Troy-Bilt 664DM Introduction, Inspectunit, Unpackingandassembly Instructions, 92 #10-32 Nut, 60 o

2Assembly

To prevent personal injury or property damage, do not start the engine until all assembly steps are complete and you have read and understandthe safety and operatinginstructionsin this Manual.

INTRODUCTION

Carefully follow these assembly steps to correctly prepareyour tiller for use. It is recommendedthat you readthis Section in its entirety before beginningassembly.

INSPECTUNIT

Inspectthe unit andcarton for damage immediatelyafter delivery. Contactthe 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 beendelivered. Contact us at the factory if you needassistance in this matter.

UNPACKINGANDASSEMBLY

INSTRUCTIONS

STEP 1: UNPACKING INSTRUCTIONS

1.Removeany cardboard inserts and packagingmaterialfrom the carton. Removeany staples from the bottom of the carton and removethe carton.

2.Cutthe large, plastic tie strap that securesthe transmission tube to the ship- ping pallet. Leavethe handlebarson top of the tiller to avoid damagingany cables.

3.A bag with loose hardware is inside the literature envelope. Checkthe con- tents against the following list and Figure 2-1. Contactyour local dealeror the factory if any items are missing or damaged.

NOTE: For electric start units, a second hardware bag is located nearthe battery.

4.The tiller is heavy. 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

12 3/8-16 x 1" HexHd. Screw

21 KeyedWasher

31 Wheel GearLever Knob

41 Height Adjustment Flange

Screw (SeeFigure 2-1A)

52 3/8" FlatWasher

62 #10 Lockwasher

72 3/8"-16 Nylock Lock Nut

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

92 #10-32 Nut

101 Cotter Pin (not used)

114 PlasticTie Strap (2 not used)

Tools/Materials Needed

for Assembly

(1)3/8" open-endwrench*

(1)7/16" open-endwrench* (electric start unit only)

(2)9/16" open-endwrench*

(1)7/8" open-endwrench or 8" long adjustable wrench

(1)Scissors (to trim plastic ties)

(1)Ruler

(1)Small board (to tap plastic knob on lever)

(1) Tire pressuregauge

(1)Cleanoilfunnel

(1)Clean,high-quality motor oil. Refer to the separateEngineOwner's Manual for motor oil specifications and quantity required.

*Adjustablewrenches may be used.

IMPORTANT: Motor oil must beaddedto

the enginecrankcasebefore the engine is started. Followthe instructions in this

"Assembly" Sectionand in the separate EngineOwner'sManual.

NOTE:LEFTand RIGHTsides of the tiller

are as viewedfrom the operator'sposi- tion behindthe handlebars.

STEP 2: ATTACH HANDLEBARS

1.On electric start units, removeone screw and Iockwasherfrom the curved

5@_, 60 o

8_ @©9

7_10_

11

Figure2-1: Loosehardware(shownin reducedsize).

Figure2-1A Handlebarheightadjustment usestheflangeheadscrew.

Figure2-2: On electric start units, move height adjustmentbracket aside.

height adjustment bracket (A, Figure2-2), loosen the secondscrew, and swing the bracketto one side.

2.Cutthe large, plastic cable ties that securethe handlebarends to the handle- bar mounting tabs on the transmission top cover.

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

Figure2-3: Forwardclutchcontrol cable not

shownfor clarity.