MTD 134-618-000 User manual

OWNERS
MANUAL
5-SPEED
TRANSAXLE
LAWN
TRACTORS
ASSEMBLY
OPERATION
MAINTENANCE
PARTS LIST
Important:
Read Safety Rules and
Instructions Carefully
Model Numbers
134 - 6 1 8 - 000
134 - 638 - 000
134 - 6 6 8-000
134 - 6 9 8 - 000
Thank you for purchasing an
American built product.
PRINTED IN U.S.A.
FORM NO. 770-3233

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INDEX
Safe Operation Practices.3
Assembly instructions...4
Controls. 9
Operation.11
Adjustments.12
Lubrication.13
Maintenance .14
Off-Season Storage.17
Trouble Shooting Chart.18,19
IIlustrated Parts for Rider.20, 22,24, 26,28, 30
Parts List for Rider.21,23, 25,27,29, 31
Illustrated Parts for Transaxle .32, 33
Electrical System.34, 35
Parts Information.Back Cover
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V
LIMITEED WARRANTY
For one year from the date of original retail purchase, MTD PRODUCTS INC will either
repair or replace, at its option, free of charge, F.O.B. factory or authorized service firm, any
part or parts found to be defective in material or workmanship. Transportation charges for
the movement of any power equipment unit or attachment are the responsibility of the pur¬
chaser. Transportation charges foi any parts submitted for replacement under this warran¬
ty must be paid by the purchaser unless such return is requested by MTD PRODUCTS INC.
This warranty will not apply to any part which has become inoperative due to misuse, ex¬
cessive use, accident, neglect, irr proper maintenance, alterations, or unless the unit has
been operated and maintained in ciccordance with the instructions furnished. This warran¬
ty does not apply to the engine, motor, battery, battery chargeror component parts thereof.
Please refer to the applicable manufacturer’s warranty on these items.
This warranty will not apply where the unit has been used commercially.
Warranty service is available through your local authorized service dealer or distributor. If
you do not know the dealer or disti ibutor in your area, please write to the Customer Service
Department of MTD.
The return of a complete unit will not be accepted by the factory unless prior written per¬
mission has been extended by M 'D.
This warranty gives you specific egai rights. You may also have other rights which vary
from state to state.
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J
\ WARNjNG j
This unit is equipped with an internal combustion engine and should not be used on or near any unim¬
proved forest-covered, brush-covered or grass-covered land unless the engine’s exhaust system is
equipped with a spark arrester meeting applicable local or state laws (if any). If a spark arrester is used, it
should be maintained in effective working order by the operator.
In the State of California the above is rec uired by law (Section 4442 of the California Public Resources
Code), ether states may have similar laws Federal laws apply on federal lands. A spark arrester muffler is
available at your nearest engine authorized service center.
2

^ WARNING I
To reduce the potential for any injury, comply with the following safety instructions. Failure to comply
with the instructions may result in personal injury.
SAFE OPERATION PRACTICES FOR RIDING VEHICLES
1. Read this owner’s manual carefully in its en¬
tirety before attempting to assemble or
operate this unit. Keep this manual in a safe
place for future and regular reference and for
ordering replacement parts.
2. This unit is a precision piece of power equip¬
ment, not a plaything. Therefore exercise ex¬
treme caution at all times.
3. Know the controls and how to stop quickly—
READ THIS OWNER’S MANUAL.
4. Do not allow children to operate vehicle. Do
not allow adults to operate it without proper
instruction. Only persons well acquainted
with these rules of safe operation should be
allowed to use your mower.
5. No one should operate this unit while intox¬
icated or while taking medication that impairs
the senses or reactions.
6. Wear sturdy, rough-soled work shoes and
close-fitting slacks and shirts to avoid en¬
tanglement in the moving parts. Never operate
a unit in bare feet, sandals, or sneakers.
7. To prevent injury, do not carry passengers or
give rides. Keep children, pets and by¬
standers out of the area while mowing. Only
the operator should ride on the unit and only
ride in the seat.
8. Check overhead clearance carefully before
driving under power lines, guy wires, bridges
or low hanging tree branches, before entering
or leaving buildings, or in any other situation
where the operator may be struck or pulled
from the unit, which could result in serious in¬
jury.
9. To maintain control of the unit and reduce the
possibility of upset or collision, operate the
tractor smoothly. Avoid erratic operation and
excessive speed.
10. Keep the area of operation clear of all per¬
sons, particularly small children and pets.
Stop engine when they are in the vicinity of
your mower. Although the area of operation
should be completely cleared of foreign ob¬
jects, a small object may have been over¬
looked and could be accidently thrown by the
mower in any direction and cause injury.
11. Clear work area of objects which might be
picked up and thrown by the mower in any
direction and cause injury.
12. Stop the blade(s) when crossing gravel drives,
walks or roads.
13. Disengage all attachment clutches and shift
into neutral before attempting to start engine.
14. Disengage power to attachment(s) and stop
engine before leaving operating position.
15. Do not put hands or feet near or under rotating
parts. Keep clear of the discharge opening at
all times as the rotating blade(s) can cause in¬
jury.
16. Disengage power to attachment(s) and stop
engine before making any repairs or ad¬
justments. Disconnect the spark plug wire
and keep the wire away from the plug to pre¬
vent accidental starting.
17. Before attempting to unclog the mower or
discharge chute, stop the engine. The mower
biade(s) may continue to rotate for a few
seconds after the engine is shut off.
Therefore, be sure the biade(s) have stopped
completely. Disconnect the spark plug wire
and keep the wire away from the plug to pre¬
vent accidental starting.
18. Disengage power to attachment(s) when
transporting or not in use.
19. Take all possible precautions when leaving
vehicle unattended such as disengaging
power-take-off, lowering attachments, shift¬
ing into neutral, setting parking brake, stop¬
ping engine and removing key.
20. Do not stop or start suddenly when going
uphill or downhill. Mow up and down face of
steep slopes; never across the face. Use ex¬
treme caution if it is necessary to drive the
tractor up an incline or back the tractor down
an incline because the front of the tractor
could lift and rapidly flip over backward which
could cause serious injury.
21. Reduce speed on slopes and in sharp turns to
prevent tipping or loss of control. Always
keep the tractor in gear when going down
steep hills to take advantage of engine brak¬
ing action.
22. Stay alert for holes in terrain and other hidden
hazards.
23. Use care when pulling loads or using heavy
equipment.
A. Use only approved drawbar hitch points.
B. Limit loads to those you can safely control.
C. Do not turn sharply. Use care when back¬
ing.
D. Use counterweight(s) or wheel weights
when suggested in owner’s manual.
24. Watch out for traffic when crossing or near
roadways.
25. When using any attachments, never direct dis¬
charge of material toward bystanders nor
allow anyone near vehicle while in operation.
26. Handle gasoline with care. It is highly flam¬
mable.
A. Use approved gasoline container.
B. Never remove cap or add gasoline to a run¬
ning or hot engine or fill fuel tank indoors.
Wipe up spilled gasoline.
C. Open doors if engine is run in garage. Ex¬
haust fumes are dangerous. Do not run
engine indoors.
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1
27. Keep the vehicle and attachments in good
operating condition, and keep safety devices
in place. Use guards as instructed in
operator’s manual.
28. Keep all nuts, bolts, and screws tiglit to be
sure the equipment is in safe working condi¬
tion.
29. Never store the equipment with gascline in
the tank inside a building where furres may
reach an open flame or spark. Allow engine to
cool before storing in any enclosure.
30. To reduce fire hazard, keep engine free of
grass, leaves or excessive grease.
31. The vehicle and attachments should be
stopped and inspected for damage after strik¬
ing a foreign object. The damage shDuld be
repaired before restarting and opera ing the
equipment.
32. Do not change the engine governor settings
or overspeed the engine.
33. When using the vehicle with mower, proceed
as follows:
(1) M o w only in daylight or in good crtificial
light.
(2) Never make a cutting height adjustment
while engine is running if operator must
dismount to do so.
(3) Shut the engine off and wait until the
blade comes to a complete stop before
removing the grass catcher.
(4) Check blade mounting bolts for proper
tightness at frequent intervals.
34. Check grass catcher bags frequently for wear
or deterioration. For safety protection, replace
only with new bag meeting original equipment
specifications.
35. Look behind to make sure the area is clear
before placing the transmission in reverse
and continue looking behind while backing
up. Disengage blades before shifting into
reverse and backing up.
36. This unit should not be driven up a ramp onto
a trailer or truck under power, because the
unit could tip over, causing serious personal
injury. The unit must be pushed manually to
load properly.
NOTE
This unit is shipped WITHOUT GAS¬
OLINE or OIL. After assembly, see
separate engine manual for proper
fuel and engine oil recommenda¬
tions.
ASSEMBLY
NOTE
Reference to right hand or left hand
side of machine is from the driver’s
seat facing forward.
This owner’s manual covers various models of
lawn tractors. The units illustrated may vary slight¬
ly from your unit. Follow the instructions which
pertain to your unit.
FIGURE 1.
Contents of Hardware Pack:
(See Figure 1)
A (1) Steering Wheel Cap
B (1) Belleville Washer
C (1) Hex Nut 5/16-18 Thread
D (1) Steering Bellow
E (2) Ignition Keys
F (1) Battery Cover
G (2) Battery Hold-Down Rods
-H (2) Wing Nuts
I (1) Cable Tie
J (1) Clevis Pin
K (1) Hairpin Cotter
Hardware for Mounting the Seat (Not Shown)
(2) Hex Bolts and Lock Washers
or
(1) Hex Nut and Lock Washer
Loose Parts in Carton:
(1) Battery Pack
(1) Steering Wheel
(1) Seat
4

BATTERY INFORMATION
i
WARNING
A. B attery acid must be handled with great care
as contact with it can burn and blister the skin.
It is also advisable to wear protective clothing
(goggles, rubber gloves and apron) when work¬
ing with it.*
B. S hould battery acid accidentally splatter into
the eyes or onto the face, rinse the affected
area immediately with clean cold water. If
there is any further discomfort, seek prompt
medical attention.
C. I f acid spills on clothing, first dilute it with
clean water, then neutralize with a solution of
ammonia/water or baking soda/water.
FIGURE 2.
D. Since battery acid is corrosive, do not pour it
into any sink or drain. Before discarding empty
electrolyte containers, rinse them with a
neutralizing solution.
E. NEVER connect or disconnect charger clips to
battery while charger is turned on as it can
cause sparks.
F. Keep all lighted materials (cigarettes, match¬
es, lighters) away from the battery as the
hydrogen gas generated during charging can
be combustible.
G. A s a further precaution, only charge the battery
in a well-ventilated area.
*Always shield eyes, protect skin and clothing
when working near batteries.
ACTIVATING AND INSTALLING THE BATTERY
1. U p on opening the battery pack, you should
receive acid pack, battery, drain tube, filling
adapter and hardware.
^ WARNING I
BATTERIES CONTAIN SULFURIC
ACID AND MAY CONTAIN EXPLO¬
SIVE GASES (when electrolyte has
been added).
2. Place the battery on table or workbench to be
filled.
3. Place one end of clear plastic drain tube on
—manifold of battery. See figure 2.
Some batteries may already have
the drain tube installed, in which
case it may be necessary to snip off
the sealed end.
4. Remove the six fill caps from the top of the
battery with a screwdriver. Care should be
taken not to damage the fill caps. See figure 2.
5. Lay acid package down, with “push in” facing
up. Using thumb, push in small perforated tab
at dot on frontof package. Tear down large tab
to solid line, exposing hose. Do not use any
sharp object to open acid package.
6. Pull out hose from package and hold upright.
Squeeze hose forcing all acid back into
package. Cut off tip of hose and insert filling
—adapter. See figure 3.
7. Fill each cell to upper level marked on front of
battery. Replace fill caps on battery. See
figure 3.
5

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DANGER
Battery contains sulfuric acid. Referto warning on
page 5. Antidote: EXTERNAL—Flush with water.
INTERNAL—Drink large quantities of witer or
milk. Follow with milk of magnesia, beaten egg or
vegetable oil. Seek prompt medical attsntion.
EYES: Flush with cool water for at least 15
minutes, then seek immediate medical att ention.
Since batteries produce explosive gases, keep all
lighted materials (cigarettes, lighters, matches,
etc.) away. Be sure to charge battery only in well-
ventilated areas.
KEEP BATTERIES
OUT OF THE REACH OF CHILDREN!
FIGURE 4.
8. Allow battery to sit for 20 to 30 minutes. Add
additional acid, if necessary, to bring it up to
the proper level.
9. The battery can be charged after the 20
minutes sitting period. SLOW CHARGE THE
BATTERY (DO NOT FAST CHARGE) at a max¬
imum bench rate of 1.4 amperes until the
specific gravity reading is 1.260-1.280. Charge
for a minimum of 2 hours and a maximum of 8
hours.
NOTE
Charging rate after battery has been
put into operation: The battery is to
be charged for a period of 14-16
hours. NO LONGER THAN 30
HOURS.
CAUTION
After battery has been in service,
add only distilled water. DO NOT
ADD ACID.
NOTE
This engine is equipped with an
alternator. The current for the bat¬
tery charger alternator is unregu¬
lated. During normal operation, it is
only necessary to charge the battery:
1. When it is activated for the first
time.
2. Before winter storage.
3. Before using the lawn tractor
after winter storage.
INSTALLING THE BATTERY
-1. Place gear shift lever in the “neutral” posi¬
tion. Unscrew the gear shift knob. See figure
4.
2. Remove the two hex bolts which secure the
—transmission cover. See figure 5.
The transmission cover on your unit
may be secured with V4 turn studs.
Push down and turn the studs one-
quarter turn to remove the cover.
6

3. L ift the transmission cover. Unplug the green
safety wire from beneath the transmission
—cover. See figure 6. Remove transmission
cover.
FIGURE 7.
4. P lace the battery in the lawn tractor so that
the positive terminal is facing the right side of
—the unit. See figure 7.
Right and left hand sides of the unit
are determined from the operating
position, facing forward.
5. Slide the square nut (provided with battery
hardware) into the positive (+) terminal. Place
the positive (heavy red wire) cable and the
small red wire on the positive terminal. Secure
with screw and lock washer provided. See
figure 7.
6. Slide the square nut (provided with battery
hardware) into the negative (-) terminal.
Place the negative (heavy black wire) cable on
the negative terminal. Secure with screw and
lock washer provided.
7. H o ok one hold-down rod (G) into the hole in
the frame beside the battery. See figure 7.
Place the battery cover (F) in position over the
hold-down rod. Secure with wing nut (H). At¬
tach other hold-down rod to the other side of
—battery cover in the same manner. See figure
8 .
7

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8. Push the locking end of cable tie (I) through
—the hole in the left frame as shown in figure 9.
Route the battery drain tube back to the cable
tie. Place end of cable tie through the slot so a
loop is formed around the drain tube to secure
it. Tighten cable tie and cut off excess end.
9. Plug the green safety wire into the switch
beneath the transmission cover. Refer to
figure 6. Replace the transmission cover and
gear shift knob.
FIGURE 9.
Plastic
Bushing
in Dash
Panel
Clevis
Pin (J)
Upper Steering
Shaft
Hairpin Cotier (K)
Lower Steering
Shaft
FiGURE 10.—Model 698 Shown
STEERING WHEEL INSTALLATION
1. For shipping purposes, the upper steering
shaft is pushed all the way down over the
lower steering shaft. Pull the upper steering
shaft up. The three holes in the shaft provide
three steering wheel heights. Select desired
hole and secure with clevis pin (J) and hairpin
-cotter (K). See figure 10.
NOTE
On model 668, the three adjustment
holes are located above the dash
panel.
2. Attach steering bellow (D) to the steering
—wheel as shown in figure 11.
NOTE
One end of the steering bellow is
slightly larger than the other. The
larger end must be assembled to the
steering wheel.
FIGURE 11.
8

FIGURE 13.
3. Place steering wheel and bellow on the steer¬
ing shaft, lining up the flats in the wheel with
the flats on the shaft.
4. Secure with belleville washer (B) (cupped side
against the steering wheel) and hex nut (C).
—See figure 12.
5. Press the steering wheel cap (A) on the steer¬
ing wheei by hand.
SEAT INSTALLATION
Your seat mounts to the unit in one of two ways.
A. Two weld nuts in the bottom of the seat:
The seat may be adjusted to three different
positions. Select desired position and secure
to seat spring with two hex bolts and lock
-washers. See figure 13.
B. Weld bolt in the bottom of the seat:
The seat may be adjusted to four different
positions. Select desired position and secure
to seat spring with one lock washer and hex
nut. See figure 13.
CONTROLS
THROTTLE CONTROL
The throttle control is used to regulate the engine
speed and to activate the choke on the engine. To
get maximum efficiency from cutting, the throttle
should be in the FAST position when operating
the mower. Pushing the throttle all the way for¬
ward past FAST, will choke the engine. See figure
14.
FIGURE 14.—Models 638 and 698 Shown
GEAR SHIFT LEVER
The gear shift lever is used to shift into one of the
forward gears, “NEUTRAL” or “REVERSE.” See
figure 14.
IGNITION SWITCH
Turn the key to the “START” position to start the
engine. When the engine is running, let the key
return to the “ON” position. To stop the engine,
turn the key to the left to the “OFF” position and
remove it to prevent accidental starting. See
figure 14.
LIGHT SWITCH (Optional)
Push the light switch to turn on the lights. The
lights will only operate when the engine is run¬
ning. See figure 14.
AMMETER (Optional)
The ammeter registers the rate of battery charge
or discharge. The ammeter will register on the
discharging side when starting the engine, it
should register on the opposite side (charging)
when the engine is running in the fast position un¬
til the battery is completely charged. With a fully
charged battery or with the engine idling, the am¬
meter will not show a charge. See figure 14.
9

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CLUTCH-BRAKE PEDAL
The clutch-brake pedal is located on the right side
of the lawn tractor. Depressing the clutch-brake
pedal part way disengages the clutch. Pnsssing
the pedal all the way down disengages the :lutch
and engages the disc brake. See figure 15.
The clutch-brake pedal must be
depressed to start the engine.
PARKING BRAKE
To set the parking brake, depress the clutch-brake
pedal and press the parking brake knob do\\/n. To
release the parking brake, depress and release the
clutch-brake pedal. See figure 15.
FIGURE 15.
INCLINE ASSISTANCE BRAKE
When stopping on a hill, hold the i icline
assistance brake lever back while you relea se the
clutch-brake pedal until the lawn tractor begins to
move, then release the lever. This lever permits
smoother starts and clutch engagement by
holding the tractor during the brake release/clutch
engagement operation. See figure 15.
INTERLOCKS (Not Shown)
Interlock safety switches are located o i the
clutch-brake pedal, and the lift and disengage¬
ment lever and gear shift lever.
Before the engine will start, the clutch-brake
pedal must be depressed all the way and t le lift
and disengagement lever must be in the disen¬
gaged position.
Before the unit can be shifted into reverse, tie lift
and disengagement must be in the disengaged
position.
CUTTING CONTROLS
A. L IFT AND DISENGAGEMENT LEVER
The lift and disengagement lever is used to raise
and lower the cutting deck. Pulling it all the way
back and locking it disengages the blades. The lift
and disengagement lever must be in the disen¬
gaged position when starting the engine and
when shifting into reverse. See figure 14.
B. D E CK LIFT INDICATOR
The deck lift indicator marks the position being
used for the lift lever. Select the lift lever position
desired, press the indicator lever outward, move it
to the position immediately below the lift lever
and release the indicator lever. See figure 15.
C. W H E EL HEIGHT ADJUSTER
Move the lever towards the wheel and set it in the
desired height. See figure 16.
D. S ETTING THE CUTTING HEIGHT
1. Select the position for the lift lever which
gives the desired cutting height. Move the
deck lift indicator so that the lift lever can be
returned to the same position after it is raised.
2. Set the wheel height adjusters on the deck so
that the wheels are Va to Vz inch above the
ground.
To set the cutting deck in the suspended position,
set the height of cut stop in the desired cutting
height and then set the deck wheels so they just
clear the ground.
10

OPERATION
A
/|\ C AUTION ^
Keep all shields in place. r
Before leaving operator’s position: ^
a. Shift transmission to neutral r
b. Set parking brake ^
c. Disengage attachment clutch ^
d. Shutoff engine ^
e. Remove ignition key ^
Wait for all movement to stop before ^
servicing machine. r
Keep people and pets a safe distance ^
away from machine. r
Look to the rear before backing up.
^ WARNING ^
TIRE PRESSURE
For shipping purposes, the tires on your unit may
be over-inflated. Tire pressure should be reduced
before unit is put into operation. Recommended
operating tire pressure shouid be 10 p.s.i.
Check sidewall of tire for manufacturer’s max¬
imum tire pressure. If this information does not
appear on your tire, maximum tire pressure under
any circumstances is 30 p.s.i. Equal tire pressure
should be maintained on all tires.
STARTiNG THE ENGINE
Ull^ NOTE
To open the hood, simply lift
up on both sides of the hood on
models 618, 638 and 698.
1. Service the engine with oil and gasoline as
described in the engine manual.
2. Depress the clutch-brake pedal and set the
parking brake. See figure 15.
3. Place the lift and disengagement lever in the
DISENGAGED position. See figure 15.
NOTE
This unit is equipped with a safety
interlock system for your protec¬
tion. The purpose of the safety inter¬
lock system is to prevent the engine
from cranking or starting unless the
clutch-brake pedal is depressed
and the lift and disengagement
lever is in the disengaged position.
In addition, the lift and disen¬
gagement lever must be in the dis¬
engaged position when the unit is
put into reverse or the engine will
shut off.
Do not operate the lawn tractor if
the interlock system is malfunction¬
ing because it is a safety device,
designed for protection.
4. Set the throttle control in the CHOKE posi¬
tion. See figure 14.
5. Turn the ignition key to the “START” position.
When the engine is running, let the key return
to the “ON” position. See figure 14.
6. Move the throttle control to desired engine
speed.
STOPPING THE ENGINE
Turn the ignition key to the left to the “OFF” posi¬
tion. Remove the key to prevent accidental start¬
ing.
■ ^^NOTE
A brief break-in period is essential
to ensure maximum engine and
mower life. The break-in consists of
running the engine at half speed for
a period of time required to use one
tank of gasoline. It is also recom¬
mended to change crankcase oil
after the first 5 hours of operation.
■ ^IMPORTANT
If you strike a foreign object, stop
the engine. Remove wire from spark
plug, thoroughly inspect the unit
for any damage, and repair the dam¬
age before restarting and operating
the mower.
OPERATING THE MOWER
1. Set the desired cutting height.
2. Start the engine as instructed in previous col¬
umn.
3. Move throttle control to desired engine speed.
4. Depress the clutch-brake pedal and shift into
first gear or reverse.
5. Release clutch-brake pedal slowly to put unit
into motion.
6. Depress the clutch-brake pedal when shifting
gears.
NOTE
Do not force the gear shift lever!
11

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7. The lawn tractor is brought to a stop by
depressing the clutch-brake pedal. The drive
belt will be disengaged and the brake vnil be
applied.
A
CAUTION
If the unit is not to be used for a
iong period, piace the gear shift
lever in NEUTRAL, stop the engine,
set the parking break and remove
the key. DO NOT ieave the machine
on an incline.
OPERATING THE CUTTING BLADES
The cutting blades may be engaged while tho lawn
tractor is moving or standing still. DO NOT e igage
the cutting blades abruptly as the sudden belt ten¬
sion on the pulley may cause the engine to stall.
t
WARNING
When the blade drive is engaged,
keep feet and hands away from the
discharge opening, the blades or
any part of the deck.
Move the lift and disengagement lever in o the
DISENGAGED position to raise the dec c and
disengage the blades,.
NOTE
When the machine is used for other
than mowing operations, the blade
drive should be disengaged.
GRASS CATCHER Model No. 015 is available as
optional equipment for the lawn tractor shewn in
this manual.
The mower should not be operated
without the entire grass catcher or
chute deflector in place.
NOTE
Under normal usage bag material is
subject to wear, and should be
checked periodically. Be sure any
replacement bag complies with the
mower manufacturer’s recommen¬
dations.
For replacement bags, use only fac¬
tory authorized replacement bag
No. 764-0121.
ADJUSTMENTS
SEAT ADJUSTMENT
The seat may be adjusted to one of several posi¬
tions. Refer to seat installation section of
assembly instructions.
STEERING WHEEL ADJUSTMENT
There are three height positions for the steering
wheel. To adjust the height of the steering wheel,
remove the hairpin cotter and clevis pin on the
steering shaft. Place the steering wheel in the
position desired and secure with hairpin cotter
and clevis pin. Refer to figure 10.
WHEEL ADJUSTMENT
The caster (forward slant of the king pin) and the
camber (tilt of the wheels out at the top) require no
adjustment. Automotive steering principles have
been used to determine the caster and camber on
the tractor. The front wheels should toe-in 1/8
inch.
To adjust the toe-in, follow these steps.
1. Remove the hex nut and lock washer, and
drop the tie rod end from the wheel bracket.
See figure 17.
2. Loosen the hex jam nut on tie rod.
3. Adjust the tie rod assembly for correct toe-in.
FIGURE 17.
Dimension “B” should be approximately 1/8" less
than Dimension “A.” See figure 18.
A. ) To increase Dimension “B,” screw tie rod into
tie rod end.
B. ) To decrease Dimension “B,” unscrew tie rod
from tie rod end.
C. ) Reassemble tie rod. Check dimensions. Read¬
just if necessary.
12

FIGURE 18. TOE-IN DIAGRAM
FIGURE 19.
CARBURETOR ADJUSTMENT
WARNING
If any adjustments are made to the
engine while the engine is running
(e.g. carburetor), disengage all
clutches, and blades. Keep clear of
all moving parts. Be careful of
heated surfaces and muffler.
3. Tighten the outside nut against the inside nut,
using two Vz" wrenches. See figure 20.
NOTE
Friction pads must be replaced when
the inside of cam lever touches the
housing.
Minor carburetor adjustment may be required to
compensate for differences in fuel, temperature,
altitude and load. To adjust the carburetor, refer to
the separate engine manual packed with your unit.
BRAKE ADJUSTMENT
During normal operation of this machine, the
brake is subject to wear and will require periodic
examination and adjustment.
CAUTION
Do not have the engine running
when you adjust the brake.
FIGURE 20.
To adjust the brake, proceed as follows.
1. Tighten the inside nut until the cam lever can
not be moved by hand.
2. Loosen the inside nut until the cam lever can
be pushed forward so that there is a 1/8" to
3/16" space between the cam lever and stop
bolt. See figure 19.
LUBRICATION
STEERING GEARS
Lubricate teeth of steering gears with automotive
multi-purpose grease after every 25 hours of
operation or once a season. See figure 21.
13

I
FIGURE 21.
STEERING SHAFT
Lubricate steering shaft at ieast once a jeason
with iight oil.
TRANSAXLE
The transaxle is lubricated and sealed at tt e fac¬
tory and does not require checking. If disassem¬
bled for any reason, lubricate with 24 oz. of E.P.
Lithium grease.
FRONT WHEELS
The front wheels are provided with grease fittings.
Lubricate at least once a season with automotive
multi-purpose grease.
PIVOT POINTS
Lubricate all pivot points with light oil a least
once a season.
AIR CLEANER
Under normal operating conditions, the air
cleaner, located on top of the carburetor, must be
serviced after every ten hours of use. Under ex¬
tremely dusty operating conditions, the air
cleaner must be serviced after every hour of
operation. To service the air cleaner, refer to the
separate engine manual packed with your unit.
CLEANING ENGINE AND BLADE HOUSING
Any fuel or oil spilled on the machine should be
wiped off promptly. Grass, leaves, and other dirt
must not be left to accumulate around the cooling
fins of the engine or on any part of the machine.
Clean the underside of the blade housing after
each mowing.
SPARK PLUG
The spark plug should be cleaned and the gap
reset once a season. Spark plug replacement is
recommended at the start of each mowing
season; check engine manual for correct plug
type and gap specification.
CUTTING BLADE
A. Removal for Sharpening or Replacement
^ WARNING \
Be sure to disconnect and ground
the spark plug wire and remove
ignition key before working on the
cutting blade to prevent accidental
engine starting.
MAINTENANCE
WARNING
Disconnect the spark plug wire
and ground against the engine be¬
fore performing any repairs or main¬
tenance.
CRANKCASE OIL
Check the oil level in the crankcase beforo each
use of the machine and after every five he urs of
operation. Oil level should be maintained as in¬
structed in the separate engine manual.
After the first five hours of operating a new
engine, drain the oil from the crankcase while
engine is still hot and refill crankcase wilh new
oil; thereafter change the oil every 25 he urs of
operation. Refer to the engine manual.
1. Remove the large bolt and lock washer which
holds the blade and adapter to the blade spin¬
dle.
2. Remove the blade and adapter from the spin¬
dle. Be careful not to lose the key on the spin¬
dle.
3. If the blade or blade adapter needs replacing,
remove the two small bolts, lock washers and
nuts which hold the blade to the adapter.
B. Sharpening
Remove the cutting blade by following the direc¬
tions of the preceding section.
When sharpening the blade, follow the original
angle of grind as a guide. It is extremely important
that each cutting edge receives an equal amount
of grinding to prevent an unbalanced blade. An un¬
balanced blade will cause excessive vibration
when rotating at high speeds, may cause damage
to the mower and could break, causing personal
injury.
14

The blade can be tested for balance by balancing
it on a round shaft screwdriver. Remove metal
^ from the heavy side until it balances evenly.
It is recommended that the blade
always be removed from the adapter
for the best test of balance.
C. Reassembly
Before reassembling the blade and the blade
adapter to the unit, lubricate the spindle and the
inner surface of the blade adapter with light oil.
Lubricating the bolt holes, bolts and inner surface
of the nuts with light oil is also recommended. A 4
oz. plastic bottle of light oil lubricant is available.
Order part number 737-0170. Engine oil may also
be used.
When replacing the blade, be sure to install the
blade with the side of the blade marked “Bottom”
(or with part number) facing the ground when the
mower is in the operating position. Make certain
key is in place on the crankshaft.
Blade Mounting Torque
3/8" Dia. Bolt 375 in. lb. min., 450 in. lb. max.
5/16" Dia. Bolt 150 in. lb. min., 250 in. lb. max.
To insure safe operation of your unit, ALL nuts
and bolts must be checked periodically for correct
tightness.
FUEL FILTER
Your unit is equipped with a replaceable in-line
fuel filter. Replace filter whenever contamination
or discoloration is noticed. Order replacement
filter through your engine authorized service
dealer.
DRIVE BELT REMOVAL AND REPLACEMENT
(D
1
WARNING
t
Disconnect the spark plug wire and
ground it against the engine.
NOTE
Figures 22 through 26 are shown
with the unit tipped up for clarity.
It is not necessary to tip the unit
to remove the belts.
1. Place the lift lever in the disengaged position.
2. Remove the two hex bolts (belt keepers) from
the engine pulley belt guard. See figure 22.
Do Not
Remove
4
FIGURE 22.
3. Unhook the deck belt from the engine pulley.
4. Remove the two bolts, lock washers and nuts
on each side of the frame which hold the
engine pulley belt guard to the frame. See
figure 23..
FIGURE 23.
5. R emove the engine pulley belt guard by slip¬
ping it back and to the right. See figure 24.
15

1
FIGURE 24.
6. Remove the bolt, lock washer and nut which
hold the idler pulley to the idler bracket. See
figure 25.
Upon reassembly, the hub side of
the idler pulley must be assembled
against the idler bracket.
FIGURE 25.
7. Remove two self-tapping screws whicf hold
the transaxle belt guard to the top of the trans¬
axle. See figure 26.
8. Remove the transaxle shift lever by rerr oving
the hex bolt and belleville washer. Lift cff the
special “D” washer. See figure 26.
9. Slide the transaxle belt guard back. Remove
the belt from the engine pulley. Lift the belt up
and over the transaxle pulley.
Hex Bolt
Belleville
Washer
Self-Tapping
Screws
FIGURE 26.
10. Reassemble with a new belt, following in¬
structions in reverse order.
IMPORTANT
The belt must be reassembled as
shown in figure 25, with the back of
the belt (flat side) against the idler
pulley. The belt must be inside the
pins. Failure to assemble the belt
correctly will damage the belt.
BATTERY REMOVAL OR INSTALLATION
(D
i
WARNING
j
When removing the battery, follow
this order of disassembly to prevent
the screwdriver from shorting
against the frame.
1. Remove the Negative cable.
2. Remove the Positive cable.
To install a battery:
1. Attach the Positive cable.
2. Attach the Negative cable.
JUMP STARTING
1. Attach the first jumper cable from the Positive
terminal of the good battery to the Positive
terminal of the dead battery.
2. Attach the second jumper cable from the
Negative terminal of the good battery to the
FRAME OF THE UNIT WITH THE DEAD BAT¬
TERY.
16

(D
t
WARNING
Failure to use this starting pro¬
cedure could cause sparking, and
the gas in either battery could ex¬
plode.
BATTERY MAINTENANCE
1. Check periodically (every two weeks or before
and after charging) to be sure electrolyte level
is above the lowest line on battery. Add only
distilled water or a good quality drinking
water. NEVER add additional acid or other
chemicals to battery after initial activation.
2. The battery should be checked with a
hydrometer after every 25 hours of operation.
If the specific gravity is less than 1.225,
remove battery and recharge.
3. Coat the terminals and exposed wiring with a
thin coat of grease or petroleum jelly for
longer service and protection against elec¬
trolyte corrosion.
4. The battery should be kept clean. Any
deposits of acid should be neutralized with
soda and water. Be careful not to get this solu¬
tion in the cells.
BATTERY STORAGE
1. Charge battery using normal methods.
NEVER store discharged battery as it will not
recover.
2. When storing battery for extended periods,
disconnect battery cables. Removing battery
from unit is recommended.
3. Store in cold, dry place.
4. Recharge battery whenever the specific gravi¬
ty is less than 1.225, before returning to ser¬
vice, or every two months, whichever occurs
first.
COMMON CAUSES FOR BATTERY FAILURE ARE:
1. Overcharging
2. Undercharging
3. Lack of water
4. Loose holds downs and/or corroded connec¬
tions
5. Excessive loads
6. Battery electrolyte substitutes
7. Freezing of electrolyte
INSTALLATION OF TIRE TO RIM
t
The following procedure must be
followed when removing or install¬
ing a tire to the rim.
1. Be sure rim is clean and rust free.
2. Lubricate both the tire and rim generously.
3. Never inflate to over 30 p.s.i. to seat beads.
Excessive inflation pressure when seating
beads may cause tire/rim assembly to burst
with force sufficient to cause serious injury.
OFF SEASON STORAGE
If the machine is to be inoperative for a period
longer than 30 days, prepare for storage as fol¬
lows.
1. C l e an the engine and the entire unit
thoroughly.
2. Lubricate all lubrication points. Wipe the en¬
tire machine with an oiled rag to protect the
surfaces.
3. Refer to the engine manual for correct engine
storage instructions. The engine must be
completely drained of fuel to prevent gum
deposits from forming on essential carburetor
parts, fuel lines and fuel tanks.
4. Refer to battery storage instructions in
previous column.
5.
Store unit in a clean, dry area.
CAUTION
When storing any type of power
equipment in an unventilated or
metal storage shed, care should be
taken to rust proof the equipment.
Using a light oil or silicone, coat the
equipment, especially any chains,
springs, bearings and cables.
THESE FAILURES DO NOT CON¬
STITUTE WARRANTY.
17

1
TROUBLE SHOOTING CHART FOR ELECTRIC START MODELS
TROUBLE
Engine will not
crank
LOOK FOR
REMEDY
Battery installed incor- The battery m ust be installed with the negative, identified at the terminal post by (Neg, N or -),
rectly grounded. Th' i positive (Pos, P or +) attaches to the large cable from the solenoid. The small
red wire from :he fuse holder or circuit breaker is also attached to the positive terminal.
Blown fuse or circuit
breaker
Replace fuse with 7'h amp. fuse Vi xV/a" Ig. Circuit breaker will reset itself when it cools off.
Fuses or circuit breakers seldom open or fail without a reason. The problem must be cor¬
rected. ChecI for loose connections in the fuse holder. Replace fuse holder if necessary. A
dead short m ly be in the cranking or charging circuit where the insulation may have rubbed
through and«xposed the bare wire. Replace the wire or repair with electrican’s tape if the wire
strands have iot been damaged. Note: Look for a wire pinched between body panels, burned
by the exhaus t pipe or muffler or rubbed against a moving part.
Use a hydron leter to check the condition of the battery. The Specific Gravity (s.g.) should be
1.265 at 80“ F (1.215 s.g. minimum needed for cranking engine). The reason for the battery fail¬
ing must be (ietermined. (1) Defective battery. Battery will not accept or hold a full charge. (2)
Short circuit. Check for grounded wire. (3) Charging system not working, either engine alter¬
nator or tricki a charger.
Trickle Chare er. Check with multimeter. Charger 725-0578—input 120 V A.C., no load output
13.5 V D.C., nited load current 1 amp. Charger 725-0507—input 120 V A.C., no load output 17.4
V D.C., rated I oad current 1/2 amp.
Alternator (d iai or single circuit) The charging system is an alternator located under the
flywheel. It is unregulated and rated 3 amp. at 3600 r.p.m. A diode (rectifier) is located in the
output lead ji st before the wire harness plug on the engine side.
Diode
Shrink
Tube
To Altei nator
Oil
3 AMP DC
(Batt.)
7 AMP AC
(Lamps)
Black
Wire
Polarized
Plug
Mechanical failure.
(Wires and switches)
The diode chi inges A.C. to D.C. to charge the battery. A bad diode can either fail to charge the
battery or discharge the battery if the alternator is shorted as well as the diode. To test: (1)
Disconnect c larger lead from the battery (small red wire). (2) Connect 12 V small test lamp be¬
tween the 3 emp. D.C. charge lead and the positive terminal of the battery. (3) With the engine
off, the lamp should not light. If it does, the diode and possibly the alternator should be re¬
placed. (4) Sturt the engine. The lamp should light. If it does not,the alternator (stator) or lead
wire is bad an 1 should be replaced.
The interlock system includes two mechanical activatec) switches which are wired in series in
the circuit ussd to energize the starter solenoid. While testing the interlock system, you will
make the mo ver temporarily unsafe by permitting the engine to be started with the blade and
clutch engage sd. WARNING: While testing, disengage the clutch, shut off the blade control, set
the parking b ake and place the gear shift lever in neutral. Attach a wire (minimum 18 gauge) to
the positive erminal of the battery and touch the other end to the small terminal on the
solenoid. If tl le engine does not crank: (1) There is a loose connection or poor ground. (2) The
solenoid may be bad. The solenoid can be checked by using a heavy wire (#8 gauge minimum)
and jumping jetween the two large terminals. If the engine cranks, the solenoid is bad. (3) If
the engine dues not crank when you jump the solenoid, have the starter motor tested by an
authorized ei gine dealer. If the engine does crank, the problem is with one of the safety
switches, ign tion switch or the wire between the fuse holder (or circuit breaker) and the small
terminal on tie solenoid. Note: Look for a poor connection at the switches or a defective
switch. Repla le if necessary.
Engine cranks
but will not
start
Throttle or choke not in
starting position
Check owner s guide for correct position for throttle control and choke (if separate control) for
starting.

TROUBLE SHOOTING CHART FOR ELECTRIC START MODELS
TROUBLE
LOOK FOR
REMEDY
No spark to spark plug
Spark plug lead disconnected. Connect lead. Hold spark plug lead away from engine block
about 1/8". Crank engine. There should be a spark. If not, have engine repaired at authorized
engine service dealer.
Faulty spark pipg. To test, remove spark plug. Attach spark plug lead to spark plug. Ground the
spark plug body against the engine block. Crank the engine. The spark plug should fire at the
electrode. Replace if it does not.
No fuel to the carburetor
Gasoline tank empty. Fill.
Fuel valve shut off. Open valve. Valve is located either at the bottom of the fuel tank or on the
carburetor.
Fuel line plugged. Remove and clean.
Air filter dirty
If the air cleaner is dirty, the engine may not start. Clean or replace as recommended by the
engine manufacturer.
Engine smokes
Engine loses crankcase
vacuum
Dipstick not seated or broken. Replace defective part.
Engine breather defective. Replace.
Excessive
vibration
Bent or damaged blade
spindle
Stop engine immediately. Check all pulleys, blade adapters, keys and bolts for tightness and
damage. Tighten or replace any damaged parts.
Bent blade
Stop engine immediately. Replace damaged blade. Only use original equipment blades.
Mower will not
discharge
grass or leaves
uncut strips
Engine speed low
Transmission selection
Blades short or dull
Throttle must be set between 3/4 and full throttle.
Use lower transmission gear. The slower your ground speed, the better the quality of cut.
Sharpen or replace blades (uncut strip problem only).
19