Yard-Man E465 Operator's Manual

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Operator's Manual

21" Three-in-One

Lawn Mower

Model E465

(Picture may vary from actual model.)

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-cov-

ered, 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,OHIO44136-0019

PRINTED IN U.S.A. FORM NO. 769-01062

(1/2004)

TABLEOFCONTENTS

Content

Important Safe Operation Practices Slope Gauge Assembling Your Lawn Mower

Know Your Lawn Mower Operating Your Lawn Mower

Page

7 10 11

Content Page

Service & Adjustments 12 Maintaining Your Lawn Mower 15 Troubleshooting 17

Illustrated Parts List 18 Warranty Back Cover

FINDINGMODELNUMBER

This Operator's Manual is an important part of your new lawn mower. Itwill 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, seek help from Customer Support or an authorized service dealer.

Copy the model number here:

Copy the serial number here:

YaRD-MaN)#MToLLC

www.yardman.com 330-220-4683

P. O. BOX 361131

CLEVELAND,OH 44136 800-800-731 O

CUSTOMERSUPPORT

Please doNOTreturnthe unittothe retailer from whichit 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.corn for many useful suggestions. Click on Customer Support button and you willget the four options reproduced here. Click on the appropriate button and help is immediately available.

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Ir _ : 8 Rt}ouse C/_C/_ 8wsy]

_uals OnliHe

Jit÷l_t_He frelll i_(:el_ _o_J ye;_rs,

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

._._ The engine manufacturer is responsible for all engine-related issues with regards to _l_°i,o performance, power-rating, specifications, warranty and service. Please refer to the Engine

Owner's/Operator's Manual, packed separately with your unit, 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 inthe 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. Ifyou 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.

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

13. Do not engage the self-propelled mechanism on

units so equipped while starting engine.

14. 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.

15. Never operate the mower in wet grass. Always be sure of your footing. A slip and fall can cause serious personal injury. Ifyou feel you are losing

yourfooting,releasethebladecontrolhandle immediatelyandthebladewillstoprotatingwithin

threeseconds.

16.Mowindaylightorgoodartificiallight.Walk,never run.Stopthebladewhencrossinggraveldrives,

walkwaysorroads.

17.Iftheequipmentshouldstarttovibrateabnormally, stoptheengineandcheckimmediatelyforthe cause.Vibrationisgenerallyawarningoftrouble.

18.Shuttheengineoffandwaituntilthebladecomes toacompletestopbeforeremovingthegrass catcheroruncloggingthechute.Thecuttingblade

continuestorotateforafewsecondsafterthe engineisshutoff.Neverplaceanypartofthebody

inthebladeareauntilyouaresurethebladehas stoppedrotating.

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

20.Mufflerandenginebecomehotandcancausea burn.Donottouch.

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

22.Ifsituationsoccurwhicharenotcoveredinthis manual,usecareandgoodjudgment.Contactyour

dealerforassistance.Telephone1-800-800-7310

forthenameofyournearestdealer.

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 near 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

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 extreme caution when changing direction on slopes.

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 may lose your footing or balance.

SafeHandlingof 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.

2. Wash your skin and change clothes immediately.

3. Use only an approved gasoline container.

4. 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.

5. If possible, 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 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. 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

lULl

SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE

A POWER POLE

A CORNER OF A BUILDING

OR A FENCE POST

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. Operate WALK-BEHIND mowers across the face of slopes, never up and down slopes.

t.O

SECTION3: ASSEMBLINGYOURLAWNMOWER

RemovingUnitFromCarton

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

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

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

operator's manual, hardware pack 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.

Lower Handle Lift lower handle

Upper Handle /

Lift upl handle

, Grass Bag

ToolsRequired

• Pair of Pliers

• Funnel

DisconnectingSparkPlug

• Before setting up your lawn mower, disconnect the

spark plug wire from the spark plug, and attach rubber boot to a bolt on the engine to ground. See Figure 1.

S ark_l! Wire

P _!"g_....

Spark Plug

Figure 1

NOTE: Reference to right or left hand side of the mower

is observed from the operating position.

IMPORTANT:This unit is shipped without gasoline or oil in the engine. Be certain to service engine with gasoline and oil before operating your mower.

AssemblingHandle

• For shipping purposes, the grass bag was placed

on top of the unit. Remove it from the unit and set it out of the way. See Figure 2.

Figure 2

Raise the lower handle, as shown in Figure 2, till it

snaps into place.

Raise the upper handle as shown in Figure 2.

Tighten the two wing nuts which are already on the

handle. See Figure 3.

Lower Bail Hal

Upper _

Handle

Figure 3

NOTE: Make sure to route the cables outside 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.

Using a pair of pliers, insert the hairpin clip into the inner hole in the weld pin. Repeat on the other side.

See Figure 4.

Lower Handle _',.X <_;_, ........

Hairpin .....;::_2]_ _

_! ......<'_

Control

Handle

Tighten these wing nuts

Lower Handle

_ Inner Hole

Figure 4

Insert post of cable ties that are on lower handle into the holes provided on the lower handle. The holes may be on the inside or outside. Pull cable ties tight and cut off the extra. See Figure 5 below.

Cable Tie

Post on

Figure 5

AttachingStarterRope

The rope guide is already attached to the right side of the lower handle of your mower. See Figure 6.

• With the spark plug wire disconnected and

grounded, hold the blade control handle against the upper handle, and pull the starter rope up to the rope guide. See Figure 6.

• Slip the rope through the rope guide as shown

below. Tighten the wing nut holding the rope guide to the lower handle.

Lower Handle

Starter

Rope_--.

• Join the rear frame and front frame assembly as shown in Figure 7A.

• Place the bag over the frame (black plastic side is the bottom of bag). Slip the openings inthe side of the plastic channels on the bag over the hooks on the grass catcher frame.

• Secure bag to frame by working the plastic channels on bag over frame as shown in Figure 7B. 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.

Frame

Front

Frame

Assembly

Rear

Frame Bag

Figure 7

Hook

Plastic

Channels

AttachingGrassCatcher

• If your mower is equipped with a rear baffle, and it

is in place on the mower, lift the rear discharge door

and remove it from the mower. See Figure 8.

Rope Guide

Figure 6

GrassCatcherAssembly

If the grass catcher is not assembled, follow the steps below to assemble it. Otherwise go to the next sub- section on Attaching Grass Catcher.

NOTE: Make certain the grass bag is turned right side out before assembling (warning label will be on the outside).

Partsfor GrassBag

1. Front Frame

2. Rear Frame

3. Bag

=gNut

Rear Baffle

Figure 8

NOTE: Make sure that the cables are routed to the

outside of the handle when attaching the grass catcher.

• Lift the rear discharge door.

• Place the hooks of the grass catcher into the slots

in the handle bracket assemblies on both sides.

See Figure 9. Release the rear discharge door.

-4

Figure 9

RemovingGrassCatcher

• Lift the rear discharge door on the mower.

• Lift the grass catcher up, out of the slots in the handle bracket assemblies.

• Reinstall the plastic rear baffle.

• Release the rear discharge door.

,_ WARNING" Never operate the mower

unless the hooks on the grass catcher are seated in the slots on the handle bracket

assemblies, and the rear discharge door rests firmly against the top of the grass catcher.

ConvertingtoSideDischarge

• Your mower has been shipped as a mulcher. To convert it to a side-discharge mower, lift the

mulching plug. Slide the two hooks on the side-

discharge deflector under the hinge pin on the

mulching plug assembly. Lower the mulching plug.

See Figure 10.

• Do not remove the side mulching plug at any time, even when you are not mulching.

Mulching Plug

/Side

Chute Deflector

Figure 10

SECTION4: KNOWYOURLAWNMOWER

Read this owner's manual and safety rules before operating your lawn mower. Compare the illustrations in Figure

11 with your lawn mower to familiarize yourself with the location of various controls and adjustments.

Blade Control Handle

Lower Bail Handle ElectricStarter Key

Starter Rope

Side Discharge___ Plug

Chute Deflector _

* Fourth lever not shown

Figure

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.

,_ WARNING" The blade control handle is a

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

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

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

Primer The primer is used to pump gas into the carburetor. Use

it to assist in starting a cold engine, but do not use it when restarting a warm engine after a short shutdown. Refer to engine manual for location of the primer.

Cutting Height

jAdjustment Lever*

Oil Plug

Gasoline Fill

-- Spark Plug

Cutting Height Adjustment Lever*

RecoilStarter

The recoil starter is attached to the handle. Stand

behind the unit and pull the starter rope to start the unit. ElectricStarter Key

The electric start ignition key is located on the left side of the handle panel. It is used only for the electric

starter. Turn the key clockwise to start the engine and release it once the engine has started.

GrassCatcher

The grass catcher, as its name implies, involves a grass bag to automatically collect the grass clippings when the intention is not to mulch or side-discharge.

MulchingPlug Make sure that the rear discharge door is closed, the

grass catcher is removed and the side-discharge chute

deflector removed from the unit while mulching. Insert the mulching baffle at the rear of the mower and lower the mulch plug at the right side of the deck to mulch.

CuttingHeightAdjustmentLever

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.

SECTION5: OPERATINGYOURLAWNMOWER

GasandOilFill-Up

_i WARNING" Never fill fuel tank indoors, or

• Service the engine with gasoline and oil as

when engine is running or hot. Do not smoke when filling up the fuel tank.

instructed inthe separate engine manual packed

with your mower. Read the instructions carefully.

ChargingtheBattery

IMPORTANT: Use only the battery charger supplied with

this mower.

,_ WARNING" The battery contains corrosivefluid and toxic material; handle with care. Keep

away from children. Do not puncture, disassemble, mutilate or incinerate the battery. Explosive gases could be vented during charging or discharging. Use ina well ventilated area, away from sources of ignition.

Protective Cap

Battery

Pack

Lead

Holder

Figure 12

• Remove the protective cap from the end of the battery pack lead. Always plug charger lead into

battery pack lead first, and then insert battery charger plug into 120 volt standard household

outlet. See Figure 12 for location. Follow this order of action every time you charge the battery.

• Charge battery for 16 hours before initial use. Do

not charge longer than 20 hours.

• After charging, disconnect battery charger plug

from household outlet first, then disconnect charger

lead from battery pack lead.

WARNING" Do not remove the battery pack

from the handle panel for any reason other than replacement. When replacing the battery pack, refer to instructions on page 14.

• Attach spark plug wire to spark plug. Make certain 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.

StartingEngine

,i_ WARNING: Be sure no one other than the

• Push the primer three times. Wait two seconds

• Standing behind the mower, depress the blade

• Electric Start: Turn the ignition key to the right to

• Recoil Start: Grasp starter handle and pull rope

• Once the engine has started, squeeze the lower

operator 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.

between each push. In temperatures below 55° F, prime five times. Do not prime to restart awarm

engine after a short shutdown.

control handle and hold it against the upper handle.

start the engine. Release key after engine starts.

out slowly until engine reaches 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.

bail handle and the blade control handle against the upper handle to run the mower.

StoppingEngine

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

• Disconnect spark plug wire and move away from spark plug to prevent accidental starting.

UsingYourLawnMower

• Do not operate the mower without the mulching cover, the grass catcher bag, or the discharge chute properly installed.

• 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,

preventing proper discharge of grass clippings, poor mulching conditions, and could cause you to slip and fall. New grass, thick grass, or wet grass may require a narrower cut.

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.

WARNING" If you strike a foreign object, stop the engine. Remove spark plug wire from

spark plug, thoroughly inspect the mower for any damage. 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.

NOTE: For best results in mowing, keep the cutting height position high until you have determined which cutting height is preferred.

BaggingGrassClippings

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

• Attach the grass catcher following instructions on

• Operate the mower till the grass bag is full.

• Stop the engine completely by releasing the control

• Lift discharge door and pull grass bag up and away

AdjustingCuttingHeight

Refer to page 14 for instruction on how to adjust cutting and handle heights.

SECTION6: SERVICE& ADJUSTMENTS

page 8 of this manual. The grass clippings will

automatically collect in the bag as you run the

mower.

handle. Make sure that the unit has come to a

complete stop.

from the mower to dispose of the grass clippings.

BladeCare

Periodically inspect the blade and blade adapter for signs of wear, especially if you strike a foreign object. Replace, if necessary, following steps below.

,_ 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 airfilter and the carburetor are up.

To RemoveBlade

• Remove the hex bolt that holds the blade adapter to the engine crankshaft and remove the blade adapter and bell support from the crankshaft.

• Using heavy gloves or thick rags, remove the blade

from the mower.

To ReplaceBlade:

• Before reinstalling the blade adapter to the unit, lubricate the engine crankshaft and the inner surface of the blade adapter with light oil.

• Also lubricate the bolt hole, bolt and the inner surface of the nut.

Adapter

Blade

Blade Bell _

Support r_

Hex Bolt _"_

Figure 13

• Place the new blade and blade bell support on the blade adapter with the side marked bottom (has a part number) facing away from the adapter. See Figure 13.

• Install the blade assembly on the engine

crankshaft. Secure with the hex bolt and tighten to the recommended torque. Refer to 'Blade Mounting Torque' information below.

IMPORTANT: The bolt used to secure the blade to the engine is specially heat-treated. Do not substitute. To

order replacement bolt, refer to the parts list in the back of this manual.

WARNING: To ensure safe operation ofyour unit, all nuts and bolts must be checked

periodically for correct tightness.

BladeMountingTorque:

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

To SharpenBlade:

• The blade can be sharpened with afile 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.

An unbalanced blade will cause excessive vibration when rotating at high speeds, may cause damage to

the mower and/or 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.

Loosen this screw

Shoulder

/Screw

ReplacingDriveBelt

• Remove two shoulder screws securing the front drive cover to the mower deck. See Figure 14.

• 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

14. Do not remove the screw completely. As you loosen the screw, the tension on the belt will be

released.

• 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.

• Slide the belt off the engine pulley and around the blade. See Figure 15.

,_ WARNING" As always, use athick piece of

rag to handle the blade while sliding the belt around it. Make sure the spark plug is disconnected and grounded for this job.

Replace with the new belt, working around the 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.

Transmission

Screw

Figure 14

• Put the mower down with all four wheels firmly placed on one level.

• Tighten the screw, loosened earlier, to secure the belt tension spring to the transmission, and

reassemble the front drive cover.

Right Front LeftFront Wheel Wheel

Front Drive Cover

Figure 15

ReplacingRearFlap

• To remove rear flap, cut off the flat end of the wire rod which secures itto the deck. See Figure 16.

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

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

Rear Discharge Door _ __x_

Brack_HandleTorsionS. _

,ring Y/F:J

, __ "_ Handle

_'_'- _J_ Bracket

_ ; __RearFlap

Figure 16

ReplacingBatteryPack

• Remove the battery pack from the handle panel for replacement only. Do not separate the batteries for any reason. Dispose of batteries properly.

• When replacing battery pack in handle panel, battery pack must be positioned with the positive terminal to the right side and the negative terminal to the left side of the panel. Replacing the battery pack incorrectly will cause serious damage. The positive lead on the wire harness has the smaller connector. Connect the positive lead to the positive side of the battery pack, then connect the negative

side.

,_ WARNING" Batteries contain sulfuric acid

which may cause burns. Do not short circuit or mutilate batteries in any way. Do not put batteries in fire as these may burst or release

toxic materials.

In-lineFuse

The unit is equipped with an in-line fuse. If the unit

fails to start, check the fuse inside the battery cover

by turning the end of the fuse holder and removing

from the battery cover. Replace with standard

automotive 7-1/2 amp fuse. Refer to Figure 12.

Notch

Lower Handle

Figure 17

CuttingHeight IMPORTANT: All wheels must be placed inthe 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

position provides cutting height adjustment. Each adjusting plate has nine height positions. Height of cut

will change 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 18.

MakingAdjustments

HandleHeight

Your mower is shipped with the handle in the higher height position. To lower height, proceed as follows.

• 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 4. Press out on the legs of the lower handle. Remove lower handle

from the mower.

• Turn lower handle around so the notch is facing

forward as shown in Figure 17. Reassemble,

placing the bottom holes in the handle over the

weld pins in the handle mounting bracket.

• Reassemble the upper handle to the lower handle.

• Insert hairpin clips in the inner holes of the weld pins and attach the starter rope as instructed in "Assembling Your Lawn Mower" section.

ght

Adjustment Lever

Figure 18

Carburetor

,_ WARNING: If any adjustments are made tothe engine (e.g. carburetor) while the engine is

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

NOTE: A dirty air cleaner may cause an engine to run rough too. Make sure that the air cleaner is clean and attached to the carburetor before deciding to adjust the

carburetor.

To adjust carburetor, please follow the engine manual.

SECTION7: MAINTAININGYOURLAWNMOWER

PivotPoints

,_ WARNING" Always stop the engine and

disconnect the spark plug wire before performing any maintenance work or adjustments on your lawn mower.

CleaningtheMower

• Clean the underside of the mower deck after each use to prevent any build-up of grass clippings. Ifthis

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 electric components, spindles, pulleys, bearings or the engine. The use of water will result in shortened life and reduced serviceability.

• Disconnect spark plug wire.

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

• Tilt the mower so that the side with the air cleaner is

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. Ifyou had put plastic under the gas cap, remove it now.

• Lubricate the pivot points on the blade control handle, lower bail hadle, and the cutting height

adjustment lever at least once a season with light oil. The blade control handle and the lower bail

handle must operate freely in both directions. The

cutting height adjustment levers should be able to

move easily.

Lubricate

icate

WARNING" Never tip the mower more than90 degrees in any direction 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.

Lubrication(See Figure 19)

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 axle bolt and the inner surface of the wheel with light oil.

ChuteDeflector& RearDischargeDoor

• Lubricate the torsion spring and the pivot point on each end of the chute deflector and the rear

discharge door using a light oil. This will prevent rusting and ensure that the deflector, which is a safety device, can always work properly.

Engine

• Follow the engine manual instructions and recommended schedule for lubricating engine components.

Lubricate

Electric starter not shown here for clarity

Figure 19

EngineMaintenance

A list of key maintenance jobs required for good

performance by the mower is given below. Follow the accompanying engine manual for detailed list and

instructions.

• Change engine oil after the first two operating hours and every 25 operating hours thereafter.

Check oil level before starting engine every time.

• Service foam filter in the air cleaner every 25 hours

of use and replace the paper filter component every

100 hours. You may have to service the air filter more frequently if you are operating the mower under extremely dusty conditions.

• Clean engine periodically with a cloth or brush.

• Clean the spark plug and reset the gap to.030" at least once a season or every 50 hours of operation.

Spark plug replacement is recommended at the start of each season.

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

can create a fire hazard. Make sure to avoid muffler and surrounding areas while the mower engine is

hot because temperature of these areas of the engine may exceed 150°F.

Off-SeasonStorage

Prepare your lawn mower for storage at the end of the season or if it will not be used for 30 days or more.

Gasoline

• Do not store gasoline from one season to another. NOTE: Gasoline, stored for more than one month, may

affect engine performance. So use fresh gasofine.

• Replace your gasoline can if it starts to rust. Rust and/or dirt in the gasoline will cause problems.

Engine

• Clean engine and remove any grass clippings, dirt, and debris from the cooling fins, air intake screen, levers, linkage and the exterior of the engine.

• Follow recommendations in engine manual for off- season storage of the engine.

Mower

• Clean underside of the mower following instructions on page 15.

NOTE: We do not recommend the use of pressure

washers or garden hose to clean your un#. They may cause damage to electric components, spindles,

pulleys, bearings or the engine. The use of water will

result in shortened life and reduce serviceability.

• Lubricate the mower as instructed on page 16.

• You can fold your mower's handle for convenience of 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 mount- ing brackets. Spread sides of the lower handle, and push it forward and down.

• Inspect and replace/sharpen blade, if required.

Refer to page 12.

• Store unit in a clean, dry area. Do not store next to corrosive materials, such as fertilizer or rocksalt.

• If storing the mower in an unventilated or metal storage shed, make sure to rustproof the equipment with a light oil or silicone.

SECTION8: TROUBLE-SHOOTINGGUIDE

Problem Possible Cause Corrective Action

Engine fails to start

Engine runs erratic

Engine overheats

Occasional skip at high speed

Idles poorly

Excessive vibration

Mower will not mulch grass

Uneven cut 1.

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 infuel system

5. Dirty air cleaner

1. Engine oil level low

2. Airflow restricted

1. Spark plug gap too close

Spark plug fouled, faulty, or gap too wide

Dirty air cleaner

Cutting blade loose or unbalanced

Bent cutting blade

Bent engine crankshaft

Wet grass

Excessively high grass

Dull blade

Wheels not in same height position

Dull 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 and start again

1. Connect and tighten spark plug wire

2. Clean fuel line, fill tank with fresh gas

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 gap to.030 inches

1. Reset gap to.030 inches or replace spark plug

2. Clean air cleaner

1. Tighten blade and adapter, balance blade

2. Replace blade

3. Contact your nearest service center

1. Wait until grass is dry to cut

2. Mow once at a high cutting height, then mow again at desired height

Sharpen or replace blade Reposition all wheels at same height

Sharpen or replace blade

NOTE: For repairs beyond the minor adjustments listed above, contact your nearest authorized service dealer. Refer to the accompanying engine manual for more engine-related information.

SECTION9: PARTSLISTFORMODELE465

111

103

X104

112

80,

\\ 3%

_%30

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.

ModelE465

Ref. Part No. No.

1. 747-1161A

2. 747-1214

3. 749-1233A

4. 710-0136

5. 746-0883

6. 712-0324

7. 746-1125

8. 749-0928A

9. 746-04127

10. 710-0606

11. 710-1174

12. 720-0284

13. 736-0451

14. 720-0279

15. 710-1205

16. 764-0310

17. 764-0311

18. 631-0075B

23. 714-0104

24. 731-1236

25. 732-0700

26. 720-0275

27. 710-0192

28. 732-0677

29. 782-5003

30. 710-1017

31. 732-0678

32. 710-0896

33. 720-0426

34. 736-0105

35. 734-04087

36. 738-0102

37. 731-0981A

38. 682-0513 682-0514

39. 14766

14765

40. 687-02018 687-02017

41. 738-0507B

42. 747-0710

43. 782-7006

44. 712-0431

46. 732-1043

47. 787-01006

48. 754-0637

49. 731-04161

50. 731-04177

51. 710-0599

52. 736-0270

53. 782-5002A

54. 618-0657

55. 7510042824

56. 731-04580

57. 715-0169

Part Description

Operator's Bail Drive Bail

Upper Handle Hex Scr. 1/4-20

Control Housing Hex Lock Nut 1/4-20

Control Cable: 50" Lower Handle Drive Cable Hex Screw 1/4-20 x 1.5"

Carriage Bolt Handle Knob

Saddle Washer

Wing Nut

Rope Guide Grass Catcher Frame: Rear

Grass Catcher Frame: Front Engine Spacer Assembly

Hairpin Clip Rear Trail Shield

Wire: Trail Shield Knob Scr. Tr. Mach. #10-24 x 0.380"

Torsion Spring LH

Rear Baffle LH Scr. AB 1/4-14 x 0.625"

Torsion Spring RH

Hex Scr. w/Wash. 1/4-14 x 0.62" Knob

Belt Washer .375 x .870

Wheel: Rear

Shoulder Screw Hubcap

Handle Bracket Assembly LH Handle Bracket Assembly RH

Pivot Bar LH Pivot Bar RH Front Lever RH Front Lever LH

Shoulder Screw Hinge Pin

Mounting Bracket Lock Nut 3/8-16

Belt Tension Spring 3-in-1 Deck: 21"

V-Belt

Mulch Plug Discharge Deflector SD

TT Screw 1/4-20 x 0.5"

Bell Washer 0.265" x 0.75" Front Baffle

Transmission Assembly Compl. Screw #12 x0.457" Front Drive Cover

Roll Pin

Ref. No.

100. 725-0298

101. 725-1428

102. 725-1276

103. 750-04143

104. 736-0270

105. 725-1442

106. 725-1206

107. 712-0324

108. 625-0021

109. 782-9012

110. 710-0969

111. 736-3090

112. 725-1538

Part No.

59. 748-0355

60. 736-0447

61. 782-0511A 782-0512B

62. 687-02044

63. 736-0524A

64. 748-04015A

65. 742-0741

67. 710-0216

68. 715-0221

69. 717-1762 717-1761

70. 714-0101

71. 736-3013

72. 716-0865

73. 782-7551

74. 716-0102

75. 736-0474

76. 756-1231

77. 710-1257

78. 736-0452

79. 664-0124

80. 782-5004A

82. 750-1166 750-1165

83. 682-0516A

84. 682-0515A

85. 687-02086

87. 732-1014

88. 726-0240

89. 710-1008

90. 682-0512A

91. 682-0511A

92. 710-1248

93. 634-04100

94. 687-02020

95. 731-04525

96. 725-0201

97. 725-0873

98. 731-0891A

99. 725-0727

Part Description

Bearing Support

Wave Washer

Height Adj. Plate LH Height Adj. Plate RH

Pivot Plate Assembly Blade Bell Support Blade Adapter Mulching Blade w/Star: 21"

Hex Screw

Dowel Pin Gear 14T RH Gear 14T LH

Hairpin Clip

Flat Washer Snap Ring

Wheel Dust Cap Snap Ring

Washer DD 1.5" O.D.

Input Pulley

Hex Bolt

Belt Washer Grass Bag

Rear Baffle RH Slev. Spacer LH

Slev. Spacer RH

Height Adj. Assembly RH Compl.

Height Adj. Assembly LH Compl.

RD Chute Door Torsion Spring

Cable Tie (not shown) TT Sems Screw

Height Adj. Assembly RH Compt.

Height Adj. Assembly LH Compl. Weld Pin

Wheel: Front Spring Lever

Engine Shroud (not shown)

Ignition Key

Key Switch

Battery Tray

Battery Charger

Fuse 7.5 Amp

Fuse Holder

Battery 12V Spacer

Belt Washer

Harnesss: Electric Start

Plug

Lock Nut 1/4-20

Harness Assembly Compl.

Lower Battery Tray TT Screw

Flat Washer

Harness Extension

MANUFACTURER'S LIMITED WARRANTY FOR

The limited warranty set forth below is given by MTD LLC with

respect to new merchandise purchased and used inthe 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 will, at its option, repair or

replace, free of charge, any part found to be defective in

materials or workmanship. This limited warranty shall only

apply if this product has been operated and maintained in

accordance with the Operator's Manual furnished with the

product, and has not been subject to misuse, abuse,

commercial use, neglect, accident, improper maintenance,

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 are 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.

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

Yard-Man E465 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual