Bad Boy 7800670 Operator's Manual

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Operator's Manual

Manual No. 7104042 (Rev. ‘-’, 12/8/2009)

21” VARIABLE SPEED

SWIVEL WHEEL

WALK BEHIND

MOWER

Model No.Description

7800670 BBRS219BS

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Reproduction

Thank You for purchasing this quality-built Bad Boy mower. We’re pleased that you placed your confidence in the Bad Boy brand. When operated and maintained according to the instructions in this manual, your Bad Boy mower will provide many years of dependable service.

This manual contains safety information to make you aware of the hazards and risks associated with the machine and how to avoid them. This machine is designed and intended only for finish cutting of established lawns and is not intended for any other purpose. It is important that you read and understand these instructions thoroughly before attempting to start or operate this equipment. Save these instructions for future reference.

PRODUCT REGISTRATION

IMPORTANT: KEEP THIS INFORMATION FOR YOUR PERSONAL RECORDS (Complete the following information on your purchase)

Date of Purchase__________________________________________________________________

Retailer_________________________________________________________________________

Retailer's Phone Number___________________________________________________________

Equipment

Model Number______________________________________________________________

Serial Number

______________________________________________________________

Engine

Model_________________________Type__________________Code___________________

Manual Content

Bad Boy and the Bad Boy logo are trademarks of Bad Boy Inc. and are used with permission.

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Operator Safety

Features and Controls Operation Maintenance Troubleshooting Warranties

Table of Contents

Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Important Operator Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Features and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Pre-Start Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Starting & Stopping Engine & Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Propelling Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Locking Swivel Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Handle Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Cutting Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Recycling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Removing the Recycling Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Installing the Discharge Deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Installing the Grass Bag Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Installing the Grass Bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Change Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Check Mower Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Check Engine Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Service - Periodic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Wheel Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Mower Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Blade Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Wheel Drive Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Belt Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Engine Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Rear Cover Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

WARNING

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

WARNING

Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer or other reproductive harm.

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Operator Safety

! !

WARNING: This powerful cutting machine is capable of amputating hands and feet and can throw objects that can cause injury and damage! Failure to comply with the following SAFETY instructions could result in serious injury or death to the operator or other persons. The owner of the machine must understand these instructions and must allow only persons who understand these instructions to operate machine. Each person operating the machine must be of sound mind and body and must not be under the influence of any substance, which might impair vision, dexterity or judgment. If you have any questions pertaining to your machine which your dealer cannot answer to your satisfaction, contact the Customer Service Department (1-877-370-7504).

Protection for Children

Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them.

1. KEEP children out of the mowing area and under the watchful care of a responsible adult other than the operator.

2. DO NOT allow children in yard when machine is operated and turn machine OFF if anyone enters the area.

3. DO NOT allow pre-teenage children to operate machine.

4. ALLOW only responsible adults & teenagers with mature judgment under close adult supervision to operate machine.

5. DO NOT pull mower backwards unless absolutely necessary. LOOK and SEE behind and down for children, pets and hazards before and while backing.

6. USE EXTRA CARE when approaching blind corners, shrubs, trees, or other objects that may obscure vision.

Slope Operation

1. Slopes are a major factor related to slip and fall accidents, which can result in severe injury. All slopes require extra caution. If you feel uneasy on a slope, DO NOT mow it.

2. Mow across slopes, never up-and-down. Exercise extreme CAUTION when changing directions on slopes. DO NOT mow steep slopes or other areas where stability or traction is in doubt. Refer to the Slope Guide at the end of this manual.

3. Use extra care with grass catchers or other attachments; these affect the handling and the stability of the machine.

Preparation

1. Read, understand, and follow instructions and warnings in this manual and on the mower, engine and attachments. Know the controls and the proper use of the mower before starting.

2. Only mature, responsible persons shall operate the machine and only after proper instruction.

3. Data indicates that operators age 60 and above, are involved in a large percentage of mower-related injuries. These operators should evaluate their ability to operate the mower safely enough to protect themselves and others from serious injury.

4. Handle fuel with extra care. Fuels are flammable and vapors are explosive. Use only an approved fuel container. DO NOT remove fuel cap or add fuel with engine running. Add fuel outdoors only with engine stopped and cool. Clean spilled fuel and oil from machine. DO NOT smoke.

Preparation (Continued From Previous Column)

5. Check the area to be mowed and remove all objects such as toys, wire, rocks, limbs and other objects that could cause injury if thrown by blade or interfere with mowing. Also note the location of holes, stumps, and other possible hazards.

6. Keep people and pets out of the mowing area. Immediately, STOP Blade, Stop engine and Stop mower if anyone enters the area.

7. Check shields, deflectors, switches, blade controls and other safety devices frequently for proper operation and location.

8. Make sure all safety decals are clearly legible. Replace if damaged.

9. Protect yourself when mowing and wear safety glasses, a dust mask, long pants, and substantial footwear. DO NOT mow barefooted or with sandals.

10. Know how to STOP blade and engine quickly in preparation for emergencies.

11. Use extra care when loading or unloading the machine into a trailer or truck.

12. Check grass catcher components frequently for signs of wear or deterioration and replace as needed to prevent injury from thrown objects going through weak or torn spots.

Safe Handling of Gasoline

To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive.

1. Extinguish all cigarettes, cigars, pipes and other sources of ignition.

2. Use only an approved fuel container.

3. DO NOT remove fuel cap or add fuel with the engine running. Allow the engine to cool before refueling.

4. DO NOT refuel the machine indoors.

5. DO NOT store the machine or fuel container inside where there is an open flame, spark or pilot light such as on a water heater or other appliances.

6. DO NOT fill fuel containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place the containers on the ground away from the vehicle before filling.

7. Remove gas-powered equipment from the vehicle or trailer and refuel it on the ground. If this is not possible, then refuel equipment using a portable container, rather than a gasoline dispenser nozzle.

Important Operator Safety Instructions

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Operator Safety

! !

Safe Handling of Gasoline (Continued From Previous Page)

8. DO NOT start gas powered equipment in enclosed vehicles or trailers.

9. Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. DO NOT use a nozzle lock-open device

10. If fuel is spilled on clothing, change clothing immediately.

11. DO NOT overfill a fuel tank. Replace fuel cap and tighten securely.

Operation

1. DO NOT put hands or feet near or under rotating parts. Keep clear of discharge area while engine is running.

2. STOP engine when crossing gravel drives, walks, or roads, and under any conditions where thrown objects might be a hazard.

3. Mow only in daylight or good artificial light.

4. DO NOT operate mower while under the influence of alcohol or drugs.

5. After striking a foreign object or if mower vibrates abnormally, STOP the engine, disconnect and secure spark plug wire. Inspect the mower for any damage and repair the damage before starting.

6. DO NOT mow near drop offs, ditches or embankments. Operator could lose footing or balance.

7. STAY ALERT for holes and other hidden hazards. Tall grass can hide obstacles. Keep away from ditches, washouts, culverts, fences and protruding objects.

8. DO NOT mow on wet grass. Always be sure of your footing. Keep a firm hold on the handle and walk, never run. Slipping could cause injury.

9. ALWAYS stay behind handle when engine (motor) is running.

10. DO NOT leave the machine with the engine running. STOP BLADE and STOP ENGINE before leaving the operators position for any reason.

11. Before cleaning, repairing or inspecting make certain engine, blade and all moving parts have STOPPED. Disconnect and secure spark plug wire away from plug to prevent accidental starting.

12. STOP engine and wait until the blade comes to complete STOP before removing grass bag and/or clearing grass.

13. DO NOT operate mower without the entire grass catcher, or guards in place discharge guard, rear guard or other safety devices in place and working. DO NOT point discharge at people, passing cars, windows or doors.

14. DO NOT discharge material against a wall or obstruction. Material may ricochet back towards the operator.

15. Slow down before turning.

16. Watch out for traffic when near or crossing roadways.

Operation (Continued From Previous Column)

17. DO NOT operate engine in enclosed areas. Engine exhaust gases contain carbon monoxide, a deadly poison.

18. Only use accessories approved by the manufacturer. See manufacturer’s instructions for proper operation and installation of accessories.

Maintenance and Storage

1. DO NOT store mower or fuel container inside where fumes may reach an open flame, spark or pilot light such as in a water heater, furnace, clothes dryer or other gas appliance. Allow engine to cool before storing machine in an enclosure. Store fuel container out of reach of children in a well ventilated, unoccupied building.

2. Keep mower and engine free of grass, leaves or excess grease to reduce fire hazard and engine overheating.

3. When draining fuel tank, drain fuel into an approved container outdoors and away from open flame.

4. Keep all bolts, especially blade bolts, nuts and screws properly tight. Check that all cotter pins are in proper position.

5. Always provide adequate ventilation when running engine. Engine exhaust gases contain carbon monoxide, a deadly poison.

6. Service engine and make adjustments only when engine is stopped. Removed spark plug wire from spark plug and secure wire away from spark plug to prevent accidental starting.

7. DO NOT change engine governor speed settings or overspeed engine.

8. Check grass bag assembly frequently for wear or deterioration to avoid thrown objects and exposure to moving parts. Replace with new bag if loose seams or tears are evident. Replace slider or bag adapter if broken or cracked.

9. Mower blades are sharp and can cut. Wrap the blades or wear heavy leather gloves and use CAUTION when handling them.

10. DO NOT test for spark by grounding spark plug next to spark plug hole; spark plug could ignite gas exiting engine.

11. Have machine serviced by an authorized dealer at least once a year and have the dealer install any new safety devices.

12. Use only genuine replacement parts to assure that original standards are maintained.

Important Operator Safety Instructions (Continued)

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Features and Controls

IMPORTANT

The figures and illustrations in this manual are provided for reference only and may differ from your specific model. Contact your dealer if you have questions.

Features and Controls

A. Oil Fill Cap and Dipstick B. Fuel Filler Cap C. Recycling Cover D. Rear Height Adjustment Latch (2) E. Front Height Adjustment Latch (2)

F. Swivel Wheel Lock Knob (2) G. Blade Control H. Rope Start Handle I. Drive Wheel Control

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Features and Controls

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Operation

Pre-Start Check List

Make the following checks and perform the service required before each start-up.

1. Check the guards, deflectors, grass bag, adapter, and covers to make sure all are in place and securely tightened.

2. Check the blade control (A, Figure 1) and wheel drive control (B) to insure they work freely.

3. Check the cutting height. Adjust to the desired height. Refer to the Section ‘Cutting Height Adjustment’.

4. Check the engine oil (A, Figure 2) and add oil as needed to bring the level up to the ‘full’ mark. Refer to the Engine Owner’s Manual for oil specifications.

5. Add fuel to the tank after pushing the mower outside where fumes can safely dissipate. Fill the tank to 1-1/2 inches below the top of the filler neck (to allow for fuel expansion). Make sure the cap is tightened after fueling. Refer to the Engine Owners Manual for fuel specifications.

6. Clean the exterior surfaces of the cutting deck and engine of any accumulation of spilled fuel, dirt, grass, oil, etc. Keep the engine air intake screen and cooling fins clear at all times.

Starting and Operation

Engine and Blade

1. Pull the blade control (A, Figure 3) against the handle.

2. Pull the rope start handle (B) to crank the engine.

NOTE: This Briggs & Stratton engine is equipped with a Ready Start

feature, and does not require priming.

4. After the engine starts, allow a brief warm-up until the engine runs smooth before beginning mower operation.

NOTE:

To stop the engine (and blade), release the blade

control.

Figure 2: Checking engine oil

Figure 1: Mower controls

Figure 3: Starting the mower

Operation

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Operation

Starting and Operation (Continued)

Propelling the Mower

1. Start the engine. Refer to the Section entitled “Starting and Operation – Engine and Blade”.

2. Begin squeezing the wheel drive control (A, Figure 4) back toward the handle to engage the wheel drive and propel the mower forward. Forward speed can be increased by squeezing the wheel drive control further back toward the handle.

Stopping

1. Stop forward motion of the mower by releasing the wheel drive control.

2. Stop the engine and blade by releasing the blade control.

Locking Swivel Wheels

The front wheels can be locked to keep the mower traveling in a straight line:

1. Move the mower straight ahead a few feet so the casters are facing forward.

2. Move the swivel caster lock knobs (A, Figure 5) to the ‘lock’ position (shown) to lock the casters in the forward position.

3. To release the casters, simply move the swivel caster lock knobs to the ‘unlock’ position (B).

Handle Height Adjustment

The height of the mower handle can be adjusted as follows:

1. Remove the T-knobs and carriage bolts securing the

lower handle (A, Figure 6) to the mounting brackets (B).

2. Align the holes in the handle assembly with one of the three handle height adjustment holes in the mounting bracket.

3. Replace the removed hardware, tightening securely.

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Figure 6: Adjusting the handle height

Figure 4: Mower drive controls

WARNING

(Components removed for clarity)

Figure 5: Locking the swivel caster

Operation (Continued)

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Operation

Cutting Height Adjustment

1. Pull the height adjusting latch (A, Figure 7) outward and

move to the desired cutting height.

2. Set all wheels at the same cutting height. The highest

cutting position is Notch 7 (Figure 8). The lowest cutting position is Notch 1.

Recycling Operation

Note:

For best recycling results, cut up to a maximum of 1/3

of grass blade length and recycle ONLY when grass is dry.

1. Set all wheels in the highest cutting position (Notch 7). Refer to the Section entitled “Cutting Height Adjustment”.

2. Move the engine speed control to the fast (Rabbit) position.

3. Move the ground speed control to the slowest speed setting.

4. Proceed mowing slowly. If the grass is very dense, lower each rear wheel latch one notch lower than the front wheel latches to improve recycling performance.

Note:

The recycling cover should remain on the machine at all times, unless alternate discharge operations are desired, such as side discharging or bagging.

Removing the Recycling Cover

1. Remove the knob nuts (A, Figure 9) and internal/ external tooth lock washers (B) securing the recycling cover (C) to the mower deck.

2. Remove the cover.

WARNING

Stop engine and mower blade by releasing the blade control before adjusting cutting height.

Figure 7: Adjusting cutting height

4.00 in1.25 in

Figure 8: Cutting height settings (approximate)

Figure 9: Removing the recycling cover

(Rear wheel shown; front wheel similar)

Operation (Continued)

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Operation

Installing the Discharge Deflector

1. Remove the recycling cover. Refer to the Section entitled “Recycling Operation”.

2. Install the deflector (A, Figure 10) to the deck in place of the recycling cover, making sure that:

• The front hole (B) on the outside front of the

deflector fits over the stud where the front of the recycling cover was originally secured

• The slot (C) on top of the deflector slips under the

restraining nut on top of the deck (under the right front corner of the engine)

• The slot (D) on the inside rear of the deflector slips

onto the stud behind the rear of the discharge opening, where the rear of the recycling cover was originally secured.

3. Install the internal/external tooth lock washers and knob nuts onto the studs and tighten securely.

Installing the Grass Bag Adapter

(Optional Accessory on Some Models)

1. Remove the recycling cover. Refer to the Section entitled “Recycling Operation”.

2. Install the adapter (A, Figure 11) to the deck in place of the recycling cover, making sure that:

• The front hole (B) on the outside front of the

adapter fits over the stud where the front of the recycling cover was originally secured

• The slot (C) on top of the adapter slips under the

restraining nut on top of the deck (under the right front corner of the engine)

• The slot (D) on the rear of the adapter slips onto

the stud behind the rear of the discharge opening, where the rear of the recycling cover was originally secured.

3. Install the internal/external tooth lock washers and knob nuts onto the studs and tighten securely.

4. Route the recoil rope around the outside of the rope guide pulley (E).

Note:

The recoil rope may need to be slackened. Refer to the

section entitled “Handle Assembly”.

Installing the Grass Bag

1. Install the grass bag adapter. Refer to the Section entitled “Installing the Grass Bag Adapter”.

2. Install the grass bag by sliding the connector (A, Figure

12) over the adapter flange.

3. Attach the grass bag hooks (B) over the middle handle cross bar.

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WARNING

Grass Catcher bags are made of woven fabric, and are subject to deterioration and wear during normal usage. Check condition of bag before each use. Immediately replace worn or damaged catcher bags with only bags recommended by the manufacturer. The grass catcher is optional equipment on some models.

WARNING

Figure 12: Installing the discharge deflector

Figure 11: Installing the grass bag adapter

Figure 12: Installing the grass bag

Operation (Continued)

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Maintenance

Introduction

To retain the quality of the mower, use genuine replacement parts only. Contact a local dealer for parts and service assistance. For the correct part or information for a particular mower, always mention the model and serial number.

Service - After First 5 Hours

Change Engine Oil

1. Refer to the Engine Manual for proper oil specifications, procedures and proper service intervals.

2. For the simplest/cleanest oil change, simply turn the mower on its side to drain the oil, as shown. Drain the oil through the dipstick tube (A, Figure 13) into a container. Allow sufficient time for all the oil to drain.

Important: Drain the fuel tank before tipping the machine. DO NOT tip the machine with the carburetor or spark plug down. Oil from the crankcase will saturate the air filter and cause the engine to be hard to start or not start at all. If contamination does occur, the air filter will have to be replaced.

3. Dispose of drain oil properly.

4. Fill the engine with oil as specified in the Engine Manual. Do Not overfill.

Check Mower Blade

1. Disconnect the spark plug wire and secure the end away from the plug.

2. Tilt the mower up on its rear wheels for access to the blade cap screw (A, Figure 14). Do not tilt the mower with the spark plug or carburetor down.

Important: Drain the fuel tank before tipping the mower. DO NOT tip the machine with the carburetor or spark plug down. Oil from the crankcase will saturate the air filter and cause the engine to be hard to start or not start at all. If contamination does occur, the air filter will have to be replaced.

3. Check the torque of the blade cap screw. Recommended torque should be 40 ft. lbs.

4. Check the blade for sharpness, wear and damage. Refer to the Section entitled “Blade Wear Limits”.

Check Engine Drive Belt

1. Visually check the engine drive belt for cracking, fraying, severed or exposed belt strands. If worn or damaged, replace the belt before operating the mower.

Service - Periodic

Perform all maintenance as described in the “Service Schedule” section of this manual.

Engine

Service the engine according to the engine owner’s manual.

Air Filter

Refer to the engine owner’s manual for service instructions.

Engine Oil

Refer to the engine owner’s manual for service instructions.

Figure 13: Draining the engine oil

WARNING

DO NOT attempt any maintenance, adjustments or service with engine and blade running. STOP engine and blade. Disconnect spark plug wire and secure away from spark plug. Engine and components are HOT. Avoid serious burns, allow sufficient time for all components to cool. Wear heavy leather gloves when handling or working around cutting blades. Blades are extremely sharp and can cause severe injury.

Figure 14: Tightening the blade cap screw

Maintenance

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Maintenance

Wheel Drive Components

1. Remove the rear cover. Refer to the Section entitled “Rear Cover Removal & Installation”.

2. Clean any debris buildup on or around the transmission, axles, pulley, belt, etc., as well as on the underside of the cover. Check components for wear or damage. Replace worn or damaged components immediately.

3. Replace the rear cover.

Important: DO NOT operate the mower without the rear cover securely in place.

Storage Procedure

Refer to the Engine Owner’s Manual for directions regarding engine storage preparations. Prepare the mower for “end of season” storage as follows:

1. Drain the fuel from the fuel tank and let the engine run until all fuel is out of the carburetor.

2. Disconnect and remove the spark plug wire away from the spark plug before any other preparations are made!

3. Tape all openings closed to prevent spraying water into the exhaust or air intakes during washing.

4. Tilt the mower up on its rear wheels and thoroughly clean the underside of the deck. Do not tilt the mower with the spark plug or carburetor down. Scrape away any accumulation of grass with a putty knife and/or wire brush.

5. Lubricate all exposed metal with a light coating of oil to prevent corrosion.

6. On self-propelled models, move the ground speed control back to the slow (‘turtle’) position to prevent stretching of the belt and/or idler spring.

7. Carefully fold the handles, “flexing” the control cables to prevent cable damage.

8. Store the mower in a shed or other dry area, protected from weather.

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WARNING

Maintenance (Continued)

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Maintenance

Mower Blade Replacement

Standard Blade Wear Limit

1. Inspect the blade (Figure 15) frequently for signs of excessive wear or damage:

(A) New blade (B) Wear limit (notch starts) (C) Dangerous condition! Do not use on the mower!

Replace with a new blade.

Blade Sharpening

1. Disconnect the spark plug wire and secure the end away from the plug.

2. Tilt the mower up on its rear wheels. Do not tilt the mower with the spark plug or carburetor down.

3. Remove the blade (B, Figure 16).

4. Sharpen the blade on a grinding wheel at an angle of 22

to 28 degrees (B, Figure 17). DO NOT sharpen the blade beyond the original cutting edge (A).

5. Check blade for balance. If necessary, correct balance by grinding heavy end of blade.

6. Reinstall blade (B, Figure 16). Note the correct assembly order:

(A) Blade hub (B) Blade (C) Blade flange (facing up) (D) Cone washer (concave side up) (E) Capscrew

7. Check torque of blade retaining cap screw. Recommended torque should be 40 ft. lbs.

WARNING

Figure 15: Mower blade wear limits

WARNING

DO NOT use a cutting blade that shows signs of excessive wear or damage. Refer to the Section entitled “MOWER BLADE REPLACEMENT” for proper blade inspection and service procedures.

Make sure that blade hub is seated between flanges

Figure 16: Removing the mower blade

Do not sharpen beyond original cutting edge

End view of blade assembly

22-28

Figure 17: Sharpening the mower blade

Maintenance (Continued)

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Maintenance

Wheel Drive Control Adjustment

The wheel drive control lever (A, Figure 18) should engage the transmission when the lever is squeezed back against the handlebar, and disengage the transmission when the lever is released.

If the transmission does not fully engage or disengage, adjustment may be performed as follows:

1. Remove the rear cover from the mower. Refer to the section entitled “Rear Cover Removal & Installation”.

2. With the wheel drive control lever in the ‘DISENGAGE’ position, the spring (A, Figure 19) on the end of the wheel drive control cable should have no tension. Measure the overall length of the unextended spring (B).

3. Fully engage the lever, and measure the length of the extended spring. The overall spring length should increase by 0.020 – 0.025”.

4. To adjust spring extension: a. Disengage the lever. b. To increase (+) the extended spring length, loosen

the jam nut (B, Figure 20) and rotate the ferrule (C) below the adjustment turnbuckle (A), located on the lower end of the wheel drive control cable, one-half turn out from the turnbuckle. Tighten the jam nut.

c. To decrease (-) the extended spring length, loosen

the jam nut, and rotate the ferrule one-half turn in toward the turnbuckle. Tighten the jam nut.

5. Engage the lever and recheck the extended spring length. Repeat Step 4 as needed.

IMPORTANT: INCORRECT ADJUSTMENT CAN CAUSE DAMAGE TO THE TRANSMISSION.

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Figure 20: Adjusting the transmission spring tension

WARNING

! !

Figure 18: Mower drive controls

(Components removed for clarity)

Maintenance (Continued)

Figure 19: Measuring the disengaged transmission spring length (viewed from below)

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Maintenance

Maintenance (Continued)

Belt Service

On self-propelled mowers, the engine belt transmits power from the engine to the transmission that powers the rear wheels. Should the belt become worn, it could cause slippage, which would impair mower performance. The condition of the engine belt should be checked after every 25 hours of mower operation.

Engine Drive Belt Replacement

1. Empty the fuel tank.

2. Remove the blade. Refer to the Section entitled “Blade Sharpening”.

3. Remove the rear cover of the mower. Refer to the Section entitled “Rear Cover Removal & Installation”.

4. To replace the belt: a. Loosen (do not remove) the engine mounting bolts

securing the belt guides (A, Figure 21), and swing the belt guides out away from the engine pulley (B).

b. Remove the hardware securing the transmission belt

guide (C), and remove the guide from the transmission pulley (D).

c. Replace the belt (E), noting the belt routing. d. Replace the belt guides, allowing approx 1/16” spacing

(F) between the guides and the belt. Torque the engine mounting bolts to 40 ft-lbs. Retighten the idler pulley bolts, making sure the idler belt guide is aligned as shown.

e. Replace the blade and the rear cover.

WARNING

! !

Figure 27: Replacing the engine drive belt (simplified view from above)

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Rear Cover Removal and Installation

To Remove the Rear Cover

1. Remove the six threaded fasteners (A, Figure 22)

securing the rear cover to the machine.

2. Lift the cover (B) from the machine. Set the components

aside.

To Install the Rear Cover

1. Place the cover (B) onto the rear of the mower, aligning

the holes in the cover with the holes in the mower.

2. Secure the cover to the mower with the threaded

fasteners (A).

WARNING

! !

Figure 22: Removing the rear cover

Maintenance

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Maintenance (Continued)

ITEM SERVICE

PERFORMED

REF. EACH

USE5HRS25HRS50HRS

100

HRS

EACH

SEASON

Engine Oil Check Oil Level Page 7 X

Initial Oil Change Page 11 X

Periodic Oil Change Page 11 X*

Air Pre-Cleaner Clean Sponge Element Engine Manual X**

Air Cleaner Clean or Replace Engine Manual X**

Spark Plug Replace Engine Manual X

Engine Cooling

System

Clean Shroud & Fins Engine Manual X**

Drive Belt Check for Wear and

Tension

Page 11, 15 X X X

Mower Blade Check for wear, Damage

& Replacement

Page 13 X

Mower Deck Clean Debris

Accumulation

Page 7 X

Wheel Drive

Components

Clean Debris

Accumulation; Check

for Wear or Damage

Page 12 X

Transmission

Clutch Cable

Spring Adjustment

Check & Adjust Page 14 X X X

* Change oil every 25 hours when operating under heavy load or high temperatures. ** Clean more often under dusty conditions or when air debris is present.

Service Schedule

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Troubleshooting

PROBLEM PROBABLE CAUSE CORRECTIVE ACTION

Engine Will Not Start

Using Recoil Starter

1. Fuel tank empty. 1. Fill fuel tank with fresh fuel.

2. Engine needs priming. 2. Prime. Check Engine Manual for Instructions.

3. Spark plug wire disconnected. 3. Place spark plug wire onto spark plug.

Engine Stalls or Stops

After Running

1. Blade control is released or is not being held securely against handle.

1. Blade control should be held securely against handle at all times during operation of mower.

2. Fuel tank empty. 2. Fill with fuel to proper level.

3. Engine air pre-cleaner and or air cleaner dirty. 3. Clean free of all debris.

4. Spark plug defective or gap set improperly. 4. Service spark plug.

5. Water, debris or stale fuel in fuel system. 5. Drain and clean fuel system.

Engine Loses Power 1. Engine air pre-cleaner or air cleaner dirty. 1. Clean or replace filters.

2. Spark plug faulty. 2. Service spark plug.

3. Water, debris or stale fuel in fuel system. 3. Drain and clean fuel system.

Excessive Vibration 1. Damaged, out of balance or bent mower

blade.

1. Service mower blade.

2. Loose blade components. 2. Service and tighten loose parts.

3. Loose or missing air lift (if equipped). 3. Replace air lifts. Tighten to proper torque.

4. Lumpy or frayed belt. 4. Replace belt.

Mower Will Not Move

Loss Of Traction

1. Build-up of debris on or around wheel drive components.

1. Clean debris.

2. Transmission clutch cable adjustment required.

2. Adjust transmission clutch cable.

3. Drive belt requires replacement. 3. Replace drive belt.

4. Damaged transmission. 4. Contact authorized dealer.

Transmission Noise 1. Transmission clutch cable adjustment

required.

1. Adjust transmission clutch cable.

2. Damaged transmission. 2. Contact authorized dealer.

Ground Speed

Too Fast / Too Slow;

Unable to Adjust

Ground Speed

1. Build-up of debris on or around ground speed control components.

1. Clean debris.

2. Ground speed control adjustment required. 2. Adjust ground speed control.

3. Drive belt requires replacement. 3. Replace drive belt.

4. Damaged transmission. 4. Contact authorized dealer.

Cutting Grass

Improperly

1. Cutting height too low or high. 1. Adjust cutting height.

2. Forward ground speed too fast. 2. Move ground speed control to a slower speed.

3. Terraced cut, side to side. 3. Adjust height of cut with height adjust levers.

4. Excessive deck pitch, front to rear. 4. Adjust height of cut with height adjust levers.

5. Cutting blade dull or damaged. 5. Sharpen cutting edges or replace blade.

Poor Grass Discharge 1. Forward speed too fast. 1. Move ground speed control to a slower speed.

2. Grass is wet. 2. Mow when grass is dry.

3. Excessively worn or damaged blade. 3. Service mower blade.

4. Build up of grass clippings and debris under deck.

4. Clean deck.

5. Improper blade installed on deck. 5. Install proper blade.

6. Blade installed improperly on deck. 6. Install blade properly.

Oil Leaking 1. Leaking engine case. 1. Contact authorized dealer.

2. Check and tighten drain plug.

3. Make sure dip stick or oil filler cap is securely in place.

Troubleshooting

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Warranties

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Warranty

BRIGGS & STRATTON POWER PRODUCTS GROUP, L.L.C. OWNER WARRANTY POLICY

WARRANTY PERIOD

ABOUT YOUR WARRANTY

Item Consumer Use Commercial Use: Equipment 2 Years 90 Days Engine* 2 Years 90 Days

LIMITED WARRANTY

Briggs & Stratton Power Products Group, LLC will repair and/or replace, free of charge, any part(s) of the equipment that is defective in material or workmanship or both. Briggs & Stratton Corporation will repair and/or replace, free of charge, any part(s) of the Briggs and Stratton engine* (if equipped) that is defective in material or workmanship or both. Transportation charges on product submitted for repair or replacement under this warranty must be borne by purchaser. This warranty is effective for the time periods and subject to the conditions stated below. For warranty service, find the nearest Authorized Service Dealer using our dealer locator at www.BriggsandStratton.com.

There is no other express warranty. Implied warranties, including those of merchantability and fitness for a particular purpose, are limited to one year from purchase or to the extent permitted by law. Liability for incidental or consequential damages are excluded to the extent exclusion is permitted by law.

Some states or countries do not allow limitations on how long an implied warranty lasts, and some states or countries do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation and exclusion may not apply to you. This warranty gives you specific legal rights and you may also have other rights which vary from state to state or country to country.

The warranty period begins on the date of purchase by the first retail consumer or commercial end user, and continues for the period of time stated above. “Consumer use” means personal residential household use by a retail consumer. “Commercial use” means all other uses, including use for commercial, income producing or rental purposes. Once product has experienced commercial use, it shall thereafter be considered as commercial use for purposes of this warranty.

No warranty registration is necessary to obtain warranty on Briggs & Stratton products. Save your proof of purchase receipt. If you do not provide proof of the initial purchase date at the time warranty service is requested, the manufacturing date of the product will be used to determine warranty eligibility.

We welcome warranty repair and apologize to you for being inconvenienced. Warranty service is available only through servicing dealers authorized by Briggs & Stratton or BSPPG, LLC.

Most warranty repairs are handled routinely, but sometimes requests for warranty service may not be appropriate. This warranty only covers defects in materials or workmanship. It does not cover damage caused by improper use or abuse, improper maintenance or repair, normal wear and tear, or stale or unapproved fuel.

Improper Use and Abuse - The proper, intended use of this product is described in the Operator’s Manual. Using the product in a way not described in the Operator’s Manual or using the product after it has been damaged will void your warranty. Warranty is not allowed if the serial number on the product has been removed or the product has been altered or modified in any way, or if the product has evidence of abuse such as impact damage, or water/chemical corrosion damage.

Improper Maintenance or Repair - This product must be maintained according to the procedures and schedules provided in the Operator’s Manual, and serviced or repaired using genuine Briggs & Stratton parts. Damage caused by lack of maintenance or use of non-original parts is not covered by warranty.

Normal Wear - Like all mechanical devices, your unit is subject to wear even when properly maintained. This warranty does not cover repairs when normal use has exhausted the life of a part or the equipment. Maintenance and wear items such as filters, belts, cutting blades, and brake pads (engine brake pads are covered) are not covered by warranty due to wear characteristics alone, unless the cause is due to defects in material or workmanship.

Stale Fuel - In order to function correctly, this product requires fresh fuel that conforms to the criteria specified in the Operator’s Manual. Damage caused by stale fuel (carburetor leaks, clogged fuel tubes, sticking valves, etc) is not covered by warranty

* Applies to Briggs and Stratton engines only. Warranty coverage of non-Briggs and Stratton engines is provided by the engine manufacturer.

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Slope Guide

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Engine Power Rating Information: The gross power rating for individual gas engine models is labeled in accordance with SAE (Society of Automotive Engineers) code J1940 (Small Engine Power & Torque Rating Procedure), and rating performance has been obtained and corrected in accordance with SAE J1995 (Revision 2002-05). Torque values are derived at 3060 RPM; horsepower values are derived at 3600 RPM. Actual gross engine power will be lower and is affected by, among other things, ambient operating conditions and engine-to-engine variability. Given both the wide array of products on which engines are placed and the variety of environmental issues applicable to operating the equipment, the gas engine will not develop the rated gross power when used in a given piece of power equipment (actual "on-site" or net power). This difference is due to a variety of factors including, but not limited to, accessories (air cleaner, exhaust, charging, cooling, carburetor, fuel pump, etc.), application limitations, ambient operating conditions (temperature, humidity, altitude), and engine-to-engine variability. Due to manufacturing and capacity limitations, Briggs & Stratton may substitute an engine of higher rated power for this Series engine.

Common Service Parts Part Number

Blade Control Cable 7100641YP Wheel Drive Control Cable 7104004YP Cutter Blade (Double Wave) 7100242AYP Drive Belt 7100883YP

Product Specifications

Deck Size (in) 21 Height of Cut (in) 1.25 - 4 Transmission Type Gear Ground Speed (mph) 0 - 4 Engine Power (gross torque) 8.75 Engine Displacement (cc) 190 Fuel Tank Capacity (qt) 1.2

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1-877-370-7504

21” VARIABLE SPEED SWIVEL WHEEL WALK BEHIND MOWER

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Bad Boy 7800670 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual