Troybilt 542, 11A-542Q711 Owner’s Manual

Safetyo Assembly o Operation oTips &Techniques oMaintenance *Troubleshooting o Parts Lists oWarranty

®

21-inch Rotary Mower- Model 542

READ SAFETY RULES AND mNSTRUCTmONS CAREFULLY BEFORE OPERATION

Warning: This unitis equippedwithan internalcombustionengineandshouldnotbeusedonornearanyunimprovedforest-covered,brush=
coveredor grass=coveredlandunlesstheengine'sexhaustsystemisequippedwithasparkarrestermeetingapplicablelocalorstatelaws(ifany),

If a sparkarresterisused,it shouldbemaintainedineffectiveworkingorderbytheoperator,Inthe StateofCaliforniatheaboveis requiredbylaw
(Section4442ofthe CaliforniaPublicResourcesCode),Otherstatesmayhavesimilarlaws,Federallawsapplyonfederallands,A sparkarrester

forthe mufflerisavailablethroughyournearestengineauthorizedservicedealerorcontacttheservicedepartment,RO,Box361131Cleveland,
Ohio44136=0019,

PRINTEDiN U,S,A MTD LLC, RO. BOX 361131 CLEVELAND, OHiO 44136-0019 FORMNO,769=02232

11/29/2005

This Operator's Manua_ is an important part of your new lawn mower, mtwH_ he_p you assemble,

prepare, and maintain the unit for best performance. P_ease read and understand what it says.

Table of Contents

Smope Gauge ....................................................... 3

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

Setup and Adjustment ....................................... 6

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

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

Finding and Recording Model Number

BEFOREASSEMBLINGYOUR NEWEQUIPMENT,please
locate the model plateon theequipmentand copythe infor=

mationto the sample modelplate providedtothe right. You
can locatethe model plate by standingat the operatingposi=

tionand lookingdown at the rearof the deck. This information
will be necessarywhen usingthe manufacturer'sweb site, to

obtainassistancefrom the CustomerSupport Department,or
whencontactingan authorizedservice dealer.

Trouble Shooting .............................................. 12

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

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

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

lVlodet Number Serial Number

0 TRO_XX--T" TROY=O[LT LLC

P. 0. BOX 361131

www.troybimt.com CLEVELAND, OH 44136

330=558=7220

Customer Support

P_ease do NOTreturn the unit to the retailer from which it was purchased, without first

contacting Customer Support.

if you havedifficulty assemblingthis productor haveany questions regardingthe controls, operation,or maintenance of this
unit,youcan seek helpfrom the experts. Choosefrom the optionsbelow:

o Visitwww.troybilt.com

Phonea Customer Support Representativeat 1-866-840-6483.

0

The enginemanufactureris responsibleforall engine-relatedissueswith regardto performance, power=rating,specifications,
warranty,and service. Please refertothe engine manufacturer'sOwner's/Operator'sManual,packedseparately with your

unit,for more information.

2

yourlawnmoweronsuchslopes.

/

t

/

/

/

/

/

o

WARNING

w_

Do not mowon inclines

with a dope in excess

of 15 degrees (a rise

of approximately

2-"

feet). A riding r
couldoverturnand

cause serious injury.

if operatinga walb
behindmoweron such

a dope, it isextremely

footing and you could

dip, resultingin serious
injury.

OperateRiDiNG
mowersupand down

dopes, neveracross

o

3

theface of dopes.

Operate
WALK-BEHIND

mowersacrossthe

face of dopes, never

up and down slopes.

\

manual.Aswithanytypeofpowerequipment,carelessnessorerroronthepartoftheoperatorcan

resultinseriousinjury.Thismachineiscapableofamputatinghandsandfeetandthrowingobjects.

! Failuretoobservethefollowingsafetyinstructionscouldresultinseriousinjuryordeath.

Children

Tragicaccidentscan occurifoperatorisnotalertto presence
ofchildren.Childrenare oftenattractedto mowerandmowing

activity.Theydonot understandthe dangers.Neverassume
thatchildrenwill remainwhereyoulastsawthem.

1. Keepchildrenoutofthe mowingareaandunderwatchful
careof aresponsibleadultotherthanthe operator.

2. Bealertandturnmoweroffifa childentersthearea.

3. Beforeand whilemovingbackwards,look behindanddown
forsmallchildren.

4. Useextremecarewhenapproachingblindcorners,
doorways,shrubs,trees,orotherobjectsthatmayobscure
yourvisionofa childwho mayrun intothemower.

5. Keepchildrenawayfromhot orrunningengines.Theycan
sufferburnsfroma hotmuffler.

6. Neverallowchildrenunder14yearsoldto operateapower
mower.Children14yearsold andovershouldreadand
understandoperationinstructionsandsafetyrulesinthis
manualandshouldbetrainedandsupervisedbyaparent.

endangerthepersonal
safetyand/orproperty

and followthewarnings 5. Tohelpavoidbladecontactorathrownobjectinjury, ._ generallya'_arningof!rouble.........

and i..struction2 stayinoperatorzone behindhandlesandkeepchildren, "

u _ competestop beforeremovngthe grasscatcheror uncog

, ,; bystanders,helpers,andpetsat least75feet frommower .

un_nusmanuau glngthechute

1. Readthis operator'smanualcarefullyin its entiretybefore

2. Thismachineisaprecisionpieceof powerequipment,

3. Neverallowchildrenunder 14yearsoldto operatethis

4. Thoroughlyinspecttheareawherethe equipmentisto

General Operation

attemptingtoassemblethismachine.Read,understand,
andfollow allinstructionsonthe machineandin the

manual(s)beforeoperation.Becompletelyfamiliarwith
thecontrolsandthe properuseof thismachinebefore
operatingit.Keepthismanualin asafeplaceforfuture
andregularreferenceandfor orderingreplacementparts.

nota plaything.Therefore,exerciseextremecautionat all
times.Yourunithasbeendesignedto performonejob: to
mowgrass.Do notuseitfor anyotherpurpose.

machine.Children14yearsoldand overshouldreadand
understandthe instructionsinthis manualandshould

betrainedand supervisedbya parent.Onlyresponsible
individualswhoarefamiliarwiththese rulesof safe

operationshouldbeallowedtousethis machine.

beused.Removeall stones,sticks,wire,bones,toysand
otherforeignobjectswhichcould betripped overor picked
upand thrownbythe blade.Thrownobjectscancause
seriouspersonalinjury.Planyourmowingpatternto avoid
dischargeofmaterialtowardroads,sidewalks,bystanders
andthe like.Also,avoiddischargingmaterialagainsta
wallorobstructionwhichmaycausedischargedmaterial
toricochetbacktowardtheoperator.

whileit isin operation.Stopmachineifanyoneenters

6. Alwayswearsafetyglassesorsafetygogglesduringopera-
tionandwhileperforminganadjustmentor repairtoprotect
youreyes.Thrownobjectswhich ricochetcancauseserious
injurytothe eyes.

7. Wearsturdy,rough-soledworkshoesand close-fitting
slacksandshirts. Shirtsand pantsthatcoverthe armsand
legsandsteel-toedshoesare recommended.Neveroperate
thismachinein barefeet,sandals, slipperyor lightweight
(e.g.canvas)shoes.

8. Donotputhandsorfeet nearrotatingpartsor undercutting
deck.Contactwithbladecanamputatehandsandfeet.

9. Amissingor damageddischargecovercancauseblade
contactor thrownobject injuries.

10.Manyinjuriesoccurasa resultofthe mowerbeingpulled
overthefoot duringafall causedby slippingortripping.
Do notholdonto the mowerifyouarefalling;releasethe
handleimmediately.

11.Neverpullthe mowerbacktowardyouwhileyouare
walking.Ifyou mustbackthe mowerawayfromawallor
obstructionfirstlookdownandbehindtoavoidtrippingand
thenfollow thesesteps:

a. Stepbackfrommowertofully extendyourarms.
b. Besureyou arewellbalancedwithsurefooting.

c. Pullthe mowerbackslowly,no morethanhalfway

towardyou.

d. Repeatthesestepsasneeded.

12.Donotoperatethe mowerwhileunderthe influenceof
alcoholor drugs.

13.Donotengage theself-propelledmechanismon unitsso
equippedwhilestartingengine.

14.Thebladecontrolhandleis asafetydevice.Neverattempt
tobypassits operation.Doingso makesthesafetydevice
inoperativeandmay resultinpersonal injurythrough
contactwiththe rotatingblade.The bladecontrolhandle
mustoperateeasilyin bothdirectionsandautomatically
returntothe disengagedpositionwhenreleased.

15.Neveroperatethe mowerinwetgrass. Alwaysbesure of
yourfooting. A slipandfallcan causeseriouspersonal
injury.If youfeelyouare losingyourfooting,releasethe
bladecontrolhandleimmediatelyandthe bladewillstop
rotatingwithinthreeseconds.

16.Mowonlyindaylightor goodartificiallight.Walk,neverrun.

17.Stopthe bladewhencrossinggraveldrives,walksor roads.

18.Ifthe equipmentshouldstart tovibrateabnormally,stopthe
engineandcheck immediatelyforthecause.Vibrationis

]_ _nutthe engne errandwar unl: me Daaecomes-coa

and on the machine, area.

..... ,J

4

Thecuttingbladecontinuesto rotatefora fewsecondsafter
the engineisshutoff. Neverplaceanypartofthe bodyin
the bladeareauntilyou aresurethe blade hasstopped

rotating.

20.Neveroperatemowerwithoutpropertrailshield,discharge
cover,grasscatcher,bladecontrolhandle,or othersafety

protectivedevicesin placeandworking.Neveroperate
mowerwithdamagedsafetydevices.Failuretodo socan
resultin personalinjury.

21.Mufflerandenginebecomehotand cancauseaburn.Do

nottouch.

22.Onlyuseparts andaccessoriesmadefor thismachineby

manufacturer.Failureto dosocanresult inpersonalinjury.

23.Ifsituationsoccurwhichare not coveredinthis manual,

usecareand goodjudgment.Contactyourdealerfor
assistance.Telephone[phone]forthe nameofyour

nearestdealer.

SJope Operation

Slopesareamajorfactorrelatedto slipandfallaccidentswhich
canresultinsevereinjury.Operationonslopesrequiresextra

caution.Ifyoufeel uneasyonaslope,donotmowit.Foryour
safety,usethe slopegaugeincludedas partofthis manualto
measureslopesbeforeoperatingthisunitona slopedor hilly
area.Iftheslopeis greaterthan15degrees,donotmowit.

Do:

1. Mowacrossthefaceof slopes;neverup anddown.

Exerciseextremecautionwhenchangingdirectionon
slopes.

2. Watchfor holes,ruts, rocks,hiddenobjects,or bumpswhich
can causeyou toslipor trip.Tallgrasscan hideobstacles.

3. Alwaysbesure ofyourfooting.A slip andfallcan cause

seriouspersonalinjury.If youfeelyouarelosingyour
balance,releasetheblade controlhandleimmediately,and

the bladewillstop rotatingwithin3seconds.

Do Not:

1. Donotmowneardrop-offs, ditchesorembankments,where
you couldloseyour footingorbalance.

2. Donotmowslopesgreaterthan15degrees asshownon
the slopegauge.

3. Donotmowon wetgrass.Unstablefootingcouldcause

slipping.

Service

Safe HandlingOf Gaso%e:

1. Toavoidpersonalinjuryor propertydamageuseextreme
carein handlinggasoline.Gasolineisextremelyflammable

andthevaporsare explosive.Seriouspersonalinjurycan
occurwhengasolineis spilledonyourselforyourclothes

whichcanignite.

2. Washyour skinand changeclothesimmediately.

3. Useonly anapprovedgasolinecontainer.

4. Neverfill containersinsideavehicleoronatruckor trailer

bedwith a plasticliner.Alwaysplacecontainerson the
groundawayfromyourvehiclebeforefilling.

5. Removegas-poweredequipmentfromthe truck ortrailer

andrefuelit on theground.Ifthisis notpossible,then refuel
suchequipmentonatrailerwitha portablecontainer,rather

thanfroma gasolinedispensernozzle.

6. Keepthe nozzleincontactwiththerim of thefuel tankor
containeropeningat alltimesuntilfuelingis complete.Do

notusea nozzlelock-opendevice.

7. Extinguishallcigarettes,cigars,pipesandothersources
ofignition.

8. Neverfuelmachineindoorsbecauseflammablevaporswill
accumulatein the area.

9. Neverremovegascap oraddfuelwhileengineishot or
running. Allowengineto coolat leasttwominutesbefore
refueling.

10.Neveroverfillfueltank. Filltankto nomorethan_ inch
belowbottomof fillerneckto provideforfuelexpansion.

11.Replacegasolinecapandtightensecurely.

12.Ifgasolineis spilled,wipeit off theengineand equipment.
Moveunitto anotherarea.Wait5 minutesbeforestarting
engine.

13.Neverstorethemachineorfuel containernearanopen
flame,sparkorpilot lightas onawater heater,space
heater,furnace,clothesdryer,orothergas appliances.

14.Toreducefire hazard,keepmowerfreeofgrass,leaves,
or otherdebrisbuild-up.Cleanupoil orfuel spillageand
removeanyfuel soakeddebris.

15.Allowamowertocool at least5 minutesbeforestoring.

General Service:

1. Neverrunanengineindoorsorina poorlyventilatedarea.
Engineexhaustcontainscarbonmonoxide,an odorlessand
deadlygas.

2. Beforecleaning,repairing,or inspecting,makecertainthe
bladeandall movingpartshavestopped.Disconnectthe
sparkplugwireandgroundagainsttheengineto prevent

unintendedstarting.

3. Checkthe bladeandenginemountingboltsatfrequent
intervalsfor propertightness.Also,visuallyinspectbladefor
damage(e.g.,bent,cracked,worn)Replacebladewiththe
originalequipmentmanufacture's(O.EM.) bladeonly,listed
inthismanual."Useofpartswhichdo notmeettheoriginal
equipmentspecificationsmayleadto improperperformance
andcompromisesafety!"

4. Mowerbladesare sharpandcancut.Wrapthebladeorwear
gloves,anduseextracautionwhenservicingthem.

5. Keepallnuts,bolts,andscrewstighttobe surethe equip-
mentisin safeworkingcondition.

6. Nevertamperwithsafetydevices.Checktheirproperopera-
tionregularly.

7. Afterstrikinga foreignobject,stopthe engine,discon-
nectthe sparkplugwireandgroundagainsttheengine.
Thoroughlyinspectthemowerforanydamage.Repairthe
damagebeforestartingandoperatingthemower.

8. Neverattempttomakea wheelorcuttingheight adjustment
whiletheengineis running.

9. Grasscatchercomponents,dischargecover,andtrail
shieldaresubjecttowear anddamagewhichcould expose
movingpartsorallow objectsto bethrown.Forsafety
protection,frequentlycheckcomponentsand replaceim-
mediatelywithoriginal equipmentmanufacturer's(O.EM.)
partsonly,listedin this manual."Useof partswhichdo
not meettheoriginalequipmentspecificationsmayleadto
improperperformanceandcompromisesafety!"

10.Donot changetheenginegovernorsettingor overspeedthe
engine.Thegovernorcontrolsthe maximumsafeoperating
speedofthe engine.

11.Maintainorreplacesafetylabels,asnecessary'.

12.Observeproperdisposallawsand regulations.Improper
disposaloffluidsand materialscanharmtheenvironment.

w o°,°o

ThisSymbolpoints

ua! before attemptingto

resuUt in personal injury_
::When you see th s
_symbol

,EEDMTSWARNmNG

Responsibility

Restrictthe use

of this powermachine

to personswhoread

understand

5

Standbehinathe
moweras ifyou were

goingb operate it,

Your righthand cor-

respondsto the right
sideof the mower;your

left hand corresponds

to the left sideof the

mower.

Makesureto route
cane outside the lower

handle. Do not crimp
cane whileliftingthe

handleup.

Figure3-1:Unfoldhandleandtightenhardware.

HardwarePack )1

WingNuts(2) CarriageBelts(2

Figure3-2:Securelowerhandletomountingbrackets.

1. Removeanypackingmaterialwhichmaybebetween
upperand lowerhandles.

a. Pullupand backon upperhandleasshownin

Figure34. Makecertainthelowerhandleisseated
securelyintothe handlemountingbrackets.Donot

crimpcane while liftingthehandleup.

b. Tightenstarknobstosecureupperhandleto

lowerhandle.Makesurethateach carriageboltis
seatedproperlyinthe handle.

2. Locatethehairpinclipon theweldpinoneachsideof
lowerhandle.

a. Removehairpinclipfromthis hole.Usinga pair

ofpliers,inserthairpinclip intothe holeon pin
closesttothe bracket,Figure3-2.Repeatonother

side.

b. Inserta carriageboltfromthe hardwarepackinto

theupperholeon thehandlemountingbracket.
Securewithoneplasticwingnut,also included
inthe hardwarepack.Repeatonothersidewith
remainingitemsfromhardwarepack.

3. Theropeguideis attachedtotherightsideofthe
upperhandle,Figure3-3.Loosenthewingnutwhich

securestheropeguide.
a. Holdbladecontrolhandleagainstupperhandle.

b. Pullstarterropeoutofthe engine.Releaseblade

controlhandle.

c. Slipstarterropeintoropeguide.
d. Tightenwingnut.

4. Insertpostoncane ties intoholesprovidedon the
lowerhandle.Pullcane tiestightandtrimexcess,

Figure3-4.

IMPORTANT

This unit is shipped

up gasolineandoil
as instructed inthe

accompanyingengine
manual BEFORE

operating yourmower.

J

Figure3-3:Pull recoilstarterthroughropeguideandtighten. Figure3-4:Securecablestohandleusingcableties.

6

5. Followstepsbelowtoassemblethegrasscatcher.
Makecertainbagisturnedrightside outbefore

assembling(warninglabelwillbe onthe outside)
a. Placebagoverframesothatitsblackplasticside

isat thebottom.

b. Slipplasticchannelofgrassbagover hooksonthe

frame,Figure3-5.All the plasticchannelsexcept
centertopof bagattachfromoutsideof bag.

c. Attachcentertopof bagfrominsideofbag.

7. Yourmowerisshippedasa mulcher.Toconvertto
sidedischarge,makesuregrasscatcherisoffof the
unitand reardischargedooris closed.

a. Onthesideof the mowerlift themulchingplug,

Figure3-7.

b. Slidetwohooksofside dischargechuteunder

hingepin onmulchingplugassembly.Lowerthe
mulchingplug.Do notremovesidemulchingplug
atanytime,evenwhenyou arenotmulching.

Figure3-7:Liftmulchplugandinstallsidedischargechute.

Figure 3-5: Assemble the grass catcher.

6. Followthestepsbelowto attachthe grasscatcher:
a. Liftreardischargedoor,Figure3-6.

b. Placegrasscatcheron thepivotrod. Letgo

ofdischargedoorso that itrestson thegrass
catcher.

_jliL WARNING:Neveroperate mower unless the
on the pivotrod and the rear discharge door rests

firmly against top of the grass catcher.

hooks on the grass catcher are firmly seated

f

Adj ustments Whenadjustingthe !

Anadiusfingplateandthumbleverateachwheel cuttungheught,aHHwheeHs!
providescuttingheightadiustment, must be positionedat

1. Depresslevertowardswheel, the same height, i

2. Moveitto anyoneof thepositionsfordesiredcutting
height,Figure3-8. Makesurethateachwheelis /}

positionedatthe sameheight. I

3. Releaselevertowardsmowerdeck.

WARNING

//

Figure3-6:Attachthegrasscatcher.

Figure3-8:Useleversto adjustcuttingheight.

7

The blade control is a
safety device. Never
attempt to bypass its

operations.

Know Your Lawn Mower

Grass Catcher--_

Cutting Height
Adjustment
Levers (front

J and rear)

Use extreme care when
handling gaaomine.

Gasemineis extremely
flammable and the

vapors are expbaMve.
Never fuel the machine

indoors or while the
engine is hot or running.

Extinguish cigarettes,
cigars, pipes, and other
sources of ignition.

Keep hands and feet

away from the cutting
deck. Refer to warning

label on the unit.

Side DischargeChute

Figure4-1:Themajorpartsonthelawnmower.

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

potential

Blade Control

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

blade=

,_ WARNING:This Made control isa safety

device. Do not bypass itsoperations.

Cutting Height Adjustment Levers

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

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

Recoil Starter

The recoi[ starter is attached to the right upper
handle= Stand behind the unit and pui[ the recoil
starter rope to start the unit=

Mulch Plug

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

clippings back to the lawn. This is called mulching=

Grass Catcher

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

Gas and Oil Fill°Up

1, Check oi{ {eve{and add oil if necessary, Follow engine

manual for this,

2, Service the engine with gasoline as instructed in the

engine manual

WARNING: Use extreme care when handling

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

ignition.

8

while operating the moweror while performing any
adjustments or repairs on it.

Starting Engine

_lb WARNING:Besure no one other thanthe
Never run engine indoorsor inenclosed, poorly

ventilated areas. Engine exhaust contains carbon
monoxide, an odorless and deadly gas. Keephands,
feet, hair and loose clothing awayfrom anymoving
parts on engineand lawnmower.

NOTE:Referto the engine manual for help with
engine relatedoperations.

1, Placethefuelvalveleverfoundontheleftsideofthe

engineintothe ON(OPEN)position,Figure4-2,

2, Movethechokeleverall thewaybackwardintothe

chokeposition,Figure4-2,

3, Standingbehindthe mower,squeezethebladecontrol

againstupperhandle,Figure4=2,Thechokewillnow

begintoslowlyreturnto theoff chokepositionafter
activatingthe bladecontrol Therefore,quicklymove
ontostepfourbelow,

4, Holdingthesetwohandlestogetherfirmly,grasprecoil

starterand pullropeout witha rapid,continuous,full
armstroke,Figure4-2,Keepingafirmgripon the
starterhandle,letthe roperewindslowly,Repeatuntil
enginecranks,Letthe roperewindeachtimeslowly,

operator is standing near the lawn mower
while starting engine or operating mower.

Stopping Engine

1, Releasebladecontroltostopthe engineandblade,

2, Disconnectsparkplugwire fromsparkplugand

groundagainsttheengine,

WARNING:Waitfor the bladeto stop
completely before performing anywork
on the mower or to removethe grass

catcher.

Using Your Lawn Mower

WARNING:Neveroperateyour mower
without either the reardoor or the entire

grass catcher assembly firmly secured.

Be surelawnisclear ofstones,sticks,wire,or other
obiectswhichcoulddamagelawnmowerorengine,
Suchobiectscouldbe accidentlythrownbythemower
in anydirectionandcauseseriouspersonaliniuryto the
operatorandothers,

Figure 4-2: Starting the mower.

1, Oncethe engineisrunning,squeezetheblade

controlagainsttheupperhandleto engagethe
blade,

• For bestresults,do notcut wetgrassand never
cutoff morethanone-thirdofthetotallengthofthe
grass,

Using as Muncher

FormulcNnggrass,removethegrasscatcherorside
dischargechutefromthemower,Thereardischarge

doorshouldbeclosed,

Foreffectivemulching,do notcut wetgrass,New
orthickgrassmayrequirea narrowercut,Adjust
groundspeedaccordingtoconditionoflawn,

• If thegrasshasbeenallowedto growinexcessof
fourinches,mulcNngis notrecommended,Usethe
grasscatcherto bagclippingsinstead,

Using Grass Catcher

YoucanusethegrasscatchertocollectclippingswNle
youareoperatingthemower,

1, AttachgrasscatcherfollowinginstructionsinSetup

section,Grassclippingswillautomaticallycollectin
bagasyou runmower,Operatemowerfillgrassbag

isfull

2, Stopenginecompletelybyreleasingtheblade

control Makesurethatthe unithascometo a
completestop,

3, Liftdischargedoorand pullgrassbagupandaway

fromthemowertoremovethebag,Disposeofthe
grassclippingsandreinstallthebagwhencomplete,

WARNING

The operation of any
lawn mower can result

in foreign objects being
thrown into the eyes,

which can damage your
eyes severely. Always
wear safety glasses

while operating the
mower or while perform°

ing any adjustments or
repairs on it.

Be sure no one other
than the operator is

standing near the
lawn mower while

starting engine or
operating mower. Never

run _ngine indoors or
in enclosed, pooHy

ventilated areas. Engine
exhaust contains carbon

monoxide, an odormess
and deadmygas. Keep

hands, feet. hair and
loose clothing away

from any moving parts
on engine and lawn

mower.

9

Deck Care

Cban undersideofthe mowerdeckaftereachuse to
preventbuild-upofgrassclippingsorotherdebris.Follow

stepsbelowforthisiob.

1. Disconnectsparkplugwire.Draingasolinefromlawn
mowerorplacea pieceof plasticunderthegas cap.

2. Tipmowersothat itrestson thehousing.Keepthe
sidewiththe aircleanerfacingup.Holdmowerfirmly.

WARNING:Nevertip the mower more
than 900in any direction and do not

leavethe mower tipped for any length of

time. Oil can drain into the upper part of the engine

causing a starting problem.

3. Scrapeandcban the undersideof thedeckwitha
suitabb tool Do notspraywithwater.

4. Putthe mowerbackonits wheelsontheground.If

Figure5-1:Areastolubricateonmower, youhadput plasticunderthe gascapearlbr, make

sureto removeitnow.

pu!!eys, bearings,Or

General Recommendations

Alwaysobservesafetyrubs whenperforming
anymaintenance.

• Thewarrantyonthislawnmowerdoesnotcover
itemsthathavebeensubiectedtooperatorabuse
or negligence.Toreceivefull valuefromwarranty,
operatormustmaintainthe lawnmoweras

instructedhere.

. Changingofengine=governedspeedwillvoid

enginewarranty.

• Alladjustmentsshouldbecheckedat bast once
eachseason.

. Periodicallycheckall fastenersand makesurethese

aretight.

i

_ ARNING:Always stop engine, discon-

Lubrication

1. Lubricatepivotpointson thebladecontrolat bast
oncea seasonwithlightoil The bladecontrolmust
operatefreelyinboth directions,Figure5-1.

2. Lubricatethewheelsat bast oncea seasonwith
lightoil (or motoroil). Ifwheelsare removedforany

reason,lubricatesurfaceof thepivotarm andinner
surfaceofthewheelwithlightoil, Figure5-1.

3. Lubricatethetorsionspringandpivotpointonthe
reardischargedoorandsidemulchplugperiodically
withlightoil to preventrust,Figure5-1.

4. Followtheaccompanyingenginemanualforlubrba-
tionschedub andinstructionforenginelubrication.

nect spark plug, and ground against

engine before performing any type of

maintenanceon your machine.

Engine Care
A listofkeyenginemaintenanceiobs requiredforgood
performanceby themoweris givenbelow.Followthe
accompanyingenginemanualforadetaibd listand

instructions.

. Maintainoillevelasinstructedinenginemanual.

Serviceaircleanerevery25 hoursundernormal
conditions.Cban everyfewhoursunderextremely

dustyconditions.Poorengineperformanceand
floodingusuallyindicatesthattheaircbaner should

beserviced.Toservicetheaircleaner,refertothe
enginemanual

.Cban sparkplugandresetthegap oncea season.

Sparkplugreplacementisrecommendedatthe start
ofeachmowingseason.Checkenginemanualfor
correctplugtypeand gapspecifications.

• Cban engineregularlywithaclothorbrush.Keepthe
coolingsystem(Newerhousingarea)cleantopermit
properaircirculation.Removeallgrass,dirt, and

combustibbdebrisfrom mufflerarea.

10

B_adeCare

WARNING:When removing the cutting
bladefor sharpeningor replacement,

protect your hands with a pair of heavy
gloves or usea heavy rag to hold the

blade.

Periodicallyinspectthe bladeadapterforcracks,
especiallyifyoustrikea foreignobiect,Replacewhen
necessary,Followthe stepsbelowforbladeservice,

1, Disconnectsparkplugwire fromsparkplug,Turn

moweron itssidemakingsurethattheairfilterand

thecarburetorarefacingup,

2, Removethe boltand the bladebellsupportwhich

holdthebladeandthe bladeadaptertotheengine

crankshaft,Figure5=2,

3, Removebladeandadapterfromthecrankshaft,

Figure5=2,

4, Thebladecan be sharpenedwitha file oron agrind=

ingwheel Do notattemptto sharpenthebladewhileit
isstillonthe mower,

Whensharpeningtheblade,followtheoriginalangle
ofgrind, Grindeachcuttingedgeequallytokeepthe

bladebalanced,

5, Totestforbalance,removebladeandbalanceon

a roundshaftscrewdriver,Removemetalfromthe

heavysideuntil itbalancesevenly,

WARNING:An unbalanced bladewill
causeexcessivevibration when rotating

at high speeds. It may causedamageto
mower and could breakcausing personal

injury.

6, Lubricatetheenginecrankshaftandtheinnersurface

ofthe bladeadapterwithlightoil Slidetheblade
adapterontotheenginecrankshaft,

7, Placethebladeontheadaptersuchthattheside

ofthe blademarked"Bottom"(orwith partnumber)
facesthe groundwhenthe mowerisin the operating

position,Makesurethatthebladeis alignedand

seatedon thebladeadapterflanges,

8, Placebladebellsupporton the blade,Alignnotches

on thebladebellsupportwithsmallholesinblade,

9, Replacehexbolt andtightenhexbolttotorque:450

in,Ibs,min,,600in, Ibs,max,

Toensuresafeoperationof yourmower,periodically
checkthe bladeboltfor correcttorque,

Replacing Rear F_ap

1, To removerearflap,cut off theflat endof thewire rod

whichsecuresitto thedeck,Figure5-3,

2, Attachthe newflap andnewrodto deck,bendingthe

endsof thenewrodoverto securetodeck,

J

Figure5-2:Removethebolt,support,andadaptertoaccess

theblade,

Figure5-3:Cutwireto removerearflap.

Off-Season Storage

Thefollowingstepsshouldbetakento prepareyour

lawnmowerfor storage,

, Cleanandlubricatemowerthoroughlyasdescribed

in thelubricationinstructions,

, Do notusea pressurewasherorgardenhoseto

dean yourunit,

, Referto enginemanualforcorrectengine

storageinstructions,

• Coatmower'scuttingbladewithchassisgreaseto
preventrusting,

• Storemowerina dry,dean area,Do notstorenext
tocorrosivematerials,suchasfertilizer,

Whenstoringanytypeof powerequipmentin apoorly

ventilatedor metalstorageshed,careshouldbetaken
torust-prooftheequipment,Usinga lightoil orsilicone,
coattheequipment,especiallycablesandall moving
partsofyourlawnmowerbeforestorage,

WARNING

When removing

thecutting blade
for sharpening or

replacement, protect
your handswith a pair
of heavygloves or use

a heavy rag to hold

the blade.

An unbalanced blade
will cause excessive

vibration when rotat-

ing at high speeds, it

may cause damage

to mower and could

break causing per-
serial injury.

11

Problem Cause

2_ Sparkp!ugwiredisconnected= 2, Connectwire tosparkplug.

Fueltankernptyoistale_uek 3. FilltankWithdean, freshgas01ineI

4. Enginenotpr!med. 4. Primeengineas instructedin !'Operat-

EaultySpa[kplug. 5. Cleanladustgapl 0i iepJace.

6. BloCkedfuel line. 6. Cleanfuel[inc.
Enginefl0oded. 7. Waita lew minutesio iestartl but do

ingYourLawnMower'!.

notprime

For repairs beyond

the minor adjustments

listed here, contact

an authorized service

dealer.

Enginerunserratic 1. Sparkplugwireloose.

2. Blockedfuellineor stalefuel.

3. Ventingas capplugged.

4. Wateror dirt infuel system.

5. Dirtyaircleaner.

6. Carburetorout of adjustment.

2. Air f!owrestricted. , 2. Removeblowerhousingandclean.

3. Carburetornotadjustedproperly. 3. Refertoenginemanuak

Occasional skips 1. Sparkpluggap tooclose. 1. Adjustgap to .030-inch.
(hesitates) at high speed 2. Carburetoridle mixtureadjustment 2. Refertoenginemanual.

improperlyset.

2. Carburetorirrlproperlyadjusted. 2. Referto enginemanual.

Excessive Vibration 1. Cuttingbladelooseor unbalanced. 1. Tightenbladeand adapter.Balance

2. Bentcutting blade. 2. Seeanauthorizedservicedealer.

1. Connectandtightensparkplugwire.

2. Cleanfuelline;fill tank withclean,
freshgasoline.

3. Clearvent.

4. Drainfueltank.Refill withfresh fuel.

5. Refertoenginemanual.

6. Refertoenginemanual.

3. Refertoenginemanual.

blade.

cuttingheight,

F k

Uneven cut 1. Wheelsnotpositionedcorrectly. 1. Placeall fourwheelsin same

heightposition.

2. Dullblade. 2. Sharpenorreplaceblade.

12

WARNING

DONOTremove safety

(or any) labeJs from

newer for any reasen,

13

\

Q

Q Q

Q

2_

14

List

1 747q161A BladeControl
2 731-04204 BailCover

3 74Gl130 ControlCable,40dnchSnap-On
4 72G0240 CableTie

5 664-04011 GrassBagAssembly
6 747-04080 GrassBagFrame
7 73b0700 TrailshieldWire

8 731-04998 Trailshield

9 747-0996 PivotRod
10 731-04134A RearDischargeDoor

11 687_02057 RearHandleBracketAss}/,_LH

687-02056 RearHandleBracketAssy,- RHt

12 787-01279 Deck21dnch
13 687-02075A FrontHeightAdiustmentAssy-LH

687_02074A FrontHeightAdiustmentAssy_RHt

14 7865002B FrontBaffle
15 748-04082 BladeAdapter

16 742-0741 21dnchMulchingBlade
17 73G0524B BellBladeSupport

18 71G1257 HexScrew,3/8-24x 2,5
19 731-04177 SideDischargeChute

20 17032A DeflectorChuteAdaptor
21 7361014 TorsionSpring
22 747-0710 HingePin
23 987-02055 HingedMulchPlugAssembly

24 71b04065 FlangeLockNut3/8d6
25 787_01290 HeightAdiustmentPlate
26 687-02077A FrontPivotArmAssembly-RH

687_02076A FrontPivotArmAssembly_LHt

27 734-04014B FrontWheel,8 x2,125GWave

28 738-0507B ShoulderScrew,,5Dx ,434
29 732-0404 FrontSpringLever
30 72G0426 HeightAdiustKnob

31 71G0599 TT Screw,1/4-20x ,500
32 73G0270 BellWasher

33 71G0654A TTScrew, 3/8-16x 1,0
34 71G0216 HexScrew,3/8d6 x ,75

35 71G1652 TT Screw,1/4-20x ,625
36 72G0312 FoamGrip
37 734-04127 RearWheel,12x2,125S-Wave
38 73G0182 SpringWasher
39 73b0866 RearHi-WheelSpringLever

40 687_02039A RearPivotArmAssy_RH

687_02040A RearPivotArmAssy_LH t
41 714-0104 HairpinClip
42 687-02192 HandleBracketAssy-RH

687_02191 HandleBracketAssy_LH
43 71G0703 CarriageBolt,1/4-20x ,75

44 731-04150C RearBaffle
45 71G04371 ScrewHL,1/4d5 x 1,00
46 732_04090A TorsionSpring_RH

732-04089A TorsionSpring- LH t
47 75G04162 Spacer
48 71b0397 WingNut

49 749-0928A LowerHandle
50 710d174 CarriageBolt,5/16-18x2

51 72G04072 StarKnob
52 72G0279 HandleKnob

53 710d205 EyeBolt
54 749-1092A UpperHandle

FACTORY PARTS

To order replacement

parts, ca[J

1-800-648-6776

or visit

www.troybi[t,com

iMPORTANT

Fora proper work-

ingmachine, use

Factory Approved Parts.

VoBELT$are specially

designed to engage

and disengage safely.

A substitute (nonOEM)

VoBe[tcan bedangerous

bynot disengaging

completely.

t NotPictured

15

\

MANUFACTURER'S LIMITED WARRANTY FOR

®

The limitedwarrantyset forthbelowis givenbyTroy_BiltLLCwithrespect

tonewmerchandisepurchasedandusedin theUnitedStates,itsposses_
sionsandterritories.

"Troy_Bilt"warrantsthisproductagainstdefectsinmaterialandworkmam
shipfor a periodof two(2)yearscommencingon thedateof original
purchaseandwill,atits option,repairorreplace,freeofcharge,anypart
foundto bedefectivein materialsor workmanship.This limitedwarranty
shallonly applyif this producthasbeenoperatedand maintainedin
accordancewiththe Operator'sManualfurnishedwiththeproduct,and
hasnotbeensubiectto misuse,abuse,commercialuse,neglect,accident,
impropermaintenance,alteration,vandalism,theft,fire,water,ordamage
becauseofother perilor naturaldisaster.Damageresultingfromthe
installationor use ofany part,accessoryorattachmentnotapprovedby

Troy_Biltforusewiththeproduct(s)coveredbythis manualwillvoidyour

warrantyastoany resultingdamage.
Normalwearpartsarewarrantedtobefreefromdefectsinmaterialand

workmanshipforaperiodof thirty(30)daysfromthedateofpurchase.
Normalwearpartsinclude,butare notlimitedto itemssuchas: batteries,
belts,blades,bladeadapters,grassbags,riderdeckwheels,seats,snow
throwerskidshoes,shaveplates,augerspiralrubberandtires.

NOWTO OBTAIN SERVICE: Warranty service is available,WITH
PROOFOF PURCHASE,through your local authorizedservice
dealer.To locate the dealer in yourarea, check your YellowPages,
or contact Troy-Bilt LLC at RO. Box 361131,Cleveland,Ohio 44136-
0019,or can 1-866-840-6483 or 1-330-558-7220,or log on to our

Web site at www.troybilt.com.
This limitedwarrantydoesnot providecoverageinthefollowingcases:

a. Theengineor componentpartsthereof.Theseitemsmay

carrya separatemanufacturer'swarranty.Refertoapplicable
manufacturer'swarrantyfortermsandconditions.

b. Logsplitterpumps,valves,andcylindershaveaseparateone

yearwarranty.

c. Routinemaintenanceitemssuchaslubricants,filters,blade

sharpening,tune_ups,brakeadiustments,clutch adiustments,
deckadiustments,andnormaldeteriorationof theexteriorfinish
duetouse orexposure.

d. Servicecompletedbysomeoneotherthananauthorizedservice

dealer.

e. Troy_Biltdoesnotextendanywarrantyforproductssoldor

exportedoutsideofthe UnitedStates,its possessionsand
territories,exceptthosesold throughTroy_Bilt'sauthorized

channelsofexportdistribution.
f. Replacementpartsthatare notgenuineTroy_Biltparts.
g. Transportationchargesandservicecalls.

Noimpliedwarranty, includinganyimpliedwarrantyof merchant°

ability of fitness for a particular purpose, applies after the applicable

period of express written warranty aboveasto the parts as identi-

fied. Noother express warranty,whetherwritten or oral, exceptas

mentioned above,given by anyperson or entity, includinga dealer or
retailer,with respect to any product, shall bind Troy-Bilt. During the
period of the warranty,the exclusive remedy is repair or replacement

of the product as setforth above.
The provisions as set forth inthis warranty providethesole and

exclusive remedyarising from the sale. Troy-Bilt shall not be liable
for incidental or consequential loss or damageincluding, without

limitation, expensesincurred for substitute or replacementlawncare

services or for rental expenses to temporarily replace a warranted

product.
Somestatesdonot allowtheexclusionorlimitationofincidentalor

consequentialdamages,or limitationson howlonganimpliedwarranty

lasts,sothe aboveexclusionsor limitationsmaynotapplyto you.
Innoeventshall recoveryof anykind begreaterthantheamountofthe

purchasepriceof theproductsold.Alteration of safety features of the
product shall void this warranty. Youassumetheriskandliabilityfor
loss,damage,orinjurytoyouand yourpropertyand/ortoothersandtheir
propertyarisingout ofthe misuseorinabilityto usethe product.

This limitedwarrantyshallnotextendto anyoneotherthanthe original

purchaseror tothe personforwhomitwaspurchasedasagift.
HOWSTATELAWRELATESTOTHiSWARRANTY:This limitedwar-

rantygh,'esyouspecificlegalrights,andyoumayalsohaveotherrights

whichvaryfromstateto state.

IMPORTANT:OwnermustpresentOriginalProofofPurchasetoobtain

warrantycoverage.

TROYBILT LLC, P.O. BOX 361131 CLEVELAM D, OHIO 44136-0019; Phone: 1(866} 840-6483, 1-330-558-7220