OPERATOR'S MANUAL

21" Rear & Side Discharge Mulching Mower Model Series 540

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IMPORTANT:

Warning:

READ SAFETY

RULES AND INSTRUCTIONS

CAREFULLY
This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forestcovered, 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

PRINTED IN U.S.A.
INC. P.O. BOX 368022 CLEVELAND,

OHIO 44136-9722

FORM NO. 770-10019B

(1o/oo)

TABLEOFCONTENTS
Content Important Safe Operation Practices.. Slope Gauge.... Assembling Your Lawn Mower... Know Your Lawn Mower... Operating Your Lawn Mower.... Making Adjustments... Page 16
Maintaining Your Lawn Mower... Troubleshooting....

Parts List...

FINDINGMODEL NUMBER
This Operator's Manual is an important part of your new lawn mower. It will help you assemble, prepare and maintain the unit for best performance. Please read and understand what it says. Before you start assembling your new equipment, please locate the model plate on the equipment and copy the information from it in the space provided below. The information on the model plate is very important if you need help from our Customer Support Department or an authorized dealer. You can locate the model number by standing at the operating position and looking down at the rear of the mower deck. A sample model plate is explained below. For future reference, please copy the model number and the serial number of the equipment in the space below.

(Model Number)

(Sedal Number)
Copy the model number here:
Copy the serial number here:

MTD PRODUCTS INC

.. CLEVELAND OHIO 44136

CALLING CUSTOMER SUPPORT

If you have difficulty assembling this product or have any questions regarding the controls, operation or maintenance of this unit, please call the Customer Support Department. Call 1- (330) 220-4MTD (4683) or 1- (800)-800-7310 to reach a Customer Support representative. Please have your unit's model number and serial number ready when you call. See previous section to locate this information. You will be asked to enter the serial number in order to process your call.
SECTION IMPORTANT 1: SAFEOPERATION RACTICES P

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.

Engine Exhaust,

some of its constituents,
and certain vehicle to cause cancer
components contain or emit chemicals known to State of California 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.

General peration O

1. Read this operator's manual carefully in its entirety before attempting to assemble this machine. Read, understand, and follow all instructions on the machine and in the manual(s) before operation. Be completely familiar with the controls and the proper use of this machine before operating it. Keep this manual in a safe place for future and regular reference and for ordering replacement parts. This machine is a precision piece of power equipment, not a plaything. Therefore, exercise extreme caution at all times. Your unit has been designed to perform one job: to mow grass. Do not use it for any other purpose. Never allow children under 14 years old to operate this machine. Children 14 years old and over should read and understand the operation instructions and safety rules in this manual and should be trained and supervised by a parent. Only responsible individuals who are familiar with these rules of safe operation should be allowed to use this machine. Thoroughly inspect the area where the equipment is to be used. Remove all stones, sticks, wire, bones, toys and other foreign objects which could be tripped over or picked up and thrown by the blade. Thrown objects can cause serious personal injury. Plan your mowing pattern to avoid discharge of material toward roads, sidewalks, bystanders and the like. Also, avoid discharging material against a wall or obstruction which may cause discharged material to ricochet back toward the operator. To help avoid blade contact or a thrown object injury, stay in the operator zone behind the handles and keep children, bystanders, helpers and pets at least 75 feet from the mower while it is in operation. Stop machine if anyone enters the area. Always wear safety glasses or safety goggles during operation and while performing an adjustment or repair to protect your eyes. Thrown objects which ricochet can cause serious injury to the eyes. Wear sturdy, rough-soled work shoes and close-fitting slacks and shirts. Shirts and pants that cover the arms and legs and steel-toed shoes are recommended. Never operate this machine in bare feet, sandals, slippery or light weight (e.g. canvas) shoes.

9. 10.

12. 13. 14.

16. 17. 18.

Do not put hands or feet near rotating parts or under the cutting deck. Contact with the blade can amputate hands and feet. A missing or damaged discharge cover can cause blade contact or thrown object injuries. Many injuries occur as a result of the mower beiog pulled over the foot during a fall caused by slipping or tripping. Do not hold on to the mower if you are falling; release the handle immediately. Never pull the mower back toward you while you are walking. If you must back the mower away from a wall or obstruction first look down and behind to avoid tripping and then follow these steps: a. Step back from the mower to fully extend your arms. b. Be sure you are well balanced with sure footing. c. Pull the mower back slowly, no more than half way toward you. d. Repeat these steps as needed. Do not operate the mower while under the influence of alcohol or drugs. Do not engage the self-propelled mechanism on units so equipped while starting engine. The blade control handle is a safety device. Never attempt to bypass its operation. Doing so makes the safety device inoperative and may result in personal injury through contact with the rotating blade. The blade control handle must operate easily in both directions and automatically return to the disengaged position when released. Never operate the mower in wet grass. Always be sure of your footing. A slip and fall can cause serious personal injury. If you feel you are losing your footing, release the blade control handle immediately and the blade will stop rotating within three seconds. Mow only in daylight or in good artificial light. Walk, never run. Stop the blade when crossing gravel drives, walks or roads. If the equipment should start to vibrate abnormally, stop the engine and check immediately for the cause. Vibration is generally a warning of trouble. Shut the engine off and wait until the blade comes to a complete stop before removing the grass catcher or
unclogging thechute. cutting continues The blade to rotateorafew f seconds the after engine isshut ff. o Never anypart fthebody place o intheblade until area youaresure theblade hasstopped rotating. 20. Never operate ower m without proper trailshield, discharge grass atcher, control cover, c blade handler o other afety rotective s p devices inplace nd a working. Never operate ower damaged devices. m with safety Failure todoso,can resultnpersonal i injury. 21. Muffler engine ecome and and b hot cancauseburn. o a D not ouch. t

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. Keep children away from hot or running engines. They can suffer burns from a hot muffler. 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 HandlingOf 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. Wash your skin and change clothes immediately. Useonly an approved gasoline container. 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. 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. 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. Extinguish all cigarettes, cigars, pipes and other sources of ignition. Never fuel machine indoors because flammable vapors will accumulate in the area. Never remove gas cap or add fuel while the engine is hot or running. Allow engine to cool at least two minutes before refueling. Neverover flllfueltank. Fill tank to no more than inch below bottom of filler neck to provide space for fuel expansion. Replace gasoline cap and tighten securely. If gasoline is spilled, wipe it off the engine and equipment. Move unit to another area. Wait 5 minutes before starting the engine. 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. 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. Allow a mower to cool at least 5 minutes before storing.

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. Watch for holes, ruts, rocks, hidden objects, or bumps which can cause you to slip or trip. Tall grass can hide obstacles. 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.

2. 3. 4.

7. 8. 9.

Do Not:

1. 2. 3. Do not mow near drep-offs, ditches or embankments, you could lose your footing or balance. Do not mow slopes greater than 15 degrees as shown on the slope gauge. Do not mow on wet grass. Unstable footing could cause slipping. 11. 12.

Children

Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the mower and the mowing activity. They do not understand the dangers. Never assume that children will remain where you last saw them. 1. Keep children out of the mowing area and under the watchful care of a responsible adult other than the operator. Be alert and turn mower off if a child enters the area. Before and while moving backwards, look behind and down for small children. Use extreme care when approaching blind corners, doorways, shrubs, trees, or other objects that may 14.

GeneralService:

1. Never run an engine indoors or in a poorly ventilated area. Engine exhaust contains carbon monoxide, an odorless and deadly gas. 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. Check the blade and engine mounting bolts at frequent

Figure 7 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 GrassCatcherToMower
NOTE: in place mower and a located located remove you are The mulching baffle, if so equipped, is already on the mower for shipping purposes. Your lawn may be equipped with both a mulching baffle mulching plug. While the mulching baffle is at the rear of the mower, the mulching plug is on the right side of the cutting deck. Do not the mulching plug from the mower even when not mulching the grass.
Converting ToSideDischarge
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 discharge door on the mower. Remove the mulching baffle. See Figure 6. Mulching__ Baffle _ _---._////,// __o

Mulching Plug

Hinge Pi_
Figure 6 IMPORTANT: Make sure cables are routed to the outside of the handle so they are net 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
SECTION KNOW 4: YOUR LAWNMOWER
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. WARNING: The operation of any lawn mower can result in foreign objects being thrown into the eyes, which can damage your eyes severely. Always wear safety glasses while operating the mower, or while performing any adjustments or repairs on it. Recoil Starter 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. BladeControlHandle 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. is a safety This Never attempt to bypass WARNING: device.blade control mechanism its operations. CuttingHeightAdjustmentLevers 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.

Mulching Catcher Starter

GrassCatcher 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.

.Blade Control Handle

Cutting Height ustment Lever
Figure 9 MulchingPlug 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 OPERATINGOUR 5: Y LAWNMOWER
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.

StartingEngine

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.
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.

GasandOilFill-Up

Service the engine with gasoline and oil as instructed in the separate engine manual packed with your mower. Read instructions carefully.
Standbehind themower ndsqueeze a theblade control handle against theupper handle. Grasp recoil tarter andle s h andpullropeoutslowly untilengine reaches thestartofcompression cycle (ropewillpullslightly harder tthispoint). etthe a L roperewind slowly. ullropewitha rapid, P continuous, fullarmstroke. eeping firmgripon K a thestarter andle,ettheropereturn h l tothestarter 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 YourLawnMower

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. 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

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.
SECTION MAKING 6: ADJUSTMENTS
adjustments Do not atfirst stopping engine without any time make any WARNING: 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.

HandleHeightAdjustment

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. Remove the hairpin clips from the weld pins on the handle brackets and remove the wing nuts and carriage bolts from the upper hole on the handle mounting bracket. Press out on the legs of the lower handle and remove lower handle from the mower. Turn lower handle around so the notch on the bottom of the lower handle is facing forward. See Figure 10. Reassemble, placing the bottom holes in the handle over the weld pins in the handle mounting bracket. Place the hairpin clips in the inner holes in the weld pins and insert the carriage bolts the upper hole on

_lotch Lower Handle

Figure 10

Cutting HeightAdjustment

An adjusting plate and spring tever at each wheel position provides cutting height adjustment. Each adjusting plate has asserted 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.

Height Adjustment

IMPORTANT: Alt 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.

Engine Adjustments

See the separate engine manual packed with your unit for adjustments to the engine.

Figure 11

SECTION MAINTAINING 7: YOUR LAWNMOWER

General ecommendations R

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. Some adjustments will have to be made 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.
Customer esponsibilities R
MAINTENANCE SCHEDULE Lubricate Wheels F0 _) Lubricate Blade Control Clean Deck _ :_ '_ em_ _ q,_ _<k _._,_ _._<_ me _' _ee "-_ no SERVICE DATES

Blade Care

Check Oil Change Oil _Z Z_

_ '_ _ _

Replace Air Filter Clean Engine Check Spark Plug
Check Spark Arrester (if any)

Lubrication

i_ plug wire before cleaning, lubricatingspark or Always stop engine and disconnect doing any kind of service work on the lawn mower. Rear Discharge 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. 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. 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. Engine: Follow engine manual for instruction and schedule of lubrication.

Handle Bracket

Figure 13 Engine Refer to the separate engine manual for all engine maintenance instructions. 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. 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). 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 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.

Jbricate

Lubricate

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.

Replacing earFlap R

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
Remove the blade and the adapter from the crankshaft.
Blade Adapter'_q Blade Bell
Slide the blade adapter onto the engine crankshaft. Place the blade on the adapter. Be certain the blade is aligned and seated on the blade adapter flanges. Place blade bell support on blade. Make sure the notches on the blade bell support are aligned with small holes in the blade. Replace hex bolt and tighten hex bolt to torque: 450 in. lbs. min., 600 in. lbs. max. NOTE: To ensure safe operation of your mower, the blade bolt must be checked periodically for correct torque.

_x Bolt

Figure 14 adapter for cracks, especially if you strike WARNING: Periodically inspect the blade a foreign object. Replace when necessary.

Storing yourLawnMower

The following steps should be taken to prepare your lawn mower for storage. Clean and lubricate mower thoroughly as described in the lubrication instructions. IMPORTANT:We do not recommend the use of a pressure washer or garden hose to clean your unit. Refer to engine manual for correct engine storage instructions. Coat 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. NOTE: When storing any type of power equipment in a poorly ventilated or metal storage shed, care should be taken to rust-preof the equipment. Using a light oil or silicone, coat the equipment, especially cables and all moving parts.
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. 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. 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.
SECTION TROUBLESHOOTING 8:
Problem Engine fails to start 1. 2. 3. 4. 5. 6. Engine runs erratic 1. 2. 3. 4. 5. 6. Engine overheats 1. 2. 3. Occasional skip (hesitates at high speed Idles poorly 1. 1. 2. 3. Excessive vibration 1. 2. Mowerwillnotmulchgras,, 1. 2. Cause Blade control handle disengaged. Spark plug wire disconnected. Fuel tank empty or stale fuel. Blocked fuel line. Faulty spark plug. Engine flooded Spark plug wire loose. Blocked fuel line or stale fuel. Vent in gas plugged. Water or dirt in fuel system. Dirty air cleaner. Carburetor out of adjustment. Engine oil level low. Air flow restricted. Carburetor not adjusted properly. Spark plug gap too close. Spark plug fouled, faulty or gap too wide. Carburetor improperly adjusted. Dirty air cleaner. Cutting blade loose or unbalanced. Bent cutting blade. Wetgrass. Excessively high grass. 1. 2. 3. 4. 5. 6. 1. 2. 3. 4. 5. 6. 1. 2. 3. 1. 1. 2. 3. 1. 2. 1. 2. Remedy Engage blade control handle. Connect wire to spark plug. Fill tank with clean, fresh gasoline. Clean fuel line. Clean, adjust gap, or replace. Wait a few minutes to restart, but do not prime. Connect and tighten spark plug wire. Clean fuel line; fill tank with clean, fresh gasoline Clear vent. Drain fuel tank. Refill with fresh fuel. Clean air cleaner. Adjust carburetor. Fill crankcase with proper oil. Remove blower housing and clean. Adjust carburetor. Adjust gap to.030". Reset gap to.030" or replace spark plug. Adjust carburetor. Clean air cleaner. Tighten blade and adapter. Balance blade. Replace blade. Do not mow when grass is wet; wait until later to cut. Mow once at a high cutting height, then mow again at desired height or make a narrower cutting path. Sharpen or replace blade. Place all four wheels in same height position. Sharpen or replace blade.

3. Uneven cut 1. 2.

Dull blade. Wheels not positioned correctly. Dull blade.

3. 1. 2.

NOTE: For repairs beyond the minor adjustments above, contact your local authorized service dealer.

ModelSeries540

Ref. No. 1. 2. 3. 4. 5. 6. 9. 11. 12. 13. 14. 15. 16. 17. 18. Part No. 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 19. 20. 21. 22. 23. 24. 30. 31. 32. 33. 34. 36. 39. 40. 41. 42. 43. 44. 47. 49. 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 15262B 732-0404 738-0507B 720-14579 tlf Equipped

Part Description

Control Handle Assembly Deluxe Control Handle Rope Guide Handle Knob Curved Hd. Bolt 5/16-18 x 2" Hex L-Nut 1/4-20 Thd. Hand Knob Screw 1/4-20 x 1.31 Upper Handle Foam Grip t Lower Handle Cable Tie Catcher Frame Control Cable 39" Control Cable 51" Throttle Cable 60" t Throttle Cable 42" t Grass Bag w/o logo Grass Bag w/logo, Yellow Grass Bag w/logo, Red Hard Top w/logo Hard Top w/o logo Internal Cotter Pin Throttle Housing w/o Lever Handle Bracket Assembly - RH Handle Brkt Ass'y - LH (Not Shown) Grass Bag Door Spacer.375 OD x.50 ID x 1.02" Wire Rod Rear Flap Blade Adapter Kit Hex Bolt 3/8-24 x 1.5" Blade Bell Support Mulching Blade Bell Washer.39" I.D. x 1.38" Hex Lock Nut 3/8-16 Height Adj. Plate Pivot Bar Spring Lever: Front Wheel Shoulder Bolt.5" Dia. x.357" Spring Lever Knob Height Adj. Assembly Comp - RH Height Adj. Assembly Comp - LH

Ref. No.

50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60.

Part No.

17488A 17489A 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
Pivot Bar- RH Pivot Bar - LH Front Baffle Wing Knob Rear Baffle 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" 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 Chute Door Pivot Rod Mulching Plug Chute Deflector Rear Mulch Plug Rear Mulch Baffle Wave Washer Spring Washer Hub Cap t Rear Axle Bolt Flat Washer Foam Grip Height Adj. Lever Hex Flange Lock Nut 3/8-16 Hex Cap Screw 3/8-16 x 1,0 Torsion Spring Hinge Pin 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 Torsion Spring Front Axle Bolt Hinged Mounting Bracket Hex Screw 1/4-14 x ,625 Mounting Bracket 8 x 1.8

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.
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
Seres Screw TT 3/8-16 x 1

MANUFACTURER'S

LIMITED WARRANTY
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. 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, 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 MTD Products Inc. for use with the product(s) covered by this manual will void your warranty as to any resulting damages. Normal wear parts or components thereof are subject to 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. 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 distribution. 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 Warranty, 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.) 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 or damages including, without limitation, incurred for substitute or replacement loss expenses

separate terms as follows: All normal wear part 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 material or workmanship of OTHER component parts. Normal wear parts and components 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. 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 PRODUCTS INC by calling 1-800-800-7310 or writing to RO. Box 368022, Cleveland. Ohio 44136-9722. 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. b. Log splitter pumps, valves and cylinders have a separate one year warranty.

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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 limitation of incidental or consequential damages, so the above exclusion or limitation 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 the safety features of the product shall void this Warrarity. 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 shall not extend to anyone other than the original purchaser, original lessee or the person for whom it was purchased as a gift. 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.