Service Engine

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.

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

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

The following oil is preferred:

TS1412

· John Deere PLUS-4®

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

· API Service Classification SG

· API Service Classification SF

· CCMC Specification G4

Oils meeting Military Specification MIL-L-46167B may be used as arctic oils.

Fuel

c CAUTION: Avoid injury! Handle fuel with care, it is highly flammable:

· DO NOT refuel machine while you smoke, when machine is near an open flame or sparks, or when engine is running. STOP engine.

· Fill fuel tank outdoors.

· Prevent fires: Clean oil, grease and dirt from machine. Clean up spilled fuel immediately.

· Do not store machine with fuel in tank in a building where fumes may reach an open flame or spark.

· To prevent fire and explosion caused by static electric discharge, while you fill tank, use a non-metal fuel container. If you use a funnel, MAKE SURE it is PLASTIC. Avoid using a funnel which has a metal screen or filter.

· Use only clean oil and fuel and clean approved containers and funnels.

· Store oil and fuel in an area protected from dust, moisture and other contamination.


IMPORTANT: Avoid damage! DO NOT mix oil with gasoline.

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.

· Use only clean, fresh, unleaded regular grade gasoline.

· Remove any trash from top of fuel tank drain area.

· Never use fuel that is stale or has been stored for a long period of time:

Warm Weather: Maximum 60 days.

Cold Weather: Maximum of 90 days.

· Fill fuel tank at the end of each day's operation. This helps to keep condensation out of fuel tank.

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 percentages of fuel oxygenates:

ETHANOL (Ethyl or Grain Alcohol): You may use gasoline containing up to 10 percent ethanol by volume.

MTBE (Methyl Tertiary Butyl Ether): You may use gasoline containing up to 15 percent MTBE by volume.

METHANOL (Methyl or Wood Alcohol): You may use gasoline containing up to 5 percent methanol by volume, as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system. Gasoline containing more than 5 percent methanol by volume may cause starting and/or performance problems. It may also damage metal, rubber, and plastic parts of your fuel system.

Filling Fuel Tank (Continued)

M86620

1. Wipe dust and dirt from around fuel cap (A) and remove cap.

2. Fill fuel tank at the end of each day's operation:

· Fill to bottom of filler neck to allow room for gas to expand.

· Fuel tank capacity: 2.5 L
(2.6 U.S. qt).

· Install fuel tank cap and tighten.

Adjusting Throttle Lever Location

M86621

1. Remove two bolts (A) (10 mm).

2. Remove handlebar cover (B).

M72968a

3. Loosen two nuts (C) (10 mm).

4. Move throttle lever plate (D) to where the throttle lever location is most comfortable to the operator.

5. Tighten nuts.

6. Install handlebar cover with two bolts and tighten.

Adjusting Throttle Lever Tension

M86621

1. Remove two bolts (A) (10 mm).

2. Remove handlebar cover (B).

M72968a

3. Using two wrenches, tighten or loosen the lock nut (C) on the throttle pivot bolt (D). At the proper tension, the throttle lever is easy to move, yet maintains the desired throttle setting during operation.

4. Install handlebar cover with two bolts and tighten.

Cleaning Air Cleaner


IMPORTANT: Avoid damage! Do not run engine with air cleaner removed.

NOTE: Clean and oil every 25 hours under normal conditions. If used under very dusty conditions, clean once a day or every ten hours.

1. Remove wing nut (A) to remove air cleaner cover (B).

M86622

2. Remove second wing nut (A) to remove air cleaner element (C) and precleaner (D).

3. Check housing, precleaner, element and rubber gasket (E) for damage. Housing must seat well and permit only filtered air to reach carburetor. Replace if necessary.


IMPORTANT: Avoid damage! Do not clean precleaner with solvent or compressed air.

4. Be sure nothing is obstructing the air passage.

5. Precleaner (D) - Clean every 25 hours of operation:

· Wash in detergent and water, rinse in clean water.

· Dry thoroughly.

· Saturate in clean engine oil and squeeze out excess.

· Air cleaner element (C) - Clean or replace every 100 hours of operation:

· If element is dirty, tap gently on your hand to remove dust.

· If element is extremely dirty or damaged, install new element.

· Assemble air cleaner assembly and install two wing nuts.

Cleaning Fuel Sediment Bowl

M86623

1. Turn fuel shut-off valve (A) to the OFF position.

2. Unscrew and remove sediment bowl (B) and O-ring (C).

3. Clean thoroughly with John Deere degreasing solvent or equivalent.

4. Reinstall bowl.

Checking Engine Oil Level


IMPORTANT: Avoid damage! · Do not check oil level or add oil while engine is running. · Engine should level prior to checking oil level.

M86624

1. Be sure engine is in a level position, if necessary, put a block under front roller to level engine.

NOTE: Do not screw dipstick into engine to check oil level.

M86629

2. Remove dipstick (A), wipe clean, and insert into filler port.

3. If no oil or only a slight amount is seen, add to full level (B). Do not overflow.(See Engine Oil in this section for correct oil.)

Oil capacity: 0.6 L (0.6 U.S. qt).

4. Wipe any spilled oil off mower.

Changing Engine Oil


IMPORTANT: Avoid damage! · Do not check oil level or add oil while engine is running. · Engine should be level prior to checking oil level.

NOTE: Change engine oil after first 20 hours of operation, then every 50 hours. Check and fill plugs are located in front and rear of machine.

M86624

1. Run engine a few minutes to warm oil.

2. Be sure engine is in a level position, if necessary, put a block under front roller to level engine.

3. Stop engine.

4. Remove drain plug (A) and drain oil into container. If necessary, use the optional drain tube to drain oil away from unit.

5. Install drain plug.

M86629

6. Remove dipstick (A), wipe clean.

7. Add to full level (C). Do not overflow. (See Engine Oil in this section for correct oil.)

Oil capacity: 0.6 L (0.6 U.S. qt).

8. Wipe any spilled oil off mower.

Cleaning Spark Plug And Adjusting Electrode Gap

c CAUTION: Avoid injury! Stop engine and let cool before removing spark plug.

M86625

1. Disconnect plug wire (A) and remove plug.

2. Thoroughly clean plug using high flash-point solvent and wire brush.

3. Inspect plug for cracked porcelain, pitted or damaged electrodes, or other damage.

NOTE: In Canada, replace plug with a resistor plug.

4. Replace plug if necessary.

M85200

5. Check plug gap (B) with a round wire-type feeler gauge.

· Gap must be 0.7-0.8 mm
(0.028-0.031 in.).

· Change gap by moving only the outer electrode toward center electrode.

6. Install and tighten plug to 25 N·m (18 lb-ft).

7. Connect spark plug wire.

Adjusting Carburetor

NOTE: The 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.

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.

Introduction

Safety Labels

Controls

Operating - Machine

Operating - Cutting Units

Service Safely

Service Interval Chart

Service Lubrication

Service Engine

Service - Cutting Units

Service - Belts

Troubleshooting

Storing Machine

Assembly

Specifications

Warranty

John Deere Quality Statement

Service Engine

Engine Warranty Maintenance Statement

Avoid Fumes

Filling Fuel Tank (Continued)

Adjusting Throttle Lever Location

Adjusting Throttle Lever Tension

Cleaning Air Cleaner

Cleaning Fuel Sediment Bowl

Checking Engine Oil Level

Changing Engine Oil

Cleaning Spark Plug And Adjusting Electrode Gap

Adjusting Carburetor