEMP
SENDER
PRE-HEAT
RELAY
FUEL
PUMP
FUEL
SOL.
HEATER
FAN
GLOW PLUGS
HEADLIGHT SWITCH
SCHEMATIC
B+
LOW
BEAM
B+
HIGH
BEAM
DASH
LOW
BEAM
B+
HIGH
BEAM
DASH
TAIL
DASH
TAIL
OFF
HIGH
BEAM
LOW
BEAM
TAIL
LOW BEAM
HIGH BEAM
IGNITION SWITCH SCHEMATIC
220
BAT
BAT
ST ACC IGN
ST ACC IGN
“OFF”
POSITION
“START”
POSITION
BAT
ST ACC
BAT
IGN
“ON”
POSITION
ST ACC IGN
“ACC”
POSITION
PARK
BRAKE
SENDER
OIL
PRESS.
SENDER
WIRING SCHEMATIC (con’t.)
PERKINS DIESEL MODELS 898726 & 898727
15A
10A
HEADLIGHT
SWITCH
10A
FLASHER
P4
P8 P17
P2
P18
P14
P3
P7
P9
P13
RIGHT TURN
HIGH BEAM
LEFT TURN
BRAKE
CONTROLLER
HORN
TURN
SIGNAL
SWITCH
BRAKE
LIGHT
SWITCH
LH FR
TURN
VOLTS
TACH
TEMP
BUZZER
DIESEL
PRE–HEAT
P15
FUEL
OIL PRESSURE
PARK BRAKE
P11
SERVICE BRAKE
P10
P12
RH FR
TURN
HORN
SWITCH
P16
DASH PANEL
LH
TAIL
CAB
STOP
LIGHT
ACC
TRAILER
BRAKE
RECEPTACLE
RH
TAIL
LH
HEAD
LIGHT
RH
HEAD
LIGHT
TURN SIGNAL SWITCH
SCHEMATIC
FLASHER
LH STOP RH
REAR SW REAR
FLASHER
LH
FRT
RH
FRT
LH STOP RH
REAR SW REAR
NEUTRAL
HAZARD
FLASHER
FLASHER
LH STOP RH
REAR SW REAR
LH
FRT
LH TURN
RH
FRT
LH STOP RH
REAR SW REAR
LH
FRT
RH
FRT
LH
FRT
RH
FRT
RH TURN
221