Service

Maintenance, repair, or replacement of the emission control devices and systems on this engine, which are being done at the customers expense, may be performed by any nonroad engine repair establishment or individual. Warranty repairs must be performed by an authorized John Deere dealer.

Adjusting Carburetor

NOTE: Carburetor is calibrated by the engine manufacturer and should not require any adjustments.

NOTE: If engine is operated at altitudes above 1829 m (6,000 ft.), some carburetors may require a special high altitude main jet. See your John Deere dealer.

If engine is hard to start or runs rough, check the TROUBLESHOOTING section of this manual.

After performing the checks in the troubleshooting section and your engine is still not performing correctly, contact your John Deere dealer.

Avoid Fumes

c CAUTION: Avoid injury! Engine exhaust fumes can cause sickness or death:

· If it is necessary to run an engine in an enclosed area, use an exhaust pipe extension to remove the fumes.

· Always try to work in a well ventilated area.

Engine Oil

MIF

Use oil viscosity based on the expected air temperature range during the period between oil changes.

The following John Deere oils are preferred:

· TORQ-GARD SUPREME® (SAE 30)

The following John Deere oils are also recommended, based on their specified temperature range:

· TURF-GARD® (SAE 10W-30)

· PLUS-4® (SAE 10W-30)

Other oils may be used if above John Deere oil is not available, provided they meet one of the following specifications:

· SAE 10W-30-API Service Classification SG or higher

· SAE 30-API Service Classification SC or higher

Checking Engine Oil Level

c CAUTION: Avoid injury! Before you check or add oil, STOP engine. Let it cool.


IMPORTANT: Avoid damage! Change oil after first 5 hours of operation.

1. Stop engine. Put mower on a level surface.

M96540

2. Turn oil dipstick (A) 1/4 turn counterclockwise. Remove dipstick and wipe it with a clean cloth.


IMPORTANT: Avoid damage! If oil level is below the ADD mark, DO NOT run the engine.

3. Install dipstick. Turn dipstick 1/4 turn clockwise and tighten.

M61459

4. Remove dipstick. Check oil level. Oil level MUST BE between ADD and FULL marks. If not, pour oil into dipstick tube to bring level to FULL mark (B).

5. Install and tighten dipstick.

Changing Engine Oil

c CAUTION: Avoid injury!

· Used oil may harm environment and people if it is dumped on the ground or into a drain or a body of water. Call your local Recycling Center or John Deere dealer to learn how to recycle used oil.

· Engine may be hot, use caution to avoid burns to the hands.


IMPORTANT: Avoid damage! · Change oil after first 5 hours of operation. · Change oil while engine is warm. · If mower is not operated 25 hours during the mowing season, change oil before storing mower. · Help prevent air cleaner damage and hard starting, turn mower onto the LEFT side when servicing.

NOTE: Two different methods can be used for changing the engine oil. Both options are acceptable service procedures based on customer preference.

TO CHANGE ENGINE OIL FROM THE TOP:

1. Park mower on a level surface.

2. Run engine until fuel tank is empty or near empty.

3. Stop engine and disconnect spark plug wire.

M88826

4. Turn oil dipstick (A) 1/4 turn left and remove from the filler tube.

M87111d

5. Insert plastic drain tube (B) firmly inside filler tube opening.

6. Place a drain pan on the left side of the mower.

c CAUTION: Avoid injury! Fuel is highly flammable. Prevent fuel from contacting hot surfaces: DO NOT drain fuel tank. Run engine until fuel tank is very low or empty before turning mower on side to change oil.

7. Turn mower onto its LEFT SIDE.

8. Allow engine oil to drain from the dipstick filler tube location into the drain pan.

9. After oil has drained, return mower to an upright position.

10. Remove plastic drain tube. Clean area around filler tube.

11. Add approximately 0.47 L (16 oz) oil through dipstick filler tube.

12. Install dipstick. Turn dipstick 1/4 turn right to tighten.

13. Remove dipstick. Check oil level. Add oil to FULL mark if necessary.

14. Install and tighten dipstick.

15. Connect spark plug wire.

c CAUTION: Avoid injury! Be careful of sharp edges on mower blades. Wear gloves when working under deck.

TO CHANGE ENGINE OIL FROM THE BOTTOM:

1. Stop engine and disconnect spark plug wire.

MIF

2. Raise cutting height adjustment levers (A) to the highest cutting position. (See Adjusting Cutting Height in the Operating section.) Elevate entire mower an additional 102 mm - 203mm (4-8 in.) using wooden blocks or bricks.

3. Place a drain pan under the mower.

M87113

4. Remove drain plug (B) from underside of mower using a 3/8 in. square drive.

5. After oil has drained, clean and install drain plug.

6. Turn oil dipstick 1/4 turn to the left. Remove dipstick.

7. Add approximately 0.47 L (16 oz) oil through the dipstick filler tube.

8. Install dipstick. Turn dipstick 1/4 turn right to tighten.

9. Remove dipstick. Check oil level. Add oil to FULL mark if necessary.

10. Install and tighten dipstick.

11. Lower mower.

12. Return cutting height adjustment levers to a desirable cutting height.

13. Connect spark plug wire.

Cleaning and Replacing Air Cleaner Element

c CAUTION: Avoid injury! Before you work on engine:

· STOP engine. Let it cool.


IMPORTANT: Avoid damage! Dirt and debris can enter the engine through a damaged filter element. · Do not wash paper element/ · Do not attempt to clean paper element by tapping against another object. · Do not use pressurized air to clean element. · Replace element only if it is very dirty, damaged or the seal is cracked.

1. Stop engine and disconnect spark plug wire.

M87083

2. Clean area around cover (A).

3. Loosen screw (B). Tilt cover (A) down.

M87084

4. Remove paper air cleaner element (C).

5. Tap element gently to remove dust.

6. Replace an element:

· That is oily or sooty.

· With a break, hole, or damaged seal.

· If engine performance is poor.

7. Install air cleaner element.

8. Rotate cover to a closed position.

9. Tighten screw. DO NOT overtighten.

Cleaning and Gapping Spark Plug

c CAUTION: Avoid injury! Before you remove plug:

· STOP engine. Let it cool.

M88829

1. Disconnect spark plug wire (A). Remove plug (B).

2. Carefully wire brush carbon from plug. Do not clean it with abrasives in a machine.

3. Inspect plug for damage. Replace damaged plug.

4. Adjust gap to 0.76 mm (0.030 in.).

5. Install and tighten plug to 20 N·m (15 lb-ft).

6. Connect spark plug wire.

Cleaning Engine Cooling Fins

c CAUTION: Avoid injury! Prevent personal injury. Wear eye protection to guard against flying debris.


IMPORTANT: Avoid damage! Keep fins clean or engine may overheat.

M88827

Clean fins (A) with a brush, rag, or compressed air.

Also, blow compressed air under the shroud.

Cleaning Drive Belt and Transmission Area JS61 and JS63

c CAUTION: Avoid injury! Before you remove shield:

· STOP engine. Let it cool.

· DO NOT operate mower without belt shield in place.

M96556

1. Remove hardware (A) and belt shield (B).

M93055

2. Remove control cables (C) from belt shield notch (D).

M96557

3. Remove clippings from belt area and top of the transmission.

4. Slide control cable into belt shield notch.

5. Install belt shield.

Checking and Replacing Drive Belt JS61 and JS63

c CAUTION: Avoid injury! Before removing belt shield:

· Stop engine and wait for all moving parts to stop.

· Prevent burns by allowing engine to cool.

· Disconnect spark plug wire.

· Wear protective gloves when service is performed within the mower blade area.

· DO NOT operate mower without belt shield.

1. Stop engine and disconnect spark plug wire.

M96556

2. Remove hardware (A) and belt shield (B).

M93055

3. Remove control cables (C) from belt shield notch (D).

M96557

4. Inspect belt (E) for excessive wear or damage.

TO REPLACE DRIVE BELT:

NOTE: On model JS61 only, the anti-rotation bracket must be removed prior to pushing the drive sheave forward to remove the drive belt.

MX1578

Picture Note: View is from underside of differential.

1. Remove cap screw (F) and anti-rotation bracket.

c CAUTION: Avoid injury! Wear protective eyewear when removing belt from drive sheave. Tension spring may come loose.

MX1576

2. Push drive sheave (G) forward to relieve spring tension on belt.

NOTE: Tension spring (H) may come loose when belt is removed.

3. Remove belt from drive sheave.

4. Move belt into underside of mower deck.

5. Turn mower onto its LEFT SIDE.

6. Remove mower blade. (See Check Blade in this section.)

7. Remove drive belt from blade sheave.

8. Install new drive belt to blade sheave.

M96554

9. Insert belt through deck opening (I).

10. Install tension spring (H) if removed.

11. Check that drive belt is installed on engine sheave.

12. Push drive sheave (J) forward and install belt to sheave.

13. Install anti-rotation bracket and secure with cap screw.

14. Install mower blade.

· Tighten mower blade bolt to 75 N·m (55 lb-ft).

15. Lower mower.

16. Slide control cables into belt shield notch.

17. Install belt shield and connect spark plug wire.

Transmission Cable Adjustment-JS63

c CAUTION: Avoid injury! Help prevent bodily injury. Before removing belt shield:

· Stop engine and wait for all moving parts to stop.

· Prevent burns by allowing engine to cool.

· Disconnect spark plug wire.

· Wear protective gloves when service is performed within the mower blade area.

· DO NOT operate mower without belt shield.

1. Stop engine and disconnect spark plug wire.

M96556

2. Remove hardware (A) and belt shield (B).

c CAUTION: Avoid injury! Avoid possible injury: Wear protective eye wear when removing belt from drive sheave. Tension spring may come loose.

NOTE: Transmission cable adjustment can be performed without removing belt and pulley. The belt and pulley have been removed for clarity of pictures.

M93055

3. Remove control cables (C) from belt shield notch (D)

MX1577

4. Push drive sheave (E) forward to relieve spring tension on belt and remove drive belt (F).

5. Remove E-clip (G) and drive sheave.

M96828

6. Measure the clutch spring length (H) in the relaxed position. Record this value.

M96831

7. Engage the transmission bail (at handle bar) and measure the spring length in the extended position (I).

8. The spring extension length (the difference between A and B measurements) must be 10 mm (0.390 in.).

M96827

9. To adjust spring extension, use an 8 mm wrench, loosen (do not remove) the cable mount bracket capscrews (J)

NOTE: For transmission clutch to operate properly, there must be a certain amount of spring pressure engaging the cones or the transmission will slip and NOT drive the wheels.

M96827

10. Slide bracket (K) the required distance to obtain the 10 mm (0.390 in.) spring extension length (difference between the length of the relaxed spring and the length of the extended spring). Tighten capscrews.

11. Repeat steps 6 and 7 to verify the 10 mm (0.390 in.) spring extension length.

12. Install cables through notch in cover.

13. Install cover and secure with two bolts and two bolts and nuts. Make sure shield is installed with cover.

14. Start engine and verify the transmission is operating properly.

NOTE: Make sure the transmission immediately disengages when the bail is released.

15. If transmission does not disengage when bail is released, reduce spring extension length, and verify transmission is operating properly.

Lubricate Drive Shaft Hub Bushings

Service Interval: Lubricate drive shaft hub bushings every 25 hours or once a year.

M96556

1. Remove hardware (A) and belt shield (B).

M93055

2. JS61 & JS63: Remove control cable (C) from belt shield notch (D).

M93048

3. Tilt mower slightly to one side. Lubricate driveshaft hub bushing (E) with a few drops of light weight motor oil. Repeat procedure for other side.

4. JS61 & JS63: Slide control cables (C) into belt shield notch (D).

5. Install belt shield.

Lubricate Mower Axles

Service Interval: Lubricate each mower axle every 25 hours or once a year.

1. Tip mower to one side to elevate mower wheels slightly off the ground. Use a wood block to keep side of mower in a raised position.

M93049

2. Remove plastic hubcaps (A).

· Use a screwdriver in slot (B) to pry the hubcap from each wheel.

M93051a

3. Remove locknut (C).

4. Remove wheel from each axle.

M93050

5. Apply a light coating of grease to each axle (D).

6. Install wheels, hardware and hubcaps.

7. Lower mower.

8. Repeat procedure on other side of mower.

Check Blade

c CAUTION: Avoid injury! Service blade safely:

· STOP engine. Let it cool.

· Disconnect spark plug wire.

· Wear gloves or wrap blade with a rag.


IMPORTANT: Avoid damage! To help prevent air cleaner damage and hard starting: · Turn mower on its LEFT SIDE.

NOTE: Sharpened edges on blade tips must face upward when installing blade.

CHECK BLADE:

· Replace damaged blade.

M87085

· Tighten Bolt (A) to 75 N·m (55 lb-ft).

· Sharpen dull blade. (See Sharpening Blade in this section.)

TO REMOVE BLADE:

· Remove bolt (A), washer (B), and blade.

Sharpening Blade

c CAUTION: Avoid injury! To avoid injury, wear gloves and goggles when sharpening, balancing or installing blade.


IMPORTANT: Avoid damage! Balance blade after you sharpen it. An unbalanced blade may cause excessive vibration.

Sharpen blade with grinder, hand file or electric blade sharpener.

M61830

Keep original bevel (A) when you grind. Blade should have 0.40 mm (1/64 in.) cutting edge (B).

Balance and Install Blade

M61524

1. Clean blade. Put it on a nail in vise or on a wall. Heavy end of blade will drop. Grind bevel of heavy end. Do not change bevel.

2. Install blade, washer, and bolt.

3. Tighten bolt to 75 N·m (55 lb-ft).

Filling Fuel Tank


IMPORTANT: Avoid damage! Dirt and water in fuel are major causes of engine performance problems. Prevent dirt and debris from entering the fuel tank when filling. Fill the tank at the end of each day's operation to help keep condensation out of the fuel tank. Fuel tank capacity is 1.5 L (1.6 qt).

1. STOP engine. If engine is hot let it cool several minutes before you add fuel.

2. Remove grass clippings and other trash from tank area.

3. Remove fuel tank cap.

4. Fill tank with fresh fuel only to bottom of filler neck.

5. Install fuel tank cap.

Cleaning Fuel Cap Vent

M73283

1. Check two vents (A) under metal ring of fuel cap and vent in top, center of cap.

2. Clean cap and vents in nonflammable solvent. Allow cap to dry.

3. Install the cap.

About Our Site | Privacy | Legal