metro 21 - user manual search engine · safety operation warning operatingengineparts,especiallythe...

METRO® 21

For Serial Nos.790,000 & HigherPart No. 4500-400 Rev. A

WARNINGCALIFORNIA

Proposition 65 Warning

The engine exhaust from this productcontains chemicals known to the State ofCalifornia to cause cancer, birth defects, orother reproductive harm.

Important: When the mower is used or operatedon any California forest, brush or grass coveredland, a working spark arrester must be attachedto the muffler. If not, the operator is violatingstate law, Section 4442 Public Resource Code. Toacquire a spark arrester for your unit, see yourEngine Service Dealer.

This spark ignition system complies with CanadianICES-002 Ce système d’allumage par ètincelle devèhicule est conforme à la norme NMB-002 duCanada

The enclosed Engine Owner’s Manual issupplied for information regarding The U.S.Environmental Protection Agency (EPA) andthe California Emission Control Regulation ofemission systems, maintenance and warranty.

Keep this engine Owner’s Manual with your unit.Should this engine Owner’s Manual becomedamaged or illegible, replace immediately.Replacements may be ordered through theengine manufacturer.

Exmark reserves the right to make changes oradd improvements to its products at any timewithout incurring any obligation to make suchchanges to products manufactured previously.Exmark, or its distributors and dealers, acceptno responsibility for variations which may beevident in the actual specifications of its productsand the statements and descriptions containedin this publication.

© 2008—Exmark Mfg. Co., Inc.Industrial Park Box 808Beatrice, NE 68310 2

Contact us at www.Exmark.com.Printed in the USA

All Rights Reserved

IntroductionCONGRATULATIONS on the purchase of yourExmark Mower. This product has been carefullydesigned and manufactured to give you a maximumamount of dependability and years of trouble-freeoperation.

This manual contains operating, maintenance,adjustment, and safety instructions for your Exmarkmower.

BEFORE OPERATING YOUR MOWER,CAREFULLY READ THIS MANUAL IN ITSENTIRETY.

By following the operating, maintenance, and safetyinstructions, you will prolong the life of your mower,maintain its maximum efficiency, and promote safeoperation.

If additional information is needed, or should yourequire trained mechanic service, contact yourauthorized Exmark equipment dealer or distributor.

All Exmark equipment dealers and distributors arekept informed of the latest methods of servicingand are equipped to provide prompt and efficientservice in the field or at their service stations. Theycarry ample stock of service parts or can secure thempromptly for you from the factory.

All Exmark parts are thoroughly tested and inspectedbefore leaving the factory, however, attention isrequired on your part if you are to obtain the fullestmeasure of satisfaction and performance.

Whenever you need service, genuine Exmark parts,or additional information, contact an AuthorizedService Dealer or Exmark Customer Service and havethe model and serial numbers of your product ready.

Figure 1 identifies the location of the model and serialnumbers on the product. Write the numbers in thespace provided.

Figure 11. Model and serial number location

Model No.

Serial No.

3

ContentsIntroduction ........................................................... 3Safety ..................................................................... 5

Safety Alert Symbol ......................................... 5Safe Operating Practices .................................. 5Safety and Instructional Decals ....................... 9

Specifications ....................................................... 12Model Numbers ............................................ 12Systems ......................................................... 12Dimensions................................................... 12

Product Overview ................................................ 13Operation ............................................................. 14

Controls ........................................................ 14Pre-Start........................................................ 15Operating Instructions .................................. 16

Maintenance ......................................................... 23RecommendedMaintenance Schedule(s) ........... 23Periodic Maintenance ....................................... 24Check Engine Oil Level ................................. 24Checking the Blade Brake Clutch (ForUnits with a Blade Brake ClutchOnly)......................................................... 24

Check the Mower Blade ................................. 24Check for Loose Hardware ............................ 26Service Air Filter(Kawasaki Units) ................. 26Service Air Filter(Honda Units) ..................... 27Change Engine Oil ........................................ 28Changing the Oil Filter (Kawasaki UnitsOnly):........................................................ 28

Servicing the Wheels ..................................... 29Check Condition Of Belt(Self-PropelledUnits Only) ............................................... 29

Lubricate the Pivot Arms............................... 29Lubricate the Gear Case(Self-PropelledUnits Only) ............................................... 30

Check Spark Plugs ......................................... 30Adjustments ..................................................... 31Adjusting the Self-PropelDrive(Self-Propelled Units Only) ............... 31

Adjusting the Blade Brake Cable .................... 31Cleaning ........................................................... 32CleanGrass Build-UpUnderDeck ................ 32Cleaning the Discharge Tunnel andPlug........................................................... 32

Cleaning Under the BeltCover(Self-PropelledModelsOnly) ........... 33

Cleaning the Blade Brake ClutchShield ........................................................ 33

Emptying the Fuel Tank and Cleaningthe Fuel Filter (Kawasaki UnitsOnly)......................................................... 34

Waste Disposal .............................................. 34Storage ................................................................. 35

Preparing the Fuel System.............................. 35Preparing the Engine ..................................... 35General Storage Information ......................... 35Removing the Lawn Mower fromStorage ...................................................... 35

Troubleshooting ................................................... 36

4

Safety

SafetySafety Alert SymbolThis lawn mower meets or exceeds the CPSC bladesafety requirements for walk-behind rotary mowersand the B71.4 specifications of the American NationalStandards Institute in effect at the time of production

Exmark designed and tested this lawn mower to offerreasonably safe service; however, failure to complywith the following instructions may result in personalinjury.

This Safety Alert Symbol (Figure 2) is used both inthis manual and on the machine to identify importantsafety messages which must be followed to avoidaccidents

This symbol means: ATTENTION! BECOMEALERT! YOUR SAFETY IS INVOLVED!

Figure 21. Safety alert symbol

The safety alert symbol appears above informationwhich alerts you to unsafe actions or situationsand will be followed by the word DANGER,WARNING, or CAUTION.

DANGER: White lettering / Red background.Indicates an imminently hazardous situation which, ifnot avoided,Will result in death or serious injury.

WARNING: Black lettering / Orange background.Indicates a potentially hazardous situation which, ifnot avoided, Could result in death or serious injury.

CAUTION: Black lettering / Yellow background.Indicates a potentially hazardous situation which, ifnot avoided,May result in minor or moderate injury.

This manual uses two other words to highlightinformation. Important calls attention to specialmechanical information and Note emphasizesgeneral information worthy of special attention.

Safe Operating Practices

Training• Read the Operator’s Manual and other training

material. If the operator(s) or mechanic(s) cannot read English it is the owner’s responsibility toexplain this material to them.

• Become familiar with the safe operation of theequipment, operator controls, and safety signs.

• All operators and mechanics should be trained.The owner is responsible for training the users.

• Never let children or untrained people operateor service the equipment. Local regulations mayrestrict the age of the operator.

• The owner/user can prevent and is responsiblefor accidents or injuries occurring to himself orherself, other people or property.

Preparation• Evaluate the terrain to determine what accessories

and attachments are needed to properly andsafely perform the job. Only use accessories andattachments approved by Exmark.

• Wear appropriate clothing including safety glasses,substantial footwear, long trousers, and hearingprotection. Do Not operate when barefoot orwhen wearing open sandals. Long hair, looseclothing or jewelry may get tangled in movingparts.

CAUTIONThis machine produces sound levels inexcess of 85 dBA at the operator’s ear andcan cause hearing loss through extendedperiods of exposure.

Wear hearing protection when operating thismachine.

• Inspect the area where the equipment is to beused and remove all rocks, toys, sticks, wires,bones, and other foreign objects which can bethrown by the machine and may cause personalinjury to the operator or bystanders.

5

Safety

DANGERIn certain conditions gasoline is extremelyflammable and vapors are explosive.

A fire or explosion from gasoline can burnyou, others, and cause property damage.

• Fill the fuel tank outdoors in an openarea, when the engine is cold. Wipe upany gasoline that spills.

• Never refill the fuel tank or drain themachine indoors or inside an enclosedtrailer.

• Do Not fill the fuel tank completelyfull. Add gasoline to the fuel tank untilthe level is 1/4 to 1/2 inch (6–13 mm)below the bottom of the filler neck. Thisempty space in the tank allows gasolineto expand.

• Never smoke when handling gasoline,and stay away from an open flame orwhere gasoline fumes may be ignited byspark.

• Store gasoline in an approved containerand keep it out of the reach of children.

• Add fuel before starting the engine.Never remove the cap of the fuel tank oradd fuel when engine is running or whenthe engine is hot.

• If fuel is spilled, Do Not attempt to startthe engine. Move away from the area ofthe spill and avoid creating any source ofignition until fuel vapors have dissipated.

• Do Not operate without entire exhaustsystem in place and in proper workingcondition.

DANGERIn certain conditions during fueling, staticelectricity can be released causing a sparkwhich can ignite gasoline vapors. A fire orexplosion from gasoline can burn you andothers and cause property damage.

• Always place gasoline containers on theground away from your vehicle beforefilling.

• Do Not fill gasoline containers inside avehicle or on a truck or trailer bed becauseinterior carpets or plastic truck bed linersmay insulate the container and slow theloss of any static charge.

• When practical, remove gas-poweredequipment from the truck or trailer andrefuel the equipment with its wheels onthe ground.

• If this is not possible, then refuel suchequipment on a truck or trailer from aportable container, rather than from agasoline dispenser nozzle.

• If a gasoline dispenser nozzle must beused, keep the nozzle in contact with therim of the fuel tank or container openingat all times until fueling is complete.

WARNINGGasoline is harmful or fatal if swallowed.Long-term exposure to vapors has causedcancer in laboratory animals. Failure to usecaution may cause serious injury or illness.

• Avoid prolonged breathing of vapors.

• Keep face away from nozzle and gastank/container opening.

• Keep away from eyes and skin.

• Never siphon by mouth.

• Check that the operator’s presence controls,safety switches, and shields are attached andfunctioning properly. Do Not operate unless theyare functioning properly.

6

Safety

Operation

WARNINGOperating engine parts, especially themuffler, become extremely hot. Severe burnscan occur on contact and debris, such asleaves, grass, brush, etc. can catch fire.

• Allow engine parts, especially the muffler,to cool before touching.

• Remove accumulated debris from mufflerand engine area.

• Install and maintain in working order aspark arrester before using equipmenton forest-covered, grass-covered, orbrush-covered unimproved land.

WARNINGEngine exhaust contains carbon monoxide,which is an odorless deadly poison that cankill you.

Do Not run engine indoors or in a smallconfined area where dangerous carbonmonoxide fumes can collect.

• Operate only in daylight or good artificial light,keeping away from holes and hidden hazards.

• Start the engine carefully according to instructionswith feet well away from the blades.

• Never raise deck with blades running.• Never operate the mower with damaged guards,

shields, or covers. Always have safety shields,guards, switches and other devices in place and inproper working condition.

• Never mow with the discharge deflector raised,removed or altered unless there is a grasscollection system or mulch kit in place andworking properly.

• Grass catcher components are subject to wear,damage and deterioration, which could exposemoving parts or allow objects to be thrown.Frequently check the components and replacethem with the manufacturer’s recommended partswhen necessary.

• Do Not change the engine governor setting oroverspeed the engine.

• Never attempt to make wheel height adjustmentswhile the engine is running.

• Stop engine, wait for all moving parts to stop,remove the spark plug wire(s) and/or remove key.– Before checking, cleaning or working on the

mower.– After striking a foreign object or abnormal

vibration occurs (inspect the mower fordamage and make repairs before restartingand operating the mower).

– Before clearing blockages.– Whenever you leave the mower.

• Stop engine, wait for all moving parts to stop:– Before refueling.– Before dumping the grass catcher.– Before making height adjustments.

WARNINGHands, feet, hair, clothing, or accessories canbecome entangled in rotating parts. Contactwith the rotating parts can cause traumaticamputation or severe lacerations.

• Do Not operate the machine withoutguards, shields, and safety devices inplace and working properly.

• Keep hands, feet, hair, jewelry, or clothingaway from rotating parts.

• Keep clear of the discharge opening at all times.• To extend the life the engine brake, place the

throttle control in the “slow” position; then stopthe engine.

• This mower was designed for one operatoronly. Keep all others away from mower duringoperation.

• DO NOT operate the mower when people,especially children, or pets are in the area.

• Be alert, slow down and use caution when makingturns. Look behind and to the side beforechanging directions.

• Stop the blades, slow down, and use caution whencrossing surfaces other than grass and whentransporting the mower to and from the area tobe mowed.

7

Safety

• Be aware of the mower discharge path and directdischarge away from others.

• Do Not operate the mower under the influenceof alcohol or drugs.

• Use extreme care when loading or unloading themachine into a trailer or truck.

• Use care when approaching blind corners, shrubs,trees, or other objects that may obscure vision.

Slope OperationUse Extreme caution when mowing and/or turningon slopes as loss of traction and/or tip-over couldoccur. The operator is responsible for safe operationon slopes.

DANGEROperating on wet grass or steep slopes cancause sliding and loss of control. Loss ofcontrol and/or loss of operator’s footingcould result in a fall with an arm or leggetting under the mower or engine deckwhich may result in serious injury, death ordrowning.

• 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.

• Reduce speed and use extreme cautionon slopes.

• Avoid sudden turns or rapid speedchanges.

• When feasible, avoid operating the equipment inwet grass.

• Progressively greater care is needed as the slopeincreases.

• Remove or mark obstacles such as rocks, treelimbs, etc. from the mowing area. Tall grass canhide obstacles.

• Watch for ditches, holes, rocks, dips and rises thatchange the operating angle, as rough terrain couldoverturn the machine.

• Use extreme care with grass catchers orattachments. These can change the stability of themachine and cause loss of control.

Maintenance and Storage• Stop the engine and remove the spark plug wire(s)

and/or remove key. Wait for all movement tostop before adjusting, cleaning or repairing.

• Keep engine and engine area free fromaccumulation of grass, leaves, excessive greaseor oil, and other debris which can accumulatein these areas. These materials can becomecombustible and may result in a fire.

• Let engine cool before storing and Do Not storenear flame or any enclosed area where open pilotlights or heat appliances are present.

• Shut off fuel while storing or transporting. DoNot store fuel near flames or drain indoors.

• Park machine on level ground. Never allowuntrained personnel to service machine.

• Remove spark plug wire before making anyrepairs.

• Use care when checking blades. Wrap the blade(s)or wear gloves, and use caution when servicingthem. Only replace blades. Never straighten orweld them.

• Keep hands and feet away from moving parts.If possible, Do Not make adjustments with theengine running.

• Keep all guards, shields and all safety devices inplace and in safe working condition.

• Check all bolts frequently to maintain propertightness.

• Frequently check for worn or deterioratingcomponents that could create a hazard.

• All replacement parts must be the same asor equivalent to the parts supplied as originalequipment.

8

Safety

Safety and Instructional Decals• Keep all safety signs legible. Remove all grease,

dirt and debris from safety signs and instructionallabels.

• Replace all worn, damaged, or missing safetysigns.

• When replacement components are installed, besure that current safety signs are affixed to thereplaced components.

• If an attachment or accessory has been installed,make sure current safety signs are visible.

• New safety signs may be obtained fromyour authorized Exmark equipment dealer ordistributor or from Exmark Mfg. Co. Inc.

• Safety signs may be affixed by peeling off thebacking to expose the adhesive surface. Applyonly to a clean, dry surface. Smooth to removeany air bubbles.

• Familiarize yourself with the following safety signsand instruction labels. They are critical to the safeoperation of your Exmark commercial mower.

39-5770For Units without a Blade Brake Clutch

(MPKA21, MPKA21CA, MSKA21, MSKA21CA,and MSHN21)

43-8480For Units with a Blade Brake Clutch

(MSKA21B, MSHN21B, and MSKA21BCA)

52-2610For Push Units

(MPKA21 and MPKA21CA)

52-2620For Self-Propelled Units

(MSKA21, MSKA21CA, MSKA21B, MSKA21BCA,MSHN21, and MSHN21B)

68-7410Common to All Units

9

Safety

74-1970For Self-Propelled Units

(MSKA21, MSKA21CA, MSKA21B, MSKA21BCA,MSHN21, and MSHN21B)

1. Transmission speeds 2. Neutral



103-6327For MPKA21, MSKA21, and MSHN21 Units Only

1. Choke 3. Continuous variablesetting

2. Fast 4. Slow

103-6328For MSKA21B and MSHN21B Units Only

1. Choke 4. Slow2. Fast 5. Engine—stop3. Continuous variable

setting



10

Safety

109-8190On MPKA21CA and MSKA21CA Units Only

1. Fast 3. Slow2. Continuous variable

setting

109-8191On MPKA21CA, MSKA21CA,and MSKA21BCA Units Only

109-8194On MSKA21BCA Units Only

1. Fast 3. Slow2. Continuous variable

setting4. Engine—stop

11

Specifications

SpecificationsModel NumbersSerial Nos: 790,000 and Higher

MPKA21; MPKA21CA; MSKA21; MSKA21CA; MSKA21B; MSKA21BCA; MSHN21; MSHN21B

SystemsEngine• Engine Specifications: See your Engine Owner’s

Manual• RPM: 3300 (No Load)

Fuel System• Capacity:

MPKA21, MSKA21, and MSKA21B Units:4.0 qt (3.8 L)

MPKA21CA, MSKA21CA, and MSKA21BCAUnits: 2.1 qt (2.0 L)

Honda Units: 2.1 qt (2.0 L)• Type of Fuel: Regular unleaded gasoline, 87

octane or higher.• Fuel Filter: Non-replaceable, in tank• Fuel Shut-Off Valve: MPKA21, MSKA21, and

MSKA21B and Honda Units: In-line 1/4 turnincrements.

MPKA21CA, MSKA21CA, and MSKA21BCAUnits Do Not have a shut-off valve.

Safety Interlock SystemFor units without a Blade Brake Clutch: Operatormust have the blade control bail depressed to startthe engine. Releasing the blade control bail will causethe engine to stop.

Transmission (Self Propelled Units)3 speeds forward

Speed Range:• 1st–2.0 mph (3.2 km/hr)• 2nd–2.9 mph (4.6 km/hr)• 3rd–4.1 mph (6.6 km/hr)

Cutting Deck• Cutting Width: 21 inches (53.3 cm)

• Blade Brake: When the blade engagement controlis moved to the disengaged position a frictionbrake pad stops the rotation of the blades.

• Blade Size: (1 ea.): 20.88 inches (53.0 cm)

• Deck: 21 inches rigid. Deck design allows forbagging, mulching or side discharge.

• Cutting Height Adjustment:

Adjusts from 3/4 inches (1.9 cm) to 3 1/4 inches(8.3 cm) in 1/2 inch (1.3 cm) increments.

• Mulching Kit: Standard

• Side Discharge Kit: Optional

Dimensions

Curb Weight:122 lb (55 kg) Weights may vary slightly dependingon engine option.

Overall Width:22.25 inches (56.5 cm)

12

Product Overview

Overall Length and Height at2 1/4 inch Cutting Height:Handle Setting Length Height

High 60.50 inches(153.7 cm)

42.75 inches(108.6 cm)

Medium 64.25 inches(163.2 cm)

40.38 inches(102.6 cm)

Low 67.00 inches(170.2 cm)

37.88 inches(96.2 cm)

Overall Length and Height atAlternate Handle Mounting Position:Handle Setting Length Height

High 62.63 inches(159.1 cm)

37.50 inches(95.3 cm)

Medium 64.38 inches(163.5 cm)

35.50 inches(90.2 cm)

Low 66.25 inches(168.3 cm)

33.63 inches(85.4 cm)

Product Overview

Figure 31. Spark plug 8. Drive Bail

(Self-Propelled UnitsOnly)

2. Oil fill/dipstick 9. Throttle/Choke control3. Discharge door handle 10. Fuel tank4. Grass bag 11. Oil filter5. Blade Control Lever

(Blade Brake Units Only)12. Air filter

6. Blade Control Bail 13. Cutting height lever7. Handle

13

Operation

OperationNote: Determine the left and right sides of themachine from the normal operating position.

ControlsBlade Control BailLocated on the upper handle as shown in Figure 4.

When the blade control bail is depressed, the systemsenses that the operator is in the normal operator’sposition.• For Units with a Blade Brake Clutch: When

the blade control bail is released, the systemsenses that the operator has moved from thenormal operating position and will stop the blade.

• For Units without a Blade Brake Clutch:When the blade control bail is released, the systemsenses that the operator has moved from thenormal operating position and will kill the engine.

Figure 41. Throttle-Choke Control 4. Handle2. Blade Control Lever

(Blade Brake Units Only)5. Drive Bail

(Self-Propelled UnitsOnly)

3. Blade Control Bail

Self-Propel Drive Bail (ForSelf-Propelled Units Only)Located on the upper handle as shown in Figure 4.

When the self-propel drive bail is squeezed, the unitwill move forward at the speed set on the speed

control lever. When this bail is released the unit willstop moving.

Throttle-Choke ControlThe throttle-choke control is located on the left sideof the handles as shown in Figure 4.

The lever is used to control engine speed. Movingthe lever to the full forward (Choke) position willplace the lever in the choke position. The choke aidsin starting a cold engine. Moving the throttle controlforward will increase engine speed and moving it tothe rear will decrease engine speed.

For units with a Blade Brake Control: Thethrottle-choke control also includes an engine killposition. Moving the lever into the full rearward(Off) position will kill the engine.

Note: MPKA21CA, MSKA21CA, andMSKA21BCA Units Do Not have a choke.

Blade Control Lever (Blade BrakeClutch Units Only):The blade control lever is located on the right side ofthe handle next to the Blade Control Bail as shownin Figure 4.

Moving the blade control lever into the full forwardposition while depressing the blade control bailengages the blade. Releasing the blade control bailautomatically disengages the blades.

Ground Speed (Shifter) Control(Self-Propelled Units Only):The ground speed control is located at the rear of thebelt cover as shown in Figure 5.

The ground speed control has three settings whichcontrol the ground speed of the mower: 1 is slow, 2is medium, and 3 is fast.

14

Operation

Figure 51. Ground speed control

Fuel Shut-Off ValveFor MPKA21, MSKA21, and MSKA21B Units:The fuel shut off valve is installed on the fuel linemidway between the fuel tank and the engine asshown in Figure 6.

Figure 6MPKA21, MSKA21, and MSKA21B Units

1. Fuel line 3. Elbow fitting2. Fuel valve

For MSHN21 and MSHN21B Units: The fuelshut off valve is located on the engine as shown inFigure 7.

Figure 7MSHN21 and MSHN21B Units

1. Fuel valve

For MPKA21CA, MSKA21CA, and MSKA21BCAUnits:Do not have a fuel shut off valve.

The fuel shut off valve shuts off the flow of fuelwhen the machine will not be used for a few days,when parking inside a building, and during transportto and from the job. Rotate the valve 1/4 turnclockwise to shut off fuel. Rotate the valve 1/4 turncounterclockwise to turn on fuel.

Pre-StartFill fuel tank. For best results use only clean, freshregular grade unleaded gasoline with an octane ratingof 87 or higher. To ensure freshness, purchase onlythe quantity of gasoline that you expect to use in30 days. Using unleaded gasoline results in fewercombustion deposits and longer engine life. SeeEngine Owner’s Manual.

Do Not add oil to gasoline.

Do Not use methanol, gasoline containing methanol,gasohol containing more the 10% ethanol, premiumgasoline or white gas. Using these fuels can damagethe engine’s fuel system.

Do Not use gasoline that has been stored since thelast mowing season or longer.

Do Not overfill fuel tank. Never fill the fuel tank sothat the fuel level rises above a level that is 1/2 inchbelow the bottom of the filler neck to allow for fuelexpansion and prevent fuel spillage.

15

Operation

Make sure you understand the controls, theirlocations, their functions, and their safetyrequirements.

Refer to the Maintenance section and perform all thenecessary inspection and maintenance steps.

Operating InstructionsHandle AdjustmentThe handle may be adjusted to different heights forcomfortable operation. Stand behind the handle todetermine the height. to adjust the handle height,position the capscrews and the locknuts that securethe handle latches to the handle into the othermounting holes in the latches.

See Figure 8A for the highest possible handle heights.

See Figure 8B for the lowest possible handle heights.

Figure 81. Handle latch 4. Spring disc washer2. Adjustment holes in

upper end of handlelatch

5. 5/16-18 x 1 3/8 inch hexcapscrew

3. Handle 6. 5/16-18 x 1 1/4 inch hexcapscrew

1. Install the hardware in the lower holes in thehandle and latches as shown in Figure 8.

2. Install hardware in one of the three adjustmentholes in the upper ends of each of the handlelatches to obtain the desired handle height withinthe selected range.

3. Slide the bag support rod through into the upper,middle, or lower mounting holes in the handleand secure each end with a cap locknut. The bagsupport rod mounting hole location correspondswith the mounting hole location for the handlelatches as shown in the table.

Bag Support RodMounting Hole Location

Handle Latch MountingHole Location

Lower Lower

Middle Middle

Upper Upper

Open the Fuel Shut-Off ValveRotate the valve 1/4 turn counterclockwise to turnthe fuel on.

Starting the Engine1. Connect the wire to the spark plug.

For MSHN21 and MSHN21B Units: seeFigure 9.

For MPKA21, MSKA21, MSKA21B,MPKA21CA, MSKA21CA, and MSKA21BCAUnits: see Figure 10.

16

Operation

Figure 9All Honda Units

1. Oil fill/dipstick 4. Air cleaner2. Recoil starter handle 5. Spark plug3. Fuel tank cap

Figure 10All Kawasaki Units

1. Muffler 5. Oil filter2. Oil fill/dipstick 6. Air cleaner3. Fuel tank cap 7. Spark plug4. Recoil starter handle

2. Open the fuel valve.

For MPKA21, MSKA21, and MSKA21B Units:see Figure 6.

For MSHN21 and MSHN21B Units: seeFigure 7.

MPKA21CA, MSKA21CA, and MSKA21BCAUnits: Do Not have a fuel valve.

3. For MSHN21 MSHN21B, MPKA21, MSKA21,and MSKA21B Units: Move the throttle-chokecontrol to the Choke position.

Note: Do Not use the choke when the engine iswarms up.

For MPKA21CA, MSKA21CA, andMSKA21BCA Units: Move the throttle controlto the Fast position. Press the primer bulb twotimes (see Figure 11).

Figure 11

4. For units without a Blade Brake Clutch: Holdthe blade control bail to the handle.

5. Pull the starter handle lightly until you feelresistance, then pull it sharply. Allow the rope toreturn slowly.

6. When the engine starts, move the throttle controlto the Fast position, and set the ground speedcontrol as desired.

Note: If the engine fails to start after three pulls,repeat steps 3 through 6).

Stopping the Engine1. Bring the unit to a full stop.

• For units without a Blade Brake Clutch:Release the blade control bail. Both theengine and the blade should stop within threeseconds.

• For units with a Blade Brake Clutch:Release the blade control bail. The bladeshould stop within three seconds. Move thethrottle to the (Off) position to kill the engine.

17

Operation

Note: If the blade does not stop within 3seconds after releasing the blade control bail,contact an Authorized Service Dealer.

2. Close the fuel shut-off valve, if equipped with,when the machine will not be in use for a fewdays, when transporting, or when the unit isparked inside a building.

Using the Self-Propel Drive(Self-Propelled Units Only)The lawn mower has three ground speeds: 1 is slow,2 is medium, and 3 is fast.1. Start the engine.2. Using the ground speed control, select the desired

ground speed.3. Squeeze the drive bail against the handle (see

Figure 4).

Note: Do Not shift speeds while squeezing theground speed control against the handle. Thiscan damage the transmission. Release the groundspeed control before changing speeds.

Note: You can vary the ground speed byincreasing or decreasing the distance between theground speed control and the handle. Lower thecontrol bar to decrease the ground speed whenyou are making a turn or if the lawn mower ismoving too fast for you. If you lower the controlbar too far the lawn mower stops self-propelling.Squeeze the ground speed control closer to thehandle to increase the ground speed. Whenyou hold the ground speed control tight againstthe handle, the lawn mower self-propels at themaximum ground speed. Move the ground speedcontrol to theNeutral position when you use thelawn mower for trimming or whenever you leavethe lawn mower.

Operating the Blade Control Lever(Blade Brake Clutch Units Only)1. Start the engine.2. Squeeze the blade control bail against the handle

(Figure 4).3. Move the blade control lever to the full forward

Latch position. Blades should engage.4. Release the blade control bail to disengage the

blades.

Note: The blade control lever will release rapidlywhen the blade control bail is released. To avoidminor injury, keep hands clear of the blade controllever when the blade control bail is released.

Using the Discharge Tunnel1. Stop the engine and wait for all moving parts to

stop.

2. Insert the plug. (Refer to Installing theDischarge Plug section).

3. To remove the plug, move the discharge doorhandle rearward and lift up the spring clip on thebottom of the plug. When the plug is unlocked,pull it out of the discharge tunnel.

Note: When grass is thick and lush, clippingsmay collect on and around the discharge tunnelplug. This may make removing the plug difficult.Clean the plug thoroughly after each use.

Checking the Blade Brake Clutch(Blade Brake Clutch Units Only)Check the Blade Brake Clutch (BBC) system beforeeach use to ensure that it is operating properly.

Normal Test:

1. Stop the engine and wait for all moving parts tostop.

2. Move the lawn mower onto a paved surface ina non-windy area.

3. Set all four wheels in to the 2 1/2 inches (6.4 cm)cutting height (see Figure 13).

4. Set the ground speed selector to theN (Neutral)position.

5. Take a half sheet of newspaper and crumpleit into ball small enough to go under the deck(about 3 inches or 7.6 cm in diameter) as shownin Figure 12.

18

Operation

Figure 121. Crumpled newspaper 2. 5 inches (12.7 cm)

6. Place the ball of newspaper 5 inches (12.7 cm) infront of the lawn mower.

7. Start the engine.

8. Squeeze the blade control bail against the handle.

9. Move the blade control lever to the full forwardLatch position. Blades should engage.

10. Release the blade control bail. You should hear a“bang.” The blade should stop in three seconds.

11. Immediately push the lawn mower over thenewspaper ball.


13. Walk around the lawn mower to check for thenewspaper ball. If the ball did not go under thedeck, repeat steps 7 through 12.

14. Pull the lawn mower away from the newspaper.If the newspaper ball unravels or is shredded,the blade has not properly stopped, resultingin an unsafe operating condition. Contact anAuthorized Service Dealer.

DANGERIf the blade brake clutch system isinoperative, the blade will continue to rotatewhen you release the blade control bail.Contact with the blade could occur, causingserious injury.

• Check the BBC operation before eachuse.

• Never use the BBC-equipped lawn mowerwith an inoperative safety system.

• Take your lawn mower to an AuthorizedService Dealer for repair if the safetysystem fails to operate properly.

Test Using the Grass Bag1. Install the empty grass bag on the discharge

tunnel.

2. Start the engine.

3. Squeeze the blade control bail against the handle.

4. Move the blade control lever to the full forwardLatch position. The bag should begin to inflate,indicating that the blade is engaged and rotating.

5. Release the blade control bail. If the bag does notimmediately deflate, it indicates that the blade isstill rotating. The blade brake clutch mechanismmay deteriorating, and, if ignored could result inan unsafe operating condition. Have the lawnmower inspected and serviced by an AuthorizedService Dealer.

Adjusting the Cutting HeightEach wheel is adjusted individually with a wheelheight adjustment lever. The cutting heights are listedin the following table.

Cutting Heights

3/4 inch (19 mm) 2 1/4 inches (57 mm)

1 1/4 inches (32 mm) 2 3/4 inches (70 mm)

1 3/4 inches (44 mm) 3 1/4 inches (83 mm)

19

Operation

WARNINGAdjusting the cutting height levers couldbring your hands into contact with a movingblade. A moving blade can cause seriousinjury.

• Stop the engine and wait for all movementto stop before adjusting the cuttingheight.

• Do Not put your fingers under thehousing when adjusting the cuttingheight.

1. Pull the wheel height adjustment lever towardthe wheel (Figure 13) and move it to the desiredsetting.

Figure 131. Pull towards wheel 3. Notches2. Wheel Height

Adjustment Lever

2. Release the wheel height adjustment lever and setit securely in the notch.

3. Adjust all the wheels to the same cutting heightsetting.

Using the Grass BagOccasionally, you may wish to use the grass bag forbagging extra long grass, lush grass, or leaves.

• Installing the Grass Bag

1. Stop the engine and wait for all moving partsto stop.

2. Ensure that the discharge door handle is fullyforward and that the pin is engaged in thecatch (Figure 14).

Figure 141. Bag Frame on retaining

post.3. Handle fully

forward—dischargedoor closed.

2. Pin engaged in catch.

3. Slide the hole in the bag frame onto theretaining post on the discharge tunnel.

4. Set the rear of the bag frame onto the bagsupport rod.

5. Pull the discharge door handle forward untilthe pin clears the catch, and move the handlerearward until the pin locks in the bag notch(Figure 15).

Figure 151. Pin locked in bag notch.

Note: The discharge door in the lawn mowerhousing is now open.

20

Operation

• Mowing with the Grass Bag

WARNINGA worn grass bag could allow small stonesand other similar debris to be thrown in theoperator’s or bystander’s direction. Thrownobjects can result serious personal injury ordeath to the operator or bystanders.

Check the grass bag frequently. If it isdamaged, install a new Exmark replacementbag.

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 partsto stop.

2. Raise the discharge door handle and moveit forward to engage the pin with the catch(Figure 14).

3. Grasp the handles at the front and the rear ofthe bag and lift the bag off the lawn mower.

4. Gradually tip the bag forward to empty theclippings.

5. To install the bag, refer to the Installing theGrass Bag section.

DANGERIf the discharge door does not closecompletely, the lawn mower could throwobjects. Thrown objects can result seriouspersonal injury or death to the operator orbystanders.

• Never open the door to the dischargeopening when the engine is running.

• If you cannot close the door because thegrass clippings clog the discharge area,stop the engine and gently move thedischarge door handle back and forthuntil you can close the door completely. Ifyou still cannot close the door, remove theobstruction with a stick, not your hand.

DANGERIf the discharge door does not closecompletely, the lawn mower could throwobjects. Thrown objects can result seriouspersonal injury or death to the operator orbystanders.

Never open the door on the discharge tunnelwhen the engine is running.

Operating Tips• 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.• Maintain a sharp blade throughout the cutting

season. Periodically file down nicks on the blade.Replace the blade when necessary with an originalExmark replacement blade.

• Clean the air filter frequently. Mulching stirs upmore clippings and dust which clogs the air filterand reduces engine performance.

Cutting Grass• Grass grows at different rates at different times

of the year. In the summer heat, it is best tocut grass at the 2 1/4 inch (57 mm), 2 3/4 inch(70 mm), or 3 1/4 inch (83 mm) cutting heightsettings. Cut only about a third of the grass bladeat a time. Do Not cut below the 2 1/4 inch (57mm) setting unless the grass is sparse or it is latefall when grass growth begins to slow down.

• When cutting grass over 6 inches (15 cm) tall,first mow at the highest cutting height setting andwalk slower; then mow again at a lower setting forthe best lawn appearance. If the grass is too longand the leaves clump on top of the lawn, the lawnmower may plug and cause the engine to stall.

• Alternate the mowing direction. This helpsdisperse the clippings over the lawn for evenfertilization.

If the finished lawn appearance is unsatisfactory,try one or more of the following:

• Sharpen the blade.• Walk at a slower pace while mowing.• Cut the grass more frequently.

21

Operation

• Overlap cutting swaths instead of cutting a fullswath with each pass.

• Set the cutting height on the front wheels onenotch lower than the rear wheels. For example,set the front wheels at 2 1/4 inches (57 mm) andthe rear wheels at the 2 3/4 inches (70 mm).

Cutting Leaves

• After cutting the lawn, ensure that half of thelawn shows through the cut leaf cover. You mayneed to make more than one pass over the leaves.

• For light leaf coverage, set all the wheels at thesame cutting height setting.

• If there are more than 5 inches (12.7 cm) of leaveson the lawn, set the front cutting height 1 or 2notches higher than the rear cutting height. Thismakes it easier to feed the leaves under the lawnmower deck.

• Slow down your mowing speed if the lawn mowerdoes not cut the leave finely enough.

• If you mow over oak leaves, you can add lime tothe grass in the spring to reduce the acidity of theoak leaves.

22

Maintenance

MaintenanceNote: Determine the left and right sides of the machine from the normal operating position.

WARNINGIf you leave the wire on the spark plug,someone could accidentally start the engine.Accidental starting of the engine couldseriously injure you or other bystanders.

Disconnect the wire from the spark plugbefore you do any maintenance. Set the wireaside so that it does not accidentally contactthe spark plug.

WARNINGThe engine can become very hot. Touchinga hot engine can cause severe burns.

Allow the engine to cool completely beforeservice or making repairs around the enginearea.

Recommended Maintenance Schedule(s)Maintenance Service

Interval Maintenance Procedure

After the first 5 hours • Change the engine oil.

Before each use or daily

• Check the engine oil level.• Check the stopping time of the blade brake. The blade must stop within 3 seconds ofreleasing the bail; if it does not, contact and Authorized Service Dealer for repair.

• Check the mower blades and the engine mounting fasteners.• Check for loose hardware.• Clean the grass build-up from under the deck.• Clean the discharge tunnel and plug.

Every 25 hours • Clean the foam pre-cleaner (Kawasaki Units).• Clean the cover, base, foam and paper elements (Honda Units).

Every 40 hours • Check the condition of the belt(s).

Every 50 hours

• Change the engine oil. (May need more often under severe conditions.)• Grease the pivot arms.• Clean under the belt cover (self-propelled models only).• Clean the blade brake clutch shield.• Check for leaks in the fuel systems and /or deteriorating fuel hose.

Every 100 hours

• Change the oil filter (Kawasaki Units Only).• Service the wheels.• Grease the gear case (self-propelled units only).• Check the spark plugs.• For Blade Brake Clutch Units: Adjust the blade brake cable.• Clean the fuel filter element (Kawasaki Units Only).

Every 250 hours • Replace the air filter elements (Honda Units). (May need more often if they are damagedor excessively dirty.)

Every 300 hours • Replace the paper air filter (Kawasaki Units). (May need more often in dusty conditions.See the Engine manual for additional information.)

Yearly • Lubricate the gear case (self-propelled units only)

Yearly or before storage • Empty the fuel tank before repairs as directed or before storage.

23

Maintenance

Periodic MaintenanceCheck Engine Oil LevelService Interval: Before each use or daily1. 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 andwipe oil off. Reinsert the dipstick and push it allthe way down into the tube. Do Not screw intoplace. Remove the dipstick and read the oil level.

Figure 16Honda Engine

1. Lower limit mark 3. Dipstick2. Upper limit mark

Figure 17Kawasaki Engine

1. Dipstick 3. Add2. Full

4. If the oil level is low, wipe off the area around theoil fill cap, remove cap and fill to the “FULL”mark on the dipstick. Use oil as specified inEngine Owner’s Manual. Do Not overfill.

Important: Do Not operate the engine with theoil level below the “LOW” (or “ADD”) mark onthe dipstick, or over the “FULL” mark.

Checking the Blade BrakeClutch (For Units with aBlade Brake Clutch Only)Service Interval: Before each use or daily

Refer to Checking the Blade Brake Clutch in theOperating Instructions section.

Check the Mower BladeService Interval: Before each use or daily

Always mow with a sharp blade. A sharp blade cutscleanly and without tearing or shredding the grassblades.


2. Disconnect the wire from the spark plug (Figure 9and Figure 10).

3. Drain the gasoline from the fuel tank.

24

Maintenance

4. Tip the lawn mower onto its right side (seeFigure 18 and Figure 19).

Figure 18Blade Brake Clutch Units Only

1. Accelerator 3. Blade2. Anti-Scalp Cup 4. Blade Nuts

Figure 19Units Without a Blade Brake Clutch Only

1. Blade 3. Accelerator2. Blade Bolt

5. Inspect the blade for sharpness and wear,especially where the flat and the curved partsmeet (see Figure 20A). Because sand and abrasivematerial can wear away the metal that connectsthe flat and curved parts of the blade, checkthe blade before using the lawn mower. If younotice a slot or wear (Figure 20B and Figure 20C),replace the blade.

Figure 201. Sail 3. Wear2. Flat 4. Slot

Note: For the best performance, install a newblade before the cutting season begins. Duringthe year, file down any small nicks to maintain thecutting edge.

DANGERA worn or damaged blade can break. Apiece of the blade could be thrown into theoperator’s or bystander’s area, resulting inserious personal injury or death.

• Inspect the blade periodically for wear ordamage.

• Replace a worn or damaged blade.

If it is necessary to remove the blade forreplacement or sharpening, complete thefollowing steps:

6. Remove the blade. Make sure to grasp the end ofthe blade using a rag or a thickly padded glove.• For Blade Brake Clutch Units: Remove the

blade nuts, anti-scalp cup, accelerator, and theblade (Figure 18).

• For Units without a Blade Brake Clutch:Remove the blade bolt, accelerator, and blade(Figure 19).

7. For Sharpening: File the top side of the blade tomaintain its original cutting angle (Figure 21A)and inner cutting edge radius (Figure 21B). Theblade will remain balanced if you remove the sameamount of material from both cutting edges.

25

Maintenance

Figure 211. Cutting angle 2. Cutting edge radius

8. Check the balance of the blade by placing thecenter hole of the blade over a nail or screwdrivershank clamped horizontally in a vise (Figure 22).If either end of the blade rotates downward, filethat end (not the cutting edge). The blade isproperly balanced when neither end drops.

Figure 221. Blade 3. Screwdriver2. Vise

9. For Installation: Make sure to grasp the end ofthe blade using a rag or a thickly padded glove.

For Blade Brake Clutch Units: Install a sharp,balanced Exmark blade, the accelerator, theanti-scalp cup, and the blade nuts. The sail ofthe blade must point toward the top of the lawnmower housing for proper installation. Torquethe blade nuts to 15-27 ft-lb (20-37 N m).

For Units without a Blade Brake Clutch: Install asharp, balanced Exmark blade, the accelerator,and blade bolt. The sail of the blade must pointtoward the top of the lawn mower housing forproper installation. Torque the blade nuts to 50ft-lb (68 N m).

DANGEROperating the lawn mower without theaccelerator in place can cause the blade toflex, bend, or break. Thrown objects from abroken blade can result in serious injury ordeath to the operator or bystanders.

Do Not operate the lawn mower without theaccelerator.

10. Return the lawn mower to its upright position.

11. Connect the wire to the spark plug.

Check for Loose HardwareService Interval: Before each use or daily1. Stop engine, wait for all moving parts to stop, and

remove key. Engage parking brake.

2. Visually inspect machine for any loose hardwareor any other possible problem. Tighten hardwareor correct the problem before operating.

Service Air Filter(Kawasaki Units)Service Interval: Every 25 hours—Clean

the foam pre-cleaner(Kawasaki Units).Every 300 hours—Replace the paper airfilter (Kawasaki Units).(May need more often industy conditions. Seethe Engine manual foradditional information.)

Note: Do Not operate the engine without the airfilter 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).

3. Remove the cover and clean it thoroughly.

26

Maintenance

Figure 231. Cover 3. Paper air filter2. Foam pre-cleaner 4. Air filter base

4. Remove the paper air filter and discard it asrequired.

Note: Do Not try to clean a paper air filter.5. Remove the foam pre-cleaner and wash it with a

mild detergent and water, then blot it dry.

6. Saturate the pre-cleaner with clean engine oil, thensqueeze it (Do Not twist) to remove the excess oil.

7. Install the foam pre-cleaner.

8. Install the new paper air filter.

9. Install the cover.

Service Air Filter(Honda Units)Service Interval: Every 25 hours—Clean

the cover, base, foam andpaper elements (HondaUnits).Every 250 hours—Replacethe air filter elements(Honda Units). (May needmore often if they aredamaged or excessivelydirty.)

Note: Do Not operate the engine without the aircleaner assembly; extreme engine damage will occur.


2. Disconnect the wire from the spark plug(Figure 9).

3. Remove the two wing nuts that secure the cover(Figure 24).

Figure 241. Wing nuts 4. Foam element2. Cover 5. Base3. Paper element

4. Remove the cover.

Note: Be careful to prevent dirt and debris fromfalling into the base.

5. Remove the foam and paper elements from thebase.

6. Remove the foam element from the paperelement.

7. Inspect the foam and paper elements, and replacethem if they are damaged or excessively dirty.

8. Tap the paper element on a hard surface severaltimes or use compressed air not exceeding 30psi (207 kPa) through the filter from the wirescreen side to remove any excess dirt. If the paperelement is excessively dirty, replace it.

Note: Never try to brush dirt off the paperelement; brushing forces the dirt into the fibers.

9. Clean the foam element in warm, soapy water orin a nonflammable solvent.

10. Rinse and dry the foam element thoroughly.

27

Maintenance

11. Dip the foam element in clean engine oil, thensqueeze out the excess oil.

Note: Excess oil in the foam element restrictsthe air flow through the element and may reachthe paper filter and clog it.

12. Wipe dirt from the base and the cover with amoist rag.

Note: Be careful to prevent dirt and debris fromentering the air duct leading to the carburetor.

13. Install the air cleaner elements and ensure thatthey are properly positioned.

14. Securely install the cover with the two wing nuts.

Change Engine OilService Interval: After the first 5 hours

Every 50 hours (May needmore often under severeconditions.)

1. Run the engine to warm the engine oil.

Note: Warm oil flows better and carries morecontaminates.

WARNINGOil may be hot after engine has beenrun. Contact with hot oil can cause severepersonal injury.

Avoid contacting the hot engine oil when youdrain it.

2. Stop engine, wait for all moving parts to stop.3. Disconnect the wire from the spark plug.4. Place a suitable drain pan under the dipstick/oil

drain.5. Clean around the dipstick.6. Remove the dipstick by rotating the cap

counterclockwise and pulling it out.7. Raise the left side of the lawn mower to drain the

oil from the dipstick fill tube into the drain pan.8. After draining the oil, return the lawn mower to

the operating position.9. Fill the crankcase with fresh oil to the upper limit

mark on the dipstick.10. Insert the dipstick into the filler neck and rotate

the cap clockwise until it is tight.

11. Wipe up any spilled oil.


13. Recycle the used oil according to local codes.

Changing the Oil Filter(Kawasaki Units Only):Service Interval: Every 100 hours1. Run the engine to warm the oil.


3. Disconnect the wire from the spark plug.

4. Drain the engine oil.

5. Place a rag under the oil filter to catch any oil thatmay leak out as you remove the filter.

6. Remove the oil filter.

7. Use your finger to coat the gasket on the newfilter with clean engine oil (see Figure 25).

Figure 251. Gasket

8. Install the new filter and hand tighten it 2/3 turnonly.

9. Fill the crankcase to the Full line on the dipstickwith fresh oil.


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.

13. Add oil to compensate for the oil in the oil filter.

14. Recycle the used oil filter according to local codes.

28

Maintenance

Servicing the WheelsService Interval: Every 100 hoursRemoving the Wheels1. Stop engine, wait for all moving parts to stop.2. Disconnect the wire from the spark plug.3. Remove the bolt, the wheel spacer, and the

locknut mounting the wheel to the pivot arm(Figure 26).

Figure 261. Plastic Cover 6. Bearing Spacer2. Locknut 7. Bearing/Hub Assembly3. Wheel half 8. Lug4. Bolt 9. Wheel Spacer5. Bearing

4. Separate the wheel halves from the tire byremoving four bolts and four locknuts.

Note: If you remove the bearings from thebearing/hub assembly, remove them by pressingon the bearing spacer.

Assembling the Wheels1. Position the tire onto one wheel half, aligning the

lugs on each.2. Place the bearing/hub assembly into the center

hole of the wheel half. Ensure that the legs of thehub are positioned over the flange of the hole.

3. Place the other wheel half onto the bearing/hubassembly, aligning the wheel and the tire lugs andthe mounting holes.

4. Using two fully threaded screws or bolts andnon-locking nuts, loosely secure the wheel halvestogether. Mount the screws or bolts in theopposing holes.

5. Check the alignment of all parts and tighten thescrews, alternating from side to side for a uniformfit until the wheel halves are drawn together.

6. Install the two cap screws and two locknutspreviously removed in the remaining holes in the

wheel halves and tighten. Remove the two longscrews or bolts and replace them with two capscrews and two locknuts.

7. Install the wheel to the pivot arm with the capscrews, a spacer, and a locknut. Ensure that thespacer is positioned between the wheel hub andthe pivot arm.


Check Condition Of Belt(Self-Propelled Units Only)Service Interval: Every 40 hours1. Stop engine, wait for all moving parts to stop.

2. Remove the bolts that secure the belt cover to thelawn mower housing.

3. Check the belt for cracks, frayed edges, burnmarks or any other damage.

4. Replace the damaged belt.

Lubricate the Pivot Arms1. Move the rear wheel cutting height levers to the

center setting.

2. Wipe the grease fittings with a clean rag(Figure 27).

Figure 271. Grease fitting

3. Install a grease gun onto the fitting and gentlyapply 2 or 3 pumps of #2 multi-purpose lithiumbase grease.

Note: Excessive grease pressure may damage theseals.

29

Maintenance

1. Stop engine, wait for all moving parts to stop, andremove key. Engage parking brake.

2. Lubricate fittings with one to two pumps ofNGLI grade #2 multi-purpose gun grease.

Refer to the following chart for fitting locationsand lubrication schedule.

Lubrication Chart

FittingLocations

InitialPumps

Number ofPlaces

ServiceInterval

1. PivotArms

2 2 50 Hours

2. GearCase

1 1 100 Hours

Lubricate the Gear Case(Self-Propelled Units Only)Service Interval: Yearly1. Stop engine, wait for all moving parts to stop.

2. Remove the grass bag.

3. Install a grease gun onto the fitting through thebelt cover opening

Figure 281. Grease fitting 2. Belt cover

4. Gently apply one to two pumps of #2multi-purpose lithium-base grease.

5. Install the grass bag.

Check Spark PlugsService Interval: Every 100 hours1. Stop the engine and wait for all moving parts to

stop.

2. Disconnect the wire from the spark plug (Figure 9and Figure 10).

3. Clean around the spark plug.

4. Remove the spark plug from the cylinder head.

Note: Replace a cracked, fouled, or dirty sparkplug. Do Not clean the electrodes because gritentering the cylinder can damage the engine.

5. Set the gap on the plug to 0.030 inch (0.76 mm)(Figure 29).

Figure 291. Side electrode 3. Air gap—0.030 inch

(0.76 mm)2. Center electrode

insulator

6. Install the spark plug and the gasket seal.

7. Torque the plug to 17 ft-lb (23 N-m).


30

Maintenance

AdjustmentsNote: Wait for all moving parts to stop and removespark plug wire before servicing, cleaning, or makingany adjustments to the unit.

Adjusting the Self-PropelDrive(Self-Propelled Units Only)If the lawn mower does not self-propel or has atendency to creep forward when the control bar isreleased, adjust the wheel drive control knob on therear of the gear box.

1. Close the door in the lawn mower housing andremove the grass bag.

2. If the lawn mower does not self propel, rotatethe control knob clockwise 1/2 turn to tightenthe belt.

If the lawn mower creeps forward, rotate theknob 1/2 turn counterclockwise to loosen the belt

Figure 301. Control knob

Adjusting the Blade BrakeCableService Interval: Every 100 hours

Adjust whenever a new blade brake cable assemblyis installed.



• For Blade Brake Clutch Units:

1. Loosen the cable clamp screw until the cableconduit slides (see Figure 31).

Figure 311. Spring 3. Cable clamp screw2. Cable conduit

2. Pull the cable to remove the slack, but DoNot put tension on the spring.

3. Tighten the screw to lock the adjustment inplace.


• For Self-Propelled Units without a BladeBrake Clutch:

1. Loosen the nut on the cable bracket (seeFigure 31).

2. Insert a 3/16 to 1/4 inch (5 to 6 mm) objectbetween the brake control lever and thehandle.

3. Turn the cable adjuster on the brake cableuntil you remove the slack.

4. Tighten the jam nut.


• For Hand-Push Units:

1. Loosen the jam nut on the blade brake cableclamp (see Figure 31).

2. Insert a 3/16 to 1/4 inch. (5 to 6 mm) objectbetween the brake control lever and thehandle. Pull down on the cable conduit untilyou remove the slack from the wire.

3. Tighten the nut.


31

Maintenance

CleaningClean Grass Build-Up UnderDeckService Interval: Before each use or daily1. Stop engine, wait for all moving parts to stop, and

remove spark plug wire.2. To ensure the best performance, keep the

underside of the lawn mower housing clean(Figure 32).

Figure 32Blade Brake Unit Shown for Reference Only

Washing Method1. 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 infront of the right rear tire (Figure 33).

Figure 33

4. Engage the blade.

Note: The blade will draw in water and wash outclippings. Let the water run until you no longersee clippings being washed out from under thehousing.

5. Disengage the blade, stop the engine and wait forall moving parts to stop.

6. Turn off the water.

7. Start the lawn mower, engage the blade, and letthe lawn mower run for a few minutes to dry outits components.

Scraping Method

If washing does not remove all debris from under thelawn mower, scrape it clean.


2. Drain the fuel from the fuel tank. Refer toEmptying the Fuel Tank and Cleaning theFuel Filter section.

WARNINGTipping the lawn mower may cause the fuelto leak from the carburetor or the fuel tank.Gasoline is extremely flammable, highlyexplosive, and under certain conditions, cancause personal injury or property damage.

Avoid fuel spills by running the engine dry orby removing the gasoline with a hand pump;never siphon.

3. Tip the lawn mower onto its right side.

4. Remove the dirt and grass clippings with ahardwood scraper. Avoid burrs and sharp edges.

5. Turn the lawn mower upright.

6. Fill the fuel tank.


Cleaning the DischargeTunnel and PlugService Interval: Before each use or daily

Always be sure that the discharge tunnel door closessecurely when you release the handle. If the debrisprevents the discharge door from closing securely,clean the inside of the discharge tunnel and the doorthoroughly.

32

Maintenance

WARNINGGrass clippings and other objects can bethrown from an open discharge tunnel.Thrown objects can cause serious injury orkill the operator or bystanders.

Never start or operate the lawn mower unlessone of the following is true:

• The discharge tunnel plug is lockedsecurely in the discharge tunnel.

• The grass bag is locked in place.

• The optional side discharge chute islocked in place.

• The discharge tunnel door is locked inplace.

Cleaning Underthe Belt Cover(Self-Propelled ModelsOnly)Service Interval: Every 50 hours1. Stop the engine and wait for all moving parts to

stop.

2. Disconnect the wire from the spark plug (seeFigure 9 and Figure 10).

3. Remove the bolts that secure the belt cover to thelawn mower housing (Figure 34).

Figure 341. Belt cover

4. Lift off the cover and brush out all the debrisaround the belt area.

5. Install the belt cover.


Cleaning the Blade BrakeClutch ShieldService Interval: Every 50 hours1. Stop the engine and wait for all moving parts to

stop.

2. Disconnect the wire from the spark plug (seeFigure 9 and Figure 10).

3. Drain the gasoline from the fuel tank.

4. Tip the lawn mower onto its right side (air filterup).

WARNINGTipping the lawn mower may cause the fuelto leak from the carburetor or the fuel tank.Gasoline is extremely flammable, highlyexplosive, and under certain conditions, cancause personal injury or property damage.

Avoid fuel spills by running the engine dry orby removing the gasoline with a hand pump;never siphon.

5. Remove the blade nuts, the anti-scalp cup, theaccelerator, and the blade (see Figure 35).

Figure 351. Tabs and nuts 3. Tab and bolt.2. BBC Shield

6. Loosen the tabs that secure the BBC shield to thedeck by loosening the nuts or the bolts on thetabs (Figure 35). Rotate the tabs 180° to movethem out of the way.

33

Maintenance

7. Remove the BBC shield and brush or blow allthe debris from under the shield and around theBBC system.

8. Install the BBC shield. Rotate the tabs 180° backinto position. Tighten the nuts to the bolts ontabs to secure the BBC shield to the deck.

9. Install the blade, the accelerator, the anti-scalpcup, and the two blade nuts.

10. Turn the lawn mower upright.11. Connect the wire to the spark plug.

Emptying the Fuel Tankand Cleaning the Fuel Filter(Kawasaki Units Only)Service Interval: Every 100 hoursThe fuel filter (screen) element is located inside thefuel tank.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 (Figure 7).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 intoan approved fuel container.

10. Install the fuel tank and fuel line.

Waste DisposalMotor Oil DisposalEngine oil and hydraulic oil are both pollutants tothe environment. Dispose of used oil at a certifiedrecycling center or according to your state and localregulations.

34

Storage

StoragePreparing the Fuel SystemTo prepare the lawn mower for off season storage,perform the recommended maintenance procedures.

Store the lawn mower in a cool, clean, dry place.Cover the lawn mower to keep it clean and protected.

WARNINGGasoline can vaporize if you store it over longperiods of time. Gasoline vapors can explodeif they come into contact with an open flame.

• Do Not store gasoline over long periodsof time.

• Do Not store the lawn mower withgasoline in the fuel tank or the carburetorin an enclosure with an open flame. (Forexample, a furnace or a water heater pilotlight.)

• Allow the engine to cool before storingit in any enclosure.

Empty the fuel tank when mowing the last timebefore storing the lawn mower.

1. Run the lawn mower until the engine stops fromrunning out of fuel.

2. Prime the engine and start it again.

3. Allow the engine to run until it stops. When youcan no longer start the engine it is sufficiently dry.

Preparing the Engine1. While the engine is still warm, change the oil from

the crankcase. Refer to Changing the EngineOil section in Maintenance.

2. Remove the spark plug.

3. Using an oil can, add about one tablespoon of oilto the crankcase through the spark plug hole.

4. Slowly rotate the engine several times, using thestarter rope, to distribute the oil.

5. Install the spark plug but Do Not connect thewire to the spark plug.

General Storage Information1. Clean the lawn mower housing. Refer to

Cleaning the Underside of the Lawn MowerHousing section in Cleaning.

2. Clean any dirt and chaff from the cylinder,cylinder head fins, and blower housing.

3. Remove grass clippings, dirt, and grime from theexternal parts of the engine, the shrouding, andthe top of the lawn mower housing.

4. Clean the BBC shield. Refer to Cleaning theBlade Brake Clutch Shield section in Cleaning.

5. Check the condition of the blade. Referto Maintaining the Blade section in theMaintenance.

6. Service the air filter. Refer to Servicing the AirFilter in Maintenance.

7. Lubricate the pivot arms. Refer to Lubricatingthe Pivot Arms section in Maintenance.

8. Tighten all nuts, bolts, and screws.

9. Touch up all rusted or chipped paint surfaces withpaint available from an Authorized Service Dealer.

Removing the Lawn Mowerfrom Storage1. Check and tighten all fasteners.

2. Remove the spark plug and spin the engine rapidlyby pulling the starter rope to blow excess oil fromthe cylinder.

3. Clean the spark plug or replace it if it is cracked,broken, or if the electrodes are worn.

4. Install the spark plug and torque it to 17 ft-lb (23N-m).

5. Perform any needed maintenance procedures.

6. Fill the fuel in the fuel tank with fresh gasoline.

7. Check the engine oil level.


35

Troubleshooting

TroubleshootingImportant: It is essential that all operator safety mechanisms be connected and in proper operatingcondition prior to mower use.

When a problem occurs, Do Not overlook the simple causes. For example: starting problems could becaused by an empty fuel tank.

The following table lists some of the common causes of trouble. If a problem continues, contact an AuthorizedService Dealer.

Problem Possible Cause Corrective Action

1. Fuel tank is empty. 1. Fill the fuel tank.

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. 5. Clean, adjust or replace spark plug.

Engine will not start, starts hard, or fails tokeep running.

6. Spark plug wire is not connected. 6. Check the spark plug wire connection.

1. Air cleaner is dirty. 1. Clean or replace the air cleaner element.

2. Oil level in the crankcase is low. 2. Add oil to the crankcase.3. Vent hole in the fuel cap is plugged. 3. Clean or replace the fuel cap.4. Dirt in fuel filter. 4. Replace the fuel filter.5. Dirt, water, or stale fuel is in the fuel

system.5. Contact an Authorized Service Dealer.

Engine loses power.

6. The underside of the lawn mower deckcontains clippings and debris

6. Clean the underside of the lawn mowerdeck.

1. The wire is not connected to the sparkplug.


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.

Engine runs rough.

4. The air filter element is dirty and isrestricting the air flow.

4. Clean the air filter pre-cleaner and/orreplace the paper air filter.

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.

Lawn mower or engine vibrates excessively.

4. The engine mounting bolts are loose. 4. Tighten the engine mounting bolts.

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. Mowing in the same pattern repeatedly. 3. Change the mowing pattern.

Uneven cutting pattern.

4. The underside of the lawn mower deckcontains clippings and debris.


1. The throttle lever is not in the Fastposition.

1. Move the throttle lever to the Fastposition.

2. The cutting height is too low. 2. Raise the cutting height.3. Mowing too fast. 3. Slow down.4. The grass is wet. 4. Allow the grass to dry before mowing.

Discharge chute plugs

5. The underside of the lawn mower deckcontains clippings and debris.


36

Troubleshooting

Problem Possible Cause Corrective Action

1. The self-propel drive cable is out ofadjustment or is damaged.

1. Adjust the self-propel drive cable. Replacethe cable if necessary.

Lawn mower does not self-propel(Self-Propelled Models Only)

2. There is debris under the belt cover. 2. Clean the debris from under the beltcover.

37

Conditions and Products CoveredExmark 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.

This warranty applies to Exmark commercial turf 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.

Warranty Exceptions Warranty Period• Bags, Belts and Tires 90 days• Engine 2 years*

* 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.

This warranty only includes the cost of parts and labor.

Items and Conditions Not CoveredThis warranty does not cover the following:• Pickup and delivery charges to and from any authorized Exmark Service Dealer.• Any damage or deterioration due to normal use, wear and tear, or exposure.• 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 turf equipment or other than as recommended in the operator's manual or other operational instructions provided by Exmark.

There are no other express warranties except for engine and special emission system coverage.

All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts.

Instructions for Obtaining Warranty ServiceThe product must be registered with original proof of purchase by an Exmark Service Dealer before obtaining any warranty service.

Contact any Exmark Service Dealer to arrange service at their dealership. To locate a dealer convenient to you, access our website at www.exmark.com. U.S. or Canada customers may also call 402-223-6375.

If for any reason you are dissatisfied with the Service Dealer’s analysis or with the assistance provided, contact us at:

Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice, NE 68310 402-223-6375 or [email protected]

Owner’s ResponsibilitiesThe 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 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.

General ConditionsThe 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.

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 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.

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.

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.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Exmark Commercial Turf Equipment1 Year Limited Warranty

G4500-426

38

Service Record

Date: Description of Work Done: Service Done By:

39

MID-MOUNT RIDING ACCESSORIES AND OPTIONS

SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS

WALK-BEHIND ACCESSORIES AND OPTIONS

GRASS CATCHER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

CUSTOM RIDE SEAT SUSPENSION SYSTEM

FULL SUSPENSION SEAT

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

12V POWER PORT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

ROLL OVER PROTECTION SYSTEM (ROPS)

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OUT-FRONT RIDING ACCESSORIES AND OPTIONS

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DUAL-TAIL WHEEL

FLOOR PAN EXTENDER

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SNOWBLOWER

SUN SHADE

TRASH CONTAINER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WEATHER CAB

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.

Model No. Engine Serial No. (E/No)

Serial No.

© 2008 Exmark Mfg. Co., Inc.Industrial Park Box 808Beatrice, NE 68310All Rights Reserved

Part No. 4500-400 Rev. A(402) 223-6300Fax (402) 223-5489Printed in the USA

www.exmark.com

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