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Lawn-Boy M Series User Manual

Lawn-Boy M Series
177 pages
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LAWN-BOY M-SERIES WPM SERVICE MANUAL
Table of Contents – Page 1 of 3
INDEX
GENERAL INFORMATION
INTRODUCTION
SAFETY SYMBOLS AND NOTES
2 CYCLE PRINCIPLES OF OPERATION
1ST CYCLE - DOWN STROKE
2ND CYCLE - UP STROKE
MOWER SPECIFICATIONS
ENGINE SPECIFICATIONS
MODEL NUMBER INDENTIFICATION
"M"-SERIES FEATURES
LUBRICATION (OIL)
GASOLINE
TORQUE REFERENCE
STORAGE PROCEDURE
REMOVING FROM STORAGE
CARBURETION
OPERATION
AIR FILTERS
CARBURETOR REMOVAL
CARBURETOR DISASSEMBLY
CARBURETOR ASSEMBLY
CARBURETOR INSTALLATION
FRESHLUBE OIL INJECTION
OPERATION
INSTALLATION
ADJUSTMENT
TESTING
CHECK VALVE TEST
GOVERNOR CONTROL AND LINKAGES
OPERATION
ADJUSTMENT
ELECTRICAL SYSTEM
IGNITION SYSTEM
SPARK PLUG
IGNITION TROUBLESHOOTING
INTERLOCK SYSTEM
INTERLOCK SYSTEM TROUBLESHOOTING
ELECTRIC START SYSTEM

Table of Contents

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Lawn-Boy M Series Specifications

General IconGeneral
Cutting Width21 inches
Engine2-cycle
FuelGasoline
Cutting Height1-3 inches
Fuel Tank Capacity0.5 gallons

Summary

GENERAL INFORMATION

CARBURETION

Carburetor Service Procedures

Covers carburetor operation, filters, removal, disassembly, assembly, and installation.

FRESHLUBE OIL INJECTION

ELECTRICAL SYSTEM

Ignition System and Troubleshooting

Details ignition system operation, spark plug, and troubleshooting.

Interlock System and Troubleshooting

Covers interlock system function and troubleshooting steps.

Electric Start System

Explains the electric start system components and testing.

STARTER SYSTEMS

Manual and Electric Starter Service

Covers manual and electric starter removal, disassembly, reassembly, installation, and adjustment.

POWER HEAD SERVICE

BLADE AND BLADE HOUSING

HANDLE AND CONTROL SYSTEMS

DRIVE SYSTEM

Drive Belt Replacement

Details the procedure for replacing the drive belt.

FLYWHEEL BRAKE SYSTEM

ENGINE TROUBLE SHOOTING

LUBRICATION (OIL)

GASOLINE

TORQUE REFERENCE

CARBURETOR REMOVAL

CARBURETOR DISASSEMBLY

CARBURETOR ASSEMBLY

CARBURETOR INSTALLATION

FRESHLUBE™ OIL INJECTION

System Operation and Service

Covers system operation, installation, adjustment, testing, and check valve.

OIL PUMP AND FILTER

GOVERNOR CONTROL and LINKAGES

IGNITION SYSTEM

SPARK PLUG

IGNITION TROUBLESHOOTING

IGNITION TROUBLESHOOTING (Blade Brake Clutch (BBC) Model - M21BMR)

IGNITION TROUBLESHOOTING (Electric Start Model - M21EMR)

THE INTERLOCK SYSTEM

Flywheel Brake Switch Test

INTERLOCK SYSTEM TROUBLESHOOTING (Zone Start Models)

INTERLOCK SYSTEM TROUBLESHOOTING (Blade Brake Clutch (BBC) Model)

Interlock System Troubleshooting (continued)

ELECTRIC START SYSTEM

Starter Relay Test

Covers starter relay resistance and continuity testing for proper function.

Starter Motor Test

WIRING DIAGRAM (Electric Start Model - M21EMR)

WIRING DIAGRAM (Zone Start Models - M21ZPR, M21ZMR)

WIRING DIAGRAM (Blade Brake Clutch (BBC) Model - M21BMR)

STARTER

Electric Starter Service

Details electric starter removal, disassembly, reassembly, installation, and adjustment.

MANUAL STARTER - TOP MOUNT

ELECTRIC STARTER

POWER HEAD

REMOVAL FROM DECK

STARTER

ALTERNATOR

CRANKCASE

GOVERNOR SEAL

CRANKSHAFT AND PISTON ASSEMBLY

Details lifting the crankshaft and piston assembly out of the cylinder.

WRIST PIN

CRANKCASE HALVES

Covers removing screws and separating the crankcase halves.

RETAINING RINGS

CRANKCASE SEALANT

Details applying adhesive sealant to the crankcase flange.

CYLINDER HEAD

GOVERNOR SPRING

AIR FILTER BASE AND CARBURETOR

Covers assembling the air filter base, carburetor, and related components.

STARTER ASSEMBLY

BRAKE ASSEMBLY

BLADE AND BLADE HOUSING

BLADE REMOVAL

Blade Brake Clutch (BBC) Models

BLADE SHARPENING

BLADE BALANCING

Explains how to check and achieve proper blade balance.

BLADE TRACKING

BLADE INSTALLATION

BLADE RELATED TROUBLESHOOTING

HANDLE AND CONTROL REPLACEMENT AND ADJUSTMENTS

Cable Replacement and Adjustment

Covers service for throttle, self-propelled, flywheel brake, gear select, and BBC cables.

THROTTLE CONTROL CABLE

Throttle Cable Adjustment

SELF-PROPELLED CABLE

Flywheel Brake Cable (Zone Start Models)

GEAR SELECT CABLE

Adjustment

HANDLE WIRE HARNESS

Covers removal of the handle wire harness from the mower.

BLADE BRAKE CLUTCH (BBC) CABLE

BBC CABLE

HANDLE WIRE HARNESS

HANDLE REPLACEMENT

Removal Procedures

Details steps for removing the handle assembly from the mower.

Self-Propelled Cable

Handle Wire Harness

Covers routing and installation of the handle wire harness.

HANDLE SHAFT ASSEMBLY REPLACEMENT

OPERATION

REMOVAL

Details removal of blade, clutch assembly, and related components.

Flywheel Brake System (Zone Start Models)

Details operation and safety precautions for the flywheel brake system.

DISASSEMBLY

Disassembly of Axle Shaft Assembly

Transmission Case Assembly

Reduction Shaft Assembly

DRIVE BELT REPLACEMENT

Blade Brake Clutch (BBC) Models

FLYWHEEL BRAKE CABLE ADJUSTMENT

BLADE BRAKE CLUTCH (BBC)

ENGINE TROUBLE SHOOTING

Engine Fails to Start or Starts with Difficulty

Lists causes and remedies for engine starting problems.

ENGINE TROUBLESHOOTING CHART (CON'T)

Common Engine Starting and Running Issues

Covers hot starting, knocking, missing, and power loss issues.

Troubleshooting Engine Performance Issues

Addresses lack of power, surges, vibration, RPM, and smoking problems.

TOOLS and SERVICE AIDS

Service Tools

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