Exmark Lawn Mower M216KA M216KASP User Guide

M216KA / M216KASP  
For Serial Nos.  
440,000 & Higher  
CONGRATULATIONS on the purchase of your new Exmark mower. This product has been carefully designed and manufactured to give  
you a maximum amount of dependability and years of trouble–free operation. If additional information is needed, or should you require trained  
mechanic service, contact your authorized Exmark equipment dealer or distributor. If you need to order replacement parts from your dealer,  
always give the model number and serial number of your mower as well as the part number, description and quantity of the part needed.  
The Serial No. plate is located on the top of the mower deck on the right hand corner of the machine. For ease of ordering and reference,  
we suggest that you record the information requested in the following identification table.  
Place Model No. and Serial No. Label Here  
Engine Model No. and Spec. No. (Code)  
(Included in Literature Pack)  
or Fill in Below  
Engine Serial No (E/No)  
Model No.  
Date Purchased  
Serial No.  
Part No. 3329-962  
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EXMARK PARTS PLUS PROGRAM  
EFFECTIVE DATE: September 1,1995  
Program  
If your Exmark dealer does not have the Exmark part in  
stock, Exmark will get the parts to the dealer the next  
business day or the part will be FREE* Guaranteed!!  
How the Program Works  
1.  
If dealer does not have part in stock for a  
"down" unit at the time of request by customer,  
the dealer contacts his distributor by 1:00 p.m.  
local time, and requests Exmark Parts Plus  
shipment of six line items or less.  
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2.  
Distributor ships part(s) to dealer or customer,  
as requested by dealer, same day, overnight  
UPS Distributor bills dealer for part and freight  
charges where applicable.  
3.  
If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus order, he contacts Exmark by 3:00 p.m., central  
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time, with an Exmark Parts Plus order of six line items or less.  
4.  
5.  
6.  
If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by distributor,  
same day, overnight UPS, Exmark bills the distributor for parts and shipping charges, where applicable.  
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The customer pays for the part and freight if it is shipped under the Exmark Parts Plus and if it arrive in accordance to the  
program.  
Who pays for the part and freight if it fails to arrive overnight in accordance to the program?  
A. Under any circumstance the customer does not pay.  
B. If the part does not arrive overnight due to:  
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1. The dealer not submitting the Exmark Parts Plus order to his Exmark distributor by 1:00 p.m., the dealer pays for  
the part and freight.  
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2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus order to Exmark  
by 3:00 p.m. central time, the Distributor pays for the part and freight.  
3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m. central time, Exmark pays  
for the part and freight.  
4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark pays for  
the part.  
The following restrictions apply –– The Exmark Parts Plus Program is available only through participating Exmark Dealers and  
applies only to orders submitted on this program Monday through Thursday. Parts Plus service is available only in the 48 contiguous United States.  
UPS has initiated a Saturday delivery program to many areas of the continental United States and can be requested for an overnight shipment on  
Friday to be delivered Saturday. The next day air charge, plus the Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will  
assume no responsibility for Saturday delivery shipments. To qualify, all Exmark Parts Plus orders must be received by Exmark by 3:00 p.m.  
central time. Orders must be six line items or less. Exclusions from the Exmark Parts Plus Program are: Any wholegood or accessory in its entirety,  
engines and engine replacement parts, 5–speed Peerless transmissions and 5–speed transaxles, hydraulic or hydrostatic wheel motors, cutter decks  
and engine decks or any item exceeding United Parcel Service size and weight restrictions.  
Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day or Second Day Air.  
Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be ordered for Next Day Air ship-  
ment but will not be guaranteed per the Parts Plus Program.  
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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.  
OPERATOR’S MANUAL  
This manual contains assembly, operating, maintenance, adjustment and safety instructions for  
your Exmark mower.  
BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS ENTIRETY.  
By following the operating, maintenance and safety instructions, you will prolong the life of your  
mower, maintain its maximum efficiency and promote safe operation.  
If additional information is needed, or should you require trained mechanic service, contact your  
authorized Exmark equipment dealer or distributor.  
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 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.  
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Contents  
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
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Page  
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Limited Warranty  
Exmark Turf Equipment . . . . . . . . . . . . . . . . . . . . .  
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
General Lawn Mower Safety . . . . . . . . . . . . . . . .  
Exmark Lawn Mower Safety . . . . . . . . . . . . . . . .  
Safety and Instruction Decals . . . . . . . . . . . . . . .  
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Installing the Handle . . . . . . . . . . . . . . . . . . . . . .  
Installing the Starter Rope . . . . . . . . . . . . . . . . . .  
Installing the Fuel Tank and the Fuel Line . . . . .  
Installing the Discharge Tunnel Plug . . . . . . . . . .  
Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Filling the Crankcase with Oil . . . . . . . . . . . . . . .  
Filling the Fuel Tank with Gasoline . . . . . . . . . .  
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . .  
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . .  
Operating the Blade and the Self-Propel Drive . .  
Using the Discharge Tunnel Plug . . . . . . . . . . . .  
Adjusting the Cutting Height . . . . . . . . . . . . . . . .  
Using the Grass Bag . . . . . . . . . . . . . . . . . . . . . . .  
Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Recommended Maintenance Schedule . . . . . . . .  
Checking the Engine Oil Level . . . . . . . . . . . . . .  
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Warning  
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CALIFORNIA  
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Proposition 65 Warning  
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The engine exhaust from this product contains  
chemicals known to the State of California to  
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cause cancer, birth defects, or other reproductive  
harm.  
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This spark ignition system complies with Canadian  
ICES-002.  
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Ce système d’allumage par étincelle de véhicule est  
conforme à la norme NMB-002 du Canada.  
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The enclosed Engine Owner’s Manual is supplied for  
information regarding The U.S. Environmental  
Protection Agency (EPA) and the California Emission  
Control Regulation of emission systems, maintenance  
and warranty.  
Keep this engine Owner’s Manual with your unit.  
Should this engine Owner’s Manual become damaged  
or illegible, replace immediately. Replacements may be  
ordered through the engine manufacturer.  
Cleaning the Underside of the  
Lawn Mower Housing . . . . . . . . . . . . . . . . . . . .  
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Cleaning the Discharge Tunnel and Plug . . . . . .  
Servicing the Air Filter . . . . . . . . . . . . . . . . . . . .  
Changing the Engine Oil . . . . . . . . . . . . . . . . . . .  
Maintaining the Cutting Blade . . . . . . . . . . . . . .  
Emptying the Fuel Tank and Cleaning the  
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
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Cleaning under the Belt Cover . . . . . . . . . . . . . .  
Lubricating the Pivot Arms . . . . . . . . . . . . . . . . .  
Adjusting the Self-propel Drive . . . . . . . . . . . . . .  
Servicing the Spark Plug . . . . . . . . . . . . . . . . . . .  
Changing the Oil Filter . . . . . . . . . . . . . . . . . . . .  
Lubricating the Gear Case . . . . . . . . . . . . . . . . . .  
Adjusting the Blade Brake Cable . . . . . . . . . . . .  
Servicing the Wheels . . . . . . . . . . . . . . . . . . . . . .  
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Preparing the Fuel System . . . . . . . . . . . . . . . . . .  
Preparing the Engine . . . . . . . . . . . . . . . . . . . . . .  
General Information . . . . . . . . . . . . . . . . . . . . . . .  
Removing the Lawn Mower from Storage . . . . .  
All Rights Reserved  
Printed in the USA  
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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.  
Specifications  
Model Number:  
M216KA, M216KASP  
Engine:  
Kawasaki 6.0HP OHV  
3300 RPM (No load)  
Safety  
Fuel System:  
Capacity:  
This lawn mower meets or exceeds the CPSC blade  
safety requirements for walk-behind rotary lawn  
mowers and the B71.4 specifications of the American  
National Standards Institute in effect at the time of  
production.  
4.0 qt. (3.8 L)  
Non-replaceable, in tank  
Fuel filter:  
Transmission:  
3 speeds forward  
Improperly using or maintaining this lawn mower can  
result in injury. To reduce the potential for injury,  
comply with these safety instructions.  
Speed range:  
First  
1.8 mph (2.9 km/h)  
2.7 mph (4.3 km/h)  
3.8 mph (6.1 km/h)  
Second  
Third  
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.  
Cutting Width:  
21 in. (53 cm)  
Cutting Height:  
Adjusts in 1/2 in. (1.3 cm) increments from  
.75 in. (1.9 cm) to 3.25 in. (8.3 cm)  
Warning  
Grass Catcher Capacity  
2.5 Bu. (88 L)  
Engine exhaust contains carbon monoxide, an  
odorless, deadly poison that can kill you.  
Weight (with bag):  
M216KA  
Do not run the engine indoors or in an enclosed  
area.  
95 lb. (43.1 kg)  
107 lb. (48.5 kg)  
M216KASP  
To ensure maximum safety, best performance, and to  
gain knowledge of the product, it is essential that you  
and any other operator of the lawn mower read and  
understand the contents of this manual before the  
engine is ever started. Pay particular attention to the  
Introduction  
Read this manual carefully to learn how to operate and  
maintain your product properly. The information in this  
manual can help you and others avoid injury and product  
damage. Although Exmark designs and produces safe  
products, you are responsible for operating the product  
properly and safely.  
safety alert symbol  
which means caution, warning,  
or danger — “personal safety instruction.” Read and  
understand the instruction because it has to do with  
safety. Failure to comply with the instruction may  
result in personal injury.  
This manual identifies potential hazards and has special  
safety messages that help you and others avoid personal  
injury and even death. Danger, Warning, and Caution are  
signal words used to identify the level of hazard.  
General Lawn Mower Safety  
This lawn mower is capable of amputating hands and feet  
and of throwing objects. Failure to observe the following  
safety instructions could result in serious injury or death.  
However, regardless of the hazard, be extremely careful.  
Danger signals an extreme hazard that will cause serious  
injury or death if you do not follow the recommended  
precautions.  
Training  
Warning signals a hazard that may cause serious injury or  
Read this operator’s manual carefully. Be thoroughly  
familiar with the controls and the proper use of the  
lawn mower before starting it.  
death if you do not follow the recommended precautions.  
Caution signals a hazard that may cause minor or  
moderate injury if you do not follow the recommended  
precautions.  
Never allow children to operate the lawn mower.  
Local regulations may restrict the age of the operator.  
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Never allow adults unfamiliar with these instructions  
to operate the lawn mower.  
If you must drain the fuel from the fuel tank, do it  
outdoors.  
Never mow while people (especially children) or pets  
are nearby. Stop the lawn mower if anyone enters the  
area.  
Replace faulty mufflers.  
Before using, always visually inspect the blades, blade  
bolts, and cutter assembly for wear or damage.  
Replace worn or damaged blades and bolts in sets to  
preserve balance.  
Tragic accidents can occur if the operator is not alert  
to the presence of children. Children are often  
attracted to the lawn mower and the mowing activity.  
Never assume that children will remain where you last  
saw them.  
On multibladed lawn mowers, use care as rotating one  
blade can cause the other blades to rotate.  
Keep children out of the mowing area and under the  
watchful care of a responsible adult.  
Operation  
Do not operate the engine in a confined space where  
Be alert and turn the lawn mower off if children enter  
the area.  
dangerous carbon monoxide fumes can collect.  
Mow only in daylight or in good artificial light.  
Always be sure of your footing on slopes.  
Walk; never run.  
Use extra care when approaching blind corners,  
shrubs, trees, or other objects that may obscure vision.  
Keep in mind that the operator or user is responsible  
for accidents or hazards occurring to other people or  
their property.  
Keep a firm hold on the handle.  
See the manufacturer’s instructions for proper  
operation and installation of accessories. Use only the  
accessories that are approved by the manufacturer.  
For wheeled rotary lawn mowers, mow across the face  
of slopes, never up and down.  
Exercise extreme caution when changing the direction  
on slopes.  
Preparation  
Do not mow excessively steep slopes.  
Thoroughly inspect the area where you will use the  
lawn mower, and remove all stones, sticks, wires,  
bones, and other foreign objects.  
Use extreme caution when reversing or pulling the  
lawn mower toward you.  
Before and while moving backward, look behind and  
down for small children.  
While mowing, always wear substantial footwear and  
long trousers.  
Stop the blade(s) if you must tilt the lawn mower for  
transportation when crossing surfaces other than grass  
and when transporting the lawn mower to and from the  
area to be mowed.  
Do not operate the lawn mower when barefoot or  
wearing open sandals.  
Always wear safety goggles or safety glasses with side  
shields when operating the lawn mower.  
Never operate the lawn mower with damaged or  
missing guards or shields, or without safety devices  
(such as deflectors and grass catchers) in place.  
Warning: Gasoline is highly flammable. Take the  
following precautions:  
Do not change the speed settings on the engine.  
Store fuel in containers specifically designed for  
this purpose.  
Disengage all blade and drive clutches before starting  
the engine.  
Refuel outdoors only and do not smoke while  
refuelling.  
Start the engine carefully according to instructions and  
with feet well away from the blade(s).  
Add fuel before starting the engine. Never remove  
the cap of the fuel tank or add gasoline while the  
engine is running or when the engine is hot.  
Do not start the engine when standing in front of the  
discharge chute.  
If gasoline is spilled, do not attempt to start the  
engine. Move the lawn mower away from the area  
of spillage to avoid creating any source of ignition  
until the gasoline vapors have dissipated.  
Do not put your hands or feet near or under rotating  
parts. Keep clear of the discharge opening at all times.  
Never pick up or carry a lawn mower while the engine  
is running.  
Replace all fuel tank and container caps securely.  
Stop the engine and disconnect the spark-plug wire:  
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before clearing blockages or unclogging the chute;  
Replace worn or damaged parts.  
before checking, cleaning, or working on the lawn  
mower;  
Use extra care when handling gasoline; gasoline  
vapors are explosive.  
after striking a foreign object. Inspect the lawn  
mower for damage and make repairs before starting  
and operating the lawn mower; and  
Never tamper with safety devices. Check their proper  
operation regularly.  
Keep the lawn mower free of grass, leaves, or other  
debris buildup. Clean up any oil or fuel spills.  
if the lawn mower starts to vibrate abnormally  
(check it immediately).  
Stop and inspect the lawn mower if you strike an  
object. Repair the lawn mower, if necessary, before  
starting the engine.  
Stop the engine:  
whenever you leave the lawn mower; and  
before refuelling.  
Never attempt to make wheel height adjustments while  
the engine is running.  
Reduce the throttle setting during engine run-out and,  
if the engine has a shutoff valve, turn the fuel off after  
mowing.  
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 blade(s) when crossing gravel drives, walks,  
or roads.  
Lawn mower blades are sharp and can cut. Wrap the  
blade(s) or wear gloves, and use extra caution when  
servicing them.  
Shut the engine off and wait until the blade comes to a  
complete stop before removing the grass catcher.  
Do not operate the lawn mower while under the  
influence of alcohol or drugs.  
Do not change the speed settings on the engine.  
If you must drain the fuel from the fuel tank, do it  
outdoors.  
If the lawn mower should start to vibrate abnormally,  
stop the engine and check immediately for the cause.  
Vibration is generally a warning of trouble.  
To ensure the best performance and safety, purchase  
only genuine Exmark replacement parts and  
accessories.  
Slopes are a major factor related to slip and fall accidents  
which can result in a severe injury. If you feel uneasy on a  
slope, do not mow it.  
Maintain or replace safety and instruction decals when  
necessary.  
Watch for holes, ruts, or bumps. Tall grass can hide  
obstacles.  
Do not mow near drop-offs, ditches, or embankments.  
You could lose your footing or balance.  
Exmark Lawn Mower Safety  
The following list contains safety information specific to  
Exmark products or other safety information that you  
must know that is not included in the ANSI/OPEI  
standard.  
Do not mow on wet grass. Reduced footing could  
cause slipping.  
Maintenance and Storage  
This product is designed for cutting and recycling grass or,  
when equipped with a grass bagger, for catching cut grass.  
Any use for purposes other than these could prove  
dangerous to the user and bystanders.  
Keep all nuts, bolts (especially blade attachment  
bolts), and screws tight to ensure that the lawn mower  
is in safe working condition.  
Note: This engine is not equipped with a spark arrester  
muffler. It is a violation of California Public Resource  
Code Section 4442 to use or operate this engine on any  
forest-, brush-, or grass-covered land. Other states or  
federal areas may have similar laws.  
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 the lawn  
mower in any enclosure.  
General Operation  
To reduce the fire hazard, keep the engine, muffler,  
battery compartment, and gasoline storage area free of  
grass, leaves, or excessive grease.  
Ensure that the area is clear of other people before  
mowing. Stop the lawn mower if anyone enters the  
area.  
Check the grass catcher frequently for wear or  
deterioration.  
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Do not mow in reverse unless it is absolutely  
necessary. Always look down and behind before and  
while backing up.  
Keep hands, feet, hair and loose clothing away from  
the attachment discharge area, the underside of the  
lawn mower, and any moving parts while the engine is  
running.  
Be aware of the lawn mower discharge direction and  
do not point it at anyone. Do not operate the lawn  
mower without either the grass catcher or the guard in  
place.  
Stop the engine before removing the grass catcher or  
unclogging the chute.  
Watch for traffic when operating near or crossing  
roadways.  
Slow down before turning with the lawn mower. Sharp  
turns on any terrain may cause loss of control.  
Do not touch the lawn mower or attachment parts  
which may be hot from operation. Allow the lawn  
mower to cool down before attempting to maintain,  
adjust, or service it.  
Turn off the blades when you are not mowing.  
Safety and Instruction Decals  
Safety decals and instructions are easily visible to the operator and are located near any  
area of potential danger. Replace any decal that is damaged or lost.  
1-213242 (Self-propel model only)  
52-2620 (Self-propel model only)  
39-5770  
68-7410  
52-2610 (Hand-push model only)  
74-1970 (Self-propel model only)  
1. Transmission speeds  
2. Neutral  
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Assembly  
Note: Determine the left and right sides of the machine  
from the normal operating position.  
77-0500  
Installing the Handle  
1. Mount the handle to the outside of the lawn mower  
housing (using the bottom hole) with 2 5/16–18 x  
1–1/4 in. cap screws, washers, and thin nylon insert  
locknuts.  
2. Secure the handle latches to the handle with 2 cap  
screws (5/16–18 x 1-1/2 in.), washers, and nylon insert  
locknuts (Fig. 1).  
82-9152  
98-8017  
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1
3
4
m-534  
Figure 1  
1. Handle latch  
3. Cap locknut (2)  
4. Handle  
2. Bag support rod  
104-1329  
Note: You can adjust the handle height for comfortable  
operation. Stand behind the handle to determine the  
height. To adjust the handle height, position the cap  
screws and the locknuts that secure the handle latches to  
the handle into the other mounting holes in the latches.  
3. Slide the bag support rod through the second from the  
top mounting holes in the handle and secure each end  
with a cap locknut (Fig. 1).  
4. Use a cable tie to secure the control cables to the left  
104-8585  
handle below the bag support rod.  
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2. Hook the plastic clips on the front of the fuel tank onto  
Installing the Starter Rope  
the fuel tank bracket (Fig. 3).  
Pull the starter rope through the rope guide on the handle  
(Fig. 2).  
3. Secure the fuel tank to the tank base with the two  
self-tapping screws (Fig. 3). Do not overtighten the  
screws.  
4. Remove the red cap from the end of the fuel line and  
from the end of the elbow fitting on the fuel tank  
(Fig. 4).  
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1
m–210  
2
Figure 2  
3
1. Starter rope  
2. Rope guide  
1
m-7283  
Note: To make the rope easier to install, squeeze the  
control bar on the handle.  
Figure 4  
1. Fuel line  
3. Fuel valve  
Installing the Fuel Tank and the  
Fuel Line  
2. Elbow fitting  
5. Slide the end of the fuel line onto the elbow fitting  
1. Start the two self-tapping screws into the bottom of the  
(Fig. 4).  
fuel tank and then remove the screws (Fig. 3).  
6. Secure the fuel line in place with the fuel line clamp  
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(Fig. 4).  
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Installing the Discharge Tunnel  
Plug  
2
1. Open the discharge door by pulling forward on the  
handle and moving it rearward (Fig. 5). Hold the  
discharge door handle to prevent the spring-loaded  
door from closing while you insert the plug.  
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1
530  
Figure 3  
1. Tank base  
4. Fuel tank  
2. Fuel tank bracket  
3. Plastic clips  
5. Self-tapping screw (2)  
m-1914  
Figure 5  
1. Discharge door handle  
2. Plug rotated clockwise  
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2. Since the plug is slightly wider than the discharge  
tunnel opening, rotate the plug clockwise slightly  
while inserting it (Fig. 5).  
Before each use, ensure that the oil level is between the  
Add and Full marks on the dipstick (Fig. 7).  
Note: Ensure that the arrow on the plug decal points  
upward.  
3. Push the plug all the way in until the spring clip on the  
bottom of the plug clicks into place, locking the plug  
securely into the discharge tunnel (Fig. 6).  
2
3
1
m-7277  
m-7278  
Figure 7  
1. Dipstick  
2. Full  
3. Add  
Note: When the crankcase is empty, pour about 3/4 of the  
crankcase capacity of oil in the crankcase, then follow the  
procedure in this section.  
m-1915  
1
To add oil:  
Figure 6  
1. Move the lawn mower to a level surface.  
2. Clean around the dipstick (Fig. 7).  
1. Spring clip  
3. Remove the dipstick by rotating the cap  
4. Release the discharge door handle to lock the top of  
counterclockwise and pulling it out.  
the plug.  
4. Wipe the dipstick clean with a clean cloth.  
5. Insert the dipstick into the filler neck, then remove it.  
Before Starting  
Filling the Crankcase with Oil  
Note: To ensure an accurate oil level reading, you must  
fully install the dipstick.  
6. Read the oil level on the dipstick (Fig. 7).  
Initially, fill the crankcase with 30 ounces (0.88 liters) of  
oil. Use only high-quality SAE 30 or SAE 10W30 weight  
detergent oil that has the American Petroleum Institute  
(API) service classification SF, SG, SH, or SJ.  
7. If the oil level reading is below the Add mark on the  
dipstick, slowly pour only enough oil into the filler  
hole to raise the oil level to the Full mark on the  
dipstick.  
Oil Capacity  
Important Do not overfill the crankcase with oil and  
run the engine; engine damage will result. Drain the  
excess oil until the oil level on the dipstick reads Full.  
With Oil Filter  
30 ounces (0.88 L)  
24 ounces (0.70 L)  
Without Oil Filter  
8. Insert the dipstick into the filler neck and rotate the  
cap clockwise until it is tight.  
8
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Filling the Fuel Tank with  
Gasoline  
For best results, use clean, fresh, lead-free gasoline with  
an octane rating of 87 or higher. To ensure freshness,  
purchase only the quantity of gasoline that you expect to  
use in 30 days. Using unleaded gasoline results in fewer  
combustion deposits and longer engine life.  
Danger  
When fueling, under certain circumstances, a  
static charge can develop, igniting the gasoline. A  
fire or explosion from gasoline can burn you and  
others and damage property.  
Always place gasoline containers on the ground  
and away from your vehicle before filling.  
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.  
Important Do not add oil to the gasoline.  
Important Do not use methanol, gasoline containing  
methanol, gasohol containing more than 10% ethanol,  
premium gasoline, or white gas. Using these fuels can  
damage the engine’s fuel system.  
When practical, remove gasoline-powered  
equipment from the truck or trailer and refuel  
the equipment with its wheels on the round.  
If this is not possible, then refuel such  
equipment on a truck or trailer from a portable  
container, not from a gasoline dispenser nozzle.  
If you must use a gasoline dispenser nozzle,  
keep the nozzle in contact with the rim of the  
fuel tank or container opening at all times until  
fueling is complete.  
Important Do not use gasoline that has been stored  
since the last mowing season or longer.  
Danger  
In certain conditions, gasoline is extremely  
flammable and highly explosive. A fire or  
explosion from gasoline can burn you and others  
and can damage property.  
Use a fuel stabilizer/conditioner regularly during  
operation and storage. A stabilizer/conditioner cleans the  
engine during operation and prevents gum-like varnish  
deposits from forming in the engine during periods of  
storage.  
Fill the fuel tank outdoors, in an open area, and  
when the engine is cold. Wipe up any gasoline  
that spills.  
Do not fill the fuel tank completely full. Add  
gasoline to the fuel tank until the level is 1/4 to  
1/2 in. (6 to 13 mm) below the bottom of the  
filler neck. This empty space in the tank allows  
the gasoline to expand.  
Important Do not use fuel additives other than a fuel  
stabilizer/conditioner. Do not use fuel stabilizers with an  
alcohol base such as ethanol, methanol, or isopropanol.  
Never smoke when handling gasoline, and stay  
away from an open flame or where a spark may  
ignite the gasoline fumes.  
1. Clean around the fuel tank cap (Fig. 8).  
Store gasoline in an approved fuel container  
and keep it out of the reach of children.  
Never buy more than a 30-day supply of  
gasoline.  
2
1
3
m-7279  
Figure 8  
1. Oil fill/Dipstick  
2. Fuel tank cap  
3. Air cleaner  
2. Remove the cap from the tank.  
9
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3. Fill the fuel tank with unleaded gasoline to within 1/4  
to 1/2 inch (6 to 13 mm) from the top of the tank. Do  
not fill into the filler neck.  
Starting the Engine  
1. Connect the wire to the spark plug (Fig. 10).  
Important Do not fill the tank more than 1/4 inch  
(6 mm) from the top of the tank because the gasoline must  
have room to expand.  
1
4. Install the fuel tank cap and wipe up any spilled  
gasoline.  
Operation  
m-7280  
Note: Determine the left and right sides of the machine  
Figure 10  
from the normal operating position.  
1. Spark-plug wire  
Each time before you mow, make sure that the self-propel  
drive and the blade control bail operate properly. When  
you release the blade control bail, the blade and  
self-propel drive should stop. If they do not, contact an  
Authorized Service Dealer.  
2. Open the fuel valve (Fig. 8).  
3. Move the throttle control to the (Choke) position  
(Fig. 9).  
Caution  
4. Move the ground speed control to the  
(Neutral)  
position (Fig. 11).  
This machine produces sound levels in excess of  
85dBA at the operator’s ear and can cause  
hearing loss through extended periods of  
exposure.  
Wear hearing protection when operating this  
machine.  
1
224  
Controls  
The blade control bail, starter handle, and throttle control  
are on the upper handle as shown in Figure 9.  
Figure 11  
1. Ground speed control  
5. Pull the starter handle (Fig. 8) lightly until you feel  
2
resistance, then pull it sharply.  
6. Regulate the throttle and the ground speed control as  
desired when the engine starts.  
3
Note: If the engine fails to start after 3 pulls, repeat steps  
3 through 6.  
1
222  
Stopping the Engine  
1. Release the blade control bail and move the throttle  
Figure 9  
1. Blade control bail  
2. Starter handle  
3. Throttle control  
control to the  
(Off) position.  
2. Disconnect the wire from the spark plug if you do not  
use the lawn mower or if you leave it unattended.  
10  
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Operating the Blade and the  
Self-Propel Drive  
Using the Discharge Tunnel  
Plug  
Note: The self-propel features are for the self-propel  
1. Stop the engine and wait for all moving parts to stop.  
model only.  
2. Insert the plug; refer to Installing the Discharge Tunnel  
1. Have the blade control bail in the A position (Fig. 12).  
Plug on page 7.  
3. To remove the plug, move the discharge door handle  
rearward and lift up the spring clip on the bottom of  
the plug. When the plug is unlocked, pull it out of the  
discharge tunnel.  
C
B
A
Note: When grass is thick and lush, clippings may collect  
on and around the discharge tunnel plug. This may make  
removing the plug difficult. Clean the plug thoroughly  
after each use.  
m-3769  
Figure 12  
Adjusting the Cutting Height  
2. Slide the blade control bail to the right and raise it to  
the B position to engage the blade (Fig. 12).  
Each wheel is adjusted individually with a wheel height  
adjustment lever. Cutting heights are 1 inch (25 mm),  
1-1/2 inches (38 mm), 2 inches (51 mm), 2-1/2 inches  
(64 mm), 3 inches (76 mm), and 3-1/2 inches (89 mm).  
3. Squeeze the blade control bail against the handle to the  
C position to drive (Fig. 12).  
Note: To disengage the traction drive but keep the blade  
engaged, gradually release the blade control bail to the B  
position. To self-propel with the blade disengaged,  
squeeze the blade control bail against handle to the C  
position without sliding the blade control bail to the right.  
Danger  
Adjusting the cutting height levers could bring  
your hands into contact with a moving blade and  
result in serious injury.  
The lawn mower has 3 ground speeds. 1 is slow, 2 is  
medium, and 3 is fast. The ground speed control is located  
at the rear of the belt cover (Fig. 11).  
Stop the engine and wait for all movement to  
stop before adjusting the cutting height.  
Do not put your fingers under the housing when  
adjusting the cutting height.  
Note: You can vary the ground speed by increasing or  
decreasing the distance between the control bar and the  
handle. Lower the control bar to slow the lawn mower  
when making a turn or if the lawn mower is moving too  
fast for you. If you lower the control bar too far, the lawn  
mower stops self-propelling. Squeeze the control bar  
closer to the handle to increase the ground speed. When  
you hold the control bar tight against the handle, the lawn  
mower self-propels at the maximum ground speed. Move  
1. Pull the wheel height adjustment lever toward the  
wheel (Fig. 13) and move it to the desired setting.  
the ground speed control to the  
(Neutral) position  
1
when you use the lawn mower for trimming and whenever  
you leave the lawn mower.  
m-225  
Figure 13  
1. Wheel height adjustment  
lever  
2. Release the wheel height adjustment lever and seat it  
securely in the notch.  
3. Adjust all the wheels to the same cutting height  
setting.  
11  
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Mowing with the Grass Bag  
Using the Grass Bag  
Occasionally, you may wish to use the grass bag for  
bagging extra long grass, lush grass, or leaves.  
Warning  
A worn grass bag could allow small stones and  
other similar debris to be thrown in the operator’s  
or bystander’s direction and result in serious  
personal injury or death to the operator or  
bystanders.  
Installing the Grass Bag  
1. Stop the engine and wait for all moving parts to stop.  
2. Ensure that the discharge door handle is fully forward  
and that the pin is engaged in the catch (Fig. 14).  
Check the grass bag frequently. If it is damaged,  
install a new Exmark replacement bag.  
1
2
Cut the grass until the bag is full.  
Important Do not overfill the bag.  
3
Removing the Grass Bag  
m-1912  
1. Stop the engine and wait for all moving parts to stop.  
2. Raise the discharge door handle and move it forward  
Figure 14  
to engage the pin with the catch (Fig. 14).  
1. Bag frame on retaining  
post  
3. Handle fully forward.  
Discharge door closed.  
3. Grasp the handles at the front and the rear of the bag  
2. Pin engaged in catch  
and lift the bag off the lawn mower.  
4. Gradually tip the bag forward to empty the clippings.  
3. Slide the hole in the bag frame onto the retaining post  
5. To install the bag, refer to Installing the Grass Bag on  
on the discharge tunnel (Fig. 14).  
page 12.  
4. Set the rear of the bag frame onto the bag support rod.  
5. Pull the discharge door handle forward until the pin  
clears the catch, and move the handle rearward until  
the pin locks in the bag notch (Fig. 15).  
Danger  
If the discharge door does not close completely,  
the lawn mower could throw objects, causing  
serious personal injury or death.  
1
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.  
Danger  
m-1913  
Figure 15  
The lawn mower can throw grass clippings and  
other objects through an open discharge tunnel.  
Objects thrown with enough force could cause  
serious personal injury or death to the operator or  
bystander.  
1. Pin locked in bag notch  
Note: The discharge door in the lawn mower housing  
is now open.  
Never open the door on the discharge tunnel when  
the engine is running.  
12  
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Cutting Grass  
Operating Tips  
Grass grows at different rates at different times of the  
year. In the summer heat, it is best to cut grass at the 2  
inch (51 mm), 2-1/2 inch (64 mm), or 3 inch (76 mm)  
cutting height settings. Cut only about a third of the  
grass blade at a time. Do not cut below the 2 inch (51  
mm) setting unless the grass is sparse or it is late fall  
when grass growth begins to slow down.  
Review the safety instructions and read this manual  
carefully before operating the lawn mower.  
Clear the area of sticks, stones, wire, branches, and  
other debris that the blade could hit and throw.  
Keep everyone, especially children and pets, away  
from the area of operation.  
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 leaves  
clump on top of the lawn, the lawn mower may plug  
and cause the engine to stall.  
Avoid striking trees, walls, curbs, or other solid  
objects. Never deliberately mow over any object.  
If the lawn mower strikes an object or starts to vibrate,  
immediately stop the engine, disconnect the wire from  
the spark plug, and examine the lawn mower for  
damage.  
Alternate the mowing direction. This helps disperse  
the clippings over the lawn for even fertilization.  
Maintain a sharp blade throughout the cutting season.  
Periodically file down nicks on the blade.  
If the finished lawn appearance is unsatisfactory, try one  
or more of the following:  
Replace the blade when necessary with an original  
Exmark replacement blade.  
Sharpen the blade.  
Mow only dry grass or leaves. Wet grass and leaves  
tend to clump on the yard and can cause the lawn  
mower to plug or the engine to stall.  
Walk at a slower pace while mowing.  
Raise the cutting height on your lawn mower.  
Cut the grass more frequently.  
Warning  
Overlap cutting swaths instead of cutting a full swath  
with each pass.  
Wet grass or leaves can cause serious injury if you  
slip and contact the blade.  
Set the cutting height on the front wheels one notch  
lower than the rear wheels. For example, set the front  
wheels at 2 inches (51 mm) and the rear wheels at  
2-1/2 inches (64 mm).  
Mow only in dry conditions.  
Clean the underside of the lawn mower deck after each  
mowing. See Cleaning the Underside of the Lawn  
Mower Housing on page 15.  
Cutting Leaves  
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.  
Keep the engine in good running condition.  
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.  
Warning  
If there are more than 5 inches (12.7 cm) of leaves on  
the lawn, set the front cutting height 1 or 2 notches  
higher than the rear cutting height. This makes it  
easier to feed the leaves under the lawn mower deck.  
Operating a lawn mower with its engine running  
at a speed greater than the factory setting can  
cause the lawn mower to throw a part of the blade  
or engine into the operator’s or bystander’s area  
and result in serious personal injury or death.  
Slow down your mowing speed if the lawn mower  
does not cut the leaves finely enough.  
If you mow over oak leaves, you can add lime to the  
grass in the spring to reduce the acidity of the oak  
leaves.  
Do not change the engine speed setting.  
If you suspect the engine speed is faster than  
normal, contact an Authorized Service Dealer.  
Clean the air filter frequently. Mulching stirs up more  
clippings and dust which clogs the air filter and  
reduces engine performance.  
13  
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Maintenance  
Note: Determine the left and right sides of the machine from the normal operating position.  
Recommended Maintenance Schedule  
Maintenance Service  
Maintenance Procedure  
Interval  
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.  
Each Use  
Remove grass clippings and dirt from under the housing.  
Clean the discharge tunnel and the discharge tunnel plug.  
Check the blade and the engine mounting fasteners. Tighten them if they are  
5 Hours  
loose.  
25 Hours  
Clean the foam pre-cleaner of the air cleaner.  
1
Change the engine oil (without the oil filter).  
Sharpen or replace the blade; maintain it more frequently if the edge dulls  
quickly in rough or in sandy conditions.  
Check for leaks in the fuel system and/or a deteriorating fuel hose. Replace  
50 Hours  
75 Hours  
parts if necessary.  
Remove grass clippings and debris from under the belt cover.  
Lubricate the pivot arms (self-propel model only).  
Adjust the self-propel drive system (self-propel model only).  
Change the oil filter.  
Inspect the spark plug and replace it if necessary.  
Clean the cooling system; remove grass clippings, debris, or dirt from the engine  
air cooling fins and starter. Clean the system more frequently in dirty or  
high-chaff conditions.  
100 Hours  
Clean the fuel filter.  
Lubricate the gear case.  
Adjust the blade brake cable.  
Service the wheels.  
Replace the paper air filter. Replace it more frequently in dusty operating  
300 Hours  
Storage  
conditions.  
Empty the fuel tank before repairs as directed or before storage.  
1
Change the engine oil after the first 8 operating hours.  
Important Refer to your engine operator’s manual for additional maintenance procedures.  
14  
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Caution  
If you leave the wire on the spark plug, someone could accidently start the engine and seriously  
injure you or other bystanders.  
Disconnect the wire from the spark plug before you do any maintenance. Set the wire aside so  
that it does not accidently contact the spark plug.  
Note: The blade will draw in water and wash out  
clippings. Let the water run until you no longer see  
Checking the Engine Oil Level  
clippings being washed out from under the housing.  
4. Stop the engine and wait for all moving parts to stop.  
5. Turn off the garden hose.  
Before you use the lawn mower, make sure that the oil  
level is between the Add and the Full marks as shown on  
the dipstick (Fig. 7). If the oil level is below the Add  
mark, and oil. Refer to Filling the Crankcase with Oil on  
page 8.  
6. Start the lawn mower and let it run for a few minutes  
to dry out the moisture on the lawn mower and its  
components.  
Cleaning the Underside of the  
Lawn Mower Housing  
To ensure the best performance, keep the underside of the  
lawn mower housing clean (Fig. 16).  
Scraping Method  
If washing does not remove all debris from under the lawn  
mower, scrape it clean.  
1. Disconnect the wire from the spark plug (Fig. 10).  
2. Drain the fuel from the fuel tank. Refer to Emptying  
the Fuel Tank and Cleaning the Fuel Filter on page 18.  
Warning  
757  
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.  
Figure 16  
Washing Method  
Avoid fuel spills by running the engine dry or by  
removing the gasoline with a hand pump; never  
siphon.  
1. Position the lawn mower on a flat concrete or asphalt  
surface near a garden hose.  
2. Start the engine.  
3. Tip the lawn mower onto its right side (Fig. 16).  
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 (Fig. 17).  
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.  
1
7. Connect the wire to the spark plug.  
1093  
Figure 17  
1. Rear right wheel  
15  
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4. Remove the cover and clean it thoroughly (Fig. 18).  
Cleaning the Discharge Tunnel  
and Plug  
5. Remove the paper air filter and discard it as required  
(Fig. 19).  
Remove the plug from the discharge tunnel and clean it  
after each use.  
1
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.  
2
Warning  
m-7281  
Grass clippings and other objects can be thrown  
from an open discharge tunnel and cause serious  
injury or kill the operator or bystanders.  
Figure 19  
1. Paper air filter  
2. Foam pre-cleaner  
Never start or operate the lawn mower unless one  
of the following is true:  
Important Do not try to clean a paper filter.  
The discharge tunnel plug is locked securely in  
the discharge tunnel.  
The grass bag is locked in place.  
The optional side discharge chute is locked in  
place.  
6. Remove the foam pre-cleaner and wash it with a mild  
detergent and water, then blot it dry (Fig. 18).  
7. Saturate the pre-cleaner with clean engine oil, then  
squeeze it (do not twist) to remove the excess oil.  
The discharge tunnel door is locked in place.  
8. Install the foam pre-cleaner.  
9. Install the new paper air filter.  
Servicing the Air Filter  
10. Install the cover and secure it with the screw.  
Clean the foam pre-cleaner every 25 operating hours.  
Replace the paper air filter once every season or every  
300 operating hours; replace it more frequently in dusty  
conditions.  
Changing the Engine Oil  
Change the oil after the first 8 operating hours and than  
after every 50 operating hours or every season (more  
frequently in dusty or dirty conditions).  
Important Do not operate the engine without the air  
filter assembly; extreme engine damage will occur.  
1. Run the engine to warm the engine oil.  
1. Stop the engine and wait for all moving parts to stop.  
2. Disconnect the wire from the spark plug (Fig. 10).  
Note: Warm oil flows better and carries more  
contaminants.  
3. Remove the screw that secures the air cleaner cover  
(Fig. 18).  
Warning  
3
Oil may be hot after engine has been run, and  
contact with hot oil can cause severe personal  
injury.  
Avoid contacting the hot engine oil when you  
drain it.  
1
m-7282  
2
2. Stop the engine and wait for all moving parts to stop.  
3. Disconnect the wire from the spark plug (Fig. 10).  
Figure 18  
1. Screw  
2. Cover  
3. Paper air filter  
4. Place a suitable drain pan beside the right side of the  
lawn mower.  
5. Remove the dipstick by rotating the cap  
counterclockwise and pulling it out (Fig. 7).  
16  
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6. Raise the left side of the lawn mower to drain the oil  
Inspecting the Blade  
into the drain pan.  
Carefully examine the blade for sharpness and wear,  
especially where the flat and the curved parts meet  
(Fig. 21A). 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 (Figs. 21B and 21C), replace the  
blade; refer to Removing the Blade on page 17.  
1
Note: You can also remove the oil from the crankcase  
using an oil extractor.  
7. Lower the left side of the lawn mower.  
8. Insert the dipstick into the filler neck and rotate the  
cap clockwise until it is tight.  
9. Recycle the used oil according to local codes.  
A
10. Fill the crankcase to the Full line on the dipstick with  
fresh oil. Refer to the Filling the Crankcase with Oil  
on page 8.  
1
2
11. Wipe up any spilled oil.  
B
12. Connect the wire to the spark plug.  
1
3
C
Maintaining the Cutting Blade  
Always mow with a sharp blade. A sharp blade cuts  
cleanly and without tearing or shredding the grass blades.  
4
270  
Figure 21  
1. Stop the engine and wait for all moving parts to stop.  
2. Disconnect the wire from the spark plug (Fig. 10).  
1. Sail  
2. Flat part of blade  
3. Wear  
4. Slot formed  
3. Drain the gasoline from the fuel tank; refer to  
Emptying the Fuel Tank and Cleaning the Fuel Filter  
on page 18.  
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.  
4. Tip the lawn mower onto its right side (Fig. 20).  
2
Danger  
1
A worn or damaged blade can break, and a piece  
of the blade could be thrown into the operator’s  
or bystander’s area, resulting in serious personal  
injury or death.  
Inspect the blade periodically for wear or  
damage.  
757  
3
Replace a worn or damaged blade.  
Figure 20  
1. Blade  
3. Accelerator  
2. Blade bolt and lock  
washer  
Removing the Blade  
1. Grasp the end of the blade using a rag or a thickly  
padded glove.  
2. Remove the blade bolt, the lock washer, the  
accelerator, and the blade (Fig. 20).  
17  
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3. Connect the wire to the spark plug.  
Sharpening the Blade  
File the top side of the blade to maintain its original  
cutting angle (Fig. 22A) and inner cutting edge radius  
(Fig. 22B). The blade will remain balanced if you remove  
the same amount of material from both cutting edges.  
Emptying the Fuel Tank and  
Cleaning the Fuel Filter  
The fuel filter (screen) element is located inside the fuel  
tank. Clean the fuel filter element every 100 operating  
hours.  
A
B
2
1
153  
1. Stop the engine and wait for it to cool down.  
Important Drain gasoline from a cold engine only.  
2. Disconnect the wire from the spark plug (Fig. 10).  
3. Close the fuel valve (Fig. 4).  
m-4783  
Figure 22  
1. Sharpen at this angle only  
2. Maintain the original  
radius here  
4. Disconnect the fuel line (Fig. 29) by loosening the  
Balancing the Blade  
tube clamp at the carburetor.  
1. 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 (Fig. 23).  
5. Open the fuel valve by turning the lever to the open  
position (Fig. 8).  
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.  
1007  
Figure 23  
10. Install the fuel tank and fuel line; refer to Installing the  
Fuel Tank and the Fuel Line on page 7.  
Note: You can also check the balance using a  
commercially manufactured blade balancer.  
2. If either end of the blade rotates downward, file that  
end (not the cutting edge or the end near the cutting  
edge). The blade is properly balanced when neither  
end drops.  
Cleaning under the Belt Cover  
Self-propel Model only  
Keep the area under the belt cover free of debris.  
1. Stop the engine and wait for all moving parts to stop.  
2. Disconnect the wire from the spark plug (Fig. 10).  
Installing the Blade  
1. Install a sharp, balanced Exmark blade, the  
accelerator, the lock washer, and the 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 50 ft-lb (68 Nm).  
3. Remove the bolts that secure the belt cover (Fig. 24) to  
the lawn mower housing.  
1
Warning  
Operating the lawn mower without the  
accelerator in place can cause the blade to flex,  
bend, or break, resulting in serious injury or  
death to the operator or bystanders.  
m-224  
Figure 24  
Do not operate the lawn mower without the  
accelerator.  
1. Belt cover  
2. Return the lawn mower to its upright position.  
18  
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4. Lift off the cover and brush out all the debris around  
2. Rotate the control knob clockwise !/2 turn if the lawn  
mower does not self-propel. If the lawn mower creeps  
forward, rotate the knob !/2 turn counterclockwise to  
loosen the belt (Fig. 26).  
the belt area.  
5. Install the belt cover.  
6. Connect the wire to the spark plug.  
Lubricating the Pivot Arms  
Self-propel Model only  
After every 50 operating hours or when the season ends,  
lubricate the pivot arms.  
1. Move the rear wheel cutting height levers to the center  
1
setting.  
m-228  
2. Wipe the grease fittings with a clean rag (Fig. 25).  
Figure 26  
1. Control knob  
3. Slowly pull the lawn mower backward while you  
gradually move the control bar toward the handle.  
Note: The adjustment is correct when the rear wheels stop  
turning and the control bar is about one inch (2.5 cm)  
from the handle (Fig. 27).  
1
m-232  
Figure 25  
1
1. Grease fitting  
3. Install a grease gun onto the fitting and gently apply 2  
or 3 pumps of #2 multi-purpose lithium base grease  
(Fig. 25).  
m-513  
Figure 27  
1. One inch (2.5 cm)  
Note: Excessive grease pressure may damage the seals.  
Adjusting the Self-propel Drive  
Self-propel Model only  
If the lawn mower does not self-propel or has a tendency  
to creep forward when the control bar is more than 1-1/2  
inches (3.8 cm) from the handle, adjust the wheel drive  
control knob on the rear of the gear box.  
1. Close the door in the lawn mower housing and remove  
the grass bag.  
19  
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Servicing the Spark Plug  
Check the spark plug after every 100 operating hours. Use  
Warning  
an NGK BPR5ES spark plug or equivalent.  
Oil may be hot after the engine has been run, and  
contact with hot oil can cause sever personal  
injury.  
1. Stop the engine and wait for all moving parts to stop.  
2. Disconnect the wire from the spark plug (Fig. 10).  
3. Clean around the spark plug.  
Avoid contacting the hot engine oil when you  
drain it.  
4. Remove the spark plug from the cylinder head.  
2. Stop the engine and wait for all moving parts to stop.  
3. Disconnect the wire from the spark plug (Fig. 10).  
Important Replace a cracked, fouled, or dirty spark  
plug. Do not clean the electrodes because grit entering the  
cylinder can damage the engine.  
4. Drain the engine oil; refer to Changing the Engine Oil  
on page 16.  
5. Set the gap on the plug to 0.030 in. (0.76 mm)  
(Fig. 28).  
5. Place a rag under the oil filter to catch any oil that  
may leak out as you remove the filter.  
1
6. Remove the oil filter.  
7. Use your finger to coat the gasket on the new filter  
with clean engine oil (Fig. 30).  
m-110  
1
Figure 28  
1. 0.030 in. (0.76 mm)  
6. Install the spark plug and the gasket seal.  
7. Torque the plug to 17 ft-lb (23 Nm).  
8. Connect the wire to the spark plug.  
mĆ3862  
Changing the Oil Filter  
Figure 30  
Replace the oil filter (Fig. 29) after every 100 operating  
hours or yearly, whichever comes first.  
1. Gasket  
8. Install the new filter and hand tighten it 2/3 turn only.  
9. Fill the crankcase to the Full line on the dipstick with  
fresh oil. Refer to Filling the Crankcase with Oil on  
page 8.  
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.  
1
2
m-7284  
13. Add oil to compensate for the oil in the oil filter. Refer  
Figure 29  
to Checking the Engine Oil Level on page 15.  
1. Oil filter  
2. Fuel line  
14. Recycle the used oil filter according to local codes.  
1. Run the engine to warm the oil.  
20  
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Hand-push Model only  
Lubricating the Gear Case  
After every 100 operating hours, grease the gear case.  
A. Loosen the jam nut on the blade brake cable  
(Fig. 32).  
1. Remove the grass bag.  
1
2. Install a grease gun onto the fitting through the belt  
cover opening (Fig. 31).  
2
2
3
1
4
5
6
483  
Figure 32  
m-224  
1. Handle  
4. Cable adjuster  
2. Brake lever  
5. Jam nut  
3. 3/16 to 1/4 in. (5 to 6 mm)  
6. cable conduit  
Figure 31  
1. Belt cover  
2. Grease fitting  
B. Insert a 3/16 to 1/4 in. (5 to 6 mm) object between  
the brake lever and the handle.  
3. Gently apply one to 2 pumps of #2 multi-purpose  
lithium-base grease.  
C. Turn the cable adjuster on the brake cable until you  
remove the slack.  
4. Install the grass bag.  
D. Tighten the jam nut.  
Self-propel Model only  
Adjusting the Blade Brake  
Cable  
A. Loosen the nut on the cable bracket (Fig. 33).  
Whenever you install a new blade brake cable assembly,  
adjust it.  
1
1. Stop the engine and wait for all moving parts to stop.  
2. Disconnect the wire from the spark plug (Fig. 8).  
3. Check the adjustment of the cable by moving the  
control bar toward the handle until you remove the  
slack in the cable.  
2
3
4
Note: The gap between the brake lever and the handle  
must be between 3/16 and 1/4 in. (5 and 6 mm). To  
adjust the cable, go to step 4.  
Figure 33  
1. Handle  
3. 3/16 to 1/4 in. (5 to 6 mm)  
4. cable bracket  
2. Brake lever  
4. To adjust the cable, do the following:  
B. Insert a 3/16 to 1/4 in. (5 to 6 mm) object between  
the brake lever and the handle.  
C. Pull down on the cable conduit until you remove  
the slack from the wire.  
D. Tighten the nut.  
21  
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6. Install the 2 cap screws and 2 locknuts previously  
removed in the remaining holes in the wheel halves  
and tighten. Remove the 2 long screws or bolts and  
replace them with 2 cap screws and 2 locknuts  
(Fig. 34).  
Servicing the Wheels  
Removing the Wheels  
1. Stop the engine and wait for all moving parts to stop.  
2. Disconnect the wire from the spark plug (Fig. 10).  
7. Install the wheel to the pivot arm with the cap screws,  
a spacer, and a locknut. Ensure that the spacer is  
positioned between the wheel hub and the pivot arm  
(Fig. 34).  
3. Remove the cap screw, the wheel spacer, and the  
locknut mounting the wheel to the pivot arm (Fig. 34).  
1
2
3
4
5
1
Storage  
To prepare the lawn mower for off-season storage,  
perform the recommended maintenance procedures. Refer  
to Maintenance on page 14.  
Store the lawn mower in a cool, clean, dry place. Cover  
the lawn mower to keep it clean and protected.  
296  
6
7
5
7
8
9
Preparing the Fuel System  
Figure 34  
1. Locknuts  
2. Wheel spacer  
6. Plastic cover (rear wheels  
only)  
Warning  
7. Lug  
3. Bearing/hub assembly  
4. Bearing spacer  
5. Wheel half  
Gasoline can vaporize if you store it over long  
periods of time and explode if it comes into  
contact with an open flame.  
8. Bearing (2)  
9. Cap screw  
Do not store gasoline over long periods of time.  
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.)  
4. Separate the wheel halves from the tire by removing 4  
cap screws and 4 locknuts (Fig. 34).  
Note: If you remove the bearings from the bearing/hub  
assembly, remove them by pressing on the bearing spacer  
(Fig. 34).  
Allow the engine to cool before storing it in any  
enclosure.  
Assembling the Wheels  
Empty the fuel tank when mowing the last time before  
storing the lawn mower.  
1. Position the tire onto one wheel half, aligning the lugs  
on each (Fig. 34).  
1. Run the lawn mower until the engine stops from  
running out of fuel.  
2. Place the bearing/hub assembly into the center hole of  
the wheel half. Ensure that the legs of the hub are  
positioned over the flange of the hole (Fig. 34).  
2. Prime the engine and start it again.  
3. Allow the engine to run until it stops. When you can  
3. Place the other wheel half onto the bearing/hub  
assembly, aligning the wheel and the tire lugs and the  
mounting holes (Fig. 34).  
no longer start the engine, it is sufficiently dry.  
4. Using 2 fully threaded screws or bolts (1/4–20 x  
1.50 in.) and non-locking nuts, loosely secure the  
wheel halves together. Mount the screws or bolts in the  
opposing holes (Fig. 34).  
5. Check the alignment of all parts and tighten the  
screws, alternating from side to side for a uniform fit,  
until the wheel halves are drawn together (Fig. 34).  
22  
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Preparing the Engine  
1. While the engine is still warm, change the oil from the  
crankcase. Refer to Changing the Engine Oil on  
page 16.  
Removing the Lawn Mower  
from Storage  
1. Check and tighten all fasteners.  
2. Remove the spark plug and spin the engine rapidly  
2. Remove the spark plug (Fig. 10).  
using the starter to blow excess oil from the cylinder.  
3. Using an oil can, add about one tablespoon of oil to  
3. Clean the spark plug or replace it if it is cracked,  
the crankcase through the spark plug hole.  
broken, or if the electrodes are worn.  
4. Slowly rotate the engine several times, using the  
4. Install the spark plug and torque it to 17 ft-lb  
starter rope, to distribute the oil.  
(23 N m).  
5. Install the spark plug but do not connect the wire to  
5. Perform any needed maintenance procedures; refer to  
the spark plug.  
Maintenance on page 14.  
6. Fill the fuel in the fuel tank with fresh gasoline.  
7. Check the engine oil level.  
General Information  
1. Clean the lawn mower housing. Refer to Cleaning the  
8. Connect the wire to the spark plug.  
Underside of the Lawn Mower Housing on page 15.  
2. Clean any dirt and chaff from the cylinder, cylinder  
head fins, and blower housing.  
Accessories  
3. Remove grass clippings, dirt, and grime from the  
external parts of the engine, the shrouding, and the top  
of the lawn mower housing.  
You may purchase the following accessory from an  
Authorized Service Dealer:  
Side Discharge Kit  
4. Check the condition of the blade. Refer to Maintaining  
the Cutting Blade on page 17.  
You can install the side discharge kit installs in seconds. It  
is rear mounted in place of the grass bag. It disperses  
clippings while trimming on both sides (Fig. 35).  
5. Service the air filter; refer to Servicing the Air Filter  
on page 16.  
6. Lubricate the pivot arms; refer to Lubricating the Pivot  
Arms on page 16.  
7. Tighten all nuts, bolts, and screws.  
8. Touch up all rusted or chipped paint surfaces with  
paint available from an Authorized Service Dealer.  
1
2047  
Figure 35  
1. Side discharge chute  
23  
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Troubleshooting  
Exmark designed and built your lawn mower for trouble-free operation. Check the following components and items  
carefully, and refer to Maintenance on page 14 for more information. If a problem continues, contact an Authorized  
Service Dealer.  
Problem  
Possible Causes  
Corrective Action  
Engine does not start  
1. The fuel tank is empty or the  
fuel system contains stale fuel.  
1. Drain and/or fill the fuel tank  
with fresh gasoline. If the  
problem persists, contact an  
Authorized Service Dealer.  
2. The throttle lever is not in the  
Choke position.  
2. Move the throttle lever to the  
Choke position.  
3. The wire is not connected to  
the spark plug.  
3. Connect the wire to the spark  
plug.  
4. The spark plug is pitted, fouled, 4. Check the spark plug and  
or the gap is incorrect.  
adjust the gap if necessary.  
Replace the spark plug if it is  
pitted, fouled, or cracked.  
Engine starts hard or loses power  
1. The fuel tank contains stale  
fuel.  
1. Drain and fill the fuel tank with  
fresh gasoline.  
2. The fuel cap vent hole is  
plugged.  
2. Clean the fuel cap vent hole or  
replace the fuel cap.  
3. The air filter element is dirty  
and is restricting the air flow.  
3. Clean the air filter pre-cleaner  
and/or replace the paper air  
filter.  
4. The underside of the lawn  
mower deck contains clippings  
and debris.  
4. Clean the underside of the lawn  
mower deck.  
5. The spark plug is pitted, fouled, 5. Check the spark plug and  
or the gap is incorrect.  
adjust the gap if necessary.  
Replace the spark plug if it is  
pitted, fouled, or cracked.  
6. The engine oil level is low or  
the oil is dirty.  
6. Check the engine oil. Change  
the oil if it is dirty or add oil if it  
is low.  
Engine runs rough  
1. The wire is not connected to  
the spark plug.  
1. Connect the wire to the spark  
plug.  
2. The spark plug is pitted, fouled, 2. Check the spark plug and  
or the gap is incorrect.  
adjust the gap if necessary.  
Replace the spark plug if it is  
pitted, fouled, or cracked.  
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.  
24  
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Problem  
Possible Causes  
Corrective Action  
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  
1. All four wheels are not at the  
same height.  
1. Place all four wheels at the  
same height.  
2. The blade is dull.  
2. Sharpen and balance the  
blade.  
3. You are mowing in the same  
pattern repeatedly.  
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.  
Discharge chute plugs  
1. The throttle lever is not in the  
Fast position.  
1. Move the throttle lever to the  
Fast position.  
2. The cutting height is too low.  
3. You are mowing too fast.  
4. The grass is wet.  
2. Raise the cutting height.  
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.  
Lawn mower does not self-propel  
(Self-propel model 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.  
25  
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Limited Warranty  
Exmark) Turf Equipment  
Conditions and Products Covered  
If for any reason you are dissatisfied with the Service Dealer’s  
analysis or with the assistance provided, contact us at:  
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 manufactured by Exmark and found by us (in the exercise  
of our reasonable discretion) to be defective in factory materials or  
workmanship.  
Exmark Customer Service Department  
The Exmark Warranty Company  
2101 Ashland Avenue  
Beatrice, NE 68310  
402–223–6375 or  
This warranty applies to Exmark turf equipment sold in the US 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  
The Exmark turf equipment, including any defective part, must be  
returned to an authorized Exmark service dealer within the  
warranty period. This warranty extends only to turf equipment  
operated under normal conditions. You must 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.  
Products  
Warranty Period  
All Products (except as noted below)  
1 year  
(90 days for rental use)  
Peerless 5–speed transmission  
1 year  
(extended beyond manufacturer’s warranty of 90 days)  
As a condition to this warranty, customer shall have read the  
operator’s manual and shall have completed and submitted to  
Exmark Warranty Company, within the prescribed time, the  
Exmark warranty registration.  
Frame, Hydrostatic Traction System,  
Electric Clutch and Exmark supplied Mufflers  
Blade Spindle Assy and Deck Jackshaft Assy  
2 years  
3 years  
(1 year parts and labor, with additional 2 years parts only)  
General Conditions  
Belts and Tires  
Battery  
90 days  
The sole liability of Exmark and Exmark Warranty Company with  
respect to this warranty shall be repair and replacement as set forth  
herein. Neither Exmark nor Exmark Warranty Company shall  
have any liability for any other cost, loss or damage, including  
Refer to the battery manufacturer’s  
warranty in the literature packet  
Engine*  
Warranty is covered by engine manufacturer  
*Please refer to the engine manufacturer’s warranty statement that but not limited to, any incidental or consequential loss or  
is included in the literature packet. We are not authorized to handle damage.  
warranty adjustments on engines.  
In particular, we shall have no liability or responsibility for:  
This warranty only includes the cost of parts and labor.  
Expenses related to gasoline, oil or lubricants.  
Travel time, overtime, after hours time or other extraordinary  
repair charges or charge relating to repairs or replacements  
outside of normal business hours at the place of business of  
the authorized Exmark service dealer.  
Items and Conditions Not Covered  
This warranty does not cover the following:  
Pickup and delivery charges to and from any authorized  
Exmark Service Dealer.  
Rental of like or similar replacement equipment during the  
period of any warranty, repair or replacement work.  
Any damage or deterioration due to normal use, wear and tear,  
or exposure.  
Any telephone or telegram charges or travel charges.  
Cost of regular maintenance service or parts, such as filters,  
fuel, lubricants, tune-up parts, and adjustments.  
Loss or damage to person or property other than that covered  
by the terms of this warranty.  
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 claims for lost revenue, lost profit or additional cost as a  
result of a claim of breach of warranty.  
Attorney’s fees.  
Any repairs necessary due to use of parts, accessories or  
supplies, including gasoline, oil or lubricants, incompatible with  
the turf equipment or other than as recommended in the  
operator’s manual or other operational instructions provided by  
Exmark.  
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 understandings, agreements, representations, or  
warranties, express or implied, including but not limited to any  
regarding the merchantability (that product is fit for ordinary use) or  
fitness for use (that product is fit for a particular purpose), not  
specified herein, respecting the equipment which is the subject of  
this warranty.  
All warranty work must be performed by an authorized Exmark  
Service Dealer using Exmark approved replacement parts.  
Instructions for Obtaining Warranty Service  
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.  
1. Contact any Exmark Service Dealer to arrange service at their  
dealership. To locate a dealer convenient to you, access our  
402–223–6375.  
This warranty gives you specific legal rights, and you may also  
have other rights which vary from state to state.  
2. Bring the product and your proof of purchase (sales receipt) to  
the Exmark Service Dealer.  
Rev. 8/1/2003  
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SERVICE RECORD  
Date  
Description Work Done  
Service Done By  
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SEE EXMARK’S COMPLETE  
LINE OF PRODUCTS FOR TURF CARE  
LAZER Z  
LAZER Z XP  
TURF RANGER  
TURF TRACER HP  
METRO  
LAZER Z HP  
LAZER Z CT  
TURF TRACER  
VIKING HYDRO  
METRO HP  
ULTRA VACt  
GRASS CATCHER  
ULTRA VACt QDS  
SELF STEERING SULKY  
MICRO-MULCHt ACCESSORY  
Warning  
CALIFORNIA  
Proposition 65 Warning  
The engine exhaust from this product contains  
chemicals known to the State of California to  
cause cancer, birth defects, or other reproductive  
harm.  
E2003  
EXMARK MFG. CO. INC.  
FORM NO. 3329-962  
(402) 223-6300  
INDUSTRIAL PARK BOX 808  
BEATRICE, NE 68310  
FAX (402) 223-5489  
ALL RIGHTS RESERVED  
PRINTED IN U. S. A.  
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