Troy-Bilt 664D-Pony, E666M-Pony

Section 2: Assembly 7

4. With the forward clutch cable (N,

Figure 2-4) on the inside of handlebar,

position 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

adjustment bracket appears as shown in

C, Figure 2-3 for non-electric start units.

For electric start units, the bracket is loos-

ened and moved to one side.

5. 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, Figure 2-4).

6. On electric start units, reattach the

height adjustment bracket (A, Figure 2-2).

Tighten both screws securely. Make sure

the handlebar cross-brace (B, Figure 2-3)

is under the bracket.

7. Move the handlebars up or down to

align the threaded hole in the cross-brace

with one of the four slots in the curved

height adjustment bracket. Place the

keyed washer (E, Figure 2-3) on the

flange head height adjustment screw (F)

with the raised keys (edges) of the

washer facing down.

8. Thread the height adjustment screw

(F, Figure 2-3) into the hole in the handle-

bar cross-brace, making sure that the

raised keys on the washer fit into the slot

on the height adjustment bracket.

Tighten the height adjustment screw

securely. Next, securely tighten the two

screws and nuts in the ends of the han-

dlebar (M, Figure 2-3).

9. To remove the tiller from its shipping

platform, first carefully unwrap the wheel

gear cable (with attached lever - see

Figure 2-5) from around the chassis.

Move the Wheel Gear Lever (G) to the

DISENGAGE position--this allows the

wheels to rotate freely. Use the handle-

bars to roll the tiller off the platform.

NOTE: The Wheel Gear Lever will be

installed later in this procedure.

IMPORTANT: Use the DISENGAGE posi-

tion only when the engine is not running.

Before starting the engine, the Wheel Gear

Lever must be placed in the ENGAGE

position (see Section 3 for details).

STEP 3: ATTACH REVERSE

CLUTCH CONTROL CABLE

1. Carefully unwrap the reverse clutch

control cable (H, Figure 2-6) from its

shipping position and route it up along

the inside edge of the left side handlebar.

A knob and large hex nut (I) is installed

on the cable.

2. Insert the cable into the slot in the

control panel and fit the threaded assem-

bly into the hole in the slot (see Figure 2-

6). Be sure that the flat side of the

threaded assembly is aligned with the flat

side of the hole. Slide the hex nut (I) up

the cable and tighten it securely.

3. Test the function of the reverse clutch

control cable by pulling the knob out and

releasing it. The knob should return to its

neutral position against the tapered

bushing. If it doesn’t, contact your local

dealer or the factory for technical

assistance.

STEP 4: ATTACH FORWARD

CLUTCH CONTROL CABLE

1. Remove any fasteners (rubber bands,

tape, etc.) that may secure the Forward

Clutch Control levers (J, Figure 2-7) to the

handlebar.

2. The forward clutch control cable (with

attached spring) is hanging loosely near

the right-side wheel. Being careful not to

kink or stretch the cable, insert the z-con-

nector (L, Figure 2-8 – end of the spring)

into the hole at the end of the forward

clutch control linkage (K, Figure 2-7).

3. Attach the cable adjuster (A, Figure

2-9) to the bracket on the right-side han-

dlebar. Use two 1/2" wrenches to loosen

the two jam nuts (B) just enough to slide

the cable adjuster onto the bracket. Then

hand tighten the jam nuts.

Figure 2-6: Attach reverse clutch control

assembly to slotted hole in handlebar panel.

Figure 2-4: Attach handlebars.

Figure 2-5: Carefully unwrap Wheel Gear

Lever and move lever to DISENGAGE.

N

P

O

➥

Left Side

Handlebar Reverse Clutch

Control Knob

Slot in

Control

Panel

Figure 2-7: Forward Clutch Control levers

(J). Forward clutch control linkage (K).

Figure 2-8

Figure 2-9