Bolens 614E, 662E, 664F, 642F, 6A4E User Manual
OPERATOR’S MANUAL
SNOW THROWER
Models
642E, 642F, 662E, 614E,
644E, 664F, & 6A4E
Model 664 Shown
IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY
Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-
covered, brush-covered or grass-covered land unless the engine’s exhaust system is equipped with a spark arrester meeting
applicable local or state laws (if any). If a spark arrester is used, it should be maintained in effective working order by the operator.
In the State of California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have
similar laws. Federal laws apply on federal lands. A spark arrester for the muffler is available through your nearest engine authorized
service dealer or contact the service department, P.O. Box 361131 Cleveland, Ohio 44136-0019.
MTD LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019
PRINTED IN U.S.A.
FORM NO.
770-10045F.fm
(6/2002)
TABLE OF CONTENTS
Content Page
Important Safe Operation Practices ...................................................................3
Hardware Pack...................................................................................................5
Assembling Your Snow Thrower ........................................................................6
Know Your Snow Thrower..................................................................................10
Operating Your Snow Thrower...........................................................................11
Making Adjustments...........................................................................................14
Maintaining Your Snow Thrower ........................................................................17
Service ...............................................................................................................17
Troubleshooting .................................................................................................20
Parts List ............................................................................................................20
FINDING MODEL NUMBER
This Operator’s Manual is an important part of your new snow thrower. It will help you assemble, prepare and
maintain the unit for best performance. Please read and understand what it says.
Before you start assembling your new equipment, please locate the model plate on the
equipment and copy the information from it in the space provided below. The information on the
model plate is very important if you need help from our Customer Support Department or an
authorized dealer.
• You can locate the model number by standing behind the unit in the operating position and looking down
at the rear frame below the engine. A sample model plate is explained below. For future reference, please
copy the model number and the serial number of the equipment in the space below.
Copy the model number here:
www.mtdproducts.com
MTD LLC
P. O. BOX
CLEVELAND,OH
330-220-4683
800-800-7310
361131
44136
Copy the serial number here:
ENGINE INFORMATION
The engine manufacturer is responsible for all engine-related issues with regards to performance, power-rating,
specifications, warranty and service. Please refer to the engine manufacturer’s Owner’s/Operator’s Manual
packed separately with your unit for more information.
CALLING CUSTOMER SUPPORT
Please do NOT return the unit to the retailer from which it was purchased, without first contacting Customer Support.
Should you have difficulty assembling this product or have any questions regarding the controls, operation or
maintenance of this unit, please call the Customer Support Department.
Call 1- (330) 220-4MTD (4683) or 1- (800)-800-7310 to reach a Customer Support
representative. Please have your unit’s model number and serial number ready when you call.
See previous section to locate this information. You will be asked to enter the serial number in
order to process your call.
For more details about your unit, visit our website at www.mtdproducts.com
2
SECTION 1: IMPORTANT SAFE OPERATION PRACTICES
This symbol points out important safety instructions, which if not followed, could endanger the personal
safety and/or property of yourself and others. Read and follow all instructions in this manual before
attempting to operate this machine. Failure to comply with these instructions may result in personal
injury. When you see this symbol—heed its warning
WARNING: Engine Exhaust, some of its constituents, and certain vehicle components
contain or emit chemicals known to the State of California to cause cancer, birth defects or
other reproductive harm
.
DANGER: This machine was built to be operated according to the rules for safe operation in this
manual. As with any type of power equipment, carelessness or error on the part of the operator can
result in serious injury. This machine is capable of amputating hands and feet and throwing objects.
Failure to observe the following safety instructions could result in serious injury or death
.
.
TRAINING
1. Read, understand, and follow all instructions on the
machine and in the manual(s) before attempting to
assemble and operate. Keep this manual in a safe place
for future and regular reference and for ordering
replacement parts.
2. Be familiar with all controls and their proper operation.
Know how to stop the machine and disengage them
quickly.
3. Never allow children under 14 years old to operate this
machine. Children 14 years old and over should read and
understand the operation instructions and safety rules in
this manual and should be trained and supervised by a
parent.
4. Never allow adults to operate this machine without
proper instruction.
5. Thrown objects can cause serious personal injury. Plan
your snow-throwing pattern to avoid discharge of material
toward roads, bystanders and the like.
6. Keep bystanders, helpers, pets and children at least 75
feet from the machine while it is in operation. Stop
machine if anyone enters the area.
7. Exercise caution to avoid slipping or falling, especially
when operating in reverse.
PREPARATION
1. Thoroughly inspect the area where the equipment is to
be used. Remove all doormats, newspapers, sleds,
boards, wires and other foreign objects, which could be
tripped over or thrown by the auger/impeller.
2. Always wear safety glasses or eye shields during
operation and while performing an adjustment or repair to
protect your eyes. Thrown objects which ricochet can
cause serious injury to the eyes.
3. Do not operate without wearing adequate winter outer
garments. Do not wear jewelry, long scarves or other
loose clothing, which could become entangled in moving
parts. Wear footwear which will improve footing on
slippery surfaces.
4. Use a grounded three-wire extension cord and
receptacle for all units with electric start engines.
5. Adjust collector housing height to clear gravel or crushed
rock surfaces.
6. Disengage all clutch levers before starting the engine.
7. Never attempt to make any adjustments while engine is
running, except where specifically recommended in the
operator’s manual.
8. Let engine and machine adjust to outdoor temperature
before starting to clear snow.
9. To avoid personal injury or property damage use extreme
care in handling gasoline. Gasoline is extremely
flammable and the vapors are explosive. Serious
personal injury can occur when gasoline is spilled on
yourself or your clothes, which can ignite. Wash your skin
and change clothes immediately.
a. Use only an approved gasoline container.
b. Extinguish all cigarettes, cigars, pipes and other
sources of ignition.
c. Never fuel machine indoors.
d. Never remove gas cap or add fuel while the
engine is hot or running.
e. Allow engine to cool at least two minutes before
refueling.
f. Never over fill fuel tank. Fill tank to no more than
½ inch below bottom of filler neck to provide space
for fuel expansion.
g. Replace gasoline cap and tighten securely.
h. If gasoline is spilled, wipe it off the engine and
equipment. Move machine to another area. Wait 5
minutes before starting the engine.
i. Never store the machine or fuel container inside
where there is an open flame, spark or pilot light
(e.g. furnace, water heater, space heater, clothes
dryer etc.).
j. Allow machine to cool at least 5 minutes before
storing.
OPERATION
1. Do not put hands or feet near rotating parts, in the auger/
impeller housing or discharge chute. Contact with the
rotating parts can amputate hands and feet.
2. The auger/impeller clutch lever is a safety device. Never
bypass its operation. Doing so makes the machine
unsafe and may cause personal injury.
3. The clutch levers must operate easily in both directions
and automatically return to the disengaged position when
released.
4. Never operate with a missing or damaged discharge
chute. Keep all safety devices in place and working.
3
5. Never run an engine indoors or in a poorly ventilated
area. Engine exhaust contains carbon monoxide, an
odorless and deadly gas.
6. Do not operate machine while under the influence of
alcohol or drugs.
7. Muffler and engine become hot and can cause a burn. Do
not touch.
8. Exercise extreme caution when operating on or crossing
gravel surfaces. Stay alert for hidden hazards or traffic.
9. Exercise caution when changing direction and while
operating on slopes.
10. Plan your snow-throwing pattern to avoid discharge
towards windows, walls, cars etc. Thus, avoiding
possible property damage or personal injury caused by a
ricochet.
11. Never direct discharge at children, bystanders and pets
or allow anyone in front of the machine.
12. Do not overload machine capacity by attempting to clear
snow at too fast of a rate.
13. Never operate this machine without good visibility or
light. Always be sure of your footing and keep a firm hold
on the handles. Walk, never run.
14. Disengage power to the auger/impeller when
transporting or not in use.
15. Never operate machine at high transport speeds on
slippery surfaces. Look down and behind and use care
when in reverse.
16. If the machine should start to vibrate abnormally, stop the
engine, disconnect the spark plug wire and ground it
against the engine. Inspect thoroughly for damage.
Repair any damage before starting and operating.
17. Disengage all clutch levers and stop engine before you
leave the operating position (behind the handles). Wait
until the auger/impeller comes to a complete stop before
unclogging the discharge chute, making any
adjustments, or inspections.
18. Never put your hand in the discharge or collector
openings. Always use the clean-out tool provided to
unclog the discharge opening. Do not unclog discharge
chute while engine is running.Shut off engine and remain
behind handles until all moving parts have stopped
before unclogging.
19. Use only attachments and accessories approved by the
manufacturer (e.g. wheel weights, tire chains, cabs etc.).
20. If situations occur which are not covered in this manual,
use care and good judgment. Contact your dealer or
telephone 1-800-800-7310 for assistance and the name
of your nearest servicing dealer.
MAINTENANCE AND STORAGE
1. Never tamper with safety devices. Check their proper
operation regularly. Refer to the maintenance and
adjustment sections of this manual.
2. Before cleaning, repairing, or inspecting machine
disengage all clutch levers and stop engine. Wait until the
auger/impeller come to a complete stop. Disconnect the
spark plug wire and ground against the engine to prevent
unintended starting.
3. Check bolts and screws for proper tightness at frequent
intervals to keep the machine in safe working condition.
Also, visually inspect machine for any damage.
4. Do not change the engine governor setting or over-speed
the engine. The governor controls the maximum safe
operating speed of the engine.
5. Snow thrower shave plates and skid shoes are subject to
wear and damage. For your safety protection, frequently
check all components and replace with original
equipment manufacturer’s (OEM) parts only. “Use of
parts which do not meet the original equipment
specifications may lead to improper performance and
compromise safety!”
6. Check clutch controls periodically to verify they engage
and disengage properly and adjust, if necessary. Refer to
the adjustment section in this operator’s manual for
instructions.
7. Maintain or replace safety and instruction labels, as
necessary.
8. Observe proper disposal laws and regulations for gas,
oil, etc. to protect the environment.
9. Prior to storing, run machine a few minutes to clear snow
from machine and prevent freeze up of auger/impeller.
10. Never store the machine or fuel container inside where
there is an open flame, spark or pilot light such as a water
heater, furnace, clothes dryer etc.
11. Always refer to the operator’s manual for proper
instructions on off-season storage.
WARNING: Restrict the use of this
power machine to persons who read,
understand and follow the warnings and
instructions in this manual and on the
machine.
4
SECTION 2: CONTENTS OF HARDWARE PACK
Lay out the hardware according to the illustration below for identification purposes. Part numbers are shown in
parentheses. (Hardware pack may contain extra items which are not used on your unit.)
ATTACHING THE HANDLES
A
Hex Bolts
710-3259 (2)
Hex Bolts
710-1880 (2)
ATTACHING CHUTE DIRECTIONAL CONTROL
C
Cupped Washer
736-0242
Flat Washers
736-0185 (2)
Lock Washers
736-0119 (4)
Eyebolt (Not Shown)
747-0697
Hex Nuts
712-3010 (2)
Saddle
784-5599 (2)
ATTACHING HANDLE PANEL
B
ATTACHING CLUTCH CABLES AND SHIFT ROD
D
(Z Fittings might be already attached to cables)
Ferrule
711-0677
E
Carriage Bolts
710-0262 (4)
Hex Patch Nuts
712-3068 (4)
Lock Washers
736-0119 (4)
Z Fitting
746-0778 (2)
Hairpin Clips
714-0104 (2)
ATTACHING THE CLUTCH GRIPS
Hex Nuts
712-0121 (2)
Flat Washers
7736-0275 (2)
F
Hairpin Clip
714-0104
ATTACHING CHUTE ASSEMBLY
Hex Bolts
710-3015 (2)
Hex Lock Nuts
712-3027 (6)
Chute Flange Keepers
731-0851 (3) Not Shown
G
Hex Screws
710-3103 (2)
REPLACEMENT SHEAR BOLTS
Hex Lock Nuts
712-0429 (2)
Spacer
750-1032 (2)
Hex Top L-Nut
712-0429 (2)
Hex Bolts
710-0890A (2)
NOTE: The augers are secured to the spiral shaft with two shear bolts and hex lock nuts. If you hit a hard foreign
object or an ice jam, the snow thrower is designed so that the bolts may shear. Two replacement shear bolts and
nuts are provided for your convenience. Store in a safe place until needed
5
SECTION 3: ASSEMBLING YOUR SNOW THROWER
NOTE: References to right or left side of the snow
thrower are determined from behind the unit in the
operating position. The “operator’s position” is defined
as standing directly behind the snow thrower, facing the
handle panel.
Unpacking
• Remove staples or break glue on top flaps of the
carton. Remove any loose parts included with unit
(i.e., operator’s manual, etc.).
• Cut corners of the carton and lay ends down flat.
Remove packing material.
• Roll unit out of carton. Check carton thoroughly for
loose parts before discarding.
Loose Parts In Carton
Handle Panel
Auger Control
Traction Control
Handle Panel
Left Bracket
Carriage
Bolts
Left Handle
(Curves in)
• Insert curved end of the Z fitting into the top hole in
the triangular metal tab on the auger control grip.
The triangular metal tab on the auger control grip
must face the center of the handle panel.
See Figure 3.
Auger Control
Hex
Patch Nuts
Lock Washers
Figure 2
Triangle
Metal Tab
Right Clutch
Bracket
Left Clutch
Bracket
Left Handle
Right Handle
Figure 1
Before Assembly
WARNING: Disconnect the spark plug
wire and ground it against the engine to
prevent unintended starting.
Attaching Handle Assembly (Hardware Group A,
B and E)
• Attach left handle and left clutch bracket to handle
panel with two carriage bolts, lock washers and hex
patch nuts. (Be sure the bend in the grip bracket is
towards the center of the handle panel.) Do not
tighten at this time. See Figure 2.
“Z” Fitting
Triangle
Metal Tab
Figure 3
• Place the auger control on top of the left handle.
The triangular metal tab must be between the
handle and the bracket. See Figure 3.
• Secure with hex bolt, spacer, and hex lock nut. Do
not overtighten this bolt as it will prevent the control
from automatically returning to their upright
position. See Figure 4.
6
Auger Control
2” Hex Bolt
Left
Handle
Spacer
Hex Bolt
Handle Panel
Left Bracket
Hex Lock Nut
“Z” Fitting
Figure 4
• Repeat process for the right side Traction Control.
• Lay handle assembly behind snow thrower.
See Figure 5.
• Insert a hex bolt 3/4” long and lock washer through
the lower hole on the bottom of the handle.
• Hold the handle assembly up to the bottom of the
snow thrower frame and thread the hex bolt into the
lower hole in snow thrower frame. Do not tighten at
this time. See Figure 5.
• Repeat process on the other side.
Saddle
Cable Roller
Guide
Lock
Washers
3/4” Hex
Bolt
Figure 6
Attaching Shift Rod (Hardware D)
• Place the shift lever in the fastest forward speed
position.
• Models 602, 642, and 662: Rotate the shift arm
assembly counter clockwise, as far as it will go.
Insert the shift rod through the shift arm assembly.
When installed the shift arm assembly should point
to the right. Secure with flat washer and hairpin clip.
See Figure 7.
• Models 602, 642, and 662: Thread the ferrule up
or down the shift rod and align with the lower hole
on the shift lever assembly behind the handle
panel. See Figure 7.
Shift
Lever
Hairpin
Clip
Traction
Drive Clutch
Handle Panel &
Handles
Hex Bolt &
Lock Washer
Figure 5
• Raise the handle assembly into the upright position
and align the top holes in the handle with the top
holes in the snow thrower frame. Attach using 2”
long hex bolts, lock washers and saddles. (Curve in
saddle must match the curve in the handle.)
See Figure 6.
• Tighten all hardware used to attach the handle
assembly to the snow thrower frame.
Auger
Drive Clutch
Ferrule
(Bottom Hole)
Shift Rod
Flat
Washer
Shift Arm
Assembly
Models 602, 642 and 662
Flat Washer
Hairpin
Clip
Figure 7
• Models 614, 644, 664 and 6A4: Rotate the shift
arm assembly counter clockwise as far as it will go.
Insert the shift rod through the shift arm assembly.
When installed, the shift arm assembly should point
left. Secure with flat washer and hairpin clip.
See Figure 8.
7
• Models 614, 644, 664, and 6A4: Thread the ferrule
onto the shift rod, up or down the shift rod and align
with the far hole on the narrow side of the shift lever
assembly behind the handle panel. See Figure 8.
Auger
Drive
Clutch
Hairpin
Clip
Models 614, 644, 664 and 6A4
Flat
Washer
Shift Rod
Shift Arm
Assembly
Shift Lever
Ferrule
Flat
Washer
Traction
Drive
Clutch
Hairpin
Clip
Figure 8
• Secure the ferrule to the shift arm assembly with
the flat washer and hairpin clip.
Attaching Clutch Cables (Hardware D)
Z fittings with jam nuts might be already inserted in
each control lever (on the handle panel) at the factory.
To attach the cables to the Z fittings, proceed as
follows:
NOTE: Two extra jam nuts are included in the
hardware pack in the event either are lost during
shipping.
• If Z fittings are not already attached, thread hex
nuts onto the “Z” fittings and insert “Z” fitting into
hole in clutch grips. See Figure 9.
• Route the left cable between engine and speed
selector plate and then between handle panel and
clutch lever pivot rod before threading onto the left
“Z” fitting.
• Assemble the right cable in the same manner.
• Both cables should have minimal slack, but not
tight.
• If Z fittings are already attached, thread the jam
nuts all the way up each of the Z fittings, toward the
handle panel.
• Make certain all cables are in the grooves of the
cable roller guides in the lower rear of the unit, one
on each side. Refer to Figure 6.
• Thread the coupling end of the cable onto the
threaded portion of the Z fitting until the rubber
bumper (located on the underside of the clutch
lever) only lightly contacts the upper handle.
IMPORTANT:
The cable should have very little slack, but
should NOT be tight. An overtightened cable may
prohibit the auger and drive from disengaging.
WARNING: Over-tightening the cable
may prohibit the auger and drive from
disengaging and compromise the safety
of the snow thrower. Do NOT overtighten
the cable.
• Once properly adjusted, tighten the jam nut against
the coupling end of the cable to lock it in position.
NOTE: Refer to Auger Control Test in the Operation
Section prior to operating your snow thrower. Read and
follow all instructions carefully and perform all
adjustments to verify your snow thrower is operating
safely and properly.
Attaching the Chute Assembly (Hardware F)
• Place chute assembly over chute opening, with the
opening in the chute assembly facing the front of
the unit.
• Place chute flange keepers beneath lip of chute
assembly, with the flat side of chute flange keeper
facing downward. See Figure 10.
• Insert hex bolt up through chute flange keeper and
chute assembly and secure with hex lock nut. After
assembling all three chute flange keepers, tighten
all nuts and bolts securely. Do not overtighten.
Chute Assembly
Hex Bolt
Cable Should
Be Straight
Figure 9
Z
Hex Nut
Hex Lock Nut
Chute Flange
Keeper
Figure 10
8
NOTE: Lock nuts cannot be threaded onto a bolt by
hand. Tighten with two 7/16” or adjustable wrenches.
Attaching The Chute Directional Control
(Hardware C)
• Thread one hex nut about halfway onto eye bolt on
the chute directional control.
• Insert eye bolt through the hole provided in the left
handle. See Figure 11.
• Secure with cupped washer (cupped side against
the handle) and other hex nut. Do not tighten until
after attaching the other end of the chute directional
control.
Carriage
Bolts
Lower Chute
Bracket
Hex Lock
Nuts
Cupped
Washer
Hex Nut
Eye Bolt
Figure 11
• To align the spiral on the chute directional control,
you may have to loosen the carriage bolts and hex
lock nuts securing lower chute bracket to the
extension on the left side of the chute assembly.
See Figure 12.
• Place one flat washer on the end of the chute
directional control, then insert the end of the control
into the hole in the plastic bushing in the lower
chute bracket.
• Place another flat washer on the end of the chute
directional control, and insert hairpin clip into hole in
the end of control. See Figure 12.
• Adjust the chute bracket so that the spiral on the
chute directional control fully engages the teeth on
the chute assembly.
• Tighten nuts on the lower chute bracket securely.
• Tighten hex nut on the eye bolt on chute directional
control.
Hairpin
Clip
Flat
Washers
Chute
Directional
Control
Lower Chute
Bracket
Figure 12
Lamp Wiring (If Equipped)
If for shipping purposes, the headlight wire was left
unattached to the alternator lead, follow the steps
below to attach it now:
• Unwrap the headlight wire which is attached to the
headlight beneath the handle panel. Wind the
headlight wire around the right handle until excess
slack is removed. See Figure 13.
Lower Handle
Alternator
Lead
Lamp
Wire
Figure 13
• Plug the wire from the headlight into the alternator
lead coming from the right side of the engine,
underneath the fuel tank.
9
SECTION 4: KNOW YOUR SNOW THROWER
WARNING: Read, understand, and
follow all instructions and warnings on
the machine and in this manual before
operating.
Shift Lever
The shift lever is located in the center of the handle
panel. The shift lever may be moved into one of six
positions. Run engine with throttle in the fast positions
Run engine with throttle in the fast position. Use the
shift lever to determine ground speed. See Figure 14.
Forward
There are five forward speeds on this snow thrower.
Position one (1) is the slowest and position five (5) is
the fastest.
Reverse
Your snow thrower has two reverse (R) speeds. R1 is
the slower, while R2 is the faster of the two.
NOTE: Model 614, 644, 664, and 6A4 has five
forward positions and two reverse.
Auger Drive Control
The auger drive control is located on the left handle.
Squeeze the control grip to engage the augers.
Release to stop the snow throwing action.
Traction Control
The traction control is located on the right handle.
Squeeze the traction control grip to engage the wheel
drive. Release to stop.
Chute Directional Control
The chute directional control is located on left side of
the snow thrower. See Figure 14.
To change the direction in which snow is thrown, turn
chute directional control as follows:
• Crank clockwise to discharge to the left.
• Crank counterclockwise to discharge to the right.
Clean-Out Tool
WARNING: Never use your hand to
clear a clogged discharged chute. Shut off
engine and remain behind handles until
all moving parts have stopped before
unclogging.
The chute clean-out tool is fastened to the top of the
auger housing with a mounting clip. The tool is
designed to clear a clogged discharged chute. Refer to
Operating Your Snow Thrower section for more detailed
information regarding the chute clean-out tool.
See Figure 14.
Discharge
Chute
Auger
Traction
Drive Clutch
Gas Cap
Oil Fill
Shift
Lever
Shift Lever
Model 664 Shown
Auger
Drive Clutch
Chute Directional
Control
Choke
Ignition
Key
Throttle
Control
Clean-out
Too l
Primer
Rope
Start
Handle
Figure 14
10
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