MTD Yard-Man 12A-449T401 User manual

YaRD-MaN)//
Operator's Manual
21" Self Starter
Rear-Discharge
Lawn Mower
Model Series
IMPORTANT: Read safety rules and instructions carefully before operating equipment.
Warning: This unit isequipped withan internal combustionengine and should notbe used on or near any unimproved forest-
covered, brush-covered or grass-covered land unlessthe engine's exhaust system is equipped witha spark arrester meeting
applicable local or state laws (ifany). If a spark arrester isused, it shouldbe maintainedin effective workingorder by the operator.
In the State of Californiathe above is requiredby law (Section4442 of the California PublicResources Code). Other states may have
similar laws. Federal laws apply onfederal lands. A sparkattester for the muffler is available throughyour nearestengine authorized
service dealer or contactthe service department, P.O. Box 368022 Cleveland, Ohio 44136-9722.
MTD PRODUCTS INC. P.O. BOX 368022 CLEVELAND, OHIO 44136-9722
ECO#
PRINTED IN U.S.A. FORM NO. 770-10478.fm
(1/2001)

TABLEOFCONTENTS
Content Page
ImportantSafe OperationPractices ................................................................... 3
Slope Gauge ...................................................................................................... 6
Unpacking .......................................................................................................... 7
Assembling Your Lawn Mower ........................................................................... 7
Know Your Lawn Mower .................................................................................... 10
Operating Your Lawn Mower ............................................................................. 10
Maintaining Your Lawn Mower ........................................................................... 13
Servicing Your Lawn Mower .............................................................................. 14
Making Adjustments .......................................................................................... 16
Off- Season Storage .......................................................................................... 17
Troubleshooting ................................................................................................. 18
Parts List............................................................................................................ 20
FINDINGMODELNUMBER
This Operator'sManual is an important part ofyour newLawn Mower. It willhelpyou 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 onthe
equipmentand copythe informationfromit inthe space providedbelow.The informationon
the model plate isvery importantifyouneed helpfromourCustomerSupportDepartmentor
an authorized dealer.
You can locatethe model number by standingbehind the unitinthe operatingposition and looking
down at the rear of the deck. A sample model plate is explained below. For future reference, please
copy the modesnumber and the serial number of the equipment in the space below.
Copy the model number here:
Copy the serial number here:
CALLINGCUSTOMERSUPPORT
Ifyou have difficulty assemblingthis product or have anyquestions regardingthe controls, operationor
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 haveyourunit'smodelnumberand serialnumber readywhen you
call.See previoussectiontolocatethisinformation,You willbeaskedto enterthe serial
numberin ordertoprocessyourcall.
2

SECTION1: IMPORTANTSAFEOPERATIONPRACTICES
WARNING: This symbol pointsout importantsafety instructionswhich, if not followed, couldendanger
the personalsafetyand/or propertyofyourselfand others. Read and followall instructionsinthis manual
beforeattemptingto operatethismachine.Failuretocomplywiththeseinstructionsmay resultin personal
injury.Whenyou see this symbol--HEED ITS WARNING.
WARNING: Engine exhaust, someof itsconstituents,and certainvehiclecomponentscontainor emit
chemicalsknowntoState of Californiatocausecancerand birthdefectsor otherreproductiveharm.
WARNING: Thismachine was builtto beoperated accordingtothe rulesfor safe operationinthis manual.As with
any type of power equipment, carelessness or error on the part of the operator can result in sedous injury. This
machine is capable of amputating hands and feet and throwing objects. Failure to observe the followingsafety
instructionscould result in sedousinjuryor death.
GeneralOperation
1. Read this operator's manual carefully in its entirety
before attempting to assemble this machine. Read,
understand, andfollow all instructions on the machine
and in the manual(s) before operation. Ba completely
familiar with the controls and the proper use of this
machine before operating it.Keep this manual in asafe
place for future and regular reference andfor ordedng
replacament parts.
2. This machine is a precision piece of power equipment,
not aplaything. Therefore, exercise extreme caution at all
times. Your unithasbeen designedto performonejob:to
mow grass.Do notuse itfor any other purpose.
3. Never allow childrenunder 14 years oldtooperate this
machine. Children 14years oldand overshouldread and
understandthe operation instructionsand safety rulesin
this manual and shouldbe trained and supervisedby a
parent,Only responsibleindividualswho are famUiarwith
these safe operationrulesshoulduse thismachine.
4. Thoroughlyinspectthe area where the equipmentisto
be used. Remove all stones,sticks,wire, bones,toys and
otherforeign objectswhichcould be tdppedoveror
pickedup andthrown bythe blade. Thrown objectscan
cause sehous personalinjury.Plan your mowingpattern
to avoiddischargeof matedal toward reeds, sidewalks,
bystandersand the like. Also, avoid dischargingmatedal
againsta wallorobstructionwhichmay cause discharged
matedal toricochetbacktoward the operator.
5. To helpavoidblade contact ora thrownobjectinjury,stay
inthe operatorzone behind the handles and keep
bystanders,helpers,childrenand petsat least 75 feet
from the machine while itisin operation.Stopmachine if
anyone enters the area.
6. Always wear safetyglasses or safety gogglesduring
operationandwhile performingan adjustmentorrepairto
protectyoureyes. Thrownobjects whichdcochetcan
cause sedous injurytothe eyes.
7. Wear sturdy,rough-soledworkshoes and close-fitting
slacks and shirts.Shirtsand pants thatcover the arms
and legsand steel-toedshoes are recommended. Never
operate this machine inbare feet, sandals, slipperyor
lightweight (e.g. canvas) shoes.
8. Do notput hands orfeet near rotatingpartsor underthe
cuttingdeck. Contactwiththe blade can amputatehands
and feet.
9. Amissingor damaged dischargecover can cause blade
contact or thrownobjectinjudes.
10. Many injuriesoccuras a resultof the mower being pulled
overthe footdudog a fall caused byslippingortripping.
Do notholdon to the mower ifyou are falling; release the
handleimmediately.
11. Never pullthe mower backtoward youwhile you are
walking. Ifyou mustback the mowerawayfroma wail or
obstructionfirstlookdown and behind toavoidtripping
and thenfollowthese steps:
a. Step back from the mower tofully extendyour
alTRS,
b. Be sureyou are well balancedwithsurefooting.
c. Pullthe mowerbackslowly,nomore than halfway
towardyou.
d. Repeat these stepsas needed.
12. Donot operate the mowerwhileunder the influenceof
alcoholor drugs.
13. Do not engage the self-propeUedmechanism onunitsso
equippedwhilestartingengine.
14. The blade control handle isa safetydevice, Never
attemptto bypass itsoperation.Doingso makesthe
safety device inoperativeand may resultinpersonal
injury throughcontact withthe rotatingblade.The blade
controlhandlemustoperate easily in both directionsand
automaticallyreturntothe disengagedposition when
released.
15. Never operatethe mowerin wet grass.Always be sureof
yourfooting. A slipandfall cancause seriouspersonal
injury.Ifyou feel you are losingyourfooting, release the
blade controlhandle immediately and the bladewillstop
rotatingwithinthree seconds.
16. Mow in daylightorgood artificiallight.Walk, never ran.
17. Stopthe bladewhen crossinggravel drives,walkways
orroads.
18. If the equipment shouldstart to vibrate abnormally, stop
the engine and check immediately for the cause.
Vibration isgenerally a warning of trouble.
19. Shut the eogine off and wait untilthe blade comes to a
completestop before removing the grass catcher or
unclogging the chute. The cutting blade continues to
rotate for afew seconds after the engine is shut off.
Never place any part of the body in the blade area until
you are sure the blede has stopped rotating.

20. Never operate mowerwithout preper trail shield, 5.
discharge cover, grass catcher, blade control handle or
other safety protective devices in place and working. 6.
Never operate mower with damaged safety devices.
Failure to do so, can result in personal injury.
21. Muffler and engine become hot and can cause a bum. Do
not touch.
22. Only use parts and accessories made for this machine by
the original equipment manufacturer(O.E.M). Failureto Service
do so can result in personal injury.
23. Ifsituations occur which are not covered in this manual,
use care and good judgment. Contact your dealer for
assistance.Telephone [phone] forthe name of
your nearest dealer.
SlopeOperation
Slopes are a major factor related to slipand fall accidents
whichcan resultin severe injury.Operationon slopes
requiresextra caution.Ifyou feel uneasy on aslope, donot
mow it.Before operating thisunit ona slope orhillyarea, use
the slopegauge on page 6 to measure slopes. Ifthe slope is
greaterthan 15degrees, do notmow it.
Do:
1. Mow acrossthe face of slopes; never up and down.
Exercise extreme caution when changingdirection on
slopes.
2. Watchfor holes, ruts,rocks,hiddenobjects, or bumps
whichcan cause you toslipor tdp.Tall grass can hide
obstacles.
3. Always be sureof your fuofing. A slipand fall cancause
seriouspersonal injury.If youfeel youare losingyour
balance, releasethe bladecontrolhandle immediately,
andthe bladewillstoprotatingwithin3 seconds.
DoNot:
1. Do not mow neardrop-offs,ditchesor embankments,
you could loseyourfooting or balance.
2. Do not mow slopssgreater than 15 degrees as shownon
the slope gauge.
3. Do not mowon wet grass. Unstablefootingcould cause
slipping.
Children
Tragic accidentscan occurifthe operator isnotalerttothe
presence ofchildren.Children are oftenattractedto the
mowerand the mowingactivity.They do not understandthe
dangers. Never assume that childrenwillremain where you
lastsaw them.
1. Keep childrenout ofthe mowing area and underthe
watchfulcare ofa responsibleadultother thanthe
operator.
2. Be alert and turn moweroff ifa childentersthe area.
3. Before and whilemoving backwards,look behindand
downfor smallchildren.
4. Use extreme care when approachingblindcomers,
doorways,shrubs,trees, orotherobjectsthat may
obscureyourvisionofa childwho may runintothe
mower.
Keep childrenaway from hotor running engines. They
can suffer bums from ahot muffler.
Never allow children under 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 betrained and
supervised bya parent.
SafeHandlingofGasoline:
1. To avoid personal injury or property damage use extreme
care in handling gasoline. Gasoline is extremely
flammable and the vapors are explosive.Sedous
personal injury can occur when gasoline is spilled on
yourself or your clothes which can ignite.
2. Wash your skinand change clothes immediately.
3. Use only an approvedgasoline container.
4. Never fill containersinside avehicle or on atruck or
trailer bed with aplastic liner. Always place containers on
the ground away from your vehicle before filling.
5. If possible, remove gas-powered equipment from the
truck or trailer and refuel it on the ground. Ifthis is not
possible, then refuel such equipmenton atrailer with a
portable container, rather than from agasoline dispenser
nozzle.
Keep the nozzle in contact with the dm of the fuel tankor
container opening atall times untilfueling iscomplete. Do
not use anozzle lock-open device.
Extinguish all cigarettes, cigars, pipes and other sources
of ignition.
Never fuel machine indoors because flammable vapors
will accumulate in the area.
Never remove gas cap or add fuel while the engine is hot
or running. Allow engine to cool at least two minutes
before refueling.
Never over fill fuel tank. Fill tank to no more than ½ inch
below bottom offiller neck to providespace for fuel
expansion.
Replace gasoline cap and tighten securely.
Ifgasoline is spilled, wipe it off the engine and
equipment. Move unit to another area. Wait 5 minutes
before starting the engine.
Never store the machine or fuel container inside where
there is an open flame, spark or pilot light as on 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 debds build-up. Clean up oil or fuel spillage and
remove any fuel soaked debds.
15. Allow a mower to cool at least 5 minutes before storing.
GeneralService:
6,
7.
8.
9.
1(3.
11.
12.
13.
1. Never runan engine indoorsorin a poody ventilated
area. Engine exhaust containscarbon monoxide,an
ododessand deadly gas.
2. Before cleaning, repairing,orinspecting,make certain
the blade and all movingpartshave stopped. Disconnect
the spark plugwireand groundagainstthe engineto
prevent unintendedstarting.

3. Check the blade and engine mounting bolts at frequent
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!"
4. Mower blades are sharp and can cut. Wrap the blade or
wear gloves, and use extra caution when servicing them.
5. Keep all nuts, bolts, and screws tight to be sure the
equipment is in safe working condition.
6. Never tamper with safety devices. Check their proper
operation regulady.
7. After sthking aforeign object, stop the engine, disconnect
the spark plug wire and de-energize the starter. (See
section "To De-energize Self Starter". Thoroughly inspect
the mower for any damage. Repair the damage before
starting and operating the mower.
8. Never attempt to make a wheel or cutting height
adjustment while the engine is running.
9. Grass catcher components, discharge cover, and trail
10.
11.
12.
13,
shield are subjectto wear and damage whichcould
expose moving parts or allowobjects to be thrown.
For safety protection, frequently check components and
replace immediately with odginal equipment
manufacturer's (O.E.M.) parts only, listed in this manual.
"Use of parts which do not meet the odginal equipment
specifications may lead to improper performance and
compromise safety!"
Do not change the engine governor setting or overspeed
the engine. The governor controls the maximum safe
operating speed of the engine.
Maintain or replace safety and instruction labels, as
necessary.
Observe properdisposallaws and regulations.Improper
disposal offluidsand materials can harm the
environment.
ALWAYS de-energize selfstarterpriorto performingany
maintenance or serviceto the engine and or mower,
Followinstructionsboth in the manualand on the engine
and ormachine to de-enen:jizestarter.
YourResponsibility
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.
DANGER
5

9SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE
A POWER POLE
A CORNER OF A BUILDING
OR A FENCE POST
15°
Q_
° A
o_ 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
Z
O 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.
(_f) Operate WALK-BEHIND mowers across the face of slopes, never up and down slopes.

SECTION3: UNPACKING
RemovingUnitFromCarton
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, hardware pack etc.).
Cut corners and lay cartondown flat. Remove
packing material.
Roll orslideunitout ofcarton.Check carton
thoroughlyfor looseparts.
SECTION4: ASSEMBLINGYOURLAWNMOWER
NOTE; Make sure not to crimp the cables while
removing the loose parts or the entire unit from the
carton.
NOTE: Reference to rightor left hand sideof the mower
isobserved from the operating position.
Tools Required
PairofPliers
Funnel
Set ofadjustablewrenches
WARNING: Disconnect the spark plug
wire and ground it against the engine to
preventunintendedstarting.Leave safety key
in lockedposition.
DisconnectingSparkPlug
Before setting up your lawn mower, disconnect the
spark plugwire from the spark plug, and ground itto
a bolt, retaining post or V-slot on the engine. See
Figure 1.
Spark Plug
Figure 1
AssemblingHandle
For shipping purposes, the grass bag was placed
on top ofthe unit. Remove it from the unit and set it
out of the way. See Figure 2.
Lift lowerhandle
GrassBag
UpperHandle
Liftu
handle
Figure 2
Raise the lower handle, as shown in Figure 2, until
it snaps into place.
Raise the upper handle as shown in Figure 2.
Tighten the two wing nuts which are already on the
handle. See Figure 3.
UpparHandle
LowerHandle
n
Nut
Figure 3
NOTE: Make sure toroute thecables outside thelower
handle. Also do not crimp the cables while lifting the
handle up.
Forshipping purposes, the hairpin clip is placed in
the outer hole of the weld pin on the lower handle.
Remove the hairpin clip from the outer hole of the
weld pin.

Usingapair of pliers, insert the hairpin clip into the
inner hole in the weld pin. Repeat on the other side.
See Figure 4.
Move hairpin clipto
this hole --
f
Weld Handle
Pin
Figure 4
Insertpost ofcable tiesthat are on lower handle
into the holes provided on the lower handle. The
holes may be on the inside or outside. Pull cable
ties tight and cut offthe extra. See Figure 5 below.
Cable Tie
Post on
Figure 5
Attaching Starter Rope
The rope guide is already attached to the right side of
the upper handle ofyour mower. See Figure 6.
With the spark plug wire disconnected and
grounded, and with the safety key in the locked
position, pull the starter rope up to the rope guide.
See Figure 6.
Slip the rope through the rope guide as shown
below. Tighten the wing nut holding the rope guide
to the upper handle. BladeControl
Handle
GrassCatcherAssembly
NOTE: Make certain the grass bag is tumed fight side
out before assembling (warning label will be on the
outside).
SoffGrass Bag
Parts for soft grass bag:
1. Front Frame
2. Rear Frame
3. Bag
Assembling soft grass bag:
Jointherear frame and front frame assemblyas
showninFigure7A.
Place thebag over theframe (blackplasticside is
the bottomofbag).Sliptheopeningsintheside of
the plasticchannels onthe bagover thehookson
the grasscatcherframe.
Secure bag toframe byworkingthe plastic
channelson bagoverframe as showninFigure7B.
All ofthe plasticchannelsexceptthecentertop of
the bag attachfrom theoutsideof bag.The center
top ofthe bag attachesfrom insidethe bag.
[] []
Front Hook
rame
sembly
Rear
Frame Plastic
Channels
Figure 7
AttachingGrassCatcher
Ifyour mowerisequipped witha mulchingplug,
and it is inplace onthe mower, lift the rear
discharge door and remove the rear mulching plug
from the mower. See Figure 8.
Recoil Rear
Mulching
Plug
RopeGude
Figure 6
Figure 8
NOTE: Make sure that the cables are muted to the
outside of the handle when attaching the grass catcher.

Liftthe rear discharge door.
Place the hooks of the grass catcher into the slots
in the handle bracket assemblies on both sides.
See Figure 9. Release the rear discharge door.
Figure 9
RemovingGrassCatcher
Lift the rear discharge door on the mower.
Lift the grass catcher up, out of the slots in the
handle bracket assemblies.
Reinstall the plastic rear mulching baffle.
Release the rear discharge door.
WARNING: Never operate the mower
unless the hooks on the grass catcher are
seated in the slots on the handle bracket
assemblies, and the rear discharge door
rests firmly against the top of the grass
catcher.
ChuteDeflector(ifequipped)
If your mower is equipped with the chute deflector,
assemble asfollows:
Rod
Chute
Slide the rod intothe upper edge of the chute
deflector so the tab on the rod istoward the left side
of the chute deflector. When assembled correctly,
the rod will extend further to the ]eftside than the
right side. See Figure 10.
Slide the push nut onto the right side of the rod to
secure.
AttachingChuteDeflector
Lift the rear discharge door on the mower.
Placethe ends of the rod into the slots in the handle
bracket assemblies. See Figure 11.
Release the rear discharge door.
/Rear
Discharge
_,,/ -Door
HandleBracket
Assemblies
Figure 11
Convertingto Mulcher
Liftthe rear discharge door.
Removethe grass bag or chute deflector.
Insert the mulch plug. See Figure 8.
Release the rear discharge door. See Figure 9.
Push
Nut
Figure 10

SECTION5: KNOWYOURLAWNMOWER
WARNING: Be familiar with all controls dl&
and theirproperoperation.Knowhow tostop
the machineand disengagethem quickly.
DriveControl BladeControlHandle
Start Control Button
Recoil
Starter Upper Handle
Lower Handle
Grass Bag Rear Discharge Door
Cutting Height
Adjustment
Figure 12
RecoilStarter
The recoil starterhandle isattached to the upper
handle. See Figure12.The recoilstarterisusedto start
the engine when theselfstarterisin thede-energized
mode.
Primer
The primer isusedto pump gas intothe carburetor.Use
it to assist in starting e cold engine, but do not use it
when restarting a warm engine after a short shutdown.
Refer to engine manual for location of the primer.
BladeControlHandle
The blade controlhandleis located on the upper handle
ofthe mower.The bladecontrolhandleand starter
controlbuttonmust bedepressedin ordertooperate
the unit.Release the bladecontrolhandletostopthe
engine and the bladeandto energizetheselfstarter.
WARNING: The blade controlhandle is a
safety device. Never attempt to bypass its
operations. Doing so, may result in personal
injurythroughcontactwith the rotatingblade.
The blade rotates whenever the engine is
running and when the self starter is de-
energized.
DriveClutchControl
The ddve control lever is located on the upper handle
and is used to engage the drive. Squeeze the lever
against the upper handle to engage the drive; release
the drive control lever toslow down or stop the mower
from propelling.
SafetyKey
The safety key is located on the engine. See Figure 12.
The safety key is a safety device used to activate and
deactivate the self starter system. The self starter
system will not work without the key in its proper
position. See engine manual for further information
pertaining to the safety key.
NOTE: The safety key must be in the run position to
start the mower for both systems, either the self starter
or recoil starter.
StartControlButton
The startcontrol buttonislocatedon theupper leftside
of the handle. See Figure 12.The start control button
must be depressed fully while pulling the blade control
handle toward the upper handle for the engine to start.
The startercontrolbuttonwillautomaticallyreturntothe
off/up position once the blade control handle is
released,
NOTE: The starter button must be depressed to start
the engine with either the serf starter or recoil starting
system.
SECTION6: OPERATINGYOURLAWN
WARNING: Read, understand, and follow
all instructions and warnings on the machine
and in this manual before operating.
Keep hands and feet away from the discharge area on
and from underthe cutting deck. See safety labels on
page 5.
MOWER
The operationof anylawn mowercan resultinforeign
objects being thrown into the eyes, which can result in
severe eyedamage. Always wear safety glasses oreye
shields.
NOTE: For bestresults raise the cutting position until it
is determined whichheight is best for your lawn. See
CuttingHeightAdjustmentSection.
lO

GasandOilFill-Up
WARNING: Use extreme care when
handling gasoline. Gasoline is extremely
flammable and the vapors are explosive.
Never fuel machine indoors or while the
engine is hot or running. Extinguish
cigarettes,cigars, pipes,and othersourcesof
ignition.
Service the engine withgasoline and oilas
instructedin the separate engine manualpacked
with your mower. Read the instructions carefully.
BeforeStartingMower
,_ WARNING: Read, understand,and follow
all instructionsand warnings onthe machine
and inthis manualbeforeoperating.
Attach spark plug wire tospark plug. Make certain
the metalcapon the end ofthe sparkplug wire
(insidethe rubberboot)isfastened securelyover
the metaltiponthe sparkplug.
Checkthe driveclutchcontrolfor proper
adjustment.If the mower does notpropelitselfor
the drivewheels hesitatewiththe driveclutch
engaged,performthedriveclutchcontrol
adjustmentas instructed on page 16.
FirstTime Starting Engine
NOTE: Use recoil starter rope to start engine for the
very firsttime. Themower isshipped withthesafetykey
in the locked position and the self starter in the de-
energized mode,followinstructionsas follows.
1. Place lawn mower on a levelsurfaceoutdoors.
2. Remove clear plasticpackagingunderfuel cap.
3. Check oillevel.
4. Addfuel.
5. Open shutoffvalve (ifequipped) 1/4turn.
6. Pushsparkplugwire firmlyon spark plug.
7. Turn safetykey 1/4turnclockwiseto RUN position.
8. Make surethatthe driveclutchcontrolisadjusted
sothe drivebeltisas looseas possible.
9. Pushthe primerthree times.
10. While standinginthe operatingposition,depress
the startercontrolbuttonfullywiththe thumbof
yourrighthand.
11. Usingyourleft hand, pullthe blade controlhandle
all theway towardthe upperhandle.See Figure13.
12. Release the button.
13. Graspthe recoilrope starterhandlewithyourright
handand slowlypulltowardsyou untilfeel a slight
resistance,then pullfirmly untilyourarmisfully
extended.
14. If engine does not start by the second pull, repeat
steps 8, 9,10, 11 and 12.
SecondTimeStartingEngine
NOTE: Follow these instructions if the self starter is
already in the energizedmode.
WARNING: NEVER assume starter is in
the de-energized mode, even if the key is in
the lockedpositionand/or removed from the
engine.ALWAYS de-energize starterpriorto
performinganymaintenance orservicetothe
engine and/or mower. Followinstructionson
the engine and/ormachinetode-energize.
Blade Control Handle Starter Control Button
Figure 13
1. Checkoillevel andadd fuel, ifnecessary.
2. Open shutoffvalve (ifequipped)1/4 turn.
3. Turn safetykey 1/4 turnclockwiseto RUN position.
4. Firmlypushprimerbulb 3 times(fora coldengine
only!).
5. While standing at the upper handle, depress the
starter control button with the thumb of your right
hand.
6. Using your left hand, pull the blade control handle
all the way toward the upper handle. See Figure 13.
Starter will de-energize and engine will start.
(NOTE: if engine does not start, release the blade
control handle and follow steps 8, 9, 1O,11 and 12
in the "First Time Starting Engine instructions.
NOTE: If any problems are encountered, refer to the
Trouble Shooting Guide for helpful information.
ToStopEngineandBlade
WARNING: The blade will continue to
rotate for three seconds after the blade
controlleverisreleased.
1. Release safetyblade controlhandle (thestart
controlbuttonwillautomaticallyreturntotheoff/up
position),engineand bladewillstopwithina few
seconds.
11

NOTE; Engine may stop with a racketing sound. This
sound isthe serf starterbeing reactivated/energizedfor
thenextstart.
2. Turn safety key 1/4turn counterclockwiseto LOCK
position. Remove key and store ina safe place.
ToDe-EnergizeSelfStarter
Remove spark plug wire from spark plug.
Turn safety key to RUN position (1/4 turn
clockwise).
While standing in the operating position, depress
the starter control button fully with the thumb of your
dght hand.
Using your left hand, pull the control handle all the
way toward the upper handle. (Release button and
wait until blade and starter stop rotating.)
Release safety blade control handle (the start
control button will automatically return to the off/up
position).
Remove safety key.
NOTE: Engine will crank over upon actuating
equipment startingcontrols, but willnot spark if spark
plug wire was removed from spark plug as described
above. Once engine has stopped cranking,serf starter
is de-energized.
_k WARNING: Self Starting System: If these
instructions are not followed, amputation or
severelacerationcan result.
ALWAYS disconnect sparkplug, de-energize
starter, lock and remove safety key BEFORE
performing ANY service to the engine or mower.
DO NOT attempt any maintenance or repairs to the
self starter.
NEVER assume starter is de-energize, even if key
isin LOCK ANDREMOVE position and/or removed
from engine.
BEFORE removing grass or other debris from
under mower deck; BEFORE changing oil, air filter
or spark plug; BEFORE removing blade for
servicing;BEFORE performing any other serviceto
engineor mower;BEFORE transportingmower-
ALWAYS DE-ENERGIZE SELF STARTER.
ALWAYS lockand removesafetykey and storein a
safe place untilnextuse. The safetykey is
designedand intendedto be removedfrom engine
when notin use. Removingkey willprevent
unsupervisedor unexpectedstartingofmower by
childrenor unsuspectingadults. The safety key
mustbein thelockedpositionbeforeitcanbe
removed.
UsingYourlawnMower
Do not operatethe mower withoutthe mulching
cover, the grass catcherbag, or thedischarge
chute propedyinstalled.
Be surethatthelawn isclear ofstones,sticks,wire,
or otherobjectswhichcoulddamage lawnmower
or engine.Such objectscouldbeaccidentlythrown
bythe mower inanydirectionand cause serious
personalinjurytothe operatorand others.
Forbestresults,donot cutwet grass becauseit
tendsto sticktothe undersideofthe mower,
preventingproperdischargeofgrass clippings,
poor mulchingconditions,and couldcause youto
slipand fall. New grass,thickgrass,orwet grass
may requirea narrowercut.
Fora healthylawn,alwayscutoffone-thirdor less
ofthe totallengthofthegrass. Lawnshouldbe
trimmedinfall as longas there isgrowth.
AWARNING: If you strike a foreign object,
stopthe engine. Remove spark plug wirefrom
spark plug, thoroughlyinspectthe mower for
any damage. Repair the damage before
restartingand operatingthe mower.Extensive
vibrationof the mower duringoperation is an
indication of damage. The unit should be
promptlyinspectedand repaired.
BaggingGrassClippings
You can use the grass catcher bag to collect clippings
while you are operating the mower. Attach the grass
catcher following instructions on page 8 of this manual.
The grass clippings will automatically collect in the bag
asyou run the mower. Operate the mower untilthe
grass bag isfull. Do NOT allow the bag to overfill with
grass clippings.
Stop the engine completely by releasing the control
handle.
Make sure that the unit has come to a complete
stop.
Lift discharge door and pull grass bag up and away
from the mower to dispose ofthe grass clippings
See Figure 14.
Figure 14
AdjustingCuttingHeight
Refer to height adjustments section of this manual on
12

page 17 for instruction on how to adjust the cutting
height and the handle height. For best results in mowing, keep the cutting height position high until you have determined which
cutting height is preferred.
SECTION7: MAINTAININGYOURLAWNMOWER
WARNING: Be sure to disconnect the
spark plug wire and DE-ENERGIZE starter
before performing any repairs or
maintenance. DO NOT attempt any
maintenance or service to the engine and/or
mower equipped with the safety key in the
unlocked and/or energized mode.
WARNING: NEVER assume starter is de-
energized, even if the key is in the locked
position and/or removed from the engine.
ALWAYS de-energize self starter prior to
performingany maintenanceor servicetothe
engine and/or mower. Follow instructionson
the engine and/or machine to de-energize
starter.
CleaningMower
Clean the underside of the mower deck after each
use to prevent any build-up ofgrass clippings. Ifthis
debris is allowed to accumulate, itwill result in rust
and corrosion.
NOTE: We do not recommend the use of pressure
washers orgarden hose to clean your unit. These may
cause damage to e/ecttic components, spindles,
pulleys, beatings or the engine. The use of water will
resultinshortened life and reduced serviceability.
Disconnect spark plug wire.
Drain the gasoline from the lawn mower, or place a
piece of plastic under the gas cap.
Tilt the mower so that the side with the air cleaner is
facing up. Hold the mower firmly.
Scrape and clean the underside ofthe deck with a
suitable tool. Do not spray with water.
Put the mower back on its wheels. If you had put
plastic under the gas cap, remove it now.
AWARNING: Never tipthe mower more than
90 degrees 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
causinga startingproblem.
EngineMaintenance
A list of key maintenance jobs required for good
performance by the mower is given below. Follow the
accompanying engine manual for detailed list and
instructions.
Change engine oilafter the firsttwooperating
hours and every25 operatinghours thereafter.
Check theoillevel beforestartingthe engineevery
time.
Service foam filterinthe air cleanerevery25 hours
ofuseand replacethe paperfiltercomponentevery
100 hours.You may havetoservicetheair filter
more frequentlyifyou are operatingthe mower
under extremelydustyconditions.
Clean engine periodically.Remove dirt and debris
witha clothor brush.
Clean the sparkplugand resetthegap to.030"at
leastonce a seasonor every50 hoursofoperation.
Spark plug replacementis recommendedat the
startofeach season.
Inspectmufflerperiodically,and replaceif
necessary. Damagedmufflersor sparkarresters
can createa firehazard. Makesure toavoidmuffler
and surroundingareas whilethe mowerengine is
hotbecausetemperature ofthese areasof the
engine may exceed 1500F.
Lubrication
Wheels
Lubricatethe wheels and bearings,ifsoequipped,
at least once a seasonwith lightoilorengine oil.
Also, ifthewheels areremovedfor any reason,
lubricatethe surfaceoftheaxle boltand the inner
surfaceofthewheel withlightoil.
ChuteDeflector& RearDischargeDoor
Lubricate the torsion spring and the pivot point on
each end of the chute deflector and the rear
discharge door using a light oil. This will prevent
rusting and ensure that the deflector, which isa
safety device, can always work properly.
Engine
Follow the engine manual instructions and
recommended schedule for lubricating engine
components.
Transmission
The transmission is pre-lubricated and sealed at
the factory and does not require lubrication on a
regular basis as part of maintenance. However, if
you disassemble the transmission for any reason,
refill with two ounces of Alvania grease (part # 737-
0168A) as part of reassembly.
13

Pivot Points
Lubricatethe pivot points on the blade control
handle, brake cable and the cuttingheight
adjustment lever at least once a season with light
oil. The blade control handle must operate freely in
both directions. The cutting height adjustment
levers should be able to move easily.
Figure 15
SECTION8: SERVICINGYOURLAWNMOWER
WARNING: Be sure to disconnect the
spark plug wire and DE-ENERGIZE starter
before lubricating, repairing, or servicing.DO
NOT attempt any maintenance or service to
the engine and/or mower equipped with the
safety key in the unlocked and/or energized
mode.
WARNING: NEVER assume starter is de-
energized, even if the key is in the locked
position and/or removed from the engine.
ALWAYS de-energize self starter pdor to
performingany maintenanceor servicetothe
engine and/or mower. Followinstructionson
the engine and/or machine to de-energize
starter.
BladeCare
AWARNING: Periodically inspectthe blade
adapterand pulley for cracks, especially ifyou
strike a foreign object. Replace when
necessary.
_hb WARNING: When removing the cutting
blade for sharpeningor replacement, protect
handsby usingheavy gloves or a thick rag to
graspthe cuttingblade.
Disconnect spark plug wirefrom spark plug.
Turn mower on its side making sure that the air filter
and the carburetor are up.
ToRemoveBlade:
To
Remove the bolt and the bell washer that hold the
blade-pulley assembly to the engine crankshaft.
See Figure 16. Remove the assembly from the
crankshaft.
Remove the two bolts and lock nuts from the blade
assembly.
Remove the blade from blade adapter and pulley.
ReplaceBlade:
Before reinstalling the blade-pulley assembly to the
unit, lubricate the engine crankshaft and the inner
surface of the blade adapter with light oil.
Also lubricate the bolt holes, bolt and the inner
surfaceof the nuts.
14

Install the blade adapteronthe pulley with the "star"
away from the pulley. See Figure 16.
LockNut Pulley
\ j semh,y
Blade _LockNut
Adapter _Blade
Bell
Washer
Figure 16
Place the new blade on the blade adapter with the
side marked bottom (has a part number) facing
away from the adapter.
Secure the blade to the assembly with two hex
bolts and lock nuts. Tighten the hex bolts to the
recommended torque. Refer to 'Blade Mounting
Torque' information below.
Install the blade assembly on the engine
crankshaft. Secure with the hex bolt and bell
washer (cupped side of washer to blade) and
tighten to the recommended torque. Refer to 'Blade
Mounting Torque' information below.
IMPORTANT:The bolt used tosecurethe bladetothe
engine isspeciallyheat-traated. Do not substitute, To
order replacementbolt, refer tothe partslistintheback
ofthismanual.
,_ WARNING: To ensure safe operation of
your unit, all nuts and bolts must be checked
periodicallyforcorrecttightness.
BladeMountingTorque:
Blade adapter bolts: 120 in.lbs, minimum, 150 in.lbs.
maximum.
Center bolt: 450 in.lbs, minimum, 600 in.lbs, maximum.
To SharpenBlade:
The blade can be sharpened with a file or on a
grinding wheel. Do not attempt to sharpen the
blade while it is still on the mower.
Follow the original angle of gdnd as a guide. Make
sure that each cutting edge receivesan equal
amount of grinding to prevent an unbalanced blade.
An unbalanced blade will cause excessive vibration
when rotating at high speeds, may cause damage to
the mower and could break, and may causing personal
injury. Test the blade by balancing it on a round shaft
screwdriver or a blade balancar.
If theblade is notbalanced, remove metal from the
heavyside untilitbalancesevenly.
ReplacingDriveBelt
WARNING: Disconnect the spark plug wire
and ground it against the engine to prevent
unintended starting. Drain fuel into an
approvedcontaineror place a piece of plastic
film underneath the gas cap to prevent
gasolinefrom leaking.
Remove the two shoulderscrewssecuringthe front
ddve coverto the mower deck, See Figure 17.
Pressinwardon thesidesofthefront ddvecover
and release thetabsthatsecurethe frontddve
covertotheheightadjusterbrackets.Remove drive
coverfrom the mower.
Remove the idlerand hardwarefrom idlerbracket
using7/16"wrenchand socket.See Figure17.
Remove the beltfromthetransmissionpulleyas
shownin Figure 17.
Bracket
Drive Belt
7Shoulder
Front Drive Screw
Cover
Figure 17
Liftand stabilizethe front of the deck.
Loosen the canter hexbolt and lower theblade and
engine pulley until there is adequate clearance to
move the belt past the belt keeper.
Remove the belt from the engine pulley and around
the blade. See Figure 18.
Reassemble new belt (part # 754-0465). Begin idler
reassembly by inserting bolt upthrough the idler
bracket hole. Adjust the drive clutch following the
instructions below.
NOTE: Torque canter hex bolt to between 450 and 600
in. Iba.
15

Right Front
Wheel
Engine _
Pulley _-
Figure 18
LeftFront
/Wheel
SECTION9: MAKINGADJUSTMENTS
AWARNING: Be sure to disconnect the
spark plug wire and DE-ENERGIZE starter
beforeperforminganyadjustmentsorrepairs.
DO NOT attemptany maintenance or service
tothe engineand/or mowerequippedwiththe
safety key in the unlocked and/or energized
mode.
WARNING: NEVER assume starter is de-
energized, even if the key is in the locked
position and/or removed from the engine.
ALWAYS de-energize self starter pdor to
performingany maintenanceor servicetothe
engine and/or mower. Followinstructionson
the engine and/or machine to de-energize
starter.
AdjustingDriveClutchControl
The drive clutch adjustment wheel is located on the
drive control lever housing and is used to tighten or
loosen tension on the drive cable. Perform this
adjustment if the following exists.
a. The mower does not propelitself with the
ddve control lever engaged.
b. The mower's drive wheels hesitate with the
drive control lever engaged.
To resolve the above problems, rotate the
adjustment wheel with your fingers: clockwise to
tighten the cable, and counter-clockwise to loosen
the cable. See Figure 19.
To loosen_
cable
Figure 19
ustment
AdjustingHandleHeight
Your mower is shipped with the handle in the higher
height position. To lower height, proceed as follows.
Remove the starter rope from the rope guide.
Remove the upper handle by removing the hand
knobs and carriage bolts. Laythe upper handle out
ofthe way, being careful not to bend or kink the
cables.
Remove the hairpin clips from the weld pins on the
handle brackets. Referto Figure 4. Press out on the
legs of the lower handle. Remove lower handle
from the mower.
Turn the lower handle around so the notch on the
bottom of the lower handle is facing forward as
shown in Figure 20. Reassemble, placing the
bottom holes in the handle over the weld pins in the
handle mounting bracket.
Reassemblethe upper handle to the lower handle.
Insert hairpin clips in the inner holes of the weld
pins and attach the starter rope as instructed in the
"Assembling Your Lawn Mower" section.
16

\
Notch
Lower
Handle
Figure 20
AdjustingCuttingHeight
IMPORTANT:All wheels must be placed in the same
relative position. For rough or unevenlawns, move the
height adjustment lever to a higher position. This will
help stop scalping of the grass.
An adjusting plate and thumb lever at each wheel
position provides cutting height adjustment. Each
adjusting plate has nine height positions. Height of cut
will change when you move the thumb lever from one
position to another.
Simply depress the lever towards the wheel and
move the lever assembly to desired position. See
Figure 21.
AH_ijguhLent
Lever
Figure 21
AdjustingCarburetor
AWARNING: Ifany adjustmentsare made to the engine (e.g. carburetor)whiletheengineis
running, keep clear of all moving parts. Be
carefulofheated surfaceslikethe muffler.
NOTE: A dirty air cleaner may cause an engine torun
rough too.Make sure that the air cleaner is clean and
attached tothe carburetorbefore decidingtoadjustthe
carburetor.
To adjust carburetor, please follow theengine manual.
SECTION10: 0FF-SEASONSTORAGE
Prepareyourlawn mowerfor storage at the end of the
season or if the unit will not be used for 30 days or
more. Store the mower in a clean, dry area.
,_ WARNING: Be sure to disconnect the
spark plug wire and DE-ENERGIZE starter
before performing any repairs or
maintenance. DO NOT attempt any
maintenance or service to the engine and/or
mower equipped with the safety key in the
unlockedand/orenergized mode.
WARNING: NEVER assume starter is de-
energized, even if the key is in the locked
position and/or removed from the engine.
ALWAYS de-energize self starter pdor to
performingany maintenanceor servicetothe
engine and/or mower. Followinstructionson
the engine and/or machine to de-energize
starter.
WARNING: Never store the machine or
fuel continuator indoors where there is an
open flame, spark or pilot light such as on
water heater, furnace, clothesdryer or other
gas appliance.
NOTE: We do not recommend the use of pressure
washers or garden hose to clean your unit. They may
cause damage to e/ecttic components, spindles,
pulleys, beatings or the engine. The use of water will
resultin shortenedlifeand reduceserviceability.
Lubricatethe moweras instructedon page 13.
You canfoldyourmower'shandlefor convenience
ofstorage:
Removethe starterropefrom the ropeguide; loosen
thetwohandknobson thesides ofthe handle,and let
theupperhandlefolddowntothe rear.
Movethe hairpinclipsto theouterholeintheweld pins
onthe handlemountingbrackets.Spreadthesidesof
the lowerhandle,and pushitforward anddown.
Inspectand replace/sharpenblade,if required.
Referto page 14.
Replaceyourgasolinecan if itstartsto rust.Rust
and/ordirtinthe gasolinewillcauseproblems.
Storeunitina clean,dryarea. Do notstorenextto
corrosivematerials,suchas fertilizeror rocksalt.
NOTE: If storingthemower in an unventilated or metal
storage shed, make sure to rustproof the equipment
with a light oil or silicone.
17

Engine
Clean engine and remove any grass clippings, dirt,
and debris from the cooling fins, air intake screen,
levers, linkage and the exterior of the engine.
Follow recommendations in the accompanying
engine manual for off-season storage of the
engine.
Change oil as stated in the engine manual.
SECTION11: TROUBLESHOOTINGGUIDE
Trouble Corrective Action
Enginefails to start
Engineruns erratic
Engineoverheats
;Occasional skip(hesitates) at
highspeed
Idles poody
Excessivevibration
Mower will not mulchgrass
Uneven cut
Possible Cause(s)
Blade controlhandle disengaged.
Start controlbuttonnot depressed.
Spark plugwire disconnected.
Safety key not in run position.
Fuel tank empty, or stale fuel.
Blockedfuel line.
Faulty spark plug.
Engine flooded.
Engine not pdmed.
Self starter already de-energized.
Spark plug wire loose.
Blockedfuel lineor stale fuel.
Vent in gas cap plugged.
Water or dirt infuel system.
Dirty air cleaner.
Carburetor out of adjustment.
Engine oil level low.
Air flow restricted.
Carburetor not adjustedpropedy.
Spark plug gap too close.
Spark plug fouled, faulty or gap too
wide.
Carburetor imprepedy adjusted.
Dirty air cleaner.
Cutting blade loose or unbalanced.
Bent cutting blade.
Wet grass,
Excessively highgrass.
Dull blade.
Wheels notpositioned correctly.
Dull blade.
Engage blade controlhandle.
Depress starter control button.
Connect wire to spark plug.
Place safety key in run position.
Filltank withclean, fresh gasoline.
Clean fuel line.
Clean, adjust gap or replace.
Wait afew minutes.
Push pdmer bulbthree timesto pdme
engine.
Use recoil starterto start engine
Connect and tightenspark plugwire.
Clean fuel line;filltank withclean, fresh
gasoline.
Clear vent.
Drainfuel tank. Refillwith fresh fuel.
Clean air cleaner.
Adjust carburetor.
Fillcrankcase with properoil.
Remove blowerhousingand clean.
Ad ust carburetor.
Adjust gap to .030".
Reset gap to .030" or replace spark plug.
_,djust carburetor.
Clean air cleaner.
Tightenblade and adapter. Balanceblade.
Replace blade.
Do not mow when grass is wet;wait until
laterto cut.
Mow once at a highcuttingheight,then
mow again at desiredheightor make a nar-
rower cuttingswath (1/2 width).
Sharpen or replace blade.
Place allfour wheels in same heightposi-
Lion.
Sharpen or replace blade.
Refer toseparate engine manual packedwithyourmowerfor more engine related information.
NOTE: For repairs beyond the minor adjustments listed above, contact your nearest authorized servicedealer.
18

NOTES
19

SECTION12: PARTSLISTFORMODELSERIES
74
71
\
7
\
8
12
23
2O
14
73
21
22
53 52
28
"30
31
35
4O
41
39
43_
49
2O