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Craftsman DGS 6500 Troubleshooting
The
Craftsman DGS 6500 is a 2WD garden tractor. This model was manufactured by AYP
built from 2007 to 2008. The Craftsman DGS6500 driveline includes a Kohler
Courage SV735 4-cycle V-twin cylinder OHV air-cooled gasoline engine and one of
three transmission options: Peerless P820-040 transmission with 6 forward and 1
reverse gears, Tuff Torq K66Y hydrostatic transmission, or Hydro Gear
hydrostatic transmission.
A 44 cu.in (725 cc) engine has a cylinder bore of 3.27" (83 mm), piston
stroke of 2.64" (67 mm), and rated power of 26 hp (19.4 kW). The maximum
travel speed (forward/reverse): 5.8 mph (9.3 km/h) and 2.4 mph (3.9
km/h).
The Craftsman DGS 6500 tractor is equipped with a manual steering,
mechanical disc brakes, 16x6.50-6 front tires, and 23x10.50-8 rear
tires. The tractor is compatible with the following attachments: 48" or
54" mid-mount 3-blade mower decks with a cutting height of 1.5-4.0 in
(37-101 mm) and manual lift system.
| Engine Troubleshooting |
| Engine will not start or difficult to start |
| Empty fuel tank - Fill fuel up |
| Incorrect fuel grade - Use quality gasoline |
| Air in fuel system - Bleed fuel system |
| Defective spark plug wire connection - Check spark plug wiring connection, repair or change |
| Damaged spark plug - Spark plug need to be replaced |
| Fuel filter is clogged - Replace fuel filter |
| Faulty safety switch - Change damaged switch |
| Carburetor components worn out - Repair or replace parts |
| Bad compression - Check and change damaged parts |
| Throttle cable is damaged or adjusted incorrectly - Replace cable or adjust correctly |
| Air intake screen is plugged - Clean and wash as required |
| Ignition system is defective - Check ignition and replace faulty components |
| Defective or stuck throttle cable - Change or service the cable |
| Air filter is blocked - Service or replace air filter |
| Fuel pump is dirty or defective - Clean or change fuel pump |
| Engine starts but stalls suddenly |
| Damaged spark plug - Change spark plug |
| Dirty or faulty carburetor - Repair or clean carburetor |
| Faulty ignition coil - Ignition coil should be replaced |
| Damaged or weak valve springs - Replace valve springs |
| Valves are stuck - Valves need to be cleaned |
| Low engine oil level - Checking oil level and add if necessary |
| Engine is under excessive load - Load reducing is recommended |
| Air intake screen is blocked - Wash or clean as required |
| Carburetor is running lean - Make the correct settings |
| Bad ignition timing - Ignition timing needs to be adjusted correctly |
| Improper valve setting - Set the valves properly |
| Engine knocking sound or abnormal noise |
| Stale gasoline - Use proper gasoline |
| Excessive engine load - Load reducing required |
| Engine oil level is insufficient - Check and refill engine oil |
| Incorrectly set low idle speed - Need to adjust idle speed |
| Fuel pump is clogged or faulty - Test fuel pump and replace if necessary |
| Worn crankshaft or main bearings - Replace crankshaft or bearings |
| Valve clearance is improper - Adjust valve clearance |
| Piston rings or cylinder bore are worn - Change faulty components |
| Carburetor is clogged or incorrectly adjusted - Service or properly adjust carburetor |
| Dirty air filter element - Replace or clean air filter |
| Fuel pump is faulty or clogged - Test fuel pump and change if necessary |
| Defective ignition system - Check ignition system and replace faulty parts |
| Damaged cylinder-head gasket - Cylinder-head gasket replacement required |
| Burned or stuck valves - Service or replace valves |
| Push rod is damaged or worn - Change push rod |
| Cylinder block parts are damaged - Change defective components |
| Excessive fuel consumption |
| Insufficient choke opening - Inspect choke cable and adjust as required |
| Carburetor main jet adjustment is improper - Adjust it correctly |
| Defective or loose spark plug - Re-tighten or change the spark plug |
| Burned, worn, or stuck valves - Service or change valves |
| Sleeve, piston, or rings are damaged - Replace defective parts as required |
| Valve clearance is improper - Adjust valve clearance |
| Excessive engine oil consumption |
| Defective seals or gaskets - Replace to repair leaks |
| Worn valve stems and valve guides - Valves need to be changed |
| Piston rings are defective or worn - Have piston rings replaced |
| Scored piston or cylinder liner - Inspect piston and liner, fit new components as necessary |
| Blocked breather pipe or hose - Service or change |
| Transmission Troubleshooting |
| Difficulty shifting gears |
| Corroded or worn gear shift linkage - Lubricate or change shift linkage |
| Worn or bent shift forks - Shift forks need to be replaced |
| Faulty parts in the gear shifting mechanism - Change faulty parts |
| Transmission is excessively noisy |
| Low transmission fluid level - Add fluid to the transmission housing |
| Dirty transmission fluid - The fluid must be changed |
| Gears are damaged or bearings are worn - Change defective parts |
| Transmission pops out of gear |
| Gear shift lever is improperly installed or bent - Reinstall the lever correctly or change it |
| Damaged or worn gears - Change defective gears |
| Worn shift forks or shift rods - Change damaged forks or rods |
| Improper drive belt/shaft adjustment or defective drive belt/shaft - Replace belt/shaft or adjust it |
| Clutch/brake is improperly adjusted or worn - Adjust clutch/brake or install a new one |
| Drive sheave is worn or faulty - Change sheave |
| Hydrostatic Transmission Troubleshooting |
| Hydrostatic transmission makes noise |
| Speed control linkage is worn or unadjusted - Adjust or replace linkage |
| Transmission overloaded - Reduce the load is required |
| Insufficient oil level or contaminated oil - Change transmission oil or top up to proper level |
| Damaged or worn components of hydrostatic transmission - Change or repair defective parts |
| Damaged or loose shift linkage - Change or repair linkage |
| Hydrostatic pump is defective or blocked - Repair or change pump |
| Misadjusted or faulty transmission shift control components - Replace or adjust as required |
| Lack of transmission fluid - Check and refill the transmission fluid |
| Drive pulley is worn or faulty - Replace pulley |
| Shifter linkage is faulty or not adjusted - Adjust properly or replace linkage |
| Speed control pedal linkage is damaged or out of adjustment - Adjust or install new linkage |
| Damaged transmission seals or gaskets - Change gaskets or seals |
| Final drive shaft leakage - Replace shaft seals |
| Cracked transmission case - Install a new transmission case |
| Mower Deck Troubleshooting |
| Mower vibrates excessively |
| Dirty or worn mower drive sheave - Service or change sheave |
| Loose or defective drive belt - Adjust belt tension or install a new belt |
| Not balanced or bent mower blades - Balance or change as needed |
| Loose blade mounting bolts - Bolts need to be tightened |
| Discharge chute is regularly plugged |
| Mowing speed is too high - Select a lower speed |
| Grass is too high - Use a lower cutting height |
| Low engine speeds - Throttle is not fully open |
| Cutting level is too low - Use a higher cutting height |
| Mower deck drive belt installed incorrectly - Check drive belt for correct installation |
| Cutting deck is clogged - Inspect and clean cutting deck |
| Excessive blade dullness - Need a blade sharpening |
| Blades are worn or damaged - Blades must be changed |
| High mowing speed - Use a lower speed |
| Cutting height is too low - Use a higher cutting height |
| Bagger is overfilled - Remove grass from bagger |
| Lawn is not level or bumpy - Lawn leveling required |
| Cutting level is too low - Use correct cutting height |
| Ground speed is too fast - Need to slow down |
| Incorrect level of mower deck - Deck needs to be adjusted properly |
| Damaged or bent blades - Change the blades |
| Tire pressure is too low - Inflate tires as required |
| Tires are not correctly inflated - Need to inflate tires |
| Incorrectly leveled mower deck - Deck should be adjusted correctly |
| Blades are not sharp - Need a blade sharpening |
| Worn or defective blades - Blades must be changed |
| Mower deck is clogged - Mower deck needs to be cleaned |
| Damaged mower deck housing - Replace or repair the deck |
| Loose or faulty mower spindle - Install new spindle or repair it |
| Electrical Troubleshooting |
| Battery cannot be charged |
| Loose or corroded wire connections - Clean or tighten wiring connections |
| Battery terminal connectors are defective - Install new terminal connectors |
| Battery failing - Install a new battery |
| Battery capacity is low - Recharge the battery |
| Battery discharges quickly - Service battery or change it |
| Corroded battery terminals or disconnected wires - Connect wiring properly or install new terminals |
| Battery is drained or worn - Battery needs to be recharged or replaced |
| Wiring is incorrectly connected or disconnected - Inspect wiring and connect correctly |
| Battery power is low - Battery is drained, charge it |
| Spark plug gapped improperly or faulty - Clean, gap or replace spark plug |
| Solenoid or starter motor failure - Repair starter or install a new solenoid |
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| Lawn and Garden Tractors Technical Specs |
