Craftsman 944.362490 User manual

Model No.
944.362490
CAUTION:
Read and follow all
Safety Rules and Instructions
before operating this equipment
Owner’s Manual
ROTARY LAWN MOWER
5.5 Horsepower
21" Multi-Cut
Sears Canada, Inc., Toronto, Ontario M5B 2B8
181668 Rev. 4 05.16.02 BY Printed in U.S.A.

2
Warranty ................................................. 2
Safety Rules ........................................ 2-4
Assembly/Pre-Operation ........................ 4
Operation ............................................. 5-9
Maintenance Schedule ........................ 10
Maintenance ................................... 10-13
Product Specifications .......................... 11
Service and Adjustments ...................... 13
Storage ........................................... 14-15
Troubleshooting ................................... 16
Repair Parts .................................... 18-23
Parts Ordering ....................... Back Cover
TABLE OF CONTENTS
SAFETY RULES
I. GENERAL OPERATION
• Read, understand, and follow all
instructions on the machine and in the
manual(s) before starting. Be thor-
oughly familiar with the controls and
the proper use of the machine before
starting.
• Do not put hands or feet near or under
rotating parts. Keep clear of the
discharge opening at all times.
• Only allow responsible individuals,
who are familiar with the instructions, to
operate the machine.
• Clear the area of objects such as
rocks, toys, wire, bones, sticks, etc.,
which could be picked up and thrown
by the blade.
• Be sure the area is clear of other
people before mowing. Stop machine if
anyone enters the area.
• Do not operate the mower when
barefoot or wearing open sandals.
Always wear substantial foot wear.
IMPORTANT: This cutting 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.
Look for this symbol to point out
important safety precautions. It means
CAUTION!!! BECOME ALERT!!! YOUR
SAFETY IS INVOLVED.
CAUTION: Always disconnect spark
plug wire and place wire where it cannot
contact spark plug in order to prevent
accidental starting when setting up,
transporting, adjusting or making repairs.
CAUTION: Muffler
and other engine parts become extremely
hot during operation and remain hot after
engine has stopped. To avoid severe
burns on contact, stay away from these
areas.
LIMITED TWO YEAR WARRANTY ON CRAFTSMAN POWER MOWER
For Two years from date of purchase Sears Canada, Inc. will repair or replace at Sears
option free of charge parts which are defective as a result of material or workmanship.
COMMERCIAL OR RENTAL USE:
Warranty on Power Mower (Gas) will be ninety (90) days from date of purchase if used
for commercial or rental purposes.
This Warranty does NOT cover:
• Pre-delivery set-up.
• Expendable items which become worn during normal use, such as rotary mower
blades, blade adapters, belts, air cleaners and spark plug.
• Repairs necessary because of operator abuse or negligence, including bent
crankshafts and the failure to maintain the equipment according to the instructions
contained in the owner’s manual.
Warranty service is available by returning the Craftsman Power Mower to the nearest
Sears Service Centre/Department in Canada. This warranty applies only while this
product is used in Canada.
This warranty is in addition to any statutory warranty and does not exclude or limit legal
rights you may have but shall run concurrently with applicable provincial legislation.
Furthermore, some provinces do NOT allow limitation on how long an implied warranty
will last so the above limitations may not apply to you.
SEARS CANADA, INC., TORONTO, ONTARIO M5B 2B8
WARRANTY
23
MODEL NUMBER GCV-160-A1AEHONDA 4-CYCLE ENGINE
CYLINDERBARREL
KEY PART
NO. NO. DESCRIPTION
1 5579982 Cylinder Assembly
2 2399780 Clip, Valve Guide
3 5579990 Cover, Head
4 5580006 Cover Comp., Breather
5 0636845 Bolt, Flange (6 x 12)
6 0803619 Bolt, Flange (6 x 14)
7 5581038 Oil Seal 25.4 x 62 x 6
8 1441112 Spark Plug (BPR6ES NGK)
CRANKSHAFT
KEY PART
NO. NO. DESCRIPTION
1 5580030 Crankshaft Comp. (N1-Type)
5 5581012 Washer Thrust
AIRCLEANER
KEY PART
NO. NO. DESCRIPTION
1 5580154 Tube, Breather
2 5580402 Element, Air Cleaner
3 5581410 Case Assembly, Air Cleaner
5 5664560 Gasket, Air Cleaner
6 5580444 Cover, Air Cleaner
7 5580964 Bolt, Flange (6 x 86)
8 2374742 Bolt, Flange (6 x 14)
OIL PAN
KEY PART
NO. NO. DESCRIPTION
1 5579974 Pan Assembly, Oil
2 4497947 Gasket, Oil Filler Cap
4 5580261 Shaft Comp., Governor Holder
5 5580279 Governor Assembly
6 5580287 Weight, Governor
7 5580295 Holder, Governor Weight
8 1427244 Pin, Governor Weight
9 1427251 Slider, Governor
10 5580303 Shaft, Governor Arm
11 0803619 Bolt Flange (6 x 14)
12 0748111 Bolt, Flange (6 x 25)
13 2413862 Washer, Thrust 6mm
14 2456697 Clip, Governor Holder
15 5581046 Oil Seal (28 x 41.25 x 6)
16 0345900 Washer, Plain, 6mm
17 0115527 Pin, Lock, 8mm
18 1417369 Pin, Dowel (8 x 20)
19 5722996 Gauge Assembly, Oil Level
PISTONCONNECTINGROD
KEY PART
NO. NO. DESCRIPTION
1 5580014 Piston
2 1426576 Pin, Piston
3 5580022 Rod Assembly, Connecting
4 1431055 Bolt, Connecting Rod
5 2605517 Clip, Piston Pin 13mm
6 5655949 Ring Set, Piston (Riken)
6 5655956 Ring Set, Piston (Teikoku)
RECOILSTARTER
KEY PART
NO. NO. DESCRIPTION
1 5597869 Starter Assy., Recoil,
NH1, Long Rope, Black
2 5580634 Knob, Recoil Starter
3 5580642 Rope, Recoil Starter
4 2866341 Nut, Flange, 6mm
MUFFLER
KEY PART
NO. NO. DESCRIPTION
1 5580485 Muffler Comp.
2 5580501 Protector, Muffler
3 5580972 Bolt, Flange (6 x 79) CT200
4 0636845 Bolt, Flange (6 x 12)
5 5737457 Gasket, Muffler (Optional)

3
• Do not pull mower backwards unless
absolutely necessary. Always look
down and behind before and while
moving backwards.
• Do not operate the mower without
proper guards, plates, grass catcher or
other safety protective devices in place.
• See manufacturer’s instructions for
proper operation and installation of
accessories. Only use accessories
approved by the manufacturer.
• Stop the blade(s) when crossing gravel
drives, walks, or roads.
• Stop the engine (motor) whenever you
leave the equipment, before cleaning
the mower or unclogging the chute.
• Shut the engine (motor) off and wait
until the blade comes to complete stop
before removing grass catcher.
• Mow only in daylight or good artificial
light.
• Do not operate the machine while
under the influence of alcohol or drugs.
• Never operate machine in wet grass.
Always be sure of your footing: keep a
firm hold on the handle and walk; never
run.
• Disengage the self-propelled mecha-
nism or drive clutch on mowers so
equipped before starting the engine
(motor).
• If the equipment should start to vibrate
abnormally, stop the engine (motor)
and check immediately for the cause.
Vibration is generally a warning of
trouble.
• Always wear safety goggles or safety
glasses with side shields when operat-
ing mower.
II. SLOPE OPERATION
Slopes are a major factor related to slip
and fall accidents which can result in
severe injury. All slopes require extra
caution. If you feel uneasy on a slope, do
not mow it.
• Mow across the face of slopes: never
up and down. Exercise extreme caution
when changing direction on slopes.
• Remove obstacles such as rocks, tree
limbs, etc.
• Watch for holes, ruts, or bumps. Tall
grass can hide obstacles.
DO NOT:
• Do not trim near drop-offs, ditches or
embankments. The operator could lose
footing or balance.
• Do not trim excessively steep slopes.
• Do not mow on wet grass. Reduced
footing could cause slipping.
III. CHILDREN
Tragic accidents can occur if the operator
is not alert to the presence of children.
Children are often attracted to the
machine and the mowing activity.
Never
assume that children will remain where
you last saw them.
• Keep children out of the trimming area
and under the watchful care of another
responsible adult.
• Be alert and turn machine off if children
enter the area.
• Before and while walking backwards,
look behind and
down for small
children.
• Never allow children to operate the
machine.
• Use extra care when approaching blind
corners, shrubs, trees, or other objects
that may obscure vision.
IV. SERVICE
• Use extra care in handling gasoline
and other fuels. They are flammable
and vapors are explosive.
- Use only an approved container.
- Never remove gas cap or add fuel
with the engine running. Allow
engine to cool before refueling. Do
not smoke.
- Never refuel the machine indoors.
- Never store the machine or fuel
container inside where there is an
open flame, such as a water heater.
• Never run a machine inside a closed
area.
• Never make adjustments or repairs with
the engine (motor) running. Disconnect
the spark plug wire, and keep the wire
away from the plug to prevent acciden-
tal starting.
• Keep nuts and bolts, especially blade
attachment bolts, tight and keep
equipment in good condition.
• Never tamper with safety devices.
Check their proper operation regularly.
• Keep machine free of grass, leaves, or
other debris build-up. Clean oil or fuel
spillage. Allow machine to cool before
storing.
• Stop and inspect the equipment if you
strike an object. Repair, if necessary,
before restarting.
• Never attempt to make wheel height
adjustments while the engine (motor) is
running.
22
MODEL NUMBER GCV-160-A1AEHONDA 4-CYCLE ENGINE

4
ASSEMBLY / PRE-OPERATION
Read these instructions and this manual
in its entirety before you attempt to
assemble or operate your new lawn
mower.
IMPORTANT: This lawn mower is
shipped WITHOUT OIL OR GASOLINE in
the engine.
Your new lawn mower has been as-
sembled at the factory with the exception
of those parts left unassembled for
shipping purposes. All parts such as
nuts, washers, bolts, etc., necessary to
complete the assembly have been placed
in the parts bag. To ensure safe and
proper operation of your lawn mower, all
parts and hardware you assemble must
be tightened securely. Use the correct
tools as necessary to ensure proper
tightness.
TO REMOVE LAWN MOWER FROM
CARTON
1. Remove loose parts included with
mower.
2. Cut down two end corners of carton
and lay end panel down flat.
3. Remove all packing materials except
padding between upper and lower
handle and padding holding operator
presence control bar to upper handle.
4. Roll lawn mower out of carton and
check carton thoroughly for additional
loose parts.
HOW TO SET UP YOUR LAWN
MOWER
TO UNFOLD HANDLE
IMPORTANT: Unfold handles carefully so
as not to pinch or damage control cables.
1. Raise handles until lower handle
section locks into place in mowing
position.
2. Remove protective padding, raise
upper handle section into place on
lower handle and tighten both handle
knobs.
3. Remove handle padding holding
operator presence control bar to
upper handle.
TO ASSEMBLE GRASS CATCHER
1. Put grass catcher frame into grass bag
with rigid part of bag on the bottom.
Make sure the frame handle is outside
of the bag top.
2. Slip vinyl bindings over frame.
NOTE: If vinyl bindings are too stiff, hold
them in warm water for a few minutes. If
bag gets wet, let it dry before using.
TO INSTALL ATTACHMENTS
Your lawn mower was shipped ready to
be used as a mulcher. To convert to
bagging or discharging, see “TO CON-
VERT MOWER” in the Operation section
of this manual.
Your lawn mower handle can be adjusted
for your mowing comfort. Refer to
“ADJUST HANDLE” in the Service and
Adjustments section of this manual.
• Grass catcher components are subject
to wear, damage, and deterioration,
which could expose moving parts or
allow objects to be thrown. Frequently
check components and replace with
manufacturer’s recommended parts,
when necessary.
• Mower blades are sharp and can cut.
Wrap the blade(s) or wear gloves, and
use extra caution when servicing them.
• Do not change the engine governor
setting or overspeed the engine.
Mowing
position
Lower handle
LIFT
UP
Operator presence
control bar
Upper handle LIFT UP
Catcher
frame
handle
Vinyl
bindings
Frame
opening
21
MODEL NUMBER GCV-160-A1AEHONDA 4-CYCLE ENGINE
CONTROL
KEY PART
NO. NO. DESCRIPTION
1 5580311 Arm, Governor
2 5580329 Rod, Governor
3 5580345 Spring, Governor
4 5580352 Spring, Throttle Return
5 4439428 Spring, Lever
6 0800466 Holder, Cable
7 5580378 Base Comp., Control (Use up to
Serial Number 1177559)
6094122 Base Comp., Control (Use from
Serial Number 1177560)
8 5580386 Rod, Choke
9 2418671 Bolt, Governor Arm
10 5580998 Bolt, Flange (6 x 45) (ct200)
11 0145557 Screw, Pan (5 x 16)
12 0471623 Nut, Flange, 6mm
CAMSHAFTPULLEY
KEY PART
NO. NO. DESCRIPTION
1 5580055 Pulley Comp., Camshaft
2 5580063 Shaft, Cam Pulley
3 5580071 Belt, Timing
4 5580089 Arm, Intake Valve Rocker
5 5580097 Arm, Exhaust Valve Rocker
6 5580105 Shaft Rocker Arm
7 5580113 Valve, Intake
8 5580121 Valve, Exhaust
9 5580139 Spring, Valve
10 1426980 Retainer, Intake Valve Spring
11 0294819 Screw, Tappet Adjuster
12 0004598 Nut, Tappet Adjuster
13 0018044 O-ring
13 2373447 O-ring
CARBURETOR
KEY PART
NO. NO. DESCRIPTION
1 3088416 Gasket Set
2 5580162 Float Set
3 4930756 Chamber Set, Float
4 4481818 Screw Set
5 1441518 Screw Set
6 5580170 Screw Set
7 5664552 Carburetor Assembly
8 5580212 Valve Float
9 5580220 Nozzle Main
10 5580238 Insulator, Carburetor
11 5580246 Gasket, Insulator
12 4581120 Gasket, Carburetor
13 5580253 Gasket, Carburetor
14 5580535 Guide Comp., Air
15 0639419 Screw, Pan (5 x 6)
15 3344520 Screw, Pan (5 x 6)
16 0635474 Jet, Main #60 (optional)
16 0635482 Jet, Main #62 (optional)
16 0636126 Jet, Main #65 (optional)
FANCOVER
KEY PART
NO. NO. DESCRIPTION
1 3683646 Rubber, Supporter, 107 mm
2 5028923 Petcock Assembly, Manual
3 5580394 Bracket, Petcock
4 5580451 Cap Assembly, Fuel Tank
5 5580469 Tube, Fuel
6 5580519 Cover Comp., Fan, NH1, Black
7 5580527 Coller, Fan Cover
8 2499440 Collar, Front Turn Signal
9 5581004 Bolt, Stud
10 0671636 Screw, Washer, 5 x 10
11 2449593 Bulk Hose, Fuel
12 0250647 Clip, Tube (B8)
13 0250985 Clip, Tube (B10)
14 0053447 Clip, Tube (C9)
FLYWHEEL
KEY PART
NO. NO. DESCRIPTION
1 0348433 Key, Special Woodruff (25 x 18)
2 5580659 Coil Assembly, Ignition
3 5723747 Flywheel Assembly
4 5580675 Wire, Stop Switch
5 5580683 Switch Assembly, Engine Stop
6 5580782 Brake Assembly
7 5580790 Spring, Brake Lever
8 0803619 Bolt Flange (6 x 14)
9 1725050 Bolt, Flange (6 x 23)
10 0671552 Bolt, Flange (6 x 20)
11 0442038 Nut, Special, 14mm
12 1824630 Clip Cable
13 0485946 Screw, Washer (4 x 12)
14 1510361 Washer, Plain

5
OPERATION
KNOW YOUR LAWN MOWER
READ THIS OWNER'S MANUALAND ALL SAFETY RULES BEFORE OPERATING YOUR
LAWN MOWER. Compare the illustrations with your lawn mower to familiarize yourself with
the location of various controls and adjustments. Save this manual for future reference.
Starter
handle Gasoline filler cap
Housing
Throttle/
choke
control
Wheel adjuster
(on each wheel)
Handle knob
Grass
catcher
Engine oil cap
with dipstick
Operator presence control bar
Fuel valve lever
MEETS CPSC SAFETY REQUIREMENTS
Sears rotary walk-behind power lawn mowers conform to the safety standards of the American
National Standards Institute and the U.S. Consumer Product Safety Commission. The blade
turns when the engine is running.
Operator presence control bar – must
be held down to the handle to start the
engine. Release to stop the engine.
Mulcher door – allows conversion to
discharging or bagging operation.
These symbols may appear on your lawn mower or in literature supplied with the product. Learn and
understand their meaning.
IMPORTANT: This lawn mower is shipped WITHOUT OIL OR GASOLINE in the engine.
Mulcher door
Throttle/choke control – used for starting
the engine; & allows you to select either
CHOKE or FAST engine speed.
Starter handle – used for starting the
engine.
Muffler
Air filter
20
MODEL NUMBER GCV-160-A1AEHONDA 4-CYCLE ENGINE

6
The operation of any lawn
mower can result in foreign
objects thrown into the
eyes, which can result in
severe eye damage.
Always wear safety glasses or eye
shields while operating your lawn mower
or performing any adjustments or repairs.
We recommend standard safety glasses
or a wide vision safety mask worn over
spectacles.
ENGINE CONTROL
The engine is controlled by a throttle
control located on the side of the upper
handle. CHOKE position is for starting a
cold engine and FAST position is for
starting a warm engine and normal
operation. The engine speed is not
adjustable.
ENGINE ZONE CONTROL
CAUTION: Federal regulations require
an engine control to be installed on this
lawn mower in order to minimize the risk
of blade contact injury. Do not under any
circumstances attempt to defeat the
function of the operator control. The blade
turns when the engine is running.
• Your lawn mower is equipped with an
operator presence control bar which
requires the operator to be positioned
behind the lawn mower handle to start
and operate the lawn mower.
LOWER WHEELS FOR HIGH CUT
RAISE WHEELS FOR LOW CUT
Plate tab
Lever
TO CONVERT MOWER
Your lawn mower was shipped ready to
be used as a mulcher. To convert to
bagging or discharging:
REAR BAGGING
• Lift rear door of the lawn mower and
place the grass catcher frame hooks
onto the door pivot pins.
• To convert to mulching or discharging
operation, remove grass catcher and
close rear door.
Pivot pins Grass
catcher
handle
Catcher frame hook
Rear
door
TO ADJUST CUTTING HEIGHT
Raise wheels for low cut and lower
wheels for high cut, adjust cutting height
to suit your requirements. Medium
position is best for most lawns.
• To change cutting height, squeeze
adjuster lever toward wheel. Move
wheel up or down to suit your require-
ments. Be sure all wheels are in the
same setting.
NOTE: Adjuster is properly positioned
when plate tab inserts into hole in lever.
Also, 9-position adjusters (if so equipped)
allow lever to be positioned between the
plate tabs.
CHOKE
FAST
19
CRAFTSMAN ROTARY LAWN MOWER - - MODEL NUMBER 944.362490
1 182870 Control Bar 2 181676 Upper Handle, with Grip 3 151721X479 Lower Handle 4 179585 Rope Guide 5 63601 Locknut 1/4-20 6 171407 Handle Bolt 7 66426 Wire Tie 8183684 Grip, Foam 9 154132 Hinge Bracket 10 165754 Mulcher Door 11 183575 Engine Zone Control Cable 12 750634 Hex Washer Head Screw 13 850733X004 Up-Stop Bracket 14 180833 Handle Knob 15 51793 Hairpin Cotter 16 147286 Hinge Rod 17 165946X479 Support Bracket 18 17600406 Screw 19 167132X004 Axle Arm Assembly - LF 20 167133X004 Axle Arm Assembly - RF 21 165858 Rear Skirt 22 168360X004 Selector Spring - Front 23 166875 Rear Door Assembly Kit (Incl. Springs) 24 751153 Locknut 5/16-18 25 166111X479 Handle Bracket Assembly (Left) 26 166112X479 Handle Bracket Assembly (Right) 27 851856 Screw 1/4-20 x 3/8 28 152124 Hinge Spring 29 160835X007 Wheel Adjusting Bracket - Front 30 19112206 Washer 31 165760 Clip on Discharge Guard 32 180077X004 Selector Spring - Rear 33 180912 Selector Knob 34 181214X004 Axle Arm Assembly - LR 35 179752 Handle Adjuster Assembly, LH
36 160828 Shoulder Bolt 5/16-18 37 180183 Wheel Assembly, Rear 38 180541 Wheel Assembly, Front 39 83923 Flanged Locknut 40 182248 Hubcap 41 88652 Hinge Screw 42 165766 Spring (LH) 43 165767 Spring (RH) 44 165912 Door Bolt 45 150406 Hex Head Thread Rolling Screw 3/8-16 x 1 46 107339X Danger Decal 47 182247 Hubcap 48 181215X004 Axle Arm Assembly - RR 49 179753 Handle Adjuster Assembly, RH 50 144929 Screw 51 182603 Throttle Control 52 181681 Housing Assembly
(Includes Key Numbers 17, 18 and 46)
53 851084 Hex Head Screw 3/8-24 x 1-3/8 Grade 8 54 850263 Helical Lockwasher 55 851074 Hardened Washer 56 175064 21'’ Blade 57 851514 Blade Adapter 58 57143 Washer, Wave 59 182003 Clip, Wireform 67 181368 Grass Bag 68 180332 Catcher Frame 70 - - - Engine, Honda, Model Number
GCV-160-A1AE (See Breakdown)
71 132004 Nut, Hex - - 162300 Warning Decal (Not Shown) - - 181668 Owner's Manual, English - - 181669 Owner’s Manual, French NOTE: All component dimensions given in U.S. inches. 1 inch = 25.4 mm
KEY PART NO. NO. DESCRIPTION
KEY PART NO. NO. DESCRIPTION

7
Open mulcher door
Discharge
deflector
SIDE DISCHARGING
• Rear door must be closed.
• Open mulcher door and install dis-
charge deflector under door as shown.
• Mower is now ready for discharging
operation.
• To convert to mulching or bagging
operation, discharge deflector must be
removed and mulcher door must be
closed.
SIMPLE STEPS TO REMEMBER WHEN
CONVERTING YOUR LAWN MOWER
FOR MULCHING -
1. Rear door closed.
2. Mulcher door closed.
FOR REAR BAGGING -
1. Grass catcher installed.
2. Mulcher door closed.
FOR SIDE DISCHARGING -
1. Rear door closed.
2. Side discharge deflector installed.
CAUTION: Do not run your lawn
mower without rear door closed, clipping
deflector or approved grass catcher in
place. Never attempt to operate the lawn
mower with the rear door removed or
propped open.
18
REPAIR PARTS
CRAFTSMAN ROTARY LAWN MOWER - - MODEL NUMBER 944.362490

8
ADD GASOLINE
• Fill fuel tank to bottom of tank filler
neck. Do not overfill. Use fresh, clean,
regular unleaded gasoline with a
minimum of 87 octane. Do not mix oil
with gasoline. Purchase fuel in
quantities that can be used within 30
days to assure fuel freshness.
CAUTION: Wipe off any spilled oil or
fuel. Do not store, spill or use gasoline
near an open flame.
CAUTION: Alcohol blended fuels
(called gasohol or using ethanol or
methanol) can attract moisture which
leads to separation and formation of
acids during storage. Acidic gas can
damage the fuel system of an engine
while in storage. To avoid engine
problems, the fuel system should be
emptied before storage of 30 days or
longer. Drain the gas tank, start the
engine and let it run until the fuel lines
and carburetor are empty. Use fresh fuel
next season. See Storage Instructions for
additional information. Never use engine
or carburetor cleaner products in the fuel
tank or permanent damage may occur.
TO START ENGINE
NOTE: Due to protective coatings on the
engine, a small amount of smoke may be
present during the initial use of the
product and should be considered
normal.
1. Be sure fuel valve is in the ON
position.
2. To start a cold engine, move handle
mounted throttle/choke control lever to
CHOKE position.
3. Hold operator presence control bar
down to the handle and pull starter
handle quickly. Do not allow starter
rope to snap back.
4. Slowly move throttle control lever to
FAST position after engine starts.
• To start a warm engine, move throttle
control lever to FAST position, then
follow steps above.
TO STOP ENGINE
• To stop engine, release operator
presence control bar. Wait until blade
and all moving parts have stopped and
turn fuel valve to OFF position if you do
not intend to restart the engine soon.
BEFORE STARTING ENGINE
ADD OIL
Your lawnmower is shipped without oil in
the engine. For type and grade of oil to
use, see “ENGINE” in the Maintenance
section of this manual.
CAUTION: DO NOT overfill engine with
oil, or it will smoke on startup.
1. Be sure lawnmower is level and area
around oil fill is clean.
2. Remove oil dipstick from oil fill spout.
Make sure that rim of spout is clean.
3. You receive a container of oil with the
unit. Slowly pour 3/4 (0,35L) of the oil
from the container down the oil fill
spout into the engine.
4. Wait one minute to allow oil to settle.
Use guage on oil fill cap/dipstick for
checking level. Insert dipstick into the
tube and rest the oil fill cap on the
tube. DO NOT thread the cap into the
tube when taking reading.
5. Continue adding small amounts of oil
and rechecking the dipstick until it
reads full. DO NOT overfill, or engine
will smoke on startup.
6. Always be sure to retighten oil dipstick
before starting engine.
• Check oil level before each use. Add
oil if needed. Fill to full line on dipstick.
• Change the oil after every 25 hours of
operation or each season. You may
need to change the oil more often
under dusty, dirty conditions.
Oil filler cap/dipstick
Lower limit
Upper limit
Gasoline
filler cap
Oil
filler
cap
17
Poor cut – 1. Worn, bent or loose blade. 1. Replace blade. Tighten
uneven blade bolt.
2. Wheel heights uneven. 2. Set all wheels at same
height.
3. Buildup of grass, leaves 3. Clean underside of
and trash under mower. mower housing.
Excessive 1. Worn, bent or loose blade. 1. Replace blade. Tighten
vibration blade bolt.
2. Bent engine crankshaft. 2. Contact a Sears or other
qualified service center.
Starter rope 1. Engine flywheel brake is on 1. Depress control bar to
hard to pull when control bar is released. upper handle before
pulling starter rope.
2. Bent engine crankshaft. 2. Contact a Sears or other
qualified service center.
3. Blade adapter broken. 3. Replace blade adapter.
4. Blade dragging in grass. 4. Move lawn mower to cut
grass or to hard surface.
Grass catcher 1. Cutting height too low. 1. Raise cutting height.
not filling 2. Lift on blade worn off. 2. Replace blade.
(If so equipped) 3. Catcher not venting air. 3. Clean grass catcher.
Hard to push 1. Grass is too high or wheel 1. Raise cutting height.
height is too low.
2. Rear of lawn mower 2. Raise rear of lawn mower
housing or cutting blade housing one (1) setting
dragging in grass. higher.
3. Grass catcher too full. 3. Empty grass catcher.
4. Handle height position not 4. Adjust handle height to suit.
right for you.
PROBLEM CAUSE CORRECTION
TROUBLESHOOTING - See appropriate section in manual unless directed
to a Sears Service Center.

9
MULCHING MOWING TIPS
IMPORTANT: For best performance, keep
mower housing free of built-up grass and
trash. See “CLEANING” in the Maintenance
section of this manual.
• The special mulching blade will recut
the grass clippings many times and
reduce them in size so that as they fall
onto the lawn they will disperse into the
grass and not be noticed. Also, the
mulched grass will biodegrade quickly
to provide nutrients for the lawn.
Always mulch with your highest engine
(blade) speed as this will provide the
best recutting action of the blades.
• Avoid cutting your lawn when it is wet.
Wet grass tends to form clumps and
interferes with the mulching action.
The best time to mow your lawn is the
early afternoon. At this time the grass
has dried and the newly cut area will
not be exposed to the direct sun.
• For best results, adjust the lawn mower
cutting height so that the lawn mower
cuts off only the top one-third of the
grass blades. If the lawn is overgrown
it will be necessary to raise the height
of cut to reduce pushing effort and to
keep from overloading the engine and
leaving clumps of mulched grass. For
extremely heavy mulching, reduce your
width of cut by overlapping previously
cut path and mow slowly.
MAX 1/3
MOWING TIPS
• Under certain conditions, such as very
tall grass, it may be necessary to raise
the height of cut to reduce pushing
effort and to keep from overloading the
engine and leaving clumps of grass
clippings. It may also be necessary to
reduce ground speed and/or run the
lawn mower over the area a second
time.
• For extremely heavy cutting, reduce
the width of cut by overlapping
previously cut path and mow slowly.
• For better grass bagging and most
cutting conditions, the engine speed
should be set in the fast position.
• Pores in cloth grass catchers can
become filled with dirt and dust with
use and catchers will collect less
grass. To prevent this, regularly hose
catcher off with water and let dry
before using.
• Keep top of engine around starter
clear and clean of grass clippings and
chaff. This will help engine air flow and
extend engine life.
Fuel valve lever
ON
OFF
• Certain types of grass and grass
conditions may require that an area be
mulched a second time to completely
hide the clippings. When doing a
second cut, mow across or perpendicu-
lar to the first cut path.
• Change your cutting pattern from week
to week. Mow north to south one week
then change to east to west the next
week. This will help prevent matting
and graining of the lawn.
16
Does not start 1. Dirty air filter. 1. Clean/replace air filter.
2. Out of fuel. 2. Fill fuel tank.
3. Stale fuel. 3. Drain tank and refill with
fresh, clean fuel.
4. Water in fuel. 4. Drain fuel tank and
carburetor and refill tank
with fresh gasoline.
5. Spark plug wire is 5. Connect wire to plug.
disconnected.
6. Bad spark plug. 6. Replace spark plug.
7. Loose blade or broken 7. Tighten blade bolt or
blade adapter. replace blade adapter.
8. Control bar in released 8. Depress control bar to
position. handle.
9. Control bar defective. 9. Replace control bar.
10.Fuel valve lever (if so 10.Turn fuel valve lever
equipped) in OFF position. to the ON position.
11.Weak battery (if equipped). 11.Charge battery.
12.Disconnected battery 12.Connect battery to engine.
connector (if equipped).
Loss of power 1. Rear of lawn mower 1. Set to “Higher Cut”
housing or cutting blade position.
dragging in heavy grass.
2. Cutting too much grass. 2. Set to “Higher Cut”
position.
3. Dirty air filter. 3. Clean/replace air filter.
4. Buildup of grass, leaves, 4. Clean underside of mower
and trash under mower. housing.
5. Too much oil in engine. 5. Check oil level.
6. Walking speed too fast. 6. Cut at slower walking speed.
PROBLEM CAUSE CORRECTION
TROUBLESHOOTING - See appropriate section in manual unless directed
to a Sears Service Center.

10
MAINTENANCE
LUBRICATIONCHARTGENERAL RECOMMENDATIONS
The warranty on this lawn mower does
not cover items that have been subjected
to operator abuse or negligence. To
receive full value from the warranty,
operator must maintain mower as
instructed in this manual.
Some adjustments will need to be made
periodically to properly maintain your
unit.
All adjustments in the Service and
Adjustments section of this manual
should be checked at least once each
season.
• Once a year, replace the spark plug,
replace air filter element and check
blade for wear. A new spark plug and
clean/new air filter element assure
proper air-fuel mixture and help your
engine run better and last longer.
• Follow the maintenance schedule in
this manual.
BEFORE EACH USE
• Check engine oil level.
• Check for loose fasteners.
LUBRICATION
Keep unit well lubricated (See "LUBRI-
CATION CHART").
À
Spray lubricant
Á
See "ENGINE" in Maintenance section.
IMPORTANT: Do not oil or grease
plastic wheel bearings. Viscous
lubricants will attract dust and dirt that
will shorten the life of the self-lubricat-
ing bearings. If you feel they must be
lubricated, use only a dry, powdered
graphite type lubricant sparingly.
Àÿ Wheel
adjuster (on
each wheel)
Á Engine oil
Àÿ Rear door
hinge
Àÿ Handle bracket mounting pins
Àÿ Mulcher
door hinge pin
15
ENGINE OIL
Drain oil (with engine warm) and replace
with clean engine oil. (See “ENGINE” in
the Maintenance section of this manual).
CYLINDER
1. Remove spark plug.
2.Pour 29 ml of oil through spark plug
hole into cylinder.
3. Pull starter handle slowly a few times
to distribute oil.
4. Replace with new spark plug.
OTHER
• Do not store gasoline from one season
to another.
• Replace your gasoline can if your can
starts to rust. Rust and/or dirt in your
gasoline will cause problems.
• If possible, store your unit indoors and
cover it to protect it from dust and dirt.
• Cover your unit with a suitable protec-
tive cover that does not retain moisture.
Do not use plastic. Plastic cannot
breathe, which allows condensation to
form and will cause your unit to rust.
IMPORTANT: Never cover mower while
engine and exhaust areas are still warm.
CAUTION: Never store the lawn
mower with gasoline in the tank inside a
building where fumes may reach an open
flame or spark. Allow the engine to cool
before storing in any enclosure.
ENGINE
FUEL SYSTEM
IMPORTANT: It is important to prevent
gum deposits from forming in essential
fuel system parts such as carburetor, fuel
filter, fuel hose or tank during storage.
Also, alcohol blended fuels (called
gasohol or using ethanol or methanol)
can attract moisture which leads to
separation and formation of acids during
storage. Acidic gas can damage the fuel
system of an engine while in storage.
1. Drain the fuel tank.
2. Start the engine and let it run until the
fuel lines and carburetor are empty.
• Never use engine or carburetor cleaner
products in the fuel tank or permanent
damage may occur.
• Use fresh fuel next season.
NOTE: Fuel stabilizer is an acceptable
alternative in minimizing the formation of
fuel gum deposits during storage. Add
stabilizer to gasoline in fuel tank or
storage container. Always follow the mix
ratio found on stabilizer container. Run
engine at least 10 minutes after adding
stabilizer to allow the stabilizer to reach
the carburetor. Do not drain the gas tank
and carburetor if using fuel stabilizer.

11
PRODUCT SPECIFICATIONS
Serial Number:
Date of Purchase:
Gasoline Capacity / Type: 0,94 Litres(Unleaded Regular)
Oil Type (API-SF-SJ): SAE 10W30
Oil Capacity: 0,55 Litres
Spark Plug (Gap: .030") NGK BRP6ES
Blade Bolt Torque: 35-40 ft. lbs.
• The model and serial numbers will be found on a decal on the rear of the mower
housing. Record both serial number and date of purchase in space provided above.
LAWN MOWER
Always observe safety rules when perform-
ing any maintenance.
TIRES
• Keep tires free of gasoline, oil, or insect
control chemicals which can harm rubber.
• Avoid stumps, stones, deep ruts, sharp
objects and other hazards that may cause
tire damage.
BLADE CARE
For best results, mower blade must be
kept sharp. Replace bent or damaged
blades.
TO REMOVE BLADE
1. Disconnect spark plug wire from spark
plug and place wire where it cannot
come in contact with spark plug.
2. Turn lawn mower on its side. Make
sure air filter and carburetor are up.
3. Use a wood block between blade and
mower housing to prevent blade from
turning when removing blade bolt.
NOTE: Protect your hands with gloves
and/or wrap blade with heavy cloth.
4. Remove blade bolt by turning counter-
clockwise.
5. Remove blade and attaching hard-
ware (bolt, lock washer and hardened
washer).
NOTE: Remove the blade adapter and
check the key inside hub of blade
adapter. The key must be in good condi-
tion to work properly. Replace adapter if
damaged.
TO REPLACE BLADE
1. Position the blade adapter on the
engine crankshaft. Be sure key in
adapter and crankshaft keyway are
aligned.
2. Position blade on the blade adapter
aligning the two (2) holes in the blade
with the raised lugs on the adapter.
3. Be sure the trailing edge of blade
(opposite sharp edge) is up toward
the engine.
4. Install the blade bolt with the lock
washer and hardened washer into
blade adapter and crankshaft.
5. Use block of wood between blade and
lawn mower housing and tighten the
blade bolt, turning clockwise.
• The recommended tightening torque is
35-40 ft. lbs.
IMPORTANT: Blade bolt is grade 8 heat
treated.
TO SHARPEN BLADE
NOTE: We do not recommend sharpen-
ing blade - but if you do, be sure the
blade is balanced.
Care should be taken to keep the blade
balanced. An unbalanced blade will
cause eventual damage to lawn mower
or engine.
• The blade can be sharpened with a file
or on a grinding wheel. Do not attempt
to sharpen while on the mower.
• To check blade balance, drive a nail
into a beam or wall. Leave about one
inch of the straight nail exposed. Place
center hole of blade over the head of
the nail. If blade is balanced, it should
remain in a horizontal position. If either
end of the blade moves downward,
sharpen the heavy end until the blade
is balanced.
Blade adapter
Blade
bolt
Crankshaft
keyway
Hardened
washer
Lockwasher
Blade adapter
Key
Blade
Trailing edge
Crank
shaft
14
Mowing
position
FOLD
BACKWARD
Operator presence
control bar FOLD
FORWARD
FOR
STORAGE
Upper handle
Lower
handle
Lower handle
SQUEEZE
TO FOLD
STORAGE
Immediately prepare your lawn mower for
storage at the end of the season or if the
unit will not be used for 30 days or more.
LAWN MOWER
When lawn mower is to be stored for a
period of time, clean it thoroughly, remove
all dirt, grease, leaves, etc. Store in a
clean, dry area.
1. Clean entire lawn mower (See
"CLEANING" in the Maintenance
section of this manual).
2. Lubricate as shown in the Mainte-
nance section of this manual.
3. Be sure that all nuts, bolts, screws,
and pins are securely fastened.
Inspect moving parts for damage,
breakage and wear. Replace if
necessary.
4. Touch up all rusted or chipped paint
surfaces; sand lightly before painting.
HANDLE
You can fold your lawn mower handle for
storage.
1. Squeeze the bottom ends of the lower
handle toward each other until the
lower handle clears the handle
bracket, then move handle forward.
2. Loosen upper handle mounting bolts
enough to allow upper handle to be
folded back.
IMPORTANT: When folding the handle
for storage or transportation, be sure to
fold the handle as shown or you may
damage the control cables.
• When setting up your handle from the
storage position, the lower handle will
automatically lock into the mowing
position.

12
GRASS CATCHER
• The grass catcher may be hosed with
water, but must be dry when used.
• Check your grass catcher often for
damage or deterioration. Through
normal use it will wear. If catcher
needs replacing, replace only with a
manufacturer approved replacement
catcher. Give the lawn mower model
number when ordering.
ENGINE
LUBRICATION
Use only high quality detergent oil rated
with API service classification SF-SJ.
Select the oil's SAE viscosity grade
according to your expected operating
temperature.
Oil filler cap/dipstick
Lower
limit
Upper
limit
AIR FILTER
Your engine will not run properly and may
be damaged by using a dirty air filter.
Replace the air filter every 100 hours of
operation or every season, whichever
occurs first. Service air cleaner more
often under dusty conditions.
TO CLEAN AIR FILTER
1. Remove cover.
2. Carefully remove cartridge.
3. Clean by gently tapping on a flat
surface. If very dirty, replace cartridge.
CAUTION: Petroleum solvents, such
as kerosene, are not to be used to clean
cartridge. They may cause deterioration of
the cartridge. Do not oil cartridge. Do not
use pressurized air to clean or dry
cartridge.
4. Install cartridge, then replace cover.
Tabs
Filter Filter
Cover
Tabs
MUFFLER
Inspect and replace corroded muffler as it
could create a fire hazard and/or dam-
age.
SPARK PLUG
Replace spark plug at the beginning of
each mowing season or after every 100
hours of operation, whichever occurs first.
Spark plug type and gap setting are
shown in “PRODUCT SPECIFICATIONS”
in Maintenance section of this manual.
NOTE: Multi-viscosity oils (5W30, 10W30
etc.) improve starting in cold weather, and
you should check your engine oil level
frequently to avoid possible engine
damage from running low on oil.
Change the oil after every 25 hours of
operation or at least once a year if the
lawn mower is not used for 25 hours in
one year.
Check the crankcase oil level before
starting the engine and after each five (5)
hours of continuous use. Tighten oil plug
securely each time you check the oil
level.
TO CHANGE ENGINE OIL
NOTE: Before tipping lawn mower to
drain oil, drain fuel tank by running
engine until fuel tank is empty.
1. Disconnect spark plug wire from spark
plug and place wire where it cannot
come in contact with spark plug.
2. Remove engine oil cap; lay aside on a
clean surface.
3. Tip lawn mower on its side as shown
and drain oil into a suitable container.
Rock lawn mower back and forth to
remove any oil trapped inside of
engine.
4. Wipe off any spilled oil from lawn
mower or side of engine.
5. Fill engine with oil. (See “ADD OIL” in
the Operation section of this manual).
6. Reconnect spark plug wire to spark
plug. 13
SERVICE AND ADJUSTMENTS
WARNING: To avoid serious injury,
before performing any service or adjust-
ments:
1. Release control bar and stop engine.
2. Make sure the blade and all moving
parts have completely stopped.
3. Disconnect spark plug wire from spark
plug and place where it cannot come
in contact with plug.
LAWN MOWER
TO ADJUST CUTTING HEIGHT
See “TO ADJUST CUTTING HEIGHT” in
the Operation section of this manual.
REAR DEFLECTOR
The rear deflector, attached between the
rear wheels of your mower, is provided to
minimize the possibility that objects will
be thrown out of the rear of the mower
into the operator mowing position. If the
deflector becomes damaged, it should be
replaced.
TO ADJUST HANDLE
The upper handle may be adjusted to
four (4) different height positions.
1. Loosen both handle knobs only
enough to allow the upper handle to
pivot to the desired adjustment
position.
2. Tighten both handle knobs securely.
CLEANING
IMPORTANT: For best performance,
keep mower housing free of built-up
grass and trash. Clean the underside of
your mower after each use.
CAUTION: Disconnect spark plug wire
from spark plug and place wire where it
cannot come in contact with the spark
plug.
• Clean the underside of your lawn mower
by scraping to remove build-up of grass
and trash.
• Clean engine often to keep trash from
accumulating. A clogged engine runs
hotter and shortens engine life.
• Keep finished surfaces and wheels free of
all gasoline, oil, etc.
• We do not recommend using a garden
hose to clean lawn mower unless the
electrical system, muffler, air filter and
carburetor are covered to keep water out.
Water in engine can result in shortened
engine life.
Handle
knob
Handle
knob
ENGINE SPEED
Your engine speed has been factory set.
Do not attempt to increase engine speed
or it may result in personal injury. If you
believe that the engine is running too fast
or too slow, take your lawn mower to a
Sears or other qualified service center for
repair and adjustment.
CARBURETOR
Your carburetor is not adjustable. If your
engine does not operate properly due to
suspected carburetor problems, take your
lawn mower to a Sears or other qualified
service center for repair or adjustment.
IMPORTANT: Never tamper with the
engine governor, which is factory set for
proper engine speed. Overspeeding the
engine above the factory high speed
setting can be dangerous. If you think the
engine-governed high speed needs
adjusting, contact a Sears or other
qualified service center, which has proper
equipment and experience to make any
necessary adjustments.