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.

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.

Possible engine surging will occur at high rpm when the transmission and the blades are disengaged. This is a normal condition due to the emission control system.

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 level surface.

MX7423

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

3. Wipe dipstick off with a clean cloth.


IMPORTANT: Avoid damage! If oil level is below ADD mark, do not run engine.

4. Install dipstick.

M73272

5. Remove dipstick. Check oil level. Oil should be between ADD and FULL marks shown on dipstick, not above FULL mark.

6. Add oil, if necessary.

7. 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.

· Fuel is highly flammable. To prevent fuel spillage from occurring, drain fuel from tank before tipping mower to drain oil.


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 its left side when servicing.

1. Park mower on a level surface.

2. Drain fuel from tank or run engine until fuel tank is empty or near empty.

3. Stop engine and disconnect spark plug wire.

MX7423

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

MX7432

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

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

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

12. Install dipstick. Turn dipstick 1/4 turn clockwise 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.

Checking and Cleaning Air Cleaner Element

1. Park machine safely. (See Parking Safely in the Safety Section.)

c CAUTION: Avoid injury! Touching hot surfaces can burn skin. The engine and components will be hot if the engine has been running. Allow the engine to cool before servicing.

2. Let engine cool.

3. Disconnect spark plug wire.

4. Clean dirt and debris from the air cleaner cover.

MX7424

5. Loosen screws (A), and remove cover.

MX7425

6. Inspect the foam pre-cleaner (B) without removing it. If the foam pre-cleaner is dirty:

a. Remove it from the filter carefully, leaving the paper element in the air cleaner housing.

b. Wash pre-cleaner in a solution of warm water and liquid detergent.

c. Rinse pre-cleaner thoroughly. Squeeze out excess water in a dry cloth until pre-cleaner is completely dry.


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.

7. Inspect the paper element without removing it. If the paper element is damaged or dirty, remove and replace it with a new element.

8. Clean air cleaner base carefully, preventing any dirt from falling into carburetor.

9. Install foam pre-cleaner onto paper element and install into air cleaner base.

10. Close cover and tighten screws. Do not overtighten.

Cleaning and Gapping Spark Plug

c CAUTION: Avoid injury! Before you remove spark plug:

· Stop engine. Let engine cool.

MX7426

1. Disconnect spark plug wire (A). Remove spark 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: 0.51 mm (0.02 in.).

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

6. Connect wire.

Cleaning Engine Cooling Fins

c CAUTION: Avoid injury! Before you clean fins:

· Stop engine.

· Let it cool.

· Wear eye protection to guard against flying debris.


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

MX7427

1. Clean fins with brush, rag, or compressed air.

2. Blow compressed air under shroud.

Adjusting Throttle Cable

c CAUTION: Avoid injury! Before you adjust cable:

· Stop engine. Let engine cool.

1. Push throttle lever to fasposition.

MX7433

2. Loosen screw (A) until cable sheath (B) moves freely.

3. Grasp cable sheath (B) and pull toward rear of machine until cable sheath stops moving.

4. Tighten screw (A).

Adjusting Traction Cable

c CAUTION: Avoid injury! Do not operate mower without belt shield. Before you adjust clutch:

· Stop engine. Let it cool.

· Keep people and pets away from mower.

· Keep hands and tools away from belt area when engine is running.

NOTE: Adjust clutch if mower slows as it goes uphill.

M88840

1. Unscrew and remove knob (A).

2. Apply slight pressure to the top of protective shield (B) to release tabs securing shield to the mower deck.

3. Remove shield.

MX7428

4. Loosen nut (C).Turn nut (D) down 6 mm (1/4 in.).

5. Tighten nut (C).

6. Start engine.

7. Engage traction clutch lever to check clutch action.

8. If clutch needs more tension, repeat Steps 4 and 5.

NOTE: Pulley (E) should not turn when engine is running and clutch lever is disengaged. If pulley turns when engine is running, traction clutch cable is adjusted too tight.

9. Stop engine.

10. Install shield and knob.

Adjusting Blade Brake Clutch

c CAUTION: Avoid injury! Do not operate mower unless belt shield is in place.

NOTE: Blade should stop within 3 seconds after you release blade stop lever. If not, adjust clutch.

1. Put blade engagement lever on handlebar all the way to the rear.

2. Remove knob and protective belt shield.

M62536

3. Loosen nut (A).

4. Pull threaded fitting to rear to remove all cable slack.

5. Turn nut (B) against deck fork.

6. Tighten nut (A).

M88842

7. Make sure there is tension on cable (C), but that it is not too loose or too tight. This will give maximum blade brake clutch engagement.

8. Install shield and knob.

Grease

MIF

Use grease based on the expected air temperature range during the service interval.

The following greases are preferred:

· John Deere MOLY HIGH TEMPERATURE EP GREASE

· John Deere HIGH TEMPERATURE EP GREASE

· John Deere GREASE-GARD

Other greases may be used if they meet one of the following:

· SAE Multipurpose EP Grease with a maximum of 5% molybdenum disulfide.

· SAE Multipurpose EP Grease

Lubricating Rear Axle Bushings

NOTE: Adjust mower height indicator until zerk is easy to get grease gun on.

1. Wipe grease fittings clean.

M61549

2. Lubricate bushing (A) on each side of mower with one shot of grease.

Cleaning Mower

c CAUTION: Avoid injury! Before you clean mower:

· Stop engine. Let engine cool.

· Disconnect spark plug wire.

· Turn mower onto its left side to clean under the deck.


IMPORTANT: Avoid damage! · Do not use high pressure spray when cleaning under the deck. High pressure spray my cause damage to clutch and transmission parts. · To help extend clutch life, wait at least 30 minutes after mowing before cleaning under the deck with water. · After cleaning with water, start the engine and engage the blade for about 15 seconds to "spin dry" the clutch. If you need to clean under the deck immediately after mowing use a scraper, not water.

· Clean grass clippings that may build up between the wheels and the mower deck.

· Remove and shake bag to remove clippings.

· If bag is caked with grass on the inside, use water under pressure to clean bag. Direct water from outside to inside of bag.

· See other Service sections for additional, specific cleaning information.

Cleaning Belt and Transmission Area

c CAUTION: Avoid injury! Before you remove shield:

· Stop engine. Let it cool.

· Do not operate mower without belt shield.


IMPORTANT: Avoid damage! Do not use water when cleaning the belt and transmission areas.

M88840

1. Unscrew and remove knob (A).

2. Apply slight pressure to the top of protective shield (B) to release tabs securing shield to the mower deck. Remove shield.

M62534

3. Remove clippings or debris from belt area and top of transmission using a brush or compressed air.

4. Install shield and knob.

Cleaning Fuel Cap Vents

c CAUTION: Avoid injury! Before you remove cap:

· Stop engine. Let it cool.

· Do not smoke.

1. Remove fuel cap.

MX7434

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

3. Clean cap and vents in nonflammable solvent. Let cap dry.

4. Install cap.

Checking 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.

Checking Blade:

· Replace damaged blade.

M88854

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

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

Removing Blade:

· Remove bolts (A) and blade.

NOTE: Make sure blade tip wing points up and washer cup is against blade.

Sharpening Blade

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

· 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).


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

Balancing and Installing 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, washers (cup-side against blade), and bolts.

3. Tighten bolts to 75 N·m (55 lb-ft).

Filling Fuel Tank


IMPORTANT: Avoid damage! Avoid spilling fuel. Fuel can damage plastic and painted surfaces. Do not mix oil with gasoline. Unleaded gasoline with an octane rating of 87 or higher is recommended. 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.

MX7429

3. Remove fuel cap (A).

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

5. Install fuel cap.

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Introduction

Product Identification

Safety

Operating

Replacement Parts

Service Intervals

Service

Troubleshooting

Storing Machine

Assembly

Specifications

Warranty

John Deere Quality Statement

Service

Engine Warranty Maintenance Statement

Adjusting Carburetor

Avoid Fumes

Engine Oil

Checking Engine Oil Level

Changing Engine Oil

Checking and Cleaning Air Cleaner Element

Cleaning and Gapping Spark Plug

Cleaning Engine Cooling Fins

Adjusting Throttle Cable

Adjusting Traction Cable

Adjusting Blade Brake Clutch

Grease

Lubricating Rear Axle Bushings

Cleaning Mower

Cleaning Belt and Transmission Area

Cleaning Fuel Cap Vents

Checking Blade

Checking Blade:

Removing Blade:

Sharpening Blade

Balancing and Installing Blade