Troy Bilt 34061, 34062, 34337, 34063, 34064 Owners Manual

OWNER’S MANUAL Sickle Bar Mowers

• Safety

• Assembly

• Controls and Features

• Operation

• Maintenance

• Parts List

GARDEN WAY INCORPORATED

Models

34061 – 34", 3-1/2 HP Recoil Start 34062 – 38", 4HP Recoil Start 34337 – 34", 4HP Recoil Start 34063 – 42", 5HP Recoil Start 34064 – 42", 5HP Electric Start

SAFETY FIRST!

Before operating this equipment, read this

Owner's Manual and the separate manual

supplied by the engine manufacturer.

Dear Owner:

Thank you for purchasing our product. We feel you now own one of the finest pieces of outdoor power equipment available. Our equipment is carefully designed, engineered and manufactured for excellent performance if properly operated and maintained.

Read this manual carefully to familiarize yourself with the unit, its features, and its safe operation. Be sure that you and any

other operators carefully follow the recommended safety practices at all times. Failure to do so could result in personal injury or property damage.

This is a safety, operation and general maintenance manual which does not attempt to cover major repairs. All information in this manual is based on the latest product information available at the time of printing. This manual is considered a permanent part of the unit and it must stay with the unit if resold. A replacement manual can be obtained from the factory or an authorized dealer.

Please fill out and return the postpaid owner registration card included with this manual. The purpose of the card is to register each unit and owner at the factory to provide product updates and warranty service.

If you have any problems or questions concerning the unit, please contact your local authorized dealer or the factory (see back cover of this manual). We want to be sure that you are completely satisfied at all times.

INTRODUCTION ................................................. 2

Service Information ...................................................... 3

Identification Numbers ................................................. 3

California Operators Warning ....................................... 3

SAFETY .......................................................... 3

Safety Decals ................................................................ 5

ASSEMBLY ...................................................... 6

FEATURES AND CONTROLS ................................... 14

Throttle/Choke Control Lever ........................................ 14

Operator Presence Controls (OPC) ............................... 14

Wheel Drive Levers ....................................................... 14

Engine Oil Dipstick/Fill Hole .......................................... 14

Shoes ........................................................................... 14

Cutter Bar (with guard) ................................................. 15

Fuel Tank Cap ............................................................... 15

Starter Rope Handle ..................................................... 15

Engine Keyswitch (electric-start units).......................... 15

Cutter Bar Lever ........................................................... 15

Weed Diverter ............................................................... 15

Engine Primer Bulb ....................................................... 15

OPERATION ..................................................... 16

Pre-start Checklist ........................................................ 16

Starting the Engine ....................................................... 16

Stopping the Engine...................................................... 17

Operator Presence Controls (OPC) System Test .......... 17

Operation....................................................................... 18

Operating on Slopes...................................................... 19

Stopping ....................................................................... 19

MAINTENANCE ................................................. 20

Maintenance Schedule................................................... 20

Tire Pressure................................................................. 20

Clearing Wheel Wrap .................................................... 20

Wheel Drive Control Rod Adjustment ........................... 20

Cutter Bar Drive Belt Removal/Replacement ................ 21

Cutter Bar Belt Guide Adjustment ................................ 21

Wheel Drive Belt Adjustment ........................................ 21

Wheel Drive Belt Removal/Replacement ....................... 21

Wheel Drive Belt Guide Adjustment .............................. 21

Drive Chain Adjustment and Lubrication ...................... 22

Cutter Bar Maintenance ............................................ 22-24

High-Wear Parts ........................................................... 24

Housing Assembly Tightening Sequence....................... 26

Front Housing Removal................................................. 26

Eccentric Shaft Removal/Replacement.......................... 26

Engine Maintenance.................................................. 26-27

Battery Maintenance...................................................... 27

Check and Tighten Hardware......................................... 27

Lubrication.................................................................... 27

Storage ......................................................................... 28

Troubleshooting ....................................................... 28-29

PARTS LIST...................................................... 30

CUSTOMER SERVICE INFORMATION ............. BACK COVER

T able of Contents

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

WARNING

Safety Alert Symbol

This is a safety alert symbol. It is used in this manual and on the unit to alert you to potential hazards. When you see this symbol, read and obey the message that follows it. Failure to obey safety messages could result in personal injury or property damage.

See Back Cover for

Customer Service Information

Left and Right Sides

Left and right sides of the unit are determined by standing in the operator position and facing the direction of forward travel.

PREPARATION

1. Unit is capable of amputating hands and feet and throwing objects. Failure to observe the following safety instructions could result in serious injury or property damage.

2. Serious accidents which may cause injury or property damage can occur if the following safety guidelines are not followed. The operator is solely responsible for accidents or hazards that occur when using the unit. Preventing accidents is the responsibility of every equipment operator. Accidents can be prevented. Be careful before, during and immediately after use of any powered equipment. The following general safety precautions must be fully understood and followed during operation. Review these instructions frequently and never take chances. If you do not understand any part of this manual or need assistance, contact your dealer or our service department.

TRAINING

1. Read, understand, and follow this Owner’s Manual, the separate engine owner’s manual, and all other literature received before you use the unit.

Be thoroughly familiar with the controls and proper use of the unit. Know how to stop the unit and disengage controls quickly in case of emergency.

Read and follow all safety information in this manual. Failure to comply could result in serious personal injury or property damage.

Make sure all operators of the equipment read, understand, and follow these safety instructions.

2. Never allow children to operate the unit. Do not allow adults to operate the unit without proper instruction. Do not allow irresponsible adults to operate the unit.

3. Keep the operating area (within 25 feet of unit) clear of all people (especially children) and pets.

PREPARATION

1. Wear proper clothing when operating unit. Always wear sturdy footwear (preferably steel-toed shoes) and hearing protection during operation.

a. Wear heavy leather gloves whenever

working near or servicing any cutting edges on the unit.

b. Do not wear loose-fitting clothing,

jewelry, scarves, ties, etc., which may get caught in moving parts. Tie up or restrain hair.

c. Do not operate the unit while bare-

foot. Do not wear sandals. d. Wear long trousers. e. Wear hearing protection.

2. Do not operate the unit when tired, ill or under the influence of alcohol and/or other drugs.

3. Be prepared for an emergency. Keep a first aid kit and fire extinguisher handy. Keep emergency telephone numbers for ambulance, fire, hospital, doctor and rescue near your telephone.

4. When charging the battery on electricstart units, use only the battery charger provided with the unit.

5. Do not operate the unit if the cutter bar assembly is not securely installed and operating properly.

6. Mow only during daylight or in good artificial light.

7. Never operate the unit in wet grass. Always be sure of your footing. Always hold handlebar grips firmly, and walk––never run.

25 Ft.

Safety

Section

SPARK ARRESTER WARNING TO RESIDENTS

OF CALIFORNIA AND SEVERAL OTHER STATES

Under California law, and under the laws of several other states, you are not permitted to operate an internal combustion engine using hydrocarbon fuels on any forest, brush, hay, grain, or grass covered land; or land covered by any flammable agricultural crop without an engine spark arrester in continuous effective working order.

The engine on the unit is an internal combustion engine which burns gasoline, a hydrocarbon fuel, and must be equipped with a spark arrester muffler in continuous effective working order. The spark arrester must be attached to the engine exhaust system in such a manner that flames or heat from the system will not ignite flammable material. Failure of the owner/operator of the unit to comply with this regulation is a misdemeanor under California law (and other states) and may also be a violation of other state and/or federal regulations, laws, ordinances or codes. Contact your local fire marshal or forest service for specific information about which regulations apply in your area.

Throttle/Choke Control Lever

Wheel Drive Levers

Cutter Bar and Guard

Cutter Bar Lever (on rear of unit)

Operator Presence Controls

Figure 1-1

4 Section 1: Safety

BEFORE OPERATION

1. Before each use, thoroughly inspect the mowing area. Remove all metal, debris, and other hazards. Inspect for holes, ruts or bumps. Uneven terrain could overturn the unit. Tall vegetation can hide hazards.

2. Never operate the unit without all guards in place and working properly (except for the plastic blade protector, which should be removed before starting the engine).

3. Before removing or installing the plastic blade protector, shut the engine off, disconnect the spark plug wire, and prevent it from touching the spark plug. On electric start models, also remove the ignition key from the keyswitch.

4. Check the operation of the control levers under each handlebar grip. See the "Operation" Section in this manual for specific instructions. Do not use the unit if control levers are not functioning properly.

CORRECT ANY MALFUNCTION BEFORE USING THE UNIT!

HANDLING GASOLINE

1. Use extreme care in handling gasoline and other fuels. Gasoline is highly flammable and its vapors are volatile, explosive, and dangerous. Keep gasoline and gasoline containers away from hot engine exhaust. Never allow flame, sparks, smoking materials or other hot objects near gasoline, gasoline fumes, the fuel container or fuel tank.

2. Use an approved fuel container only. Wipe up any spilled gasoline immediately.

3. Leave one inch of air space at top of fuel tank to allow room for expansion.

4. Store gasoline in a cool, well-ventilated area. Never store unit or fuel container inside where there is an open flame or spark, such as a hot water heater, furnace, etc.

5. Never remove fuel fill cap, or add fuel to fuel tank, if engine is running or hot. Allow the engine to cool for several minutes before filling the fuel tank. Always replace fuel fill cap before starting engine.

6. Never refuel unit indoors. Refuel outdoors in a well-ventilated area only.

7. Check the gasoline level in the fuel tank outdoors, before starting the engine. Reinstall the fuel tank cap securely and clean up any spilled gasoline before starting the engine.

8. Do not smoke while mowing.

9. Move the unit away from gasoline fumes before starting the engine.

OPERATION

1. Keep the plastic blade protector on the cutter bar blade until you are ready to start the engine.

2. Do not put hands or feet near or under any moving parts. Keep clear of the cutter bar at all times while the engine is running.

3. Never leave the operator position while the engine is running. Stop the engine, disconnect the spark plug wire and move it away from the spark plug to help prevent accidental starting whenever leaving the unit unattended. On electric start models, remove the ignition key to help prevent accidental starting or unauthorized use.

4. Before removing or installing the plastic blade protector, shut the engine off, disconnect the spark plug wire, and prevent it from touching the spark plug. On electric start models, also remove the ignition key from the keyswitch.

5. Do not change the engine governor setting. Over-speeding may damage the engine and unit and will void the warranty. See an authorized engine service dealer if an engine problem exists.

6. Disengage the cutter bar when crossing gravel drives, walkways or roads.

7. Watch for, and avoid, traffic when operating near roadways.

8. Disengage the cutter bar drive and the wheel drive if you are approached by a child, inattentive person or a pet.

9. Before inspecting, adjusting or repairing the unit or cutter bar, stop the engine, let all moving parts come to a complete stop, disconnect the spark plug wire, and install the plastic blade guard. On electric start models, remove the ignition key from the keyswitch.

10. If the unit should start to vibrate abnormally, stop the engine, wait for all moving parts to stop completely, disconnect the spark plug wire and prevent it from touching the spark plug. Remove the engine ignition key on electric start models. Inspect the unit for damage. Repair any damage before continuing.

11. If the unit should strike a foreign object, stop the engine, wait for all moving parts to stop completely, disconnect the spark plug wire and prevent it from touching the spark plug. Remove the engine ignition key on electric start models. Inspect the unit for damage. Repair any damage before continuing.

12. Do not run the engine in an enclosed area. Engine exhaust contains carbon monoxide, a deadly, poisonous gas that is odorless, colorless and tasteless. Always run the engine outdoors with adequate ventilation.

13. Always mow across the face of slopes. Do not operate unit on slopes steeper than 15°.

14. Keep all movements on a slope slow and gradual. Do not make sudden changes in speed or direction.

15. Do not touch engine parts which may be hot from operation. Let parts cool for several minutes before going near them.

16. Keep children out of the mowing area and under the supervision of a responsible adult other than the unit operator.

17. Before and when backing, check for and avoid obstacles and hazards.

18. Disengage the cutter bar drive when not mowing.

19. Do not mow near drop-offs, ditches or embankments. If a wheel drops off an edge, the unit could suddenly overturn.

20. To help reduce fire hazard, keep the engine free of grass, leaves, grease and other debris.

CHILDREN

1. Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the unit and the mowing activity. Never assume that children will remain where you last saw them.

2. Never allow children to operate the unit, even under adult supervision. Local

regulations may restrict operator age. Only allow responsible adults, who are familiar with these instructions, to operate the unit.

Section 1: Safety 5

3. Never carry children as passengers. Do not carry ANY passengers. They may fall off, become seriously injured, or interfere with safe unit operation.

4. Keep children out of the work area and under the watchful care of a responsible adult other than the unit operator.

5. Be alert and turn unit off if children enter the area.

6. Before and when backing, look behind and down for children.

7. Use extra care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.

8. Keep children away while performing maintenance or adjustments.

MAINTENANCE AND STORAGE

1. Before inspecting, cleaning, adjusting or repairing the unit, stop the engine, let all moving parts come to a complete stop, disconnect the spark plug wire, and install the plastic blade guard on the cutter bar. On electric start models, remove the ignition key from the keyswitch.

2. Always wear sturdy footwear (preferably steel-toed shoes), long trousers, hearing and eye protection while doing any maintenance on the unit. Do not wear loose-fitting clothing, jewelry, scarves, ties, etc., which could get caught in moving parts. Tie up or restrain hair.

3. Install the plastic blade guard before removing the cutter bar assembly and wear sturdy leather gloves to help protect your fingers and hands.

4. Keep children away while performing maintenance or adjustments.

5. Remove any metal jewelry when working on or near electrical system components.

6. Use only original equipment replacement parts. Parts manufactured by others could create a hazard even though they may fit on the unit.

7. Keep the equipment in safe working condition. Keep all nuts, bolts and screws tight. Frequently check the engine mounting bolts and cutter bar mounting bolts for tightness.

8. Provide safe, adequate light in your work area. NEVER USE AN OPEN FLAME FOR ILLUMINATION! Use only a portable safety light enclosed in a wire cage for working on unit. NOTE:

Hot filaments from a broken light bulb can ignite spilled fuel or oil.

9. If the unit has gasoline in its fuel tank, do not store it inside a building where fumes from the gasoline could reach an open flame or spark. Let the engine cool before storing the unit.

10. Store gasoline in a cool, well-ventilated area, away from spark- or flame-producing equipment. Store gasoline in an approved container, away from children.

11. Keep unit free of grass, leaves or build-up of other debris. Clean up oil or fuel spillage. Allow unit to cool before storing.

12. Replace muffler if worn or defective.

13. Use extra care when loading or unloading unit into a trailer or truck.

14. Do not use food or beverage containers to store waste materials. Using such containers could result in accidental poisoning.

ENGINE

1. Before starting the engine or operating the unit, read the separate engine manual completely. Read and follow all safety instructions provided in that manual.

2. BEFORE SERVICING THE ENGINE: Disconnect the spark plug wire and keep it from touching the spark plug.

3. Keep the engine free of grass, leaves, oil, and grease.

4. Engine exhaust is extremely hot. Keep grass, oil, fuel, and other combustible materials far away from engine exhaust.

5. Do not change the engine governor setting. Over-speeding may damage the engine and unit and will void the warranty. See an authorized engine service dealer if a problem exists.

6. Never run an internal combustion engine inside a closed area. Engine exhaust contains carbon monoxide gas, a deadly poison. Carbon monoxide is odorless, colorless and tasteless. Do not operate the unit near buildings, windows, or air conditioners. If the engine is run in a garage, open all doors and allow for adequate ventilation.

Place Hand Here When

Pulling Starter Rope

Hot Surfaces

Warning

Sharp Cutter Bar

Blades Danger

Danger - Keep Hands

and Feet Away

On Rear Panel

Warning - Operating Engine - Electric

Start Only

Cover “Top” Decal

Engine Throttle Settings

SAFETY DECAL LOCATION

Operator Presence

Controls

SAFETY DECALS

Keep all safety decals clean and in good condition. The location of each decal is shown in Figure 1-2.

Refer to the Parts List for ordering replacement decals.

Figure 1-2

Assembly

Section

BEFORE ASSEMBLY

Carefully follow all steps in this section to assemble the unit.

CARTON INSPECTION

Inspect the unit immediately after delivery. Check the carton and contents for any damage.

Contact the carrier (trucking company) immediately if the unit is damaged. Inform the carrier that you wish to file a claim. The carrier will let you know how to proceed with the claim. To protect your rights, file a written claim with the carrier within 15 days of receiving the unit. Contact our service department if you need assistance.

Do not start the engine until oil is added! The engine is shipped without oil. Engine damage will occur if engine is started before oil is added.

IMPORTANT: Oil must be added before

starting the engine. Starting or operating the engine without oil will damage the engine and void the warranty. See the engine manual.

Do not overfill engine with oil. Engine damage will occur.

Cutter bar blades are extremely sharp. To help avoid serious injury:

• Keep the plastic guard on the CUTTER BAR ASSEMBLY when the unit is not running.

• Wear heavy leather gloves when han-

dling the cutter bar.

• Do not place fingers between blades.

Amputation could result.

UNPACKING THE UNIT

The cutter bar blade and attached plastic blade guard are packaged separately within the main shipping crate. Leave the cutter bar blade attached to the shipping pallet until instructed to remove it.

The handlebars are packed on each side of the unit, connected with wiring to the underside of the unit. IMPORTANT: Do not damage the wiring when removing the handlebars from the carton.

The included parts and hardware required for assembly are listed on the following pages.

Remove and discard the two screws that secure the front of the unit to the wooden pallet (see Fig. 2-1). However, leave the unit on the pallet until instructed to remove it. Fig. 2-1 shows the position of the unit for assembly.

TOOLS/MATERIALS NEEDED

(2 ea.) Wrenches: 7/16", 1/2", 9/16" (or

adjustable wrenches) (1) Adjustable Wrench (1) 13mm Socket (1) Phillips (or thin straight blade)

Screwdriver (1) All-purpose Oil (1) Tire Pressure Gauge (1) Measuring Tape or Ruler

DANGER

CAUTION

WARNING

Fig. 2-1

Remove shipping screws

Remove control rods

from handlebar

To prevent personal injury or property damage, do not start the engine until all assembly steps are complete and you have read and understand the safety and operating instructions in this Manual and the engine manual.

WARNING

Section 2: Assembly 7

Ref. Description Qty.

Right Handlebar (shipped connected to

unit by wiring)...............................................1

Left Handlebar (shipped connected to

unit by wiring)...............................................1

1 Hex Head Capscrew, 5/16"–18 x 2-1/4" ........2

2 Locknut, 5/16"–18.......................................10

3 Handlebar Bridge..........................................1

4 Cable Ties (total of six - two already

installed on unit)...........................................4

5 Hex Head Capscrew, 1/4"–20 x 2".................1

6 Locknut, 1/4".................................................1

7 Control Rod..................................................2

8 Hair Pin ..................................................2

9 Plastic Blade Guard (on blade)......................1

10 Cutter Bar......................................................1

HARDWARE IS APPROXIMATE SIZE SHOWN

Large parts (with

*) shown reduced

10*

Ref. Description Qty.

-- Right Handlebar (shipped connected to

unit by wiring)..............................................1

-- Left Handlebar (shipped connected to

unit by wiring)..............................................1

1 Hex Head Capscrew, 5/16"–18 x 2-1/4" ...........2

2 Toplock Nuts, 5/16"–18 (to mount

handlebars)..................................................2

2a Nylock Nuts, 5/16"–18 .....................................8

3 Handlebar Bridge .............................................1

4 Cable Ties (total of six - two already

installed on unit)..........................................4

5 Hex Head Capscrew, 1/4"–20 x 2" ....................1

6 Locknut, 1/4"....................................................1

7 Control Rod (attached to handlebars)..............2

8 Hair Pin Clip.....................................................2

9 Plastic Blade Guard (on Cutter Bar Assembly) .1

10 Cutter Bar.........................................................1

NOTE: Control rods are attached to one handlebar with a wire tie (see Fig. 2-1). Cut wire tie and remove rods before starting assembly steps.

10*

HARDWARE IS SHOWN APPROXIMATE SIZE

(Large parts [with *] shown reduced size)

8 Section 2: Assembly

11*

15*

Ref. Description Qty.

11 Mounting Bracket (already installed).............1

12 Hex Flange Screw, 3/8"–16 x 1-1/4" long......3

13 Flat Washer, 3/8"...........................................3

14 Centerlock Nut, 3/8"–16................................3

15 Knife Head.....................................................1

16 Metric Hex Head Screw, M8 x M25...............2

17 Metric Internal Tooth Lockwasher, M8 .........2

18 Pitman Arm Assembly ..................................1

19 Shoe Holder..................................................2

20 Carriage Bolt, 5/16"–18 x 1"..........................4

21 Shoe..............................................................2

22 U-Bolt, 5/16" x 18..........................................2

23 Flat Washer, 5/16".........................................4

24 Weed Diverter...............................................1

25 Upper Hook ..................................................1

26 Doubler Plate................................................1

27 Flange Nut 1/4"– 20.......................................2

28 Flat Washer, 1/4"...........................................1

29 Hex Head Screw, 1/4"–20 x 1-1/4" long.........1

30 Battery Charger (optional - not shown).........1

31 Key (In Keyswitch) (optional - not shown)....1

18*

19*

21*

24*

26*

Ref. Description Qty.

11 Loctite®Thread Fastener, (bottle or tube)....1

12 Hex Cap Screw, 3/8"–16 x 1-1/4" (Grade 8) ..3

13 Flat Washer, hardened, 3/8"..........................3

14 Centerlock Nut, 3/8"–16................................3

15 Knife Head.....................................................1

16 Metric Hex Head Screw, M8 x M12...............2

-- Flat Washer, hardened, 5/16" (wire-tied to

knife head (Ref. 15) -- do not remove

until instructed to do so) ..........................2

18 Pitman Arm Assembly ..................................1

19 Shoe Holder..................................................2

20 Carriage Bolt, 5/16"–18 x 1"..........................4

21 Shoe..............................................................2

22 U-Bolt, 5/16" x 18..........................................2

23 Flat Washer, 5/16".........................................5

24 Weed Diverter...............................................1

25 Upper Hook ..................................................1

26 Doubler Plate................................................1

27 Flange Nut 1/4"– 20.......................................2

28 Hex Head Screw, 1/4"–20 x 1-1/4" ...............1

29 Battery Charger (optional - not shown).........1

30 Key (optional - not shown)...........................1

18*

19*

24*

26*

21*

15*

Section 2: Assembly 9

HANDLEBAR INSTALLATION

NOTE: Handlebar wiring from the operator presence controls (OPC) is connected to a switch under the unit. DO NOT disconnect this wiring!

1. Before beginning assembly, disconnect the spark plug wire from the spark plug.

2. Place the handlebars on the ground behind the unit.

3. With the ends of the bridge (C, Fig. 2-2) positioned as shown, insert the bridge in between the handlebars into the upper set of handlebar holes.

4. Align the holes in the plastic sleeves (on the bottom ends of the handlebars) with the corresponding handlebar holes in the deck. For easier installation, apply a small amount of oil to the sleeve ends.

5. Insert the bottom ends of the handlebars into their mounting brackets in the deck (Fig. 2-3). Do not pinch or damage the attached wiring. Align the screw holes (it may be helpful to align the holes with a punch or drift pin prior to installing the screws in the next step).

NOTE: Position the handlebars with thumb latches (F, Fig. 2-5) on the inner sides of handlebars.

6. Secure each handlebar with a 5/16-18 x 2-1/4 hex head capscrew (A, Fig. 2-3) and 5/16"-18 toplock nut (B).

NOTE: When correctly installed, the handlebars feel loose. The looseness or “play”

is intentionally designed to reduce vibration which occurs during operation. The rubber sleeves on the handlebar ends act as “shock absorbers” and also help reduce vibration.

WHEEL DRIVE CONTROL ROD INSTALLATION

1. Place the control rods (D, Fig. 2-4) BETWEEN the handlebars and UNDER the bridge, with the threaded ends down. For easier installation, apply oil or grease to the threads. Thread the rods into the pivots (E) twelve turns each. If necessary, use a screwdriver or a punch to move the pivots into position. Be sure that the wire harness on each handlebar is located to the outside of each control rod.

2. Insert the upper end of each control rod (G, Fig. 2-5) into the plastic thumb latch (F) slots, then outward through the holes in the wheel drive levers (H).

3. Insert hair pin clips (J, Fig. 2-5) through the hole in each control rod. Position hair pin clips with loops up, as shown.

CONTROL ROD ADJUSTMENT

1. With the controls positioned as shown (Fig. 2-6), measure the gap between the top of the slot in the thumb latch bracket and the control rod. Do not put any pressure on the handlebars when measuring. The gap must measure 1-1/4" (32mm).

If adjustment is required, remove the hair pin clip (J, Fig. 2-5) from the control rod. Remove the control rod from the wheel drive lever (H) and thumb latch (F). Turn the control rod as needed to achieve the 1-1/4" (32mm) gap.

NOTE: Adjust the wheel drive control rods properly. Improper adjustment will result in broken thumb latches.

Install hair pins (D) OUTSIDE levers (C)

J on outside with loop up

Fig. 2-2

Fig. 2-3

Fig. 2-4

Fig. 2-5 Outer view of left handlebar

10 Section 2: Assembly

THROTTLE CONTROL LEVER INSTALLATION

1. Unwind the throttle cable from around the left side of the engine, then position the throttle control lever (Z, Fig. 2-7) on the inside of the right handlebar as shown (Figs. 2-7 and 2-8). THE CABLE MUST BE ROUTED UNDERNEATH THE CONTROL ROD (see AA, Fig. 2-8).

2. Secure the throttle control lever to the handlebar with a 1/4–20 x 2" hex-head capscrew (A, Fig. 2-7) and 1/4"-20 locknut (B). TO AVOID DAMAGING PLASTIC ASSEMBLY, DO NOT OVER-TIGHTEN SCREW AND LOCKNUT.

CABLE TIE INSTALLATION

Secure the throttle cable and OPC wiring to the handlebars with cable ties (C, Fig. 2-8) to help prevent them from being damaged during operation. Two of the cable ties are already installed at the upper end of the handlebars. Remove any slack

from the bottom of the OPC wires (see Fig. 2-8A) to avoid catching the cutter bar lever on the wires. Twist the OPC wires (but not the throttle cable) in a corkscrew pattern along the length of the handlebars and install the four cable ties (two on each side). Cut off excess cable tie with scissors.

UNIT REMOVAL

Squeeze the four control levers on the handlebars and carefully roll the unit from off the shipping crate. Park the unit on a flat, clean surface where you can complete the remaining assembly steps.

CUTTER BAR ASSEMBLY AND INSTALLATION

Cutter bar blades are extremely sharp! To help avoid serious injury:

• When handling cutter bar, wear heavy leather gloves and wrap cutter bar with rags.

• Keep plastic guard on blade assembly until you are ready to start engine.

• Contact with the blades will cause serious personal injury.

Avoid contact with the cutter bar blades.

1. Remove the screws securing the cutter

bar to the crate. Wear heavy leather gloves and wrap cutter bar with rags to avoid cutting yourself on the blades.

2. Carefully remove the cutter bar from

the shipping crate. Keep the plastic blade guard on the cutter bar to protect yourself from injury.

IMPORTANT: To help prevent the unit from tipping, have an assistant stand in the operator position and firmly hold the handlebars during installation of the cutter bar.

3. REMOVE SPARK PLUG WIRE FROM

SPARK PLUG (IF ATTACHED).

4. Have an assistant available to hold the

unit firmly by the handlebars.

DANGER

" (32mm)

Gap here

(right side shown)

" (32mm)

Bridge

Fig. 2-6

Fig. 2-7

Fig. 2-8

Fig. 2-8A

Remove

slack in wire

(on both

handlebars).

Section 2: Assembly 11

Disconnect the spark plug wire from the spark plug before attempting to install the cutter bar. Move the spark plug wire away from the spark plug and prevent the wire from contacting the plug.

5. Center eccentric arm (A, Fig. 2-14), if necessary, by moving cutter bar lever to ON (Fig. 2-15) and pulling starter rope.

6. Position the cutter bar (B, Fig. 2-9) at the front of the cutter bar mounting bracket (C) as shown. Place the doubler bracket (D) on the cutter bar and align the three mounting holes as shown.

7. Apply a small amount of Loctite® Thread Fastener (use only a small amount, as a total of five screws need to be coated during the assembly procedure) to the threads of the three 3/8-16 x 1-1/4 hex cap screws (E, Fig. 2-9). Have an assistant hold the unit firmly by the handlebars and raise the front of the unit a few inches off the ground. Securely attach the cutter bar and doubler bracket to the cutter bar mounting bracket with the three hex cap screws (E), 3/8 flat washers (F) and 3/816 center locknuts (G). Torque to 35 ftlbs. if you have a torque wrench. Lower the unit to the ground.

IMPORTANT: Allow the Loctite® to cure for at least one hour (preferably 24 hours at 72oF.) before operating unit.

8. Align the middle hole (B, Fig. 2-10) in the cutter bar with the middle locknut (CC, Fig. 2-10) on the cutter mounting bracket. If needed, tap the ends of the cutting blade back and forth (see inset, Fig. 2-10) to align the middle hole (use a wood block to avoid damaging the blade).

9. Slide the pitman assembly (H, Fig. 210A-1) onto the post of the knife head (I). The “Top” decal on the pitman assembly must be facing up. Remove the two 5/16 hardened flat washers that are wire-tied to the knife head for shipping purposes.

CAUTION

Fig. 2-9

Fig. 2-10

Fig. 2-10A

Tap top section of

cutting blade from

side-to-side to

align middle hole

(B) with middle

locknut (CC).

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