Troy-Bilt 909J Tuff-Cut Operator's Manual

TRnV BILT

Operator's Manual

Model

909J--Tuff-Cut e

IMPORTANT:READ SAFETY RULES AND INSTRUCTIONS CAREFULLY

Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-covered, brush-

covered or grass-covered land unless the engine's exhaust system is equipped with a spark arrester meeting applicable local or state laws (if any).

If a spark arrester is used, it should be maintained in effective working order by the operator. In the State of California the above is required by law

(Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands. A spark arrester
for the muffler is available by contacting the service department at Troy-Bilt LLC, P.O. Box 361131 Cleveland, Ohio 44136-0019.

TROY-BILT LLC, P.O. BOX 361131, CLEVELAND, OH 44136-0019

PRINTED IN USA FORM NO. 770-10601A

(01/2002)

TABLE OF CONTENTS

Content Page

Calling Customer Support .................................................... 2

Safety ................................................................... 3

Assembly................................................................. 6

Features and Controls ....................................................... 8

Operation ................................................................ 10

Maintenance .............................................................. 15

Parts List................................................................. 22

Warrany Information ........................................................ Back Cover

FINDING MODEL NUMBER

This Operator's Manual is an important part of your new Mower. It will help you assemble, prepare and maintain the
unit for best performance. Please read and understand what it says.

Before you start assembling your new equipment, please locate the model plate on the equipment and copy the infor-
mation from it in the space provided below. This information is very important if you need help from our Customer
Support Department or an authorized dealer.

You can locate the model number by looking at the rear surface of the cutting deck. A sample model plate is
explained below. For future reference, please copy the model number and the serial number of the equipment

in the space below

O BILT. TROY-BILT LL(

P. O. BOX 361131

www.troybilt.com CLEVELAND, OH 44136

330-558-7220

• 866-840-5483

Copy Model Number Here

Copy Serial Number Here

ENGINEINFORMATION

The engine manufacturer is responsible for all engine-related issues with regards to performance, power-rating, speci-
fications, warranty and service. Please refer to the engine manufacturer's Owner's/Operator's Manual packed sepa-

rately with your unit for more information.

CALLINGCUSTOMERSUPPORT

If you have difficulty assembling this product or have any questions regarding the controls, operation or maintenance
of this unit, please call the Customer Support Department.

Call 1- [phone] or 1- [phone] to reach a Customer Support representative. Please have

your unit's model number and serial number ready when you call. See previous section to locate this infor-
mation. You wilt be asked to enter the serial number in order to process your call.

2

Safety

SafetyAlert Symbol

,_ This is a safety alertsymbol. It is used in this

manualand on the unit to alert you to potential
hazards. Whenyou seethis symbol, readand

obey the messagethat follows it. Failureto obey
safety messagescould result in personal injury or property
damage.

This machine meets voluntary safety standard B71.1 -
1998, which is sponsored by the Outdoor Power
Equipment Institute, Inc., and is published bythe American

National StandardsInstitute.

• lL WARNING

The engine exhaust from this product contains
chemicals known to the State of California to cause

cancer, birth defects or other reproductive harm.

IMPORTANT

SafeOperationPracticesfor Walk-BehindMowers

Thiscuttingmachineis capableofamputatinghandsandfeet andthrowingobjects.

Failureto observethefollowingsafetyinstructionscouldresultinseriousinjuryordeath.

I. GENERALOPERATION

.

1. Read,understandand follow all
instructions on the machineand in

the manuals provided with the unit.
Bethoroughly familiar with the 10.

controls andthe proper use ofthe
mower before starting. 11.

2. Do not put handsor feet nearor
under rotating parts. Keepclear of
the mower bladeand discharge
opening at all times. 12.

3. Onlyallow responsible individuals,
who are familiar with the instruc-

tions, to operate the mower.

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

5. Be sure the area is clear of other
people before mowing. Stop mower if

anyoneenters the area. Keep
bystanders at least 25 feetaway from 13.

the areaof operation.

6. Do not operatethe mower when 14.
barefoot or wearing open sandals.

Alwayswear substantial foot wear. 15.

7. Do not pull mower backwards unless
absolutely necessary.Look down and
behind before andwhile moving
backwards. 16.

8. Do not operatemower without all
guards in placeand eitherthe entire 17.
Grass Catcher,the Mulching Plug or
the optional Side-DischargeChute

installed. ROTATINGBLADES-- Do
not open discharge guard while

engine is running.

Referto providedinstructions for 18.
proper operation andaccessory

installation. Useonly accessories
approved by GardenWay Inc. 19.
Shut off engine when crossing gravel

drives, walks, or roads. 20.
Stop engineand disconnectspark

plug wire from spark plug whenever
you leaveunit, beforecleaningmower
or unclogging chute.

Shut the engine off andwait until the

bladecomesto acompletestop

beforeinstalling or removing the

Mulching Plug, optional Side-

DischargeChuteor the Grass
Catcher. Makecertain that an attach-

ment is installed before operating the

mower. Emptythe GrassCatcher
after each use- decomposing debris

could generateenough heat to catch
fire.

Mow only in daylight or in good arti-
ficial light.

Do not operatemower while under
the influenceof alcohol or drugs.

Neveroperatemower in wet grass.
Always besure of your footing; keep

a firm hold on the handleand walk;

neverrun.

Besure WheelDrive Bail is disen-
gaged before starting engine.

If the unit should start to vibrate
abnormally, stop the engineand dis-

connect the spark plugwire. Then
check immediately for the cause.
Vibration is generallya warning of

trouble.

21.

22.

Werecommendthat you wear safety
gogglesor safety glasseswhen
operatingthe mower.

Watchfor traffic when operating
near,or when crossing roadways.

Neverattempt to carry children or
other passengersonthe mower.
Theycould fall off and beseriously
injured, or they could interfere with
thesafe operation of the mower.

Checkthe operation ofthe Operator
PresenceControl Bail (top bail,
mounted on handlebar) beforeeach
use.The OperatorPresenceControl
Bail is a safety devicethat is designed

to stop the mower blade within three

secondsafter releasingthe bail. The
bail must operatefreely when pulled
backagainst the handlebarand
return automatically to the disen-
gaged position when released.If the
engine runs longer than three
secondsafter releasingthe bail, the
system is not working properly.
Immediately contact an authorized
servicedealeror the Factory
TechnicalServiceDepartmentfor

instructions. Donot usethe mower
until the mechanismis repaired.

Neverrun the enginein anenclosed
area.Engineexhaustcontains carbon
monoxide,a deadly gas that is

odorless,colorless andtasteless.
Alwaysrun the engine outdoors and

makesure there is adequate
ventilation.

Section1: Safety

II. OPERATING ON A SLOPE
Slopesare a major factorrelatedto slip

and fail accidentswhichcanresultin
severeinjury. All slopesrequire extra

caution,if youfeel uneasyona slope,
do notmow it.

DO:

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

caution when changing direction on
slopes. Avoid slopesgreater than 15o.

Removeobjects such as rocks, tree
limbs, etc.

Watch for holes, ruts, or bumps. Tall
grass can hide obstacles.

DONOT:

Donot mow near drop-offs, ditches,
or embankments. Theoperator could

loosefooting or balance.

Donot mow excessivelysteep slopes.
Donot mow on wet grass. Reduced

footing could causeslipping.

III. CHILDREN

Tragic accidentscanoccurif the
operatorisnotalert tothe presenceof
children.Childrenare oftenattractedto

the mowerandtothe mowingactivity.

Neverassumethatchildrenwill remain

whereyou lastsawthem.

1. Keepchildren out of the mowing area
and under the watchful careof a

responsible adult.

2. Bealert and turn mower off if
children enter thearea.

3. Beforeand while moving backwards,
look behindand down for small

children.

4. Neverallow children to operatethe 7.

mower.

5. Useextra carewhenapproaching
blind corners, shrubs, trees, or other

objects that may obscure vision. 8.

IV.SERVICE

1. Useextra carein handling gasoline 9.

and other fuels. Theyare flammable
and their vapors areexplosive.

a) Useonly an approved container.

b) Neverremove gascapor add fuel

when theengine is running.
Allow engine to cool before

refueling. Do not smoke. 10.

c) Neverrefuelthe machine

indoors.

11.

d) Neverstore the machine or fuel

container inside where there is an
open flame, such asa water 12.

heater,etc.

e) Move mower away from any

gasolinefumes beforestarting
the engine. 13.

insidea closed

2. Neverrun an engine

a_a.

3.

.

.

6.

Nevermakeadjustments or repairs

with the engine running. Disconnect
the spark plug wire and movethe
wire awayfrom the plug to prevent
accidentalstarting.

Keepall nuts and screws, especially

the bladeattachmentbolts, tight and

keepequipment in good condition.
Nevertamper with safety devices.

Checktheir operation regularly.

Keepmower free of grass, leavesor

other debris build-up. Clean up oil or
fuel spillage. Allow mower to cool

beforestoring.

After striking an object, stopthe

engineand disconnectthe spark plug
wire. Inspect the mower and repair, if

necessary,beforerestarting.
Neverattempt to make mowercutting

height adjustmentswhile the engine
is running.

Grasscatchercomponents are
subject to wear, damageand deterio-

ration, which could expose moving
parts or allow objects to bethrown.

Frequentlycheck components and
replacewith factory recommended

parts,when necessary.
Themower bladeis sharp and can

cut. Wrapthe bladeor wear gloves,
and use extra caution when servicing.

Do notchangethe engine governor
setting or overspeedthe engine.

Do nottouch engine parts which may
be hot from operation.Allow parts to
cool completely before inspecting,
cleaningor repairing the mower.

Maintain or replacesafetyand
instructional decals. Refertothe

Parts List for replacementdecal
information.

Section1: Safety

SAFETY DECALS

Foryour safety andthe safety of others,various safetydecals are located on your unit (below - sizenot to scale).
Keepthe decalscleanand legibleat all times. Contactyour local service dealeror the Factoryfor replacementsif any decals are

damagedor missing. Referto the PartsList pagesin this Manualfor decal part numbers.

Locatedonthebelt
cover. Thisdecal

providesa list of

warningsto helpavoid

seriousinjury.

Locatedonthedischargeoutletguard. Thisdecalwarns
nottooperatethemowerwithoMthedischargeoutlet

guardinplaceandeithertheGrassCatcherorMulching
Pluginstalled.Thisdecalalsowarnsthatthereare
rotatingblades.Donotopenthedischargeoutletguard
whiletheengineisrunning.

Locatedontheleftsideof the
mowerdeck. Thisdecalcautions

tokeephandsaway.

Before operating your machine,
carefully read and understand all

safety, controls and operating instruc-
tions in this Manual, the separate

Engine Owner's Manual, and on the
decals onthemachine.

Failure to follow these instructionscan
resultin seriouspersonalinjury.

INTRODUCTION

This Sectioncovers unboxing and assem-
bling your newmower. Pleasecarefully
read all the instructions before you

attempt to assemblethe mower. After
you finish assemblingthe mower, read

Section 1: Safety,Section3: Featuresand

Controls,and Section4: Operation,before

using the mower.

INSPECTION

Inspectthe mower immediately after

delivery. Makesurethat neitherthe
carton nor the contents havebeen

damaged.

If you find or suspectany damage,
contact the carrier (trucking company)
right away. Inform them ofthe specific
damageandthat you wish to file a claim.
To protect your rights, besureto put this
in writing to the carrierwithin 15 days
after your machinearrives. The carrier
will let you know how to proceedwith
your claim.

LOOSE PARTS

Thefollowing items areshipped loose
within the container.

NOTE: Themower is
shipped with the

Mulching Plug
(B, Figure2-2)

installed in the
discharge outlet

(Figure 2-1).
,, The Grass

Catcherattachmer

(A,Figure2-2).

A B

Figure2-2: Attachments

ASSEMBLING NEW UNITS

Themower bladeis sharpand cancause
serious personal injury. When working

near the mower blade, wear heavy
leather gloves to protectyourself from

thesharpedges.

IMPORTANT:Themower isshipped

without motor oil inthe enginecrankcase.
Add motor oil to the engine before

starting. Follow instructionsin this
Section.

Step 1: Unpack Mower

1. The mower comesfullyassembled

with the handlebarsfolded compactly for
shipment. Removethe mower from the

shipping container.

2. Thecontrol bails (P,Figure2-6) are
securedto the handlebar(Q) with a cable

tie. Cutthe cabletie off and removethe
protective packingmaterial.

3. Followsteps 2 through 8to complete
mower assembly.

Step 2: Unfold Handlebar Assembly

1. Loosenthe two lower handlebar

adjustment knobs (1, Figure2-5).

2. Carefullyunfold lower section ofthe
handlebarassembly (2, Figure2-5).
Watchthe cableswhile unfolding and

makesure that they do not pinch, kink, or
over-stretch while unfolding.

3. Tighten the two lower handlebar
adjustment knobsjust enoughto allow

thetwo handlebarstruts (H, Figure2-3)
to move in and out slightly.

4. Insertthe tab (F, Figure2-3) on each
handlebarstrut into the slot (G) one each
side ofthe deck. Becertain to route the
cables inside the left side strut asshown

in Figure 2-4.

5. Tighten both lower handlebaradjust-
ment knobs securely.

6. Loosenthe two upper handlebar

adjustment knobs (3, Figure 2-5).

7. Unfold the upper handlebarassembly
(4, Figure2-5) and align with the lower

handlebarassembly. Besure not to
pinch, kink, or over-stretch the cables

while unfolding.

8. Tighten both upper handlebaradjust-
ment knobs securely.

9. Checkthe starter rope. Makesure

that it doesnot catch under thetop

handlebaradjustment knob (I, Figure
2-6). Thestarter rope should stretch

unobstructed to the engine.

Figure2-3: Assemblinghandlebar,(Right-

sidehandlebarstrutshown.)

Figure2-4: Cablescorrectlyroutedinside
handlebarstrut,

Section2: Assembly

Figure2-5: Unfoldingthehandlebar.

Step 3: Adjust Handlebar Height

1. Loosenone of the lower handlebar

adjustment knobs (K, Figure2-6) and give
the knob a tap inwardto freethe square
shaft on thescrew (N, Figure2-7) from

the keyedslot (0) in the handlebarstrut.

Repeatthis step for the otherside.

2. Movethe handlebarstrut up or down
to align the squareshaft (N, Figure2-7)
with one of the three squarekeyedslots

(0). Themiddle slot is the medium
heightsetting.

3. Tighten the handlebar adjustment
knobs very securely.

NOTE:Make sure that thesquare shaft

seatssquarely into the slot beforetight-
ening the adjustment knobs.

Step 4: Add Motor Oil to Engine

1. Movethe mowerto a levelarea.

2. Add motor oil according to the specifi-

cations and instructions providedin the
separateEngine Owner'sManual.

• Keepoil level at the FULL mark on the

dipstick to avoid engine damage.

• Changeoil accordingto scheduleand

instructions in EngineOwner's Manual.

Figure2-6: Fullyassembledhandlebar
assembly.

Step 5: Perform
Final Assembly Check

1. Checkall nuts, screws, and handlebar

adjustment knobs for tightness.

2. Besure to read Section 1: Safety,
Section3: Featuresand Controlsand

Section4: Operationbefore usingthe
mower.

Figure2-7:Adjustinghandlebarheight.

Step 6: Set Up Mowing Mode

Your mower can be set up for either of
two mowing modes. These mowing

modes can bag clippings or mulch

clippings. SeeSetting Up Mowing Modes

in Section 4 for detaileddescriptions and
instructions on how to set up each mode.

NOTE:Themower is shipped in Mulching
Mode. This meansthat the Mulching

Plug is installed into the discharge outlet
(Figure2-1) and that the mower is ready

to mulch grass clippings.

FeaturesandControls

/

/

/

0

H

G

A: OperatorPresenceControlBail
B: Wheel Speed Control

C:WheelDrive Bail

D: RecoilRope Starter
E: UpperHandlebarAdjustmentKnob(2)

Figure3-1

Before operating your machine,
carefully read and understand all
safety, controls and operating instruc-
tions in this Manual, the separate
Engine Owner's Manual and on the

decals onthemachine.
Failure to follow these instructionscan

resultin seriouspersonalinjury.

INTRODUCTION

This Section introducesthe features and
controls found on the lawn mower.

Carefullyreview the information in this
Section,then readSection4, Operation

beforeusingthe mower.

F:SmartBagTM GrassFiBIndicator
G:GrassCatcher

H:DischargeOutletGuard
l:LowerHandlebarAdjustmentKnob(2)

J:HandlebarHeigMAdjuster(2)

MOWERATTACHMENTS

Themower is supplied with two easily
changedattachments --the Grass

Catcher(I, Figure3-1) and the Mulching
Plug (M)-- which provide two different
mowing modes. SeeSettingUp Mowing

Modes in Section 4 for detailed informa-

tion on how to install and usetheattach-

ments.

A uniquefeature,the TROY-BILT®Rapid
AttachTM System, is incorporated into the
design of the attachments. This system
enablesyou to quickly and easily install
the attachments without using tools.

K:CuttingHeightAdjustmentLever
L:Belt Cover

M: Mulching Plug
N:DischargeOutlet
O:ClutchCable Adjuster

GrassCatcher Attachment

Usethe GrassCatcher(G, Figure3-1) to
collect clippings for disposal. The bag
can hold over two bushels of clippings.

TheGrass Catcheris equippedwith the
Troy-Bilt@Smart BagTM feature (F, Figure
3-1). TheSmart Bagfeature is a grass fill

indicator that provides a visual alert when
the bagis full. SeeBagging Mode in

Section 4 for detailed information.

Mulching Plug Attachment

Usethe Mulching Plug (M, Figure 3-1) to

mulch lawn clippings. SeeMulching

Modein Section 4.

Section3: FeaturesandControls

MOWERCONTROLS

Thefollowinginformationidentifiesand
describesthecontrolsforall mower

models.

Operator Presence Control Bail

TheOperator PresenceControl Bail

(A,Figure3-1) must be pulledback
against the handlebarand held there
while starting the engineand operating
the unit. Releasingthe bail will shut off
the engine andstop the mower blade.
Theengine will not restart unless the bail

is pulled back againstthe handlebar.

NOTE:This control disengagesan engine

brakewhen pulled backagainst the

handlebarand engagestheengine brake
when released. Themower blade is

bolteddirectly to the engineshaft,
therefore it stops whenthe engine stops.
Theengine will not restart unless the bail

is pulled back againstthe handlebar. See

Stopping theEngineand Mower Bladein
Section 4 for more information.

Wheel Drive Bail

TheWheel Drive Bail (C,Figure 3-1)
engagesthe poweredrearwheels when it

is pulled up against the handlebar,and
disengagesthe wheelswhen released.

See Mowingand Turning the Mowerin
Section 4 for more information.

To move the mower without engine

power, releasethe controls and pushor

pull the mower.

NOTE:Thepinion gears inside the rear
wheels may produce an occasional

knockingsound when pushing or pulling
the mower manually. This sound is

harmless. Do not lubricate the drive
wheels. Servicethe drive assembly only

as instructed in Section 5.

Wheel Speed Control

TheWheelSpeedControl (B, Figure3-1)

provides three different wheel speeds.
Selectionsare:

• 1 for low speed

• 2 for medium speed

• 3 for high speed
SeeMowing in Section4 for more infor-

mation.

Cutting Height AdjustmentLever

This control (K, Figure3-1) provides eight
cutting heights, enabling youto choose
the most appropriate height for the lawn
condition. Cutting heights rangefrom
3/4-inches to 4-1/4-inches. See Prepara-

tion forMowing in Section 4 for more
nforrnation.

NOTE:Actual cutting heightw_llvary

according to turf conditions..

ENGINECONTROLS

Throttle

Models 909J has an enginethat is
equipped with a fixed throttle speedfor
the mostefficient engine performance

undervarying loads.

Primer Bulb

The Primer Bulb is usedto start a cold
engine. Seethe EngineOwner's Manual
for information specific to your engine.

Fuel Shut-Off Valve

The FuelShut-Off Valve (if so equipped)
opensand closes the fuel line. Seethe

EngineOwner'sManualfor information
specific to your engine.

Recoil Rope Start

Therecoil rope start (D. Figure3-1) Es

usedto pull-start the engine. Seethe
EngineOwner's Manualfor starting infor-
matEonspecific to your engine. Alsosee
Starting the Enginein Section4

Adjustable Handlebar Height

Themower provides three handlebar

heightsettings (J, Figure 3-1). SeeStep
5:Adjust Handlebar Height in Section2.

Operation

Before operating the mower, carefully
read and understandall safety, control
and operating instructions in this
Manual, the separate Engine Owner's

Manual andthe decalson themachine.

Failureto follow these instructionscan

resultin seriouspersonalinjury.

• Never operate the mower with the
discharge outlet guard removed or
proppedopen.

• Do not operate mower without the
Grass Catcher, Mulching Plug or

optional Side-Discharge Chute in
place.

• Never change mowing modes or
empty the Grass Catcher while the

engine is running.

• Check the condition of the Grass
Catcherfor excessivewear or deterio-

ration. If damaged, contactan autho-
rized dealer or the factory for a
replacement.

TheGrass Catcherand the optional Side-
DischargeChute both use the same
system. This system consists of an
elongatedtab (A, Figure4-1) on the top of
the discharge outlet and a receptacle(B)
built into the top of the GrassCatcher
door and the optional Side-Discharge

Chute.

Figure4-1: TROY-BIL7_RapidAttachTM
System,

bagwhen emptying.

TheGrass Catcheralso has a Smart BagTM
grass-fill indicator (Figure4-3) which

makesit easyto tell when the bag is full.
The indicator is a rectangularpieceof
cloth sewn to the top ofthe bag. The

indicator lays flat againstthe bagwhen
the bagis full (F, Figure4-3) and billows

(G) when the bag is not full.

NOTE:Windy conditions mayaffect the

indicator's ability to provide an accurate

bagfill reading.

SettingUp BaggingMode

1. With the engineand bladestopped,

removethe Mulching Plug or optional
Side-DischargeChute.

10

INTRODUCTION

Readthis Section thoroughly before you

start the engine. Thentakethe time to
familiarizeyourself with the mower's

basicoperation.
Findan open,levelareaand practice

usingthe mower controls. Onlyafter you
becomefamiliar with the mower should

you useit in smaller areasor on uneven
terrain.

TROY-BILT®
RAPIDATTACHTM SYSTEM

The RapidAttach System (Figure 4-1) is a
feature designed into the mower deck

which enablesyou to install and remove
the GrassCatcher,the (optional) Side-

DischargeChuteand the Mulching Plug

quickly and easily.

Attaching the Mulching Plug isjust as
easy. Hold openthe discharge outlet
guard (K, Figure4-1) and insert the plug
(L), with the word "TOP"facing up, into
the discharge outlet.

SETTINGUPMOWINGMODES

Thelawn mower hastwo mowing modes:
bagging mode and mulching mode. The
following provides descriptions of the two
modes and howto implement them.

Bagging Mode
Themower is set up for bagging mode

when the GrassCatcher is attached to the
discharge outlet.

TheGrass Catcheris equipped with two
handlesand a swing-open door that
makesemptying easy. Usethe wire-
formed handle to help attach, remove,
transport and emptythe bag. Usethe

rear cloth handle to lift the bottom of the

Figure4-2: AttachingGrassCatcher.

2. Graspthe Grass Catcherby thewire-
formed handle. With the other hand, hold
open the discharge outlet guard (C, Figure
4-2).

3. Lower (atan angle) the bagdoor (D,

Figure4-2) onto the tab (E) onthe
discharge outlet. Makesure the bag door
seatssquarely onto the tab and covers
the tab completely.

Removingthe GrassCatcher

1. When mowing, the Grass Catcheris
full when the grass fill indicator laysflat
against the bag (F, Figure4-3).

An alternative method for judging bag
fullness isto nudgethe bagwith your
foot. The bagwill giveeasily when not
full, and will resist when full.

Section4: Operation

Figure4-3: SmartBagTM indicateswhenbagisfull(F)andnotfull(G),

2. With the engineand blade stopped,
hold open the discharge outletguard (C,

Figure4-2). With the other hand, grasp

the wire-formed handleand guidethe bag

up and off the discharge outlet.

Mulching Mode

The mulching modecuts and recutsgrass

clippings within the mower housing
beforerecycling the finely cut clippings
into the lawn. Mulching makesit easier

for the the lawn to absorb the grass

nutrients back into the soil.

SettingUpMulchingMode

1. With the engineand blade stopped,
removethe Grass Catcheror the optional

Side-Dischargeattachment.

2. Lift open the discharge outlet guard
(K, Figure4-1).

3. Position the plug with the word "TOP"
facing up and pushthe Mulching Plug
firmly into the discharge outlet (Figure

4-4).

4. Theplug's flange (rim) must fit snugly
against the edge of thedischarge outlet to

ensureefficient mulching (Figure 4-4).

Figure4-4: Installed MulchingPlug,

2. Graspthe Mulching Plug's hand-grip
with one handand pull back until the plug

clears the discharge outlet.

PREPARATION FOR MOWING

ReviewSection 1: Safetyand Section 3:
Featuresand Controls. Thenreadthis

Section completely beforestarting the
mower.

1. Move lawn mowerto a clear, level
area - If on a grassyarea,make sure the

grass is low enough as to not interfere
with blade rotation when starting.

2. Inspectarea to be cut- Checkfor and
remove debris such as rocks, toys, wire,
bones, sticks, etc., which could be picked
up and thrown bythe blade. Also inspect

the terrain for holes or other obstacles.

3. Checkmower-

• Checkthe mower for loose or missing

hardware. Tighten or replacebefore

starting the mower.

• Checkthe Operator PresenceControl

Bailfor freedomof movement.

• ChecktheWheel Drive Control Bail for

freedom of movement.

• Checkbladefor excessivewear or

damage. Do not operatethe mower
with a damagedblade.

• Securelyconnectthe spark plug wire to

the spark plug.

4. Adjusthandlebarheight- The mower
hasthree handlebarheights which can be

adjusted as follows:

a. Loosenone ofthe lower handlebar

adjustment knobs (H, Figure4-5) and

givethe knob atap to free the
handlebarstrut (K) for adjustment.
Repeatfor the other side.

Removingthe MulchingPlug

1. With the engineand blade stopped, lift
openthe discharge outlet guard.

Figure4-5: Adjustinghandlebarheight.

b. Adjust the handlebarsto the

desired height and thentighten the

handlebaradjustment knobs. Make

sure that the square shank onthe
screw (J, Figure4-5) seatssquarely

into one of the squareslots (I).

5. Set cuttingheight - Youcan set the
mower to any of eight cutting heights.

Cutting heights rangefrom 3/4" to 4-1/4".

To avoid personal injury, never adjust
cutting height while engine is running.

Release all handlebar controlsandwait
for all motion to stop before adjusting

cuttingheight.

NOTE: Actual cutting heightwill vary
according to grass,terrain, and soil con-

ditions.

a. Toadjust cutting height, pullthe

Cutting Height Lever (A, Figure4-6)

away from the mower to releasethe
tab from the slot. Besureto grip the

leverfirmly to preventthe mower deck

from dropping down rapidly.

Figure4-6:CuMngheightadjustmenL

11

Section4: Operation

12

b. While pulling the leveraway from

the mower, move the levertowards the

backof the mower (B, Figure 4-6) for a
higher cut or towards the front ofthe

mower (C) for a lower cut.
c. Seatthe lever'stab squarely into

the slot.

IMPORTANT: Themower is equipped
with a safety flap located on the rear of

the mower deck. After setting the cutting

height, be certain that the flap hangs

freely and is not caught under the deck.

6. PrepareEngine-

• Checkoil level - If this is a new mower,

add motor oil asdescribed in the Engine
Owner's Manual;otherwise, checkoil

leveland add as recommendedin the
EngineOwner's Manual.

GASOLINEIS HIGHLYFLAMMABLEAND
ITSVAPORSAREEXPLOSIVE.

Followthe gasoline safety rules in this
Manual (Section 1) and in the separate

EngineOwner'sManual.
Failuretofollow gasolinesafetyinstruc-

tions can result in serious personal

injuryand propertydamage.

• Addfuel - Fill the fuel tank with gasoline
according to the directions in the

separateEngineOwner's Manual.
Follow all instructions and Safetyrules

carefully.

• Checkair filter - Theengine is equipped
with an air filtration system. When

clogged, it causes starting difficulties
and operatesinefficiently. Seethe

EngineOwner's Manualfor information
on how to maintain the air filter system.

OPERATINGTHEMOWER

Thefollowing procedures explain how to
start, stop and operatethe mower.

Do not operate the engine in an
enclosedarea. Engineexhaustcontains
carbon monoxide, a deadly gas that is
odorless, colorless and tasteless.
Always run the engine outdoors and
make surethere is adequateventilation.

Starting the Engine

1. Openthe fuel shut-off valve,if so

equipped.

2. Primethe engine by pushingthe
primer bulb firmly 3 times.

NOTE:Priming may not be necessary

when restarting a warm engine.

However,cool weather may require
priming again. Seethe EngineOwner's

Manualfor priming information.

To avoid injury or property damage,
thoroughlyinspectarea where mower is

to be used and remove all stones,
sticks, wires, bones, nails and other
foreignobjects.

3. Standbehind the mower handlebar

and pull the Operator PresenceControl

Bail(A, Figure3-1) backagainstthe
handlebarand hold.

4. Checkbehind you for obstacles, then

slowly pull the recoil rope (E, Figure3-1)

until resistance is felt. Pull the rope out
rapidlyto start engine. Letthe rope

returnslowly. If the enginefails to start

after three pulls, repeat steps 2-4.

Stopping the
Engine and Mower Blade

To avoid personal injury, keep hands
and feet clear of mower blade or other

rotatingparts.

1. Releasethe Operator PresenceControl

Bail(A, Figure3-1) to stop the engineand
blade.

EmergencyStopping

Releaseall controls. This stops the

engine,wheel movement and the blade.

IMPORTANT:The mower is equipped

with a BladeControl System which is
designedto stop the mower bladewithin
three (3) secondsafter releasingthe

OperatorPresenceControl Bail. This

system also stops theengine.

If the Blade Control System does not

operate properly, the blade could
continueto rotate for longerthan three
(3) secondsafter releasing the Operator

Presence Control Bail. If this occurs,
discontinueusingthe mowerand imme-

diately contact your local authorized
dealer or the factory for instructions.

Do not operate the mower until the

BladeControlSystemisrepaired.

Failure to do this could result in

personalinjuryor propertydamage.

Mowing

1. Start the engine. SeeStarting the
Enginein this Section.

2. Usethe WheelSpeedControlto select

a wheel speed. The mower has three
wheel speeds. Selecta slower speed
when first starting out (or when learning

howto usethe mower), then move into

faster speedsif needed.

• Low Speed(1) - is engagedwhen the

lever is pulled allthe way back. Low
speedprovides the most efficient cut.

• Medium Speed(2)- is engagedwhen

the lever is movedto the middle detent
position (thecontrol leverwill click into

place). This speedisa good compro-
mise for speedand cutting perfor-

mance.

• High Speed(3) - isengagedwhen the

lever is pushedall the way forward.
High speedenablesyou to coverthe
cutting areamore quickly, but may
result in a less efficient cut. This speed
is most effective on short, thin grass.

3. Pull the Wheel Drive Bail (B, Figure

4-7) up against the handlebarto power
the rearwheelsand move forward.

NOTE: ReleasetheWheel Drive Bailand

continue to hold the Operator Presence
Control Bail (A, Figure4-7) to pause

during mowing with the enginerunning,
or to maneuverin tight conditions.

TurningtheMower

1. Forshort turns, releasethe Wheel
Drive Bail (B,Figure4-7) but continue to

hold the Operator PresenceControl Bail
(A). This disengagesthe wheel drive, but

the engine continues to run.

Section4: Operation

Figure4-7: Disengagingthewheelswith

enginerunning,

2. Pressdown onthe handlebarto raise
the front end slightly.

3. Pushthe handlebar opposite the
direction to which you want to turn.

4. Forlonger, wider turns, there is no
needto disengagethe poweredwheels.

MOWINGTIPSANDHINTS

Mow When Lawn Is Dry

Donot mow grass when it iswet. Wet

grass isdifficult to mow andclumps
together insidethe mower housing. This

causesinefficient operation and an

unevencut. Additionally, wet clippings

stick together inunsightly clumps on top
of the lawn which causesinefficient

absorption of nutrients back into the soil.

Avoid Midday Mowing

If possible, mow in the late afternoon or

early eveningto avoid exposing newlycut
grass to thedrying effects of direct

sunlight.

Never Cut Lower Than One-Third Grass
Height In One Pass

If possible, mow 1

often enough or _

high enough to

avoid cutting off

morethan 1/3of

the grass height.

Forexample, if you

are maintaining your lawn at 2", mow

beforeit reaches3".
Removingmore than 1/3 of total grass

bladelength may exposetender, shaded

stems to thedrying effects of the sunand
wind and producea dull, brown-looking

lawn. Cutting off too much leafarea is

also a shock to the root system and it

maytake weeksto repairthe damage.

Clean Mower Frequently

Cleanthe mowing housing frequently to
removeanygrass build-up. Referto the

cleaning instructions in Section5.

Vary Cutting Pattern

Varythe cutting

patternfrom week __]]P_

to week. Oneweek

mow horizontally.
Mow vertically the following week. This
helpsprevent wear patterns and soil com-
paction.

AvoidSharpTurns

Sharpturns may producean uneven cut.

If possible, follow naturalground
contours or usegentle, sweepingturns
for a better looking lawn.

Mow LongGrassTwice

If the grass

is5"long or

more, cut it __

onceat the

highest setting andthen mow it againat
the desired height. This method may

producetoo manyclippings to usethe

mulcher effectively. Usethe Grass

Catcherto remove the grass clippings.

Use ExtremeCaution on Slopes

When operatingon
sloping ground,

exerciseextreme
caution and usegood

common senseto
avoid possible

personalinjury or property damage.

Do not mow steepslopes! Avoidslopes
greaterthan 15 degrees,or wherever
footing is unsure. If a slope is difficult to
stand on, it is probably too steep to mow

(in such a case,it may bebest to
establish a ground cover that doesn't

require mowing).

Donot mow on slopes whenthe ground

iswet. Mow acrossthe face of slopes,

neverup and down. Slow down and
exerciseextremecaution when changing
direction on slopes. Keepthe Wheel

Drive Bailengagedto ensureeasier

operationand better control of the mower

To avoid injuryor propertydamage:

• Maximumsafe operatingangle is t5 o.

• Exceeding maximum safe operating
angle may cause tipping or loss of

footing.

• Do notmowwet slopes.

• Mow acrossslopes,not upand down.

*Exercise extreme caution when

changingdirectionon slopes.

EmptyGrassCatcher WhenFull

Emptyingthe GrassCatcherwhen it is full
results in bettercollection and mower

performance. Emptythe bag assoon as

the bagis filled. SeeBagging Modefor

more information on the Smart Bag

feature.

Match Speed
To Terrain and Conditions

Adjust the speedto grass conditions and
terrain. UseLow and Medium speedsfor

normal mowing conditions. You'll get
better results at slower speeds, especially

if thegrass istall or lush. Use High
speedto transport the mower or when
grass conditions are light and appearance

is not asimportant.

Keep Mower Blade Sharp

A sharp bladecutsthe grass cleanly,

resulting in a smooth, evenlycut lawn. A
dull bladetears at the grassand will fray
the tips so that they dry out quickly

resulting in a dull, brown-looking lawn.
See BladeSharpeningand Balancingin

Section 5 of this manualfor more infor-

mation.

Mulching Leaves

A light covering of leavescanbe effec-
tively mulched into the turf. Asthe leaves
decompose,they provide valuableorganic

matterand mineralsto the soil.
To ensureeffectivemulching, be surethe

leavesare dry. Useaslow travel speed
and don't try to mulch a deeplayer of

leaves.

13

Maintenance

Beforeinspecting,cleaning orservicingthe machine,shot off engine,wait for movingpartsto stop,dis-

connectsparkplugwire andmovewire away fromsparkplug.

Failureto followthese instructionscanresult inseriouspersonalinjuryor propertydamage.

REQUIRED MAINTENANCE SCHEDULE

PROCEDURE

Checkengine oil level

Changeengine oil

Servicespark plug

Checknutsandscrews
Servicefoampre-cleanerairfilter

(if soequipped)
Servicepaperairfilter

(if soequipped)
Inspectsparkarrester(ifsoequipped)
Cleanengine

Cleanmowerhousing
Cleanunderbeltcover

Checkclutchspringextension
Cleandrive-wheelpiniongears

Before Every10 Every25

Using Hours Hours

AsNoted

Aftereach5

operatinghours

41,A

Aftereach100

operatinghours

1"

Annually

Aftereachuse

€

Aftereach50

operatinghours

• Changemorefrequentlyin dustyor dirtyconditions.Changeafterfirst 2 hoursof
break-inoperation,

i" Checkafterfirst2 hoursof break-inoperation.

• SeeEngineOwner'sManualforservicerecommendations.

• Beforeandafterstoringunitfor3 weeksor more,

REMOVING AND
REPLACING THE BELT COVER

Removingthe Belt Cover

1. Usea 3/8"wrench to remove both
screws (D, E,Figure5-1).

Figure5-1: Beltcover

2. Lift the backend of the cover then
carefully pull out.

Do not operate the mower without the
belt cover in place. Doing so could
result in personal injury or damage to
components.

When working near the blade, wear
heavy leather gloves to protectyourself
fromthe sharpedgesonthe blade.

ENGINEOIL SERVICE

Checktheengine oil level before starting
the engine eachday and after each 5

hours of continuous operation. Running

the engine when the oil level is low will
quickly ruin the engine.

Changeengine oil after the first 2 hours
of break-inoperation, thereafter, in accor-

dancewith your EngineOwnersManual.
Changemore often in extremely dirty or

dusty conditions. Refertothe Engine

Owner'sManual for detailedinformation
on changing oil.

SERVICING THE AIR CLEANER

Theengine air cleanerfilters dirt and dust

out of the air before it enters the carbure-

tor. Operatingthe engine with a dirty,
clogged air cleaner can cause poor per-
formance and damageto the engine.

Neveroperatethe engine without the air
cleaner installed. Inspectand servicethe
air cleaner more often if operating in very
dusty or dirty conditions.

Servicethe air cleaneras instructed in the
separate EngineOwner's Manual.

Replacing the Belt Cover

1. Seatthe rear end of the cover. Make

sorethat both control cablesare routed
through the cutout in the rear of the

cover. This will help prevent damage
caused by pinching the cablesunder the

cover or contact with the transmission

pulleyor belt.

2. Tighten screws snugly. Do not over-
tighten (D, E, Figure5-1).

TIPPINGTHEMOWERFOR
SERVICE

1. Beforetipping the mower, make sure

that the fuel tank is emptyto prevent the

possibility of gasolinespillage. See

"DANGER"statement that follows.

14

Section5: Maintenance

_ eforeinspecting,cleaning orservicingthe machine, shutoff engine,wait for movingpartsto stop, dis-

connectsparkplugwire andmovewire awayfrom sparkplug.

Failureto followtheseinstructionscanresult inseriouspersonalinjuryor propertydamage.

2. When servicing the undersideof the

mower,the mower should betipped only
in the direction of the muffler. Tipping

the mower awayfrom the muffler could

result in enginedamageor difficult

starting.

SPARKPLUGSERVICE

Inspectand cleanor replacethe spark
plug after every 100 operating hours or

annually. Setthe gapas described in the
separateEngine Owner'sManual.

Insome areas,local law requiresusing
resistor spark plugs to suppress ignition

signals. If the engine was originally
equipped with a resistor spark plug,

replacewith the sametype.

CLEANINGTHEENGINE

Theengine must be keptcleanto insure
smooth operationand to prevent damage
from overheating. Refertothe Engine

Owner's Manualfor more information.

CLEANINGUNDER
THE MOWER HOUSING

Checkthe mower regularly for grass

build-up. Cleaningunder the mowerdeck
should bedoneafter (rather than before)
operating the mower, asgrass is moist
and removedmore easily.

1. Tip mower towards the muffler onto

its side. See Tipping the Mower for

Servicein this Section.

2. Brushorscrapeoffgrassbuild-up.
CLEANINGTHEGRASSCATCHER

Bagcleanlinessaffects collection perfor-

manceasa dirty bagwill restrict air flow.
Cleanthe GrassCatcherbag annually,

moreoften in dusty environments.
IMPORTANT: Do not wash or dry the

Grass Catcherin a washingmachine or
dryer.

1. To cleanthe bag, remove itfrom the

mower and hand wash the fabric with

mild detergent.

Before servicing the underside of the
mower:

• MOVINGPARTSHAZARD!

Stop engine, wait for all partsto stop

moving, and disconnect spark plug

wire.

• FIRE- EXPLOSIONHAZARD!

Gasolineis highly flammable and its

vaporsare explosive.

1. Drain fuel into an approved con-
tainer outdoors, away from open

flame.

2. Be sure engine and muffler are
coolbeforedraining gasoline.

3. Do notsmoke.

Failure to comply with the above can
result in serious personal injury and
propertydamage.

2. Rinsethe bag thoroughly with clean
water and allow to dry completely before

using. Donot usea damp bag.

CLEANINGUNDERBELTCOVER

Checkunderside of beltcover for grass

clippings every 10 hours of use.

1. Removethe beltcover. See
Removingthe Belt Coverin this Section.

2. Removeany grass clippings or debris.

3. Replacebeltcover. See Replacingthe
Belt Coverin this Section.

SPARKARRESTER
SCREENSERVICE

If the engine muffler is equippedwith a

spark arrester screen, removeand clean it
according to thetime intervalsand

instructions in the separateEngine
Owner'sManual.

CARBURETOR/GOVERNOR
CONTROL ADJUSTMENTS

Thecarburetor was adjustedat the
factory for best operatingspeed. Referto
the separateEngineOwner's Manual for
anyadjustment information or seeyour
authorized engine servicedealer.

Thegovernor controls the maximum safe
operating speedand protects the engine

and all moving parts from damage caused

byoverspeeding. Do not tamper with the

engine governor settings. Seekautho-

rizedserviceif a problem exists.

MOWERBLADEMAINTENANCE

Blade Inspection

1. Tip mower towards the muffler onto

its side. See Tipping the Mower for
Servicein this Section.

Never reach under mower deck while
the engine is running. Mower blade

rotates at all times while engine is
runningand up to 3 secondsafter it is

shutoff.

2. Inspect periodically for a dull or

slightly nicked blade. Sharpenif needed.
Also checkfor a deformed,cracked, or
excessivelyworn blade(Figure5-2). Do

not usethe mower if anyof these condi-
tions exist. Replacethe bladeimmedi-
ately.

3. Checkthe bladescrew for tightness.

If loose,tighten to 35 ft-lbs with a 3/4"
torque wrench.

NewBlade

Replaceblade immediately if cracked,

deformed or badly nicked.

Figure5-2: Mower blade inspection,

15

Section5: Maintenance

Beforeinspecting,cleaning orservicingthe machine,shot off engine,wait for movingpartsto stop,dis-

connectsparkplugwire andmovewire away fromsparkplug.

Failureto followthese instructionscanresult inseriouspersonalinjuryor propertydamage.

Mower bladeis sharp.
*Wear heavy leather gloves when

workingnear or with bladefor protec-
tionfromsharp edges.

, Wear safety approved eye protection

whensharpeningbladeto protecteyes
fromflying metal debris.

RemovingMower Blade
IMPORTANT:Theblade coupler

(D, Figure 5-5) may come off the engine
shaft when removing the blade. If it does,
do not losethe square key (C). Thekey
fits into a squareslot insidethe blade
coupler. Without it, the bladewill not

rotate.

1. Removethe spark plug wire from the
spark plug and move it away.

2. Tip mower towards the muffler onto

its side. See Tipping the Mower for

Servicein this Section.

3. Usea 3/4"wrench to loosenthe blade
screw (A, Figure5-5). Hold the blade

with a gloved hand to prevent the blade
from rotating.

Figure5-3: Removingorinstallingblade.

4. Removebladescrew and Belleville
washer (A, B, Figure5-5).

5. Removeblade.You may haveto give
the blade atap to jar it loose from the

mounting tabs.

16

Curved end down

Curved end down

/ Mower Deck

Figure5-4:Correctbladeinstallation.

Lawn

Figure5-5: Mower bladeassembly.

Installing Mower Blade

1. Removethe spark plug wire from the

spark plug and move it away.

2. Tip mower towards the muffler onto
its side. See Tipping the Mower for

Servicein this Section.

3. If the bladecoupler (D, Figure5-5)

and/or square key (C)came off the engine
shaft during bladeremoval, reinstall those

parts back onto the engineshaft.

4. Position the bladewith the curved

endsfacing downward (Figure 5-4).

5. Slip the Belleville washer (B, Figure

5-5) ontothe screw (A). Facethe dished-

in side to the blade.

6. Mount the bladeonto the two tabs of

the blade coupler. Makesure that you
seat the bladecompletely onto the
coupler.

7. Insertthe screw and washerthrough

the bladeand into the bladecoupler.
Tighten with a torque wrench to 35 ft-lbs.

Sharpeningand
Balancing Mower Blade

IMPORTANT:We recommendthat the

bladebe sharpenedby a professional
sharpeningservice. Replacea cracked or
severelyworn bladewith a new one.

1. Removebladefrom the mower. See

RemovingMower Blade.

2. Clampthe blade in a vise. Usea metal
file or grinder to sharpenthe bladewhile

maintaining the original cutting angle. It

isvery important to maintain the original
cutting bevelto insurethe most effective

cut.

3. To retain blade balance,removethe
same amount of materialfrom both ends

of the blade.

4. To check bladebalance,placethe

bladeon a rounded pivot such as a pencil
or penunder the center hole. Hold blade

parallelto ground then release. See

Figure5-6. If bladeis unbalanced,the

heavierside will leandownward.

5. Usea file to lightly remove material
from the heavierside of the blade.

6. SeeInstalling Mower Bladefor infor-

mation on how to re-install the blade.

REMOVING AND
REPLACING DRIVE BELT

This procedure can bemade easierby

removing the blade (seeRemoving

Mower Blade);however, bladeremoval is

not absolutelynecessary.

I

Figure5-6: Balancebladeonpivottocheckbladebalance.

Section5: Maintenance

_ eforeinspecting,cleaning orservicingthe machine, shutoff engine,wait for movingpartsto stop, dis-

connectsparkplugwire andmovewire awayfrom sparkplug.

Failureto followtheseinstructionscanresult inseriouspersonalinjuryor propertydamage.

Figure5-7:Pressdownonpoint"A"to
removeorinstallbelt.

1. Removethe beltcover. See

Removingthe Belt Coverin this Section.

2. Pressfirmly downward on the cable
mounting bracket (A,Figure5-7) until it

tilts and the beltslackens.

3. Removebelt (B, Figure5-7) from
transaxle pulley.

4. Tipthe mower onto its side (towards
the muffler) and pull the beltthrough the

cutout in the housing.

5. Dothis step only if you did not
removethe mower blade-- otherwise, go
onto step 6.

a. Make sure the spark plug wire is

removed from the sparkplug and

moved away from theplug. Rotatethe
bladesothat one end issomewhere

within the front of the mower housing.

b. Work the belt around andover that

end of the blade(Figure 5-8).

c. Rotate the bladeso that the other

end is somewhere within thefront of
the mower housing and work the belt

around and off the mower.

d. Work the new beltaround and over

the same end ofthe blade.

e. Rotatethe bladeso that the other

end of the bladeis somewhere within
the front area of the mower housing

and work the new belt around and over
the same end.

6. Seatthe newbelt into the groove on

the engine pulley that is locatedon the

bladedrive shaft.

7. Graspone end ofthe new beltand
insert it in and through the cutout in the
housing.

Figure5-8: Removeorinstallbeltaround

blade.

8. Tip the mower backdown to its
normal position.

9. Apply firm pressureagainst the cable
mounting bracket on the transaxle

assembly (A, Figure 5-7) until it tilts
forward.

18. Pullthe beltover thetransaxle pulley

and into the groove.

11. Releasepressure onthe transaxle
bracketslowly. Makesurethat the belt

seats properly into the pulleygroove.

12. Checkthe other end of the belt
(engine pulley) to insure that it is seated

properly into the groove.

13. Reinstallthe belt cover. See
Replacing the Belt Coverin this Section.

ADJUSTING
WHEELDRIVECONTROL

Loss of wheel drive indicatesthat the

Wheel Drive Control may needadjust-

ment. This condition couldalso be the
result of not completely engaginga wheel

speedgear setting. Beforeyou adjust the
wheel drive control cable, move theWheel

SpeedControl Leverto 1 (allthe way
back) or to 3 (all the way forward). Ifthe

wheels still do not engage, adjust the
wheel drive clutch spring.

1. Removethe beltcover (SeeRemoving
and Replacing theBelt cover) andlocate

the wheeldrive clutch spring.

2. Measurethe length of the body of the

wheel drive clutch spring (Figure5-9).

Figure5-9: Firstmeasurementwithdrive
clutchspringdisengaged.

3. Engagethe Wheel DriveControl Bail
and measurethe extendedlength of the
spring bodyagain (Figure5-10).

Figure5-10: Secondmeasurementwith
driveclutchspringengaged,

4. Thedifference betweenthe two mea-
surements should be approximately 1/4".

Adjust if the result does not meet this
specification. Spring extension is

adjusted with a cableadjuster (R, Figure
3-1) on the wheel drive cable. To adjust,
hold the turnbuckle (A, Figure5-11) while
turning eachadjuster (B, Figure5-11)
awayfrom theturnbuckle 1/2 turn each.

Figure5-11: Drivecable adjustment.

17

Section5: Maintenance

_ eforeinspecting,cleaning orservicingthe machine, shutoff engine,wait for movingpartsto stop, dis-

connectsparkplugwire andmovewire awayfrom sparkplug.

Failureto followtheseinstructionscanresult inseriouspersonalinjuryor propertydamage.

5. Measureagain,as in steps 2, 3 and4 2. Removethe Grass Catcherdoor. See

to determine if you needto continue Replacing the Grass CatcherDoor.
adjusting. Adjust until the two spring 3. Thebagis mounted overthe wire

measurementsdiffer in length by approxi- frame and underthe door, and is held in
mately1/4". placewith four plasticclips (E,Figure

6. Reinstallthe belt cover. See 5-13). Removeeachof theclips by
Replacingthe Belt Cover. pulling from an end and off the frame (F).

GRASS CATCHER
PARTS REPLACEMENT

The GrassCatcheris made up of three

parts:the door, the frame, and the cloth
bag. Thefollowing procedure explains

how to removeand replace each of the
parts.

Replacing the GrassCatcher Door

1. Removethe GrassCatcherfrom the

mower.

2. Thedoor is mounted onto rods at both

endsof the wire-formed handle. Squeeze
the handlewith one hand while pulling the
top-side ofthe door (C,Figure 5-12) out
and off the end ofthe rod (D).

Figure5-12: Replacingbag door,

Figure5-13

4. Pullthe bagoff the frame.

5. To replacethe frame or bag, position

the top of the bag (long side) up.

Position the top ofthe frame (wire-

formed handleside) up. Pull the open
end of the bag overthe rear end of the

frame and under the handle.

6. Presseach of the bag'sfour plastic
clips (E,Figure5-13) onto the frame

opening (F).

7. Installthe door. Seestep 3,

Replacing the Grass CatcherDoor.

3. To replacethe door, insert one of the

endsof the wire-formed handle (D, Figure

5-12) into the hole in the top-side of the

door (C).

4. Squeezethe handlewith one hand
while you pull the other side of the door

(C, Figure5-12) up and over the endof
the other rod (D). The door should swing
freely when done.

Replacing the Cloth Bag or Frame

1. Removethe GrassCatcherfrom the

mower.

EXTENDED STORAGE

Usethe following suggestions when

storing the mower for extendedperiods of
time.

• Store mower in a level position.

• Thoroughly inspectthe
mower for any loose,
broken, or missing parts.
Repairor replaceas
necessary.

• Removeall fuel from fuel

tank or use a fuel stabilizer

additive as directed in
EngineOwner's Manual.

• Never store mower with fuel in fuel
tank inside a building where fumes can

reach an openflame or spark, or where

ignitionsourcesare presentsuchas hot
water and space heaters, furnaces,
clothes dryers, stoves, electric motors,
etc. Make sure engine is cool before
storing.

• Drain gasoline outdoors into an
approvedcontainer.

• Do not smoke and keep away from
openflame.

Failure to follow these instructionswill
result in serious personal injury or

propertydamage.

• Perform engine maintenanceas

described in the Storage instructions of
the EngineOwner's Manual.

• Checkall nuts andscrews for tightness.

• On electric start models removekey

from keyswitch.

• Chargethe batteryfor 24 to 48 hours

beforeand after seasonalstorage.

• Disconnectspark plug wire from spark

plug.

Folding the Handlebar Assembly
IMPORTANT:Toavoid damageto the

cablesand wiring, always fold the top
section of the handlebarassembly

backward. Cablescanbe severelybent if
folded incorrectly.

1. Loosenthe top two handlebaradjust-
ment knobs (1, Figure5-16) while sup-

porting the assembly with one hand.

[]

18 Figure5-16:Foldingthemowerforstorage.

Section5: Maintenance

_ eforeinspecting,cleaning orservicingthe machine, shutoff engine,wait for movingpartsto stop, dis-

connectsparkplugwire andmovewire awayfrom sparkplug.

Failureto followtheseinstructionscanresult inseriouspersonalinjuryor propertydamage.

Figure5-17: Dislodginghand/ebarstruts.

2. Foldthe top section of theassembly
backward(2, Figure5-16). Guidethe

cables carefully while folding. Besure

notto bend, pinch, or stretch the cables.

IMPORTANT:Toavoid damageto cables,
alwaysfold the top section of the

handlebarassembly backwardand the
bottom section forward.

3. Still supporting the handlebar

assembly with one hand, loosenthetwo

lower handlebaradjustment knobs
(3, Figure5-16) just enoughto dislodge

both handlebarstruts (L, Figure5-17)

from theslots (K) in the wheelbracket
assembly.

NOTE:Thehandlebar height could inad-

vertently change if the lower adjustment

knobs are loosenedexcessivelyduring

this step.

4. Carefullyfold the bottom section of

the handlebarassembly forward over the
engine (4, Figure 5-16). Guidethe cables
carefully while folding. Besure not to

bend,pinch, or stretch the cables;also,
keepcablesaway from muffler-- the

outer cablecovering canbe burned if the
engine is still hot.

5. To unfold handlebarassembly,
perform folding steps in reverseorder.

PINIONGEARSERVICE

The mower drive wheels (rear wheels)
eachcontain a pinion gear. This gear
transfers drive powerto the wheels which

propelsthe mower forward. It is very
important to keepthese internal parts

clean. Thefollowing procedureexplains

howto disassemble,cleanand reassem-
blethe mowerdrive wheels. Conductthis

maintenanceon the pinion gearsafter

every 50 operating hours.

Figure5-18: Drive wheel assembly.

Tools and Materials

• 9/16" Socketand Ratchet

• Small Snap-Ring Pliers

• CleaningRags

Procedure

NOTE:This procedure is done only on

the drive wheels (rearwheels).

1. Placea sturdy, stable block under the
mower to elevatea rear wheeloff the

ground.

2. Usea 9/16" wrenchto removewheel

assembly (A, B, C,D, E,Figure5-18).

3. Removesnap-ring (J, Figure5-18)

from axle.

4. Removeshim(s) (I, Figure5-18). The
numberof shims vary from mower to
mower. Put them nextto the snap-ring.

5. Pull off pinion gear (H, Figure5-18).

6. Removedrive pin (G, Figure5-18).

7. Removeplasticwasher/seal
(F, Figure5-18).

8. Thoroughly clean off debris from the

drive pin,axle, hole in axle(for drive pin)
and the washer/seal.

9. Reinstallwasher/seal (F,Figure5-18).
Besureto installflat side of washer

against bearing(mower deck).

10. Insert the drive pin (G,Figures5-18)
intothe hole in the axle.

NOTE:Thepin should slidefreely within

the hole.

11. Thoroughly clean pinion gear,
including surfaceareaand cavity.

12. Slidethe pinion gear (H, Figure5-18)

onto the axlewith the cavity toward the

mower. Pressthe gearfirmly against the

washer/seal (F, Figure5-18). Becertain
that the gear is flush against the surface

of the washer/sealand that the
washer/seal is flush against the wheel

mounting bracket.

18. Slidethe shims (I, Figure 5-18) onto

the axleand against the pinion gear. Be
sure to install the same numberof shims

as were removedfrom the unit.

14. Install the snap-ring onto the axle
(J, Figures 5-18) and into the groove in

the axle. Pullthe pinion gearoutward to

besure that the snap-ring seats properly.
NOTE: If you can't get the snap-ring into

the slot in the axle, press the pinion gear

morefirmly against the washer/seaL Do
not leaveoff shims.

15. Insert wheelscrew (A, Figure

5-18) through wheel (B),flat washer (C),
center hole in wheelshield (D), and
spacer (E). Thewheelshield has a double
edge on the rim. Positionthis side

toward the wheel.

16. Align pinion gear with the hole inthe

wheel shield. At the same time, align the
wheel screwwith the welded nut on the

wheel bracketand tighten securely.

19

PartsList Modo_909J

23

22

I

21

24

62

I

16

55

41

39 35

f

18

/

54

56

/ 63

/

59

52

/

36 F 49

48_ J

_48

i

tJ 45

I 34

/

/

56

59

2O

Mode 909J PartsList

Ref. # Part # Description Qty.

! 1917000 Mower Deck........................................... 1

2 Engine.................................................... 1

3 1917072 Support Bracket..................................... 1

4 1917045 Torsion Spring ....................................... 1

5 19!7044 Discharge Outlet Cover........................... 1

6 777S30145 Decal- Warning...................................... 1

7 19! 7086 Pin.......................................................... 1

8 1727342 FlangePush Nut,5/!6 dia ...................... 1

9 1754128 HexHd.FlangeScrew, 1/4-20 x 3/4,

Self-Thrd.............................................. 10

10 1918076 HexHd. Screw, 3/8-16 x 1-1/4,

Self-Thrd.............................................. 3

11 777D06222 Decal - Logo ........................................... 1

12 1918339 SpacerTube, Plastic............................... 1

13 777S32021 Decal- Warning, BeltCover ................... 1

14 1918223 BeltCover............................................... 1

15 1917088 HexHd. FlangeScrew, 1/4-20 x 2-1/4,

Self-Thrd.............................................. 1

16 1917002 DischargeOutlet Baffle........................... 1

17 1917071 SafetyFlap.............................................. 1

18 1917073 FlapRod................................................. 1

19 777S32022 Decal- Danger, BBCOpening................. 1

20 1918284 Rubber Extrusion................................... 1

2! 1917029 GrassCatcher Door................................ 1

22 1917030 GrassCatcher Frame.............................. 1

23 1918182 GrassCatcher Bag.................................. 1

24 1917084 Mulching Plug ........................................ I

25 1917056 Side-DischargeDeflector**. ................... 1

26 1917054 Mower Blade.......................................... 1

27 1917017 EnginePulley/BladeCouplerAssy.......... 1

28 GW-9928 BellevilleWasher, 1/2"............................ 1

29 1917060 Shoulder Screw, 3/8-24 x 1.65............... 1

30 1917005 V-Belt..................................................... I

31 GW-9302 SquareKey, .188x 1-1/4 ........................ 1

32 1746425 Rope Stop.............................................. 1

33 1917004 Transaxle................................................ I

34 1917038 HandleSupport Bracket, Lett-Hand........ I

Ref. #

35 1917018
36 1723037

Part# Description Qty.

37 1917014
38 1917079
39 1918323
40 1909380

1909382
41 GW-9516
42 1918322
43 777122012
44 1909044
45 1917003
46 1186309
47 1917009
48 GW-9552

49 1917032
50 1917037
51 1715127
52 1767754

53 720-0313
54 1917011
55 1917074
56 1909311
57 1917083
58 1765750
59 1903416
60 1917012
61 1185257
62 1917010
63 1765740
64 1917015
65 1917068

HandleSupport Bracket, Right-Hand...... 1

Hex Hd. FlangeScrew, 3/8-16 x 3/4,

Self-Thrd.............................................. 4

RearAxle Bearing................................... 2

Washer/Seal, Nylon................................ 2

Pinion Gear, Right-Hand......................... !

Shim, .016'L............................................ A/R

Shim, .062"............................................. A!R

Snap-Ring.............................................. 2

Pinion Gear, Lett-Hand........................... I

Decal- BladeCutting Height................... 1

Round Pin.............................................. 2

Transaxle Pulley..................................... I

Hex Hd. Screw, 114-2Ox 5/8, GR. 5 ....... I

CableMounting Bracket......................... I

Hex FlangeHd.Screw, I14-20 x I/2,

Self-Thrd.............................................. 2

DriveControl Cable................................ I

SpeedControl Cable/Lever..................... I

CableClamp ........................................... I

HexWasher Hd.FlangeScrew,

#10-24 x 112......................................... I

LeverGrip............................................... 1

RearAxleAssembly................................ 1

Spacer.................................................... 4

FlatWasher, .406" ID.............................. 4

Wheel Shield .......................................... 2

RearWheel/TireAssembly ..................... 2

Shoulder Screw, 3/8-16 x 2.42 ............... 4

Deck HeightAdjust Linkage.................... 1

E-Clip..................................................... 2

FrontAxle Assembly............................... I

FrontWheel/Tire Assembly .................... 2

FrontAxle Bearing.................................. 2

Compression Spring............................... !

Orderparts from your local authorized engine dealer. Refer to engine/model type nameplate on engine.

** Optional Equipment

A/R As Required.

21

PartsList Mode 9o9J

22

19

4

10

22

Ref. # Part# Description Qty.

!
2

3
4

5
6

7
8

9

10
11

1917021
1917026

1917036
1763767

1177038
1731025

1917087
1110108

1100068
1763682

1917050

Lower Handlebar.................................... 1

Upper Handlebar.................................... 1

HandlebarSupport Strut ........................ 2

HandlebarAdjustment Knob................... 4

Ext.Tooth Lock Washer, 5/!6 ................ 4

Curved HeadScrew, 5/16-18 x 1-3/4 ..... 2

CarriageBolt, 5/16-18 x 1-3/4, Special... 2

Hex Lock Nut, 3/8-16 ............................. 2

Hex Hd. Screw, 3/8-16 x 3/4, GR.5 ....... 2

CableTie................................................. 2

BailGrip ................................................. 1

Ref. # Part# Description Qty.

!2 1917053
!3 1917085

14 1917081
15 1918161

16 710-1205
!7 720-0279

!8 1917037
19 1917032

10 1908677
21 1917091

22 1917092

OperatorPresenceControl Bail .............. 1

Wheel Drive Bail..................................... 1

OperatorPresenceControl Cable........... 1

Decal- BailOperating Instructions ......... 1

RopeGuide............................................. 1

Wing Knob, 1/4-20 ................................ 1

Speed Control Lever/Cable..................... 1

DriveControl Cable................................ 1

Bushing, Nyliner..................................... 4

Hex Hd. Screw, M6................................. 1

Hex Nut, M6 ........................................... 1

Mod_909J Notes

MANUFACTURER'S LIMITED WARRANTY FOR:

0 TRIIKBILT°

The limited warranty set forth below is given by Troy-Bilt LLC
with respect to new merchandise purchased and used in the

United States, its possessions and territories.

Troy-Bilt LLC warrants this product against defects for a period
of two (2) years commencing on the date of original purchase

and will, at its option, repair or replace, free of charge, any part
found to be defective in materials or workmanship. This limited
warranty shall only apply if this product has been operated and
maintained in accordance with the Operator's Manual furnished
with the product, and has not been subject to misuse, abuse,

commercial use, neglect, accident, improper maintenance, alter-
ation, vandalism, theft, fire, water, or damage because of other
peril or natural disaster. Damage resulting from the installation
or use of any accesson/or attachment not approved by Troy-Bilt
LLC for use with the product(s) covered by this manual will void

your warranty as to any resulting damage.

Normal wear parts or components thereof are subject to
separate terms as follows: All normal wear parts or component
failures will be covered on the product for a period of 90 days

regardless of cause. After 90 days, but within the two year
period, normal wear part failures will be covered ONLY IF
caused by defects in materials or workmanship of OTHER
component parts. Normal wear parts and components include,
but are not limited to: batteries, belts, blades, blade adapters,

grass bags, rider deck wheels, seats, snow thrower skid shoes,
shave plates, auger spiral rubber, tires.

HOW TO OBTAIN SERVICE: Warranty service is available,
WITH PROOF OF PURCHASE, through your local authorized

service dealer. To locate the dealer in your area, check your
Yellow Pages, or contact Troy-Bilt LLC at P.O. Box 361131,
Cleveland, Ohio 44136-0019, 1-866-840-6483, or log on to our
Web site at www.troybilt.com.

This limited warranty does not provide coverage in the following
cases:

a. The engine or component parts thereof. These items

carry a separate manufacturer's warranty. Refer to the
applicable manufacturer's warranty for terms and cond

tions.

b. Log splitter pumps, valves, and cylinders have a separate

one year warranty.

c. Routine maintenance items such as lubricants, filters,

blade sharpening, tune-ups, brake adjustments, clutch
adjustments, deck adjustments, and normal deterioration of

the exterior finish due to use or exposure.

d. Troy-Bilt LLC does not extend any warranty for products

sold or exported outside of the United States, its pos-
sessions and territories, except those sold through Troy-
Bilt LLC's authorized channels of export distribution.

e. Parts that are not genuine Troy-Bilt parts are not covered by

this warranty.

f. Service completed by someone other than an authorized

service dealer is not covered by this warranty.

g. Transportation charges and service calls are not covered.

No implied warranty, including any implied warranty of mer-
chantability of fitness for a particular purpose, applies after

the applicable period of express written warranty above as
to the parts as identified. No other express warranty,
whether written or oral, except as mentioned above, given

by any person or entity, including a dealer or retailer, with
respect to any product, shall bind Troy-Bilt LLC. During the

period of the warranty, the exclusive remedy is repair or
replacement of the product as set forth above.

The provisions as set forth in this warranty provide the sole
and exclusive remedy arising from the sale. Troy-Bilt LLC

shall not be liable for incidental or consequential loss or
damage including, without limitation, expenses incurred for
substitute or replacement lawn care services or for rental

expenses to temporarily replace a warranted product.

Some states do not allow the exclusion or limitation of incidental
or consequential damages, or limitations on how long an implied

warranty lasts, so the above exclusions or limitations may not

apply to you.

In no event shall recovery of any kind be greater than the

amount of the purchase price of the product sold. Alteration of
the safety features of the product shall void this warranty.
You assume the risk and liability for loss, damage, or injury to

you and your property and/or to others and their property arising

out of the misuse or inability to use the product.

This limited warranty shall not extend to anyone other than the

original purchaser or to the person for whom it was purchased

as a gift.

HOW STATE LAW RELATES TO THIS WARRANTY: This

limited warranty gives you specific legal rights, and you

may also have other rights which vary from state to state.

TROY-BILT LLC, P.O. BOX 361131, CLEVELAND, OHIO 44136-0019, 1-866-840-6483