Manual

SECTION2: ASSEMBLY
WARNING: To prevent
personal injury or property
damage,do not start the engine
until all assemblysteps are
complete andyou have read
and understandthe safety and
operating instructions in this
manual.
INTRODUCTION
Carefullyfollow these assemblysteps to
correctly prepareyour tiller for use. It is
recommended that you readthis Section
in its entirety before beginning assembly.
NOTE: Various tiller models are
ASSEMBLYSTEPS
STEP 1: UNPACKINGINSTRUCTIONS
NOTE: While unpacking, do not severely
bendany control cables.
1. Thetiller weighs approximately133 lbs.
Do not attempt to remove it from the ship-
ping platform until instructed to do so m
these Assembly steps.
2. Removeanypackaging materialfrom
the carton. Removeany staples from the
bottom of the carton and removethe car-
ton from the shipping platform.
3. Removeall unassembledpartsand the
separatehardware bagfrom the carton.
presented in this Manual Use only the Checkthat you havethe items listed in the
information appropriate for your tiller LooseParts List (contactyour localdealer
model Engine styles vary by model Your or the factory items are missing or dam-
engine may appear differently than those aged).
illustrated in this manual.
INSPECTUNIT
Inspectthe unit and carton for damage Lm-
mediately after delivery. Contactthe cam-
er (trucking company) if you find or
suspectdamage. Inform them of the dam-
1
ageand request instructions for filing a 1
claim. To protect your rights, put your
claim inwriting and ma_la copyto the car- 1
rier within 15 days after the unit has been 1
delive'ed. Contact Troy-Bilt LLC il you 6
needassistance in this matter. 2
2
TOOLSMATERIALSNEEDED
NOTE: Use the screw length template
(Fig.2-1) to identify screws
LoosePartsList
Qty. Description
HandlebarSupport (seeA, Fig. 2-2_
HandlebarAssembly(see K, Fig.2-2)
Hardwarebag contents:
Slotted hd. screw #10-24 x 2'
Hex hd. screw 1/4-20 x 1-1 '4
Hex hd. screw 5/16-18 x 1-1 2"
Hex hd. screw. 3/8-16 x 3/4
FlatWasher.3/8
6 Split Iockwashe_5/16"
m
Figure2-1: Toidentifylengthofscrews,place
screwontemplateasshownandmeasuredis-
tancebetweenbottomofscrewheadandtipof
scrBw,
STEP 2: ATTACH HANDLEBAR
1. Looselyattach the legs of the handlebar
support (A, Fig.2-2) to the inner sides of
the tiller frame using two 3/8"-16 x 3/4"hex
hd. screws (B), 3/8" flat washers(C), 3/8"
lock washers (GG_,and 3/8"-16 hex lock-
nuts (D_,
2. Therearethree height adjustment holes
in the two handlebarsupport brackets (.E
and E Fig. 2-2). Usea setting that will po-
sition the handlebarsat approximately
waist levelwhen the tines are3"-4" into the
so_l. Looselyattach the support brackets
to the handlebarsupport (.A_using two
1 Hex Iocknut. 1/4"-20 5Pi6"-18x 1-1/2" screws (G). 5/16" split
Ill 3,8" open-endwrench* 6 Hex nut. 5/16"-18 Iockwashers(.H)and5/16"-18 hexnuts (I).
(.2) 7/16' open-end wrench" 1 Hex nut #10-24 NOTE: If a support bracket will not move
12_ 1/2" open-end wrench* 2 Hex Iocknut. 3,8"-16 loosen attaching screw (J) and nut.
(2) 946" open-end wrench* 1 Spring, cable(seeW, Fig.2-5_ 3. Attach the handlebarassembly (.K_to
1 Bracket.forward clutchcable the handlebarsupport (A) using four 5.
(1) Largead Jstable wrench (.seeP, Fig.2-4_ 16"-18 x 1-1/2" screws (.G_,5/16" split
_Models634F/634Bonly} 2 Lockwasher 3/8
(.1J Scissors to trim plastic ties/
(1) Ruler (for belt tension check_
111 Block of wood (to support tiller when
remowng wheels)
111 Tire pressure gauge(for modelswith
pneumatic tires_
Ill Cleanoil funnel
111 Motor oil Referto the Engine0wner's
Manualfor oil specificationsand
quantityrequired.
* Adjustablewrenches may Deused,
2
1 *Bracket reverseclutch cable
*Model 634F & 634B only
IMPORTANT: Motor oil must beaddedto
the enginecrankcase beforethe engine is
started. Followthe instructions inthis
Sectionand in the separateEngine
Owner'sManual.
*Self-tappingscrew. 1/4-20 x 1/2" IockwashersIHI and5/16"-18 hexnuts (I).
Tightenthe four screws securely
4. Tighten all handlebar mounting hard-
ware securely.
STEP3: MOVE TILLER OFF
To roll the tiller off the shipping platform.
put the wheels in freewhee as follows:
1. Placea sturdy block underthe transmis-
NOTE: LEFTandRIGHTsidesofthetiller sion to raise one wheelabout l" off the
are as viewedfrom the operator's position ground.
behind the handlebars.