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Assembly


Attach Handlebar


MX12973

1. Remove bracket (A) by removing bolt, washer and lock nut (F) (one on each side).

2. Remove lock nut (B).


MX11276

3. Assemble handlebar (C) onto bolts (D). If necessary loosen bolt on right side to allow handlebar to slide onto bolt.

NOTE: Do not over tighten lock nuts into handlebar. The handlebar needs to move freely.

4. Install with lock nut (B) on both sides.

5. Install brackets to mower using bolts and washers removed above.

6. Adjust handlebar.

NOTE: Make sure brackets are straight up and down, and not at an angle.

Install Brake And Travel
Clutch Cables


MX11277

1. Route cables (A) through slotted hole in lower handlebar bracket (B).

NOTE: Slide caps (C) up and remove top nut (D) in order to get cables into slots. Make sure one nut is on either side of bracket before tightening.


MX11279

2. Put brake cable (E) into upper slot in handlebar bracket (F) and clutch cable (G) into lower slot.


MX11278

3. Remove carriage bolt and nut (H) and rotate brake lever (I) to put end of cable (J) in hole in brake arm lever.

NOTE: Cable end must swivel freely.

4. Install carriage bolt and nut and tighten

5. Apply a small amount of grease to the cable end.


MX11278

6. Fasten end of travel clutch cable to hole in travel clutch bracket with drilled pin (K) and cotter pin (L).

7. If necessary, adjust cables. Tighten jam nuts to 11 N•m (96 lb-in.).

8. Install tie straps.

9. Adjust cables. (See “Drive Belt Tension Check and Adjustment” and “Adjusting Brake” in this section.)

Install Throttle Cable

1. On handlebar console, move throttle lever to the slow position.

2. Remove air cleaner assembly.


M88114

3. On carburetor linkage, loosen screws (A and B).

4. Put throttle cable (C) under bracket and screw (A) and through swivel and screw (B).

5. Tighten screws (A and B).

6. On handlebar console, move throttle lever from the slow position to the fast position.

7. Observe carburetor linkage, linkage must travel from slow idle stop to full throttle.

8. If necessary, loosen both screws, reposition throttle cable and tighten screws.

9. Repeat steps 6 - 8 until carburetor linkage has full travel between the slow idle stop to full throttle.

10. Install air cleaner assembly.

Install Run Switch Cable

1. Route run\off switch wiring harness:


M86645

• Route wiring harness (A) over recoil starter.

• Bend tabs (B) to hold harness.

• Attach run\off switch ground wire (C) with bolt (D).

• Put male end of connector (F) into female end of connector (E).

Install Front Roller


MX12980A

1. Loosen jam nut and remove square head bolt (A) on both sides.

2. Remove lock nut (B), flat washer and bolt.

3. Remove bracket (C).


M86651

4. Position brackets (C) onto roller.


MX12980

5. Install roller assembly (F). If necessary, remove adjusting bolt (G) to fit the roller assembly.

NOTE: Do not put square head bolts into holes in roller shafts. The square head bolts will be facing the rear without brush or GTC and facing forward with brush or GTC.


M86653

6. Tighten square head bolt (A) to hold bracket onto roller shaft.

7. Tighten jam nut (E).


MX12980

8. Install bolt washer and lock nut (B).


MX11261

9. Lubricate roller at point (G) on both sides of roller.

NOTE: Do not over-lubricate. Excess grease could fall from the mower during operation.

10. Adjust cutting height.

Check Fluid Levels

NOTE: Refer to the Service sections of the operator’s manual for information regarding check locations and proper fluid levels.

Drive Belt Tension Check and Adjustment

When properly adjusted, with engine OFF and clutch in NEUTRAL, machine should move freely. With clutch ENGAGED, traction roller should not move.

When properly adjusted, with engine ON and set at low idle, brake OFF and clutch in NEUTRAL, machine should not move. With engine ON and set at low idle, brake OFF, clutch ENGAGED and holding machine by handlebars, transport wheels should spin on gravel or concrete surface. With engine ON, brake OFF, clutch ENGAGED, unit should propel itself up an incline.

Check Procedure

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position.

3. Move travel clutch lever to NEUTRAL position.

4. Pull the machine backward: transport wheels and roller should turn freely.

• If transport wheels and roller turn freely, proceed to next step.

• If transport wheels or roller do not turn, adjust belt tension.

5. Move clutch lever to ENGAGED position.

6. Pull the machine backward: transport wheels and roller should not turn.

• If transport wheels or roller turn, or excessive force is required to engage clutch, adjust belt tension.

• If transport wheels and roller do not turn, proceed to next step.

7. Move clutch lever to DISENGAGED position.

8. Start engine and run at low idle. The machine should not move forward. If it does, adjust belt tension.

9. With engine running at low idle, hold machine by the handlebars to prevent it from moving. Release the brake and engage the clutch.

• If transport wheels spin on gravel or concrete, belt is properly adjusted.

• If transport wheels will not spin on gravel or concrete, belt adjustment is required.

Adjustment Procedure

Depending on the results in the check procedure in the previous steps, either a COARSE or FINE adjustment might be required.

• A coarse adjustment involves movement of the engine. If the machine moves quickly in NEUTRAL or if the machine will not spin the tires, a coarse adjustment is likely to be required.

• A fine adjustment involves adjustment of the cable. If the machine creeps while running at low idle in NEUTRAL, a fine adjustment is likely to be adequate.

1. Park machine on a level surface.

2. Move RUN/OFF switch to OFF position.

3. Move travel clutch lever to NEUTRAL position.


MX6008

4. Remove cap screw (A) and drive belt cover (B).

5. Go to “Determine Type of Adjustment Required”.

Determine Type of Adjustment Required


MX6020

1. Center jam nuts (A) on upper cable ferrule.


MX6071


MX14815

2. Adjust the lower cable anchor (B) to achieve 1-3 mm (0.039-0.118 in.) clearance (C) between the idler and the belt cover support.


MX14816

3. With the machine OFF, compress both drive belts. The distance (D) between the bottom of the idler and the top of the belt should be 12-18 mm (0.472-0.709 in.).

• If distance is not correct, proceed to “Coarse Adjustment Procedure”.

• If distance is correct, proceed to “Fine Adjustment Procedure”.

Coarse Adjustment Procedure


MX6009

Picture Note: Front of Engine


M83761

Picture Note: Rear of Engine

1. Loosen engine mounting bolts (A).

2. Slide engine forward (loosen belt) or rearward (tighten belt) to adjust belt tension until the distance between belts and idler is correct. (See “Determine Type of Adjustment Required”.)

IMPORTANT: Avoid damage! Engine PTO sheave and differential gear case sheave MUST align.


3. Use a straightedge to verify that sheaves are aligned.

4. Tighten engine mounting bolts.

5. Proceed to “Fine Adjustment Procedure”.

Fine Adjustment Procedure


MX6020

1. Loosen upper cable jam nuts (A) and lengthen (decrease belt tension) or shorten (increase belt tension) ferrule length to change belt tension.

2. Tighten jam nuts to 11 N•m (96 lb-in.).

3. Repeat check procedure. (See “Check Procedure”.)

4. If adjusting upper cable is not adequate, proceed to next step.

5. Center jam nuts (A) on upper cable ferrule.


MX6071

6. Loosen jam nuts (B).

7. Lengthen (decrease belt tension) or shorten (increase belt tension) ferrule length to change belt idler tension.

8. Tighten jam nuts to 11 N•m (96 lb-in.).

9. Repeat check procedure and readjust as necessary. (See “Check Procedure”.)

10. Install drive belt cover.

Adjusting Brake

NOTE: Make sure reel clutch is disengaged.

1. Check operation of park brake (see Testing Park Brake, in Operating section).

2. If adjustment is needed do the following:


MX21100

a. Remove cover by loosening bolt (C).


MX11272

b. Loosen jam nuts (D) holding brake cable near the brake.

c. Shorten ferrule length (E).

d. Tighten jam nuts (D).

e. Repeat Step 1.

f. If still not properly adjusted, replace the brake band.

g. Install cover and tighten bolt.

Engine Break-In

c CAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death.

Move the machine to an outside area before running the engine.

Do not run an engine in an enclosed area without adequate ventilation.

• Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area.

• Allow fresh outside air into the work area to clear the exhaust fumes out.

IMPORTANT: Avoid damage! Break in engine before using machine.


Advise customer to follow this engine break-In procedure.


MX21101

1. Reel clutch handle (A) should be in the stop position. The handle towards the rear as shown.

2. Allow engine to run and warm up for 15 minutes at 1/2–3/4 throttle before applying load.

3. After first 20 hours, change engine oil while engine is warm.

Optional Equipment

Install Transport Wheels

Qty

Description

Size

1

Hex Flange Bolt

M8x16

2

Wheel and Tire Assemblies

1

Kick Stand and Torsion Spring


c CAUTION: Avoid injury! The kick stand spring is under tension. Use care when assembling the stand to the machine as the spring may cause unexpected movement.


MX12985

1. Install kick stand (A) through left side tab (B) on the rear cross brace support.

2. Install spring (C) onto the end of the kick stand and continue inserting the kick stand through the right side tab (D).

NOTE: Using a punch as a guide to help position the spring loop with the hole on the kick stand may ease installation of the bolt.

3. Preload the spring 1/2 turn using the vise-grip pliers.

4. Secure the spring and kick stand by installing the bolt (E) through the spring loop and into the tapped hole in the kick stand and tighten nut.

NOTE: Before removing or installing wheels, disengage travel clutch and stop engine.


MX12983

5. Raise mower on stand (F).


MX12984

6. Slide transport wheel on shaft.

7. Engage plate (G) in groove of shaft. Repeat for the other side.

8. Lower mower.

9. Check tire pressure, 125 -140 kPa (18 - 20 psi).

Check Machine Safety System

NOTE: Refer to the Operating section of the operator’s manual for information regarding safety systems.

Perform safety system checks to make sure the electronic safety interlock circuit is functioning properly.