Husqvarna 5521BBC User Manual LAWN MOWER Manuals And Guides L0502208

HUSQVARNA Walk Behind Lawnmower, Gas Manual L0502208 HUSQVARNA Walk Behind Lawnmower, Gas Owner's Manual, HUSQVARNA Walk Behind Lawnmower, Gas installation guides

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Husqvarna

5521 BBC
Owner's Manual

532 19 45-38

10.12.04

Printed in U.S.A.

SAFETY
RULES
Practices for Walk-Behind

Safe Operation

Mowers

IMPORTANT: THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROWING OBJECTS. FAILURE
TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH.
Look for this symbol to point out important safety precautions.
It means
CAUTION!!!
BECOME ALERT!!!
YOUR
SAFETY IS INVOLVED.

CAUTION: Always disconnect spark plug
wire and place wire where it cannot contact
spark plug in order to prevent accidental
starting when setting up, transporting,
adjusting or making repairs.

WARNING: Engine exhaust, some of its
constituents, and certain vehicle components contain or emit chemicals known to
the State of California to cause cancer and
birth defects or other reproductive harm.

WARNING: Battery posts, terminals and
related accessories contain lead and lead
compounds, chemicals known to the State
of California to cause cancer and birth
defects or other reproductive harm. Wash
hands after handling.

•

Stop the blade(s) when crossing gravel drives, walks,
or roads.

•

Stop the engine (motor) whenever you leave the equipment, before cleaning the mower or unclogging the
chute.

•

Shutthe engine (motor) offand wait untilthe blade comes
to complete stop before removing grass catcher.
Mow only in daylight or good artificial light.
Do not operate the machine while under the influence
of alcohol or drugs.
Never operate machine in wet grass. Always be sure of
your footing: keep a firm hold on the handle and walk;
never run.
Disengage the self-propelled mechanism or drive clutch
onmowerssoequipped beforestartingtheengine(motor).
If the equipment should start to vibrate abnormally,
stop the engine (motor) and check immediately for the
cause. Vibration is generally a warning of trouble.
Always wear safety goggles or safety glasses with side
shields when operating mower.

•
•
•

•
•

•

II. SLOPE

Slopes are a major factor related to slip and fall accidents
which can result in severe injury. All slopes require extra
caution. If you feel uneasy on a slope, do not mow it.
DO:
•

CAUTION:
Muffler and
engine
parts
become extremely
hot other
during
operation
and remain hot after engine has stopped.
_

from these areas.
o avoid severe burns on contact,

I. GENERAL
•

•
•
•

•

stay away

OPERATION

Read, understand, and follow all instructions on the
machine and in the manual(s) before starting. Be thoroughly familiar with the controls and the proper use of
the machine before starting.
Do not put hands or feet near or under rotating parts.
Keep clear of the discharge opening at all times.
Only allow responsible individuals, who are familiar
with the instructions, to operate the machine.
Clear the area of objects such as rocks, toys, wire,
bones, sticks, etc., which could be picked up and thrown
by the blade.
Be sure the area is clear of other people before mowing. Stop machine if anyone enters the area.
Do not operate the mower when barefoot or wearing
open sandals. Always wear substantial foot wear.
Do not pull mower backwards unless absolutely necessary. Always look down and behind before and while
moving backwards.
Never direct discharged material toward anyone.
Avoid discharging material against a wall or obstruction. Material may richochet back toward the operator.
Stop the blade when crossing gravel surfaces.
Do not operate the mower without proper guards,
plates, grass catcher or other safety protective devices
in place.
See manufacturer's instructions for proper operation
and installation of accessories. Only use accessories
approved by the manufacturer.

OPERATION

•
•

Mowacrossthe face of slopes: never up and down. Exercise extreme caution when changing direction on slopes.
Remove obstacles such as rocks, tree limbs, etc.
Watch for holes, ruts, or bumps. Tall grass can hide
obstacles.

DO NOT:
•
Do not trim near drop-offs, ditches or embankments.
The operator could lose footing or balance.
•
Do not trim excessively steep slopes.
•
Do not mow on wet grass. Reduced footing could cause
slipping.

II1. CHILDREN
Tragic accidents can occur if the operator is not alert to
the presence of children. Children are often attracted to
the machine and the mowing activity. Never assume that
children will remain where you last saw them.
•
Keep children out of the trimming area and under the
watchful care of another responsible adult.
•
Be alert and turn machine off if children enter the
a rea.
•

Before and while walking backwards, look behind and
down for small children.

•
•

Never allow children to operate the machine.
Use extra care when approaching blind corners, sh rubs,
trees, or other objects that may obscure vision.

IV. SAFE HANDLING OF GASOLINE
Use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive.
•
Extinguish all cigarettes, cigars, pipes and other sources
of ignition.
•
Use only an approved container.
•
Never remove gas cap or add fuel with the engine running. Allow engine to cool before refueling.

•
•
•
•

•
•
•

Neverrefuelthemachineindoors.
Neverstorethemachineorfuelcontainerwherethere
is anopenflame,sparkor pilotlightsuchas a water
heateroron otherappliances.
Neverfillcontainers
insideavehicle,onatruckortrailer
bedwitha plasticliner.Alwaysplacecontainerson
thegroundawayfromyourvehiclebeforefilling.
Remove
gas-powered
equipment
fromthetruckortrailer
andrefuelitontheground.Ifthisis notpossible,
then
refuelsuchequipment
witha portablecontainer,
rather
thanfroma gasolinedispensernozzle.
Keepthenozzleincontactwiththerimofthefueltank
orcontainer
opening
atalltimesuntilfuelingiscomplete.
Donotusea nozzlelock-open
device.
If fuelis spilledonclothing,changeclothingimmediately.
Neveroverfillfueltank. Replacegascapandtighten
securely.

V. GENERAL
•
•

•
•
•

•

SERVICE

•

Never run a machine inside a closed area.
Never make adjustments or repairs with the engine
(motor) running. Disconnect spark plug wire, and keep

•

wire away from plug to prevent accidental starting.
Keep nuts and bolts, especially blade attachement
bolts, tight and keep equipment in good condition.
Never tamper with safety devices. Check their proper
operation regularly.
Keep machine free of grass, leaves, or other debris
build-up. Clean oil or fuel spillage. Allow machine to
cool before storing.
Stop and inspect the equipment if you strike an object.
Repair, if necessary, before restarting.
Never attempt to make wheel height adjustments while
the engine (motor)is running.
Grass catcher components are subject to wear, damage, and deterioration, which could expose moving
parts or allow objects to be thrown. Frequently check
components and replace with manufacturer's recommended parts, when necessary.
Mower blade is sharp and can cut. Wrap the blade or
wear gloves, and use extra caution when servicing it.
Do not change the engine governor setting or overspeed
the engine.
Maintain or replace safety and instruction labels, as
necessary.

&WARNING: This lawn mower is equipped with an internal combustion engine and should not be used on or near any
unimproved forest-covered, brush-covered or grass-covered land unless the engine's exhaust system is equipped with
a spark arrester meeting applicable local or state laws (if any). If a spark arrester is used, it should be maintained in
effective working order by the operator.
In the state of California the above is required by law (Section 4442 of the California Public Resources Code). Other
states may have similar laws. Federal laws apply on federal lands. A spark arrester for the muffler is available
through your nearest authorized service center.

PRODUCT

CONGRATULATIONS
on your purchase of a new lawn
mower. It has been designed, engineered and manufactured
to give you the best possible dependability and performance.
Should you experience any problem you cannot easily
remedy, please contact your nearest authorized service
center/department.
We have competent, well-trained
technicians and the proper tools to service or repair this
lawn mower.
Please read and retain this manual. The instructions will
enable you to assemble and maintain your lawn mower
properly. Always observe the "SAFETY RULES".
SERIAL
NUMBER:

SPECIFICATIONS

Gasoline Capacity
and Type:

1.0 Quarts
(Unleaded Regular Only)

Oil Type (API SG-SL):

SAE 30 (above 0°C / 32°F)
SAE 10W-30 (below 0°C / 32°F)

Oil Capacity:

18.5 Ounces

Spark Plug:

NGK BPR6ES (Gap: .030")

Valve Clearance:
(_+0.04 mm)

Intake: 0.015 mm
Exhaust: 0.020 mm

Blade Bolt Torque:

35-40 ft. Ibs.

DATE OF PURCHASE:

CUSTOMER

THE MODELAND SERIAL NUMBERSWlLL BE FOUND
ON A DECALATTACHEDTOTHE REAR OFTHE LAWN
MOWER HOUSING.
YOU SHOULD RECORD BOTH SERIAL NUMBER AND
DATE OF PURCHASE AND KEEP IN A SAFE PLACE
FOR FUTURE REFERENCE.

RESPONSIBILITIES

•

Read and observe the safety rules.

•

Follow a regular schedule in maintaining, caring for and
using your lawn mower.
Follow the instructions under "Maintenance" and "Storage" sections of this owner's manual.

•

TABLE OF CONTENTS
SAFETY RULES .........................................................
2-3
PRODUCT SPECIFICATIONS ....................................... 3
CUSTOMER RESPONSIBILITIES ................................. 3
ASSEMBLY ....................................................................
4
OPERATION ...............................................................
5-9
MAINTENANCE SCHEDULE ...................................... 10

MAINTENANCE ......................................................
10-12
SERVICE AND ADJUSTMENTS ................................. 13
STORAGE ...............................................................
13-14
TROUBLESHOOTING .................................................
15
REPAIR PARTS .......................................................
16-19
WARRANTY .................................................................
20

ASSEMBLY
Read these instructions and this manual in its entirety before
you attempt to assemble or operate your new lawn mower.
IMPORTANT: THIS LAWN MOWER IS SHIPPED WITHOUT OIL OR GASOLINE IN THE ENGINE.

KNOB

Your new lawn mower has been assembled at the factory
with the exception of those parts left unassembled for shipping purposes. All parts such as nuts, washers, bolts, etc.,
necessary to complete the assembly have been placed in
the parts bag. To ensure safe and proper operation of your
lawn mower, all parts and hardware you assemble must
be tightened securely. Use the correct tools as necessary
to ensure proper tightness.

TO REMOVE

LAWN MOWER

FROM CARTON

Remove loose parts included with mower.

Cut down two end corners of carton and lay end panel
down flat.

Remove all packing materials except padding between
upper and lower handle and padding holding operator
presence control bar to upper handle.
Roll lawn mower out of carton and check carton thorougly for additional loose parts.

HANDLE
BRACKET

FIG. 2

TO ASSEMBLE
(See Fig. 3)

GRASS

CATCHER

Put grass catcher frame into grass bag with rigid part
of bag on the bottom. Make sure the frame handle is
outside of the bag top.
Slip vinyl bindings over frame.

HOWTO SET UPYOUR

LAWN MOWER

TO UNFOLD

Figs.

NOTE: If vinyl bindings are too stiff, hold them in warm water
for a few minutes. If bag gets wet, let it dry before using.

HANDLE

(See

1 and 2)

IMPORTANT: UNFOLD HANDLE CAREFULLY SO AS
NOTTO PINCH OR DAMAGE CONTROL CABLES.
1.

Raise lower handle section to operating position and
align hole in handle with one of three height positioning
holes.

CATCHER
FRAME
HANDLE

Insert handle bolt through handle and bracket and
secure with knob.

Repeat for opposite side of handle.

Remove protective padding, raise upper handle section
into place on lower handle and tighten both handle knobs.

Remove any packing material from around control bar.
\

Your handles may be adjusted for your mowing comfort.
Refer to"ADJUST HANDLE"in the Service and Adjustments
section of this manual.

FRAME
OPENING

OPERATOR PRESENCE
CONTROLBAR

FIG. 3

UPPER HANDLE

TO INSTALL ATTACHMENTS

LOWER HANDLE

Your lawn mower was shipped ready to be used as a
mulcher. To convert mower to bagging or discharging,
see "TO CONVERT MOWER" in the Operation section of
this manual.

LIFT

MOWING
POSITION

FIG. 1

OPERATION
KNOWYOUR

LAWN MOWER

READ THIS OWNER'S MANUAL AND SAFETY RULES BEFORE OPERATING YOUR LAWN MOWER.
Compare the illustrations with you r lawn mower to familiarize yourself with the location of various controls and adjustments.
Save this manual for future reference.
These symbols
their meaning.

CAUTION
OR WARNING

may appear on your lawn mower or in literature

ENGINE
ON

ENGINE
OFF

FAST

SLOW

OPERATOR
PRESENCE
CONTROL

supplied

CHOKE

with the product.

FUEL

OIL

Learn and understand

DANGER, KEEP HANDS
AND FEET AWAY

BLADE/BRAKECONTROL

DRIVE CONTROL
THROTTLE/
ENGINE
CONTROL

LEVER

HANDLE KNOBS

DRIVE COVER

STARTER HANDLE

GASOLINEFILLERCAP

GRASSCATCHER

LEVER

AIR FILTER

MULCHER
PLUG

SPARK
-PLUG

SINGLE POINT HEIGHT ADJUSTER

HANDLE

ENGINE OIL CAPWITH

DIPSTICK
HOUSING

IMPORTANT: This lawn mower is shipped
WITHOUT OIL OR GASOLINE in the engine.

MEETS

DOOR

CPSC SAFETY

MUFFLER

REQUIREMENTS

Our rotary walk-behind power lawn mowers conform to the safety standards of the American National Standards Institute
and the U.S. Consumer Product Safety Commission.
OPERATOR PRESENCE CONTROL BAR - must be
held down to the handle to start the blade. Release to
stop the blade.

THROTTLE / ENGINE CONTROL - used for starting and
stopping the engine; and allows you to select either FAST
or SLOW engine speed.

DRIVE CONTROL LEVER - used to engage power-propelled forward motion lawn mower.

STARTER HANDLE - used for starting the engine.

BLADE / BRAKE CONTROL - used to engage the blade
after the engine is started.
SINGLE POINT HEIGHT ADJUSTER
cutting height of lawn mower.

- used to adjust

MULCHER DOOR - allows conversion
bagging operation.

to discharge or

MULCH ER PLUG-located at the discharge opening, must
be removed when converting to bagging operation.

OPERATION
The operation of any lawn mower can result in foreign objects thrown into the eyes, which can result in
severe eye damage. Always wear safety glasses or eye shields while operating your lawn mower or performing any adjustments or repairs. We recommend standard safety glasses or a wide vision safety mask
over spectacles.

HOW TO USE YOUR LAWN MOWER
THROTTLE

/ ENGINE

CONTROL

OPERATOR

PRESENCE

CONTROL

BAR

BLADE/BRAKE
CONTROL LEVER

(See Fig. 5)

The engine is controlled by a throttle control located on the
side of the upper handle. CHOKE position is for starting a
cold engine; FAST position is for starting a warm engine,
normal cutting, trimming and better grass bagging; SLOW
position is for light cutting, trimming and fuel economy, and
STOP position is for stopping the engine.
TO ENGAGE

BLADE

DISENGAGED

FIG. 6

DRIVE CONTROL

(See Fig. 7)

•

Self-propelling is controlled by holding the operator
presence control bar down to the handle and pulling
the drive control lever rearward to the handle. The
farther toward the handle the lever is pulled, the faster
the unit will travel.

•

Forward motion will stop when either the operator presence control bar or drive control lever are released. To
stop forward motion without stopping engine, release
the drive control lever only. Hold operator presence
control bar down against handle to continue mowing
without self-propelling.

NOTE: If after releasing the drive control the mower will
not roll backwards, push the mower forward slightly to
disengage drive wheels.
FIG. 5

BLADE

&
•

CONTROL

(See

PRESENCECONTROLBAR

Fig. 6)

CAUTION: When the blade control is
engaged, the blade turns. When the
blade control is disengaged, the blade
stops.

Your lawn mower has a blade/brake clutch fastened to
the engine crankshaft, which starts or stops the blade.
To start the blade, hold the operator presence control
bar down tothe handle and push the blade/brake control
lever forward until it latches. To stop the blade, release
the operator presence control bar.

NOTE: Allow a cold engine to warm up for one minute
before starting the blade. Do not start the blade in deep,
uncut grass. Move lawn mower out of uncut grass before
starting blade.

OPERATOR

CAUTION: Federal regulations require
this blade/brake control to minimize the
risk of blade contact injury. Do not under
any circumstances attempt to defeat the
function of this control.

DRIVE
CONTROL
LEVER
ADJUSTMENT
BUTTON (ON
UNDERSIDE)

TO ENGAGE
DRIVE CONTROL

DRIVE CONTROL
DISENGAGED

FIG. 7

DRIVE CONTROL

ADJUSTMENT

(See Fig. 7)

Over time, the drive control system may become "loose",
resulting in decreased speed. There is a button on the
underside of the drive control housing to increase tension
on the drive cable. Proceed as follows:
1.

Turn unit off and disconnect spark plug wire from spark
plug.

Pull out button on underside of drive control, then push
button back in.

Operate mower to test drive speed. If condition becomes worse after the above steps (forward speed
has become slower), your system was not "loose".

OPERATION
4.

Repeating the above steps will return your unit to the
proper adjustment and speed.

TO EMPTY GRASS

If condition fails to improve after the above steps (forward speed remains the same), your drive belt is worn
and should be replaced.

Lift up on grass catcher using the frame handle.

Remove grass catcher with clippings from under lawn
mower handle.

Emptyclippingsfrom
bag handle.

TO ADJUST

CUTTING

HEIGHT

(See Fig. 8)

(See Fig. 10)

bag using bothframe handle and

NOTE: Do not dmg the bag when emptying; it willcause
unnecessary wear.

All four wheels are adjusted by a single lever.
•

CATCHER

Pull adjuster lever toward wheel.To raise mower, move
lever forward to desired position, To lower mower, move
the lever toward the rear.

LEVER
BACKWARD
TO
LOWER
MOWER
WHEEL
LEVER
GRASS
CATCHER
FRAME
HANDLE

BAG
HANDLE

FIG. 10

LEVER
FORWARD TO
RAISE MOWER

TO CONVERT

MOWER

Your lawn mower was shipped ready to be used as a
mulcher. To convert to bagging or discharging:

FIG. 8
TO ATTACH
GRASS CATCHER
(See Fig. 9)
1. Lift the reardoorof the lawn mowerand place the grass
catcher frame side hooks onto the door pivot pins.

REAR BAGGING (See Fig. 11)
•
Open rear door and remove mulcher plug.
mulcher plug in a safe place.

•

You can now install the grass catcher.

•

To convert to mulching or discharging operation, install
mulcher plug into rear discharge opening of mower.

The grasscatcheris secured to the lawn mower housing
when the rear door is lowered onto the grass catcher
frame.

&
\

CAUTION: Do not run your lawn mower
without mulcher plug or approved grass
catcher in place. Never attempt to operate the lawn mower with the rear door
removed or propped open.

DOOR

PIVOT PINS

GRASS
CATCHER

MULCHER

CATCHER

PLUG

FRAME HOOK

FIG. 9

FIG. 11

Store

OPERATION
SIMPLE STEPS TO REMEMBER
WHEN CONVERTING YOUR LAWN MOWER

SIDE DISCHARGING (See Fig. 12)
•

Mulcher plug must be installed into rear discharge
opening of mower.

FOR MULCHING -

•

Open mulcher door and install discharge deflector
under door as shown.

1.
2.

•

Mower is now ready for discharging operation.

•

To convert to mulching or bagging operation, discharge
deflector must be removed and mulcher door closed.
\

FOR REAR BAGGING 1.
2.
3.

Rear mulcher plug installed.
Mulcher door closed.
Rear mulcher plug removed.
Grass catcher installed.
Mulcher door closed.

FOR SIDE DISCHARGING
1.
2.

Rear mulcher plug installed.
Discharge deflector installed.

&
OPEN
MULCHER
DOOR

CAUTION: Do not run your lawn mower
without mulcher plug or approved grass
catcher in place. Never attempt to operate the lawn mower with the rear door
removed or propped open.

BEFORE STARTING

I
I

ADD

OIL (See

ENGINE

Fig. 13)

Your lawnmower is shipped without oil in the engine. For type
and grade of oil to use, see "ENGINE" in the Maintenance
section of this manual.

DISCHARGE
DEFLECTOR

_1)

oil,
or it willDO
smoke
on startup.
CAUTION:
NOT overfill
engine with

Be sure lawnmower is level.

Remove oil fill cap/dipstick from oil fill spout.

You recieve a container of oil with the unit. Slowly
pour the entire container down the oil fill spout into the
engine.

Insert and tighten oil fill cap/dipstick.

IMPORTANT:
Check oil level before each use. Add oil if needed. Fill
to full line on dipstick.
Change the oil after every25 hours of operation or each
season. You may need to change the oil more often
under dusty, dirty conditions. See "TO CHANGE ENGINE OIL" in the Maintenance section of this manual.
OIL FILL
CAP /
DIPSTICK

FIG. 12

UPPER
MARK

GASOLINE
FILLER
CAP

LOWER
MARK

FIG. 13

OPERATION
MOWING TIPS

ADD GASOLINE
(See Fig. 13)
•
Fill fuel tank to bottom of tank filler neck. Do not overfill. Use fresh, clean, regular unleaded gasoline with
a minimum of 87 octane. Do not mix oil with gasoline.
Purchase fuel in quantities that can be used within 30
days to assure fuel freshness.

CAUTION: Wipe off any spilled oil or fuel. Do not
store, spill or use gasoline near an open flame.

Under certain conditions, such as very tall grass, it
may be necessary to raise the height of cut to reduce
pushing effort and to keep from overloading the engine
and leaving clumps of grass clippings. It may also be
necessary to reduce ground speed and/or run the lawn
mower over the area a second time.

Alcohol blended fuels (called gasohol
or using ethanol or methanol) can attract moisture which leads to separation
and formation of acids during storage.
Acidic gas can damage the fuel system of an engine while in storage. To
avoid engine problems, the fuel system
should be emptied before storage of
30 days or longer. Empty the gas tank,
start the engine and let it run until the
fuel lines and carburetor are empty. Use
fresh fuel next season. See Storage
Instructions for additional information.
Never use engine or carburetor cleaner
products in the fuel tank or permanent
damage may occur.

To stop engine, move throttle
position. Wait until blade and
stopped and turn fuel valve to
not intend to restart the engine

•

For extremely heavy cutting, reduce the width of cut
by overlapping previously cut path and mow slowly.

•

For better grass bagging and most cutting conditions,
the engine speed should be set in the fast position.

•

Pores in cloth grass catchers can become filled with
dirt and dust with use and catchers will collect less
grass. To prevent this, regularly hose catcher off with
water and let dry before using.

•

Keep top of engine around starter clear and clean of
grass clippings and chaff. This will help engine air flow
and extend engine life.

MULCHING

TO STOP ENGINE
•

•

The special mulching blade will recut the grass clippings many times and reduce them in size so that as
they fall onto the lawn they will disperse into the grass
and not be noticed. Also, the mulched grass will biodegrade quickly to provide nutrients for the lawn. Always
mulch with your highest engine (blade) speed as this
will provide the best recurring action of the blades.

•

Avoid cutting your lawn when it is wet. Wet grass tends
to form clumps and interferes with the mulching action.
The best time to mow your lawn is the early afternoon.
At this time the grass has dried, yet the newly cut area
will not be exposed to direct sunlight.

•

For best results, adjust the lawn mower cutting height
so that the lawn mower cuts off only the top one-third
of the grass blades (See Fig. 15). If the lawn is overgrown it will be necessary to raise the height of cut to
reduce pushing effort and to keep from overloading
the engine and leaving clumps of mulched grass. For
extremely heavy mulching, reduce your width of cut by
overlapping previously cut path and mow slowly.

TO START ENGINE (See Fig. 14)
NOTE: Due to protective coatings on the engine, a small
amount of smoke may be present during the initial use of
the product and should be considered normal.
Be sure fuel valve is in the ON position.

To start a cold engine, move handle mounted throttle/
choke control lever to CHOKE position.

Pull starter handle quickly. Do not allow starter rope to
snap back.

Slowly move throttle control lever to
after engine starts.

•

To start a warm engine, move throttle control lever to
FAST position, then follow steps above.

MOWING TIPS

IMPORTANT: FOR BEST PERFORMANCE, KEEP MOWER
HOUSING FREE OF BUILT-UP GRASS AND TRASH. SEE
"CLEANING" IN MAINTENANCE SECTION OF THIS MANUAL.

control lever to STOP
all moving parts have
OFF position if you do
soon.

CAUTION:
Do not use de-thatcher
blade attachments. Such attachments
are hazardous, will damage your mower
and could void your warranty.

FAST position

NOTE: Allow a cold engine to warm up for one minute
before starting the blade. See "BLADE CONTROU' in this
section of this manual.

MAX 1/3
ON

FIG. 15

FUEL
VALVE
LEVER

FIG. 14

•

Certain types of grassand grass conditions may require
that an area be mulched a second time to completely
hide the clippings. When doing a second cut, mow
across (perpendicular) to the first cut path.

•

Change your cutting pattern from week to week. Mow
north to south one weekthen east to west the next week.
This will help prevent matting and graining of the lawn.

MAINTENANCE
MAINTENANCE
SCHEDULE

BEFORE
EACH
USE

AFTER
EACH
USE

EVERY
10
HOURS

EVERY
25HOURS
OR SEASON

EVERY
100
HOURS

BEFORE
STO RAG E

Check for Loose Fasteners

Check

Clean / Inspect Grass Catcher *

v'
v'

Tires

N Check Drive Wheels ***
Clean Lawn Mower ....

M Clean under Drive Cover ***

O Check Drive Bek / Pulleys ***
_

Check / Sharpen / Rephce

Bhde

Lubrication
Clean and Recharge Battery **

v'
v'

Check Engine Oil level
E Change Engine Oil
Clean Air Fiker
t

Inspect

Muffler

Rephce Spark Plug
Rephce Air Fiker Paper Cartridge

t4
V'

Empty fuel system or add Stabilizer
*
**
***
****

(if so equipped)
Electric=Start mowers
Power=Propelled mowers
Use a scraper
to clean under deck

GENERAL

1
2
3
4
5

=Change more often if operating under a heavy load or in high outdoor temperatures.
- Service more often if operating in dirty or dusty conditions.
- Replace blades more often when mowing in sandy soil.
- Charge 48 hours at end of season.
- And after each 5 hours of use.

RECOMMENDATIONS

LUBRICATION

The warranty on this lawn mower does not cover items that
have been subjected to operator abuse or negligence. To
receive full value from the warranty, operator must maintain
mower as instructed in this manual. Some adjustments
will need to be made periodically to properly maintain your
unit. At least once a season, check to see if you should
make any of the adjustments described in the Service and
Adjustments section of this manual.
•
At least once a year, replace the spark plug, clean or
replace air filter element and check blade for wear. A
new spark plug and clean/new air filter element assure
proper air-fuel mixture and help your engine run better
and last longer.
•
Follow the maintenance schedule in this manual.

BEFORE
1.
2.

"__

CHART

@ ENGINE OIL

I
1
1\

MULCHER
DOOR

HINGE PIN

EACH USE

REAR DOOR HINGE

Check engine oil level.
Check for loose fasteners.

LUBRICATION
Keep unit well lubricated (See "LUBRICATION CHART").
IMPORTANT: DO NOT OIL OR GREASE PLASTIC WHEEL
BEARINGS. VISCOUS LUBRICANTS WILL ATTRACT DUST
AND DIRT THAT WILL SHORTEN THE LIFE OF THE SELFLUBRICATING BEARINGS. IF YOU FEEL THEY MUST BE
LUBRICATED, USE ONLY A DRY, POWDERED GRAPHITE
TYPE LUBRICANT SPARINGLY.

HANDLE

BRACKET MOUNTING PINS

SPRAY LUBRICANT

SEE "ENGINE"

IN MAINTENANCE

SECTION

MAINTENANCE
LAWN MOWER

TO SHARPEN BLADE

Always observe safety rules when performing maintenance.

NOTE: We do not recommend sharpening blade - but if you
do, be sure the blade is balanced. Care should be taken to
keep the blade balanced. An unbalanced blade will cause
eventual damage to lawn mower or engine.

TIRES
•

Keep tires free of gasoline, oil, or insect control chemicals which can harm rubber.

•

Avoid stumps, stones, deep ruts, sharp objects and
other hazards that may cause tire damage.

•

The blade can be sharpened with a file or on a grinding wheel. Do not attempt to sharpen while on the
mower.
To check blade balance, drive a nail into a beam or
wall. Leave about one inch of the straight nail exposed.
Place center hole of blade over the head of the nail.
If blade is balanced, it should remain in a horizontal
position. If either end of the blade moves downward,
sharpen the heavy end until the blade is balanced.

DRIVE WHEELS
Check rear drive wheels each time you mowto be sure they
move freely. The wheels not turning freely means trash,
grass cuttings, etc., may be inside the drive wheel and dust
cover area and must be cleaned out to free drive wheels.
If necessary to clean drive wheels, check both rear wheels.

GRASS

BLADE

•

The grass catcher may be hosed with water, but must
be dry when used.

•

Check your grass catcher often for damage or deterioration. Through normal use it will wear. If catcher
needs replacing, replace only with approved replacement catcher shown in the Repair Parts section of this
manual. Give the mower model number when ordering.

CARE

For best results, mower blade must be kept sharp. Replace
a bent or damaged blade.
CAUTION: Use only a replacement blade
approved by the manufacturer of your
mower. Using a blade not approved
by the manufacturer of your mower is
hazardous, could damage your mower
and void your warranty.

GEAR CASE
•

TO REMOVE BLADE (See Fig. 16)
1. Disconnect spark plug wire from spark plug and place
wire where it cannot come in contact with plug.
2. Turn lawn mower on its side. Make sure air filter and
carburetor are up.
3.

To keep your drive system working properly, the gear
case and area around the drive should be kept clean
and free of trash build-up. Clean under the drive cover
twice a season.
The gear case is filled with lubricant to the proper
level at the factory. The only time the lubricant needs
attention is if service has been performed on the gear
case.

Use a wood block between blade and mower housing to
prevent blade from turning when removing blade bolts.

•

NOTE: Protect your hands with gloves and/or wrap blade
with heavy cloth.
4.

CATCHER

If lubricant is required, use only Texaco Starplex Premium 1 Grease, Part No. 750369. Do not substitute.

ENGINE

Remove blade bolts by turning counter-clockwise.

LUBRICATION

TO REPLACE BLADE (See Fig. 16)
1. Position the blade adapter and the blade. Be sure trailing edge of blade (opposite sharp edge) is up toward
the engine and install the blade bolts.
2. Use block of wood between blade and lawn mower housing and tighten the blade bolts, turning clockwise.

Use only high quality detergent oil rated with API service
classification SG-SL. Select the oil's SAE viscosity grade
according to your expected operating temperature.
SAE VISCOSITY GRADES
_I,]

•
The recommended tightening torque is 35-40 ft. Ibs.
IMPORTANT: BLADE BOLTSARE HEATTREATED. IF BOLTS
NEED REPLACING,REPLACEONLYWlTH APPROVED BOLTS
SHOWN IN THE REPAIR PARTSSECTION OF THIS MANUAL.

Did
°F

-20

-2o
TEMPERATURE

NOTE:
starting
oil level
running

ADAPTER

BOLTS

FIG. 16

-1;

;

RANGE ANTICIPATED

100

i;
BEFORE

NEXT OIL CHANGE

Multi-viscosity oils (5W30, 10W30 etc.)improve
in cold weather, and you should check your engine
frequently to avoid possible engine damage from
low on oil.

TRAILING
EDGE

Change the oil after every 25 hours of operation or at least
once a year if the lawn mower is not used for 25 hours in
one year.

BLADE

Check the crankcase oil level before starting the engine
and after each five (5) hours of continuous use. Tighten oil
plug securely each time you check the oil level.
11

MAINTENANCE
TO CHANGE

ENGINE

OIL (See Figs. 17 & 18)

AIR FILTER

NOTE: Before tipping lawn mower to drain oil, empty fuel
tank by running engine until fuel tank is empty.
1.

Disconnect spark plug wire from spark plug and place
wire where it cannot come in contact with plug.

Remove oil fill cap/dipstick; lay aside on a clean surface.

Tip lawn mower on its side as shown and drain oil into
a suitable container. Rock lawn mower back and forth
to remove any oil trapped inside of engine.

Your engine will not run properly and may be damaged
by using a dirty air filter. Replace the air filter every 100
hours of operation or every season, whichever occurs first.
Service air cleaner more often under dusty conditions. See
the maintenance section of your engine manual.

MUFFLER
Inspect and replace corroded muffler as it could create a
fire haflard and/or damage.

SPARK PLUG
Replace spark plug at the beginning of each mowing season
or after every 100 hours of operation, whichever occurs
first. Spark plug type and gap setting are shown in the
"PRODUCT SPECIFICATIONS" section of this manual.

CLEANING
IMPORTANT: FOR BEST PERFORMANCE, KEEP MOWER
HOUSING FREE OF BUILT-UPGRASS AND TRASH. CLEAN
THE UNDERSIDE OFYOUR MOWER AFTER EACH USE.
CAUTION: Disconnect spark plug wire
from spark plug and place wire where it
cannot come in contact with plug,
FIG. 17

•

Clean the underside of your lawn mower by scraping
to remove build-up of grass and trash.

I
I

Wipe off any spilled oil from lawn mower or side of
engine.

•

Clean engine often to keep trash from accumulating. A
clogged engine runs hotter and shortens engine life.

Fill engine with oil. Slowly pour oil down the oil fill spout
into the engine.

•

Keep finished surfaces and wheels free of gasoline,
oil, etc.

Wait one minute to allow oil to settle. Use guage on oil
fill cap/dipstick for checking level. Insert dipstick into
the tube and rest the oil fill cap on the tube. DO NOT
thread the cap into the tube when taking reading.

•

We do not recommend using a garden hose to clean
lawn mower unless the electrical system, muffler, air
filter and carburetor are covered to keep water out.
Water in engine can result in shortened engine life.

Continue adding small amounts of oil and rechecking
the dipstick until it reads full. DO NOT overfill, or engine
will smoke on startup.

CLEAN

Always be sure to retighten oil fill cap/dipstick before
starting engine.

Reconnect spark plug wire to spark plug.

LOWER
MARK

FIG. 18

DRIVE COVER

Clean under drive cover at least twice a season. Scrape underside of cover with putty knife or similar tool to remove any
build-up of trash or grass on underside of drive cover.

OIL FILL
CAP /
DIPSTICK

UPPER
MARK

UNDER

SERVICE AND ADJUSTMENTS
CAUTION: To avoid serious injury, before
performing any service or adjustments:

MED. _

_BOLT

1. Release control bar and stop engine.
2. Make sure the blade and all moving parts
have completely stopped.
HANDLE
BRACKET

3. Disconnect spark plug wire from spark
plug and place where it cannot come in
contact with plug.

LAWN MOWER
TO ADJUST

CUTTING

FIG. 19

HEIGHT

See "TO ADJUST CUTTING
section of this manual.

ENGINE

HEIGHT" in the Operation

Maintenance, repair, or replacement of the emission control devices and systems, which are being done at the
customers expense, may be performed by any non-road
engine repair establishment or individual. Warranty repairs
must be performed by an authorized engine manufacturer's
service outlet.

REAR DEFLECTOR
The rear deflector, attached between the rear wheels of
your mower, is provided to minimize the possibility that
objects will be thrown out of the rear of the mower into
the operator's mowing position. If the deflector becomes
damaged, it should be replaced.

TO REMOVE

ENGINE

Your engine speed has been factory set. Do not attempt to
increase engine speed or it may result in personal injury. If
you believe that the engine is running too fast or too slow,
take your lawn mower to an authorized service center for
repair and adjustment.

DRIVE BELT

If your mower does not operate properly due to suspected
drive belt problems, take your mower to a qualified service
center for repair and/or adjustment.

TO ADJUST

HANDLE

SPEED

CARBURETOR

(See Fig. 19)

Your carburetor
is not adjustable.
If your engine does not
operate properly due to suspected
carburetor
problems,
take your lawn mower to an authorized
service center for
repair and/or adjustment.

The handle on your lawn mower has three (3) height positions - adjust to height that suits you.
1.

Remove knob and carriage bolt on one side of the
lower handle.

While holding handle assembly, remove knob and carriage bolt from opposite side, align hole in handle with
desired hole in handle bracket and reassemble bolt and
knob and tighten securely.

Align opposite side of handle with same positioning
hole and secure with bolt and knob.

IMPORTANT: NEVERTAMPERWlTHTHE ENGINE GOVERNOR,
WHICH IS FACTORY SET FOR PROPER ENGINE SPEED.
OVERSPEEDING THE ENGINE ABOVE THE FACTORY HIGH
SPEED SETTING CAN BE DANGEROUS. IF YOU THINK THE
ENGINE-GOVERNED
HIGH SPEED NEEDS ADJUSTING,
CONTACTYOU R NEARESTAUTHORIZED
SERVICE CENTER,
WHICH HAS PROPER EQUIPMENT AND EXPERIENCE TO
MAKE ANY NECESSARY ADJUSTMENTS.

STORAGE
Immediately prepare your mower for storage at the end of the season or if the unit will not be used for 30 days or more.

LAWN MOWER

HANDLE

When lawn mower is to be stored for a period of time, clean
it thoroughly, remove all dirt, grease, leaves, etc. Store in
a clean, dry area.

You can fold your lawn mower handle for storage.
1.

Loosen the two (2) handle knobs on sides of the upper
handle and allow handle to fold down to the rear.

Remove the two (2) handle knobs and carriage bolts
on sides of the lower handle and pivot entire handle
assembly forward and allow it to rest on mower.

Reinstall knobs and carriage bolts to lower handle or
handle brackets for safe keeping.

2.
3.

Clean entire lawn mower (See "CLEANING" in the
Maintenance section of this manual).
Lubricate as shown in the Maintenance section of this
manual.
Be sure that all nuts, bolts, screws, and pinsare securely
fastened. Inspect moving parts for damage, breakage
and wear. Replace if necessary.

•

(See

Figs.

20 and 21)

When setting up your handle from the storage position,
the lower handle will require manually locking into the
mowing position.
IMPORTANT: WHEN FOLDING THE HANDLE FOR STORAGE
OR TRANSPORTATION,BE SURE TO FOLD THE HANDLE AS
SHOWN OR YOU MAY DAMAGE THE CONTROL CABLES.

Touch up all rusted or chipped paint surfaces; sand
lightly before painting.

STORAGE
ENGINE

OPERATOR PRESENCE
CONTROL BAR

FUEL SYSTEM
IMPORTANT: IT IS IMPORTANTTOPREVENTGUM DEPOSITS
FROM FORMING IN ESSENTIAL FUEL SYSTEM PARTS
SUCH AS CARBURETOR, FUEL FILTER, FUEL HOSE, OR
TANK DURING STORAGE. ALCOHOL BLENDED FUELS
(CALLED GASOHOL OR USING ETHANOL OR METHANOL)
CAN ATTRACT MOISTURE WHICH LEADS TO SEPARATION
AND FORMATIONOF ACIDS DURINGSTORAGE. ACIDIC GAS
CAN DAMAGE THE FUEL SYSTEM OF AN ENGINE WHILE IN
STORAGE.

UPPER

FOLD
BACKWARD

•

Empty the fuel tank by starting the engine and letting
it run until the fuel lines and carburetor are empty.

•

Never use engine or carburetor cleaner products in the
fuel tank or permanent damage may occur.
Use fresh fuel next season.

•
MOWING
POSITION

NOTE: Fuel stabilizer is an acceptable alternative in minimizing the formation of fuel gum deposits during storage.
Add stabilizer to gasoline in fuel tank or storage container.
Always follow the mix ratio found on stabilizer container.
Run engine at least 10 minutes after adding stabilizer to
allow the stabilizer to reach the carburetor. Do not empty
the gas tank and carburetor if using fuel stabilizer.

FIG. 20

KNOB

._'_BOLT

ENGINE

OIL

Drain oil (with engine warm) and replace with clean engine oil. (See "ENGINE" in the Maintenance section of
this manual).

HANDLE
BRACKET

CYLINDER
1.

Remove spark plug.

Pour one ounce (29 ml) of oil through spark plug hole
into cylinder.

Pull starter handle slowly a few times to distribute oil.

Replace with new spark plug.

OTHER

FIG. 21

•

Do not store gasoline from one season to another.

•

Replace your gasoline can if your can starts to rust.
Rust and/or dirt in your gasoline will cause problems.

•

If possible, store your unit indoors and cover it to give
protection from dust and dirt.

•

Cover your unit with a suitable protective cover that
does not retain moisture. Do not use plastic. Plastic
cannot breathe, which allows condensation to form and
will cause your unit to rust.
IMPORTANT: NEVER COVER MOWER WHILE ENGINE AND
EXHAUST AREAS ARE STILL WARM.
CAUTION: Never store the lawn mower
with gasoline in the tank inside a building where fumes may reach an open
flame or spark. Allow the engine to cool
before storing in any enclosure.

TROUBLESHOOTING
PROBLEM
Does not start

CAUSE
1.
2.
3.

Dirty air filter.
Out of fuel.
Stale fuel.

Water in fuel.

CORRECTION
1.
2.
3.

5.
6.
7.
8.
9.
10.

Spark plug wire is disconnected.
Bad spark plug.
Loose blade or broken blade adapter.
Control bar in released position.
Control bar defective.
Fuel valve lever (if so equipped)
is in the OFF position.
11. Weak battery (if equipped).
12. Disconnected battery connector (if equipped).
13. Engine control lever is
in STOP position.
Loss of power

Clean/replace air filter.
Fill fuel tank.
Drain fuel tank and refill tank
with fresh, clean gasoline.
4. Drain fuel tank and refill tank
with fresh, clean gasoline.
5. Connect wire to plug.
6. Replace spark plug.
7. Tighten blade bolt or replace adapter.
8. Depress control bar to handle.
9. Replace control bar.
10. Turn fuel valve lever to the ON position.
11. Charge battery.
12. Connect battery to engine.
13. Place engine control lever
in FAST position.
1.

Raise cutting height.

2.
3.
4.
5.
6.

Rear of lawn mower housing or
cutting blade dragging in heavy grass.
Cutting too much grass.
Dirty air filter.
Buildup of grass, leaves, trash under mower.
Too much oil in engine.
Walking speed too fast.

2.
3.
4.
5.
6.

Raise cutting height.
Clean/replace air filter.
Clean underside of mower housing.
Check oil level.
Cut at slower walking speed.

Poor cutuneven

1.
2.
3.

Worn, bent or loose blade.
Wheel heights uneven.
Buildup of grass, leaves, trash under mower.

1.
2.
3.

Replace blade. Tighten blade bolt.
Set all wheels at same height.
Clean underside of mower housing.

Excessive
vibration

1.
2.

Worn, bent or loose blade.
Bent engine crankshaft.

1.
2.

Replace blade. Tighten blade bolt.
Contact a qualified service center.

Starter rope
hard to pull

2.
3.
4.
5.

Engine flywheel brake is on
when control bar is released.
Bent engine crankshaft.
Blade adapter broken.
Blade dragging in grass.
Defective blade/brake clutch.

2.
3.
4.
5.

Depress control bar to upper handle
before pulling starter rope.
Contact a qualified service center.
Replace blade adapter.
Move mower to cut grass / hard surface.
Replace blade/brake clutch.

Grass catcher
is not filling
(If so equipped)

1.
2.
3.

Cutting height too low.
Lift on blade worn off.
Catcher not venting air.

1.
2.
3.

Raise cutting height.
Replace blade.
Clean grass catcher.

Hard to push

1.
2.

Raise cutting height.
Raise cutting height.

3.
4.

Grass is too high or wheel height is too low.
Rear of lawn mower housing or
cutting blade dragging in heavy grass.
Grass catcher too full.
Handle height position is not right for you.

3.
4.

Empty grass catcher.
Adjust handle height to suit.

Blade / brake
does not engage

Defective blade / brake control.

Replace blade / brake control.

Engine dies when
starting blade

1.
2.

Cold engine.
Mower is in uncut grass.

1.
2.

Allow engine to warm up for one minute.
Move mower to cleared area.

Loss of drive
or slowing of
drive speed
(if self-propelled)

1.
2.
3.
4.

Belt wear.
Belt off of pulley.
Drive cable worn or broken.
"Loose" drive control system.

1.
2.
3.
4.

Check/replace drive belt.
Check/reinstall drive belt.
Replace drive cable.
Adjust drive control.

ROTARY LAWN MOWER - - MODEL NUMBER 5521BBC

(96145000200)

- PRODUCT

NUMBER

961 45 00-02

4
8

42
41

68
31

18
\

I
I

I
I
I

ROTARY LAWN MOWER - - MODEL NUMBER 5521BBC
KEY
NO.

PART
NO.

1
2
3
4
5
6
7
8
9
10
11
12
13
16
17
18
19
20
21
22
23
24
25
26
27
28
30
31
37
38

532
532
532
532
532
532
532
532
532
532
873
532
532
532
532
532
532
532
532
532
532
873
532
532
532
532
532
532
532

39
40
41
42
45
46
47
50
51
52
53
54
55

532
532
532
532
532
532
532
532
532
532
532
532
532

IMPORTANT:

DESCRIPTION

18 97-40
16 45-56
18 60-53
17 95-85
13 20-04
06 64-26
19 15-74
18 55-88
19 49-19
18 88-21
93 05-00
05 17-93
18 60-52
19 05-74
18 41-93
18 75-35
19 49-16
19 49-17
19 49-18
15 00-78
1631-83
80 05-00
16 13-33
16 34-09
18 89-86
08 86-52
18 50-46
18 04-59
15 04-06
- -19
18
10
05
19
19
08
05
18
14
15
18
16

47-19
88-17
73-39
45-83
05-10
05-76
83-49
78-08
45-43
52-12
55-52
58-98
60-43

Handle, Upper (Includes Foam Grip)
Handle, Lower
Spring, Rear Door, RH
Guide, Rope, Side
Nut, Hex Lockwasher Insert 1/4-20
Wire, Tie
Bolt, Handle 5/16-18 x 1.75
Knob, Handle
Bar, Control, Auto-Walk
Bolt, Carriage
Nut, Hex, Centerlock 5/16-18 UNC
Cotter, Hairpin
Spring, Rear Door, LH
Rear Door Assembly
Bolt, Rear Door
Plug, Mulcher
Kit, Housing
Handle Bracket Assembly, LH
Handle Bracket Assembly, RH
Screw, Hex Washer Head
Bolt, Hex Head 5/16-18x5/8
Nut, Hex, with Lock Washer Insert 5/16-18
Baffle, Side
Screw 12 x 5/8
Skirt, Rear
Screw, Hinge 1/4-20 x 1.25
Spacer, Blade
Blade, 21"
Bolt, Engine
Engine, Honda, Model No. GCV160 (For engine service
and replacement parts, call Honda at 1-800-426-7701 )
G rassbag
Frame, G rassbag
Danger Decal
Screw
Mulcher Door Assembly
Deflector, Discharge
Nut, Hex
Screw
Pulley Assembly, V-Groove
Flange Nut
Locknut
Idler Arm
Idler Pulley

(96145000200)
KEY
NO.
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
---

PART
NO.
532 16 08-29
532 18 58-99
532 18 20-03
532 18 27-48
532 19 08-78
532 18 33-65
532 18 21-31
532 85 02-63
873 90 06-00
532 19 09-03
532 18 99-37
532 18 37-07
532 18 04-60
--532 19 49-20
532 18 01-91
532 75 00-97
532 18 03-93
873 90 04-00
532 19 09-29
8747804-10
532 05 39-98
873 51 06-00
532 18 21-32
532 18 03-94
532 18 01-88
532 19 50-49
532 19 50-72
532 19 50-53
532 19 50-73
532 19 50-74
532 19 50-57
532 19 50-60
532 19 50-63
532 19 50-64
532 19 50-65
532 19 50-67
532 19 50-68
532 19 50-69
532 19 50-70
532 16 23-00
532 19 45-38

- PRODUCT

NUMBER

961 45 00-02

DESCRIPTION
Shoulder Bolt
Bracket Assembly
Clip
Grip, Handle, Foam, Smooth
Throttle / Engine Control
Screw, Hex Head 1/4-20 x 2-1/8
Belt Guide, Stud
Washer, Lock 3/8
Nut, Hex 3/8-16
Bracket, Throttle
Screw, Hex Washer Head 1/4-20 x 1/2
Blade Brake / Clutch Control
Bolt, Hex Head
Blade Brake / Clutch (Includes Key Numbers 82-95)
Belt Cover, Upper
Belt Cover, Lower
Screw, Tapping, Hex Washer Head #10-24
Spring
Nut, Hex, Centerlock, Zinc Plated 1/4-20
Bracket
Bolt, Hex Cap Head 1/4-20 x 5/8
Washer, Flat
Nut, Hex 3/8-16
Belt Keeper
Spring
Link, Torque
Holder Assembly, Blade
Plate Assembly, Ball Control
Ball, Steel
Plate, Spring Hook
Plate, Brake
Spring, Ball Plate
Disk, Drive
Disk, Driven
Pulley, Drive
Spring, Clutch
Bolt, Flange (10 x 24)
Bearing, Radial Ball (6006)
Bearing, Radial Ball (6204)
Key, Woodruff (16 x 15)
Warning Decal (not shown)
Owner's Manual, English / French

NOTE: All component dimensions given in U.S. inches. 1 inch = 25.4 mm

Use only Original Equipment Manufacturer (O.E.M.) replacement parts. Failure to do so could be hazardous, damage your unit and void your warranty.

ROTARY LAWN MOWER - - MODEL NUMBER 5521BBC

X
\

(96145000200)

- PRODUCT

NUMBER

961 45 00-02

9
\

_14

13
60

I
I
I

24 _

22
2,

34
29
QO

57
47

f
|

\,
\
\.

\
\

4O
\

\
27

34
\

g
\ Ii
\

33
36

ROTARY LAWN MOWER - - MODEL NUMBER 5521BBC

KEY
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32

IMPORTANT:

PART
NO.
532
532
532
532
532
532
532
532
532
532
532
532
532
532
532
532
532
532
532
812
532
532
532
532
532
532
532
812
532
532
532
532

18
18
18
19
18
18
18
18
19
18
18
18
18
18
13
16
16
19
19
00
16
16
16
05
19
75
05
00
18
17
18
18

DESCRIPTION
97-41
82-79
73-53
00-39
82-78
16-98
70-97
62-97
02-84
90-74
59-13
76-53
86-45
94-08
20-10
15-84
16-02
07-94
06-22
00-22
33-65
99-11
45-55
78-08
05-14
06-34
21-60
00-58
94-03
51-04
41-72
07-74

Drive Control Assembly, Auto-Walk
Cover, Top, Auto-Walk Drive Control
Pulley
Lever, Auto-Walk Drive Control
Cover, Bottom, Auto-Walk Drive Control
Screw, Phillips Head #10 x 5/8
Plate, Trigger, Auto-Walk Drive Control
Cap, Drive Control, Bottom
Cable, Drive Control
Decal, Drive Control
Decal, Drive Control Adjustment (bottom)
Screw
Gear Case Assembly, Complete
Pulley, Drive
Nut, Hex, Flangleck, Zinc Plated 3/8-16
Rod, Connecting
Spring, Extension
Spring Selector
Knob, Selector Spring
E-Ring
Bearing, Support
Bearing, Ball
Retainer, Drive Assembly, Stamped
Screw, Tapping, Hex Head 1/4-20 x .75
Cover Drive
Screw, Threaded, Rolled #10-25 x .50
Washer
E-Ring 7/16
Cover, Dust, Wheel
Disc, Drive
Seal, Friction
Wheel, Driven, Rear 9 x 2

(96145000200)

KEY
NO.

PART
NO.

33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62

532
532
532
532
532
532
532
532
532
532
532
532
532
532
532
532
532
532
532
532
532
532
532
532
532
532
532
532
532
532

08
18
19
16
16
16
70
15
18
14
18
18
17
18
06
17
17
17
18
18
18
18
19
18
18
18
18
19
18
18

- PRODUCT

NUMBER

961 45 00-02

DESCRIPTION
39-23
06-26
12-05
45-50
14-63
34-09
02-79
03-39
83-30
52-12
83-31
22-12
50-98
82-91
77-25
51-05
51-03
51-02
75-30
75-31
75-32
75-33
12-49
35-06
35-08
35-09
35-11
09-48
35-13
35-14

Nut, Hex, Flangelock 3/8-16
Hubcap
Shaft Assembly, Rear
Shaft Assembly, Front
Retainer, Front Shaft
Screw #12 x 5/8
Clip, Retainer
Wheel, Front 8 x 2
Pinion Assembly, RH
Nut, Hex
Pinion Assembly, LH
V-Belt
Pawl
Spring, Torsion
Washer 1/2 x 1-1/2 x .134
Retainer, Drive, LH
Gear, Pinion
Retainer, Drive, RH
Case, Lower
Case, Upper
Gear, 24 Teeth
Shaft, Input
Wire, Formed
Bearing, Ball
Seal, Output Shaft
Washer
Bushing
Shaft, Output
Screw
Seal, Input Shaft

NOTE: All component dimensions given in U.S. inches.
1 inch = 25.4 mm

Use only Original Equipment Manufacturer (O.E.M.) replacement parts. Failure to do so could be hazardous, damage your unit and void your warranty.

usqvarna

WARRANTY

MENT

SECTION 1: LIMITED WARRANTY

SECTION 4: EXCEPTIONS

Husqvarna Forest & Garden Company ("Husqvarna") warrants Husqvarna product to the original purchaser to be free from defects in material and workmanship from the date of purchase for the "Warranty
Period" of the product as set forth below:

This warranty shail be inapplicable to defects resulting from the following:
(1)Accident, abuse, misuse, negligence and neglect, including stale fuel, dirt, abrasives, moisture, rust,
corrosion, or any adverse reaction due to incorrect storage or use habits;
(2)Failure to operate or maintain the unit in accordance with the Owner's/Operator's
manual or instruction sheet furnished by Husqvarna;
(3)Alterations or modifications that change the intended use of the product or affects the product's performance, operation, safety, or durability, or causes the product to fail to comply with any applicable
laws; or:
(4)Additional damage to parts or components due to continued use occurring after any of the above.

_if, e:time _Narranty:
ela proauct.
3 Year Warranty:

AIt tiller tines aga nst breakage,

Spindles

(on ZeroTum

trimmer shafts, ignition coils and modules on hand

Riders and Commercial

2 Year COMMERCIAL-Warranty:
Husqvarna Commercial
walks, and ground engaging commercial equipment.

Walk-Behinds)

Turf Equipment--zero

turn riders, wide area

2 Year NON*COMMERCIAL
Warranty: Automatic Mower, Riding lawn mowers, yard and garden tractors,
walk behind mowers, tillers, chain saws, trimmers, brushcutters, clearing saws, snow bIowers, handhetd
blowers, backpack blowers, hedge trimmers, electrical products and power-assist collection systems for
noncommercia!,
noninstitutionai or nonincome producing use. except as herein stated.
Emission controi system components necessary to comply with CARB-TIERql and EPA regulations,
except for those components which are part of engine systems manufactured by third party engine manufacturers for which the purchaser has received a separate warranty with product information supplied at
time of purchase.
1 Year Warranty:

AND LIMITATIONS

REPAIR OR REPLACEMENT AS PROVIDED UNDER THIS WARRANTY ISTHE EXCLUSIVE REMEDY OF
THE PURCHASER. HUSQVARNA SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL
DAMAGES FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY ON THESE PRODUCTS EXCEPT
TO THE EXTENT PROHIBITED BY APPLICABLE
LAW. ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ON THESE PRODUCTS IS LIMITED IN DURATION TO
THE WARRANTY PERIOD AS DEFINED IN THE LIMITED WARRANTY STATEMENT. HUSQVARNA RESERVES THE RIGHT TO CHANGE OR IMPROVE THE DESIGN OF THE PRODUCT WITHOUT NOTICE,
AND DOES NOT ASSUME OBLIGATION TO UPDATE PREVIOUSLY MANUFACTURED
PRODUCTS.

Power cutters, stump grinder, pole pruners and pote saws for non-commercia!,
non-proat or non-income producinq use. Aft trimmers, brushcutters, clearing saws, hovering trimmers, stick edgers, backpack btowers, hand held blowers, hedge trimmers, power-assist collection
systems used for
rofessionat or income producing purposes or use.

Some states do not allow the exclusion of incidental or consequential damages, or limitations on how long
an implied warranty lasts, so the above limitations or exclusions may not apply to you. This warranty gives
you specific tegat rights, and you may also have other rights which vary from state to state.

Batteries

SECTION

have a one-year

prorated

limited warranty with 100% replacement

during the first 6 months.

CUSTOMER

RESPONSIBILITIES

O
90 Day Warranty:
Automatic Mower, Chain saws, power cutters, stump grinders, pole saws, pote pruners, snow throwers, model series 580 & 600 walk-behind mowers and commercial turf equipment or any
Husqvarna product used for
nat or income producing purposes or use
except as otherwise provided herein.
Husqvarna Safety Apparel carries a 90-day warranty from the date of the customer's original purchase
for defects in materiat and workmanship. Normal wear, tear or abuse is not covered under warranty. Product must be returned to Charlotte with a warranty claim form. Aft care and maintenance instructions must
be followed as stated by the manufacturer on the care label. The fit of the protective apparel/boot is not
covered under warranty.
30 Day Warranty:

Replacement

parts, accessories

SECTION 2: HUSQVARNA'S

including

OBLIGATIONS

ITEMS

NOT COVERED

BYTHIS

SECTION 6: PROCEDURE TO OBTAIN WARRANTY

CONSIDERATION

It is the Owner's and Dealer's responsibility to make certain that the Warranty Registration Card is properly
filled out and mailed to Husqvarna Forest & Garden Company.This card should be mailed within ten (10) days
from the date of purchase in order to confirm the warranty and to facilitate post-sate service.

bars and chains, tools and display items.

UNDER THE WARRANTY

Husqvarna will repair or replace defective components without charge for parts or labor if a component
falls because of a defect in material or workmanship during the warranty period.

SECTION

The product must exhibit reasonable care, maintenance, operation, storage and generat upkeep as written
in the maintenance section of the Owner's/Operator's
manual. Should an operational problem or failure occur,
the product should not be used, but delivered as is to an authorized Husqvarna dealer for evaluation. Proof
of purchase, as explained in section 6, rests solely with the customer.

WARRANTY

The following items are not covered by this warranty:
(1)Normal customer maintenance items which become worn through normal regular use, including, but
not iimited to, belts, blades, blade adapters, bulbs, filters, guide bars, lubricants, rewind springs, saw
chain, spark plugs, starter ropes and tines;
(2)Natural discoloration of material due to ultraviolet light;
(3)Engine and drive systems not manufactured by Husqvarna; these items are covered by the respective
manufacturer's warranty as provided in writing with the product information supplied at the time of purchase; all claims must be sent to the appropriate manufacturer;
(4)Lawn and garden attachments are covered by a third party which gives a warranty, aiI claims for warranty should be sent to the manufacturer; and
(5)Emission Control System components necessary to comply with CARB-TIERdl and EPA regulations
which are manufactured by third party engine manufacturer.

Proof of purchase must be presented to the authorized Husqvarna dealer in order to obtain warranty service.This proof must include date purchased, model number, serial number, and complete name and address
of the selling dealer.
To obtain the benefit of this warranty, the product believed to be defective must be delivered to an authorized Husqvarna dealer in a timely manner, no later than thirty (30) days from date of the operational
problem or failure. The product must be delivered at the owner's expense. Pick-up and delivery charges are
not covered by this warranty. An authorized Husqvarna dealer can be normally located through the "Yellow
Pages" of the local telephone directory or by cailing 1-800-HUSKY62 for a dealer in your area.

HUSQVARNA
7349 Statesville Road
Charlotte, NC 28269
53t 83 8t-23

2002

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Husqvarna 5521BBC User Manual LAWN MOWER Manuals And Guides L0502208

HUSQVARNA Walk Behind Lawnmower, Gas Manual L0502208 HUSQVARNA Walk Behind Lawnmower, Gas Owner's Manual, HUSQVARNA Walk Behind Lawnmower, Gas installation guides

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