Replacing the Reverse Disc

Troy-Bilt 683-Horse Replacing the Reverse Disc, Checking and Adjusting Reverse the Drive System

Section 5: Maintenance

WARNING Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to come

to a complete stop, disconnect spark plug wire and move wire away from spark plug. Remove ignition key, if so equipped.

Failure to follow these instructions can result in serious personal injury or property damage.

Follow these steps to replace the reverse disc. (If your tiller has a Bumper Attach- ment mounted, it must be removed first.)

Removing the Reverse Disc

1.Move Wheels/Tines/PTO Drive Lever in NEUTRAL position.

2.Wedge a 5/16"-thick board between top of engine pulley (avoid contacting reverse disc) and cast iron housing next to it.

This immobilizes pulley.

3.Use a 9/16" wrench to loosen the mounting bolt shown in Figure 5-23. Remember to immobilize the pulley with the wood wedge while loosening the bolt. If necessary, pry the disc from the pulley with the tip of a screwdriver. Back the bolt out as far as possible. Then angle the disc a little to remove it. Bring the bolt and lockwasher along with the disc.

Figure 5-23: Removing Reverse Disc.

Installing a New Reverse Disc

1.Do steps 1-through-3, described previ- ously, in reverse.

2.Tighten mounting bolt securely,

and check for correct operation — see Checking and Adjusting Reverse Drive System.

Checking and Adjusting

Reverse the Drive System

When the Wheels/Tines/PTO Drive Lever is moved up into REVERSE, the engine

and engine mount move down to press on the reverse adjustment bolt (Figure 5- 24). This action compresses the reverse spring and plunger assembly, requiring you to hold the lever up in REVERSE. When you release the lever, the spring automatically pushes the lever back into NEUTRAL position.

The spring and plunger assembly is designed to prevent the reverse disc from making contact with the transmis- sion pulley until you shift into REVERSE. When the lever is in NEUTRAL, the switch body on the bottom of the engine mount tab should be resting squarely on top of the reverse adjustment bolt (Figure 5-

24). The reverse adjustment bolt can be adjusted up or down to correct a number of reverse drive operating problems, as explained next.

Switch Body

Adjustment

Bolt

Spring &

Plunger

Figure 5-24: Spring and plunger assembly.

Checking and Adjusting Reverse Disc

1.Verify that linkages for Wheels/Tines/ PTO Drive Lever are lubricated with oil and engine mount bars and belt adjust- ment block are lubricated with grease. (See Tiller Lubrication in this section.)

2.Place Wheels/Tines/PTO Drive Lever in NEUTRAL. Briefly pull out engine recoil start rope while watching reverse disc. The disc should turn, but lower pulley should not (Figure 5-25). If reverse disc turns lower pulley, or if it is located closer than 3/16" to the pulley, reverse adjust- ment bolt should be adjusted upward (see

instructions that follow). Moving adjust- ment bolt upward will also solve problem of a tiller that goes into REVERSE on its own.

Reverse

Disc

Figure 5-25: Checking Reverse Disc in NEUTRAL.

3.Use your left hand to hold Wheels/ Tines/PTO Drive Lever up in REVERSE, while briefly pulling out engine start rope. The reverse disc should turn lower pulley (see Figure 5-26). If not, or it requires a lot of pressure to hold lever up in REVERSE, then reverse adjustment bolt must be adjusted downward. When correctly adjusted, the Wheels/Tines/PTO Drive Lever should pop out of reverse when the lever is released, but not require exceptional effort to hold it up in reverse position.

Both Pulleys

Should Turn

Figure 5-26: Checking Reverse Disc in REVERSE.

4.Shift the Wheels/Tines/PTO Drive Lever to REVERSE and then let it go. The lever should return to NEUTRAL. If not, the reverse adjustment bolt will have to be adjusted upward.