Craftsman 917.378590 User Manual

SEARS

/:RBFTZ

®

MODEL NUMBER 917.378590

oAssembly

• Operation

• Customer
Responsibilities

• Service

OWNER'S MANUAL

,,,--t _,,d,__.d ,tj d,d dd_,,,.*t d L,w,,,_

• Repair Parts

Caution:

Read and Follow

all Safety Rules
and Instructions

Before Operating

This Equipment

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SAFETY RULES

PLUGTO PREVENTACCIDENTALSTARTINGWHENSETTING UP,TRANSPORTING,ADJUSTINGORMAKING
CAUTION:ALWAYSDISCONNECTSPARKPLUGWIREANDPLACEWIREWHEREITCANNOTCONTACTSPARK

REPAIRS IMPORTANT

SAFETY STANDARDSREQUIRE OPERATORPRESENCECONTROLSTO MINIMIZETHERISK OFINJURY. YOURUNIT ISEQUIPPED WITH
SUCH CONTROLS. DO NOT ATTEMPT TO DEFEAT THE FUNCTION OF THE OPERATORPRESENCE CONTROLS UNDER ANY CIRCUM-

STANCES.

TRAINING:

• Read-this operator's manual carefully.. Become familiar with
the controls and know how to operate your mower properly.

Learn how to quickly stop mower.

• Do not allow children to use your mower. Never allow adults
to use mower without proper instructions.

• Keep the area of operation clear of all persons, especially
small children and pets.

• Use mower only as the manufacturer intended and as de-
scribed in this manual.

- Do not operate mower if it has been dropped or damaged in
any manner. Always have damage repaired before using

your mower.

• Do notuse accessory attachments that are not recommended
by the manufacturer. Use of such attachments may be

hazardous_

The blade turns when the engine is running.

PREPARATION:

• Always thoroughly check the area to be mowed and clear it of
all stones, sticks, wires, bones, and other foreign objects.

These objects will be thrown by the blade and can cause
severe injury.

• Always wear safety glasses or eye shields when starting and
while using your mower.

• Dress properly. Do not operate mower when barefoot or

wearing open sandals. Wear only solid shoes with good
traction when mowing,

• Check fuel +_nk before startina engine. Oo not fitf _.as t_nk

Allow the engine to cool for several minutes before filling the

gas tank. Clean off any spilled gasoline before starting the
engine.

• Always make wheel height adjustments before starting your
mower, Never attempt to do this while the engine is running.

• Mow only in daylight or good artificial light.

OPERATION:

• Keep your eyes and mind on your mower and the area being
cut. Do not let other interests distract you.

• Do not mow wet or slippery grass. Never run while operating
your mower. Always be sure of your footing -keep a firmhold

on the handles and walk.
Do not put hands or feet near or under rotating parts. Keep

clear of the discharge opening at alf times.

Always step the engine whenever you leave or are not using
your mowe r,orbefore crossing driveways, walks, roads, and

any gravel-covered areas.

• Never direct discharge of material toward bystanders nor
allow anyone near the mower while you are operating it.

• Before cleaning, inspecting, or repairing your mower, stop

the engine and make absolutely sure the blade and all
moving parts have stopped. Then discon nect the spa rk plug

wire and keep it away from the spark plug to prevent
accidental starting.

• Do not continue to run yourmower if you hit a foreign object.

Follow the procedure outlined above, then repair any dam-
age before restarting and operating you mower.

• Do not change the governor settings or overspeed the
engine. Engine damage or personal injury may result,

• Do not operate your mower if itvibrates abnormally. Exces-
sive vibration is an indication of damage; stop the engine,

safely check for the cause ofvibration and repair as required.

• Do not run the engine indoors. Exhaust fumes are danger-

ous.

Never cut grass by pulling the mower towards you. Mow

across the face of slopes, never up and down or you might

lose your footing. Do not mow excessively steep slopes.
Use caution when operating the mower on uneven terrain or

when changing directions - maintain good footing.
Never operate your mower without proper guards, plates,

grass catcher or other safety devices in place.

MAINTENANCE AND STORAGE:

• Check the blaae and the engine mounting bolts often to be

sure they are tightened properly.

• Check all bolts, nuts and screws at frequent intervals for

proper tightness to be sure mower is insafe working condi-
tion.

Keep all safety devices in place and working.

To reduce fire hazard, keep the engine free of grass, leaves

or excessive grease and oil.

• Check grass catcher often for deterioration and wear and
replace worn bags. Use only replacement bags that are

recommended by and comply with specifications of the
manufacturer of your mower.

• Always keep a sharp blade on your mower.

• Allow engine to coot before storing in any enclosure.

• Never store mower with fuel in the tank inside a building
where fumes may reach an open flame or an ignitionsource

such as a hot water heater, space heater, clothes dryer, etc.

LOOK FOR THIS SYMBOL TO POINT OUT IMPORTANT SAFETY PRECAUTIONS.
IT MEANS - ATTENTION!!! BECOME ALERT!!! YOUR SAFETY IS INVOLVED.

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CONGRATULATIONS on your purchase ofa Sears Lawn

Mower. It has been designed, engineered and manufac-
tured to give you the best possible dependability and
performance.

Should you experience any problem you cannot easily

remedy, please contact your nearest Sears Authorized
Service Center/Department. We have competent, well-

trained technicians and the proper tools to service or repair

this lawn mower.

Please read and retain this manual. The instructions will

enable you to assemble and maintain your lawn mower
properly. Always observe the "SAFETY RULES".

MODEL
NUMBER 917.378590

SERIAL
NUMBER

DATEOFPURCHASE

THE MODELAND SERIAL NUMBERSWtLL BEFOUND
ON A DECAL A-I-rACHED TO THE REAR OF THE
LAWN MOWER HOUSING

YOUSHOULDRECORDBOTHSERIALNUMBERAND
DATE OF PURCHASE AND KEEP IN A SAFE PLACE

FOR FUTURE REFERENCE.

PRODUCT SPECIFICATIONS

HORSEPOWER: 5.5
DISPLACEMENT: 9.0 CU.IN.
GASOLINECAPACITY 1.6 QUARTS

ANDTYPE: UNLEADEDREGULAR
OILTYPE(APFSG): SAE 30 (ABOVE32°F)

SAE 5W-30(below 32°F)

OIL CAPACITY: 20 OZS.
SPARKPLUG: CHAMPION RJ19-LM

(GAP: .030") STD361458
VALVECLEARANCE: INTAKE: .008"

EXHAUST: .008"

SOLID STATE IGNITION

AIRGAP: .0125IN.
BLADEBOLTTORQUE: 35-40 FT.LBS.

MAINTENANCE AGREEMENT

A Sears Maintenance Agreement is available on this product. Contact your nearest Sears store for details.

CUSTOMER RESPONSIBILITIES

• Read and observe the safety rules.

• Follow a regular schedule inmaintaining, caring for and using your lawn mower.

• Follow the instructions under "Customer Responsibilities" and "Storage" sections of this owner's manual.

LIMITED TWO YEAR WARRANTY ON CRAFTSMAN POWER MOWER

For two years from date of purchase, when this Craftsman Lawn Mower is maintained, lubricated, and tuned up
according to the operating and maintenance instructions in the owner's manual, Sears will repair free of charge any

defect in material or workmanship.
If this Craftsman Lawn Mower is used for commercial or rental purposes, this warranty applies for only 90 days from

the date of purchase.
This Warranty does not cover:

• Expendable items which become worn during normal use, such as rotary mower blades, blade adapters, belts,
air cleaners and spark plug.

• Repairs necessary because of operator abuse or negligence, including bent crankshafts and the failure to maintain
the equipment according to the instructions contained in the owner's manual.

WARRANTY SERVICE IS AVAILABLE BY RETURNING THE CRAFTSMAN POWER MOWER TO THE NEAREST

SEARS SERVICE CENTER/DEPARTMENT INTHE UNITED STATES. THIS WARRANTY APPLIES ONLYWHILE

THIS PRODUCT IS IN USE INTHE UNITED STATES.
This Warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

SEARS, ROEBUCK AND CO., D/817 WA, HOFFMAN ESTATES, ILLINOIS 60179

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TABLE OF CONTENTS

SAFETY RULES ............................................................ 2

PRODUCT SPECIFICATIONS ....................................... 3

CUSTOMER RESPONSIBILITIES ....................... 3, 9-11

WARRANTY ................................................................... 3

ASSEMBLY ................................................................... 5

OPERATION .................................................................. 6

INDEX

A

Accessories ..................................... 5

Adjustments:

Carburetor .............................. 14

Drive Control Cable ................ 12

Engine Speed ......................... 14

Handle Height ......................... 13

Height of Cut ............................. 7

Air Filter:

Replacement .......................... 11

Service .................................... 11

Assembly ......................................... 5

B

Blade:

Sharpening ............................. 10

Replacement .......................... 10

C

Controls:

Drive Control ............................. 6

Engine Zone Control ................. 6

Engine Speed Control .............. 6

Operator Presence

Control Bar ............................... 6

Customer Responsibilities.....3, 9-11

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

Blade Care/Replacement ....... 10

DriveWheels .......................... 10

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

Lubrication.............................. 11

Spark Plug .............................. 11

Cutting Levels ................................. 7

Engine:

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

Oil Change .............................. 12

Oil Level .................................. 12

Oil Type .................................. 12

Starting ..................................... 8

Stopping ................................... 8

Storage ................................... 15

Fuel:

Capacity .................................... 3

Storage ................................... 15

Type .......................................... 8

Handle Adjustment:

Assembly .................................. 5

Cutting Height ........................... 7

Lubrication:

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

Lawn Mower ............................. 9

Maintenance Agreement ................. 3

Maintenance Schedule ................... 9

Mowing Tips .................................... 8

Oil:

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

Storage ................................... 15

MAINTENANCE SCHEDULE ........................................ 9

SERVICE AND ADJUSTMENTS ................................. 12

STORAGE .................................................................... 15

TROUBLESHOOTING ................................................. 27

REPAIR PARTS- LAWN MOWER ........................ 16-20

REPAIR PARTS- ENGINE .................................... 21-26

PARTS ORDERING/SERVICE ................ BACK COVER

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F

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L

M

O

Operation:

Drive Control ............................. 7

Engine Control .......................... 7

Grass Catcher ........................ 10

Mower ....................................... 7

Operator Presence

Control Bar ............................... 7

Options:

Accessories .............................. 5

R

Repair Parts:

Engine ............................... 21-26

Lawn Mower ...................... 16-20

Responsibilities, Customer ....3, 9-11

s

Safety Rules .................................... 2

Service and Adjustments .............. 12

Carburetor .............................. 14

DischargeGuard .................... 12

Drive Belt................................ 12

Engine Speed ......................... 14

Handle .................................... 13

Spark Plug..................................... 11

Specifications.................................. 3

Speed Control:

Engine .................................... 14

Starting the Engine .......................... 8

Stopping the Engine ........................ 8

Storage .......................................... 15

T

Trouble Shooting Chart ................. 27

W

Warranty .......................................... 3

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LAWN MOWER RIES

These accessories were available when thislawnmower was produced. They are also available at most Sears retail outlets

and service centers. Most Sears stores can also order repair parts for you, when you provide the model number of your lawn
mower. Some of these accessories may not apply to your lawn mower.

ENGINE

SPARK PLUG MUFFLER AIR FILTER GAS CAN ENGINE OIL STABILIZER

...... •......... •I• iii i ii i i i IIHI,I Illll

LAWN MOWER PERFORMANCE

LAWN MOWER MAINTENANCE i

BELT

BLADE

MULCHER KIT

WHEELS

LAWN MOWER

COVER

.......... EMBLY

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Read these instructions and this :manual in its entirety _PPERATOR PRESENCE

before you attempt to assemble or operate your new lawn
mower. Your new lawn mower has been assembled at the

factory with the exception of those parts left unassembled
for shipping purposes. To ensure safe and proper opera-
tion of your lawn mower, all parts and hardware you
assemble must be tightened securely. Use the correct
tools as necessary to ensure proper tightness. All parts
such as nuts, washers, bolts, etc., necessary to complete

the assembly have been placed in the partsbag.

TO REMOVE LAWN MOWER FROM

CARTON

• Remove loose parts includedw!th mower.

• Cut down two end corners of carton and laYend panel

down flat. .....

• Remove all packing materials except padding between
upper and lower handle and padding holding opera*or

presence control bar to upper handle.

• Roll lawn mower out of carton and check carton thor-

oughly for additional loose parts. •

HOW TO SET UP YOUR LAWN

MOWER

TO UNFOLD HANDLE (See Fig. 1)

IMPORTANT: UNFOLD HANDLE CAREFULLY SO AS
NOT TO PINCH OR DAMAGE CONTROL CABLES.

CONTROL BAR

UPPER HANDLE

LIFT UP

LOWER HANDLE

Raise handles until lower handle section locks inte
place in mowing position.

Raise upper handle section into place on lower handle,
remove protective padding and tighten both handle

knobs.

• Remove handle padding holding operator presence
control bar to upper handle.

• Your lawn mower handle can be adjusted for your

mowing comfort. Refer to "Adjust Handle" in the

5 Service and Adjustments section of this manual.

MOWING POSITION

FIG. 1

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KNOW YOUR LAWN MOWER

READ THIS OWNER'S MANUAL AND SAFEr/RULES BEFORE OPERATING YOUR LAWN MOWER. Compare the
illustrations with your lawn mower to familiarize yourself with the location of various controls and adjustments. Save this

manual for future reference.

OPERATOR PRESENCE

ZONE CONTROL CABLE

STARTER HANDLE

HANDLE KNOB

GASOLINE RLL CAP,

ENGINE SPEED
CONTROL LEVER

CONTROL BAR

DRIVE CONTROL LEVER

,ENGINE OIL CAP WITH DIPSTICK

: i¸

DRIVE COVER

DISCHARGEGUARD

H

WHEEL ADJUSTER .... HOUSING

(ON EACH WHEEL)

FIG. 2

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MEETS CPSC SAFETY REQUIREMENTS

Sears rotary walk-behindpower lawnmowers conform to the safety standards of the American National Standards Institute

and the U.S. Consumer Product Safety Commission. The blade turns when the engine is running.

OPERATOR PRESENCE CONTROL -must be helddown
to the handle to start the engine. Release to stop the

engine.

STARTER HANDLE - usedfor starting the engine.

DRIVE CONTROL LEVER - used to engage power-pro-

PRIMER - pumps additional fuel from the carburetor to the

cylinder for use when starting a cold engine.
ENGINE SPEED CONTROL LEVER - locatedon the side
of the engine which allows you to select either fast (_)or

slow (_) engine speed ..........

pel!ed forward motion of lawn mower. ....

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ATION

HOW TO USE YOUR LAWN MOWER

ENGINE SPEED (See Fig. 3)

The engine speed iscontrolled bya lever locatedon the
side ofthe engine. Fast (_Bi)positionisfor startingengine,

normal cutting and better grass bagging. _Slow (-_m_)

positionis for light cuttingltr!mmingand fuel economy.

ENGINE ZONE CONTROL

risk of blade contact injury. Do not
under any circumstances attempt to

lawn mower in order to minimize the
defeat the function of the operator con-

trol. The blade turns when the engine is

running.

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• Your lawn mower is equipped with an operator pres-
ence control bar which requires the operator to be
positioned behind the lawnmower handle to start and

operate the lawn mower.

DRIVE CONTROL (See Fig. 4)

° Self-propelling is controlledby holding the operator

presence control bar down to the handle and pushing
the drive control lever forward until it clicks; then

release the lever.

• Forward motionwili stop whenthe operatorpresence
controlbar is released. To stopforward motionwithout

stopping engine,releasethe operatorpresencecontrol
bar slightly untl the :drive control disengages. Hold

operator presence control bar downto handleto con-
tinue mowingwithoutself-propelling, ':

• To keep drive controlengaged when turningcomers,
push down on handle and liftfront wheels off ground
whileturning lawn mower.

TO ADJUST CUTTING HEIGHT (See Fig. 5)

• Raisewheels for lowcutand lowerwheelsfor highcut.

• Wheels are set in lowcutfor shipping. Adjust cutting

height to suit your requirements. Medium position is
bestfor most lawns.

To change cutting height, squeeze adjusterlever to-

ward wheel. Move wheel up or down to suit your
requirements. Be sure all wheels are in the same

setting.

ENGINE SPEED CONTROL LEVER

lIVER

FIG. 3

OPERATOR PRESENCE
CONTROL BAR

CONTROL

TO ENGAGE DRIVE CONTROL
DRIVE CONTROL DISENGAGED

FIG. 4

LOWER WHEELS RAISE WHEELS
FOR HIGH CUT FOR LOW CUT

FIG. 5

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BEFORE STARTING ENGINE

OIL (See Fig. 6)

Your lawn mower isshipped withoutoil inthe engine.

Be sure mower is level and area around oilfill is clean.

o

Remove engine oilcap w/dipstickand fillto the full line

on the dipstick.

• Use 20 ozs. of oi!. Fortypeandgradeofoiltouse, see
"ENGINE" in Customer Responsibilities section ofthis
manual.

• Pour oil slowly. Do not over fill.

• Check oil level before each use. Add oil if needed. Fill
to full line on dipstick.

• To read proper level, tighten engine oil cap each time.

• Reinstall engine oil cap and tighten.

= After the first two (2) hours of mowing, change the oil,

and every 25 hours thereafter. You may need to

change the oil more often under dusty, dirtyconditions.

GAS (See Fig, 6)

• Fillgasolinetank withfresh, clean, unleadedgasoline.

DO NOT USE PREMIUM GASOLINE. BE CAREFUL
NOT TO OVER FILL TANK.

WARNING: Experience ndicates that alcohol blended
fuels (called gasohol or using ethanol or methanol) can

attractmoisturewhich leadsto separationand formation of
acids during storage. Acidic gas can damage the fuel
system of an engine while in storage. To avoid engine
problems, the fuel system should be emptiedbefore stor-
age of 30 days or longer. Drain thefuel tank, start the

engine and let it run until fuel linesand carburetor are
empty. Use freshfuel next season. See Storage Instruc-

tions for additional information. Never use engine or
carburetor cleaner products in fuel tank or permanent

damage may occur.

TO START ENGINE

To start a cold engine, push primer three (3) times

before tryingto start. Use-.afirm push. Thisstep is not
usually necessary when startingan engine which has
already run for a few minutes.

Push engine speed controllever to fast (_) position.
Holdoperatorpresence controlbar downto thehandle

and pul!starter handle quickly. DO NOT allowstarter

rope tosnap back.

To STOP engine, release operator presence control

bar.

NOTE: In cooler weather it may be necessary to repeat

priming steps. Inwarmer weather over priming may cause
flooding and engine will not start. If you do flood engine,
wait a few minutes before attempting to start and DO NOT
repeat priming steps.

GASOLINE RLLER CAP

FIG, 6

ENGINE OIL CAP
W/DIPSTICK

MOWING TIPS

• Undercertain conditions,suchas verytatt grass, itmay
be necessary to raise the height of cut to reduce
pushing effort and to keep from overloading the engine

and leaving clumps of grass clippings.

• For extremely heavy cutting, reduce the width of cut by

overlapping previously cut path and mow slowly.

• For better grass bagging and most cutting conditions,
the engine speed should be set inthe fast (_) position,

• For side discharge !awn mowers, cutting in a counter-
clockwise direction, starting at the outside of the area
to be cut, spreads grass clippings more evenly and

puts Iess load on the engine. To keep clippings off of

walkways, flower beds, etc., make the first cuts in a
clockwise direction.

• Pores incloth grass catcherscan become filled with dirt

and dust with use and catchers will collect less grass.

To prevent this, regularly hose catcher off with water

and let dry before using.

• Keep top of engine around starter clear and clean of

grass clippings and chaff. This will help engine airflow
and extend engine life.

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BILITIES

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MAINTENANCE SCHEDULE _ _ _ ___,,_o_ __ _O_

F,L,,NOATES

AS YOU COMPLETE

REGULAR SERVICE ............ E,,,,,,,,DATES

Check for,,Lo0se Fasteners b_'.... If

Clean/inspect Grass Catch'er(if Equipp.ed ) .. .. _ !_ if ....... tf ....

Inspect!Clean 'D'rive"Wheels

Clean Lawn Mower tk/ I_

(Self-Propelled Mowers) V'

R SharPen/aep.!ace.Mower Blade _ S

Lubrication Chart V' If ......

.........Ci'ean BatterylRecharge'

(EIe.ct.r.!cStart Mowers) If t_4

E ..Check Engine Oil Level :........ Ill/ ""

N Change Engine Oil .. tf I/1.2

G Clean.....Air Filter V'2

I lnspec.t Muff!er ..... .V'.

N Replace spa.rk. P!ug ....... t/'

!E Replace Air Filter Paper,,Cartridge ........................................ I/'2 .. '....

1 - Change mere often when operating under a heavy load er in high ambient temperatures.
2 - Service more often when operatfng _n dirty or dusty conditions,

3 - Replace blades more often when mowfng in sandy soil.

4 - Charge 48 hours at end of season.

GENERAL RECOMMENDATIONS

The warranty on this lawn mower does not cover items that
have been subjected to operator abuse or negligence. To

receive full value from the warranty, operator must maintain
mower as instructed in this manual.

Some adjustments will need to be made periodically to

properly maintain your unit.

All adjustments in the Service and Adjustments section of
this manual should be checked at least once each season.

• Once a year, replace the spark plug, clean or replace
air fiiterelement and checkblade forwear. A newspark

plug and clean/new air filter element assures proper
air-fuel mixture and helps your engine run better and

last longer.

• Follow the maintenance schedule in this manual.

BEFORE EACH USE

• Check engine oil level.

• Check for loose fasteners.

LUBRICATION

Keep unit well lubricated (See "LUBRICATION CHART!').

LUBRICATION CHART

(_) WHEEL

ADJUSTER

!_ DISCHARGE

GUARD
HINGE PIN

/

(_ HANDLE BRACKET

MOUNTING PIN

(_) SPRAY LUBRICANT
(_ REFER TO CUSTOMER RESPONSIBILITIES "ENGINE"

SECTION,

IMPORTANT: DO NOT OIL OR GREASE PLASTIC WHEEL

BEARINGS. VISCOUS LUBRICANTS WILL ATTRACT

DUST AND DIRT THAT WtLL SHORTEN THE LIFE OF

THE SELF-LUBRICATING BEARINGS. IF YOU FEEL
THEY MUST BE LUBRICATED, USE ONLY A DRY,

POWERED GRAPHITE TYPE LUBRICANT SPARINGLY.

9

ENGINE OIL