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8

SECTION 4:   ASSEMBLING YOUR LAWN MOWER

IMPORTANT:

 This unit is shipped without gasoline or oil 

in the engine. Be certain to service engine with gasoline 
and oil as instructed in the separate engine manual 
before operating your mower.

NOTE: Reference to right or left hand side of the mower
is observed from the operating position.

Removing Unit From Carton

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., 
operator’s manual, etc.)

Cut along corners, lay carton down flat, and remove 
packing material.

Roll or slide unit out of carton and check carton 
thoroughly for loose parts.

Disconnecting Spark Plug Wire

Before setting up your lawn mower, disconnect the 
spark plug wire from the spark plug and ground to a bolt 
on the engine. See Figure 2.

Figure 2

Setting Up Your Lawn Mower

Assembling Handle

Lift up and pull back on the upper handle to raise 
the handle into the operating position. Make certain 
the lower handle is seated securely into the handle 
bracket assemblies. Tighten the wing nuts on each 
side of the handle (carriage bolts must be seated 
properly into the handle). See Figure 3.

NOTE:  Your mower is shipped with the handle in the
higher position. If you wish to lower the height of the
handle, refer to the Adjustment Section at this time.

Figure 3

Remove the hairpin clips from the outer hole in the 
weld pins on the handle bracket assemblies. Using 
a pair of pliers, squeeze one leg of the lower handle 
against the handle bracket assemblies. Insert the 
hairpin clip into the inner hole on the weld pin. 
Repeat on other side. See Figure 4.

Figure 4

Fasten the cables to the lower handle with the two 
cable ties found on the lower handle. Be sure to 
insert the post on the cable ties into the holes 
provided on the lower handle. These holes may be 
found on either the inside or outside of the handles. 
Pull the cable ties tight and trim off the excess.
See Figure 5.

Figure 5

Spark

Plug Wire

Bolt

Spark Plug

Spark Plug
Wire

Wing Nuts

Handle Bracket
Assemblies

Handle
Assembly

Handle Bracket
Assembly

Lower
Handle

Hairpin
Clip

Cable Tie

Lower

 

Handle

Summary of Contents for 509 Series

Page 1: ...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 In the S...

Page 2: ...t if you need help from our Customer Support Department or an authorized dealer You can locate the model number by looking down at the rear of the deck A sample model plate is explained below For futu...

Page 3: ...n overlooked and could be accidentally thrown by the mower in any direction and cause serious personal injury to the operator or any others allowed in the area Wear sturdy rough soled work shoes and c...

Page 4: ...embankments The operator could lose footing or balance Do not mow slopes greater than 15 degrees as shown on the slope gauge Do not mow on wet grass Reduced footing could cause slipping CHILDREN Tragi...

Page 5: ...re subject to wear damage and deterioration which could expose moving parts or allow objects to be thrown For safety protection frequently check components and replace with manufacturer s recommended...

Page 6: ...N T I N G A 1 5 S L O P E WARNING 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 If...

Page 7: ...th the hardware shown on this page See Figure 1 The hardware pack may contain extra items which are not used on your unit Figure 1 NOTE Hardware pieces illustrated here are not drawn to actual size Ax...

Page 8: ...position Make certain the lower handle is seated securely into the handle bracket assemblies Tighten the wing nuts on each side of the handle carriage bolts must be seated properly into the handle See...

Page 9: ...f the mower are not already assembled proceed as follows Block the rear of the mower up securely Move rear cutting height adjusters to the highest position The rear axle shaft has a right side and a l...

Page 10: ...e with lock washer and hex nut from the hardware pack Repeat step on the other side See Figure 11 Tighten all nuts and bolts on both ends of the strut securely Removing Chute Retainer The chute deflec...

Page 11: ...blade control handle is located on the upper handle of the mower The blade control handle must be depressed in order to operate the unit Release blade control handle to stop engine and blade WARNING T...

Page 12: ...d cause serious personal injury to the operator and others For best results do not cut wet grass because it tends to stick to the underside of the mower preventing proper discharge of grass clippings...

Page 13: ...t each wheel position provides cutting height adjustment Each adjusting plate has nine height positions When the spring lever is moved from one location to another the height of cut will be changed Si...

Page 14: ...ine and disconnect spark plug wire before cleaning lubricating or doing any kind of service work on the lawn mower Blade Control Lubricate the pivot points on the blade control handle at least once a...

Page 15: ...oval Replacement and Sharpening 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 Remove the bolt and th...

Page 16: ...will result in shorten life and reduce serviceability Refer to engine manual for correct engine storage instructions Coat mower s cutting blade with chassis grease to prevent rusting Store mower in a...

Page 17: ...h fresh fuel 5 Clean air cleaner 6 Adjust carburetor Engine overheats 1 Engine oil level low 2 Air flow restricted 3 Carburetor not adjusted properly 1 Fill crankcase with proper oil 2 Remove blower h...

Page 18: ...18 Models 500 509 1 24 2 3 4 5 6 8 12 14 15 17 18 23 22 21 34 25 26 27 28 29 30 31 32 33 35 36 36 37 38 39 40 41 20 42 43 44 45 46 47 48 18 49 50 19 51 52 53 54 55 56 57 39 40 58 59 60 61 62 64 63...

Page 19: ...Assembly 22 28 710 0654A Hex Washer Screw 29 720 0279 Handle Knob 1 4 20 30 736 0504 Wave Washer 31 782 0519A Pivot Bar LH 782 0520A Pivot Bar RH 32 712 3020 Hex Jam Nut 3 8 16 33 749 0705 Upper Handl...

Page 20: ...ty on these items b Log splitter pumps valves and cylinders have a separate one year warranty c Routine maintenance items such as lubricants filters blade sharpening and tune ups or adjustments such a...

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