Troy-Bilt 31-2 HP User Manual
o
$7 50
If-BIL
Owner/Operator
Manual
TRAIL BLAZER
Sickle Bar Mower
« Safety
Models
• Assembly
« Controls
• Operation
• Maintenance
3V2 HP
4 HP
ADANGER
Awarning
The mower’s cutter bar can cause serious
personal injury. Read this Owner/Operator Manual thoroughly for precautions you must follow
when operating the mower. Always follow these
precautions.
PLEASE NOTE
All directions in this Manual are determined from the
operator’s position, standing behind the handlebars
and facing forward. Please refer to the figure below.
Avoid fires due to sparks.
Do not operate engine if spark arrester screen is
loose or damaged.
IMPORTANT!
If you notice any freight damage either at the time of
delivery or later during assembly, make sure that you
notify the truck terminal that delivered your mower that
you intend to file a claim. If you have any problems
with this procedure, please call us so that we can help
you get satisfaction. Our phone numbers are listed on
Page 3 and on the back cover of this manual.
TABLE OF CONTENTS
Page
Section 1: Safety.................................................................... 4
Training ............................................................................. 4
Preparation ....................................................................... 4
Operation .......................................................................... 4
Disconnecting the Spark Plug Wire ................................ 5
Maintenance and Storage
Decals ............................................................................... 5
.........................................
Section 2: Easy Assembly
Section 3: Engine and Mower Controls
Blade Drive Lever
Wheel Drive Lever
Cutting Height Adjusters
Handlebar Height Adjustment ........................................13
Engine Throttle Lever .....................................................14
Engine Choke ..................................................................14
Recoil Starter
Engine Ignition Switch
(Electric Start Models)
...........................................................
..........................................................
................................................
...................................................................
.......................................
.........................
... 14
12
12
12
13
14
Section 4: Mower Operation ........................................15
Filling the Engine’s Gas Tank.........................................15
Starting the Mower ..........................................................16
Mowing
Stopping
General Mowing Tips.......................................................17
............................................................................
..........................................................................
16
17
Page
Sections; Maintenance............................................18
Engine Maintenance ...........................................18
Checking the Engine Oil Level and
Adding Oil to the Engine ..............................18
Changing the Engine Oil
5
Air Filter Maintenance
.................................
.....................................
19
19
Spark Arrester .................................................20
Air Cooling System Maintenance
.....................
21
Carburetor Adjustment (Engine
Speed & Mixture) ..........................................21
Engine Ignition System
..................................
21
Spark Plug.......................................................21
Liquid Lock
Mower Maintenance
Lubrication
Removing and Reinstalling the Wheels
.....................................................
...........................................
.......................................................
...........
21
22
22
23
Wheel Drive Belt Removal and
Installation
Wheel Drive Adjustment (General)
...................................................
..................
23
27
Wheel Drive Check.......................................27
Wheel Drive Initial Setting
Wheel Drive Main Adjustment
...........................
.....................
28
28
Cutter Bar Drive Belt Removal and
Installation
Cutter Bar Drive Adjustment (General)
Cutter Bar Drive Check
Cutter Bar Drive Initial Setting
...................................................
...........
...............................
.....................
29
32
32
32
Cutter Bar Drive Main Adjustment ...............33
Cutter Bar Maintenance
...................................
34
Removal and Installation of the
Cutter Bar Assembly.................................34
Blade Guide Maintenance ...........................35
Blade Guide Adjustment...........................36
Removing and Installing the Cutter
Blade Assembly .......................................36
Tightening a Loose Individual Blade
Replacing Individual Blades
.........................
Electric Starting System Maintenance
Battery Charging
.........................................
...........
............
37
38
40
40
Seasonal Charging ......................................40
Battery Removal & Installation
...................
41
Storage....................................................................42
Maintenance Schedule
...........................................
42
Troubleshooting Chart ............................................43
Alphabetical Index
Specifications
.............................
...................................
inside rear cover
inside rear cover
Dear Owner:
Congratulations on the purchase of your TROY-BILT TRAIL BLAZER® Sickle Bar Mower. You will find this mower
to be a unique and useful piece of equipment that can be used for many projects on your property. You can
use this mower for numerous tasks, such as taming those unsightly areas on your property that you never had
the time to mow, cleaning up any badly overgrown spots that are threatening to surround your out-buildings,
making an occasional pass over the edges of your property to keep your property lines clear, or making a single
path through head-high weeds and saplings to make a nature trail or a cross country trail that can be enjoyed all
year long.
Because of the TROY-BILT TRAIL BLAZER® Mower’s ease of operation and well-balanced build, you can do all
of the above-mentioned projects easily with little more effort than simply walking behind the mower. The mower’s
cutter bar has induction hardened teeth that slice through weeds and small saplings in a single pass, leaving a
wide swath behind.
To help you get the most value from your mower, we’ve prepared this Owner/Operator Manual for your use.
This Manual will tell you how to easily assemble your mower and operate its controls. It also provides you with
easy-to-follow procedures for performing required maintenance.
And, of course, we are never more than a phone call away. If you should ever have any questions about your
mower, or need to order any parts, please call us. Our phone numbers are listed on Page 3 and on the back cover
of this Manual. One of our helpful, friendly Technical Service people will be glad to assist you.
Sincerely,
Dean Leith, Jr.
Sales Manager
RECORD YOUR MOWER’S SERIAL AND
MODEL NUMBERS
The arrow in the photo shows the location of the
serial number and model number decals on your
TRAIL BLAZER® Mower. Please record these numbers
in the spaces below. If you should ever need any
replacement parts, or if you have any questions for
us, we will need to know these numbers. Also please
be sure to tell us if you have an electric start or a
standard start model.
MY TRAIL BLAZER® MOWER IS (CHECK ONE);
□ AN ELECTRIC START MODEL.
□ A STANDARD START MODEL.
ITS SERIAL NUMBER IS
ITS MODEL NUMBER IS
ITS DATE OF DELIVERY WAS.
_____________________________
_____________________________
RECORD YOUR MOWER ENGINE’S
IDENTIFICATION NUMBERS
Please refer to the Briggs & Stratton Operating and
Maintenance Instructions Manual that was included in
the literature package. This manual will show you the
location of the engine’s identification numbers. If you
ever need any engine parts, you will need to provide
its identification numbers.
To obtain engine parts or service, please look in
the yellow pages of your telephone book under
“ENGINES-GASOLINE” or “GASOLINE ENGINES”.
Then look for the name of the nearest Authorized
Briggs & Stratton Service Center. If you have trouble
finding a service shop, please feel free to call us and
we will provide you with the name, telephone number,
and address of the service center nearest you.
Please record the important engine information in
the blank spaces below. This will give you a handy
reference for later use.
ENGINE HORSEPOWER RATING
ENGINE MODELATYPE/
CODE NUMBER
________
_____________________
FOR SERVICE OR PARTS:
If you should ever need service assistance or
replacement parts for your mower, call us at the
numbers listed below:
TROY-BILT MANUFACTURING CO.
102nd St. & 9th Ave., Troy, New York 12180
For Technical Service, call Toll-Free: 1-800-833-6990
For Parts Sales, call Toll-Free: 1-800-648-6776
M-F 8 a.m. to 7 p.m.
Sat. 9 a.m. to 4:00 p.m.
GARDEN WAY BRANCH CANADA
1515 Matheson Blvd. E, Unit B11
Mississauga, Ontario L4W 2P5
Call Toll-Free: 1-800-225-3585
M-F 8 .m. to 4:30 p.m.
If you are ordering parts for your mower, please
give us the following information:
1. The serial number of your mower.
2. Whether you have an electric start model or a
standard start model.
3. The PART NUMBER of the part you need (from
the TRAIL BLAZER® Mower Parts Catalog).
4. The PART DESCRIPTION of the part you need
(from the TRAIL BLAZER® Mower Parts Catalog).
5. The QUANTITY of that particular part that you
need.
(Please remember that you can get many of the
common hardware items from a nearby well-stocked
hardware store as well as from us.)
AWARNING TO ALL CALIFORNIA MOWER OPERATORS
Under California Law, you are not permitted to operate an internal combustion engine using hydrocarbon
fuels on any forest-covered, brush-covered, or grass-covered land, or land covered with grain, hay, or other
flammable agricultural crop, without an engine spark arrester in continuous effective working order. The
engine on your mower, like most lawn or garden equipment, is an internal combustion engine that burns
gasoline (a hydrocarbon fuel); therefore it must be equipped with a spark arrester muffler in proper working
order. The spark arrester must be attached to the engine exhaust system in such a manner that flames or heat
from the system will not ignite flammable material. Failure of the operator to comply with this regulation is a
misdemeanor under California Law. Other states may have similar laws. Federal laws apply on Federal lands.
The TRAIL BLAZER® Mower is equipped with a
screen-type spark arrester on its muffler.
Please refer to Page 20 in this Manual and to the
Briggs & Stratton Operating and Maintenance Instruc
tions Manual for specific inspection and maintenance
procedures for the spark arrester.
SECTION 1: SAFETY
IMPORTANT—Safe Operation Practices for Sickle Bar Mowers
When operating or servicing the mower always
follow the safe operating practices described in this
Section. If you should ever lend this mower to another
person, make sure that he or she understands the
safe operation of the mower.
TRAINING
1. Read this Owner/Operator Manual, the separate
engine owner’s manual, and any other literature you
may have received before you use the mower. Be
thoroughly familiar with the controls and proper use
of the mower. Know how to stop the mower and
disengage its controls quickly in case of an emergency.
2. Never allow children to operate the mower. Do not
allow adults to operate the mower without proper
instruction. Do not allow irresponsible adults to oper
ate the mower.
3. Keep the area of operation clear of all persons,
particularly small children, and pets.
PREPARATION
1. Thoroughly inspect the area where the mower is to
be used. Remove all metal debris, limbs, and other
hazards. Also inspect this area for holes, ruts, or
bumps. Uneven terrain could overturn the mower. Be
aware that tall vegetation can hide many hazards.
2. Do not operate the mower when barefoot or when
wearing open sandals. Always wear substantial foot
wear which will protect your feet and help improve
traction.
3. Do not wear loose fitting clothing or jewelry that
could get caught in moving parts. Also be aware that
vines, branches, etc. can snag loose fitting clothing or
jewelry.
4. Remove any rings or other metal jewelry when
working on or near the electric starting system.
5. Before starting the engine, make sure that the
plastic blade protector is removed from the blade and
that both handlebar levers are disengaged (released).
Also check the muffler’s spark arrester screen for
security and damage.
6. Mow only in daylight.
7. Never operate the mower in wet grass. Always be
sure of your footing; keep a firm hold on the handle
bar grips, and walk, never run.
8. Never operate the mower without the weed deflec
tor and all guards in place (except for the plastic
blade protector, which should be removed before
starting the engine).
9. Never attempt to disconnect or remove guards or
other safety devices, or to defeat the purpose of
these safefy devices.
10. Gasoline is highly flammable and its vapors are
explosive. Handle it with extreme care. Use an
4 approved fuel container.
If you should ever have any questions about oper
ating or servicing your TRAIL BLAZER® Mower, please
call us immediately. One of our trained technical
service representatives will be happy to assist you.
Our phone numbers are listed on Page 3 and on the
back cover of this Manual.
11. Check the gas level in the gas tank before starting
the engine. Do not fill the gas tank when the mower is
indoors, when the mower’s engine is running, or when
the mower’s engine is hot. Allow the mower’s engine
to cool for several minutes before filling the gas tank.
Reinstall the gas tank cap securely and clean up any
spilled gasoline before starting the engine.
12. Keep smoking materials, sparks, and flame away
from the gas tank and the fuel container.
13. Move the mower away from gas fumes before
starting the engine.
14. If you are mowing in a dry area, do not smoke.
Do not smoke while mowing.
15. Do not charge the battery (on electric start mod
els) in an airtight space.
16. When charging the (electric start) mower’s bat
tery, do not use a battery charger other than the one
provided with the mower.
17. The electric start mower’s battery contains toxic
materials. Do not damage the battery case. If the case
is broken or damaged, avoid contact with the battery
contents.
18. Dispose of the battery properly. Check with local
authorities for proper disposal methods.
19. Do not operate the mower if the cutter bar assem
bly is not securely installed.
OPERATION
1. Before each use, check the operation of the han
dlebar levers. See Page 16 in this Manual for specific
instructions. Do not use the mower if either handlebar
lever is not functioning properly.
2. Do not put hands or feet near or under any moving
parts. Keep clear of the cutter bar at all times when
the engine is running.
3. Keep the plastic blade protector on the blade until
you are ready to start the engine.
4. Before removing or installing the plastic blade
protector: shut the engine off, disconnect the spark
plug wire and prevent it from touching the spark plug.
On electric start models, also remove the Engine
Ignition key from the keyswitch.
5. Do not change the engine governor settings or
overspeed the engine.
6. Stop the cutter bar blade when crossing gravel
drives, walks, or roads.
7. Watch for traffic when operating near, or when
crossing roadways.
SAFETY
8. Stop both the cutter bar blade and the wheel drive
when you are approached by any child, inattentive
person, or pet.
9. Before inspecting, cleaning, adjusting, or repairing
the mower or cutter bar: stop the engine, disconnect
the spark plug wire and prevent it from touching the
spark plug, wait for all moving parts to stop, and
reinstall the plastic blade protector on the blade. On
electric start models, also remove the Engine Ignition
key from the keyswitch.
10. Never leave the operator’s position while the
mower’s engine is running. Stop the engine, discon
nect the spark plug wire and prevent it from touching
the spark plug to help prevent accidental starting. Also,
remove the Engine Ignition key from the keyswitch on
electric start models to help prevent accidental starting
or unauthorized use.
11. If the mower should start to vibrate abnormally,
stop the engine, disconnect the spark plug wire and
prevent it from touching the spark plug. Also, remove
the Engine ignition key from the keyswitch on electric
start models. Wait for ail moving parts to completely
stop and then inspect the mower for damage. Repair
the damage before restarting the engine and operating
the mower.
12. Do not run the engine in an enclosed area.
Engine exhaust contains carbon monoxide gas,
a deadly poison that is odorless, colorless and
tasteless.
13. Do not mow excessively steep slopes.
14. Keep all movements on a slope slow and gradual.
Do not make sudden changes in speed or direction.
15. Do not touch engine parts which may be hot from
operation. Allow parts to cool before inspecting,
cleaning, or repairing.
16. Whenever you pull the mower rearward, release
both handlebar levers. Always check behind you for
hazards when backing up.
17. If you’re not mowing, disengage the blade drive.
18. Do not operate the mower while under the influ
ence of alcohol or drugs.
19. Do not mow near drop-offs, ditches, or embank
ments. If the mower’s wheel goes over the edge, or if
the edge caves in, the mower could suddenly overturn.
20. Keep children out of the mowing area. Keep them
under the watchful eye of an adult other than the
person operating the mower. Never assume that chil
dren will remain where you last saw them.
21. Before you back the mower up, and while you’re
backing it up, be sure to look behind you for small
children.
22. Never attempt to carry children on the mower.
They could fall off and be seriously injured, or they
could interfere with the safe operation of the mower.
23. Use extra care when approaching blind corners,
shrubs, trees, and any other object that may obscure
vision.
24. When removing the cutter bar blade from the
cutter bar assembly, wear sturdy leather gloves to
help prevent the blades from accidentally pinching or
cutting your fingers or hands.
Disconnecting the Spark Plug Wire
Whenever you perform any type of cleaning, inspec
tion, or maintenance on the mower, shut the engine
off and then disconnect the spark plug wire from the
spark plug. Then prevent the wire from touching the
spark plug by placing the spark plug wire’s boot on
the V-shaped holder that is on the rear of the engine.
See the photo below.
Preventing the spark plug wire from touching the
spark plug helps to prevent the engine from being
accidentally started.
Preventing the spark plug wire from touching the spark plug.
MAINTENANCE AND STORAGE
1. Keep all nuts, bolts, and screws tight to be sure
that the equipment is in safe working condition.
2. If the mower has gasoline in its gas tank, do not
store it inside a building where fumes from the gaso
line could reach an open flame or spark.
3. Allow the engine to cool before storing the mower
in any enclosure.
4. To reduce fire hazard, keep the engine free of
grass, leaves, or excessive grease.
5. Store gasoline in a cool, well-ventilated area, safely
away from any spark- or flame-producing equipment.
Store gasoline in an approved container, safely out of
the reach of children.
6. Before inspecting, cleaning, adjusting, or repairing
the mower: Stop the engine, disconnect the spark
plug wire and prevent it from touching the spark plug,
wait for all moving parts to stop, and reinstall the
plastic blade protector on the blade. On electric start
models, also remove the Engine Ignition key from the
keyswitch.
7. Do not allow children to be around you when you
are working on the mower.
DECALS
We’ve placed operating and safety decals on the
mower to help you when operating the mower or to
warn you of any hazards. If any of these decals is
missing, iilegible, or damaged, please contact us
immediately for replacements. Please refer to your
TRAIL BLAZER® Parts Catalog for decal location and
replacement information.
SECTION 2: EASY ASSEMBLY
Please follow the assembly steps given in this Sec
tion to properly assemble your mower. These steps
will not take very long and they will assure you of
having assembled your mower correctly.
To assemble the mower, you’ll need the following
items:
1. One pair of scissors.
2. One flat-tipped screwdriver.
3. One quart of high quality engine oil. (See “Specifi
cations” on the inside rear cover of this Manual for
recommended types of oil.)
4. One 3/8-inch wrench.
5. A piece of wood (to tap the handle onto the
Throttle Lever).
Step 1: Check your Parts
We’ve carefully packed your mower here at the
factory. After unpacking it, compare the contents of
the cartons to Photo 2-1 to make sure that you have
the necessary parts to assemble your mower. If any
parts are missing, please call us for replacements.
The following list of components is keyed to the
callouts in Photo 2-1.
1. The upper handlebar assembly.
2. The mower body/engine assembly.
Before you begin assembly, please read this Sec
tion all the way through to familiarize yourself with the
assembly steps. Then gather the necessary tools.
6.
A 13 MM (millimeter) wrench. (You can substitute
a V2-inch wrench).
7.
A clean funnel.
8.
For electric start mowers, you’ll also need a
13/16-inch wrench (you can substitute a large
adjustable wrench).
9.
An assistant to help steady the mower.
10.
Grease, multi-purpose type.
The mower hardware packages.
3.
4.
The cutter bar assembly, which consists of;
a. The ledger bar.
b. The cutter blade.
c. The plastic blade protector.
5.
The drive socket.
6.
The drive pin.
7.
Two forward height adjuster halves.
Two rear height adjuster halves.
8.
m .
Photo 2-1: The contents of the shipping cartons.
Open the hardware packages. Compare their con
tents with Photo 2-2 and the following list. If any
pieces are missing, call us for replacements.
1. Two handlebar lock clamps.
2. Two handlebar knobs.
3. Two handlebar star washers.
4. Tie straps (four for electric start models; two for
standard start models).
5. Two curved head handlebar bolts.
6. Two #10 lockwashers.
7. Two 10-32 nuts.
8. Two 10-32 X Va-inch slotted head screws.
9. One keyswitch (with nut and lockwasher).*
10. One pair of keys.*
11. One battery charger.*
12. Two 8 MM X 20 MM hex head screws.
13. Two 5/16-inch lockwashers.
14. Four 5/16-18 X iy4-inch carriage bolts.
15. Four 5/16-18 locknuts.
16. Throttle Lever knob.
17. Height adjuster hardware (not shown):
a. Two U-bolts.
b. Four U-bolt nuts.
c. Four flat washers for U-bolts.
d. Four 8MM X 30MM carriage bolts.
e. Four 8MM flat washers.
f. Four 8MM lock nuts.
* Electric start models only.
EASY ASSEMBLY
6,8
9
10
^ mm
12
13
O
c>
15
Photo 2-2: The contents of the hardware packages.
14
16
Step 2: Attaching the Handlebars
1. Slide the upper handlebars into position over the
lower handlebars and align the holes.
NOTE
Use the upper set of holes (in the lower handle
bars) for the higher handlebar height position.
Use the lower set of holes for the lower handle
bar height position.
2. From the inner side, push one of the curved head
handlebar bolts through these holes.
3. Place a handlebar lock clamp over the end of this
bolt. The curved side of the lock clamp faces in.
4. Place a lockwasher on the bolt.
5. Install a handlebar knob on the bolt.
6. Repeat Steps 2 through 5 for the other side of the
handlebars. Very securely tighten both handlebar
knobs.
NOTE
The lower handlebars are rubber mounted at
their lower end to help reduce vibration to the
operator. This may make them feel somewhat
loose, however this is normal.
Photo 2-3: Attaching the handlebars.
EASY ASSEMBLY
Step 3: Installing the Throttle Lever
1. The throttle cable is already attached to the Throt
tle Lever and the carburetor. Unwrap the throttle cable
and lever from the mower.
2. From underneath the control panel, insert the
Throttle Lever’s handle up, through the small rectan
gular cut-out in the control panel.
3. From above the control panel, insert one of the
#10-32 X Vz-inch screws down through one of the
cut-outs in the control panel decal. Make sure that
this screw goes through the hole in the base of the
Throttle Lever. Loosely install one of the #10 lockwashers and one of the #10-32 nuts on this screw.
4. Install the second screw, lockwasher, and nut in
the remaining hole. Then tighten both nuts with a
%-inch wrench and screwdriver.
Step 4: Assembling and Installing the Cutter Bar
À CAUTION
The cutter blades are sharp. Keep the plastic
blade protector on the cutter bar when working
on or near the cutter bar.
Failure to do so could result in personal injury
or property damage.
1. If the drive pin is not installed on the cutter blade,
place it on top of the blade. Align the holes in the
base of the drive pin with the holes in the cutter bar.
Secure the drive pin in place with two 8 MM x 25 MM
bolts and two 8 MM lockwashers. Use a 13 MM (or a
Vz-inch) wrench to evenly and securely tighten both
bolts. See Photo 2-6.
APPLY
GREASE
Photo 2-4: Installing the throttle lever.
5. Move the Throttle Lever forward and backward
several times. If the lever binds or does not have full
travel, loosen both nuts that you installed in Steps 3
and 4. From underneath the control panel, push the
base of the Throttle Lever slightly to the right.
Retighten both nuts and again check the Throttle
Lever for free movement. If the Throttle Lever should
still not move, push the carburetor's throttle arm
(where the lower end of the Throttle Lever cable is
secured) to the left. (Occasionally dried paint on the
throttle arm pivot keeps it from moving.)
6. Place the Throttle Lever knob on top of the Throttle
Lever handle. Use a piece of wood to gently tap the
knob onto the Throttle Lever handle.
Photo 2-6: Installing the drive pin.
2. Grasp the drive pin with one hand. Steady the cut
ter bar with your other hand. Try to move the cutter
blade from side to side. Occasionally dried paint will
prevent the blade from moving. If you can’t move the
blade, rap the side of the drive pin with a rubber mal
let to break the cutter blade free of the dried paint.
3. Place the drive socket on the drive pin. Place the
cutter bar assembly in front of the mower's nose
piece.
4. Lubricate the drive pin with multi-purpose grease.
5. Have an assistant push down on the handlebars to
very slightly raise the nose of the mower.
6. Slowly slide the cutter bar assembly rearward.
Make sure that; a) the cutter bar mount rests on top
of the cutter bar and its four holes align with the four
(square) holes in the cutter bar mount, and b) the
shaft on the drive socket enters the hole in the front
of the drive arm.
8 Photo 2-5; Installing the throttle lever knob.
7. From underneath, insert a 5/16-18 x VA-inch car
riage bolt up through one of the holes in the cutter
bar. Loosely install a 5/16-18 nut on this bolt. Repeat
this for the remaining three holes. Then tighten ail
four nuts.
EASY ASSEMBLY
DRIVE
Photo 2-7: Installing the cutter bar assembly
8. Place the forward (shorter) half of one of the height
adjusters beneath the rear of the cutter bar. Make sure
that the “hump” on the height adjuster faces up. Align
the two holes in this half of the height adjuster with
the two holes in the rear of the cutter bar. See Photo 2-8.
Photo 2-8: Installing the forward half of the height adjuster.
Photo 2-9: Installing the rear half of the height adjuster.
12. Repeat Steps 8 through 11 for the remaining side
of the cutter bar and height adjuster halves.
13. Flave your assistant lower the nose of the mower.
NOTE
To adjust the height adjusters for blade cutting
height, piease refer to “Cutting Fleight Adjusters”
in Section 3 of this Manual.
Step 5: Attach the Tie Straps (Standard Start
Models Only)
NOTE
If you have an electric start model, the tie straps
wiil be installed in Step 9.
1. On the right-hand handlebar, loop a tie strap
(serrated side faces in) around the handiebar, the
biade drive lever control cable and the throttle cable.
Make sure that the strap is located ABOVE the adjuster
assembly on the control cable. See Figure 2-10.
Tighten the strap and trim off any excess iength.
2. Use a second tie to attach the wheel drive lever
control cable to the left-hand handlebar. Again, make
sure that the strap is located ABOVE the adjuster
assembly on the cable.
9. From underneath, insert two 8MM x 30MM car
riage bolts up through the holes in the height adjuster
and blade. Place an 8MM flat washer and an 8MM
lock nut on each of these carriage bolts. Use a 13MM
(or a Va-inch) wrench to evenly and securely tighten
both of these nuts.
NOTE
Use care to not use the 5/16-18 nuts on the
8MM carriage bolts. Although it is possibie to
make them fit, you will ruin the bolt.
10. Place the rear (longer) half of the height adjuster
(again, with its “hump” facing up) beneath the for
ward half of the height adjuster.
11. From underneath, insert a U-bolt through the two
holes in the height adjuster halves. Place a flat washer
and a locknut on each of the threaded ends of the U-bolt.
Use a Vainch wrench to evenly tighten the nuts.
Figure 2-10: Attaching the tie straps (standard start models
only).
EASY ASSEMBLY
Step 6: Add Oil to the Engine
1. Push the mower to a level area.
2. Unscrew the dipstick from the engine. Wipe the
dipstick clean.
3. Insert a clean funnel into the oil fill tube as shown
in Photo 2-11.
4. Pour the oil into the engine. The engine will hold
approximately Vk pints. See Photo 2-11.
NOTE
Please refer to “Specifications” on the inside
rear cover of this Manual to determine the type
of oil to add to the engine.
5. Remove the funnel. Screw the dipstick back into
the oil fill tube. Unscrew the dipstick and check the
oil level. It should be up to the FULL mark on the
dipstick.
If it is not up to this level, re-insert the funnel into
the oil fill tube. Then slowly add more oil until the oil
level is correct. While you’re adding the oil, frequently
pause and check the oil level with the dipstick to
prevent overfilling.
Photo 2-11: Adding oil to the engine.
Step 7: Check Tire Air Pressure
Use an automotive-type tire pressure gauge to
check the air pressure in both tires. The tires may
have been over-inflated for shipping purposes. Make
sure that the air pressure in both tires is the same or
the mower could pull to one side. The correct tire
pressure is from 10 to 20 pounds per square inch (PSI).
If you have a standard start TRAIL BLAZER® Mower, you
have now finished assembling it. Before you begin opera
tion, review Section 1: Safety, and read Sections 3 and 4 to
make sure that you know how to properly and safely operate
your new mower.
If you have an electric start TRAIL BLAZER® Mower, you
will have a few additional assembly steps to complete to
assemble some of the electric starting system parts on the
mower. Please go on to these following steps.
Step 8: Installing the Keyswitch
1. Unscrew the large nut off the keyswitch. Remove
the large toothed lockwasher from the keyswitch.
2. From underneath the mower’s control panel, insert
the threaded end of the keyswitch into the hole in the
rear of the control panel. (The hole for the keyswitch is
marked “ENGINE IGNITION’’.)
3. Place the large toothed lockwasher back onto the
keyswitch. Reinstall the nut on the keyswitch. Use a
13/16-inch wrench (or a large adjustable wrench) to
securely tighten the nut.
NUT LOCKWASHER
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Photo 2-12: Installing the keyswitch.
EASY ASSEMBLY
Step 9: Connecting the Wiring Harness
1. Unwrap the wiring harness from the mower.
2. Route the wiring harness beneath the left-hand
handlebar tube. Plug the connector at the top of the
wiring harness into the back of the keyswitch. (You can
attach the connector to the two keyswitch terminals
either way.)
3. For now, leave the plug on the lower end of the
wiring harness disconnected. You’ll connect it later,
after you’ve charged the battery.
5. Move the lower part of the wiring harness to the
right and secure it to the engine’s bracket with the tie
strap as shown in Figure 2-14. Make sure that the
large connector on the wiring harness is ABOVE the tie
strap. Be certain that the battery connector wires are
NOT secured to the engine’s bracket with the tie strap.
6. Secure the upper part of the wiring harness to the
left-hand handlebar tube (above the lock clamp) with
a wide tie strap as shown in Figure 2-15. Make sure
that the serrated side of the strap faces in when you
loop it around the handlebar. After tightening the strap,
snip off any excess length.
7. Use another wide tie strap to secure the Wheel
Drive Cable and the wiring harness to the left-hand
handlebar tube below the handlebar’s control panel
as shown in Figure 2-15. Make sure that the tie strap
is located ABOVE the cable adjuster.
8. Use another wide tie strap to secure the Blade
Drive Cable and the throttle cable to the right-hand
handlebar tube as shown in Figure 2-15. Make sure
that the tie strap is located ABOVE the cable adjuster.
Photo 2-13: Attaching the Wiring Harness to the Keyswitch.
4. Insert the narrow plastic tie strap into the hole in
the bracket that is located on the front part of the
engine housing (to the left of the oil fill tube).
See Figure 2-14.
Figure 2-14: Secure the lower end of the wiring harness to
the engine bracket (electric start models).
Handlebar
Figure 2-15: Attaching the tie straps (electric start models).
Step 10: Charge the Battery
Charge the mower’s battery by following the battery
charging instructions given on Page 40 of this Manual.
After you’ve charged the battery, you’ve finished
assembling the mower. Before operating the mower,
be sure to review Section 1: Safety, and read Sec
tions 3 and 4 to make sure that you know how to
properly and safely operate your new mower.
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SECTION 3: ENGINE AND MOWER CONTROLS
This Section shows the location and describes the
function of the various mower and engine controls
you will need to use when operating the mower.
After reading this Section and familiarizing yourself
with the various controls, please refer to “Section 4:
Operation” for step-by-step engine starting and
mower operation instructions.
Wheel Drive Lever
This lever is located beneath the left-hand handle
bar grip. To make the mower’s wheels turn (when the
engine is running) you simply rest your left hand on
the left-hand handlebar grip and squeeze the lever
upward. The wheels will begin turning and will
continue to turn as long as you are squeezing the
Wheel Drive Lever.
To stop the wheels from turning, simply release the
Wheel Drive Lever.
Photo 3-1: The handlebar control levers.
Blade Drive Lever
This lever is located beneath the right-hand handle
bar grip. To operate the cutter bar (when the engine is
running) you simply rest your right hand on the
right-hand handlebar grip and squeeze the lever
upward. The cutter bar will begin oscillating (moving
back and forth) and will continue to do so as long as
you are squeezing the Blade Drive Lever.
To stop the cutter bar from oscillating, simply
release the Blade Drive Lever.
ADANGER
If the cutter bar does not stop oscillating when
you release the Blade Drive Lever, or if it oscillates
before you squeeze this lever, shut the mower’s
engine off, wait until it cools, disconnect the spark
plug wire and prevent it from touching the spark
plug. Do not use the mower until the cutter bar
drive mechanism is repaired so that the cutter
bar stops oscillating when the Blade Drive Lever
is released. See “Cutter Bar Drive Adjustment
(General)” in Section 5 of this Manual.
^WARNING
If the wheels do not stop turning when you release
the Wheel Drive Lever, shut the mower’s engine
off, wait until the engine cools, disconnect the
spark plug wire and prevent it from touching the
spark plug. Do not use the mower until the wheel
drive mechanism is repaired so that the wheeis
stop turning when the Wheel Drive Lever is re
leased. See “Wheel Drive Adjustment (General)”
in Section 5 of this Manual.
Failure to do so could result in personal injury or
property damage.
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Failure to follow this instruction could result in
personal injury or property damage.
MOWER CONTROLS
Cutting Height Adjusters
There are two cutting height adjusters, one on each
side of the rear end of the cutter bar. These adjusters
are used to raise or lower the blade’s cutting height.
You can adjust the blade’s cutting height from approx
imately 11/4-inch to 5-inches.
To prevent excessive wear on the blade, set both
height adjusters so that the blade is raised off the
ground and will not dig into the ground.
To change the cutter bar’s cutting height;
A CAUTION
Before changing the cutter bar’s cutting height,
shut the engine off, disconnect the spark plug
wire and prevent it from touching the spark plug,
and reinstall the plastic blade protector on the
front of the cutter bar. On electric start models,
also remove the Engine Ignition key from the
key switch.
Failure to do so could result in personal injury or
property damage.
1. Move the mower to a flat area such as a paved
driveway or a garage floor.
2. Use a 13 MM wrench (or a '/2-inch or an adjustable
wrench) to loosen the two nuts that hold the halves of
the height adjusters together.
3. Move the rear half of the height adjuster rearward
to raise the cutting height. Move the rear half of the
height adjuster forward to lower the cutting height.
Handlebar Height Adjustment
You can adjust the handlebars on your mower to
either of two positions. The lower handlebar height is
approximately 36 inches high and the higher handle
bar height is approximately 38 inches high.
NOTE
The lower handlebars are rubber mounted at
their lower end (to help reduce vibration to the
operator). This may make them feel somewhat
loose, however this is normal.
To adjust the handlebar height:
Acaution
Before adjusting the handlebar height, shut the
engine off, allow it to cool, disconnect the spark
plug wire and prevent it from touching the spark
plug. For electric start models, also remove the
Engine Ignition key from the keyswitch.
Failure to do so could result in personal injury or
property damage.
1. Unscrew the handlebar knobs from both sides of
the lower handlebars. Then remove the lockwashers
and handlebar lock clamps.
2. Remove one of the handlebar bolts by pushing it
inward.
3. Use one hand to hold the upper handlebars while
you push the remaining handlebar bolt inward all the
way.
LOWER CUTTING X
HEIGHT HIGHER CUTTING
HEIGHT
Photo 3-2: Adjusting the blade height
4. Hold the rear half of the height adjuster in place
while you tighten the two nuts that you loosened in
Step 2.
5. Repeat Steps 1 through 4 for the height adjuster
on the other side of the cutter bar. Visually check the
blade to make sure it is parallel to the driveway or
garage fioor. Otherwise the cutting height will be
uneven and you’ll get a sloping cut when you mow.
4. Slide the upper handlebars up or down to align
the holes in their ends with the holes in the lower
handlebar.
5. Reinstall the two handlebar bolts, two handlebar
lock clamps, and the two lockwashers.
6. Place the two handlebar knobs on the handlebar
bolts and very securely tighten them.
&
Photo 3-3: Adjusting the handlebar height
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