Bolens 824A Owner's manual

$4.50
BMbm/s,
/lodels
824A
24", 8 HP
^ 1026
26", 10 HP
Owner/Operator
Manual
Snowthrowers
• Safety
• Assembly
• Controls
• Operation
• Maintenance
1993 Garden Way Inc.
FORM 1760404 (7/93)

Thank you for purchasing this product. We believe you
now own one of the finest snowthrowers available.
This is a safety, operation and general maintenance
manual which does not attempt to cover major repairs.
All information in this manual is based on the latest
product information available at the time of printing.
This manual is considered a permanent part of this unit
and must stay with the unit if resold. A replacement
manual can be obtained from the factory, free of charge.
Our equipment is carefully designed, engineered and
manufactured for excellent performance if properly
operated and maintained. Read this manual to learn
about your unit, its features and operation. Review this
manual each season to refamiliarize yourself with using
and caring for your snowthrower.
Our products have passed the rigid safety standards set
by the Outdoor Power Equipment Institute and an inde¬
pendent testing laboratory.
The snowthrower’s warranty statement is included on the
back cover of this manual. Carefully read and understand
the warranty, its requirements and limitations. Also, please
complete and return the postpaid owner registration card
included with this manual to register each unit and keep
the owner informed with important product bulletins and
safety literature.
Table of Contents
Service Information .
. 3
SECTION 5
3 Operation .
. 11
SECTION 1
Pre-Start Checklist.
. 11
Safety .
. 4
Filling Fuel Tank .
. 11
4
Starting .
. 12
Preparation .
. 4
Testing Auger and Wheel Drive.
. 12
Operation .
. 4
Stopping .
. 12
Maintenance and Storage .
. 5
Changing Gears.
. 12
Decals .
. 5
Snowthrowing Tips .
. 13
SECTION 2
Snowthrowing Patterns .
. 14
Attachments & Kits .
. 6
SECTION 6
SECTION 3
Maintenance .
. 15
Assembly .
. 6
Checking and Adding Oil .
. 15
SECTION 4
Changing Oil .
. 15
g
Spark Plug .
. 15
Auger Drive Control Lever.
. 9
Lubrication..
. 16
Wheel Drive Control Lever .
. 9
Wheel Drive Belt Adjustment .
. 16
Gear Shift Lever .
. 9
Wheel Drive Belt Replacement .
. 17
Discharge Chute Crank & Cap.
. 9
Auger Drive Belt Adjustment.
. 17
Engine Ignition Keyswitch.
. 10
Auger Drive Belt Replacement .
. 18
Throttle .
. 10
Slip Differential Adjustment .
. 18 .
Skid Shoes.
. 10
Drive Disc Clearance Adjustment...
. 18
Scraper Blade.
. 10
Maintenance Chart .
. 20
10 Storage .
. . 20
Pre-Start Primer Button .
. 10
Troubleshooting .
. 21
10
Specifications .
. 24
Fuel Shutoff Valve .
. 10
Warranty .
.. Outside Back Cover
2

Service Information
Unit Service and Repair
To service your unit, contact a factory-authorized dealer.
Provide the dealer with the unit's model/seriai number and
the part's description. Do not return parts directly to the
factory.
Warranty Service
The warranty for this unit is printed on the back cover of
this manual.
Left and Right Sides
Left and right sides are determined from the operator's
position, facing the direction of forward travel.
Engine Service
For engine service, contact an authorized engine dealer.
To locate an authorized engine dealer, refer to the "Yellow
Pages" under "Engines—Gasoline" or "Gasoline —
Engines". Provide the dealer with the engine model and
serial numbers.
Identification Numbers
For prompt service, provide the authorized dealer with the
identification numbers of your unit. Fill in the spaces below
with the identification numbers for future reference.
Date of Purchase:
Unit Serial Number:
Engine Model/Serial Numbers:
Warning to all operators in California
and other applicable states
Under California law, and under the laws of several other states, it is not lawful to operate an internal combustion engine using
hydrocarbon fuels on any forest covered, brush covered, or grass covered land, or on land covered with grain, hay, or other
flammable agricultural crop, without an engine spark arrester in continuous effective working order.
The engine on this unit, like most outdoor power equipment, is an internal combustion engine that burns gasoline, a hydro¬
carbon fuel. Therefore, this unit must be equipped with a spark arrester muffler in continuous effective working order. Contact
your authorized dealer for information about obtaining a spark arrester. The spark arrester must be attached to the engine
exhaust system in such a manner that flames or heat from the system will not ignite flammable material. Failure of the
owner/operator of this unit to comply with this regulation is a misdemeanor under California law, and may also be a violation of
other state and/or federal regulations, laws, ordinances, or codes. Contact the local fire marshal or forest service for specific
information about which regulations apply in your area.
3

Section 1
Safety
Important!
Safe Operating Practices For This Snowthrower
A The triangle with an exclamation mark inside is a safety alert symbol. The safety alert symbol is
used in this manual and on the snowthrower's decals to alert you to potential hazards. Whenever
you see this symbol, read and obey the safety message that follows it. Failure to obey the safety
message could result in death, personal injury, property destruction or damage.
Preventing accidents is the responsibility
of every equipment operator. The
operator is responsible for hazards
and/or accidents occurring to people or
property. The following general safety
precautions must be fully understood
and adhered to when operating this
snowthrower. Although these safety
precautions are thorough, they can not
be all-inclusive and do not take the place
of common sense. Review these safety
precautions frequently and never take
chances. Be careful before, during and
immediately after use of any powered
equipment. Accidents can be prevented.
Training
1. Very carefully read this manual, the
engine manual and all literature received
with unit. Understand safe operation of
unit. Thoroughly know all controls and
how to stop unit and disengage controls
quickly in event of emergency.
2. Never allow children or untrained or
irresponsible adults to operate unit.
3. Keep area of operation clear of all
people, particularly small children and pets.
Preparation
1. Thoroughly inspect snowthrowing
area. Clear area of all objects (doormats,
sleds, rocks, branches, wires, etc.).
2. Disengage all clutches before starting
engine.
3. Wear adequate winter clothing and
footwear that will improve traction on
slippery surfaces.
4. Adjust the collector housing height to
clear gravel or crushed rock surfaces.
5. Never make adjustments with unit
running unless otherwise specified in this
manual.
6. Let engine and snowthrower adjust to
outdoor temperatures before clearing
snow.
7. Always wear eye protection during
operation or while performing adjustment
or repair.
8. Check engine oil level before starting.
9. Handle gasoline with care. Gasoline is
highly flammable and its vapors are explo¬
sive. Check gas level in tank before starting
engine. DO NOT fill gas tank indoors or
with engine running or hot. Allow engine to
cool for several minutes before filling tank.
10. Use an approved fuel container. Use
a funnel or spout to help prevent spills.
After filling, securely reinstall gas tank and
fuel container caps. Wipe up spilled
gasoline before starting the engine.
11. Do not fill gas tank completely. Fill
tank only to within 1/2-inch of bottom of
filler neck to allow for expansion.
12. Keep smoking materials, sparks and
flames away from gas tank and fuel
container.
13. DO NOT operate unit without guards
and safety devices in place. DO NOT
attempt to defeat the purpose of any safety
device.
14. Before starting engine, check unit for
loose or missing fasteners (nuts, screws,
bolts, etc.).
15. Before starting engine, auger and
discharge chute must be free of ice.
16. F ollow instructions provided with
optional battery charger and electric start
kits and:
A. Use a three-pronged, outdoor¬
rated and approved electrical cord and
outlet. Do not use a damaged cord.
B. When connecting or discon¬
necting cord, stand on dry ground. Do not
stand in puddles or on wet or damp
ground. Hands or gloves must be dry. Do
not use electric starter during rainy
weather.
C. When connecting cord, first
connect cord to engine terminal, then to
properly grounded 110V outlet.
D. Do not abuse cord or yank to
disconnect. Never pull unit with cord. Keep
cord away from oil, sharp edges and exces¬
sive heat.
Operation
1. Before each use, check operation of
controls. Do not operate unit unless all
controls are functioning properly.
2. Do not put hands or feet near or under
rotating parts. Always keep clear of intake
and discharge openings.
3. Exercise extreme caution when oper¬
ating near or crossing gravel drives,
walkways or roadways. Stay alert for and
avoid hazards and traffic.
4. After striking an object, stop engine,
disconnect spark plug wire and prevent it
from touching spark plug. Remove key
from keyswitch. Carefully check for and
repair damage before restarting and oper¬
ating unit.
4

Safety (continued)
5. If unit should vibrate abnormally,
stop engine, disconnect spark plug wire
and prevent it from touching spark plug.
Remove key from keyswitch. Carefully
check for cause of vibration. Repair
damage before restarting and operating
unit.
6. Before clearing, repairing, or
inspecting unit or unclogging
auger/impeller housing or discharge
chute, stop engine and allow all moving
parts to stop. Disconnect spark plug wire
and prevent it from touching spark plug.
Remove key from keyswitch.
7. Do not run engine indoors. Exhaust
fumes contain carbon monoxide, a deadly
poison that is colorless, odorless and
tasteless.
8. Do not clear snow across the face of
slopes or hills. Be extremely cautious when
changing direction on slopes or hills. Do
not attempt to clear snow on slopes or hills
with more than a 10° incline.
9. Never operate unit without proper
guards, plates and other safety/protective
devices in place.
10. Never operate unit near buildings,
glass enclosures, automobiles, window
wells, drop-offs, etc. without proper
adjustment of snow discharge angle and
direction. Keep children and pets safely
away from unit and out of discharge
range.
11. Do not overload unit's capacity by
attempting to clear snow too fast.
12. Never operate unit at high transport
speeds on slippery surfaces.
13. Avoid throwing snow while backing.
If running unit in reverse becomes neces¬
sary, look in the direction you are moving
and proceed with caution. If you have to
pull unit rearward, release both drive
control levers. Always check behind you
for hazards.
14. Never direct discharge toward
bystanders. Never allow anyone in front of
unit while it is running.
15. Disengage power to auger when
transporting or not using unit.
16. Use only attachments and acces¬
sories recommended by Bolens
Corporation.
17. Never operate unit in poor visibility or
inadequate light.
18. Always be sure of your footing to help
avoid falling. Grasp handles firmly. Walk, do
not run, while operating unit.
19. NEVER use hands or feet to remove
snow from clogged auger/impeller or
discharge chute. Stop engine, disconnect
spark plug wire and prevent it from
touching spark plug. Remove spark plug to
help prevent engine compression from
causing movement. Remove key from
keyswitch. Use a long stick (at least three
feet long) to unclog the snow.
20. Do not alter engine governor setting
or overspeed engine.
21. Stop both wheel drive and auger drive
when any child, inattentive person or
animal approaches.
22. Do not touch engine parts which may
be hot from operation. Allow engine to
cool before inspecting, cleaning or
repairing unit.
23. Do not operate unit while under the
influence of alcohol or drugs.
24. Never carry children, people or
animals on unit. They could fall off and be
seriously injured, or interfere with safe
operation of unit.
25. Proceed with extra caution when
operating near corners, shrubs, trees and
objects which can obscure vision.
26. Keep children out of operating area and
under supervision of a responsible adult other
than person operating the unit. Children or
others may appear at any time, so be
prepared to stop suddenly and avoid them.
Never assume children will remain where last
seen.
27. Do not use unit near drop-offs,
ditches or embankments. If a wheel should
go over an edge, or if an edge caves in,
unit could fall or suddenly overturn.
28. Do not wear long, loose clothing or hair
that could get caught in rotating parts.
29. Exercise extreme caution to avoid
slipping or falling, especially while oper¬
ating in reverse.
Maintenance and Storage
1. Never perform maintenance with
engine running or when spark plug wire is
connected to spark plug.
2. Before season and every eight hours
of operation, check unit for loose or
missing fasteners (nuts, screws, bolts,
etc.). Check shear bolts and other
fasteners at frequent intervals for proper
tightness to help ensure unit is in safe
working condition.
3. Never store unit with gas in gas tank
inside a building where fumes may reach
an open flame or spark. Allow engine to
cool before storing unit in any enclosure.
4. Refer to “Storage” if storing unit
longer than three months.
5. Maintain or replace safety and
instructional labels as necessary. See
enclosed Parts Catalog for location of
replaceable labels.
6. Continue njnning unit for a few minutes
after throwing snow to help prevent auger
from freezing up. After stopping the engine,
bojsh snow off unit.
7. Use only genuine Bolens replacement
parts. Replacement parts manufactured by
others could present safety hazards even
though they may fit on this snowthrower.
8. Store gasoline in a cool, well-venti¬
lated area, safely away from sparks or
flame-producing equipment. Store
gasoline in an approved container, safely
out of the reach of children.
Decals
1. For your personal safety and the
safety of others, safety message decals are
affixed to your snowthrower. Keep these
decals clean and legible at all times.
Contact your local factory-authorized
servicing dealer or Bolens Corporation at
the address listed on the back cover of this
manual if any of these decals is missing or
becomes illegible.
2. Refer to the Snowthrower Parts
Catalog for decal locations, part(s)
number(s) and ordering instructions.
5

Section 2
Attachments & Kits
Below is a list of attachments and kits available for your snowthrower. The information is the most current at the time
this manual was printed. Check with your local factory-authorized Bolens dealer for more recent information.
Number
Description
Number
Description
42501
Blizzard Pack
6857
Starter Kit-110 Volt
42500
Cab Kit
N/A
Drift Slicers- Order two (2) 1715427 drift
1745785
Light Kit Assembly
slicer blades, four (4) 1100044 hex head
6918,
Tire Chains
cap screws and four (4) 1732499 lock nuts.
Section 3
Assembiy
Handlebars
Secure handlebars to chassis with four
3/8-16x3/4 bolts (A, Fig. 3-1).
Install Throttle Lever
1. Insert throttle lever (X, Fig. 3-2) up
through slot in left-hand side of control
panel. Secure with #10-24 x 5/8 screws
and #10 external lockwasher nuts (C).
Screws must pass through holes in
throttle base plate.
2. Place throttle lever knob (B, Fig. 3-1)
in 200° F water for 30 minutes. Tap knob
onto upper end of throttle lever.
Discharge Chute Assembly
1. Remove both side sets of shims and
clips (F and 6, Fig. 3-1 inset). Loosen but
do not remove front shim and clip. Apply
multi-purpose grease on surface of
discharge chute flange (P).
2. Reinstall discharge chute. Hook front
clip over deflector chute flange. Position
shims above clips between chute and
chute flange. Resecure all clips.
3. Install worm gear support bracket
(L). Teeth in worm gear must mesh with
teeth in base of discharge chute assembly.
Insert bolt (K) through hole in worm gear
support bracket (L) and mounting tab on
unit. Install and tighten nut on bolt (K).
4. Attach control rod sections (H, I, J):
A. Insert end of upper chute control
rod (I, Fig. 3-1 inset) as shown into nylon
swivel block (D) on end of middle chute
control rod (H).
B. Insert a cotter pin through hole in
upper section (I) of chute control rod.
Bend cotter pin so it remains in hole.
Repeat steps A and B for lower end of
control rod middle section (H).
5. Rotate chute control crank (M, Fig. 3-
1) at handlebar console. Deflector chute
should turn without binding. Readjust
bracket (L) and locknut (R) as necessary.
Auger Drive Control Rod
One end of auger drive control rod is
already attached to auger drive handlebar
control lever (l\l. Fig. 3-1).
1. Hook spring (0, Fig. 3-3) on lower
end of auger drive control rod into hole in
control arm (X). Press arm (X) down fully.
2. Measure and note spring (0) length,
then fully depress auger drive control lever
on right-hand handlebar. Spring should
now be 11/16" +/-1/16" (17 mm +/-1.5
mm) longer than earlier measurement. To
adjust:
A. Loosen jam nut (XX) and thread
upward on rod. Turn adjuster (YY) to
increase or decrease length as needed.
NOTE: 1-1/4 turns of adjuster equals
1/16“ (1.5 mm) of spring extension.
Wheel Drive Control Rod
One end of wheel drive control rod is
already attached to wheel drive handlebar
control lever (Q, Fig. 3-1).
1. Hook spring (00, Fig. 3-3) on lower
end of control rod into hole in control arm
(Z). Press control arm (Z) down fully.
2. Measure and note spring (00, Fig. 3-
3) length. Fully depress wheel drive
control lever on left-hand handlebar.
6

ATTENTION: OWNERS OF BOLENS® 8 AND 10 HP SNOWTHROWERS
SUPPLEMENT TO THE SAFETY AND OPERATION INSTRUCTIONS MANUAL
FOR BOLENS® LARGE FRAME SNOWTHROWERS
MODELS 624, 824. 824A, 1026 AND 1032
(This information is in addition to information in your Owners Manual,
Form 4210-2).
Keep this sheet with your owners manual. Please insert between
Pages 6 and 7.
PRE-OPERATIONAL CHECK
Before starting the engine on your BOLENS® snowthrower , please operate
the auger and wheel drive levers to make sure they release freely
(return to neutral) .
If levers do not operate freely, spread lower portion of both levers
outward to provide clearance of 1/16" between the lever and handle
(see illustration). Levers can be spread apart with an adjustable
wrench or pliers.
Form 4374-1

IMPORTANT PRODUCT NOTICE

Assembly (continued)
Spring should now be approximately
11/16" +/-1/16” (17 mm +/-1.5 mm)
longer. If not:
A. Loosen jam nut (JJ) and thread
upward on rod. Turn adjuster (SS) to
increase or decrease length as needed.
NOTE: 1-1/4 turns of adjuster equals
1/16" (1.5 mm) of spring extension.
B. Tighten jam nut (JJ) against
adjuster (SS).
NOTE: DO NOT over-tighten hardware.
Lever must move freeiy.
Gear Shift Rods
4. While holding gear shift lower rod
down, thread pivot block (Z, Fig. 3-2) so it
fits into hole in gear shift lever upper
section (U).
5. Reinstall pivot block (Z) in gear shift
control lever hole and secure with flat
washer and hairpin cotter. Tighten jam nut
against pivot block,
6. Move gear shift control lever (W, Fig.
3-1) through full range of travel and check
for binding, interference, etc.
7. Perform Drive Disc Clearance
Adjustment. See page 18.
1. A ttach gear shift lever upper section
(U, Fig. 3-2) and lower section (Z) together.
1. Attach gear shift upper rod (U, Fig. 3-
3) and lower rod (Y) together with 1/4-20 x
3/4 hex screws and 1/4-20 locknuts.
2. Move gear shift lever (W, Fig. 3-1) to
fifth gear. Remove hairpin cotter and flat
washer from pivot block (Z, Fig. 3-2).
Disconnect pivot block from gear shift
iever.
3. Push gear shift lower rod (Y, Fig. 3-3)
downward as far as possible.

Assembly (continued)
Wiring Harness Instailation
1. Connect lead wire (AB, Fig. 3-4) to
engine wiring harness connector. Plug lead
wire into connector receptacle containing
yellow wire (AC).
2. Connect eye terminal to screw (AD)
on engine shroud. Plug connector (AE)
into engine plug.
3. Secure wires to handlebars with tie
straps (E, Fig. 3-5).
Brake Arm Adjustment
1. Remove bolts securing belt cover
(AG. Fig. 3-5). Lift belt cover (C) up and off
unit.
2. Check brake arm adjustment:
A. Fully depress and hold auger
drive handlebar control lever (N). A second
person may need to hold handle down.
B. Look down through pulleys and
belts at front of engine (A, Fig. 3-6). Check
gap between brake arm (AH, Fig. 3-7) and
belt (AL). Gap should measure between
1/16" and 1/8" (1.5-3 mm).
C. T o adjust gap, loosen nut (Al).
Hold set screw (AK) in place with an alien
wrench and turn nut (AJ) until proper
clearance is obtained. Retighten nut (Al).
3. R einstall belt cover.
Engine Oil
A CAUTION
Engine is shipped WITHOUT oil.
DO NOT start engine before adding
correct type and amount of engine oil.
See engine owner's manual.
1. Unscrew oil fill cap (AM, Fig. 3-8) and
place aside. Insert a clean funnel into oil filler
tube (AL).
2. Slowly pour oil of the correct type
(see engine owner's manual) through
funnel and into oil filler tube. Engine holds
approximately 26 ounces. Fill to FULL
mark on dipstick.
NOTE: DO NOT overfill. While adding
oil to engine, frequently stop and check
oil level.
Tire Pressure
1. Check tire inflation pressure.
2. To help prevent pulling to one side,
inflate both tires evenly (8 to 12 psi).
Auger Gear Case Oil
Check auger gear case oil level. See
"Lubrication" on page 16 for instructions.
8

Assembly (continued)
Controls
Wheel Drive Control Lever
Wheel drive control lever (C, Fig. 4-1) is
iocated on top of left-hand handlebar tube
in front of hand grip. Push down to
engage wheel drive. Release to disengage.
Auger Drive Control Lever
Auger drive control lever (A, Fig. 4-1) is
located on top of right-hand handlebar
tube in front of hand grip. Push down to
engage auger (auger will rotate). Release
lever to disengage.
Gear Shift Lever
Located just left of center on control panel
(D, Fig. 4-1). Use to select one of five
forward gears or one of two reverse gears.
Gear shift lever does not control auger
speed. Select a gear by moving lever left,
then forward or rearward. Align lever with
notch for desired gear. While operating
unit, release wheel drive control lever and
come to a complete stop if moving. Select
desired notch and re-engage wheel drive
control lever.
When familiarizing yourself with gears or
when operating near obstacles, use lower
gears (first or second gear).
Discharge Chute Crank & Cap
Located slightly to right at center of
control panel (E, Fig. 4-1). Turning
discharge chute control crank clockwise
turns discharge chute left. Approximately
10 turns of crank are required to move
discharge chute from full left to full right.
9

Controls (continued)
Discharge snow in the same direction the
wind is blowing (as long as it is safe to do
so). As you change directions while
throwing snow, reposition discharge chute
so snow is discharged in the same direc¬
tion the wind is blowing (see
"Snowthrowing Patterns", page 14).
Discharge chute deflector cap (F, Fig. 4-3)
is located at top of discharge chute and
directs angle of snow discharge.
Adjust discharge angle by moving lever
(G) outward, moving cap up or down as
required and then releasing lever. During
usual snowthrowing operations, especially
during windy conditions, keep angle of
discharge low. Always operate unit with
chute guard (D) installed.
Engine Ignition Keyswitch
Keyswitch (D, Fig. 4-2) is located at front
edge of control panel, just left of center.
Keyswitch has two positions; RUN and
OFF. Turn key to RUN before starting unit.
Turn to OFF to stop.
Always remove ignition key when storing,
cleaning or performing any maintenance
on the snowthrower. Store in a safe place
out of reach of children.
Throttle
Located on left-hand side of control panel,
throttle (B, Fig. 4-2) alters engine speed.
For best performance, always operate
engine at FULL speed.
Skid Shoes
Skid shoes (H, Fig. 4-5) are located at
bottom sides of auger housing. Skid
shoes adjust housing height. A lower
auger housing makes a cleaner path when
throwing snow off smooth surfaces. When
operating across clear, level ground,
adjust skid shoes so scraper blade clears
ground by approximately 1/8" (3 mm).
Before operating on rough surfaces such
as gravel-covered roadways, adjust skid
shoes so the scraper blade travels above
gravel and doesn't collect or throw it.
Before operating on a gravel-covered area,
adjust skid shoes as follows:
1. Place unit on level surface, shut
engine OFF. Allow all moving parts to
come to a complete stop. Disconnect
spark plug wire and prevent it from
touching spark plug.
2. Loosen bolts securing skid shoes to
auger housing sides. Move skid shoes as
necessary to obtain desired gap between
scraper blade and ground. Adjust skid
shoes evenly or a sloping path will result.
Scraper Blade
Located at lower rear of auger housing,
scraper blade (I, Fig. 4-5) is adjustable.
Loosen nuts attaching blade to housing
and adjust blade as required.
Blade may wear. Inspect before operating
unit. Check for wear or damage and
service as necessary.
Engine Choke Knob
Engine choke knob (L, Fig. 4-6) is located at
engine rear on left-hand side of carburetor
heat box.
Before starting cold engine, rotate choke
knob clockwise to FULL CFIOKE position.
After engine starts and runs, gradually
rotate knob counterclockwise to CHOKE
OFF position.
A warm engine may require little or no
choking.
Pre-Start Primer Button
Pre-start primer button (M, Fig. 4-6) is
located at engine rear on upper left-hand
side. Pressing button pumps a small
amount of gasoline into engine to improve
cold starting.
NOTE: When pressing pre-start primer
button, cover small hole in button center
with one finger.
Engine Recoil Starter
Located at engine rear, engine recoil starter
is used to "pull-start” engine.
^ WARNING
DO NOT run engine indoors
or in poorly-ventilated areas.
Before using recoil starter, make sure there
are no obstacles behind you. Slowly pull
black plastic handle until you feel resis¬
tance, then rapidly and vigorously puli
handle. Maintain control of rope so it
slowly returns into starter mechanism.
Repeat pulling actions until engine starts.
Fuel Shutoff Valve
Located beneath gas tank, fuel shutoff valve
(Fig. 4-4) controls fuel flow to carburetor.
10

Controls (continued)
Fig. 4-6
Section 5
Operation
Pre-start Checklist
1. Review "Safety" and "Controls".
2. Check unit for loose or missing
lardware. Service as required.
3. Check engine oil level.
4. Check gas level in tank.
5. Check skid shoes and scraper blade
'or wear and proper adjustment.
7. Check discharge chute crank for
reedom of movement. Adjust discharge
;hute and deflector cap to desired direc-
:ion and angle of discharge.
8. Make sure chute guard is installed.
9. Check handlebar control levers for
reedom of movement.
: 0. Inflate tires evenly (8 to 12 psi).
lOTE: To help prevent snow from
iticking inside deflector, spray discharge
:hute and auger-impeller housing with
ilicone lubricant.
Filling Fuel Tank
1. Fill tank as follows:
A DANGER
EXPLOSION AND FIRE HAZARD.
• Never fill gas tank when engine is
running or hot. Allow engine and
muffler to cool at least two minutes
before refueling.
• DO NOT allow flames, sparks,
matches or smoking
within 50 feet of unit.
• Fill fuel tank outdoors in a well-
ventilated area.
• Wipe up ail spills and move unit
away from gasoline fumes
before starting engine.
• Store gasoline in an approved
gasoline container out of
reach of children.
A DANGER
EXPLOSION AND FIRE HAZARD.
• Store gasoline only in
a well-ventilated area.
• DO NOT store gasoline where vapors
may reach an open spark or flame.
• Never refuel gas tank
with optional
electrical starter installed.
A. Unscrew gas tank cap.
B. Insert a clean funnel into gas tank
or use a fuel container with a flexible pour
spout to pour gas into tank.
C. DO NOT fill gas tank completely.
Leave approximately 1/2" (13 mm) of air
space between fuel and tank neck.
D. Reinstall gas tank cap and wipe
up spilled gas.
11

Operation (continued)
Starting
1. Turn ignition key to RUN.
2. Move choke knob to FULL CHOKE
(warm engines require little or no
choking). Push pre-starting primer button
two or three times. If engine is warm,
push primer button once. If temperature is
below 15° F., you may have to push
button more than 2 or 3 times.
4. Move engine control lever to FAST.
5. Release auger and wheel drive levers.
6. To start engine with recoil starter:
A. Before using recoil starter, make
sure there are no obstacles behind you.
Place one hand on handlebar to stabilize
unit when you puli starter rope.
B. Pull rope handle until you feel
resistance. At point of resistance, pull
rapidly and vigorously. Maintain control of
rope so it slowly returns into starter mech¬
anism. Repeat pulling actions until engine
starts.
C. Gradually move choke knob to
NO CHOKE as engine warms up.
For optional 110V electric starter:
A WARNING
• DO NOT use 110V electric
starter during rainy weather.
• DO NOT stand in puddles or on damp
surfaces when connecting cord.
• DO NOT run engine indoors or in
poorly-ventilated areas.
A. Plug electrical cord into
switchbox on top of engine.
B. Plug other end of electrical cord
into a properly grounded 110V outlet.
C. Push starter button on top of
switchbox. As soon as engine starts,
release button.
NOTE: Starter is thermally protected.
When overheated from continuous use,
starter will automatically stop func¬
tioning. Allow starter to cool for several
minutes before making further attempts
to start engine.
D. A fter engine starts, gradually
move choke knob to NO CHOKE as engine
warms up.
Testing Auger and Wheel Drive
A WARNING
PERSONAL INJURY HAZARD.
• DO NOT use snowthrower if auger
spins before you squeeze
auger drive lever.
• DO NOT use snowthrower if auger
continues to spin after you release
auger drive lever.
1. To test auger drive, squeeze and
release auger drive lever. Auger should
begin spinning when lever is squeezed and
stop spinning when lever is released.
2. To test wheel drive, shift into first
gear.
A WARNING
PERSONAL INJURY HAZARD.
• DO NOT use snowthrower if wheels
turn before you squeeze
wheel drive lever.
• DO NOT use snowthrower if wheels
continue to turn after you release
wheel drive lever.
3. Squeeze and release wheel drive
lever. Wheels should begin turning when
lever is squeezed and stop turning when
lever is released.
4. Move gear shift lever to desired gear.
Starting in first gear is not necessary.
4. If both handlebar levers operate
properly, re-engage and begin operation.
NOTE: To move unit without throwing
snow, engage wheel drive lever. Leave
auger drive lever disengaged (released)
while moving.
Stopping
To quickly stop snowthrower:
1. R elease both handlebar levers.
2. T urn ignition key to OFF position.
To Stop snowthrower (normal condi¬
tions):
1. Release both handlebar levers.
2. Move throttle lever to idle position.
Allow engine to run at idle for several
minutes to melt snow off engine.
To help avoid possible freezing of starter
when snowthrower is not in use:
1. For pull start engines:
With engine OFF, pull recoil starter
rope all the way out. Repeat 3 or 4 times.
For engines with 110V electric start
kit installed:
A. Connect electrical cord to
switchbox.
B. Connect other end of cord to
110V outlet.
C. With engine OFF, push starter
button and spin starter for several
seconds.
D. Disconnect electrical cord from
outlet, then from switchbox.
2. Turn ignition key to OFF.
3. Disconnect spark plug wire and
prevent it from touching spark plug.
To help avoid possible freezing of
controls:
1. Wipe engine of all snow and moisture
in, on, near and around throttle control
lever linkage and choke knob. Spray
linkage and levers with a non-silicone
lubricant.
2. Move throttle control lever and choke
knob back and forth several times.
3. Move choke to FULL CHOKE and
leave in this position.
4. Move throttle to start position and
leave it there.
5. Close fuel valve located beneath fuel
tank.
Changing Gears
Begin operating in any gear, including
reverse. Shifting from first gear through
fifth is not necessary.
12

A CAUTION
Unit must be completely
stopped while shifting. Damage to
transmission will result if
this instruction is not followed.
• DO NOT shift whiie in motion!
DO NOT shift from one gear into any other
with unit in motion. Damage to transmis¬
sion may resuit. Aliow unit to stop
compieteiy before shifting into any other
gear, especialiy before shifting into
reverse.
To shift into reverse:
1. Reiease both handiebar ievers (auger
drive wheel drive levers). Allow unit to
come to a complete stop.
2. Move gear control lever into reverse.
A CAUTION
Faiiure to foiiow this instruction
couid resuit in personal injury
or property damage.
• Before engaging wheel drive lever,
look behind for and avoid obstacles.
3. Slowly begin squeezing wheel drive
lever and guide unit rearward.
4. Allow unit to stop completely before
shifting into a forward gear.
Before shifting to another gear, release
handlebar levers. Allow unit to stop
completely. Then, move gear control lever
re-engage wheel drive lever. Wheel drive
lever may be engaged with gear control
lever in any gear, including reverse.
Snowthrowing Tips
Run engine at full throttle when throwing
snow. Use slower wheel speed (first or
second gear) in heavy, wet snow.
Spray auger, inside auger housing, inside
discharge chute and inside deflector chute
with silicone spray to help prevent snow
from sticking.
Inspect operating area before snowfall.
Remove all objects from surface such as
rocks, mats, boards, wires, nails, etc.
For best results, remove snow as soon as
possible after it falls.
Slightly overlap your previous path on
each pass to help assure complete snow
removal.
Throw snow downwind whenever possible,
or snow may blow back.
When throwing snow from a smooth area,
adjust skid shoes so scraper blade to
ground clearance is approximately 1/8“ (3
mm). When operating on gravel-covered
or similar terrain, adjust skid shoes so
scraper blade clears gravel.
A WARNING
• DO NOT use hands or feet to dislodge
snow stuck in deflector chute or
auger!
• Shut engine off, disconnect spark
plug wire from spark plug and prevent
wire from contacting plug.
• Use a stick at least three feet long
to unclog snowthrower.
DO NOT use hands or feet to dislodge
snow stuck in deflector chute or auger.
Shut engine off, disconnect spark plug
wire and prevent it from touching spark
plug. Use a long stick (at least three feet
long) to unclog deflector chute or auger.

Operation (continued)
Snowthrowing Patterns
Use pattern in Fig. 5-1 when snow cannot
be thrown to one side. Begin throwing
snow closest to the side where it cannot
be thrown, angling discharge chute to
direct snow away from that side. When
turning unit around after each pass, crank
discharge chute as you proceed so snow
is thrown in proper direction.
Use pattern in Fig. 5-2 to throw snow on
both right and left sides. When turning
snowthrower, crank discharge chute as
necessary to throw snow in proper direc¬
tion.
<.* « cr__ Ci
SNOW IS THROWN TO EITHER SIDE
Discharge chute direction
stays the same except
when turning.
Snow is thrown to each
side.
SNOW IS THROWN TO EITHER SIDE
Fig. 5-2

Sections
Maintenance
Checking and adding oil
1. Shut engine off. Unscrew oil fill
cap/dipstick (AM, Fig. 6-1) and wipe with
clean, lint-free cloth.
2. Re-insert and firmly screw dipstick
into oil fill tube (AL), then unscrew and
check oil level. Level should be between
FULL and ADD marks on dipstick. Add oil
as necessary.
NOTE: DO NOT overfill. Damage to
engine seals may result.
Changing oil
IMPORTANT: After the first two hours of
use, change engine oil.
After initial change, change oil every 25
hours of operation or at end of each
snowthrowing season.
1. To change engine oil, start and run
engine to operating temperature.
2. SHUT ENGINE OFF.
3. F old a piece of cardboard approxi¬
mately 3" X 6" (7.5 X15 cm) in size length¬
wise into a shallow V-shape (see Fig. 6-2).
4. Loosen BUT DO NOT REMOVE engine
oil drain plug cap (AK, Fig. 6-1). Place
folded cardboard beneath drain as shovi/n
in Fig. 6-2.
5. Place a suitable container (minimum
capacity; 1 quart) underneath end of card¬
board to catch draining oil. Slowly,
unscrew oil drain plug cap. Allow oil to run
down cardboard and into container. After
oil stops draining, reinstall oil drain plug
cap.
6. Unscrew oil fill cap/dipstick and wipe
with a clean, lint-free cloth. Insert a clean
funnel into oil filler tube.
7. Add fresh, clean oil of correct type
(see engine owner's manual) through
funnel and into oil filler tube. Engine will
hold approximately 26 ounces of oil.
Check oil level.
NOTE: DO NOT overfill. Overfilling
engine may damage engine seals.
8. Wipe up oil spills and drips immedi¬
ately. Dispose of oil in accordance with local
regulations.
Fig.6-2
Spark Plug
Yearly or after every 100 hours of opera¬
tion, remove, clean and inspect spark plug.
Clean plug by scraping (don't wire brush
or sandblast) deposits and residue away.
Replace spark plug with new one of same
type (see engine owner's manual) if elec¬
trodes are pitted or burned or if porcelain
is cracked.
If your unit came equipped with a resistor-
type spark plug when new, always replace
with a resistor-type spark plug. Refer to
the engine owner's manual.
Before installing spark plug, set electrode
gap to 0.030" (O.BOmm). See Fig. 6-3.
.030 (.8 mm)
FEELER GAUGE
COMPLIANCE WITH RADIO
INTERFERENCE REGULATIONS
CERTIFIED. REPLACE SPARK
PLUG WITH RESISTOR SPARK
PLUG ONLY.
Fig. 6-3
15

Maintenance (continued)
Lubrication
At the beginning and end of each season
or after every 25 hours of operation, iubri-
cate unit as recommended beiow.
1. Lightly oii both deflector chute cap
pivot points (D, Fig. 6-4) located on each
side of the defiector chute cap.
2. Appiy oii to discharge chute control
rod pivot points w/here crank enters;
A. Control panel rear lip (A, Fig. 6-5);
B. Support tab on front edge of
control panel (B, Fig. 6-5);
C. Support on left rear end of
snowthrovirer housing (S, Fig. 6-7).
3. Remove left-hand wheel (J, Fig. 6-4).
Ciean wheel shaft and apply fresh bearing
grease to shaft. Reinstali left-hand wheel.
4. Apply oil to bearings on sides of auger
shaft (P, Fig. 6-4). Wipe off excess oil.
5. Clean dirt and remove old grease
from toothed portion on flange at bottom
of discharge chute (B, Fig. 6-4). Apply
fresh grease to worm gear, toothed portion
of flange and flange. Adjust lock nut (R)
and friction shims (S) to help prevent
force of snow discharge from turning
chute. Periodically check tightness of lock
nut (R). Do not overtighten lock nut (R).
6. Lubricate handlebar levers at pivot
points (C, Fig. 6-5) with engine oil or a
non-slllcone spray. DO NOT get oil or
lubricating spray on levers.
7. Apply a few drops of ciean engine oil
to pivot points on throttle control lever and
gear shift control lever (D, Fig. 6-5).
8. Remove shear bolts from auger shaft,
then lubricate the four auger grease
fittings (0, Fig. 6-6) using a grease gun
dispensing multipurpose automotive lubri¬
cant. Carefully and slowly spin auger three
or four times. Reinstall shear bolts.
NOTE: If replacing an auger shear bolt,
order part number 1735625. Only use
auger shear bolts supplied by Bolens.
Other bolts may not shear properly and
could cause damage to unit.
9. Check oil level in auger gear box;
A. Place snowthrower on smooth,
level surface. Unscrew plug (R, Fig. 6-6)
from front of gear box.
B. Inspect plug hole. Oil should just
begin to seep out of hole. If oil does not
appear, add SAE 90 gear oil until oil just
begins to flow out of hole.
C. Reinstall plug. Wipe oil from gear
box, snowthrower and work surface.
10. Remove bolts (V and W, Fig. 6-7)
securing bottom cover to unit. Remove
bottom cover. Apply a light coating of
grease to shafts (A and B, Fig. 6-9).
Prevent grease from contacting rubber
drive wheel (C) ordrippng onto drive disc
(D). If grease should contact these parts,
clean thoroughly to deter slippage and
help assure trouble-free operation.
Wheel Drive Belt Adjustment
To check wheel drive belt tension:
1. Measure length of spring (T, Fig. 6-7)
on lower end of wheel drive control rod
(Z). Squeeze wheel drive control lever.
Hold lever down and remeasure length of
spring. Spring should now measure
11/16 in. +/-1/16 in. (17 mm +/-1.5 mm)
longer than first measurement.
2. If difference between measurements
is not 11/16 in., adjust belt tension:
A. Loosen jam nut (U, Fig. 6-7).
Turn adjuster (X) up the control rod to
increase or down to decrease distance
measured in step 1 (each 1 -1/4 turn of
adjuster will equal 1/16 in. (1.5 mm) of
spring extension).
B. Repeat step 1. If difference in
measurements is not 11/16 in., repeat
adjustment. When measurement differ¬
ence is 11/16 in., tighten jam nut (U)
against adjuster (X).
16

Maintenance (continued)
Wheel Drive Belt Replacement
To replace wheel drive belt:
1. Remove two bolts (AG, Fig. 6-4) and
belt cover from unit.
2. Remove two bolts securing belt guide
(0, Fig. 6-8) to back of engine. Remove
belt guide.
3. Moveaugerdrivebelt(N)outof
groove in auger drive pulley (P). Release
tension on idler (JJ).
4. Move wheel drive belt (F) off lower
drive pulley (I). Depress wheel drive
handle on left handlebar (Q, Fig. 6-4) to
increase gap between lower pulleys as
needed. Move lower part of wheel drive
belt up through gap.
5. Move belt off upper drive pulley.
Remove belt from unit.
6. Insert lower end of wheel drive belt
down through gap between both lower
drive pulleys. Place lower end of belt into
lower drive pulley groove.
7. Pivot idler (JJ, Fig. 6-8) rearward.
Place upper end of belt into groove closest
to engine. Reinstall auger drive belt in its
pulley groove.
8. Reinstall belt guide (0). Perform
wheel drive belt adjustment.
9. Reinstall belt cover.
Auger Drive Belt Adjustment
Eventually, due to wear, auger drive belt
may begin to slip when auger drive handle
is engaged. To adjust auger drive belt:
1. Check spring (K, Fig. 6-7) tension as
follows:
A. Measure spring length.
B. Engage auger drive control lever.
Flold lever down and remeasure spring
length. Difference should be 11/16 in. +/-
1/16 in. (17 mm +/-1.5mm).
2. If difference is not 11/16 in., adjust
control rod as follows:
17

Maintenance (continued)
A. Loosen jam nut (M) seated
against adjuster (N) on lower end of
control rod. Turn adjuster (N) up the rod
to increase spring length or down to
decrease length. Each 1-1/4 turn of
adjuster (N) equals 1/16" (1.5 mm) of
spring length.
B. Repeat as necessary until 11/16
in. +/-1/16 in. (17 mm +/-1.5 mm) differ¬
ence between both spring measurements
is obtained, then tighten jam nut (M)
against adjuster (N).
3. E nsure that there is 1/16-1/8 in.
(1.5-3 mm) of clearance between brake
arm and auger drive belt. See "Brake Arm",
page 7.
Auger Drive Belt Replacement
To remove auger drive belt:
1. Remove two bolts securing belt cover
(AG, Fig. 6-4) to snowthrower. Remove
belt cover.
2. Remove two bolts securing belt guide
(0, Fig. 6-10) to back of engine. Remove
belt guide.
3. Move auger drive belt (N) out of
groove in auger drive pulley (P).
4. Move lower part of auger drive belt
off lower drive pulley (Q). To allow more
room for belt removal, pull brake arm (R)
outward.
5. M ove lower part of auger drive belt up
through gap between lower pulleys.
To install auger drive belt:
1. Push lower end of auger drive belt (l\l)
down through gap between both lower
drive pulleys. Move belt forward and place
in lower drive pulley (Q) groove. When
placing lower end of auger drive belt on
pulley, push outward on brake arm (R) for
additional clearance.
2. Place upper end of auger drive belt
(N) into groove in pulley (P). Reinstall belt
guide (0).
3. Check auger drive belt and adjust as
necessary. See "Auger Drive Beit
Adjustment" on page 17.
4. Reinstall belt cover.
Slip Differential Adjustment
1. R emove black plastic cover (A, Fig. 6-
11) at end of right-hand axle shaft.
Remove outer jam nut (B). Remove inner
jam nut (C) and both pairs (four single) of
disc springs (D). Each pair consists of two
curved washers aligned so the concave
side of one washer faces the concave side
of the other washer. Reinstall disc springs
(D) and inner jam nut (C). Tighten jam nut
(C) by hand until it contacts disc spring,
then tighten 1 to 1-1/4 turns more. DO
NOT force nut further than 1-1/4 turns or
slip differential will not work properly.
2. R einstall outer jam nut (B). Hold inner
nut (C) in place,. Use wrench to tighten
outer nut (B). Reinstall black plastic cover
(A) at end of right-hand axle shaft.
Drive Disc Clearance Adjustment
If gear shift lever does not move freely
through all positions in shift quadrant with
wheel drive lever disengaged, adjustment
may be required.
1. Remove bolts attaching bottom plate
to rear of chassis. Remove plate.
2. Check clearance (A, Fig. 6-12)
between disc and rubber drive wheel.
Clearance should measure between 0.060"
and 0.125" (3-15 mm) when wheel drive
lever is disengaged (released). If clearance
is correct, drive disc clearance adjustment
is correct.
To adjust:
A. Loosen jam nut (C, Fig. 6-13).
Turn adjusting screw (D) until clearance is
correct.
B. Tighten jam nut and re-check
clearance. Ensure that gear shift lever
moves without hindrance through all posi¬
tions in shift quadrant.
3. Slide bottom plate back into place.
Secure with bolts previously removed.
4. Perform auger drive belt adjustment.
18