Troy-Bilt 565 User manual

SafetyoAssembly®OperationoAdjustmentsoMaintenanceoTroubleshooting o Parts Lists oWarranty
®
m m m_ m m_m
21" Seifopropelted Mutching Mower -- Model 565
READ SAFETY RULES AND mNSTFIUCTmONS CAREFULLY BEFORE OPEFIATmON
Warning: Thisunitisequippedwithan internalcombustionengineandshouldnotbeusedon or nearanyunimprovedforest-covered,brush-
coveredor grass-coveredlandunlesstheengine'sexhaustsystemisequippedwitha sparkarrestermeetingapplicablelocalorstatelaws(if any),
If a sparkarresterisused,itshouldbemaintainedineffectiveworkingorderbytheoperator,Inthe StateofCaliforniatheaboveisrequiredbylaw
(Section4442oftheCaliforniaPublicResourcesCode),Otherstatesmayhavesimilarlaws,Federallawsapplyonfederallands,A sparkarrester
forthemufflerisavailablethroughyournearestengineauthorizedservicedealeror contacttheservicedepartment,RO,Box361131Cleveland,
Ohio44136-0019,
FORMNO,769-02187A
PRINTEDIN U,S,A TROYBILT LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019 12/2005

This Operator's Manua_ is an important part of your new lawn mower, mtwi_ he_p you assemble,
prepare and maintain the unit for best performance. Please read and understand what it says.
Table of Contents
Slope Gauge ....................................................... 3
Safe Operation Practices ................................... 4
Setup and Adjustment ....................................... 6
Operating Your Lawn Mower .............................. 8
Maintaining Your Lawn Mower ......................... 10
TrouMe Shooting .............................................. 12
Off-Season Storage and Safety Labels .......... 13
Parts List ........................................................... 14
Notes .................................................................. 18
Warranty ............................................ Back Cover
Finding and Recording Model Number
BEFOREYOU STARTASSEMBLING
YOURNEW EQUIPMENT,
please locatethe modelplate onthe equipmentand copythe
informationtothe samplemodel plate providedto the righL
Youcan locatethe modelplate by standingatthe operating
positionand lookingdown at the rearof the deck. This
informationwill be necessaryto use the manufacturer'sweb
site and/or obtainassistancefrom the CustomerSupport
Departmentor an authorizedservice dealer.
Model Number Serial Number
OTPDV B T TROY-B LTLLC
P. O. BOX 361131
www.troybiit.com CLEVELAND,0H44136
330=558=722Q
Customer Support
P_ease do NOTreturn the unit to the retai_er from which it was
purchased, without first contacting Customer Support.
ifyou havedifficulty assemblingthis productor have anyquestions regardingthe controls,operation or maintenanceofthis unit,
you canseek help fromtheexperts. Choosefrom the options below:
1.Visit troybit.com for many usefulsuggestions. Click on CustomerSupport buttonand you will getthe four options
reproducedin this sample to the right. Clickon theappropriatebutton and help
2. Phone a Customer Support Representative
at 1(866)840-6483.
3. The engine manufacturer is responsiblefor allengine-relatedissues with regards to performance,power-rating,
specifications,warrantyand service. Pleaserefer tothe engine manufacturer'sOwner's/Operator'sManual,packed
separatelywith your unit,for more information.

yourlawnmoweronsuchslopes.
/
/
/
/
o
/
/
t
o
w_ WARNING
Do not mowon inclines
with a dope in excess
of 15degrees(a rise
of approximately
2-"
feet). A riding r
couldoverturnand
cause seriousinjury.
if operatinga walb
behindmower on such
a dope, it isextremely
footing and youcould
dip, resultingin serious
injury.
OperateRiDiNG
mowersup and down
dopes, neveracross
thefaceof dopes.
Operate
WALK-BEHIND
mowersacrossthe
face of dopes, never
up and downslopes.
\
3

manual.Aswithanytypeofpowerequipment,carelessnessorerroronthepartoftheoperatorcan
resultinseriousinjury.Thismachineiscapableofamputatinghandsandfeetandthrowingobjects.
! Failuretoobservethefollowingsafetyinstructionscouldresultinseriousinjuryordeath.
endangerthepersonal
safetyand/orproperty
Children
Tragicaccidentscan occurifoperatorisnotalerttopresence
ofchildren.Childrenareoftenattractedto mowerandmowing
activity.Theydonot understandthe dangers.Neverassume
thatchildrenwill remainwhereyoulastsawthem.
1. Keepchildrenoutofthe mowingareaandunderwatchful
careof aresponsibleadultotherthanthe operator.
2. Bealertandturnmoweroffifachildentersthearea.
3. Beforeand whilemovingbackwards,lookbehindanddown
forsmallchildren.
4. Useextremecarewhenapproachingblindcorners,
doorways,shrubs,trees,orotherobjectsthatmayobscure
yourvisionofachildwhomayrunintothemower.
5. Keepchildrenawayfromhot orrunningengines.Theycan
sufferburnsfroma hotmuffler.
6. Neverallowchildrenunder14yearsoldto operateapower
mower.Children14yearsold andovershouldreadand
understandoperationinstructionsandsafetyrulesinthis
manualandshouldbetrainedandsupervisedbyaparent.
General Operation
1. Readthis operator'smanualcarefullyin its entiretybefore
attemptingtoassemblethismachine.Read,understand,
andfollow allinstructionsonthe machineandin the
manual(s)beforeoperation.Becompletelyfamiliarwith
thecontrolsandthe properuseofthis machinebefore
operatingit.Keepthis manualin a safeplaceforfuture
andregularreferenceandfor orderingreplacementparts.
2. Thismachineisaprecisionpieceof powerequipment,
nota plaything.Therefore,exerciseextremecautionat all
times.Yourunithasbeendesignedto performonejob: to
mowgrass.Do notuseitfor anyotherpurpose.
3. Neverallowchildrenunder14yearsoldto operatethis
machine.Children14yearsoldandovershouldreadand
understandthe instructionsinthismanualandshould
betrainedandsupervisedbya parent.Only responsible
individualswhoarefamiliarwiththeserulesofsafe
operationshouldbeallowedtousethismachine.
4. Thoroughlyinspectthe areawherethe equipmentisto
beused.Removeall stones,sticks,wire,bones,toysand
otherforeignobjectswhichcould betripped overor picked
upand thrownbythe blade.Thrownobjectscancause
seriouspersonalinjury.Planyourmowingpatternto avoid
dischargeofmaterialtowardroads,sidewalks,bystanders
andthe like.Also,avoiddischargingmaterialagainsta
wallorobstructionwhichmaycausedischargedmaterial
toricochetbacktowardtheoperator.
6. Alwayswear safetyglassesor safetygogglesduringopera-
tionandwhile performinganadjustmentor repairto protect
youreyes.Thrownobjectswhichricochetcancauseserious
injurytothe eyes.
7. Wearsturdy,rough-soledworkshoesand close-fitting
slacksandshirts. Shirtsand pantsthat coverthe armsand
legsandsteel-toedshoesarerecommended.Neveroperate
this machinein barefeet,sandals,slipperyor lightweight
(e.g.canvas)shoes.
8. Do notputhandsorfeet nearrotatingpartsor undercutting
deck.Contactwithbladecanamputatehandsandfeet.
9. Amissingor damageddischargecovercancauseblade
contactor thrownobject injuries.
10.Manyinjuriesoccurasa resultofthe mowerbeingpulled
overthefoot duringa fall causedby slippingortripping.
Do notholdonto the mowerifyouarefalling;releasethe
handleimmediately.
11.Neverpullthe mowerbacktowardyouwhileyouare
walking.If youmustbackthe mowerawayfroma wallor
obstructionfirstlookdownandbehindtoavoidtrippingand
thenfollowthesesteps:
a. Stepbackfrommowertofully extendyourarms.
b. Besureyou arewellbalancedwithsurefooting.
c. Pullthe mowerbackslowly,no morethanhalfway
towardyou.
d. Repeatthesestepsasneeded.
12.Do notoperatethe mowerwhileunderthe influenceof
alcoholor drugs.
13.Do notengage theself-propelledmechanismon unitsso
equippedwhilestartingengine.
14.Thebladecontrolhandleis a safetydevice.Neverattempt
tobypassits operation.Doingsomakesthe safetydevice
inoperativeandmay resultinpersonalinjurythrough
contactwiththe rotatingblade.The bladecontrolhandle
mustoperateeasilyin bothdirectionsandautomatically
returntothe disengagedpositionwhenreleased.
15.Neveroperatethe mowerinwetgrass.Alwaysbesureof
yourfooting. Aslipand fallcan causeseriouspersonal
injury.Ifyoufeelyouarelosingyourfooting,releasethe
bladecontrolhandleimmediatelyandthe bladewillstop
rotatingwithinthreeseconds.
16.Mowonlyindaylightor goodartificiallight.Walk,neverrun.
17.Stopthe bladewhencrossinggraveldrives,walksor roads.
18.Ifthe equipmentshouldstarttovibrateabnormally,stopthe
engineandcheckimmediatelyforthe cause.Vibrationis
and followthewarnings 5. Tohelpavoidbladecontactora thrownobjectinjury, ._ generallya '_arningof!rouble.........
]_ _nutthe engne errandwar unl: me Daaecomes-coa
and i..struction2stayinoperatorzone behindhandlesandkeepchildren, "
u _ competestop beforeremovngthe grasscatcheror uncog
, ,; bystanders,helpers,andpetsat least75feet frommower .
un_nusmanuau glngthechute
whileit isin operation.Stopmachineifanyoneenters
and onthe machine, area.
..... ,J 4

Thecuttingbladecontinuesto rotatefora fewsecondsafter
the engineisshutoff. Neverplaceanypartofthe bodyin
the bladeareauntilyouaresurethe bladehasstopped
rotating.
20.Neveroperatemowerwithoutpropertrailshield,discharge
cover,grasscatcher,bladecontrolhandle,or othersafety
protectivedevicesin placeandworking.Neveroperate
mowerwithdamagedsafetydevices.Failuretodo socan
resultin personalinjury.
21.Mufflerandenginebecomehotandcancausea burn.Do
nottouch.
22.Onlyusepartsandaccessoriesmadeforthismachineby
manufacturer.Failureto doso canresultinpersonalinjury.
23.Ifsituationsoccurwhichare not coveredin this manual,
usecareand goodjudgment.Contactyourdealerfor
assistance.Telephone[phone]forthe nameofyour
nearestdealer.
SJope Operation
Slopesarea majorfactorrelatedto slipandfallaccidentswhich
canresultinsevereinjury.Operationonslopesrequiresextra
caution.Ifyoufeeluneasyonaslope,donotmowit.Foryour
safety,usethe slopegaugeincludedaspartofthismanualto
measureslopesbeforeoperatingthisunitonaslopedor hilly
area.Iftheslopeis greaterthan15degrees,do notmowit.
Do:
1. Mowacrossthe faceof slopes;neverup anddown.
Exerciseextremecautionwhenchangingdirectionon
slopes.
2. Watchfor holes,ruts, rocks,hiddenobjects,or bumpswhich
can causeyou toslipor trip.Tallgrasscan hideobstacles.
3. Alwaysbesureofyourfooting.A slip andfall cancause
seriouspersonalinjury.Ifyoufeelyouarelosingyour
balance,releasethe blade controlhandleimmediately,and
the bladewillstop rotatingwithin 3seconds.
Do Not:
1. Do notmowneardrop-offs,ditchesorembankments,where
you couldloseyourfootingor balance.
2. Do notmowslopesgreaterthan15degreesas shownon
the slopegauge.
3. Do notmowon wetgrass.Unstablefootingcouldcause
slipping. Service
Safe HandlingOf Gasoline:
1. Toavoidpersonalinjury or propertydamageuseextreme
carein handlinggasoline.Gasolineisextremelyflammable
andthevaporsareexplosive.Seriouspersonalinjurycan
occurwhengasolineis spilledonyourselforyourclothes
whichcanignite.
2. Washyourskinandchangeclothesimmediately.
3. Useonlyanapprovedgasolinecontainer.
4. Neverfill containersinsideavehicleor ona truckor trailer
bedwith a plasticliner.Alwaysplacecontainersonthe
groundawayfromyourvehiclebeforefilling.
5. Removegas-poweredequipmentfromthe truckortrailer
andrefuelit onthe ground.Ifthisis notpossible,then refuel
suchequipmentona trailerwitha portablecontainer,rather
thanfromagasolinedispensernozzle.
6. Keepthe nozzlein contactwith therim ofthefueltank or
containeropeningat alltimesuntilfuelingis complete.Do
notusea nozzlelock-opendevice.
7. Extinguishallcigarettes,cigars,pipesandothersources
ofignition.
8. Neverfuel machineindoorsbecauseflammablevaporswill
accumulatein the area.
9. Neverremovegascap oradd fuelwhileengineishot or
running. Allowengineto coolatleasttwominutesbefore
refueling.
10.Neveroverfillfueltank. Filltankto nomorethan_ inch
belowbottomoffillerneckto providefor fuelexpansion.
11.Replacegasolinecapandtightensecurely.
12.Ifgasolineis spilled,wipeit offthe engineandequipment.
Moveunitto anotherarea.Wait5minutesbeforestarting
engine.
13.Neverstorethe machineorfuel containernearanopen
flame,sparkorpilotlightas onawaterheater,space
heater,furnace,clothesdryer,orothergas appliances.
14.Toreducefire hazard,keepmowerfreeofgrass,leaves,
or otherdebrisbuild-up.Cleanupoil orfuel spillageand
removeanyfuel soakeddebris.
15.Allowa mowertocoolat least5 minutesbeforestoring.
General Service:
1. Neverrunanengineindoorsor inapoorlyventilatedarea.
Engineexhaustcontainscarbonmonoxide,an odorlessand
deadlygas.
2. Beforecleaning,repairing,or inspecting,makecertainthe
bladeandall movingpartshavestopped.Disconnectthe
sparkplugwireandgroundagainsttheengineto prevent
unintendedstarting.
3. Checkthe bladeandenginemountingboltsatfrequent
intervalsfor propertightness.Also,visuallyinspectbladefor
damage(e.g.,bent,cracked,worn)Replacebladewiththe
originalequipmentmanufacture's(O.EM.) bladeonly,listed
inthis manual."Useofpartswhichdo notmeettheoriginal
equipmentspecificationsmayleadto improperperformance
andcompromisesafety!"
4. Mowerbladesaresharpandcancut.Wrapthebladeorwear
gloves,anduseextracautionwhenservicingthem.
5. Keepallnuts,bolts,andscrewstight tobesurethe equip-
mentisin safeworkingcondition.
6. Nevertamperwithsafetydevices.Checktheirproperopera-
tionregularly.
7. Afterstrikinga foreignobject,stopthe engine,discon-
nectthe sparkplugwireandgroundagainsttheengine.
Thoroughlyinspectthe mowerfor anydamage.Repairthe
damagebeforestartingandoperatingthe mower.
8. Neverattempttomakeawheelorcuttingheightadjustment
whilethe engineis running.
9. Grasscatchercomponents,dischargecover,andtrail
shieldaresubjecttowearanddamagewhichcould expose
movingpartsorallow objectsto bethrown.Forsafety
protection,frequentlycheckcomponentsand replaceim-
mediatelywithoriginalequipmentmanufacturer's(O.EM.)
partsonly,listedin thismanual.'Use of partswhich do
not meettheoriginalequipmentspecificationsmayleadto
improperperformanceandcompromisesafety!"
10.Donot changetheenginegovernorsettingor overspeedthe
engine.Thegovernorcontrolsthe maximumsafeoperating
speedofthe engine.
11.Maintainor replacesafetylabels,asnecessary'.
12.Observeproperdisposallawsand regulations.Improper
disposaloffluidsand materialscanharmtheenvironment.
ThisSymbolpoints
ua! before attemptingto
resuUt in personalinjury_
::When you see th s
_symbol
,EEDMTSWARNmNG
Responsibility
Restrictthe use
of this powermachine
to personswhoread
understand
5

left handcorresponds
to the left side ofthe
IMPORTANT
DO NOTcrimp the
cableswhen liftingthe
handleup. Make sure
to routethe cables
insidethe lower handUe,
iMPORTANT
without gasoline or
oil inthe engine. Fill
up gasolineand oil
as instructedin the
accompanyingengine
manual BEFORE
operatingyour mower,
Step 1
Step 2
1, Removeanypackingmaterialwhichmaybebetween
upperand lowerhandles,
a, Pullupand backon upperhandleasshownin
Step1,Makecertainthelowerhandleisseated
securelyintothe handlemountingbrackets,
b, Tightenstarknobssecuringupperhandleto
lowerhandle,Makesurethateachcarriageboltis
seatedproperlyin thehandle,
2, Locatehairpinclipin oneholeontheweldpinon each
sideof lowerhandle,
a, Removehairpinclipfromthis hole,Usinga pairof
pliers,inserthairpinclipintotheotherholeon the
weldpin,Repeaton otherside,
b, Inserta carriageboltfromthehardwarepackinto
theupperholeon thehandlemountingbracket,
Securewithoneplasticwingnut,alsoincluded
inthe hardwarepack,Repeatonothersidewith
remainingitemsfromhardwarepack,
3, Theropeguideisattachedtotherightsideofthe
upperhandle,Loosenthewingnutwhichsecuresthe
ropeguide,
a, Holdthebladecontrolagainstupperhandle,
b, Pullstarterropeoutoftheengine,Releasethe
bladecontrol,
c, Slipstarterropeintoropeguide,
d, Tightenwingnut,
4, Insertpostoncableties intoholesprovidedon the
lowerhandle,Pullcabletietightandtrimexcess,
5, Anadiustingplateandthumbleverateachwheel
positionprovidescuttingheightadiustment,
a, Depresslevertowardswheel,
b, Moveit toanyoftheninepositionsfordesired
cuttingheight,SeeStep5,
c, Releaselevertowardsmowerdeck,
\
Step 3 Step 4
6

isatthebottom,
b, Slipplasticchannelofgrassbagoverhooksonthe
frame,SeeStep6,All theplasticchannelsexcept
centertopof bagattachfromoutsideof bag,
c, Attachcentertopof bagfrominsideofbag,
7, Followstepsbelowtoattachgrasscatcher:
a, Liftreardischargedoor,
b, Placegrasscatcheron thepivotrod,Letgo
ofdischargedoorsothat itrestson thegrass
catcher,SeeStep7,
Toremovegrasscatcherorconverttoa mulcher(if
equipped),liftreardischargedooronthe moweras
showninStep8, Liftgrasscatcherupand outofthepivot
rod,Releasereardischargedoorto allow,ittocloserear
openingofmower,
,1_ WARNING: Never operate mower
unJess the hooks on the grass
catcher are firmJyseated on the
pivot rod, and the rear discharge
door rests firmly against top of
the grass catcher.
8, ifcoverfingtosidedischarge,makesuregrasscatcher
isoffunitandreardischargedoorisclosed,
a, Liftmulchingplugon therightsideof mower,
b, Slidetwo hooksofsidedischargechuteunder
thehingepinonthemulchingplugassemblyand
lowerthesidemulchingplug,SeeStep8,
NOTE:Donotremovethesidemulchingplugatanytime,
evenwhenyouarenotmulching,
\\_ \ • \ /ii
\Step 5
Step 6
J
_Make certain bagis
J
Step 8 Step 7
Never operate mower
unless the hooks on
the glass catcher are
firmly seated on
pivot rod, and the
_reardischarg e door
rests firm!yaga!nst
7

WARNING
The blade control
mechanism is a
safety device. Never
attempt to bypassits
operations.
Use extreme care
when handling
gasoline. Gasoline is
extremely flammable
and the vapors are
explosive. Neverfuel
the machine indoors
or while the engine
is hot or running.
Extinguish cigarettes,
cigars, pipes and
other sources of
ignition.
Keep handsand feet
_way from the chute
tea on cutting deck.
Refer to warning
label on the unit.
Recoil Starter
GrassBag
Cutting
Height
Adiustment
Levers
Mulching Plug
Side DischargeChute
Figure 1
Now that you have set up your lawn mower for op-
eration, get aquainted with its controls and features.
These are described below and illustrated on this
page. This knowledge will allow you to use your
new equipment to its fullest potential.
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 bladecontrol mecha-
nism isa safety device. Neverattempt
to bypass itsoperations.
Drive Contro_
The drive controI is located on the underside of
the upper handIe and is used to engage the drive.
Squeeze it against the upper handle to engage the
drive; release it to slow down or stop mower from
propelling. See Figure 1.
Mulching Plug
The mulching plug is used only for mulching
purposes= Instead of coIIecting the grass clippings
in the grass catcher, your mower has the option of
recirculating the clippings back to the Iawn. Make
sure that the rear discharge door is closed and the
grass catcher is removed from unit while mulching=
Cutting Height Adjustment Levers
One adjustment lever is !ocated on each wheel and
is used to adjust the cutting height. All four levers
have to be at the same relative position to ensure a
uniform cut.
Recoi_ Starter
The recoiI starter is attached to the right upper
handle. Stand behind the unit and puII the recoil
starter rope to start the unit=
Gas and OH Fill-Up
1. Check oil bvel and add oil if necessary. Followengine
manual for this. See Figure 1above for locationof the
oil fill
2. Service the engine with gasoline as instructed in the
engine manual See Figure 1above for location of
gas fill
WARNING: Use extreme care when han-
dling gasoline. Gasoline is extremely
flammable and the vapors are explosive.
Never fuel the machine indoors or while
the engine ishot or running. Extinguish
cigarettes, cigars, pipes and other
sources of ignition.
WARNING: The operation of any lawn
mower can result in foreign objects
being thrown intothe eyes, which can
damage your eyes severely. Always
wear safety glasses while operating
the mower, or while pedorming any
adjustments or repairs on it.
8

1, Placethefuelvalveleverfoundontheleft sideofthe
engineintotheONposition,SeeFigure2 inset,
2, Standingbehindthe mower,squeezethebladecontrol
againstupperhandle,SeeFigure2,
3, Holdingthesetwo handlestogetherfirmly,grasprecoil
starterhandleand pullropeoutwitha rapid,continu_
ous,fullarmstroke,SeeFigure2,Keepinga firm
gripon thestarterhandle,lettheroperewindslowly,
Repeatuntilenginecranks,Lettheroperewindeach
timeslowly,
Stopping Engine
1, Releasebladecontroltostoptheengne andblade,
2, Disconnectsparkplugwirefromsparkplugand
groundagainsttheengine,
_ ARNING:Wait for the blade to stop
completely beforedoing anywork
on the moweror to removethe grass
catcher.
Using Your Lawn Mower
WARNING:Neveroperateyour mower
without either the rear door or the entire
grass catcher assembly firmly secured.
Be surelawnisdear ofstones,sticks,wire,or other
obiectswhichcoulddamagelawnmowerorengine,
Suchobiectscouldbe acddentlythrownbythemower
in anydirectionandcauseseriouspersonaliniurytothe
operatorandothers,
_ ARNING:If you strike a foreign object,
stop the engine. Removewirefrom the
spark plug, thoroughly inspectmower
for anydamage,and repair damage
before restarting and operating.
Extensivevibration of mowerduring
operation is an indication of damage.
Theunit should be promptly inspected
and repaired.
Figure 2
1, Oncetheengineisrunning,squeezethedrive
controlagainsttheupperhandleto propelmower,
2, Forbestresults,do notcut wetgrass,
3, Fora healthierlawn,nevercutoff morethanone-
thirdofthetotallengthofthegrass,
Using as Mulcher
Formulchinggrass,removethegrasscatcherfromthe
mower,Thereardischargedoorshouldbeclosed,
1, Foreffectivemulching,do notcut wetgrass,
2, Neworthickgrassmayrequirea narrowercut,
Adiustgroundspeedaccordingtoconditionoflawn,
3, if thegrasshasbeenallowedto growinexcessof
4 inches,mulchingisnotrecommended,Usethe
grasscatchertobagclippingsinstead,
Using Grass Catcher
Youcanusethegrasscatchertocollectclippingswhile
youareoperatingthemower,
1, Attachgrasscatcherfollowinginstructionsonpage
7,Grassclippingswillautomaticallycollectinbagas
yourun mower,Operatemowertillgrassbagisfull,
2, Stopenginecompletelybyreleasingtheblade
controlhandle,Makesurethattheunithascometo
a completestop,
3, Liftdischargedoorand pullgrassbagup andaway
fromthemowertodisposeofthegrassclippings,
being thrown into
the eyes, which can
damage your eyes
severely. Always wear
safety glasses while
iioperating the mower,
_ngine or operating
_ower. Never tun
engine !ndoors or
in enclosed poorly
ventilated areas' En_
gine exhaust Contains
carbon monoxide, an /
odorless and deadly
_gas, Keep hands, feet,
_hair and loose clothing
away from any moving
_parts on engine and
9

MOWer
WARNING
Nways stopengine,
disconnect spark
plug, and ground
against engine before
eJeaning,lubricating
or doing any kind of
maintenance on your
machine.
Figure 3
Figure 4
Genera_ Recommendations
1, Alwaysobservesafetyruleswhenperforming
anymaintenance,
2, Thewarrantyon thislawnmowerdoesnotcover
itemsthathavebeensubiectedtooperatorabuse
or negligence,Toreceivefullvaluefromwarranty,
operatormustmaintainthe lawnmoweras
instructedhere,
3, Changingofengine=governedspeedwillvoid
enginewarranty,
4, Alladiustmentsshouldbecheckedat leastonce
eachseason,
5, Periodicallycheckall fastenersand makesurethese
aretight, WARNING:Alwaysstop engine,
disconnect spark plug, and ground
against engine beforecleaning,
lubricating or doing any kind of
maintenanceon your machine.
mustoperatefreelyin bothdirections,SeeFigure3,
2, Lubricatethewheelsatleastoncea seasonwith
lightoil (or motoroil), If wheelsareremovedforany
reason,lubricatesurfaceofthepivotarmandinner
surfaceofthewheelwithlightoil SeeFigure3,
3, Lubricatethetorsionspringandpivotpointontherear
dischargedoorperiodicallywithlightoil toprevent
rust,SeeFigure3,
4, Thetransmissionisprequbricatedandsealedatthe
factoryanddoesnotrequirelubrication,
5, Followtheaccompanyingenginemanualforlubrica-
tionscheduleandinstructionforenginelubrication,
Deck Care
The undersideofthemowerdeckshouldbecleaned
aftereachuseto preventanybuild=upofgrassclippings,
leaves,dirt,or otherdebris,Ifthisdebrisis allowedto
accumulate,itwillresultinrustandcorrosion,
1, Disconnectsparkplugwire,Draingasolinefromlawn
mower,or placea pieceof plasticunderthegascap,
2, Tipmowersothat itrestson thehousing,Keepthe
sidewiththeaircleanerfacingup,Holdmowerfirmly,
WARNING:Nevertip the mower more
than 90degrees inany directions and
do not leavethe mowertipped for any
length of time. Oil can drain intothe
upper part of the engine causing a
starting problem.
3, Scrapeandcleantheundersideofthedeckwitha
suitabletool Donotspraywithwater,
4, Putthemowerbackonits wheelsontheground,If
youhadputplasticunderthegascapearlier,make
suretoremoveitnow,
Engine Care
A listofkeymaintenancejobsrequiredforgood
performancebythemowerisgivenbelow,Followthe
accompanyingenginemanualfordetailedlistand
instructions,
1, Maintainoil levelasinstructedin enginemanual,
2, Serviceaircleanerevery25 hoursundernormal
conditions,Cleaneveryfewhoursunderextremely
dustyconditions,Refertoenginemanual
3, Cleansparkplugandresetthegap oncea season,
Checkenginemanualforcorrectplugtype andgap
specifications,
4, Cleanengineregularlywitha clothorbrush,Keepthe
coolingsystem(blowerhousingarea)dean topermit
properaircirculation,Removeallgrass,dirtand
combustibledebrisfrom mufflerarea,
Replacing Rear F_ap
1, Toremoverearflap,cut offtheflatendofthewirerod
whichsecuresittothedeck,SeeFigure4,
2, Attachthenewflapand newrodtodeck,bendingthe
endsofthenewrodovertosecuretodeck,
10

Blade Care _ -'_
WARNING:When removing cutting
bladefor sharpeningor replacement,
protect your handswith a pair of heavy
gloves or usea heavy rag to hold blade.
1, Disconnectsparkplugwirefromsparkplug,Turn
moweron itssidemakingsurethattheairfilterand
thecarburetorareup,
2, Removebolt,bladebensupport,blade,andblade
adapterfromtheenginecrankshaft,SeeFigure5,
3, Thebladecanbe sharpenedwitha fileoron agrind=
ingwheel Donotattempttosharpenthebladewhile
itisstillon themower,Whensharpeningblade,follow
originalangleofgrind,Grindcuttingedgesequallyto
keepbladebalanced,
4, Removebladefromtheadapterfortestingbalance,
Balancethebladeona roundshaftscrewdriverto
check,Removemetalfromtheheavysideuntilit
balancesevenly,
WARNING:An unbalanced bladewill
cause excessivevibration when rotating
at high speeds. It may causedamage
to mower,and could breakcausing
personal injury.
5, Lubricatetheenginecrankshaftandtheinnersurface
ofthe bladeadapterwithNghtoil Slidetheblade
adapterontotheenginecrankshaft,Placetheblade
on theadaptersuchthat thesideoftheblademarked
"Bottom"(orwithpartnumber)facesthegroundwhen
themoweris intheoperatingposition,Makesurethat
bladeisalignedandseatedon bladeadapterflanges,
6, Placebladebensupporton theblade,Alignnotches
on thebladebellsupportwithsmallholesin blade,
Replacehexboltandtightenhexbolttotorque:450
in,Ibs,rain,,600 in,Ibs,max,
Toensuresafeoperationof yourmower,periodically
checkthebladeboltforcorrecttorque,
Belt Care
1, Removetwoshoulderscrewssecuringfrontdrive
coverto mowerdeck,SeeFigure6, Pressinwardon
sidesoffrontdrivecoverand releasetabsthatsecure
ittotheheightadjusterbrackets,Removedrivecover
frommower,
2, PuNup onthebeltkeeperwireand pivotit outaway
fromthedrivepulley,SeeFigure6 inset,
3, Rollthebeltoff thetransmissionpulley,Tipmower
on itssidewiththeairfilterupto accessbeltfrom
undersideofmower,SNdebeltoff ofenginepulleyand
threadthroughtheopeningin thebeltkeeperbracket,
Thenremovethebeltfromaroundthebladeby remov=
ingoveroneendata time,SeeFigure7,
iiii
i L.i
Figure 5
Ji ,,/
Figure 8
.................... ¢
i
Figure 7
4, Replacewith newbelt,workingaroundbladeand
upthroughthebeltkeeperbracket,Makesurebelt
isfirmlyseatedonenginepulleywhilepullingfrom
theothersideandslidingitaroundthetransmis=
sionpulley,Pivotthebeltkeeperwirebackintoits
operatingpostionandsnapintotheslot provided,
Reassemblefrontdrivecover,
pair of heavy g oves
or use a heavy rag to
hold the blade.
An unbalanced blade
will cause excessive
vibration when rotat-
ing at high speeds. It
may cause damage
I:omower, and could
break causing per-
sonal injury.
\
11

P,ob o co Romody
Enginefails to start I 1. BiadeCoetr01disengaged. 1 il EngagebiadecontioL
Shooting
l
il_ _ i i i
!i_ii_i_i_ii_i _ii iiilt t t t t t t t t t __i
I 2, Sparkp!ugwile dsconnec_ed. 2. Connectwiretosparkplug,
3, Fueltankemptyorstalefue!. 3. Filltankwjth clean freshgasoline,
4. Eue rave Cosed. Openfuelvalve.See enginemanual
5, Faultyspa[kp{gg, 5, Clean,adJustgap,or[eplace.
Engineruns erratic 1. Sparkplugwireloose. 1. Connectandtightensparkplugwire.
2. Blockedfuel lineor stalefuel. 2. Cleanfuelline:filltank withclean,
freshgasoline.
3. Ventingas capplugged.
4. Wateror dirt infuel system.
5. Dirtyaircleaner.
6. Carburetorout ofadjustment.
3. Clearvent.
4. Drainfueltank.Refillwithfreshfuel.
5. Refertoenginemanual.
6. Refertoenginemanual.
Engineoverheats 1. Engineoi! levellow. 1. Fillcrankcasewith properoi!.
2. Air flowrestricted. 2. Removeblowerhousing
andclean.
: 3. Carburetornot adjustedproperly, : 3. Referto enginemanual.
Occasionalskips
(hesitates)at
highspeed
Vibration
1. Sparkpluggaptooclose.
2. Carburetoridlemixtureadjustment
improperlyset.
1. Adjustgapto .030".
2. Refertoenginemanual.
2. Refertoenginemanual.
3. Dirtyair cleaner. ! 3. Refertoenginemanual.
Excessive 1. Cuttingbladelooseor unbalanced. 1. Tightenbladeand adapter.Balance
blade.
2. Bentcuttingblade. 2. Seeanauthorizedservicedealer.
I B
1. Wheelsnotpositionedcorrectly.
2. Dullblade.
Uneven cut 1. Placeall fourwheelsin same
heightposition.
2. Sharpenor replaceblade.
wire,andclean outdebris.
• 3. Damagedorwornbelt. .3. nspectand repacebet.
12

Off-Season Storage
Thefollowingstepsshouldbetakentoprepareyourlawn
mowerforstorage,
1, Cleanand lubricatemowerthoroughlyasdescribedin
thelubricationinstructions,
2, Wedonotrecommendtheuseofa pressurewasher
or gardenhosetodean yourunit,
3, Referto enginemanualforcorrectengine
storageinstructions,
4, Coatmower'scuttingbladewithchassisgreaseto
preventrusting,
5, Storemowerina dry,cleanarea,Donotstorenext
tocorrosivematerials,suchasfertilizer,
Whenstoringanytypeof powerequipmentin apoorly
ventilatedor metalstorageshed,careshouldbetaken
torust-prooftheequipment,Usinga lightoil orsilicone,
coattheequipment,especiallycanes andall moving
partsofyourlawnmowerbeforestorage,
Safety Labels Found On Your Lawn Mower
DONOT remove safety I
(or any) labels from l
mower for any reason,
\
13

[]
Q
©
14

1. 71b0214 HexLockNut,3/8_24 35. 618_04377 TransmissionAssembly
2. 736-0105 BellWasher.325x.930x.45 36. 687-02193 HeightAdi.Assembly- LH
3. 756-04132 Pulley,3.82x.313x.68 687-02194 HeightAdi.Assembly- RH
4. 710_04329 TorxScrew 37. 787_01298 FrontHeightAdi.Plate_RH
5. 707-04567A TransmissionBracket 787-01299 FrontHeightAdi.Plate-LH
6. 726_04043 PushNut 38. 687_02044 PivotPlateAssembly
7. 736_04178A SIottedWasher 39. 732_0706 FrontLever_RH
8. 731-05187 ClutchLever 73b0707 FrontLev'er-LH
9. 721-04110 Odng 40. 782-5002B FrontBaffle
10. 731-05099A UpperHousing 41. 71b04065 FlangeLockNut,3/8-16
11. 721-04107 Oil Seal 42. 734-04018A FrontWhee18x2.125
12. 741-04116 BallBearing 43. 734-04127 RearWheel,12x 2.125
13. 710-04374 HexScrew 44. 710-04531 Screw1/4-20x .390
14. 711-04317 PinionShaft 45. 717q762 Gear14TRHFWDRH
15. 715-04030 DowelPin 717q761 Gear14TLHFWDLH
16. 715-0129 SpiroIPin 46. 715-0221 DoweIPin
17. 707_04409A ShifterFork 47. 782_7551A WheelDustCap
18. 711-04429 OutputShaft 48. 716-0102 SnapRing
19. 736-0572 FlatWasher 49. 736-0474 FlatWasher
20. 736-04224 FlatWasher 50. 710-0216 HexScrew,3/8d6 x.75
21. 741-04106 PlasticBushing 51. 736-0447 WaveWasher
22. 731-04883 LowerHousing 52. 748-0355 BearingSupport
23. 717-04194 28ToothGear 53. 741-0604A SleeveBearing
24. 73b04290 CompressionSpring 54. 73b0708 BearingRetainer
25. 750_04405 Slev.Spacer1.8"Lg. 55. 720_0426 AdiustmentKnob
26. 750-04404 SleeveSpacer9.10"Lg. 56. 710d652 TT Scr.w/Washer1/4-20x.625
27. 710-0854A SelhTappingSemsScrew 57. 738-0507B ShoulderScr.500Dia.x.434
28. 787-01278 21"Deck3 in1SP 58. 687-02039A PivotArmAssembly-RH
29. 710-0599 TT Screw1/4-20x 0.5 687-02040A PivotArmAssembly_LH
30. 738-0270 BelIWasher 59. 73b0866 RearSpringLever
31. 687-02055 HingedMulchPlugAssembly 60. 720-0312 FoamGrip
32. 17032A ChuteDeflectorAdapter 61. 687_02192 HandleBracket_RH
33. 731-04161 MulchPlug 687-02191 HandleBracket_LH
34. 732q014 TorsionSpring 62. 687-02057 HandleBracketAssembly-LH
34. 747-0710 HingePin 687-02056 HandleBracketAssembly- RH
ous by notdisengaging
For parts and/or
accessories
please call '
1o866o840-6483, or
1-330-558-2'220.
www.troybiR.com
\
15

__\\\\\\\\
\
\\\\ \\ \
@
Q
QI \
16

1 746-04206A VariableSpeedCable 24 747-0996 PivotRod
2 731-04150C RearBaffle21"Rd, 25 731-05020A TransmissionCover(Black)
3 710-04371 Screw1/4-15 26 710-1650 ShoulderScrew# 12-24
4 731-04204 DeluxeBaiICover 27 787-01265A BeltKeeperBracket
5 747-1161A BladeControl 28 749-0928A LowerHandle
6 749-04206 UpperHandle 29 754-04101 V-Belt
7 787-01258A CableMountBracket 30 756-04161 UpperPulleyHalf25mmx2,62
8 753-0833 ControlLeverAssembly 31 756-04160 LowerPulleyHalf25mmx2,62
9 720-0279 HandleKnob 32 750-04438A SleeveSpacer25mmx 1,375x,62
10 720-04072 StarKnob 33 748-04082 BladeAdapter
11 710-1205 EyeBolt 34 736-0524B BladeBelISupport
12 746-1113 ControICable-37,75" 35 736-04173 SpaceWasher
13 710-1174 CarriageBolt5/16-18x 2,0 36 736-0250 FlatWasher
14 726-0240 CableTie 37 710-1257 HexScrew3/8-24x2,50
15 714-0104 CotterPin 38 742-0741 21"MulchingBlade
16 712-0397 WingNut 39 731-04177 SideDischargeChute
17 664-04011 GrassbagAssembly 40 732-04317 ExtensionSpring
18 747-04080 GrassBagFrame 41 732-04294 BeltKeeperWire
19 732-0700 Wire 42 710-04329 TorxScrew
20 731-04998 RearTrailingShield 43 710-1652 TTScr,w/Washer1/4-20x,625
21 731-04134A RearDischargeDoor 44 710-0599 TT Screw1/4-20x0,5
22 750-04162 Spacer 45 710-0703 CarriageBolt1/4-20
23 732-0408% TorsionSpring-LH 46 738-1002 ShoulderScrew1/4-14
732-04090A TorsionSpring-RR
oUSby not disengaging
Forparts and/or
accessories
please call
1o866o840o6483,or
1o330o558o7220.
www.troybiJt.com
\
17

MANUFACTURER'S LIMITED WARRANTY FOR
®
The limitedwarrantyset forthbelowisgivenbyTroy_BiltLLCwithrespect
tonewmerchandisepurchasedandusedin theUnitedStates,itsposses_
sionsandterritories.
"Troy_Bilt"warrantsthis productagainstdefectsinmatedalandworkmam
shipfora periodof two(2)yearscommencingon thedateoforiginal
purchaseandwill,atits option,repairorreplace,freeofcharge,anypart
foundtobedefectivein materialsor workmanship.This limitedwarranty
shallonlyapplyifthis producthasbeenoperatedand maintainedin
accordancewiththeOperator'sManualfurnishedwiththeproduct,and
hasnotbeensubiectto misuse,abuse,commercialuse,neglect,accident,
impropermaintenance,alteration,vandalism,theft,fire,water,or damage
becauseofotherperilor naturaldisaster.Damageresultingfromthe
installationor useofanypart,accessoryor attachmentnotapprovedby
Troy_Biltforusewiththeproduct(s)coveredbythis manualwillvoidyour
warrantyastoanyresultingdamage.
Normalwearpartsarewarrantedtobefreefromdefectsinmaterialand
workmanshipfora periodofthirty(30)daysfromthedateofpurchase.
Normalwearpartsinclude,butare notlimitedto itemssuchas: batteries,
belts,blades,bladeadapters,grassbags,riderdeckwheels,seats,snow
throwerskidshoes,shaveplates,augerspiralrubberandtires.
NOWTO OBTAIN SERVICE: Warranty service is available, WITH
PROOFOF PURCHASE,through yourlocal authorizedservice
dealer.To locate the dealer in yourarea, check your YellowPages,
or contact Troy-Bilt LLC at RO. Box 361131,Cleveland,Ohio 44136-
0019,or can 1-866-840-6483 or 1-330-558-7220,or log on to our
Web site at www.troybilt.com.
This limitedwarrantydoesnot providecoverageinthefollowingcases:
a. Theengineor componentpartsthereof.Theseitemsmay
carrya separatemanufacturer'swarranty.Refertoapplicable
manufacturer'swarrantyfortermsandconditions.
b. Logsplitterpumps,valves,andcylindershaveaseparateone
yearwarranty.
c. Routinemaintenanceitemssuchaslubricants,filters,blade
sharpening,tune_ups,brakeadiustments,clutch adiustments,
deckadiustments,andnormaldeteriorationoftheexteriorfinish
duetouseorexposure.
d. Servicecompletedbysomeoneotherthananauthorizedservice
dealer.
e. Troy_Biltdoesnotextendanywarrantyforproductssoldor
exportedoutsideoftheUnitedStates,its possessionsand
territories,exceptthosesoldthroughTroy_Bilt'sauthorized
channelsofexportdistribution.
f. Replacementpartsthatare notgenuineTroy_Biltparts.
g. Transportationchargesandservicecalls.
Noimpliedwarranty, includinganyimpliedwarrantyof merchant°
ability offitness for a particular purpose, applies after the applicable
period of express written warranty aboveasto the parts as identi-
fied. Noother express warranty, whether written or oral, exceptas
mentioned above,given by anyperson or entity, including a dealer or
retailer,with respectto any product, shall bind Troy-Bilt. Duringthe
period of the warranty,the exclusive remedy is repair or replacement
of the product as set forth above.
The provisions as set forth inthis warranty provide the sole and
exclusive remedyarising from the sale. Troy-Bilt shall not be liable
for incidental or consequential loss or damageincluding, without
limitation, expensesincurred for substitute or replacementlawncare
services or for rental expensesto temporarily replacea warranted
product.
Somestatesdo notallowtheexclusionor limitationofincidentalor
consequentialdamages,or limitationson howlonganimpliedwarranty
lasts,sotheaboveexclusionsor limitationsmaynotapplytoyou.
Innoeventshallrecoveryofanykindbegreaterthantheamountofthe
purchasepriceoftheproductsold.Alteration of safety features of the
product shall void this warranty. Youassumetheriskandliabilityfor
loss,damage,or iniurytoyouand yourpropertyand/ortoothersandtheir
propertyarisingoutofthemisuseor inabilitytousetheproduct.
This limitedwarrantyshallnotextendto anyoneotherthantheoriginal
purchaseror tothepersonforwhomitwaspurchasedasa gift.
HOWSTATELAWRELATESTOTHISWARRANTY:Thislimitedwar-
rantygh,'esyouspecificlegalrights,andyoumayalsohaveotherrights
whichvaryfromstatetostate.
IMPORTANT:OwnermustpresentOriginalProofofPurchasetoobtain
warrantycoverage.
TROYBILT LLC, P.O. BOX 361131 CLEVELAN D, OHIO 44136-0019; Phone: 1(866} 840-6483, 1-330-558-7220