Service Manual
TABLE OF CONTENTS
iToro Z Master G3 3000/5000/6000 Series Service Manual
1 - Safety Information
General Information .........................................................................................................................................1-1
Think Safety First.............................................................................................................................................1-1
2 - Specications
Torque Specications ......................................................................................................................................2-1
Standard Torque for Dry, Zinc Plated & Steel Fasteners (Inch Series) ...........................................................2-2
Standard Torque for Dry, Zinc & Steel Fasteners (Metric Fasteners) ..............................................................2-3
Other Torque Specications ............................................................................................................................2-4
Equivalents & Conversions..............................................................................................................................2-5
Decimal & Millimeter Equivalents ..............................................................................................................2-5
U.S. to Metric Conversions .......................................................................................................................2-6
G3 3000/5000/6000 Series Specications ......................................................................................................2-7
G3 3000/5000/6000 Series Specications cont...............................................................................................2-8
G3 3000/5000/6000 Series Specications cont...............................................................................................2-9
Dimensions ....................................................................................................................................................2-10
Commercial 3000 Series .........................................................................................................................2-10
G3/Professional 5000 Series ..................................................................................................................2-10
Dimensions .................................................................................................................................................... 2-11
G3/Professional 6000 Series .................................................................................................................. 2-11
Dimensions ....................................................................................................................................................2-12
G3/Professional 6000 Series cont. .........................................................................................................2-12
3 - Chassis
Caster Fork Assembly Replacement ...............................................................................................................3-1
Caster Fork Assembly Removal ................................................................................................................3-1
Caster Bearing Replacement ..........................................................................................................................3-2
Caster Fork Assembly Installation .............................................................................................................3-4
Front Wheel Bearing Replacement .................................................................................................................3-5
Front Wheel Bearing Removal ..................................................................................................................3-5
Front Wheel Bearing Installation ...............................................................................................................3-7
Fuel Tank Replacement ...................................................................................................................................3-9
Fuel Tank Removal ...................................................................................................................................3-9
Fuel Tank Installation ..............................................................................................................................3-12
Throttle Control Assembly Replacement (Kohler EFI Engine).......................................................................3-14
Throttle Control Assembly Removal ........................................................................................................3-14
Throttle Control Assembly Installation .....................................................................................................3-16
Park Brake Handle Assembly Replacement (2012 & Later) ..........................................................................3-18
Park Brake Handle Removal (2012 & Later) ...........................................................................................3-18
Park Brake Handle Installation (2012 & Later) ........................................................................................3-20
Park Brake Cable Replacement (2011 & Prior) .............................................................................................3-21
Left Park Brake Cable Removal (2011 & Prior).......................................................................................3-21
Left Park Brake Cable Installation (2011 & Prior)....................................................................................3-24
Right Park Brake Cable Removal (2011 & Prior) ....................................................................................3-27
Right Park Brake Cable Installation (2011 & Prior) .................................................................................3-29
Adjusting the Parking Brake ..........................................................................................................................3-32
Park Brake Cable Replacement (2012 & Later) ............................................................................................3-34
Left Park Brake Cable Removal (2012 & Later) ......................................................................................3-34
Left Park Brake Cable Installation (2012 & Later) ...................................................................................3-37
Right Park Brake Cable Removal (2012 & Later) ...................................................................................3-41
Right Park Brake Cable Installation (2012 & Later) ................................................................................3-44