Troy-Bilt 682J, E686N, E682L Introduction, Inspect Unit, Attach Handlebar, Unpacking Instructions

Section

2Assembly

WARNING

To prevent personal injury or property damage, do not start the engine until all assembly steps are complete and you have read and understand the safety and operating instructions in this manual.

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.

NOTE: Three different Horse model tillers are covered in this Manual. Use only the information applicable to your model.

Tiller engines vary by model. Your engine may appear differently than those found in illustrations of this manual.

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.

STEP 1: Unpacking Instructions

NOTE: Do not severely bend any of the control cables on the unit.

1. The tiller is heavy. Do not attempt to remove it from the shipping platform until instructed to do so in these Assembly steps.

2.Remove all unassembled parts from the carton. The hardware bag is included in your literature packaging.

3.Check that you have the items listed below (contact your local dealer or the

Factory if any items are missing or damaged).

NOTE: Use the screw length template (Figure 2-1) to identify screws.

Loose Parts List

Qty. Description

1Handlebar Assembly

1Wheels/Tines PTO Drive Lever

The following items are in the hardware bag:

126 oz. Bottle SAE 30W Oil

1Clutch Pawl Spring

1Belt Adjusting Tool

2Plastic Cable Ties

1Curved Head Screw, 1/4-20 x 2

1Flanged Lock Nut, 1/4-20

1Pan Head Screw, #10-32 x 1/2

The following parts (electric start models only), packaged separately.

2Nuts, 1/4-20

(for battery terminals)

2Screws, 1/4-20 x 5/8 (for battery terminals)

2Keys

(in ignition switch)

NOTE: LEFT and RIGHT sides of the tiller are as viewed from the operator’s position behind the han- dlebars (unless otherwise noted).

Tools/Materials Needed for Assembly

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

(2)7/16" open-end wrench*

(2) 1/2" open-end wrench*

(1) 9/16" open-end wrench*

(1) 3/4" open-end wrench*

(1) Flat blade screwdriver

(1) Scissors (to trim plastic ties)

(1) Tire pressure gauge

(1)4-1/2" high wood block to prop unit * Adjustable wrenches may be used.

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Figure 2-1: To identify length of screw, place screw on template as shown and measure distance between bottom of screw head and tip of screw.

STEP 2: Attach Handlebar

IMPORTANT: When disassembling handlebar assembly, keep left-side clamp and ratchet separated from the right-side clamp and ratchet.

1.Disassemble the handlebar assembly. To do this, remove the height adjustment lever by turning the lever in a counter- clockwise direction (Figure 2-2).

2.Place the handlebar ends on either side of the base, with the wire harness toward the rear of the base (Figure 2-2).

3.Install the height adjustment lever through the right-side clamp, handlebar end, ratchet, and base; then out through the left-side ratchet, handlebar end, and clamp (Figure 2-2). Secure with nut, but don't fully tighten.

IMPORTANT: Do not force the height adjustment lever through the handlebars. The interlock wires may be blocking the

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