21A121R765 - Rototiller MTD - Free user manual and instructions

USER MANUAL 21A121R765 MTD

Thank you for buying this quality product. This modern outdoor power tool will provide many hours of useful service. You will find it to be a great labor-saving device. This operator's manual provides you with easy-to-understand operating instructions. Read the whole manual and follow all the instructions to keep your new outdoor power tool in top operating condition.

PRODUCT REFERENCES, ILLUSTRATIONS AND SPECIFICATIONS

All information, illustrations, and specifications in this manual are based on the latest product information available at the time of printing. We reserve the right to make changes at any time without notice.

Copyright ©2003 MTD SOUTHWEST INC, All Rights Reserved.

SERVICE INFORMATION

Service on this unit both within and after the warranty period should be performed only by an authorized and approved service dealer.

For service call 1-800-520-5520 to obtain a list of authorized service dealers near you.

DO NOT RETURN THE UNIT TO THE RETAILER. PROOF OF PURCHASE WILL BE REQUIRED FOR WARRANTY SERVICE.

Before beginning, locate the unit's model plate. It lists the model and serial numbers of your unit. Refer to the sample plate below and copy the information for future reference.

Copy the model / parent part

number here:

Copy the serial number here:

Make sure you carefully read and understand this manual before starting or operating this equipment.

THIS PRODUCT IS COVERED BY ONE OR MORE U.S. PATENTS. OTHER PATENTS PENDING.

TABLE OF CONTENTS

Service Information 2

Rules for Safe Operation 3

Know Your Unit 6

Assembly Instructions 7

Oil and Fuel Information 8

Starting/Stopping Instructions 9

Operating Instructions 10

Maintenance and Repair Instructions 11

Cleaning and Storage 14

Accessories and Replacement Parts 14

Troubleshooting Chart 15

Specifications 16

Warranty Information 18

Parts List .Inside Back Cover

CALIFORNIA PROPOSITION 65 WARNING

WARNING

THE ENGINE EXHAUST FROM THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS, OR OTHER REPRODUCTIVE HARM.

NOTE: For users on U.S. Forest Land and in the states of California, Maine, Oregon, and Washington. All U.S. Forest Land and the state of California (Public Resources Codes 4442 and 4443), Oregon, and Washington require by law that certain internal combustion engines operated on forest brush and/or grass-covered areas be equipped with a spark arrestor, maintained in effective working order, or the engine be constructed, equipped, and maintained for the prevention of fire. Check with your state or local authorities for regulations pertaining to these requirements. Failure to follow these requirements could subject you to liability or a fine. This unit is factory equipped with a spark arrestor. If it requires replacement, ask your LOCAL SERVICE DEALER to install the Accessory Part #182747 Spark Arrestor.

Read the Operator's Manual(s) and follow all warnings and safety instructions.

Failure to do so can result in serious injury to the operator and/or bystanders.

FOR QUESTIONS, CALL 1-800-520-5520

SAFETY SYMBOLS

The purpose of safety symbols is to attract your attention to possible dangers. The safety symbols, and their explanations, deserve your careful attention and understanding. The safety warnings do not by themselves eliminate any danger. The instructions or warnings they give are not substitutes for proper accident prevention measures.

SYMBOL

MEANING

SAFETY ALERT SYMBOL: Indicates danger, warning or caution. Attention is required in order to avoid serious personal injury. May be used in conjunction with other symbols or pictographs.

DANGER: Failure to obey a safety warning will result in serious injury to yourself or to others. Always follow the safety precautions to reduce the risk of fire, electric shock and personal injury.

SYMBOL

MEANING

WARNING: Failure to obey a safety warning can result in injury to yourself and others. Always follow the safety precautions to reduce the risk of fire, electric shock, and personal injury.

CAUTION: Failure to obey a safety warning may result in property damage or personal injury to yourself or to others. Always follow the safety precautions to reduce the risk of fire, electric shock, and personal injury.

NOTE: Advises you of information or instructions vital to the operation or maintenance of the equipment.

- IMPORTANT SAFETY INFORMATION

READ ALL INSTRUCTIONS

WARNING: When using the unit, you must follow the safety rules. Please read these instructions before operating the unit in order to ensure the safety of the operator and any bystanders. Please keep these instructions for later use.

BEFORE OPERATING

• Read the instructions carefully. Become familiar with the controls and proper use of the unit.
• Do not operate this unit when tired, ill or under the influence of alcohol, drugs or medication.
• Children under the age of 15 must not use the unit; teens may operate the unit with adult guidance.
• Inspect the unit before use. Replace damaged parts. Check for fuel leaks. Make sure all fasteners are in place and secure. Replace parts that are cracked, chipped or damaged in any way. Do not operate with loose or damaged parts.

• Be aware of the potential risk of injury to your head, hands and feet.

• Clear the area to be cultivated before each use. Remove rocks, broken glass, nails, wire, string and other objects which may be thrown by the unit. Clear the area of children, bystanders and pets; keep them outside a 50-foot (15 m.) radius, at a minimum. Even then, they are still at risk from thrown objects. Encourage bystanders to wear eye protection. If you are approached, stop the unit immediately.

• Squeeze the throttle control and make sure that it automatically returns to the idle position. Make all adjustments or repairs before using the unit.

SAFETYWARNINGS FOR GAS UNITS

• Store fuel only in containers specifically designed and approved for the storage of such materials.
• Avoid creating a source of ignition for spilled fuel. Do not start the engine until fuel vapors dissipate.

WARNING: Gasoline is highly flammable and its vapors can explode if ignited. Follow the ensuing precautions.

- IMPORTANT SAFETY INFORMATION

• Always stop the engine and allow it to cool before filling the fuel tank. Never remove the cap of the fuel tank, or add fuel, when the engine is hot. Never operate the unit without the fuel cap securely in place. Loosen the fuel tank cap slowly to relieve any pressure in the tank.
• Add fuel in a clean, well-ventilated outdoor area where there are no sparks or flames. Slowly remove the fuel cap only after stopping engine. Do not smoke while fueling. Wipe up any spilled fuel from the unit immediately.
• Move the unit at least 30 feet (9.1 m) from the fueling source and site before starting the engine. Do not smoke. Keep sparks and open flames from the area while adding fuel or operating the unit.

WHILE OPERATING

• Never start or run the unit inside a closed room or building. Breathing exhaust fumes can be lethal. Operate this unit only in a well ventilated area outdoors.
• Wear safety glasses or goggles that are marked as meeting ANSI Z87.1 standards, and ear/hearing protection when operating this unit. Wear a face or dust mask if the operation is dusty.
• Wear heavy, long pants, boots, gloves and a long sleeve shirt. Do not wear, short pants, sandals or go barefoot.
• To reduce the risk of injury associated with objects pulled into rotating parts, do not wear loose clothing, jewelry, scarves, etc. Secure hair above shoulder level.
• Use the unit only in daylight or good artificial light.
• Keep outside surfaces free from oil and fuel.
• This unit has a clutch. The tines remain stationary when the engine is idling. If they do not, have the unit adjusted by an authorized service technician.
• Be sure the tines are not in contact with anything before starting the unit.
• Avoid accidental starting. Be in the starting position whenever pulling the starter rope. The operator and unit must be in a stable position while starting. Refer to the Starting/Stopping Instructions.
• Use the right tool. Only use this tool for the purpose intended.
• Do not force the unit. It will do the job more effectively, with a smaller chance of injury, if you use the unit for the task it was designed.
• Use extreme caution when reversing or pulling the unit towards you.
• Do not overreach. Take extra care when working on steep slopes or inclines. Always keep proper footing and balance.

• Always hold the unit with both hands when operating. Keep a firm grip on the handlebar grips.

• Keep hands, face and feet at a distance from all moving parts. Do not touch or try to stop the tines when they are rotating. Do not operate without guards in place.

• Do not touch the engine, muffler or gearbox. These parts get extremely hot from operation. When turned off they remain hot for a short time.
• Do not operate the engine faster than the speed needed to do the job. Do not run the engine at high speed when not in use.
• Always stop the engine during suspended or delayed operation, or when you walk from one location to another.
• Stop the engine for maintenance, repair or to install or remove the tines. To avoid injury, stop the unit and make sure the tines no longer turn.
• The tines become very sharp from use. Always wear heavy gloves when handling, removing, installing or cleaning the tines.
• Use only Genuine Factory Parts™ replacement parts and accessories for this unit. These are available from your authorized service dealer. Use of any non original factory parts or accessories could lead to serious injury to the user, or damage to the unit, and void your warranty.
• Keep the unit clean of vegetation and other materials. They may become lodged between the tines and gearbox or guard.
• To reduce the risk of fire, replace a faulty muffler and spark arrester. Keep the engine and muffler free from grass, leaves, excessive grease or carbon build up.

OTHER SAFETY WARNINGS

• Never store the unit, with fuel in the tank, inside a building where fumes may reach an open flame or spark.
• Allow the engine to cool before storing or transporting. Be sure to secure the unit while transporting.
• Store the unit in a dry place, either locked up or up high to prevent unauthorized use or damage. Keep out of the reach of children.
• Clean the tines with a hose and water. Wipe the tines with a light machine oil to prevent rust.
• Never douse or squirt the engine with water or any other liquid. Keep handles dry, clean and free from debris. Clean after each use, as described in the Cleaning and Storage section.
• Keep these instructions. Refer to them often and use them to instruct other users. If you loan someone this unit, also loan them these instructions.

SAVE THESE INSTRUCTIONS

SAFETY AND INTERNATIONAL SYMBOLS

This operator's manual describes safety and international symbols and pictographs that may appear on this product. Read the operator's manual for complete safety, assembly, operating and maintenance and repair information.

SYMBOL

MEANING

• SAFETY ALERT SYMBOL

Indicates danger, warning or caution. May be used in conjunction with other symbols or pictographs.

WARNING - READ OPERATOR'S MANUAL

Read the operator's manual(s) and follow all warnings and safety instructions. Failure to do so can result in serious injury to the operator and/or bystanders.

• WEAR EYE AND HEARING PROTECTION

WARNING: Thrown objects and loud noise can cause severe eye injury and hearing loss. Wear eye protection meeting ANSI Z87.1 standards and ear protection when operating this unit. Use a full face shield when needed.

• KEEP BYSTANDERS AWAY

WARNING: Keep all bystanders, especially children and pets, at least 50 feet (15 m) from the operating area.

• UNLEADED FUEL

Always use clean, fresh unleaded fuel.

OIL

Refer to operator's manual for the proper type of oil.

• THROWN OBJECTS AND ROTATING CUTTER CAN CAUSE SEVERE INJURY

WARNING: Do not operate without the proper attachments and guards in place. Keep away from the rotating tines.

SYMBOL

MEANING

ON/OFF STOP CONTROL

ON/START/RUN

ON/OFF STOP CONTROL

OFF or STOP

• HOT SURFACE WARNING

Do not touch a hot muffler, gear housing or cylinder. You may get burned. These parts get extremely hot from operation. They remain hot for a short time after the unit is turned off.

• CHOKE CONTROL

1·FULL choke position.
2·PARTIAL choke position.
3·RUN position.

GARDEN CULTIVATORS - ROTATING TINES CAN CAUSE SEVERE INJURY

WARNING: Stop the engine and allow the tines to stop before installing or removing tines, or before cleaning or performing any maintenance. Keep hands and feet away from rotating tines.

NO STEP

Always keep proper footing and balance. Do not overreach, take extra care when working on steep slopes or inclines.

• PLACE LEFT FOOT HERE

Avoid accidental starting. Stand in the starting position whenever pulling the starter rope. The operator and unit must be in a stable position while starting.

KNOW YOUR UNIT

Application:

• Cultivating sod and light to medium soil
• Cultivating in garden areas, around trees, etc.

ASSEMBLING THE UNIT

Before operating, position the unit's handlebars.

NOTE: You may also need to reposition the wheel height before using the cultivator. Refer to the Adjusting Tine Depth section.

Begin by carefully unpacking the contents and making sure that nothing is damaged.

POSITIONING THE HANDLEBARS

1. Loosen the two knobs on the inside of the handlebars (Fig. 1).
2. With the unit upright, swing the handlebars up into the operating position (Fig. 1).

NOTE: Take care not to pinch the throttle cable or switch wires when positioning the handlebar.

1. Tighten the knobs to secure the handlebars in place.
   NOTE: Do not over-tighten the knobs.
2. Readjust the throttle cable and switch the wires so they are smooth and tight against the handlebar assembly. This will help prevent them from catching or snagging during normal operation.

1. Remove the knobs and mounting bolts and reinstall them through either the top or bottom holes in the handlebar assembly (Fig. 2) in order to adjust the height of the handlebars.
2. Be sure to tighten the knobs to secure the handlebars in place.

INSTALLING THE WHEEL BRACKET ASSEMBLY

If the wheel bracket assembly is not installed, or if you ever need to remove or reinstall it, follow the ensuing instructions.

WARNING: To avoid injury from the tines, wear heavy gloves and a long sleeve shirt when installing the wheel bracket assembly.

WARNING: To prevent serious personal injury, the wheel bracket assembly must be installed when operating the unit.

1. With the unit on its side, place the wheel bracket assembly on the underside of the tine guard (Fig. 3).
2. Install a carriage bolt through each of the slotted holes in the wheel bracket and into the tine guard.
3. On the TOP side of the tine guard, install a lock washer and a wing nut onto each of the bolts (Fig. 3).
4. Make sure the square shoulder of the bolts is pushed through the slotted holes in the wheel bracket. Tighten the wing nuts (Fig. 4).

NOTE: Do not over-tighten the wing nuts. Loosen the wing nuts to adjust wheel height.

OIL AND FUEL MIXING INSTRUCTIONS

Old and/or improperly mixed fuel are the main reasons for the unit not running properly. Be sure to use fresh, clean unleaded fuel. Follow the instructions carefully for the proper fuel/oil mixture.

Definition of Blended Fuels

Today's fuels are often a blend of gasoline and oxygenates such as ethanol, methanol, or MTBE (ether). Alcohol-blended fuel absorbs water. As little as 1% water in the fuel can make fuel and oil separate. It forms acids when stored. When using alcohol-blended fuel, use fresh fuel (less than 60 days old).

Using Blended Fuels

If you choose to use a blended fuel, or its use is unavoidable, follow recommended precautions:

• Always use fresh fuel mix per your operator's manual
• Always agitate the fuel mix before fueling the unit
• Drain the tank and run the engine dry before storing the unit

Using Fuel Additives

The bottle of 2-cycle oil that came with your unit contains a fuel additive which will help inhibit corrosion and minimize the formation of gum deposits. It is recommended that you use our 2-cycle oil with this unit.

If unavailable, use a good 2-cycle oil designed for air-cooled engines along with a fuel additive, such as STA-BIL® Gas Stabilizer or an equivalent. Add 0.8 oz. (23 ml.) of fuel additive per gallon of fuel according to the instructions on the container. NEVER add fuel additives directly to the unit's fuel tank.

CAUTION: For proper engine operation and maximum reliability, pay strict attention to the oil and fuel mixing instructions on the 2-cycle oil container. Using improperly mixed fuel can severely damage the engine.

Thoroughly mix the proper ratio of 2-cycle engine oil with unleaded gasoline in a separate fuel can. Use a 40:1 fuel/oil ratio. Do not mix them directly in the engine fuel tank. See the following table for specific gas and oil mixing ratios.

NOTE: One gallon (3.8 liters) of unleaded gasoline mixed with one 3.2 fl oz. (95 ml.) bottle of 2-Cycle Oil makes a 40:1 fuel/oil ratio.

MIXING RATIO = 40 : 1

+ UNLEADED GAS	2 CYCLE OIL
1 US. GALLON (3.8 LITERS)	3.2 FL OZs. (95 ml)
1 LITER	25 ml

WARNING: Gasoline is extremely flammable. Ignited vapors may explode. Always stop the engine and allow it to cool before filling the fuel tank. Do not smoke while filling the tank. Keep sparks and open flames at a distance from the area.

WARNING: Remove fuel cap slowly to avoid injury from fuel spray. Never operate the unit without the fuel cap securely in place.

WARNING Add fuel in a clean, well ventilated area outdoors. Wipe up any spilled fuel immediately. Avoid creating a source of ignition for spilled fuel. Do not start the engine until fuel vapors dissipate

NOTE: Dispose of the old fuel/oil mix in accordance to Federal, state, and local regulations.

FILLING THE FUEL TANK

Make sure the cultivator is in a horizontal position when filling or adding fuel to the tank.

STARTING INSTRUCTIONS

WARNING: Operate this unit only in a well-ventilated outdoor area. Carbon monoxide exhaust fumes can be lethal in a confined area.

WARNING: Avoid accidental starting. Make sure you are in the starting position when pulling the starter rope (Fig. 8). To avoid serious injury, the operator and unit must be in a stable position while starting.

1. Mix gas with oil. Fill fuel tank with fuel/oil mixture. Refer to Oil and Fuel Mixing Instructions.
2. Make sure the On/Off Stop Control in the ON [I] position (Fig. 6).
3. Place the choke lever in Position 1 (Fig. 7).
4. Fully press and release the primer bulb 10 times, slowly. Some amount of fuel should be visible in the primer bulb and fuel lines (Fig. 7). If you can't see fuel in the bulb, press and release the bulb as many times as it takes before you can see fuel in it.
5. Stand between the handlebars and support the unit by placing your left foot on the wheel bracket assembly and gripping the handlebar grip with your right hand (Fig. 8).

NOTE: Tilt the unit back slightly to bring the tines off the ground when starting.

1. While squeezing the throttle control to the wide open (full throttle) position, grasp the starter rope grip with your left hand. Pull the starter rope out a short distance, until you feel some resistance. This is usually around 2-4 inches. Then pull the rope smoothly and briskly. Repeat this 5 times.
2. Move the choke lever to Position 2.
3. While squeezing the throttle control, pull the starter rope in the same manner as explained in Step 6. Pull 1 to 3 times to start the engine.
4. Keep the throttle squeezed and allow the engine to warm up for 15 to 30 seconds.
5. Place the choke lever in Position 3. Release the throttle control to the idle position and begin operation.

IF... The engine does not start, go back to step 3.

IF... The engine fails to start after a few attempts, place the choke lever in Position 3 and squeeze the throttle control. Pull the starter rope briskly 3 to 8 times. The engine should start. If not, repeat.

IF WARM... If the engine is already warm, make sure the On/Off Stop control is in the ON position and start the unit with the choke lever in Position 2. After the unit starts, move the choke lever to Position 3.

STOPPING INSTRUCTIONS

1. Release your hand from the throttle control (Fig. 8). Allow the engine to cool down by idling.
2. Put the On/Off Stop Control in the STOP (O) position (Fig. 6).

OPERATING TIPS

WARNING: Always wear eye, hearing, foot and body protection to reduce the risk of injury when operating this unit.

1. Move the cultivator to the work area prior to starting the engine. Transport the cultivator by pushing it on its wheels.

WARNING: To prevent serious personal injury, never pick-up or carry the unit while the engine is running.

1. Start the unit as described in the Starting Instructions.
2. With the engine running and the tines off the ground, depress the throttle control to increase the engine speed.
3. Holding both of the handlebar grips firmly, slowly lower the cultivator until the tines make contact with the ground (Fig. 9).
4. As cultivating action begins, pull back on the cultivator so that the tines can penetrate the ground.
5. Once the ground has been broken, continue at a moderate pace until you are familiar with the controls and the handling of the cultivator.
6. Pull the cultivator backwards to improve the depth of cultivation and reduce your effort.

WARNING: To prevent serious personal injury, use extreme caution when reversing or pulling the unit towards you.

1. If the tines are digging too deep or not deep enough, adjust them according to Adjusting Tine Depth.

ADJUSTING TINE DEPTH

Tine adjustment will vary depending on the type of soil being cultivated and how it will be used. Generally, adjusting the tines to break the soil 4 to 6 inches is recommended for most gardens. Adjust the tines as follows:

1. Stop the engine and disconnect the spark plug wire.
2. Loosen (do not remove) the two wing nuts on the tine guard (Fig. 10).
3. Slide the wheel bracket assembly down for shallower penetration, and up for deeper tine penetration.
4. Once the tines are in the desired position, tighten the wing nuts, making sure that the carriage bolts are seated properly through the bracket.
5. If the sine depth is incorrect, repeat steps 2 to 4.
6. Reconnect the spark plug wire and continue use.

TRANSPORTING THE UNIT

WARNING: To prevent serious personal injury, always stop the engine when operation is delayed or when transporting the unit from one location to another.

1. Stop the engine.
2. Slide the wheel bracket assembly all the way down.
3. Tilt the unit back until the tines clear the ground.
4. Push or pull the unit to the next location.

MAINTENANCE SCHEDULE

Perform these required maintenance procedures at the frequency stated in the table. These procedures should also be a part of any seasonal tune-up.

NOTE: Some maintenance procedures may require special tools or skills. If you are unsure about these procedures take your unit to any non-road engine repair establishment, individual or authorized service dealer.

WARNING: To prevent serious injury, never perform maintenance or repairs with unit running. Always service and repair a cool unit. Disconnect the spark plug wire to ensure that the unit cannot start.

NOTE: Maintenance, replacement, or repair of the emission control devices and system may be performed by any non-road engine repair establishment, individual or authorized service dealer.

In order to assure peak performance of your engine, inspection of the engine exhaust port may be necessary after 50 hours of operation. If you notice lost RPM, poor performance or general lack of acceleration, this service may be required. If you feel your engine is in need of this inspection, refer service to any non-road engine repair establishment, individual or authorized service dealer for repair. DO NOT attempt to perform this process yourself as engine damage may result from contaminants involved in the cleaning process for the port.

FREQUENCY	MAINTENANCE REQUIRED	REFER TO
Before starting engine	Fill fuel tank with fresh fuel mix	Page 8
Every 10 hours	Clean and re-oil air filter	Page 12
Every 25 hours	Check and clean spark arrestor	Page 12
	Check spark plug condition and gap	Page 13
Every 50 hours	Inspect exhaust port and spark arrestor screen for clogging or obstruction to assure maximum performance levels	Page 12

TINE REMOVAL AND REPLACEMENT

Replace all four (4) tines at the same time, because they will wear evenly through normal use. Work on one side at a time.

WARNING: To prevent serious personal injury, always wear heavy gloves when handling the tines.

1. Put the On/Off Stop Control in the STOP (O) position and disconnect the spark plug wire.
2. Remove the clevis pin clips and clevis pins (Fig. 11).
3. Remove the tines and felt washers from the shaft.
4. Clean and oil the shaft.
5. The tines are stamped with the letter "R" or "L" to identified their position on each side of the gearbox when facing the front of the unit.
6. Replace the tines and felt washers onto the shaft with the hubs on the tines facing each other.

1. Before you reinstall the clevis pins and pin clips, ensure that the tips on the tines are staggered when compared to each other (Fig. 12).
2. Repeat this procedure on the opposite side.

NOTE: When installed correctly, there will be an "R" and "L" tine on both the sides of the gearbox and the tips of the tines. These letters will line up in the same direction for each side. It is important that the tines are installed correctly.

AIR FILTER MAINTENANCE

Removing the Air Filter/Muffler Cover

WARNING: To avoid serious personal injury, always turn your unit off and allow it to cool before you clean or service it.

1. Place the choke control in Position 2.

NOTE: The choke control must be in Position 2 (Fig. 13) to remove the air filter/ muffler cover.

1. Remove the four (4) screws securing the air filter/muffler cover (Fig. 13). Use a flat blade or # T20 Torx bit screwdriver.
2. Pull the cover from the engine. Do not force.

Cleaning the Air Filter

Clean and re-oil the air filter every 10 hours of operation. It is an important item to maintain. Failure to maintain the air filter will Void the warranty.

1. Remove the air filter/muffler cover. Refer to the Removing the Air filter/Muffler Cover section.
2. Remove the air filter from inside the air filter/muffler cover (Fig. 14).
3. Wash the filter in detergent and water (Fig. 14). Rinse the filter thoroughly. Squeeze out excess water. Allow it to dry completely.
4. Apply enough SAE 30 oil to lightly coat the filter (Fig. 15).
5. Squeeze the filter to spread and remove extra oil (Fig. 15).
6. Replace the air filter inside the muffler cover (Fig. 14).

NOTE: Operating the unit without the air filter and cover assembly will Void the warranty.

Reinstalling the Air filter/Muffler Cover

1. Place the air filter/muffler cover over the back of the carburetor and muffler.

NOTE: The choke control must be in Position 2 (Fig. 13) to remove the air filter/ muffler cover.

1. Insert the four (4) screws into the holes in the air filter/ muffler cover (Fig. 13) and tighten. Use a flat blade or # T20 Torx bit screwdriver. Do not over tighten. Do not force.

SPARK ARRESTOR MAINTENANCE

1. Remove the air filter/muffler cover. Refer to Removing the Air Filter/Muffler Cover.
2. Locate the muffler front and the two (2) bolts securing it to the engine (Fig. 16). Remove the two (2) bolts using a flatblade screwdriver or 5/16-inch socket or nut driver. Pull the muffler off of the engine.
3. Turn the muffler over to the back side and locate the exhaust gasket. Remove the muffler gasket from the muffler (Fig. 16).

NOTE: If the exhaust gasket is torn or damaged, replace it with a new gasket before you reassemble the muffler.

1. Using a small flatblade screwdriver, carefully pry up the spark arrester from the recessed hole (Fig. 17). Remove the spark arrester from the muffler.
2. Clean the spark arrestor with a wire brush. Replace it if it is damaged or if it can't be cleaned thoroughly (Fig. 17).
3. Reinstall the spark arrester by pressing it into the recessed hole on the muffler's back side. Make sure it fits tightly against the muffler and is not raised up.

4. Place the exhaust gasket against muffler's back side. Align the gasket bolt holes with the bolt holes in the muffler. While holding exhaust gasket in place, insert the bolts into the muffler's front side (Fig. 16).

5. Place the muffler (with the exhaust gasket in place and bolts inserted), against the engine, aligning the bolt holes. Tighten the bolts to secure the muffler to the engine. If using a torque wrench, torque to:

80-90 in. · lb. (9-10.2 N·m)

1. Reinstall the air filter/muffler cover.

WARNING: If the muffler is not tightened securely, it could fall off causing damage to the unit and possible serious personal injury.

CARBURETOR ADJUSTMENTS

The engine's idle speed adjuster is adjustable through the air filter/muffler cover (Fig 18).

NOTE: Careless adjustments can seriously damage your unit. An authorized service dealer should make carburetor adjustments.

Check Fuel Mixture

Old and/or improperly mixed fuel is usually the reason for the unit not running properly. Drain and refill the tank with fresh, properly mixed fuel prior to making any adjustments. Refer to Oil and Fuel Information.

Clean Air Filter

The condition of the air filter is important to the operation of the unit. A dirty air filter will restrict air flow and change the air/fuel mixture. This is often mistaken for an out of adjustment carburetor. Check the condition of the air filter before adjusting the idle speed adjuster. Refer to Air Filter Maintenance.

Adjust Idle Speed Adjuster

WARNING: The unit may still run during idle speed adjustments. Wear protective clothing and observe all safety instructions to prevent serious personal injury.

If after checking the fuel mixture and cleaning the air filter the engine still will not idle, adjust the idle speed screw as follows:

1. Start the engine and let it run for about 2-3 minutes at a high speed (full throttle) to warm up. Refer to the Starting/Stopping Instructions.
   NOTE: Ensure the tines are not in contact with the ground when adjusting the idle.
2. Release the throttle control and let the engine idle. If the engine stops, insert a small phillips or flat blade screwdriver into the hole in the muffler cover (Fig. 18). Turn the idle speed screw clockwise 1/8 of a turn at a time (as needed) until the engine idles smoothly.

NOTE: The tines should not rotate during engine idle.
3. If the tines rotate when the engine idles, turn the idle speed screw counterclockwise 1/8 of a turn at a time (as needed), to reduce idle speed.

Checking the fuel mixture, cleaning the air filter, and adjusting the idle speed screw should solve most engine problems. If not and all the following are true:

• The engine will not idle
• The engine hesitates or stalls on acceleration
• There is a loss of engine power

Have the carburetor adjusted by an authorized service dealer.

REPLACING THE SPARK PLUG

Use a Champion RDJ7Y spark plug (or equivalent). The correct air gap is 0.020 in. (0.5 mm). Remove the plug after every 25 hours of operation to check its condition.

1. Stop the engine and allow it to cool. Grasp the plug wire firmly and pull the cap from the spark plug.
2. Clean dirt from around the spark plug. Remove the spark plug from the cylinder head by turning a 5/8 in. socket counterclockwise.

NOTE: Replace a cracked, fouled or dirty spark plug.

1. Set the air gap at 0.020 in. (0.5 mm) using a feeler gauge (Fig. 19).

CAUTION: Do not sand blast, scrape or clean electrodes. Grit in the engine could damage the cylinder.

Fig. 19

1. Install a correctly gapped spark plug in the cylinder head. Tighten by turning the 5/8 in. socket clockwise until snug.

If using a torque wrench torque to:

110-120 in. lb. (12.3-13.5 N·m)

Do not over tighten.

CLEANING THE UNIT

WARNING: To avoid serious personal injury, always turn the off and allow it to cool before you clean or service it.

• Use a small brush to clean off the outside of the unit and to keep the air vents free of obstructions.
• Do not use strong detergents or petroleum based cleaners, like kerosene. Some household cleaners contain aromatic oils such as pine and lemon that can damage the plastic housings or handles. Wipe off any moisture with a soft cloth.

STORAGE

• Never store a fueled unit where fumes may reach an open flame or spark.
• Allow the engine to cool before storing.
• Store the unit in a locked up area to prevent unauthorized use or damage.
• Store the unit in a dry, well-ventilated area.
• Store the unit out of the reach of children.

LONG TERM STORAGE

If you plan to store the unit for an extended time:

1. Drain all fuel from the fuel tank into a container. Do not use fuel that has been stored for more than 60 days. Dispose of the old fuel in accordance to local regulations.
2. Start the engine and allow it to run until it stalls. This ensures that all fuel has been drained from the carburetor.
3. Allow the engine to cool. Remove the spark plug and put 1 oz. (30 ml) of high quality motor oil into the cylinder. Pull the starter rope slowly to distribute the oil. Reinstall the spark plug.

NOTE: Remove the spark plug and drain all of the oil from the cylinder before attempting to start the unit after storage.

1. Thoroughly clean the unit and inspect for any loose or damaged parts. Repair or replace damaged parts and tighten loose screws, nuts or bolts. The unit is ready for storage.

TRANSPORTING

• Allow the engine to cool before transporting.
• Secure the unit while transporting.
• Drain the fuel tank before transporting.
• Tighten fuel cap before transporting.

MOVING THE UNIT

1. Allow the unit to cool before moving.
2. Loosen the knobs on the handlebar.
3. Fold the handlebars down as shown (Fig. 20).

1. Either carry the unit by the shaft tube grip or grasp the center of the handlebar to use it as a carrying handle (Fig. 21).
2. After the unit has been moved, reposition the handlebars and continue operation.

ACCESSORIES/REPLACEMENT PARTS

2-Cycle Oil 147543
Spark Plug 610311
Fuel Cap 180000
Tine (L) (Left Side Outer or Right Side Inner) 182729
Tine (R) (Right Side Outer or Left Side Inner) 182730
Clevis Pin with Clip 147473

ENGINE WILL NOT START

CAUSE

On/Off Stop Control in the STOP position

Empty fuel tank

Primer bulb wasn't pressed enough.

Engine flooded

Old or improperly mixed fuel

Fouled spark plug

Plugged spark arrestor

ACTION

Turn the On/Off Stop Control to START

Fill fuel tank

Press primer bulb fully and slowly 10 times

Use starting procedure with choke control in Position 2

Drain fuel tank / Add fresh fuel mixture

Replace or clean the spark plug

Clean or replace spark arrestor

ENGINE WILL NOT IDLE

CAUSE

Air Filter is Plugged

Old or improperly mixed fuel

Improper carburetor adjustment

ACTION

Replace or clean the air filter

Drain fuel tank / Add fresh fuel mixture

Adjust according to the Carburetor Adjustments section

ENGINE WILL NOT ACCELERATE

CAUSE

Old or improperly mixed fuel

Improper carburetor adjustment

Cultivator tines bound with dirt or grass

Dirty air filter

Plugged spark arrestor

ACTION

Drain fuel tank / Add fresh fuel mixture

Take to an authorized service dealer for a carburetor adjustment

Stop the unit, switch the On/Off Stop Control to STOP, clean and remove any debris binding the tine

Clean or replace the air filter

Clean or replace spark arrestor

ENGINE LACKS POWER OR STALLS WHEN UNDER LOAD

CAUSE

Old or improperly mixed fuel

Improper carburetor adjustment

Fouled spark plug

Plugged spark arrestor

ACTION

Drain fuel tank / Add fresh fuel mixture

Take to an authorized service dealer for a carburetor adjustment

Replace or clean the spark plug

Clean or replace spark arrestor

ENGINE

Engine Type.. Air-Cooled, 2-Cycle

Displacement 31 cc

Idle Speed RPM 2,800 - 3,600 rpm

Operating RPM 7,700+ rpm

Clutch Type Centrifugal

Ignition Type Electronic

On/Off Stop Control Rocker Switch

Spark Plug Gap 0.020 inch (0.5 mm)

Lubrication.. Fuel/Oil Mixture

Fuel/Oil Ratio 40:1

Carburetor. Diaphragm, All-Position

Starter Auto Rewind

Muffler . Baffled with Guard

Throttle Spring Return

Fuel Tank Capacity. 14 ounces (415 ml)

DRIVE SHAFT AND CULTIVATOR

Drive Shaft Tube Steel Tube

Throttle Control. Finger-Tip Trigger

Cultivating Path Width (Maximum) 9 inches (22.86 cm)

Cultivating Depth (Maximum) 6 inches (15.24 cm)

Approximate Unit Weight (no fuel) 26 lb. (12 kg)

EPA Emission Control Warranty Statement

Your Warranty Rights and Obligations

The Environmental Protection Agency and Troy-Bilt LLC are pleased to explain the emission control system warranty on your 2002 and later small off-road engine. New small off-road engines must be designed, built and equipped to meet stringent anti-smog standards. Bolens must warrant the emission control system on your small off-road engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your small off-road engine.

Your emission control system may include parts such as the carburetor or fuel-injected system, the ignition system, and catalytic converter. Also included may be hoses, belts, connectors and other emission-related assemblies.

Where a warrantable condition exists, Bolens will repair your small off-road engine at no cost to you including diagnosis, parts and labor.

The 2002 and later small off-road engines are warranted for two years. If any emission-related part on your engine is defective, the part will be repaired or replaced my Bolens.

Owners Warranty Responsibilities

• As the small off-road engine owner, you are responsible for the performance of the required maintenance listed in your operator's manual. Bolens recommends that you retain all receipts covering maintenance on your small off-road engine, but Bolens cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

• As the small off-road engine owner, you however should be aware that Bolens may deny you warranty coverage if your small off-road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

• You are responsible for presenting your small off-road engine to a Bolens Authorized Service Center as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

If you have any questions regarding your warranty rights and responsibilities, you should call 1-800-520-5520.

Manufacturer's Warranty Coverage

• The warranty period begins on the date the engine or equipment is delivered to the retail purchaser.
• The manufacturer warrants to the initial owner and each subsequent purchaser, that the engine is free from defects in material and workmanship which cause the failure of a warranted part for a period of two years.
  Repair or replacement of warranted part will be performed at no charge to the owner at an Authorized Bolens Service Center. For the nearest location please contact Bolens at: 1-800-520-5520.
• Any warranted part which is not scheduled for replacement, as required maintenance or which is scheduled for only for regular inspection to the effect of "Repair or Replace as Necessary" is warranted for the warranty period. Any warranted part which is scheduled for replacement as required maintenance will be warranted for the period of time up to the first scheduled replacement point for that part.
• The owner will not be charged for diagnostic labor which leads to the determination that a warranted part is defective, if the diagnostic work is performed at an Authorized Bolens Service Center.
• The manufacturer is liable for damages to other engine components caused by the failure of a warranted part still under warranty.
• Failures caused by abuse, neglect or improper maintenance are not covered under warranty.
• The use of add-on or modified parts can be grounds for disallowing a warranty claim. The manufacturer is not liable to cover failures of warranted parts caused by the use of add-on or modified parts.
  In order to file a claim, go to your nearest Authorized Bolens Service Center. Warranty services or repairs will be provided at all Authorized Bolens Service Centers.
• Any manufacturer approved replacement part may be used in the performance of any warranty maintenance or repair of emission related parts and will be provided without charge to the owner. Any replacement part that is equivalent in performance or durability may be used in non-warranty maintenance or repair and will not reduce the warranty obligations of the manufacturer
• The following components are included in the emission related warranty of the engine, air filter, carburetor, primer, fuel lines, fuel pick up/ fuel filter, ignition module, spark plug and muffler.

MANUFACTURER'S LIMITED WARRANTY FOR:

Bolens)byMTD

The limited warranty set forth below is given by Troy-Bilt LLC with respect with new merchandise purchased and used in the United States, its possessions and territories.

Troy-Bilt warrants this product against defects in material and workmanship 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 material or workmanship. This limited warranty shall only apply if this product has been operated and maintained in accordance with the Operator's Manual furnished with the product, and has not been subject to misuse, abuse, commercial use, neglect, accident, improper maintenance, alteration, vandalism, theft, fire, water or damage because of other peril or natural disaster. Damage resulting from the installation or use of any accessory or attachment not approved by Troy-Bilt for use with the product(s) covered by this manual will void your warranty as to any resulting damage.

This warranty is limited to ninety (90) days from the date of original retail purchase for any Bolens product that is used for rental or commercial purposes, or any other income-producing purpose.

HOW TO OBTAIN SERVICE: Warranty service is available, WITH PROOF OF PURCHASE THROUGH YOUR LOCAL AUTHORIZED SERVICE DEALER. To locate the dealer in your area, please check for a listing in the Yellow Pages or contact the Customer Service Department of Troy-Bilt LLC by calling 1-800-520-5520 or writing to PO Box 361131, Cleveland, Ohio 44136-0019. No product returned directly to the factory will be accepted unless prior written permission has been extended by the Customer Service Department of Troy-Bilt LLC.

This limited warranty does not provide coverage in the following cases:

A. Tune-ups - Spark Plugs, Carburetor Adjustments, Filters
B. Wear items - Bump Knobs, Outer Spools, Cutting Line, Inner Reels, Starter Pulley, Starter Ropes, Drive Belts
C. Troy-Bilt does not extend any warranty for products sold or exported outside of the United States of America, its possessions and territories, except those sold through Troy-Bilt's authorized channels of export distribution.

Trot-Bilt reserves the right to change or improve the design of any Bolens Product without assuming any obligation to modify any product previously manufactured.

No implied warranty, including any implied warranty of merchantability or fitness for a particular purpose, applies after the applicable period of express written warranty above as to the parts as identified. No other express warranty or guaranty, whether written or oral, except as mentioned above, given by any person or entity, including a dealer or retailer, with respect to any product shall bind Troy-Bilt LLC. During the period of the Warranty, the exclusive remedy is repair or replacement of the product as set forth above. (Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.)

The provisions as set forth in this Warranty provide the sole and exclusive remedy arising from the sales. Troy-Bilt LLC shall not be liable for incidental or consequential loss or damages including, without limitation, expenses incurred for substitute or replacement lawn care services, for transportation or for related expenses, or for rental expenses to temporarily replace a warranted product. (Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.)

In no event shall recovery of any kind be greater than the amount of the purchase price of the product sold. Alteration of the safety features of the product shall void this Warranty. You assume the risk and liability for loss, damage, or injury to you and your property and/or to others and their property arising out of the use or misuse or inability to use the product.

This limited warranty shall not extend to anyone other than the original purchaser, original lessee or the person for whom it was purchased as a gift.

How State Law Relates to this Warranty: This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

To locate your nearest service dealer dial 1-800-520-5520.

TROY-BILT LLC

PO Box 361131

Cleveland, OH 44136-0019 U.S.A.

SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE

FOR QUESTIONS CALL 1-800-520-5520

OPERATOR'S MANUAL PART NO. 769-00488A

PRINTED IN U.S.A.

11/03

Bolens)byMTD

RÉFERENCES, ILLUSTRATIONS ET SPECIFICATIONS RELATIVES AU PRODUIT

INSTRUCTIONS D'ARRÉT

Item Part No. Description

1 791-182059

Air Cleaner/Muffler Cover Assembly

(includes 2 & 40)

2 791-180350

Air Cleaner Filter

3 791-180351

Carburetor Mounting Screw Assembly

4 791-180226

Wavey Washer

5 791-182160

Choke Lever Assembly (includes 6)

6 791-182161

Choke Knob and Screw

7 791-182162

Choke Lever and Plate (includes 5)

8 753-04333

Carburetor Assembly (includes 9 & 20)

9 791-610675

Carburetor Gasket

10 791-181860

Carb Mount Screw

11 791-182607

Primer and Hose Assembly

12 753-1196

Carb Mount Assembly (includes 10 & 14)

13 791-684451

Reed Assembly

14 753-1208

Carburetor Mount Gasket

15 753-04369

Crank Case Service Assembly

(includes 10 & 23)

16 791-612134

Rear Mounting Pad

17 753-04306

Fuel Tank Assembly (includes 18-20)

791-182612

Fuel Cap Assembly

791-181168

Fuel Return Line

20 791-682039

Fuel Line Assembly

21 791-145308

Front Mounting Pad

22 791-683065

Shroud Assembly (includes 23)

23 791-181861

Shroud Screw

24 791-182064

Shroud Extension and Stand

25 791-182736

Flywheel Assembly

26 791-181065

Spacer

27 753-04232

Recoil Pulley Assembly

28 791-613102

Recoil Spring

29 791-180930

Pulley Retainer Assembly

30 791-611061

Rope Guide

31 791-180317

Fuel Tank Guard Assembly

32 791-181079

Pull Handle

33 791-613103

Rope

34 791-181912

Screw

Item Part No. Description

35 753-04238

36 791-182368

37 791-182369

38 791-153592

39 791-180098

40 791-181345 Screw

41 791-153597 Upper Clamp Assembly

42 753-04337 Module Assembly

43 791-182880 Wire Lead

44 791-610311

45 753-04159

46 791-182174

47 791-182464

48 753-04323

49 753-1207

50 753-1197

51 791-182723

52 791-611063

53 791-182747 Spark Arrestor

• 753-04134

• 791-180090 O.E.M. Carburetor Repa

• 791-180091 Gasket-Diaphragm Repair Kit

• 753-1209 Piston Ring

• 753-04359 Short Block Assembly

(includes 15,44,48-51)

• 791-181599 Clutch Springs (Qty. 2)

* not shown

Description

Starter Housing Assembly

(includes 27-30, 32-34 & 40)

Clutch Washer

Clutch Rotor Assembly

Clutch Drum Assembly

Clutch Cover Assembly (includes 40)

Screw

Upper Clamp Assembly

Module Assembly

Wire Lead

Spark Plug

Exhaust Gasket

Muffler Assembly (includes 45, 47 & 53)

Muffler Mounting Bolt Assembly

Cylinder Assembly (includes 50 & 51)

Piston and Rod Assembly

Cylinder Gasket

Cylinder Bolt

Ground Tab

Spark Arrestor

Engine Gasket Kit

O.E.M. Carburetor Repair Kit

Gasket-Diaphragm Repair Kit

Piston Ring

Short Block Assembly

(includes 15, 44, 48-51)

Clutch Springs (Qty. 2)

BOOM AND CULTIVATOR PARTS - MODEL BL410 2-CYCLE GAS CULTIVATOR

Item Part No. Description

1 791-00023
2 791-182882
3 791-182675
4 791-182676
5 791-182678
6 791-182899
7 791-182898 Knob,3 prong
8 791-180943
9 791-181577
10 791-683295 Handle Bracket Assembly (includes 11-15)
791-181811 Screw
12 791-181812 Upper Handle Clamp
13 791-181813 Middle Handle Clamp
791-181814 Lower Handle Clamp
791-181815 Nut
16 791-181575 Grip
791-182900 Lower Handle Bar
18 791-182681 Hardware, Handle Bar Mounting (lower)
19 791-147467 Wheel Bracket Mounting Hardware
20 753-04266 Guard Mounting Hardware
Guard
791-180320 Wheel Bracket Assembly
23 791-180944 Wheel Assembly
24 753-04489 Gear Box Assembly
25 791-182195 Screw
26 791-180288 Sleeve Retainer Bolt
27 791-147473 Tine Fastener Assembly
28 791-182729 Tine Assembly (Left Outer or Right Inner)
29 791-182730 Tine Assembly (Left Inner or Right Outer)

Optional Accessories

• 791-147543 2-Cycle Oil

GARANTÍA LIMITADA DEL FABRICANTE PARA:

Bolens)byMTD