John Deere LTR155 LTR166 and LTR180 Lawn Tractors Technical Manual TM1768 01FEB02

INDEX
B
Battery Specifications . . . . . . . . . . . . . . . . . . . . . 6-8
Belt
Mower Blade Timing
Adjustment . . . . . . . . . . . . . . . . . . . . . . 9-17
Removal & Installation . . . . . . . . . . . . . 9-26
Mower Drive
Removal & Installation
LTR155/166 . . . . . . . . . . . . . . . . . . 9-23
LTR180 . . . . . . . . . . . . . . . . . . . . . 9-24
Tension Adjustment . . . . . . . . . . . . . . . 9-20
Traction Drive
Removal & Installation . . . . . . . . . . . . . 7-20
Tension Adjustment . . . . . . . . . . . . . . . 7-16
Blade Brake
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Replacement . . . . . . . . . . . . . . . . . . . . . . . 9-29
Blade Removal and Installation . . . . . . . . . . . . 9-30
Brake Pedal & Linkage
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Removal & Installation . . . . . . . . . . . . . . . . 7-27
Briggs & Stratton Engine
Air Cleaner Service . . . . . . . . . . . . . . . . . . . 4-16
Breather Valve Service . . . . . . . . . . . . . . . . 4-42
Cam Gear Removal/Installation . . . . . . . . . 4-38
Carburetor
Assembly . . . . . . . . . . . . . . . . . . . . . . . 4-21
Disassembly . . . . . . . . . . . . . . . . . . . . . 4-18
Inspection . . . . . . . . . . . . . . . . . . . . . . . 4-20
Removal and Installation . . . . . . . . . . . 4-16
Choke Cable Adjustment . . . . . . . . . . . . . . 4-10
Compression Relief . . . . . . . . . . . . . . . . . . 4-39
Compression Test . . . . . . . . . . . . . . . . . . . 4-11
Connecting Rod & Camshaft Specifications . 4-4
Connecting Rods Inspection . . . . . . . . . . . . 4-33
Crankshaft Removal/Installation . . . . . . . . . 4-38
Cylinder Air Guides Removal/Installation . . 4-26
Cylinder Bore
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Honing . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Inspection . . . . . . . . . . . . . . . . . . . . . . . 4-35
Resizing . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Cylinder Bore, Piston & Ring Specifications . 4-4
Cylinder Head Inspection & Repair . . . . . . 4-29
Cylinder Head Removal/Installation . . . . . . 4-26
Cylinder Leak Test
With Cylinder Leak Tester . . . . . . . . . . 4-11
Without Cylinder Leak Tester . . . . . . . . 4-11
Engine Removal and Installation . . . . . . . . 4-23
Flywheel Removal and Installation . . . . . . . 4-37
Fuel Shutoff Solenoid Test . . . . . . . . . . . . . 4-10
General Specifications . . . . . . . . . . . . . . . . . 4-3
Governor Adjustment . . . . . . . . . . . . . . . . . 4-13
Intake Manifold Removal/Installation . . . . . 4-26
Magneto Bearing Inspection . . . . . . . . . . . . 4-40
Oil Pump Removal and Installation . . . . . . 4-43
Piston Inspection . . . . . . . . . . . . . . . . . . . . 4-32
PTO Bearing Removal/Installation . . . . . . . 4-41
Repair Specifications . . . . . . . . . . . . . . . . . . 4-3
Rings & Rod Removal/Installation . . . . . . . 4-31
Starting Motor
Assembly . . . . . . . . . . . . . . . . . . . . . . . 4-46
Disassembly . . . . . . . . . . . . . . . . . . . . . 4-44
Pinion Gear Replacement . . . . . . . . . . 4-48
Removal and Installation . . . . . . . . . . . 4-44
Tests & Adjustments . . . . . . . . . . . . . . . . . . 4-10
Tests & Adjustments Specifications . . . . . . . 4-3
Throttle Cable Adjustment . . . . . . . . . . . . . 4-10
Torque Specifications . . . . . . . . . . . . . . . . . . 4-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-5
Engine Cranks But Will Not Start . . . . . . 4-8
Engine Erratic/Loss of Power . . . . . . . . . 4-9
Engine Will Not Crank . . . . . . . . . . . . . . 4-7
Upper Blower Housing Remove/Install . . . . 4-15
Valve Clearance Adjustment . . . . . . . . . . . 4-13
Valves
Inspection & Repair . . . . . . . . . . . . . . . 4-29
Installation . . . . . . . . . . . . . . . . . . . . . . 4-31
Ream . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Specifications . . . . . . . . . . . . . . . . . . . . . 4-3
C
Component Location
Electrical
LTR155 . . . . . . . . . . . . . . . . . . . . . . . . 6-11
LTR166 . . . . . . . . . . . . . . . . . . . . . . . . 6-25
LTR180 . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Grass Collector
Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Mounting Hardware . . . . . . . . . . . . . . . . 9-6
Kawasaki Engine
Carburetor . . . . . . . . . . . . . . . . . . . . . . . 5-8
Mower Deck (S/N -020000) . . . . . . . . . . . . . 9-4
Mower Deck Lift Linkage
LTR155/166 . . . . . . . . . . . . . . . . . . . . . . 9-8
LTR180 . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Mower Deck PTO Linkage . . . . . . . . . . . . . . 9-5
Power Train . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Product Identification Number Locations . . 2-11
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Control Pedals & Linkage
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Removal & Installation . . . . . . . . . . . . . . . . 7-23
Cross Shaft Assembly
Removal & Installation . . . . . . . . . . . . . . . . 7-26
D
Diagnostics
Mower Deck
Blades Will Not Rotate . . . . . . . . . . . . . 9-11
Drive Belt Slips . . . . . . . . . . . . . . . . . . . 9-12
Drive Belt Will Not Stay On Pulleys . . . 9-13
Uneven Cutting Or Striping . . . . . . . . . 9-15
Vibration . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Power Train . . . . . . . . . . . . . . . . . . . . . . . . 7-14
E
Electrical
Common Circuit Tests . . . . . . . . . . . . . . . . . 6-7
Diagnostic Information . . . . . . . . . . . . . . . . . 6-5
Diode Test . . . . . . . . . . . . . . . . . . . . . . . . 6-150
Headlight Circuit Diagnosis . . . . . . . . . . . 6-138
Headlight Circuit Operation . . . . . . . . . . . 6-134
Headlight Circuit Schematic . . . . . . . . . . . 6-135
Key Switch Test-3 Position . . . . . . . . . . . . 6-151
Key Switch Test-4 Position . . . . . . . . . . . . 6-151
Kohler Engine Wiring Harnesses 15 Amp . 6-40
Kohler Engine Wiring Harnesses 3 Amp . . 6-40
LTR155
Charging/Shunt Circuit
Diagnosis 15 Amp . . . . . . . . . . . . . 6-94
Diagnosis 3 Amp . . . . . . . . . . . . . . 6-90
Diagnosis-4 Position Key Switch . . 6-98
Operation 15 Amp . . . . . . . . . . . . . 6-92
Operation 3 Amp . . . . . . . . . . . . . . 6-88
Operation-4 Position Key Switch . . 6-96
Schematic 15 Amp . . . . . . . . . . . . 6-93
Schematic 3 Amp . . . . . . . . . . . . . 6-89
Schematic-3 Position Key Switch . 6-97
Component Location . . . . . . . . . . . . . . 6-11
Cranking Circuit Diagnosis 15 Amp . . . 6-66
Cranking Circuit Diagnosis 3 Amp . . . . 6-62
Cranking Circuit Operation 15 Amp . . . 6-64
Cranking Circuit Operation 3 Amp . . . . 6-60
Cranking Circuit Schematic 15 Amp . . 6-65
Cranking Circuit Schematic 3 Amp . . . 6-61
Grass Collection System
Circuit Diagnosis-15 Amp . . . . . . 6-124
Circuit Diagnosis-3 Amp . . . . . . . 6-120
Circuit Diagnosis-4 Pos. Key . . . . 6-128
Circuit Operation-15 Amp . . . . . . 6-122
Circuit Operation-3 Amp . . . . . . . 6-118
Circuit Operation-4 Pos. Key . . . . 6-126
Circuit Schematic . . . . . . . . . . . . . 6-123
Circuit Schematic-3 Amp . . . . . . . 6-119
Circuit Schematic-4 Pos. Key . . . 6-127
Ignition Circuit Diagnosis . . . . . . . . . . . 6-80
Ignition Circuit Diagnosis-15 Amp . . . . 6-77
Ignition Circuit Diagnosis-3 Amp . . . . . 6-74
Ignition Circuit Operation . . . . . . . . . . . 6-72
Ignition Circuit Schematic-15 Amp . . . . 6-76
Ignition Circuit Schematic-3 Amp . . . . . 6-73
Ignition Schematic-4 Pos. Key Switch . 6-79
Main Electrical Schematic 15 Amp . . . . 6-16
Main Electrical Schematic 3 Amp . . . . . 6-12
Main Electrical Schematic-4 Pos. Key . 6-20
Main Wiring Harness 15 Amp . . . . . . . 6-18
Main Wiring Harness 3 Amp . . . . . . . . 6-14
Main Wiring Harness-4 Pos. Key . . . . . 6-22
Power Circuit Diagnosis 15 Amp . . . . . 6-50
Power Circuit Diagnosis 3 Amp . . . . . . 6-46
Power Circuit Diagnosis-4 Pos. Key . . 6-54
Power Circuit Operation 15 Amp . . . . . 6-48
Power Circuit Operation 3 Amp . . . . . . 6-44
Power Circuit Operation-4 Pos. Key . . 6-52
Power Circuit Schematic 15 Amp . . . . . 6-49
Power Circuit Schematic 3 Amp . . . . . . 6-45
Power Circuit Schematic-4 Pos. Key . . 6-53
PTO w/RIO Circuit Schematic . . . . . . 6-105
PTO with RIO Circuit Operation . . . . . 6-104
PTO/RIO Circuit Diagnosis . . . . . . . . 6-108
Starting Motor
Drive Replacement . . . . . . . . . . . . 3-49
Removal and Installation . . . . . . . . 3-49
Starting Motor Remove and Install . . . 6-160
Stator and Ignition Module . . . . . . . . . 6-159
LTR166
Charging Circuit Diagnosis . . . . . . . . . 6-102
Charging Circuit Operation . . . . . . . . . 6-100
Charging Circuit Schematic . . . . . . . . 6-101
Component Location . . . . . . . . . . . . . . 6-25
Cranking Circuit Diagnosis . . . . . . . . . . 6-70
Cranking Circuit Operation . . . . . . . . . . 6-68
Grass Collection System
Circuit Diagnosis . . . . . . . . . . . . . 6-132
Circuit Operation . . . . . . . . . . . . . 6-130
Circuit Schematic . . . . . . . . . . . . . 6-131
Ignition Circuit Diagnosis . . . . . . . . . . . 6-85
Ignition Circuit Schematic . . . . . . . . . . . 6-83
Ignition Circuit Schematic-4 Pos. Key . 6-84
Main Electrical Schematic . . . . . . . . . . 6-26
Main Electrical Schematic-4 Pos. Key . 6-30
Main Wiring Harness . . . . . . . . . . . . . . 6-28
Main Wiring Harness-4 Pos. Key . . . . . 6-32
Power Circuit Diagnosis . . . . . . . . . . . . 6-58
Power Circuit Operation . . . . . . . . . . . . 6-56
Power Circuit Schematic . . . . . . . . . . . 6-57
PTO with RIO Circuit Operation 6-110, 6-114
Stator And Ignition Module . . . . . . . . . 6-163
LTR180
Charging Circuit Schematic . . . . . . . . 6-101
Component Location . . . . . . . . . . . . . . 6-35
Cranking Circuit Diagnosis . . . . . . . . . . 6-70
Cranking Circuit Operation . . . . . . . . . . 6-68
Grass Collection System
Circuit Diagnosis . . . . . . . . . . . . . 6-132
Circuit Operation . . . . . . . . . . . . . 6-130
Circuit Schematic . . . . . . . . . . . . . 6-131
Ignition Circuit Diagnosis . . . . . . . . . . . 6-85
Main Electrical Schematic . . . . . . . . . . 6-36
Main Wiring Harness . . . . . . . . . . . . . . 6-38
Power Circuit Diagnosis . . . . . . . . . . . . 6-58
Power Circuit Operation . . . . . . . . . . . . 6-56
PTO with RIO Circuit Operation . . . . . 6-114
Voltage Regulator/Rectifier Test . . . . 6-149
Reading Electrical Schematics . . . . . . . . . . . 6-6
Relay Test . . . . . . . . . . . . . . . . . . . . . . . . 6-150
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-158
RIO Switch Adjustment . . . . . . . . . . . . . . . 6-158
Spark Test . . . . . . . . . . . . . . . . . . . . . . . . 6-156
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Starting Motor
Kawasaki Engine . . . . . . . . . . . . . . . . . 5-53
LTR155
Brush Replacement . . . . . . . . . . . 6-161
Drive Replacement . . . . . . . . . . . 6-160
LTR166
Assembly . . . . . . . . . . . . . . . . . . . 6-166
Disassembly . . . . . . . . . . . . . . . . 6-164
Pinion Gear Replacement . . . . . . 6-168
Removal and Installation . . . . . . . 6-164
Solenoid Test . . . . . . . . . . . . . . . . . . . 6-142
Tests & Adjustments
Flywheel Magnet Test . . . . . . . . . . . . 6-146
Stator Output Test
LTR155 15 Amp . . . . . . . . . . . . . 6-147
Stator Regulated Voltage . . . . . . . . . . 6-145
Voltage Regulator/Rectifier Test
LTR155 . . . . . . . . . . . . . . . . . . . . 6-149
LTR180 . . . . . . . . . . . . . . . . . . . . 6-149
Theory of Operation Information . . . . . . . . . . 6-5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 6-43
Wire Color Abbreviation Chart . . . . . . . . . . . 6-5
Wiring Harness
(LTR155 15 Amp)
W1 Main Harness . . . . . . . . . . . . . 6-18
W2 Engine Wiring Harness . . . . . . 6-40
(LTR155 3 Amp)
W1 Main Harness . . . . . . . . . . . . . 6-14
W2 Engine Wiring Harness . . . . . . 6-40
(LTR155)
W3 Headlight Wiring Harness . . . . 6-40
Y1 Fuel Shutoff Solenoid . . . . . . . . 6-40
(LTR155-4 Pos. Key)
W1 Main Harness . . . . . . . . . . . . . 6-22
(LTR166)
W1 Main Harness . . . . . . . . . . . . . 6-28
W1 Main Harness-4 Pos. Key . . . . 6-32
W2 Engine Wiring Harness . . . . . . 6-41
W3 Engine Wiring Harness . . . . . . 6-41
W4 Headlight Wiring Harness . . . . 6-41
Y1 Fuel Shutoff Solenoid . . . . . . . . 6-41
(LTR180)
W1 Main Harness . . . . . . . . . . . . . 6-38
W2 Engine Wiring Harness . . . . . . 6-42
W3 Engine Wiring Harness . . . . . . 6-42
Kohler Engine 15 Amp . . . . . . . . . . . . . 6-40
Kohler Engine 3 Amp . . . . . . . . . . . . . . 6-40
Engine
Briggs & Stratton
Engine Repair . . . . . . . . . . . . . . . . . . . 4-23
Fuel and Air Repair . . . . . . . . . . . . . . . 4-15
Tests & Adjustments . . . . . . . . . . . . . . 4-10
Kawasaki
Repair . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Tests & Adjustments . . . . . . . . . . . . . . 5-18
Kohler
Fuel and Air Repair . . . . . . . . . . . . . . . 3-25
Repair . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Tests & Adjustments . . . . . . . . . . . . . . 3-16
Engine Repair Specifications
Briggs & Stratton . . . . . . . . . . . . . . . . . . . . . 4-3
Kawasaki . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Kohler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
F
Forward & Reverse Pedals
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Removal & Installation . . . . . . . . . . . . . . . . 7-23
Front Axle Removal and Installation . . . . . . . . . . 8-6
Front Wheel Bearing Repair . . . . . . . . . . . . . . . 10-5
Front Wheel Removal & Installation . . . . . . . . . 10-4
Fuel Tank Removal/Installation . . . . . . . . . . . . . 10-6
G
Gasoline
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Storage-North America . . . . . . . . . . . . . . . . . 2-7
Grass Collector
Component Location
Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Mounting Hardware . . . . . . . . . . . . . . . . 9-6
Fill Sensor Adjustment . . . . . . . . . . . . . . . . 9-21
Latch Adjustment . . . . . . . . . . . . . . . . . . . . 9-22
Removal and Installation . . . . . . . . . . . . . . 9-36
Grease
Anti-Corrosion . . . . . . . . . . . . . . . . . . . . . . . . 2-9
North America . . . . . . . . . . . . . . . . . . . . . . . 2-10
H
Hood Removal and Installation . . . . . . . . . . . . . 10-6
Hydrostatic Transaxle
Forward & Reverse Pedal Adjustment . . . . 7-17
Removal & Installation . . . . . . . . . . . . . . . . 7-18
Torque Specifications . . . . . . . . . . . . . . . . . . 7-3
I
Inch Fastener Torque Values . . . . . . . . . . . . . . . 2-6
K
Kawasaki Engine
Air Cleaner Assembly . . . . . . . . . . . . . . . . . 5-30
Air Gap Adjustment . . . . . . . . . . . . . . . . . . 5-51
Armature Air Gap Adjustment . . . . . . . . . . . 5-51
Armature Removal & Installation . . . . . . . . 5-50
Blower Housing Removal & Installation . . . 5-33
Breather Inspection . . . . . . . . . . . . . . . . . . 5-34
Camshaft & Tappets
Removal & Installation . . . . . . . . . . . . . 5-44
Carburetor
Component Location . . . . . . . . . . . . . . . 5-8
Removal and Installation . . . . . . . . . . . 5-30
Choke Cable Adjustment . . . . . . . . . . . . . . 5-18
Choke Plate . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Component Location . . . . . . . . . . . . . . . . . . 5-7
Crankcase
Cover Removal & Installation . . . . . . . . 5-39
Vacuum . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Crankshaft
Oil Seals Removal & Installation . . . . . 5-46
Removal & Installation . . . . . . . . . . . . . 5-45
Cylinder Compression Test . . . . . . . . . . . . 5-23
Cylinder Head
Disassembly/Assembly . . . . . . . . . . . . 5-35
Inspection . . . . . . . . . . . . . . . . . . . . . . . 5-36
Removal/Installation . . . . . . . . . . . . . . . 5-35
Cylinders
Deglaze Cylinder Bore . . . . . . . . . . . . . 5-47
Resize Cylinder Bore . . . . . . . . . . . . . . 5-47
Engine Removal and Installation . . . . . . . . 5-28
Engine Repair . . . . . . . . . . . . . . . . . . . . . . . 5-28
Fast Idle Adjustment . . . . . . . . . . . . . . . . . . 5-21
Flywheel Removal & Installation . . . . . . . . . 5-33
Fuel Pump
Replacement . . . . . . . . . . . . . . . . . . . . 5-32
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
General Specifications . . . . . . . . . . . . . . . . . 5-3
Governor
Adjustment . . . . . . . . . . . . . . . . . . . . . . 5-20
Governor Shaft . . . . . . . . . . . . . . . . . . . 5-50
Removal & Installation . . . . . . . . . . . . . 5-49
Lubrication System Operation . . . . . . . . . . 5-10
Oil Filter Manifold
Removal & Installation . . . . . . . . . . . . . 5-49
Oil Pressure Test . . . . . . . . . . . . . . . . . . . . 5-25
Oil Pump Removal & Installation . . . . . . . . 5-48
Piston & Connecting Rod
Removal & Installation . . . . . . . . . . . . . 5-39
Repair Specifications . . . . . . . . . . . . . . . . . . 5-3
Rocker Arm Assembly
Inspection . . . . . . . . . . . . . . . . . . . . . . . 5-35
Removal/Installation . . . . . . . . . . . . . . . 5-34
Slow Idle Adjustment . . . . . . . . . . . . . . . . . 5-20
Spark Plug Gap . . . . . . . . . . . . . . . . . . . . . 5-27
Spark Test . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Starting Motor . . . . . . . . . . . . . . . . . . . . . . . 5-51
No-Load Amperage & RPM Test . . . . . 5-53
Troubleshooting Guide . . . . . . . . . . . . . 5-17
Stator Removal & Installation . . . . . . . . . . . 5-50
Test & Adjustments Specifications . . . . . . . . 5-3
Theory of Operation . . . . . . . . . . . . . . . . . . 5-10
Throttle Cable Adjustment . . . . . . . . . . . . . 5-18
Torque Specifications . . . . . . . . . . . . . . . . . . 5-5
Troubleshooting Chart . . . . . . . . . . . . . . . . 5-11
Troubleshooting Guide . . . . . . . . . . . . . . . . 5-13
Valve Clearance, Check and Adjustment . . 5-22
Valves
Lap Valves . . . . . . . . . . . . . . . . . . . . . . 5-38
Recondition Valve Seats . . . . . . . . . . . 5-38
Kohler Engine
Air Intake System Components . . . . . . . . . 3-25
Automatic Compression Release (ACR) . . 3-20
Balancer Shaft
Inspection . . . . . . . . . . . . . . . . . . . . . . . 3-38
Removal/Installation . . . . . . . . . . . . . . . 3-37
Repair Specifications . . . . . . . . . . . . . . . 3-5
Breather Inspection . . . . . . . . . . . . . . . . . . 3-33
Camshaft
End Play Measurement . . . . . . . . . . . . 3-36
Inspection . . . . . . . . . . . . . . . . . . . . . . . 3-35
Removal/Installation . . . . . . . . . . . . . . . 3-35
Repair Specifications . . . . . . . . . . . . . . . 3-5
Carburetor Inspection . . . . . . . . . . . . . . . . . 3-26
Choke Adjustment . . . . . . . . . . . . . . . . . . . 3-16
Connecting Rod Repair Specifications . . . . . 3-6
Crankcase Oil Seal Removal/Installation . . 3-46
Crankcase Vacuum Test . . . . . . . . . . . . . . 3-21
Crankshaft
Alignment . . . . . . . . . . . . . . . . . . . . . . . 3-45
Removal and Installation . . . . . . . . . . . 3-43
Repair Specifications . . . . . . . . . . . . . . . 3-4
Crankshaft & Main Bearing Inspection . . . . 3-44
Cylinder Block
Inspection . . . . . . . . . . . . . . . . . . . . . . . 3-48
Removal and Installation . . . . . . . . . . . 3-47
Cylinder Bore Deglazing . . . . . . . . . . . . . . . 3-48
Cylinder Bore, Piston & Rings
Repair Specifications . . . . . . . . . . . . . . . 3-5
Cylinder Head
Inspection . . . . . . . . . . . . . . . . . . . . . . . 3-31
Removal and Installation . . . . . . . . . . . 3-30
Repair Specifications . . . . . . . . . . . . . . . 3-4
Cylinder Leak Test . . . . . . . . . . . . . . . . . . . 3-18
Engine
Removal and Installation . . . . . . . . . . . 3-27
Tests & Adjustments . . . . . . . . . . . . . . 3-16
Tests & Adjustments Specifications . . . . 3-3
Engine Repair . . . . . . . . . . . . . . . . . . . . . . . 3-27
Fast Idle Speed Adjustment . . . . . . . . . . . . 3-17
Flywheel Removal/Installation . . . . . . . . . . 3-34
Fuel & Air Repair . . . . . . . . . . . . . . . . . . . . 3-25
Fuel Flow Test . . . . . . . . . . . . . . . . . . . . . . 3-22
Fuel Pump Remove & Install . . . . . . . . . . . 3-27
General Specifications . . . . . . . . . . . . . . . . . 3-3
Governor
Adjustment . . . . . . . . . . . . . . . . . . . . . . 3-17
Inspection . . . . . . . . . . . . . . . . . . . . . . . 3-39
Removal and Installation . . . . . . . . . . . 3-39
Repair Specifications . . . . . . . . . . . . . . . 3-6
Hydraulic Valve Lifters Inspection . . . . . . . 3-37
Hydraulic Valve Lifters Remove/Install . . . . 3-36
Oil Pan Removal/Installation . . . . . . . . . . . 3-45
Oil Pan Seal Removal and Installation . . . . 3-46
Oil Pickup Inspection . . . . . . . . . . . . . . . . . 3-46
Oil Pressure Test . . . . . . . . . . . . . . . . . . . . 3-23
Oil Pump Relief Valve Inspection . . . . . . . . 3-47
Oil Pump Removal and Installation . . . . . . 3-47
Piston Assembly . . . . . . . . . . . . . . . . . . . . . 3-42
Disassemble . . . . . . . . . . . . . . . . . . . . 3-40
Inspection . . . . . . . . . . . . . . . . . . . . . . . 3-40
Installation . . . . . . . . . . . . . . . . . . . . . . 3-43
Measurement . . . . . . . . . . . . . . . . . . . . 3-41
Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Piston Ring
End Gap Measurement . . . . . . . . . . . . 3-41
Side Clearance Measurement . . . . . . . 3-41
Push Rod Repair Specifications . . . . . . . . . . 3-4
Repair Specifications . . . . . . . . . . . . . . . . . . 3-4
Rocker Arms
Removal and Installation . . . . . . . . . . . 3-30
Repair Specifications . . . . . . . . . . . . . . . 3-4
Rocker Shaft Repair Specifications . . . . . . . 3-4
Slow Idle Speed Adjustment . . . . . . . . . . . . 3-18
Test & Adjustments Specifications . . . . . . . . 3-3
Throttle Cable Adjustment . . . . . . . . . . . . . 3-16
Torque Specifications . . . . . . . . . . . . . . . . . . 3-7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 3-9
Valve Guides Inspection . . . . . . . . . . . . . . . 3-32
Valve Seats Recondition . . . . . . . . . . . . . . 3-33
Valves
Inspection . . . . . . . . . . . . . . . . . . . . . . . 3-31
Lap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Removal and Installation . . . . . . . . . . . 3-31
Valves & Valve Lifter Repair Specifications . 3-4
L
Lubricants
Alternative Lubricants . . . . . . . . . . . . . . . . . 2-10
Anti-Corrosion Grease . . . . . . . . . . . . . . . . . 2-9
Engine Break-In Oil . . . . . . . . . . . . . . . . . . . 2-8
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Mixing of Lubricants . . . . . . . . . . . . . . . . . . 2-10
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Synthetic Lubricants . . . . . . . . . . . . . . . . . . 2-10
M
Metric Fastener Torque Values . . . . . . . . . . . . . . 2-5
Miscellaneous
Hood Removal and Installation . . . . . . . . . . 10-6
Seat & Support Removal & Installation . . . 10-7
Mower Deck
Blade Brake
Adjustment . . . . . . . . . . . . . . . . . . . . . . 9-19
Replacement . . . . . . . . . . . . . . . . . . . . 9-29
Blade Removal and Installation . . . . . . . . . 9-30
Blade Timing Belt
Adjustment . . . . . . . . . . . . . . . . . . . . . . 9-17
Removal and Installation . . . . . . . . . . . 9-26
Component Location (S/N -020000) . . . . . . . 9-4
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Drive Belt
Removal & Installation
LTR155/166 . . . . . . . . . . . . . . . . . . 9-23
LTR180 . . . . . . . . . . . . . . . . . . . . . 9-24
Tension Adjustment . . . . . . . . . . . . . . . 9-20
Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Lift Linkage Component Location
LTR155/166 . . . . . . . . . . . . . . . . . . . . . . 9-8
LTR180 . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Lift Linkage Removal and Installation
LTR155/166 . . . . . . . . . . . . . . . . . . . . . 9-30
LTR180 . . . . . . . . . . . . . . . . . . . . . . . . 9-33
PTO Linkage Component Location . . . . . . . 9-5
Removal & Installation
LTR155/166 . . . . . . . . . . . . . . . . . . . . . 9-22
LTR180 . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 9-10
P
Power Train
Component Location . . . . . . . . . . . . . . . . . . 7-4
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Tests & Adjustments . . . . . . . . . . . . . . . . . . 7-15
Theory of Operation . . . . . . . . . . . . . . . . . . . 7-8
Traction Drive Belt
Removal & Installation . . . . . . . . . . . . . 7-20
Tension Adjustment . . . . . . . . . . . . . . . 7-16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 7-12
Product Identification Numbers (PIN) . . . . . . . . 2-11
R
Rear Wheel Removal & Installation . . . . . . . . . 10-5
Regulated Amperage Test . . . . . . . . . . . . . . . 6-145
Repair
Blade Brake Replacement . . . . . . . . . . . . . 9-29
Brake Pedal & Linkage
Removal & Installation . . . . . . . . . . . . . 7-27
Control Pedals & Linkage
Removal & Installation . . . . . . . . . . . . . 7-23
Cross Shaft Assembly
Removal & Installation . . . . . . . . . . . . . 7-26
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . 6-158
Engine
Briggs & Stratton . . . . . . . . . . . . . . . . . 4-23
Kawasaki Engine . . . . . . . . . . . . . . . . . 5-28
Kohler . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Grass Collector Removal and Installation . 9-36
Hydrostatic Transaxle
Removal & Installation . . . . . . . . . . . . . 7-18
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . 10-4
Mower Blade Removal & Installation . . . . . 9-30
Mower Deck
Drive Belt Removal & Installation
LTR155/166 . . . . . . . . . . . . . . . . . . 9-23
LTR180 . . . . . . . . . . . . . . . . . . . . . 9-24
Lift Linkage Removal/Installation
LTR155/166 . . . . . . . . . . . . . . . . . . 9-30
LTR180 . . . . . . . . . . . . . . . . . . . . . 9-33
Removal & Installation
LTR155/166 . . . . . . . . . . . . . . . . . . 9-22
LTR180 . . . . . . . . . . . . . . . . . . . . . 9-23
Spindle Removal & Installation . . . . . . 9-24
Timing Belt Removal & Installation . . . 9-26
Shock Absorber Removal & Installation . . . 7-27
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Traction Drive Belt Tensioner Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
S
Safety
Handle Chemical Products Safely . . . . . . . . 1-5
Handling And Servicing Batteries . . . . . . . . . 1-3
Park Machine Safely . . . . . . . . . . . . . . . . . . . 1-4
Support Machine Properly . . . . . . . . . . . . . . 1-4
Using High Pressure Washers . . . . . . . . . . . 1-4
Work In Ventilated Area . . . . . . . . . . . . . . . . 1-4
Seat & Support Removal & Installation . . . . . . . 10-7
Shock Absorber Removal & Installation . . . . . . 7-27
Spark Plug
Spark Test . . . . . . . . . . . . . . . . . . . . . . . . 6-156
Specifications
Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Metric Torque Values . . . . . . . . . . . . . . . . . . 2-5
Power Train . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Spindles (Mower Deck)
Bearing Replacement . . . . . . . . . . . . . . . . . 9-24
Removal & Installation . . . . . . . . . . . . . . . . 9-24
Starting Motor
Kawasaki Engine . . . . . . . . . . . . . . . . . . . . 5-51
LTR155
Removal and Installation . . . . . .3-49, 6-160
LTR166
Removal and Installation . . . . . . . . . . 6-164
Steering
Component Location . . . . . . . . . . . . . . . . . . 8-4
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Torque Specifications . . . . . . . . . . . . . . . . . . 8-3
Steering Gear Assembly Removal & Installation 8-5
T
Tests & Adjustments
Alternator
DC Output Test
LTR155 3 Amp . . . . . . . . . . . . . . 6-146
LTR166 . . . . . . . . . . . . . . . . . . . . 6-148
Diode Test
LTR155 . . . . . . . . . . . . . . . . . . . . 6-147
LTR166 . . . . . . . . . . . . . . . . . . . . 6-148
Battery Charge . . . . . . . . . . . . . . . . . . . . . 6-141
Battery Load . . . . . . . . . . . . . . . . . . . . . . . 6-141
Battery Voltage & Specific Gravity . . . . . . 6-140
Brake Linkage Adjustment . . . . . . . . . . . . . 7-15
Diode Test . . . . . . . . . . . . . . . . . . . . . . . . 6-150
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . 6-140
Forward & Reverse Pedal Adjustment . . . . 7-17
Fuel Shutoff Solenoid Test . . . . . . . . . . . . 6-156
Grass Collection System
Bag Full Alarm Test . . . . . . . . . . . . . . 6-156
Bag Full Switch Test . . . . . . . . . . . . . 6-155
Bag in Place Switch Test . . . . . . . . . . 6-154
Enable Switch Test . . . . . . . . . . . . . . 6-155
Fill Sensor Adjustment . . . . . . . . . . . . . 9-21
Latching Adjustment . . . . . . . . . . . . . . 9-22
Ground Circuit . . . . . . . . . . . . . . . . . . . . . 6-140
Ignition Diode Test (LTR166) . . . . . . . . . . 6-157
Kawasaki Engine . . . . . . . . . . . . . . . . . . . . 5-18
Key Switch Test-3 Position . . . . . . . . . . . . 6-151
Key Switch Test-4 Position . . . . . . . . . . . . 6-151
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . 10-4
Mower Deck
Blade Brake Adjustment . . . . . . . . . . . 9-19
Blade Timing Belt Adjustment . . . . . . . 9-17
Drive Belt Tension Adjustment . . . . . . . 9-20
Leveling . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Power Train
Drive Belt Adjustment . . . . . . . . . . . . . 7-16
Transport (Free Wheel) Test . . . . . . . . 7-17
PTO and Brake Switch Test . . . . . . . . . . . 6-152
PTO Switch Test . . . . . . . . . . . . . . . . . . . . 6-152
Relay Test . . . . . . . . . . . . . . . . . . . . . . . . 6-150
RIS Switch Test . . . . . . . . . . . . . . . . . . . . 6-153
Seat Switch Test . . . . . . . . . . . . . . . . . . . . 6-153
Seat Switch Test (W/4 position key switch) 6-154
Spark Test . . . . . . . . . . . . . . . . . . . . . . . . 6-156
Starting Motor
Amperage Draw . . . . . . . . . . . . . . . . . 6-142
Loaded . . . . . . . . . . . . . . . . . . . . . 6-144
No-Load . . . . . . . . . . . . . . . . . . . . 6-143
Solenoid Test . . . . . . . . . . . . . . . . . . . 6-142
Tire Pressure Adjustment . . . . . . . . . . . . . . 10-4
Traction Drive System Test . . . . . . . . . . . . 7-15
Torque Values
Inch Fastener . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Metric Fastener . . . . . . . . . . . . . . . . . . . . . . . 2-5
Traction Drive Belt
Belt Tensioner Removal & Installation . . . . 7-22
Removal & Installation . . . . . . . . . . . . . . . . 7-20
Tension Adjustment . . . . . . . . . . . . . . . . . . 7-16
Troubleshooting
Briggs & Stratton Engine . . . . . . . . . . . . . . . 4-5
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Kawasaki Engine . . . . . . . . . . . . . . . . . . . . 5-11
Kohler Engine . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Power Train . . . . . . . . . . . . . . . . . . . . . . . . 7-12

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