MTD 86M User manual

MTD LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019
Printed In USA
Safe Operation Practices • Set-Up • Operation • Maintenance • Service • Troubleshooting • Warranty
WARNING
READ AND FOLLOW ALL SAFETY RULES AND INSTRUCTIONS IN THIS MANUAL
BEFORE ATTEMPTING TO OPERATE THIS MACHINE.
FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Op e r a t O r ’sMa n u a l
Form No. 769-05894
(February 2, 2010)
Self-Propelled Mower — Model 86M

Customer Support
Please do NOT return the machine to the retailer or dealer without first contacting our Customer Support Department.
If you have difficulty assembling this product or have any questions regarding the controls, operation, or maintenance of
this machine, you can seek help from the experts. Choose from the options below:
Visit us on the web at www.mtdproducts.com◊
Call a Customer Support Representative at [phone] or [phone]◊
Write us at MTD LLC • P.O. Box 361131 • Cleveland, OH • 44136-0019◊
Thank you for purchasing a Lawn Mower manufactured by MTD.
It was carefully engineered to provide excellent performance
when properly operated and maintained.
Please read this entire manual prior to operating the equipment.
It instructs you how to safely and easily set up, operate and
maintain your machine. Please be sure that you, and any other
persons who will operate the machine, carefully follow the
recommended safety practices at all times. Failure to do so could
result in personal injury or property damage.
All information in this manual is relative to the most recent
product information available at the time of printing. Review
this manual frequently to familiarize yourself with the machine,
its features and operation. Please be aware that this Operator’s
Manual may cover a range of product specifications for various
models. Characteristics and features discussed and/or illustrated
in this manual may not be applicable to all models. We reserve
the right to change product specifications, designs and
equipment without notice and without incurring obligation.
If you have any problems or questions concerning the machine,
phone your local authorized MTD service dealer or contact us
directly. MTD’s Customer Support telephone numbers, website
address and mailing address can be found on this page. We want
to ensure your complete satisfaction at all times.
Throughout this manual, all references to right and left side of the
machine are observed from the operating position
Thank You
Record Product Information
Before setting up and operating your new equipment, please
locate the model plate on the equipment and record the
information in the provided area to the right. You can locate the
model plate by standing at the operator’s position and looking
down at the rear of the deck. This information will be necessary,
should you seek technical support via our web site, Customer
Support Department, or with a local authorized service dealer.
Mo d e l Nu M b e r
Se r i a l Nu M b e r
Safe Operation Practices ........................................ 3
Assembly & Set-Up .................................................. 9
Controls & Features................................................12
Operation................................................................13
Maintenance & Adjustments.................................14
Service .....................................................................16
Troubleshooting .....................................................17
Engine Operation...................................................18
Engine Maintenance............................................. 20
Replacement Parts ................................................ 25
To The Owner 1
2
Table of Contents

Important Safe Operation Practices 2
3
General Operation
Read this operator’s manual carefully in its entirety before 1.
attempting to assemble this machine. Read, understand,
and follow all instructions on the machine and in the
manual(s) before operation. Keep this manual in a safe
place for future and regular reference and for ordering
replacement parts.
Be completely familiar with the controls and the proper use 2.
of this machine before operating it.
This machine is a precision piece of power equipment,3.
not a plaything. Therefore, exercise extreme caution at all
times. This machine has been designed to perform one job:
to mow grass. Do not use it for any other purpose.
Never allow children under 14 years of age to operate this4.
machine. Children 14 and over should read and understand
the instructions and safe operation practices in this manual
and on the machine and should be trained and supervised
by an adult.
Only responsible individuals who are familiar with these 5.
rules of safe operation should be allowed to use this
machine.
Thoroughly inspect the area where the equipment is to be6.
used. Remove all stones, sticks, wire, bones, toys and 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 7.
toward roads, sidewalks, bystanders and the like. Also,
avoid discharging material against a wall or obstruction,
which may cause discharged material to ricochet back
toward the operator.
To help avoid blade contact or a thrown object injury,8.
stay in operator zone behind handles and keep children,
bystanders, helpers and pets at least 75 feet from mower
while it is in operation. Stop machine if anyone enters area.
Always wear safety glasses or safety goggles during9.
operation and while performing an adjustment or repair
to protect your eyes. Thrown objects which ricochet can
cause serious injury to the eyes.
Wear sturdy, rough-soled work shoes and close-fitting10.
slacks and shirts. Shirts and pants that cover the 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.
Do not put hands or feet near rotating parts or under the11.
cutting deck. Contact with blade can amputate fingers,
hands, toes and feet.
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!
DANGER: This machine was built to be operated according to the safe operation practices 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 fingers, hands,
toes and feet and throwing objects. Failure to observe the following safety instructions could
result in serious injury or death.
CALIFORNIA PROPOSITION 65
WARNING: Engine Exhaust, some of its constituents, and certain vehicle components
contain or emit chemicals known to State of California to cause cancer and birth defects
or other reproductive harm.
WARNING: Battery posts, terminals, and related accessories contain lead and lead
compounds, chemicals known to the State of California to cause cancer and reproductive
harm. Wash hands after handling.

4se c t i O n 2 — iM p O r t a n t sa f e Op e r a t i O n pr a c t i c e s
A missing or damaged discharge cover can cause blade12.
contact or thrown object injuries.
Many injuries occur as a result of the mower being pulled13.
over the foot during a fall caused by slipping or tripping.
Do not hold on to the mower if you are falling; release the
handle immediately.
Never pull the mower back toward you while you are14.
walking. If you must back the mower away from a wall or
obstruction first look down and behind to avoid tripping
and then follow these steps:
Step back from mower to fully extend your arms.a.
Be sure you are well balanced with sure footing.b.
Pull the mower back slowly, no more than half way c.
toward you.
Repeat these steps as needed.d.
Do not operate the mower while under the influence of15.
alcohol or drugs.
Do not engage the self-propelled mechanism on machines16.
so equipped while starting engine.
The blade control is a safety device. Never attempt to17.
bypass its operation. Doing so makes the safety device
inoperative and may result in personal injury through
contact with the rotating blade. The blade control must
operate easily in both directions and automatically return
to the disengaged position when released.
Never operate the mower in wet grass. Always be sure of18.
your footing. A slip and fall can cause serious personal
injury. If you feel you are losing your footing, release the
blade control handle immediately and the blade will stop
rotating within three seconds.
Mow only in daylight or good artificial light. Walk, never19.
run.
Stop the blade when crossing gravel drives, walks or roads.20.
If the equipment should start to vibrate abnormally, stop21.
the engine and check immediately for the cause. Vibration
is generally a warning of trouble.
Shut the engine off and wait until the blade comes to22.
a complete stop before removing the grass catcher or
unclogging the chute. The cutting blade continues to
rotate for a few seconds after the blade control is released.
Never place any part of the body in the blade area until you
are sure the blade has stopped rotating.
Never operate mower without proper trail shield,23.
discharge cover, grass catcher, blade control or other safety
protective devices in place and working. Never operate
mower with damaged safety devices. Failure to do so can
result in personal injury.
Muffler and engine become hot and can cause a burn. Do24.
not touch.
Never attempt to make a wheel or cutting height25.
adjustment while the engine is running.
Only use parts and accessories made for this machine by 26.
the manufacturer. Failure to do so can result in personal
injury.
When starting engine, pull cord slowly until resistance27.
is felt, then pull rapidly. Rapid retraction of starter cord
(kickback) will pull hand and arm toward engine faster than
you can let go. Broken bones, fractures, bruises or sprains
could result.
If situations occur which are not covered in this manual,28.
use care and good judgement. Contact Customer Support
for assistance or the name of the nearest service dealer.
Slope Operation
Slopes are a major factor related to slip and fall 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 included as part of this manual to
measure slopes before operating this machine on a sloped or
hilly area. If the slope is greater than 15 degrees, do not mow it.
Do:
Mow across the face of slopes; never up and down. Exercise1.
extreme caution when changing direction on slopes.
Watch for holes, ruts, rocks, hidden objects, or bumps2.
which can cause you to slip or trip. Tall grass can hide
obstacles.
Always be sure of your footing. A slip and fall can cause3.
serious personal injury. If you feel you are losing your
balance, release the blade control handle immediately and
the blade will stop rotating within three (3) seconds.
Do Not:
Do not mow near drop-offs, ditches or embankments, you1.
could lose your footing or balance.
Do not mow slopes greater than 15 degrees as shown on2.
the slope gauge.
Do not mow on wet grass. Unstable footing could cause3.
slipping.
Children
Tragic accidents can occur if the operator is not alert to the
presence of children. Children are often attracted to the mower
and the mowing activity. They do not understand the dangers.
Never assume that children will remain where you last saw them.
Keep children out of the mowing area and under watchful1.
care of a responsible adult other than the operator.
Be alert and turn mower off if a child enters the area.2.
Before and while moving backwards, look behind and 3.
down for small children.
Use extreme care when approaching blind corners,4.
doorways, shrubs, trees, or other objects that may obscure
your vision of a child who may run into the mower.
Keep children away from hot or running engines. They can5.
suffer burns from a hot muffler.
Never allow children under 14 years of age to operate this6.
machine. Children 14 and over should read and understand
the instructions and safe operation practices in this manual
and on the machine and be trained and supervised by an
adult.

5se c t i O n 2 — iM p O r t a n t sa f e Op e r a t i O n pr a c t i c e s
Service
Safe Handling Of Gasoline:
To avoid personal injury or property damage use extreme1.
care in handling gasoline. Gasoline is extremely flammable
and the vapors are explosive. Serious personal injury can
occur when gasoline is spilled on yourself or your clothes,
which can ignite. Wash your skin and change clothes
immediately.
Use only an approved gasoline container.2.
Never fill containers inside a vehicle or on a truck or trailer3.
bed with a plastic liner. Always place containers on the
ground away from your vehicle before filling.
Remove gas-powered equipment from the truck or4.
trailer and refuel it on the ground. If this is not possible,
then refuel such equipment on a trailer with a portable
container, rather than from a gasoline dispenser nozzle.
Keep the nozzle in contact with the rim of the fuel tank or5.
container opening at all times until fueling is complete. Do
not use a nozzle lock-open device.
Extinguish all cigarettes, cigars, pipes and other sources6.
of ignition.
Never fuel machine indoors because flammable vapors will7.
accumulate in the area.
Never remove gas cap or add fuel while engine is hot or8.
running. Allow engine to cool at least two minutes before
refueling.
Never over fill fuel tank. Fill tank to no more than 1 inch9.
below bottom of filler neck to provide for fuel expansion.
Replace gasoline cap and tighten securely.10.
If gasoline is spilled, wipe it off the engine and equipment.11.
Move machine to another area. Wait 5 minutes before
starting engine.
Never store the machine or fuel container near an open12.
flame, spark or pilot light as on a water heater, space
heater, furnace, clothes dryer or other gas appliances.
To reduce fire hazard, keep machine free of grass, leaves,13.
or other debris build-up. Clean up oil or fuel spillage and
remove any fuel soaked debris.
Allow machine to cool at least 5 minutes before storing.14.
General Service:
Never run an engine indoors or in a poorly ventilated area.1.
Engine exhaust contains carbon monoxide, an odorless
and deadly gas.
Before cleaning, repairing, or inspecting, make certain the 2.
blade and all moving parts have stopped. Disconnect the
spark plug wire and ground against the engine to prevent
unintended starting.
Check the blade and engine mounting bolts at frequent3.
intervals for proper tightness. Also, visually inspect blade
for damage (e.g., bent, cracked, worn) Replace blade with
the 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!”
Mower blades are sharp and can cut. Wrap the blade or4.
wear gloves, and use extra caution when servicing them.
Keep all nuts, bolts, and screws tight to be sure the5.
equipment is in safe working condition.
Never tamper with safety devices. Check their proper6.
operation regularly.
After striking a foreign object, stop the engine, disconnect7.
the spark plug wire and ground against the engine.
Thoroughly inspect the mower for any damage. Repair the
damage before starting and operating the mower.
Never attempt to make a wheel or cutting height8.
adjustment while the engine is running.
Grass catcher components, discharge cover, and trail shield9.
are subject to wear and damage 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 specifications
may lead to improper performance and compromise
safety!”
Do not change the engine’s governor setting or over-speed 10.
the engine. The governor controls the maximum safe
operating speed of the engine.
Check fuel line, tank, cap, and fittings frequently for cracks11.
or leaks. Replace if necessary.
Do not crank engine with spark plug removed.12.
Maintain or replace safety and instruction labels, as13.
necessary.
Observe proper disposal laws and regulations. Improper 14.
disposal of fluids and materials can harm the environment.
According to the Consumer Products Safety Commission 15.
(CPSC) and the U.S. Environmental Protection Agency (EPA),
this product has an Average Useful Life of seven (7) years,
or 140 hours of operation. At the end of the Average Useful
Life have the machine inspected annually by an authorized
service dealer to ensure that all mechanical and safety
systems are working properly and not worn excessively.
Failure to do so can result in accidents, injuries or death.
Do not modify engine
To avoid serious injury or death, do not modify engine in any
way. Tampering with the governor setting can lead to a runaway
engine and cause it to operate at unsafe speeds. Never tamper
with factory setting of engine governor.

6se c t i O n 2 — iM p O r t a n t sa f e Op e r a t i O n pr a c t i c e s
Notice Regarding Emissions
Engines which are certified to comply with California and federal
EPA emission regulations for SORE (Small Off Road Equipment)
are certified to operate on regular unleaded gasoline, and
may include the following emission control systems: Engine
Modification (EM), Oxidizing Catalyst (OC), Secondary Air
Injection (SAI) and Three Way Catalyst (TWC) if so equipped.
Spark Arrestor
WARNING: This machine is equipped with an
internal combustion engine and should not be used
on or near any unimproved 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 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 361131 Cleveland, Ohio 44136-0019.

7se c t i O n 2 — iM p O r t a n t sa f e Op e r a t i O n pr a c t i c e s
WARNING: Your Responsibility—Restrict the use of this power machine to persons who read, understand and
follow the warnings and instructions in this manual and on the machine.
SAVE THESE INSTRUCTIONS!
Safety Symbols
This page depicts and describes safety symbols that may appear on this product. Read, understand, and follow all instructions on the
machine before attempting to assemble and operate.
Symbol Description
READ THE OPERATOR’S MANUAL(S)
Read, understand, and follow all instructions in the manual(s) before attempting to
assemble and operate
DANGER — ROTATING BLADES
To reduce the risk of injury, keep hands and feet away. Do not operate unless discharge cover
or grass catcher is in its proper place. If damaged, replace immediately.
DANGER — BYSTANDERS
Do not mow when children or others are around.
DANGER — HAND/ FOOT CUT
Keep hands and feet away from rotating parts.
DANGER — THROWN DEBRIS
Remove objects that can be thrown by the blade in any direction. Wear safety glasses.
DANGER — SLOPES
Use extra caution on slopes. Do not mow slopes greater than 15°.
WARNING—GASOLINE IS FLAMMABLE
Allow the engine to cool at least two minutes before refueling.
WARNING— CARBON MONOXIDE
Never run an engine indoors or in a poorly ventilated area. Engine exhaust contains carbon
monoxide, an odorless and deadly gas.
WARNING— HOT SURFACE
Engine parts, especially the muffler, become extremely hot during operation. Allow engine
and muffler to cool before touching.

8se c t i O n 2 — iM p O r t a n t sa f e Op e r a t i O n pr a c t i c e s
Sight and hold this level with a vertical tree...
or a corner of a building...
or a fence post
Fold along dotted line (represents a 15° slope)
15°
Use this page as a guide to determine slopes where you may not operate safely.
WARNING: Do not operate your lawn mower on such slopes. 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. 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.

Assembly & Set-Up 3
9
Assembly
NOTE: This unit is shipped without gasoline or oil in the engine.
Fill up gasoline and oil as instructed in the accompanying engine
manual BEFORE operating your mower.
Handle
Remove any packing material which may be between1.
upper and lower handles.
Pull up and back on upper handle as shown in Fig. a.
3-1. Make certain the lower handle is seated securely
into the handle mounting brackets. Do not crimp
cables while lifting the handle up.
Tighten star knobs to secure upper handle to lowerb.
handle. Make sure that each carriage bolt is seated
properly in the handle.
A
B
B
Figure 3-1
Locate the hairpin clip on the weld pin on each side of2.
lower handle.
Remove hairpin clip from this hole. Using a pair ofa.
pliers, insert hairpin clip into the hole on pin closest
to the bracket. See Fig. 3-2. Repeat on other side.
Insert a carriage bolt found in the manual bag intob.
the lower hole on the handle mounting bracket.
Secure with one plastic wing nut, also included
in the manual bag. Repeat on other side with
remaining hardware.
The rope guide is attached to the right side of the upper3.
handle. See Fig. 3-3. Loosen the wing nut which secures the
rope guide.
Handle Hardware
Wing Nuts (2)
Carriage
Bolts (2)
A
B
Figure 3-2
Contents of Carton
One Lawn Mower• One Lawn Mower Operator’s Manual• One Bottle of Oil•
One Grass Catcher• One Side Discharge Chute•

10 se c t i O n 3 — as s e M b l y & se t -up
IMPORTANT: Be certain to attach the smaller, rear channel
on each side of the bag to ensure the proper fit of bag.
Refer to Fig. 3-4.
Attach center top of bag from inside of frame.c.
Before attaching the grass catcher, the rear mulching baffle 2.
must be removed.
Lift rear discharge door.a.
Remove rear mulching baffle. See Fig. 3-5.b.
Follow the steps below to attach the grass catcher:3.
Lift rear discharge door. See Fig. 3-6.a.
Place grass catcher on the pivot rod. Let go of b.
discharge door so that it rests on the grass catcher.
Hold blade control against upper handle.a.
Pull starter rope out of the engine. Release blade b.
control.
Slip starter rope into rope guide.c.
Tighten wing nut.d.
Grass Catcher
Follow steps below to assemble the grass catcher. Make1.
certain bag is turned right side out before assembling
(warning label will be on the outside).
Place bag over frame so that its black plastic side is a.
at the bottom. See Fig. 3-4.
Slip plastic channels of grass bag over hooks onb.
the frame. Begin with the bottom channel, then
proceed to the side channels. All the plastic channels
except center top of bag attach from outside of
frame.
A
C
D
B
Figure 3-3
Figure 3-4
A
C
B
Rear Channel
Figure 3-5
B
A
Figure 3-6

11se c t i O n 3 — as s e M b l y & se t -up
Adjustments
Cutting Height
The cutting height adjustment lever is located above the rear
right wheel.
Depress height adjustment lever towards wheel.1.
Slide lever to desired position for a change in cutting2.
height. See Fig. 3-8.
Release lever towards deck.3.
Set-Up
Gas and Oil Fill-Up
Refer to the separate engine owner’s manual for additional
engine information.
Add oil provided before starting unit for the first time out1.
of the box.
Service the engine with gasoline as instructed in the2.
separate engine owner’s manual.
WARNING: Use extreme care when handling
gasoline. Gasoline is extremely flammable and the
vapors are explosive. Never fuel the machine
indoors or while the engine is hot or running.
Extinguish cigarettes, cigars, pipes and other
sources of ignition.
WARNING: Never operate mower unless the hooks
on the grass catcher are firmly seated on the pivot
rod and the rear discharge door rests firmly against
top of the grass catcher.
Side Discharge Chute
To convert to side discharge, make sure grass catcher is off of the
unit, insert rear mulching baffle, and close rear discharge door.
On the side of the mower, lift the mulching plug. See Fig. 1.
3-7.
Slide two hooks of side discharge chute under hinge pin on2.
mulching plug assembly. Lower the mulching plug.
NOTE: Do not remove side mulching plug at any time, even
when you are not mulching.
1
2
Figure 3-7
1
2
3
Figure 3-8

Controls and Features 4
12
Blade Control
The blade control is attached to the upper handle of the mower.
Depress and squeeze it against the upper handle to operate the
unit. Release it to stop engine and blade.
WARNING: This blade control is a safety device.
Never attempt to bypass its operations.
Drive Control
The drive control is located on the underside of the upper
handle and is used to engage the drive. Squeeze it against the
upper handle to engage the drive; release it to stop mower from
propelling. See Fig. 4-1.
Cutting Height Adjustment Lever
The cutting height adjustment lever is located above the right
rear wheel. To adjust the cutting height, refer to the “Assembly &
Set-Up” Section.
Figure 4-1
Recoil Starter
Blade Control
Drive Control
Cutting Height
Adjustment Lever
Mulch Plug
Speed Control
1
2
3
4
Recoil Starter
The recoil starter is attached to the right upper handle. Stand
behind the unit and pull the recoil starter rope to start the unit.
Speed Control
The speed control is located on the variable speed control
housing on the upper handle. This control is used to select the
forward speed of the mower. See Fig. 4-1 inset.
IMPORTANT: Move the speed control only when the engine is
running. Changing the speed control setting with the engine off
can damage the mower.
Mulch Plug
The mulch plug is used for mulching purpose. Instead of
collecting the grass clippings in the grass catcher, your mower
has the option of recirculating the clippings back to the lawn.
Make sure that the rear discharge door is closed and the grass
catcher is removed from unit while mulching.

Operation 5
13
Figure 5-1
Starting Engine
WARNING: Be sure no one other than the operator
is standing near the lawn mower while starting
engine or operating mower. Never run engine
indoors or in enclosed, poorly ventilated areas.
Engine exhaust contains carbon monoxide, an
odorless and deadly gas. Keep hands, feet, hair and
loose clothing away from any moving parts on
engine and lawn mower.
Standing behind the mower, depress the blade control1.
handle and hold it against the upper handle.
Pull the starter grip lightly until resistance is felt, then pull 2.
rapidly to overcome compression, prevent kickback and
start engine. Repeat if necessary. See Fig. 5-1.
IMPORTANT: Do not allow the starter grip to snap back
against the engine. Return it gently to prevent damage to
the starter.
Stopping Engine
Release blade control to stop the engine and blade.1.
WARNING: Wait for the blade to stop completely
before performing any work on the mower or to
remove the grass catcher.
Using Your Lawn Mower
Be sure lawn is clear of stones, sticks, wire, or other objects
which could damage lawn mower or engine. Such objects could
be accidently thrown by the mower in any direction and cause
serious personal injury to the operator and others.
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.
Once the engine is running, squeeze the drive control 1.
against the upper handle to propel mower.
To change speed, move speed control to the desired speed.2.
NOTE: When selecting a drive speed, use the first speed
until you are comfortable and familiar with the operation
of the mower.
WARNING: If you strike a foreign object, stop the
engine. Remove wire from the spark plug,
thoroughly inspect mower for any damage, and
repair damage before restarting and operating.
Extensive vibration of mower during operation is an
indication of damage. The unit, especially the blade
adapter, should be promptly inspected and
repaired.
Using as Mulcher
For mulching grass, remove the grass catcher, insert rear mulch
plug, and remove side discharge chute from the mower. For
effective mulching, do not cut wet grass. If the grass has been
allowed to grow in excess of four inches, mulching is not
recommended. Use the grass catcher to bag clippings instead.
Using Grass Catcher
You can use the grass catcher to collect clippings while you are
operating the mower.
Attach grass catcher following instructions in the1.
“Assembly & Set-Up” section. Grass clippings will
automatically collect in bag as you run mower. Operate
mower till grass bag is full.
Stop engine completely by releasing the blade control.2.
Make sure that the unit has come to a complete stop.
Lift discharge door and pull grass bag up and away from3.
the mower to remove the bag. Dispose of the grass
clippings and reinstall the bag when complete.

Maintenance & Adjustments 6
14
Maintenance
General Recommendations
Always observe safety rules when performing any•
maintenance.
The warranty on this lawn mower does not cover items that•
have been subjected to operator abuse or negligence. To
receive full value from warranty, operator must maintain
the lawn mower as instructed here.
Changing of engine-governed speed will void engine•
warranty.
All adjustments should be checked at least once each•
season.
Periodically check all fasteners and make sure these are •
tight.
WARNING: Always stop engine, disconnect spark
plug, and ground against engine before performing
any type of maintenance on your machine.
Lubrication
Lubricate pivot points on the blade and drive controls1.
at least once a season with light oil. These controls must
operate freely in both directions. See Fig. 6-1.
Lubricate the wheels and rear wheel gears at least once a2.
season with light oil (or motor oil). If wheels are removed
for any reason, lubricate surface of the pivot arm and inner
surface of the wheel with light oil. See Fig. 6-1.
Lubricate the torsion spring and pivot points on the rear3.
discharge door and side mulch plug periodically with light
oil to prevent rust. See Fig. 6-1.
The transmission is pre-lubricated and sealed at the factory4.
and does not require lubrication.
Follow the accompanying engine manual for lubrication5.
schedule and instruction for engine lubrication.
Deck Care
Clean underside of the mower deck after each use to prevent
build-up of grass clippings or other debris. Follow steps below
for this job.
Disconnect spark plug wire. Drain gasoline from lawn1.
mower or place a piece of plastic under the gas cap.
Tip mower so that it rests on the engine housing. Keep the2.
side with the air cleaner facing up. Hold mower firmly.
WARNING: Never tip the mower more than 90º in
any direction and do not leave the mower tipped for
any length of time. Oil can drain into the upper part
of the engine causing a starting problem.
3. Scrape and clean the underside of the deck with a suitable
tool. Do not spray with water.
IMPORTANT: Do not use a pressure washer or garden hose
to clean your unit. These may cause damage to bearings,
or the engine. The use of water will result in shortened life
and reduce serviceability.
4. Put the mower back on its wheels on the ground. If you had
put plastic under the gas cap earlier, make sure to remove it
now.
Figure 6-1

15se c t i O n 6 — Ma i n t e n a n c e & ad j u s t M e n t s
Engine Care
A list of key engine maintenance jobs required for good
performance by the mower is given below. Follow the
accompanying engine manual for a detailed list and instructions.
Maintain oil level as instructed in engine manual.•
Service air cleaner every 25 hours under normal conditions.•
Clean every few hours under extremely dusty conditions.
Poor engine performance and flooding usually indicates
that the air cleaner should be serviced. To service the air
cleaner, refer to the engine manual.
Clean spark plug and reset the gap once a season. Spark•
plug replacement is recommended at the start of each
mowing season. Check engine manual for correct plug
type and gap specifications.
Clean engine regularly with a cloth or brush. Keep the•
top of the engine clean to permit proper air circulation.
Remove all grass, dirt, and combustible debris from muffler
area.
Replacing Rear Flap
To remove rear flap, lift rear door, remove screw, and press1.
flap in on either side to remove from hole. See Fig. 6-2.
Remove screw and flap from opposite hole and replace2.
with new flap in the opposite order and manner of
removal.
Adjustments
Variable Speed Cable
Periodic adjustment of the variable speed cable may be
necessary due to normal wear on the drive system. Adjustment is
needed if unit begins to run too slow or too fast.
Start engine and place shift lever in the third speed1.
position.
Stop engine and disconnect spark plug wire and ground it2.
against engine.
With engine off, shift back to first speed. This will provide3.
slack in the cable.
Remove back cover of speed control housing by removing4.
the three screws securing it to the housing. See Fig. 6-3.
Remove screw and flat washer securing cable. See Fig. 6-3.5.
NOTE: Make sure to take note of which slot in housing
cable is in.
Using a pair of needle nose pliers or similar tool, move6.
eyelet in cable only one slot to the left in housing as shown
in Fig. 6-4.
NOTE: Moving eyelet to the left speeds unit up; moving it
to the right slows it down.
Replace screw and washer removed earlier and reassemble7.
back of housing.
Figure 6-2
Figure 6-3
Figure 6-4

Service 7
16
WARNING: An unbalanced blade will cause
excessive vibration when rotating at high speeds. It
may cause damage to mower and could break
causing personal injury.
5. Lubricate the engine crankshaft and the inner surface
of the blade adapter with light oil. Slide the blade
adapter (and wave washer, if applicable) onto the engine
crankshaft. Place the blade on the adapter such that the
side of the blade marked “Bottom” (or with part number)
faces the ground when the mower is in the operating
position. Make sure that the blade is aligned and seated on
the blade adapter flanges.
6. Place blade bell support on the blade. Align notches on the
blade bell support with small holes in blade.
7. Replace hex bolt and tighten hex bolt to torque: 450 in. lbs.
min., 600 in. lbs. max.
To ensure safe operation of your mower, periodically check the
blade bolt for correct torque.
Belt Care
NOTE: Several components must be removed in order to change
the mower’s belt. See an authorized Service Dealer to have your
belt replaced.
Off-Season Storage
The following steps should be taken to prepare your lawn mower
for storage.
Clean and lubricate mower thoroughly as described in the•
lubrication instructions.
Do not use a pressure washer or garden hose to clean your•
unit.
Coat mower’s cutting blade with chassis grease to prevent •
rusting.
Refer to engine manual for correct engine storage•
instructions.
Store mower in a dry, clean area. Do not store next to•
corrosive materials, such as fertilizer.
When storing any type of power equipment in a poorly
ventilated or metal storage shed, care should be taken to
rust-proof the equipment. Using a light oil or silicone, coat the
equipment, especially cables and all moving parts of your lawn
mower before storage.
Blade Care
WARNING: When removing the cutting blade for
sharpening or replacement, protect your hands with
a pair of heavy gloves or use a heavy rag to hold the
blade.
Periodically inspect the blade adapter for cracks, especially if you
strike a foreign object. Replace when necessary. Follow the steps
below for blade service.
Disconnect spark plug boot from spark plug. Turn mower1.
on its side making sure that the air filter and the carburetor
are facing up.
Remove the bolt and the blade bell support which hold the2.
blade and the blade adapter to the engine crankshaft. See
Fig. 7-1.
Remove blade and adapter from the crankshaft. See Fig.3.
7-1.
IMPORTANT: When removing these items, a wave washer
may also come off with the adapter. Be sure to include this
washer when reassembling the blade adapter. Failure to do
so will result in the unit not being able to change speeds.
Remove blade from the adapter for testing balance.4.
Balance the blade on a round shaft screwdriver to check.
Remove metal from the heavy side until it balances evenly.
When sharpening the blade, follow the original angle of
grind. Grind each cutting edge equally to keep the blade
balanced.
Figure 7-1
Blade
Blade
Adapter
Bolt
Blade Bell
Support

Troubleshooting 8
17
Problem Cause Remedy
Engine Fails to start Blade control disengaged.1.
Spark plug boot disconnected.2.
Fuel tank empty or stale fuel.3.
Faulty spark plug.4.
Blocked fuel line.5.
Engine flooded.6.
Engage blade control.1.
Connect wire to spark boot.2.
Fill tank with clean, fresh gasoline.3.
Clean, adjust gap, or replace.4.
Clean fuel line.5.
Wait a few minutes to restart.6.
Engine runs erratic Spark plug boot loose.1.
Blocked fuel line or stale fuel.2.
Vent in gas cap plugged.3.
Water or dirt in fuel system.4.
Dirty air cleaner.5.
Connect and tighten spark plug boot.1.
Clean fuel line; fill tank with clean, fresh2.
gasoline.
Clear vent.3.
Drain fuel tank. Refill with fresh fuel.4.
Refer to engine manual.5.
Engine overheats Engine oil level low.1.
Air flow restricted.2.
Fill crankcase with proper oil.1.
Clean area around and on top of engine.2.
Occasional skips
(hesitates) at
high speed
Spark plug gap too close.1. Adjust gap to .030”.1.
Idles poorly Spark plug fouled, faulty, or gap too wide.1.
Dirty air cleaner.2.
Reset gap to .030” or replace spark plug.1.
Refer to engine manual.2.
Excessive Vibration Cutting blade loose or unbalanced.1.
Bent cutting blade.2.
Tighten blade and adapter. Balance blade.1.
See an authorized service dealer.2.
Mower will not
mulch grass
Wet grass.1.
Excessively high grass.2.
Dull blade.3.
Do not mow when grass is wet; wait until1.
later to cut.
Mow once at a high cutting height, then2.
mow again at desired height or make a
narrower cutting path.
Sharpen or replace blade.3.
Uneven cut Wheels not positioned correctly.1.
Dull blade.2.
Place all four wheels in same height position1.
(if equipped with individual height adjusters).
Sharpen or replace blade.2.
Mower will not self propel Debris clogging drive operation.1.
Belt not installed properly.2.
Damaged or worn belt.3.
Stop engine, disconnect spark plug boot,1.
and clean out debris.
Have belt checked for proper pulley 2.
installation and movement.
Have belt inspected and replaced.3.

Engine Operation 9
18
-30º -20º
10w
20w
20
30
40
20w40, 20w50
15w40, 15w50
10w40
10w30
-10º 0º
0º 20º 40º 60º 80º 100º
10º 20º 30º 40º
-20º
(ºC)
(ºF)
1
2
Figure 9-1
Fuel Cap
Air Cleaner
Spark Plug
Oil Drain
Oil Fill
Cap
Starter
Grip
Ambient Temperature
Single Viscosity1.
Multi Viscosity2.
NOTE: Using non detergent oil or 2-stroke engine oil could
shorten the engine’s service life.
Pre-Operation Check
Oil Recommendations
NOTE: This engine is shipped without gasoline or oil in the
engine. Running the engine with insufficient oil can cause
serious engine damage and void the engine warranty.
Before starting engine, fill with oil. Do not over-fill. Oil •
capacity is about 20 oz.
Use a 4-stroke, or an equivalent high detergent, premium
quality motor oil certified to meet or exceed U.S. automobile
manufacturer’s requirements for service classification SG/SF.
Motor oils classified SG/SF will show this designation on the
container.
SAE 10W-30 is recommended for general, all temperature use. If
single viscosity oil is used, select the appropriate viscosity for the
average temperature in your area from the chart to the right.

19se c t i O n 9 — Op e r a t i O n
Figure 9-2
Figure 9-3
Check Oil Level
NOTE: Be sure to check the engine on a level surface with the
engine stopped.
Remove the oil filler cap and wipe the dipstick clean. See1.
Fig. 9-2.
Insert the dipstick into the oil filler neck. Turn the dipstick a2.
1/4 turn into the locked position to fully seat.
If the level is low, slowly add oil to the upper limit on the3.
dipstick. See Fig. 9-2 inset.
Reinsert the dipstick into the locked position before4.
starting the engine.
NOTE: Do not overfill. Overfilling with oil may cause
smoking, hard starting, spark plug fouling, or oil saturation
of air cleaner.
Fuel Recommendations
Use automotive gasoline (unleaded or low leaded to minimize
combustion chamber deposits) with a minimum of 87 octane.
Gasoline with up to 10% ethanol or 15% MTBE (Methyl Tertiary
Butyl Ether) can be used. Never use an oil/gasoline mixture, dirty
gasoline, or gasoline over 30 days old. Avoid getting dirt, dust, or
water in the fuel tank. DO NOT USE E85 GASOLINE.
WARNING: Gasoline is extremely flammable and is
explosive under certain conditions. Refuel in a well-
ventilated area with the engine stopped. Do not
smoke or allow flames or sparks in the area where
the engine is refueled or where gasoline is stored.
Avoid repeated or prolonged contact with skin or
breathing of vapor.
WARNING: Do not overfill the fuel tank (there
should be no fuel in the filler neck). After refueling,
make sure the tank cap is closed properly and
securely. Be careful not to spill fuel when refueling.
Spilled fuel or fuel vapor may ignite. If any fuel is
spilled, make sure the area is dry before starting the
engine.
Check Fuel Level
Clean around fuel fill before removing cap to fuel.1.
Fill tank to approximately 1-inch below lowest portion of2.
neck to allow for fuel expansion. Be careful not to overfill.
NOTE: Before refueling, allow engine to cool 2 minutes.
Starting The Engine
WARNING: Always keep hands and feet clear of
equipment moving parts. Do not use a pressurized
starting fluid. Vapors are flammable.
Standing behind the mower, depress the blade control1.
handle and hold it against the upper handle. See Fig. 9-3.
Pull the starter grip lightly until resistance is felt, then pull 2.
rapidly to overcome compression, prevent kickback and
start engine. Repeat if necessary.
IMPORTANT: Do not allow the starter grip to snap back
against the engine. Return it gently to prevent damage to
the starter.
Stopping The Engine
Release the blade control.1.
2
1
Upper Limit
Oil Filler
Cap/Dipstick

Engine Maintenance 10
20
WARNING: Shut off the engine before performing
any maintenance. To prevent accidental start-up,
disconnect the spark plug boot.
IMPORTANT: If engine must be tipped to transport equipment
or to inspect or remove grass, keep spark plug side of engine
up. Transporting or tipping engine spark plug down may cause
smoking, hard starting, spark plug fouling, or oil saturation of air
cleaner.
Periodic inspection and adjustment of the engine is essential
if high level performance is to be maintained. Regular
maintenance will also ensure a long service life. The required
service intervals and the kind of maintenance to be performed
are described in the table below. Follow the hourly or calendar
intervals, whichever occur first. More frequent service is required
when operating in adverse conditions.
WARNING: If the engine has been running, the
muffler will be very hot. Be careful not to touch the
muffler.
† Service more frequently when used in dusty areas.
†† Every season or 25 hours if operating under heavy load or high ambient temperature.
Maintenance Schedule
First 5 Hours Each Use or
Every 5 Hrs.
Every Season
or 25 Hours
Every Season
or 50 Hours
Every Season
or 100 Hours
Service
Dates
Check Engine Oil Level P
Change Engine Oil †† P P
Check Air Cleaner P
Service Air Cleaner † P
Check Spark Plug P
Replace Spark Plug P
Clean Engine Shroud P
Clean around muer P
Replace Fuel Filter P