Poulan PR65Y21RDP, CH65Y21RDP, 917371590, 917371580, PR675Y21RHH Owner’s Manual

II

OPERATO °$

UAL

SELF-PROPELLED ROTARY

LAWN MOWER

Assembmy

Operation

o Maintenance

• Service and Adjustments
o Storage

o Troubleshooting

_,WARNING: This lawn mower isequippedwith 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 slate laws (ifany). Ifa spark arreeter is used, it
should be maintained in effective working order by the operator
In Ihe 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

authorized service center.

193733 Rev. 9 09.16.10 BY Printed in U.SoA.

SafetyRules......................2-3 Maintenance.............22-26Storage..........................33-34

Assembly...........................5-B Serviceand Troubleshooting..............35-36

Operation......................9-21 Adjustments..................27-32

IMPORTANT"Thiscuttingmachineiscapableofamputatinghandsandfeetandthrowingob-
jects_Failuretoobservethefollowingsafelyinstructionscouldresultinserious injury or death,

_Look for this symbol to point out impor_ ', Do not pull mower backwards unless
tant safely precaulions. It means absolutely necessary. Always look down

CAUTIONII! BECOME ALERTI!I
YOUR SAFETY IS INVOLVED_
_, WARNING: In order to prevent accidental

starting when selting up, transporting, ad-
justing or maklng repairs, always disconnect
spark plug wire and place wire where itcannot
come in contact with plug
_,WARNING: Engine exhaust, some of its

constituents, and certain vehicle compo-
nents contain or emit chemicals known to

the 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 birth

defects or other reproductive harm_ Wash

hends after handling,

_,CAUTION: Muffler and
olher engine parts become

extremely hot during
operation and remain hot

after engine has stopped
To avoid severe burns on

contact, stay away from these areas,,
I. GENERAL OPERATION

- Read, understand, and follow all
instructions on the machine and in the

manual(s) before starting, Be thoroughly
lamiliar with the controls and the proper

use of the machine before starting.

- Do not put hands or feet near or under
rotatingpads. Keep clear of the dis-
charge opening at all times.,

° Only allow responsible individuals, who

are familiar with the instructions, to oper-
ate the machine.

• Clear the area of objects such as rocks,
toys, wire, bones, sticks, etc., which
could be picked up and thrown by blade,

° Be sure the area is clear of other people

before mowing, Stop machine if anyone
enters the area°

° Do not operate the mower when bare-

foot or wearing open sandals. Always
wear substantial foot wear.

and behind before and while moving
backwards.

,, Never direct discharged material toward

anyOne. Avoid discharging material against
a wall or obstruction. Material may richo-
chet back toward the operator Stop the

blade when crossing gravel surfaces

• Do not operate the mower without
proper guards, plates, grass catcher or

other safety protective devices in place

• See manufacturer's instructions for
proper operation and installation of

accessories. Only use accessories ap-

proved by the manufacturer..

• Stop the blade(s) when crossing gravel

drives, walks, or roads,

° Stop the engine (motor) whenever you

leave the equipment, before cleaning the
mower or unclogging the chute.,

° Shut the engine (motor) off and watt until

Ihe blade comes to complete stop before
removing grass catcher.,

• Mow only in daylight / good artificial lighL

. Do not operate the machine while under

the influence of alcohol or drugs,,

° Never operate machine in wet grass,

Always be sure of your footing: keep a
firm hold on the handle; walk, never run,

° Disengage the self-propelled mech-

anism or drive clutch on mowers so
equipped before startfng the engine.

. Ifthe equipment should start to vibrate

abnormally, stop the engine (motor) and
check immediately for the cause, Vibra_

lion is generally a warning of trouble.

• Always wear safety goggles orsafetyglass-

eswith side shieldswhen operating mowen

II, SLOPE OPERATION
Slopes are a major factor related to slip &

fall accidents which can result in severe in-

jury.,All slopes require extra caution,, If you

feeDuneasy on a slope, do not mow it
DO:

• Mow across the face of slopes: never

up and down. Exercise extreme caution

2 when changing direction on slopes_

• Removeobstacles(rocks,treelimbs,etc,,)

• Watchforholes,ruts,orbumps_Tall
grasscanhideobstacles

DO NOT:

,, Do not trim near drop-offs, ditches or

embankments° The operator could lose
footing or balance°

• Do not trim excessively steep slopes,

o Do not mow on wet grass, Reduced foot-

ing could cause slipping,,

III. CHILDREN
Tragic accidents can occur if the operator is

not alert to thepresence of children, Children
are often attracted to the machine and the

mowing activity, Neverassume that children
will remain where you last saw them°
,, Keep children out of the trimming area

and under the watchful care of another
responsible adult,

,, Be alert and turn machine off if children

enter the area°

• Before and while walking backwards,

look behind and down for small children,

. Neveral!ow children to operate the mowero
. Use extra care when approaching blind

corners, shrubs, trees, or other obiects
that may obscure vision_

IV. SAFE HANDLING OF GASOLINE

Use extreme care in handling gasollne_
Gasoline is extremely flammable and the
vapors are explosive.
° Extinguish all cigarettes, cigars, pipes

and other sources of ignition°

o Use only an approved container,
° Never remove gas cap or add fuel with

the engine running_ Allow engine to cool
before refueling.

o Never refuel the machine indoors,

° Never store the machine or fuel contain-

er where there is an open flame, spark
or pilot fightsuch as a water heater or on

otherappliances,,

° Never fill containers inside a vehicle, on

a truck or trailer bed with a plastic liner.
Always place containers on the ground

CONGRATULATIONS onyour purchase of a new Lawn Mower, it has been designed, engi-

neered end manufactured togive you the best possible dependablltty and performance.

Should you experience any problems you cannot easily remedy, please contact your

nearest authorized service center, They have competent, well trained technicians and

the proper tools to service or repair this unit,

° Read the SAFETY RULES and this Operator's Manual in its entirety before you at-

tempt to assemble or operate your new lawn mower to insure proper operation and to
prevent injury to yourself and others., Save this manual for future reference.,

o Your new lawn mower has been assembled at the factory with the exception of those

paris left unassembled for shipping purposes. To ensure safe and proper operation
of your lawn mower, all parts and hardware you assemble must be tightened securely,

Use the correct tools as necessary to ensure proper tightness°

,, All parts such as nuts, washers, bolts, etc,, necessary to complete the assembly have

been placed in the parts bag° 3

away from your vehicle before filling,.

,, Remove gas-powered equipment from the

truckortrailerand refuelitonthe ground, tf
this isnot possible, then refuel such equip-
ment with a portable container, rather than
from a gasoline dispenser nozzle.

, Keep the nozzle in conlact with the rim

of the fuel tank or container opening at
all times until fueling is completer Do not

use a nozzle lock-open device.

° If fuel is spilled on clothing, change

clothing immediately,

° Never overfill fuel tank. Replace gas cap

and tighten securely.

V, GENERAL SERVICE
° Never run machine inside a closed area_
. Never make adjustments or repairs with

the engine (molor) running. Disconnect the
spark plug wire, and keep the wire away
from the plug toprevent accidentalstading

• Keep nuts and bolts, especially blade
attachment bolts, tight and keep equip-

ment in good condition.

° Never tamper with safety devices,. Check

their proper operation regularly_

.. Keep machine free ofgrass, leaves,orother

debris build-up, Clean oil or fuel spillage_
Allow machine to cool before storing,

• Stop and Inspect the equipment if you
strike an object., Repair, if necessary,
before restarting.

° Never attempt to make wheel height

adjustments while the engine is running°

• Grass catcher components are subject to
wear, damage, and deterioration, which

could expose moving parts or allow objects
tobethrown. Frequently check components
and replace with manufacturer's recom_

mended parts, when necessary,

• Mower blades are sharp and can cut,
Wrap the blade(s) or wear gloves, and

use extra caution when servicing them,

• Do not change the engine governor set-

ting or overspeed the engine,

o Maintain or replace safety and instruc-

tion labels, as necessary.

TO REMOVE LAWN MOWER

FROM CARTON

o Remove all loose parts from carton°

• Remove lawn mower housing wilh care,,
Avoid touching blade under housing_
Always wear gloves or other protection

when working under or lifting mower,,

THINGS TO KNOW BEFORE YOU
ASSEMBLE OR OPERATE YOUR

LAWN MOWER

Do I have a side or rear discharge lawn
mower?

Look for the grass discharge opening on
your mower.. If the opening ison the right
side of the mower housing, itis a side
discharge mower. If the opening isat the
back of the mower housing, it is a rear dis-
charge mower, Only rear discharge lawn
mowers have a grass catcher included
wilh the mower. Approved grass catch-

ers for side discharge mowers may be
purchased from your nearest authorized

dealer.,

Do I have a mulching lawn mower?

Look for the grass discharge opening on

your mower.. Raise the discharge guard

(rear door on rear discharge mowers), If
the opening is closed off by a plate, then

your lawn mower is mulcher ready.. To

convert to a discharging mower, see the
Operation section of this manual.

What is the right and left side of the
lawn mower?

When right hand (RH) or lefthand (LH) is

mentionedin this manual, it means when

you are in the operating position (standing

behind the handle),,

FRONT

LEFT

HAND

SIDE

BACK or REAR

(Operating Position)

What kind of engine is on my lawn

mower?

When learning how to operate your new
lawn mower, you willneed to know what

kind of engtne powers the mower, A decal
on the engine witl indicate the manu-
facturer and type or brand name of the
engine,,

BR1GGS& STRAT£ON ENGINES

RIGHT

HAND

SIDE

QU HTUm.

OTHER ENGINES

RATO °

_CAUTION" Do not operate this lawn
mower without the discharge guard or an
entire approved grass catcher in place°

These guards are for your protection and
are required by the American National

Standards Institute and Consumer Prod-
ucts Safety Commission°

_GAUTION: Disconnect spark plug wire
from spark plug and place wire where it
cannot come in contact wilh plug

HOW TO SET UP YOUR MOWER
UNFOLD HANDLE
IMPORTANT: Unfold handle carefully so

as not to pinch or damage control cables.
2 POSITION / "ADJUSTABLE" HANDLES

o Raise handles until lower handle section

locks into place in operating position°

"QUICK RELEASE" HANDLES
,, Move height adjustment lever forward to

raise mower to highest position,.

- Tighten handle bolts (on both sides),
Operator MOWING

presence

control

UP

handle

Handle

lever

, Insert handle bolt through handle and

bracket and secure with knob_

o Repeat for opposite side of handle,

Knob

Handle
bracket

Bolt

3 POSITION "QUICK" HANDLES

• Raise lower handle section to operating
position and squeeze lhe bottom ends
of lower handle towards each other

until the pin in handle can be inserted
into one of the three height adjustment

holes.

SQUEEZE

J

Handle

adJ,
bracket

p_n

Handle

Height
adjuster
level

LEVER
FORWARD
TO RAISE
MOWER

3 POSITION "EZ" HANDLES
° Raise lower handle section to operating

position and align hole in handle with
one of three height positioning holes_

ALL HANDLES
" Raise upper handle section into place on

bolt

lower handle, remove protective padding
and tighten both handle knobs.

,, Remove handle padding holding opera-

tor presence control bar to upper handler

• Your lawn mower handle can be ad-
justed lor your mowing comfort. Refer to

"ADJUST HANDLE" in the Service and
Adjustments section of this manual

NOTE: For shipping purposes, the rear
wheels on your lawn mower may not be

adjusted to the same position as the front
wheels. Before operating mower adjust all

5 wheels to the same cutting height,

INSTALL REAR WHEELS "FABRIC TOP" GRASS CATCHERS

("HIGH WHEEL" MOWERS ONLY)

Some high wheel models require washers
which will be provided in a parts bag, If
provided, install washers on the axle first

as shown,
+ Install one (1) rear wheel on the axle of

rear wheel adjuster_

, Install 3/8-16 locknut and tighten se+

curely.

,, Repeat procedure for other rear wheel,

Axle

TO ASSEMBLE AND ATTACH GRASS
CATCHER

• Put grass catcher frame into grass bag
with rigid part of bag on the bottom,,

° Slip vinyl bindings over frame+
NOTE: Ifvinyl bindings are too stiff, hold

them inwarm water for a few minutes° if
bag gets wet, tet it dry before using+

= Lift the rear door on the mower housing,,
, For HINGE BRACKET mounted catcher,

place the grass catcher frame onto the
formed tabs on the rear door hinge

bracket.

"_'---_ Reardoor

Hingebracket

tocknut assembly

ASSEMBLE GRASS CATCHER
(REAR DISCHARGE MOWERS ONLY)
IMPORTANT: Ifyour model lawn mower

Formed tabs

is mulcher ready, the mutcher plate or plug
must be removed before using mower as

a bagger+To converl mower to bagging or

discharging, see the Operation section in
this manual,

Look at the different grass catcher illustra-
tions that follow, Determine which type

° For HANDLE BRACKET mounted

catcher, place frame side hooks into
slots in handle brackets,

of grass catcher you have and follow the
appropriate instructions+,

\

Frame

handle

Handte bracket Rear

Grass

catcher

frame

Grass

catcher

handle

Frame

opening

\

Catcherframesidehook

. For DOOR PIVOT PIN mounted cafcller,

place lhe grass catcher Irame tlooks

onto the door pivot pins

_tns Rear Grass

catcher

handle

Catcher frame hook ",

SPARK PLUG BOOT
On some models a spark plug boot is

packed loose in the parts bag.. If your
model has the boot, install on spark plug
wire and reconnect spark plug wire to
spark plug..

. For DOOR SLOT mounted catcher,

place the grass catcher frame hooks into

the slots of the rear door.
NOTE: The grass catcher is secured to the
lawn mower housing when the rear door is
lowered onto the grass catcher frame..

__ ._.__ Reardoor slots

Grass

Catcherframehook "_'_.. ""'-. "" -. t

ALL GRASS CATCHERS
,_CAUTION; Under normal usage, the

catcher material is subjec! to deterioration
and wear and should, therefore, be

checked frequently for replacement° Any

replacement catcher should be checked to

ensure compliance with original manufac*
turer's specilicalions_

_,CAUTION: Do not run lawn mower
without the discharge guard (rear door),

approved grass catcher, clipping deflector
or mulcher plate in place. Never attempt

to operate mower with the discharge guard

(rear door) removed or propped open.

\

Boot

TO PREPARE BATTERY
(ELECTRIC START MODELS ONLY)

NOTE: Your battery must be charged
before you can start your lawn mower°
= Open battery box (if equipped)°

• Disconnect engine connector (male)

(if equipped) from battery connector
(female),

o Connect battery charger connector

(male) to harness connector (female),.

o Plug battery charger into 110 voll AC_

outlet,,

• Leave batterycharger connected for 24

hours before startingyour engine lor the

first time,

, Reconnect engine connector(male) (if

equipped) to battery connector (female)_

- After charging, connect engine connector

(male) (if equipped) to battery connector

(female),
Connect your battery charger to charge
battery after each use°
IMPORTANT: The engine will not recharge

your battery_

At lhe end of the mowing season the
battery should be charged for 48 hours to

tect the battery during winter storage_

AUTION: Always disconnect the

engine connector from the battery con-
nector to prevent accidental starting when

transportingor storing your lawn mower

after the season,

HANDLE-MOUNTED KEY SWITCH

Engine Harness

connector connector

\

connector(male)

22PLUS FRONT WHEEL DRIVE

Englne battery Battery

Charger

connector

(male)

Battery connector (female)

ale)

Charger

DECK-MOUNTED BATFERY

Battery Batlery

Charger

Harness
connector

connector

(m_

box

(female)

Engfne connector (male)

22PLUS REAR WHEEL DRIVE

Harness

connector

Battery char!

hale)

Battery
box

The operation of any lawn mower can result in foreign objects thrown into
the eyes, which can result in severe eye damage, Always wear safety

glasses or eye shields while operating your lawn mower or performing any
adjustments or repairs. We recommend standard safety glasses or a wide

vision safety mask worn over spectacles.

HOW TO USE YOUR LAWN MOWER
ENGINE SPEED CONTROL
MODELS WITH REMOTE THROTTLE

Engine speed is controlled by the throttle
control located on the upper handle,,
° Move lever forward to FAST engine

speed for starting and better bagging°

. Move lever backward for SLOW engine

speed.

o Some models have engines equipped

with a choke feature° Move the lever all

the way forward to the CHOKE position

when starling a cold engine,
NOTE: Be sure engine STARTtSTOP
switch(if equipped) isin theON positiom

FAST _ ..

SLOW

CHOKE _" _ t ;' IJ 1€1 .'
{START)// _' ,,/_'/"t'- : C ",_"

I /// \| . / I,,, ,'
\ Ill Ih. _/ / t "

TO ADJUST CUTTING HEIGHT

ALL MODELS:

Adjust cutting height to su_tyour require-

mentso Medium position is best for most
lawns° Raise wheels for low cut and lower

wheels for high cut..

NOTE: For shipping purposes, the rear
wheels on your lawn mower may not be
adjusted to the same position as the front

wheels, Before operaling mower adjust aH
wheels to the same cutting height..

"MANUAL" ADJUSTMENT
° Remove wheel, bolt, and hardware and

reassemble indesired adjustment holeo

° Reinstall wheel components in the same

order as they were before removal.
Tighten securely.

= Make sure ait wheels are af same height.

Fiat washer

Z

emote

_'_( J "throttle

_ff control

MODELS WITH FIXED SPEED ENGINES

Engine speed was set at the factory for

optimum performance,. Engine speed is
not adjustable.

Spacer Locknut

"QUICK" ADJUSTMENT
° To changecutting height, squeeze adjuster

lever toward wheel., Move wheel up or
down to suit your requirements. Be sure
all wheels are in the same setting.

NOTE: Adjuster isproperly positioned when
plate tab inserts intohole in lever, Also, 9-
position adjusters (if so equipped) allow lever

to be positioned between the plate tabs.

LEVERBACKWARD Plate tab

TO LOWERMOWER

LEVERFORWARDTO RAISEMOWER Lever

9

31B-16

"QUICK+PIN"ADJUSTMENT

. To change cutting height, pull up on

adjuster lever, move wheel up or down
to suit your requirements and release

adjuster lever. Be sure all wheels are in

the same setting.
NOTE: Adjuster is properly positioned
when lever inserts into hote in plate,.
LEVERBACKWARD

TO LOWERMOWER

LEVER
FORWARD

TO RAISE MOWER

"SINGLE POINT" ADJUSTMENT
o Pull adjuster lever toward wheel. To

raise mower, move lever forward to

desired position.. To lowermower, move

the lever toward the rear

Height

adjl

"DUAL POINT" ADJUSTMENT
Both front wheels are adjusted by a single

lever on the lett front wheel.. Likewise,
both rear wheels are adjusted by a single

lever on the lelt rear wheel+
, Pull adjuster lever toward wheel. To

raise mower, move fever forward to

desired position.. To lower mower, move

the lever toward the rear+.
Be sure to adjust both front and rear
wheels to the same height,

ght fever

LEVER BACKWARD
TO LOWER MOWER

LEVER FORWARD

TO RAfSE MOWER

LEVER
BACKWARD
TO LOWER
MOWER

LEVER
FORWARD

TO RAfSE
MOWER

\

'1o

"THREE POINT" ADJUSTMENT
(18" (45cm) HI-VAC MODELS ONLY)

Both rear wheels are adjusted by a single
lever on lhe left rear wheel,

o Pull adjuster lever toward wheel° To

raise mower, move lever forward to
desired position. To lower mower, move

lhe lever toward the rear.

NOTE; There are seven (7) height adjust-
ment positions for the rear wheels..
Both front wheels are adjusted as follows:

!.. Remove wheel, bolt, and hardware and

reassemble in desired adjustmenl hole..

2o Reinstall wheel components in the

same order as they were before re-
moval. Tighten securely.

NOTE: There are seven (7) height adjust-
ment holes for the front wtleels, Be sure

both front wheels are in the same hole.
IMPORTANT: Be sure to adjust both front

and rear wheels to the same heighL

LEVER BACKWARD
TO LOWER REAR
OF MOWER

LEVER FORWARD

TO RAISE REAR

OF MOWER

Bolt

Lockbar

(

postllon)

Wing

CASTER WHEEL OPERATION
("THREE POINT" ADJUSTMENT ONLY)

The front wheels can be "locked" into
position or set to "freewheel" for better

maneuverability.. Placing the lockbars in
the outer holes of the adjustment brackets

"locks" the front wheels. Likewise, placing
the !ockbars in the inner holes of the ad-

justment brackets al]ows the front wheels
to spin freely ("freewheeF).

• Lift Iockbar until the frontmost end clears
the adjustment bracket, then pivot lock-

bar to desired position,.

IMPORTANT: Front wheels must be
"locked" into position when operating on

a sloper Mow across the face of slopes:
never up and down.

Washer

Lockbar

("treowheel"

position)

TO CONVERT MOWER:

Most mowers are shipped ready to be

used as a mulchero
"REAR DISCHARGE ONLY" MOWERS

Some models have a seperate mulcher
plug, other models have the mulcher plug

built into the rear door, To convert to bag-
ging or discharging, lhe plate or plug (if

so equipped) must be removed from the
discharge opening of the lawn mower.
. Open rear door and remove mulcher

plate or plug (if so equipped). Store
mulcher plate or plug in a safe place.

. You can now install grass catcher or

optionat clipping defleclor accessory.

° To return to mulching operation, install

mulcher plate or plug into discharge

opening of mower.

,,_CAUTION: Do not run your lawn mower
without mutcher plate/plug in place or ap-
proved clipping defteclor or grass catcher

in place.. Never attempt to operate the
lawn mower with the rear door removed or

propped open,

MULCHER

"PLATE"

Slots

Mutcher

plale tabs

__i_ MULCHER

__ "PLUG"

Mutcher j...J... It{ _.JJ

plugf --/ -,.j_C..I--

MULCHER PLUG BUILT iNTO REAR DOOR

I1

"SIDEDISCHARGE ONLY" MOWERS

MULCHER PLATE

To convert to bagging or discharging,

mulcher plate must be removed from un-

derside of lawn mower_
o Remove thefour (4) screws and locknuts

securing the mulcher plate tothe mower,,

* Store mulcher plate and hardware in a

sale place.

o Mower can now be used for side

discharging or optional grass catcher
accessory can be attached

o To return to mulching operation, simply

reinstall mulcher plate and tighten hard-
ware securely.

locknut

Mulcher

plate

MULCHER PLUG TYPE "B"

To convert to bagging or discharging:
,, Lift discharge guard and remove

mulcher plug.

• Mower can now be used for side dis-
charging or optional grass catcher can

be attached.

° To return to mulching operation, simply

reinstallmulcher plug as shown, making

sure tab is seated properly,.
_CAUT1ON: Do not runyour lawn mower
without discharge guard, approved grass
catcher or mulcher plug in place.

Lift

dtschar

guard

MULCHER PLUG TYPE "A"
To convert to mulching operation, mulcher
plug must be installed into discharge open-

ing o! mower,

• Open discharge guard°
. Insert tab of mulch plug Into housing

opening

• Alignhooksofmulchplugoverhinge

rodofdischargeguard Push mulch plug

down until mulch plug is seated in hous-

_}ing opening.

CAUTION: Do not run your lawn mower

without discharge guard, approved grass
catcher or mulcher plug in place.

Hinge

Discharge

Mulcher plug 12

Install Tab
mulcher

MOWER IS

NOW READY

FOR MULCHING

OPERATION

"MULTI-CUT" MOWERS

Your lawn mower was shipped ready to be

used as a mutcher To convert to bagging

or discharging:

REAR BAGGING

o Open rear door and remove mulcher

plate or plug (if equipped) Store
mulcher plate or plug in a safe place

• You can now tnslall grass catcher.
= To convert to mulching or discharging

operation, install mulcher plate or plug (if
equipped) into rear discharge opening of

mower, making sure all labs are seated

properly_ Close rear door.

SIDE DISCHARGING

• Mulcher plate or plug (if equipped) must
be installed into rear discharge opening

of mower. Rear door must be clesed_

o Open mulcher door and installdischarge

deflector under door as shown.

o Mower is now ready for discharging

operation.

o To convert to mulching or bagging

operation, discharge deflector must be
removed and mulcher door must be

closed and locked..

bracket Grass

g

catcher

handle

catcher
frame :-,:,..

hook equipped)

"REAR DOOR PROP" (IF EQUIPPED)
(22PLUS MODELS ONLY)
NOTE: Rear door will remain open until

operator presence control bar is held down

to the handler
,_,CAUTION, Do NOT force rear door to

close° Serious damage to your mower

Open muicher door

Discharge
deliector

\

t3

SIMPLESTEPSTOREMEMBER

WHENCONVERTINGYOUR

"MULTI-CUT"LAWNMOWER:

FORMULCHING-
oRearmulcherplateorplug(ifequipped)

installedandreardoorclosed.,

. Mulcherdoorclosed,.
FORREARBAGGING-

° Rear mutcher plate or plug (if equipped)

remove&
o Grass catcher installed,
° Mulcher door closed°

FOR SIDE DISCHARGING

° Rear mulcher plate or plug (if eqLlippsd)

installed and rear door closed.

- Discharge deflector installed.
_CAUTION: Do not run your lawn mower

without rear mulcher plate or plug ihplace
or approved grass catcher in place° Ne,_er...

attempt to operate the lawn mower with
the rear door removed oT:'prop.pedopen.

....-,..,; Mower is now ready for rear bagging

18" (45cm) HI-VAC MODELS:
Your lawn mower was shipped ready to

be used as a mulchero To convert to rear
bagging or side discharging:

REAR BAGGING

1o Remove knob securing mulcher door

to lawn mower housing.

2. Open mulcher door and position dis-
charge chute over both threaded studs,

3. Secure discharge chute to lawn mower
housing with both knobs.,

4. Place the grass catcher on the rear
door as shown°

NOTE: Be sure the grass catcher is se-
curely locked in place_

bperation,,

Grass catcher

TO EMPTY GRASS CATCHER (REAR .......

DISCHARGE AND MULTI-CUT MODELS)If='.'/

• Simply open rear door and lift grass " ,':_._y:':'_
catcher up and away from mower,

NOTE: Do not drag the bag when
emptying, it will cause unnecessary wear. Dts-

_,CAUTION: Under normal usage, the charge
catcher material issubject to deterioration
and wear and should, therefore, be

checked frequentlyforreplacemenL Any
replacement catcher should be checked

to ensure compliance with original
manufacturer's specifications.

&CAUTION: Do not run lawn mower
without the rear door, approved grass

catcher or clipping deflector in place.,
Never attempt to operate mower with lhe

rear door removed or propped open_

j' // Gross

/ / catcher

//_ \ t frame

.......... ; ;-";,._jr a

(if equipped) _,_,

Threaded stud

SIDE DISCHARGING

I, Discharge chute must be removed.

2. Open mulcher door and installside dis-
charge deflector beneath it as shown.

andle

14 Side discharge deflector

Rear door

Knobs

Mutcher

door

door

3. Secure rear of side discharge deflector
to lawn mower housing with knob_

= Mower isnow ready for side discharging

operation,

SIMPLE STEPS TO REMEMBER WHEN

CONVERTING YOUR 18" HI-VAC:
FOR MULCHING -
1- Grass catcher, discharge chute and

side discharge deflector removed

2. Mulcher door secured to mower hous-
ing with knob

FOR REAR BAGGING -

1. Side discharge deflector removed.

2. Grass catcher and discharge chute
installedwith discharge chute secured
to lawn mower housing with knob,

FOR SIDE DISCHARGING -
1_ Grass catcher and discharge chute

removed

2. Side discharge deflector installed and
secured to mower housing with knob_

,_CAUTION: Do not run your lawn mower
wllhout mulcher door closed; side dis-
charge deflector installed, or discharge
chute and approved grass catcher in
place,, Never attempt to operate the lawn

mower with mulcher door removed or
propped open.
TO EMPTY GRASS CATCHER

1. Remove grass catcher with clippings
from lawn mower using both front and

center of handle as shown°

2 Empty clippings from grass catcher,
3, Reinstall grass catcher on rear door,

NOTE: Do not drag the bag when empty-
ing; it will cause unnecessary wear,

Handle

21" (53cm) HI-VAC MODELS:

Your lawn mower was shipped ready to
be used as a mulcher., To convert to rear

bagging or side discharging:
REAR BAGGING

1, Remove knob securing mulcher door to

lawn mower housing°

handle

,Crossbar

Grass

Round

door

_%_Knob

chute

Threaded

stud

Mulchor door

2_

Open mulcher door and insert tabs
of discharge chute into hinge bracket
opening and position rear of chute over

threaded stud,,

15

Hinge bracket Muicher door

3,,Securerearofdischargechute;tolawn........

mowerhousingwithknob,

4, Placerearhandleofgrasscatcheron

thecrossbarofthelawn mower's tower

handle as shown.

5,, Lift the round door of the discharge

chute and place the grass catcher _nto

place on the discharge chute,
NOTE: Be sure the grass catcher is se-
curely locked in place and the round door
of the discharge chute rests on the grass

catcher as shown°

• Mower is now ready for rear bagging

operation,.

° To convert to mulchtng operation,

remove grass catcher and discharge
chute_ Secure mulcher door to mower

housing with knob,,

° To convert to side discharging operation,

remove grass catcher and discharge
chute, Install side discharge deflector
and secure it to lawn mower housing

with knob°

SIDE DISCHARGING

1. Grass catcher and discharge chute
must be removed,,

2. Open mulcher door and install front of
side discharge deflector beneath it as

shown,

3. Secure rear of side discharge deflector
to lawn mower housing with knob°

,, Mower is now ready for side discharging

operation°

° To convert to mulching operation, side

discharge deflector must be removed
and mulcher door secured to mower

housing with knob.

,, To convert to rear bagging opera-

tion, side discharge deflector must be

removed; discharge chute and grass
catcher installed and discharge chute
secured to mower housing with knob.,

Mulcherdoor

\

stud

Side
discharge

deflector

WHEN CONVERTING YOUR 21" HI-VAC:
FOR MULCHING -

1, Grass catcher, discharge chule and

2, Mulcher door secured to mower hous-

FOR REAR BAGGING -

1. Side discharge deflector removed

2., Grass catcher and discharge chule

3o Round door of discharge chute resting

FOR SIDE DISCHARGING -

1, Grass catcher and discharge chute
2- Side discharge deflector _nstal]edand
,_CAUTION: Do not run your lawn mower

without mulcher door closed; side dis-
charge deflector installed, or discharge

chute and approved grass catcher in
place° Never attempt to operate the lawn

mower with mulcher door or round door
removed or propped open.

TO EMPTY GRASS CATCHER

1. Open round door of discharge chute to

' _\. Front

OPEN

Round Starter
door rope

2, Remove grass catcher with clippings

3, Empty clippings from grass catcher

4. Snap door shut over frame before
NOTE: Do not drag the bag when empty-

16ing; il will cause unnecessary wear.

SIMPLE STEPS TO REMEMBER

stde discharge deflector removed,
ing with knob.

installed with discharge chute secured
to lawn mower housing with knob

on top of grass catcher.

removed_
secured to mower housing with knob,

move starter rope out and away from
grass catcher,,

from lawn mower using both front and
rear handles,

using rear handle° The weight of the

grass will open the door°

installing grass catcher on mower.

OPERATORPRESENCE CONTROL

BAR (ALL MODELS)

Your lawn mower is equipped with an op-

erator presence control bar which requires

the operator to be positioned behind the

lawnmower handle in order to start and

erate the lawn mower_

AUTION: Federal regulations require

an engine control to be installed on this
lawn mower in order to minimize the risk

of blade contact injury, Do not under
any circumstances attempt to defeat the

function of the operator control. The blade

turnswhen the engine is running,

DRIVE CONTROL

"STANDARD" DRIVE CONTROL

° Self-propelling is controlled by holding

the operatorpresence control bar down
tothe handle and pushing the drive

controllever forward until itclicks;then
re_easing the lever,

o Forward motion will stop when the op-

erator presence control bar is released,,
To stop forward motion without stopping
engine, release the operator presence
control bar slightly until the drive control
disengages_ Hold operator presence
control bar down against handle to con-
tinue mowing without self-propelling,

o To keep drive control engaged when

turning corners, push down on handle
and lift front wheels off ground while

turning lawn mower,,

TO ENGAGE DRIVE CONTROL

17

Operator

presence
contro_bar

DRIVE CONTROL DISENGAGED

"DUALBAIL" DRIVE CONTROL

. Tostart forward motion, lift drive control

bar up to handle°

° Tostop forward motion, release drive

control bar_

Operator
presence

control bar

DRIVE CONTROL ENGAGED

DRIVE CONTROL DISENGAGED

"AUTOWALK" DRIVE CONTROL

o Self-propelling is controlled by holding

the operator presence control bar down
to the handle and pulling the ddve con-
trollever(s) rearward to the handle. The
farther toward the handle the lever(s)
are pulled, the faster the unit will travel.

. Forward motion will stop when either

the operator presence control bar or a
drive control lever are released° To stop

forward motion without stopping engine,
release the drive control lever(s) only.

Hold operator presence control bar

down against handle to continue mowing

withoutself-propelling,

NOTE: If after releasing thedrive control the
mowerwili not rollbackwards, push the mower

forward slightly to disengage drive wheels,,

control presence

lever(s) control ba_

TO ENGAGE DRIVE CONTROL

turnbuckle

DRIVE CONTROL DISENGAGED

FRONT WHEEL DRIVE MODELS ONLY:

- To keep drive control engaged when
turning corners, push down on the

handle to lift the front wheels off the
ground while turning lawn mower,

18

Overtime,thedrivecontrolsystemmay
become"loose",resultingindecreased

speed°Thereisatumbucldeonthe

undersideofthedrivecontrolhousingto
increasetensiononthedrivecable.Pro-

ceedasfollows:

- Turnunitoffanddisconnectspad(plug
wirefromsparkplug.

,, Turn nut on underside of drive control to

increase drive speed.

,' Operate mower to test drive speed°

Readjust as required

, Ifcondition fails to improve after the

above steps (forward speed remains
the same), your drive bait is worn and

should be replaced.

turnbuckEe

/

"VARI-SPEED"DRIVECONTROL

o Serf-propelling is controlled by hold-

ing the operator presence control bar
down to the handle and pulling the drive

control bar up to the handle. The closer
to the handle the bar is pulled, the faster
the unit wilt travel..

o Forward motion will stop when either the

operator presence control bar or drive
control bar are released, To stop forward
motion without stopping engine, release
the drive control bar only Hold operator
presence control bar down against

handle to continue mowing without self-

propelling.
NOTE: If alter releasing the drive control the
mowerwi!l not rollbackwards, push the mower

forward slightly to disengage drive wheels.
FRONT WHEEL DRIVE MODELS ONLY:

- To keep drive control engaged when

turning corners, push down on the
handle to lift the front wheels off the

ground while turning lawn mower,.

oratorpresencecontrolbar

controlbar

DRIVE

CONTROL

DISENGAGED

TO ADJUST,

MOVE DOWN

TO NEXT HOLE

Over time, the drive control system may
become "loose", resulting in decreased
speed.. There are holes in the drive control

housing to increase tension on the drive

cable. Proceed asfollows:
, Turn unit off and disconnect spark plug

wire from spark plug.

° Loosen nut, move drive control hous-

ing down handle to the next hole and
retigh|en nut.

,, Operate mower to test drive speed.

° Ifcondition falls to improve after the

above steps (forward speed remafns
the same), your drive belt is worn and
should be replaced.

19

BEFORE STARTING ENGINEI:' :::::::::::::::::::::::Ifyour mower has a primer, to start a
Read the engine manual packed with your

mower,,
FILL ENGINE WITH OIL

Your lawn mower is shipped without oil in

the engine.
o Be sure mower is level and area around

oil fill is clean,

o Remove engine oil rifler plug (oil fill cap/

dipstick on models so equipped)°

- Slowly add oil For type and grade of
oil to use, see "ENGINE" in the Mainte-

nance section of this manual,,

• Fill to the top of slot in filler hole (to
"FULL" line on dipstick on models so
equipped). Do not overfill

• Replace plug (oil fill cap/dipstick on
models so equipped) and tighten.

o Ctteck oil level before each use,, Add oil

as needed.

o To change oil, see Maintenance section

of this manual,

FILL GASOLINE TANK

• Fill gasoline tank with fresh, clean,
unleaded gasoline, DO NOT USE PRE-

MIUM GASOLINE, BE CAREFUL NOT
TO OVERFILL TANK,

WARNING: Alcohol blended tuels (called
gasohol or using ethanol or methanol) can

attract moisture which leads to separation
and formation of acids during storage. Acidic

gas can damage the fuel system ofan engine
whiEein storage,, To avold engine problems,
the fuel system should be emptied before

storage of 30 days or longer° Drain the fuel
tank, start the engine and let it run until fuel

lines and carburetor are empty. Use fresh
fuel next season, See Storage Instructions

for additional Information. Never use engine
or carburetor cleaner products inrue!tankor

permanent damage may occur,

TO START ENGINE
_CAUTION: The mower blade rotates
whenever the engine is running_

NOTE: Due to protective coatings on the
engine, a small amount of smoke may be
presentduring the initial use of the product

and should be considered normal,

,, Place engine START/STOP switch (if

equipped) in the ON position.,

• Move engine speed control to FAST
position (or to CHOKE/START position

on models equipped with choke feature),

cold engine, push primer as many times
as instructed in the engine manual
packed with your mower_ Use a firm
push_This step is not usually necessary

when starting an engine which has
already run for a few minutes

• Hold operator presence control bar
down against handle.

MODELS WITH RECOIL STARTER
o Pull starter handle quickly, Do not allow

starter rope to snap back.

MODELS WITH ELECTRIC STARTER

• Push the engine start button (or turnthe
key on models so equipped).

IMPORTANT: Do not crank engine more
than five continous seconds each time you

tnj tostart,, Wait 5 to !0 seconds between
each attempt°
ALL MODELS

° For engines equipped with choke, slowly

move engine speed control lever to

FAST after engine starts.,

TO STOP ENGINE
° To stop engine, release operator pres-

ence control bar and/or place engine
START/STOP switch (it equipped) in the
OFF position..

NOTE: For engines with a primer, it may
be necessary to repeat priming steps
incooler weather, In warmer weather,

overpriming may cause flooding and
engine will not start,, If you do flood

engine, wait a few minutes before
attempting tostart and DO NOT repeat

priming steps,,

2O

MOWING TIPS

CAUTION: Do not use de-thatcher
blade attachments on your mower, Such
attachments are hazardous, will damage

your mower and could void your warranty_
° For most cutting conditions and better

bagging performance, the engine speed
should be set in the FAST position,,

o Under certain conditions, such as when

mowing very tal_grass, raise the mower
height on the first cut to reduce pushing

effort, to avoid overheating the engine,
and to avo+dleaving clumps of grass

c}ippings,. Make the second cut to the
desired height,

• For extremely heavy cutting, reduce the
width of cuL

. For side discharge lawn mowers, cut in

a counterclockwise direction, starting at
the outside o! the area to be cut, in order

to spread grass clippings more evenly
and toput less load on the engine. To
keep clippings off of walkways+ flower

beds, elc. make the first cuts in a clock-
wise direction,

, When using a rear discharge lawn

mower in moist, heavy grass, clumps
of cut grass may not enter the grass
catcher. Reduce ground speed (pushing

speed) and/or run the lawn mower over
the area a second time,,

o tf a trailof grass clipping is left on the

right side of a rear discharge lawnmow-
er,mow in a clockwise direction with a

small overlap to collect the clippings on

the next pass,

FOR MULCHING MOWERS ONLY
+MULCHING MOWING TIPS
IMPORTANT; For best performance, keep

mower housing free of built-up grass and
trash, See '*CLEANING" in the Mainte-

nance section of this manual.

, The special mulching blade wilt recut the

grass clippings many times and reduce
them in size so that as Ihey fall onto the

lawn they will disperse into the grass
and not be noticed., Also, the mulched

grass will biodegrade quickly to provide
nutrients for the lawn. Always mulch with

your highest engine (blade) speed as

thiswilt provide the best recutting action

of the blades°

. Avoid cutting your lawn when it is wet

Wet grass tends to form clumps and
interferes with the mulching action. The
best time to mow your lawn is the early
afternoon, At this timethe grass has
dried, yet the newly cut area will not be
exposed to direct sunlight,

• For best results, adjust the lawn mower
cutting height so that the lawn mower

cuts off only the top one-third of the
grass blades, tf the lawn is overgrown it
will be necessary to raise the height of
cut to reduce pushing effort and to keep
from overloading the engine and leaving

clumps of mulched grass. For extremely

heavy grass, reduce your width of cut

by overlapping previously cut path and
mow slowly.

MAX tt3

Pores in cloth grass catchers can

become filled with dirt and dust with use
and the catcher will collect less grass,

To prevent this, regularly hose catcher
off with water and let dry'before use+

,tl

Certain types of grass and grass

conditions may require that an area be
mulched a second time to completely
hide the clippings. When doing a second

cut, mow across (perpendicular) to the
first cut path+

Change your cutting pattern from week
to week, Mow north to south one week
then change to east towest the next

week, This will help prevent matting and
graining of the lawn..

21

MAINTENANCE ieEFORE

SCNEDILILIE USE

JJ

Check {orLoose Fasteners V'

L Clean /inspect G'mssCatcher"

_i_ec_T.es ......................V'

W Check DriveWheels "" '............

EACH

t/

AFTER ! EVERY EVERY EVERY

EACH !0 25 HOURS 100 BEFORE

USE HOURS OR SEASON HOURS STORAGE

V' .................. v'

, J,, :

CieanLawnMower"_';; J

l,,n'_'i'ean'underDrivecowr'" .... [ ..............I' 'F' ....

0 Check Drb'_ Be'li'7'Pulreye"'* " ........................ ti/ ..............

w Check/Sharpa./ .epla_,;'Bi_d;' V'_ '

Lubrication ............... _ .............

IR Clean and Recharge Batlery '" 1_ l_

Check Engine OIl level V_ .........

E Eo, n,Oii .......... ' ..... ................

N

Clean ,_ir Fiiie'i;................ J .......... _/2' '

?

_=p,ciMu,,er...................... I _iii'7'iii"ii'ii'

NI--'RePleCe_§paik Plug ........... l ...... V

E RePlace Air Filler.Paper Cartridge I_

Empty fuef system or add Slabllizer 1_ .....

* (If so equipped} 1 - Change more often if operating under a heavy load or In t_,Ighoutdoor temperatures

** Eleclrlc-Slart mowers 2 - Service more ellen IIoperating indilly or dusty cof_ditions

*** Power-Propelled mowers 3 - Replace bLRdes more alton whsn mowing tn sandy soil

**** Use a scraper 4 - Charge 4B hours at end el season

to cteen trader deck 5 - And after each 5 hours el use,

GENERAL RECOMMENDATIONS

The warranty on this lawn mower does not
cover items that have been subjected to op-

erator abuse or negligence., To receive fu_l
value from the warranty, operator must main-

tain mower as instructed in this manual..
Some adjustments will need to be made

periodically to properly maintain your uniL
All adjustments in the Service and Adjust-

ments section of this manual should be
checked at least once each season°

• Once a year, replace the spark plug,
clean or replace air tilter element, and

check blade for wear. A new spark plug
and clean/new air filter elemenl assures

proper airfuel mixture and helps your
engine run better and last longer.

• Fol!ow the Maintenance Schedule in this
manual.

BEFORE EACH USE

_') Handle bracket mounting ptns

• Check engine olilevel..

• Check for loose fasteners.

_) Spray lubricant

LUBRICATION

(_) See "ENGINE" tn Maintenance section,

Keep unil well lubricated
(See "LUBRICATION CHART"),.

attract dust and dirt thai wilt shorten the life

of the self-lubricating bearings., Ifyou feel
IMPORTANT: Do not oil or grease plastic
wheel bearings. Viscous lubricants will

they must be lubricated, use only a dry,

22Powdered graphite type lubricant sparingly°

'r:

LUBRICATION CHART

adjusler (on

each wheel)

Engine oil

Side dis-

charge mower

guard hinge rod

Rear dis-

charge mower

rear door

hinge rod

Wheel

LAWN MOWER

Always observe safety' rules when per-
forming any maintenance

TIRES
o Keep tires free of gasoline, oil, or insect

control chemicals which can harm rub-
ber_

o Avoid stumps, stones, deep ruts, sharp

objects and other hazards that may
cause tire damage

BLADE CARE
For best results, blade must be kept sharp_

eplace a bent or damaged blade.

CAUTION: Use only a replacement
blade approved by the manufacturer of
your mower. Using a blade not approved
by the manufacturer of your mower is
hazardous, could damage your mower and
void your warranty.

TO REMOVE BLADE

1. Disconnect spark plug wire from spark

plug and place wire where itcannot
come incontact with plug

2. Turn lawn mower on its side. Make
sure air filter and carburetor are up.

3 Use a wood bFockbetween blade and

mower housing to prevent blade from
turningwhen removing blade bOlto

NOTE: Protect your hands with gloves

and/or wrap blade with heavy cloth,

4. Remove blade bolt by turningcounter-

c/ockwise_

5. Remove blade and attaching hard-

ware (bolt, lock washer and hardened
washer).

6. Remove debris shield (if equipped)

NOTE: Remove the blade adapter and
check the key inside hub of blade adapter.
The key must be in good condition to work

properly,. Replace adapter if damaged.

Belt

Ing edge

Debris shield Hardened

(if equfpped) washer

Blade Blade bolt

TO REPLACE BLADE

1. Position the blade adapter on the en-
gine crankshaft. Be sure key in adapter
and crankshaft keyway are aligned;

and that the drive belt is inside the tabs
of the belt retainer (if equipped).

2. Position blade on the blade adapter
aligning the two (2) holes in the blade

with the raised lugs on the adapter,

3,. Be sure the trailing edge of blade (op-

positesharp edge) is up toward the
engine,,

4, Inslalt the blade bolt with the lock

washer and hardened washer into
blade adapter and crankshaft,

5, Use block of wood between blade and

lawn mower housing and tightenthe
blade bolt, turning clockwise..

• The recommended tightening torque is
3540 frolbs..

IMPORTANT: Blade bolt is heat treated,.
If bolt needs replacing, replace only with

approved bolt shown in the Repair Parts
section of this manual.

TO SHARPEN BLADE
NOTE: We do not recommend sharpening

blade - but if you do, be sure the blade
is balanced. An unbalanced brade will

cause eventual damage to fawn mower or
engine°

• The blade can be sharpened with a file

or on a grinding wheel. Do not attempt
to sharpen while on the mower..

23

BLADESWITH ROUND HOLE:

" To check blade balance, drive a nail into

a beam or wall. Leave about one inch of
tl_estraight nail exposed.. Place center

hole of blade over the head of the nail..
II blade is balanced, it should remain in

a horizontal position, If either end of the
blade moves downward, sharpen the
heavy end until the blade is balanced..

BLADES WITH "STAR" HOLE:
. To check blade balance, you will need

a 5/8" diameter steel boll, pin, or a cone
balancer. (When using a cone balancer,
follow the instructions supplied with
balancer..)

NOTE: Do not use a nail for balancing
blade The lobes ol the center hole may

appear to be centered, but are noL
o Slide blade on to an unthreaded portion

of the steel bolt or pin and hold the bolt
or pin parallel wilh the ground. If blade

is balanced, it should remain in a hori-
zontal position. If either end of the blade

moves downward, sharpen the heavy
end until the blade Is balanced

18" (45cm) HI-VAC MODELS ONLY:
I. Remove hubcaps (if equipped) and

locknuts=

2. Remove wheels from wheel adjuster
axles,

3o Remove any trash or grass cuttings

from inside the dust cover, pinion gear
and drive wheel gear teeth..

4. If you remove the pinion gears, wipe
clean with dry cloth Reassemble

dry. Do not lubricate. Do not use oil or
grease.

IMPORTANT: The pinion gears (on both
sides of the mower) are the same, how-

ever, they must be installed correctly_ If
installed incorrectly, the drive system will

not work_
5o There are arrows embossed on both

sides of the pinion gear_ Wilh the ar-
row at the top of the pinion, the arrow
must point towards the front of the
mower., If the arrow points to the rear
of the mower, turn the pinion around,

then assemble it to the mower.

6. Place wheels back on adjuster axles,.

7. Replace locknuts and hubcaps.

FRONT

OF

MOWER

CORRECT INCORRECT

DRIVE WHEELS
Check drive wheels each time before you

mow to be sure they move freely.
The wheels not turning freely means trash,

grass cuttings, etc. are in the drive wheel
area and must be cleaned to free drive
wheels.

If necessary to clean the drive wheels,
check both drive wheels

. Ifafter cleaning, the drive wheels do not

turn freely, contact your nearest autho-

rized service center,.

Plnton
gear

Washer Dust

Locknut

• If after cleaning, the drive wheels do not
turn freely, contact your nearest autho-

rized service center..

24

Cover

GEARCASE

o To keep your drive system working

properly, the gear case and area around
the drive should be kept clean and free
of trash build-up. Clean under the drive

cover twice a season.

o The gear case is filled with lubricant to

the proper level at the factory, The only
time the lubricant needs attention is if

service has been performed on the gear

case,

ENGINE

Read the maintenance section of your
engine manual

LUBRICATION
Change the oil after the first twohours of

operationand every 25 hours thereafter or

at least once a year if the lawn mower is
not used for 25 hours in one year. Refer to

engine manual,,

TO CHANGE ENGINE OIL
(SEE ENGINE MANUAL)

, Be sure lawn mower ison level surface.

,, Oil will drain more freely when warm°
,, Catch oil in a suitable container.

. For engines without dipstick, remove

bottom oil drain plug,

° For engines with oil fill cap/dipstick,

remove bottom drain plug or remove en-
gine oil cap and turnmower on its side.

. After oil has drained completely, replace

oil drain plug and tighten securely°

. Refill engine with oil. Pour slowly. Do

not overfill.

= Fill to top of slot inside of filler hole or

to "FULL" line on dipstick on models so
equipped. Keep oil at proper level

AIR FILTER

Your engine will not runproperlyand may
be damaged by using a dirty air filter.
Clean the element after every 25 hours

of operation or every season_ Replace
the air filter every 100 hours of operation
or every season, whichever occurs first.
Service air cleaner more often under dusty

conditions° See the maintenance section
of your engine manual°

IN-LINE FUEL FILTER
(KOHLER ENGINES ONLY)

The fuel filter should be replaced once
each season, If fuel filler becomes

clogged, obstructing fuel flow to carburetor,
replacement is required.

1.. With engine cool, remove filter and plug
fuel line sections.

2. Place new fuel filter in position in tuel

line with arrow pointing towards carbu-
retor,

3, Be sure thereare no fuel line leaks and

clamps are properly positioned.

4 Immediately wipe up any spilled gaso-

line.

MUFFLER

inspect and replace corroded muffler as it
could create a fire hazard and/or damage

SPARK PLUG

Replace spark plug at the beginning of
each mowing season or after every 100

hours of operation, whichever occurs first.
Set spark plug gap according to engine
manual specifications°

CLEANING
IMPORTANT: Forbest performance, keep

mower housingfree of grass build-up and
trash.Clean the underside of your mower

after each use°

° Clean the underside of your lawn mower

by scraping to remove buildup of grass
and trash.

,, Clean engine often to keep trashfrom

accumulating,. A clogged engine runs
hotter and shortens engine life.

° Keep finished surfaces and wheels free

of all gasoline, oil, etc

We do not recommend using a garden

hose to clean your lawn mower unless the
electrical syslem, muffler, air filter, and
carburetor are covered to keep water out
Water in engine can shorten engine life.

CLEAN UNDER DRIVE COVER
Clean under the drive cover at least twice

a season,. Scrape underside of cover with
a putty knife or similar tool to remove any

buildup of trash or grass°

25

WATER WASHOUT FEATURE
(IF EQUIPPED)

Your lawn mower may be equipped with a
fitting that allows quick and easy cleaning

of the underside of the housing° To use
this feature, proceed as follows:

1• Move lawn mower to an area of cut

grass or another hard surface

NOTE: Water, grass and other debris will

drain from beneath the mower housing
during the washout process,

2,, Remove grass catcher and discharge

chute assembly from lawn mower°

3, Close mulcher door (if equipped).
4, Connect a garden hose to the fitting

where shown,

IMPORTANT: Be sure the garden hose is
nol routed under the lawn mower housing

or entangled in the wheels,
5, Turn on water supply and check for

leaks at the fitting,
If no leaks are present, start engine (as
described in the Operation section of this
manual) and let engine run until the under-

side of the lawn mower is clean.
_, WARNING: Do not engage the drive
system during the washout process,

6, Shut off the engine.

7. Shut off water supply and remove hose

from fitting,

CAUTION: Do not remove hose from
tilting while engine isrunning,, Water in
engine can result inshortened engine life
& Start engine (as described in the Op-

eration section of this manual) and let
engine run for a full minute to remove

excess water from mower.,

Fitting

GRASS CATCHER (IF EQUIPPED)
Grass catcher may be hosed withwater

but must be dry when used°

_,CAUTION: Under normal usage, the
catcher material is subject to deterioralion

and wear and should therefore be checked
to ensure compliance with original

manufacturer specifications

26

,_CAUTION:Beforeperforminganyser-
viceoradjustments:

oReleaseoperatorpresencecontrolbar
. Makesurethebladeandallmoving

parishavecompletelystopped.

,'Disconnectsparkplugwirefromspark

p)ugandplacewirewhereitcannot
comeincontactwithplug,

LAWN MOWER

TO ADJUST CUTTING HEIGHT

See "TO ADJUST CUTTING HEIGHT" in
the Operation section of this manual,

REAR DEFLECTOR

The rear deflector, attached between the

rear wheels of your mower, is provided to
minimize the possibility that obiects will

be thrown out of the rear of the mower
into the operator's mowing position Ifthe

deflector becomes damaged, it should be

replaced,

DISCHARGE GUARD (IF EQUIPPED)

The discharge guard, attached to the side

discharge opening of your lawn mower, is
provided to prevent the possibility of injury'

resulting from objects being thrown out of
the discharge opening into the operator
mowing position,. If the discharge guard
becomes damaged, itshould be replaced,

TO ADJUST HANDLE

"2 POSITION" HANDLES
The handle can be mounted in a high or

low position, The mounting holes in the
bottom of lower handle are off center for

raising or towering the handle,
) Remove upper handle and a)l parts at-

tached to lower handle,

• Remove hairpin cotters from lower

handle bracket mounting pin.

° Squeeze lower handle in to remove it

from mounting pins_

- Turn lower handle over to raise or lower
handle_

o Squeeze lower handle in and posilion

holes onto mounting pins on handle
bracket.

- Reassemble hairpin cotters onto pins,

° Reassemble upper handle and all parts

removed from lower handle,,

TURN LOWER
HANDLE OVER
TO ADJUST HEIGHT

3 POSITION "EZ" HANDLES
The handte on your lawn mower has three

(3) height positions +adjust to height that
suits you.

• Remove knob and carriage bolt on one
side of the lowerhandle.,

• While holding handle assembly, remove
knob and carriage boil from opposite

side, align hole in handle with desired

hole in handle bracket and reassemble
bolt and knob and tightensecurely.

" Align opposite side of handle with same

positioning hole and secure with bolt and
knob+

Hi -_ Boll

Knob

f

J/Handte

ustment

_\\iii cket

27

3 POSITION "QUICK" HANDLES _'.... ;__'::TO REMOVE/REPLACE DRIVE BELT

The handle on your lawn mower has three FRONT WHEEL DRIVE MODELS:

(3) height positions - adjust to height that

suits you.
,, Squeeze the bottom ends of lower

handle towards each other until the pin

in handle can be inserted into one of the
three height adjustment holes,

Handle

Mediurr

SQ

Low

adjustment

brackel

: "STANDARD" OR "DUAL BAIU' MODELS:

° Remove drive cover., Remove belt from

gearcase pulley by pushing down on
pulley and rolling belt off it,

* Turn lawn mower on its side., See

engine manual for proper direction of
turningover the engine,,

o Remove blade.,
° Remove belt from engine pulley on

crankshaft°

° Install new belt by reversing above steps,

NOTE; Always use factory approved belt

to assure fit and long life.

PUSH
DOWN-..

Drive

cover

Pull

"AUTO WALK" or'_/ARI-SPEED" MODELS:
° Remove drive cover and belt keeper°

"QUICK RELEASE" HANDLES
The upper handle may be adjusted to

three (3) different height positions.,

1_ Loosen both handle levers enough to

allow the upper handle to pivotto the
desired adjustment posilion,

24 Tighten both handle levers securely_

° Remove beltfrom gearcase pulley bypush-

ing down on pulley and roiling belt off it,

• Turn lawn mower on its side,. See
engine manual for proper direction of

turningover the engine.

. Remove blade and debris shield°
° Remove belt from engine pulley on

crankshaft.

. Install new belt by reversing above

steps°

NOTE: Always use factory approved belt
toassure fit and long life.

Drive

cover

LEVERS'._
DOWN

TOADJUST
HANDLE

levers

28

Bell ",

PUSH

DOWN

%

MODELS WITH GEARCASE-MOUNTED
BELT KEEPER:

o Remove drive cover and belt keeper.
o Remove belt from gearcase pulley°

• Turn lawn mower on its side. See
engine manual for proper direction of

turning over the engine,

o Remove blade and blade adapter.
, Remove belt from pulley of blade

adapter..

° Install new belt by reversing above

steps,

NOTE: Always use factory approved belt
to assure fit and long life.

o Remove drive cable from anchor, then

detach it and return spring (if equipped)
from idler arm assembly,.

o Remove idler arm assembly from hous-

ing by removing hex nut; then remove
drive bell from drive pulley, belt keepers
and idler arm assembly..

Drive anchor

ng holes

Bladeadapter

Crankshaft

Lockwasher _.

ielt

bolt Hardened

washer

Tralltn edge

retainer

REAR WHEEL DRIVE MODELS:

MODELS WITH IDLER ASSEMBLY:

• Disconnect spark plug wire from spark
plug and place wire where it cannot

come in contact with plug.

• Remove screws retainingdrive cover
(not shown); and remove drive cover
from lawn mower housing.

Belt a_m

Hex nut spring assembly

• Turn lawn mower on its side See engine
manual for proper direction of turning
over the engine°

• Use a wood block between blade and
mower housing to prevent blade from

turning when removing blade bolt.

NOTE: Protect your hands with gloves
and/or wrap blade with heavy cloth°

° Remove blade bolt.
= Remove blade, attaching hardware (bolt,

lock washer, hardened washer) and

blade adapter.

, Remove drive belt from engine pulley;

discard old belt,.

, Install new belt by reversing above

steps,

NOTE: Always use factory approved belt
to assure fit and long file.

o The recommended tightening torque is

35-40 ft. tbs.

IMPORTANT: Blade bolt is grade 8 heat
treated_

Blade adapteL Key

Crankshaft

t_ "_ .keyway

_J_',L°ckwasher _'_, !

Blade Hardenec
bolt washer

Trailing edge"

r,,_._ Belt

Crankshaft retafnsr

29

MODELSWITHGEARCASE-MOUNTEDRoutetheotherendofthenewdrivebelt
BELTKEEPER:

,, Removedrivecover,

• Removespringandbeltkeeper,
oRemovebe_tfromgearcasepulley,,

i

Gearcase

Drive

coVer

Belt

through hole in housing.

• Return mower to upright position.

• Install new belt on gearcase pulley.

• Reinstall belt keeper and spring.

_i. Reinstall drive cover.

NOTE; Always use factory approved belt

to assure proper fit and long lifeo
. Turn lawn mower on its side with air filter

and carburetor down,.

. Reinstall blade and blade adapter

HFVAC MODELS:

1. Disconnect spark plug wire from spark
plug and place wire where it cannot

come in contact with plug.

2, Remove screws retaining drive cover

and remove drive cover from lawn
mower housing.

3. Remove drive cable from anchor, then
detach it and return spring from idler
arm assembly..

t8" (45cm) HI-VAC MODELS:

Drivecable anchor \ Returnspring

\

,, Turn Dawnmower on its side. See

engine manual for proper direction of

turning over the engine.
,' Remove blade and blade adapter_
o Remove belt from blade adapter..

• Position the blade adapter on the engine

crankshaft° Be sure key in adapter and

crankshaft keyway are aligned; and that

the drive belt is inside the tabs of the

belt retainer.

Btade ada Crankshaft

Lockwasher

Blade
boff Hardened

washer

edge retainer

Belt

_' /Housing:hole

__"_" _&-B_biy

21" (53cm) HI-VAC MODELS:

_ _ ..,.j.*. Drivecable Housing

/l i / "7"_4V ':'_ _W Idlerarm

DriVe _;_ r)_ assembly

pu_l_ybet_..'v_OT

4, Pivot idler arm assembly to slacken

drive belt, then remove drive belt from
drive pulley, belt keepers and idler arm.

5. Turn lawn mower on its side, Make
sure air filter and carburetor are up.

3O

6 Remove screw securing debris shield,,

Note that the debris shield has a tab
which fits into a gap in the housing,,

Crankshaft Tab

Housing
hole _ Blade

Hardened

washer

21" (53cm) HI-VAC MODELS:

shield

TraIIlngedge Lock-washer

7. Use a wood block between blade and
mower housing to prevent blade from

turning when removing blade bolt,

NOTE: Protect your hands with gloves
and/or wrap blade with heavy cloth

8. Remove blade bolt.

9. Remove blade, altaching hardware
(boll, lock washer, hardened washer),

blade adapter and debris shield as one
assembly_

10.Remove drive belt from blade adapter
and debris shield; discard old bell

TO REPLACE DRIVE BELT
1o Place new drive belt in the belt retainer

of the debris shield,_ Be sure lo route
belt between belt keepers and through

slol as shown_

18" (45cm) HI-VAC MODELS:

Drive Debris

belt _. shield

etalners

2. Route the other end of the new drive
belt through hole in housing.

3. Reattach debris shield to housing with
screw previously removed, Be sure tab

of debris shield ts in gap of housing°

4. Position blade on the blade adapter
aligning the two (2) holes in the blade
with the raised tugs on the adapter.

5 Be sure the trailing edge of blade (op-

posite sharp edge) ts up toward the
engine as shown,.

6 Install the blade boll with the lock

washer and hardened washer into
blade adapter and crankshaft,

7. Use block of wood between blade and
lawn mower l_ousing and tightenthe

blade bolt, turning clockwise.

o The recommended tighteningtorque is

35-40 IL lbso

IMPORTANT: Blade bolt is grade 8 heat

treated.

8. Return mower to upright position.
9, Instalt new drive belt into idler arm as-

sembly, then around the drive pulley,,
Be sure belt is inside of belt keepers,

NOTE; Pulling on the drive belt (to install
iton the drive pulley) wilt cause the other

end of the belt to free itselffrom the debris
shield retainer and come into contact with

the pulley end of the blade adapter.

10oReattach drive cable and return spring

to the idlerarm assembly, then realtach
drive cable to anchor.

11.Realtach drive cover with screws prevl-
ously removed.

!2.Connect spark plug wire to spark plug

31

22PLUS REAR WHEEL DRIVE MODELS: "ENGINE

1, Remove screws securing rear baffle,

2,, Turn lawn mower on its side with air

filler and carburetor down.,

3., Remove rear baffle from mower,

4., Remove blade bolt, lockwasher, hard-
ened washer and blade_

5o Remove debris shield,
6o Remove gearcase belt keeper,

7., Remove drive belt.

CARBURETOR

The carburetor has been preset at the fac-

tory and adjustment should not be neces-

sary, However, minor adjustment may be

required to compensate for differences In
fuel, temperature, altitude or load,
. The air filter must be assembled to the

carburetor when running engine,,

. Best carburetor adjustment is obtained

when fuel tank is 1/4 full.,

. In order for the engine to run, the opera-

tor presence control bar must be held
in the operating position. Therefore,
and assistant will be required to hold
the control bar in the operating position
when making final adjustment to the

carburetor.

Rear

Gearcase

belt keeper

Bel!

retainer

See the ADJUSTMENT section of your
engine manual for further instructions.

ENGINE SPEED

The engine speed has been factory set,

Do not attempt to increase engine speed
as it may result inpersonal injury. If you
believe the engine is running too fast
or too slow, take your lawn mower to an
authorized engine service center for repair
and adjustment,,

THROTTLE CONTROL

Ifit becomes necessary to adjust or re-
place the throttle control, see the ADJUST-
MENT section of your engine manual,

Blade

bolt

TO REPLACE DRIVE BELT

1o Place new drive belt on gearcase pul-

ley,,

NOTE: Always use factory approved bel!

to assure proper fit and long life_
2, Reinstall gearcase belt keeper. Be

sure the new drive belt is inside the
tabs of the gearcase belt keeper.

3, Position the blade adapter on the en-

gine crankshaft. Be sure key in adapter
and crankshaft keyway are aligned;

and that the drive belt is inside the tabs
of the belt retainer,

4_, Place rear baffle in mower housing,
5o Reinstall debris shield,

6. Reinstall blade.
7_ Return mower to upright position

8., Reinstall rear baffle screws. 32

tmmediatemyprepareyourlawn mower for

storage at the end of the season or if the
unit will not be used for 30 days or more.

_CAUTtON: Never store the lawn mower
with gasoline in the tank inside a building

where fumes may reach an open flame
or spark. Allow the engine to cool before

storing in any enclosure_
LAWN MOWER

When lawn mower is to be stored for a pe-
riod of time, clean it thoroughly, remove all
dirt, grease, leaves, etc.. Store in a clean,
dry area.,
, Clean entire lawn mower (See "CLEAN-

ING" in the Maintenance section of this
manual)..

• Lubricate as shown in the Maintenance
section of this manual.

, Be sure that al! nuts, bolts, screws, and

pins are securely fastened. Inspect
moving parts for damage, breakage and

wear. Replace if necessary..

• Touch up all rusted or chipped paint
surfaces; sand tightly before painting..

HANDLE

Your handle may be folded for storage as
shown..

° Squeeze the bottom ends of lower

handle towardseach other until handle
clears the handle brackets and swing

handles forward over mower.

• Loosen upper handle mounting hard-

ware enough to allow upper handle to be
folded back..

IMPORTANT; When folding handles for
storage or transportation, be sure to fold

handles as shown or you may damage the
control cables.

Operator MOWING

F _. POSITION

cenlrolbar

,f?,

FOLD "._'_"_
FORWARD Upper

FOR handle
STORAGE

Handle

knob

Lower handle

2 POSITION / "ADJUSTABLE" HANDLES
When setting you handles up from the

storage position, the lower handle will
automatically lock into mowing position.

3 POSITION HANDLES
When setting up your handle from the stor-

age position, the lower handle will require
manually locking into the mowing position..

3 POSITION "EZ"

J Handle

adjustment

bracket

33

Handle

bracket

3 POSITION "QUICK"

Handlepin

J

"QUICK-RELEASE"HANDLES
Youcanfoldyourlawnmowerhandlefor

storage,

1..Loosenthetwo(2)handleleverson
sidesoftheupperhandleandallow
handletofolddowntotherear.

2_Moveheightadjustmenlleverforward

toraisemowertohighestposition°

3. Loosenhandlebolts(onbothsides),
thenpivotentirehandleassembly

forwardandallowit to rest on mower°

• When setting up your handle from the
storage position, 1helower handle will
automatically lock into the mowlng
position.

IMPORTANT: When folding the handle for
storage or transportation, be sure to fold
the handle as shown or you may damage

the control cables,,
Operator MOWING

FOLD
FORWARD
FOR
STORAGE

Height

adjuster

lever
LEVER

FORWARD
TO RAISE
MOWER

ENGINE
FUEL SYSTEM

IMPORTANT: it is importanttopreventgum

deposits from formingin essentialluelsystem engine and exhaust areas are still warm
parts such as carburetor, fuelfilter, fuelhose, ,_CAUTION: Never store the lawn mower
or tank during storage° Alcohol blended fuels with gasoline in the tank insidea building
(cal_edgasoholorusingethanolormethanol) where fumes may reach an open flame

can attract moisture which leads to separa- or spark° Allow the engine to cool before
tion and formation of acids during st°rage°3"st°ring4 in any enclosure.

handle

Handle

handle

Acidic gas can damage the fuel system of
an engine while in storage,

• Drain the fuel tank.
o Slart the engine and let tt run until the

fuel lines and carburetor are empty,,

° Never use engine or carburetor cleaner

products in the fuel tank or permanent
damage may occur.

° Use fresh fuel next season
NOTE: Fuel stabilizer is an acceptable al-

ternative in minimizing the formation of fuel
gum deposits during storage. Add stabilizer
to gasoline in fuel tank or storage container,
Always follow the mix ratio foundon stabilizer
container. Run engine at least 10 minutes
after adding stabilizer to allow lhe stabilizer
to reach lhe carburetor° Do not drain the gas
tank and carburetor if using fue! stabilizer°

ENGINE OIL

Drain oil (with engine warm) and replace
with clean oil (See "ENGINE" in the Main-
tenance section of this manual)._

CYLINDER
,' Remove spark plug

• Pour one ounce (29 ml) of oil through
spark plug hole into cylinder,,

• Pull starter handle slowly to distribute oil

• Replace with new spark plugo

BATTERY (IF EQUIPPED)

lever

Disconnect the battery from the engine
connectorand charge battery 48 hours°

OTHER
. Do not store gasoline from one season

to another_

- Replace your gasoline can if your can
starts to rust,, Rust and/or dirt in your

gasoline wiil cause problems.

= Ifpossible, store your unit indoorsand

cover itto protect it from dust and dirt,

, Cover your unit with a suitable protective

cover that does not retain moisture_ Do

not use plastic,, Plastic cannot breathe,

which allows condensation toform and
will cause your unit to rust,

IMPORTANT: Never cover mower while

See appropriate section in manual unless directed to an authorized
Service Center.

CORRECTIONPROBLEM CAUSE

Does not start 1_

Loss of power

Poor cut -

uneven

Excessive

vibration

Dirty air filter

2o

Out of fuel

3,

Stale fuel,

1o Cleanlreplace air filter_

2o Fill fuel tank,,
3, Drain fuel tank and refill tank

with fresh, clean gasoline.,

4.

Water in fuel

4o Drain fuel tank and refill tank

with fresh, clean gasoline_

5.

Spark plug wire is

disconnected.

6o

Bad spark plug,

7.

Loose blade or broken
blade adapter,

8

Control bar in released
position.

9. Control bar defective.,
!0_ Fuel valve lever (if so

equipped) in OFF position,

11,Weak battery (if equipped).

12. Disconnected battery

5, Connect wire to plug_
6,. Replace spark plug,

7., Tighten blade bolt or
replace blade adapter.,

8. Depress control bar to
handle.

9. Replace control bar.,

tO,,Turnfue! valve lever

to the ON position

! I. Charge battery°

12.Connect batter:/to engine,,

connector(if equipped),

13 Blown fuse (if equipped).,
1, Rear of lawn mower

! 3, Replace fuse..

1_ Raise cutting height.
housing or cutting blade
dragging in heavy grass.,

2, Cutting too much grass,
3,, Dirty air filter,

4, Buildup of grass, leaves,

and trash under mower°

5 Too much oil in engine
6, Walking speed too fast.,

2. Raise cutting height
3,, Clean!replace air filter°

4.. Clean underside of mower
heusing_

5, Check oil level,
6_ Cut at slower walking speed°

1_ Worn, bent or loose blade,, 1_, Replace blade° Tighten

blade bolt,,

2. 2. Set al! wheels at same

Wheel heights uneven°

height,

3o 3. Clean underside of

Buildup of grass, leaves
and trash under mower,.

_. I. Replace blade.Tighten

Worn, bent or loose blade,

mower housing

blade boil

2. 2_ Contact a qualified service

Bent engine crankshaft.

center.

Starterrope

hard to pull

1o Engine flywheel brake is on

when controlbar is released.

2. Bent engine crankshafL

3. Blade adapter broken°

4. Blade dragging in grass.

35

1., Depress control bar to
upper handle before

pulling starter rope.

2_ Contact a qualified service

center,

3. Replace blade adapter_

4., Move lawn mower tocut

grass or to hard surface.

See appropriate section in manual unless directed to an authorized
Service Center.

PROBLEM

Grass catcher
not filling
(if so equipped)

Hard to push

CAUSE CORRECTION

1, Cutting height too low, 1,,

2o Lifton brade worn oil 2,,
3 Catcher not venting air. 3.,

t_ Grass is too high or wheel t,

Raise cutting height°
Replace blade°
Crean grass catcher_

Raise cutting height.

height is too low,,

2_ Rear of lawn mower 2o

housing or cutting blade
dragging in grass.

3,

Grass catcher too full 3,

4o

Handle height position not 4,

Raise rear of lawn mower
housing one (1) setting

higher°
Empty grass catcher,

Adjust handle height to suiL

rightfor you°

Loss of drive t_
or slowing of 2_

drive speed 3_

Belt wear_ 1
Belt off of pulley. 2o

Drive cable worn or broken° 3,

4,

"Loose" drive control system 4o

Check/replace drive belt,
Check/reinstall drive belt,

Replace drive cable_

Adjust drive conlrol,