Operator's Manual 21" Self-Propelled Mower Models 977A & E977C IMPORTANT: Read safety rules and instructions carefully Warning: This unit is equipped with an internal combustion engine and should net 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.
TABLEOFCONTENTS Content Page Important Safe Operation Practices ...................................................................... 3 Slope Gauge ......................................................................................................... 6 Assembling Your Lawn Mower ............................................................................. 7 Know Your Lawn Mower ....................................................................................... 9 Operating Your Lawn Mower .
SECTION 1: IMPORTANT SAFEOPERATION PRACTICES 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.
immediately andthebladewillstoprotatingwithin 3. Do not mow on wet grass. Unstable footing could threeseconds. cause slipping. 9. Mowindaylightorgoodartificiallight;walk,notrun. 10.Stopthebladewhencrossinggraveldrives, Children walkways or roads. Tragic accidents can occur if the operator is not alert to 11. Iftheequipment shouldstarttovibrateabnormally, the presence of children. Children are often attracted to stoptheengineandcheckimmediately forthe the mower and the mowing activity. They do not cause.
10.Neveroverfillfueltank.Filltankto nomorethanV2 inch below bottom of filler neck to provide space for fuel expansion. 11. Replace gasoline cap and tighten securely. 12. If gasoline is spilled, wipe it off the engine and equipment. Move unit to another area. Wait 5 minutes before starting the engine. 13. Never store the machine or fuet 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. 14.
SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE A POWER POLE A CORNER OF A BUILDING OR A FENCE POST | 15° o •5 WARNING ¢o _ 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 O _ o. -_ _ .c o. .-_ and you could slip, resulting in serious injury. overturn and cause seriousupinjury. If operating a walk-behind mower onslopes.
SECTION3: ASSEMBLING YOURLAWNMOWER RemovingUnitFromCarton SettingUpYourLawnMower • AssemblingHandle • • • Remove staples, break glue on top flaps, or cut tape at carton end and peel along top flap to open carton. • Remove loose parts, if included with unit (i.e., grass bag etc.), and save it appropriately. Cut along corners, lay the carton down flat, and remove all packing material.
• Fasten the cable to the lower handle with the two cable ties found on the lower handle. Pull the cable Grass Bag ties tight and trim off the excess. See Figure 5. Cable Tie. Handle Win( Nuts Figure 5 Figure 7 AttachingStarterRope • 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. Lift chute door on the grass bag adapter and slide grass bag onto the adapter. See Figure 8.
SECTION4: KNOWYOURLAWNMOWER Read this operator's 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 future reference. WARNING: The operation of any lawn mower can result in foreign objects being thrown into the eyes, which can damage your eyes severely.
SECTION5: OPERATING YOURLAWNMOWER d_lb outlet. See Figure 11. Follow this order of action every time you charge the battery. Charge battery for 16 hours before initial use. Do not charge longer than 20 hours. After charging, disconnect battery charger plug from household outlet first, then disconnect charger lead from battery pack lead. WARNING: understand, and follow all instructions andRead, warnings on the machine and in this manual before operating.
• • • • Pushprimeronce.Donotprimetorestartawarm • For a healthy lawn, always cut off one-third or less engineaftera shortshutdown. of the total length of the grass. Lawn should be Standingbehindthemower,depresstheblade trimmed in fall as long as there is growth. controlhandleandholditagainsttheupperhandle. IMPORTANT: Move the shift lever only when the engine ElectricStart:Turntheignitionkeytotherightto is running. Changing the shift lever setting with the starttheengine.
• Press out on the legs of the lower handle and remove lower handle from the mower. Turn lower handle around so the notch on the bottom of the lower handle is facing forward. See Figure 12. Bottom View ® ® Adjustment Handle Wheel_ Lower Handle Shift Lever e Clutch Control Figure 13 Figure 12 • • • • NOTE: For some people the drive clutch control may not be in a comfortable position.
SECTION7: MAINTAINING YOURLAWNMOWER Inspect muffler periodically, and replace if necessary. Damaged mufflers or spark arresters can create a fire hazard. Make sure to avoid muffler WARNING: Always stop the engine and disconnect the spark plug wire before performing any maintenance work or adjustments on your lawn mower. and surrounding areas while the mower engine is hot because temperature of these areas of the engine may exceed 150 ° F.
SECTION8: SERVICING THEMOWER • WARNING: Always stop the engine and disconnect the spark plug wire before performing any maintenance work or adjustments on your lawn mower. • BladeCare • 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. Place the blade on the adapter. Be certain the blade is aligned and seated on the blade adapter flanges. Place blade bell support on blade.
Remove the hex bolt from the rear of unit holding the transmission to the mower housing. See Figure 18. • • Lift off the lower pulley assembly and remove the old belt from around the crankshaft. • Place the new belt over the transmission pulley. Start the belt in the pulley groove and rotate the pulley until the belt is seated in transmission pulley. Place the belt between the idler pulley and the belt keeper bracket.
• Six-Speed Attach the new flap and new rod to deck, bending the ends of the new rod over to secure to deck. ReplacingBatteryPack (Model E977 only) • • Control Arm Figure 23 • • • • • Make sure the belt is routed inside the pulley halves and the belt guard pin. Reinstall the bolt securing transmission to rear mower housing. Pivot the baffle back to its original position and secure with three hex screws removed earlier.
SECTION 10: TROUBLESHOOTING Problem Cause Remedy Engine fails to start 1. 2. 3. 4. 5. 6. Blade control handle disengaged. Spark plug wire disconnected. Fuel tank empty or stale fuel. Blocked fuel line. Faulty spark plug. Engine flooded 1. 2. 3. 4. 5. 6. Engage blade control handle. Connect wire to spark plug. Fill tank with clean, fresh gasoline. Clean fuel line. Clean, adjust gap, or replace. Wait a few minutes to restart, do not prime. Engine runs erratic 1. 2. Spark plug wire loose.
SECTION 11: PARTSLISTFORMODELS977 & E977 f 48 27 29 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 nol disengaging completely.
Models977 & E977 Ref. No. Pa_ No. Ref. No. Description Pa_ No. Description 1. _47-04008 Control Handle 2. 731-0904A Upper Control Handle 3. 16064 53. 738-0137A 4. 731-0620 6 Spd. Rack Cable Bracket Control Lever 54. 748-0318 5. 713-0397 Gear Insert 55. 736-0270 Wheel Rachet Bell Washer .265 ID x .75 OD 6. 732-0627 Shift Lever Spring 56. 710-0751 Hex Cap Screw 1/4-20 x .620 7. 731-0924 6 Speed Shift Lever 57. 731-0982A 8. 9.
Models977& E977 16 28 15 17 11 I 13 29 I I 30 31 I I 20 ) 60 38 I I 62 63 20
Models977 & E977 Ref. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. Part No. 720-0223 732-0803A 738-0529 710-0751 736-0270 748-0318 736-0369 682-0531 750-0515 741-0978 750-1056 710-0653 682-7528 741-0324 682-7526 618-0263A 710-0604A 713-0453 638-0012 741-0522 732-0832 750-0151 710-1315 711-0835 750-0807 782-0568 710-1652 714-0474 712-3025 736-0425 756-0656 736-3084 Ref. No. Part Description Grip Spring Lever Shoulder Nut .
ModelE977 Ref. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1\ 18 19 Pe_ No. 725-0201 725-0873 731-0891A 725-0727 725-0298 725-1428 725-1276 710-0501 736-0270 712-0329 725-1206 712-0267 736-0242 712-0287 710-1250 710-0111 782-9012 710-0969 725-1538 625-0022 Description Ignition Key Key Switch Battery Tray Battery Charger Fuse 7,5 Amp Fuse Holder Battery 12V Hex Screw:l/4-20:2.
EngineManualfor KawasakiEngine SAFETYAWARENESS ,_ WARNING: Whenever you see the symbols shown on the left, heed their instructions!Always follow safe operating and maintenance practices. 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.
READTHIS FIRST 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.
gasses are led to a breather chamber through the crankcase and from there to the air cleaner. necessary to ensure compliance with the applicable standards. Engine EmissionsCompliancePeriod California As the owner of the engine, you have the responsibility to make sure that the recommended maintenance is Model Year - 2006 and later Vertical Crankshaft carried out according to the instructions in this Owner's Manual at your own expense.
GeneralInformation Locationof Safety RelatedLabels Figure 3 A. Fuel Tank Cap B. Fuel Tank (capacity 2.0L [0.528US gal.]) C. Fuel Tu be Figure 1 a. b. D. Carburetor Warning (Refer to) Engine Maintenance (Refer to)) E. Priming Pump F. Air Cleaner AWARNING G. Recoit starter H. Recoil Starter Grip I. Oil Drain Plugs (engine oil capacity 0.65L [0.69US gaI.]) KEEPAWAY FNO_FLAME OR SPARKS.
FuelAndOilRecommendations Fuel J Use only clean, fresh, unleaded regular grade gasoline. I I I Octane Rating t!i 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 q index is posted on service station pumps in the U.S.A. I NOTE: If "knocking or pinging" occurs, use a different brsndofgasotineorhigher octanerating. I I I s.
Remove the oil gauge to check the oil level. Level should be between "ADD" and "FULL" marks. Do not overfill. ° Install and tighten the oil gauge. Engine Oil Capacity, 0.65 L (0.69 us.qt) . CAUTION:The engine oil. engine is shipped • • without . ° 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.
A.BrakeControlLever B.Handle Adjustment EngineSpeedAdjustment NOTE: Do not tamper with the govemor setting or the carburetor setting to increase the engine speed. Each carburetor is adjusted at the factory with either a cap or stop plate installed on the mixture screw. Any adjustments must be performed an authorized Kawasaki dealer.
. Air Cleaner Service 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. CAUTION: To prevent excessive engine wear, do not run the engine with the air cleaner ,_ ventilated area Clean and take that there are no WAFINING: the care elements in a wellsparks or flame anywhere near the working area, this includes any appliance with a pilot light.
CAUTION: Do not oil foam element. * Checkthe 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. Paper Element * , Clean the paper eiement every 100 hours. Clean the element bytapping genttyto remove dust. If very dirty, replace the element with a new -Install and tighten the spark plug to 23 N-m (2.3kgf-m, 17fMb). one. , Replace with a new paper-element yearly or 300 hours.
o Remove the spark plug and pour approx. 1-2 mL (0.06-0.1 cu.in) of new engine oil through the plug hole (A), slowly pull the recoil starter grip several times and reinstall the spark plug. A. Spark Plug Hole , , , , Figure 18 32 Slowly pull the recoil starter grip until you feel compression and leave it there. Clean every part of the engine. After period of storage, change engine oil. (Refer to "Oil Change" section in "MAINTENANCE" section).
Troubleshooting Guide Symptom Engine won't start output is low Probable Insufficient compression 1. Remedy 2. 3. 4. Faulty piston, cylinder, piston ring, and head gasket Faulty valves Loose spark plug Loose cylinder head bolts 1. 2. 3. 4. No fuel in fuel tank Blocked rue tube Blocked air vent in fuel tank cap Faulty carburetor 1. Over-rich fueWair mixture 2. 3. 4. 5. Clogged air cleaner Faulty carburetor Incorrect grade/type of fuel Water in fuel No spark or weak spark 1. 2. 3.
KAWASAKI LIMITED WARRANTY CALIFORNIA AND FEDERAL EMISSION CONTROL SYSTEMS SMALL OFF-ROAD ENGINES The California Air Resources Board, the Environmenta! Protection Agency (EPA), and Kawasaki Motors Corp., U.S.A. (hereinafter "Kawasaki") are pleased to explain the Emission Control Systems Warranty on your Kawasaki smalt off-road engine. In California and other states, new smalt off-road engines must be designed, built and equipped to meet stringent anti-smog standards.
2. LIMITATIONS. This Emission Control Systems Warranty shall not cover any of the following: Ca) Repair or replacement required as repairs improperly performed or replacements conforming to Kawasaki specifications which modifications not recommended or approved a result of (i) misuse or neglect, (ii) Iack of required maintenance. (iii) improperly installed, (iv) use of replacement parts or accessories not adversely affect performance and/or durability, (v) alterations or in writing by Kawasaki.
MANUFACTURER'S LIMITED WARRANTY 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 for a period of two (2) years commencing on the date of original purchase and will, at its option, repair or replace, free of charge, any part found to be defective in materials or workmanship.