Troy-Bilt 664D-Pony, E666M-Pony Assembly, Introduction, Inspect Unit, Hardware BAG Parts List

6

Section

2

Assembly

WARNING

To prevent personal injury or property damage, do not start the engine until all assembly steps are complete and you

HARDWARE BAG PARTS LIST

Fig.
Ref. Qty.	Description

1 2 3/8-16 x 1" Hex Hd. Screw

1 2 3 4

56

have read and understand the safety and

2 1 Keyed Washer

7

89

operating instructions in this Manual.

3	1	Wheel Gear Lever Knob
4	1	Height Adjustment Flange

11

10

INTRODUCTION

Carefully follow these assembly steps to correctly prepare your tiller for use. It is recommended that you read this Section in its entirety before beginning assembly.

INSPECT UNIT

Inspect the unit and carton for damage immediately after delivery. Contact the carrier (trucking company) if you find or suspect damage. Inform them of the damage and request instructions for filing a claim. To protect your rights, put your claim in writing and mail a copy to the carrier within 15 days after the unit has been delivered. Contact us at the factory if you need assistance in this matter.

UNPACKING AND ASSEMBLY INSTRUCTIONS

STEP 1: UNPACKING INSTRUCTIONS

1.Remove any cardboard inserts and packaging material from the carton. Remove any staples from the bottom of the carton and remove the carton.

2.Cut the large, plastic tie strap that secures the transmission tube to the ship- ping pallet. Leave the handlebars on top of the tiller to avoid damaging any cables.

3. A bag with loose hardware is inside the literature envelope. Check the con- tents against the following list and Figure 2-1. Contact your local dealer or the factory if any items are missing or damaged.

NOTE: For electric start units, a second hardware bag is located near the battery.

4. The tiller is heavy. You should not attempt to remove it from the shipping platform until instructed to do so in these “Assembly” steps.

		Screw (See Figure 2-1A)
5	2	3/8" Flat Washer
6	2	#10 Lockwasher
7	2	3/8"-16 Nylock Lock Nut
8	2	#10-32 x 1/2" Round Hd.
		Screw
9	2	#10-32 Nut
10	1	Cotter Pin (not used)
11	4	Plastic Tie Strap (2 not used)

Tools/Materials Needed for Assembly

(1) 3/8" open-end wrench*

(1)7/16" open-end wrench* (electric start unit only)

(2)9/16" open-end wrench*

(1)7/8" open-end wrench or 8" long adjustable wrench

(1) Scissors (to trim plastic ties)

(1) Ruler

(1)Small board (to tap plastic knob on lever)

(1) Tire pressure gauge

(1) Clean oil funnel

(1)Clean, high-quality motor oil. Refer to the separate Engine Owner’s Manual for motor oil specifications and quantity required.

*Adjustable wrenches may be used.

IMPORTANT: Motor oil must be added to the engine crankcase before the engine is started. Follow the instructions in this “Assembly” Section and in the separate Engine Owner’s Manual.

NOTE: LEFT and RIGHT sides of the tiller are as viewed from the operator’s posi- tion behind the handlebars.

STEP 2: ATTACH HANDLEBARS

1.On electric start units, remove one screw and lockwasher from the curved

Figure 2-1: Loose hardware (shown in reduced size).

Flange

Figure 2-1A Handlebar height adjustment uses the flange head screw.

A

Figure 2-2: On electric start units, move height adjustment bracket aside.

height adjustment bracket (A, Figure 2-2), loosen the second screw, and swing the bracket to one side.

2.Cut the large, plastic cable ties that secure the handlebar ends to the handle- bar mounting tabs on the transmission top cover.

3.Gently lift handlebar (do not over- stretch attached cable) and place handle- bar cross-brace (B, Figure 2-3) in front of curved height adjustment bracket (C).

M	C	E
		F
B

Figure 2-3: Forward clutch control cable not shown for clarity.