ROTARY LAWN MOWER 160Cc Honda Engine

Owner’s Manual

ROTARY LAWN MOWER 160cc Honda Engine

21" Multi-Cut

Model No. 944.364152

02489

CAUTION: Read and follow all Safety Rules and Instruc tions before operating this equipment

587785901 12.21.15 BY Printed in U.S.A. Sears Canada, Inc., Toronto, Ontario M5B 2B8 TABLE OF CONTENTS SERVICE NOTES Safety Rules ...... 2-3 Maintenance ...... 12-15 Warranty - Lawn Mower ...... 4-5 Service and Adjustments ...... 15-16 Product Speci fi cations ...... 5 Storage ...... 16-17 Assembly/Pre-Operation ...... 6-7 Troubleshooting ...... 18-19 Operation ...... 8-11 Repair Parts ...... 20-27 Maintenance Schedule ...... 12 Warranty - Honda Motor ...... 28-29 Sears Service ...... Back Cover SAFETY RULES IMPORTANT: This cutting machine is II. GENERAL OPERATION capable of amputating hands and feet and • Read, understand, and follow all throwing objects. Failure to observe the in structions on the machine and in the following safety instructions could result in manual(s) before starting. Be thorough ly serious injury or death. familiar with the controls and the proper Look for this symbol to point out impor- use of the machine before starting. tant safety precautions. It means • Do not put hands or feet near or under CAU TION!!! BECOME ALERT!!! rotating parts. Keep clear of the dis- YOUR SAFE TY IS INVOLVED. charge opening at all times. WARNING: In order to prevent acci- • Only allow responsible individuals, who den tal starting when setting up, transport- are familiar with the instruc tions, to ing, ad justing or making repairs, always operate the machine. dis connect spark plug wire and place wire • Clear the area of objects such as rocks, where it cannot come in contact with plug. toys, wire, bones, sticks, etc., which CAUTION: Muffler and other engine could be picked up and thrown by parts become extremely blade. Stay behind the handle when the hot during operation and engine (motor) is running. remain hot after engine • Be sure the area is clear of other people has stopped. To avoid before mowing. Stop ma chine if anyone severe burns on contact, enters the area. stay away from these areas. • Do not operate machine barefooted or while wearing sandals. Al ways wear I. CHILDREN substantial footwear with good ankle WARNING: CHILDREN CAN support while mowing. BE SERIOUSLY INJURED OR • Do not pull mower backwards unless KILLED BY THIS EQUIPMENT. absolutely neces sary. Always look down Carefully read and follow all of and behind before and while moving the safety instructions below. backwards. The American Academy of Pediatrics • Never direct discharged material toward recommends that children be a minimum anyone. Avoid discharging material of 12 year of age before operating a against a wall or obstruction. Material may pedestrian controlled lawn mower and a richochet back toward the operator. Stop minimum of 16 years of age before operat- blade when crossing gravel surfaces. ing a riding lawn mower. • Do not operate the mower without Tragic accidents can occur if the oper a tor is proper guards, plates, grass catcher or not alert to the presence of children. Children other safety protective devices in place. are often attracted to the machine and the • See manufacturer’s instructions for mowing activity. Never assume that children proper operation and installation of will remain where you last saw them. accessories. Only use accessories ap- • Keep children out of the mowing area proved by the manufacturer. and under the watchful care of a re- • Stop the blade(s) when crossing gravel spon si ble adult other than the operator. drives, walks, or roads. • Be alert and turn machine off if children • Never leave a running machine unattended. enter the area. • Stop the engine (motor) and wait until the • Before and while walking back wards, look blade comes to a complete stop before behind and down for small chil dren. cleaning the machine, removing the grass • Never allow children to operate the catcher, or unclogging the discharge machine. 2 chute. 31 SERVICE NOTES • Mow only in daylight or good artificial light. • Never refuel the machine indoors. • Do not operate the machine while under • Never store the machine or fuel contain- the influence of alcohol or drugs. er where there is an open flame, spark • Never operate machine in wet grass. or pilot light such as a water heater or Always be sure of your footing: keep a on other appliances. firm hold on the handle; walk, never run. • Never fill containers inside a vehicle, on • Disengage the drive system, if so equipped, a truck or trailer bed with a plastic liner. before starting the engine (motor). Always place containers on the ground • If the equipment should start to vibrate away from your vehicle before filling. abnormally, stop the engine (motor) and • Remove gas-powered equipment from check immediately for the cause. Vibra- the truck or trailer and refuel it on the tion is generally a warning of trouble. ground. If this is not possible, then • Always wear eye protection when oper- refuel such equipment with a portable ating machine. container, rather than from a gasoline • Use extra care when approaching blind dispenser nozzle. corners, shrubs, trees, or other objects • Keep the nozzle in contact with the rim that may obscure vision. of the fuel tank or container opening at • When loading or unloading this ma- all times until fueling is complete. Do chine, do not exceed the maximum not use a nozzle lock-open device. recommended operation angle of 15°. • If fuel is spilled on clothing, change • Wear proper Personal Protective Equip- clothing immediately. ment (PPE) while operating this machine, • Never overfill fuel tank. Replace gas including (at a minimum) sturdy footwear, cap and tighten securely. eye protection, and hearing protection. Do not mow in shorts or open toed footwear. V. GENERAL SERVICE Always let someone know you are outside • Never run a machine inside a closed area. mowing. • Never make adjustments or repairs with the engine (motor) running. Discon nect III. SLOPE OPERATION the spark plug wire, and keep the wire Slopes are a major factor related to slip & away from the plug to prevent acci den- fall accidents, which can result in severe tal starting. injury. All slopes require extra caution. If • Keep all nuts and bolts tight to be sure the you feel uneasy on a slope, do not mow it. equipment is in safe working condition. DO: • Never tamper with safety devices. • Mow across the face of slopes: never Check their proper operation regu lar ly. up and down. Exercise extreme caution Never do anything to interfere with the when changing direction on slopes. intended function of a safety device or • Remove obstacles such as rocks, tree reduce the protection provided by a limbs, etc. safety device. • Watch for holes, ruts, bumps or hidden ob- • Keep machine free of grass, leaves, or jects. Uneven terrain could cause a slip and other debris build-up. Clean oil or fuel spill- fall accident. Tall grass can hide obstacles. age. Allow machine to cool before storing. DO NOT: • Stop and inspect the equipment if you • Do not mow near drop-offs, ditches or strike an object. Repair, if neces sary, embankments. You could lose your foot- before restarting. ing or balance. • Never attempt to make wheel height • Do not mow on wet grass or excessively adjustments while the engine is running. steep slopes. Poor footing could cause • Grass catcher components are subject a slip and fall accident. to wear, damage, and dete ri o ra tion, which could expose moving parts or IV. SAFE HANDLING OF GASOLINE allow objects to be thrown. Frequently To avoid personal injury or property dam- check compo nents and replace with age, use extreme care in handling gaso- manu fac turer’s recommended parts, line. Gasoline is extremely flammable and when necessary. the vapors are explosive. • Mower blades are sharp and can cut. • Extinguish all cigarettes, cigars, pipes Wrap the blade(s) or wear gloves, and and other sources of ignition. use extra caution when servic ing them. • Use only an approved container. • Do not change the engine governor set- • Never remove gas cap or add fuel with ting or overspeed the engine. the engine running. • Maintain or replace safety and instruc- 30 • Allow engine to cool before refueling. 3 tion labels, as necessary. Only Honda approved replacement parts may be used in the performance of any warranty repairs WARRANTY and must be provided without charge to the owner. The use of replacement parts not equivalent to the original parts may impair the effectiveness of your engine emission control system. If such GENERAL: Craftsman products are warranted to be free from defects in materials a replacement part is used in the repair or maintenance of your engine, and an authorized Honda or workmanship for a specific time period as set-out below (the “Warranty Period”). dealer determines it is defective or causes a failure of a warranted part, your claim for repair of Warranties extend to the original purchaser of a Craftsman product only. Purchases your engine may be denied. If the part in question is not related to the reason your engine requires made through an online auction or through any website other than www.sears.ca are repair, your claim will not be denied. excluded. The relevant Warranty Period commences on the original date of purchase. TO OBTAIN WARRANTY SERVICE: Within this period, Sears Canada, Inc. will, at its sole option, repair or replace any You must, at your own expense, take your Honda Power Equipment engine or the product on products or components which fail in normal use. Such repairs or replacement will be which it is installed, along with your sales registration card or other proof of original purchase date, made at no charge to the customer for parts or labor, provided that the customer shall be to any Honda Power Equipment dealer who is authorized by Honda to sell and service that Honda product during his normal business hours. Claims for repair or adjustment found to be caused responsible for any transportation cost. solely by defects in material or workmanship will not be denied because the engine was not prop- EXCLUSIONS: This warranty does not cover failures due to normal wear, abuse, misuse, erly maintained and used. neglect (including but not limited to the use of stale fuel, dirt, abrasives, moisture, rust, If you are unable to obtain emission warranty service or are dissatisfied with the warranty service corrosion, or any adverse reaction due to improper storage or use habits), improper you received, contact the owner of the dealership involved. Normally this should resolve your maintenance or failure to follow maintenance guidelines and/or instructions, failure to problem. However, if you require further assistance, contact the Honda office in your region: operate the product in accordance with the owner’s manual or any additional instructions American Honda Motor Co., Inc. Honda Canada Inc. or information provided at the time of purchase or in subsequent communications with Power Equipment Customer Relations Power Equipment Customer Relations 4900 Marconi Drive Visit www.honda.ca the original purchaser, accident or unauthorized alterations or repairs made or attempted or by others. Also excluded from warranty coverage – except as provided below - are Alpharetta, Georgia 30005-8847 for contact information. the following: maintenance, adjustments, components subject to wear including but Telephone: (888) 888-3139 Telephone: (888) 946-6329 Email: [email protected] not limited to: cosmetic components, belts, blades, blade adapters, bulbs, tires, filters, guide bars, lubricants, seats, grips, recoil assy’s, saw chains and bars, trimmer lines and EXCLUSIONS: spools, spark plugs, starter ropers and tines, and discoloration resulting from ultraviolet Failures other than those resulting from defects in material or workmanship are not covered by this light. Any product missing the model and/or serial number identification label will be warranty. This warranty does not extend to emission control systems or parts that are affected or dam- disqualified from coverage under this warranty. aged by owner abuse, neglect, improper maintenance, misuse, misfueling, improper storage, colli- sion, the incorporation of, or use of, unsuitable attachments, or the unauthorized alteration of any part. REPAIRS: Repairs have a 90 day warranty. If the defective product is still within the This warranty does not cover replacement of expendable maintenance items made in connec- Warranty Period, then the new warranty is 90 days from the date of repair or to the end of tion with required maintenance service after the item’s first scheduled replacement as listed in the the original Warranty Period, whichever period is longer. maintenance section of the product owner’s manual, such as: spark plugs and filters. DISCLAIMERS: THE WARRANTIES AND REMEDIES CONTAINED HEREIN ARE Disclaimer of Consequential Damage and Limitation of Implied Warranties: EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER ORAL OR American Honda Motor Co., Inc. and Honda Canada Inc. disclaim any responsibility for inciden- WRITTEN (OTHER THAN AS STATED HEREIN), AND WHETHER EXPRESS, IMPLIED tal or consequential damages such as loss of time or the use of the power equipment, or any commercial loss due to the failure of the equipment; and any implied warranties are limited to the OR STATUTORY, INCLUDING BUT NOT LIMITED TO ANY. THIS WARRANTY GIVES YOU duration of this written warranty. This warranty is applicable only where the California, U.S. EPA, or SPECIFIC LEGAL RIGHTS, WHICH MAY VARY FROM PROVINCE TO PROVINCE. Environment Canada emission control system warranty regulation is in effect. IN NO EVENT SHALL SEARS BE LIABLE FOR ANY INCIDENTAL, SPECIAL, INDIRECT EMISSION CONTROL SYSTEM WARRANTY PARTS: OR CONSEQUENTIAL DAMAGES, WHETHER RESULTING FROM THE USE, MISUSE SYSTEMS PARTS OR INABILITY TO USE THE PRODUCT OR FROM DEFECTS IN THE PRODUCT. THE COVERED: DESCRIPTION: EXCLUSIONS IN THIS PARAGRAPH SHALL NOT APPLY IN JURISDICATIONS WHERE Fuel Metering Carburetor Assembly (Includes Starting Enrichment System), Engine Temp- APPLICABLE LAW DOES NOT ALLOW FOR THE EXCLUSION OF INCIDENTAL OR erature Sensor, Engine Control Module, Fuel Regulator, Intake Manifold CONSEQUENTIAL DAMAGES. IN SUCH JURISDICTIONS, THIS PARAGRAPH SHALL NOT APPLY, BUT THE REMAINING PROVISIONS OF THIS DOCUMENT SHALL REMAIN Evaporative Fuel Tank, Fuel Cap, Fuel Hoses, Vapor Hoses, Carbon Canister, Canister VALID. Mounting Brackets, Fuel Strainer, Fuel Cock, Fuel Pump, Fuel Hose Joint, Canister Purge Hose Joint Sears retains the exclusive right to repair or replace the product or offer a full refund of Exhaust Catalyst, Exhaust Manifold the purchase price at its sole discretion. SUCH REMEDY SHALL BE YOUR SOLE AND EXCLUSIVE REMEDY FOR ANY BREACH OF WARRANTY. Air Induction Air Filter Housing, Air Filter Element* Ignition Flywheel Magneto, Ignition Pulse Generator, Crankshaft Position Sensor, Power CUSTOMER RESPONSIBILITIES: In additional to complying with all suggested Coil, Ignition Coil Assembly, Ignition Control Module, Spark Plug Cap, Spark Plug* maintenance guidelines and instructions, customers’ obligations shall include but shall Crankcase Emission Control Crankcase Breather Tube, Oil Filler Cap not be limited to: operating the product in accordance with the owner’s manual or any additional instructions or information provided at the time of purchase or in subsequent Misc. Items Tubing, Fittings, Seals, Gaskets & Clamps associated with these listed systems communications to the purchaser from time to time, exhibit reasonable care in the use, Note: This list applies to parts supplied by Honda and does not cover parts supplied by the operation, maintenance, general upkeep and storage of the product. Failure to comply equipment manufacturer. Please see the original equipment manufacturer’s emissions warranty for with these requirements will void any applicable warranty. non-Honda parts. * Covered up to the first required replacement only. See the Maintenance Schedule in the owner’s manual. American Honda Motor Co., Inc. / Honda Canada Inc. 10/2009 00X51-ZG0-6110 PWL50975-M 4 29 WARRANTY EMISSION CONTROL SYSTEM WARRANTY Your new Honda Power Equipment engine complies with the U.S. EPA, Environment Canada, and LIST OF APPLICABLE WARRANTY PERIODS: The following list contains the applicable State of California emission regulations (models certified for sale in California only). American Hon- Warranty Period for your Craftsman product and is based on a combination of the type da Motor Co., Inc. provides the emission warranty coverage for engines in the United States and of product or component and the intended and actual use of the product or component: its territories. Honda Canada Inc. provides the emission warranty for engines in the 13 provinces 1. 90 DAYS: Craftsman products intended for use or actually used for commercial, and territories of Canada. In the remainder of this Emission Control System Warranty, American institutional, professional or income-producing purposes Honda Motor Company Inc. and Honda Canada Inc. will be referred to as Honda. YOUR WARRANTY RIGHTS AND OBLIGATIONS: 2. 2 YEARS: Craftsman riding lawn mowers, yard and garden tractors, walk behind California mowers, tillers, brush cutters, snow blowers, handheld blowers, backpack blowers, The California Air Resources Board and Honda are pleased to explain the emission control system hedge trimmers and electrical products for noncommercial, nonprofessional, non- warranty on your Honda Power Equipment engine. In California, new spark-ignited small off-road institutional, or non-income-producing use, except for those components which are equipment engines must be designed, built, and equipped to meet the State's stringent anti-smog part of engine systems manufactured by third party engine manufacturers for which standards. the purchase has received an separate warranty with product information supplied Other States, U.S. territories, and Canada at the time of purchase. In other areas of the United States and in Canada, your engine must be designed, built, and equipped to meet the U.S. EPA and Environment Canada emission standards for spark-ignited en- 3. 1 YEAR: Craftsman power cutters, stump grinders, pole pruners, gas chain saws, gines at or below 19 kilowatts. Specific Honda products that do not meet the California emissions electric chain saws, trimmer attachments, baggers and pole saws for noncommercial, regulations can be identified by a “Not for sale in California” decal. nonprofessional, non-institutional, or non-income-producing use. All of the United States and Canada 4. 90 DAYS: All defective batteries, which will be replaced during this 90-day Warranty Honda must warrant the emission control system on your power equipment engine for the period Period. of time listed below, provided there has been no abuse, neglect, or improper maintenance of your power equipment engine. Where a warrantable condition exists, Honda will repair your power 5. 60 DAYS: Additional Warranty Period of 60 days will apply to adjustments and worn equipment engine at no cost to you including diagnosis, parts, and labor. products or components BUT DOES NOT INCLUDE WEAR OR ADJUSTMENTS Your emission control system may include such parts as the carburetor or fuel injection system, for products used for commercial, institutional, professional or income-producing the ignition system, and catalytic converter. Also included may be hoses, connectors, and other purposes. Wear items include but are not limited to: belts, blades, tires, spark plugs, emission-related assemblies (see next page for additional covered parts). air filters, chains, shear bolts, skid plates, scraper bars, drift cutters, ropes, tines, OWNER'S WARRANTY RESPONSIBILITY: collection bags and pulleys. As the power equipment engine owner, you are responsible for the performance of the required As the Warranty Period runs from the date of purchase and NOT from the date that a maintenance listed in your owner's manual. Honda recommends that you retain all receipts covering product is delivered, opened, assembled or first used, plea se ensure during this time maintenance on your power equipment engine, but Honda cannot deny warranty coverage solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. period that your product or component has been assembled and tested for correction operation regardless of when you intend to actually use it. Claims made after the As the power equipment engine owner, you should however be aware Honda may deny you warranty coverage if your power equipment engine or a part has failed due to abuse, neglect, Warranty Period has expired will not be honored. improper maintenance, or unapproved modifications. PROOF OF PURCHASE/DOCUMENTATION: Warranty coverage is conditioned upon You are responsible for presenting your power equipment engine to a Honda Power Equipment the original purchaser furnishing Sears Canada or its authorized third party service dealer as soon as a problem exists. The emission related warranty repairs should be completed provider if applicable, with the original sales receipt or other adequate written proof in a reasonable amount of time, not to exceed 30 days. If you have any questions regarding your of the original purchase date and identification of the product. In the event that the emission warranty rights and responsibilities, you should contact the Honda office in your region: original purchaser is unable to provide a company of the original sales receipt, Sears American Honda Motor Co., Inc. Honda Canada Inc. Canada Inc. reserves the right to determine in its sole discretion what other written Power Equipment Customer Relations Power Equipment Customer Relations proof of the original purchase date and identification of the product is acceptable. 4900 Marconi Drive Visit www.honda.ca or Alpharetta, Georgia 30005-8847 for contact information. Telephone: (888) 888-3139 Telephone: (888) 946-6329 PRODUCT SPECIFICATIONS Email: [email protected] Serial Number: WARRANTY COVERAGE: Date of Purchase: Honda power equipment engines sold in the United States and Canada are covered by this warranty for a period of two years from the date of delivery to the original retail purchaser or the length Gasoline Capacity / Type: 1 Quart/0,94 Liters (Unleaded Regular) of the Honda Distributor’s Limited Warranty, whichever is longer. This warranty is transferable to Oil Capacity: 0,58 Quart/0,55 Liter each subsequent purchaser for the duration of the warranty period. Oil Type (API SG–SL): SAE 30 (above 0°C/32°F) or SAE 10W-30 If any emission-related part on your engine is defective, the part will be repaired or replaced by Honda without charge for diagnosis, parts, or labor. All defective parts replaced under this warran- Spark Plug (Gap: 0,03"/0,76 mm) NGK BPR5ES ty become the property of Honda. A list of warranted parts is on the reverse side of this warranty statement. Normal maintenance items, such as spark plugs and filters, that are on the warranted Valve Clearance (± 0.04 mm): Intake: 0.015 mm; Exhaust: 0.020 mm parts list are warranted up to their required replacement interval only. Blade Bolt Torque: 35–40 ft. lbs. (47–54 Nm) Honda will also replace other engine components damaged by a failure of any warranted part during the warranty period. • The model and serial numbers will be found on a decal on the rear of the lawn mower housing. Record both serial number and date of purchase in space provided above. American Honda Motor Co., Inc. / Honda Canada Inc. 10/2009 00X51-ZG0-6110 PWL50975-M 28 5 HONDA 4-CYCLE ENGINE MODEL NUMBER GCV160-LAOS3B ASSEMBLY / PRE-OPERATION Read these instructions and this manual HOW TO SET UP YOUR LAWN in its entirety before you attempt to as- MOW ER semble or operate your new lawn mower. IMPORTANT: This lawn mower is TO UNFOLD HANDLE shipped WITHOUT OIL OR GASOLINE in IMPORTANT: Unfold handle carefully so CAMSHAFT PULLEY PISTON / CONNECTING ROD the engine. as not to pinch or damage control cables. KEY PART KEY PART Your new lawn mower has been assem- 1. Raise handles until lower handle sec- NO. NO. DESCRIPTION NO. NO. DESCRIPTION bled at the factory with the exception of tion locks into place in mowing posi- 1 14320-ZL8-010 Pulley, Camshaft 1 13101-Z2A-010 Piston those parts left unassembled for shipping tion. 2 14324-ZL8-000 Shaft, Cam Pulley 2 13111-ZE0-000 Pin, Piston purposes. All parts such as nuts, wash- 2. Insert bolt through handle and bracket 3 14400-Z0J-014 Belt, Timing 3 13200-Z0J-000 Connecting Rod Assem- and secure with nut. ers, bolts, etc., neces sary to complete the (84HU7 G-200) bly 3. Remove protective padding, raise up- as sembly have been placed in the parts 6 14461-ZL8-000 Shaft, Rocker Arm 4 90001-ZE1-000 Bolt, Connecting Rod bag. To ensure safe and proper operation per handle section into place on lower handle and tighten both handle knobs. 11 90112-333-000 Screw, Tappet Adjusting 5 90551-ZE0-000 Clip, Piston Pin (13 mm) of your lawn mower, all parts and hard- 12 90206-001-000 Nut, Tappet Adjusting 6 13010-Z0L-014 Ring Set, Piston, Standard ware you assemble must be tightened 4. Remove handle padding holding 13 91301-ZM0-V31 O-Ring (6.8 x 1.9) (ARAI) (Teikoku) securely. Use the correct tools as neces- operator pres ence control bar to upper sary to ensure proper tightness. handle. 15 14431-Z0J-000 Rocker Arm, Intake Valve Your lawn mower handle can be adjusted 16 14441-Z0J-000 Rocker Arm, LABELS for your mowing comfort. Refer to "AD- Exhaust Valve KEY PART TO REMOVE MOWER FROM JUST HANDLE" in the Service and Adjust- NO. NO. DESCRIPTION CAR TON ments section of this manual. OIL PAN 9 87528-Z0L-V20 Mark, Choke Indication 1. Remove loose parts included with KEY PART 20 87114-ZH7-821 Label, Warning mower. Operator MOWING NO. NO. DESCRIPTION 30 87101-Z8B-000 Mark, Emblem (GCV160) 2. Cut down two end corners of carton presence POSITION 1 11300-ZM0-811 Pan Assembly, Oil 31 87169-Z8E-000 Mark, Recoil Cover control bar and lay end panel down flat. 2 15650-ZM0-801 Gauge Assembly, 32 87524-Z8B-000 Mark, Caution, 3. Remove all packing materials except LIFT Oil Level Fuel Petcock UP padding between upper and lower 4 15625-ZE6-000 Gasket, Oil Filler Cap handle and padding holding operator 5 15631-ZM0-000 Extension, Oil Filler CHOKE BASE presence control bar to upper handle. 6 15639-ZM0-000 Lock Washer, Extension KEY PART 4. Roll mower out of carton and check Upper 8 16508-ZM0-010 Shaft, Governor Holder NO. NO. DESCRIPTION LIFT handle carton thorough ly for additional loose UP 9 16510-ZM0-010 Governor Assembly 2 16592-Z2D-800 Spring, Return parts. 10 16511-ZL8-000 Weight, Governor 5 16614-Z2D-800 Spring, Choke Lever 11 16512-ZM0-000 Holder, Governor Weight 8 16632-Z0L-801 Rod, Stop Handle 12 16513-ZE1-000 Pin, Governor Weight 9 90022-888-010 Bolt, Flange (#6 x 20) knob 13 16531-ZE1-000 Slider, Governor (CT200) 14 16541-ZM0-000 Shaft, Governor Arm 14 16610-Z2D-801 Lever Assembly, Choke 15 90014-952-000 Bolt, Flange (#6 x 14) 16610-Z2D-802 Lever Assembly, Choke Lower handle Bolt (CT200) Nut 16 90121-952-000 Bolt, Flange (#6 x 25) Bracket (CT200) 17 90451-ZE1-000 Washer, Thrust (6 mm) 18 90602-ZE1-000 Clip, Governor Holder 19 91202-ZL8-003 Oil Seal (28 x 41.25 x 6) 20 91356-MA6-005 O-Ring (14.8 x 2.4) (NOK) 21 94101-068000 Washer, Plain (6 mm) 22 94251-08000 Pin, Lock (8 mm) 23 94301-08200 Pin, Dowel (#8 x 20)

6 27 HONDA 4-CYCLE ENGINE MODEL NUMBER GCV160-LAOS3B TO ASSEMBLE GRASS CATCH ER INSTALL STARTER ROPE 1. Put grass catcher frame into grass bag 1. Loosen T-knob. with rigid part of bag on the bottom. 2. Hold control bar against upper handle. Make sure the frame handle is outside 3. Slowly pull engine starter rope out until of the bag top. rope will slip into loop of rope guide. 2. Slip vinyl bindings over frame. 4. Tighten T-knob. NOTE: If vinyl bindings are too stiff, hold them in warm water for a few minutes. If bag gets wet, let it dry before using. Frame handle

Control bar

Upper handle

Vinyl Frame bindings opening

Rope guide T-Knob

Engine starter rope

TO INSTALL ATTACHMENTS Your lawn mower was shipped ready to be used as a mulcher. To convert to bagging, see “TO CONVERT MOWER” in the Operation section of this manu al.

26 7 HONDA 4-CYCLE ENGINE MODEL NUMBER GCV160-LAOS3B OPERATION

KNOW YOUR LAWN MOWER FAN COVER FLYWHEEL READ THIS OWNER'S MANUAL AND ALL SAFETY RULES BEFORE OPERATING YOUR KEY PART KEY PART LAWN MOWER. Compare the illustrations with your lawn mower to familiarize yourself with NO. NO. DESCRIPTION NO. NO. DESCRIPTION the location of various controls and adjustments. Save this manual for future reference. 6 16950-Z0Y-003 Petcock Assembly 1 13331-357-000 Key, Special, Woodruff These symbols may appear on your lawn mower or in literature supplied with the product. 7 16952-ZA8-800 Filter, Fuel (25 x 18) Learn and understand their meaning. 8 16961-Z0L-900 Stay, Fuel Petcock 3 30500-ZL8-014 Coil Assembly, Ignition 9 17511-Z0L-030 Tank, Fuel 4 31105-ZM0-000 Flywheel Assembly 10 17514-Z0L-000 Seal, Fuel Filler Neck 5 32195-ZM0-800 Wire, Stop Switch 11 17516-Z0L-000 Clip, Tank Mounting 6 35120-ZM0-003 Switch Assembly, 12 17532-Z0L-000 Rubber A, Tank Mounting Engine Stop (NC) 13 17533-Z0L-000 Rubber B, Tank Mounting 8 75113-ZM0-000 Spring, Brake Lever 14 17534-Z0L-000 Nut, Tank Mounting 10 90014-952-000 Bolt, Flange (#6 x 14) 15 17620-Z0J-800 Cap Assembly, Fuel Tank (CT200) 16 17636-Z0L-000 Gauge, Fuel Level 11 90018-ZE1-000 Bolt, Flange (#6 x 23) 21 19610-Z0L-861ZC Cover Assembly, Fan (CT200) Operator presence control bar “T89” (Craftsman Red) 12 90018-ZE1-000 Bolt, Flange (#6 x 23) 19610-Z0L-861ZA Cover Assembly, Fan (CT200) “T89” (“NH1”) (Black) 13 90201-Z0T-800 Nut, Special (14 mm) 19610-Z0L-861ZD Cover Assembly, Fan 14 51125-Z0L-003 Holder, Wire (Fastex) “T93” (Husqvarna Grey) 90681-959-003 Clip A, Cable (3.8mm) 19610-Z0L-861ZE Cover Assembly, Fan (Black) (NIFCO) Handle knob “T98” (M.T.D. Red) 15 93892-04012-00 Screw, Washer Head 22 19619-ZL8-300 Collar, Fan Cover (#4 x 12) 24 90013-883-000 Bolt, Flanged (#6 x 12) 16 94103-04000 Washer, Plain (4 mm) Gasoline filler cap (CT200) 21 75110-Z0Y-000 Brake Sub Assembly 25 90015-883-000 Bolt, Flanged (#6 x 28) 25 91601-Z0L-300 Grommet, Brake Plate (CT200) Starter 27 90043-ZL8-000 Bolt, Stud (H=42.5mm) AIR CLEANER handle Fuel valve lever 28 90043-ZL8-000 Bolt, Stud (H=42.5mm) KEY PART 33 93913-25220 Screw, Tapping (PO) NO. NO. DESCRIPTION (#5 x 12) 1 15721-ZM0-000 Tube, Breather Air filter 35 91424-Z8B-821 Tube, Fuel Tank 2 17211-ZL8-023 Element, Air Cleaner Grass 36 91427-Z8B-821 Tube, Fuel (7.3 x 160) 3 17220-ZM0-010 Case Assy., Air Cleaner catcher 40 95002-40800-08 Clip, Tube (D8) (S/N 1167575 and below) Housing 42 95002-41200-08 Clip, Tube (D12) 17220-ZM0-020 Case Assy., Air Cleaner (S/N 1167576–1239013) MUFFLER 17220-ZM0-030 Case Assy., Air Cleaner Engine oil plug KEY PART (S/N 1239014 and above) NO. NO. DESCRIPTION 5 17228-ZM0-000 Gasket, Air Cleaner 1 18310-ZM0-000 Muffler 6 17231-Z0L-030 Cover, Air Cleaner Muffler 2 18321-Z0L-J00 Protector, Muffler (S/N 1167575 and below) Spark plug (S/N 1243452 and below) 17231-Z0L-040 Cover, Air Cleaner Mulcher door 18321-Z0L-J01 Protector, Muffler (S/N 1167575 and below) Wheel adjuster (S/N 1243453 and above) 17231-Z0L-050 Cover, Air Cleaner IMPORTANT: This lawn mower is shipped (on each wheel) WITHOUT OIL OR GASOLINE in the engine. 3 90004-ZL8-000 Bolt, Flange #6 x 79 7 90003-ZM0-010 Bolt, Flange (#6 x 85) NOTE: Gasoline containing up to 10% ethanol (E10) is acceptable for use in this machine. (CT200) (CT200) The use of any gasoline exceeding 10% ethanol (E10) will void the product warranty. 4 90013-883-000 Bolt, Flange #6 x 12 (CT200) MEETS CPSC SAFETY REQUIREMENTS 5 18381-ZL8-305 Gasket, Muffler Sears rotary walk-behind power lawn mowers conform to the safety standards of the 9 18350-ZL8-000 Arrester, Spark American National Standards Institute and the U.S. Consumer Product Safety Commis- 10 18356-ZL8-000 Plate, Arrester Number sion. WARNING: The blade turns when the engine is running. 11 90055-ZE1-000 Screw, Tapping #4 x 6 Operator presence control bar – must Mulcher door – allows con version to 12 06180-Z0J-000 Kit, Spark Arrester be held down to the handle to start the discharging or bagging operation. engine. Release to stop the engine. 8 Starter handle – used for starting engine. 25 HONDA 4-CYCLE ENGINE MODEL NUMBER GCV160-LAOS3B The operation of any lawn mower can result in foreign objects Use ear thrown into the eyes, which can result in severe eye damage. protec- Always wear safety glasses or eye shields while operating your tors to lawn mower or performing any adjustments or repairs. We recom- avoid mend standard safety glasses or a wide vision safety mask over spectacles. damage to hearing. HOW TO USE YOUR LAWN MOWER Pivot pins Rear Grass ENGINE SPEED door catcher Engine speed was set at the factory for handle optimum performance. It is not adjustable. ENGINE ZONE CONTROL CAUTION: Federal regulations require an engine control to be installed on this lawn mower in order to minimize the risk of blade contact injury. Do not under any circumstances attempt to defeat the function of the operator control. The blade Catcher frame hook turns when the engine is running. SIDE DISCHARGING • Your lawn mower is equipped with an operator pres ence control bar which • Rear door must be closed. requires the operator to be positioned • Open mulcher door and install dis- behind the lawn mower handle to start charge deflector under door as shown. and operate the lawn mower. • Mower is now ready for discharging operation. TO ADJUST CUTTING HEIGHT • To convert to mulching or bagging Raise wheels for low cut and lower wheels operation, dis charge deflector must be for high cut, adjust cutting height to suit removed and mulcher door must be your requirements. Medi um position is closed. best for most lawns. • To change cutting height, squeeze adjuster lever toward wheel. Move wheel up or down to suit your require ments. Be sure all wheels are in the same setting. NOTE: Adjuster is properly positioned when plate tab inserts into hole in lever. Also, 9-position adjusters (if so equipped) allow lever to be positioned between the plate tabs. Open mulcher door LEVER BACKWARD TO Plate tab LOWER MOWER Discharge deflector

LEVER FORWARD TO RAISE MOWER Lever TO CONVERT MOWER Your lawn mower was shipped ready to be used as a mulcher. To convert to bagging or discharging: MOWER REAR BAGGING IS NOW • Lift rear door of the lawn mower and READY FOR place the grass catcher frame hooks DISCHARGING onto the door pivot pins. OPERATION • To convert to mulching or discharg ing operation, remove grass catcher and 24 close rear door. 9 SIMPLE STEPS TO REMEMBER WHEN CHANGE ENGINE OIL” in the Mainte- HONDA 4-CYCLE ENGINE MODEL NUMBER GCV160-LAOS3B CONVERTING YOUR LAWN MOWER nance section of this manual. FOR MULCHING - ADD GASOLINE 1. Rear door closed. • Fill fuel tank to bottom of tank filler 2. Mulcher door closed. neck. Do not overfill. Use fresh, clean, FOR REAR BAGGING - regular unleaded gasoline with a mini- 1. Grass catcher installed. mum of 87 octane. Do not mix oil with CYLINDER BARREL CONTROL 2. Mulcher door closed. gasoline. Purchase fuel in quanti ties KEY PART KEY PART FOR SIDE DISCHARGING - that can be used within 30 days to as- NO. NO. DESCRIPTION NO. NO. DESCRIPTION 1. Rear door closed. sure fuel freshness. 1 12000-Z0L-406 Cylinder Assembly 1 16551-ZM0-010 Arm, Governor 2. Discharge deflector installed. CAUTION: Wipe off any spilled oil or 12000-Z0L-840 Cylinder Assembly 2 16555-Z0L-801 Rod, Governor CAUTION: Do not run your lawn mow- fuel. Do not store, spill or use gasoline 3 12310-Z0J-000 Cover, Cylinder Head 3 16561-Z0L-000 Spring, Governor er without rear door closed or ap proved near an open flame. 12311-ZL8-D00 Cover, Head 4 16562-ZM0-000 Spring, Throttle Return grass catcher in place. Never attempt to CAUTION: Alcohol blended fuels 12311-ZL8-000 Cover, Head 10 90015-ZE5-010 Bolt, Governor Arm op erate the lawn mower with the rear door (called gasohol or using ethanol or meth- removed or propped open. 4 12355-ZL8-000 Cover, Breather 13 94050-06000 Nut, Flange (6 mm) anol) can attract moisture which leads to (Breather Valve Assembly) 15 93892-04012-00 Screw, Washer Head TO EMPTY GRASS CATCHER separation and for mation of acids during 5 90013-883-000 Bolt, Flange (#6 x 12) (#4 x 12) storage. Acidic gas can damage the fuel 1. Lift up on grass catcher using the (CT200) 16 94103-04000 Washer, Plain (4 mm) system of an engine while in storage. To frame handle. 6 90014-952-000 Bolt, Flange (#6 x 14) 2. Remove grass catcher with clippings avoid engine problems, the fuel system should be emptied before stor age of 30 (CT200) CRANKSHAFT from under lawn mower handle. 7 91201-ZL8-003 Oil Seal (25.4 x 62 x 6) KEY PART 3. Empty clippings from bag. days or longer. Empty the gas tank, start the engine and let it run until the fuel lines 8 98079-55846 Spark Plug (BPR5ES) NO. NO. DESCRIPTION NOTE: Do not drag the bag when empty- (NGK) 3 13310-ZM0-610 Crankshaft ing; it will cause unnecessary wear. and carburetor are empty. Use fresh fuel next season. See Storage Instruc tions for 10 12209-ZM0-003 Seal, Valve Stem 5 90402-ZL8-000 Washer, Thrust 11 14711-ZL8-000 Valve, Intake Grass additional information. Never use engine RECOIL STARTER catcher or carburetor cleaner products in the fuel (Technostar) frame tank or permanent damage may occur. 14711-Z0J-000 Valve, Intake (Rocknel) KEY PART handle 14711-Z0J-800 Valve, Intake NO. NO. DESCRIPTION Oil fill cap / Gasoline dipstick filler cap 12 14721-ZL8-000 Valve, Exhaust 1 28400-Z0L-V20ZA Starter Assembly, 13 14751-ZL8-000 Spring, Valve Recoil, “NH1” 14 14771-Z0J-000 Retainer, Valve Spring (Long Rope) (Black) 8 28461-ZL8-003 Grip, Recoil Starter CARBURETOR 9 28462-Z0L-V20 Rope, Recoil Starter, KEY PART “Long Type” (Black) NO. NO. DESCRIPTION 11 90201-ZM0-000 Nut, Flange (6 mm) 1 16010-883-015 Gasket Set BEFORE 2 16013-ZL1-003 Float Set STARTING ENGINE 3 16015-Z0L-881 Chamber Set, Float 5 16028-ZE0-005 Screw Set ADD OIL Upper Lower Your lawnmower is shipped without oil in mark mark 16028-ZK7-S91 Screw Set the engine. For type and grade of oil to 7 16100-Z0L-852 Carburetor Assembly use, see “ENGINE” in the Maintenance TO STOP ENGINE (BB62Z B) section of this manual. • To stop engine, release operator pres- 8 16155-ZM0-013 Valve, Float CAUTION: DO NOT overfill engine with ence control bar. Wait until blade and 9 16166-ZM0-003 Nozzle, Main oil, or it will smoke on startup. all moving parts have stopped and turn 10 16211-ZL8-000 Insulator, Carburetor 1. Be sure lawnmower is level. fuel valve to OFF position if you do not 11 16212-ZL8-000 Gasket, Insulator 2. Remove oil dipstick from oil fill spout. intend to restart the engine soon. 13 16228-ZL8-000 Gasket, Carburetor 3. You recieve a container of oil with the 15 93500-05006-0H Screw, Pan (#5 x 6) unit. Slowly pour the entire container TO START ENGINE 16 99101-124-0600 Jet, Main (#60) down the oil fill spout into the engine. NOTE: Due to protective coatings on the 99101-124-0620 Jet, Main (#62) 4. Insert and tighten dipstick. engine, a small amount of smoke may be 99101-124-0650 Jet, Main (#65) present during the initial use of the prod- IMPORTANT: 26 16951-Z0L-000 Guide, Air • Check oil level before each use. Add uct and should be considered normal. oil if needed. Fill to full line on dipstick. 1. Be sure fuel valve is in ON posi tion. • Change the oil after every 25 hours of 2. Hold operator presence control bar operation or each season. You may down to the handle and pull starter need to change the oil more often handle quickly. Do not allow starter under dusty, dirty conditions. See “TO 10 rope to snap back. 23 HONDA 4-CYCLE ENGINE MODEL NUMBER GCV160-LAOS3B OFF • Keep top of engine around starter clear and clean of grass clippings and chaff. This will help engine air flow and extend ON engine life. MULCHING MOWING TIPS IMPORTANT: For best performance, keep mower housing free of built-up grass and trash. See “CLEANING” in the Maintenance section of this manual. Fuel • The special mulching blade will recut valve the grass clip pings many times and lever reduce them in size so that as they fall onto the lawn they will disperse into MOWING TIPS the grass and not be noticed. Also, CAUTION: Do not use de-thatcher the mulched grass will bio de grade blade attachments on your mower. Such quick ly to provide nutri ents for the lawn. attachments are hazardous, will damage Always mulch with your highest engine your mower and could void your warranty. (blade) speed as this will provide the best recutting action of the blades. • Under certain conditions, such as very • Avoid cutting your lawn when it is wet. tall grass, it may be necessary to raise Wet grass tends to form clumps and the height of cut to reduce pushing effort in terferes with the mulching action. The and to keep from overload ing the engine best time to mow your lawn is the early and leaving clumps of grass clippings. It afternoon. At this time the grass has may also be necessary to reduce ground dried, yet the newly cut area will not be speed and/or run the lawn mower over exposed to direct sunlight. the area a second time. • For best results, adjust the lawn mower • For extremely heavy cutting, reduce the cutting height so that the lawn mower width of cut by overlapping pre vi ous ly cuts off only the top one-third of the cut path and mow slowly. grass blades. If the lawn is overgrown • For side discharge operation, cut in it will be neces sary to raise the height a counter clock wise di rection, starting of cut to reduce pushing effort and to at the outside of the area to be cut, in keep from over load ing the engine and order to spread grass clip pings more leaving clumps of mulched grass. For evenly and to put less load on the extremely heavy grass, reduce your engine. To keep clippings off of walk- width of cut by overlapping previously ways, flower beds, etc., make the first cut path and mow slowly. cuts in a clockwise direction.

MAX 1/3

BEFORE AFTER EVERY EVERY EVERY EACH EACH 10 25 HOURS 100 BEFORE USE USE HOURS OR SEASON HOURS STORAGE Check for Loose Fasteners Clean / Inspect Grass Catcher * Check Tires Check Drive Wheels *** Clean Lawn Mower **** wer and void your warranty. Clean under Drive Cover *** Check Drive Belt / Pulleys *** Check / Sharpen / Replace Blade Lubrication Clean and Recharge Battery ** Check Engine Oil level

Change Engine Oil Washer Hardened Blade 55 851074 21" Adapter 56 406712 Blade Spring 57 418373 Hinge 58 152124 59 - 61 Flat 409148 62 Washer, Engine, Honda GCV160- 73800400 65 88348 O-Ring Locknut, Hex, Flanged 66 197480 Locknut, Hex 1/4-20 73 401630 74 Zinc-Plated LAOS3B (See Breakdown) 851201X004 Special, Engine, Rear Washer, Curved, Cylindrical Washer, 76 410589 Baffle, 77 Front 17411312 83 428501 Baffle, 84 Rear Baffle Carriage Screw, 17000510 87 Bolt, Hex 437516 88 586212501 Baffle Front Screw, Nut, 89 73970500 - Plug, Handle Bar - 404764 581276301 Decal (not shown) Warning - (Includes Key Bag of Parts - 587785901 587785902 Owner’s Manual, English Owner’s Manual, French Numbers 88 and 89) KEY PART KEY PART NO. NO. DESCRIPTION Clean Air Filter 944.364152 Inspect Muffler Replace Spark Plug Replace Air Filter Paper Cartridge Empty fuel system or add Stabilizer * (if so equipped) 1 - Change more often if operating under a heavy load or in high outdoor temperatures. ** Electric-Start mowers 2 - Service more often if operating in dirty or dusty conditions. *** Power-Propelled mowers 3 - Replace blades more often when mowing in sandy soil. **** Use a scraper 4 - Charge 48 hours at end of season. to clean under deck 5 - And after each 5 hours of use.

GENERAL RECOM MEN DATIONS LUBRICATION CHART The warranty on this lawn mower does not cover items that have been subject ed to Wheel operator abuse or negligence. To receive adjuster (on full value from the warranty, operator must each wheel) maintain unit as instruct ed in this manual. Engine oil Some adjustments will need to be made periodically to properly maintain your unit. Mulcher 31 165760 Discharge Deflector Discharge 31 165760 Knob 32 Selector 440858X004 33 701037 Selector Spring, Rear 34 401176X004 35 LH Rear, Axle Arm Assembly, 426589 36 Hex 401638 37 Nut, Grassbag Locknut, Hex 5/16-18 194230X427 39 409149 Frame, Screw Front Assembly, Wheel & Tire Bolt, Shoulder 5/16-18 40 411949 Hinge 41 194186 42 405421 43 405423 44 LH Spring, Rear Door, 184193 45 Decal RH Spring, Rear Door, 150406 Danger Bolt, Rear Door 46 404763 Hex Head, Threaded, Screw, 47 751153 48 401177X004 49 Grassbag Rod RH Rear, Axle Arm Assembly, Locknut, Hex 5/16-18 431880X427 50 408955 Hinge Rear Assembly, Wheel & Tire 51 147286 Rolled 3/8-16 x 1 52 441963 53 Lockwasher Kit, Mower Housing 851084 Helical 54 850263 Hex Head, Grade 8 Screw, Number 46) (Includes Key 3/8-24 x 1-3/8 door hinge pin KEY PART NO. NO. DESCRIPTION At least once a season, check to see if All component dimensions given in U.S. inches. 1 inch = 25.4 mm. All component dimensions given in U.S.

your engine run better and last longer. CRAFTSMAN • Follow the maintenance schedule in this Handle bracket mounting pins manual. Spray lubricant BEFORE EACH USE See "ENGINE" in Maintenance section. • Check engine oil level.

54 • Avoid stumps, stones, deep ruts, sharp 53 42

37 objects and other hazards that may 9 3 9 36 cause tire damage. Blade 4 bolt Hardened BLADE CARE

73 washer Trailing edge Crankshaft 23 9 For best results, blade must be kept 1 55 sharp. Replace a bent or damaged blade. TO SHARPEN BLADE 22 30 33 83 CAUTION: Use only a replacement NOTE: We do not recommend sharp- ening blade - but if you do, be sure the 43 blade approved by the manufacturer of 36 9 your mower. Using a blade not approved blade is balanced. An un bal anced blade 2

73 will cause eventual damage to lawn 44 by the manufacturer of your mower is 84 8 34 35 mower or engine. 52

65 hazardous, could damage your mower 944.364152

30 and void your warranty. • The blade can be sharpened with a file 25

66 or on a grinding wheel. Do not attempt 9 32 TO REMOVE BLADE to sharpen while on the mower. 5 33 1. Disconnect spark plug wire from spark • To check blade balance, drive a nail into plug and place wire where it cannot a beam or wall. Leave about one inch of

9 come in contact with plug.

8 the straight nail exposed. Place center 2. Turn lawn mower on its side. Make hole of blade over the head of the nail. sure air filter and carburetor are up. If blade is balanced, it should remain in 3. Use a wood block between blade and a horizontal position. If either end of the 84 74 45 mower housing to prevent blade from blade moves downward, sharpen the turning when remov ing blade bolt. heavy end until the blade is balanced. 9 47 41 2 30 NOTE: Protect your hands with gloves

22 GRASS CATCHER

33 and/or wrap blade with heavy cloth. • The grass catcher may be hosed with 46 4. Remove blade bolt by turning counter- 20 35

21 water, but must be dry when used.

18 clockwise. 62 73 7 • Check your grass catcher often for dam- 15 5. Remove blade and attaching hardware 36 9 88 (bolt, lock washer, hardened washer). age or de teri o ra tion. Through normal use 41 NOTE: Remove the blade adapter and check it will wear. If catcher needs replacing, 6

3 replace only with approved replacement 47

51 the key inside hub of blade adapter. The key 14 must be in good condi tion to work properly. catcher shown in the Repair Parts section

58 Replace adapter if damaged. of this manual. Give the lawn mower model 87 61 37 number when ordering. TO REPLACE BLADE

ROTARY LAWN MOWER - MODEL NUMBER LAWN ROTARY 1. Position the blade adapter on the engine ENGINE 77 76 crankshaft. Be sure key in adapter and Maintenance, repair, or replacement of the 8 30 emission control devices and systems, which

10 crankshaft keyway are aligned. 9

33 are being done at the customers expense, 26 8 2. Position blade on the blade adapter 32

48 aligning the two (2) holes in the blade may be performed by any non-road engine 11 with the raised lugs on the adapter. repair establishment or individual. Warranty 36 5 3. Be sure the trailing edge of blade (op- repairs must be performed by an authorized 12

14 posite sharp edge) is up toward engine. engine manufacturer’s service outlet. CRAFTSMAN 13 4. Install the blade bolt with the lock LUBRICATION 4 73 31 2

9 washer and hardened washer into Use only high quality detergent oil rated with 4 blade adapter and crankshaft. API service classification SG–SL. Select the 66 5. Use block of wood between blade and oil's SAE viscosity grade according to your 65 lawn mower housing and tighten the expected operating temperature. blade bolt, turning clockwise.

50 • The recommended tightening torque is 35–40 ft. lbs. (47–54 Nm). 40 9

3 IMPORTANT: Blade bolt is heat treated. 1 If bolt needs replacing, replace only with approved bolt shown in the Repair Parts 20 section of this manual. 13 NOTE: Multi-viscosity oils (5W30, 10W30 Oil fill cap / TROUBLESHOOTING - See appropriate section in manual unless directed etc.) improve starting in cold weather, and dipstick to a Sears Parts & Repair Centre. you should check your engine oil level frequently to avoid possible engine damage PROBLEM CAUSE CORRECTION from running low on oil. Loss of power 1. Rear of mower housing or 1. Raise cutting height. Change the oil after every 25 hours of opera- blade dragging in grass. tion or at least once a year if the lawn mower Upper 2. Cutting too much grass. 2. Raise cutting height. is not used for 25 hours in one year. mark 3. Dirty air filter. 3. Clean/replace air filter. Check the crankcase oil level before 4. Buildup of grass, leaves, 4. Clean underside of mower starting the engine and after each five (5) Lower and trash under mower. housing. hours of continuous use. Tighten oil plug mark 5. Too much oil in engine. 5. Check oil level. securely each time you check the oil level. 6. Walking speed too fast. 6. Cut at slower walking speed. AIR FILTER TO CHANGE ENGINE OIL Your engine will not run properly and may 1. Worn, bent or loose blade. 1. Replace blade. Tighten NOTE: Before tipping lawn mower to Poor cut – be damaged by using a dirty air filter. drain oil, empty fuel tank by running en- uneven blade bolt. Replace the air filter every 100 hours of gine until fuel tank is empty. 2. Wheel heights uneven. 2. Set all wheels at same operation or every season, whichever oc- 1. Disconnect spark plug wire from spark height. curs first. Service air cleaner more often plug and place wire where it cannot 3. Buildup of grass, leaves 3. Clean underside of under dusty conditions. come in contact with plug. and trash under mower. mower housing. 2. Remove engine oil cap; lay aside on a TO CLEAN AIR FILTER clean surface. Excessive 1. Worn, bent or loose blade. 1. Replace blade. Tighten 1. Remove cover. vibration blade bolt. 3. Tip lawn mower on its side as shown 2. Carefully remove cartridge. and drain oil into a suitable container. 2. Bent engine crankshaft. 2. Contact a Sears or other 3. Clean by gently tapping on a flat sur- qualified service centre. Rock lawn mower back and forth to re- face. If very dirty, replace cartridge. move any oil trapped inside of engine. CAUTION: Petroleum solvents, such Starter rope 1. Engine flywheel brake is on 1. Depress control bar to as ker o sene, are not to be used to clean hard to pull when control bar is released. upper handle before cartridge. They may cause dete ri o ra tion pulling the starter rope. of the cartridge. Do not oil cartridge. Do 2. Bent engine crankshaft. 2. Contact a Sears or other not use pressur ized air to clean or dry qualified service centre. cartridge. 3. Blade adapter broken. 3. Replace blade adapter. 4. Install cartridge, then replace cover. 4. Blade dragging in grass. 4. Move lawn mower to cut grass or to hard surface. Slot Grass catcher 1. Cutting height too low. 1. Raise cutting height. not filling 2. Lift on blade worn off. 2. Replace blade. (If so equipped) 3. Catcher not venting air. 3. Clean grass catcher. Container Tab 4. Wipe off any spilled oil from lawn Hard to push 1. Grass is too high or wheel 1. Raise cutting height. mower or side of engine. height is too low. 5. Fill engine with oil. The engine oil 2. Rear of mower housing or 2. Raise rear of mower housing capacity is 0.58 quarts. If oil is not blade dragging in grass. one (1) setting higher. complete ly drained from engine, you 3. Grass catcher too full. 3. Empty grass catcher. may not need the entire container of a Cartridge 4. Handle height position not 4. Adjust handle height to suit. 20 oz. bottle of oil. Slowly pour 3/4 of right for you. the oil from the container down the oil fill spout into the engine. 6. Wait one minute to allow oil to settle. Filter cover Use guage on oil fill cap/dipstick for checking level. Insert dipstick into MUFFLER the tube and rest the oil fill cap on the Inspect and replace corroded muffler as it tube. DO NOT thread the cap into the could create a fire hazard and/or damage. tube when taking reading. SPARK PLUG 7. Continue adding small amounts of oil and rechecking the dipstick until it Replace spark plug at the beginning of reads full. DO NOT overfill, or engine each mowing season or after every 100 will smoke on startup. hours of operation, whichever occurs 8. Always be sure to retighten oil dipstick first. Spark plug type and gap setting before starting engine. are shown in the “PRODUCT SPECI FI CA- TIONS” section of this manual. 9. Reconnect spark plug wire to plug. 14 19 TROUBLESHOOTING - See appropriate section in manual unless directed CLEANING • Clean engine often to keep trash from to a Sears Parts & Repair Centre. IMPORTANT: For best performance, accumulating. A clogged engine runs hotter and shortens engine life. PROBLEM CAUSE CORRECTION keep mower housing free of built-up grass and trash. Clean the underside of your • Keep finished surfaces and wheels free Does not start 1. Dirty air filter. 1. Clean/replace air filter. mower after each use. of all gasoline, oil, etc. 2. Out of fuel. 2. Fill fuel tank. • With the exception of the water washout CAUTION: Disconnect spark plug wire port (if equipped), we do not recommend 3. Stale fuel. 3. Empty fuel tank and refill tank from spark plug and place wire where it with fresh, clean gasoline. using a garden hose to clean the outside cannot come in contact with plug. 4. Water in fuel. 4. Empty fuel tank and refill tank of your lawn mower unless the electri cal with fresh, clean gasoline. • Clean the underside of your lawn system, muffler, air filter and carburetor 5. Spark plug wire is 5. Connect wire to plug. mower by scraping to remove build-up are covered to keep water out. Water in disconnected. of grass and trash. engine can result in shortened engine life. 6. Bad spark plug. 6. Replace spark plug. 7. Loose blade or broken 7. Tighten blade bolt or blade adapter. replace blade adapter. SERVICE AND ADJUSTMENTS 8. Control bar in released 8. Depress control bar to position. handle. WARNING: To avoid serious injury, before per form ing any service or adjust ments: 9. Control bar defective. 9. Replace control bar. 1. Release control bar and stop engine. 10. Fuel valve lever (if so 10. Turn fuel valve lever 2. Make sure the blade and all moving parts have completely stopped. equipped) in OFF position. to the ON position. 3. Disconnect spark plug wire from spark plug and place wire where it cannot come in 11. Weak battery (if equipped). 11. Charge battery. contact with plug. 12. Disconnected battery 12. Connect battery to engine. connector (if equipped). LAWN MOWER SQUEEZE TO ADJUST CUTTING HEIGHT TO ADJUST See “TO ADJUST CUTTING HEIGHT” in the Operation section of this manual. Lower handle Mounting pin REAR DEFLECTOR Handle The rear deflector, attached between the bracket Hairpin cotter rear wheels of your mower, is provided to minimize the possibility that objects will be thrown out of the rear of the mower into the operator mowing position. Re- place the deflector if damaged. Mowing Mowing TO ADJUST HANDLE position position The handle can be mounted in a high or low position. The mounting holes in the Bolt bottom of lower handle are off center for and raising or lowering the handle. nut 1. Remove upper handle and wire tie(s) securing cable(s) to lower handle. Hairpin 2. Remove hairpin cotters from lower cotter Handle handle bracket mounting pin. Mounting bracket 3. Remove bolts and nuts. pin LOW POSITION HIGH POSITION 4. Squeeze lower handle in to remove it from mounting pins. 5. Turn lower handle over to raise or ENGINE lower handle. Maintenance, repair, or re place ment of the 6. Squeeze lower handle in and posi tion emission control devic es and systems, which holes onto mounting pins on handle are being done at the custom ers expense, bracket. may be performed by any non-road engine 7. Reinstall bolts and nuts. repair es tab lish ment or individual. Warranty 8. Reassemble upper handle and all repairs must be performed by an authorized parts removed from lower handle. engine manu fac turer's service outlet.

18 15 ENGINE SPEED IMPORTANT: Never tamper with the FUEL SYS TEM ENGINE OIL Your engine speed has been factory set. engine governor, which is factory set IMPORTANT: It is important to prevent Drain oil (with engine warm) and replace for proper engine speed. Over speed- CARBURETOR gum deposits from forming in essential with clean engine oil. (See “ENGINE” in ing the engine above the factory high the Maintenance section of this manual). Your carburetor is not adjustable. If your fuel system parts such as carburetor, fuel speed setting can be dangerous. If you filter, fuel hose or tank during storage. engine does not operate properly due to think the engine-governed high speed suspected carburetor problems, take your Also, alcohol blended fuels (called CYLINDER needs adjusting, contact a Sears or other gasohol or using ethanol or methanol) lawn mower to a Sears or other qualified qualified service centre, which has proper 1. Remove spark plug. can attract moisture which leads to service center for repair and/or adjust- equip ment and expe ri ence to make any 2. Pour 1 ounce/29 ml of oil through ment. neces sary adjustments. separation and formation of acids during spark plug hole into cylinder. storage. Acidic gas can damage the fuel 3. Pull starter handle slowly a few times system of an engine while in storage. to dis trib ute oil. STORAGE • Empty the fuel tank by starting the en- 4. Replace with new spark plug. gine and letting it run until the fuel lines Immediately prepare your lawn mower for and carbu retor are empty. OTHER SQUEEZE • Never use engine or carburetor cleaner • Do not store gasoline from one season storage at the end of the season or if the TO FOLD unit will not be used for 30 days or more. prod ucts in the fuel tank or perma nent to another. Lower handle damage may occur. • Replace your gasoline can if your can • Use fresh fuel next season. starts to rust. Rust and/or dirt in your LAWN MOWER NOTE: Fuel stabilizer is an acceptable gasoline will cause problems. When lawn mower is to be stored for a al terna tive in minimizing the formation • If possible, store your unit indoors and period of time, clean it thoroughly, remove of fuel gum deposits during stor age. cover it to protect it from dust and dirt. all dirt, grease, leaves, etc. Store in a Add stabilizer to gasoline in fuel tank or • Cover your unit with a suitable protec- clean, dry area. storage contain er. Always follow the mix tive cover that does not retain moisture. 1. Clean entire lawn mower (See ratio found on stabilizer container. Run Do not use plastic. Plastic cannot “CLEANING” in the Maintenance sec- engine at least 10 minutes after adding breathe, which allows conden sa tion to tion of this manual). Operator MOWING stabilizer to allow the stabilizer to reach form and will cause your unit to rust. 2. Lubricate as shown in the Mainte- presence POSITION the carbu retor. Do not empty the gas tank IMPORTANT: Never cover mower while nance section of this manual. control bar and carburetor if using fuel stabilizer. engine and exhaust areas are still warm. 3. Be sure that all nuts, bolts, screws, CAUTION: Never store the lawn and pins are securely fastened. Inspect moving parts for damage, mower with gasoline in the tank inside a breakage and wear. Replace if neces- build ing where fumes may reach an open sary. FOLD flame or spark. Allow the engine to cool FORWARD Upper before storing in any enclo sure. 4. Touch up all rusted or chipped paint FOR handle surfaces; sand lightly before painting. STORAGE

HANDLE Handle You can fold your lawn mower handle for knob storage. 1. Remove bolts and nuts. 2. Squeeze the bottom ends of the Lower handle lower handle toward each other until Bolt the lower handle clears the handle Nut bracket, then move handle forward. Bracket 3. Loosen upper handle mounting bolts enough to allow upper handle to be folded back. IMPORTANT: When folding the handle ENGINE for storage or transportation, be sure to Maintenance, repair, or re place ment of the fold the handle as shown or you may emission control devic es and systems, which damage the control cables. are being done at the custom ers expense, • When setting up your handle from the may be performed by any non-road engine storage position, the lower handle will repair es tab lish ment or individual. Warranty automatically lock into the mowing repairs must be performed by an authorized position. engine manu fac turer's service outlet.

16 17 ENGINE SPEED IMPORTANT: Never tamper with the FUEL SYS TEM ENGINE OIL Your engine speed has been factory set. engine governor, which is factory set IMPORTANT: It is important to prevent Drain oil (with engine warm) and replace for proper engine speed. Over speed- CARBURETOR gum deposits from forming in essential with clean engine oil. (See “ENGINE” in ing the engine above the factory high the Maintenance section of this manual). Your carburetor is not adjustable. If your fuel system parts such as carburetor, fuel speed setting can be dangerous. If you filter, fuel hose or tank during storage. engine does not operate properly due to think the engine-governed high speed suspected carburetor problems, take your Also, alcohol blended fuels (called CYLINDER needs adjusting, contact a Sears or other gasohol or using ethanol or methanol) lawn mower to a Sears or other qualified qualified service centre, which has proper 1. Remove spark plug. can attract moisture which leads to service center for repair and/or adjust- equip ment and expe ri ence to make any 2. Pour 1 ounce/29 ml of oil through ment. neces sary adjustments. separation and formation of acids during spark plug hole into cylinder. storage. Acidic gas can damage the fuel 3. Pull starter handle slowly a few times system of an engine while in storage. to dis trib ute oil. STORAGE • Empty the fuel tank by starting the en- 4. Replace with new spark plug. gine and letting it run until the fuel lines Immediately prepare your lawn mower for and carbu retor are empty. OTHER SQUEEZE • Never use engine or carburetor cleaner • Do not store gasoline from one season storage at the end of the season or if the TO FOLD unit will not be used for 30 days or more. prod ucts in the fuel tank or perma nent to another. Lower handle damage may occur. • Replace your gasoline can if your can • Use fresh fuel next season. starts to rust. Rust and/or dirt in your LAWN MOWER NOTE: Fuel stabilizer is an acceptable gasoline will cause problems. When lawn mower is to be stored for a al terna tive in minimizing the formation • If possible, store your unit indoors and period of time, clean it thoroughly, remove of fuel gum deposits during stor age. cover it to protect it from dust and dirt. all dirt, grease, leaves, etc. Store in a Add stabilizer to gasoline in fuel tank or • Cover your unit with a suitable protec- clean, dry area. storage contain er. Always follow the mix tive cover that does not retain moisture. 1. Clean entire lawn mower (See ratio found on stabilizer container. Run Do not use plastic. Plastic cannot “CLEANING” in the Maintenance sec- engine at least 10 minutes after adding breathe, which allows conden sa tion to tion of this manual). Operator MOWING stabilizer to allow the stabilizer to reach form and will cause your unit to rust. 2. Lubricate as shown in the Mainte- presence POSITION the carbu retor. Do not empty the gas tank IMPORTANT: Never cover mower while nance section of this manual. control bar and carburetor if using fuel stabilizer. engine and exhaust areas are still warm. 3. Be sure that all nuts, bolts, screws, CAUTION: Never store the lawn and pins are securely fastened. Inspect moving parts for damage, mower with gasoline in the tank inside a breakage and wear. Replace if neces- build ing where fumes may reach an open sary. FOLD flame or spark. Allow the engine to cool FORWARD Upper before storing in any enclo sure. 4. Touch up all rusted or chipped paint FOR handle surfaces; sand lightly before painting. STORAGE

16 17 TROUBLESHOOTING - See appropriate section in manual unless directed CLEANING • Clean engine often to keep trash from to a Sears Parts & Repair Centre. IMPORTANT: For best performance, accumulating. A clogged engine runs hotter and shortens engine life. PROBLEM CAUSE CORRECTION keep mower housing free of built-up grass and trash. Clean the underside of your • Keep finished surfaces and wheels free Does not start 1. Dirty air filter. 1. Clean/replace air filter. mower after each use. of all gasoline, oil, etc. 2. Out of fuel. 2. Fill fuel tank. • With the exception of the water washout CAUTION: Disconnect spark plug wire port (if equipped), we do not recommend 3. Stale fuel. 3. Empty fuel tank and refill tank from spark plug and place wire where it with fresh, clean gasoline. using a garden hose to clean the outside cannot come in contact with plug. 4. Water in fuel. 4. Empty fuel tank and refill tank of your lawn mower unless the electri cal with fresh, clean gasoline. • Clean the underside of your lawn system, muffler, air filter and carburetor 5. Spark plug wire is 5. Connect wire to plug. mower by scraping to remove build-up are covered to keep water out. Water in disconnected. of grass and trash. engine can result in shortened engine life. 6. Bad spark plug. 6. Replace spark plug. 7. Loose blade or broken 7. Tighten blade bolt or blade adapter. replace blade adapter. SERVICE AND ADJUSTMENTS 8. Control bar in released 8. Depress control bar to position. handle. WARNING: To avoid serious injury, before per form ing any service or adjust ments: 9. Control bar defective. 9. Replace control bar. 1. Release control bar and stop engine. 10. Fuel valve lever (if so 10. Turn fuel valve lever 2. Make sure the blade and all moving parts have completely stopped. equipped) in OFF position. to the ON position. 3. Disconnect spark plug wire from spark plug and place wire where it cannot come in 11. Weak battery (if equipped). 11. Charge battery. contact with plug. 12. Disconnected battery 12. Connect battery to engine. connector (if equipped). LAWN MOWER SQUEEZE TO ADJUST CUTTING HEIGHT TO ADJUST See “TO ADJUST CUTTING HEIGHT” in the Operation section of this manual. Lower handle Mounting pin REAR DEFLECTOR Handle The rear deflector, attached between the bracket Hairpin cotter rear wheels of your mower, is provided to minimize the possibility that objects will be thrown out of the rear of the mower into the operator mowing position. Re- place the deflector if damaged. Mowing Mowing TO ADJUST HANDLE position position The handle can be mounted in a high or low position. The mounting holes in the Bolt bottom of lower handle are off center for and raising or lowering the handle. nut 1. Remove upper handle and wire tie(s) securing cable(s) to lower handle. Hairpin 2. Remove hairpin cotters from lower cotter Handle handle bracket mounting pin. Mounting bracket 3. Remove bolts and nuts. pin LOW POSITION HIGH POSITION 4. Squeeze lower handle in to remove it from mounting pins. 5. Turn lower handle over to raise or ENGINE lower handle. Maintenance, repair, or re place ment of the 6. Squeeze lower handle in and posi tion emission control devic es and systems, which holes onto mounting pins on handle are being done at the custom ers expense, bracket. may be performed by any non-road engine 7. Reinstall bolts and nuts. repair es tab lish ment or individual. Warranty 8. Reassemble upper handle and all repairs must be performed by an authorized parts removed from lower handle. engine manu fac turer's service outlet.

18 15 NOTE: Multi-viscosity oils (5W30, 10W30 Oil fill cap / TROUBLESHOOTING - See appropriate section in manual unless directed etc.) improve starting in cold weather, and dipstick to a Sears Parts & Repair Centre. you should check your engine oil level frequently to avoid possible engine damage PROBLEM CAUSE CORRECTION from running low on oil. Loss of power 1. Rear of mower housing or 1. Raise cutting height. Change the oil after every 25 hours of opera- blade dragging in grass. tion or at least once a year if the lawn mower Upper 2. Cutting too much grass. 2. Raise cutting height. is not used for 25 hours in one year. mark 3. Dirty air filter. 3. Clean/replace air filter. Check the crankcase oil level before 4. Buildup of grass, leaves, 4. Clean underside of mower starting the engine and after each five (5) Lower and trash under mower. housing. hours of continuous use. Tighten oil plug mark 5. Too much oil in engine. 5. Check oil level. securely each time you check the oil level. 6. Walking speed too fast. 6. Cut at slower walking speed. AIR FILTER TO CHANGE ENGINE OIL Your engine will not run properly and may 1. Worn, bent or loose blade. 1. Replace blade. Tighten NOTE: Before tipping lawn mower to Poor cut – be damaged by using a dirty air filter. drain oil, empty fuel tank by running en- uneven blade bolt. Replace the air filter every 100 hours of gine until fuel tank is empty. 2. Wheel heights uneven. 2. Set all wheels at same operation or every season, whichever oc- 1. Disconnect spark plug wire from spark height. curs first. Service air cleaner more often plug and place wire where it cannot 3. Buildup of grass, leaves 3. Clean underside of under dusty conditions. come in contact with plug. and trash under mower. mower housing. 2. Remove engine oil cap; lay aside on a TO CLEAN AIR FILTER clean surface. Excessive 1. Worn, bent or loose blade. 1. Replace blade. Tighten 1. Remove cover. vibration blade bolt. 3. Tip lawn mower on its side as shown 2. Carefully remove cartridge. and drain oil into a suitable container. 2. Bent engine crankshaft. 2. Contact a Sears or other 3. Clean by gently tapping on a flat sur- qualified service centre. Rock lawn mower back and forth to re- face. If very dirty, replace cartridge. move any oil trapped inside of engine. CAUTION: Petroleum solvents, such Starter rope 1. Engine flywheel brake is on 1. Depress control bar to as ker o sene, are not to be used to clean hard to pull when control bar is released. upper handle before cartridge. They may cause dete ri o ra tion pulling the starter rope. of the cartridge. Do not oil cartridge. Do 2. Bent engine crankshaft. 2. Contact a Sears or other not use pressur ized air to clean or dry qualified service centre. cartridge. 3. Blade adapter broken. 3. Replace blade adapter. 4. Install cartridge, then replace cover. 4. Blade dragging in grass. 4. Move lawn mower to cut grass or to hard surface. Slot Grass catcher 1. Cutting height too low. 1. Raise cutting height. not filling 2. Lift on blade worn off. 2. Replace blade. (If so equipped) 3. Catcher not venting air. 3. Clean grass catcher. Container Tab 4. Wipe off any spilled oil from lawn Hard to push 1. Grass is too high or wheel 1. Raise cutting height. mower or side of engine. height is too low. 5. Fill engine with oil. The engine oil 2. Rear of mower housing or 2. Raise rear of mower housing capacity is 0.58 quarts. If oil is not blade dragging in grass. one (1) setting higher. complete ly drained from engine, you 3. Grass catcher too full. 3. Empty grass catcher. may not need the entire container of a Cartridge 4. Handle height position not 4. Adjust handle height to suit. 20 oz. bottle of oil. Slowly pour 3/4 of right for you. the oil from the container down the oil fill spout into the engine. 6. Wait one minute to allow oil to settle. Filter cover Use guage on oil fill cap/dipstick for checking level. Insert dipstick into MUFFLER the tube and rest the oil fill cap on the Inspect and replace corroded muffler as it tube. DO NOT thread the cap into the could create a fire hazard and/or damage. tube when taking reading. SPARK PLUG 7. Continue adding small amounts of oil and rechecking the dipstick until it Replace spark plug at the beginning of reads full. DO NOT overfill, or engine each mowing season or after every 100 will smoke on startup. hours of operation, whichever occurs 8. Always be sure to retighten oil dipstick first. Spark plug type and gap setting before starting engine. are shown in the “PRODUCT SPECI FI CA- TIONS” section of this manual. 9. Reconnect spark plug wire to plug. 14 19 LAWN MOWER Blade adapter Key Crankshaft REPAIR PARTS Always observe safety rules when per- keyway form ing any mainte nance. Lockwasher TIRES Blade • Keep tires free of gasoline, oil, or insect 44 61 56 control chemicals which can harm rubber. 57

54 • Avoid stumps, stones, deep ruts, sharp 53 42

37 objects and other hazards that may 9 3 9 36 cause tire damage. Blade 4 bolt Hardened BLADE CARE

73 will cause eventual damage to lawn 44 by the manufacturer of your mower is 84 8 34 35 mower or engine. 52

65 hazardous, could damage your mower 944.364152

30 and void your warranty. • The blade can be sharpened with a file 25

9 come in contact with plug.

22 GRASS CATCHER

33 and/or wrap blade with heavy cloth. • The grass catcher may be hosed with 46 4. Remove blade bolt by turning counter- 20 35

21 water, but must be dry when used.

3 replace only with approved replacement 47

51 the key inside hub of blade adapter. The key 14 must be in good condi tion to work properly. catcher shown in the Repair Parts section

58 Replace adapter if damaged. of this manual. Give the lawn mower model 87 61 37 number when ordering. TO REPLACE BLADE

10 crankshaft keyway are aligned. 9

33 are being done at the customers expense, 26 8 2. Position blade on the blade adapter 32

14 posite sharp edge) is up toward engine. engine manufacturer’s service outlet. CRAFTSMAN 13 4. Install the blade bolt with the lock LUBRICATION 4 73 31 2

50 • The recommended tightening torque is 35–40 ft. lbs. (47–54 Nm). 40 9

3 IMPORTANT: Blade bolt is heat treated. 1 If bolt needs replacing, replace only with approved bolt shown in the Repair Parts 20 section of this manual. 13 MAINTENANCE

you should make any of the adjustments MOWER - MODEL NUMBER LAWN ROTARY described in the Service and Ad justments Rear door section of this manual. hinge NOTE: • At least once a year, replace the spark plug, clean or replace air filter element and check blade for wear. A new spark plug and clean/new air filter element assure proper air-fuel mix ture and help your engine run better and last longer. CRAFTSMAN • Follow the maintenance schedule in this Handle bracket mounting pins manual. Spray lubricant BEFORE EACH USE See "ENGINE" in Maintenance section. • Check engine oil level.

• Check for loose fasteners. IMPORTANT: Do not oil or grease plastic to do so could be hazardous, damage your lawn mo replacement parts. Failure Use only Original Equipment Manufacturer (O.E.M.) wheel bearings. Viscous lubri cants will LUBRICATION attract dust and dirt that will shorten the life Keep unit well lubricated of the self-lubri cating bearings. If you feel (See “LUBRI CA TION CHART”). they must be lubri cated, use only a dry, IMPORTANT: pow dered graphite type lubricant sparingly. Bar Handle Control 1 194176X428 Upper 2 447814X479 Guide Bolt 3 Rope Handle Tie 4 581902101 580638602 T-Knob 5 581912601 Wire Lower Handle Bar, Bracket 6 191574 Hinge 7 66426 8 Door 9 154132 Mulcher 74780512 10 165754 Bolt, Hex Head 5/16-18 x 3/4 11 Bracket 440934 12 Up-Stop Knob 178848 13 429930X004 Handle Cotter Engine Zone Control Cable 14 189713X428 Hairpin Head Screw Hex Washer 15 51793 18 17600406 19 Skirt 401174X004 20 Rear Screw 1/4-20 x 3/8 LH Front, Axle Arm Assembly, 401175X004 21 416860 RH Front, Axle Arm Assembly, 22 401621X004 23 Selector Spring, Front 401814X428 25 Rear Door Assembly 580915602 26 LH 580915702 Handle Bracket Assembly, 29 Spacer RH 407494X005 Handle Bracket Assembly, 30 401629 Wheel Adjusting Bracket KEY PART KEY PART NO. NO. DESCRIPTION 12 21 HONDA 4-CYCLE ENGINE MODEL NUMBER GCV160-LAOS3B OFF • Keep top of engine around starter clear and clean of grass clippings and chaff. This will help engine air flow and extend ON engine life. MULCHING MOWING TIPS IMPORTANT: For best performance, keep mower housing free of built-up grass and trash. See “CLEANING” in the Maintenance section of this manual. Fuel • The special mulching blade will recut valve the grass clip pings many times and lever reduce them in size so that as they fall onto the lawn they will disperse into MOWING TIPS the grass and not be noticed. Also, CAUTION: Do not use de-thatcher the mulched grass will bio de grade blade attachments on your mower. Such quick ly to provide nutri ents for the lawn. attachments are hazardous, will damage Always mulch with your highest engine your mower and could void your warranty. (blade) speed as this will provide the best recutting action of the blades. • Under certain conditions, such as very • Avoid cutting your lawn when it is wet. tall grass, it may be necessary to raise Wet grass tends to form clumps and the height of cut to reduce pushing effort in terferes with the mulching action. The and to keep from overload ing the engine best time to mow your lawn is the early and leaving clumps of grass clippings. It afternoon. At this time the grass has may also be necessary to reduce ground dried, yet the newly cut area will not be speed and/or run the lawn mower over exposed to direct sunlight. the area a second time. • For best results, adjust the lawn mower • For extremely heavy cutting, reduce the cutting height so that the lawn mower width of cut by overlapping pre vi ous ly cuts off only the top one-third of the cut path and mow slowly. grass blades. If the lawn is overgrown • For side discharge operation, cut in it will be neces sary to raise the height a counter clock wise di rection, starting of cut to reduce pushing effort and to at the outside of the area to be cut, in keep from over load ing the engine and order to spread grass clip pings more leaving clumps of mulched grass. For evenly and to put less load on the extremely heavy grass, reduce your engine. To keep clippings off of walk- width of cut by overlapping previously ways, flower beds, etc., make the first cut path and mow slowly. cuts in a clockwise direction.

MAX 1/3

• Certain types of grass and grass condi tions may require that an area be • If a trail of grass clipping is left on the mulched a second time to completely right side of the lawn mower during rear hide the clippings. When doing a sec- discharge operation, mow in a clock- ond cut, mow across (perpendicular) to wise direction with a small overlap to the first cut path. collect the clippings on the next pass. • Change your cutting pattern from week • Pores in cloth grass catchers can be- to week. Mow north to south one week come filled with dirt and dust with use then change to east to west the next and catchers will collect less grass. To week. This will help prevent matting prevent this, regularly hose catcher off and graining of the lawn. with water and let dry before using. 22 11 SIMPLE STEPS TO REMEMBER WHEN CHANGE ENGINE OIL” in the Mainte- HONDA 4-CYCLE ENGINE MODEL NUMBER GCV160-LAOS3B CONVERTING YOUR LAWN MOWER nance section of this manual. FOR MULCHING - ADD GASOLINE 1. Rear door closed. • Fill fuel tank to bottom of tank filler 2. Mulcher door closed. neck. Do not overfill. Use fresh, clean, FOR REAR BAGGING - regular unleaded gasoline with a mini- 1. Grass catcher installed. mum of 87 octane. Do not mix oil with CYLINDER BARREL CONTROL 2. Mulcher door closed. gasoline. Purchase fuel in quanti ties KEY PART KEY PART FOR SIDE DISCHARGING - that can be used within 30 days to as- NO. NO. DESCRIPTION NO. NO. DESCRIPTION 1. Rear door closed. sure fuel freshness. 1 12000-Z0L-406 Cylinder Assembly 1 16551-ZM0-010 Arm, Governor 2. Discharge deflector installed. CAUTION: Wipe off any spilled oil or 12000-Z0L-840 Cylinder Assembly 2 16555-Z0L-801 Rod, Governor CAUTION: Do not run your lawn mow- fuel. Do not store, spill or use gasoline 3 12310-Z0J-000 Cover, Cylinder Head 3 16561-Z0L-000 Spring, Governor er without rear door closed or ap proved near an open flame. 12311-ZL8-D00 Cover, Head 4 16562-ZM0-000 Spring, Throttle Return grass catcher in place. Never attempt to CAUTION: Alcohol blended fuels 12311-ZL8-000 Cover, Head 10 90015-ZE5-010 Bolt, Governor Arm op erate the lawn mower with the rear door (called gasohol or using ethanol or meth- removed or propped open. 4 12355-ZL8-000 Cover, Breather 13 94050-06000 Nut, Flange (6 mm) anol) can attract moisture which leads to (Breather Valve Assembly) 15 93892-04012-00 Screw, Washer Head TO EMPTY GRASS CATCHER separation and for mation of acids during 5 90013-883-000 Bolt, Flange (#6 x 12) (#4 x 12) storage. Acidic gas can damage the fuel 1. Lift up on grass catcher using the (CT200) 16 94103-04000 Washer, Plain (4 mm) system of an engine while in storage. To frame handle. 6 90014-952-000 Bolt, Flange (#6 x 14) 2. Remove grass catcher with clippings avoid engine problems, the fuel system should be emptied before stor age of 30 (CT200) CRANKSHAFT from under lawn mower handle. 7 91201-ZL8-003 Oil Seal (25.4 x 62 x 6) KEY PART 3. Empty clippings from bag. days or longer. Empty the gas tank, start the engine and let it run until the fuel lines 8 98079-55846 Spark Plug (BPR5ES) NO. NO. DESCRIPTION NOTE: Do not drag the bag when empty- (NGK) 3 13310-ZM0-610 Crankshaft ing; it will cause unnecessary wear. and carburetor are empty. Use fresh fuel next season. See Storage Instruc tions for 10 12209-ZM0-003 Seal, Valve Stem 5 90402-ZL8-000 Washer, Thrust 11 14711-ZL8-000 Valve, Intake Grass additional information. Never use engine RECOIL STARTER catcher or carburetor cleaner products in the fuel (Technostar) frame tank or permanent damage may occur. 14711-Z0J-000 Valve, Intake (Rocknel) KEY PART handle 14711-Z0J-800 Valve, Intake NO. NO. DESCRIPTION Oil fill cap / Gasoline dipstick filler cap 12 14721-ZL8-000 Valve, Exhaust 1 28400-Z0L-V20ZA Starter Assembly, 13 14751-ZL8-000 Spring, Valve Recoil, “NH1” 14 14771-Z0J-000 Retainer, Valve Spring (Long Rope) (Black) 8 28461-ZL8-003 Grip, Recoil Starter CARBURETOR 9 28462-Z0L-V20 Rope, Recoil Starter, KEY PART “Long Type” (Black) NO. NO. DESCRIPTION 11 90201-ZM0-000 Nut, Flange (6 mm) 1 16010-883-015 Gasket Set BEFORE 2 16013-ZL1-003 Float Set STARTING ENGINE 3 16015-Z0L-881 Chamber Set, Float 5 16028-ZE0-005 Screw Set ADD OIL Upper Lower Your lawnmower is shipped without oil in mark mark 16028-ZK7-S91 Screw Set the engine. For type and grade of oil to 7 16100-Z0L-852 Carburetor Assembly use, see “ENGINE” in the Maintenance TO STOP ENGINE (BB62Z B) section of this manual. • To stop engine, release operator pres- 8 16155-ZM0-013 Valve, Float CAUTION: DO NOT overfill engine with ence control bar. Wait until blade and 9 16166-ZM0-003 Nozzle, Main oil, or it will smoke on startup. all moving parts have stopped and turn 10 16211-ZL8-000 Insulator, Carburetor 1. Be sure lawnmower is level. fuel valve to OFF position if you do not 11 16212-ZL8-000 Gasket, Insulator 2. Remove oil dipstick from oil fill spout. intend to restart the engine soon. 13 16228-ZL8-000 Gasket, Carburetor 3. You recieve a container of oil with the 15 93500-05006-0H Screw, Pan (#5 x 6) unit. Slowly pour the entire container TO START ENGINE 16 99101-124-0600 Jet, Main (#60) down the oil fill spout into the engine. NOTE: Due to protective coatings on the 99101-124-0620 Jet, Main (#62) 4. Insert and tighten dipstick. engine, a small amount of smoke may be 99101-124-0650 Jet, Main (#65) present during the initial use of the prod- IMPORTANT: 26 16951-Z0L-000 Guide, Air • Check oil level before each use. Add uct and should be considered normal. oil if needed. Fill to full line on dipstick. 1. Be sure fuel valve is in ON posi tion. • Change the oil after every 25 hours of 2. Hold operator presence control bar operation or each season. You may down to the handle and pull starter need to change the oil more often handle quickly. Do not allow starter under dusty, dirty conditions. See “TO 10 rope to snap back. 23 HONDA 4-CYCLE ENGINE MODEL NUMBER GCV160-LAOS3B The operation of any lawn mower can result in foreign objects Use ear thrown into the eyes, which can result in severe eye damage. protec- Always wear safety glasses or eye shields while operating your tors to lawn mower or performing any adjustments or repairs. We recom- avoid mend standard safety glasses or a wide vision safety mask over spectacles. damage to hearing. HOW TO USE YOUR LAWN MOWER Pivot pins Rear Grass ENGINE SPEED door catcher Engine speed was set at the factory for handle optimum performance. It is not adjustable. ENGINE ZONE CONTROL CAUTION: Federal regulations require an engine control to be installed on this lawn mower in order to minimize the risk of blade contact injury. Do not under any circumstances attempt to defeat the function of the operator control. The blade Catcher frame hook turns when the engine is running. SIDE DISCHARGING • Your lawn mower is equipped with an operator pres ence control bar which • Rear door must be closed. requires the operator to be positioned • Open mulcher door and install dis- behind the lawn mower handle to start charge deflector under door as shown. and operate the lawn mower. • Mower is now ready for discharging operation. TO ADJUST CUTTING HEIGHT • To convert to mulching or bagging Raise wheels for low cut and lower wheels operation, dis charge deflector must be for high cut, adjust cutting height to suit removed and mulcher door must be your requirements. Medi um position is closed. best for most lawns. • To change cutting height, squeeze adjuster lever toward wheel. Move wheel up or down to suit your require ments. Be sure all wheels are in the same setting. NOTE: Adjuster is properly positioned when plate tab inserts into hole in lever. Also, 9-position adjusters (if so equipped) allow lever to be positioned between the plate tabs. Open mulcher door LEVER BACKWARD TO Plate tab LOWER MOWER Discharge deflector

KNOW YOUR LAWN MOWER FAN COVER FLYWHEEL READ THIS OWNER'S MANUAL AND ALL SAFETY RULES BEFORE OPERATING YOUR KEY PART KEY PART LAWN MOWER. Compare the illustrations with your lawn mower to familiarize yourself with NO. NO. DESCRIPTION NO. NO. DESCRIPTION the location of various controls and adjustments. Save this manual for future reference. 6 16950-Z0Y-003 Petcock Assembly 1 13331-357-000 Key, Special, Woodruff These symbols may appear on your lawn mower or in literature supplied with the product. 7 16952-ZA8-800 Filter, Fuel (25 x 18) Learn and understand their meaning. 8 16961-Z0L-900 Stay, Fuel Petcock 3 30500-ZL8-014 Coil Assembly, Ignition 9 17511-Z0L-030 Tank, Fuel 4 31105-ZM0-000 Flywheel Assembly 10 17514-Z0L-000 Seal, Fuel Filler Neck 5 32195-ZM0-800 Wire, Stop Switch 11 17516-Z0L-000 Clip, Tank Mounting 6 35120-ZM0-003 Switch Assembly, 12 17532-Z0L-000 Rubber A, Tank Mounting Engine Stop (NC) 13 17533-Z0L-000 Rubber B, Tank Mounting 8 75113-ZM0-000 Spring, Brake Lever 14 17534-Z0L-000 Nut, Tank Mounting 10 90014-952-000 Bolt, Flange (#6 x 14) 15 17620-Z0J-800 Cap Assembly, Fuel Tank (CT200) 16 17636-Z0L-000 Gauge, Fuel Level 11 90018-ZE1-000 Bolt, Flange (#6 x 23) 21 19610-Z0L-861ZC Cover Assembly, Fan (CT200) Operator presence control bar “T89” (Craftsman Red) 12 90018-ZE1-000 Bolt, Flange (#6 x 23) 19610-Z0L-861ZA Cover Assembly, Fan (CT200) “T89” (“NH1”) (Black) 13 90201-Z0T-800 Nut, Special (14 mm) 19610-Z0L-861ZD Cover Assembly, Fan 14 51125-Z0L-003 Holder, Wire (Fastex) “T93” (Husqvarna Grey) 90681-959-003 Clip A, Cable (3.8mm) 19610-Z0L-861ZE Cover Assembly, Fan (Black) (NIFCO) Handle knob “T98” (M.T.D. Red) 15 93892-04012-00 Screw, Washer Head 22 19619-ZL8-300 Collar, Fan Cover (#4 x 12) 24 90013-883-000 Bolt, Flanged (#6 x 12) 16 94103-04000 Washer, Plain (4 mm) Gasoline filler cap (CT200) 21 75110-Z0Y-000 Brake Sub Assembly 25 90015-883-000 Bolt, Flanged (#6 x 28) 25 91601-Z0L-300 Grommet, Brake Plate (CT200) Starter 27 90043-ZL8-000 Bolt, Stud (H=42.5mm) AIR CLEANER handle Fuel valve lever 28 90043-ZL8-000 Bolt, Stud (H=42.5mm) KEY PART 33 93913-25220 Screw, Tapping (PO) NO. NO. DESCRIPTION (#5 x 12) 1 15721-ZM0-000 Tube, Breather Air filter 35 91424-Z8B-821 Tube, Fuel Tank 2 17211-ZL8-023 Element, Air Cleaner Grass 36 91427-Z8B-821 Tube, Fuel (7.3 x 160) 3 17220-ZM0-010 Case Assy., Air Cleaner catcher 40 95002-40800-08 Clip, Tube (D8) (S/N 1167575 and below) Housing 42 95002-41200-08 Clip, Tube (D12) 17220-ZM0-020 Case Assy., Air Cleaner (S/N 1167576–1239013) MUFFLER 17220-ZM0-030 Case Assy., Air Cleaner Engine oil plug KEY PART (S/N 1239014 and above) NO. NO. DESCRIPTION 5 17228-ZM0-000 Gasket, Air Cleaner 1 18310-ZM0-000 Muffler 6 17231-Z0L-030 Cover, Air Cleaner Muffler 2 18321-Z0L-J00 Protector, Muffler (S/N 1167575 and below) Spark plug (S/N 1243452 and below) 17231-Z0L-040 Cover, Air Cleaner Mulcher door 18321-Z0L-J01 Protector, Muffler (S/N 1167575 and below) Wheel adjuster (S/N 1243453 and above) 17231-Z0L-050 Cover, Air Cleaner IMPORTANT: This lawn mower is shipped (on each wheel) WITHOUT OIL OR GASOLINE in the engine. 3 90004-ZL8-000 Bolt, Flange #6 x 79 7 90003-ZM0-010 Bolt, Flange (#6 x 85) NOTE: Gasoline containing up to 10% ethanol (E10) is acceptable for use in this machine. (CT200) (CT200) The use of any gasoline exceeding 10% ethanol (E10) will void the product warranty. 4 90013-883-000 Bolt, Flange #6 x 12 (CT200) MEETS CPSC SAFETY REQUIREMENTS 5 18381-ZL8-305 Gasket, Muffler Sears rotary walk-behind power lawn mowers conform to the safety standards of the 9 18350-ZL8-000 Arrester, Spark American National Standards Institute and the U.S. Consumer Product Safety Commis- 10 18356-ZL8-000 Plate, Arrester Number sion. WARNING: The blade turns when the engine is running. 11 90055-ZE1-000 Screw, Tapping #4 x 6 Operator presence control bar – must Mulcher door – allows conver sion to 12 06180-Z0J-000 Kit, Spark Arrester be held down to the handle to start the discharging or bagging operation. engine. Release to stop the engine. 8 Starter handle – used for starting engine. 25 HONDA 4-CYCLE ENGINE MODEL NUMBER GCV160-LAOS3B TO ASSEMBLE GRASS CATCH ER INSTALL STARTER ROPE 1. Put grass catcher frame into grass bag 1. Loosen T-knob. with rigid part of bag on the bottom. 2. Hold control bar against upper handle. Make sure the frame handle is outside 3. Slowly pull engine starter rope out until of the bag top. rope will slip into loop of rope guide. 2. Slip vinyl bindings over frame. 4. Tighten T-knob. NOTE: If vinyl bindings are too stiff, hold them in warm water for a few minutes. If bag gets wet, let it dry before using. Frame handle

Control bar

Upper handle

Vinyl Frame bindings opening

Rope guide T-Knob

Engine starter rope

TO INSTALL ATTACHMENTS Your lawn mower was shipped ready to be used as a mulcher. To convert to bagging, see “TO CONVERT MOWER” in the Operation section of this manu al.

26 7 HONDA 4-CYCLE ENGINE MODEL NUMBER GCV160-LAOS3B ASSEMBLY / PRE-OPERATION Read these instructions and this manual HOW TO SET UP YOUR LAWN in its entirety before you attempt to as- MOW ER semble or operate your new lawn mower. IMPORTANT: This lawn mower is TO UNFOLD HANDLE shipped WITHOUT OIL OR GASOLINE in IMPORTANT: Unfold handle carefully so CAMSHAFT PULLEY PISTON / CONNECTING ROD the engine. as not to pinch or damage control cables. KEY PART KEY PART Your new lawn mower has been assem- 1. Raise handles until lower handle sec- NO. NO. DESCRIPTION NO. NO. DESCRIPTION bled at the factory with the exception of tion locks into place in mowing posi- 1 14320-ZL8-010 Pulley, Camshaft 1 13101-Z2A-010 Piston those parts left unassembled for shipping tion. 2 14324-ZL8-000 Shaft, Cam Pulley 2 13111-ZE0-000 Pin, Piston purposes. All parts such as nuts, wash- 2. Insert bolt through handle and bracket 3 14400-Z0J-014 Belt, Timing 3 13200-Z0J-000 Connecting Rod Assem- and secure with nut. ers, bolts, etc., neces sary to complete the (84HU7 G-200) bly 3. Remove protective padding, raise up- as sembly have been placed in the parts 6 14461-ZL8-000 Shaft, Rocker Arm 4 90001-ZE1-000 Bolt, Connecting Rod bag. To ensure safe and proper operation per handle section into place on lower handle and tighten both handle knobs. 11 90112-333-000 Screw, Tappet Adjusting 5 90551-ZE0-000 Clip, Piston Pin (13 mm) of your lawn mower, all parts and hard- 12 90206-001-000 Nut, Tappet Adjusting 6 13010-Z0L-014 Ring Set, Piston, Standard ware you assemble must be tightened 4. Remove handle padding holding 13 91301-ZM0-V31 O-Ring (6.8 x 1.9) (ARAI) (Teikoku) securely. Use the correct tools as neces- operator pres ence control bar to upper sary to ensure proper tightness. handle. 15 14431-Z0J-000 Rocker Arm, Intake Valve Your lawn mower handle can be adjusted 16 14441-Z0J-000 Rocker Arm, LABELS for your mowing comfort. Refer to "AD- Exhaust Valve KEY PART TO REMOVE MOWER FROM JUST HANDLE" in the Service and Adjust- NO. NO. DESCRIPTION CAR TON ments section of this manual. OIL PAN 9 87528-Z0L-V20 Mark, Choke Indication 1. Remove loose parts included with KEY PART 20 87114-ZH7-821 Label, Warning mower. Operator MOWING NO. NO. DESCRIPTION 30 87101-Z8B-000 Mark, Emblem (GCV160) 2. Cut down two end corners of carton presence POSITION 1 11300-ZM0-811 Pan Assembly, Oil 31 87169-Z8E-000 Mark, Recoil Cover control bar and lay end panel down flat. 2 15650-ZM0-801 Gauge Assembly, 32 87524-Z8B-000 Mark, Caution, 3. Remove all packing materials except LIFT Oil Level Fuel Petcock UP padding between upper and lower 4 15625-ZE6-000 Gasket, Oil Filler Cap handle and padding holding operator 5 15631-ZM0-000 Extension, Oil Filler CHOKE BASE presence control bar to upper handle. 6 15639-ZM0-000 Lock Washer, Extension KEY PART 4. Roll mower out of carton and check Upper 8 16508-ZM0-010 Shaft, Governor Holder NO. NO. DESCRIPTION LIFT handle carton thorough ly for additional loose UP 9 16510-ZM0-010 Governor Assembly 2 16592-Z2D-800 Spring, Return parts. 10 16511-ZL8-000 Weight, Governor 5 16614-Z2D-800 Spring, Choke Lever 11 16512-ZM0-000 Holder, Governor Weight 8 16632-Z0L-801 Rod, Stop Handle 12 16513-ZE1-000 Pin, Governor Weight 9 90022-888-010 Bolt, Flange (#6 x 20) knob 13 16531-ZE1-000 Slider, Governor (CT200) 14 16541-ZM0-000 Shaft, Governor Arm 14 16610-Z2D-801 Lever Assembly, Choke 15 90014-952-000 Bolt, Flange (#6 x 14) 16610-Z2D-802 Lever Assembly, Choke Lower handle Bolt (CT200) Nut 16 90121-952-000 Bolt, Flange (#6 x 25) Bracket (CT200) 17 90451-ZE1-000 Washer, Thrust (6 mm) 18 90602-ZE1-000 Clip, Governor Holder 19 91202-ZL8-003 Oil Seal (28 x 41.25 x 6) 20 91356-MA6-005 O-Ring (14.8 x 2.4) (NOK) 21 94101-068000 Washer, Plain (6 mm) 22 94251-08000 Pin, Lock (8 mm) 23 94301-08200 Pin, Dowel (#8 x 20)

6 27 WARRANTY EMISSION CONTROL SYSTEM WARRANTY Your new Honda Power Equipment engine complies with the U.S. EPA, Environment Canada, and LIST OF APPLICABLE WARRANTY PERIODS: The following list contains the applicable State of California emission regulations (models certified for sale in California only). American Hon- Warranty Period for your Craftsman product and is based on a combination of the type da Motor Co., Inc. provides the emission warranty coverage for engines in the United States and of product or component and the intended and actual use of the product or component: its territories. Honda Canada Inc. provides the emission warranty for engines in the 13 provinces 1. 90 DAYS: Craftsman products intended for use or actually used for commercial, and territories of Canada. In the remainder of this Emission Control System Warranty, American institutional, professional or income-producing purposes Honda Motor Company Inc. and Honda Canada Inc. will be referred to as Honda. YOUR WARRANTY RIGHTS AND OBLIGATIONS: 2. 2 YEARS: Craftsman riding lawn mowers, yard and garden tractors, walk behind California mowers, tillers, brush cutters, snow blowers, handheld blowers, backpack blowers, The California Air Resources Board and Honda are pleased to explain the emission control system hedge trimmers and electrical products for noncommercial, nonprofessional, non- warranty on your Honda Power Equipment engine. In California, new spark-ignited small off-road institutional, or non-income-producing use, except for those components which are equipment engines must be designed, built, and equipped to meet the State's stringent anti-smog part of engine systems manufactured by third party engine manufacturers for which standards. the purchase has received an separate warranty with product information supplied Other States, U.S. territories, and Canada at the time of purchase. In other areas of the United States and in Canada, your engine must be designed, built, and equipped to meet the U.S. EPA and Environment Canada emission standards for spark-ignited en- 3. 1 YEAR: Craftsman power cutters, stump grinders, pole pruners, gas chain saws, gines at or below 19 kilowatts. Specific Honda products that do not meet the California emissions electric chain saws, trimmer attachments, baggers and pole saws for noncommercial, regulations can be identified by a “Not for sale in California” decal. nonprofessional, non-institutional, or non-income-producing use. All of the United States and Canada 4. 90 DAYS: All defective batteries, which will be replaced during this 90-day Warranty Honda must warrant the emission control system on your power equipment engine for the period Period. of time listed below, provided there has been no abuse, neglect, or improper maintenance of your power equipment engine. Where a warrantable condition exists, Honda will repair your power 5. 60 DAYS: Additional Warranty Period of 60 days will apply to adjustments and worn equipment engine at no cost to you including diagnosis, parts, and labor. products or components BUT DOES NOT INCLUDE WEAR OR ADJUSTMENTS Your emission control system may include such parts as the carburetor or fuel injection system, for products used for commercial, institutional, professional or income-producing the ignition system, and catalytic converter. Also included may be hoses, connectors, and other purposes. Wear items include but are not limited to: belts, blades, tires, spark plugs, emission-related assemblies (see next page for additional covered parts). air filters, chains, shear bolts, skid plates, scraper bars, drift cutters, ropes, tines, OWNER'S WARRANTY RESPONSIBILITY: collection bags and pulleys. As the power equipment engine owner, you are responsible for the performance of the required As the Warranty Period runs from the date of purchase and NOT from the date that a maintenance listed in your owner's manual. Honda recommends that you retain all receipts covering product is delivered, opened, assembled or first used, plea se ensure during this time maintenance on your power equipment engine, but Honda cannot deny warranty coverage solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. period that your product or component has been assembled and tested for correction operation regardless of when you intend to actually use it. Claims made after the As the power equipment engine owner, you should however be aware Honda may deny you warranty coverage if your power equipment engine or a part has failed due to abuse, neglect, Warranty Period has expired will not be honored. improper maintenance, or unapproved modifications. PROOF OF PURCHASE/DOCUMENTATION: Warranty coverage is conditioned upon You are responsible for presenting your power equipment engine to a Honda Power Equipment the original purchaser furnishing Sears Canada or its authorized third party service dealer as soon as a problem exists. The emission related warranty repairs should be completed provider if applicable, with the original sales receipt or other adequate written proof in a reasonable amount of time, not to exceed 30 days. If you have any questions regarding your of the original purchase date and identification of the product. In the event that the emission warranty rights and responsibilities, you should contact the Honda office in your region: original purchaser is unable to provide a company of the original sales receipt, Sears American Honda Motor Co., Inc. Honda Canada Inc. Canada Inc. reserves the right to determine in its sole discretion what other written Power Equipment Customer Relations Power Equipment Customer Relations proof of the original purchase date and identification of the product is acceptable. 4900 Marconi Drive Visit www.honda.ca or Alpharetta, Georgia 30005-8847 for contact information. Telephone: (888) 888-3139 Telephone: (888) 946-6329 PRODUCT SPECIFICATIONS Email: [email protected] Serial Number: WARRANTY COVERAGE: Date of Purchase: Honda power equipment engines sold in the United States and Canada are covered by this warranty for a period of two years from the date of delivery to the original retail purchaser or the length Gasoline Capacity / Type: 1 Quart/0,94 Liters (Unleaded Regular) of the Honda Distributor’s Limited Warranty, whichever is longer. This warranty is transferable to Oil Capacity: 0,58 Quart/0,55 Liter each subsequent purchaser for the duration of the warranty period. Oil Type (API SG–SL): SAE 30 (above 0°C/32°F) or SAE 10W-30 If any emission-related part on your engine is defective, the part will be repaired or replaced by Honda without charge for diagnosis, parts, or labor. All defective parts replaced under this warran- Spark Plug (Gap: 0,03"/0,76 mm) NGK BPR5ES ty become the property of Honda. A list of warranted parts is on the reverse side of this warranty statement. Normal maintenance items, such as spark plugs and filters, that are on the warranted Valve Clearance (± 0.04 mm): Intake: 0.015 mm; Exhaust: 0.020 mm parts list are warranted up to their required replacement interval only. Blade Bolt Torque: 35–40 ft. lbs. (47–54 Nm) Honda will also replace other engine components damaged by a failure of any warranted part during the warranty period. • The model and serial numbers will be found on a decal on the rear of the lawn mower housing. Record both serial number and date of purchase in space provided above. American Honda Motor Co., Inc. / Honda Canada Inc. 10/2009 00X51-ZG0-6110 PWL50975-M 28 5 Only Honda approved replacement parts may be used in the performance of any warranty repairs WARRANTY and must be provided without charge to the owner. The use of replacement parts not equivalent to the original parts may impair the effectiveness of your engine emission control system. If such GENERAL: Craftsman products are warranted to be free from defects in materials a replacement part is used in the repair or maintenance of your engine, and an authorized Honda or workmanship for a specific time period as set-out below (the “Warranty Period”). dealer determines it is defective or causes a failure of a warranted part, your claim for repair of Warranties extend to the original purchaser of a Craftsman product only. Purchases your engine may be denied. If the part in question is not related to the reason your engine requires made through an online auction or through any website other than www.sears.ca are repair, your claim will not be denied. excluded. The relevant Warranty Period commences on the original date of purchase. TO OBTAIN WARRANTY SERVICE: Within this period, Sears Canada, Inc. will, at its sole option, repair or replace any You must, at your own expense, take your Honda Power Equipment engine or the product on products or components which fail in normal use. Such repairs or replacement will be which it is installed, along with your sales registration card or other proof of original purchase date, made at no charge to the customer for parts or labor, provided that the customer shall be to any Honda Power Equipment dealer who is authorized by Honda to sell and service that Honda product during his normal business hours. Claims for repair or adjustment found to be caused responsible for any transportation cost. solely by defects in material or workmanship will not be denied because the engine was not prop- EXCLUSIONS: This warranty does not cover failures due to normal wear, abuse, misuse, erly maintained and used. neglect (including but not limited to the use of stale fuel, dirt, abrasives, moisture, rust, If you are unable to obtain emission warranty service or are dissatisfied with the warranty service corrosion, or any adverse reaction due to improper storage or use habits), improper you received, contact the owner of the dealership involved. Normally this should resolve your maintenance or failure to follow maintenance guidelines and/or instructions, failure to problem. However, if you require further assistance, contact the Honda office in your region: operate the product in accordance with the owner’s manual or any additional instructions American Honda Motor Co., Inc. Honda Canada Inc. or information provided at the time of purchase or in subsequent communications with Power Equipment Customer Relations Power Equipment Customer Relations 4900 Marconi Drive Visit www.honda.ca the original purchaser, accident or unauthorized alterations or repairs made or attempted or by others. Also excluded from warranty coverage – except as provided below - are Alpharetta, Georgia 30005-8847 for contact information. the following: maintenance, adjustments, components subject to wear including but Telephone: (888) 888-3139 Telephone: (888) 946-6329 Email: [email protected] not limited to: cosmetic components, belts, blades, blade adapters, bulbs, tires, filters, guide bars, lubricants, seats, grips, recoil assy’s, saw chains and bars, trimmer lines and EXCLUSIONS: spools, spark plugs, starter ropers and tines, and discoloration resulting from ultraviolet Failures other than those resulting from defects in material or workmanship are not covered by this light. Any product missing the model and/or serial number identification label will be warranty. This warranty does not extend to emission control systems or parts that are affected or dam- disqualified from coverage under this warranty. aged by owner abuse, neglect, improper maintenance, misuse, misfueling, improper storage, colli- sion, the incorporation of, or use of, unsuitable attachments, or the unauthorized alteration of any part. REPAIRS: Repairs have a 90 day warranty. If the defective product is still within the This warranty does not cover replacement of expendable maintenance items made in connec- Warranty Period, then the new warranty is 90 days from the date of repair or to the end of tion with required maintenance service after the item’s first scheduled replacement as listed in the the original Warranty Period, whichever period is longer. maintenance section of the product owner’s manual, such as: spark plugs and filters. DISCLAIMERS: THE WARRANTIES AND REMEDIES CONTAINED HEREIN ARE Disclaimer of Consequential Damage and Limitation of Implied Warranties: EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER ORAL OR American Honda Motor Co., Inc. and Honda Canada Inc. disclaim any responsibility for inciden- WRITTEN (OTHER THAN AS STATED HEREIN), AND WHETHER EXPRESS, IMPLIED tal or consequential damages such as loss of time or the use of the power equipment, or any commercial loss due to the failure of the equipment; and any implied warranties are limited to the OR STATUTORY, INCLUDING BUT NOT LIMITED TO ANY. THIS WARRANTY GIVES YOU duration of this written warranty. This warranty is applicable only where the California, U.S. EPA, or SPECIFIC LEGAL RIGHTS, WHICH MAY VARY FROM PROVINCE TO PROVINCE. Environment Canada emission control system warranty regulation is in effect. IN NO EVENT SHALL SEARS BE LIABLE FOR ANY INCIDENTAL, SPECIAL, INDIRECT EMISSION CONTROL SYSTEM WARRANTY PARTS: OR CONSEQUENTIAL DAMAGES, WHETHER RESULTING FROM THE USE, MISUSE SYSTEMS PARTS OR INABILITY TO USE THE PRODUCT OR FROM DEFECTS IN THE PRODUCT. THE COVERED: DESCRIPTION: EXCLUSIONS IN THIS PARAGRAPH SHALL NOT APPLY IN JURISDICATIONS WHERE Fuel Metering Carburetor Assembly (Includes Starting Enrichment System), Engine Temp- APPLICABLE LAW DOES NOT ALLOW FOR THE EXCLUSION OF INCIDENTAL OR erature Sensor, Engine Control Module, Fuel Regulator, Intake Manifold CONSEQUENTIAL DAMAGES. IN SUCH JURISDICTIONS, THIS PARAGRAPH SHALL NOT APPLY, BUT THE REMAINING PROVISIONS OF THIS DOCUMENT SHALL REMAIN Evaporative Fuel Tank, Fuel Cap, Fuel Hoses, Vapor Hoses, Carbon Canister, Canister VALID. Mounting Brackets, Fuel Strainer, Fuel Cock, Fuel Pump, Fuel Hose Joint, Canister Purge Hose Joint Sears retains the exclusive right to repair or replace the product or offer a full refund of Exhaust Catalyst, Exhaust Manifold the purchase price at its sole discretion. SUCH REMEDY SHALL BE YOUR SOLE AND EXCLUSIVE REMEDY FOR ANY BREACH OF WARRANTY. Air Induction Air Filter Housing, Air Filter Element* Ignition Flywheel Magneto, Ignition Pulse Generator, Crankshaft Position Sensor, Power CUSTOMER RESPONSIBILITIES: In additional to complying with all suggested Coil, Ignition Coil Assembly, Ignition Control Module, Spark Plug Cap, Spark Plug* maintenance guidelines and instructions, customers’ obligations shall include but shall Crankcase Emission Control Crankcase Breather Tube, Oil Filler Cap not be limited to: operating the product in accordance with the owner’s manual or any additional instructions or information provided at the time of purchase or in subsequent Misc. Items Tubing, Fittings, Seals, Gaskets & Clamps associated with these listed systems communications to the purchaser from time to time, exhibit reasonable care in the use, Note: This list applies to parts supplied by Honda and does not cover parts supplied by the operation, maintenance, general upkeep and storage of the product. Failure to comply equipment manufacturer. Please see the original equipment manufacturer’s emissions warranty for with these requirements will void any applicable warranty. non-Honda parts. * Covered up to the first required replacement only. See the Maintenance Schedule in the owner’s manual. American Honda Motor Co., Inc. / Honda Canada Inc. 10/2009 00X51-ZG0-6110 PWL50975-M 4 29 SERVICE NOTES • Mow only in daylight or good artificial light. • Never refuel the machine indoors. • Do not operate the machine while under • Never store the machine or fuel contain- the influence of alcohol or drugs. er where there is an open flame, spark • Never operate machine in wet grass. or pilot light such as a water heater or Always be sure of your footing: keep a on other appliances. firm hold on the handle; walk, never run. • Never fill containers inside a vehicle, on • Disengage the drive system, if so equipped, a truck or trailer bed with a plastic liner. before starting the engine (motor). Always place containers on the ground • If the equipment should start to vibrate away from your vehicle before filling. abnormally, stop the engine (motor) and • Remove gas-powered equipment from check immediately for the cause. Vibra- the truck or trailer and refuel it on the tion is generally a warning of trouble. ground. If this is not possible, then • Always wear eye protection when oper- refuel such equipment with a portable ating machine. container, rather than from a gasoline • Use extra care when approaching blind dispenser nozzle. corners, shrubs, trees, or other objects • Keep the nozzle in contact with the rim that may obscure vision. of the fuel tank or container opening at • When loading or unloading this ma- all times until fueling is complete. Do chine, do not exceed the maximum not use a nozzle lock-open device. recommended operation angle of 15°. • If fuel is spilled on clothing, change • Wear proper Personal Protective Equip- clothing immediately. ment (PPE) while operating this machine, • Never overfill fuel tank. Replace gas including (at a minimum) sturdy footwear, cap and tighten securely. eye protection, and hearing protection. Do not mow in shorts or open toed footwear. V. GENERAL SERVICE Always let someone know you are outside • Never run a machine inside a closed area. mowing. • Never make adjustments or repairs with the engine (motor) running. Discon nect III. SLOPE OPERATION the spark plug wire, and keep the wire Slopes are a major factor related to slip & away from the plug to prevent acci den- fall accidents, which can result in severe tal starting. injury. All slopes require extra caution. If • Keep all nuts and bolts tight to be sure the you feel uneasy on a slope, do not mow it. equipment is in safe working condition. DO: • Never tamper with safety devices. • Mow across the face of slopes: never Check their proper operation regu lar ly. up and down. Exercise extreme caution Never do anything to interfere with the when changing direction on slopes. intended function of a safety device or • Remove obstacles such as rocks, tree reduce the protection provided by a limbs, etc. safety device. • Watch for holes, ruts, bumps or hidden ob- • Keep machine free of grass, leaves, or jects. Uneven terrain could cause a slip and other debris build-up. Clean oil or fuel spill- fall accident. Tall grass can hide obstacles. age. Allow machine to cool before storing. DO NOT: • Stop and inspect the equipment if you • Do not mow near drop-offs, ditches or strike an object. Repair, if neces sary, embankments. You could lose your foot- before restarting. ing or balance. • Never attempt to make wheel height • Do not mow on wet grass or excessively adjustments while the engine is running. steep slopes. Poor footing could cause • Grass catcher components are subject a slip and fall accident. to wear, damage, and de teri o ra tion, which could expose moving parts or IV. SAFE HANDLING OF GASOLINE allow objects to be thrown. Frequently To avoid personal injury or property dam- check compo nents and replace with age, use extreme care in handling gaso- manu fac turer’s recommended parts, line. Gasoline is extremely flammable and when necessary. the vapors are explosive. • Mower blades are sharp and can cut. • Extinguish all cigarettes, cigars, pipes Wrap the blade(s) or wear gloves, and and other sources of ignition. use extra caution when servic ing them. • Use only an approved container. • Do not change the engine governor set- • Never remove gas cap or add fuel with ting or overspeed the engine. the engine running. • Maintain or replace safety and instruc- 30 • Allow engine to cool before refueling. 3 tion labels, as necessary. TABLE OF CONTENTS SERVICE NOTES Safety Rules ...... 2-3 Maintenance ...... 12-15 Warranty - Lawn Mower ...... 4-5 Service and Adjustments ...... 15-16 Product Speci fi cations ...... 5 Storage ...... 16-17 Assembly/Pre-Operation ...... 6-7 Troubleshooting ...... 18-19 Operation ...... 8-11 Repair Parts ...... 20-27 Maintenance Schedule ...... 12 Warranty - Honda Motor ...... 28-29 Sears Service ...... Back Cover SAFETY RULES IMPORTANT: This cutting machine is II. GENERAL OPERATION capable of amputating hands and feet and • Read, understand, and follow all throwing objects. Failure to observe the in structions on the machine and in the following safety instructions could result in manual(s) before starting. Be thorough ly serious injury or death. familiar with the controls and the proper Look for this symbol to point out impor- use of the machine before starting. tant safety precautions. It means • Do not put hands or feet near or under CAU TION!!! BECOME ALERT!!! rotating parts. Keep clear of the dis- YOUR SAFE TY IS INVOLVED. charge opening at all times. WARNING: In order to prevent acci- • Only allow responsible individuals, who den tal starting when setting up, transport- are familiar with the instruc tions, to ing, ad justing or making repairs, always operate the machine. dis connect spark plug wire and place wire • Clear the area of objects such as rocks, where it cannot come in contact with plug. toys, wire, bones, sticks, etc., which CAUTION: Muffler and other engine could be picked up and thrown by parts become extremely blade. Stay behind the handle when the hot during operation and engine (motor) is running. remain hot after engine • Be sure the area is clear of other people has stopped. To avoid before mowing. Stop ma chine if anyone severe burns on contact, enters the area. stay away from these areas. • Do not operate machine barefooted or while wearing sandals. Al ways wear I. CHILDREN substantial footwear with good ankle WARNING: CHILDREN CAN support while mowing. BE SERIOUSLY INJURED OR • Do not pull mower backwards unless KILLED BY THIS EQUIPMENT. absolutely neces sary. Always look down Carefully read and follow all of and behind before and while moving the safety instructions below. backwards. The American Academy of Pediatrics • Never direct discharged material toward recommends that children be a minimum anyone. Avoid discharging material of 12 year of age before operating a against a wall or obstruction. Material may pedestrian controlled lawn mower and a richochet back toward the operator. Stop minimum of 16 years of age before operat- blade when crossing gravel surfaces. ing a riding lawn mower. • Do not operate the mower without Tragic accidents can occur if the oper a tor is proper guards, plates, grass catcher or not alert to the presence of children. Children other safety protective devices in place. are often attracted to the machine and the • See manufacturer’s instructions for mowing activity. Never assume that children proper operation and installation of will remain where you last saw them. accessories. Only use accessories ap- • Keep children out of the mowing area proved by the manufacturer. and under the watchful care of a re- • Stop the blade(s) when crossing gravel spon si ble adult other than the operator. drives, walks, or roads. • Be alert and turn machine off if children • Never leave a running machine unattended. enter the area. • Stop the engine (motor) and wait until the • Before and while walking back wards, look blade comes to a complete stop before behind and down for small chil dren. cleaning the machine, removing the grass • Never allow children to operate the catcher, or unclogging the discharge machine. 2 chute. 31 Owner’s Manual

ROTARY LAWN MOWER 160cc Honda Engine

21" Multi-Cut

Model No. 944.364152

02489

CAUTION: Read and follow all Safety Rules and Instruc tions before operating this equipment

587785901 12.21.15 BY Printed in U.S.A. Sears Canada, Inc., Toronto, Ontario M5B 2B8