Part of the John Deere Repair Manuals.
This is the full technical repair manual for the John Deere X500, X520, X530, X534 and X540 lawn tractors, 2006 to 2015. It is not a diagnosis-only book: it takes you from theory of operation and testing all the way through complete teardown and rebuild of the engine, hydrostatic transaxle and power steering. Three complete engine sections are included - the Kawasaki FH721V air-cooled V-twin, the liquid-cooled John Deere FD731V, and the Kawasaki FS730V fitted to the X500 - each with its own specs, diagnostics and repair procedures. Electrical coverage runs schematics and harnesses for both serial number breaks, plus charging, starting, PTO clutch and instrument circuits. Wear limits, torque values and pressure test specs are printed where you need them.
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety (Section 10) | 7-23 | Safe Operation and Service Practices, Safety Labels and Decal Locations for the X500 Select Series |
| Specifications (Section 20) | 24-40 | Generic Metric and Unified-Inch Bolt Torque Charts, O-Ring Seal Service Recommendations, Fuels and Lubricants, Serial Number Locations |
| Engine (FH721V) (Section 30) | 41-180 | Kawasaki FH721V Air-Cooled V-Twin: Specifications, Tools, Component Location, Theory of Operation, Diagnostics, Tests and Adjustments, Full Repair |
| Engine (FD731V) (Section 30A) | 181-319 | John Deere K-Series FD731V Liquid-Cooled V-Twin: Specifications, Tools, Component Location, Theory of Operation, Diagnostics, Tests and Adjustments, Full Repair Including Cooling System |
| Engine (FS730V) (Section 30B) | 320-477 | Kawasaki FS730V Air-Cooled Twin (Stated As the X500 Engine): Specifications, Tools, Component Location, Theory of Operation, Diagnostics, Tests and Adjustments, Full Repair |
| Electrical (Section 40) | 478-837 | Electrical Information and Specifications, Schematics and Harnesses for Both Serial Breaks, Theory of Operation, Diagnostics, Tests and Adjustments, Charging, Starting, PTO Clutch and Instrument Circuits |
| Power Train (Section 50) | 838-974 | Hydrostatic Transaxle: Pedals and Linkage, Cruise Control, Brake, Clutch, Tie Rods, Kingpins, Charge Pump, Final Drive and Axle, Wear Limits |
| Hydraulics (Section 60) | 975-1010 | Hydraulics: Mower Deck Lift, Oil Flow and Pressure Checks, Relief Valve, Control Valve, Hoses and Fittings |
| Steering (Section 70) | 1011-1053 | Power Steering: Steering Cylinder, Hoses, Wheel and Column, Performance Test |
| Attachments (Section 80) | 1054-1129 | Attachments: Mower Decks and Their Drive, Lift Linkage and Adjustment |
| Miscellaneous (Section 90) | 1130-1145 | Miscellaneous Service Information and Reference Material |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| X500, X520 | ||
| Transaxle oil type (X500, X520) | 10W30 engine oil | p. 839 |
| X534, X540 | ||
| Transaxle oil type (X534, X540) | John Deere Hy-Gard | p. 839 |
| All models | ||
| Transaxle oil capacity | 5.3 L (5.6 qt) | p. 839 |
| Spark plug gap | 0.76 mm (0.030 in.), torque 25 N.m (18 lb-ft) on the FD731V | p. 107 |
| Mower deck lift time (oil flow and pressure check) | 2 seconds at 2700 - 3000 engine rpm | p. 975 |
| Hydraulic relief valve opening pressure | 4480 +/- 340 kPa (650 +/- 50 psi) | p. 994 |
| Battery | 12 V DC, BCI Group 51, 500 CCA at -18 C (0 F) | p. 483 |
| Starting motor maximum draw | 180 A | p. 809 |
| Stator AC output at full throttle | 28 V minimum | p. 803 |
| PTO clutch coil resistance | 2.8 - 3.3 ohms | p. 815 |
| Brake wear limit | maximum clearance 1.5 mm (0.060 in.) | p. 965 |
| Transaxle thrust bearing wear limit | 1.45 - 1.55 mm new, replace at 1.30 mm (0.051 in.) | p. 931 |
| Kingpin bolt torque | 150 N.m (203 lb-ft) | p. 911 |
| Tie rod ball joint nut torque | 60 N.m (44 lb-ft) | p. 910 |
| Clutch bolt torque | 75 N.m (55 lb-ft) | p. 905 |
| Forward / reverse pedal height (under side to foot mat) | 48 mm (1.9 in.) forward / 41 mm reverse | p. 838 |
| X500 | ||
| Engine (stated for the X500) | Kawasaki FS730V, air cooled, 2 cyl, 726 cm3, bore 78 x stroke 76 mm | p. 320 |
| Fast idle speed (FS730V) | 3600 +/- 100 rpm | p. 320 |
| Cylinder compression, minimum (FS730V) | 390 kPa (57 psi), max difference between cylinders 41 kPa (6 psi) | p. 320 |
| Valve clearance, cold (FS730V) | 0.05 - 0.10 mm (0.0020 - 0.0039 in.) | p. 320 |
| Covered in the manual | ||
| Engine, second section | Kawasaki FH721V, air cooled V-twin, 675 cm3, bore 75.2 x stroke 76 mm, 8.1:1 | p. 41 |
| Engine, third section | John Deere FD731V, LIQUID cooled V-twin, 675 cm3, coolant 2.7 L | p. 181 |
| FH721V-powered models | ||
| Fast idle speed (FH721V) | 3350 +/- 100 rpm | p. 41 |
| Cylinder compression, minimum (FH721V) | 390 kPa (57 psi) | p. 41 |
| Valve clearance, cold (FH721V) | 0.075 - 0.125 mm (0.003 - 0.005 in.) | p. 41 |
| Engine oil pressure, minimum (FH721V) | 69 kPa (10 psi); 240 - 310 kPa (35 - 45 psi) at fast idle | p. 103 |
| FD731V-powered models | ||
| Fast idle speed (FD731V) | 3350 rpm | p. 181 |
| Cylinder compression, minimum (FD731V) | 682 kPa (99 psi) | p. 181 |
| Valve clearance (FD731V) | 0.15 mm (0.006 in.) | p. 181 |
| Thermostat opening (FD731V, liquid cooled) | begins 80.5 - 83.5 C, fully open 95 C; cooling system test pressure 90 kPa | p. 181 |
| Cylinder head bolt torque (FD731V) | 32 N.m (24 lb-ft) new / 25 N.m (18 lb-ft) reused | p. 182 |
| FH721V and FD731V | ||
| Flywheel bolt torque | 56 N.m (41 lb-ft) | p. 42 |
