Poulan Self Propelled Rotary Lawn Mower 2010 01 Mowers Consumer Walk Behinds Owners Manual OM, MOWER, 01,

193733 to the manual 747e6332-dcdb-4819-8505-a884d9cf778b

2014-07-31

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SELF-PROPELLED ROTARY
LAWN MOWER

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.

193733 Rev. 8 01.20.10 BY

Printed in U.S.A.

TROUBLESHOOTING - See appropriate section in manual unless directed
to an authorized Service Center.

TABLE OF CONTENTS
Safety Rules ................. 2-3
Assembly ...................... 4-7
Operation.................... 8-15

Maintenance ............. 16-19
Service and
Adjustments.............. 19-24

Storage ..................... 25-26
Troubleshooting ........ 26-27

PROBLEM
Loss of power

SAFETY RULES
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 impor• Do not pull mower backwards unless
tant safety precautions. It means
absolutely necessary. Always look down
CAUTION!!! BECOME ALERT!!!
and behind before and while moving
YOUR SAFETY IS INVOLVED.
backwards.
WARNING: In order to prevent accidental • Never direct discharged material toward
starting when setting up, transporting, adanyone. Avoid discharging material against
justing or making repairs, always disconnect
a wall or obstruction. Material may richospark plug wire and place wire where it cannot
chet back toward the operator. Stop the
come in contact with plug.
blade when crossing gravel surfaces.
WARNING: Engine exhaust, some of its • Do not operate the mower without
constituents, and certain vehicle compoproper guards, plates, grass catcher or
nents contain or emit chemicals known to
other safety protective devices in place.
the State of California to cause cancer and • See manufacturer’s instructions for
birth defects or other reproductive harm.
proper operation and installation of
WARNING: Battery posts, terminals and
accessories. Only use accessories aprelated accessories contain lead and lead
proved by the manufacturer.
compounds, chemicals known to the State • Stop the blade(s) when crossing gravel
of California to cause cancer and birth
drives, walks, or roads.
defects or other reproductive harm. Wash
• Stop the engine (motor) whenever you
hands after handling.
leave the equipment, before cleaning the
mower or unclogging the chute.
CAUTION: Muffler and
• Shut the engine (motor) off and wait until
other engine parts become
the blade comes to complete stop before
extremely hot during
removing grass catcher.
operation and remain hot
• Mow only in daylight / good artificial light.
after engine has stopped.
• Do not operate the machine while under
To avoid severe burns on
the influence of alcohol or drugs.
contact, stay away from these areas.
• Never operate machine in wet grass.
Always be sure of your footing: keep a
I. GENERAL OPERATION
firm hold on the handle; walk, never run.
• Read, understand, and follow all
• Disengage the self-propelled mechinstructions on the machine and in the
anism or drive clutch on mowers so
manual(s) before starting. Be thoroughly
equipped before starting the engine.
familiar with the controls and the proper
• If the equipment should start to vibrate
use of the machine before starting.
abnormally, stop the engine (motor) and
• Do not put hands or feet near or under
check immediately for the cause. Vibrarotating parts. Keep clear of the distion is generally a warning of trouble.
charge opening at all times.
• Always wear safety goggles or safety glass• Only allow responsible individuals, who
es with side shields when operating mower.
are familiar with the instructions, to operate the machine.
II. SLOPE OPERATION
• Clear the area of objects such as rocks,
Slopes are a major factor related to slip &
toys, wire, bones, sticks, etc., which
fall accidents which can result in severe incould be picked up and thrown by blade.
jury. All slopes require extra caution. If you
• Be sure the area is clear of other people
feel uneasy on a slope, do not mow it.
before mowing. Stop machine if anyone
DO:
enters the area.
• Mow across the face of slopes: never
• Do not operate the mower when bareup and down. Exercise extreme caution
foot or wearing open sandals. Always
wear substantial foot wear.
2 when changing direction on slopes.

Poor cut –
uneven

CAUSE

CORRECTION

1. Rear of lawn mower
housing or cutting blade
dragging in heavy grass.
2. Cutting too much grass.
3. Dirty air filter.
4. Buildup of grass, leaves,
and trash under mower.
5. Too much oil in engine.
6. Walking speed too fast.
1. Worn, bent or loose blade.
2. Wheel heights uneven.
3. Buildup of grass, leaves
and trash under mower.

Excessive
vibration

1. Worn, bent or loose blade.
2. Bent engine crankshaft.

1. Raise cutting height.
2. Raise cutting height.
3. Clean/replace air filter.
4. Clean underside of mower
housing.
5. Check oil level.
6. Cut at slower walking speed.
1. Replace blade. Tighten
blade bolt.
2. Set all wheels at same
height.
3. Clean underside of
mower housing.
1. Replace blade. Tighten
blade bolt.
2. Contact a qualified service
center.

Starter rope
hard to pull

1. Engine flywheel brake is on 1. Depress control bar to
when control bar is released.
upper handle before
pulling starter rope.
2. Bent engine crankshaft.
2. Contact a qualified service
center.
3. Blade adapter broken.
3. Replace blade adapter.
4. Blade dragging in grass.
4. Move lawn mower to cut
grass or to hard surface.

Grass catcher
not filling
(If so equipped)

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

1. Raise cutting height.
2. Replace blade.
3. Clean grass catcher.

Hard to push

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

1. Raise cutting height.

Loss of drive
or slowing of
drive speed

1.
2.
3.
4.

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

2. Raise rear of lawn mower
housing one (1) setting
higher.
3. Empty grass catcher.
4. Adjust handle height to suit.
1.
2.
3.
4.

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

ENGINE
FUEL SYSTEM
IMPORTANT: It is important to prevent gum
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 formation of acids during storage.
Acidic gas can damage the fuel system of
an engine while in storage.
• Drain the fuel tank.
• Start the engine and let 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.
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 drain the gas
tank and carburetor if using fuel stabilizer.
ENGINE OIL
Drain oil (with engine warm) and replace
with clean oil. (See “ENGINE” in the Maintenance section of this manual).

CYLINDER
• Remove spark plug.
• Pour one ounce (29 ml) of oil through
spark plug hole into cylinder.
• Pull starter handle slowly to distribute oil.
• Replace with new spark plug.
BATTERY (IF EQUIPPED)
Disconnect the battery from the engine
connector and charge battery 48 hours.

OTHER
• 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 protect it 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 - See appropriate section in manual unless directed
to an authorized Service Center.
PROBLEM
Does not start

CAUSE

CORRECTION

1. Dirty air filter.
2. Out of fuel.
3. Stale fuel.
4. Water in fuel.
5. Spark plug wire is
disconnected.
6. Bad spark plug.
7. Loose blade or broken
blade adapter.
8. Control bar in released
position.
9. Control bar defective.
10. Fuel valve lever (if so
equipped) in OFF position.
11. Weak battery (if equipped).
12. Disconnected battery
connector (if equipped).
26

1. Clean/replace air filter.
2. Fill fuel tank.
3. 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 blade 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.

• Remove obstacles (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.

III. 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 area.
• Before and while walking backwards,
look behind and down for small children.
• Never allow children to operate the mower.
• Use extra care when approaching blind
corners, shrubs, trees, or other objects
that may obscure vision.

away from your vehicle before filling.
• Remove gas-powered equipment from the
truck or trailer and refuel it on the ground. If
this is not possible, then refuel such equipment with a portable container, rather than
from a gasoline dispenser nozzle.
• Keep the nozzle in contact with the rim
of the fuel tank or container opening at
all times until fueling is complete. Do not
use a nozzle lock-open device.
• If fuel is spilled on clothing, change
clothing immediately.
• Never overfill fuel tank. Replace gas cap
and tighten securely.

V. GENERAL SERVICE

• Never run machine inside a closed area.
• Never make adjustments or repairs with
the engine (motor) running. Disconnect the
spark plug wire, and keep the wire away
from the plug to prevent accidental starting.
• Keep nuts and bolts, especially blade
attachment 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.
IV. SAFE HANDLING OF GASOLINE • Stop and inspect the equipment if you
Use extreme care in handling gasoline.
strike an object. Repair, if necessary,
Gasoline is extremely flammable and the
before restarting.
vapors are explosive.
• Never attempt to make wheel height
• Extinguish all cigarettes, cigars, pipes
adjustments while the engine is running.
and other sources of ignition.
• Grass catcher components are subject to
• Use only an approved container.
wear, damage, and deterioration, which
• Never remove gas cap or add fuel with
could expose moving parts or allow objects
the engine running. Allow engine to cool
to be thrown. Frequently check components
before refueling.
and replace with manufacturer’s recom• Never refuel the machine indoors.
mended parts, when necessary.
• Never store the machine or fuel contain- • Mower blades are sharp and can cut.
er where there is an open flame, spark
Wrap the blade(s) or wear gloves, and
or pilot light such as a water heater or on
use extra caution when servicing them.
other appliances.
• Do not change the engine governor set• Never fill containers inside a vehicle, on
ting or overspeed the engine.
a truck or trailer bed with a plastic liner.
• Maintain or replace safety and instrucAlways place containers on the ground
tion labels, as necessary.
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 problems you cannot easily remedy, please contact your
nearest authorized service center. They have competent, well trained technicians and
the proper tools to service or repair this unit.
• Read the SAFETY RULES and this Operator's Manual in its entirety before you attempt to assemble or operate your new lawn mower to insure proper operation and to
prevent injury to yourself and others. Save this manual for future reference.
• Your new lawn mower has been assembled at the factory with the exception of those
parts left unassembled for shipping purposes. 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.
• All parts such as nuts, washers, bolts, etc., necessary to complete the assembly have
been placed in the parts bag.
3

TO REMOVE MOWER FROM CARTON
• Remove all loose parts from carton.
• Remove lawn mower housing with care. Avoid touching blade under housing. Always
wear gloves or other protection when working under or lifting mower.

THINGS TO KNOW BEFORE YOU ASSEMBLE OR OPERATE YOUR LAWN
MOWER
Do I have a side or rear discharge lawn
mower?
Look for the grass discharge opening on
your mower. If the opening is on the right
side of the mower housing, it is a side
discharge mower. If the opening is at the
back of the mower housing, it is a rear discharge mower. Only rear discharge lawn
mowers have a grass catcher included with
the mower. Approved grass catchers for
side discharge mowers may be purchased
from your nearest authorized dealer.
Do I have a mulching lawn mower?
Look for the grass discharge opening on
your mower. Raise the discharge guard
(rear door on rear discharge mowers). If
the opening is closed off by a plate, then
your lawn mower is mulcher ready. To
convert to a discharging mower, see the
Operation section of this manual.

What is the right and left side of the
lawn mower?
When right hand (RH) or left hand (LH) is
mentioned in this manual, it means when
you are in the operating position (standing
behind the handle).
What kind of engine is on my lawn
mower?
When learning how to operate your new
lawn mower, you will need to know what
kind of engine powers the mower. A decal
on the engine will indicate the manufacturer and type or brand name of the
engine.
BRIGGS & STRATTON ENGINES

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

LAWN MOWER
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.
• 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
pins are securely fastened. Inspect
moving parts for damage, breakage and
wear. Replace if necessary.
• Touch up all rusted or chipped paint
surfaces; sand lightly before painting.

HANDLE

FRONT

LEFT
HAND
SIDE

STORAGE

RIGHT
HAND
SIDE

TECUMSEH
ENGINES

HONDA
ENGINES

BACK or REAR
(Operating Position)

ASSEMBLY
HOW TO SET UP YOUR LAWN
MOWER

CAUTION: Do not operate this lawn
mower without the discharge guard or an
entire approved grass catcher in place.
These guards are for your protection and
are required by the American National
Standards Institute and Consumer Products Safety Commission.
CAUTION: Disconnect spark plug wire
from spark plug and place wire where it
cannot come in contact with plug.

UNFOLD HANDLE
IMPORTANT: Unfold handle carefully so
as not to pinch or damage control cables.

Your handle may be folded for storage as
shown.
• Squeeze the bottom ends of lower
handle towards each other until handle
clears the handle brackets and swing
handles forward over mower.
• Loosen upper handle mounting hardware enough to allow upper handle to be
folded back.
IMPORTANT: When folding handles for
storage or transportation, be sure to fold
handles as shown or you may damage the
control cables.

Operator
presence
control bar

FOLD
FORWARD
FOR
STORAGE

Upper
handle

Handle
knob

Lower handle

2 POSITION / “ADJUSTABLE” HANDLES
When setting you handles up from the
storage position, the lower handle will
automatically lock into mowing position.
3 POSITION HANDLES
When setting up your handle from the storage position, the lower handle will require
manually locking into the mowing position.
3 POSITION “EZ”
Knob

Bolt
Handle
adjustment
bracket

SQUEEZE
TO FOLD

3 POSITION “QUICK”

Lower handle

Handle pin
SQUEEZE
Handle
adjustment
bracket

2 POSITION / “ADJUSTABLE” HANDLES
• Raise handles until lower handle section
locks into place in operating position.

MOWING
POSITION

MODELS WITH GEARCASE-MOUNTED
BELT KEEPER AND NO DEBRIS SHIELD:
• Remove drive cover.
• Remove spring and belt keeper.
• Remove belt from gearcase pulley.

• Route the other end of the new drive belt
through hole in housing.
• Return mower to upright position.
• Install new belt on gearcase pulley.
• Reinstall belt keeper and spring.
• Reinstall drive cover.
NOTE: Always use factory approved belt
to assure proper fit and long life.
• Turn lawn mower on its side with air filter
and carburetor down.
• Reinstall blade and blade adapter.

Operator
presence
control bar

MOWING
POSITION

ALL HANDLES
• Raise upper handle section into place on
lower handle, remove protective padding
and tighten both handle knobs.
• Remove handle padding holding operator presence control bar to upper handle.
• Your lawn mower handle can be adjusted for your mowing comfort. Refer to
“ADJUST HANDLE” in the Service and
Adjustments section of this manual.
NOTE: For shipping purposes, the rear
wheels on your lawn mower may not be
adjusted to the same position as the front
wheels. Before operating mower adjust all
wheels to the same cutting height.

LIFT
UP

Upper
handle

Handle
knob

ENGINE

Gearcase pulley

Drive
cover
Spring
Belt
keeper
Belt

• Turn lawn mower on its side. See
engine manual for proper direction of
turning over the engine.
• Remove blade and blade adapter.
• Remove belt from blade adapter.
• Position the blade adapter on the engine
crankshaft. Be sure key in adapter and
crankshaft keyway are aligned; and that
the drive belt is inside the tabs of the
belt retainer.
Blade adapter

Key

Crankshaft
keyway

Lockwasher
Blade

Blade
bolt Hardened
washer

CARBURETOR
The carburetor has been preset at the factory and adjustment should not be necessary. However, minor adjustment may be
required to compensate for differences in
fuel, temperature, altitude or load.
• The air filter must be assembled to the
carburetor when running engine.
• Best carburetor adjustment is obtained
when fuel tank is 1/4 full.
• In order for the engine to run, the operator presence control bar must be held
in the operating position. Therefore,
and assistant will be required to hold
the control bar in the operating position
when making final adjustment to the
carburetor.
See the ADJUSTMENT section of your
engine manual for further instructions.
ENGINE SPEED
The engine speed has been factory set.
Do not attempt to increase engine speed
as it may result in personal injury. If you
believe the engine is running too fast
or too slow, take your lawn mower to an
authorized engine service center for repair
and adjustment.
THROTTLE CONTROL
If it becomes necessary to adjust or replace the throttle control, see the ADJUSTMENT section of your engine manual.

Lower handle

3 POSITION “EZ” HANDLES
• Raise lower handle section to operating
position and align hole in handle with
one of three height positioning holes.
• Insert handle bolt through handle and
bracket and secure with knob.
• Repeat for opposite side of handle.
Knob

INSTALL REAR WHEELS
(HIGH WHEEL MOWERS ONLY)
Some high wheel models require washers
which will be provided in a parts bag. If provided, install washers on the axle first as shown.
• Install one (1) rear wheel on the axle of
rear wheel adjuster.
• Install 3/8-16 locknut and tighten securely.
• Repeat procedure for other rear wheel.

Bolt
Handle
adjustment
bracket

O-Ring

Washer
Flanged
locknut

3 POSITION “QUICK” HANDLES
• Raise lower handle section to operating
position and squeeze the bottom ends
of lower handle towards each other until
the pin in handle can be inserted into
one of the three height adjustment holes.
SQUEEZE

Belt
retainer

Wheel
assembly

ASSEMBLE GRASS CATCHER
(REAR DISCHARGE MOWERS ONLY)
IMPORTANT: If your model lawn mower
is mulcher ready, the mulcher plate or plug
must be removed before using mower as
a bagger. To convert mower to bagging or
discharging, see the Operation section in
this manual.
Look at the different grass catcher illustrations that follow. Determine which type
of grass catcher you have and follow the
appropriate instructions.

Handle pin

Handle
adjustment
bracket
Trailing edge

Axle

“FABRIC TOP” GRASS CATCHERS
TO ASSEMBLE AND ATTACH GRASS
CATCHER
• Put grass catcher frame into grass bag
with rigid part of bag on the bottom.
• Slip vinyl bindings over frame.
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.
• Lift the rear door on the mower housing.
• For HINGE BRACKET mounted catcher,
place the grass catcher frame onto the
formed tabs on the rear door hinge
bracket.
• For HANDLE BRACKET mounted
catcher, place frame side hooks into
slots in handle brackets.
• For DOOR PIVOT PIN mounted catcher,
place the grass catcher frame hooks
onto the door pivot pins.
• For DOOR SLOT mounted catcher,
place the grass catcher frame hooks into
the slots of the rear door.
NOTE: The grass catcher is secured to the
lawn mower housing when the rear door is
lowered onto the grass catcher frame.

Crankshaft

HINGE BRACKET MOUNTED
Rear door

Blade
adapter

Housing hole

Hinge bracket
Grass
catcher
frame

Hardened
washer
Tab

Debris shield

Gearcase pulley

Spring

OR:
Crankshaft

HANDLE BRACKET MOUNTED
Handle bracket hooks

Rear
door

Grass
catcher
handle

Drive
cover

Lock-washer

Trailing edge

Formed tabs

Blade
bolt

Belt
keeper

Tab

Housing
hole

Blade
adapter

Belt

Hardened
washer

Frame
handle

• Place new drive belt in engine pulley
and belt retainer of debris shield.
Debris
shield

Blade
bolt

Engine pulley

Catcher frame side hook
Screw

Trailing edge

Lock-washer

DOOR PIVOT PIN MOUNTED
Pivot pins

Vinyl
bindings

Rear
door

Drive belt

Grass
catcher
handle

Frame
opening

Belt
retainer
Debris shield

CAUTION: Under normal usage, the
catcher material is subject to deterioration
and wear and should, therefore, be
checked frequently for replacement. Any
replacement catcher should be checked to
ensure compliance with original manufacturer's specifications.
CAUTION: Do not run lawn mower
without the discharge guard (rear door),
approved grass catcher, clipping deflector
or mulcher plate in place. Never attempt
to operate mower with the discharge guard
(rear door) removed or propped open.

Catcher frame hook

DOOR SLOT MOUNTED
Rear door slots
Grass
catcher
handle

Catcher frame hook

MODELS WITH GEARCASE-MOUNTED
BELT KEEPER AND DEBRIS SHIELD:
• Remove drive cover.
• Remove spring and belt keeper.
• Remove belt from gearcase pulley.
• Turn lawn mower on its side. See
engine manual for proper direction of
turning over the engine.
• Remove blade, engine pulley and debris
shield.
• Remove engine pulley and belt from
debris shield.

• Route the other end of the new drive belt
through hole in housing.
• Reinstall debris shield.
• Return mower to upright position.
• Install new belt on gearcase pulley.
• Reinstall belt keeper and spring.
• Reinstall drive cover.
NOTE: Always use factory approved belt
to assure proper fit and long life.
• Turn lawn mower on its side with air filter
and carburetor down.
• Reinstall blade.

MODELS WITH GEARCASE-MOUNTED
BELT KEEPER AND NO DEBRIS SHIELD:
• Remove drive cover and belt keeper.
• Remove belt from gearcase pulley.
• Turn lawn mower on its side. See
engine manual for proper direction of
turning over the engine.
• Remove blade and blade adapter.
• Remove belt from pulley of blade
adapter.
• Install new belt by reversing above
steps.
NOTE: Always use factory approved belt
to assure fit and long life.

Drive
cover

REAR WHEEL DRIVE MODELS:
MODELS WITH IDLER ASSEMBLY:
• Disconnect spark plug wire from spark
plug and place wire where it cannot
come in contact with plug.
• Remove screws retaining drive cover
(not shown); and remove drive cover
from lawn mower housing.
• Remove drive cable from anchor, then
detach it and return spring (if equipped)
from idler arm assembly.
• Remove idler arm assembly from housing by removing hex nut; then remove
drive belt from drive pulley, belt keepers
and idler arm assembly.
Drive pulley

Gearcase
pulley

Key

Crankshaft
keyway

Lockwasher
Blade

Blade
bolt Hardened
washer

Trailing edge

Belt
retainer

Spark plug

ALL UNITS:
At the end of the mowing season the
battery should be charged for 48 hours to
protect the battery during winter storage.
CAUTION: Always disconnect the
engine connector from the battery connector to prevent accidental starting when
transporting or storing your lawn mower
after the season.

Boot

HANDLE-MOUNTED KEY SWITCH

TO PREPARE BATTERY
(ELECTRIC START MODELS ONLY)

Engine
connector
(male)

NOTE: Your battery must be charged
before you can start your lawn mower.
Belt
keepers

Hex nut

Return Idler arm
spring assembly

Belt

Blade adapter

UNITS WITH DECK-MOUNTED
BATTERY:
• After charging, connect engine connector
(male) to battery connector (female).
Your engine has an integral alternator for
partial charging. Connect your battery
charger to charge battery as required.
IMPORTANT: The engine alternator will
not charge a discharged battery.

On some models a spark plug boot is
packed loose in the parts bag. If your
model has the boot, install on spark plug
wire and reconnect spark plug wire to
spark plug.

Drive cable anchor
Housing holes

Drive belt

Belt
keeper

SPARK PLUG BOOT

• Turn lawn mower on its side. See engine
manual for proper direction of turning
over the engine.
• Use a wood block between blade and
mower housing to prevent blade from
turning when removing blade bolt.
NOTE: Protect your hands with gloves
and/or wrap blade with heavy cloth.
• Remove blade bolt.
• Remove blade, attaching hardware (bolt,
lock washer, hardened washer), blade
adapter and debris shield. Note that the
debris shield has a tab which fits into the
housing hole.
• Remove drive belt from engine pulley;
discard old belt.
• Install new belt by reversing above
steps.
NOTE: Always use factory approved belt
to assure fit and long life.
• The recommended tightening torque is
35-40 ft. lbs.
IMPORTANT: Blade bolt is grade 8 heat
treated.

Harness
connector
(female)

UNITS WITH HANDLE-MOUNTED KEY
SWITCH:
• Connect battery charger connector
(male) to harness connector (female).
UNITS WITH DECK-MOUNTED
BATTERY:
• Disconnect engine connector (male)
from battery connector (female).
• Connect battery charger connector
(male) to battery connector (female).

Battery
charger
Charger
connector (male)

DECK-MOUNTED BATTERY

ALL UNITS:
• Plug battery charger into 110 volt A.C.
outlet.
• Leave battery charger connected for 24
hours before starting your engine for the
first time.

Battery charger
Charger
Harness connector
(male)
connector
(female)

UNITS WITH HANDLE-MOUNTED KEY
SWITCH:
• After charging, disconnect harness
connector (female) from battery charger
connector (male).
Connect your battery charger to charge
battery after each use.
IMPORTANT: The engine will not recharge
your battery.

Engine connector (male)

Battery
box

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 worn over spectacles.

HOW TO USE YOUR LAWN MOWER

• Reinstall wheel components in the same
order as they were before removal.
Tighten securely.
• Make sure all wheels are at same height.

ENGINE SPEED CONTROL
MODELS WITH REMOTE THROTTLE
Engine speed is controlled by the throttle
control located on the upper handle.
• Move lever forward to FAST engine
speed for starting and better bagging.
• Move lever backward for SLOW engine
speed.
• Some models have engines equipped
with a choke feature. Move the lever all
the way forward to the CHOKE position
when starting a cold engine.

Flat washer

MODELS WITH GEARCASE-MOUNTED
BELT KEEPER AND DEBRIS SHIELD:
• Remove drive cover and belt keeper.
• Remove belt from gearcase pulley.
• Turn lawn mower on its side. See
engine manual for proper direction of
turning over the engine.
• Remove blade, engine pulley and debris
shield.
• Remove belt and engine pulley from
debris shield.
• Install new belt by reversing above
steps.
NOTE: Always use factory approved belt
to assure fit and long life.

Wheel

Drive
cover

Bolt
Spacer

FAST

“AUTO WALK” or “VARI-SPEED” MODELS:
• Remove drive cover and belt keeper.
• Remove belt from gearcase pulley by
pushing down on pulley and rolling belt
off it.
• Turn lawn mower on its side. See
engine manual for proper direction of
turning over the engine.
• Remove blade and debris shield.
• Remove belt from engine pulley on
crankshaft.
• Install new belt by reversing above
steps.
NOTE: Always use factory approved belt
to assure fit and long life.

3/8-16
Locknut

SLOW

Drive
cover

Belt
Gearcase
pulley

Belt keeper

MODELS WITH “QUICK ADJUST”
WHEEL HEIGHT ADJUSTERS
NOTE: For shipping purposes, the rear
wheels on your lawn mower may not be
adjusted to the same position as the front
wheels. Before operating mower adjust all
wheels to the same cutting height.
• Raise wheels for low cut and lower
wheels for high cut.
• Adjust cutting height to suit your requirements. Medium position is best for most
lawns.
• To change cutting height, squeeze adjuster
lever toward wheel. Move wheel up or
down to suit your requirements. Be sure
all wheels are in the same setting.
NOTE: Adjuster is properly positioned when
plate tab inserts into hole in lever. Also, 9position adjusters (if so equipped) allow lever
to be positioned between the plate tabs.

CHOKE
(START)

Remote
throttle
control

MODELS WITH FIXED SPEED ENGINES
Engine speed was set at the factory for
optimum performance. Engine speed is
not adjustable.

TO ADJUST CUTTING HEIGHT

LEVER BACKWARD
TO LOWER MOWER

Adjust cutting height to suit your requirements. Medium position is best for most
lawns. Raise wheels for low cut and lower
wheels for high cut.
MODELS WITH MANUAL ADJUST
BOLT-ON WHEELS
• Remove wheel, bolt, and hardware and
reassemble in desired adjustment hole.

PUSH DOWN
Belt
keeper

OR:
Belt

Drive
cover

Engine pulley

Belt
keeper

Belt

Drive belt
PUSH
DOWN

Belt
retainer
Debris shield

Plate tab

LEVER FORWARD TO RAISE MOWER Lever

3 POSITION “EZ”
The handle on your lawn mower has three
(3) height positions - adjust to height that
suits you.
• 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.
High
Med.
Low

Bolt

TO REMOVE / REPLACE DRIVE BELT

FOR MULCHING MOWERS ONLY

FRONT WHEEL DRIVE MODELS:
“STANDARD” OR “DUAL BAIL” MODELS:
• Remove drive cover. Remove belt from
gearcase pulley by pushing down on
pulley and rolling belt off it.
• Turn lawn mower on its side. See
engine manual for proper direction of
turning over the engine.
• Remove blade.
• Remove debris shield.
• Remove belt from engine pulley on
crankshaft.
• Place new drive belt in the belt retainers
of the debris shield (if equipped).
• Install new belt by reversing above steps.
NOTE: Always use factory approved belt
to assure fit and long life.

Most mulching mowers are shipped ready
to be used as a mulcher.
“REAR DISCHARGE ONLY” MOWERS
Some models have a seperate mulcher
plug, other models have the mulcher plug
built into the rear door. To convert to bagging or discharging, the plate or plug (if
so equipped) must be removed from the
discharge opening of the lawn mower.
• Open rear door and remove mulcher
plate or plug (if so equipped). Store
mulcher plate or plug in a safe place.
• You can now install grass catcher or
optional clipping deflector accessory.
• To return to mulching operation, install
mulcher plate or plug into discharge
opening of mower.
CAUTION: Do not run your lawn mower
without mulcher plate/plug in place or approved clipping deflector or grass catcher
in place. Never attempt to operate the
lawn mower with the rear door removed or
propped open.

Handle
adjustment
bracket

PUSH
DOWN

Knob

3 POSITION “QUICK”
The handle on your lawn mower has three
(3) height positions - adjust to height that
suits you.
• Squeeze the bottom ends of lower
handle towards each other until the pin
in handle can be inserted into one of the
three height adjustment holes.
High
Medium

Drive
cover

“SIDE DISCHARGE ONLY” MOWERS
MULCHER PLATE TYPE
To convert to bagging or discharging,
mulcher plate must be removed from underside of lawn mower.
• Remove the four (4) screws and lock nuts
securing the mulcher plate to the mower.
• Store mulcher plate and hardware in a
safe place.
• Mower can now be used for side
discharging or optional grass catcher
accessory can be attached.
• To return to mulching operation, simply
reinstall mulcher plate and tighten hardware securely.
Screw and
lock nut

MULCHER "PLATE"

Belt
Pulley

Mulcher plate

DEBRIS SHIELDS WITH BELT RETAINERS:

MULCHER PLUG TYPE “A”
To convert to mulching operation, mulcher
plug must be installed into discharge opening of mower.
• Open discharge guard.
• Insert tab of mulch plug into housing
opening.
• Align hooks of mulch plug over hinge
rod of discharge guard. Push mulch plug
down until mulch plug is seated in housing opening.
CAUTION: Do not run your lawn mower
without discharge guard, approved grass
catcher or mulcher plug in place.

Belt retainers
Slots
Drive belt

Handle pin
Handle
adjustment
bracket

Mulcher
plate tabs
MULCHER "PLUG"

SQUEEZE
Low

Debris shield

OR:

Hinge rod

Mulcher
plug

Engine pulley

Discharge
guard

MULCHER PLUG BUILT INTO REAR DOOR
Drive belt

REAR DEFLECTOR (IF EQUIPPED)
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
Belt
into the operator mowing position. If the
retainer
deflector becomes damaged, it should be
replaced.
Debris shield
20

Housing
opening
Hooks

Mulcher plug

Tab

MULCHER PLUG TYPE “B”
To convert to bagging or discharging:
• Lift discharge guard and remove
mulcher plug.
• Mower can now be used for side discharging or optional grass catcher can
be attached.
• To return to mulching operation, simply
reinstall mulcher plug as shown, making
sure tab is seated properly.
CAUTION: Do not run your lawn mower
without discharge guard, approved grass
catcher or mulcher plug in place.

Slots
Mulcher
plate tabs

SIDE DISCHARGING
• Mulcher plate must be installed into rear
discharge opening of mower (see above
instructions).
• Open mulcher door and install discharge
deflector under door as shown.
• Mower is now ready for discharging
operation.
• To convert to mulching or bagging
operation, discharge deflector must be
removed and mulcher door must be
closed.

Lift
discharge
guard

Install
mulcher plug

3. Close mulcher door (if equipped).
4. Connect a garden hose to the fitting
where shown.
IMPORTANT: Be sure the garden hose is
not routed under the lawn mower housing
or entangled in the wheels.
5. Turn on water supply and check for
leaks at the fitting.
If no leaks are present, start engine (as
described in the Operation section of this
manual) and let engine run until the underside of the lawn mower is clean.
WARNING: Do not engage the drive
system during the washout process.
6. Shut off the engine.
7. Shut off water supply and remove hose
from fitting.
CAUTION: Do not remove hose from
fitting while engine is running. Water in
engine can result in shortened engine life.
8. Start engine (as described in the Operation section of this manual) and let
engine run for a full minute to remove
excess water from mower.

Fitting

GRASS CATCHER (IF SO EQUIPPED)
Grass catcher may be hosed with water
but must be dry when used.
CAUTION: Under normal usage, the
catcher material is subject to deterioration
and wear and should therefore be checked
to ensure compliance with original
manufacturer specifications.

SERVICE AND ADJUSTMENTS
CAUTION: Before performing any service or adjustments:
• Release operator presence control bar.
• Make sure the blade and all moving parts have completely stopped.
• Disconnect spark plug wire from spark plug and place wire where it cannot come in
contact with plug.

Tab

LAWN MOWER
Open mulcher door
MOWER IS
NOW READY
FOR MULCHING
OPERATION

Hose

Discharge deflector

“COMBI-CUT” MOWERS
Your lawn mower was shipped ready to be
used as a mulcher. To convert to bagging
or discharging:
REAR BAGGING
• Open rear door and remove mulcher
plate. Store mulcher plate in a safe
place.
• You can now install grass catcher.
• To convert to mulching or discharging
operation, install mulcher plug into rear
discharge opening of mower, making
sure all tabs are seated properly.
10

TO ADJUST CUTTING HEIGHT
See “TO ADJUST CUTTING HEIGHT” in
the Operation section of this manual.

Mowing
position

TO ADJUST HANDLE
Hairpin
Handle
2 POSITION HANDLES
cotter
bracket
The handle can be mounted in a high or
Mounting
low position. The mounting holes in the
pin
bottom of lower handle are off center for
LOW POSITION
HIGH POSITION
raising or lowering the handle.
• Remove upper handle and all parts attached to lower handle.
• Remove hairpin cotters from lower
handle bracket mounting pin.
• Squeeze lower handle in to remove it
from mounting pins.
• Turn lower handle over to raise or lower
handle.
• Squeeze lower handle in and position
holes onto mounting pins on handle
TURN LOWER
bracket.
HANDLE OVER
• Reassemble hairpin cotters onto pins.
TO ADJUST HEIGHT
• Reassemble upper handle and all parts
removed from lower handle.
19

DRIVE WHEELS
Check drive wheels each time before you
mow to be sure they move freely.
The wheels not turning freely means trash,
grass cuttings, etc. are in the drive wheel
area and must be cleaned to free drive
wheels.
If necessary to clean the drive wheels,
check both drive wheels.
• If after cleaning, the drive wheels do not
turn freely, contact your nearest authorized service center.

• Fill to top of slot inside of filler hole or
to “FULL” line on dipstick on models so
equipped. Keep oil at proper level.
AIR FILTER
Your engine will not run properly and may
be damaged by using a dirty air filter.
Clean the element after every 25 hours
of operation or every season. 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.

GEAR CASE
• 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.

MUFFLER
Inspect and replace corroded muffler as it
could create a fire hazard 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.
Set spark plug gap according to engine
manual specifications.

GEAR CASE WITH METAL HOUSING:
• If lubricant is required, use only Texaco
Starplex Premium 1 Grease, Part No.
750369. Do not substitute.

CLEANING

GEAR CASE WITH PLASTIC HOUSING:
• If lubricant is required, use only ELF
Multis EP00. Do not substitute.

ENGINE
Read the maintenance section of your
engine manual.
LUBRICATION
Change the oil after the first two hours of
operation and every 25 hours thereafter or
at least once a year if the lawn mower is
not used for 25 hours in one year. Refer to
engine manual.
TO CHANGE ENGINE OIL
(SEE ENGINE MANUAL)
• Be sure lawn mower is on level surface.
• Oil will drain more freely when warm.
• Catch oil in a suitable container.
• For engines without dipstick, remove
bottom oil drain plug.
• For engines with oil fill cap/dipstick,
remove bottom drain plug or remove engine oil cap and turn mower on its side.
• After oil has drained completely, replace
oil drain plug and tighten securely.
• Refill engine with oil. Pour slowly. Do
not overfill.

IMPORTANT: For best performance, keep
mower housing free of grass build-up and
trash. Clean the underside of your mower
after each use.
• Clean the underside of your lawn mower
by scraping to remove buildup of grass
and trash.
• Clean engine often to keep trash from
accumulating. A clogged engine runs
hotter and shortens engine life.
• Keep finished surfaces and wheels free
of all gasoline, oil, etc.
We do not recommend using a garden
hose to clean your lawn mower unless the
electrical system, muffler, air filter, and
carburetor are covered to keep water out.
Water in engine can shorten engine life.

SIMPLE STEPS TO REMEMBER WHEN
CONVERTING YOUR “COMBI-CUT”
LAWN MOWER
FOR MULCHING • Rear mulcher plate installed and rear
door closed.
• Mulcher door closed.
FOR REAR BAGGING • Rear mulcher plate removed.
• Grass catcher installed.
• Mulcher door closed.
FOR SIDE DISCHARGING • Rear mulcher plate installed and rear
door closed.
• Discharge deflector installed.
CAUTION: Do not run your lawn mower
without rear mulcher plate or plug in place
or approved grass catcher in place. Never
attempt to operate the lawn mower with
the rear door removed or propped open.

GRASS CATCHER
(REAR BAGGING MODELS ONLY)
TO EMPTY GRASS CATCHER
• Simply open rear door and lift grass
catcher up and away from mower.
NOTE: Do not drag the bag when
emptying. It will cause unnecessary wear.
CAUTION: Under normal usage, the
catcher material is subject to deterioration
and wear and should, therefore, be
checked frequently for replacement. Any
replacement catcher should be checked
to ensure compliance with original
manufacturer's specifications.
CAUTION: Do not run lawn mower
without the rear door, approved grass
catcher or clipping deflector in place.
Never attempt to operate mower with the
rear door removed or propped open.

OPERATOR PRESENCE CONTROL
BAR
Your lawn mower is equipped with an operator presence control bar which requires
the operator to be positioned behind the
lawn mower handle in order to start and
operate the lawn mower.
CAUTION: Federal regulations require
an engine control to be installed on this
lawn mower in order to minimize the risk
of blade contact injury. Do not under
any circumstances attempt to defeat the
function of the operator control. The blade
turns when the engine is running.

DRIVE CONTROL
“STANDARD DRIVE” CONTROL
• Self-propelling is controlled by holding
the operator presence control bar down
to the handle and pushing the drive
control lever forward until it clicks; then
releasing the lever.
• Forward motion will stop when the operator presence control bar is released.
To stop forward motion without stopping
engine, release the operator presence
control bar slightly until the drive control
disengages. Hold operator presence
control bar down against handle to continue mowing without self-propelling.
• To keep drive control engaged when
turning corners, push down on handle
and lift front wheels off ground while
turning lawn mower.

Drive
control
TO ENGAGE DRIVE CONTROL

WATER WASHOUT FEATURE
Your lawn mower is equipped with a fitting
that allows quick and easy cleaning of
the underside of the housing. To use this
feature, proceed as follows:
1. Move lawn mower to an area of cut
grass or another hard surface.
NOTE: Water, grass and other debris will
drain from beneath the mower housing
during the washout process.
2. Remove grass catcher and discharge
chute assembly from lawn mower.
18

Operator
presence
control bar
DRIVE CONTROL DISENGAGED

“DUAL BAIL” DRIVE CONTROL
• To start forward motion, lift drive control
bar up to handle.
• To stop forward motion, release drive
control bar.

LAWN MOWER
Always observe safety rules when performing any maintenance.

Drive Operator
control presence
lever(s) control bar
TO ENGAGE DRIVE CONTROL
Operator
presence
control bar

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.

BLADE CARE

DRIVE CONTROL ENGAGED
Adjustment
turnbuckle
DRIVE CONTROL DISENGAGED

DRIVE CONTROL DISENGAGED

“AUTOWALK” DRIVE CONTROL
• Self-propelling is controlled by holding
the operator presence control bar down
to the handle and pulling the drive control lever(s) rearward to the handle. The
farther toward the handle the lever(s)
are pulled, the faster the unit will travel.
• Forward motion will stop when either
the operator presence control bar or a
drive control lever are released. To stop
forward motion without stopping engine,
release the drive control lever(s) 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.
FRONT WHEEL DRIVE MODELS ONLY:
• To keep drive control engaged when
turning corners, push down on the
handle to lift the front wheels off the
ground while turning lawn mower.

“AUTOWALK” ADJUSTMENT
Over time, the drive control system may
become “loose”, resulting in decreased
speed. There is a turnbuckle on the
underside of the drive control housing to
increase tension on the drive cable. Proceed as follows:
• Turn unit off and disconnect spark plug
wire from spark plug.
• Turn nut on underside of drive control to
increase drive speed.
• Operate mower to test drive speed.
Readjust as required.
• If condition fails to improve after the
above steps (forward speed remains
the same), your drive belt is worn and
should be replaced.

Adjustment
turnbuckle

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.
TO REMOVE BLADE
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. Use a wood block between blade and
mower housing to prevent blade from
turning when removing blade bolt.
NOTE: Protect your hands with gloves
and/or wrap blade with heavy cloth.
4. Remove blade bolt by turning counterclockwise.
5. Remove blade and attaching hardware (bolt, lock washer and hardened
washer).
NOTE: Remove the blade adapter and
check the key inside hub of blade adapter.
The key must be in good condition to work
properly. Replace adapter if damaged.

• The recommended tightening torque is
35-40 ft. lbs.
IMPORTANT: Blade bolt is heat treated.
If bolt needs replacing, replace only with
approved bolt shown in the Repair Parts
section of this manual.
MODELS WITH BLADE ADAPTER
Blade adapter

Key

Crankshaft
keyway

Lockwasher
Blade

Blade
bolt Hardened
washer

Trailing edge

Crankshaft

MODELS WITH BLADE ADAPTER/PULLEY
Blade adapter

Key

Crankshaft
keyway

Lockwasher
Blade

Blade Hardened
washer
bolt
Trailing edge

Belt
Crankshaft retainer

TO SHARPEN BLADE
NOTE: We do not recommend sharpening
blade - but if you do, be sure the blade
is balanced. An unbalanced blade will
cause eventual damage to lawn mower or
engine.
• 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.

TO REPLACE BLADE
1. Position the blade adapter on the engine crankshaft. Be sure key in adapter
and crankshaft keyway are aligned.
2. Position blade on the blade adapter
aligning the two (2) holes in the blade
with the raised lugs on the adapter.
3. Be sure the trailing edge of blade (opposite sharp edge) is up toward the
engine.
DRIVE COVER
4. Install the blade bolt with the lock
Clean under the drive cover at least twice
washer and hardened washer into
a season. Scrape underside of cover with
blade adapter and crankshaft.
a putty knife or similar tool to remove any
5. Use block of wood between blade and
buildup of trash or grass.
lawn mower housing and tighten the
blade bolt, turning clockwise.
17

MAINTENANCE
BEFORE
EACH
USE

AFTER
EACH
USE

EVERY
10
HOURS

EVERY
25 HOURS
OR SEASON

EVERY
100
HOURS

BEFORE
STORAGE

Check for Loose Fasteners
Clean / Inspect Grass Catcher *
Check Tires
Check Drive Wheels ***
Clean Lawn Mower ****
Clean under Drive Cover ***
Check Drive Belt / Pulleys ***
Check / Sharpen / Replace Blade
Lubrication
Clean and Recharge Battery **
Check Engine Oil level
Change Engine Oil
Clean Air Filter
Inspect Muffler
Replace Spark Plug
Replace Air Filter Paper Cartridge
Empty fuel system or add Stabilizer

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

“VARI-SPEED” DRIVE CONTROL
• Self-propelling is controlled by holding the operator presence control bar
down to the handle and pulling the drive
control bar up to the handle. The closer
to the handle the bar is pulled, the faster
the unit will travel.
• Forward motion will stop when either the
operator presence control bar or drive
control bar are released. To stop forward
motion without stopping engine, release
the drive control bar only. Hold operator
presence control bar down against
handle to continue mowing without selfpropelling.
NOTE: If after releasing the drive control the
mower will not roll backwards, push the mower
forward slightly to disengage drive wheels.
FRONT WHEEL DRIVE MODELS ONLY:
• To keep drive control engaged when
turning corners, push down on the
handle to lift the front wheels off the
ground while turning lawn mower.

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

GENERAL RECOMMENDATIONS
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.
All adjustments in the Service and Adjustments section of this manual should be
checked at least once each season.
• 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 assures
proper air-fuel mixture and helps your
engine run better and last longer.
• Follow the Maintenance Schedule in this
manual.
BEFORE EACH USE
• Check engine oil level.
• Check for loose fasteners.
LUBRICATION
Keep unit well lubricated
(See “LUBRICATION CHART”).

LUBRICATION CHART

➀ Wheel
adjuster (on
each wheel)

Operator
presence
control bar
TO ENGAGE DRIVE CONTROL

➁ Engine oil
➀ Side discharge mower
guard hinge rod
➀ Rear discharge mower
rear door
hinge rod

➀ Handle bracket mounting pins
➀ Spray lubricant
➁ See “ENGINE” in Maintenance section.

attract dust and dirt that will shorten the life
of the self-lubricating bearings. If you feel
IMPORTANT: Do not oil or grease plastic
they must be lubricated, use only a dry,
wheel bearings. Viscous lubricants will
powdered graphite type lubricant sparingly.
16

• Rotate thumbscrew counter-clockwise to
tighten the drive cable.
• Operate mower to test drive speed.
• If condition fails to improve after the
above steps (forward speed remains
the same), your drive belt is worn and
should be replaced.
NOTE: If mower begins to "creep" forward,
the drive cable is too tight. Rotate thumbscrew clockwise to loosen drive cable.

Thumbscrew

VARI-SPEED “BLOCK” ADJUSTMENT
Over time, the drive control system may
become “loose”, resulting in decreased
speed. There are holes in the drive control
housing to increase tension on the drive
cable. Proceed as follows:
• Turn unit off and disconnect spark plug
wire from spark plug.
• Loosen nut, move drive control housing down handle to the next hole and
retighten nut.
• Operate mower to test drive speed.
• If condition fails to improve after the
above steps (forward speed remains
the same), your drive belt is worn and
should be replaced.
Operator presence control bar

Drive
control bar
DRIVE
CONTROL
ENGAGED

DRIVE CONTROL DISENGAGED

Drive
control bar
DRIVE
CONTROL
DISENGAGED

VARI-SPEED “THUMBSCREW”
ADJUSTMENT
Over time, the drive control system may
become “loose”, resulting in decreased
speed. There is a thumbscrew on the
underside of the drive control housing to
increase tension on the drive cable. Proceed as follows:
• Turn unit off and disconnect spark plug
wire from spark plug.

TO ADJUST,
MOVE DOWN
TO NEXT HOLE

BEFORE STARTING ENGINE
Read the engine manual packed with your
mower.
FILL ENGINE WITH OIL
Your lawn mower is shipped without oil in
the engine.
• Be sure mower is level and area around
oil fill is clean.
• Remove engine oil filler plug (oil fill cap/
dipstick on models so equipped).
• Slowly add oil. For type and grade of
oil to use, see “ENGINE” in the Maintenance section of this manual.
• Fill to the top of slot in filler hole (to
“FULL” line on dipstick on models so
equipped). Do not overfill.
• Replace plug (oil fill cap/dipstick on
models so equipped) and tighten.
• Check oil level before each use. Add oil
as needed.
• To change oil, see Maintenance section
of this manual.
FILL GASOLINE TANK
• Fill gasoline tank with fresh, clean,
unleaded gasoline. DO NOT USE PREMIUM GASOLINE. BE CAREFUL NOT
TO OVERFILL TANK.
WARNING: 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. Drain the fuel
tank, start the engine and let it run until 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 fuel tank or
permanent damage may occur.

TO START ENGINE

MODELS WITH RECOIL STARTER
• Pull starter handle quickly. Do not allow
starter rope to snap back.

Operator
presence
control bar

Recoil
starter
handle

MODELS WITH ELECTRIC STARTER
• Push the engine start button (or turn the
key on models so equipped).
IMPORTANT: Do not crank engine more
than five continous seconds each time you
try to start. Wait 5 to 10 seconds between
each attempt.
ALL MODELS
• For engines equipped with choke, slowly
move engine speed control lever to
FAST after engine starts.

TO STOP ENGINE
• To STOP engine, release operator presence control bar.
NOTE: For engines with a primer, it may
be necessary to repeat priming steps
in cooler weather. In warmer weather,
overpriming may cause flooding and
engine will not start. If you do flood
engine, wait a few minutes before
attempting to start and DO NOT repeat
priming steps.

CAUTION: The mower blade rotates
whenever the engine is running.
• Move engine speed control to FAST
position (or to CHOKE/START position
on models equipped with choke feature).
• If your mower has a primer, to start a
cold engine, push primer as many times
as instructed in the engine manual
packed with your mower. Use a firm
push. This step is not usually necessary
when starting an engine which has
already run for a few minutes.
• Hold operator presence control bar
down against handle.
14

MOWING TIPS
CAUTION: Do not use de-thatcher
blade attachments on your mower. Such
attachments are hazardous, will damage
your mower and could void your warranty.
• For most cutting conditions and better
bagging performance, the engine speed
should be set in the FAST position.
• Under certain conditions, such as when
mowing very tall grass, raise the mower
height on the first cut to reduce pushing
effort, to avoid overheating the engine,
and to avoid leaving clumps of grass
clippings. Make the second cut to the
desired height.
• For extremely heavy cutting, reduce the
width of cut.
• For side discharge lawn mowers, cut in
a counterclockwise direction, starting at
the outside of the area to be cut, in order
to spread grass clippings more evenly
and to put less load on the engine. To
keep clippings off of walkways, flower
beds, etc., make the first cuts in a clockwise direction.
• When using a rear discharge lawn
mower in moist, heavy grass, clumps
of cut grass may not enter the grass
catcher. Reduce ground speed (pushing
speed) and/or run the lawn mower over
the area a second time.
• If a trail of grass clipping is left on the
right side of a rear discharge lawn mower, mow in a clockwise direction with a
small overlap to collect the clippings on
the next pass.

FOR MULCHING MOWERS ONLY
- MULCHING MOWING TIPS
IMPORTANT: For best performance, keep
mower housing free of built-up grass and
trash. See "CLEANING" in the Maintenance section of this manual.
• 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 recutting 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. 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 grass, reduce your width of cut
by overlapping previously cut path and
mow slowly.
MAX 1/3

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

• Certain types of grass and 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 week
then change to east to west the next
week. This will help prevent matting and
graining of the lawn.

TO START ENGINE

MODELS WITH RECOIL STARTER
• Pull starter handle quickly. Do not allow
starter rope to snap back.

Operator
presence
control bar

Recoil
starter
handle

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

MAINTENANCE
BEFORE
EACH
USE

AFTER
EACH
USE

EVERY
10
HOURS

EVERY
25 HOURS
OR SEASON

EVERY
100
HOURS

BEFORE
STORAGE

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

LUBRICATION CHART

➀ Wheel
adjuster (on
each wheel)

Operator
presence
control bar
TO ENGAGE DRIVE CONTROL

➁ Engine oil
➀ Side discharge mower
guard hinge rod
➀ Rear discharge mower
rear door
hinge rod

➀ Handle bracket mounting pins
➀ Spray lubricant
➁ See “ENGINE” in Maintenance section.

Thumbscrew

Drive
control bar
DRIVE
CONTROL
ENGAGED

DRIVE CONTROL DISENGAGED

Drive
control bar
DRIVE
CONTROL
DISENGAGED

TO ADJUST,
MOVE DOWN
TO NEXT HOLE

“DUAL BAIL” DRIVE CONTROL
• To start forward motion, lift drive control
bar up to handle.
• To stop forward motion, release drive
control bar.

LAWN MOWER
Always observe safety rules when performing any maintenance.

Drive Operator
control presence
lever(s) control bar
TO ENGAGE DRIVE CONTROL
Operator
presence
control bar

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.

BLADE CARE

DRIVE CONTROL ENGAGED
Adjustment
turnbuckle
DRIVE CONTROL DISENGAGED

DRIVE CONTROL DISENGAGED

Adjustment
turnbuckle

Key

Crankshaft
keyway

Lockwasher
Blade

Blade
bolt Hardened
washer

Trailing edge

Crankshaft

MODELS WITH BLADE ADAPTER/PULLEY
Blade adapter

Key

Crankshaft
keyway

Lockwasher
Blade

Blade Hardened
washer
bolt
Trailing edge

Belt
Crankshaft retainer

GEAR CASE WITH METAL HOUSING:
• If lubricant is required, use only Texaco
Starplex Premium 1 Grease, Part No.
750369. Do not substitute.

CLEANING

GEAR CASE WITH PLASTIC HOUSING:
• If lubricant is required, use only ELF
Multis EP00. Do not substitute.

Drive
control
TO ENGAGE DRIVE CONTROL

Operator
presence
control bar
DRIVE CONTROL DISENGAGED

Slots
Mulcher
plate tabs

Lift
discharge
guard

Install
mulcher plug

Fitting

Tab

LAWN MOWER
Open mulcher door
MOWER IS
NOW READY
FOR MULCHING
OPERATION

Hose

Discharge deflector

TO ADJUST CUTTING HEIGHT
See “TO ADJUST CUTTING HEIGHT” in
the Operation section of this manual.

Mowing
position

Bolt

TO REMOVE / REPLACE DRIVE BELT

FOR MULCHING MOWERS ONLY

Handle
adjustment
bracket

PUSH
DOWN

Knob

Drive
cover

MULCHER "PLATE"

Belt
Pulley

Mulcher plate

DEBRIS SHIELDS WITH BELT RETAINERS:

Belt retainers
Slots
Drive belt

Handle pin
Handle
adjustment
bracket

Mulcher
plate tabs
MULCHER "PLUG"

SQUEEZE
Low

Debris shield

OR:

Hinge rod

Mulcher
plug

Engine pulley

Discharge
guard

MULCHER PLUG BUILT INTO REAR DOOR
Drive belt

Housing
opening
Hooks

Mulcher plug

Tab

HOW TO USE YOUR LAWN MOWER

• Reinstall wheel components in the same
order as they were before removal.
Tighten securely.
• Make sure all wheels are at same height.

Flat washer

Wheel

Drive
cover

Bolt
Spacer

FAST

3/8-16
Locknut

SLOW

Drive
cover

Belt
Gearcase
pulley

Belt keeper

CHOKE
(START)

Remote
throttle
control

MODELS WITH FIXED SPEED ENGINES
Engine speed was set at the factory for
optimum performance. Engine speed is
not adjustable.

TO ADJUST CUTTING HEIGHT

LEVER BACKWARD
TO LOWER MOWER

PUSH DOWN
Belt
keeper

OR:
Belt

Drive
cover

Engine pulley

Belt
keeper

Belt

Drive belt
PUSH
DOWN

Belt
retainer
Debris shield

Plate tab

LEVER FORWARD TO RAISE MOWER Lever

Drive
cover

Gearcase
pulley

Key

Crankshaft
keyway

Lockwasher
Blade

Blade
bolt Hardened
washer

Trailing edge

Belt
retainer

Spark plug

Boot

HANDLE-MOUNTED KEY SWITCH

TO PREPARE BATTERY
(ELECTRIC START MODELS ONLY)

Engine
connector
(male)

NOTE: Your battery must be charged
before you can start your lawn mower.
Belt
keepers

Hex nut

Return Idler arm
spring assembly

Belt

Blade adapter

On some models a spark plug boot is
packed loose in the parts bag. If your
model has the boot, install on spark plug
wire and reconnect spark plug wire to
spark plug.

Drive cable anchor
Housing holes

Drive belt

Belt
keeper

SPARK PLUG BOOT

Harness
connector
(female)

Battery
charger
Charger
connector (male)

DECK-MOUNTED BATTERY

ALL UNITS:
• Plug battery charger into 110 volt A.C.
outlet.
• Leave battery charger connected for 24
hours before starting your engine for the
first time.

Battery charger
Charger
Harness connector
(male)
connector
(female)

Engine connector (male)

Battery
box

Crankshaft

HINGE BRACKET MOUNTED
Rear door

Blade
adapter

Housing hole

Hinge bracket
Grass
catcher
frame

Hardened
washer
Tab

Debris shield

Gearcase pulley

Spring

OR:
Crankshaft

HANDLE BRACKET MOUNTED
Handle bracket hooks

Rear
door

Grass
catcher
handle

Drive
cover

Lock-washer

Trailing edge

Formed tabs

Blade
bolt

Belt
keeper

Tab

Housing
hole

Blade
adapter

Belt

Hardened
washer

Frame
handle

• Place new drive belt in engine pulley
and belt retainer of debris shield.
Debris
shield

Blade
bolt

Engine pulley

Catcher frame side hook
Screw

Trailing edge

Lock-washer

DOOR PIVOT PIN MOUNTED
Pivot pins

Vinyl
bindings

Rear
door

Drive belt

Grass
catcher
handle

Frame
opening

Belt
retainer
Debris shield

Catcher frame hook

DOOR SLOT MOUNTED
Rear door slots
Grass
catcher
handle

Catcher frame hook

MODELS WITH GEARCASE-MOUNTED
BELT KEEPER AND NO DEBRIS SHIELD:
• Remove drive cover.
• Remove spring and belt keeper.
• Remove belt from gearcase pulley.

Operator
presence
control bar

MOWING
POSITION

LIFT
UP

Upper
handle

Handle
knob

ENGINE

Gearcase pulley

Drive
cover
Spring
Belt
keeper
Belt

Key

Crankshaft
keyway

Lockwasher
Blade

Blade
bolt Hardened
washer

Lower handle

Bolt
Handle
adjustment
bracket

O-Ring

Washer
Flanged
locknut

Belt
retainer

Wheel
assembly

Handle pin

Handle
adjustment
bracket
Trailing edge

Axle

HANDLE

FRONT

LEFT
HAND
SIDE

STORAGE

RIGHT
HAND
SIDE

TECUMSEH
ENGINES

HONDA
ENGINES

BACK or REAR
(Operating Position)

ASSEMBLY
HOW TO SET UP YOUR LAWN
MOWER

UNFOLD HANDLE
IMPORTANT: Unfold handle carefully so
as not to pinch or damage control cables.

Operator
presence
control bar

FOLD
FORWARD
FOR
STORAGE

Upper
handle

Handle
knob

Lower handle

Bolt
Handle
adjustment
bracket

SQUEEZE
TO FOLD

3 POSITION “QUICK”

Lower handle

Handle pin
SQUEEZE
Handle
adjustment
bracket

2 POSITION / “ADJUSTABLE” HANDLES
• Raise handles until lower handle section
locks into place in operating position.

MOWING
POSITION

TROUBLESHOOTING - See appropriate section in manual unless directed
to an authorized Service Center.
PROBLEM
Does not start

CAUSE

CORRECTION

V. GENERAL SERVICE

TROUBLESHOOTING - See appropriate section in manual unless directed
to an authorized Service Center.

TABLE OF CONTENTS
Safety Rules ................. 2-3
Assembly ...................... 4-7
Operation.................... 8-15

Maintenance ............. 16-19
Service and
Adjustments.............. 19-24

Storage ..................... 25-26
Troubleshooting ........ 26-27

PROBLEM
Loss of power

Poor cut –
uneven

CAUSE

CORRECTION

Excessive
vibration

1. Worn, bent or loose blade.
2. Bent engine crankshaft.

Starter rope
hard to pull

Grass catcher
not filling
(If so equipped)

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

1. Raise cutting height.
2. Replace blade.
3. Clean grass catcher.

Hard to push

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

1. Raise cutting height.

Loss of drive
or slowing of
drive speed

1.
2.
3.
4.

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

2. Raise rear of lawn mower
housing one (1) setting
higher.
3. Empty grass catcher.
4. Adjust handle height to suit.
1.
2.
3.
4.

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

SELF-PROPELLED ROTARY
LAWN MOWER

193733 Rev. 8 01.20.10 BY

Printed in U.S.A.

Source Exif Data:

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Modify Date                     : 2010:03:23 09:09:05-04:00
Create Date                     : 2010:01:20 11:57:04-05:00
Metadata Date                   : 2010:03:23 09:09:05-04:00
Format                          : application/pdf
Title                           : OM, SELF PROPELLED ROTARY LAWN MOWER, 2010-01, LAWN MOWERS: CONSUMER WALK-BEHINDS
Description                     : NOUS2010_193733
Creator                         : POULAN
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Subject                         : NOUS2010_193733
Author                          : POULAN
Warning                         : [Minor] Ignored duplicate Info dictionary

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Poulan Self Propelled Rotary Lawn Mower 2010 01 Mowers Consumer Walk Behinds Owners Manual OM, MOWER, 01,

193733 to the manual 747e6332-dcdb-4819-8505-a884d9cf778b

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