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Section 5: Maintenance
WARNING
Before inspecting, cleaning or servicing the machine, shut off engine, wait for moving parts to stop, dis-
connect spark plug wire and move wire away from spark plug.
Failure to follow these instructions can result in serious personal injury or property damage.
K
Figure 5-17: Dislodging handlebar struts.
2. Fold the top section of the assembly
backward (2, Figure 5-16). Guide the
cables carefully while folding. Be sure
not to bend, pinch, or stretch the cables.
IMPORTANT: To avoid damage to cables,
always fold the top section of the
handlebar assembly backward and the
bottom section forward.
3. Still supporting the handlebar
assembly with one hand, loosen the two
lower handlebar adjustment knobs
(3, Figure 5-16) just enough to dislodge
both handlebar struts (L, Figure 5-17)
from the slots (K) in the wheel bracket
assembly.
NOTE: The handlebar height could inad-
vertently change if the lower adjustment
knobs are loosened excessively during
this step.
4. Carefully fold the bottom section of
the handlebar assembly forward over the
engine (4, Figure 5-16). Guide the cables
carefully while folding. Be sure not to
bend, pinch, or stretch the cables; also,
keep cables away from muffler — the
outer cable covering can be burned if the
engine is still hot.
5. To unfold handlebar assembly,
perform folding steps in reverse order.
PINION GEAR SERVICE
The mower drive wheels (rear wheels)
each contain a pinion gear. This gear
transfers drive power to the wheels which
propels the mower forward. It is very
important to keep these internal parts
clean. The following procedure explains
how to disassemble, clean and reassem-
ble the mower drive wheels. Conduct this
maintenance on the pinion gears after
every 50 operating hours.
E
L
Figure 5-18: Drive wheel assembly.
Tools and Materials
• 9/16" Socket and Ratchet
• Small Snap-Ring Pliers
• Cleaning Rags
Procedure
NOTE: This procedure is done only on
the drive wheels (rear wheels).
1. Place a sturdy, stable block under the
mower to elevate a rear wheel off the
ground.
2. Use a 9/16" wrench to remove wheel
assembly (A, B, C, D, E, Figure 5-18).
3. Remove snap-ring (J, Figure 5-18)
from axle.
4. Remove shim(s) (I, Figure 5-18). The
number of shims vary from mower to
mower. Put them next to the snap-ring.
5. Pull off pinion gear (H, Figure 5-18).
6. Remove drive pin (G, Figure 5-18).
7. Remove plastic washer/seal
(F, Figure 5-18).
8. Thoroughly clean off debris from the
drive pin, axle, hole in axle (for drive pin)
and the washer/seal.
9. Reinstall washer/seal (F, Figure 5-18).
Be sure to install flat side of washer
against bearing (mower deck).
10. Insert the drive pin (G, Figures 5-18)
into the hole in the axle.
B
C
D
H
G
F
NOTE: The pin should slide freely within
the hole.
11. Thoroughly clean pinion gear,
including surface area and cavity.
12. Slide the pinion gear (H, Figure 5-18)
onto the axle with the cavity toward the
mower. Press the gear firmly against the
washer/seal (F, Figure 5-18). Be certain
that the gear is flush against the surface
of the washer/seal and that the
washer/seal is flush against the wheel
mounting bracket.
13. Slide the shims (I, Figure 5-18) onto
the axle and against the pinion gear. Be
sure to install the same number of shims
as were removed from the unit.
14. Install the snap-ring onto the axle
(J, Figures 5-18) and into the groove in
the axle. Pull the pinion gear outward to
be sure that the snap-ring seats properly.
NOTE: If you can't get the snap-ring into
the slot in the axle, press the pinion gear
more firmly against the washer/seal. Do
not leave off shims.
15. Insert wheel screw (A, Figure
5-18) through wheel (B), flat washer (C),
center hole in wheel shield (D), and
spacer (E). The wheel shield has a double
edge on the rim. Position this side
toward the wheel.
16. Align pinion gear with the hole in the
wheel shield. At the same time, align the
wheel screw with the welded nut on the
wheel bracket and tighten securely.
J
I
A
20
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