Owner's Manual CRAFTSMAN° 5.0 HORSEPOWER 22" ECONOMY SIDE DISCHARGE ROTARY LAWN MOWER Model No. 917.388230 • • • • • • Safety Assembly Operation Maintenance Espafiol Repair Parts CAUTION: Read and follow all Safety Rules and Insuuc_u_ before operating this equ_hF Sears, Roebuck and Co., Hoffman Estates, IL 60179 Warranty Safety Rules Assembly Operation Maintenance Schedule Maintenance 2 2 4 5 8 8 Product Specifications Service and Adjustments Storage Troubleshooting Repair Parts Parts Ordering 9 12 13 14 32 Back Cover LIMITED TWO YEAR WARRANTY ON CRAFTSMAN POWER MOWER For two years from date of purchase, when this Craftsman Lawn Mower is maintained, lubricated, and tuned up according to the operating and maintenance instructions in the owner's manual, Sears will repair free of charge any defect in matedal or workmanship. If this Craftsman Lawn Mower is used for commercial or rental purposes, this warranty applies for only 90 days from the date of purchase. This Warranty does not cover: • Expendable items which become worn during normal use, such as rotary mower blades, blade adapters, belts, air cleaners and spark plug. • Repairs necessary because of operator abuse or negligence, including bent crankshafts and the failure to maintain the equipment according to the instructions contained in the owner's manual. Warranty service is available by returning the Craftsman power mower to the nearest Sears Service Center/Department in the United States. This warranty applies only while this product is in use in the United States. This Warranty gives you specific legal rights, and you may also have other rights which vary from state to state. SEARS, ROEBUCKAND CO., D/817 WA, HOFFMAN ESTATES, ILLINOIS 60179 Safety standards require operator presence controls to minimize the risk of injury. Your unit is equipped with such controls. Do not attempt to defeat the function of the operator presence controls under any circumstances. • Do not operate mower if it has been dropped or damaged in any manner. Always have damage repaired before using your mower. • Do not use accessory attachments that are not recommended by the manufacturer. Use of such attachments may be hazardous. • The blade turns when the engine is running. TRAINING: • Read this operator's manual carefully. Become familiar with the controls and know how to operate your mower properly. Learn how to quickly stop mower. • Do not allow children to useyour mower. Never allow adults to use mower without proper instructions. • Keep the area of operation clear of all persons, especially small children and pets. • Use mower only as the manufacturer intended and as described in this manual. PREPARATION: • Always thoroughly check the area to be mowed and clear it of all stones, sticks, wires, bones, and other foreign objects. These objects will be thrown by the blade and can cause severe injury. • Always wear safety glasses or eye shields when starting and while using your mower. 2 • • Do not run the engine indoors. Exhaust fumes are dangerous. • Never cut grass by pulling the mower "towards you. Mow across the face of slopes, never up and down or you might lose your footing. Do not mow excessively steep slopes. Use caution when operating the mower on uneven terrain or when changing directions -- maintain good footing. • Never operate your mower without proper guards, plates, grass catcher or other safety devices in place. Dress properly. Do not operate mower when barefoot or wearing open sandals. Wear only solid shoes with good traction when mowing. • Check fuel tank before starting engine. Do not fill gas tank indoors, when the engine is running or when the engine is hot. Allow the engine to cool for several minutes before filling the gas tank. Clean off any spilled gasoline before starting the engine. • Always make wheel height adjustments beforestarting your mower. Never attempt to do this while the engine is runnin_]. • Mow only in daylight or good artificial light. MAINTENANCE AND STORAGE: • Check the blade and the engine mounting bolts often to be sure they are tightened properly. • Check all bolts, nuts and screws at frequent intervals for proper tightness to be sure mower is in safe working condition. • Keep all safety devices in place and working. • To reduce fire hazard, keep the engine free of grass, leaves or excessive grease and oil. • Check grass catcher often for deterioration and wear and replace worn bags. Use only replacement bags that are recommended by and comply with specifications of the manufacturer of your mower. • Always keep a sharp blade on your mower. • Allow engine to cool before storing in any enclosure. • Never store mower with fuel in the tank inside a building where fumes may reach an open flame or an ignition source such as a hot water heater, space heater, Aclothes dryer, etc. CAUTION: Always disconnect spark plug wire and place wire where it cannot contact spark plug in order to prevent accidental starting when setting up, transporting, adjusting or making repairs. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. OPERATION: • Keep your eyes and mind on your mower and the area being cut. Do not let other interests distract you. • Do not mow wet or slippery grass. Never run while operating your mower. Always be sure of your footing -- keep a firm hold on the handles and walk. , Do not put hands or feet near or under rotating parts. Keep clear of the discharge opening at all times. Always stop the engine whenever you leave or are not using your mower, or before crossing driveways, walks, roads, and any gravel--covered areas. Never direct discharge of material toward bystanders nor allow anyone near the mower while you are operating it. Before cleaning, inspecting, or repairing your mower, stop the engine and make absolutely sure the blade and all moving parts have stopped. Then disconnect the spark plug wire and keep it away from the spark plug to prevent accidental starting. Do not continue to run your mower if you hit a foreign object. Follow the procedure outlined above, then repair any damage before restarting and operating you mower. Do not change the governor settings or overspeed the engine. Engine damage or personal injury may result. Do not operate your mower if it vibrates abnormally. Excessive vibration is an indication of damage; stop the engine, safely check for the cause of vibration and repair as required. 3 Theseaccessories were available when this lawn mower was produced. They are also available at most Sears retail outlets and service centers. Most Sears stores can also order repair parts for you, when you provide the model number of your lawn mower. Some of these accessories may not apply to your lawn mower. LAWN MOWER PERFORMANCE CUPPING DEFLECTOR FOR REAR DISCHARGE LAWN MOWERS MULCHER KITS GRASS CATCHERS FOR REAR DISCHARGE LAWN MOWERS STABIMZER FOR SIDE DISCHARGE GRASS LAWN CATCHERS MOWERS GAS CANS LAWN MOWER MAINTENANCE MUFFLERS AIR RLTERS SPARK PLUGS % BELTS BLADES BLADE ADAPTERS WHEELS ENGINE OIL Read these instructions and this manual in its entirety before you attempt to assemble or operate your new lawn mower. Your new lawn mower has been assembled at the factory with the exception of those parts left unassembled for shipping purposes. All parts such as nuts, washers, bolts, etc., necessary to complete the assembly have been placed in the parts bag. To ensure safe and proper operation of your lawn mower, all parts and hardware you assemble must be tightened securely. Use the correct tools as necessary to ensure proper tightness. • Remove all packing materials except padding between upper and lower handle and padding holding operator presence control bar to upper handle. • Roll lawn mower out of carton and check carton thoroughly for additional loose parts. TO REMOVE CARTON locks into place in mowing position. • Remove protective padding, raise upper handle section into place on lower handle and tighten both handle knobs. • Remove handle padding holding operator presence control bar to upper handle. LAWN MOWER HOW TO SET UP YOUR LAWN MOWER TO UNFOLD HANDLE IMPORTANT: Unfold handle carefully so as not to pinch or damage control cables. • Raise handles until lower handle section FROM • Remove loose parts included with mower. . • Cut down two end corners of carton and lay end panel down flat. 4 • Your lawn mower handle can be adjusted for your mowing comfort. Refer to "Adjust Handle" in the Service and Adjustment section of this manual. Operator presence controlbar Upper handle _ _,_t Lift up __ .,_ Mowing /// position -:__,_2-" KNOW YOUR LAWN /_ MOWER READ THIS OWNER'S MANUALAND SAFETY RULES BEFORE OPERATING YOUR LAWN MOWER. Compare the illustrationswith your lawn mower to familiarize yourselfwith the locationof various controls and adjustments. Save this manual for future reference. These symbols may appear on your lawn mower or in literature supplied with the product. Learn and understand their meaning. CAUTION OR WARN_G ENGINE ON ENGINE OFF FAST SLOW CHOKE FUEL OIL DANGER, KEEP HANDS ANt) FEET AWAY Operator presence controlbar Engine zone controlcable Handle knob Starter handle Engine oil cap with dipstick Gasoline fillercap Mulcher door Primer Wheel adjuster (on each wheel) MEETS CPSC SAFETY REQUIREMENTS Sears rotary walk-behind power lawn mowers conform to the safety standards of the American National Standards Institute and the U.S. Consumer Product Safety Commission. The blade turns when the engine is running. operator presence control bar- must be held down to the handle to start the engine. Release to stop the engine. Primer - pumps additionalfuel from the carburetor to the cylinderfor use when starting a cold engine. Starter handle - used for startingthe engine. Mulcher- allows conversion to discharge or bagging operation. 5 The operation of any lawn mower can result in foreign objects thrown into the eyes, which can result in severe eye damage. Always wear safety glasses or eye shields while operating your lawn mower or performing any adjustments or repairs. We recommend a wide vision safety mask over spectacles or standard safety glasses. HOW TO USE YOUR LAWN MOWER ENGINE SPEED CONTROL The engine speed was set at the factory for optimum performance. Speed is not adjustable. ENGINE ZONE CONTROL ACAUTION: Federal regulations requ re an engine control to be installed on this lawn mower in order to minimize the risk of blade contact injury. Do not under any circumstances attempt to defeat the function of the operator control. The blade turns when the engine is running. • Your lawn mower is equipped with an operator presence control bar which requires the operator to be positioned behind the lawn mower handle to start and operate the lawn mower. TO ADJUST CUTFING HEIGHT • Raise wheels for low cut and lower wheels for high cut. • Adjust cutting height to suit your requirements. Medium position is best for most lawns. • To change cutting height, squeeze adjuster lever toward wheel. Move wheel up or down to suit your requirements. Be sure all wheels are in the same setting. NOTE: Adjuster is properly positioned when plate tab inserts into hole in lever. Also, 9-position adjusters (if so equipped) allow lever to be positioned between the plate tabs. Lower wheels for high cut _ Lever Plate tab _ Raise wheels for low cut BEFORE STARTING ENGINE OIL • Use 20 ozs. of oil. For type and grade of oil to use, see "ENGINE" in Maintenance section of this manual. • Pouroil slowly. Do not overfill. • Check oil level before each use. Add oil if needed. Fill to full line on dipstick. • To read proper level, tighten engine oil cap each time. • Reinstall engine oil cap and tighten. • Change the oil after every 25 hours of operation or each season. You may need to change the oil more often under dusty, dirty conditions. GAS • Fill fuel tank. Use fresh, clean, regular unleaded gasoline with a minimum of 87 octane. Do not mix oil with gasoline. Purchase fuel in quantities that can be used within 30 days to assure fuel freshness. WARNING: Experience indicates that alcohol blended fuels (called gasohol or using ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. To avoid engine problems, the fuel system should be emptied before storage of 30 days or longer. Drain the fuel tank, start the engine and let it run until fuel lines and carburetor are empty. Use fresh fuel next season. See Storage Instructions for additional information. Never use engine or carburetor cleaner products in fuel tank or permanent damage may occur. Gasoline filler Engine oil cap cap TO START ENGINE • To start a cold engine, push primer three (3) times before trying to start. Use a firm push. This step is not usually necessary when starting an engine which has already run for a few minutes. • Hold operator presence control bar down to the handle and pull starter handle quickly. Do not allow starter rope to snap back. • To stop engine, release operator presence control bar. NOTE: In cooler weather it may be necessary to repeat priming steps. In warmer weather over priming may cause Your lawn mower is shipped without oil in the engine. • Be sure mower is level and area around oil fill is clean. • Remove engine oil cap and fill to the full line on the dipstick. 6 flooding and engine will not start. If you do floodengine, wait a few minutes before attempting to start and do not repeat priming steps. TO CONVERT MOWER TO DISCHARGING Your mower is shipped ready to be used as a mulcher. To convert to bagging or discharging: • Lift discharge guard and remove mulcher plate. • Mower can now be used for side discharge or optional grass catcher can be attached. • To return to mulching operation, simply reinstall mulcher plate as shown. CAUTION: Do not run your lawn mower without discharge guard, approved grass catcher or mulcher plate in place. J_ Hooks .=rod Mulch MOWING TIPS • Under certain conditions, such as very tall grass, it may be necessary to raise the height of cut to reduce pushing effort and to keep from overloading the engine and leaving clumps of grass clippings. It may also be necessary to reduce ground speed and/or run the lawn mower over the area a second time. • For extremely heavy cutting, reduce the width of cut by overlapping previously cut path and mow slowly. • For better grass bagging and most cutting conditions, the engine speed should be set in the fast position. • For side discharge lawn mowers, cutting in a counter-clockwise direction, starting at the outside of the area to be cut, spreads grass clippings more evenly and puts less load on the engine. To keep clippings off of walkways, flower beds, etc., make the first cuts in a clockwise direction. • Pores in cloth grass catchers can become filled with dirt and dust with use and catchers will collect less grass. To prevent this, regularly hose catcher off with water and let dry before using. • Keep top of engine around starter clear and clean of grass clippings and chaff. This will help engine air flow and extend engine life. MULCHING MOWING TIPS IMPORTANT: For best performance, keep mower housing free of built-up grass and trash. See "Cleaning" in MAINTENANCE section of this manual. • The special mulching blade will recut the grass clippingsmany times and reduce them in size so that as they fall onto the lawn they will disperse intothe grass and not be noticed. Also, the mulched grass will biodegrade quickly to provide nutriantsfor the lawn. Always mulch with your highest engine (blade) speed as this will provide the best recuttingaction of the blades. • Avoid cutting your lawn when it is weL Wet grass tends to form dumps and interferes with the mulching action. The best time to mow your lawn is the early aftemcon. At this time the grass has dried and the newly cut area will not be exposed to the direct sun. • For best results, adjust the lawn mower cuttingheight so that the lawn mower cuts off only the top one-third of the grass blades. If the lawn is overgrown itwill be necessary to raise the height of cut to reduce pushing effort and to keep from overloading the engine and leaving clumps of mulched grass. For extremely heavy mulching, reduce your width of cut by overlapping previously out path and mow slowly. • Certain types of grass and grass conditions may require that an area be mulched a second time to completely hide the clippings. When doing a second cut, mow across or perpendicular to the firstcut path. • Change your cutting pattern from weekto week. Mow north to south one week then change to east to west the next week. This willhelp prevent matting and grainingof the lawn. 7 .A'NTENANCESC.EOULE .s YOU COMPL o,,,,... REGULAR SERVICE f__-_t_(_:_._-_ Check for Loose Fasteners a O SERVICE _ (if Equipped) Clean/Inspect Grass Catcher Clean Lawn Mower DATE:_ t## _ (power-Propelled Ctean Under DriveMowers) Cover Check drive belt/pulleys RE (Power-Propelled Mowers) C hecWSharpen/Repla"ceBlade _ Lubrication Chart Clean BatteP//Recharge IElactrla Start Mowers) E Check Engine Oil Level N Char_le Engine Oil G I CLeanAir Filter Inspect Muffler N Clean or Replace Spark Plug IV# (I,/4 t/_,z I_ 2 i,/°z t - Change more ofl_ v_en operating under a heavy load or in high a'_0i*nl 2 -Ser, dce rnore onen '/A'_n operating in dirty or dwl'/condllk_s. GENERAL (I/ _/' E Replace Air Filter Paper Cartridge 3 - Repk:q blade= morro on_ wi_m mow_g 4 - ChaiSe 48 hours at end of =euon. 3 If Ii_tp*rals'es. in =andy K*IIL (_) RECOMMENDATIONS LUBRICATION Wheel adjuster The warranty on this lawn mower does not cover items that have been subjected to operator abuse or negligence. To receive full value from the warranty, operator must maintain mower as Instructed in this manual. Some adjustments will need to be made periodicallyto pmpedy maintain your unit. All adjustments in the Service and Adjustmerits section of this manual should be checked at least once each season. • Once a year, replace the spark plug, clean or replace air filterelement and check blade for wear. A new spark plug and clean/new air filterelement assures proper air-fuel mixture and helps your engine run better and last longer. • Follow the maintenance schedule in this manual. BEFORE EACH USE CHART (_) Mulcher door _J oil __ (_) Handle bracket mounting pin (_ (_) Spray lubricante Referto MAINTINANCE"ENGiNE" SECTION. IMPORTANT: Do not oil or grease plastic wheel bearings. Viscous lubricantswill attract dust and dirtthat will shorten the life of the self lubricatingbearings, if you feel they must be lubricated,use only a dry, powdered graphite type lubricant sparingly. • Check engine oil level. • Check for loose fasteners. LUBRICATION Keep unit well lubricated (See "LUBRICATION CHART"). 8 PRODUCT SPECIFICATIONS MODEL NUMBER SERIAL 917.388230 NUMBER DATE OF PURCHASE HORSEPOWER: 5.0 DISPLACEMENT: 11.5 CU. IN. GASOLINE 1.5 QUARTS CAPACITY/TYPE: UNLEADED dL TYPE (API-SF/SG/SH): REGULAR SAE 30 (ABOVE 32°F) SAE 5W-30 (BELOW )IL CAPACITY: SPARK PLUG(GAP: 32°F) 20 OZS. .030") VALVE CLEARANCE: CHAMPION RJ19LM OR J19LM INTAKE: .004 - .008 EXHAUST: .004 - .008 SOLID STATE iGNITION AIR GAP: .0125 IN. BLADE BOLT TORQUE: 35-40 FT. LBS. • The model and serial numbers will be found on a decal attached to the rear of the lawn mower housing.Record both serial number and date of purchase in space provided above. LAWN MOWER Always obsewe safety rules when performing any maintenance. TIRES • Keep tires free of gasoline, oil, or insect control chemicals which can harm rubber. • Avoid stumps,stones,deep ruts, sharp objects and otherhazardsthatmay cause tire damage. BLADE CARE For best results, mower blade must be kept sharp. Replace bent or damaged blades. TO REMOVE BLADE • Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with spark plug. • Turn lawn mower on its side. Make sure air filter and carburetor are up. • Use a wood block between blade and mower housing to prevent blade from turning when removing blade bolt. • Protect your hands with gloves and/or wrap blade with heavy cloth. • Remove blade bolt by turning counterclockwise. • Remove blade and attaching hardware (bolt, lock washer and hardened washer). NOTE: Remove the blade adapter and check the key inside hub of blade adapter. The key must be in good condition to work properly. Replace adapter if damaged. TO REPLACE BLADE • Position the blade adapter on the engine crankshaft. Be sure key in adapter and crankshaft keyway are aligned. • Position blade on the blade adapter aligning the two (2) holes in the blade with the raised lugs on the adapter. • Be sure the trailing edge of blade (opposite sharp edge) is up toward the engine. • Install the blade bolt with the lock washer and hardened washer into blade adapter and crankshaft. • Use block of wood between blade and lawn mower housing and tighten the blade bolt, turning clockwise. • The recommended tightening torque is 35-40 ft. Ibs. IMPORTANT: treated. Blade bolt is grade 8 heat TO SHARPEN BLADE NOTE: We do not recommend sharpening blade - but if you do, be sure the blade is balanced. Care should be taken to keep the blade balanced. An unbalanced blade will cause eventual damage to lawn mower or engine. • The blade can be sharpened with a file or on a grinding wheel. Do not attempt to sharpen while on the mower. • To check blade balance, drive a nail into a beam or wall. Leave about one inch of the straight nail exposed. Place center hole of blade over the head of the nail. If blade is balanced, it should remain in a horizontal position. If either end of the blade moves downward, sharpen the heavy end until the blade is balanced. Blade Crankshaft Key keyway Blade Lockwasher \ Blade bolt shaft Hardened washer Trailing edge Blade adapter GRASS CATCHER (If purchased as an accessory) • The grass catcher may be hosed with water, but must be dry when used. • Check your grass catcher often for damage or deterioration. Through normal use it will wear. If catcher needs replacing, replace only with a manufacturer approved replacement catcher. Give the lawn mower model number when ordering. ENGINE LUBRICATION Use only high quality detergent oil rated with API service classification SF, SG or SH. Select the oil'sSAE viscositygrade according to your expected operating temperature. SAE VISCOSITY •30- -_. .,o- o- GRADES _. _- _ TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OILCHANGE ,G. NOTE: Although multi-viscosityoils (5W30, 10W30 etc.) improve starting in cold weather, these multi-viscosity oils will result in increased oil consumption when used above 32°F. Check your engine oil level more frequently to avoid possible engine damage from running low on oil. Change the oil after every 25 hours of operation orat least once a year if the lawn mower is not used for 25 hours in one year. Check the crankcase oil level before starting the engine end after each five (5) hours of continuous use. _ghten oil plug securely each time you check the oillevel. TO CHANGE ENGINE OIL NOTE: Before tipping lawn mower to drain oil, drain fuel tank by running engine until fuel tank is empty. • Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with spark plug. • Remove engine oil cap; lay aside on a clean surface. • Tip lawn mower on its side as shown and drain oil into a suitable container. Rock lawn mower back and forth to remove any oil trapped inside of engine. • Wipe off any spilled oil on lawn mower and on side of engine. • Fill engine with oil. Fill only to the "FULL" line on the dipstick. DO NOT OVER FILL. • Replace engine oil cap. • Reconnect spark plug wire to spark plug. Container AIR FILTER Your engine will not run properly and may be damaged by using a dirty air filter. Replace the air filterevery year, more often if you mow in very dusty, dirtyconditions. Do not wash air filter. TO CHANGE AIR FILTER • Loosen screw and tilt cover to remove. • Carefully remove cartridge. • Clean by gently tapping on a flat surface. If very dirty, replace cartridge. ,ACAUTION: Petroleum solvents, such as kerosene, are not to be used to clean 10 ;artridge. They may cause deterioration of the cartridge. Do not oil cartridge. Do not use pressurized air to clean or dry cartridge. • Install cartridge, then replace cover making sure the tabs are aligned with the slots in the back plate. Fasten screw securely. Back plate Lip Cover tabs Slots Cover Ca_ddge CLEANING IMPORTANT: For best performance, kiip mower housing free of built-grass and trash. Clean the underside of your mower after each use. ACAUTION: Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with the spark plug. • Turn lawn mower on its side. Make sure air filter and carburetor are up. Clean the underside of your lawn mower by scraping to remove build-up of grass and trash. • Clean engine often to keep trash from accumulating. A clogged engine runs hotter and shortens engine life. • Keep finished surfaces and wheals free of all gasoline, oil,etc. • We do not recommend using a garden hose to clean lawn mower unless the electrical system, muffler, air filter and carburetor are covered to keep water out. Water in engine can result in shortened engine life. MUFFLER Inspect and replace corroded muffler as it could create a fire hazard and/or damage. SPARK PLUG Change your spark plug each year to make your engine start easier and run better. Set spark plug gap at .030 inch. 11 • Reassemble the starter rope guide. " • Reassemble the controls and the operator presence control bar to the upper handle. ShippingPosition Medium low Medium high A.CAUTION: Before performing any service and adjustments: • Release control bar and stop engine. • Make sure the blade and all moving parts have completely stopped. • Disconnect spark plug wire from spark plug and place where it cannot come in contact with plug. LAWN MOWER TO ADJUST cu'n'ING HEIGHT See "TO ADJUST CUTTING HEIGHT" in the Operation section of this manual. L REAR DEFLECTOR The rear deflector, attached between the rear wheels of your mower, is provided to minimize the possibility that objects will be thrown out of the rear of the mower into the operator's mowing position. If the deflector becomes damaged, it should be replaced. DISCHARGE _ High Low GUARD The discharge guard, attached to the discharge opening of your lawn mower, is provided to prevent the possibility of injury resulting from objects being thrown out of the discharge opening into the operator mowing position. If the discharge guard becomes damaged, it should be replaced. TO ADJUST HANDLE Your lawn mower handle can be raised or lowered for your mowing comfort. Four (4) positions are available: high, medium high, medium low and low. Handles are shipped mounted in the medium low position. • To change from medium low to medium high position, the upper and lower handle sections will have to be turned over. • Remove the cable clips. • Remove the controls and operator presence control bar from the upper handle. • Remove the starter rope guide from the upper handle. • Remove hairpin cotters. • Disconnect the lower handle from the handle brackets. • Turn the handle over and reassemble the hairpin cStters that have been removed. _.CAUTION: The operator presence control bar must pivot freely to permit blade/brake engagement when control bar is released. Do not overtighten the fasteners holding the controls to the upper handle. • To change from medium low to high position only the upper handle section will have to be turned over. • To change from medium low to low position, only the lower handle section will have to be turned over. Squeeze to remove Handle bracket Mountin pin Hairpin cotter ENGINE ENGINE SPEED Your_engine speed has been factory set. Do not attempt to increase engine speed or it may result in personal injury. If you believe that engine is running too fast or too slow, take your mower to an authorized service center for repair and adjustment. 12 CARBURETOR Your carburetor has a non-adjustable fixed main jet for mixture control. If your engine does not operate properly due to suspected carburetor problems, take your lawn mower to an authorized service center for repair and/or adjustment. IMPORTANT: Never tamper with the engine governor, which is factory set for the proper engine speed. Overspeeding the engine above the factory high speed scan be dangerous. If you think the engine-governed high speed needs adjusting, contact your nearest authorized service center, which has proper equipment and experience to make any necessary adjustments. Immediately 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. LAWN Operator presence control bar \_ Upper handle -......._/// MOWER ., When lawn mower is to be stored for a period of time, clean it thoroughly, remove all dirt, grease, leaves, etc. Store in a clean, dry area. • Clean entire lawn mower (See "CLEANING" in the Maintenance section of this manual). • Lubricate as shown in the Maintenance section of this manual. • Be sure that all nuts, bolts, screws, and pins are securely fastened. Inspect moving parts for damage, breakage and wear. Replace if necessary. • Touch up all rusted or chipped paint surfaces; sand lightly before painting. HANDLE You can fold your lawn mower handle for storage. • Squeeze the bottom ends of the lower handle toward each other untilthe lower handle clears the handle bracket, then move handle forward. • Loosen upper handle mounting bolts enough to allow upper handle to he folded back. IMPORTANT: When folding the handle for storage or transportation,be sure to fold the handle as shown oryou may damage the controlcables. • When setting up your handle from the storage position,the lower handle will automaticallylock into the mowing position. Lower handle Squeeze to <_ _'._ remove_ /. Hairpin r Fold forward for _ storage "_ f'J .=..... F",,, ,,Yl Fold ,y / boekward Mowing position Lower handle ENGINE FUEL SYSTEM IMPORTANT: It is importantto prevent gum deposits from forming in essential fuel system parts such as carburetor,fuel filter, fuel hose, or tank during storage. Also, experience indicates that alcohol blended fuels (called gasohol or using ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. • Drain the fuel tank. • Start the engine and let it run untilthe fuel lines and carburetor are empty. • Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur. • Use fresh fuel next season. NOTE: Fuel stabilizer is an acceptable alternative in minimizing the formation of fuel gum deposits during storage. Add stabilizerto gasoline in fuel tank or storage container. Always follow the mix ratiofound on stabilizer container. Run engine at least 10 minutes after adding stabilizer to allow the stabilizer to reach the carburetor. Do not drain the gas tank and carburetor ifusing fuel stabilizer. pin 13 ENGINE OIL OTHER • Do not store gasoline from one season to another. • Replace your gasoline can if your can starts to rust. Rust and/or dirt in your gasoline will cause problems. • If possible, store your unit indoors and cover itto give protectionfrom dust and dirt. • Cover your unitwith a suitable protective cover that does not retain moisture. Do not use plastic. Plastic cannot breathe which allows condensation to form and will cause your unitto rust. IMPORTANT: Never cover mower while engine and exhaust areas are still warm. ACAUTION: Never store the lawn Drain oil (with engine warm) and replace with clean engine oil. (See "ENGINE" in the Maintenance section of this manual). CYMNDER • Remove spark plug. • Pour one ounce (29 ml) of oil through spark plug hole into cylinder. • Pull starter handle slowly a few times to distribute oil. • Replace with new spark plug. mower with gasoline in the tank inside a building where fumes may reach an open flame or spark. Allow the engine to cool before storing in any enclosure. TROUBLESHOOTING PROBLEM Does not start CHART CAUSE CORRECTION • Dirty air filter. • Out of fuel. • Stale fuel. • Clean/replace air filter. • Fill fuel tank. • Drain tank and refill with fresh dean fuel. .o Drain fuel tank and carburetor and refilltank • Waterinfuel. with fresh gasoline. • Connect wire to plug. • Spark plug wire is disconnected. • Bad spark plug. • Loose blade or broken blade adapter. • Control bar in released position. • Control bar defective. 14 • Replace spark plug. • Tighten blade bolt or replace blade adapter. • Depress control barto handle. • Replace control bar. TROUBLESHOOTING CHART PROBLEM CAUSE CORRECTION Lossofpower • Rear of lawn mower housing or cutting blade dragging in heavy grass. • Cutting too much grass • Set to "Higher Cut" position. • Dirty air filter. • Buildupof grass, leaves, and trash under mower. • Too much oil in engine. • Walking speed too fast. • Set to "Higher Cut" position. • Clean/replace air filter. • Clean underside of mower housing. • Check oil level. • Cut at slower walking speed. Poor cut- uneven •Wom, bent or loose blade. • Wheel heights uneven. • Buildupof grass, leaves and trash under mower. Excessive vibration • Worn, bent or loose blade. • Bent engine crankshaft. Starter rope hard to pull • Engine flywheel brake is on when control bar is released. • Bent engine crankshaft. • Blade adapter broken. • Blade dragging in grass. • Replace blade.'Tightan blade bolt. • Set all wheels at same height • Clean underside of mower housing. • Replace blade. "lighten blade bolt. • Contact an authorized service center. • Depress controlbar to upper handle before pullingstarter rope. • Contact an authorized service center. • Replace blade adapter. • Move lawn mower to cut grass or to hard surface Grass catcher not filling (if so equipped) Hard to push • Cutting height too low. • Lift on blade wom off. • Catcher not venting air. • Raise cutting height. • Replace blade. • Clean grass catcher. • Grass istoo high or wheal height is too low. • Rear of lawn mower • Raise cutting height. housing or blade dragging in grass. • Grass catcher too full. housing one (1) setting higher. • Empty grass catcher. • Adjust handle height to suit. • Handle height position not right for you. 15 • Raise rear of lawn mower SERVICE 31 NOTES 32 XX o XXXX _o_o8_=__ _ 33 X_ _ BRIGGS & STRATI'ON ENGINE 969_ MODEL NUMBER 12HS02-1978-E1 968 6O6 971A 843 967 o _163 _134 % 124 _634 130 95 110_ 7 9_ o;i 34 BRIGGS & STRATTON ENGINE MODEL NUMBER 12H802-1978-E1 15 22 _54 625 9/ 51 383 306 lk REQUIRES SPECIAL TOOLS TO INSTALL SEE REPAIR INSTRUCTION MANUAL. 35 BRIGGS & STRA'I-FON _) 670A ENGINE _ 358 GASKET SET MODEL NUMBER 12H802-1978-E1 3 1 104 _) 634 977 CARBURETOR 134 617 127 617 GASKET SET I 121 CARBURETOR _88A 36 110 ° 634 KIT BRIGGS & _TRAI-rON MODEL NUMBER 12H802-1978-E1 ENGINE 1095 VALVE OVERHAUL GASKET SET 930 605 55 _332 455 i 461 37 1036 LABEL KIT - EMISSION [ BRIGGS & STRA'rTON KEY NO. 1 2 3 4 5 7 8 9 9A 10 11 12 13 15 16 20 22 23 24 25 PART NO. 493260 293708 299819 493279 214368 272916 495786 272481 272238 94650 231933 272198 94547 94880 498566 94388 399781 94220 94612 492177 222698 499429 499430 499431 499432 26 499425 27 28 499426 499427 499428 263190 499423 29 499424 32 33 34 35 40 45 94699 262651 262652 262224 93312 262204 DESCRIPTION • .... .... * • * MODEL NUMBER ENGINE KEY NO, Cylinder Assembly Bushing, Cylinder Seal, Oil Sump, Engine Head, Cylinder Gasket, Cylinder Head Breather Assembly Gasket, Valve Cover Gasket, Baffle Plate Screw, Hex Head Tube, Breather Gasket, Crankcase Screw, Cylinder Head Plug, Oil Drain Crankshaft Timing Gear Key Seal, Oil Screw, Hex Head Screw, Hex Head (Used in Hole Nearest Breather) Flywheel Key, Flywheel Piston Assembly, Standard Size Piston Assy. (.010" O.S.) Piston Assy. (.020" O.S.) Piston Assy. (.030" O.S.) Ring Set, Piston, Standard Size Ring Set (.010" O.S.) Ring Set (.020• O.S.) Ring Set (.030• O.S.) Lock, PistonPin Pin, Piston,Standard Size Rod, Connecting, Standard Size Screw, ConnectingRod Valve, Exhaust Valve, Intake Spring,Valve Retainer,Valve Spring Tappet, Valve PART NO. 46 47 51 54 55 56 58 498275 493737 272199 94526 497442 498144 280399 60 65 81 98 104 110 281434 94696 223664 94098 231371 - -- 117 121 124 494870 498260 94840 125 127 498170 --- 130 131 133 134 224908 493267 398187 398188 137 --- 163 187 188 188A 202 209 272653 298049 398540 94644 262579 263044 12H802-1978-E1 DESCRIPTION Gear, Cam Slinger, Oil • Gasket, Intake Elbow Screw, Hex Head Housing, Rewind Starter Pulley, Rewind Starter Rope, Rewind Starter (Cut To 88-5/8•) Grip, Starter Rope Screw, Phillips Lock, Muffler Screw Screw, Round Head "• Pin, Float Hinge •** Gasket, Sealing (Sold in Kit Only) Jet, Main Carburetor Kit Screw, Carburetor Mounting Carburetor •" Plug, Welch (Sold in Kit Only) Valve, Throttle Shaft, Throttle Float, Carburetor Valve, Inlet (Includes Seat) *•" Gasket, Bowl (Sold in Kit Only) • Gasket, Air Cleaner Hose, Fuel Screw, Hex Head Screw, Hex Head Link, Governor Spring, Governor Included in Gasket Set (497316) *" ••• Included in Carburetor Kit (498260) Included in both Carburetor Kit (498260), and Carburetor Gasket Set (498261) .... Included in both Gasket Set (497316), Set (497316) and Valve overhaul Gasket Set (498528). NOTE: All componentdimensionsgiven in U.S. inches 1 inch= 28.4 mm 38 BRIGG S & STRATTON KEY NO. PART NO. 227 492349 230 67072 258 94512 284 94511 300 497838 304 493293 305 94744 306 224324 307 94515 332 94877 333 802574 334 94731 337 802592 356 497833 358 497316 363 19069 383 89838 387 496115 447 95013 455 225121 456 281503 459 281505 481 94943 515 263073 523 495264 524 280393 525 495265 529 281299 562 94852 572 224328 592 231082 601 93053 605 225103 606 224815 608 497680 Includes: 94904 94908 613 94231 615 94474 616 263175 617 270344 620 499836 621 396847 625 497466 634 --° ENGINE DESCRIPTION Lever, Governor Washer, Thrust Screw, Hex Head Screw. Hex Head Muffler, Exhaust Housing. Blower Screw, Seres Shield, Cylinder Screw, Hex Head Nut, Flywheel Armature, Magneto Screw, Seres Plug, Spark Wire;. Ground Gasket Set Puller, Flywheel Wrench, Spark Plug Primer, Carburetor Screw, Hex Cup, Starter Retainer, Starter Pawl, Rachet Screw, Shoulder Spring, Retainer Cap, Oil Fifler * Seal, Filler Tube Tube. Oil Fill Grommet Bolt, Govemor Lever Baffle, Cylinder Nut, Hex Clamp, Hose Cover, Control Strap, Bracket Starter, Rewind MODEL NUMBER 12H802-1978-E1 KEY NO. 635 670 670A 741 842 843 847 851 869 870 871 922 923 925 930 957 966 967 968 969 3971 971A 972 975 977 1036 1095 2500 ---- PART NO. 66538 280512 493823 262598 280966 272616 495263 493880 213512 213513 262001 63709 262640 493442 261145 281136 397974 496116 491588 281340 94872 94873 94749 495224 493640 498261 499341 498258 12J802-2915 498826 RPM Settings: DESCRIP_ON Elbow,Spark Plug Spacer, Fuel Tank • Spacer, Bracket Gear, Timing • Seal, O-Ring Sleeve, Lever Tube Assembly,Oil Terminal,ignitionCable Seat, Intake Valve Seat, ExhaustValve Guide, ExhaustValve Guide, Intake Valve Spring,Brake BrakeAssembly Cover, Linkage Guard, Finger Cap, Fuel"tank Base, Air Cleaner Filter,Air Cover,Air Cleaner Screw, Hex Head Screw, Hsx Head Screw, Hex Head Tank, Fuel Bowl,Float Gasket Set, Carburetor Label Kit, Emission Gasket Set, Valve Overhaul ReplacementEngine ReplacementShortblock Low: 1900-2100; 3000-3200 High: Includedin Gasket Set (497316) Screw, Hex Nut, Hex Screw, Hex Head Fastener Crank, Governor "*" Seal, Intake Elbow Bracket, Carburetor Switch, Stop Tube, Fuel Intake *** Washer, Shaft (Sold in Kit Only) Includedin CarburetorKit (498260) Included in both CarburetorKit(498260), and CarburetorGasket Set (498261) ***t Included in both Gasket Set (497316), Sot (497316) and Valve overhaul Gasket Set (498528). NOTE: All componentdimensionsgiven in U,S. inches 1 inch= 25.4 mm 39 For the repair or replacement parts you need delivered directly to your home Call 7 am - 7 pm, 7 days a week 1-800-366-PART (1-800-366-7278) Para ordenar piezas con entrega a domicUio - 1-800-659-7084 For in-house major brand repair service Call 24 hours a day, 7 days a week 1-800-4-REPAIR (1-800-473-7274) Para pedir servicio de reparaci6n domicilio - 1-800-676-5811 a For the location of a Sears Parts and Repair Center in your area Call 24 hours a day, 7 days a week 1-800-488-1222 For information on purchasing a Sears Maintenance Agreement or to inquire about an existing Agreement Call 9 am - 5 pm, Monday-Saturday 1-800-827-6655 When requesting service or ordering parts, always provide the following information: • Product Type • Part Number • Model Number • Part Description SE /ARS Amenca's 166865 12.28.98 VB Repair Specianst$ Printed in U.S.A.