MTD 2005 500 Series User manual

Service Manual
2005 500 Series (569) Self Propelled Walk Behind Mower
MTD Products Inc - Product Training and Education Department
FORM NUMBER - 769-02088
10/2005
NOTE: These materials are for use by trained technicians who are experienced in the service and repair of outdoor power
equipment of the kind described in this publication, and are not intended for use by untrained or inexperienced individuals.
These materials are intended to provide supplemental information to assist the trained technician. Untrained or inexperi-
enced individuals should seek the assistance of an experienced and trained professional. Read, understand, and follow all
instructions and use common sense when working on power equipment. This includes the contents of the product’s Oper-
ators Manual, supplied with the equipment. No liability can be accepted for any inaccuracies or omission in this publication,
although care has been taken to make it as complete and accurate as possible at the time of publication. However, due to
the variety of outdoor power equipment and continuing product changes that occur over time, updates will be made to these
instructions from time to time. Therefore, it may be necessary to obtain the latest materials before servicing or repairing a
product. The company reserves the right to make changes at any time to this publication without prior notice and without
incurring an obligation to make such changes to previously published versions. Instructions, photographs and illustrations
used in this publication are for reference use only and may not depict actual model and component parts.
© Copyright 2005 MTD Products Inc. All Rights Reserved

1
Introduction ........................................................................................................................... 1
Belt Removal ........................................................................................................................ 1
Blade Removal ..................................................................................................................... 3
Traction Control Cable Removal .......................................................................................... 3
Engine Control Cable ...........................................................................................................4
Transmission Removal/Replacement ................................................................................... 5
Rear Discharge Door Removal/Replacement ...................................................................... 6
Servicing Front Wheel Brackets ........................................................................................... 9
TABLE OF CONTENTS

2

SERIES 569 SELF PROPELLED
1
1. INTRODUCTION
1.1. Disclaimer: This service manual was intended
for the use, by trained technicians. The informa-
tion contained in this manual is current and
accurate at the time of writing, but is subject to
change without notice.
1.2. Description: The 569 is a multi function front-
wheel-drive self propelled lawn mower. This
mower features 12” rear wheels and will bag,
mulch, or side-discharge the grass using the
included grass defector. See Figure 1.2.
Figure 1.2
2. BELT REMOVAL
2.1. Disconnect and ground the spark plug wire.
2.2. Drain out any fuel that is in the fuel tank.
2.3. Remove the two hex head shoulder screws that
secure the belt guard using a 1/4” driver.
See Figure 2.3.
2.4. Squeeze the belt cover inward from both sides
of the cover to release the lock tabs.
See Figure 2.4.
NOTE: Tabs on both sides of the cover that
secure in each front wheel height adjuster.
Figure 2.3
1/4” hex
Shoulder screws
Figure 2.4
Locking Tabs
SERIES 569 SELF PROPELLED

SERIES 569 SELF PROPELLED
2
2.5. Loosen the belt guide with a pair of 7/16”
wrenches. See Figure 2.5.
NOTE: The belt guide dose not need to be
removed simply loosen enough to allow the belt
to clear the pulley.
NOTE: Notice the holes on each of the wheel
brackets designed to stabilize the belt cover.
2.6. Slip the belt off of the transmission pulley.
See Figure 2.6.
2.7. Position the mower on its left side to keep the air
cleaner and carburetor elevated.
NOTE: Due to the orientation of the vent on the
transmission positioning the mower on its left
side is also advisable
2.8. Pull the belt in towards the rear of mower deck.
See Figure 2.8.
2.9. Remove the old belt from the crank shaft this
can be done with the blade still on the machine.
See Figure 2.9.
NOTE: It may be necessary to spin the blade to
allow the belt to fit between the blade tip and the
deck.
Figure 2.5
Belt Guide
Holes for
tabs on belt cover.
Figure 2.6
Figure 2.8
Figure 2.9

SERIES 569 SELF PROPELLED
3
2.10. When installing the new belt be sure that the belt
is riding within the belt keepers.
See Figure 2.10.
3. BLADE REMOVAL
3.1. Disconnect and ground the spark plug wire.
3.2. Drain the fuel tank or place a piece of plastic
under the fuel cap to prevent gas from leaking.
3.3. Tip the mower on its side so the air cleaner is up.
3.4. Secure the blade from rotating with a block of
wood or a blade lock.
See Figure 3.4.
NOTE: Torque for crack shaft bolt is 450-600
inch pounds
Figure 2.10
Belt Keepers
Figure 3.4
4. TRACTION CONTROL CABLE REMOVAL
4.1. Disconnect and ground the spark plug wire.
4.2. Remove the belt cover.
4.3. Disconnect the Z-fitting from the cable to the sta-
tionary bracket. See Figure 4.3.
NOTE: Slight back pressure will give the cable
slack to disconnect the Z- fitting easily.
NOTE: The cable end is barbed, and fits into a
snap-in cable mount to hold the cable in place.
NOTE: A Ford fuel-line disconnect tool is handy
for releasing barbed cable ends.
4.4. Squeeze the tabs together to allow the cable to
slip through the bracket.
4.5. Cut the cable ties to remove them from the han-
dle. Replace them with new ones during installa-
tion.
4.6. Loosen the wing nuts that secure the upper han-
dle to the lower handle, and carefully fold the
upper handle upward for easy access to the bot-
tom of the self-propel control housing.
NOTE: Use caution not to kink the control
cables.
Figure 4.3

SERIES 569 SELF PROPELLED
4
4.7. Remove the two Phillips head screws on the bot-
tom of the control panel housing. See Figure 4.7.
4.8. Once the screws have been removed, take the
cover off to expose the cable end of the handle.
See Figure 4.8.
NOTE: Having the lever in a neutral position
releases cable tension, easing cable removal.
4.9. Assemble mower by reversing the removal pro-
cedures.
5. ENGINE CONTROL CABLE
5.1. Push the bail handle to the forward limit of its
travel to give the cable slack.
5.2. Disconnect the z-fitting from the bail handle.
5.3. Disconnect the z-fitting from the engine.
NOTE: The cable is held secure with a snap
mount. Squeeze the tabs together to allow the
cable to back out of the bracket.
See Figure 5.3.
5.4. Snap the handle bar fitting off of the handle bar.
The handle bar fitting is part of the control cable.
See Figure 5.4.
5.5. Install cable by reversing the removal proce-
dures.
Figure 4.7
Figure 4.8
Figure 5.3
Snap mount
Figure 5.4

SERIES 569 SELF PROPELLED
5
6. TRANSMISSION REMOVAL/REPLACEMENT
6.1. Remove the belt cover by removing the shoulder
screws, squeeze the housing together to clear
the tabs that go into the wheel bracket.
6.2. Loosen the belt guide and take the belt off of the
transmission pulley.
6.3. Disconnect the drive cable from the cable
mounting bracket and transmission.
6.4. Disconnect the return spring.
See Figure 6.4.
NOTE: Notice the orientation of the spring prior
to disconnecting.
6.5. Remove the Wheels with a 9/16” socket.
6.6. Remove the snap ring that holds the drive gear
in place. See Figure 6.6.
Figure 6.4
Return Spring
Figure 6.6
Snap Ring
6.7. When removing the drive gears be careful of the
dowel pins not to lose them. See Figure 6.7.
NOTE: The drive gears have an “R” and “L” on
the outer edge for side indicators.
6.8. Remove the dust cover.
6.9. Remove left side front wheel height adjuster and
loosen the bolts that hold right side front wheel
height adjuster to the deck. See Figure 6.9.
NOTE: Tilt the left side of the transmission and
twist the transmission back to remove from the
right wheel bracket.
Figure 6.7
Dowel Pin
Figure 6.9

SERIES 569 SELF PROPELLED
6
6.10. Install the transmission in reverse order of dis-
asembly. See Figure 6.10.
NOTE: Make sure the front baffle is lined up with
the bolt holes for the front wheel brackets
NOTE: Upon installation apply a high quality
axle grease to the shaft. and the inner side of the
bearing sleeve.
6.11. Examine both sleeve spacers for damage or
excessive wear. See Figure 6.11.
6.12. Assemble mower by reversing the transmission
removal procedures.
7. REAR DISCHARGE DOOR REMOVAL/
REPLACEMENT
7.1. Elevate the rear of mower with a couple of 4X4
blocks or similar material. See Figure 7.1.
7.2. Prior to elevating, position the rear height adjust-
ers in third notch from the top to expose the
mounting hardware. See Figure 7.2.
Figure 6.10
Figure 6.11
Figure 7.1
Figure 7.2

SERIES 569 SELF PROPELLED
7
7.3. Remove both wheels with a 9/16” socket.
See Figure 7.3.
NOTE: The height adjuster lever can remain on
the wheel brackets. They have been removed in
this manual for visibility purposes.
7.4. Remove the wing nuts and hairpin clips that hold
the handle on the handle brackets.
See Figure 7.4.
7.5. Lay the handle forward out of the work area.
Figure 7.3
Figure 7.4
Hairpin Clip
Wing nut
7.6. Remove the 2 socket head screws from the rear
o n t h e m o w e r u s i n g a T- 8 0 To r x d r i v e r.
See Figure 7.6.
NOTE: Lift The deck slightly to free the rear baf-
fle from the back of the deck. This will give clear-
ance to reach the flange nuts on inner deck.
7.7. Remove both flange nuts and bolts that were
obscured behind the rear baffle.
See Figure 7.7.
Figure 7.6
Socket head screws
Figure 7.7
9/16”
Flange nuts

SERIES 569 SELF PROPELLED
8
7.8. Discharge the torsion springs that hold the rear
door closed. See Figure 7.8.
NOTE: Use a screw driver to release the torsion
spring, discharging the tension.
7.9. Remove the top hex head screw that holds each
end of the pivot rod to the handle bracket.
See Figure 7.9.
7.10. Remove the self tapping screws that stabilize
handle brackets on each side of the deck.
See Figure 7.10.
7.11. Slide the rear door out from between the handle
brackets.
7.12. Upon installation remember the spacers that fit
inside of the springs. See Figure 7.12.
Figure 7.8
Figure 7.9
3/8” Wrench
Hex Head
Figure 7.10
Self-tapping screw
3/8” wrench size
9/16” wrench size
Figure 7.12
Spacers
Pivot Rod
Torsion Springs

SERIES 569 SELF PROPELLED
9
7.13. When reinstalling the torsion spring, use a piece
of rope or a spring puller to pull back on the
spring to avoid the possibility of injury.
See Figure 7.13.
8. SERVICING FRONT WHEEL BRACKETS
8.1. In some cases the front wheel brackets may
need to be serviced. See Figure 8.1.
Figure 7.13
Figure 8.1
8.2. After removing the wheel bracket you will need
to take off the snap ring that holds the assembly
together. See Figure 8.2.
NOTE: The height adjustment assembly is
spring loaded by a wave washer.
8.3. After the snap ring is remover the assembly will
come apart very easily. See Figure 8.3.
Figure 8.2
Figure 8.3
Bearing
Sleeve
Wave Washer
Height Index
Bracket
Wheel Axle
Height Adjustment
Lever
Flat Washer

SERIES 569 SELF PROPELLED
10
8.4. During reassembly it may be necessary to com-
press the wave washer in order to reinstall the
snap ring. See Figure 8.4.
NOTE: Prior to reassembling replace the wave
washer p/n 736-0447 with a new one if the origi-
nal has lost tension.
8.5. Use a bench top vise with a 1 1/4” open-end
wrench and a deep 1” socket See Figure 8.5.
8.6. Use the Socket to press against the sleeve bear-
ing side of the bracket. Use the wrench to
press against the flat washer.
8.7. Center the wrench to allow enough room to put
the snap ring on. See Figure 8.7.
Figure 8.4
Figure 8.5
Deep 1” socket
1-1/4 open end wrench
Figure 8.7
Wrench
Snap Ring