Cub Cadet Lawn Mower E977C User Manual

Operator’s Manual  
21” Self-Propelled  
Mower  
Models 977A & E977C  
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 Cub Cadet dealer or contact the service department, P.O. Box  
361131 Cleveland, Ohio 44136-0019.  
Cub Cadet LLC., P.O. Box 361131, Cleveland, Ohio 44136-0019  
PRINTED IN U.S.A.  
Form No.769-00483.
(11/2002)  
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SECTION 1: IMPORTANT SAFE OPERATION PRACTICES  
WARNING: This symbol points out important safety instructions which, if not followed, could endanger  
the personal safety and/or property of yourself and others. Read and follow all instructions in this manual  
before attempting to operate this machine. Failure to comply with these instructions may result in personal  
injury. When you see this symbolHEED ITS WARNING.  
WARNING: Engine exhaust, some of its constituents, and certain vehicle components contain or emit  
chemicals known to State of California to cause cancer and birth defects or other reproductive harm.  
WARNING: 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.  
7. Wear sturdy, rough-soled work shoes and close-  
General Operation  
fitting slacks and shirts. Shirts and pants that cover  
1. Read this operators manual carefully in its entirety  
the arms and legs and steel-toed shoes are  
before attempting to assemble this machine. Read,  
recommended. Never operate this machine in bare  
understand, and follow all instructions on the  
feet, sandals, slippery or light weight (e.g. canvas)  
machine and in the manual(s) before operation. Be  
shoes.  
completely familiar with the controls and the proper  
8. Do not put hands or feet near rotating parts or  
use of this machine before operating it. Keep this  
under the cutting deck. Contact with the blade can  
manual in a safe place for future and regular  
reference and for ordering replacement parts.  
amputate hands and feet.  
9. A missing or damaged discharge cover can cause  
2. This machine is a precision piece of power  
blade contact or thrown object injuries.  
equipment, not a plaything. Therefore, exercise  
10. Many injuries occur as a result of the mower being  
extreme caution at all times. Your unit has been  
pulled over the foot during a fall caused by slipping  
designed to perform one job: to mow grass. Do not  
or tripping. Do not hold on to the mower if you are  
use it for any other purpose.  
falling; release the handle immediately.  
3. Never allow children under 14 years old to operate  
11. Never pull the mower back toward you while you  
this machine. Children 14 years old and over  
should read and understand the operation  
are walking. If you must back the mower away from  
a wall or obstruction first look down and behind to  
instructions and safety rules in this manual and  
avoid tripping and then follow these steps:  
should be trained and supervised by a parent. Only  
a. Step back from the mower to fully extend  
responsible individuals who are familiar with these  
your arms.  
safe operation rules should use this machine.  
b. Be sure you are well balanced with sure  
4. Thoroughly inspect the area where equipment is to  
footing.  
be used. Remove all stones, sticks, wire, bones,  
c. Pull the mower back slowly, no more than  
toys and other foreign objects which could be  
half way toward you.  
tripped over or picked up and thrown by the blade.  
d. Repeat these steps as needed.  
Thrown objects can cause serious personal injury.  
5. Do not operate the mower while under the influence  
Plan your mowing pattern to avoid discharge of  
of alcohol or drugs.  
material toward roads, sidewalks, bystanders and  
6. Do not engage the self-propelled mechanism on  
the like. Also, avoid discharging material against a  
units so equipped while starting engine.  
wall or obstruction which may cause discharged  
7. The blade control handle is a safety device. Never  
material to ricochet back toward the operator.  
attempt to bypass its operation. Doing so makes  
5. To help avoid blade contact or a thrown object  
the safety device inoperative and may result in  
injury, stay in the operator zone behind the handles  
personal injury through contact with the rotating  
and keep bystanders, helpers, children and pets at  
blade. The blade control handle must operate  
least 75 feet from the machine while it is in  
easily in both directions and automatically return to  
operation. Stop machine if anyone enters the area.  
the disengaged position when released.  
6. Always wear safety glasses to protect your eyes  
8. Never operate the mower in wet grass. Always be  
during equipment operation and while performing  
sure of your footing. A slip and fall can cause  
an adjustment or repair. Thrown objects which  
serious personal injury. If you feel you are losing  
ricochet can cause serious injury to the eyes.  
your footing, release the blade control handle  
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immediately and the blade will stop rotating within  
three seconds.  
3. Do not mow on wet grass. Unstable footing could  
cause slipping.  
9. Mow in daylight or good artificial light; walk, not run.  
10. Stop the blade when crossing gravel drives,  
walkways or roads.  
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.  
11. If the equipment should start to vibrate abnormally,  
stop the engine and check immediately for the  
cause. Vibration is generally a warning of trouble.  
12. Shut the engine off and wait until the blade comes  
to a complete stop before removing the grass  
catcher or unclogging the chute. The cutting blade  
continues to rotate for a few seconds after the  
engine is shut off. Never place any part of the body  
in the blade area until you are sure the blade has  
stopped rotating.  
13. 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.  
1. Keep children out of the mowing area and under  
the watchful care of a responsible adult other than  
the operator.  
2. Be alert and turn mower off if a child enters the  
area.  
3. Before and while moving backwards, look behind  
and down for small children.  
4. Use extreme care when approaching blind corners,  
doorways, shrubs, trees, or other objects that may  
obscure your vision of a child who may run into the  
mower.  
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.  
14. Muffler and engine become hot and can cause a  
burn. Do not touch.  
15. Only use parts and accessories made by the  
original equipment manufacturer (O.E.M). Failure  
to do so can result in personal injury.  
16. If situations occur which are not covered in this  
manual, use care and good judgment. Contact your  
dealer for assistance. Call 1-877-282-8684 for the  
name of your nearest dealer.  
Service  
Safe Handling of Gasoline:  
Slope Operation  
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. If possible, remove gas-powered equipment from  
the truck or trailer and refuel it on the ground. If this  
is not possible, then refuel such equipment on a  
trailer with a portable container, rather than from a  
gasoline dispenser nozzle.  
6. Keep the nozzle in contact with the rim of the fuel  
tank or container opening at all times until fueling is  
complete. Do not use a nozzle lock-open device.  
7. Extinguish all cigarettes, cigars, pipes and other  
sources of ignition.  
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.  
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. Before operating this unit on a  
slope or hilly area, use the slope gauge on page 6 to  
measure slopes . 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 caution when changing direction.  
2. Watch for holes, ruts, rocks, hidden objects, or  
bumps which can cause you to slip or trip. Tall  
grass can hide obstacles.  
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.  
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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.  
4. Mower blades are sharp and can cut. Wrap the  
blade or wear gloves, and use extra caution when  
servicing them.  
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.  
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.  
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.  
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 mower to cool 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.  
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 here. 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.  
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!”  
12. Observe proper disposal laws and regulations.  
Improper disposal of fluids and materials can harm  
the environment.  
Your Responsibility  
Restrict the use of this power machine to persons who read, understand and follow the warnings and  
instructions in this manual and on the machine.  
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SECTION 2: SLOPE GAUGE  
Use this page as a guide to determine slopes where you may not operate safely. Do not operate your lawn mower  
on such slopes.  
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SECTION 3: ASSEMBLING YOUR LAWN MOWER  
Removing Unit From Carton  
Setting Up Your Lawn Mower  
Assembling Handle  
Remove staples, break glue on top flaps, or cut  
tape at carton end and peel along top flap to open  
carton.  
Lift up and pull back on the upper handle to raise  
the handle into the operating position. See Figure  
3. Make certain the lower handle is seated securely  
into the handle bracket assemblies.  
Remove loose parts, if included with unit (i.e., grass  
bag etc.), and save it appropriately.  
Cut along corners, lay the carton down flat, and  
remove all packing material.  
Roll or slide unit out of carton and check carton  
thoroughly for loose parts.  
Handle Assembly  
Loose Parts in Carton  
1. Grass Bag  
2. Grass Bag Adapter  
3. Side Discharge Chute  
4. Hardware Pack  
Wing Nut  
Handle Mounting  
Bracket  
Hardware Pack  
Please identify each piece of the hardware pack as  
shown in Figure 1.  
Figure 3  
Tighten wing nuts on each side of the handle  
making sure that the carriage bolts are seated  
properly into the handle. See Figure 3.  
Remove hairpin clip from the outer hole of the weld  
pin on each handle brackets. Using a pair of pliers,  
squeeze one leg of the lower handle against the  
handle bracket. Insert the hairpin clip into the inner  
hole on the weld pin. Repeat on the other side. See  
Figure 4.  
Carriage Bolt  
Wing Nut  
Figure 1  
After moving the hairpin clip, insert the carriage  
bolt, from the hardware pack, in the upper hole on  
the handle mounting bracket and secure with  
plastic wing nut, also from the hardware pack. See  
Figure 4. Repeat on the other side.  
Before Assembly  
Before setting up your lawn mower, disconnect the  
spark plug wire from the spark plug and ground  
against the engine. See Figure 2.  
Carriage Bolt  
Lower  
Handle  
Spark Plug  
Wire  
Inner Hole  
Wing Nut  
Hairpin  
Clip  
Handle Mounting  
Bracket  
Spark Plug  
Figure 2  
NOTE: Reference to right or left side of the mower is  
observed from the operating position.  
Figure 4  
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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 5.  
Grass Bag  
Adapter  
Cable Tie  
Lower  
Handle  
Wing  
Nuts  
Figure 5  
Figure 7  
Lift chute door on the grass bag adapter and slide  
grass bag onto the adapter. See Figure 8.  
Attaching Starter Rope  
NOTE: Make certain the drive cable is routed around  
the outside and above the lower handle so it does not  
interfere with attaching the grass bag.  
NOTE: The chute door has been designed to move the  
starter rope out of the way of the bag when the chute  
door is opened.  
The rope guide, which is connected to the support  
rod, is located on the right side of the lower handle.  
See Figure 6.  
Chute  
Door  
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.  
Grass  
Bag  
Lower  
Handle  
Starter  
Rope  
Figure 8  
Support  
Rod  
Attaching Side Discharge Chute  
Rope  
Guide  
Remove mulching baffle or grass bag adapter from  
unit by disconnecting wing nuts.  
Attach side discharge chute to unit and secure with  
the three wing nuts. See Figure 9 .  
Figure 6  
Attaching The Grass Bag  
The mower was shipped with the mulching baffle  
installed on the unit. You can keep this baffle on as long  
as you want to mulch the grass clippings. For bagging  
purposes, you will have to attach the grass bag and its  
adapter in place of the mulching baffle.  
Remove three wing nuts holding the mulching  
baffle or side discharge chute in place and remove  
the accessory from the unit.  
Replace with grass bag adapter, while making  
sure the front lip of adapter goes under the edge of  
the deck. Secure with wing nuts previously  
removed. See Figure 7 .  
Side Discharge  
Chute  
Figure 9  
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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.  
Drive Clutch Control  
The drive clutch control is located on the upper handle.  
Squeeze the drive control to engage the drive system.  
Release the clutch control to disengage the drive  
system. Release the clutch control to slow down when  
approaching an obstacle, making a turn, or stopping. .  
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.  
Shift Lever  
The shift lever is located on the drive clutch control  
housing on the upper handle. This lever is used to  
select the forward speed of the mower. When changing  
speed selection, release the drive clutch control.  
NOTE: Move the shift lever only when the engine is  
running. Changing the shift lever setting with the engine  
off can damage the mower.  
Blade Control Handle  
The blade control handle is located on the upper handle  
of the mower. The blade control handle must be  
depressed in order to operate the unit. Release blade  
control handle to stop engine and blade.  
Grass Bag  
The grass bag is equipped with a bag-fill indicator  
called a Grass Guage, to add convenience to your  
work. While the mower is running, air will flow through  
the bag and into the sail.If the grass catcher is empty,  
air flows through easily pushing the sail up. If the grass  
catcher is full, air does not flow through it allowing the  
sail to fall. So the position of the sail acts as a bag-fill  
indicator signifying when to empty the grass bag.  
WARNING: This blade control mechanism is  
a safety device. Never attempt to bypass its  
operations.  
Cutting Height Adjustment Levers  
The cutting height adjustment lever is located above  
the left rear wheel. To adjust the cutting height, refer to  
the Adjustment Section in this manual.  
Mulching Plug  
The mulching plug is used only for mulching purposes.  
Instead of collecting grass clippings in a grass catcher,  
this mower has the option of recirculating the clippings  
back to the lawn.  
Recoil Starter  
The recoil starter is attached to the right upper handle.  
Stand behind the unit and pull the recoil starter rope to  
start the unit.  
Blade Control Handle  
Electric Start Switch (Model E977 only)  
Drive Clutch  
Height Adjustment  
Lever  
Grass Guage  
Shift Lever  
Recoil Starter  
Gas Cap  
Grass Catcher  
Side-Discharge  
Mulch Plug  
Chute  
Figure 10  
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SECTION 5: OPERATING YOUR LAWN MOWER  
outlet. See Figure 11. Follow this order of action  
every time you charge the battery.  
WARNING: Read, understand, and follow all  
instructions and warnings on the machine and  
in this manual before operating.  
Charge battery for 16 hours before initial use. Do  
not charge longer than 20 hours.  
After charging, disconnect battery charger plug  
from household outlet first, then disconnect charger  
lead from battery pack lead.  
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 determined  
which height is best for your lawn. See the Adjustment  
Section for details.  
WARNING: Do not remove the battery pack  
from the handle panel for any reason other  
than replacement. When replacing the battery  
pack, refer to instructions on page 16.  
Gas & Oil Fill-Up  
Check oil level and add oil if necessary. Follow  
relevant instructions in the engine manual for this.  
Service the engine with gasoline as instructed in  
the engine manual.  
Attach spark plug wire to spark plug. Make certain  
the metal cap on the end of the spark plug wire  
(inside the rubber boot) is fastened securely over  
the metal tip on the spark plug.  
Check for proper drive clutch operation using the  
neutral adjustment test described below.  
WARNING: Use extreme care when  
handling gasoline. Gasoline is extremely  
flammable and the vapors are explosive. Never  
fuel the machine indoors or while the engine is  
hot or running. Extinguish cigarettes, cigars,  
pipes and other sources of ignition.  
Neutral Adjustment Test  
To perform the neutral adjustment test, answer the  
following questions.  
With the drive clutch control released, push mower  
forward and pull it backward. Does it move freely?  
Squeeze the drive clutch control and pull the  
mower backward. Do the rear wheels lock?  
Is the drive clutch control cable free of kinks or  
sharp bends?  
If you answered yesto all three questions, your  
mower passed the test and you can start your  
mower.  
Before Starting Mower  
Charging the Battery (Model E977 only)  
IMPORTANT: Use only the battery charger supplied with  
this mower.  
WARNING: The battery contains corrosive  
fluid and toxic material; handle with care. Keep  
away from children. Do not puncture,  
disassemble, mutilate or incinerate the battery.  
Explosive gases could be vented during  
charging or discharging. Use in a well  
If you answered noto any of the three questions,  
you will have to adjust the drive clutch control as  
instructed in the ADJUSTMENT SECTION.  
Starting Engine  
ventilated area, away from sources of ignition.  
WARNING: Be sure no one other than the  
operator is standing near the lawn mower while  
starting engine or operating mower.  
Protective  
Cap  
WARNING: Never run engine indoors or in  
enclosed, poorly ventilated areas. Engine  
exhaust contains carbon monoxide, an  
odorless and deadly gas.  
Battery  
pack  
lead  
WARNING: Keep hands, feet, hair and  
loose clothing away from any moving parts on  
engine and lawn mower.  
Figure 11  
WARNING: When starting the unit for the  
first time, face the mower against a wall or a  
fence. Start the unit and if it shows any signs of  
motion while the drive clutch control is still  
disengaged, shut engine off immediately.  
Remove the protective cap from the end of the  
battery pack lead. Always plug charger lead into  
battery pack lead first, and then insert battery  
charger plug into 120 volt standard household  
10  
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Push primer once. Do not prime to restart a warm  
engine after a short shutdown.  
For a healthy lawn, always cut off one-third or less  
of the total length of the grass. Lawn should be  
trimmed in fall as long as there is growth.  
Standing behind the mower, depress the blade  
control handle and hold it against the upper handle.  
Electric Start: Turn the ignition key to the right to  
start the engine. Release the key after the engine  
starts.  
IMPORTANT: Move the shift lever only when the engine  
is running. Changing the shift lever setting with the  
engine off can cause damage to the mower.  
Recoil Start: Grasp starter handle and pull rope  
out slowly until engine reaches 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 rewind slowly.  
WARNING: If the mower strikes a foreign  
object, stop the engine. Remove spark plug  
wire from the spark plug and thoroughly inspect  
for any damage. Repair the damage promptly  
before restarting and operating the mower.  
Mulching  
Stopping Engine  
For effective mulching, do not cut wet grass. New or  
thick grass may require a narrower cut. If the grass has  
grown in excess of 4, mulching is not recommended.  
Mow using the side discharge to reduce the grass  
height to 3.25maximum before mulching.  
Release blade control handle to stop the engine  
and the blade.  
Disconnect spark plug wire and move away from  
spark plug to prevent accidental starting.  
Using Your Lawn Mower  
Bagging Grass Clippings  
You can use the grass catcher bag to collect clippings  
while you are operating the mower.  
WARNING: Never operate the mower  
unless the hooks on the grasscatcher are  
seated in the slots on the handle bracket  
assemblies, and the rear discharge door rests  
firmly against the top of the grasscatcher.  
Attach grass catcher following instructions on page  
8 of this manual. Grass clippings will automatically  
collect in the bag as you run the mower.  
Operate the mower till the grass bag is full.  
Stop engine completely by releasing the blade  
control handle. Make sure that the unit has come to  
a complete stop.  
Do not operate the mower without any one of the  
mulching baffle, discharge chute or grass catcher  
properly installed.  
While holding the grass bag by both the rear handle  
and the lower handle, lift the grass bag straight up  
off the adapter. The chute door will move the rope  
out of the way of the bag.  
Continue to hold the lower handle and raise the  
rear of the grass bag up toward your chest. The  
grass bag will open and the grass clippings will  
disperse. When replacing the grass bag, be sure  
the top of the bag rests on the wire support  
between the handles.  
WARNING: Be sure that the lawn is clear of  
stones, sticks, wire, or other objects which  
could damage lawn mower or engine. Such  
objects could be accidently thrown by the  
mower in any direction and cause serious  
personal injury to the operator and others.  
For best results, do not cut wet grass. It may stick to  
the underside of the mower, preventing proper  
discharge of grass clippings, and could cause you  
to slip and fall. New grass or thick grass may  
require a narrower cut.  
SECTION 6: MAKING ADJUSTMENTS  
Remove the starter rope from the rope guide.  
Remove the wing nuts and carriage bolts securing  
the upper handle. Remove and lay the upper  
handle out of the way, being careful not to bend or  
kink the cables.  
WARNING: Do not at any time make any  
adjustments without first stopping engine and  
disconnecting spark plug wire.  
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.  
Handle Height  
Your mower is shipped with the handle in the higher  
height position. To lower the height, proceed as follows:  
11  
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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 12.  
Bottom View  
Upper  
Handle  
Adjustment  
Wheel  
Notch  
Lower Handle  
Drive Clutch  
Control  
Shift Lever  
Figure 13  
Figure 12  
NOTE: For some people the drive clutch control may  
not be in a comfortable position. You can adjust the  
handle out by tightening the adjustment wheel.  
Reassemble the handles, 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 through the upper  
hole on the handle mounting bracket and secure  
with plastic wing nuts.  
Reassemble the upper handle to the lower handle.  
Attach the starter rope as instructed on page 8.  
Shift Lever Cable  
Periodic adjustment of the six speed shift cable may be  
necessary due to normal wear on the cable. Adjustment  
is needed if all six speeds do not work.  
The adjustable cable bracket is located on the left side  
of the mower beside the engine. See Figure 14.  
Cutting Height  
Adjustable Cable  
Bracket  
Your mower is shipped with the cutting height in the  
lowest position. The cutting height adjustment lever is  
located above the left rear wheel. To adjust the cutting  
height, proceed as follows:  
Hex Nut  
Pull the lever out and away from the mower and  
then move it forward or backward to another slot.  
For rough or uneven lawns, move the height  
adjustment lever to a higher position. This will help  
stop scalping.  
PUSH  
Figure 14  
Drive Clutch Control  
Start engine and place shift lever in the sixth speed  
position. Refer to Figure 13.  
Stop engine and disconnect spark plug wire and  
ground it against engine.  
Loosen hex nut which secures the adjustable cable  
bracket. See Figure 14.  
Push back on the adjustable cable bracket and  
tighten hex nut.  
The adjustment wheel is located in the drive clutch  
control handle housing and is used to tighten or loosen  
the drive belt. You will have to adjust the drive clutch  
control if any of the following happens:  
1. The mower does not propel itself with the drive  
clutch engaged.  
2. The mowers drive wheels hesitate with the drive  
clutch engaged.  
Engine Adjustments  
To resolve the above problems, rotate the  
adjustment wheel with your fingers: clockwise to  
tighten the cable and counter-clockwise to loosen  
the cable. See Figure 13.  
Refer to the engine manual for these adjustments.  
12  
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SECTION 7: MAINTAINING YOUR LAWN MOWER  
Inspect muffler periodically, and replace if  
WARNING: Always stop the engine and  
disconnect the spark plug wire before  
performing any maintenance work or  
adjustments on your lawn mower.  
necessary. Damaged mufflers or spark arresters  
can create a fire hazard. Make sure to avoid muffler  
and surrounding areas while the mower engine is  
hot because temperature of these areas of the  
engine may exceed 150o F.  
Cleaning Mower  
Lubrication  
The underside of the mower deck should be cleaned  
after each use to prevent any build-up of debris. If  
allowed to accumulate, it will cause rust and corrosion.  
Refer to the lubrication chart in Figure 15.  
Blade Control Handle  
NOTE: We do not recommend the use of pressure  
washers or garden hose to clean your unit. These may  
cause damage to electric components, spindles,  
pulleys, bearings, or the engine. The use of water will  
result in shortened life and reduce serviceability.  
Lubricate the pivot points on the blade control  
handle at least once a season with light oil. The  
blade control must operate freely in both directions.  
Rear Discharge Door  
Lubricate the torsion spring and the pivot point on  
each end of the rear discharge door using a light oil.  
This will prevent rusting of the discharge door.  
Disconnect spark plug wire.  
Drain the gasoline from the lawn mower, or place a  
piece of plastic under the gas cap.  
Wheels  
Lubricate the wheels and bearings, if so equipped,  
Tip the mower so that it rests on the housing. Keep  
the side with the air cleaner facing up. Hold the  
mower firmly.  
at least once a season with light oil or engine oil.  
Also, 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.  
Scrape and clean the underside of the deck with a  
suitable tool. Do not spray with water.  
Put the mower back on its wheels on the ground. If  
you had put plastic under the gas cap, make sure to  
remove it now.  
Engine  
Follow the engine manual instructions and  
recommended schedule for lubricating engine  
components.  
WARNING: Never tip the mower more than  
90 degrees in any directions 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.  
Lubricate  
Lubricate  
Engine Care  
A list of key maintenance jobs required for good  
performance by the mower is given below. Follow the  
accompanying engine manual for detailed list and  
instructions.  
Change engine oil regularly, as instructed in the  
engine manual. Check oil level before starting  
engine every time. Change oil while the engine is  
warm, not hot or cold.  
Service foam filter in the air cleaner every 25 hours  
of use and replace the paper filter component every  
100 hours. You may have to service the air filter  
more frequently if you are operating the mower  
under extremely dusty conditions.  
Lubricate  
Clean the engine periodically. Remove dirt and  
debris with a cloth or brush.  
Clean the spark plug and reset the gap to .030at  
least once a season. Refer to the engine manual for  
correct spark plug type.  
Figure 15: Lubrication Chart  
13  
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SECTION 8: SERVICING THE MOWER  
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.  
WARNING: Always stop the engine and  
disconnect the spark plug wire before  
performing any maintenance work or  
adjustments on your lawn mower.  
Replace hex bolt and tighten hex bolt to torque: 450  
in. lbs. min., 600 in. lbs. max.  
Blade Care  
WARNING: When removing the cutting  
blade for sharpening or replacement, protect  
your hands with a pair of heavy gloves or use a  
heavy rag to hold the blade.  
NOTE: To ensure safe operation of your mower,  
periodically check the blade bolt for correct torque.  
Blade  
Periodically inspect the blade adapter for cracks,  
especially if you strike a foreign object. Replace when  
necessary.  
Adapter  
Blade Bell  
Support  
Removing the Blade  
Disconnect spark plug wire from spark plug.  
Turn mower on its side making sure that the air filter  
and the carburetor are up.  
Hex Bolt  
Remove the bolt and the blade bell support which  
hold the blade and the blade adapter to the engine  
crankshaft. See Figure 16.  
Remove the blade and the adapter from the  
crankshaft.  
Figure 16  
Drive Belt Replacement  
Sharpening the Blade  
The blade can be sharpened with a file or on a  
grinding wheel. Do not attempt to sharpen the  
blade while it is still on the mower.  
Disconnect the spark plug wire and ground it  
against the engine.  
Drain the fuel tank or place a piece of plastic  
beneath the cap to prevent gasoline leakage.  
Place shift lever in the first position and tip the  
mower on its side with air filter facing up.  
Remove the center bolt which secures the blade to  
the crankshaft followed by blade bell support,  
blade, and blade adapter.  
Follow the original angle of grind as a guide. Make  
sure that each cutting edge receives an equal  
amount of grinding to prevent an unbalanced blade.  
WARNING: 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.  
Move the cutting height adjustment to the highest  
position.  
Remove the three hex screws holding the baffle to  
the deck and pivot baffle towards the rear of the  
mower. See Figure 17.  
Balancing the Blade  
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.  
Installing the Blade  
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.  
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.  
Baffle  
Slide the blade adapter onto the engine crankshaft.  
Figure 17  
14  
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Remove the hex bolt from the rear of unit holding  
the transmission to the mower housing.  
See Figure 18.  
Pivot the control arm down away from the pulley  
and belt.  
Lift off the lower pulley assembly and remove the  
old belt from around the crankshaft.  
Place the new belt over the transmission pulley.  
Start the belt in the pulley groove and rotate the  
pulley until the belt is seated in transmission pulley.  
Place the belt between the idler pulley and the belt  
keeper bracket.  
Wheel  
Hex Bolt  
Using pliers, rotate the belt keeper bracket so that it  
snaps into slot on the idler bracket.  
Tighten the idler pulley bolt and lock nut half a turn.  
Place the belt between the two pulley halves on the  
crankshaft. Make sure to route the belt inside the  
belt guard pin. See Figure 21.  
Cutting Height  
Adjustment  
Wheel  
Figure 18  
Upper Pulley  
Half  
Tilt the transmission forward and loosen the idler  
pulley bolt and lock nut half a turn. See Figure 19.  
Tab  
Transmission  
Pulley  
Belt  
Belt  
Lower Pulley  
Half  
Belt Keeper  
Bracket  
Belt  
Guard Pin  
Idler Pulley  
Transmission  
Bracket  
Figure 21  
Idler Pulley  
IMPORTANT: When replacing the belt, do not disas-  
semble the lower pulley assembly.  
Bolt and  
Locknut  
Pinch both sides of the belt together so that the belt  
is not in the pulley groove, and the lower pulley can  
be pushed towards the engine. See Figure 22.  
Figure 19  
Using a pair of pliers, pull back and rotate belt  
keeper bracket from the slot on the idler pulley.  
Slide the belt out from between the belt keeper  
bracket and the idler pulley.See Figure 19.  
Squeeze the belt together and push it forward,  
while pressing the control arm inward towards the  
deck and remove the six speed cable from the slot.  
See Figure 20.  
Lower Pulley  
Half  
Belt  
Six-Speed  
Cable Slot  
Belt  
Control  
Arm  
Belt  
Guard Pin  
Figure 22  
Pivot the control arm back to its original position  
and reinstall the six-speed cable into the slot.  
See Figure 23.  
Figure 20  
15  
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Attach the new flap and new rod to deck, bending  
the ends of the new rod over to secure to deck.  
Six-Speed  
Cable Slot  
Replacing Battery Pack  
(Model E977 only)  
Remove the battery pack from the handle panel for  
replacement only. Do not separate the batteries for  
any reason. Dispose of batteries properly.  
When replacing battery pack in handle panel,  
battery pack must be positioned with the positive  
terminal to the right side and the negative terminal  
to the left side of the panel. Replacing the battery  
pack incorrectly will cause serious damage. The  
positive lead on the wire harness has the smaller  
connector. Connect the positive lead to the positive  
side of the battery pack, then connect the negative  
side.  
Control  
Arm  
Figure 23  
Make sure the belt is routed inside the pulley halves  
and the belt guard pin.  
Reinstall the bolt securing transmission to rear  
mower housing.  
Pivot the baffle back to its original position and  
secure with three hex screws removed earlier.  
Lightly lubricate the inside of the blade adapter and  
reinstall the spacer, wave washer, blade adapter  
assembly, and blade in the correct order.  
Tighten the hex bolt to secure the blade to torque:  
450-600 in. lbs.  
WARNING: Batteries contain sulfuric acid  
which may cause burns. Do not short circuit or  
mutilate batteries in any way. Do not put  
batteries in fire as these may burst or release  
toxic materials.  
In-line Fuse  
(Model E977 only)  
The unit is equipped with an in-line fuse. If the unit fails  
to start, check the fuse inside the battery cover by  
turning the end of the fuse holder and removing from  
the battery cover. Replace with standard automotive 7-  
1/2 amp fuse.  
Replacing Rear Flap  
To remove rear flap, cut off the flat end of the wire  
rod which secures it to the deck.  
SECTION 9: OFF-SEASON STORAGE  
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.  
Storing Your Lawn Mower  
The following steps should be taken to prepare your  
lawn mower for storage.  
Clean and lubricate mower thoroughly as described  
in the lubrication instructions.  
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.  
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.  
16  
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SECTION 10: 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, 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  
wide.  
1. Reset gap to .030or replace spark plug.  
2. Adjust carburetor.  
2. Carburetor improperly adjusted.  
3. Dirty air cleaner.  
3. Clean air cleaner.  
Excessive vibration  
1. Cutting blade loose or unbalanced.  
2. Bent cutting blade.  
1. Tighten blade and adapter. Balance  
blade.  
2. Replace blade.  
Mower will not mulch grass 1. Wet grass.  
2. Excessively high grass.  
1. Do not mow when grass is wet; wait until  
later to cut.  
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.  
17  
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SECTION 11: PARTS LIST FOR MODELS 977 & E977  
1
2
3
4
15  
14  
8
5
17  
9
6
7
12  
20  
18  
13  
10  
16  
19  
11  
35  
37  
36  
39  
38  
40  
56  
54  
52  
57  
33  
48  
21  
43  
44  
50  
41  
45  
88  
42  
94  
55  
53  
89  
28  
57  
58  
51  
34  
27  
32  
49  
59  
46  
62  
45  
90  
63  
47  
64  
73  
29  
65  
91  
92  
66  
60  
61  
68  
31  
33  
69  
70  
67  
71  
74  
75  
72  
76  
77  
78  
79  
81  
80  
30  
IMPORTANT: For  
machine, use Factory Approved Parts.  
V-BELTS are specially designed to engage  
and disengage safely. A substitute (non  
OEM) V-Belt can be dangerous by not  
disengaging completely.  
a
proper working  
82  
83  
84  
85  
86  
87  
18  
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Models 977 & E977  
Ref.  
No.  
Part No.  
Description  
Ref.  
No.  
Part No.  
Description  
1. 647-04008  
2. 731-0904A  
3. 16864  
Control Handle  
52. 748-0381  
748-0188B  
Pawl RH  
Pawl LH  
Upper Control Handle  
6 Spd. Rack Cable Bracket  
Control Lever  
53. 738-0137A  
54. 748-0318  
55. 736-0270  
56. 710-0751  
57. 731-0982A  
58. 738-0102  
59. 736-0504  
60. 734-2008A  
61. 736-0105  
62. 710-1348  
63. 710-0896  
64. 710-0654A  
65. 611-0064  
66. 736-0204  
67. 710-0703  
68. 710-1242  
69. 741-0492A  
70. 710-1241  
71. 731-1836  
72. 754-0460  
73. 656-0613  
74. 750-1071  
75. 750-1070  
76. 782-7597  
77. 710-0654A  
78. 782-7596  
79. 732-0807  
80. 711-1114  
81. 736-0526  
82. 731-1828  
83. 710-0653  
84. 753-0609  
85. 742-0741  
86. 736-0524A  
87. 710-1257  
88. 731-1874  
89. 732-0819  
90. 726-0111  
91. 747-0965  
92. 731-1713B  
94. 682-3052  
682-3053  
Shld Screw .340 ID x .285 OD  
Wheel Rachet  
4. 731-0620  
5. 713-0397  
6. 732-0627  
7. 731-0924  
8. 731-0905A  
9. 710-1667A  
10. 731-0906  
11. 746-0711A  
12. 712-0324  
13. 746-0883  
14. 710-1270  
15. 746-04055  
16. 749-0439D  
17. 720-0284  
18. 736-0451  
19. 710-1174  
20. 726-0240  
21. 749-0907B  
27. 731-1901  
28. 732-0842  
29. 631-0066  
30. 731-1832  
31. 731-1833  
32. 782-0078B  
33. 712-0397  
34. 710-0703  
35. 746-0939  
36. 782-7574A  
37. 736-0270  
38. 712-0287  
39. 710-0167  
40. 712-0138  
41. 782-7575A  
42. 736-0329  
43. 756-0625  
44. 738-0924  
45. 714-0104  
46. 736-0286  
47. 782-0565  
48. 734-2010  
49. 712-0414  
50. 16855  
Gear Insert  
Bell Washer .265 ID x .75 OD  
Hex Cap Screw 1/4-20 x .620  
Hubcap  
Shift Lever Spring  
6 Speed Shift Lever  
Lower Control Housing  
C Sunk Tap Screw #10 x .75 Lg  
Cable Mounting Cap  
Drive Cable 51.0  
Shoulder Screw .498 x 1.445  
Wave Washer .510 ID x .750 OD  
Wheel 8 x 2.125  
Spring Washer .401 ID x .870 OD  
Screw 1/4-14 x .500  
Screw 1/4-14 x .625  
Hex Washer Screw 3/8-16 x 1.0  
Front Axle Assembly  
Flat Washer .344 ID x .62 OD  
Carriage Screw 1/4-20 x .75  
Torx Screw  
Top Lock Nut 1/4-20  
Control Housing  
Oval C-Sunk Screw  
Control Cable  
Upper Handle  
Wing Nut  
Saddle Washer .320 ID x .830 OD  
Carriage Bolt 5/16-18 x 2.0  
Cable Tie  
Block Bushing  
Hex Washer Screw  
Front Axle Cover  
Lower Handle  
Trail Shield  
Belt 3/8 x 39.24  
Trail Shield Wire  
Pulley Assembly  
Chute Assembly  
Sleeve Spacer .88 ID x 1.13 OD  
Sleeve Spacer .88 ID x 1.00 OD  
Pivot Bracket  
Side Discharge Chute  
Mulch Cover  
Deck 21”  
Screw 3/8-18 x 1.0  
Wing Nut  
Control Arm  
Carriage Bolt 1/4-20 x .75  
6 Speed Cable  
Torsion Spring  
Pivot Shaft  
Cable Adjustment Bracket  
Bell Washer .265 ID x .75 OD  
Hex Nut 1/4-20  
Wave Washer 1.38 ID x .88 OD  
Baffle  
Screw 1/4-20 x 3.75  
Blade Adapter Kit  
Carriage Screw 1/4-20 x .50  
Hex Nut 1/4-28  
21Mulching Blade  
Blade Bell Support  
Cable Mounting Bracket  
Lock Washer 1/4  
Hex Bolt 3/8-24 x 2.5  
Chute Door  
Roller Cable  
Shoulder Screw .375 ID x 1/4-14  
Cotter Pin  
Torsion Spring  
Push Cap  
Bowed Washer  
Pivot Rod  
Single Lever Control Arm  
Wheel 9 x 2.125  
Discharge Chute  
Handle Bracket Assembly - RH  
Handle Bracket Assembly - LH  
Cup Assembly (Part of #73)  
Top Lock Tab Weld Nut 1/4-20  
Ratchet Pawl Plate  
Plastic Spring Ratchet  
95. 682-7527  
51. 10622B  
19  
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Models 977 & E977  
1
8
2
15  
16  
3
17  
28  
27  
11  
4
26  
5
6
25  
7
9
24  
10  
18  
12  
21  
14  
29  
7
13  
23  
14  
30  
19  
22  
7
31  
30  
20  
33  
34  
35  
32  
36  
60  
59  
37  
38  
40  
39  
43  
41  
42  
44  
45  
48  
61  
46  
47  
51  
49  
50  
58  
52  
62  
53  
54  
55  
56  
63  
57  
20  
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Models 977 & E977  
Ref.  
Ref.  
No.  
Part No.  
Part Description  
Part No.  
Part Description  
Hex Jam Nut 1/4-28  
No.  
1.  
2.  
3.  
4.  
5.  
6.  
7.  
8.  
9.  
720-0223  
732-0803A  
738-0529  
710-0751  
736-0270  
748-0318  
736-0369  
682-0531  
750-0515  
Grip  
Spring Lever  
33. 712-0896  
34. 782-7598  
35. 741-0600  
36. 732-0849A  
37. 750-1050  
38. 682-0027A  
39. 710-0299  
40. 741-0682A  
41. 736-0570  
42. 721-0329  
43. 721-0325  
44. 618-0253  
45. 782-7601A  
46. 741-0690  
47. 736-0616  
48. 782-7595  
49. 741-0324  
50. 711-1168  
51. 717-1469  
52. 741-0674  
53. 717-1487  
54. 736-0314  
55. 736-0569  
56. 618-0252  
57. 710-0642  
58. 611-0066  
59. 664-0121  
60. 747-0940A  
61. 747-0939  
62. 747-0937  
63. 631-0071  
Belt Keeper  
Bearing  
Shoulder Nut .825 x .165 Lg.  
Cap Screw 1/4-20 x .620  
Bell Washer .285 ID x .75 OD  
Wheel Rachet  
Flat Washer .508 ID x 1.0 OD  
Pivot Arm Assembly  
Spacer .510 ID x .70 OD  
Sleeve Bearing .504 ID x .830 OD  
Shoulder  
Tap Screw 1/4-20 x .375  
Chain Cover Assembly  
Flange Bearing .506 ID x .590 Lg  
Transmission Axle Assembly  
Transmission Assembly Complete  
Hex Screw 5/16-18  
Chain  
Rear Axle Assembly  
Flange Bearing .506 ID x .715 Lg  
Torsion Spring  
Spacer .550 ID x .750 OD  
Screw 3/8-16 x .25  
Clevis Pin .50 Dia x 4.82 Lg.  
Spacer .385 ID x .624 OD  
Hgt Adjustment Spring Bracket  
Screw 1/4-14 x .825  
Extension Spring  
Flange Spacer  
Idler Bracket Assembly  
Hex Cap Screw 1/4-28 x 1.0  
Bearing Sleeve  
Flat Washer .885 ID x 1.45 OD  
Oil Seal  
Plug  
Upper Housing Assembly  
Cable Bracket  
Bearing  
Thrust Washer .504 ID x .70 OD  
Pivot Bracket  
Flange Bearing  
Output Shaft 6T  
Gear 34T  
Bearing  
Pinion Shaft 10T  
Thrust Washer 3/8 x .70  
Thrust Washer .388 x .625  
Lower Housing Assembly  
Hex Screw 1/2-20 x .75  
Shaft Assembly  
Grassbag  
10. 741-0978  
11. 750-1056  
12. 710-0653  
13. 682-7528  
14. 741-0324  
15. 682-7526  
16. 618-0263A  
17. 710-0604A  
18. 713-0453  
19. 638-0012  
20. 741-0522  
21. 732-0832  
22. 750-0151  
23. 710-1315  
24. 711-0835  
25. 750-0807  
26. 782-0568  
27. 710-1652  
28. 714-0474  
29. 712-3025  
30. 736-0425  
31. 756-0656  
32. 736-3084  
Cotter Pin  
Support Rod w/ Rope Guide  
Pivot Rod  
Grassbag Frame  
Grassbag Cover  
Hex Jam Nut 5/16-24  
Bell Washer .325 ID x .930 OD  
Pulley  
Flat Washer .510 ID x 1.120 OD  
21  
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Model E977  
1
Ref. No.  
Part No.  
725-0201  
Description  
Ignition Key  
Key Switch  
2
1
2
3
7
8
725-0873  
731-0891A  
725-0727  
725-0298  
725-1428  
725-1276  
710-0501  
736-0270  
712-0329  
725-1206  
712-0267  
736-0242  
712-0287  
710-1250  
710-0111  
782-9012  
710-0969  
725-1538  
625-0022  
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
Battery Tray  
5
6
Battery Charger  
Fuse 7.5 Amp  
Fuse Holder  
Battery 12V  
Hex Screw:1/4-20:2.0  
Bell Washer  
Special Hex Nut 5/16-18  
Plug  
Nut 5/16-18  
10  
14  
12  
9
13  
15  
16  
11  
9
17  
4
Bell Washer  
Hex Nut 1/4-20  
Carriage Bolt  
Carriage Screw  
Lower Battery Tray  
Tapp Screw  
20  
18  
19  
Harness Extension  
Harness  
Safety & Decorative Labels  
Some of the labels found on your mower are represented here with the corresponding part numbers. Please use  
part numbers when ordering replacement labels.  
777S30118  
777I20291  
777S30128  
777S30116  
R
U
F
I
R
L
AVOID SERIOUS INJURY OR DEATH  
• KEEP HANDS AND FEET AWAY FROM  
ROTATING PARTS.  
S
REMOVE OBJECTS THAT CAN BE THROWN  
BY THE BLADE IN ANY DIRECTION.  
WEAR SAFETY GLASSES.  
L
A
• DO NOT MOW WHEN CHILDREN OR OTHERS  
ARE AROUND.  
777S30145  
TO REDUCE THE RISK OF INJURY, DO NOT  
OPERATE UNLESS DISCHARGE COVER OR  
GRASS CATCHER IS IN ITS PROPER PLACE.  
IF DAMAGED, REPLACE IMMEDIATELY.  
USE EXTRA CAUTION ON SLOPES. DO NOT MOW  
SLOPES GREATER THAN 15˚. MOW ACROSS NEVER  
UP AND DOWN. NEVER PULL MOWER CLOSE TO  
YOUR FEET. LOOK DOWN AND BEHIND BEFORE  
AND WHILE MOVING BACKWARDS.  
777D06697  
READ OPERATOR'S MANUAL . KEEP SAFETY DEVICES (BLADE CONTROL, TRAILING SHIELD,  
DISCHARGE COVER, ETC.) IN PLACE AND WORKING. IF DAMAGED, REPLACE IMMEDIATELY.  
22  
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Engine Manual for Kawasaki Engine  
SAFETY AWARENESS  
WARNING: Whenever you see the symbols shown on the left, heed their instructions! Always follow safe  
operating and maintenance practices.  
FORWARD  
We wish to thank you for purchasing this Kawasaki engine. Please read this Owner's manual carefully before  
starting your new engine so that you will be thoroughly familiar with the proper operation of your engine's  
control, its features, capabilities and limitations. Also read the manual of the equipment to which this engine  
is attached. To ensure a long, trouble-free life for your engine, give it the proper care and maintenance  
described in this manual.  
Always keep this manual at your fingertip so that you can refer to it whenever you need information. This  
manual should be considered a permanent part of the engine and should remain with the engine when it is  
sold. All rights reserved. No part of this publication may be reproduced without our prior written permission.  
This publication includes the latest information available at the time of printing. However, there may be minor  
differences between the actual product and illustrations and text in this manual. All products are subject to  
change without prior notice or obligation.  
EMISSION CONTROL INFORMATION .................................................. 24  
GENERAL INFORMATION..................................................................... 26  
FUEL AND OIL RECOMMENDATIONS.................................................. 27  
PREPARATION ...................................................................................... 27  
Fuel............................................................................................. 27  
Engine Oil................................................................................... 27  
STARTING.............................................................................................. 28  
Starting Engine ........................................................................... 28  
OPERATING........................................................................................... 28  
Anti-engine inclination................................................................. 28  
STOPPING.............................................................................................. 28  
Stopping Engine ......................................................................... 28  
ADJUSTMENT........................................................................................ 29  
Engine Speed Adjustment .......................................................... 29  
MAINTENANCE...................................................................................... 29  
Periodic Maintenance Chart ....................................................... 29  
Oil Level Check........................................................................... 29  
Oil Change.................................................................................. 29  
Air Cleaner Service..................................................................... 30  
Spark Plug Service ..................................................................... 30  
STORAGE............................................................................................... 31  
TROUBLESHOOTING GUIDE................................................................ 33  
ENVIRONMENTAL PROTECTION......................................................... 33  
SPECIFICATIONS .................................................................................. 33  
23  
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READ THIS FIRST  
WARNING: Never allow children to operate the engine or equipment.  
Keep people and pets out of area where you are using the engine or equipment.  
Never wear loose, torn, or bulky clothing. It may catch on moving parts or controls, leading to the risk of  
accident.  
Never consume alcohol or drug before or while operating this engine.  
Do not run the engine in a closed area. Exhaust gas contains carbon monoxide, an odorless and deadly  
poison.  
Gasoline is extremely flammable and can be explosive under certain condition.  
Stop engine and allow the engine to cool before refueling.  
Do not smoke. Make sure area is well ventilated and free from any source of flame or sparks including the  
pilot light of any appliance while refueling, servicing fuel system, draining gasoline and/or adjusting  
carburetor.  
Do not fill the tank so the fuel level rises into the filler neck. If the tank is overfilled, heat may cause the fuel  
to expand and overflow through the vents in the tank cap.  
Wipe off any spilled gasoline immediately.  
To prevent fire hazard:  
Keep the engine at least 1 m (3.3 ft.) away from buildings, obstructions and other burnable objects.  
Do not place flammable objects close to the engine.  
Do not expose combustible materials to the engine exhaust.  
Do not use the engine on any forest covered, bush covered or grass covered unimproved land unless spark  
arrester is installed on the muffler.  
To avoid getting an electric shock, do not touch spark plug, plug cap or spark plug lead during engine  
running.  
To avoid a serious burn, do not touch a hot engine or muffler. The engine becomes hot during operation.  
Before you service or remove parts, stop engine and allow the engine to cool.  
Do not place hands or feet near moving or rotating parts.  
Do not run engine at excessive speeds. This may result in injury.  
Always remove the spark plug lead from spark plug when servicing the engine to prevent accidental  
starting.  
Board. Also, depending on when your engine was  
produced, it may have an assigned emissions durability  
period. * See below for the engine emissions durability  
period that may apply to your engine.  
Emission Control Information  
Fuel Information  
THIS ENGINE IS CERTIFIED TO OPERATE ON  
UNLEADED REGULAR GRADE GASOLINE ONLY.  
Exhaust Emission Control System  
A minimum of 87 octane of the antiknock index is  
recommended. The antiknock index is posted on  
service station pumps in the U.S.A.  
The exhaust emission control system applied to this  
engine consists of a fuel system and an ignition system  
having optimum ignition timing characteristics. The fuel  
system has been calibrated to provide lean air/fuel  
mixture characteristics and optimum fuel economy with  
a suitable air cleaner and exhaust system  
To protect the environment in which we all live,  
Kawasaki has incorporated an exhaust emission  
control system in compliance with applicable  
regulations of the United States Environmental  
Protection Agency and the California Air Resources  
A sealed-type crankcase emission control system is  
also used to eliminate blow-by gasses. The blow-by  
24  
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gasses are led to a breather chamber through the  
crankcase and from there to the air cleaner.  
necessary to ensure compliance with the applicable  
standards.  
As the owner of the engine, you have the responsibility  
to make sure that the recommended maintenance is  
carried out according to the instructions in this Owner's  
Manual at your own expense.  
Engine Emissions Compliance Period  
California  
Model Year - 2006 and later Vertical Crankshaft  
Durability Period - 500 hours  
The Kawasaki Limited Emission Control System  
Warranty requires that you return your engine to an  
authorized Kawasaki dealer for remedy under warranty.  
Please read the warranty carefully, and keep it valid by  
complying with the owner's obligations it contains.  
All Other States  
Model Year - 2003 and later (new)  
2007 and later (carry over)  
Durability Period - 500 hours (Category A}  
Tampering with Emission Control System Prohibited  
Federal law and California State law prohibit the  
following acts or the causing thereof: (1) the removal or  
rendering inoperative by any person other than for  
purposes of maintenance, repair, or replacement, of  
any device or element of design incorporated into any  
new engine for the purposes of emission control prior to  
its sale or delivery to the ultimate purchaser or while it is  
in use, or (2) the use of the engine after such device or  
element of design has been removed or rendered  
inoperative by any person.  
If your engine has an assigned emissions durability  
period it will be located on the certification label  
attached to the engine (IMPORTANT ENGINE  
INFORMATION).  
High Altitude Performance Adjustment Information  
To improve the EMISSIONS CONTROL  
PERFORMANCE of engines operated above 1,000  
meters (3,300 feet), Kawasaki recommends the  
following Environmental Protection Agency (EPA) and  
the California Air Resources Board (CARB) approved  
modifications.  
Among those acts presumed to constitute tampering  
are the acts listed below:  
NOTE: When properly performed, these specified  
modifications only are not considered to be emissions  
system "tampering" and engine performance is  
generally unchanged as a result.  
Do not tamper with the original emission related parts:  
Carburetor and internal parts  
Spark Plug  
Magneto or electronic ignition system  
Fuel filter element  
Air cleaner elements  
Crankcase  
Cylinder head  
Installation Instructions:  
High altitude adjustment requires replacement of  
carburetor main jet. Installation of these optional parts  
may be performed by an authorized Kawasaki dealer,  
or the consumer, following repair recommendations  
specified in the appropriate Kawasaki Service Bulletin.  
Breather chamber and internal parts  
Intake pipe and tube  
Maintenance and Warranty  
Proper maintenance is necessary to ensure that your  
engine will continue to have low emission levels. This  
Owner's Manual contains those maintenance  
recommendations for your engine. Those items  
identified by the Periodic Maintenance Chart are  
25  
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General Information  
Location of Safety Related Labels  
C
Figure 3  
A. Fuel Tank Cap  
B. Fuel Tank (capacity 2.0L [0.528US gal.])  
C. Fuel Tube  
Figure 1  
a. Warning (Refer to )  
D. Carburetor  
b. Engine Maintenance (Refer to ))  
E. Priming Pump  
F. Air Cleaner  
G. Recoil starter  
H. Recoil Starter Grip  
I. Oil Drain Plugs (engine oil capacity 0.65L [0.69US  
gal.])  
Figure 4  
J. Oil Gauge / Filler Cap  
K. Spark Plug Cap / Spark Plug  
L. Muffler  
Engine Serial Number  
M. P.T.O. Shaft  
The engine serial number is your only means of  
identifying your particular engine from others of the  
same model type.This engine serial number is needed  
by your dealer when ordering parts. Refer to Figure 2.  
Tune-up Specifications  
ITEM  
SPECIFICATION  
Valve Clearance  
IN 0.12mm(0.005 in.)  
EX 0.12mm{0.005 in.}  
Ignition Timing  
High Idle Speed  
Spark Plug Gap  
Unadjustable  
3200 r/min (rpm)  
0.7- 0.8mm(0.028-0.032 in.)  
Other Specifica-  
tions  
NO OTHER ADJUSTMENT  
NEEDED  
Figure 2  
26  
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Fuel And Oil Recommendations  
Fuel  
A
K
Use only clean, fresh, unleaded regular grade  
gasoline.  
<
SAE5W-20  
>
t.  
1
<
SAE5W-20  
>
Octane Rating  
Y
F
k
The octane rating of a gasoline is a measure of its  
resistance to "knocking".Use a minimum of 87 octane of  
the antiknock index is recommended. The antiknock  
index is posted on service station pumps in the U.S.A.  
A
V
<
SAE1OW-30/SAE1OW-40  
>
h
SAE5W-20  
F
F
F
F
F
NOTE: If "knocking or pinging" occurs, use a different  
brand of gasoline or higher octane rating.  
Figure 5  
CAUTION: Do not mix oil with gasoline  
Oxygenated Fuel  
NOTE: Using multi grade oils (5W-20, 10W-30, and  
10W-40) will increase oil consumption. Check oil level  
more frequently when using them.  
Oxygenates (either ethanol or MTBE) are added to the  
gasoline. If you use the oxygenated fuel be sure it is  
unleaded and meets the minimum octane rating  
requirement.The following are the EPA approved  
percentages of fuel oxygenates.  
ETHANOL: (Ethyl or Grain Alcohol)  
You may use gasoline containing up to 10% ethanol by  
volume.  
MTBE: (Methyl Tertiary Butyl Ether)  
You may use gasoline containing up to 15% MTBE by  
volume.  
METHANOL: (Methyl or Wood Alcohol) 5% by volume  
Figure 6  
You may use gasoline containing up to 5% methanol by  
volume, as long as it also contains co solvents and  
corrosion inhibitors to protect the fuel system.  
Preparation  
Fuel  
Gasoline containing more than 5% methanol by volume  
may cause starting and/or performance problems. It  
may also damage metal, rubber, and plastic parts of  
your fuel system.  
Level the engine (equipment) before fueling.  
Remove the fuel tank cap.  
Slowly pour fuel into the fuel tank to bottom (B) of  
the filler (A).  
Do not over fill the fuel tank, fill only to bottom (B) of the  
filler (A) to prevent spill out of the fuel from the tank cap.  
WARNING: Gasoline is extremely  
flammable and can be explosive under certain  
conditions. Do not smoke. Make sure the area  
is well ventilated and free from any source of  
flame or sparks; this includes any appliance  
with a pilot light. Never fill the tank so the fuel  
level rises into the filler neck. If the tank is  
overfilled, heat may cause the fuel to expand  
and overflow through the vents in the tank cap.  
Fuel Tank Capacity, 2.0 L (0.528 us.gal)  
Close the tank cap securely by turning it clockwise  
as far as it will go.  
Engine Oil  
Check the engine oil level daily before starting the  
engine otherwise shortage of the engine oil may cause  
serious damage to the engine such as seizure.  
Engine Oil  
Place the engine (equipment) on level surface.  
Clean area around the oil gauge before removing it.  
Remove the oil gauge (A) and wipe it with clean  
cloth.  
Pour the oil slowly to "FULL" mark on the oil gauge.  
Insert the oil gauge into the oil filler (B)WITHOUT  
SCREWING IT IN.  
The following engine oils are recommended:  
API Service Classification: SF, SG, SH, or SJ.  
Oil Viscosity  
Choose the viscosity according to the temperature as  
follows:  
27  
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Remove the oil gauge to check the oil level. Level  
should be between "ADD" and "FULL" marks. Do  
not overfill.  
damage to the recoil starter or pad system of  
the engine.  
DO NOT pull the recoil starter grip out of the  
end.  
DO NOT let the recoil starter grip snap back  
itself. This may cause damage to the recoil  
starter assembly.  
Hold the brake control lever (A) on the equipment  
against the handle (B) on the equipment.  
Pull the recoil starter grip (C) slowly until you feel  
compression, then pull fast and steady.  
Install and tighten the oil gauge.  
Engine Oil Capacity, 0.65 L (0.69 us.qt)  
CAUTION: The engine is shipped without  
engine oil.  
Figure 7  
Starting  
Band Pad System  
Figure 9  
Upon releasing the brake control lever on the  
equipment, the cutting blade and the engine will stop  
automatically.  
A. Brake Control Lever  
B. Handle  
Therefore, the brake control lever must be held against  
the handle while the engine is started and running.  
C. Recoil Starter Grip  
Warming up  
Starting Engine  
CAUTION: Allow engine to warm up before loading.  
This will allow oil to reach all the engine parts, and  
the piston clearance to reach design specification,  
before the engine is ready for loading.  
Fully push the priming button (A) by thumb only  
once.  
NOTE: When the engine is already warm or on hot  
days, do not push the priming button to prevent faulty  
starting engine caused by flooding carburetor.  
After engine starts, warm up the engine, run it for a  
few minutes.  
Operating  
Anti-engine inclination  
This engine will operate continuously at angles up  
to 30°in any direction.  
Refer to the operating instructions of the equipment  
this engine powers.  
Because of equipment design or application, there  
may be more stringent restrictions regarding the  
angle of operation.  
CAUTION: Do not operate this engine continuously  
at angles exceeding 30° in any direction. Engine  
damage could result from insufficient lubrication.  
Figure 8  
CAUTION:  
Stopping  
Stopping Engine  
Release the brake control lever (A) on the equipment  
from the handle (B) on the equipment to stop the engine  
and the cutting blade.  
DO NOT start the engine when the cutting blade  
is in contact with long, uncut grass, it may  
cause difficulties in starting and damage to the  
recoil starter.  
DO NOT attempt to start the engine when the  
brake control lever on the equipment is  
released from your hands; this may cause  
28  
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A. Brake Control Lever  
B. Handle  
Adjustment  
Engine Speed Adjustment  
NOTE: Do not tamper with the governor setting or the  
carburetor setting to increase the engine speed. Each  
carburetor is adjusted at the factory with either a cap or  
stop plate installed on the mixture screw. Any  
adjustments must be performed an authorized  
Kawasaki dealer.  
Figure 10  
MAINTENANCE  
MAINTENANCE  
INTERVAL  
DAILY  
FIRST 8  
HOURS  
EVERY 25 EVERY 50  
EVERY  
100  
EVERY  
200  
EVERY  
300  
HOURS  
HOURS  
HOURS  
HOURS  
HOURS  
z
z
z
z
z
Check oil level and add  
engine oil  
Check for loose or lost  
nuts and screws  
Check for fuel and oil  
leakage  
Check for brake control  
lever function  
Check or clean recoil  
starter and air intake  
screen Tighten nuts and  
screws  
z
z
z
z
z
z
z
Clean air cleaner foam  
element  
Clean air cleaner paper  
element  
z
Change engine oil  
Clean and re-gap spark  
Plug  
z
z
z
Replace air cleaner  
paper element  
Clean dust and dirt from  
cylinder and cylinder head  
fins  
z
z
z
Clean combustion  
chamber  
Check and adjust valve  
clearance  
Clean and lap valve  
seating surface  
Periodic Maintenance Chart  
NOTE: The service intervals indicated are to be used as a guide. Service should be performed more frequently as  
necessary by operating condition. Service more frequently under dusty conditions.  
: Have an authorized Kawasaki dealer perform these services.  
Oil Level Check  
Check oil level daily and before each time of operation.  
Be sure oil level is maintained. See PREPARATION .  
WARNING: Hot engine oil can cause severe  
burns. Allow engine temperature to drop from  
hot to warm before draining and handling oil.  
Oil Change  
Run the engine to warm oil.  
Be sure the engine (equipment) is level.  
Stop the engine.  
Change oil after first 8 hours of operation. Thereafter  
change oil every 50 hours.  
29  
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Remove the oil drain plug (A) on side of the engine  
or on bottom of the engine to drain oil into suitable  
container (B) while the engine is warm.  
Air Cleaner Service  
CAUTION: To prevent excessive engine wear, do  
not run the engine with the air cleaner  
WARNING: Clean the elements in a well-  
ventilated area and take care that there are no  
sparks or flame anywhere near the working  
area, this includes any appliance with a pilot  
light. Do not use gasoline or low flash-point  
solvents to clean the element. A fire or  
explosion could result.  
Unfasten the air cleaner case (C) fastened with the  
air cleaner body (D) by sliding the two fasteners (A)  
toward the recoil starter (B).Then, with two hands,  
pulling the two latches (E) toward you and upward  
as shown, separate the air cleaner case from the air  
cleaner body.  
Figure 11  
A. Oil Drain Plug (On side of engine)  
B. Container  
Figure 14  
A. Fasteners  
B. Recoil Starter  
C. Air Cleaner Case  
D. Air Cleaner body  
E. Latches  
Figure 12  
A. Oil Drain Plug (On bottom of engine)  
Reinstall the oil drain plug.  
Remove oil gauge and refill with new oil (See FUEL  
AND OIL RECOMMENDATIONS chapter).  
Check the oil level (See PREPARATION chapter).  
Remove the paper element (A) and the foam element  
(B) from the air cleaner body (C).  
WARNING: Engine oil is toxic substance.  
Dispose of used oil properly. Contact your local  
authorities for approved disposal methods for  
possible recycling.  
Cooling System Cleaning  
Before each use, check that the recoil starter (A) is free  
from grass and debris and clean to prevent engine  
overheating.  
Figure 15  
A. Paper Element  
B. Foam Element  
C. Air Cleaner body  
Foam Element  
Clean the foam element every 25 hours.  
Wash the element in detergent and water, and dry it  
thoroughly.  
Figure 13  
30  
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CAUTION: Do not oil foam element.  
Check the spark plug gap and reset it if necessary.  
The gap must be between 0.7 and 0.8 mm (0.028  
and 0.032").  
Paper Element  
Clean the paper element every 100 hours.  
Clean the element by tapping gently to remove  
dust. If very dirty, replace the element with a new  
one.  
To change the gap, bend only the side-electrode, using  
a spark plug tool.  
-Install and tighten the spark plug to 23 N-m (2.3kgf-m,  
17fMb).  
Replace with a new paper-element yearly or 300  
hours.  
-Fit the spark plug cap on the spark plug securely.  
CAUTION: Do not wash paper-element.Do not use  
pressurized air to clean or dry paper element.  
-Pull up the spark plug cap lightly to make sure of the  
installation of the spark plug cap.  
NOTE: Operating in a dusty condition may require  
more frequent maintenance than above.  
Recommended Spark Plug  
NGK... BPR5ES  
Reinstall the foam element and then the paper  
element on the air cleaner body.  
Reinstall the air cleaner case on the air cleaner  
body by first fitting the projection (B) on the edge of  
the air cleaner case into the slit (A) in the air cleaner  
body. Then, sliding the fasteners (C) toward the air  
cleaner case, securely fasten the air cleaner case  
with the air cleaner body.  
Figure 17  
A.  
B.  
Spark Plug Gap  
Electrodes  
CAUTION: Be sure to use the same type of spark  
plug for change. Resistor spark plug is required in  
some areas by local law.  
Storage  
Figure 16  
Engine to be stored over 30 days should be completely  
drained of fuel (gasoline) to prevent gum deposits  
forming on essential carburetor parts and the fuel  
system.  
A. Slit in the air cleaner body  
B. Projection on the air cleaner case  
C. Fasteners  
CAUTION: After servicing the air cleaner, be sure  
all the removed parts are reinstalled properly in  
place. Failure to secure fastening of the air cleaner  
case with the air cleaner body may cause dirt or  
other foreign materials to enter the engine, while it  
is running, through the air cleaner, resulting in  
engine troubles or failures.  
WARNING: Gasoline is extremely  
flammable and can be explosive under certain  
conditions. Drain gasoline before storing the  
equipment for extended periods. Drain  
gasoline in a well-ventilated area away from  
any source of flame or sparks, including any  
appliances with a pilot light. Store gasoline in  
an approved container in safe location.  
WARNING: Hot engine components can  
cause severe burns. Stop engine and allow it to  
cool before checking spark plug.  
Remove the spark plug cap from spark plug to  
prevent accidental starting the engine.  
Empty the fuel from the fuel tank with a pump or  
siphon.  
Fit the plug cap on the spark plug securely  
Start and run the engine at idle speed to used up  
the fuel in the fuel system.  
Clean or replace the spark plug and reset gap (A)  
every 100 hours of operation.  
Disconnect the spark plug cap from spark plug and  
remove the spark plug.  
Clean the electrodes (B) by scraping or with a wire  
brush to remove carbon deposits.  
Inspect for cracked porcelain or other wear and  
damage. Replace the spark plug with a new one if  
necessary.  
WARNING: Before maintaining engine, stop  
the engine and allow it cool.  
31  
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Remove the spark plug and pour approx. 1-2 mL  
(0.06-0.1 cu.in) of new engine oil through the plug  
hole (A), slowly pull the recoil starter grip several  
times and reinstall the spark plug.  
A. Spark Plug Hole  
Slowly pull the recoil starter grip until you feel  
compression and leave it there.  
Clean every part of the engine.  
After period of storage, change engine oil.  
(Refer to "Oil Change" section in  
"MAINTENANCE" section).  
Figure 18  
32  
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Troubleshooting Guide  
Symptom  
Probable Cause  
Remedy  
Engine won't start Insufficient  
1. Faulty piston, cylinder, piston ring, 1. Tighten properly  
and head gasket  
output is low  
compression  
2. Faulty valves  
2. Tighten properly  
3. Loose spark plug  
3. Tighten properly  
4. Loose cylinder head bolts  
4. Tighten properly  
No fuel to  
1. No fuel in fuel tank  
1. Fill fuel tank  
2. Clean  
3. Clean  
4. ‡  
combustion chamber 2. Blocked rue tube  
3. Blocked air vent in fuel tank cap  
4. Faulty carburetor  
Spark plug fouled by 1. Over-rich fuel/air mixture  
fuel  
1. Slowly pull the recoil starter grip with  
spark plug removed to discharge  
excess fuel. clean spark plug  
2.Clean  
2. Clogged air cleaner  
3. Faulty carburetor  
4. Incorrect grade/type of fuel  
5. Water in fuel  
3.‡  
4. Change Gasoline  
5. Change Gasoline  
1. Replace spark plug  
2.‡  
No spark or weak  
spark  
1. Faulty spark plug  
2. Faulty ignition coil  
3. Faulty engine switch  
3.‡  
Low Output  
Engine Overheats  
1. Clogged air cleaner  
2. Recoil Starter or cooling air path  
clogged with dirt  
1. Clean  
2. Clean  
3. Insufficient engine oil  
4. carbon built -up in combustion  
chamber  
3. Replenish or change oil  
4.‡  
5. Select a better location  
5. Poor ventilation around engine  
1. Engine speed  
1. Faulty Governor  
wont increase  
If the engine malfunctions, carefully examine the symptoms and the operating conditions, and use the table above  
as a guide to troubleshooting.Have an authorized Kawasaki dealer perform these service  
Environmental Protection  
To protect our environment, properly discard used batteries, engine oil, gasoline, coolant, or other components that  
you might dispose of in the future.  
Consult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal procedure.  
Specifications  
Type of Engine  
Bore X Stroke  
Air-cooled, 4-stroke OHV, single cylinder, gasoline Engine  
65 x 54mm (2.6 x 2.1 in.)  
179mL (109. cu.in.)  
Solid-state ignition  
Recoil starter  
Displacement  
Ignition system  
Starting system  
Dry weight  
13.5kg (29.lb)  
Specifications subject to change without notice  
33  
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KAWASAKI LIMITED WARRANTY  
CALIFORNIA AND FEDERAL  
EMISSION CONTROL SYSTEMS  
SMALL OFF-ROAD ENGINES  
The California Air Resources Board, the Environmental Protection Agency (EPA), and Kawasaki Motors Corp.,  
U.S.A. (hereinafter "Kawasaki") are pleased to explain the Emission Control Systems Warranty on your Kawasaki  
small off-road engine. In California and other states, new small off-road engines must be designed, built and  
equipped to meet stringent anti-smog standards. Kawasaki must warrant the emission control system on your small  
off-road engine for the period of time listed below provided there has been no abuse, neglect or improper  
maintenance of your small off-road engine. Your emission control system may include parts such as the carburetor  
or fuel-injection system, the ignition system, and catalytic converter. Also included may be hoses, belts, connectors  
and other emission related assemblies. Where a warrantable condition exists, Kawasaki will repair your small off-  
road engine at no cost to you including diagnosis (if the diagnostic work is Performed at a Kawasaki small off-road  
engine dealer), parts and labor.  
OWNERS WARRANTY RESPONSIBILITIES. The following obligations must be fulfilled by the owner to maintain  
the validity of the Kawasaki California / EPA Emissions Systems Warranty:  
(a)  
As the small off-road engine owner, you are responsible for the performance of the required maintenance  
listed in your owner's manual. Kawasaki recommends that you retain all receipts covering maintenance on your  
small off-road engine, but Kawasaki cannot deny warranty solely for the lack of receipts or for your failure to ensure  
the performance of all scheduled maintenance.  
(b)  
You are responsible for presenting your small off-road engine to an authorized Kawasaki small off-road  
engine Dealer as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of  
time, not to exceed 30 days.  
(c)  
AS the small off-road engine owner, you should also be aware that Kawasaki may deny you warranty  
coverage if your small off-road engine or a part has failed due to abuse, neglect, improper maintenance or  
unapproved modifications.  
(d)  
If you have any questions regarding your warranty rights and responsibilities, you should contact  
Kawasaki Motors Corp., U.S.A., Consumer Services Department, 5080 36th Street, S.E., Grand Rapids, Ml 49512,  
616/949-6500..  
1. COVERAGE. Kawasaki warrants to the initial owner and each subsequent purchaser that the small off-road  
engine is free from defects in materials and workmanship which cause a failure of a warranted part for a period of  
two years. Kawasaki is liable for damages to other engine components caused by the failure of a warranted part still  
under warranty. The 1995 and later small off-road engines are warranted for two years in California. In all other  
states, 1997 and later model year small off-road engines are warranted for two years. If any emission-related part  
on your engine is defective, the part will be repaired or replaced by Kawasaki. This warranty time period shall begin  
on the date the small off?road engine is delivered to the initial purchaser, or on the date the small off?road engine is  
first placed in service.  
Warranty defects shall be remedied during customary business hours at any authorized Kawasaki small off-road  
engine dealer located within the United States of America. Any manufacturer-approved replacement part may be  
used in the performance of any warranty maintenance or repairs on emission-related parts, and must be provided  
without charge to the owner if the part is still under warranty. Any part or parts replaced under this warranty shall  
become the property of Kawasaki.  
The emission related warranted parts are specifically defined by the California Air Resources Board's Emission  
Warranty Parts List. (EPA's regulations do not include a parts list, but EPA considers emission-related parts to  
include all parts listed here.) These warranted parts are: carburetor and internal parts, spark advance/retard  
system. cold start enrichment system, magneto or electronic ignition system, catalytic converter, intake manifold,  
exhaust manifold, air cleaner element, and spark plugs if failure occurs prior to the first required scheduled  
replacement, hoses, clamps, fittings, gaskets, sealing devices, mounting hardware and tubing used directly in  
these parts.  
Since emission related parts may vary slightly from model to model,certain models may not contain all of these parts  
and certain models may contain functionally equivalent parts.  
34  
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2. LIMITATIONS. This Emission Control Systems Warranty shall not cover any of the following:  
(a) Repair or replacement required as a result of (i) misuse or neglect, (ii) lack of required maintenance. (iii)  
repairs improperly performed or replacements improperly installed, (iv) use of replacement parts or accessories not  
conforming to Kawasaki specifications which adversely affect performance and/or durability, (v) alterations or  
modifications not recommended or approved in writing by Kawasaki.  
(b)  
Replacement of parts and other services and adjustments necessary for required maintenance at and  
after the first scheduled replacement point.  
LIMITED LIABILITY.  
(a)  
The liability of Kawasaki under this Emission Control Systems Warranty is limited solely to the remedying  
of defects in materials or workmanship by any authorized Kawasaki small off-road engine dealer at its place of  
business during customary business hours. This warranty does not cover inconvenience or loss of use of the small  
off-road engine or transportation of the small off-road engine to or from the Kawasaki Dealer. KAWASAKI SHALL  
NOT BE LIABLE FOR ANY OTHER EXPENSE, LOSS OR DAMAGE, WHETHER DIRECT, INCIDENTAL,  
CONSEQUENTIAL (EXCEPTION LISTED UNDER COVERAGE) OR EXEMPLARY ARISING IN CONNECTION  
WITH THE SALE OR USE OF OR INABILITY TO USE THE KAWASAKI SMALL OFF-ROAD ENGINE FOR ANY  
PURPOSE.  
(b)  
NO EXPRESS EMISSION CONTROL SYSTEMS WARRANTY IS GIVEN BY KAWASAKI WITH  
RESPECT TO THE KAWASAKI SMALL OFF-ROAD ENGINE EXCEPT AS SPECIFICALLY SET FORTH HEREIN.  
ANY EMISSION CONTROL SYSTEMS WARRANTY IMPLIED BY LAW, INCLUDING ANY WARRANTY OF  
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, IS EXPRESSLY LIMITED TO THE  
EMISSION CONTROL SYSTEMS WARRANTY TERMS SET FORTH HEREIN. THE FOREGOING STATEMENTS  
OF WARRANTY ARE EXCLUSIVE AND IN LIEU OF ALL OTHER REMEDIES.  
(c)  
(d)  
No dealer is authorized to modify this Kawasaki Limited Emission Control Systems Warranty.  
Kawasaki is not liable for parts which are not genuine Kawasaki parts except when genuine Kawasaki  
parts cause damage to non-Kawasaki parts.  
LEGAL RIGHTS. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE  
OTHER RIGHTS.  
THIS WARRANTY IS IN ADDITION TO THE KAWASAKI LIMITED SMALL OFF-ROAD ENGINE WARRANTY.  
35  
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MANUFACTURERS LIMITED WARRANTY FOR:  
The limited warranty set forth below is given by Cub Cadet  
LLC with respect to new merchandise purchased and used in  
the United States, its possessions and territories.  
d.  
Cub Cadet LLC does not extend any warranty for  
products sold or exported outside of the United States,  
its possesions and territories, except those sold  
through Cub Cadet LLCs authorized channels of  
export distribution.  
Parts that are not genuine Cub Cadet parts are not  
covered by this warranty.  
Service completed by someone other than an  
authorized service dealer is not covered by this  
warranty.  
Cub Cadet 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 Cub  
Cadet 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 Cub Cadet 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. Cub  
Cadet 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 Cub Cadet LLC at P.O. Box 361131,  
Cleveland, Ohio 44136-0019, or call 1-877-282-8684, or log  
Some states do not allow the exclusion or limitation of  
incidental or consequential damages, or limitations on how  
long an implied warranty lasts, so the above exclusions or  
limitations may not apply to you.  
In no event shall recovery of any kind be greater than the  
amount of the purchase price of the product sold. Alteration  
of safety features of the product shall void this warranty.  
You assume the risk and liability for loss, damage, or injury to  
you and your property and/or to others and their property  
arising out of the misuse or inability to use the product.  
This limited warranty does not provide coverage in the  
following cases:  
a.  
The engine or component parts thereof. These items  
carry a separate manufacturers warranty. Refer to  
applicable manufacturers warranty for terms and  
conditions.  
This limited warranty shall not extend to anyone other than the  
original purchaser or to the person for whom it was purchased  
as a gift.  
b.  
c.  
Log splitter pumps, valves, and cylinders have a sepa  
rate one year warranty.  
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.  
Cub Cadet LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019; Phone: 1-877-282-8684  
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