alto jdm 660

Engine Parts Manual

19

17

18

13

6

5

9

15

16

7 8

10

4

3

11

1 - INCLUDES ITEMS 3 - 16

WARNINGIf incorrectly used, this machine can cause severe injury. Those who useand maintain this machine should be trained in its proper use, warned of itsdangers and should read the entire manual before attempting to set up,operate, adjust, or service the machine.

By Jacobsen

When Performance Matters.™

GB

Suzuki 660 K6A YH625

2011 Turf Truckster2011 Haulster2011 Spraytek DS175

4241728-Rev A

© Copyright 2011, Jacobsen, A Textron Company. “All rights reserved, including the right to reproduce this material or portions

thereof in any form.”

This manual contains a parts list for your new Cushman®

vehicle. This manual should be stored with the equipment for reference during operation.

Before you operate your vehicle, you and each operator you employ should read the manual carefully in its entirety. By following the safety, operating and maintenance instructions you will prolong the life of your equipment and maintain its maximum efficiency.

If additional information is needed contact your Cushman Dealer.

2

Proposition 65 Warning

This product contains or emits chemicals known to State of California to cause cancer and birth defects or other reproductive harm.

FOREWORD

Suggested Stocking Guide

To Keep your equipment fully operational and productive, Jacobsen suggests you maintain a stock of the more commonly used maintenance items. We have also included part numbers for additional support materials and training aids.

To order any of the following material:

1. Write your full name and complete address on your order form.

2. Explain where and how to make shipment:

❑ UPS ❑ Regular Mail

❑ Overnight ❑ 2nd Day

3. Order by the quantity desired, the part number, and the description of the part.

4. Send or bring the order to your authorized Jacobsen Dealer.

Litho in U.S.A. 1-2011

Service Parts

Service Support Material

Qty. Part No. Description Qty. Part No. Description

2701908 Gas Engine Oil Filter 4139265 Gas Alternator-Power Steering Belt2701898 Gas Engine Fuel Filter 4235370 Gas Governor-Hydraulic Pump Belt4140919 Gas Water Pump Belt 840352 Gas Engine Air Filter Element4119606 Spark Plug (Nkg, dcpr7e) 2701832 Spark Plug (Denzo xu22epr-u)4246615 Gasket Set, Engine

Qty. Part No. Description

4241722 Spraytek DS175 Parts & Maintenance4241724 Truckster Parts & Maintenance4241726 Haulster Parts & Maintenance4241728 Suzuki K6A Engine Parts Manual

Qty. Part No. Description

4171985 Suzuki K6A Service Manual

3

Table of Contents1.1.........Engine Gaskets ................................................... 42.1.........Cylinder Head...................................................... 63.1.........Cylinder Block..................................................... 84.1.........Oil Pan................................................................ 105.1.........Engine Mounts .................................................. 126.1.........Crankshafts ....................................................... 147.1.........Camshafts.......................................................... 167.1.........Camshafts (Continued) .................................... 188.1.........Cam Chain ......................................................... 209.1......... Intake Manifold & Throttle Body...................... 2210.1.......Throttle Body..................................................... 2411.1.......Breather Hose ................................................... 2612.1.......Exhaust Manifold .............................................. 2813.1.......Fuel Components.............................................. 3014.1.......Fuel Rail ............................................................. 3215.1.......Oil Pump ............................................................ 3416.1.......Water Pump ....................................................... 3617.1.......Cooling Tubes ................................................... 3818.1.......Engine Electrical ............................................... 4019.1.......Alternator........................................................... 4220.1.......Manual Transmission Starter........................... 4421.1.......Automatic Transmission Starter ..................... 46

22.1....... Clutch................................................................. 4823.1....... Gear Shafts........................................................ 5023.1....... Gear Shafts (Continued)................................... 5224.1....... Shift Linkage ..................................................... 5425.1....... Gear Shift Fork .................................................. 5626.1....... Transmission Case ........................................... 5827.1....... Shift Brackets.................................................... 6028.1....... Torque Converter & Flex Plate ........................ 6229.1....... Case Gaskets .................................................... 6430.1....... Transmission Case ........................................... 6631.1....... Oil Pump ............................................................ 6832.1....... Input Shaft & Clutch ......................................... 7033.1....... Planetary Gears................................................. 7234.1....... Output Shafts .................................................... 7435.1....... Parking Brake.................................................... 7636.1....... Brake Band ........................................................ 7837.1....... Oil Pan................................................................ 8038.1....... Valve................................................................... 8239.1....... Cooling Tubes ................................................... 8440.1....... Shift Switch ....................................................... 8641.1....... Emission Control System ................................ 88

SUZUKI 660 K6A YH625

4

2

4

5

6

7

8

3

19

1.1 Engine Gaskets Serial No. All


5

> Change from previous revision

Item Part No. Qty. Description Serial Numbers/Notes

4246615 1 Gasket Set, Engine

1 4246597 1 • Gasket, Cylinder Head

2 4140891 1 • Gasket, Cylinder Head Cover3 4148145 1 • Gasket, Intake Manifold4 4246631 1 • Gasket, Throttle Body5 4140981 1 • Gasket, Exh Manf6 4119965 1 • O Ring, Water Pump7 4119967 1 • Gasket, Thermostat Case8 4119609 1 • O Ring, Water Inlet Pipe9 4140893 1 • Gasket, Tens Adjuster


6

2

4

5

6

7

8

9

11

12

14

3

10

1

13

2.1 Cylinder Head Serial No. All


7



1 4246610 1 Head Assy, Cylinder

2 4140895 12 • Guide, Valve3 2701816 2 • Plug (Od:20)4 4246611 17 • Bolt (6x36)5 2701821 14 • Pin6 4119956 8 Bolt, Cylinder Head (10x95)7 4119966 2 Pin8 4246597 1 Gasket, Cylinder Head9 4246613 1 Cover, Cylinder Head

10 4140891 1 Gasket, Head Upper Cover11 4246590 5 Bolt12 4119971 1 Bolt13 4148202 1 Cap, Oil Filler14 4119606 3 Spark Plug (Ngk,dcpr7e)14 2701832 3 Spark Plug (Denso,xu22epr-u)


8

1

2

3

4

5

6

78

9

10

11

12

3.1 Cylinder Block Serial No. All


9



1 4140898 1 Block Assy, Cylinder

2 4119956 8 • Bolt, Crankcase (10x95)3 4120006 8 • Bolt, Crankcase No.2 (8x59)4 4148088 1 • Plug, Oil Venturi5 4120007 1 • Plug, Oil Gallery No.26 4120008 1 • Gasket, Oil Gallery Plug7 4119604 1 • Plug, Oil Gallery8 4246600 4 Pin9 4120009 1 Stand, Oil Filter

10 2701908 1 Filter Assy, Oil11 4140899 1 Plate, Clutch Housing Upper Manual Transmission11 4140900 1 Plate, Clutch Housing Upper Automatic Transmission12 4140901 1 Sensor Assy, Knock


10

1

2

3

3

4

4

56

78

910

1112

13

14

15

16

1718

4.1 Oil Pan Serial No. All


11



1 4139968 1 Pan, Oil

2 4148062 12 Bolt (6x16)3 4120013 3 Stud Bolt4 2701914 3 Nut5 4246616 1 Plug, Drain (14x22)6 2701916 1 Gasket, Drain Plug7 4140902 1 Plate, Oil Pan Baffle8 2701829 1 Bolt9 4140903 1 Strainer, Oil Pump

10 2701920 1 O Ring11 4246595 1 Stud Bolt12 2701914 1 Nut13 2701921 2 Bolt14 4140904 1 Gauge, Oil Level15 4148203 1 Guide, Gauge16 4119605 1 O Ring17 4120015 1 Stud Bolt18 2701914 1 Nut


12

6

7

25

1

3

4

5.1 Engine Mounts Serial No. All


13



1 2703002 2 Nut, Rear Mtg Brkt

2 4120017 1 Bracket, Fr Mtg Rh3 4120018 1 Mounting, Fr Lh4 2701827 4 Bolt, Mtg Brkt Lh & Eng5 4140905 3 Bolt, Mtg Brkt Rh & Eng6 4148095 1 Mounting, Rear Manual Transmission6 4148094 1 Mounting, Rear Automatic Transmission7 2702661 2 Bolt, Rr Mtg & T/m


14

7

7

5

2

9

1

6

4

34

8

16

19

10

17

18

14

22

21 23

13

15 20

11

12

262524

6.1 Crankshafts Serial No. All


15



1 4119978 3 Ring Set, Piston (Std)

1 4119979 3 Ring Set, Piston (Os:0.50)2 4119980 3 Piston (Std,mark 1)2 4119981 3 Piston (Std,mark 2)2 4119982 3 Piston (Os:0.50)3 4119983 3 Pin, Piston4 4119984 6 Circlip5 4140906 3 Connrod Assy6 2701931 6 • Nut7 4140907 6 Bearing Set, Connrod T:1.58 4119986 1 Crankshaft9 4246619 4 Bearing Set, Crankshaft T:2 (Color:green)9 4246620 4 Bearing Set, Crankshaft T:2 (Color:black)9 4246621 4 Bearing Set, Crankshaft T:2 (Non Color)9 4246622 4 Bearing Set, Crankshaft T:2 (Color:yellow)9 4246623 4 Bearing Set, Crankshaft T:2 (Color:brown)

10 2701937 1 Bearing Set, Crank Thrust STD,T:2.510 2701938 1 Bearing Set, Crank Thrust OS,T:2.56311 4246602 1 Seal, Crankshaft Front Oil12 4140918 1 Sprocket, Crank Timing13 4246617 1 Pulley, Crankshaft14 4120021 1 Key15 4246625 1 Bolt16 4120023 1 Seal, Oil17 4120024 1 Flywheel Manual Transmission Only18 4119955 6 Bolt (10x18.5) Manual Transmission Only19 2701952 1 Bearing, Input Shaft Manual Transmission Only20 4140919 1 Belt, Water Pump (4pk870)21 4148205 1 Tensioner Assy22 4120028 2 Bolt23 4120029 1 Pin24 2701829 1 Bolt25 4246624 1 Bracket, Crank Angle Sensor26 2701949 2 Pin

Serial No. All 7.1 Camshafts
16

1

2

3

4

5

5

6

6

77

77

8

8

9

9

10

10

11

11



1 4246626 1 Camshaft, Intake

2 4246627 1 Camshaft, Exhaust3 4120032 6 Valve, Intake4 4120033 6 Valve, Exhaust5 4246628 12 Spring, Valve6 4120035 12 Retainer, Spring7 2701970 24 Cotter, Valve8 2701972 12 Seal, Valve Stem Oil9 2701971 12 Seat, Spring

10 4140965 12 Tappet11 4148102 AR Shim, Tappet (T:2.18)11 4148103 AR Shim, Tappet (T:2.20)11 4148104 AR Shim, Tappet (T:2.22)11 4148105 AR Shim, Tappet (T:2.24)11 4148106 AR Shim, Tappet (T:2.26)11 4148107 AR Shim, Tappet (T:2.28)11 4148108 AR Shim, Tappet (T:2.30)11 4148109 AR Shim, Tappet (T:2.32)11 4148110 AR Shim, Tappet (T:2.34)11 4148111 AR Shim, Tappet (T:2.36)11 4148112 AR Shim, Tappet (T:2.38)11 4148113 AR Shim, Tappet (T:2.40)11 4148114 AR Shim, Tappet (T:2.42)11 4148115 AR Shim, Tappet (T:2.44)11 4148116 AR Shim, Tappet (T:2.46)11 4148117 AR Shim, Tappet (T:2.48)11 4148118 AR Shim, Tappet (T:2.50)11 4148119 AR Shim, Tappet (T:2.52)11 4148120 AR Shim, Tappet (T:2.54)11 4148121 AR Shim, Tappet (T:2.56)11 4148122 AR Shim, Tappet (T:2.58)11 4148123 AR Shim, Tappet (T:2.60)11 4148124 AR Shim, Tappet (T:2.62)11 4148125 AR Shim, Tappet (T:2.64)11 4148126 AR Shim, Tappet (T:2.66)11 4148127 AR Shim, Tappet (T:2.68)11 4148128 AR Shim, Tappet (T:2.70)11 4148129 AR Shim, Tappet (T:2.72)11 4148130 AR Shim, Tappet (T:2.74)11 4148131 AR Shim, Tappet (T:2.76)11 4148132 AR Shim, Tappet (T:2.78)11 4148133 AR Shim, Tappet (T:2.80)11 4148134 AR Shim, Tappet (T:2.82)11 4148135 AR Shim, Tappet (T:2.84)11 4148136 AR Shim, Tappet (T:2.86)

17


7.1 Camshafts (Continued)
18

1

2

3

4

5

5

6

6

77

77

8

8

9

9

10

10

11

11


11 4148137 AR Shim, Tappet (T:2.88)11 4148138 AR Shim, Tappet (T:2.90)11 4148139 AR Shim, Tappet (T:2.92)11 4148140 AR Shim, Tappet (T:2.94)11 4148141 AR Shim, Tappet (T:2.96)11 4148142 AR Shim, Tappet (T:2.98)11 4148143 AR Shim, Tappet (T:3.00)


19



20

1

2

3

4

5

6

7

8

9

10

11

12

8.1 Cam Chain Serial No. All


21



1 4120037 1 Chain, Timing

2 4120038 1 Guide, Chain3 4120039 2 Bolt4 4148100 1 Tensioner, Chain5 4120041 1 Spacer6 2702469 1 Bolt7 4120042 1 Pad, Tensioner8 4148101 1 Link, Tensioner9 2702486 2 Bolt

10 4140970 1 Adjuster Assy, Tensioner11 4140893 1 Gasket12 2701834 2 Bolt


22

2

4

5

7

8

9

3

1

6

10

12

11

9.1 Intake Manifold & Throttle Body Serial No. All


23



1 4148144 1 Intake Manifold

2 4148145 1 • Gasket, Intake Manifold3 4246631 1 • Gasket, Throttle Body4 4246594 3 Stud Bolt, Intake Manifold5 2702520 4 Bolt, Intake Manifold6 4141031 5 Bolt, Intake Manifold7 2701914 3 Nut8 4148146 1 Stiffener, Intake Manifold9 2702475 3 Bolt

10 2702431 1 Plug11 4140618 1 Sensor, Air Temp12 4140617 1 Grommet


24

7 1

4

23

6

5

10.1 Throttle Body Serial No. All


25



1 4246629 1 Throttle Body Assembly

2 4246630 1 • Sensor, Throttle Position3 4246633 2 • Screw (4 x 12)4 4246652 1 • Sensor, Pressure5 4246510 2 • Screw (5 x 14)6 4246631 1 Gasket7 2702001 4 Bolt


26

1

2

4

3

5

6

2

6

AIRCLEANER

INTAKEMANIFOLD

11.1 Breather Hose Serial No. All


27



1 4148090 1 Hose, Breather

2 2702484 2 Clip3 4148091 1 Hose, Pcv4 2702489 1 Seal, Pcv Valve5 4120056 1 Valve, Pcv6 2702491 2 Clip


28

3

5

15

1

2

4

6 13

9 8

14

7 10

11 12

12.1 Exhaust Manifold Serial No. All


29



1 4148151 1 Manifold, Exhaust

2 4246596 2 Bolt3 4148152 1 Cover, Exh Manf Upper4 4140981 1 Gasket5 4148061 8 Bolt (6x10)6 4120063 4 Stud Bolt7 2703002 4 Nut8 2702475 1 Bolt9 2702759 1 Hook, Engine

10 2702500 1 Ring, Seal Exh Pipe11 2702501 2 Spring, Exh Pipe12 2702502 2 Bolt (10x65)13 4246649 1 Sensor, Oxygen14 4246651 1 Bracket15 4235966 1 Sensor, AF


30

1 2

3

5

6

4

13.1 Fuel Components Serial No. All


31



1 2701897 1 Pump Assy, Fuel

2 2701898 1 Filter, Fuel3 2701899 1 Regulator Assy, Fuel Pressure4 4148198 1 Bracket, Fuel and Breather Hose5 4148199 1 Clamp6 2702486 2 Bolt


32

3

4

6

1

5

2

14.1 Fuel Rail Serial No. All


33



1 4148197 1 Pipe, Delivery

2 2701978 1 Bolt3 4246638 3 Injector Assy, Fuel4 4246639 3 • Grommet5 4246637 3 • O-Ring6 2702513 3 Cushion


34

2

4

5

6

7

8

9

11

12

13

3

10

1

9

15.1 Oil Pump Serial No. All


35



1 4246634 1 Pump Assy, Oil

2 4148201 1 • Rotor Set3 2702517 7 • Screw4 4246640 1 • Valve Set5 08331-41156 1 • • Circlip6 2701820 1 Plug7 2701949 2 Pin8 2702519 6 Bolt9 2702001 4 Bolt

10 2702659 5 Bolt11 4140988 1 Bolt (8x40)12 4140989 1 Switch Assy, Oil Pressure13 4140990 1 Filter, Oil Gallery


36

2

3

1

16.1 Water Pump Serial No. All


37



1 4246641 1 Pump Set, Water

2 4119965 1 • O Ring3 2702470 4 Bolt


38

WATER PUMP 8

4

14

12

12

2

11

1

7

6

10

5

5

14

3

13

9

15

16

17

18

17.1 Cooling Tubes Serial No. All


39



1 4148150 1 Sensor, Water Temp

2 4120076 1 Cap, Water Thermostat3 4246644 1 Cap, Water Outlet4 4140992 1 Bolt5 2703002 2 Nut6 4148206 1 Thermostat, Water7 4148207 1 Case, Thermostat8 4119967 1 Gasket9 4119609 1 O Ring, Water Inlet Pipe

10 4120081 1 Pipe, Water Inlet11 452392 2 Bolt12 2702486 2 Bolt13 2702541 1 Gasket14 4148058 2 Stud Bolt15 2702540 1 Union, Air Vent16 2701442 1 Housing, Temperature Sender17 2701513 1 Gasket, Thermostat18 843857 1 Sender, Temperature


40

32

5

4

6

7

18

9

8

16

19

17

26

12

13

20

1

22

21

23

11

25

24

1610

15

14

18.1 Engine Electrical Serial No. All


41



1 4246716 1 Sensor Assy, Cam Position

2 4246706 3 Coil Assy, Ignition (Denso)2 4246718 3 Coil Assy, Ignition ( Mitsubishi)3 4140993 3 Bolt4 4239342 1 Controller, Fuel Injection Manual Transmission4 4239343 1 Controller, Fuel Injection Automatic Transmission5 4246715 1 Sensor Assy, Crank Position6 4148386 1 Sensor Assy, Speed Manual Transmission6 4120114 1 Sensor Assy, Speed Automatic Transmission7 2701978 1 Bolt Manual Transmission7 2702764 1 Bolt Automatic Transmission8 4244102 1 Harness Assy, Engine Manual Transmission8 4246030 1 Harness Assy, Engine Automatic Transmission9 4148389 1 Bracket, Engine Harness

10 4148390 1 Bracket, Engine Harness11 4140999 1 Bracket, Engine Harness/connector12 4141000 1 Bracket, Harness13 4141002 1 Bracket, Engine Harness14 2702486 2 Bolt, Bracket15 2702475 1 Bolt, Ground16 2702486 1 Bolt17 2702953 1 Bracket, Harness AT18 4148385 1 Cable, Battery Ground No.219 4120117 1 Clamp, Harness20 2702475 1 Bolt21 4148389 1 Bracket, Harness Automatic Transmissions Only22 2701978 1 Bolt23 4246722 1 Wire, Noise Suppressor24 4246714 1 Bracket, Engine Harness25 4246720 1 Bracket, Engine Harness26 4246721 1 Wire, Crank


42

21

24

20

18

1917

23

16

15

13

14

11

12

3

5 6

8

10

9

4

7

2

1

22

19.1 Alternator Serial No. All


43



1 4246717 1 Generator Assy

2 Not Used 1 • Pulley Order Item 273 4119618 1 • Nut, Pulley4 4119617 1 • Screw Set5 4120121 1 • Screw6 4120122 1 • Bearing7 4120123 1 • Retainer, Bearing8 4120124 1 • Bush9 4120125 1 • Rotor Assy

10 4119615 1 • • Bearing, Rear11 4120126 1 • Stator Assy12 4148376 1 • Terminal Set13 4148381 1 • Regulator Assy14 4119616 1 • • Brush15 4120129 1 • Rectifier Assy16 4246723 1 Bracket, Generator17 2702659 1 Bolt18 4246719 1 Arm, Generator19 4148059 1 Bolt20 2702469 1 Bolt21 2702469 1 Bolt22 2702469 4 Bolt, Generator Brkt23 2701914 1 Nut24 4149901 1 Pulley, Alternator Order this pulley for use with

Cushman Turf Trucksters, Spraytek DS175 and Haulsters. Do not use the pulley included with Alternator


44

3

5

6

7

9

10

12

4

11

2

3

13

8

1

20.1 Manual Transmission Starter Serial No. All


45



1 4148360 1 Motor Assy, Starting

2 4148362 1 • Yoke Assy3 2702895 1 • Screw Assy4 4148364 1 • Bush5 4148365 1 • Bearing6 4246708 1 • Holder Assy, Brush7 4246710 1 • Lever Assy8 4148368 1 • Switch Assy9 4148369 2 • Bolt

10 4246712 1 • Armature11 4148371 1 • Stopper Set12 4148372 1 • Clutch Assy13 2702470 2 Bolt


46

3

5

6

7

9

10

12

4

11

2

3

13

1

8

21.1 Automatic Transmission Starter Serial No. All


47



1 4148361 1 Motor Assy, Starting

2 4148363 1 • Yoke Assy3 2702895 1 • Screw Assy4 4148364 1 • Bush5 4148365 1 • Bearing6 4246708 1 • Holder Assy, Brush7 4246710 1 • Lever Assy8 4148368 1 • Switch Assy9 4148369 2 • Bolt

10 4246712 1 • Armature11 4148371 1 • Stopper Set12 4148373 1 • Clutch Assy13 2702470 2 Bolt


48

3

1

2

4

5 6

8 7

9

22.1 ClutchManual Transmission

Serial No. All


49



1 2702548 1 Clutch, Disc and Cover Set

2 4117900 1 • Cover Assy, Clutch Limited Availability3 2702547 6 Bolt,(8x16)4 2702549 1 Bearing, Clutch Release5 2702550 1 Clip, Clutch Release Brg6 4148214 1 Fork, Clutch Release7 2702552 1 Support, Clutch Release Fork8 2702553 1 Clip, Clutch Release Fork9 2702554 1 Cap, T/M Front Case

Serial No. All 23.1 Gear Shafts
Manual Transmission

50

4546

10

3932

36

41

36

315

30

38

351614

13

15

12

8

2320

22

18 37

28

25

3440

34 2421

17

29

1922

42

35

306

26

27

9

43

47

23

4

1

711

44

33

4948

50



1 4246654 1 Shaft, Transmission Input

2 4148083 1 Seal, Oil3 4148219 1 Seal, Pump4 4148222 1 Ring, Input Shaft Brg Snap5 4148223 1 Gear, Input Shaft 3rd6 4148224 1 Gear, Input Shaft 4th7 4148076 1 Bearing (25x52x15)8 4148079 1 Bearing (15x20x15.8)9 4148080 1 Bearing (25x30x23.8)

10 4148080 1 Bearing (25x30x23.8)11 2702559 1 Circlip12 4148216 1 Shaft, T/m Output13 4148217 1 Gear, T/m Output Shaft14 4148077 1 Bearing (25x52x15)15 4148078 1 Bearing (35x62x14)16 2702559 1 Circlip17 4148218 1 Shaft, Transmission Counter18 4148225 1 Gear, Counter Shaft 1st19 4148226 1 Gear, Counter Shaft 2nd20 4148075 1 Bearing (25x55x10)21 4148074 1 Bearing (20x52x15)22 4148081 2 Bearing (30x35x24.8)23 2702559 1 Circlip24 4148227 AR Shim, Countershaft Rr Brg (T1.00)24 4148228 AR Shim, Countershaft Rr Brg (T1.10)24 4148229 AR Shim, Countershaft Rr Brg (T1.20)24 4148230 AR Shim, Countershaft Rr Brg (T1.30)24 4148231 AR Shim, Countershaft Rr Brg (T1.40)24 4148232 AR Shim, Countershaft Rr Brg (T1.50)24 4148233 AR Shim, Countershaft Rr Brg (T1.60)24 4148234 AR Shim, Countershaft Rr Brg (T1.70)24 4148235 AR Shim, Countershaft Rr Brg (T1.80)25 4148236 1 Hub Assy, Low Speed Sync26 4148237 1 Hub Assy, High Speed Sync27 4148238 1 Hub Assy, 5th Speed Sync28 4148239 1 Ring, Low Gear Synchronizer29 2702602 1 Ring, 2nd Gear Sync30 4246655 2 Ring, High Speed Sync31 4148241 1 Ring, 5th Speed Sync32 4148242 1 Ring, 5th Speed Sync33 4148243 1 Spring, Sync Ring 5th34 2702603 2 Spring, Low Speed Sync35 4148244 2 Spring, High Speed Sync36 4148245 2 Spring, 5th Speed Sync37 2702598 1 Circlip, Low Speed Sync Hub

51


23.1 Gear Shafts (Continued)Manual Transmission
52

4546

10

3932

36

41

36

315

30

38

351614

13

15

12

8

2320

22

18 37

28

25

3440

34 2421

17

29

1922

42

35

306

26

27

9

43

47

23

4

1

711

44

33

4948

50


38 2702604 1 Circlip, High Speed Sync Hub39 2702581 1 Circlip, 5th Speed Sync Hub40 4148246 3 Key, Low Speed Sync41 2702600 3 Key, High Speed Sync42 4148247 3 Key, 5th Speed Sync43 4148248 1 Shaft, T/m Rev Gear44 4148249 1 Gear, Reverse Idler45 4148250 1 Bolt, Reverse Shaft46 4148067 1 Washer (16x24x3)47 4246643 1 Gasket (8.2x14x1)48 4148357 1 Ring, Speedometer Exciter49 2702559 1 Circlip50 4148060 1 Ball


53



54

9 2

6

14

1

3

7

5

4

8

10

13

12

15

17 19

11

2825

23

28

25

16

18

26

27

2221

2220

24

13

24.1 Shift LinkageManual Transmission

Serial No. All


55



1 4246694 1 Case, Gr Shf Lever

2 4246696 1 Plate, Gear Shift Interlock3 4120092 1 Bolt, Gear Shift Stop4 4246697 1 Lever, Gear Shift & Select5 4246698 1 Yoke, Rev Shift Lim6 4246699 1 Retainer, Rev Shift Lim Yoke7 2702635 1 Bush, Select Lever Shaft8 4246656 1 Shaft, Gear Shift9 4148275 1 Spring, Low Select Return

10 4148276 1 Spring, 5th & Rev Sel Return11 4246690 1 Lever, Shift Cable12 4246700 1 Lever, Select Cable13 4246701 2 Bush, Select Lever14 4246591 1 Bolt (6x25)15 4148063 4 Bolt (8x30)16 2702648 1 Spring Pin (3.5x28)17 2702649 1 Spring Pin (3x25)18 2702651 1 Spring Pin (6x28)19 2702652 1 Spring Pin (6x25)20 2701816 1 Plug21 4246601 1 Seal, Oil (14x22x7)22 4148084 2 Bush23 4148086 1 Spring24 2702658 2 Pin (9x16)25 2702655 2 Washer26 2702883 1 Washer27 2702884 1 E Ring28 2702654 2 E Ring


56

10

9

1

2

3

511

7

12

12

7

11

4

8

11

7

12

12

6

11

25.1 Gear Shift ForkManual Transmission

Serial No. All


57



1 4148260 1 Fork Assy, Low Speed Gear Shift

2 4148262 1 Fork Assy, High Speed Gear Shift3 4148263 1 Fork Assy, 5th & Rev Gear Shift4 4148264 1 Locating5 4148266 1 Shaft, Low Speed Gear Shf6 4148267 1 Spring, Low Speed Locating7 4148268 3 Spring, High & 5th Locating8 4148269 1 Lever, Reverse Gear Shift9 4148270 1 Lever, Low Gr Shf Inverse

10 4148064 2 Bolt (8x20)11 4148072 4 Bolt (10x10.5)12 2702630 4 Ball


58

6 7

13

2

14

276

24

24

23

8 12

15

19

19

17

16

18

20

17

11

9

10

5

4

3

11 8

12

21 22 1

26

25

26.1 Transmission CaseManual Transmission

Serial No. All


59



1 4148251 1 Case, Transmission Front

2 4148253 1 Case, Transmission Rear3 2702694 1 Plug4 2702693 1 Hose (7x11x600)5 2702692 1 Plug, Breather6 4148073 2 Plug7 4246598 1 Gasket (14x20x1.5)8 2702688 2 Bolt, Stud9 2702686 1 Bolt

10 2702687 1 Bolt11 2702690 2 Pin12 2702689 2 Nut13 2702659 9 Bolt14 2702690 2 Pin15 4148255 1 Case, Extension16 4119610 1 Seal, Ext Case Oil17 2702684 2 Plug18 2702659 8 Bolt19 2702690 2 Pin20 4246693 1 Hook21 4148391 1 Switch Assy, Back Up22 4148082 1 O Ring23 4141013 1 Stiffener, Eng & T/m24 2702470 5 Bolt25 4148096 1 Hook Transmission26 2701827 1 Bolt27 4148069 1 Gasket


60

1

2

3

5

4

27.1 Shift BracketsManual Transmission

Serial No. All


61



1 4140431 1 Knob, Cont Lever (Black)

2 2702696 1 Boot, Gear Shf Cont Lever3 4142772 1 Bracket, Cont Cable4 4148066 4 Bolt5 2701827 3 Bolt


62

3 45

6

2

7 1

8

28.1 Torque Converter & Flex PlateAutomatic Transmission

Serial No. All


63



1 4246691 1 Transmission Assy, Automatic

2 4120096 1 Flange, Drive Plate3 4120097 1 Plate, Drive4 4120098 1 Plate, Drive Rear5 4119955 6 Bolt (10x18.5)6 4148213 1 Converter, Torque7 4246592 5 Bolt (8x9.5)8 4246593 1 Bolt


64

1

2

29.1 Case GasketsAutomatic Transmission

Serial No. All


65



1 2702748 1 Gasket Set, At

2 2702749 1 • Gasket, T/m Oil Pan


66

18

18

1617

9

9

1

2

15

20

19

6

8

7

10

13

1214

13 12

5

5

4

14

3

11

24

21

24

23

22

30.1 Transmission CaseAutomatic Transmission

Serial No. All


67



1 4141032 1 Case Set, Transmission

2 2702751 1 • Plug, Breather3 4148252 1 Housing, Torque Converter4 2702753 6 Bolt, Housing5 4148280 2 Washer6 4148256 1 Housing Set, Extension7 4119610 1 • Seal, Ext Case Oil8 4141034 5 Bolt (8x35)9 2702494 2 Nut

10 2702756 1 Bolt11 2702686 1 Bolt12 2702688 2 Stud Bolt13 2702689 2 Nut14 2702690 2 Pin15 2702759 1 Hook, Engine16 2702760 1 Plug, Booster17 2702761 1 • O Ring18 2702762 2 Bolt, Case Stud19 2702763 1 Bracket, Connector Clamp20 4120102 1 Bolt, Connector Clamp Brkt21 2702764 1 Bolt22 4141035 1 Stiffener, Eng & T/m23 2702519 1 Bolt24 2702470 4 Bolt


68

1

2

4

3

31.1 Oil PumpAutomatic Transmission

Serial No. All


69



1 4141014 1 Pump Assy, Oil

2 2702766 1 • Seal, Oil Pump Body Oil3 2702767 8 Bolt4 2702768 1 Seal Ring Set, Oil Pump


70

57

6

8

4

3

1

2

32.1 Input Shaft & ClutchAutomatic Transmission

Serial No. All


71



1 4120103 1 Shaft Set, Input

2 4119612 1 • Plate Set, Forward3 4120104 1 • O Ring Set, Forward Cl4 4148220 1 Thrust Brg Set, No.15 4148358 1 Clutch Assy, Direct Mult Disk6 4119613 1 • Plate Set, Direct Clutch7 4120106 1 • O Ring Set Direct Clutch8 2702776 1 Washer Set, Direct Clutch


72

6

13

12

5

3

4

2

11

7

8

9

10

14

1

33.1 Planetary GearsAutomatic Transmission

Serial No. All


73



1 2702777 1 Gear Assy, Fr Plnty Ring

2 2702778 1 Thrust Brg Set, No.33 2702779 1 Gear Assy, Front Plnty4 2702780 1 Thrust Brg Set, No.45 2702781 1 Thrust Brg Set, No.56 4246695 1 Gear Assy, Plnty Sun7 2702783 1 Thrust Washer Set8 2702784 1 Gear Assy, Rear Planetary9 4148221 1 Thrust Brg Set, No.1

10 4120107 1 Clutch Set, One Way11 4141015 1 Plate Set, 1st & Rev12 2702788 1 Piston Set, 1st & Rev13 2702789 1 • O Ring Set, 1st & Rev14 4120108 1 Retainer, Outer Race


74

4

6

2

3

51

34.1 Output ShaftsAutomatic Transmission

Serial No. All


75



1 2702790 1 Shaft Set, Output

2 2702791 1 • Ring, Parking Lock Gear3 2702792 1 Seal Ring Set, Shaft4 2702793 1 Ring, Speedometer Exciter5 2702794 1 Circlip, Exciter Ring6 2702795 1 Thrust Brg Set, No.6


76

4

4

3

56

7

1

2

35.1 Parking BrakeAutomatic Transmission

Serial No. All


77



1 2702796 1 Parking Pawl Set

2 2701921 3 • Bolt3 4141016 1 Shaft Set, Mnl Lever4 2702798 2 • Seal, Manual Shift Shaft Oil5 2702494 1 • Nut6 4246702 1 • Washer, Manual Shift Shaft7 4141017 1 • Lever, Manual Shift Shaft


78

1

2

4

3

5

36.1 Brake BandAutomatic Transmission

Serial No. All


79



1 4141018 1 Band Set, 2nd Brake

2 4148359 1 Piston Assy, 2nd Brake3 2702803 1 Seal Ring Set, 2nd Brake4 2702804 1 Cover Set, 2nd Bk Piston5 2702805 1 Spring, 2nd Brake Pstn


80

8

11

13

12

5

2

1

4

3

67

9

37.1 Oil PanAutomatic Transmission

Serial No. All


81



1 2702806 1 Pan, T/m Oil

2 2702807 15 Bolt, Oil Pan3 2702808 1 Plug4 2702809 1 Gasket (12x16.7x2)5 2702810 1 Magnet, Oil Cleaner6 4148257 1 Tube Assy, Oil Filler7 2702813 1 • O Ring8 2702475 1 Bolt9 4148258 1 Gauge, Oil Level

10 4148254 1 Harness, Solenoid Wire11 2702817 1 Plate, Solenoid Wire Harn Hold12 2701921 1 Bolt


82

1

4

5

62

3

6

7

9

8

13

12

16

1724

14

15

23

182020202010

19

218

212018

920 922

11

11

910

8

38.1 ValveAutomatic Transmission

Serial No. All


83



1 4246703 1 Body Assy, T/m Valve

2 2702822 1 • Solenoid Assy, Direct Clutch3 2702823 1 • • O Ring4 2702824 1 • Solenoid Assy, 2nd Brake5 2702823 1 • • O Ring6 2702764 2 • Bolt, Solenoid7 2702825 1 • Strainer, T/m Oil8 2702826 2 • Bolt, Valve Body No.59 2702827 3 • Bolt, Valve Body No.6

10 2702839 2 • Bolt, Valve Body No.111 2702840 2 • Bolt, Valve Body No.212 4141020 1 Piston Set, C1 Acc13 4141021 1 Spring, Acc 2nd Brake Piston14 2702830 1 Piston Set, B1 Accum15 2702831 1 Spring, Acc 2nd Bk Pstn No.116 4141022 1 Spring, Acc Fwd Piston Lower17 4141023 1 Seal Ring Set, Acc18 2702834 2 Bolt, Valve Body No.219 2702835 1 Bolt, Valve Body No.320 2702836 6 Bolt, Valve Body No.121 2702837 2 Bolt, Valve Body No.422 2702838 1 Bolt, Valve Body No.623 2702841 1 Spring, Acc 2nd Bk Pstn No.224 4246704 1 Spring, Acc 2nd Bk Pstn No.3


84

1

5 22

22

4

43

39.1 Cooling TubesAutomatic Transmission

Serial No. All


85



1 2702844 1 Pipe, Oil

2 4246653 4 Gasket, Oil Pipe3 2702662 1 Cap4 4148085 2 Union5 2702537 1 Screw


86

5

4

3

21

40.1 Shift SwitchAutomatic Transmission

Serial No. All


87



1 2702545 1 Clamp

2 2702880 2 Bolt, Cable Bracket3 2702885 1 Switch Assy, Shift4 2702886 1 Bolt5 4246705 1 Bracket, Select Cable

88


SUZUKI 660 K6A YH625 41.1 Emission Control System

Serial No. All

Description Notes

Fuel Metering System:

Throttle BodyIntake ManifoldFuel FilterFuel Deliver RailFuel Injector

Ignition System:

Engine Coolant SensorThrottle Position SensorPressure SensorIdle Speed Control (ISC) ValveSpark Plug Covered up to the first replacement onlyKnock SensorCam Position SensorIgnition CoilIgnition ResitorElectronic Control Module (ECM)Crank Position Sensor

Exhaust System:

Catalytic ConverterExhaust ManifoldOxygen SensorAir/Fuel Sensor

Air Intake System:

Air Inlet Temperature SensorAir Cleaner Covered up to the first replacement onlyAir Cleaner Housing

Crankcase Emission Control System:

Oil Fill CapPositive Crankcase Ventilation (PCV) Valve

Parts Associated with the Systems Above

Tubing, Fittings, Clamps, Gaskets, Grommets, Hoses andMounting Hardware

INDEX

08331-41156............... 352701442...................... 392701513...................... 392701816.................. 7, 552701820...................... 352701821........................ 72701827.......... 13, 59, 612701829................ 11, 152701832........................ 72701834...................... 212701897...................... 312701898...................... 312701899...................... 312701908........................ 92701914.......... 11, 23, 432701916...................... 112701920...................... 112701921.......... 11, 77, 812701931...................... 152701937...................... 152701938...................... 152701949................ 15, 352701952...................... 152701970...................... 172701971...................... 172701972...................... 172701978................ 33, 412702001................ 25, 352702431...................... 232702469................ 21, 432702470...37, 45, 47, 59,

672702475.... 23, 29, 41, 812702484...................... 272702486.... 21, 31, 39, 412702489...................... 272702491...................... 272702494................ 67, 772702500...................... 292702501...................... 292702502...................... 292702513...................... 332702517...................... 352702519................ 35, 672702520...................... 232702537...................... 852702540...................... 392702541...................... 392702545...................... 872702547...................... 492702548...................... 492702549...................... 492702550...................... 492702552...................... 492702553...................... 492702554...................... 49

2702559 ................ 51, 532702581 ...................... 532702598 ...................... 512702600 ...................... 532702602 ...................... 512702603 ...................... 512702604 ...................... 532702630 ...................... 572702635 ...................... 552702648 ...................... 552702649 ...................... 552702651 ...................... 552702652 ...................... 552702654 ...................... 552702655 ...................... 552702658 ...................... 552702659 ..........35, 43, 592702661 ...................... 132702662 ...................... 852702684 ...................... 592702686 ................ 59, 672702687 ...................... 592702688 ................ 59, 672702689 ................ 59, 672702690 ................ 59, 672702692 ...................... 592702693 ...................... 592702694 ...................... 592702696 ...................... 612702748 ...................... 652702749 ...................... 652702751 ...................... 672702753 ...................... 672702756 ...................... 672702759 ................ 29, 672702760 ...................... 672702761 ...................... 672702762 ...................... 672702763 ...................... 672702764 ..........41, 67, 832702766 ...................... 692702767 ...................... 692702768 ...................... 692702776 ...................... 712702777 ...................... 732702778 ...................... 732702779 ...................... 732702780 ...................... 732702781 ...................... 732702783 ...................... 732702784 ...................... 732702788 ...................... 732702789 ...................... 732702790 ...................... 752702791 ...................... 752702792 ...................... 75

2702793 ...................... 752702794 ...................... 752702795 ...................... 752702796 ...................... 772702798 ...................... 772702803 ...................... 792702804 ...................... 792702805 ...................... 792702806 ...................... 812702807 ...................... 812702808 ...................... 812702809 ...................... 812702810 ...................... 812702813 ...................... 812702817 ...................... 812702822 ...................... 832702823 ...................... 832702824 ...................... 832702825 ...................... 832702826 ...................... 832702827 ...................... 832702830 ...................... 832702831 ...................... 832702834 ...................... 832702835 ...................... 832702836 ...................... 832702837 ...................... 832702838 ...................... 832702839 ...................... 832702840 ...................... 832702841 ...................... 832702844 ...................... 852702880 ...................... 872702883 ...................... 552702884 ...................... 552702885 ...................... 872702886 ...................... 872702895 ................45, 472702953 ...................... 412703002 ..........13, 29, 394117900 ...................... 494119604 ........................ 94119605 ...................... 114119606 ........................ 74119609 ..................5, 394119610 ................59, 674119612 ...................... 714119613 ...................... 714119615 ...................... 434119616 ...................... 434119617 ...................... 434119618 ...................... 434119955 ................15, 634119956 ....................7, 94119965 ..................5, 374119966 ........................ 7

4119967 ..................5, 394119971 ........................74119978 ......................154119979 ......................154119980 ......................154119981 ......................154119982 ......................154119983 ......................154119984 ......................154119986 ......................154120006 ........................94120007 ........................94120008 ........................94120009 ........................94120013 ......................114120015 ......................114120017 ......................134120018 ......................134120021 ......................154120023 ......................154120024 ......................154120028 ......................154120029 ......................154120032 ......................174120033 ......................174120035 ......................174120037 ......................214120038 ......................214120039 ......................214120041 ......................214120042 ......................214120056 ......................274120063 ......................294120076 ......................394120081 ......................394120092 ......................554120096 ......................634120097 ......................634120098 ......................634120102 ......................674120103 ......................714120104 ......................714120106 ......................714120107 ......................734120108 ......................734120114 ......................414120117 ......................414120121 ......................434120122 ......................434120123 ......................434120124 ......................434120125 ......................434120126 ......................434120129 ......................434139968 ......................114140431 ......................61

89

INDEX

4140617.......................234140618.......................234140891.....................5, 74140893...................5, 214140895.........................74140898.........................94140899.........................94140900.........................94140901.........................94140902.......................114140903.......................114140904.......................114140905.......................134140906.......................154140907.......................154140918.......................154140919.......................154140965.......................174140970.......................214140981...................5, 294140988.......................354140989.......................354140990.......................354140992.......................394140993.......................414140999.......................414141000.......................414141002.......................414141013.......................594141014.......................694141015.......................734141016.......................774141017.......................774141018.......................794141020.......................834141021.......................834141022.......................834141023.......................834141031.......................234141032.......................674141034.......................674141035.......................674142772.......................614148058.......................394148059.......................434148060.......................534148061.......................294148062.......................114148063.......................554148064.......................574148066.......................614148067.......................534148069.......................594148072.......................574148073.......................594148074.......................51

4148075.......................514148076.......................514148077.......................514148078.......................514148079.......................514148080.......................514148081.......................514148082.......................594148083.......................514148084.......................554148085.......................854148086.......................554148088.........................94148090.......................274148091.......................274148096.......................594148100.......................214148101.......................214148102.......................174148103.......................174148104.......................174148105.......................174148106.......................174148107.......................174148108.......................174148109.......................174148110.......................174148111.......................174148112.......................174148113.......................174148114.......................174148115.......................174148116.......................174148117.......................174148118.......................174148119.......................174148120.......................174148121.......................174148122.......................174148123.......................174148124.......................174148125.......................174148126.......................174148127.......................174148128.......................174148129.......................174148130.......................174148131.......................174148132.......................174148133.......................174148134.......................174148135.......................174148136.......................174148137.......................194148138.......................194148139.......................19

4148140 ...................... 194148141 ...................... 194148142 ...................... 194148143 ...................... 194148144 ...................... 234148145 .................. 5, 234148146 ...................... 234148150 ...................... 394148151 ...................... 294148152 ...................... 294148197 ...................... 334148198 ...................... 314148199 ...................... 314148201 ...................... 354148202 ........................ 74148203 ...................... 114148205 ...................... 154148206 ...................... 394148207 ...................... 394148213 ...................... 634148214 ...................... 494148216 ...................... 514148217 ...................... 514148218 ...................... 514148219 ...................... 514148220 ...................... 714148221 ...................... 734148222 ...................... 514148223 ...................... 514148224 ...................... 514148225 ...................... 514148226 ...................... 514148227 ...................... 514148228 ...................... 514148229 ...................... 514148230 ...................... 514148231 ...................... 514148232 ...................... 514148233 ...................... 514148234 ...................... 514148235 ...................... 514148236 ...................... 514148237 ...................... 514148238 ...................... 514148239 ...................... 514148241 ...................... 514148242 ...................... 514148243 ...................... 514148244 ...................... 514148245 ...................... 514148246 ...................... 534148247 ...................... 534148248 ...................... 534148249 ...................... 534148250 ...................... 534148251 ...................... 59

4148252 ...................... 674148253 ...................... 594148254 ...................... 814148255 ...................... 594148256 ...................... 674148257 ...................... 814148258 ...................... 814148260 ...................... 574148262 ...................... 574148263 ...................... 574148264 ...................... 574148266 ...................... 574148267 ...................... 574148268 ...................... 574148269 ...................... 574148270 ...................... 574148275 ...................... 554148276 ...................... 554148280 ...................... 674148357 ...................... 534148358 ...................... 714148359 ...................... 794148360 ...................... 454148361 ...................... 474148362 ...................... 454148363 ...................... 474148364 ................ 45, 474148365 ................ 45, 474148368 ................ 45, 474148369 ................ 45, 474148371 ................ 45, 474148372 ...................... 454148373 ...................... 474148376 ...................... 434148381 ...................... 434148385 ...................... 414148386 ...................... 414148389 ...................... 414148390 ...................... 414148391 ...................... 594149901 ...................... 434235966 ...................... 294239342 ...................... 414239343 ...................... 414244102 ...................... 414246030 ...................... 414246510 ...................... 254246590 ........................ 74246591 ...................... 554246592 ...................... 634246593 ...................... 634246594 ...................... 234246595 ...................... 114246596 ...................... 294246597 ....................5, 74246598 ...................... 59

90

INDEX

4246600........................ 94246601...................... 554246602...................... 154246610........................ 74246611........................ 74246613........................ 74246615........................ 54246616...................... 114246617...................... 154246619...................... 154246620...................... 154246621...................... 154246622...................... 154246623...................... 154246624...................... 154246625...................... 154246626...................... 174246627...................... 174246628...................... 174246629...................... 254246630...................... 254246631............ 5, 23, 254246633...................... 254246634...................... 354246637...................... 334246638...................... 334246639...................... 334246640...................... 354246641...................... 374246643...................... 534246644...................... 394246649...................... 294246651...................... 294246652...................... 254246653...................... 854246654...................... 514246655...................... 514246656...................... 554246690...................... 554246691...................... 634246693...................... 594246694...................... 554246695...................... 734246696...................... 554246697...................... 554246698...................... 554246699...................... 554246700...................... 554246701...................... 554246702...................... 774246703...................... 834246704...................... 834246705...................... 874246706...................... 414246708................ 45, 474246710................ 45, 47

4246712 ................ 45, 474246714 ...................... 414246715 ...................... 414246716 ...................... 414246717 ...................... 434246718 ...................... 414246719 ...................... 434246720 ...................... 414246721 ...................... 414246722 ...................... 414246723 ...................... 43452392 ........................ 39843857 ........................ 39

91

Jacobsen, A Textron Company11108 Quality Drive, Charlotte, NC 28273www.Jacobsen.com800-848-1636

When Performance Matters.™

Equipment from Jacobsen is built to exactingstandards ensured by ISO 9001 and ISO 14001

registration at all of our manufacturing locations.

A worldwide dealer network and factory trainedtechnicians backed by Genuine Jacobsen Partsprovide reliable, high-quality product support.

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