Parts List Complete for PIONEER XL24
 

Deck Assembly - 154-0075
RefNbr Part Number Description Req Notes
401 999-0124 Screw 1/4-20 x 1 1/4 button head socket cap plain finish 6
402 999-0016 Washer 1/4 flat plain finish 12
403 154-1070 BX49 belt 1
404 154-0128 Flexi-disc 1
405 154-0268 Washer 3/4 x 39/64 stainless steel 1
406 154-0127 Velcro stud 76
407 154-0534 24 inch pad driver assembly 1
408 999-0152 Nut 1/4-20 nylon insert lock zinc plated 6
410 154-0689 Spindle with 7 1/4 inch pulley 1
411 154-0285 Clevis pin 2
412 999-0024 Washer 5/16 flat stainless steel 4
413 999-0211 Nut 5/16-18 hex nylon insert lock zinc plated 4
414 154-0691 Front wheel bracket assembly 2
415 991-2015 Rear caster wheel 1
416 991-2012 5 inch wheel 2
417 154-0393 24 inch low profile shroud bumper 1
418 997-1002 Pop rivet 3/16 x 7/16 7
420 154-0199 Grommet 1
421a 991-2201 Center-Lok II pad holder - right hand thread (black) 1
421b 991-2202 Big mouth pad holder set (blue) 1 (NON-OEM)
422 999-0050 Nut 1/2-13 hex jam plain finish 1
423 997-2515 Cotter pin 2
424 999-0115 Bolt 1/2-13 x 1 hex head grade 5 4
426a 154-0019 Hour meter 1 (OEM)
426b 991-8559 Hour meter 1 (NON-OEM)
427 999-0225 Screw 5/16-18 x 1 button head socket plain finish 4
428 999-0033 Washer 7/16 SAE flat 1
429 154-0263 Hour meter ground wire (OBSOLETE) 1
42c 991-8577 Pad retainer 1 (NON-OEM)
430 154-0733 Deck 24 inch (OBSOLETE) 1
431 154-0681 24 inch low profile skirt assembly (OBSOLETE) 1
433 154-0557 24 inch pad driver with studs 1
434 999-0649 Bolt 3/8-16 x 1 1/4 hex head stainless steel 1

Handle Assembly - 154-0076
RefNbr Part Number Description Req Notes
100 154-0146 Mounting base with adhesive (OBSOLETE) 2
101 154-0117 Trim (sold by the foot) 9.25 in
103 154-0147 Throttle cable for Briggs and Kawasaki (OBSOLETE) 1
104 154-0148 Throttle plate for Briggs and Kawasaki (OBSOLETE) 1
105 154-0149 Throttle knob 1
106 999-0225 Screw 5/16-18 x 1 button head socket plain finish 4
107 999-0226 Screw 6-32 x 1/2 round head slotted zinc plated 2
109 999-0144 Nut 6-32 k-lock zinc plated 2
110 999-0211 Nut 5/16-18 hex nylon insert lock zinc plated 4
111 999-0152 Nut 1/4-20 nylon insert lock zinc plated 6
112 154-0319 Starter switch with ground prong (2 keys) 1
114 999-0229 Screw 1/4-20 x 1 button head socket plain finish 2
115 999-0086 Nut 10-32 nylon insert lock zinc plated 4
116 154-0082 Hinge (OBSOLETE) 2
117 999-0231 Screw 10-24 x 1/2 round head slotted zinc plated 4
118 154-0208 Regulator sub assembly (OBSOLETE) 1
119 992-0001 Velcro loop (sold by the inch) 2 in
120 999-0242 Screw 3/8-16 x 4 carriage head grade 5 zinc 2
124 154-0337 Positive battery cable 1
125a 154-0077 Handle grip 2
125b 991-8571 Handle grip 2 (NON-OEM)
126 999-0024 Washer 5/16 flat stainless steel 6
127 154-0071 Adjustable handle lever 1
128 999-0234 Nut 3/8-16 acorn nickel plated 1
129 999-0032 Washer 3/8 USS flat plain finish 1
130 154-0338 Negative battery cable 1
132 999-0235 Screw 1/4-20 x 3/4 button head socket plain finish 1
133 154-0279 Starter solenoid (remote mounted) 1
134 154-0005 Propane tank strap 1
135 999-0232 Screw 3/8-16 x 1 1/4 carriage head grade 5 zinc 5
136 999-0188 Nut 3/8-16 nylon insert lock zinc plated 5
137 992-0002 Velcro hook (sold by the inch) 2 in
138 999-0016 Washer 1/4 flat plain finish 2
139 154-0232 Battery clamp (OBSOLETE) 1
140 154-0086 Rubber battery clamp (OBSOLETE) 2
141 154-0084 Battery clamp hook (OBSOLETE) 2
142 162-0001 12V 35Ah AGM battery 1
143 154-0093 Battery pad (OBSOLETE) 2
144 154-0636 Battery tray assembly 1
145 999-0019 Bolt 1/4-20 x 5/8 hex head grade 5 zinc plated 2
146 999-0054 Screw 8-32 x 1 round head slotted zinc plated 1
147 999-0151 Nut 8-32 nylon insert lock zinc plated 1
148 154-0355 Banding buckle (OBSOLETE) 1
149 154-0036 Plastic hose clamp 2
150 154-0320 Fuel line (sold by the foot) 3 ft
151 154-0351 Vacuum hose (sold by the foot) 3 ft
152 154-0600 Lock washer 4
154 992-0001 Velcro loop (sold by the inch) 20 in
155 992-0001 Velcro loop (sold by the inch) 14 in
156 992-0001 Velcro loop (sold by the inch) 12 in
157 991-6004 Female quick coupler 1
158a 154-0098 12 inch regulator hose 1
158b 154-0206 12 inch regulator hose with fittings kit 1
159 154-0341 Regulator assembly 1
160 154-0168 Fuel adjustment 1
161 154-0169 Female brass fitting 1
162 154-0090 Fitting (regulator to fuel lock) 1
163 154-0228 Hosebarb 1/8 x 1/4 inch 2
164 999-0130 Screw 5/16-18 x 3/4 socket head alloy plain finish 2
165 999-0028 Washer 5/16 split lock plain finish 2
166 999-0211 Nut 5/16-18 hex nylon insert lock zinc plated 2
167 154-1065 Steel propane tank 1
168 991-6002 12V fuel lock off (Model 152) 1
169 154-0066 Fitting 49 x 6 (regulator to fuel lock) 2

- Kawasaki - Muffler - Dust Bonnet - Emission System - 154-1036
RefNbr Part Number Description Req Notes
001 154-0244 Kawasaki dust bonnet
002 154-0245 Filter cage
003 178-0001 Exhaust manifold gasket
004 N/A Not available (Emission system)
005 154-0249 Kawasaki manifold and muffler
006 N/A Not available (Muffler clamp)
007 154-0249 Kawasaki manifold and muffler
008 991-1601 Oxygen sensor 1 wire (OBSOLETE)

-Engine- Kawasaki FH381V - 154-2046
RefNbr Part Number Description Req Notes
1 178-0137 Woodruff key 1
2 178-7114 Flywheel 1
4 178-0023 Voltage regulator 1
5 178-7115 Charging coil 1
6 178-0104 Spring 1
7 178-7116 Camshaft assembly 1
8 178-7081 120V electric starter 1 (includes 9 and 10)
9 N/A Not available 1 (Starter gear assembly)
10 178-7117 Armature 1
11a 178-0014 Plastic Kawasaki dipstick 1
11b 178-0016 O-ring 1
12a 178-0003 Oil filter Kawasaki 1 (OEM)
12b 991-7117 Oil filter 1 (NON-OEM)
14 178-7118 Stud bolt 2
15 178-7101 Ignition coil assembly 1
17 166-0004 Spark plug (Kawasaki FH500V/FH541V/FH381V) 2
18a 154-0143 Oil pressure switch with 2 prongs 1 (Pioneer)
18b 170-3221 Oil pressure switch, 3-prong molded plug 1 (Alto-Clarke)
18c 372-3186 Adapter 1 (Alto-Clarke)
19a 178-7096 Carburetor 1
19b 178-0042 Carb intake gasket 1
21 170-3241 Spud kit 1 (Alto-Clarke)
22a 178-7085 Air filter element 1
22b 178-0222 Air filter 1
23 178-0223 Pre-filter 1
24 178-7071 Front air filter case 1
25 178-7073 Rear air filter case 1
27 178-7119 Breather plate and gasket 1
28 178-0043 Top oil seal (upper crankshaft - Kawasaki) 1
29 178-7120 Crankcase 1
30 178-7121 Crankcase cover 1
31 178-0084 Oil seal 1
32 178-0033 Bottom oil seal 1
33 178-7092 Cylinder head gasket 2
34a 178-7099 Bare cylinder head #1 1
34b 178-7100 Bare cylinder head #2 1
35a 178-0013 Rocker cover gasket 2 (OEM)
36 178-0078 Rocker case 2
37 178-0076 Rocker arm 2
38 178-0047 Valve spring 2
39 178-0030 Intake valve 1
40 178-0029 Exhaust valve 1
41 178-0010 Oil drain adapter 1
42 154-0362 Oil drain valve 1 (Pioneer)
43 154-0037 Tubing 1/2 x 5/8 (clear) (sold by the foot) 1 ft
44 154-0038 Oil drain cap 1 (Pioneer)
45 178-0129 Spark plug wiring harness 1
46 178-7080 13 HP crankcase cover gasket 1
N/S 178-0287 Intake manifold 1
N/S 178-7022 Intake manifold gasket 1
N/S 270-0757 Catalytic muffler 1 (Alto-Clarke)
N/S 154-3432 Catalytic muffler and manifold assembly 1 (Pioneer)
N/S 169-0142 Muffler plug 1
N/S 178-0001 Exhaust manifold gasket 2
N/S 991-1601 Oxygen sensor 1 wire (OBSOLETE) 1
N/S 154-0008 Electric clutch assembly 1 (Pioneer clutch models)
N/S 178-7097 Fuel filter 1
N/S 991-1810 Compression tester 1
N/S 991-1832 Emission tester 1
N/S 154-1042 SafeSense emission monitoring module retro kit 1 (Pioneer)
N/S 991-6002 12V fuel lock off (Model 152) 1
N/S 991-6001 Fuel regulator (T60) 1
N/S 170-2003 Catalytic converter muffler (OBSOLETE) 1
KIT 050-0113 Kawasaki FH381V 100 hour kit 1 (includes oil filter, pre-air filter, air filter and spark plug)
N/S 991-4039 Spark plug tester 1

- Commonly Asked For Parts - 154-9998
RefNbr Part Number Description Req Notes
01 154-9026 13HP recoil filter
02 154-9027 17HP dust bonnet
03 160-0006 48 inch throttle control cable
04 154-3563 Wiring harness for 12V start (OBSOLETE)
05 999-0208 Bolt 7/16-20 x 1 1/2 hex head grade 5 zinc plated (holds the engine pulley on)

-Engine- Onan Elite - 169-4001
RefNbr Part Number Description Req Notes
101 991-6004 Female quick coupler 1
102 164-0565 90 degree brass elbow 1
103 991-6007 Propane fuel hose 1
104 169-0046 Engine wiring harness 1
105a 169-0072 Fuel shutoff valve (OBSOLETE) 1
105b 169-0048 Fuel and sensor system assembly (OBSOLETE) 1 (includes fuel lock-off, duty solenoid, power supply harness, vapor regulator, control unit and oxygen sensor)
106a 169-0049 Oil filter 1
106b 164-0903 Oil filter wrench (OBSOLETE) 1
107 154-0143 Oil pressure switch with 2 prongs 1
108 169-0051 12V starter 1
109 169-0052 Dust bonnet 1 (dust bonnet)
110 164-0907 Decal kit (OBSOLETE) 1
112 N/A Not available 1 (LPG control unit)
113 169-0054 Voltage regulator 1
114 164-0907 Decal kit (OBSOLETE) 1
115 169-0055 Muffler guard 1
116 169-0026 Spark arrestor 1
117 169-0009 Catalytic muffler (Onan 14) 1
119 166-0003 Spark plug for propane buffers 1
120 169-0058 Spark plug boot 1
121 991-1601 Oxygen sensor 1 wire (OBSOLETE) 1
122 169-0060 Air cleaner cover 1
123 999-0022 Bolt M10-1.5 x 30mm hex head full thread 1
124 999-0671 Washer M10 split lock plain finish 1
125 999-0035 Washer 3/8 x 1 1/2 fender 1
126a 164-0922 Centrifugal clutch (OBSOLETE) 1
127 164-0923 Square keyway 1
128 164-0924 Motor shaft collar 1
129 169-0021 Air cleaner lock nut (OBSOLETE) 1
131 154-0042 Oil drain valve kit 1
132 169-0062 Inner cover knob 1
133 169-0063 Element cover 1
134 169-0064 Element wrapper 1
135 169-0065 Air cleaner element 1
136 999-0030 Bolt 5/16-18 x 5/8 hex head grade 5 zinc plated 1
137 999-0028 Washer 5/16 split lock plain finish 1
138 999-0024 Washer 5/16 flat stainless steel 1
139 164-0934 P clamp 1
140 999-0188 Nut 3/8-16 nylon insert lock zinc plated 1
141 N/A Not available 1 (Fuel solenoid)
142 169-0067 Fuel hose 1
143 169-0068 Vapor regulator (OBSOLETE) 1
144 999-0016 Washer 1/4 flat plain finish 1
145 999-0297 Bolt 1/4-20 x 1 hex head stainless steel 1
146 999-0032 Washer 3/8 USS flat plain finish 1
147 999-0039 Bolt 3/8-16 x 1 1/4 hex head grade 5 zinc plated 1
148 164-0943 Fuel system bracket (OBSOLETE) 1
149 999-0015 Nut 1/4-20 k-lock zinc plated 1
150 999-0016 Washer 1/4 flat plain finish 1
151 164-0945 Fuel system clamp 1
152 999-0018 Bolt 1/4-20 x 1/2 hex cap grade 5 zinc plated 1
153 999-0015 Nut 1/4-20 k-lock zinc plated 1
154 164-0947 45 degree elbow 1
155 169-0093 Crankshaft lower seal 14 HP 1
156 154-0264 Silicon rectifier diode 1
N/S 155-0003 Motor oil 10W30 1
N/S 169-0007 Muffler bracket for 14 HP Onan 1
N/S 169-0139 Governor spring 14 HP (OBSOLETE) 1
N/S 169-0141 Gasket set 1
N/S 169-0174 Dipstick with cap 5-3/4 inch (Onan 14 HP) (OBSOLETE) 1
N/S 169-0179 Vacuum hose 1
N/S 169-0598 Dipstick with cap 9-5/8 inch (Onan 14 HP) (OBSOLETE) 1
N/S 991-1301 30amp glass fuse 1
N/S 991-1803 Oxygen sensor socket 1
N/S 991-1804 13/16 Spark plug wrench with rubber boot & 1/2 drive 1
N/S 991-1810 Compression tester 1
N/S 991-1832 Emission tester 1
N/S 991-1901 Key 1
N/S 999-0546 Screw 5/16-18 x 1 socket head alloy plain finish 1
N/S 991-4039 Spark plug tester 1
KIT 050-0005 Onan 100 hour service kit 14 HP 1 (includes oil filter, pre-air filter, air filter and spark plug)

-Engine- Onan Performer - 169-4002
RefNbr Part Number Description Req Notes
101 991-6004 Female quick coupler 1
102 164-0947 45 degree elbow 1
103 991-6007 Propane fuel hose 1
104 991-1901 Key 2
105 169-0016 Key switch assembly with two keys 1
106 169-0017 Dust bonnet 1 (dust bonnet)
107 999-0670 Screw 10-32 x 1/2 button head 2
108a 169-0187 Engine mounted auto-shut down control unit (OBSOLETE) 1 (All models)
108b 164-3096 Handle mounted box oxygen sensor with wires (OBSOLETE) 1 (Warhorse only)
109 169-0018 Oil filter wrench (OBSOLETE) 1
110 164-0907 Decal kit (OBSOLETE) 1
112a 169-0021 Air cleaner lock nut (OBSOLETE) 1
112b 169-0013 Hood support stud 1 (has three legs) (the stud the air cleaner cover fastens to)
113 169-0019 Oil filter Onan 20 1
114 154-0143 Oil pressure switch with 2 prongs 1
115 169-0069 20HP voltage regulator 1
116a 169-0023 Ignition coil with brackets 1
116b 169-0045 Ignition coil without brackets 1
117 164-1154 Engine wire insulator (OBSOLETE) 1 (new models)
118 169-0024 Air filter pre filter wrapper 1
120 169-0025 Air filter cartridge (OBSOLETE) 1
121 164-0911 Caution decal (OBSOLETE) 1
122 166-0002 Spark plug for Onan 20 2
123a 169-0090 Oxygen sensor 3 wire 1 (newer style - mounts in barrel of muffler)
123b 991-1601 Oxygen sensor 1 wire (OBSOLETE) 1 (older style - mounts in arm of muffler)
123c 164-4001 Engine sensor kit 1 (for handle mounted sensor)
124a 169-0006 Plug wire kit 1
124b 165-0012 Spark plug boot (OBSOLETE) 1
125a 169-0008 Catalytic muffler (oxygen sensor in barrel) (Onan 20) 1 (newer style - as shown) (old style with arm mounted oxygen sensor not available)
125b 169-0010 Muffler gasket for 20 HP Onan 2
126 169-0026 Spark arrestor 1
127 999-0043 Bolt 7/16-20 x 1 1/4 hex head grade 5 zinc plated 1
128 999-0044 Washer 7/16 medium split lock 1
129 999-0033 Washer 7/16 SAE flat 1
130 999-0187 Washer 1/2 flat plain finish 1
131a 164-1042 Drive clutch (OBSOLETE) 1
132 164-0923 Square keyway 1
133 164-1043 Motor shaft collar 1
135 164-0398 Control valve (white clamp) 1
136 164-9118 P clamp 2
138 169-0027 Starter (ONAN PERFORMER ENGINE ONLY) 1
139 169-0028 Fuel regulator 1
140a 169-0072 Fuel shutoff valve (OBSOLETE) 1 (for the new style engine mounted emission control system)
140b 991-6002 12V fuel lock off (Model 152) 1 (you will need to clip the grounded wire for old style handle mounted sensor system)
141 169-0030 Wire harness assembly 1
142a 169-0142 Muffler plug 1 (old style)
142b 169-0143 Muffler plug shim 1 (old style)
143 154-0037 Tubing 1/2 x 5/8 (clear) (sold by the foot) 1 ft
144 169-0180 Fuel hose 1
145 154-0264 Silicon rectifier diode 1
KIT 050-0003 Onan 20 -100 hour service 1 (includes oil filter, pre-air filter, air filter and spark plug)
N/S 154-0042 Oil drain valve kit 1
N/S 155-0003 Motor oil 10W30 1
N/S 164-6531 Gasket-oil base-performer 1
N/S 169-0003 Valve cover gasket 1
N/S 169-0014 Hood for covering the air cleaner 1
N/S 169-0044 Head gasket (Onan 20) 1
N/S 169-0045 Ignition coil without brackets 1
N/S 169-0091 Capacitor (condenser) 1
N/S 169-0204 Crankcase breather 1
N/S 169-0346 Filter cage 1
N/S 169-0440 Breather tube 1
N/S 169-0684 Dipstick with cap 14-1/4 inch (Onan 20) (OBSOLETE) 1
N/S 991-1810 Compression tester 1
N/S 991-1832 Emission tester 1
N/S 169-0138 Governor Rod spring 1
N/S 169-0095 Governor return spring 20 HP 1
N/S 999-0018 Bolt 1/4-20 x 1/2 hex cap grade 5 zinc plated 2
N/S 999-0060 Washer 1/4 split lock plain finish 2
N/S 991-1800 5/8 Spark plug socketwrench w/rubber boot 3/8drive (OBSOLETE 1
N/S 169-0034 Intake manifold gasket 2
N/S 999-0031 Bolt 5/16-18 x 1 hex head grade 5 zinc plated 3
N/S 999-0132 Bolt 5/16-18 x 3/4 hex head grade 5 zinc plated 4
N/S 999-0028 Washer 5/16 split lock plain finish 4
N/S 169-0010 Muffler gasket for 20 HP Onan 2
N/S 991-4039 Spark plug tester 1
N/S 991-1803 Oxygen sensor socket 1

Typical Kawasaki and Honda Fuel Parts - 173-1536
RefNbr Part Number Description Req Notes
001 991-6004 Female quick coupler 1
002 991-6007 Propane fuel hose 1
003 160-0054 45 degree elbow fitting 1
004a 991-6006 Vacuum hose (sold by the foot) 3 ft (Honda)
004b 991-6006 Vacuum hose (sold by the foot) 2 ft (Kawasaki 13HP & 17HP)
005 991-6005 Fuel hose (sold by the foot) 2 ft
006 160-0049 Barb fitting 3/8 x 3/8mp 1
007a 991-6001 Fuel regulator (T60) 1
007b 154-0267 LP regulator kit -- everything needed to rebuild a regulator 1
008 991-6002 12V fuel lock off (Model 152) 1
009a 164-1343 Fitting 1/4 x 1/4 (OBSOLETE) 2 (Honda)
009b 164-1343 Fitting 1/4 x 1/4 (OBSOLETE) 1 (Kawasaki)
010 160-0153 Fitting 3/8 flare x 1/4mp 1
011 160-0047 Vacuum tee 1
012 160-0051 Regulator to lock-off hose (OBSOLETE) 1
013 991-6003 Vacuum fuel lock-off 1
014 161-0002 O-ring 1
016 189-0390 90 degree elbow fitting 1
017 991-6002 12V fuel lock off (Model 152) 1
018 999-1032 Screw 1/4-20 x 5/8 hex head stainless steel 2
019 189-6194 Fuel regulator (Model 60E) 1
020 991-6004 Female quick coupler 1
021 189-0392 Screw #10 x 5/8 pan head phillips 1
022 189-8264 Tube clip .75 1
023 991-6007 Propane fuel hose 1
024 189-0393 Fitting 3/8 MNPT x 1/2 barb 1
025 189-0394 Fuel hose 1
026 189-0395 Vacuum hose (Sold by foot) 1
027 189-0396 Fitting 1/4-28 brass 1
028a 154-1075 Fuel regulator 1
028b 991-6001 Fuel regulator (T60) 1 (NON-OEM)
029 154-0168 Fuel adjustment 1
030 154-1051 12V fuel lock off 1
031 154-2333 12 inch fuel hose assembly 1
032 154-0066 Fitting 49 x 6 (regulator to fuel lock) 1
033 154-1076 Female quick coupler 1
034 154-2348 Brass fitting 1
035 154-2349 Brass elbow fitting 1

-Engine- Honda - GXV340 and GXV390 - 177-9000
RefNbr Part Number Description Req Notes
001 154-0023 Bolt M8 x 30mm flanged 2 (2800 only)
002a N/A Not available 1 (includes 002b) (120v electric starter)
002b 154-0599 Electric starter cord (OBSOLETE) 1
003 154-0440 Screw M6 x 20mm 2
004 154-0539 Screw 8 x 2 1/2 sheet metal 2
005 177-0133 Bolt M6 x 40mm flanged 1
006 177-0141 Silicon rectifier assembly 1
007 N/A Not available 1 (Ignition coil assembly)
008 177-0128 Bolt 6 x 28mm flanged 2
009 999-0446 Screw 5/16-18 x 1 3/4 round head slotted zinc plated 1
010 999-0665 Nut M8-1.25 flange lock 2
011 N/A Not available 1 Re-coil dust filter for Honda 11 HP
012 999-0295 Nut 4-40 nylon insert lock stainless steel 1
013 154-0541 Throttle control cable 1
014 154-0542 Spacer (OBSOLETE) 1
015 999-1158 Washer #6 flat stainless steel 1
016 154-0544 Screw 4-40 x 3/4 UNF round head machine 1
017 154-0545 Choke lever knob (OBSOLETE) 1
018 154-0548 Choke lever bushing (OBSOLETE) 1
019 154-0547 Choke lever (OBSOLETE) 1
020 154-0546 Choke extension spring (OBSOLETE) 1
021 177-0190 Air cleaner cover (dual) 1
022 177-0202 Wing nut 1
023 177-0193 Air cleaner grommet 1
024 177-0203 Nut tool box setting 1
025 177-0022 Air filter element 1
026 177-0359 Bolt M8 x 16mm flanged 1
027 177-0188 Outer filter 1
028 177-0186 Elbow gasket 1
029 N/A Not available 1 (Air cleaner elbow)
030 154-0555 Centrifugal top clutch spacer (OBSOLETE) 1
031 154-0549 Square keyway 1
032a 154-0552 Centrifugal clutch 1 (includes 032b)
032b 154-0553 4 inch pulley AB sheave 1
033 154-0016 Bottom clutch spacer 1
034 999-0208 Bolt 7/16-20 x 1 1/2 hex head grade 5 zinc plated 1
035 999-0024 Washer 5/16 flat stainless steel 4
036 999-0028 Washer 5/16 split lock plain finish 2
037 154-0554 Screw 5/16-24 x 1 1/4 cap 2
038 999-0211 Nut 5/16-18 hex nylon insert lock zinc plated 2
039 177-0454 Cylinder head support gasket 1
040 177-0453 Cylinder head 1
041 177-0290 Valve guide (intake) 1
042 177-0288 Valve guide (exhaust) 1
043 177-0303 Spark plug (BPR5ES) (NGK) 1
044 177-0298 Washer 2
045 177-0294 Valve cover bolt 2
046 177-0014 Valve cover gasket 1
047 177-0293 Valve cover 1
048 177-0295 Valve cover bolt 1
049 177-0299 Valve cover washer 1
050 177-0301 Bolt M10-1.25 flange 2
051 177-0291 Valve guide clip 2
052 177-0206 Muffler protector 1
053 177-0204 Muffler (non-catalytic) 1
055 177-0214 Pipe gasket 1
056 177-0216 Stud bolt M8 x 70mm 1
057 154-0273 Stud bolt M8 x 60mm 1
058 177-0209 Pipe 1
059 999-0665 Nut M8-1.25 flange lock 6
061 177-0211 Pipe gasket 1
062 177-0139 Noise suppressor cap assembly 1
065a 177-0045 Oil filler cap assembly (OBSOLETE) 1 (includes 065b and 066)
065b 177-0015 Dipstick 1
066 177-0046 Oil filler cap gasket 1
067 177-0047 Oil filler tube 1 (includes 068)
068 177-0073 Extension collar 1
069 177-0076 Bolt 6x35 flange 1
070 177-0021 O-ring 1
071 177-0052 Bolt 20mm drain plug 1
072 177-0054 Washer 6mm plain 1
073 177-0055 Washer 20mm drain plug 1
074 177-0404 Recoil starter case assembly 1
075 177-0394 Recoil starter pulley 1
076 177-0397 Starter return ring 1
077 177-0400 Starter grip 1
078 177-0401 200 foot recoil starter rope 1
079 177-0405 Bolt 6 x 10 flange 3
N/S 177-0388 Oil filter 1 (GXV340)
N/S 991-1832 Emission tester 1
N/S 991-1810 Compression tester 1
N/S 991-6002 12V fuel lock off (Model 152) 1
N/S 991-6001 Fuel regulator (T60) 1
N/S 177-0158 Insulator gasket 1
N/S 177-0052 Bolt 20mm drain plug 1
N/S 177-0043 Oil level switch 1
N/S 177-0259 Engine Stop Switch Assembly 1
N/S 155-0003 Motor oil 10W30 1
KIT 050-0112 Honda GXV340/390 100 hour service kit 1 (includes oil filter, pre-air filter, air filter and spark plug)
N/S 991-4039 Spark plug tester 1

-Engine- Kawasaki FH500V/FH541V - 178-4021
RefNbr Part Number Description Req Notes
207a 178-0003 Oil filter Kawasaki 1 (OEM)
207b 991-7117 Oil filter 1 (NON-OEM)
217 999-0024 Washer 5/16 flat stainless steel 8
219 178-0004 Long rear stud 2
222 178-0006 Short front stud 2
228 999-0211 Nut 5/16-18 hex nylon insert lock zinc plated 4
229 154-0143 Oil pressure switch with 2 prongs 1
233 999-0673 Nut M6-1 acorn zinc plated 4
238 178-0043 Top oil seal (upper crankshaft - Kawasaki) 1
239 178-0010 Oil drain adapter 1
240 178-0016 O-ring 1
241a 178-0211 Left (while operating) cylinder head assembly (FH500V) 1 (This is an assembled cylinder head. Gaskets are included. You will need to reuse your rocker arms and rocker arm studs. Includes (1) 178-0013, (2) 178-0047, (1) 178-0030, (1) 178-0029, (1) 178-0028, (1) 178-0035, (1) 178-0001, (2) 178-0036, and (2) 178-0032)
241b 178-0212 Right (while operating) cylinder head assembly (FH500V) 1 (This is an assembled cylinder head. Gaskets are included. You will need to reuse your rocker arms and rocker arm studs. Includes (1) 178-0013, (2) 178-0047, (1) 178-0030, (1) 178-0029, (1) 178-0028, (1) 178-0035, (1) 178-0001, (2) 178-0036, and (2) 178-0032)
241c 178-7181 Left (while operating) cylinder head assembly (FH541V) 1 (This is an assembled cylinder head. Gaskets are included. You will need to reuse your rocker arms and rocker arm studs. Includes (1) 178-0013, (2) 178-0047, (1) 178-0030, (1) 178-0029, (1) 178-7038, (1) 178-0035, (1) 178-0001, (2) 178-0036, and (2) 178-0032)
241d 178-7180 Right (white operating) cylinder head assembly (FH541V) 1 (This is an assembled cylinder head. Gaskets are included. You will need to reuse your rocker arms and rocker arm studs. Includes (1) 178-0013, (2) 178-0047, (1) 178-0030, (1) 178-0029, (1) 178-7038, (1) 178-0035, (1) 178-0001, (2) 178-0036, and (2) 178-0032)
241e 178-0013 Rocker cover gasket 2 (OEM)
241g 178-0030 Intake valve 2
241h 178-0029 Exhaust valve 2
241i 178-0028 Cylinder head gasket (FH500V engine only) 2
241j 178-7038 Cylinder head gasket (FH541V engine only) 2
241k 178-0035 Intake gasket 2
241l 178-0001 Exhaust manifold gasket 2
241m 178-0036 Exhaust stud bolt 4
241n 178-0032 Valve stem seal 4
242 154-0042 Oil drain valve kit 1
243 154-0037 Tubing 1/2 x 5/8 (clear) (sold by the foot) 1 ft
244 164-0398 Control valve (white clamp) 1
245 178-0020 Air filter clip (includes swivel) 2 (includes 259)
246a 178-0014 Plastic Kawasaki dipstick 1
246b 154-0367 Kawasaki dipstick 1
246c 178-0015 Dipstick tube 1
246d 178-0016 O-ring 1
246e 178-0123 Flanged bolt 1
247 178-0021 Fan housing 1
248 N/A Not available 1 (Starter gear assembly)
249a 178-0024 Ignition coil assembly Kawasaki FH500V/FH541V 2 (OEM)
250 166-0004 Spark plug (Kawasaki FH500V/FH541V/FH381V) 2
257a 160-0083 Starter solenoid (remote mounted) 1
257b 991-9257 SOLENOID -STARTER 12V (NON-OEM)
258a 178-0025 12V starter assembly kit (Kawasaki FH500V & FH541V engines) 1 (Entire starter assembly, includes reference 248)
258b 178-7081 120V electric starter 1 (110V start units)
259 N/A Not available 2 (Swivel) (included with 245)
260 178-0023 Voltage regulator 1
264 164-1536 Spacer (OBSOLETE) 2
265 999-0744 Screw 10-32 x 1 3/4 pan head phillips zinc plated 2
266 999-0053 Washer #10 split lock plain finish 2
267 999-0412 Washer #8 SAE flat 2
268 160-0141 Stud M6 x 130 2
269 164-1538 Rubber cap (OBSOLETE) 1
270 178-0042 Carb intake gasket 2
271 160-0115 Fuel load block 1 (Eagle specific)
272 178-0195 Flanged nut 2
273 160-0116 Brass plug 1/8 1
274 160-0117 Elbow 3/8 x 1/4 mp 1
275 165-0012 Spark plug boot (OBSOLETE) 2
276 178-0129 Spark plug wiring harness 1
280 178-0085 Bolt 6 x 12 flanged 1 (old style)
281a 178-0079 Breather cover and gasket kit 1 (old style)
281b 178-7039 Plate 1 (old style)
282 178-0307 Cover and gasket kit 1 (old style)
284 178-0043 Top oil seal (upper crankshaft - Kawasaki) 1
285 178-0036 Exhaust stud bolt 4
286 178-0081 Crankcase complete 1
287 178-0017 Crankcase gasket 1
288 178-0082 Snap ring 2
289 178-0083 Pin 6
290a 178-0028 Cylinder head gasket (FH500V engine only) 2
290b 178-7038 Cylinder head gasket (FH541V engine only) 1
291 178-0032 Valve stem seal 4
292 178-0078 Rocker case 2
293 178-0060 Bolt 6 x 40 flange 4
294a 178-0013 Rocker cover gasket 2 (OEM)
295 178-0087 Flanged bolt 2
296a 178-0027 Left (while operating) bare cylinder head 1 See 178-0211 or 178-7181 for head assembly
296b 178-0026 Right (while operating) bare cylinder head 1 See 178-0212 or 178-7180 for head assembly
297 178-0086 Flanged bolt 8
299 178-0080 Crankcase cover 1
300 178-0084 Oil seal 1
301 178-0033 Bottom oil seal 1
302 178-0309 Breather cover (new style) 1 (new style)
303 178-0308 Breather gasket (new style) 1 (new style)
304 178-0310 Bolt flanged 14mm 1 (new style)
305 178-7002 Air filter assembly 1 (includes 306-310)
306a 178-7004 Air filter case assembly 1
306b 178-0041 Air cleaner rear housing (includes filters and gasket) 1
307a 178-0005 Air pre-cleaner Kawasaki 1 (OEM)
307b 991-7118 Pre-filter (green) 1 (NON-OEM)
308 178-0019 Air filter cover 1
309a 178-0007 Air filter Kawasaki 1 (OEM)
310 178-0197 Nut 1
N/S 050-0006 Kawasaki 100 hour service kit 1
N/S 154-0269 Carbon monoxide safety patch 1
N/S 991-9251 CO DETECTOR 1 (NON-OEM option to 154-0269)
N/S 170-2004 Isolator (OBSOLETE) 5 (for dust control units)
N/S 170-3235 Support bracket 1
N/S 170-3259 Nut M6 x 2 hex 4
N/S 178-0039 Push rod 4
N/S 189-8544 Emissions shutdown module with oxygen sensor 1 (original shut-down system has been made unavailable. This part will need additional wiring that is not included.)
N/S 991-1601 Oxygen sensor 1 wire (OBSOLETE) 1
N/S 991-1810 Compression tester 1
N/S 991-1832 Emission tester 1
N/S 999-0565 Screw 10 x 3/4 pan head phillips sheet metal 2 (not included in kit)
N/S 154-0412 Carburetor for Kawasaki (OBSOLETE) 1 (Pioneer)
N/S 154-0250 Muffler bracket 1 (Super Buffer)
N/S 991-4039 Spark plug tester 1
KIT 050-0006 Kawasaki 100 hour service kit 1 (includes oil filter, pre-air filter, air filter and spark plug)

NON-OEM Dust Bonnet and Cage Option - 178-4041
RefNbr Part Number Description Req Notes
1 991-9014 Kawasaki dust bonnet 1
2a 160-0198 3 tab filter cage with support ring for 17HP (metal) 1 (includes 2b)
2b 160-0297 Filter cage support ring for 17HP (converts 3 tab/4 tab) 1
3 999-0250 Bolt M5-.8 x 10mm hex head full thread 3 (to secure cage to ring)
4 999-0740 Nut M5-.8 hex stainless steel 3 (to secure cage to ring)
5 999-0673 Nut M6-1 acorn zinc plated 4 (to secure ring to engine)
6 999-0123 Washer 1/4 SAE flat zinc plated 7 (to secure cage and ring to engine)
7 160-0123 3 tab filter cage for 18HP (metal) 1

-Engine- Kawasaki FS481V - 189-6100
RefNbr Part Number Description Req Notes
001 178-0329 Bolt 12 x 30 1
002 178-0135 Washer 1 (DS10 only)
003 178-0137 Woodruff key 1
004 178-7107 Flywheel assembly 1
005 189-5152 Propane emission decal 1
006 189-0392 Screw #10 x 5/8 pan head phillips 2
007a 189-8544 Emissions shutdown module with oxygen sensor 1 (Betco)
007b 154-1042 SafeSense emission monitoring module retro kit 1 (Pioneer)
008a 189-3090 Oil dipstick 1 (Plastic oil dipsticks are only good for a short time because the last couple inches of the dipstick are always in oil and will eventually stain, get brittle, and then break off inside the engine due to the high heat of the oil. The pieces of plastic can cause problems inside the engine and the only way to get them out is to remove the crankcase, which is very labor intensive.)
008b 154-0367 Kawasaki dipstick 1
009a 178-0306 Dipstick tube 1
009b 178-0016 O-ring 2
010 178-0265 Voltage regulator 1
011 178-0330 Wire lead 1
012 178-0331 Screw 2
013 178-0123 Flanged bolt 4
014 178-7106 Electric starter 1
015a 178-0264 Ignition coil assembly Kawasaki FS481V 2
015b 991-7143 Ignition coil assembly 2 (NON-OEM)
016a 166-0008 Spark plug (Kawasaki FS481V) 2
016b 178-7104 Spark plug wiring harness 1
017 178-0280 Intake manifold 1
018a 178-0255 Air pre-filter 1 (OEM)
018b 991-6028 Air pre-filter 1 (NON-OEM)
019a 178-0256 Air filter 1 (Betco) (OEM)
019b 991-6029 Air filter 1 (NON-OEM)
019c 178-0256 Air filter 1 (Kawasaki)
019d 178-7207 Air filter assembly with prefilter 1 (Kawasaki)
020 178-0281 Hose clamp 1
021 178-0282 Hose 1
022 178-0279 Air filter case 1
023 178-0278 O-ring 2
024 178-0277 Thumb nut 2
025 178-0283 Hose clamp 1
026a 178-0290 Carburetor assembly 1 (Pioneer, Nilfisk, Kawasaki)
026b 189-5148 Carburetor aluminum block (keep internal parts of old carb) 1 (Betco)
027 178-0284 Stud bolt 2
028 178-0332 Plug 1
029 178-0333 Clamp 1
030 178-0195 Flanged nut 2
031 178-0334 Intake pipe 1
032 178-0042 Carb intake gasket 2
033 178-0257 Gasket 2
034 178-0036 Exhaust stud bolt 4
035 178-0335 Bolt 6 x 12 7
036 178-7108 Breather cover 1
037 178-0263 Breather gasket 1
038 189-8452 J clip stamped hook 1
039 178-7109 Breather pipe 1
040 178-0151 Screw pan head 1
041 178-7110 Breather plate 1
042 178-7111 Breather valve 1
043 178-0043 Top oil seal (upper crankshaft - Kawasaki) 1
044a 178-0113 Plug 1
044b 178-0010 Oil drain adapter 1
044c 178-0016 O-ring 2
045a 178-0254 Oil filter 1 (OEM)
045b 991-6027 Oil filter 1 (NON-OEM)
046 154-0143 Oil pressure switch with 2 prongs 1
047 178-0206 Clamp 1
048 178-7012 Plug 1
049 178-0336 Crankcase complete 1 (includes 50)
050 178-0337 Joint 1
051 178-0302 O-ring 1
052 178-0338 Pipe 3
053 178-0273 Dowell pin 6
054 178-0261 Cylinder head gasket (FS481V engine only) 2
055a 178-0304 #1 right cylinder head assembly (FS481V) 1 (Includes (1) rocker cover gasket, (2) valve springs, (1) intake valve, (1) exhaust valve, (1) cylinder head gasket, (1) intake gasket, (1) exhaust gasket, (2) exhaust studs)
055b 178-0258 Right (while operating) bare cylinder head #1 1
055c 178-0305 #2 left cylinder head assembly (FS481V) 1 (Includes (1) rocker cover gasket, (2) valve springs, (1) intake valve, (1) exhaust valve, (1) cylinder head gasket, (1) intake gasket, (1) exhaust gasket, (2) exhaust studs)
055d 178-0259 Left (while operating) bare cylinder head #2 1
056 178-0272 Head bolt 14
058 178-0339 Lift hook 1
059 178-0032 Valve stem seal 4
060 178-0124 Bolt 6 x 25 flange 10
061a 178-7112 Rocker case (cylinder #2) 1
061b 178-7113 Rocker case (cylinder #1) 1
062 178-0262 Rocker case gasket 2
064 178-0272 Head bolt 14
065 178-0036 Exhaust stud bolt 4
066 178-0271 Head bolt 6
067 999-1489 Screw 3/8-16 x 1 1/2 hex head stainless steel 4
068 999-0034 Washer 3/8 split lock plain finish 4
069 178-0260 Bottom oil seal 1
071 178-0236 Plug 2
073 178-0340 Plug 1
074 178-0084 Oil seal 1
075 178-0322 Crankcase cover 1
076 178-0338 Pipe 3
077 178-0273 Dowell pin 6
078 204-0071 Bolt 1
079 999-0120 Washer 3/8 SAE flat 1
080 189-8544 Emissions shutdown module with oxygen sensor 1 (Betco)
081 189-5147 Nut 1
082a 169-0142 Muffler plug 1 (Pioneer)
082b 991-1601 Oxygen sensor 1 wire (OBSOLETE) 1
083a 189-3087 Catalytic muffler and manifold assembly 1 (Betco)
083b 154-1044 Catalytic muffler and manifold assembly (Kawasaki FS481V) 1 (Pioneer)
084 178-0286 Fan housing kit 1
090 178-7133 Bolt 4
091 178-0386 Washer 4
092 178-0098 Collet (valve keeper) (sold individually - need 2 per valve) 8
093 178-0048 Valve retainer ring 4
094 178-0276 Valve spring 4
095 178-0270 Intake valve 2
096 178-0045 Lifter 4
097 178-0268 Push rod 4
098 178-0269 Exhaust valve 2
099 178-7134 Nut 4
100 178-0353 Bracket 4
101 178-0384 Bolt 8 x 14 flange 4
102 178-7132 Collar 4
103 178-0383 Rocker arm 4
KIT 050-0007 Kawasaki FS481V 100 hour kit 1 (includes oil filter, pre-air filter, air filter and spark plug)
N/S 189-8544 Emissions shutdown module with oxygen sensor 1
N/S 991-1810 Compression tester 1
N/S 991-1832 Emission tester 1
N/S 178-0274 Throttle control plate 1
N/S 178-0313 Charging coil (stator) 1
N/S 178-0275 Spring 1
N/S 178-0316 Fan 1
N/S 991-4039 Spark plug tester 1

- Pads - 255-2400
RefNbr Part Number Description Req Notes
01 255-2440 24 inch aqua plus burnishing pad (pkg of 5)
02 255-2435 24 inch Armadillo concrete scrubbing pad (pkg of 5)
03 255-2464 24 inch Blue ace pad (pkg of 5)
04 255-2442 24 inch Blue Jay burnishing pad (pkg of 5)
05 255-2412 24 inch Cure white pad (pkg of 5)
06 255-2477 24 inch Diamondback extreme stripping pad (pkg of 5)
07 255-2438 24 inch EHD Extra Heavy Duty Concrete Leveling Pad (pkg of 2
08 255-2421 24 inch gorilla lite burnishing pad (pkg of 5)
09 255-2450 24 inch gorilla spray buff/polish/burnish pad (pkg of 5)
10 255-2465 24 inch Heat concrete bonding pad (pkg of 5)
11 255-2430 24 inch jaguar burnishing pad (pkg of 5)
12 255-2469 24 inch Micropolish polishing and burnishing pad (pkg of 2)
13 255-2490 24 inch premium black stripping pad (pkg of 5)
14 255-2470 24 inch premium blue cleaning pad (pkg of 5)
15 255-2492 24 inch premium brown stripping pad (pkg of 5)
16 255-2480 24 inch premium green scrubbing pad (pkg of 5)
17 255-2460 24 inch premium red scrubbing pad (pkg of 5)
18 255-2452 24 inch premium tan polishing pad (pkg of 5)
19 255-2420 24 inch premium white polishing pad (pkg of 5)
20 255-2411 24 inch superspped rubberized pad (pkg of 5)
21 255-2495 24 inch razorback stripping pad (pkg of 5)
22 255-2447 24 inch Redwood maroon floor prep pad (pkg of 10)
23 255-0174 24 inch Professional sand screen 100 grit (pkg of 10)
24 255-0175 24 inch Professional sand screen 180 grit (pkg of 10)
25 255-0176 24 inch Professional sand screen 220 grit (pkg of 10)
26 255-0267 24 inch Superscreen sand screen 100 grit (pkg of 10)
27 255-0268 24 inch Superscreen sand screen 180 grit (pkg of 10)
28 255-0269 24 inch Superscreen sand screen 220 grit (pkg of 10)
29 255-9619 24 inch Diamond by Gorilla 11000 Grit (pkg of 2)
30 255-9616 24 inch Diamond by Gorilla 1500 Grit (pkg of 2)
31 255-9613 24 inch Diamond by Gorilla 200 Grit (pkg of 2)
32 255-9617 24 inch Diamond by Gorilla 3000 Grit (pkg of 2)
33 255-9614 24 inch Diamond by Gorilla 400 Grit (pkg of 2)
34 255-9615 24 inch Diamond by Gorilla 800 Grit (pkg of 2)
35 255-9618 24 inch Diamond by Gorilla 8000 Grit (pkg of 2)
36 255-9649 24 inch Diamond starter pack (1 of each grit)
37 255-2415 24 inch Duala clean and shine pad - low speed (pkg of 5)
38 255-2416 24 inch 2001 Duala clean and shine pad - high speed (pkg 5)

- Pad Holders - 275-9029
RefNbr Part Number Description Req Notes
1 991-2214 Center-Lok II pad holder - left hand thread (red)
2a 991-2201 Center-Lok II pad holder - right hand thread (black) (Pad driver side female, Floor side male)
2b 991-8577 Pad retainer (Pad driver side male, Floor side female)
3a 991-2202 Big mouth pad holder set (blue) (includes 3 screws)
3b 991-2205 Deep lock ring and pad grip ring
4 991-2203 Big mouth pad holder male thread portion
5 991-2206 Center-Lok 3 pad holder (includes 3 screws)
6 996-0372 Big mouth pad holder (left hand thread)
7 N/A Not available
8 991-2209 Split retainer - pad holder ring (OBSOLETE)
9 N/A Not available (replaced by #3 991-2202)
10 991-2211 Center lock pad holding cup (male) (yellow) (OBSOLETE)

Fuel System Overview -

RefNbr Part Number Description Req Notes
Webpage Problem Reporting