Yard-Man 500 User Manual
Safety • Set-Up • Operation • Adjustments • Maintenance • Troubleshooting • Parts Lists • Warranty
OPERATOR’S MANUAL
21” Self-Propelled Rotary Mower — Model Series 500
IMPORTANT:
READ SAFETY RULES AND INSTRUCTIONS
CAREFULLY BEFORE OPERATING EQUIPMENT.
PRINTED IN U.S.A. MTD Products Ltd., P. O. Box 1386, KITCHENER, ONTARIO N2G
This Operator’s Manual is an important part of your new equipment. It will help you assemble,
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prepare and maintain the unit for best performance. Please read and understand what it says.
Table of Contents
Slope Gauge........................................................ 3
Safe Operation Practices ................................... 4
Set-Up & Adjustments ........................................ 6
Operation ............................................................. 8
Maintenance ...................................................... 10
Finding and Recording Model Number
BEFORE YOU START ASSEMBLING
YOUR NEW EQUIPMENT,
please locate the model plate on the equipment and copy the
model number and the serial number to the sample model
plate provided to the right. You can locate the model plate by
standing at the operating position and looking down at the rear
of the machine.
Off-Season Storage .......................................... 11
Trouble Shooting ..............................................12
Warranty ............................................................ 13
Illustrated Parts Lists ....................................... 14
Customer Support
Please do
If you have difficulty assembling this product or have any questions regarding the controls, operation or maintenance of this unit,
you can seek help from the experts. Choose from the options below:
1. Visit www.mtdcanada.ca for many useful suggestions, click on Customer Support button.
2. Call a Customer Support Representative at 1-800-668-1238.
3. The engine manufacturer is responsible for all engine-related issues in terms of performance, power-rating, specifications,
warranty, and service. Depending on the engine manufacturer, more information is included in this publication or packed
separately with this product.
Please have your unit’s model number and serial number ready when you call. See previous section to locate this information.
You will be asked to enter the serial number in order to process your call.
NOT
return the unit to the retailer from which it was purchased,
without first contacting Customer Support.
2
1
Slope
Gauge
WARNING
Do not mow on inclines
with a slope in excess
of 15 degrees (a rise
of approximately
2-1/2 feet every 10
feet). A riding mower
could overturn and
cause serious injury.
If operating a walkbehind mower on such
a slope, it is extremely
difficult to maintain your
footing and you could
slip, resulting in serious
injury.
Operate RIDING
mowers up and down
slopes, never across
the face of slopes.
Operate
WALK-BEHIND
mowers across the
face of slopes, never
up and down slopes.
3
2
Safe
Operation
Practices
WARNING
This symbol points
out important safety
instructions which, if
not followed, could
endanger the personal
safety and/or property
of yourself and others.
Read and follow all
instructions in this
manual before attempting to operate
this machine. Failure
to comply with these
instructions may result
in personal injury. When
you see this symbol.
HEED ITS WARNING!
Your Responsibility
Restrict the use
of this power machine
to persons who read,
understand
and follow the warnings
and instructions
in this manual
and on the machine.
WARNING: Engine Exhaust, some of its constituents, and certain vehicle components contain
or emit chemicals known to the State of California to cause cancer and birth defects or other
reproductive harm.
DANGER: This machine was built to be operated according to the rules for safe operation in this manual. As with
any type of power equipment, carelessness or error on the part of the operator can result in serious injury. This
machine is capable of amputating hands and feet and throwing objects. Failure to observe the following safety
instructions could result in serious injury or death.
General Operation
1. Read this operator’s manual carefully in its entirety before
attempting to assemble this machine. Read, understand, and
follow all instructions on the machine and in the manual(s)
before operation. Keep this manual in a safe place for future
and regular reference and for ordering replacement parts.
2. Be completely familiar with the controls and the proper use of
this machine before operating it.
3. This machine is a precision piece of power equipment, not a
plaything. Therefore, exercise extreme caution at all times.
Your unit has been designed to perform one job: to mow grass.
Do not use it for any other purpose.
4. Never allow children under 14 years old to operate this
machine. Children 14 years old and over should read and
understand the instructions in this manual and should be
trained and supervised by a adult.
5. Only responsible individuals who are familiar with these rules
of safe operation should be allowed to use this machine.
6. Thoroughly inspect the area where the equipment is to be
used. Remove all stones, sticks, wire, bones, toys and other
foreign objects which could be tripped over or picked up
and thrown by the blade. Thrown objects can cause serious
personal injury.
7. Plan your mowing pattern to avoid discharge of material toward
roads, sidewalks, bystanders and the like. Also, avoid discharging material against a wall or obstruction which may cause
discharged material to ricochet back toward the operator.
8. To help avoid blade contact or a thrown object injury, stay
in the operator zone behind the handles and keep children,
bystanders, helpers and pets at least 75 feet from the mower
while it is in operation. Stop machine if anyone enters the area.
9. Always wear safety glasses or safety goggles during operation
and while performing an adjustment or repair to protect your eyes.
Thrown objects which ricochet can cause serious injury to the
eyes.
10. Wear sturdy, rough-soled work shoes and close-fitting slacks
and shirts. Shirts and pants that cover the arms and legs
and steel-toed shoes are recommended. Never operate this
machine in bare feet, sandals, slippery or light weight (e.g.
canvas) shoes.
11. Do not put hands or feet near rotating parts or under the cutting
deck. Contact with the blade can amputate hands and feet.
12. A missing or damaged discharge cover can cause blade
contact or thrown object injuries.
13. Many injuries occur as a result of the mower being pulled
over the foot during a fall caused by slipping or tripping. Do
not hold on to the mower if you are falling; release the handle
immediately.
14. Never pull the mower back toward you while you are walking. If
you must back the mower away from a wall or obstruction first
look down and behind to avoid tripping and then follow these
steps:
a. Step back from the mower to fully extend your arms.
b. Be sure you are well balanced with sure footing.
c. Pull the mower back slowly, no more than half way toward you.
d. Repeat these steps as needed.
15. Do not operate the mower while under the influence of alcohol or
drugs.
16. Do not engage the self-propelled mechanism on units so
equipped while starting engine.
17. The blade control handle is a safety device. Never attempt
to bypass its operation. Doing so makes the safety device
inoperative and may result in personal injury through contact with
the rotating blade. The blade control handle must operate easily
in both directions and automatically return to the disengaged
position when released.
18. Never operate the mower in wet grass. Always be sure of your
footing. A slip and fall can cause serious personal injury. If you
feel you are losing your footing, release the blade control handle
immediately and the blade will stop rotating within three seconds.
19. Mow only in daylight or in good artificial light. Walk, never run.
20. Stop the blade when crossing gravel drives, walks or roads.
21. If the equipment should start to vibrate abnormally, stop the
engine and check immediately for the cause. Vibration is generally a warning of trouble.
22. Shut the engine off and wait until the blade comes to a complete
stop before removing the grass catcher or unclogging the chute.
The cutting blade continues to rotate for a few seconds after the
engine is shut off. Never place any part of the body in the blade
area until you are sure the blade has stopped rotating.
23. Never operate mower without proper trail shield, discharge cover,
grass catcher, blade control handle or other safety protective
devices in place and working. Never operate mower with
damaged safety devices. Failure to do so, can result in personal
injury.
24. Muffler and engine become hot and can cause a burn. Do not
touch.
25. Never attempt to make a wheel or cutting height adjustment while
the engine is running.
26. Only use parts and accessories made for this machine by the
manufacturer. Failure to do so can result in personal injury.
27. When starting engine, pull cord slowly until resistance is felt, then
pull rapidly. Rapid retraction of starter cord (kickback) will pull
hand and arm toward engine faster than you can let go. Broken
bones, fractures, bruises or sprains could result.
28. If situations occur which are not covered in this manual, use care
and good judgment. Call customer assistance for the name of
your nearest servicing dealer.
Slope Operation
Slopes are a major factor related to slip and fall accidents which can
result in severe injury. Operation on slopes requires extra caution.
If you feel uneasy on a slope, do not mow it. For your safety, use
the slope gauge included as part of this manual to measure slopes
before operating this unit on a sloped or hilly area. If the slope is
greater than 15 degrees, do not mow it.
Do:
Mow across the face of slopes; never up and down. Exercise
1.
extreme caution when changing direction on slopes.
2. Watch for holes, ruts, rocks, hidden objects, or bumps which can
cause you to slip or trip. Tall grass can hide obstacles.
4
3. Always be sure of your footing. A slip and fall can cause serious
personal injury. If you feel you are losing your balance, release
the blade control handle immediately, and the blade will stop
rotating within 3 seconds.
Do Not:
1. Do not mow near drop-offs, ditches or embankments, you could
lose your footing or balance.
2. Do not mow slopes greater than 15 degrees as shown on the slope
gauge.
3. Do not mow on wet grass. Unstable footing could cause slipping.
Children
Tragic accidents can occur if the operator is not alert to the presence
of children. Children are often attracted to the mower and the mowing
activity. They do not understand the dangers. Never assume that
children will remain where you last saw them.
1. Keep children out of the mowing area and under the watchful
care of a responsible adult other than the operator.
2. Be alert and turn mower off if a child enters the area.
3. Before and while moving backwards, look behind and down for
small children.
4. Use extreme care when approaching blind corners, doorways,
shrubs, trees, or other objects that may obscure your vision of a
child who may run into the mower.
5. Keep children away from hot or running engines. They can suffer
burns from a hot muffler.
6. Never allow children under 14 years old to operate a power
mower. Children 14 years old and over should read and understand the operation instructions and safety rules in this manual
and should be trained and supervised by a parent.
Service
Safe Handling Of Gasoline:
1. To avoid personal injury or property damage use extreme care
in handling gasoline. Gasoline is extremely flammable and the
vapors are explosive. Serious personal injury can occur when
gasoline is spilled on yourself or your clothes which can ignite.
Wash your skin and change clothes immediately.
2. Use only an approved gasoline container.
3. Never fill containers inside a vehicle or on a truck or trailer bed
with a plastic liner. Always place containers on the ground away
from your vehicle before filling.
4. Remove gas-powered equipment from the truck or trailer and
refuel it on the ground. If this is not possible, then refuel such
equipment on a trailer with a portable container, rather than from
a gasoline dispenser nozzle.
5. Keep the nozzle in contact with the rim of the fuel tank or
container opening at all times until fueling is complete. Do not
use a nozzle lock-open device.
6 Extinguish all cigarettes, cigars, pipes and other sources of
ignition.
7. Never fuel machine indoors because flammable vapors will
accumulate in the area.
8. Never remove gas cap or add fuel while the engine is hot or run
ning. Allow engine to cool at least two minutes before refueling.
9. Never over fill fuel tank. Fill tank to no more than ½ inch below
bottom of filler neck to provide for fuel expansion.
10. Replace gasoline cap and tighten securely.
11. If gasoline is spilled, wipe it off the engine and equipment. Move
unit to another area. Wait 5 minutes before starting the engine.
12. Never store the machine or fuel container near an open flame,
spark or pilot light as on a water heater, space heater, furnace,
clothes dryer or other gas appliances.
-
13. To reduce fire hazard, keep mower free of grass, leaves, or
other debris build-up. Clean up oil or fuel spillage and remove
any fuel soaked debris.
14. Allow a mower to cool at least 5 minutes before storing.
General Service:
1. Never run an engine indoors or in a poorly ventilated area.
Engine exhaust contains carbon monoxide, an odorless and
deadly gas.
2. Before cleaning, repairing, or inspecting, make certain the
blade and all moving parts have stopped. Disconnect the spark
plug wire and ground against the engine to prevent unintended
starting.
3. Check the blade and engine mounting bolts at frequent
intervals for proper tightness. Also, visually inspect blade for
damage (e.g., bent, cracked, worn) Replace blade with the
original equipment manufacture’s (O.E.M.) blade only, listed
in this manual. “Use of parts which do not meet the original
equipment specifications may lead to improper performance
and compromise safety!”
4. Mower blades are sharp and can cut. Wrap the blade or wear
gloves, and use extra caution when servicing them.
5. Keep all nuts, bolts, and screws tight to be sure the equipment
is in safe working condition.
6. Never tamper with safety devices. Check their proper operation
regularly.
7. After striking a foreign object, stop the engine, disconnect the
spark plug wire and ground against the engine. Thoroughly
inspect the mower for any damage. Repair the damage before
starting and operating the mower.
8. Never attempt to make a wheel or cutting height adjustment
while the engine is running.
9. Grass catcher components, discharge cover, and trail shield
are subject to wear and damage which could expose moving
parts or allow objects to be thrown. For safety protection,
frequently check components and replace immediately with
original equipment manufacturer’s (O.E.M.) parts only, listed
in this manual. “Use of parts which do not meet the original
equipment specifications may lead to improper performance
and compromise safety!”
10. Do not change the engine governor setting or overspeed the
engine. The governor controls the maximum safe operating
speed of the engine.
11. Check fuel line, tank, cap, and fittings frequently for cracks or
leaks. Replace if necessary.
12. Do not crank engine with spark plug removed.
13. Maintain or replace safety labels, as necessary.
14. Observe proper disposal laws and regulations. Improper
disposal of fluids and materials can harm the environment.
Do not modify engine
To avoid serious injury or death, do not modify engine in any way.
Tampering with the governor setting can lead to a runaway engine
and cause it to operate at unsafe speeds. Never tamper with
factory setting of engine governor.
Average Useful Life
According to the Consumer Products Safety Commission (CPSC)
and the U.S. Environmental Protection Agency (EPA), this product
has an Average Useful Life of seven (7) years, or 60 hours of
operation. At the end of the Average Useful Life, buy a new
machine or have the machine inspected annually by an authorized
service dealer to ensure that all mechanical and safety systems
are working properly and not worn excessively. Failure to do so can
result in accidents, injuries or death.
2
Safe
Operation
Practices
WARNING
This machine is equipped
with an internal combustion engine and should
not be used on or near
any unimproved forestcovered, brushcovered or
grass-covered land unless
the engine’s exhaust
system is equipped with a
spark arrester meeting applicable local or provincial
laws (if any).
If a spark arrester is used,
it should be maintained in
effective working order by
the operator.
A spark arrester for the muffler is available through your
nearest engine authorized
service dealer.
Notice regarding Emissions
Engines which are certified
to comply with California
and federal EPA emission
regulations for SORE (Small
Off Road Equipment) are
certified to operate on regular unleaded gasoline, and
may include the following
emission control systems:
Engine Modification (EM)
and Three Way Catalyst
(TWC) if so equipped.
5
3
Setup and
Adjustment
Figure 1
NOTE: Reference to
right, left, front and rear
of the lawn mower is in
relation to the operating
position.
IMPORTANT
Make sure to route
cable outside the
lower handle. Do not
crimp cable while
lifting the handle up.
IMPORTANT
This unit is shipped
without gasoline or
oil in the engine. Fill
up gasoline and oil
as instructed in the
accompanying engine
manual BEFORE
operating your mower.
Figure 2
Figure 3
Figure 4
6
3
Setup and
Adjustment
Figure 6
WARNING
2
1
3
Figure 7
Figure 8
7
4
Operating
Your Lawn
Mower
WARNING
Read, understand,
and follow all instructions and warnings
on the machine and
in this manual before
operating.
Know Your Lawn Mower
Figure 9
This blade control
mechanism is a
safety device. Never
attempt to bypass its
operations.
Use extreme care
when handling
gasoline. Gasoline is
extremely flammable
and the vapors are
explosive. Never fuel
the machine indoors
or while the engine
is hot or running.
Extinguish cigarettes,
cigars, pipes and
other sources of
ignition.
Blade Control Handle
The blade control handle is located on the upper handle
of the mower. See Figure 9. The blade control handle
must be depressed in order to operate the unit. Release
the blade control handle to stop the engine and blade.
Drive Control Handle
The drive control handle is located on the upper handle.
Squeeze the drive control handle against the upper
handle to engage drive system. Release the control
handle to disengage the drive system in order to stop,
slow down, or backup.
Mulching Plug (optional)
The mulching plug is used to close the side discharge
chute opening when mulching or bagging grass. Do
not remove the hinged mulching plug at any time, even
when you are not mulching.
Recoil Starter
The recoil starter is attached to the right upper handle.
Stand behind the unit and pull the recoil starter rope to
start the unit.
Cutting Height Adjustment Levers
One adjustment lever is located on each wheel and is
used to adjust the cutting height. All four levers have to be
at the same relative position to ensure uniform cut.
Before Starting
1. Service the engine with gasoline and oil as instructed
in the separate engine manual.
2. Attach spark plug wire to spark plug. If unit is
equipped with a rubber boot over the end of the spark
plug wire, make certain the metal loop on the end of
the spark plug wire (inside the rubber boot) is fastened
securely over the metal tip on the spark plug.
3. Before each use, check for proper drive clutch operation by performing the following before starting the
engine:
a. With the drive control released, push mower
forward. It should move freely. Pull mower backward. It should move with only a small amount of
resistance.
8
Figure 10
/.
/&&
b. If it does not the clutch may not be releasing
completely. Do not start the engine until corrections have been made. Check the control cable
for severe bend, kinks and binding. Also check for
grass build-up around the belt.
To Start Engine
1. If your unit is equipped with a primer, choke or fuel
valve lever operate as instructed in the separate
engine manual packed with your unit.
2. Standing behind the unit, depress the blade control
handle and hold it against the upper handle as shown
in Figure 10.
3. Grasp the starter handle as shown and pull slowly
until resistance is felt, then pull rapidly to start engine
and avoid kickback. Return it slowly to the rope guide.
To Stop Engine
1. Release the blade control handle to stop the engine
and blade.
WARNING: The blade continues
to rotate for a few seconds after
the engine is shut off.
2. Disconnect and ground the spark plug wire as
instructed in the separate engine manual to prevent
accidental starting while equipment is unattended.
Using Your Lawn Mower
Be sure the lawn is clear of stones, sticks, wire, or other
objects which could damage the lawn mower or the
engine. Such objects could be accidently thrown by the
mower in any direction and cause serious personal injury
to the operator and others.
WARNING: If you strike a foreign
object, stop the engine. Remove
wire from the spark plug, thoroughly inspect the mower for any
damage, and repair the damage
before restarting and operating
the mower. Extensive vibration
of the mower during operation is
an indication of damage. The unit
should be promptly inspected
and repaired.
Operating Tips
1. To engage the drive, squeeze the drive control handle
towards the upper handle. Release the drive control
to slow down when negotiating an obstacle, making a
turn, or stopping.
2. For best results do not cut wet grass.
3. New grass, thick grass, or wet grass may require a
narrower cut.
4. For a healthier lawn, never cut off more than one-third
of the total length of the grass.
5. Your lawn should be cut in the fall as long as there
is growth.
6. If the grass has been allowed to grow in excess of 4
inches, mulching is not recommended. Mow using
the side discharge to reduce the grass height to 3-1/4
inches or less before mulching.
General Recommendations
1. Always observe safety rules when performing
any maintenance.
2. The warranty on this lawn mower does not cover
items that have been subjected to operator abuse
or negligence. To receive full value from warranty,
operator must maintain the lawn mower as
instructed here.
3. Changing of engine-governed speed will void
engine warranty.
4. All adjustments should be checked at least once each
season.
5. Periodically check all fasteners and make sure these
are tight.
NOTE: To operate your unit using the grass catcher,
mulcher or optional side discharge refer to page 7.
4
Operating
Your Lawn
Mower
WARNING
The operation of any
lawn mower can result
in foreign objects
being thrown into
the eyes, which can
damage your eyes
severely. Always wear
safety glasses while
operating the mower,
or while performing
any adjustments or
repairs on it.
Be sure no one other
than the operator is
standing near the lawn
mower while starting
engine or operating
mower. Never run
engine indoors or
in enclosed, poorly
ventilated areas. Engine exhaust contains
carbon monoxide, an
odorless and deadly
gas. Keep hands, feet,
hair and loose clothing
away from any moving
parts on engine and
lawn mower.
9
The deck may be cleaned by tilting the mower and scraping clean with a suitable tool (make certain the spark plug
wire is disconnected).
5
WARNING
Figure 5-1
Lubrication
1. Lubricate the pivot points on the blade control handle
at least once a season with light oil. The blade
control must operate freely in both directions. See
Figure 5-1.
2. If your mower is equipped with ball bearing wheels,
lubricate at least once a season with a light oil, all
other types require no lubrication. However, if the
wheels are removed for any reason, lubricate the
surface of the axle bolt and the inner surface of the
wheel with light automotive oil.
3. Lubricate the torsion spring and pivot point periodi
cally with light oil to prevent rust. See Figure 5-1.
4. The transmission is pre-lubricated and sealed at the
factory and does not require lubrication.
-
Replacing Rear Flap
The rear flap is attached to the back of the mower deck. If
the rear flap becomes damaged, replace it by cutting off
the flat end of the wire rod which secures it to the deck
using a pair of side-cutters. Attach the new rear flap using
the new rod provided with the rear flap, bending the ends
of the rod over to secure.
Blade Care
Periodically inspect the blade adapter for cracks,
especially if you strike a foreign object. Replace when
necessary. Follow the steps below for blade service:
1. Remove the bolt and the blade bell support which
hold the blade and the blade adapter to the engine
crankshaft. See Figure 5-2.
Figure 5-2
Engine
1. Refer to the separate engine manual for engine
maintenance instructions.
2. Maintain engine oil as instructed in the separate
engine manual packed with your unit. Read and
follow instructions carefully.
3. Service air cleaner every 25 hours under normal
conditions. Clean every few hours under extremely
dusty conditions.
4. Clean the engine regularly with a cloth or brush.
Keep the cooling system (blower housing area)
clean to permit proper air circulation which is essential to engine performance and life. Be certain to
remove all grass, dirt and combustible debris from
muffler area.
Deck
The underside of the mower deck should be cleaned
after each use to prevent a buildup of grass clippings,
leaves, dirt or other matter. If this debris is allowed to
accumulate, it will invite rust and corrosion, and may
prevent proper mulching.
10
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