Cub Cadet 898C Lawn Mower User Manual

Operator’s Manual
21” Self-Propelled
Mower
Models 977A & E977C
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 Cub Cadet dealer or contact the service department, P.O. Box
361131 Cleveland, Ohio 44136-0019.
Cub Cadet LLC., P.O. Box 361131, Cleveland, Ohio 44136-0019
PRINTED IN U.S.A.
Form No.769-00483.fm
(11/2002)
TABLE OF CONTENTS
Content
Page
Important Safe Operation Practices...................................................................... 3
Slope Gauge......................................................................................................... 6
Assembling Your Lawn Mower ............................................................................. 7
Know Your Lawn Mower ....................................................................................... 9
Operating Your Lawn Mower ................................................................................ 10
Making Adjustments ............................................................................................. 11
Maintaining Your Lawn Mower ............................................................................. 13
Troubleshooting.................................................................................................... 17
Parts List............................................................................................................... 18
Engine Manual...................................................................................................... 23
FINDING MODEL NUMBER
This Operator’s Manual is an important part of your new lawn mower. It will help you assemble, prepare and
maintain the unit for best performance. Please read and understand what it says.
Before you start assembling your new equipment, please locate the model plate on the
equipment and copy the information from it in the space provided below. The information on
the model plate is very important if you need help from our Customer Support Department or
an authorized dealer.
•
You can locate the model number by standing at the operating position and looking down at the rear
of the mower deck. A sample model plate is explained below. For future reference, please copy the
model number and the serial number of the equipment in the space below.
(Model Number)
(Serial Number)
Copy the model number here:
Copy the serial number here:
CUB CADET LLC
P. O. BOX 361131
CLEVELAND, OH 44136
DEALER LOCATOR PHONE NUMBER: 877-282-8684
www.cubcadet.com
ENGINE INFORMATION
The engine manufacturer is responsible for all engine-related issues with regards to performance, powerrating, specifications, warranty and service. Please refer to the engine manufacturer’s Owner’s/Operator’s
Manual packed separately with your unit for more information.
CALLING CUSTOMER SUPPORT
If you have difficulty assembling this product or have any questions regarding the controls, operation or
maintenance of this unit, please call the Customer Support Department.
Call 1-877-282-8684 to reach a Customer Support representative. Please have your unit’s
model number and serial number ready when you call. See previous section to locate this
information. You will be asked to enter the serial number in order to process your call.
For more details about your unit, visit our website at www.cubcadet.com
2
SECTION 1: 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 this machine. Failure to comply with these instructions may result in personal
injury. When you see this symbol—HEED ITS WARNING.
WARNING: Engine exhaust, some of its constituents, and certain vehicle components contain or emit
chemicals known to State of California to cause cancer and birth defects or other reproductive harm.
WARNING: This machine 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 machine is capable of amputating hands and feet and throwing objects. Failure to
observe the following safety instructions could result in serious injury or death.
General Operation
7. Wear sturdy, rough-soled work shoes and closefitting slacks and shirts. Shirts and pants that cover
the arms and legs and steel-toed shoes are
recommended. Never operate this machine in bare
feet, sandals, slippery or light weight (e.g. canvas)
shoes.
8. Do not put hands or feet near rotating parts or
under the cutting deck. Contact with the blade can
amputate hands and feet.
9. A missing or damaged discharge cover can cause
blade contact or thrown object injuries.
10. Many injuries occur as a result of the mower being
pulled over the foot during a fall caused by slipping
or tripping. Do not hold on to the mower if you are
falling; release the handle immediately.
11. Never pull the mower back toward you while you
are walking. If you must back the mower away from
a wall or obstruction first look down and behind to
avoid tripping and then follow these steps:
a. Step back from the mower to fully extend
your arms.
b. Be sure you are well balanced with sure
footing.
c. Pull the mower back slowly, no more than
half way toward you.
d. Repeat these steps as needed.
5. Do not operate the mower while under the influence
of alcohol or drugs.
6. Do not engage the self-propelled mechanism on
units so equipped while starting engine.
7. 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.
8. Never operate the mower in wet grass. Always be
sure of your footing. A slip and fall can cause
serious personal injury. If you feel you are losing
your footing, release the blade control handle
1. 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 parts.
2. This machine 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.
3. Never allow children under 14 years old to operate
this machine. Children 14 years old and over
should read and understand the operation
instructions and safety rules in this manual and
should be trained and supervised by a parent. Only
responsible individuals who are familiar with these
safe operation rules should use this machine.
4. Thoroughly inspect the area where equipment is to
be used. Remove all stones, sticks, wire, bones,
toys and other foreign objects which could be
tripped over or picked up and thrown by the blade.
Thrown objects can cause serious personal injury.
Plan your mowing pattern to avoid discharge of
material toward roads, sidewalks, bystanders and
the like. Also, avoid discharging material against a
wall or obstruction which may cause discharged
material to ricochet back toward the operator.
5. To help avoid blade contact or a thrown object
injury, stay in the operator zone behind the handles
and keep bystanders, helpers, children and pets at
least 75 feet from the machine while it is in
operation. Stop machine if anyone enters the area.
6. Always wear safety glasses to protect your eyes
during equipment operation and while performing
an adjustment or repair. Thrown objects which
ricochet can cause serious injury to the eyes.
3
9.
10.
11.
12.
13.
14.
15.
16.
3. Do not mow on wet grass. Unstable footing could
cause slipping.
immediately and the blade will stop rotating within
three seconds.
Mow in daylight or good artificial light; walk, not run.
Stop the blade when crossing gravel drives,
walkways 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 are sure the blade has
stopped rotating.
Never operate mower without proper trail shield,
discharge cover, grass catcher, blade control
handle or other safety protective devices in place
and working. Never operate mower with damaged
safety devices. Failure to do so can result in
personal injury.
Muffler and engine become hot and can cause a
burn. Do not touch.
Only use parts and accessories made by the
original equipment manufacturer (O.E.M). Failure
to do so can result in personal injury.
If situations occur which are not covered in this
manual, use care and good judgment. Contact your
dealer for assistance. Call 1-877-282-8684 for the
name of your nearest dealer.
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. They do not
understand the dangers. Never assume that children
will remain where you last saw them.
1. Keep children out of the mowing area and under
the watchful care of a responsible adult other than
the operator.
2. Be alert and turn mower off if a child enters the
area.
3. Before and while moving backwards, look behind
and down for small children.
4. Use extreme care when approaching blind corners,
doorways, shrubs, trees, or other objects that may
obscure your vision of a child who may run into the
mower.
5. Keep children away from hot or running engines.
They can suffer burns from a hot muffler.
6. Never allow children under 14 years old to operate
a power mower. Children 14 years old and over
should read and understand the operation
instructions and safety rules in this manual and
should be trained and supervised by a parent.
Service
Safe Handling of Gasoline:
Slope Operation
1. To avoid personal injury or property damage use
extreme care in handling gasoline. Gasoline is
extremely flammable and the vapors are explosive.
Serious personal injury can occur when gasoline is
spilled on yourself or your clothes which can ignite.
2. Wash your skin and change clothes immediately.
3. Use only an approved gasoline container.
4. Never fill containers inside a vehicle or on a truck or
trailer bed with a plastic liner. Always place
containers on the ground away from your vehicle
before filling.
5. If possible, remove gas-powered equipment from
the truck or trailer and refuel it on the ground. If this
is not possible, then refuel such equipment on a
trailer with a portable container, rather than from a
gasoline dispenser nozzle.
6. Keep the nozzle in contact with the rim of the fuel
tank or container opening at all times until fueling is
complete. Do not use a nozzle lock-open device.
7. Extinguish all cigarettes, cigars, pipes and other
sources of ignition.
8. Never fuel machine indoors because flammable
vapors will accumulate in the area.
9. Never remove gas cap or add fuel while the engine
is hot or running. Allow engine to cool at least two
minutes before refueling.
Slopes are a major factor related to slip and fall
accidents which can result in severe injury. Operation
on slopes requires extra caution. If you feel uneasy on a
slope, do not mow it. Before operating this unit on a
slope or hilly area, use the slope gauge on page 6 to
measure slopes . If the slope is greater than 15
degrees, do not mow it.
Do:
1. Mow across the face of slopes; never up and down.
Exercise caution when changing direction.
2. Watch for holes, ruts, rocks, hidden objects, or
bumps which can cause you to slip or trip. Tall
grass can hide obstacles.
3. 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 rotating
within 3 seconds.
Do Not:
1. Do not mow near drop-offs, ditches or
embankments, you could lose your footing or
balance.
2. Do not mow slopes greater than 15 degrees as
shown on the slope gauge.
4
4. Mower blades are sharp and can cut. Wrap the
blade or wear gloves, and use extra caution when
servicing them.
5. Keep all nuts, bolts, and screws tight to be sure the
equipment is in safe working condition.
6. Never tamper with safety devices. Check their
proper operation regularly.
7. After striking a foreign object, stop the engine,
disconnect the spark plug wire and ground against
the engine. Thoroughly inspect the mower for any
damage. Repair the damage before starting and
operating the mower.
8. Never attempt to make a wheel or cutting height
adjustment while the engine is running.
9. Grass catcher components, discharge cover, and
trail shield are subject to wear and damage which
could expose moving parts or allow objects to be
thrown. For safety protection, frequently check
components and replace immediately with original
equipment manufacturer’s (O.E.M.) parts only,
listed here. Use of parts which do not meet the
original equipment specifications may lead to
improper performance and compromise safety.
10. Do not change the engine governor setting or
overspeed the engine. The governor controls the
maximum safe operating speed of the engine.
11. Maintain or replace safety and instruction labels, as
necessary.
12. Observe proper disposal laws and regulations.
Improper disposal of fluids and materials can harm
the environment.
10. Never over fill fuel tank. Fill tank to no more than ½
inch below bottom of filler neck to provide space for
fuel expansion.
11. Replace gasoline cap and tighten securely.
12. If gasoline is spilled, wipe it off the engine and
equipment. Move unit to another area. Wait 5
minutes before starting the engine.
13. Never store the machine or fuel container inside
where there is an open flame, spark or pilot light as
on a water heater, space heater, furnace, clothes
dryer or other gas appliances.
14. To reduce fire hazard, keep mower free of grass,
leaves, or other debris build-up. Clean up oil or fuel
spillage and remove any fuel soaked debris.
15. Allow mower to cool 5 minutes before storing.
General Service:
1. Never run an engine indoors or in a poorly
ventilated area. Engine exhaust contains carbon
monoxide, an odorless and deadly gas.
2. Before cleaning, repairing, or inspecting, make
certain the blade and all moving parts have
stopped. Disconnect the spark plug wire and
ground against the engine to prevent unintended
starting.
3. Check the blade and engine mounting bolts at
frequent intervals for proper tightness. Also,
visually inspect blade for damage (e.g., bent,
cracked, worn) Replace blade with the original
equipment manufacture’s (O.E.M.) blade only,
listed in this manual. “Use of parts which do not
meet the original equipment specifications may
lead to improper performance and compromise
safety!”
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.
1299 AC
•
5
SECTION 2: SLOPE GAUGE
Use this page as a guide to determine slopes where you may not operate safely. Do not operate your lawn mower
on such slopes.
FOL
D ON
D
OTT
ED
L IN E
15°
,
S EN
TI
NG A
15
° SL
O PE
OR A FENCE POST
A CORNER OF A BUILDING
A POWER POLE
SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE
R EP
RE
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.
Operate WALK-BEHIND mowers across the face of slopes, never up and down slopes.
6
SECTION 3: ASSEMBLING YOUR LAWN MOWER
Removing Unit From Carton
Setting Up Your Lawn Mower
•
Assembling Handle
•
•
•
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., grass
bag etc.), and save it appropriately.
Cut along corners, lay the carton down flat, and
remove all packing material.
Roll or slide unit out of carton and check carton
thoroughly for loose parts.
•
Lift up and pull back on the upper handle to raise
the handle into the operating position. See Figure
3. Make certain the lower handle is seated securely
into the handle bracket assemblies.
Handle Assembly
Loose Parts in Carton
1.
2.
3.
4.
Grass Bag
Grass Bag Adapter
Side Discharge Chute
Hardware Pack
Wing Nut
Handle Mounting
Bracket
Hardware Pack
Please identify each piece of the hardware pack as
shown in Figure 1.
Figure 3
•
•
Carriage Bolt
Wing Nut
Figure 1
•
Before Assembly
•
Before setting up your lawn mower, disconnect the
spark plug wire from the spark plug and ground
against the engine. See Figure 2.
Tighten wing nuts on each side of the handle
making sure that the carriage bolts are seated
properly into the handle. See Figure 3.
Remove hairpin clip from the outer hole of the weld
pin on each handle brackets. Using a pair of pliers,
squeeze one leg of the lower handle against the
handle bracket. Insert the hairpin clip into the inner
hole on the weld pin. Repeat on the other side. See
Figure 4.
After moving the hairpin clip, insert the carriage
bolt, from the hardware pack, in the upper hole on
the handle mounting bracket and secure with
plastic wing nut, also from the hardware pack. See
Figure 4. Repeat on the other side.
Carriage Bolt
Lower
Handle
Spark Plug
Inner Hole
Wire
Wing Nut
Hairpin
Clip
Handle Mounting
Bracket
Spark Plug
Figure 2
NOTE: Reference to right or left side of the mower is
observed from the operating position.
Figure 4
7
•
Fasten the cable to the lower handle with the two
cable ties found on the lower handle. Pull the cable
ties tight and trim off the excess. See Figure 5.
Grass Bag
Adapter
Cable Tie
Lower
Handle
Wing
Nuts
Figure 5
Figure 7
Attaching Starter Rope
•
NOTE: Make certain the drive cable is routed around
the outside and above the lower handle so it does not
interfere with attaching the grass bag.
•
•
Lift chute door on the grass bag adapter and slide
grass bag onto the adapter. See Figure 8.
NOTE: The chute door has been designed to move the
starter rope out of the way of the bag when the chute
door is opened.
The rope guide, which is connected to the support
rod, is located on the right side of the lower handle.
See Figure 6.
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. Release the blade control handle. Slip the
starter rope into the rope guide.
Chute
Door
Grass
Bag
Lower
Handle
Starter
Rope
Figure 8
Attaching Side Discharge Chute
Support
Rod
Rope
Guide
•
•
Figure 6
Remove mulching baffle or grass bag adapter from
unit by disconnecting wing nuts.
Attach side discharge chute to unit and secure with
the three wing nuts. See Figure 9 .
Attaching The Grass Bag
The mower was shipped with the mulching baffle
installed on the unit. You can keep this baffle on as long
as you want to mulch the grass clippings. For bagging
purposes, you will have to attach the grass bag and its
adapter in place of the mulching baffle.
•
•
Remove three wing nuts holding the mulching
baffle or side discharge chute in place and remove
the accessory from the unit.
Replace with grass bag adapter, while making
sure the front lip of adapter goes under the edge of
the deck. Secure with wing nuts previously
removed. See Figure 7 .
Side Discharge
Chute
Figure 9
8
SECTION 4: KNOW YOUR LAWN MOWER
Drive Clutch Control
Read this operator’s manual and safety rules before
operating your lawn mower. Compare the illustration in
Figure 10 with your lawn mower to familiarize yourself
with the location of various controls and adjustments.
Save this manual for future reference.
The drive clutch control is located on the upper handle.
Squeeze the drive control to engage the drive system.
Release the clutch control to disengage the drive
system. Release the clutch control to slow down when
approaching an obstacle, making a turn, or stopping. .
WARNING: The operation of any lawn
Shift Lever
mower can result in foreign objects being
thrown into the eyes, which can damage your
eyes severely. Always wear safety glasses
while operating the mower, or while performing
any adjustments or repairs on it.
The shift lever is located on the drive clutch control
housing on the upper handle. This lever is used to
select the forward speed of the mower. When changing
speed selection, release the drive clutch control.
NOTE: Move the shift lever only when the engine is
running. Changing the shift lever setting with the engine
off can damage the mower.
Blade Control Handle
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 blade
control handle to stop engine and blade.
Grass Bag
The grass bag is equipped with a bag-fill indicator
called a Grass Guage, to add convenience to your
work. While the mower is running, air will flow through
the bag and into the “sail.” If the grass catcher is empty,
air flows through easily pushing the sail up. If the grass
catcher is full, air does not flow through it allowing the
sail to fall. So the position of the sail acts as a bag-fill
indicator signifying when to empty the grass bag.
WARNING: This blade control mechanism is
a safety device. Never attempt to bypass its
operations.
Cutting Height Adjustment Levers
The cutting height adjustment lever is located above
the left rear wheel. To adjust the cutting height, refer to
the Adjustment Section in this manual.
Mulching Plug
Recoil Starter
The mulching plug is used only for mulching purposes.
Instead of collecting grass clippings in a grass catcher,
this mower has the option of recirculating the clippings
back to the lawn.
The recoil starter is attached to the right upper handle.
Stand behind the unit and pull the recoil starter rope to
start the unit.
Blade Control Handle
Electric Start Switch (Model E977 only)
Drive Clutch
Grass Guage
Shift Lever
Recoil Starter
Gas Cap
Grass Catcher
Side-Discharge
Mulch Plug
Chute
Figure 10
9
Height Adjustment
Lever
SECTION 5: OPERATING YOUR LAWN MOWER
WARNING: Read, understand, and follow all
•
instructions and warnings on the machine and
in this manual before operating.
•
NOTE: For shipping purposes your mower is set with
the wheels in a low cutting height position. For best
results, raise the cutting position until it is determined
which height is best for your lawn. See the Adjustment
Section for details.
WARNING: Do not remove the battery pack
from the handle panel for any reason other
than replacement. When replacing the battery
pack, refer to instructions on page 16.
Gas & Oil Fill-Up
•
•
outlet. See Figure 11. Follow this order of action
every time you charge the battery.
Charge battery for 16 hours before initial use. Do
not charge longer than 20 hours.
After charging, disconnect battery charger plug
from household outlet first, then disconnect charger
lead from battery pack lead.
Check oil level and add oil if necessary. Follow
relevant instructions in the engine manual for this.
Service the engine with gasoline as instructed in
the engine manual.
•
•
WARNING: Use extreme care when
handling gasoline. Gasoline is extremely
flammable and the vapors are explosive. Never
fuel the machine indoors or while the engine is
hot or running. Extinguish cigarettes, cigars,
pipes and other sources of ignition.
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 for proper drive clutch operation using the
neutral adjustment test described below.
Neutral Adjustment Test
To perform the neutral adjustment test, answer the
following questions.
•
Before Starting Mower
•
Charging the Battery (Model E977 only)
•
IMPORTANT: Use only the battery charger supplied with
•
this mower.
WARNING: The battery contains corrosive
•
fluid and toxic material; handle with care. Keep
away from children. Do not puncture,
disassemble, mutilate or incinerate the battery.
Explosive gases could be vented during
charging or discharging. Use in a well
ventilated area, away from sources of ignition.
With the drive clutch control released, push mower
forward and pull it backward. Does it move freely?
Squeeze the drive clutch control and pull the
mower backward. Do the rear wheels lock?
Is the drive clutch control cable free of kinks or
sharp bends?
If you answered “yes” to all three questions, your
mower passed the test and you can start your
mower.
If you answered “no” to any of the three questions,
you will have to adjust the drive clutch control as
instructed in the ADJUSTMENT SECTION.
Starting Engine
WARNING: Be sure no one other than the
operator is standing near the lawn mower while
starting engine or operating mower.
Protective
Cap
WARNING: Never run engine indoors or in
enclosed, poorly ventilated areas. Engine
exhaust contains carbon monoxide, an
odorless and deadly gas.
Battery
pack
lead
WARNING: Keep hands, feet, hair and
loose clothing away from any moving parts on
engine and lawn mower.
WARNING: When starting the unit for the
Figure 11
•
first time, face the mower against a wall or a
fence. Start the unit and if it shows any signs of
motion while the drive clutch control is still
disengaged, shut engine off immediately.
Remove the protective cap from the end of the
battery pack lead. Always plug charger lead into
battery pack lead first, and then insert battery
charger plug into 120 volt standard household
10
•
•
•
•
•
Push primer once. Do not prime to restart a warm
engine after a short shutdown.
Standing behind the mower, depress the blade
control handle and hold it against the upper handle.
Electric Start: Turn the ignition key to the right to
start the engine. Release the key after the engine
starts.
Recoil Start: Grasp starter handle and pull rope
out slowly until engine reaches 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.
IMPORTANT: Move the shift lever only when the engine
is running. Changing the shift lever setting with the
engine off can cause damage to the mower.
WARNING: If the mower strikes a foreign
object, stop the engine. Remove spark plug
wire from the spark plug and thoroughly inspect
for any damage. Repair the damage promptly
before restarting and operating the mower.
Mulching
Stopping Engine
•
•
For effective mulching, do not cut wet grass. New or
thick grass may require a narrower cut. If the grass has
grown in excess of 4”, mulching is not recommended.
Mow using the side discharge to reduce the grass
height to 3.25” maximum before mulching.
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
Bagging Grass Clippings
WARNING: Never operate the mower
You can use the grass catcher bag to collect clippings
while you are operating the mower.
unless the hooks on the grasscatcher are
seated in the slots on the handle bracket
assemblies, and the rear discharge door rests
firmly against the top of the grasscatcher.
•
•
•
•
Do not operate the mower without any one of the
mulching baffle, discharge chute or grass catcher
properly installed.
WARNING: 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 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.
•
For best results, do not cut wet grass. It may stick to
the underside of the mower, preventing proper
discharge of grass clippings, and could cause you
to slip and fall. New grass or thick grass may
require a narrower cut.
Attach grass catcher following instructions on page
8 of this manual. Grass clippings will automatically
collect in the bag as you run the mower.
Operate the mower till the grass bag is full.
Stop engine completely by releasing the blade
control handle. Make sure that the unit has come to
a complete stop.
While holding the grass bag by both the rear handle
and the lower handle, lift the grass bag straight up
off the adapter. The chute door will move the rope
out of the way of the bag.
Continue to hold the lower handle and raise the
rear of the grass bag up toward your chest. The
grass bag will open and the grass clippings will
disperse. When replacing the grass bag, be sure
the top of the bag rests on the wire support
between the handles.
SECTION 6: MAKING ADJUSTMENTS
•
•
WARNING: Do not at any time make any
adjustments without first stopping engine and
disconnecting spark plug wire.
Handle Height
•
Your mower is shipped with the handle in the higher
height position. To lower the height, proceed as follows:
11
Remove the starter rope from the rope guide.
Remove the wing nuts and carriage bolts securing
the upper handle. Remove and 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 and remove the wing nuts and
carriage bolts from the upper hole on the handle
mounting bracket.
•
•
Press out on the legs of the lower handle and
remove lower handle from the mower.
Turn lower handle around so the notch on the
bottom of the lower handle is facing forward.
See Figure 12.
Bottom View
Upper
Handle
Adjustment
Wheel
Notch
Lower Handle
Shift Lever
Drive Clutch
Control
Figure 13
Figure 12
•
•
•
•
NOTE: For some people the drive clutch control may
not be in a comfortable position. You can adjust the
handle out by tightening the adjustment wheel.
Reassemble the handles, placing the bottom holes
in the handle over the weld pins in the handle
mounting bracket.
Place the hairpin clips in the inner holes in the weld
pins and insert the carriage bolts through the upper
hole on the handle mounting bracket and secure
with plastic wing nuts.
Reassemble the upper handle to the lower handle.
Attach the starter rope as instructed on page 8.
Shift Lever Cable
Periodic adjustment of the six speed shift cable may be
necessary due to normal wear on the cable. Adjustment
is needed if all six speeds do not work.
The adjustable cable bracket is located on the left side
of the mower beside the engine. See Figure 14.
Cutting Height
Adjustable Cable
Bracket
Your mower is shipped with the cutting height in the
lowest position. The cutting height adjustment lever is
located above the left rear wheel. To adjust the cutting
height, proceed as follows:
•
Hex Nut
Pull the lever out and away from the mower and
then move it forward or backward to another slot.
For rough or uneven lawns, move the height
adjustment lever to a higher position. This will help
stop scalping.
PUSH
Figure 14
Drive Clutch Control
•
The adjustment wheel is located in the drive clutch
control handle housing and is used to tighten or loosen
the drive belt. You will have to adjust the drive clutch
control if any of the following happens:
•
•
1. The mower does not propel itself with the drive
clutch engaged.
2. 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.
•
Start engine and place shift lever in the sixth speed
position. Refer to Figure 13.
Stop engine and disconnect spark plug wire and
ground it against engine.
Loosen hex nut which secures the adjustable cable
bracket. See Figure 14.
Push back on the adjustable cable bracket and
tighten hex nut.
Engine Adjustments
Refer to the engine manual for these adjustments.
12
SECTION 7: MAINTAINING YOUR LAWN MOWER
•
WARNING: Always stop the engine and
disconnect the spark plug wire before
performing any maintenance work or
adjustments on your lawn mower.
Cleaning Mower
Lubrication
The underside of the mower deck should be cleaned
after each use to prevent any build-up of debris. If
allowed to accumulate, it will cause rust and corrosion.
Refer to the lubrication chart in Figure 15.
Blade Control Handle
NOTE: We do not recommend the use of pressure
washers or garden hose to clean your unit. These may
cause damage to electric components, spindles,
pulleys, bearings, or the engine. The use of water will
result in shortened life and reduce serviceability.
•
•
•
•
•
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 150o F.
•
Lubricate the pivot points on the blade control
handle at least once a season with light oil. The
blade control must operate freely in both directions.
Rear Discharge Door
•
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.
Lubricate the torsion spring and the pivot point on
each end of the rear discharge door using a light oil.
This will prevent rusting of the discharge door.
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.
Engine
•
WARNING: Never tip the mower more than
Follow the engine manual instructions and
recommended schedule for lubricating engine
components.
90 degrees in any directions and do not leave
the mower tipped for any length of time. Oil can
drain into the upper part of the engine causing
a starting problem.
Lubricate
Engine Care
Lubricate
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 regularly, as instructed in the
engine manual. Check oil level before starting
engine every time. Change oil while the engine is
warm, not hot or cold.
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.
Clean the engine periodically. Remove dirt and
debris with a cloth or brush.
Clean the spark plug and reset the gap to .030” at
least once a season. Refer to the engine manual for
correct spark plug type.
Lubricate
Figure 15: Lubrication Chart
13
SECTION 8: SERVICING THE MOWER
•
WARNING: Always stop the engine and
disconnect the spark plug wire before
performing any maintenance work or
adjustments on your lawn mower.
•
Blade Care
•
WARNING: When removing the cutting
Place the blade on the adapter. Be certain the
blade is aligned and seated on the blade adapter
flanges.
Place blade bell support on blade. Make sure the
notches on the blade bell support are aligned with
small holes in the blade.
Replace hex bolt and tighten hex bolt to torque: 450
in. lbs. min., 600 in. lbs. max.
NOTE: To ensure safe operation of your mower,
periodically check the blade bolt for correct torque.
blade for sharpening or replacement, protect
your hands with a pair of heavy gloves or use a
heavy rag to hold the blade.
Blade
Adapter
Periodically inspect the blade adapter for cracks,
especially if you strike a foreign object. Replace when
necessary.
Blade Bell
Support
Removing the Blade
•
•
•
•
Disconnect spark plug wire from spark plug.
Turn mower on its side making sure that the air filter
and the carburetor are up.
Remove the bolt and the blade bell support which
hold the blade and the blade adapter to the engine
crankshaft. See Figure 16.
Remove the blade and the adapter from the
crankshaft.
Hex Bolt
Figure 16
Sharpening the Blade
Drive Belt Replacement
•
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.
•
WARNING: An unbalanced blade will cause
•
•
•
•
excessive vibration when rotating at high
speeds. It may cause damage to the mower,
and could break causing personal injury.
•
•
Balancing the Blade
•
The blade can be tested by balancing it on a round
shaft screwdriver. Remove metal from the heavy
side until it balances evenly. It is recommended that
the blade always be removed from the adapter
when testing for balance.
Disconnect the spark plug wire and ground it
against the engine.
Drain the fuel tank or place a piece of plastic
beneath the cap to prevent gasoline leakage.
Place shift lever in the first position and tip the
mower on its side with air filter facing up.
Remove the center bolt which secures the blade to
the crankshaft followed by blade bell support,
blade, and blade adapter.
Move the cutting height adjustment to the highest
position.
Remove the three hex screws holding the baffle to
the deck and pivot baffle towards the rear of the
mower. See Figure 17.
Installing the 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.
Be sure to install the blade with the side of the
blade marked “Bottom” (or with part number) facing
the ground when the mower is in the operating
position.
Slide the blade adapter onto the engine crankshaft.
Baffle
Figure 17
14
•
•
Remove the hex bolt from the rear of unit holding
the transmission to the mower housing.
See Figure 18.
•
Wheel
•
•
Hex Bolt
•
•
•
Cutting Height
Adjustment
Wheel
Figure 18
•
Pivot the control arm down away from the pulley
and belt.
Lift off the lower pulley assembly and remove the
old belt from around the crankshaft.
Place the new belt over the transmission pulley.
Start the belt in the pulley groove and rotate the
pulley until the belt is seated in transmission pulley.
Place the belt between the idler pulley and the belt
keeper bracket.
Using pliers, rotate the belt keeper bracket so that it
snaps into slot on the idler bracket.
Tighten the idler pulley bolt and lock nut half a turn.
Place the belt between the two pulley halves on the
crankshaft. Make sure to route the belt inside the
belt guard pin. See Figure 21.
Upper Pulley
Half
Tilt the transmission forward and loosen the idler
pulley bolt and lock nut half a turn. See Figure 19.
Tab
Transmission
Pulley
Belt
Belt
Belt Keeper
Bracket
Idler Pulley
Bracket
Transmission
Figure 21
Idler Pulley
Bolt and
Locknut
IMPORTANT: When replacing the belt, do not disas-
semble the lower pulley assembly.
•
Figure 19
•
•
•
Using a pair of pliers, pull back and rotate belt
keeper bracket from the slot on the idler pulley.
Slide the belt out from between the belt keeper
bracket and the idler pulley.See Figure 19.
Squeeze the belt together and push it forward,
while pressing the control arm inward towards the
deck and remove the six speed cable from the slot.
See Figure 20.
Six-Speed
Cable Slot
Lower Pulley
Half
Belt
Guard Pin
Pinch both sides of the belt together so that the belt
is not in the pulley groove, and the lower pulley can
be pushed towards the engine. See Figure 22.
Lower Pulley
Half
Belt
Belt
Control
Arm
Belt
Guard Pin
Figure 22
•
Figure 20
15
Pivot the control arm back to its original position
and reinstall the six-speed cable into the slot.
See Figure 23.
•
Six-Speed
Cable Slot
Attach the new flap and new rod to deck, bending
the ends of the new rod over to secure to deck.
Replacing Battery Pack
(Model E977 only)
•
•
Control
Arm
Figure 23
•
•
•
•
•
Make sure the belt is routed inside the pulley halves
and the belt guard pin.
Reinstall the bolt securing transmission to rear
mower housing.
Pivot the baffle back to its original position and
secure with three hex screws removed earlier.
Lightly lubricate the inside of the blade adapter and
reinstall the spacer, wave washer, blade adapter
assembly, and blade in the correct order.
Tighten the hex bolt to secure the blade to torque:
450-600 in. lbs.
WARNING: Batteries contain sulfuric acid
which may cause burns. Do not short circuit or
mutilate batteries in any way. Do not put
batteries in fire as these may burst or release
toxic materials.
In-line Fuse
(Model E977 only)
The unit is equipped with an in-line fuse. If the unit fails
to start, check the fuse inside the battery cover by
turning the end of the fuse holder and removing from
the battery cover. Replace with standard automotive 71/2 amp fuse.
Replacing Rear Flap
•
Remove the battery pack from the handle panel for
replacement only. Do not separate the batteries for
any reason. Dispose of batteries properly.
When replacing battery pack in handle panel,
battery pack must be positioned with the positive
terminal to the right side and the negative terminal
to the left side of the panel. Replacing the battery
pack incorrectly will cause serious damage. The
positive lead on the wire harness has the smaller
connector. Connect the positive lead to the positive
side of the battery pack, then connect the negative
side.
To remove rear flap, cut off the flat end of the wire
rod which secures it to the deck.
SECTION 9: OFF-SEASON STORAGE
Storing Your Lawn Mower
•
The following steps should be taken to prepare your
lawn mower for storage.
•
•
Clean and lubricate mower thoroughly as described
in the lubrication instructions.
NOTE: When storing any type of power equipment in a
poorly ventilated or metal storage shed, care should be
taken to rust-proof the equipment. Using a light oil or
silicone, coat the equipment, especially cables and all
moving parts.
IMPORTANT: We do not recommend the use of a
pressure washer or garden hose to clean your unit.
•
Coat mower’s cutting blade with chassis grease to
prevent rusting.
Store mower in a dry, clean area. Do not store next
to corrosive materials, such as fertilizer.
Refer to engine manual for correct engine storage
instructions.
16
SECTION 10: TROUBLESHOOTING
Problem
Cause
Remedy
Engine fails to start
1.
2.
3.
4.
5.
6.
Blade control handle disengaged.
Spark plug wire disconnected.
Fuel tank empty or stale fuel.
Blocked fuel line.
Faulty spark plug.
Engine flooded
1.
2.
3.
4.
5.
6.
Engage blade control handle.
Connect wire to spark plug.
Fill tank with clean, fresh gasoline.
Clean fuel line.
Clean, adjust gap, or replace.
Wait a few minutes to restart, do not
prime.
Engine runs erratic
1.
2.
Spark plug wire loose.
Blocked fuel line or stale fuel.
1.
2.
3.
4.
5.
6.
Vent in gas plugged.
Water or dirt in fuel system.
Dirty air cleaner.
Carburetor out of adjustment.
3.
4.
5.
6.
Connect and tighten spark plug wire.
Clean fuel line; fill tank with clean, fresh
gasoline
Clear vent.
Drain fuel tank. Refill with fresh fuel.
Clean air cleaner.
Adjust carburetor.
Engine overheats
1.
2.
3.
Engine oil level low.
Air flow restricted.
Carburetor not adjusted properly.
1.
2.
3.
Fill crankcase with proper oil.
Remove blower housing and clean.
Adjust carburetor.
Occasional skip (hesitates)
at high speed
1.
Spark plug gap too close.
1.
Adjust gap to .030”.
Idles poorly
1.
2.
3.
Spark plug fouled, faulty or gap too
wide.
Carburetor improperly adjusted.
Dirty air cleaner.
1.
2.
3.
Reset gap to .030” or replace spark plug.
Adjust carburetor.
Clean air cleaner.
1.
2.
Cutting blade loose or unbalanced.
Bent cutting blade.
1.
Tighten blade and adapter. Balance
blade.
Replace blade.
Excessive vibration
2.
Mower will not mulch grass
Uneven cut
1.
Wet grass.
1.
2.
Excessively high grass.
2.
3.
Dull blade.
3.
1.
Wheels not positioned correctly.
1.
2.
Dull blade.
2.
17
Do not mow when grass is wet; wait until
later to cut.
Mow once at a high cutting height, then
mow again at desired height or make a
narrower cutting path.
Sharpen or replace blade.
Place all four wheels in same height
position.
Sharpen or replace blade.
SECTION 11: PARTS LIST FOR MODELS 977 & E977
1
2
3
4
15
14
8
5
17
9
7 6
12
20
18
13
10
19
16
11
35
36 37
38
21
43
88
42
44
89
40
41 45
48
50
57
54
52
94
28
27
56
39
33
32 34
49
46
51
55
53
57
59
45
90
62
29
91
63
64
92
66
31
33
67
65
47
58
61
68
69
70
73
71
72
76
77
74
75
78
79
81
80
30
IMPORTANT: For a proper working
machine, use Factory Approved Parts.
V-BELTS are specially designed to engage
and disengage safely. A substitute (non
OEM) V-Belt can be dangerous by not
disengaging completely.
82
83
84
85
86
87
18
60
Models 977 & E977
Ref.
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
Part No.
647-04008
731-0904A
16864
731-0620
713-0397
732-0627
731-0924
731-0905A
710-1667A
731-0906
746-0711A
712-0324
746-0883
710-1270
746-04055
749-0439D
720-0284
736-0451
710-1174
726-0240
749-0907B
731-1901
732-0842
631-0066
731-1832
731-1833
782-0078B
712-0397
710-0703
746-0939
782-7574A
736-0270
712-0287
710-0167
712-0138
782-7575A
736-0329
756-0625
738-0924
714-0104
736-0286
782-0565
734-2010
712-0414
16855
10622B
Description
Ref.
Part No.
No.
52. 748-0381
748-0188B
53. 738-0137A
54. 748-0318
55. 736-0270
56. 710-0751
57. 731-0982A
58. 738-0102
59. 736-0504
60. 734-2008A
61. 736-0105
62. 710-1348
63. 710-0896
64. 710-0654A
65. 611-0064
66. 736-0204
67. 710-0703
68. 710-1242
69. 741-0492A
70. 710-1241
71. 731-1836
72. 754-0460
73. 656-0613
74. 750-1071
75. 750-1070
76. 782-7597
77. 710-0654A
78. 782-7596
79. 732-0807
80. 711-1114
81. 736-0526
82. 731-1828
83. 710-0653
84. 753-0609
85. 742-0741
86. 736-0524A
87. 710-1257
88. 731-1874
89. 732-0819
90. 726-0111
91. 747-0965
92. 731-1713B
94. 682-3052
682-3053
95. 682-7527
Control Handle
Upper Control Handle
6 Spd. Rack Cable Bracket
Control Lever
Gear Insert
Shift Lever Spring
6 Speed Shift Lever
Lower Control Housing
C Sunk Tap Screw #10 x .75 Lg
Cable Mounting Cap
Drive Cable 51.0
Top Lock Nut 1/4-20
Control Housing
Oval C-Sunk Screw
Control Cable
Upper Handle
Wing Nut
Saddle Washer .320 ID x .830 OD
Carriage Bolt 5/16-18 x 2.0
Cable Tie
Lower Handle
Trail Shield
Trail Shield Wire
Chute Assembly
Side Discharge Chute
Mulch Cover
Deck 21”
Wing Nut
Carriage Bolt 1/4-20 x .75
6 Speed Cable
Cable Adjustment Bracket
Bell Washer .265 ID x .75 OD
Hex Nut 1/4-20
Carriage Screw 1/4-20 x .50
Hex Nut 1/4-28
Cable Mounting Bracket
Lock Washer 1/4
Roller Cable
Shoulder Screw .375 ID x 1/4-14
Cotter Pin
Bowed Washer
Single Lever Control Arm
Wheel 9 x 2.125
Top Lock Tab Weld Nut 1/4-20
Ratchet Pawl Plate
Plastic Spring Ratchet
19
Description
Pawl RH
Pawl LH
Shld Screw .340 ID x .285 OD
Wheel Rachet
Bell Washer .265 ID x .75 OD
Hex Cap Screw 1/4-20 x .620
Hubcap
Shoulder Screw .498 x 1.445
Wave Washer .510 ID x .750 OD
Wheel 8 x 2.125
Spring Washer .401 ID x .870 OD
Screw 1/4-14 x .500
Screw 1/4-14 x .625
Hex Washer Screw 3/8-16 x 1.0
Front Axle Assembly
Flat Washer .344 ID x .62 OD
Carriage Screw 1/4-20 x .75
Torx Screw
Block Bushing
Hex Washer Screw
Front Axle Cover
Belt 3/8 x 39.24
Pulley Assembly
Sleeve Spacer .88 ID x 1.13 OD
Sleeve Spacer .88 ID x 1.00 OD
Pivot Bracket
Screw 3/8-18 x 1.0
Control Arm
Torsion Spring
Pivot Shaft
Wave Washer 1.38 ID x .88 OD
Baffle
Screw 1/4-20 x 3.75
Blade Adapter Kit
21” Mulching Blade
Blade Bell Support
Hex Bolt 3/8-24 x 2.5
Chute Door
Torsion Spring
Push Cap
Pivot Rod
Discharge Chute
Handle Bracket Assembly - RH
Handle Bracket Assembly - LH
Cup Assembly (Part of #73)
Models 977 & E977
1
2
15
16
8
3
17
28
27
11
4
26
5
6
25
9
24
7
10
18
12
21
14
29
7
13
23
14
22
30
19
7
31
30
20
33
32
34
60
35
36
59
37
38
40
39
43
41
42
44
45
61
46
48
47
49
51
58
52
62
50
53
56
54
55
63
57
20
Models 977 & E977
Ref.
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Part No.
720-0223
732-0803A
738-0529
710-0751
736-0270
748-0318
736-0369
682-0531
750-0515
741-0978
750-1056
710-0653
682-7528
741-0324
682-7526
618-0263A
710-0604A
713-0453
638-0012
741-0522
732-0832
750-0151
710-1315
711-0835
750-0807
782-0568
710-1652
714-0474
712-3025
736-0425
756-0656
736-3084
Ref.
No.
Part Description
Grip
Spring Lever
Shoulder Nut .825 x .165 Lg.
Cap Screw 1/4-20 x .620
Bell Washer .285 ID x .75 OD
Wheel Rachet
Flat Washer .508 ID x 1.0 OD
Pivot Arm Assembly
Spacer .510 ID x .70 OD
Sleeve Bearing .504 ID x .830 OD
Shoulder
Tap Screw 1/4-20 x .375
Chain Cover Assembly
Flange Bearing .506 ID x .590 Lg
Transmission Axle Assembly
Transmission Assembly Complete
Hex Screw 5/16-18
Chain
Rear Axle Assembly
Flange Bearing .506 ID x .715 Lg
Torsion Spring
Spacer .550 ID x .750 OD
Screw 3/8-16 x .25
Clevis Pin .50 Dia x 4.82 Lg.
Spacer .385 ID x .624 OD
Hgt Adjustment Spring Bracket
Screw 1/4-14 x .825
Cotter Pin
Hex Jam Nut 5/16-24
Bell Washer .325 ID x .930 OD
Pulley
Flat Washer .510 ID x 1.120 OD
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
21
Part No.
712-0896
782-7598
741-0600
732-0849A
750-1050
682-0027A
710-0299
741-0682A
736-0570
721-0329
721-0325
618-0253
782-7601A
741-0690
736-0616
782-7595
741-0324
711-1168
717-1469
741-0674
717-1487
736-0314
736-0569
618-0252
710-0642
611-0066
664-0121
747-0940A
747-0939
747-0937
631-0071
Part Description
Hex Jam Nut 1/4-28
Belt Keeper
Bearing
Extension Spring
Flange Spacer
Idler Bracket Assembly
Hex Cap Screw 1/4-28 x 1.0
Bearing Sleeve
Flat Washer .885 ID x 1.45 OD
Oil Seal
Plug
Upper Housing Assembly
Cable Bracket
Bearing
Thrust Washer .504 ID x .70 OD
Pivot Bracket
Flange Bearing
Output Shaft 6T
Gear 34T
Bearing
Pinion Shaft 10T
Thrust Washer 3/8 x .70
Thrust Washer .388 x .625
Lower Housing Assembly
Hex Screw 1/2-20 x .75
Shaft Assembly
Grassbag
Support Rod w/ Rope Guide
Pivot Rod
Grassbag Frame
Grassbag Cover
Model E977
1
2
3
8
5
10
12
15
9 7
13
16
6
11
9
14
17
4
20
18
19
Ref. No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Part No.
725-0201
725-0873
731-0891A
725-0727
725-0298
725-1428
725-1276
710-0501
736-0270
712-0329
725-1206
712-0267
736-0242
712-0287
710-1250
710-0111
782-9012
710-0969
725-1538
625-0022
Description
Ignition Key
Key Switch
Battery Tray
Battery Charger
Fuse 7.5 Amp
Fuse Holder
Battery 12V
Hex Screw:1/4-20:2.0
Bell Washer
Special Hex Nut 5/16-18
Plug
Nut 5/16-18
Bell Washer
Hex Nut 1/4-20
Carriage Bolt
Carriage Screw
Lower Battery Tray
Tapp Screw
Harness Extension
Harness
Safety & Decorative Labels
Some of the labels found on your mower are represented here with the corresponding part numbers. Please use
part numbers when ordering replacement labels.
777S30118
777I20291
777S30128
777S30116
WA R N I N G
TO A
ER
MOW R
U N L V OID THE R
O
PERATE
E N T E S S S I D E ISK OF INJURY, NEVER O L C H P L U G E .
IRE
CHUTE DEFLECTOR, MU
LAC
GRA
ER P
I F D A S S C A T C H E R I S I N I T ' S P R O PE L Y .
MAGED,
REPLACE IMMEDIAT
777S30145
TO REDUCE THE RISK OF INJURY, DO NOT
OPERATE UNLESS DISCHARGE COVER OR
GRASS CATCHER IS IN ITS PROPER PLACE.
IF DAMAGED, REPLACE IMMEDIATELY.
777D06697
AVOID SERIOUS INJURY OR DEATH
• KEEP HANDS AND FEET AWAY FROM
ROTATING PARTS.
• REMOVE OBJECTS THAT CAN BE THROWN
BY THE BLADE 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.
READ OPERATOR'S MANUAL . KEEP SAFETY DEVICES (BLADE CONTROL, TRAILING SHIELD,
DISCHARGE COVER, ETC.) IN PLACE AND WORKING. IF DAMAGED, REPLACE IMMEDIATELY.
22
SAFETY AWARENESS
WARNING: Whenever you see the symbols shown on the left, heed their instructions! Always follow safe
operating and maintenance practices.
FORWARD
We wish to thank you for purchasing this Kawasaki engine. Please read this Owner's manual carefully before
starting your new engine so that you will be thoroughly familiar with the proper operation of your engine's
control, its features, capabilities and limitations. Also read the manual of the equipment to which this engine
is attached. To ensure a long, trouble-free life for your engine, give it the proper care and maintenance
described in this manual.
Always keep this manual at your fingertip so that you can refer to it whenever you need information. This
manual should be considered a permanent part of the engine and should remain with the engine when it is
sold. All rights reserved. No part of this publication may be reproduced without our prior written permission.
This publication includes the latest information available at the time of printing. However, there may be minor
differences between the actual product and illustrations and text in this manual. All products are subject to
change without prior notice or obligation.
EMISSION CONTROL INFORMATION .................................................. 24
GENERAL INFORMATION ..................................................................... 26
FUEL AND OIL RECOMMENDATIONS.................................................. 27
PREPARATION ...................................................................................... 27
Fuel............................................................................................. 27
Engine Oil ................................................................................... 27
STARTING. ............................................................................................. 28
Starting Engine ........................................................................... 28
OPERATING ........................................................................................... 28
Anti-engine inclination................................................................. 28
STOPPING.............................................................................................. 28
Stopping Engine ......................................................................... 28
ADJUSTMENT ........................................................................................ 29
Engine Speed Adjustment .......................................................... 29
MAINTENANCE ...................................................................................... 29
Periodic Maintenance Chart ....................................................... 29
Oil Level Check........................................................................... 29
Oil Change.................................................................................. 29
Air Cleaner Service..................................................................... 30
Spark Plug Service ..................................................................... 30
STORAGE............................................................................................... 31
TROUBLESHOOTING GUIDE................................................................ 33
ENVIRONMENTAL PROTECTION......................................................... 33
SPECIFICATIONS .................................................................................. 33
23
ENGINE MANUAL
Engine Manual for Kawasaki Engine
READ THIS FIRST
WARNING: Never allow children to operate the engine or equipment.
Keep people and pets out of area where you are using the engine or equipment.
Never wear loose, torn, or bulky clothing. It may catch on moving parts or controls, leading to the risk of
accident.
Never consume alcohol or drug before or while operating this engine.
Do not run the engine in a closed area. Exhaust gas contains carbon monoxide, an odorless and deadly
poison.
Gasoline is extremely flammable and can be explosive under certain condition.
Stop engine and allow the engine to cool before refueling.
Do not smoke. Make sure area is well ventilated and free from any source of flame or sparks including the
pilot light of any appliance while refueling, servicing fuel system, draining gasoline and/or adjusting
carburetor.
Do not fill the tank so the fuel level rises into the filler neck. If the tank is overfilled, heat may cause the fuel
to expand and overflow through the vents in the tank cap.
Wipe off any spilled gasoline immediately.
To prevent fire hazard:
Keep the engine at least 1 m (3.3 ft.) away from buildings, obstructions and other burnable objects.
Do not place flammable objects close to the engine.
Do not expose combustible materials to the engine exhaust.
Do not use the engine on any forest covered, bush covered or grass covered unimproved land unless spark
arrester is installed on the muffler.
To avoid getting an electric shock, do not touch spark plug, plug cap or spark plug lead during engine
running.
To avoid a serious burn, do not touch a hot engine or muffler. The engine becomes hot during operation.
Before you service or remove parts, stop engine and allow the engine to cool.
Do not place hands or feet near moving or rotating parts.
Do not run engine at excessive speeds. This may result in injury.
Always remove the spark plug lead from spark plug when servicing the engine to prevent accidental
starting.
Emission Control Information
Board. Also, depending on when your engine was
produced, it may have an assigned emissions durability
period. * See below for the engine emissions durability
period that may apply to your engine.
Fuel Information
THIS ENGINE IS CERTIFIED TO OPERATE ON
UNLEADED REGULAR GRADE GASOLINE ONLY.
Exhaust Emission Control System
A minimum of 87 octane of the antiknock index is
recommended. The antiknock index is posted on
service station pumps in the U.S.A.
The exhaust emission control system applied to this
engine consists of a fuel system and an ignition system
having optimum ignition timing characteristics. The fuel
system has been calibrated to provide lean air/fuel
mixture characteristics and optimum fuel economy with
a suitable air cleaner and exhaust system
To protect the environment in which we all live,
Kawasaki has incorporated an exhaust emission
control system in compliance with applicable
regulations of the United States Environmental
Protection Agency and the California Air Resources
A sealed-type crankcase emission control system is
also used to eliminate blow-by gasses. The blow-by
24
gasses are led to a breather chamber through the
crankcase and from there to the air cleaner.
necessary to ensure compliance with the applicable
standards.
Engine Emissions Compliance Period
As the owner of the engine, you have the responsibility
to make sure that the recommended maintenance is
carried out according to the instructions in this Owner's
Manual at your own expense.
California
Model Year - 2006 and later Vertical Crankshaft
Durability Period - 500 hours
The Kawasaki Limited Emission Control System
Warranty requires that you return your engine to an
authorized Kawasaki dealer for remedy under warranty.
Please read the warranty carefully, and keep it valid by
complying with the owner's obligations it contains.
All Other States
Model Year - 2003 and later (new)
2007 and later (carry over)
Durability Period - 500 hours (Category A}
Tampering with Emission Control System Prohibited
If your engine has an assigned emissions durability
period it will be located on the certification label
attached to the engine (IMPORTANT ENGINE
INFORMATION).
Federal law and California State law prohibit the
following acts or the causing thereof: (1) the removal or
rendering inoperative by any person other than for
purposes of maintenance, repair, or replacement, of
any device or element of design incorporated into any
new engine for the purposes of emission control prior to
its sale or delivery to the ultimate purchaser or while it is
in use, or (2) the use of the engine after such device or
element of design has been removed or rendered
inoperative by any person.
High Altitude Performance Adjustment Information
To improve the EMISSIONS CONTROL
PERFORMANCE of engines operated above 1,000
meters (3,300 feet), Kawasaki recommends the
following Environmental Protection Agency (EPA) and
the California Air Resources Board (CARB) approved
modifications.
Among those acts presumed to constitute tampering
are the acts listed below:
NOTE: When properly performed, these specified
modifications only are not considered to be emissions
system "tampering" and engine performance is
generally unchanged as a result.
Do not tamper with the original emission related parts:
•
•
•
•
•
•
•
•
•
Installation Instructions:
High altitude adjustment requires replacement of
carburetor main jet. Installation of these optional parts
may be performed by an authorized Kawasaki dealer,
or the consumer, following repair recommendations
specified in the appropriate Kawasaki Service Bulletin.
Maintenance and Warranty
Proper maintenance is necessary to ensure that your
engine will continue to have low emission levels. This
Owner's Manual contains those maintenance
recommendations for your engine. Those items
identified by the Periodic Maintenance Chart are
25
Carburetor and internal parts
Spark Plug
Magneto or electronic ignition system
Fuel filter element
Air cleaner elements
Crankcase
Cylinder head
Breather chamber and internal parts
Intake pipe and tube
General Information
Location of Safety Related Labels
C
Figure 3
A. Fuel Tank Cap
B. Fuel Tank (capacity 2.0L [0.528US gal.])
Figure 1
C. Fuel Tube
D. Carburetor
a. Warning (Refer to )
b. Engine Maintenance (Refer to ))
E. Priming Pump
F. Air Cleaner
G. Recoil starter
H. Recoil Starter Grip
I. Oil Drain Plugs (engine oil capacity 0.65L [0.69US
gal.])
Figure 4
J. Oil Gauge / Filler Cap
K. Spark Plug Cap / Spark Plug
L. Muffler
Engine Serial Number
M. P.T.O. Shaft
The engine serial number is your only means of
identifying your particular engine from others of the
same model type.This engine serial number is needed
by your dealer when ordering parts. Refer to Figure 2.
Tune-up Specifications
ITEM
Figure 2
26
SPECIFICATION
• Valve Clearance
• IN 0.12mm(0.005 in.)
• EX 0.12mm{0.005 in.}
• Ignition Timing
• Unadjustable
• High Idle Speed
• 3200 r/min (rpm)
• Spark Plug Gap
• 0.7- 0.8mm(0.028-0.032 in.)
• Other Specifications
• NO OTHER ADJUSTMENT
NEEDED
Fuel And Oil Recommendations
Fuel
A
Use only clean, fresh, unleaded regular grade
gasoline.
K
< SAE5W-20
t.
1
Octane Rating
<
The octane rating of a gasoline is a measure of its
resistance to "knocking".Use a minimum of 87 octane of
the antiknock index is recommended. The antiknock
index is posted on service station pumps in the U.S.A.
SAE5W-20
>
Y k
A
<
>
SAE1OW-30/SAE1OW-40
V
>
h
SAE5W-20
F
F
F
F
F
F
NOTE: If "knocking or pinging" occurs, use a different
brand of gasoline or higher octane rating.
Figure 5
CAUTION: Do not mix oil with gasoline
Oxygenated Fuel
NOTE: Using multi grade oils (5W-20, 10W-30, and
10W-40) will increase oil consumption. Check oil level
more frequently when using them.
Oxygenates (either ethanol or MTBE) are added to the
gasoline. If you use the oxygenated fuel be sure it is
unleaded and meets the minimum octane rating
requirement.The following are the EPA approved
percentages of fuel oxygenates.
ETHANOL: (Ethyl or Grain Alcohol)
You may use gasoline containing up to 10% ethanol by
volume.
MTBE: (Methyl Tertiary Butyl Ether)
You may use gasoline containing up to 15% MTBE by
volume.
METHANOL: (Methyl or Wood Alcohol) 5% by volume
Figure 6
You may use gasoline containing up to 5% methanol by
volume, as long as it also contains co solvents and
corrosion inhibitors to protect the fuel system.
Preparation
Gasoline containing more than 5% methanol by volume
may cause starting and/or performance problems. It
may also damage metal, rubber, and plastic parts of
your fuel system.
•
•
•
Fuel
Level the engine (equipment) before fueling.
Remove the fuel tank cap.
Slowly pour fuel into the fuel tank to bottom (B) of
the filler (A).
Do not over fill the fuel tank, fill only to bottom (B) of the
filler (A) to prevent spill out of the fuel from the tank cap.
WARNING: Gasoline is extremely
flammable and can be explosive under certain
conditions. Do not smoke. Make sure the area
is well ventilated and free from any source of
flame or sparks; this includes any appliance
with a pilot light. Never fill the tank so the fuel
level rises into the filler neck. If the tank is
overfilled, heat may cause the fuel to expand
and overflow through the vents in the tank cap.
Fuel Tank Capacity, 2.0 L (0.528 us.gal)
•
Close the tank cap securely by turning it clockwise
as far as it will go.
Engine Oil
Check the engine oil level daily before starting the
engine otherwise shortage of the engine oil may cause
serious damage to the engine such as seizure.
Engine Oil
•
The following engine oils are recommended:
•
API Service Classification: SF, SG, SH, or SJ.
Oil Viscosity
•
•
Choose the viscosity according to the temperature as
follows:
27
Place the engine (equipment) on level surface.
Clean area around the oil gauge before removing it.
Remove the oil gauge (A) and wipe it with clean
cloth.
Pour the oil slowly to "FULL" mark on the oil gauge.
Insert the oil gauge into the oil filler (B)WITHOUT
SCREWING IT IN.
•
Remove the oil gauge to check the oil level. Level
should be between "ADD" and "FULL" marks. Do
not overfill.
• Install and tighten the oil gauge.
Engine Oil Capacity, 0.65 L (0.69 us.qt)
•
•
CAUTION: The engine is shipped without
engine oil.
•
•
damage to the recoil starter or pad system of
the engine.
DO NOT pull the recoil starter grip out of the
end.
DO NOT let the recoil starter grip snap back
itself. This may cause damage to the recoil
starter assembly.
Hold the brake control lever (A) on the equipment
against the handle (B) on the equipment.
Pull the recoil starter grip (C) slowly until you feel
compression, then pull fast and steady.
Figure 7
Starting
Band Pad System
Figure 9
Upon releasing the brake control lever on the
equipment, the cutting blade and the engine will stop
automatically.
A. Brake Control Lever
Therefore, the brake control lever must be held against
the handle while the engine is started and running.
C. Recoil Starter Grip
B. Handle
Warming up
Starting Engine
•
CAUTION: Allow engine to warm up before loading.
This will allow oil to reach all the engine parts, and
the piston clearance to reach design specification,
before the engine is ready for loading.
Fully push the priming button (A) by thumb only
once.
NOTE: When the engine is already warm or on hot
days, do not push the priming button to prevent faulty
starting engine caused by flooding carburetor.
•
After engine starts, warm up the engine, run it for a
few minutes.
Operating
•
•
Anti-engine inclination
This engine will operate continuously at angles up
to 30°in any direction.
• Refer to the operating instructions of the equipment
this engine powers.
• Because of equipment design or application, there
may be more stringent restrictions regarding the
angle of operation.
CAUTION: Do not operate this engine continuously
at angles exceeding 30° in any direction. Engine
damage could result from insufficient lubrication.
Figure 8
CAUTION:
•
•
Stopping
DO NOT start the engine when the cutting blade
is in contact with long, uncut grass, it may
cause difficulties in starting and damage to the
recoil starter.
DO NOT attempt to start the engine when the
brake control lever on the equipment is
released from your hands; this may cause
Stopping Engine
Release the brake control lever (A) on the equipment
from the handle (B) on the equipment to stop the engine
and the cutting blade.
28
Adjustment
A. Brake Control Lever
B. Handle
Engine Speed Adjustment
NOTE: Do not tamper with the governor setting or the
carburetor setting to increase the engine speed. Each
carburetor is adjusted at the factory with either a cap or
stop plate installed on the mixture screw. Any
adjustments must be performed an authorized
Kawasaki dealer.
Figure 10
MAINTENANCE
DAILY
Check oil level and add
engine oil
Check for loose or lost
nuts and screws
Check for fuel and oil
leakage
Check for brake control
lever function
Check or clean recoil
starter and air intake
screen Tighten nuts and
screws
♦ Clean air cleaner foam
element
♦Clean air cleaner paper
element
Change engine oil
Clean and re-gap spark
Plug
♦ Replace air cleaner
paper element
♦ Clean dust and dirt from
cylinder and cylinder head
fins
♦Clean combustion
chamber
♦Check and adjust valve
clearance
♦Clean and lap valve
seating surface
FIRST 8
HOURS
MAINTENANCE
INTERVAL
EVERY 25 EVERY 50
HOURS
HOURS
EVERY
100
HOURS
EVERY
200
HOURS
EVERY
300
HOURS
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
Periodic Maintenance Chart
NOTE: The service intervals indicated are to be used as a guide. Service should be performed more frequently as
necessary by operating condition. Service more frequently under dusty conditions.
‡: Have an authorized Kawasaki dealer perform these services.
Oil Level Check
WARNING: Hot engine oil can cause severe
Check oil level daily and before each time of operation.
Be sure oil level is maintained. See PREPARATION .
burns. Allow engine temperature to drop from
hot to warm before draining and handling oil.
Oil Change
•
•
•
Change oil after first 8 hours of operation. Thereafter
change oil every 50 hours.
29
Run the engine to warm oil.
Be sure the engine (equipment) is level.
Stop the engine.
•
Air Cleaner Service
Remove the oil drain plug (A) on side of the engine
or on bottom of the engine to drain oil into suitable
container (B) while the engine is warm.
CAUTION: To prevent excessive engine wear, do
not run the engine with the air cleaner
WARNING: Clean the elements in a wellventilated area and take care that there are no
sparks or flame anywhere near the working
area, this includes any appliance with a pilot
light. Do not use gasoline or low flash-point
solvents to clean the element. A fire or
explosion could result.
•
Figure 11
A. Oil Drain Plug (On side of engine)
Unfasten the air cleaner case (C) fastened with the
air cleaner body (D) by sliding the two fasteners (A)
toward the recoil starter (B).Then, with two hands,
pulling the two latches (E) toward you and upward
as shown, separate the air cleaner case from the air
cleaner body.
B. Container
Figure 14
A. Fasteners
B. Recoil Starter
Figure 12
A. Oil Drain Plug (On bottom of engine)
C. Air Cleaner Case
•
•
D. Air Cleaner body
•
Reinstall the oil drain plug.
Remove oil gauge and refill with new oil (See FUEL
AND OIL RECOMMENDATIONS chapter).
Check the oil level (See PREPARATION chapter).
E. Latches
Remove the paper element (A) and the foam element
(B) from the air cleaner body (C).
WARNING: Engine oil is toxic substance.
Dispose of used oil properly. Contact your local
authorities for approved disposal methods for
possible recycling.
Cooling System Cleaning
Before each use, check that the recoil starter (A) is free
from grass and debris and clean to prevent engine
overheating.
Figure 15
A. Paper Element
B. Foam Element
C. Air Cleaner body
Foam Element
Clean the foam element every 25 hours.
Wash the element in detergent and water, and dry it
thoroughly.
Figure 13
30
•
Check the spark plug gap and reset it if necessary.
The gap must be between 0.7 and 0.8 mm (0.028
and 0.032").
To change the gap, bend only the side-electrode, using
a spark plug tool.
CAUTION: Do not oil foam element.
Paper Element
•
•
Clean the paper element every 100 hours.
Clean the element by tapping gently to remove
dust. If very dirty, replace the element with a new
one.
• Replace with a new paper-element yearly or 300
hours.
CAUTION: Do not wash paper-element.Do not use
pressurized air to clean or dry paper element.
-Install and tighten the spark plug to 23 N-m (2.3kgf-m,
17fMb).
-Fit the spark plug cap on the spark plug securely.
-Pull up the spark plug cap lightly to make sure of the
installation of the spark plug cap.
NOTE: Operating in a dusty condition may require
more frequent maintenance than above.
•
•
Recommended Spark Plug
NGK... BPR5ES
Reinstall the foam element and then the paper
element on the air cleaner body.
Reinstall the air cleaner case on the air cleaner
body by first fitting the projection (B) on the edge of
the air cleaner case into the slit (A) in the air cleaner
body. Then, sliding the fasteners (C) toward the air
cleaner case, securely fasten the air cleaner case
with the air cleaner body.
Figure 17
A.
Spark Plug Gap
B.
Electrodes
CAUTION: Be sure to use the same type of spark
plug for change. Resistor spark plug is required in
some areas by local law.
Storage
Figure 16
Engine to be stored over 30 days should be completely
drained of fuel (gasoline) to prevent gum deposits
forming on essential carburetor parts and the fuel
system.
A. Slit in the air cleaner body
B. Projection on the air cleaner case
C. Fasteners
CAUTION: After servicing the air cleaner, be sure
all the removed parts are reinstalled properly in
place. Failure to secure fastening of the air cleaner
case with the air cleaner body may cause dirt or
other foreign materials to enter the engine, while it
is running, through the air cleaner, resulting in
engine troubles or failures.
WARNING: Gasoline is extremely
flammable and can be explosive under certain
conditions. Drain gasoline before storing the
equipment for extended periods. Drain
gasoline in a well-ventilated area away from
any source of flame or sparks, including any
appliances with a pilot light. Store gasoline in
an approved container in safe location.
WARNING: Hot engine components can
cause severe burns. Stop engine and allow it to
cool before checking spark plug.
•
•
•
•
•
Clean or replace the spark plug and reset gap (A)
every 100 hours of operation.
Disconnect the spark plug cap from spark plug and
remove the spark plug.
Clean the electrodes (B) by scraping or with a wire
brush to remove carbon deposits.
Inspect for cracked porcelain or other wear and
damage. Replace the spark plug with a new one if
necessary.
•
•
•
Remove the spark plug cap from spark plug to
prevent accidental starting the engine.
Empty the fuel from the fuel tank with a pump or
siphon.
Fit the plug cap on the spark plug securely
Start and run the engine at idle speed to used up
the fuel in the fuel system.
WARNING: Before maintaining engine, stop
the engine and allow it cool.
31
•
A. Spark Plug Hole
Remove the spark plug and pour approx. 1-2 mL
(0.06-0.1 cu.in) of new engine oil through the plug
hole (A), slowly pull the recoil starter grip several
times and reinstall the spark plug.
•
•
•
•
Figure 18
32
Slowly pull the recoil starter grip until you feel
compression and leave it there.
Clean every part of the engine.
After period of storage, change engine oil.
(Refer to "Oil Change" section in
"MAINTENANCE" section).
Troubleshooting Guide
Symptom
Engine won't start
output is low
Probable Cause
Insufficient
compression
1.
Faulty piston, cylinder, piston ring,
and head gasket
Faulty valves
Loose spark plug
Loose cylinder head bolts
1. Tighten properly
No fuel to
1.
combustion chamber 2.
3.
4.
No fuel in fuel tank
Blocked rue tube
Blocked air vent in fuel tank cap
Faulty carburetor
1. Fill fuel tank
2. Clean
3. Clean
4. ‡
Spark plug fouled by
fuel
1.
Over-rich fuel/air mixture
2.
3.
4.
5.
Clogged air cleaner
Faulty carburetor
Incorrect grade/type of fuel
Water in fuel
1. Slowly pull the recoil starter grip with
spark plug removed to discharge
excess fuel. clean spark plug
2.Clean
3.‡
4. Change Gasoline
5. Change Gasoline
No spark or weak
spark
1.
2.
3.
Faulty spark plug
Faulty ignition coil
Faulty engine switch
1. Replace spark plug
2.‡
3.‡
Engine Overheats
1.
2.
1. Clean
2. Clean
5.
Clogged air cleaner
Recoil Starter or cooling air path
clogged with dirt
Insufficient engine oil
carbon built -up in combustion
chamber
Poor ventilation around engine
1.
Faulty Governor
‡
2.
3.
4.
Low Output
Remedy
3.
4.
1.
Engine speed
won’t increase
2. Tighten properly
3. Tighten properly
4. Tighten properly
3. Replenish or change oil
4.‡
5. Select a better location
If the engine malfunctions, carefully examine the symptoms and the operating conditions, and use the table above
as a guide to troubleshooting.‡ Have an authorized Kawasaki dealer perform these service
Environmental Protection
To protect our environment, properly discard used batteries, engine oil, gasoline, coolant, or other components that
you might dispose of in the future.
Consult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal procedure.
Specifications
Type of Engine
Air-cooled, 4-stroke OHV, single cylinder, gasoline Engine
• Bore X Stroke
• 65 x 54mm (2.6 x 2.1 in.)
• Displacement
• 179mL (109. cu.in.)
• Ignition system
• Solid-state ignition
• Starting system
• Recoil starter
• Dry weight
• 13.5kg (29.lb)
Specifications subject to change without notice
33
KAWASAKI LIMITED WARRANTY
CALIFORNIA AND FEDERAL
EMISSION CONTROL SYSTEMS
SMALL OFF-ROAD ENGINES
The California Air Resources Board, the Environmental Protection Agency (EPA), and Kawasaki Motors Corp.,
U.S.A. (hereinafter "Kawasaki") are pleased to explain the Emission Control Systems Warranty on your Kawasaki
small off-road engine. In California and other states, new small off-road engines must be designed, built and
equipped to meet stringent anti-smog standards. Kawasaki must warrant the emission control system on your small
off-road engine for the period of time listed below provided there has been no abuse, neglect or improper
maintenance of your small off-road engine. Your emission control system may include parts such as the carburetor
or fuel-injection system, the ignition system, and catalytic converter. Also included may be hoses, belts, connectors
and other emission related assemblies. Where a warrantable condition exists, Kawasaki will repair your small offroad engine at no cost to you including diagnosis (if the diagnostic work is Performed at a Kawasaki small off-road
engine dealer), parts and labor.
OWNERS WARRANTY RESPONSIBILITIES. The following obligations must be fulfilled by the owner to maintain
the validity of the Kawasaki California / EPA Emissions Systems Warranty:
(a)
As the small off-road engine owner, you are responsible for the performance of the required maintenance
listed in your owner's manual. Kawasaki recommends that you retain all receipts covering maintenance on your
small off-road engine, but Kawasaki cannot deny warranty solely for the lack of receipts or for your failure to ensure
the performance of all scheduled maintenance.
(b)
You are responsible for presenting your small off-road engine to an authorized Kawasaki small off-road
engine Dealer as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of
time, not to exceed 30 days.
(c)
AS the small off-road engine owner, you should also be aware that Kawasaki may deny you warranty
coverage if your small off-road engine or a part has failed due to abuse, neglect, improper maintenance or
unapproved modifications.
(d)
If you have any questions regarding your warranty rights and responsibilities, you should contact
Kawasaki Motors Corp., U.S.A., Consumer Services Department, 5080 36th Street, S.E., Grand Rapids, Ml 49512,
616/949-6500..
1. COVERAGE. Kawasaki warrants to the initial owner and each subsequent purchaser that the small off-road
engine is free from defects in materials and workmanship which cause a failure of a warranted part for a period of
two years. Kawasaki is liable for damages to other engine components caused by the failure of a warranted part still
under warranty. The 1995 and later small off-road engines are warranted for two years in California. In all other
states, 1997 and later model year small off-road engines are warranted for two years. If any emission-related part
on your engine is defective, the part will be repaired or replaced by Kawasaki. This warranty time period shall begin
on the date the small off?road engine is delivered to the initial purchaser, or on the date the small off?road engine is
first placed in service.
Warranty defects shall be remedied during customary business hours at any authorized Kawasaki small off-road
engine dealer located within the United States of America. Any manufacturer-approved replacement part may be
used in the performance of any warranty maintenance or repairs on emission-related parts, and must be provided
without charge to the owner if the part is still under warranty. Any part or parts replaced under this warranty shall
become the property of Kawasaki.
The emission related warranted parts are specifically defined by the California Air Resources Board's Emission
Warranty Parts List. (EPA's regulations do not include a parts list, but EPA considers emission-related parts to
include all parts listed here.) These warranted parts are: carburetor and internal parts, spark advance/retard
system. cold start enrichment system, magneto or electronic ignition system, catalytic converter, intake manifold,
exhaust manifold, air cleaner element, and spark plugs if failure occurs prior to the first required scheduled
replacement, hoses, clamps, fittings, gaskets, sealing devices, mounting hardware and tubing used directly in
these parts.
Since emission related parts may vary slightly from model to model,certain models may not contain all of these parts
and certain models may contain functionally equivalent parts.
34
2. LIMITATIONS. This Emission Control Systems Warranty shall not cover any of the following:
(a)
Repair or replacement required as a result of (i) misuse or neglect, (ii) lack of required maintenance. (iii)
repairs improperly performed or replacements improperly installed, (iv) use of replacement parts or accessories not
conforming to Kawasaki specifications which adversely affect performance and/or durability, (v) alterations or
modifications not recommended or approved in writing by Kawasaki.
(b)
Replacement of parts and other services and adjustments necessary for required maintenance at and
after the first scheduled replacement point.
LIMITED LIABILITY.
(a)
The liability of Kawasaki under this Emission Control Systems Warranty is limited solely to the remedying
of defects in materials or workmanship by any authorized Kawasaki small off-road engine dealer at its place of
business during customary business hours. This warranty does not cover inconvenience or loss of use of the small
off-road engine or transportation of the small off-road engine to or from the Kawasaki Dealer. KAWASAKI SHALL
NOT BE LIABLE FOR ANY OTHER EXPENSE, LOSS OR DAMAGE, WHETHER DIRECT, INCIDENTAL,
CONSEQUENTIAL (EXCEPTION LISTED UNDER COVERAGE) OR EXEMPLARY ARISING IN CONNECTION
WITH THE SALE OR USE OF OR INABILITY TO USE THE KAWASAKI SMALL OFF-ROAD ENGINE FOR ANY
PURPOSE.
(b)
NO EXPRESS EMISSION CONTROL SYSTEMS WARRANTY IS GIVEN BY KAWASAKI WITH
RESPECT TO THE KAWASAKI SMALL OFF-ROAD ENGINE EXCEPT AS SPECIFICALLY SET FORTH HEREIN.
ANY EMISSION CONTROL SYSTEMS WARRANTY IMPLIED BY LAW, INCLUDING ANY WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, IS EXPRESSLY LIMITED TO THE
EMISSION CONTROL SYSTEMS WARRANTY TERMS SET FORTH HEREIN. THE FOREGOING STATEMENTS
OF WARRANTY ARE EXCLUSIVE AND IN LIEU OF ALL OTHER REMEDIES.
(c)
No dealer is authorized to modify this Kawasaki Limited Emission Control Systems Warranty.
(d)
Kawasaki is not liable for parts which are not genuine Kawasaki parts except when genuine Kawasaki
parts cause damage to non-Kawasaki parts.
LEGAL RIGHTS. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE
OTHER RIGHTS.
THIS WARRANTY IS IN ADDITION TO THE KAWASAKI LIMITED SMALL OFF-ROAD ENGINE WARRANTY.
35
MANUFACTURER’S LIMITED WARRANTY FOR:
The limited warranty set forth below is given by Cub Cadet
LLC with respect to new merchandise purchased and used in
the United States, its possessions and territories.
Cub Cadet LLC warrants this product against defects for a
period of two (2) years commencing on the date of original
purchase and will, at its option, repair or replace, free of
charge, any part found to be defective in materials or
workmanship. This limited warranty shall only apply if this
product has been operated and maintained in accordance
with the Operator’s Manual furnished with the product, and
has not been subject to misuse, abuse, commercial use,
neglect, accident, improper maintenance, alteration,
vandalism, theft, fire, water, or damage because of other peril
or natural disaster. Damage resulting from the installation or
use of any accessory or attachment not approved by Cub
Cadet LLC for use with the product(s) covered by this manual
will void your warranty as to any resulting damage.
Normal wear parts or components thereof are subject to
separate terms as follows: All normal wear parts or
component failures will be covered on the product for a period
of 90 days regardless of cause. After 90 days, but within the
two year period, normal wear part failures will be covered
ONLY IF caused by defects in materials or workmanship of
OTHER component parts. Normal wear parts and
components include, but are not limited to: batteries, belts,
blades, blade adapters, grass bags, rider deck wheels, seats,
snow thrower skid shoes, shave plates, auger spiral rubber,
and tires.
HOW TO OBTAIN SERVICE: Warranty service is available,
WITH PROOF OF PURCHASE, through your local authorized
service dealer. To locate the dealer in your area, check your
Yellow Pages, or contact Cub Cadet LLC at P.O. Box 361131,
Cleveland, Ohio 44136-0019, or call 1-877-282-8684, or log
on to our Web site at www.cubcadet.com.
This limited warranty does not provide coverage in the
following cases:
a.
b.
c.
The engine or component parts thereof. These items
carry a separate manufacturer’s warranty. Refer to
applicable manufacturer’s warranty for terms and
conditions.
Log splitter pumps, valves, and cylinders have a sepa
rate one year warranty.
Routine maintenance items such as lubricants, filters,
blade sharpening, tune-ups, brake adjustments, clutch
adjustments, deck adjustments, and normal
deterioration of the exterior finish due to use or
exposure.
d.
e.
f.
g.
Cub Cadet LLC does not extend any warranty for
products sold or exported outside of the United States,
its possesions and territories, except those sold
through Cub Cadet LLC’s authorized channels of
export distribution.
Parts that are not genuine Cub Cadet parts are not
covered by this warranty.
Service completed by someone other than an
authorized service dealer is not covered by this
warranty.
Transportation charges and service calls are not
covered.
No implied warranty, including any implied warranty of
merchantability of fitness for a particular purpose,
applies after the applicable period of express written
warranty above as to the parts as identified. No other
express warranty, whether written or oral, except as
mentioned above, given by any person or entity,
including a dealer or retailer, with respect to any product,
shall bind Cub Cadet LLC. During the period of the
warranty, the exclusive remedy is repair or replacement
of the product as set forth above.
The provisions as set forth in this warranty provide the
sole and exclusive remedy arising from the sale. Cub
Cadet LLC shall not be liable for incidental or
consequential loss or damage including, without
limitation, expenses incurred for substitute or
replacement lawn care services or for rental expenses to
temporarily replace a warranted product.
Some states do not allow the exclusion or limitation of
incidental or consequential damages, or limitations on how
long an implied warranty lasts, so the above exclusions or
limitations may not apply to you.
In no event shall recovery of any kind be greater than the
amount of the purchase price of the product sold. Alteration
of safety features of the product shall void this warranty.
You assume the risk and liability for loss, damage, or injury to
you and your property and/or to others and their property
arising out of the misuse or inability to use the product.
This limited warranty shall not extend to anyone other than the
original purchaser or to the person for whom it was purchased
as a gift.
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.
Cub Cadet LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019; Phone: 1-877-282-8684