OWNER'S MANUAL Sickle Bar Mowers

OWNER’S MANUAL

Sickle Bar Mowers

• Safety

• Assembly

• Controls and Features

• Operation

• Maintenance

• Parts List

GARDEN WAY INCORPORATED

Models

34061 – 34", 3-1/2 HP Recoil Start

34062 – 38", 4HP Recoil Start

34337 – 34", 4HP Recoil Start

34063 – 42", 5HP Recoil Start

34064 – 42", 5HP Electric Start

SAFETY FIRST!

Before operating this equipment, read this

Owner's Manual and the separate manual

supplied by the engine manufacturer.

Dear Owner:

Thank you for purchasing our product. We feel you now own

one of the finest pieces of outdoor power equipment available.

Our equipment is carefully designed, engineered and manufac-

tured for excellent performance if properly operated and main-

tained.

Read this manual carefully to familiarize yourself with the unit,

its features, and its safe operation. Be sure that you and any

other operators carefully follow the recommended safety prac-

tices at all times. Failure to do so could result in personal injury

or property damage.

This is a safety, operation and general maintenance manual

which does not attempt to cover major repairs. All information

in this manual is based on the latest product information avail-

able at the time of printing. This manual is considered a perma-

nent part of the unit and it must stay with the unit if resold. A

replacement manual can be obtained from the factory or an

authorized dealer.

Please fill out and return the postpaid owner registration card

included with this manual. The purpose of the card is to register

each unit and owner at the factory to provide product updates

and warranty service.

If you have any problems or questions concerning the unit,

please contact your local authorized dealer or the factory (see

back cover of this manual). We want to be sure that you are

completely satisfied at all times.

INTRODUCTION ................................................. 2

Service Information ...................................................... 3

Identification Numbers ................................................. 3

California Operators Warning ....................................... 3

SAFETY .......................................................... 3

Safety Decals ................................................................ 5

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

FEATURES AND CONTROLS ................................... 14

Throttle/Choke Control Lever ........................................ 14

Operator Presence Controls (OPC) ............................... 14

Wheel Drive Levers ....................................................... 14

Engine Oil Dipstick/Fill Hole .......................................... 14

Shoes ........................................................................... 14

Cutter Bar (with guard) ................................................. 15

Fuel Tank Cap ............................................................... 15

Starter Rope Handle ..................................................... 15

Engine Keyswitch (electric-start units).......................... 15

Cutter Bar Lever ........................................................... 15

Weed Diverter ............................................................... 15

Engine Primer Bulb ....................................................... 15

OPERATION ..................................................... 16

Pre-start Checklist ........................................................ 16

Starting the Engine ....................................................... 16

Stopping the Engine ...................................................... 17

Operator Presence Controls (OPC) System Test .......... 17

Operation....................................................................... 18

Operating on Slopes...................................................... 19

Stopping ....................................................................... 19

MAINTENANCE ................................................. 20

Maintenance Schedule................................................... 20

Tire Pressure................................................................. 20

Clearing Wheel Wrap .................................................... 20

Wheel Drive Control Rod Adjustment ........................... 20

Cutter Bar Drive Belt Removal/Replacement ................ 21

Cutter Bar Belt Guide Adjustment ................................ 21

Wheel Drive Belt Adjustment ........................................ 21

Wheel Drive Belt Removal/Replacement ....................... 21

Wheel Drive Belt Guide Adjustment .............................. 21

Drive Chain Adjustment and Lubrication ...................... 22

Cutter Bar Maintenance ............................................ 22-24

High-Wear Parts ........................................................... 24

Housing Assembly Tightening Sequence....................... 26

Front Housing Removal................................................. 26

Eccentric Shaft Removal/Replacement.......................... 26

Engine Maintenance.................................................. 26-27

Battery Maintenance...................................................... 27

Check and Tighten Hardware......................................... 27

Lubrication .................................................................... 27

Storage ......................................................................... 28

Troubleshooting ....................................................... 28-29

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

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

Table of Contents

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects or other reproductive harm.

WARNING

Safety Alert Symbol

This is a safety alert symbol. It is used in this

manual and on the unit to alert you to potential haz-

ards. When you see this symbol, read and obey the

message that follows it. Failure to obey safety mes-

sages could result in personal injury or property

damage.

See Back Cover for

Customer Service Information

Left and Right Sides

Left and right sides of the unit are determined by standing in

the operator position and facing the direction of forward

travel.

PREPARATION

1. Unit is capable of amputating hands

and feet and

throwing

objects.

Failure to

observe the

following safety instructions could result

in serious injury or property damage.

2. Serious accidents which may cause

injury or property damage can occur if the

following safety guidelines are not fol-

lowed. The operator is solely responsible

for accidents or hazards that occur when

using the unit. Preventing accidents is the

responsibility of every equipment oper-

ator. Accidents can be prevented. Be

careful before, during and immediately

after use of any powered equipment. The

following general safety precautions must

be fully understood and followed during

operation. Review these instructions fre-

quently and never take chances. If you do

not understand any part of this manual or

need assistance, contact your dealer or

our service department.

TRAINING

1. Read, understand, and follow this

Owner’s Manual, the separate engine

owner’s manual, and all other literature

received before you use the unit.

Be thoroughly familiar with the controls

and proper use of the unit. Know how to

stop the unit and disengage controls

quickly in case of emergency.

Read and follow all safety information in

this manual. Failure to comply could result

in serious personal injury or property

damage.

Make sure all operators of the equipment

read, understand, and follow these safety

instructions.

2. Never allow children to operate the unit.

Do not allow adults to operate the unit

without proper instruction. Do not allow

irresponsible adults to operate the unit.

3. Keep the operating area (within 25 feet

of unit) clear of all people (especially chil-

dren) and pets.

PREPARATION

1. Wear proper clothing when operating

unit. Always wear sturdy footwear (prefer-

ably steel-toed shoes) and hearing protec-

tion during operation.

a. Wear heavy leather gloves whenever

working near or servicing any cutting

edges on the unit.

b. Do not wear loose-fitting clothing,

jewelry, scarves, ties, etc., which may

get caught in moving parts. Tie up or

restrain hair.

c. Do not operate the unit while bare-

foot. Do not wear sandals.

d. Wear long trousers.

e. Wear hearing protection.

2. Do not operate the unit when tired, ill

or under the influence of alcohol and/or

other drugs.

3. Be prepared for an emergency. Keep a

first aid kit and fire extinguisher handy.

Keep emergency telephone numbers for

ambulance, fire, hospital, doctor and

rescue near your telephone.

4. When charging the battery on electric-

start units, use only the battery charger

provided with the unit.

5. Do not operate the unit if the cutter bar

assembly is not securely installed and

operating properly.

6. Mow only during daylight or in good

artificial light.

7. Never operate the unit in wet grass.

Always be sure of your footing. Always hold

handlebar grips firmly, and walk––never

run.

25 Ft.

Safety

Section

SPARK ARRESTER WARNING TO RESIDENTS

OF CALIFORNIA AND SEVERAL OTHER STATES

Under California law, and under the laws of several

other states, you are not permitted to operate an

internal combustion engine using hydrocarbon fuels on

any forest, brush, hay, grain, or grass covered land; or

land covered by any flammable agricultural crop

without an engine spark arrester in continuous effective

working order.

The engine on the unit is an internal combustion engine

which burns gasoline, a hydrocarbon fuel, and must be

equipped with a spark arrester muffler in continuous

effective working order. The spark arrester must be

attached to the engine exhaust system in such a

manner that flames or heat from the system will not

ignite flammable material. Failure of the owner/oper-

ator of the unit to comply with this regulation is a mis-

demeanor under California law (and other states) and

may also be a violation of other state and/or federal

regulations, laws, ordinances or codes. Contact your

local fire marshal or forest service for specific informa-

tion about which regulations apply in your area.

Throttle/Choke Control Lever

Wheel Drive

Levers

Cutter Bar and Guard

Cutter Bar Lever

(on rear of unit)

Operator Presence Controls

Figure 1-1

4 Section 1: Safety

BEFORE OPERATION

1. Before each use, thoroughly inspect the

mowing area. Remove all

metal, debris, and other

hazards. Inspect for holes,

ruts or bumps. Uneven ter-

rain could overturn the unit.

Tall vegetation can hide

hazards.

2. Never operate the unit without all

guards in place and working properly

(except for the plastic blade protector,

which should be removed before starting

the engine).

3. Before removing or installing the

plastic blade protector, shut the engine

off, disconnect the spark plug wire, and

prevent it from touching the spark plug.

On electric start models, also remove the

ignition key from the keyswitch.

4. Check the operation of the control

levers under each handlebar grip. See the

"Operation" Section in this manual for spe-

cific instructions. Do not use the unit if

control levers are not functioning properly.

CORRECT ANY MALFUNCTION BEFORE

USING THE UNIT!

HANDLING GASOLINE

1. Use extreme care in handling gaso-

line and other fuels.

Gasoline is highly

flammable and its vapors

are volatile, explosive,

and dangerous. Keep gasoline and gaso-

line containers away from hot engine

exhaust. Never allow flame, sparks,

smoking materials or other hot objects

near gasoline, gasoline fumes, the fuel

container or fuel tank.

2. Use an approved fuel container only.

Wipe up any spilled gasoline immediately.

3. Leave one inch of air space at top of

fuel tank to allow room for expansion.

4. Store gasoline in a cool, well-ventilated

area. Never store unit or fuel container

inside where there is an open flame or

spark, such as a hot water heater, furnace,

etc.

5. Never remove fuel fill cap, or add fuel

to fuel tank, if engine is running or hot.

Allow the engine to cool for several min-

utes before filling the fuel tank. Always

replace fuel fill cap before starting engine.

6. Never refuel unit indoors. Refuel out-

doors in a well-ventilated area only.

7. Check the gasoline level in the fuel tank

outdoors, before starting the engine.

Reinstall the fuel tank cap securely and

clean up any spilled gasoline before

starting the engine.

8. Do not smoke while mowing.

9. Move the unit away from gasoline

fumes before starting the engine.

OPERATION

1. Keep the plastic blade protector on the

cutter bar blade until you are ready to start

the engine.

2. Do not put hands or feet near or under

any moving parts. Keep clear of the cutter

bar at all times while the engine is

running.

3. Never leave the operator position while

the engine is running. Stop

the engine, disconnect the

spark plug wire and move it

away from the spark plug to

help prevent accidental

starting whenever leaving the unit unat-

tended. On electric start models, remove

the ignition key to help prevent accidental

starting or unauthorized use.

4. Before removing or installing the

plastic blade protector, shut the engine

off, disconnect the spark plug wire, and

prevent it from touching the spark plug.

On electric start models, also remove the

ignition key from the keyswitch.

5. Do not change the engine governor set-

ting. Over-speeding may damage the

engine and unit and will void the warranty.

See an authorized engine service dealer if

an engine problem exists.

6. Disengage the cutter bar when

crossing gravel drives, walkways or roads.

7. Watch for, and avoid, traffic when

operating near roadways.

8. Disengage the cutter bar

drive and the wheel drive if

you are approached by a child,

inattentive person or a pet.

9. Before inspecting, adjusting or

repairing the unit or cutter

bar, stop the engine, let all

moving parts come to a

complete stop, disconnect

the spark plug wire, and

install the plastic blade guard. On electric

start models, remove the ignition key from

the keyswitch.

10. If the unit should start to vibrate

abnormally, stop the engine, wait for all

moving parts to stop completely, discon-

nect the spark plug wire and prevent it

from touching the spark plug. Remove the

engine ignition key on electric start

models. Inspect the unit for damage.

Repair any damage before continuing.

11. If the unit should strike a foreign

object, stop the engine, wait for all moving

parts to stop completely, disconnect the

spark plug wire and prevent it from

touching the spark plug. Remove the

engine ignition key on electric start

models. Inspect the unit for damage.

Repair any damage before continuing.

12. Do not run the engine in an enclosed

area. Engine exhaust contains carbon

monoxide, a deadly, poisonous gas that is

odorless, colorless and tasteless. Always

run the engine outdoors with adequate

ventilation.

13. Always mow across the face of slopes.

Do not operate unit on slopes steeper than

15°.

14. Keep all movements on a slope slow

and gradual. Do not make sudden changes

in speed or direction.

15. Do not touch engine parts which may

be hot from operation. Let parts cool for

several minutes before going near them.

16. Keep children out of the mowing area

and under the supervision of a responsible

adult other than the unit operator.

17. Before and when backing, check for

and avoid obstacles and hazards.

18. Disengage the cutter bar drive when

not mowing.

19. Do not mow near drop-offs, ditches or

embankments. If a wheel drops off an

edge, the unit could suddenly overturn.

20. To help reduce fire hazard, keep the

engine free of grass, leaves, grease and

other debris.

CHILDREN

1. Tragic accidents can occur if the oper-

ator is not alert to the presence of chil-

dren. Children are often attracted to the

unit and the mowing activity. Never

assume that children will remain where

you last saw them.

2. Never allow children to operate the

unit, even under adult supervision. Local

regulations may restrict operator age. Only

allow responsible adults, who are familiar

with these instructions, to operate the

unit.

Section 1: Safety 5

3. Never carry children as passengers.

Do not carry ANY passengers. They may

fall off, become seriously injured, or inter-

fere with safe unit operation.

4. Keep children out of the work area and

under the watchful care of a responsible

adult other than the unit operator.

5. Be alert and turn unit off if children

enter the area.

6. Before and when backing, look behind

and down for children.

7. Use extra care when approaching blind

corners, shrubs, trees, or other objects

that may obscure vision.

8. Keep children away while performing

maintenance or adjustments.

MAINTENANCE AND STORAGE

1. Before inspecting, cleaning, adjusting

or repairing the unit, stop the engine, let

all moving parts come to a

complete stop, disconnect

the spark plug wire, and

install the plastic blade

guard on the cutter bar. On

electric start models, remove the ignition

key from the keyswitch.

2. Always wear sturdy footwear (prefer-

ably steel-toed shoes), long trousers,

hearing and eye protection while doing

any maintenance on the unit. Do not wear

loose-fitting clothing, jewelry, scarves,

ties, etc., which could get caught in

moving parts. Tie up or restrain hair.

3. Install the plastic blade guard before

removing the cutter bar assembly and

wear sturdy leather gloves to help protect

your fingers and hands.

4. Keep children away while performing

maintenance or adjustments.

5. Remove any metal jewelry when

working on or near electrical system com-

ponents.

6. Use only original equipment replace-

ment parts. Parts manufactured by others

could create a hazard even though they

may fit on the unit.

7. Keep the equipment in safe working

condition. Keep all nuts, bolts and screws

tight. Frequently check the engine

mounting bolts and cutter bar mounting

bolts for tightness.

8. Provide safe, adequate light in your

work area. NEVER USE AN OPEN FLAME

FOR ILLUMINATION! Use only a portable

safety light enclosed in a wire cage for

working on unit. NOTE:

Hot filaments from a

broken light bulb can

ignite spilled fuel or oil.

9. If the unit has gasoline in its fuel tank,

do not store it inside a building where

fumes from the gasoline could reach an

open flame or spark. Let the engine cool

before storing the unit.

10. Store gasoline in a cool, well-venti-

lated area, away from spark- or flame-pro-

ducing equipment. Store gasoline in an

approved container, away from children.

11. Keep unit free of grass, leaves or

build-up of other debris. Clean up oil or

fuel spillage. Allow unit to cool before

storing.

12. Replace muffler if worn or defective.

13. Use extra care when loading or

unloading unit into a trailer or truck.

14. Do not use food or beverage con-

tainers to store waste materials. Using

such containers could result in accidental

poisoning.

ENGINE

1. Before starting the engine or operating

the unit, read the separate engine manual

completely. Read and follow all safety

instructions provided in that manual.

2. BEFORE SERVICING THE ENGINE:

Disconnect the spark plug wire and keep it

from touching the spark plug.

3. Keep the engine free of grass, leaves,

oil, and grease.

4. Engine exhaust is extremely hot. Keep

grass, oil, fuel, and other combustible

materials far away from engine exhaust.

5. Do not change the engine governor set-

ting. Over-speeding may damage the

engine and unit and will void the warranty.

See an authorized engine service dealer if

a problem exists.

6. Never run an internal combustion

engine inside a closed area. Engine

exhaust contains carbon monoxide gas, a

deadly poison. Carbon monoxide is odor-

less, colorless and tasteless. Do not

operate the unit near buildings, windows,

or air conditioners. If the engine is run in a

garage, open all doors and allow for ade-

quate ventilation.

Place Hand Here When

Pulling Starter Rope

Hot Surfaces

Warning

Sharp Cutter Bar

Blades Danger

Danger - Keep Hands

and Feet Away

On Rear Panel

Warning - Operating

Engine - Electric

Start Only

Cover “Top” Decal

Engine Throttle Settings

SAFETY DECAL LOCATION

Operator Presence

Controls

SAFETY DECALS

Keep all safety decals clean and in

good condition. The location of each

decal is shown in Figure 1-2.

Refer to the Parts List for ordering

replacement decals.

Figure 1-2

Assembly

Section

BEFORE ASSEMBLY

Carefully follow all steps in this section to

assemble the unit.

CARTON INSPECTION

Inspect the unit immediately after delivery.

Check the carton and contents for any

damage.

Contact the carrier (trucking company)

immediately if the unit is damaged. Inform

the carrier that you wish to file a claim.

The carrier will let you know how to pro-

ceed with the claim. To protect your

rights, file a written claim with the carrier

within 15 days of receiving the unit. Con-

tact our service department if you need

assistance.

Do not start the engine until oil is added!

The engine is shipped without oil.

Engine damage will occur if engine is

started before oil is added.

IMPORTANT: Oil must be added before

starting the engine. Starting or operating

the engine without oil will damage the

engine and void the warranty. See the

engine manual.

Do not overfill engine with oil. Engine

damage will occur.

Cutter bar blades are extremely sharp.

To help avoid serious injury:

• Keep the plastic guard on the CUTTER

BAR ASSEMBLY when the unit is not

running.

• Wear heavy leather gloves when han-

dling the cutter bar.

• Do not place fingers between blades.

Amputation could result.

UNPACKING THE UNIT

The cutter bar blade and attached plastic

blade guard are packaged separately

within the main shipping crate. Leave the

cutter bar blade attached to the shipping

pallet until instructed to remove it.

The handlebars are packed on each side of

the unit, connected with wiring to the

underside of the unit. IMPORTANT: Do

not damage the wiring when removing the

handlebars from the carton.

The included parts and hardware required

for assembly are listed on the following

pages.

Remove and discard the two screws that

secure the front of the unit to the wooden

pallet (see Fig. 2-1). However, leave the

unit on the pallet until instructed to

remove it. Fig. 2-1 shows the position of

the unit for assembly.

TOOLS/MATERIALS NEEDED

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

adjustable wrenches)

(1) Adjustable Wrench

(1) 13mm Socket

(1) Phillips (or thin straight blade)

Screwdriver

(1) All-purpose Oil

(1) Tire Pressure Gauge

(1) Measuring Tape or Ruler

DANGER

CAUTION

WARNING

Fig. 2-1

Remove shipping

screws

Remove control rods

from handlebar

To prevent personal injury or property

damage, do not start the engine until all

assembly steps are complete and you

have read and understand the safety and

operating instructions in this Manual

and the engine manual.

WARNING

Section 2: Assembly 7

Ref. Description Qty.

Right Handlebar (shipped connected to

unit by wiring)...............................................1

Left Handlebar (shipped connected to

unit by wiring)...............................................1

1 Hex Head Capscrew, 5/16"–18 x 2-1/4" ........2

2 Locknut, 5/16"–18.......................................10

3 Handlebar Bridge ..........................................1

4 Cable Ties (total of six - two already

installed on unit)...........................................4

5 Hex Head Capscrew, 1/4"–20 x 2" .................1

6 Locknut, 1/4".................................................1

7 Control Rod ..................................................2

8 Hair Pin ..................................................2

9 Plastic Blade Guard (on blade)......................1

10 Cutter Bar......................................................1

HARDWARE IS APPROXIMATE SIZE SHOWN

Large parts (with

*) shown reduced

10*

Ref. Description Qty.

-- Right Handlebar (shipped connected to

unit by wiring)..............................................1

-- Left Handlebar (shipped connected to

unit by wiring)..............................................1

1 Hex Head Capscrew, 5/16"–18 x 2-1/4" ...........2

2 Toplock Nuts, 5/16"–18 (to mount

handlebars)..................................................2

2a Nylock Nuts, 5/16"–18 .....................................8

3 Handlebar Bridge .............................................1

4 Cable Ties (total of six - two already

installed on unit) ..........................................4

5 Hex Head Capscrew, 1/4"–20 x 2" ....................1

6 Locknut, 1/4"....................................................1

7 Control Rod (attached to handlebars) ..............2

8 Hair Pin Clip.....................................................2

9 Plastic Blade Guard (on Cutter Bar Assembly).1

10 Cutter Bar.........................................................1

NOTE: Control rods are attached to one handlebar with a wire tie (see Fig. 2-1). Cut

wire tie and remove rods before starting assembly steps.

10*

HARDWARE IS SHOWN APPROXIMATE SIZE

(Large parts [with *] shown reduced size)

8 Section 2: Assembly

11*

15*

Ref. Description Qty.

11 Mounting Bracket (already installed).............1

12 Hex Flange Screw, 3/8"–16 x 1-1/4" long ......3

13 Flat Washer, 3/8"...........................................3

14 Centerlock Nut, 3/8"–16................................3

15 Knife Head.....................................................1

16 Metric Hex Head Screw, M8 x M25...............2

17 Metric Internal Tooth Lockwasher, M8 .........2

18 Pitman Arm Assembly ..................................1

19 Shoe Holder..................................................2

20 Carriage Bolt, 5/16"–18 x 1" ..........................4

21 Shoe..............................................................2

22 U-Bolt, 5/16" x 18..........................................2

23 Flat Washer, 5/16".........................................4

24 Weed Diverter ...............................................1

25 Upper Hook ..................................................1

26 Doubler Plate ................................................1

27 Flange Nut 1/4"– 20.......................................2

28 Flat Washer, 1/4"...........................................1

29 Hex Head Screw, 1/4"–20 x 1-1/4" long.........1

30 Battery Charger (optional - not shown).........1

31 Key (In Keyswitch) (optional - not shown)....1

18*

19*

21*

24*

26*

Ref. Description Qty.

11 Loctite

Thread Fastener, (bottle or tube)....1

12 Hex Cap Screw, 3/8"–16 x 1-1/4" (Grade 8) ..3

13 Flat Washer, hardened, 3/8" ..........................3

14 Centerlock Nut, 3/8"–16................................3

15 Knife Head.....................................................1

16 Metric Hex Head Screw, M8 x M12...............2

-- Flat Washer, hardened, 5/16" (wire-tied to

knife head (Ref. 15) -- do not remove

until instructed to do so) ..........................2

18 Pitman Arm Assembly ..................................1

19 Shoe Holder..................................................2

20 Carriage Bolt, 5/16"–18 x 1" ..........................4

21 Shoe..............................................................2

22 U-Bolt, 5/16" x 18..........................................2

23 Flat Washer, 5/16".........................................5

24 Weed Diverter ...............................................1

25 Upper Hook ..................................................1

26 Doubler Plate ................................................1

27 Flange Nut 1/4"– 20.......................................2

28 Hex Head Screw, 1/4"–20 x 1-1/4" ...............1

29 Battery Charger (optional - not shown).........1

30 Key (optional - not shown) ...........................1

18*

19*

24*

26*

21*

15*

Section 2: Assembly 9

HANDLEBAR INSTALLATION

NOTE: Handlebar wiring from the oper-

ator presence controls (OPC) is connected

to a switch under the unit. DO NOT dis-

connect this wiring!

1. Before beginning assembly, disconnect

the spark plug wire from the spark plug.

2. Place the handlebars on the ground

behind the unit.

3. With the ends of the bridge (C,

Fig. 2-2) positioned as shown, insert the

bridge in between the handlebars into the

upper set of handlebar holes.

4. Align the holes in the plastic sleeves

(on the bottom ends of the handlebars)

with the corresponding handlebar holes in

the deck. For easier installation, apply a

small amount of oil to the sleeve ends.

5. Insert the bottom ends of the handle-

bars into their mounting brackets in the

deck (Fig. 2-3). Do not pinch or damage

the attached wiring. Align the screw holes

(it may be helpful to align the holes with a

punch or drift pin prior to installing the

screws in the next step).

NOTE: Position the handlebars with

thumb latches (F, Fig. 2-5) on the inner

sides of handlebars.

6. Secure each handlebar with a 5/16-18

x 2-1/4 hex head capscrew (A, Fig. 2-3)

and 5/16"-18 toplock nut (B).

NOTE: When correctly installed, the han-

dlebars feel loose. The looseness or “play”

is intentionally designed to reduce vibra-

tion which occurs during operation. The

rubber sleeves on the handlebar ends act

as “shock absorbers” and also help reduce

vibration.

WHEEL DRIVE CONTROL ROD

INSTALLATION

1. Place the control rods (D, Fig. 2-4)

BETWEEN the handlebars and UNDER the

bridge, with the threaded ends down. For

easier installation, apply oil or grease to

the threads. Thread the rods into the

pivots (E) twelve turns each. If necessary,

use a screwdriver or a punch to move the

pivots into position. Be sure that the wire

harness on each handlebar is located to

the outside of each control rod.

2. Insert the upper end of each control

rod (G, Fig. 2-5) into the plastic thumb

latch (F) slots, then outward through the

holes in the wheel drive levers (H).

3. Insert hair pin clips (J, Fig. 2-5)

through the hole in each control rod. Posi-

tion hair pin clips with loops up, as

shown.

CONTROL ROD ADJUSTMENT

1. With the controls positioned as shown

(Fig. 2-6), measure the gap between the

top of the slot in the thumb latch bracket

and the control rod. Do not put any pres-

sure on the handlebars when measuring.

The gap must measure 1-1/4" (32mm).

If adjustment is required, remove the hair

pin clip (J, Fig. 2-5) from the control rod.

Remove the control rod from the wheel

drive lever (H) and thumb latch (F). Turn

the control rod as needed to achieve the

1-1/4" (32mm) gap.

NOTE: Adjust the wheel drive control rods

properly. Improper adjustment will result

in broken thumb latches.

Install hair pins (D) OUTSIDE levers (C)

(l ft id h )

J on outside with loop up

Fig. 2-2

Fig. 2-3

Fig. 2-4

Fig. 2-5 Outer view of left handlebar

10 Section 2: Assembly

THROTTLE CONTROL LEVER

INSTALLATION

1. Unwind the throttle cable from around

the left side of the engine, then position

the throttle control lever (Z, Fig. 2-7) on

the inside of the right handlebar as shown

(Figs. 2-7 and 2-8). THE CABLE MUST BE

ROUTED UNDERNEATH THE CONTROL

ROD (see AA, Fig. 2-8).

2. Secure the throttle control lever to the

handlebar with a 1/4–20 x 2" hex-head

capscrew (A, Fig. 2-7) and 1/4"-20 locknut

(B). TO AVOID DAMAGING PLASTIC

ASSEMBLY, DO NOT OVER-TIGHTEN

SCREW AND LOCKNUT.

CABLE TIE INSTALLATION

Secure the throttle cable and OPC wiring

to the handlebars with cable ties (C, Fig.

2-8) to help prevent them from being

damaged during operation. Two of the

cable ties are already installed at the upper

end of the handlebars. Remove any slack

from the bottom of the OPC wires (see Fig.

2-8A) to avoid catching the cutter bar lever

on the wires. Twist the OPC wires (but not

the throttle cable) in a corkscrew pattern

along the length of the handlebars and

install the four cable ties (two on each

side). Cut off excess cable tie with scissors.

UNIT REMOVAL

Squeeze the four control levers on the

handlebars and carefully roll the unit from

off the shipping crate. Park the unit on a

flat, clean surface where you can complete

the remaining assembly steps.

CUTTER BAR ASSEMBLY

AND INSTALLATION

Cutter bar blades are extremely sharp!

To help avoid serious injury:

• When handling cutter bar, wear heavy

leather gloves and wrap cutter bar

with rags.

• Keep plastic guard on blade assembly

until you are ready to start engine.

• Contact with the blades will cause

serious personal injury.

Avoid contact with the cutter bar blades.

1. Remove the screws securing the cutter

bar to the crate. Wear heavy leather

gloves and wrap cutter bar with rags to

avoid cutting yourself on the blades.

2. Carefully remove the cutter bar from

the shipping crate. Keep the plastic blade

guard on the cutter bar to protect yourself

from injury.

IMPORTANT: To help prevent the unit

from tipping, have an assistant stand in

the operator position and firmly hold the

handlebars during installation of the cutter

bar.

3. REMOVE SPARK PLUG WIRE FROM

SPARK PLUG (IF ATTACHED).

4. Have an assistant available to hold the

unit firmly by the handlebars.

DANGER

" (32mm)

Gap here

(right side shown)

" (32mm)

Bridge

Fig. 2-6

Fig. 2-7

Fig. 2-8

Fig. 2-8A

Remove

slack in wire

(on both

handlebars).

Section 2: Assembly 11

Disconnect the spark plug wire from the

spark plug before attempting to install

the cutter bar. Move the spark plug wire

away from the spark plug and prevent the

wire from contacting the plug.

5. Center eccentric arm (A, Fig. 2-14), if

necessary, by moving cutter bar lever to

ON (Fig. 2-15) and pulling starter rope.

6. Position the cutter bar (B, Fig. 2-9) at

the front of the cutter bar mounting

bracket (C) as shown. Place the doubler

bracket (D) on the cutter bar and align the

three mounting holes as shown.

7. Apply a small amount of Loctite®

Thread Fastener (use only a small amount,

as a total of five screws need to be coated

during the assembly procedure) to the

threads of the three 3/8-16 x 1-1/4 hex

cap screws (E, Fig. 2-9). Have an assistant

hold the unit firmly by the handlebars and

raise the front of the unit a few inches off

the ground. Securely attach the cutter bar

and doubler bracket to the cutter bar

mounting bracket with the three hex cap

screws (E), 3/8 flat washers (F) and 3/8-

16 center locknuts (G). Torque to 35 ft-

lbs. if you have a torque wrench. Lower

the unit to the ground.

IMPORTANT: Allow the Loctite® to cure

for at least one hour (preferably 24 hours

at 72

F.) before operating unit.

8. Align the middle hole (B, Fig. 2-10) in

the cutter bar with the middle locknut (CC,

Fig. 2-10) on the cutter mounting bracket.

If needed, tap the ends of the cutting blade

back and forth (see inset, Fig. 2-10) to

align the middle hole (use a wood block to

avoid damaging the blade).

9. Slide the pitman assembly (H, Fig. 2-

10A-1) onto the post of the knife head (I).

The “Top” decal on the pitman assembly

must be facing up. Remove the two 5/16

hardened flat washers that are wire-tied to

the knife head for shipping purposes.

CAUTION

Fig. 2-9

Fig. 2-10

Fig. 2-10A

Tap top section of

cutting blade from

side-to-side to

align middle hole

(B) with middle

locknut (CC).

12 Section 2: Assembly

10. As shown in Fig. 2-10A, rotate the

pitman assembly sideways and slide the

shaft on the pitman assembly into the

hole in the eccentric arm (J). Next, rotate

the pitman assembly to its upright posi-

tion and turn the knife head so it is par-

allel with the cutting blade. Finally, align

the small centering pin on the bottom of

the knife head (I) with the middle hole in

the cutter bar (B, Fig. 2-10) and position

the knife head on the cutter bar.

11. Apply Loctite

Thread Fastener to the

two 8M x 12M hex head screws (L, Fig. 2-

10A) and place the two 5/16" hardened

washers (K) on the screws. Securely

attach the knife head to the cutter bar with

the two screws (torque to 16-20 ft-lbs if

you have a torque wrench).

12. At the inner set of mounting holes (M,

Fig. 2-11), position the shoe holders (N)

under the cutter bar. Securely attach each

shoe holder with two 5/16–18 x 1" car-

riage bolts (O) and 5/16–18 locknuts (P).

13. Securely attach the shoes (Q, Fig. 2-

12) to the bottom of the holders with a U-

bolt (R), 5/16" flat washers (S) and

5/16"-18 locknuts (T). Adjust the shoes

the same, to level the cutter bar assembly.

14. Oil the area beneath each hold-down

clip (U, Fig. 2-13) on the cutter bar.

15. Move the cutter bar lever (Fig. 2-15)

all the way right to the OFF position.

Cutter Bar On

Fig. 2-11

Fig. 2-12

Fig. 2-13

Fig. 2-14

Fig. 2-15

Section 2: Assembly 13

WEED DIVERTER INSTALLATION

NOTE: The weed diverter (V, Fig. 2-16) is

designed to vibrate from cutter bar

motion and the vibration helps clear

debris away from the front of the unit.

1. Thread a 1/4"–20 flange nut (W,

Fig. 2-16) onto the upper hook (X).

Secure the hook to the fender (as shown)

with a second 1/4"–20 flange nut (W)

located below the fender.

2. Insert a 1/4–20 x 1-1/4" screw (Y)

through a 1/4" washer (Z) and one end of

the weed diverter (V). Secure the screw to

the threaded post on the end of the eccen-

tric arm.

3. Stretch and hook the other end of the

weed diverter over the upper hook (X).

Fig. 2-16

ENGINE OIL

DO not add oil past FULL mark on dip-

stick. See the engine manual for details.

1. Squeeze the four control levers and

move the unit to a level area.

2. Unscrew the dipstick (A, Fig. 2-17).

3. Insert a clean funnel into oil fill hole

and slowly add correct amount and type

of oil specified in engine manual.

WARNING

4. While adding oil, pause frequently,

remove the funnel, replace the dipstick

and check the oil level.

5. When the oil level reaches the FULL

mark, replace and tighten the dipstick.

Wipe up any spilled oil.

BATTERY CHARGING

(for electric start models only)

Risk of serious personal injury or

property damage.

• Use only the battery charger supplied

with the unit. Use of any other battery

charger may damage the battery.

• Do not short circuit the battery by

touching the connectors or wires

together, or by touching metal objects

against the connectors.

• Remove all metal jewelry when

working near the electrical system.

• Do not charge the battery for more

than 48 hours.

NOTE: All units can be started using the

starter rope (B, Fig. 2-17) if the battery is

not charged.

Remove the battery charger (A, Fig. 2-18)

from the main shipping carton.

NOTE: The battery charger is designed

for indoor use only. Do not get the battery

charger wet. Keep the battery charger

away from water, rain, snow, etc.

Initially, charge the battery for 24 to 48

hours (24 hours minimum) before using

the electric starter.

Battery charging:

1. Plug the connector lead from the bat-

tery (B, Fig. 2-18) into the mating con-

nector (C) on the battery charger.

3. Plug the battery charger into a

grounded, 120-volt AC wall outlet.

4. Charge the battery for 24 to 48 hours

(24 hours minimum).

5. Unplug the battery charger from the

wall outlet first, then unplug the connec-

tors (B and C, Fig. 2-18).

WARNING

6. After initially charging the battery,

store the battery charger in an easily

remembered location out of the reach of

children.

7. Remember to charge the battery at the

start and end of each mowing season for

24 to 48 hours (24 hours minimum).

TIRE PRESSURE

Check tire pressure. Inflate both tires

equally to 10-17 psi.

Fig. 2-18

A (to grounded

wall outlet)

C (from battery

charger)

B (from battery)

Fig. 2-17

Learn the location and function of all con-

trols before starting the engine. For

detailed operating instructions, see the

“Operation” section of this manual.

A. THROTTLE/CHOKE CONTROL

LEVER

The throttle control lever (A, Fig. 3-1) is

located on the right handlebar. The throttle

control lever is used when starting and

stopping the engine, and regulates engine

speed (revolutions per minute, or RPM).

Engines without primer bulbs are

equipped with manual chokes. On these

engines, the CHOKE position is all the way

forward, past the FAST position.

Engines with primer bulbs do not have a

choke control.

B. OPERATOR PRESENCE

CONTROLS (OPC)

The operator presence controls (OPC) (B,

Figs. 3-1 and 3-2) are levers located above

the handgrips at the top of the handlebars.

The OPC is part of a safety system

designed for your protection. Never

attempt to bypass, disconnect or defeat

the OPC system.

If the OPC levers are released when either

the cutter bar drive or the wheel drive is

engaged, the OPC system should shut the

engine off. If the engine does not shut off,

DO NOT operate the unit until the OPC

system is repaired.

C. WHEEL DRIVE LEVERS

The wheel drive levers (C, Fig. 3-1) are

located beneath the handgrips on each

handlebar and control the wheel drive belt

system.

Squeezing the levers disengages the drive

belt and allows the unit to be moved man-

ually (freewheeling). Releasing the levers

engages the drive belt and causes the

wheels to move forward (when the engine

is running).

The wheel drive levers consist of two

parts: wheel drive levers (C, Fig. 3-2),

which engage and disengage the drive

wheels, and thumb latches (M), used for

locking the wheel drive levers into the dis-

engaged (freewheel) position.

D. ENGINE OIL DIPSTICK/FILL HOLE

The engine oil dipstick (D, Figs. 3-1

3-3) and oil fill hole is located on top of

the engine.The dipstick is used to check

the engine oil level. Oil is added through

the fill hole.

E. SHOES

Shoes (E, Fig. 3-1) are located on the rear

edge of the cutter bar.

The shoes adjust the height of the cutter

bar to clear ground debris that might

damage or jam the blades.

Features and Controls

Section

Before operating your machine, carefully

read and understand all safety, controls

and operating instructions in this

Manual, the separate Engine Owner’s

Manual, and on the decals on the

machine.

Failure to follow these instructions can

result in serious personal injury.

WARNING

Fig. 3-1

OFF

INSET

Section 3: Features and Controls 15

F. CUTTER BAR (WITH GUARD)

Sharp cutter bar blades move back and

forth at high speed. Contact with the

blades will cause serious personal

injury. Keep the protective plastic cutter

bar guard in place and avoid contact with

the cutter bar blades.

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

lower front of the unit.

For safety, keep the plastic guard on the

cutter bar until just before starting engine.

The cutter bar assembly scissors back and

forth 14 times per second and can sever

grass, weeds, brush and saplings up to

one-inch thick.

G. FUEL TANK CAP

The fuel tank cap (G, Figs. 3-1 and 3-3) is

located on the top right side of the engine.

Keep the area around the fuel tank cap

clean and free of debris to help avoid con-

taminating the fuel or clogging fuel

system.

H. STARTER ROPE HANDLE

The starter rope handle (H, Figs. 3-1 and

3-3) is located on top of the engine at the

edge of the flywheel screen.

The starter rope handle is used to pull-

start the engine.

NOTE: Electric-start models can also be

pull-started with the starter rope.

J. ENGINE KEYSWITCH

(ELECTRIC-START UNITS ONLY)

The engine keyswitch (J, Fig. 3-1—INSET)

is used to start the engine on electric-start

models.

K. CUTTER BAR LEVER

The cutter bar lever (K, Fig. 3-1—INSET)

is located at the rear of the unit.

The cutter bar lever engages (ON position)

and disengages (OFF position) the cutter

bar drive and is operated by foot. The OFF

position is all the way to the right, and the

ON position is all the way to the left.

L. WEED DIVERTER

The rubber weed diverter (L, Fig. 3-1) is

located on the top front of the unit and

stretches from the eccentric arm to the

top of the hood.

The weed diverter is designed to vibrate

from cutter bar motion and the vibration

helps clear debris away from the front of

the unit.

N. ENGINE PRIMER BULB

Some engines are equipped with an

engine primer bulb (N, Fig. 3-4).

Pushing the bulb “primes” or prepares the

engine for starting by injecting fuel into

the combustion chamber.

WARNING

Fig. 3-3

Fig. 3-4

DISENGAGED

Fig. 3-2

Operation

Section

BEFORE OPERATION

PRE-START CHECKLIST

Perform the following checks before each

use of the unit:

✔ Review Section 1: Safety, and Section

3: Features and Controls.

✔ Inspect the operating area. Watch for

hidden obstacles, such as gullies or

covered posts, holes, and other hidden

obstructions. Remember, tall grass or

vegetation can hide hazards.

✔ Connect the spark plug wire.

✔ Disengage the cutter bar lever.

✔ Lock the wheel drive levers into the

disengaged position (Fig. 4-2).

✔ Check the unit for loose or missing

parts and hardware.

✔ Check control rod adjustment before

each use and adjust as needed (see

Section 2: Assembly.

✔ Check tire pressure. Inflate both tires

equally (10-17 psi / 68.5-117 KPa).

✔ Check the amount of gasoline in the

fuel tank.

✔ Check that the shoes are set to the

proper cutting height for the terrain.

✔ Remove the plastic blade guard just

before starting engine.

✔ Before starting the engine, check the

engine oil level (see Section 2:

Assembly.

✔ Perform the operator presence control

(OPC) system test after starting unit.

FILL THE FUEL TANK

GASOLINE IS HIGHLY FLAMMABLE

AND ITS VAPORS ARE EXPLOSIVE.

TO HELP PREVENT PERSONAL

INJURY OR PROPERTY DAMAGE:

• Check the fuel level in the fuel tank

before starting the engine.

• Never fill fuel tank indoors. Do not add

gasoline to the tank with the engine

running, or when the engine is hot.

Allow the engine to cool for several

minutes before filling the fuel tank. Do

not overfill the tank.

• Re-install the fuel tank cap securely

after filling, and clean up any spilled

gasoline before starting the engine.

• Keep gasoline and its vapors away

from all sources of sparks and flame.

• Move unit away from gasoline fumes

before starting the engine.

Use clean, fresh unleaded regular automo-

tive gasoline. See engine manual for spe-

cific fuel octane information.

1. Unscrew the fuel tank cap (A, Fig. 4-1).

Add gasoline. Leave at least two inches of

space below the filler neck to allow room

for expansion.

2. Re-install the cap. Wipe up spilled

gasoline.

ADJUST THE SHOES

With the plastic blade guard installed on

the cutter bar, loosen the nuts securing

the U-bolts and adjust the shoes (A, Fig.

4-6) so the cutter bar clears ground clutter

such as gravel, broken glass and other

small, hard objects, which might damage

the cutter bar or blade. Adjust the shoes

equally, so the blade is level. Securely

tighten the U-bolts when the shoes are

adjusted.

STARTING THE ENGINE

• Always squeeze the wheel drive levers

up against the handlebar grips and

place the control rods into the thumb

latch slots (in the disengaged posi-

tion) before starting the engine.

• Always move the cutter bar lever to

the OFF position before starting the

engine.

• Do not operate the unit when children

or bystanders are in the operating

area.

• Never run the engine in an enclosed

area. Engine exhaust contains carbon

monoxide, a deadly poison that is

odorless, colorless and tasteless. Do

not operate the equipment near build-

ings, windows, or air conditioners.

Before starting the engine, place the unit

on level ground and check the oil level

(see instructions for adding oil in the

“Assembly” Section).

TO START THE ENGINE:

1. Connect the spark plug wire to the

spark plug (if necessary).

2. Move the cutter bar lever to the OFF

position (Fig. 4-1) with your foot. Remove

the plastic blade guard. Stand directly

behind the unit in the operator position.

DANGER

Cutter Bar Off

Fig. 4-1

Before operating your machine, carefully

read and understand all safety (Section

1), controls (Section 3) and operating

instructions (Section 4) in this Manual,

in the separate Engine Owner’s Manual,

and on the decals on the machine. Keep

the blade guard in place on the cutter bar

when the unit is not in use.

Failure to follow these instructions can

result in serious personal injury or prop-

erty damage.

WARNING

Section 4: Operation 17

3. Squeeze the wheel drive levers (E, Fig.

4-2) and pull slightly backward and down

on the thumb latches (D) until the wheel

drive control rods (F) drop into the slots in

the thumb latches.

4. Move the throttle control lever (G, Fig.

4-3) all the way forward.

For engines equipped with a primer bulb,

push the bulb three times. When

restarting a warm engine, priming is usu-

ally unnecessary, although cool weather

may require priming to be repeated.

5. Pull-starting (all units can be pull

started):

Place one hand on the right handlebar

(see the decal on the handlebar) to stabi-

lize the unit when pulling the starter rope.

Pull the starter rope handle (B, Fig. 4-1)

until some resistance is felt, then pull

rapidly to start the engine. Do not allow

the rope to snap back– let it rewind gradu-

ally. Repeat as necessary until the engine

starts.

NOTE: If the engine fails to start, see the

engine manual.

Do not crank the starter for more than

five seconds. If the engine does not

start, wait one minute before trying to

start again to help prevent overheating

or damaging the electric starter.

6. On electric start units:

Turn the key clockwise and hold (no

longer than five seconds) until the engine

starts. Release the key. Repeat if neces-

sary, after pausing for one minute. Elec-

tric-start units can also be pull started.

7. As the engine warms up, move the

throttle control lever to SLOW until ready

to begin mowing. Always mow with the

throttle control lever in the FAST position.

THROTTLE SETTING

ALWAYS OPERATE WITH THE ENGINE AT

FULL THROTTLE (FAST). While operating

under heavy load conditions, listen to the

engine RPM. If the engine begins to slow

down, operate slowly and allow the engine

RPM to increase.

STOPPING THE ENGINE

To stop the engine, move the throttle con-

trol lever to the STOP position.

For electric-start units, turn the key

counter-clockwise and remove the key

from the keyswitch.

OPERATOR PRESENCE CONTROL

(OPC) SYSTEM TEST

If the engine does not stop when either

Operator Presence Control (OPC) lever is

released, stop the engine, and wait for

all moving parts to come to a complete

stop. Move the cutter bar lever to the

OFF position. Replace the plastic blade

guard on the cutter bar. Disconnect the

spark plug wire and prevent it from con-

tacting the spark plug. On electric-start

units, remove the ignition key. Do not

use the unit until the OPC System is

repaired. Contact an authorized dealer

for repairs. Failure to follow these

instructions could result in personal

injury or property damage.

Perform the operator presence control

(OPC) system test before each use of the

unit. When the cutter bar is engaged, the

OPC system should shut the engine off

when both OPC levers are released.

1. Remove the plastic blade guard from

the cutter bar.

2. Start the engine.

3. Hold down the left operator presence

control (OPC) lever (C, Fig. 4-2), then place

the cutter bar lever in the ON position (Fig.

4-1).

4. Release the left OPC lever. The engine

should stop in a few seconds.

5. Restart the engine. Engage the wheel

drive lever. Release both OPC levers, one

at a time.

If the engine stopped within a few seconds

after releasing each lever, the OPC system

is working properly.

If the engine does not stop within a few

seconds after releasing each lever, per-

form the following steps:

a) Stop the engine. Wait for all moving

parts to stop. Move the cutter bar lever to

the OFF position. Replace the plastic

blade guard on the cutter bar. Disconnect

the spark plug wire, and prevent it from

contacting the spark plug. On electric-

start units, remove the ignition key.

b) Check that the wire connectors

leading from the operator presence con-

trols on the handlebars are firmly con-

nected to the screw at the front of the

engine, and to the engine mounting bolt.

If these connections are loose, tighten,

then repeat the test procedure.

WARNING

CAUTION

FAST

SLOW

STOP

CHOKE

FAST

SLOW

STOP

Engines with

primer bulb

Engines without

primer bulb

DISENGAGED

➠

Fig. 4-2

Fig. 4-3

Fig. 4-4

WHEEL DRIVE

DISENGAGED

(Freewheel Position)

18 Section 4: Operation

c) If the engine still does not stop

within a few seconds after releasing

either lever, the OPC system is not func-

tioning properly. DO NOT operate the

unit. Contact the nearest authorized

dealer or our factory for repair. DO NOT

operate the unit until the operator pres-

ence control system (OPC) is repaired.

For general OPC system operation infor-

mation, refer to Note 4-1.

OPERATION

WHEEL DRIVE LEVER OPERATION

Releasing the wheel drive levers (E, Fig.

4-5 ) will engage the wheel drive and

propel the unit forward (note wheel drive

lever position when engaged in Fig. 4-5).

To stop forward movement, squeeze both

wheel drive levers all the way up against

the grips.

To lock the levers in the disengaged posi-

tion, squeeze wheel drive levers and pull

slightly backward and down on the thumb

latches (D) until the wheel drive control

rods (G) drop into the slots (F) in the

thumb latches.

Use the wheel drive levers to control

steering. To turn toward the right, squeeze

the right lever up against the handlebar

grip to allow the unit to pivot on the right

wheel. To turn toward the left, squeeze the

left wheel drive lever.

CUTTER BLADE OPERATION

To engage the cutter blade:

1. Remove the plastic blade guard from

the cutter bar.

2. Start the engine.

3. Move the cutter bar lever (Fig. 4-7) all

the way to the left, to the ON position.

The cutter bar assembly will move rapidly

back and forth.

NOTE: Unit vibrates when cutter bar drive

is engaged.

If the handlebars are gripped too tightly,

vibration increases. DO NOT attempt to

hold the unit down. Guide the unit with a

light grip on the handlebars.

To disengage the cutter bar drive, move

the cutter bar lever all the way to the right

to the OFF position (Fig. 4-7). Always dis-

engage the cutter bar drive, stop the

engine and re-install the plastic blade

guard when transporting the unit.

USE AND ADJUSTMENT OF SHOES

Use the shoes (A, Fig. 4-6) to adjust cutter

bar height to avoid stones and debris, or

when mowing areas containing loose dirt

or soft, spongy growth.

NOTE: Shoes can be staggered along the

cutter bar and set at different heights to

accommodate unusual terrain conditions.

NOTE: Shoes are not always necessary,

particularly when mowing lush, green veg-

etation on even terrain free of debris.

GENERAL OPERATION

• Before operating the unit, remove all

debris, small bushes and trees thicker than

one inch in diameter from the operating

area. Cut trees low enough for the cutter

bar to clear them.

ALWAYS DISENGAGE THE CUTTER BAR

DRIVE WHEN TRANSPORTING THE

UNIT!

• Always run the engine with the throttle in

the FAST position.

• Use the wheel drive control levers to

steer the unit.

• Use a slow ground speed when using the

unit for the first time. Increase speed as

you become familiar with operating the

unit.

• Vibration is normal. Grip the handlebars

lightly.

• If forward motion is stopped or the unit

hits an object, immediately disengage the

wheel drive levers. This will help prevent

belt slippage, and premature wear, and the

wrapping of tall grass and vegetation

around moving parts.

• Ease into heavy cutting by first slightly

disengaging the wheel drive levers. Do not

start heavy cutting at full wheel speed. Let

the blades saw their way through the

material being mowed a little at a time.

The unit will usually cut any brush and

saplings which can fit between the blades.

To Operate:

1. Move the cutter bar lever to the OFF

position. Remove the blade guard. Disen-

gage the wheel drive levers.

2. Connect the spark plug wire to the

spark plug. Start the engine. Stand behind

the unit in the operator position. Move the

throttle lever to the FAST position.

3. To move forward, release the wheel

drive levers.

NOTE: To move the unit without mowing,

engage the wheel drive without engaging

the cutter bar drive.

Proper Operator Presence

Control (OPC) System Operation

1. Engine WILL stop if both conditions A

and B exist:

A. Both OPC levers released.

B. Cutter bar lever in ON position or

thumb latches unlocked (wheel drive

ON).

2. Engine WILL NOT stop if either condition

“C” or “D” exist:

C. One or both OPC levers engaged.

D. Cutter bar lever in OFF position and

thumb latches engaged (wheel drive

OFF).

Note 4-1

ENGAGED

DISENGAGED

To Release

Fig. 4-5

Fig. 4-6

WHEEL DRIVE

DISENGAGED

(Freewheel)

Cutter Bar Off

Fig. 4-7

Section 4: Operation 19

Turning:

4. To turn the unit, hold the wheel drive

control lever up against the handlebar grip

(Figure 4-8) on the side you are turning

toward. The unit will pivot on the sta-

tionary wheel.

Guide the unit completely through the turn

and slightly release the wheel drive control

lever as necessary to control the unit

through the turn.

BECOME FAMILIAR WITH MOVING AND

TURNING THE UNIT BEFORE ENGAGING

THE CUTTER BAR!

Cutting:

5. Move the cutter bar lever to the ON

position (Fig. 4-7). The unit should begin

vibrating, which is normal, and the cutter

blade will move rapidly from side to side.

6. When mowing, proceed slowly and

with caution.

DISENGAGE WHEEL DRIVE IF UNIT

STOPS MOVING FORWARD. DEBRIS

MAY WRAP AROUND MOVING PARTS IF

WHEEL DRIVE IS ENGAGED AND THE

UNIT IS NOT TRAVELING.

If the Unit Becomes Stuck

or Stops:

1. Disengage the cutter bar and wheel

drive control levers.

2. Look behind for and avoid obstacles,

back up a few steps, and check the oper-

ating area. The terrain may not be suitable

for safe or continued operation.

3. Poor traction may be caused by grass

wrapping around the tires or the axle.

Here are some tips to help avoid grass

wrapping:

• Allow grass to dry before cutting.

• Do not allow tires to spin on cut grass.

• As soon as any wrapping begins, you

should do the following:

a.) Disengage the cutter bar and wheel

drive control levers.

b.) Look behind for and avoid obsta-

cles and then pull the unit back-

wards. This should unwind the

grass.

c.) If unsuccessful, and you have an

assistant available, have the assis-

tant squeeze the wheel drive

levers, tilt the machine, and pull

the unit backward as you clear the

grass away.

d.) If necessary, the wheels can be

removed to untangle the grass.

See “Clearing Wheel Wrap” in

Section 5: Maintenance for

detailed instructions.

If the Cutter Blade Should Clog:

1. Disengage the cutter bar lever and the

wheel drive levers.

2. Check behind for and avoid obstacles.

3. Pull the unit rearward a few feet.

4. Push down on the handlebars and raise

the cutter blade slightly off the ground.

5. Re-engage the cutter bar lever to shake

excess material off the cutter bar.

6. Lower the unit, re-engage the wheel

drive levers and continue mowing.

OPERATING ON SLOPES

Do not operate on slopes with an incline

greater than 15°. Oil will slant away

from internal engine parts, reducing

lubrication. Do not mow straight down a

slope or hill. Mow from side to side.

Mow with the carburetor on the high side

to help prevent oil spillage. Failure to

follow these instructions may result in

personal injury or property damage.

Keep the oil level at FULL, especially when

mowing on slopes. DO NOT operate on

slopes with an incline greater than 15°.

Recheck the oil level every 30 minutes of

operation. Oil will shift in the crankcase

and excess tilting of the unit could leave

engine parts unlubricated, which will

result in engine damage.

Always mow slopes (hills) from side-to-

side, not up and down. Do not mow on

slopes with an incline greater than 15°.

Mow with the carburetor on the high side

of the slope.

STOPPING

If the wheels do not stop turning when

you disengage the wheel drive levers

(pull the wheel drive levers up against

the handlebar grips), lock the thumb

latches, stop the engine, wait for all

moving parts to come to a complete

stop, disconnect the spark plug wire and

prevent it from contacting the spark

plug. Do not use the unit until the wheel

drive has been repaired. Failure to do so

could result in personal injury or prop-

erty damage.

NORMAL STOPPING

1. Disengage the wheel drive levers (pull

the levers up against the handlebar grips).

2. Pull slightly backward and down on the

thumb latches and lock the wheel drive

rods into the thumb-latch slots.

3. Move the cutter bar lever to the OFF

position.

4. Move the throttle lever to the STOP

position. Wait for all moving parts to stop

completely.

5. Disconnect the spark plug wire from

the spark plug to help prevent accidental

starting. Remove the key from the

keyswitch on electric-start units.

EMERGENCY STOPPING

To stop forward motion: Squeeze both

wheel drive levers up against the handle-

bars.

To stop cutter blade movement: Move the

cutter bar lever to the OFF position.

If operating properly, the Operator Pres-

ence Control (OPC) system will stop the

unit within a few seconds when the han-

dlebars are released if the cutter bar or

wheel drive levers are engaged.

If the engine does not stop when either

operator presence control (OPC) lever is

released, stop the engine and wait for all

moving parts to come to a complete

stop. Move the cutter bar lever to the

OFF position. Replace the plastic blade

guard on the cutter bar. Disconnect the

spark plug wire and prevent it from con-

tacting the spark plug. On electric-start

units, remove the ignition key. Do not

use the unit until the OPC System is

repaired. Contact an authorized dealer

for repairs. Failure to follow these

instructions could result in personal

injury or property damage.

WARNING

DISENGAGED

➠

To Disengage

Wheel Drive

Fig. 4-8

Maintenance

Section

IMPORTANT: Many of the maintenance

procedures in this section are required

only as needed or when a part needs

replacement. Other procedures are fully

described in this section but not listed in

this chart.

NOTE: If unit must be tipped for an

excess of 5 minutes for any reason, drain

oil from unit to prevent leakage.

NOTE: Some maintenance procedures

require expertise and/or tools which may

not be available to the average person. Read

each procedure thoroughly and note any

required special tools before beginning

maintenance. Procedures can be performed

by your local dealer. Advice is available

from our Technical Service Department (see

back cover).

TIRE PRESSURE

Check tire pressure. Inflate both tires

equally (10-17 psi).

CLEARING WHEEL WRAP

Occasionally, tall grass may wrap around

the wheel axle (known as “wheel wrap”),

making maneuvering the unit difficult or

impossible. This procedure explains how

to clear wheel wrap (also see “If the unit

becomes stuck or stops” on page 19).

To Disassemble:

NOTE: Performing all steps listed may not

be required! Clear grass or other matter

from around the axle and belt housing

after each step until grass or other matter

is eliminated, then reassemble unit.

Repeat for other side as required.

1. Stop the engine, wait for all moving

parts to come to a complete stop, discon-

nect the spark plug wire and prevent it

from contacting the spark plug.

2. Slide belt cover (A, Fig. 5-1) up and off

unit.

3. Remove three wheel mounting nuts (B)

and slide wheel/tire assembly (C) and belt

seal (F) off axle. (A sheet metal spacer

may also come off with the wheel/tire

assembly. If so, replace the spacer on the

axle.) The belt drive pulley shown in Fig.

5-1 will remain on the axle.

4. Clear grass or other matter from the

exposed areas.

To Re-Assemble:

1. Slide wheel/tire assembly (C, Fig. 5-1)

onto axle. Note that belt seal tabs (F) fit

inside the belt guard (D).

2. Secure wheel/tire assembly with three

mounting nuts (B) removed earlier.

3. Install drive belt cover (A). Note that

finger (E) on drive cover points toward the

front of the unit.

WHEEL DRIVE CONTROL ROD

ADJUSTMENT

NOTE: This adjustment does not control

drive belt tension. Springs (B, Fig. 5-2)

control drive belt tension.

Before inspecting, cleaning or

servicing the machine, shut off engine,

wait for all moving parts to come to a

complete stop, disconnect spark plug

wire and move wire away from spark

plug. Remove ignition key on electric

start models. Install plastic blade guard

on cutter bar assembly.

Failure to follow these instructions can

result in serious personal injury or prop-

erty damage.

WARNING

MAINTENANCE SCHEDULE

PROCEDURE NOTES

Adjust hold-down clips 3, 6, 7

Check and tighten nuts and bolts 4, 6, 7

General lubrication 3, 6, 13

Check parts for wear 6, 7

Check motor oil level 2, 3, 9

Change motor oil 8, 5, 7, 9

Service air filter system 5, 6, 7, 9

Check spark plug 6, 7, 9

Charge battery 1, 6, 7, 10, 11

Oil drive chain 4, 6, 7

Oil all cutter bar parts 3, 6, 7

Oil hold-down clips 3, 6, 7

Check tire air pressure 4, 12

NOTES

1 - Before first use.

2 - Before each use.

3 - Every 5 operating hours.

4 - Every 10 operating hours.

5 - Every 25 operating hours.

6 - Start of season.

7 - End of season.

8 - After first two operating hours.

9 - See Engine Owner’s Manual for service

recommendations.

10 - Charge battery for 24 (minimum) to 48

hours.

11 - After extended storage.

12 - Inflate each tire equally, 10 - 17 psi.

13 - Parts require lubrication at different time

intervals. Refer to this Section for more

lubrication information.

" (32mm)

Gap here

(right side shown)

" (32mm)

Fig. 5-1

Right Handlebar

Fig. 5-2

Fig. 5-3

Section 5: Maintenance 21

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to

come to a complete stop, disconnect spark plug wire and move wire away from spark plug. Remove

the key from the keyswitch on units so equipped.

Failure to follow these instructions can result in serious personal injury or property damage.

WARNING

1. Stop the engine, wait for all moving

parts to come to a complete stop, discon-

nect the spark plug wire and prevent it

from contacting the spark plug.

2. Remove the hair pin cotters securing

the upper ends of the control rods to the

plastic thumb latches and wheel drive con-

trol levers (see J, Fig. 2-5).

3. Thread the rods in or out of the idler

arm (A, Fig. 5-2) as needed. Adjust each

wheel drive control rod (A, Fig. 5-3) until

there is a 1-1/4" (32mm) gap between the

rod and the plastic thumb latch. Adjust

both control rods evenly.

4. Re-install the hair pin cotters on the

outside of the wheel drive levers.

CUTTER BAR DRIVE BELT

REMOVAL/REPLACEMENT

Replace the cutter bar drive belt if it is

cracked, severely frayed, or worn to the

point where proper tension can no longer

be applied by the spring loaded idler.

1. Stop the engine, wait for all moving

parts to come to a complete stop, discon-

nect the spark plug wire and prevent it

from contacting the spark plug.

2. Put the cutter bar lever in the OFF posi-

tion (Fig. 4-7). Reach up underneath the

unit and remove the belt from the small

lower pulley (Fig. 5-4).

3. Remove screws and washers (B, Fig. 5-

5) and both belt guides (A). Remove the

belt from the large pulley.

4. Install new belt as shown in Fig. 5-4.

5. Reinstall belt guides (A, Fig. 5-5) and

screws and washers (B). Adjust the guides

1/16" - 1/8" (1.6-3.2mm) away from belt.

CUTTER BAR BELT GUIDE

ADJUSTMENT

1. Stop the engine, wait for all moving

parts to come to a complete stop, discon-

nect the spark plug wire and prevent it

from contacting the spark plug.

2. Place the belt under tension (Fig. 4-7)

by moving the cutter bar lever to the ON

position.

3. Adjust front belt guides (Y, Fig. 5-4)

1/16"—1/8" (1.6—3.17 mm) away from

belt.

4. Secure guides.

5. Adjust the right rear belt guide (Z) 1/4"

(6.35 mm) from the belt (Fig. 5-4).

6. Secure the guide.

WHEEL DRIVE BELT

ADJUSTMENT

Poor wheel traction can result if the belt

tension spring (B, Fig. 5-2) has loosened,

or if the wheel drive belt has worn.

To Adjust Wheel Belt Tension:

1. Move the end of spring (B, Fig. 5-2),

located on the underside of the deck, to

the lower hole (C).

2. If the belt tension is still too loose, the

spring or the belt may need replacing.

WHEEL DRIVE BELT

REMOVAL/REPLACEMENT

When a wheel drive belt is frayed, broken

or worn to the point where tension can no

longer be controlled with the idler pulley,

the belt or spring must be replaced.

NOTE: Prop the unit up by placing sturdy

supports under the engine deck.

To Remove the Wheel Drive Belt:

1. Remove drive belt cover (A, Fig. 5-6).

2. Remove snap ring (B) and washer (C)

from drive axle.

3. Remove wheel assembly (F).

4. Slip the drive belt off the pulleys and

off the unit.

To Replace the Wheel Drive Belt:

1. Slide wheel assembly (F, Fig. 5-6) onto

axles. Note that seal tabs (AA) fit inside

the belt guard (J).

2. Route belt (E) into place around pulley

on wheel assembly (F).

3. Secure wheel with washer (C) and snap

ring (B) removed earlier.

4. Install drive belt cover assembly (A).

Note that finger (H) on drive belt cover

points toward the front of the unit.

WHEEL DRIVE BELT GUIDE

ADJUSTMENT

1. Place belt under tension by engaging

wheel drive clutch lever. See Fig. 4-5.

2. Remove Drive Belt Cover (A, Fig. 5-6).

3. Adjust belt guide (A, Fig. 5-7) to 1/16”

(1.6mm) or less away from belt.

4. Adjust belt guide (B) 1/4” (6.4mm)

away from pulley (D).

5. Tighten belt guide (B) at bolt (C) after

adjusting.

6. Install belt cover (A, Fig. 5-6).

Fig. 5-5

Fig. 5-6

1/16"-1/8"

(1.6-3.2mm)

1/4"

(6.4mm)

FRONT

Fig. 5-4

1/16"-1/8"

(1.6-3.2mm)

22 Section 5: Maintenance

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to

come to a complete stop, disconnect spark plug wire and move wire away from spark plug. Remove

the key from the keyswitch on units so equipped.

Failure to follow these instructions can result in serious personal injury or property damage.

WARNING

DRIVE CHAIN ADJUSTMENT

AND LUBRICATION

Check chain tension when oiling the chain

(every 10 operating hours).

1. Remove the #10 screw (A, Fig. 5-8)

and slide off the chain cover (B).

2. If the chain is slack, loosen nut (C) and

adjust chain idler (D) until the chain

deflects slightly with moderate finger pres-

sure. Secure the nut (C) in the adjustment

slot. Loosening the lock nuts (D) is not

necessary.

3. Lightly oil the chain. Spread oil over as

much of the chain surface as possible

4. Replace the chain cover and secure

with the hex head screw removed earlier.

CUTTER BAR MAINTENANCE

Cutter bar maintenance is easier if it is

first removed from the unit.

Cutter bar is capable of inflicting severe

injury. Be extremely careful when per-

forming any maintenance on the cutter

bar assembly.

• Before performing maintenance or

repairs on the cutter bar, stop the

engine, wait for all moving parts to

come to a complete stop, disconnect

the from contacting the spark plug. On

electric start models, remove the key

from the keyswitch.

• Have an assistant help you.

• Install the plastic blade guard on the

cutter bar.

• Wear heavy leather gloves when

working on or near the cutter bar

assembly.

• Wear safety goggles or a face guard.

Failure to follow these instructions may

result in serious personal injury or prop-

erty damage.

CUTTER BAR REMOVAL

• Put plastic blade guard on cutter bar.

Wear heavy leather gloves and wrap

blades in rags when handling the cutter

bar assembly.

• When removing or replacing

blades/sections, always wear safety

goggles or a face guard.

Failure to follow these instructions may

result in serious personal injury or prop-

erty damage.

NOTE: An assistant should stand in the

operator position and firmly hold the han-

dlebars while the cutter bar is being

removed to help prevent the unit from tip-

ping unexpectedly.

1. Stop the engine, wait for all moving

parts to come to a complete stop, discon-

nect the spark plug wire and prevent it

from contacting the spark plug. On electric

start models, remove the key from the

keyswitch.

2. Align the pitman arm assembly (A, Fig.

5-9) directly above the blade mounting

bracket (B). If the pitman arm is not

aligned, move the cutter bar lever to the

ON position (Fig. 4-7). Slowly pull the

starter rope while watching pitman arm

movement. Stop when the pitman arm is

aligned.

3. To remove the cutter bar, remove the

three screws, flat washers and locknuts

that secure the cutter blade and doubler

plate to the blade mounting bracket (B,

Fig. 5-9).

4. After removing the cutter bar, the knife

head (C, Fig. 5-9) can be removed (if nec-

essary) by removing the two 8M x 12M

screws and 5/16" hardened washers.

Leave the pitman arm (A, Fig. 5-9) on the

knife head for safe keeping.

CUTTER BAR REPLACEMENT

IMPORTANT: To help prevent the unit

from tipping, have an assistant stand in

the operator position and firmly hold the

handlebars during installation of the cutter

bar.

1. Stop the engine, wait for all moving

parts to come to a complete stop, discon-

nect the spark plug wire and prevent it

from contacting the spark plug. On electric

start models, remove the key from the

keyswitch.

2. Have an assistant hold the unit firmly

by the handlebars.

3. Slowly pull the starter rope while

watching eccentric arm movement. Stop

pulling the starter rope when the arm

aligns with the hole (C, Fig. 5-9).

4. Using the hardware and parts removed

in the “Cutter Bar Removal” steps, replace

the cutter bar by following steps 4 through

11 of the “Cutter Bar Assembly and Instal-

lation” instructions that begin on Page 10.

5. Oil the area between the hold-down

clips and wear plates (C, Fig. 5-10).

DANGER

WARNING

DANGER

1/16"

1/4"

Front – right side

Fig. 5-7

(1.6mm)

(6.4mm)

Fig. 5-8

Fig. 5-9

Section 5: Maintenance 23

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to

come to a complete stop, disconnect spark plug wire and move wire away from spark plug. Remove

the key from the keyswitch on units so equipped.

Failure to follow these instructions can result in serious personal injury or property damage.

WARNING

CUTTER BAR DISASSEMBLY

• Put plastic blade guard on cutter bar

assembly. Wear heavy leather gloves

and wrap blades in rags when handling

the cutter bar assembly.

• When removing or replacing

blades/sections, always wear safety

goggles or a face guard.

Failure to follow these instructions may

result in serious personal injury or prop-

erty damage.

If the blades are worn and need replace-

ment, the entire cutter bar assembly can

be removed and individual blades/sections

can be replaced.

1. Remove the knife head (see “Cutter Bar

Removal” instructions earlier in this Sec-

tion).

2. Loosen screws (D, Fig 5-11).

Scissor action of cutter bar can easily

amputate fingers and toes. Be extremely

careful when sliding blade assembly out

of cutter bar assembly.

3. Slide the blade assembly (E, Fig. 5-11)

out one end of the cutter bar assembly. If

the blade assembly does not slide readily,

tap each end of the blade assembly using

a rubber mallet or hammer and block of

wood (Fig. 5-11).

4. Inspect the blade assembly to deter-

mine if sharpening or replacement of

blade sections is necessary. If blades are

dull, contain nicks, or have pieces

missing, the blades must be sharpened or

replaced.

BLADE SHARPENING

NOTE: For best safety and performance,

We recommend the blades be sharpened

by a professional sharpening service.

Sharpen the blades with a grinder or hand

file.

To sharpen with a hand file:

1. Clamp the blade assembly in a vise,

with the blade points facing away from

you.

2. Push the file away from you while

maintaining the same cutting angle as the

original sharpened edge. File or grind only

the top (angled) surface of the blade. The

bottom edge of the blade must remain flat

to provide good shearing action.

BLADE SECTION OR LEDGER

PLATE REMOVAL

NOTE: Blade sections are riveted to the

cutter blade assembly (E, Fig. 5-11).

Ledger plates (G) are blades riveted to the

cutter bar assembly (F).

1. File the rivet heads off the blade rein-

forcement bar. See Fig. 5-12.

2. Place the blade or ledger plate

assembly on a sturdy surface such as a

workbench. Position so the part of the

blade from which rivets will be driven is

over the edge.

When driving rivets from the middle of the

bar, place the bar on top of two supports,

such as jackstands, or wood blocks. Posi-

tion so the part of the blade from which

rivets will be driven between the objects or

blocks.

3. Use a flat punch to clean out the rivet

holes (Fig. 5-13).

BLADE OR LEDGER PLATE

REPLACEMENT

The underside of the blade sections have

countersunk holes to accept flush-type

rivets. See the parts catalog for rivet sizes

and an exploded view of the assembly.

1. Align the holes in the new blade, blade

section, or ledger plate, with the corre-

sponding holes in the cutter blade

assembly or cutter bar.

2. Insert two rivets into the countersunk

holes. Place the rivet heads flush against

the blade.

NOTE: When installing a blade section

(not an individual blade), install four rivets

in each blade section.

3. Place the cutter blade or bar assembly

(with the new blade and rivets in place) on

a sturdy support, with the rivet heads

positioned between the support and the

blade.

4. Strike the protruding rivet sharply with

a hammer until satisfactory heads are

formed (Fig. 5-14) and the rivets are tight.

NOTE: Longer rivets are needed for the

blade sections at wear plate locations. See

the parts catalog for rivet sizes and an

exploded view of the assembly.

5. After installing new blades or ledger

plates, grind or file all rivet heads on the

lower edge of the cutter bar flush with the

bar surface.

DANGER

Fig. 5-10

Fig. 5-11

Fig. 5-12

Fig. 5-13

24 Section 5: Maintenance

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to

come to a complete stop, disconnect spark plug wire and move wire away from spark plug. Remove

the key from the keyswitch on units so equipped.

Failure to follow these instructions can result in serious personal injury or property damage.

WARNING

NOTE: The unit will not cut properly if

there are protrusions on the mating sur-

faces of the cutter bar and blades.

CUTTER BLADE REASSEMBLY

Scissor action of cutter bar can easily

amputate fingers and toes. Be extremely

careful when sliding blade assembly out

of cutter bar assembly.

Slide blade assembly back into cutter bar

assembly. If blade assembly does not slide

readily, loosen screws (D, Fig. 5-11).

Put plastic blade guard on back onto

cutter bar assembly whenever cutter bar

is not in use.

CUTTER BAR HOLD-DOWN CLIP

ADJUSTMENT

Blades are very sharp! Wear heavy

leather gloves when working on or near

cutter blades. Failure to follow this

instruction may result in serious

personal injury.

Tighten hold-down clips every five oper-

ating hours, or when the unit is not cutting

effectively, or when the unit is excessively

noisy during normal operation. Best cut-

ting performance is obtained when there is

slight tension between hold-down clips (B,

Fig. 5-10) and wear plates (C).

Hold-Down Clip Tension Adjustment:

1. To increase tension on wear plate (C,

Fig. 5-10), loosen lock nuts (D) in hold-

down clip (B). Slide clip backward until it

contacts the wear plate. Re-tighten the

lock nuts.

2. Turn adjustment screw (F, Fig. 5-10)

clockwise to increase tension on cutter

blades (E). Hold-down clips should be

tight enough to prevent sloppy action, yet

allow the cutter bar assembly to slide

freely from side to side.

Blade/Ledger Plate Tightening:

1. Remove cutter bar assembly from unit

(see instructions earlier in this section).

2. Remove the blade assembly from the

cutter bar assembly (see instructions ear-

lier in this section).

3. Place the blade section with the loose

rivet(s) on a steel block or anvil. Position

the punch in the middle of the counter-

sunk area of the rivet (Fig. 5-14).

4. Strike the punch with the hammer,

expanding the rivet within the hole. Repeat

this procedure for all loose rivets in the

section.

5. If the blade (or ledger) section remains

loose, replace the rivets (see instructions

in this section).

HIGH-WEAR PARTS

Increased vibration or noise are indica-

tions of worn or damaged parts.

CHECKING THE ECCENTRIC RADIAL

BEARING/CHANNEL

The eccentric channel (A, Fig. 5-15) and

radial bearing (B) are high-wear parts.

Check for excessive wear at the end of

each mowing season. With engine off, and

spark plug wire disconnected, reach under

the unit and grasp the back of the eccen-

tric channel. Move the eccentric shaft (C,

Fig. 5-15) from side-to-side and back and

forth. If there is noticeable play in the

parts, replace the eccentric radial bearing

(B) and/or the eccentric arm (A).

ECCENTRIC RADIAL BEARINGS AND

CHANNEL REMOVAL/REPLACEMENT

Eccentric Radial Bearing and Channel

Removal:

1. Remove the six 5/16"-18 x 3/4" hex

head cap screws securing front fender.

Remove fender.

2. Remove eight screws securing eccen-

tric housing (M, Fig. 5-16) to engine deck.

3. Check the position of the eccentric

radial bearing (B, Fig. 5-16) in the eccen-

tric channel groove (A).

4. Position the radial bearing so it is all

the way back in the groove in the channel.

5. Remove the retaining ring (F, Fig. 5-16)

and bearing (B) from the eccentric shaft

and discard.

Eccentric Radial Bearing and Channel

Replacement:

Install a new bearing and retaining ring on

the eccentric shaft. Replace eccentric

housing (M). (See “Housing Assembly

Tightening Sequence” in this Section).

ECCENTRIC ARM WELDMENT/PARTS

The eccentric arm weldment tube (D, Fig.

5-17), the pitman assembly shaft (E), and

the synthetic insert (F) can wear and will

eventually loosen. To check:

WARNING

DANGER

IDEAL

UNACCEPTABLE

Fig. 5-14: Rivet Heads

Fig. 5-15

Section 5: Maintenance 25

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to

come to a complete stop, disconnect spark plug wire and move wire away from spark plug. Remove

the key from the keyswitch on units so equipped.

Failure to follow these instructions can result in serious personal injury or property damage.

WARNING

1. Remove the six 5/16"-18 x 3/4" hex

head cap screws securing fender. Remove

fender.

2. Remove the cutter bar drive belt (see

instructions in this Section).

3. Rotate the drive mechanism by hand

and watch for any noticeable play between

the parts. Worn and loose parts can cause

early parts failure.

CHECKING ECCENTRIC SHAFT

BEARINGS

Check shaft bearings (E, Fig. 5-16) when-

ever the eccentric radial bearing (B) is

replaced. The shaft bearings do not need

replacement as often as the eccentric

radial bearing.

1. Check the eccentric shaft bearings (E,

Fig. 5-16) for play. Move the eccentric shaft

2. Check for play in the eccentric arm

pivot bearings (D, Fig. 5-16 & 5-18) by

moving the eccentric arm (E, Fig. 5-18)

back and forth.

3. Wear and looseness can be caused by

loose bearing flange bolts (F, Fig. 5-18).

Tighten and re-check all bolts before

replacing bearings.

ECCENTRIC SHAFT BEARINGS

REMOVAL/REPLACEMENT

The procedure for removing and replacing

the eccentric shaft bearings (E, Fig. 5-16)

requires special tools and a high degree of

mechanical aptitude. Contact the factory

Technical Service Department before

attempting this repair (or have the unit

serviced by your authorized dealer).

NOTE: Raise and support the unit from

underneath.

To Remove the Eccentric Shaft Bearings:

1. Clamp the eccentric housing (M, Fig.

5-16) in an arbor press with the top end of

the eccentric shaft facing up. Press the

shaft (C) through the eccentric shaft bear-

ings (E). Use a short length of 3/4" round

bar stock to press the eccentric shaft com-

pletely through the bearings.

2. Press out the upper bearing in the

housing (M) and discard. Remove and

save the spacer (N).

3. Remove the lower bearing from the

eccentric shaft (C) with a bearing puller.

4. Inspect all parts for wear or damage,

clean parts thoroughly and replace any

worn or damaged parts.

To Replace the Eccentric Shaft Bearings:

Using the 3/4" round bar stock, press new

bearings onto the eccentric shaft and into

the housing.

NOTES:

• Never press or pound directly on the

bearing race when installing the bearing

in the eccentric housing. Use a pipe with

an outer diameter slightly smaller than

the opening in the housing.

• Never press or pound directly on the

bearing race when installing the bearing

on the eccentric shaft– use a pipe with

an inner diameter slightly larger than the

shaft diameter to press on the bearing.

• Clean the opening in the eccentric

housing. Remove foreign material which

could prevent bearings from seating

squarely in the housing. Lubricate all

surfaces of press-fit parts.

When installing the engine deck

assembly, the front housing assembly,

or the housing assembly, the flange

screws (A, B, and C, Fig. 5-19) must be

tightened in the proper sequence to

avoid damage.

CAUTION

Fig. 5-16

Fig. 5-17

Fig. 5-18

26 Section 5: Maintenance

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to

come to a complete stop, disconnect spark plug wire and move wire away from spark plug. Remove

the key from the keyswitch on units so equipped.

Failure to follow these instructions can result in serious personal injury or property damage.

WARNING

HOUSING ASSEMBLY

TIGHTENING SEQUENCE

First, tighten screws (A, Fig. 5-19).

Second, tighten screws (B).

Last, tighten screws (C).

FRONT HOUSING REMOVAL

1. Move the cutter bar lever into the OFF

position (Fig. 4-7).

2. Remove the cutter bar assembly (see

instructions in this Section).

3. Remove the cutter bar drive belt (see

instructions in this Section).

4. Remove 3/8"-16 x 3/4" long hex head

screws (C, Fig. 5-18) securing the sides

and bottom of the front housing (B).

5. Lower and slide the front assembly off

the unit.

ECCENTRIC SHAFT

REMOVAL/REPLACEMENT

The procedure for removing and replacing

the eccentric shaft requires special tools

and a high degree of mechanical aptitude.

Contact the factory Technical Service

Department before attempting this repair

(or have the unit serviced by your autho-

rized dealer).

To Remove the Eccentric Shaft:

1. Remove the 5/8–18 hex nut (H, Fig. 5-16)

and 5/8 flat washer (J) from the top of the

eccentric shaft (C).

2. Thread a spare 5/8"–18 hex nut onto

the shaft until the nut is flush with the end

of the shaft. Use the nut only to remove

the eccentric shaft pulley (K).

NOTE: The eccentric shaft is tapered to fit

snugly in the pulley hub.

3. Apply prying pressure with a small pry

bar or suitable tool between the pulley and

the eccentric housing (M, Fig. 5-16). At

the same time, rap the nut on the eccentric

shaft sharply with a hammer to loosen the

pulley from the shaft.

4. Remove the spare 5/8–18 hex nut and

separate the pulley (K) from the eccentric

shaft (C).

5. Remove the 15/16 retaining ring (L)

from the eccentric shaft.

To Replace the Eccentric Shaft:

1. Slide eccentric shaft back into bearings

and housing.

2. Replace the 15/16 retaining ring (L)

onto the eccentric shaft.

3. Replace the pulley (K) back onto the

eccentric shaft (C).

4. Secure pulley to eccentric shaft with

the 5/8–18 hex nut (H, Fig. 5-16) and 5/8

flat washer (J) (removed earlier) on the

top of the eccentric shaft (C).

5. Tighten securely.

ENGINE MAINTENANCE

CHECK ENGINE OIL LEVEL

Before starting the engine, check the

engine oil level. Check the oil level every

five operating hours.

NOTE: Oil can flow away from internal

engine parts when the unit is operated on

slopes. Keep the oil level at the FULL mark

on the dipstick when operating, especially

on slopes. Recheck the oil level every 30

minutes of operation.

1. Place the unit on a level surface.

2. Clean any debris away from the oil dip-

stick (E, Fig. 5-20).

3. Unscrew the dipstick.

4. Use a clean, lint-free rag to wipe the

dipstick.

5. Firmly screw the dipstick all the way

into the oil fill hole.

6. Unscrew the dipstick and check the oil

level. The level should be at the FULL mark.

ADD OIL

1. Insert a clean funnel into the oil fill

hole.

2. Select a clean, high quality detergent

oil as specified in the Engine Owner’s

Manual.

3. Slowly pour oil into the funnel. Check

the oil level frequently and do not overfill.

Over-filling can cause engine damage.

4. When the oil level is at the FULL mark

(see Engine Owner’s Manual), reinstall the

dipstick. Wipe up spilled oil.

CHANGING ENGINE OIL

Change the engine oil after the first two

hours of operation and after every 25

operating hours. Change the oil more fre-

quently if the unit is operated in very dirty,

dusty conditions.

1. Run unit until engine is warm.

2. Stop the engine, wait for all moving

parts to come to a stop, disconnect the

spark plug wire and prevent it from con-

tacting the spark plug. Install the plastic

blade guard.

3. Place a drain pan with a capacity of at

least two quarts beneath the engine drain

plug (on underside of deck). Remove

plug.

4. Allow the oil to drain completely. Wipe

up spills or drips.

5. Replace the oil drain plug.

6. Refill the engine with fresh oil of the

proper type and amount as stated in the

engine manual.

Before checking the oil level, adding oil

to the engine or changing the engine oil,

stop the engine, wait for all parts to

come to a stop, disconnect the spark

plug wire and prevent it from contacting

the spark plug. Remove the key on elec-

tric start models.

Failure to follow these instructions may

result in serious personal injury or prop-

erty damage.

WARNING

Fig. 5-19

Section 5: Maintenance 27

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to

come to a complete stop, disconnect spark plug wire and move wire away from spark plug. Remove

the key from the keyswitch on units so equipped.

Failure to follow these instructions can result in serious personal injury or property damage.

WARNING

AIR CLEANER

Inspect the air cleaner elements every 25

hours of engine operation, or more fre-

quently if operating under very dirty, dusty

conditions. Never operate the engine

without the air cleaner assembly installed.

See the separate engine manual for air

cleaner maintenance instructions.

INSPECT SPARK PLUG

Inspect spark plug every 100 operating

hours. Follow the spark plug cleaning and

replacement recommendations in the sep-

arate engine manual. Always replace a

damaged spark plug.

AIR COOLING SYSTEM CLEANING

Dry grass or debris can clog engine

cooling fins, air intake screen, levers,

guards and linkages. Clean all debris from

these areas to help avoid engine damage

caused by overheating. See the separate

engine manual for instructions.

BATTERY MAINTENANCE

(Electric-Start Units)

• Before charging battery after operating

unit, stop engine, wait for all moving

parts to come to a complete stop, dis-

connect spark plug wire and prevent it

from contacting spark plug. Remove

key from keyswitch. Install blade

guard.

• Do not use any battery charger other

than the one which was supplied with

the unit. Use of any other battery

charger may permanently damage the

battery.

• Do not short circuit the battery wires

by touching the connectors together,

or by touching metal objects with

connectors.

• Remove all metal jewelry when

working near the electrical system.

• Do not smoke, use any flame, or gen-

erate sparks near the battery during

battery charging.

• Do not charge the battery for more than

48 hours.

Failure to follow these instructions could

result in serious personal injury or prop-

erty damage.

1. Unplug the battery charger (A, Fig. 5-

20) from the wall outlet.

2. Plug the battery wire lead (B) into the

battery charger lead (C).

3. Plug the battery charger into a

grounded 120-volt wall outlet. The battery

charger is designed for use indoors and

should not get wet. Keep the battery

charger away from water, rain, snow, etc.

Charge the battery for 24 to 48 hours (24

hours minimum).

4. Unplug the battery charger from the

wall outlet first, then unplug the battery

wire lead (B) from the battery charger lead

(C).

SEASONAL BATTERY CHARGING

The engine alternator continuously

charges the battery while the engine is

running. To help ensure that the battery is

always fully-charged, it should additionally

be charged for 24 (minimum) to 48 hours

at the start and end of the mowing season.

BATTERY REMOVAL/REPLACEMENT

1. Remove the two screws securing the

panel at the rear of the unit. Remove the

panel.

2. Unplug the black wire from the nega-

tive (-) terminal on the battery and the red

wire from the positive (+) terminal on the

battery.

3. Remove the two screws that secure the

battery bracket (behind the panel).

Remove the battery bracket and heat

shield and lift out the battery.

4. Install the new battery and re-install the

battery bracket, heat shield and panel.

Reconnect the red wire to the positive (+)

terminal on the battery and the black wire

to the negative (-) terminal.

CHECK AND TIGHTEN

HARDWARE

Vibration occurs during operation and can

loosen parts and hardware. Check all parts

and hardware every 10 operating hours.

Tighten or replace as needed.

LUBRICATION

Every Five Operating Hours:

• Put a drop or two of general purpose oil

under the hold-down clips and the wear

plates (G, Fig. 5-10).

Every Ten Operating Hours:

• Lightly oil the drive chain (see “Drive

Chain Adjustment and Lubrication” to

access chain). Spread oil over as much

of the chain surface as possible.

• With a hand-operated grease gun, apply

grease through the zerk fittings in the

attachment mounting bracket and

pitman assembly pivot shafts (see Fig.

5-21).

• Wipe old, dirty grease from the eccentric

channel (A, Fig. 5-16) and apply fresh

grease.

WARNING

Fig. 5-20

(to grounded

wall outlet)

(from

battery

charger)

(from

battery)

Fig. 5-21

Grease

Fittings

28 Section 5: Maintenance

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to

come to a complete stop, disconnect spark plug wire and move wire away from spark plug. Remove

the key from the keyswitch on units so equipped.

Failure to follow these instructions can result in serious personal injury or property damage.

WARNING

TROUBLESHOOTING

Before performing any corrections in this troubleshooting chart, refer to the appropriate information in this manual for correct

safety precautions and operating or maintenance procedures. Contact your local authorized engine service dealer for engine

service. Contact your local authorized dealer or our factory for help with service problems.

PROBLEM POSSIBLE CAUSE CORRECTION

Poor cutting performance. 1. Dull/damaged blades/sections/ledger plates. 1. Replace blades/sections/ledger plates.

2. Blade guides not properly adjusted. 2. Readjust blade guides.

Sloping/uneven cut. 1. Left and right height adjusters not set 1. Reset height adjusters.

at equal heights.

Cutter bar does not 1. Disconnected spring. 1. Replace spring.

move when cutter bar 2. Broken or bent blade section. 2. Replace blade section.

lever is engaged. 3. Broken blade drive mechanism. 3. See dealer

4. Worn or broken blade drive belt. 4. Replace belt.

Cutter bar does not stop 1. Broken or worn idler spring. 1. Replace spring.

moving when cutter bar

lever is disengaged.

Wheels do not rotate 1. Control rods not properly adjusted. 1. Adjust wheel drive control rods.

when wheel drive levers 2. Worn or broken wheel drive belt. 2. Replace belt.

are engaged. 3. Stretched or disconnected belt tension spring. 3. Reconnect or replace spring.

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

STORAGE

• Never perform maintenance while the

engine is running or when the spark

plug wire is connected, except where

specifically instructed to do so.

• Use a gasoline stabilizer, or drain

gasoline outdoors into an approved

container. Do not smoke and keep

away from open flame.

• Never store the unit with fuel in the

fuel tank inside a building where

fumes may reach an open flame or

spark, or where ignition sources are

present such as hot water and space

heaters, furnaces, clothes dryers,

stoves, electric motors, etc. Allow

engine to cool before storing.

Failure to follow these instructions could

result in serious personal injury or prop-

erty damage.

NOTE: When storing the unit for more

than 90 days, follow these procedures to

help keep the unit in good condition for

future use:

1. Install the plastic blade protector on the

blade.

2. Add a fuel stabilizer to the fuel tank.

Follow the stabilizer manufacturer’s direc-

tions. Or, if draining fuel is absolutely nec-

essary, drain fuel from the engine as

described in the Engine Owner’s Manual.

Avoid leaving non-stabilized gasoline in

the fuel tank for longer than 30 days

because gum and other deposits can form

that will foul the carburetor and fuel line.

3. Change the engine oil (see the Engine

Owner’s Manual).

4. Remove the spark plug and squirt 1/2

ounce of engine oil into the spark plug

hole. Hold a rag over the spark plug hole

(be careful to prevent rag from entering

hole). Slowly pull the recoil starter rope

several times to coat the cylinder wall with

oil. Reinstall the spark plug.

5. Clean any dirt, grass, or debris from

the recoil housing screen, cooling fins,

and other parts of the engine.

6. Lubricate the unit (see instructions in

this Section).

7. Thoroughly inspect the unit for any

loose, broken, or missing parts. Repair or

replace them as necessary.

8. Check all nuts and bolts for tightness.

9. Disconnect the spark plug wire from

the spark plug. Prevent the wire from con-

tacting the spark plug by placing the spark

plug wire boot on the engine holding tab.

10. Apply a light coat of oil to the blade.

11. On electric start models, fully charge

the battery (see instructions in this Sec-

tion), and remove the key from the

keyswitch.

12. Store the unit in a level position out of

reach of children.

WARNING

Section 5: Maintenance 29

TROUBLESHOOTING (continued)

PROBLEM POSSIBLE CAUSE CORRECTION

Wheels continue to 1. Control rods not properly adjusted. 1. Adjust wheel drive control rods.

rotate when wheel drive 2. Broken or excessively worn wheel clutch 2. Replace spring.

levers are disengaged. spring.

Unit pulls to one side 1. Unevenly inflated tires. 1. Check tire pressure. Inflate both tires

while mowing. equally (10-17 psi [

68.5-117 KPa]).

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

Excessive noise or vibration. 1. Blade guides out of adjustment. 1. Adjust blade guides.

2. Loose blade sections or ledger plates. 2. Tighten loose rivets.

3. Loose cutter bar mounting bracket. 3. Tighten the nuts and bolts which attach the

bracket to the cutter bar.

4. Worn eccentric radial bearing and/or 4. Replace bearing and/or channel.

channel.

5. Worn eccentric shaft bearings. 5. Replace bearings.

6. Loose frame nuts and bolts. 6. Tighten bolts and nuts properly.

7. Engine speed set too high. 7. See engine service dealer.

Engine Does Not Start. 1. Spark plug wire disconnected. 1. Reconnect wire.

2. Fuel tank empty. 2. Fill fuel tank with fresh gasoline.

3. Stale/contaminated gasoline in fuel tank. 3. Drain fuel tank and fill with fresh gasoline.

4. Wheel drive lever not disengaged. 4. Lock wheel drive levers in disengaged position.

5. Cutter bar lever not disengaged. 5. Move cutter bar lever into disengaged position.

6. a. Engines with primer bulb. 6. a. Depress primer bulb three times.

b. Engines without primer bulb. b. Place throttle lever in choke position.

7. Dirty air filter. 7. Clean or replace air filter.

8. Defective or incorrectly gapped spark plug. 8. Inspect/service spark plug.

9. Carburetor out of adjustment. 9. See engine service dealer.

10. Defective wheel drive or cutter bar 10. Inspect wires. See engine service dealer

switch or wiring. to replace switch.

Engine runs poorly. 1. Defective spark plug. 1. Replace spark plug.

2. Incorrect throttle setting. 2. Put throttle in correct setting.

3. Dirty air filter. 3. Clean or replace air filter.

4. Carburetor out of adjustment. 4. See engine service dealer.

5. Contaminated or decomposed gasoline. 5. Drain fuel tank and fill with gasoline.

6. Stale/contaminated gasoline in fuel tank. 6. Drain fuel tank and fill with gasoline.

7. Engine cooling system clogged. 7. Clean engine cooling fins and vents..

Engine overheats. 1. Engine cooling system clogged. 1. Clean engine flywheel screen.

2. Carburetor out of adjustment. 2. See engine service dealer.

3. Oil level is low. 3. Check and add oil.

Engine does not stop. 1. Defective engine shut-off switch, 1. See dealer.

wheel drive switch, or wiring.

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

Keyswitch does not operate 1. Engine does not turn over when keyswitch 1. Start engine with starter rope. If engine starts,

starter. is in START position. engine is not seized, problem is with starting

system.

2. Wiring harness loose/wiring broken. 2. Check wiring harness connection/wiring.

3. Corroded connectors. 3. Clean connectors.

4. Discharged battery. 4. Charge battery for 24 (minimum) to 48 hours.

5. Malfunctioning keyswitch. 5. Replace keyswitch.

6. Malfunctioning starter motor. 6. Contact local engine service dealer.

Battery does not charge 1. Broken wire in engine recharging circuit. 1. Contact local engine service dealer.

during operation. 2. Dead battery. 2. Replace battery.

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

Battery charger does 1. Broken battery lead. 1. Repair/replace lead.

not charge battery. 2. Damaged battery charger 2. Replace battery charger (must be same

type as original).

3. Dead battery. 3. Replace battery.

30 Parts List

Models 34061, 34062, 34337, 34063 & 34064

S/N 340610500101-340611599999

S/N 340620500101-340621599999

S/N 340630500101-340631599999

S/N 340640500101-340641599999

S/N 343371100101-343371599999

159

131

302

312 53

303

319

321

318

321

306

117

118

119

301

155

1564

115

116

313

112

311

128

107

162

163

104

167

154

167

160

161

322

323

316 Red Spray Paint (order part # 1900706)

317 Black Spray Paint (order part # 1735222)

TOUCH-UP PAINT

Parts List 31

Models 34061, 34062, 34337, 34063 & 34064

1 1767711010 Left Wheel Drive Housing ............................ 1

2 1765981001 Left Handlebar ............................................. 1

3 1767717 Throttle........................................................ 1

4 1100807 Hex Hd. Capscrew, 1/4-20 x 2 ..................... 1

5 1766603 Wheel Clutch Lever...................................... 2

6 1107382 Flat Washer, 5/16......................................... 1

7 1100811 Hex Hd. Capscrew, 1/4-20 x 1-1/2............... 2

8 1767712010 Right Wheel Drive Housing.......................... 1

9 9126 Handle Grip.................................................. 2

10 1110106 Center Lock Nut, 1/4-20............................... 3

11 1768430 Operator Interlock Harness

(Incl. Refs. 313 & 325. Also Ref. 134 from

page 33).................................................... 1

12 1768426 Wheel Clutch Rod........................................ 2

13 1766608 Handlebar Bridge ......................................... 1

14 1767552 Flange Bearing............................................. 2

16 1186230 Hex Nut, 5/16-18 ......................................... 4

17 1110645 Lock Washer, 5/16....................................... 4

19 1107387 Flat Washer, 3/4........................................... 2

20 1766611 Shock Absorber........................................... 2

21 1732499 Top Lock Nut, 5/16-18................................. 2

22 1104436 Woodruff Key, #9, 3/16 x 3/4....................... 3

23 1767545 Countershaft................................................ 1

24 1773216010 Engine Deck................................................. 1

26 1766890010 Chain Idler Bracket....................................... 1

27 1186009 Hex Hd. Screw, #10-24 x 1/2....................... 1

29 1766622010 Chain Cover ................................................. 1

30 1766623 Carriage Bolt, 1/4-20 x 1/2........................... 4

31 1766624 Wheel Clutch Spring.................................... 2

32 1769517 Decal, “Top”................................................. 2

34 1766627 Chain (Incl. Ref. 311)................................... 1

35 1766628 Chain Idler ................................................... 1

36 1766629 Sprocket, 12T .............................................. 1

37 1766630 Idler Arm Pivot............................................. 2

38 1185257 Snap Ring, 3/8, "E" Type .............................. 2

39 1766631 Wheel Clutch Idler Arm................................ 2

41 1766714 Wheel Idler Spacer....................................... 2

43 1100241 Lock Washer, 1/4......................................... 4

44 1186229 Hex Nut, 1/4-20 ........................................... 4

45 1769982 Spacer.......................................................... 2

46 1766636 Countershaft Pulley...................................... 2

48 1710566 Idler Pulley................................................... 2

49 1100049 Hex Hd. Capscrew, 3/8-16 x 2-1/4............... 2

50 1770480 Left Wheel Assembly

(Incl. Refs. 302, 303 & 312)..................... 1

51 1770470 Right Wheel Assembly

(Incl. Refs. 302, 303 & 312)..................... 1

52 1769972010 Belt Seal....................................................... 2

53 1764070 Top Lock Nut, 3/8-24................................... 6

57 1100044 Hex Hd. Capscrew, 5/16-18 x 3/4 ................ 3

60 1120210 Roll Pin, 3/16 x 1......................................... 1

61 1186469 Carriage Bolt, 5/16-18 x 3/4......................... 2

81 1773272 Flat Washer (hardened), 5/16 ...................... 2

82 1100255 Flat Washer, 5/16......................................... 5

84 1773423 Hex Hd. Capscrew, 3/8-16 x 3/4, Grade 8.... 2

93 1768516 Belt Guide .................................................... 3

95 1764121001 Belt Guide .................................................... 2

98 1111607 Hex Hd. Capscrew,

5/16-18 x 2-1/4, Grade 5 .......................... 2

104 1740496 Self-Tapping Screw, 5/16-18 x 5/8 .............. 6

107 1185219 Retaining Ring, 1/2...................................... 2

112 1717897 Hair Pin........................................................ 2

115 1765993 Pivot Pin, 1/4............................................... 2

116 1766992 Crescent Ring .............................................. 4

117 1765925 Decal, Operator Presence Control................ 2

118 1765923 Compression Spring.................................... 2

119 1735531 Cable Tie...................................................... 6

128 1186102 Carriage Bolt, 5/16-18 x 1-1/4 ..................... 1

131 1701447 Shim Washer............................................... 2

154 1767091 Decal, Oil Drain............................................ 1

155 1767645 Decal, Throttle (A) (B) (E)............................ 1

1767111 Decal, Throttle (C) (D).................................. 1

156 1767124 Decal, Place Hand........................................ 1

159 1185388 Retaining Ring............................................. 2

160 1767128 Left Control Return Spring........................... 1

161 1767129 Right Control Return Spring ........................ 1

162 1110108 Center Lock Nut, 3/8.................................... 2

163 1766808 V-Belt........................................................... 2

167 1773460 Belt Guide .................................................... 2

301 1767159 Right Handlebar Assembly

(Incl. Refs. 155 & 156).............................. 1

302 1767718 Tire, 13 x 5 x 6 Traction Lug........................ 2

303 1770455 Wheel Rim Assembly................................... 2

306 1767160 Operator Presence Control Lever Assembly

(Incl. Ref. 117 ).......................................... 2

311 1730343 Chain Connector Link................................... 2

312 1718086 Valve Stem................................................... 2

313 1768429 Thumb Latch Assembly ............................... 2

316 1900706 Red Spray Paint (13 oz. can) ....................... N/I

317 1735222 Black Spray Paint (13 oz. can)..................... N/I

318 1770460 Drive Hub/Pulley.......................................... 2

319 1770465 Spacer Tube................................................. 2

321 1766810 Bearing ........................................................ 4

322 1770490 Right Belt Cover Assembly (Incl. Ref. 32).... 1

323 1770495 Left Belt Cover Assembly (Incl. Ref. 32) ...... 1

325 1767256 Cable Tie...................................................... 3

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

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

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

32 Parts List

Models 34061, 34062, 34337, 34063 & 34064

158

124

111

109

149

304

157

151

104

162

114

135

134

113

119

144

139

166

162

310

307

119

148

308

309

137

153

145

152

141

142

140

138

178

106

122

108

318

317

319

162

130

178

108

143

172

173

176

175

149

174

148

335

S/N 340610500101-340611599999

S/N 340620500101-340621599999

S/N 340630500101-340631599999

S/N 340640500101-340641599999

S/N 343371100101-343371599999

Parts List 33

Models 34061, 34062, 34337, 34063 & 34064

11 1768430 Operator Interlock Harness (Incl. Ref. 134.

Also Refs. 313 & 325 from page 31) ......... 1

15 * Engine, Briggs & Stratton, 3.5 HP (A).......... 1

* Engine, Briggs & Stratton, 4 HP (B) (E)....... 1

* Engine, Briggs & Stratton, 5 HP (C)............. 1

* Engine, Briggs & Stratton, 5 HP

w/elec. start (D) ........................................ 1

16 1186230 Hex Nut, 5/16-18 ......................................... 10

17 1110645 Lock Washer, 5/16....................................... 15

18 1100275 Woodruff Key, #6, 5/23 x 5/8....................... 1

33 1766626 Bearing Insert .............................................. 2

47 1767142 V-Belt........................................................... 1

57 1100044 Hex Hd. Capscrew, 5/16-18 x 3/4 ................ 11

62 1100047 Hex Hd. Capscrew, 3/8-16 x -1/2................. 1

63 1766650 Engine Pulley............................................... 1

64 1186216 Hex Nut, 5/8-18 ........................................... 1

65 1107386 Flat Washer, 5/8........................................... 1

66 1766651 Eccentric Pulley ........................................... 1

68 1766926 Decal, Troy-Bilt ............................................ 1

71 1185102 Retaining Ring............................................. 1

72 1766657 Ball Bearing.................................................. 2

73 1773137001 Housing Assembly....................................... 1

74 1766664 Bearing Retainer .......................................... 2

75 1766665 Upper Pivot Bearing Support....................... 1

76 1773565 Eccentric Arm Assembly.............................. 1

77 1773537 Pitman Assembly

(Incl. Refs. 317, 318 & 319)..................... 1

79 1773452 Hex Hd. Capscrew, 3/8-16 x 1-1/4, Grade 8. 3

80 1772711001 Attachment Mounting Bracket Assembly ..... 1

81 1773272 Flat Washer (hardened), 5/16 ...................... 2

83 1773218010 Front Housing Assembly.............................. 1

84 1773423 Hex Hd. Capscrew, 3/8-16 x 3/4, Grade 8.... 6

86 1118809 Retaining Ring............................................. 1

87 1766795 Eccentric Bearing......................................... 1

88 1766895 Eccentric Shaft............................................. 1

89 1729245 Flat Washer, 5/16......................................... 1

90 1736221 Shoulder Screw ........................................... 1

91 1713803 Idler Pulley, 3 x 1......................................... 1

92 1767715001 Knife Clutch Arm.......................................... 1

94 1111610 Hex Hd. Capscrew, 5/16-18 x 3 ................... 1

96 1111613 Hex Hd. Capscrew, 5/16-18 x 4, Grade 5..... 1

97 1111611 Hex Hd. Capscrew, 5/16-18 x 3-1/2............. 1

104 1740496 Self-Tapping Screw, 5/16-18 x 5/8 .............. 6

106 1100806 Hex Hd. Capscrew, 1/4-20 x 1-1/4............... 1

108 1767609 Grease Fitting, 1/4-28 x 90°......................... 2

109 1766704 Upper Hook, 1/4-20..................................... 1

111 1766805 Weed diverter Strap, 14-1/2" ....................... 1

113 1185985 Hex Nut, #10-24........................................... 2

114 1758070 Truss Hd. Screw, #10-24 x 5/8.................... 2

119 1735531 Cable Tie...................................................... 3

122 1100254 Flat Washer, 1/4........................................... 1

124 1766558 Engine Cable Clip......................................... 1

130 1767687001 Doubler Bracket ........................................... 1

134 1751340 Switch.......................................................... 1

135 1766947 Grommet...................................................... 2

137 1900455 Key Switch (D)............................................. 1

138 1909647 Battery (D) ................................................... 1

139 1772392 Battery Clamp (D) ........................................ 1

140 1756549 Battery Pad (D) ............................................ 1

141 1768449 Charger (D).................................................. 1

142 1763875 Thread-Forming Screw, 1/4-20 x 3/8 (D)..... 2

143 1772168 2-amp Fuse.................................................. 1

144 1772130 Start Harness (D)......................................... 1

145 1766959 Decal, Electric Start (D)................................ 1

148 1724492 Self-Tapping Fl. Screw, 1/4-20 x 1/2............ 3

149 1186389 Hex Flange Lock Nut, 1/4-20........................ 3

151 1739687 Decal, OPEI Danger...................................... 1

152 1767077 Decal, Warning ............................................ 1

153 1901899 Decal, American Legend .............................. 1

157 1767141 Decal, Danger .............................................. 1

158 1983202 Decal, Hot Surface ....................................... 1

162 1110108 Center Lock Nut, 3/8.................................... 5

166 1705792 Torsion Spring............................................. 1

172 1773451 Flat Washer.................................................. 2

173 1118813 Retaining Ring............................................. 1

174 1773528001 Switch Cover................................................ 1

175 1773529 Heat Reflector (D)........................................ 1

176 1773530 Spacer.......................................................... 1

178 1757032 Loctite

Thread Compound......................... 1

304 1767156 Fender (Incl. Refs. 151 & 157 ).................... 1

307 92018 Hex Nut (D).................................................. 1

308 1187950 Lock Washer (D).......................................... 1

309 1767155 Keyswitch Plate (Incl. Ref. 152)................... 1

310 96520 Key (D)......................................................... 1

317 1772940 Pitman Bearing ............................................ 1

318 1715301 Thrust Washer ............................................. 1

319 1767593 Retaining Ring............................................. 1

335 --- See pages 34 & 35

Ref # Part # Description Qty.

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

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

A/R - As Required

34 Parts List

Models 34061, 34062, 34337, 34063 & 34064

333

178

133

132

120

*335

*15

150

126

170

127

129

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

334

S/N 340610500101-340611599999

S/N 340620500101-340621599999

S/N 340630500101-340631599999

S/N 340640500101-340641599999

S/N 343371100101-343371599999

Parts List 35

Models 34061, 34062, 34337, 34063 & 34064

1 1860218 Hex Hd. Screw, M8 x 0.30..................... 4

2 1766746 Hold-Down Clip ..................................... 4

3 1766747 Lock Nut, M8......................................... 12

4 1766748 Knife Guide............................................ 4

5 1765991 34" Ledger Plate Bar ............................. 1

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

1766754 42" Ledger Plate Bar.............................. 1

6 1766755 Wear Plate............................................. 4

7 1766929 34" Blade Knife Bar................................ 1

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

1766757 42" Blade Knife Bar................................ 1

8 1766758 Blade (single)......................................... 1

9 1767069 Blade (double) 34"................................. 8

1767069 Blade (double) 38"................................. 9

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

10 1768294 Rivet Section, 5 x 17 (pack of 12).......... A/R

11 1768295 Rivet Section, 5 x 20 (pack of 12).......... A/R

12 1766764 Ledger Plate (single).............................. A/R

13 1766765 Ledger Plate (double) ............................ A/R

14 1766767 Runner................................................... 4

15 1766769 Skid Assembly (Incl. Refs. 16, 23,

24, 127, 150 & 170).......................... 2

18 1768296 Ledger Rivet, 6 x 20 (pack of 12) .......... A/R

20 1765992 34" Blade Assembly

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

1766762 38" Blade Assembly

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

1766763 42" Blade Assembly

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

24 1107382 Flat Washer, 5/16................................... 4

29 1766777 Blade Guard, 34".................................... 1

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

1766935 Blade Guard, 42".................................... 1

31 1766768 Hex Hd. Screw, M8 x 45........................ 8

120 1773057 Knife Head............................................. 1

126 1766770001 Shoe Holder........................................... 2

127 1767071 U-Bolt, 5/16........................................... 2

129 1766773001 Shoe ...................................................... 2

132 1773271 Flat Washer (hardened), 5/16 ................ 2

133 1773424 Hex Hd. Capscrew, M8 x 12................... 2

150 1983038 Nylock Nut, 5/16-18............................... 8

170 1186100 Carriage Bolt, 5/16-18 x 1, Grade 5 ....... 4

178 1757032 Loctite

Thread Compound................... A/R

332 1766766 Blade Maintenance Kit (Incl.

Ref. # 8 [qty. 1], 9 [qty. 4], 10 [qty. 12],

11 [qty. 6], 132 [qty. 2]

& 133 [qty. 2])..................................... N/I

333 1770597 34" Ledger Plate Assembly .................... 1

1770598 38" Ledger Plate Assembly .................... 1

1770599 42" Ledger Plate Assembly .................... 1

334 1766792 Hold-Down Clip Kit

(Incl. Refs. # 1 [qty. 1], 2 [qty. 1],

3 [qty. 3], 4 [qty. 1], 14 [qty. 1]

& 31 [qty. 2])....................................... 4

335 1773564 Knife Head & Pitman Kit (Incl. Refs. 77,

79, 81, 130, 162 & 178 from page 33,

and Refs. 120, 132 and 133

listed above)........................................ N/I

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

Cutter Bar Assembly

34"–1765990

38"–1766743

42"–1766744

N/I Not included with unit, order separately.

A/R - As Required.

CUSTOMER SERVICE INFORMATION

Owner Registration Card

Please fill out and mail the enclosed owner

registration card. The purpose of this card is

to register each unit at the factory so that we

can provide you with warranty benefits and

informational bulletins.

Warranty Service

The warranty statement is included in the unit’s literature

package.

Model/Serial Numbers

A Model/Serial Numbers decal is located on top of the fender

next to the left wheel. For ready reference, record these num-

bers in the spaces below.

Date of Purchase:

Model Number:

Serial Number:

Authorized Dealer Information

If you purchased your unit from an authorized dealer, record

the dealer’s address and phone number below for ready

reference:

Dealer Name:

Address:

Phone:

IMPORTANT:

Left and right sides of the unit are determined by standing

behind the unit, in the operator’s position, and facing in the

direction of forward travel.

NOTICE:

We reserve the right to change specifications, add

improvements or discontinue the manufacture of any of our

equipment without notice or obligation to purchasers of our

equipment.

Customer Service and Technical Service

If you have questions or problems with the

unit, contact your local dealer or the factory.

(When calling or writing, provide the

Model/Serial Numbers of the unit.)

Replacement Parts

Factory specified replacement parts are

available from your authorized dealer or

directly from the factory. When ordering

parts, be sure to provide the following:

• Model/Serial Numbers of the unit.

• Part number of the part needed.

• Part Description.

• Quantity needed.

NOTE: All replacement parts must conform

to our rigid quality specifications. Although some replacement

parts we provide may vary slightly in shape, color or texture

from the original parts, any variations will not affect the fit or

performance of these parts on your unit.

Engine Service and Repair

For engine service or repair, contact your nearest authorized

engine dealer (look in the Yellow Pages

under “Engines–Gasoline”). The engine is

warranted by the engine manufacturer. Any

unauthorized work performed on the engine

during the warranty period may void this

warranty. For complete details on the

engine warranty, refer to the Engine Owner’s

Manual.

For customer assistance, contact your nearest authorized dealer or:

GARDEN WAY INCORPORATED • 1 Garden Way • Troy, New York 12180

Customer Service: 1-800-437-8686 • Technical Service: 1-800-520-5520 • Parts Service: 1-800-648-6776

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

Outside the United States and Canada:

Customer Service: (518) 233-4807 • Technical Service: (518) 233-4808 • Parts Service: (518) 233-4806 • FAX (518) 233-4622

We urge using only genuine replacement parts, which

meet all the latest requirements. Replacement parts

manufactured by others could present safety hazards,

even though they may fit on the unit.

WARNING