Bolens BL410 Cultivator Owner's Manual

Operator's

Manual

Since it began making garden tools in

7850,Bolens has been knownfor

longlasting, dependable products. Bolens eventually carried that hard-working heritage

into the outdoor power

equipment industry, when it designed and built the first-everpower-driven garden tractor.

Today,homeowners around the country rely on Bolens for durable, reliable power equipment at an affordable price.

2-Cycle Garden Cultivator

Model

BL410

THAN K YOU

Thank you for buying this quality product. This modern outdoor power tool will provide many hours of useful service.

You will find it to be a great labor-saving device. This operator's manual provides you with easy-to-understand operating instructions.

Read the whole manual and follow all the instructions to keep your new outdoor power tool in top operating condition.

PRODUCT REFERENCES, ILLUSTRATIONS AND

SPECIFICATIONS

All information, illustrations, and specifications in this manual are based on the latest product information available at the time of printing.

We reserve the right to make changes at any time without notice.

Copyright ©2002 MTD SOUTHWESTINC,All Rights Reserved.

SERVICE INFORMATION

Service on this unit both within and after the warranty period should be performed only by an authorized and approved service dealer.

For service call 1-330-558-7220 or 1-866-840-6483 to obtain a list of authorized servicedealers near you.

DO NOT RETURNTHE UNITTO THE RETAILER.PROOFOF

PURCHASEWILL BEREQUIREDFORWARRANTYSERVICE.

Before beginning, locate the unit's model plate, It lists the model and serial numbers of your unit. Refer to the sample plate below and copy the information for future reference,

£811£I £I1111

11£8111ai@II IIR IIIIIII

=

INTRODUCTION

TABLE OF CONTENTS

Service Information ...................................

Rules for Safe Operation ...............................

Know Your Unit .......................................

Assembly Instructions .................................

Oil and Fuel Information ...............................

Starting/Stopping Instructions .........................

Operating Instructions ...............................

Maintenance and Repair Instructions .................

Cleaning and Storage ................................

Accessories and Replacement Parts ...................

Troubleshooting Chart ...............................

Specifications ........................................

14

14

15

16

Warranty Information ................................

Parts List ..............................

18

Inside Back Cover

9

10

11

7

8

2

3

6

CONTENTS OF CARTON

• Model BL410 Garden Cultivator with Handlebars and

Wheel Bracket Assembly

• Bottle of 2-Cycle Oil

• Operator's Manual

• Product Registration Card

Examine all parts to make certain that nothing is missing and no breakage has occurred during shipping.

Any damaged or missing part must be replaced before using this product.

_ADL _.N J S_Ao

Copy the model / parent part

number here:

Copy the serial number here:

Make sureyou carefully read and understand this manual before starting or operating this equipment.

THISPRODUCTISCOVEREDBY ONE ORMORE U.S.PATENTS.

OTHERPATENTSPENDING.

CALIFORNIA

PROPOSITION 65 WARNING

THE ENGINE EXHAUST FROM THIS PRODUCT

CONTAINS CHEMICALS KNOWN TO THE STATE

OF CALIFORNIA TO CAUSE CANCER, BIRTH

DEFECTS,OR OTHER REPRODUCTIVE HARM.

2

RULESFOR SAFE OPERATION

NOTE: For users on U.S. Forest Land and in the states of California,

Maine, Oregon, and Washington.

All U.S. Forest Land and the state of California (Public Resources Codes 4442 and 4443), Oregon, and Washington require by law that certain internal combustion engines operated on forest brush and/or grass-covered areas be equipped with a spark arrestor, maintained in effective working order, or the engine be constructed, equipped, and maintained for the prevention of fire. Check with your state or local authorities for regulations pertaining to these requirements.

Failure to follow these requirements could subject you to liability or a fine. This unit is factory

equipped with a spark arrestor.

If it requires replacement, ask your LOCAL SERVICE DEALER to install the Accessory Part #182747

Spark Arrestor.

Read the Operator's Manual(s) and follow all warnings and safety instructions.

Failure to do so can result in serious injury to the operator and/or bystanders.

FOR QUESTIONS, CALL 1-330-558-7720 or 1-866-840-6483

• SAFETY SYMBOLS

•

The purpose of safety symbols is to attract your attention to possible dangers. The safety symbols, and their explanations, deserve your careful attention and understanding.

The safety warnings do not by themselves eliminate any danger.

The instructions or warnings they give are not substitutes for proper accident prevention measures.

SYMBOL

NOTE:

MEANING

SYMBOL

MEANING

SAFETY ALERT SYMBOL: Indicates danger, warning or caution.

Attention is required in order to avoid serious personal injury. May be used in conjunction with other symbols or pictographs.

WARNING:Failure

to obey a safety warning can result in i nj ury to yourself and others. Always follow the safety precautions to reduce the risk of fire, electric shocki and personal injury

CAUTION:

Failure to obey a safety warning may 1 result in property damage or personal injury to yourself or to others.

Always follow the safety precautions to reduce the risk of fire, electric shock, and personal injury.

Advises you of information or instructions vital to the operation or maintenance of the equipment.

A

A"

• IMPORTANT SAFETY INFORMATION •

READ ALL INSTRUCTIONS

WARNING: When using the unit, you must fol-I

Iowthe safety rules, Please read these instruc, I tions before operating the unit in order to I ensure the safety of the operator and any bystanders. Please keep these instructions for I

BEFORE OPERATING

• Read the instructions carefully.

Become familiar with the controls and proper use of the unit.

• Do not operate this unit when tired, ill or under the influence of alcohol, drugs or medication.

• Children under the age of 15 must not use the unit; teens may operate the unit with adult guidance.

Inspect the unit before use. Replace damaged parts. Check for fuel leaks. Make sure all fasteners are in place and secure.

Replace parts that are cracked, chipped or damaged in any way. Do not operate with loose or damaged parts.

• Be aware of the potential risk of injury to your head, hands and feet.

Clear the area to be cultivated before each use. Remove rocks, broken glass, nails, wire, string and other objects which may be thrown by the unit. Clear the area of children, bystanders and pets; keep them outside a 50-foot (15 m.) radius, at a minimum.

Even then, they are still at risk from thrown objects.

Encourage bystanders to wear eye protection. If you are approached, stop the unit immediately.

Squeeze the throttle control and make sure that it automatically returns to the idle position.

Make all adjustments or repairs before using the unit.

SAFETY WARNINGS FOR GAS UNITS

• Store fuel only in containers specifically designed and approved for the storage of such materials.

• Avoid creating a source of ignition for spilled fuel. Do not start the engine until fuel vapors dissipate.

WARNING: Gasoline is highly flammable

and its vapors can explode if ignited:

Follow the

ensuing precautions.

3

RULESFOR SAFE OPERATION

• IMPORTANT SAFETY INFORMATION

•

Always stop the engine and allow it to cool before filling the fuel tank. Never remove the cap of the fuel tank, or add fuel, when the engine is hot. Never operate the unit without the fuel cap securely in place. Loosen the fuel tank cap slowly to relieve any pressure in the tank.

Add fuel in a clean, well-ventilated outdoor area where there are no sparks or flames. Slowly remove the fuel cap only after stopping engine.

Do not smoke while fueling.

Wipe up any spilled fuel from the unit immediately.

Keep hands, face and feet at a distance from all moving parts. Do not touch or try to stop the tines when they are rotating.

Do not operate without guards in place.

Do not touch the engine, muffler or gearbox.

These parts get extremely hot from operation.

When turned off they remain hot for a short time.

Do not operate the engine faster than the speed needed to do thejob.

Do not run the engine at high speed when not in use.

Move the unit at least 30 feet (9.1 m) from the fueling source and site before starting the engine.

Do not smoke,

Keep sparks and open flames from the area while adding fuel or operating the unit.

WHILE OPERATING

• Never start or run the unit inside a closed room or building. Breathing exhaust fumes can be lethal.

Operate this unit only in a well ventilated area outdoors.

Always stop the engine during suspended or delayed operation, or when you walk from one location to another.

Stop the engine for maintenance, repair or to install or remove the tines. To avoid injury, stop the unit and make sure the tines no longer turn.

The tines become very sharp from use. Always wear heavy gloves when handling, removing, installing or cleaning the tines.

• Wear safety glasses or goggles that are marked as meeting

ANSI Z87.1 standards, and ear/hearing protection when operating this unit. Wear a face or dust mask if the operation is dusty.

• Wear heavy, long pants, boots, gloves and a long sleeve shirt. Do not wear, short pants, sandals or go barefoot.

• To reduce the risk of injury associated with objects pulled into rotating parts, do not wear loose clothing, jewelry, scarves, etc. Secure hair above shoulder level.

• Use the unit only in daylight or good artificial light.

Use only genuine factory replacement parts and accessories for this unit. These are available from your authorized service dealer. Use of any non original factory parts or accessories could lead to serious injury to the user, or damage to the unit, and void your warranty.

Keep the unit clean of vegetation and other materials. They may become lodged between the tines and gearbox or guard.

To reduce the risk of fire, replace a faulty muffler and spark arrestor.

Keep the engine and muffler free from grass, leaves, excessive grease or carbon build up.

• Keep outside surfaces free from oil and fuel.

• This unit has a clutch.

The tines remain stationary when the engine is idling.

If they do not, have the unit adjusted by an authorized service technician.

• Be sure the tines are not in contact with anything before starting the unit.

OTHER SAFETY WARNINGS

Never store the unit, with fuel in the tank, inside a building where fumes may reach an open flame or spark.

Allow the engine to cool before storing or transporting.

Be sure to secure the unit while transporting.

Avoid accidental starting.

Be in the starting position whenever pulling the starter rope. The operator and unit must be in a stable position while starting.

Refer to the Starting/

Stopping Instructions,

Store the unit in a dry place, either locked up or up high to prevent unauthorized reach of children.

use or damage.

Keep out of the

Clean the tines with a hose and water. Wipe the tines with a light machine oil to prevent rust.

Never douse or squirt the engine with water or any other liquid. Keep handles dry, clean and free from debris. Clean after each use, as described in the Cleaning and Storage section.

• Use the right tool. Only use this tool for the purpose intended.

• Do not force the unit.

It will do the job more effectively, with a smaller chance of injury, if you use the unit for the task it was designed.

• Use extreme caution when reversing or pulling the unit towards you.

• Do not overreach. Take extra care when working on steep slopes or inclines. Always keep proper footing and balance.

• Always hold the unit with both hands when operating.

Keep a firm grip on the handlebar grips.

Keep these instructions.

Refer to them often and use them to instruct other users. If you loan someone this unit, also loan them these instructions.

SAVE THESE INSTRUCTIONS

4

RULESFOR SAFE OPERATION

SAFETY AND INTERNATIONAL SYMBOLS

Th s operator's manua descr bes safety and internat ona symbo s and pictographs that may appear on th s product

Read the operator!s

manual for complete safety, assembly, operating and maintenance and repair information.

SYMBOL MEANING SYMBOL MEANING

• ON/OFF STOP CONTROL

ON I STARTI RUN

Indicatesdanger, warning or caution.

symbols or pictographs.

WARNING - READ

OPERATOR'S MANUAL

Read the operator's manual(s) and follow all warnings and safety instructions.

Failure to do so can result in serious injury to the operator and/or bystanders.

WEAR EYE AND HEARING

PROTECTION

WARNING: Thrown objects and loud noise can cause severe eye injury and hearing loss. Wear eye protection meeting ANSI Z87.1 standards and ear protection when operating this unit. Use a full face shield when needed.

• KEEP BYSTANDERS AWAY

WARNING:

Keep all bystanders, especially children and pets, at least 50 feet (15 m) from the operating area.

• UNLEADED FUEL

Always use clean, fresh unleaded fuel.

i

O

• ON/OFF STOP CONTROL

OFFor STOP

• HOT SURFACE WARNING

Do not touch a hot muffler, gear housing or cylinder.

You may get burned. These parts get extremely hot from operation.

They remain hot for a short time after the unit is turned off.

• CHOKE CONTROL

A • FULL choke position.

B • PARTIAL choke position.

C • RUN position.

• GARDEN CULTIVATORS - ROTATING

TINES CAN CAUSE SEVERE INJURY

WARNING:

Stop the engine and allow the tines to stop before installing or removing tines, or before cleaning or performing any maintenance.

Keep hands and feet away from rotating tines.

• OIL

Refer to operator's manual for the proper type of oil.

• THROWN OBJECTS AND ROTATING

CUTTER CAN CAUSE SEVERE

INJURY

WARNING:

Do not operate without the proper attachments and guards in place.

Keep away from the rotating tines.

• NO STEP

Always keep proper footing and balance,

Do not overreach, take extra care when working on steep slopes or inclines,

• PLACELEFTFOOTHERE

Avoid accidental starting.

Stand in the starting position whenever pulling the starter rope. The operator and unit must be in a stable position while starting.

5 x

RULESFOR SAFE OPERATION

KNOW YOUR UNIT

Application:

• Cultivating sod and tight to medium soil

• Cultivating in garden areas, around trees, etc.

STOP/OFF (0)

Handgrip

Throttle

Control

Throttle

Cable and

Switch Wires

Handgrip

Handlebar

Handlebar

Knob

Primer Bulb

Choke Control

Air Filter/

On/Off Stop

Control

START/ON

(I)

Fuel Cap

Starter Rope Grip

Handlebar

Knob

Shaft Tube Grip

Tine Guard

Gearbox

Spark

Plug

Muffler

Wheel Bracket

Assembly

Tines

ASSEMBLYINS TRUCTIONS

ASSEMBLING THE UNIT

Before operating, position the unit's handlebars.

NOTE:

You may also need to reposition the wheel height before using the cultivator.

Refer to the

Adjusting

Tine Depth section.

Begin by carefully unpacking the contents and making sure that nothing is damaged.

POSITIONING THE HAN DLEBARS

1.

Loosen the two knobs on the inside of the handlebars

(Fig. 1).

2.

With the unit upright, swing the handlebars up into the operating position (Fig. 1).

NOTE."

Take care not to pinch the throttle cable or switch wires when positioning the handlebar.

3.

Tighten the knobs to secure the handlebars in place.

NOTE:

Do not over-tighten the knobs.

4.

ReadJust the throttle cable and switch the wires so they are smooth and tight against the handlebar assembly.

This will help prevent them from catching or snagging during normal operation.

ADJUSTING THE HANDLEBAR HEIGHT

1.

Remove the knobs and mounting bolts and reinstall them through either the top or bottom holes in the handlebar assembly (Fig. 2) in order to adjust the height of the handlebars.

2.

Be sure to tighten the knobs to secure the handlebars in place.

INSTALLING THE WHEEL BRACKET ASSEMBLY

If the wheel bracket assembly is not installed, or if you ever need to remove or reinstall it, follow the ensuing instructions.

WARNING:

To pievent Serious personal injury, the wheel bracket assembly must be installed when operating the unit.

1.

With the unit on its side, place the wheel bracket assembly on the underside of the tine guard (Fig. 3).

2.

Install a carriage bolt through each of the slotted holes in the wheel bracket and into the tine guard.

3.

On the TOP side of the tine guard, install a lock washer and a wing nut onto each of the bolts (Fig. 3).

4.

Make sure the square shoulder of the bolts is pushed through the slotted holes in the wheel bracket. Tighten the wing nuts (Fig. 4).

NOTE."

Do not over-tighten the wing nuts. Loosen the wing nuts to adjust wheel height.

Fig. 3

Wheel

Bracket

Assembly

Lock Washer

I F'g'

Bottom Hole

_''

Washer

I

Fig. 2

Handlebar

Knob

OIL& FUEL INFORMATiON

OIL AND FUEL MIXING INSTRUCTIONS

Old and/or improperly mixed fuel are the main reasons for the unit not running properly.

Be sure to use fresh, clean unleaded fuel. Follow the instructions carefully for the proper fuel/oil mixture.

Definition of Blended Fuels

Today's fuels are often a blend of gasoline and oxygenates such as ethanol, methanol, or MTBE (ether). Alcohol-blended fuel absorbs water. As little as 1% water in the fuel can make fuel and oil separate.

It forms acids when stored. When using alcohol-blended fuel, use fresh fuel (less than 60 days old).

Using Blended Fuels

If you choose to use a blended fuel, or its use is unavoidable, follow recommended precautions:

• Always use fresh fuel mix per your operator's manual

• Always agitate the fuel mix before fueling the unit

• Drain the tank and run the engine dry before storing the unit

Using Fuel Additives

The bottle of 2-cycle oil that came with your unit contains a fuel additive which will help inhibit corrosion and minimize the formation of gum deposits.

It is recommended that you use our 2-cycle oil with this unit.

If unavailable, use a good 2-cycle oil designed for air-cooled engines along with a fuel additive, such as STA-BIL ® Gas

Stabilizer or an equivalent.

Add 0.8 oz. (23 ml.) of fuel additive per gallon of fuel according to the instructions on the container.

NEVER add fuel additives directly to the unit's fuel tank.

UNLEADED

(3i8

GAS

US. GALLON!il

LITERS)

MIXINGRATIO=

i i 2 il i!4FLOZs.

i(118ml)

CYCLE OIL

32:1

T WARNING: Gasoline is extremely flammable, 1

I •• _lgnited vaporsmay explode, Alwaysstop the_

I_L, _ engine and allow it to cool before filling the fuel

I__tar/klDonot smoke while filling the tank: Keep _ sparks and open flames at a distance from the area.

NOTE: Dispose of the old fuel/oil mix in accordance to

Federal, state, and local regulations.

Thoroughly mix the proper ratio of 2-cycle engine oil with unleaded gasoline in a separate fuel can. Use a 32:1 fuel/oil ratio.

Do not mix them directly in the engine fuel tank. See the following table for specific gas and oil mixing ratios.

NOTE:

One gallon (3.8 liters) of unleaded gasoline mixed with one 4 fi.oz. (118 ml.) bottle of 2-Cycle

Oil makes a 32:1 fuelloil ratio.

Make sure the cultivator is in a horizontal position when filling or adding fuel tothe tank.

I

Fig. 5

STARTING/STOPPING INSTRUC TiONS

STARTING INSTRUCTIONS

WARNING: Operate this unit only in a well- ventilated outdoor area. Carbon monoxide exhaust fumes can be lethal in a confined area,

WARNING:

Avoid accidental starting.

Make sure you are in the starting position when pulling the starter rope (Fig. 8). To avoid serious injury, the operator and unit must be in a stable position

STOP (O)

_ ...... ......

START 111

Start / Stop Control

1.

Mix gas with oil. Fill fuel tank with fuel/oil mixture.

Refer to Oil and Fuel Mixing Instructions.

2.

Put the Start/Stop Control in the START (I) position

(Fig. 6).

3.

Fully press and release the primer bulb 5 to 7 times, slowly, until FUEL IS VISIBLE IN THE PRIMER BULB

(Fig. 7). If you can't see fuel in the bulb, press and release the bulb three (3) additional times, or as many times as it takes before you can see fuel in it.

4.

Place the choke lever in the FULL choke position (A H )

(Fig. 7).

5.

Stand between the handlebars and support the unit by placing your left foot on the wheel bracket assembly and gripping the handlebar grip with your right hand (Fig. 8).

NOTE: Tilt the unit back slightly to bring the tines off the ground when starting.

6.

While squeezing the throttle control to the wide open

(full throttle) position, grasp the starter rope grip with your left hand and pull the starter rope briskly 5 times. If the engine attempts to run before the fifth pull, proceed to step 7.

NOTE: The unit will not run in the FULL choke position

(A H ).

7.

Place the choke lever in the PARTIAL choke position

(B I_1) (Fig. 7).

8.

Pull starter rope briskly I to 3 times to start the engine

(Fig. 8).

NOTE: Squeeze the throttle control until the engine has started and warmed up.

9.

If the engine does not start, repeat steps 4 through 8.

NOTE:

If the engine floods while trying to start, place the choke lever in the RUN position (C

I_1 )

(Fig. 7). Squeeze the throttle control.

Pull the starter rope briskly.

The engine should start within three (3) to eight (8) pulls.

10. Squeeze the throttle control to warm up engine for 5 to

10 seconds. Place the choke lever in the RUN position

(C I+1) (Fig. 7).

NOTE:

Choking is unnecessary when starting a warm engine.

Put the On/Off Stop Control in the

START (I) position (Fig. 6), and start in PARTIAL choke position (B

)

(Fig. 7).

Full Choke

Position (A)

Throttle

Control

Partial Position (13)

Fig. 7

Run

Position (C)

Choke Control

Primer Bulb

Fig. 6

I

Fig. 8

Starter

Rope

STOPPING INSTRUCTIONS

1.

Release your hand from the throttle control (Fig. 8).

Allow the engine to cool down by idling.

2.

Put the On/Off Stop Control in the STOP (O) position

(Fig. 6).

9

OPERATING INS TRUCTiONS

OPERATING TIPS

WARNING:Always wear

eye, hearinglfoot and j body protection to reduce the risk of injury

when operating this unit.

.

Move the cultivator to the work area prior to starting the engine, Transport the cultivator by pushing it on its wheels,

WARNING:To

prevent serious personal in never pick,up or carry the unit while the engine is runnin(

2.

Start the unit as described in the Starting Instructions.

3, With the engine running and the tines off the ground, depress the throttle control to increase the engine speed,

4.

Holding both of the handlebar grips firmly, slowly lower the cultivator until the tines make contact with the ground (Fig. 9).

5.

As cultivating action begins, pull back on the cultivator so that the tines can penetrate the ground.

6.

Once the ground has been broken, continue at a moderate pace until you are familiar with the controls and the handling of the cultivator.

7.

Pull the cultivator backwards to improve the depth of cultivation and reduce your effort.

WARNING:

To prevent seriouS perSonal injury, use extreme caution when reversing or pu!ling

the unit towards you

8.

If the tines are digging too deep or not deep enough, adjust them according to Adjusting

Tine Depth.

I

Fig. 9

ADJUSTING

TINE DEPTH

Tine adjustment will vary depending on the type of soil being cultivated and how it will be used, Generally, adjusting the tines to break the soil 4 to 6 inches is recommended for most gardens, Adjust the tines as follows:

1.

Stop the engine and disconnect the spark plug wire.

2.

Loosen (do not remove) the two wing nuts on the tine guard (Fig. 10).

3.

Slide the wheel bracket assembly down for shallower penetration, and up for deeper tine penetration.

4.

Once the tines are in the desired position, tighten the wing nuts, making sure that the carriage bolts are seated properly through the bracket.

5.

If the tine depth is incorrect, repeat steps 2 to 4.

6.

Reconnect the spark plug wire and continue use.

/

Transporting the Unit

.....

/

',

/

\

1.

Stop the engine.

2.

Slide the wheel bracket assembly all the way down.

3.

Tilt the unit back until the tines clear the ground.

4.

Push or pull the unit to the next location.

10

MAINTENANCE& REPAIRINSTRUCTIONS

MAINTENANCE SCHEDULE

Perform these required maintenance procedures at the frequency stated in the table. These procedures should also be a part of any seasonal tune-up.

NOTE:

Some maintenance procedures may require special tools or skills.

If you are unsure about these procedures take your unit to any nonroad engine repair establishment, individual or authorized service dealer.

NOTE:

Maintenance, replacement, or repair of the emission control devices and system may be performed by any non-road engine repair establishment, individual or authorized service dealer,

In order to assure peak performance of your engine, inspection of the engine exhaust port may be necessary after 50 hours of operation.

If you notice lost RPM, poor performance or general lack of acceleration, this service may be required.

If you feel your engine is in need of this inspection, refer service to any non-road engine repair establishment, individual or authorized service dealer for repair. DO NOT attempt to perform this process yourself as engine damage may result from contaminants involved in the cleaning process for the port.

FREQUENCY

Before starting engine

Every 10 hours

Every 25 hourS

Every 50 hours

MAINTENANCE REQUIRED

Fiil fuel tank with fresh fuel mix

Clean and re,oi! air fiiter

Check and €lean spark arrestor

Check spark plug condition and gap

Inspect exhaust port and spark arrestor Screen for c!ogging

or

TINE REMOVAL AND REPLACEMENT

Replace all four (4) tines at the same time, because they will wear evenly through normal use. Work on one side at a time.

WARNING:

To prevent seri0us personal inJuryI always wear heavy gloves when handling the tinesl

3.

4.

5.

,

,

Put the On/Off Stop Control in the STOP (0) position and disconnect the spark plug wire.

Remove the clevis pin clips and clevis pins (Fig. 11).

Remove the tines and felt cushions from the shaft.

Clean and oil the shaft.

,

The tines are stamped with the letter "R" or "L" to identified their position on each side of the gearbox when facing the front of the unit.

Replace the tines and felt cushions onto the shaft with the hubs on the tines facing each other.

REFER TO

Page 8

Page 12

Page 12

Page 13

Page 12

7.

Ensure the tips on tines are aligned in the same direction with each other before reinstalling the clevis pins and pin clips (Fig. 12).

8.

Repeatthis procedure on the opposite Side.

NOTE: When installed correctly, there will bean R

J and"L, tine on both the gearbox and the tips of the tinesl These letters will line up inthe same tines direction for each side. It is important that the are installed correctly.

Felt

Cushion

Fig.12

Align Tips

Clevis Pin "

Tine Hubs

L

Shaft

R

L

Clevis Pin Clip

11 ¸

MAINTENANCE& REPAIRINSTRUCTIONS

AIR FILTER MAINTENANCE

Removing the Air Filter/Muffler Cover

WARNING:

To avoid seri0uS personal injury,

Fig,14

1.

Place the choke control in the PARTIAL choke position (B).

NOTE:

The choke control must be in the PARTIAL choke position (B) (Fig. 13) to remove the air filter/ muffler cover.

2.

Remove the four (4) screws securing the air filter/muffler cover (Fig. 13). Use a flat blade or # T20 Torx bit screwdriver.

3.

Pull the cover from the engine.

Do not force.

Fig. 13

Choke

Screws

©

Partial Choke

Position (B)

. Screws

I

I

\

\

\

I

I

I

I

I

I

I

I

I

I

/

/

j

I

I

Air Filter

_

Cover

Inside Muffler

C

Cleaning the Air Filter

Clean and re-oil the air filter every 10 hours of operation.

It is an important item to maintain.

Failure to maintain the air filter will VOID the warranty.

1.

Remove the air filter/muffler cover. Refer to the

Removing the Air filter/Muffler

Cover section.

2.

Remove the air filter from inside the air filter/muffler cover (Fig. 14).

3.

Wash the filter in detergent and water (Fig. 14). Rinse the filter thoroughly.

Squeeze out excess water. Allow it to dry completely.

4.

Apply enough SAE 30 oil to lightly coat the filter (Fig. 15).

5.

Squeeze the filter to spread and remove extra oil (Fig. 15).

6.

Replace the air filter inside the muffler cover (Fig. 14).

NOTE:

Operating the unit without the air filter and cover assembly will VOID the warranty.

Reinstalling

the Air filter/Muffler

Cover

1.

Place the air filter/muffler cover over the back of the carburetor and muffler.

NOTE: The choke control must be in the PARTIAL choke position (B) (Fig. 13) to remove the air filter/ muffler cover.

2.

Insert the four (4) screws into the holes in the air filter/ muffler cover (Fig. 13) and tighten.

Use a flat blade or # T20

Torx bit screwdriver. Do not over tighten.

Do not force.

SPARK ARRESTOR MAINTENANCE

1.

Remove the air filter/muffler cover. Refer to Removing the

Air Filter/Muffler Cover.

,

,

Locate the muffler front and the two (2) bolts securing it to the engine (Fig. 16). Remove the two (2) bolts using a flatblade screwdriver or 5/16-inch socket or nut driver.

Pull the muffler off of the engine.

Turn the muffler over to the back side and locate the exhaust gasket. Remove the muffler gasket from the muffler (Fig. 16).

NOTE: If the exhaust gasket is torn or damaged, replace it with a new gasket before you reassemble the muffler,

4.

Using a small flatblade screwdriver, carefully pry up the spark arrestor from the recessed hole (Fig. 17). Remove the spark arrestor from the muffler.

5, Clean the spark arrestor with a wire brush, Replace it if it is damaged or if it can't be cleaned thoroughly (Fig, 17),

6.

Reinstall the spark arrestor by pressing it into the recessed hole on the muffler's back side. Make sure it fits tightly against the muffler and is not raised up.

7.

Place the exhaust gasket against muffler's back side.

Align the gasket bolt holes with the bolt holes in the muffler. While holding exhaust gasket in place, insert the bolts into the muffler's front side (Fig. 16).

12

Bolts

Muffler

- Front Side

Spark Arrestor

MAINTENANCE& REPAIRINSTRUCTIONS

8. Place the muffler(with the exhaust gasket in place and bolts inserted), against the engine, aligning the bolt holes.

Tighten the bolts to Secure the muffler to the engine. If using a torque wrench, torque to:

80-90

&Reinstall in..Ib, (9.10.2

N.m) the air filter/muffler cover:

WARNING:

If the muffler is not tig htened securely, it could fall off causing damage to the unit and

Spark

Arrestor

Exhaust Gasket

Muffler - Back Side

Screwdriver

Adjust Idle Speed Adjuster

_ speed adjustments: and observe unit

Wear protective all safety instructions clothing to prevent

I serious Pe!sona!

injury.

I

If after checking the fuel mixture and cleaning the air filter the engine still will not idle, adjust the idle speed screw as follows:

1.

Start the engine and let it run for about 2-3 minutes at a high speed (full throttle) to warm up. Refer to the

Starting/Stopping Instructions.

NOTE:

Ensure the tines are not in contact with the ground when adjusting the idle.

,

Release the throttle control and let the engine idle. If the engine stops, insert a small phillips or flat blade screwdriver into the hole in the muffler cover (Fig. 18).

Turn the idle speed screw clockwise 1/8 of a turn at a time (as needed) until the engine idles smoothly.

NOTE:

The tines should not rotate during engine idle,

3.

If the tines rotate when the engine idles, turn the idle speed screw counterclockwise 1/8 of a turn at a time

(as needed), to reduce idle speed.

Checking the fuel mixture, cleaning the air filter, and adjusting the idle speed screw should solve most engine problems.

If not and all the following are true:

• The engine will not idle

• The engine hesitates or stalls on acceleration

• There is a loss of engine power

Have the carburetor adjusted by an authorized service dealer.

Spark Arrestor

Muffler - Back Side

CARBURETOR ADJUSTMENTS

The engine's idle speed adjuster is adjustable through the air filter/muffler cover (Fig 18).

NOTE:

Careless adjustments can seriously damage your unit. An authorized service dealer should make carburetor adjustments.

Check Fuel Mixture

Old and/or improperly mixed fuel is usually the reason for the unit not running properly.

Drain and refill the tank with fresh, properly mixed fuel prior to making any adjustments.

Refer to Oil and Fuel Information.

Clean Air Filter

The condition of the air filter is important to the operation of the unit. A dirty air filter will restrict air flow and change the air/fuel mixture.

This is often mistaken for an out of adjustment carburetor.

Check the condition of the air filter before adjusting the idle speed adjuster. Refer to AirFilter

Maintenance.

13

REPLACING THE SPARK PLUG

Use a Champion RDJ7Y spark plug (or equivalent).

The correct air gap is 0.020 in. (0.5 ram). Remove the plug after every 25 hours of operation to check its condition.

1.

Stop the engine and allow it to cool. Grasp the plug wire firmly and pull the cap from the spark plug.

2.

Clean dirt from around the spark plug. Remove the spark plug from the cylinder head by turning a 5/8 in. socket counterclockwise.

NOTE: Replace a cracked, fouled or dirty spark plug.

3.

Set the air gap at 0.020 in. (0.5 ram) using a feeler gauge

(Fig. 19).

CAUTION:

Do not sand blast, scrape or clean electrodes.

Grit in the engine could damage the cylinder.

MAINTENANCE& REPAIRINSTRUCTIONS

0.020 in.

(0.5 mm)

4, Install a correctly gapped spark plug in the cylinder head

Tighten by turning the 5/8 in, socket clockwise until snug,

If using a torque wrench torque to:

110-120 in.-Ib.

(12.3-13.5

N.m)

Do not over tighten.

CLEANING THE UNIT

TRANSPORTING

•

•

• Allow the engine to cool before transporting.

Secure the unit while transporting.

Drain the fuel tank before transporting

• Tighten fuel cap before transporting

MOVING THE UNIT

1.

Allow the unit to cool before moving.

2.

Loosen the knobs on the handlebar.

3.

Fold the handlebars down as shown (Fig. 20).

always turn the off and allow it to cool before l WARNING: To avoid serious personal injury, you clean or service it.

•

•

Use a small brush to clean off the outside of the unit and to keep the air vents free of obstructions.

Do not use strong detergents or petroleum based cleaners, like kerosene. Some household cleaners contain aromatic oils such as p_ne and lemon that can damage the plastic housings or handles. Wipe off any moisture with a soft cloth.

STORAGE

• Never store a fueled unit where fumes may reach an open flame or spark.

•

Allow the engine to cool before storing.

•

Store the unit in a locked up area to prevent unauthorized use or damage.

•

Store the unit in a dry, well-ventilated area.

•

Store the unit out of the reach of children.

LONG TERM STORAGE

If you plan to store the unit for an extended time:

1.

Drain all fuel from the fuel tank into a container.

Do not use fuel that has been stored for more than 60 days.

Dispose of the old fuel in accordance to local regulations.

2, Start the engine and allow it to run until it stalls, This ensures that all fuel has been drained from the carburetor,

,

Allow the engine to cool. Remove the spark plug and put

1 oz. (30 ml) of high quality motor oil into the cylinder.

Pull the starter rope slowly to distribute the oil. Reinstall the spark plug.

NOTE: Remove the spark plug and drain all of the oil from the cylinder before attempting to start the unit after storage.

4.

Thoroughly clean the unit and inspect for any loose or damaged parts. Repair or replace damaged parts and tighten loose screws, nuts or bolts. The unit is ready for storage.

x

Handlebar Knobs

4.

Either carry the unit bythe shaft tube grip or grasp the center of the hand lebar to use it as a carrying handle

5.

After the unit has been moved, reposition the ......................

handlebars and continue operation.

Fig,21

14

ACCESSORIES/REPLACEMENT PARTS

2-Cycle Oil .........................................

Spark Plug .........................................

Fuel Cap ...........................................

Tine (L) (Left Side Outer or Right Side Inner) .........

Tine (_ (Right Side Outer or Left Side Inner) .........

Clevis Pin with Clip ..................................

147543

610311

180000

182729

182730

147473

ENGINE WILL NOT START

CAUSE

On/Off Stop Control in the STOP position

Empty fuel tank

Primer bulb wasn't pressed enough

Engine flooded

Old or improperly mixed fuel

Fouled spark plug

Plugged spark arrestor

ENGINE WILL NOT IDLE

CAUSE

Air Filter is Plugged

Old or improperly mixed fuel

Improper carburetor adjustment

ENGINE WILL NOT ACCELERATE

CAUSE

Old or improperly mixed fuel

Improper carburetor adjustment

Cultivator tines bound with dirt or grass

Dirty air filter

Plugged spark arrestor

ACTION

Turn the On/Off Stop Control to START

Fill fuel tank

Press primer bulb fully and slowly 5-7 times

Use starting procedure with choke control in RUN

Drain fuel tank / Add fresh fuel mixture

Replace or clean the spark plug

Clean or replace spark arrestor

ACTION

Replace or clean the air filter

Drain fuel tank / Add fresh fuel mixture

AdJust according to the Carburetor Adjustments section

ACTION

Drain fuel tank / Add fresh fuel mixture

Take to an authorized service dealer for a carburetor adjustment

Stop the unit, switch the On/Off Stop Control to STOP, clean and remove any debris binding the tine

Clean or replace the air filter

Clean or replace spark arrestor

ENGINE LACKS POWER OR STALLS WHEN UNDER LOAD

CAUSE

Old or improperly mixed fuel

Improper carburetor adjustment

Fouled spark plug

Plugged spark arrestor

ACTION

Drain fuel tank / Add fresh fuel mixture

Take to an authorized service dealer for a carburetor adjustment

Replace or clean the spark plug

Clean or replace spark arrestor

ENGINE

DRIVE SHAFT AN D CULTIVATOR

16

EPA Emission Control Warranty Statement

Your Warranty Rights and Obligations

The Environmental Protection Agency and MTD SOUTHWEST INC (MTD) are pleased to explain the emission control system warranty on your 2002 and later small off-road engine.

New small off-road engines must be designed, built and equipped to meet stringent anti-smog standards.

MTD must warrant the emission control system on your small off-road engine for the periods 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-injected system, the ignition system, and catalytic converter.

Also included may be hoses, belts, connectors and other emission-related assemblies.

Where a warrantable condition exists, MTD will repair your small off-road engine at no cost to you including diagnosis, parts and labor.

The 2002 and later 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 my MTD.

Owners Warranty Responsibilities

• As the small off-road engine owner, you are responsible for the performance of the required maintenance listed in your

operator's manual. MTD recommends that you retain all receipts covering maintenance on your small off-road engine, but MTD cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

• As the small off-road engine owner, you however should be aware that MTD 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.

• You are responsible for presenting your small off-road engine to a MTD Authorized Service Center as soon as a problem exists.

The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

If you have any questions regarding your warranty rights and responsibilities, you should call 1-800-345-8746.

Manufacturer's Warranty Coverage

• The warranty period begins on the date the engine or equipment is delivered to the retail purchaser.

• The manufacturer warrants to the initial owner and each subsequent purchaser, that the engine is free from defects in material and workmanship which cause the failure of a warranted part for a period of two years.

• Repair or replacement of warranted part will be performed at no charge to the owner at an Authorized MTD Service Center. For the nearest location please contact MTD at: 1-800-345-8746.

• Any warranted part which is not scheduled for replacement, as required maintenance or which is scheduled for only for regular inspection to the effect of "Repair or Replace as Necessary" is warranted for the warranty period. Any warranted part which is scheduled for replacement as required maintenance will be warranted for the period of time up to the first scheduled replacement point for that part.

• The owner will not be charged for diagnostic labor which leads to the determination that a warranted part is defective, if the diagnostic work is performed at an Authorized MTD Service Center.

• The manufacturer is liable for damages to other engine components caused by the failure of a warranted part still under warranty.

• Failures caused by abuse, neglect or improper maintenance are not covered under warranty.

• The use of add-on or modified parts can be grounds for disallowing a warranty claim. The manufacturer is not liable to cover failures of warranted parts caused by the use of add-on or modified parts.

• In order to file a claim, go to your nearest Authorized MTD Service Center. Warranty services or repairs will be provided at all

Authorized MTD Service Centers.

• Any manufacturer approved replacement part may be used in the performance of any warranty maintenance or repair of emission related parts and will be provided without charge to the owner. Any replacement part that is equivalent in performance or durability may be used in non-warranty maintenance or repair and will not reduce the warranty obligations of the manufacturer

• The following components are included in the emission related warranty of the engine, air filter, carburetor, primer, fuel lines, fuel pick up/fuel filter, ignition module, spark plug and muffler.

PARTS LIST

ENGINE PARTS - MODEL BL410

2-CYCLE GAS CULTIVATOR

21AK410G163

Item

1

Part No.

791-182059

5

6

7

8

2

3

4

791-180350

791-180351

791-180226

791-182160

791-182161

791-182162

753-04106

791-610675

791-181860

791-181558

753-1196

791-684451

753-1208

791-180026

791-612134

753-04237

791-182612

791-181168

791-682039

791-145308

791-683065

791-181861

791-182064

791-181867

791-181065

791-181597

791-613102

791-180930

791-611061

791-180317

791-181079

791-613103

791-181912

25

26

27

28

29

30

31

32

33

34

16

17

18

19

20

21

22

23

24

9

10

11

12

13

14

15

Description

Air Cleaner/Muffler Cover Assembly

(includes 2 & 40)

Air Cleaner Filter

Carburetor Mounting Screw Assembly

Wavey Washer

Choke Lever Assembly (includes 6)

Choke Knob and Screw

Choke Lever and Plate (includes 5)

Carburetor Assembly W/Limiter Caps

(includes 9 & 21)

Carburetor Gasket

Carb Mount Screw

Primer and Hose Assembly

Carb Mount Assembly (includes 10)

Reed Assembly

Carburetor Mount Gasket

Crank Case Service Assembly

(includes 10, 14 & 24)

Rear Mounting Pad

Fuel Tank Assembly (includes 19-21)

Fuel Cap Assembly

Fuel Return Line

Fuel Line Assembly

Front Mounting Pad

Shroud Assembly

Shroud Screw

Shroud Extension and Stand

Flywheel Assembly

Spacer

Recoil Pulley Assembly

Recoil Spring

Pulley Retainer Assembly

Rope Guide

Fuel Tank Guard Assembly

Pull Handle

Rope

Housing Screw

Item

35

45

46

47

48

41

42

43

44

49

50

51

36

37

38

39

40

*

*

*

*

Part No.

753-04238

791-182368

791-182369

791-153592

791-180098

791-181345

791-153597

791-181937

791-182880

791-610311

753-04159

791-182174

791-182464

791-181622

753-1207

753-1197

791-182723

753-04134

791-180602

791-180090

791-181069

791-180091

753-1209

753-1210

791-181501

791-181873

791-181562

791-610309

791-181599 notshown

Description

Starter Housing Assembly

(includes items 27-30, 32-34)

Clutch Washer

Clutch Rotor Assembly

Clutch Drum Assembly

Clutch Cover Assembly (includes item 40)

Clutch Cover Screw

Upper Clamp Assembly

Module Assembly

Wire Lead

Spark Plug

Exhaust Gasket

Muffler Assembly (includes item 45 & 47)

Muffler Mounting Bolt Assembly

Cylinder Assembly (includes items 51 & 52)

Piston and Rod Assembly

Cylinder Gasket

Cylinder Bolt

Engine Gasket Kit

O.E.M Carburetor Repair Kit (Walbro)

O.EM. Carburetor Repair Kit (Zama)

Gasket-Diaphragm Repair Kit (Walbro)

Gasket-Diaphragm Repair Kit (Zama)

Piston Ring

Short Block Assembly (items 14, 44, 48-51)

Starter Housing Screw Set

Carburetor Limiter Cap Set (Walbro)

Carburetor Limiter Cap Set (Zama)

Crankcase Seal

Clutch Springs (Qty. 2)

I

PARTS

BOOM AND CULTIVATOR PARTS - MODEL BL410

2-CYCLE GAS CULTIVATOR

21AK410G163

LIST

23

24

25

26

27

19

20

21

22

12

13

14

15

16

17

18

28

29

30

7

8

9

10

11

Item Part No.

1 791-00023

2

3

4

5

6

791-182882

791-182675

791-182676

791-182678

791-182899

791-182898

791-180943

791-181577

791-683295

791-181811

791-181812

791-181813

791-181814

791-181815

791-145569

791-181575

791-182900

791-182681

791-147467

791-181579

753-04240

791-180320

791-180944

791-147474

791-182195

791-180288

791-147473

791-182729

791-182730

Descr_tion

Throttle Trigger and Cable Assembly

Handle Bar Assembliy, Upper (includes 3& 4)

Grip

Tube Closure

Washer

Bolt

Knob, 3 prong

Drive Shaft Housing Assembly

Flexible Drive Shaft

Handle Bracket Assembly (includes 11-16)

Screw

Upper Handle Clamp

Middle Handle Clamp

Lower Handle Clamp

Nut

Anti-Rotation Screw

Grip

Lower Handle Bar

Hardware, Handle Bar Mounting (lower)

Wheel Bracket Mounting Hardware

Guard Mounting Hardware

Guard

Wheel Bracket Assembly

Wheel Assembly

Gear Box Assembly

Screw

Sleeve Retainer Bolt

Tine Fastener Assembly

Tine Assembly (Left Outer or Right Inner)

Tine Assembly (Left Inner or Right Outer)

_tional

*

Accessories

147543 £yobi 2-Cycle Oil

*not shown

MANUFACTURER'SLIMITEDWARRANTYFOR:

The limited warranty set forth below is given by Troy-Bilt

LLC with respect with new merchandise purchased and used in the United States, its possessions and territories.

Troy-Bilt warrants this product against defects in material and workmanship 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 material 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 Troy-Bilt for use with the product(s) covered by this manual will void your warranty asto any resulting damage.

This warranty is limited to ninety (90) days from the date of original retail purchase for any Bolens product that is used for rental or commercial purposes, or any other income-producing purpose.

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, please check for a listing in the Yellow Pages or contact the Customer Service Department of Troy-Bilt LLC by calling 1-866-840-6483 or writing to PO Box 361131,

Cleveland, Ohio 44136-0019.

No product returned directly to the factory will be accepted unless prior written permission has been extended by the Customer Service

Department of Troy-Bilt LLC.

This limited warranty does not provide coverage

in the

following cases:

A.Tune-ups - Spark Plugs, Carburetor AdJustments, Filters

B. Wear items - Bump Knobs, Outer Spools,Cutting Line,

Inner Reels, Starter Pulley, Starter Ropes, Drive Belts

C. Troy-Bilt does not extend any warranty for products sold or exported outside of the United States of

America, its possessions and territories, except those sold through Troy-Bilt's authorized channels of export distribution.

Trot-Bilt reserves the right to change or improve the design of any Bolens Product without assuming any obligation to modify any product previously manufactured.

No implied

warranty, including any implied warranty of merchantability or 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 or guaranty, 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 Troy-Bilt LLC. During the period of the Warranty, the exclusive remedy is repair or replacement of the product as set forth above.

(Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you,)

The provisions as set forth in this Warranty provide the

sole and exclusive

remedy arising from the sales. Troy-Bilt

LLC shall not be liable for incidental or consequential loss or damages including, without limitation,

expenses

incurred for substitute or replacement lawn care services, for transportation or for related

expenses,

or for rental

expenses

to temporarily replace a warranted product.

(Some states do not allow limitations on how long an implied warranty lasts, so the above limitation 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 the 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 use or misuse or inability to use the product.

This limited warranty shall not extend to anyone other than the original purchaser, original lessee or the person for whom it was purchased as a gift.

How State Law Relates to this Warranty:

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state,

To locate your nearest service dealer dial 1-866-840-6483,

TROY-BILT LLC

PO Box 361131

Cleveland, OH 44136-0019 U.S.A.

SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE

FOR QUESTIONS CALL 1-866-840-6483

OPERATOR'S MANUAL PART NO. 769-00413

PRINTED IN U.S.A.

08/02