Bolens Lawn Mower Series 544 User Manual

Operator’s Manual  
21” Mulching Mower  
Model Series 544  
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  
PRINTED IN U.S.A.  
769-00447A.
FORM NO.  
(12/02)  
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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.  
6. Always wear safety glasses or safety goggles  
General Operation  
during operation and while performing an  
adjustment or repair to protect your eyes. Thrown  
objects which ricochet can cause serious injury to  
the eyes.  
1. Read this operators manual carefully in its entirety  
before attempting to assemble this machine. Read,  
understand, and follow all instructions on the  
machine and in the manual(s) before operation. Be  
completely familiar with the controls and the proper  
use of this machine before operating it. Keep this  
manual in a safe place for future and regular  
reference and for ordering replacement parts.  
2. This machine is a precision piece of power  
equipment, not a plaything. Therefore, exercise  
extreme caution at all times. Your unit has been  
designed to perform one job: to mow grass. Do not  
use it for any other purpose.  
7. Wear sturdy, rough-soled work shoes and close-  
fitting slacks and shirts. Shirts and pants that cover  
the arms and legs and steel-toed shoes are  
recommended. Never operate this machine in bare  
feet, sandals, slippery or light weight (e.g. canvas)  
shoes.  
8. Do not put hands or feet near rotating parts or  
under the cutting deck. Contact with the blade can  
amputate hands and feet.  
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 over the foot during a fall caused by slipping  
or tripping. Do not hold on to the mower if you are  
falling; release the handle immediately.  
11. Never pull the mower back toward you while you  
are walking. If you must back the mower away from  
a wall or obstruction first look down and behind to  
avoid tripping and then follow these steps:  
a. Step back from the mower to fully extend your  
arms.  
3. Never allow children under 14 years old to operate  
this machine. 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. Only  
responsible individuals who are familiar with these  
rules of safe operation should be allowed to use this  
machine.  
4. Thoroughly inspect the area where the equipment  
is to be used. Remove all stones, sticks, wire,  
bones, toys and other foreign objects which could  
be tripped over or picked up and thrown by the  
blade. Thrown objects can cause serious personal  
injury. Plan your mowing pattern to avoid discharge  
of material toward roads, sidewalks, bystanders  
and the like. Also, avoid discharging material  
against a wall or obstruction which may cause  
discharged material to ricochet back toward the  
operator.  
b. Be sure you are well balanced with sure footing.  
c. Pull the mower back slowly, no more than half way  
toward you.  
d. Repeat these steps as needed.  
5. Mow only in daylight or in good artificial light. Walk,  
never run.  
6. Stop the blade when crossing gravel drives, walks  
or roads.  
7. If the equipment should start to vibrate abnormally,  
stop the engine and check immediately for the  
cause. Vibration is generally a warning of trouble.  
8. Shut the engine off and wait until the blade comes  
to a complete stop before removing the grass  
catcher or unclogging the chute. The cutting blade  
5. To help avoid blade contact or a thrown object  
injury, stay 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.  
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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.  
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.  
9. 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.  
10. Muffler and engine become hot and can cause a  
burn. Do not touch.  
11. Only use parts and accessories made for this  
machine by the manufacturer. Failure to do so, can  
result in personal injury.  
4. Use extreme care when approaching blind corners,  
doorways, shrubs, trees, or other objects that may  
obscure your vision of a child who may run into the  
mower.  
5. 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.  
12. If situations occur which are not covered in this  
manual, use care and good judgment. Contact your  
dealer for assistance. Telephone 1-866-840-6483  
for the name of your nearest dealer.  
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.  
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.  
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.  
8. Never fuel machine indoors because flammable  
vapors will accumulate in the area.  
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.  
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.  
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.  
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.  
Children  
Tragic accidents can occur if the operator is not alert to  
the presence of children. Children are often attracted to  
the mower and the mowing activity. They do not  
understand the dangers. Never assume that children  
will remain where you last saw them.  
1. Keep children out of the mowing area and under  
the watchful care of a responsible adult other than  
the operator.  
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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.  
15. Allow a mower to cool at least 5 minutes before  
storing.  
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.  
General Service:  
1. Never run an engine indoors or in a poorly  
ventilated area. Engine exhaust contains carbon  
monoxide, an odorless and deadly gas.  
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  
meet the original equipment specifications may  
lead to improper performance and compromise  
safety!”  
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 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!”  
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.  
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.  
6. Never tamper with safety devices. Check their  
proper operation regularly.  
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  
Roll or slide unit out of carton and check carton  
thoroughly for loose parts.  
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.  
Loose Parts in Carton  
Grass Bag  
Side Discharge Chute  
Rear Wheels  
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  
Spark Plug  
Wire  
Insert Hairpin  
Clip  
Weld Pin  
Hairpin  
Clip  
Figure 3  
Spark  
Plug Wire  
Spark Plug  
Figure 1  
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.  
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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Secure bag to frame by working the plastic  
Attaching Rear Wheels  
channels on bag over frame as shown in Figure 7B.  
All of the plastic channels except the center top of  
the bag attach from the outside of bag. The center  
top of the bag attaches from inside the bag.  
Remove hardware from hardware pack.  
Insert shoulder screw through wave washer, flat  
washer, rear wheel, and spring washer.  
Secure shoulder screw with hardware to rear pivot  
bar. See Figure 5.  
Plastic  
B
A
Channels  
Frame  
Spring Washer  
Hook  
Wave Washer  
Frame  
Shoulder  
Screw  
Assembly  
Bag  
Plastic  
Channels  
Flat Washer  
Figure 5  
Rear Wheel  
Attaching Starter Rope  
Figure 7  
Attaching Grass Catcher To Mower  
The rope guide is attached to the right side of upper  
handle. Loosen the wing nut which secures the  
rope guide. See Figure 6.  
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.  
Upper Handle  
Starter  
Rope  
Wing Nut  
Rope  
Guide  
Lower  
Handle  
Figure 6  
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.  
Figure 8  
Grass Catcher Assembly  
NOTE: Make certain the grass bag is turned right side  
out before assembling (warning label will be on the  
outside).  
IMPORTANT: Make sure cables are routed to the  
outside of the handle so they are not in the way when  
attaching the grass catcher.  
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.  
1. Frame Assembly  
2. Bag  
Assembling Soft Top Grass Catcher  
Place the bag over the frame (black plastic side is  
the bottom of bag). Slip the openings in the side of  
the plastic channels on the bag over the hooks on  
the grass catcher frame.  
Removing Grass Catcher  
Lift the rear discharge door on the mower, and lift  
the grass catcher up.  
Release the rear discharge door.  
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Do not remove the side mulching plug at any time,  
even when you are not mulching.  
Converting To Side Discharge  
Your mower has been shipped as a mulcher. To  
convert it to a side-discharge mower, lift the mulch-  
ing plug. Slide the two hooks on the side-discharge  
deflector under the hinge pin on the mulching plug  
assembly. Lower the mulching plug.See Figure 9.  
Mulching  
Plug  
Hinge  
Pin  
Side  
Chute  
Deflector  
Figure 9  
WARNING: Never operate the mower  
without the mulching cover, the grass  
catcher bag, or the discharge chute  
properly installed.  
SECTION 4: KNOW YOUR LAWN MOWER  
Read this operators manual and safety rules before  
operating your lawn mower. Compare the illustration in  
Figure 10 with your lawn mower to familiarize yourself  
with the location of various controls and adjustments.  
Save this manual for future reference.  
Blade Control  
Handle  
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.  
Recoil  
Starter  
Cutting Height  
Adjustment Lever  
Grass  
Catcher  
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. See  
Figure 10.  
Mulching Plug  
Figure 10  
Mulching Plug  
The mulching plug is 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. See Figure  
10.  
Recoil Starter  
The recoil starter is attached to the right handle. Stand  
behind the unit and pull the recoil starter to start the  
unit. See Figure 10.  
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Cutting Height Adjustment Levers  
Blade Control Handle  
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 10.  
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 10.  
This blade control mechanism is a safety  
device. Never attempt to bypass its  
operations.  
SECTION 5: OPERATING YOUR LAWN MOWER  
WARNING: Keep hands and feet away from  
Using Your Lawn Mower  
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.  
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.  
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.  
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  
designed to be operated at full throttle to give you the  
best cut and do the most effective job of mowing or  
mulching.  
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.  
Never fill fuel tank indoors with engine  
running or until the engine has been  
allowed to cool for at least two minutes  
after running.  
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.  
Starting Engine  
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.  
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.  
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.  
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SECTION 6: MAKING ADJUSTMENTS  
WARNING: Do not at any time make any  
adjustments without first stopping engine  
and disconnecting spark plug wire.  
Cutting Height Adjustment  
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 12.  
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.  
Height Adjustment  
Lever  
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.  
Turn lower handle around so the notch on the  
bottom of the lower handle is facing forward.  
See Figure 11.  
Reassemble, placing the bottom holes in the  
handle over the weld pins in the handle mounting  
bracket.  
Place the hairpin clips in the inner holes in the weld  
pins and insert the carriage bolts the upper hole on  
the handle mounting bracket and secure with  
plastic wing nuts.  
Figure 12  
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.  
Reassemble the upper handle to the lower handle.  
Attach the starter rope as instructed in the  
Assembly Section  
Engine Adjustments  
See the separate engine manual packed with your unit  
for adjustments to the engine.  
Notch  
Lower Handle  
Figure 11  
11  
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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)  
12  
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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 13.  
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 14  
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 13  
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.  
Replacing Rear Flap  
Cutting Blade Removal, Replacement, and Sharpening  
To remove rear flap, cut off the flat end of the wire  
rod which secures it to the deck. See Figure 14.  
Attach the new flap and new rod to deck, bending  
the ends of the new rod over to secure to deck.  
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 15.  
13  
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Remove the blade and the adapter from the  
crankshaft.  
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.  
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.  
Replace hex bolt and tighten hex bolt to torque: 450  
in. lbs. min., 600 in. lbs. max.  
Blade  
Adapter  
Blade Bell  
Support  
Hex Bolt  
NOTE: To ensure safe operation of your mower, the  
blade bolt must be checked periodically for correct  
torque.  
Figure 15  
WARNING: Periodically inspect the blade  
adapter for cracks, especially if you strike  
a foreign object. Replace when necessary.  
Storing your Lawn Mower  
The following steps should be taken to prepare your  
lawn mower for storage.  
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.  
Clean and lubricate mower thoroughly as described  
in the lubrication instructions.  
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.  
14  
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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.  
15  
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Model Series 544  
1
2
10  
9
3
4
11  
8
6
5
19  
7
12  
13  
18  
28  
61  
57  
41  
59  
14  
20  
21  
17  
16  
60  
40  
30  
33  
15  
24  
35  
34  
25  
19  
22  
23  
38  
29  
39  
31  
44  
36  
62  
42  
32  
27  
45  
43  
37  
47  
26  
52  
53  
36  
46  
48  
54  
55  
35  
49  
50  
41  
58  
56  
51  
16  
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Model Series 544  
Ref.  
Ref.  
No.  
Part No.  
No.  
Part Description  
Upper Handle  
Part No.  
Part Description  
749-1092A  
747-1161A  
720-0279  
710-1205  
710-1174  
736-0451  
720-0284  
749-0928A  
746-0957  
664-04005  
747-04080  
714-0104  
731-04134  
732-0700  
731-1236  
750-04162  
732-04090  
687-02032  
687-02034  
734-1864  
787-01104  
710-0654A  
736-0270  
710-0599  
712-0431  
782-5004A  
782-5003  
710-1017  
710-0703  
687-02033  
687-02031  
710-0286  
710-0896  
710-0216  
17488A  
Hex Cap Screw 3/8-16 x 1.0  
Pivot Bar - RH  
1.  
2.  
32.  
33.  
Control Handle  
Handle Knob  
17489A  
Pivot Bar - LH  
3.  
Rope Guide  
738-0507B  
736-0105  
732-0866  
736-0182  
736-0272  
738-0481A  
14578  
Shoulder Screw  
4.  
5.  
34.  
35.  
36.  
37.  
38.  
39.  
40.  
Carriage Bolt 5/16-18 x 2”  
Shoulder Washer.320 ID x.930 OD  
Wing Nut  
Spring Washer.375 ID x.870 OD  
Spring Lever  
6.  
Wave Washer.500 ID x 1.0 OD  
Flat Washer.510 ID x 1.37 OD  
Shoulder Screw  
7.  
8.  
Lower Handle  
Control Cable 37.25”  
Grass Bag  
9.  
Front Height Adjuster - RH  
Front Height Adjuster - LH  
Front Wheel Assembly 7 x1.8  
Flange Lock Nut 3/8-16  
Front Baffle  
10.  
11.  
12.  
13.  
14.  
15.  
16.  
17.  
18.  
Grass Catcher Frame  
Hairpin Clip  
14579  
734-1988  
712-0431  
782-5002A  
732-1014  
747-0710  
17032A  
41.  
42.  
43.  
44.  
45.  
46.  
47.  
48.  
49.  
50.  
51.  
52.  
53.  
54.  
55.  
56.  
57.  
58.  
59.  
60.  
61.  
62.  
Grass Bag Door  
Wire Rod  
Trail shield  
Torsion Spring  
Spacer.390 O.D. x.810 I.D. x.950”  
Door Spring-RH  
Hinge Pin  
Hinge Mounting Bracket  
Mulching Plug Assy Complete  
Blade Adapter  
Handle Brkt. w/Adj Assy Comp- LH  
Handle Brkt. w/Adj Assy Comp- RH  
Rear Wheel Assembly 14 x 1.8  
Deck 21”  
687-02055  
748-0376C  
742-0741  
736-0524A  
710-1044  
15261A  
21Mulching  
19.  
20.  
21.  
22.  
23.  
24.  
25.  
26.  
27.  
28.  
29.  
Blade Bell Support  
Hex Cap Screw 3/8-24 x 1.5  
Height Adjustment Plate  
Height Adjustment Knob  
Pivot Bar  
Hex Washer Screw 3/8-16 x 1.0  
Bell Washer.265 ID x.75 OD  
Hex Washer Screw 1/4-20 x.500  
Hex Lock Nut 3/8-16  
Rear Baffle - RH  
720-0426  
15262B  
732-0404  
738-0102  
747-0996  
731-04177  
732-04089  
712-3005  
712-0397  
720-0312  
Spring Lever  
Rear Baffle - LH  
Shoulder Bolt  
Tap Screw 1/4-14 x.625.  
Hex Carriage Screw 1/4-20  
Handle Bracket Assembly - RH  
Handle Bracket Assembly - LH  
Machine Screw 1/4-20 x.500  
Hex Washer Screw 1/4-14 x.625  
Chute Door Pivot Rod  
Side Discharge Deflector  
Door Spring - LH  
Flange Lock Nut 3/8-16  
Wing Nut  
30.  
31.  
Foam Grip  
17  
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NOTES  
18  
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NOTES  
19  
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MANUFACTURERS LIMITED WARRANTY FOR:  
The limited warranty set forth below is given by Troy-Bilt LLC  
with respect to new merchandise purchased and used in the  
United States, its possessions and territories.  
d.  
Troy-Bilt LLC does not extend any warranty for  
products sold or exported outside of the United States,  
its possessions and territories, except those sold  
through Troy-Bilt LLCs authorized channels of export  
distribution.  
Parts that are not genuine Troy-Bilt parts are not  
covered by this warranty.  
Service completed by someone other than an  
authorized service dealer is not covered by this  
warranty.  
Troy-Bilt 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 Troy-Bilt  
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 Troy-Bilt 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. Troy-Bilt  
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 Troy-Bilt LLC at P.O. Box 361131,  
Cleveland, Ohio 44136-0019, or call 1-866-840-6483 or 1-  
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.  
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.  
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.  
Troy-Bilt LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019; Phone: 1-866-840-6483, 1-330-558-7220  
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