Bolens 540 User Manual

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OPERATOR’S MANUAL

21” Rear & Side

Discharge

Mulching Mower

Model Series 540

IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY

Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-

covered, brush-covered or grass-covered land unless the engine’s exhaust system is equipped with a spark arrester meeting applicable local or state laws (if any). If a spark arrester is used, it should be maintained in effective working order by the operator. In the State of California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands. A spark arrester for the muffler is available through your nearest engine authorized service dealer or contact the service department, P.O. Box 368022 Cleveland, Ohio 44136-9722.

MTD PRODUCTS INC. P.O. BOX 368022 CLEVELAND, OHIO 44136-9722

PRINTED IN U.S.A.

FORM NO.

770-10019B.FM (10/00)

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TABLE OF CONTENTS

Content Page

Important Safe Operation Practices...................................................................3

Slope Gauge......................................................................................................6

Assembling Your Lawn Mower...........................................................................7

Know Your Lawn Mower ....................................................................................9

Operating Your Lawn Mower .............................................................................9

Making Adjustments ..........................................................................................10

Maintaining Your Lawn Mower...........................................................................11

Troubleshooting.................................................................................................14

Parts List............................................................................................................16

FINDING MODEL NUMBER

This Operator’s Manual is an important part of your new lawn mower. It will help you assemble, prepare and maintain the unit for best performance. Please read and understand what it says.

Before you start assembling your new equipment, please locate the model plate on the equipment and copy the information from it in the space provided below. The information on the model plate is very important if you need help from our Customer Support Department or an authorized dealer.

• You can locate the model number by standing at the operating position and looking down at the rear of the mower deck. A sample model plate is explained below. For future reference, please copy the model number and the serial number of the equipment in the space below.

(Model Number)

(Serial Number)

MTD PRODUCTS INC

CLEVELAND, OHIO 44136

Copy the model number here:

Copy the serial number here:

CALLING CUSTOMER SUPPORT

If you have difficulty assembling this product or have any questions regarding the controls, operation or maintenance of this unit, please call the Customer Support Department.

Call 1- (330) 220-4MTD (4683) or 1- (800)-800-7310 to reach a Customer Support representative. Please have your unit’s model number and serial number ready when you call. See previous section to locate this information. You will be asked to enter the serial number in order to process your call.

For more details about your unit, visit our website at www.mtdproducts.com

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SECTION 1: IMPORTANT SAFE OPERATION PRACTICES

WARNING: This symbol points out important safety instructions which, if not followed, could

endanger the personal safety and/or property of yourself and others. Read and follow all instructions in this manual before attempting to operate this machine. Failure to comply with these instructions may result in personal injury. When you see this symbol - heed its warning.

WARNING: Engine Exhaust, some of its constituents, and certain vehicle

components contain or emit chemicals known to State of California to cause cancer and birth defects or other reproductiv e harm.

DANGER: This machine was built to be operated according to the rules for safe operation in this

manual. As with any type of power equipment, carelessness or error on the part of the operator can result in serious injury. This machine is capable of amputating hands and feet and throwing objects. Failure to observe the following safety instructions could result in serious injury or death.

General Operation

1. Read this operator’s manual c arefully in its e ntirety before attempting to a ssembl e this mac hine. Read, understand, and fo llow al l instruct ions on th e machin e and in the manua l(s) befo re operatio n. Be com pletely familiar with the c ontrols and the proper use o f this machine before operating it. Keep this manual in a safe place for future and re gular refe rence and for ordering replacement parts.

2. This machine is a precision piece of power equipment, not a plaything. Th erefore, exercise extre me caution at all times. Your unit has been designed to p erform one job: to mow grass. Do not u se it for any other purpose.

3. Never allow childre n under 14 y ears old to operate this machine. Children 14 years old and over should rea d and understand the op eration in struction s and sa fety rules i n this manual and should be trained and sup ervised b y a parent. Only respons ible indiv iduals who a re famili ar with these rules of s afe operati on shoul d be allow ed to us e this machine.

4. Thoroughly inspect the area wh ere the equipment i s to be used. Remove al l stones, sticks , wire, bones, toys and other foreign objec ts which could b e tripped over or picked up and th rown by th e blade. T hrown obje cts can cause serious persona l injury . Plan your m owing patte rn to avoid discharge of materi al toward ro ads, sid ewalks, bystanders and the like. Also, avo id discharging material against a wall or obstructi on which m ay cause discharged material to ri cochet back tow ard the operator.

5. To help avoid blade contact or a thro wn object injury, stay in the operator zo ne behind the hand les and keep children, bystanders , helpers a nd pets a t least 7 5 feet from the mower wh ile it is in opera tion. Stop machine if anyone enters the area.

6. Always wear safet y glasses or safety goggles during operation and while performing an adjustment or repair to protect your eyes. T hrown ob jects whi ch ricochet can cause serious inj ury to the eyes.

7. Wear sturdy, rough-sol ed work shoes a nd close-fi tting slacks and shirts . Shirts an d pants that cove r the a rms and legs and steel -toed shoes are recommend ed. Never operate this machin e in bare feet, san dals, sl ippery or light weight (e.g. c anvas) sho es.

8. Do not put hands o r feet near rotating p arts or un der the cutting deck. Con tact with the blade can am putate ha nds and feet.

9. A missing or damaged discharg e cover can cause b lade contact or thrown ob ject inj uries.

10. Many injuries occur as a resul t of the mower being pul led over the foot during a fall caused by slipping or tripping. Do not hold on to the mower if you are falling; releas e the handle immediately .

11. Never pull the mowe r back to ward yo u while y ou are walking. If you mus t back th e mower aw ay from a wall or obstruction first look down and behind to avoid trippi ng and then follow these st eps:

a. Step back from the mower to fu lly exte nd your

arms. b. Be sure you are well balance d with sure footing. c. Pull the mower back slowly, no more than half way

toward you. d. Repeat these steps as neede d.

12. Do not operate the m ower whi le under t he influe nce of alcohol or drugs.

13. Do not engage the self-pro pelled mechan ism on uni ts so equipped while st arting engine.

14. The blade control handle is a safety device. Never attempt to bypas s its operat ion. Doi ng so m akes the safety device inoperat ive and may result in per sonal injury through contact with the rotating blade. The blade control handle m ust opera te easily i n both di rections and automatically return to the di sengaged positio n when released.

15. Never operate the mow er in wet gra ss. Always be sure of your footing. A s lip and fa ll can c ause se rious person al injury. If you fee l you are lo sing yo ur footi ng, releas e the blade control han dle immedi ately an d the bla de will stop rotating within three second s.

16. Mow only in daylig ht or in goo d artifici al light. Wa lk, never run.

17. Stop the blade wh en crossin g gravel drives, wa lks or roads.

18. If the equipment should start to vibrate abnormally, stop the engine and check immedia tely for the cause . Vibration is gener ally a warn ing of tro uble.

19. Shut the engine off and wa it until t he bla de come s to a complete stop before removi ng the grass catcher or

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unclogging the c hute. The cutting b lade co ntinues t o rotate for a few second s after the engine is shut off. Never place any part of the body in the blade area until you are sure the b lade has s topped rot ating.

20. Never operate mower wi thout prop er trail shield, discharge cover , grass c atcher, blad e cont rol handle or other safety protec tive dev ices in p lace and working. Never operate mower with damaged sa fety devices. Failure to do so, ca n result i n persona l injury .

21. Muffler and engine beco me hot and can cause a burn. Do not touch.

22. Only use parts and accessories made for this machine by the manufacturer. F ailure to do so, c an result in perso nal injury.

23. If situations occur which are not covered in this manua l, use care and good judgment. Cont act your dealer for assistance. Tel ephone 1- 800-800-731 0 for the name of your nearest dealer.

Slope Operation

Slopes are a major f actor re lated to slip and fall accid ents which can result in seve re inju ry. Opera tion on s lopes requires extra cauti on. If you feel une asy on a slope, do not mow it. For your safet y, use th e slope gauge in cluded a s part of this manual to measure s lopes before o perating t his unit on a sloped or hill y area. If the slop e is greater than 15 d egrees, do not mow it.

Do:

1. Mow across the face of sl opes; never up and down. Exercise extreme cauti on when changing d irection on slopes.

2. Watch for holes, ru ts, rocks, hidden ob jects, o r bumps which can cause you to s lip or tri p. Tall grass c an hide obstacles.

3. Always be sure of your footi ng. A slip and fall can ca use serious personal in jury. If y ou feel y ou are lo sing yo ur balance, release the blade c ontrol han dle imm ediately , and the blade w ill stop rotating wi thin 3 se conds.

Do Not:

1. Do not mow near d rop-offs, d itches o r embank ments, you could lose your foot ing or bal ance.

2. Do not mow slopes greater th an 15 degre es as shown on the slope gauge.

3. Do not mow on wet grass. U nstable footing c ould cau se slipping.

Children

Tragic accident s can occu r if the o perator is not al ert to the presence of childre n. Chil dren are of ten attrac ted to the mower and the mowi ng activ ity. They do not unde rstand the dangers. Never assum e that c hildren wil l remain where you last saw them.

1. Keep children out of t he mow ing area a nd under the watchful care of a responsi ble adul t other than the operator.

2. Be alert and turn mower off if a child enters the area.

3. Before and while moving backw ards, look behin d and down for small ch ildren.

4. Use extreme care when approaching blind corners, doorways, shrubs, tree s, or othe r objects th at may

obscure your vision of a child who may run into the mower.

5. Keep children away from hot or running engines. They can suffer burns from a hot muffler.

6. Never allow children u nder 14 y ears old to operate a power mower. Child ren 14 ye ars old a nd over shou ld read and understand t he ope ration inst ructions a nd safety rules in this manual and sho uld be tra ined and supervised by a parent.

Service

Safe Handling Of Gasoline:

1. To avoid personal injury or property damage use extre me care in handling gasolin e. Gasol ine is e xtremely flammable and the v apors are explosiv e. Serious personal injury c an occur w hen gas oline is spilled o n yourself or your c lothes which can ignit e.

2. Wash your skin and chan ge clothe s imme diatel y.

3. Use only an appro ved gaso line con tainer.

4. Never fill contain ers insi de a veh icle or o n a truck or trailer bed with a p lastic liner. Al ways place containers o n the ground away from your v ehicle b efore filli ng.

5. When practical, re move ga s-powered e quipment from the truck or tr ailer and ref uel it on the ground. If this is not possible, then re fuel such e quipment on a trailer with a portable container, ra ther than from a gasoli ne dispenser nozzle.

6. Keep the nozzle i n contact w ith the rim of the fuel tank or container opening a t all times until fue ling is complete. D o not use a nozzle l ock-open device.

7. Extinguish all ciga rettes, c igars, pip es and othe r sources of ignition.

8. Never fuel machin e indoors becaus e flammable vapors will accumulate in the area.

9. Never remove gas ca p or a dd fuel wh ile the e ngine is hot or running. Allow e ngine to c ool at l east two m inutes before refueling.

10. Never over fill fue l tank. Fi ll tank to no mor e than ½ inch below bottom of fil ler neck to provi de space for fuel expansion.

11. Replace gasoline cap and tighten s ecurely.

12. If gasoline is spi lled, wi pe it off the engin e and equipment. Move unit to a nother area. Wait 5 minute s before starting the en gine.

13. Never store the machine or fuel cont ainer inside whe re there is an open flame, spark or pilot light as on a w ater heater, space heater , furnace ,cloth es dryer or other g as appliances.

14. To reduce fire hazard, k eep mower free of gras s, leav es, or other debris bui ld-up. C lean up o il or fue l spillage and remove any fuel soaked debris .

15. Allow a mower to coo l at least 5 minutes before stori ng.

General Service:

1. Never run an engine indoors or in a poorly ven tilated area. Engine exhau st conta ins carb on monox ide, an odorless and dea dly gas .

2. Before cleaning, re pairing, o r inspec ting, mak e certain the blade and al l moving p arts hav e stopped . Disconn ect the spark plug wir e and ground aga inst the engine to prevent unintended starting .

3. Check the blade a nd engine mountin g bolts at frequ ent

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intervals for proper tigh tness. Also, visu ally inspec t blade for damage (e.g., b ent, crack ed, worn) R eplace bl ade with the original equip ment manufacture’s (O. E.M.) blade only, listed in this manual . “Use of p arts which do not meet the original equipment specific ations m ay lead to improper performance and com promise sa fety!”

4. Mower blades are s harp and can cut. Wrap the b lade or wear gloves, and u se extra caution when se rvicing the m.

5. Keep all nuts, bolts, and screws tight to be sure the equipment is in safe work ing cond ition.

6. Never tamper with safety devices. Check their proper operation regularly.

7. After striking a foreign o bject, stop the engine, dis connect the spark plug wire and grou nd agains t the engine. Thoroughly inspect the mower for any da mage. R epair the damage before st arting and operat ing the mow er.

8. Never attempt to ma ke a w heel or c utting hei ght adjustment while the engin e is runn ing.

9. Grass catcher componen ts, discharge cover, and trail shield are subject to wear and dama ge which could expose moving pa rts or allo w objec ts to be thrown. For safety protection, frequentl y check componen ts and replace immediatel y with original equipm ent manufacturer’s (O.E.M .) parts only , listed in this ma nual. “Use of parts which do not m eet the ori ginal eq uipment specifications ma y lead t o imprope r performan ce and compromise safety!”

10. Do not change t he engine governor setting o r overs peed the engine. The go vernor co ntrols th e maxim um safe operating speed o f the engi ne.

11. Maintain or replac e safety and ins truction labels, a s necessary.

12. Observe proper disp osal law s and regulation s. Improp er disposal of flui ds and mate rials ca n harm th e environment.

WARNING - YOUR RESPONSIBILITY: Restrict the use of th is power mac hine to p ersons wh o read,

understand and fo llow th e warnings and ins tructions in this manual a nd on the mach ine.

NOTE: Not all safety labels shown may apply to your lawn mower.

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SECTION 2: SLOPE GAUGE

Use this page as a guide to determine slopes where you may not operate safely. Do not operate your lawn mower on such slopes.

Operate RIDING mowers up and down slopes, never across the face of slopes.

Operate WALK-BEHIND mowers across the face of slopes, never up and down slopes.

Do not mow on inclin es with a s lo pe i n e xces s of 1 5 de gr ees ( a r ise o f approximately 2-1/2 f eet every 10 feet). A ridi ng m owe r could

overturn and cause serio us injur y. If oper ating a walk-be hind mo wer on suc h a slope, i t is ex tremely diffic ult to maint ain your footing

and you could slip, resulting in serious injury.

A CORNER OF A BUILDING

OR A FENCE POST

SIGHT AND HOLD THIS LEVE L WITH A VERTICAL TREE

A POWER POLE

WARNING

15°

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SECTION 3: ASSEMBLING YOUR LAWN MOWER

IMPORT ANT :

in the engine. Be certain to service engine with gasoline and oil as instructed in the separate engine manual before operating your mower.

NOTE: Reference to right or left hand side of the mower is observed from the operating position.

This unit is shipped without gasoline or oil

Removing Unit From Carton

• Remove staples, break glue on top flaps, or cut tape at carton end and peel along top flap to open carton.

• Remove loose parts if included with unit (i.e., operator’s manual, etc.)

• Cut along corners, lay carton down flat, and remove packing material.

• Roll or slide unit out of carton and check carton thoroughly for loose parts.

Loose Parts in Carton

• Grass Bag

• Side Discharge Chute

• Hardware Pack

Disconnecting Spark Pl ug Wire

Before setting up your lawn mower, disconnect the spark plug wire from the spark plug and ground against the engine. See Figure 1.

Bolt

Spark Plug Wire

Figure 2

• Remove the hairpin clips from the outer hole in the weld pins on the handle mounting brackets. Using a pair of pliers, squeeze one leg of the lower handle against the handle mounting bracket. Insert the hairpin clip into the inner hole on the weld pin. Repeat on the other side. See Figure 3.

• After moving the hairpin clip, insert the carriage bolt from hardware pack in the upper hole on the handle mounting bracket and secure with plastic wing nut from the hardware pack. Repeat on other side.

Handle Mounting Bracket

Carriage Bolt

Wing Nut

Insert Ha ir p in Clip

Spark

Plug Wire

Spark Plug

Figure 1

Setting Up Y our Lawn Mower

Assembling Handle

• Lift up and pull back on the upper handle to raise the handle into the operating position. Make certain the lower handle is seated securely into the handle bracket assemblies. Tighten the wing nuts on each side of the handle (carriage bolts must be seated properly into the handle). See Figure 2.

NOTE: Your mower is shipped with the handle in the higher position. If you wish to lower the height of the handle, refer to the Adjustment Section at this time.

Hairpin Clip

Figure 3

• Fasten the cable to the lower handle with the two cable ties found on the lower handle. Pull the cable ties tight and trim off the excess. See Figure 4.

Cable Tie

Lower Handle

Figure 4

Weld Pin

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Attaching Starter Rope

• The rope guide is attached to the right side of upper handle. Loosen the wing nut which secures the rope guide. See Figure 5.

Starter Rope

Rope Guide

Upper Handle

Wing Nut

Lower Handle

Discharge Door

Grass Bag

Figure 5

• With the spark plug wire disconnected and grounded, hold the blade control handle against the upper handle, and pull the starter rope out of the engine. Release the blade control handle. Slip the starter rope into the rope guide. Tighten the wing nut.

Attaching Grass Catcher To Mower

NOTE: The mu lching baffle, if so equip ped, is already in place on the mower for shipping purposes. Your lawn mower may be equipped with both a mulching baffle and a mulching plug. While the mulching baffle is located at the rear of the mower, the mu lching plug is located on the right side of the cutting deck. Do not remove the mulching plug from the mower even when you are not mulching the grass.

• To remove the mulching baffle, lift the rear discharge door on the mower. Remove the mulching baffle. See Figure 6.

Mulching Baffle

Figure 7

• To remove the grass catcher, lift the rear discharge door on the mower, lift the grass catcher up and off the pivot rod. Reinstall the mulching baffle and release the rear discharge door.

WARNING: Never operate the mower unless the hooks on the grass catcher are firmly seated on the chute pivot rod, and the rear discharge door rests firmly against the top of the grass catcher.

Converting To Side Dischar ge

If your unit is equipped with a side discharge chute, you can convert to a side discharge mower as follows:

• Lift the rear discharge door and install the mulching baffle. See Figure 6.

• On the side of the mower, lift the mulching plug and slide the two hooks of the side discharge chute under the hi nge pin on the mulching pl ug assembly. Lower the side mulching plug. See Figure 8.

• Do not remove the side mulching plug at any time, even when you are not mulching.

Figure 6

IMPORT ANT :

Make sure cables are routed to the outside of the handle so they are not in the way when attaching the grass catcher.

• Lift the rear discharge door on the mower.

• Place the hooks, found on both sides of the grass

catcher frame, over the chute door pivot rod at the rear of the mower. Release the rear discharge door. See Figure 7.

Mulching Plug

Hinge Pin

Deflector

Hook

Figure 8

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SECTION 4: KNOW YOUR LAWN MOWER

Read this operator’s manual and safety rules before operating your lawn mower. Compare the illustration in Figure 9 with your lawn mower to familiarize yourself with the location of various controls and adjustments. Save this manual for future reference.

WARNING: The operation of any lawn mower can result in foreign objects being thrown into the eyes, which can damage your eyes severely. Always wear safety glasses while operating the mower, or while performing any adjustments or repairs on it.

Recoil Starter

The recoil starter is attached to the right handle. Stand behind the unit and pull the recoil starter to start the unit. See Figure 9.

Blade Control Handle

The blade control handle is located on the upper handle of the mower. The blade control handle must be depressed in order to operate the unit. Release blade control handle to stop engine and blade. See Figure 9.

Grass Catcher

The grass catcher, located at the rear of the mower, is used to bag the grass clippings for disposal at another site. Once the bag is full, it has to be removed from the mower and emptied before any further mowing.

Recoil Starter

Grass Catcher

Blade Control Handle

Cutting Height Adjustment Lever

WARNING: This blade contro l mechanism is a safety device. Never attempt to bypass its operations.

Cutting Height Adjustment Levers

These levers are located on each wheel and are used to adjust the cu tting hei ght. Thes e levers hav e to be at the same relative position to ensure uniform cut. See Figure 9.

Mulching Plug

Both the mulching baffle and the mulching plug are used only for mulching purposes. Instead of collecting the grass clippings in a grass catcher, some mower models have the option of recirculating the clippings back to the lawn.

SECTION 5: OPERATING YOUR LAWN MOWER

WARNING: Keep hands and feet away from chute area on the cutting deck. The operation of any lawn mower can result in foreign objects being thrown into the eyes, which can result in severe eye damage. Always wear safety glasses or eye shields.

NOTE: For shipping pur poses your mower is set with

the wheels in a low cutting height position. For best results raise the cutting position until it is determine which height is best for your lawn. See the Adjustment Section for details.

Gas and Oil Fill-Up

Service the engine with gasoline and oil as instructed in the separate engine manual packed with your mower. Read instructions carefully.

Starting Engine

• Attach spark plug wire to spark plug. Make certain

• Prime engine as instructed in the separate engine

• Your lawn mower may be equipped with a constant

Never fill fuel tank indoors with engine running or until the engine has been allowed to cool for at least two minutes after running.

the metal c ap on the end o f the spar k plug i s fastened securely over the metal tip on the spark plug.

manual packed with your unit. speed throttle, which is set at full throttle for best

performance.

Mulching Plug

Figure 9

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• Stand behind the mower and squeeze the blade

control handle against the upper handle.

• Grasp recoil starter handle and pull rope out slowly

until engine reaches the start of compression cycle (rope will pull slightly harder at this point). Let the rope rewind slowly. Pull rope with a rapid, continuous, full arm stroke. Keeping a firm grip on the starter handle, let the rope return to the starter slowly.

Using Y our Lawn Mow er

Be sure that the lawn is clear of stones, sticks, wire, or other obj ects wh ich could d amage the la wn mo wer or the engine. Such objects could be accidently thrown by the mower in any di rection and cause serious pers onal injury to the operator and others.

For best results, do not cut wet grass because it tends to stick to the underside of the mower, preventing proper discharge of grass clippings, and could cause you to slip and fall. New grass, thick grass, or wet grass may require a narrower cut.

For a healthier lawn, never cut off more than one-third of the total length of the grass. Your lawn should be cut in the fall as long as there is growth. This mower is

designed to be operated at full throttle to give you the best cut and do the most effective job of mowing or mulching.

WARNING: If you strike a foreign object, stop the engine. Remove wire from the spark plug, thoroughly inspect the mower for any damage, and repair the damage before restarting and operating the mower. Extensive vibration of the mower during operation is an indication of damage. The unit should be promptly inspected and repaired.

Mulching

For effective mulching, do not cut wet grass because it tends to stick to the underside of the deck, preventing proper mulching of grass clippings. New or thick grass may require a narrower cut. The ground speed should be adjusted to the condition of the lawn. If mowing has been delayed and the grass has been allowed to grow in excess of 4”, mulching is not recommended. Mow using the side discharge to reduce the grass height to 3 1/4” maximum before mulching.

SECTION 6: MAKING ADJUSTMENTS

WARNING: Do not at any time make any adjustments without first stopping engine and disconnecting spark plug wire.

Handle Height Adjustment

Your mower is shipped with the handle in the higher height position. To lower the height proceed as follows:

• Remove the start er ro pe fr om the rope g uide .

• Remove the upper handle by removing the hand

knobs and carriage bolts. Lay the upper handle out of the way, being careful not to bend or kink the cables.

• Remove the hairpi n clip s from the w eld pin s on t he

handle brackets and remove the wing nuts and carriage bolts from the upper hole on the handle mounting bracket. Press out on the legs of the lower handle and remove lower handle from the mower.

• Turn lower handle around so the notch on the

bottom of the lower handle is facing forward. See Figure 10.

• Reassemble, placing the bottom holes in the

handle over the weld pins in the handle mounting bracket.

• Place the hairpin clips in the inner holes in the weld

pins and insert the carriage bolts the upper hole on

the handle mounting bracket and secure with plastic wing nuts.

• Reassemble the upper handle to the lower handle.

• Attach the starter rope as instructed in the

Assembly Section.

Notch

Lower Handle

Figure 10

Cutting Height Adjustment

An adjusting plate and spring lever at each wheel position provid es cut ting heig ht adju stme nt. Eac h adjusting plate has assorted height positions. When the spring lever is moved from one location to another the height of cut will be changed. Simply depress the lever towards wheel and move lever assembly to desired position. See Figure 11.

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Height Adjustment Lever

IMPORT ANT :

relative position. For rough or uneven lawns, move the height adjustment lever to a higher position. This will

All wheels must be placed in the same

help stop scalping of the grass.

Engine Adjustments

See the separate engine manual packed with your unit for adjustments to the engine.

Figure 11

SECTION 7: MAINTAINING YOUR LAWN MOWER

General Recommendations

• Always observe safety rules when performing any

maintenance.

• The warran ty on this lawn m ower does n ot co ver

items that have been subjected to operator abuse or negligence. To receive full value from the warranty, operator must maintain the lawn mower as instructed in this manual.

• Changing of engine governed speed will void

engine warranty.

Customer Responsibilities

MAINTENANCE

SCHEDULE

Lubricate Wheels

T C

Lubricate Blade Control

U D

Clean Deck

O R P

Blade Care

• Some adjustm ents will have to be m ade periodically to maintain your unit properly. All adjustments in the Making Adjustments section of this manual should be checked at least once each season.

• Periodically check all fasteners and make sure these are tight.

• Follow the maintenance schedule under Customer Responsibilities to get quality performance from your lawn mower.

SERVICE

DATES

Check Oil Change Oil

Replace Ai r Filter

I G

Clean Engine

N E

Check Spark Plug Check Spark Arrester (if any)

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Lubrication

Always stop engine and disconnect spark plug wire before cleaning, lubricating or doing any kind of service work on the lawn mower.

Blade Control: Lubricate the pivot points on the blade

control handle and the brake cable at least once a season with light oil. The blade control must operate freely in both directions. See Figure 12.

Rear & Side Discharge Doors: The torsion springs and pivot points should be lubricated periodically with light oil to prevent any rust or binding. Door must work freely.

Wheels: The wheels require no lubrication. However, if the wheels are removed for any reason, lubricate the surface of the axle bolt and the inner surface of the wheel with light oil. Engine oil may also be used.

Engine: Follow engine manual for instruction and schedule of lubrication.

Lubricate

Figure 12

Maintenance

NOTE: When tippin g the unit or emp tying the fuel tank keep the air cl eaner side of engine up. Never t ip the mower more than 90 degrees and do not leave the mower tipped for any length of time. O il can drain into the upper part of the engine causing a starting problem.

Replacing Rear Flap

• To remove rear flap, cut off the flat end of the wire rod which secures it to the deck. See Figure 13.

• Attach the new flap and new rod to deck, bending the ends of the new rod over to secure to deck

Rear Discharge Door

Handle Bracket

Rear Flap

Figure 13

Engine

Refer to the separate engine manual for all engine maintenance instructions.

• Maintain engine oil as instructed in the separate engine manual packed with your unit.

• Service air cleaner every 25 hours under normal conditions. Poor engine performance and flooding usually indicate that the air cleaner should be serviced. To service the air cleaner, refer to the separate engine manual packed with your unit.

• The spark plug should be cleaned and the gap reset once a season. Spark plug replacement is recommended at the start of each mowing season.

• Clean the engine regularly with a cloth or brush. Keep the cooling system (blower housing area) clean to permit proper air circulation which is essential to engine performance and life. Be certain to remove all grass, dirt, and combustible debris from muff ler area.

Deck

The underside of the mower deck should be cleaned after eac h use to pr even t a bu ildup of gr ass c lippi ngs, leaves, dirt, or other matter. If this debris is allowed to accumulate, it will invite rust and corrosion, and may prevent proper mulching, discharge, or bagging. The deck may be cleaned by tilting the mower and scraping clean with a suitable tool (make certain the spark plug wire is disconnected).

IMPORT ANT :

pressure washer or garden hose to clean your unit. The use of water will result in shorten life and reduce serviceability.

We do not recommend the use of a

Cutting Blade Removal, Replacement, and Sharpening

• When removing the cutting blade for sharpening or replacement, protect your hands with a pair of heavy gloves or use a heavy rag to hold the blade.

• Remove the bolt and the blade bell support which hold the blade and the blade adapter to the engine crankshaft. See Figure 14.

Page 13

• Remove the blade and the adapter from the crankshaft.

Blade

Adapter

Blade Bell

Support

Hex Bolt

• Slide the blade adapter onto the engine crankshaft.

• Place the blade on the adapter. Be certain the

blade is aligned and seated on the blade adapter flanges.

• Place blade bell support on blade. Make sure the notches on the blade bell support are aligned with small holes in the blade.

• Replace hex bolt and tighten hex bolt to torque: 450 in. lbs. min., 600 in. lbs. max.

NOTE: To ensure safe operation of your mower, the blade bolt must be checked periodically for correct torque.

Figure 14

WARNING: Periodical ly inspect the blade adapter for cracks, especially if you strike a foreign object. Replace when necessary.

When sharpening the blade, follow the original angle of grind as a guide. It is extremely important that each cutting edge receives an equal amount of grinding to prevent an unbalanced blade. An unbalanced blade will cause excessive vibration when rotating at high speeds. It may cause damage to the mower, and could break causing personal injury.

The blade can be tested by balancing it on a round shaft screwdriver. Remove metal from the heavy side until it balances evenly. It is recommended that the blade always be removed from the adapter when testing for balance. Before reinstalling the blade and the blade adapter to the unit, lubricate the engine crankshaft and the inner surface of the blade adapter with light oil.

• Be sure to install the blade with the side of the blade marked “Bottom” (or with part number) facing the ground when the mower is in the operating position.

Storing your Lawn Mower

The following steps should be taken to prepare your lawn mower for storage.

• Clean and lubricate mower thoroughly as described in the lubrication instructions.

IMPORT ANT :

pressure washer or garden hose to clean your unit.

• Refer to engine manual for correct engine storage instructions.

• Coat mower’s cutting blade with chassis grease to prevent rusting.

• Store mower in a dry, clean area. Do not store next to corrosive materials, such as fertilizer.

NOTE: When storing any type of power equipment in a poorly ventilated or metal storage shed, care should be taken to rust-proof the equi pment. Using a light oil or silicone, coat the equipment, e specially cab les and all moving parts.

We do not recommend the use of a

Page 14

SECTION 8: TROUBLESHOOTING

Problem Cause Remedy

Engine fails to start 1. Blade control handle disengaged.

2. Spark plug wire disconnected.

3. Fuel tank empty or stale fuel.

4. Blocked fuel line.

5. Faulty spark plug.

6. Engine flooded

Engine runs er ratic 1. Spa rk plug wir e loose.

2. Blocked fuel line or stale fuel.

3. Vent in gas plugged.

4. Water or dirt in fuel system.

5. Dirty air cleaner.

6. Carburetor out of adjustment.

Engine overheats 1. Engine oil level low.

2. Air flow restricted.

3. Carburetor not adjusted properly.

Occasional skip (hesitates) at high speed

Idles poorly 1. Spark plug fouled, faulty or gap too

Excessive vibration 1. Cutting blade loose or unbalanced.

Mower will not mulch grass 1. Wet grass.

Uneven cut 1. Wheels not positioned correctly.

NOTE: For repairs beyond the minor adjustments above, contact your local authorized service dealer.

1. Spark plug gap too close. 1. Adjust gap to .030”.

wide.

2. Carburetor improperly adjusted.

3. Dirty air cleaner.

2. Bent cutting blade.

2. Excessively high grass.

3. Dull blade.

2. Dull blade.

1. Engage blade control handle.

2. Connect wire to spark plug.

3. Fill tank with clean, fresh gasoline.

4. Clean fuel line.

5. Clean, adjust gap, or replace.

6. Wait a few minutes to restart, but do not prime.

1. Connect and tighten spark plug wire.

2. Clean fuel line; fill tank with clean, fresh gasoline

3. Clear ve nt.

4. Drain fuel tank. Refill with fresh fuel.

5. Clean air cleaner.

6. Adjust carburetor.

1. Fill crankcase with proper oil.

2. Remove blower housing and clean.

3. Adjust carburetor.

1. Reset gap to .030” or replace spark plug.

2. Adjust carburetor.

3. Clean air cleaner.

1. Tighten blade and adapter. Balance blade.

2. Replace blade.

1. Do not mow when grass is wet; wait until later to cut.

2. Mow once at a high cutting height, then mow again at desired height or make a narrower cutting path.

3. Sharpen or replace blade.

1. Place all four wheels in same height position.

2. Sharpen or replace blade.

Page 15

Notes

Page 16

Model Series 540

43 44

Page 17

Model Series 540

Ref.

No.

1. 747-0824 Control Handle Assembly

2. 710-1205 Rope Guide

3. 720-0279 Handle Knob

4. 710-1174 Curved Hd. Bolt 5/16-18 x 2”

5. 712-0324 Hex L-Nut 1/4-20 Thd.

6. 720-0314 Hand Knob

9. 710-1270 Screw 1/4-20 x 1.31

11. 749-0438C Upper Handle

12. 720-0295 Foam Grip †

13. 749-0907A Lower Handle

14. 726-0240 Cable Tie

15. 747-0995A Catcher Frame

16. 746-0550 Control Cable 39”

17. 746-0841 Throttle Cable 60” †

18. 664-0084 Grass Bag w/o log o

19. 731-0066 Hard Top w/ logo

20. 714-0104 Internal Cotter Pin

21. 746-0883 Throttle Housing w /o Lever

22. 682-3058 Handle Bracket Asse mbly - RH

23. 782-7599A Grass Bag Door

24. 750-0434 Spacer .375 OD x .5 0 ID x 1.0 2”

30. 732-0700 Wire Rod

31. 731-1236 Rear Flap

32. 753-0588 Blade Adapter Kit

33. 710-1044 Hex Bolt 3/8-24 x 1. 5”

34. 736-0524A Blade Bell Support

36. 742-0741 Mulching Blade

39. 736-0356 Bell Washer .39” I.D. x 1 .38”

40. 712-0130 Hex Lock Nut 3/8 -16

41. 15261A Height Adj. Plate

42. 15262B Pivot Bar

43. 732-0404 Spring Lever: Front Whee l

44. 738-0507B Shoulder Bolt .5” Dia. x .357”

47. 720-0190 Spring Lever Knob

49. 14578 Height Adj. Assembly Comp - RH

Part No. Part Description

647-0004 Deluxe Control Han dle

746-0737 Control Cable 51”

746-0847 Throttle Cable 42” †

664-0085 Grass Bag w/ logo, Yellow 664-0086 Grass Bag w/ logo, Red

731-0068 Hard Top w/o logo

682-3059 Handle Brkt Ass’y - LH (N ot Shown)

14579 Height Adj. Assembly Comp - LH

Ref.

No.

50. 17488A Pivot Bar - RH

51. 782-5002 Front Baffle

52. 712-0397 Wing Knob

53. 782-5003 Rear Baffle

54. 710-1017 Torx Mach. AB-Tap Scr.

55. 710-0896 Hex Washer Screw 1/4 -14 x .62 5

56. 682-3058 Handle Bracket Assembly —R.H.

57. 710-0703 Carriage Bolt, 1/4-20 x .75”

58. 782-0047 Deck 21”

59. 734-1860 Rear Wheel Ass’y 14 x 2

60. 734-1818 Front Wheel Ass’y. 8 x 2

61. 747-0996 Chute Door Pivot Ro d

62. 710-0654A Sems Screw TT 3/8-16 x 1

63. 682-7000 Mulching Plug

64. 731-1409 Chute Deflector

66. 782-5007A Rear Mulch Plug

67. 782-5004 Rear Mulch Baffle

70. 736-0182 Wave Washer

71. 736-0105 Spring Washer

72. 731-1426 Hub Cap †

73. 738-0481A Rear Axle Bolt

76. 736-0456 Flat Washer

80. 720-0312 Foam Grip

81. 732-0866 Height Adj. Lever

82. 712-3005 Hex Flange Lock Nut 3/8-16

83. 710-0514 Hex Cap Screw 3/8-16 x 1. 0

84. 732-0731 Torsion Spring

85. 747-0710 Hinge Pin

87. 736-0270 Bell Washer .265 x .75 x .062

88. 710-0216 Hex Screw 3/8-16 x .75

89. 736-0331 Bell Washer .39 x 1.1 3 x .062

90. 712-0798 Hex Nut 3/8-16

92. 732-0809 Torsion Spring

93. 738-0102 Front Axle Bolt

94. 782-7006 Hinged Mounting Bracket

95. 710-0896 Hex Screw 1/4-14 x .625

96. 782-9050 Mounting Bracket

Part No. Part Description

17489A Pivot Bar - LH

682-3059 Handle Bracket Assembly —L.H.

734-1864 Rear Wheel Ass’y. 14 x 1.8

734-1781 Front Wheel Ass’y 8 x 1.75 734-1841 Front Wheel Ass’y 8 x 1.7 734-1987 Front Wheel Assembly 8 x 1.8

† If Equipped

Page 18

Page 19

Page 20

MANUFACTURER’S LIMITED WARRAN TY FOR:

The limited warranty set forth below is given by MTD PRODUCTS INC (“MTD”) with respect to new mercha ndise purchased and used in the United States, its possessions and territories.

MTD warrants this product against defects in material and workmanship for a period of two (2) years commencing on the date of original purc ha se an d w i ll, at its option, repair or replace, free of charge, any part found to be defective in material or workmanship. This limited warranty shal l only apply if this product has been operated and maintained in accordance with the Operator’s Manual furnished with the product, a nd has not bee n subj ect to misuse, abuse, commercial use, neglect, accident, improper maintenance, alteration, vandalism, theft, fire, water or damage because of other peril or natur al di sa ste r. Damage resulting from the installation or use of any accessory or attachment not approved by MTD Products Inc. for use with the product(s) covered by this manual will void your warranty as to any resulting damages.

Normal wear parts or components thereof are subject to separate terms as follows: All normal wear part or component failures will be covered on the product for a period of 90 days regardless of cause. After 90 days, but within the two year period, normal wear part failures will be covered ONLY IF caused by defects in material or workmanship of OTHER component parts. Normal wear parts and components include, but are not limited to, belts, blades, blade adapters, grass bags, rider deck wheels, seats, snow thrower skid shoes, shave plates and tires. Batteries are covered by a 90-day limited replacement warranty.

HOW T O OBTAIN SERVICE: Warr a nty service is a v a ilab le , WITH PROOF OF PURCHASE THROUGH YOUR LOCAL AUTHORIZED SERVICE DEALER. To locate the dealer in your area, please check for a listing in the Yellow Pages or contact the Customer Service Department of MTD PRODUCTS INC by calling 1-800-800-7310 or writing to P.O. Box 368022, Clev e la nd, Ohio 44136-9722.

This limited warranty does not provide coverage in the following cases:

a.The engine or component parts thereof. These items

carry a separate manufacturer’s warranty. Please refer to the applicable manufacturer’s warranty on these items.

b.Log splitter pumps, valves and cylinders have a sepa-

rate one year warr an ty.

c. Routine maintenance items such as lubricants, filters,

blade sharpening and tune-ups, or adjustments such as brake adjustments, clutch adjustments or deck adjustments; and normal deterioration of the exterior finish due to use or exposure.

d. MTD does not extend any warranty for products sold

or exported outside of the United States of America, its possessions and territories, except those sold through MTD’s authorized channels of export distribu- tion.

No implied warranty, including any implied warranty of merchantability or fitness for a particular purpose, applies after the applicable period of express written warranty above as to the par ts as ident ified. No o ther express war ranty or guaranty, whether wri tten or or al, except as mentioned above, given by any person or entity, including a dealer or retailer, with respect to any product shall bind MTD. During the period of the Warranty, the exclusive remedy is repair or replacement of the product as set forth above. (Some states do not

allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.)

The provisions as set f orth in this W a rranty pr o vide the sole and exclusive remedy arising from the sales. MTD shall not be liable for incidental or consequential loss or damages including, without limitation, expenses incurred for substitute or replacement lawn care services, for transportation or for related expenses, or for rental expenses to temporarily replace a warranted product. (Some states do not allow the exclusion or limita-

tion of incidental or consequential damages, so the above exclusion or limitation may not apply to you.)

In no event shall recover y of any kind be greater than the amount of the purchase price o f the pro duct sold . Alter ati on of the safety features of the product shall void this Warranty. You assume the risk and liability for loss, damage, or injury to you and your property and/or to others and their property arising out of the use or misuse or inability to use the product.

This limited warranty shall not extend to anyone other than the original purchaser, original lessee or the person for whom it was purchased as a gift.

How State Law Relates to this Warranty: This limited warranty gives you specific legal rights, and you may also have other rights which vary from state to state.