Craftsman 37948 Owner's Manual
Owner's Manual CRAFTSMAN 55 HORSEPOWER 22 REAR DISCHARGE POWER PROPELLED ROTARY LAWN MOWER Model No. 917.379480 ⢠Safety ⢠Assembly ⢠Operation ⢠Maintenance ⢠Espa_ol ⢠Repair Parts CAUTION: Read and follow all Safety Rules and Instructions before operating this equipment Sears, Roebuck and Co., Hoffman Estates, IL 60179 Visit our Craftsman website:www.sea rs.com/craftsman
Warranty .............................................. 2 Safety Rules ........................................ 2 Assembly ............................................. 4 Operation ............................................. 6 Maintenance Schedule ....................... 10 Maintenance ........................................ 10 Product Specifications ......................... 11 Service and Adjustments ..................... 14 Storage ................................................ 16 Troubleshooting .................................. 17 Repair Parts ......................................... 37 Parts Back Cover LIMITED TWO YEAR WARRANTY ON CRAFTSMAN POWER MOWER For two years from date of purchase, when this Craftsman Lawn Mower is maintained, lubricated, and tuned up according to the operating and maintenance instructions in the owner's manual, Sears will repair free of charge any defect in material or workman- ship. If.this Craftsman Lawn Mower is used for commercial or rental purposes, this warranty applies for only 90 days from the date of purchase. This Warranty does not cover: ⢠Expendable items which become worn during normal use, such as rotary mower blades, blade adapters, belts, air cleaners and spark plug. ⢠Repairs necessary because of operator abuse or negligence, including bent crankshafts and the failure to maintain the equipment according to the instructions contained in the owner's manual. Warranty service is available by returning the Craftsman power mower to the nearest Sears Service Center/Department in the United States. This warranty applies only while this product is in use in the United States. This Warranty gives you specific legal rights, and you may also have other rights which vary from state to state. SEARS, ROEBUCKAND CO., D/817 WA, HOFFMAN ESTATES, ILLINOIS 60179 Safety standard's require operator presence controls to mimimize the risk of injury. Your unit is equipped with such controls. Do not attempt to defeat the function of the operator presence controls under any circumstances. TRAINING: ⢠Read this operator's manual carefully. Become familiar with the controls and know how to operate your mower -properly. Learn how to quickly stop mower. ⢠Do not allow children to use your mower. Never allow adults to use mower without proper instructions. ⢠Keep the area of operation clear of all persons, especially small children and pets. ⢠Use mower only as the manufacturer intended and as described in this manual. ⢠Do not operate mower if it has been dropped or damaged in any manner. Always have damage repaired before using your mower. ⢠Do not use accessory attachments that are not recommended by the manufac- turer. Use of such attachments may be hazardous. ⢠The blade turns when the engine is running. PREPARATION: ⢠Always thoroughly check the area to be mowed and clear it of all stones, sticks, wires, bones, and other foreign objects. These objects will be thrown by the blade and can cause severe injury. ⢠Always wear safety glasses or eye shields when starting and while using your mower. 2
⢠Dress properly. Do not operate mower when barefoot or wearing open sandals. Wear only solid shoes with good traction when mowing. ⢠Check fuel tank before starting engine. Do not fill gas tank indoors, when the engine is running or when the engine is hot. Allow the engine to cool for several minutes before filling the gas tank. Clean off any spilled gasoline before starting the engine. ⢠Always make wheel height adjustments before starting your mower. Never attempt to do this while the engine is running. ⢠Mow only in daylight or good artificial light. OPERATION: ⢠Keep your eyes and mind on your mower and the area being cut. Do not let other interests distract you. ⢠Do not mow wet or slippery grass. Never run while operating your mower. Always be sure of your footing - keep a firm hold on the handles and walk. ⢠Do not put hands or feet near or under rotating parts. Keep clear of the dis- charge opening at all times. ⢠Always stop the engine whenever you leave or are not using your mower, or before crossing driveways, walks, roads, and any gravel-covered areas. ⢠Never direct discharge of material toward bystanders nor allow anyone near the mower while you are operating it. ⢠Before cleaning, inspecting, or repairing your mower, stop the engine and make absolutely sure the blade and all moving parts have stopped. Then disconnect the spark plug wire and keep it away from the spark plug to prevent accidental starting. ⢠Do not continue to run your mower if you hit a foreign object. Follow the proce- dure outlined above, then repair any damage before restarting and operating your mower. ⢠Do not change the governor settings or overspeed the engine. Engine damage or personal injury may result. ⢠Do not operate your mower if it vibrates abnormally. Excessive vibration is an indication of damage; stop the engine, safely check for the cause of vibration and repair as required. ⢠Do not run the engine indoors. Exhaust fumes are dangerous. ⢠Never cut grass by pulling the mower towards you. Mow across the face of slopes, never up and down or you might lose your footing. Do not mow exces- sively steep slopes. Use caution when operating the mower on uneven terrain or when changing directions - maintain good footing. ⢠Never operate your mower without proper guards, plates, grass catcher or other safety devices in place. MAINTENANCE AND STORAGE: ⢠Check the blade and the engine mounting bolts often to be sure they are tightened properly. ⢠Check all bolts, nuts and screws at frequent intervals for proper tightness to be sure mower is in safe working condition ⢠Keep all safety devices in place and working. ⢠To reduce fire hazard, keep the engine free of grass, leaves or excessive grease and oil. ⢠Check grass catcher often for deteriora- tion and wear and replace worn bags Use only replacement bags that are recommended by and comply with specifications of the manufacturer of your mower. ⢠Always keep a sharp blade on your mower. ⢠Allow engine to cool before storing in any enclosure ⢠Never store mower with fuel in the tank inside a building where fumes may reach an open flame or an ignition source such as a hot water heater, space heater, clothes dryer, etc. A, Look for this symbol to point out important safety precautions It,means CAUTION!!! BECOMEALERT!t! YOUR SAFETY IS INVOLVED. _CAUTION: Always disconnect spark plug wire and place wire where it cannot contact spark plug in order to prevent accidental starting when setting up, transporting, adjusting or making repairs. _:_WARNING: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. 3
These accessories were available when this lawn mower was produced, are not shipped with your mower. They are also available at most Sears retail outlets and service centers. Most Sears stores can also order repair parts for you, when you provide the model number of your lawn mower. Some of these accessories may not apply to your lawn mower. LAWN MOWER PERFORMANCE CLIPPING DEFLECTOR FOR REAR DISCHARGE LAWN MOWERS GRASS CATCHERS FOR REAR DISCHARGE LAWN MOWERS ,f(.vi.l_=*,. - MULCHERK_S GRASS CATCHERS FOR SIDE DISCHARGE LAWN MOWERS LAWN MOWER MAINTENANCE STABILIZER GAS CANS MUFFLERS BELTS BLADES AIR FILTERS BLADE ADAFrERS WHEELS SPARK PLUGS ENGINE OIL Read these instructions and this manual in its entirety before you attempt to assemble or operate your new lawn mower. IMPORTANT: This lawn mower is shipped without oil or gasoline in the engine. Your new lawn mower has been as- sembled at the factory with the exception of those parts left unassembled for shipping purposes. To ensure safe and proper olberation of your lawn mower, all parts and hardware you assemble must be tightened securely. Use the correct tools as neces- sary to ensure proper tightness. All parts such as nuts, washers, bolts, etc., neces- sary to complete the assembly have been placed in the parts bag. TO REMOVE LAWN MOWER FROM CARTON ⢠Remove loose parts included with mower. ⢠Cut down two end comers of carton and lay end pana down fiat ⢠Remove all pacldng materials except padding between upper and lower handle and padding holding operator presence control bar to upper handle. ⢠Roll lawn mower out of carton and check carton thoroughly for additional loose parts. 4
HOWTO SET UPYOUR LAWN MOWER TO UNFOLD HANDLE IMPORTANT: Unfold handles carefully so as not to pinch or damage control cables ⢠Raise handles until lower handle section locks into place in mowing position. ⢠Remove protective padding, raise upper handle section into place on lower handle and tighten both handle knobs. ⢠Remove handle padding holding operator presence control bar to upper handle. ⢠Your lawn mower handle can be adjusted for your mowing comfort. Refer to "Adjust Handle" in the Service and Adjustment section of this manual. Operator presence control bar Upper handle _ _ ⢠,fup/ Lower handle Mowing position TO INSTALL ATTACHMENTS Your lawn mower was shipped ready to be used as a mulcher. To convert to bagging or discharging: ⢠Open rear door and remove muleher plug. Store mulcher plug in a safe place. ⢠You can now install catcher or optional clipping deflector. ⢠To retum to mulching operation, install mulcher plug into discharge opening of mower. Mulcher plug ,__ ACAUTION: Do not run your lawn mower without mulcher plug in place or approved clipping deflector or grass catcher in place. Never attempt to operate the lawn mower with the rear door removed or propped open. 5
_NOWYOUR LAWN MOWER READ THIS OWNER'S MANUALAND SAFETY RULES BEFORE OPERATING YOUR LAWN MOWER. Compare the illustrations with your lawn mower to familiarize yourself with the location of various controls and adjustments. Save this manual for future I ° These symbols may appear on your lawn mower or in literature supplied with the product. Learn and understand their meaning. CAUTION ENGfNE ENGINE FAST SLOW CHOKE FUEL OIL DANGER, KEEPHANDS OR WARNING ON OFF AND FEET AWAY Engine zone control cable Throttle control )resence control bar _Drive control lever Grass catcher_, Handle knob ⢠Mulcher plug Engine oil ca_: Housing IMPORTANT: This lawn mower is shipped without oil or gasoline in the engine. Drive cover , Wheel adjuster (on every wheel) MEETS CPSC SAFETY REQUIREMENTS Sears rotary walk-behind power lawn mowers conform to the safety standards of the American National Standards Institute and the U.S, Consumer Product Safety Commis- sion. The blade turns when the en_]ine is running, Operator presence control bar - must be held down to the handle to start the engine. Release to stop the engine. Starter handle- used for starting the engine. Drive control lever - used to engage power-propelled forward motion of lawn mower. Mulcher plug - must be removed to convert to bagging or discharging operation. Throttle control - Used for starting the engine and allows you to select either fast or slow engine speed. 6
The operation of any lawn mower can result in foreign objects thrown into the eyes, which can result in severe eye damage. Always wear safety glasses or eye shields while operating your lawn mower or performing any adjustments or repairs. We recommend a wide vision safety mask over spectacles or standard safety glasses. ENGINE SPEED The engine speed is controlled by a throttle control located on the side of the upper handle. Choke position is for starting a cold engine and fast position is for normal cutting, trimming, and better grass bagging. Slow position is for light cutting, trimming and fuel economy. FAST _ _ SLOW CHOKE '" "'" ' "" ⢠.-,; ,,,; . #11 L II ENGINE ZONE CONTROL _CAUTION: Federal regulations require an engine control to be installed on this lawn mower in order to minimize the risk of blade contact injury. Do not under any circumstances attempt to defeat the function of the operator control. The blade turns when the engine is running. ⢠Your _awn mower is equipped with an operator presence control bar which requires the operator to be positioned behind the lawn mower handle to start and operate the lawn mower. TO ADJUST CUTTING HEIGHT ⢠Raise wheels for low cut and lower wheels for high cut. ⢠Adjust cutting height to suit your requirements. Medium position is best for most lawns. ⢠To change cutting height, squeeze adjuster lever toward wheel. Move wheel up or down to suit your require- ments. Be sure all wheels are in the same setting. NOTE: Adjuster is properly positioned when plate tab inserts into hole in lever. Also, 9-position adjusters (if so equipped) allow lever to be positioned between the plate tabs. Lower Wheels for High Cut Plate Tab Lever Raise Wheels for Low Cut TO ATTACH GRASS CATCHER ⢠Lift the rear door of the lawn mower and place the grass catcher frame hooks onto the door pivot pins. ⢠The grass catcher is secured to the lawn mower housing when the rear door is lowered onto the grass catcher frame. _I, CAUTION: Do not run your lawn mower without clipping deflector or approved grass catcher in place. Never attempt to operate the lawn mower with the rear door removed or propped open. Pivot _ins Rear door Grass catcher handle / Catcher frame hook TO EMPTY GRASS CATCHER ⢠Lift up on grass catcher using the frame handle. ⢠Remove grass catcher with clippings from under lawn mower handle, ⢠Empty clippings from bag using both frame handle and bag handle. NOTE: Do not drag the bag when emptying; it will cause unnecessary wear ga¢ handle _rass catcher *frame handle 7
DRIVE CONTROL ⢠Self-propelling is controlled by holding the operator presence control bar down to the handle and pushing the drive control lever forward until it clicks; then release the drive control lever. ⢠Forward motion will stop when the operator presence control bar is released. To stop forward motion without stopping engine, release the operator presence control bar slightly until the drive control disengages. Hold operator presence control bar down to handle to continue mowing without self- propelling. ⢠To keep drive control engaged when turning comers, push down on handle and lift front wheels off ground while turning lawn mower. Operator presence control bar Drive Drive control control To engage Drive control drive control disengaged BEFORE STARTING ENGINE OIL Your lawn mower is shipped without oil in the engine. ⢠Be sure mower is level and area around oil fill is clean. ⢠Remove engine oil cap and fill to the full line on the dipstick. NOTE: Allow oil to settle down into engine for accurate dipstick reading. ⢠Engine holds 18.5 ozs. of oil. For type and grade of oil to use, see "ENGINE" in Maintenance section of this manual. ⢠Pour oil slowly. Do not over fill. ⢠Check oil level before each use. Add oil if needed. Fill to full line on dipstick. ⢠To read proper level, tighten engine oil cap each time. ⢠Reinstall engine oil cap and tighten. ⢠Change the oil after every 25 hours of operation or each season. You may need to change the oil more often under dusty, dirty conditions. ADD GASOLINE ⢠Fill fuel tank. Use fresh, clean, regular unleaded gasoline with a minimum of 87 octane(Use of leaded gasoline will increase carbon and lead oxide deposits and reduce valve life). Do not mix oil with gasoline. Purchase fuel in quantities that can be used within 30 days to assure fuel freshness. AWARNING: Experience indicates that alcohol blended fuels (called gasohol or using ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. To avoid engine problems, the fuel system should be emptied before storage of 30 days or longer, Drain the gas tank, start the engine and let it run until the fuel lines and carburetor are empty. Use fresh fuel next season. See Storage Instructions for additional information. Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur. _IbCAUTION: Fill to bottom of gas tank filler neck, Do not overfill, Wipe off any spilled oil or fuel. Do not store, spill or use gasoline near an open flame. filler cap Oil filler cap J J __ __-Oil filler cap/dipstick Lower limit ----_ -Upper limit TO START ENGINE â¢Tum fuel valve to ON position. ⢠To start a cold engine, move handle mounted throttle/choke control lever to choke position. ⢠Hold operator presence control bar down to the handle and pull starter handle quickly. Do not allow starter rope to snap back. ⢠Slowly move throttle control lever to fast position after engine starts. ⢠To start a warm engine, move throttle control lever to fast or slow position 8 then follow steps above.
⢠To stop engine, release operator presence control bar. Wait until blade and all moving parts have stopped and turn fuel valve to OFF position if you do not intend to restart the engine soon. On Fuel Valve lever MOWING TIPS ⢠Under certain conditions, such as very tall grass, it may be necessary to raise the height of cut to reduce pushing effort and to keep from overloading the engine and leaving clumps of grass clippings. It may also be necessary to reduce ground speed and/or run the lawn mower over the area a second time. ⢠For extremely heavy cutting, reduce the width of cut by overlapping previously cut path and mow slowly. ⢠For better grass bagging and most cutting conditions, the engine speed should be set in the fast position. ⢠When using a rear discharge lawn mower in moist, heavy grass, clumps of cut grass may not enter the grass catcher. Reduce ground speed (pushing speed) and/or run the lawn mower over the area a second time. ⢠If a trail of clippings is left on the right side of a rear discharge mower, mow in a clockwise direction with a small ovedap to collect the clippings on the next pass. ⢠Pores in cloth grass catchers can become filled with dirt and dust with use and catchers will collect less grass. To prevent this, regularly hose catcher off with water and let dry before using. ⢠Keep top of engine around starter clear and clean of grass clippings and chaff. This will help engine air flow and extend engine life. MULCHING MOWING TIPS IMPORTANT: For best performance, keep mower housing free of built-up grass and trash. See =Cleaning" in MAINTENANCE section of this manual. ⢠The special mulching blade will recut the grass clippings many times and reduce them in size so that as they fall onto the lawn they will disperse into the grass and not be noticed. Also, the mulched grass will biedegrade quickly to provide nutrients for the lawn. Always mulch with your highest engine (blade) speed as this will provide the best recutting action of the blades. ⢠Avoid cutting your lawn when it is wet. Wet grass tends to form dumps and interferes with the mulching action. The best time to mow your lawn is the eady aftemcon. At this time the grass has dried and the newly cut area will not be exposed to the direct sun. ⢠For best results, adjust the lawn mower cutting height so that the lawn mower cuts off only the top one-third of the grass blades. If the lawn is overgrown it will be necessary to raise the height of cut to reduce pushing effort and to keep from overloading the engine and leaving clumps of mulched grass. For extremely heavy mulching, reduce your width of cut by overlapping previously cut path and mow slowly. ⢠Certain types of grass and grass condi- tions may require that an area be mulched a second time to completely hide the clippings. When doing a second cut, mew across or perpendicular to the first cut path. ⢠Change your cutting pattem from week to week. Mow north to south one week then change to east to west the next week. This will help prevent matting and graining of the lawn. 9
MAINTENANCE SCHEDULE FILL IN DATES AS YOU COMPLETE REGULAR SERVICE SERVICE DATES Check for Loose Fasteners !/ Clean/Inspect Grass Catcher (If Equipped) ¥/ _ oM Clean Lawn Mower Clean Under Drive Cover (Power-Propelled Mowers) W Check drive belt/pulleys (Power-Propelled Mowers} ¥/ R Check/Sharpen/Replace Blade . .Ip#.3 Lubrication Chart I_ If # Clean Battery/Recharge IElectric Start Mowers I I/ 1/14 NE Check Engine Oil Level !/ Change Engine Oil I/1.2 Clean Air Filter _2 Inspect Muffler .... N; Clean or Replace Spark Plug Replace Air Filter Paper Cartridge I/2 ,ll I - Change mote often when operating under a heavy load or in high ambient temperatures. 2 - Service more often when operating in dirty Or dusty conditions. 3 - Replace blades more often when mowing In sandy SOIL 4 - Charge 48 hours at end or season. LUBRICATION CHART GENERAL RECOMMENDATIONS 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 mower as instructed in this manual. Some adjustments will need to be made periodically to properly maintain your unit. All adjustments in the Service and Adjustments section of this manual should be checked at least once each season. ⢠Once a year, replace the spark plug, "replace air filter element and check blade for wear. A new spark plug and clean/new air filter element assures proper air-fuel mixture and helps your engine run better and last longer. ⢠Follow the maintenance schedule in this manual. BEFORE EACH USE ⢠Check engine oil level. ⢠Check for loose fasteners. LUBRICATION Keep unit well lubricated (See "LUBRICA- TION CHART"). Wheel Adjuster (_ Rear door (_) Handle bracket hinge mounting pin (_ Spay lubricant (_) Refer to MAINTENANCE "ENGINE" section. ine oil 10 IMPORTANT: Do not oil or grease plastic wheel bearings. Viscous lubricants will attract dust and dirt that will shorten the life of the self lubricating bearings. If you feel they must be lubricated, use only a dry, powdered graphite type lubricant sparingly.
PRODUCT SPECIFICATIONS SERIAL NUMBER DATE OF PURCHASE GASOLINE CAPACITY/TYPE: 1.0 QUARTS JNLEADED REGULAR OIL TYPE (API-SF/SG/SH): OIL CAPACITY: SPARK PLUG(GAP: .030") VALVE CLEARANCE: SAE 30 (ABOVE 32°F) SAE 5W-30 (BELOW 32°F) 18.50ZS. CHAMPIONR J19LM OR J19LM I NTAKE: .005" - .007" EXHAUST: .007" - .009" SOLID STATE IGNITION AIR GAP: .010 IN. BLADE BOLT TORQUE: 35-40 FT. LBS. ⢠The model and serial numbers will be found on a decal attached to the rear of the lawn mower housing.Record both serial number and date of purchase in space provided above. LAWN MOWER Always observe safety rules when performing any maintenance. TIRES ⢠Keep tires free of gasoline, oil, or insect control chemicals which can harm rubber. ⢠Avoid stumps, stones, deep ruts, sharp objects and other hazards that may cause tire damage. BLADE CARE For best results, mower blade must be kept sharp. Replace bent or damaged blades. TO REMOVE BLADE ⢠Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with spark plug. ⢠Turn lawn mower on its side. Make sure air filter and carburetor are up. ⢠Use a wood block between blade and mower housing to prevent blade from turning when removing blade bolt. ⢠Protect your hands with gloves and/or wrap blade with heavy cloth. ⢠Remove blade bolt by turning counter- clockwise. Use a 9/16" box or open- end wrench. ⢠Remove blade and attaching hard- ware. TO REPLACE BLADE ⢠Position the blade adapter on the engine crankshaft. Be sure the spacer is in the adaptor and key in shaft and adaptor keyway are aligned. ⢠Position blade on the blade adapter. Be sure the trailing edge of blade (opposite sharp edge) is up toward the engine. ⢠Install the blade bolt with washers into blade adapter and crankshaft. ⢠Use block of wood between blade and lawn mower housing and tighten the blade bolt, turning clockwise. ⢠The recommended tightening torque is 35-40 ft. Ibs. IMPORTANT: BLADE BOLT IS GRADE 8 HEATTREATED. TO SHARPEN BLADE NOTE: We do not recommend sharpen- ing blade - but if you do, be sure the blade is balanced. Care should be taken to keep the blade balanced. An unbalanced blade will cause eventual damage to lawn mower or engine. ⢠The blade can be sharpened with a file or on a grinding wheel. Do not attempt to sharpen while on the mower. 11
⢠To check blade balance, drive a nail into a beam or wall. Leave about one inch of the straight nail exposed. Place center hole of blade over the head of the nail. If blade is balanced, it should remain in a horizontal position. If either end of the blade moves downward, sharpen the heavy end until the blade is balanced. Lockwasher Spacer Blade Sic Blade washer bolt Trailing/edge adapter GRASS CATCHER ⢠The grass catcher may be hosed with water, but must be dry when used. ⢠"Check your grass catcher often for damage or deterioration. Through normal use it will wear. If catcher needs replacing, replace only with a manufacturer approved replacement catcher. Give the lawn mower model number when ordering. DRIVE WHEELS Check front drive wheels each time before you mow to be sure they move freely. The wheels not turning freely means trash, grass cuttings, etc. are in the drive wheel area and must be cleaned to free drive wheels. If necessary to clean the drive wheels, check both front wheels. ,, Remove hubcaps, hairpin cotters and washers. ⢠Remove wheels from wheel adjusters. ⢠Remove any trash or grass cuttings from inside the dust cover, pinion and/ or drive wheel gear teeth. ⢠Put wheels back in place. ⢠If after cleaning, the drive wheels do not turn freely, contact your nearest .authorized service center. GEAR CASE ⢠To keep your drive system working properly, the gear case and area around the drive should be kept clean and free of trash build-up. Clean under the drive cover twice a season. ⢠The gear case is filled with lubricant to the proper level at the factory. The only time the lubricant needs attention is if service has been performed on the gear case. ⢠If lubricant is required, use only Texaco Starplex Premium 1 Grease, Part No. 750369. Do not substitute. 12 ENGINE LUBRICATION Use only high quality detergent oil rated with API service classif_tion SI-, SG or SH. Select the oil's SAE v'_,osily grade according to your expected operating temperature. SAE VISCOSITY GRADES O. ._ .10. O* I0. 20" 3_, TEMPERATURE RANGE ANTICtPAT_D BEFORE NEXT OIL CHANGE NOTE: Although multi-viscosity oils (5W30, 10W30 etc.) improve starting in cold weather, these multi-viscosity oils will result in increased oil consumption when used above 32°F. Check your engine oil level more frequen T to avoid possible engine damage from running low on oil. Change the oil after every 25 hours of operation or at least once a year if the lawn mower is not used for 25 hours in one year. Check the crankcase oil level before starting the engine and after each five (5) hours of continuous use. Tighten oil plug securely each time you check the oil level. TO CHANGE ENGINE OIL NOTE: Before tipping lawn mower to drain oil, drain fuel tank by running engine until fuel tank is empty. ⢠Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with spark plug. ⢠Remove engine oil cap; lay aside on a clean surface. ⢠Tip lawn mower on its side as shown and drain oil into a suitable container. Rock lawn mower back and forth to remove any oil trapped inside of engine. ⢠Wipe off any spilled oil on lawn mower and on side of engine. ⢠Fill engine with oil. Fill to the upper limit mark on the dipstick. DO NOT OVER FILL.
⢠To read proper level, insert the dipstick into the tube and rest oil fill cap on the tube. Do not thread the cap onto the tube. Remove and read the oil level. ⢠Replace engine oil cap. ⢠Reconnect spark plug wire to spark plug. Oil filler cap/dipstick __Upper limit _Lower limit AIR FILTER Your engine will not run properly and may be damaged by using a dirty air filter. Replace the air filter every year, more often if you mow in very dusty, dirty conditions. TO CLEAN AIR FILTER ⢠Remove cover. ⢠Carefully remove cartridge. ⢠Clean by gently tapping on a flat surface. If very dirty, replace cartridge. ACAUTION: Petroleum solvents, such as kerosene, are not to be used to clean cartridge. They may cause deterioration of the cartridge. Do not oil cartridge. Do not use pressurized air to clean or dry cartridge. ⢠Install cartridge, then replace cover. Filter Filter Tabs Cover MUFFLER Inspect and replace corroded muffler as it could create a fire hazard and/or dam- age. SPARK PLUG Change your spark plug each year to make your engine start easier and run better. Set spark plug gap at .030 inch. CLEANING IMPORTANT: For best performance, keep mower housing free of built-up grass and trash. Clean the underside of your mower after each use. ACAUTION: Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with the spark plug. ⢠Tum lawn mower on its side. Make sure air filter and carburetor are up. Clean the underside of your lawn mower by scraping to remove buildup of grass and trash. ⢠Clean engine often to keep trash from accumulating. A clogged engine runs hotter and shortens engine life. ⢠Keep finished surfaces and wheels free of all gasoline, oil, etc. ⢠We de not recommend using a garden hose to clean lawn mower unless the electrical system, muffler, air filter and carburetor are covered to keep water out. Water in engine can result in shortened engine life. CLEAN UNDER DRIVE COVER Clean under ddve cover at least twice a season. Scrape underside of cover with putty knife or similar tool to remove any buildup of trash or grass on underside of drive cover. Tabs 13
ACAUTION: Before performing anyservice or adjustments. ⢠Release control bar and stop engine. ⢠Make sure the blade and all moving parts have completely stopped. ⢠Disconnect spark plug wire from spark plug and place where it cannot come in contact with plug. LAWN MOWER TO ADJUST CUTTING HEIGHT See "TO ADJUST CUTTING HEIGHT" in the Operation section of this manual. REAR DEFLECTOR The rear deflector, attached between the rear wheels of your lawn mower, is provided to minimize the possibility that objects will be thrown out the rear of the lawn mower into the operator's mowing position. If the rear deflector becomes damaged, it should be replaced. TO REMOVFJREPLACE DRIVE BELT ⢠Remove drive cover. Remove belt by pushing down on gear case pulley and rolling belt off it. ⢠Turn lawn mower on its side with carburetor and fuel cap up. ⢠Remove blade. ⢠Remove debris shield. ⢠Remove belt from engine pulley on crankshaft. ⢠Install new belt by reversing above steps. ⢠Always use factory approved belt to assure fit and long life. TO ADJUST HANDLE The upper handle may be adjusted to four (4) different height positions. ° Loosen both handle knobs only enough to allow the upper handle to pivot to the desired adjustment position.. ⢠Tighten both handle knobs securely. Handle Knob Handle Knob TO ASSEMBLE GRASS CATCHER ⢠Put grass catcher frame into grass bag with rigid part of bag on the bottom. Make sure the frame handle is outside of the bag top. ⢠Slip vinyl bindings over frame. NOTE: If vinyl bindings are too stiff, hold them in warm water for a few minutes. If bag gets wet, let it dry before using. _,CAUTION: Do not run your lawn mower without clipping deflector or approved grass catcher in place. Never attempt to operate the lawn mower with the rear door removed or propped open. Drive cover Belt Catcher frame handle Push down ⢠Frame opening 14
ENGINE ENGINE SPEED Your engine speed has been factory set. Do not attempt to increase engine speed or it may result in personal injury. If you believe that the engine is running too fast or too slow, take your lawn mower to an authorized service center for repair and adjustment. CARBURETOR Your carburetor is not adjustable. If your engine does not operate properly due to suspected carburetor problems, take your lawn mower to an authorized service center for repair and/or adjustment. IMPORTANT: Never tamper with the engine governor, which is factory set for proper engine speed. Overspeeding the engine above the factory high speed setting can be dangerous. If you think the engine-governed high speed needs adjusting, contact your nearest authorized service center, which has proper equipment and experience to make any necessary adjustments. 15
Immediately prepare your lawn mower for storage at the end of the season or if the unit will not be used for 30 days or more. LAWN MOWER When lawn mower is to be stored for a period of time, clean it thoroughly, remove all dirt, grease, leaves, etc. Store in a clean, dry area. ⢠Clean entire lawn mower (See "CLEANING" in the Maintenance "section of this manual). ⢠Lubricate as shown in the Maintenance section of this manual. ⢠Be sure that all nuts, bolts, screws, and pins are securely fastened. Inspect moving parts for damage, breakage and wear. Replace if necessary. ⢠Touch up all rusted or chipped paint surfaces; sand lightly before painting. HANDLE You can fold your lawn mower handle for storage. ⢠Squeeze the bottom ends of the lower handle toward each other until the lower handle clears the handle bracket, then move handle forward. ⢠Loosen upper handle mounting bolts enough to allow upper handle to be folded back. IMPORTANT: When folding the handle for storage or transportation, be sure to fold the handle as shown or you may damage the control cables. ⢠When setting up your handle from the storage position, the lower handle will automatically lock into the mowing .position. Lower handle Squeeze to fold Handle bracket Hairpin cotter Operator presence control bar Upper Handle -_ //,,,._P_)_ Fold _/_'_----_ ,"_ forward for __.__,_';;'_'/J storage __, ,J_ Fold \ backward "__ Mowing Lower handle position ENGINE FUELSYSTEM IMPORTANT: It is important to prevent gum deposits from forming in essential fuel system parts such as carburetor, fuel filter, fuel hose, or tank during storage. Also, experience indicates that alcohol blended fuels (called gasohol or using ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. ⢠Drain the fuel tank. ⢠Start the engine and let it run until the fuel lines and carburetor are empty. ⢠Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur. ⢠Use fresh fuel next season. NOTE: Fuel stabilizer is an acceptable alternative in minimizing the formation of fuel gum deposits during storage. Add stabilizer to gasoline in fuel tank or storage container. Always follow the mix ratio found on stabilizer container. Run engine at least 10 minutes after adding stabilizer to allow the stabilizer to reach the carburetor. Do not drain the gas tank and carburetor if using fuel stabilizer. ENGINEOIL Drain oil (with engine warm) and replace with clean engine oil. (See "ENGINE" in the Maintenance section of this manual). CYLINDER ⢠Remove spark plug. ⢠Pour one ounce (29 ml) of oil through spark plug hole into cylinder. ⢠Pull starter handle slowly a few times to distribute oil. 16 ⢠Replace with new spark plug.
OTHER ⢠Do not store gasoline from one season to another. ⢠Replace your gasoline can if your can starts to rust. Rust and/or dirt in your gasoline will cause problems. ⢠If possible, store your unit indoors and cover it to give protection from dust and dirt. ⢠Cover your unit with a suitable protec- tive cover that does not retain moisture. Do not use plastic. Plastic cannot breathe which allows condensation to form and will cause your unit to rust. TROUBLESHOOTING CHART PROBLEM CAUSE CORRECTION Does not start 1. Dirty air filter. Loss of power Poor cut - uneven IMPORTANT: Never cover mower while engine and exhaust areas are still warm. ACAUTION: Never store the lawn mower with gasoline in the tank inside a building where fumes may reach an open flame or spark. Allow the engine to cool before storing in any enclosure. 2. Out of fuel. 3. Stale fuel. 4. Water in fuel. 5. Spark plug wire is disconnected. 6. Bad spark plug. 7. Loose blade or broken blade adapter. 8. Control bar in released position. 9, Control bar defective. 1. Rear of lawn mower housing or cutting blade dragging in heavy grass. 2. Cutting too much grass. 3. Dirty air filter. 4. Buildup of grass, leaves, and trash under mower. 5. Too much oil in angine. 6. Walking speed too fast. 1. Wom, bent or loose blade, 2. Wheel heights uneven. 3. Low engine speed 4. Buildup of grass, leaves and trash under mower. 1. Clean/replace air filter. 2. Fig fuel tank, 3. Drain tank and refill with fresh clean fuel. 4. Drain fuel tank and carburetor and refill tank with fresh gasoline. 5. Connect wire to plug. 6. Replace spark plug. 7. Tighten blade bolt or replace blade adapter. 8. Depress control bar to handle. 9. Replace control bar. 1. Set to "Higher Cut" position, 2. Set to 'l-ligher Cur' position. 3. Clean/replace air filter. 4. Clean underside of mower housing. 5. Check oil level. 6. Cut at slower walking speed. 1. Replace blade. TKjhten blade bolt. 2. Set all wheels at same height 3. Contact an authorized center/ department 4. Clean _-_lemide of mower housing. 17
TROUBLESHOOTING CHART PROBLEM CAUSE Excessive vibration Starter rope hard topull Loss of drive Gross catcher hot filling (if so equipped) Hard to push 1. Worn, bent or loose blade. 2. Bent engine crankshaft. 1. Engine flywheel brake is on when control bar is released. 2. Bent engine crankshaft. 3. Blade adapter broken. 4. Blade dragging in grass. 1. Drive wheels not tuming with drive control engaged. 2. Belt not driving 1. Cutting height tee low. 2. Lift on blade wom off. 3. Catcher not venting air. 4. Low engine speed 1. Grass is too high or wheel height is too low. 2. Rear of lawn mower housing or blade dragging in grass. 3, Grass catcher too full. 4. Handle height position not right for you, CORRECTION 1. Replace blade. ]]ghten blade bolt. 2. Contact an authorized service center. 1. Depress control bar to upper handle before pulling starter rope. 2. Contact an authorized service center. 3. Replace blade adapter. 4. Move lawn mower to cut grass or to hard surface. 1. Adjust or replace drive control cable. 2. Put belt on pulleys or replace belts if broken. 1. Raise cutting height. 2. Replace blade. 3. Clean grass catcher. 4. Set throttle to fast position. 1. Raise cutting height. 2. Raise rear of lawn mower housing one (1) setting higher. 3. Empty grass catcher. 4. Adjust handle height to suit. 18
36
ROTARY LAWN MOWER -- MODEL NO. 917.379480 GEAR CASE ASSEMBLY PART NUMBER 702511 s J 14 KEY NO. 2 3 4 6 7 8 9 PART NO. 17490416 137055X004 137053 57072 48373 77881 137051 137074 DESCRIPTION KEY PART NO. NO. DESCRIPTION Tapping Screw 1/4-20 x 10 57079 HardenedWasher 1-1/4 11 131484 Clutch Yoke Engagement Bracket 12 700343 Bushing Shifter 13 86447 Plug Seal 14 137050 Helical Gear Gear Case Halves Kit 15 750436X Clutch Jaw (includes Key Nos, 4, 15 750369 Grease and 7) 17 12000003 E-Ring Beadng 18 850848 Hi-ProKay Worm Shaft 19 81585X004 Spring Bracket Drive Shaft NOTE: All component dimensions given in U.S. inches. 1 inch = 25.4 mm 37
ROTARY LAWN MOWER MODEL.NUMBER 917.379480 78 57 27 25 13 10 14 12 10, .J < < 15 3O 2O 37 52 72 22 1_23 35 37 30 27 28 29 41 13
ROTARY LAWN MOWER MODEL NUMBER 917.379480 KEY NO. PART NO. DESCRIPTION KEY PART NO. NO. DESCRIPTION 1 2 4 5 6 8 9 10 11 12 13 14 15 16 17 18 20 22 23 25 27 28 29 3O 31 32 34 35 37 39 40 41 44 169933X479 130861 150425 66426 136376 169936 170947 128415 15O050 STD512505 150191 156374X479 700365X479 1331g0x479 140661X479 63601 140540 84596 87677 83923 150341 142748 62335 145935X004 701037 700331 X004 146630 700325X007 150078 173569X479 173570X479 150406 172835 46 851514 Upper Handle 47 141114 Engine Zone Control Cable 48 851074 Mulcher Plug 49 850263 WireTie 50 851084 Handle Knob 51 170031 Control Bar 52 85463 Rear Door Kit 55 751592 Pop Rivet 56 88652 Self Tapping Screw #10-24 x 5/8 57 51793 Hex Tapping Screw w/Seres 1/4-20 x 1/2 58 151590X479 Hubcap 59 171407 Back Plate 61 132001 Side Baffle 62 134612 Discharge Baffle 64 ...... Rear Baffle Keps Locknut 1/4-20 65 17600406 Rear Skirt 66 163340 Engine Pulley 67 144929 HI-Pro Key #505 71 170939 Hex Flange Nut 72 170938 Wheel 73 165912 Shoulder Bolt 3/8-16 x 1 78 170954 Washer 79 170953 Axle Arm Assembly 80 170554 Selector Knob 81 170955 Selector Spdng 82 170956 Spacer - - 161058 Wheel Adjusting Bracket - - 172340 Thread Cutting Screw w/Seres 5/16-18 x 3/4 Handle Bracket Assembly (Left) Handle Bracket Assembly (Right) Hex H_ad Thread Rolling Screw 3/8-16 x 1-1/8 Lawn Mower Housing (Incl. Key #14, 15, 51) Blade Adapter Blade 22' Hardened Washer Helical Washer 3/8-24 x 1-3/8 Gr. 8 Hex Head Machine Screw 3/8-24 x 1-3/8 Gr. 8 Front Baffle Kit Danger Decal Locknut 3/8-16 Hinge Screw 1/4o20 x 1-1/4 HeirpinCotter Lower Handle Handle Bolt RopeGuide Debds Shield Engine - (See Engine Breakdown) Model Honda GCV160A1A Screw Hx Serrated 1/4 x 20 Throttle control Screw Spring RH Spring LH Bolt Handle Adjuster, Outside, LH Handle Adjuster, Inside, LH Handle Adjuster Spnng Handle Adjuster, Inside, RH Handle Adjuster, Outside, RH Waming Decal (Not Shown) Owner's Manuel (EnglisWSpanish) Available accessories not included with lawn mower: -- D/98 33313 Clipping Deflector -- 71 33623 Gas Can -- 71 33500 Fuel Stabilzer - - 71 33300 SAE 30W Oil (20 oz.)
ROTARY LAWN MOWER MODEL NUMBER 917.379480 54 53 14 18 12 ⢠° 14 15 13 16 11 / 13
ROTARY LAWN MOWER MODEL NUMBER 917.379480 KEY NO. 1 ⢠3 4 5 6 8 9 11 12 13 14 15 16 18 26 PART NO. 146323 751152 158755 146527 150495 150182 145212 15O340 1200OO58 137054 88O8O 88118 67725 701037 143603 KEY PART DESCRIPTION NO. NO. Control Cable Assembly 28 154990 Locknut #10-24 31 132010 Pan Head Machine Screw 1/4 x 2.12 32 137052 V-Belt 35 151521 Spring Retainer 36 702511 Hubcap 37 137090 Flanged Nut 38 63601 Wheel & Tire Assembly 40 75192 E-Ring 41 151520 Pinion 53 169931 Dust Cover 54 169932 Felt Washer 55 86012 Washer 1/2 x 1-1/2 x .134 Selector Knob Pan Head Tapping Screw #10-24 x 2-3/4 DESCRIPTION Drive Cover Hex Flange Nut Drive Pulley Wheel Adjuster Assembly (Left) Gear Case Assembly Spnng Nut Spring Wheel Adjustor Assembly (Right) Frame Grassbag Assembly Driveshaft Cover
HONDA 4-CYCLE ENGINE MODEL NO. GCV160-A1A CONTROL I CAMSHAFT I CARBURETOR I 11 10 t 14 4 42
HONDA 4-CYCLE ENGINE MODEL NO. GCV160-A1A _FANCOVERJ I 6_ 13 13 FLYWHEEL I 1 3 5 7 14 5 nn , i ,n RECOIL STARTER I 1 l AIR CLEANER 43
HONDA 4-CYCLE ENGINE MODEL NO. GCV160-A1A 4 44
HONDA 4-CYCLE ENGINE MODEL NO. GCV160-A1A CONTROL KEY PART NO. NO. DESCRIPTION 1 5580311 Arm, Governor 2 5580329 Rod, Governor 3 5580345 Spring, Governor 4 5580352 Spring, Throttle Return 5 4439428 Spring, Lever 6 0800466 Holder, Cable 7 5580378 Base Comp., Control Use up to sn 1177559. 7 6094122 Base Comp., Control Use from sn 1177560. 8 5580386 Rod, Choke 9 2418671 Bolt, Governor Arm 10 5580998 Bolt, Flange (6x45) (ct200) 11 0145557 Screw, Pan (5x16) 12 0471623 Nut, Flange (6mm) CAMSHAFT PULLEY KEY PART NO. NO. DESCRIPTION 1 5580055 2 5580063 3 5580071 4 5580089 5 5580097 6 5580105 7 5580113 8 5580121 9 5580139 10 1426980 11 0294819 12 0004598 13 0018044 13 2373447 Pulley Comp., Camshaft Shaft, Cam Pulley Belt, Timing Arm In. Valve Rocker Arm, Ex. Valve Rocker Shaft Rocker Arm Valve, In. Valve, Ex. Spring, Valve Retainer, In. Valve Spring Screw, Tappet Adj. Nut, Tappet Adj. O-ring O-ring CARBURETOR KEY PART NO. NO. 1 3088416 2 5580162 3 4930756 4 4481818 5 1441518 6 5580170 7 5664552 8 5580212 9 5580220 10 5580238 11 5580246 12 4581120 13 5580253 14 5580535 15 0639419 15 3344520 16 0635474 16 0635482 16 0636126 DESCRIPTION Gasket Set Float Set Chamber Set, Float Screw Set Screw Set Screw Set Carburetor assy. Valve Float Nozzle Main Insulator, Carburetor Gasket, Insulator Gasket, Carburetor Gasket, Carburetor Guide Comp., air Screw, Pan (5x6) Screw, Pan (5x6) Jet, Main #60 (optional) Jet, Main #62 (optional) Jet, Main #65 (optional) 45
HONDA 4-CYCLE ENGINE MODEL NO. GCV160-AIA FAN COVER KEY PART NO. NO. 1 3683646 2 5028923 3 5580394 4 5580451 5 5580469 6 5580519 7 5580527 8 2499440 9 5581004 10 0671636 11 2449593 12 0250647 13 0250985 14 0053447 FLYWHEEL KEY PART NO. NO. 1 0348433 2 5580659 3 5723747 4 5580675 5 5580683 6 5580782 7 5580790 8 0803619 9 1725050 10 0671552 11 0442038 12 1824630 13 0485946 14 1510361 AIR CLEANER KEY PART DESCRIPTION NO. NO. DESCRIPTION Rubber, Supporter 107 mm 1 5580154 Petcock Assy. Man 2 5580402 Bracket, Petcock 3 5581410 Cap Assy., Fuel Tank 5 5664560 Tube, Fuel 6 5580444 Cover Comp., Fan NH1 Black 7 5580964 Coller, Fan Cover 8 2374742 Collar, Ft. Turn Signal Bolt, Stud Screw-Washer 5X10 RECOIL STARTER Bulk Hose, Fuel Clip, Tube (B8) KEY PART Clip, Tube (B10) NO. NO. Clip, Tube (C9) DESCRIPTION Key, Special Woodruff (25X18) Coil Assy., Ignition FlywheelAssy. Wire, Stop Switch Switch Assy., Engine Stop Brake Assy. Spring, Brake Lever Bolt Range (6X14) Bolt, Flange (6X23) Bolt, Flange (6X20) Nut, Special 14mm Clip Cable Screw-Washer (4X12) Washer, Plain Tube, Breather Element, Air Cleaner Case Assy., Air Cleaner Gasket, Air Cleaner Cover, Air Cleaner Bolt, Flange (6X86) Bolt, Flang8 (6X14) DESCRIPTION 2 3 4 5597869 5580634 5580642 2866341 Starter Assy., Recoil NH1 Long Rope Black Knob, Recoil Starter Rope, Recoil Starter Nut, Flange 6ram 46
HONDA 4-CYCLE ENGINE MODEL NO. GCV160-AIA II II ⢠CYLINDER BARREL KEY PART NO. NO. 1 5579982 2 2399780 3 5579990 4 5580006 5 0636845 6 0803619 7 5581038 8 1441112 DESCRIPTION Cylinder Assy. Clip, Valve Guide Cover, Head Cover Comp., Breather Bolt, Flange (6X12) Bolt, Flange (6X14) Oil Seal 25.4X62X6 Spark Plug (BPR6ES NGK) OIL PAN KEY PART NO. NO, 1 5579974 2 4497947 4 5580261 5 5580279 6 5580287 7 5580295 8 1427244 9 1427251 10 5580303 11 0803619 12 0748111 13 2413862 14 2456697 15 5581046 16 0345900 17 0115527 18 1417369 19 5722996 DESCRIPTION Pan Assy., Oil Gasket, Oil Filler Cap Shaft Comp., Governor Holder Governor Assy. Weight, Governor Holder, Governor Weight Pin, Governor Weight Slider, Governor Shaft, Governor Arm Bolt Flange (6X14) Bolt, Flange (6X25) Washer, Thrust 6ram Clip, Governor Holder Oil Seal (28X41.25X6) Washer, Plain 6mm Pin, Lock 8mm Pin Dowel (8X20) Gauge Assy., Oil Leve CRANKSHAFT KEY PART NO. NO. 1 5580030 5 5581012 DESCRIPTION Crankshaft Comp. (N1-Type) Washer Thrust PISTON CONNECTING ROD KEY PART NO. NO. DESCRIPTION 1 2 3 4 5 6 6 5580014 1426576 5580022 1431055 2605517 5655949 5655956 Piston Pin, Piston Rod Assy., Connecting Bolt, Connecting Rod Clip, Piston Pin 13mm Ring Set, Piston (Riken) Ring Set, Piston (Teikoku) MUFFLER 1 5580485 2 5580501 3 5580972 4 0636845 5 5737457 DESCRIPTION Muffler Comp. Protector, Muffler Bolt, Flange (6X79) CT200 Bolt, Flange (6X12) Gasket, Muffler (Optional) 47
For repair of major brand appliances in your own home... no matter who made it, no matter who sold it! 1"800-4-MY-HOME s" Anytime, dayor night (1-800-469-4663) www.sears.com To bring in products such as vacuums, lawn equipment and electronics for repair, call for the location of your nearest Sears Parts & Repair Center. 1-800-488-1222 Anytime, day or night www.sears.com iiiiiiii!iii_iiii iiii!!iiiii!iiii ii!!!!i!iii_iiii iii!!:ii!i!iiiii_i iii_iiiiii!_i!_!i! i!ii_!iiiiiiiiiill iii[_!iiiii]i!!!i iiiii!iiiiiiiiii iii!iiiiiiiill iiiii!iiii!i_iiiii iii_i!ilil]ii_ill iii!iiiii_i_iill For the replacement parts, accessories and owner's manuals ................ ⢠::: : that you need to do-it-yourself, call Sears PartsDirectSM! 1 800 366 PART " " " 6 a.m. - 11 p.m. CST, iii i!!iiiiiiiiii! (1-800-366-7278) 7 days a week :_ ............ www. sears . com/partsdirect ::: iliiiiiiiii!ili_ To purchase or inquire about a Sears Service Agreement: !_ii[ii!i!ii!!i !:ii:i_i:i:! i ! 1 800 827 6655 '"_ ...... ⢠= m m : ¢::i: 7 a.m. - 5 p.m. CST, Mon.- Sat. Para pedir servido de reparaciSn a dornicilio, y para ordenar piezas con entrega a domicilio: 1-888-SU-HOGAR = (1-888-784-6427 HomeCentral =' Au Canada pour service en francis: 1-877-LE-FOYER _ (1-877-533-6937) © Seam, Roebuck and Co. ® Registered Trademark / _ Trademark of Seam, Roebuck and Co. ® Merca Registrada / TM Mama de Rtbdca de Seam, Roebuck and Co. 172340 2.11.00 TR Printed in U.S.A.
Warranty .............................................. 2 Safety Rules ........................................ 2 Assembly ............................................. 4 Operation ............................................. 6 Maintenance Schedule ....................... 10 Maintenance ........................................ 10 Product Specifications ......................... 11 Service and Adjustments ..................... 14 Storage ................................................ 16 Troubleshooting .................................. 17 Repair Parts ......................................... 37 Parts Back Cover LIMITED TWO YEAR WARRANTY ON CRAFTSMAN POWER MOWER For two years from date of purchase, when this Craftsman Lawn Mower is maintained, lubricated, and tuned up according to the operating and maintenance instructions in the owner's manual, Sears will repair free of charge any defect in material or workman- ship. If.this Craftsman Lawn Mower is used for commercial or rental purposes, this warranty applies for only 90 days from the date of purchase. This Warranty does not cover: ⢠Expendable items which become worn during normal use, such as rotary mower blades, blade adapters, belts, air cleaners and spark plug. ⢠Repairs necessary because of operator abuse or negligence, including bent crankshafts and the failure to maintain the equipment according to the instructions contained in the owner's manual. Warranty service is available by returning the Craftsman power mower to the nearest Sears Service Center/Department in the United States. This warranty applies only while this product is in use in the United States. This Warranty gives you specific legal rights, and you may also have other rights which vary from state to state. SEARS, ROEBUCKAND CO., D/817 WA, HOFFMAN ESTATES, ILLINOIS 60179 Safety standard's require operator presence controls to mimimize the risk of injury. Your unit is equipped with such controls. Do not attempt to defeat the function of the operator presence controls under any circumstances. TRAINING: ⢠Read this operator's manual carefully. Become familiar with the controls and know how to operate your mower -properly. Learn how to quickly stop mower. ⢠Do not allow children to use your mower. Never allow adults to use mower without proper instructions. ⢠Keep the area of operation clear of all persons, especially small children and pets. ⢠Use mower only as the manufacturer intended and as described in this manual. ⢠Do not operate mower if it has been dropped or damaged in any manner. Always have damage repaired before using your mower. ⢠Do not use accessory attachments that are not recommended by the manufac- turer. Use of such attachments may be hazardous. ⢠The blade turns when the engine is running. PREPARATION: ⢠Always thoroughly check the area to be mowed and clear it of all stones, sticks, wires, bones, and other foreign objects. These objects will be thrown by the blade and can cause severe injury. ⢠Always wear safety glasses or eye shields when starting and while using your mower. 2
⢠Dress properly. Do not operate mower when barefoot or wearing open sandals. Wear only solid shoes with good traction when mowing. ⢠Check fuel tank before starting engine. Do not fill gas tank indoors, when the engine is running or when the engine is hot. Allow the engine to cool for several minutes before filling the gas tank. Clean off any spilled gasoline before starting the engine. ⢠Always make wheel height adjustments before starting your mower. Never attempt to do this while the engine is running. ⢠Mow only in daylight or good artificial light. OPERATION: ⢠Keep your eyes and mind on your mower and the area being cut. Do not let other interests distract you. ⢠Do not mow wet or slippery grass. Never run while operating your mower. Always be sure of your footing - keep a firm hold on the handles and walk. ⢠Do not put hands or feet near or under rotating parts. Keep clear of the dis- charge opening at all times. ⢠Always stop the engine whenever you leave or are not using your mower, or before crossing driveways, walks, roads, and any gravel-covered areas. ⢠Never direct discharge of material toward bystanders nor allow anyone near the mower while you are operating it. ⢠Before cleaning, inspecting, or repairing your mower, stop the engine and make absolutely sure the blade and all moving parts have stopped. Then disconnect the spark plug wire and keep it away from the spark plug to prevent accidental starting. ⢠Do not continue to run your mower if you hit a foreign object. Follow the proce- dure outlined above, then repair any damage before restarting and operating your mower. ⢠Do not change the governor settings or overspeed the engine. Engine damage or personal injury may result. ⢠Do not operate your mower if it vibrates abnormally. Excessive vibration is an indication of damage; stop the engine, safely check for the cause of vibration and repair as required. ⢠Do not run the engine indoors. Exhaust fumes are dangerous. ⢠Never cut grass by pulling the mower towards you. Mow across the face of slopes, never up and down or you might lose your footing. Do not mow exces- sively steep slopes. Use caution when operating the mower on uneven terrain or when changing directions - maintain good footing. ⢠Never operate your mower without proper guards, plates, grass catcher or other safety devices in place. MAINTENANCE AND STORAGE: ⢠Check the blade and the engine mounting bolts often to be sure they are tightened properly. ⢠Check all bolts, nuts and screws at frequent intervals for proper tightness to be sure mower is in safe working condition ⢠Keep all safety devices in place and working. ⢠To reduce fire hazard, keep the engine free of grass, leaves or excessive grease and oil. ⢠Check grass catcher often for deteriora- tion and wear and replace worn bags Use only replacement bags that are recommended by and comply with specifications of the manufacturer of your mower. ⢠Always keep a sharp blade on your mower. ⢠Allow engine to cool before storing in any enclosure ⢠Never store mower with fuel in the tank inside a building where fumes may reach an open flame or an ignition source such as a hot water heater, space heater, clothes dryer, etc. A, Look for this symbol to point out important safety precautions It,means CAUTION!!! BECOMEALERT!t! YOUR SAFETY IS INVOLVED. _CAUTION: Always disconnect spark plug wire and place wire where it cannot contact spark plug in order to prevent accidental starting when setting up, transporting, adjusting or making repairs. _:_WARNING: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. 3
These accessories were available when this lawn mower was produced, are not shipped with your mower. They are also available at most Sears retail outlets and service centers. Most Sears stores can also order repair parts for you, when you provide the model number of your lawn mower. Some of these accessories may not apply to your lawn mower. LAWN MOWER PERFORMANCE CLIPPING DEFLECTOR FOR REAR DISCHARGE LAWN MOWERS GRASS CATCHERS FOR REAR DISCHARGE LAWN MOWERS ,f(.vi.l_=*,. - MULCHERK_S GRASS CATCHERS FOR SIDE DISCHARGE LAWN MOWERS LAWN MOWER MAINTENANCE STABILIZER GAS CANS MUFFLERS BELTS BLADES AIR FILTERS BLADE ADAFrERS WHEELS SPARK PLUGS ENGINE OIL Read these instructions and this manual in its entirety before you attempt to assemble or operate your new lawn mower. IMPORTANT: This lawn mower is shipped without oil or gasoline in the engine. Your new lawn mower has been as- sembled at the factory with the exception of those parts left unassembled for shipping purposes. To ensure safe and proper olberation of your lawn mower, all parts and hardware you assemble must be tightened securely. Use the correct tools as neces- sary to ensure proper tightness. All parts such as nuts, washers, bolts, etc., neces- sary to complete the assembly have been placed in the parts bag. TO REMOVE LAWN MOWER FROM CARTON ⢠Remove loose parts included with mower. ⢠Cut down two end comers of carton and lay end pana down fiat ⢠Remove all pacldng materials except padding between upper and lower handle and padding holding operator presence control bar to upper handle. ⢠Roll lawn mower out of carton and check carton thoroughly for additional loose parts. 4
HOWTO SET UPYOUR LAWN MOWER TO UNFOLD HANDLE IMPORTANT: Unfold handles carefully so as not to pinch or damage control cables ⢠Raise handles until lower handle section locks into place in mowing position. ⢠Remove protective padding, raise upper handle section into place on lower handle and tighten both handle knobs. ⢠Remove handle padding holding operator presence control bar to upper handle. ⢠Your lawn mower handle can be adjusted for your mowing comfort. Refer to "Adjust Handle" in the Service and Adjustment section of this manual. Operator presence control bar Upper handle _ _ ⢠,fup/ Lower handle Mowing position TO INSTALL ATTACHMENTS Your lawn mower was shipped ready to be used as a mulcher. To convert to bagging or discharging: ⢠Open rear door and remove muleher plug. Store mulcher plug in a safe place. ⢠You can now install catcher or optional clipping deflector. ⢠To retum to mulching operation, install mulcher plug into discharge opening of mower. Mulcher plug ,__ ACAUTION: Do not run your lawn mower without mulcher plug in place or approved clipping deflector or grass catcher in place. Never attempt to operate the lawn mower with the rear door removed or propped open. 5
_NOWYOUR LAWN MOWER READ THIS OWNER'S MANUALAND SAFETY RULES BEFORE OPERATING YOUR LAWN MOWER. Compare the illustrations with your lawn mower to familiarize yourself with the location of various controls and adjustments. Save this manual for future I ° These symbols may appear on your lawn mower or in literature supplied with the product. Learn and understand their meaning. CAUTION ENGfNE ENGINE FAST SLOW CHOKE FUEL OIL DANGER, KEEPHANDS OR WARNING ON OFF AND FEET AWAY Engine zone control cable Throttle control )resence control bar _Drive control lever Grass catcher_, Handle knob ⢠Mulcher plug Engine oil ca_: Housing IMPORTANT: This lawn mower is shipped without oil or gasoline in the engine. Drive cover , Wheel adjuster (on every wheel) MEETS CPSC SAFETY REQUIREMENTS Sears rotary walk-behind power lawn mowers conform to the safety standards of the American National Standards Institute and the U.S, Consumer Product Safety Commis- sion. The blade turns when the en_]ine is running, Operator presence control bar - must be held down to the handle to start the engine. Release to stop the engine. Starter handle- used for starting the engine. Drive control lever - used to engage power-propelled forward motion of lawn mower. Mulcher plug - must be removed to convert to bagging or discharging operation. Throttle control - Used for starting the engine and allows you to select either fast or slow engine speed. 6
The operation of any lawn mower can result in foreign objects thrown into the eyes, which can result in severe eye damage. Always wear safety glasses or eye shields while operating your lawn mower or performing any adjustments or repairs. We recommend a wide vision safety mask over spectacles or standard safety glasses. ENGINE SPEED The engine speed is controlled by a throttle control located on the side of the upper handle. Choke position is for starting a cold engine and fast position is for normal cutting, trimming, and better grass bagging. Slow position is for light cutting, trimming and fuel economy. FAST _ _ SLOW CHOKE '" "'" ' "" ⢠.-,; ,,,; . #11 L II ENGINE ZONE CONTROL _CAUTION: Federal regulations require an engine control to be installed on this lawn mower in order to minimize the risk of blade contact injury. Do not under any circumstances attempt to defeat the function of the operator control. The blade turns when the engine is running. ⢠Your _awn mower is equipped with an operator presence control bar which requires the operator to be positioned behind the lawn mower handle to start and operate the lawn mower. TO ADJUST CUTTING HEIGHT ⢠Raise wheels for low cut and lower wheels for high cut. ⢠Adjust cutting height to suit your requirements. Medium position is best for most lawns. ⢠To change cutting height, squeeze adjuster lever toward wheel. Move wheel up or down to suit your require- ments. Be sure all wheels are in the same setting. NOTE: Adjuster is properly positioned when plate tab inserts into hole in lever. Also, 9-position adjusters (if so equipped) allow lever to be positioned between the plate tabs. Lower Wheels for High Cut Plate Tab Lever Raise Wheels for Low Cut TO ATTACH GRASS CATCHER ⢠Lift the rear door of the lawn mower and place the grass catcher frame hooks onto the door pivot pins. ⢠The grass catcher is secured to the lawn mower housing when the rear door is lowered onto the grass catcher frame. _I, CAUTION: Do not run your lawn mower without clipping deflector or approved grass catcher in place. Never attempt to operate the lawn mower with the rear door removed or propped open. Pivot _ins Rear door Grass catcher handle / Catcher frame hook TO EMPTY GRASS CATCHER ⢠Lift up on grass catcher using the frame handle. ⢠Remove grass catcher with clippings from under lawn mower handle, ⢠Empty clippings from bag using both frame handle and bag handle. NOTE: Do not drag the bag when emptying; it will cause unnecessary wear ga¢ handle _rass catcher *frame handle 7
DRIVE CONTROL ⢠Self-propelling is controlled by holding the operator presence control bar down to the handle and pushing the drive control lever forward until it clicks; then release the drive control lever. ⢠Forward motion will stop when the operator presence control bar is released. To stop forward motion without stopping engine, release the operator presence control bar slightly until the drive control disengages. Hold operator presence control bar down to handle to continue mowing without self- propelling. ⢠To keep drive control engaged when turning comers, push down on handle and lift front wheels off ground while turning lawn mower. Operator presence control bar Drive Drive control control To engage Drive control drive control disengaged BEFORE STARTING ENGINE OIL Your lawn mower is shipped without oil in the engine. ⢠Be sure mower is level and area around oil fill is clean. ⢠Remove engine oil cap and fill to the full line on the dipstick. NOTE: Allow oil to settle down into engine for accurate dipstick reading. ⢠Engine holds 18.5 ozs. of oil. For type and grade of oil to use, see "ENGINE" in Maintenance section of this manual. ⢠Pour oil slowly. Do not over fill. ⢠Check oil level before each use. Add oil if needed. Fill to full line on dipstick. ⢠To read proper level, tighten engine oil cap each time. ⢠Reinstall engine oil cap and tighten. ⢠Change the oil after every 25 hours of operation or each season. You may need to change the oil more often under dusty, dirty conditions. ADD GASOLINE ⢠Fill fuel tank. Use fresh, clean, regular unleaded gasoline with a minimum of 87 octane(Use of leaded gasoline will increase carbon and lead oxide deposits and reduce valve life). Do not mix oil with gasoline. Purchase fuel in quantities that can be used within 30 days to assure fuel freshness. AWARNING: Experience indicates that alcohol blended fuels (called gasohol or using ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. To avoid engine problems, the fuel system should be emptied before storage of 30 days or longer, Drain the gas tank, start the engine and let it run until the fuel lines and carburetor are empty. Use fresh fuel next season. See Storage Instructions for additional information. Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur. _IbCAUTION: Fill to bottom of gas tank filler neck, Do not overfill, Wipe off any spilled oil or fuel. Do not store, spill or use gasoline near an open flame. filler cap Oil filler cap J J __ __-Oil filler cap/dipstick Lower limit ----_ -Upper limit TO START ENGINE â¢Tum fuel valve to ON position. ⢠To start a cold engine, move handle mounted throttle/choke control lever to choke position. ⢠Hold operator presence control bar down to the handle and pull starter handle quickly. Do not allow starter rope to snap back. ⢠Slowly move throttle control lever to fast position after engine starts. ⢠To start a warm engine, move throttle control lever to fast or slow position 8 then follow steps above.
⢠To stop engine, release operator presence control bar. Wait until blade and all moving parts have stopped and turn fuel valve to OFF position if you do not intend to restart the engine soon. On Fuel Valve lever MOWING TIPS ⢠Under certain conditions, such as very tall grass, it may be necessary to raise the height of cut to reduce pushing effort and to keep from overloading the engine and leaving clumps of grass clippings. It may also be necessary to reduce ground speed and/or run the lawn mower over the area a second time. ⢠For extremely heavy cutting, reduce the width of cut by overlapping previously cut path and mow slowly. ⢠For better grass bagging and most cutting conditions, the engine speed should be set in the fast position. ⢠When using a rear discharge lawn mower in moist, heavy grass, clumps of cut grass may not enter the grass catcher. Reduce ground speed (pushing speed) and/or run the lawn mower over the area a second time. ⢠If a trail of clippings is left on the right side of a rear discharge mower, mow in a clockwise direction with a small ovedap to collect the clippings on the next pass. ⢠Pores in cloth grass catchers can become filled with dirt and dust with use and catchers will collect less grass. To prevent this, regularly hose catcher off with water and let dry before using. ⢠Keep top of engine around starter clear and clean of grass clippings and chaff. This will help engine air flow and extend engine life. MULCHING MOWING TIPS IMPORTANT: For best performance, keep mower housing free of built-up grass and trash. See =Cleaning" in MAINTENANCE section of this manual. ⢠The special mulching blade will recut the grass clippings many times and reduce them in size so that as they fall onto the lawn they will disperse into the grass and not be noticed. Also, the mulched grass will biedegrade quickly to provide nutrients for the lawn. Always mulch with your highest engine (blade) speed as this will provide the best recutting action of the blades. ⢠Avoid cutting your lawn when it is wet. Wet grass tends to form dumps and interferes with the mulching action. The best time to mow your lawn is the eady aftemcon. At this time the grass has dried and the newly cut area will not be exposed to the direct sun. ⢠For best results, adjust the lawn mower cutting height so that the lawn mower cuts off only the top one-third of the grass blades. If the lawn is overgrown it will be necessary to raise the height of cut to reduce pushing effort and to keep from overloading the engine and leaving clumps of mulched grass. For extremely heavy mulching, reduce your width of cut by overlapping previously cut path and mow slowly. ⢠Certain types of grass and grass condi- tions may require that an area be mulched a second time to completely hide the clippings. When doing a second cut, mew across or perpendicular to the first cut path. ⢠Change your cutting pattem from week to week. Mow north to south one week then change to east to west the next week. This will help prevent matting and graining of the lawn. 9
MAINTENANCE SCHEDULE FILL IN DATES AS YOU COMPLETE REGULAR SERVICE SERVICE DATES Check for Loose Fasteners !/ Clean/Inspect Grass Catcher (If Equipped) ¥/ _ oM Clean Lawn Mower Clean Under Drive Cover (Power-Propelled Mowers) W Check drive belt/pulleys (Power-Propelled Mowers} ¥/ R Check/Sharpen/Replace Blade . .Ip#.3 Lubrication Chart I_ If # Clean Battery/Recharge IElectric Start Mowers I I/ 1/14 NE Check Engine Oil Level !/ Change Engine Oil I/1.2 Clean Air Filter _2 Inspect Muffler .... N; Clean or Replace Spark Plug Replace Air Filter Paper Cartridge I/2 ,ll I - Change mote often when operating under a heavy load or in high ambient temperatures. 2 - Service more often when operating in dirty Or dusty conditions. 3 - Replace blades more often when mowing In sandy SOIL 4 - Charge 48 hours at end or season. LUBRICATION CHART GENERAL RECOMMENDATIONS 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 mower as instructed in this manual. Some adjustments will need to be made periodically to properly maintain your unit. All adjustments in the Service and Adjustments section of this manual should be checked at least once each season. ⢠Once a year, replace the spark plug, "replace air filter element and check blade for wear. A new spark plug and clean/new air filter element assures proper air-fuel mixture and helps your engine run better and last longer. ⢠Follow the maintenance schedule in this manual. BEFORE EACH USE ⢠Check engine oil level. ⢠Check for loose fasteners. LUBRICATION Keep unit well lubricated (See "LUBRICA- TION CHART"). Wheel Adjuster (_ Rear door (_) Handle bracket hinge mounting pin (_ Spay lubricant (_) Refer to MAINTENANCE "ENGINE" section. ine oil 10 IMPORTANT: Do not oil or grease plastic wheel bearings. Viscous lubricants will attract dust and dirt that will shorten the life of the self lubricating bearings. If you feel they must be lubricated, use only a dry, powdered graphite type lubricant sparingly.
PRODUCT SPECIFICATIONS SERIAL NUMBER DATE OF PURCHASE GASOLINE CAPACITY/TYPE: 1.0 QUARTS JNLEADED REGULAR OIL TYPE (API-SF/SG/SH): OIL CAPACITY: SPARK PLUG(GAP: .030") VALVE CLEARANCE: SAE 30 (ABOVE 32°F) SAE 5W-30 (BELOW 32°F) 18.50ZS. CHAMPIONR J19LM OR J19LM I NTAKE: .005" - .007" EXHAUST: .007" - .009" SOLID STATE IGNITION AIR GAP: .010 IN. BLADE BOLT TORQUE: 35-40 FT. LBS. ⢠The model and serial numbers will be found on a decal attached to the rear of the lawn mower housing.Record both serial number and date of purchase in space provided above. LAWN MOWER Always observe safety rules when performing any maintenance. TIRES ⢠Keep tires free of gasoline, oil, or insect control chemicals which can harm rubber. ⢠Avoid stumps, stones, deep ruts, sharp objects and other hazards that may cause tire damage. BLADE CARE For best results, mower blade must be kept sharp. Replace bent or damaged blades. TO REMOVE BLADE ⢠Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with spark plug. ⢠Turn lawn mower on its side. Make sure air filter and carburetor are up. ⢠Use a wood block between blade and mower housing to prevent blade from turning when removing blade bolt. ⢠Protect your hands with gloves and/or wrap blade with heavy cloth. ⢠Remove blade bolt by turning counter- clockwise. Use a 9/16" box or open- end wrench. ⢠Remove blade and attaching hard- ware. TO REPLACE BLADE ⢠Position the blade adapter on the engine crankshaft. Be sure the spacer is in the adaptor and key in shaft and adaptor keyway are aligned. ⢠Position blade on the blade adapter. Be sure the trailing edge of blade (opposite sharp edge) is up toward the engine. ⢠Install the blade bolt with washers into blade adapter and crankshaft. ⢠Use block of wood between blade and lawn mower housing and tighten the blade bolt, turning clockwise. ⢠The recommended tightening torque is 35-40 ft. Ibs. IMPORTANT: BLADE BOLT IS GRADE 8 HEATTREATED. TO SHARPEN BLADE NOTE: We do not recommend sharpen- ing blade - but if you do, be sure the blade is balanced. Care should be taken to keep the blade balanced. An unbalanced blade will cause eventual damage to lawn mower or engine. ⢠The blade can be sharpened with a file or on a grinding wheel. Do not attempt to sharpen while on the mower. 11
⢠To check blade balance, drive a nail into a beam or wall. Leave about one inch of the straight nail exposed. Place center hole of blade over the head of the nail. If blade is balanced, it should remain in a horizontal position. If either end of the blade moves downward, sharpen the heavy end until the blade is balanced. Lockwasher Spacer Blade Sic Blade washer bolt Trailing/edge adapter GRASS CATCHER ⢠The grass catcher may be hosed with water, but must be dry when used. ⢠"Check your grass catcher often for damage or deterioration. Through normal use it will wear. If catcher needs replacing, replace only with a manufacturer approved replacement catcher. Give the lawn mower model number when ordering. DRIVE WHEELS Check front drive wheels each time before you mow to be sure they move freely. The wheels not turning freely means trash, grass cuttings, etc. are in the drive wheel area and must be cleaned to free drive wheels. If necessary to clean the drive wheels, check both front wheels. ,, Remove hubcaps, hairpin cotters and washers. ⢠Remove wheels from wheel adjusters. ⢠Remove any trash or grass cuttings from inside the dust cover, pinion and/ or drive wheel gear teeth. ⢠Put wheels back in place. ⢠If after cleaning, the drive wheels do not turn freely, contact your nearest .authorized service center. GEAR CASE ⢠To keep your drive system working properly, the gear case and area around the drive should be kept clean and free of trash build-up. Clean under the drive cover twice a season. ⢠The gear case is filled with lubricant to the proper level at the factory. The only time the lubricant needs attention is if service has been performed on the gear case. ⢠If lubricant is required, use only Texaco Starplex Premium 1 Grease, Part No. 750369. Do not substitute. 12 ENGINE LUBRICATION Use only high quality detergent oil rated with API service classif_tion SI-, SG or SH. Select the oil's SAE v'_,osily grade according to your expected operating temperature. SAE VISCOSITY GRADES O. ._ .10. O* I0. 20" 3_, TEMPERATURE RANGE ANTICtPAT_D BEFORE NEXT OIL CHANGE NOTE: Although multi-viscosity oils (5W30, 10W30 etc.) improve starting in cold weather, these multi-viscosity oils will result in increased oil consumption when used above 32°F. Check your engine oil level more frequen T to avoid possible engine damage from running low on oil. Change the oil after every 25 hours of operation or at least once a year if the lawn mower is not used for 25 hours in one year. Check the crankcase oil level before starting the engine and after each five (5) hours of continuous use. Tighten oil plug securely each time you check the oil level. TO CHANGE ENGINE OIL NOTE: Before tipping lawn mower to drain oil, drain fuel tank by running engine until fuel tank is empty. ⢠Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with spark plug. ⢠Remove engine oil cap; lay aside on a clean surface. ⢠Tip lawn mower on its side as shown and drain oil into a suitable container. Rock lawn mower back and forth to remove any oil trapped inside of engine. ⢠Wipe off any spilled oil on lawn mower and on side of engine. ⢠Fill engine with oil. Fill to the upper limit mark on the dipstick. DO NOT OVER FILL.
⢠To read proper level, insert the dipstick into the tube and rest oil fill cap on the tube. Do not thread the cap onto the tube. Remove and read the oil level. ⢠Replace engine oil cap. ⢠Reconnect spark plug wire to spark plug. Oil filler cap/dipstick __Upper limit _Lower limit AIR FILTER Your engine will not run properly and may be damaged by using a dirty air filter. Replace the air filter every year, more often if you mow in very dusty, dirty conditions. TO CLEAN AIR FILTER ⢠Remove cover. ⢠Carefully remove cartridge. ⢠Clean by gently tapping on a flat surface. If very dirty, replace cartridge. ACAUTION: Petroleum solvents, such as kerosene, are not to be used to clean cartridge. They may cause deterioration of the cartridge. Do not oil cartridge. Do not use pressurized air to clean or dry cartridge. ⢠Install cartridge, then replace cover. Filter Filter Tabs Cover MUFFLER Inspect and replace corroded muffler as it could create a fire hazard and/or dam- age. SPARK PLUG Change your spark plug each year to make your engine start easier and run better. Set spark plug gap at .030 inch. CLEANING IMPORTANT: For best performance, keep mower housing free of built-up grass and trash. Clean the underside of your mower after each use. ACAUTION: Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with the spark plug. ⢠Tum lawn mower on its side. Make sure air filter and carburetor are up. Clean the underside of your lawn mower by scraping to remove buildup of grass and trash. ⢠Clean engine often to keep trash from accumulating. A clogged engine runs hotter and shortens engine life. ⢠Keep finished surfaces and wheels free of all gasoline, oil, etc. ⢠We de not recommend using a garden hose to clean lawn mower unless the electrical system, muffler, air filter and carburetor are covered to keep water out. Water in engine can result in shortened engine life. CLEAN UNDER DRIVE COVER Clean under ddve cover at least twice a season. Scrape underside of cover with putty knife or similar tool to remove any buildup of trash or grass on underside of drive cover. Tabs 13
ACAUTION: Before performing anyservice or adjustments. ⢠Release control bar and stop engine. ⢠Make sure the blade and all moving parts have completely stopped. ⢠Disconnect spark plug wire from spark plug and place where it cannot come in contact with plug. LAWN MOWER TO ADJUST CUTTING HEIGHT See "TO ADJUST CUTTING HEIGHT" in the Operation section of this manual. REAR DEFLECTOR The rear deflector, attached between the rear wheels of your lawn mower, is provided to minimize the possibility that objects will be thrown out the rear of the lawn mower into the operator's mowing position. If the rear deflector becomes damaged, it should be replaced. TO REMOVFJREPLACE DRIVE BELT ⢠Remove drive cover. Remove belt by pushing down on gear case pulley and rolling belt off it. ⢠Turn lawn mower on its side with carburetor and fuel cap up. ⢠Remove blade. ⢠Remove debris shield. ⢠Remove belt from engine pulley on crankshaft. ⢠Install new belt by reversing above steps. ⢠Always use factory approved belt to assure fit and long life. TO ADJUST HANDLE The upper handle may be adjusted to four (4) different height positions. ° Loosen both handle knobs only enough to allow the upper handle to pivot to the desired adjustment position.. ⢠Tighten both handle knobs securely. Handle Knob Handle Knob TO ASSEMBLE GRASS CATCHER ⢠Put grass catcher frame into grass bag with rigid part of bag on the bottom. Make sure the frame handle is outside of the bag top. ⢠Slip vinyl bindings over frame. NOTE: If vinyl bindings are too stiff, hold them in warm water for a few minutes. If bag gets wet, let it dry before using. _,CAUTION: Do not run your lawn mower without clipping deflector or approved grass catcher in place. Never attempt to operate the lawn mower with the rear door removed or propped open. Drive cover Belt Catcher frame handle Push down ⢠Frame opening 14
ENGINE ENGINE SPEED Your engine speed has been factory set. Do not attempt to increase engine speed or it may result in personal injury. If you believe that the engine is running too fast or too slow, take your lawn mower to an authorized service center for repair and adjustment. CARBURETOR Your carburetor is not adjustable. If your engine does not operate properly due to suspected carburetor problems, take your lawn mower to an authorized service center for repair and/or adjustment. IMPORTANT: Never tamper with the engine governor, which is factory set for proper engine speed. Overspeeding the engine above the factory high speed setting can be dangerous. If you think the engine-governed high speed needs adjusting, contact your nearest authorized service center, which has proper equipment and experience to make any necessary adjustments. 15
Immediately prepare your lawn mower for storage at the end of the season or if the unit will not be used for 30 days or more. LAWN MOWER When lawn mower is to be stored for a period of time, clean it thoroughly, remove all dirt, grease, leaves, etc. Store in a clean, dry area. ⢠Clean entire lawn mower (See "CLEANING" in the Maintenance "section of this manual). ⢠Lubricate as shown in the Maintenance section of this manual. ⢠Be sure that all nuts, bolts, screws, and pins are securely fastened. Inspect moving parts for damage, breakage and wear. Replace if necessary. ⢠Touch up all rusted or chipped paint surfaces; sand lightly before painting. HANDLE You can fold your lawn mower handle for storage. ⢠Squeeze the bottom ends of the lower handle toward each other until the lower handle clears the handle bracket, then move handle forward. ⢠Loosen upper handle mounting bolts enough to allow upper handle to be folded back. IMPORTANT: When folding the handle for storage or transportation, be sure to fold the handle as shown or you may damage the control cables. ⢠When setting up your handle from the storage position, the lower handle will automatically lock into the mowing .position. Lower handle Squeeze to fold Handle bracket Hairpin cotter Operator presence control bar Upper Handle -_ //,,,._P_)_ Fold _/_'_----_ ,"_ forward for __.__,_';;'_'/J storage __, ,J_ Fold \ backward "__ Mowing Lower handle position ENGINE FUELSYSTEM IMPORTANT: It is important to prevent gum deposits from forming in essential fuel system parts such as carburetor, fuel filter, fuel hose, or tank during storage. Also, experience indicates that alcohol blended fuels (called gasohol or using ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. ⢠Drain the fuel tank. ⢠Start the engine and let it run until the fuel lines and carburetor are empty. ⢠Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur. ⢠Use fresh fuel next season. NOTE: Fuel stabilizer is an acceptable alternative in minimizing the formation of fuel gum deposits during storage. Add stabilizer to gasoline in fuel tank or storage container. Always follow the mix ratio found on stabilizer container. Run engine at least 10 minutes after adding stabilizer to allow the stabilizer to reach the carburetor. Do not drain the gas tank and carburetor if using fuel stabilizer. ENGINEOIL Drain oil (with engine warm) and replace with clean engine oil. (See "ENGINE" in the Maintenance section of this manual). CYLINDER ⢠Remove spark plug. ⢠Pour one ounce (29 ml) of oil through spark plug hole into cylinder. ⢠Pull starter handle slowly a few times to distribute oil. 16 ⢠Replace with new spark plug.
OTHER ⢠Do not store gasoline from one season to another. ⢠Replace your gasoline can if your can starts to rust. Rust and/or dirt in your gasoline will cause problems. ⢠If possible, store your unit indoors and cover it to give protection from dust and dirt. ⢠Cover your unit with a suitable protec- tive cover that does not retain moisture. Do not use plastic. Plastic cannot breathe which allows condensation to form and will cause your unit to rust. TROUBLESHOOTING CHART PROBLEM CAUSE CORRECTION Does not start 1. Dirty air filter. Loss of power Poor cut - uneven IMPORTANT: Never cover mower while engine and exhaust areas are still warm. ACAUTION: Never store the lawn mower with gasoline in the tank inside a building where fumes may reach an open flame or spark. Allow the engine to cool before storing in any enclosure. 2. Out of fuel. 3. Stale fuel. 4. Water in fuel. 5. Spark plug wire is disconnected. 6. Bad spark plug. 7. Loose blade or broken blade adapter. 8. Control bar in released position. 9, Control bar defective. 1. Rear of lawn mower housing or cutting blade dragging in heavy grass. 2. Cutting too much grass. 3. Dirty air filter. 4. Buildup of grass, leaves, and trash under mower. 5. Too much oil in angine. 6. Walking speed too fast. 1. Wom, bent or loose blade, 2. Wheel heights uneven. 3. Low engine speed 4. Buildup of grass, leaves and trash under mower. 1. Clean/replace air filter. 2. Fig fuel tank, 3. Drain tank and refill with fresh clean fuel. 4. Drain fuel tank and carburetor and refill tank with fresh gasoline. 5. Connect wire to plug. 6. Replace spark plug. 7. Tighten blade bolt or replace blade adapter. 8. Depress control bar to handle. 9. Replace control bar. 1. Set to "Higher Cut" position, 2. Set to 'l-ligher Cur' position. 3. Clean/replace air filter. 4. Clean underside of mower housing. 5. Check oil level. 6. Cut at slower walking speed. 1. Replace blade. TKjhten blade bolt. 2. Set all wheels at same height 3. Contact an authorized center/ department 4. Clean _-_lemide of mower housing. 17
TROUBLESHOOTING CHART PROBLEM CAUSE Excessive vibration Starter rope hard topull Loss of drive Gross catcher hot filling (if so equipped) Hard to push 1. Worn, bent or loose blade. 2. Bent engine crankshaft. 1. Engine flywheel brake is on when control bar is released. 2. Bent engine crankshaft. 3. Blade adapter broken. 4. Blade dragging in grass. 1. Drive wheels not tuming with drive control engaged. 2. Belt not driving 1. Cutting height tee low. 2. Lift on blade wom off. 3. Catcher not venting air. 4. Low engine speed 1. Grass is too high or wheel height is too low. 2. Rear of lawn mower housing or blade dragging in grass. 3, Grass catcher too full. 4. Handle height position not right for you, CORRECTION 1. Replace blade. ]]ghten blade bolt. 2. Contact an authorized service center. 1. Depress control bar to upper handle before pulling starter rope. 2. Contact an authorized service center. 3. Replace blade adapter. 4. Move lawn mower to cut grass or to hard surface. 1. Adjust or replace drive control cable. 2. Put belt on pulleys or replace belts if broken. 1. Raise cutting height. 2. Replace blade. 3. Clean grass catcher. 4. Set throttle to fast position. 1. Raise cutting height. 2. Raise rear of lawn mower housing one (1) setting higher. 3. Empty grass catcher. 4. Adjust handle height to suit. 18
36
ROTARY LAWN MOWER -- MODEL NO. 917.379480 GEAR CASE ASSEMBLY PART NUMBER 702511 s J 14 KEY NO. 2 3 4 6 7 8 9 PART NO. 17490416 137055X004 137053 57072 48373 77881 137051 137074 DESCRIPTION KEY PART NO. NO. DESCRIPTION Tapping Screw 1/4-20 x 10 57079 HardenedWasher 1-1/4 11 131484 Clutch Yoke Engagement Bracket 12 700343 Bushing Shifter 13 86447 Plug Seal 14 137050 Helical Gear Gear Case Halves Kit 15 750436X Clutch Jaw (includes Key Nos, 4, 15 750369 Grease and 7) 17 12000003 E-Ring Beadng 18 850848 Hi-ProKay Worm Shaft 19 81585X004 Spring Bracket Drive Shaft NOTE: All component dimensions given in U.S. inches. 1 inch = 25.4 mm 37
ROTARY LAWN MOWER MODEL.NUMBER 917.379480 78 57 27 25 13 10 14 12 10, .J < < 15 3O 2O 37 52 72 22 1_23 35 37 30 27 28 29 41 13
ROTARY LAWN MOWER MODEL NUMBER 917.379480 KEY NO. PART NO. DESCRIPTION KEY PART NO. NO. DESCRIPTION 1 2 4 5 6 8 9 10 11 12 13 14 15 16 17 18 20 22 23 25 27 28 29 3O 31 32 34 35 37 39 40 41 44 169933X479 130861 150425 66426 136376 169936 170947 128415 15O050 STD512505 150191 156374X479 700365X479 1331g0x479 140661X479 63601 140540 84596 87677 83923 150341 142748 62335 145935X004 701037 700331 X004 146630 700325X007 150078 173569X479 173570X479 150406 172835 46 851514 Upper Handle 47 141114 Engine Zone Control Cable 48 851074 Mulcher Plug 49 850263 WireTie 50 851084 Handle Knob 51 170031 Control Bar 52 85463 Rear Door Kit 55 751592 Pop Rivet 56 88652 Self Tapping Screw #10-24 x 5/8 57 51793 Hex Tapping Screw w/Seres 1/4-20 x 1/2 58 151590X479 Hubcap 59 171407 Back Plate 61 132001 Side Baffle 62 134612 Discharge Baffle 64 ...... Rear Baffle Keps Locknut 1/4-20 65 17600406 Rear Skirt 66 163340 Engine Pulley 67 144929 HI-Pro Key #505 71 170939 Hex Flange Nut 72 170938 Wheel 73 165912 Shoulder Bolt 3/8-16 x 1 78 170954 Washer 79 170953 Axle Arm Assembly 80 170554 Selector Knob 81 170955 Selector Spdng 82 170956 Spacer - - 161058 Wheel Adjusting Bracket - - 172340 Thread Cutting Screw w/Seres 5/16-18 x 3/4 Handle Bracket Assembly (Left) Handle Bracket Assembly (Right) Hex H_ad Thread Rolling Screw 3/8-16 x 1-1/8 Lawn Mower Housing (Incl. Key #14, 15, 51) Blade Adapter Blade 22' Hardened Washer Helical Washer 3/8-24 x 1-3/8 Gr. 8 Hex Head Machine Screw 3/8-24 x 1-3/8 Gr. 8 Front Baffle Kit Danger Decal Locknut 3/8-16 Hinge Screw 1/4o20 x 1-1/4 HeirpinCotter Lower Handle Handle Bolt RopeGuide Debds Shield Engine - (See Engine Breakdown) Model Honda GCV160A1A Screw Hx Serrated 1/4 x 20 Throttle control Screw Spring RH Spring LH Bolt Handle Adjuster, Outside, LH Handle Adjuster, Inside, LH Handle Adjuster Spnng Handle Adjuster, Inside, RH Handle Adjuster, Outside, RH Waming Decal (Not Shown) Owner's Manuel (EnglisWSpanish) Available accessories not included with lawn mower: -- D/98 33313 Clipping Deflector -- 71 33623 Gas Can -- 71 33500 Fuel Stabilzer - - 71 33300 SAE 30W Oil (20 oz.)
ROTARY LAWN MOWER MODEL NUMBER 917.379480 54 53 14 18 12 ⢠° 14 15 13 16 11 / 13
ROTARY LAWN MOWER MODEL NUMBER 917.379480 KEY NO. 1 ⢠3 4 5 6 8 9 11 12 13 14 15 16 18 26 PART NO. 146323 751152 158755 146527 150495 150182 145212 15O340 1200OO58 137054 88O8O 88118 67725 701037 143603 KEY PART DESCRIPTION NO. NO. Control Cable Assembly 28 154990 Locknut #10-24 31 132010 Pan Head Machine Screw 1/4 x 2.12 32 137052 V-Belt 35 151521 Spring Retainer 36 702511 Hubcap 37 137090 Flanged Nut 38 63601 Wheel & Tire Assembly 40 75192 E-Ring 41 151520 Pinion 53 169931 Dust Cover 54 169932 Felt Washer 55 86012 Washer 1/2 x 1-1/2 x .134 Selector Knob Pan Head Tapping Screw #10-24 x 2-3/4 DESCRIPTION Drive Cover Hex Flange Nut Drive Pulley Wheel Adjuster Assembly (Left) Gear Case Assembly Spnng Nut Spring Wheel Adjustor Assembly (Right) Frame Grassbag Assembly Driveshaft Cover
HONDA 4-CYCLE ENGINE MODEL NO. GCV160-A1A CONTROL I CAMSHAFT I CARBURETOR I 11 10 t 14 4 42
HONDA 4-CYCLE ENGINE MODEL NO. GCV160-A1A _FANCOVERJ I 6_ 13 13 FLYWHEEL I 1 3 5 7 14 5 nn , i ,n RECOIL STARTER I 1 l AIR CLEANER 43
HONDA 4-CYCLE ENGINE MODEL NO. GCV160-A1A 4 44
HONDA 4-CYCLE ENGINE MODEL NO. GCV160-A1A CONTROL KEY PART NO. NO. DESCRIPTION 1 5580311 Arm, Governor 2 5580329 Rod, Governor 3 5580345 Spring, Governor 4 5580352 Spring, Throttle Return 5 4439428 Spring, Lever 6 0800466 Holder, Cable 7 5580378 Base Comp., Control Use up to sn 1177559. 7 6094122 Base Comp., Control Use from sn 1177560. 8 5580386 Rod, Choke 9 2418671 Bolt, Governor Arm 10 5580998 Bolt, Flange (6x45) (ct200) 11 0145557 Screw, Pan (5x16) 12 0471623 Nut, Flange (6mm) CAMSHAFT PULLEY KEY PART NO. NO. DESCRIPTION 1 5580055 2 5580063 3 5580071 4 5580089 5 5580097 6 5580105 7 5580113 8 5580121 9 5580139 10 1426980 11 0294819 12 0004598 13 0018044 13 2373447 Pulley Comp., Camshaft Shaft, Cam Pulley Belt, Timing Arm In. Valve Rocker Arm, Ex. Valve Rocker Shaft Rocker Arm Valve, In. Valve, Ex. Spring, Valve Retainer, In. Valve Spring Screw, Tappet Adj. Nut, Tappet Adj. O-ring O-ring CARBURETOR KEY PART NO. NO. 1 3088416 2 5580162 3 4930756 4 4481818 5 1441518 6 5580170 7 5664552 8 5580212 9 5580220 10 5580238 11 5580246 12 4581120 13 5580253 14 5580535 15 0639419 15 3344520 16 0635474 16 0635482 16 0636126 DESCRIPTION Gasket Set Float Set Chamber Set, Float Screw Set Screw Set Screw Set Carburetor assy. Valve Float Nozzle Main Insulator, Carburetor Gasket, Insulator Gasket, Carburetor Gasket, Carburetor Guide Comp., air Screw, Pan (5x6) Screw, Pan (5x6) Jet, Main #60 (optional) Jet, Main #62 (optional) Jet, Main #65 (optional) 45
HONDA 4-CYCLE ENGINE MODEL NO. GCV160-AIA FAN COVER KEY PART NO. NO. 1 3683646 2 5028923 3 5580394 4 5580451 5 5580469 6 5580519 7 5580527 8 2499440 9 5581004 10 0671636 11 2449593 12 0250647 13 0250985 14 0053447 FLYWHEEL KEY PART NO. NO. 1 0348433 2 5580659 3 5723747 4 5580675 5 5580683 6 5580782 7 5580790 8 0803619 9 1725050 10 0671552 11 0442038 12 1824630 13 0485946 14 1510361 AIR CLEANER KEY PART DESCRIPTION NO. NO. DESCRIPTION Rubber, Supporter 107 mm 1 5580154 Petcock Assy. Man 2 5580402 Bracket, Petcock 3 5581410 Cap Assy., Fuel Tank 5 5664560 Tube, Fuel 6 5580444 Cover Comp., Fan NH1 Black 7 5580964 Coller, Fan Cover 8 2374742 Collar, Ft. Turn Signal Bolt, Stud Screw-Washer 5X10 RECOIL STARTER Bulk Hose, Fuel Clip, Tube (B8) KEY PART Clip, Tube (B10) NO. NO. Clip, Tube (C9) DESCRIPTION Key, Special Woodruff (25X18) Coil Assy., Ignition FlywheelAssy. Wire, Stop Switch Switch Assy., Engine Stop Brake Assy. Spring, Brake Lever Bolt Range (6X14) Bolt, Flange (6X23) Bolt, Flange (6X20) Nut, Special 14mm Clip Cable Screw-Washer (4X12) Washer, Plain Tube, Breather Element, Air Cleaner Case Assy., Air Cleaner Gasket, Air Cleaner Cover, Air Cleaner Bolt, Flange (6X86) Bolt, Flang8 (6X14) DESCRIPTION 2 3 4 5597869 5580634 5580642 2866341 Starter Assy., Recoil NH1 Long Rope Black Knob, Recoil Starter Rope, Recoil Starter Nut, Flange 6ram 46
HONDA 4-CYCLE ENGINE MODEL NO. GCV160-AIA II II ⢠CYLINDER BARREL KEY PART NO. NO. 1 5579982 2 2399780 3 5579990 4 5580006 5 0636845 6 0803619 7 5581038 8 1441112 DESCRIPTION Cylinder Assy. Clip, Valve Guide Cover, Head Cover Comp., Breather Bolt, Flange (6X12) Bolt, Flange (6X14) Oil Seal 25.4X62X6 Spark Plug (BPR6ES NGK) OIL PAN KEY PART NO. NO, 1 5579974 2 4497947 4 5580261 5 5580279 6 5580287 7 5580295 8 1427244 9 1427251 10 5580303 11 0803619 12 0748111 13 2413862 14 2456697 15 5581046 16 0345900 17 0115527 18 1417369 19 5722996 DESCRIPTION Pan Assy., Oil Gasket, Oil Filler Cap Shaft Comp., Governor Holder Governor Assy. Weight, Governor Holder, Governor Weight Pin, Governor Weight Slider, Governor Shaft, Governor Arm Bolt Flange (6X14) Bolt, Flange (6X25) Washer, Thrust 6ram Clip, Governor Holder Oil Seal (28X41.25X6) Washer, Plain 6mm Pin, Lock 8mm Pin Dowel (8X20) Gauge Assy., Oil Leve CRANKSHAFT KEY PART NO. NO. 1 5580030 5 5581012 DESCRIPTION Crankshaft Comp. (N1-Type) Washer Thrust PISTON CONNECTING ROD KEY PART NO. NO. DESCRIPTION 1 2 3 4 5 6 6 5580014 1426576 5580022 1431055 2605517 5655949 5655956 Piston Pin, Piston Rod Assy., Connecting Bolt, Connecting Rod Clip, Piston Pin 13mm Ring Set, Piston (Riken) Ring Set, Piston (Teikoku) MUFFLER 1 5580485 2 5580501 3 5580972 4 0636845 5 5737457 DESCRIPTION Muffler Comp. Protector, Muffler Bolt, Flange (6X79) CT200 Bolt, Flange (6X12) Gasket, Muffler (Optional) 47
For repair of major brand appliances in your own home... no matter who made it, no matter who sold it! 1"800-4-MY-HOME s" Anytime, dayor night (1-800-469-4663) www.sears.com To bring in products such as vacuums, lawn equipment and electronics for repair, call for the location of your nearest Sears Parts & Repair Center. 1-800-488-1222 Anytime, day or night www.sears.com iiiiiiii!iii_iiii iiii!!iiiii!iiii ii!!!!i!iii_iiii iii!!:ii!i!iiiii_i iii_iiiiii!_i!_!i! i!ii_!iiiiiiiiiill iii[_!iiiii]i!!!i iiiii!iiiiiiiiii iii!iiiiiiiill iiiii!iiii!i_iiiii iii_i!ilil]ii_ill iii!iiiii_i_iill For the replacement parts, accessories and owner's manuals ................ ⢠::: : that you need to do-it-yourself, call Sears PartsDirectSM! 1 800 366 PART " " " 6 a.m. - 11 p.m. CST, iii i!!iiiiiiiiii! (1-800-366-7278) 7 days a week :_ ............ www. sears . com/partsdirect ::: iliiiiiiiii!ili_ To purchase or inquire about a Sears Service Agreement: !_ii[ii!i!ii!!i !:ii:i_i:i:! i ! 1 800 827 6655 '"_ ...... ⢠= m m : ¢::i: 7 a.m. - 5 p.m. CST, Mon.- Sat. Para pedir servido de reparaciSn a dornicilio, y para ordenar piezas con entrega a domicilio: 1-888-SU-HOGAR = (1-888-784-6427 HomeCentral =' Au Canada pour service en francis: 1-877-LE-FOYER _ (1-877-533-6937) © Seam, Roebuck and Co. ® Registered Trademark / _ Trademark of Seam, Roebuck and Co. ® Merca Registrada / TM Mama de Rtbdca de Seam, Roebuck and Co. 172340 2.11.00 TR Printed in U.S.A.