owner’s manual sickle bar mowers - m-and-d.com · pdf fileowner’s manual sickle...

OWNER’S MANUALSickle Bar Mowers

• Safety• Assembly• Controls and Features• Operation• Maintenance• Parts List

GARDEN WAY INCORPORATED

Models

34061 – 34", 3-1/2 HP Recoil Start34062 – 38", 4HP Recoil Start34337 – 34", 4HP Recoil Start34063 – 42", 5HP Recoil Start34064 – 42", 5HP Electric Start

SAFETY FIRST!Before operating this equipment, read thisOwner's Manual and the separate manual

supplied by the engine manufacturer.

2

Dear Owner:

Thank you for purchasing our product. We feel you now ownone of the finest pieces of outdoor power equipment available.Our equipment is carefully designed, engineered and manufac-tured for excellent performance if properly operated and main-tained.

Read this manual carefully to familiarize yourself with the unit,its features, and its safe operation. Be sure that you and anyother operators carefully follow the recommended safety prac-tices at all times. Failure to do so could result in personal injuryor property damage.

This is a safety, operation and general maintenance manualwhich does not attempt to cover major repairs. All informationin this manual is based on the latest product information avail-able at the time of printing. This manual is considered a perma-nent part of the unit and it must stay with the unit if resold. Areplacement manual can be obtained from the factory or anauthorized dealer.

Please fill out and return the postpaid owner registration cardincluded with this manual. The purpose of the card is to registereach unit and owner at the factory to provide product updatesand warranty service.

If you have any problems or questions concerning the unit,please contact your local authorized dealer or the factory (seeback cover of this manual). We want to be sure that you arecompletely satisfied at all times.

INTRODUCTION ................................................. 2Service Information ...................................................... 3Identification Numbers ................................................. 3California Operators Warning ....................................... 3

SAFETY .......................................................... 3Safety Decals ................................................................ 5

ASSEMBLY ...................................................... 6

FEATURES AND CONTROLS ................................... 14Throttle/Choke Control Lever ........................................ 14Operator Presence Controls (OPC) ............................... 14Wheel Drive Levers ....................................................... 14Engine Oil Dipstick/Fill Hole .......................................... 14Shoes ........................................................................... 14Cutter Bar (with guard) ................................................. 15Fuel Tank Cap ............................................................... 15Starter Rope Handle ..................................................... 15Engine Keyswitch (electric-start units) .......................... 15Cutter Bar Lever ........................................................... 15Weed Diverter ............................................................... 15Engine Primer Bulb ....................................................... 15

OPERATION ..................................................... 16Pre-start Checklist ........................................................ 16Starting the Engine ....................................................... 16Stopping the Engine ...................................................... 17Operator Presence Controls (OPC) System Test .......... 17Operation....................................................................... 18Operating on Slopes ...................................................... 19Stopping ....................................................................... 19

MAINTENANCE ................................................. 20Maintenance Schedule................................................... 20Tire Pressure ................................................................. 20Clearing Wheel Wrap .................................................... 20Wheel Drive Control Rod Adjustment ........................... 20Cutter Bar Drive Belt Removal/Replacement ................ 21Cutter Bar Belt Guide Adjustment ................................ 21Wheel Drive Belt Adjustment ........................................ 21Wheel Drive Belt Removal/Replacement ....................... 21Wheel Drive Belt Guide Adjustment .............................. 21Drive Chain Adjustment and Lubrication ...................... 22Cutter Bar Maintenance ............................................ 22-24High-Wear Parts ........................................................... 24Housing Assembly Tightening Sequence....................... 26Front Housing Removal ................................................. 26Eccentric Shaft Removal/Replacement .......................... 26Engine Maintenance .................................................. 26-27Battery Maintenance...................................................... 27Check and Tighten Hardware......................................... 27Lubrication .................................................................... 27Storage ......................................................................... 28Troubleshooting ....................................................... 28-29

PARTS LIST...................................................... 30

CUSTOMER SERVICE INFORMATION ............. BACK COVER

Table of Contents

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects or other reproductive harm.

WARNING

Safety Alert SymbolThis is a safety alert symbol. It is used in thismanual and on the unit to alert you to potential haz-ards. When you see this symbol, read and obey themessage that follows it. Failure to obey safety mes-sages could result in personal injury or propertydamage.

See Back Cover for Customer Service Information

Left and Right SidesLeft and right sides of the unit are determined by standing inthe operator position and facing the direction of forwardtravel.

PREPARATION1. Unit is capable of amputating handsand feet andthrowingobjects.Failure toobserve thefollowing safety instructions could resultin serious injury or property damage.2. Serious accidents which may causeinjury or property damage can occur if thefollowing safety guidelines are not fol-lowed. The operator is solely responsiblefor accidents or hazards that occur whenusing the unit. Preventing accidents is theresponsibility of every equipment oper-ator. Accidents can be prevented. Becareful before, during and immediatelyafter use of any powered equipment. Thefollowing general safety precautions mustbe fully understood and followed duringoperation. Review these instructions fre-quently and never take chances. If you donot understand any part of this manual orneed assistance, contact your dealer orour service department.

TRAINING1. Read, understand, and follow thisOwner’s Manual, the separate engineowner’s manual, and all other literaturereceived before you use the unit.

Be thoroughly familiar with the controlsand proper use of the unit. Know how tostop the unit and disengage controlsquickly in case of emergency.

Read and follow all safety information inthis manual. Failure to comply could resultin serious personal injury or propertydamage.

Make sure all operators of the equipmentread, understand, and follow these safetyinstructions.2. Never allow children to operate the unit.Do not allow adults to operate the unitwithout proper instruction. Do not allowirresponsible adults to operate the unit.

3. Keep the operating area (within 25 feetof unit) clear of all people (especially chil-dren) and pets.

PREPARATION1. Wear proper clothing when operatingunit. Always wear sturdy footwear (prefer-ably steel-toed shoes) and hearing protec-tion during operation.

a. Wear heavy leather gloves wheneverworking near or servicing any cuttingedges on the unit.

b. Do not wear loose-fitting clothing,jewelry, scarves, ties, etc., which mayget caught in moving parts. Tie up orrestrain hair.

c. Do not operate the unit while bare-foot. Do not wear sandals.

d. Wear long trousers.e. Wear hearing protection.

2. Do not operate the unit when tired, illor under the influence of alcohol and/orother drugs.3. Be prepared for an emergency. Keep afirst aid kit and fire extinguisher handy.Keep emergency telephone numbers forambulance, fire, hospital, doctor andrescue near your telephone.4. When charging the battery on electric-start units, use only the battery chargerprovided with the unit.5. Do not operate the unit if the cutter barassembly is not securely installed andoperating properly.6. Mow only during daylight or in goodartificial light.7. Never operate the unit in wet grass.Always be sure of your footing. Always holdhandlebar grips firmly, and walk––neverrun.

25 Ft. 25 Ft.25 Ft.25 Ft.

Safety1Section

3

SPARK ARRESTER WARNING TO RESIDENTS OF CALIFORNIA AND SEVERAL OTHER STATES

Under California law, and under the laws of severalother states, you are not permitted to operate aninternal combustion engine using hydrocarbon fuels onany forest, brush, hay, grain, or grass covered land; orland covered by any flammable agricultural cropwithout an engine spark arrester in continuous effectiveworking order.

The engine on the unit is an internal combustion enginewhich burns gasoline, a hydrocarbon fuel, and must beequipped with a spark arrester muffler in continuouseffective working order. The spark arrester must beattached to the engine exhaust system in such amanner that flames or heat from the system will notignite flammable material. Failure of the owner/oper-ator of the unit to comply with this regulation is a mis-demeanor under California law (and other states) andmay also be a violation of other state and/or federalregulations, laws, ordinances or codes. Contact yourlocal fire marshal or forest service for specific informa-tion about which regulations apply in your area.

Throttle/Choke Control Lever

Wheel DriveLevers

Cutter Bar and Guard

Cutter Bar Lever(on rear of unit)

Operator Presence Controls

Figure 1-1

4 Section 1: Safety

BEFORE OPERATION1. Before each use, thoroughly inspect themowing area. Remove allmetal, debris, and otherhazards. Inspect for holes,ruts or bumps. Uneven ter-rain could overturn the unit.Tall vegetation can hide hazards.2. Never operate the unit without allguards in place and working properly(except for the plastic blade protector,which should be removed before startingthe engine).3. Before removing or installing theplastic blade protector, shut the engineoff, disconnect the spark plug wire, andprevent it from touching the spark plug.On electric start models, also remove theignition key from the keyswitch.4. Check the operation of the controllevers under each handlebar grip. See the"Operation" Section in this manual for spe-cific instructions. Do not use the unit ifcontrol levers are not functioning properly.CORRECT ANY MALFUNCTION BEFOREUSING THE UNIT!

HANDLING GASOLINE1. Use extreme care in handling gaso-line and other fuels.Gasoline is highlyflammable and its vaporsare volatile, explosive,and dangerous. Keep gasoline and gaso-line containers away from hot engineexhaust. Never allow flame, sparks,smoking materials or other hot objectsnear gasoline, gasoline fumes, the fuelcontainer or fuel tank.2. Use an approved fuel container only.Wipe up any spilled gasoline immediately.3. Leave one inch of air space at top offuel tank to allow room for expansion.4. Store gasoline in a cool, well-ventilatedarea. Never store unit or fuel containerinside where there is an open flame orspark, such as a hot water heater, furnace,etc.5. Never remove fuel fill cap, or add fuelto fuel tank, if engine is running or hot.Allow the engine to cool for several min-utes before filling the fuel tank. Alwaysreplace fuel fill cap before starting engine.6. Never refuel unit indoors. Refuel out-doors in a well-ventilated area only.

7. Check the gasoline level in the fuel tankoutdoors, before starting the engine.Reinstall the fuel tank cap securely andclean up any spilled gasoline beforestarting the engine.8. Do not smoke while mowing.9. Move the unit away from gasolinefumes before starting the engine.

OPERATION1. Keep the plastic blade protector on thecutter bar blade until you are ready to startthe engine.2. Do not put hands or feet near or underany moving parts. Keep clear of the cutterbar at all times while the engine is running.3. Never leave the operator position whilethe engine is running. Stopthe engine, disconnect thespark plug wire and move itaway from the spark plug tohelp prevent accidentalstarting whenever leaving the unit unat-tended. On electric start models, removethe ignition key to help prevent accidentalstarting or unauthorized use.4. Before removing or installing theplastic blade protector, shut the engineoff, disconnect the spark plug wire, andprevent it from touching the spark plug.On electric start models, also remove theignition key from the keyswitch.5. Do not change the engine governor set-ting. Over-speeding may damage theengine and unit and will void the warranty.See an authorized engine service dealer ifan engine problem exists.6. Disengage the cutter bar whencrossing gravel drives, walkways or roads.7. Watch for, and avoid, traffic whenoperating near roadways.8. Disengage the cutter bardrive and the wheel drive ifyou are approached by a child,inattentive person or a pet.9. Before inspecting, adjusting orrepairing the unit or cutterbar, stop the engine, let allmoving parts come to acomplete stop, disconnectthe spark plug wire, andinstall the plastic blade guard. On electricstart models, remove the ignition key fromthe keyswitch.

10. If the unit should start to vibrateabnormally, stop the engine, wait for allmoving parts to stop completely, discon-nect the spark plug wire and prevent itfrom touching the spark plug. Remove theengine ignition key on electric startmodels. Inspect the unit for damage.Repair any damage before continuing.11. If the unit should strike a foreignobject, stop the engine, wait for all movingparts to stop completely, disconnect thespark plug wire and prevent it fromtouching the spark plug. Remove theengine ignition key on electric startmodels. Inspect the unit for damage.Repair any damage before continuing.12. Do not run the engine in an enclosedarea. Engine exhaust contains carbonmonoxide, a deadly, poisonous gas that isodorless, colorless and tasteless. Alwaysrun the engine outdoors with adequateventilation.

13. Always mow across the face of slopes.Do not operate unit on slopes steeper than15°.14. Keep all movements on a slope slowand gradual. Do not make sudden changesin speed or direction.15. Do not touch engine parts which maybe hot from operation. Let parts cool forseveral minutes before going near them.16. Keep children out of the mowing areaand under the supervision of a responsibleadult other than the unit operator.17. Before and when backing, check forand avoid obstacles and hazards.18. Disengage the cutter bar drive whennot mowing.19. Do not mow near drop-offs, ditches orembankments. If a wheel drops off anedge, the unit could suddenly overturn.20. To help reduce fire hazard, keep theengine free of grass, leaves, grease andother debris.

CHILDREN1. Tragic accidents can occur if the oper-ator is not alert to the presence of chil-dren. Children are often attracted to theunit and the mowing activity. Neverassume that children will remain whereyou last saw them.2. Never allow children to operate theunit, even under adult supervision. Localregulations may restrict operator age. Onlyallow responsible adults, who are familiarwith these instructions, to operate theunit.

Section 1: Safety 5

3. Never carry children as passengers.Do not carry ANY passengers. They mayfall off, become seriously injured, or inter-fere with safe unit operation.4. Keep children out of the work area andunder the watchful care of a responsibleadult other than the unit operator.5. Be alert and turn unit off if childrenenter the area.6. Before and when backing, look behindand down for children.7. Use extra care when approaching blindcorners, shrubs, trees, or other objectsthat may obscure vision.8. Keep children away while performingmaintenance or adjustments.

MAINTENANCE AND STORAGE1. Before inspecting, cleaning, adjustingor repairing the unit, stop the engine, letall moving parts come to acomplete stop, disconnectthe spark plug wire, andinstall the plastic bladeguard on the cutter bar. Onelectric start models, remove the ignitionkey from the keyswitch.2. Always wear sturdy footwear (prefer-ably steel-toed shoes), long trousers,hearing and eye protection while doingany maintenance on the unit. Do not wearloose-fitting clothing, jewelry, scarves,ties, etc., which could get caught inmoving parts. Tie up or restrain hair.3. Install the plastic blade guard beforeremoving the cutter bar assembly andwear sturdy leather gloves to help protectyour fingers and hands.

4. Keep children away while performingmaintenance or adjustments.5. Remove any metal jewelry whenworking on or near electrical system com-ponents.6. Use only original equipment replace-ment parts. Parts manufactured by otherscould create a hazard even though theymay fit on the unit.7. Keep the equipment in safe workingcondition. Keep all nuts, bolts and screwstight. Frequently check the enginemounting bolts and cutter bar mountingbolts for tightness.8. Provide safe, adequate light in yourwork area. NEVER USE AN OPEN FLAMEFOR ILLUMINATION! Use only a portablesafety light enclosed in a wire cage forworking on unit. NOTE:Hot filaments from abroken light bulb canignite spilled fuel or oil.9. If the unit has gasoline in its fuel tank,do not store it inside a building wherefumes from the gasoline could reach anopen flame or spark. Let the engine coolbefore storing the unit.10. Store gasoline in a cool, well-venti-lated area, away from spark- or flame-pro-ducing equipment. Store gasoline in anapproved container, away from children.11. Keep unit free of grass, leaves orbuild-up of other debris. Clean up oil orfuel spillage. Allow unit to cool beforestoring.

12. Replace muffler if worn or defective.13. Use extra care when loading orunloading unit into a trailer or truck.14. Do not use food or beverage con-tainers to store waste materials. Usingsuch containers could result in accidentalpoisoning.

ENGINE1. Before starting the engine or operatingthe unit, read the separate engine manualcompletely. Read and follow all safetyinstructions provided in that manual.2. BEFORE SERVICING THE ENGINE:Disconnect the spark plug wire and keep itfrom touching the spark plug.3. Keep the engine free of grass, leaves,oil, and grease.4. Engine exhaust is extremely hot. Keepgrass, oil, fuel, and other combustiblematerials far away from engine exhaust.5. Do not change the engine governor set-ting. Over-speeding may damage theengine and unit and will void the warranty.See an authorized engine service dealer ifa problem exists.6. Never run an internal combustionengine inside a closed area. Engineexhaust contains carbon monoxide gas, adeadly poison. Carbon monoxide is odor-less, colorless and tasteless. Do notoperate the unit near buildings, windows,or air conditioners. If the engine is run in agarage, open all doors and allow for ade-quate ventilation.

Place Hand Here WhenPulling Starter Rope

Hot SurfacesWarning

Sharp Cutter BarBlades Danger

Danger - Keep Handsand Feet Away

On Rear PanelWarning - OperatingEngine - Electric

Start Only

Cover “Top” Decal

Engine Throttle Settings

SAFETY DECAL LOCATION

Operator PresenceControls

SAFETY DECALSKeep all safety decals clean and ingood condition. The location of eachdecal is shown in Figure 1-2.Refer to the Parts List for orderingreplacement decals.

Figure 1-2

Assembly2Section

6

BEFORE ASSEMBLY

Carefully follow all steps in this section toassemble the unit.

CARTON INSPECTIONInspect the unit immediately after delivery.Check the carton and contents for anydamage.

Contact the carrier (trucking company)immediately if the unit is damaged. Informthe carrier that you wish to file a claim.The carrier will let you know how to pro-ceed with the claim. To protect yourrights, file a written claim with the carrierwithin 15 days of receiving the unit. Con-tact our service department if you needassistance.

Do not start the engine until oil is added!The engine is shipped without oil.Engine damage will occur if engine isstarted before oil is added.

IMPORTANT: Oil must be added beforestarting the engine. Starting or operatingthe engine without oil will damage theengine and void the warranty. See theengine manual.

Do not overfill engine with oil. Enginedamage will occur.

Cutter bar blades are extremely sharp.To help avoid serious injury:

• Keep the plastic guard on the CUTTERBAR ASSEMBLY when the unit is notrunning.

• Wear heavy leather gloves when han-dling the cutter bar.

• Do not place fingers between blades.Amputation could result.

UNPACKING THE UNITThe cutter bar blade and attached plasticblade guard are packaged separatelywithin the main shipping crate. Leave thecutter bar blade attached to the shippingpallet until instructed to remove it.

The handlebars are packed on each side ofthe unit, connected with wiring to theunderside of the unit. IMPORTANT: Donot damage the wiring when removing thehandlebars from the carton.

The included parts and hardware requiredfor assembly are listed on the followingpages.

Remove and discard the two screws thatsecure the front of the unit to the woodenpallet (see Fig. 2-1). However, leave theunit on the pallet until instructed toremove it. Fig. 2-1 shows the position ofthe unit for assembly.

TOOLS/MATERIALS NEEDED(2 ea.) Wrenches: 7/16", 1/2", 9/16" (or

adjustable wrenches)(1) Adjustable Wrench(1) 13mm Socket (1) Phillips (or thin straight blade)

Screwdriver(1) All-purpose Oil(1) Tire Pressure Gauge(1) Measuring Tape or Ruler

DANGER

CAUTION

WARNING

Fig. 2-1

Remove shippingscrews

Remove control rodsfrom handlebar

To prevent personal injury or propertydamage, do not start the engine until allassembly steps are complete and youhave read and understand the safety andoperating instructions in this Manualand the engine manual.

WARNING

Section 2: Assembly 7

2

Ref. Description Qty.

Right Handlebar (shipped connected to unit by wiring)...............................................1Left Handlebar (shipped connected to unit by wiring)...............................................1

1 Hex Head Capscrew, 5/16"–18 x 2-1/4" ........22 Locknut, 5/16"–18.......................................103 Handlebar Bridge ..........................................14 Cable Ties (total of six - two already

installed on unit) ...........................................45 Hex Head Capscrew, 1/4"–20 x 2" .................16 Locknut, 1/4".................................................17 Control Rod ..................................................28 Hair Pin ..................................................29 Plastic Blade Guard (on blade)......................110 Cutter Bar......................................................1

HARDWARE IS APPROXIMATE SIZE SHOWNLarge parts (with *) shown reduced

1

4*

8

7*

9*

10*

5 6

3*


-- Right Handlebar (shipped connected to unit by wiring)..............................................1

-- Left Handlebar (shipped connected to unit by wiring)..............................................1

1 Hex Head Capscrew, 5/16"–18 x 2-1/4" ...........22 Toplock Nuts, 5/16"–18 (to mount

handlebars) ..................................................22a Nylock Nuts, 5/16"–18 .....................................83 Handlebar Bridge .............................................14 Cable Ties (total of six - two already

installed on unit) ..........................................45 Hex Head Capscrew, 1/4"–20 x 2" ....................16 Locknut, 1/4"....................................................17 Control Rod (attached to handlebars) ..............28 Hair Pin Clip .....................................................29 Plastic Blade Guard (on Cutter Bar Assembly) .110 Cutter Bar.........................................................1

5

8

1

6

2 2a

3*

7* NOTE: Control rods are attached to one handlebar with a wire tie (see Fig. 2-1). Cutwire tie and remove rods before starting assembly steps.

9*

10*

4*

HARDWARE IS SHOWN APPROXIMATE SIZE(Large parts [with *] shown reduced size)

8 Section 2: Assembly

11*

15*

13

16

17

14


11 Mounting Bracket (already installed).............112 Hex Flange Screw, 3/8"–16 x 1-1/4" long ......313 Flat Washer, 3/8" ...........................................314 Centerlock Nut, 3/8"–16 ................................315 Knife Head.....................................................116 Metric Hex Head Screw, M8 x M25...............217 Metric Internal Tooth Lockwasher, M8 .........218 Pitman Arm Assembly ..................................119 Shoe Holder ..................................................220 Carriage Bolt, 5/16"–18 x 1" ..........................421 Shoe..............................................................222 U-Bolt, 5/16" x 18..........................................223 Flat Washer, 5/16".........................................424 Weed Diverter ...............................................125 Upper Hook ..................................................126 Doubler Plate ................................................127 Flange Nut 1/4"– 20.......................................228 Flat Washer, 1/4" ...........................................129 Hex Head Screw, 1/4"–20 x 1-1/4" long.........130 Battery Charger (optional - not shown).........131 Key (In Keyswitch) (optional - not shown)....1

18* 19*

21*

20

25

27

24*

2223

26*

12


11 Loctite® Thread Fastener, (bottle or tube) ....112 Hex Cap Screw, 3/8"–16 x 1-1/4" (Grade 8) ..313 Flat Washer, hardened, 3/8" ..........................314 Centerlock Nut, 3/8"–16 ................................315 Knife Head.....................................................116 Metric Hex Head Screw, M8 x M12...............2-- Flat Washer, hardened, 5/16" (wire-tied to

knife head (Ref. 15) -- do not remove until instructed to do so) ..........................2

18 Pitman Arm Assembly ..................................119 Shoe Holder ..................................................220 Carriage Bolt, 5/16"–18 x 1" ..........................421 Shoe..............................................................222 U-Bolt, 5/16" x 18..........................................223 Flat Washer, 5/16".........................................524 Weed Diverter ...............................................125 Upper Hook ..................................................126 Doubler Plate ................................................127 Flange Nut 1/4"– 20.......................................228 Hex Head Screw, 1/4"–20 x 1-1/4" ...............129 Battery Charger (optional - not shown).........130 Key (optional - not shown) ...........................1

11

12

1314

16

18* 19*

20

22

23

25

27 28

24*

26*

21*

15*


HANDLEBAR INSTALLATIONNOTE: Handlebar wiring from the oper-ator presence controls (OPC) is connectedto a switch under the unit. DO NOT dis-connect this wiring!

1. Before beginning assembly, disconnectthe spark plug wire from the spark plug.

2. Place the handlebars on the groundbehind the unit.

3. With the ends of the bridge (C, Fig. 2-2) positioned as shown, insert thebridge in between the handlebars into theupper set of handlebar holes.

4. Align the holes in the plastic sleeves(on the bottom ends of the handlebars)with the corresponding handlebar holes inthe deck. For easier installation, apply asmall amount of oil to the sleeve ends.

5. Insert the bottom ends of the handle-bars into their mounting brackets in thedeck (Fig. 2-3). Do not pinch or damagethe attached wiring. Align the screw holes(it may be helpful to align the holes with apunch or drift pin prior to installing thescrews in the next step).

NOTE: Position the handlebars withthumb latches (F, Fig. 2-5) on the innersides of handlebars.

6. Secure each handlebar with a 5/16-18x 2-1/4 hex head capscrew (A, Fig. 2-3)and 5/16"-18 toplock nut (B).

NOTE: When correctly installed, the han-dlebars feel loose. The looseness or “play”

is intentionally designed to reduce vibra-tion which occurs during operation. Therubber sleeves on the handlebar ends actas “shock absorbers” and also help reducevibration.

WHEEL DRIVE CONTROL RODINSTALLATION1. Place the control rods (D, Fig. 2-4)BETWEEN the handlebars and UNDER thebridge, with the threaded ends down. Foreasier installation, apply oil or grease tothe threads. Thread the rods into thepivots (E) twelve turns each. If necessary,use a screwdriver or a punch to move thepivots into position. Be sure that the wireharness on each handlebar is located tothe outside of each control rod.

2. Insert the upper end of each controlrod (G, Fig. 2-5) into the plastic thumblatch (F) slots, then outward through theholes in the wheel drive levers (H).

3. Insert hair pin clips (J, Fig. 2-5)through the hole in each control rod. Posi-tion hair pin clips with loops up, asshown.

CONTROL ROD ADJUSTMENT1. With the controls positioned as shown(Fig. 2-6), measure the gap between thetop of the slot in the thumb latch bracketand the control rod. Do not put any pres-sure on the handlebars when measuring.The gap must measure 1-1/4" (32mm).

If adjustment is required, remove the hairpin clip (J, Fig. 2-5) from the control rod.Remove the control rod from the wheeldrive lever (H) and thumb latch (F). Turnthe control rod as needed to achieve the1-1/4" (32mm) gap.

NOTE: Adjust the wheel drive control rodsproperly. Improper adjustment will resultin broken thumb latches.

C

A

B

D

D

C

B

Install hair pins (D) OUTSIDE levers (C)(l ft id h )

D

AJ on outside with loop up

Fig. 2-2 Fig. 2-3 Fig. 2-4

Fig. 2-5 Outer view of left handlebar

F

JG

H J

E


THROTTLE CONTROL LEVERINSTALLATION1. Unwind the throttle cable from aroundthe left side of the engine, then positionthe throttle control lever (Z, Fig. 2-7) onthe inside of the right handlebar as shown(Figs. 2-7 and 2-8). THE CABLE MUST BEROUTED UNDERNEATH THE CONTROLROD (see AA, Fig. 2-8).

2. Secure the throttle control lever to thehandlebar with a 1/4–20 x 2" hex-headcapscrew (A, Fig. 2-7) and 1/4"-20 locknut(B). TO AVOID DAMAGING PLASTICASSEMBLY, DO NOT OVER-TIGHTENSCREW AND LOCKNUT.

CABLE TIE INSTALLATIONSecure the throttle cable and OPC wiringto the handlebars with cable ties (C, Fig.2-8) to help prevent them from beingdamaged during operation. Two of thecable ties are already installed at the upperend of the handlebars. Remove any slack

from the bottom of the OPC wires (see Fig.2-8A) to avoid catching the cutter bar leveron the wires. Twist the OPC wires (but notthe throttle cable) in a corkscrew patternalong the length of the handlebars andinstall the four cable ties (two on eachside). Cut off excess cable tie with scissors.

UNIT REMOVALSqueeze the four control levers on thehandlebars and carefully roll the unit fromoff the shipping crate. Park the unit on aflat, clean surface where you can completethe remaining assembly steps.

CUTTER BAR ASSEMBLY AND INSTALLATION

Cutter bar blades are extremely sharp!To help avoid serious injury:• When handling cutter bar, wear heavy

leather gloves and wrap cutter barwith rags.

• Keep plastic guard on blade assemblyuntil you are ready to start engine.

• Contact with the blades will causeserious personal injury.

Avoid contact with the cutter bar blades.

1. Remove the screws securing the cutterbar to the crate. Wear heavy leathergloves and wrap cutter bar with rags toavoid cutting yourself on the blades.

2. Carefully remove the cutter bar fromthe shipping crate. Keep the plastic bladeguard on the cutter bar to protect yourselffrom injury.IMPORTANT: To help prevent the unitfrom tipping, have an assistant stand inthe operator position and firmly hold thehandlebars during installation of the cutterbar.

3. REMOVE SPARK PLUG WIRE FROMSPARK PLUG (IF ATTACHED).

4. Have an assistant available to hold theunit firmly by the handlebars.

DANGER

B

A

(C) Already installed

11/4" (32mm)Gap here

(right side shown)

11/4" (32mm)

A

C

C

C

Bridge

Fig. 2-6

Fig. 2-7 Fig. 2-8

ZB

A

Z

C

AA

Fig. 2-8A

Removeslack in wire

(on bothhandlebars).


Disconnect the spark plug wire from thespark plug before attempting to installthe cutter bar. Move the spark plug wireaway from the spark plug and prevent thewire from contacting the plug.

5. Center eccentric arm (A, Fig. 2-14), ifnecessary, by moving cutter bar lever toON (Fig. 2-15) and pulling starter rope.

6. Position the cutter bar (B, Fig. 2-9) atthe front of the cutter bar mountingbracket (C) as shown. Place the doublerbracket (D) on the cutter bar and align thethree mounting holes as shown.

7. Apply a small amount of Loctite®Thread Fastener (use only a small amount,as a total of five screws need to be coatedduring the assembly procedure) to thethreads of the three 3/8-16 x 1-1/4 hexcap screws (E, Fig. 2-9). Have an assistanthold the unit firmly by the handlebars andraise the front of the unit a few inches offthe ground. Securely attach the cutter barand doubler bracket to the cutter barmounting bracket with the three hex capscrews (E), 3/8 flat washers (F) and 3/8-16 center locknuts (G). Torque to 35 ft-lbs. if you have a torque wrench. Lowerthe unit to the ground.

IMPORTANT: Allow the Loctite® to curefor at least one hour (preferably 24 hoursat 72oF.) before operating unit.

8. Align the middle hole (B, Fig. 2-10) inthe cutter bar with the middle locknut (CC,Fig. 2-10) on the cutter mounting bracket.If needed, tap the ends of the cutting bladeback and forth (see inset, Fig. 2-10) toalign the middle hole (use a wood block toavoid damaging the blade).

9. Slide the pitman assembly (H, Fig. 2-10A-1) onto the post of the knife head (I).The “Top” decal on the pitman assemblymust be facing up. Remove the two 5/16hardened flat washers that are wire-tied tothe knife head for shipping purposes.

CAUTION

Fig. 2-9

B

E

GF

CD

J

Fig. 2-10

Fig. 2-10A

BCC

Tap top section ofcutting blade from

side-to-side toalign middle hole(B) with middlelocknut (CC).

H

I

1

2

3

4

L

K


10. As shown in Fig. 2-10A, rotate thepitman assembly sideways and slide theshaft on the pitman assembly into thehole in the eccentric arm (J). Next, rotatethe pitman assembly to its upright posi-tion and turn the knife head so it is par-allel with the cutting blade. Finally, alignthe small centering pin on the bottom ofthe knife head (I) with the middle hole inthe cutter bar (B, Fig. 2-10) and positionthe knife head on the cutter bar.

11. Apply Loctite® Thread Fastener to thetwo 8M x 12M hex head screws (L, Fig. 2-10A) and place the two 5/16" hardenedwashers (K) on the screws. Securelyattach the knife head to the cutter bar withthe two screws (torque to 16-20 ft-lbs ifyou have a torque wrench).

12. At the inner set of mounting holes (M,Fig. 2-11), position the shoe holders (N)under the cutter bar. Securely attach eachshoe holder with two 5/16–18 x 1" car-riage bolts (O) and 5/16–18 locknuts (P).

13. Securely attach the shoes (Q, Fig. 2-12) to the bottom of the holders with a U-bolt (R), 5/16" flat washers (S) and5/16"-18 locknuts (T). Adjust the shoesthe same, to level the cutter bar assembly.

14. Oil the area beneath each hold-downclip (U, Fig. 2-13) on the cutter bar.

15. Move the cutter bar lever (Fig. 2-15)all the way right to the OFF position.

R

U

S

T

Q

A

Cutter Bar On

Fig. 2-11

Fig. 2-12

Fig. 2-13

Fig. 2-14

Fig. 2-15

M

M

N

N P

O

O

P


WEED DIVERTER INSTALLATIONNOTE: The weed diverter (V, Fig. 2-16) isdesigned to vibrate from cutter barmotion and the vibration helps cleardebris away from the front of the unit.

1. Thread a 1/4"–20 flange nut (W,Fig. 2-16) onto the upper hook (X).Secure the hook to the fender (as shown)with a second 1/4"–20 flange nut (W)located below the fender.

2. Insert a 1/4–20 x 1-1/4" screw (Y)through a 1/4" washer (Z) and one end ofthe weed diverter (V). Secure the screw tothe threaded post on the end of the eccen-tric arm.

3. Stretch and hook the other end of theweed diverter over the upper hook (X).

Fig. 2-16

X

W

W

Z

V

Y

ENGINE OIL

DO not add oil past FULL mark on dip-stick. See the engine manual for details.

1. Squeeze the four control levers andmove the unit to a level area.2. Unscrew the dipstick (A, Fig. 2-17).

3. Insert a clean funnel into oil fill holeand slowly add correct amount and typeof oil specified in engine manual.

WARNING

4. While adding oil, pause frequently,remove the funnel, replace the dipstickand check the oil level.

5. When the oil level reaches the FULLmark, replace and tighten the dipstick.Wipe up any spilled oil.

BATTERY CHARGING(for electric start models only)

Risk of serious personal injury or property damage.• Use only the battery charger supplied

with the unit. Use of any other batterycharger may damage the battery.

• Do not short circuit the battery bytouching the connectors or wirestogether, or by touching metal objectsagainst the connectors.

• Remove all metal jewelry whenworking near the electrical system.

• Do not charge the battery for morethan 48 hours.

NOTE: All units can be started using thestarter rope (B, Fig. 2-17) if the battery isnot charged.Remove the battery charger (A, Fig. 2-18)from the main shipping carton.NOTE: The battery charger is designedfor indoor use only. Do not get the batterycharger wet. Keep the battery chargeraway from water, rain, snow, etc.Initially, charge the battery for 24 to 48hours (24 hours minimum) before usingthe electric starter. Battery charging:1. Plug the connector lead from the bat-tery (B, Fig. 2-18) into the mating con-nector (C) on the battery charger.3. Plug the battery charger into agrounded, 120-volt AC wall outlet.4. Charge the battery for 24 to 48 hours(24 hours minimum).5. Unplug the battery charger from thewall outlet first, then unplug the connec-tors (B and C, Fig. 2-18).

WARNING

6. After initially charging the battery,store the battery charger in an easilyremembered location out of the reach ofchildren.7. Remember to charge the battery at thestart and end of each mowing season for24 to 48 hours (24 hours minimum).

TIRE PRESSURECheck tire pressure. Inflate both tiresequally to 10-17 psi.

Fig. 2-18

A (to groundedwall outlet)

C (from batterycharger)

B (from battery)

Fig. 2-17

BA

Learn the location and function of all con-trols before starting the engine. Fordetailed operating instructions, see the“Operation” section of this manual.

A. THROTTLE/CHOKE CONTROLLEVERThe throttle control lever (A, Fig. 3-1) islocated on the right handlebar. The throttlecontrol lever is used when starting andstopping the engine, and regulates enginespeed (revolutions per minute, or RPM). Engines without primer bulbs areequipped with manual chokes. On theseengines, the CHOKE position is all the wayforward, past the FAST position.Engines with primer bulbs do not have achoke control.

B. OPERATOR PRESENCE CONTROLS (OPC)The operator presence controls (OPC) (B,Figs. 3-1 and 3-2) are levers located abovethe handgrips at the top of the handlebars.The OPC is part of a safety systemdesigned for your protection. Neverattempt to bypass, disconnect or defeatthe OPC system.If the OPC levers are released when eitherthe cutter bar drive or the wheel drive isengaged, the OPC system should shut theengine off. If the engine does not shut off,DO NOT operate the unit until the OPCsystem is repaired.

C. WHEEL DRIVE LEVERSThe wheel drive levers (C, Fig. 3-1) arelocated beneath the handgrips on eachhandlebar and control the wheel drive beltsystem.

Squeezing the levers disengages the drivebelt and allows the unit to be moved man-ually (freewheeling). Releasing the leversengages the drive belt and causes thewheels to move forward (when the engineis running).

The wheel drive levers consist of twoparts: wheel drive levers (C, Fig. 3-2),which engage and disengage the drivewheels, and thumb latches (M), used forlocking the wheel drive levers into the dis-engaged (freewheel) position.

D. ENGINE OIL DIPSTICK/FILL HOLEThe engine oil dipstick (D, Figs. 3-13-3) and oil fill hole is located on top ofthe engine.The dipstick is used to checkthe engine oil level. Oil is added throughthe fill hole.

E. SHOESShoes (E, Fig. 3-1) are located on the rearedge of the cutter bar.

The shoes adjust the height of the cutterbar to clear ground debris that mightdamage or jam the blades.

Features and Controls3Section

14

Before operating your machine, carefullyread and understand all safety, controlsand operating instructions in thisManual, the separate Engine Owner’sManual, and on the decals on themachine.Failure to follow these instructions canresult in serious personal injury.

WARNING

Fig. 3-1

K

F

E

J

B

AC

C

G

HD

E

ON

OFF

L

INSET

Section 3: Features and Controls 15

F. CUTTER BAR (WITH GUARD)

Sharp cutter bar blades move back andforth at high speed. Contact with theblades will cause serious personalinjury. Keep the protective plastic cutterbar guard in place and avoid contact withthe cutter bar blades.

The cutter bar (F, Fig. 3-1) is located at thelower front of the unit.

For safety, keep the plastic guard on thecutter bar until just before starting engine.

The cutter bar assembly scissors back andforth 14 times per second and can severgrass, weeds, brush and saplings up toone-inch thick.

G. FUEL TANK CAPThe fuel tank cap (G, Figs. 3-1 and 3-3) islocated on the top right side of the engine.

Keep the area around the fuel tank capclean and free of debris to help avoid con-taminating the fuel or clogging fuelsystem.

H. STARTER ROPE HANDLEThe starter rope handle (H, Figs. 3-1 and3-3) is located on top of the engine at theedge of the flywheel screen.

The starter rope handle is used to pull-start the engine.

NOTE: Electric-start models can also bepull-started with the starter rope.

J. ENGINE KEYSWITCH(ELECTRIC-START UNITS ONLY)The engine keyswitch (J, Fig. 3-1—INSET)is used to start the engine on electric-startmodels.

K. CUTTER BAR LEVERThe cutter bar lever (K, Fig. 3-1—INSET)is located at the rear of the unit.

The cutter bar lever engages (ON position)and disengages (OFF position) the cutterbar drive and is operated by foot. The OFFposition is all the way to the right, and theON position is all the way to the left.

L. WEED DIVERTERThe rubber weed diverter (L, Fig. 3-1) islocated on the top front of the unit andstretches from the eccentric arm to thetop of the hood.

The weed diverter is designed to vibratefrom cutter bar motion and the vibrationhelps clear debris away from the front ofthe unit.

N. ENGINE PRIMER BULBSome engines are equipped with anengine primer bulb (N, Fig. 3-4).

Pushing the bulb “primes” or prepares theengine for starting by injecting fuel intothe combustion chamber.

WARNING

H

N

Fig. 3-3

GD

Fig. 3-4

DISENGAGED

Fig. 3-2

B

C

M

Operation4Section

16

BEFORE OPERATION

PRE-START CHECKLISTPerform the following checks before eachuse of the unit:✔ Review Section 1: Safety, and Section

3: Features and Controls.

✔ Inspect the operating area. Watch forhidden obstacles, such as gullies orcovered posts, holes, and other hiddenobstructions. Remember, tall grass orvegetation can hide hazards.

✔ Connect the spark plug wire.

✔ Disengage the cutter bar lever.

✔ Lock the wheel drive levers into thedisengaged position (Fig. 4-2).

✔ Check the unit for loose or missingparts and hardware.

✔ Check control rod adjustment beforeeach use and adjust as needed (seeSection 2: Assembly.

✔ Check tire pressure. Inflate both tiresequally (10-17 psi / 68.5-117 KPa).

✔ Check the amount of gasoline in thefuel tank.

✔ Check that the shoes are set to theproper cutting height for the terrain.

✔ Remove the plastic blade guard justbefore starting engine.

✔ Before starting the engine, check theengine oil level (see Section 2:Assembly.

✔ Perform the operator presence control(OPC) system test after starting unit.

FILL THE FUEL TANK

GASOLINE IS HIGHLY FLAMMABLE AND ITS VAPORS ARE EXPLOSIVE. TO HELP PREVENT PERSONAL INJURY OR PROPERTY DAMAGE:• Check the fuel level in the fuel tank

before starting the engine.• Never fill fuel tank indoors. Do not add

gasoline to the tank with the enginerunning, or when the engine is hot.Allow the engine to cool for severalminutes before filling the fuel tank. Donot overfill the tank.

• Re-install the fuel tank cap securelyafter filling, and clean up any spilledgasoline before starting the engine.

• Keep gasoline and its vapors awayfrom all sources of sparks and flame.

• Move unit away from gasoline fumesbefore starting the engine.

Use clean, fresh unleaded regular automo-tive gasoline. See engine manual for spe-cific fuel octane information.1. Unscrew the fuel tank cap (A, Fig. 4-1).Add gasoline. Leave at least two inches ofspace below the filler neck to allow roomfor expansion.2. Re-install the cap. Wipe up spilledgasoline.

ADJUST THE SHOESWith the plastic blade guard installed onthe cutter bar, loosen the nuts securingthe U-bolts and adjust the shoes (A, Fig.4-6) so the cutter bar clears ground cluttersuch as gravel, broken glass and othersmall, hard objects, which might damagethe cutter bar or blade. Adjust the shoesequally, so the blade is level. Securelytighten the U-bolts when the shoes areadjusted.

STARTING THE ENGINE

• Always squeeze the wheel drive leversup against the handlebar grips andplace the control rods into the thumblatch slots (in the disengaged posi-tion) before starting the engine.

• Always move the cutter bar lever tothe OFF position before starting theengine.

• Do not operate the unit when childrenor bystanders are in the operatingarea.

• Never run the engine in an enclosedarea. Engine exhaust contains carbonmonoxide, a deadly poison that isodorless, colorless and tasteless. Donot operate the equipment near build-ings, windows, or air conditioners.

Before starting the engine, place the uniton level ground and check the oil level(see instructions for adding oil in the“Assembly” Section).

TO START THE ENGINE:1. Connect the spark plug wire to thespark plug (if necessary).

2. Move the cutter bar lever to the OFFposition (Fig. 4-1) with your foot. Removethe plastic blade guard. Stand directlybehind the unit in the operator position.

DANGERDANGER

Cutter Bar Off

On

A

Fig. 4-1

B

Before operating your machine, carefullyread and understand all safety (Section1), controls (Section 3) and operatinginstructions (Section 4) in this Manual,in the separate Engine Owner’s Manual,and on the decals on the machine. Keepthe blade guard in place on the cutter barwhen the unit is not in use.

Failure to follow these instructions canresult in serious personal injury or prop-erty damage.

WARNING

Section 4: Operation 17

3. Squeeze the wheel drive levers (E, Fig.4-2) and pull slightly backward and downon the thumb latches (D) until the wheeldrive control rods (F) drop into the slots inthe thumb latches.

4. Move the throttle control lever (G, Fig.4-3) all the way forward.

For engines equipped with a primer bulb,push the bulb three times. Whenrestarting a warm engine, priming is usu-ally unnecessary, although cool weathermay require priming to be repeated.

5. Pull-starting (all units can be pullstarted):

Place one hand on the right handlebar(see the decal on the handlebar) to stabi-lize the unit when pulling the starter rope.Pull the starter rope handle (B, Fig. 4-1)until some resistance is felt, then pullrapidly to start the engine. Do not allowthe rope to snap back– let it rewind gradu-ally. Repeat as necessary until the enginestarts.

NOTE: If the engine fails to start, see theengine manual.

Do not crank the starter for more thanfive seconds. If the engine does notstart, wait one minute before trying tostart again to help prevent overheatingor damaging the electric starter.

6. On electric start units:

Turn the key clockwise and hold (nolonger than five seconds) until the enginestarts. Release the key. Repeat if neces-sary, after pausing for one minute. Elec-tric-start units can also be pull started.

7. As the engine warms up, move thethrottle control lever to SLOW until readyto begin mowing. Always mow with thethrottle control lever in the FAST position.

THROTTLE SETTINGALWAYS OPERATE WITH THE ENGINE ATFULL THROTTLE (FAST). While operatingunder heavy load conditions, listen to theengine RPM. If the engine begins to slowdown, operate slowly and allow the engineRPM to increase.

STOPPING THE ENGINETo stop the engine, move the throttle con-trol lever to the STOP position.For electric-start units, turn the keycounter-clockwise and remove the keyfrom the keyswitch.

OPERATOR PRESENCE CONTROL(OPC) SYSTEM TEST

If the engine does not stop when eitherOperator Presence Control (OPC) lever isreleased, stop the engine, and wait forall moving parts to come to a completestop. Move the cutter bar lever to theOFF position. Replace the plastic bladeguard on the cutter bar. Disconnect thespark plug wire and prevent it from con-tacting the spark plug. On electric-startunits, remove the ignition key. Do notuse the unit until the OPC System isrepaired. Contact an authorized dealerfor repairs. Failure to follow theseinstructions could result in personalinjury or property damage.

Perform the operator presence control(OPC) system test before each use of theunit. When the cutter bar is engaged, theOPC system should shut the engine offwhen both OPC levers are released.

1. Remove the plastic blade guard fromthe cutter bar.

2. Start the engine.

3. Hold down the left operator presencecontrol (OPC) lever (C, Fig. 4-2), then placethe cutter bar lever in the ON position (Fig.4-1).

4. Release the left OPC lever. The engineshould stop in a few seconds.

5. Restart the engine. Engage the wheeldrive lever. Release both OPC levers, oneat a time.If the engine stopped within a few secondsafter releasing each lever, the OPC systemis working properly.If the engine does not stop within a fewseconds after releasing each lever, per-form the following steps:

a) Stop the engine. Wait for all movingparts to stop. Move the cutter bar lever tothe OFF position. Replace the plasticblade guard on the cutter bar. Disconnectthe spark plug wire, and prevent it fromcontacting the spark plug. On electric-start units, remove the ignition key.b) Check that the wire connectorsleading from the operator presence con-trols on the handlebars are firmly con-nected to the screw at the front of theengine, and to the engine mounting bolt.If these connections are loose, tighten,then repeat the test procedure.

WARNING

CAUTION

GFAST

SLOW

STOP

CHOKEFAST

SLOW

STOP

Engines withprimer bulb Engines without

primer bulb

DISENGAGED

➠

Fig. 4-2x

Fig. 4-3

Fig. 4-4

EF

DC

WHEEL DRIVEDISENGAGED

(Freewheel Position)

18 Section 4: Operation

c) If the engine still does not stopwithin a few seconds after releasingeither lever, the OPC system is not func-tioning properly. DO NOT operate theunit. Contact the nearest authorizeddealer or our factory for repair. DO NOToperate the unit until the operator pres-ence control system (OPC) is repaired.

For general OPC system operation infor-mation, refer to Note 4-1.

OPERATION

WHEEL DRIVE LEVER OPERATIONReleasing the wheel drive levers (E, Fig. 4-5 ) will engage the wheel drive andpropel the unit forward (note wheel drivelever position when engaged in Fig. 4-5).To stop forward movement, squeeze bothwheel drive levers all the way up againstthe grips.To lock the levers in the disengaged posi-tion, squeeze wheel drive levers and pullslightly backward and down on the thumblatches (D) until the wheel drive controlrods (G) drop into the slots (F) in thethumb latches.Use the wheel drive levers to controlsteering. To turn toward the right, squeezethe right lever up against the handlebargrip to allow the unit to pivot on the rightwheel. To turn toward the left, squeeze theleft wheel drive lever.

CUTTER BLADE OPERATIONTo engage the cutter blade:1. Remove the plastic blade guard fromthe cutter bar.2. Start the engine.3. Move the cutter bar lever (Fig. 4-7) allthe way to the left, to the ON position. The cutter bar assembly will move rapidlyback and forth.

NOTE: Unit vibrates when cutter bar driveis engaged.If the handlebars are gripped too tightly,vibration increases. DO NOT attempt tohold the unit down. Guide the unit with alight grip on the handlebars.

To disengage the cutter bar drive, movethe cutter bar lever all the way to the rightto the OFF position (Fig. 4-7). Always dis-engage the cutter bar drive, stop theengine and re-install the plastic bladeguard when transporting the unit.

USE AND ADJUSTMENT OF SHOESUse the shoes (A, Fig. 4-6) to adjust cutterbar height to avoid stones and debris, orwhen mowing areas containing loose dirtor soft, spongy growth.NOTE: Shoes can be staggered along thecutter bar and set at different heights toaccommodate unusual terrain conditions.NOTE: Shoes are not always necessary,particularly when mowing lush, green veg-etation on even terrain free of debris.

GENERAL OPERATION• Before operating the unit, remove alldebris, small bushes and trees thicker thanone inch in diameter from the operatingarea. Cut trees low enough for the cutterbar to clear them.ALWAYS DISENGAGE THE CUTTER BARDRIVE WHEN TRANSPORTING THEUNIT!• Always run the engine with the throttle inthe FAST position. • Use the wheel drive control levers tosteer the unit. • Use a slow ground speed when using theunit for the first time. Increase speed asyou become familiar with operating theunit.• Vibration is normal. Grip the handlebarslightly.• If forward motion is stopped or the unithits an object, immediately disengage thewheel drive levers. This will help preventbelt slippage, and premature wear, and thewrapping of tall grass and vegetationaround moving parts.• Ease into heavy cutting by first slightlydisengaging the wheel drive levers. Do notstart heavy cutting at full wheel speed. Letthe blades saw their way through thematerial being mowed a little at a time.The unit will usually cut any brush andsaplings which can fit between the blades.

To Operate:1. Move the cutter bar lever to the OFFposition. Remove the blade guard. Disen-gage the wheel drive levers.2. Connect the spark plug wire to thespark plug. Start the engine. Stand behindthe unit in the operator position. Move thethrottle lever to the FAST position.3. To move forward, release the wheeldrive levers.NOTE: To move the unit without mowing,engage the wheel drive without engagingthe cutter bar drive.

Proper Operator Presence Control (OPC) System Operation

1. Engine WILL stop if both conditions Aand B exist:A. Both OPC levers released.B. Cutter bar lever in ON position or

thumb latches unlocked (wheel driveON).

2. Engine WILL NOT stop if either condition“C” or “D” exist:C. One or both OPC levers engaged.D. Cutter bar lever in OFF position and

thumb latches engaged (wheel driveOFF).

Note 4-1

ENGAGED

DISENGAGED

E

F

C

E

D

To Release

Fig. 4-5

D

Fig. 4-6

A

G

G

WHEEL DRIVE

WHEEL DRIVEDISENGAGED

(Freewheel)

Cutter Bar Off

On

Fig. 4-7

Section 4: Operation 19

Turning:4. To turn the unit, hold the wheel drivecontrol lever up against the handlebar grip(Figure 4-8) on the side you are turningtoward. The unit will pivot on the sta-tionary wheel.

Guide the unit completely through the turnand slightly release the wheel drive controllever as necessary to control the unitthrough the turn.

BECOME FAMILIAR WITH MOVING ANDTURNING THE UNIT BEFORE ENGAGINGTHE CUTTER BAR!

Cutting:5. Move the cutter bar lever to the ONposition (Fig. 4-7). The unit should beginvibrating, which is normal, and the cutterblade will move rapidly from side to side.6. When mowing, proceed slowly andwith caution.DISENGAGE WHEEL DRIVE IF UNITSTOPS MOVING FORWARD. DEBRISMAY WRAP AROUND MOVING PARTS IFWHEEL DRIVE IS ENGAGED AND THEUNIT IS NOT TRAVELING.

If the Unit Becomes Stuck or Stops:1. Disengage the cutter bar and wheeldrive control levers. 2. Look behind for and avoid obstacles,back up a few steps, and check the oper-ating area. The terrain may not be suitablefor safe or continued operation.3. Poor traction may be caused by grasswrapping around the tires or the axle.Here are some tips to help avoid grasswrapping:• Allow grass to dry before cutting.• Do not allow tires to spin on cut grass.• As soon as any wrapping begins, you

should do the following:a.) Disengage the cutter bar and wheel

drive control levers.b.) Look behind for and avoid obsta-

cles and then pull the unit back-wards. This should unwind thegrass.

c.) If unsuccessful, and you have anassistant available, have the assis-tant squeeze the wheel drivelevers, tilt the machine, and pullthe unit backward as you clear thegrass away.

d.) If necessary, the wheels can beremoved to untangle the grass.See “Clearing Wheel Wrap” in Section 5: Maintenance fordetailed instructions.

If the Cutter Blade Should Clog:1. Disengage the cutter bar lever and thewheel drive levers. 2. Check behind for and avoid obstacles. 3. Pull the unit rearward a few feet.4. Push down on the handlebars and raisethe cutter blade slightly off the ground.5. Re-engage the cutter bar lever to shakeexcess material off the cutter bar. 6. Lower the unit, re-engage the wheeldrive levers and continue mowing.

OPERATING ON SLOPES

Do not operate on slopes with an inclinegreater than 15°. Oil will slant awayfrom internal engine parts, reducinglubrication. Do not mow straight down aslope or hill. Mow from side to side.Mow with the carburetor on the high sideto help prevent oil spillage. Failure tofollow these instructions may result inpersonal injury or property damage.

Keep the oil level at FULL, especially whenmowing on slopes. DO NOT operate onslopes with an incline greater than 15°.Recheck the oil level every 30 minutes ofoperation. Oil will shift in the crankcaseand excess tilting of the unit could leaveengine parts unlubricated, which willresult in engine damage.Always mow slopes (hills) from side-to-side, not up and down. Do not mow onslopes with an incline greater than 15°.Mow with the carburetor on the high sideof the slope.

STOPPING

If the wheels do not stop turning whenyou disengage the wheel drive levers(pull the wheel drive levers up againstthe handlebar grips), lock the thumblatches, stop the engine, wait for allmoving parts to come to a completestop, disconnect the spark plug wire andprevent it from contacting the sparkplug. Do not use the unit until the wheeldrive has been repaired. Failure to do socould result in personal injury or prop-erty damage.

NORMAL STOPPING1. Disengage the wheel drive levers (pullthe levers up against the handlebar grips).2. Pull slightly backward and down on thethumb latches and lock the wheel driverods into the thumb-latch slots.3. Move the cutter bar lever to the OFFposition.4. Move the throttle lever to the STOPposition. Wait for all moving parts to stopcompletely.5. Disconnect the spark plug wire fromthe spark plug to help prevent accidentalstarting. Remove the key from thekeyswitch on electric-start units.

EMERGENCY STOPPINGTo stop forward motion: Squeeze bothwheel drive levers up against the handle-bars.To stop cutter blade movement: Move thecutter bar lever to the OFF position.If operating properly, the Operator Pres-ence Control (OPC) system will stop theunit within a few seconds when the han-dlebars are released if the cutter bar orwheel drive levers are engaged.

If the engine does not stop when eitheroperator presence control (OPC) lever isreleased, stop the engine and wait for allmoving parts to come to a completestop. Move the cutter bar lever to theOFF position. Replace the plastic bladeguard on the cutter bar. Disconnect thespark plug wire and prevent it from con-tacting the spark plug. On electric-startunits, remove the ignition key. Do notuse the unit until the OPC System isrepaired. Contact an authorized dealerfor repairs. Failure to follow theseinstructions could result in personalinjury or property damage.

WARNING

WARNING

WARNING

DISENGAGED

➠To DisengageWheel Drive

Fig. 4-8

Maintenance5Section

20

IMPORTANT: Many of the maintenanceprocedures in this section are requiredonly as needed or when a part needsreplacement. Other procedures are fullydescribed in this section but not listed inthis chart.

NOTE: If unit must be tipped for anexcess of 5 minutes for any reason, drainoil from unit to prevent leakage.

NOTE: Some maintenance proceduresrequire expertise and/or tools which maynot be available to the average person. Readeach procedure thoroughly and note anyrequired special tools before beginningmaintenance. Procedures can be performedby your local dealer. Advice is availablefrom our Technical Service Department (seeback cover).

TIRE PRESSURECheck tire pressure. Inflate both tiresequally (10-17 psi).

CLEARING WHEEL WRAPOccasionally, tall grass may wrap aroundthe wheel axle (known as “wheel wrap”),making maneuvering the unit difficult orimpossible. This procedure explains howto clear wheel wrap (also see “If the unitbecomes stuck or stops” on page 19).

To Disassemble:NOTE: Performing all steps listed may notbe required! Clear grass or other matterfrom around the axle and belt housingafter each step until grass or other matteris eliminated, then reassemble unit.Repeat for other side as required.

1. Stop the engine, wait for all movingparts to come to a complete stop, discon-nect the spark plug wire and prevent itfrom contacting the spark plug.2. Slide belt cover (A, Fig. 5-1) up and offunit.3. Remove three wheel mounting nuts (B)and slide wheel/tire assembly (C) and beltseal (F) off axle. (A sheet metal spacermay also come off with the wheel/tireassembly. If so, replace the spacer on theaxle.) The belt drive pulley shown in Fig.5-1 will remain on the axle.4. Clear grass or other matter from theexposed areas.

To Re-Assemble:1. Slide wheel/tire assembly (C, Fig. 5-1)onto axle. Note that belt seal tabs (F) fitinside the belt guard (D).2. Secure wheel/tire assembly with threemounting nuts (B) removed earlier.3. Install drive belt cover (A). Note thatfinger (E) on drive cover points toward thefront of the unit.

WHEEL DRIVE CONTROL RODADJUSTMENTNOTE: This adjustment does not controldrive belt tension. Springs (B, Fig. 5-2)control drive belt tension.

Before inspecting, cleaning or servicing the machine, shut off engine,wait for all moving parts to come to acomplete stop, disconnect spark plugwire and move wire away from sparkplug. Remove ignition key on electricstart models. Install plastic blade guardon cutter bar assembly.Failure to follow these instructions canresult in serious personal injury or prop-erty damage.

WARNING

MAINTENANCE SCHEDULEPROCEDURE NOTES

Adjust hold-down clips 3, 6, 7Check and tighten nuts and bolts 4, 6, 7General lubrication 3, 6, 13Check parts for wear 6, 7Check motor oil level 2, 3, 9Change motor oil 8, 5, 7, 9Service air filter system 5, 6, 7, 9Check spark plug 6, 7, 9Charge battery 1, 6, 7, 10, 11Oil drive chain 4, 6, 7Oil all cutter bar parts 3, 6, 7Oil hold-down clips 3, 6, 7Check tire air pressure 4, 12

NOTES1 - Before first use.2 - Before each use.3 - Every 5 operating hours.4 - Every 10 operating hours.5 - Every 25 operating hours.6 - Start of season.7 - End of season.8 - After first two operating hours.9 - See Engine Owner’s Manual for service

recommendations.10 - Charge battery for 24 (minimum) to 48

hours.11 - After extended storage.12 - Inflate each tire equally, 10 - 17 psi.13 - Parts require lubrication at different time

intervals. Refer to this Section for morelubrication information.

11/4" (32mm)Gap here

(right side shown)

11/4" (32mm)

Fig. 5-1

AE C

D

BF

Right Handlebar

A

Fig. 5-2

C

B

Fig. 5-3

A

Section 5: Maintenance 21

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts tocome to a complete stop, disconnect spark plug wire and move wire away from spark plug. Removethe key from the keyswitch on units so equipped.Failure to follow these instructions can result in serious personal injury or property damage.

WARNING

1. Stop the engine, wait for all movingparts to come to a complete stop, discon-nect the spark plug wire and prevent itfrom contacting the spark plug.2. Remove the hair pin cotters securingthe upper ends of the control rods to theplastic thumb latches and wheel drive con-trol levers (see J, Fig. 2-5).3. Thread the rods in or out of the idlerarm (A, Fig. 5-2) as needed. Adjust eachwheel drive control rod (A, Fig. 5-3) untilthere is a 1-1/4" (32mm) gap between therod and the plastic thumb latch. Adjustboth control rods evenly.4. Re-install the hair pin cotters on theoutside of the wheel drive levers.

CUTTER BAR DRIVE BELTREMOVAL/REPLACEMENTReplace the cutter bar drive belt if it iscracked, severely frayed, or worn to thepoint where proper tension can no longerbe applied by the spring loaded idler.1. Stop the engine, wait for all movingparts to come to a complete stop, discon-nect the spark plug wire and prevent itfrom contacting the spark plug.2. Put the cutter bar lever in the OFF posi-tion (Fig. 4-7). Reach up underneath theunit and remove the belt from the smalllower pulley (Fig. 5-4).

3. Remove screws and washers (B, Fig. 5-5) and both belt guides (A). Remove thebelt from the large pulley.4. Install new belt as shown in Fig. 5-4.5. Reinstall belt guides (A, Fig. 5-5) andscrews and washers (B). Adjust the guides1/16" - 1/8" (1.6-3.2mm) away from belt.

CUTTER BAR BELT GUIDE ADJUSTMENT1. Stop the engine, wait for all movingparts to come to a complete stop, discon-nect the spark plug wire and prevent itfrom contacting the spark plug.2. Place the belt under tension (Fig. 4-7)by moving the cutter bar lever to the ONposition.3. Adjust front belt guides (Y, Fig. 5-4)1/16"—1/8" (1.6—3.17 mm) away frombelt.4. Secure guides.5. Adjust the right rear belt guide (Z) 1/4"(6.35 mm) from the belt (Fig. 5-4).6. Secure the guide.

WHEEL DRIVE BELT ADJUSTMENTPoor wheel traction can result if the belttension spring (B, Fig. 5-2) has loosened,or if the wheel drive belt has worn.To Adjust Wheel Belt Tension:1. Move the end of spring (B, Fig. 5-2),located on the underside of the deck, tothe lower hole (C).2. If the belt tension is still too loose, thespring or the belt may need replacing.

WHEEL DRIVE BELTREMOVAL/REPLACEMENTWhen a wheel drive belt is frayed, brokenor worn to the point where tension can nolonger be controlled with the idler pulley,the belt or spring must be replaced.NOTE: Prop the unit up by placing sturdysupports under the engine deck.To Remove the Wheel Drive Belt:1. Remove drive belt cover (A, Fig. 5-6).2. Remove snap ring (B) and washer (C)from drive axle.3. Remove wheel assembly (F).4. Slip the drive belt off the pulleys andoff the unit.To Replace the Wheel Drive Belt:1. Slide wheel assembly (F, Fig. 5-6) ontoaxles. Note that seal tabs (AA) fit insidethe belt guard (J).2. Route belt (E) into place around pulleyon wheel assembly (F).3. Secure wheel with washer (C) and snapring (B) removed earlier.4. Install drive belt cover assembly (A).Note that finger (H) on drive belt coverpoints toward the front of the unit.

WHEEL DRIVE BELT GUIDE ADJUSTMENT1. Place belt under tension by engagingwheel drive clutch lever. See Fig. 4-5.2. Remove Drive Belt Cover (A, Fig. 5-6).3. Adjust belt guide (A, Fig. 5-7) to 1/16”(1.6mm) or less away from belt. 4. Adjust belt guide (B) 1/4” (6.4mm)away from pulley (D).5. Tighten belt guide (B) at bolt (C) afteradjusting.6. Install belt cover (A, Fig. 5-6).

AAB

Fig. 5-5

A

H

JE

F

CBAA

Fig. 5-6

1/16"-1/8"(1.6-3.2mm)

1/4"(6.4mm)

FRONT

Fig. 5-4

Y Y

Z

1/16"-1/8"(1.6-3.2mm)

22 Section 5: Maintenance


WARNING

DRIVE CHAIN ADJUSTMENT AND LUBRICATIONCheck chain tension when oiling the chain(every 10 operating hours).1. Remove the #10 screw (A, Fig. 5-8)and slide off the chain cover (B).

2. If the chain is slack, loosen nut (C) andadjust chain idler (D) until the chaindeflects slightly with moderate finger pres-sure. Secure the nut (C) in the adjustmentslot. Loosening the lock nuts (D) is notnecessary.3. Lightly oil the chain. Spread oil over asmuch of the chain surface as possible4. Replace the chain cover and securewith the hex head screw removed earlier.

CUTTER BAR MAINTENANCECutter bar maintenance is easier if it isfirst removed from the unit.

Cutter bar is capable of inflicting severeinjury. Be extremely careful when per-forming any maintenance on the cutterbar assembly.

• Before performing maintenance orrepairs on the cutter bar, stop theengine, wait for all moving parts tocome to a complete stop, disconnectthe from contacting the spark plug. Onelectric start models, remove the keyfrom the keyswitch.

• Have an assistant help you.• Install the plastic blade guard on the

cutter bar.• Wear heavy leather gloves when

working on or near the cutter barassembly.

• Wear safety goggles or a face guard.Failure to follow these instructions mayresult in serious personal injury or prop-erty damage.

CUTTER BAR REMOVAL

• Put plastic blade guard on cutter bar.Wear heavy leather gloves and wrapblades in rags when handling the cutterbar assembly.

• When removing or replacingblades/sections, always wear safetygoggles or a face guard.

Failure to follow these instructions mayresult in serious personal injury or prop-erty damage.

NOTE: An assistant should stand in theoperator position and firmly hold the han-dlebars while the cutter bar is beingremoved to help prevent the unit from tip-ping unexpectedly.

1. Stop the engine, wait for all movingparts to come to a complete stop, discon-nect the spark plug wire and prevent itfrom contacting the spark plug. On electricstart models, remove the key from thekeyswitch.

2. Align the pitman arm assembly (A, Fig.5-9) directly above the blade mountingbracket (B). If the pitman arm is notaligned, move the cutter bar lever to theON position (Fig. 4-7). Slowly pull thestarter rope while watching pitman armmovement. Stop when the pitman arm isaligned.

3. To remove the cutter bar, remove thethree screws, flat washers and locknutsthat secure the cutter blade and doublerplate to the blade mounting bracket (B,Fig. 5-9).

4. After removing the cutter bar, the knifehead (C, Fig. 5-9) can be removed (if nec-essary) by removing the two 8M x 12Mscrews and 5/16" hardened washers.Leave the pitman arm (A, Fig. 5-9) on theknife head for safe keeping.

CUTTER BAR REPLACEMENTIMPORTANT: To help prevent the unitfrom tipping, have an assistant stand inthe operator position and firmly hold thehandlebars during installation of the cutterbar.

1. Stop the engine, wait for all movingparts to come to a complete stop, discon-nect the spark plug wire and prevent itfrom contacting the spark plug. On electricstart models, remove the key from thekeyswitch.

2. Have an assistant hold the unit firmlyby the handlebars.

3. Slowly pull the starter rope whilewatching eccentric arm movement. Stoppulling the starter rope when the armaligns with the hole (C, Fig. 5-9).

4. Using the hardware and parts removedin the “Cutter Bar Removal” steps, replacethe cutter bar by following steps 4 through11 of the “Cutter Bar Assembly and Instal-lation” instructions that begin on Page 10.

5. Oil the area between the hold-downclips and wear plates (C, Fig. 5-10).

DANGER

WARNING

DANGER

A

1/16"

1/4"

C

B

Front – right side

D

Fig. 5-7

(1.6mm)

(6.4mm)

A

B

CD

Fig. 5-8

B

AC

Fig. 5-9



WARNING

CUTTER BAR DISASSEMBLY

• Put plastic blade guard on cutter barassembly. Wear heavy leather glovesand wrap blades in rags when handlingthe cutter bar assembly.

• When removing or replacingblades/sections, always wear safetygoggles or a face guard.

Failure to follow these instructions mayresult in serious personal injury or prop-erty damage.

If the blades are worn and need replace-ment, the entire cutter bar assembly canbe removed and individual blades/sectionscan be replaced.1. Remove the knife head (see “Cutter BarRemoval” instructions earlier in this Sec-tion).2. Loosen screws (D, Fig 5-11).

Scissor action of cutter bar can easilyamputate fingers and toes. Be extremelycareful when sliding blade assembly outof cutter bar assembly.

3. Slide the blade assembly (E, Fig. 5-11)out one end of the cutter bar assembly. Ifthe blade assembly does not slide readily,tap each end of the blade assembly usinga rubber mallet or hammer and block ofwood (Fig. 5-11).4. Inspect the blade assembly to deter-mine if sharpening or replacement ofblade sections is necessary. If blades aredull, contain nicks, or have piecesmissing, the blades must be sharpened orreplaced.

BLADE SHARPENINGNOTE: For best safety and performance,We recommend the blades be sharpenedby a professional sharpening service.Sharpen the blades with a grinder or handfile. To sharpen with a hand file:1. Clamp the blade assembly in a vise,with the blade points facing away fromyou.2. Push the file away from you whilemaintaining the same cutting angle as theoriginal sharpened edge. File or grind onlythe top (angled) surface of the blade. Thebottom edge of the blade must remain flatto provide good shearing action.

BLADE SECTION OR LEDGER PLATE REMOVALNOTE: Blade sections are riveted to thecutter blade assembly (E, Fig. 5-11).Ledger plates (G) are blades riveted to thecutter bar assembly (F).1. File the rivet heads off the blade rein-forcement bar. See Fig. 5-12.2. Place the blade or ledger plateassembly on a sturdy surface such as aworkbench. Position so the part of theblade from which rivets will be driven isover the edge. When driving rivets from the middle of thebar, place the bar on top of two supports,such as jackstands, or wood blocks. Posi-tion so the part of the blade from whichrivets will be driven between the objects orblocks.3. Use a flat punch to clean out the rivetholes (Fig. 5-13).

BLADE OR LEDGER PLATE REPLACEMENTThe underside of the blade sections havecountersunk holes to accept flush-typerivets. See the parts catalog for rivet sizesand an exploded view of the assembly.1. Align the holes in the new blade, bladesection, or ledger plate, with the corre-sponding holes in the cutter bladeassembly or cutter bar.2. Insert two rivets into the countersunkholes. Place the rivet heads flush againstthe blade.NOTE: When installing a blade section(not an individual blade), install four rivetsin each blade section.3. Place the cutter blade or bar assembly(with the new blade and rivets in place) ona sturdy support, with the rivet headspositioned between the support and theblade.4. Strike the protruding rivet sharply witha hammer until satisfactory heads areformed (Fig. 5-14) and the rivets are tight.

NOTE: Longer rivets are needed for theblade sections at wear plate locations. Seethe parts catalog for rivet sizes and anexploded view of the assembly.

5. After installing new blades or ledgerplates, grind or file all rivet heads on thelower edge of the cutter bar flush with thebar surface.

DANGER

DANGER

D BF

A

CE

Fig. 5-10

G

Fig. 5-11

DE

FG

Fig. 5-12

Fig. 5-13



WARNING

NOTE: The unit will not cut properly ifthere are protrusions on the mating sur-faces of the cutter bar and blades.

CUTTER BLADE REASSEMBLY

Scissor action of cutter bar can easilyamputate fingers and toes. Be extremelycareful when sliding blade assembly outof cutter bar assembly.

Slide blade assembly back into cutter barassembly. If blade assembly does not slidereadily, loosen screws (D, Fig. 5-11).

Put plastic blade guard on back ontocutter bar assembly whenever cutter baris not in use.

CUTTER BAR HOLD-DOWN CLIPADJUSTMENT

Blades are very sharp! Wear heavyleather gloves when working on or nearcutter blades. Failure to follow thisinstruction may result in serious personal injury.

Tighten hold-down clips every five oper-ating hours, or when the unit is not cuttingeffectively, or when the unit is excessivelynoisy during normal operation. Best cut-ting performance is obtained when there isslight tension between hold-down clips (B,Fig. 5-10) and wear plates (C).

Hold-Down Clip Tension Adjustment:1. To increase tension on wear plate (C,Fig. 5-10), loosen lock nuts (D) in hold-down clip (B). Slide clip backward until itcontacts the wear plate. Re-tighten thelock nuts.2. Turn adjustment screw (F, Fig. 5-10)clockwise to increase tension on cutterblades (E). Hold-down clips should betight enough to prevent sloppy action, yetallow the cutter bar assembly to slidefreely from side to side.

Blade/Ledger Plate Tightening:1. Remove cutter bar assembly from unit(see instructions earlier in this section).2. Remove the blade assembly from thecutter bar assembly (see instructions ear-lier in this section).3. Place the blade section with the looserivet(s) on a steel block or anvil. Positionthe punch in the middle of the counter-sunk area of the rivet (Fig. 5-14).4. Strike the punch with the hammer,expanding the rivet within the hole. Repeatthis procedure for all loose rivets in thesection.5. If the blade (or ledger) section remainsloose, replace the rivets (see instructionsin this section).

HIGH-WEAR PARTSIncreased vibration or noise are indica-tions of worn or damaged parts.

CHECKING THE ECCENTRIC RADIALBEARING/CHANNELThe eccentric channel (A, Fig. 5-15) andradial bearing (B) are high-wear parts.Check for excessive wear at the end ofeach mowing season. With engine off, andspark plug wire disconnected, reach underthe unit and grasp the back of the eccen-tric channel. Move the eccentric shaft (C,Fig. 5-15) from side-to-side and back andforth. If there is noticeable play in theparts, replace the eccentric radial bearing(B) and/or the eccentric arm (A).

ECCENTRIC RADIAL BEARINGS ANDCHANNEL REMOVAL/REPLACEMENTEccentric Radial Bearing and ChannelRemoval:1. Remove the six 5/16"-18 x 3/4" hexhead cap screws securing front fender.Remove fender.2. Remove eight screws securing eccen-tric housing (M, Fig. 5-16) to engine deck.3. Check the position of the eccentricradial bearing (B, Fig. 5-16) in the eccen-tric channel groove (A).4. Position the radial bearing so it is allthe way back in the groove in the channel.5. Remove the retaining ring (F, Fig. 5-16)and bearing (B) from the eccentric shaftand discard.

Eccentric Radial Bearing and ChannelReplacement:Install a new bearing and retaining ring onthe eccentric shaft. Replace eccentrichousing (M). (See “Housing AssemblyTightening Sequence” in this Section).

ECCENTRIC ARM WELDMENT/PARTSThe eccentric arm weldment tube (D, Fig.5-17), the pitman assembly shaft (E), andthe synthetic insert (F) can wear and willeventually loosen. To check:

WARNING

DANGER

DANGER

IDEAL

UNACCEPTABLE

Fig. 5-14: Rivet Heads A

B

C

H

G

D

E

F

Fig. 5-15



WARNING

1. Remove the six 5/16"-18 x 3/4" hexhead cap screws securing fender. Removefender.2. Remove the cutter bar drive belt (seeinstructions in this Section).3. Rotate the drive mechanism by handand watch for any noticeable play betweenthe parts. Worn and loose parts can causeearly parts failure.

CHECKING ECCENTRIC SHAFT BEARINGS Check shaft bearings (E, Fig. 5-16) when-ever the eccentric radial bearing (B) isreplaced. The shaft bearings do not needreplacement as often as the eccentricradial bearing.1. Check the eccentric shaft bearings (E,Fig. 5-16) for play. Move the eccentric shaft(C) up and down and from side to side.2. Check for play in the eccentric armpivot bearings (D, Fig. 5-16 & 5-18) bymoving the eccentric arm (E, Fig. 5-18)back and forth.

3. Wear and looseness can be caused byloose bearing flange bolts (F, Fig. 5-18).Tighten and re-check all bolts beforereplacing bearings.

ECCENTRIC SHAFT BEARINGSREMOVAL/REPLACEMENTThe procedure for removing and replacingthe eccentric shaft bearings (E, Fig. 5-16)requires special tools and a high degree ofmechanical aptitude. Contact the factoryTechnical Service Department beforeattempting this repair (or have the unitserviced by your authorized dealer).NOTE: Raise and support the unit fromunderneath.

To Remove the Eccentric Shaft Bearings:1. Clamp the eccentric housing (M, Fig. 5-16) in an arbor press with the top end ofthe eccentric shaft facing up. Press theshaft (C) through the eccentric shaft bear-ings (E). Use a short length of 3/4" roundbar stock to press the eccentric shaft com-pletely through the bearings.2. Press out the upper bearing in thehousing (M) and discard. Remove andsave the spacer (N).3. Remove the lower bearing from theeccentric shaft (C) with a bearing puller.4. Inspect all parts for wear or damage,clean parts thoroughly and replace anyworn or damaged parts.

To Replace the Eccentric Shaft Bearings:Using the 3/4" round bar stock, press newbearings onto the eccentric shaft and intothe housing.

NOTES: • Never press or pound directly on the

bearing race when installing the bearingin the eccentric housing. Use a pipe withan outer diameter slightly smaller thanthe opening in the housing.

• Never press or pound directly on thebearing race when installing the bearingon the eccentric shaft– use a pipe withan inner diameter slightly larger than theshaft diameter to press on the bearing.

• Clean the opening in the eccentrichousing. Remove foreign material whichcould prevent bearings from seatingsquarely in the housing. Lubricate allsurfaces of press-fit parts.

When installing the engine deckassembly, the front housing assembly,or the housing assembly, the flangescrews (A, B, and C, Fig. 5-19) must betightened in the proper sequence toavoid damage.

CAUTION

D

H

J

K

L

M

E

C

N

B

F

A

E

Fig. 5-16

A

B

C

D

E

FFig. 5-17

C

B

D

EF

Fig. 5-18



WARNING

HOUSING ASSEMBLY TIGHTENING SEQUENCEFirst, tighten screws (A, Fig. 5-19).Second, tighten screws (B).Last, tighten screws (C).

FRONT HOUSING REMOVAL1. Move the cutter bar lever into the OFFposition (Fig. 4-7).2. Remove the cutter bar assembly (seeinstructions in this Section).3. Remove the cutter bar drive belt (seeinstructions in this Section).4. Remove 3/8"-16 x 3/4" long hex headscrews (C, Fig. 5-18) securing the sidesand bottom of the front housing (B).5. Lower and slide the front assembly offthe unit.

ECCENTRIC SHAFTREMOVAL/REPLACEMENTThe procedure for removing and replacingthe eccentric shaft requires special toolsand a high degree of mechanical aptitude.Contact the factory Technical ServiceDepartment before attempting this repair(or have the unit serviced by your autho-rized dealer).

To Remove the Eccentric Shaft:1. Remove the 5/8–18 hex nut (H, Fig. 5-16)and 5/8 flat washer (J) from the top of theeccentric shaft (C).2. Thread a spare 5/8"–18 hex nut ontothe shaft until the nut is flush with the endof the shaft. Use the nut only to removethe eccentric shaft pulley (K).NOTE: The eccentric shaft is tapered to fitsnugly in the pulley hub.

3. Apply prying pressure with a small prybar or suitable tool between the pulley andthe eccentric housing (M, Fig. 5-16). Atthe same time, rap the nut on the eccentricshaft sharply with a hammer to loosen thepulley from the shaft.4. Remove the spare 5/8–18 hex nut andseparate the pulley (K) from the eccentricshaft (C).5. Remove the 15/16 retaining ring (L)from the eccentric shaft.

To Replace the Eccentric Shaft:1. Slide eccentric shaft back into bearingsand housing.2. Replace the 15/16 retaining ring (L)onto the eccentric shaft.3. Replace the pulley (K) back onto theeccentric shaft (C).4. Secure pulley to eccentric shaft withthe 5/8–18 hex nut (H, Fig. 5-16) and 5/8flat washer (J) (removed earlier) on thetop of the eccentric shaft (C).5. Tighten securely.

ENGINE MAINTENANCE

CHECK ENGINE OIL LEVEL

Before starting the engine, check theengine oil level. Check the oil level everyfive operating hours.NOTE: Oil can flow away from internalengine parts when the unit is operated onslopes. Keep the oil level at the FULL markon the dipstick when operating, especiallyon slopes. Recheck the oil level every 30minutes of operation.1. Place the unit on a level surface.2. Clean any debris away from the oil dip-stick (E, Fig. 5-20).

3. Unscrew the dipstick.4. Use a clean, lint-free rag to wipe thedipstick.5. Firmly screw the dipstick all the wayinto the oil fill hole.6. Unscrew the dipstick and check the oillevel. The level should be at the FULL mark.

ADD OIL1. Insert a clean funnel into the oil fillhole.2. Select a clean, high quality detergentoil as specified in the Engine Owner’sManual.3. Slowly pour oil into the funnel. Checkthe oil level frequently and do not overfill.Over-filling can cause engine damage.4. When the oil level is at the FULL mark(see Engine Owner’s Manual), reinstall thedipstick. Wipe up spilled oil.

CHANGING ENGINE OILChange the engine oil after the first twohours of operation and after every 25operating hours. Change the oil more fre-quently if the unit is operated in very dirty,dusty conditions.1. Run unit until engine is warm.2. Stop the engine, wait for all movingparts to come to a stop, disconnect thespark plug wire and prevent it from con-tacting the spark plug. Install the plasticblade guard.3. Place a drain pan with a capacity of atleast two quarts beneath the engine drainplug (on underside of deck). Removeplug.4. Allow the oil to drain completely. Wipeup spills or drips.5. Replace the oil drain plug.6. Refill the engine with fresh oil of theproper type and amount as stated in theengine manual.

Before checking the oil level, adding oilto the engine or changing the engine oil,stop the engine, wait for all parts tocome to a stop, disconnect the sparkplug wire and prevent it from contactingthe spark plug. Remove the key on elec-tric start models.Failure to follow these instructions mayresult in serious personal injury or prop-erty damage.

WARNING

A

A

B

A

A

C

Fig. 5-19



WARNING

AIR CLEANERInspect the air cleaner elements every 25hours of engine operation, or more fre-quently if operating under very dirty, dustyconditions. Never operate the enginewithout the air cleaner assembly installed.See the separate engine manual for aircleaner maintenance instructions.

INSPECT SPARK PLUGInspect spark plug every 100 operatinghours. Follow the spark plug cleaning andreplacement recommendations in the sep-arate engine manual. Always replace adamaged spark plug.

AIR COOLING SYSTEM CLEANINGDry grass or debris can clog enginecooling fins, air intake screen, levers,guards and linkages. Clean all debris fromthese areas to help avoid engine damagecaused by overheating. See the separateengine manual for instructions.

BATTERY MAINTENANCE(Electric-Start Units)

• Before charging battery after operatingunit, stop engine, wait for all movingparts to come to a complete stop, dis-connect spark plug wire and prevent itfrom contacting spark plug. Removekey from keyswitch. Install bladeguard.

• Do not use any battery charger otherthan the one which was supplied withthe unit. Use of any other batterycharger may permanently damage thebattery.

• Do not short circuit the battery wires by touching the connectors together, or by touching metal objects with connectors.

• Remove all metal jewelry whenworking near the electrical system.

• Do not smoke, use any flame, or gen-erate sparks near the battery duringbattery charging.

• Do not charge the battery for more than48 hours.

Failure to follow these instructions couldresult in serious personal injury or prop-erty damage.

1. Unplug the battery charger (A, Fig. 5-20) from the wall outlet.2. Plug the battery wire lead (B) into thebattery charger lead (C).

3. Plug the battery charger into agrounded 120-volt wall outlet. The batterycharger is designed for use indoors andshould not get wet. Keep the batterycharger away from water, rain, snow, etc.Charge the battery for 24 to 48 hours (24hours minimum).

4. Unplug the battery charger from thewall outlet first, then unplug the batterywire lead (B) from the battery charger lead(C).

SEASONAL BATTERY CHARGINGThe engine alternator continuouslycharges the battery while the engine isrunning. To help ensure that the battery isalways fully-charged, it should additionallybe charged for 24 (minimum) to 48 hoursat the start and end of the mowing season.

BATTERY REMOVAL/REPLACEMENT1. Remove the two screws securing thepanel at the rear of the unit. Remove thepanel.2. Unplug the black wire from the nega-tive (-) terminal on the battery and the redwire from the positive (+) terminal on thebattery.

3. Remove the two screws that secure thebattery bracket (behind the panel).Remove the battery bracket and heatshield and lift out the battery.4. Install the new battery and re-install thebattery bracket, heat shield and panel.Reconnect the red wire to the positive (+)terminal on the battery and the black wireto the negative (-) terminal.

CHECK AND TIGHTEN HARDWAREVibration occurs during operation and canloosen parts and hardware. Check all partsand hardware every 10 operating hours.Tighten or replace as needed.

LUBRICATIONEvery Five Operating Hours:• Put a drop or two of general purpose oil

under the hold-down clips and the wearplates (G, Fig. 5-10).

Every Ten Operating Hours:• Lightly oil the drive chain (see “Drive

Chain Adjustment and Lubrication” toaccess chain). Spread oil over as muchof the chain surface as possible.

• With a hand-operated grease gun, applygrease through the zerk fittings in theattachment mounting bracket andpitman assembly pivot shafts (see Fig.5-21).

• Wipe old, dirty grease from the eccentricchannel (A, Fig. 5-16) and apply freshgrease.

WARNING

Fig. 5-20

E

A (to groundedwall outlet)

C (frombatterycharger)

B (frombattery)

Fig. 5-21

GreaseFittings



WARNING

TROUBLESHOOTINGBefore performing any corrections in this troubleshooting chart, refer to the appropriate information in this manual for correctsafety precautions and operating or maintenance procedures. Contact your local authorized engine service dealer for engineservice. Contact your local authorized dealer or our factory for help with service problems.

PROBLEM POSSIBLE CAUSE CORRECTIONPoor cutting performance. 1. Dull/damaged blades/sections/ledger plates. 1. Replace blades/sections/ledger plates.

2. Blade guides not properly adjusted. 2. Readjust blade guides.Sloping/uneven cut. 1. Left and right height adjusters not set 1. Reset height adjusters.

at equal heights.Cutter bar does not 1. Disconnected spring. 1. Replace spring.move when cutter bar 2. Broken or bent blade section. 2. Replace blade section.lever is engaged. 3. Broken blade drive mechanism. 3. See dealer

4. Worn or broken blade drive belt. 4. Replace belt.Cutter bar does not stop 1. Broken or worn idler spring. 1. Replace spring.moving when cutter bar lever is disengaged. Wheels do not rotate 1. Control rods not properly adjusted. 1. Adjust wheel drive control rods.when wheel drive levers 2. Worn or broken wheel drive belt. 2. Replace belt.are engaged. 3. Stretched or disconnected belt tension spring. 3. Reconnect or replace spring.

4. Loose spring tension. 4. Move spring to lower hole or replace spring.

STORAGE

• Never perform maintenance while theengine is running or when the sparkplug wire is connected, except wherespecifically instructed to do so.

• Use a gasoline stabilizer, or draingasoline outdoors into an approvedcontainer. Do not smoke and keepaway from open flame.

• Never store the unit with fuel in thefuel tank inside a building wherefumes may reach an open flame orspark, or where ignition sources arepresent such as hot water and spaceheaters, furnaces, clothes dryers,stoves, electric motors, etc. Allowengine to cool before storing.

Failure to follow these instructions couldresult in serious personal injury or prop-erty damage.

NOTE: When storing the unit for morethan 90 days, follow these procedures tohelp keep the unit in good condition forfuture use:1. Install the plastic blade protector on theblade.2. Add a fuel stabilizer to the fuel tank.Follow the stabilizer manufacturer’s direc-tions. Or, if draining fuel is absolutely nec-essary, drain fuel from the engine asdescribed in the Engine Owner’s Manual.Avoid leaving non-stabilized gasoline inthe fuel tank for longer than 30 daysbecause gum and other deposits can formthat will foul the carburetor and fuel line.3. Change the engine oil (see the EngineOwner’s Manual).4. Remove the spark plug and squirt 1/2ounce of engine oil into the spark plughole. Hold a rag over the spark plug hole(be careful to prevent rag from enteringhole). Slowly pull the recoil starter ropeseveral times to coat the cylinder wall withoil. Reinstall the spark plug.

5. Clean any dirt, grass, or debris fromthe recoil housing screen, cooling fins,and other parts of the engine.6. Lubricate the unit (see instructions inthis Section).7. Thoroughly inspect the unit for anyloose, broken, or missing parts. Repair orreplace them as necessary.8. Check all nuts and bolts for tightness.9. Disconnect the spark plug wire fromthe spark plug. Prevent the wire from con-tacting the spark plug by placing the sparkplug wire boot on the engine holding tab.10. Apply a light coat of oil to the blade.11. On electric start models, fully chargethe battery (see instructions in this Sec-tion), and remove the key from thekeyswitch.12. Store the unit in a level position out ofreach of children.

WARNING


TROUBLESHOOTING (continued)

PROBLEM POSSIBLE CAUSE CORRECTION

Wheels continue to 1. Control rods not properly adjusted. 1. Adjust wheel drive control rods.rotate when wheel drive 2. Broken or excessively worn wheel clutch 2. Replace spring.levers are disengaged. spring.

Unit pulls to one side 1. Unevenly inflated tires. 1. Check tire pressure. Inflate both tireswhile mowing. equally (10-17 psi [68.5-117 KPa]).

2. Broken or worn wheel drive belt. 2. Replace wheel drive belt.

Excessive noise or vibration. 1. Blade guides out of adjustment. 1. Adjust blade guides.2. Loose blade sections or ledger plates. 2. Tighten loose rivets.3. Loose cutter bar mounting bracket. 3. Tighten the nuts and bolts which attach the

bracket to the cutter bar.4. Worn eccentric radial bearing and/or 4. Replace bearing and/or channel.

channel.5. Worn eccentric shaft bearings. 5. Replace bearings.6. Loose frame nuts and bolts. 6. Tighten bolts and nuts properly.7. Engine speed set too high. 7. See engine service dealer.

Engine Does Not Start. 1. Spark plug wire disconnected. 1. Reconnect wire.2. Fuel tank empty. 2. Fill fuel tank with fresh gasoline.3. Stale/contaminated gasoline in fuel tank. 3. Drain fuel tank and fill with fresh gasoline.4. Wheel drive lever not disengaged. 4. Lock wheel drive levers in disengaged position.5. Cutter bar lever not disengaged. 5. Move cutter bar lever into disengaged position.6. a. Engines with primer bulb. 6. a. Depress primer bulb three times.

b. Engines without primer bulb. b. Place throttle lever in choke position.7. Dirty air filter. 7. Clean or replace air filter.8. Defective or incorrectly gapped spark plug. 8. Inspect/service spark plug.9. Carburetor out of adjustment. 9. See engine service dealer.

10. Defective wheel drive or cutter bar 10. Inspect wires. See engine service dealerswitch or wiring. to replace switch.

Engine runs poorly. 1. Defective spark plug. 1. Replace spark plug.2. Incorrect throttle setting. 2. Put throttle in correct setting.3. Dirty air filter. 3. Clean or replace air filter.4. Carburetor out of adjustment. 4. See engine service dealer.5. Contaminated or decomposed gasoline. 5. Drain fuel tank and fill with gasoline.6. Stale/contaminated gasoline in fuel tank. 6. Drain fuel tank and fill with gasoline.7. Engine cooling system clogged. 7. Clean engine cooling fins and vents..

Engine overheats. 1. Engine cooling system clogged. 1. Clean engine flywheel screen.2. Carburetor out of adjustment. 2. See engine service dealer.3. Oil level is low. 3. Check and add oil.

Engine does not stop. 1. Defective engine shut-off switch, 1. See dealer.wheel drive switch, or wiring.

2. Defective throttle control lever. 2. See dealer.

Keyswitch does not operate 1. Engine does not turn over when keyswitch 1. Start engine with starter rope. If engine starts,starter. is in START position. engine is not seized, problem is with starting

system.2. Wiring harness loose/wiring broken. 2. Check wiring harness connection/wiring.3. Corroded connectors. 3. Clean connectors.4. Discharged battery. 4. Charge battery for 24 (minimum) to 48 hours.5. Malfunctioning keyswitch. 5. Replace keyswitch.6. Malfunctioning starter motor. 6. Contact local engine service dealer.

Battery does not charge 1. Broken wire in engine recharging circuit. 1. Contact local engine service dealer.during operation. 2. Dead battery. 2. Replace battery.

3. Malfunctioning charging system. 3. Contact local engine service dealer.

Battery charger does 1. Broken battery lead. 1. Repair/replace lead.not charge battery. 2. Damaged battery charger 2. Replace battery charger (must be same

type as original).3. Dead battery. 3. Replace battery.

30 Parts ListModels 34061, 34062, 34337, 34063 & 34064

S/N 340610500101-340611599999S/N 340620500101-340621599999S/N 340630500101-340631599999

S/N 340640500101-340641599999S/N 343371100101-343371599999

159

131

302

5051

312 53

303

52

319321

318

321

2

12

9

306117

118

11

13

119

10

3

301155

12

1564

115

116

313

112 105

7

9

27

29

22

2223

34311

36

60

35

128

93 82

57

38

37

107

31

39

162

95

41

46

49

163

4845

30

104

14

18

4344

26

166 61 84

4443

167

2021 154

24

17

16

98 16

17

93

82

57

84 167

160161

322323

32

19

81

81

316 Red Spray Paint (order part # 1900706)317 Black Spray Paint (order part # 1735222)

TOUCH-UP PAINT

Parts List 31Models 34061, 34062, 34337, 34063 & 34064

1 1767711010 Left Wheel Drive Housing ............................ 12 1765981001 Left Handlebar ............................................. 13 1767717 Throttle ........................................................ 14 1100807 Hex Hd. Capscrew, 1/4-20 x 2 ..................... 15 1766603 Wheel Clutch Lever ...................................... 26 1107382 Flat Washer, 5/16......................................... 17 1100811 Hex Hd. Capscrew, 1/4-20 x 1-1/2 ............... 28 1767712010 Right Wheel Drive Housing.......................... 19 9126 Handle Grip.................................................. 2

10 1110106 Center Lock Nut, 1/4-20............................... 311 1768430 Operator Interlock Harness

(Incl. Refs. 313 & 325. Also Ref. 134 from page 33).................................................... 1

12 1768426 Wheel Clutch Rod ........................................ 213 1766608 Handlebar Bridge ......................................... 114 1767552 Flange Bearing ............................................. 216 1186230 Hex Nut, 5/16-18 ......................................... 417 1110645 Lock Washer, 5/16....................................... 419 1107387 Flat Washer, 3/4........................................... 220 1766611 Shock Absorber ........................................... 221 1732499 Top Lock Nut, 5/16-18................................. 222 1104436 Woodruff Key, #9, 3/16 x 3/4....................... 323 1767545 Countershaft ................................................ 124 1773216010 Engine Deck ................................................. 126 1766890010 Chain Idler Bracket....................................... 127 1186009 Hex Hd. Screw, #10-24 x 1/2 ....................... 129 1766622010 Chain Cover ................................................. 130 1766623 Carriage Bolt, 1/4-20 x 1/2........................... 431 1766624 Wheel Clutch Spring .................................... 232 1769517 Decal, “Top”................................................. 234 1766627 Chain (Incl. Ref. 311)................................... 135 1766628 Chain Idler ................................................... 136 1766629 Sprocket, 12T .............................................. 137 1766630 Idler Arm Pivot............................................. 238 1185257 Snap Ring, 3/8, "E" Type .............................. 239 1766631 Wheel Clutch Idler Arm................................ 241 1766714 Wheel Idler Spacer....................................... 243 1100241 Lock Washer, 1/4......................................... 444 1186229 Hex Nut, 1/4-20 ........................................... 445 1769982 Spacer.......................................................... 246 1766636 Countershaft Pulley...................................... 248 1710566 Idler Pulley................................................... 249 1100049 Hex Hd. Capscrew, 3/8-16 x 2-1/4 ............... 250 1770480 Left Wheel Assembly

(Incl. Refs. 302, 303 & 312) ..................... 151 1770470 Right Wheel Assembly

(Incl. Refs. 302, 303 & 312) ..................... 152 1769972010 Belt Seal....................................................... 2

53 1764070 Top Lock Nut, 3/8-24................................... 657 1100044 Hex Hd. Capscrew, 5/16-18 x 3/4 ................ 360 1120210 Roll Pin, 3/16 x 1 ......................................... 161 1186469 Carriage Bolt, 5/16-18 x 3/4......................... 281 1773272 Flat Washer (hardened), 5/16 ...................... 282 1100255 Flat Washer, 5/16......................................... 584 1773423 Hex Hd. Capscrew, 3/8-16 x 3/4, Grade 8 .... 293 1768516 Belt Guide .................................................... 395 1764121001 Belt Guide .................................................... 298 1111607 Hex Hd. Capscrew,

5/16-18 x 2-1/4, Grade 5 .......................... 2104 1740496 Self-Tapping Screw, 5/16-18 x 5/8 .............. 6107 1185219 Retaining Ring, 1/2 ...................................... 2112 1717897 Hair Pin........................................................ 2115 1765993 Pivot Pin, 1/4 ............................................... 2116 1766992 Crescent Ring .............................................. 4117 1765925 Decal, Operator Presence Control ................ 2118 1765923 Compression Spring .................................... 2119 1735531 Cable Tie ...................................................... 6128 1186102 Carriage Bolt, 5/16-18 x 1-1/4 ..................... 1131 1701447 Shim Washer ............................................... 2154 1767091 Decal, Oil Drain ............................................ 1155 1767645 Decal, Throttle (A) (B) (E) ............................ 1

1767111 Decal, Throttle (C) (D).................................. 1156 1767124 Decal, Place Hand ........................................ 1159 1185388 Retaining Ring ............................................. 2160 1767128 Left Control Return Spring........................... 1161 1767129 Right Control Return Spring ........................ 1162 1110108 Center Lock Nut, 3/8 .................................... 2163 1766808 V-Belt ........................................................... 2167 1773460 Belt Guide .................................................... 2301 1767159 Right Handlebar Assembly

(Incl. Refs. 155 & 156) .............................. 1302 1767718 Tire, 13 x 5 x 6 Traction Lug ........................ 2303 1770455 Wheel Rim Assembly................................... 2306 1767160 Operator Presence Control Lever Assembly

(Incl. Ref. 117 ).......................................... 2311 1730343 Chain Connector Link................................... 2312 1718086 Valve Stem................................................... 2313 1768429 Thumb Latch Assembly ............................... 2316 1900706 Red Spray Paint (13 oz. can) ....................... N/I317 1735222 Black Spray Paint (13 oz. can) ..................... N/I318 1770460 Drive Hub/Pulley .......................................... 2319 1770465 Spacer Tube................................................. 2321 1766810 Bearing ........................................................ 4322 1770490 Right Belt Cover Assembly (Incl. Ref. 32).... 1323 1770495 Left Belt Cover Assembly (Incl. Ref. 32) ...... 1325 1767256 Cable Tie ...................................................... 3

Ref # Part # Description Qty. Ref # Part # Description Qty.

(A) Model 34061 (B) Model 34062 (C) Model 34063 (D) Model 34064 (E) Model 34337

N/I - Not included with unit, order separately.


15 158

124

111

109

16

17

16

11

18

97

9694

149

304

68

157

151

104

162

62

64

65

66

63

91

47

114

135

134

113

119

144

139

166

71

72

73

72

88

87

86

16

1774

3357

17

7557

92

90

162

310307

119

148

308

309

137

153

145

152

141

142

140 138

76

57

17884

106

122

77

108

318317

31983

33

162

8180

130

17879

10874

17

1689

17

57

143

81

172173

176

175

149

174

148

335

S/N 340610500101-340611599999S/N 340620500101-340621599999S/N 340630500101-340631599999

S/N 340640500101-340641599999S/N 343371100101-343371599999


11 1768430 Operator Interlock Harness (Incl. Ref. 134.Also Refs. 313 & 325 from page 31) ......... 1

15 * Engine, Briggs & Stratton, 3.5 HP (A).......... 1* Engine, Briggs & Stratton, 4 HP (B) (E) ....... 1* Engine, Briggs & Stratton, 5 HP (C)............. 1* Engine, Briggs & Stratton, 5 HP

w/elec. start (D) ........................................ 116 1186230 Hex Nut, 5/16-18 ......................................... 1017 1110645 Lock Washer, 5/16....................................... 1518 1100275 Woodruff Key, #6, 5/23 x 5/8....................... 133 1766626 Bearing Insert .............................................. 247 1767142 V-Belt ........................................................... 157 1100044 Hex Hd. Capscrew, 5/16-18 x 3/4 ................ 1162 1100047 Hex Hd. Capscrew, 3/8-16 x -1/2 ................. 163 1766650 Engine Pulley ............................................... 164 1186216 Hex Nut, 5/8-18 ........................................... 165 1107386 Flat Washer, 5/8........................................... 166 1766651 Eccentric Pulley ........................................... 168 1766926 Decal, Troy-Bilt ............................................ 171 1185102 Retaining Ring ............................................. 172 1766657 Ball Bearing.................................................. 273 1773137001 Housing Assembly ....................................... 174 1766664 Bearing Retainer .......................................... 275 1766665 Upper Pivot Bearing Support ....................... 176 1773565 Eccentric Arm Assembly .............................. 177 1773537 Pitman Assembly

(Incl. Refs. 317, 318 & 319) ..................... 179 1773452 Hex Hd. Capscrew, 3/8-16 x 1-1/4, Grade 8. 380 1772711001 Attachment Mounting Bracket Assembly ..... 181 1773272 Flat Washer (hardened), 5/16 ...................... 283 1773218010 Front Housing Assembly.............................. 184 1773423 Hex Hd. Capscrew, 3/8-16 x 3/4, Grade 8 .... 686 1118809 Retaining Ring ............................................. 187 1766795 Eccentric Bearing ......................................... 188 1766895 Eccentric Shaft............................................. 189 1729245 Flat Washer, 5/16......................................... 190 1736221 Shoulder Screw ........................................... 191 1713803 Idler Pulley, 3 x 1 ......................................... 192 1767715001 Knife Clutch Arm.......................................... 194 1111610 Hex Hd. Capscrew, 5/16-18 x 3 ................... 196 1111613 Hex Hd. Capscrew, 5/16-18 x 4, Grade 5 ..... 197 1111611 Hex Hd. Capscrew, 5/16-18 x 3-1/2 ............. 1

104 1740496 Self-Tapping Screw, 5/16-18 x 5/8 .............. 6106 1100806 Hex Hd. Capscrew, 1/4-20 x 1-1/4 ............... 1

108 1767609 Grease Fitting, 1/4-28 x 90° ......................... 2109 1766704 Upper Hook, 1/4-20 ..................................... 1111 1766805 Weed diverter Strap, 14-1/2" ....................... 1113 1185985 Hex Nut, #10-24........................................... 2114 1758070 Truss Hd. Screw, #10-24 x 5/8 .................... 2119 1735531 Cable Tie ...................................................... 3122 1100254 Flat Washer, 1/4........................................... 1124 1766558 Engine Cable Clip ......................................... 1130 1767687001 Doubler Bracket ........................................... 1134 1751340 Switch.......................................................... 1135 1766947 Grommet...................................................... 2137 1900455 Key Switch (D) ............................................. 1138 1909647 Battery (D) ................................................... 1139 1772392 Battery Clamp (D) ........................................ 1140 1756549 Battery Pad (D) ............................................ 1141 1768449 Charger (D) .................................................. 1142 1763875 Thread-Forming Screw, 1/4-20 x 3/8 (D) ..... 2143 1772168 2-amp Fuse.................................................. 1144 1772130 Start Harness (D) ......................................... 1145 1766959 Decal, Electric Start (D)................................ 1148 1724492 Self-Tapping Fl. Screw, 1/4-20 x 1/2............ 3149 1186389 Hex Flange Lock Nut, 1/4-20........................ 3151 1739687 Decal, OPEI Danger...................................... 1152 1767077 Decal, Warning ............................................ 1153 1901899 Decal, American Legend .............................. 1157 1767141 Decal, Danger .............................................. 1158 1983202 Decal, Hot Surface ....................................... 1162 1110108 Center Lock Nut, 3/8 .................................... 5166 1705792 Torsion Spring ............................................. 1172 1773451 Flat Washer.................................................. 2173 1118813 Retaining Ring ............................................. 1174 1773528001 Switch Cover................................................ 1175 1773529 Heat Reflector (D) ........................................ 1176 1773530 Spacer.......................................................... 1178 1757032 Loctite® Thread Compound ......................... 1304 1767156 Fender (Incl. Refs. 151 & 157 ).................... 1307 92018 Hex Nut (D).................................................. 1308 1187950 Lock Washer (D).......................................... 1309 1767155 Keyswitch Plate (Incl. Ref. 152)................... 1310 96520 Key (D)......................................................... 1317 1772940 Pitman Bearing ............................................ 1318 1715301 Thrust Washer ............................................. 1319 1767593 Retaining Ring ............................................. 1335 --- See pages 34 & 35

Ref # Part # Description Qty. Ref # Part # Description Qty.

(A) Model 34061 (B) Model 34062 (C) Model 34063 (D) Model 34064 (E) Model 34337

* Purchase engine parts from your local Briggs & Stratton Dealer. Refer to engine for type and code.

A/R - As Required


20

333

178133

132

120

11

11

11

10

1010

10

6

1110

6

6

6

1

3

4

3

2

*335

*15

7

9

9

8

9

9

913

13

13

13

13

13

13

12

13

13

13

5

9

9

9

9

9

18

18

18

18

18

150

24

14

14

14

14

31

31

31

31

29

15024

126

170

127

129

18

18

18

1818

18

* Items not Included in Cutter Bar Assemblies 1765990, 1766743 & 1766744

1

3

4

3

2

1

3

4

3

2

1

3

4

3

2

334

S/N 340610500101-340611599999S/N 340620500101-340621599999S/N 340630500101-340631599999S/N 340640500101-340641599999S/N 343371100101-343371599999


1 1860218 Hex Hd. Screw, M8 x 0.30 ..................... 42 1766746 Hold-Down Clip ..................................... 43 1766747 Lock Nut, M8......................................... 124 1766748 Knife Guide ............................................ 45 1765991 34" Ledger Plate Bar ............................. 1

1766753 38" Ledger Plate Bar ............................. 11766754 42" Ledger Plate Bar .............................. 1

6 1766755 Wear Plate ............................................. 47 1766929 34" Blade Knife Bar ................................ 1

1766756 38" Blade Knife Bar ................................ 11766757 42" Blade Knife Bar ................................ 1

8 1766758 Blade (single)......................................... 19 1767069 Blade (double) 34" ................................. 8

1767069 Blade (double) 38" ................................. 91767069 Blade (double) 42" ................................. 10

10 1768294 Rivet Section, 5 x 17 (pack of 12).......... A/R11 1768295 Rivet Section, 5 x 20 (pack of 12).......... A/R12 1766764 Ledger Plate (single).............................. A/R13 1766765 Ledger Plate (double) ............................ A/R14 1766767 Runner................................................... 415 1766769 Skid Assembly (Incl. Refs. 16, 23,

24, 127, 150 & 170) .......................... 218 1768296 Ledger Rivet, 6 x 20 (pack of 12) .......... A/R20 1765992 34" Blade Assembly

(Incl. Refs. 6, 7, 8, 9, 10 & 11) ........... 11766762 38" Blade Assembly

(Incl. Refs. 6, 7, 8, 9, 10 & 11) ........... 11766763 42" Blade Assembly

(Incl. Refs. 6, 7, 8, 9, 10 & 11) ........... 1

24 1107382 Flat Washer, 5/16................................... 429 1766777 Blade Guard, 34" .................................... 1

1766934 Blade Guard, 38" .................................... 11766935 Blade Guard, 42" .................................... 1

31 1766768 Hex Hd. Screw, M8 x 45 ........................ 8120 1773057 Knife Head ............................................. 1126 1766770001 Shoe Holder........................................... 2127 1767071 U-Bolt, 5/16 ........................................... 2129 1766773001 Shoe ...................................................... 2132 1773271 Flat Washer (hardened), 5/16 ................ 2133 1773424 Hex Hd. Capscrew, M8 x 12................... 2150 1983038 Nylock Nut, 5/16-18............................... 8170 1186100 Carriage Bolt, 5/16-18 x 1, Grade 5 ....... 4178 1757032 Loctite® Thread Compound................... A/R332 1766766 Blade Maintenance Kit (Incl.

Ref. # 8 [qty. 1], 9 [qty. 4], 10 [qty. 12],11 [qty. 6], 132 [qty. 2] & 133 [qty. 2])..................................... N/I

333 1770597 34" Ledger Plate Assembly .................... 11770598 38" Ledger Plate Assembly .................... 11770599 42" Ledger Plate Assembly .................... 1

334 1766792 Hold-Down Clip Kit (Incl. Refs. # 1 [qty. 1], 2 [qty. 1], 3 [qty. 3], 4 [qty. 1], 14 [qty. 1] & 31 [qty. 2])....................................... 4

335 1773564 Knife Head & Pitman Kit (Incl. Refs. 77,79, 81, 130, 162 & 178 from page 33,and Refs. 120, 132 and 133 listed above) ........................................ N/I

Ref # Part # Description Qty.Ref # Part # Description Qty.

Cutter Bar Assembly34"–176599038"–176674342"–1766744

N/I Not included with unit, order separately.A/R - As Required.

1905480 Rev. A (4/01) Printed in U.S.A. © 2001 Garden Way Incorporated

CUSTOMER SERVICE INFORMATION

Owner Registration CardPlease fill out and mail the enclosed ownerregistration card. The purpose of this card isto register each unit at the factory so that wecan provide you with warranty benefits andinformational bulletins.

Warranty ServiceThe warranty statement is included in the unit’s literaturepackage.

Model/Serial NumbersA Model/Serial Numbers decal is located on top of the fendernext to the left wheel. For ready reference, record these num-bers in the spaces below.

Date of Purchase:

Model Number:

Serial Number:

Authorized Dealer InformationIf you purchased your unit from an authorized dealer, recordthe dealer’s address and phone number below for ready reference:

Dealer Name:

Address:

Phone:

IMPORTANT:Left and right sides of the unit are determined by standing

behind the unit, in the operator’s position, and facing in thedirection of forward travel.

NOTICE:We reserve the right to change specifications, add

improvements or discontinue the manufacture of any of ourequipment without notice or obligation to purchasers of our

equipment.

M IA LM IA L

Customer Service and Technical ServiceIf you have questions or problems with theunit, contact your local dealer or the factory.(When calling or writing, provide theModel/Serial Numbers of the unit.)

Replacement PartsFactory specified replacement parts areavailable from your authorized dealer ordirectly from the factory. When orderingparts, be sure to provide the following:• Model/Serial Numbers of the unit.• Part number of the part needed.• Part Description.• Quantity needed.NOTE: All replacement parts must conformto our rigid quality specifications. Although some replacementparts we provide may vary slightly in shape, color or texturefrom the original parts, any variations will not affect the fit orperformance of these parts on your unit.

Engine Service and RepairFor engine service or repair, contact your nearest authorizedengine dealer (look in the Yellow Pagesunder “Engines–Gasoline”). The engine iswarranted by the engine manufacturer. Anyunauthorized work performed on the engineduring the warranty period may void thiswarranty. For complete details on theengine warranty, refer to the Engine Owner’sManual.

For customer assistance, contact your nearest authorized dealer or:

GARDEN WAY INCORPORATED • 1 Garden Way • Troy, New York 12180Customer Service: 1-800-437-8686 • Technical Service: 1-800-520-5520 • Parts Service: 1-800-648-6776

• FAX: (518) 233-4622 • WEBSITE: www.troybilt.com

Outside the United States and Canada:Customer Service: (518) 233-4807 • Technical Service: (518) 233-4808 • Parts Service: (518) 233-4806 • FAX (518) 233-4622

We urge using only genuine replacement parts, whichmeet all the latest requirements. Replacement parts manufactured by others could present safety hazards,even though they may fit on the unit.

WARNING

owner’s manual sickle bar mowers - m-and-d.com · pdf fileowner’s manual sickle...

Documents