1. Disengage PTO & Park ZTR
WARNING: Engine, muffler and transmission will be extremely hot. Be careful not to touch these areas to avoid injury.
- Make sure the PTO switch is in the disengaged position.
- Park the ZTR on a level surface and engage the parking brake.
- Allow the engine to cool down.
2. Remove Transmission Belt Cover
- Place the transmission belt cover wrench (Part #191512) over the end of the transmission shaft and turn counter clockwise until the belt cover comes off.
3. Remove Idler Arm Spring
- Remove the cotter pin and pull the idler arm spring off of the idler arm.
4. Loosen Drive Belt Idler Bolt
- With a 15/16" socket and ratchet, turn the drive belt idler bolt counter clockwise to loosen the belt.
- While holding the drive belt idler bolt, loosen the spring bolt by turning counter clockwise half of a turn with a 9/16" wrench. This will relieve the pressure on the idler arm.
- Then continue turning the drive belt idler bolt counterclockwise until the belt can be removed.
5. Remove Existing Transmission Belt
- Pull the belt off of the PTO clutch pulley and slide the belt up and over the idler pulley and off of the engine pulley.
6. Inspect Idler Arm Pulley
- While the belt is off, inspect the idler arm pulley for damage.
- If the bearing in the idler arm pulley feels rough, replace the pulley.
- If the pulley spins freely and there is no looseness, reinstall the pulley.
- If necessary, replace the idler arm spring.
- Make sure the idler arm moves smoothly and is not damaged.
- If the idler arm is damaged or will not move smoothly, replace it.
7. Install New Drive Belt
- Slide the new drive belt onto the engine pulley.
- Run the belt up over the idler pulley and slide the belt onto the PTO clutch pulley.
8. Tighten Drive Belt
- With the belt installed on all the pulleys, hold the drive belt idler pulley against the belt with a 15/16" socket and ratchet and turn the drive belt idler tension bolt clockwise until the belt has .25" to .30" of deflection when pressed in the middle of its longest span with 10 lbs. of force.
9. Reinstall Idler Arm Spring
- Slip the idler arm spring onto the idler arm and install the cotter pin to secure it.
10. Reinstall Transmission Belt Cover
- Place the transmission belt cover over the pulley system so that the belt is inside the channel and the cover lip goes behind the idler arm pulley and the PTO arm.
- Ensure the belt cover lip is also behind the idler arm pivot bolt.
- Push down on the cover and turn clockwise until it pops in place.
NOTE: Verify the belt is properly installed and seated on all pulleys.
