IMPORTANT: THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROW ING OBJECTS. FAILURE
TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH.
I. GENERAL OPERATION
• Read, understand, and follow all instructions on the
machine and in the manual(s) before starting. Be thor ough ly familiar with the controls and the proper use of
the machine before starting.
• Do not put hands or feet near or under rotating parts.
Keep clear of the discharge opening at all times.
• Only allow responsible individuals, who are familiar
with the instructions, to operate the machine.
• Clear the area of objects such as rocks, toys, wire,
bones, sticks, etc., which could be picked up and thrown
by the blade.
• Be sure the area is clear of other people before mow ing. Stop machine if anyone enters the area.
• Do not operate the mower when barefoot or wearing
open sandals. Always wear substantial foot wear.
• Do not pull mower backwards unless absolutely nec es sary. Always look down and behind before and while
moving backwards.
• Do not operate the mower without proper guards,
plates, grass catcher or other safety protective devices
in place.
• See manufacturer’s instructions for proper operation
and installation of accessories. Only use accessories
approved by the manufacturer.
• Stop the blade(s) when crossing gravel drives, walks,
or roads.
• Stop the engine (motor) whenever you leave the equip ment, before cleaning the mower or unclogging the
chute.
• Shut the engine (motor) off and wait until the blade comes
to complete stop before removing grass catch er.
• Mow only in daylight or good artifi cial light.
• Do not operate the machine while under the infl uence
of alcohol or drugs.
• Never operate machine in wet grass. Always be sure of
your footing: keep a fi rm hold on the handle and walk;
never run.
• Disengage the self-propelled mechanism or drive clutch
on mowers so equipped before starting the engine (motor).
• If the equipment should start to vibrate abnormally,
stop the engine (motor) and check immediately for the
cause. Vibration is generally a warning of trouble.
• Always wear safety goggles or safety glasses with side
shields when operating mower.
II. SLOPE OPERATION
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.
DO:
• Mow across the face of slopes: never up and down. Exercise extreme caution when changing direction on slopes.
• Remove obstacles such as rocks, tree limbs, etc.
• Watch for holes, ruts, or bumps. Tall grass can hide
obstacles.
DO NOT:
• Do not trim near drop-offs, ditches or embankments.
The operator could lose footing or balance.
• Do not trim excessively steep slopes.
• Do not mow on wet grass. Reduced footing could cause
slipping.
III. 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.
children will remain where you last saw them.
• Keep children out of the trimming area and under the
watchful care of another re spon si ble adult.
• Be alert and turn machine off if children enter the
area.
• Before and while walking backwards, look behind and
down
for small children.
• Never allow children to operate the machine.
• Use extra care when approaching blind corners, shrubs,
trees, or other objects that may obscure vision.
Never
assume that
IV. SERVICE
• Use extra care in handling gasoline and other fuels.
They are fl ammable and vapors are explosive.
- Use only an approved container.
- Never remove gas cap or add fuel with the
engine running. Allow engine to cool before
refueling. Do not smoke.
- Never refuel the machine indoors.
- Never store the machine or fuel container inside
where there is an open fl ame, such as a water
heater.
• Never run a machine inside a closed area.
• Never make adjustments or repairs with the engine
(motor) running. Disconnect the spark plug wire, and
keep the wire away from the plug to prevent accidental
starting.
• Keep nuts and bolts, especially blade attachement
bolts, tight and keep equipment in good condition.
• Never tamper with safety devices. Check their proper
operation regularly.
• Keep machine free of grass, leaves, or other debris
build-up. Clean oil or fuel spillage. Allow machine to
cool before storing.
• Stop and inspect the equipment if you strike an object.
Repair, if necessary, before restarting.
• Never attempt to make wheel height adjustments while
the engine (motor) is running.
• Grass catcher components are subject to wear, dam age, and deterioration, which could expose moving
parts or allow objects to be thrown. Frequently check
com po nents and replace with manufacturer’s rec om mend ed parts, when necessary.
• Mower blades are sharp and can cut. Wrap the blade(s)
or wear gloves, and use extra caution when servicing
them.
• Do not change the engine governor setting or overspeed
2
the engine.
Page 3
Look for this symbol to point out im por tant safety precautions. It means
CAUTION!!! BE COME ALERT!!! YOUR
SAFE TY IS IN VOLVED.
CAUTION: Always disconnect spark plug
wire and place wire where it cannot contact
spark plug in order to prevent ac ci den tal
starting when setting up, trans port ing,
adjusting or making re pairs.
WARNING: Engine exhaust, some of
its con stit u ents, and certain vehicle
com po nents contain or emit chem icals known to the State of Cal i for nia
to cause can cer and birth defects or
oth er re pro duc tive harm.
WARNING: Battery posts, terminals and
related ac ces so ries contain lead and
lead compounds, chemicals known to
the State of Cal i for nia to cause can cer
and birth defects or oth er re pro duc tive
harm. Wash hands after handling.
CAUTION: Muffl er and other engine
parts become extremely hot during
operation and remain hot after engine
has stopped. To avoid severe burns on
contact, stay away from these areas.
CONGRATULATIONS on your purchase of a new lawn
mower. It has been designed, engineered and man u fac tured
to give you the best possible dependability and performance.
Should you experience any problem you cannot easily
remedy, please contact your nearest authorized service
center/department. We have competent, well-trained
tech ni cians 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”.
SERIAL
NUMBER: _________________________________
DATE OF PURCHASE: _______________________
THE MODEL AND SERIAL NUMBERS WILL BE FOUND
ON A DECAL ATTACHED TO THE REAR OF THE LAWN
MOWER HOUSING.
YOU SHOULD RECORD BOTH SERIAL NUMBER AND
DATE OF PURCHASE AND KEEP IN A SAFE PLACE
FOR FUTURE REFERENCE.
PRODUCT SPECIFICATIONS
Gasoline Capacity 1.0 Quarts
and Type: (Unleaded Regular Only)
Oil Type (API-SF-SJ): SAE 10W-30
Oil Capacity: 18.5 Ounces
Spark Plug: NGK BPR6ES (Gap: .030")
Valve Clearance: Intake: 0.015 mm
(± 0.04 mm) Exhaust: 0.020 mm
Blade Bolt Torque: 35-40 ft. lbs.
CUSTOMER RESPONSIBILITIES
• Read and observe the safety rules.
• Follow a regular schedule in maintaining, caring for and
using your lawn mower.
• Follow the instructions under “Maintenance” and “Stor age” sec tions of this own er’s manual.
Read these instructions and this man u al in its entirety before
you attempt to assemble or operate your new lawn mow er.
IMPORTANT: THIS LAWN MOWER IS SHIPPED WITH OUT OIL OR GASOLINE IN THE ENGINE.
Your new lawn mower has been as sem bled at the factory
with the ex cep tion of those parts left unassembled for shipping purposes. All parts such as nuts, washers, bolts, etc.,
necessary to com plete the as sem bly have been placed in
the parts bag. To ensure safe and proper operation of your
lawn mow er, all parts and hard ware you assemble must
be tightened se cure ly. Use the correct tools as nec es sary
to ensure proper tightness.
TO RE MOVE LAWN MOW ER FROM CAR TON
1. Remove loose parts included with mower.
2. Cut down two end corners of car ton and lay end panel
down fl at.
3. Remove all packing materials ex cept padding be tween
upper and lower handle and padding holding operator
presence control bar to up per handle.
4. Roll lawn mower out of carton and check carton thorougly for ad di tion al loose parts.
HOW TO SET UP YOUR LAWN MOW ER
TO UNFOLD HANDLE (See Figs. 1 and 2)
IMPORTANT: UNFOLD HANDLE CAREFULLY SO AS
NOT TO PINCH OR DAMAGE CON TROL CABLES.
1. Raise handles until lower handle section locks into
place in mowing position.
2. Remove protective padding, raise upper handle sec tion into place on lower handle and tighten both handle
knobs.
3. Remove handle padding holding operator pres ence
control bar to upper handle.
Your handles may be adjusted for your mowing comfort.
Refer to “ADJUST HANDLE” in the Service and Ad just ments
sec tion of this man u al.
OPERATOR PRESENCE
CONTROL BAR
UPPER HANDLE
LOWER HANDLE
LIFT
UP
LIFT UP
MOWING
PO SI TION
FIG. 1
TO ASSEMBLE GRASS CATCHER
(See Fig. 2)
1. Put grass catcher frame into grass bag with rigid part
of bag on the bottom. Make sure the frame handle is
outside of the bag top.
2. Slip vinyl bindings over frame.
NOTE: If vinyl bindings are too stiff, hold them in warm water
for a few minutes. If bag gets wet, let it dry before using.
CATCHER
FRAME
HANDLE
VINYL
BINDINGS
OPENING
FIG. 2
TO INSTALL ATTACHMENTS
Your lawn mower was shipped ready to be used as a
mulcher. To convert mower to bagging or discharging,
see “TO CON VERT MOWER” in the Operation section of
this man u al.
4
FRAME
Page 5
OPERATION
KNOW YOUR LAWN MOWER
READ THIS OWNER'S MANUAL AND SAFETY 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.
These symbols may appear on your lawn mower or in literature supplied with the product. Learn and understand
their meaning.
DRIVE
CONTROL
BAR
STARTER
HANDLE
GRASS
CATCHER
EN GINE OIL CAP
WITH DIPSTICK
OPERATOR PRESENCE CON TROL BAR
HANDLE KNOB
GAS O LINE FILL ER CAP
FUEL VALVE LEVER
AIR FILTER
HOUSING
DRIVE
COVER
MULCHER DOOR
MUFFLER
IMPORTANT: This lawn mower is shipped
WITHOUT OIL OR GASOLINE in the engine.
WHEEL ADJUSTER (ON EACH WHEEL)
MEETS CPSC SAFETY REQUIREMENTS
Our rotary walk-behind power lawn mowers 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 BAR – must be held
down to the handle to start the engine. Release to stop
the engine.
STARTER HANDLE – used for starting the engine.
DRIVE CONTROL BAR – used to engage power-propelled
forward motion lawn mower.
MULCHER DOOR – allows conversion to discharge or
bagging operation.
5
Page 6
OPERATION
The operation of any lawn mower can result in foreign objects thrown into the eyes, which can result
in severe eye damage. Always wear safety glasses or eye shields while operating your lawn mower or
performing any adjustments or repairs. We recommend standard safety glasses or a wide vision safety
mask over spectacles.
HOW TO USE YOUR LAWN MOWER
ENGINE SPEED
The engine speed was set at the factory for optimum performance. Speed is not adjustable.
ENGINE ZONE CONTROL
CAUTION: Federal regulations require
an engine control to be installed on this
lawn mower in order to minimize the risk
of blade contact injury. Do not un der
any cir cum stanc es attempt to defeat
the function of the operator control.
The blade turns when the engine is
running.
• Your lawn mower is equipped with an operator presence
control bar which requires the operator to be positioned
behind the lawn mower handle to start and operate the
lawn mower.
DRIVE CONTROL (See Fig. 3)
• Self-propelling is controlled by hold ing the operator
presence control bar down to the handle and pulling
the drive control bar up to the handle. The closer to the
handle the bar is pulled, the faster the unit will travel.
• Forward motion will stop when either the operator presence control bar or drive control bar are released. To
stop forward motion without stop ping engine, re lease
the drive control bar only. Hold op er a tor presence control
bar down against handle to con tin ue mowing without
self-propelling.
NOTE: If after releasing the drive control the mower will
not roll backwards, push the mower forward slightly to
disengage drive wheels.
• To keep drive control engaged when turning corners,
push down on the handle to lift the front wheels off the
ground while turning lawn mower.
DRIVE CONTROL ADJUSTMENT (See Fig. 3)
Over time, the drive control system may become “loose”,
resulting in decreased speed. There is a thumbscrew on
the un der side of the drive control housing to increase tension on the drive cable. Pro ceed as follows:
1. Turn unit off and disconnect spark plug wire from spark
plug.
2. Rotate thumbscrew counter-clockwise to tighten the
drive cable.
3. Operate mower to test drive speed.
4. If condition fails to improve after the above steps (forward speed remains the same), your drive belt is worn
and should be re placed.
NOTE: If mower begins to “creep” forward, the drive cable
is too tight. Rotate thumbscrew clockwise to loosen drive
cable.
OPERATOR PRESENCE CONTROL BAR
THUMBSCREW
DRIVE
CONTROL
ENGAGED
DRIVE
CONTROL
BAR
DISENGAGED
DRIVE
CONTROL
FIG. 3
TO ADJUST CUTTING HEIGHT (See Fig. 4)
Raise wheels for low cut and lower wheels for high cut,
adjust cutting height to suit your requirements. Me di um
position is best for most lawns.
• To change cutting height, squeeze adjuster lever to ward
wheel. Move wheel up or down to suit your re quire ments.
Be sure all wheels are in the same setting.
NOTE: Adjuster is properly positioned when plate tab inserts
into hole in lever. Also, 9-position adjusters (if so equipped)
allow lever to be positioned between the plate tabs.
LEVER BACKWARD TO LOWER MOWER
PLATE
TAB
LEVER FORWARD TO RAISE MOWER
FIG. 4
TO CONVERT MOWER
Your lawn mower was shipped ready to be used as a
mulcher. To convert to bagging or discharging:
REAR BAGGING (See Fig. 5)
• Lift rear door of the lawn mower and place the grass
catcher frame hooks onto the door pivot pins.
• To convert to mulching or dis charg ing operation, remove
grass catch er and close rear door.
SIDE DISCHARGING (See Fig. 6)
• Rear door must be closed.
• Open mulcher door and install dis charge defl ector
under door as shown.
• Mower is now ready for discharging operation.
• To convert to mulching or bagging operation, dis charge
defl ector must be removed and mulcher door must be
closed.
6
LEVER
Page 7
OPERATION
PIVOT PINSREAR
CATCH ER FRAME HOOK
FIG. 5
DOOR
GRASS
CATCHER
HANDLE
OPEN
MULCHER
DOOR
SIMPLE STEPS TO REMEMBER
WHEN CONVERTING YOUR LAWN MOWER
FOR MULCHING -
1. Rear door closed.
2. Mulcher door closed.
FOR REAR BAGGING -
1. Grass catcher installed.
2. Mulcher door closed.
FOR SIDE DISCHARGING -
1. Rear door closed.
2. Discharge defl ector installed.
CAUTION: Do not run your lawn mower
with out rear door closed or ap proved
grass catcher in place. Never at tempt
to op er ate the lawn mow er with the rear
door re moved or propped open.
TO EMPTY GRASS CATCHER (See Fig. 7)
1. Lift up on grass catcher using the frame han dle.
2. Remove grass catcher with clippings from under lawn
mower han dle.
3. Empty clippings from bag using both frame handle and
bag handle.
NOTE: Do not drag the bag when emptying; it will cause
unnecessary wear.
DISCHARGE
DEFLECTOR
FIG. 6
GRASS
CATCHER
FRAME
HANDLE
BAG
HANDLE
FIG. 7
7
Page 8
OPERATION
BEFORE STARTING ENGINE
ADD OIL (See Figs. 7 and 8)
Your lawnmower is shipped without oil in the engine. For type
and grade of oil to use, see “EN GINE” in the Maintenance
section of this manual.
CAUTION: DO NOT overfi ll engine with
oil, or it will smoke heavily from the muffl er on startup.
1. Be sure lawnmower is level.
2. Remove oil dipstick from oil fi ll spout.
3. You receive a container of oil with the unit. Slowly
pour the entire container down the oil fi ll spout into the
engine.
4. Insert and tighten dipstick.
IMPORTANT:
• Check oil level before each use. Add oil if needed. Fill
to full line on dipstick.
• Change the oil after every 25 hours of operation or each
season. You may need to change the oil more often
under dusty, dirty conditions. See “TO CHANGE ENGINE OIL” in the Maintenance section of this manual.
OIL FILLER CAP/DIPSTICK
ADD GASOLINE (See Fig. 8)
• Fill fuel tank to bottom of tank fi ller neck. Do not overfi ll. Use fresh, clean, regular unleaded gasoline with
a minimum of 87 octane. Do not mix oil with gasoline.
Purchase fuel in quan ti ties that can be used within 30
days to assure fuel freshness.
CAUTION: Wipe off any spilled oil or
fuel. Do not store, spill or use gasoline
near an open fl ame.
Alcohol blended fuels (called gasohol
or using ethanol or methanol) can attract moisture which leads to separation
and for ma tion 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 emptied before stor age of
30 days or longer. Empty the gas tank,
start the engine and let it run until the
fuel lines and carburetor are empty. Use
fresh fuel next season. See Storage
In struc tions for additional information.
Never use engine or carburetor cleaner
products in the fuel tank or permanent
damage may occur.
TO STOP ENGINE
• To stop engine, release operator presence control bar.
Wait until blade and all moving parts have stopped and
turn fuel valve to OFF position if you do not intend to
re start the engine soon.
OIL
FILLER
CAP
FIG. 7
FIG. 8
UPPER LIMIT
LOWER LIMIT
GASOLINE
FILLER CAP
TO START ENGINE (See Fig. 9)
NOTE: Due to protective coatings on the engine, a small
amount of smoke may be present during the initial use of
the product and should be considered normal.
1. Be sure fuel valve is in the ON po si tion.
2. Move choke lever to ON ( ) position.
3. Hold operator presence control bar down to the han dle
and pull starter handle quickly. Do not allow starter rope
to snap back.
NOTE: The choke lever automatically begins moving to
the OFF position when operator presence control bar is
held down to handle.
8
Page 9
OPERATION
OFF
ON
()
ON
FUEL VALVE LEVER
FIG. 9
CHOKE LEVER
OFF
MOWING TIPS
• Under certain conditions, such as very tall grass, it
may 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. It may also be
necessary to reduce ground speed and/or run the lawn
mower over the area a second time.
• 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 in the fast position.
• Pores in cloth grass catchers can become fi lled 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 air fl ow
and extend engine life.
MULCHING MOWING TIPS
IMPORTANT: FOR BEST PERFORMANCE, KEEP MOWER
HOUSING FREE OF BUILT-UP GRASS AND TRASH. SEE
“CLEANING” IN THE MAINTENANCE SECTION OF THIS
MANUAL.
• The special mulching blade will recut the grass clippings many times and reduce them in size so that as
they fall onto the lawn they will disperse into the grass
and not be noticed. Also, the mulched grass will biodegrade quickly to provide nutrients for the lawn. Always
mulch with your highest engine (blade) speed as this
will provide the best recutting action of the blades.
• Avoid cutting your lawn when it is wet. Wet grass tends
to form clumps and interferes with the mulching action.
The best time to mow your lawn is the early afternoon.
At this time the grass has dried, yet the newly cut area
will not be exposed to direct sunlight.
• For best results, adjust the lawn mower cutting height
so that the lawn mower cuts off only the top one-third
of the grass blades (See Fig. 10). If the lawn is overgrown it will be necessary to raise the height of cut to
reduce pushing effort and to keep from overloading
the engine and leaving clumps of mulched grass. For
extremely heavy mulching, reduce your width of cut by
overlapping previously cut path and mow slowly.
MAX 1/3
FIG. 10
• Certain types of grass and grass conditions may require
that an area be mulched a second time to completely
hide the clippings. When doing a second cut, mow
across (perpendicular) to the fi rst cut path.
• Change your cutting pattern from week to week. Mow
north to south one week then change to east to west the
next week. This will help prevent matting and graining
of the lawn.
Check Engine Oil level
Change Engine Oil
Clean Air Filter
Inspect Muffler
Replace Spark Plug
Replace Air Filter Paper Cartridge
Empty fuel system or add Stabilizer
BEFORE
EACH
USE
AFTER
EACH
USE
EVERY
10
HOURS
EVERY
25 HOURS
OR SEASON
EVERY
100
HOURS
BEFORE
STORAGE
(if so equipped)
*
Electric-Start mowers
**
Power-Propelled mowers
***
Use a scraper
****
to clean under deck
1 - Change more often if operating under a heavy load or in high outdoor temperatures.
2 - Service more often if operating in dirty or dusty conditions.
3 - Replace blades more often when mowing in sandy soil.
4 - Charge 48 hours at end of season.
5 - And after each 5 hours of use.
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.
At least once a season, check to see if you should make
any of the adjustments described in the Service and Ad just ments section of this manual.
• At least once a year, replace the spark plug, clean or
replace air fi lter element and check blade for wear. A
new spark plug and clean/new air fi lter element assure
proper air-fuel mixture and help your engine run better
and last longer.
• Follow the maintenance schedule in this manual.
BEFORE EACH USE
1. Check engine oil level.
2. Check for loose fasteners.
LUBRICATION CHART
REAR DOOR HINGE
➀
WHEEL
➀
ADJUSTER
(ON EACH
WHEEL)
ENGINE OIL
➁
MULCHER
➀
HINGE PIN
DOOR
LUBRICATION
Keep unit well lubricated (See “LUBRICATION CHART”).
IMPORTANT: DO NOT OIL OR GREASE PLASTIC WHEEL
BEARINGS. VISCOUS LU BRI CANTS WILL ATTRACT DUST
AND DIRT THAT WILL SHORT EN THE LIFE OF THE SELFLU BRI CAT ING BEARINGS. IF YOU FEEL THEY MUST BE
LU BRI CATED, USE ONLY A DRY, POW DERED GRAPHITE
TYPE LUBRICANT SPAR INGLY.
10
HANDLE BRACK ET MOUNT ING PINS
➀
SPRAY LUBRICANT
➀
SEE “ENGINE” IN MAINTENANCE SECTION
➁
Page 11
MAINTENANCE
LAWN MOWER
Always observe safety rules when performing any main te nance.
TIRES
• Keep tires free of gasoline, oil, or insect control chem i cals which can harm rubber.
• Avoid stumps, stones, deep ruts, sharp objects and
other hazards that may cause tire damage.
DRIVE WHEELS
Check front drive wheels each time be fore you mow to be
sure they move freely.
The wheels not turning freely means trash, grass cuttings,
etc. are in the drive wheel area and must be cleaned to
free drive wheels.
If necessary to clean the drive wheels, be sure to clean
both front wheels.
1. Remove hubcaps, locknuts and washers.
2. Remove wheels from wheel ad just ers.
3. Remove any trash or grass cuttings from inside the
dust cover, pinion and/or drive wheel gear teeth.
4. Put wheels back in place.
NOTE: If after cleaning, the drive wheels do not turn freely,
contact a qualifi ed service center.
BLADE CARE
For best results, mower blade must be kept sharp. Re place
bent or dam aged blades.
TO REMOVE BLADE (See Fig. 11)
1. Disconnect spark plug wire from spark plug and place
wire where it cannot come in contact with plug.
2. Turn lawn mower on its side. Make sure air fi lter and
carburetor are up.
3. Use a wood block between blade and mower hous ing
to prevent blade from turning when re mov ing blade bolt.
NOTE: Protect your hands with gloves and/or wrap blade
with heavy cloth.
4. Remove blade bolt by turning counter-clockwise.
5. Remove blade and attaching hardware (bolt, lock wash er
and hardened wash er).
NOTE: Remove the blade adapter and check the key inside
hub of blade adapter. The key must be in good condition to
work properly. Replace adapter if dam aged.
TO REPLACE BLADE (See Fig. 11)
1. Position the blade adapter on the engine crank shaft.
Be sure key in adapter and crankshaft key way are
aligned.
2. Position blade on the blade adapter aligning the two
(2) holes in the blade with the raised lugs on the
adapter.
3. Be sure the trailing edge of blade (opposite sharp edge)
is up toward the engine.
4. Install the blade bolt with the lock washer and hard ened
washer into blade adapter and crank shaft.
5. Use block of wood between blade and lawn mower
housing and tighten the blade bolt, turning clock wise.
• The recommended tightening torque is 35-40 ft. lbs.
IMPORTANT: BLADE BOLT IS HEAT TREATED. IF BOLT NEEDS
REPLACING, REPLACE ONLY WITH APPROVED BOLT SHOWN
IN THE REPAIR PARTS SECTION OF THIS MANUAL.
BLADE ADAPTER
KEY
BLADE
LOCK
WASHER
BLADE
BOLT
HARDENED
WASHER
TRAILING EDGE
CRANKSHAFT
KEY WAY
CRANK-
SHAFT
BLADE ADAPT ER
FIG. 11
TO SHARPEN BLADE
NOTE: We do not recommend sharp en ing blade - but if
you do, be sure the blade is balanced.
Care should be taken to keep the blade balanced. An
un bal anced blade will cause eventual damage to lawn
mower or engine.
• The blade can be sharp ened with a fi le or on a grinding
wheel. Do not attempt to sharpen while on the mower.
• To check blade balance, drive a nail into a beam or
wall. Leave about one inch of the straight nail ex posed.
Place center hole of blade over the head of the nail.
If blade is balanced, it should remain in a horizontal
position. If either end of the blade moves downward,
sharpen the heavy end until the blade is balanced.
GRASS CATCHER
• The grass catcher may be hosed with water, but must
be dry when used.
• Check your grass catcher often for damage or de te ri o ra tion. Through normal use it will wear. If catcher
needs replacing, replace only with ap proved replacement catcher shown in the Repair Parts section of this
manual. Give the lawn mower model number when
ordering.
GEAR CASE
• To keep your drive system working properly, the gear
case and area around the drive should be kept clean
and free of trash build-up. Clean under the drive cover
twice a season.
• The gear case is fi lled with lubricant to the proper
level at the factory. The only time the lubricant needs
attention is if service has been performed on the gear
case.
• If lubricant is required, use only ELF Multis EP00.
Do not substitute.
11
Page 12
MAINTENANCE
ENGINE
LUBRICATION
Use only high quality detergent oil rated with API service
classifi cation SF-SJ. Select the oil's SAE viscosity grade
according to your expected operating temperature.
NOTE: Multi-viscosity oils (5W30, 10W30 etc.) improve
starting in cold weather, and you should check your engine
oil level frequently to avoid possible engine damage from
running low on oil.
Change the oil after every 25 hours of operation or at least
once a year if the lawn mower is not used for 25 hours in
one year.
Check the crankcase oil level before starting the engine
and after each fi ve (5) hours of continuous use. Tighten oil
plug securely each time you check the oil level.
TO CHANGE ENGINE OIL (See Fig. 12)
NOTE: Before tipping lawn mower to drain oil, empty fuel
tank by running engine until fuel tank is empty.
1. Disconnect spark plug wire from spark plug and place
wire where it cannot come in contact with plug.
2. Remove engine oil cap; lay aside on a clean surface.
3. Tip lawn mower on its side as shown and drain oil into
a suitable container. Rock lawn mower back and forth
to remove any oil trapped inside of engine.
OIL FILLER CAP/DIPSTICK
5. Fill engine with oil. The engine oil capacity is 18.5 oz.
If oil is not com plete ly drained from engine, you may
not need the entire container of a 20 oz. bottle of oil.
Slowly pour 3/4 of the oil from the container down the
oil fi ll spout into the engine.
6. Wait one minute to allow oil to settle. Use guage on oil
fi ll cap/dipstick for checking level. Insert dipstick into
the tube and rest the oil fi ll cap on the tube. DO NOT
thread the cap into the tube when taking reading.
7. Continue adding small amounts of oil and rechecking
the dipstick until it reads full. DO NOT overfi ll, or engine
will smoke on startup.
8. Always be sure to retighten oil dipstick before starting
engine.
9. Reconnect spark plug wire to spark plug.
AIR FILTER
Your engine will not run properly and may be damaged
by using a dirty air fi lter. Replace the air fi lter every 100
hours of operation or every season, whichever occurs fi rst.
Ser vice air cleaner more often under dusty conditions. See
the main te nance section of your engine manual.
MUFFLER
Inspect and replace corroded muffl er as it could create a
fi re hazard and/or damage.
SPARK PLUG
Replace spark plug at the beginning of each mowing season
or after every 100 hours of operation, whichever occurs
fi rst. Spark plug type and gap setting are shown in the
“PROD UCT SPEC I FI CA TIONS” section of this manual.
CLEANING
IMPORTANT: FOR BEST PERFORMANCE, KEEP MOWER
HOUSING FREE OF BUILT-UP GRASS AND TRASH. CLEAN
THE UNDERSIDE OF YOUR MOWER AFTER EACH USE.
CAUTION: Disconnect spark plug wire
from spark plug and place wire where it
cannot come in contact with plug.
UPPER
LIMIT
LOWER
LIMIT
FIG. 12
4. Wipe off any spilled oil from lawn mower or side of
engine.
• Clean the underside of your lawn mower by scraping
to remove build-up of grass and trash.
• Clean engine often to keep trash from accumulating. A
clogged engine runs hotter and shortens engine life.
• Keep fi nished surfaces and wheels free of all gasoline,
oil, etc.
• We do not recommend using a garden hose to clean
lawn mower unless the electrical system, muffl er, air
fi lter and carburetor are covered to keep water out.
Water in engine can result in shortened engine life.
CLEAN UNDER DRIVE COVER
Clean under drive cover at least twice a season. Scrape underside of cover with putty knife or similar tool to remove any
build-up of trash or grass on underside of drive cover.
12
Page 13
SERVICE AND ADJUSTMENTS
CAUTION: TO AVOID SERIOUS INJURY, BEFORE PERFORMING ANY SERVICE OR ADJUSTMENTS:
1. Release control bar and stop engine.
2. Make sure the blade and all moving parts have completely stopped.
3. Disconnect spark plug wire from spark plug and place where it cannot come in contact with plug.
LAWN MOWER
TO ADJUST CUTTING HEIGHT
See “TO ADJUST CUTTING HEIGHT” in the Operation
section of this manual.
REAR DEFLECTOR
The rear defl ector, attached between the rear wheels of
your mower, is provided to minimize the possibility that
objects will be thrown out of the rear of the mower into
the operator's mowing position. If the defl ector becomes
damaged, it should be replaced.
TO REMOVE DRIVE BELT (See Fig. 13)
1. Remove drive cover and belt keeper.
2. Remove belt from gearcase pulley by push ing down
on pulley and rolling belt off it.
3. Turn lawn mower on its side with air fi lter and car bu re tor up.
4. Remove blade and debris shield.
5. Remove belt from engine pulley on crankshaft.
TO REPLACE DRIVE BELT (See Fig. 13)
1. Install new belt on engine pulley.
2. Reinstall debris shield and blade.
3. Return mower to upright po si tion.
4. Install new belt on gearcase pulley.
5. Reinstall belt keeper and drive cover.
NOTE: Always use factory approved belt to assure fi t and
long life.
2. Remove hairpin cotters from lower handle bracket
mount ing pin.
3. Squeeze lower handle in to remove it from mounting pins.
4. Turn lower handle over to raise or lower handle.
5. Squeeze lower handle in and po si tion holes onto
mount ing pins on handle bracket.
6. Reassemble upper handle and all parts removed from
lower handle.
LOWER
HANDLE
ROTATE
FIG. 14
MOWING
POSITION
HAIRPIN
COTTER
MOUNTING
PIN
MOWING
POSITION
HANDLE
BRACKET
HIGH POSITIONLOW POSITION
DRIVE
COVER
BELT KEEPER
PUSH DOWN
BELT
FIG. 13
TO ADJUST HANDLE (See Figs. 14 and 15)
The handle can be mounted in a high or low position. The
mounting holes in the bottom of lower handle are off center
for raising or lowering the handle.
1. Remove upper handle and all wire tie(s) securing
cable(s) to lower handle.
ENGINE
FIG. 15
ENGINE SPEED
Your engine speed has been factory set. Do not attempt to
increase engine speed or it may result in personal injury. If
you believe that the engine is running too fast or too slow,
take your lawn mower to an authorized service center for
repair and adjustment.
CARBURETOR
Your carburetor is not adjustable. If your engine does not
operate properly due to suspected carburetor problems,
take your lawn mower to an authorized service center for
repair and/or adjustment.
IMPORTANT: NEVER TAMPER WITH THE ENGINE GOVERNOR,
WHICH IS FACTORY SET FOR PROPER ENGINE SPEED.
OVER SPEED ING THE ENGINE ABOVE THE FACTORY HIGH
SPEED SETTING CAN BE DANGEROUS. IF YOU THINK THE
ENGINE-GOVERNED HIGH SPEED NEEDS ADJUSTING,
CONTACT YOUR NEAREST AUTHORIZED SER VICE CEN TER,
WHICH HAS PROPER EQUIP MENT AND EXPERIENCE TO
13
MAKE ANY NEC ES SARY ADJUSTMENTS.
Page 14
STORAGE
Immediately prepare your lawn mower for storage at the end of the season or if the unit will not be used for 30 days or more.
LAWN MOWER
When lawn mower is to be stored for a period of time, clean
it thoroughly, remove all dirt, grease, leaves, etc. Store in
a clean, dry area.
1. Clean entire lawn mower (See “CLEANING” in the
Maintenance section of this manual).
2. Lubricate as shown in the Maintenance section of this
manual.
3. Be sure that all nuts, bolts, screws, and pins are securely fastened. Inspect moving parts for damage,
breakage and wear. Replace if necessary.
4. Touch up all rusted or chipped paint surfaces; sand
lightly before painting.
HANDLE (See Figs. 16 and 17)
You can fold your lawn mower handle for storage.
1. Squeeze the bottom ends of the lower handle toward
each other until the lower handle clears the handle
bracket, then move handle forward.
2. Loosen upper handle mounting bolts enough to allow
upper handle to be folded back.
IMPORTANT: WHEN FOLDING THE HANDLE FOR STORAGE
OR TRANSPORTATION, BE SURE TO FOLD THE HANDLE AS
SHOWN OR YOU MAY DAMAGE THE CONTROL CABLES.
• When setting up your handle from the storage position,
the lower han dle will automatically lock into mow ing
position.
SQUEEZE
TO ADJUST
LOWER HANDLE
ENGINE
FUEL SYSTEM
IMPORTANT: IT IS IMPORTANT TO PREVENT GUM DEPOSITS
FROM FORMING IN ESSENTIAL FUEL SYSTEM PARTS SUCH
AS CARBURETOR, FUEL FILTER, FUEL HOSE, OR TANK
DURING STORAGE. ALSO, ALCOHOL BLENDED FUELS
(CALLED GASOHOL OR USING ETHANOL OR METHANOL)
CAN ATTRACT MOISTURE WHICH LEADS TO SEPARATION
AND FORMATION OF ACIDS DURING STORAGE. ACIDIC GAS
CAN DAMAGE THE FUEL SYSTEM OF AN ENGINE WHILE IN
STORAGE.
• Empty the fuel tank by starting the engine and letting
it run until the fuel lines and carburetor are empty.
• Never use engine or carburetor cleaner products in the
fuel tank or permanent damage may occur.
• Use fresh fuel next season.
NOTE: Fuel stabilizer is an acceptable alternative in minimizing the formation of fuel gum deposits during stor age.
Add stabilizer to gasoline in fuel tank or storage container.
Always follow the mix ratio found on stabilizer container.
Run engine at least 10 minutes after adding stabilizer to
allow the stabilizer to reach the carburetor. Do not empty
the gas tank and carburetor if using fuel stabilizer.
ENGINE OIL
Drain oil (with engine warm) and replace with clean engine oil. (See “ENGINE” in the Maintenance section of
this manual).
CYLINDER
1. Remove spark plug.
2. Pour one ounce (29 ml) of oil through spark plug hole
into cylinder.
3. Pull starter handle slowly a few times to distribute oil.
4. Replace with new spark plug.
OPERATOR PRES ENCE
CONTROL BAR
UPPER HANDLE
LOWER
HANDLE
FIG. 16
FOLD
FORWARD
STORAGE
FIG. 17
FOR
FOLD
BACKWARD
MOWING
POSITION
OTHER
• Do not store gasoline from one season to another.
• Replace your gasoline can if your can starts to rust.
Rust and/or dirt in your gasoline will cause problems.
• If possible, store your unit indoors and cover it to give
protection from dust and dirt.
• Cover your unit with a suitable protective cover that
does not retain moisture. Do not use plastic. Plastic
cannot breathe, which allows condensation to form and
will cause your unit to rust.
IMPORTANT: NEVER COVER MOWER WHILE ENGINE AND
EXHAUST AREAS ARE STILL WARM.
CAUTION: Never store the lawn mower
with gasoline in the tank inside a build ing where fumes may reach an open
fl ame or spark. Allow the engine to cool
before storing in any enclosure.
14
Page 15
TROUBLESHOOTING POINTS
PROBLEM CAUSE CORRECTION
Does not start 1. Dirty air fi lter. 1. Clean/replace air fi lter.
2. Out of fuel. 2. Fill fuel tank.
3. Stale fuel. 3. Empty fuel tank and refi ll tank with fresh,
clean gasoline.
4. Water in fuel. 4. Empty fuel tank and refi ll tank with fresh,
clean gasoline.
5. Spark plug wire is disconnected. 5. Connect wire to plug.
6. Bad spark plug. 6. Replace spark plug.
7. Loose blade or broken blade adapter. 7. Tight en blade bolt or replace blade adapter.
8. Control bar in released position. 8. Depress control bar to handle.
9. Control bar defective. 9. Replace control bar.
10. Fuel valve lever (if equipped) in OFF position. 10. Turn fuel valve lever to the ON position.
Loss of power 1. Rear of lawn mower housing or cutting 1. Raise cutting height.
blade dragging in heavy grass.
2. Cutting too much grass. 2. Raise cutting height.
3. Dirty air fi lter. 3. Clean/replace air fi lter.
4. Buildup of grass, leaves and trash under 4. Clean underside of mower housing.
mower.
5. Too much oil in engine. 5. Check oil level.
6. Walking speed too fast. 6. Cut at slower walking speed.
Poor cut – 1. Worn, bent or loose blade. 1. Replace blade. Tighten blade bolt.
uneven 2. Wheel heights uneven. 2. Set all wheels at same height.
3. Buildup of grass, leaves and trash under 3. Clean underside of mower housing.
mower.
Excessive 1. Worn, bent or loose blade. 1. Replace blade. Tighten blade bolt.
vibration 2. Bent engine crankshaft. 2. Contact a qualifi ed service center.
Starter rope 1. Engine fl ywheel brake is on when control 1. Depress control bar to upper handle before
hard to pull bar is released. pulling starter rope.
2. Bent engine crankshaft. 2. Contact a qualifi ed service center.
4. Blade dragging in grass. 4. Move lawn mower to cut grass or other
hard surface before starting.
Grass catcher 1. Cutting height too low. 1. Raise cutting height.
not fi lling 2. Lift on blade worn off. 2. Replace blade.
(if so equipped) 3. Catcher not venting air. 3. Clean grass catcher.
Hard to push 1. Grass is too high or wheel height is too low. 1. Raise cutting height.
2. Rear of lawn mower housing or cutting 2. Raise rear of lawn mower housing one (1)
blade dragging in heavy grass. setting higher.
3. Grass catcher too full. 3. Empty grass catcher.
4. Handle height position not right for you. 4. Adjust handle height to suit.
Loss of drive 1. Belt wear. 1. Check/replace drive belt.
(or slowing of 2. Belt off of pulley. 2. Check/reinstall drive belt.
drive speed) 3. Drive cable worn or broken. 3. Put belt on pulleys / replace belts if broken.
4. “Loose” drive control system. 4. Adjust drive control.
15
Page 16
ROTARY LAWN MOWER - - MODEL NUMBER 5521CHV (5521CHVB) - PRODUCT NUMBER 954 22 38-83
16
Page 17
ROTARY LAWN MOWER - - MODEL NUMBER 5521CHV (5521CHVB) - PRODUCT NUMBER 954 22 38-83
17
KEY PART
NO. NO. DESCRIPTION
1 532 18 60-24 Upper Handle (Includes Foam Grip)
2 532 15 34-18 Lower Handle
3 532 18 60-11 Control Bar
4 532 18 27-55 Engine Zone Control Cable
5 532 13 19-59 Handle Bolt
6 532 18 55-77 Handle Knob
7 532 05 17-93 Hairpin Cotter
8 532 06 64-26 Wire Tie
9 532 18 04-79 Rear Door Kit (Includes Key #16 and 17)
10 532 12 84-15 Pop Rivet
11 532 18 25-38 Support Bracket, LH
12 532 18 25-39 Support Bracket, RH
13 817 06 04-10 Screw 1/4-20 x 5/8
14 532 18 25-43 Handle Bracket Assembly (Left)
15 532 18 25-45 Handle Bracket Assembly (Right)
16 532 18 00-71 Spring, LH
17 532 18 00-72 Spring, RH
18 532 18 81-52 O-Ring
19 532 17 95-85 Rope Guide
20 532 18 90-05 Rear Skirt
21 532 08 86-52 Hinge Screw 1/4-20 x 1-1/4
22 532 18 50-05 Engine Pulley
23 532 18 77-23 Hi-Pro Key
24 - - - Engine, Honda, Model Number GCV160
(For engine service and replacement parts,
call Honda at 1-800-426-7701)
25 532 15 04-06 Hex Head Thread Rolling Screw 3/8-16 x 1-1/8
26 532 08 39-23 Hex Flange Nut
27 532 18 55-72 Wheel
28 532 16 08-28 Shoulder Bolt 5/16-18 x .33
29 532 08 83-48 Washer, Flat 3/8
30 532 18 25-41 Axle Arm Assembly RR
31 532 18 55-75 Selector Knob
32 532 18 25-37 Selector Spring