Introduction, Inspect unit, Attach Handlebars

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.

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

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.Remove the handlebars from the carton. To avoid damaging parts, do not uncoil any cables until instructed to do so.

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. The parts in that bag are described later in this Section.

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

Hardware Bag Parts List

Fig.
Ref. Qty.	Description

11 Height Adjustment Handle

21 Keyed Washer

33 Hairpin Cotter (one spare)

42 3/8-16 x 1" Hex Hd. Screw

52 3/8" Flat Washer

62 3/8"-16 Nylock Lock Nut

71 Throttle Lever Knob

81 Wheel Gear Lever Knob

94 #10-32 x 1/2" Round Hd. Screw

104 #10 Lockwasher

114 #10-32 Nut

124 Plastic Tie Strap

131 Cotter Pin (not used on unit)

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 knobs on levers)

(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.

7 8

510

613

Figure 2-1: Loose hardware (see parts list).

STEP 2: Attach Handlebars

1.On electric start units, remove one screw and lockwasher from the curved height adjustment bracket (A, Figure 2-2), loosen the second screw, and swing the bracket to one side.

2.Place the handlebar cross-brace (B, Figure 2-3) in front of the curved height adjustment bracket (C) and position the handlebar ends on the outside of the two mounting tabs on the transmission cover.

3.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 Nylock lock nuts (see D, Figure 2-3).

4.On electric start units, reattach the height adjustment bracket (A, Figure 2-2). Tighten both screws securely.

5.Move the handlebars up or down to align the hole in the cross-brace with one of the four slots in the curved height adjustment bracket. Place the keyed washer (E, Figure 2-4) on the height adjustment handle (F) with the raised keys (edges) on the washer facing down.