Assembly, Introduction, Inspect unit | Troy-Bilt 675B-Pony instruction

SECTION 2: ASSEMBLY

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.

Inspect unit

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

Unpacking and Assembly Instrutions

STEP1: UNPACKING INSTRUCTIONS

1.Remove any card-board inserts and packaging material from the carton. Re- move any staples from the bottom of the carton and remove the carton.

2.Cut the large, plastic tie strap that se- cures the transmission tube to the shipping 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 contents 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 at- tempt to remove it from the shipping plat- form until instructed to do so in these “Assembly” steps.

Hardware Bag Parts List

Ref. Qty. Description

12 3/8-16 x 1" Hex Hd. Screw

21 Keyed Washer

31 Wheel Gear Lever Knob

41 Height Adjustment Flange

(See Figure 2-2)

52 3/8" Flat Washer

62 #10 Lockwasher

72 3⁄8"-16 Nylock Lock Nut

82 #10-32 x 1/2" Rnd Hd Screw

92 #10-32 Nut

101 Cotter Pin (not used)

114 Plastic Tie Strap (2 not used)

Tools / Materials Needed

for Assembly

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

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

(1) 7/8" open-end 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 quan- tity 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 position behind the handlebars.

STEP 2: ATTACH HANDLEBARS

1.Cut the large, plastic cable ties that se- cure the handlebar ends to the handlebar mounting tabs on the transmission top cover.

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

1 2 3

9 4

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

Flange

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

M	C	E
		E
		F
B

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

3.With the forward clutch cable (N, Fig- ure 2-4) on the inside of handlebar, posi- tion the handlebar ends on the outside of the two mounting tabs (M, Figure 2-3) on the transmission top cover.

NOTE: The curved handlebar height ad- justment bracket appears as shown in C, Figure 2-3 for non-electric start units. For electric start units, the bracket is loosened and moved to one side.

4.Loosely attach the handlebars to the mounting tabs with two 3/8-16 x 1" screws (heads of screws go to inside of tabs), 3/8" flat washers and 3/8"-16 lock nuts (O, Fig- ure 2-4).