Exmark-Kohler to PA-ZT720-3017

Procedure Steps:

• Step: 1

  Prepare chassis for installation:

  • Remove old engine, PTO clutch and pump drive pulley.
  • Drill out the four engine mounting holes to 25/32 to accommodate the larger bolts needed on new engine.
  • Relocate the throttle cable to the right side of the engine deck, alongside the choke cable.
  • Extend the OEM ground wire (double-black on the left side of engine deck) so that it will reach the starter motor on the right side, and terminate extension with a ring connector.
  • Cut the chassis wire harness 4-pin connector, as close to the plug end as possible, and discard connector. Strip insulation from wire ends.
  • Terminate violet wire (charging), which will not be used.
  • Attach non-interchangeable, insulated terminal ends to the three remaining wires.

• Step: 2

  Uncrate new engine and prepare for installation on chassis:

  • Install heat deflectors, exhaust manifold and muffler.
    Transfer oil drain hose from old engine to right hand side drain port on new engine.
  • Tap the engine mounting holes to 3/8-16 NC.
  • Remove the rear starter motor mounting bolt and lifting eye. Retain the bolt, and discard lifting eye.
  • Connect violet wire (with fuse) to starter motor battery terminal.
  • Cut the engine wire harness 6-pin connector as close to plug end as possible, and discard connector. Strip insulation from red, green and white wire ends.
    Attach non-interchangeable, insulated terminal ends to mate with connectorson OEM wire harness.

  

  The three connections to be made to the Exmark OEM harness are:
  

  Magneto kill: Confidant white to Exmark white/black double wire.
  

  Fuel solenoid: Confidant red to Emark orange wire.
  Hour meter (oil pressure): Confidant green to Exmark blue wire.
  

  NOTE-This is the basic wiring scheme used on all Turf Tracers with carbureted engines. Exmark wire colors may vary on newer or older serial numbers. Refer to appropriate wiring diagram for specific unit if needed.

• Step: 3

  Installation:

  • Mount prepared engine on chassis, and secure with four 3/8-16 x 1.25 cap screws and lock washers. A spring disc lock washer (Toro P/N 98-5975) is preferable, but split washers will work also.
  • Install pump drive pulley and PTO clutch.
  • Connect Magneto, Fuel Solenoid and Hour Meter wire ends to each other as prepared in previous step.
  • Connect Exmark 6-gauge positive battery cable to starter motor.
  • Connect Exmark starter spade connector (cranking) to starter solenoid.
  • Connect Exmark 6-gauge negative battery cable and extended Exmark ground wire to the engine block using the rear starter motor mounting bolt.

  

  Attach throttle and choke cables to control plate. Both can be secured using a single clamp.

  

  Connect fuel line to new fuel filter on engine.
  

  Add oil, start and adjust RPM as needed.

• Step: 4

  

  Finished.