Operator’s Manual
21” Rear & Side
Discharge Mulching
Mower
Model Series
540
IMPORTANT: Read safety rules and instructions carefully before operating equipment.
Warning:
covered, brush-covered or grass-covered land unless the engine’s exhaust system is equipped with a spark arrester meeting
applicable local or state laws (if any). If a spark arrester is used, it should be maintained in effective working order by the operator.
In the State of California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have
similar laws. Federal laws apply on federal lands. A spark arrester for the muffler is available through your nearest engine authorized
service dealer or contact the service department, P.O. Box 368022 Cleveland, Ohio 44136-9722.
PRINTED IN U.S.A.
This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-
MTD PRODUCTS INC. P.O. BOX 368022 CLEVELAND, OHIO 44136-9722
FORM NO.
770-10019A.FM
(10/99)
TABLE OF CONTENTS
Content Page
Important Safe Operation Practices................................................................... 3
Slope Gauge...................................................................................................... 6
Assembling Your Lawn Mower........................................................................... 7
Know Your Lawn Mower .................................................................................... 9
Operating Your Lawm Mower ............................................................................ 10
Making Adjustments .......................................................................................... 11
Maintaining Your Lawn Mower ........................................................................... 12
Off-Season Storage ........................................................................................... 14
Troubleshooting ................................................................................................. 14
Parts List............................................................................................................ 16
FINDING MODEL NUMBER
This Operator’s Manual is an important part of your new lawn mower. It will help you assemble, prepare and
maintain the unit for best performance. Please read and understand what it says.
Before you start assembling your new equipment, please locate the model plate on the
equipment and copy the information from it in the space provided below. The information on
the model plate is very important if you need help from our Customer Support Department or
an authorized dealer.
• You can locate the model number by standing at the operating position and looking down at the rear
of the mower deck. A sample model plate is explained below. For future reference, please copy the
model number and the serial number of the equipment in the space below.
(Model Number)
CLEVELAND, OHIO 44136
(Serial Number)
MTD PRODUCTS INC
Copy the model number here:
Copy the serial number here:
CALLING CUSTOMER SUPPORT
If you have difficulty assembling this product or have any questions regarding the controls, operation or
maintenance of this unit, please call the Customer Support Department.
Call 1- (330) 220-4MTD (4683) or 1- (800)-800-7310 to reach a Customer Support
representative. Please have your unit’s model number and serial number ready when you
call. See previous section to locate this information. You will be asked to enter the serial
number in order to process your call .
2
SECTION 1: IMPORTANT SAFE OPERATION PRACTICES
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 your lawn mower. Failure to comply with these instructions may result in personal
injury. When you see this symbol, heed its warning.
WARNING: The Engine Exhaust from this product contains chemicals known to the State of California to
cause cancer, birth defects or other reproductive harm.
DANGER: Your lawn mower was built to be operated according to the rules for safe operation in this manual. As
with any type of power equipment, carelessness or error on the part of the operator can result in serious injury. This
lawn mower is capable of amputating hands and feet and throwing objects. Failure to observe the following safety
instructions could result in serious injury or death.
GENERAL OPERATION
• Read this operator’s manual carefully in its entirety
before attempting to assemble this machine. Read,
understand, and follow all instructions on the
machine and in the manual(s) before operation. Be
completely familiar with the controls and the proper
use of this machine before operating it. Keep this
manual in a safe place for future and regular
reference and for ordering replacement parts.
• Your rotary mower is a precision piece of power
equipment, not a plaything. Therefore, exercise
extreme caution at all times. Your unit has been
designed to perform one job: to mow grass. Do not
use it for any other purpose.
• Never allow children under 14 years old to operate
a power mower. Children 14 years old and over
should only operate mower under close parental
supervision. Only responsible individuals who are
familiar with these rules of safe operation should be
allowed to use your mower.
• Keep the area of operation clear of all persons,
particularly small children and pets. Stop engine
when they are in the vicinity of your mower to help
prevent blade contact or thrown object injury.
Although the area of operation should be
completely cleared of foreign objects, an object may
have been overlooked and could be accidentally
thrown by the mower in any direction and cause
serious personal injury to the operator or any others
allowed in the area.
• Wear sturdy, rough-soled work shoes and closefitting slacks and shirts. Shirts and pants that cover
the arms and legs and steel-toed shoes are
recommended. Do not wear loose fitting clothes or
jewelry. They can be caught in moving parts. Never
operate a unit in bare feet, sandals, slippery or light
weight (e.g. canvas) shoes.
• Always wear safety glasses or safety goggles
during operation or while performing an adjustment
or repair, to protect eyes from foreign objects that
may be thrown from the machine in any direction.
• Thoroughly inspect the area where the equipment is
to be used. Remove all stones, sticks, wire, bones,
toys and other foreign objects which could be
picked up and thrown by the mower in any direction
and cause serious personal injury to the operator or
any others allowed in the area. Plan your mowing
pattern to avoid discharge of material toward roads,
sidewalks, bystanders and the like. To help avoid a
thrown objects injury, keep children, bystanders
and helpers at least 75 feet from the mower while it
is in operation.
• Do not put hands or feet near or under rotating
parts. Keep clear of discharge opening at all times
as the rotating blade can cause injury.
• Many injuries occur as a result of the mower being
pulled over the foot during a fall. Do not hang on to
the mower if you are falling; release the handle
immediately.
• Never pull the mower toward you while you are
walking. If you must back the mower away from a
wall or obstruction first look down and behind, and
then follow these steps:
a. Step back from the mower to fully extend your
arms.
b. Be sure you are well balanced with sure
footing.
c. Pull the mower back slowly, no more than half
way toward you.
d. Repeat these steps as needed.
• Do not operate the mower while under the influence
of alcohol or drugs.
• Do not engage the self-propelled mechanism on
units so equipped while starting engine.
• The blade control handle is a safety device. Never
attempt 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 your footing. A slip and fall can cause
serious personal injury. Keep a firm hold on the
handle and walk, never run. If you feel you are
losing your footing, RELEASE THE BLADE
CONTROL HANDLE IMMEDIATELY and the blade
will stop rotating within three seconds.
3
• Mow only in daylight or good artificial light.
• Stop the blade when crossing gravel drives, walks
or roads.
• If the equipment should start to vibrate abnormally,
stop 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 a complete stop before removing the grass
catcher or unclogging the chute. The cutting blade
continues to rotate for a few seconds after the
engine is shut off. 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 guards, grass
catcher, plates or other safety protective devices in
place.
• Muffler and engine become hot and can cause a
burn. Do not touch.
• Only use accessories approved for this machine by
the manufacturer. Read, understand, and follow all
instructions provided with the approved accessory.
• If situations occur which are not covered in this
manual, use care and good judgment. Contact your
dealer for assistance. Telephone 1-800-800-7310
for the name of your nearest dealer.
Slope Operation
• For your safety, use the slope gauge included as
part of this manual to measure slopes before
operating this unit on a sloped or hilly area. If the
slope is greater than 15 degrees as shown on the
slope gauge, do not operate this unit on that area or
serious injury could result.
Do:
• Mow across the face of slopes; never up and down.
Exercise extreme caution when changing direction
on slopes.
• Watch for holes, ruts, hidden objects, or bumps. Tall
grass can hide obstacles.
• Always be sure of your footing. A slip and fall can
cause serious personal injury. If you feel you are
losing your balance release the blade control
handle immediately and the blade will stop in less
than 3 seconds.
Do NOT:
• Do not mow near drop-offs, ditches or
embankments. The operator could lose footing or
balance.
• Do not mow slopes greater than 15 degrees as
shown on the slope gauge.
• Do not mow on wet grass. Reduced footing could
cause 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.
Never assume that children will remain where you
last saw them.
• Keep children out of the mowing area and under the
watchful care of a responsible adult other than the
operator.
• Be alert and turn mower off if a child enters the
area.
• Before and while moving backwards, look behind
and down for small children or other objects.
• Never allow children under age 14 to operate the
mower. Children 14 years of age and above should
read and understand the operation instructions and
safety rules in this manual.
• Use extreme care when approaching blind corners,
shrubs, trees, or other objects that may obscure
your vision of a child or hazard.
Service
• Use extreme care in handling gasoline and other
fuels. They are extremely flammable and the vapors
are explosive.
• Use only an approved gasoline container.
• Never remove gas cap or add fuel while the engine
is running. Allow engine to cool at least two minutes
before refueling.
• Replace gasoline cap securely and wipe off any
spilled gasoline before starting the engine as it may
cause a fire or explosion.
• Extinguish all cigarettes, cigars, pipes and other
sources of ignition.
• Never refuel machine indoors because flammable
vapors will accumulate in the area.
• Never store the machine or fuel container inside
where there is an open flame or spark such as a gas
water heater, space heater, or furnace.
• Never run an engine inside a closed area.
• To reduce fire hazard, keep mower free of grass,
leaves, or other debris build-up. Clean up oil or fuel
spillage. Allow mower to cool at least 5 minutes
before storing.
• Before cleaning, repairing, or inspecting, make
certain the blade and all moving parts have
stopped. Disconnect the spark plug wire, and keep
the wire away from the spark plug to prevent
accidental starting.
• Check the blade and engine mounting bolts at
frequent intervals for proper tightness. Also, visually
inspect blade for damage (e.g., bent, cracked or
worn). Replace with blade which meets original
equipment specifications listed in this manual.
• Keep all nuts, bolts, and screws tight to be sure the
equipment is in safe working condition.
• Never tamper with safety devices. Check their
proper operation regularly.
• After striking a foreign object, stop the engine,
remove the wire from the spark plug, and
thoroughly inspect the mower for any damage.
Repair the damage before starting and operating
the mower.
4
• Never attempt to make a wheel or cutting height
adjustment while the engine is running.
• Grass catcher components are subject to wear,
damage and deterioration, which could expose
moving parts or allow objects to be thrown. For
safety protection, frequently check components and
• 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 the engine. Excessive engine speeds
are dangerous.
replace with manufacturer’s recommended parts,
when necessary.
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.
1299 AC
5
SECTION 2: SLOPE GAUGE
Use this page as a guide to determine slopes where you may not operate the lawn mower safely.
E
P
O
L
S
°
5
1
A
G
N
I
T
N
E
S
E
R
P
E
R
,
E
N
I
L
D
E
T
T
A POWER POLE
O
D
N
O
D
L
O
F
15°
WARNING
A CORNER OF A BUILDING
OR A FENCE POST
USE THIS PAGE AS A GUIDE TO DETERMINE SLOPES WHERE YOU MAY NOT OPERATE SAFELY.
SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE
6
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. If operating a walk-behind mower on such a slope, it is
extremely difficult to maintain your footing and you could slip, resulting in 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.
SECTION 3: ASSEMBLING YOUR LAWN MOWER
To Remove Unit From Carton
• Remove staples, break glue on top flaps, or cut tape at
carton end and peel along top flap to open carton.
• Remove loose parts included with your unit (i.e.,
operator’s manual, etc.).
• Cut along corners and lay carton down flat. Remove
packing material.
• Roll or slide unit out of carton.
Hardware Pack
1. Carriage Bolt 1/4-20 x .75” (2)
2. Wing Nut with Bell Washer (2)
Tools Required
1. Pair of Pliers
2. Funnel
Disconnect Spark Plug Wire
• Before setting up your lawn mower, disconnect the
spark plug wire from the spark plug, and ground it
against the engine. See Figure 1.
NOTE: On engines with a rubber boot, attach rubber
boot to a bolt on the engine to ground.
NOTE: Reference to right or left hand side of the mower
is observed from the operating position.
Setting Up Your Lawn Mower
NOTE: This owner’s guide covers various models of
mowers. Follow only those instructions which pertain to
your unit.
• Remove the grass catcher from the unit and set it
out of the way. See Figure 2 (step 1).
• Raise the lower handle in the direction shown in
Figure 2 (step 2) till it snaps into place.
• Raise the upper handle in the direction shown in
Figure 2 (step 3). Tighten the wing nuts which are
already on the handle.
2. Lift lower
handle
3. Lift upper
handle
1. Move bag
away
Spark Plug Wire
With Rubber Boot
Spark Plug
All Engines
With Rubber
Boot
Briggs & Stratton
Retaining
Post
Spark Plug Wire
V-Slot
on Engine
Engines
Tecumseh
Engines
Spark
Plug
Wire
Spark
Plug
Figure 1
IMPORTANT:
This unit is shipped without gasoline or oil
in the engine. Be certain to service engine with gasoline
and oil before operating your mower.
Figure 2
NOTE: Your mower is shipped with the handle in the
higher height position. If you wish to lower the height of
the handle, refer to the Adjustment Section at this time.
• Remove the hairpin clips from the outer hole in the
weld pins on the handle mounting brackets. Using a
pair of pliers, squeeze one leg of the lower handle
against the handle mounting bracket. Insert the
hairpin clip into the inner hole on the weld pin.
Repeat on the other side. See Figure 3.
Handle Mounting
Bracket
Insert hairpin
clip here
Hairpin
Clip
Weld
Pin
Figure 3
7
• The rope guide is attached to the right side of upper
handle. Loosen the wing nut which secures the
rope guide. See Figure 4.
• With spark plug wire disconnected and grounded,
hold the blade control handle against the upper
handle, and pull the starter rope out of the engine.
Release blade control handle. Slip the rope into the
rope guide. Tighten the wing nut. See Figure 4.
• Tighten all nuts and bolts securely.
• Attach the cables to the lower handle with the two
cable ties already on the lower handle. Pull tight the
cable ties and cut off the extra
located on the right side of the cutting deck. Do not
remove the mulching plug from the mower even when
you are not mulching the grass.
• To remove the mulching baffle, lift the rear
discharge door on the mower. Remove the
mulching baffle. See Figure 7.
Deck
Slip rope into
rope guide
Rope
Guide
Wing Nut
Figure 4
• After you have moved the hairpin clips as shown in
Figure 3, place one carriage bolt (found in the
hardware pack included with your unit) in the upper
hole of the right handle mounting bracket from the
inside outward. See Figure 5. Secure with one
plastic wing nut. Repeat process on the left side.
Carriage
Bolt
Upper
Hole
Mulching
Baffle
Figure 6
IMPORTANT:
Make sure cables are routed to the
outside of the handle so they are not in the way when
attaching the grass catcher.
• Lift the rear discharge door on the mower.
• Place the hooks, found on both sides of the grass
catcher frame, over the chute door pivot rod at the
rear of the mower. See Figure 7. Release the rear
discharge door.
• To remove the grass catcher, lift the rear
discharge door on the mower. Lift the grass catcher
up and off the pivot rod. reinstall the mulghing baffle
and release the rear discharge door. See Figure 7.
WARNING: Never operate the mower
unless the hooks on the grass catcher are
firmly seated on the chute pivot rod, and
the rear discharge door rests firmly
against the top of the grass catcher.
Wing Nut
Hairpin Clip
Figure 5
Attaching Grass Catcher To Mower
NOTE: The mulching baffle, if so equipped, is already
in place on the mower for shipping purposes. Your lawn
mower may be equipped with both a mulching baffle
and a mulching plug. While the mulching baffle is
located at the rear of the mower, the mulching plug is
Discharge Door
Grass Bag
Figure 7
8
Converting To Side Discharge
If your unit is equipped with a side discharge chute, you
can convert to a side discharge mower as follows:
• Lift the rear discharge door and install the mulching
baffle. See Figure 6.
• On the side of the mower, lift the mulching plug.
See Figure 8.
• Slide the two hooks of the side discharge chute
under the hinge pin on the mulching plug assembly
as shown in Figure 8. Lower the side mulching plug.
• Do not remove the side mulching plug at any time,
even when you are not mulching.
Hinge Pin
(Slide hooks under the two
sides of hinge pin)
Figure 8
Mulching Plug
Deflector
Hook
SECTION 4: KNOW YOUR LAWN MOWER
Compare the illustration in Figure 9 with your lawn mower to familiarize yourself with the location of various controls
and adjustments.
WARNING: The operation of any lawn mower can result in foreign objects being thrown into the
eyes, which can result in severe eye damage. Always wear safety glasses or eye shields.
Upper
Handle
Recoil Starter
Grass
Catcher
Side Discharge
Chute
Figure 9
Blade Control Handle
WARNING: This control mechanism is a
safety device. Never attempt to bypass its
operations.
The blade control handle is located on the upper handle
of the mower.The blade control handle must be
depressed in order to operate the unit. Release the
Blade Control Handle
Throttle Control
(If equipped)
Lower
Handle
Rear
Discharge
Door
Mulching
Plug
Oil Fill
Spark
Plug
Cutting Height
Adjustment Lever
blade control handle to stop the engine and the blade.
Recoil Starter
The recoil starter handle is attached to the handle and
is used to start the engine.
Grass Catcher
The grass catcher, located at the rear of the mower, is
used to bag the grass clippings for disposal at another
9
site. Once the bag is full, it has to be removed from the
mower and emptied before any further mowing.
Mulching Plug
Both the mulching baffle and the mulching plug are
used only for mulching purposes. Instead of collecting
the grass clippings in a grass catcher, some mower
models have the option of recirculating the clippings
back to the lawn. This is called mulching.
Throttle Control
Your unit is equipped with one of three throttle controls
described below. Follow instructions which pertain to
your unit.
1. The throttle control is located on the left side of the
upper handle. It is used to regulate the engine
speed.
2. The throttle control is located on the engine. It is
used to regulate the engine speed.
3. Your engine is equipped with a constant speed
throttle, which is set at full throttle for best
performance.
WARNING: The throttle control cannot be
used to stop the engine. If the throttle
control is located on the engine, do not
adjust it with the engine running.
Cutting Height Adjustment Lever
This lever, located at each wheel, lets you adjust
cutting height of the grass. Remember to put all four
levers at the same height to avoid uneven cut.
SECTION 5: OPERATING YOUR LAWN MOWER
WARNING: Keep hands and feet away
from the chute area on cutting deck. The
blade will be rotating whenever the engine
is running.
NOTE: For shipping purposes your mower is set with
the wheels in a low cutting height position. For best
results, raise the cutting position until it is determined
which height is best for your lawn. Refer to instructions
for cutting height adjustment on page 11.
Gas and Oil Fill-Up
Service the engine with gasoline and oil as
instructed in the separate engine manual packed with
your mower. Follow instructions carefully.
WARNING: Never fill fuel tank indoors,
with engine running or until the engine
has been allowed to cool for at least two
minutes after running.
Before Starting
• Attach spark plug wire to spark plug. If unit is
equipped with a rubber boot over the spark plug
wire, ensure that the metal cap on the end of the
spark plug wire (inside the rubber boot) is fastened
securely over the metal tip on the spark plug.
To Start Engine and Engage Blade
• Move throttle control lever (if equipped) to the fast
(rabbit) position.
• If engine is equipped with a primer, prime engine as
instructed in the separate engine manual packed
with your unit.
• Standing behind the unit, depress the blade control
handle and hold it against the upper handle.
• Grasp starter handle and pull rope out slowly until
engine reaches start of compression cycle (rope
will pull slightly harder at this point). Let the rope
rewind slowly.
• Pull rope with a rapid, continuous, full arm stroke.
Keep a firm grip on starter handle. Return it slowly
to the rope guide.
NOTE: If any problems are encountered, refer to the
Trouble Shooting Guide.
To Stop Engine and Blade
• Release the blade control handle to stop the engine
and blade.
WARNING: The blade continues to rotate
for a few seconds after engine is shut off.
•Disconnect the spark plug wire and ground it
against the engine to prevent accidental starting
while equipment is unattended.
Using Your Rotary Mower
WARNING: Never operate your unit without
either the rear deflector or entire grass
catcher assembly in place.
• Be sure that lawn is clear of stones, sticks, wire, or
other objects which could damage lawn mower or
engine. Such objects could be accidentally thrown
by the mower in any direction and cause serious
personal injury to the operator and others.
• For best results, do not cut wet grass because it
tends to stick to the underside of the mower,
preventing proper discharge of grass clippings, and
could cause you to slip and fall. New grass, thick
grass or wet grass may require a narrower cut.
10
• Blade speed should be adjusted to the condition of
the lawn.
• For a healthy lawn, never cut more than onethird of the total length of the grass at any one
cutting. Lawn should be cut in the fall as long as
there is growth.
• This mower is designed to be operated at full
throttle to give you the best cut and do the most
effective job of bagging the cut grass.
WARNING: If you strike a foreign object,
stop the engine. Remove wire from spark
plug and ground it. Thoroughly inspect
the mower for any damage, and repair the
damage before restarting and operating
the mower again.
SECTION 6: MAKING ADJUSTMENTS
Using the Mulcher
• For effective mulching, do not cut wet grass
because it tends to stick to the underside of the
deck, preventing proper mulching of grass
clippings. New or thick grass may require a
narrower cut. The ground speed should be
adjusted to the condition of the lawn. If mowing has
been delayed and the grass has been allowed to
grow in excess of 4", mulching is not
recommended. Mow using the grass bag (if so
equipped) to reduce the grass height to 3-1/4"
maximum before mulching.
WARNING: Do not at any time make any
adjustment to lawn mower without first
stopping engine and disconnecting spark
plug wire.
Carburetor
WARNING: If any adjustments are made
to the engine while the engine is running
(e.g. carburetor), keep clear of all moving
parts. Be careful of heated surfaces and
muffler.
Minor carburetor adjustments may be required to
compensate for differences in fuel, temperature,
altitude and load. To adjust carburetor, refer to the
separate engine manual packed with your mower.
NOTE: A dirty air cleaner will cause an engine to run
rough. Be certain air cleaner is clean and attached to
the carburetor before adjusting carburetor.
Throttle Control
• If your lawn mower engine is equipped with a
throttle control that needs adjustment or if it has
been replaced, proceed as follows. Note that
engines with fixed throttle cannot be adjusted.
• Remove the screw that secures the cable clamp.
Remove the cable clamp from the cable.
“click.” Make certain the throttle control lever
remains in this position.
• Push the control lever on the engine as far toward
the rear of the engine as it will go. Secure the cable
in this position with the cable clamp and screw.
Briggs & Stratton Quantum Engines
Screw
Cable
Clamp
Tecumseh Engines
Control
Lever on
Engine
Cable
Clamp
NOTE: If you have a Tecumseh engine, simply loosen
the screw shown in Figure 10 so the cable will move
freely beneath the clamp. It is not necessary to remove
the screw and clamp completely.
• Push the throttle control lever on the handle all the
way forward as far as it will go, then back it off one
11
Control
Lever
On Engine
Screw
Figure 10
Handle Height
Your mower is shipped with the handle in the higher
height position.To lower the handle height for your
convenience, proceed as follows.
Lower
Handle
Figure 11
• Remove the starter rope from the rope guide.
• Remove the upper handle by removing the hand
knobs and carriage bolts. Lay the upper handle out
of the way, being careful not to bend or kink the
cables.
• Remove the hairpin clips from the weld pins on the
handle brackets. Press outward on the legs of the
lower handle, and remove it from the mower.
• Turn the lower handle around so the notches on the
bottom of the lower handle are facing forward as
shown in Figure 11. Reassemble, placing the
bottom holes in the handle over the weld pins in the
handle mounting bracket.
Notch
• Reassemble the upper handle.
• Place the hairpin clips in the inner holes in the weld
pins and attach the starter rope as instructed in the
assembly instructions.
Cutting Height
An adjusting plate and thumb lever at each wheel
position provides cutting height adjustment. Each
adjusting plate has nine height positions. Height of cut
will be changed when the thumb lever is moved from
one hole to another.
• Simply depress the lever towards wheel and move
wheel and lever assembly to desired position. All
wheels must be placed in the same relative
position. See Figure 12.
Height
Adjustment
Lever
Figure 12
SECTION 7: MAINTAINING YOUR LAWN MOWER
Deck Care
NOTE: We do not recommend the use of pressure
washers or garden hose to clean your unit.These may
cause damage to electric components, spindles,
pulleys, bearings or the engine. The use of water will
shorten life of the mower and reduce its serviceability.
• The underside of the mower deck should be
cleaned after each use to prevent a buildup of
grass clippings, leaves, dirt or other matter. If this
debris is allowed to accumulate, it will invite rust
and corrosion, and may cause an uneven
discharge of grass clippings at the next cutting.
• The deck may be cleaned by tilting the mower and
scraping clean with a suitable tool (make certain the
spark plug wire is disconnected).
Engine
• Refer to the separate engine manual.
Replacing Rear Flap
• To remove rear flap, cut off the flat end of the wire
rod which secures it to the deck. See Figure 13.
• Attach the new flap and new rod to deck, bending
the ends of the new rod over to secure to deck.
Handle
Bracket
Rear Discharge
Door
e
r
i
W
Figure 13
d
o
R
Handle
Bracket
Rear
Flap
12
Lubrication
(Refer to Lubrication Chart in Figure 14.)
WARNING: Always stop engine and
disconnect spark plug wire before
cleaning, lubricating or doing any kind of
work on lawn mower.
• Periodically inspect the blade adapter for cracks,
especially if you strike a foreign object. Replace
when necessary.
• Remove the bolt and blade support or bell washer
which hold the blade and adapter to the engine
crankshaft. See Figure 15. Remove the blade and
adapter from the crankshaft.
Lube
Lube
Lube
Lube
Lube
Figure 14: Lubrication Chart
Blade Control
• Lubricate the pivot points on the blade control
handle and the brake cable at least once a season
with light oil. The blade control must operate freely
in both directions.
Rear & Side Discharge Doors
• The torsion springs and pivot points should be
lubricated periodically with light oil to prevent any
rust or binding. Door must work freely.
Wheels
• The wheels require no lubrication. However, if the
wheels are removed for any reason, lubricate the
surface of the axle bolt and the inner surface of the
wheel with light oil. Engine oil may also be used.
Engine
• Follow engine manual for instruction and schedule
of lubrication.
NOTE: When tipping the unit, empty the fuel tank and
keep engine spark plug side up.
Blade Care
WARNING: When removing the cutting
blade for sharpening or replacement,
protect hands by using heavy gloves or a
thick rag to grasp the cutting blade.
Blade Adapter
Blade
Blade
Bell
Support
Hex Bolt
Figure 15
• When sharpening the blade, follow the original
angle of grind as a guide. It is extremely important
that each cutting edge receives an equal amount of
grinding to prevent an unbalanced blade.
NOTE: An unbalanced blade will cause excessive
vibration when rotating at high speeds and may cause
damage to the mower and/or personal injury.
• The blade can be tested by balancing it on a round
shaft screwdriver. See Figure 16. Remove metal
from the heavy side until it balances evenly. It is
recommended that the blade always be removed
from the adapter for the best test of balance.
1. Insert screw driver through hole
2. Blade should be parallel to ground
Screw
Driver
Blade
Ground
Figure 16
• Before reassembling the blade and the blade
adapter to the unit, lubricate the engine crankshaft
and the inner surface of the blade adapter with light
oil (or engine oil). Also lubricate the bolt holes, bolts
and inner surface of the nuts.
• Install the blade adapter on the crankshaft with the
“star” away from the engine. Refer to Figure 15.
Place the blade with the side marked bottom (or
with part number) facing away from the adapter.
13
• Align the blade bell support over the blade with the
tabs in the holes of the blade and insert the hex
bolt. Tighten the hex bolt to the torque listed in the
“Blade Mounting Torque” section below.
Blade Mounting Torque
Center Bolt: 450 in. lbs. min., 600 in. lbs. max.
IMPORTANT:
bolts must be checked periodically for correct tightness.
To ensure safe operation, all nuts and
SECTION 8: OFF-SEASON STORAGE
The following steps should be taken to prepare lawn
mower for storage.
• Clean and lubricate mower thoroughly as described
in the lubrication instructions.
• Refer to engine manual for correct engine storage
instructions.
• Coat mower’s cutting blade with chassis grease to
prevent rusting.
• Store mower in a dry, clean area. Do not store next
to corrosive materials, such as fertilizer.
NOTE: When storing any type of power equipment in
an unventilated 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.
SECTION 9: TROUBLE SHOOTING GUIDE
Trouble Possible Cause(s) Corrective Actions
Engine fails to
start
Engine runs
erratic
Engine
overheats
Occasional skip
(hesitates) at
high speed
Idles poorly 1. Spark plug fouled, faulty or gap too wide.
Excessive
vibration
Mower will not
mulch grass
Uneven cut 1. Wheels positioned incorrectly.
1. Blade control handle disengaged.
2. Spark plug wire disconnected.
3. Dirty air cleaner.
4. Primer button not depressed.
5. Throttle control lever not in correct starting
position (if so equipped).
6. Fuel tank empty or stale fuel.
7. Blocked fuel line .
8. Faulty spark plug.
9. Engine flooded.
1. Unit running in START position.
2. Spark plug wire loose.
3. Blocked fuel line or stale fuel.
4. Carburetor out of adjustment.
1. Engine oil level low.
2. Dirty aircleaner.
3. Air flow restricted.
4. Carburetor not adjusted properly.
1. Spark plug gap too close.
2. Carburetor idle mixture adjustment
improperly set.
2. Carburetor not adjusted.
1. Cutting blade loose or unbalanced.
2. Bent cutting blade.
1. Engine speed too low (not applicable in
mowers with fixed throttle)
2. Wet grass.
3. Excessively high grass.
2. Dull blade.
1. Engage blade control handle.
2. Connect wire to spark plug.
3. Refer to the engine manual.
4. Refer to the engine manual.
5. Move throttle lever to FAST or START position.
6. Clean fuel line.
7. Clean, adjust gap or replace.
8. Refer to the engine manual.
9. Wait for a while and crank the engine.
1. Move throttle lever to FAST position.
2. Connect and tighten spark plug wire. Check spark plug
for fouling.
3. Clean fuel line; fill tank with clean, fresh gasoline.
4. Refer to the engine manual.
1. Fill crankcase with proper oil.
2. Refer to the engine manual packed with your unit.
3. Stop engine and disconnect spark plug wire. Remove
blower housing and clean.
4. Refer to the engine manual..
1. Adjust gap to .030".
2. Refer to the engine manual.
1. Reset gap to .030" or replace spark plug.
2. Refer to the engine manual.
1. Tighten blade and adapter. Balance blade.
2. See an authorized service dealer.
1. Set throttle between 3/4 and full throttle.
2. Wait until later to cut.
3. Mow once at a high cutting height, then mow again at
desired height.
1. Place all four wheels in same height position.
2. Sharpen or replace blade.
NOTE: For repairs beyond the minor adjustments above, contact your local authorized service dealer.
14
SECTION 10: SHROUD CHART
Shroud Color
751B281439 Dark Red
751B281440 Black
751B281443 Bright Red
Hardware: 710-1256
Shroud Color
731-1585B Black
Hardware: 710-1274
Shroud Color
731-1395A Red
731-1396A Black
731-1397A Grey
Hardware: 710-1256
Shroud Color
731-1586B Black
731-1612A Red
Hardware: 7510042823
Shroud Color
731-1402A Yellow
731-1694 Black
731-1695 Silver
731-1934A Charcoal
Hardware: 710-1256
Shroud Color
7510143208 Black
Hardware: 7510042823
Shroud Color
7511681311 Black
7511681911 Red
7511682011 Grey
Shroud Color
751B281451 Dark Red
Hardware: 710-1256
15
Shroud Color
751B281476 Black
751B281777 Yellow
Hardware: 710-1237
SECTION 11: PARTS LIST FOR MODELS 540 THROUGH 549
18
1
21
12
10
25
26
3
5
2
6
4
13
52
5
11
7
8
6
17
57
20
30
15
9
16
4
14
57
20
23
52
24
68
61
92
95
96
19
97
86
98
99
67
66
73
76
54
59
53
70
71
81
64
44
80
50
83
55
85
63
87
56
31
39
72
84
93
82
39
86
43
44
40
49
87
71
60
47
42
32
94
41
33
34
62
36
58
89
88
90
51
16
Models 540 through 549
Ref. No. Part No. Description
1 747-0824 Control Handle Assembly
647-0004 Deluxe Control Handle Assembly
2 710-1205 Rope Guide
3 720-0279 Handle Knob
4 710-1174 Curved Hd. Bolt 5/16-18 x 2”
5 712-0324 Hex L-Nut 1/4-20 Thd.
6 720-0314 Hand Knob
7 710-0605 Oval C-Sunk Screw †
8 736-0501 Spring Washer †
9 710-1270 Screw 1/4-20 x 1.31
10 746-0876 Throttle Lever †
11 749-0438C Upper Handle
12 720-0295 Foam Grip †
13 749-0907A Lower Handle
14 726-0240 Cable Tie
15 747-0995A Catcher Frame
16 746-0550 Control Cable 39”
746-0737 Control Cable 51”
17 746-0841 Throttle Cable 60” †
746-0847 Throttle Cable 42” †
18 664-0084 Grass Bag w/o logo
664-0085 Grass Bag w/ logo, Yellow
664-0086 Grass Bag w/ logo, Red
19 731-0066 Hard Top w/ logo
731-0068 Hard Top w/o logo
20 714-0104 Internal Cotter Pin
21 746-0883 Throttle Housing w/o Lever
23 782-7599A Grass Bag Door
24 751B213146 Cable Clamp †
7510007775 Cable Clamp †
25 646-0875 Throttle Body †
26 811-00303 Throttle Box Comp. (B&S) †
811-00500 Throttle Box Comp. (Tec.) †
30 732-0700 Wire Rod
31 731-1236 Rear Flap
32 753-0588 Blade Adapter Kit
33 710-1044 Hex Bolt 3/8-24 x 1.5”
34 736-0524A Blade Bell Support
36 742-0741 Mulching Blade
39 736-0356 Bell Washer .39” I.D. x 1.38”
40 712-0798 Hex Nut 3/8-16 Thd.
41 15261A Height Adj. Plate
42 15262B Pivot Bar
Ref. No. Part No. Description
43 732-0404 Spring Lever: Front Wheel
44 738-0507B Shoulder Bolt .5” Dia. x .357”
47 720-0190 Spring Lever Knob
49 14578 Height Adj. Assembly Comp - RH
14579 Height Adj. Assembly Comp - LH
50 17488A Pivot Bar - RH
17489A Pivot Bar - LH
51 782-5002 Front Baffle
52 712-0397 Wing Knob
53 782-5003 Rear Baffle
54 710-1017 Torx Mach. AB-Tap Scr.
55 710-0896 Hex Washer Screw 1/4-14 x .625
56 682-3058 Handle Bracket Assembly—R.H.
682-3059 Handle Bracket Assembly—L.H.
57 710-0703 Carriage Bolt, 1/4-20 x .75”
58 782-0047 Deck
59 734-1860 Rear Wheel Ass’y 14 x 2
734-1864 Rear Wheel Ass’y. 14 x 1.8
60 734-1818 Front Wheel Ass’y. 8 x 2
734-1781 Front Wheel Ass’y 8 x 1.75
734-1841 Front Wheel Ass’y 8 x 1.7
734-1987 Front Wheel Assembly 8 x 1.8
61 747-0996 Chute Door Pivot Rod
62 710-0654A Sems Screw TT 3/8-16 x 1
63 682-7000 Mulching Plug (Hinged)
64 731-1409 Chute Deflector
66 782-5007A Rear Mulch Plug
67 782-5004 Rear Mulch Baffle
68 710-1237 Hex Washer Hd. Screw (B&S ) †
710-0871 Hex Screw (Tec) †
70 736-0182 Wave Washer
71 736-0105 Spring Washer
72 731-1426 Hub Cap Yellow †
73 738-0481A Rear Axle Bolt
76 736-0456 Flat Washer
80 720-0312 Foam Grip
81 732-0866 Height Adj. Lever
82 712-3005 Hex Flange Lock Nut 3/8-16
84 732-0731 Torsion Spring
85 747-0710 Hinge Pin
86 710-0599 Tapp Scr. 1/4-20 x .500
87 736-0270 Bell Washer .265 x .75 x .062
88 710-0216 Hex Screw 3/8-16 x .75
† If equipped
Table continued on next page
17
Models 540 through 549
Table continued from previous page
Ref. No. Part No. Description
89 736-0331 Bell Washer .39 x 1.13 x .062
90 712-0798 Hex Nut 3/8-16
92 732-0809 Torsion Spring
93 738-0102 Front Axle Bolt
94 782-7006 Hinged Mounting Bracket
95 710-0896 Hex Screw 1/4-14 x .625
96 782-9050 Mounting Bracket
97 751B224511 Flywheel Guard (B&S) †
98 710-1268 Hex Screw
99 751B224437 Muffler Guard †
† If equipped
Your Notes
Date Comments
18
Your Notes
Date Comments
19
MANUFACTURER’S LIMITED WARRANTY FOR:
The limited warranty set forth below is given by MTD
PRODUCTS INC (“MTD”) with respect to new merchandise
purchased and used in the United States, its possessions
and territories.
MTD warrants this product against defects in material and
workmanship for a period of two (2) years commencing on
the date of original purchase and will, at its option, repair or
replace, free of charge, any part found to be defective in
material or workmanship. This limited warranty shall only
apply if this product has been operated and maintained in
accordance with the Operator’s Manual furnished with the
product, and has not been subject to misuse, abuse, commercial use, neglect, accident, improper maintenance,
alteration, vandalism, theft, fire, water or damage because
of other peril or natural disaster. Damage resulting from the
installation or use of any accessory or attachment not
approved by MTD Products Inc. for use with the product(s)
covered by this manual will void your warranty as to any
resulting damages.
Normal wear parts or components thereof are subject to
separate terms as follows: All normal wear part or component failures will be covered on the product for a period of
90 days regardless of cause. After 90 days, but within the
two year period, normal wear part failures will be covered
ONLY IF caused by defects in material or workmanship of
OTHER component parts. Normal wear parts and components include, but are not limited to, belts, blades, blade
adapters, grass bags, rider deck wheels, seats, snow
thrower skid shoes, shave plates and tires. Batteries are
covered by a 90-day limited replacement warranty.
HOW TO OBTAIN SERVICE: Warranty service is available,
WITH PROOF OF PURCHASE THROUGH YOUR LOCAL
AUTHORIZED SERVICE DEALER. To locate the dealer in
your area, please check for a listing in the Yellow Pages or
contact the Customer Service Department of MTD PRODUCTS INC by calling 1-800-800-7310 or writing to P.O. Box
368022, Cleveland, Ohio 44136-9722.
This limited warranty does not provide coverage in the
following cases:
a. The engine or component parts thereof. These items
carry a separate manufacturer’s warranty. Please refer
to the applicable manufacturer’s warranty on these
items.
b. Log splitter pumps, valves and cylinders have a sepa-
rate one year warranty.
c. Routine maintenance items such as lubricants, filters,
blade sharpening and tune-ups, or adjustments such
as brake adjustments, clutch adjustments or deck
adjustments; and normal deterioration of the exterior
finish due to use or exposure.
d. MTD does not extend any warranty for products sold
or exported outside of the United States of America,
its possessions and territories, except those sold
through MTD’s authorized channels of export distribu-
tion.
No implied warranty, including any implied warranty of
merchantability or fitness for a particular purpose,
applies after the applicable period of express written
warranty above as to the parts as identified. No other
express warranty or guaranty, whether written or oral,
except as mentioned above, given by any person or
entity, including a dealer or retailer, with respect to any
product shall bind MTD. During the period of the Warranty, the exclusive remedy is repair or replacement of
the product as set forth above. (Some states do not
allow limitations on how long an implied warranty lasts, so
the above limitation may not apply to you.)
The provisions as set forth in this Warranty provide the
sole and exclusive remedy arising from the sales. MTD
shall not be liable for incidental or consequential loss
or damages including, without limitation, expenses
incurred for substitute or replacement lawn care services, for transportation or for related expenses, or for
rental expenses to temporarily replace a warranted
product. (Some states do not allow the exclusion or limita-
tion of incidental or consequential damages, so the above
exclusion or limitation may not apply to you.)
In no event shall recovery of any kind be greater than the
amount of the purchase price of the product sold. Alteration
of the safety features of the product shall void this Warranty. You assume the risk and liability for loss, damage, or
injury to you and your property and/or to others and their
property arising out of the use or misuse or inability to use
the product.
This limited warranty shall not extend to anyone other than
the original purchaser, original lessee or the person for
whom it was purchased as a gift.
How State Law Relates to this Warranty: This limited
warranty gives you specific legal rights, and you may also
have other rights which vary from state to state.
Loading...