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Cub Cadet 898C Lawn Mower User Manual

1. Board Also depending on when your engine was produced it may have an assigned emissions durability period See below for the engine emissions durability period that may apply to your engine Exhaust Emission Control System The exhaust emission control system applied to this engine consists of a fuel system and an ignition system having optimum ignition timing characteristics The fuel system has been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system A sealed type crankcase emission control system is also used to eliminate blow by gasses The blow by gasses are led to a breather chamber through the crankcase and from there to the air cleaner Engine Emissions Compliance Period California Model Year 2006 and later Vertical Crankshaft Durability Period 500 hours All Other States Model Year 2003 and later new 2007 and later carry over Durability Period 500 hours Category A If your engine has an assigned emissions durability period it will be located on the certification label attached to the engine IMPORTANT ENGINE INFORMATION High Altitude Performance Adjustment Information To improve the EMISSIONS CONTROL PERFORMANCE of engines operated above 1 000 meters 3 300 feet Kawasaki recommends the following Environmental Protection Agency EPA and the California Air Resources Board CARB approved modifications NOTE Wh
2. 4 Clean combustion chamber Check and adjust valve clearance e Clean and lap valve seating surface Periodic Maintenance Chart NOTE The service intervals indicated are to be used as a guide Service should be performed more frequently as necessary by operating condition Service more frequently under dusty conditions Have an authorized Kawasaki dealer perform these services Oil Level Check Check oil level daily and before each time of operation WARNING Hot engine oil can cause severe Be sure oil level is maintained See PREPARATION burns Allow engine temperature to drop from hot to warm before draining and handling oil Oil Change I e Run the engine to warm oil Change oil after first 8 hours of operation Thereafter Be sure the engine equipment is level change oil every 50 hours x Stop the engine 29 e Remove the oil drain plug A on side of the engine or on bottom of the engine to drain oil into suitable container B while the engine is warm EJ04B000 P Figure 11 A Oil Drain Plug On side of engine B Container EJ048001 P Figure 12 A Oil Drain Plug On bottom of engine e Reinstall the oil drain plug e Remove oil gauge and refill with new oil See FUEL AND OIL RECOMMENDATIONS chapter e Check the oil level See PREPARATION chapter WARNING Engine oil is toxic substance A Dispose of used oil properly Contact your local auth
3. e Remove the battery pack from the handle panel for replacement only Do not separate the batteries for any reason Dispose of batteries properly e When replacing battery pack in handle panel battery pack must be positioned with the positive terminal to the right side and the negative terminal to the left side of the panel Replacing the battery pack incorrectly will cause serious damage The positive lead on the wire harness has the smaller connector Connect the positive lead to the positive side of the battery pack then connect the negative side WARNING Batteries contain sulfuric acid A which may cause burns Do not short circuit or mutilate batteries in any way Do not put batteries in fire as these may burst or release toxic materials In line Fuse Model E977 only The unit is equipped with an in line fuse If the unit fails to start check the fuse inside the battery cover by turning the end of the fuse holder and removing from the battery cover Replace with standard automotive 7 1 2 amp fuse e Coat mower s cutting blade with chassis grease to prevent rusting e Store mower in a dry clean area Do not store next to corrosive materials such as fertilizer NOTE When storing any type of power equipment in a poorly ventilated or metal storage shed care should be taken to rust proof the equipment Using a light oil or silicone coat the equipment especially cables and all moving parts SECTION 10 TROUBLESHOO
4. 747 0939 Pivot Rod 30 1736 0425 Bell Washer 325 ID x 930 OD 62 747 0937 Grassbag Frame 31 756 0656 Pulley 63 631 0071 Grassbag Cover 32 736 3084 Flat Washer 510 ID x 1 120 OD 21 Model E977 777830118 KEEP HANDS and FEET AWAY 777830145 TO REDUCE THE RISK OF INJURY DO NOT OPERATE UNLESS DISCHARGE COVER OR GRASS CATCHER IS IN ITS PROPER PLACE IF DAMAGED REPLACE IMMEDIATELY DANGER KEEP HANDS and FEET AWAY Safety amp Decorative Labels Some of the labels found on your mower are represented here with the corresponding part numbers Please use part numbers when ordering replacement labels 777120291 Ref No Part No Description 1 725 0201 Ignition Key 2 725 0873 Key Switch 3 731 0891A Battery Tray 4 725 0727 Battery Charger 5 725 0298 Fuse 7 5 Amp 6 725 1428 Fuse Holder 7 725 1276 Battery 12V 8 710 0501 Hex Screw 1 4 20 2 0 9 736 0270 Bell Washer 10 712 0329 Special Hex Nut 5 16 18 11 725 1206 Plug 12 712 0267 Nut 5 16 18 13 736 0242 Bell Washer 14 712 0287 Hex Nut 1 4 20 15 710 1250 Carriage Bolt 16 710 0111 Carriage Screw 17 782 9012 Lower Battery Tray 18 710 0969 Tapp Screw 19 725 1538 Harness Extension 20 625 0022 Harness N OD THE RISK NTIRE gle CHU SSCA IF Li Die MACED REPLACE IMMED 777830128 OF INJURY NEVER OPER TE DEFLECTOR wu PR CHER IS IN IT S TAMEL 777D06697 22 ave W wet 7778301
5. 8684
6. can cause you to slip or trip Tall grass can hide obstacles 3 Always be sure of your footing A slip and fall can cause serious personal injury If you feel you are losing your balance release the blade control handle immediately and the blade will stop rotating within 3 seconds Do Not 1 Do not mow near drop offs ditches or embankments you could lose your footing or balance 2 Donot mow slopes greater than 15 degrees as shown on the slope gauge 3 Do not mow on wet grass Unstable footing could cause slipping Children Tragic accidents can occur if the operator is not alert to the presence of children Children are often attracted to the mower and the mowing activity They do not understand the dangers Never assume that children will remain where you last saw them 1 Keep children out of the mowing area and under the watchful care of a responsible adult other than the operator 2 Be alert and turn mower off if a child enters the area 3 Before and while moving backwards look behind and down for small children 4 Use extreme care when approaching blind corners doorways shrubs trees or other objects that may obscure your vision of a child who may run into the mower 5 Keep children away from hot or running engines They can suffer burns from a hot muffler 6 Never allow children under 14 years old to operate a power mower Children 14 years old and over should read and understand the operation instr
7. consumption Check oil level more frequently when using them EL Figure 6 Preparation Fuel e Level the engine equipment before fueling e Remove the fuel tank cap e Slowly pour fuel into the fuel tank to bottom B of the filler A Do not over fill the fuel tank fill only to bottom B of the filler A to prevent spill out of the fuel from the tank cap Fuel Tank Capacity 2 0 L 0 528 us gal e Close the tank cap securely by turning it clockwise as far as it will go Engine Oil Check the engine oil level daily before starting the engine otherwise shortage of the engine oil may cause serious damage to the engine such as seizure e Place the engine equipment on level surface Clean area around the oil gauge before removing it e Remove the oil gauge A and wipe it with clean cloth e Pour the oil slowly to FULL mark on the oil gauge e Insert the oil gauge into the oil filler B WITHOUT SCREWING IT IN e Remove the oil gauge to check the oil level Level should be between ADD and FULL marks Do not overfill e Install and tighten the oil gauge Engine Oil Capacity 0 65 L 0 69 us qt CAUTION The engine is shipped without engine oil ADD oG FULL FoR map ED038000 P Figure 7 Starting Band Pad System Upon releasing the brake control lever on the equipment the cutting blade and the engine will stop automatically Therefore the brake control lever must be held
8. mower back toward you while you are walking If you must back the mower away from a wall or obstruction first look down and behind to avoid tripping and then follow these steps a Step back from the mower to fully extend your arms b Be sure you are well balanced with sure footing c Pull the mower back slowly no more than half way toward you d Repeat these steps as needed Do not operate the mower while under the influence of alcohol or drugs Do not engage the self propelled mechanism on units so equipped while starting engine The blade control handle is a safety device Never attempt to bypass its operation Doing so makes the safety device inoperative and may result in personal injury through contact with the rotating blade The blade control handle must operate easily in both directions and automatically return to the disengaged position when released Never operate the mower in wet grass Always be sure of your footing A slip and fall can cause serious personal injury If you feel you are losing your footing release the blade control handle immediately and the blade will stop rotating within three seconds 9 Mow in daylight or good artificial light walk not run 10 Stop the blade when crossing gravel drives walkways or roads 11 If the equipment should start to vibrate abnormally stop the engine and check immediately for the cause Vibration is generally a warning of trouble 12 Shut the engine off and wait unt
9. off any spilled gasoline immediately To prevent fire hazard Keep the engine at least 1 m 3 3 ft away from buildings obstructions and other burnable objects Do not place flammable objects close to the engine Do not expose combustible materials to the engine exhaust Do not use the engine on any forest covered bush covered or grass covered unimproved land unless spark arrester is installed on the muffler To avoid getting an electric shock do not touch spark plug plug cap or spark plug lead during engine running To avoid a serious burn do not touch a hot engine or muffler The engine becomes hot during operation Before you service or remove parts stop engine and allow the engine to cool Do not place hands or feet near moving or rotating parts Do not run engine at excessive speeds This may result in injury Always remove the spark plug lead from spark plug when servicing the engine to prevent accidental starting Emission Control Information Fuel Information THIS ENGINE IS CERTIFIED TO OPERATE ON UNLEADED REGULAR GRADE GASOLINE ONLY A minimum of 87 octane of the antiknock index is recommended The antiknock index is posted on service station pumps in the U S A To protect the environment in which we all live Kawasaki has incorporated an exhaust emission control system in compliance with applicable regulations of the United States Environmental Protection Agency and the California Air Resources 24
10. pack refer to instructions on page 16 e Attach spark plug wire to spark plug Make certain the metal cap on the end of the spark plug wire inside the rubber boot is fastened securely over the metal tip on the spark plug e Check for proper drive clutch operation using the neutral adjustment test described below Neutral Adjustment Test To perform the neutral adjustment test answer the following questions e With the drive clutch control released push mower forward and pull it backward Does it move freely e Squeeze the drive clutch control and pull the mower backward Do the rear wheels lock e Is the drive clutch control cable free of kinks or sharp bends e If you answered yes to all three questions your mower passed the test and you can start your mower e f you answered no to any of the three questions you will have to adjust the drive clutch control as instructed in the ADJUSTMENT SECTION Starting Engine 1 VVARNING Be sure no one other than the operator is standing near the lawn mower while starting engine or operating mower WARNING Never run engine indoors or in enclosed poorly ventilated areas Engine exhaust contains carbon monoxide an odorless and deadly gas WARNING Keep hands feet hair and loose clothing away from any moving parts on engine and lawn mower WARNING When starting the unit for the first time face the mower against a wall ora fence Start the unit and if it shows
11. selection release the drive clutch control NOTE Move the shift lever only when the engine is running Changing the shift lever setting with the engine off can damage the mower Grass Bag The grass bag is equipped with a bag fill indicator called a Grass Guage to add convenience to your work While the mower is running air will flow through the bag and into the sail If the grass catcher is empty air flows through easily pushing the sail up If the grass catcher is full air does not flow through it allowing the sail to fall So the position of the sail acts as a bag fill indicator signifying when to empty the grass bag Mulching Plug The mulching plug is used only for mulching purposes Instead of collecting grass clippings in a grass catcher this mower has the option of recirculating the clippings back to the lawn Blade Control Handle Electric Start Switch Model E977 only Height Adjustment Figure 10 SECTION 5 OPERATING YOUR LAWN MOWER WARNING Read understand and follow all instructions and warnings on the machine and in this manual before operating NOTE For shipping purposes your mower is set with the wheels in a low cutting height position For best results raise the cutting position until it is determined which height is best for your lawn See the Adjustment Section for details Gas amp Oil Fill Up Check oil level and add oil if necessary Follow relevant instructions in the eng
12. slopes Operate WALK BEHIND mowers across the face of slopes never up and down slopes SECTION 3 ASSEMBLING YOUR LAWN MOWER Removing Unit From Carton e Remove staples break glue on top flaps or cut tape at carton end and peel along top flap to open carton e Remove loose parts if included with unit i e grass bag etc and save it appropriately e Cutalong corners lay the carton down flat and remove all packing material e Roll or slide unit out of carton and check carton thoroughly for loose parts Loose Parts in Carton 1 Grass Bag 2 Grass Bag Adapter 3 Side Discharge Chute 4 Hardware Pack Hardware Pack Please identify each piece of the hardware pack as shown in Figure 1 Carriage Bolt Wing Nut Figure 1 Before Assembly e Before setting up your lawn mower disconnect the spark plug wire from the spark plug and ground against the engine See Figure 2 x TS Spark Plug Wire Spark Plug Figure 2 NOTE Reference to right or left side of the mower is observed from the operating position Setting Up Your Lawn Mower Assembling Handle e Lift up and pull back on the upper handle to raise the handle into the operating position See Figure 3 Make certain the lower handle is seated securely into the handle bracket assemblies x Handle Assembly Wing Nut Handle Mounting Bracket Figure 3 e Tigh
13. the element by tapping gently to remove dust If very dirty replace the element with a new one e Replace with a new paper element yearly or 300 hours CAUTION Do not wash paper element Do not use pressurized air to clean or dry paper element NOTE Operating in a dusty condition may require more frequent maintenance than above e Reinstall the foam element and then the paper element on the air cleaner body e Reinstall the air cleaner case on the air cleaner body by first fitting the projection B on the edge of the air cleaner case into the slit A in the air cleaner body Then sliding the fasteners C toward the air cleaner case securely fasten the air cleaner case with the air cleaner body EJO8B004 P Figure 16 A Slit in the air cleaner body B Projection on the air cleaner case C Fasteners CAUTION After servicing the air cleaner be sure all the removed parts are reinstalled properly in place Failure to secure fastening of the air cleaner case with the air cleaner body may cause dirt or other foreign materials to enter the engine while it is running through the air cleaner resulting in engine troubles or failures A e Clean or replace the spark plug and reset gap A every 100 hours of operation e Disconnect the spark plug cap from spark plug and remove the spark plug e Clean the electrodes B by scraping or with a wire brush to remove carbon deposits e Inspect for cracked porcelain
14. the engine The governor controls the maximum safe operating speed of the engine Maintain or replace safety and instruction labels as necessary Observe proper disposal laws and regulations Improper disposal of fluids and materials can harm the environment AVOID SERIOUS INJURY OR DEATH KEEP HANDS AND FEET AWAY FROM ROTATING PARTS THE e REMOVE OBJECTS THAT CAN BE THROWN BY BLADE IN ANY DIRECTION WEAR SAFETY ney DO NOT MOW WHEN CHILDREN OR OTHERS ARE AROE e USE EXTRA CAUTION ON SLOPES DO NOT MOW SLIC iN GREATER THAN 15 MOW ACROSS NEVER UF NEVER PULL MOWER CLOSE TO YOUR FEET LOOK En Ei BEFORE AND WHILE MOVING res MENG SHIELD DISCHARGE COVER ETC IN PLACE SLOPE GAUGE SECTION 2 Use this page as a guide to determine slopes where you may not operate safely Do not operate your lawn mower on such slopes LE SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE i gg A POWER POLE l Mt A CORNER OF A BUILDING OR AFENCE POST Do not mow on inclines with a slope in excess of 15 degrees a rise of approximately 2 1 2 feet every 10 feet A riding mower could overturn and cause serious injury If operating a walk behind mower on such a slope it is extremely difficult to maintain your footing and you could slip resulting in serious injury Operate RIDING mowers up and down slopes never across the face of
15. the six speed cable from the slot YOR See Figure 20 Six Speed Belt Cable Slot q SN P ls Q a CS Bhar Figure 22 e Pivot the control arm back to its original position and reinstall the six speed cable into the slot See Figure 23 Figure 20 Six Speed Cable Slot Control Arm Figure 23 e Make sure the belt is routed inside the pulley halves and the belt guard pin e Reinstall the bolt securing transmission to rear mower housing e Pivot the baffle back to its original position and secure with three hex screws removed earlier e Lightly lubricate the inside of the blade adapter and reinstall the spacer wave washer blade adapter assembly and blade in the correct order e Tighten the hex bolt to secure the blade to torque 450 600 in Ibs Replacing Rear Flap e To remove rear flap cut off the flat end of the wire rod which secures it to the deck SECTION 9 OFF SEASON STORAGE Storing Your Lawn Mower The following steps should be taken to prepare your lawn mower for storage e Clean and lubricate mower thoroughly as described in the lubrication instructions IMPORTANT We do not recommend the use of a pressure washer or garden hose to clean your unit e Refer to engine manual for correct engine storage instructions e Attach the new flap and new rod to deck bending the ends of the new rod over to secure to deck Replacing Battery Pack Model E977 only
16. 16 AVOID SERIOUS INJURY OR DEATH e KEEP HANDS AND FEET AWAY FROM ROTATING PARTS e REMOVE OBJECTS THAT CAN BE THROWN BY THE BLADE IN ANY DIRECTION WEAR SAFETY GLASSES DO NOT MOW WHEN CHILDREN OR OTHERS ARE AROUND USE EXTRA CAUTION ON SLOPES DO NOT MOW USI SLOPES GREATER THAN 15 MOW ACROSS NEVER UP AND DOWN NEVER PULL MOWER CLOSE TO YOUR FEET LOOK DOWN AND BEHIND BEFORE ots AND WHILE MOVING BACKWARDS READ OPERATOR S MANUAL KEEP SAFETY DEVICES BLADE CONTROL TRAILING SHIELD DISCHARGE COVER ETC IN PLACE AND WORKING IF DAMAGED REPLACE IMMEDIATELY Engine Manual for Kawasaki Engine SAFETY AWARENESS WARNING Whenever you see the symbols shown on the left heed their instructions Always follow safe operating and maintenance practices m Z D Z m gt Z gt m FORWARD We wish to thank you for purchasing this Kawasaki engine Please read this Owner s manual carefully before starting your new engine so that you will be thoroughly familiar with the proper operation of your engine s control its features capabilities and limitations Also read the manual of the equipment to which this engine is attached To ensure a long trouble free life for your engine give it the proper care and maintenance described in this manual Always keep this manual at your fingertip so that you can refer to it whenever you need information This manual should be considered a permanent part of the
17. AL CONSEQUENTIAL EXCEPTION LISTED UNDER COVERAGE OR EXEMPLARY ARISING IN CONNECTION WITH THE SALE OR USE OF OR INABILITY TO USE THE KAWASAKI SMALL OFF ROAD ENGINE FOR ANY PURPOSE b NO EXPRESS EMISSION CONTROL SYSTEMS WARRANTY IS GIVEN BY KAWASAKI WITH RESPECT TO THE KAWASAKI SMALL OFF ROAD ENGINE EXCEPT AS SPECIFICALLY SET FORTH HEREIN ANY EMISSION CONTROL SYSTEMS WARRANTY IMPLIED BY LAW INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IS EXPRESSLY LIMITED TO THE EMISSION CONTROL SYSTEMS WARRANTY TERMS SET FORTH HEREIN THE FOREGOING STATEMENTS OF WARRANTY ARE EXCLUSIVE AND IN LIEU OF ALL OTHER REMEDIES c No dealer is authorized to modify this Kawasaki Limited Emission Control Systems Warranty d Kawasaki is not liable for parts which are not genuine Kawasaki parts except when genuine Kawasaki parts cause damage to non Kawasaki parts LEGAL RIGHTS THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS THIS WARRANTY IS IN ADDITION TO THE KAWASAKI LIMITED SMALL OFF ROAD ENGINE WARRANTY 35 MANUFACTURER S LIMITED VVARRANTY FOR Cub Cadet The limited warranty set forth below is given by Cub Cadet LLC with respect to new merchandise purchased and used in the United States its possessions and territories Cub Cadet LLC warrants this product against defects fora period of two 2 years commencing on the date of original purchase and will at its option repair or repl
18. Cub Cadel Operators Manual 21 Self Propelled Mower Models 977A amp E977C IMPORTANT Read safety rules and instructions carefully Warning This unit is equipped with an internal combustion engine and should 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 should be maintained in effective working order by the operator 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 A spark arrester for the muffler is available through your Cub Cadet dealer or contact the service department P O Box 361131 Cleveland Ohio 44136 0019 Cub Cadet LLC P O Box 361131 Cleveland Ohio 44136 0019 PRINTED IN U S A Form No 769 00483 11 2002 TABLE OF CONTENTS Content Page Important Safe Operation Practices 2422222022a2aannaraamnananeninanenananenie 3 OPO Gau ge aiaee ingaan an asec nantes alerta tanta ad aA aa ea aaas 6 Assembling Your Lawn MOWED cececceeeeeenneeeteeeeeeeeeeeeeaaeeeeeeeaeeeeeeeaeeeeeeeeeaeeees 7 Know Your Lawn MOWEM cccccescccceeeesecceeeeeneeceeeeeneeeeeeeeeseeseneeeseeaeessesseeeenenenaes 9 Operating Your LAWN MOWED cccecceeceeeeeeeeeeeeeeeeeeeaeeeeeeeese
19. Figure 6 Attaching The Grass Bag The mower was shipped with the mulching baffle installed on the unit You can keep this baffle on as long as you want to mulch the grass clippings For bagging purposes you will have to attach the grass bag and its adapter in place of the mulching baffle e Remove three wing nuts holding the mulching baffle or side discharge chute in place and remove the accessory from the unit e Replace with grass bag adapter while making sure the front lip of adapter goes under the edge of the deck Secure with wing nuts previously removed See Figure 7 Grass Bag Adapter Wing Nuts gt Q Figure 7 e Lift chute door on the grass bag adapter and slide grass bag onto the adapter See Figure 8 NOTE The chute door has been designed to move the starter rope out of the way of the bag when the chute door is opened Chute BR op WK Ll Grass Bag Figure 8 Attaching Side Discharge Chute e Remove mulching baffle or grass bag adapter from unit by disconnecting wing nuts e Attach side discharge chute to unit and secure with the three wing nuts See Figure 9 Side Discharge ______ gt Chute Figure 9 SECTION 4 KNOW YOUR LAWN MOWER Read this operators manual and safety rules before operating your lawn mower Compare the illustration in Figure 10 with your lawn mower to familiarize yourself with the location of various controls and adjustments Save this manual for fu
20. N GE vive ise et a eaaa ee eee 29 Air Cleaner Service c ccccccceeeeceeeeeeeeeeeeeeeeaeeeseaeeeeeaeeseeneeeesaees 30 Spark Plug Service s aa aana a atana eai tesi esti faci 30 STORAGE REE E T TTE ED SR SA 31 TROUBLESHOOTING GUIDE 0 cccccceccceceteeeeeeeeeeeneeeeeeeeeseneeetesneeensaees 33 ENVIRONMENTAL PROTECTION 0 cccccceceeeeeeeeeeeeeeeeeeeseneeeseneeeee 33 SPECIFICATIONS aese oeae aasia aaeeea kas eaa ainada 33 23 READ THIS FIRST 1 WARNING Never allow children to operate the engine or equipment Keep people and pets out of area where you are using the engine or equipment Never wear loose torn or bulky clothing It may catch on moving parts or controls leading to the risk of accident Never consume alcohol or drug before or while operating this engine Do not run the engine in a closed area Exhaust gas contains carbon monoxide an odorless and deadly poison Gasoline is extremely flammable and can be explosive under certain condition Stop engine and allow the engine to cool before refueling Do not smoke Make sure area is well ventilated and free from any source of flame or sparks including the pilot light of any appliance while refueling servicing fuel system draining gasoline and or adjusting carburetor Do not fill the tank so the fuel level rises into the filler neck If the tank is overfilled heat may cause the fuel to expand and overflow through the vents in the tank cap Wipe
21. Replace blade Mower will not mulch grass 1 Wet grass 1 Do not mow when grass is wet wait until later to cut 2 Excessively high grass 2 Mowonce ata high cutting height then mow again at desired height or make a narrower cutting path 3 Dull blade 3 Sharpen or replace blade Uneven cut 1 Wheels not positioned correctly 1 Place all four wheels in same height position 2 Dull blade 2 Sharpen or replace blade SECTION 11 PARTS LIST FOR MODELS 977 amp E977 IMPORTANT For a proper working machine use Factory Approved Parts V BELTS are specially designed to engage and disengage safely A substitute non OEM V Belt can be dangerous by not disengaging completely Models 977 amp E977 Ref Part No Description Ref Part No Description No No 1 647 04008 Control Handle 52 748 0381 Pawl RH 2 731 0904A Upper Control Handle 748 0188B Pawl LH 3 16864 6 Spd Rack Cable Bracket 53 738 0137A Shld Screw 340 ID x 285 OD 4 1731 0620 Control Lever 54 1748 0318 Wheel Rachet 5 1713 0397 Gear Insert 55 736 0270 Bell Washer 265 ID x 75 OD 6 1732 0627 Shift Lever Spring 56 710 0751 Hex Cap Screw 1 4 20 x 620 7 1731 0924 6 Speed Shift Lever 57 731 0982A Hubcap 8 731 0905A Lower Control Housing 58 738 0102 Shoulder Screw 498 x 1 445 9 710 1667A C Sunk Tap Screw 10 x 75 Lg 59 736 0504 Wave Washer 510 ID x 750 OD 10 731 0906 Cable Mounting Cap 60 734 2008A Whee
22. Slowly pull the recoil starter grip with fuel spark plug removed to discharge excess fuel clean spark plug 2 Clogged air cleaner 2 Clean 3 Faulty carburetor 3 F 4 Incorrect grade type of fuel 4 Change Gasoline 5 Water in fuel 5 Change Gasoline No spark or weak 1 Faulty spark plug 1 Replace spark plug spark 2 Faulty ignition coil 2 3 Faulty engine switch 3 4 Low Output Engine Overheats 1 Clogged air cleaner 1 Clean 2 Recoil Starter or cooling air path 2 Clean clogged with dirt 3 Insufficient engine oil 4 carbon built up in combustion 3 Replenish or change oil chamber 4 4 5 Poor ventilation around engine 5 Select a better location 1 Engine speed 1 Faulty Governor t If the engine malfunctions carefully examine the symptoms and the operating conditions and use the table above as a guide to troubleshooting Have an authorized Kawasaki dealer perform these service Environmental Protection To protect our environment properly discard used batteries engine oil gasoline coolant or other components that you might dispose of in the future Consult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal procedure Specifications Type of Engine Air cooled 4 stroke OHV single cylinder gasoline Engine e Bore X Stroke e 65 x 54mm 2 6 x 2 1 in e Displacement e 179mL 109 cu in e Ignition system e Solid state ignition e Starting s
23. TING Problem Cause Remedy Engine fails to start 1 Blade control handle disengaged 1 Engage blade control handle 2 Spark plug wire disconnected 2 Connect wire to spark plug 3 Fuel tank empty or stale fuel 3 Fill tank with clean fresh gasoline 4 Blocked fuel line 4 Clean fuel line 5 Faulty spark plug 5 Clean adjust gap or replace 6 Engine flooded 6 Wait afew minutes to restart do not prime Engine runs erratic 1 Spark plug wire loose 1 Connect and tighten spark plug wire 2 Blocked fuel line or stale fuel 2 Clean fuel line fill tank with clean fresh gasoline 3 Ventin gas plugged 3 Clear vent 4 Water or dirt in fuel system 4 Drain fuel tank Refill with fresh fuel 5 Dirty air cleaner 5 Clean air cleaner 6 Carburetor out of adjustment 6 Adjust carburetor Engine overheats 1 Engine oil level low 1 Fill crankcase with proper oil 2 Air flow restricted 2 Remove blower housing and clean 3 Carburetor not adjusted properly 3 Adjust carburetor Occasional skip hesitates 1 Spark plug gap too close 1 Adjust gap to 030 at high speed Idles poorly 1 Spark plug fouled faulty or gap too 1 Reset gap to 030 or replace spark plug wide 2 Adjust carburetor 2 Carburetor improperly adjusted 3 Clean air cleaner 3 Dirty air cleaner Excessive vibration 1 Cutting blade loose or unbalanced 1 Tighten blade and adapter Balance 2 Bentcutting blade blade 2
24. ace free of charge any part found to be defective in materials or workmanship This limited warranty shall only apply if this product has been operated and maintained in accordance with the Operator s Manual furnished with the product and has not been subject to misuse abuse commercial use neglect accident improper maintenance alteration vandalism theft fire water or damage because of other peril or natural disaster Damage resulting from the installation or use of any accessory or attachment not approved by Cub Cadet LLC for use with the product s covered by this manual will void your warranty as to any resulting damage Normal wear parts or components thereof are subject to separate terms as follows All normal wear parts or component failures will be covered on the product for a period of 90 days regardless of cause After 90 days but within the two year period normal wear part failures will be covered ONLY IF caused by defects in materials or workmanship of OTHER component parts Normal wear parts and components include but are not limited to batteries belts blades blade adapters grass bags rider deck wheels seats snow thrower skid shoes shave plates auger spiral rubber and tires HOW TO OBTAIN SERVICE Warranty service is available WITH PROOF OF PURCHASE through your local authorized service dealer To locate the dealer in your area check your Yellow Pages or contact Cub Cadet LLC at P O Box 361131 Clevela
25. aeeeeeeeeeseaeessneeeeaes 10 Making Adjustments zicisicaceceicsscecsscabicuvs teh ENE AEIR E uenei 11 Maintaining Your Lawn MOWE ccccecsceeeeeeeneeeeeeeeneeeeeseeaeeeeeseeaeeeeneeiaeeeeeneaaes 13 TROUBIOSMOOUING ession des alineat Eaa EAK bine eee neared 17 Parts LiStieee iii item dis vs exci etstoies ma tenien A ieee wena 18 Engine Mantal seisear iira nR OaE a AA Ea EaR NA 23 FINDING MODEL NUMBER This Operator s Manual is an important part of your new lawn mower It will help you assemble prepare and maintain the unit for best performance Please read and understand what it says Before you start assembling your new equipment please locate the model plate on the equipment and copy the information from it in the space provided below The information on the model plate is very important if you need help from our Customer Support Department or an authorized dealer You can locate the model number by standing at the operating position and looking down at the rear of the mower deck A sample model plate is explained below For future reference please copy the model number and the serial number of the equipment in the space below Model Number Serial Number Copy the model number here Copy the serial number here Cub Cadet EP EXPER SSS P 0 BOX 361131 www cubcadet com CLEVELAND OH 44136 DEALER LOCATOR PHONE NUMBER 877 282 8684 ENGINE INFORMATION The engine manufacturer is responsible for all en
26. against the handle while the engine is started and running Starting Engine e Fully push the priming button A by thumb only once NOTE When the engine is already warm or on hot days do not push the priming button to prevent faulty starting engine caused by flooding carburetor Figure 8 CAUTION e DO NOT start the engine when the cutting blade is in contact with long uncut grass it may cause difficulties in starting and damage to the recoil starter DO NOT attempt to start the engine when the brake control lever on the equipment is released from your hands this may cause 28 damage to the recoil starter or pad system of the engine DO NOT pull the recoil starter grip out of the end DO NOT let the recoil starter grip snap back itself This may cause damage to the recoil starter assembly Hold the brake control lever A on the equipment against the handle B on the equipment Pull the recoil starter grip C slowly until you feel compression then pull fast and steady Figure 9 A Brake Control Lever B Handle C Recoil Starter Grip Warming up CAUTION Allow engine to warm up before loading This will allow oil to reach all the engine parts and the piston clearance to reach design specification before the engine is ready for loading e After engine starts warm up the engine run it for a few minutes Operating e Anti engine inclination e This engine will operate continuously at angle
27. any signs of motion while the drive clutch control is still disengaged shut engine off immediately e Push primer once Do not prime to restart a warm engine after a short shutdovvn e Standing behind the mower depress the blade control handle and hold it against the upper handle e Electric Start Turn the ignition key to the right to start the engine Release the key after the engine starts e Recoil Start Grasp starter handle and pull rope out slowly until engine reaches start of compression cycle rope will pull slightly harder at this point Let the rope rewind slowly Pull rope with a rapid continuous full arm stroke Keeping a firm grip on the starter handle let the rope rewind slowly Stopping Engine e Release blade control handle to stop the engine and the blade e Disconnect spark plug wire and move away from spark plug to prevent accidental starting Using Your Lawn Mower T WARNING Never operate the mower unless the hooks on the grasscatcher are seated in the slots on the handle bracket assemblies and the rear discharge door rests firmly against the top of the grasscatcher e Do not operate the mower without any one of the mulching baffle discharge chute or grass catcher properly installed WARNING Be sure that the lawn is clear of A stones sticks wire or other objects which could damage lawn mower or engine Such objects could be accidently thrown by the mower in any direction and cause serious pe
28. dically and replace if necessary Damaged mufflers or spark arresters can create a fire hazard Make sure to avoid muffler and surrounding areas while the mower engine is hot because temperature of these areas of the engine may exceed 150 F Lubrication Refer to the lubrication chart in Figure 15 Blade Control Handle e Lubricate the pivot points on the blade control handle at least once a season with light oil The blade control must operate freely in both directions Rear Discharge Door e Lubricate the torsion spring and the pivot point on each end of the rear discharge door using a light oil This will prevent rusting of the discharge door Wheels e Lubricate the wheels and bearings if so equipped at least once a season with light oil or engine oil Also if the wheels are removed for any reason lubricate the surface of the axle bolt and the inner surface of the wheel with light oil Engine e Follow the engine manual instructions and recommended schedule for lubricating engine components Figure 15 Lubrication Chart SECTION 8 SERVICING THE MOWER WARNING Always stop the engine and disconnect the spark plug wire before performing any maintenance work or adjustments on your lawn mower Blade Care WARNING When removing the cutting blade for sharpening or replacement protect your hands with a pair of heavy gloves or use a heavy rag to hold the blade Periodically inspect the blade adapter for crac
29. en properly performed these specified modifications only are not considered to be emissions system tampering and engine performance is generally unchanged as a result Installation Instructions High altitude adjustment requires replacement of carburetor main jet Installation of these optional parts may be performed by an authorized Kawasaki dealer or the consumer following repair recommendations specified in the appropriate Kawasaki Service Bulletin Maintenance and Warranty Proper maintenance is necessary to ensure that your engine will continue to have low emission levels This Owner s Manual contains those maintenance recommendations for your engine Those items identified by the Periodic Maintenance Chart are 25 necessary to ensure compliance with the applicable standards As the owner of the engine you have the responsibility to make sure that the recommended maintenance is carried out according to the instructions in this Owner s Manual at your own expense The Kawasaki Limited Emission Control System Warranty requires that you return your engine to an authorized Kawasaki dealer for remedy under warranty Please read the warranty carefully and keep it valid by complying with the owner s obligations it contains Tampering with Emission Control System Prohibited Federal law and California State law prohibit the following acts or the causing thereof 1 the removal or rendering inoperative by any person other than fo
30. engine and should remain with the engine when it is sold All rights reserved No part of this publication may be reproduced without our prior written permission This publication includes the latest information available at the time of printing However there may be minor differences between the actual product and illustrations and text in this manual All products are subject to change without prior notice or obligation EMISSION CONTROL INFORMATION 0 2 cceeeeeeeeteeeeeeeeeeteeeeeeeeeee 24 GENERAL INFORMATION cccccceeeeeeeeeeeeeeeeeeeeeeeecaeeeseeeeeniaeeeseaeeens 26 FUEL AND OIL RECOMMENDATION SG ccccceeeeeeeeeeeeeeeeeeeeneeeee 27 PREPARATION ese iot teta decir tes aae toa denans eaaa TeaTS 27 EU l EE A sta E E A AE E E T T 27 Engine OiP e isla Sadie EN DES 27 SEARTINGi cient sau tied dea iii ci ghee eee cm antes ar DL 28 Starting ENGINE citi etat e a AnA a aTa Raan 28 OPERATING cna aeiiae a niaii ea e ian 28 Anti engine inclination sessssessssrreserrrrsssrrnnesrernnersrrnneerernneenen 28 STOPPING A E E AEA A ES 28 Stopping EngiNe seansla aai arde antata aaeoa eea e 28 ADJUSTMENT i aare hi arar aak t A a aara entity 29 Engine Speed Adjustment ccccceeeeeeeeeeeeeneeeteeeeeeaeeeteeeeeeas 29 MAINTENANCE paa e eai aaaea i a aaan AeA Taa akaa ni iaai 29 Periodic Maintenance Chart cccccceseeeeeseeeeeeeeeeeteeeesseeeteas 29 Oil Level Check iris parni aana e aa iiaia Gi i 29 Oil CA
31. engine owner you are responsible for the performance of the required maintenance listed in your owner s manual Kawasaki recommends that you retain all receipts covering maintenance on your small off road engine but Kawasaki cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance b You are responsible for presenting your small off road engine to an authorized Kawasaki small off road engine Dealer as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days c AS the small off road engine owner you should also be aware that Kawasaki may deny you warranty coverage if your small off road engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications d If you have any questions regarding your warranty rights and responsibilities you should contact Kawasaki Motors Corp U S A Consumer Services Department 5080 36th Street S E Grand Rapids MI 49512 616 949 6500 1 COVERAGE Kawasaki warrants to the initial owner and each subsequent purchaser that the small off road engine is free from defects in materials and workmanship which cause a failure of a warranted part for a period of two years Kawasaki is liable for damages to other engine components caused by the failure of a warranted part still under warranty The 1995 and later small off road engines are warranted for
32. erating position e Slide the blade adapter onto the engine crankshaft e Place the blade on the adapter Be certain the blade is aligned and seated on the blade adapter flanges e Place blade bell support on blade Make sure the notches on the blade bell support are aligned with small holes in the blade e Replace hex bolt and tighten hex bolt to torque 450 in lbs min 600 in lbs max NOTE To ensure safe operation of your mower periodically check the blade bolt for correct torque Blade Adapter Blade Bell Support Figure 16 Drive Belt Replacement e Disconnect the spark plug wire and ground it against the engine e Drain the fuel tank or place a piece of plastic beneath the cap to prevent gasoline leakage e Place shift lever in the first position and tip the mower on its side with air filter facing up e Remove the center bolt which secures the blade to the crankshaft followed by blade bell support blade and blade adapter e Move the cutting height adjustment to the highest position e Remove the three hex screws holding the baffle to the deck and pivot baffle towards the rear of the mower See Figure 17 Figure 17 e Remove the hex bolt from the rear of unit holding e Pivot the control arm down away from the pulley the transmission to the mower housing and belt See Figure 18 e Lift off the lower pulley assembly and remove the old belt from around the crankshaft des Oe e Place the ne
33. espect to any product shall bind Cub Cadet LLC During the period of the warranty the exclusive remedy is repair or replacement of the product as set forth above The provisions as set forth in this warranty provide the sole and exclusive remedy arising from the sale Cub Cadet LLC shall not be liable for incidental or consequential loss or damage including without limitation expenses incurred for substitute or replacement lawn care services or for rental expenses to temporarily replace a warranted product Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied warranty lasts so the above exclusions or limitations may not apply to you In no event shall recovery of any kind be greater than the amount of the purchase price of the product sold Alteration of safety features of the product shall void this warranty You assume the risk and liability for loss damage or injury to you and your property and or to others and their property arising out of the misuse or inability to use the product This limited warranty shall not extend to anyone other than the original purchaser or to the person for whom it was purchased as a gift HOW STATE LAW RELATES TO THIS WARRANTY This limited warranty gives you specific legal rights and you may also have other rights which vary from state to state Cub Cadet LLC P 0 BOX 361131 CLEVELAND OHIO 44136 0019 Phone 1 877 282
34. ex Nut 1 4 20 83 710 0653 Screw 1 4 20 x 3 75 39 710 0167 Carriage Screw 1 4 20 x 50 84 753 0609 Blade Adapter Kit 40 1712 0138 Hex Nut 1 4 28 85 1742 0741 21 Mulching Blade 41 782 7575A Cable Mounting Bracket 86 736 0524A Blade Bell Support 42 736 0329 Lock Washer 1 4 87 1710 1257 Hex Bolt 3 8 24 x 2 5 43 1756 0625 Roller Cable 88 731 1874 Chute Door 44 1738 0924 Shoulder Screw 375 ID x 1 4 14 89 732 0819 Torsion Spring 45 1714 0104 Cotter Pin 90 1726 0111 Push Cap 46 1736 0286 Bovved VVasher 91 1747 0965 Pivot Rod 47 1782 0565 Single Lever Control Arm 92 731 1713B Discharge Chute 48 1734 2010 Wheel 9 x 2 125 94 682 3052 Handle Bracket Assembly RH 49 1712 0414 Top Lock Tab Weld Nut 1 4 20 682 3053 Handle Bracket Assembly LH 50 16855 Ratchet Pawl Plate 95 682 7527 Cup Assembly Part of 73 51 10622B Plastic Spring Ratchet 19 Models 977 8 E977 20 Models 977 amp E977 fn Part No Part Description da Part No Part Description 1 1720 0223 Grip 33 1712 0896 Hex Jam Nut 1 4 28 2 732 0803A Spring Lever 34 1782 7598 Belt Reeper 3 1738 0529 Shoulder Nut 825 x 165 Lg 35 741 0600 Bearing 4 710 0751 Cap Screw 1 4 20 x 620 36 732 0849A Extension Spring 5 1736 0270 Bell Washer 285 ID x 75 OD 37 1750 1050 Flange Spacer 6 748 0318 Wheel Rachet 38 682 0027A Idler Bracket Assembly 7 1736 0369 Flat Washer 508 ID x 1 0 OD 39 710 0299 Hex Cap Sc
35. gine related issues with regards to performance power rating specifications warranty and service Please refer to the engine manufacturer s Owner s Operator s Manual packed separately with your unit for more information CALLING CUSTOMER SUPPORT If you have difficulty assembling this product or have any questions regarding the controls operation or maintenance of this unit please call the Customer Support Department Call 1 877 282 8684 to reach a Customer Support representative Please have your unit s model number and serial number ready when you call See previous section to locate this information You will be asked to enter the serial number in order to process your call For more details about your unit visit our website at www cubcadet com SECTION 1 IMPORTANT SAFE OPERATION PRACTICES A WARNING This symbol points out important safety instructions which if not followed could endanger the personal safety and or property of yourself and others Read and follow all instructions in this manual before attempting to operate this machine Failure to comply with these instructions may result in personal injury When you see this symbol HEED ITS WARNING WARNING Engine exhaust some of its constituents and certain vehicle components contain or emit chemicals known to State of California to cause cancer and birth defects or other reproductive harm WARNING This machine was built to be operated according to the
36. il the blade comes to a complete stop before removing the grass catcher or unclogging the chute The cutting blade continues to rotate for a few seconds after the engine is shut off Never place any part of the body in the blade area until you are sure the blade has stopped rotating 13 Never operate mower without proper trail shield discharge cover grass catcher blade control handle or other safety protective devices in place and working Never operate mower with damaged safety devices Failure to do so can result in personal injury 14 Muffler and engine become hot and can cause a burn Do not touch 15 Only use parts and accessories made by the original equipment manufacturer O E M Failure to do so can result in personal injury 16 If situations occur which are not covered in this manual use care and good judgment Contact your dealer for assistance Call 1 877 282 8684 for the name of your nearest dealer Slope Operation Slopes are a major factor related to slip and fall accidents which can result in severe injury Operation on slopes requires extra caution If you feel uneasy ona slope do not mow it Before operating this unit ona slope or hilly area use the slope gauge on page 6 to measure slopes If the slope is greater than 15 degrees do not mow it Do 1 Mow across the face of slopes never up and down Exercise caution when changing direction 2 Watch for holes ruts rocks hidden objects or bumps which
37. in the handle mounting bracket e Place the hairpin clips in the inner holes in the weld pins and insert the carriage bolts through the upper hole on the handle mounting bracket and secure with plastic wing nuts e Reassemble the upper handle to the lower handle e Attach the starter rope as instructed on page 8 Cutting Height Your mower is shipped with the cutting height in the lowest position The cutting height adjustment lever is located above the left rear wheel To adjust the cutting height proceed as follows e Pull the lever out and away from the mower and then move it forward or backward to another slot For rough or uneven lawns move the height adjustment lever to a higher position This will help stop scalping Drive Clutch Control The adjustment wheel is located in the drive clutch control handle housing and is used to tighten or loosen the drive belt You will have to adjust the drive clutch control if any of the following happens 1 The mower does not propel itself with the drive clutch engaged 2 The mower s drive wheels hesitate with the drive clutch engaged e To resolve the above problems rotate the adjustment wheel with your fingers clockwise to tighten the cable and counter clockwise to loosen the cable See Figure 13 Bottom View Upper Handle eee SS Adjustment oN Drive Clutch hift L Snitt Lever Control Figure 13 NOTE For some people the drive clutch contr
38. ine manual for this e Service the engine with gasoline as instructed in the engine manual WARNING Use extreme care when handling gasoline Gasoline is extremely flammable and the vapors are explosive Never fuel the machine indoors or while the engine is hot or running Extinguish cigarettes cigars pipes and other sources of ignition Before Starting Mower Charging the Battery Model E977 only IMPORTANT Use only the battery charger supplied with this mower WARNING The battery contains corrosive A fluid and toxic material handle with care Keep away from children Do not puncture disassemble mutilate or incinerate the battery Explosive gases could be vented during charging or discharging Use in a well ventilated area away from sources of ignition Protective Cap Battery pack Figure 11 e Remove the protective cap from the end of the battery pack lead Always plug charger lead into battery pack lead first and then insert battery charger plug into 120 volt standard household outlet See Figure 11 Follow this order of action every time you charge the battery e Charge battery for 16 hours before initial use Do not charge longer than 20 hours e After charging disconnect battery charger plug from household outlet first then disconnect charger lead from battery pack lead WARNING Do not remove the battery pack from the handle panel for any reason other than replacement When replacing the battery
39. instructions in this manual and on the machine TO REDUCE THE RISK OF INJURY DO NOT OPERATE MOWER UNLESS DISCHARGE CHUTE COVER OR GRASS CATCHER IS IN ITS PROPER PLACE DANGER KEEP HANDS and FEET AWAY A WARNING TO REDUCE THE RISK OF INJURY DO NOT OPERATE MOWER UNLESS THIS GUARD OR ENTIRE GRASS CATCHER IS IN ITS PROPER PLACE 10 11 12 REA D TRAI Mower blades are sharp and can cut Wrap the blade or wear gloves and use extra caution when servicing them Keep all nuts bolts and screws tight to be sure the equipment is in safe working condition Never tamper with safety devices Check their proper operation regularly After striking a foreign object stop the engine disconnect the spark plug wire and ground against the engine Thoroughly inspect the mower for any damage Repair the damage before starting and operating the mower Never attempt to make a wheel or cutting height adjustment while the engine is running Grass catcher components discharge cover and trail shield are subject to wear and damage which could expose moving parts or allow objects to be thrown For safety protection frequently check components and replace immediately with original equipment manufacturer s O E M parts only listed here Use of parts which do not meet the original equipment specifications may lead to improper performance and compromise safety Do not change the engine governor setting or overspeed
40. is needed by your dealer when ordering parts Refer to Figure 2 Figure 2 26 E EB038008 P o Figure 3 A Fuel Tank Cap B Fuel Tank capacity 2 0L 0 528US gal C Fuel Tube D Carburetor E Priming Pump F Air Cleaner G Recoil starter H Recoil Starter Grip Oil Drain Plugs engine oil capacity 0 65L 0 69US gal Figure 4 J Oil Gauge Filler Cap K Spark Plug Cap Spark Plug L Muffler M P T O Shaft Tune up Specifications ITEM SPECIFICATION e Valve Clearance e IN 0 12mm 0 005 in e EX 0 12mm 0 005 in e Ignition Timing e Unadjustable e High Idle Speed e 3200 r min rpm e Spark Plug Gap e 0 7 0 8mm 0 028 0 032 in NO OTHER ADJUSTMENT NEEDED e Other Specifica tions Fuel And 0il Recommendations Fuel Use only clean fresh unleaded regular grade gasoline Octane Rating The octane rating of a gasoline is a measure of its resistance to knocking Use a minimum of 87 octane of the antiknock index is recommended The antiknock index is posted on service station pumps in the U S A NOTE f knocking or pinging occurs use a different brand of gasoline or higher octane rating CAUTION Do not mix oil with gasoline Oxygenated Fuel Oxygenates either ethanol or MTBE are added to the gasoline If you use the oxygenated fuel be sure it is unleaded and meets the minimum octane rating requirement The following are the EPA approved perce
41. ked up and thrown by the blade Thrown objects can cause serious personal injury Plan your mowing pattern to avoid discharge of material toward roads sidewalks bystanders and the like Also avoid discharging material against a wall or obstruction which may cause discharged material to ricochet back toward the operator To help avoid blade contact or a thrown object injury stay in the operator zone behind the handles and keep bystanders helpers children and pets at least 75 feet from the machine while it is in operation Stop machine if anyone enters the area Always wear safety glasses to protect your eyes during equipment operation and while performing an adjustment or repair Thrown objects which ricochet can cause serious injury to the eyes 7 10 11 co Wear sturdy rough soled work shoes and close fitting slacks and shirts Shirts and pants that cover the arms and legs and steel toed shoes are recommended Never operate this machine in bare feet sandals slippery or light weight e g canvas shoes Do not put hands or feet near rotating parts or under the cutting deck Contact with the blade can amputate hands and feet A missing or damaged discharge cover can cause blade contact or thrown object injuries Many injuries occur as a result of the mower being pulled over the foot during a fall caused by slipping or tripping Do not hold on to the mower if you are falling release the handle immediately Never pull the
42. ks especially if you strike a foreign object Replace when necessary Removing the Blade e Disconnect spark plug wire from spark plug e Turn mower on its side making sure that the air filter and the carburetor are up e Remove the bolt and the blade bell support which hold the blade and the blade adapter to the engine crankshaft See Figure 16 e Remove the blade and the adapter from the crankshaft Sharpening the Blade e The blade can be sharpened with a file or on a grinding wheel Do not attempt to sharpen the blade while it is still on the mower e Follow the original angle of grind as a guide Make sure that each cutting edge receives an equal amount of grinding to prevent an unbalanced blade WARNING An unbalanced blade will cause excessive vibration when rotating at high speeds It may cause damage to the mower and could break causing personal injury Balancing the Blade e The blade can be tested by balancing it on a round shaft screwdriver Remove metal from the heavy side until it balances evenly It is recommended that the blade always be removed from the adapter when testing for balance Installing the Blade e Before reinstalling the blade and the blade adapter to the unit lubricate the engine crankshaft and the inner surface of the blade adapter with light oil e Be sure to install the blade with the side of the blade marked Bottom or with part number facing the ground when the mower is in the op
43. l 8 x 2 125 11 746 0711A Drive Cable 51 0 61 736 0105 Spring Washer 401 ID x 870 OD 12 712 0324 Top Lock Nut 1 4 20 62 710 1348 Screw 1 4 14 x 500 13 746 0883 Control Housing 63 710 0896 Screw 1 4 14 x 625 14 710 1270 Oval C Sunk Screw 64 710 0654A Hex Washer Screw 3 8 16 x 1 0 15 746 04055 Control Cable 65 611 0064 Front Axle Assembly 16 749 0439D Upper Handle 66 736 0204 Flat Washer 344 ID x 62 OD 17 720 0284 Wing Nut 67 710 0703 Carriage Screw 1 4 20 x 75 18 736 0451 Saddle Washer 320 ID x 830 OD 68 710 1242 Torx Screw 19 1710 1174 Carriage Bolt 5 16 18 x 2 0 69 741 0492A Block Bushing 20 726 0240 Cable Tie 70 1710 1241 Hex Washer Screw 21 749 0907B Lower Handle 71 1731 1836 Front Axle Cover 27 731 1901 Trail Shield 72 1754 0460 Belt 3 8 x 39 24 28 732 0842 Trail Shield Wire 73 656 0613 Pulley Assembly 29 631 0066 Chute Assembly 74 1750 1071 Sleeve Spacer 88 ID x 1 13 OD 30 1731 1832 Side Discharge Chute 75 1750 1070 Sleeve Spacer 88 ID x 1 00 OD 31 1731 1833 Mulch Cover 76 1782 7597 Pivot Bracket 32 782 0078B Deck 21 77 710 0654A Screw 3 8 18 x 1 0 33 712 0397 Wing Nut 78 1782 7596 Control Arm 34 710 0703 Carriage Bolt 1 4 20 x 75 79 732 0807 Torsion Spring 35 746 0939 6 Speed Cable 80 711 1114 Pivot Shaft 36 782 7574A Cable Adjustment Bracket 81 736 0526 Wave Washer 1 38 ID x 88 OD 37 736 0270 Bell Washer 265 ID x 75 OD 82 731 1828 Baffle 38 712 0287 H
44. mps fittings gaskets sealing devices mounting hardware and tubing used directly in these parts Since emission related parts may vary slightly from model to model certain models may not contain all of these parts and certain models may contain functionally equivalent parts 34 2 LIMITATIONS This Emission Control Systems Warranty shall not cover any of the following a Repair or replacement required as a result of i misuse or neglect ii lack of required maintenance iii repairs improperly performed or replacements improperly installed iv use of replacement parts or accessories not conforming to Kawasaki specifications which adversely affect performance and or durability v alterations or modifications not recommended or approved in writing by Kawasaki b Replacement of parts and other services and adjustments necessary for required maintenance at and after the first scheduled replacement point LIMITED LIABILITY a The liability of Kawasaki under this Emission Control Systems Warranty is limited solely to the remedying of defects in materials or workmanship by any authorized Kawasaki small off road engine dealer at its place of business during customary business hours This warranty does not cover inconvenience or loss of use of the small off road engine or transportation of the small off road engine to or from the Kawasaki Dealer KAWASAKI SHALL NOT BE LIABLE FOR ANY OTHER EXPENSE LOSS OR DAMAGE WHETHER DIRECT INCIDENT
45. nd Ohio 44136 0019 or call 1 877 282 8684 or log on to our Web site at www cubcadet com This limited warranty does not provide coverage in the following cases a The engine or component parts thereof These items carry a separate manufacturer s warranty Refer to applicable manufacturer s warranty for terms and conditions b Log splitter pumps valves and cylinders have a sepa rate one year warranty C Routine maintenance items such as lubricants filters blade sharpening tune ups brake adjustments clutch adjustments deck adjustments and normal deterioration of the exterior finish due to use or exposure Cub Cadet LLC does not extend any warranty for products sold or exported outside of the United States its possesions and territories except those sold through Cub Cadet LLC s authorized channels of export distribution e Parts that are not genuine Cub Cadet parts are not covered by this warranty f Service completed by someone other than an authorized service dealer is not covered by this warranty g Transportation charges and service calls are not covered No implied warranty including any implied warranty of merchantability of fitness for a particular purpose applies after the applicable period of express written warranty above as to the parts as identified No other express warranty whether written or oral except as mentioned above given by any person or entity including a dealer or retailer with r
46. nk to no more than 4 inch below bottom of filler neck to provide space for fuel expansion Replace gasoline cap and tighten securely equipment Move unit to another area Wait 5 minutes before starting the engine Never store the machine or fuel container inside where there is an open flame spark or pilot light as on a water heater space heater furnace clothes dryer or other gas appliances To reduce fire hazard keep mower free of grass leaves or other debris build up Clean up oil or fuel spillage and remove any fuel soaked debris Allow mower to cool 5 minutes before storing General Service 1 Never run an engine indoors or in a poorly ventilated area Engine exhaust contains carbon monoxide an odorless and deadly gas Before cleaning repairing or inspecting make certain the blade and all moving parts have stopped Disconnect the spark plug wire and ground against the engine to prevent unintended starting Check the blade and engine mounting bolts at frequent intervals for proper tightness Also visually inspect blade for damage e g bent cracked worn Replace blade with the original equipment manufacture s O E M blade only listed in this manual Use of parts which do not meet the original equipment specifications may lead to improper performance and compromise safety Your Responsibility Restrict the use of this power machine to persons who read understand and follow the warnings and
47. nk with a pump or siphon e Fit the plug cap on the spark plug securely e Start and run the engine at idle speed to used up the fuel in the fuel system A WARNING Before maintaining engine stop the engine and allow it cool e Remove the spark plug and pour approx 1 2 mL A Spark Plug Hole 0 06 0 1 cu in of new engine oil through the plug e Slowly pull the recoil starter grip until you feel hole A slowly pull the recoil starter grip several compression and leave it there times and reinstall the spark plug e Clean every part of the engine e After period of storage change engine oil e Refer to Oil Change section in MAINTENANCE section J WARNING Gasoline is a toxic substance Dispose of gasoline properly Contact your local authorities for approved disposal methods EKO3B000 P Figure 18 32 Troubleshooting Guide won t increase Symptom Probable Cause Remedy Engine won t start Insufficient 1 Faulty piston cylinder piston ring 1 Tighten properly output is low compression and head gasket 2 Faulty valves 2 Tighten properly 3 Loose spark plug 3 Tighten properl 4 Loose cylinder head bolts mg Nen EE OP EY 4 Tighten properly No fuel to 1 No fuel in fuel tank 1 Fill fuel tank combustion chamber 2 Blocked rue tube 2 Clean 3 Blocked air vent in fuel tank cap 3 Clean 4 Faulty carburetor 4 Spark plug fouled by 1 Over rich fuel air mixture 1
48. ntages of fuel oxygenates ETHANOL Ethyl or Grain Alcohol You may use gasoline containing up to 10 ethanol by volume MTBE Methyl Tertiary Butyl Ether You may use gasoline containing up to 15 MTBE by volume METHANOL Methyl or Wood Alcohol 5 by volume You may use gasoline containing up to 5 methanol by volume as long as it also contains co solvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performance problems It may also damage metal rubber and plastic parts of your fuel system flammable and can be explosive under certain conditions Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Never fill the tank so the fuel level rises into the filler neck If the tank is overfilled heat may cause the fuel to expand and overflow through the vents in the tank cap 1 WARNING Gasoline is extremely Engine Oil The following engine oils are recommended API Service Classification SF SG SH or SJ Oil Viscosity Choose the viscosity according to the temperature as follows A K lt SAESW 20 gt SAESW 20 gt lt A SAE1OW 30 SAE1OW 40 I y h SAESW 20 F F F F F F Figure 5 NOTE Using multi grade oils 5W 20 10W 30 and 10W 40 will increase oil
49. ol may not be in a comfortable position You can adjust the handle out by tightening the adjustment wheel Shift Lever Cable Periodic adjustment of the six speed shift cable may be necessary due to normal wear on the cable Adjustment is needed if all six speeds do not work The adjustable cable bracket is located on the left side of the mower beside the engine See Figure 14 Adjustable Cable Bracket Figure 14 e Start engine and place shift lever in the sixth speed position Refer to Figure 13 e Stop engine and disconnect spark plug wire and ground it against engine e Loosen hex nut which secures the adjustable cable bracket See Figure 14 e Push back on the adjustable cable bracket and tighten hex nut Engine Adjustments Refer to the engine manual for these adjustments SECTION 7 MAINTAINING YOUR LAWN MOWER WARNING Always stop the engine and disconnect the spark plug wire before performing any maintenance work or adjustments on your lawn mower Cleaning Mower The underside of the mower deck should be cleaned after each use to prevent any build up of debris If allowed to accumulate it will cause rust and corrosion NOTE We do not recommend the use of pressure washers or garden hose to clean your unit These may cause damage to electric components spindles pulleys bearings or the engine The use of water will result in shortened life and reduce serviceability e Disconnect spark plug wi
50. or other wear and damage Replace the spark plug with a new one if necessary WARNING Hot engine components can cause severe burns Stop engine and allow it to cool before checking spark plug 31 e Check the spark plug gap and reset it if necessary The gap must be between 0 7 and 0 8 mm 0 028 and 0 032 To change the gap bend only the side electrode using a spark plug tool Install and tighten the spark plug to 23 N m 2 3kgf m 17fMb Fit the spark plug cap on the spark plug securely Pull up the spark plug cap lightly to make sure of the installation of the spark plug cap Recommended Spark Plug NGK BPR5ES Figure 17 7 A Spark Plug Gap B Electrodes CAUTION Be sure to use the same type of spark plug for change Resistor spark plug is required in some areas by local law Storage Engine to be stored over 30 days should be completely drained of fuel gasoline to prevent gum deposits forming on essential carburetor parts and the fuel system WARNING Gasoline is extremely A flammable and can be explosive under certain conditions Drain gasoline before storing the equipment for extended periods Drain gasoline in a well ventilated area away from any source of flame or sparks including any appliances with a pilot light Store gasoline in an approved container in safe location e Remove the spark plug cap from spark plug to prevent accidental starting the engine e Empty the fuel from the fuel ta
51. orities for approved disposal methods for possible recycling Cooling System Cleaning Before each use check that the recoil starter A is free from grass and debris and clean to prevent engine overheating EJ12B000 P Drs Figure 13 30 Air Cleaner Service CAUTION To prevent excessive engine vvear do not run the engine vvith the air cleaner A WARNING Clean the elements in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or low flash point solvents to clean the element A fire or explosion could result e Unfasten the air cleaner case C fastened with the air cleaner body D by sliding the tvvo fasteners A toward the recoil starter B Then with two hands pulling the two latches E toward you and upward as shown separate the air cleaner case from the air cleaner body EJ08B002 P Figure 14 A Fasteners B Recoil Starter C Air Cleaner Case D Air Cleaner body E Latches Remove the paper element A and the foam element B from the air cleaner body C EJ088003 P Figure 15 A Paper Element B Foam Element C Air Cleaner body Foam Element Clean the foam element every 25 hours Wash the element in detergent and water and dry it thoroughly CAUTION Do not oil foam element Paper Element e Clean the paper element every 100 hours e Clean
52. r purposes of maintenance repair or replacement of any device or element of design incorporated into any new engine for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the engine after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Do not tamper with the original emission related parts Carburetor and internal parts Spark Plug Magneto or electronic ignition system Fuel filter element Air cleaner elements Crankcase Cylinder head Breather chamber and internal parts Intake pipe and tube General Information Location of Safety Related Labels s EB02B000 P Figure 1 a Warning Refer to b Engine Maintenance Refer to AWARNING FOR SAFE OPERATION READ OWNER S MANUAL eGASOLINE IS FLAMMABLE KEEP AWAY FROM FLAME LL AR OR SPARKS EXHAUST GAS IS POISONOUS DO NOT RUN ENGINE IN AN ENCLOSED AREA eTO AVOID BURN DO NOT TOUGH HOT MUFFLER EB02002BZ2 C ENGINE MAINTENANCE 1 CHECK OIL LEVEL 2 CHECK amp CLEAN AIR CLEANER 3 CLEAN FINS amp SCREEN 4 CHANGE OIL 8 OIL FILTER REFER TO QUNER S MANUAL FOR FURTHER INFORMATION Engine Serial Number The engine serial number is your only means of identifying your particular engine from others of the same model type This engine serial number
53. re e Drain the gasoline from the lawn mower or place a piece of plastic under the gas cap Tip the mower so that it rests on the housing Keep the side with the air cleaner facing up Hold the mower firmly e Scrape and clean the underside of the deck with a suitable tool Do not spray with water e Put the mower back on its wheels on the ground If you had put plastic under the gas cap make sure to remove it now WARNING Never tip the mower more than A 90 degrees in any directions and do not leave the mower tipped for any length of time Oil can drain into the upper part of the engine causing a starting problem Engine Care A list of key maintenance jobs required for good performance by the mower is given below Follow the accompanying engine manual for detailed list and instructions e Change engine oil regularly as instructed in the engine manual Check oil level before starting engine every time Change oil while the engine is warm not hot or cold e Service foam filter in the air cleaner every 25 hours of use and replace the paper filter component every 100 hours You may have to service the air filter more frequently if you are operating the mower under extremely dusty conditions e Clean the engine periodically Remove dirt and debris with a cloth or brush e Clean the spark plug and reset the gap to 030 at least once a season Refer to the engine manual for correct spark plug type Inspect muffler perio
54. rew 1 4 28 x 1 0 8 682 0531 Pivot Arm Assembly 40 741 0682A Bearing Sleeve 9 750 0515 Spacer 510 ID x 70 OD 41 736 0570 Flat Washer 885 ID x 1 45 OD 10 741 0978 Sleeve Bearing 504 ID x 830 OD 42 721 0329 Oil Seal 11 750 1056 Shoulder 43 1721 0325 Plug 12 1710 0653 Tap Screw 1 4 20 x 375 44 618 0253 Upper Housing Assembly 13 682 7528 Chain Cover Assembly 45 782 7601A Cable Bracket 14 1741 0324 Flange Bearing 506 ID x 590 Lg 46 741 0690 Bearing 15 682 7526 Transmission Axle Assembly 47 1736 0616 Thrust Washer 504 ID x 70 OD 16 618 0263A Transmission Assembly Complete 48 782 7595 Pivot Bracket 17 710 0604A Hex Screw 5 16 18 49 741 0324 Flange Bearing 18 1713 0453 Chain 50 1711 1168 Output Shaft 6T 19 1638 0012 Rear Axle Assembly 51 1717 1469 Gear 34T 20 1741 0522 Flange Bearing 506 ID x 715 Lg 52 1741 0674 Bearing 21 732 0832 Torsion Spring 53 1717 1487 Pinion Shaft 10T 22 1750 0151 Spacer 550 ID x 750 OD 54 736 0314 Thrust Washer 3 8 x 70 23 1710 1315 Screw 3 8 16 x 25 55 736 0569 Thrust Washer 388 x 625 24 711 0835 Clevis Pin 50 Dia x 4 82 Lg 56 618 0252 Lower Housing Assembly 25 1750 0807 Spacer 385 ID x 624 OD 57 1710 0642 Hex Screw 1 2 20 x 75 26 782 0568 Hgt Adjustment Spring Bracket 58 611 0066 Shaft Assembly 27 1710 1652 Screw 1 4 14 x 825 59 1664 0121 Grassbag 28 1714 0474 Cotter Pin 60 747 0940A Support Rod w Rope Guide 29 1712 3025 Hex Jam Nut 5 16 24 61
55. rsonal injury to the operator and others e For best results do not cut wet grass It may stick to the underside of the mower preventing proper discharge of grass clippings and could cause you to slip and fall New grass or thick grass may require a narrower cut SECTION 6 MAKING ADJUSTMENTS WARNING Do notat any time make any adjustments without first stopping engine and disconnecting spark plug wire Handle Height Your mower is shipped with the handle in the higher height position To lower the height proceed as follows e Fora healthy lawn always cut off one third or less of the total length of the grass Lawn should be trimmed in fall as long as there is growth IMPORTANT Move the shift lever only when the engine is running Changing the shift lever setting with the engine off can cause damage to the mower WARNING If the mower strikes a foreign A object stop the engine Remove spark plug wire from the spark plug and thoroughly inspect for any damage Repair the damage promptly before restarting and operating the mower Mulching For effective mulching do not cut wet grass New or thick grass may require a narrower cut If the grass has grown in excess of 4 mulching is not recommended Mow using the side discharge to reduce the grass height to 3 25 maximum before mulching Bagging Grass Clippings You can use the grass catcher bag to collect clippings while you are operating the mower e Attach gras
56. rules for safe operation in this manual As with any type of power equipment carelessness or error on the part of the operator can result in serious injury This machine is capable of amputating hands and feet and throwing objects Failure to observe the following safety instructions could result in serious injury or death General Operation 1 Read this operators manual carefully in its entirety before attempting to assemble this machine Read understand and follow all instructions on the machine and in the manual s before operation Be completely familiar with the controls and the proper use of this machine before operating it Keep this manual in a safe place for future and regular reference and for ordering replacement parts This machine is a precision piece of power equipment not a plaything Therefore exercise extreme caution at all times Your unit has been designed to perform one job to mow grass Do not use it for any other purpose Never allow children under 14 years old to operate this machine Children 14 years old and over should read and understand the operation instructions and safety rules in this manual and should be trained and supervised by a parent Only responsible individuals who are familiar with these safe operation rules should use this machine Thoroughly inspect the area where equipment is to be used Remove all stones sticks wire bones toys and other foreign objects which could be tripped over or pic
57. s catcher following instructions on page 8 of this manual Grass clippings will automatically collect in the bag as you run the mower e Operate the mower till the grass bag is full e Stop engine completely by releasing the blade control handle Make sure that the unit has come to a complete stop e While holding the grass bag by both the rear handle and the lower handle lift the grass bag straight up off the adapter The chute door will move the rope out of the way of the bag e Continue to hold the lower handle and raise the rear of the grass bag up toward your chest The grass bag will open and the grass clippings will disperse When replacing the grass bag be sure the top of the bag rests on the wire support between the handles e Remove the starter rope from the rope guide e Remove the wing nuts and carriage bolts securing the upper handle Remove and lay the upper handle out of the way being careful not to bend or kink the cables e Remove the hairpin clips from the weld pins on the handle brackets and remove the wing nuts and carriage bolts from the upper hole on the handle mounting bracket e Press out on the legs of the lower handle and remove lower handle from the mower e Turn lower handle around so the notch on the bottom of the lower handle is facing forward See Figure 12 I gt Notch Lower Handle 9 Figure 12 e Reassemble the handles placing the bottom holes in the handle over the weld pins
58. s up to 30 in any direction e Refer to the operating instructions of the equipment this engine powers e Because of equipment design or application there may be more stringent restrictions regarding the angle of operation CAUTION Do not operate this engine continuously at angles exceeding 30 in any direction Engine damage could result from insufficient lubrication Stopping Stopping Engine Release the brake control lever A on the equipment from the handle B on the equipment to stop the engine and the cutting blade A Brake Control Lever Adjustment B Handl andle Engine Speed Adjustment NOTE Do not tamper with the governor setting or the PE carburetor setting to increase the engine speed Each carburetor is adjusted at the factory vvith either a cap or stop plate installed on the mixture screw Any adjustments must be performed an authorized Kawasaki dealer EG028000 P Figure 10 MAINTENANCE MAINTENANCE INTERVAL DAILY FIRST 8 EVERY 25 EVERY 50 HOURS HOURS HOURS Check oil level and add engine oil Check for loose or lost nuts and screws Check for fuel and oil leakage lever function Check or clean recoil starter and air intake screen Tighten nuts and screws 4 Clean air cleaner foam element Clean air cleaner paper element Change engine oil Clean and re gap spark Plug Replace air cleaner paper element Clean dust and dirt from cylinder and cylinder head fins
59. ten wing nuts on each side of the handle making sure that the carriage bolts are seated properly into the handle See Figure 3 e Remove hairpin clip from the outer hole of the weld pin on each handle brackets Using a pair of pliers squeeze one leg of the lower handle against the handle bracket Insert the hairpin clip into the inner hole on the weld pin Repeat on the other side See Figure 4 e After moving the hairpin clip insert the carriage bolt from the hardware pack in the upper hole on the handle mounting bracket and secure with plastic wing nut also from the hardware pack See Figure 4 Repeat on the other side a Carriage Bolt Lower Handle Wing Nut Handle Mounting Bracket Figure 4 e Fasten the cable to the lower handle with the two cable ties found on the lower handle Pull the cable ties tight and trim off the excess See Figure 5 Cable Tie Lower va f Handle Figure 5 Attaching Starter Rope NOTE Make certain the drive cable is routed around the outside and above the lower handle so it does not interfere with attaching the grass bag e The rope guide which is connected to the support rod is located on the right side of the lower handle See Figure 6 e With the spark plug wire disconnected and grounded hold the blade control handle against the upper handle and pull the starter rope out of the engine Release the blade control handle Slip the starter rope into the rope guide
60. ture reference WARNING The operation of any lawn A mower can result in foreign objects being thrown into the eyes which can damage your eyes severely Always wear safety glasses while operating the mower or while performing any adjustments or repairs on it Blade Control Handle The blade control handle is located on the upper handle of the mower The blade control handle must be depressed in order to operate the unit Release blade control handle to stop engine and blade WARNING This blade control mechanism is a safety device Never attempt to bypass its operations Cutting Height Adjustment Levers The cutting height adjustment lever is located above the left rear wheel To adjust the cutting height refer to the Adjustment Section in this manual Recoil Starter The recoil starter is attached to the right upper handle Stand behind the unit and pull the recoil starter rope to start the unit Side Discharge Chute xy amp Mulch Plug Drive Clutch Control The drive clutch control is located on the upper handle Squeeze the drive control to engage the drive system Release the clutch control to disengage the drive system Release the clutch control to slow down when approaching an obstacle making a turn or stopping Shift Lever The shift lever is located on the drive clutch control housing on the upper handle This lever is used to select the forward speed of the mower When changing speed
61. two years in California In all other states 1997 and later model year small off road engines are warranted for two years If any emission related part on your engine is defective the part will be repaired or replaced by Kawasaki This warranty time period shall begin on the date the small off road engine is delivered to the initial purchaser or on the date the small off road engine is first placed in service Warranty defects shall be remedied during customary business hours at any authorized Kawasaki small off road engine dealer located within the United States of America Any manufacturer approved replacement part may be used in the performance of any warranty maintenance or repairs on emission related parts and must be provided without charge to the owner if the part is still under warranty Any part or parts replaced under this warranty shall become the property of Kawasaki The emission related warranted parts are specifically defined by the California Air Resources Board s Emission Warranty Parts List EPA s regulations do not include a parts list but EPA considers emission related parts to include all parts listed here These warranted parts are carburetor and internal parts spark advance retard system cold start enrichment system magneto or electronic ignition system catalytic converter intake manifold exhaust manifold air cleaner element and spark plugs if failure occurs prior to the first required scheduled replacement hoses cla
62. uctions and safety rules in this manual and should be trained and supervised by a parent Service Safe Handling of Gasoline 1 To avoid personal injury or property damage use extreme care in handling gasoline Gasoline is extremely flammable and the vapors are explosive Serious personal injury can occur when gasoline is spilled on yourself or your clothes which can ignite Wash your skin and change clothes immediately Use only an approved gasoline container Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner Always place containers on the ground away from your vehicle before filling 5 If possible remove gas powered equipment from the truck or trailer and refuel it on the ground If this is not possible then refuel such equipment on a trailer with a portable container rather than froma gasoline dispenser nozzle 6 Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete Do not use a nozzle lock open device 7 Extinguish all cigarettes cigars pipes and other sources of ignition 8 Never fuel machine indoors because flammable vapors will accumulate in the area 9 Never remove gas cap or add fuel while the engine is hot or running Allow engine to cool at least two minutes before refueling BON 10 11 If gasoline is spilled wipe it off the engine and 13 14 15 Never over fill fuel tank Fill ta
63. w belt over the transmission pulley Start the belt in the pulley groove and rotate the pulley until the belt is seated in transmission pulley e Place the belt between the idler pulley and the belt keeper bracket e Using pliers rotate the belt keeper bracket so that it snaps into slot on the idler bracket e Tighten the idler pulley bolt and lock nut half a turn e Place the belt between the two pulley halves on the crankshaft Make sure to route the belt inside the belt guard pin See Figure 21 Hex Bolt Cutting Height Adjustment Wheel Figure 18 e Tilt the transmission forward and loosen the idler pulley bolt and lock nut half a turn See Figure 19 ee Pull A s ont a Belt eases Ke Belt Keeper Ud Bracket a es Idler Pulley ee T Bracket Transmission Figure 21 Idler Pulley I Bolt and IMPORTANT When replacing the belt do not disas Locknut semble the lower pulley assembly Figure 19 e Pinch both sides of the belt together so that the belt is not in the pulley groove and the lower pulley can e Using a pair of pliers pull back and rotate belt be pushed towards the engine See Figure 22 keeper bracket from the slot on the idler pulley e Slide the belt out from between the belt keeper Lower Pulley bracket and the idler pulley See Figure 19 Half 89 DS e Squeeze the belt together and push it forward o Belt while pressing the control arm inward towards the deck and remove
64. ystem e Recoil starter e Dry weight e 13 5kg 29 Ib Specifications subject to change without notice 33 KAWASAKI LIMITED WARRANTY CALIFORNIA AND FEDERAL EMISSION CONTROL SYSTEMS SMALL OFF ROAD ENGINES The California Air Resources Board the Environmental Protection Agency EPA and Kawasaki Motors Corp U S A hereinafter Kawasaki are pleased to explain the Emission Control Systems Warranty on your Kawasaki small off road engine In California and other states new small off road engines must be designed built and equipped to meet stringent anti smog standards Kawasaki must warrant the emission control system on your small off road engine for the period of time listed below provided there has been no abuse neglect or improper maintenance of your small off road engine Your emission control system may include parts such as the carburetor or fuel injection system the ignition system and catalytic converter Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists Kawasaki will repair your small off road engine at no cost to you including diagnosis if the diagnostic work is Performed at a Kawasaki small off road engine dealer parts and labor OWNERS WARRANTY RESPONSIBILITIES The following obligations must be fulfilled by the owner to maintain the validity of the Kawasaki California EPA Emissions Systems Warranty a As the small off road

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