Bolens Lawn Mower Series 540 User Manual

OPERATOR’S MANUAL  
21” Rear & Side  
Discharge  
Mulching Mower  
Model Series 540  
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 368022 Cleveland, Ohio 44136-9722.  
MTD PRODUCTS INC. P.O. BOX 368022 CLEVELAND, OHIO 44136-9722  
770-10019B.
(10/00)  
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 symbol - heed its warning.  
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.  
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 instructions could result in serious injury or death.  
8. Do not put hands or feet near rotating parts or under the  
General Operation  
cutting deck. Contact with the blade can amputate hands  
1. Read this operator’s manual carefully in its entirety  
and feet.  
before attempting to assemble this machine. Read,  
understand, and follow all instructions on the machine  
contact or thrown object injuries.  
and in the manual(s) before operation. Be completely  
9. A missing or damaged discharge cover can cause blade  
10. Many injuries occur as a result of the mower being pulled  
familiar with the controls and the proper use of this  
over the foot during a fall caused by slipping or tripping.  
machine before operating it. Keep this manual in a safe  
Do not hold on to the mower if you are falling; release the  
place for future and regular reference and for ordering  
handle immediately.  
replacement parts.  
11. Never pull the mower back toward you while you are  
2. This machine is a precision piece of power equipment,  
walking. If you must back the mower away from a wall or  
not a plaything. Therefore, exercise extreme caution at all  
obstruction first look down and behind to avoid tripping  
times. Your unit has been designed to perform one job: to  
and then follow these steps:  
mow grass. Do not use it for any other purpose.  
a. Step back from the mower to fully extend your  
3. Never allow children under 14 years old to operate this  
arms.  
machine. Children 14 years old and over should read and  
b. Be sure you are well balanced with sure footing.  
understand the operation instructions and safety rules in  
c. Pull the mower back slowly, no more than half way  
this manual and should be trained and supervised by a  
toward you.  
parent. Only responsible individuals who are familiar with  
d. Repeat these steps as needed.  
these rules of safe operation should be allowed to use  
12. Do not operate the mower while under the influence of  
this machine.  
alcohol or drugs.  
4. Thoroughly inspect the area where the equipment is to  
13. Do not engage the self-propelled mechanism on units so  
be used. Remove all stones, sticks, wire, bones, toys and  
equipped while starting engine.  
other foreign objects which could be tripped over or  
14. The blade control handle is a safety device. Never  
picked up and thrown by the blade. Thrown objects can  
attempt to bypass its operation. Doing so makes the  
cause serious personal injury. Plan your mowing pattern  
safety device inoperative and may result in personal  
to avoid discharge of material toward roads, sidewalks,  
injury through contact with the rotating blade. The blade  
bystanders and the like. Also, avoid discharging material  
control handle must operate easily in both directions and  
against a wall or obstruction which may cause  
automatically return to the disengaged position when  
discharged material to ricochet back toward the operator.  
released.  
5. To help avoid blade contact or a thrown object injury, stay  
15. Never operate the mower in wet grass. Always be sure of  
in the operator zone behind the handles and keep  
your footing. A slip and fall can cause serious personal  
children, bystanders, helpers and pets at least 75 feet  
injury. If you feel you are losing your footing, release the  
from the mower while it is in operation. Stop machine if  
blade control handle immediately and the blade will stop  
anyone enters the area.  
rotating within three seconds.  
6. Always wear safety glasses or safety goggles during  
16. Mow only in daylight or in good artificial light. Walk, never  
operation and while performing an adjustment or repair to  
run.  
protect your eyes. Thrown objects which ricochet can  
17. Stop the blade when crossing gravel drives, walks or  
cause serious injury to the eyes.  
roads.  
7. Wear sturdy, rough-soled work shoes and close-fitting  
18. If the equipment should start to vibrate abnormally, stop  
slacks and shirts. Shirts and pants that cover the arms  
the engine and check immediately for the cause.  
and legs and steel-toed shoes are recommended. Never  
Vibration is generally a warning of trouble.  
operate this machine in bare feet, sandals, slippery or  
19. Shut the engine off and wait until the blade comes to a  
light weight (e.g. canvas) shoes.  
complete stop before removing the grass catcher or  
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unclogging the chute. The cutting blade continues to  
rotate for a few seconds after the engine is shut off.  
Never place any part of the body in the blade area until  
you are sure the blade has stopped rotating.  
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.  
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.  
obscure your vision of a child who may run into the  
mower.  
5. Keep children away from hot or running engines. They  
can suffer burns from a hot muffler.  
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.  
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  
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  
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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!”  
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.  
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  
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!”  
10. Do not change the engine governor setting or overspeed  
the engine. The governor controls the maximum safe  
operating speed of the engine.  
6. Never tamper with safety devices. Check their proper  
operation regularly.  
7. 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.  
8. Never attempt to make a wheel or cutting height  
adjustment while the engine is running.  
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.  
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.  
NOTE: Not all safety labels shown may apply to your lawn mower.  
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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.  
NOTE: Reference to right or left hand side of the mower  
is observed from the operating position.  
Removing Unit From Carton  
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.)  
Cut along corners, lay carton down flat, and remove  
packing material.  
Figure 2  
Remove the hairpin clips from the outer hole in the  
weld pins on the handle mounting brackets. Using a  
pair of pliers, squeeze one leg of the lower handle  
against the handle mounting bracket. Insert the  
hairpin clip into the inner hole on the weld pin.  
Repeat on the other side. See Figure 3.  
After moving the hairpin clip, insert the carriage bolt  
from hardware pack in the upper hole on the handle  
mounting bracket and secure with plastic wing nut  
from the hardware pack. Repeat on other side.  
Roll or slide unit out of carton and check carton  
thoroughly for loose parts.  
Loose Parts in Carton  
Grass Bag  
Side Discharge Chute  
Hardware Pack  
Disconnecting Spark Plug Wire  
Before setting up your lawn mower, disconnect the spark  
plug wire from the spark plug and ground against the  
engine. See Figure 1.  
Handle Mounting  
Bracket  
Carriage Bolt  
Bolt  
Wing Nut  
Insert Hairpin  
Clip  
Spark Plug  
Wire  
Weld Pin  
Hairpin  
Clip  
Figure 3  
Spark  
Plug Wire  
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.  
Spark Plug  
Figure 1  
See Figure 4.  
Cable Tie  
Setting Up Your Lawn Mower  
Assembling Handle  
Lift up and pull back on the upper handle to raise the  
handle into the operating position. Make certain the  
lower handle is seated securely into the handle  
bracket assemblies. Tighten the wing nuts on each  
side of the handle (carriage bolts must be seated  
properly into the handle). See Figure 2.  
Lower  
Handle  
Figure 4  
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.  
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Attaching Starter Rope  
Discharge Door  
The rope guide is attached to the right side of upper  
handle. Loosen the wing nut which secures the  
rope guide. See Figure 5.  
Upper Handle  
Starter  
Rope  
Wing Nut  
Rope  
Guide  
Lower  
Handle  
Grass Bag  
Figure 5  
Figure 7  
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 the wing  
nut.  
To remove the grass catcher, lift the rear discharge  
door on the mower, lift the grass catcher up and off  
the pivot rod. Reinstall the mulching baffle and  
release the rear discharge door.  
WARNING: Never operate the mower  
unless the hooks on the grass catcher are  
firmly seated on the chute pivot rod, and  
the rear discharge door rests firmly  
against the top of the grass catcher.  
Attaching Grass Catcher To Mower  
NOTE: The mulching baffle, if so equipped, is already  
in place on the mower for shipping purposes. Your lawn  
mower may be equipped with both a mulching baffle  
and a mulching plug. While the mulching baffle is  
located at the rear of the mower, the mulching plug is  
located on the right side of the cutting deck. Do not  
remove the mulching plug from the mower even when  
you are not mulching the grass.  
Converting To Side Discharge  
If your unit is equipped with a side discharge chute, you  
can convert to a side discharge mower as follows:  
Lift the rear discharge door and install the mulching  
baffle. See Figure 6.  
On the side of the mower, lift the mulching plug and  
slide the two hooks of the side discharge chute  
under the hinge pin on the mulching plug assembly.  
Lower the side mulching plug. See Figure 8.  
Do not remove the side mulching plug at any time,  
even when you are not mulching.  
To remove the mulching baffle, lift the rear dis-  
charge door on the mower. Remove the mulching  
baffle. See Figure 6.  
Mulching  
Baffle  
Mulching Plug  
Hinge Pin  
Deflector  
Figure 6  
Hook  
IMPORTANT: Make sure cables are routed to the  
outside of the handle so they are not in the way when  
attaching the grass catcher.  
Lift the rear discharge door on the mower.  
Place the hooks, found on both sides of the grass  
catcher frame, over the chute door pivot rod at the  
rear of the mower. Release the rear discharge door.  
See Figure 7.  
Figure 8  
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SECTION 4: KNOW YOUR LAWN MOWER  
Read this operator’s manual and safety rules before  
operating your lawn mower. Compare the illustration in  
Figure 9 with your lawn mower to familiarize yourself  
with the location of various controls and adjustments.  
Save this manual for future reference.  
Grass Catcher  
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.  
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.  
Blade Control  
Handle  
Recoil  
Starter  
Recoil Starter  
Cutting Height  
Adjustment Lever  
The recoil starter is attached to the right handle. Stand  
behind the unit and pull the recoil starter to start the  
unit. See Figure 9.  
Grass  
Catcher  
Blade Control Handle  
The blade control handle is located on the upper handle  
of the mower. The blade control handle must be  
depressed in order to operate the unit. Release blade  
control handle to stop engine and blade. See Figure 9.  
WARNING: This blade control mechanism  
is a safety device. Never attempt to bypass  
its operations.  
Mulching Plug  
Figure 9  
Cutting Height Adjustment Levers  
Mulching Plug  
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.  
Both the mulching baffle and the mulching plug are  
used only for mulching purposes. Instead of collecting  
the grass clippings in a grass catcher, some mower  
models have the option of recirculating the clippings  
back to the lawn.  
SECTION 5: OPERATING YOUR LAWN MOWER  
WARNING: Keep hands and feet away from  
chute area on the cutting deck. The  
operation of any lawn mower can result in  
foreign objects being thrown into the eyes,  
which can result in severe eye damage.  
Always wear safety glasses or eye shields.  
Never fill fuel tank indoors with engine  
running or until the engine has been  
allowed to cool for at least two minutes  
after running.  
Starting Engine  
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 it is determine  
which height is best for your lawn. See the Adjustment  
Section for details.  
Attach spark plug wire to spark plug. Make certain  
the metal cap on the end of the spark plug is  
fastened securely over the metal tip on the spark  
plug.  
Prime engine as instructed in the separate engine  
manual packed with your unit.  
Your lawn mower may be equipped with a constant  
speed throttle, which is set at full throttle for best  
performance.  
Gas and Oil Fill-Up  
Service the engine with gasoline and oil as instructed in  
the separate engine manual packed with your mower.  
Read instructions carefully.  
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Stand behind the mower and squeeze the blade  
control handle against the upper handle.  
Grasp recoil starter handle and pull rope out slowly  
until engine reaches the start of compression cycle  
(rope will pull slightly harder at this point). Let the  
rope rewind slowly. Pull rope with a rapid,  
continuous, full arm stroke. Keeping a firm grip on  
the starter handle, let the rope return to the starter  
slowly.  
designed to be operated at full throttle to give you the  
best cut and do the most effective job of mowing or  
mulching.  
WARNING: If you strike a foreign object,  
stop the engine. Remove wire from the  
spark plug, thoroughly inspect the mower  
for any damage, and repair the damage  
before restarting and operating the  
mower. Extensive vibration of the mower  
during operation is an indication of  
damage. The unit should be promptly  
inspected and repaired.  
Using Your Lawn Mower  
Be sure that the lawn is clear of stones, sticks, wire, or  
other objects which could damage the lawn mower or  
the engine. Such objects could be accidently thrown by  
the mower in any direction and cause serious personal  
injury to the operator and others.  
Mulching  
For effective mulching, do not cut wet grass because it  
tends to stick to the underside of the deck, preventing  
proper mulching of grass clippings. New or thick grass  
may require a narrower cut. The ground speed should  
be adjusted to the condition of the lawn. If mowing has  
been delayed and the grass has been allowed to grow  
in excess of 4, mulching is not recommended. Mow  
using the side discharge to reduce the grass height to 3  
1/4maximum before mulching.  
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 could cause  
you to slip and fall. New grass, thick grass, or wet grass  
may require a narrower cut.  
For a healthier lawn, never cut off more than one-third  
of the total length of the grass. Your lawn should be cut  
in the fall as long as there is growth. This mower is  
SECTION 6: MAKING ADJUSTMENTS  
WARNING: Do not at any time make any  
adjustments without first stopping engine  
and disconnecting spark plug wire.  
the handle mounting bracket and secure with  
plastic wing nuts.  
Reassemble the upper handle to the lower handle.  
Attach the starter rope as instructed in the  
Assembly Section.  
Handle Height Adjustment  
Your mower is shipped with the handle in the higher  
height position. To lower the height proceed as follows:  
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 the  
cables.  
Notch  
Lower Handle  
Remove the hairpin clips from the weld pins on the  
handle brackets and remove the wing nuts and  
carriage bolts from the upper hole on the handle  
mounting bracket. Press out on the legs of the  
lower handle and remove lower handle from the  
mower.  
Figure 10  
Cutting Height Adjustment  
Turn lower handle around so the notch on the  
bottom of the lower handle is facing forward.  
See Figure 10.  
Reassemble, placing the bottom holes in the  
handle over the weld pins in the handle mounting  
bracket.  
An adjusting plate and spring lever at each wheel  
position provides cutting height adjustment. Each  
adjusting plate has assorted height positions. When the  
spring lever is moved from one location to another the  
height of cut will be changed. Simply depress the lever  
towards wheel and move lever assembly to desired  
position. See Figure 11.  
Place the hairpin clips in the inner holes in the weld  
pins and insert the carriage bolts the upper hole on  
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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.  
Height Adjustment  
Lever  
Engine Adjustments  
See the separate engine manual packed with your unit  
for adjustments to the engine.  
Figure 11  
SECTION 7: MAINTAINING YOUR LAWN MOWER  
Some adjustments will have to be made  
General Recommendations  
periodically to maintain your unit properly. All  
adjustments in the Making Adjustments section of  
this manual should be checked at least once each  
season.  
Periodically check all fasteners and make sure  
these are tight.  
Follow the maintenance schedule under Customer  
Responsibilities to get quality performance from  
your lawn mower.  
Always observe safety rules when performing any  
maintenance.  
The warranty on this lawn mower does not cover  
items that have been subjected to operator abuse  
or negligence. To receive full value from the  
warranty, operator must maintain the lawn mower  
as instructed in this manual.  
Changing of engine governed speed will void  
engine warranty.  
Customer Responsibilities  
MAINTENANCE  
SCHEDULE  
SERVICE  
DATES  
Lubricate Wheels  
Lubricate Blade Control  
Clean Deck  
Blade Care  
Check Oil  
Change Oil  
Replace Air Filter  
Clean Engine  
Check Spark Plug  
Check Spark Arrester (if any)  
11  
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Lubrication  
Always stop engine and disconnect spark  
Rear Discharge  
Door  
plug wire before cleaning, lubricating or  
doing any kind of service work on the lawn  
mower.  
Handle  
Bracket  
Blade Control: Lubricate the pivot points on the blade  
control handle and the brake cable at least once a  
season with light oil. The blade control must operate  
freely in both directions. See Figure 12.  
Handle  
Bracket  
Rear & Side Discharge Doors: The torsion springs  
and pivot points should be lubricated periodically with  
light oil to prevent any rust or binding. Door must work  
freely.  
Rear Flap  
Wheels: The wheels require no lubrication. However, if  
the wheels are removed for any reason, lubricate the  
surface of the axle bolt and the inner surface of the  
wheel with light oil. Engine oil may also be used.  
Figure 13  
Engine  
Refer to the separate engine manual for all engine  
maintenance instructions.  
Engine: Follow engine manual for instruction and  
schedule of lubrication.  
Maintain engine oil as instructed in the separate  
engine manual packed with your unit.  
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  
separate engine manual packed with your unit.  
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.  
Lubricate  
Lubricate  
Lubricate  
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).  
Figure 12  
Maintenance  
NOTE: When tipping the unit or emptying the fuel tank  
keep the air cleaner 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.  
IMPORTANT: We do not recommend the use of a  
pressure washer or garden hose to clean your unit. The  
use of water will result in shorten life and reduce  
serviceability.  
Cutting Blade Removal, Replacement, and Sharpening  
Replacing Rear Flap  
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.  
Remove the bolt and the blade bell support which  
hold the blade and the blade adapter to the engine  
crankshaft. See Figure 14.  
To remove rear flap, cut off the flat end of the wire  
rod which secures it to the deck. See Figure 13.  
Attach the new flap and new rod to deck, bending  
the ends of the new rod over to secure to deck  
12  
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Remove the blade and the adapter from the  
crankshaft.  
Slide the blade adapter onto the engine crankshaft.  
Place the blade on the adapter. Be certain the  
blade is 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.  
Blade  
Adapter  
Replace hex bolt and tighten hex bolt to torque: 450  
in. lbs. min., 600 in. lbs. max.  
Blade Bell  
Support  
NOTE: To ensure safe operation of your mower, the  
blade bolt must be checked periodically for correct  
torque.  
Hex Bolt  
Storing your Lawn Mower  
Figure 14  
The following steps should be taken to prepare your  
lawn mower for storage.  
WARNING: Periodically inspect the blade  
adapter for cracks, especially if you strike  
a foreign object. Replace when necessary.  
Clean and lubricate mower thoroughly as described  
in the lubrication instructions.  
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. An unbalanced blade will  
cause excessive vibration when rotating at high  
speeds. It may cause damage to the mower, and could  
break causing personal injury.  
IMPORTANT:We do not recommend the use of a  
pressure washer or garden hose to clean your unit.  
Refer to engine manual for correct engine 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.  
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.  
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.  
Be sure to install the blade with the side of the  
blade marked Bottom(or with part number) facing  
the ground when the mower is in the operating  
position.  
13  
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SECTION 8: TROUBLESHOOTING  
Problem  
Cause  
Remedy  
Engine fails to start  
1. Blade control handle disengaged.  
2. Spark plug wire disconnected.  
3. Fuel tank empty or stale fuel.  
4. Blocked fuel line.  
1. Engage blade control handle.  
2. Connect wire to spark plug.  
3. Fill tank with clean, fresh gasoline.  
4. Clean fuel line.  
5. Faulty spark plug.  
6. Engine flooded  
5. Clean, adjust gap, or replace.  
6. Wait a few minutes to restart, but do not  
prime.  
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.  
Occasional skip (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 1. Reset gap to .030or replace spark  
wide.  
plug.  
2. Carburetor improperly adjusted.  
3. Dirty air cleaner.  
2. Adjust carburetor.  
3. Clean air cleaner.  
Excessive vibration  
1. Cutting blade loose or unbalanced. 1. Tighten blade and adapter. Balance  
blade.  
2. Bent cutting 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 above, contact your local authorized service dealer.  
14  
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Notes  
15  
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Model Series 540  
19  
15  
1
11  
12  
21  
5
3
16  
95  
9
6
96  
2
18  
4
14  
52  
17  
57  
4
57  
20  
13  
20  
23  
61  
92  
52  
30  
58  
31  
39  
24  
89  
56  
55  
82  
88  
80  
50  
40  
81  
62  
59  
71  
90  
94  
22  
84  
87  
51  
76  
73  
47  
42  
86  
83  
44  
43  
44  
85  
63  
41  
70  
49  
32  
53  
36  
66  
67  
64  
54  
34  
33  
71  
60  
93  
72  
16  
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Model Series 540  
Ref.  
Ref.  
No.  
Part No.  
No.  
Part Description  
Part No.  
17488A  
Part Description  
Pivot Bar - RH  
1.  
747-0824  
647-0004  
710-1205  
720-0279  
710-1174  
712-0324  
720-0314  
710-1270  
749-0438C  
720-0295  
749-0907A  
726-0240  
747-0995A  
746-0550  
746-0737  
746-0841  
746-0847  
664-0084  
664-0085  
664-0086  
731-0066  
731-0068  
714-0104  
746-0883  
682-3058  
682-3059  
782-7599A  
750-0434  
732-0700  
731-1236  
753-0588  
710-1044  
736-0524A  
742-0741  
736-0356  
712-0130  
15261A  
Control Handle Assembly  
Deluxe Control Handle  
Rope Guide  
50.  
17489A  
Pivot Bar - LH  
2.  
3.  
51.  
52.  
53.  
54.  
55.  
56.  
782-5002  
712-0397  
782-5003  
710-1017  
710-0896  
682-3058  
682-3059  
710-0703  
782-0047  
734-1860  
734-1864  
734-1818  
734-1781  
734-1841  
734-1987  
747-0996  
710-0654A  
682-7000  
731-1409  
782-5007A  
782-5004  
736-0182  
736-0105  
731-1426  
738-0481A  
736-0456  
720-0312  
732-0866  
712-3005  
710-0514  
732-0731  
747-0710  
736-0270  
710-0216  
736-0331  
712-0798  
732-0809  
738-0102  
782-7006  
710-0896  
782-9050  
Front Baffle  
Handle Knob  
Wing Knob  
4.  
Curved Hd. Bolt 5/16-18 x 2”  
Hex L-Nut 1/4-20 Thd.  
Hand Knob  
Rear Baffle  
5.  
Torx Mach. AB-Tap Scr.  
Hex Washer Screw 1/4-14 x .625  
Handle Bracket AssemblyR.H.  
Handle Bracket AssemblyL.H.  
Carriage Bolt, 1/4-20 x .75”  
Deck 21”  
6.  
9.  
Screw 1/4-20 x 1.31  
Upper Handle  
11.  
12.  
13.  
14.  
15.  
16.  
Foam Grip †  
57.  
58.  
59.  
Lower Handle  
Cable Tie  
Rear Wheel Assy 14 x 2  
Rear Wheel Assy. 14 x 1.8  
Front Wheel Assy. 8 x 2  
Front Wheel Assy 8 x 1.75  
Front Wheel Assy 8 x 1.7  
Front Wheel Assembly 8 x 1.8  
Chute Door Pivot Rod  
Sems Screw TT 3/8-16 x 1  
Mulching Plug  
Catcher Frame  
Control Cable 39”  
60.  
Control Cable 51”  
17.  
18.  
Throttle Cable 60” †  
Throttle Cable 42” †  
Grass Bag w/o logo  
Grass Bag w/ logo, Yellow  
Grass Bag w/ logo, Red  
Hard Top w/ logo  
61.  
62.  
63.  
64.  
66.  
67.  
70.  
71.  
72.  
73.  
76.  
80.  
81.  
82.  
83.  
84.  
85.  
87.  
88.  
89.  
90.  
92.  
93.  
94.  
95.  
96.  
19.  
Chute Deflector  
Hard Top w/o logo  
Rear Mulch Plug  
20.  
21.  
22.  
Internal Cotter Pin  
Rear Mulch Baffle  
Throttle Housing w/o Lever  
Handle Bracket Assembly - RH  
Handle Brkt Assy - LH (Not Shown)  
Grass Bag Door  
Wave Washer  
Spring Washer  
Hub Cap †  
23.  
24.  
30.  
31.  
32.  
33.  
34.  
36.  
39.  
40.  
41.  
42.  
43.  
44.  
47.  
49.  
Rear Axle Bolt  
Spacer .375 OD x .50 ID x 1.02”  
Wire Rod  
Flat Washer  
Foam Grip  
Rear Flap  
Height Adj. Lever  
Blade Adapter Kit  
Hex Flange Lock Nut 3/8-16  
Hex Cap Screw 3/8-16 x 1.0  
Torsion Spring  
Hex Bolt 3/8-24 x 1.5”  
Blade Bell Support  
Mulching Blade  
Hinge Pin  
Bell Washer .39I.D. x 1.38”  
Hex Lock Nut 3/8-16  
Height Adj. Plate  
Bell Washer .265 x .75 x .062  
Hex Screw 3/8-16 x .75  
Bell Washer .39 x 1.13 x .062  
Hex Nut 3/8-16  
15262B  
Pivot Bar  
732-0404  
738-0507B  
720-0190  
14578  
Spring Lever: Front Wheel  
Shoulder Bolt .5Dia. x .357”  
Spring Lever Knob  
Height Adj. Assembly Comp - RH  
Height Adj. Assembly Comp - LH  
Torsion Spring  
Front Axle Bolt  
Hinged Mounting Bracket  
Hex Screw 1/4-14 x .625  
Mounting Bracket  
14579  
If Equipped  
17  
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18  
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19  
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MANUFACTURERS LIMITED WARRANTY FOR:  
c. Routine maintenance items such as lubricants, filters,  
blade sharpening and tune-ups, or adjustments such  
as brake adjustments, clutch adjustments or deck  
adjustments; and normal deterioration of the exterior  
finish due to use or exposure.  
The limited warranty set forth below is given by MTD  
PRODUCTS INC (MTD) with respect to new merchandise  
purchased and used in the United States, its possessions  
and territories.  
d. MTD does not extend any warranty for products sold  
or exported outside of the United States of America,  
its possessions and territories, except those sold  
through MTDs authorized channels of export distribu-  
tion.  
MTD warrants this product 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  
material 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, com-  
mercial 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 Products Inc. for use with the product(s)  
covered by this manual will void your warranty as to any  
resulting damages.  
No implied warranty, including any implied warranty of  
merchantability or 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 or guaranty, 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 War-  
ranty, the exclusive remedy is repair or replacement of  
the product as set forth above. (Some states do not  
allow limitations on how long an implied warranty lasts, so  
the above limitation may not apply to you.)  
Normal wear parts or components thereof are subject to  
separate terms as follows: All normal wear part or compo-  
nent 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 material or workmanship of  
OTHER component parts. Normal wear parts and compo-  
nents include, but are not limited to, belts, blades, blade  
adapters, grass bags, rider deck wheels, seats, snow  
thrower skid shoes, shave plates and tires. Batteries are  
covered by a 90-day limited replacement warranty.  
The provisions as set forth in this Warranty provide the  
sole and exclusive remedy arising from the sales. MTD  
shall not be liable for incidental or consequential loss  
or damages including, without limitation, expenses  
incurred for substitute or replacement lawn care ser-  
vices, for transportation or for related expenses, or for  
rental expenses to temporarily replace a warranted  
product. (Some states do not allow the exclusion or limita-  
tion of incidental or consequential damages, so the above  
exclusion or limitation 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, please check for a listing in the Yellow Pages or  
contact the Customer Service Department of MTD PROD-  
UCTS INC by calling 1-800-800-7310 or writing to P.O. Box  
368022, Cleveland, Ohio 44136-9722.  
In no event shall recovery of any kind be greater than the  
amount of the purchase price of the product sold. Alteration  
of the safety features of the product shall void this War-  
ranty. 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 use or 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. Please refer  
to the applicable manufacturers warranty on these  
items.  
This limited warranty shall not extend to anyone other than  
the original purchaser, original lessee or the person for  
whom it was purchased as a gift.  
b. 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.  
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