Troy-Bilt 664Dpony, 665B Pro-line, E66M PonyES manual Assembly, Attach Reverse Clutch Control Cable

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).

C

P

N O

Figure 2-4: Attach handlebars.

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-

G ➥

Figure 2-5: Carefully unwrap Wheel Gear Lever and move lever to DISENGAGE.

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.

Left Side	Reverse Clutch
Handlebar
	Control Knob
	Slot in
	Control
I	Panel
H

Figure 2-6: Attach reverse clutch control assembly to slotted hole in handlebar panel.

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.

K

J

Figure 2-7: Forward Clutch Control levers

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

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).

L

Figure 2-8

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.

A

B

Figure 2-9