Lubrication

Always stop engine and disconnect spark plug wire before cleaning, lubricating or doing any kind of service work on the lawn mower.

Blade Control: Lubricate the pivot points on the blade control handle and the brake cable at least once a season with light oil. The blade control must operate freely in both directions. See Figure 12.

Rear & Side Discharge Doors: The torsion springs and pivot points should be lubricated periodically with light oil to prevent any rust or binding. Door must work freely.

Wheels: The wheels require no lubrication. However, if the wheels are removed for any reason, lubricate the surface of the axle bolt and the inner surface of the wheel with light oil. Engine oil may also be used.

Engine: Follow engine manual for instruction and schedule of lubrication.

Lubricate

Lubricate

Lubricate

Figure 12

Maintenance

NOTE: When tipping the unit or emptying the fuel tank keep the air cleaner side of engine up. Never tip the mower more than 90 degrees and do not leave the mower tipped for any length of time. Oil can drain into the upper part of the engine causing a starting problem.

Replacing Rear Flap

To remove rear flap, cut off the flat end of the wire rod which secures it to the deck. See Figure 13.

Attach the new flap and new rod to deck, bending the ends of the new rod over to secure to deck

Rear Discharge

Door

Handle

Bracket

 

od

 

R

 

e

r

i

 

W

 

Handle

Bracket

Rear Flap

Figure 13

Engine

Refer to the separate engine manual for all engine maintenance instructions.

Maintain engine oil as instructed in the separate engine manual packed with your unit.

Service air cleaner every 25 hours under normal conditions. Poor engine performance and flooding usually indicate that the air cleaner should be serviced. To service the air cleaner, refer to the separate engine manual packed with your unit.

The spark plug should be cleaned and the gap reset once a season. Spark plug replacement is recommended at the start of each mowing season.

Clean the engine regularly with a cloth or brush. Keep the cooling system (blower housing area) clean to permit proper air circulation which is essential to engine performance and life. Be certain to remove all grass, dirt, and combustible debris from muffler area.

Deck

The underside of the mower deck should be cleaned after each use to prevent a buildup of grass clippings, leaves, dirt, or other matter. If this debris is allowed to accumulate, it will invite rust and corrosion, and may prevent proper mulching, discharge, or bagging. The deck may be cleaned by tilting the mower and scraping clean with a suitable tool (make certain the spark plug wire is disconnected).

IMPORTANT: We do not recommend the use of a pressure washer or garden hose to clean your unit. The use of water will result in shorten life and reduce serviceability.

Cutting Blade Removal, Replacement, and Sharpening

When removing the cutting blade for sharpening or replacement, protect your hands with a pair of heavy gloves or use a heavy rag to hold the blade.

Remove the bolt and the blade bell support which hold the blade and the blade adapter to the engine crankshaft. See Figure 14.

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Bolens Series 540 manual Lubrication, Maintenance Replacing Rear Flap, Engine, Deck