YaRD'MaN:)/(

OPERATOR'S MANUAL

21" Self-Propelled

Mulching Mower

Model No.

247.375590

Fa_ow No.

12A-559K402

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 forestcovered, 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). tf a spark attester is used, it should be maintained in effec_we 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. 770-10212

(11/98)

SECTION 1: FINDING MODEL NUMBER

This owner's guide is an important part of your new Yard-Man 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 information on the model plate is very important if you need help from your nearest service center or the Yard-Man customer support department.

• 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. An example of the model plate is shown below.

This is where mower model number will be.

This is where mower serial number will be.

Copy the model number here:

Copy the serial number here:

SECTION 2: CALLING CUSTOMER SUPPORT

• LOCATE YOUR MODEL NUMBER AND SERIAL NUMBER -Record this information in the space provided, To find your unit's specific model number and serial number, see SECTION 1: FINDING YOUR

MODEL NUMBER.

• If you are having difficulty assembling this product or if you have any questions regarding the controls, operation or maintenance of this unit, please call the Customer Support Department.

• Customer Support can be reached by dialing: 1- (330) 220-4MTD

(4683) or

1- (800)-800-7310

• Please have your model number and serial number ready when you call.

• Although both numbers are important, you will be asked to enter only your aerial number before your call can be processed.

SECTION 3: IMPORTANT SAFE OPERATION PRACTICES

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 sedous injury or death.

1. GENERAL OPERATION

• Read this operator's manual 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 pads.

• 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 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 ovedooked 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 duringoperationor whileperformingan adjustment or repair, to protect eyes from foreign objects that may be thrown from the machine in any direction.

Thoroughlyinspectthe area where the equipment is to be used. Remove all stones, sticks, wire,

bones, toys and other foreign objectswhich could be picked up and thrown by the mower in any directionand cause serious personalinjury to the

operator or any others allowed in the area. Plan your mowingpatternto avoid dischargeof material toward roads, sidewalks, bystandersand the like.

To help avoid a thrown objects injury, keep

children, bystanders and helpers at least 75 feet from the mowerwhile 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 rotatingblade can cause injury.

Many injudes 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.

3

• Do not engage the self-propelled mechanism on units so equipped while starting engine.

• 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 rotating blade.

The blade control handle must operate easily in both directions and automatically return to the disengaged position when released,

• Never operate the mower in wet grass. Always be

sure of your footing.

A slip and fall can cause

serious personal injury. Keep a firm hold on the handle and walk, never run. tf you feel you are losing your footing, RELEASE THE BLADE

CONTROL HANDLE IMMEDIATELY and the blade will stop rotating within three seconds.

• Mow only in daylight or good artificial light.

• Stop the blade when crossinggravel 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.

• 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 an_ sure the blade has stopped rotating.

• Never operate mower without proper guards, grass

catcher, plates or other safety protective devices in place.

• Muffler and engine become hot and can cause a bum. Do not touch.

• 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. Contactyour

dealer for assistance.

2. SLOPE OPERATION

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 !5

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 end 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.

DO NOT:

• DO not mow near drep-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 footingcould cause slipping.

3. 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 watchfulcare of a responsibleadult otherthan 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 childrenunder age 14 to operate the mower.

Children 14 years of age and above should read and understand the operation instructionsand safety rulesin this manual.

• Use extreme care when approaching blind corners,

shrubs, trees, or other objects that may obscure your vision of a child or hazard.

4. SERVICE

• Use extreme care in handling gasoline and other fuels.

They are extremely flammable and the vapors are explosive.

• Use onlyan approvedgasolinecontainer.

• Never remove gas cap or add fuel whilethe 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 debds 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 starling.

• Check the blade and engine mounting bolts at frequent intervals for proper tightness.

Also, visually inspect blade for damage (e.g., bent, cracked or worn). Replace with blade which meets original equipment specifications listed in this manual.

• Keep all nuts, bolts, and screws tight to be sure the

equipment is in safe working condition.

• Never tamper with safety devices. Check their properoperationregularly.

• After striking a foreign object, stop the engine, remove the wire from the spark plug, and

WARNING

- YOUR

RESPONSIBILITY:

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

adjustmentwhile 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.

DANGER

o

.,|

I

I

15o

L

WARNING

Do not mow on inclines with a slope in excess of 15 degrees (a rise of approximately 2-1/2 feet every 10 feet). A riding mower

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 5: 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.).

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.

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 6: SETTING UP MOWER

Tools Required

• Pair of Pliers

• Funnel

• Set of adjustable wrenches

Disconnecting Spark Plug

• Before setting up your lawn mower, disconnect the spark plug wire from the spark plug, and ground it against the engine. See Figure 1.

• Attach the spark plug wire to a bolt on the engine to ground it.

Spark Plug _[ I

Wire

/

2_

sperkP,o0

II!1/1 1111!//

FIGURE 1

Assembling Handle

• Remove grass bag from the unit and set it out of the way. See Figure 2 (step 1),

2. Lift lower handle

1. Move bag away

3. Lift upper handle

FIGURE 2

?

•

Raise the lower handle in the direction shown in Figure 2 (step 2) till it snaps into place.

• Raise the upper handle in the direction shown in Figure 2 (step 3). Tighten the wing nuts which are already on the handle. See Figure 3A.

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 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.

• Using a pair of pliers, insert the hairpin clip into the inner hole in the weld pin. Repeat on other side.

See Figure 3B,

• Attach the cables to the lower handle with the two cable ties already on the lower handle. Pull tight the cable ties and cut off the extra. See Figure 3C below.

Cable Tie

Ipper Handle

Lower Handle

Move hairpin clip to this hole

Tighten wing nut

Lower

Handle

A B

C

FIGURE 3

Attaching Starter Rope

The rope guide is already attached to the right side of the upper handle of your mower. See Figure 4.

• 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.

Recoil

Starte_

Wing Nut

Upper Handle

Rope _'uide

Lower Handle

FIGURE 4

Attaching Grasscatcher

• Lift the rear discharge door and remove the rear mulching baffle from the mower. See Figure 5.

Rear Mulching Baffle

FIGURE 5

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 6. 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.

Lift discharge door

Pull grass bag out and away

FIGURE 6

NOTE: For instructions on how to bag the grass clippings, please refer to page 13 of this manual.

,_ WARNING: Never operate the mower unless the hooks on the grasscatcher are seated in against the top of the grasscatcher.

SECTION 7: CONTROLS

Read this owner's manual and safety rules before operating your lawn mower. Compare the illustrations in Figure

7 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

Recoil _

Grasscatcher

Gas

Oil Fill Cap

Throttle Control Lever

Cutting Height

Adjustment Levers

Primer

FIGURE 7

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 assist in starting a cold engine, but do not use it when restarting a warm engine after a short shutdown. Refer to Figure 8.

Blade Control Handle

WARNING: This control mechanism Is a safety device. Never attempt to bypass its operations or

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 Lever

_lb ARNING: Never attempt to adjust the engine's throttle speed while the engine is running. Always

The throttle control lever is located on the side of the engine and is used to regulate engine speed. l0

Drive Clutch Control

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.

SECTION 8: OPERATION

Gas And Oil Fill-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

_[b

• 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.

Before

Starting

Mower

• 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 ddve clutch control for proper adjustment. If the mower does not propel itself or the drive wheels

hesitate with the drive clutch engaged, perform the drive clutch control adjustment as instructed on page 18 of this manual.

Adjusting Throttle Speed

The throttle control lever is located on the dght side of the engine. Adjust as follows:

• Slide the throttle control lever toward the turtle (front of the engine) to slow the engine's RPM. Slide the throttle control lever toward the rabbit (rear of the engine) to speed up the engine's RPM. See Figure 8.

Throttle Control Lever

Primer

FIGURE 8

]]

• Always operate your mower with the engine in the full throttle (rabbit) position for the most effective mulching or bagging of the cut grass.

d_lb WARNING: Never attempt to adjust the engine's throttle speed while the engine Is running. Always

Starting Engine

WARNING: Be sure no one other than the operator Is standing near the lawn mower while starting engine or operating mower.

Never run engine indoors or in enclosed, poorly ventilated areas. Engine exhaust contains carbon monoxide, an odorless and deadly gas.

Keep hands, feet, hair and loose clothing away from any moving parts on engine and lawn mower.

When starting the unit for the first time, face the mower against a solid object such as a wall, fence, etc.

Start the unit and if it shows any signs of motion while the drive clutch control is still disengaged, 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 artthe way back to the "rabbit" position.

• Push primer three times. Wait about two seconds between each push. In cold weather around 55 o F or below, pdme five times. Do not pdme 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.

Stopping Engine

• 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.

Using Your Lawn Mower

• Do not operate the mower without the mulching cover or the grasscatcher bag properly 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.

• Always operate your mower with the engine in the full throttle (rabbit) position for the most effective mulching or bagging of the cut grass.

WARNING: If you strike a 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.

12

Bagging Grass Clippings

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 will automatically collect in the bag as you run

the mower. Operate the mower till the grass bag is full. 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 9.

FIGURE 9

Adjusting Cutting Height

Refer to height adjustments section of this manual on page 16 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

Cleaning Mower

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.

• 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 tool. Do NOT spray with water.

• 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.

WARNING: Never tip the mower more than 90 degrees In any direction and do not leave the mower

13

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.

• Service foam filter in the air cleaner every 25 hours ol use and replace the paper filter component every 100 hours. You may haye to service the air filter more frequently if you are operating the mower under extremely dusty conditions.

• Clean the engine periodically.

Remove dirt and debris with a cloth or brush. Do not use 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 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, 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 & Rear Discharge Door

• Lubricate the torsion spring and the pivot point on each end of the chute deflector and the rear discharge door using a light oil. This will prevent rusting and ensure that the deflector, which 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 reaseembly.

Pivot Points

• Lubricate the pivot points on the blade control handle, brake cable and the 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.

SECTION 9: SERVICE & ADJUSTMENTS

Blade Care

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

• Disconnect spark plug wire from spark plug.

• Turn mower on its side making sure that the air filter and the carburetor are up.

14

To Remove Blade

• Remove the bolt and bell washer which hold the blade-puney assembly to the engine crankshaft.

See Figure

10. 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 Replace Blade:

• 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 10.

Lock Nut Pulley

,,.,//Assembly

Lock Nut Blade

Adapter

'_

_

,;

_m _

, Blade

Hex Bolt _ n_ n'_--_'--_ )

/2 _"

Bell _ "Hex

Washer

Hex Bolt

Bolt

FIGURE 10

• 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 is specially heat-treated. Do not substitute. To order replacement bolt, refer to the parts list in the back of of this manual.

WARNING: To ensure safe operation of your unit, all nuts and bolts must be checked periodically

To Sharpen Blade:

• The blade can be sharpened with a file or on a grinding wheel. Do not attempt to sharpen the blade while it is still on the mower.

• Follow the original angle of 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.

Blade Mounting Torque:

Blade adapter bolts: 120 in.lbs, minimum, 150 in.lbs, maximum.

Center bolt: 450 in.lbs, minimum, 600 in.lbs, maximum.

]5

Replacing

Drive Belt

• Remove the two shoulder screws from on top of the deck which secures the front drive cover to the mower deck. See Figure 11.

• Remove the front drive cover from the unit by lightly pressing inward on the sides of the front drive cover.

This will release the tabs that secure the front drive cover to the height adjuster brackets.

• Remove the idler from the idler bracket using 7/16" wrench and socket. See Figure 11.

• Remove the belt from the transmission pulley as shown in Figure 11.

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

I the job.

"Belt_

Keeper'- Lock Nut

Idler

Shoulder

Screw

Front DriveCover

FIGURE 11

• Lift and stabilize the front of the deck.

• Loosen the center hex bolt and lower the blade and engine pulley until there is adequate clearance to move the belt past the belt keeper.

• Remove the belt from the engine pulley and around the blade, See Figure 12.

• Reassemble in reverse order with new belt (part # 754-0465). NOTE: Begin idler reassembly by inserting bott up through the idler bracket hole. Adjust the drive clutch following instructions on page 17.

]6

• IMPORTANT" Torque center hex bolt to between 450 and 600 in. Ibs.

_hgheteFr°nL ___ _ _ _--_ J

Engine

Pu,,ey

Oen r,t

.-.

\ _ _ _

LehfteF;Ont

/ _

" Remove belt

/ from around

/

pu,,eyandb,ade

'/

FIGURE 12

Adjusting Drive Clutch 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 13.

To tighten cable

Adjustment

Wheel

To loosen cable

FIGURE 13

Adjusting Handle Height

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 3. Press out on the legs of the lower handle. Remove lower handle from the mower.

]?

• Turn the tower hand_ around so the notch on the bottom of the !ower handle is facing to.yard as shown in Figure

14A. Reassemble, placing the bottom holes in the handle over the weld pins in the handle mounting bracket.

Height Adjustment

Lever

Notch

Lower

Handle

A B

FIGURE 14

• 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.

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 the wheel and move the lever assembly to desired position. See Figure 14B.

• For rough or uneven lawns, move the height adjustment handles to higher cutting height position,

Adjusting Engine Throttle Speed

See page 11 of this manual for instructions on adjusting the engine throttle speed,

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.

,_

SECTION 10: OFF-SEASON STORAGE

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 a clean, dry area,

Mower

• Clean underside of the mower following instructions in the Maintenance section of this manual.

• Lubricate mower as instructed on page 14 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.

18

I!

• Inspect and replace/sharpen blade, if required.

Refer to the Maintenance 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.

SECTION 11: TROUBLE-SHOOTING GUIDE

PROBLEM

Engine fails to start

Engine runs erratic

Engine overheats

POSSIBLE CAUSE

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. 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. Engine oil level low

2. Air flow restricted

1. Spark plug gap too close

CORRECTIVE ACTION

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 fuel line

6. Clean, adjust gap, or replace

7. Crank engine with throttle in FAST

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.

1. Fill crankcase with proper oil.

2. Clean lawn mower engine.

1. Adjust gap to.030 inches.

Occasional skip

(hesitates) at high speed

Idles poorly

Excessive vibration

Mower will not mulch grass

Uneven cut

1. Spark plug fouled, faulty, or gap too wide

2. Dirty air cleaner

1. Cuffing blade loose or unbalanced

2. Bent cutting blade

3. Bent engine crankshaft

1. Engine speed too low

2. Wet grass

3. Excessively high grass

4. Dull blade

1. Wheels not in same height position

2. Dull blade

19

1. Reset gap to.030 inches or replace spark plug.

2. Clean air cleaner.

1. Tighten blade and adapter, balance blade.

2. Replace blade.

3. Contact your nearest service center

1. Move throttle lever to FAST position.

2. Wait until grass is dry to cut.

3. Mow once at a high cutting height, then

mow again at desired height.

4. Sharpen or replace blade.

1. Reposition all wheels at same height.

2. Sharpen or replace blade.

Model 559K

7

3

/

17

19

20

27

74

75

23

68

38

64

37

24

2O

Model 559K

28.

29.

30.

31.

32.

33.

34.

24.

25.

26.

27.

19.

20.

21.

23.

35.

36.

Ref.No

1.

2.

7.

8.

9.

10.

11.

3.

4.

5.

6.

12.

13.

14.

15.

16.

17.

18.

Part No.

731-1057

731-0620

731-1058

731-1059

710-0841

746-0960

747-0824

749-0439C

720-0294

712-0234

746-0883

710-1270

720-0279

720-0276

710-1205

746-0550

710-1174

682-3058

682-3059

726-0240

714-0104

710-1007

664-0085

7510042824

631-0075A

751B213146

710-1237

782-0080.6,

782-5004

710-1017

782-5003

710-0216

736-0331

712-0798

731-1937A

782-5002

Description

Upper Drive Cover

Drive Lever

Lower Drive Cover

Mounting Cap

Screw # 10-12 x .75

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

Screw # 12 x .457

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

Hax Screw 3/8-16 x .75

Bell Washer .39 x 1.13 x .062

Hex Nut 3/8-16

Transmission Cover (Yellow)

Front Baffle

72.

73.

74.

75.

76.

68.

69.

70.

71.

64.

65.

66.

67.

60.

61.

62.

63.

Ref. No

37.

Pert No.

754-0465

712-0324

42.

43.

44.

45.

52.

38.

39.

40.

41.

756-1146

748-0411

742-0741

736-0452

710-0606

710-1257

749-0907A

712-0798

736-0356 53.

54.

55.

56.

57.

58.

59.

712-3005

710-0896

682-3056A

682-3057A

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

782-5007

Description

V-Belt, 3/8 x 35.68"

Hex Nut 1/4-20

Drive Pulley

Blade Adapter

21" Mulching Btade

Flat Washer .516 x 1.5 x.134

Hex Screw 1/4-20 x 1.50

Hex Screw 3/8-24 x 2.50

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 .062

Hex Screw l-r 1/4-20 x .500

RH Pivot Bar

LH Pivot Bar (not shown)

Height Adj. Lever

Foam Grip

Shoulder Scr .500 Dia. x .434

Washer .401 x .870 x .063

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

NOTE: For painted parts, please refer to the list of color codes below.

Please add the applicable color code, wherever needed, to the part number to order a replacement part.

For instance, if a part numbered 700-xxxx is painted Yard-Man

Green, the part number to order would be

700-xxxx-0665.

Yard-Man Green: 0665

Yard-Man Yellow: 0674

Powder Black: 0637

2!

Model 559K

47

\

46

®

1

13

®

/

39

40 /

51

."

42

41 o-"

.-• o

31

32

19

\

35."

46

52

53

20

2O

22

Model 559K

26.

27.

28.

29.

22.

23.

24.

25.

18.

19.

20.

21.

Ref. No

1.

2.

3.

4.

5.

6.

7.

8.

13.

14.

15.

16.

17.

9.

10.

11.

12.

Pad No.

712-3025

736-0425

756-1042

736-0425

712-0896

736-0406

782-7598

741-0124

721-0457

750-1050

682-0028

741-0682A

732-0849A

710-0299

736-0570

741-0699

721-0325

618-0300A

721-0329

741-0673

611-0105

736-0520

717-1492

736-0314

736-0569

618-0299A

741-0672

710-1276

618-0298A

Description

Hex Jam Nut 5/16-24

Bell Washer .325 x .930 x .045

Pulley, 3.82 x .313 x .68

Bell Washer .325 x .930 x .045

Lock Nut 1/4-28

Flat Washer .442 x 1.38 x .060

Belt Keeper

Ball Bearing

Oil Seal

Flange Spacer

Idler Bracket Assembly

Bearing Sleeve

Flat Washer .504 x .700 x.030

Hex Cap Screw 1/4-28 x 1.00

Flat Washer .865 x 1.145 x .030

Needle Bearing .438 x .625 x .500

Plug 1/4 x .437

Upper Housing

Oil Seal .500 x .687 x .094

-

Range Bearing

Output Shaft

Flat Washer .504 x .700 x .030

Pinion Shaft 10T

Thrust Washer .375 x .70 x .030

Thrust Washer .388 x .625 x .062

Lower Housing

Flange Bearing .378 x .531 x .370

Hex Screw w/Washer 1/4-20 x .750

Transmission Assembly

Includes Ref. # 1to Ref. #30)

47,

48.

49.

50.

51.

52.

53.

54.

55.

30.

31.

32.

37.

38.

39.

40.

41.

33.

34.

35.

36.

42.

43.

44.

45.

46.

Ref. No Pad No.

732-0708

741-0604

748-0355

736-0447

782-0512B

782-0511A

682-0509

732-0706

732-0707

720-0190

710-0216

736-0474

716-0102

782-7551

717-1534

717-1533

734-1983

731-1426

682-0512A

682-0511A

682-0030

715-0221

736-3013

714-0101

738-1002

754-0465

Description

Bearing Retainer

Beadng Sleeve .50 I.D.

Bearing Support

Wave Washer 1.5 x 1.0 x .029

RH Height Adj. Plate

LH Height Adj. Plate

Pivot Plate Assembly

RH Front Lever

LH Front Lever

Knob

Hex Cap Screw 3/8-16 x .75

Washer DD 1.5" O.D.

Snap Ring 1.0 dia.

Wheel Dust Cap

Gear 14T RH FWD

Gear 14T LH FWD

Wheel, 8x2

Hubcap: Yellow

RH Height Adj. Complete

LH Height Adj. Complete

Cable idler Bracket

Dowel Pin

Flat Washer 1/2 x 1.00 x .063

Cotter Pin .08 x 1.42

Screw

Belt

23

MANUFACTURER'S LIMITED WARRANTY FOR:

YaRD-IVlaN,)//

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 pumhaser, 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, alteration.

accident, improper maintenance or

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 purchase, through your local authodzed 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 products sold or exported outside of the United

States of America, its possessions and territories, except those sold through MTD PRODUCTS INC's authodzed channels of export distribution.

Other Warranties:

1.

The engine or component parts thereof carry

separate warranties from their manufacturers.

Please refer to the applicable manufacturer's warranty on these items.

2.

*Battedes 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 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 tOstate. 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.