Operator's Manual 21" Self-Propelled Mower Model 997 IMPORTANT: Warning: READ SAFETY RULES AND INSTRUCTIONS This unit is equipped with an internal combustion CAREFULLY engine and should not 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 3 6 7 9 10 Important Safe Operation Practices Slope Gauge Assembling Your Lawn Mower Know Your Lawn Mower Operating Your Lawn Mower Making Adjustments 11 Content Maintaining Your Lawn Mower Servicing Your Lawn Mower Off-Season Storage Troubleshooting Illustrated Parts List Page 13 14 16 17 18 Warranty 36 FINDINGMODELNUMBER This Operator's Manual is an important part of your new lawn mower. It will help you assemble, prepare and maintain the unit for best performance.
SECTION1: 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 walkwaysorroads. accidents can occur if the operator is not alert to 11.Iftheequipment shouldstarttovibrateabnormally, Tragic the presence of children. Children are often attracted to stoptheengineandcheckimmediately forthe the mower and the mowing activity. They do not cause.
10.Neveroverfillfueltank.Filltanktonomorethan½ inchbelowbottomoffillernecktoprovidespacefor fuelexpansion. 11.Replacegasolinecapandtightensecurely. 12.If gasolineisspilled,wipeitofftheengineand equipment. Moveunittoanotherarea.Wait5 minutesbeforestartingtheengine. 13.Neverstorethemachineorfuelcontainer inside wherethereisanopenflame,sparkor pilotlightas ona waterheater,spaceheater,furnace,clothes dryerorothergasappliances. 14.Toreducefirehazard,keepmowerfreeofgrass, leaves,orotherdebrisbuild-up.
SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE o E i,,II t- A POWER POLE I O A CORNER OF A BUILDING I OR A FENCE POST QI O cO r_ d) o *6 r- cO E o (D I rd) o 15 ° r,D o WARNING O3 64 cu 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 overturn and cause serious injury.
SECTION3: ASSEMBLING YOURLAWNMOWER RemovingUnitFromCarton Setting UpYourLawn Mower • 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 ties tight and trim off the excess. See Figure 5. Grass Bag Adapter Cable Tie Lower Handle win Nuts Figure 5 Figure 7 Attaching StarterRope 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. ,_ mower can result WARNING" Theinoperation foreign objects of any being lawn thrown into the eyes, which can damage your eyes severely.
SECTION5: OPERATING YOURLAWNMOWER ,_ ,i_ WARNING" understand, and follow all instructions andRead, warnings on the machine and in this manual before operating. NOTE: For shipping purposes your mower is set with the wheels in a low cutting height posfion. For best results, raise the cutting position until it is determined which height is best for your lawn. See the Adjustment Section for details. WARNING: Never run engine indoors or in enclosed, poorly ventilated areas.
Mulching BaggingGrassClippings IMPORTANT: Be sure that the lawn is clear of stones, sticks, wire, or other objects which could damage lawn mower or engine. Such objects could be accidently thrown by the mower in any direction and cause serious personal injury to the operator and others. You can use the grass catcher bag to collect clippings while you are operating the mower. • • • ,l_ WARNING" the mower strikesspark a foreign object, stop the Ifengine.
The front wheel cutting height is determined by selecting one of six positions on each caster assembly. To adjust front cutting height, proceed as follows: • • NOTE: For some operators, the drive clutch control may not be in a comfortable position. You can adjust the handle out by tightening the adjustment wheel. Remove the wing nut from the axle bolt. See Figure 13. Slide the axle bolt and spring washer from the assembly and select a cutting height.
SECTION7: MAINTAININGYOURLAWNMOWER ,i_ Inspect muffler periodically, and replace if necessary. Damaged mufflers or spark arresters can create a fire hazard. Make sure to avoid muffler WARNING" the Always stopwire the before engine and disconnect spark plug 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 19. • • • • jHex Bolt • • • Cutting Height Adjustment \\ \ 4-- \ S Wheel Pivot the control arm down away from the pulley and belt. 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.
• Six-Speed Cable Slot • • • • Control Arm 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. Lightly lubricate the inside of the blade adapter and reinstall the blade adapter, blade, and blade bell support in the correct order. Tighten the hex bolt to secure the blade to torque: 450-600 in. Ibs.
SECTION10: TROUBLESHOOTING Problem Engine fails to start Cause Remedy 1. 2. 3. 4. Blade control handle disengaged. Spark plug wire disconnected. Fuel tank empty or stale fuel. Blocked fuel line. 1. 2. 3. 4. Engage blade control handle. Connect wire to spark plug. Fill tank with clean, fresh gasoline. Clean fuel line. 5. 6. Faulty spark plug. Engine flooded 5. 6. Clean, adjust gap, or replace. Wait a few minutes to restart, do not prime. 1. 2. Spark plug wire loose.
SECTION11: PARTSLISTFORMODEL997 5 17 / 20 35 < \ \ 28 27 10% _ / \ 32 \ 91 31 78 99 98 30 -80 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 not disengaging completely.
Model997 Ref. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. Part No.
Model997 26 15 16 _81 2] 24 17 11 \ 4 5 25 \8 12 7 4 31 60 49 64 ]1 I 46\ 47_ 14 51 62 20 -58
Model997 Ref, No. Part No. Ref. No, Part Description Part No. Part Description 1. 720-0223 Grip 33. 712-0896 Hex Jam Nut 1/4-28 2. 732-0803A Spring Lever 34. 782-7598 Belt Keeper 3. 738-0529 Shoulder Nut.825 x.165 Lg. 35. 741-0124 Bearing 4. 5. 710-0751 736-0270 Cap Screw 1/4-20 x.620 Belt Washer.285 ID x.75 OD 36. 37. 732-0849A 750-1050 Extension Spring 6. 748-0318 Wheel Rachet 38. 682-0027A Idler Bracket Assembly 7. 736-0369 Flat Washer.508 ID x 1.00D 39.
EngineManualforKawasaki Engine SAFETYAWARENESS ,i_ WARNING"and maintenance Whenever you see the symbols shown on the left, heed their instructions! Always follow safe operating 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. EngineEmissionsCompliancePeriod 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 Figure 1 B. Fuel Tank (capacity 2.0L [0.528US gal.]) C. Fuel Tube a. Warning b. Engine Maintenance D. Carburetor E. Priming Pump F. Air Cleaner AWARNING G. Recoil starter _]loFORREADOWNER'S SAFEOPERATION MANUAL. • GASOLINE IS FLAMMABLE. KEEPAWAY FROMFLAME ORSPARKS, H. Recoil Starter Grip I. Oil Drain Plugs (engine oil capacity 0.65L [0.69US gal.
FuelAndOilRecommendations -20°C -10°C 0°C 10°C 20°C 30°C 40°C Fuel Use only clean, fresh, unleaded regular grade gasoline. SA_10W- OctaneRating 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 index is posted on service station pumps in the U.S.A. s /10w Figure 5 NOTE: If "knocking or pinging" occurs, use a different brand of gasoline or higher octane rating.
CAUTION:The engine oil. engine is shipped without • • • DO NOT let the recoil starter grip snap back itself. This may cause damage to the recoil starter assembly. Hold the brake control lever (A) on the equipment against the handle (B) on the equipment. Pull the recoil starter grip (C) slowly until you feel compression, then pull fast and steady.
B. Handle Adjustment EngineSpeed Adjustment NOTE: Do not tamper with the governor 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.
• Put the mower back to its operating position (on all four wheels). RefillingFresh0il • Dipstick Remove dipstick and refill with new oil (See FUEL AND OIL RECOMMENDATIONS chapter). NOTE: If you followed the second method of draining oil, the dipstick is already removed from the engine. • Crank Case _Muffier ,_ Tilt mower so engine tips this way Figure Check the oil level (See PREPARATION and secure dipstick to the filler plug. chapter), WARNING: Dispose of usedEngine oil properly.
A. Fasteners A. Slit in the air cleaner body B. Recoil Starter B. Projection on the air cleaner case C. Air Cleaner Case C. Fasteners D. Air Cleaner body CAUTION: After servicing the air cleaner, be sure all the removed parts are reinstalled properly in place. Failure to secure fastening of the air cleaner case with the air cleaner body may cause dirt or other foreign materials to enter the engine, while it is running, through the air cleaner, resulting in engine troubles or failures. E.
Storage Engine to be stored over 30 days should be completely drained of fuel (gasoline) to prevent gum deposits forming on essential carburetor parts and fuel system. WARNING: Gasoline is extremely flammable and can be explosive under certain conditions. Drain gasoline before storing the equipment for extended periods. Drain gasoline in a well-ventilated area away from any source of flame or sparks, including any appliances with a pilot light. Store gasoline in an approved container in safe location.
Troubleshooting Guide Probable Cause Symptom Engine won't start output is low Insufficient compression 1. 2. 3. 4. Remedy Faulty piston, cylinder, piston ring, and head gasket Faulty valves Loose spark plug Loose cylinder head bolts 1.Tighten properly 2. Tighten properly 3. Tighten properly 4. Tighten properly No fuel to combustion chamber 1. 2. 3. 4. No fuel infueltank Blocked rue tube Blocked air vent in fuel tank cap Faulty carburetor 1. Over-rich fuel/air mixture 2. 3. 4. 5.
Kawasaki Limited Warranty: California And Federal Emission Control Systems: Small Off-Road Engines The California Air Resources Board, the Environmental Protection Agency (EPA), and Kawasaki Motors Corp., U.S.A. (hereinafter "Kawasaki") are pleased to explain the Emission Control Systems Warranty on your Kawasaki small off-road engine. In California and other states, new small offroad engines must be designed, built and equipped to meet stringent anti-smog standards.
NOTES 34
NOTES 35
MANUFACTURER'S LIMITED WARRANTY The limited warranty set forth below is given by MTD LLC with respect to new merchandise purchased and used in the United States, its possessions and territories. "MTD" warrants this product against defects in material and workmanship for a period of two (2) years commencing on the date of original purchase and wilt, at its option, repair or replace, free of charge, any part found to be defective in materials or workmanship.