X540 200 hour service stage 1
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    X540 200 hour service stage 1

    Decided to start on my service today. Did the engine oil & filter along with the fuel filter.
    The new fuel filter has 2 sizes molded into the plastic body. 1/4" & 5/16" I think. Seeing the fuel line was all the way against the fat part of the old filter. I figured that the 1/4" ends needed to be cut off the new filter. Was trying to have everything ready to go before pulling the old one off. Well after removing the old filter I found the 1/4" ends still attached. Apparently JD just stuck the whole tube into the fuel line. I got the 5/16" ends into the stock fuel hoses without too much problem. Then I found out that the stock spring clamps wouldn't fit over the bulge at the end of the new filter. So I pulled it back apart to remove the metal spring clamps from the fuel lines. Then used small zip ties for hose clamps.

    Has anyone else ever come across this? If the fuel line is only 1/4" it shouldn't be shoved all the way up to the filter part. If the fuel line is 5/16" the 1/4" ends should be cut off. So the smaller orifice doesn't restrict fuel flow.

    Another problem I ran into is trying to remove the small plastic panel next to the fuel filter. Figured it would give me better access to the filter. I removed the middle bolt and small plastic push in fastener at the top. That made it loose but I still couldn't get it to come out. Even loosened the metal bar for the snow plow angling handle the sticks through the middle of the panel. What am I missing?

    I did work on the fuel filter while the oil filter was removed. This gave me some extra room to at least get one hand in.
    TJR345 likes this.
    2014 X540 with HDAP tires, 54" deck, brush guard, arm rests and cargo bag.
    JD 48" plow with angle from seat kit & heavy duty skid shoes.
    4 suitcase weights and chains.
    JD tow behind spreader.
    JD 42" lawn sweeper.
    JD 10P cart.
    JD JS61 RWD walk behind mower.
    Stihl KM110 power head with pole saw, shaft extension, power scythe, curved shaft edger, 2 straight shaft cutters (string & blade).
    Stihl MS180-CBE 16" saw.
    Stihl SH86C hand held blower vac.

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    jgayman's Avatar
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    Hmmm... never noticed anything special about the fuel filter. My X500 uses the same fuel filter as your X540 (AM116304). I just did my 200 hr service 2 weeks ago. I just pulled the old one off and plugged the new one on. I just pushed the fuel line up until it was at the same position as the old filter, which was very close to the filter body. I never had to cut anything off and the stock spring hose clamps fit fine.

    Click image for larger version. 

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    H-D dealer dude and TJR345 like this.
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    xcopterdoc's Avatar
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    Fuel filter is just pluck and chuck. The fuel lines should be flexible enough to go all the way on. The clamps can be a bugger for a quick second sometimes.

    Sent from my LGL52VL using Tapatalk

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    Quote Originally Posted by jgayman View Post
    Hmmm... never noticed anything special about the fuel filter. My X500 uses the same fuel filter as your X540 (AM116304). I just did my 200 hr service 2 weeks ago. I just pulled the old one off and plugged the new one on. I just pushed the fuel line up until it was at the same position as the old filter, which was very close to the filter body. I never had to cut anything off and the stock spring hose clamps fit fine.

    Click image for larger version. 

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    Yep that's the one. Looks like JD couldn't make up there mind what size and just jammed it in the hose. Probably too much trouble to cut every filter going down the assembly line. How it didn't leak I don't know.

    The engine never showed any signs of fuel starvation. Even with the smaller opening.

    My old filter part looked pretty good. The ends stuck up inside the hose were all yellow and distorted.

    I wanted to post some pictures of the old filter but my girlfriend threw a bunch of trash on it and I wasn't digging it out. lol
    Last edited by H-D dealer dude; 07-26-2017 at 06:52 PM.
    TJR345 likes this.
    2014 X540 with HDAP tires, 54" deck, brush guard, arm rests and cargo bag.
    JD 48" plow with angle from seat kit & heavy duty skid shoes.
    4 suitcase weights and chains.
    JD tow behind spreader.
    JD 42" lawn sweeper.
    JD 10P cart.
    JD JS61 RWD walk behind mower.
    Stihl KM110 power head with pole saw, shaft extension, power scythe, curved shaft edger, 2 straight shaft cutters (string & blade).
    Stihl MS180-CBE 16" saw.
    Stihl SH86C hand held blower vac.

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    Zebrafive's Avatar
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    I bet the filtering element restricts fuel flow more than the ID of the 1/4" hose connections. A JD engineer probably specified the minimum flow the filter had to meet when bids for supplying the filter where sent out.
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    Quote Originally Posted by Zebrafive View Post
    I bet the filtering element restricts fuel flow more than the ID of the 1/4" hose connections. A JD engineer probably specified the minimum flow the filter had to meet when bids for supplying the filter where sent out.

    I consider them one size fits most. lol
    It probably doesn't have any better flow just fits the 5/16" hose.
    TJR345 likes this.
    2014 X540 with HDAP tires, 54" deck, brush guard, arm rests and cargo bag.
    JD 48" plow with angle from seat kit & heavy duty skid shoes.
    4 suitcase weights and chains.
    JD tow behind spreader.
    JD 42" lawn sweeper.
    JD 10P cart.
    JD JS61 RWD walk behind mower.
    Stihl KM110 power head with pole saw, shaft extension, power scythe, curved shaft edger, 2 straight shaft cutters (string & blade).
    Stihl MS180-CBE 16" saw.
    Stihl SH86C hand held blower vac.

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    Stage 2

    Moved on to stage 2 of my X540's 201.6 hour service.

    Adjusted all 4 valves. Both sides were about.002 to tight. Replaced both valve cover gaskets.

    Replaced both spark plugs.

    Was also going to change the coolant. No way a drain pan is going to fit under the tractor with the mower deck on. Not where it's going to catch any of it anyway. lol
    The fluid looks to be in good shape. So the coolant will get done with the transmission service. After the mower deck comes off for the year.
    2014 X540 with HDAP tires, 54" deck, brush guard, arm rests and cargo bag.
    JD 48" plow with angle from seat kit & heavy duty skid shoes.
    4 suitcase weights and chains.
    JD tow behind spreader.
    JD 42" lawn sweeper.
    JD 10P cart.
    JD JS61 RWD walk behind mower.
    Stihl KM110 power head with pole saw, shaft extension, power scythe, curved shaft edger, 2 straight shaft cutters (string & blade).
    Stihl MS180-CBE 16" saw.
    Stihl SH86C hand held blower vac.

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    Stage 3

    Got 226.7 hours as of today.

    Removed the 54" mower deck.

    Drain and refill cooling system with Cool Guard 2 premix 50/50.
    Didn't see any signs of dirt or corrosion inside the system.

    Replaced both air filters.

    Changed the transmission oil and filter with Low Vis HyGuard. Glad I waited until the end of the cutting season to change it. Seeing the first service was done at 50 hours. So it was around 24 hours short of hitting the 200 hours.
    The fluid looked fairly clean when it drained out.

    Also found a small nail in my right front tire so it got plugged.
    2014 X540 with HDAP tires, 54" deck, brush guard, arm rests and cargo bag.
    JD 48" plow with angle from seat kit & heavy duty skid shoes.
    4 suitcase weights and chains.
    JD tow behind spreader.
    JD 42" lawn sweeper.
    JD 10P cart.
    JD JS61 RWD walk behind mower.
    Stihl KM110 power head with pole saw, shaft extension, power scythe, curved shaft edger, 2 straight shaft cutters (string & blade).
    Stihl MS180-CBE 16" saw.
    Stihl SH86C hand held blower vac.

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    Seen this problem posted on another thread. Couldn't find it to bump the post. Had the same thing happento me. This was on a 500 series tractor.

    Just recently serviced the transmission of my 540. Dumped the drain plug and plug for the oil filter. Let everything drain good. Installed new filter and fluid. The level was just under the full when cold line on the tank. Drove it around the fields across the street for about a 1/2 mile. Then parked it back in the garage.

    After the transmission cooled the level was still just below the full mark. So I made a note of topping it off when I had a chance. Well 4-5 days went by before I got to it. When I did the tank was almost empty again. Of course I don't see it leaking anywhere. So it must of had an air pocket that freed itself from sitting.
    Last edited by H-D dealer dude; 12-04-2017 at 07:27 AM.
    2014 X540 with HDAP tires, 54" deck, brush guard, arm rests and cargo bag.
    JD 48" plow with angle from seat kit & heavy duty skid shoes.
    4 suitcase weights and chains.
    JD tow behind spreader.
    JD 42" lawn sweeper.
    JD 10P cart.
    JD JS61 RWD walk behind mower.
    Stihl KM110 power head with pole saw, shaft extension, power scythe, curved shaft edger, 2 straight shaft cutters (string & blade).
    Stihl MS180-CBE 16" saw.
    Stihl SH86C hand held blower vac.

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    Tom

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