Troy-Bilt 5210R manual Attach the Deflector Chute Assembly, Attach Cables to Control Levers

Step 3: Attach the Deflector Chute Assembly.

1.Use a 3/8-inch wrench and a 5/16-inch wrench to remove two of the three sets of shims and clips (Figure

2-3, Items D & E) from the lower, rear part of the deflector chute assembly. Don'tremove the shim and clip that is in front of the chute opening.

2.Apply multipurpose automotive grease all around the surface of the deflector chute flange (Figure 2-3, Item F).

3.Place the deflector chute onto the flange as shown in Figure 2-3.

4.Reinstall the two sets of shims and clips you previously removed. Make sure that the shims (Figure 2-3, Item D) are above the deflector chute flange (Figure 2-3, Item F).

5.Connect the chute crank (Figure 2-1, Item G) to the plastic universal joint (Figure 2-1, Item H) by using the hammer and block of wood to gently tap the roll pin into the universal joint and chute crank.

6.Move the discharge chute deflector cap (Fig. 2-3) upward.

7.Rotate the chute control crank at the handlebar console to make sure that the deflector chute turns without binding. If the deflector chute binds, readjust bracket (Figure 2-1, Item J) as follows:

A.Loosen screw (Figure 2-1, Item K).

B.Adjust bracket (Figure 2-1, Item J) by moving it inward or outward as necessary.

C.Retighten screw (Figure 2-1, Item K).

D.Repeat Step 7.

Step 4: Attach Cables to Control Levers.

1.Place one of the hex screws (Figure 2-1, Item L) through the hole in the right-hand handlebar lever. Hold the screw in place and put a spacer (Figure 2-1, Item M) over the threaded end of the hex screw. Run the auger drive cable from the right- hand side of the snowthrower, upward beneath the handlebar control panel, and place the upper end of the cable over the spacer.

2.Place a flat washer and nut onto the threaded end of the hex screw. Use a 5/16-inch and a 3/8-inch wrench to securely tighten the nut and hex screw.

3.Repeat Steps 4-1 and 4-2 for the left-hand handle- bar lever and wheel drive cable.

EASY ASSEMBLY

4.Attach the cable brackets to the lower inner side of the handlebar tubes as follows:

A.Remove a 114-20x 3/4 screw from the inside bottom of the handlebar and insert it into one of the cable brackets (Figure 2-2, Item AA).

B.Place the legs of the bracket and screw on the lower inside of the handlebar tube. See Figure

2-2. Use a 3/8-inch wrench to securely tighten the screw. Make sure that the bracket is positioned as shown in Figure 2-2 - with the horizontal leg of the bracket above the screw head.

C.Repeat Steps 4-A and 4-B for the remaining bracket and screw.

5.Secure the adjustment section (Figure 2-2, Item N) of the cable to the cable bracket as follows:

A.Pull downward on the cable and insert the adjustment section of the cable into the slot in the cable bracket. The horizontal leg of the cable bracket should fit between the two nuts that are on the threaded portion of the cable'sadjustment section.

B.Loosely tighten the adjustment section'stwo nuts to prevent the cable from pulling free of the adjustment section. You'lltighten these nuts later, after you'vechecked the cable tension.

C.Repeat Steps 5-A and 5-B for the remaining cable bracket and cable.

6.Check the tautness of the cables. The cables should just barely be taut when the handlebar levers are not engaged. If the cables have to be adjusted, proceed as follows.

A.Unscrew the upper nut on the adjustment sec- tion several turns.

B.If the cable tension is too loose, screw the lower adjustment section nut counterclockwise (as viewed from above) until the cable is taut.

If the cable is too taut, screw the lower adjust- ment section nut clockwise (as viewed from above) until the cable is just taut.

C.Use a 112-inch open-end wrench to hold the lower nut in place. Screw the upper nut clockwise until it touches the cable bracket. Use another

112-inch open end wrench to securely tighten the adjustment section'supper nut tight against the cable bracket.

D.Again check the tension of the cable to make sure that the tightening procedure did not upset the cable'sadjustment.

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