Dixon KODIAK 52, 21 KAW/968999576, KODIAK 52, HONDA/968999577, KODIAK 52, 20 KOH/968999578, KODIAK 52, 25 KOH/968999579, KODIAK 60, 25 KOH/968999580, manual

KODIAK ® ZTR ® Operator ’ s manual KODIAK 52, 21 KAW/968999576, KODIAK 52, HONDA/968999577, KODIAK 52, 20 KOH/968999578, KODIAK 52, 25 KOH/968999579, KODIAK 60, 25 KOH/968999580, KODIAK 60, 25 B&S/968999581 English Please read the operator’s manual carefully and make sure you understand the instructions before using the unit.[...]

2 IMPORT ANT - READ CAREFULL Y The Dixon ® ZTR ® mower is both easy and fun to operate. However , any power mower must be operated properly to be safe. It is not a toy or a recreational vehicle. Before you start to use the mower , read this Operator ’ s Manual carefully . It contains valuable information that is necessary for the safe operation[...]

3 T ABLE OF CONTENTS Page SAFETY & W ARNING ....................................4-15 W ARRANTY ........................................................16 SPECIFICA TIONS.............................................17 SEA T ADJUSTMENT .........................................18 CONTROLS.................................................. 19-21 OPE[...]

SAFETY 4 Blade Contact Tip Over Run Over Back Over RIDING LA WN MOWERS, IF IMPROPERL Y OPERA TED CAN CAUSE SERIOUS INJURY OR DEA TH Pictured below are the most common causes of injury to the operator or bystander . Please read and understand this manual to prevent injuries.[...]

SAFETY 5 Safety Alert Symbol When you see this symbol, BE ALERT to the potential for injury . Follow the recommended safety precautions and safe operating practices. DANGER (highlighted in red) indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury . WARNING (highlighted in orange) indicates a pote[...]

W ARNING 6 Failure to observe the following safety instructions could result in serious injury or death. GENERAL OPERA TION: Read, understand, and follow all instructions in this manual and on the mower before starting. Only allow responsible adults, who are familiar with the instructions, to operate the mower . Clear the area of objects such as ro[...]

W ARNING 7 GENERAL OPERA TION (continued): Never leave a running mower unattended. Always turn off blades, set parking brake, stop engine and remove key before dismounting. T urn off blades when not mowing. Injury could occur from contact with moving parts. Under no circumstances should you place hands or feet under the mower deck or in the chute w[...]

W ARNING 8 Never dismount mower without applying parking brake or stopping engine. Protect your eyes. Always wear safety goggles or safety glasses with side shields when operating mower . Data indicates that operators, age 60 years and above, are involved in a large percentage of riding mower- related injuries. These operators should evaluate their[...]

W ARNING 9 SLOPE OPERA TION: Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. All slopes require extra caution. If you feel uneasy on a slope, do not mow it! DO Mow across the slope with your Dixon® ZTR® -- never up or down. This will decrease the risk of tip-over . Remove ob[...]

W ARNING 10 Keep all movement on the slopes slow and gradual. Do not make sudden changes in speed or direction. Use extreme caution when operating the mower with attachments to prevent tip-over or roll-over . If front wheels lift off the ground, pull levers back to stabilize the mower . Discontinue mowing the slope! When operating on slopes over 15[...]

W ARNING 11 SLOPE OPERA TION (continued): DO NOT Do not turn on slopes unless necessary , and then, turn slowly and gradually downhill, if possible. Rapid uphill turns may cause tip-over . Do not mow near drop-offs, ditches, or embank- ments. The mower could suddenly turn over if a wheel is over the edge of a cliff or ditch or if an edge caves in. [...]

W ARNING 12 FIRE HAZARDS: Use extra care when handling gasoline and other fuels. They are flammable and vapors are explosive. Store all fuel in approved containers specifically designed for that purpose. Allow engine to cool before refueling. Never remove fuel cap or add fuel with engine running. Do not smoke while refueling or operating the mower [...]

W ARNING 13 FIRE HAZARDS (continued): T o prevent fire or explosion, keep sparks and open flames away from battery . Keep electrical connections clean and tight. Inspect them often. Loose connections and corrosion increase fire risk. Before disconnecting the negative ground cable, make sure all switches are off. This decreases the chance of sparkin[...]

W ARNING 14 CHILDREN: Tragic accidents can occur if the operator is not alert to the presence of children. Children are attracted to lawn mowers and the mowing activity . NEVER assume children will stay where they were last seen. Be alert to avoid accidents. Keep children out of the mowing area and under the watchful care of another responsible adu[...]

W ARNING 15 SERVICE: Never run a mower inside a closed area or without proper ventilation. Keep nuts and bolts tight, especially blade attachment bolts, and keep equipment in good condition. Never tamper with safety devices. Check their proper operation regularly . Stop and inspect the equipment if you strike an object. Repair , if necessary , befo[...]

16 DIXON ® ZTR ® PRO SERIES COMMERCIAL/RESIDENTIAL W ARRANTY POLICY Black Bear TM , Kodiak ® , Mountain Kodiak ® , Kodiak ® Diesel, Grizzly™ & SilverTip™ Mowers DIXON® WARRANTS ITS ZTR® MOWERS AGAINST DEFECTS IN MA TERIAL AND WORKMANSHIP FOR THE PERIODS SET FORTH BELOW. THE SOLE REMEDY UNDER THIS WARRANTY IS REPLACEMENT OR REP AIR OF[...]

SPECIFICA TIONS 17 SPECIFICA TIONS SUBJECT TO CHANGE WITHOUT NOTICE Additional information may be provided elsewhere in this manual. KODIAK ® CHASSIS: 1 1 GA - rectangular tube SE A T : Designed for operator comfort by use of high-density closed cell foam padded back and arm rests, upholstered with Cordura TM water-repellent fabric. Seat is adjust[...]

18 SEA T ADJUSTMENT INSTRUCTIONS 1. Grasp seat slide adjuster and move it into adjustment position. 2. Slide seat forward or backward. 3. Release seat slide adjuster .[...]

CONTROLS 19 CONTROL LEVERS Note: For access to the seat, move control levers to neutral position and swing them outward. T O GO FOR W ARD •From neutral position, gently push control levers for- ward. •T o increase speed, move levers further forward. T O GO BACKW ARDS •From neutral position, gently pull control levers toward you. TURNING •T [...]

CONTROLS 20 CAUTION MOWER DECK CUT HEIGHT LIFT LEVER: • Located to the right and front of the operator . • Controls the cutting height. • Fifteen positions of adjustment • Depress trigger and move lever forward to lower deck. • Depress trigger and pull lever back to raise deck. Note: Always use high position for transport. P ARKING BRAKE:[...]

CONTROLS 21 BLADE DRIVE: •Located on the control panel, on operator’s right. •T o engage the mower blade, pull up on the switch. •T o disengage mower blade, push down. CHOKE AND THROTTLE CONTROL LEVERS: •Located on control panel to operator ’ s right. •Throttle control for engine speed. •Choke for engine starting. •Throttle contro[...]

OPERA TION INSTRUCTIONS 22 The safe and successful operation of the KODIAK™ will depend upon the operator having the correct knowledge of all controls used on the mower and making good judgements about the terrain to be mowed. NEVER allow anyone to operate the mower without complete knowledge of all controls and their functions. NEVER dismount mo[...]

OPERA TION INSTRUCTIONS 23 CAUTION Failure to follow these instructions may result in personal injury . ST ARTING INSTRUCTIONS: 1. Parking brake must be on, control levers in outward position and blade drive disengaged. 2. Position throttle to 1/2 speed setting. If engine is cold, position choke lever to the “on” position. NOTE: Engine may requ[...]

OPERA TION INSTRUCTIONS 24 P ARKING BRAKE SWITCH TEST : a) Swing control levers to outward position b) Disengage blade drive switch c) Put parking brake in OFF position d) Turn ignition switch to ST AR T Engine should not turn over or attempt to start. CONTROL LEVER SWITCH TEST : a) Disengage blade drive switch b) Put parking brake in ON position c[...]

OPERA TION INSTRUCTIONS 25 TESTING OF SAFETY INTERLOCK SYSTEMS: BLADE DRIVE SWITCH TEST : a) Put parking brake in ON position. b) Swing control levers to outward position. c) Engage blade drive switch. d) Turn ignition switch to ST AR T . Engine should not turn over or attempt to start. SEA T SWITCH TEST : a) In a SAFE AREA away from bystanders, st[...]

OPERA TION INSTRUCTIONS 26 MOWING WITH A MULCHING A TT ACHMENT : Mulching or recycling the grass clippings requires a totally different mowing approach than would be normal when side discharging or bagging the grass. There may be instances or conditions where it is not possible to hide all the recycled or mulched clippings. In order to achieve the [...]

OPERA TION INSTRUCTIONS 27 MOWING WITH A MULCHING A TT ACHMENT (continued): 7. Keep the underside of the mower deck clean. Remove all grass and dirt build-up from the underside of the pan, the baffles and deflectors after each use. Never , under any circumst ances, should you place hands or feet under the mower deck or in the chute while blades or [...]

OPERA TION INSTRUCTIONS 28 MOWING WITH A GRASS CA TCHER A TT ACHMENT : In order to achieve optimum performance when mowing with a grass catching attachment, please read and follow the tips listed below . 1. Read and follow the installation instructions that are included with your grass catcher . 2. Set engine speed control to the wide open or full [...]

OPERA TION INSTRUCTIONS 29 MOWING WITH A GRASS CA TCHER A TT ACHMENT (continued): 7. Maintain sharp blades throughout the cutting season. Some grass catching attachments require a “high-lift” blade. See your dealer for advice on the type of blade(s) needed for your mower . 8. Some mowing applications/use of grass catchers may require that an ad[...]

OPERA TION INSTRUCTIONS 30 SIDE DISCHARGE OF THE CLIPPINGS: In order to achieve optimum performance when side discharging the grass clippings, please read and follow the tips listed below . Additional information can be found in the T roubleshooting guide. CAUTION T o avoid personal injury , be sure that the deflector is properly installed on the d[...]

OPERA TION INSTRUCTIONS 31 GRASS HEIGHT & CUTTING SUGGESTIONS: Do not attempt to cut grass when it is wet. If the grass is tall, place the mower deck cut height lever in the top or second notch. “Initially” overlap cutting swaths instead of a full swath with each pass. Some applications may require a second cutting. Keep the underside of th[...]

OPERA TION INSTRUCTIONS 32 TOWING TRAILERS AND OTHER A TT ACHMENTS: T owing a trailer or other attachment is not recommended. TO FREE WHEEL MACHINE (Unlock Transmission): Always turn off engine before engaging or disengaging the hydro release (free wheel) lever . Never attempt to move the lever with the engine running. The hydro release valves are [...]

CARE AND MAINTENANCE 33 W ARNING Failure to observe the following instructions may result in personal injury . Before performing any maintenance, turn off engine, allow to cool & remove key . Use extreme care when working on machinery . Do not wear watch or jewelry . Do not wear loose fitting clothes, and observe all common safety practices wit[...]

CARE AND MAINTENANCE 34 CUTTER BLADE MAINTENANCE: CAUTION Stop engine and remove ignition key for safety . W ear heavy , thick gloves when holding onto cutter blade, avoid the sharp edge of the blade. Blades should be discarded when worn excessiv ely . DANGEROUS! DO NOT USE BLADE IN THIS CONDITION! When notch starts, discard blade New Blade Check s[...]

CARE AND MAINTENANCE 35 ENGINE: For complete maintenance and operating information of the engine, please refer to the maintenance instructions furnished by the engine manufacturer included in your Zero T urn Radius mower information packet. BA TTER Y : This is a maintenance-free battery and the fluid level cannot be checked. •Charge battery if re[...]

CARE AND MAINTENANCE 36 TIRES: Correct tire pressure is essential for efficient operation of the mower . Check tire pressure periodically . Inflate tires to the pressure listed below . Front tires 15 lbs. Rear tires 15 lbs. Lug nuts or lug bolts should be checked regularly for tightness. LUBRICA TION: CHASSIS: (1 1) grease zerks LOCA TIONS: deck li[...]

CARE AND MAINTENANCE 37 BEL TS: Check belts every 50 hours. Replace any belts found to be in poor condition.[...]

CARE AND MAINTENANCE 38 CAUTION HOT oil may cause burns. Allow engine to cool before draining oil. Hex Head Valve Stem CHANGING THE ENGINE OIL: 1. The oil drain valve is located on either side of the engine crankcase (depending on the type of engine installed on your ZTR®). 2. Place a suitable container under the drain valve hose. 3. T o drain, tu[...]

CARE AND MAINTENANCE 39 HOT oil may cause burns. Allow engine to cool before draining oil. OIL FILL: 1. Clean any spilled oil from engine and chassis. 2. Refill engine with type, and quantity of oil recom- mended by the engine manufacturer in engine literature. NOTE: Engine oil changes on the KODIAK™ will require replacement of the oil filter . T[...]

CARE AND MAINTENANCE 40 HYDROST A TIC TRANSMISSION FLUID & FIL TER SER VICE: Dirt or water in fluid can ruin the hydrostatic transmissions. SER VICE INTER V ALS: 1. Initial filter service - 100 hours 2. Every 500 hours or once a year thereafter . RECOMMENDED FLUID: All temperatures - 15W-50 Synthetic Hydrostatic Fluid ~or if not available~ Norm[...]

CARE AND MAINTENANCE 41 HYDROST A T FLUID MAINTENANCE PROCEDURE: Check the fluid level in hydrostatic transmission fluid reservoir after every 25 hours of usage. Clean the fluid reservoir cap and the area around it prior to removal. Check the fluid level. Fluid should be approximately 1/4” below top of fluid tank baffle. Replenish as needed with [...]

CARE AND MAINTENANCE 42 NEUTRAL ADJUSTMENT 1. Lift seat. 2. Block up the unit so that the drive wheels are off the ground. 3. Loosen ball joint jam nuts on control rod. Note: The front jam nuts are left hand threads. 4. With steering control arms in the “out” neutral position, start the engine and run at fast idle. 5. Adjust the neutral positio[...]

CARE AND MAINTENANCE 43 ELECTRICAL SYSTEMS: Keep all connections clean and tight. CLEANING THE MOWER: W ash mower periodically . Clean above and below deck. High pressure washing and alkaline based soaps can cause damage to bearings and other parts of the mower . After washing your mower , start the engine and engage the mower deck for a few minute[...]

CARE AND MAINTENANCE 44 MOWER DECK LEVELING PROCEDURE: Before performing any service or adjustment check list: 1. Engage parking brake. 2. Place blade-switch in the disengaged position. 3. Turn ignition switch to “OFF” position and remove key . 4. Make sure blades and all moving parts have com- pletely stopped. 5. Disconnect spark plug wire fro[...]

CARE AND MAINTENANCE 45 MOWER DECK LEVELING PROCEDURE (continued): 6. Check rear blade measurement, should be 4 1/4” from ground, if not turn locknut on top of rear eyelbolt to achieve measurement. Repeat procedure on opposite side. 8. If deck leveling cannot be achieved call T echnical Support at toll free number 1-877-288-6673. Leveling mower d[...]

46 1. ENGINE WON’T TURN OVER Mower blades engaged- - - - - - - - - - - - - - - - - - - disengage blades Parking brake not on- - - - - - - - - - - - - - - - - - engage parking brake Circuit breaker trips- - - - - - - - - - - - - - - - - - - - - - - - -reset breaker Dead battery- - - - - - - - - - - - - - - - - - - - - - - - - - charge or replace S[...]

47 TROUBLESHOOTING 6. ENGINE RUNS BUT MOWER WON’T MOVE FORWARD Drive belt broken or slipping- - - - - - - - - - - - - - - - replace drive belt T ransmission oil low- - - - - - - - - - - - - - - - - - - - - - - - - - - - add oil Damaged transmission- - - - - - - - - - - - - - - - - - - - - -consult dealer T ransmission by-pass may be engaged- - - [...]

48 ENGINE AIR AND OIL FIL TERS Refer to Engine Operator’s Manual for correct service intervals for engine oil changes and air filter maintenance. Protect your engine investment, use only original equipment filters. Refer to the Engine Operator’s Manual or ask your dealer for correct replacement parts. ST ANDARD SERVICE P ARTS LIST 52" Blad[...]

OWNER’S INFORMA TION Date of Purchase Mower Model Number Mower Serial Number Purchased From Name Address DA TE OIL CHANGED DA TE ENGINE TUNED Dixon~401 N. Commerce St. Beatrice, NE 68310[...]

Dixon® and ZTR® are registered trademarks of Dixon DIXON 401 N. Commerce S t.. Beatrice, NE 68310 KODIAK ® Part No. 1 14518Rir - 1 1/07/06 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. WARNING :[...]