MTD Yard-Man 12A-559K401 User manual

Operator's Manual
21" Self Propelled
Mulching Mower
Model No.
12A-559K401
IMPORTANT: Read safety rules and instructions carefully before operating equipment.
Warning: This unit 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 368022 Cleveland, Ohio 44136-9722.
MTD PRODUCTS INC. P.O. BOX 368022 CLEVELAND, OHIO 44136-9722
PRINTED IN U.S.A. FORM NO. 770-10145A
(12/99)

TABLEOFCONTENTS
Content Page
Maintaining Safe Operation Practices ............................................................... 3
Slope Guage ...................................................................................................... 6
Hardware Pack .................................................................................................. 7
Unpacking .......................................................................................................... 7
Assembling Your Lawn Mower ........................................................................... 7
Know Your Lawn Mower .................................................................................... 9
Operating Your Lawn Mower ............................................................................. 10
Maintaining Your Lawn Mower ........................................................................... 12
Service ............................................................................................................... 13
Off-Season Storage ........................................................................................... 16
Troubleshooting ................................................................................................. 17
Parts List ............................................................................................................ 18
FINDINGMODELNUMBER
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 behind the unit in the operating position and looking
down at the cutting 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.
Copy the model number here:
Copy the serial number here:
CALLINGCUSTOMERSUPPORT
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.

SECTION1: MAINTAININGSAFEOPERATIONPRACTICES
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 YOUR LAWN MOWER. FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY
RESULT IN PERSONAL INJURY. WHEN YOU SEE THIS SYMBOL, HEED ITS WARNING.
WARNING: The Engine Exhaust from this product contains chemicals known to the State of California to
cause cancer, birth defects or other reproductive harm.
DANGER: Your lawn mower 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 lawn mower is capable of amputating hands and feet and throwing objects.
Failure to observe the following safety instructions could result in serious injury or death.
GENERALOPERATION
Read this operator's manual carefully in its entirety
before attempting to assemble this machine. Read,
understand, and follow alt instructions on the
machine and in the manual(s) before operation. Be
completely familiar with the controls and the proper
use of this machine before operating it. Keep this
manual in a safe place for future and regular
reference and for ordering replacement parts.
Your rotary mower is a precision piece of power
equipment, not a plaything. Therefore, exercise
extreme caution at all times. Your unit has been
designed to perform one job: to mow grass. Do not
use it for any other purpose.
Never allow children under 14 years old to operate
a power mower. Children 14 years old and over
should only operate mower under close parental
supervision. Only responsible individuals who are
familiar with these rules of safe operation should be
allowed to use your mower.
Keep the area of operation clear of alt persons,
particularly small children and pets. Stop engine
when they are in the vicinity of your mower to help
prevent blade contact or thrown object injury.
Although the area of operation should be
completely cleared of foreign objects, an object
may have been overlooked and could be
accidentally thrown by the mower in any direction
and cause serious personal injury to the operator or
any others allowed in the area.
Wear sturdy, rough-soled work shoes and close-
fitting slacks and shirts. Shirts and pants that cover
the arms and legs and steel-toed shoes are
recommended. Do not wear loose fitting clothes or
jewelry. They can be caught in moving parts. Never
operate a unit in bare feet, sandals, slippery or light
weight (e.g. canvas) shoes.
Always wear safety glasses or safety goggles
during operation or while performing an adjustment
or repair, to protect eyes from foreign objects that
may be thrown from the machine in any direction.
Thoroughly inspect the area where the equipment
is to be used. Remove all stones, sticks, wire,
bones, toys and other foreign objects which could
be picked up and thrown by the mower in any
direction and cause serious personal injury to the
operator or any others allowed in the area. Plan
your mowing pattern to avoid discharge of material
toward roads, sidewalks, bystanders and the like.
To help avoid a thrown objects injury, keep
children, bystanders and helpers at least 75 feet
from the mower while it is in operation.
Do not put hands or feet near or under rotating
parts. Keep clear of discharge opening at all times
as the rotating blade can cause injury.
Many injuries occur as a result of the mower being
pulled over the foot during a fall. Do not hang on to
the mower if you are falling; release the handle
immediately.
Never pull the mower toward you while you are
walking. If you must back the mower away from a
wall or obstruction first look down and behind, and
then follow these steps:
Step back from the mower to fully extend your
arms.
Be sure you are well balanced with sure footing.
Pull the mower back slowly, no more than half way
toward you.
Repeat these steps as needed.
Do not operate the mower while under the influence
of alcohol or drugs.
Do not engage the self-propelled mechanism on
units so equipped while starting engine.

Thebladecontrolhandleisasafetydevice.Never
attempttobypassitsoperation.Doingsomakes
thesafetydeviceinoperativeandmayresultin
personalinjurythroughcontactwiththerotating
blade.Thebladecontrolhandlemustoperate
easilyinbothdirectionsandautomaticallyreturnto
thedisengagedpositionwhenreleased.
Neveroperatethemowerinwetgrass.Alwaysbe
sureofyourfooting.Aslipandfallcancause
seriouspersonalinjury.Keepafirmholdonthe
handleandwalk,neverrun.Ifyoufeelyouare
losingyourfooting,RELEASETHEBLADE
CONTROLHANDLEIMMEDIATELYandtheblade
willstoprotatingwithinthreeseconds.
Mowonlyindaylightorgoodartificiallight.
Stopthebladewhencrossinggraveldrives,walks
orroads.
Iftheequipmentshouldstarttovibrateabnormally,
stoptheengineandcheckimmediatelyforthe
cause.Vibrationisgenerallyawarningoftrouble.
Shuttheengineoffandwaituntilthebladecomes
toacompletestopbeforeremovingthegrass
catcheroruncloggingthechute.Thecuttingblade
continuestorotateforafewsecondsafterthe
engineisshutoff.Neverplaceanypartofthebody
inthebladeareauntilyouaresurethebladehas
stoppedrotating.
Neveroperatemowerwithoutproperguards,grass
catcher,platesorothersafetyprotectivedevicesin
place.
Mufflerandenginebecomehotandcancausea
bum.Donottouch.
Only use accessories approved for this machine by
the manufacturer. Read, understand, and follow all
instructions provided with the approved accessory.
If situations occur which are not covered in this
manual, use care and good judgment. Contact your
dealer for assistance.
SLOPEOPERATION
For your safety, use the slope gauge included as part of this
manual to measure slopes before operating this unit on a
sloped or hilly area. If the slope is greater than 15 degrees
as shown on the slope gauge, do not operate this unit on
that area or serious injury could result.
DO:
Mow across the face of slopes; never up and down.
Exercise extreme caution when changing direction
on slopes.
Always be sure of your footing. A slip and fall can
cause serious personal injury. If you feel you are
losing your balance release the blade control
handle immediately and the blade will stop in less
than 3 seconds.
Watch for holes, ruts, hidden objects, or bumps.
Tall grass can hide obstacles.
DONOT:
Do not mow near drop-offs, ditches or
embankments. The operator could lose footing or
balance.
Do not mow slopes greater than 15 degrees as
shown on the slope gauge.
Do not mow on wet grass. Reduced footing could
cause slipping.
CHILDREN
Tragic accidents can occur ifthe operator is not alert to
the presence of children. Children are often attracted to
the mower and the mowing activity. Never assume that
children will remain where you last saw them.
Keep children out of the mowing area and under
the watchful care of a responsible adult other than
the operator.
Be alert and turn mower off if a child enters the
area.
Before and while moving backwards, look behind
and down for small children or other objects.
Never allow children under age 14 to operate the
mower. Children 14 years of age and above should
read and understand the operation instructions and
safety rules in this manual.
Use extreme care when approaching blind corners,
shrubs, trees, or other objects that may obscure
your vision of a child or hazard.
SERVICE
•Use extreme care in handling gasoline and other
fuels. They are extremely flammable and the vapors
are explosive.
• Use only an approved gasoline container.
• Never remove gas cap or add fuel while the engine is
running. Allow engine to cool at least two minutes
before refueling.
• Replace gasoline cap securely and wipe off any
spilled gasoline before starting the engine as it may
cause a fire or explosion.
• Extinguish all cigarettes, cigars, pipes and other
sources of ignition.
• Never refuel machine indoors because flammable
vapors will accumulate in the area.
• Never store the machine or fuel container inside
where there is an open flame or spark such as a gas
water heater, space heater, or furnace.
• Never run an engine inside a closed area.
• To reduce fire hazard, keep mower free of grass,
leaves, or other debris build-up. Clean up oil or fuel
spillage. Allow mower to cool at least 5 minutes
before storing.

• Beforecleaning,repairing,or inspecting,make
certainthebladeandallmovingpartshavestopped. •
Disconnectthesparkplugwire,andkeepthewire
awayfromthe sparkplugto preventaccidental
starting.
• Checkthe bladeandenginemountingboltsat
frequentintervalsforpropertightness.Also,visually
inspectbladefor damage(e.g.,bent,crackedor
worn).Replacewith bladewhichmeetsoriginal
equipmentspecificationslistedinthismanual.
• Keepallnuts,bolts,andscrewstighttobesurethe
equipmentisinsafeworkingcondition.
• Nevertamperwithsafetydevices.Checktheirproper
operationregularly.
• Wedonotrecommendtheuseofpressurewashers
orgardenhosetocleanyourunit.Theymaycause
damageto electriccomponents,spindles,pulleys,
bearingsortheengine.Theuseofwaterwillresultin
shortenedlifeandreduceserviceability.
Afterstrikinga foreignobject,stopthe engine,
removethewirefromthesparkplug,and thoroughly
inspect the mower for any damage. Repair the
damage before starting and operating the mower.
Never attempt to make a wheel or cutting height
adjustment while the engine is running.
Grass catcher components are subject to wear,
damage and deterioration, which could expose
moving parts or allow objects to be thrown. For safety
protection, frequently check components and replace
with manufacturer's recommended parts, when
necessary.
Mower blades are sharp and can cut. Wrap the
blade(s) or wear gloves, and use extra caution when
servicing them.
Do not change the engine governor setting or
overspeed the engine. Excessive engine speeds are
dangerous.
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.
DANGER
READ OPERATOR'S MANUAL KEEP SAFETY DEVICES LADE CONll_OL,
IN PLAi(EBAND WORIONG.

.11
I nq A POWER POLE
>, ,_ lq A CORNER OF A BUILDING
I"""""-'. I 'i_ ORAFENCEPOST
oJrOo
L.IIV
._. _ A wARNING
&
_D
m OperateRIDING mowers up and down slopes,neveracrossthefaceofslopes.
SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE
69
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.
£O

SECTION3: HARDWAREPACK
Please identify each piece of the hardware pack as
shown in Figure 1. Figure 1
Wing Nut 1/4-20 (2) Carriage Bolt 1/4-20 (2)
SECTION4: 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 included with unit (i.e.,
operator's manual, oil, etc.).
Cut corners and lay carton clown flat. Remove
packing matedaL
Roll or slide unit out of carton. Check carton
thoroughly for loose parts.
NOTE: Make sure not to crimp the cables while
removing the loose parts or the entire unit from the
carton.
NOTE: Reference to right or left hand side of the mower
and/or front or behind the mower is observed from the
operating position.
SECTION5: ASSEMBLINGYOURLAWNMOWER
ToolsRequired
Pair of Pliers
Funnel
Set of adjustable wrenches
DisconnectingSparkPlug
Before setting up your lawn mower, disconnect the
spark plug wire from the spark plug, and ground it
against the engine. See Figure 2.
Attach the spark plug wire to a bolt on the engine to
ground it.
AssemblingHandle
Remove grass bag from the unit and set it out of the
way. See Figure 3 (step 1).
Remove any packing material which may be
between the upper and lower handles for shipping
purposes.
2. Lift lower handle
Move bag
away
3. Lift u
_-Spark Plug
Figure 2
Figure 3
Raise the lower handle in the direction shown in
Figure 3 (step 2) till it snaps into place.

Raisetheupperhandleinthedirectionshownin
Figure3(step3).Tightenthewingnutswhichare
alreadyonthehandle.SeeFigure4.
UpperHandle
/_ \ \/ Lower Handle
t
Figure 4
NOTE: Make sure to route the cables inside the lower
handle. Also do not crimp the cables while lifting the
handle up.
For shipping purposes, the hairpin clip isplaced in
the outer hole of the weld pin on the lower handle.
Remove the hairpin clip from the outer hole of the
weld pin.
Using a pair of pliers, insert the hairpin clip into the
inner hole in the weld pin. Repeat on other side.
See Figure 5.
Carriage,Bolt
Mounting
Brkt.
Wing
Move Hairpin Clip
Figure 5
After you have moved the hairpin clip, install the
carriage bolt, (carriage bolt must go to the inside of
handle) included in the hardware pack, in the upper
hole on the handle mounting bracket. Secure with
one plasticwing nut,also included in the hardware
pack. Repeat process on other side.
Attach the cables to the lower handle with the two
cable ties already on the lower handle, insert pegs
on cable ties into the holes on the lower handle.
Pull cable ties tightand cuteffthe extra. See Figure
6.
Cable Tie
Lower
Handle
Figure 6
AttachingStarterRope
The rope guide is already attached to the right side of
the upper handle of your mower. See Figure 7.
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.
Slip the rope through the rope guide as shown
below. Tighten the wing nut holding the rope guide
to the upper handle.
Starter Wing Nut
Rope_
Upper Handle
Rope_uide Lower Handle
Figure 7
NOTE: Leave rear mulching baffle in if your want to use
your mower as a mulcher.
AttachingGrasscatcher
Lift the rear discharge door and remove the rear
mulching baffle from the mower. See Figure 8.
Rear Mulching Baffle
Figure 8

NOTE: Make sure that the cables are routed to the
outside of the handle and out of the way when attaching
the grasscatcher.
Place the hooks of the grasscatcher into the slots in
the handle bracket assemblies on both sides. See
Figure 9. Release the rear discharge door.
To remove the grasscatcher, lift the rear discharge
door on the mower. Lift the grasscatcher up, out of
the slots in the handle bracket assemblies.
Reinstall the plastic rear mulching baffle and
release the rear discharge door.
door
Pull
out and away
Figure 9
NOTE: For instructions on how to bag the grass
clippings, please refer to page 11 ofthis manual.
WARNING: Never operate the mower
unless the hooks on the grasscatcher are
seated in the slots on the handle bracket
assemblies, and the rear discharge door
rest firmly against the top of the
grasscatcher.
SECTION6: KNOWYOURLAWNMOWER
Read this owner's manual and safety rules before
operating your lawn mower. Compare the illustrations
in Figure 10 with your lawn mower to familiarize
yourself with the location of various controls and
adjustments. Save this manual for future reference.
The operation of any lawn mower can result in foreign
objects being thrown into the operator's eyes thus
causing severe eye damage. Always wear safety
glasses while operating the mower, or while
performing any adjustments or repairs on it.
Drive Clutch Control Blade Control Handle
Upper Handle
Lower Han_
Gas Oil Fill Cap
Grasscatcher
Cutting Height
Adjustment Levers Primer
Figure 10

StarterRope
The starter rope is attached to the handle. Stand behind
the unit and pull the starter rope to start the unit.
Primer
The primer is used to pump gas into the carburetor. Use
it to assist in starting a cold engine, but do not use it
when restarting a warm engine after a short shutdown.
Refer to Figure 10.
BladeControlHandle
AWARNING: This control mechanism is a
safety device. Never attempt to bypass its
operations or alter it in any way.
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 the
blade control handle to stop the engine and the blade.
DriveClutchControl
The drive clutch 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 clutch control to slow down or stop the
mower.
SECTION7: OPERATINGYOURLAWNMOWER
GasAndOilFill-Up
Oil:
Only use high quality detergent oil rated with API
service classification SF, SG or SH. Use SAE30 oil
only.
Fill oil sump and check the oil level following steps
below.
a. Position the mower on level ground and
clean area around oil fill cap.
b. Remove oil fill cap and dipstick. Wipe
dipstick clean, insert it into oil fill hole and
tighten securely.
c. Remove dipstick and check oil level. If the oil
is not upto FULL mark on the dipstick, pour
recommended oil through the oil fill and
check the level again.
Install oil fill cap and dipstick, tighten securely.
NOTE: Although multi-viscosity oils (5W30, 10W30,
etc.) improve starting in cold weather, these
multiviscosity oils will result in increased oil
consumption when used above 32°F. Check the oil
level more frequently to avoid possible engine damage
from running low on oil.
Gasoline
AWARNING: Never fill fuel tank indoors, or
when engine is running or hot. Do not
smoke when filling up the fuel tank.
Clean area around gas cap. Remove cap. Use a
funnel to prevent spillage.
Pour approximately 1.5 quarts of fresh, regular
grade, unleaded gasoline slowly into the fuel tank.
IMPORTANT: Never mix engine oil with gasoline.
Fill tank to 1/2" below the bottom of the filler neck to
allow space for fuel expansion. Wipe any fuel
spillage. Do not fill fuel tank completely.
BeforeStartingMower
Attach spark plug wire to spark plug. Make certain
the metal cap on the end of the spark plug wire
(inside the rubber boot) is fastened securely over
the metal tip on the spark plug.
Check the drive clutch control for proper
adjustment. If the mower does not propel itselfor
the drive wheels hesitate with the drive clutch
engaged, perform the drive clutch control
adjustment as instructed on page 18 of this manual.
ThrottleSpeed
Your engine is equipped with a constant speed throttle,
which is set at full throttle for best performance.
10

StartingEngine
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. When
starting the unit for the first time, face the
mower against a solid object such as wall,
fence, etc. Start the unit and if it shows
any signs of motion while the drive clutch
control is still engaged, shut the engine
off immediately.
Make sure that the drive clutch control is adjusted
so the drive belt is as loose as possible.
Move throttle control lever all the way back to the
"rabbit" position.
Push primer three times, See Figure 10. Wait about
two seconds between each push. In cold weather
around 55° F or below, prime five times. Do not
prime to restart a warm engine after a short
shutdown.
Standing behind the mower, depress the blade
control handle and hold it against the upper handle.
Grasp starter handle and pull rope out slowly until
engine reaches the start of compression 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 rewind slowly.
StoppingEngine
Release blade control handle to stop the engine
and the blade.
Disconnect spark plug wire and move away from
spark plug to prevent accidental starting.
UsingyourLawnMower
You can use your mower as a mulching mower or a
rear bagger.
Do not operate the mower without the rear
mulching baffle or the grasscatcher bag propedy
installed.
Be sure that the 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.
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 healthy lawn, always cut off one-third or less
of the total length of the grass. Lawn should be
trimmed in fall as long as there is growth.
WARNING: If you strike a foreign object,
stop the engine. Remove spark plug wire
from spark plug, thoroughly inspect the
mower for any damage. 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.
BaggingGrassClippings
You can use the grasscatcher bag to collect clippings
while you are operating the mower. Attach the
grasscatcher following instructions on page 9 of this
manual. The grass clippings wilt automatically collect in
the bag as you run the mower. Operate the mower till
the 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. To empty the grass bag
proceed as follows:
Lift discharge door and pull grass bag up and away
from the mower to dispose of the grass clippings
See Figure 11.
Figure 11
AdjustingCuttingHeight
Refer toheight adjustments section of this manual on
page 15 for instructionon how to adjust the cutting
height and the handle height.
For best results in mowing, keep the cutting height
position high until it is determined which height is
best for your lawn.
11

SECTION8: MAINTAININGYOURLAWN
&, WARNING: Always stop the engine and
disconnect the spark plug wire before
performing any maintenance work or
adjustments on your lawn mower.
CleaningMower
The underside of the mower deck should be cleaned
after each use to prevent any build-up of grass
clippings, leaves, dirt, or other debris. If this debris is
allowed to accumulate, it will result in rust and
corrosion.
NOTE: We do not recommend the use of pressure
washers or garden hose to clean your unit. They may
cause damage to electric components, spindles,
pulleys, bearings, or the engine. The use of water will
result in shortened life and reduce serviceability.
Disconnect spark plug wire.
Drain the gasoline from the lawn mower, or place a
piece of plastic under the gas cap.
Tip the mower so that it rests on the housing. Keep
the side with the air cleaner facing UP. Hold the
mower firmly.
Scrape and clean the underside of the deck with a
suitable toot. Do NOT spray with water.
Put the mower back on itswheels on the ground. If
you had put plastic under the gas cap, make sure to
remove it now.
WARNING: Never tip the mower more than
90 degrees in any directions 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.
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 oil after the first two operating
hours and every 25 operating hours thereafter.
Check the oil level before starting the engine every
time.
MOWER
Service foam filter in the air cleaner every 25 hours
of use and replace the paper filter component every
100 hours. You may have to service the air filter
more frequently ifyou are operating the mower
under extremely dusty conditions.
Clean the engine periodically. Remove dirt and
debris with a cloth or brush.
Clean the spark plug and reset the gap to .030" at
least once a season or every 50 hours of operation.
Spark plug replacement isrecommended at the
start of each season. Refer to the engine manual
for correct spark plug type.
Inspect muffler periodically, and replace if
necessary. Damaged mufflers or spark arresters
can create a fire hazard. Make sure to avoid muffler
and surrounding areas while the mower engine is
hot because temperature of these areas of the
engine may exceed 150° F.
Lubrication
Wheels
Lubricate the wheels and bearings, if so equipped,
at least once a season with light oil or engine oil.
Also, ifthe wheels are removed for any reason,
lubricate the surface of the axle bolt and the inner
surface of the wheel with light oil.
Chute Deflector& RearDischargeDoor
Lubricate the torsion spring and the pivotpoint on
each end ofthe chute deflector and the rear
discharge door using a light oil. This will prevent
rusting and ensure that the deflector, which is a
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-
0168) as part of reassembly.
12

SECTION9: SERVICE
BladeCare
Periodically inspect the blade adapter and pulley for
cracks, especially if you strike a foreign object. Replace
when necessary.
WARNING: When removing the cutting
blade for sharpening or replacement,
protect hands by using heavy gloves or a
thick rag to grasp the cutting blade.
Disconnect spark plug wire from spark plug.
Turn mower on itsside making sure that the air filter
and the carburetor are up.
To RemoveBlade:
Remove the bolt and bell washer which hold the
blade-pulley assembly to the engine crankshaft.
See Figure 12. Remove the assembly from the
crankshaft.
Remove the two bolts and lock nuts from the blade
assembly.
Remove the blade from the blade adapter and
pulley.
To 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 or engine
oil.
Also lubricate the bolt holes, bolt and the inner
surface of the nuts.
Install the blade adapter on the pulley with the "star"
away from the pulley. See Figure 12.
Lock Nut Pulley
-,_ /Assembly
Blade ee[_ee ,,---- Lock Nut
Adapter. _
_,_ Blade
Hex Bolt
_=xBolt
Bell _x Bolt
Washer
Figure 12
Place the new blade on the blade adapter with the
side marked bottom (or with 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' section on this page.
Install the blade assembly on the 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' section on this page.
IMPORTANT:The bolt used to secure the blade to the
engine isspecially heat-treated. Do not substitute. To
order replacement bolt, refer to the parts list in the back
of this manual.
WARNING: To ensure safe operation of
your unit, all nuts and bolts must be
checked periodically for correct tightness.
To SharpenBlade:
The blade can be sharpened with a file or on a
grinding wheel. Do not attempt to sharpen the
blade while itisstill on the mower.
Follow the original angle of grind as a guide. Make
sure that each cutting edge receives an equal
amount of grinding to prevent an unbalanced blade.
NOTE: An unbalanced blade will cause excessive
vibration when rotating at high speeds, may cause
damage to the mower and could break, causing
personal injury. Test the blade by balancing it on a
round shaft screwdriver or a blade balancer.
If the blade is not balanced, remove metal from the
heavy side until it balances evenly.
BladeMountingTorque:
Blade adapter bolts: 120 in.lbs, minimum, 150
in.lbs.maximum Center bolt: 450 in.lbs, minimum, 600
in.lbs, maximum.
ReplacingDriveBelt
Remove the two shoulder screws from on top ofthe
deck which secures the front drive cover to the
mower deck. See Figure 13.
Remove the front drive cover from the unit by lightly
pressing inward on the sides of thefront drive
cover. This will release the tabs that secure the
front drive cover to the height adjuster brackets.
Remove the idler and related hardware from the
idler bracket using 7/16" wrench and socket. See
Figure 13.
Remove the belt from the transmission pulley as
shown in Figure 14.
Lift and stabilize the front of the deck.
13

Loosenthecenterhexboltandlowerthebladeand
enginepulleyuntilthereisadequateclearanceto
movethebeltpastthebeltkeeper.
Removethebeltfromtheenginepulleyandaround
theblade.SeeFigure14.
Reassembleinreverseorderwithnewbelt(part#
754-0465).NOTE:Beginidlerreassemblyby
insertingboltupthroughtheidlerbrackethole.
Adjustthedriveclutchfollowinginstructionson
page14.
Drive Belt
NOTE: The wheels have
been moved forward in
this picture for clarity.
Do not remove the
wheels away from the
mower housing while
doing the job.
Bel
Keeper" Lock Nut
/
Front Drive Cover
Right Front Left Front
1eel Engine
Pulley
Hex Bolt
Remove
from around
pulley and blade
Figure 14
Idler
Shoulder
Screw
Figure 13
AdjustingDriveClutch Control
The drive clutch adjustment wheel is located on the
drive clutch control handle 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 propel itself with the
drive clutch engaged.
b. The mower's drive wheels hesitate with the
drive clutch 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 15 .
TO
cable
Adjustment
Wheel
To loosen
cable
Figure 15
14

AdjustingHandleHeight
Your mower is shipped with the handle in the higher
height position. To lower the handle 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. Refer to Figure 5. Press outon 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 16. Reassemble, placing the
bottom holes in the handle over the weld pins in the
handle mounting bracket.
\
Notch
Lower
Handle
Figure 16
Reassemble the upper handle to the lower handle.
Place the hairpin clips in the inner holes of the weld
pins and attach the starter rope as instructed in the
Assembly section.
AdjustingCuttingHeight
IMPORTANT: All wheels must be placed in the same
relative position. For rough or uneven lawns, 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 be changed when the thumb lever is moved from
one location to another.
Simply depress the lever towards the wheel and
move the lever assembly to desired position. See
Figure 17.
For rough or uneven lawns, move the height
adjustment handles to higher cutting height
position. Height Adjustment
Lever
_1
Figure 17
AdjustingCarburetor
If the engine isrunning rough, minor adjustments tothe
carburetor may be required to compensate for
differences in fuel, temperature, altitude and load.
NOTE: A dirty air cleaner may cause an engine to run
rough.
Make sure that the air cleaner is clean and attached to
the carburetor before deciding to adjust the carburetor.
To adjust the carburetor, please follow the
recommendations and instructions on carburetor
adjustment in the engine manual.
WARNING: If any adjustments are made to the
engine (e.g. carburetor) while the engine is running,
keep clear of all moving parts. Be careful of heated
surfaces like the muffler.
15

SECTION10: OFF-SEASONSTORAGE
Prepare your lawn mower for storage at the end of the
season or if the unit will not be used for 30 days or
more. Store the mower in aclean, dry area.
Mower
Clean underside of the mower following
instructions in the Maintaing your lawn mower
section of this manual.
Lubricate mower as instructed on page 12 of this
manual.
You can fold your mower's handle for convenient
storage: Remove the starter rope from the rope
guide; loosen the two hand knobs on the sides of
the handle, and let the upper handle fold down to
the rear. Move the hairpin clips to the outer hole in
the weld pins on the handle mounting brackets.
Spread the sides of the lower handle, and push it
forward and down.
Inspect and replacelsharpen blade, if required.
Refer to the Service section of this manual for blade
care instructions.
Engine
Follow recommendations in the accompanying
engine manual for off-season storage of the
engine.
Change oil if it has not been changed in the last
three months. For instructions on how to change oil,
refer to the engine manual.
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.
Other
Do not store gasoline from one season to another.
Replace your gasoline can if it starts to rust. Rust
and/or dirt in the gasoline will cause problems.
Store unit in a clean, dry area. Do not store next to
corrosive materials, such as fertilizer.
NOTE: If storing in an unventilated or metal storage
shed, be certain to rustproof the equipment by coating
with a light oil or silicone.
16

SECTION11:TROUBLE-SH00TINGGUIDE
PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION
Engine fails to start
Engine runs erratic
1. Blade control handle disengaged
2. Spark plug wire disconnected
3. Fuel tank empty, or stale fuel
4. Blocked fuel line
5. Faulty spark plug
6. Engine flooded
1. Spark plug wire loose
2. Blocked fuel line or stale fuel
3. Vent in gas cap plugged
4. Water or dirt infuel system
5. Dirty air cleaner
1. Engage blade control handle
2. Connect wire to spark plug
3. Fill up tank with fresh gasoline
4. Clean fuel line
5. Clean, adjust gap, or replace
6. Wait a few minutes to restart, Do not
prime.
1. Connect and tighten spark plug wire.
2. Clean fuel line, fill tank with clean,
fresh gasoline.
3. Clear vent.
4. Drain fuel tank. Refill with fresh fuel.
5. Clean air cleaner. Refer to engine
manual.
Fill crankcase with proper oil.
Clean lawn mower engine.
Adjust gap to.030 inches.
Engine overheats 1. Engine oil level low 1.
2. Air flow restricted 2.
Occasional skip 1. Spark plug gap too close 1.
(hesitates) at high
speed
Idles poorly 1. Spark plug fouled, faulty, or gap too wide 1. Reset gap to.030 inches or replace
2. Dirty air cleaner spark plug.
2. Clean aircleaner.
Excessive vibration 1. Cutting blade loose or unbalanced 1. Tighten blade and adapter, balance
2. Bent cutting blade blade.
3. Bent engine crankshaft 2. Replace blade.
3. Contact your nearest service center
Mower will not 1. Engine speed too low 1. Wait until grass is dry to cut.
mulch grass 2. Wet grass 2. Mow once at a high cutting height,
3. Excessively high grass then mow again at desired height.
4. Dull blade 3. Sharpen or replace blade.
Uneven cut 1. Wheels not in same height position 1. Reposition all wheels at same height.
2. Dull blade 2. Sharpen or replace blade.
17

SECTION12: PARTSLISTFORMODEL559K
23
7
12
8_ /
13 '_
45
68
72
27
17 _,18
19
75
74
79
65 24
6\ 63
64
42
36
41
37
78
18

19

MODEL559K
Re& No Pad No.
1. 731-1057
2. 731-0620
3. 731-1058
4. 731-1059
5. 710-1667A
6. 746-0960
7. 747-0824
8. 749-0439B
9. 720-0294
10. 712-0324
11. 746-6883
12. 710-1270
13. 720-0279
14. 720-0276
15. 710-1205
16. 746-0550
17. 710-1174
18. 682-3658
682-3059
19. 726-0240
20. 714-0104
21. 710-1007
23. 664-0085
24. 710-1650
25. 631-6675
26. 751B213146
27. 710-1237
28. 782-6686
29. 782-5OO4
30. 710-1017
31. 782-5003
32. 710-0216
33. 736-0331
34. 712-0798
35. 731-1937
36. 782-5602
37. 754-0465
38. 712-0324
Description
Upper Drive Cover
Drive Lever
Lower Drive Cover
Mounting Cap
Screw# 16-16 x .625
Drive Cable
Control Lever
Upper Handle (IncL Ref. No. 9)
Foam Grip, 9"
Hex Lock Nut, 1/4-20
Throttle Housing
Oval C-Sunk Screw 1/4-20 x 1.31
Handle Knob
Handle Knob
Eye Bolt
Control Cable, 39"
Carriage Bolt 5/16-18 x 2.0
RH Bracket Ass'y
Incl. Ref. 54, 56, 59, 60 & 62)
LH Bracket Ass'y (Not Shown)
Cable Tie
Cotter Pin
Self-tapping Screw
Grassbag w/logo
Shoulder Screw # 12 -24
Engine Spacer
Clamp Casing
Hex Screw TT #10-32 x .625
21" Rear Discharge Deck
RH Rear Baffle
Screw AB: 1/4-14:.625
LH Rear Baffle
Hex Screw 3/8-16 x .75
Bell Washer.39 x 1.13 x .062
Hex Nut 3/8-16
Transmission Cover (Yellow)
Front Baffle
V-Belt, 3/8 x 35.68"
Hex Nut 1/4-20
Ref.No
39.
40.
41.
42.
43.
44.
45.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
Part No.
756-1146
748-0411
742-0741
736-0452
710-0606
710-1257
749-0907A
712-0798
736-0356
712-3005
710-0896
682-3056
682-3057
736-0270
710-0599
17488A
17489A
732-0866
720-0312
738-0507B
736-0105
734-1860
736-0182
736-0456
738-0481
732-0700
731-1236
747-0996
732-0809
782-7599A
747-0995A
712-0271
711-1293
782-5007A
750-0434
738-1002
710-0703
712-0397
Description
Drive Pulley
Blade Adapter
21" Mulching Blade
Fiat Washer.516 x 1,5 x, 134
Hex Screw 1/4-26 x 1.66
Hex Screw 3/8-24 x 2.56
Lower Handle
Hex Nut 3/8-16
Bell Washer .39 I.D. x 1.38 O.D.
Hex Flange Lock Nut 3/8-16
Hex Scr. w/Washer 1/4-14 x .625
RH Handle Bracket
LH Handle Bracket (not shown)
Bell Washer .265 x.75 x.662
Hex Screw TT 1/4-20 x .500
RH Pivot Bar
LH Pivot Bar (not shown)
Height Adj. Lever
Foam Grip
Shoulder Scr .560 Dia. x.434
Washer .401 x.876 x.663
Wheel, 14 x 2 Yellow (Link Trd.)
Spring Washer .50 I.D. x 1.00.D.
Flat Washer .510 x 1.373 x .04
Shoulder Screw
Wire
Rear Trailing Shield
Pivot Rod
Torsion Spring
Rear Discharge Door
Grasscatcher Frame
Hex Nut
Screw
Plastic Mulching Baffle
Spacer ,375 x ,50 x 1,02" Lg,
Shoulder Screw 1/4-14
Carriage Bolt 1/4-20
Wing Nut
2O