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Part of the John Deere Repair Manuals.
All 672 pages of this John Deere EZtrak Technical Manual (OEM #TM113119) are factory-written for the Z625, Z645, Z655, and Z665 residential mowers, covering both Briggs & Stratton and Kawasaki engine variants in one reference. Inside: full wiring schematics with connector pinouts, hydraulic circuit diagrams, a complete troubleshooting section with engine and electrical diagnosis trees, and torque tables spanning every major system. Exploded views and component locations break down both serial number ranges (S.N. -130000 and 130001-), so you're reading the right procedure for your exact machine. Set the ignition coil air gap to 0.20–0.30 mm on the B&S engine or 0.20–0.40 mm on Kawasaki-powered Z645, Z655, and Z665 units, then torque armature mounting screws to 3 N·m. No more hunting forum threads for a number your dealer won't give you. Bookmarked sections jump you straight to the right chapter; download once, search any spec, and get back to mowing.
What's Inside This John Deere Z625, Z645, Z655, Z665 Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 7-45 | Safety (Recognize Safety Information, Understand Signal Words, Follow Safety Instructions, Practice Safe Maintenance, Use Proper Tools, Handle Fluids Safely, Avoid Fires) |
| Engine Repair B&S | 46-135 | Group 10 - Repair Engine Twin Cylinder |
| Engine Repair Kawasaki | 136-224 | Group 10 - Engine Repair, Group 20 - Starting Motor Repair |
| Electrical Repair | 225-239 | Group 10 - Component Location, Group 20 - Wiring Harness |
| Power Train Repair | 240-306 | Group 10 - Component Location (S.N. -130000), Group 15 - Component Location (S.N. 130001- ), Group 20 - Repair (S.N. -130000), Group 25 - Repair (S.N. 130001- ) |
| Attachments Repair | 307-342 | Group 10 - Component Location, Group 20 - Repair |
| Miscellaneous Repair | 343-368 | Group 10 - Component Location, Group 20 - Repair |
| Engine Diagnosis, Tests, and Adjustments B&S | 369-394 | Group 10 - Diagnosis, Group 20 - Tests and Adjustments |
| Engine Diagnosis, Tests, and Adjustments Kawasaki | 395-454 | Group 10 - Component Location, Group 20 - General Information, Group 30 - Theory of Operation, Group 40 - Diagnosis, Group 50 - Tests and Adjustments |
| Electrical Diagnosis, Tests, and Adjustments | 455-613 | Group 10 - Theory of Operation, Group 20 - Diagnosis, Group 30 - Tests and Adjustments, Group 40 - Wiring Schematics, Group 50 - Connector Information |
| Power Train Diagnosis, Tests, and Adjustments | 614-655 | Group 10 - Theory of Operation (S.N. -130000), Group 15 - Theory of Operation (S.N. 130001- ), Group 20 - Diagnosis (S.N. -130000), Group 25 - Diagnosis (S.N. 130001- ) |
| Attachments Diagnosis, Tests, and Adjustments | 656-664 | Group 10 - Diagnosis, Group 20 - Tests and Adjustments |
| Miscellaneous Tests and Adjustments | 665-668 | Group 10 - Tests and Adjustments |
| Service Tools and Kits | 669-672 | Group 10 - Service Tools |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Mower Belt Tension Spring Length | 42–43 cm (16.5–16.9 in.) | p. 663 |
| Cylinder Head Distortion (Maximum) Out-of-Flat | 0.05 mm (0.002 in.) | p. 138 |
| Z625 (Briggs & Stratton engine) | ||
| Ignition Coil Air Gap | 0.20–0.30 mm (0.008–0.012 in.) | p. 43 |
| Armature Mounting Screws Torque | 3 N·m (25 lb.-in.) | p. 389 |
| Spark Plug Torque | 20 N·m (180 lb.-in.) | p. 48 |
| Spark Plug Gap | 0.76 mm (0.030 in.) | p. 49 |
| Briggs & Stratton engines | ||
| Engine Crankcase Capacity (with Filter) | 1.9 L (2.0 qt.) | p. 38 |
| Valve Spring Free Length (minimum) | 33.50 mm (1.319 in.) | p. 49 |
| Z625 (SN. 170001-) | ||
| Spark Plug Torque | 20 N·m (180 lb.-in.) | p. 43 |
| Kawasaki engines | ||
| Spark Plug Torque | 22 N·m (195 lb.-in.) | p. 41 |
| Z645, Z655, Z665 (SN. -130000) | ||
| Hydraulic System Oil Capacity (Includes Reservoir) | 6.1 L (1.65 gal.) | p. 38 |
| Z645, Z655, Z665 (SN. 130001-) | ||
| Transaxle Oil Capacity (approximate) | 1550-1650 ml (53.4-55.8 oz.) | p. 40 |
John Deere Z625, Z645, Z655, Z665 Common Problems This Manual Covers
John Deere Z625 engine cranks normally but fails to start and run in cold weather. p. 369
Inspect the ignition coil for damage. Adjust the ignition coil air gap to 0.20-0.30 mm (0.008-0.012 in.) as shown on page 43. Replace the coil if damaged. Torque the armature mounting screws to 3 N·m (25 lb.-in.) according to the procedure on page 389. Verify spark before starting.
Manual Section: Engine Diagnosis, Tests, and Adjustments B&SEngine bogs down and loses RPM under heavy cutting load or when engaging the mower deck. p. 395
Remove and inspect the spark plugs for heavy fouling or wear. Measure the spark plug gap and set it to 0.70-0.80 mm (0.028-0.031 in.) using the guidelines on page 425. Install new plugs if electrodes are burnt. Torque the spark plugs to 22 N·m (195 lb.-in.) as specified on page 41.
Manual Section: Engine Diagnosis, Tests, and Adjustments KawasakiUnexpected bouncing motion and complete loss of operator control during steering or normal forward travel. p. 614
Inspect the steering arm dampers for proper installation and replace if binding. Drain and refill the transaxle fluid if aeration is present. Add approximately 1550-1650 ml (53.4-55.8 oz.) of oil as detailed on page 40. Bleed the hydraulic system to remove trapped air before testing the steering controls.
Manual Section: Power Train Diagnosis, Tests, and AdjustmentsMower deck drive belt slips or jumps off the pulleys when engaging the PTO clutch switch. p. 656
Inspect the mower drive belt for glazing or cracks. Adjust the mower belt tension spring length to 42-43 cm (16.5-16.9 in.) using the procedure on page 659. Test the PTO clutch resistance on page 554. Replace the clutch if the reading falls outside 3.0 ohm ± 10%.
Manual Section: Attachments Diagnosis, Tests, and AdjustmentsFrequently Asked Questions
What are the torque specs for drive belt pulley on John Deere Z645?
For John Deere Z645 models with serial numbers 130001- and higher, the Transaxle Drive Sheave Nut should be tightened to a torque of 41–59 N·m (30–43 lb.-ft.). This specification is found in the procedure for replacing the input shaft seal.
What causes no start no click on John Deere Z625?
For B&S V-Twin engines, if the starting motor does not rotate when the ignition switch is turned to the start position (no click), possible causes include a cranking circuit problem, key switch malfunction, or starting relay malfunction. For Kawasaki engines, if there is no clicking sound from the starter solenoid, the starter solenoid or key switch may be defective.
What are the replacement specifications for Ignition coil?
For Briggs & Stratton engines, the Ignition Coil Air Gap specification is 0.20–0.30 mm (0.008–0.012 in.). For Kawasaki engines, the Ignition Coil Air Gap specification is 0.20–0.40 mm (0.008–0.016 in.). These air gap measurements are crucial for proper ignition coil function.
What are the replacement specifications for Fuel hose?
The manual states that fuel lines must be replaced if they are brittle, cracked, excessively soft, or damaged. However, specific dimensions or material specifications for replacement fuel hoses are not provided.
What do I get after purchasing this John Deere Z625–Z665 Series manual?
Instant PDF download. You get the full 672-page searchable Technical Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Is this John Deere Z625–Z665 Series Technical Manual printable?
Yes, print as many copies as you want, and there are no restrictions. Many mechanics print the section they need and bring it to the shop floor.
Are hydraulic system diagrams in this John Deere Z625–Z665 Series manual?
Yes. The manual includes a hydraulic system diagram covering the main circuits.
