Yard Machines 540 manual

O PERA T OR’S M ANU AL IMPOR T ANT : READ SAFETY R ULES AND INSTR UCTIONS CAREFULL Y MTD PR ODUCTS INC. P .O . BO X 368022 CLEVELAND, OHIO 44136-9722 21” T wo-in-One Mulching Mo wer 540 Ser ies PRINTED IN U .S .A. FORM NO . 770-0912A Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimprov[...]

2 Content Page Safe Operation Practices ......................................................................... 3 Slope Guage ............................................................................................ 5 Finding Model Number............................................................................. 6 Unpacking .................[...]

3 1. GENERAL OPERATION • Read this owner’s guide carefully in its entirety before attempting to assemble this machine. Read, understand, and follow all instructions on the machine and in the manual(s) before operation. Be completely familiar with the controls and the proper use of this machine before operating it. Keep this manual in a safe pla[...]

4 DO: • Mow across the face of slopes; never up and down. Exercise extreme caution when changing direction on slopes. • Watch for holes, ruts, hidden objects, or bumps. Tall grass can hide obstacles. • Always be sure of your footing. A slip and fall can cause serious personal injury. If you feel you are losing your balance release the blade c[...]

5 SECTION 1: SLOPE GAUGE Use this page as a guide to determine slopes where you may not operate safely. 15o SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE A POWER POLE A CORNER OF A BUILDING OR A FENCE POST FOLD ON DOTTED LINE, REPRESENTING A 15 o SLOPE WARNING Do not mow on inclines with a slope in excess of 15 degrees (a rise of approximately 2-1[...]

6 SECTION 3: FINDING MODEL NUMBER This owner’s guide is an important part of your new Yard-Machine lawn mower. It will help you to assemble, prepare and maintain your mower. Please read and understand what it says. Before you start assembling the mower for its first use, please locate its model plate and copy the information on to this owner’s [...]

7 SECTION 5: SETTING UP MOWER T ools Required • Pair of Pliers • Funnel • Set of adjustable wrenches Disconnecting Spark Plug • Before setting up your lawn mower, disconnect the spark plug wire from the spark plug, and ground it against the engine. See Figure 3. • If the engine is equipped with the optional rubber boot, attach the boot to[...]

8 • Raise the lower handle in the direction shown in Figure 4 (step 2) till it snaps into place. • Raise the upper handle in the direction shown in Figure 4 (step 3). Tighten the wing nuts which are already on the handle. See Figure 5A. Note: Make sure to route the cables inside the lower handle. Also do not crimp the cables while lifting the h[...]

9 Following parts are included with a hard top grass bag: front frame, rear frame, grass bag, hardtop cover, mounting bracket, phillips screw and hex lock nut. Assemble soft grass bag as f ollo ws: NOTE: Make certain bag is turned right side out before assembling (warning label will be on the outside) . • Join the rear frame and front frame assem[...]

10 Attaching Grasscatcher to Mo wer NOTE: Your mower was shipped with the rear mulching baffle in place on the mower. Remove the mulching baffle in order to install and use the grass catcher. For instructions on how to bag the grass clippings, please refer to page 14 of this manual. • Lift the rear discharge door and remove the rear mulching baff[...]

11 • Slide the two hooks on the side discharge chute under the hinge pin on the mulching plug assembly. See Figure 11. Lower the mulching plug. Do not remove the mulching plug at any time, even when you are not mulching. FIGURE 11 WARNING: Never operate the mower unless the hooks on the grass catcher are firmly seated in the slots on the handle b[...]

12 Recoil Starter The recoil starter is attached to the handle. Stand behind the unit and pull the recoil starter to start the unit. Primer The primer is used to pump gas into the carburetor. Use it to start a cold engine, but do not use it to restart a warm engine after short shutdown. Refer to engine manual for illustration. Blade Control Handle [...]

13 FIGURE 13 • Attach spark plug wire to spark plug. Make certain the metal cap on the end of the spark plug wire is fastened securely over the metal tip on the spark plug. • To prevent the unit from sliding, place your foot firmly against the tire. • Move throttle control all the way forward. This step is not applicable in case of mowers wit[...]

14 Bagging Grass Clippings FIGURE 14 You can use the grasscatcher bag to collect clippings while you are operating the mower. Attach the grasscatcher following instructions on page 10 of this manual. Operate the mower till the grass bag is full, or the job is completed whichever is earlier. Stop the engine completely by releasing the control lever.[...]

15 WARNING: Never tip the mower more than 90 degrees and do not leave the mower tipped for any length of time. Oil can drain into the upper part of the engine causing a starting problem. Lubrication For complete lubrication chart, see Figure 15. Wheels • Lubricate the wheels and bearings, if so equipped, at least once a season with light oil or e[...]

16 • Clean the engine periodically. Remove dirt and debris with a cloth or brush. We do not recommend using a garden hose to clean mower unless the muffler, air filter and the carburetor are covered to keep water out. Water in engine can shorten engine life. • Clean the spark plug and reset the gap to .030” at least once a season or every 50 [...]

17 IMPORTANT: The bolt, used to secure the blade to the engine, is specially heat-treated. Do not substitute. To order replacement bolt, refer to the Parts List section of this manual. WARNING: To ensure safe operation of your unit, all nuts and bolts must be checked periodically for correct tightness. To Sharpen Blade: • The blade can be sharpen[...]

18 • Push the throttle control lever on the handle all the way forward as far as it will go, then back it off one “click.” Make certain the throttle control lever remains in this position. • Push the control lever on the engine as far toward the rear of the engine as it will go. Secure the cable in this position with the cable clamp and scr[...]

19 Other • Do not store gasoline from one season to another. • Replace your gasoline can if it starts to rust. Rust and/or dirt in the gasoline will cause problems. Store unit in a clean, dry area. Do not store next to corrosive materials, such as fertilizer. NOTE: If storing in an unventilated or metal storage shed, be certain to rustproof the[...]

20 SECTION 12: REPAIR PARTS 1 19 2 11 3 9 25 8 10 7 13 6 14 20 23 67 53 58 88 89 90 30 31 73 76 75 36 32 34 33 70 59 45 44 80 50 55 56 39 82 39 40 85 83 84 63 64 72 71 60 44 43 42 41 93 16 17 Remote Throttle Assembly F ix e d Throttle Assemb ly 68 24 26 81 87 94 86 87 92 74 69 12 4 15 18 47 51 54 61[...]

21 Ref . No . P art No. Code Description 1 747-0824 Control Handle Assembly 2 710-1205 Rope Guide 3 720-0279 Handle Knob 4 710-1174 Curved Hd. Bolt 5/16-18 x 2” 6 720-0276 Hand Knob 7 710-0605 Oval C-Sunk Screw 8 736-0501 Spring Washer 9 712-0324 Hex Lock Nut 1/4-20 Thd. 10 746-0876 Throttle Lever 11 749-0438B N Upper Handle 12 720-0295 N Foam Gr[...]

22 68 710-0871 Hex Slot Sems Scr. (Tec.) 710-1237 Hex Washer Hd. Screw (B&S ) 69 710-1174 Carr. Bolt 5/16-18 x 2.0 70 736-0182 N Wave Washer 71 736-0105 Spring Washer 72 731-1426 731-0982A 731-0981A Hub Cap: Radial Yellow Hub Cap: Radial Beige Hub Cap: Radial Grey 73 738-0481 N Rear Axle Bolt 74 731-0066 731-0068 Hardtop Cover: Grass bag ( w/lo[...]

23 SECTION 14: SHROUD CHART P ar t No . 751B281439 751B281440 751B281443 Color Dark Red Black Bright Red P ar t No . 731-1395A 731-1396A 731-1397A Color Red Black Gra y P ar t No . 731-1587A 731-1603A 731-1610A 731-1620A Color Black Y ellow P e wter Gra y P ar t No . 731-1561 Color Black Hardware: 710-1256 (Screw) Hardware: 710-1256 (Screw) Hardwar[...]

MANUF A CTURER’S LIMITED W ARRANTY FOR: For TWO YEARS from the date of retail purchase within the United States of America, its possessions and territories, MTD PRODUCTS INC will, at its option, repair or replace, for the original purchaser, free of charge, any part or parts found to be defective in material or workmanship. This warranty covers u[...]