Yard-Man 567 Operator's Manual

Operator's Manual

21" Self Propelled

Mulching Mower

Model 567

IMPORTANT: Read safety rules and instructions carefully before operating equipment.

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 through your nearest engine authorized service dealer or contact the service department, P.O. Box 361131 Cleveland, Ohio 44136-0019.

MTD LLC, P.O.BOX361131CLEVELAND,0HI0 44136-0019

PRINTED IN U.S.A.

FORM NO. 769-00981

(11/2003)

TABLEOFCONTENTS

Content

Important Safe Operation Practices Slope Gauge Assembling Your Lawn Mower

Know Your Lawn Mower Operating Your Lawn Mower

Maintaining Your Lawn Mower

Page Content Page

3 Service &Adjustments 13 6 Off Season Storage 14

7 Trouble Shooting 15 9 Illustrated Parts List 16

10 Engine Manual 18 11 Warranty 32

FINDINGMODELNUMBER

This Operator's Manual is an important part of your new lawn 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 information from it in the space provided below. A sample model plate is also given below. You can locate the model plate by standing at the operating position and looking down at the rear of the deck. This information will be necessary to use the manufacturer's web site and/or help from the Customer Support Department or an authorized

service dealer.

Copy the model number here:

YaRD-MaN,I(Po°ox=o,,=,

vwwv.yardman.com 338-228-4683

MTD LLC

CLEVELAND,OH 44136

888-888-7318

Copy the serial number here:

CUSTOMERSUPPORT

Please doNOTretum theunit to theretailer fromwhereit waspurchased,withoutfirstcontactingCustomerSupport.

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:

Visit yardman.com for many useful suggestions. Click on Customer Support button and you will get the four options reproduced here. Click on the appropriate button and help is immediately available.

answer you are

looking for could be just

a mouse c//cA awayf

'r f

L<}_i_kto cl_eck tie stat_ls of yo_ _l_esli<>l_

If you prefer to reach a Customer Support Representative, please call 1-800-800-7310.

answer are

looking for could be just

a mouse c//cA away!

'r f

The engine manufacturer is responsible for all engine-related issues with regards to

M nual

_JEn ine

performance, power-rating, specifications, warranty and service. Please refer to the engine manufacturer's manual at the end of this manual for more information.

SECTION1: IMPORTANTSAFEOPERATIONPRACTICES

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.

WARNING" Engine exhaust, some of its constituents, and certain vehicle components contain or emit

chemicals known to State of California to cause cancer and birth defects or other reproductive harm.

WARNING" 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.

GeneralOperation

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. Be

completely familiar with the controls and the proper use of this machine before operating it. Keep this manual in a safe place for future and regular reference and for ordering replacement parts.

2. 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.

3. Never allow children under 14 years old to operate this machine. 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. Only responsible individuals who are familiar with these safe operation rules should use this machine.

4. Thoroughly inspect the area where 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. 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.

5. To help avoid blade contact or a thrown object injury, stay in the operator zone behind the handles and keep bystanders, helpers, children and pets at

least 75 feet from the machine while it is in operation. Stop machine if anyone enters the area.

6. Always wear safety glasses to protect your eyes during equipment operation and while performing an adjustment or repair. Thrown objects which ricochet can cause serious injury to the eyes.

7. 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.

8. Do not put hands or feet near rotating parts or

under the cutting deck. Contact with the blade can

amputate hands and feet.

9. A missing or damaged discharge cover can cause

blade contact or thrown object injuries.

10. 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.

11. 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.

5. Do not operate the mower while under the influence of alcohol or drugs.

6. Do not engage the self-propelled mechanism on

units so equipped while starting engine.

7. 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.

8. 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

yourfooting,releasethebladecontrolhandle immediatelyandthebladewillstoprotatingwithin

threeseconds.

9. Mowindaylightorgoodartificiallight;walk,notrun.

10.Stopthebladewhencrossinggraveldrives, walkwaysorroads.

11.Iftheequipmentshouldstarttovibrateabnormally,

stoptheengineandcheckimmediatelyforthe cause.Vibrationisgenerallyawarningoftrouble.

12.Shuttheengineoffandwaituntilthebladecomes

toacompletestopbeforeremovingthegrass catcheroruncloggingthechute.Thecuttingblade

continuestorotateforafewsecondsafterthe engineisshutoff.Neverplaceanypartofthebody

inthebladeareauntilyouaresurethebladehas stoppedrotating.

13.Neveroperatemowerwithoutpropertrailshield,

dischargecover,grasscatcher,bladecontrol handleorothersafetyprotectivedevicesinplace andworking.Neveroperatemowerwithdamaged safetydevices.Failuretodosocanresultin personalinjury.

14.Mufflerandenginebecomehotandcancausea

burn.Donottouch.

15.Onlyusepartsandaccessoriesmadebythe

originalequipmentmanufacturer(O.E.M).Failure todosocanresultinpersonalinjury.

16.Ifsituationsoccurwhicharenotcoveredinthis

manual,usecareandgoodjudgment.Contactyour dealerforassistance.Telephone1-800-800-7310

forthenameofyournearestdealer.

SlopeOperation

Slopes are a major factor related to slip and fall accidents which can result in severe injury. Operation on slopes requires extra caution. Ifyou feel uneasy on a slope, do not mow it. Before operating this unit on a slope or hilly area, use the slope gauge on page 6 to measure slopes. If the slope is greater than 15 degrees,

do not mow it.

Do:

Mow across the face of slopes; never up and down. Exercise caution when changing direction.

Watch for holes, ruts, rocks, hidden objects, or bumps which can cause you to slip or trip. Tall grass can hide obstacles.

Always be sure of your footing. A slip and fall can cause serious personal injury. Ifyou feel you are losing your balance, release the blade control handle immediately, and the blade will stop rotating

within 3 seconds.

DoNot:

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

SafeHandlingofGasoline:

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.

2. Wash your skin and change clothes immediately.

3. Use only an approved gasoline container.

4. Never fill containers inside avehicle or on a truck or trailer bed with a plastic liner. Always place

containers on the ground away from your vehicle

before filling.

5. Ifpossible, 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.

6. 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.

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

8. Never fuel machine indoors because flammable vapors will accumulate in the area.

9. Neverremovegascaporaddfuelwhiletheengine ishotorrunning.Allowenginetocoolatleasttwo minutesbeforerefueling.

10.Neveroverfillfueltank.Filltanktonomorethan½ inchbelowbottomoffillernecktoprovidespacefor

fuelexpansion.

11.Replacegasolinecapandtightensecurely.

12.Ifgasolineisspilled,wipeitofftheengineand equipment.Moveunittoanotherarea.Wait5 minutesbeforestartingtheengine.

13.Neverstorethemachineorfuelcontainerinside

wherethereisanopenflame,sparkorpilotlightas

onawaterheater,spaceheater,furnace,clothes dryerorothergasappliances.

14.Toreducefirehazard,keepmowerfreeofgrass, leaves,orotherdebrisbuild-up.Cleanupoilorfuel spillageandremoveanyfuelsoakeddebris.

15.Allowamowertocoolatleast5minutesbefore storing.

GeneralService:

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 aforeign 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. Maintain or replace safety and instruction labels, as

necessary.

12. Observe proper disposal laws and regulations.

Improper disposal of fluids and materials can harm

the environment.

YourResponsibility

• 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.

DAN@ER

/ WARNINGo

i,II

I.I.I

SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE

A POWER POLE

A CORNER OF A BUILDING

15 °

,_ 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 walk-behind 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.

SECTION3: ASSEMBLINGYOURLAWNMOWER

RemovingUnitFromCarton

• Remove staples, break glue on top flaps, or cut

tape at carton end and peel along top flap to open.

• Remove loose parts included with unit (i.e.,

operator's manual, oil, etc.).

• Cut corners and lay carton down flat. Remove

packing material.

• Roll or slide unit out of carton. Check carton

thoroughly for loose parts.

NOTE: Make sure not to crimp cables while removing loose parts or the entire unit from the carton.

ToolsRequired

• Pair of Pliers

• Funnel

NOTE: Reference to right or left hand side of the mower and/or front or behind the mower is observed from the

operating position.

HardwarePack

Please identify each piece of the hardware pack as shown in figure here.

Wing

Nut (2)

Carriage Bolt (2)

Raise the lower handle in the direction shown in Figure 1 (step 2) till it snaps into place.

Raise the upper handle in the direction shown in Figure 1 (step 3). Tighten the wing nuts which are

already on the handle. See Figure 2.

_ Upper Handle

_!_ower Handle

i/-

i , htenth,s

Figure 2

NOTE: Make sure to route the cables inside the lower

handle. Also do not crimp the cables while lifting the handle up.

• For shipping purposes, the hairpin clip is placed in the outer hole of the weld pin on the lower handle.

Remove the hairpin clip from the outer hole of the

weld pin. See Figure 3.

• Using a pair of pliers, insert the hairpin clip into the

inner hole on the weld pin. Repeat on other side.

See Figure 3.

DisconnectingSparkPlug

• Before setting up your lawn mower, disconnect the spark plug wire from the spark plug.

AssemblingHandle

• Remove grass bag from the unit and set it out of the

way. See Figure 1 (step 1).

• Remove any packing material which may be between the upper and lower handles for shipping purposes.

2. Lift lower handle

Move bag

away

3. Lift upper handle

Figure 1

Carriage Bolt

Wing Nut

Hairpin ClipF%_

• Insert the carriage bolt, included in the hardware pack, in the upper hole on the handle mounting bracket (carriage bolt must go to the inside of handle). Secure with one plastic wing nut, also included in the hardware pack. Repeat on the other

side with remaining items from the hardware pack.

• Attach cables to the lower handle with the two cable

ties already on the lower handle. Insert pegs on cable ties into the holes on the lower handle. Pull

cable ties tight and cut off the extra.

.d_dandle

Mounting Bracket

Figure 3

AttachingStarterRope

The rope guide is already attached to the right side of the upper handle of your mower. See Figure 4.

• With spark plug wire disconnected and grounded, hold the blade control handle against the upper handle, and pull the starter rope out of the engine.

• Slip the rope through the rope guide as shown below. Tighten the wing nut holding the rope guide to the upper handle.

\\ Wing Nut

Starter ...... f/_ \ \ _,/ Upper

_ll ARNING: When using the mower to baggrass clippings, make sure the hooks on the

grass catcher are firmly seated on the chute

pivot rod, and the rear discharge door rests

firmly against the top of the grass catcher.

AttachingHardTopCover(ifEquipped)

• Slide the hardtop cover under the grass catcher handle, positioning it so the handle rests snugly into

the notch in the cover, and press the frame into the tabs at the back of the cover. See Figure 6.

Rope Guid

Rope e__re_\_ I'lanale

Figure 4

AssemblingGrassCatcher

NOTE: If the grass catcher came pre-assembled,

proceed to the next section. If not, follow the steps below to assemble it before attaching to the mower.

Insert frame into grass bag with the black plastic side on the bottom of bag. See Figure 5.

Grass Catcher

Plastic

Channel

Insertframe

Grass Catcher Assembly Complete

Grass Catcher

Self Tapping

Screws

Bracket

Figure 6

Position the mounting bracket facing down between the front of the handle and the front of the

hardtop cover so that the holes in the cover line up

with the holes in the bracket. Insert the self tapping screws down through the hardtop cover and

mounting bracket.

AttachingGrassCatcher

• Lift the rear discharge door and place the grass

catcher on the pivot rod. Let go of discharge door so that it rests on the grass catcher. See Figure 7.

Rear Discharge Door

Figure 5

Slip the openings in the side of the plastic channel on bag over the hooks on the grass catcher frame. Secure bag to the frame by working the six plastic channels on bag over frame. All of the plastic channels except the center top of the bag attach

from the outside of bag. The center top of the bag

attaches from inside the bag. See Figure 5.

Figure 7

Converting To Mulcher

• Lift the rear discharge door on the mower and lift

the grass catcher up. Release the discharge door to allow it to close the rear opening of the mower.

Do not remove the side mulching plug at any time,

even when you are not mulching.

MulchingPlug

ConvertingToSideDischarge

• Make sure the grass catcher is off the unit and the rear discharge door is closed. Refer to Figure 8.

• On the side of the mower, lift the mulching plug. See Figure 8.

• Slide the two hooks of the side-discharge chute under the hinge pin on the mulching plug assembly. Lower the side mulching plug.

SECTION4: KNOWYOURLAWNMOWER

Read this owner's manual and safety rules before operating your lawn mower. Compare the illustrations in Figure 9 with your lawn mower to familiarize yourself with the location of various controls and adjustments.

Save this manual for future reference.

,i_ WARNING" The operation of any lawn

StarterRope

The starter rope is attached to the handle. Stand behind the unit and pull the starter rope to start the unit.

BladeControlHandle

The blade control handle is located on the upper handle of the mower. The blade control handle must be

depressed in order to operate the unit. Release the blade control handle to stop the engine and the blade.

mower can result in foreign objects being thrown into the operator's eyes thus causing severe eye damage. Always wear safety glasses while operating the mower, or while performing any adjustments or repairs on it.

Hinge

Hooks

(Slide hooks under the two sides of hinge pin)

Figure 8

Control Handle

Cutting Height

Adjustment Levers

,i_ WARNING" The blade control handle is a

Lower Bail Handle The lower bail handle is located on the upper handle

and is used to engage the drive. Squeeze the lower bail handle against the upper handle to engage the drive; release it to slow down or stop the mower from propelling.

Cutting HeightAdjustmentLever These levers are located on each wheel and they are

used to adjust the cutting height. All four levers have to be at the same relative position to ensure uniform cut.

safety device. Never attempt to bypass its operations or alter it in any way.

Bag

Side-Discharge

Chute

Plug

NOTE: For engine controls, please refer to

the engine manual.

Figure 9

MulchingPlug

The mulching plug is used only for mulching purposes.

Instead of collecting the grass clippings in a grass catcher, your mower has the option of recirculating the clippings back to the lawn. Make sure that the rear discharge door is closed and the grass catcher is removed from the unit while mulching.

SECTION5: OPERATINGYOURLAWNMOWER

NOTE: See page 23 of this manual for more detailed instructions on starting the engine.

,_ WARNING" Read and understand all

Gas&OilFill-Up

• Check oil level and add oil if necessary. Follow

• Service the engine with gasoline as instructed in

,_ WARNING" Use extreme care when

BeforeStartingMower

• Attach spark plug wire to spark plug. Make certain

instructions and warnings on the machine and in this manual before operating.

relevant instructions in the engine manual for this.

the engine manufacturer's manual at the end of this manual.

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.

the metal cap on the end of the spark plug wire (inside the rubber boot) is fastened securely over the metal tip on the spark plug.

ToStopEngine

• Release the blade control handle to stop the engine and blade.

• Disconnect spark plug wire and ground it against the engine to prevent accidental starting while equipment is unattended.

UsingYourLawnMower

• You can use your mower as a mulcher or a rear

bagger or for side discharge of grass.

• Be sure that the lawn is clear of stones, sticks, wire, or other objects which could damage lawn mower

or engine. Such objects could be accidently thrown

by the mower in any direction and cause serious personal injury to the operator and others.

• For best results, do not cut wet grass because it tends to stick to the underside of the mower.

• For a healthy lawn, always cut off one-third or less of the total length of the grass. Lawn should be trimmed in fall as long as there is growth.

ThrottleSpeed

Your lawn mower engine is equipped with a constant speed throttle, which is set at full throttle for best performance.

StartingEngine

,_ WARNING" Be sure no one other than theoperator is standing near the lawn mower while

starting engine or operating mower.

WARNING: Never run engine indoors or in

enclosed, poorly ventilated areas. Engine exhaust contains carbon monoxide, an

odorless and deadly gas.

WARNING: Keep hands, feet, hair and

loose clothing away from any moving parts on engine and lawn mower.

Push primer once. Do not prime to restart a warm engine after a short shutdown. Standing behind the mower, depress the blade control handle and hold it against the upper handle. Grasp starter handle and pull rope out slowly until engine reaches the start of compression cycle (rope will pull slightly harder at this point). Let the rope rewind slowly. Pull rope with a rapid, continuous, full arm stroke. Keeping a firm grip on the starter handle, let the rope rewind slowly.

,_ WARNING: If the mower strikes a foreignobject, stop the engine. Remove spark plug

wire from the spark plug and thoroughly inspect for any damage. Repair the damage promptly

before restarting and operating the mower.

AdjustingCuttingHeight

Refer to height adjustments section of this manual on page 14 for instruction on how to adjust the cutting height and the handle height.

For best results in mowing, keep the cutting height position high until you can determine a suitable height.

BaggingGrassClippings

You can use the grass catcher bag to collect clippings while you are operating the mower.

• Attach grass catcher following instructions on page

8. Grass clippings will automatically collect in the

bag as you run the mower. Operate the mower till

the grass bag isfull.

• Stop engine completely by releasing the blade control handle. Make sure that the unit has come to

a complete stop.

• Lift discharge door and pull grass bag up and away from the mower to dispose of the grass clippings.

SECTION6: MAINTAININGYOURLAWNMOWER

,_ WARNING" Always stop the engine anddisconnect the spark plug wire before

performing any maintenance work or adjustments on your lawn mower.

CleaningMower

The underside of the mower deck should be cleaned after each use to prevent any build-up of grass

clippings, leaves, dirt, or other debris. If this debris is allowed to accumulate, it will result in rust and corrosion.

NOTE: We do not recommend the use of pressure washers or garden hose to clean your unit. These may cause damage to pulleys, bearings, or the engine. The

use of water will result in shortened life and reduce serviceability.

• Disconnect spark plug wire.

• Drain the gasoline from the lawn mower, or place a piece of plastic under the gas cap.

• Tip the mower so that it rests on the housing. Keep the side with the air cleaner facing up. Hold the mower firmly.

• Scrape and clean the underside of the deck with a suitable tool. Do not spray with water.

• Put the mower back on its wheels on the ground. If you had put plastic under the gas cap, make sure to

remove it now.

,i_ WARNING: Avoid muffler and surrounding

areas while the mower engine is hot because

temperature of these areas of the engine may

exceed 150°F.

Lubrication

Lube

,_ WARNING" Never tip the mower more than

90 degrees in any directions and do not leave the mower tipped for any length of time. Oil can drain into the upper part of the engine causing a starting problem.

EngineCare

A list of key maintenance jobs required for good performance by the mower is given below. Follow the engine manufacturer's manual at the end of this manual

for a detailed list and instructions.

• Change engine oil regularly, as instructed in the engine manual. Check oil level before starting engine every time.

• Service air cleaner regularly. You may have to service this more frequently ifyou are operating the mower under extremely dusty conditions.

• Clean the engine periodically. Remove dirt and debris with a cloth or brush.

• Clean the spark plug and reset the gap to.030" at least once a season. Refer to the engine manual for correct spark plug type.

• Inspect muffler periodically, and replace if necessary. Damaged mufflers or spark arresters

can create a fire hazard.

Figure 10: Lubrication Chart

Wheels

• Lubricate the wheels and bearings, if so equipped, at least once a season with light oil or engine oil. Also, if the wheels are removed for any reason,

lubricate the surface of the pivot arm axle and the inner surface of the wheel with light oil.

MulchPlug & RearDischargeDoor

• Lubricate the torsion spring and the pivot point on each end of the rear discharge door using a light oil.

Transmission

• The transmission is pre-lubricated and sealed at the factory and does not require lubrication on a

regular basis as part of maintenance.

BladeControl

• Lubricate the pivot points on the blade control

handle and the brake cable at least once a season

with light oil. The blade control must operate freely

in both directions.

Engine

• Follow the engine manual instructions at the end of

this manual and recommended schedule for lubricating engine components.

BladeCare

• Periodically inspect the blade adapter and pulley for cracks, especially if you strike a foreign object.

Replace when necessary.

_ WARNING" When removing the cuttingblade for sharpening or replacement, protect

hands by using heavy gloves or a thick rag to grasp the cutting blade.

• Disconnect spark plug wire from spark plug.

• Turn mower on its side making sure that the air filter

and the carburetor are up.

To RemoveBlade:

• Remove the hex bolt which holds the blade

adapter-pulley assembly to the engine crankshaft. See Figure 11. Remove the pulley assembly and the bell support from the crankshaft. Remove blade from the blade adapter and pulley.

Adapter-Pulley

Assembly

BladJ

To ReplaceBlade:

• Before reinstalling the blade-pulley assembly to the unit, lubricate the engine crankshaft and the inner

surface of the blade adapter with light oil.

• Also lubricate the bolt hole and the hex bolt.

• Insert the hex bolt, earlier removed, through the

center holes on the blade bell support and the

blade adapter-pulley assembly respectively.

• Install the blade assembly on the crankshaft.

Tighten the hex bolt to the recommended torque.

Blade Mounting Torque:

Center bolt: 450 in.lbs, minimum, 600 in.lbs, maximum.

To Sharpen Blade:

• The blade can be sharpened with a file or on a

grinding wheel. Do not attempt to sharpen the

blade while it is still on the mower.

• Follow the original angle of grind as a guide. Make

sure that each cutting edge receives an equal amount of grinding to prevent an unbalanced blade.

NOTE: An unbalanced blade will cause excessive vibration when rotating at high speeds, may cause

damage to the mower and could break, causing

personal injury. Test the blade by balancing it on a

round shaft screwdriver or a blade balancer.

• If the blade is not balanced, remove metal from the heavy side until it balances evenly.

Blade Bell

Support

Hex Bolt

Figure 11

SECTION7: SERVICE& ADJUSTMENTS

ReplacingDriveBelt

• Remove two shoulder screws securing the front drive cover to the mower deck. See Figure 12.

Loosen this screw

Shoulder

_Screw

Transmission

• Press inward on the sides of the front drive cover and release the tabs that secure the front drive

cover to the height adjuster brackets. Remove drive cover from the mower.

• Using a torx wrench, loosen the screw holding the belt tension spring to the transmission. See Figure

12. Do not remove the screw completely. As you loosen the screw, tension on the belt will release.

• Push the transmission up a little and slide the belt off the transmission pulley.

• Lift the mower to access the belt from the underside of the mower.

,_ WARNING" Use a thick piece of rag to

• Slide the belt off the engine pulley and around the

• Replace with the new belt, working around the

• Put the mower down with all four wheels firmly

handle the blade while sliding the belt in the next step. Make sure the engine does not start at all while doing this job.

blade. See Figure 13.

blade. Make sure the belt is firmly seated on the engine pulley while pulling from the other side and sliding it around the transmission pulley.

placed on one level.

Screw

Figure 12

Front Drive Cover

Tighten the screw, loosened earlier, to secure the

belt tension spring to the transmission, and reassemble the front drive cover.

Right Front Left Front Wheel _ Wheel

Figure 13

ReplacingRearFlap

• To remove rear flap, cut off the flat end of the wire rod which secures itto the deck. See Figure 14.

• Attach the new flap and new rod to deck, bending

the ends of the new rod over to secure to deck.

Discharge

Door

Bracket

Handle __

AdjustingHandleHeight

Your mower is shipped with the handle in the higher

height position.

• Remove the starter rope from the rope guide.

• Remove the upper handle by removing the hand knobs and carriage bolts. Lay the upper handle out

of the way, being careful not to bend or kink cables.

• Remove the hairpin clips from the weld pins on the handle brackets. Refer to Figure 3.

• Remove the carriage bolts and wing nuts from the handle brackets. Press out on the legs of the lower

handle. Remove lower handle from the mower.

• Turn the lower handle around so the notch on the bottom of the lower handle is facing forward as

shown in Figure 15. Reassemble, placing the

bottom holes in the handle over the weld pins in the handle mounting bracket.

Rear _nd

_o_..........

Bracket

Rear

Flap

Figure 14

Notch

Lower Handle

Figure 15

Reassemble the upper handle to the lower handle. Place the hairpin clips in the inner holes of the weld pins and replace the carriage bolts and wing nuts on the handle brackets. Attach the starter rope as instructed in the Assembly section.

AdjustingCuttingHeight

IMPORTANT: All wheels must be placed in the same

relative position. For rough or uneven lawns, move the height adjustment lever to a higher position. This will help stop scalping of the grass.

An adjusting plate and thumb lever at each wheel provides cutting height adjustment. Each adjusting plate has nine height positions. Height of cut will be changed when you move the thumb lever from one position to another.

• Simply depress the lever towards the wheel and move the lever assembly to desired position. See Figure 16.

For rough or uneven lawns, move the height

adjustment handles to higher cutting height

position.

Height Adjustment Lever

Figure 16

AdjustingCarburetor

If the engine is running rough, minor adjustments to the carburetor may be required to compensate for differences in fuel, temperature, altitude and load.

NOTE: Dirty air cleaner may cause an engine to run rough. Before adjusting carburetor, check air cleaner.

To adjust the carburetor, please follow the

recommendations and instructions on carburetor adjustment in the engine manufacturer's manual at the

end of this manual.

,_ WARNING: If any adjustments are made to

the engine (e.g. carburetor) while the engine is

running, keep clear of all moving parts. Be careful of heated surfaces like the muffler.

SECTION8: OFF-SEASONSTORAGE

Prepare your lawn mower for storage at the end of the season or if the unit will not be used for 30 days or more. Store the mower in a clean, dry area.

Mower

• Clean underside of the mower following instructions in the Maintain Your Lawn Mower

section of this manual.

• Lubricate mower as instructed on page 11.

• You can fold your mower's handle for convenient storage: Remove the starter rope from the rope guide; loosen the two hand knobs on the sides of the handle, and let the upper handle fold down to the rear. Move the hairpin clips to the outer hole in the weld pins on the handle mounting brackets. Spread the sides of the lower handle, and push it

forward and down.

• Inspect and replace/sharpen blade, if required.

Engine

• Follow recommendations inthe engine manufacturer's manual at the end of this manual for

off-season storage of the engine.

• Change oil if it has not been changed in the last

three months. For instructions on how to change oil,

refer to the engine manual.

• Clean engine and remove any grass clippings.

Other

Do not store gasoline from one season to another. Replace your gasoline can if it starts to rust. Rust

and/or dirt in the gasoline will cause problems. Store unit in a clean, dry area. Do not store next to

corrosive materials, such as fertilizer.

NOTE: If storing in an unventilated or metal storage shed, be certain to rustproof the equipment by coating with a light oil or silicone.

SECTION9: TROUBLE-SHOOTING

Problem Possible Cause Corrective Action

Engine fails to start

Engine runs erratic

Engine overheats

Occasional skip Spark plug gap too close (hesitates) at high speed

Idles poorly 1. Spark plug faulty, or gap too wide 1. Reset gap to.030 inches or replace spark plug.

Excessive vibration 1. Blade loose or unbalanced 1. Tighten blade and adapter, balance blade.

Mower will not 1. Wet grass 1. Wait until grass is dry to cut. mulch grass 2. Excessively high grass 2. Mow once at a high cutting height, then mow

Uneven cut 1. Wheels not at same height 1. Reposition all wheels at same height.

1. Blade control handle disengaged

2. Spark plug wire disconnected

3. Fuel tank empty, or stale fuel

4. Blocked fuel line

5. Faulty spark plug

6. Engine flooded

1. Spark plug wire loose

2. Blocked fuel line or stale fuel

3. Vent in gas cap plugged

4. Water or dirt in fuel system

5. Dirty air cleaner

1. Engine oil level low

2. Airflow restricted

2. Dirty air cleaner 2. Clean air cleaner.

2. Bent cutting blade 2. Replace blade.

3. Bent engine crankshaft 3. Contact the nearest service center

3. Dull blade 3. Sharpen or replace blade.

2. Dull blade 2. Sharpen or replace blade.

1. Engage blade control handle.

2. Connect wire to spark plug.

3. Fill up tank with fresh gasoline.

4. Clean fuel line.

5. Clean, adjust gap, or replace.

6. Wait a few minutes to restart. Do not prime.

1. Connect and tighten spark plug wire.

2. Clean fuel line, fill tank with fresh gasoline.

3. Clear vent.

4. Drain fuel tank. Refill with fresh fuel.

5. Clean air cleaner. Refer to engine manual.

1. Fill crankcase with proper oil.

2. Clean lawn mower engine.

1. Adjust gapto.030 inches.

again at desired height.

NOTE: For repairs beyond the minor adjustments fisted above, contact your local authorized service dealer.

SECTION10: PARTSLISTFORMODEL567

I 22

\\\\\\\

_ 15_ ,

34. 51

\\\\

IMPORTANT: For a proper working machine, use Factory Approved Parts. V-BELTS are specially designed to engage and disengage safely. A

substitute (non OEM) V-Belt can be dangerous by not disengaging completely.

_57

Model567

Ref. No Part No.

1. 747-1214

2. 710-0599

3. 736-0270

4. 17032A

5. 732-1014

6. 756-04017

7. 747-1161A

8. 749-1092A

9. 731-04177

10. 687-02055

11. 747-0710

12. 732-0708

13. 720-0279

14. 720-0284

15. 710-1205

16. 746-04104

17. 710-1174

18. 687-02033 687-02031

19. 726-0240

20. 714-0104

21. 710-1008

22. 746-04112

23. 664-04027

24. 710-1650

25. 631-0075B

26. 741-0604A

27. 748-0355

28. 787-01106

29. 782-5003

30. 710-1017

31. 782-5004A

32. 710-0216

33. 732-04090

34. 712-0431

35. 731-04580

36. 782-5002A

37. 754-0637A

38. 736-0447

39. 750-04178

40. 748-04015A

41. 742-0741

42. 736-0524A

43. 687-02044

* Not shown in illustration

Description Lower Bail Handle TT Screw 1/4-20 x 0.5 Bell Washer.265 x 0.75

Deflector Chute Adapter Torsion Spring Input Pulley

Blade Control Handle Upper Handle

Chute Deflector Mulch Plug Complete

Hinge Pin Bearing Retainer

Handle Knob Handle Knob

Eye Bolt Control Cable - 40"

Carriage Bolt 5/16-18 x 2.0 RH Handle Bracket

LH Handle Bracket Cable Tie

Cotter Pin Self-Tapping Sems Screw

Drive Cable - 50.50" Grassbag Assembly

Shoulder Screw # 12 -24 Engine Spacer

Bearing Sleeve Bearing Support

21" Deck LH Rear Baffle Screw AB: 1/4-14:.625 RH Rear Baffle Hex Screw 3/8-16 x.75

Torsion Spring RH Flange Lock Nut 3/8-16 Transmission Cover (Yellow)

Front Baffle V-Belt Wave Washer

Sleeve Spacer 9.04" Lg. Blade Adapter w/Pulley 21" Mulching Blade Blade Belt Support Pivot Plate Assembly

Ref.No

44.

45.

47.

48.

49.

50.

51.

52.

53.

54.

55.

56.

57.

58.

59.

60.

61.

62.

63.

64.

65.

66.

67.

68.

69.

70.

75.

76.

77.

78.

79.

80.

81.

82.

88.

89.

90.

91.

Part No.

710-1257 749-0928A 720-0426 732-04089 734-2042 716-0865 717-1762 717-1761

747-04080 736-0451 712-3005 710-1652 687-02056 687-02057

715-0221 736-0474 687-02039 687-02040

732-0866 720-0312 738-0507B 734-04046 782-0512B 782-0511A

732-0706 732-0707

732-0700 731-1236 747-0996 716-0102 731-04134 782-7551 750-1166 750-04162 715-04011 710-0703 712-0397 618-0657 732-1043 682-0512A 682-0511A

787-01121 731-04300 731-1426A

Description Hex Screw 3/8-24 x 2.50 Lower Handle

Adjustment Knob Torsion Spring LH

Wheel 8 x 2.125 Snap Ring

Gear 14T RH FWD Gear 14T LH FWD * Grass Bag Frame

Saddle Washer

Hex Flange Lock Nut 3/8-16

]-T Scr. w/Washer 1/4-20 x.625

RH Handle Bracket Assembly LH Handle Bracket Assembly

Dowel Pin

Washer

Pivot Arm Assembly - RH Pivot Arm Assembly - LH

Rear Spring Lever Foam Grip

Shoulder Scr.500 Dia. x.434 Wheel, 12 x 2.125

Height Adjuster Plate - RH Height Adjuster Plate - LH*

Front Lever- RH Front Lever- LH*

Wire

Rear Trailing Shield Pivot Rod

Snap Ring

Rear Discharge Door

Wheel Dust Cap Slev. Spacer 2.1" Lg. Spacer.375 x.50 x 1.02" Lg.

Roll Pin

Carriage Bolt 1/4-20 Wing Nut Transmission Assembly

Belt Tension Spring Height Adjustment Assembly RH* Height Adjustment Assembly LH

Grass Bag Mounting Bracket

Hardtop Cover Hub Cap

EngineManualforKawasakiEngine

SAFETYAWARENESS

,i_ WARNING" Whenever you see the symbols shown on the left, heed their instructions! Always follow safe

operating and maintenance practices.

FORWARD

We wish to thank you for purchasing this Kawasaki engine. Please read this Owner's manual carefully before starting your new engine so that you will be thoroughly familiar with the proper operation of your engine's control, its features, capabilities and limitations. Also read the manual of the equipment to which this engine is attached. To ensure a long, trouble-free life for your engine, give it the proper care and maintenance

described in this manual. Always keep this manual at your fingertip so that you can refer to it whenever you need information. This

manual should be considered a permanent part of the engine and should remain with the engine when it is sold. All rights reserved. No part of this publication may be reproduced without our prior written permission. This publication includes the latest information available at the time of printing. However, there may be minor differences between the actual product and illustrations and text in this manual. All products are subject to change without prior notice or obligation.

EMISSION CONTROL INFORMATION .................................................. 19

GENERAL INFORMATION ..................................................................... 21

FUEL AND OIL RECOMMENDATIONS .................................................. 22

PREPARATION ...................................................................................... 22

Fuel............................................................................................. 27

Engine Oil ................................................................................... 27

STARTING .............................................................................................. 23

Starting Engine ........................................................................... 23

OPERATING ........................................................................................... 23

Anti-engine inclination ................................................................. 28

STOPPING .............................................................................................. 23

Stopping Engine ......................................................................... 23

ADJUSTMENT ........................................................................................ 24

Engine Speed Adjustment .......................................................... 24

MAINTENANCE ...................................................................................... 24

Periodic Maintenance Chart ....................................................... 29

Oil Level Check ........................................................................... 29

Oil Change .................................................................................. 29

Air Cleaner Service ..................................................................... 30

Spark Plug Service ..................................................................... 30

STORAGE ............................................................................................... 27

TROUBLESHOOTING GUIDE ................................................................ 28

ENVIRONMENTAL PROTECTION ......................................................... 28

SPECIFICATIONS .................................................................................. 28

READTHISFIRST

WARNING" Never allow children to operate the engine or equipment.

Keep people and pets out of area where you are using the engine or equipment. Never wear loose, torn, or bulky clothing. It may catch on moving parts or controls, leading to the risk of

accident. Never consume alcohol or drug before or while operating this engine.

Do not run the engine in a closed area. Exhaust gas contains carbon monoxide, an odorless and deadly poison.

Gasoline is extremely flammable and can be explosive under certain condition. Stop engine and allow the engine to cool before refueling. Do not smoke. Make sure area is well ventilated and free from any source of flame or sparks including the

pilot light of any appliance while refueling, servicing fuel system, draining gasoline and/or adjusting carburetor.

Do not fill the tank so the fuel level rises into the filler neck. Ifthe tank is overfilled, heat may cause the fuel to expand and overflow through the vents inthe tank cap.

Wipe off any spilled gasoline immediately. To prevent fire hazard: Keep the engine at least 1 m (3.3 ft.) away from buildings, obstructions and other burnable objects. Do not place flammable objects close to the engine. Do not expose combustible materials to the engine exhaust. Do not use the engine on any forest covered, bush covered or grass covered unimproved land unless spark

arrester is installed on the muffler. To avoid getting an electric shock, do not touch spark plug, plug cap or spark plug lead during engine

running. To avoid a serious burn, do not touch a hot engine or muffler. The engine becomes hot during operation.

Before you service or remove parts, stop engine and allow the engine to cool. Do not place hands or feet near moving or rotating parts. Do not run engine at excessive speeds. This may result in injury. Always remove the spark plug lead from spark plug when servicing the engine to prevent accidental

starting.

EmissionControlInformation

FuelInformation

THIS ENGINE IS CERTIFIED TO OPERATE ON

UNLEADED REGULAR GRADE GASOLINE ONL Y.

A minimum of 87 octane of the antiknock index is recommended. The antiknock index is posted on

service station pumps in the U.S.A. To protect the environment in which we all live,

Kawasaki has incorporated an exhaust emission control system in compliance with applicable regulations of the United States Environmental Protection Agency and the California Air Resources

Board. Also, depending on when your engine was produced, it may have an assigned emissions durability period. * See below for the engine emissions durability period that may apply to your engine.

ExhaustEmissionControlSystem

The exhaust emission control system applied to this

engine consists of a fuel system and an ignition system having optimum ignition timing characteristics. The fuel system has been calibrated to provide lean air/fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system

A sealed-type crankcase emission control system is

also used to eliminate blow-by gasses. The blow-by

gasses are led to a breather chamber through the crankcase and from there to the air cleaner.

EngineEmissionsCompliancePeriod

California

Model Year - 2006 and later Vertical Crankshaft Durability Period - 500 hours

All Other States

Model Year - 2003 and later (new) 2007 and later (carry over) Durability Period - 500 hours (Category A} If your engine has an assigned emissions durability

period it will be located on the certification label attached to the engine (IMPORTANT ENGINE INFORMATION).

HighAltitudePerformance AdjustmentInformation To improve the EMISSIONS CONTROL

PERFORMANCE of engines operated above 1,000 meters (3,300 feet), Kawasaki recommends the following Environmental Protection Agency (EPA) and the California Air Resources Board (CARB) approved

modifications.

NOTE: When properly performed, these specified modifications only are not considered to be emissions system "tampering" and engine performance is generally unchanged as a result.

InstallationInstructions:

High altitude adjustment requires replacement of carburetor main jet. Installation of these optional parts may be performed by an authorized Kawasaki dealer, or the consumer, following repair recommendations specified in the appropriate Kawasaki Service Bulletin.

MaintenanceandWarranty

Proper maintenance is necessary to ensure that your engine will continue to have low emission levels. This

Owner's Manual contains those maintenance

recommendations for your engine. Those items identified by the Periodic Maintenance Chart are necessary to ensure compliance with the applicable

standards.

As the owner of the engine, you have the responsibility to make sure that the recommended maintenance is

carried out according to the instructions in this Owner's Manual at your own expense.

The Kawasaki Limited Emission Control System Warranty requires that you return your engine to an

authorized Kawasaki dealer for remedy under warranty. Please read the warranty carefully, and keep it valid by complying with the owner's obligations it contains.

TamperingwithEmissionControl SystemProhibited

Federal law and California State law prohibit the

following acts or the causing thereof: (1) the removal or

rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new engine for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the engine after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering

are the acts listed below:

Do not tamper with the original emission related parts:

• Carburetor and internal parts

• Spark Plug

• Magneto or electronic ignition system

• Fuel filter element

• Air cleaner elements

• Crankcase

• Cylinder head

• Breather chamber and internal parts

• Intake pipe and tube

GeneralInformation

LocationofSafetyRelatedLabels

Figure 1

a. Warning b. Engine Maintenance

AWARNING

_]loFOR SAFEOPERATION

_°TO AVOID BURN, DO NOT

READOWNER'SMANUAL.

•GASOLINEIS FLAMMABLE.

KEEPAWAYFROMFLAME ORSPARKS,

DONOT RUNENGINEIN

OEXHAUSTGAS IS POISONOUS

AN ENCLOSEDAREA,

TOUCHHOTMUFFLER,

Figure 3

A. Fuel Tank Cap

B. Fuel Tank (capacity 2.0L [0.528US gal.]) C. Fuel Tube

D. Carburetor E. Priming Pump

F. Air Cleaner G. Recoil starter

H. Recoil Starter Grip I. Oil Drain Plugs (engine oil capacity 0.65L [0.69US

gal.])

J EBO2OO2BZ2 C

ENGINE MAINTENANCE

i_ 1.CHECK OIL LEVEL

REFERTO OWNER'SMANUALFORFURTHERINFORMATION

2. CHECK & CLEAN AIR CLEANER

3.CLEAN FINS & SCREEN

4.CHANGE OIL & OIL FILTER

EngineSerial Number

The engine serial number is your only means of identifying your particular engine from others of the same model type.This engine serial number is needed by your dealer when ordering parts. Refer to Figure 2.

Figure 2

Figure 4

J. Oil Gauge / Filler Cap

K. Spark Plug Cap / Spark Plug L. Muffler

M. P.T.O. Shaft

Tune-upSpecifications

ITEM

• Valve Clearance

• Ignition Timing • Unadjustable

• High Idle Speed • 3200 r/min (rpm)

• Spark Plug Gap • 0.7- 0.8mm(0.028-0.032 in.)

• Other Specifica- • NO OTHER ADJUSTMENT tions NEEDED

SPECIFICATION

• IN 0.12mm(0.005 in.)

• EX 0.12mm{0.005 in.}

FuelAndOilRecommendations

Fuel

Use only clean, fresh, unleaded regular grade gasoline.

OctaneRating

The octane rating of a gasoline is a measure of its resistance to "knocking".Use a minimum of 87 octane of

the antiknock index is recommended. The antiknock index is posted on service station pumps in the U.S.A.

NOTE: If "knocking or pinging" occurs, use a different brand of gasoline or higher octane rating.

CAUTION: Do not mix oil with gasoline

OxygenatedFuel Oxygenates (either ethanol or MTBE) are added to the

gasoline. If you use the oxygenated fuel be sure it is unleaded and meets the minimum octane rating requirement.The following are the EPA approved percentages of fuel oxygenates.

ETHANOL: (Ethyl or Grain Alcohol) You may use gasoline containing up to 10% ethanol by

volume. MTBE: (Methyl Tertiary Butyl Ether)

You may use gasoline containing up to 15% MTBE by volume.

METHANOL: (Methyl or Wood Alcohol) 5% by volume You may use gasoline containing up to 5% methanol by

volume, as long as it also contains co solvents and corrosion inhibitors to protect the fuel system.

Gasoline containing more than 5% methanol by volume may cause starting and/or performance problems. It may also damage metal, rubber, and plastic parts of your fuel system.

WARNING" Gasoline is extremely flammable and can be explosive under certain

conditions. Do not smoke. Make sure the area is well ventilated and free from any source of

flame or sparks; this includes any appliance with a pilot light. Never fill the tank so the fuel

level rises into the filler neck. If the tank is overfilled, heat may cause the fuel to expand

and overflow through the vents in the tank cap.

Engine0il The following engine oils are recommended:

API Service Classification: SF, SG, SH, or SJ. 0il Viscosity

Choose the viscosity according to the temperature following chart in Figure 5.

-20°C -10°C 0°C 10°C 20°C 30°C 40°C

SA_10W-

NOTE: Using multi grade oils (5W-20, 10W-30, and

10W-40) will increase oil consumption. Check oil level

more frequently when using them.

/10w

Figure 5

Figure 6

Preparation

Fuel

• Level the engine (equipment) before fueling.

• Remove the fuel tank cap.

• Slowly pour fuel into the fuel tank to bottom (B) of the filler (A).

Do not over fill the fuel tank, fill only to bottom (B) of the

filler (A) to prevent spill out of the fuel from the tank cap.

Fuel Tank Capacity, 2.0 L (0.528 us.gal)

• Close the tank cap securely by turning it clockwise as far as it will go.

Engine0il Check the engine oil level daily before starting the

engine otherwise shortage of the engine oil may cause serious damage to the engine such as seizure.

• Place the engine (equipment) on level surface. Clean area around the oil gauge before removing it.

• Remove the oil gauge (A) and wipe itwith clean cloth.

• Pour the oil slowly to "FULL" mark on the oil gauge.

• Insert the oil gauge into the oil filler (B)WITHOUT SCREWING IT IN.

• Remove the oil gauge to check the oil level. Level should be between "ADD" and "FULL" marks. Do

not overfill.

• Install and tighten the oil gauge.

Engine Oil Capacity, 0.65 L (0.69 us.qt)

CAUTION:The engine is shipped without engine oil.

E_3Br_ P

Figure 7

Starting

BandPad System

Upon releasing the brake control lever on the equipment, the cutting blade and the engine will stop automatically.

Therefore, the brake control lever must be held against the handle while the engine is started and running.

StartingEngine

• Fully push the priming button (A) by thumb only once.

NOTE: When the engine is already warm or on hot days, do not push the priming button to prevent faulty starting engine caused by flooding carburetor.

• DO NOT let the recoil starter grip snap back itself. This may cause damage to the recoil

starter assembly.

• Hold the brake control lever (A) on the equipment against the handle (B) on the equipment.

• Pull the recoil starter grip (C) slowly until you feel compression, then pull fast and steady.

Figure 9

A. Brake Control Lever

B. Handle C. Recoil Starter Grip

Warmingup

CAUTION: Allow engine to warm up before loading.

This will allow oil to reach all the engine parts, and the piston clearance to reach design specification,

before the engine is ready for loading.

• After engine starts, warm up the engine, run itfor a few minutes.

Figure 8

CAUTION:

• DO NOT start the engine when the cutting blade is in contact with long, uncut grass, it may cause difficulties in starting and damage to the

recoil starter.

• DO NOT attempt to start the engine when the brake control lever on the equipment is released from your hands; this may cause damage to the recoil starter or pad system of the engine.

• DO NOT pull the recoil starter grip out of the

end.

Operating

• Anti-engine inclination

• This engine will operate continuously at angles up to 30°in any direction.

• Refer to the operating instructions of the equipment this engine powers.

• Because of equipment design or application, there

may be more stringent restrictions regarding the

angle of operation.

CAUTION: Do not operate this engine continuously at angles exceeding 30° in any direction. Engine damage could result from insufficient lubrication.

Stopping

StoppingEngine

Release the brake control lever (A) on the equipment

from the handle (B) on the equipment to stop the engine

and the cutting blade.

A. Brake Control Lever

B. Handle

MAINTENANCE

Check oil level and add engine oil Check for loose or lost nuts and

screws Check for fuel and oil leakage

Check for brake control lever

function

Check or clean recoil starter and air intake screen Tighten nuts

and screws Clean air cleaner foam element

Clean air cleaner paper element Change engine oil Clean and re-gap spark Plug

Replace air cleaner paper element

Clean dust and dirt from cylinder and cylinder head fins

Clean combustion chamber Check and adjust valve clearance

Clean and lap valve seating surface

Figure 10

DAILY

Q Q

FIRST 8 HOURS

Adjustment

EngineSpeedAdjustment

NOTE: Do not tamper with the governor setting or the

carburetor setting to increase the engine speed. Each carburetor is adjusted at the factory with either a cap or stop plate installed on the mixture screw. Any adjustments must be performed an authorized

Kawasaki dealer.

MAINTENANCE

INTERVAL

EVERY25

HOURS

EVERY 50

HOURS

EVERY 100

HOURS

EVERY 200

HOURS

EVERY 300

HOURS

Periodic Maintenance Chart

NOTE: The service intervals indicated are to be used as a guide. Service should be performed more frequently as

necessary by operating condition. Service more frequently under dusty conditions.

0il Level Check

Check oil level daily and before each operation. Be sure oil level is maintained. See PREPARATION.

0il Change

,_ WARNING" Hot engine oil can cause severeburns. Allow engine temperature to drop from

hot to warm before draining and handling oil.

Change oil after first 8 hours of operation. Thereafter change oil every 50 hours.

• Run the engine to warm oil.

• Be sure the engine (equipment) is level.

• Stop the engine.

Two alternate methods of draining oil are described in the following lines. For convenient handling, the first

method is recommended.

1.Draining0il FromCrankCase

Tip the mower as shown in Figure 11 below. Remove the dipstick from the engine and pour entire oil from the

crank case into an appropriate container.

,_ WARNING: Before tipping the equipment,make sure to run the engine till fuel runs dry.

WARNING: While tipping the engine, keep

muffler side down as shown below.

• Put the mower back to its operating position (on all four wheels).

Dipstick

RefillingFresh0il

• Remove dipstick and refill with new oil (See FUEL AND OIL RECOMMENDATIONS chapter).

NOTE: If you followed the second method of draining oil, the dipstick is already removed from the engine.

Crank Case

_Muffier

Tilt mower so engine tips this way

Figure 11

2.Using0il DrainPlug IMPORTANT:The oil drain plug on this engine is located

at the bottom and can only be accessed by removing the baffle and other components. This method of draining oil involves complicated steps. The first method, described earlier, is simpler and takes less time; hence it is the preferred method.

• Run the engine for a few minutes and stop the engine. Tip the mower as shown in Figure 12.

• Access the oil drain plug by removing the baffle and

other components following instructions in

"Changing Belts" section on page 13. See Figure 12 for location of the baffle.

• Remove the oil drain plug from bottom of the engine. See Figure 12 inset for location of the oil drain plug. Drain oil into suitable container.

• Baffle

• Check the oil level (See PREPARATION chapter), and secure dipstick to the filler plug.

,_ WARNING: Engine oil is toxic substance.Dispose of used oil properly. Contact your local

authorities for approved disposal methods for possible recycling.

CoolingSystemCleaning

Before each use, make sure recoil starter (A) is free

from grass and debris to prevent engine overheating.

Figure 13

Air CleanerService

CAUTION: To prevent excessive engine wear, do not run the engine with the air cleaner

WARNING: Clean the elements in a well-

ventilated area and take care that there are no

sparks or flame anywhere near the working area, this includes any appliance with a pilot light. Do not use gasoline or low flash-point

solvents to clean the element. A fire or explosion could result.

A. Oil Drain Plug (on

bottom of engine)

Figure 12

• Reinstall the oil drain plug.

• Reinstall the baffle and other components removed earlier. Make sure to secure these now.

• Put the mower back on its four wheels and on level

ground.

Unfasten the air cleaner case (C) fastened with the air cleaner body (D) by sliding the two fasteners (A) toward the recoil starter (B).Then, with two hands,

pulling the two latches (E) toward you and upward as shown, separate the air cleaner case from the air cleaner body.

Figure 14

A. Fasteners B. Recoil Starter

C. Air Cleaner Case D. Air Cleaner body

E. Latches Remove the paper element (A) and the foam element

(B) from the air cleaner body (C).

A. Slit in the air cleaner body

B. Projection on the air cleaner case C. Fasteners

CAUTION: After servicing the air cleaner, be sure all the removed parts are reinstalled properly in

place. Failure to secure fastening of the air cleaner case with the air cleaner body may cause dirt or other foreign materials to enter the engine, while it is running, through the air cleaner, resulting in

engine troubles or failures.

Figure 15

A. Paper Element B. Foam Element

C. Air Cleaner body Foam Element

Clean the foam element every 25 hours. Wash the element in detergent and water, and dry it

thoroughly.

CAUTION: Do not oil foam element. PaperElement

• Clean the paper element every 100 hours.

• Clean the element by tapping gently to remove dust. If very dirty, replace the element.

• Replace paper-element yearly or every 300 hours.

CAUTION: Do not wash paper-element. Do not use pressurized air to clean or dry paper element.

NOTE: Operating in a dusty condition may require

more frequent maintenance than above.

_ WARNING: Hot engine components can

cause severe burns. Stop engine and allow itto cool before checking spark plug.

• Clean or replace the spark plug and reset gap (A) every 100 hours of operation.

• Disconnect the spark plug cap from spark plug and

remove the spark plug.

• Clean the electrodes (B) by scraping or with a wire

brush to remove carbon deposits.

• Inspect for cracked porcelain or other wear and damage. Replace the spark plug with a new one if

necessary.

• Check the spark plug gap and reset it if necessary. The gap must be between 0.7 and 0.8 mm (0.028 and 0.032").

To change the gap, bend only the side-electrode, using

a spark plug tool.

-Install and tighten the spark plug to 23 N-m (2.3kgf-m, 17fMb).

-Fit the spark plug cap on the spark plug securely.

-Pull up the spark plug cap lightly to make sure of the installation of the spark plug cap.

RecommendedSparkPlug NGK... BPR5ES

Reinstall the foam element and then the paper element on the air cleaner body.

Reinstall the air cleaner case on the air cleaner body by first fitting the projection (B) on the edge of

the air cleaner case into the slit (A) in the air cleaner body. Then, sliding the fasteners (C) toward the air cleaner case, securely fasten the air cleaner case

with the air cleaner body.

Figure 16

Figure 17

A. Spark Plug Gap

B. Electrodes

CAUTION: Be sure to use the same type of spark plug for change. Resistor spark plug is required in

some areas by local law.

Storage

Engine to be stored over 30 days should be completely drained of fuel (gasoline) to prevent gum deposits forming on essential carburetor parts and fuel system.

WARNING: Gasoline is extremely flammable and can be explosive under certain

conditions. Drain gasoline before storing the equipment for extended periods. Drain gasoline in a well-ventilated area away from any source of flame or sparks, including any appliances with a pilot light. Store gasoline in an approved container in safe location.

• Remove the spark plug cap from spark plug to prevent accidental starting the engine.

• Empty the fuel from the fuel tank with a pump or siphon.

• Fit the plug cap on the spark plug securely

• Start and run the engine at idle speed to used up the fuel inthe fuel system.

Figure 18

A. Spark Plug Hole

• Slowly pull the recoil starter grip until you feel compression and leave it there.

• Clean every part of the engine.

• After period of storage, change engine oil.

(Refer to "Oil Change" section in "MAINTENANCE" section).

_ ARNING" Before maintaining engine, stop

the engine and allow it cool.

Remove the spark plug and pour approx. 1-2 mL (0.06-0.1 cu.in) of new engine oil through the plug hole (A), slowly pull the recoil starter grip several times and reinstall the spark plug.

TroubleshootingGuide

Symptom

Engine won't start output is low

Low Output

Insufficient

compression

No fuel to combustion chamber

Spark plug fouled by fuel

No spark or weak spark

Engine Overheats

1. Engine speed 1. won't increase

1. 1.Tighten properlyFaulty piston, cylinder, piston ring,

2. Faulty valves

3. Loose spark plug

4. Loose cylinder head bolts

1. No fuel infueltank

2. Blocked rue tube

3. Blocked air vent in fuel tank cap

4. Faulty carburetor

1. Over-rich fuel/air mixture

2. Clogged air cleaner

3. Faulty carburetor

4. Incorrect grade/type of fuel

5. Water in fuel

1. Faulty spark plug

2. Faulty ignition coil

3. Faulty engine switch

1. Clogged air cleaner

2. Recoil Starter or cooling air path

3. Insufficient engine oil

4. carbon built -up in combustion

Probable Cause Remedy

and head gasket

2. Tighten properly

3. Tighten properly

4. Tighten properly

1. Fill fuel tank

2. Clean

3. Clean

4.:1:

1. Slowly pull the recoil starter grip with spark plug removed to discharge excess fuel. clean spark plug

2.Clean

3.:1:

4. Change Gasoline

5. Change Gasoline

1. Replace spark plug

2.:1:

3.:1:

1. Clean

2. Clean

clogged with dirt

3. Replenish or change oil

chamber Poor ventilation around engine

Faulty Governor

4.:1:

5. Select a better location

If the engine malfunctions, carefully examine the symptoms and the operating conditions, and use the table above as a guide to troubleshooting.:l: Have an authorized Kawasaki dealer perform these service

EnvironmentalProtection

To protect our environment, properly discard used batteries, engine oil, gasoline, coolant, or other components that you might dispose of in the future.

Consult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal procedure.

Specifications

Type of Engine Air-cooled, 4-stroke OHV, single cylinder, gasoline Engine

• Bore X Stroke • 65 x 54mm (2.6 x 2.1 in.)

• Displacement • 179mL (109. cu.in.)

• Ignition system • Solid-state ignition

• Starting system • Recoil starter

• Dry weight • 13.5kg (29.1b)

Specifications subject to change without notice

Kawasaki Limited Warranty: California And Federal

Emission Control Systems: Small Off-Road Engines

The California Air Resources Board, the Environmental Protection Agency (EPA), and Kawasaki Motors Corp., U.S.A. (hereinafter "Kawasaki") are pleased to explain the Emission Control Systems Warranty on your Kawasaki small off-road engine. In California and other states, new small off-road engines must be designed, built and equipped to meet stringent anti-smog standards. Kawasaki must warrant the emission control system on your small off-road engine for the period of time listed below provided there has been no abuse, neglect or improper maintenance of your small off-road engine. Your emission control system may include parts such as the carburetor or fuel-injection system, the ignition system, and catalytic converter. Also included may be hoses, belts, connectors and other emission related assemblies. Where a warrantable condition exists, Kawasaki will repair your small off-road engine at no cost to you including diagnosis (if the diagnostic work is Performed at a Kawasaki small off-road engine dealer), parts and labor.

OWNERS WARRANTY RESPONSIBILITIES. The following obligations must be fulfilled by the owner to maintain the validity of the Kawasaki California / EPA Emissions Systems Warranty:

(a) As the small off-road engine owner, you are responsible for the performance of the required maintenance listed in your owner's manual.

Kawasaki recommends that you retain all receipts covering maintenance on your small off-road engine, but Kawasaki cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

(b) You are responsible for presenting your small off-road engine to an authorized Kawasaki small off-road engine Dealer as soon as a problem

exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

(c) AS the small off-road engine owner, you should also be aware that Kawasaki may deny you warranty coverage if your small off-road engine

or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

(d) If you have any questions regarding your warranty rights and responsibilities, you should contact Kawasaki Motors Corp., U.S.A.,

Consumer Services Department, 5080 36th Street, S.E., Grand Rapids, M149512, 616/949-6500.

1. COVERAGE. Kawasaki warrants to the initial owner and each subsequent purchaser that the small off-road engine is free from defects in materials and workmanship which cause a failure of a warranted part for a period of two years. Kawasaki is liable for damages to other engine components caused by the failure of a warranted part still under warranty. The 1995 and later small off-road engines are warranted for two years in California. In all other states, 1997 and later model year small off-road engines are warranted for two years. If any emission- related part on your engine is defective, the part will be repaired or replaced by Kawasaki. This warranty time period shall begin on the date the small off road engine is delivered to the initial purchaser, or on the date the small off road engine is first placed in service.

Warranty defects shall be remedied during customary business hours at any authorized Kawasaki small off-road engine dealer located within the United States of America. Any manufacturer-approved replacement part may be used in the performance of any warranty maintenance or repairs on emission-related parts, and must be provided without charge to the owner if the part is still under warranty. Any part or parts replaced under this warranty shall become the property of Kawasaki.

The emission related warranted parts are specifically defined by the California Air Resources Board's Emission Warranty Parts List. (EPA's regulations do not include a parts list, but EPA considers emission-related parts to include all parts listed here.) These warranted parts are: carburetor and internal parts, spark advance/retard system, cold start enrichment system, magneto or electronic ignition system, catalytic converter, intake manifold, exhaust manifold, air cleaner element, and spark plugs if failure occurs prior to the first required scheduled replacement, hoses, clamps, fittings, gaskets, sealing devices, mounting hardware and tubing used directly in these parts.

Since emission related parts may vary slightly from model to model, certain models may not contain all of these parts and certain models may contain functionally equivalent parts.

2. LIMITATIONS. This Emission Control Systems Warranty shall not cover any of the following:

(a) Repair or replacement required as a result of (i) misuse or neglect, (ii) lack of required maintenance. (iii) repairs improperly performed or

replacements improperly installed, (iv) use of replacement parts or accessories not conforming to Kawasaki specifications which adversely affect performance and/or durability, (v) alterations or modifications not recommended or approved in writing by Kawasaki.

(b) Replacement of parts, other services and adjustments necessary for required maintenance at and after the first scheduled replacement

point.

LIMITED LIABILITY. (a) The liability of Kawasaki under this Emission Control Systems Warranty is limited solely to the remedying of defects in materials or

workmanship by any authorized Kawasaki small off-road engine dealer at its place of business during customary business hours. This warranty does not cover inconvenience or loss of use of the small off-road engine or transportation of the small off-road engine to or from

the Kawasaki Dealer. KAWASAKI SHALL NOT BE LIABLE FOR ANY OTHER EXPENSE, LOSS OR DAMAGE, WHETHER DIRECT,

INCIDENTAL, CONSEQUENTIAL (EXCEPTION LISTED UNDER COVERAGE) OR EXEMPLARY ARISING IN CONNECTION WITH THE SALE OR USE OF OR INABILITY TO USE THE KAWASAKI SMALL OFF-ROAD ENGINE FOR ANY PURPOSE.

NO EXPRESS EMISSION CONTROL SYSTEMS WARRANTY IS GIVEN BY KAWASAKI WITH RESPECT TO THE KAWASAKI SMALL

(b)

OFF-ROAD ENGINE EXCEPT AS SPECIFICALLY SET FORTH HEREIN. ANY EMISSION CONTROL SYSTEMS WARRANTY IMPLIED BY LAW, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, IS EXPRESSLY

LIMITED TO THE EMISSION CONTROL SYSTEMS WARRANTY TERMS SET FORTH HEREIN. THE FOREGOING STATEMENTS OF

WARRANTY ARE EXCLUSIVE AND IN LIEU OF ALL OTHER REMEDIES.

(c) No dealer is authorized to modify this Kawasaki Limited Emission Control Systems Warranty. (d) Kawasaki is not liable for parts which are not genuine Kawasaki parts except when genuine Kawasaki parts cause damage to non-

Kawasaki parts.

LEGAL RIGHTS: THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS. THIS

WARRANTY IS IN ADDITION TO THE KAWASAKI LIMITED SMALL OFF-ROAD ENGINE WARRANTY.

NOTES

MANUFACTURER'S LIMITED WARRANTY FOR:

YaRD.MaNTM

The limited warranty set forth below is given by MTD LLC with respect to new merchandise purchased and used in the United States, its possessions and territories.

"MTD" warrants this product against defects in material and workmanship for a period of two (2) years commencing on the date of original purchase and wilt, 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, alteration, vandalism, theft, fire, water, or damage because of other peril or natural disaster. Damage resulting from the installation or use of any part, accessory or attachment not approved by MTD for use with the product(s) covered by this manual will void your warranty as to any resulting damage.

Normal wear parts are warranted to be free from defects in material and workmanship for a period of thirty (30) days from the date of purchase. Normal wear parts include, but not limited to items such as: batteries, belts, blades, blade adapters, grass bags, rider deck wheels, seats, snow thrower skid shoes, shave plates, auger spiral rubber and 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 MTD LLC at P.O. Box 361131, Cleveland, Ohio 44136-0019, or call 1-800-800-7310 or log on to our Web site at www.mtdproducts.com.

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

The engine or component parts thereof. These items

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

conditions.

Log splitter pumps, valves, and cylinders have a

separate one year warranty.

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.

Service completed by someone other than an

authorized service dealer.

MTD does not extend any warranty for products sold or

exported outside of the United States, its possessions and territories, except those sold through MTD's authorized channels of export distribution.

Replacement parts that are not genuine MTD parts. Transportation charges and service calls.

No implied warranty, including any implied warranty of merchantability 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 MTD. 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. MTD 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 safety features of the product shall void this warranty.

You assume the risk and liability for toss, 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.

IMPORTANT:Owner must present Original Proof of Purchase to obtain warranty coverage.

MTD LLC, P.O.BOX361131CLEVELAND,OHIO44136-0019;Phone:1-800-800-7310

Yard-Man 567 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual