OPERATOR’S MANUAL
21” Rear & Side
Discharge
Mulching Mower
Model Series 540
IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY
Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-
covered, brush-covered or grass-covered land unless the engine’s exhaust system is equipped with a spark arrester meeting
applicable local or state laws (if any). If a spark arrester is used, it should be maintained in effective working order by the operator.
In the State of California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have
similar laws. Federal laws apply on federal lands. A spark arrester for the muffler is available through your nearest engine authorized
service dealer or contact the service department, P.O. Box 368022 Cleveland, Ohio 44136-9722.
MTD PRODUCTS INC. P.O. BOX 368022 CLEVELAND, OHIO 44136-9722
770-10019B.
(10/00)
PRINTED IN U.S.A.
FORM NO.
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SECTION 1: IMPORTANT SAFE OPERATION PRACTICES
WARNING: This symbol points out important safety instructions which, if not followed, could
endanger the personal safety and/or property of yourself and others. Read and follow all instructions in
this manual before attempting to operate this machine. Failure to comply with these instructions may
result in personal injury. When you see this symbol - heed its warning.
WARNING: Engine Exhaust, some of its constituents, and certain vehicle
components contain or emit chemicals known to State of California to cause cancer
and birth defects or other reproductive harm.
DANGER: This machine was built to be operated according to the rules for safe operation in this
manual. As with any type of power equipment, carelessness or error on the part of the operator can
result in serious injury. This machine is capable of amputating hands and feet and throwing objects.
Failure to observe the following safety instructions could result in serious injury or death.
8. Do not put hands or feet near rotating parts or under the
General Operation
cutting deck. Contact with the blade can amputate hands
1. Read this operator’s manual carefully in its entirety
and feet.
before attempting to assemble this machine. Read,
understand, and follow all instructions on the machine
contact or thrown object injuries.
and in the manual(s) before operation. Be completely
9. A missing or damaged discharge cover can cause blade
10. Many injuries occur as a result of the mower being pulled
familiar with the controls and the proper use of this
over the foot during a fall caused by slipping or tripping.
machine before operating it. Keep this manual in a safe
Do not hold on to the mower if you are falling; release the
place for future and regular reference and for ordering
handle immediately.
replacement parts.
11. Never pull the mower back toward you while you are
2. This machine is a precision piece of power equipment,
walking. If you must back the mower away from a wall or
not a plaything. Therefore, exercise extreme caution at all
obstruction first look down and behind to avoid tripping
times. Your unit has been designed to perform one job: to
and then follow these steps:
mow grass. Do not use it for any other purpose.
a. Step back from the mower to fully extend your
3. Never allow children under 14 years old to operate this
arms.
machine. Children 14 years old and over should read and
b. Be sure you are well balanced with sure footing.
understand the operation instructions and safety rules in
c. Pull the mower back slowly, no more than half way
this manual and should be trained and supervised by a
toward you.
parent. Only responsible individuals who are familiar with
d. Repeat these steps as needed.
these rules of safe operation should be allowed to use
12. Do not operate the mower while under the influence of
this machine.
alcohol or drugs.
4. Thoroughly inspect the area where the equipment is to
13. Do not engage the self-propelled mechanism on units so
be used. Remove all stones, sticks, wire, bones, toys and
equipped while starting engine.
other foreign objects which could be tripped over or
14. The blade control handle is a safety device. Never
picked up and thrown by the blade. Thrown objects can
attempt to bypass its operation. Doing so makes the
cause serious personal injury. Plan your mowing pattern
safety device inoperative and may result in personal
to avoid discharge of material toward roads, sidewalks,
injury through contact with the rotating blade. The blade
bystanders and the like. Also, avoid discharging material
control handle must operate easily in both directions and
against a wall or obstruction which may cause
automatically return to the disengaged position when
discharged material to ricochet back toward the operator.
released.
5. To help avoid blade contact or a thrown object injury, stay
15. Never operate the mower in wet grass. Always be sure of
in the operator zone behind the handles and keep
your footing. A slip and fall can cause serious personal
children, bystanders, helpers and pets at least 75 feet
injury. If you feel you are losing your footing, release the
from the mower while it is in operation. Stop machine if
blade control handle immediately and the blade will stop
anyone enters the area.
rotating within three seconds.
6. Always wear safety glasses or safety goggles during
16. Mow only in daylight or in good artificial light. Walk, never
operation and while performing an adjustment or repair to
run.
protect your eyes. Thrown objects which ricochet can
17. Stop the blade when crossing gravel drives, walks or
cause serious injury to the eyes.
roads.
7. Wear sturdy, rough-soled work shoes and close-fitting
18. If the equipment should start to vibrate abnormally, stop
slacks and shirts. Shirts and pants that cover the arms
the engine and check immediately for the cause.
and legs and steel-toed shoes are recommended. Never
Vibration is generally a warning of trouble.
operate this machine in bare feet, sandals, slippery or
19. Shut the engine off and wait until the blade comes to a
light weight (e.g. canvas) shoes.
complete stop before removing the grass catcher or
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unclogging the chute. The cutting blade continues to
rotate for a few seconds after the engine is shut off.
Never place any part of the body in the blade area until
you are sure the blade has stopped rotating.
20. Never operate mower without proper trail shield,
discharge cover, grass catcher, blade control handle or
other safety protective devices in place and working.
Never operate mower with damaged safety devices.
Failure to do so, can result in personal injury.
21. Muffler and engine become hot and can cause a burn. Do
not touch.
22. Only use parts and accessories made for this machine by
the manufacturer. Failure to do so, can result in personal
injury.
23. If situations occur which are not covered in this manual,
use care and good judgment. Contact your dealer for
assistance. Telephone 1-800-800-7310 for the name of
your nearest dealer.
obscure your vision of a child who may run into the
mower.
5. Keep children away from hot or running engines. They
can suffer burns from a hot muffler.
6. Never allow children under 14 years old to operate a
power mower. Children 14 years old and over should
read and understand the operation instructions and
safety rules in this manual and should be trained and
supervised by a parent.
Service
Safe Handling Of Gasoline:
1. To avoid personal injury or property damage use extreme
care in handling gasoline. Gasoline is extremely
flammable and the vapors are explosive. Serious
personal injury can occur when gasoline is spilled on
yourself or your clothes which can ignite.
2. Wash your skin and change clothes immediately.
3. Use only an approved gasoline container.
4. Never fill containers inside a vehicle or on a truck or
trailer bed with a plastic liner. Always place containers on
the ground away from your vehicle before filling.
5. When practical, remove gas-powered equipment from
the truck or trailer and refuel it on the ground. If this is not
possible, then refuel such equipment on a trailer with a
portable container, rather than from a gasoline dispenser
nozzle.
6. Keep the nozzle in contact with the rim of the fuel tank or
container opening at all times until fueling is complete. Do
not use a nozzle lock-open device.
7. Extinguish all cigarettes, cigars, pipes and other sources
of ignition.
Slope Operation
Slopes are a major factor related to slip and fall accidents
which can result in severe injury. Operation on slopes
requires extra caution. If you feel uneasy on a slope, do not
mow it. For your safety, use the slope gauge included as part
of this manual to measure slopes before operating this unit on
a sloped or hilly area. If the slope is greater than 15 degrees,
do not mow it.
Do:
1. Mow across the face of slopes; never up and down.
Exercise extreme caution when changing direction on
slopes.
2. Watch for holes, ruts, rocks, hidden objects, or bumps
which can cause you to slip or trip. Tall grass can hide
obstacles.
8. Never fuel machine indoors because flammable vapors
will accumulate in the area.
3. Always be sure of your footing. A slip and fall can cause
serious personal injury. If you feel you are losing your
balance, release the blade control handle immediately,
and the blade will stop rotating within 3 seconds.
9. Never remove gas cap or add fuel while the engine is hot
or running. Allow engine to cool at least two minutes
before refueling.
10. Never over fill fuel tank. Fill tank to no more than ½ inch
below bottom of filler neck to provide space for fuel
expansion.
11. Replace gasoline cap and tighten securely.
12. If gasoline is spilled, wipe it off the engine and
equipment. Move unit to another area. Wait 5 minutes
before starting the engine.
13. Never store the machine or fuel container inside where
there is an open flame, spark or pilot light as on a water
heater, space heater, furnace ,clothes dryer or other gas
appliances.
Do Not:
1. Do not mow near drop-offs, ditches or embankments,
you could lose your footing or balance.
2. Do not mow slopes greater than 15 degrees as shown on
the slope gauge.
3. Do not mow on wet grass. Unstable footing could cause
slipping.
Children
14. To reduce fire hazard, keep mower free of grass, leaves,
or other debris build-up. Clean up oil or fuel spillage and
remove any fuel soaked debris.
Tragic accidents can occur if the operator is not alert to the
presence of children. Children are often attracted to the
mower and the mowing activity. They do not understand the
dangers. Never assume that children will remain where you
last saw them.
15. Allow a mower to cool at least 5 minutes before storing.
General Service:
1. Keep children out of the mowing area and under the
watchful care of a responsible adult other than the
operator.
1. Never run an engine indoors or in a poorly ventilated
area. Engine exhaust contains carbon monoxide, an
odorless and deadly gas.
2. Be alert and turn mower off if a child enters the area.
3. Before and while moving backwards, look behind and
down for small children.
4. Use extreme care when approaching blind corners,
doorways, shrubs, trees, or other objects that may
2. Before cleaning, repairing, or inspecting, make certain
the blade and all moving parts have stopped. Disconnect
the spark plug wire and ground against the engine to
prevent unintended starting.
3. Check the blade and engine mounting bolts at frequent
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intervals for proper tightness. Also, visually inspect blade
for damage (e.g., bent, cracked, worn) Replace blade
with the original equipment manufacture’s (O.E.M.) blade
only, listed in this manual. “Use of parts which do not
meet the original equipment specifications may lead to
improper performance and compromise safety!”
4. Mower blades are sharp and can cut. Wrap the blade or
wear gloves, and use extra caution when servicing them.
5. Keep all nuts, bolts, and screws tight to be sure the
equipment is in safe working condition.
9. Grass catcher components, discharge cover, and trail
shield are subject to wear and damage which could
expose moving parts or allow objects to be thrown. For
safety protection, frequently check components and
replace immediately with original equipment
manufacturer’s (O.E.M.) parts only, listed in this manual.
“Use of parts which do not meet the original equipment
specifications may lead to improper performance and
compromise safety!”
10. Do not change the engine governor setting or overspeed
the engine. The governor controls the maximum safe
operating speed of the engine.
6. Never tamper with safety devices. Check their proper
operation regularly.
7. After striking a foreign object, stop the engine, disconnect
the spark plug wire and ground against the engine.
Thoroughly inspect the mower for any damage. Repair
the damage before starting and operating the mower.
8. Never attempt to make a wheel or cutting height
adjustment while the engine is running.
11. Maintain or replace safety and instruction labels, as
necessary.
12. Observe proper disposal laws and regulations. Improper
disposal of fluids and materials can harm the
environment.
WARNING - YOUR RESPONSIBILITY: Restrict the use of this power machine to persons who read,
understand and follow the warnings and instructions in this manual and on the machine.
NOTE: Not all safety labels shown may apply to your lawn mower.
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SECTION 2: SLOPE GAUGE
Use this page as a guide to determine slopes where you may not operate safely. Do not operate your lawn mower
on such slopes.
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SECTION 3: ASSEMBLING YOUR LAWN MOWER
IMPORTANT: This unit is shipped without gasoline or oil
in the engine. Be certain to service engine with gasoline
and oil as instructed in the separate engine manual
before operating your mower.
NOTE: Reference to right or left hand side of the mower
is observed from the operating position.
Removing Unit From Carton
•
•
•
•
Remove staples, break glue on top flaps, or cut tape
at carton end and peel along top flap to open carton.
Remove loose parts if included with unit (i.e.,
operator’s manual, etc.)
Cut along corners, lay carton down flat, and remove
packing material.
Figure 2
•
•
Remove the hairpin clips from the outer hole in the
weld pins on the handle mounting brackets. Using a
pair of pliers, squeeze one leg of the lower handle
against the handle mounting bracket. Insert the
hairpin clip into the inner hole on the weld pin.
Repeat on the other side. See Figure 3.
After moving the hairpin clip, insert the carriage bolt
from hardware pack in the upper hole on the handle
mounting bracket and secure with plastic wing nut
from the hardware pack. Repeat on other side.
Roll or slide unit out of carton and check carton
thoroughly for loose parts.
Loose Parts in Carton
•
•
•
Grass Bag
Side Discharge Chute
Hardware Pack
Disconnecting Spark Plug Wire
Before setting up your lawn mower, disconnect the spark
plug wire from the spark plug and ground against the
engine. See Figure 1.
Handle Mounting
Bracket
Carriage Bolt
Bolt
Wing Nut
Insert Hairpin
Clip
Spark Plug
Wire
Weld Pin
Hairpin
Clip
Figure 3
Spark
Plug Wire
•
Fasten the cable to the lower handle with the two
cable ties found on the lower handle. Pull the cable
ties tight and trim off the excess.
Spark Plug
Figure 1
See Figure 4.
Cable Tie
Setting Up Your Lawn Mower
Assembling Handle
•
Lift up and pull back on the upper handle to raise the
handle into the operating position. Make certain the
lower handle is seated securely into the handle
bracket assemblies. Tighten the wing nuts on each
side of the handle (carriage bolts must be seated
properly into the handle). See Figure 2.
Lower
Handle
Figure 4
NOTE: Your mower is shipped with the handle in the
higher position. If you wish to lower the height of the
handle, refer to the Adjustment Section at this time.
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Attaching Starter Rope
Discharge Door
•
The rope guide is attached to the right side of upper
handle. Loosen the wing nut which secures the
rope guide. See Figure 5.
Upper Handle
Starter
Rope
Wing Nut
Rope
Guide
Lower
Handle
Grass Bag
Figure 5
Figure 7
•
With the spark plug wire disconnected and
grounded, hold the blade control handle against the
upper handle, and pull the starter rope out of the
engine. Release the blade control handle. Slip the
starter rope into the rope guide. Tighten the wing
nut.
•
To remove the grass catcher, lift the rear discharge
door on the mower, lift the grass catcher up and off
the pivot rod. Reinstall the mulching baffle and
release the rear discharge door.
WARNING: Never operate the mower
unless the hooks on the grass catcher are
firmly seated on the chute pivot rod, and
the rear discharge door rests firmly
against the top of the grass catcher.
Attaching Grass Catcher To Mower
NOTE: The mulching baffle, if so equipped, is already
in place on the mower for shipping purposes. Your lawn
mower may be equipped with both a mulching baffle
and a mulching plug. While the mulching baffle is
located at the rear of the mower, the mulching plug is
located on the right side of the cutting deck. Do not
remove the mulching plug from the mower even when
you are not mulching the grass.
Converting To Side Discharge
If your unit is equipped with a side discharge chute, you
can convert to a side discharge mower as follows:
•
Lift the rear discharge door and install the mulching
baffle. See Figure 6.
•
On the side of the mower, lift the mulching plug and
slide the two hooks of the side discharge chute
under the hinge pin on the mulching plug assembly.
Lower the side mulching plug. See Figure 8.
Do not remove the side mulching plug at any time,
even when you are not mulching.
•
To remove the mulching baffle, lift the rear dis-
charge door on the mower. Remove the mulching
baffle. See Figure 6.
•
Mulching
Baffle
Mulching Plug
Hinge Pin
Deflector
Figure 6
Hook
IMPORTANT: Make sure cables are routed to the
outside of the handle so they are not in the way when
attaching the grass catcher.
•
•
Lift the rear discharge door on the mower.
Place the hooks, found on both sides of the grass
catcher frame, over the chute door pivot rod at the
rear of the mower. Release the rear discharge door.
See Figure 7.
Figure 8
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SECTION 4: KNOW YOUR LAWN MOWER
Read this operator’s manual and safety rules before
operating your lawn mower. Compare the illustration in
Figure 9 with your lawn mower to familiarize yourself
with the location of various controls and adjustments.
Save this manual for future reference.
Grass Catcher
The grass catcher, located at the rear of the mower, is
used to bag the grass clippings for disposal at another
site. Once the bag is full, it has to be removed from the
mower and emptied before any further mowing.
WARNING: The operation of any lawn
mower can result in foreign objects being
thrown into the eyes, which can damage
your eyes severely. Always wear safety
glasses while operating the mower, or
while performing any adjustments or
repairs on it.
Blade Control
Handle
Recoil
Starter
Recoil Starter
Cutting Height
Adjustment Lever
The recoil starter is attached to the right handle. Stand
behind the unit and pull the recoil starter to start the
unit. See Figure 9.
Grass
Catcher
Blade Control Handle
The blade control handle is located on the upper handle
of the mower. The blade control handle must be
depressed in order to operate the unit. Release blade
control handle to stop engine and blade. See Figure 9.
WARNING: This blade control mechanism
is a safety device. Never attempt to bypass
its operations.
Mulching Plug
Figure 9
Cutting Height Adjustment Levers
Mulching Plug
These levers are located on each wheel and are used
to adjust the cutting height. These levers have to be at
the same relative position to ensure uniform cut.
See Figure 9.
Both the mulching baffle and the mulching plug are
used only for mulching purposes. Instead of collecting
the grass clippings in a grass catcher, some mower
models have the option of recirculating the clippings
back to the lawn.
SECTION 5: OPERATING YOUR LAWN MOWER
WARNING: Keep hands and feet away from
chute area on the cutting deck. The
operation of any lawn mower can result in
foreign objects being thrown into the eyes,
which can result in severe eye damage.
Always wear safety glasses or eye shields.
Never fill fuel tank indoors with engine
running or until the engine has been
allowed to cool for at least two minutes
after running.
Starting Engine
NOTE: For shipping purposes your mower is set with
the wheels in a low cutting height position. For best
results raise the cutting position until it is determine
which height is best for your lawn. See the Adjustment
Section for details.
•
Attach spark plug wire to spark plug. Make certain
the metal cap on the end of the spark plug is
fastened securely over the metal tip on the spark
plug.
•
•
Prime engine as instructed in the separate engine
manual packed with your unit.
Your lawn mower may be equipped with a constant
speed throttle, which is set at full throttle for best
performance.
Gas and Oil Fill-Up
Service the engine with gasoline and oil as instructed in
the separate engine manual packed with your mower.
Read instructions carefully.
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•
•
Stand behind the mower and squeeze the blade
control handle against the upper handle.
Grasp recoil starter handle and pull rope out slowly
until engine reaches the start of compression cycle
(rope will pull slightly harder at this point). Let the
rope rewind slowly. Pull rope with a rapid,
continuous, full arm stroke. Keeping a firm grip on
the starter handle, let the rope return to the starter
slowly.
designed to be operated at full throttle to give you the
best cut and do the most effective job of mowing or
mulching.
WARNING: If you strike a foreign object,
stop the engine. Remove wire from the
spark plug, thoroughly inspect the mower
for any damage, and repair the damage
before restarting and operating the
mower. Extensive vibration of the mower
during operation is an indication of
damage. The unit should be promptly
inspected and repaired.
Using Your Lawn Mower
Be sure that the lawn is clear of stones, sticks, wire, or
other objects which could damage the lawn mower or
the engine. Such objects could be accidently thrown by
the mower in any direction and cause serious personal
injury to the operator and others.
Mulching
For effective mulching, do not cut wet grass because it
tends to stick to the underside of the deck, preventing
proper mulching of grass clippings. New or thick grass
may require a narrower cut. The ground speed should
be adjusted to the condition of the lawn. If mowing has
been delayed and the grass has been allowed to grow
in excess of 4”, mulching is not recommended. Mow
using the side discharge to reduce the grass height to 3
1/4” maximum before mulching.
For best results, do not cut wet grass because it tends
to stick to the underside of the mower, preventing
proper discharge of grass clippings, and could cause
you to slip and fall. New grass, thick grass, or wet grass
may require a narrower cut.
For a healthier lawn, never cut off more than one-third
of the total length of the grass. Your lawn should be cut
in the fall as long as there is growth. This mower is
SECTION 6: MAKING ADJUSTMENTS
WARNING: Do not at any time make any
adjustments without first stopping engine
and disconnecting spark plug wire.
the handle mounting bracket and secure with
plastic wing nuts.
Reassemble the upper handle to the lower handle.
Attach the starter rope as instructed in the
Assembly Section.
•
•
Handle Height Adjustment
Your mower is shipped with the handle in the higher
height position. To lower the height proceed as follows:
•
•
Remove the starter rope from the rope guide.
Remove the upper handle by removing the hand
knobs and carriage bolts. Lay the upper handle out
of the way, being careful not to bend or kink the
cables.
Notch
Lower Handle
•
Remove the hairpin clips from the weld pins on the
handle brackets and remove the wing nuts and
carriage bolts from the upper hole on the handle
mounting bracket. Press out on the legs of the
lower handle and remove lower handle from the
mower.
Figure 10
Cutting Height Adjustment
•
•
•
Turn lower handle around so the notch on the
bottom of the lower handle is facing forward.
See Figure 10.
Reassemble, placing the bottom holes in the
handle over the weld pins in the handle mounting
bracket.
An adjusting plate and spring lever at each wheel
position provides cutting height adjustment. Each
adjusting plate has assorted height positions. When the
spring lever is moved from one location to another the
height of cut will be changed. Simply depress the lever
towards wheel and move lever assembly to desired
position. See Figure 11.
Place the hairpin clips in the inner holes in the weld
pins and insert the carriage bolts the upper hole on
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IMPORTANT: All wheels must be placed in the same
relative position. For rough or uneven lawns, move the
height adjustment lever to a higher position. This will
help stop scalping of the grass.
Height Adjustment
Lever
Engine Adjustments
See the separate engine manual packed with your unit
for adjustments to the engine.
Figure 11
SECTION 7: MAINTAINING YOUR LAWN MOWER
•
Some adjustments will have to be made
General Recommendations
periodically to maintain your unit properly. All
adjustments in the Making Adjustments section of
this manual should be checked at least once each
season.
Periodically check all fasteners and make sure
these are tight.
Follow the maintenance schedule under Customer
Responsibilities to get quality performance from
your lawn mower.
•
Always observe safety rules when performing any
maintenance.
•
The warranty on this lawn mower does not cover
items that have been subjected to operator abuse
or negligence. To receive full value from the
warranty, operator must maintain the lawn mower
as instructed in this manual.
•
•
•
Changing of engine governed speed will void
engine warranty.
Customer Responsibilities
MAINTENANCE
SCHEDULE
SERVICE
DATES
Lubricate Wheels
Lubricate Blade Control
Clean Deck
Blade Care
Check Oil
Change Oil
Replace Air Filter
Clean Engine
Check Spark Plug
Check Spark Arrester (if any)
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Lubrication
Always stop engine and disconnect spark
Rear Discharge
Door
plug wire before cleaning, lubricating or
doing any kind of service work on the lawn
mower.
Handle
Bracket
Blade Control: Lubricate the pivot points on the blade
control handle and the brake cable at least once a
season with light oil. The blade control must operate
freely in both directions. See Figure 12.
Handle
Bracket
Rear & Side Discharge Doors: The torsion springs
and pivot points should be lubricated periodically with
light oil to prevent any rust or binding. Door must work
freely.
Rear Flap
Wheels: The wheels require no lubrication. However, if
the wheels are removed for any reason, lubricate the
surface of the axle bolt and the inner surface of the
wheel with light oil. Engine oil may also be used.
Figure 13
Engine
Refer to the separate engine manual for all engine
maintenance instructions.
Engine: Follow engine manual for instruction and
schedule of lubrication.
•
Maintain engine oil as instructed in the separate
engine manual packed with your unit.
•
Service air cleaner every 25 hours under normal
conditions. Poor engine performance and flooding
usually indicate that the air cleaner should be
serviced. To service the air cleaner, refer to the
separate engine manual packed with your unit.
The spark plug should be cleaned and the gap
reset once a season. Spark plug replacement is
recommended at the start of each mowing season.
Clean the engine regularly with a cloth or brush.
Keep the cooling system (blower housing area)
clean to permit proper air circulation which is
essential to engine performance and life. Be certain
to remove all grass, dirt, and combustible debris
from muffler area.
Lubricate
Lubricate
•
•
Lubricate
Deck
The underside of the mower deck should be cleaned
after each use to prevent a buildup of grass clippings,
leaves, dirt, or other matter. If this debris is allowed to
accumulate, it will invite rust and corrosion, and may
prevent proper mulching, discharge, or bagging. The
deck may be cleaned by tilting the mower and scraping
clean with a suitable tool (make certain the spark plug
wire is disconnected).
Figure 12
Maintenance
NOTE: When tipping the unit or emptying the fuel tank
keep the air cleaner side of engine up. Never tip the
mower more than 90 degrees and do not leave the
mower tipped for any length of time. Oil can drain into
the upper part of the engine causing a starting problem.
IMPORTANT: We do not recommend the use of a
pressure washer or garden hose to clean your unit. The
use of water will result in shorten life and reduce
serviceability.
Cutting Blade Removal, Replacement, and Sharpening
Replacing Rear Flap
•
When removing the cutting blade for sharpening or
replacement, protect your hands with a pair of
heavy gloves or use a heavy rag to hold the blade.
Remove the bolt and the blade bell support which
hold the blade and the blade adapter to the engine
crankshaft. See Figure 14.
•
To remove rear flap, cut off the flat end of the wire
rod which secures it to the deck. See Figure 13.
Attach the new flap and new rod to deck, bending
the ends of the new rod over to secure to deck
•
•
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•
Remove the blade and the adapter from the
crankshaft.
•
•
Slide the blade adapter onto the engine crankshaft.
Place the blade on the adapter. Be certain the
blade is aligned and seated on the blade adapter
flanges.
Place blade bell support on blade. Make sure the
notches on the blade bell support are aligned with
small holes in the blade.
Blade
Adapter
•
•
Replace hex bolt and tighten hex bolt to torque: 450
in. lbs. min., 600 in. lbs. max.
Blade Bell
Support
NOTE: To ensure safe operation of your mower, the
blade bolt must be checked periodically for correct
torque.
Hex Bolt
Storing your Lawn Mower
Figure 14
The following steps should be taken to prepare your
lawn mower for storage.
WARNING: Periodically inspect the blade
adapter for cracks, especially if you strike
a foreign object. Replace when necessary.
•
Clean and lubricate mower thoroughly as described
in the lubrication instructions.
When sharpening the blade, follow the original angle of
grind as a guide. It is extremely important that each
cutting edge receives an equal amount of grinding to
prevent an unbalanced blade. An unbalanced blade will
cause excessive vibration when rotating at high
speeds. It may cause damage to the mower, and could
break causing personal injury.
IMPORTANT:We do not recommend the use of a
pressure washer or garden hose to clean your unit.
•
•
•
Refer to engine manual for correct engine storage
instructions.
Coat mower’s cutting blade with chassis grease to
prevent rusting.
Store mower in a dry, clean area. Do not store next
to corrosive materials, such as fertilizer.
The blade can be tested by balancing it on a round
shaft screwdriver. Remove metal from the heavy side
until it balances evenly. It is recommended that the
blade always be removed from the adapter when
testing for balance. Before reinstalling the blade and
the blade adapter to the unit, lubricate the engine
crankshaft and the inner surface of the blade adapter
with light oil.
NOTE: When storing any type of power equipment in a
poorly ventilated or metal storage shed, care should be
taken to rust-proof the equipment. Using a light oil or
silicone, coat the equipment, especially cables and all
moving parts.
•
Be sure to install the blade with the side of the
blade marked “Bottom” (or with part number) facing
the ground when the mower is in the operating
position.
13
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SECTION 8: TROUBLESHOOTING
Problem
Cause
Remedy
Engine fails to start
1. Blade control handle disengaged.
2. Spark plug wire disconnected.
3. Fuel tank empty or stale fuel.
4. Blocked fuel line.
1. Engage blade control handle.
2. Connect wire to spark plug.
3. Fill tank with clean, fresh gasoline.
4. Clean fuel line.
5. Faulty spark plug.
6. Engine flooded
5. Clean, adjust gap, or replace.
6. Wait a few minutes to restart, but do not
prime.
Engine runs erratic
Engine overheats
1. Spark plug wire loose.
2. Blocked fuel line or stale fuel.
1. Connect and tighten spark plug wire.
2. Clean fuel line; fill tank with clean, fresh
gasoline
3. Clear vent.
4. Drain fuel tank. Refill with fresh fuel.
5. Clean air cleaner.
3. Vent in gas plugged.
4. Water or dirt in fuel system.
5. Dirty air cleaner.
6. Carburetor out of adjustment.
6. Adjust carburetor.
1. Engine oil level low.
2. Air flow restricted.
3. Carburetor not adjusted properly.
1. Fill crankcase with proper oil.
2. Remove blower housing and clean.
3. Adjust carburetor.
Occasional skip (hesitates) 1. Spark plug gap too close.
at high speed
1. Adjust gap to .030”.
Idles poorly
1. Spark plug fouled, faulty or gap too 1. Reset gap to .030” or replace spark
wide.
plug.
2. Carburetor improperly adjusted.
3. Dirty air cleaner.
2. Adjust carburetor.
3. Clean air cleaner.
Excessive vibration
1. Cutting blade loose or unbalanced. 1. Tighten blade and adapter. Balance
blade.
2. Bent cutting blade.
2. Replace blade.
Mower will not mulch grass 1. Wet grass.
1. Do not mow when grass is wet; wait
until later to cut.
2. Excessively high grass.
2. Mow once at a high cutting height, then
mow again at desired height or make a
narrower cutting path.
3. Dull blade.
3. Sharpen or replace blade.
Uneven cut
1. Wheels not positioned correctly.
1. Place all four wheels in same height
position.
2. Dull blade.
2. Sharpen or replace blade.
NOTE: For repairs beyond the minor adjustments above, contact your local authorized service dealer.
14
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Notes
15
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Model Series 540
19
15
1
11
12
21
5
3
16
95
9
6
96
2
18
4
14
52
17
57
4
57
20
13
20
23
61
92
52
30
58
31
39
24
89
56
55
82
88
80
50
40
81
62
59
71
90
94
22
84
87
51
76
73
47
42
86
83
44
43
44
85
63
41
70
49
32
53
36
66
67
64
54
34
33
71
60
93
72
16
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Model Series 540
Ref.
Ref.
No.
Part No.
No.
Part Description
Part No.
17488A
Part Description
Pivot Bar - RH
1.
747-0824
647-0004
710-1205
720-0279
710-1174
712-0324
720-0314
710-1270
749-0438C
720-0295
749-0907A
726-0240
747-0995A
746-0550
746-0737
746-0841
746-0847
664-0084
664-0085
664-0086
731-0066
731-0068
714-0104
746-0883
682-3058
682-3059
782-7599A
750-0434
732-0700
731-1236
753-0588
710-1044
736-0524A
742-0741
736-0356
712-0130
15261A
Control Handle Assembly
Deluxe Control Handle
Rope Guide
50.
17489A
Pivot Bar - LH
2.
3.
51.
52.
53.
54.
55.
56.
782-5002
712-0397
782-5003
710-1017
710-0896
682-3058
682-3059
710-0703
782-0047
734-1860
734-1864
734-1818
734-1781
734-1841
734-1987
747-0996
710-0654A
682-7000
731-1409
782-5007A
782-5004
736-0182
736-0105
731-1426
738-0481A
736-0456
720-0312
732-0866
712-3005
710-0514
732-0731
747-0710
736-0270
710-0216
736-0331
712-0798
732-0809
738-0102
782-7006
710-0896
782-9050
Front Baffle
Handle Knob
Wing Knob
4.
Curved Hd. Bolt 5/16-18 x 2”
Hex L-Nut 1/4-20 Thd.
Hand Knob
Rear Baffle
5.
Torx Mach. AB-Tap Scr.
Hex Washer Screw 1/4-14 x .625
Handle Bracket Assembly—R.H.
Handle Bracket Assembly—L.H.
Carriage Bolt, 1/4-20 x .75”
Deck 21”
6.
9.
Screw 1/4-20 x 1.31
Upper Handle
11.
12.
13.
14.
15.
16.
Foam Grip †
57.
58.
59.
Lower Handle
Cable Tie
Rear Wheel Ass’y 14 x 2
Rear Wheel Ass’y. 14 x 1.8
Front Wheel Ass’y. 8 x 2
Front Wheel Ass’y 8 x 1.75
Front Wheel Ass’y 8 x 1.7
Front Wheel Assembly 8 x 1.8
Chute Door Pivot Rod
Sems Screw TT 3/8-16 x 1
Mulching Plug
Catcher Frame
Control Cable 39”
60.
Control Cable 51”
17.
18.
Throttle Cable 60” †
Throttle Cable 42” †
Grass Bag w/o logo
Grass Bag w/ logo, Yellow
Grass Bag w/ logo, Red
Hard Top w/ logo
61.
62.
63.
64.
66.
67.
70.
71.
72.
73.
76.
80.
81.
82.
83.
84.
85.
87.
88.
89.
90.
92.
93.
94.
95.
96.
19.
Chute Deflector
Hard Top w/o logo
Rear Mulch Plug
20.
21.
22.
Internal Cotter Pin
Rear Mulch Baffle
Throttle Housing w/o Lever
Handle Bracket Assembly - RH
Handle Brkt Ass’y - LH (Not Shown)
Grass Bag Door
Wave Washer
Spring Washer
Hub Cap †
23.
24.
30.
31.
32.
33.
34.
36.
39.
40.
41.
42.
43.
44.
47.
49.
Rear Axle Bolt
Spacer .375 OD x .50 ID x 1.02”
Wire Rod
Flat Washer
Foam Grip
Rear Flap
Height Adj. Lever
Blade Adapter Kit
Hex Flange Lock Nut 3/8-16
Hex Cap Screw 3/8-16 x 1.0
Torsion Spring
Hex Bolt 3/8-24 x 1.5”
Blade Bell Support
Mulching Blade
Hinge Pin
Bell Washer .39” I.D. x 1.38”
Hex Lock Nut 3/8-16
Height Adj. Plate
Bell Washer .265 x .75 x .062
Hex Screw 3/8-16 x .75
Bell Washer .39 x 1.13 x .062
Hex Nut 3/8-16
15262B
Pivot Bar
732-0404
738-0507B
720-0190
14578
Spring Lever: Front Wheel
Shoulder Bolt .5” Dia. x .357”
Spring Lever Knob
Height Adj. Assembly Comp - RH
Height Adj. Assembly Comp - LH
Torsion Spring
Front Axle Bolt
Hinged Mounting Bracket
Hex Screw 1/4-14 x .625
Mounting Bracket
14579
† If Equipped
17
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18
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19
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MANUFACTURER’S LIMITED WARRANTY FOR:
c. Routine maintenance items such as lubricants, filters,
blade sharpening and tune-ups, or adjustments such
as brake adjustments, clutch adjustments or deck
adjustments; and normal deterioration of the exterior
finish due to use or exposure.
The limited warranty set forth below is given by MTD
PRODUCTS INC (“MTD”) with respect to new merchandise
purchased and used in the United States, its possessions
and territories.
d. MTD does not extend any warranty for products sold
or exported outside of the United States of America,
its possessions and territories, except those sold
through MTD’s authorized channels of export distribu-
tion.
MTD warrants this product against defects in material and
workmanship for a period of two (2) years commencing on
the date of original purchase and will, at its option, repair or
replace, free of charge, any part found to be defective in
material or workmanship. This limited warranty shall only
apply if this product has been operated and maintained in
accordance with the Operator’s Manual furnished with the
product, and has not been subject to misuse, abuse, com-
mercial use, neglect, accident, improper maintenance,
alteration, vandalism, theft, fire, water or damage because
of other peril or natural disaster. Damage resulting from the
installation or use of any accessory or attachment not
approved by MTD Products Inc. for use with the product(s)
covered by this manual will void your warranty as to any
resulting damages.
No implied warranty, including any implied warranty of
merchantability or fitness for a particular purpose,
applies after the applicable period of express written
warranty above as to the parts as identified. No other
express warranty or guaranty, whether written or oral,
except as mentioned above, given by any person or
entity, including a dealer or retailer, with respect to any
product shall bind MTD. During the period of the War-
ranty, the exclusive remedy is repair or replacement of
the product as set forth above. (Some states do not
allow limitations on how long an implied warranty lasts, so
the above limitation may not apply to you.)
Normal wear parts or components thereof are subject to
separate terms as follows: All normal wear part or compo-
nent failures will be covered on the product for a period of
90 days regardless of cause. After 90 days, but within the
two year period, normal wear part failures will be covered
ONLY IF caused by defects in material or workmanship of
OTHER component parts. Normal wear parts and compo-
nents include, but are not limited to, belts, blades, blade
adapters, grass bags, rider deck wheels, seats, snow
thrower skid shoes, shave plates and tires. Batteries are
covered by a 90-day limited replacement warranty.
The provisions as set forth in this Warranty provide the
sole and exclusive remedy arising from the sales. MTD
shall not be liable for incidental or consequential loss
or damages including, without limitation, expenses
incurred for substitute or replacement lawn care ser-
vices, for transportation or for related expenses, or for
rental expenses to temporarily replace a warranted
product. (Some states do not allow the exclusion or limita-
tion of incidental or consequential damages, so the above
exclusion or limitation may not apply to you.)
HOW TO OBTAIN SERVICE: Warranty service is available,
WITH PROOF OF PURCHASE THROUGH YOUR LOCAL
AUTHORIZED SERVICE DEALER. To locate the dealer in
your area, please check for a listing in the Yellow Pages or
contact the Customer Service Department of MTD PROD-
UCTS INC by calling 1-800-800-7310 or writing to P.O. Box
368022, Cleveland, Ohio 44136-9722.
In no event shall recovery of any kind be greater than the
amount of the purchase price of the product sold. Alteration
of the safety features of the product shall void this War-
ranty. You assume the risk and liability for loss, damage, or
injury to you and your property and/or to others and their
property arising out of the use or misuse or inability to use
the product.
This limited warranty does not provide coverage in the
following cases:
a. The engine or component parts thereof. These items
carry a separate manufacturer’s warranty. Please refer
to the applicable manufacturer’s warranty on these
items.
This limited warranty shall not extend to anyone other than
the original purchaser, original lessee or the person for
whom it was purchased as a gift.
b. Log splitter pumps, valves and cylinders have a sepa-
rate one year warranty.
How State Law Relates to this Warranty: This limited
warranty gives you specific legal rights, and you may also
have other rights which vary from state to state.
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