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Yard Machines 540 Lawn Mower User Manual

1. 751B224437 Muffler Guard not included 1710 1268 10 16 3 8 Screw not included Ref No 81 82 84 85 86 87 88 89 90 92 93 94 Part No 732 0866 712 3005 732 0731 747 0710 710 0599 736 0270 710 0216 736 0331 712 0798 732 0809 738 0102 782 7006 Code Description Height Adj Lever Hex Flange Lock Nut 3 8 16 Torsion Spring Hinge Pin Tapp Scr 1 4 20 x 500 Bell Washer 265 x 75 x 062 Hex Screw 3 8 16 x 75 Bell Washer 39 x 1 13 x 062 Hex Nut 3 8 16 Torsion Spring Front Axle Bolt Hinged Mounting Bracket 22 SECTION 14 SHROUD CHART 710 1256 Screw 710 1256 Screw 710 1184 Screw Part No Color Part No Color Part No Color Part No Color 751B281439 Dark Red 731 1395A Red 731 1587A Black 731 1561 Black 751B281440 Black 731 1396A Black 731 1603A Yellow 751B281443 Bright Red 731 1397A Gray 731 1610A Pewter 731 1620A Gray Hardware Hardware Hardware Hardware 7510042823 Screw 710 1258 Screw 7510042823 Screw 710 1274 Screw Part No Color Part No Color Part No Color Part No Color 731 1402A Yellow 7510143208 Black 731 1585B Black 731 1586B Black 731 1694 Black 731 1612A Red 731 1695 Silver 731 1934 Charcoal Hardware Hardware Hardware Hardware 7510042823 Screw Part No Color Part No Color Part No
2. For rough or uneven lawns move the height adjustment handles to higher cutting height position Adjusting Throttle Control If the throttle control needs adjustment or if it has been replaced adjust as follows e Remove the screw shown in Figure 18 Remove the cable clamp from the cable 17 e Push the throttle control lever on the handle all the way forward as far as it will go then back it off one click Make certain the throttle control lever remains in this position e Push the control lever on the engine as far toward the rear of the engine as it will go Secure the cable in this position with the cable clamp and screw Control Leveron Engine FIGURE 18 Adjusting Carburetor If the engine is running rough minor adjustments to the 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 too So 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 A keep clear of all moving parts Be careful of heated surfaces like the muffler SECTION 10 OFF SEASON STORAGE Prepare your lawn mower for storage at the end of the season o
3. 710 0599 782 5007 782 5004 Code Description Spring Lever Front Wheel Shoulder Bolt 5 Dia x 357 Bell Washer 38 I D x 88 O D Spring Lever Knob Height Adj Assembly Comp R H Height Adj Assembly Comp L H not shown Pivot Bar R H Pivot Bar L H not shown Front Baffle Rear Baffle Torx Mach AB Tap Scr Hex Screw TT Handle Bracket Assembly R H Handle Bracket Assembly L H Deck Black Deck Orange Deck Red Deck Grey Deck Blue Deck Charcoal Deck Silver Deck MTD Red Rear Wheel Ass y 14 Rear Wheel Ass y Models 543 5451 549 Front Wheel Ass y 8 Front Wheel Ass y Models 543 5451 Front Wheel Ass y Models 545 549 Chute Door Pivot Rod Mulching Plug Hinged Chute Deflector Hex Hd TT Screw 1 4 20 x 5 Rear Mulch Plug Rear MulcatRatiin next page 21 able continued from previous page Rer Part No Code Description No 68 710 0871 Hex Slot Sems Scr Tec 710 1237 Hex Washer Hd Screw B amp S 69 710 1174 Carr Bolt 5 16 18 x 2 0 70 736 0182 Wave Washer 71 736 0105 Spring Washer 72 731 1426 Hub Cap Radial Yellow 731 0982A Hub Cap Radial Beige 731 0981A Hub Cap Radial Grey 73 738 0481 Rear Axle Bolt 74 731 0066 Hardtop Cover Grass bag w logo 731 0068 Hardtop Cover Grass bag w logo 75 731 1506 Front End Cover Yellow 76 736 0456 Flat Washer 80 732 0866 Spring Lever Rear Wheel
4. Color Part No Color 751B281451 Gray 751B281476 Black 7511681311 Black 751B281777 Yellow 7511681911 Red 7511682011 Gray Hardware 710 1256 Hardware 710 1237 Hardware Hardware 23 MANUFACTURER S LIMITED WARRANTY FOR YARD MACHINES 1 4 For TWO YEARS from the date of retail purchase within the United States of America its possessions and territories MTD PRODUCTS INC will at its option repair or replace for the original purchaser free of charge any part or parts found to be defective in material or workmanship This warranty covers units which have been operated and maintained in accordance with the operating instructions furnished with the unit and which have not been subject to misuse abuse commercial use neglect accident improper maintenance or alteration Normal wear parts or components thereof are subject to separate terms as noted below in the No Fault Ninety Day Consumer Warranty clause All normal wear part failures will be covered on this product for a period of 90 days regardless of cause After 90 days but within the two year period normal wear parts failures will be covered ONLY IF caused by defects in material or workmanship of OTHER component parts Normal wear parts are defined as batteries belts blades blade adapters grass bags rider deck wheels seats snow thrower skid shoes shave plates and tires How to obtain service Warranty service is available with proof of pu
5. IN ANY DIRECTION WEAR SAFETY GLASSES DO NOT MOW WHEN CHILDREN OR OTHERS ARE AROUND USE EXTRA CAUTION ON SLOPES DO NOT MOW SLOPES GREATER THAN 15 MOW ACROSS NEVER UP AND DOWN NEVER PULL MOWER CLOSE TO YOUR FEET LOOK DOWN AND BEHIND BEFORE AND WHILE MOVING BACKWARDS 1595C READ OPERATOR S MANUAL KEEP SAFETY DEVICES BLADE CONTROL TRAILING SHIELD DISCHARGE COVER ETC IN PLACE AND WORKING SLOPE GAUGE SECTION 1 Use this page as a guide to determine slopes where you may not operate safely 3 AN nrrr SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE Ng APOWERPOLE a 1 CORNER OF A BUILDING lu ORAFENCE POST Do not mow on inclines with a slope in excess of 15 degrees a rise of approximately 2 1 2 feet every 10 feet A riding mower could overturn and cause serious injury If operating a walk behind mower on such a slope it is extremely difficult to maintain your footing and you could slip resulting in serious injury Operate RIDING mowers up and down slopes never across the face of slopes SECTION 3 FINDING MODEL NUMBER This owner s guide is an important part of your new Yard Machine lawn mower It will help you to assemble prepare and maintain your mower Please read and understand what it says Before you start assembling the mower for its first use please locate its model plate and copy the information on to this owner s guide The informatio
6. baffles must be in place while using the mower to mulch or side discharge grass 1 WARNING Never operate the mower unless the hooks on the grass catcher are firmly seated in the slots SECTION 6 CONTROLS Read this owner s manual and safety rules before operating your lawn mower Compare the illustrations in Figure 12 with your lawn mower to familiarize yourself with the location of various controls and adjustments Always wear safety glasses while operating the mower or while performing any adjustments or repairs on it Blade Control Handle Recoil Starter Cutting Height Adjustment Lever Grasscatcher Side Mulching Plug FIGURE 12 11 Recoil Starter The recoil starter is attached to the handle Stand behind the unit and pull the recoil starter to start the unit Primer The primer is used to pump gas into the carburetor Use it to start a cold engine but do not use it to restart a warm engine after short shutdown Refer to engine manual for illustration Blade Control Handle 1 WARNING This control mechanism is a safety device Never attempt to bypass its operations 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 Throttle Control The throttle control is located on the side of the upper handle and is used to regulate engine speed It cannot be
7. cutting height adjustment lever at least once a season with light oil The blade control handle must operate freely in both directions The cutting height adjustment lever should be able to move easily Lubricate Lubricate ta Lubricate Lubricate Wheel Bearings Lubricate Lubricate Wheel Bearings Lubricate FIGURE 15 Engine Maintenance 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 e 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 if you are operating the mower under extremely dusty conditions 15 Clean the engine periodically Remove dirt and debris with a cloth or brush We do not recommend using a garden hose to clean mower unless the muffler air filter and the carburetor are covered to keep water out Water in engine can shorten engine life Clean the spark plug and reset the gap to 030 at least once a season or every 50 hours of operation Spark plug replacement is recommended at the start of each season Refer to the engine manual for correct spark plug type Inspect muffler periodicall
8. the sole and exclusive remedy of MTD PRODUCTS INC s obligations arising from the sales of its products MTD PRODUCTS INC will not be liable for incidental or consequential loss or damage How state law relates to this warranty This limited warranty gives you specific legal rights and you may also have other rights which vary from state to state Certain disclaimers are not allowed in some states and therefore they may not apply to you under all circumstances NOTE This warranty does not cover routine maintenance items such as lubricants filters blade sharpening and tune ups or adjustments such as brake adjustments clutch adjustments or deck adjustments Nor does this warranty cover normal deterioration of the exterior finish due to use or exposure WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm
9. used to stop the engine SECTION 7 OPERATION Gas And Oil Fill Up Oil e Only use high quality detergent oil rated with API service classification SF SG or SH Use SAE30 oil do not use 10W40 oil e Fill oil sump and check the oil level following steps below a Position the mower on level ground and clean area around oil fill plug b Remove oil fill plug 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 e Install oil fill plug 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 WARNING Never fill fuel tank indoors or when engine is running or hot Do not smoke when A filling up the fuel tank Clean area around fuel cap Remove cap Use a funnel to prevent spillage e Pour approximately 1 5 quarts of fresh regular grade unleaded gasoline slowly to the fuel tank IMPORTANT Never mix engine oil with gasoline Fill tank to 1 2 below the bottom of the filler neck Wipe any fuel spillage Do not fill fuel tank completely Provide space for fuel expansion Starting Engine W
10. ARNING Be sure no one other than the operator is standing near the lawn mower while starting A 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 12 Hold control lever firmly against upper handle Pull starter rope FIGURE 13 Attach spark plug wire to spark plug Make certain the metal cap on the end of the spark plug wire is fastened securely over the metal tip on the spark plug To prevent the unit from sliding place your foot firmly against the tire Move throttle control all the way forward This step is not applicable in case of mowers with fixed throttle Push primer three times 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 Hold the control lever against the upper handle and pull starter 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 control lever let the rope return to the starter slowly After the engine starts move throttle control to desired engine speed Stopping Engine Release blade control handle to stop the engine an
11. YARD MACHINES 1 4 OPERATOR S MANUAL 21 Two in One Mulching Mower 540 Series For A Growing World MID y IMPORTANT READ SAFETY RULES AND INSTRUCTIONS CAREFULLY 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 0912A 12 97 Table of Contents Content Page Safe Operation Practices oooooccccnnnccinonnccccnnnnnncccccncononannnnnnnnnnnnnnnaannncnnnnn 3 SIOD CGUGJO AA AA haere AA 5 Finding Model NUDE a is 6 UNBACKINO tonta 6 Setting Up R ONA EA oe Na haka 7 E ZNANE EA 11 OPS weak ts 12 Maintenance au a bel 14 E a AR fara ak ale ieee a GANI ae nt 15 Service S AGUSIMICING ana nA aed een a ek a Ae ak 16 Off Season SI TAJCw o AO R S ines a
12. asure 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 DO Mow across the face of slopes never up and down Exercise extreme caution when changing direction on slopes Watch for holes ruts hidden objects or bumps Tall grass can hide obstacles 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 DO NOT 3 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 if the 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 Never allow children under age 14 to operate the mower Use extreme care when approaching blind corners shrubs trees or other objects that may obscure your vi
13. d the blade Disconnect spark plug wire and move away from spark plug to prevent accidental starting Using Your Lawn Mower Do not operate the mower without the mulching cover or the discharge chute properly installed and tightly secured 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 Blade speed should be adjusted to the condition of the lawn The best mowing pattern is one that allows the clippings to discharge towards the uncut part of the lawn This permits recutting of the clippings to further pulverize them When cutting high weeds discharge towards cut portion then recut at right angles to first direction 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 This mower is designed to run at full throttle to give you the best cut and do the most effective job of bagging the cut grass thoroughly inspect the mower for any damage Repair the damage before restarting and operating the WARNING If you strike a
14. e with the side marked bottom or with part number facing away from the adapter Place the bell support next Make sure to align the tabs in the holes of the blade with the hole in the bell support Insert the hex bolt through the blade assembly Figure 16A shows the correct order of assembly Use block of wood to hold blade again while you tighten the bolt clockwise Follow the recommended torque for the bolt which is 450 600 in lbs 16 IMPORTANT The bolt used to secure the blade to the engine is specially heat treated Do not substitute To order replacement bolt refer to the Parts List section of this manual WARNING To ensure safe operation of your unit all nuts and bolts must be checked periodically for A correct tightness To Sharpen Blade The blade can be sharpened with a file or on a grinding wheel Do not attempt to sharpen while operator is 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 See Figure 16B Ifthe blade is not balanced remove metal from the heavy side until it balances evenly Adjusting Handle Height Your mower is shipped with the handle in the higher
15. eaves dirt or other debris If this debris is allowed to accumulate it will result in rust and corrosion 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 e Scrape and clean the underside of the deck with a suitable tool Put the mower back on its wheels on the ground If you had put plastic under the gas cap make sure to remove it now 14 WARNING Never tip the mower more than 90 degrees and do not leave the mower tipped for any A length of time Oil can drain into the upper part of the engine causing a starting problem Lubrication For complete lubrication chart see Figure 15 Wheels e Lubricate the wheels and bearings if so equipped at least once a season with light oil or engine oil Also if the 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 e Lubricate the torsion spring and the pivot point on each end of the chute deflector 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 Pivot Points e Lubricate the pivot points on the blade control handle brake cable and the
16. er 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 all 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 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 object s injury keep children bystanders and helpers at least 75 feet from the mower while it is in op
17. eration 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 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 or sneakers 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 e 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 e 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 e Repeat these steps as needed Do not operate the mower while under the influence of alcohol or drugs The blade control handle is a safety device Never attempt to bypass its operation Doing so makes the safety device inoperative and may result in personal injury through contact with the rotat
18. foreign object stop the engine Remove spark plug wire from spark plug mower Extensive vibration of the mower during operation is an indication of damage The unit should be promptly inspected and repaired 13 Bagging Grass Clippings Hold firmly and Remove bag FIGURE 14 You can use the grasscatcher bag to collect clippings while you are operating the mower Attach the grasscatcher following instructions on page 10 of this manual Operate the mower till the grass bag is full or the job is completed whichever is earlier Stop the engine completely by releasing the control lever 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 away from the mower See Figure 14A Lift the bag up and away from the mower and dispose of the grass clippings See Figure 14B Adjusting Cutting Height Refer to height adjustments section of this manual on 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 it is determined which height is best for your lawn SECTION 8 MAINTENANCE WARNING Always stop the engine and disconnect the spark plug wire before performing any A maintenance work or adjustments on your lawn mower Cleaning Mower The underside of the mower deck should be cleaned after each use to prevent any build up of grass clippings l
19. height position To lower the handle height proceed as follows Remove the starter rope from the rope guide e 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 e Remove the hairpin clips from the weld pins on the handle brackets Refer to Figure 5 inset Press out on the legs of the lower handle Remove lower handle from the mower e Turn the lower handle around so the notch on the bottom of the lower handle is facing forward as shown in Figure 17A Reassemble placing the bottom holes in the handle over the weld pins in the handle mounting bracket Height Adjustment Lever Notch Lower Handle O FIGURE 17 e Reassemble the upper handle to the lower handle e Place the hairpin clips in the inner holes in the weld pins and attach the starter rope as instructed in the Assembly section Adjusting Cutting Height 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 hole to another Simply depress the lever towards wheel and move lever assembly to desired position See Figure 17B
20. ic channels on bag over frame as shown in Figure 7C All the plastic channels except center top of bag attach from the outside of bag Center top of bag attaches from the inside of bag See Figure 7D Plastic Rear Frame Insert frame into bag Center top of y Channel bag attaches from inside Front Frame Grass Bag FIGURE 7 Assemble hard top grass bag as follows Follow the first three steps of assembling the soft top bag given above Hold the bag and the frame so that the grass bag hangs from the frame and is not bunched around it Slide the handle on the grass catcher frame down into the slot in the hard top cover as shown in Figure 8A Press the rear frame into the two tabs at the back of the hard top cover and the cross bar on the front frame into the channel on the front of the hard top cover Some force may be required Place the mounting bracket under the front of the handle with the tabs on the bracket facing up Insert the phillips head screw through the hard top cover and the mounting bracket Secure with hex lock nut See Figure 8B Grass Ka Phillips Hard Top Insert handle through Cover NG DJ slot on cover a Lock B FIGURE 8 Attaching Grasscatcher to Mower NOTE Your mower was shipped with the rear mulching baffle in place on the mower Remove the mulching baffle in order to install and use the grass catcher For instructions on how t
21. ing blade The blade control handle must operate easily in both directions and automatically return to the disengaged position when released e Never operate the mower in wet grass Always be sure of your footing A slip and fall can cause serious personal injury Keep a firm hold on the handle and walk never run Mow only in daylight or in good artificial light e Stop the blade when crossing gravel drives walks or roads If the equipment should start to vibrate abnormally stop the engine and check immediately for the cause Vibration is generally a warning of trouble e Shut the engine off and wait until the blade comes to a complete stop before removing the grass catcher or unclogging the chute The cutting blade continues to rotate for a few seconds after the engine is shut off Never place any part of the body in the blade area until you are sure the blade has stopped rotating e Never operate mower without proper guards grass catcher plates or other safety protective devices in place e Muffler and engine become hot and can cause a burn Do not touch e Only use accessories approved for this machine by the manufacturer Read understand and follow all instructions provided with the approved accessory e If situations occur which are not covered in this manual use care and good judgment Contact your dealer for assistance 2 SLOPE OPERATION For your safety use the slope gauge included as part of this manual to me
22. ing condition Never tamper with safety devices Check their proper operation regularly After striking a foreign object stop the engine remove the wire from the spark plug 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 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 Following are representations of the safety labels on your lawn mower Maintain safety while operating the mower TO REDUCE THE RISK OF INJURY DO NOT OPERATE MOWER UNLESS REAR TRAILING SHIELD AND THIS GUARD OR ENTIRE GRASS CATCHER IS IN ITS PROPER PLACE KEEP HANDS and FEET AWAY r A DANGER my AVOID SERIOUS INJURY OR DEATH KEEP HANDS AND FEET AWAY FROM ROTATING PARTS REMOVE OBJECTS THAT CAN BE THROWN BY THE BLADE
23. ire 60 746 0842 Throttle Control Wire 51 746 0847 Throttle Control Wire 42 18 747 0995 N Front Catcher Frame 19 664 0084 Grass Bag Ass y w o logo 664 0085 Grass Bag Ass y w logo 664 0086 Grass Bag Ass y w logo red 20 714 0104 Internal Cotter Pin 21 Engine 23 782 7599A N Grass Bag Door 24 751B213146 Cable Clamp 7510007775 Cable Clampt 25 646 0875 Throttle Body 26 811 00500 Throttle Box Comp t 811 00303 Throttle Box Comp 811 00212 Throttle Box Comp Fixed 29 735 0639 Spark Plug Boot Optional 30 732 0700 Wire Rod 31 731 1236 Rear Flap 32 753 0588 Blade Adapter Kit 748 0376B Blade Adapter 33 710 1044 Hex Bolt 3 8 24 x 1 5 34 736 0524A Blade Bell Support 36 742 0741 Mulching Blade 39 736 0356 Bell Washer 39 I D x 1 38 40 712 0798 Hex Nut 3 8 16 Thd 41 15261A Height Adj Plate 42 15262B Pivot Bar Includes ref 7 8 9 10 amp 25 t Models 543 545 Ref No 43 44 45 47 49 50 51 53 54 55 56 57 58 59 60 61 63 64 65 66 67 Part No 732 0404 738 0507B 736 0105 720 0190 14578 14579 17488 17489 782 5002 782 5003 710 1017 710 0549 682 3058 682 3059 782 0047 0691 782 0047 0606 782 0047 0650 782 0047 0662 782 0047 0667 782 0047 0483 782 0047 0629 782 0047 0638 734 1860 734 1864 734 1818 734 1781 734 1841 747 0996 682 7000 731 1409
24. lems 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 SECTION 11 TROUBLE SHOOTING GUIDE PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Engine fails to start 1 Blade control handle disengaged 2 Spark plug wire disconnected 3 Throttle control lever not in starting position 4 Fuel tank empty or stale fuel 5 Blocked fuel line 6 Faulty spark plug 7 Engine flooded 1 Engage blade control handle 2 Connect wire to spark plug 3 Move throttle lever to correct position 4 Fill up tank with fresh gasoline 5 Clean fule line 6 Clean adjust gap or replace 7 Crank engine with throttle in FAST Engine runs erratic 1 Spark plug wire loose 2 Blocked fuel line or stale fuel 3 Vent in gas cap plugged 4 Water or dirt in fuel system 5 Dirty air cleaner 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 Engine overheats 1 Engine oil level low 2 Air flow restricted 1 Fill crankcase with proper oil 2 Clean lawn mower engine Excessive vibration 1 Cutting blade loose or unbalanced 2 Bent cutting blade 3 Bent engine crankshaft 1 Tighten blade and adap
25. lready on the lower handle Pull tight the cable ties and cut off the extra See Figure 5C below Cable Tie Upper Handle Move hairpin clip to this hole Lower Handle Weld Pin Handle Tighten Lower wing nut Handle A B C FIGURE 5 Attaching Starter Rope The rope guide is already attached to the right side of the upper handle of your mower See Figure 6 e 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 Tighten the wing nut holding the rope guide to the upper handle Recoil Wing Nut Starter Upper Handle Rope Guide J Lower Handle FIGURE 6 NN Assembling Grass Catcher Following parts are included with a soft top grass bag front frame rear frame and grass bag Following parts are included with a hard top grass bag front frame rear frame grass bag hardtop cover mounting bracket phillips screw and hex lock nut Assemble soft grass bag as follows NOTE Make certain bag is turned right side out before assembling warning label will be on the outside e Join the rear frame and front frame assembly following Figure 7A Insert frame into grass bag as shown in Figure 7B black plastic side is the bottom of bag Slip the openings in the side of the plastic channel on bag over the hooks on the grass catcher frame Secure bag to frame by working the five plast
26. n on the model plate is very important if you contact a service center or the Yard Machine customer support department e Every mower has a model plate You can locate it by standing behind the unit in the operating position and looking down at the cutting deck The model plate will look like Figure 1 This is where mower model number will be XXX X XXX X XXX XXXXXXXXXXX This is where mower serial number will be Copy the model number here MTD MTD PRODUCTS INC Copy the serial number here CLEVELAND OHIO 44136 FIGURE 1 SECTION 4 UNPACKING Removing Unit From Carton Remove staples break glue on top flaps or cut tape at carton end and peel along top flap to open carton Remove loose parts if included with unit i e owner s manual etc See Figure 2 FIGURE 2 Cut along dotted lines and lay carton down flat Remove packing material Roll or slide unit out of carton Check carton thoroughly for loose parts See Figure 2 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 SECTION 5 SETTING UP MOWER Tools Required Pair of Pliers e Funnel Set of adjustable wrenches Disconnecting Spark Plug Before setting up your lawn mower disconnect the spark plug wire from the spark plug a
27. nd ground it against the engine See Figure 3 If the engine is equipped with the optional rubber boot attach the boot to a bolt on the engine to ground Spark Plug Rubber Boot Wire Spark Plug Engine with rubber boot FIGURE 3 Assembling Handle NOTE If your mower is equipped with a hardtop grass bag which is packed on top of the mower in the carton remove the grass bag from the unit and set it out of the way now See Figure 4 step 1 If your mower is equipped with a soft top grass bag or a hard top bag which is packed unassembled in the carton please follow the instructions given later in this section to assemble the grass bag 2 Lift lower handle 1 Move bag away 3 Lift upper handle FIGURE 4 Raise the lower handle in the direction shown in Figure 4 step 2 till it snaps into place e Raise the upper handle in the direction shown in Figure 4 step 3 Tighten the wing nuts which are already on the handle See Figure 5A Note Make sure to route the cables inside the lower handle Also do not crimp the cables while lifting the handle up e For shipping 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 e Using a pair of pliers insert the hairpin clip into the inner hole in the weld pin Repeat on other side See Figure 5B Attach the cables to the lower handle with the two cable ties a
28. o bag the grass clippings please refer to page 14 of this manual Lift the rear discharge door and remove the rear mulching baffle from the mower See Figure 9 Rear Mulching Baffle LE FIGURE 9 Hard Top Grass Bag Holding open the rear discharge door as shown below place the grass bag on the pivot rod See Figure 10A Let go of the discharge door so that it rests on the grass bag Discharge Door Grass Bag A Grass Bag FIGURE 10 Soft Top Grass Bag Place the hooks on the grass catcher into the slots in the handle bracket assemblies on both sides See Figure 10B Release the rear discharge door To remove the grass catcher lift the rear discharge door on the mower Lift the grass catcher up out of the slots in the handle bracket assemblies Reinstall the rear mulching baffle and release the rear discharge door Converting from Mulching to Side Discharge To convert to a side discharge mower lift the side mulching plug 10 e Slide the two hooks on the side discharge chute under the hinge pin on the mulching plug assembly See Figure 11 Lower the mulching plug Do not remove the mulching plug at any time even when you are not mulching Mulching Plug Hinge Pi ae a Slide hooks under the sides of hinge pin FIGURE 11 on the handle bracket assemblies and the rear discharge door rests firmly against the top of the grass catcher Both the mulch
29. r if the unit will not be used for 30 days or more Store the mower in a clean dry area Mower Clean underside of the mower following instructions in the Maintenance section of this manual e Inspect and replace sharpen blade if required Refer to the Maintenance section of this manual for blade care instructions e Lubricate mower following the lubrication chart in Figure 15 on page 15 Follow these steps to fold the 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 NOTE When folding the handle for storage or transportation be careful not to bend or kink the cables Engine Follow recommendations in the accompanying engine manual for off season storage of the engine e 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 or chaff from the exterior of the engine e Remove any dirt or debris from cooling fins air intake screen levers and linkage 18 Other Do not store gasoline from one season to another e Replace your gasoline can if it starts to rust Rust and or dirt in the gasoline will cause prob
30. rchase through your local authorized service dealer To locate the dealer in your area please check the yellow pages or contact the Customer Service Department of MTD PRODUCTS INC P O Box 368022 Cleveland Ohio 44136 9722 Phone 1 800 800 7310 The return of a complete unit will not be accepted by the factory unless prior written permission has been extended by the Customer Service Department of MTD PRODUCTS INC Transportation charges Transportation charges for the movement of any power equipment unit or attachment are the responsibility of the purchaser Units exported out of the United States MTD PRODUCTS INC does not extend any warranty for A products sold or exported outside of the United States of America its possessions and territories except those sold through MTD PRODUCTS INC s authorized channels of export distribution Other Warranties 1 The engine or component parts thereof carry separate warranties from their manufacturers Please refer to the applicable manufacturers warranty on these items 2 Batteries are covered by a 90 day replacement warranty 3 Log splitter pumps valves and cylinders or component parts thereof are covered by a one year warranty 4 All other warranties express or implied including any implied warranty of merchantability or fitness for a particular purpose are hereby expressly disclaimed in their entirety 5 The provisions as set forth in this warranty provide
31. sion 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 Before cleaning repairing or inspecting make certain the blade and all moving parts have stopped Disconnect the spark plug wire and keep the wire away from the spark plug to prevent accidental starting Check the blade and engine mounting bolts at frequent intervals for proper tightness Also visually inspect blade for damage e g bent cracked Replace with blade which meets original equipment specifications Keep all nuts bolts and screws tight to be sure the equipment is in safe work
32. ter balance blade 2 Replace blade 3 Contact your nearest service center Mower will not 1 Engine speed too low 1 Move throttle lever to FAST position 2 Dull blade mulch grass 2 Wet grass 2 Wait until later to cut 3 Excessively high grass 3 Mow once at a high cutting height then mow again at desired height 4 Dull blade 4 Sharpen or replace blade Uneven cut 1 Wheels not in same height position 1 Place all four wheels in same relative height position 2 Sharpen or replace blade y 19 For repairs beyond the minor adjustments listed above please contact your nearest service center or call 1 800 800 7310 SECTION 12 REPAIR PARTS Remote Throttle Assembly Fixed Throttle Assembly Na NA 4 26 A NG 68 NA Pi 24 w A 53 67 20 Ref No Part No Code Description 1 747 0824 Control Handle Assembly 2 710 1205 Rope Guide 3 720 0279 Handle Knob 4 710 1174 Curved Hd Bolt 5 16 18 x 2 6 720 0276 Hand Knob 7 710 0605 Oval C Sunk Screw 8 736 0501 Spring Washer 9 712 0324 Hex Lock Nut 1 4 20 Thd 10 746 0876 Throttle Lever 11 749 0438B N Upper Handle 12 720 0295 N Foam Grip 13 749 0907A N Lower Handle 14 726 0240 Cable Tie 15 747 0995 Rear Catcher Frame 16 746 0554 Control Cable 40 746 0550 Control Cable 55 746 0737 Control Cable 51 17 746 0841 Throttle Control W
33. uc ees be tet iene a wees 18 Trouble Shooting Guide coooononccccnnonncoccccnonccnnnonancccnnnnnnnnnnennnnnnnnnnanennnos 19 Parts A e AN 20 A 23 A 24 This owner s guide covers various models of mowers Follow only those instructions which pertain to your unit SECTION 1 IMPORTANT SAFE OPERATION PRACTICES 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 self herself or others Your lawn mower was built to be operated according to the rules for safe operation in this manual DANGER As with any type of power equipment carelessness or error on the part of the operator can result in serious injury If the operator violates any of these rules he she may cause serious injury to him 1 GENERAL OPERATION Read this owners guide carefully in its entirety before attempting to assemble this machine Read understand and follow all 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 mow
34. y 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 SECTION 9 SERVICE amp ADJUSTMENTS Blade Care Periodically inspect the blade adapter 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 A heavy gloves or a rag to grasp the cutting blade Disconnect spark plug wire from spark plug e Turn mower on its side making sure that the air filter and the carburetor are up To Remove Blade e Remove the bolt and blade bell support which hold the blade and adapter to the engine crankshaft See Figure 16A Remove the blade and adapter from the crankshaft To Replace Blade Before reinstalling the blade and the blade adapter to the unit lubricate the engine crankshaft and the inner surface of the blade adapter with light oil e Install the blade adapter on the crankshaft with the star away from the engine See Figure 16A A Blade B 1 Insert screw driver through hole Adapter Crankshaft Ne Single Bolt 7 Blade 2 Blade should be parallel to ground Screw 7 Driver 5 Blade o o ES Bell Hex Bolt B Support Ground FIGURE 16 Place the new blad

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