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repair and adjustment

1. x E A TEN RT O EN IT AA AAA NN NE T5 AN CE CP A D PS ARD ARCA 25 F 88516 qu al alas anar yRP Pr TIMI a en uale i se annt TUTT ON umi PT WS a u y panas quale nic AM d EY amp REPAIR AND ADJUSTMENT How To Check The Front Drive Chain Put the rider mower on a level surface Stop the engine Push the clutch brake pedal forward Move the shift lever to any forward speed Release the clutch brake pedal Look at the distance between the top and bottom halves of the front drive chain ifthe distance is or less the drive chain must be adjusted as follows 1 Make sure the brake is correctly adjusted See the instruc tions on How To Adjust The Brake 2 Move the shift l ver to the NEUTRAL position 3 Disconnect the spring from the chain idlers 4 Engage the parking brake 5 Loosen the three nuts on the chain bridge 6 To adjust the chain slide the chain bridge back Hold the bridge in place Tighten the three nuts to hold the bridge in place 7 Check the front drive chain Make sure the chain has no more than 3 18 inch of movement as shown 8 Connect the spring to the chain idlers 9 After the front drive chain is adjusted the rear drive chain must be adjusted See the instructions on How To Adjust The Rear Drive Chain F 88516 Front Drive Chain D 4603 1 26 Front Drive Chain Rear Drive Chain te If distance is or less
2. O Transport Pull Behind Attachments nm 3 SLOW FAST HOW TO STOP THE UNIT S 1 Push the pedal completely forward to stop the unit Keep 6 your foot on the pedal 7 2 Move the blade engagement control to the DISENGAGE position 3 Move the shift lever to the NEUTRAL position Set the parking brake 12 F 88516 1 2 WARNING Make sure the parking brake will 8 hold the unit 9 HOW TO START THE ENGINE WARNING The electrical system has an operator presence system that includes a sensor switch mounted in the seat These components tell the electrical system if the operatoris sitting on the seat For your protection always make sure this system operates correctly This system will stop the engine when the operator leaves the seat if the blade engagement control is engaged Check the oil Fill the fuel tank with regular unleaded gasoline Make sure the gasoline is clean Leaded gasoline will increase deposits and shorten the life of the valves NOTE Do not use gasohol or methanol Do not use premium unleaded gasoline WARNING Always use a safety gasoline container Do not smoke when adding gasoline to the fuel tank When inside an enclosure do not add gasoline Before you add gasoline stop the engine and let the engine cool for several minutes Sit in the seat Push the clutch brake peda completely for ward Keep your foot on the pedal Move the shift lever to the neutral N posit
3. 2 Move the seat to the best position for operating the unit Tighten the hex bolts 3 Connect the wire from the seat switch sensor to the wire harness Make sure the tab part of the connector from the seat switch sensor locks into the latch of the wire harness connector WARNING For correct and safe operation ofthe unit you must connect the wire from the seat switch sensor to the wire harness 4 Some models have two seat spring caps in the parts bag Mount the caps on the seat springs as shown FR Wire from Seat Sensor Seat Support Tie Strap F 88516 Steering Post D x gt Bellows Sz TT s A JR 3D DA et PA UN Z1 AC pr nr tet vd etu tren Steering Wheel cai AS Bezel D 4677 CE LA AN o tm D PPT AET En OCA TIER ant eu pes tas Punt E ten x d TET Ern Cra CHECK THE TIRES Check the air pressure in the tires Tires with too much air pressure will cause the unit to ride rough Also the wrong air pressure will keep the mower housing from cutting level The correct air pressure is shown on the side of the tires If the air pressure is not shown inflate the tires from 10 to 12 PSI 0 7 to 0 85 kg cm2 HOW TO CHECK THE MOVVER HOUSING Make sure the level of cut set at the factory is still correct After you mow a short distance look at the area that was cut If the mower housing does not cut level see the instructions on How To Level The Mower
4. mo odel 502 254152 CAUTION Read And Follow All Safety Rules Assembly And Instructions Before Operating This Operation Maintenance Equipment Repair and Adjustment Repair Parts DE oo a MEN ARTE Pr CAN 0 10 Ti 12 13 14 15 16 SAFETY RULES Safe Operation Practices for Riding Vehicles As Recommended by American National Standards Institute Know the controls and how to stop quickly READ THIS INSTRUCTION BOOK and any instructions furnished with attachments Do not allow children to operate the machine Do not allow adults to operate it without proper instruction Clear the work area of objects wire rocks etc which might be discharged by the machine Handle gasoline with care It is highly flammable a Use an approved gasoline container b Never remove the fuel cap or add gasoline to a running or hot engine or an engine that has not been allowed to cool for several minutes after running Never fill the fuel tank indoors Clean up spilled gasoline c Do not run the engine indoors Exhaust fumes are dangerous Always wear safety glasses or a eye shield when you operate the unit to protect your eyes from foreign objects that can be thrown from the unit Always wear eye protection when you make an adjustment or repairs to the unit Keep all nuts bolts and screws tight to be sure the equip ment is in safe working condition D
5. 1 4 dia Lever Assy ONCE For ed Crank 3 Screw pins Mtg Elbow Muffler 90 Street Housing Blower Screw Blower Housing Mounting Sem Shield Cylinder Screw Cylinder Shield Mounting Sem Cover Cylinder Head Motor Starting 12 Volt See Chart on Page 5 for Replacement Parts for Starting Motors Thru Bolt Assembly Brush Assembly Armature Assy Less Trigger Coil Nut Hex Armature Group Screw Armature Mounting Sem Plug Spark 101 1 2 high Screw Terminal Fillister Hd Washer Insulating P oomodo 4voo00 ooo 51 1 er 01 93053 877 887 897 93307 261116 270382 66538 280118 93496 222311 93572 392134 395405 93535 261196 212359 391373 298909 93875 394856 395537 393825 270920 392067 221798 261463 210940 291961 Note 393814 391529 394970 DESCRIPTION Nut Hex 10 24 BRIGGS amp STRATTON ENGINE MODEL 500 253707 0213 01 Clamp Fuel Pipe Cotter Hair Pin Retainer E Ring Spring Choke Return Washer Choke Shaft Elbow Spark Plug Support Air Cleaner Element Screw Sem Bracket Carburetor Screw Gear Ring includes Mounting Parts Cover Starter Includes Mounting Screws Screw Sem Gear Timing Link Counterweight Counterweight Assy Pin Counterweihgt 1 Screw Counterweight 1 End Cap Assembly Drive End Cap Assembly Commutator Housing Assembly Seal Oil Filler Cap Filler Group Oil Terminal Ignition Cable Seat In
6. 17 F 88516 MAINTENANCE amp HOURS once a year EVERY E WHERE TO LUBRICATE Lubricate the areas shown with engine gil Nas Apply grease with a brush to the areas shown IMPORTANT If the unit is operated in dry areas that have sand use a dry graphite spray to lubricate the unit HOW TO CHECK THE MUFFLER Check the muffler every 50 hours Make sure the muffler is correctly mounted and is not loose if the muffler is worn or burnt replace with a new muffler worn muffler is a fire hazard and also can damage the engine If you mount a spark arrestor to the muffler also check the spark arrestor every 50 hours If the spark arrestor is worn or damaged replace it with a new spark arrestor HOW TO CLEAN AND CHECK THE BATTERY BM E n hat d Nr Remove the black cable from the negative terminal Remove the red cable from the positive terminal Remove the battery clamp from the battery Remove the battery from the unit site Wash the battery with a solution of one gallon of water and four tablespoons of baking soda sodium bicarbonate Make sure the solution does not get into the battery cells 6 Clean the terminals and the ends of the cables with a wire brush Install the battery See How To Install The Battery Check the level of the battery acid The battery acid must touch the bottom of the vent If the battery acid has fallen below the correct level add water to the correct level Do
7. 18 Pin Pull Washer Pin Hair Mower Housing Complete These parts are included with key no 33 F 88516 43 MOWER HOUSING BOTTOM HALF PART MFG NO NO 37x57 55452 18x33 15x101 STD541450 15x41 91178 5592 1E601 55895 55979 STD541431 15x88 29x99 244712 STD523106 1x45 STD624003 31x6 55977 55920E601 STD533107 2x537 SID541031 15x797 55894 55273Z STD525015 1x127 55962 559562 55974 164x1 STD541431 15x432 166x4 28x23 21197Z 55963 165x68 56065E601 55916 26x216 STD523117 1x75 55971 55445 56060HT 17x155 17x154 15x100 908282 STD551050 17x67Z STD624005 31x4 403224 REPLACEMENT PARTS MODEL NO 502 254152 TRANSMISSION F 88516 KEY NO DESCRIPTION SO N C O1 PN Lu Washer Thrust Washer Locknut 14 20 Yoke Left Yoke Right Bolt Hex 4 20x1 Ya Lever Shift Spring Extension Shift Rod Assembly Bearing Flanged Washer Pin Cotter Bearing Flanged Ring Retainer Locknut 16 Rod Carriage Washer Curved Spring Arm Actuator Bolt Shoulder Support Carriage Pin Cotter Washer Roller Idler Assembly Left Idler Assembly Right Ring Retainer Sprocket 35 9 Tooth Bearing Flanged Spring Extension Rod Brake Stop Ring Retainer Mandrel PART MFG NO NO 15x98 55500 17x147Z 17x149 STD541425 15x89 555782 555882 STD522512 1x94 55476Z 165x71 557112 55549 17x36Z 30x50 55548 11x8 STD541437
8. Before you adjust the blade engagement control lever check and level the mower housing See How To Leve The Mower Housing Set the height of the mower housing in the lowest position Move the blade engagement control to the DISENGAGE position Check the blade engagement control lever Before the blade engagement control engages there must be 1 8 to 3 8 3mm to 9mm of free movement if an adjustment is needed disconnect the clevis from the pivot rod and bracket assembly Turn the clevis clockwise to decrease the free movement of the blade engagement control Turn the clevis counterclockwise to increase the free movement Connect the clevis to the pivot rod and bracket assembly Move the blade engagement control to the DISENGAGE position Check the free movement of the blade engagement control u N Pivot Rod And Bracket Assembly D 4755 10 11 12 Check the operation of the blade brake Rotate the pulley with your hand Make sure that the blade brake pad presses tightly against the pulley Move the blade engagement control to the ENGAGE posi tion Check the blade brake pad If the blade brake pad is excessively worn or damaged replace the blade brake pad assembly Correct replacement parts and assistance are available from an authorized service center Mow for a short distance and again check the operation of the blade engagement control When you move the blade engagement control to the DIS ENGAGE
9. adjust the drive chain SA MN M A HC M MCA wh ie Ae PAN M rec cta cau M B OP PT PON A RP RUM bj WARNING Before you tighten the front chain engage the parking brake Chain Idlers zi a A FES Wo REPAIRS AND ADJUSTM How To Check The Rear Drive Chain ENTS Engage the parking brake Push the unit forward This causes the 6 Check the tension of the chain Make sure the chain has no loose part of the chain to be on top between the two sprockets The more than 1 4 to 3 8 inch of movement as shown top part of the rear chain must have 1 4 to 3 8 inch of movement as 7 Tighten the other two nuts at each axle bracket shown If the movement is more than 3 8 inch adjust as follows WARNING Do not wear clothing that is loose Loose clothing can get into the moving parts 1 Engage the parking brake 2 Loosen the three nuts on each axle bracket at the rear wheels 3 Pull the right axle bracket toward the back of the unit until th chain is tight 4 Hold the right axle bracket in place Tighten one of the nuts to hold the axle bracket in place 5 Look at the side of the frame above the axle Find the index notches These index notches are a measurement of the location of the axle brackets Make sure the position of the axle bracket on the left side of the unit is like the right side If the position is the same tighten one of the nuts on the left side Axle Mounting Bracke Top View Rear Dr
10. 10 Spark Plug n 18 DOS des trous T N i Mower Housing A opaa 22 Remove and Install nas 20 O Oil Check masses uen inposita 14 Chad acsi iei adn ene 19 Operation mt aaa 11 13 Mower Housing onam NAE 13 Operate On Hills sus IS Operate The Unit cian AG Start Engine sosie m P Stop The Unit TE we P Parts Bag iota echt oi EVE VV RS m R Repair and Adjustment 20 30 Mower Drive Belt coronan vies 22 Carburetor nes dina LO Drive Chains TEEN 26 27 Level Mower Housing 22 Motion Drive Belt o 21 Mower Housing Install nenn 20 Mower Housing Remove emmm 20 S Safety Rules eene 2 SUBE ci s CO REN EROR rev eds Sharpen Blade saserionioneenss nn 17 Shift LOVET iia T2 Side Panel Remove e 13 Slope Guide coincide D I Spark Plug wusste 18 Speed Control Chart nee Start Engine n s Ve Steering Wheel eee 8 Stop Riding Mower 12 Storage ke9t 83343343444 amp b RV SA SELLES HARADA VIANA THEN Lac SSS SEER ES 30 T Throttle Control Cable Adjust 29 Tire Pressure a ii 10 17 Transmission Friction Drive se 23 28 Trouble Shooting Chart ns 31 W Warranty PtP PSPSPS STI SES RENA AAA EFE RIIIE 3 Wiring Schematic nw dd ASSEM
11. 15x84Z 55559 20x1 55643 9x30 55562E701 STD560907 30x20 STD551037 17x53Z 55570 55514Z 55513Z 11x18 55543 55651 165x27 56021 11x13 55635 This part includes Key Number 34 F 88516 KEY NO 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 45 DESCRIPTION Locknut 5 16 18 Housing Bearing Screw Set Carriage Arm Ball Bearing Assmbly Ring Retainer Hex Shaft Assembly Brake Arm Assembly Bearing Flanged Bushing Flanged Pivot Rod Assembly Washer Curved Spring Washer Screw Bracket Neutral Linkage Shifter Ring Retainer Screw Retainer Bearing Ball Bearing Assembly Washer Arm Neutral Clip Carrier Arm Arm Carrier Hub Friction Disc Disc Friction Screw Spring Grip Inner Switch Limit Screw Grip Outer Spacer REPLACEMENT PARTS PART NO TRANSMISSION MFG NO STD541431 15x88 55596 22x57 55638 55639 11x17 56020 55889 55547 55546 55569Z 20x2 STD551037 17x53Z 26x49 556072 555262 11x12 26x174 55509Z 55541 STD551031 17x47Z 556067 556587 556082 55501 55550 26x207 165x46 20476 24273 26x233 55449 115x2Z MODEL NO 143 100 029A F 88516 KEY NO OVER GE 11 14 DESCRIPTION Housing Differential carrier Incl No 13 Housing Differential carrier Incl No 13 Axle 8 1 1 64 long Axle 19 3 32 long Gear Bevel Ge
12. Choke Valve Mtg Sem 270916 Gasket Crankcase 98 81920 Screw Machine Fill Cover 009 thick 99 26157 Spring Throttle Adjustment 13 193723 Screw Cylinder Head 101 93043 Pin Throttie Stop 3 long 104 12308986 Pin Float Hinge 15 191084 Plug Oil Drain 108 222010 Valve Choke 16 392299 Crankshaft 118 1396568 Valve Needie Note To replace Crankshaft Gear Pin 121 394698 Carburetor Overhall Kit Order Part No 230978 123 193357 Screw Carburetor Mtg 18 391784 Sump Oil 125 396501 Carburetor Assembly 20 291675 Seal Oil 126 396574 Body Assembly 22 93585 Screw Sump Mounting Sem Carburetor 23 391988 Fly wheel and Ring Two 271013 Foam Gear Assy Magneto Washers Included in 24 222698 Key Flywheel All Ref 126 25 394661 Piston Assy Std 127 1221997 Plug Welch 394662 Piston Assembly 128 211960 Venturi Carburetor 010 0 5 130 222858 Valve Throttle 394663 Piston Assembly 131 391512 Shaft and Lever 020 O S Throttle 394664 Piston Assembly 132 211712 Stop Throttle 030 O S 133 299707 Float Carburetor PISTON RING SETS 134 1299096 Valve Fuel inlet Note For Chrome Piston Ring 136 221995 Bowl Float Set Standard Size 137 1270511 Gasket Float Bowl Order No 392331 138 1222014 Washer Float Bowl 26 394665 Ring Set Piston Std 141 390684 Shatt and Lever Choke 391781 Ring Set Piston 010 O S 142 1299740 Nozzle Carb
13. Toassernble the cover put the tab in the control panel Fasten the top of the cover with the two screws as shown 7 Slide the bellows over the steering post Make sure the collar of the bellows is on top Push on the top of the bellows Fasten the adapter to the steering post with the fasteners as shown 8 Fasten the adapter to the steering post with the bolt and nut as shown Tighten to a torque of 18 foot pounds ASSEMBLY 9 Make sure the front wheels point to the front Attach the steering wheel to the adapter Fasten the steering wheel with the large washer the lockwasher washer and the bolt shown in the illustration 10 Attach the steering wheel cap to the steering wheel 11 Connect the ends of the wires for the headlight Before the bezel can be assembled the two screws at the front of the control panel must be removed Put the bezel in position on the end ofthe control panel Fasten the bezel with the screws that were removed NOTE if you do not follow the above assembly instructions correctly the steering system will feel loose and the unit will not steer correctly HOW TO INSTALL THE TILT SEAT Assemble the seat with the fasteners shown full size below 1 Align the four long holes in the seat support to the four holes in the seat Make sure the wire from the seat switch sensor goes through the large hole in the seat support Fasten the seat to the seat support with the fasteners as shown Do not tighten
14. are present Never store the equipment with gasoline in the tank inside a building where fumes may reach an open flame or spark Allow the engine to cool before storing in any enclosure Take all possible precautions when leaving the vehicle unattended such as disengaging the blade engagement control lever lowering the attachment s shifting into neutral setting the parking brake stopping the engine and removing the key Keep the vehicle and attachments in good operating condi tion and keep safety devices in place and working Disengage power to attachment s and stop the engine before making any repairs or adjustments The carburetor can be adjusted with the engine running E Wait for all movement to stop before servicing any part of the unit IM M E O e ME o ee Read and follow the instructions in this book concerning a safety and operation of the mower WARNING This unit is equipped with an internal combustion engine and must not be used on or near any unimproved forest covered brush covered or grass covered land unless the engine s exhaust system is equipped with a spark arrester meeting applicable local or state laws if any If a spark arrester is used it must be maintained in effective working order by the operator gt In the State of California the above is required by law Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on federal lands See an Aut
15. damage must be repaired before restarting and operating the equipment Do not change the engine governor settings or overspeed the engine When using the vehicle with a mower proceed as follows a Mow only in daylight or in good artificial light b Never make a cutting height adjustment while the engine is running if the operator must dismount c Stop the engine before removing a grass catcher or unclogging the chute d Checkthe blade s and mounting nut s for proper tight ness at frequent intervals Frequently check the blade for wear or damage such as cracks and nicks blade that is bent or damaged must be immediately replaced with a factory replacement blade For safety replace the blade every two years Frequently check the nut s that hold the blade s Replace damaged nuts and tighten loose nuts Disengage power to the mower before backing up Do not mow in reverse unless absolutely necessary and then only after careful observation of the entire area behind the mower Under normal usage the grass catcher bag material is subject to deterioration and wear It should be checked frequently for bag replacement Replacement bags should be checked to ensure compliance with the original manufac turers recommendations or specifications Do notoperate the mower without either the grass catcher or guards in place Read the instructions provided with the grass catcher Do not carry passengers Do not mow when children and others
16. lever to a forward speed position Disconnect the spring from the carriage arm Move the shift lever to the NEUTRAL position Use a screwdriver and remove the E ring from the carriage rod Loosen the setscrew at the carriage arm Remove the carriage arm from the hex shaft and the carriage rod Use a 1 2 inch wrench to remove the three screws from the friction disc Remove the friction disc Use a factory replacement part to replace the friction disc Use the three screws to fasten the new disc in place Tighten the screws to a torque of 36 to 40 inch pounds Slide the carriage arm on to the hex shaft and the carriage rod Fasten the E ring on the carriage rod Tighten the setscrew on the carr age arm to a torque of 8 to 10 foot pounds Move the shift lever to a forward speed position Attach the spring to the carriage arm How To Adjust The Index Bracket nabh Engage the parking brake Move the shift lever to the slowest speed position Tiltthe seatforward Check the distance between the neutral arm and the neutral bracket The distance must be approx imately 1 16 inch as shown If the distance is not correct adjust as follows Loosen the two nuts on the index bracket To find the location for the index bracket hold a 1 8 inch shim or a screwdriver between the neutral arm and the neutral bracket as shown Move the index bracket so that the neutral arm is tight against the shim but keep the shift lever in the s
17. to the fastest speed position Disconnect the spring from the carriage arm Set the mower housing in the lowest height of cut position To keep the drive disc from rotating put a large screwdriver under the drive disc between the fins and the frame chassis Use a 9 16 inch socket wrench to remove the nut that holds the drive disc in place Remove the motion drive belt from the beit idler See the drawing Insert A below Pull on the motion drive pulley until the drive disc separates from the shaft Spring D 4684 1 F 88516 f After the parts are assembled torque to 16 18 foot pounds 4 Drive Disc 23 10 11 12 Remove the old drive disc Lift the motion drive pulley into position Align the shim washer and the special double D ID washer on the shaft Replace the drive disc Fasten the hex nut to the shaft To keep the drive disc from turning put a screwdriver under the drive disc between the fins and the frame chassis Use a 9 16 inch socket wrench and tighten the nut to a tor que of 18 foot pounds Remove the screwdriver Attach the spring to the carriage arm ER CO nenad rE ET 4 Special Washer Double D ID 4 Shim Washer Motion Drive Pulley Drive Bolt X SA p Vo b i Belt Idler u Belt Guide 2m Stack Pulley D 4729 1 PUN on 10 12 13 REPAIR AND ADJUSTMENT How To Replace The Friction Disc Move the shift
18. viscosity grades 0 32 40 60 80 100 CAUTION To protect the starting system use SAE 5W30 oil when the temperature is below 32 F Oil Drain fe Valve p DE Plastic Tube Container 0 4661 1 EVERY 5 Clean the area around the dipstick Remove the dipstick Slowly pour approximately 3 pints 1 4 liters of oil into the oil extension tube insert the dipstick into the oil extension tube Turn the dipstick in a clockwise direction until it is tight Remove tha dipstick Check the oil level on the dipstick The oil level must reach the FULL mark on the dipstick HOURS every 5 mowings HOW TO CHECK THE OIL IMPORTANT Do not check the level of the oil when the engine runs Stop the engine Wait several minutes to let the oil drain Make sure the unit is level Clean the area around the dipstick Remove the dipstick Wipe the oil from the dipstick Insert the dipstick into the oil fill tube Turn the dipstick clock wise until it is tight Remove the dipstick Check the oil level on the dipstick The oil level must reach the FULL mark on the dipstick if necessary add oil until the oil reaches the FULL mark on the dipstick Do not add too much oil F 88516 EVERY 23 HOURS twice a year HOW TO CHECK AND ADJUST THE BLADE ENGAGEMENT CONTROL WARNING To prevent an injury the blade engagement control must operate correctly Stop the engine Disconnect the wire from the spark plug
19. ze Tee 1e 9 v F 9 G6 PF 9 h H 9 5 OG A EX 8 amp 5 EE ww A RE IG JE JE M AR OE XC OR UE IC LUE OR OE UE OR DR CR RC OR I JE OR UR ROO A 5 MO BL NO M Nn s BER PER TFT HERE bb a V 0 9 EDER 4 4 5535 A o DA P SML UR OR OUR AC EUR OR OE OR RR a a eM E ORC RIOR A RC aC OC M II Pew a wow o9 o WX 4o NOW WO WO EEE AI EII P9 PN CONC 4 Z ES Go d Mp n uta wwe WOW wo WoS 4 NOW WOW ON 9 o Mo WO o te e T IE Se ERRE n a a a n a n e a A e i s o w dd Ua e e m me 9 9 A 5 4 amp S u t 4 T A IR AA O esters sere AAA o re e a 2 2 sa E A x Ka a AMY a OS AS AR AS A j Not shown fuli size Not shown full siza Not shown full size 56022 20107 24582 4 Hub Cap For Wheels 55804 1 Cover For Battery Clamp 1 Bearing For Steering Post 2 Y gt C mm ES a Y 9 m a D Y v o wu 17x132 1 Washer LD For Steer 328 LES Post ing Not shown full siza Not shown full size 55705 1 Tube O Drain Not shown full size Not shown full size 55911 1 Adapter For Steering Wheel 55919 1 Cap For Steering Wheel 55253Z 1 Clamp Battery For Engine For Battery 54148 1 Cable Cover For Red Battery Cable A o Pa O9 Bo BRE RER TE So E MIO Mf ww w m 4 3 je woo dod ao n 4 OO et Fe EES i Fy 4 ECO 9 5E MB N 4 REE W 4 X FA b A o dk de k dE db oh diod
20. Adjust the carburetor 1 Clean air screen 2 Add oil 1 Replace the blade 2 Tighten the engine bolts 3 Decrease the air pressure in the tires Correct air pressure on side of tire 1 Stop the engine Clean the mower housing 2 Replace or sharpen the blade 1 Replace or sharpen the blade 2 Check the air pressure in the tires Correct air pressure on side of tire 3 Raise the height of cut TT 12 13 14 Tos 16 17 NO y ap e w T Replace the spark plug Tighten the limit switch Check for a loose wire See the wiring diagram Adjust the carburetor Drain the fuel tank Clean the fuel line Replace the fuel filter Check the wiring harness for damage or loose connections Repair damaged wire Add water and charge the battery Clean the battery terminals or tighten the battery cable On electric starts replace the solenoid On recoil starts replace the module Connect the wire to the sensor in the seat Add oil Adjust the carburetor Move the throttle control to FAST Try to start the engine to clear out excess fuel Replace the spark plug Clean the air filter _ To activate the seat sensor always sit in the middle of the seat Adjust the throttle control Drain the fuel tank Clean the fuel line Replace the fuel filter Adjust the carburetor Adjust the carburetor Check for a damaged belt or damaged pulley Move the shift lever to a slowe
21. BLY SET UP Your unit was carefully inspected and put in a carton for protection from damage The unit is assembled except for the items shown on this page These items are n the carton with a bag of fasteners and loose parts needed for assembly Find and remove these items The fasteners and loose parts are shown on the next page HOW TO REMOVE FROM THE CARTON To remove the riding mower from the carton follow the instruc tions below 1 2 3 MA oP Open the top of the carton The items shown at the right are in a smail box Remove and check each item Remove the small box Cut each corner of the carton from the top to the bottom with a knife Move the shift lever to the NEUTRAL position Make sure the parking brake is disengaged Move the lift lever to the HIGH position Carefully push the riding mower backwards off the wood frame TOOLS YOU NEED TO ASSEMBLE THE UNIT nonpun Adjustable wrench Open end wrench 1 2 9 16 Open end wrench 7 16 1 2 Blade type screwdriver Phillips screwdriver Low Tire pressure gauge Knife F 88516 D 4656 2 1 Seat 2 Bezel 3 Steering Wheel 4 Steering Post b Parts Bag 6 Owner s Manual 7 Battery 8 Battery Tray 9 Battery Acid 10 Bellows 11 Upper Console 12 Cover PARTS BAG contents in brackets mues ize with the quant The fasteners are shown full s The fasteners and loose parts are s
22. Body Rear Plate Index Receptacle PART NO 91451 55359E601 STD551031 18x16 STD523106 STD541437 164x17 26x49 90014 55062 55366 STD522506 15x76 55617E801 9x29 55823E701 26x238 55414 26x161 55413 STD610803 55717 56022 70231SE 26x201 55351C 55428 55422 26x214 55349E701 55424 STD541425 55430E601 55487 55485 55067E601 55486 70240 55365 28x52 MFG NO 17x47Z 1x45 15x84 1x38 26x159 15x82 See replacement parts page 47 for component parts F 88516 KEY NO 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 36 REPLACEMENT PARTS DESCRIPTION Screw J Nut 20 Locknut 5 16 18 Grommet Bracket Panel Front U Nut 20 Support Console Clamp Battery Support Body Mat Left Mat Right Cover Battery Clamp Frame Channel Screw Screw Hex Head Washer Shakeproof Boit Engine Mount Washer Shakeproof Bolt Hex 5 16 18x334 Muffler Engine Briggs amp Stratton BODY AND CHASSIS MFG NO PART NO 91330 28x18 STD541431 15x88 21268 55358E601 55392E601 28x20 55350E701 55253Z 55360 55103 55102 55804 55946 26x213 6x74 STD551231 19x6 25x6 l 19x8 1x118 56029 Model 500 253707 0213 01 55811PA Fitting Oil Drain Hose Oil Drain Screw HX 10 24x 2 Nut 10 24 Screw VA AB x34 Bolt Shoulder Cap Fuel Tank Tank Fuel Br
23. Housing in the maintenance section of this instruction book HOW TO ATTACH THE HUB CAPS Push each hub cap onto the center hub of each wheel Make sure the washer holds the hub cap in place FINAL ASSEMIBLY 1 Theengine is filled with oil Check the oil See How To Check The Oil in the Maintenance section 2 Make sure all the fasteners are tight 3 Read and follow the instructions in the Operation section Know the location and purpose of all the controls HOW TO INSTALL THE BATTERY Use the fasteners shown below to install the battery The fasteners are shown full size 1 Check the level of the acid If the acid has fallen below the correct level add water to the correct level 2 install the battery and the battery tray as shown in the illus tration Make sure the positive terminal is toward the front of the unit 3 Slide the plastic sleeve over the end of the battery clamp Fasten the battery with the battery clamp as shown 4 Slidethe cover for the positive terminal on to the red battery cable as shown cable to the positive terminal before you connect the black cable to the negative F terminat 5 Fastenthe red battery cable to the positive terminal with the nut and bolt as shown in the iltustration 6 Slide the cover on to the positive terminal 7 Fasten the black battery cable to the negative terminal with the nut and bolt as shown in the illustration 8 To prevent cor
24. OPERATION Lever Fax oe i Tat i CS OUR OM a rr IE DO CC S wat Er e A DG HD D mi ale M ren x 0 x ud hn A EEE a ey E DONS y 20 P A E at t ter a tet An a EEES MW ta ere ated PP Fe OC MNA ta DONC we HM HN im EIAS r DEM t vius pm n s alata as ae t A A S UU C sR Ne 2 ta ate ok WA UNS MEM A PS DOC OUR quite x ob v E AY aa e AE V a A A Ca V XU cr ets MODO E ord CN 0 et ma x en 2 j th so RR ts A er e AN PO ORAL put nt iii ON TNT uium FLEURS LEN AD FORAS XXE s SCR LA HOW TO USE THE CLUTCH BRAKE PEDAL This unit has only one pedal that is located on the left side of the unit The pedal has two functions The first function is a clutch The second function is a brake Push the pedal completely forward to stop the unit HOW TO USE THE LIFT LEVER The lift lever is on the right side of the unit To change the height of cut raise or lower the lift lever When you ride on a sidewalk or a road move the lift lever to the Hl position Acid TO SET THE PARKING BRAKE Push the clutch brake pedal completely forward Hold the clutch brake pedal in the down position To engage the parking brake raise the parking brake lever and then release the clutch brake pedal 2 Torelease the parking brake depress the clutch brake pedal The parking brake will automatically disenga
25. RT NO STD533107 55650 701 55839 55556PA 56018 STD560907 STD541431 9x25 55838E601 STD551231 STD551037 STD624003 STD541437 55825 165x58 165x43 STD541431 55512Z 9x30 55634 55100 15x98 91178 37x51 55961Z STD551243 1x80 55982Z 26x49 55597 55065E601 55872 55656 57890 55664Z 21920 55666 407059 55915 STD541031 17x115Z 24373 90589 91523 STD580105 STD581075 STD551050 24582 558227 55873 STD560907 558217 17x36Z 55820 29x95 ENT PARTS DRIVE SYSTEM MFG NO 2x53Z 30x20 15x88 19x6 17x53Z 31x6 15x84 15x76 19x35 15x79Z 21553 11x3 17x103 30x50 REPLACEMENT PARTS STEERING SYSTEM MODEL NO 502 254152 D 4608 3 F 88516 MODEL NO 502 254152 KEY NO BOON AOR WH DESCRIPTION Cap Steering Wheel Steering Wheel Hex Bolt 5 16 18x1 2 Locknut Flange 5 16 13 Steering Post Washer Carriage Bolt 5 16 18x94 Screw Tapping Suspension Plate Left Hex Nut Flange 5 16 18 Suspension Plate Right Locknut Flange Ys 24 Front Axle Support Assembly Cotter Pin Spindle Bearing Front Axle Hanger Assembly Front Axle Assembly Pinion Gear Sector Assembiy Drag Link Hex Nut 24 Steering Ball Joint Washer Cotter Pin Hex Bolt Ye 24x2 Left Spindie Assembly Tie Rod Right Spindle Assembly Bearing Flanged Wheel Only Tire Only Valve Stem and Cap Washer Hub Cap Bearing Washer Bushing Nylon Bolt Hex 3 16x34 Wa
26. Z l 7 Mandrel Pulley Engine Stack Pulley Belt Guide REPAIR HOW TO LEVEL THE MOWER HOUSING WARNING Before you make an inspection adjustment or repair to the unit disconnect the wire to the spark plug Remove the spark plug wire to prevent the engine from starting by accident Make sure the unit is on a hard level surface Check the air pressure in the tires If the air pressure is incorrect the mower housing will not cut level Make sure the tires are inflated to the pressure shown on the side of the tire If the air pressure is not shown inflate the tires from 10 to 12 psi Move the lever for the blade engagement control to the ENGAGE position Move the lever for the height of cut to the middle position There are two adjustment procedures below that will level the blade housing THE SIDE TO SIDE ADJUSTMENT Use a ruler and measure the distance from the level surface to the bottom of the mower housing Measure the distances at the bot tom of the mower housing under the two side X marks The X marks are on the top of the mower housing as shown in the illustra tion The measurements must be within Ya of the same height If the measurements are more than Ys adjust as follows 1 2 Disconnect one or both of the hangers from the adjuster plates The higher numbers on the side of the adjuster plates will raise the height of the mower housing The lower numbers will lower th
27. acket Fuel Tank Filter Fuel Clamp Hose Hose Fuel Line Cover Seat Spring Hose Clamp Screw Rod Hinge Pin Cotter 55704 55705 4x20Z 15x81Z 26x239 9x30 55988 55805 55806E701 STD611005 26x235 560662 STD560907 30x50 MODEL NO 502 254152 REPLACEMENT PARTS DRIVE SYSTEM D 4702 3 eunt F 88516 36 MODEL NO 502 254152 KEY NO 00 Ad No 10 DESCRIPTION Bolt Carriage Drive Assembly Friction Chain Roller Link Master Sprocket Assembly Pin Cotter Locknut 5 16 18 Bolt Shoulder Bridge Washer Shakeproof Washer Pin Hair Locknut 16 Pedal Spring Brake Arm Spring Drive Idler Locknut 5 16 18 Idler Arm Assembly Bolt Shoulder Key Square Pulley Motion Drive Locknut 16 Puliey Idler Belt Motion Drive Pulley Stack Washer Shakeproof Bolt Hex 7 16 20x1 Guide Belt Screw Bearing Flange Bracket Rear Axle Differential Peerless Model No 100 029A Lever Assembly Link Spring Wire Rod Brake Nut Adjuster Chain Roller Link Master Sprocket and Guard Assembly Nut Hex 5 16 18 Washer Valve Stem and Cap Tire Only Wheel Only Key Square Retainer Ring Washer Hub Cap Rod Parking Brake Grip Parking Brake Pin Cotter Link Parking Brake Washer Stop Parking Brake Pin Clevis See replacement parts page 44 for component parts See replacement parts page 46 for component parts F 88516 37 REPLACEM PA
28. an and Check ss 18 Emergency Start sesser miss DO A da PrnenVerl eri a M s SOA nai 30 Belt Motion Drive Replace 21 Mower Drive Adjust esee 15 Mower Drive Replace 21 Blade Remove and Install 16 Blade Shiarpen iioii te vincia 17 Blade Engagement Control Adjust ooa uen isis MB Operations 11 Brake Pedal Operation ss 11 C Carburetor Adjust seen 29 Chains Check and Adjust 26 27 Charge Battery mener 7 Clutch Brake Pedal mms 11 Controls MES ne li T4 E Engine Carburetor E ET A Oil Change emmm eese 14 19 Oll Level Check nnn 14 Oll IVDe aser donna 14 Operation Speed Chart zer 12 SED tune puente Le Stopping PARS 12 Storage essu uote CR Throttle Control e 11 28 Trouble Shooting Chart iud F 88516 INDEX F Filter Al soie as 19 ui yc e a Fuel System Storage economic SU FUSE iaa r E SL oS L Lubrication 953359334394534343A49AN SZ ESE SU ZU 2 2 7 EEE 18 M Maintenance TE 13 19 Air FIHOE iia i ao reed 19 Battery cs 18 Blade anna iii 10 17 Blade Engagement Control 15 Drive Brake occ 25 Drive Chains emmm sis 20 27 Engine OI cassis anons 14 19 LUBNICALION a PORE IB Muffler Check a 18 Spark Arrester mccccormemmm m9m lt in me
29. an be caused if the blade is not correctly balanced or if the blade is damaged A blade that is damaged with cracks can break and cause an accident 1 Sharpen the blade two times a year or every 25 hours 2 Remove the blade according to the instructions in How To Remove The Blade AL Dh D 3509 1 3 Clean the blade with a brush soap and water Check the gt has blade Look for cracks nicks or other damage If the blade is bent badly worn or damaged replace with a factory replacement blade 4 Sharpen the blade with a file Make sure you keep the original bevel angle Screwdriver 5 Make sure the blade is balanced Use a screwdriver and hold the blade parallel to the ground as shown A biade that is balanced will stay parallel to the ground If the blade is not balanced the heavy end will rotate toward the ground Sharpen the heavy end until the blade is balanced 6 A new blade will cut better than a badly worn blade Every three years have an authorized service person inspect the blade or replace the old blade with a factory replacement blade Ground D 4169 1 CHECK THE TIRES Check the air pressure in the tires Tires with too much air pressure Will cause the unit to ride rough Also the wrong air pressure will keep the mower housing from cutting level The correct air pressure is shown on the side of the tires If the air pressure fs not shown inflate the tires from 10 to 12 PSI 0 7 to 0 85 kg cm2
30. ange All oils must be A P 1 service grade SD SE or SF IE S LI me LPTEIPSEEERRE z RTS ROSES RES wl Tra iode nf Te Tare LM MA A Cad pranka tet wa ua mut aru anu aumente n atat A AA A CAUTION To protect the starting system use SAE 5W30 oil when the temperature is below 32 F 19 F 88516 Cover Screws Foam Filter Paper Filter Base D 4771 Dipstick Oil Drain Valve Plastic Tube Container 4 Clean the area around the dipstick Remove the dipstick Slowly pour approximately 3 pints 1 4 liters of oil into the oil extension tube 5 Insert the dipstick into the oil extension tube Turn the dipstick in a clockwise direction until it is tight Remove the dipstick Check the oil level on the dipstick The oil level must reach the FULL mark on the dipstick REPAIR AND ADJUSTMENT HOW TO INSTALL THE MOWER HOUSING on TO REMOVE THE MOWER HOUSING c gt oo Move the lift lever to the MIDDLE position Move the blade engagement control lever to the DIS ENGAGE position Disconnect the blade drive link from the pivot rodsand bracket assembly See illustration C below Remove the hair pins that hold the hangers to the adjuster plates See illustrations A and B below Move the mower housing to the left until the right side hanger separates from the adjuster plate Then move the mower housing to the right until the left side hanger separates from the adj
31. ar Pinion Pin Drive Washer Thrust Washer Ring Snap Screw Hex 5 16 18x334 Bushing Washer 46 REPLACEMENT PARTS PEERLESS DIFFERENTIAL PART NO 774345 774344 774532A 774531A 778067 778068 786040 780096 780001 792018 792041 780077 792061 BRIGGS 8 STRATTON ENGINE MODEL 500 253707 0213 01 657 le 355 352 353 9354 Len SPECIAL TOOLS F 88516 47 SEARS RIDING MOWER BRIGGS amp STRATTON ENGINE MODEL 502 254152 MODEL 500 253707 0213 01 186 En q Assemblies include all parts shown in frames F 88516 48 BRIGGS STRATTON ENGINE MODEL 500 253707 0213 01 Assemblies include all parts shown in frames F 88516 49 SEARS RIDING MOWER MODEL 502 254152 NO NO DESCRIPTION NO NO DESCRIPTION BRIGGS amp STRATTON ENGINE MODEL 500 253707 0213 01 395705 Cylinder Assembly 42 33630 Retainer Exhaust 391086 Seal Oil Valve Rotocoil 2 5 212914 Head Cylinder 45 2611 83 Tappet Valve 7 271075 Gasket Cylinder Head 46 212897 Gear Cam 8 391406 Breather Assembly 52 270872 Gasket Carburetor 9 27803 Gasket Valve Cover Mounting 10 93394 Screw Sem 75 220865 Washer Spring Sealing 11 280100 Tube Breather 78 93805 Screw Sem 12 270808 Gasket Crankcase 94 1292681 Valve Assembly Cover 1 64 thick Carburetor Idle 270915 Gasket Crankcase 95 93499 Screw Throttle Valve Cover 005 thick
32. blade that is not sharp will cause the ends of the grass to become brown WARNING Before you remove the blade dis connact the wire to the spark plug The blade has sharp edges When you hold the blade use gloves or cloth material to protect your hands Remove the mower housing See the instructions on How To Remove The Mower Housing Use a piece of wood to keep the blade from rotating Remove the nut that holds the biade Check the blade according to the Blade Service instruc tions Replace a badly worn or damaged blade with a factory replacement blade PI PON e the grass and debris Mount the blade so that the hi lift edges are up as shown If the blade is upside down the blade will not cut correctly and can cause an accident 7 Fasten the blade with the original washers and nut Make sure the outside rim of the belleville washer is against the blade as shown 8 Tighten the nut that holds the blade to a torque of 30 foot pounds 41 5Nm WARNING Always keep the nut tight that holds the blade loose nut or blade can cause an accident F 88516 HOW TO REMOVE AND INSTALL THE BLADE Clean the top and bottom of the mower housing Remove ali Mandrel D 4607 1 D 4663 Belleville Du Washer O Washer Nut Blade ee Belleville Washer A RL un E Washer Nut MAINTENANCE EVERY 28 HOURS twice a year HOW TO SHARPEN THE BLADE WARNING Vibration c
33. d Battery Ammeter Limit Switch Fuse 15 AMP Tray Battery Limit Switch Part is not shown F 88516 STD522506 54148 24x3 90729 24273 54212 55792 91032 MFG NO 15x66 1x38 KEY REPLACEMENT PARTS PICTORIAL WIRING DIAGRAM NO DESCRIPTION 33 14 15 16 17 18 19 20 21 22 23 24 26 27 28 29 Ain niil Wiring Harness Switch ignition Key Only Light Switch Light Socket Light Bulb Solenoid Cap Washer Shakeproof Nut Hex Switch Seat Sensor Cap Switch Tie Wire Clamp Wire Cover Seat Switch Screw Owner s Manual STARTER MFG NO PART NO 250xb 21064 91275 90647 90155 90084 90565 19x40 91489 91031SE 91488 32618 21980 56062 STD610803 F 88516 26x159 REPLACEMENT PARTS BODY AND CHASSIS MODEL NO 502 254152 hi o y amp F 88516 MODEL NO 502 254152 KEY NO SO DD OT amp Wh DESCRIPTION Seat Seat Mount Washer Lockwasher Bolt Hex 5 16 20x5 Locknut 16 Spring Seat Screw Retainer Seat Spring Hanger Seat Spring Support Seat Bolt Hex 4 20x9s Locknut 5 16 18 Strut Index Bracket Bolt Shoulder Panel Control Screw Y Type AB x2 Cover Upper Console Screw Console Upper Screw Bushing Bearing Steering Post Console Screw Reflector Lens Bezel Screw Bulkhead Throttle Control Locknut 4 20 Bracket index Receiver Retainer Stud Panel Access Stud
34. e mower housing Connect the hangers into the hole of the adjuster plates that will level the mower housing Fasten the hangers to the adjuster plates with the hair pins Check the measurements at each side of the mower housing See the above instructions THE FRONT TO BACK ADJUSTMENT Use a ruler and measure the distance from the level surface to the bottom of the mower housing Measure the distances at the bot tom of the mower housing under the front X mark and the rear X mark The X marks are on the top of the mower housing as shown in the illustration The front measurement must be 4 lower than the rear measurement Adjust as follows 1 Loosen the jam nut from the suspension rod Turn the lock nut clockwise to raise the front of the mower housing Turn the locknut counterclockwise to lower the front of the mower housing Check the front and rear measurements for the correct adjustment Tighten the jam nut as shown F 88516 AND AL 22 EN Ma rk X Mark X Mark bs D 4605 2 Suspension Rod ront Suspension O Bracket Locknut Jam Nut Counterclockwise Adi i E A djusting Clevis cat REPAIR AND ADJUSTMENT HOW TO SERVICE THE FRICTION DRIVE How To Replace The Drive Disc NOTE Itis not necessary to disassemble the friction drive system to replace the drive disc Sr UE ibo en Engage the parking brake _ Move the shift lever
35. e om od dm mi lI m NH amp A 9 2 SEH d w Wow ow FI Ba k x 9 M om de hom dw mom m mw o x Af LE V OP AR NOW W o3 X o ow MUS t EO U o REOR BR 4 4 o9 Wow M ow amp 9 9 A cM ai Se E e AS For lgnition F 88516 m HOW TO PREPARE AND CHARGE THE BATTERY IMPORTANT Before you install the battery add the battery acid Electrolyte to the battery Battery acid will damage paint and parts WARNING Read the instructions included with the battery acid container Protect your hands and eyes from the battery acid Use clothing that will protect you If not installed on the battery remove the vent caps from the plastic bag Read the instructions included with the vent caps If medal tape covers the vents remove the metal tape from the vents Discard the metal tape Pour battery acid into each battery cell until the battery acid touches the bottom of the vent as shown Do not add the battery acid above the bottom of the vent If you add too much battery acid the excessive battery acid will flow from the battery when you charge the battery Wait 20 to 30 minutes before you put the vent caps on the battery The level of the battery acid can drop below the vent described in step 3 Add more battery acid until the correct battery acid level is reached Install the vent caps Wash the top of the battery with water to remove any battery acid Discard the battery acid container and any battery acid t
36. e tight yos can damage the valves 3 Turn the needle valve 1 1 2 turns counterclockwise Turn the idle valve 1 1 4 turns counterclockwise This first adjust ment will permit the engine to start and get warm so that a last adjustment can be done 4 Move the throttle contro to the FAST position Turn the needle valve clockwise until the engine starts missing lean mixture Then turn the needle valve counterclockwise past the smooth operating position rich mixture 5 Turn the needle valve to a position between rich and lean so that the engine can run smooth 3400 100 RPM 6 Adjust the RPM Move the throttle control to the SLOW position Turn the idle speed screw until a fast idle is obtained 1750 200 RPM Turn the idle valve clockwise lean and counterclockwise rich until the engine idles smoothly Then turn the idle speed screw so that the engine idles at 1750 200 RPM 7 Move the throttle control to the FAST position if the engine does not accelerate correctly adjust the carburetor to a rich mixture HOW TO ADJUST THE THROTTLE CONTROL Move the throttle control to the FAST position Loosen screw C that holds the throttle cable in position Pull the throttle cable up until the lever E touches link F as shown 4 Tighten screw C Move the throttle control to the STOP position wu Iv HOW TO REPLACE THE LIGHT BULB 1 Remove the two screws frorn the headlight assembly Remove the headlight assembl
37. eeds and one reverse to let you select the correct speed for your type of yard A drive chain connects the transmission to an automotive type differential l Tilt Seat The seat tilts forward for easy access to the battery and the engine Side Panels to the engine The side panels can be easily removed for access Mower Housing The fuli floating suspension and single blade give an even cut The lift lever has an eight position height adjustment ATTACHMENTS This unit can use attachments available at the nearest Sears Store This unit can pull attachments like a lawn sweeper a lawn aerator or a hopper spreader This unit can not use attachments that engage the ground like a plow a disk harrow or a cultivator MAINTENANCE AGREEMENT Sears Maintenance Agreement is available on this unit See the nearest Sears Store for information 4 rs TWO YEAR WARRANTY ON ELECTRIC START RIDING EQUIPMENT d 4 eS For two years from the date of purchase when this riding equipment is maintained lubricated and tuned up according to the operating V and maintenance instructions in the Owner s Manual Sears will repair free of charge any defect in material or workmanship in this X O electric start riding equipment x x A x This warranty excludes blade s blade adapter s spark plug s air cleaner and belt s which are expendable arid become worn during e WM normal use P This warranty does not cover X tire replaceme
38. engine is difficult to start and the performance is bad The engine does not run smooth at fast speed On slopes the engine stops The engine will not idle hot engine causes a reduction of power Excessive vibration The grass does not discharge correctly The height of cut is not level or the performance is bad The unit will not move when the clutch is engaged The unit moves slow or stops when the clutch is engaged F 88516 NN a SHOOTING CHAF IRocoil Start And Electric Models Cause Repair Turn the ignition key to the ON position Fill the fuel tank with clean gasoline Connect the wire to the spark plug Make sure the CHOKE is activated Move blade engagement control to the DISENGAGE position Push the pedal forward Move the shift lever to the NEUTRAL position 7 Remove and dry the spark plug Move the throttle to the OFF or SLOW pos tion Turn the ignition key several times o to the START position Install the spark plug 8 Replace tho fuse 1 Check the wiring harness for damage or loose connections Repair damaged wire 1 Connect and tighten the wire to the spark plug Clean the air filter Clean the air screen Drain the fuel tank Replace the fuel filter Fili with clean gasoline PON 1 Replace the spark plug Adjust the throttle control 1 Mow up and down slopes Never mow across a slope 1 Replace the spark plug 2 Clean the air filter 3
39. ever Make sure the mower housing is level See the instructions How To Level The Mower Housing in the maintenance section of this book Blade Engagement Control Pull Pin Suspension Bracket Pivot Rod and Bracket Mace N C HOW TO REPLACE TH 1 gt E MOWER DRIVE BELT Move the lift lever into the low cut position Slide the mower drive belt between the stack pulley and the belt guide Remove the mower drive belt from the stack pulley Pull the belt guide away from the idler pulley Remove the belt from the idler pulley While you push the belt guides away from the mandrel pulley remove the mower drive belt from the pulley Install the new mower drive belt IMPORTANT Replace the mower drive belt with a factory replacement belt Make sure the V side of the mower drive belt is against the mandrel pulley Also make sure the mower drive belt is not twisted Puli the belt guide away from the idler pulley Put the mower drive belt around the idler pulley Make sure the V side of the mower drive belt is against the pulley Also make sure the mower drive belt is not twisted Make sure the mower drive belt is inside all the belt guides WARNING H the mower drive belt is outside of a belt guide when the blade engagement control lever is in the DISENGAGE position the blade can continue to rotate and damage the mower drive belt Before you operate tho mower make sure the mower drive belt is
40. ge WARNING Before you leave the operator s position move the shift lever to the neutral N position Set the parking brake Move the blade engagement control to the DISENGAGE position Stop the engine and remove the ignition key HOW TO USE THE THROTTLE CONTROL Use the throttle control to increase or decrease the speed of the engine To start a cold engine move the lever to the left and into the START or CHOKE position For normal operations move the lever to the FAST position The engine governor is set at the factory for maximum performance Do not adjust the governor to increase the speed of the engine 11 OPERATION HOW TO USE THE SHIFT LEVER To change the forward speed or the direction of the unit follow the steps below 1 Fully apply the clutch brake pedal WARNING Before you move the shift lever ior out of NEUTRAL or REVERSE fully apply the clutch brake pedal 2 Move the shift lever to FIRST or to REVERSE 3 Slowly release the clutch brake pedal Do not ride with your foot on the clutch brake pedal 4 While the unit moves forward you can select any forward speed Just move the shift lever to the next faster or next slower speed You do not have to use the clutch brake pedal 5 The shift lever positions for operation of your unit are shown in the chart below 5 Move the throttle control to the SLOW position 6 To stop the engine turn the ignition key to the OFF position Remove the key
41. hat was not used as follows Fill the container half full with water Add baking soda and mix together using a piece of wood Add more baking soda until the solution does not foam Dis card the solution and wash the container with water Destroy the container WARNING When you charge the battery do not smoke Keep the battery away from any sparks The fumes from the battery acid can cause an explosion Use a 12 voltbattery charger to charge the battery Charge at a rate of 2 amperes for 3 to 4 hours After the battery is charged check the level of the battery acid If the level of the battery acid falis add water Do not add battery acid to a chargad battery or the result can be an explosion F 88516 DANGER Remove and discard the metal tape Vent Cap D 4552 1 CUT AWAY VIEW Correct Liquid Laval AUAAAAA AA MARA LAMA BATTERY ACID WILL CAUSE SEVERE BURNS Contains sulphuric acid Do not let the battery acid come in contact with the skin the eyes or the clothing To prevent accidents neutralize the battery acid that was not used To neutralize fill the container half full with water Add baking soda and mix using a piece of wood until the solution does not foam Discard the solution and wash the container with water Destroy the container ANTIDOTE External Wash the area with water then wash with a solution of water and sodium bicarbonate Internal Drink large amounts of water milk or
42. he foam filter from the cloth Completely dry the foam filter DARAN CAUTION Do not wash the filters in gasoline or other solvents that will burn 7 Evenly apply S A E 30W oil to the dry foam filter 8 To clean the paper filter lightly tap the paper filter against a hard flat surface 9 Ifthe paper filter is very dirty replace the filter or wash the paper filter in a detergent and warm water solution Use a detergent that has low suds or no suds 10 Wash the paper filter with water flowing from the inside out until the water is clear 11 Before you assemble let the paper filter completely dry in the air Do not put oil on the paper filter 12 Assemble the air filters 13 install the cover Fasten the cover with the cover screws HOW TO CHANGE THE OIL NOTE Drain the oil when the engine is warm Be careful do not get oil on the belts 1 Put the plastic drain tube into the oil drain valve Put the other end of the drain tube into a container as shown Turn the oil drain valve counterclockwise to open the valve Drain the oil completely from the engine Turn the oil drain valve clockwise to close the valve Remove the plastic drain tube 2 UseaSD SE or SF detergent grade oil Detergent oil helps to clean the engine Nothing must be added to the oil 3 Before you change the oil use the temperature chart below to select the viscosity grade of the oil to use Temperature range before the next oil ch
43. horized Service Center for a spark arrester for the muffler F 88516 Look for this symbol to point out important safety precautions It means Attention Your Safety Is Involved Become Alert y This product is made to give you many hours of performance and safe operation To keep the unit in good condition you must correctly service the unit For safety and performance follow the ASSEMBLY OPERATION and MAINTENANCE instructions If you can not correct a problem see the nearest Sears Service Center CUSTOMER RESPONSIBILITIES Follow all the assembly instructions Correctly adjust the unit Carefully read and follow the rules for safe operation Inspect the unit Complete all maintenance on the unit Know how to operate ali standard and accessory equipment on the unit Make sure that the operator can correctly operate the unit Operate the unit only with guards shields and other safety items in place and working correctly Service the unit only with authorized or approved replacement parts 2n RIDING LAWN MOWER Record in the space below the serial number and the date of purchase of this unit The model number and serial number are found under the seat on a plate attached to the seat support Serial Number Date of Purchase Keep these numbers for future reference REAR ENGINE RIDER FEATURES Craftsman Engine Air cooled and long life with solid state ignition Ail Gear Transmission Eight forward sp
44. hown below 1 Hex Bolt 6x90 1 Bolt 2 Hex Bolt 1 4 20 x 5 8 For Battery Cables STD522506 1 Hex Bolt 5 16 x 1 1 2 4 Hex Bolt 5 16 x 5 8 3 8 X 3 4 For Steering Wheel ST0523707 5 16 x 1 1 4 For Steering Post For Adapter STD523115 Far Seat STD523106 El 15x66 2 Screw 19x39 1 Lockwasher 1 Locknut 5 16 18 I D 3 8 For Steering Wheel STD551237 For Adapter STD541431 E 2 S S zoo x O4 que Qi amp o st 210 m wm nS S dt a Y e uU ey 12 co aoe Mr aeuo 5f Me 7 gt Pe Im 380 opo San 3 oN E 259 5 Y e LL E o Mo E a Y he amp W Sas AL tT GO Ac co t Ogre pom g a 0 7 8 P e o Li Er ea SES e WT E DU QUE dE ons wo C eu E M oL eo ua hs m er amp e EN SO BD 2730 gare ep bas B emm A unio PIT sech U e a a u a ww x A wow eee hae d aO wow WX X A 2 A a aT as a su A u at OM m CS He Rn OB BOE WC 6 5 5 xs LCR RER COR OOOO MOMIA NO O EE OI E AA E PA JE EJE JA JO TE JE JE JE JE JE ERE ETA MEM om im m d MON UOm 4 NUM UN E ON o OR UR BU NC EO eS A s ub fi pP uw w d d da A Alte E ETE TEE SAT TE TOA ML AAA oe OM od o m OUO Om OUT M OG OH OW o 59 6 X4 ul 7 ES E E JE RE AA TE EE TE EA E A AE OCIO AREA AAA AAA AS D eT Ww 4 4 4 4 4 8 NN RR X CE WO ROUX ow M RIA MO a dA lib wow cw Ce
45. inside all the belt guides Before you mow check the blade engagement control lever See the instructions on How To Adjust The Blade Engage ment Control Lever HOW TO REPLACE THE MOTION DRIVE BELT 1 2 3 4 10 Remove the mower housing See the instructions on How To Remove The Mower Housing Slide the motion drive belt off the idler puiley Remove the motion drive belt from the drive pulley At the stack pulley remove the motion drive belt from the upper pulley Remove the motion drive belt from the stack pulley as follows Pull the motion drive belt completely toward the rear Slide the motion drive belt between the stack pulley and the belt guide Install the new motion drive belt around the top pulley of the stack pulley IMPORTANT Replace the motion drive belt with a factory replacement belt Make sure the V side of the motion drive belt is against the stack pulley Put the motion drive belt around the drive pulley Put the motion drive belt around the idler pulley as shown Make sure the V side of the motion drive belt is against the idler pulley Also make sure the belt is not twisted install the mower housing See the instructions on How To Install The Mower Housing F 88516 Motion Drive Belt 0 4729 1 21 REPAIR AND ADJUSTMENT Doro seed gunt er pany ae LEID es HAH Li Lures Kor teme 33 AA E Met 7 BEREITEN TI ee SD 7 T See teh nt og TET RETE RS AA
46. ion Make sure the blade engagement controi is in the DIS ENGAGE position Move the throttle control to the CHOKE position Turn the ignition key to the START position Release the key when the engine starts NOTE If the engine does not start after four or five tries move the throttle control to the FAST position Again try to start the engine If the engine will not Start see the TROUBLE SHOOTING CHART Slowly move the throttle control to the SLOW position Let a cold engine run for several minutes Begin work when the engine is warm To start a hot engine move the throttle control to a position between FAST and SLOW te 2 x E Amt mt mmm A rs 8 er ariete e anre eremo mme mie en e AA AM B et a ent LAB A FACTIS mie Asie Fed Br b Vere eSATA A e MEL A MANCHA MU Se Nana ta Vo TE SENER ETA A TTN iS DESPIDOS REI EN OSA IIIS A9 UNI TIT IE RYDE P S TER S A aos eee t er rm EAN D rem hl en regnen mn m den ak ca miis aln lia VS Kc SR ik au ncm o dn P ala AE ATA URNA HIA Fr AE OPERATION HOW TO OPERATE WITH THE MOWER HOUSING WARNING The deflector is a safety device Do not ramove the deflector The deflector forces the discharged material toward the ground Always keep the deflector in the down position if the deflector is damaged replace it with a factory replacement part 1 Start the engine 2 Move the lift lever to a height of cut position In high or thick grass c
47. isengage all attachment clutches and shift into neutral before attempting to start the engine Disengage power attachment s when transporting or not in use Do not stop or start suddenly when going uphill or downhill Mow up and down the face of steep slopes never across the face See the Guide in the back this book to check for safe operation Reduce speed and exercise extreme caution on slopes and in sharp turns to prevent tipping or loss of control Be especially cautious when changing directions on slopes Stay alert for holes rocks roots in the terrain and other hidden hazards Keep away from drop offs Use care when pulling loads or using heavy equipment a Use only approved drawbar hitch points b Limit loads to those you can safely control c Do not turn sharply Use care when backing d Usecounterweight s or wheel weights when suggested in the instruction book Watch out for traffic when crossing or near roadways When using any attachments never direct discharge of material toward bystanders or allow anyone near the unit while in operation Disengage power to attachment s and stop the engine before leaving the operator s position To reduce fire hazards keep the engine free of grass leaves or excessive grease 17 18 19 20 21 22 23 24 25 26 27 28 29 The vehicle and attachments must be stopped and inspected for damage after striking a foreign object All
48. ive Chain Axle Bracket ue m o cu ant V D 4601 2 EEE EINEN WO A A AIME 27 F 88516 REPAIR AND ADJUSTMENT How To Replace The Bearings In The Carriage Arms NOTE Tho Bearings are pressed into the carriage arms 1 Remove the carriage arms gt Put the carriage arm on a vise or between two blocks of wood Allow enough clearance around the surface of the bearing so that the bearing can be removed WARNING For your protection use safety aye glasses 3 Puta punch against the top side of the bearing Use a hammer and hit the punch until the bearing releases from the carriage arm CAUTION Do not use a hammer to put the new bearing into place You will damage the bearing 4 Set the new bearing in the carriage arm Put the carriage arm and bearing with a piece of wood against the bearing into a vise Tighten the vise to press the bearing into the carriage arm J A Kr gt D xd E ar ta rd d B ea ring ridi Es E Piste 4 Carriage Arm 28 F 88516 REPAIRS AND AD HOW TO ADJUST THE CARBURETOR The carb retor was adjusted at the factory for most conditions Differences in fuel temperature and work load will require a adjust ment follows 1 Remove the side panel See the instructions on How To Remove AThe Side Panel 2 Turn the needle valve clockwise until it just closes Turn the idle valve until t just closes CAUTION If you turn the valves until they ar
49. late Adjuster Plate Mounting Rod Assembly Suspension Bolt Carriage Rod Lifter Washer Strut Frame Bolt Hex 5 16 18x5 Locknut Hex 4 20 41 IMOWER HOUSING SUSPENSION PART MFG NO NO 55449 559287 STD541425 15x89 STD522510 1x76 55440 STD551050 17x67Z 55853 55439 56031 3x149 STD541431 15x84 55365 26x49 9x9Z 21920 STD551037 17x53Z STD560907 30x20 STD541431 15x88 17x48 55656 55930D 165x67 55179D 55139 55298 9x17 STD541237 15x73 55957 55271Z 9x4Z 244712 STD541031 15x2 STD624005 31x4 55344 55270 55346 STD533107 2x64 24839D 17x122Z 55326 STD523106 1x45 STD541425 15x66 D 4745 MOVER HOUSING BOTTOM HALF 42 MODEL NO 502 254152 F 88516 MODEL NO 502 LA ARE ES taaak AAA 2 Ax mr Ee 5 4 5 P NO DESCRIPTION Belt Mower Drive Pulley Splined Lockwasher Locknut 9 16x18 Nut Hex Pulley Idler Bracket Upper Idler Spacer Assembly Blade Idler Locknut Flange Pin Clevis Clevis Bolt Hex Pin Hair Guide Belt Bracket Lower idler Bolt Carriage Nut Flange Guide Belt Spacer Bolt Hex Housing Mandrel Guide Belt Bracket Hanger Spring Compression Nut Hex Spring Torsional Push On Cap Rod Bracket Chute Deflector Spring Extension Housing Blade Bracket Front Screw Bolt Hex 5 16 18x Deflector Chute Mandrel Blade Washer Belleville Washer Hardened Nut Hex 9 16
50. lowest speed position Tighten the two nuts on the index bracket Move the shift lever to the NEUTRAL position Make sure the neutral arm sets in the notch of the neutral bracket Move the shift lever to the slowest speed position Check the distance between the neutral arm and the bracket The dis tance must be approximately 1 16 to 1 8 inch F 88516 8 7654321 N Neutral Arm Ut RE AM UNE ONE PT ETG TE D 4626 1 meti i gt ag ssl COE Friction Disc Neutral Arm 1 16 to 1 8 Neutral Bracket Ms t ATI RO PERCENT NECEM Bini edt up Dee IY O LI A NAE MU e A NN PP A A T te e TIRO NS 24 A fae gsi op cae me REPAIR AND ADJUSTMENT How To Adjust The Brake 1 Move the shift lever to any speed setting 2 Release the parking brake 3 Check the distance between the brake pad and the brake drum The distance must be approximately 3 16 to 1 4 inch If the distance is not correct adjust as follows 4 Move the mower housing to the lowest height of cut for more work clearance Disconnect the adjustable nut from the brake rod To reduce the distance between the brake pad and the brake drum turn the adjustable nut clockwise To increase the dis tance turn the adjustable nut counterclockwise 9m Clockwise Brake Rod 3 16 to 1 4 Washer Adjustable Nut Hair Pin D 4510 Pedal Parking Brake Brake Arm D 4609 2 c 7 NINE
51. milk of magnesia Drink water mixed with the whites of eggs Call a Doctor immediately i Eyes Flush with water for 15 minutes and then get immediate medical help POISION KEEP AWAY FROM CHILDREN D 5213 ASSEMBLY HOW TO INSTALL THE STEERING WHEEL Attach the steering wheel with the fasteners shown full size Attach y dn lc A Bearing u Steering Post Control Panel Upper Steering Shaft D 4679 1 1 Look at the hole in the upper steering shaft Turn the front tires to the leftuntil the hole in the upper steering shaft points toward the front 2 Slide the steering post through the control panel and on the upper steer ng shaft as shown Fasten with the fasteners as shown in the illustration 3 Turn the front wheels until a 1 2 wrench will fit on the lock nut Make sure the head of the bolt fits around the steering post Tighten the locknut to a torque of 18 foot pounds 4 Slide the bearing on the steering post Align the holes in the Control Panel bearing with the holes in the top of the control panel Fasten the bearing with the screws as shown D 4584 1 l WARNING For safe operation make sure the err triana becomes loose or is damaged replace immediately 5 Attach the steering panel to the control panel as follows Attach the front tab into the control panel Move the steering panel back Put the two tabs of the steering panel in the control panel as shown 6
52. ne block l 5 Start the engine that has the weak battery last Allow the engine to run 6 To disconnect the Jumper Cables reverse the above steps STORAGE Over 30 Days if the unit is not used for over 30 days prepare the unit for storage as follows THE ENGINE 1 Runthe engine until the engine is warm 2 Stop the engine 3 Change the oil 4 Clean the air fliter THE FUEL SYSTEM WARNING Always use a safety gasoline container Do not smoke when adding gasoline to the engine When inside an enclosure do not fill with gasoline Before you add gasoline stop the engine Let the engine cool for several minutes gasoline stabilizer Sta Bil must be added to the gasoline when the unit is put in storage A gasoline stabilizer will prevent deposits from stopping up the carburetor F 88516 30 THE BATTERY 1 Completely charge the battery See the instructions on How To Prepare nd Charge The Battery 2 Clean the battery terminals and the top of the battery of any deposits 3j Do not remove the battery from the unit NOTE After a long period of time in storage the battery must be charged CLEAN THE UNIT 1 Clean the dirt and grass from the engine 2 Clean the mower housing 3 Use wax to protect the paint LUBRICATE THE UNIT See the Lubrication instructions in this book Problem The engine will not start The engine stops when the blades are engaged The
53. not add battery acid to a charged battery or the resuit can be an explosion a ES e TI Tr a ror a wo He us rr m I On t HL Euge Se edd sb TITRE ada DT PST D 4729 1 M IMPORTANT The battery will be damaged if the battery acid is not Kopt ette onec level en icy G au ge BE gt b 030 MA ONLA Front Drive Chain UL ED arts j F ngar Drive Chain HOW TO CHECK THE SPARK PLUG 1 Check the gap of the spark plug with a feeler gauge The correct gap is 0 030 AS 2 For easy starting and good performance replace the spark N Check and Set Spark Plug Gap plug every two years D 42896 F 88516 18 MAINTENANCE EVERY 30 HOURS once a year HOW TO CLEAN THE AIR FILTERS The engine has two filters an outer foam filter around an inner paper filter Clean the air filters every 50 hours If you operate in dirty conditions service more often NOTE Never run the engine with the air filters removed The air filters will help protect the engine against wear For the correct replacement filter see the parts list for the engine Remove the cover screws from the cover Remove the cover from the air cleaner Remove the filters Clean the inside of the base and the cover with a cloth Remove the foam filter from the paper filter Wash the foam filter in a detergent and water solution To remove the water solution tightly roll the foam filter in a dry cloth Remove t
54. nt or repair caused by punctures from outside objects such as nails thorns stumps or glass and d A repairs necessary because of operator abuse or negligence including the failure to maintain the equipment according to 2 6 instructions contained in the Owner s Manual and X riding equipment used for commercial or rental purposes d h e gt X x FULL 90 DAY WARRANTY ON BATTERY b X For 90 days from the date of purchase if any battery included with this riding equipment proves defective in material or workmanship X and our testing determines the battery will not hold a charge Sears will replace the battery at no charge x 4 X WARRANTY SERVICE IS AVAILABLE BY CONTACTING THE NEAREST SEARS SERVICE CENTER DEPARTMENT IN THE UNITED STATES This warranty appl es only while this product is in use in the United States X 4 This warranty gives you specific legal rights and you may also have other rights which vary from state to state x m Sears Roebuck and Co D 698 731A Sears Tower Chicago IL 60684 x amp F 88516 6 A Adjustments Blade Engagement Control 15 Brake Drive isi PE D Carburetor ss 29 Chain Front Drive eese 26 Chain Rear Drive een ZT Mower Housing Level 22 Throttle Control Cable TE TONES A D TO Attachments tm TP M es B Battery Charge PT ee i7 Cle
55. position all movement will stop within five seconds if the adjustment is correct If all movement does not stop again adjust the blade engagement control begin ning with the first step If you need assistance take the unit to an authorized service center If you replace the mower drive belt adjust the blade engage ment control lever F 88516 MAINTENANCE CN RT Engaged EN Position E x y AL Lever N A Control Lever Position Where Ai Blade ee To 7 Disengaged f Position Pad Against Pulley With Blade Control in DISENGAGE position Brake Pad Away From Pulley With Blade Control in ENGAGE position DS ER MAINTENANCE EVERY 25 HOURS twice a year BLADE SERVICE WARNING Before you inspect the blade dis connect the wire to the spark plug If the blade hits an object stop the engine Disconnect the wire to the spark plug Check the unit for damage Frequently check the blade for excessive wear cracks or other damage Frequently check the nut that holds the blade Keep the nut tight If the blade hits an object stop the engine Disconnect the wire to the spark plug See if the blade is bent or damaged Before you operate the unit replace damaged parts with factory replace ment parts Every three years have an authorized service person inspect the blade or replace the old blade with a factory replace ment biade Keep a sharp edge on the blade A
56. r speed Move the throttle control to the FAST position Clean the mower housing Adjust the level of the mower housing Adjust the blade engagement control Replace the blade idier spring EL MY re Tr S A mm sit innennenc HHH ht E ERR A AAA A MM A rer SS RA tt 1 Replace the motion drive belt 31 Replace the motion drive belt MODEL NO 502 254152 ELECTRICAL SCHEMATIC Battery Red Dlack amp u Rad 2V 2 Turns Clockwise Solenoid Starter From The Solenoid p 4 Ammeter pt 9 A Fuse e 3 ro 1 SO Amp Taro Seat j Black Switch seat unoccupied Red Are Ignition Me en h Su Li ch a A at Black Black o ojB asko Yellow Yellow Yellow EA NC ciar T m espe f Talon Gold State un Ignition BASEL Light Headlight 2 2 Amp Switch O Red O b _Red DO e Rectifier Charging Bed Diode Co i o Kt YYYYYY o Inductive type wire coiled as seen from back of control panel Lights will nof register 3 Amps 20 Vac Min on ameter at Max RPM Ignition Switch Chassis round F 88516 32 MODEL NO 502 254152 D 4637 5 KEY NO DESCRIPTION 10 11 12 13 Cable Battery Solenoid Screw Nut Locknut Y4 20 Battery Type U1 7R PART NO 24x24 24285 26x233 STD541425 56033 Electrolyte Battery Acid 90665 Bolt Hex 20x Cover Battery Terminal Cable Groun
57. rosion apply grease to the battery terminals F 88516 Gas Fill dis ee WARNING To prevent sparks fasten the red ASSEMBLY gt gt Battery Battery Tray Clutch Brake Pedal TN OU OO NN TN TU OTTO KNOW THE PRODUCT MERKEN DEUX DORA MRNA D 4757 LR MEN Before you operate the unit read this instruction book If you understand the unit and how the unit operates you will get the best performance When you read this instruction book compare the illustrations to the unit Learn the location of the controls To help prevent an accident follow the operating instructions and the safety rules Keep this instruction book for future reference THE BLADE ENGAGEMENT CONTROL See the location of the blade engagement control in the illustra tion Use the blade engagement control to start and stop the rotary blade 1 Before you start the engine make sure the control lever is in the DISENGAGE position 2 Move the control lever to the ENGAGE position to rotate the blade 3 Move the control lever to the DISENGAGE position to stop the rotary blade Before you leave the operator s position make sure the blade has stopped rotating 4 Before you ride the unit on a sidewalk or a road move the control lever to the DISENGAGE position WARNING Always keep your hands and feet away from the blade deflector opening and the mower housing when the engine runs F 88516
58. sher Shakeproof Washer Adapter Steering Wheel Locknut 5 16 18 Bolt Contour 5 16 18x114 Bellows Steering Post Washer Formed The part is also included with Key No 31 F 88516 39 REPLACEMENT PARTS STEERING SYSTEM PART MFG NO NO 55919 55909 STD523115 1x102 STD541431 15x88 91444C 17x132 STD533107 2x64 26x49 55384 STD541031 15x79 56023 STD541537 15x87 55937 STD561 220 30x49 55003 55655 55024 56057 55746 55046D 15x61 21031 STD551037 17x53Z STD560907 30x20 STD623725 1x69 55381 b5026D 55380 55598 91527 55386 24373 24583 24682 55168 17x100 55547 STD523707 1x85 19x39 200947 55911 STD541431 15x76 6x90 55410 17x161 MODEL NO 502 254152 MOWER HOUSING SUSPENSION D 4529 5 40 F 88516 MODEL NO 502 254152 KEY DESCRIPTION CHOIAMEYWNAF F 88516 Grip Blade Control Lever Lever Blade Control Locknut Flange Y 20 Bolt Hex 14 20 Cap Lifter Lever Knob Washer Cam PTO Grip Knob Lever Assembly Lifter Screw 5 16 18x1 Locknut Flange Y 16 Plate Index Screw Bolt Shoulder 34 16 Nut Adjuster Washer Pin Cotter Nut Hex Flange 5 16 18 Washer Lever Assembly Rod amp Arm Assembly Spring Extension Link Front Deck Bracket Front Suspension Clevis Bolt Shoulder 16 Nut Hex Jam 3 16 Rod Assembly Link Bolt Shoulder Clevis Adjuster Nut Hex 5 16 18 Hairpin P
59. take Valve Standard Seat Exhaust Valve Standard Guide Exhaust Valve 231218 Guide Exhaust Valve brass See Repair Manual Diode and Connector Assy D C Stator Assembiy Alternator D C Trigger Coil tincluded in Carburetor Overhaul Kit Part No 394698 tincluded in Carburetor Overhaul Kit Part No 394698 A includes Brush Set Inchides 391135 Clutch Assembly Ref No 513 280104 Gear Ref No 783 391462 Retainer and Pin Ref No 773 93754 Rool Pin Ref No 896 EET mq atm nena ce ri TT by re er NOTES F 88516 ES NOTES F 88516 m NOTES F 88516 54 A ie le aa N oae NS xd E gt Te y n 2 n ANNEE Arar qun BF ELM X us DEAE ER MEE yum hs E 122 ity E dz rat 2 wur a ee ge ates UT n Tues C Ad CAT TARA AMA A A A NA E SIGHT AND HOLD THIS GUIDE LEVEL WITH A VERTICAL TREE A CORNER OF A STRUCTURE A POWER LIME POLE 2 ORA FENCE POST i Lo 5 5433 f r 2 T R u x P us ru La f a 7 2 fe j esf A doc ES RATS M A A OY m dS Dn id 7 Wa P d A Sida DN ty a et aetu dia Vue x A LEE ER n 4 QUEE VM Ee ros TEMA Con A 4 ee Yan MEL AI E ad In WO A ICY RE UA gat A ES LAN ar ae ans dolls ub jJ 1 H T e 1 A M T GEJA ATAT ARE ST Cie Rite btn Ok EN FL d A NE AU LC LEP ES Sv IS ONE TO oa STC check a slope and determine ifit is safe to mow is to 1 disengage the bla le s 2 putth back straight up the slope If
60. the shift lever to the slowest speed 2 Do not stop or change speed settings on a hill If you must stop quickly push the clutch brake pedal forward and set the parking brake 3 Tostart again make sure the shift lever is the slowest speed Move the throttle control to the SLOW position Slowly release the pedal 4 If you must stop or start on a hill always have enough space for the unit to roll when you release the brake and engage the clutch 5 Bevery careful when you change directions on a hill To help prevent an accident move the throttle control to the slow position on a slope and in a turn Remove Screws MAINTENANCE FIRST HOURS after 2 mowings HOW TO CHANGE THE OIL NOTE Drain the oil when the engine is warm Be careful do not get oil on the belts m 1 Put the plastic drain tube into the oii drain valve Put the other end of the drain tube into a container as shown Turn the oil drain valve counterclockwise to open the valve Drain the oil completely from the engine Turn the oil drain valve clockwise to close the valve Remove the plastic drain tube 2 UseaSD SE orSF detergent grade oil Detergent oil helps to clean the engine Nothing must be added to the oil 3 Before you change the oil use the temperature chart below to select the viscosity grade of the oil to use Temperature range before the next oil change All oils must be A P l service grade SD SE or SF Recommended SAE
61. uretor 391782 Ring Set Piston 020 O S 147 1231323 Screw Nozzle 391783 Ring Set Piston 030 O S 27 260924 Lock Piston Pin 28 299691 Pin Assembly Piston Standard 391286 Pin Assembly Piston 005 0 5 29 391775 Rod Assembly Connecting Note For Connecting Rod with 020 undersize Crankpin Bore Order No 393712 31 222299 Lock Conn Rod Screw 186 167218 Connector Fuel Pipe 32 192909 Screw Conn Rod 187 299146 Line Fuel 28 long 33 261185 Valve Exhaust Cut to Suit 34 261462 Valve Intake 35 65906 Spring Intake Valve 201 261609 Link Governor 36 26828 Spring Exhaust Valve 209 261306 Spring Gov 40 221596 Retainer Intake Valve 216 261610 Link Choke 41 292260 Rotocoil Exhaust Valve 50 310 311 319 332 333 334 337 351 352 353 354 355 356 358 363 383 422 423 455 468 482 520 523 524 525 534 534A 535 536 537 544 552 562 1391764 396199 231058 391733 222450 260584 221535 93804 91308 391556 93158 222744 93163 222725 394805 94003 395538 395326 92264 395492 93381 298809 91920 66068 92791 90576 66554 299500 393411 19203 89838 222502 93964 222561 222562 93621 93722 391841 68838 280134 93323 93622 270843 391786 270853 392747 231055 92613 l Oil Slinger Gov Gear DESCRIPTION and Bracket Assembly Plate Gov Control _ 5i Crank Governor
62. uster plate Remove the long pin from the front suspension bracket See illustration D below Remove the mower drive belt from the stack pulley Slide the mower drive belt between the stack pulley and the belt guide Completely turn the steering wheel to the right Pull the mower housing away from the left side of the unit Stack Pulley gt UCC US n ad Belt Guide ge SAK gt NEA gt Adjuster Plate D 4746 1 F 88516 20 Completely turn the steering wheel to the right Push the mower housing under the left side of the unit Slide the mower drive belt between the stack pulley and the beit guide Put the mower drive belt around the stack pulley Make sure the V side of the mower drive belt is against the stack pulley Make sure the drive belt is not twisted Attach the mower housing to the front suspension bracket with the long pin Fasten with the washer and hair pin See illustration D below Attach the rear hangers to the adjuster plates Fasten with the hair pins See illustrations A and B below Connect the blade drive link to the pivot rod and bracket assembly Fasten with a clevis pin and a hair pin See illustra tion C below Move the blade engagement control lever to the ENGAGE position Make sure the mower drive belt is inside all the belt guides Check the operation of the blade engagement control lever See the instructions on How To Adjust The Blade Engage ment Control L
63. ut the grass in the high position first and then lower the lift lever to a lower position 3 Move the throttle control to the SLOW position 4 Move the blade engagement control to the ENGAGE position 5 Push the clutch brake pedal completely forward 6 Move the shift lever to the first speed setting IMPORTANT When you mow in heavy grass or mow with a bagger put the shift lever in the slowest speed 7 Slowly release the clutch brake pedal 8 Move the throttle control to the FAST position If you need to go faster or slower move the shift levar to another speed setting WARNING For better control of the unit always select a safe speed Use the following maintenance section to keep your unit in good operating condition WARNING Before you make an inspection adjustment except carburetor or repair dis connect the wire from the spark plug HOW TO REMOVE THE SIDE PANEL To help service and clean the engine or the transmission the rear side panels can be easily removed 1 Remove the large screws that hold the front of the side panel 2 Slide the side panel back app ximately one inch Remove the side panel F 88516 HOW TO OPERATE THE UNIT ON HILLS WARNING Do not ride up or down siopes that are too steep to back straight up Never ride the unit across a slope See the Slope Guide in the back of this book for information on how to check slopes 1 Before you ride up or down a hill move
64. y Press in the sides of the light socket Remove the light socket from the bezel Turn the light bulb counterclockwise and remove the bulb 3 Install a new light bulb 4 Fasten the headlight assembly with the two screws as shown F 88516 D 5241 JUSTMENTS idie Valve Located under the air filter Screw Needle Valve Throttle Contrrol Cable FAST POSITION Light Bulb Screws Headlight Assembly Console Light Socket REPAIRS AND HOW TO START WITH A WEAK BATTERY If the battery is too weak to start the engine the battery needs to be charged If Jumper Cables are used to start the engine in an emergency follow the procedure below NOTE The unit is equipped with a 12 volt negative to ground system Also the other vehicle must have a 12 volt negative to ground system WARNING Do not smoke The fumes from the battery acid can cause an explosion Keep the battery away from any flames or sparks To pre vent sparks fasten the red jumper cable to the positive terminal before connecting the black jumper cable 1 Puta wet cloth over the vent caps of each battery 2 Connect each end of the RED Jumper Cable to the positive terminals of each battery Make sure you do not touch the chassis with the cables 3 Connect one end of the BLACK Jumper Cable to the negative terminal of the charged battery 4 Connect the other end of the BLACK Jumper Cable to the engi
65. you can back up the slope it is generally safe you are not completely sure use this guide and do not mow a slope tha A 15 degree slope is a hill that increases in height at approxomately 2 5 feet in 10 feet Use extreme ca re atali times and avoid sudden turns or maneuvers Follow other instructions in this manual for safety in mowing on slopes Operate a riding mower up and down slopes never across the face of slopes Operate a walking mower across the face of siopes never up or down slopes F 88516 The Model Number is found under the seat on a plate attached to the seat sup port Always give the Model Number when you call for service or order repair parts for your unit Repair parts can be ordered from any Sears Service Center Departments and most Sears Stores WHEN ORDERING REPAIR PARTS ALWAYS HAVE THE FOLLOWING INFORMATION AS SHOWN IN THIS LIST PART NUMBER PART DESCRIPTION MODEL NUMBER NAME OF ITEM ENGINE MODEL NUMBER A A GN Your Sears merchandise has added value when you consider Sears has service units nationwide staffed with Sears trained technicians Sears technicians have the necessary parts tools and equipment to meet the Sears pledge We Service What We Sell ERREUR Ake CN ae am hazet HL EC ETT uma win F 38516 Sears Roebuck and Co Chicago IL 60684 U S A LURO tp see sitet va met NOM MR CAE ve Fm Pre

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