Safetyo Assembly o Operation oTips &Techniques oMaintenance *Troubleshooting o Parts Lists oWarranty
®
21-inch Rotary Mower- Model 542
READ SAFETY RULES AND mNSTRUCTmONS CAREFULLY BEFORE OPERATION
Warning: This unitisequippedwithan internalcombustionengineandshouldnotbeusedon or nearanyunimprovedforest-covered,brush=
coveredor grass=coveredlandunlesstheengine'sexhaustsystemisequippedwithasparkarrestermeetingapplicablelocalorstatelaws(ifany),
If a sparkarresterisused,itshouldbemaintainedineffectiveworkingorderbytheoperator,Inthe StateofCaliforniatheaboveisrequiredbylaw
(Section4442oftheCaliforniaPublicResourcesCode),Otherstatesmayhavesimilarlaws,Federallawsapplyonfederallands,A sparkarrester
forthemufflerisavailablethroughyournearestengineauthorizedservicedealeror contacttheservicedepartment,RO,Box361131Cleveland,
Ohio44136=0019,
PRINTEDiN U,S,A MTD LLC, RO. BOX 361131 CLEVELAND, OHiO 44136-0019 FORMNO,769=02232
11/29/2005
This Operator's Manua_ is an important part of your new lawn mower, mtwH_ he_p you assemble,
prepare, and maintain the unit for best performance. P_ease read and understand what it says.
Table of Contents
Smope Gauge ....................................................... 3
Safe Operation Practices ................................... 4
Setup and Adjustment ....................................... 6
Operating Your Lawn Mower .............................. 8
Maintaining Your Lawn Mower ......................... 10
Trouble Shooting .............................................. 12
Safety Labels .................................................... 13
Parts List ........................................................... 14
Warranty ............................................ Back Cover
Finding and Recording Model Number
BEFOREASSEMBLINGYOUR NEWEQUIPMENT,please
locate themodel plateon theequipmentand copythe infor=
mationto thesample modelplate providedtothe right.You
can locatethe modelplate by standingat the operatingposi=
tionand lookingdown at the rearof the deck.This information
will be necessarywhen usingthe manufacturer'swebsite, to
obtainassistancefromthe CustomerSupport Department,or
whencontactingan authorizedservice dealer.
lVlodet Number Serial Number
0 TRO_XX--T" TROY=O[LT LLC
P. 0. BOX 361131
www.troybimt.com CLEVELAND, OH44136
330=558=7220
Customer Support
P_ease do NOTreturn the unit to the retailer from which it was purchased, without first
contacting Customer Support.
if you havedifficultyassemblingthis productor haveanyquestionsregardingthecontrols, operation,or maintenanceof this
unit,youcan seek helpfrom theexperts. Choosefromthe optionsbelow:
o Visitwww.troybilt.com
0
Phonea CustomerSupport Representativeat 1-866-840-6483.
The enginemanufactureris responsiblefor all engine-relatedissueswith regardto performance,power=rating,specifications,
warranty,and service. Please refertothe engine manufacturer'sOwner's/Operator'sManual,packedseparatelywithyour
unit,for more information.
2
yourlawnmoweronsuchslopes.
/
/
/
/
o
/
/
t
o
w_
WARNING
Do not mowon inclines
with a dope in excess
of 15degrees(a rise
of approximately
2-"
feet). A riding r
couldoverturnand
cause seriousinjury.
if operatinga walb
behindmoweron such
a dope, it isextremely
footing and youcould
dip, resultingin serious
injury.
OperateRiDiNG
mowersupand down
dopes, neveracross
theface of dopes.
Operate
WALK-BEHIND
mowersacrossthe
face of dopes, never
up and down slopes.
\
3
manual.Aswithanytypeofpowerequipment,carelessnessorerroronthepartoftheoperatorcan
resultinseriousinjury.Thismachineiscapableofamputatinghandsandfeetandthrowingobjects.
! Failuretoobservethefollowingsafetyinstructionscouldresultinseriousinjuryordeath.
endangerthepersonal
safetyand/orproperty
Children
Tragicaccidentscan occurifoperatorisnotalerttopresence
ofchildren.Childrenareoftenattractedto mowerandmowing
activity.Theydonot understandthedangers.Neverassume
thatchildrenwill remainwhereyoulastsawthem.
1. Keepchildrenoutofthe mowingareaandunderwatchful
careof aresponsibleadultotherthanthe operator.
2. Bealertandturnmoweroffifachildentersthearea.
3. Beforeandwhilemovingbackwards,lookbehindanddown
forsmallchildren.
4. Useextremecarewhenapproachingblindcorners,
doorways,shrubs,trees,orotherobjectsthat mayobscure
yourvisionofachildwhomayrunintothemower.
5. Keepchildrenawayfromhot orrunningengines.Theycan
sufferburnsfroma hotmuffler.
6. Neverallowchildrenunder14yearsoldto operateapower
mower.Children14yearsold andovershouldreadand
understandoperationinstructionsandsafetyrulesinthis
manualandshouldbetrainedandsupervisedbyaparent.
General Operation
1. Readthis operator'smanualcarefullyin its entiretybefore
attemptingtoassemblethismachine.Read,understand,
andfollow allinstructionsonthe machineandin the
manual(s)beforeoperation.Becompletelyfamiliarwith
thecontrolsandthe properuseofthismachinebefore
operatingit.Keepthismanualinasafeplaceforfuture
andregularreferenceandfor orderingreplacementparts.
2. Thismachineisa precisionpieceof powerequipment,
nota plaything.Therefore,exerciseextremecautionat all
times.Yourunithasbeendesignedto performonejob: to
mowgrass.Donotuseitfor anyotherpurpose.
3. Neverallowchildrenunder14yearsoldto operatethis
machine.Children14yearsoldand overshouldreadand
understandthe instructionsinthis manualandshould
betrainedand supervisedbya parent.Onlyresponsible
individualswhoarefamiliarwiththeserulesofsafe
operationshouldbeallowedtousethismachine.
4. Thoroughlyinspectthe areawherethe equipmentisto
beused.Removeall stones,sticks,wire,bones,toysand
otherforeignobjectswhichcould betrippedoveror picked
upand thrownbythe blade.Thrownobjectscancause
seriouspersonalinjury.Planyourmowingpatternto avoid
dischargeofmaterialtowardroads,sidewalks,bystanders
andthe like.Also,avoiddischargingmaterialagainsta
wallorobstructionwhichmaycausedischargedmaterial
toricochetbacktowardtheoperator.
6. Alwayswearsafetyglassesor safetygogglesduringopera-
tionandwhileperforminganadjustmentorrepairtoprotect
youreyes.Thrownobjectswhichricochetcancauseserious
injurytothe eyes.
7. Wearsturdy,rough-soledworkshoesandclose-fitting
slacksandshirts.Shirtsand pantsthatcoverthe armsand
legsandsteel-toedshoesarerecommended.Neveroperate
thismachineinbarefeet,sandals,slipperyor lightweight
(e.g.canvas)shoes.
8. Donotputhandsorfeetnearrotatingpartsor undercutting
deck.Contactwithbladecanamputatehandsandfeet.
9. Amissingor damageddischargecovercancauseblade
contactor thrownobjectinjuries.
10.Manyinjuriesoccurasa resultofthe mowerbeingpulled
overthefootduringafall causedbyslippingortripping.
Do notholdontothe mowerifyouarefalling;releasethe
handleimmediately.
11.Neverpullthe mowerbacktowardyouwhileyouare
walking.Ifyoumustbackthe mowerawayfromawallor
obstructionfirstlookdownandbehindtoavoidtrippingand
thenfollowthesesteps:
a. Stepbackfrommowertofully extendyourarms.
b. Besureyou arewellbalancedwithsurefooting.
c. Pullthemowerbackslowly,no morethanhalfway
towardyou.
d. Repeatthesestepsasneeded.
12.Donotoperatethe mowerwhileunderthe influenceof
alcoholor drugs.
13.Donotengage theself-propelledmechanismon unitsso
equippedwhilestartingengine.
14.Thebladecontrolhandleis asafetydevice.Neverattempt
tobypassits operation.Doingsomakesthe safetydevice
inoperativeandmay resultinpersonalinjurythrough
contactwiththe rotatingblade.The bladecontrolhandle
mustoperateeasilyin bothdirectionsandautomatically
returntothe disengagedpositionwhenreleased.
15.Neveroperatethe mowerinwetgrass.Alwaysbesureof
yourfooting. Aslipand fallcan causeseriouspersonal
injury.If youfeelyouarelosingyourfooting,releasethe
bladecontrolhandleimmediatelyandthe bladewillstop
rotatingwithinthreeseconds.
16.Mowonlyindaylightorgoodartificiallight.Walk,neverrun.
17.Stopthe bladewhencrossinggraveldrives,walksor roads.
18.Ifthe equipmentshouldstarttovibrateabnormally,stopthe
engineandcheckimmediatelyforthe cause.Vibrationis
and followthe warnings 5. Tohelpavoidbladecontactora thrownobjectinjury, ._ generallya'_arningof!rouble.........
]_ _nutthe engne errandwar unl: me Daaecomes-coa
and i..struction2 stayinoperatorzonebehindhandlesandkeepchildren, "
u _ competestop beforeremovngthe grasscatcheror uncog
, ,; bystanders,helpers,andpetsat least75feet frommower .
un_nusmanuau glngthechute
whileit isin operation.Stopmachineifanyoneenters
and onthe machine, area.
..... ,J
4
Thecuttingbladecontinuesto rotatefora fewsecondsafter
the engineisshutoff. Neverplaceanypartofthe bodyin
the bladeareauntilyouaresurethe bladehasstopped
rotating.
20.Neveroperatemowerwithoutpropertrailshield,discharge
cover,grasscatcher,bladecontrolhandle,or othersafety
protectivedevicesin placeandworking.Neveroperate
mowerwithdamagedsafetydevices.Failuretodo socan
resultin personalinjury.
21.Mufflerandenginebecomehotandcancausea burn.Do
nottouch.
22.Onlyusepartsandaccessoriesmadeforthismachineby
manufacturer.Failureto dosocanresultinpersonalinjury.
23.Ifsituationsoccurwhicharenot coveredinthismanual,
usecareand goodjudgment.Contactyourdealerfor
assistance.Telephone1-866-840-6483forthe nameofyour
nearestdealer.
SJope Operation
Slopesarea majorfactorrelatedto slipandfallaccidentswhich
canresultinsevereinjury.Operationonslopesrequiresextra
caution.Ifyoufeeluneasyonaslope,donotmowit.Foryour
safety,usethe slopegaugeincludedaspartofthis manualto
measureslopesbeforeoperatingthisunitonaslopedor hilly
area.Iftheslopeis greaterthan15degrees,do notmowit.
Do:
1. Mowacrossthe faceof slopes;neverup anddown.
Exerciseextremecautionwhenchangingdirectionon
slopes.
2. Watchfor holes,ruts,rocks,hiddenobjects,or bumpswhich
can causeyou toslipor trip.Tallgrasscan hideobstacles.
3. Alwaysbesureofyourfooting.Aslip andfall cancause
seriouspersonalinjury.If youfeelyouarelosingyour
balance,releasethe bladecontrolhandleimmediately,and
the bladewillstop rotatingwithin 3seconds.
Do Not:
1. Donotmowneardrop-offs,ditchesorembankments,where
you couldloseyourfootingorbalance.
2. Donotmowslopesgreaterthan15degreesasshownon
the slopegauge.
3. Donotmowon wetgrass.Unstablefootingcouldcause
slipping.
Service
Safe HandlingOf Gaso%e:
1. Toavoidpersonalinjury orpropertydamageuseextreme
carein handlinggasoline.Gasolineisextremelyflammable
andthevaporsareexplosive.Seriouspersonalinjurycan
occurwhengasolineis spilledonyourselforyourclothes
whichcanignite.
2. Washyourskinandchangeclothesimmediately.
3. Useonlyanapprovedgasolinecontainer.
4. Neverfill containersinsideavehicleor onatruckor trailer
bedwith aplasticliner.Alwaysplacecontainersonthe
groundawayfromyourvehiclebeforefilling.
5. Removegas-poweredequipmentfromthe truckortrailer
andrefuelit onthe ground.Ifthisis notpossible,then refuel
suchequipmentonatrailerwitha portablecontainer,rather
thanfroma gasolinedispensernozzle.
6. Keepthe nozzlein contactwith therim ofthefueltank or
containeropeningat alltimesuntilfuelingis complete.Do
notusea nozzlelock-opendevice.
7. Extinguishallcigarettes,cigars,pipesandothersources
ofignition.
8. Neverfuel machineindoorsbecauseflammablevaporswill
accumulatein the area.
9. Neverremovegascap oradd fuelwhileengineishot or
running. Allowengineto coolatleasttwominutesbefore
refueling.
10.Neveroverfillfueltank. Filltankto nomorethan_ inch
belowbottomoffillerneckto provideforfuelexpansion.
11.Replacegasolinecapandtightensecurely.
12.Ifgasolineis spilled,wipeit offthe engineandequipment.
Moveunitto anotherarea.Wait5minutesbeforestarting
engine.
13.Neverstorethe machineorfuel containernearanopen
flame,sparkorpilotlightas onawaterheater,space
heater,furnace,clothesdryer,orothergas appliances.
14.Toreducefire hazard,keepmowerfreeofgrass,leaves,
or otherdebrisbuild-up.Cleanupoil orfuel spillageand
removeanyfuel soakeddebris.
15.Allowamowertocoolat least5 minutesbeforestoring.
General Service:
1. Neverrunanengineindoorsor ina poorlyventilatedarea.
Engineexhaustcontainscarbonmonoxide,an odorlessand
deadlygas.
2. Beforecleaning,repairing,or inspecting,makecertainthe
bladeandall movingpartshavestopped.Disconnectthe
sparkplugwireandgroundagainsttheengineto prevent
unintendedstarting.
3. Checkthe bladeandenginemountingboltsatfrequent
intervalsfor propertightness.Also,visuallyinspectbladefor
damage(e.g.,bent,cracked,worn)Replacebladewiththe
originalequipmentmanufacture's(O.EM.) bladeonly,listed
inthismanual."Useofpartswhichdo notmeettheoriginal
equipmentspecificationsmayleadto improperperformance
andcompromisesafety!"
4. Mowerbladesaresharpandcancut.Wrapthebladeorwear
gloves,anduseextracautionwhenservicingthem.
5. Keepallnuts,bolts,andscrewstight tobesurethe equip-
mentisin safeworkingcondition.
6. Nevertamperwithsafetydevices.Checktheirproperopera-
tionregularly.
7. Afterstrikingaforeignobject,stopthe engine,discon-
nectthe sparkplugwireandgroundagainsttheengine.
Thoroughlyinspectthe mowerforanydamage.Repairthe
damagebeforestartingandoperatingthemower.
8. Neverattempttomakeawheelorcuttingheightadjustment
whilethe engineis running.
9. Grasscatchercomponents,dischargecover,andtrail
shieldaresubjecttowear anddamagewhichcould expose
movingpartsorallow objectsto bethrown.Forsafety
protection,frequentlycheckcomponentsand replaceim-
mediatelywithoriginalequipmentmanufacturer's(O.EM.)
partsonly,listedin thismanual."Useof partswhichdo
not meettheoriginalequipmentspecificationsmayleadto
improperperformanceandcompromisesafety!"
10.Donot changetheenginegovernorsettingor overspeedthe
engine.Thegovernorcontrolsthe maximumsafeoperating
speedofthe engine.
11.Maintainor replacesafetylabels,asnecessary'.
12.Observeproperdisposallawsandregulations.Improper
disposaloffluidsand materialscanharmtheenvironment.
w o°,°o
ThisSymbolpoints
ua! before attemptingto
resuUt in personalinjury_
::When you see th s
_symbol
,EEDMTSWARNmNG
Responsibility
Restrictthe use
of this powermachine
to personswhoread
understand
5
Standbehinathe
moweras ifyou were
goingb operateit,
Your righthandcor-
respondsto the right
sideof the mower;your
left handcorresponds
to the left sideof the
mower.
Makesureto route
cane outsidethe lower
handle. Do not crimp
cane while liftingthe
handleup.
IMPORTANT
This unitis shipped
up gasolineand oil
as instructedinthe
accompanyingengine
manual BEFORE
operating yourmower.
Figure3-1:Unfoldhandleandtightenhardware.
HardwarePack )1
WingNuts(2) CarriageBelts(2
1. Removeanypackingmaterialwhichmaybebetween
upperand lowerhandles.
a. Pullupand backon upperhandleasshownin
Figure34. Makecertainthelowerhandleisseated
securelyintothe handlemountingbrackets.Donot
crimpcane whileliftingthehandleup.
b. Tightenstarknobstosecureupperhandleto
lowerhandle.Makesurethateachcarriageboltis
seatedproperlyin thehandle.
2. Locatethehairpinclipon theweldpinon eachsideof
lowerhandle.
a. Removehairpinclipfromthis hole.Usinga pair
ofpliers,inserthairpinclipintotheholeon pin
closesttothebracket,Figure3-2.Repeatonother
side.
b. Inserta carriageboltfromthehardwarepackinto
theupperholeon thehandlemountingbracket.
Securewithoneplasticwingnut,alsoincluded
inthe hardwarepack.Repeatonothersidewith
remainingitemsfromhardwarepack.
3. Theropeguideisattachedtotherightsideofthe
upperhandle,Figure3-3.Loosenthewingnutwhich
securestheropeguide.
a. Holdbladecontrolhandleagainstupperhandle.
b. Pullstarterropeoutoftheengine.Releaseblade
controlhandle.
c. Slipstarterropeintoropeguide.
d. Tightenwingnut.
4. Insertpostoncane ties intoholesprovidedon the
lowerhandle.Pullcane tiestightandtrimexcess,
Figure3-4.
Figure3-2:Securelowerhandletomountingbrackets.
Figure3-3:Pull recoilstarterthroughropeguideandtighten. Figure3-4:Securecablestohandleusingcableties.
J
6
5. Followstepsbelowtoassemblethegrasscatcher.
Makecertainbagisturnedrightsideoutbefore
assembling(warninglabelwillbe ontheoutside)
a. Placebagoverframesothatitsblackplasticside
isatthebottom.
b. Slipplasticchannelofgrassbagoverhooksonthe
frame,Figure3-5.All theplasticchannelsexcept
centertopof bagattachfromoutsideof bag.
c. Attachcentertopofbagfrominsideofbag.
7. Yourmowerisshippedasa mulcher.Toconvertto
sidedischarge,makesuregrasscatcherisoffofthe
unitand reardischargedoorisclosed.
a. Onthesideof themowerlift themulchingplug,
Figure3-7.
b. Slidetwohooksofsidedischargechuteunder
hingepin onmulchingplugassembly.Lowerthe
mulchingplug.Donotremovesidemulchingplug
atanytime,evenwhenyouarenotmulching.
Figure 3-5: Assemble the grass catcher.
6. Followthestepsbelowtoattachthegrasscatcher:
a. Liftreardischargedoor,Figure3-6.
b. Placegrasscatcheron thepivotrod.Letgo
ofdischargedoorsothat itrestson thegrass
catcher.
_jliL WARNING:Neveroperate mower unless the
hooks on the grass catcher are firmly seated
on the pivotrod and the rear discharge door rests
firmly against top of the grass catcher.
f
//
Figure3-6:Attachthegrasscatcher.
Figure3-7:Liftmulchplugandinstallsidedischargechute.
Adj ustments Whenadjustingthe !
Anadiusfingplateandthumbleverateachwheel cuttungheught,aHHwheeHs!
providescuttingheightadiustment, must bepositionedat
1. Depresslevertowardswheel, the same height, i
2. Moveitto anyoneofthepositionsfordesiredcutting
height,Figure3-8.Makesurethateachwheelis /}
positionedatthesameheight. I
3. Releaselevertowardsmowerdeck.
Figure3-8:Useleversto adjustcuttingheight.
WARNING
7
Know Your Lawn Mower
Grass Catcher--_
Cutting Height
Adjustment
Levers (front
J and rear)
The blade control is a
safety device. Never
attempt to bypass its
operations.
Use extreme care when
handling gaaomine.
Gasemineis extremely
flammable and the
vapors are expbaMve.
Never fuel the machine
indoors or while the
engine is hot or running.
Extinguish cigarettes,
cigars, pipes, and other
sources of ignition.
Keep hands and feet
away from the cutting
deck. Refer to warning
label on the unit.
Side DischargeChute
Figure4-1:Themajorpartsonthelawnmower.
Now that you have set up your lawn mower for
operation, read this section to become acquainted
with its controls and features. This knowledge will
allow you to use your new equipment to its fullest
potential
Blade Control
The biade control is attached to the upper handle.
Depress and squeeze it against the upper handle
to operate the unit=Release it to stop engine and
blade=
,_ WARNING:This Madecontrol isa safety
device. Donot bypass itsoperations.
Cutting Height Adjustment Levers
One adjustment lever is located on each wheel and
is used to adjust the cutting height. All four wheels
must be at the same position to ensure a uniform
cut.
Recoil Starter
The recoi[ starter is attached to the right upper
handle= Stand behind the unit and pui[ the recoil
starter rope to start the unit=
Mulch Plug
The mulch plug is used for mulching purposes=
Instead of collecting the grass clippings in a grass
catcher or using the side discharge chute, some
mower models have the option of recirculating the
clippings back to the lawn. This is called mulching=
Grass Catcher
The grass catcher, located at the rear of the mower,
is used to bag the grass clippings for disposai at an-
other site=Once the bag is fuiL it has to be removed
from the mower and emptied before any further
mowing.
Gas and Oil Fill°Up
1, Check oi{ {eve{and add oil if necessary, Follow engine
manual for this,
2, Service the engine with gasoline as instructed in the
engine manual
WARNING: Use extreme care when handling
gasoline. Gasoline is extremely flammable
and the vapors are explosive. Never fuel the machine
indoors or while the engine is hot or running.Extin-
guish cigarettes, cigars, pipes, and other sources of
ignition.
8
while operating the moweror while performing any
adjustments or repairs on it.
Starting Engine
_lb WARNING:Besure nooneother thanthe
operator isstanding near the lawn mower
while starting engine or operating mower.
Never run engine indoorsor inenclosed, poorly
ventilated areas. Engine exhaustcontains carbon
monoxide, an odorless and deadlygas. Keephands,
feet, hair and looseclothing awayfrom anymoving
parts on engineand lawnmower.
NOTE:Referto the engine manualfor help with
engine relatedoperations.
1, Placethefuelvalveleverfoundontheleft sideofthe
engineintotheON(OPEN)position,Figure4-2,
2, Movethechokeleverall thewaybackwardintothe
chokeposition,Figure4-2,
3, Standingbehindthe mower,squeezethebladecontrol
againstupperhandle,Figure4=2,Thechokewillnow
begintoslowlyreturntotheoff chokepositionafter
activatingthe bladecontrol Therefore,quicklymove
ontostepfourbelow,
4, Holdingthesetwo handlestogetherfirmly,grasprecoil
starterand pullropeoutwitha rapid,continuous,full
armstroke,Figure4-2,Keepinga firmgripon the
starterhandle,lettheroperewindslowly,Repeatuntil
enginecranks,Lettheroperewindeachtimeslowly,
Stopping Engine
1, Releasebladecontroltostoptheengineandblade,
2, Disconnectsparkplugwirefromsparkplugand
groundagainsttheengine,
WARNING:Waitfor the bladeto stop
completely before performing anywork
on the mower or to removethe grass
catcher.
Using Your Lawn Mower
WARNING:Neveroperateyour mower
without eitherthe reardoor or the entire
grass catcher assembly firmly secured.
Be surelawnisclearofstones,sticks,wire,or other
obiectswhichcoulddamagelawnmowerorengine,
Suchobiectscouldbe accidentlythrownbythemower
in anydirectionandcauseseriouspersonaliniurytothe
operatorandothers,
Figure 4-2: Starting the mower.
1, Oncetheengineisrunning,squeezetheblade
controlagainsttheupperhandletoengagethe
blade,
• Forbestresults,do notcut wetgrassand never
cutoff morethanone-thirdofthetotallengthofthe
grass,
Using as Muncher
FormulcNnggrass,removethegrasscatcherorside
dischargechutefromthemower,Thereardischarge
doorshouldbeclosed,
Foreffectivemulching,do notcut wetgrass,New
orthickgrassmayrequirea narrowercut,Adjust
groundspeedaccordingtoconditionoflawn,
• If thegrasshasbeenallowedto growinexcessof
fourinches,mulcNngisnotrecommended,Usethe
grasscatchertobagclippingsinstead,
Using Grass Catcher
YoucanusethegrasscatchertocollectclippingswNle
youareoperatingthemower,
1, AttachgrasscatcherfollowinginstructionsinSetup
section,Grassclippingswillautomaticallycollectin
bagasyourunmower,Operatemowerfillgrassbag
isfull
2, Stopenginecompletelybyreleasingtheblade
control Makesurethattheunithascometo a
completestop,
3, Liftdischargedoorand pullgrassbagup andaway
fromthemowertoremovethebag,Disposeofthe
grassclippingsandreinstallthebagwhencomplete,
9
WARNING
The operation of any
lawn mower can result
in foreign objects being
thrown intothe eyes,
which can damage your
eyes severely. Always
wear safety glasses
while operating the
mower or while perform°
ing any adjustments or
repairs on it.
Be sure no one other
than the operator is
standing near the
lawn mower while
starting engine or
operating mower. Never
run _ngine indoors or
in enclosed, pooHy
ventilated areas. Engine
exhaust contains carbon
monoxide, an odormess
and deadmygas. Keep
hands, feet. hair and
loose clothing away
from any moving parts
on engine and lawn
mower.
Deck Care
Cban undersideofthe mowerdeckaftereachuseto
preventbuild-upofgrassclippingsorotherdebris.Follow
stepsbelowforthisiob.
1. Disconnectsparkplugwire.Draingasolinefromlawn
mowerorplacea pieceof plasticunderthegascap.
2. Tipmowersothat itrestson thehousing.Keepthe
sidewiththeaircleanerfacingup.Holdmowerfirmly.
WARNING:Nevertip the mower more
than 900in anydirection and do not
leavethe mower tipped for anylength of
time. Oil candrain into the upper part of the engine
causing a starting problem.
3. Scrapeandcban theundersideofthedeckwitha
suitabb tool Donotspraywithwater.
4. Putthemowerbackonits wheelsontheground.If
Figure5-1:Areastolubricateonmower, youhadputplasticunderthegascapearlbr, make
suretoremoveitnow.
i
pu!!eys, bearings,Or
General Recommendations
Alwaysobservesafetyrubs whenperforming
anymaintenance.
• Thewarrantyon thislawnmowerdoesnotcover
itemsthathavebeensubiectedtooperatorabuse
or negligence.Toreceivefullvaluefromwarranty,
operatormustmaintainthe lawnmoweras
instructedhere.
. Changingofengine=governedspeedwillvoid
enginewarranty.
• Alladjustmentsshouldbecheckedat bast once
eachseason.
. Periodicallycheckall fastenersand makesurethese
aretight.
_ ARNING:Always stop engine, discon-
nect spark plug, and ground against
engine before performing anytype of
maintenanceon your machine.
Engine Care
A listofkeyenginemaintenanceiobs requiredforgood
performancebythemowerisgivenbelow.Followthe
accompanyingenginemanualforadetaibd listand
instructions.
. Maintainoil levelasinstructedin enginemanual.
Serviceaircleanerevery25 hoursundernormal
conditions.Cban everyfewhoursunderextremely
dustyconditions.Poorengineperformanceand
floodingusuallyindicatesthattheaircbaner should
beserviced.Toservicetheaircleaner,refertothe
enginemanual
.Cban sparkplugandresetthegap oncea season.
Sparkplugreplacementisrecommendedatthestart
ofeachmowingseason.Checkenginemanualfor
correctplugtypeand gapspecifications.
• Cban engineregularlywitha clothorbrush.Keepthe
coolingsystem(Newerhousingarea)cleantopermit
properaircirculation.Removeallgrass,dirt, and
combustibbdebrisfrom mufflerarea.
Lubrication
1. Lubricatepivotpointson thebladecontrolat bast
oncea seasonwithlightoil Thebladecontrolmust
operatefreelyinbothdirections,Figure5-1.
2. Lubricatethewheelsatbast oncea seasonwith
lightoil (or motoroil). Ifwheelsare removedforany
reason,lubricatesurfaceofthepivotarmandinner
surfaceofthewheelwithlightoil,Figure5-1.
3. Lubricatethetorsionspringandpivotpointonthe
reardischargedoorandsidemulchplugperiodically
withlightoil topreventrust,Figure5-1.
4. Followtheaccompanyingenginemanualforlubrba-
tionschedub andinstructionforenginelubrication.
10
B_adeCare
WARNING:When removing the cutting
bladefor sharpeningor replacement,
protect your handswith a pair of heavy
gloves or usea heavy rag to hold the
blade.
Periodicallyinspectthebladeadapterforcracks,
especiallyifyoustrikea foreignobiect,Replacewhen
necessary,Followthestepsbelowforbladeservice,
1, Disconnectsparkplugwirefromsparkplug,Turn
moweron itssidemakingsurethattheairfilterand
thecarburetorarefacingup,
2, Removetheboltand thebladebellsupportwhich
holdthebladeandthebladeadaptertotheengine
crankshaft,Figure5=2,
3, Removebladeandadapterfromthecrankshaft,
Figure5=2,
4, Thebladecanbe sharpenedwitha fileoron agrind=
ingwheel Donotattempttosharpenthebladewhileit
isstillonthemower,
Whensharpeningtheblade,followtheoriginalangle
ofgrind,Grindeachcuttingedgeequallyto keepthe
bladebalanced,
5, Totestforbalance,removebladeand balanceon
a roundshaftscrewdriver,Removemetalfromthe
heavysideuntilitbalancesevenly,
WARNING:An unbalanced bladewill
causeexcessivevibration when rotating
at high speeds. It may causedamageto
mower and could breakcausing personal
injury.
6, Lubricatetheenginecrankshaftandtheinnersurface
ofthebladeadapterwithlightoil Slidetheblade
adapterontotheenginecrankshaft,
7, Placethebladeontheadaptersuchthattheside
oftheblademarked"Bottom"(orwith partnumber)
facesthegroundwhenthemowerisin theoperating
position,Makesurethatthebladeisalignedand
seatedon thebladeadapterflanges,
8, Placebladebellsupporton theblade,Alignnotches
on thebladebellsupportwithsmallholesin blade,
9, Replacehexboltandtightenhexbolttotorque:450
in,Ibs,min,,600 in,Ibs,max,
Toensuresafeoperationof yourmower,periodically
checkthebladeboltforcorrecttorque,
Replacing Rear F_ap
1, Toremoverearflap,cut off theflat endofthewirerod
whichsecuresitto thedeck,Figure5-3,
2, Attachthenewflapandnewrodto deck,bendingthe
endsof thenewrodovertosecuretodeck,
J
Figure5-2:Removethebolt,support,andadaptertoaccess
theblade,
Figure5-3:Cutwireto removerearflap.
Off-Season Storage
Thefollowingstepsshouldbetakento prepareyour
lawnmowerforstorage,
, Cleanandlubricatemowerthoroughlyasdescribed
in thelubricationinstructions,
, Donotusea pressurewasherorgardenhoseto
dean yourunit,
, Refertoenginemanualforcorrectengine
storageinstructions,
• Coatmower'scuttingbladewithchassisgreaseto
preventrusting,
• Storemowerina dry,dean area,Donotstorenext
tocorrosivematerials,suchasfertilizer,
Whenstoringanytypeof powerequipmentin apoorly
ventilatedor metalstorageshed,careshouldbetaken
torust-prooftheequipment,Usinga lightoil orsilicone,
coattheequipment,especiallycablesandall moving
partsofyourlawnmowerbeforestorage,
11
WARNING
When removing
thecutting blade
for sharpening or
replacement, protect
your handswith a pair
of heavygloves or use
a heavy rag to hold
the blade.
An unbalanced blade
will cause excessive
vibration when rotat-
ing at high speeds, it
may cause damage
to mower and could
break causing per-
serial injury.
For repairs beyond
the minor adjustments
listed here, contact
an authorized service
dealer.
Problem Cause
2_ Sparkp!ugwiredisconnected= 2, Connectwiretosparkplug.
Fueltankernptyoistale_uek 3. FilltankWithdean, freshgas01ineI
4. Enginenotpr!med. 4. Primeengineasinstructedin !'Operat-
ingYourLawnMower'!.
EaultySpa[kplug. 5. Cleanladustgapl 0i iepJace.
6. BloCkedfuel line. 6. Cleanfuel[inc.
Enginefl0oded. 7. Waitalew minutesio iestartlbut do
notprime
Enginerunserratic 1. Sparkplugwireloose.
2. Blockedfuel lineor stalefuel.
3. Ventingas capplugged.
4. Wateror dirt infuel system.
5. Dirtyaircleaner.
6. Carburetorout ofadjustment.
1. Connectandtightensparkplugwire.
2. Cleanfuelline;filltank withclean,
freshgasoline.
3. Clearvent.
4. Drainfueltank.Refillwithfreshfuel.
5. Refertoenginemanual.
6. Refertoenginemanual.
2. Air f!owrestricted. , 2. Removeblowerhousingandclean.
3. Carburetornotadjustedproperly. 3. Refertoenginemanuak
Occasional skips 1. Sparkpluggap tooclose. 1. Adjustgapto .030-inch.
(hesitates) at high speed 2. Carburetoridlemixtureadjustment 2. Refertoenginemanual.
improperlyset.
2. Carburetorirrlproperlyadjusted. 2. Refertoenginemanual.
3. Refertoenginemanual.
Excessive Vibration 1. Cuttingbladelooseor unbalanced. 1. Tightenbladeandadapter.Balance
blade.
2. Bentcuttingblade. 2. Seeanauthorizedservicedealer.
cuttingheight,
F k
Uneven cut 1. Wheelsnotpositionedcorrectly. 1. Placeall fourwheelsin same
heightposition.
2. Dullblade. 2. Sharpenorreplaceblade.
12
WARNING
DONOTremove safety
(or any) labeJs from
newer for any reasen,
\
13
Q Q
Q
Q
2_
14
1 747q161A BladeControl
2 731-04204 BailCover
3 74Gl130 ControlCable,40dnchSnap-On
4 72G0240 CableTie
5 664-04011 GrassBagAssembly
6 747-04080 GrassBagFrame
7 73b0700 TrailshieldWire
8 731-04998 Trailshield
9 747-0996 PivotRod
10 731-04134A RearDischargeDoor
11 687_02057 RearHandleBracketAss}/,_LH
687-02056 RearHandleBracketAssy,- RHt
12 787-01279 Deck21dnch
13 687-02075A FrontHeightAdiustmentAssy-LH
687_02074A FrontHeightAdiustmentAssy_RHt
14 7865002B FrontBaffle
15 748-04082 BladeAdapter
16 742-0741 21dnchMulchingBlade
17 73G0524B BellBladeSupport
18 71G1257 HexScrew,3/8-24x 2,5
19 731-04177 SideDischargeChute
20 17032A DeflectorChuteAdaptor
21 7361014 TorsionSpring
22 747-0710 HingePin
23 987-02055 HingedMulchPlugAssembly
24 71b04065 FlangeLockNut3/8d6
25 787_01290 HeightAdiustmentPlate
26 687-02077A FrontPivotArmAssembly-RH
687_02076A FrontPivotArmAssembly_LHt
27 734-04014B FrontWheel,8 x2,125GWave
28 738-0507B ShoulderScrew,,5Dx ,434
29 732-0404 FrontSpringLever
30 72G0426 HeightAdiustKnob
31 71G0599 TTScrew,1/4-20x ,500
32 73G0270 BellWasher
33 71G0654A TTScrew,3/8-16x 1,0
34 71G0216 HexScrew,3/8d6 x ,75
35 71G1652 TTScrew,1/4-20x ,625
36 72G0312 FoamGrip
37 734-04127 RearWheel,12x2,125S-Wave
38 73G0182 SpringWasher
39 73b0866 RearHi-WheelSpringLever
40 687_02039A RearPivotArmAssy_RH
687_02040A RearPivotArmAssy_LHt
41 714-0104 HairpinClip
42 687-02192 HandleBracketAssy- RH
687_02191 HandleBracketAssy_LH
43 71G0703 CarriageBolt,1/4-20x ,75
44 731-04150C RearBaffle
45 71G04371 ScrewHL,1/4d5 x 1,00
46 732_04090A TorsionSpring_RH
732-04089A TorsionSpring- LHt
47 75G04162 Spacer
48 71b0397 WingNut
49 749-0928A LowerHandle
50 710d174 CarriageBolt,5/16-18x2
51 72G04072 StarKnob
52 72G0279 HandleKnob
53 710d205 EyeBolt
54 749-1092A UpperHandle
t NotPictured
List
FACTORY PARTS
To order replacement
parts, ca[J
1-800-648-6776
or visit
www.troybi[t,com
iMPORTANT
Fora proper work-
ingmachine, use
Factory Approved Parts.
VoBELT$are specially
designed to engage
and disengage safely.
A substitute (nonOEM)
VoBe[tcan bedangerous
bynot disengaging
completely.
\
15
MANUFACTURER'S LIMITED WARRANTY FOR
®
The limitedwarrantyset forthbelowisgivenbyTroy_BiltLLCwithrespect
tonewmerchandisepurchasedandusedin theUnitedStates,itsposses_
sionsandterritories.
"Troy_Bilt"warrantsthis productagainstdefectsinmaterialandworkmam
shipfora periodof two(2)yearscommencingon thedateoforiginal
purchaseandwill,atits option,repairorreplace,freeofcharge,anypart
foundtobedefectivein materialsor workmanship.This limitedwarranty
shallonlyapplyifthis producthasbeenoperatedand maintainedin
accordancewiththeOperator'sManualfurnishedwiththeproduct,and
hasnotbeensubiectto misuse,abuse,commercialuse,neglect,accident,
impropermaintenance,alteration,vandalism,theft,fire,water,or damage
becauseofotherperilor naturaldisaster.Damageresultingfromthe
installationor useofanypart,accessoryor attachmentnotapprovedby
Troy_Biltforusewiththeproduct(s)coveredbythis manualwillvoidyour
warrantyastoanyresultingdamage.
Normalwearpartsarewarrantedtobefreefromdefectsinmaterialand
workmanshipforaperiodofthirty(30)daysfromthedateofpurchase.
Normalwearpartsinclude,butare notlimitedto itemssuchas: batteries,
belts,blades,bladeadapters,grassbags,riderdeckwheels,seats,snow
throwerskidshoes,shaveplates,augerspiralrubberandtires.
NOWTO OBTAIN SERVICE: Warranty service is available, WITH
PROOFOF PURCHASE,through yourlocal authorizedservice
dealer.To locate the dealer in yourarea, check your YellowPages,
or contact Troy-Bilt LLC at RO. Box 361131,Cleveland,Ohio 44136-
0019,or can 1-866-840-6483 or 1-330-558-7220,or log on to our
Web site at www.troybilt.com.
This limitedwarrantydoesnot providecoverageinthefollowingcases:
a. Theengineor componentpartsthereof.Theseitemsmay
carrya separatemanufacturer'swarranty.Refertoapplicable
manufacturer'swarrantyfortermsandconditions.
b. Logsplitterpumps,valves,andcylindershaveaseparateone
yearwarranty.
c. Routinemaintenanceitemssuchaslubricants,filters,blade
sharpening,tune_ups,brakeadiustments,clutch adiustments,
deckadiustments,andnormaldeteriorationoftheexteriorfinish
duetouseorexposure.
d. Servicecompletedbysomeoneotherthananauthorizedservice
dealer.
e. Troy_Biltdoesnotextendanywarrantyforproductssoldor
exportedoutsideoftheUnitedStates,its possessionsand
territories,exceptthosesoldthroughTroy_Bilt'sauthorized
channelsofexportdistribution.
f. Replacementpartsthatare notgenuineTroy_Biltparts.
g. Transportationchargesandservicecalls.
Noimpliedwarranty, includinganyimpliedwarrantyof merchant°
ability offitness for a particular purpose, applies after the applicable
period of express written warranty aboveasto the parts as identi-
fied. Noother express warranty, whether written or oral, exceptas
mentioned above,given by anyperson or entity, includinga dealer or
retailer,with respectto any product, shall bind Troy-Bilt. Duringthe
period of the warranty,the exclusive remedy is repair or replacement
of the product as set forth above.
The provisions as set forth inthis warranty providethe sole and
exclusive remedyarising from the sale. Troy-Bilt shall not be liable
for incidental or consequential loss or damageincluding, without
limitation, expensesincurred for substitute or replacementlawncare
services or for rental expensesto temporarily replacea warranted
product.
Somestatesdo notallowtheexclusionor limitationofincidentalor
consequentialdamages,or limitationson howlonganimpliedwarranty
lasts,sotheaboveexclusionsor limitationsmaynotapplytoyou.
Innoeventshallrecoveryofanykindbegreaterthantheamountofthe
purchasepriceoftheproductsold.Alteration of safety features of the
product shall void this warranty. Youassumetheriskandliabilityfor
loss,damage,or injurytoyouand yourpropertyand/ortoothersandtheir
propertyarisingoutofthemisuseor inabilitytousetheproduct.
This limitedwarrantyshallnotextendto anyoneotherthantheoriginal
purchaseror tothepersonforwhomitwaspurchasedasa gift.
HOWSTATELAWRELATESTOTHiSWARRANTY:This limitedwar-
rantygh,'esyouspecificlegalrights,andyoumayalsohaveotherrights
whichvaryfromstatetostate.
IMPORTANT:OwnermustpresentOriginalProofofPurchasetoobtain
warrantycoverage.
TROYBILT LLC, P.O. BOX 361131 CLEVELAM D, OHIO 44136-0019; Phone: 1(866} 840-6483, 1-330-558-7220
/