Exmark Lawn Mower MPKA21 User Guide

METRO® 21  
For Serial Nos.  
790,000 & Higher  
Part No. 4500-400 Rev. A  
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Introduction  
CONGRATULATIONS on the purchase of your  
Exmark Mower. This product has been carefully  
designed and manufactured to give you a maximum  
amount of dependability and years of trouble-free  
operation.  
This manual contains operating, maintenance,  
adjustment, and safety instructions for your Exmark  
mower.  
Figure 1  
1. Model and serial number location  
BEFORE OPERATING YOUR MOWER,  
CAREFULLY READ THIS MANUAL IN ITS  
ENTIRETY.  
By following the operating, maintenance, and safety  
instructions, you will prolong the life of your mower,  
maintain its maximum efficiency, and promote safe  
operation.  
Model No.  
Serial No.  
If additional information is needed, or should you  
require trained mechanic service, contact your  
authorized Exmark equipment dealer or distributor.  
All Exmark equipment dealers and distributors are  
kept informed of the latest methods of servicing  
and are equipped to provide prompt and efficient  
service in the field or at their service stations. They  
carry ample stock of service parts or can secure them  
promptly for you from the factory.  
All Exmark parts are thoroughly tested and inspected  
before leaving the factory, however, attention is  
required on your part if you are to obtain the fullest  
measure of satisfaction and performance.  
Whenever you need service, genuine Exmark parts,  
or additional information, contact an Authorized  
Service Dealer or Exmark Customer Service and have  
the model and serial numbers of your product ready.  
Figure 1 identifies the location of the model and serial  
numbers on the product. Write the numbers in the  
space provided.  
3
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Contents  
Introduction ........................................................... 3  
Periodic Maintenance ....................................... 24  
Service Air Filter(Honda Units) ..................... 27  
Drive(Self-Propelled Units Only)............... 31  
Cover(Self-Propelled Models Only) ........... 33  
4
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Safety  
Safe Operating Practices  
Safety  
Training  
Safety Alert Symbol  
• Read the Operator’s Manual and other training  
material. If the operator(s) or mechanic(s) can  
not read English it is the owner’s responsibility to  
explain this material to them.  
This lawn mower meets or exceeds the CPSC blade  
safety requirements for walk-behind rotary mowers  
and the B71.4 specifications of the American National  
Standards Institute in effect at the time of production  
• Become familiar with the safe operation of the  
equipment, operator controls, and safety signs.  
Exmark designed and tested this lawn mower to offer  
reasonably safe service; however, failure to comply  
with the following instructions may result in personal  
injury.  
• All operators and mechanics should be trained.  
The owner is responsible for training the users.  
• Never let children or untrained people operate  
or service the equipment. Local regulations may  
restrict the age of the operator.  
This Safety Alert Symbol (Figure 2) is used both in  
this manual and on the machine to identify important  
safety messages which must be followed to avoid  
accidents  
• The owner/user can prevent and is responsible  
for accidents or injuries occurring to himself or  
herself, other people or property.  
This symbol means: ATTENTION! BECOME  
ALERT! YOUR SAFETY IS INVOLVED!  
Preparation  
• Evaluate the terrain to determine what accessories  
and attachments are needed to properly and  
safely perform the job. Only use accessories and  
attachments approved by Exmark.  
Figure 2  
1. Safety alert symbol  
• Wear appropriate clothing including safety glasses,  
substantial footwear, long trousers, and hearing  
protection. Do Not operate when barefoot or  
when wearing open sandals. Long hair, loose  
clothing or jewelry may get tangled in moving  
parts.  
The safety alert symbol appears above information  
which alerts you to unsafe actions or situations  
and will be followed by the word DANGER,  
WARNING, or CAUTION.  
DANGER: White lettering / Red background.  
Indicates an imminently hazardous situation which, if  
not avoided, Will result in death or serious injury.  
CAUTION  
WARNING: Black lettering / Orange background.  
Indicates a potentially hazardous situation which, if  
not avoided, Could result in death or serious injury.  
This machine produces sound levels in  
excess of 85 dBA at the operator’s ear and  
can cause hearing loss through extended  
periods of exposure.  
CAUTION: Black lettering / Yellow background.  
Indicates a potentially hazardous situation which, if  
not avoided, May result in minor or moderate injury.  
Wear hearing protection when operating this  
machine.  
This manual uses two other words to highlight  
information. Important calls attention to special  
mechanical information and Note emphasizes  
general information worthy of special attention.  
• Inspect the area where the equipment is to be  
used and remove all rocks, toys, sticks, wires,  
bones, and other foreign objects which can be  
thrown by the machine and may cause personal  
injury to the operator or bystanders.  
5
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Safety  
DANGER  
DANGER  
In certain conditions gasoline is extremely  
flammable and vapors are explosive.  
In certain conditions during fueling, static  
electricity can be released causing a spark  
which can ignite gasoline vapors. A fire or  
explosion from gasoline can burn you and  
others and cause property damage.  
A fire or explosion from gasoline can burn  
you, others, and cause property damage.  
• Fill the fuel tank outdoors in an open  
area, when the engine is cold. Wipe up  
any gasoline that spills.  
• Always place gasoline containers on the  
ground away from your vehicle before  
filling.  
• Never refill the fuel tank or drain the  
machine indoors or inside an enclosed  
trailer.  
• Do Not fill gasoline containers inside a  
vehicle or on a truck or trailer bed because  
interior carpets or plastic truck bed liners  
may insulate the container and slow the  
loss of any static charge.  
• Do Not fill the fuel tank completely  
full. Add gasoline to the fuel tank until  
the level is 1/4 to 1/2 inch (6–13 mm)  
below the bottom of the filler neck. This  
empty space in the tank allows gasoline  
to expand.  
• When practical, remove gas-powered  
equipment from the truck or trailer and  
refuel the equipment with its wheels on  
the ground.  
• Never smoke when handling gasoline,  
and stay away from an open flame or  
where gasoline fumes may be ignited by  
spark.  
• If this is not possible, then refuel such  
equipment on a truck or trailer from a  
portable container, rather than from a  
gasoline dispenser nozzle.  
• Store gasoline in an approved container  
and keep it out of the reach of children.  
• If a gasoline dispenser nozzle must be  
used, keep the nozzle in contact with the  
rim of the fuel tank or container opening  
at all times until fueling is complete.  
• Add fuel before starting the engine.  
Never remove the cap of the fuel tank or  
add fuel when engine is running or when  
the engine is hot.  
WARNING  
• If fuel is spilled, Do Not attempt to start  
the engine. Move away from the area of  
the spill and avoid creating any source of  
ignition until fuel vapors have dissipated.  
Gasoline is harmful or fatal if swallowed.  
Long-term exposure to vapors has caused  
cancer in laboratory animals. Failure to use  
caution may cause serious injury or illness.  
• Do Not operate without entire exhaust  
system in place and in proper working  
condition.  
• Avoid prolonged breathing of vapors.  
• Keep face away from nozzle and gas  
tank/container opening.  
• Keep away from eyes and skin.  
• Never siphon by mouth.  
• Check that the operator’s presence controls,  
safety switches, and shields are attached and  
functioning properly. Do Not operate unless they  
are functioning properly.  
6
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Safety  
• Never attempt to make wheel height adjustments  
while the engine is running.  
Operation  
• Stop engine, wait for all moving parts to stop,  
remove the spark plug wire(s) and/or remove key.  
WARNING  
Operating engine parts, especially the  
muffler, become extremely hot. Severe burns  
can occur on contact and debris, such as  
leaves, grass, brush, etc. can catch fire.  
– Before checking, cleaning or working on the  
mower.  
– After striking a foreign object or abnormal  
vibration occurs (inspect the mower for  
damage and make repairs before restarting  
and operating the mower).  
• Allow engine parts, especially the muffler,  
to cool before touching.  
• Remove accumulated debris from muffler  
and engine area.  
– Before clearing blockages.  
– Whenever you leave the mower.  
• Stop engine, wait for all moving parts to stop:  
– Before refueling.  
• Install and maintain in working order a  
spark arrester before using equipment  
on forest-covered, grass-covered, or  
brush-covered unimproved land.  
– Before dumping the grass catcher.  
– Before making height adjustments.  
WARNING  
Engine exhaust contains carbon monoxide,  
which is an odorless deadly poison that can  
kill you.  
WARNING  
Hands, feet, hair, clothing, or accessories can  
become entangled in rotating parts. Contact  
with the rotating parts can cause traumatic  
amputation or severe lacerations.  
Do Not run engine indoors or in a small  
confined area where dangerous carbon  
monoxide fumes can collect.  
• Do Not operate the machine without  
guards, shields, and safety devices in  
place and working properly.  
• Operate only in daylight or good artificial light,  
keeping away from holes and hidden hazards.  
• Keep hands, feet, hair, jewelry, or clothing  
away from rotating parts.  
• Start the engine carefully according to instructions  
with feet well away from the blades.  
• Never raise deck with blades running.  
• Keep clear of the discharge opening at all times.  
• Never operate the mower with damaged guards,  
shields, or covers. Always have safety shields,  
guards, switches and other devices in place and in  
proper working condition.  
• To extend the life the engine brake, place the  
throttle control in the “slow” position; then stop  
the engine.  
• This mower was designed for one operator  
only. Keep all others away from mower during  
operation.  
• Never mow with the discharge deflector raised,  
removed or altered unless there is a grass  
collection system or mulch kit in place and  
working properly.  
DO NOT operate the mower when people,  
especially children, or pets are in the area.  
• Grass catcher components are subject to wear,  
damage and deterioration, which could expose  
moving parts or allow objects to be thrown.  
Frequently check the components and replace  
them with the manufacturer’s recommended parts  
when necessary.  
• Be alert, slow down and use caution when making  
turns. Look behind and to the side before  
changing directions.  
• Stop the blades, slow down, and use caution when  
crossing surfaces other than grass and when  
transporting the mower to and from the area to  
be mowed.  
• Do Not change the engine governor setting or  
overspeed the engine.  
7
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Safety  
• Be aware of the mower discharge path and direct  
discharge away from others.  
Maintenance and Storage  
• Stop the engine and remove the spark plug wire(s)  
and/or remove key. Wait for all movement to  
stop before adjusting, cleaning or repairing.  
• Do Not operate the mower under the influence  
of alcohol or drugs.  
• Use extreme care when loading or unloading the  
machine into a trailer or truck.  
• Keep engine and engine area free from  
accumulation of grass, leaves, excessive grease  
or oil, and other debris which can accumulate  
in these areas. These materials can become  
combustible and may result in a fire.  
• Use care when approaching blind corners, shrubs,  
trees, or other objects that may obscure vision.  
Slope Operation  
• Let engine cool before storing and Do Not store  
near flame or any enclosed area where open pilot  
lights or heat appliances are present.  
Use Extreme caution when mowing and/or turning  
on slopes as loss of traction and/or tip-over could  
occur. The operator is responsible for safe operation  
on slopes.  
• Shut off fuel while storing or transporting. Do  
Not store fuel near flames or drain indoors.  
• Park machine on level ground. Never allow  
untrained personnel to service machine.  
DANGER  
Operating on wet grass or steep slopes can  
cause sliding and loss of control. Loss of  
control and/or loss of operator’s footing  
could result in a fall with an arm or leg  
getting under the mower or engine deck  
which may result in serious injury, death or  
drowning.  
• Remove spark plug wire before making any  
repairs.  
• Use care when checking blades. Wrap the blade(s)  
or wear gloves, and use caution when servicing  
them. Only replace blades. Never straighten or  
weld them.  
• Keep hands and feet away from moving parts.  
If possible, Do Not make adjustments with the  
engine running.  
• Mow across slopes, never up and down.  
• Do Not mow slopes when grass is wet.  
• Do Not mow near drop-offs or near water.  
• Do Not mow excessively steep slopes.  
• Keep all guards, shields and all safety devices in  
place and in safe working condition.  
• Check all bolts frequently to maintain proper  
tightness.  
• Reduce speed and use extreme caution  
on slopes.  
• Frequently check for worn or deteriorating  
components that could create a hazard.  
• Avoid sudden turns or rapid speed  
changes.  
• All replacement parts must be the same as  
or equivalent to the parts supplied as original  
equipment.  
• When feasible, avoid operating the equipment in  
wet grass.  
• Progressively greater care is needed as the slope  
increases.  
• Remove or mark obstacles such as rocks, tree  
limbs, etc. from the mowing area. Tall grass can  
hide obstacles.  
• Watch for ditches, holes, rocks, dips and rises that  
change the operating angle, as rough terrain could  
overturn the machine.  
• Use extreme care with grass catchers or  
attachments. These can change the stability of the  
machine and cause loss of control.  
8
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Safety  
Safety and Instructional Decals  
• Keep all safety signs legible. Remove all grease,  
dirt and debris from safety signs and instructional  
labels.  
• New safety signs may be obtained from  
your authorized Exmark equipment dealer or  
distributor or from Exmark Mfg. Co. Inc.  
• Replace all worn, damaged, or missing safety  
signs.  
• Safety signs may be affixed by peeling off the  
backing to expose the adhesive surface. Apply  
only to a clean, dry surface. Smooth to remove  
any air bubbles.  
• When replacement components are installed, be  
sure that current safety signs are affixed to the  
replaced components.  
• Familiarize yourself with the following safety signs  
and instruction labels. They are critical to the safe  
operation of your Exmark commercial mower.  
• If an attachment or accessory has been installed,  
make sure current safety signs are visible.  
52-2610  
For Push Units  
(MPKA21 and MPKA21CA)  
39-5770  
For Units without a Blade Brake Clutch  
(MPKA21, MPKA21CA, MSKA21, MSKA21CA,  
and MSHN21)  
52-2620  
For Self-Propelled Units  
(MSKA21, MSKA21CA, MSKA21B, MSKA21BCA,  
MSHN21, and MSHN21B)  
68-7410  
43-8480  
Common to All Units  
For Units with a Blade Brake Clutch  
(MSKA21B, MSHN21B, and MSKA21BCA)  
9
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Safety  
74-1970  
For Self-Propelled Units  
(MSKA21, MSKA21CA, MSKA21B, MSKA21BCA,  
MSHN21, and MSHN21B)  
1. Transmission speeds  
2. Neutral  
77-0500  
103-6328  
Common to All Units  
For MSKA21B and MSHN21B Units Only  
1. Choke  
2. Fast  
4. Slow  
5. Engine—stop  
3. Continuous variable  
setting  
93-7398  
Common to All Units  
104-1329  
Common to All Units  
104-8585  
Common to All Units  
103-6327  
For MPKA21, MSKA21, and MSHN21 Units Only  
1. Choke  
3. Continuous variable  
setting  
2. Fast  
4. Slow  
10  
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Safety  
109-8190  
On MPKA21CA and MSKA21CA Units Only  
1. Fast  
3. Slow  
2. Continuous variable  
setting  
109-8191  
On MPKA21CA, MSKA21CA,  
and MSKA21BCA Units Only  
109-8194  
On MSKA21BCA Units Only  
1. Fast  
2. Continuous variable  
3. Slow  
4. Engine—stop  
setting  
11  
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Specifications  
Specifications  
Model Numbers  
Serial Nos: 790,000 and Higher  
MPKA21; MPKA21CA; MSKA21; MSKA21CA; MSKA21B; MSKA21BCA; MSHN21; MSHN21B  
Systems  
Cutting Deck  
• Cutting Width: 21 inches (53.3 cm)  
Engine  
• Blade Brake: When the blade engagement control  
is moved to the disengaged position a friction  
brake pad stops the rotation of the blades.  
• Engine Specifications: See your Engine Owner’s  
Manual  
• RPM: 3300 (No Load)  
• Blade Size: (1 ea.): 20.88 inches (53.0 cm)  
• Deck: 21 inches rigid. Deck design allows for  
bagging, mulching or side discharge.  
Fuel System  
• Capacity:  
• Cutting Height Adjustment:  
MPKA21, MSKA21, and MSKA21B Units:  
4.0 qt (3.8 L)  
Adjusts from 3/4 inches (1.9 cm) to 3 1/4 inches  
(8.3 cm) in 1/2 inch (1.3 cm) increments.  
MPKA21CA, MSKA21CA, and MSKA21BCA  
Units: 2.1 qt (2.0 L)  
• Mulching Kit: Standard  
• Side Discharge Kit: Optional  
Honda Units: 2.1 qt (2.0 L)  
• Type of Fuel: Regular unleaded gasoline, 87  
octane or higher.  
Dimensions  
• Fuel Filter: Non-replaceable, in tank  
Curb Weight:  
• Fuel Shut-Off Valve: MPKA21, MSKA21, and  
MSKA21B and Honda Units: In-line 1/4 turn  
increments.  
122 lb (55 kg) Weights may vary slightly depending  
on engine option.  
MPKA21CA, MSKA21CA, and MSKA21BCA  
Units Do Not have a shut-off valve.  
Overall Width:  
22.25 inches (56.5 cm)  
Safety Interlock System  
For units without a Blade Brake Clutch: Operator  
must have the blade control bail depressed to start  
the engine. Releasing the blade control bail will cause  
the engine to stop.  
Transmission (Self Propelled Units)  
3 speeds forward  
Speed Range:  
• 1st–2.0 mph (3.2 km/hr)  
• 2nd–2.9 mph (4.6 km/hr)  
• 3rd–4.1 mph (6.6 km/hr)  
12  
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Product Overview  
Overall Length and Height at  
2 1/4 inch Cutting Height:  
Product Overview  
Handle Setting Length  
Height  
High  
60.50 inches  
(153.7 cm)  
42.75 inches  
(108.6 cm)  
Medium  
Low  
64.25 inches  
(163.2 cm)  
40.38 inches  
(102.6 cm)  
67.00 inches  
(170.2 cm)  
37.88 inches  
(96.2 cm)  
Overall Length and Height at  
Alternate Handle Mounting Position:  
Handle Setting Length  
Height  
High  
62.63 inches  
(159.1 cm)  
37.50 inches  
(95.3 cm)  
Figure 3  
8. Drive Bail  
Medium  
Low  
64.38 inches  
(163.5 cm)  
35.50 inches  
(90.2 cm)  
1. Spark plug  
(Self-Propelled Units  
Only)  
9. Throttle/Choke control  
66.25 inches  
(168.3 cm)  
33.63 inches  
(85.4 cm)  
2. Oil fill/dipstick  
3. Discharge door handle 10. Fuel tank  
4. Grass bag  
5. Blade Control Lever  
(Blade Brake Units Only)  
11. Oil filter  
12. Air filter  
6. Blade Control Bail  
7. Handle  
13. Cutting height lever  
13  
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Operation  
control lever. When this bail is released the unit will  
stop moving.  
Operation  
Note: Determine the left and right sides of the  
machine from the normal operating position.  
Throttle-Choke Control  
The throttle-choke control is located on the left side  
of the handles as shown in Figure 4.  
Controls  
The lever is used to control engine speed. Moving  
the lever to the full forward (Choke) position will  
place the lever in the choke position. The choke aids  
in starting a cold engine. Moving the throttle control  
forward will increase engine speed and moving it to  
the rear will decrease engine speed.  
Blade Control Bail  
Located on the upper handle as shown in Figure 4.  
When the blade control bail is depressed, the system  
senses that the operator is in the normal operator’s  
position.  
For Units with a Blade Brake Clutch: When  
the blade control bail is released, the system  
senses that the operator has moved from the  
normal operating position and will stop the blade.  
For units with a Blade Brake Control: The  
throttle-choke control also includes an engine kill  
position. Moving the lever into the full rearward  
(Off) position will kill the engine.  
For Units without a Blade Brake Clutch:  
When the blade control bail is released, the system  
senses that the operator has moved from the  
normal operating position and will kill the engine.  
Note: MPKA21CA, MSKA21CA, and  
MSKA21BCA Units Do Not have a choke.  
Blade Control Lever (Blade Brake  
Clutch Units Only):  
The blade control lever is located on the right side of  
the handle next to the Blade Control Bail as shown  
in Figure 4.  
Moving the blade control lever into the full forward  
position while depressing the blade control bail  
engages the blade. Releasing the blade control bail  
automatically disengages the blades.  
Ground Speed (Shifter) Control  
(Self-Propelled Units Only):  
The ground speed control is located at the rear of the  
belt cover as shown in Figure 5.  
Figure 4  
1. Throttle-Choke Control  
2. Blade Control Lever  
(Blade Brake Units Only)  
4. Handle  
5. Drive Bail  
The ground speed control has three settings which  
control the ground speed of the mower: 1 is slow, 2  
is medium, and 3 is fast.  
(Self-Propelled Units  
Only)  
3. Blade Control Bail  
Self-Propel Drive Bail (For  
Self-Propelled Units Only)  
Located on the upper handle as shown in Figure 4.  
When the self-propel drive bail is squeezed, the unit  
will move forward at the speed set on the speed  
14  
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Operation  
Figure 5  
1. Ground speed control  
Figure 7  
MSHN21 and MSHN21B Units  
Fuel Shut-Off Valve  
1. Fuel valve  
For MPKA21, MSKA21, and MSKA21B Units:  
The fuel shut off valve is installed on the fuel line  
midway between the fuel tank and the engine as  
shown in Figure 6.  
For MPKA21CA, MSKA21CA, and MSKA21BCA  
Units:Do not have a fuel shut off valve.  
The fuel shut off valve shuts off the flow of fuel  
when the machine will not be used for a few days,  
when parking inside a building, and during transport  
to and from the job. Rotate the valve 1/4 turn  
clockwise to shut off fuel. Rotate the valve 1/4 turn  
counterclockwise to turn on fuel.  
Pre-Start  
Fill fuel tank. For best results use only clean, fresh  
regular grade unleaded gasoline with an octane rating  
of 87 or higher. To ensure freshness, purchase only  
the quantity of gasoline that you expect to use in  
30 days. Using unleaded gasoline results in fewer  
combustion deposits and longer engine life. See  
Engine Owner’s Manual.  
Figure 6  
MPKA21, MSKA21, and MSKA21B Units  
1. Fuel line  
2. Fuel valve  
3. Elbow fitting  
Do Not add oil to gasoline.  
For MSHN21 and MSHN21B Units: The fuel  
shut off valve is located on the engine as shown in  
Figure 7.  
Do Not use methanol, gasoline containing methanol,  
gasohol containing more the 10% ethanol, premium  
gasoline or white gas. Using these fuels can damage  
the engine’s fuel system.  
Do Not use gasoline that has been stored since the  
last mowing season or longer.  
Do Not overfill fuel tank. Never fill the fuel tank so  
that the fuel level rises above a level that is 1/2 inch  
below the bottom of the filler neck to allow for fuel  
expansion and prevent fuel spillage.  
15  
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Operation  
Make sure you understand the controls, their  
locations, their functions, and their safety  
requirements.  
1. Install the hardware in the lower holes in the  
handle and latches as shown in Figure 8.  
2. Install hardware in one of the three adjustment  
holes in the upper ends of each of the handle  
latches to obtain the desired handle height within  
the selected range.  
Refer to the Maintenance section and perform all the  
necessary inspection and maintenance steps.  
3. Slide the bag support rod through into the upper,  
middle, or lower mounting holes in the handle  
and secure each end with a cap locknut. The bag  
support rod mounting hole location corresponds  
with the mounting hole location for the handle  
latches as shown in the table.  
Operating Instructions  
Handle Adjustment  
The handle may be adjusted to different heights for  
comfortable operation. Stand behind the handle to  
determine the height. to adjust the handle height,  
position the capscrews and the locknuts that secure  
the handle latches to the handle into the other  
mounting holes in the latches.  
Bag Support Rod  
Handle Latch Mounting  
Mounting Hole Location Hole Location  
Lower  
Middle  
Upper  
Lower  
Middle  
Upper  
See Figure 8A for the highest possible handle heights.  
See Figure 8B for the lowest possible handle heights.  
Open the Fuel Shut-Off Valve  
Rotate the valve 1/4 turn counterclockwise to turn  
the fuel on.  
Starting the Engine  
1. Connect the wire to the spark plug.  
For MSHN21 and MSHN21B Units: see  
Figure 9.  
For MPKA21, MSKA21, MSKA21B,  
MPKA21CA, MSKA21CA, and MSKA21BCA  
Units: see Figure 10.  
Figure 8  
1. Handle latch  
4. Spring disc washer  
2. Adjustment holes in  
upper end of handle  
latch  
5. 5/16-18 x 1 3/8 inch hex  
capscrew  
3. Handle  
6. 5/16-18 x 1 1/4 inch hex  
capscrew  
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Operation  
For MSHN21 and MSHN21B Units: see  
Figure 7.  
MPKA21CA, MSKA21CA, and MSKA21BCA  
Units: Do Not have a fuel valve.  
3. For MSHN21 MSHN21B, MPKA21, MSKA21,  
and MSKA21B Units: Move the throttle-choke  
control to the Choke position.  
Note: Do Not use the choke when the engine is  
warms up.  
For MPKA21CA, MSKA21CA, and  
MSKA21BCA Units: Move the throttle control  
to the Fast position. Press the primer bulb two  
times (see Figure 11).  
Figure 9  
All Honda Units  
1. Oil fill/dipstick  
2. Recoil starter handle  
3. Fuel tank cap  
4. Air cleaner  
5. Spark plug  
Figure 11  
4. For units without a Blade Brake Clutch: Hold  
the blade control bail to the handle.  
5. Pull the starter handle lightly until you feel  
resistance, then pull it sharply. Allow the rope to  
return slowly.  
6. When the engine starts, move the throttle control  
to the Fast position, and set the ground speed  
control as desired.  
Note: If the engine fails to start after three pulls,  
repeat steps 3 through 6).  
Stopping the Engine  
Figure 10  
All Kawasaki Units  
1. Bring the unit to a full stop.  
For units without a Blade Brake Clutch:  
Release the blade control bail. Both the  
engine and the blade should stop within three  
seconds.  
1. Muffler  
2. Oil fill/dipstick  
3. Fuel tank cap  
4. Recoil starter handle  
5. Oil filter  
6. Air cleaner  
7. Spark plug  
For units with a Blade Brake Clutch:  
Release the blade control bail. The blade  
should stop within three seconds. Move the  
throttle to the (Off) position to kill the engine.  
2. Open the fuel valve.  
For MPKA21, MSKA21, and MSKA21B Units:  
see Figure 6.  
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Operation  
Note: If the blade does not stop within 3  
seconds after releasing the blade control bail,  
contact an Authorized Service Dealer.  
Note: The blade control lever will release rapidly  
when the blade control bail is released. To avoid  
minor injury, keep hands clear of the blade control  
lever when the blade control bail is released.  
2. Close the fuel shut-off valve, if equipped with,  
when the machine will not be in use for a few  
days, when transporting, or when the unit is  
parked inside a building.  
Using the Discharge Tunnel  
1. Stop the engine and wait for all moving parts to  
stop.  
Using the Self-Propel Drive  
(Self-Propelled Units Only)  
2. Insert the plug. (Refer to Installing the  
Discharge Plug section).  
The lawn mower has three ground speeds: 1 is slow,  
2 is medium, and 3 is fast.  
3. To remove the plug, move the discharge door  
handle rearward and lift up the spring clip on the  
bottom of the plug. When the plug is unlocked,  
pull it out of the discharge tunnel.  
1. Start the engine.  
2. Using the ground speed control, select the desired  
ground speed.  
Note: When grass is thick and lush, clippings  
may collect on and around the discharge tunnel  
plug. This may make removing the plug difficult.  
Clean the plug thoroughly after each use.  
3. Squeeze the drive bail against the handle (see  
Figure 4).  
Note: Do Not shift speeds while squeezing the  
ground speed control against the handle. This  
can damage the transmission. Release the ground  
speed control before changing speeds.  
Checking the Blade Brake Clutch  
(Blade Brake Clutch Units Only)  
Note: You can vary the ground speed by  
increasing or decreasing the distance between the  
ground speed control and the handle. Lower the  
control bar to decrease the ground speed when  
you are making a turn or if the lawn mower is  
moving too fast for you. If you lower the control  
bar too far the lawn mower stops self-propelling.  
Squeeze the ground speed control closer to the  
handle to increase the ground speed. When  
you hold the ground speed control tight against  
the handle, the lawn mower self-propels at the  
maximum ground speed. Move the ground speed  
control to the Neutral position when you use the  
lawn mower for trimming or whenever you leave  
the lawn mower.  
Check the Blade Brake Clutch (BBC) system before  
each use to ensure that it is operating properly.  
Normal Test:  
1. Stop the engine and wait for all moving parts to  
stop.  
2. Move the lawn mower onto a paved surface in  
a non-windy area.  
3. Set all four wheels in to the 2 1/2 inches (6.4 cm)  
cutting height (see Figure 13).  
4. Set the ground speed selector to the N (Neutral)  
position.  
5. Take a half sheet of newspaper and crumple  
it into ball small enough to go under the deck  
(about 3 inches or 7.6 cm in diameter) as shown  
in Figure 12.  
Operating the Blade Control Lever  
(Blade Brake Clutch Units Only)  
1. Start the engine.  
2. Squeeze the blade control bail against the handle  
(Figure 4).  
3. Move the blade control lever to the full forward  
Latch position. Blades should engage.  
4. Release the blade control bail to disengage the  
blades.  
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Operation  
DANGER  
If the blade brake clutch system is  
inoperative, the blade will continue to rotate  
when you release the blade control bail.  
Contact with the blade could occur, causing  
serious injury.  
• Check the BBC operation before each  
use.  
• Never use the BBC-equipped lawn mower  
with an inoperative safety system.  
• Take your lawn mower to an Authorized  
Service Dealer for repair if the safety  
system fails to operate properly.  
Figure 12  
1. Crumpled newspaper 2. 5 inches (12.7 cm)  
6. Place the ball of newspaper 5 inches (12.7 cm) in  
front of the lawn mower.  
Test Using the Grass Bag  
1. Install the empty grass bag on the discharge  
tunnel.  
7. Start the engine.  
8. Squeeze the blade control bail against the handle.  
2. Start the engine.  
9. Move the blade control lever to the full forward  
Latch position. Blades should engage.  
3. Squeeze the blade control bail against the handle.  
4. Move the blade control lever to the full forward  
Latch position. The bag should begin to inflate,  
indicating that the blade is engaged and rotating.  
10. Release the blade control bail. You should hear a  
“bang.” The blade should stop in three seconds.  
11. Immediately push the lawn mower over the  
newspaper ball.  
5. Release the blade control bail. If the bag does not  
immediately deflate, it indicates that the blade is  
still rotating. The blade brake clutch mechanism  
may deteriorating, and, if ignored could result in  
an unsafe operating condition. Have the lawn  
mower inspected and serviced by an Authorized  
Service Dealer.  
12. Stop the engine and wait for all moving parts to  
stop.  
13. Walk around the lawn mower to check for the  
newspaper ball. If the ball did not go under the  
deck, repeat steps 7 through 12.  
14. Pull the lawn mower away from the newspaper.  
If the newspaper ball unravels or is shredded,  
the blade has not properly stopped, resulting  
in an unsafe operating condition. Contact an  
Authorized Service Dealer.  
Adjusting the Cutting Height  
Each wheel is adjusted individually with a wheel  
height adjustment lever. The cutting heights are listed  
in the following table.  
Cutting Heights  
3/4 inch (19 mm)  
2 1/4 inches (57 mm)  
2 3/4 inches (70 mm)  
3 1/4 inches (83 mm)  
1 1/4 inches (32 mm)  
1 3/4 inches (44 mm)  
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Operation  
WARNING  
Adjusting the cutting height levers could  
bring your hands into contact with a moving  
blade. A moving blade can cause serious  
injury.  
• Stop the engine and wait for all movement  
to stop before adjusting the cutting  
height.  
• Do Not put your fingers under the  
housing when adjusting the cutting  
height.  
Figure 14  
1. Bag Frame on retaining 3. Handle fully  
1. Pull the wheel height adjustment lever toward  
the wheel (Figure 13) and move it to the desired  
setting.  
post.  
forward—discharge  
door closed.  
2. Pin engaged in catch.  
3. Slide the hole in the bag frame onto the  
retaining post on the discharge tunnel.  
4. Set the rear of the bag frame onto the bag  
support rod.  
5. Pull the discharge door handle forward until  
the pin clears the catch, and move the handle  
rearward until the pin locks in the bag notch  
(Figure 15).  
Figure 13  
1. Pull towards wheel  
2. Wheel Height  
Adjustment Lever  
3. Notches  
2. Release the wheel height adjustment lever and set  
it securely in the notch.  
3. Adjust all the wheels to the same cutting height  
setting.  
Using the Grass Bag  
Figure 15  
Occasionally, you may wish to use the grass bag for  
bagging extra long grass, lush grass, or leaves.  
1. Pin locked in bag notch.  
• Installing the Grass Bag  
1. Stop the engine and wait for all moving parts  
to stop.  
Note: The discharge door in the lawn mower  
housing is now open.  
2. Ensure that the discharge door handle is fully  
forward and that the pin is engaged in the  
catch (Figure 14).  
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Operation  
• Mowing with the Grass Bag  
DANGER  
If the discharge door does not close  
completely, the lawn mower could throw  
objects. Thrown objects can result serious  
personal injury or death to the operator or  
bystanders.  
WARNING  
A worn grass bag could allow small stones  
and other similar debris to be thrown in the  
operator’s or bystander’s direction. Thrown  
objects can result serious personal injury or  
death to the operator or bystanders.  
Never open the door on the discharge tunnel  
when the engine is running.  
Check the grass bag frequently. If it is  
damaged, install a new Exmark replacement  
bag.  
Operating Tips  
• Review the Safety section and read this manual  
carefully before operating the lawn mower.  
Cut the grass until the bag is full.  
Note: Do Not overfill the bag.  
• Set the engine speed to the fastest position for  
the best cutting results.  
• Removing the Grass Bag  
• Maintain a sharp blade throughout the cutting  
season. Periodically file down nicks on the blade.  
Replace the blade when necessary with an original  
Exmark replacement blade.  
1. Stop the engine and wait for all moving parts  
to stop.  
2. Raise the discharge door handle and move  
it forward to engage the pin with the catch  
(Figure 14).  
• Clean the air filter frequently. Mulching stirs up  
more clippings and dust which clogs the air filter  
and reduces engine performance.  
3. Grasp the handles at the front and the rear of  
the bag and lift the bag off the lawn mower.  
Cutting Grass  
4. Gradually tip the bag forward to empty the  
clippings.  
• Grass grows at different rates at different times  
of the year. In the summer heat, it is best to  
cut grass at the 2 1/4 inch (57 mm), 2 3/4 inch  
(70 mm), or 3 1/4 inch (83 mm) cutting height  
settings. Cut only about a third of the grass blade  
at a time. Do Not cut below the 2 1/4 inch (57  
mm) setting unless the grass is sparse or it is late  
fall when grass growth begins to slow down.  
5. To install the bag, refer to the Installing the  
Grass Bag section.  
DANGER  
If the discharge door does not close  
completely, the lawn mower could throw  
objects. Thrown objects can result serious  
personal injury or death to the operator or  
bystanders.  
• When cutting grass over 6 inches (15 cm) tall,  
first mow at the highest cutting height setting and  
walk slower; then mow again at a lower setting for  
the best lawn appearance. If the grass is too long  
and the leaves clump on top of the lawn, the lawn  
mower may plug and cause the engine to stall.  
• Never open the door to the discharge  
opening when the engine is running.  
• Alternate the mowing direction. This helps  
disperse the clippings over the lawn for even  
fertilization.  
• If you cannot close the door because the  
grass clippings clog the discharge area,  
stop the engine and gently move the  
discharge door handle back and forth  
until you can close the door completely. If  
you still cannot close the door, remove the  
obstruction with a stick, not your hand.  
If the finished lawn appearance is unsatisfactory,  
try one or more of the following:  
• Sharpen the blade.  
• Walk at a slower pace while mowing.  
• Cut the grass more frequently.  
21  
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Operation  
• Overlap cutting swaths instead of cutting a full  
swath with each pass.  
• Set the cutting height on the front wheels one  
notch lower than the rear wheels. For example,  
set the front wheels at 2 1/4 inches (57 mm) and  
the rear wheels at the 2 3/4 inches (70 mm).  
Cutting Leaves  
• After cutting the lawn, ensure that half of the  
lawn shows through the cut leaf cover. You may  
need to make more than one pass over the leaves.  
• For light leaf coverage, set all the wheels at the  
same cutting height setting.  
• If there are more than 5 inches (12.7 cm) of leaves  
on the lawn, set the front cutting height 1 or 2  
notches higher than the rear cutting height. This  
makes it easier to feed the leaves under the lawn  
mower deck.  
• Slow down your mowing speed if the lawn mower  
does not cut the leave finely enough.  
• If you mow over oak leaves, you can add lime to  
the grass in the spring to reduce the acidity of the  
oak leaves.  
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Maintenance  
Maintenance  
Note: Determine the left and right sides of the machine from the normal operating position.  
WARNING  
WARNING  
If you leave the wire on the spark plug,  
someone could accidentally start the engine.  
Accidental starting of the engine could  
seriously injure you or other bystanders.  
The engine can become very hot. Touching  
a hot engine can cause severe burns.  
Allow the engine to cool completely before  
service or making repairs around the engine  
area.  
Disconnect the wire from the spark plug  
before you do any maintenance. Set the wire  
aside so that it does not accidentally contact  
the spark plug.  
Recommended Maintenance Schedule(s)  
Maintenance Service  
Maintenance Procedure  
Interval  
• Change the engine oil.  
After the first 5 hours  
• Check the engine oil level.  
• Check the stopping time of the blade brake. The blade must stop within 3 seconds of  
releasing the bail; if it does not, contact and Authorized Service Dealer for repair.  
• Check the mower blades and the engine mounting fasteners.  
• Check for loose hardware.  
Before each use or daily  
• Clean the grass build-up from under the deck.  
• Clean the discharge tunnel and plug.  
• Clean the foam pre-cleaner (Kawasaki Units).  
• Clean the cover, base, foam and paper elements (Honda Units).  
Every 25 hours  
Every 40 hours  
• Check the condition of the belt(s).  
• Change the engine oil. (May need more often under severe conditions.)  
• Grease the pivot arms.  
• Clean under the belt cover (self-propelled models only).  
• Clean the blade brake clutch shield.  
• Check for leaks in the fuel systems and /or deteriorating fuel hose.  
Every 50 hours  
Every 100 hours  
• Change the oil filter (Kawasaki Units Only).  
• Service the wheels.  
• Grease the gear case (self-propelled units only).  
• Check the spark plugs.  
• For Blade Brake Clutch Units: Adjust the blade brake cable.  
• Clean the fuel filter element (Kawasaki Units Only).  
• Replace the air filter elements (Honda Units). (May need more often if they are damaged  
or excessively dirty.)  
Every 250 hours  
Every 300 hours  
• Replace the paper air filter (Kawasaki Units). (May need more often in dusty conditions.  
See the Engine manual for additional information.)  
• Lubricate the gear case (self-propelled units only)  
Yearly  
• Empty the fuel tank before repairs as directed or before storage.  
Yearly or before storage  
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Maintenance  
Periodic Maintenance  
Check Engine Oil Level  
Service Interval: Before each use or daily  
1. Stop engine and wait for all moving parts to stop.  
Make sure unit is on a level surface.  
2. Check with engine cold.  
3. Clean area around dipstick. Remove dipstick and  
wipe oil off. Reinsert the dipstick and push it all  
the way down into the tube. Do Not screw into  
place. Remove the dipstick and read the oil level.  
Figure 17  
Kawasaki Engine  
1. Dipstick  
2. Full  
3. Add  
4. If the oil level is low, wipe off the area around the  
oil fill cap, remove cap and fill to the “FULL”  
mark on the dipstick. Use oil as specified in  
Engine Owner’s Manual. Do Not overfill.  
Important: Do Not operate the engine with the  
oil level below the “LOW” (or “ADD”) mark on  
the dipstick, or over the “FULL” mark.  
Figure 16  
Honda Engine  
1. Lower limit mark  
2. Upper limit mark  
3. Dipstick  
Checking the Blade Brake  
Clutch (For Units with a  
Blade Brake Clutch Only)  
Service Interval: Before each use or daily  
Refer to Checking the Blade Brake Clutch in the  
Operating Instructions section.  
Check the Mower Blade  
Service Interval: Before each use or daily  
Always mow with a sharp blade. A sharp blade cuts  
cleanly and without tearing or shredding the grass  
blades.  
1. Stop the engine and wait for all moving parts to  
stop.  
2. Disconnect the wire from the spark plug (Figure 9  
and Figure 10).  
3. Drain the gasoline from the fuel tank.  
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Maintenance  
4. Tip the lawn mower onto its right side (see  
Figure 18 and Figure 19).  
Figure 20  
3. Wear  
1. Sail  
2. Flat  
Figure 18  
4. Slot  
Blade Brake Clutch Units Only  
1. Accelerator  
2. Anti-Scalp Cup  
3. Blade  
4. Blade Nuts  
Note: For the best performance, install a new  
blade before the cutting season begins. During  
the year, file down any small nicks to maintain the  
cutting edge.  
DANGER  
A worn or damaged blade can break. A  
piece of the blade could be thrown into the  
operator’s or bystander’s area, resulting in  
serious personal injury or death.  
• Inspect the blade periodically for wear or  
damage.  
• Replace a worn or damaged blade.  
Figure 19  
Units Without a Blade Brake Clutch Only  
If it is necessary to remove the blade for  
replacement or sharpening, complete the  
following steps:  
1. Blade 3. Accelerator  
2. Blade Bolt  
6. Remove the blade. Make sure to grasp the end of  
the blade using a rag or a thickly padded glove.  
5. Inspect the blade for sharpness and wear,  
especially where the flat and the curved parts  
meet (see Figure 20A). Because sand and abrasive  
material can wear away the metal that connects  
the flat and curved parts of the blade, check  
the blade before using the lawn mower. If you  
notice a slot or wear (Figure 20B and Figure 20C),  
replace the blade.  
• For Blade Brake Clutch Units: Remove the  
blade nuts, anti-scalp cup, accelerator, and the  
blade (Figure 18).  
• For Units without a Blade Brake Clutch:  
Remove the blade bolt, accelerator, and blade  
(Figure 19).  
7. For Sharpening: File the top side of the blade to  
maintain its original cutting angle (Figure 21A)  
and inner cutting edge radius (Figure 21B). The  
blade will remain balanced if you remove the same  
amount of material from both cutting edges.  
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Maintenance  
10. Return the lawn mower to its upright position.  
11. Connect the wire to the spark plug.  
Check for Loose Hardware  
Service Interval: Before each use or daily  
Figure 21  
2. Cutting edge radius  
1. Cutting angle  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
8. Check the balance of the blade by placing the  
center hole of the blade over a nail or screwdriver  
shank clamped horizontally in a vise (Figure 22).  
If either end of the blade rotates downward, file  
that end (not the cutting edge). The blade is  
properly balanced when neither end drops.  
2. Visually inspect machine for any loose hardware  
or any other possible problem. Tighten hardware  
or correct the problem before operating.  
Service Air Filter  
(Kawasaki Units)  
Service Interval: Every 25 hours—Clean  
the foam pre-cleaner  
(Kawasaki Units).  
Figure 22  
Every 300 hours—  
1. Blade  
2. Vise  
3. Screwdriver  
Replace the paper air  
filter (Kawasaki Units).  
(May need more often in  
dusty conditions. See  
the Engine manual for  
additional information.)  
9. For Installation: Make sure to grasp the end of  
the blade using a rag or a thickly padded glove.  
For Blade Brake Clutch Units: Install a sharp,  
balanced Exmark blade, the accelerator, the  
anti-scalp cup, and the blade nuts. The sail of  
the blade must point toward the top of the lawn  
mower housing for proper installation. Torque  
the blade nuts to 15-27 ft-lb (20-37 N m).  
Note: Do Not operate the engine without the air  
filter assembly; extreme engine damage will occur.  
1. Stop engine, wait for all moving parts to stop.  
2. Disconnect the wire from the spark plug  
(Figure 10).  
For Units without a Blade Brake Clutch: Install a  
sharp, balanced Exmark blade, the accelerator,  
and blade bolt. The sail of the blade must point  
toward the top of the lawn mower housing for  
proper installation. Torque the blade nuts to 50  
ft-lb (68 N m).  
3. Remove the cover and clean it thoroughly.  
DANGER  
Operating the lawn mower without the  
accelerator in place can cause the blade to  
flex, bend, or break. Thrown objects from a  
broken blade can result in serious injury or  
death to the operator or bystanders.  
Do Not operate the lawn mower without the  
accelerator.  
26  
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Maintenance  
2. Disconnect the wire from the spark plug  
(Figure 9).  
3. Remove the two wing nuts that secure the cover  
(Figure 24).  
Figure 23  
3. Paper air filter  
4. Air filter base  
1. Cover  
2. Foam pre-cleaner  
4. Remove the paper air filter and discard it as  
required.  
Note: Do Not try to clean a paper air filter.  
Figure 24  
5. Remove the foam pre-cleaner and wash it with a  
mild detergent and water, then blot it dry.  
1. Wing nuts  
2. Cover  
3. Paper element  
4. Foam element  
5. Base  
6. Saturate the pre-cleaner with clean engine oil, then  
squeeze it (Do Not twist) to remove the excess oil.  
4. Remove the cover.  
7. Install the foam pre-cleaner.  
8. Install the new paper air filter.  
9. Install the cover.  
Note: Be careful to prevent dirt and debris from  
falling into the base.  
5. Remove the foam and paper elements from the  
base.  
Service Air Filter  
(Honda Units)  
6. Remove the foam element from the paper  
element.  
Service Interval: Every 25 hours—Clean  
the cover, base, foam and  
paper elements (Honda  
Units).  
7. Inspect the foam and paper elements, and replace  
them if they are damaged or excessively dirty.  
8. Tap the paper element on a hard surface several  
times or use compressed air not exceeding 30  
psi (207 kPa) through the filter from the wire  
screen side to remove any excess dirt. If the paper  
element is excessively dirty, replace it.  
Every 250 hours— Replace  
the air filter elements  
(Honda Units). (May need  
more often if they are  
damaged or excessively  
dirty.)  
Note: Never try to brush dirt off the paper  
element; brushing forces the dirt into the fibers.  
9. Clean the foam element in warm, soapy water or  
Note: Do Not operate the engine without the air  
cleaner assembly; extreme engine damage will occur.  
in a nonflammable solvent.  
10. Rinse and dry the foam element thoroughly.  
1. Stop the engine and wait for all moving parts to  
stop.  
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Maintenance  
11. Dip the foam element in clean engine oil, then  
squeeze out the excess oil.  
11. Wipe up any spilled oil.  
12. Connect the wire to the spark plug.  
13. Recycle the used oil according to local codes.  
Note: Excess oil in the foam element restricts  
the air flow through the element and may reach  
the paper filter and clog it.  
Changing the Oil Filter  
(Kawasaki Units Only):  
12. Wipe dirt from the base and the cover with a  
moist rag.  
Note: Be careful to prevent dirt and debris from  
entering the air duct leading to the carburetor.  
Service Interval: Every 100 hours  
1. Run the engine to warm the oil.  
13. Install the air cleaner elements and ensure that  
they are properly positioned.  
2. Stop the engine and wait for all moving parts to  
stop.  
14. Securely install the cover with the two wing nuts.  
3. Disconnect the wire from the spark plug.  
4. Drain the engine oil.  
Change Engine Oil  
Service Interval: After the first 5 hours  
5. Place a rag under the oil filter to catch any oil that  
may leak out as you remove the filter.  
Every 50 hours (May need  
more often under severe  
conditions.)  
6. Remove the oil filter.  
7. Use your finger to coat the gasket on the new  
filter with clean engine oil (see Figure 25).  
1. Run the engine to warm the engine oil.  
Note: Warm oil flows better and carries more  
contaminates.  
WARNING  
Oil may be hot after engine has been  
run. Contact with hot oil can cause severe  
personal injury.  
Avoid contacting the hot engine oil when you  
drain it.  
Figure 25  
2. Stop engine, wait for all moving parts to stop.  
3. Disconnect the wire from the spark plug.  
1. Gasket  
4. Place a suitable drain pan under the dipstick/oil  
drain.  
8. Install the new filter and hand tighten it 2/3 turn  
only.  
5. Clean around the dipstick.  
9. Fill the crankcase to the Full line on the dipstick  
with fresh oil.  
6. Remove the dipstick by rotating the cap  
counterclockwise and pulling it out.  
10. Connect the wire to the spark plug.  
11. Run the engine for about 3 minutes.  
7. Raise the left side of the lawn mower to drain the  
oil from the dipstick fill tube into the drain pan.  
8. After draining the oil, return the lawn mower to  
the operating position.  
12. Stop the engine, wait for all moving parts to stop,  
and check for oil leakage around the filter.  
9. Fill the crankcase with fresh oil to the upper limit  
mark on the dipstick.  
13. Add oil to compensate for the oil in the oil filter.  
14. Recycle the used oil filter according to local codes.  
10. Insert the dipstick into the filler neck and rotate  
the cap clockwise until it is tight.  
28  
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Maintenance  
wheel halves and tighten. Remove the two long  
screws or bolts and replace them with two cap  
screws and two locknuts.  
Servicing the Wheels  
Service Interval: Every 100 hours  
Removing the Wheels  
1. Stop engine, wait for all moving parts to stop.  
2. Disconnect the wire from the spark plug.  
3. Remove the bolt, the wheel spacer, and the  
locknut mounting the wheel to the pivot arm  
(Figure 26).  
7. Install the wheel to the pivot arm with the cap  
screws, a spacer, and a locknut. Ensure that the  
spacer is positioned between the wheel hub and  
the pivot arm.  
8. Connect the wire to the spark plug.  
Check Condition Of Belt  
(Self-Propelled Units Only)  
Service Interval: Every 40 hours  
1. Stop engine, wait for all moving parts to stop.  
2. Remove the bolts that secure the belt cover to the  
lawn mower housing.  
Figure 26  
3. Check the belt for cracks, frayed edges, burn  
marks or any other damage.  
1. Plastic Cover  
2. Locknut  
3. Wheel half  
4. Bolt  
6. Bearing Spacer  
7. Bearing/Hub Assembly  
8. Lug  
4. Replace the damaged belt.  
9. Wheel Spacer  
5. Bearing  
Lubricate the Pivot Arms  
1. Move the rear wheel cutting height levers to the  
center setting.  
4. Separate the wheel halves from the tire by  
removing four bolts and four locknuts.  
2. Wipe the grease fittings with a clean rag  
(Figure 27).  
Note: If you remove the bearings from the  
bearing/hub assembly, remove them by pressing  
on the bearing spacer.  
Assembling the Wheels  
1. Position the tire onto one wheel half, aligning the  
lugs on each.  
2. Place the bearing/hub assembly into the center  
hole of the wheel half. Ensure that the legs of the  
hub are positioned over the flange of the hole.  
3. Place the other wheel half onto the bearing/hub  
assembly, aligning the wheel and the tire lugs and  
the mounting holes.  
Figure 27  
4. Using two fully threaded screws or bolts and  
non-locking nuts, loosely secure the wheel halves  
together. Mount the screws or bolts in the  
opposing holes.  
1. Grease fitting  
3. Install a grease gun onto the fitting and gently  
apply 2 or 3 pumps of #2 multi-purpose lithium  
base grease.  
5. Check the alignment of all parts and tighten the  
screws, alternating from side to side for a uniform  
fit until the wheel halves are drawn together.  
Note: Excessive grease pressure may damage the  
seals.  
6. Install the two cap screws and two locknuts  
previously removed in the remaining holes in the  
29  
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Maintenance  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Check Spark Plugs  
Service Interval: Every 100 hours  
2. Lubricate fittings with one to two pumps of  
NGLI grade #2 multi-purpose gun grease.  
1. Stop the engine and wait for all moving parts to  
stop.  
Refer to the following chart for fitting locations  
and lubrication schedule.  
2. Disconnect the wire from the spark plug (Figure 9  
and Figure 10).  
Lubrication Chart  
3. Clean around the spark plug.  
Fitting  
Locations  
Initial  
Pumps  
Number of  
Places  
Service  
Interval  
4. Remove the spark plug from the cylinder head.  
Note: Replace a cracked, fouled, or dirty spark  
plug. Do Not clean the electrodes because grit  
entering the cylinder can damage the engine.  
1. Pivot  
Arms  
2
1
2
50 Hours  
2. Gear  
Case  
1
100 Hours  
5. Set the gap on the plug to 0.030 inch (0.76 mm)  
(Figure 29).  
Lubricate the Gear Case  
(Self-Propelled Units Only)  
Service Interval: Yearly  
1. Stop engine, wait for all moving parts to stop.  
2. Remove the grass bag.  
3. Install a grease gun onto the fitting through the  
belt cover opening  
Figure 29  
1. Side electrode  
3. Air gap—0.030 inch  
(0.76 mm)  
2. Center electrode  
insulator  
6. Install the spark plug and the gasket seal.  
7. Torque the plug to 17 ft-lb (23 N-m).  
8. Connect the wire to the spark plug.  
Figure 28  
1. Grease fitting  
2. Belt cover  
4. Gently apply one to two pumps of #2  
multi-purpose lithium-base grease.  
5. Install the grass bag.  
30  
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Maintenance  
For Blade Brake Clutch Units:  
Adjustments  
Note: Wait for all moving parts to stop and remove  
spark plug wire before servicing, cleaning, or making  
any adjustments to the unit.  
1. Loosen the cable clamp screw until the cable  
conduit slides (see Figure 31).  
Adjusting the Self-Propel  
Drive  
(Self-Propelled Units Only)  
Figure 31  
If the lawn mower does not self-propel or has a  
tendency to creep forward when the control bar is  
released, adjust the wheel drive control knob on the  
rear of the gear box.  
1. Spring  
2. Cable conduit  
3. Cable clamp screw  
2. Pull the cable to remove the slack, but Do  
Not put tension on the spring.  
1. Close the door in the lawn mower housing and  
remove the grass bag.  
3. Tighten the screw to lock the adjustment in  
place.  
2. If the lawn mower does not self propel, rotate  
the control knob clockwise 1/2 turn to tighten  
the belt.  
4. Connect the wire to the spark plug.  
For Self-Propelled Units without a Blade  
If the lawn mower creeps forward, rotate the  
knob 1/2 turn counterclockwise to loosen the belt  
Brake Clutch:  
1. Loosen the nut on the cable bracket (see  
Figure 31).  
2. Insert a 3/16 to 1/4 inch (5 to 6 mm) object  
between the brake control lever and the  
handle.  
3. Turn the cable adjuster on the brake cable  
until you remove the slack.  
4. Tighten the jam nut.  
5. Connect the wire to the spark plug.  
For Hand-Push Units:  
Figure 30  
1. Loosen the jam nut on the blade brake cable  
clamp (see Figure 31).  
1. Control knob  
2. Insert a 3/16 to 1/4 inch. (5 to 6 mm) object  
between the brake control lever and the  
handle. Pull down on the cable conduit until  
you remove the slack from the wire.  
Adjusting the Blade Brake  
Cable  
3. Tighten the nut.  
Service Interval: Every 100 hours  
4. Connect the wire to the spark plug.  
Adjust whenever a new blade brake cable assembly  
is installed.  
1. Stop the engine and wait for all moving parts to  
stop.  
2. Disconnect the wire from the spark plug.  
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Maintenance  
6. Turn off the water.  
Cleaning  
7. Start the lawn mower, engage the blade, and let  
the lawn mower run for a few minutes to dry out  
its components.  
Clean Grass Build-Up Under  
Deck  
Scraping Method  
Service Interval: Before each use or daily  
If washing does not remove all debris from under the  
lawn mower, scrape it clean.  
1. Stop engine, wait for all moving parts to stop, and  
remove spark plug wire.  
1. Disconnect the wire from the spark plug.  
2. To ensure the best performance, keep the  
underside of the lawn mower housing clean  
(Figure 32).  
2. Drain the fuel from the fuel tank. Refer to  
Emptying the Fuel Tank and Cleaning the  
Fuel Filter section.  
WARNING  
Tipping the lawn mower may cause the fuel  
to leak from the carburetor or the fuel tank.  
Gasoline is extremely flammable, highly  
explosive, and under certain conditions, can  
cause personal injury or property damage.  
Figure 32  
Blade Brake Unit Shown for Reference Only  
Avoid fuel spills by running the engine dry or  
by removing the gasoline with a hand pump;  
never siphon.  
Washing Method  
3. Tip the lawn mower onto its right side.  
1. Position the lawn mower on a flat concrete or  
asphalt surface near a garden hose.  
4. Remove the dirt and grass clippings with a  
hardwood scraper. Avoid burrs and sharp edges.  
2. Start the engine.  
3. Hold the running garden hose at handle level and  
direct the water to flow on the ground just in  
front of the right rear tire (Figure 33).  
5. Turn the lawn mower upright.  
6. Fill the fuel tank.  
7. Connect the wire to the spark plug.  
Cleaning the Discharge  
Tunnel and Plug  
Service Interval: Before each use or daily  
Figure 33  
Always be sure that the discharge tunnel door closes  
securely when you release the handle. If the debris  
prevents the discharge door from closing securely,  
clean the inside of the discharge tunnel and the door  
thoroughly.  
4. Engage the blade.  
Note: The blade will draw in water and wash out  
clippings. Let the water run until you no longer  
see clippings being washed out from under the  
housing.  
5. Disengage the blade, stop the engine and wait for  
all moving parts to stop.  
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Maintenance  
5. Install the belt cover.  
WARNING  
6. Connect the wire to the spark plug.  
Grass clippings and other objects can be  
thrown from an open discharge tunnel.  
Thrown objects can cause serious injury or  
kill the operator or bystanders.  
Cleaning the Blade Brake  
Clutch Shield  
Never start or operate the lawn mower unless  
one of the following is true:  
Service Interval: Every 50 hours  
1. Stop the engine and wait for all moving parts to  
stop.  
• The discharge tunnel plug is locked  
securely in the discharge tunnel.  
2. Disconnect the wire from the spark plug (see  
Figure 9 and Figure 10).  
• The grass bag is locked in place.  
• The optional side discharge chute is  
locked in place.  
3. Drain the gasoline from the fuel tank.  
4. Tip the lawn mower onto its right side (air filter  
up).  
• The discharge tunnel door is locked in  
place.  
WARNING  
Cleaning Under  
the Belt Cover  
(Self-Propelled Models  
Only)  
Tipping the lawn mower may cause the fuel  
to leak from the carburetor or the fuel tank.  
Gasoline is extremely flammable, highly  
explosive, and under certain conditions, can  
cause personal injury or property damage.  
Avoid fuel spills by running the engine dry or  
by removing the gasoline with a hand pump;  
never siphon.  
Service Interval: Every 50 hours  
1. Stop the engine and wait for all moving parts to  
stop.  
5. Remove the blade nuts, the anti-scalp cup, the  
accelerator, and the blade (see Figure 35).  
2. Disconnect the wire from the spark plug (see  
Figure 9 and Figure 10).  
3. Remove the bolts that secure the belt cover to the  
lawn mower housing (Figure 34).  
Figure 35  
1. Tabs and nuts  
2. BBC Shield  
3. Tab and bolt.  
Figure 34  
1. Belt cover  
6. Loosen the tabs that secure the BBC shield to the  
deck by loosening the nuts or the bolts on the  
tabs (Figure 35). Rotate the tabs 180° to move  
them out of the way.  
4. Lift off the cover and brush out all the debris  
around the belt area.  
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Maintenance  
7. Remove the BBC shield and brush or blow all  
the debris from under the shield and around the  
BBC system.  
8. Install the BBC shield. Rotate the tabs 180° back  
into position. Tighten the nuts to the bolts on  
tabs to secure the BBC shield to the deck.  
9. Install the blade, the accelerator, the anti-scalp  
cup, and the two blade nuts.  
10. Turn the lawn mower upright.  
11. Connect the wire to the spark plug.  
Emptying the Fuel Tank  
and Cleaning the Fuel Filter  
(Kawasaki Units Only)  
Service Interval: Every 100 hours  
The fuel filter (screen) element is located inside the  
fuel tank.  
1. Stop the engine and wait for it to cool down.  
Note: Drain gasoline for a cold engine only.  
2. Disconnect the wire from the spark plug  
(Figure 10).  
3. Close the fuel valve (Figure 7).  
4. Disconnect the fuel line by loosening the tube  
clamp at the carburetor.  
5. Open the fuel valve by turning the lever to the  
open position.  
6. Drain the gasoline completely from the tank and  
fuel line into an approved fuel container.  
7. Remove the fuel tank from the mower.  
8. Close the fuel valve.  
9. Pour a small amount of fuel in the fuel tank, move  
the fuel around in the tank, and pour it out into  
an approved fuel container.  
10. Install the fuel tank and fuel line.  
Waste Disposal  
Motor Oil Disposal  
Engine oil and hydraulic oil are both pollutants to  
the environment. Dispose of used oil at a certified  
recycling center or according to your state and local  
regulations.  
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Storage  
General Storage Information  
1. Clean the lawn mower housing. Refer to  
Cleaning the Underside of the Lawn Mower  
Housing section in Cleaning.  
Storage  
Preparing the Fuel System  
To prepare the lawn mower for off season storage,  
perform the recommended maintenance procedures.  
2. Clean any dirt and chaff from the cylinder,  
cylinder head fins, and blower housing.  
Store the lawn mower in a cool, clean, dry place.  
Cover the lawn mower to keep it clean and protected.  
3. Remove grass clippings, dirt, and grime from the  
external parts of the engine, the shrouding, and  
the top of the lawn mower housing.  
WARNING  
Gasoline can vaporize if you store it over long  
periods of time. Gasoline vapors can explode  
if they come into contact with an open flame.  
4. Clean the BBC shield. Refer to Cleaning the  
Blade Brake Clutch Shield section in Cleaning.  
5. Check the condition of the blade. Refer  
to Maintaining the Blade section in the  
Maintenance.  
• Do Not store gasoline over long periods  
of time.  
6. Service the air filter. Refer to Servicing the Air  
Filter in Maintenance.  
• Do Not store the lawn mower with  
gasoline in the fuel tank or the carburetor  
in an enclosure with an open flame. (For  
example, a furnace or a water heater pilot  
light.)  
7. Lubricate the pivot arms. Refer to Lubricating  
the Pivot Arms section in Maintenance.  
8. Tighten all nuts, bolts, and screws.  
9. Touch up all rusted or chipped paint surfaces with  
paint available from an Authorized Service Dealer.  
• Allow the engine to cool before storing  
it in any enclosure.  
Empty the fuel tank when mowing the last time  
before storing the lawn mower.  
Removing the Lawn Mower  
from Storage  
1. Run the lawn mower until the engine stops from  
running out of fuel.  
1. Check and tighten all fasteners.  
2. Remove the spark plug and spin the engine rapidly  
by pulling the starter rope to blow excess oil from  
the cylinder.  
2. Prime the engine and start it again.  
3. Allow the engine to run until it stops. When you  
can no longer start the engine it is sufficiently dry.  
3. Clean the spark plug or replace it if it is cracked,  
broken, or if the electrodes are worn.  
Preparing the Engine  
1. While the engine is still warm, change the oil from  
the crankcase. Refer to Changing the Engine  
Oil section in Maintenance.  
4. Install the spark plug and torque it to 17 ft-lb (23  
N-m).  
5. Perform any needed maintenance procedures.  
6. Fill the fuel in the fuel tank with fresh gasoline.  
7. Check the engine oil level.  
2. Remove the spark plug.  
3. Using an oil can, add about one tablespoon of oil  
to the crankcase through the spark plug hole.  
8. Connect the wire to the spark plug.  
4. Slowly rotate the engine several times, using the  
starter rope, to distribute the oil.  
5. Install the spark plug but Do Not connect the  
wire to the spark plug.  
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Troubleshooting  
Troubleshooting  
Important: It is essential that all operator safety mechanisms be connected and in proper operating  
condition prior to mower use.  
When a problem occurs, Do Not overlook the simple causes. For example: starting problems could be  
caused by an empty fuel tank.  
The following table lists some of the common causes of trouble. If a problem continues, contact an Authorized  
Service Dealer.  
Problem  
Possible Cause  
1. Fuel tank is empty.  
Corrective Action  
1. Fill the fuel tank.  
Engine will not start, starts hard, or fails to  
keep running.  
2. Fuel shutoff valve is closed.  
2. Open the fuel shutoff valve.  
3. The throttle lever is not in the correct  
position.  
3. Move the throttle lever to the Choke  
position.  
4. Dirt, water, or stale fuel is in the fuel  
system.  
4. Contact an Authorized Service Dealer.  
5. Faulty spark plug.  
6. Spark plug wire is not connected.  
5. Clean, adjust or replace spark plug.  
6. Check the spark plug wire connection.  
Engine loses power.  
1. Air cleaner is dirty.  
1. Clean or replace the air cleaner element.  
2. Oil level in the crankcase is low.  
3. Vent hole in the fuel cap is plugged.  
4. Dirt in fuel filter.  
2. Add oil to the crankcase.  
3. Clean or replace the fuel cap.  
4. Replace the fuel filter.  
5. Dirt, water, or stale fuel is in the fuel  
system.  
5. Contact an Authorized Service Dealer.  
6. The underside of the lawn mower deck  
contains clippings and debris  
6. Clean the underside of the lawn mower  
deck.  
Engine runs rough.  
1. The wire is not connected to the spark  
plug.  
1. Connect the wire to the spark plug.  
2. Faulty spark plug.  
2. Clean, adjust or replace spark plug.  
3. The throttle lever is not in the Fast  
position.  
3. Move the throttle lever to the Fast  
position.  
4. The air filter element is dirty and is  
restricting the air flow.  
4. Clean the air filter pre-cleaner and/or  
replace the paper air filter.  
Lawn mower or engine vibrates excessively.  
1. The blade is bent or is out of balance.  
1. Balance the blade. If the blade is bent,  
replace it.  
2. The blade mounting bolt is loose.  
2. Tighten the blade mounting bolt.  
3. The underside of the lawn mower deck  
contains clippings and debris.  
3. Clean the underside of the lawn mower  
deck.  
4. The engine mounting bolts are loose.  
4. Tighten the engine mounting bolts.  
Uneven cutting pattern.  
Discharge chute plugs  
1. All four wheels are not at the same height. 1. Place all four wheels at the same height.  
2. The blade is dull.  
3. Mowing in the same pattern repeatedly.  
2. Sharpen and balance the blade.  
3. Change the mowing pattern.  
4. The underside of the lawn mower deck  
contains clippings and debris.  
4. Clean the underside of the lawn mower  
deck.  
1. The throttle lever is not in the Fast  
position.  
1. Move the throttle lever to the Fast  
position.  
2. The cutting height is too low.  
3. Mowing too fast.  
2. Raise the cutting height.  
3. Slow down.  
4. The grass is wet.  
4. Allow the grass to dry before mowing.  
5. The underside of the lawn mower deck  
contains clippings and debris.  
5. Clean the underside of the lawn mower  
deck.  
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Troubleshooting  
Problem  
Possible Cause  
Corrective Action  
Lawn mower does not self-propel  
(Self-Propelled Models Only)  
1. The self-propel drive cable is out of  
adjustment or is damaged.  
1. Adjust the self-propel drive cable. Replace  
the cable if necessary.  
2. There is debris under the belt cover.  
2. Clean the debris from under the belt  
cover.  
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Exmark Commercial Turf Equipment  
1Year Limited Warranty  
If for any reason you are dissatisfied with the Service Dealer’s  
analysis or with the assistance provided, contact us at:  
Conditions and Products Covered  
Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty  
Company, pursuant to an agreement between them, jointly  
warrant on the terms and conditions herein, that we will repair,  
replace or adjust any part on these products and found by us  
(in the exercise of our reasonable discretion) to be defective in  
factory materials or workmanship for a period of one year.  
Exmark Customer Service Department  
The Exmark Warranty Company  
2101 Ashland Avenue  
Beatrice, NE 68310  
402-223-6375 or  
This warranty applies to Exmark commercial turf equipment  
sold in the U.S. or Canada. This warranty may only be  
assigned or transferred to a second (or third) owner by an  
authorized Exmark dealer. The warranty period commences  
upon the date of the original retail purchase.  
Owner’s Responsibilities  
The Exmark turf equipment, including any defective part,  
must be returned to an authorized Exmark service dealer  
within the warranty period. This warranty extends only to turf  
equipment operated under normal conditions. You must read  
the operator’s manual. You must also properly service and  
maintain your Exmark product as described in the operator’s  
manual. Such routine maintenance, whether performed by a  
dealer or by you, is at your expense.  
Warranty Exceptions  
• Bags, Belts and Tires  
• Engine  
Warranty Period  
90 days  
2 years*  
* The Engine warranty is covered by the engine manufacturer.  
Please refer to the engine manufacturer’s warranty statement  
that is included in the literature packet.  
General Conditions  
This warranty only includes the cost of parts and labor.  
The sole liability of Exmark and Exmark Warranty Company  
with respect to this warranty shall be repair or replacement of  
defective components as set forth herein. Neither Exmark  
nor Exmark Warranty Company shall be liable for any  
incidental or consequential loss or damage.  
Items and Conditions Not Covered  
This warranty does not cover the following:  
• Pickup and delivery charges to and from any authorized  
Exmark Service Dealer.  
• Any damage or deterioration due to normal use, wear and  
tear, or exposure.  
• Cost of regular maintenance service or parts, such as filters,  
fuel, lubricants, tune-up parts, and adjustments.  
• Any product or part which has been altered or misused or  
required replacement or repair due to normal wear,  
accidents, or lack of proper maintenance.  
• Any repairs necessary due to use of parts, accessories or  
supplies, including gasoline, oil or lubricants, incompatible  
with the turf equipment or other than as recommended in  
the operator's manual or other operational instructions  
provided by Exmark.  
Such damages include but are not limited to:  
• Expenses related to gasoline, oil or lubricants.  
• Travel time, overtime, after hours time or other  
extraordinary repair charges or charges relating to repairs or  
replacements outside of normal business hours at the place  
of business of the authorized Exmark Service Dealer.  
• Rental of like or similar replacement equipment during the  
period of any warranty, repair or replacement work.  
• Any telephone or telegram charges or travel charges.  
• Loss or damage to person or property other than that  
covered by the terms of this warranty.  
• Any claims for lost revenue, lost profit or additional cost as  
a result of a claim of breach of warranty.  
• Attorney's fees.  
There are no other express warranties except for engine and  
special emission system coverage.  
No Claim of breach of warranty shall be cause for cancellation  
or rescission of the contract of sale of any Exmark mower.  
All warranty work must be performed by an authorized  
Exmark Service Dealer using Exmark approved replacement  
parts.  
All implied warranties of merchantability (that the  
product is fit for ordinary use) and fitness for use (that the  
product is fit for a particular purpose) are limited to the  
duration of the express warranty.  
Instructions for Obtaining Warranty Service  
The product must be registered with original proof of purchase  
by an Exmark Service Dealer before obtaining any warranty  
service.  
Some states do not allow exclusions of incidental or  
consequential damages, or limitations on how long an  
implied warranty lasts, so the above exclusions and  
limitations may not apply to you.  
Contact any Exmark Service Dealer to arrange service at their  
dealership. To locate a dealer convenient to you, access our  
also call 402-223-6375.  
This warranty gives you specific legal rights, and you may  
also have other rights which vary from state to state.  
G4500-426  
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Service Record  
Date:  
Description of Work Done:  
Service Done By:  
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SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS  
MID-MOUNT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
FULL SUSPENSION SEAT  
DECK LIFT ASSIST KIT  
HITCH KIT  
OPERATOR CONTROLLED DISCHARGE  
ROLL OVER PROTECTION SYSTEM (ROPS)  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
TURF STRIPER  
12V POWER PORT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
MICRO-MULCH SYSTEM  
OUT-FRONT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
DUAL-TAIL WHEEL  
SNOW BLADE  
SNOWBLOWER  
FLOOR PAN EXTENDER  
HITCH KIT  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
WEATHER CAB  
MICRO-MULCH SYSTEM  
ROLL OVER PROTECTION SYSTEM (ROPS)  
WALK-BEHIND ACCESSORIES AND OPTIONS  
GRASS CATCHER  
TURF STRIPER  
STANDON  
MICRO-MULCH SYSTEM  
Place Model No. and Serial No.  
Label Here (Included in the Literature  
Pack) or Fill in Below  
Date Purchased  
Engine Model No. and Spec. No.  
Engine Serial No. (E/No)  
Model No.  
Serial No.  
© 2008 Exmark Mfg. Co., Inc.  
Industrial Park Box 808  
Beatrice, NE 68310  
Part No. 4500-400 Rev. A  
(402) 223-6300  
Fax (402) 223-5489  
Printed in the USA  
All Rights Reserved  
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