MTD 11A-546B729, 11A-543B700 Owner’s Manual

Safety • Assembly • Operation • Tips & Techniques • Maintenance • Troubleshooting • Parts Lists • Warranty

A O A AL

21" Hi=Wheel Mower- Model Series 540

iMPORTANT

READ SAFETY RULES AND iNSTRUCTiONS CAREFULLY BEFORE OPERATION

Warning: Thisunitisequippedwithaninternalcombustionengineandshouldnotbeusedon or nearanyunimprovedforest-covered,brush- coveredor grass-coveredlandunlesstheengine'sexhaustsystemisequippedwitha sparkarrestermeetingapplicablelocalor statelaws(if any). If a sparkarresterisused,it shouldbemaintainedineffectiveworkingorderby theoperator.IntheStateofCaliforniatheaboveisrequiredbylaw (Section4442oftheCaliforniaPublicResourcesCode).Otherstatesmayhavesimilarlaws.Federallawsapplyonfederallands.A sparkarrester forthemufflerisavailablethroughyournearestengineauthorizedservicedealeror contactthe servicedepartment,RO.Box361131Cleveland,

Ohio44136-0019.

FORMNO.769-00447E

PRINTEDIN U.S.A.

MTD LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019

3/17/2006

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.

Table of Contents

Customer Support .............................................. 2

Slope Guage ........................................................ 3

Safe Operation Practices ................................... 4

Setup And Adjustment ....................................... 6

Operating Your Lawn Mower .............................. 8

Finding and Recording Model Number

BEFOREASSEMBLINGYOURNEW EQUIPMENT, please locatethe modelplate onthe equipmentand copy

the informationto the sample modelplate providedto the right.You can locatethe model plate bystanding at the

operatingposition and looking down at the rear of the deck.This informationwill be necessarywhen using the manufacturer'swebsite, to obtainassistance from the

CustomerSupport Department, or when contacting an authorizedservice dealer.

Maintaining Your Lawn Mower ......................... 10

Troubleshooting ................................................ 12

Safety Labels .................................................... 13

Parts List ........................................................... 14

Warranty ............................................ Back Cover

Model Number

Serial Number

MTD LLC

P.O. BOX 361131 CLEVELAND, OH 44136

www.mtdproducts,com

330 -220 -4683 800-800-731 0

Customer Support

Please do NOTreturn the unit to the retailer from which it was

purchased, without first contacting Customer Support.

Ifyou havedifficulty assembling this productor haveany questionsregarding the controls, operation, or maintenanceof this

unit,youcan seek helpfrom the experts. Choose from the options below:

1. Visit mtdproducts.com. Clickon the Service& Support menuoption.

MTD Intem_fic_al Award Wi_n i_ IProd_cf_ i _r Compe_y ct L& _ri'_,ocy Polly

Ser,#ice 8,_Suppe_ Product Registration

2. Phonea Customer Support Representative at 1 (800) 800-7310.

3. Theengine manufacturer is responsible for all engine-related issues with regards to performance,power-rating,specifica- tions,warrantyand service. Pleaserefer to the engine manufacturer'sOwner's/Operator'sManual, packedseparatelywith your unit,for more information.

Sightandholdthis levelwith a verticaltree...

>:.

(13

O3 (13

(13 O-

O O

(--

(13 (13

also

o3 (13

O- O

o3 (13

(]3

(13

O- O

(13

-5

('5

O3 O5

(13

t"b

(13 O9

15°

WARNING: EngineExhaust,some of its constituents,andcertain vehicle compo- nentscontain or emit chemicals knownto Stateof Californiato cause cancerand

birth defects or other reproductiveharm.

DANGER: This machinewas builtto beoperatedaccordingto the rulesfor safe operationin this manual.As with anytypeof power equipment,carelessnessor error on the part of the operator can result in seriousinjury.This machine iscapableof amputatinghands andfeet andthrowing objects.

Failureto observethe followingsafetyinstructionscould result in serious injury or death.

WARNING

Thissymbolpoints out importantsafety

instructionswhich,if notfollowed,could

endangerthe personal

i safetyand/or property I ofyourselfandothers.

Readandfollowall instructionsinthis

manualbeforeat-

temptingto operate

i this machine.Failure I to complywiththese

instructionsmayresult

i inpersonalinjury.When

youseethis symbol.

i HEED ITS WARNING!

Your Responsibility

Restrictthe use ofthis powermachine

to personswho read,

_understand

ano followthe warnings and instructions

inthis manual

and on the machine.

Children

Tragicaccidentscanoccurifoperatorisnotalertto presence ofchildren.Childrenareoftenattractedtomowerandmowing activity.Theydonot understandthe dangers.Neverassume thatchildrenwill remainwhereyoulastsawthem.

1. Keepchildrenoutof the mowingareaandunderwatchful careof a responsibleadultotherthanthe operator.

2. Bealert andturn moweroff if a childentersthearea.

3. Beforeandwhilemovingbackwards,lookbehindanddown forsmallchildren.

4. Useextremecarewhenapproachingblindcorners, doorways,shrubs,trees,or otherobjectsthatmayobscure yourvisionofachild whomayrunintothe mower.

5. Keepchildrenawayfromhotorrunningengines.Theycan sufferburnsfroma hotmuffler.

6. Neverallowchildrenunder14yearsoldto operateapower mower.Children14yearsoldandovershouldreadand understandoperationinstructionsandsafetyrulesinthis manualandshouldbetrainedandsupervisedbya parent.

General Operation

1. Readthis operator'smanualcarefullyin its entiretybefore attemptingtoassemblethismachine.Read,understand,

andfollowall instructionsonthemachineandin the manual(s)beforeoperation.Becompletelyfamiliarwith

thecontrolsandthe properuseofthis machinebefore operatingit.Keepthis manualin asafeplaceforfuture andregularreferenceandfor orderingreplacementparts.

2. Thismachineisaprecisionpieceof powerequipment, nota plaything.Therefore,exerciseextremecautionat all times.Yourunithas beendesignedto performonejob: to mowgrass.Do notuseitfor anyotherpurpose.

3. Neverallow childrenunder 14yearsoldto operatethis machine.Children14yearsoldand overshould readand

understandthe instructionsinthismanualandshould betrainedand supervisedbya parent.Onlyresponsible

individualswhoarefamiliarwiththeserulesofsafe operationshouldbeallowedto usethis machine.

4. Thoroughlyinspectthe areawherethe equipmentisto beused.Removeallstones,sticks,wire,bones,toys andotherforeignobjects,whichcouldbetrippedoveror pickedupandthrownbytheblade.Thrownobjectscan causeseriouspersonalinjury.Planyour mowingpattern toavoiddischargeofmaterialtowardroads,sidewalks, bystandersandthe like.Also,avoiddischargingmaterial againsta wall or obstruction,whichmaycausedischarged materialto ricochetbacktowardthe operator.

5. Tohelpavoidbladecontactorathrownobjectinjury, stayinoperatorzone behindhandlesand keepchildren, bystanders,helpersandpetsatleast75feetfrom mower whileitis inoperation.Stopmachineifanyoneenters

area.

6. Alwayswearsafetyglassesor safetygogglesduringopera- tionandwhile performinganadjustmentor repairto protect youreyes.Thrownobjectswhichricochetcancauseserious injurytothe eyes.

7. Wearsturdy,rough-soledworkshoesand close-fitting slacksandshirts. Shirtsand pantsthatcoverthe armsand legsandsteel-toedshoesarerecommended.Neveroperate thismachinein barefeet,sandals,slipperyorlight-weight (e.g.canvas)shoes.

8. Do notputhandsorfeet nearrotatingpartsor undercutting deck.Contactwithbladecanamputatehandsandfeet.

9. A missingor damageddischargecovercancauseblade contactor thrownobject injuries.

10.Manyinjuriesoccuras a resultofthemowerbeing pulled overthefoot duringa fall causedbyslippingor tripping. Do notholdontothe mowerifyouarefalling;releasethe handleimmediately.

11.Neverpullthe mowerbacktowardyouwhileyouare walking.Ifyoumust backthe mowerawayfroma wallor obstructionfirstlookdownandbehindtoavoidtrippingand thenfollowthesesteps:

a. Stepbackfrommowertofullyextendyourarms. b. Besure youarewellbalancedwithsurefooting.

c. Pullthe mowerbackslowly,no morethan half way

towardyou.

d. Repeatthesestepsas needed.

12.Donotoperatethe mowerwhileunderthe influenceof alcoholordrugs.

13.Donotengagetheself-propelledmechanismon unitsso equippedwhilestartingengine.

14.Thebladecontrolhandleisasafetydevice.Neverattempt tobypassitsoperation.Doingso makesthe safetydevice inoperativeandmayresult in personalinjurythrough contactwiththe rotatingblade.Thebladecontrolhandle mustoperateeasily in bothdirectionsandautomatically returntothe disengagedpositionwhenreleased.

15.Neveroperatethe mowerinwetgrass.Alwaysbesureof yourfooting. A slipandfall cancauseseriouspersonal injury.If youfeelyouarelosingyourfooting,releasethe bladecontrolhandleimmediatelyand the bladewillstop

rotatingwithinthreeseconds.

16.Mowonlyin daylightor goodartificiallight.Walk,neverrun.

17.Stopthe bladewhencrossinggraveldrives,walksor roads.

18.Iftheequipmentshouldstartto vibrateabnormally,stopthe engineandcheckimmediatelyforthe cause.Vibrationis generallya warningoftrouble.

19.Shuttheengineoff andwait untilthebladecomesto a completestopbeforeremovingthegrasscatcheror unclog- ging thechute. The cuttingbladecontinuesto rotatefor a fewsecondsafter the engineisshutoff.Neverplaceany partofthe bodyin the bladearea untilyou are surethe blade hasstopped

rotating.

20. Neveroperatemowerwithoutpropertrail shield,discharge cover,grasscatcher,bladecontrolhandleor othersafety

protectivedevicesin placeandworking.Neveroperate mowerwithdamagedsafetydevices.Failuretodo so can resultin personalinjury.

21. Mufflerandenginebecomehotandcan causeaburn.Do

nottouch.

22.Onlyusepartsand accessoriesmadeforthis machineby

manufacturer.Failuretodo so canresultinpersonalinjury.

23. Ifsituationsoccurwhicharenotcoveredinthis manual,

usecareand goodjudgment.Contactyourdealerfor

assistance.Telephone1-800-800-7310forthe nameofyour

nearestdealer.

Slope Operation

Slopesare amajorfactorrelatedto slipandfallaccidents,which can resultinsevereinjury.Operationonslopesrequiresextra

caution.Ifyoufeeluneasyona slope,do notmowit.Foryour safety,usetheslopegaugeincludedaspartof this manualto

measureslopesbeforeoperatingthis unitonaslopedor hilly

area.Iftheslopeisgreaterthan 15degrees,donot mowit.

Do:

1. Mowacrossthefaceof slopes;neverupanddown.Exercise extremecautionwhenchangingdirectiononslopes.

2. Watchfor holes,ruts,rocks, hiddenobjects,or bumpswhich can causeyouto slipor trip.Tallgrass canhideobstacles.

3. Alwaysbesureofyourfooting.A slip andfallcancause seriouspersonalinjury.Ifyoufeelyouare losingyour

balance,releasethebladecontrolhandleimmediately,and

the bladewill stoprotatingwithin 3seconds.

Do Not:

1. Donot mowneardrop-offs,ditchesorembankments,you could loseyourfootingorbalance.

2. Donot mowslopesgreaterthan 15degreesasshownon the slopegauge.

3. Donot mowon wetgrass.Unstablefootingcouldcause slipping.

Service

Safe HandlingOf Gasoline:

1. To avoidpersonalinjury orpropertydamageuseextreme care inhandlinggasoline.Gasolineisextremelyflammable andthevaporsareexplosive.Seriouspersonalinjurycan occurwhengasolineisspilledonyourselforyourclothes, whichcanignite.

2. Wash yourskin andchangeclothesimmediately.

3. Useonly anapprovedgasolinecontainer.

4. Neverfillcontainersinsideavehicleoron atruckor trailer bedwitha plasticliner.Alwaysplacecontainersonthe

groundawayfromyourvehicle beforefilling.

5. Removegas-poweredequipmentfromthetruck ortrailer

andrefuelit onthe ground.Ifthis is notpossible,thenrefuel suchequipmenton a trailerwitha portablecontainer,rather thanfroma gasoline dispensernozzle.

6. Keepthe nozzleincontactwiththe rimofthefueltank or

containeropeningat alltimesuntil fuelingis complete.Do

notuseanozzlelock-opendevice.

7. Extinguishallcigarettes,cigars, pipesandothersources ofignition.

8. Neverfuel machineindoorbecauseflammablevaporswill accumulatein thearea.

9. Neverremovegascap oraddfuelwhileengineishot or running. Allowengineto coolatleasttwo minutesbefore refueling.

10.Neveroverfillfueltank.Filltankto nomorethanY2inch belowbottomoffiller neckto providefor fuelexpansion.

11.Replacegasolinecap andtightensecurely.

12.Ifgasolineis spilled,wipeitoff theengineandequipment. Moveunitto anotherarea.Wait5minutesbeforestarting engine.

13.Neverstorethe machineorfuel containernearanopen flame,sparkor pilot lightasona waterheater,space heater,furnace,clothesdryeror othergasappliances.

14.Toreducefire hazard,keepmowerfreeof grass,leaves, orotherdebrisbuild-up.Cleanupoil orfuelspillageand removeanyfuel soakeddebris.

15.Allowa mowertocool at least5 minutesbeforestoring.

GeneralService:

1. Neverrunanengineindoorsorina poorlyventilatedarea. Engineexhaustcontainscarbonmonoxide,anodorlessand deadlygas.

2. Beforecleaning,repairing,orinspecting,makecertainthe bladeandall movingpartshavestopped.Disconnectthe sparkplugwireandgroundagainstthe engineto prevent unintendedstarting.

3. Checkthebladeandenginemountingboltsatfrequent intervalsfor propertightness.Also,visuallyinspectbladefor

damage(e.g.,bent,cracked,worn)Replacebladewiththe originalequipmentmanufacture's(O.E.M.)bladeonly,listed

inthismanual."Useof partswhichdo notmeetthe original equipmentspecificationsmayleadto improperperformance

andcompromisesafety!"

4. Mowerbladesaresharpandcancut.Wrapthebladeor wear gloves,anduseextracautionwhenservicingthem.

5. Keepallnuts,bolts,andscrewstightto besurethe equip- mentis insafeworkingcondition.

6. Nevertamperwithsafetydevices.Checktheirproperopera- tionregularly.

7. Afterstrikingaforeignobject,stopthe engine,discon- nectthesparkplugwireandgroundagainsttheengine.

Thoroughlyinspectthemowerforanydamage.Repairthe damagebeforestartingandoperatingthemower.

8. Neverattemptto makeawheelor cuttingheightadjustment whiletheengineis running.

9. Grasscatchercomponents,dischargecover,andtrail shieldaresubjecttowear anddamagewhichcouldexpose movingpartsor allowobjectsto bethrown.Forsafety protection,frequentlycheckcomponentsandreplaceim- mediatelywithoriginal equipmentmanufacturer's(O.E.M.) partsonly,listedinthis manual."Useofpartswhich do notmeetthe originalequipmentspecificationsmayleadto improperperformanceandcompromisesafety!"

10.Donotchangetheenginegovernorsettingor over-revthe engine.Thegovernorcontrolsthe maximumsafeoperating speedoftheengine.

11.Maintainorreplacesafetylabels,asnecessary.

12.Observeproperdisposallawsand regulations.Improper disposaloffluidsand materialscanharmtheenvironment.

Operation

WARNING

Thissymbol points out importantsafety instructions,which if notfollowed,could

endangerthe personal safety and/or property

of yourselfand others.

Readand followall

instructions inthis man- ual before attemptingto

operatethis machine.

Failureto comply with

these instructionsmay result in personalinjury.

Whenyou seethis symbol.

HEED IT'S WARNING!

YourResponsibility

Restrictthe use

of this powermachine to personswho read.

understand and followthe warnings and instructions

in this manua and on the machine.

Standbehindthe mowerasifyouwere

goingtooperateit.

Yourrighthandcor- respondstotheright

sideofthemower;your lefthandcorresponds

totheleftsideofthe

mower.

I Makesureto route i cable outsidethe lower

handle. Do not crimp cablewhile liftingthe

handleup.

Figure3-1:Unfoldhandle,tightenhardwareandattachwheel.

Hardware Pack

Wing Nuts (2) Carriage Bolts (2)

Figure3-2:Securelowerhandleto mountingbrackets.

1. Removeanypackingmaterialwhichmaybebetween upperandlowerhandles.

a. Pullupand backon upperhandleasshownin

Figure3-1.Makecertainthelowerhandleisseated securelyintothehandlemountingbrackets.Donot crimpcablewhile liftingthe handleup.

b. Tightenstarknobstosecureupperhandleto

lowerhandle.Makesurethateachcarriageboltis seatedproperlyinthehandle.

c. Placeablockunderthemowerdecktoraisethe

unitoffofthegroundandremovetheflangelock nutfromthe axle.Installrearwheelandreplaceand tightentheflangelocknut.Repeatontheotherside.

2. Locatethe hairpinclipon the weldpinon eachsideof lowerhandle.

Removehairpinclipfromthishole.Usinga pair ofpliers,inserthairpinclipintothe holeon pin closesttothebracket,Figure3-2.Repeatonother

side.

b. Insertacarriageboltfromthehardwarepackinto

theupperholeonthehandlemountingbracket. Securewithone plasticwingnut,alsoincluded inthehardwarepack.Repeatonothersidewith remainingitemsfromhardwarepack.

Theropeguideisattachedtotherightsideofthe upperhandle,Figure3-3.Loosenthewingnutwhich securestheropeguide.

a. Holdbladecontrolhandleagainstupperhandle. b. Pullstarterropeoutofthe engine.Releaseblade

controlhandle.

c. Slipstarterropeinto ropeguide. d. Tightenwingnut.

Insertpostoncabletiesintoholesprovidedon the lowerhandle.Pullcabletiestightandtrimexcess, Figure3-4.

IMPORTANT

i This unitis shipped

without gasolineor oil in the engine. Fill

upgasolineand oil

as instructed inthe accompanyingengine

i manual BEFORE

operatingyour mower.

Figure3-3:Pullrecoilstarterthroughropeguideandtighten.

Figure3-4:Securecablestohandleusingcableties.

5. 7. Yourmoweris shippedasa mulcher.Toconvertto

Followstepsbelowtoassemblethegrasscatcher. Makecertainbagisturnedrightsideout before

assembling(warninglabelwillbe ontheoutside) a. Placebagoverframesothat itsblackplasticside

is at thebottom.

b. Slip plasticchannelof grassbagoverhooksonthe

frame,Figure3-5.All theplasticchannelsexcept centertopofbagattachfromoutsideofbag.

c. Attachcentertopofbagfrominsideof bag.

sidedischarge,makesuregrasscatcherisoff ofthe unitand reardischargedoorisclosed.

a. Onthesideofthe mower,liftthemulchingplug,

Figure3-7.

b. Slidetwohooksofside dischargechuteunder

hingepinonmulchingplugassembly.Lowerthe mulchingplug.Donotremovesidemulchingplug atanytime,evenwhenyouarenotmulching.

Figure3-7:Liftmulchplugandinstallsidedischargechute.

Adjustment

'_ .y

Figure3-5:Assemblethegrasscatcher.

6. Followthestepsbelowtoattachthe grasscatcher: a. Liftreardischargedoor,Figure3-6. b. Placegrasscatcheron thepivotrod.Letgo

ofdischargedoorsothatit restson thegrass catcher.

_ WARNING:Neveroperate mower unless the on the pivotrod and the reardischargedoor rests

firmly against top of thegrasscatcher.

hooksonthe grasscatcherarefirmly seated

Adjustments

Anadjustingplateandthumbleverateachwheel providescuttingheightadjustment.

1. Depresslevertowardswheel.

2. Moveittoanyoneofthepositionsfordesiredcutting height,Figure3-8. Makesurethateachwheelis positionedatthesameheight.

3. Releaselevertowardsmowerdeck.

When adjustingthe

cutting height, all wheels must be positioned at

the sameheighL

WARNING

Neveroperate mower

w thootthem,,o, og

plug, the grasscatcher, or the discharge chute

properly installed'

Figure3-6:Attachthegrasscatcher.

j'i

Figure3-8:Useleverstoadjustcuttingheight.

Mower

WARNING

Know Your Lawn Mower

f BladeControl

Recoil Starter=====_,

GrassCatcher_

The blade control isa safety device. Never

attempt to bypass its operations.

i Useextreme carewhen

; handling gasoline.

Gasoline is extremely

flammable and the vapors are explosive.

Neverfuel the machine

i indoors or while the

; engine is hot or running. ; Exhngwsh c_garettes,

cigars, pipes, and other sources of ignition.

Keep hands and feet

away from the cutting deck. Referto warning

label on the unit.

MulchPlug--

Side Discharge Chute _,.__

Figure4-1:The majorparts onthelawnmower.

Now that you have set up your lawn mower for operation, read this section to become acquainted with its controls and features. This knowledge will allow you to use your new equipment to its fullest

potential.

Blade Control

The blade control is attached to the upper handle. Depress and squeeze it against the upper handle to operate the unit. Release it to stop engine and

blade.

_1_11=WARNING:Thisbladecontrolis a safety

device.Donot bypass its operations.

Cutting Height Adjustment Levers

One adjustment lever is located on each wheel and is used to adjust the cutting height. All four wheels

must be at the same position to ensure a uniform cut.

Recoil Starter

The recoil starter is attached to the right upper handle. Stand behind the unit and pull the recoil starter rope to start the unit.

Mulch Plug

The mulch plug is used for mulching purposes. Instead of collecting the grass clippings in a grass catcher or using the side discharge chute, some mower models have the option of recirculating the

clippings back to the lawn. This is called mulching.

Grass Catcher

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

Gas and Oil Fill-Up

1. Check oil level and add oil if necessary. Follow engine owner's manual forthis.

2. Servicethe enginewithgasolineasinstructedinthe engineowner'smanual.

_b ARNING:Useextremecarewhenhandling

gasoline.Gasolineisextremelyflammable and thevapors are explosive. Neverfuel the machine indoorsor while the engineishotor running.Extin- guish cigarettes,cigars,pipes,and other sourcesof

ignition.

_ ARNING:Theoperationofany lawn youreyesseverely.Alwayswearsafetyglasses

whileoperatingthe moweror whileperformingany adjustmentsor repairson it.

mowercan result inforeign objects being thrownintothe eyeswhichcan damage

Starting Engine

,4_i_ WARNING:Besurenooneotherthan the

Neverrunengineindoorsorin enclosed,poorly ventilatedareas.Engineexhaustcontainscarbon monoxide, an odorlessand deadlygas. Keephands, feet,hairand looseclothingawayfromanymoving partsonengineandlawnmower.

NOTE:Referto the enginemanualfor help with enginerelatedoperations.

1. Pushprimerthreetimes.Waitabouttwoseconds betweeneachpush.SeeFigure4-2.Intemperature around550For below,primefivetimes.Donotprime to restarta warmengine.

2. Standingbehindthe mower,squeezethebladecontrol againstupperhandle.SeeFigure4-2.

3. Holdingthesetwo handlestogetherfirmly,grasp recoil starterhandleand pullropeoutwitha rapid,continu- ous,fullarmstroke.SeeFigure4-2.Keepinga firm grip onthestarterhandle,letthe roperewindslowly.

Repeatuntilenginecranks.Letthe roperewindeach

timeslowly.

operatorisstandingnearthe lawnmower whilestartingengineor operatingmower.

Stopping Engine

1. Releasebladecontrolto stoptheengineand blade.

2. Disconnectsparkplugwirefromsparkplugand groundagainsttheengine.

_ ARNING:Wait for the blade to stop

completely before performinganywork on the mower or to removethe grass

catcher.

UsingYour Lawn Mower

,__ WARNING:Neveroperateyourmower __ grasscatcher assembly firmly secured.

Besurelawnisclearof stones,sticks,wire,or other

objectswhichcoulddamagelawnmowerorengine. Suchobjectscouldbe accidentlythrownbythemower in anydirectionandcauseseriouspersonalinjurytothe operatorandothers.

without eitherthe reardoor or the entire

Figure4-2:Startingthe mower.

_ ARNING:ifyou strikea foreign object, for any damage,and repair damagebefore restart-

ingand operating. Extensive vibration of mower during operation is an indicationof damage.The unit should be promptlyinspectedand repaired.

1. Oncetheengineis running,squeezethe blade controlagainsttheupperhandletoengagethe

blade.

• Forbestresults,donotcutwetgrassand never cutoffmorethanone-thirdofthe totallengthofthe grass.

stop the engine.Removewirefrom the sparkplug,thoroughly inspectmower

Using as Mulcher

Formulchinggrass,removethegrasscatcherorside dischargechutefromthemower.Thereardischarge

doorshouldbeclosed.

Foreffectivemulching,do notcutwetgrass.New orthickgrassmayrequirea narrowercut. Adjust groundspeedaccordingtoconditionoflawn.

• If thegrasshas beenallowedto growinexcessof fourinches,mulchingisnotrecommended.Usethe grasscatcherto bagclippingsinstead.

Using Grass Catcher

Youcanusethegrasscatchertocollectclippingswhile youareoperatingthemower.

AttachgrasscatcherfollowinginstructionsinSetup section.Grassclippingswillautomaticallycollectin bagasyourunmower.Operatemowertillgrassbag

isfull.

2. Stopenginecompletelybyreleasingtheblade control.Makesurethattheunithas cometoa

completestop.

3. Liftdischargedoorandpullgrassbagup andaway fromthe mowerto removethebag.Disposeofthe grassclippingsand reinstallthebagwhencomplete.

You r LaWn

Mow

WARNING

The operation of any

lawn mower can result inforeign objects being

thrown intothe eyes, which can damage your

eyes severely. Always wear safety glasses

while operating the

mower or while perform-

ingany adjustments or repairs on it.

Be sure no one other

than the operator is standing near the

lawn mower while

starting engine or operating mower. Never

run engine indoors or in enclosed, poorly

ventilated areas. Engine exhaust contains carbon

monoxide, an odorless and deadly gas. Keep

hands, feet, hair and loose clothing away

from any moving parts on engine and lawn

mower....

Lubricate these

points before reassembly.

Deck Care

Cleanundersideofthe mowerdeckaftereachuseto preventbuild-upofgrassclippingsorotherdebris.Follow

stepsbelowforthisjob.

1. Disconnectsparkplugwire.Draingasolinefromlawn mowerorplacea pieceof plasticunderthegascap.

2. Tip mowersothat itrestsonthe housing.Keepthe sidewiththeaircleanerfacingup.Hold mowerfirmly.

A vays

disconnectspark

plugl and ground

againsten- nebefore

performinganytype

ofmaintenanceon

your macNnel

I iii i _ i

Do not usea pressure

WaSheror garden

hose to clean your

uniLThese may cause

damage to electriC

componentS;s indlesl

pulleys; bearings,or the engine:The use

of water will resut in shortened lifeand

reduceserviceability:

Figure5-1:Areasto lubricateonmower.

General Recommendations

• Alwaysobservesafetyruleswhen performing anymaintenance.

• Thewarrantyonthislawnmowerdoesnotcover itemsthathavebeensubjectedtooperatorabuse ornegligence.Toreceivefullvaluefromwarranty, operatormustmaintainthelawn moweras

instructedhere.

• Changingofengine-governedspeedwillvoid enginewarranty.

• Alladjustmentsshouldbecheckedat leastonce eachseason.

• Periodicallycheckallfastenersandmakesurethese aretight.

_kl= ARNING:Alwaysstopengine,discon-

nect spark plug, and groundagainst engine before performinganytype of maintenanceon your machine.

Lubrication

1. Lubricatepivotpointson thebladecontrolatleast oncea seasonwithlightoil.Thebladecontrolmust operatefreelyinboth directions,Figure5-1.

2. Lubricatethewheelsatleastonceaseasonwith lightoil (ormotoroil). If wheelsareremovedforany

reason,lubricatesurfaceof thepivotarmandinner surfaceof thewheelwithlightoil,Figure5-1.

3. Lubricatethetorsionspringandpivotpointonthe reardischargedoorandsidemulchplugperiodically withlightoil topreventrust,Figure5-1.

4. Followtheaccompanyingenginemanualforlubrica- tionscheduleandinstructionforenginelubrication.

,_ WARNING:Nevertip the mower more time. Oil can drain intothe upper partof theengine

causing a starting problem.

3. Scrapeandcleantheundersideofthedeckwitha suitabletool.Donotspraywithwater.

4. Putthemowerbackonitswheelsonthe ground.If youhadputplasticunderthegascapearlier,make

sureto removeitnow.

than 90°in anydirection anddo not leavethe mower tipped for any length of

Engine Care

A listofkeyenginemaintenancejobs requiredforgood performanceby themowerisgivenbelow.Followthe accompanyingenginemanualforadetailedlistand

instructions.

• Maintainoillevelasinstructedin enginemanual.

• Serviceaircleanerevery25hoursundernormal conditions.Cleaneveryfewhoursunderextremely dustyconditions.Poorengineperformanceand floodingusuallyindicatesthattheaircleanershould

beserviced.Toservicetheaircleaner,referto the enginemanual.

• Cleansparkplugandresetthegaponcea season. Sparkplugreplacementisrecommendedat thestart ofeachmowingseason.Checkenginemanualfor correctplugtypeand gapspecifications.

• Cleanengineregularlywitha clothorbrush.Keepthe coolingsystem(blowerhousingarea)cleantopermit properaircirculation.Removeall grass,dirt,and

combustibledebrisfrommufflerarea.

Blade Care

_ ARNING:Whenremovingthe cutting

Periodicallyinspectthebladeadapterforcracks, especiallyifyoustrikeaforeignobject.Replacewhen necessary.Followthe stepsbelowforbladeservice.

1. Disconnectsparkplugwirefromsparkplug.Turn moweron itssidemakingsurethattheairfilterand thecarburetorarefacingup.

2. Removetheboltandthe bladebellsupportwhich holdthebladeand thebladeadaptertotheengine crankshaft,Figure5-2.

3. Removebladeandadapterfromthecrankshaft,

Figure5-2.

4. The bladecanbe sharpenedwithafileor on a grind-

ingwheel.Do notattemptto sharpenthebladewhileit isstillonthemower.

Whensharpeningtheblade,followtheoriginalangle ofgrind.Grindeachcuttingedgeequallyto keepthe

bladebalanced.

5. Totestforbalance,removebladeandbalanceon a roundshaftscrewdriver.Removemetalfromthe

heavysideuntilitbalancesevenly.

_ ARNING:Anunbalanced bladewill

6. Lubricatetheenginecrankshaftandthe innersurface ofthebladeadapterwithlightoil. Slidetheblade adapterontotheenginecrankshaft.

7. Placethebladeon theadaptersuchthattheside oftheblademarked"Bottom"(orwithpartnumber) facesthe groundwhenthe mowerisintheoperating position.Makesurethatthebladeisalignedand seatedon thebladeadapterflanges.

8. Placebladebellsupportonthe blade.Alignnotches on thebladebell supportwith smallholesinblade.

9. Replacehexboltandtightenhexboltto torque:450 in.Ibs. rain.,600 in.Ibs.max.

Toensuresafeoperationofyourmower,periodically checkthe bladeboltforcorrecttorque.

bladefor sharpeningor replacement, protectyourhandswith a pairof heavy

gloves or usea heavy ragto hold the blade.

causeexcessivevibration when rotating at high speeds. It maycausedamageto mower and could break causing personal

injury.

Replacing Rear Flap

1. To removerearflap,cutofftheflat endofthewirerod whichsecuresitto thedeck,Figure5-3.

2. Attachthenewflapandnewrodto deck,bendingthe endsofthenewrodovertosecuretodeck.

Blade Bell Support / _,_ Bolt .........................

Figure5-2:Removethebolt,support,andadaptertoaccess theblade.

Figure5-3:Cut wireto removerearflap.

Off-Season Storage

Thefollowingstepsshouldbetakento prepareyour lawnmowerfor storage.

• Cleanandlubricatemowerthoroughlyas described inthe lubricationinstructions.

• Donot usea pressurewasherorgardenhoseto cleanyourunit.

Refertoenginemanualforcorrectengine storageinstructions.

Coatmower'scuttingbladewithchassisgreaseto preventrusting.

Storemowerina dry,cleanarea.Donot storenext tocorrosivematerials,suchas fertilizer.

Whenstoringanytypeof powerequipmentinapoorly ventilatedor metalstorageshed,careshouldbetaken torust-prooftheequipment.Usingalightoil or silicone, coattheequipment,especiallycablesandall moving partsofyourlawnmowerbeforestorage.

Your LaWn

MoWer

WARNING

When removing the cuttingblade for sharpening or

replacement, protect

your handswith a pair of heavy glovesor use

a heavy rag to hold the blade.

An unbalanced blade will causeexcessive

vibrationwhen rotat=

ing at high speeds, it

may causedamage to mower and could

break causing per-

sonal injury.

Problem Cause Remedy

Engine fails to Start i adecontroldisengagedl b!adecontro!,

21 sparkplugWire disconnected• connect wiretospark p!ug•

31 FueltankemptyOrStalefuel• Ell!tankWithclean,!reshgasoline•

4. Enginenotprreed. 4. Primeengineas instructedin'fOperat, ingyour LawnMowei!I,

5: Faultyspark pug 5, Clean,adjustgap, or replace.

6. BloCkedfuel linel 6, cieanfueliinel 7: Engineflooded. 7: Wait afew minutesto restart,but do

I netprime:

_iiii _ ii _ _ i _ _i _ i

Enginerunserratic 1. Sparkplugwireloose.

2. Blockedfuel lineor stalefuel.

3. Ventingascap plugged.

4. Wateror dirt infuel system.

5. Dirtyair cleaner.

6. Carburetorout ofadjustment.

Engine overheats 1 Engineoil levellow. 1. Fillcrankcasewithproperoil.

2....A rfow restrcted I 2 Removebower housngandcean

3. Carburetornotadjustedpropery. 3• Referto engne manua.

Occasional skips 1. Sparkpluggap tooclose. 1. Adjust gapto .030-inch. (hesitates) at high speed 2. Carburetoridlemixtureadjustment 2. Referto enginemanual.

improperlyset.

Idles poorly 1. Sparkplugfouled,faultyorgaptoo wide. 1. Resetgapto .030-inchor replace

2 Carburetorimproperlyadjusted 2. Referto enginemanual•

. 3. Dirtyair cleaner• 3. Referto enginemanual•

Excessive Vibration 1. Cuttingbladelooseor unbalanced. 1. Tighten bladeandadapter.Balance

2. Bentcuttingblade. 2. See anauthorizedservicedealer.

Mower will not mulch grass 1 Wetgrass• 1. Donot mowwhengrassiswet wait

2. Excessivelyhighgrass. 2. Mowonceata highcuttingheight,

, 3• Du bade. , 3• Sharpenor replaceblade•

1. Connectandtightensparkplugwire.

2. Cleanfuelline;fill tank withclean, freshgasoline.

3. Clearvent.

4. Drainfueltank. Refillwithfreshfuel.

5. Referto enginemanual.

6. Referto enginemanual.

sparkpug.

blade.

untillaterto cut.

then mowagainatdesirecJheightor

I makea narrowerCuttingpath.

i i i ¸ ! !

i_ i_ _i!: _ i ii _ii__ii_I iiiii_

Uneven cut 1. Wheelsnotpositionedcorrectly. 1. Placeallfour wheelsin same

heightposition.

2. Dullblade. 2. Sharpenor replaceblade.

WARNING

DO NOTremove safety

(or any)labels from mower for any reason:

ii i _iI_ ii

747-1161A BladeControl 732-0404 FrontSpringLever

2 749-1092A UpperHandle 30 720-0426 HeightAdjustKnob 3 746-1130 Cntrl.Cable,40" Model546&549 31 710-0599 TTScrew,1/4-20x .500

746-1137 CntrlCable,53"Model543 32 736-0270 BellWasher 4 726-0240 CableTie 33 710-0654A TTScrew,3/8-16x 1.0 5 664-04080 GrassBagAssembly 34 710-0216 HexScrew,3/8-16x .75 6 747-04080 GrassBagFrame 35 710-1652 TTScrew,1/4-20x .625 7 732-0700 TrailshieldWire 36 720-0312 FoamGrip

8 731-04998 Trailshield 37 734-04082 RearWheel,12x 1.8GrayBar 9 747-0996 PivotRod 38 710-1205 EyeBolt

10 731-04134A RearDischargeDoor 39 732-0866 RearHi-WheelSpringLever 11 687-02057 RearHandleBracketAssy.-LH 40 687-02039A RearPivotArmAssy- RH

687-02056 Rear HandleBracketAssy.- RH 687-02040A RearPivotArmAssy- LH

12 787-01279 Deck21-inch 41 714-0104 HairpinClip 13 687-02075A FrontHeightAdj.Assy-LH 42 687-02192 HandleBracketAssy- RH

687-02074A FrontHeightAdj.Assy-RH 687-02191 HandleBracketAssy- LH

14 782-5002B FrontBaffle 43 710-0703 CarriageBolt,1/4-20x.75 15 748-0377C BladeAdapter 44 731-04150C RearBaffle

748-04082 BladeAdapterw/Star t 45 710-04371 ScrewHL,1/4-15x 1.00

16 742-0741 21-inchMulchingBlade 46 732-04090A TorsionSpring- RH 17 736-0524B Bell BladeSupport 18 710-1257 HexScrew,3/8-24x 2.5 47 19 731-04177 SideDischargeChute 48

20 17032A DeflectorChuteAdaptor 49 21 732-1014 TorsionSpring 50

22 747-0710 HingePin 51 23 687-02055 HingedMulchPlugAssembly 52

24 712-04065 FlangeLockNut3/8-16 25 787-01290 HeightAdjustmentPlate 26 687-02077A FrontPivotArmAssembly-RH

687-02076A FrontPivotArmAssembly- LH 27 734-1987 FrontWheel,8 x 1.8GrayBar

734-1988 FrontWheel,7 x 1.8GrayBart 28 738-0507B ShoulderScrew,.5Dx .434

732-04089A TorsionSpring-LH 750-04162 Spacer 712-0397 WingNut

749-0928A 710-1174 720-04072

720-0279 751B281440 710-1256 751A1432613

7510042823 751B790880 EngineShroudModel546Bt

751B095050 ScrewModel546Bt

LowerHandle CarriageBolt,5/16-18x2

StarKnob HandleKnob

EngineShroudModel549Rt Screw#8-18 x 1.250549Rt EngineShroudModel543Bt

ScrewModel543Bt

Parts List

To order replacement

parts, call

1o330'220'4683,

1'800.800-7310

orvisit

www,rntdproducts.com

ii i _iI_ ii

t NotShown

MANUFACTURER'S LiMiTED WARRANTY FOR

ThelimitedwarrantysetforthbelowisgivenbyMTDLLCwithrespect tonewmerchandisepurchasedandusedin the UnitedStates,its possessionsandterritories. "MTD"warrantsthisproductagainstdefectsinmaterialandworkman- shipfor a periodoftwo (2)yearscommencingonthedateof original purchaseandwill,at itsoption,repairor replace,freeof charge,any partfoundto bedefectiveinmaterialsorworkmanship.Thislimitedwar- rantyshallonlyapplyifthisproducthasbeenoperatedand maintained inaccordancewiththe Operator'sManualfurnishedwiththeproduct, andhasnotbeensubjectto misuse,abuse,commercialuse,neglect, accident,impropermaintenance,alteration,vandalism,theft,fire,water, ordamagebecauseofotherperilor naturaldisaster.Damageresulting fromthe installationor useof anypart,accessoryorattachmentnot approvedby MTDforusewiththeproduct(s)coveredbythis manual willvoid yourwarrantyastoanyresultingdamage. Normalwearpartsarewarrantedto befreefromdefectsinmaterialand workmanshipfora periodofthirty(30)daysfromthedateof purchase. Normalwearpartsinclude,butarenotlimitedto itemssuchas:batter- ies,belts,blades,bladeadapters,grassbags,riderdeckwheels,seats, snowthrowerskidshoes,shaveplates,augerspiralrubberandtires. NOW TO OBTAIN SERVICE: Warrantyservice isavailable,WITH PROOFOF PURCHASE,throughyour localauthorized service dealer.Tolocatethe dealer in yourarea, check yourYellowPages,

or contact MTDLLC at RO. Box 361131,Cleveland,Ohio44136- 0019,or call 1-800-800-7310or 1-330-220-4683 or logonto our

Website at www.mtdproducts.com. Thislimitedwarrantydoesnotprovidecoverageinthefollowingcases: a. Theengineor componentpartsthereof.Theseitemsmaycarrya

separatemanufacturer'swarranty.Refertoapplicablemanufacturer's warrantyfortermsandconditions.

b. Logsplitterpumps,valves,andcylindershavea separateoneyear

warranty.

c. Routinemaintenanceitemssuchaslubricants,filters,blade

sharpening,tune-ups,brakeadjustments,clutchadjustments,deck adjustments,andnormaldeteriorationoftheexteriorfinishdueto

useor exposure.

d. Servicecompletedbysomeoneotherthananauthorizedservice

dealer.

e. MTDdoesnot extendanywarrantyforproductssoldor exported

outsideoftheUnitedStates,itspossessionsandterritories,except thosesoldthroughMTD'sauthorizedchannelsofexportdistribution.

f. ReplacementpartsthatarenotgenuineMTDparts. g. Transportationchargesandservicecalls.

Noimpliedwarranty,includingany impliedwarrantyof mer- chantabilityof fitness for a particular purpose,appliesafter the applicable periodof expresswritten warranty aboveas to the partsasidentified.Nootherexpresswarranty,whetherwritten or oral, except as mentioned above,givenby anypersonor entity,

includinga dealeror retailer, withrespect to any product,shall bindMTD.Duringthe periodof the warranty,the exclusiveremedy isrepairor replacementof the productas setforth above. Theprovisionsasset forth inthis warrantyprovidethesoleand exclusiveremedy arising from the sale.MTDshallnot be liable

for incidentalor consequentiallossordamageincluding,without limitation, expensesincurredfor substituteor replacementlawn careservicesor for rentalexpensesto temporarily replacea warranted product.

Somestatesdo notallowtheexclusionor limitationofincidentalor consequentialdamages,orlimitationsonhowlonganimpliedwarranty

lasts,sothe aboveexclusionsor limitationsmaynot applyto you. Innoeventshallrecoveryofanykindbegreaterthanthe amountofthe

purchasepriceof theproductsold.Alterationof safetyfeaturesof the product shallvoid this warranty. Youassumetheriskand liability forloss,damage,orinjurytoyou andyourpropertyand/ortoothersand theirpropertyarisingoutofthe misuseorinabilityto usethe product. Thislimitedwarrantyshallnotextendtoanyoneotherthan theoriginal purchaserorto thepersonforwhomitwas purchasedasagift.

HOWSTATELAWRELATESTOTHISWARRANTY:This limited warrantygivesyouspecificlegalrights,and youmayalsohaveother

rightswhichvaryfromstatetostate. IMPORTANT:OwnermustpresentOriginalProofof Purchasetoobtain warrantycoverage.

MTD LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136=0019; Phone: 1=800=800=7310, 1=330=220=4683

MTD 11A-546B729, 11A-543B700 Owner’s Manual

Specifications and Main Features

Frequently Asked Questions

User Manual