MTD 41M User Manual

Safe Operation Practices • Set-Up • Operation • Maintenance • Service • Troubleshooting • Warranty

OperatOr’s Manual

Push Mower — Model 41M

WARNING

READ AND FOLLOW ALL SAFETY RULES AND INSTRUCTIONS IN THIS MANUAL

BEFORE ATTEMPTING TO OPERATE THIS MACHINE.

FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.

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

Printed In USA

Form No. 769-03429 (September 5, 2007)

To The Owner

Thank You

Thank you for purchasing a Lawn Mower manufactured by MTD LLC. It was carefully engineered to provide excellent performance when properly operated and maintained.

Please read this entire manual prior to operating the equipment. It instructs you how to safely and easily set up, operate and maintain your machine. Please be sure that you, and any other persons who will operate the machine, carefully follow the recommended safety practices at all times. Failure to do so could result in personal injury or property damage.

All information in this manual is relative to the most recent product information available at the time of printing. Review this manual frequently to familiarize yourself with the machine, its features and operation. Please be aware that this Operator’s Manual may cover a range of product specifications for various models. Characteristics and features discussed and/or illustrated in this manual may not be applicable to all models. MTD LLC reserves the right to change product specifications, designs and equipment without notice and without incurring obligation.

Table of Contents

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

Assembly & Set-Up .................................................. 8

Controls & Features ................................................11

Operation ................................................................12

Maintenance & Adjustment .................................13

Service .....................................................................15

This product has met the rigid safety standards of the Outdoor Power Equipment Institute and an independent testing laboratory. If you have any problems or questions concerning the machine, phone your local authorized MTD service dealer or contact us directly. MTD’s Customer Support telephone numbers, website address and mailing address can be found on this page. We want to ensure your complete satisfaction at all times.

Throughout this manual, all references to right and left side of the machine are observed from the operating position

The engine manufacturer is responsible for all engine-related issues with regards to performance, power-rating, specifications, warranty and service. Please refer to the engine manufacturer’s Owner’s/Operator’s Manual, packed separately with your machine, for more information.

Troubleshooting .....................................................16

Engine Operation ...................................................17

Engine Maintenance ..............................................19

Illustrated Parts List .............................................. 24

Warranty ................................................................ 30

Spanish ....................................................................31

Record Product Information

Before setting up and operating your new equipment, please locate the model plate on the equipment and record the information in the provided area to the right. You can locate the model plate by standing at the operator’s position and looking down at the rear of the deck. This information will be necessary, should you seek technical support via our web site, Customer Support Department, or with a local authorized service dealer.

MOdel nuMber

serial nuMber

Customer Support

Please do NOT return the machine to the retailer or dealer without first contacting our Customer Support Department.

If you have difficulty assembling this product or have any questions regarding the controls, operation, or maintenance of this machine, you can seek help from the experts. Choose from the options below:

Visit us on the web at www.mtdproducts.com

◊

Call a Customer Support Representative at (800) 800-7310 or (330) 220-4683

◊

Write us at MTD LLC • P.O. Box 361131 • Cleveland, OH • 44136-0019

◊

Important Safe Operation Practices

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

could endanger the personal safety and/or property of yourself and others. Read and follow all instructions in this manual before attempting to operate this machine. Failure to comply with these instructions may result in personal injury. When you see this symbol. HEED ITS WARNING!

CALIFORNIA PROPOSITION 65

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

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

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

DANGER: This machine was built to be operated according to the safe operation practices in this manual. As with any type of power equipment, carelessness or error on the part of the operator can result in serious injury. This machine is capable of amputating fingers, hands, toes and feet and throwing objects. Failure to observe the following safety instructions could result in serious injury or death.

General Operation

Read this operator’s manual carefully in its entirety before

1. attempting to assemble this machine. Read, understand, and follow all instructions on the machine and in the manuals) before operation. Keep this manual in a safe place for future and regular reference and for ordering replacement parts

Be completely familiar with the controls and the proper use

2. of this machine before operating it.

This machine is a precision piece of power equipment,

3. not a plaything. Therefore, exercise extreme caution at all times. This machine has been designed to perform one job: to mow grass. Do not use it for any other purpose.

Never allow children under 14 years of age to operate this

4. machine. Children 14 and over should read and understand the instructions and safe operation practices in this manual and on the machine and should be trained and supervised by an adult.

Only responsible individuals who are familiar with these

5. rules of safe operation should be allowed to use this machine.

Thoroughly inspect the area where the equipment is to be

6. used. Remove all stones, sticks, wire, bones, toys and other foreign objects, which could be tripped over or picked up and thrown by the blade. Thrown objects can cause serious personal injury.

Plan your mowing pattern to avoid discharge of material

7. toward roads, sidewalks, bystanders and the like. Also, avoid discharging material against a wall or obstruction, which may cause discharged material to ricochet back toward the operator.

To help avoid blade contact or a thrown object injury,

8. stay in operator zone behind handles and keep children, bystanders, helpers and pets at least 75 feet from mower while it is in operation. Stop machine if anyone enters area.

Always wear safety glasses or safety goggles during

9. operation and while performing an adjustment or repair to protect your eyes. Thrown objects which ricochet can cause serious injury to the eyes.

Wear sturdy, rough-soled work shoes and close-fitting

10. slacks and shirts. Shirts and pants that cover the arms and legs and steel-toed shoes are recommended. Never operate this machine in bare feet, sandals, slippery or lightweight (e.g. canvas) shoes.

Do not put hands or feet near rotating parts or under the

11. cutting deck. Contact with blade can amputate fingers, hands, toes and feet.

A missing or damaged discharge cover can cause blade

12. contact or thrown object injuries.

Many injuries occur as a result of the mower being pulled

13. over the foot during a fall caused by slipping or tripping. Do not hold on to the mower if you are falling; release the handle immediately.

Never pull the mower back toward you while you are

14. walking. If you must back the mower away from a wall or obstruction first look down and behind to avoid tripping and then follow these steps:

Step back from mower to fully extend your arms.

Be sure you are well balanced with sure footing.

Pull the mower back slowly, no more than half way

toward you. Repeat these steps as needed.

Do not operate the mower while under the influence of

15. alcohol or drugs.

Do not engage the self-propelled mechanism on machines

16. so equipped while starting engine.

The blade control handle is a safety device. Never attempt

17. to bypass its operation. Doing so makes the safety device inoperative and may result in personal injury through contact with the rotating blade. The blade control handle must operate easily in both directions and automatically return to the disengaged position when released.

Never operate the mower in wet grass. Always be sure of

18. your footing. A slip and fall can cause serious personal injury. If you feel you are losing your footing, release the blade control handle immediately and the blade will stop rotating within three seconds.

Mow only in daylight or good artificial light. Walk, never

19. run.

Stop the blade when crossing gravel drives, walks or roads.

20. If the equipment should start to vibrate abnormally, stop

21. the engine and check immediately for the cause. Vibration is generally a warning of trouble.

Shut the engine off and wait until the blade comes to

22. a complete stop before removing the grass catcher or unclogging the chute. The cutting blade continues to rotate for a few seconds after the blade control is released. Never place any part of the body in the blade area until you are sure the blade has stopped rotating.

Never operate mower without proper trail shield, discharge

23. cover, grass catcher, blade control handle or other safety protective devices in place and working. Never operate mower with damaged safety devices. Failure to do so can result in personal injury.

Muffler and engine become hot and can cause a burn. Do

24. not touch.

Never attempt to make a wheel or cutting height

25. adjustment while the engine is running.

Only use parts and accessories made for this machine by

26. the manufacturer. Failure to do so can result in personal injury.

27.

When starting engine, pull cord slowly until resistance is felt, then pull rapidly. Rapid retraction of starter cord (kickback) will pull hand and arm toward engine faster than you can let go. Broken bones, fractures, bruises or sprains could result.

28.

If situations occur which are not covered in this manual, use care and good judgement. Contact Customer Support for assistance or the name of the nearest service dealer.

Slope Operation

Slopes are a major factor related to slip and fall accidents, which can result in severe injury. Operation on slopes requires extra caution. If you feel uneasy on a slope, do not mow it. For your safety, use the slope gauge included as part of this manual to measure slopes before operating this machine on a sloped or hilly area. If the slope is greater than 15 degrees, do not mow it.

Do:

Mow across the face of slopes; never up and down. Exercise

1. extreme caution when changing direction on slopes.

Watch for holes, ruts, rocks, hidden objects, or bumps

2. which can cause you to slip or trip. Tall grass can hide obstacles.

Always be sure of your footing. A slip and fall can cause

3. serious personal injury. If you feel you are losing your balance, release the blade control handle immediately and the blade will stop rotating within three (3) seconds.

Do Not:

Do not mow near drop-offs, ditches or embankments, you

1. could lose your footing or balance.

Do not mow slopes greater than 15 degrees as shown on

2. the slope gauge.

Do not mow on wet grass. Unstable footing could cause

3. slipping.

Children

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

Keep children out of the mowing area and under watchful

1. care of a responsible adult other than the operator.

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

2. Before and while moving backwards, look behind and

3. down for small children.

Use extreme care when approaching blind corners,

4. doorways, shrubs, trees, or other objects that may obscure your vision of a child who may run into the mower.

Keep children away from hot or running engines. They can

5. suffer burns from a hot muffler.

Never allow children under 14 years of age to operate this

6. machine. Children 14 and over should read and understand the instructions and safe operation practices in this manual and on the machine and be trained and supervised by an adult.

4 sectiOn 2 — iMpOrtant safe OperatiOn practices

Service

Safe Handling Of Gasoline:

To avoid personal injury or property damage use extreme

1. care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive. Serious personal injury can occur when gasoline is spilled on yourself or your clothes, which can ignite. Wash your skin and change clothes immediately.

Use only an approved gasoline container.

2. Never fill containers inside a vehicle or on a truck or trailer

3. bed with a plastic liner. Always place containers on the ground away from your vehicle before filling.

Remove gas-powered equipment from the truck or

4. trailer and refuel it on the ground. If this is not possible, then refuel such equipment on a trailer with a portable container, rather than from a gasoline dispenser nozzle.

Keep the nozzle in contact with the rim of the fuel tank or

5. container opening at all times until fueling is complete. Do not use a nozzle lock-open device.

Extinguish all cigarettes, cigars, pipes and other sources

6. of ignition.

Never fuel machine indoors because flammable vapors will

7. accumulate in the area.

Never remove gas cap or add fuel while engine is hot or

8. running. Allow engine to cool at least two minutes before refueling.

Never over fill fuel tank. Fill tank to no more than 1 inch

9. below bottom of filler neck to provide for fuel expansion.

Replace gasoline cap and tighten securely.

10. If gasoline is spilled, wipe it off the engine and equipment.

11. Move machine to another area. Wait 5 minutes before starting engine.

Never store the machine or fuel container near an open

12. flame, spark or pilot light as on a water heater, space heater, furnace, clothes dryer or other gas appliances.

To reduce fire hazard, keep machine free of grass, leaves,

13. or other debris build-up. Clean up oil or fuel spillage and remove any fuel soaked debris.

Allow machine to cool at least 5 minutes before storing.

14.

General Service:

Never run an engine indoors or in a poorly ventilated area.

1. Engine exhaust contains carbon monoxide, an odorless and deadly gas.

Before cleaning, repairing, or inspecting, make certain the

2. blade and all moving parts have stopped. Disconnect the spark plug wire and ground against the engine to prevent unintended starting.

Check the blade and engine mounting bolts at frequent intervals for proper tightness. Also, visually inspect blade for damage (e.g., bent, cracked, worn) Replace blade with the original equipment manufacture’s (O.E.M.) blade only, listed in this manual. “Use of parts which do not meet the original equipment specifications may lead to improper performance and compromise safety!”

Mower blades are sharp and can cut. Wrap the blade or

4. wear gloves, and use extra caution when servicing them.

Keep all nuts, bolts, and screws tight to be sure the

5. equipment is in safe working condition.

Never tamper with safety devices. Check their proper

6. operation regularly.

After striking a foreign object, stop the engine, disconnect

7. the spark plug wire and ground against the engine. Thoroughly inspect the mower for any damage. Repair the damage before starting and operating the mower.

Never attempt to make a wheel or cutting height

8. adjustment while the engine is running.

Grass catcher components, discharge cover, and trail shield

9. are subject to wear and damage which could expose moving parts or allow objects to be thrown. For safety protection, frequently check components and replace immediately with original equipment manufacturer’s (O.E.M.) parts only, listed in this manual. “Use of parts which do not meet the original equipment specifications may lead to improper performance and compromise safety!”

Do not change the engine’s governor setting or over-speed

10. the engine. The governor controls the maximum safe operating speed of the engine.

Check fuel line, tank, cap, and fittings frequently for cracks

11. or leaks. Replace if necessary.

Do not crank engine with spark plug removed.

12. Maintain or replace safety and instruction labels, as

13. necessary.

Observe proper disposal laws and regulations. Improper

14. disposal of fluids and materials can harm the environment.

Do not modify engine

To avoid serious injury or death, do not modify engine in any way. Tampering with the governor setting can lead to a runaway engine and cause it to operate at unsafe speeds. Never tamper with factory setting of engine governor.

Notice Regarding Emissions

Engines which are certified to comply with California and federal EPA emission regulations for SORE (Small Off Road Equipment) are certified to operate on regular unleaded gasoline, and may include the following emission control systems: Engine Modification (EM) and Three Way Catalyst (TWC) if so equipped.

5sectiOn 2 — iMpOrtant safe OperatiOn practices

Spark Arrestor

WARNING: This machine is equipped with an

internal combustion engine and should not be used on or near any unimproved forest-covered, brush covered or grass-covered land unless the engine’s exhaust system is equipped with a spark arrester meeting applicable local or state laws (if any).

If a spark arrester is used, it should be maintained in effective working order by the operator. In the State of California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands. A spark arrester for the muffler is available through your nearest engine authorized service dealer or contact the service department, P.O. Box 361131 Cleveland, Ohio 44136-0019.

Average Useful Life

According to the Consumer Products Safety Commission (CPSC) and the U.S. Environmental Protection Agency (EPA), this product has an Average Useful Life of seven (7) years, or 140 hours of operation. At the end of the Average Useful Life, buy a new machine or have the machine inspected annually by an authorized service dealer to ensure that all mechanical and safety systems are working properly and not worn excessively. Failure to do so can result in accidents, injuries or death.

WARNING: Your Responsibility—Restrict the use of this power machine to persons who read, understand and

follow the warnings and instructions in this manual and on the machine.

6 sectiOn 2 — iMpOrtant safe OperatiOn practices

SAVE THESE INSTRUCTIONS!

Sight and hold this level with a vertical tree...

or a corner of a building...

or a fence post

Fold along dotted line (represents a 15° slope)

15°

Use this page as a guide to determine slopes where you may not operate safely.

WARNING: Do not operate your lawn mower on such slopes. Do not mow on inclines with a slope in excess of 15 degrees

(a rise of approximately 2-1/2 feet every 10 feet). A riding mower could overturn and cause serious injury. Operate riding

mowers up and down slopes, never across the face of slopes. Operate walk-behind mowers across the face of slopes, never

up and down slopes.

7sectiOn 2 — iMpOrtant safe OperatiOn practices

Assembly & Set-Up

Hardware Pack

Wing Nuts (2)

Carriage Bolts (2)

Contents of Carton

One Lawn Mower• One Lawn Mower Operator’s Manual• One Bottle of Oil•

One Grass Catcher• One Hardware Pack•

Insert a carriage bolt from the hardware pack into the

Assembly

NOTE: This unit is shipped without gasoline or oil in the engine. Fill up gasoline and oil as instructed in the accompanying engine manual BEFORE operating your mower.

Handle

Remove any packing material which may be between

upper and lower handles.

Pull up and back on upper handle as shown in Fig.

3-1. Make certain the lower handle is seated securely into the handle mounting brackets. Do not crimp cable while lifting the handle up.

2. upper hole on the handle mounting bracket. Secure with one plastic wing nut, also included in the hardware pack. See Fig. 3-2. Repeat on other side with remaining items from hardware pack.

Figure 3-2

Figure 3-1

Tighten star knobs to secure upper handle to lower

handle. Make sure that each carriage bolt is seated properly in the handle.

The rope guide is attached to the right side of the upper

3. handle. See Fig. 3-3. Loosen the wing nut which secures the rope guide.

Figure 3-3

Hold blade control against upper handle.

Pull starter rope out of the engine. Release blade

control. Slip starter rope into rope guide.

Tighten wing nut.

Insert post on cable tie into hole provided on the lower

4. handle. Pull cable tie tight and trim excess. See Fig. 3-4.

Grass Catcher

Follow steps below to assemble the grass catcher. Make

1. certain bag is turned right side out before assembling (warning label will be on the outside).

Place bag over frame so that its black plastic side is

at the bottom. Slip plastic channel of grass bag over hooks on the

frame. See Fig. 3-5. All the plastic channels except center top of bag attach from outside of bag.

Figure 3-5

Attach center top of bag from inside of bag.

Figure 3-4

9Section 3 — ASSembly & Set-Up

Follow the steps below to attach the grass catcher:

2. Lift rear discharge door. See Fig. 3-6.

Figure 3-6

Place grass catcher on the pivot rod. Let go of

discharge door so that it rests on the grass catcher.

To remove grass catcher, lift rear discharge door on the mower. Lift grass catcher up and out, off of the pivot rod. Release rear discharge door to allow it to close rear opening of mower.

WARNING: Never operate mower unless the hooks

on the grass catcher are firmly seated on the pivot rod and the rear discharge door rests firmly against top of the grass catcher.

Adjustments

Each wheel has a height adjustment lever to change the cutting height of the mower.

Depress height adjustment lever towards wheel.

1. Slide lever to desired position for a change in cutting

2. height. See Fig. 3-7.

Figure 3-7

Release lever towards deck.

3. IMPORTANT: All wheels must be placed in the same

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

Gas and Oil Fill-Up

Refer to the Engine Operation section in this manual for additional engine information.

Add oil provided before starting unit for the first time out

1. of the box.

Service the engine with gasoline as instructed in the

2. Engine Operation section of this manual.

WARNING: Use extreme care when handling

gasoline. Gasoline is extremely flammable and the vapors are explosive. Never fuel the machine indoors or while the engine is hot or running. Extinguish cigarettes, cigars, pipes and other sources of ignition.

10 sectiOn 3 — asseMbly & set-up

Controls and Features

Blade Control

Recoil Starter

Cutting Height Adjustment Lever (one at each wheel)

Grass Catcher

Choke Control

Figure 4-1

Blade Control

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

WARNING: This blade control is a safety device.

Never attempt to bypass its operations.

Cutting Height Adjustment Lever

One adjustment lever is located on each wheel and is used to adjust the cutting height. All four levers have to be at the same relative position to ensure a uniform cut. To adjust the cutting height, refer to the “Assembly & Set-Up” Section.

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.

Choke Control

The choke control is located on the left side of the handle and when activated, closes the choke plate on the carburetor and aids in starting the engine. Pull the choke control to activate the choke on the engine. Use of the choke may not be necessary if the engine is warm or the air temperature is high.

Grass Catcher

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

Operation

Starting Engine

WARNING: 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.

Pull out the choke knob located on the left side of the

1. upper handle. See Fig. 5-1.

NOTE: Use of the choke may not be necessary if the engine is warm or the air temperature is high.

2. Standing behind the mower, squeeze and hold the blade control against upper handle.

3. Pull the recoil starter lightly until resistance is felt, then pull rapidly to overcome compression, prevent kickback, and start the engine. Repeat if necessary. See Fig. 5-1.

NOTE: Do not allow the recoil starter to snap back against the rope guide.

4. When engine warms up, push in the choke knob.

Stopping Engine

Release blade control to stop the engine and blade.

WARNING: Wait for the blade to stop completely

before performing any work on the mower or to remove the grass catcher.

Using Your Lawn Mower

Be sure lawn is clear of stones, sticks, wire, or other objects which could damage lawn mower or engine. Such objects could be accidently thrown by the mower in any direction and cause serious personal injury to the operator and others.

WARNING: The operation of any lawn mower can

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

Figure 5-1

Using Grass Catcher

You can use the grass catcher to collect clippings while you are operating the mower.

Attach grass catcher following instructions in the

1. “Assembly & Set-Up” section. Grass clippings will automatically collect in bag as you run mower. Operate mower till grass bag is full.

Stop engine completely by releasing the blade control.

2. Make sure that the unit has come to a complete stop.

Lift discharge door and pull grass bag up and away from

3. the mower to remove the bag. Dispose of the grass clippings and reinstall the bag when complete.

WARNING: If you strike a foreign object, stop the

engine. Remove wire from the spark plug, thoroughly inspect mower for any damage, and repair damage before restarting and operating. Extensive vibration of mower during operation is an indication of damage. The unit should be promptly inspected and repaired.

Maintenance & Adjustments

Maintenance

General Recommendations

Always observe safety rules when performing any

• maintenance.

The warranty on this lawn mower does not cover items that

• have been subjected to operator abuse or negligence. To receive full value from warranty, operator must maintain the lawn mower as instructed here.

Changing of engine-governed speed will void engine

• warranty.

All adjustments should be checked at least once each

• season.

Periodically check all fasteners and make sure these are

• tight.

WARNING: Always stop engine, disconnect spark

plug, and ground against engine before performing any type of maintenance on your machine.

Lubrication

Lubricate pivot points on the blade control at least once

1. a season with light oil. This control must operate freely in both directions. See Fig. 6-1.

Lubricate the wheels at least once a season with light oil (or

2. motor oil). If wheels are removed for any reason, lubricate surface of the pivot arm and inner surface of the wheel with light oil. See Fig. 6-1.

Lubricate the torsion springs and pivot points on the rear

3. discharge door periodically with light oil to prevent rust. See Fig. 6-1.

Follow the Engine Maintenance section for lubrication

4. schedule and instruction for engine lubrication.

Deck Care

Clean underside of the mower deck after each use to prevent build-up of grass clippings or other debris. Follow steps below for this job.

Disconnect spark plug wire. Drain gasoline from lawn

1. mower or place a piece of plastic under the gas cap.

Tip mower so that it rests on the housing. Keep the side

2. with the air cleaner facing up. Hold mower firmly.

WARNING: Never tip the mower more than 90º in

any direction and do not leave the mower tipped for any length of time. Oil can drain into the upper part of the engine causing a starting problem.

3. Scrape and clean the underside of the deck with a suitable tool. Do not spray with water.

IMPORTANT: Do not use a pressure washer or garden hose to clean your unit. These may cause damage to the engine. The use of water will result in shortened life and reduce serviceability.

4. Put the mower back on its wheels on the ground. If you had put plastic under the gas cap earlier, make sure to remove it now.

Engine Care

NOTE: Refer to the Engine Operation and Maintenance sections in this manual for detailed instructions.

Maintain oil level.

• Service air cleaner every 25 hours under normal conditions.

• Clean every few hours under extremely dusty conditions.

Clean spark plug and reset the gap once a season.

• Clean engine regularly with a cloth or brush. Keep the area

• around the top of the engine clean to permit proper air circulation. Remove all grass, dirt, and combustible debris from muffler area.

Figure 6-1

Replacing Rear Flap

To remove rear flap, lift rear door, and press flap in on

1. either side to remove from hole. See Fig. 6-2.

Remove flap from opposite hole and replace with new flap

2. in the opposite order and manner of removal.

Figure 6-2

14 sectiOn 6— Maintenance & adjustMents

Service

Blade

Adapter

Bolt

Blade Bell

Support

Blade Care

WARNING: When removing the cutting blade for

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

Periodically inspect the blade adapter for cracks, especially if you strike a foreign object. Replace when necessary. Follow the steps below for blade service.

Disconnect spark plug boot from spark plug. Turn mower on its side making sure that the air filter and the carburetor are facing up.

Remove the bolt and the blade bell support which hold the blade and the blade adapter to the engine crankshaft. See Fig. 7-1.

Figure 7-1

WARNING: An unbalanced blade will cause

excessive vibration when rotating at high speeds. It may cause damage to mower and could break causing personal injury.

5. Lubricate the engine crankshaft and the inner surface of the blade adapter with light oil. Slide the blade adapter onto the engine crankshaft. Place the blade on the adapter such that the side of the blade marked “Bottom” (or with part number) faces the ground when the mower is in the operating position. Make sure that the blade is aligned and seated on the blade adapter flanges.

6. Place blade bell support on the blade. Align notches on the blade bell support with small holes in blade.

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

To ensure safe operation of your mower, periodically check the blade bolt for correct torque.

Off-Season Storage

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

Clean and lubricate mower thoroughly as described in the

• lubrication instructions.

Do not use a pressure washer or garden hose to clean your

• unit.

Coat mower’s cutting blade with chassis grease to prevent

• rusting.

Store mower in a dry, clean area. Do not store next to

• corrosive materials, such as fertilizer.

When storing any type of power equipment in a poorly ventilated or metal storage shed, care should be taken to rust-proof the equipment. Using a light oil or silicone, coat the equipment, especially cables and all moving parts of your lawn mower before storage.

Remove blade and adapter from the crankshaft. See Fig. 7-1.

Remove blade from the adapter for testing balance. Balance the blade on a round shaft screwdriver to check. Remove metal from the heavy side until it balances evenly. When sharpening the blade, follow the original angle of grind. Grind each cutting edge equally to keep the blade balanced.

Troubleshooting

Problem Cause Remedy

Engine Fails to start Blade control disengaged.

Engine runs erratic Spark plug boot loose.

Engine overheats Engine oil level low.

Spark plug boot disconnected.

Fuel tank empty or stale fuel.

Engine not primed (if equipped with primer).

Faulty spark plug.

Blocked fuel line.

Engine flooded.

Fuel valve (if equipped) closed.

Engine not choked (if equipped with choke).

Blocked fuel line or stale fuel.

Vent in gas cap plugged.

Water or dirt in fuel system.

Dirty air cleaner.

Unit running with CHOKE (if equipped)

6. applied.

Air flow restricted.

Engage blade control.

Connect wire to spark boot.

Fill tank with clean, fresh gasoline.

Prime engine as instructed in the Operation

4. section.

Clean, adjust gap, or replace.

Clean fuel line.

Wait a few minutes to restart, but do not

7. prime.

Open fuel valve. See engine manual.

Choke engine. See engine manual.

Connect and tighten spark plug boot.

Clean fuel line; fill tank with clean, fresh

2. gasoline.

Clear vent.

Drain fuel tank. Refill with fresh fuel.

Refer to engine manual.

Push CHOKE knob in.

Fill crankcase with proper oil.

Clean area around and on top of engine.

Occasional skips (hesitates) at high speed

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

Excessive Vibration Cutting blade loose or unbalanced.

Mower will not mulch grass

Uneven cut Wheels not positioned correctly.

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

Dirty air cleaner.

Bent cutting blade.

Wet grass.

Excessively high grass.

Dull blade.

Reset gap to .030” or replace spark plug.

Refer to engine manual.

Tighten blade and adapter. Balance blade.

See an authorized service dealer.

Do not mow when grass is wet; wait until

1. later to cut.

Mow once at a high cutting height, then

2. mow again at desired height or make a narrower cutting path.

Sharpen or replace blade.

3. Place all four wheels in same height position

1. (if equipped with individual height adjusters).

Sharpen or replace blade.

Engine Operation

-30º -20º

10w

20w

20w40, 20w50

15w40, 15w50

10w40

10w30

-10º 0º

0º 20º 40º 60º 80º 100º

10º 20º 30º 40º

-20º

(ºC) (ºF)

Fuel Cap

Air Cleaner

Spark Plug

Oil Drain

Oil Fill Cap

Starter Grip

Pre-Operation Check

Oil Recommendations

NOTE: This engine is shipped without gasoline or oil in the engine. Running the engine with insufficient oil can cause serious engine damage and void the engine warranty.

•

Use a 4-stroke, or an equivalent high detergent, premium quality motor oil certified to meet or exceed U.S. automobile manufacturer’s requirements for service classification SG/SF. Motor oils classified SG/SF will show this designation on the container.

SAE 10W-30 is recommended for general, all temperature use. If single viscosity oil is used, select the appropriate viscosity for the average temperature in your area from the chart to the right.

Before starting engine, fill with oil. Do not over-fill. Oil capacity is about 20 oz.

Figure 10-1

Ambient Temperature

Single Viscosity

1. Multi Viscosity

NOTE: Using non detergent oil or 2-stroke engine oil could shorten the engine’s service life.

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