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 contain carbon monoxide and can cause serious illness or death.

Move the vehicle to an outside area before running the engine.

Do not run an engine in an enclosed area without adequate ventilation.

· Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area.

· Allow fresh outside air into the work area to clear the exhaust fumes out.

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 and let it cool.


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

1. Park mower on level surface and stop engine.

MX7423

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

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


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

M X7488

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

5. Add oil if necessary.

6. Install and tighten dipstick.

Changing Engine Oil

c CAUTION: Avoid injury!

· Used oil will harm environment and people if it is dumped on ground or into drain or 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 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 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.

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


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

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5. Insert plastic drain tube supplied with mower 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 dipstick filler tube location into drain pan.

9. After oil has drained, return mower to 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 mower on level surface and stop engine.

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

2. Let engine cool.

3. Disconnect spark plug wire.

4. Clean dirt and debris from air cleaner cover.

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

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

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

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

c. Rinse pre-cleaner thoroughly. Squeeze out excess water in 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 paper element without removing it. If paper element is damaged or dirty, remove and replace it with 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 it cool.

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1. Park mower on level surface and stop engine.

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

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

4. Inspect plug for damage. Replace damaged plug.

5. Adjust gap: 0.51 mm (0.02 in.).

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

7. 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.

1. Park mower on level surface and stop engine.

2. Let engine cool.

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3. Clean fins (A) and under cover (B) with brush, rag, or compressed air.

Cleaning Drive Belt and Transmission Area

c CAUTION: Avoid injury! Before you remove shield:

· Stop engine. Let it cool.

· Do not operate mower without belt shield in place.

1. Park mower on level surface and stop engine.

2. Disconnect spark plug wire.

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3. Remove screws (A), belt shield (B), and drag flap (C).

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4. Remove control cables (D) from belt shield notch (E).

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Picture Note: Belt area and top of transmission

5. Remove grass clippings from belt area and top of transmission.

6. Slide control cables into belt shield notch.

7. Install drag flap and belt shield with screws.

Checking and Replacing Drive Belt

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 mower blade area.

· Do not operate mower without belt shield.

1. Park mower on level surface and stop engine.

2. Disconnect spark plug wire.

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3. Remove screws (A), belt shield (B), and drag flap (C).

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4. Remove control cables (D) from belt shield notch (E).

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5. Inspect belt (F) for excessive wear or damage.

To Replace Drive Belt:

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

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1. Push down on front of drive sheave (G) to relieve spring tension on belt (F) and remove drive belt.

NOTE: Tension spring (H) may come loose when drive belt is removed. Install after you replace belt.

2. Move belt through deck opening (I) into underside of mower deck.

3. Turn mower on its left side.

c CAUTION: Avoid injury! Mower blades are sharp. Always wear gloves when handling mower blades or working near blades.

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4. Remove drive belt (F) from blade sheave (J) and mower blade.

5. Install new drive belt over mower blade and onto blade sheave.

MX7491

6. Insert belt back through deck opening (I).

7. Return mower to upright position.

8. Install tension spring (H) if removed.

9. Push down on front of drive sheave (G) and install belt on sheave.

10. Slide control cables into belt shield notch.

11. Install drag flap and belt shield with screws.

Adjusting Transmission Cable

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. Park mower on level surface and stop engine.

2. Disconnect spark plug wire.

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3. Remove screws (A), belt shield (B), and drag flap (C).

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

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4. Remove control cables (D) from belt shield notch (E).

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5. Push down on front of drive sheave (F) to relieve spring tension on belt and remove drive belt (G).

6. Remove E-clip (H) and drive sheave.

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7. Measure the clutch spring length (I) in the relaxed position. Record this value.

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8. Engage the traction clutch lever (at handle bar) and measure the spring length in the extended position (J).

· The spring extension length (the difference between I and J measurements) must be 10 mm (0.390 in.).

M96827

9. Use 8 mm wrench to loosen (but not remove) cable mount bracket capscrews (K) to adjust spring extension.

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

M96827

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

11. Repeat steps 7-8 to verify 10 mm (0.390 in.) spring extension length.

12. Install cables through notch in belt shield.

13. Install drag flap and belt shield with screws.

14. Connect spark plug wire.

15. Start engine and check that transmission is operating properly.

NOTE: Make sure transmission immediately disengages when traction clutch lever is released.

16. If transmission does not disengage when lever is released, reduce spring extension length and check that transmission is operating properly.

Lubricating Drive Shaft Hub Bushings

MX7489

1. Remove screws (A), belt shield (B), and drag flap (C).

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

M93048

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

4. Slide control cables (D) into belt shield notch (E).

5. Install drag flap and belt shield with screws.

Lubricating Mower Axles

1. Tip mower to one side to raise mower wheels slightly off ground. Use wood blocks to keep side of mower raised.

MX7493

2. Use a screwdriver in slot (A) to pry hubcap from each wheel.

M93051a

3. Remove locknut (B).

4. Remove wheel from each axle.

M93050

5. Apply a light coating of multi-purpose grease to each axle (C).

6. Install wheels, hardware and hubcaps.

7. Lower mower.

8. Repeat procedure for wheels on other side of mower.

Greasing Caster Wheel Spindle

MX7501

1. Grease caster wheel spindle hole with multi-purpose grease.

2. Repeat for other caster wheel.

Cleaning Caster Wheel Pin

MX7498

1. Remove cover (A) on caster wheel.

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2. Clean dirt from around and on pin and spring (B).

3. Install cover.

Checking and Removing Blade

c CAUTION: Avoid injury! Service blade safely:

· Stop engine. Let it cool.

· Disconnect spark plug wire.

· Wear gloves or wrap blade with 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.

M87085

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

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

Removing Blade:

· Remove bolt (A), washer (B), and 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

c CAUTION: Avoid injury! Fuel vapors are explosive and flammable:

· Shut engine off before filling fuel tank.

· Do not smoke while handling fuel.

· Keep fuel away from flames or sparks

· Fill fuel tank outdoors or in well ventilated area.

· Clean up spilled fuel immediately.

· Use clean approved non-metal container to prevent static electric discharge.

· Use clean approved plastic funnel without screen or filter to prevent static electric discharge.


IMPORTANT: Avoid damage! Dirt and water in fuel can cause engine damage: · Clean dirt and debris from the fuel tank opening. · Use clean, fresh, stabilized fuel. · Fill the fuel tank at the end of each day's operation to keep condensation out of the fuel tank. · Use a non-metallic funnel with a plastic mesh strainer when filling the fuel tank or container.

Use regular grade 87 octane unleaded fuel.

Add John Deere fuel stabilizer to fuel before using it in your machine to prevent engine damage due to stale fuel. Follow directions on stabilizer container.

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.

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3. Remove fuel cap (A).

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

5. Install fuel cap.

Cleaning Fuel Cap Vents

c CAUTION: Avoid injury! Before you remove cap:

· Stop engine. Let it cool.

· Do not smoke.

1. Remove fuel cap.

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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.

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