MTD Lawn Mower Push Mower User Manual

Safe Operation Practices • Set-Up • Operation • Maintenance • Service • Troubleshooting • Warranty  
OperatOrs Manual  
Push Mower — Model Series 540  
WARNING  
READ AND FOLLOW ALL SAFETY RULES AND INSTRUCTIONS IN THIS MANUAL  
BEFORE ATTEMPTING TO OPERATE THIS MACHINE.  
FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.  
MTD LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019  
Printed In USA  
Form No. 769-03420  
(August 27, 2007)  
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Important Safe Operation Practices  
2
WARNING: This symbol points out important safety instructions which, if not followed,  
could endanger the personal safety and/or property of yourself and others. Read and follow  
all instructions in this manual before attempting to operate this machine. Failure to comply  
with these instructions may result in personal injury.  
When you see this symbol. HEED ITS WARNING!  
CALIFORNIA PROPOSITION 65  
WARNING: Engine Exhaust, some of its constituents, and certain vehicle components  
contain or emit chemicals known to State of California to cause cancer and birth defects  
or other reproductive harm.  
WARNING: Battery posts, terminals, and related accessories contain lead and lead  
compounds, chemicals known to the State of California to cause cancer and reproductive  
harm. Wash hands after handling.  
DANGER: This machine was built to be operated according to the safe operation practices in  
this manual. As with any type of power equipment, carelessness or error on the part of the  
operator can result in serious injury. This machine is capable of amputating fingers, hands,  
toes and feet and throwing objects. Failure to observe the following safety instructions  
could result in serious injury or death.  
6.  
Thoroughly inspect the area where the equipment is to be  
used. Remove all stones, sticks, wire, bones, toys and other  
foreign objects, which could be tripped over or picked up  
and thrown by the blade. Thrown objects can cause serious  
personal injury.  
Operation  
General Operation  
1.  
Read this operator’s manual carefully in its entirety before  
attempting to assemble this machine. Read, understand,  
and follow all instructions on the machine and in the  
manuals) before operation. Keep this manual in a safe  
place for future and regular reference and for ordering  
replacement parts  
7.  
Plan your mowing pattern to avoid discharge of material  
toward roads, sidewalks, bystanders and the like. Also,  
avoid discharging material against a wall or obstruction,  
which may cause discharged material to ricochet back  
toward the operator.  
2.  
3.  
Be completely familiar with the controls and the proper use  
of this machine before operating it.  
8.  
9.  
To help avoid blade contact or a thrown object injury,  
stay in operator zone behind handles and keep children,  
bystanders, helpers and pets at least 75 feet from mower  
while it is in operation. Stop machine if anyone enters area.  
This machine is a precision piece of power equipment,  
not a plaything. Therefore, exercise extreme caution at all  
times. This machine has been designed to perform one job:  
to mow grass. Do not use it for any other purpose.  
Always wear safety glasses or safety goggles during  
operation and while performing an adjustment or repair  
to protect your eyes. Thrown objects which ricochet can  
cause serious injury to the eyes.  
4.  
5.  
Never allow children under 14 years of age to operate this  
machine. Children 14 and over should read and understand  
the instructions and safe operation practices in this manual  
and on the machine and should be trained and supervised  
by an adult.  
10. Wear sturdy, rough-soled work shoes and close-fitting  
slacks and shirts. Shirts and pants that cover the arms  
and legs and steel-toed shoes are recommended. Never  
operate this machine in bare feet, sandals, slippery or light-  
weight (e.g. canvas) shoes.  
Only responsible individuals who are familiar with these  
rules of safe operation should be allowed to use this  
machine.  
11. Do not put hands or feet near rotating parts or under the  
cutting deck. Contact with blade can amputate fingers,  
hands, toes and feet.  
3
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12. A missing or damaged discharge cover can cause blade  
contact or thrown object injuries.  
27. When starting engine, pull cord slowly until resistance  
is felt, then pull rapidly. Rapid retraction of starter cord  
(kickback) will pull hand and arm toward engine faster than  
you can let go. Broken bones, fractures, bruises or sprains  
could result.  
13. Many injuries occur as a result of the mower being pulled  
over the foot during a fall caused by slipping or tripping.  
Do not hold on to the mower if you are falling; release the  
handle immediately.  
28. If situations occur which are not covered in this manual,  
use care and good judgement. Contact Customer Support  
for assistance or the name of the nearest service dealer.  
14. Never pull the mower back toward you while you are  
walking. If you must back the mower away from a wall or  
obstruction first look down and behind to avoid tripping  
and then follow these steps:  
Slope Operation  
Slopes are a major factor related to slip and fall accidents, which  
can result in severe injury. Operation on slopes requires extra  
caution. If you feel uneasy on a slope, do not mow it. For your  
safety, use the slope gauge included as part of this manual to  
measure slopes before operating this machine on a sloped or  
hilly area. If the slope is greater than 15 degrees, do not mow it.  
a. Step back from mower to fully extend your arms.  
b. Be sure you are well balanced with sure footing.  
c. Pull the mower back slowly, no more than half way  
toward you.  
d. Repeat these steps as needed.  
Do:  
1.  
15. Do not operate the mower while under the influence of  
alcohol or drugs.  
Mow across the face of slopes; never up and down. Exercise  
extreme caution when changing direction on slopes.  
16. Do not engage the self-propelled mechanism on machines  
so equipped while starting engine.  
2.  
Watch for holes, ruts, rocks, hidden objects, or bumps  
which can cause you to slip or trip. Tall grass can hide  
obstacles.  
17. The blade control handle is a safety device. Never attempt  
to bypass its operation. Doing so makes the safety device  
inoperative and may result in personal injury through  
contact with the rotating blade. The blade control handle  
must operate easily in both directions and automatically  
return to the disengaged position when released.  
3.  
Always be sure of your footing. A slip and fall can cause  
serious personal injury. If you feel you are losing your  
balance, release the blade control handle immediately and  
the blade will stop rotating within three (3) seconds.  
18. Never operate the mower in wet grass. Always be sure of  
your footing. A slip and fall can cause serious personal  
injury. If you feel you are losing your footing, release the  
blade control handle immediately and the blade will stop  
rotating within three seconds.  
Do Not:  
1.  
2.  
3.  
Do not mow near drop-offs, ditches or embankments, you  
could lose your footing or balance.  
Do not mow slopes greater than 15 degrees as shown on  
the slope gauge.  
19. Mow only in daylight or good artificial light. Walk, never  
run.  
Do not mow on wet grass. Unstable footing could cause  
slipping.  
20. Stop the blade when crossing gravel drives, walks or roads.  
21. If the equipment should start to vibrate abnormally, stop  
the engine and check immediately for the cause. Vibration  
is generally a warning of trouble.  
Children  
Tragic accidents can occur if the operator is not alert to the  
presence of children. Children are often attracted to the mower  
and the mowing activity. They do not understand the dangers.  
Never assume that children will remain where you last saw them.  
22. Shut the engine off and wait until the blade comes to  
a complete stop before removing the grass catcher or  
unclogging the chute. The cutting blade continues to  
rotate for a few seconds after the blade control is released.  
Never place any part of the body in the blade area until you  
are sure the blade has stopped rotating.  
1.  
Keep children out of the mowing area and under watchful  
care of a responsible adult other than the operator.  
2.  
3.  
Be alert and turn mower off if a child enters the area.  
Before and while moving backwards, look behind and  
down for small children.  
23. Never operate mower without proper trail shield, discharge  
cover, grass catcher, blade control handle or other safety  
protective devices in place and working. Never operate  
mower with damaged safety devices. Failure to do so can  
result in personal injury.  
4.  
Use extreme care when approaching blind corners,  
doorways, shrubs, trees, or other objects that may obscure  
your vision of a child who may run into the mower.  
5.  
6.  
Keep children away from hot or running engines. They can  
suffer burns from a hot muffler.  
24. Muffler and engine become hot and can cause a burn. Do  
not touch.  
Never allow children under 14 years of age to operate this  
machine. Children 14 and over should read and understand  
the instructions and safe operation practices in this manual  
and on the machine and be trained and supervised by an  
adult.  
25. Never attempt to make a wheel or cutting height  
adjustment while the engine is running.  
26. Only use parts and accessories made for this machine by  
the manufacturer. Failure to do so can result in personal  
injury.  
4
sectiOn 2 — iMpOrtant safe OperatiOn practices  
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3.  
Check the blade and engine mounting bolts at frequent  
intervals for proper tightness. Also, visually inspect blade  
for damage (e.g., bent, cracked, worn) Replace blade with  
the original equipment manufacture’s (O.E.M.) blade only,  
listed in this manual. “Use of parts which do not meet the  
original equipment specifications may lead to improper  
performance and compromise safety!”  
Service  
Safe Handling Of Gasoline:  
1.  
To avoid personal injury or property damage use extreme  
care in handling gasoline. Gasoline is extremely flammable  
and the vapors are explosive. Serious personal injury can  
occur when gasoline is spilled on yourself or your clothes,  
which can ignite. Wash your skin and change clothes  
immediately.  
4.  
5.  
6.  
7.  
Mower blades are sharp and can cut. Wrap the blade or  
wear gloves, and use extra caution when servicing them.  
Keep all nuts, bolts, and screws tight to be sure the  
equipment is in safe working condition.  
2.  
3.  
Use only an approved gasoline container.  
Never fill containers inside a vehicle or on a truck or trailer  
bed with a plastic liner. Always place containers on the  
ground away from your vehicle before filling.  
Never tamper with safety devices. Check their proper  
operation regularly.  
After striking a foreign object, stop the engine, disconnect  
the spark plug wire and ground against the engine.  
Thoroughly inspect the mower for any damage. Repair the  
damage before starting and operating the mower.  
4.  
5.  
Remove gas-powered equipment from the truck or  
trailer and refuel it on the ground. If this is not possible,  
then refuel such equipment on a trailer with a portable  
container, rather than from a gasoline dispenser nozzle.  
8.  
9.  
Never attempt to make a wheel or cutting height  
adjustment while the engine is running.  
Keep the nozzle in contact with the rim of the fuel tank or  
container opening at all times until fueling is complete. Do  
not use a nozzle lock-open device.  
Grass catcher components, discharge cover, and trail shield  
are subject to wear and damage which could expose  
moving parts or allow objects to be thrown. For safety  
protection, frequently check components and replace  
immediately with original equipment manufacturer’s  
(O.E.M.) parts only, listed in this manual. “Use of parts  
which do not meet the original equipment specifications  
may lead to improper performance and compromise  
safety!”  
6.  
7.  
8.  
Extinguish all cigarettes, cigars, pipes and other sources  
of ignition.  
Never fuel machine indoors because flammable vapors will  
accumulate in the area.  
Never remove gas cap or add fuel while engine is hot or  
running. Allow engine to cool at least two minutes before  
refueling.  
9.  
Never over fill fuel tank. Fill tank to no more than 1 inch  
below bottom of filler neck to provide for fuel expansion.  
10. Do not change the engine’s governor setting or over-speed  
the engine. The governor controls the maximum safe  
operating speed of the engine.  
10. Replace gasoline cap and tighten securely.  
11. Check fuel line, tank, cap, and fittings frequently for cracks  
or leaks. Replace if necessary.  
11. If gasoline is spilled, wipe it off the engine and equipment.  
Move machine to another area. Wait 5 minutes before  
starting engine.  
12. Do not crank engine with spark plug removed.  
12. Never store the machine or fuel container near an open  
flame, spark or pilot light as on a water heater, space  
heater, furnace, clothes dryer or other gas appliances.  
13. Maintain or replace safety and instruction labels, as  
necessary.  
14. Observe proper disposal laws and regulations. Improper  
disposal of fluids and materials can harm the environment.  
13. To reduce fire hazard, keep machine free of grass, leaves,  
or other debris build-up. Clean up oil or fuel spillage and  
remove any fuel soaked debris.  
Do not modify engine  
14. Allow machine to cool at least 5 minutes before storing.  
To avoid serious injury or death, do not modify engine in any  
way. Tampering with the governor setting can lead to a runaway  
engine and cause it to operate at unsafe speeds. Never tamper  
with factory setting of engine governor.  
General Service:  
1.  
Never run an engine indoors or in a poorly ventilated area.  
Engine exhaust contains carbon monoxide, an odorless  
and deadly gas.  
Notice Regarding Emissions  
2.  
Before cleaning, repairing, or inspecting, make certain the  
blade and all moving parts have stopped. Disconnect the  
spark plug wire and ground against the engine to prevent  
unintended starting.  
Engines which are certified to comply with California and federal  
EPA emission regulations for SORE (Small Off Road Equipment)  
are certified to operate on regular unleaded gasoline, and  
may include the following emission control systems: Engine  
Modification (EM) and Three Way Catalyst (TWC) if so equipped.  
sectiOn 2 — iMpOrtant safe OperatiOn practices  
5
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Spark Arrestor  
Average Useful Life  
According to the Consumer Products Safety Commission  
(CPSC) and the U.S. Environmental Protection Agency (EPA),  
this product has an Average Useful Life of seven (7) years, or 140  
hours of operation. At the end of the Average Useful Life, buy  
a new machine or have the machine inspected annually by an  
authorized service dealer to ensure that all mechanical and  
safety systems are working properly and not worn excessively.  
Failure to do so can result in accidents, injuries or death.  
WARNING: This machine is equipped with an  
internal combustion engine and should not be used  
on or near any unimproved forest-covered, brush  
covered or grass-covered land unless the engine’s  
exhaust system is equipped with a spark arrester  
meeting applicable local or state laws (if any).  
If a spark arrester is used, it should be maintained in  
effective working order by the operator. In the State of California  
the above is required by law (Section 4442 of the California  
Public Resources Code). Other states may have similar laws.  
Federal laws apply on federal lands.  
A spark arrester for the muffler is available through your  
nearest engine authorized service dealer or contact the service  
department, P.O. Box 361131 Cleveland, Ohio 44136-0019.  
WARNING: Your Responsibility—Restrict the use of this power machine to persons who read, understand and  
follow the warnings and instructions in this manual and on the machine.  
SAVE THESE INSTRUCTIONS!  
6
sectiOn 2 — iMpOrtant safe OperatiOn practices  
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sectiOn 2 — iMpOrtant safe OperatiOn practices  
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Assembly & Set-Up  
3
Contents of Carton  
One Lawn Mower  
One Lawn Mower Operator’s Manual  
One Engine Operator’s Manual  
One Bottle of Oil  
One Grass Catcher  
One Hardware Pack  
One Side Discharge Chute  
2.  
Locate the hairpin clip on the weld pin on each side of  
lower handle.  
Assembly  
NOTE: This unit is shipped without gasoline or oil in the engine.  
Fill up gasoline and oil as instructed in the accompanying engine  
manual BEFORE operating your mower.  
a. Remove hairpin clip from this hole. Using a pair of  
pliers, insert hairpin clip into the hole on pin closest  
to the bracket. See Fig. 3-2. Repeat on other side.  
Handle  
Hardware Pack  
1.  
Remove any packing material which may be between  
upper and lower handles.  
Carriage Bolts (2)  
a. Pull up and back on upper handle as shown in Fig.  
3-1. Make certain the lower handle is seated securely  
into the handle mounting brackets. Do not crimp  
cable while lifting the handle up.  
Wing Nuts (2)  
B
A
A
Figure 3-2  
b. Insert a carriage bolt from the hardware pack into  
the upper hole on the handle mounting bracket.  
Secure with one plastic wing nut, also included  
in the hardware pack. Repeat on other side with  
remaining items from hardware pack.  
B
Figure 3-1  
b. Tighten star knobs to secure upper handle to lower  
handle. Make sure that each carriage bolt is seated  
properly in the handle.  
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3.  
The rope guide is attached to the right side of the upper  
handle. See Fig. 3-3. Loosen the wing nut which secures the  
rope guide.  
1.  
2.  
Place rear of the mower deck on raised blocks.  
Remove lock nut from pivot arm assembly (on select  
models, these may be included separately in a plastic bag).  
3.  
4.  
Slide wheel, with hollow side in, onto pivot arm and secure  
with lock nut.  
Assemble the other side in the same manner.  
A
Grass Catcher  
1.  
Follow steps below to assemble the grass catcher. Make  
certain bag is turned right side out before assembling  
(warning label will be on the outside).  
a. Place bag over frame so that its black plastic side is  
at the bottom.  
B
b. Slip plastic channel of grass bag over hooks on the  
frame. See Fig. 3-5. All the plastic channels except  
center top of bag attach from outside of bag.  
D
C
A
Figure 3-3  
a. Hold blade control against upper handle.  
b. Pull starter rope out of the engine. Release blade  
control.  
c. Slip starter rope into rope guide.  
d. Tighten wing nut.  
C
4.  
Insert post on cable tie into hole provided on the lower  
handle. Pull cable tie tight and trim excess.  
B
Rear Wheels  
Install rear wheels as follows in Fig. 3-4 (wheels maybe already  
installed at factory, if so disregard this step):  
Figure 3-5  
c. Attach center top of bag from inside of bag.  
Figure 3-4  
sectiOn 3 — asseMbly & set-up  
9
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2.  
Follow the steps below to attach the grass catcher:  
a. Lift rear discharge door. See Fig. 3-6.  
2.  
Slide two hooks of side discharge chute under hinge pin on  
mulching plug assembly. Lower the mulching plug. Do not  
remove side mulching plug at any time, even when you are  
not mulching.  
Adjustments  
Each wheel has a height adjustment lever to change the cutting  
height of the mower.  
1.  
2.  
Depress height adjustment lever towards wheel.  
B
Slide lever to desired position for a change in cutting  
height. See Fig. 3-8.  
B
2
A
1
3
Figure 3-6  
b. Place grass catcher on the pivot rod. Let go of  
discharge door so that it rests on the grass catcher.  
WARNING: Never operate mower unless the hooks  
on the grass catcher are firmly seated on the pivot  
rod and the rear discharge door rests firmly against  
top of the grass catcher.  
Side Discharge Chute  
Figure 3-ꢂ  
Your mower is shipped as a mulcher. To convert to side  
discharge, make sure grass catcher is off of the unit and rear  
discharge door is closed.  
3.  
Release lever towards deck.  
IMPORTANT: All wheels must be placed in the same  
relative position. For rough or uneven lawns, move the  
height adjustment lever to a higher position. This will stop  
scalping of grass.  
1.  
On the side of the mower, lift the mulching plug. See  
Figure 3-7.  
Gas and Oil Fill-Up  
Refer to the separate engine owner’s manual for additional  
1
engine information.  
1.  
2.  
Add oil provided before starting unit for the first time out  
of the box.  
Service the engine with gasoline as instructed in the  
separate engine owner’s manual.  
WARNING: Use extreme care when handling  
gasoline. Gasoline is extremely flammable and the  
vapors are explosive. Never fuel the machine  
indoors or while the engine is hot or running.  
Extinguish cigarettes, cigars, pipes and other  
sources of ignition.  
2
Figure 3-ꢁ  
10  
sectiOn 3 — asseMbly & set-up  
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Controls and Features  
4
Blade Control  
Recoil Starter  
Grass  
Catcher  
Side Discharge  
Chute  
Mulch  
Plug  
Cutting Height  
Adjustment Levers  
Figure 4-1  
Grass Catcher  
Blade Control  
The grass catcher, located at the rear of the mower, is used to bag  
the grass clippings for disposal at another site. Once the bag is  
full, it has to be removed from the mower and emptied before  
any further mowing.  
The blade control is attached to the upper handle of the mower.  
Depress and squeeze it against the upper handle to operate the  
unit. Release it to stop engine and blade.  
WARNING: This blade control is a safety device.  
Never attempt to bypass its operations.  
Side Discharge Chute  
Your mower is shipped as a mulcher. To discharge the grass  
clippings to the side instead, follow the instructions in the  
Assembly & Set-Up section to attach the side discharge chute.  
Cutting Height Adjustment Levers  
One adjustment lever is located on each wheel and is used to  
adjust the cutting height. All four levers have to be at the same  
relative position to ensure a uniform cut.  
WARNING: Keep hands and feet away from the  
chute area on cutting deck. Refer to warning label  
on the unit.  
Mulch Plug  
Recoil Starter  
The recoil starter is attached to the right upper handle. Stand  
The mulch plug is used for mulching purposes. Instead of  
collecting the grass clippings in a grass catcher or using the  
side discharge chute, some mower models have the option  
of recirculating the clippings back to the lawn. This is called  
mulching.  
behind the unit and pull the recoil starter rope to start the unit.  
11  
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Operation  
5
Starting Engine  
WARNING: Be sure no one other than the operator  
is standing near the lawn mower while starting  
engine or operating mower. Never run engine  
indoors or in enclosed, poorly ventilated areas.  
Engine exhaust contains carbon monoxide, an  
odorless and deadly gas. Keep hands, feet, hair and  
loose clothing away from any moving parts on  
engine and lawn mower.  
2
3
Follow the set of instructions pertaining to your unit. Refer to  
engine manual for help with the engine.  
1
Briggs & Stratton/ Kawasaki Engine:  
3
1.  
If equipped, push primer three times (Kawasaki - one time).  
Wait about two seconds between each push. See Fig. 5-1.  
In temperature around 55° F or below, prime five times. Do  
not prime to restart a warm engine.  
2.  
3.  
Standing behind the mower, squeeze the blade control  
against upper handle.  
Figure 5-1  
Holding these two handles together firmly, grasp recoil  
starter handle and pull rope out with a rapid, continuous,  
full arm stroke. See Fig. 5-1. Keeping a firm grip on the  
starter handle, let the rope rewind slowly. Repeat until  
engine cranks. Let the rope rewind each time slowly.  
Honda Engine:  
1.  
2.  
3.  
Place the fuel valve lever found on the left side of the  
engine into the ON (OPEN) position. See Fig. 5-2.  
3
Move the choke lever (if equipped) all the way backward  
into the choke position.  
Standing behind the mower, squeeze the blade control  
against upper handle. The choke will now begin to slowly  
return to the off choke position after activating the blade  
control. Therefore, quickly move onto step four below.  
4.  
Holding these two handles together firmly, grasp recoil  
starter handle and pull rope out with a rapid, continuous,  
full arm stroke. See Fig. 5-2. Keeping a firm grip on the  
starter handle let the rope rewind slowly. Repeat until  
engine cranks. Let the rope rewind each time slowly.  
4
2
OFF  
ON  
Stopping Engine  
1
1.  
Release blade control to stop the engine and blade.  
WARNING: Wait for the blade to stop completely  
before performing any work on the mower or to  
remove the grass catcher.  
Figure 5-ꢀ  
1ꢀ  
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Using Your Lawn Mower  
Using Grass Catcher  
You can use the grass catcher to collect clippings while you are  
operating the mower. Refer to the Assembly & Set-Up section for  
instructions on attaching the grass catcher.  
Be sure lawn is clear of stones, sticks, wire, or other objects  
which could damage lawn mower or engine. Such objects could  
be accidently thrown by the mower in any direction and cause  
serious personal injury to the operator and others.  
WARNING: If you strike a foreign object, stop the  
engine. Remove wire from the spark plug,  
thoroughly inspect mower for any damage, and  
repair damage before restarting and operating.  
Extensive vibration of mower during operation is an  
indication of damage. The unit should be promptly  
inspected and repaired.  
WARNING: The operation of any lawn mower can  
result in foreign objects being thrown into the eyes,  
which can damage your eyes severely. Always wear  
safety glasses while operating the mower, or while  
performing any adjustments or repairs on it.  
Using as Mulcher  
For mulching grass, remove the grass catcher and side discharge  
chute from the mower. For effective mulching, do not cut wet  
grass. If the grass has been allowed to grow in excess of four  
inches, mulching is not recommended. Use the grass catcher to  
bag clippings instead.  
sectiOn 5 — OperatiOn  
13  
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Maintenance & Adjustments  
6
2.  
Lubricate the wheels at least once a season with light oil (or  
motor oil). If wheels are removed for any reason, lubricate  
surface of the pivot arm and inner surface of the wheel  
with light oil. See Fig. 6-1.  
Maintenance  
General Recommendations  
Always observe safety rules when performing any  
maintenance.  
3.  
4.  
Lubricate the torsion spring and pivot points on the rear  
discharge door and side mulch plug periodically with light  
oil to prevent rust. See Fig. 6-1.  
The warranty on this lawn mower does not cover items that  
have been subjected to operator abuse or negligence. To  
receive full value from warranty, operator must maintain  
the lawn mower as instructed here.  
Follow the accompanying engine manual for lubrication  
schedule and instruction for engine lubrication.  
Changing of engine-governed speed will void engine  
warranty.  
Deck Care  
Clean underside of the mower deck after each use to prevent  
build-up of grass clippings or other debris. Follow steps below  
for this job.  
All adjustments should be checked at least once each  
season.  
Periodically check all fasteners and make sure these are  
tight.  
1.  
Disconnect spark plug wire. Drain gasoline from lawn  
mower or place a piece of plastic under the gas cap.  
2.  
Tip mower so that it rests on the housing. Keep the side  
with the air cleaner facing up. Hold mower firmly.  
WARNING: Always stop engine, disconnect spark  
plug, and ground against engine before performing  
any type of maintenance on your machine.  
WARNING: Never tip the mower more than 90º in  
any direction and do not leave the mower tipped for  
any length of time. Oil can drain into the upper part  
of the engine causing a starting problem.  
Lubrication  
1.  
Lubricate pivot points on the blade control at least once a  
season with light oil. The blade control must operate freely  
in both directions. See Fig. 6-1.  
3.  
4.  
Scrape and clean the underside of the deck with a suitable  
tool. Do not spray with water.  
IMPORTANT: Do not use a pressure washer or garden hose  
to clean your unit. These may cause damage to bearings,  
or the engine. The use of water will result in shortened life  
and reduce serviceability.  
Put the mower back on its wheels on the ground. If you  
had put plastic under the gas cap earlier, make sure to  
remove it now.  
Figure 6-1  
14  
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Engine Care  
Replacing Rear Flap  
A list of key engine maintenance jobs required for good  
performance by the mower is given below. Follow the  
accompanying engine manual for a detailed list and instructions.  
1.  
To remove rear flap, lift rear door, and press flap in on  
either side to remove from hole. See Fig. 6-2.  
Maintain oil level as instructed in engine manual.  
Service air cleaner every 25 hours under normal conditions.  
Clean every few hours under extremely dusty conditions.  
Poor engine performance and flooding usually indicates  
that the air cleaner should be serviced. To service the air  
cleaner, refer to the engine manual.  
Clean spark plug and reset the gap once a season. Spark  
plug replacement is recommended at the start of each  
mowing season. Check engine manual for correct plug  
type and gap specifications.  
Clean engine regularly with a cloth or brush. Keep the  
top of the engine clean to permit proper air circulation.  
Remove all grass, dirt, and combustible debris from muffler  
area.  
Figure 6-2  
2.  
Remove flap from opposite hole and replace with new flap  
in the opposite order and manner of removal.  
Section 6 — Maintenance & adjuStMentS  
15  
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Service  
7
WARNING: An unbalanced blade will cause  
Blade Care  
excessive vibration when rotating at high speeds. It  
may cause damage to mower and could break  
causing personal injury.  
WARNING: When removing the cutting blade for  
sharpening or replacement, protect your hands with  
a pair of heavy gloves or use a heavy rag to hold the  
blade.  
5.  
Lubricate the engine crankshaft and the inner surface of  
the blade adapter with light oil. Slide the blade adapter  
onto the engine crankshaft. Place the blade on the adapter  
such that the side of the blade marked “Bottom” (or with  
part number) faces the ground when the mower is in the  
operating position. Make sure that the blade is aligned and  
seated on the blade adapter flanges.  
Periodically inspect the blade adapter for cracks, especially if you  
strike a foreign object. Replace when necessary. Follow the steps  
below for blade service.  
1.  
Disconnect spark plug boot from spark plug. Turn mower  
on its side making sure that the air filter and the carburetor  
are facing up.  
6.  
7.  
Place blade bell support on the blade. Align notches on the  
blade bell support with small holes in blade.  
2.  
Remove the bolt and the blade bell support which hold the  
blade and the blade adapter to the engine crankshaft. See  
Fig. 7-1.  
Replace hex bolt and tighten hex bolt to torque: 450 in. lbs.  
min., 600 in. lbs. max.  
To ensure safe operation of your mower, periodically check the  
blade bolt for correct torque.  
Off-Season Storage  
The following steps should be taken to prepare your lawn mower  
for storage.  
Clean and lubricate mower thoroughly as described in the  
lubrication instructions.  
Do not use a pressure washer or garden hose to clean your  
unit.  
Blade  
Coat mower’s cutting blade with chassis grease to prevent  
rusting.  
Blade  
Adapter  
Refer to engine manual for correct engine storage  
instructions.  
Store mower in a dry, clean area. Do not store next to  
corrosive materials, such as fertilizer.  
Blade Bell  
Support  
Bolt  
When storing any type of power equipment in a poorly  
ventilated or metal storage shed, care should be taken to  
rust-proof the equipment. Using a light oil or silicone, coat the  
equipment, especially cables and all moving parts of your lawn  
mower before storage.  
Figure ꢁ-1  
3.  
4.  
Remove blade and adapter from the crankshaft. See Fig.  
7-1.  
Remove blade from the adapter for testing balance.  
Balance the blade on a round shaft screwdriver to check.  
Remove metal from the heavy side until it balances evenly.  
When sharpening the blade, follow the original angle of  
grind. Grind each cutting edge equally to keep the blade  
balanced.  
16  
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Troubleshooting  
8
Problem  
Cause  
Remedy  
Engine Fails to start  
1. Blade control disengaged.  
1. Engage blade control.  
2. Spark plug boot disconnected.  
3. Fuel tank empty or stale fuel.  
2. Connect wire to spark boot.  
3. Fill tank with clean, fresh gasoline.  
4. Engine not primed (if equipped with primer).  
4. Prime engine as instructed in the Operation  
section.  
5. Faulty spark plug.  
6. Blocked fuel line.  
7. Engine flooded.  
5. Clean, adjust gap, or replace.  
6. Clean fuel line.  
7. Wait a few minutes to restart, but do not  
prime.  
8. Fuel valve (if equipped) closed.  
9. Engine not choked (if equipped with choke).  
1. Spark plug boot loose.  
8. Open fuel valve. See engine manual.  
9. Choke engine. See engine manual.  
1. Connect and tighten spark plug boot.  
Engine runs erratic  
2. Blocked fuel line or stale fuel.  
2. Clean fuel line; fill tank with clean, fresh  
gasoline.  
3. Vent in gas cap plugged.  
4. Water or dirt in fuel system.  
5. Dirty air cleaner.  
3. Clear vent.  
4. Drain fuel tank. Refill with fresh fuel.  
5. Refer to engine manual.  
6. Push CHOKE knob in.  
6. Unit running with CHOKE (if equipped)  
applied.  
Engine overheats  
1. Engine oil level low.  
2. Air flow restricted.  
1. Fill crankcase with proper oil.  
2. Clean area around and on top of engine.  
1. Adjust gap to .030”.  
Occasional skips  
(hesitates) at  
high speed  
1. Spark plug gap too close.  
Idles poorly  
1. Spark plug fouled, faulty, or gap too wide.  
2. Dirty air cleaner.  
1. Reset gap to .030” or replace spark plug.  
2. Refer to engine manual.  
Excessive Vibration  
1. Cutting blade loose or unbalanced.  
2. Bent cutting blade.  
1. Tighten blade and adapter. Balance blade.  
2. See an authorized service dealer.  
Mower will not  
mulch grass  
1. Wet grass.  
1. Do not mow when grass is wet; wait until  
later to cut.  
2. Excessively high grass.  
2. Mow once at a high cutting height, then  
mow again at desired height or make a  
narrower cutting path.  
3. Dull blade.  
3. Sharpen or replace blade.  
Uneven cut  
1. Wheels not positioned correctly.  
1. Place all four wheels in same height position  
(if equipped with individual height adjusters).  
2. Dull blade.  
2. Sharpen or replace blade.  
1ꢁ  
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Model Series 540  
51  
5
3
1
6
2
7
38  
4
42  
47  
8
49  
52  
10  
48  
9
46  
44  
45  
11  
43  
12  
24  
24  
33  
41  
40  
13  
32  
31  
37  
39  
50  
34  
35  
36  
14  
15  
30  
29  
28  
24  
25  
53  
26  
24  
16  
23  
24  
17  
18  
54  
27  
21  
20  
22  
19  
Wheel Treads  
55  
Zag  
Pin Bar  
K2 Bar  
Bar  
18  
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Model Series 540  
Ref  
No.  
Ref  
No.  
Part Number  
Description  
Part Number  
Description  
734-1987  
Front Wheel, 8 x 1.8, Bar  
1.  
2.  
3.  
747-1161A  
749-1092A  
746-1130  
Blade Control  
734-2005A  
734-04087  
738-0507B  
738-04266  
732-0404  
720-0426  
710-0599  
Front Wheel, 8 x 2.125, Zag  
Front Wheel, 8 x 1.8, Pin Bar  
Shoulder Scr., .5D x .434 - LH Rear  
Shoulder Scr., .5D x .385 - RH Rear  
Front Spring Lever  
Upper Handle  
Control Cable, 40”  
28.  
746-04104  
746-1137  
Control Cable, 40”, Snap-On, Kaw  
Control Cable, 53”  
29.  
30.  
31.  
32.  
33.  
34.  
35.  
36.  
37.  
4.  
726-0240  
764-04065  
747-04728  
720-0279  
731-05642  
747-04588  
731-05865  
687-02280A  
687-02279A  
787-01279  
687-02075B  
687-02074B  
687-02099B  
687-02100B  
782-5002B  
748-0377C  
748-04082  
742-0741  
Cable Tie  
Height Adjust Knob  
TT Screw, 1/4-20 x .500  
Bell Washer  
5.  
Grass Bag Assembly  
Grass Bag Frame  
6.  
736-0270  
7.  
Handle Knob  
710-0654A  
710-0216  
TT Screw, 3/8-16 x 1.0  
Hex Screw, 3/8-16 x .75  
TT Screw, 1/4-20 x .625  
Foam Grip  
8.  
Trailshield  
9.  
Pivot Rod  
710-1652  
10.  
11.  
Rear Discharge Door  
Rear Handle Bracket Assy. - LH  
Rear Handle Bracket Assy. - RH  
Deck 21-inch  
720-0312  
734-04217  
734-04082  
734-04093  
734-04089  
710-1205  
Rear Wheel, 12 x 1.8, K2 Bar  
Rear Wheel, 12 x 1.8, Bar  
Rear Wheel, 12 x 2.125, Zag  
Rear Wheel, 12 x 1.8, Pin Bar  
Eye Bolt  
12.  
13.  
Front Hgt. Adj. Assy., 8” Whl. - LH  
Front Hgt. Adj. Assy., 8” Whl. - RH  
Front Hgt. Adj. Assy., 7” Whl. - LH  
Front Hgt. Adj. Assy., 7” Whl. - RH  
Front Baffle  
38.  
39.  
40.  
732-0866  
687-02335  
687-02040A  
714-0104  
Rear Hi-Wheel Spring Lever  
Rear Pivot Arm Assy - RH  
Rear Pivot Arm Assy - LH  
Hairpin Clip  
14.  
15.  
Blade Adapter w/Star  
Blade Adapter - 25mm  
21-inch Mulching Blade  
Bell Blade Support  
41.  
42.  
43.  
44.  
45.  
46.  
47.  
720-04072  
710-0703  
Star Knob  
16.  
17.  
Carriage Bolt ,1/4-20 x .75  
Rear Baffle  
736-0524B  
710-1257  
731-04150C  
710-1241  
18.  
19.  
20.  
21.  
22.  
23.  
24.  
25.  
26.  
Hex Screw, 3/8-24 x 2.5  
Side Discharge Chute  
Deflector Chute Adaptor  
Torsion Spring  
Screw HL, 1/4-15 x 1.00  
Torsion Spring - RH  
731-04177  
17032A  
732-04090A  
710-1174  
Carriage Bolt, 5/16-18 x 2  
Wing Nut  
732-1014  
48.  
49.  
50.  
51..  
712-0397  
747-0710  
Hinge Pin  
749-0928A  
736-0182†  
731-04204†  
731-04859†  
732-04089A  
738-04266  
731-0981A†  
736-0504†  
Lower Handle  
687-02055  
712-04065  
787-01290  
687-02337  
687-02338  
687-02337  
687-02338  
734-04215  
734-1988  
Mulch Plug Assembly  
Flange Lock Nut 3/8-16  
Height Adjustment Plate  
Pivot Arm Assy LH (7” wheel)  
Pivot Arm Assy RH (7” wheel)  
Pivot Arm Assy RH (8” wheel)  
Pivot Arm Assy LH (8” wheel)  
Front Wheel, 8 x 1.8, K2 Bar  
Front Wheel, 7 x 1.8, Bar  
Spring Washer  
Deluxe Bail Cover - Red  
Deluxe Bail Cover - Gray  
Torsion Spring - LH  
52.  
53.  
54.  
55.  
Shoulder Screw, .5 D x .385 - Front  
Hub Cap  
Wave Washer, .510 x .750 x .017  
27.  
† If Equipped  
NOTE: Mower features/components vary by model. NOT all parts listed above and pictured on the previous page are standard  
equipment.  
19  
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MANUFACTURER’S LIMITED WARRANTY FOR  
The limited warranty set forth below is given by MTD LLC with  
c. Routine maintenance items such as lubricants, filters, blade  
sharpening, tune-ups, brake adjustments, clutch adjustments,  
deck adjustments, and normal deterioration of the exterior finish  
due to use or exposure.  
respect to new merchandise purchased and used in the United States  
and/or its territories and possessions, and by MTD Products Limited  
with respect to new merchandise purchased and used in Canada and/  
or its territories and possessions (either entity respectively, “MTD”).  
d. Service completed by someone other than an authorized service  
dealer.  
“MTD” warrants this product (excluding its Normal Wear Parts and  
Attachments as described below) against defects in material and  
workmanship for a period of two (2) years commencing on the date  
of original purchase and will, at its option, repair or replace, free of  
charge, any part found to be defective in materials or workmanship.  
This limited warranty shall only apply if this product has been  
operated and maintained in accordance with the Operator’s Manual  
furnished with the product, and has not been subject to misuse,  
abuse, commercial use, neglect, accident, improper maintenance,  
alteration, vandalism, theft, fire, water, or damage because of other  
peril or natural disaster. Damage resulting from the installation or use  
of any part, accessory or attachment not approved by MTD for use  
with the product(s) covered by this manual will void your warranty as  
to any resulting damage.  
e. MTD does not extend any warranty for products sold or exported  
outside of the United States and/or Canada, and their respective  
possessions and territories, except those sold through MTD’s  
authorized channels of export distribution.  
f. Replacement parts that are not genuine MTD parts.  
g. Transportation charges and service calls.  
h. MTD does not warrant this product for commercial use.  
No implied warranty, including any implied warranty of  
merchantability of fitness for a particular purpose, applies after  
the applicable period of express written warranty above as to the  
parts as identified. No other express warranty, whether written or  
oral, except as mentioned above, given by any person or entity,  
including a dealer or retailer, with respect to any product, shall  
bind MTD. During the period of the warranty, the exclusive remedy  
is repair or replacement of the product as set forth above.  
Normal Wear Parts are warranted to be free from defects in material  
and workmanship for a period of thirty (30) days from the date of  
purchase. Normal wear parts include, but are not limited to items  
such as: batteries, belts, blades, blade adapters, tines, grass bags,  
wheels, rider deck wheels, seats, snow thrower skid shoes, friction  
wheels, shave plates, auger spiral rubber and tires.  
The provisions as set forth in this warranty provide the sole and  
exclusive remedy arising from the sale. MTD shall not be liable  
for incidental or consequential loss or damage including, without  
limitation, expenses incurred for substitute or replacement lawn  
care services or for rental expenses to temporarily replace a  
warranted product.  
Attachments MTD warrants attachments for this product against  
defects in material and workmanship for a period of one (1) year,  
commencing on the date of the attachment’s original purchase or  
lease. Attachments include, but are not limited to items such as:  
grass collectors and mulch kits.  
Some states do not allow the exclusion or limitation of incidental  
or consequential damages, or limitations on how long an implied  
warranty lasts, so the above exclusions or limitations may not apply  
to you.  
HOW TO OBTAIN SERVICE: Warranty service is available, WITH  
PROOF OF PURCHASE, through your local authorized service dealer.  
To locate the dealer in your area:  
In no event shall recovery of any kind be greater than the amount of  
the purchase price of the product sold. Alteration of safety features of  
the product shall void this warranty. You assume the risk and liability  
for loss, damage, or injury to you and your property and/or to others  
and their property arising out of the misuse or inability to use the  
product.  
In the U.S.A.  
Check your Yellow Pages, or contact MTD LLC at P.O. Box 361131,  
Cleveland, Ohio 44136-0019, or call 1-800-800-7310, 1-330-220-  
.
In Canada  
This limited warranty shall not extend to anyone other than the  
original purchaser or to the person for whom it was purchased as a  
gift.  
Contact MTD Products Limited, Kitchener, ON N2G 4J1, or call 1-800-  
This limited warranty does not provide coverage in the following  
cases:  
HOW STATE LAW RELATES TO THIS WARRANTY: This limited  
warranty gives you specific legal rights, and you may also have other  
rights which vary from state to state.  
a. The engine or component parts thereof. These items may carry a  
separate manufacturer’s warranty. Refer to applicable manufactur-  
er’s warranty for terms and conditions.  
IMPORTANT: Owner must present Original Proof of Purchase to  
obtain warranty coverage.  
b. Log splitter pumps, valves, and cylinders have a separate one-  
year warranty.  
MTD LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019; Phone: 1-800-800-7310, 1-330-220-4683  
MTD Canada Limited - KITCHENER, ON N2G 4J1; Phone 1-800-668-1238  
GDOC-100015 REV. B  
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