Owner's Manual

CRAFTSMAN°5.0 HORSEPOWER22" ECONOMYSIDE DISCHARGEROTARY LAWN MOWER

Model No.917.388230

• Safety• Assembly• Operation• Maintenance• Espafiol• Repair Parts

CAUTION:Read and follow all

Safety Rules and Insuuc_u_before operating this equ_hF

Sears, Roebuck and Co., Hoffman Estates, IL 60179

Warranty 2 Product Specifications 9Safety Rules 2 Service and Adjustments 12Assembly 4 Storage 13Operation 5 Troubleshooting 14Maintenance Schedule 8 Repair Parts 32Maintenance 8 Parts Ordering Back Cover

LIMITED TWO YEAR WARRANTY ON CRAFTSMAN POWER MOWERFor two years from date of purchase, when this Craftsman Lawn Mower is maintained,lubricated, and tuned up according to the operating and maintenance instructions in theowner's manual, Sears will repair free of charge any defect in matedal or workmanship.If this Craftsman Lawn Mower is used for commercial or rental purposes, this warrantyapplies for only 90 days from the date of purchase.This Warranty does not cover:• Expendable items which become worn during normal use, such as rotary mower

blades, blade adapters, belts, air cleaners and spark plug.• Repairs necessary because of operator abuse or negligence, including bent crank-

shafts and the failure to maintain the equipment according to the instructions con-tained in the owner's manual.

Warranty service is available by returning the Craftsman power mower to the nearestSears Service Center/Department in the United States. This warranty applies only whilethis product is in use in the United States.This Warranty gives you specific legal rights, and you may also have other rights whichvary from state to state.SEARS, ROEBUCKAND CO., D/817 WA, HOFFMAN ESTATES, ILLINOIS 60179

Safety standards require operator pres-ence controls to minimize the risk of injury.Your unit is equipped with such controls.Do not attempt to defeat the function of theoperator presence controls under anycircumstances.

TRAINING:

• Read this operator's manual carefully.Become familiar with the controls and

know how to operate your mowerproperly. Learn how to quickly stopmower.

• Do not allow children to useyour mower.Never allow adults to use mower withoutproper instructions.

• Keep the area of operation clear of allpersons, especially small children andpets.

• Use mower only as the manufacturerintended and as described in this manual.

• Do not operate mower if it has beendropped or damaged in any manner.Always have damage repaired beforeusing your mower.

• Do not use accessory attachments thatare not recommended by the manufac-turer. Use of such attachments may behazardous.

• The blade turns when the engine isrunning.

2

PREPARATION:

• Always thoroughly check the area to bemowed and clear it of all stones, sticks,wires, bones, and other foreign objects.These objects will be thrown by the bladeand can cause severe injury.

• Always wear safety glasses or eyeshields when starting and while usingyour mower.

• Dress properly. Do not operate mowerwhen barefoot or wearing open sandals.Wear only solid shoes with good tractionwhen mowing.

• Check fuel tank before starting engine.Do not fill gas tank indoors, when theengine is running or when the engine ishot. Allow the engine to cool for severalminutes before filling the gas tank. Cleanoff any spilled gasoline before starting theengine.

• Always make wheel height adjustmentsbeforestarting your mower. Neverattempt to do this while the engine isrunnin_].

• Mow only in daylight or good artificiallight.

OPERATION:• Keep your eyes and mind on your mower

and the area being cut. Do not let otherinterests distract you.

• Do not mow wet or slippery grass. Neverrun while operating your mower. Alwaysbe sure of your footing -- keep a firmhold on the handles and walk.

, Do not put hands or feet near or underrotating parts. Keep clear of the dischargeopening at all times.Always stop the engine whenever youleave or are not using your mower, orbefore crossing driveways, walks, roads,and any gravel--covered areas.Never direct discharge of material towardbystanders nor allow anyone near themower while you are operating it.Before cleaning, inspecting, or repairingyour mower, stop the engine and makeabsolutely sure the blade and all movingparts have stopped. Then disconnect thespark plug wire and keep it away from thespark plug to prevent accidental starting.Do not continue to run your mower if youhit a foreign object. Follow the procedureoutlined above, then repair any damagebefore restarting and operating youmower.

Do not change the governor settings oroverspeed the engine. Engine damage orpersonal injury may result.Do not operate your mower if it vibratesabnormally. Excessive vibration is anindication of damage; stop the engine,safely check for the cause of vibrationand repair as required.

• Do not run the engine indoors. Exhaustfumes are dangerous.

• Never cut grass by pulling the mower"towards you. Mow across the face ofslopes, never up and down or you mightlose your footing. Do not mow exces-sively steep slopes. Use caution whenoperating the mower on uneven terrainor when changing directions -- maintaingood footing.

• Never operate your mower withoutproper guards, plates, grass catcher orother safety devices in place.

MAINTENANCE AND STORAGE:• Check the blade and the engine mount-

ing bolts often to be sure they aretightened properly.

• Check all bolts, nuts and screws atfrequent intervals for proper tightness tobe sure mower is in safe workingcondition.

• Keep all safety devices in place andworking.

• To reduce fire hazard, keep the enginefree of grass, leaves or excessive greaseand oil.

• Check grass catcher often for deteriora-tion and wear and replace worn bags.Use only replacement bags that arerecommended by and comply withspecifications of the manufacturer of yourmower.

• Always keep a sharp blade on yourmower.

• Allow engine to cool before storing in anyenclosure.

• Never store mower with fuel in the tankinside a building where fumes may reachan open flame or an ignition source suchas a hot water heater, space heater,

Aclothes dryer, etc.CAUTION: Always disconnect spark

plug wire and place wire where it cannotcontact spark plug in order to preventaccidental starting when setting up,transporting, adjusting or making repairs.WARNINGThe engine exhaust from this productcontains chemicals known to the State ofCalifornia to cause cancer, birth defects,or other reproductive harm.

3

Theseaccessories were available when this lawn mower was produced. They are alsoavailable at most Sears retail outlets and service centers. Most Sears stores can alsoorder repair parts for you, when you provide the model number of your lawn mower.Some of these accessories may not apply to your lawn mower.

LAWN MOWER PERFORMANCE

CUPPING DEFLECTORFOR REAR DISCHARGE LAWN MOWERS

GRASS CATCHERSFOR

REAR DISCHARGELAWN MOWERS

MULCHER KITS

GRASS CATCHERS

FORSIDE DISCHARGELAWN MOWERS

STABIMZER

GAS CANS

LAWN MOWER MAINTENANCE

MUFFLERS

BELTS BLADES

%BLADE ADAPTERS

AIR RLTERS

WHEELS

SPARK PLUGS

ENGINE OIL

Read these instructions and this manual in • Remove all packing materials exceptits entirety before you attempt to assembleor operate your new lawn mower. Yournew lawn mower has been assembled atthe factory with the exception of thoseparts left unassembled for shippingpurposes. All parts such as nuts, washers,bolts, etc., necessary to complete theassembly have been placed in the partsbag. To ensure safe and proper operation MOWERof your lawn mower, all parts and hardware TO UNFOLD HANDLEyou assemble must be tightened securely.Use the correct tools as necessary toensure proper tightness.

TO REMOVE LAWN MOWER FROMCARTON

• Remove loose parts included withmower. .

• Cut down two end corners of carton andlay end panel down flat.

padding between upper and lowerhandle and padding holding operatorpresence control bar to upper handle.

• Roll lawn mower out of carton and checkcarton thoroughly for additional looseparts.

HOW TO SET UP YOUR LAWN

IMPORTANT: Unfold handle carefully soas not to pinch or damage control cables.• Raise handles until lower handle section

locks into place in mowing position.• Remove protective padding, raise upper

handle section into place on lowerhandle and tighten both handle knobs.

• Remove handle padding holdingoperator presence control bar to upperhandle.

4

• Your lawn mower handle can beadjusted for your mowing comfort.Refer to "Adjust Handle" in the Serviceand Adjustment section of this manual.

Operator presence controlbar

Upper handle _ _,_t /_

Liftup __ .,_ Mowing

-:__,_2-" /// position

KNOW YOUR LAWN MOWER

READ THIS OWNER'S MANUALAND SAFETY RULES BEFORE OPERATING YOUR LAWN

MOWER. Compare the illustrationswithyour lawn mower to familiarize yourselfwith thelocationof various controls and adjustments. Save this manual for future reference.

These symbols may appear on your lawn mower or in literature supplied with theproduct. Learn and understand their meaning.

CAUTION ENGINE ENGINE FAST SLOW CHOKE FUEL OIL DANGER, KEEP HANDSOR WARN_G ON OFF ANt) FEET AWAY

Enginezone controlcable

Starter handle

Operator presence controlbar

Handle knob

Engineoil cap withdipstick

Gasoline fillercap

Mulcher door

Primer Wheel adjuster(on each wheel)

MEETS CPSC SAFETY REQUIREMENTSSears rotary walk-behind power lawn mowers conform to the safety standards of theAmerican National Standards Institute and the U.S. Consumer Product Safety Commis-sion. The blade turns when the engine is running.

operatorpresence control bar- must beheld down to the handle to start the engine.Release to stopthe engine.Primer - pumps additionalfuel from thecarburetorto the cylinderfor use when startinga cold engine.

Starter handle - used for startingthe engine.Mulcher- allows conversionto discharge orbagging operation.

5

The operation of any lawn mower can result inforeign objects thrown into the eyes, which canresult in severe eye damage. Always wearsafety glasses or eye shields while operatingyour lawn mower or performing any adjust-ments or repairs. We recommend a widevision safety mask over spectacles or standardsafety glasses.

HOW TO USE YOUR LAWN MOWERENGINE SPEED CONTROL

The engine speed was set at the factoryfor optimum performance. Speed is notadjustable.ENGINE ZONE CONTROLACAUTION: Federal regulations requ re anengine control to be installed on this lawnmower in order to minimize the risk of bladecontact injury. Do not under any circumstancesattempt to defeat the function of the operatorcontrol. The blade turns when the engine isrunning.• Your lawn mower is equipped with an

operator presence control bar whichrequires the operator to be positionedbehind the lawn mower handle to start andoperate the lawn mower.

TO ADJUST CUTFING HEIGHT

• Raise wheels for low cut and lowerwheels for high cut.

• Adjust cutting height to suit yourrequirements. Medium position is bestfor most lawns.

• To change cutting height, squeezeadjuster lever toward wheel. Movewheel up or down to suit your require-ments. Be sure all wheels are in thesame setting.

NOTE: Adjuster is properly positionedwhen plate tab inserts into hole in lever.Also, 9-position adjusters (if so equipped)allow lever to be positioned between the

plate tabs. Lever Plate tabLower wheels for

high cut _ _

Raise wheels for low cutBEFORE STARTING ENGINE OIL

Your lawn mower is shipped without oil in theengine.• Be sure mower is level and area around oil

fill is clean.• Remove engine oil cap and fill to the full line

on the dipstick.

• Use 20 ozs. of oil. For type and grade of oilto use, see "ENGINE" in Maintenancesection of this manual.

• Pouroil slowly. Do not overfill.• Check oil level before each use. Add oil if

needed. Fill to full line on dipstick.• To read proper level, tighten engine oil cap

each time.

• Reinstall engine oil cap and tighten.• Change the oil after every 25 hours of

operation or each season. You may needto change the oil more often under dusty,dirty conditions.

GAS

• Fill fuel tank. Use fresh, clean, regularunleaded gasoline with a minimum of 87octane. Do not mix oil with gasoline.Purchase fuel in quantities that can beused within 30 days to assure fuelfreshness.

WARNING: Experience indicates that alcoholblended fuels (called gasohol or using ethanolor methanol) can attract moisture which leadsto separation and formation of acids duringstorage. Acidic gas can damage the fuelsystem of an engine while in storage. To avoidengine problems, the fuel system should beemptied before storage of 30 days or longer.Drain the fuel tank, start the engine and let itrun until fuel lines and carburetor are empty.Use fresh fuel next season. See StorageInstructions for additional information. Neveruse engine or carburetor cleaner products infuel tank or permanent damage may occur.

Gasoline filler Engine oil cap

cap

TO START ENGINE

• To start a cold engine, push primer three(3) times before trying to start. Use afirm push. This step is not usuallynecessary when starting an enginewhich has already run for a few minutes.

• Hold operator presence control bardown to the handle and pull starterhandle quickly. Do not allow starterrope to snap back.

• To stop engine, release operatorpresence control bar.

NOTE: In cooler weather it may benecessary to repeat priming steps. Inwarmer weather over priming may cause

6 flooding and engine will not start. If you do

floodengine, wait a few minutes beforeattempting to start and do not repeatpriming steps.

TO CONVERT TO DISCHARGINGMOWER

Your mower is shipped ready to be usedas a mulcher. To convert to bagging ordischarging:• Lift discharge guard and remove

mulcher plate.• Mower can now be used for side

discharge or optional grass catcher canbe attached.

• To return to mulching operation, simplyreinstall mulcher plate as shown.

CAUTION: Do not run your lawn mowerwithout discharge guard, approved grasscatcher or mulcher plate in place.

J_ Hooks

Mulch

.=rod

MOWING TIPS

• Under certain conditions, such as verytall grass, it may be necessary to raisethe height of cut to reduce pushing effortand to keep from overloading the engineand leaving clumps of grass clippings. Itmay also be necessary to reduceground speed and/or run the lawnmower over the area a second time.

• For extremely heavy cutting, reduce thewidth of cut by overlapping previouslycut path and mow slowly.

• For better grass bagging and mostcutting conditions, the engine speedshould be set in the fast position.

• For side discharge lawn mowers, cuttingin a counter-clockwise direction, startingat the outside of the area to be cut,spreads grass clippings more evenlyand puts less load on the engine. Tokeep clippings off of walkways, flowerbeds, etc., make the first cuts in aclockwise direction.

• Pores in cloth grass catchers canbecome filled with dirt and dust with useand catchers will collect less grass. Toprevent this, regularly hose catcher offwith water and let dry before using.

• Keep top of engine around starter clearand clean of grass clippings and chaff.This will help engine air flow and extendengine life.

MULCHING MOWING TIPS

IMPORTANT: For best performance, keepmower housingfree of built-upgrass andtrash. See "Cleaning" in MAINTENANCEsection of this manual.

• The special mulching blade will recutthegrass clippingsmany times and reducethem in size so that as they fallonto thelawn they will disperse intothe grassandnot be noticed. Also, the mulched grass willbiodegrade quicklyto provide nutriantsforthe lawn. Always mulch with your highestengine (blade) speed as this will provide thebest recuttingaction of the blades.

• Avoid cutting your lawn when it is weL Wetgrass tends to form dumps and interfereswith the mulching action. The best time tomow your lawn is the early aftemcon. Atthis time the grass has dried and the newlycut area will not be exposed to the directsun.

• For best results,adjust the lawn mowercuttingheight so that the lawn mower cutsoff only the top one-thirdof the grass blades.If the lawn is overgrown itwill be necessaryto raisethe height of cut to reduce pushingeffortand to keep from overloadingtheengine and leavingclumps of mulchedgrass. For extremely heavy mulching,reduce your width of cut by overlappingpreviouslyout path and mow slowly.

• Certain types of grass and grass conditionsmay require that an area be mulched asecond time to completely hide theclippings. When doing a second cut, mowacross or perpendicular to the firstcut path.

• Change your cuttingpattern from weektoweek. Mow northto south one week thenchange to east to west the next week. Thiswillhelp prevent matting and grainingof thelawn.

7

.A'NTENANCESC.EOULE.s YOUCOMPL o,,,,...REGULAR SERVICE f__-_t_(_:_._-_ SERVICE DATE:_

Check for Loose Fasteners _ t##

Clean/Inspect Grass Catcher _(if Equipped)

a Clean Lawn Mower

O Ctean Under Drive Cover(power-Propelled Mowers)Check drive belt/pulleys

RE (Power-Propelled Mowers)ChecWSharpen/Repla"ceBlade _ 3

LubricationChart If (I/Clean BatteP//RechargeIElactrla Start Mowers) IV# (I,/4

E Check Engine Oil Level _/'N Char_le Engine Oil t/_,z

G CLeanAir Filter I_ 2I Inspect Muffler

N Clean or Replace Spark Plug

E Replace Air Filter Paper Cartridge i,/°z

t - Change more ofl_ v_en operating under a heavy load or in high a'_0i*nl Ii_tp*rals'es.2 -Ser, dce rnore onen '/A'_n operating in dirty or dwl'/condllk_s.

3 - Repk:q blade= morroon_ wi_m mow_g in =andy K*IIL4 - ChaiSe 48 hours at end of =euon.

GENERAL RECOMMENDATIONS

The warranty on this lawn mower does notcover items that have been subjected tooperator abuse or negligence. To receive fullvalue from the warranty, operator mustmaintain mower as Instructed in this manual.Some adjustmentswill need to be madeperiodicallyto pmpedy maintain your unit.All adjustments in the Service and Adjust-merits section of this manual should bechecked at least once each season.• Once a year, replace the spark plug, clean

or replace air filterelement and check bladefor wear. A new spark plug and clean/newair filterelement assures proper air-fuelmixture and helps your engine run betterand last longer.

• Follow the maintenance schedule in thismanual.

BEFORE EACH USE

• Check engine oil level.• Check for loose fasteners.LUBRICATION

Keep unit well lubricated(See "LUBRICATIONCHART").

(_) LUBRICATION CHARTWheeladjuster (_) Mulcher door

_J

oil __

(_) Handle bracket

mountingpin

(_ Spray lubricante(_) Referto MAINTINANCE"ENGiNE"

SECTION.

IMPORTANT: Do not oil or grease plasticwheel bearings. Viscous lubricantswill attractdust and dirtthat will shortenthe lifeof the selflubricatingbearings, if you feel they must belubricated,use only a dry, powdered graphitetype lubricant sparingly.

8

PRODUCT SPECIFICATIONS

MODEL NUMBER 917.388230

SERIAL NUMBER

DATE OF PURCHASE

HORSEPOWER: 5.0

DISPLACEMENT: 11.5 CU. IN.

GASOLINE CAPACITY/TYPE: 1.5 QUARTS

UNLEADED REGULAR

dL TYPE (API-SF/SG/SH): SAE 30 (ABOVE 32°F)

SAE 5W-30 (BELOW 32°F)

)IL CAPACITY: 20 OZS.

SPARK PLUG(GAP: .030") CHAMPION RJ19LM OR J19LM

VALVE CLEARANCE: INTAKE: .004 - .008

EXHAUST: .004 - .008

SOLID STATE iGNITION

AIR GAP: .0125 IN.

BLADE BOLT TORQUE: 35-40 FT. LBS.

• The model and serial numbers will be found on a decal attached to the rear of thelawn mower housing.Record both serial number and date of purchase in spaceprovided above.

LAWN MOWER

Always obsewe safety rules when performingany maintenance.TIRES

• Keep tiresfree of gasoline, oil, or insectcontrol chemicals which can harm rubber.

• Avoidstumps,stones,deep ruts,sharpobjectsand otherhazardsthatmay cause

tiredamage.

BLADE CARE

For best results, mower blade must bekept sharp. Replace bent or damagedblades.

TO REMOVE BLADE

• Disconnect spark plug wire from sparkplug and place wire where it cannotcome in contact with spark plug.

• Turn lawn mower on its side. Make sureair filter and carburetor are up.

• Use a wood block between blade and

mower housing to prevent blade fromturning when removing blade bolt.

• Protect your hands with gloves and/orwrap blade with heavy cloth.

• Remove blade bolt by turning counter-clockwise.

• Remove blade and attaching hardware(bolt, lock washer and hardenedwasher).

NOTE: Remove the blade adapter andcheck the key inside hub of blade adapter.The key must be in good condition to workproperly. Replace adapter if damaged.

TO REPLACE BLADE

• Position the blade adapter on the enginecrankshaft. Be sure key in adapter andcrankshaft keyway are aligned.

• Position blade on the blade adapteraligning the two (2) holes in the bladewith the raised lugs on the adapter.

• Be sure the trailing edge of blade(opposite sharp edge) is up toward theengine.

• Install the blade bolt with the lockwasher and hardened washer into bladeadapter and crankshaft.

• Use block of wood between blade andlawn mower housing and tighten theblade bolt, turning clockwise.

• The recommended tightening torque is35-40 ft. Ibs.

IMPORTANT: Blade bolt is grade 8 heattreated.

TO SHARPEN BLADE

NOTE: We do not recommend sharpeningblade - but if you do, be sure the blade isbalanced.Care should be taken to keep the bladebalanced. An unbalanced blade will cause

eventual damage to lawn mower orengine.• The blade can be sharpened with a file

or on a grinding wheel. Do not attemptto sharpen while on the mower. -

• To check blade balance, drive a nail intoa beam or wall. Leave about one inch ofthe straight nail exposed. Place centerhole of blade over the head of the nail.If blade is balanced, it should remain ina horizontal position. If either end of theblade moves downward, sharpen theheavy end until the blade is balanced.

BladeCrankshaft

Key keyway

Blade

Lockwasher\

Blade shaftbolt

Hardened Trailingwasher edge Blade adapter

GRASS CATCHER

(If purchased as an accessory)• The grass catcher may be hosed with

water, but must be dry when used.• Check your grass catcher often for

damage or deterioration. Throughnormal use it will wear. If catcher needsreplacing, replace only with a manufac-turer approved replacement catcher.Give the lawn mower model numberwhen ordering.

ENGINELUBRICATION

Use only high qualitydetergent oil rated withAPI service classificationSF, SG or SH.Select the oil'sSAE viscositygrade accordingto your expected operating temperature.

SAE VISCOSITY GRADES

NOTE: Although multi-viscosityoils (5W30,10W30 etc.) improve starting in cold weather,these multi-viscosity oils will result in increasedoil consumption when used above 32°F.Check your engine oil level more frequently toavoid possible engine damage from runninglow on oil.

Change the oil after every 25 hours ofoperation orat least once a year if the lawn

mower is not used for 25 hours in one year.

Check the crankcase oil level before startingthe engine end after each five (5) hours ofcontinuous use. _ghten oil plug securely eachtime you check the oillevel.TO CHANGE ENGINE OIL

NOTE: Before tipping lawn mower to drainoil, drain fuel tank by running engine untilfuel tank is empty.• Disconnect spark plug wire from spark

plug and place wire where it cannotcome in contact with spark plug.

• Remove engine oil cap; lay aside on aclean surface.

• Tip lawn mower on its side as shownand drain oil into a suitable container.Rock lawn mower back and forth toremove any oil trapped inside of engine.

• Wipe off any spilled oil on lawn mowerand on side of engine.

• Fill engine with oil. Fill only to the"FULL" line on the dipstick. DO NOTOVER FILL.

• Replace engine oil cap.• Reconnect spark plug wire to spark

plug.

Container

AIR FILTER

Your engine will not run properly and may bedamaged by usinga dirty air filter.Replace the air filterevery year, more often ifyou mow in very dusty, dirtyconditions. Do notwash air filter.

TO CHANGE AIR FILTER

• Loosen screw and tilt cover to remove.• Carefully remove cartridge.• Clean by gently tapping on a flat

surface. If very dirty, replace cartridge.,ACAUTION: Petroleum solvents, suchas kerosene, are not to be used to clean

•30- -_. .,o- o- _. _- _ ,G.TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OILCHANGE 10

;artridge. They may cause deterioration ofthe cartridge. Do not oil cartridge. Do notuse pressurized air to clean or drycartridge.

• Install cartridge, then replace covermaking sure the tabs are aligned withthe slots in the back plate. Fasten

screw securely. Back

plate

CoverLip tabs

Ca_ddge

Slots

Cover

MUFFLER

Inspect and replace corroded muffler as itcould create a fire hazard and/or damage.SPARK PLUG

Change your spark plug each year to makeyour engine start easier and run better. Setspark plug gap at .030 inch.

CLEANING

IMPORTANT: For best performance, kiipmower housing free of built-grassand trash.Clean the underside of your mower after eachuse.

ACAUTION: Disconnect spark plug wirefrom spark plug and place wire where it cannotcome incontact with the spark plug.• Turn lawn mower on its side. Make sure air

filter and carburetor are up. Clean theunderside of your lawn mower by scrapingto remove build-up of grass and trash.

• Clean engine often to keep trash fromaccumulating. A clogged engine runs hotterand shortens engine life.

• Keep finished surfaces and wheals free ofall gasoline, oil,etc.

• We do not recommend using a gardenhose to clean lawn mower unless theelectricalsystem, muffler,air filter andcarburetor are covered to keep water out.Water inengine can result in shortenedengine life.

11

A.CAUTION: Before performing anyservice and adjustments:• Release control bar and stop engine.• Make sure the blade and all moving

parts have completely stopped.• Disconnect spark plug wire from spark

plug and place where it cannot comein contact with plug.

LAWN MOWER

TO ADJUST cu'n'ING HEIGHTSee "TO ADJUST CUTTING HEIGHT" inthe Operation section of this manual.

REAR DEFLECTOR

The rear deflector, attached between therear wheels of your mower, is provided tominimize the possibility that objects will bethrown out of the rear of the mower intothe operator's mowing position. If thedeflector becomes damaged, it should bereplaced.

DISCHARGE GUARD

The discharge guard, attached to thedischarge opening of your lawn mower, isprovided to prevent the possibility of injuryresulting from objects being thrown out ofthe discharge opening into the operatormowing position. If the discharge guardbecomes damaged, it should be replaced.TO ADJUST HANDLE

Your lawn mower handle can be raised orlowered for your mowing comfort. Four(4) positions are available: high, mediumhigh, medium low and low. Handles areshipped mounted in the medium lowposition.• To change from medium low to medium

high position, the upper and lowerhandle sections will have to be turnedover.

• Remove the cable clips.• Remove the controls and operator

presence control bar from the upperhandle.

• Remove the starter rope guide from theupper handle.

• Remove hairpin cotters.• Disconnect the lower handle from the

handle brackets.• Turn the handle over and reassemble

the hairpin cStters that have beenremoved.

• Reassemble the starter rope guide. "• Reassemble the controls and the

operator presence control bar to theupper handle.

ShippingPositionMediumlow Medium high

L

_ High Low

_.CAUTION: The operator presence

control bar must pivot freely to permitblade/brake engagement when control baris released. Do not overtighten thefasteners holding the controls to the upperhandle.• To change from medium low to high

position only the upper handle sectionwill have to be turned over.

• To change from medium low to lowposition, only the lower handle sectionwill have to be turned over.

Squeeze toremove

Handle bracket

Mountin pin

Hairpin cotter

ENGINE

ENGINE SPEED

Your_engine speed has been factory set.Do not attempt to increase engine speedor it may result in personal injury. If youbelieve that engine is running too fast ortoo slow, take your mower to an authorizedservice center for repair and adjustment.

12

CARBURETOR

Your carburetor has a non-adjustable fixedmain jet for mixture control. If your enginedoes not operate properly due to sus-pected carburetor problems, take yourlawn mower to an authorized servicecenter for repair and/or adjustment.

IMPORTANT: Never tamper with theengine governor, which is factory set forthe proper engine speed. Overspeedingthe engine above the factory high speedscan be dangerous. If you think theengine-governed high speed needsadjusting, contact your nearest authorizedservice center, which has proper equip-ment and experience to make anynecessary adjustments.

Immediately prepare your lawn mower forstorage at the end of the season or if the unitwill not be used for 30 days or more.

LAWN MOWER

When lawn mower is to be stored for a periodof time, clean it thoroughly, remove all dirt,grease, leaves, etc. Store in a clean, dry area.• Clean entire lawn mower (See "CLEANING"

in the Maintenance section of this manual).• Lubricate as shown in the Maintenance

section of this manual.• Be sure that all nuts, bolts, screws, and pins

are securely fastened. Inspect movingparts fordamage, breakage and wear.Replace if necessary.

• Touch up all rusted or chipped paintsurfaces; sand lightly before painting.

HANDLEYou can fold your lawn mower handle forstorage.• Squeeze the bottom ends of the lower

handle toward each other untilthe lowerhandle clears the handle bracket, thenmove handle forward.

• Loosen upper handle mounting boltsenough to allow upper handle to he foldedback.

IMPORTANT: When folding the handle forstorage or transportation,be sure to fold thehandle as shown oryou may damage thecontrolcables.

• When setting up your handle from thestorage position,the lower handle willautomaticallylock into the mowing position.

Lower handle

Squeeze to <_ _'._ /. Hairpin

remove_ r

pin

Operator presence controlbar \_

Upper handle -......._///., f'J

Fold forward for _ .=.....storage "_ F",,,

,,YlFold,y / boekward

Mowingposition

Lower handleENGINEFUEL SYSTEMIMPORTANT: It is importantto prevent gumdeposits from forming inessential fuel systemparts such as carburetor,fuel filter, fuel hose,or tank during storage. Also, experienceindicates that alcohol blended fuels (calledgasohol or using ethanol or methanol) canattract moisture which leads to separation andformation of acids during storage. Acidic gascan damage the fuel system of an enginewhile in storage.• Drain the fuel tank.• Start the engine and let it run untilthe fuel

lines and carburetor are empty.• Never use engine or carburetor cleaner

products in the fuel tank or permanentdamage may occur.

• Use fresh fuel next season.

NOTE: Fuel stabilizer is an acceptablealternative in minimizing the formation of fuelgum depositsduringstorage. Add stabilizertogasoline in fuel tank or storage container.Always follow the mix ratiofound on stabilizercontainer. Run engine at least 10 minutesafter adding stabilizerto allow the stabilizer toreach the carburetor. Do not drain the gastank and carburetor ifusingfuel stabilizer.

13

ENGINEOILDrain oil (with engine warm) and replace withclean engine oil. (See "ENGINE" intheMaintenance section of this manual).CYMNDER• Remove spark plug.• Pour one ounce (29 ml) of oil throughspark

plug hole into cylinder.• Pull starter handle slowly a few times to

distributeoil.• Replace with new spark plug.

OTHER• Do notstore gasoline from one season to

another.• Replace your gasoline can if your can starts

to rust. Rust and/or dirt inyour gasoline willcause problems.

• If possible,storeyour unit indoorsand coveritto give protectionfrom dust and dirt.

• Cover your unitwith a suitable protectivecover that does not retain moisture. Do notuse plastic. Plasticcannot breathe whichallows condensation to form and will causeyour unitto rust.

IMPORTANT: Never cover mower whileengine and exhaust areas are still warm.ACAUTION: Never store the lawn

mower with gasoline in the tank inside abuilding where fumes may reach an openflame or spark. Allow the engine to coolbefore storing in any enclosure.

TROUBLESHOOTING CHART

PROBLEM

Does not start

CAUSE

• Dirty air filter.• Out of fuel.• Stale fuel.

• Waterinfuel.

CORRECTION

• Clean/replace air filter.• Fill fuel tank.• Drain tank and refill with

fresh dean fuel..oDrain fuel tank and

• Spark plug wire isdisconnected.

• Bad spark plug.• Loose blade or broken blade

adapter.• Control bar in released

position.• Control bar defective.

carburetor and refilltank

withfresh gasoline.• Connect wireto plug.

• Replace spark plug.• Tighten blade bolt or

replace blade adapter.• Depress control barto

handle.

• Replace control bar.

14

TROUBLESHOOTING CHART

PROBLEM CAUSE

Lossofpower

Poor cut- uneven

Excessivevibration

Starter rope hardto pull

Grass catcher

not filling (if soequipped)

Hard to push

• Rear of lawn mower housingor cuttingblade draggingin heavy grass.

• Cutting too much grass

• Dirty air filter.• Buildupof grass, leaves,and trash under mower.

• Too much oil in engine.• Walking speed too fast.

•Wom, bent or loose blade.

• Wheel heights uneven.

• Buildupof grass, leavesand trash under mower.

• Worn, bent or loose blade.

• Bent engine crankshaft.

• Engine flywheel brake is onwhen control bar is released.

• Bent engine crankshaft.

• Blade adapter broken.• Blade dragging ingrass.

• Cutting height too low.• Lifton blade wom off.

• Catcher notventing air.

• Grass istoo high or whealheight is too low.

• Rear of lawn mower

housing or blade draggingin grass.

• Grass catcher too full.

• Handle height positionnotrightforyou.

CORRECTION

• Set to "HigherCut"position.

• Set to "Higher Cut"position.

• Clean/replace air filter.• Clean underside of mower

housing.• Check oil level.

• Cut at slower walkingspeed.

• Replace blade.'Tightanblade bolt.

• Set all wheels at same

height• Clean underside of

mower housing.

• Replace blade. "lightenblade bolt.

• Contact an authorizedservice center.

• Depress controlbar toupper handle beforepullingstarter rope.

• Contact an authorizedservice center.

• Replace blade adapter.• Move lawn mower to cut

grass orto hard surface

• Raise cuttingheight.• Replace blade.• Clean grass catcher.

• Raise cutting height.

• Raise rear of lawn mower

housingone (1) settinghigher.

• Empty grass catcher.• Adjust handle heightto

suit.

15

SERVICE NOTES

31

32

XX o XXXX X_

_o_o8_=__ _ _

33

BRIGGS & STRATI'ON ENGINE MODEL NUMBER 12HS02-1978-E1

969_ 968

843

%124

6O6

967

o

_634

130

957

_134

110_ 9_

o;i

971A

_163

34

BRIGGS & STRATTON ENGINE MODEL NUMBER 12H802-1978-E1

_54

625

51

9/

15

22

383

306

lk REQUIRES SPECIAL TOOLSTO INSTALL SEE REPAIRINSTRUCTION MANUAL.

35

BRIGGS & STRA'I-FON ENGINE MODEL NUMBER 12H802-1978-E1

_) 670A _ 3

358 GASKET SET 1

_) 634 617

977 CARBURETOR GASKET SET

104 127 110134

°617 634

I 121 CARBURETOR KIT

_88A

36

BRIGGS & _TRAI-rON ENGINE MODEL NUMBER 12H802-1978-E1

1095 VALVE OVERHAULGASKET SET

605

930

55

i 461

_332

455

1036 LABEL KIT - EMISSION [

37

BRIGGS & STRA'rTON ENGINE MODEL NUMBER 12H802-1978-E1

KEY PARTNO. NO.

1 4932602 2937083 2998194 4932795 2143687 2729168 4957869 272481

9A 27223810 9465011 23193312 27219813 9454715 9488016 498566

9438820 39978122 94220

94612

23 49217724 22269825 499429

499430499431499432

26

2728

29

323334354045

499425

499426499427499428263190499423

499424

9469926265126265226222493312262204

KEYDESCRIPTION NO,

PARTNO. DESCRIPTION

Cylinder Assembly 46 498275Bushing, Cylinder 47 493737

• Seal, Oil 51 272199Sump, Engine 54 94526Head, Cylinder 55 497442

.... Gasket, Cylinder Head 56 498144Breather Assembly 58 280399

.... Gasket, Valve Cover* Gasket, Baffle Plate 60 281434

Screw, Hex Head 65 94696Tube, Breather 81 223664

• Gasket, Crankcase 98 94098Screw, Cylinder Head 104 231371Plug, Oil Drain 110 - - -CrankshaftTiming Gear Key 117 494870

* Seal, Oil 121 498260Screw, Hex Head 124 94840Screw, Hex Head(Used in Hole Nearest 125 498170Breather) 127 - - -FlywheelKey, Flywheel 130 224908Piston Assembly, 131 493267Standard Size 133 398187Piston Assy. (.010" O.S.) 134 398188Piston Assy. (.020" O.S.)Piston Assy. (.030" O.S.) 137 - - -

Ring Set, Piston,Standard SizeRing Set (.010" O.S.)Ring Set (.020• O.S.)Ring Set (.030• O.S.)Lock,PistonPinPin, Piston,StandardSizeRod, Connecting,Standard SizeScrew, ConnectingRodValve, ExhaustValve, IntakeSpring,ValveRetainer,Valve SpringTappet, Valve

163 272653187 298049188 398540

188A 94644202 262579209 263044

Gear, CamSlinger, Oil

• Gasket, Intake ElbowScrew, Hex HeadHousing, Rewind StarterPulley, Rewind StarterRope, Rewind Starter(Cut To 88-5/8•)Grip, Starter RopeScrew, PhillipsLock, Muffler ScrewScrew, Round Head

"• Pin, Float Hinge•** Gasket, Sealing (Sold in

Kit Only)Jet, MainCarburetor KitScrew, CarburetorMountingCarburetor

•" Plug, Welch (Sold in KitOnly)Valve, ThrottleShaft, ThrottleFloat, CarburetorValve, Inlet (IncludesSeat)

*•" Gasket, Bowl (Sold in KitOnly)

• Gasket, Air CleanerHose, FuelScrew, Hex HeadScrew, Hex HeadLink, GovernorSpring, Governor

Included in Gasket Set (497316)

*" Included in Carburetor Kit (498260)

••• Included in both Carburetor Kit (498260),and Carburetor Gasket Set (498261)

.... Included in both Gasket Set (497316),Set (497316) and Valve overhaulGasket Set (498528).

NOTE: All componentdimensionsgiven in U.S. inches1 inch= 28.4 mm

38

BRIGG S & STRATTON ENGINE MODEL NUMBER 12H802-1978-E1

KEY PARTNO. NO. DESCRIPTION

227 492349 Lever, Governor230 67072 Washer, Thrust258 94512 Screw, Hex Head284 94511 Screw. Hex Head300 497838 Muffler, Exhaust304 493293 Housing. Blower305 94744 Screw, Seres306 224324 Shield, Cylinder307 94515 Screw, Hex Head332 94877 Nut, Flywheel333 802574 Armature, Magneto334 94731 Screw, Seres337 802592 Plug, Spark356 497833 Wire;. Ground358 497316 Gasket Set363 19069 Puller, Flywheel383 89838 Wrench, Spark Plug387 496115 Primer, Carburetor447 95013 Screw, Hex455 225121 Cup, Starter456 281503 Retainer, Starter459 281505 Pawl, Rachet481 94943 Screw, Shoulder515 263073 Spring, Retainer523 495264 Cap, Oil Fifler524 280393 * Seal, Filler Tube525 495265 Tube. Oil Fill529 281299 Grommet562 94852 Bolt, Govemor Lever572 224328 Baffle, Cylinder592 231082 Nut, Hex601 93053 Clamp, Hose605 225103 Cover, Control606 224815 Strap, Bracket608 497680 Starter, Rewind

Includes:94904 Screw, Hex94908 Nut, Hex

613 94231 Screw, Hex Head615 94474 Fastener616 263175 Crank, Governor617 270344 "*" Seal, Intake Elbow620 499836 Bracket, Carburetor621 396847 Switch, Stop625 497466 Tube, Fuel Intake634 - - ° *** Washer, Shaft (Sold in

Kit Only)

KEY PARTNO. NO. DESCRIP_ON

635 66538670 280512

670A 493823741 262598842 280966843 272616847 495263851 493880869 213512870 213513871 262001

63709922 262640923 493442925 261145930 281136957 397974966 496116967 491588968 281340969 948723971 94873971A 94749972 495224975 493640977 498261

1036 4993411095 498258

2500 12J802-2915---- 498826

RPM Settings:

***t

NOTE:

Elbow,Spark PlugSpacer,Fuel Tank

• Spacer,BracketGear, Timing

• Seal, O-RingSleeve, LeverTube Assembly,OilTerminal,ignitionCableSeat, IntakeValveSeat, ExhaustValveGuide,ExhaustValveGuide, IntakeValveSpring,BrakeBrakeAssemblyCover,LinkageGuard, FingerCap, Fuel"tankBase, AirCleanerFilter,AirCover,Air CleanerScrew, Hex HeadScrew, Hsx HeadScrew, Hex HeadTank, FuelBowl,FloatGasket Set, CarburetorLabelKit,EmissionGasket Set, ValveOverhaulReplacementEngineReplacementShortblock

Low: 1900-2100; High:3000-3200

Includedin Gasket Set (497316)

Includedin CarburetorKit (498260)

Included inboth CarburetorKit(498260),and CarburetorGasket Set (498261)

Included in both Gasket Set (497316),Sot (497316) and Valve overhaulGasket Set (498528).

All componentdimensionsgiven inU,S. inches1 inch= 25.4 mm

39

For the repair or replacement parts you needdelivered directly to your homeCall 7 am - 7 pm, 7 days a week

1-800-366-PART(1-800-366-7278)Para ordenar piezas con entrega adomicUio - 1-800-659-7084

For in-house major brand repair serviceCall 24 hours a day, 7 days a week

1-800-4-REPAIR(1-800-473-7274)Para pedir servicio de reparaci6n adomicilio - 1-800-676-5811

For the location of a Sears Parts andRepair Center in your areaCall 24 hours a day, 7 days a week

1-800-488-1222

For information on purchasing a SearsMaintenance Agreement or to inquireabout an existing AgreementCall 9 am - 5 pm, Monday-Saturday

1-800-827-6655

When requesting service or orderingparts, always provide the followinginformation:• Product Type • Part Number• Model Number • Part Description

SE /ARSAmenca's Repair Specianst$

166865 12.28.98 VB Printed in U.S.A.