Bolens Lawn Mower 589 User Manual

Operator’s Manual  
21” Self Starter  
High-Wheel  
Rotary Mower  
Model 589  
IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY  
Warning: This unit 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.  
MTD LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019  
769-00004A.
(10/2002)  
PRINTED IN U.S.A.  
FORM NO.  
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SECTION 1: IMPORTANT SAFE OPERATION PRACTICES  
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 symbolHEED ITS WARNING.  
WARNING: The Engine Exhaust from this product contains chemicals known to the State of California  
to cause cancer, birth defects or other reproductive harm.  
DANGER: This machine was built to be operated according to the rules for safe operation 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 hands and feet and throwing objects. Failure to observe the following safety instruc-  
tions could result in serious injury or death.  
9. A missing or damaged discharge cover can cause blade  
contact or thrown object injuries.  
10. Many injuries occur as a result of the mower being pulled  
General Operation  
1. Read this operators manual carefully in its entirety  
before attempting to assemble this machine. Read,  
over the foot during a fall caused by slipping or tripping.  
understand, and follow all instructions on the machine  
Do not hold on to the mower if you are falling; release the  
and in the manual(s) before operation. Be completely  
familiar with the controls and the proper use of this  
handle immediately.  
11. Never pull the mower back toward you while you are  
machine before operating it. Keep this manual in a safe  
walking. If you must back the mower away from a wall or  
place for future and regular reference and for ordering  
obstruction first look down and behind to avoid tripping  
replacement parts.  
2. This machine is a precision piece of power equipment,  
and then follow these steps:  
a. Step back from the mower to fully extend your  
not a plaything. Therefore, exercise extreme caution at all  
arms.  
times. Your unit has been designed to perform one job: to  
mow grass. Do not use it for any other purpose.  
3. Never allow children under 14 years old to operate this  
b. Be sure you are well balanced with sure footing.  
c. Pull the mower back slowly, no more than half way  
toward you.  
machine. Children 14 years old and over should read and  
d. Repeat these steps as needed.  
understand the operation instructions and safety rules in  
12. Do not operate the mower while under the influence of  
this manual and should be trained and supervised by a  
alcohol or drugs.  
parent. Only responsible individuals who are familiar with  
13. Do not engage the self-propelled mechanism on units so  
these rules of safe operation should be allowed to use  
this machine.  
equipped while starting engine.  
14. The blade control handle is a safety device. Never  
4. Thoroughly inspect the area where the equipment is to  
attempt to bypass its operation. Doing so makes the  
be used. Remove all stones, sticks, wire, bones, toys and  
safety device inoperative and may result in personal  
other foreign objects which could be tripped over or  
injury through contact with the rotating blade. The blade  
picked up and thrown by the blade. Thrown objects can  
control handle must operate easily in both directions and  
cause serious personal injury. Plan your mowing pattern  
automatically return to the disengaged position when  
to avoid discharge of material toward roads, sidewalks,  
released.  
bystanders and the like. Also, avoid discharging material  
15. Never operate the mower in wet grass. Always be sure of  
against a wall or obstruction which may cause  
discharged material to ricochet back toward the operator.  
your footing. A slip and fall can cause serious personal  
injury. If you feel you are losing your footing, release the  
5. To help avoid blade contact or a thrown object injury,stay  
blade control handle immediately and the blade will stop  
in the operator zone behind the handles and keep  
children, bystanders, helpers and pets at least 75 feet  
from the mower while it is in operation. Stop machine if  
anyone enters the area.  
rotating within three seconds.  
16. Mow only in daylight or in good artificial light. Walk, never  
run.  
17. Stop the blade when crossing gravel drives, walks or  
6. Always wear safety glasses or safety goggles during  
roads.  
operation and while performing an adjustment or repair to  
18. If the equipment should start to vibrate abnormally, stop  
protect your eyes. Thrown objects which ricochet can  
cause serious injury to the eyes.  
the engine and check immediately for the cause.  
Vibration is generally a warning of trouble.  
7. Wear sturdy, rough-soled work shoes and close-fitting  
19. Shut the engine off and wait until the blade comes to a  
slacks and shirts. Shirts and pants that cover the arms  
complete stop before removing the grass catcher or  
and legs and steel-toed shoes are recommended. Never  
unclogging the chute. The cutting blade continues to  
operate this machine in bare feet, sandals, slippery or  
light weight (e.g. canvas) shoes.  
rotate for a few seconds after the engine is shut off.  
Never place any part of the body in the blade area until  
8. Do not put hands or feet near rotating parts or under the  
you are sure the blade has stopped rotating.  
cutting deck. Contact with the blade can amputate hands  
and feet.  
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20. 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.  
21. Muffler and engine become hot and can cause a burn. Do  
not touch.  
22. Only use parts and accessories made for this machine by  
the manufacturer. Failure to do so, can result in personal  
injury.  
6. Never allow children under 14 years old to operate a  
power mower. Children 14 years old and over should  
read and understand the operation instructions and  
safety rules in this manual and should be trained and  
supervised by a parent.  
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.  
23. If situations occur which are not covered in this manual,  
use care and good judgment. Contact your dealer for  
assistance. Telephone 1-800-800-7310 for the name of  
your nearest dealer.  
2. Wash your skin and change clothes immediately.  
3. Use only an approved gasoline container.  
4. 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.  
5. When practical, 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.  
6. 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.  
7. Extinguish all cigarettes, cigars, pipes and other sources  
of ignition.  
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 unit on  
a sloped or hilly area. If the slope is greater than 15 degrees,  
do not mow it.  
Do:  
1. Mow across the face of slopes; never up and down.  
Exercise extreme caution when changing direction on  
slopes.  
2. Watch for holes, ruts, rocks, hidden objects, or bumps  
which can cause you to slip or trip. Tall grass can hide  
obstacles.  
8. Never fuel machine indoors because flammable vapors  
will accumulate in the area.  
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 3 seconds.  
9. Never remove gas cap or add fuel while the engine is hot  
or running. Allow engine to cool at least two minutes  
before refueling.  
10. Never over fill fuel tank. Fill tank to no more than ½ inch  
below bottom of filler neck to provide space for fuel  
expansion.  
11. Replace gasoline cap and tighten securely.  
12. If gasoline is spilled, wipe it off the engine and equipment.  
Move unit to another area. Wait 5 minutes before starting  
the engine.  
13. Never store the machine or fuel container inside where  
there is an open flame, spark or pilot light as on a water  
heater, space heater, furnace, clothes dryer or other gas  
appliances.  
Do Not:  
1. Do not mow near drop-offs, ditches or embankments, you  
could lose your footing or balance.  
2. Do not mow slopes greater than 15 degrees as shown on  
the slope gauge.  
3. Do not mow on wet grass. Unstable footing could cause  
slipping.  
Children  
14. To reduce fire hazard, keep mower free of grass, leaves,  
or other debris build-up. Clean up oil or fuel spillage and  
remove any fuel soaked debris.  
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.  
15. Allow a mower to cool at least 5 minutes before storing.  
General Service:  
1. Keep children out of the mowing area and under the  
watchful care of a responsible adult other than the  
operator.  
1. Never run an engine indoors or in a poorly ventilated  
area. Engine exhaust contains carbon monoxide, an  
odorless and deadly gas.  
2. Be alert and turn mower off if a child enters the area.  
3. Before and while moving backwards, look behind and  
down for small children.  
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.  
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.  
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 manufactures (O.E.M.) blade  
only, listed in this manual. Use of parts which do not  
5. Keep children away from hot or running engines. They  
can suffer burns from a hot muffler.  
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meet the original equipment specifications may lead to  
improper performance and compromise safety!”  
4. Mower blades are sharp and can cut. Wrap the blade or  
wear gloves, and use extra caution when servicing them.  
5. Keep all nuts, bolts, and screws tight to be sure the  
equipment is in safe working condition.  
safety protection, frequently check components and  
replace immediately with original equipment  
manufacturers (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. Never tamper with safety devices. Check their proper  
operation regularly.  
10. Do not change the engine governor setting or overspeed  
the engine. The governor controls the maximum safe  
operating speed of the engine.  
11. Maintain or replace safety and instruction labels, as  
necessary.  
12. Observe proper disposal laws and regulations. Improper  
disposal of fluids and materials can harm the  
environment.  
13. ALWAYS de-energize self starter prior to performing any  
maintenance or service to the engine and or mower.  
Follow instructions both in manual and on the engine and  
or machine to de-energize starter.  
7. After striking a foreign object, stop the engine, disconnect  
the spark plug wire and de-energize the starter. (See  
section To De-energize Self Starter). Thoroughly  
inspect the mower for any damage. Repair the damage  
before starting and operating the mower.  
8. Never attempt to make a wheel or cutting height  
adjustment while the engine is running.  
9. 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  
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.  
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SECTION 2: SLOPE GAUGE  
Use this page as a guide to determine slopes where you may not operate safely. Do not operate your lawn mower  
on such slopes.  
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SECTION 3: ASSEMBLING YOUR LAWN MOWER  
IMPORTANT: This unit is shipped without gasoline or oil  
in the engine. Be certain to service engine with gasoline  
and oil as instructed in the separate engine manual  
before operating your mower.  
2. Lift lower handle  
1. Move bag  
away  
Removing Unit From Carton  
3. Lift upper  
Remove staples, break glue on top flaps, or cut  
tape at carton end and peel along top flap to open  
carton. Remove loose parts if included with unit  
(i.e., operators manual, etc.)  
handle  
Cut along corners, lay carton down flat, and remove  
packing material.  
Roll or slide unit out of carton and check carton  
thoroughly for loose parts.  
Figure 2  
Remove the hairpin clips from the outer hole in the  
weld pins on the handle bracket assemblies. Using  
a pair of pliers, squeeze one leg of the lower handle  
against the handle bracket assemblies. Insert the  
hairpin clip into the inner hole on the weld pin.  
Repeat on other side. See Figure 3.  
After you have moved the hairpin clip, install the  
carriage bolt, (carriage bolt must go to the inside of  
handle) included in the hardware pack, in the upper  
hole on the handle mounting bracket. Secure with  
one plastic wing nut, also included in the hardware  
pack. See Figure 3. Repeat process on other side.  
Hardware Pack  
Please identify each piece  
of the hardware pack as  
shown here.  
Carriage  
Bolt  
1/4-20 (2)  
Wing  
Nut  
1/4-20 (2)  
Disconnecting Spark Plug Wire  
Before setting up your lawn mower, disconnect the  
spark plug wire from the spark plug and ground to a bolt  
on the engine. Leave safety key in locked position. See  
Figure 1.  
Carriage Bolt  
Spark Plug  
Wire  
Upper  
Hole  
Handle  
Mounting  
Brkt.  
Spark Plug  
Wing Nut  
Figure 1  
Move Hairpin Clip  
NOTE: Reference to right or left hand side of the mower  
is observed from the operating position.  
Figure 3  
Fasten the cable to the lower handle with the two  
cable ties found on the lower handle. Pull the cable  
ties tight and trim off the excess. See Figure 4.  
Assembling Handle  
Lift up and pull back on the upper handle to raise  
the handle into the operating position.  
Cable Tie  
Make certain the lower handle is seated securely  
into the handle bracket assemblies.  
Tighten the wing nuts between the upper handle  
and the lower handle (carriage bolts must be  
seated properly into the handle). See Figure 2.  
Lower  
Handle  
NOTE: Your mower is shipped with the handle in the  
higher position. If you wish to lower the height of the  
handle, refer to the Adjustment Section at this time.  
Figure 4  
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All the plastic channels attach from the outside of  
bag. See Figure 7.  
Attaching Starter Rope  
The rope guide is attached to the right side of upper  
handle. Loosen the wing nut which secures the  
rope guide. See Figure 5.  
Plastic  
Channel  
Grass Catcher  
Upper Handle  
Starter  
Rope  
Wing Nut  
Rope  
Guide  
Lower  
Handle  
Figure 7  
Attaching Grass Catcher To Mower  
Figure 5  
Lift the rear discharge door and place the grass  
catcher on the pivot rod. Let go of discharge door  
so that it rests on the grass catcher.  
See Figure 8.  
With the spark plug wire disconnected and  
grounded, hold the blade control handle against the  
upper handle, and pull the starter rope out of the  
engine. Release the blade control handle. Slip the  
starter rope into the rope guide. Tighten wing nut.  
Assembling Grass Catcher  
NOTE: If your mower’s grass catcher has been already  
assembled before shipping, proceed to the next  
section. If it is unassembled, follow the steps below.  
Insert frame into grass bag with the black plastic  
side on the bottom of bag. See Figure 6.  
Insert frame  
into bag  
Figure 8  
Grass Catcher  
Converting To Mulcher  
Frame  
Grass  
Lift the rear discharge door on the mower and lift  
the grass catcher up. Release the rear discharge  
door to allow it to cover the rear opening of the  
machine.  
Bag  
Figure 6  
Slip the side openings of the plastic channel on the  
bag over the hooks on the grass catcher frame.  
Secure bag to the frame by working the six plastic  
channels on bag over frame.  
WARNING: Never operate the lawn mower  
without the grass catcher assembly or the  
mulching baffle firmly secured on the machine.  
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SECTION 4: KNOW YOUR LAWN MOWER  
Read this owners manual and safety rules before operating your lawn mower. Compare the illustrations in Figure 9  
with your lawn mower to familiarize yourself with the location of various controls and adjustments. Save this manual  
for future reference.  
WARNING: The operation of any lawn mower can result in foreign objects being thrown into the  
operators eyes and causing severe eye damage. Always wear safety glasses while operating the mower,  
or while performing any adjustments or repairs on it.  
Blade Control  
Handle  
Start Control  
Button  
Recoil  
Starter  
Grass  
Catcher  
Front Cutting Height  
Adjustment Lever  
Spark  
Plug  
Rear Cutting Height  
Adjustment Lever  
Safety  
Key  
Figure 9  
Recoil Starter  
Cutting Height Adjustment Levers  
The recoil starter handle is attached to the upper  
handle. See Figure 9. The recoil starter is used to start  
the engine when the self starter is in the de-energized  
mode.  
These levers are located on each wheel and are used  
to adjust the cutting height. These levers have to be at  
the same relative position to ensure uniform cut.  
See Figure 9.  
Blade Control Handle  
Safety Key  
The blade control handle is located on the upper handle  
of the mower. The blade control handle and starter  
control button must be depressed in order to operate  
the unit. Release blade control handle to stop engine  
and blade and to energize the self starter. See Figure 9.  
The safety key is located on the engine. See Figure 9.  
The safety key is a safety device used to activate and  
deactivate the self starter system. The self starter  
system will not work without the key in its proper  
position. See engine manual for further information  
pertaining to the safety key.  
WARNING: The blade control handle is a  
safety device. Never attempt to bypass its  
operations. Doing so, may result in personal  
injury through contact with the rotating blade.  
The blade rotates whenever the engine is  
running and when the self starter is de-  
energized.  
NOTE: The safety key must be in the run position to  
start the mower for both systems, either the self starter  
or recoil starter.  
Start Control Button  
The start control button is located on the upper left side  
of the handle. See Figure 9. The start control button  
must be depressed fully while pulling the blade control  
handle toward upper handle for the engine to start. The  
starter control button will automatically return to the off/  
up position once the blade control handle is released.  
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NOTE: The starter button must be depressed to start  
the engine with either the self starter or recoil starting  
system.  
Stopping Engine  
Release safety blade control handle (the start  
control button will automatically return to the off/up  
position), engine and blade will stop within a few  
seconds.  
Engine Controls  
See the separate engine manual for the location and  
function of the controls on the engine.  
NOTE: Engine may stop with a ratcheting sound. This  
sound is the self starter being reactivated/energized for  
the next start  
Turn safety key 1/4 turn counterclockwise to LOCK  
position. Remove key and store in a safe place.  
WARNING: The blade will continue to rotate  
for three seconds after the blade control lever  
is released.  
SECTION 5: OPERATING YOUR LAWN MOWER  
8. Firmly push primer bulb 3 times.  
WARNING: Read, understand, and follow  
all instructions and warnings on the machine  
and in this manual before operating.  
9. While standing in the operating position, depress  
the starter control button fully with the thumb of  
your right hand.  
10. Using your left hand, pull the control handle all the  
way toward the upper handle. See Figure 10.  
11. Release the button.  
12. Grasp the recoil rope starter handle with your right  
hand and slowly pull towards you until you feel a  
slight resistance, then pull firmly until your arm is  
fully extended.  
Gas & Oil Fill-Up  
Check oil level and add oil if necessary. Follow  
relevant instructions in the engine manual for this.  
Service the engine with gasoline as instructed in  
the engine 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.  
13. If engine does not start by the second pull, repeat  
steps 8, 9, 10,11 and 12.  
Second Time Starting Engine  
NOTE: Follow these instructions if the self starter is  
already in the energized mode.  
Before Starting Mower  
WARNING: NEVER assume starter is in  
the de-energized mode, even if the key is in  
the locked position and/or removed from the  
engine. ALWAYS de-energize starter prior to  
performing any maintenance or service to the  
engine and/or mower. Follow instructions on  
the engine and/or machine to de-energize  
starter.  
Attach spark plug wire to spark plug. Make certain  
the metal cap on the end of the spark plug wire  
(inside the rubber boot) is fastened securely over  
the metal tip on the spark plug.  
First Time Starting Engine  
NOTE: Use recoil starter rope to start engine for the  
very first time. The mower is shipped with the safety key  
in the locked position and the self starter in the de-  
energized mode, follow instructions as follows.  
Starter Control  
Button  
Blade Control  
Handle  
1. Place lawn mower on a level surface outdoors.  
2. Remove clear plastic packaging under fuel cap.  
3. Check oil level.  
4. Add fuel.  
5. Open shut off valve (if equipped) 1/4 turn.  
6. Push spark plug wire firmly on spark plug.  
7. Turn safety key 1/4 turn clockwise to RUN position.  
Figure 10  
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1. Check oil level and add fuel, if necessary.  
2. Open shut off valve (if equipped) 1/4 turn.  
3. Turn safety key 1/4 turn clockwise to RUN position.  
4. Firmly push primer bulb 3 times (For a cold engine  
only!).  
5. While standing at upper handle, depress the starter  
control button with the thumb of your right hand.  
6. Using your left hand, pull the blade control handle  
all the way toward the upper handle. See Figure 10.  
Starter will de-energize and engine will start.  
(NOTE: If engine does not start, release the blade  
control handle and follow steps 8, 9, 10,11 and 12  
in the First Time Starting Engineinstructions.)  
ALWAYS disconnect spark plug, de-energize  
starter, lock and remove safety key BEFORE  
performing ANY service to the engine or mower.  
DO NOT attempt any maintenance or repairs to the  
self starter.  
NEVER assume starter is de-energize, even if key  
is in LOCK AND REMOVE position and/or removed  
from engine.  
BEFORE removing grass or other debris from  
under mower deck; BEFORE changing oil, air filter  
or spark plug; BEFORE removing blade for  
servicing; BEFORE performing any other service to  
engine or mower; BEFORE transporting mower-  
ALWAYS DE-ENERGIZE SELF STARTER.  
ALWAYS lock and remove safety key and store in a  
safe place until next use. The safety key is  
designed and intended to be removed from engine  
when not in use. Removing key will prevent  
unsupervised or unexpected starting of mower by  
children or unsuspecting adults. The safety key  
must be in the locked position before it can be  
removed.  
NOTE: If any problems are encountered, refer to the  
Trouble Shooting Guide for helpful information.  
To Stop Engine And Blade  
1. Release safety blade control handle (the start  
control button will automatically return to the off/up  
position), engine and blade will stop within a few  
seconds.  
NOTE: Engine may stop with a ratcheting sound. This  
sound is the self starter being reactivated/energized for  
the next start.  
Throttle Speed  
Your lawn mower engine is equipped with a constant  
speed throttle, which is set at full throttle for best  
performance.  
2. Turn safety key 1/4 turn counterclockwise to LOCK  
position. Remove key and store in a safe place.  
Using Your Lawn Mower  
WARNING: The blade will continue to  
rotate for three seconds after the blade  
control lever is released.  
WARNING: Never operate the mower  
unless the hooks on the grass catcher are  
seated in the slots on the handle bracket  
assemblies, and the rear discharge door rests  
firmly against the top of the grass catcher.  
To De-Energize Self Starter  
Remove spark plug wire from spark plug.  
Turn safety key to RUN position (1/4 turn  
clockwise).  
You can use your mower as a mulching mower or a  
rear bagger.  
Do not operate the mower without the rear  
mulching baffle or the grass catcher bag properly  
installed.  
While standing in the operating position, depress  
the starter control button fully with the thumb of your  
right hand.  
Using your left hand, pull the control handle all the  
way toward the upper handle. (Release button and  
wait until engine and starter stop rotating.)  
Release safety blade control handle (the start  
control button will automatically return to the off/up  
position.)  
Be sure that the 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.  
For best results, do not cut wet grass because it  
tends to stick to the underside of the mower,  
preventing proper discharge of grass clippings, and  
possibly causing you to slip and fall. New grass,  
thick grass or wet grass may require a narrower cut.  
For a healthy lawn, always cut off one-third or less  
of the total length of the grass. Lawn should be  
trimmed in fall as long as there is growth.  
Remove safety key.  
NOTE: Engine will crank over upon actuating  
equipment starting controls, but will not spark if spark  
plug wire was removed from spark plug as described  
above. Once engine has stopped cranking, self starter  
is de-energized.  
WARNING: Self Starting System: If these  
instructions are not followed, amputation or  
severe laceration can result.  
11  
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NOTE: For shipping purposes your mower is set with  
the wheels in a low cutting height position. For best  
results, raise the cutting position until you have  
determined which height is best for your lawn.  
WARNING: If you strike a foreign object,  
stop the engine. Remove wire from spark plug  
and de-energize, thoroughly inspect the  
mower for any damage, and repair the  
damage before restarting and operating the  
mower. Excessive vibration of the mower  
during operation is an indication of damage.  
The unit should be promptly inspected and  
repaired.  
SECTION 6: MAKING ADJUSTMENTS  
WARNING: Be sure to disconnect the  
spark plug wire and DE-ENERGIZE starter  
before performing any adjustments or repairs.  
DO NOT attempt any maintenance or service  
to the engine and/or mower equipped with the  
safety key in the unlocked and/or energized  
mode.  
Handle Height  
Your mower is shipped with the handle in the higher  
height position.  
Remove the starter rope from the rope guide.  
Remove the upper handle by removing the hand  
knobs and carriage bolts. Lay the upper handle out  
of the way, being careful not to bend or kink cables.  
Remove the hairpin clips from the weld pins on the  
handle brackets. Refer to Figure 3.  
Remove the carriage bolts and wing nuts from the  
handle brackets. Press out on the legs of the lower  
handle. Remove lower handle from the mower.  
Turn the lower handle around so the notch on the  
bottom of the lower handle is facing forward as  
shown in Figure 12. Reassemble, placing the  
bottom holes in the handle over the weld pins in the  
handle mounting bracket.  
WARNING: NEVER assume starter is de-  
energized, even if the key is in the locked  
position and/or removed from the engine.  
ALWAYS de-energize self starter prior to  
performing any maintenance or service to the  
engine and/or mower. Follow instructions on  
the engine and/or machine to de-energize  
starter.  
Cutting Height  
Height Adjustment  
Lever  
Notch  
Lower  
Handle  
Figure 12  
Reassemble the upper handle to the lower handle.  
Place the hairpin clips in the inner holes of the weld  
pins and replace the carriage bolts and wing nuts  
on the handle brackets. Attach the starter rope as  
instructed in the Assembly section.  
Figure 11  
An adjusting plate and spring lever at each wheel  
position provides cutting height adjustment. Each  
adjusting plate has several height positions.  
Move the spring lever to one of these height  
positions and the height of cut will be changed.  
Simply depress the lever towards wheel and move  
lever assembly to desired position. See Figure 11.  
Engine Adjustments  
Refer to the engine manual for details and instructions  
regarding engine adjustments.  
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  
help stop scalping of the grass.  
12  
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SECTION 7: MAINTAINING YOUR LAWN MOWER  
IMPORTANT: We do not recommend the use of a  
WARNING: Be sure to disconnect the  
pressure washer or garden hose to clean your unit. The  
use of water will result in shorter life and less  
serviceability.  
spark plug wire and DE-ENERGIZE starter  
before  
performing  
any  
repairs  
or  
maintenance. DO NOT attempt any  
maintenance or service to the engine and/or  
mower equipped with the safety key in the  
unlocked and/or energized mode.  
Cutting Blade  
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.  
NEVER assume starter is de-energized, even  
if the key is in the locked position and/or  
removed from the engine. ALWAYS de-  
energize self starter prior to performing any  
maintenance or service to the engine and/or  
mower. Follow instructions on the engine  
and/or machine to de-energize starter.  
To Remove Blade  
Remove the bolt and the blade bell support which  
hold the blade and the blade adapter to the engine  
crankshaft. See Figure 13.  
Remove the blade and the adapter from the  
crankshaft.  
Engine  
Blade  
Adapter  
NOTE: When tipping the unit, empty the fuel tank and  
keep the spark plug side of engine up. Never tip the  
mower more than 90 degrees 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.  
Blade Bell  
Support  
Refer to the engine manual for all engine maintenance  
instructions.  
Hex Bolt  
Maintain engine oil as instructed in the engine  
manual. Check oil level before starting mower.  
Service air cleaner every 25 hours under normal  
conditions. Poor engine performance and flooding  
usually indicate that the air cleaner should be  
serviced. To service the air cleaner, refer to the  
engine manual.  
Figure 13  
WARNING: Periodically inspect the blade  
adapter for cracks, especially if you strike a  
foreign object. Replace when necessary.  
When sharpening the blade, follow the original  
angle of grind as a guide. It is extremely important  
that each cutting edge receives an equal amount of  
grinding to prevent an unbalanced blade.  
The spark plug should be cleaned and the gap  
reset once a season. Spark plug replacement is  
recommended at the start of each mowing season.  
Clean the engine regularly with a cloth or brush. Keep  
the cooling system (blower housing area) clean to  
permit proper air circulation which is essential to engine  
performance and life. Be certain to remove all grass,  
dirt, and combustible debris from muffler area.  
WARNING: An unbalanced blade will  
cause excessive vibration when rotating at  
high speeds. It may damage the mower, and/  
or cause personal injury.  
The blade can be tested by balancing it on a round  
shaft screwdriver. Remove metal from the heavy  
side until it balances evenly. It is recommended that  
the blade always be removed from the adapter  
when testing for balance. Before reinstalling the  
blade and the blade adapter to the unit, lubricate  
the engine crankshaft and the inner surface of the  
blade adapter with light oil.  
Deck  
The underside of the mower deck should be cleaned  
after each use to prevent a buildup of grass clippings,  
leaves, dirt, or other matter. If this debris is allowed to  
accumulate, it will invite rust and corrosion, and may  
prevent proper mulching, discharge, or bagging. The  
deck may be cleaned by tilting the mower and scraping  
clean with a suitable tool (make certain the spark plug  
wire is disconnected).  
To Reinstall Blade  
Be sure to install the blade with the side marked  
Bottom(or with part number) facing the ground  
when the mower is in the operating position.  
13  
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Slide the blade adapter onto the engine crankshaft.  
Place the blade on the adapter.The blade has to be  
aligned and seated on the blade adapter flanges.  
Place blade bell support on blade. Make sure the  
notches on the blade bell support are aligned with  
small holes in the blade.  
Engine  
Follow the engine manual for lubrication instructions.  
Lubricate  
Replace hex bolt and tighten hex bolt to torque: 450  
in. lbs. min., 600 in. lbs. max.  
NOTE: To ensure safe operation, the blade bolt must  
be checked periodically for correct torque.  
Lubrication  
WARNING: Always stop engine and  
disconnect spark plug wire before cleaning,  
lubricating or doing any kind of service work  
on the lawn mower.  
Figure 14  
Replacing Rear Flap  
To remove rear flap, cut off the flat end of the wire  
rod which secures it to the deck. See Figure 15.  
Attach the new flap and new rod to deck, bending  
the ends of the new rod over to secure to deck.  
Blade Control  
Lubricate the pivot points on the blade control handle at  
least once a season with light oil. The blade control  
must operate freely in both directions.See Figure 14.  
Rear Discharge  
Door  
Wheels  
Lubricate the wheels at least once a season with light  
oil (or motor oil). If the wheels are removed for any  
reason, lubricate the surface of the axle bolt and inner  
surface of the wheel with light oil. See Figure 14.  
Handle  
Bracket  
Handle  
Bracket  
Rear Discharge Door  
Lubricate the torsion springs and pivot points on rear  
discharge door using light oil. This will insure the door,  
which is a safety device, can always work properly.  
Rear  
Flap  
Figure 15  
SECTION 8: OFF-SEASON STORAGE  
The following steps should be taken to prepare your  
lawn mower for storage.  
WARNING: Never store the machine or  
fuel container indoors where there is an open  
flame, spark or pilot light such as on water  
heater, furnace, clothes dryer or other gas  
appliance.  
WARNING: Be sure to disconnect the  
spark plug wire and DE-ENERGIZE starter  
before  
performing  
any  
repairs  
or  
maintenance. DO NOT attempt any  
maintenance or service to the engine and/or  
mower equipped with the safety key in the  
unlocked and/or energized mode.  
NOTE: We do not recommend the use of pressure  
washers or garden hose to clean your unit. They may  
cause damage to electric components, spindles,  
pulleys, bearings or the engine. The use of water will  
result in shortened life and reduce serviceability.  
WARNING: NEVER assume starter is de-  
energized, even if the key is in the locked  
position and/or removed from the engine.  
ALWAYS de-energize self starter prior to  
performing any maintenance or service to the  
engine and/or mower. Follow instructions on  
the engine and/or machine to de-energize  
starter.  
Refer to engine manual for storage instructions.  
Coat mowers cutting blade with chassis grease to  
prevent rusting.  
Store mower in a dry, clean area. Do not store next  
to corrosive materials, such as fertilizer.  
NOTE: 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.  
14  
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SECTION 9: TROUBLESHOOTING  
Problem  
Cause  
Remedy  
Engine fails to start  
1. Blade control handle disengaged.  
2. Start control button not depressed.  
3. Spark plug wire disconnected.  
4. Safety key not in run position  
5. Fuel tank empty or stale fuel.  
6. Blocked fuel line.  
1. Engage blade control handle.  
2. Depress starter control button.  
3. Connect wire to spark plug.  
4. Place safety key in run position.  
5. Fill tank with clean, fresh gasoline.  
6. Clean fuel line.  
7. Faulty spark plug.  
8. Engine flooded  
7. Clean, adjust gap, or replace.  
8. Wait a few minutes to restart, but do not  
prime.  
9. Use recoil starter to start engine.  
9. Self starter already de-energized  
Engine runs erratic  
Engine overheats  
1. Spark plug wire loose.  
2. Blocked fuel line or stale fuel.  
1. Connect and tighten spark plug wire.  
2. Clean fuel line; fill tank with clean, fresh  
gasoline  
3. Clear vent.  
4. Drain fuel tank. Refill with fresh fuel.  
5. Clean air cleaner.  
3. Vent in gas plugged.  
4. Water or dirt in fuel system.  
5. Dirty air cleaner.  
6. Carburetor out of adjustment.  
6. Adjust carburetor.  
1. Engine oil level low.  
2. Air flow restricted.  
3. Carburetor not adjusted properly.  
1. Fill crankcase with proper oil.  
2. Remove blower housing and clean.  
3. Adjust carburetor.  
Occasionally skips (hesitates) 1. Spark plug gap too close.  
at high speed  
1. Adjust gap to.030.  
Idles poorly  
1. Spark plug fouled, faulty or gap too  
wide.  
1. Reset gap to.030or replace spark plug.  
2. Carburetor improperly adjusted.  
3. Dirty air cleaner.  
2. Adjust carburetor.  
3. Clean air cleaner.  
Excessive vibration  
1. Cutting blade loose or unbalanced.  
2. Bent cutting blade.  
1. Tighten blade and adapter. Balance blade.  
2. Replace blade.  
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.  
2. Dull blade.  
2. Sharpen or replace blade.  
NOTE: For repairs beyond the minor adjustments listed above, contact your nearest authorized service dealer.  
15  
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SECTION 10: PARTS LIST FOR MODEL 589  
70  
73  
69  
65  
72  
2
14  
1
68  
67  
71  
63  
64  
12  
15  
66  
9
5
76  
8
7
75  
10  
9
8
13  
28  
18  
6
19  
24  
77  
23  
18  
46  
25  
32  
26  
45  
22  
47  
74  
20  
28  
27  
17  
21  
29  
78  
33  
41  
37  
38  
34  
31  
42  
32  
53  
38  
49  
25  
35  
39  
36  
54  
40  
40  
46  
51  
52  
55  
43  
44  
50  
57  
56  
61  
38  
62  
59  
74  
60  
47  
58  
16  
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Model 589 Series  
Ref.  
Ref.  
No.  
Part No.  
No.  
Part Description  
Upper Handle  
Part No.  
Part Description  
Shoulder Screw  
1.  
749-04001  
647-0070  
712-0324  
712-0397  
710-1205  
710-1174  
736-0451  
720-0284  
746-1141  
749-0907B  
664-0085  
747-04080  
782-5004A  
714-0104  
731-04134  
732-0700  
731-1236  
732-04090  
747-0996  
750-04162  
687-02032  
40.  
41.  
42.  
43.  
44.  
45.  
738-0507B  
734-2043  
736-0272  
736-0182  
738-0481A  
14578  
2.  
Control Handle  
Rear Wheel Assembly 14 x 2.1  
Flat Washer.510 ID x 1.00 OD  
Wave Washer.500 ID x 1.0 OD  
Shoulder Screw  
5.  
Hex Lock Nut 1/4-20  
Wing Nut  
6.  
7.  
Rope Guide  
8.  
Carriage Bolt 5/16-18 x 2”  
Shoulder Washer.320 ID x.930 OD  
Wing Nut  
Front Height Adjuster - RH  
Front Height Adjuster - LH  
Front Wheel Assembly 8 x 2.1  
Shoulder Bolt  
9.  
14579  
10.  
12.  
13.  
14.  
15.  
17.  
18.  
19.  
20.  
21.  
22.  
23.  
24.  
25.  
46.  
47.  
49.  
50.  
51.  
52.  
53.  
54.  
55.  
56.  
57.  
58.  
59.  
60.  
61.  
62.  
63.  
64.  
65.  
66.  
67.  
68.  
69.  
70.  
71.  
72.  
73.  
74.  
75.  
76.  
77.  
78.  
734-2004A  
738-0102  
712-0431  
782-5002  
782-5003  
710-1017  
15261A  
Self Start Control Cable 58.25”  
Lower Handle  
Flange Lock Nut 3/8-16  
Front Baffle  
Grass Bag  
Grass Catcher Frame  
Rear Baffle - RH  
Hairpin Clip  
Rear Baffle - LH  
Tap Screw 1/4-14 x.625.  
Height Adjustment Plate  
Height Adjustment Knob  
Pivot Bar  
Grass Bag Door  
720-0426  
15262B  
Wire Rod  
Trail Shield  
732-0404  
748-0376C  
742-0741  
736-0524A  
710-1044  
731-1506  
731-1426  
710-0501  
710-1256  
731-2532  
731-2533  
715-0168  
732-1171  
720-0428  
716-0209  
732-1172  
782-0156  
731-2623  
736-0504  
726-0240  
720-0279  
732-04089  
782-5003  
Spring Lever  
Door Spring R.H.  
Chute Door Pivot Rod  
Spacer.375 O.D. X.50 I.D. X. 1.02”  
Blade Adapter  
21Mulching Blade  
Blade Bell Support  
Hex Cap Screw 3/8-24 x 1.5  
Front End Cover  
Handle Bracket Assy. Complete - LH  
(Includes 29, 32, 37, 39, 40)  
687-02034  
Handle Bracket Assy. Complete - RH  
(Includes 29, 32, 37, 39, 40)  
Hub Cap  
Hex Hd. Cap Scr. 1/4-20 Gr.5  
Hi-Low Screw  
26.  
27.  
28.  
29.  
31.  
32.  
787-01103  
710-0654A  
710-0703  
712-3005  
712-0431  
687-02033  
687-02031  
710-0286  
710-0896  
710-0216  
720-0312  
17488A  
Deck 21”  
Hex Washer Screw 3/8-16 x 1.0  
Hex Carriage Screw 1/4-20  
Flange Lock Nut 3/8-16  
Flange Lock Nut 3/8-16  
Handle Bracket Assembly - RH  
Handle Bracket Assembly - LH  
Machine Screw 1/4-20 x.500  
Hex Washer Screw 1/4-14 x.625  
Hex Cap Screw 3/8-16 x.75  
Foam Grip  
Control Cover LH  
Control Cover RH  
Pin  
Compression Spring  
Button  
Retention Spring  
Torsion Spring  
33.  
34.  
35.  
36.  
37.  
Lever  
Bail Cover (Not shown)  
Wave Washer.510 x.750  
Cable Tie  
Pivot Bar - RH  
17489A  
Pivot Bar - LH  
Wing Nut  
38.  
39.  
736-0105  
732-0866  
Spring Washer.375 ID x.870 OD  
Spring Lever  
Door Spring L.H.  
Left Rear Baffle  
17  
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MANUFACTURERS LIMITED WARRANTY FOR:  
The limited warranty set forth below is given by MTD LLC with  
respect to new merchandise purchased and used in the  
United States, its possessions and territories.  
d.  
MTD LLC does not extend any warranty for products  
sold or exported outside of the United States, its  
possessions and territories, except those sold through  
MTD LLCs authorized channels of export distribution.  
Parts that are not genuine MTD parts are not covered  
by this warranty.  
Service completed by someone other than an  
authorized service dealer is not covered by this  
warranty.  
MTD LLC warrants this product against defects 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 Operators  
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  
accessory or attachment not approved by MTD LLC for use  
with the product(s) covered by this manual will void your  
warranty as to any resulting damage.  
e.  
f.  
g.  
Transportation charges and service calls are not  
covered.  
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 LLC. During the period of the warranty,  
the exclusive remedy is repair or replacement of the  
product as set forth above.  
Normal wear parts or components thereof are subject to  
separate terms as follows: All normal wear parts or  
component failures will be covered on the product for a period  
of 90 days regardless of cause. After 90 days, but within the  
two year period, normal wear part failures will be covered  
ONLY IF caused by defects in materials or workmanship of  
OTHER component parts. Normal wear parts and  
components include, but are not limited to: batteries, belts,  
blades, blade adapters, grass bags, rider deck wheels, seats,  
snow thrower skid shoes, 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  
LLC 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.  
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, check your  
Yellow Pages, or contact MTD LLC at P.O. Box 361131,  
Cleveland, Ohio 44136-0019, or call 1-800-800-7310 or log  
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.  
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.  
This limited warranty does not provide coverage in the  
following cases:  
a.  
The engine or component parts thereof. These items  
carry a separate manufacturers warranty. Refer to  
applicable manufacturers warranty for terms and  
conditions.  
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.  
b.  
c.  
Log splitter pumps, valves, and cylinders have a sepa  
rate one year warranty.  
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.  
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.  
MTD LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019; Phone: 1-800-800-7310  
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