Exmark Lawn Mower COMMERCIAL 21 User Manual

COMMERCIAL 21  
For Serial Nos.  
312,000,000 & Higher  
Part No. 4500-927 Rev. A  
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Introduction  
CONGRATULATIONS on the purchase of your  
Exmark Mower. This product has been carefully  
designed and manufactured to give you a maximum  
amount of dependability and years of trouble-free  
operation.  
This manual contains operating, maintenance,  
adjustment, and safety instructions for your Exmark  
mower.  
BEFORE OPERATING YOUR MOWER,  
CAREFULLY READ THIS MANUAL IN ITS  
ENTIRETY.  
Figure 1  
1. Model and serial number location  
By following the operating, maintenance, and safety  
instructions, you will prolong the life of your mower,  
maintain its maximum efficiency, and promote safe  
operation.  
Model No.  
Serial No.  
If additional information is needed, or should  
you require trained mechanic service, contact your  
authorized Exmark equipment dealer or distributor.  
Exmark parts manuals are available online at  
All Exmark equipment dealers and distributors are  
kept informed of the latest methods of servicing  
and are equipped to provide prompt and efficient  
service in the field or at their service stations. They  
carry ample stock of service parts or can secure them  
promptly for you from the factory.  
All Exmark parts are thoroughly tested and inspected  
before leaving the factory, however, attention is  
required on your part if you are to obtain the fullest  
measure of satisfaction and performance.  
Whenever you need service, genuine Exmark parts,  
or additional information, contact an Authorized  
Service Dealer or Exmark Customer Service and have  
the model and serial numbers of your product ready.  
Figure 1 identifies the location of the model and serial  
numbers on the product. Write the numbers in the  
space provided.  
3
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Contents  
Periodic Maintenance ........................................22  
(Self-Propelled Units Only).........................28  
(Self-Propelled Units Only).........................30  
4
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Safety  
Safe Operating Practices  
Safety  
Safety Alert Symbol  
This lawn mower meets or exceeds the Consumer  
Product Safety Commission (CPSC) blade safety  
requirements for walk-behind rotary mowers and  
the B71.4 specifications of the American National  
Standards Institute in effect at the time of production.  
Training  
• Read the Operator’s Manual and other training  
material. If the operator(s) or mechanic(s) can  
not read English it is the owner’s responsibility to  
explain this material to them.  
• Become familiar with the safe operation of the  
equipment, operator controls, and safety signs.  
Exmark designed and tested this lawn mower to offer  
reasonably safe service; however, failure to comply  
with the following instructions may result in personal  
injury.  
• All operators and mechanics should be trained.  
The owner is responsible for training the users.  
• Never let children or untrained people operate  
or service the equipment. Local regulations may  
restrict the age of the operator.  
This Safety Alert Symbol (Figure 2) is used both in  
this manual and on the machine to identify important  
safety messages which must be followed to avoid  
accidents.  
• Only adults and mature teenagers should operate  
a mower, and even mature teenagers should have  
adult supervision. Be sure a teenager:  
This symbol means: ATTENTION! BECOME  
ALERT! YOUR SAFETY IS INVOLVED!  
1. has read and understands the Operator's  
Manual and recognizes the risks involved;  
2. is sufficiently mature to use caution; and  
3. is of sufficient size and weight to operate  
the controls comfortably and to manage the  
mower without taking risks.  
Figure 2  
Safety Alert Symbol  
• The owner/user can prevent and is responsible  
for accidents or injuries occurring to himself or  
herself, other people or property.  
The safety alert symbol appears above information  
which alerts you to unsafe actions or situations  
and will be followed by the word DANGER,  
WARNING, or CAUTION.  
Preparation  
• Evaluate the terrain to determine what accessories  
and attachments are needed to properly and  
safely perform the job. Only use accessories and  
attachments approved by Exmark.  
DANGER: White lettering / Red background.  
Indicates an imminently hazardous situation which, if  
not avoided, Will result in death or serious injury.  
• Wear appropriate clothing including safety glasses,  
substantial footwear, long trousers, and hearing  
protection. Do Not operate when barefoot or  
when wearing open sandals. Long hair, loose  
clothing or jewelry may get tangled in moving  
parts.  
WARNING: Black lettering / Orange background.  
Indicates a potentially hazardous situation which, if  
not avoided, Could result in death or serious injury.  
CAUTION: Black lettering / Yellow background.  
Indicates a potentially hazardous situation which, if  
not avoided, May result in minor or moderate injury.  
CAUTION  
This manual uses two other words to highlight  
information. Important calls attention to special  
mechanical information and Note emphasizes  
general information worthy of special attention.  
This machine produces sound levels in excess  
of 85 dBA at the operator’s ear and can cause  
hearing loss through extended periods of  
exposure.  
Wear hearing protection when operating this  
machine.  
5
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Safety  
• Inspect the area where the equipment is to be  
used and remove all rocks, toys, sticks, wires,  
bones, and other foreign objects which can be  
thrown by the machine and may cause personal  
injury to the operator or bystanders.  
DANGER  
In certain conditions during fueling, static  
electricity can be released causing a spark  
which can ignite gasoline vapors. A fire or  
explosion from gasoline can burn you and  
others and cause property damage.  
DANGER  
In certain conditions gasoline is extremely  
flammable and vapors are explosive.  
• Always place gasoline containers on the  
ground away from your vehicle before  
filling.  
A fire or explosion from gasoline can burn  
you, others, and cause property damage.  
• Do Not fill gasoline containers inside a  
vehicle or on a truck or trailer bed because  
interior carpets or plastic truck bed liners  
may insulate the container and slow the  
loss of any static charge.  
• Fill the fuel tank outdoors on level ground,  
in an open area, when the engine is cold.  
Wipe up any gasoline that spills.  
• Never refill the fuel tank or drain the  
machine indoors or inside an enclosed  
trailer.  
• When practical, remove gas-powered  
equipment from the truck or trailer and  
refuel the equipment with its wheels on  
the ground.  
• Do Not fill the fuel tank completely  
full. Add gasoline to the fuel tank until  
the level is 1/4 to 1/2 inch (6–13 mm)  
below the bottom of the filler neck. This  
empty space in the tank allows gasoline  
to expand.  
• If this is not possible, then refuel such  
equipment on a truck or trailer from a  
portable container, rather than from a  
gasoline dispenser nozzle.  
• If a gasoline dispenser nozzle must be  
used, keep the nozzle in contact with the  
rim of the fuel tank or container opening  
at all times until fueling is complete.  
• Never smoke when handling gasoline, and  
stay away from an open flame or where  
gasoline fumes may be ignited by spark.  
• Store gasoline in an approved container  
and keep it out of the reach of children.  
WARNING  
• Add fuel before starting the engine. Never  
remove the cap of the fuel tank or add  
fuel when engine is running or when the  
engine is hot.  
Gasoline is harmful or fatal if swallowed.  
Long-term exposure to vapors has caused  
cancer in laboratory animals. Failure to use  
caution may cause serious injury or illness.  
• If fuel is spilled, Do Not attempt to start  
the engine. Move away from the area of  
the spill and avoid creating any source of  
ignition until fuel vapors have dissipated.  
• Avoid prolonged breathing of vapors.  
• Keep face away from nozzle and gas  
tank/container opening.  
• Do Not operate without entire exhaust  
system in place and in proper working  
condition.  
• Keep away from eyes and skin.  
• Never siphon by mouth.  
• Check that the operator's presence controls,  
safety switches, and shields are attached and  
functioning properly. Do Not operate unless they  
are functioning properly.  
6
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Safety  
• Park the machine on level ground. Stop engine,  
wait for all moving parts to stop, and remove the  
spark plug wire(s).  
Operation  
WARNING  
Operating engine parts, especially the muffler,  
become extremely hot. Severe burns can occur  
on contact and debris, such as leaves, grass,  
brush, etc. can catch fire.  
– Before checking, cleaning or working on the  
mower.  
– After striking a foreign object or abnormal  
vibration occurs (inspect the mower for  
damage and make repairs before restarting  
and operating the mower).  
• Allow engine parts, especially the muffler, to  
cool before touching.  
• Remove accumulated debris from muffler and  
engine area.  
– Before clearing blockages.  
– Whenever you leave the mower.  
• Stop engine, wait for all moving parts to stop:  
– Before refueling.  
• Install and maintain in working order a  
spark arrester before using equipment  
on forest-covered, grass-covered, or  
brush-covered unimproved land.  
– Before dumping the grass catcher.  
– Before making height adjustments.  
WARNING  
Engine exhaust contains carbon monoxide,  
which is an odorless deadly poison that can kill  
you.  
WARNING  
Hands, feet, hair, clothing, or accessories can  
become entangled in rotating parts. Contact  
with the rotating parts can cause traumatic  
amputation or severe lacerations.  
Do Not run engine indoors or in a small confined  
area where dangerous carbon monoxide fumes  
can collect.  
• Do Not operate the machine without  
guards, shields, and safety devices in place  
and working properly.  
• Operate only in daylight or good artificial light,  
keeping away from holes and hidden hazards.  
• Start the engine carefully according to instructions  
with feet well away from the blade.  
• Keep hands, feet, hair, jewelry, or clothing  
away from rotating parts.  
• Never raise deck with blade running.  
• Keep clear of the discharge opening at all times.  
• Never operate the mower with damaged guards,  
shields, or covers. Always have safety shields,  
guards, switches and other devices in place and in  
proper working condition.  
• This mower was designed for one operator  
only. Keep all others away from mower during  
operation.  
• Never mow with the discharge door raised,  
removed or altered unless there is a grass  
collection system or mulch kit in place and  
working properly.  
DO NOT operate the mower when people,  
especially children, or pets are in the area.  
• Be alert, slow down and use caution when  
making turns. Look behind and to the side before  
changing directions.  
• Grass catcher components are subject to wear,  
damage and deterioration, which could expose  
moving parts or allow objects to be thrown.  
Frequently check the components and replace  
them with the manufacturer’s recommended parts  
when necessary.  
• Stop the blades, slow down, and use caution  
when crossing surfaces other than grass and when  
transporting the mower to and from the area to  
be mowed.  
• Be aware of the mower discharge path and direct  
discharge away from others.  
• Do Not change the engine governor setting or  
overspeed the engine.  
• Never attempt to make wheel height adjustments  
while the engine is running.  
• Do Not operate the mower under the influence  
of alcohol or drugs.  
7
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Safety  
• Use extreme care when loading or unloading the  
machine into a trailer or truck.  
• Keep engine and engine area free from  
accumulation of grass, leaves, excessive grease  
or oil, and other debris which can accumulate  
in these areas. These materials can become  
combustible and may result in a fire.  
• Use care when approaching blind corners, shrubs,  
trees, or other objects that may obscure vision.  
• Let engine cool before storing and Do Not store  
near flame or any enclosed area where open pilot  
lights or heat appliances are present.  
Slope Operation  
Use Extreme caution when mowing and/or turning  
on slopes as loss of traction and/or tip-over could  
occur. The operator is responsible for safe operation  
on slopes.  
• Shut off fuel while storing or transporting. Do  
Not store fuel near flames or drain indoors.  
• Park machine on level ground. Never allow  
untrained personnel to service machine.  
DANGER  
• Remove spark plug wire before making any  
repairs.  
Operating on wet grass or steep slopes can  
cause sliding and loss of control. Loss of control  
and/or loss of operator's footing could result in a  
fall with an arm or leg getting under the mower  
or engine deck which may result in serious injury,  
death or drowning.  
• Use care when checking blades. Wrap the blade(s)  
or wear gloves, and use caution when servicing  
them. Only replace damaged blades. Never  
straighten or weld them.  
• Mow across slopes, never up and down.  
• Do Not mow slopes when grass is wet.  
• Do Not mow near drop-offs or near water.  
• Do Not mow excessively steep slopes.  
• Keep hands and feet away from moving parts.  
If possible, Do Not make adjustments with the  
engine running.  
• Keep all guards, shields and all safety devices in  
place and in safe working condition.  
• Reduce speed and use extreme caution on  
slopes.  
• Check all bolts frequently to maintain proper  
tightness.  
• Avoid sudden turns or rapid speed changes.  
• Frequently check for worn or deteriorating  
components that could create a hazard.  
• When feasible, avoid operating the equipment in  
wet grass.  
WARNING  
• Progressively greater care is needed as the slope  
increases.  
Removing standard original equipment parts  
and accessories may alter the warranty, traction,  
and safety of the machine. Failure to use original  
Exmark parts could cause serious injury or  
death. Making unauthorized changes to the  
engine, fuel or venting system, may violate EPA  
and CARB regulations.  
• Remove or mark obstacles such as rocks, tree  
limbs, etc. from the mowing area. Tall grass can  
hide obstacles.  
• Watch for ditches, holes, rocks, dips and rises that  
change the operating angle, as rough terrain could  
overturn the machine.  
Replace all parts including, but not limited to,  
tires, belts, blades, and fuel system components  
with original Exmark parts.  
• Use extreme care with grass catchers or  
attachments. These can change the stability of the  
machine and cause loss of control.  
Maintenance and Storage  
• Stop the engine and remove the spark plug  
wire(s). Wait for all movement to stop before  
adjusting, cleaning or repairing.  
8
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Safety  
Safety and Instructional Decals  
• Keep all safety signs legible. Remove all grease,  
dirt and debris from safety signs and instructional  
labels.  
• New safety signs may be obtained from  
your authorized Exmark equipment dealer or  
distributor or from Exmark Mfg. Co. Inc.  
• Replace all worn, damaged, or missing safety  
signs.  
• Safety signs may be affixed by peeling off the  
backing to expose the adhesive surface. Apply  
only to a clean, dry surface. Smooth to remove  
any air bubbles.  
• When replacement components are installed, be  
sure that current safety signs are affixed to the  
replaced components.  
• Familiarize yourself with the following safety signs  
and instruction labels. They are critical to the safe  
operation of your Exmark commercial mower.  
• If an attachment or accessory has been installed,  
make sure current safety signs are visible.  
68-7410  
103-6327  
ECXHN21  
1. Choke–on  
2. Throttle–fast  
3. Continuous variable setting  
94-8072  
4. Throttle–slow  
109-8191  
ECXKABBC21, ECXKA21  
9
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Safety  
109-9317  
116-1922  
117–2718  
116-2737  
10  
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Specifications  
Specifications  
Model Numbers  
Serial Nos: 312,000,000 and Higher  
ECSKAP21; ECSKA21; ECXKA21; ECXHN21; ECXKABBC21; ECXHNBBC21  
Systems  
Safety Interlock System  
For units without a Blade Brake Clutch: Operator  
must have the blade control bail depressed to start  
the engine. Releasing the blade control bail will cause  
the engine to stop.  
Engine  
• Engine Specifications: See your Engine Owner’s  
Manual  
• Engine Oil Type: Exmark 4–Cycle Premium  
Engine Oil  
Transmission (Self Propelled Units)  
Variable  
• RPM: 3300 RPM (No Load)  
Speed Range: 0–4.2 mph (6.8 km/hr)  
Fuel System  
• Capacity:  
Cutting Deck  
ECSKA21 and ECSKAP21 Units:  
2.0 qt (1.9 L)  
• Cutting Width: 21 inches (53.3 cm)  
• Blade Brake: When the blade engagement control  
is moved to the disengaged position a friction  
brake pad stops the rotation of the blades.  
All other units: 4.0 qt (3.8 L)  
• Fuel Recommendations:  
– For best results, use only clean, fresh, unleaded  
gasoline with an octane rating of 87 or higher  
((R+M)/2 rating method).  
• Blade Size: (1 ea.): 20.88 inches (53.0 cm)  
• Deck: 21 inches rigid. Deck design allows for  
bagging, mulching or rear discharge.  
– Oxygenated fuel with up to 10% ethanol or  
15% MTBE by volume is acceptable.  
• Cutting Height Adjustment:  
Adjusts from 1 inch (2.5 cm) to 4 1/2 inches (11.4  
cm) in 1/2 inch (1.3 cm) increments.  
Do Not use ethanol blends of gasoline (such  
as E15 or E85) with more than 10% ethanol  
by volume. Performance problems and/or  
engine damage may result which may not be  
covered under warranty.  
• Mulching Kit: Standard on ECXKA21;  
ECXHN21; ECXKABBC21, and  
ECXHNBBC21 Units  
Do Not use gasoline containing methanol.  
Do Not store fuel either in the fuel tank or  
fuel containers over the winter unless a fuel  
stabilizer is used.  
Dimensions  
Curb Weight:  
Do Not add oil to gasoline.  
• Fuel Filter: Non-replaceable, in tank  
• Fuel Shut-Off Valve:  
98-122 lb (44-55 kg) Weights may vary slightly  
depending on engine option.  
ECSKA21 and ECSKAP21 Units Do Not have a  
shut-off valve.  
Overall Width:  
22 inches (55.9 cm)  
All other units have a shut-off valve.  
11  
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Product Overview  
Overall Length and Height at  
2 1/2 inch Cutting Height:  
Product Overview  
Handle Setting Length  
Height  
High  
61.00 inches  
(154.9 cm)  
39.00 inches (99.1  
cm)  
Medium  
Low  
63.00 inches  
(160.0 cm)  
37.50 inches (95.3  
cm)  
64.50 inches  
(163.8 cm)  
35.00 inches (88.9  
cm)  
Figure 3  
1. Grass bag  
2. Handle  
5. Discharge door  
6. Rear wheel height  
adjustment  
3. Drive Bail  
7. Front wheel height  
adjuster  
(Self-Propelled Units  
Only)  
4. Blade Control Bail  
12  
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Operation  
is depressed toward the handle. When this bail is  
released the unit will stop moving.  
Operation  
Note: Determine the left and right sides of the  
Throttle-Choke Lever (ECXHN21)  
machine from the normal operating position.  
Located on the left side of the handle bar.  
Controls  
The lever is used to control engine speed. Moving  
the throttle to the full forward (Choke) position will  
place the lever in the choke position. The choke aids  
in starting a cold engine. Moving the throttle control  
forward will increase engine speed and moving it to  
the rear will decrease engine speed.  
Blade Control Bail  
Located on the upper handle as shown in Figure 4.  
When the blade control bail is depressed, the system  
senses that the operator is in the normal operator's  
position.  
Choke Control (ECXHNBBC21)  
For Units with a Blade Brake Clutch: When  
the blade control bail is released, the system  
senses that the operator has moved from the  
normal operating position and will stop the blade.  
Located on the front left side of the engine as shown  
in Figure 9.  
The choke aids in starting a cold engine. Pulling  
outward will place the control in the choke position.  
Pushing the control inward shuts off the choke.  
For Units without a Blade Brake Clutch:  
When the blade control bail is released, the system  
senses that the operator has moved from the  
normal operating position and will kill the engine.  
Blade Control Lock Lever (Blade  
Brake Clutch Units Only)  
The blade control lock lever is located on the right  
side of the handle next to the Blade Control Bail as  
shown in Figure 4.  
Moving the blade control lock lever into the full  
forward position releases the blade control bail.  
Squeezing the blade control bail against the handle  
engages the blade. Releasing the blade control bail  
automatically disengages the blade. The blade control  
lock lever will reset to lock the blade control bail.  
Figure 4  
Engine Stop Switch  
Blade Brake Unit Shown  
Located on the left side of the engine in front of the  
fuel tank as shown in Figure 5. The engine stop switch  
is used on ECXHNBBC21 and ECXKABBC21 (see  
Figure 9 and Figure 10 ).  
1. Blade control lock lever (Blade Brake Units Only)  
2. Blade control bail  
3. Handle  
4. Drive bail (Self-Propelled Units Only)  
Press the switch to “STOP” to kill the engine. Press  
“|” before starting the engine.  
Self-Propel Drive Bail (Self-Propelled  
Units Only)  
Located on the upper handle as shown in Figure 4.  
When the self-propel drive bail is squeezed, the  
unit will move forward based on how far the bail  
13  
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Operation  
Figure 7  
1. Rotate clockwise to close  
2. Rotate counterclockwise to open  
On ECXHN21 and ECXHNBBC21 units, the fuel  
shut off valve is located on the engine as shown in  
Figure 8. Rotate 1/4 turn clockwise to shut off fuel.  
Rotate the valve 1/4 turn counterclockwise to turn  
on fuel.  
Figure 5  
Clear plastic cover removed for clarity  
1. Engine stop switch  
2. Press “STOP” to kill engine  
3. Press “I” before starting engine  
Fuel Shut-Off Valve  
The fuel shut off valve is located between the  
carburetor and the fuel tank. The fuel shut off valve  
shuts off the flow of fuel when the machine will  
not be used for a few days, when parking inside a  
building, and during transport to and from the job.  
Figure 8  
1. Fuel valve  
Pre-Start  
Fill fuel tanks. See Fuel Recommendations in  
the Specifications section for additional gasoline  
information.  
Do Not add oil to gasoline.  
Figure 6  
Kawasaki Unit  
Do Not overfill fuel tank. Fill the fuel tank to the  
bottom of the filler neck. The empty space in the  
tank allows gasoline to expand. Overfilling may result  
in fuel leakage or damage to the engine or emission  
system.  
1. Fuel valve  
On ECXKA21 and ECXKABBC21 units, rotate the  
valve 1/4 turn clockwise to shut off fuel. Rotate the  
valve 1/4 turn counterclockwise to turn on fuel.  
Make sure you understand the controls, their  
locations, their functions, and their safety  
requirements.  
Refer to the Maintenance section and perform all the  
necessary inspection and maintenance steps.  
14  
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Operation  
Operating Instructions  
Handle Adjustment  
The height of the handle can be adjusted for  
comfortable operation. Stand behind the handle to  
determine the height. To adjust the handle height,  
position the hardware into one of the three holes in  
the handle bracket.  
Open the Fuel Shut-Off Valve  
Rotate the valve 1/4 turn counterclockwise to turn  
the fuel on (if equipped).  
Figure 10  
Kawasaki units with large fuel tank shown  
1. Muffler  
2. Oil fill/dipstick  
Starting the Engine  
1. Connect the wire to the spark plug.  
3. Recoil starter handle (located on handle bar for zone  
start units)  
4. Fuel tank cap (fuel tank varies)  
5. Engine stop switch (if equipped)  
6. Oil filter (if equipped)  
7. Air cleaner  
8. Primer bulb  
9. Spark plug  
2. Open the fuel valve.  
3. For ECXKABBC21 Units: Turn the engine stop  
switch to “|” (see Figure 5).  
4. For Kawasaki Units: Press the primer bulb two  
Figure 9  
times (see Figure 11).  
Honda unit  
1. Muffler  
2. Oil fill/dipstick  
3. Fuel tank cap  
4. Recoil starter handle (located on handle bar for zone  
start units)  
5. Engine stop switch (if equipped)  
6. Air filter  
7. Choke (BBC only)  
Figure 11  
Throttle/Choke (located on handle bar for zone  
start units)  
8. Spark plug  
For ECXHNBBC21 Units: Turn the engine  
stop switch to “|” and pull outward on the choke  
control.  
For ECXHN21 Units: Move the choke/throttle  
control forward to the choke position.  
Note: Do Not use the choke when the engine  
is warmed up.  
15  
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Operation  
5. For units without a Blade Brake Clutch: Hold  
self-propels at the maximum ground speed.  
Release the drive bail to stop moving when you  
use the lawn mower for trimming or whenever  
you leave the lawn mower.  
the blade control bail to the handle.  
6. Pull the starter handle lightly until you feel  
resistance, then pull it sharply. Allow the rope to  
return slowly.  
3. To disengage the self-propel drive, release the  
drive bail.  
7. For ECXHNBBC21 Units: Gradually push in  
the choke control as the engine warms up.  
Note: The mower comes with freewheeling  
clutches which make it easier to pull the mower  
rearward. To disengage the clutches, you may  
need to push the mower forward one inch (2.5  
cm) or more after you release the self-propel drive  
bail.  
8. For ECXHN21 Units: When the engine starts,  
move the choke/throttle control back to the fast  
position.  
Stopping the Engine  
1. Bring the unit to a full stop.  
Operating the Blade Control Bail  
(Units Without Blade Brake Clutch)  
1. Squeeze the blade control bail against the handle.  
2. Start the engine.  
For units without a Blade Brake Clutch:  
Release the blade control bail. Both the  
engine and the blade should stop within three  
seconds.  
For units with a Blade Brake Clutch: Press  
the switch to “STOP” to kill the engine (see  
Figure 5).  
3. When the blade control bail is squeezed against  
the handle, the blade should engage.  
4. Release the blade control bail. Both the engine  
and the blade should stop.  
Note: If the blade does not stop within 3 seconds  
after releasing the blade control bail, contact an  
Authorized Service Dealer.  
Operating the Blade Control Lever  
(Blade Brake Clutch Units Only)  
1. Start the engine.  
2. Close the fuel shut-off valve, if equipped, when  
the machine will not be in use for a few days,  
when transporting, or when the unit is parked  
inside a building.  
2. Push and hold the blade control lock lever forward  
to release the blade control bail (Figure 12).  
Operating the Self-Propel Drive  
(Self-Propelled Units Only)  
The lawn mower is variable speed, the more you  
squeeze the drive bail the faster the machine travels.  
1. Start the engine.  
2. Squeeze the drive bail against the handle (see  
Figure 4).  
Figure 12  
Note: You can vary the ground speed by  
increasing or decreasing the distance between  
the ground speed control bail and the handle.  
Lower the control bail to decrease the ground  
speed when you are making a turn or if the lawn  
mower is moving too fast for you. If you lower  
the control bail too far the lawn mower stops  
self-propelling. Squeeze the ground speed control  
bail closer to the handle to increase the ground  
speed. When you hold the ground speed control  
bail tight against the handle, the lawn mower  
1. Blade control lock lever  
2. Locked position  
4. Push forward  
5. Unlocked position  
3. Blade control bail  
6. Squeeze against handle  
3. Squeeze the blade control bail against the handle  
and release the blade control lock lever; the blade  
should engage.  
4. Release the blade control bail to disengage the  
blade. The blade control lock lever will reset to  
lock the blade control bail.  
16  
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Operation  
Using the Mulch Plug  
1. Stop the engine and wait for all moving parts to  
stop.  
Occasionally you may wish to use the mulch plug to  
mulch the grass and leaf clippings back into the lawn.  
2. Move the lawn mower onto a paved surface in  
a non-windy area.  
• Installing the Mulch Plug:  
3. Set all four wheels to the 2 1/2 inches (6.4 cm)  
cutting height (see Figure 15 and Figure 16)  
1. Stop the engine and wait for all moving parts  
to stop.  
4. Take a half sheet of newspaper and crumple  
it into ball small enough to go under the deck  
(about 3 inches or 7.6 cm in diameter) as shown  
in Figure 14.  
2. Remove the grass bag if it is on the mower.  
3. Raise the discharge door and insert the mulch  
plug into the discharge opening. The lip on  
the plug will snap into the mower housing.  
Figure 14  
1. Crumpled newspaper  
2. 5 inches (12.7 cm)  
Figure 13  
5. Place the ball of newspaper 5 inches (12.7 cm) in  
front of the lawn mower.  
1. Mulch plug  
3. Lip  
2. Discharge door  
4. Mower housing  
6. Start the engine.  
7. Push the blade control lock lever forward to  
release the blade control bail (Figure 4).  
4. Lower the discharge door.  
• Removing the Mulch Plug:  
8. Squeeze the blade control bail against the handle.  
blade should engage.  
Note: When grass is thick and lush, clippings  
may collect on and around the discharge tunnel  
plug. This may make it difficult to remove the  
plug. Clean the plug thoroughly after each use.  
9. Release the blade control bail. You should hear a  
“bang.” The blade should stop in three seconds.  
The blade control lock lever should reset to lock  
the blade control bail.  
1. To remove the mulch plug, raise the discharge  
door and pull the mulch plug out of the  
discharge tunnel.  
10. Immediately push the lawn mower over the  
newspaper ball.  
2. Lower the discharge door.  
11. Stop the engine and wait for all moving parts to  
stop.  
Checking the Blade Brake Clutch  
(Blade Brake Clutch Units Only)  
12. Walk around the lawn mower to check for the  
newspaper ball. If the ball did not go under the  
deck, repeat steps 6 through 11.  
Check the Blade Brake Clutch (BBC) system before  
each use to ensure that it is operating properly.  
13. Pull the lawn mower away from the newspaper.  
If the newspaper ball unravels or is shredded,  
Normal Test:  
17  
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Operation  
the blade has not properly stopped, resulting  
in an unsafe operating condition. Contact an  
Authorized Service Dealer.  
WARNING  
Adjusting the cutting height levers could bring  
your hands into contact with a moving blade. A  
moving blade can cause serious injury.  
DANGER  
• Stop the engine and wait for all movement to  
stop before adjusting the cutting height.  
If the blade brake clutch system is inoperative,  
the blade will continue to rotate when you  
release the blade control bail. Contact with  
the blade could occur, causing serious injury.  
• Do Not put your fingers under the housing  
when adjusting the cutting height.  
• Check the BBC operation before each use.  
Rear Wheel Adjustment:  
• Never use the BBC-equipped lawn mower  
with an inoperative safety system.  
1. Pull the wheel height adjustment rod upward  
to release the pin from the notch in the  
adjustment bracket (Figure 15).  
• Take your lawn mower to an Authorized  
Service Dealer for repair if the safety  
system fails to operate properly.  
Test Using the Grass Bag  
1. Install the empty grass bag on the discharge  
tunnel.  
2. Start the engine.  
3. For units with a Blade Brake Clutch: Push the  
blade control lock lever forward to release the  
blade control bail (Figure 4).  
4. Squeeze the blade control bail against the handle.  
5. The bag should begin to inflate, indicating that  
the blade is engaged and rotating.  
6. Release the blade control bail. If the bag does not  
immediately deflate, it indicates that the blade is  
still rotating. The blade brake clutch mechanism  
may be deteriorating, and, if ignored could result  
in an unsafe operating condition. Have the lawn  
mower inspected and serviced by an Authorized  
Service Dealer.  
Figure 15  
1. Pull upward  
4. Pin  
2. Wheel height adjustment 5. Rotate to desired setting  
rod  
3. Adjustment bracket  
6. Indicator  
2. Apply downward pressure or lift the housing  
to rotate the height adjustment bracket. Use  
the indicator to determine the desired setting.  
Adjusting the Cutting Height  
The rear wheels are adjusted together with a height  
adjustment rod located on the mower housing by  
the left rear wheel. The front wheels are adjusted  
separately by removing the front wheel shaft  
assemblies, adjusting the height, and then replacing  
the shaft assemblies. The cutting height can be  
adjusted from 1 inch (25 mm) to 4 1/2 inches (114  
mm) in 1/2 inch (12.7 mm) increments.  
3. Release the wheel height adjustment rod to set  
the pin securely in the desired notch.  
Front Wheel Adjustment  
1. Pull up on the height adjuster and pull the  
front wheel shaft assembly outward as shown  
in Figure 16.  
18  
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Operation  
Figure 16  
4. Front quadrant block cut  
1. Front wheel shaft  
assembly  
heights  
2. Pull up  
5. Pull outward  
6. Shaft groove  
3. Height adjuster  
2. Insert the front wheel shaft assembly into the  
desired cut height setting in the front quadrant  
block. Lower the height adjuster into the  
groove on the front wheel shaft. Pull and  
push the wheel shaft assembly to make sure it  
has locked into place.  
Figure 17  
1. Bag  
4. Handle bracket notch  
2. Handle  
3. Bag frame  
5. Rear door  
6. Lower  
4. Once the bag is seated, lower the rear door  
onto the bag.  
Using the Grass Bag  
• Mowing with the Grass Bag  
• Installing the Grass Bag  
1. Stop the engine and wait for all moving parts  
to stop.  
WARNING  
A worn grass bag could allow small stones  
and other similar debris to be thrown in the  
operator’s or bystander’s direction. Thrown  
objects can result serious personal injury or  
death to the operator or bystanders.  
2. Open the rear door.  
3. Grasp the handle on the bag and set the rear  
of the bag frame onto the handle bracket  
notch (Figure 17).  
Check the grass bag frequently. If it is  
damaged, install a new Exmark replacement  
bag.  
Cut the grass until the bag is full.  
Note: Do Not overfill the bag.  
• Removing the Grass Bag  
1. Stop the engine and wait for all moving parts  
to stop.  
2. Raise the rear discharge door and grasp the  
handle on the bag.  
3. Lift the bag off of the lawn mower and lower  
the rear discharge door.  
4. Gradually tip the bag forward to empty the  
clippings.  
5. To install the bag, refer to the section on  
Installing the Grass Bag.  
19  
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Operation  
• Alternate the mowing direction. This helps  
disperse the clippings over the lawn for even  
fertilization.  
DANGER  
If the discharge door does not close  
completely, the lawn mower could throw  
objects. Thrown objects can result in  
serious personal injury or death to the  
operator or bystanders.  
• If the finished lawn appearance is unsatisfactory,  
try one or more of the following:  
– Sharpen the blade.  
• Never open the door to the discharge  
opening when the engine is running.  
– Walk at a slower pace while mowing.  
– Cut the grass more frequently.  
• If you cannot close the door because  
the grass clippings clog the discharge  
area, stop the engine and gently move  
the discharge door handle back and  
forth until you can close the door  
completely. If you still cannot close the  
door, remove the obstruction with a  
stick, not your hand.  
– Overlap cutting swaths instead of cutting a  
full swath with each pass.  
– Set the desired cutting height on the front  
wheels. Set the rear wheels one to two notches  
higher. For example, set the front wheels at 2  
1/2 inches (64 mm) and the rear wheels at 3  
inches (76 mm).  
Cutting Leaves  
Operating Tips  
• After cutting the lawn, ensure that half of the  
lawn shows through the cut leaf cover. You may  
need to make more than one pass over the leaves.  
• Review the Safety section and read this manual  
carefully before operating the lawn mower.  
• Set the engine speed to the fastest position for  
the best cutting results.  
• For light leaf coverage, set all the wheels at the  
same cutting height setting.  
• Maintain a sharp blade throughout the cutting  
season. Periodically file down nicks on the blade.  
Replace the blade when necessary with an original  
Exmark replacement blade.  
• If there are more than 5 inches (12.7 cm) of leaves  
on the lawn, set the front cutting height one or  
two notches higher than the rear cutting height.  
This makes it easier to feed the leaves under the  
lawn mower deck.  
• Clean the air filter frequently. Mulching stirs up  
more clippings and dust which clogs the air filter  
and reduces engine performance.  
• Slow down your mowing speed if the lawn mower  
does not cut the leaves finely enough.  
Cutting Grass  
• If you mow over oak leaves, you can add lime to  
the grass in the spring to reduce the acidity of the  
oak leaves.  
• Grass grows at different rates at different times  
of the year. In the summer heat, it is best to cut  
grass at the 2 1/2 inch (64 mm), 3 inch (76 mm),  
or 3 1/2 inch (90 mm) cutting height settings. Cut  
only about a third of the grass blade at a time. Do  
Not cut below the 2 1/2 inch (64 mm) setting  
unless the grass is sparse or it is late fall when  
grass growth begins to slow down.  
• When cutting grass over 6 inches (15 cm) tall,  
first mow at the highest cutting height setting and  
walk slower; then mow again at a lower setting for  
the best lawn appearance. If the grass is too long  
and the grass clump on top of the lawn, the lawn  
mower may plug and cause the engine to stall.  
20  
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Maintenance  
Maintenance  
Note: Determine the left and right sides of the machine from the normal operating position.  
WARNING  
WARNING  
If you leave the wire on the spark plug, someone  
could accidentally start the engine. Accidental  
starting of the engine could seriously injure you  
or other bystanders.  
Tipping the lawn mower may cause the fuel  
to leak from the carburetor or the fuel tank.  
Gasoline is extremely flammable, highly  
explosive, and under certain conditions, can  
cause personal injury or property damage.  
Disconnect the wire from the spark plug before  
you do any maintenance. Set the wire aside so  
that it does not accidentally contact the spark  
plug.  
Avoid fuel spills by running the engine dry or by  
removing the gasoline with a hand pump; never  
siphon.  
WARNING  
The engine can become very hot. Touching a hot  
engine can cause severe burns.  
Allow the engine to cool completely before  
service or making repairs around the engine area.  
Recommended Maintenance Schedule(s)  
Maintenance Service  
Maintenance Procedure  
Interval  
• Change the engine oil.  
After the first 5 hours  
• Check the engine oil level.  
• Check the stopping time of the blade brake. The blade must stop within 3 seconds of  
releasing the bail; if it does not, contact an Authorized Service Dealer for repair.  
• Check the mower blade and the engine mounting fasteners.  
• Check for loose hardware.  
Before each use or daily  
• Check the Blade Brake Clutch Bail operation (Blade Brake Clutch Units Only)  
• Clean the grass build-up from under the deck.  
• Clean the discharge tunnel and plug.  
• Clean the foam pre-cleaner (Kawasaki Units).  
• Clean the cover, base, foam and paper elements (ECXHNBBC21 and ECXHN21 Units).  
Every 25 hours  
Every 40 hours  
• Check the condition of the belt(s).  
• Change the engine oil. (May need more often under severe conditions.)  
• Check for leaks in the fuel systems and /or deteriorating fuel hose.  
• Clean under the belt cover (self-propelled units only).  
• Clean the blade brake clutch shield.  
Every 50 hours  
• Clean under the cover plate (Non-BBC Units).  
• Change the oil filter (ECXKA21 and ECXKABBC21 Units).  
• Check the spark plugs.  
• Clean the fuel filter element.  
Every 100 hours  
Every 250 hours  
• Replace the air filter elements (ECXHNBBC21 and ECXHN21 Units). (May need more  
often if they are damaged or excessively dirty.)  
21  
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Maintenance  
Maintenance Service  
Interval  
Maintenance Procedure  
• Replace the paper air filter (Kawasaki Units). (May need more often in dusty conditions.  
See the Engine manual for additional information.)  
Every 300 hours  
• Empty the fuel tank before repairs as directed or before storage.  
Yearly or before storage  
Periodic Maintenance  
Check Engine Oil Level  
Service Interval: Before each use or daily  
1. Stop engine and wait for all moving parts to stop.  
Make sure unit is on a level surface.  
2. Check with engine cold.  
3. Clean area around dipstick. Remove dipstick and  
wipe oil off. Reinsert the dipstick and push it all  
the way down into the tube. Do Not screw into  
place. Remove the dipstick and read the oil level.  
Figure 19  
Kawasaki Engine  
1. Dipstick  
2. Full  
3. Add  
4. If the oil level is low, wipe off the area around the  
oil fill cap, remove cap and fill to the “FULL”  
mark on the dipstick. Exmark 4-Cycle Premium  
Engine Oil is recommended; refer to the Engine  
Owner's manual for an acceptable alternative. Do  
Not overfill.  
Figure 18  
Honda Engine  
1. Lower limit mark  
2. Upper limit mark  
3. Dipstick  
Important: Do Not operate the engine with the  
oil level below the “LOW” (or “ADD”) mark on  
the dipstick, or over the “FULL” mark.  
Checking the Blade Brake  
Clutch (Blade Brake Clutch  
Only)  
Service Interval: Before each use or daily  
Refer to Checking the Blade Brake Clutch in the  
Operating Instructions section.  
Check the Mower Blade  
Service Interval: Before each use or daily  
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Maintenance  
Always mow with a sharp blade. A sharp blade cuts  
cleanly and without tearing or shredding the grass  
blade.  
DANGER  
A worn or damaged blade can break. A  
piece of the blade could be thrown into the  
operator’s or bystander’s area, resulting in  
serious personal injury or death.  
1. Stop the engine and wait for all moving parts to  
stop.  
2. Disconnect the wire from the spark plug  
(Figure 9 and Figure 10).  
• Inspect the blade periodically for wear or  
damage.  
3. Drain the gasoline from the fuel tank. Refer to  
Emptying the Fuel Tank and Cleaning the  
Fuel Filter section.  
• Replace a worn or damaged blade.  
If it is necessary to remove the blade for  
replacement or sharpening, complete the  
following steps:  
4. Tip the lawn mower onto its right side.  
5. Inspect the blade for sharpness and wear,  
especially where the flat and the curved parts  
meet (see Figure 20). Because sand and abrasive  
material can wear away the metal that connects  
the flat and curved parts of the blade, check  
the blade before using the lawn mower. If you  
notice a slot or wear (Figure 20B and Figure 20C),  
replace the blade.  
A. To remove the blade, use a block of wood to  
hold the blade steady (see Figure 21). Make  
sure to grasp the end of the blade using a rag  
or a thickly padded glove.  
For Blade Brake Clutch Units: Remove  
the blade nuts, blade support, and blade.  
For Units without a Blade Brake  
Clutch: Remove the blade bolt, blade  
support, and blade.  
Figure 21  
Figure 20  
1. Sail  
2. Flat  
3. Wear  
4. Slot  
B. For Sharpening: File the top side of the  
blade to maintain its original cutting angle  
(Figure 22A and B) and inner cutting edge  
radius (Figure 22A). The blade will remain  
balanced if you remove the same amount of  
material from both cutting edges.  
Note: For the best performance, install a new  
blade before the cutting season begins. During  
the year, file down any small nicks to maintain the  
cutting edge.  
23  
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Maintenance  
Figure 22  
1. Inner cutting edge radius 2. Cutting angle  
C. Check the balance of the blade by placing  
the center hole of the blade over a nail or  
screwdriver shank clamped horizontally in a  
vise (Figure 23). If either end of the blade  
rotates downward, file that end (not the  
cutting edge). The blade is properly balanced  
when neither end drops.  
Figure 24  
1. Blade Brake Clutch Units  
2. Units without a Blade Brake Clutch  
6. Return the lawn mower to its upright position.  
7. Connect the wire to the spark plug.  
Figure 23  
Check for Loose Hardware  
Service Interval: Before each use or daily  
1. Blade  
2. Vise  
3. Screwdriver  
1. Stop engine, wait for all moving parts to stop.  
D. For Installation: Make sure to grasp the end of  
the blade using a rag or a thickly padded glove.  
2. Visually inspect machine for any loose hardware  
or any other possible problem. Tighten hardware  
or correct the problem before operating.  
For Blade Brake Clutch Units: Install a sharp,  
balanced Exmark blade, blade support, and  
the blade nuts. The sail of the blade must  
point toward the top of the lawn mower  
housing for proper installation. Torque the  
blade nuts to 23-27 ft-lb (31-37 N m).  
Check the Blade Brake  
Clutch Bail Operation (Blade  
Brake Clutch Units Only)  
Service Interval: Before each use or daily  
For Units without a Blade Brake Clutch:  
Install a sharp, balanced Exmark blade, blade  
support, and blade bolt. The sail of the blade  
must point toward the top of the lawn mower  
housing for proper installation. Torque the  
blade bolt to 35-45 ft-lb (47-61 N m).  
Check the Blade Brake Clutch (BBC) bail operation  
for any operation problems or deteriorating  
components, such as the spring. Replace components  
or correct any problems before operating. Refer to  
Operating the Blade Control Lever in Operation.  
24  
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Maintenance  
Service Air Filter  
(Kawasaki Units)  
Service Interval: Every 25 hours—Clean  
the foam pre-cleaner  
(Kawasaki Units).  
Every 300 hours—  
Replace the paper air  
filter (Kawasaki Units).  
(May need more often in  
dusty conditions. See  
the Engine manual for  
additional information.)  
Note: Do Not operate the engine without the air  
filter assembly; extreme engine damage will occur.  
1. Stop engine, wait for all moving parts to stop.  
2. Disconnect the wire from the spark plug  
(Figure 10).  
Figure 26  
3. Remove the cover and clean it thoroughly.  
ECSKA21 and ECSKCP21 Units  
1. Cover  
3. Foam element  
2. Paper air filter  
4. Remove the paper air filter and discard it as  
required.  
Note: Do Not try to clean a paper air filter.  
5. Remove the foam element and wash it with a mild  
detergent and water, then blot it dry.  
6. Saturate the element with clean engine oil, then  
squeeze it (Do Not twist) to remove the excess oil.  
7. Install the foam element.  
8. Install the new paper air filter.  
9. Install the cover.  
Figure 25  
ECXKA21 and ECXKABBC21 Units  
1. Cover  
3. Paper air filter  
4. Air filter base  
Service Air Filter  
(ECXHNBBC21 and  
ECXHN21 Units)  
2. Foam element  
Service Interval: Every 25 hours—Clean  
the cover, base, foam  
and paper elements  
(ECXHNBBC21 and  
ECXHN21 Units).  
Every 250 hours— Replace  
the air filter elements  
25  
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Maintenance  
(ECXHNBBC21 and  
ECXHN21 Units). (May  
need more often if they are  
damaged or excessively  
dirty.)  
psi (207 kPa) through the filter from the wire  
screen side to remove any excess dirt. If the paper  
element is excessively dirty, replace it.  
Note: Never try to brush dirt off the paper  
element; brushing forces the dirt into the fibers.  
Note: Do Not operate the engine without the air  
cleaner assembly; extreme engine damage will occur.  
9. Clean the foam element in warm, soapy water or  
in a nonflammable solvent.  
1. Stop the engine and wait for all moving parts to  
stop.  
10. Rinse and dry the foam element thoroughly.  
11. Dip the foam element in clean engine oil, then  
squeeze out the excess oil.  
2. Disconnect the wire from the spark plug  
(Figure 9).  
Note: Excess oil in the foam element restricts  
the air flow through the element and may reach  
the paper filter and clog it.  
3. Remove the two wing nuts that secure the cover  
(Figure 27).  
12. Wipe dirt from the base and the cover with a  
moist rag.  
Note: Be careful to prevent dirt and debris from  
entering the air duct leading to the carburetor.  
13. Install the air cleaner elements and ensure that  
they are properly positioned.  
14. Securely install the cover with the two wing nuts.  
Change Engine Oil  
Service Interval: After the first 5 hours  
Every 50 hours (May need  
more often under severe  
conditions.)  
Figure 27  
1. Run the engine to warm the engine oil.  
1. Wing nuts  
4. Foam element  
5. Base  
Note: Warm oil flows better and carries more  
2. Cover  
contaminates.  
3. Paper element  
WARNING  
4. Remove the cover.  
Oil may be hot after engine has been run.  
Contact with hot oil can cause severe personal  
injury.  
Note: Be careful to prevent dirt and debris from  
falling into the base.  
5. Remove the foam and paper elements from the  
base.  
Avoid contacting the hot engine oil when you  
drain it.  
6. Remove the foam element from the paper  
element.  
2. Stop engine, wait for all moving parts to stop.  
3. Disconnect the wire from the spark plug.  
7. Inspect the foam and paper elements, and replace  
them if they are damaged or excessively dirty.  
4. Drain the gasoline from the fuel tank. Refer to  
Emptying the Fuel Tank and Cleaning the  
Fuel Filter section.  
8. Tap the paper element on a hard surface several  
times or use compressed air not exceeding 30  
26  
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Maintenance  
5. Place a suitable drain pan under the dipstick/oil  
drain.  
6. Clean around the dipstick.  
7. Remove the dipstick by rotating the cap  
counterclockwise and pulling it out.  
8. Raise the left side of the lawn mower to drain the  
oil from the dipstick fill tube into the drain pan.  
9. After draining the oil, return the lawn mower to  
the operating position.  
Figure 28  
10. Fill the crankcase with fresh oil to the upper limit  
mark on the dipstick. Use oil recommended in  
the Check Engine Oil Level section. Do Not  
overfill  
1. Gasket  
8. Install the new filter and hand tighten it 2/3 turn  
only.  
11. Insert the dipstick into the filler neck and rotate  
the cap clockwise until it is tight.  
9. Fill the crankcase as stated in Check Engine Oil  
Level section. Exmark 4–Cycle Premium Engine  
oil is recommended. Refer to the Engine Owner's  
Manual for an acceptable alternative.  
12. Wipe up any spilled oil.  
13. Connect the wire to the spark plug.  
14. Recycle the used oil according to local codes.  
10. Connect the wire to the spark plug.  
11. Run the engine for about 3 minutes.  
12. Stop the engine, wait for all moving parts to stop,  
and check for oil leakage around the filter.  
Change Oil Filter  
(ECXKA21 and  
ECXKABBC21)  
13. Add oil to compensate for the oil in the oil filter.  
14. Recycle the used oil filter according to local codes.  
Service Interval: Every 100 hours  
Check Condition Of Belt  
(Self-Propelled Units Only)  
1. Run the engine to warm the oil.  
2. Stop the engine and wait for all moving parts to  
stop.  
Service Interval: Every 40 hours  
3. Disconnect the wire from the spark plug.  
4. Drain the engine oil.  
1. Stop engine, wait for all moving parts to stop.  
2. Remove the belt cover to the lawn mower housing.  
3. Check the belt for cracks, frayed edges, burn  
marks or any other damage.  
5. Place a rag under the oil filter to catch any oil that  
may leak out as you remove the filter.  
4. Replace the damaged belt.  
6. Remove the oil filter.  
7. Use your finger to coat the gasket on the new  
filter with clean Exmark 4–Cycle Premium Engine  
oil (see Figure 28).  
Check Spark Plugs  
Service Interval: Every 100 hours  
1. Stop the engine and wait for all moving parts to  
stop.  
2. Disconnect the wire from the spark plug  
(Figure 9 and Figure 10).  
3. Clean around the spark plug.  
4. Remove the spark plug from the cylinder head.  
27  
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Maintenance  
Note: Replace a cracked, fouled, or dirty spark  
plug. Do Not clean the electrodes because grit  
entering the cylinder can damage the engine.  
Adjustments  
Note: Wait for all moving parts to stop and remove  
spark plug wire before servicing, cleaning, or making  
any adjustments to the unit.  
5. Set the gap on the plug to 0.030 inch (0.76 mm)  
(Figure 29).  
Adjusting the Self-Propel  
Drive  
(Self-Propelled Units Only)  
If the lawn mower does not self-propel or has a  
tendency to creep forward when the control bail  
is released, adjust the drive cable nuts as shown in  
Figure 31.  
Figure 29  
1. Side electrode  
3. Air gap—0.030 inch  
(0.76 mm)  
DANGER  
2. Center electrode  
insulator  
Checking the operation of the mower with the  
belt cover removed will allow debris to be thrown  
in the operator's or bystander's direction and can  
result in serious personal injury or death.  
6. Install the spark plug and the gasket seal.  
7. Torque the plug to 17 ft-lb (23 N-m).  
8. Connect the wire to the spark plug.  
Do Not operate the unit when cover is not in  
place.  
Emptying the Fuel Tank and  
Cleaning the Fuel Filter  
Service Interval: Every 100 hours  
1. Stop the engine and wait for all moving parts to  
stop.  
2. Remove the belt cover by pulling upward on the  
back of the cover to unsnap the front and back  
cover tabs. Remove any debris under the cover.  
The fuel filter (screen) element is located inside the  
fuel tank (if applicable).  
1. Stop the engine and wait for it to cool down.  
Note: Drain gasoline for a cold engine only.  
2. Disconnect the wire from the spark plug  
(Figure 10).  
3. Close the fuel valve.  
4. Disconnect the fuel line by loosening the tube  
clamp at the carburetor.  
5. Open the fuel valve by turning the lever to the  
open position.  
6. Drain the gasoline completely from the tank and  
fuel line into an approved fuel container.  
7. Remove the fuel tank from the mower.  
8. Close the fuel valve.  
9. Pour a small amount of fuel in the fuel tank, move  
the fuel around in the tank, and pour it out into  
an approved fuel container.  
Figure 30  
1. Belt cover tabs  
10. Install the fuel tank and fuel line.  
28  
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Maintenance  
3. If the lawn mower does not self propel with bail  
engaged, tighten the belt by turning the drive  
cable nuts clockwise. To maximize belt life, Do  
Not overtighten the belt.  
cover tabs (see Figure 30). Remove any debris  
under the cover.  
4. Loosen the cable clamp screw until the cable  
conduit slides (see Figure 32).  
If the lawn mower creeps forward without the  
bail engaged, loosen the belt by turning the drive  
cable nuts counterclockwise.  
Figure 31  
1. Adjustment of drive cable nuts  
Figure 32  
4. Reinstall the belt cover by pushing down on the  
rear first and then snapping the front onto the  
mower housing.  
1. Spring  
3. Cable clamp screw  
2. Cable conduit  
5. Check the operation for desired drive control.  
5. Pull the cable until there is approximately 1/8  
inch in slack. Do Not put tension on the spring.  
6. Repeat steps 2 through 5 as necessary for further  
adjustment.  
6. Tighten the screw to lock the adjustment in place.  
Note: Adjustment to obtain desired ground  
speed at full bail travel may be made in order to  
accommodate slower speeds.  
7. Reinstall the belt cover by pushing down on the  
rear first and then snapping the front onto the  
mower housing.  
Adjusting the Blade  
Brake Cable  
(Blade Brake Clutch Units  
Only)  
8. Connect the wire to the spark plug.  
9. Check the operation of the blade control lock  
lever (see Figure 12). The lever must reset itself  
to lock out the blade control bail. If it does not,  
repeat steps 4 through 8.  
10. Perform the “Checking the Blade Brake Clutch  
(Blade Brake Clutch Units Only)” procedure in  
Operation.  
Adjust whenever a new blade brake cable assembly is  
installed or if the blade control lock lever does not  
operate properly.  
1. Stop the engine and wait for all moving parts to  
stop.  
2. Disconnect the wire from the spark plug.  
3. Remove the belt cover by pulling upward on the  
back of the cover to unsnap the front and back  
29  
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Maintenance  
Scraping Method  
Cleaning  
If washing does not remove all debris from under the  
lawn mower, scrape it clean.  
Clean Grass Build-Up Under  
Deck  
1. Disconnect the wire from the spark plug.  
2. Drain the fuel from the fuel tank. Refer to  
Emptying the Fuel Tank and Cleaning the  
Fuel Filter section.  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove spark plug wire.  
3. Tip the lawn mower onto its right side.  
2. To ensure the best performance, keep the  
underside of the lawn mower housing clean.  
4. Remove the dirt and grass clippings with a  
hardwood scraper. Avoid burrs and sharp edges.  
5. Turn the lawn mower upright.  
6. Fill the fuel tank.  
CAUTION  
The mower may dislodge material from under  
the mower housing.  
7. Connect the wire to the spark plug.  
• Wear eye protection.  
Cleaning the Discharge  
Tunnel and Plug  
• Stay in the operating position (behind the  
handle).  
• Do Not allow bystanders in the area.  
Service Interval: Before each use or daily  
Washing Method  
Always be sure that the discharge tunnel door closes  
securely when you release the handle. If the debris  
prevents the discharge door from closing securely,  
clean the inside of the discharge tunnel and the door  
thoroughly.  
1. Position the lawn mower on a flat concrete or  
asphalt surface near a garden hose.  
2. Start the engine.  
3. Hold the running garden hose at handle level and  
direct the water to flow on the ground just in  
front of the right rear tire (Figure 33).  
WARNING  
Grass clippings and other objects can be thrown  
from an open discharge tunnel. Thrown objects  
can cause serious injury or kill the operator or  
bystanders.  
Never start or operate the lawn mower unless one  
of the following is true:  
• The discharge tunnel plug is locked securely  
in the discharge tunnel.  
Figure 33  
• The grass bag is locked in place.  
4. Engage the blade.  
• The optional rear discharge chute is locked  
in place.  
Note: The blade will draw in water and wash out  
clippings. Let the water run until you no longer  
see clippings being washed out from under the  
housing.  
• The discharge tunnel door is closed.  
Cleaning Under the Belt  
Cover (Self-Propelled Units  
Only)  
5. Disengage the blade, stop the engine and wait for  
all moving parts to stop.  
6. Turn off the water.  
Service Interval: Every 50 hours  
7. Start the lawn mower, engage the blade, and let  
the lawn mower run for a few minutes to dry out  
its components.  
1. Stop the engine and wait for all moving parts to  
stop.  
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Maintenance  
2. Disconnect the wire from the spark plug (see  
Figure 9 and Figure 10).  
7. Remove the BBC shield and brush or blow all  
the debris from under the shield and around the  
BBC system.  
3. Pull upward on the back of the cover to unsnap  
the front and back cover tabs (see Figure 30).  
8. Install the BBC shield. Tighten the screws to  
secure the BBC shield to the deck.  
4. Lift off the cover and brush out all the debris  
around the belt area.  
9. Install the blade and the two blade nuts.  
10. Turn the lawn mower upright.  
5. Install the belt cover by pushing down on the rear  
first and then snapping the front onto the mower  
housing.  
11. Connect the wire to the spark plug.  
6. Connect the wire to the spark plug.  
Cleaning Under the Cover  
Plate (Non-Blade Brake  
Clutch Units Only)  
Cleaning the Blade  
Brake Clutch Shield  
(Blade Brake Clutch Units  
Only)  
Service Interval: Every 50 hours  
1. Stop the engine and wait for all moving parts to  
stop.  
Service Interval: Every 50 hours  
2. Disconnect the wire from the spark plug (see  
Figure 9 and Figure 10).  
1. Stop the engine and wait for all moving parts to  
stop.  
3. Drain the gasoline from the fuel tank. Refer to  
Emptying the Fuel Tank and Cleaning the  
Fuel Filter section.  
2. Disconnect the wire from the spark plug (see  
Figure 9 and Figure 10).  
3. Drain the gasoline from the fuel tank. Refer to  
Emptying the Fuel Tank and Cleaning the  
Fuel Filter section.  
4. Tip the lawn mower onto its right side (air filter  
up).  
5. Remove the blade bolt, blade support, and the  
blade (see Figure 24).  
4. Tip the lawn mower onto its right side (air filter  
up).  
5. Remove the blade nuts and the blade (see  
Figure 24).  
Figure 35  
1. Blade bolt  
2. Blade support  
3. Blade  
4. Cover plate  
5. Screw  
Figure 34  
6. Remove the three screws holding the cover plate  
onto the unit (see Figure 35).  
1. Screws  
2. BBC Shield  
6. Remove the three screws holding the BBC shield  
onto the unit (see Figure 34).  
7. Remove the cover plate and brush or blow all the  
debris from under the plate.  
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Maintenance  
8. Reinstall the cover plate and torque the screws to  
35-45 ft-lb (47-61 N-m).  
9. Install the blade, blade support, and the blade  
bolt.  
10. Turn the lawn mower upright.  
11. Connect the wire to the spark plug.  
Waste Disposal  
Motor Oil Disposal  
Engine oil and hydraulic oil are both pollutants to  
the environment. Dispose of used oil at a certified  
recycling center or according to your state and local  
regulations.  
32  
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Storage  
2. Clean any dirt and chaff from the cylinder,  
Storage  
cylinder head fins, and blower housing.  
3. Remove grass clippings, dirt, and grime from the  
external parts of the engine, the shrouding, and  
the top of the lawn mower housing.  
Preparing the Fuel System  
To prepare the lawn mower for off season storage,  
perform the recommended maintenance procedures.  
4. Clean the BBC shield. Refer to Cleaning the  
Blade Brake Clutch Shield section in Cleaning.  
Store the lawn mower in a cool, clean, dry place.  
Cover the lawn mower to keep it clean and protected.  
5. Check the condition of the blade. Refer  
to Maintaining the Blade section in the  
Maintenance.  
WARNING  
Gasoline can vaporize if you store it over long  
periods of time. Gasoline vapors can explode if  
they come into contact with an open flame.  
6. Service the air filter. Refer to Servicing the Air  
Filter in Maintenance.  
7. Tighten all nuts, bolts, and screws.  
• Do Not store gasoline over long periods of  
time.  
8. Touch up all rusted or chipped paint surfaces with  
paint available from an Authorized Service Dealer.  
• Do Not store the lawn mower with gasoline in  
the fuel tank or the carburetor in an enclosure  
with an open flame. (For example, a furnace  
or a water heater pilot light.)  
Removing the Lawn Mower  
from Storage  
• Allow the engine to cool before storing it in  
any enclosure.  
1. Check and tighten all fasteners.  
Empty the fuel tank when mowing the last time  
before storing the lawn mower.  
2. Remove the spark plug and spin the engine rapidly  
by pulling the starter rope to blow excess oil from  
the cylinder.  
1. Run the lawn mower until the engine stops from  
running out of fuel.  
3. Clean the spark plug or replace it if it is cracked,  
broken, or if the electrodes are worn.  
2. Prime the engine and start it again.  
3. Allow the engine to run until it stops. When you  
can no longer start the engine it is sufficiently dry.  
4. Install the spark plug and torque it to 17 ft-lb (23  
N-m).  
5. Perform any needed maintenance procedures.  
6. Fill the fuel in the fuel tank with fresh gasoline.  
7. Check the engine oil level.  
Preparing the Engine  
1. While the engine is still warm, change the oil from  
the crankcase. Refer to Change Engine Oil  
section in Maintenance.  
8. Connect the wire to the spark plug.  
2. Remove the spark plug.  
3. Using an oil can, add about one tablespoon of oil  
to the crankcase through the spark plug hole.  
4. Slowly rotate the engine several times, using the  
starter rope, to distribute the oil.  
5. Install the spark plug but Do Not connect the  
wire to the spark plug.  
General Storage Information  
1. Clean the lawn mower housing. Refer to  
Cleaning the Underside of the Lawn Mower  
Housing section in Cleaning.  
33  
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Troubleshooting  
Troubleshooting  
Important: It is essential that all operator safety mechanisms be connected and in proper operating  
condition prior to mower use.  
When a problem occurs, Do Not overlook the simple causes. For example: starting problems could be  
caused by an empty fuel tank.  
The following table lists some of the common causes of trouble. If a problem continues, contact an Authorized  
Service Dealer.  
Problem  
Possible Cause  
1. Fuel tank is empty.  
Corrective Action  
1. Fill the fuel tank.  
Engine will not start, starts hard, or fails to  
keep running.  
2. Fuel shutoff valve is closed.  
2. Open the fuel shutoff valve.  
3. The throttle lever is not in the correct  
position.  
3. Move the throttle lever to the Choke  
position.  
4. Dirt, water, or stale fuel is in the fuel  
system.  
4. Contact an Authorized Service Dealer.  
5. Faulty spark plug.  
6. Spark plug wire is not connected.  
5. Clean, adjust or replace spark plug.  
6. Check the spark plug wire connection.  
Engine loses power.  
1. Air cleaner is dirty.  
1. Clean or replace the air cleaner element.  
2. Oil level in the crankcase is low.  
3. Vent hole in the fuel cap is plugged.  
4. Dirt in fuel filter.  
2. Add oil to the crankcase.  
3. Clean or replace the fuel cap.  
4. Replace the fuel filter.  
5. Dirt, water, or stale fuel is in the fuel  
system.  
5. Contact an Authorized Service Dealer.  
6. The underside of the lawn mower deck  
contains clippings and debris.  
6. Clean the underside of the lawn mower  
deck.  
Engine runs rough.  
1. The wire is not connected to the spark  
plug.  
1. Connect the wire to the spark plug.  
2. Faulty spark plug.  
2. Clean, adjust or replace spark plug.  
3. The throttle lever is not in the Fast  
position.  
3. Move the throttle lever to the Fast  
position.  
4. The air filter element is dirty and is  
restricting the air flow.  
4. Clean the air filter pre-cleaner and/or  
replace the paper air filter.  
Lawn mower or engine vibrates excessively.  
1. The blade is bent or is out of balance.  
1. Balance the blade. If the blade is bent,  
replace it.  
2. The blade mounting bolt is loose.  
2. Tighten the blade mounting bolt.  
3. The underside of the lawn mower deck  
contains clippings and debris.  
3. Clean the underside of the lawn mower  
deck.  
4. The engine mounting bolts are loose.  
4. Tighten the engine mounting bolts.  
Uneven cutting pattern.  
Discharge chute plugs.  
1. All four wheels are not at the same height. 1. Place all four wheels at the same height.  
2. The blade is dull.  
3. Mowing in the same pattern repeatedly.  
2. Sharpen and balance the blade.  
3. Change the mowing pattern.  
4. The underside of the lawn mower deck  
contains clippings and debris.  
4. Clean the underside of the lawn mower  
deck.  
1. The throttle lever is not in the Fast  
position.  
1. Move the throttle lever to the Fast  
position.  
2. Cutting too much grass in one pass  
2. Raise the cutting height. If necessary, cut  
a second time at lower cutting height.  
3. Mowing too fast.  
4. The grass is wet.  
3. Slow down.  
4. Allow the grass to dry before mowing.  
5. The underside of the lawn mower deck  
contains clippings and debris.  
5. Clean the underside of the lawn mower  
deck.  
34  
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Troubleshooting  
Problem  
Possible Cause  
Corrective Action  
Lawn mower does not self-propel.  
(Self-Propel Units Only)  
1. The self-propel drive cable is out of  
adjustment or is damaged.  
1. Adjust the self-propel drive cable. Replace  
the cable if necessary.  
2. There is debris under the belt cover.  
2. Clean the debris from under the belt  
cover.  
Difficult to pull lawnmower rearward  
(Self-Propelled Units Only).  
1. Transmission is locked.  
1. Push mower forward to disengage the  
transmission and then pull rearward.  
35  
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Exmark Commercial Equipment  
1Year Limited Warranty  
If for any reason you are dissatisfied with the Service Dealer’s  
analysis or with the assistance provided, contact us at:  
Conditions and Products Covered  
Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty  
Company, pursuant to an agreement between them, jointly  
warrant on the terms and conditions herein, that we will repair,  
replace or adjust any part on these products and found by us  
(in the exercise of our reasonable discretion) to be defective in  
factory materials or workmanship for a period of one year.  
Exmark Customer Service Department  
The Exmark Warranty Company  
2101 Ashland Avenue  
Beatrice, NE 68310  
402-223-6375 or  
This warranty applies to Exmark commercial equipment sold  
in the U.S. or Canada. This warranty may only be assigned or  
transferred to a second (or third) owner by an authorized  
Exmark dealer. The warranty period commences upon the date  
of the original retail purchase.  
Owner’s Responsibilities  
If your product requires warranty service it must be returned  
to an authorized Exmark service dealer within the warranty  
period. This warranty extends only to equipment operated  
under normal conditions. You must read the operator’s  
manual. You must also properly service and maintain your  
Exmark product as described in the operator’s manual. Such  
routine maintenance, whether performed by a dealer or by  
you, is at your expense.  
Warranty Exceptions  
• Bags, Belts and Tires  
• Battery  
Warranty Period  
90 days  
1 Year Prorated  
*
• Engine  
* The Engine warranty is covered by the engine manufacturer.  
Please refer to the engine manufacturer’s warranty statement  
that is included in the literature packet.  
General Conditions  
The sole liability of Exmark and Exmark Warranty Company  
with respect to this warranty shall be repair or replacement of  
defective components as set forth herein. Neither Exmark  
nor Exmark Warranty Company shall be liable for any  
incidental or consequential loss or damage.  
This warranty only includes the cost of parts and labor.  
Items and Conditions Not Covered  
This warranty does not cover the following:  
• Pickup and delivery charges to and from any authorized  
Exmark Service Dealer.  
Such damages include but are not limited to:  
• Expenses related to gasoline, oil or lubricants.  
• Travel time, overtime, after hours time or other  
extraordinary repair charges or charges relating to repairs or  
replacements outside of normal business hours at the place  
of business of the authorized Exmark Service Dealer.  
• Rental of like or similar replacement equipment during the  
period of any warranty, repair or replacement work.  
• Any telephone or telegram charges or travel charges.  
• Loss or damage to person or property other than that  
covered by the terms of this warranty.  
• Any damage or deterioration due to normal use, wear and  
tear, or exposure including standard service items such as  
blades, brushes, cutting teeth, tines, bushings, bearings,  
chains, or sprockets.  
• Cost of regular maintenance service or parts, such as filters,  
fuel, lubricants, tune-up parts, and adjustments.  
• Any product or part which has been altered or misused or  
required replacement or repair due to normal wear,  
accidents, or lack of proper maintenance.  
• Any repairs necessary due to use of parts, accessories or  
supplies, including gasoline, oil or lubricants, incompatible  
with the equipment or other than as recommended in  
the operator's manual or other operational instructions  
provided by Exmark.  
• Any claims for lost revenue, lost profit or additional cost as  
a result of a claim of breach of warranty.  
• Attorney's fees.  
No Claim of breach of warranty shall be cause for cancellation  
or rescission of the contract of sale of any Exmark mower.  
There are no other express warranties except for engine and  
special emission system coverage.  
All implied warranties of merchantability (that the  
product is fit for ordinary use) and fitness for use (that the  
product is fit for a particular purpose) are limited to the  
duration of the express warranty.  
All warranty work must be performed by an authorized  
Exmark Service Dealer using Exmark approved replacement  
parts.  
Some states do not allow exclusions of incidental or  
consequential damages, or limitations on how long an  
implied warranty lasts, so the above exclusions and  
limitations may not apply to you.  
Instructions for Obtaining Warranty Service  
The product must be registered with original proof of purchase  
by an Exmark Service Dealer before obtaining any warranty  
service.  
This warranty gives you specific legal rights, and you may  
also have other rights which vary from state to state.  
Contact any Exmark Service Dealer to arrange service at their  
dealership. To locate a dealer convenient to you, access our  
also call 402-223-6375.  
G4500-426_D  
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Notes:  
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Service Record  
Date:  
Description of Work Done:  
Service Done By:  
38  
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SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS  
MID-MOUNT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
FULL SUSPENSION SEAT  
DECK LIFT ASSIST KIT  
HITCH KIT  
OPERATOR CONTROLLED DISCHARGE  
ROLL OVER PROTECTION SYSTEM (ROPS)  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
TURF STRIPER  
12V POWER PORT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
MICRO-MULCH SYSTEM  
OUT-FRONT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
DUAL-TAIL WHEEL  
SNOW BLADE  
SNOWBLOWER  
FLOOR PAN EXTENDER  
HITCH KIT  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
WEATHER CAB  
MICRO-MULCH SYSTEM  
ROLL OVER PROTECTION SYSTEM (ROPS)  
WALK-BEHIND ACCESSORIES AND OPTIONS  
GRASS CATCHER  
TURF STRIPER  
STANDON  
MICRO-MULCH SYSTEM  
Place Model No. and Serial No.  
Label Here (Included in the Literature  
Pack) or Fill in Below  
Date Purchased  
Engine Model No. and Spec. No.  
Engine Serial No. (E/No)  
Model No.  
Serial No.  
©2011 Exmark Mfg. Co., Inc.  
Industrial Park Box 808  
Beatrice, NE 68310  
Part No. 4500-927 Rev. A  
(402) 223-6300  
Fax (402) 223-5489  
Printed in the USA  
All Rights Reserved  
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