SECTION2: ASSEMBLY
WARNING: Toprevent
personalinjury or property
damage,do notstart theengine
untilall assembly steps are
completeandyou have read
andunderstandthe safety and
operatinginstructions inthis
manual.

INTRODUCTION

Carefullyfollow theseassembly steps to
correctly prepareyour tiller for use. It is
recommendedthat you read this Section
in its entirety beforebeginning assembly.
NOTE: Various tiller models are

ASSEMBLYSTEPS

STEP1: UNPACKING INSTRUCTIONS
NOTE:While unpacking, do not severely
bendany control cables.
1.Thetiller weighsapproximately133 lbs.
Donot attempt to remove it from the ship-
ping platform untilinstructed to do so m
theseAssembly steps.
2. Removeanypackaging material from
thecarton. Removeanystaples from the
bottom ofthe carton andremove the car-
tonfrom the shipping platform.
3. Removeall unassembled partsand the
separatehardwarebag from the carton.
presented in this Manual Use only the Checkthat you havethe items listedin the
information appropriate for your tiller LooseParts List (contactyour local dealer
model Enginestyles varyby model Your orthe factory itemsare missing or dam-
engine may appear differently than those aged).
illustratedin thismanual.

INSPECTUNIT

Inspectthe unit and carton for damage Lm-
mediatelyafter delivery. Contactthe cam-
er(trucking company) if you find or
suspectdamage. Inform them of the dam- 1
ageand request instructions for filing a 1
claim. Toprotect your rights, put your
claim inwriting and ma_la copyto the car- 1
rier within 15 days after the unit has been 1
delive'ed.Contact Troy-Bilt LLCil you 6
needassistancein this matter. 2
2

TOOLSMATERIALSNEEDED

NOTE: Use the screw length template
(Fig.2-1) toidentify screws

LoosePartsList

Qty. Description
HandlebarSupport (seeA, Fig.2-2_
HandlebarAssembly(seeK,Fig.2-2)
Hardwarebag contents:
Slottedhd. screw #10-24 x 2'
Hexhd. screw 1/4-20 x1-1 '4
Hexhd. screw 5/16-18 x 1-1 2"
Hexhd. screw. 3/8-16 x 3/4
FlatWasher.3/8
6SplitIockwashe_ 5/16"
m
Figure2-1:Toidentifylengthofscrews,place
screwontemplateasshownandmeasuredis-
tancebetweenbottomofscrewheadandtipof
scrBw,
STEP2: ATTACH HANDLEBAR
1.Loosely attachthe legs of the handlebar
support (A, Fig.2-2) to the innersides of
thetiller frame using two 3/8"-16 x 3/4"hex
hd.screws (B), 3/8"flat washers(C), 3/8"
lockwashers (GG_,and 3/8"-16 hex lock-
nuts (D_,
2.There arethree heightadjustment holes
inthe two handlebarsupport brackets (.E
andE Fig. 2-2). Useasetting that will po-
sitionthe handlebarsat approximately
waistlevel when the tines are 3"-4" intothe
so_l. Looselyattach the support brackets
tothe handlebar support (.A_usingtwo
1 Hex Iocknut. 1/4"-20 5Pi6"-18x 1-1/2" screws (G).5/16" split
Ill 3,8"open-endwrench* 6 Hex nut.5/16"-18 Iockwashers(.H)and5/16"-18 hexnuts (I).
(.2) 7/16'open-end wrench" 1 Hex nut #10-24 NOTE: Ifa support bracketwill not move
12_ 1/2" open-end wrench* 2 HexIocknut.3,8"-16 loosen attaching screw (J)and nut.
(2) 94 6" open-end wrench* 1 Spring, cable(see W, Fig.2-5_ 3.Attach the handlebarassembly (.K_to
1 Bracket. forward clutch cable thehandlebar support (A) using four 5.
(1) Large ad Jstable wrench (.seeP,Fig.2-4_ 16"-18x 1-1/2" screws (.G_,5/16"split
_Models634F/634Bonly} 2 Lockwasher 3/8
(.1J Scissors to trim plasticties/
(1) Ruler (for belt tension check_
111 Block of wood (to support tiller when
remowngwheels)
111 Tire pressure gauge(for modelswith
pneumatictires_
Ill Cleanoilfunnel
111 Motor oil Referto the Engine0wner's
Manualfor oil specificationsand
quantityrequired.
* Adjustablewrenches may De used,
2
1 *Bracket reverseclutch cable
*Model 634F& 634B only
IMPORTANT:Motor oil must be addedto
theengine crankcase beforethe engine is
started. Followthe instructions inthis
Sectionand in theseparate Engine
Owner'sManual.
*Self-tappingscrew.1/4-20 x 1/2" IockwashersIHI and5/16"-18 hexnuts (I).
Tightenthe four screwssecurely
4.Tighten all handlebar mounting hard-
waresecurely.
STEP3: MOVE TILLER OFF
Toroll the tiller off the shipping platform.
putthe wheels in freewhee asfollows:
1. Placea sturdy block underthe transmis-
NOTE: LEFTandRIGHTsidesofthetiller sionto raise one wheelabout l" off the
areas viewed from the operator'sposition ground.
behindthe handlebars.