MTD 540 Series User manual

IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY
MTD PRODUCTS INC. P.O. BOX 368022 CLEVELAND, OHIO 44136-9722
Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-
covered, brush-covered orgrass-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 ofCaliforniathe above is required by law (Section 4442 of the California Public Resources Code).Other states may have
similar laws. Federal laws apply on federal lands. A spark arrester for the muffler is available through your nearest engine authorized
service dealer or contact the service department, P.O. Box 368022 Cleveland, Ohio 44136-9722.
PRINTED IN U.S.A.
FORM NO.
770-10019C.fm
(10/01)
21” Rear & Side
Discharge
Mulching Mower
Model Series 540
OPERATOR’S MANUAL

2
TABLE OF CONTENTS
Content Page
Important Safe Operation Practices...................................................................3
Slope Gauge......................................................................................................6
Assembling Your Lawn Mower...........................................................................7
Know Your Lawn Mower....................................................................................9
Operating Your Lawn Mower .............................................................................9
Making Adjustments ..........................................................................................10
Maintaining Your Lawn Mower...........................................................................11
Troubleshooting.................................................................................................14
Parts List............................................................................................................16
FINDING MODEL NUMBER
This Operator’s Manual is an important part of your new lawn mower. It will help you assemble, prepare and
maintain the unit for best performance. Please read and understand what it says.
Before you start assembling your new equipment, please locate the model plate on the
equipment and copy the information from it in the space provided below. The information on
the model plate is very important if you need help from our Customer Support Department or
an authorized dealer.
• You can locate the model number by standing at the operating position and looking down at the rear
of the mower deck. A sample model plate is explained below. For future reference, please copy the
model number and the serial number of the equipment in the space below.
ENGINE INFORMATION
The engine manufacturer is responsible for all engine-related issues with regards to performance, power-
rating, specifications, warranty and service. Please refer to the engine manufacturer’s Owner’s/Operator’s
Manual packed separately with your unit for more information.
CALLING CUSTOMER SUPPORT
If you have difficulty assembling this product or have any questions regarding the controls, operation or
maintenance of this unit, please call the Customer Support Department.
Call 1- (330) 220-4MTD (4683) or 1- (800)-800-7310 to reach a Customer Support
representative. Please have your unit’s model number and serial number ready when you
call. See previous section to locate this information. You will be asked to enter the serial
number in order to process your call.
Copy the model number here:
Copy the serial number here:
(Model Number) (Serial Number)
MTD PRODUCTS INC
CLEVELAND, OHIO 44136
For more details about your unit, visit our website at www.mtdproducts.com

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SECTION 1: IMPORTANT SAFE OPERATION PRACTICES
WARNING: This symbol points out important safety instructions which, if not followed, could
endanger the personal safety and/or property of yourself and others. Read and follow all instructions in
this manual before attempting to operate this machine. Failure to comply with these instructions may
result in personal injury. When you see this symbol - heed its warning.
WARNING: Engine Exhaust, some of its constituents, and certain vehicle
components containor emit chemicals known to Stateof California to cause cancer
and birth defects or other reproductive harm.
DANGER:This machine was built to be operated according to the rules for safe operation in this
manual. As with any type of power equipment, carelessness or error on the part of the operator can
result in serious injury. This machine is capable of amputating hands and feet and throwing objects.
Failure to observe the following safety instructions could result in serious injury or death.
General Operation
1. Read this operator’smanual carefully in its entirety
before attempting to assemble this machine. Read,
understand, and follow all instructions on themachine
and in the manual(s) before operation. Be completely
familiarwith the controls and the proper useof this
machine before operating it. Keep this manual in a safe
place for future and regular reference and for ordering
replacement parts.
2. This machine is a precision piece of powerequipment,
nota plaything.Therefore,exerciseextremecautionat all
times. Your unit hasbeen designed to perform one job: to
mow grass. Do not use it for any other purpose.
3. Never allow children under 14 years old to operate this
machine. Children 14 years old andover shouldread and
understand the operation instructions and safety rules in
this manual and should be trained and supervised by a
parent. Only responsible individuals who are familiar with
theserules ofsafe operation should be allowedto use
this machine.
4. Thoroughly inspect the area where the equipment is to
be used.Remove all stones,sticks, wire, bones, toysand
other foreign objects which could be tripped over or
picked up and thrown by the blade. Thrown objects can
cause serious personal injury. Plan your mowing pattern
to avoid discharge of material toward roads, sidewalks,
bystanders and the like. Also, avoid discharging material
against a wall or obstruction which may cause
discharged materialto ricochet back toward the operator.
5. To helpavoid blade contactor a thrown object injury, stay
in the operator zone behind thehandles and keep
children, bystanders, helpers and pets at least 75 feet
from the mower while it is inoperation. Stop machine if
anyone enters the area.
6. Always wear safety glasses or safety goggles during
operation and while performing an adjustment or repair to
protect your eyes. Thrown objects which ricochet can
cause serious injury to the eyes.
7. Wear sturdy, rough-soled work shoesand close-fitting
slacks and shirts. Shirtsand pantsthat coverthe arms
and legs and steel-toed shoes are recommended. Never
operate this machine in bare feet, sandals, slippery or
light weight (e.g. canvas) shoes.
8. Do not puthands or feet nearrotating parts or under the
cutting deck. Contactwith theblade can amputate hands
and feet.
9. A missing or damaged dischargecover can cause blade
contact or thrown object injuries.
10. Many injuries occur asa resultof the mowerbeing pulled
over the foot during a fall caused by slipping ortripping.
Do nothold on to the mowerif you are falling; releasethe
handle immediately.
11. Never pull the mower back toward you while you are
walking. If you mustback the mower away from a wall or
obstruction first look down andbehind to avoid tripping
and then follow these steps:
a. Step back from the mower to fully extend your
arms.
b. Be sure you are well balanced with sure footing.
c. Pullthemowerback slowly, nomore than half way
toward you.
d. Repeatthese steps as needed.
12. Do not operate the mowerwhile under the influenceof
alcohol or drugs.
13. Do not engage the self-propelled mechanism on units so
equipped while starting engine.
14. The blade control handle is a safety device. Never
attempt to bypass itsoperation. Doing so makes the
safety device inoperative and may resultin personal
injury through contact with the rotating blade. The blade
control handle must operate easily in both directions and
automatically return to the disengaged position when
released.
15. Never operate the mower in wet grass. Always be sure of
your footing. A slip andfallcan cause seriouspersonal
injury. If youfeel you are losing your footing,release the
bladecontrol handle immediately and the blade will stop
rotating within three seconds.
16. Mow only in daylight or in good artificiallight. Walk, never
run.
17. Stop the blade when crossinggravel drives, walks or
roads.
18. If the equipment should start to vibrate abnormally, stop
the engine andcheck immediately forthe cause.
Vibration is generally a warning of trouble.
19. Shut the engineoff and wait until the blade comes to a
complete stop before removing the grass catcher or

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unclogging the chute. The cutting blade continues to
rotate fora few seconds afterthe engine is shut off.
Never place anypart of the body in theblade area until
you are sure the blade hasstoppedrotating.
20. Never operate mower without proper trail shield,
discharge cover, grass catcher, blade control handle or
othersafety protective devices in place and working.
Never operate mower with damaged safety devices.
Failure todo so, can resultin personal injury.
21. Muffler and engine become hot and can cause a burn. Do
not touch.
22. Only use parts and accessories made for this machine by
the manufacturer. Failure to do so,can resultin personal
injury.
23. If situations occur which are not covered in this manual,
use care and good judgment. Contact your dealer for
assistance.Telephone [phone] for the name of
your nearest dealer.
Slope Operation
Slopesare a majorfactor related to slip andfall accidents
which can result in severe injury. Operation on slopes
requires extra caution. If you feel uneasy on a slope, do not
mow it. For your safety, use the slope gauge includedas part
of this manual to measure slopes before operating this unit on
a sloped or hilly area. If the slope isgreater than15 degrees,
do not mow it.
Do:
1. Mow acrossthe face of slopes; never up and down.
Exercise extremecaution whenchanging direction on
slopes.
2. Watch for holes, ruts, rocks, hidden objects, or bumps
whichcan cause you to slip or trip.Tall grass can hide
obstacles.
3. Always be sure of your footing. A slip and fall can cause
serious personal injury. Ifyou feel you are losing your
balance, release the blade control handle immediately,
and the blade willstop rotating within 3 seconds.
Do Not:
1. Do not mow near drop-offs, ditches or embankments,
you could lose your footing orbalance.
2. Do not mow slopes greater than 15 degrees as shown on
the slope gauge.
3. Do not mow onwet grass.Unstable footingcould cause
slipping.
Children
Tragic accidents can occur if the operator is not alert to the
presence of children.Children areoftenattracted to the
mower and the mowing activity. They do not understand the
dangers. Never assume that children will remain where you
last saw them.
1. Keep children out of the mowingarea and underthe
watchful care of a responsible adult otherthan the
operator.
2. Be alert and turn mower off if a child enters the area.
3. Before and while moving backwards, look behind and
down for small children.
4. Use extreme care when approaching blind corners,
doorways, shrubs, trees, or other objects that may
obscure your vision ofa child whomay run into the
mower.
5. Keep children away from hot or running engines. They
can suffer burns from a hot muffler.
6. Never allow childrenunder 14years old to operate a
power mower.Children 14 years old and over should
read and understand the operation instructions and
safety rules in this manual and should be trained and
supervised bya parent.
Service
Safe Handling Of Gasoline:
1. To avoid personalinjury orproperty damage use extreme
care in handling gasoline. Gasoline is extremely
flammableand the vapors are explosive. Serious
personal injury can occur when gasoline is spilled on
yourself oryour clothes which can ignite.
2. Wash your skin and change clothes immediately.
3. Use onlyan approved gasoline container.
4. Never fill containers inside a vehicle or on a truck or
trailer bed with a plastic liner. Always place containers on
the ground away from your vehicle before filling.
5. When practical, remove gas-powered equipment from
the truck or trailer and refuel it on the ground. If this is not
possible, then refuel such equipment on a trailerwith a
portable container, ratherthan from a gasoline dispenser
nozzle.
6. Keep the nozzle in contactwith the rim of thefuel tank or
containeropeningat alltimesuntilfuelingiscomplete.Do
not use a nozzle lock-open device.
7. Extinguish all cigarettes, cigars, pipes and other sources
of ignition.
8. Never fuel machine indoorsbecause flammablevapors
will accumulate in the area.
9. Never remove gas cap oradd fuel while the engine is hot
or running. Allow engine to cool at least twominutes
before refueling.
10. Never over fill fuel tank. Fill tank to no more than ½ inch
below bottom offillerneck to provide space for fuel
expansion.
11. Replace gasoline cap and tighten securely.
12. If gasoline is spilled, wipe it off the engine and
equipment. Move unit to another area. Wait 5 minutes
before starting the engine.
13. Never store the machine or fuel container inside where
there is anopen flame,spark or pilotlight ason a water
heater, space heater, furnace ,clothes dryer or other gas
appliances.
14. To reduce fire hazard, keep mower free of grass, leaves,
or other debris build-up. Clean up oil orfuelspillage and
remove any fuel soaked debris.
15. Allow amower to cool at least 5 minutes before storing.
General Service:
1. Never run an engine indoors or in apoorly ventilated
area. Engine exhaust contains carbon monoxide, an
odorless and deadly gas.
2. Before cleaning, repairing, orinspecting, make certain
the blade and all moving parts have stopped. Disconnect
the spark plug wireand ground against the engine to
prevent unintended starting.
3. Check the blade and engine mounting bolts at frequent

5
intervals for proper tightness. Also, visually inspect blade
for damage (e.g., bent, cracked, worn) Replace blade
withthe original equipment manufacture’s(O.E.M.) blade
only, listed in this manual. “Use of parts which do not
meet the original equipment specifications may lead to
improper performance and compromise safety!”
4. Mower blades are sharpand can cut.Wrap the blade or
wear gloves,and use extra caution when servicing them.
5. Keep allnuts,bolts, and screws tight to besure the
equipment is in safe working condition.
6. Never tamper with safety devices. Check their proper
operation regularly.
7. Afterstriking a foreign object,stopthe engine, disconnect
the spark plug wireand ground against the engine.
Thoroughly inspect the mower for any damage. Repair
the damage before starting and operating the mower.
8. Never attempt to makea wheel orcutting height
adjustment while the engine is running.
9. Grass catcher components, discharge cover, and trail
shield aresubject to wear anddamage which could
expose moving parts or allow objects to be thrown. For
safety protection, frequently check components and
replace immediately with original equipment
manufacturer’s (O.E.M.) parts only, listed in this manual.
“Use of parts which do not meet the original equipment
specificationsmay lead to improperperformanceand
compromise safety!”
10. Do not change the engine governorsetting or overspeed
the engine.The governor controlsthe maximum safe
operating speed of the engine.
11. Maintain or replace safety and instruction labels, as
necessary.
12. Observe proper disposal laws and regulations. Improper
disposal of fluids and materialscan harm the
environment.
WARNING - YOUR RESPONSIBILITY: Restrict theuse of this power machine topersons who read,
understand andfollow the warnings and instructions in this manual and on themachine.
NOTE: Not all safety labels shown may apply to your lawn mower.

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SECTION 2: SLOPE GAUGE Use this page as a guide to determine slopes where you may not operate safely. Do not operate your lawn mower on such slopes.
15°
SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE
A POWER POLE
A CORNER OF A BUILDING
OR A FENCE POST
FOLDONDOTTEDLINE,REPRESENTINGA15°SLOPE
WARNING
Do not mow on inclines with a slope in excess of 15 degrees (a rise of approximately 2-1/2 feet every 10 feet). A riding mower could
overturn and cause serious injury. If operating a walk-behind mower on such a slope, it is extremely difficult to maintain your footing
and you could slip, resulting in serious injury.
Operate RIDING mowers up and down slopes, never across the face of slopes.
Operate WALK-BEHIND mowers across the face of slopes, never up and down slopes.

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SECTION 3: ASSEMBLING YOUR LAWN MOWER
IMPORTANT: This unit is shipped without gasoline or oil
in the engine. Be certain to service engine with gasoline
and oil as instructed in the separate engine manual
before operating your mower.
NOTE: Reference to right or left hand side of the mower
is observed from the operating position.
Removing Unit From Carton
•Remove staples, break glue on top flaps, or cut tape
at carton end and peel along top flap to open carton.
•Remove loose parts if included with unit (i.e.,
operator’s manual, etc.)
•Cut along corners, lay carton down flat, and remove
packing material.
•Roll or slide unit out of carton and check carton
thoroughly for loose parts.
Loose Parts in Carton
•Grass Bag
•Side Discharge Chute
•Rear Wheels
•Hardware Pack
Disconnecting Spark Plug Wire
Before setting up yourlawn mower, disconnect the spark
plug wire from the spark plug and ground against the
engine. See Figure 1.
Figure 1
Setting Up Your Lawn Mower
Assembling Handle
•Lift up and pull back on the upper handle to raise the
handle into the operating position. Make certain the
lower handle is seated securely into the handle
bracket assemblies. Tighten the wing nuts on each
side of the handle (carriage bolts must be seated
properly into the handle). See Figure 2.
NOTE: Your mower is shipped with the handle in the
higher position. If you wish to lower the height of the
handle, refer to the Adjustment Section at this time.
Figure 2
•Remove the hairpin clips from the outer hole in the
weld pins on the handle mounting brackets. Using a
pair of pliers, squeeze one leg of the lower handle
against the handle mounting bracket. Insert the
hairpin clip into the inner hole on the weld pin.
Repeat on the other side. See Figure 3.
•After moving the hairpin clip, insert the carriage bolt
from hardware pack in the upper hole on the handle
mounting bracket and secure with plastic wing nut
from the hardware pack. Repeat on other side.
Figure 3
•Fasten the cable to the lower handle with the two
cable ties found on the lower handle. Pull the cable
ties tight and trim off the excess. See Figure 4.
Figure 4
Spark Plug
Spark Plug
Wire
Spark
Plug Wire
Bolt
Insert Hairpin
Weld Pin
Handle Mounting
Bracket
Hairpin
Clip
Wing Nut
Clip
Carriage Bolt
Cable Tie
Lower
Handle

8
Attaching Rear Wheels
•Remove hardware from rear pivot bars.
•Insert shoulder screw through flat washer, wave
washer, rear wheel, and spring washer.
•Secure shoulder screw with hardware to rear pivot
bar. See Figure 5.
Figure 5
Attaching Starter Rope
•The rope guide is attached to the right side of upper
handle. Loosen the wing nut which secures the
rope guide. See Figure 6.
Figure 6
•With the spark plug wire disconnected and
grounded, hold the blade control handle against the
upper handle, and pull the starter rope out of the
engine. Release the blade control handle. Slip the
starter rope into the rope guide. Tighten the wing
nut.
Attaching Grass Catcher To Mower
NOTE: The mulching baffle, if so equipped, is already
in place on the mower for shipping purposes. Your lawn
mower may be equipped with both a mulching baffle
and a mulching plug. While the mulching baffle is
located at the rear of the mower, the mulching plug is
located on the right side of the cutting deck. Do not
remove the mulching plug from the mower even when
you are not mulching the grass.
•To remove the mulching baffle, lift the rear dis-
charge door on the mower. Remove the mulching
baffle. See Figure 7.
Figure 7
IMPORTANT: Make sure cables are routed to the
outside of the handle so they are not in the way when
attaching the grass catcher.
•Lift the rear discharge door on the mower.
•Place the hooks, found on both sides of the grass
catcher frame, over the chute door pivot rod at the
rear of the mower. Release the rear discharge door.
See Figure 8.
Figure 8
•To remove the grass catcher, lift the rear discharge
door on the mower, lift the grass catcher up and off
the pivot rod. Reinstall the mulching baffle and
release the rear discharge door.
WARNING: Never operate the mower
unless the hooks on the grass catcher are
firmly seated on the chute pivot rod, and
the rear discharge door rests firmly
against the top of the grass catcher.
ConvertingTo Side Discharge
If your unit is equipped with a side discharge chute, you
can convert to a side discharge mower as follows:
•Lift the rear discharge door and install the mulching
baffle. See Figure 7.
•On the side of the mower, lift the mulching plug and
slide the two hooks of the side discharge chute
under the hinge pin on the mulching plug assembly.
Lower the side mulching plug.
•Do not remove the side mulching plug at any time,
even when you are not mulching.
Spring Washer
Wave Washer
Rear Wheel
Flat Washer
Shoulder
Screw
Wing Nut
Starter Upper Handle
Rope
Rope
Guide Lower
Handle
Rear Mulching
Baffle
Discharge Door
Grass Bag

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SECTION 4: KNOW YOUR LAWN MOWER
Read this operator’s manual and safety rules before
operating your lawn mower. Compare the illustration in
Figure 9 with your lawn mower to familiarize yourself
with the location of various controls and adjustments.
Save this manual for future reference.
WARNING: The operation of any lawn
mower can result in foreign objects being
thrown into the eyes, which can damage
your eyes severely. Always wear safety
glasses while operating the mower, or
while performing any adjustments or
repairs on it.
Recoil Starter
The recoil starter is attached to the right handle. Stand
behind the unit and pull the recoil starter to start the
unit. See Figure 9.
Blade Control Handle
The blade control handle is located on the upper handle
of the mower. The blade control handle must be
depressed in order to operate the unit. Release blade
control handle to stop engine and blade. See Figure 9.
WARNING: This blade control mechanism
is a safety device. Never attempt to bypass
its operations.
Cutting Height Adjustment Levers
These levers are located on each wheel and are used
to adjust the cutting height. These levers have to be at
the same relative position to ensure uniform cut.
See Figure 9.
Grass Catcher
The grass catcher, located at the rear of the mower, is
used to bag the grass clippings for disposal at another
site. Once the bag is full, it has to be removed from the
mower and emptied before any further mowing.
Figure 9
Mulching Plug
Both the mulching baffle and the mulching plug are
used only for mulching purposes. Instead of collecting
the grass clippings in a grass catcher, some mower
models have the option of recirculating the clippings
back to the lawn.
SECTION 5: OPERATING YOUR LAWN MOWER
WARNING: Keep hands and feet away from
chute area on the cutting deck. The
operation of any lawn mower can result in
foreign objects being thrown into the eyes,
which can result in severe eye damage.
Always wear safety glasses or eye shields.
NOTE: For shipping purposes your mower is set with
the wheels in a low cutting height position. For best
results raise the cutting position until it is determine
which height is best for your lawn. See the Adjustment
Section for details.
Gas and Oil Fill-Up
Service the engine with gasoline and oil as instructed in
the separate engine manual packed with your mower.
Read instructions carefully.
Never fill fuel tank indoors with engine
running or until the engine has been
allowed to cool for at least two minutes
after running.
Starting Engine
•Attach spark plug wire to spark plug. Make certain
the metal cap on the end of the spark plug is
fastened securely over the metal tip on the spark
plug.
•Prime engine as instructed in the separate engine
manual packed with your unit.
•Your lawn mower may be equipped with a constant
speed throttle, which is set at full throttle for best
performance.
Blade Control
Handle
Cutting Height
Adjustment Lever
Recoil
Starter
Grass
Catcher
Mulching Plug

10
•Stand behind the mower and squeeze the blade
control handle against the upper handle.
•Grasp recoil starter handle and pull rope out slowly
untilengine reaches the start ofcompression cycle
(rope will pull slightly harder at this point). Let the
rope rewind slowly. Pull rope with a rapid,
continuous, full arm stroke. Keeping a firm grip on
the starter handle, let the rope return to the starter
slowly.
Using Your Lawn Mower
Be sure that the lawn is clear ofstones, sticks,wire, or
other objects which could damage the lawn mower or
the engine. Such objects could be accidently thrown by
the mower in any direction and cause serious personal
injury to the operator and others.
For best results, do not cut wet grass because it tends
to stick to the underside of the mower, preventing
proper discharge of grass clippings, and could cause
you to slip and fall. New grass, thick grass, or wet grass
may require a narrower cut.
For a healthier lawn, never cut off more than one-third
of the total length of the grass. Your lawn should be cut
in the fall as long as there is growth. This mower is
designed to be operated at full throttle to give you the
best cut and do the most effective job of mowing or
mulching.
WARNING: If you strike a foreign object,
stop the engine. Remove wire from the
spark plug, thoroughly inspect the mower
for any damage, and repair the damage
before restarting and operating the
mower. Extensive vibration of the mower
during operation is an indication of
damage. The unit should be promptly
inspected and repaired.
Mulching
For effective mulching, do not cut wet grass because it
tends to stick to the underside of the deck, preventing
proper mulching of grass clippings. New or thick grass
may require a narrower cut. The ground speed should
be adjusted to the condition of the lawn. If mowing has
been delayed and the grass has been allowed to grow
in excess of 4”, mulching is not recommended. Mow
using the side discharge to reduce the grass height to 3
1/4”maximum before mulching.
SECTION 6: MAKING ADJUSTMENTS
WARNING: Do not at any time make any
adjustments without first stopping engine
and disconnecting spark plug wire.
Handle Height Adjustment
Your mower is shipped with the handle in the higher
height position. To lower the height proceed as follows:
•Remove the starter rope from the rope guide.
•Remove the upper handle by removing the hand
knobs and carriage bolts. Lay the upper handle out
of the way, being careful not to bend or kink the
cables.
•Remove the hairpin clips from the weld pins on the
handle brackets and remove the wing nuts and
carriage bolts from the upper hole on the handle
mounting bracket. Press out on the legs of the
lower handle and remove lower handle from the
mower.
•Turn lower handle around so the notch on the
bottom of the lower handle is facing forward.
See Figure 10.
•Reassemble, placing the bottom holes in the
handle over the weld pins in the handle mounting
bracket.
•Place the hairpin clips in the inner holes in the weld
pins and insert the carriage bolts the upper hole on
the handle mounting bracket and secure with
plastic wing nuts.
•Reassemble the upper handle to the lower handle.
•Attach the starter rope as instructed in the
Assembly Section.
Figure 10
Cutting Height Adjustment
An adjusting plate and spring lever at each wheel
position provides cutting height adjustment. Each
adjusting plate has assorted height positions. When the
spring lever is moved from one location to another the
height of cut will be changed. Simply depress the lever
towards wheel and move lever assembly to desired
position. See Figure 11.
Notch
Lower Handle