Troybilt 41ADT49C063 Owner’s Manual

TRnV:BILT

m iwm m mmm r®

Operator's Manual

4-Cycle Gasoline

Trimmer / Brushcutter

Model TB490BC

IMPORTANT:READ SAFETY RULES AND INSTRUCTIONS CAREFULLY

NOTE: For users on U,S, Forest Land and in the states of California. Maine, Oregon and Washington. All U.S, Forest Land and the state of California

(Public Resources Codes 4442 and 4443), Oregon and Washington require, by Iaw that certain internal combustion engines operated on forest brush
and/or grass-covered areas be equipped with a spark arrestor, maintained in effective working order, or the engine be constructed, equipped and
maintained for the prevention of fire, Check with your state or local authorities for regulations pertaining to these requirements, Failure to follow these
requirements could subject you to liability or a fine. This unit is factory equipped with a spark arrestor, If it requires replacement, Accessory Part 791-

180890 Spark Arrestor Screen is available by contacting the service department at Troy-Biff LLC, P.O. Box 36t 131 Cleveland, Ohio 44I 36-0019.

TROY-BILT LLC, P.O. BOX 361131, CLEVELAND, OH 44136-0019

P!N 771-10661 (11/01 rev. P00)

PRINTED IN USA

Content Page

Calling Customer Support .................................................... 2

Rules for Safe Operation ..................................................... 3

Know Your Unit ............................................................ 7

Assembly Instructions ....................................................... 8

Oil and Fuel Information ..................................................... 11

Starting/Stepping Instructions ................................................. 13

Operating Instructions ....................................................... 14

Maintenance and Repair Instructions ........................................... 17

Accessories and Replacement Parts ........................................... 24

Cleaning and Storage ....................................................... 25

Troubleshooting Chart ....................................................... 26

Specifications ............................................................. 27

Warranty Information ........................................................ 32

This Operator's Manual is an important part of your new Trimmer/Brushcutter. 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. This information is very important if you need help from our Customer Support

Department or an authorized dealer.

• You can locate the model number by looking at the side of the engine housing. 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

Serial Number Model/Parent Part Number

Copy the model / parent part

number here:

Copy the serial number here:

lllllill!,H%r!l!llL,LtL

If you have difficulty assembIing this product or have any questions regarding the controls, operation or maintenance of this
unit, please call the Customer Support Department.

Call 1- [phone] or 1- [phone] 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.

Thepurposeofsafetysymbolsistoattractyour

attentiontopossibledangers.Thesafety symbols, and

their explanations, deserve your careful attention and

understanding. The safety warnings do not by
themselves eliminate any danger. The instructions or
warnings they give are not substitutes for proper

accident prevention measures.

SYMBOL MEANING

SAFETY ALERT SYMBOL: Indicates

danger, warning, or caution. Attention is
required in order to avoid serious personal

injury. May be used in conjunction with other
symbols or pictographs.

NOTE: Advises you of information or instructions vital

to the operation or maintenance of the equipment.

DANGER: Failure to obey a safety warning

will result in serious injury to yourself or to

others. Always follow the safety precautions
to reduce the risk of fire, electric shock, and

personal injury.

WARNING: Failure to obey a safety warning
can result in injury to yourself and others.

Always follow the safety precautions to
reduce the risk of fire, electric shock, and
personal injury.

CAUTION: Failure to obey a safety warning
may result in property damage or personal

injury to yourself or to others. Always fellow
the safety precautions to reduce the risk of
fire, electric shock, and personal injury.

California Proposition 65 Warning:

READ ALL INSTRUCTIONS

BEFORE OPERATING

• Read the instructions carefully. Be familiar with the
controls and proper use of the unit.

• Do not operate this unit when tired, ill, or under the
influence of alcohol, drugs, or medication.

• Children and teens under the age of 15 must not use

the unit, except for teens guided by an adult.

• Inspect the unit before use. Replace damaged parts.
Check for fue! leaks. Make sure all fasteners are in

place and secure. Replace cutting attachment parts

that are cracked, chipped, or damaged in any way.

Make sure the cutting attachment is properly installed
and securely fastened. Be sure the cutting attachment

shield is properly attached, and positioned as
recommended. Failure to so can result in personal
injury to the operator and bystanders, as well as

damage to the unit.

• Use only 0.105 inch (2.667 mm) diameter genuine

Troy-BiIt LLC replacement line. Never use metal-

reinforced line, wire, or rope, etc. These can break off

and become a dangerous projectile.

• Be aware of the risk of injury to the head, hands and

feet.

• Clear the area to be cut before each use. Remove all
objects such as rocks, broken glass, nails, wire, or

string which can be thrown or become entangled in

the cutting attachment. Clear the area of children,
bystanders, and pets. At a minimum, keep all children,

bystanders and pets outside a 50 feet (15 m) radius;
there sdll may be a risk to bystanders from thrown

objects. Bystanders should be encouraged to wear
eye protection. If you are approached, stop the engine

and cutting attachment immediately.

• Squeeze the throttle control and check that it returns
automatically to the idle position. Make all adjustments
or repairs before using unit.

SAFETY WARNINGS FOR GAS TRIMMERS
WARNING: Gasoline is highly flammable, and its vapors

can explode if ignited. Take the following precautions:

• Store fuel only in containers specifically designed and
approved for the storage of such materials.

• Always stop the engine and allow it to cool before
filling the fue_tank. Never remove the cap of the fuel

tank, or add fuel, when the engine is hot. Never
operate the unit without the fuel cap securely in place.
Loosen the fuel tank cap slowly to relieve any pressure

in the tank.

,, Add fueI in a clean, well-ventilated area outdoors

where there are no sparks or flames. Slowly remove
the fuel cap only after stopping engine. Do not smoke

while fueling or mixing fue!. Wipe up any spilled fuel
from the unit immediately,

• Avoid creating a source of ignition for spilled fuel. Do
not start the engine until fuel vapors dissipate.

• Move the unit at least 30 feet (9.1 m) from the fueling
source and site before starting the engine. Do not
smoke, keep sparks and open flames from the area
while adding fuel or operating the unit.

WHILE OPERATING

• Never start or run the unit inside a closed room or
building. Breathing exhaust fumes can kilt. Operate

this unit only in a well ventilated area outdoors.

• Wear safety glasses or goggles that are marked as
meeting ANSI Z87.1 standards, and ear/hearing

protection when operating this unit. Wear a face or
dust mask if the operation is dusty.

3

• Wear heavy, long pants, boots, gloves and a long
sleeve shirt. Do not wear loose clothing, jewelry, short

pants, sandals or go barefoot. Secure hair above
shoulder level.

• The cutting attachment shield must always be in place
while operating the unit. Do not operate unit without

both trimming lines extended, and the proper line
installed. Do not extend the trimming line beyond the

length of the shield.

• This unit has a clutch. The cutting attachment remains

stationary when the engine is idling. If it does not, have

the unit adjusted by an authorized service technician.

• Adjust the J-Handle to your size to provide the best

grip.

• Be sure the cutting attachment is not in contact with

anything before starting the unit.

• Use the unit only in daylight or good artificial light.

. Avoid accidental starting. Be in the starting position

whenever pulling the starter rope. The operator and
unit must be in a stable position while starting. See
Starting!Stopping Instructions.

• Use the right tool. Only use this tool for the purpose

intended.

• Do not overreach. Always keep proper footing and

balance.

• Always hold the unit with both hands when operating.

Keep a firm grip on both the front and rear handle or

grips.

,, Keep hands, face, and feet at a distance from all

moving parts. Do not touch or try to stop the cutting

attachment when it is rotating.

• Do not touch the engine, gear housing or muffler,
These parts get extremely hot from operation. When

turned off they remain hot for a short time.

• Do not operate the engine faster than the speed

needed to cut, trim or edge. Do not run the engine at
high speed when not cutting.

• Always stop the engine when cutting is delayed or

when walking from one cutting location to another.

• If you strike or become entangled with a foreign

object, stop the engine immediately and check for
damage. Do not operate before repairing damage. Do

not operate the unit with loose or damaged parts.

• Stop and switch the engine to off for maintenance,

repair, or for changing the cutting attachment or other
attachments.

• Use only genuine manufacturer's replacement parts

and accessories for this unit. These are available from
your authorized service dealer. Use of any non Troy-

Bilt LLC parts or accessories could lead to serious

injury to the user, or damage to the unit, and void your
warranty.

• Keep unit clean of vegetation and other materials.

They may become lodged between the cutting
attachment and shield.

• To reduce fire hazard, replace faulty muffler and spark
arrestor, keep the engine and muffler free from grass,

leaves, excessive grease or carbon build up.

WHILE OPERATING WITH CUTTING BLADE

• Read and understand all safety warnings before
operating this unit.

• Always use the shoulder harness when using the
brush blade accessory.

• Keep the J-handle between the operator and cutting
attachment or blade at all times.

• NEVER cut with the cutting blade located over 30
inches (76 cm) or more above the ground level.

• Blade thrust may occur when the spinning blade
contacts an object that it does not immediately cut.
Blade thrust can be violent enough to cause the unit

and/or operator to be propelled in any direction, and
possibly lose control of the unit. Blade thrust can

occur without warning if the blade snags, stalls or
binds. This is more likely to occur in areas where it is
difficult to see the material being cut.

• For operation with the brush blade, do not cut
anything thicker than 1/2 inch or a violent kickback

could occur.

• Do not attempt to touch or stop the blade when it is
rotating.

A coasting blade can cause injury while it continues to
spin after the engine is stopped or the throttle trigger

is released. Maintain proper control until the blade has

completely stopped rotating.

• Do not run the unit at high speed when not cutting,

• If you strike or become entangled with a foreign
object, stop the engine immediately and check for

damage. Have any damage repaired before attempting

further operations. De not operate unit with a bent,

cracked or dull blade. Discard blades that are bent,

warped, cracked or broken.

• Do not sharpen the cutting blade. Sharpening the

blade can cause the blade tip to break off while in use.

This can result in severe personal injury. Replace the

blade.

• Do not use the cutting blade for edging or as an

edger, severe personal injury to yourself or others can
occur. Use the cutting blade only for the purpose as

described in this manual.

• Stop the engine IMMEDIATELY if you feel excessive

vibration. Vibration is a sign of trouble. Inspect
thoroughly for loose nuts, bolts or damage before
continuing. Repair or replace affected parts as

necessary.

AFTER USE

• Clean cutting blades with a household cleaner to

remove any gum buildup. Oil the blade with machine

oil to prevent rust.

• Lock up and store the cutting blade in an appropriate

area to protect the blade from unauthorized use or
damage.

OTHER SAFETY WARNINGS

• Never store the unit, with fuel in the tank, inside a
building where fumes may reach an open flame or

spark.

• Allow the engine to cool before storing or transporting.
Be sure to secure the unit while transporting.

• Store the unit in a dry area, locked up or up high

to prevent unauthorized use or damage, out of the

reach of children.

SAFETY AND INTERNATIONAL SYMBOLS
This operator's manual describes safety and international symbols and pictographs that may appear on this product.

Read the operator's manual for complete safety, assembly, operating and maintenance and repair information.

SYMBOL MEANING

• SAFETY ALERT SYMBOL
Indicates danger, warning, or caution, May be used in conjunction with other

symbols or pictographs.

• WARNING - READ OPERATOR'S MANUAL

Read the Operator's Manual(s) and follow all warnings and safety instructions.
Failure to do so can result in serious injury to the operator and/or bystanders.

• Never douse or squirt the unit with water or any other
liquid. Keep handles dry, clean and free from debris.

Clean after each use, see Cleaning and Storage
instructions.

• Keep these instructions. Refer to them often and use

them to instruct other users. If you loan someone this
unit, also loan them these instructions+

SAVE THESE INSTRUCTIONS

i

e

5-7x

• FOR SERVICE INFORMATION, CALL:
1-866-840-6483 or

1-330-558-7220

• WEAR EYE AND HEARING PROTECTION

WARNING: Thrown objects and loud noise can cause severe eye injury and hearing loss.

Wear eye protection meeting ANSI Z87.1 standards and ear protection when
operating this unit.

• KEEP BYSTANDERS AWAY

WARNING: Keep all bystanders, especially children and pets, at least 50 feet (15 m)

from the operating area.

• PRIMER BULB
Push primer bulb, fully and slowly, 5 to 7 times.

• UNLEADED FUEL

Always use clean, fresh unleaded fue!.

5

SYMBOL MEANING

• OIL

Refer to operator's manual for the proper type of oil.

* THROWN OBJECTS AND ROTATING CUTTER CAN CAUSE SEVERE INJURY

WARNING: Do not operate without the cutting attachment shield in place,

Keep away from the rotating cutting attachment.

• ON/OFF STOP CONTROL

ON / START / RUN

• ON/OFF STOP CONTROL

OFF OR STOP

• HOT SURFACE WARNING
Do not touch a hot muffler, gear housing or cylinder. You may get burned. These parts get

extremely hot from operation. When turned off they remain hot for a short time.

• SHARP BLADE

WARNING: Sharp blade on cutting attachment shield. To prevent serious injury, do not

touch line cutting blade.

A B C

I+1I'qI+1

• CHOKE CONTROL
A ° FULL choke position.

B • PARTIAL choke position.
C ° RUN position,

• BRUSHCUTTERS • Replace dull blade.

Do not sharpen the cutting blade. Sharpening the blade can cause the blade tip to

break off while in use. This can result in severe personal injury.

• TRIMMER/BRUSHCUTTER SAFETY
WARNING: Thrown objects and rotating cutter can cause severe injury. Keep bystanders,

especially children and pets, at least 50 feet (15 m.) away from the cutting area. The cutting
attachment shield must be used when using the trimmer cutting attachment.

WARNING: The operation of any power tool can cause foreign objects to be thrown into your

eyes. This can lead to severe eye damage. Before commencing power tool operation, always
wear safety glasses or goggles that are marked as meeting ANSI Z87.1 standards, and a full

face shield when needed+

APPLICATIONS

AS a trimmer:

• CuRing gross and light weeds.

• Edging.

• Decorative trimming around trees, fences, etc.

AS a brushcu_er;

• Cutting weeds and light bush of up to 1/2 inch in

diameter.

Other optional accessories may be used with the
TB490BC. See list of add-ons on page 14,

On/Off Stop

Shoulder Strap Clip

Spark Arrestor

•=p---Spark Plug

Muffler Guard -->

Fuel Cap

Starter Rope

Shaft Grip

Throt'de

Throttle

Control

Brush
Blade

Gear Housing

Blade Shield /

Shield Mount

EZ-Unk TM

Shaft

Housing

Cutting Attachment

Shield

/

Air Filter Cover

\

Engine Feet

J-Handle

Choke Lever

Spark Plug

Oil Fill Plug / Dipstick

Cutting Attachment

Line Cuffing Blade

7

INSTALLINGANDADJUSTINGTHEJ-HANDLE

1. Place the J-handle between the top and middle
clamp pieces (Fig. 1).

J-Handle

(4)

6, While holding the unit in the operating position

(Fig. 3), position the J-handle to the location
that provides you the best grip.

7. Tighten the clamp screws evenly, until the J-handle

is secure.

INSTALLING THE HARNESS

Top Clamp

Middle Clamp

Bottom Clamp

Nuts

Fig, 1 .....................................

2. While holding the three pieces together, install the

four (4) screws through the top clamp and into
middle clamp.

NOTE: The holes in the top and middle clamp will tine up

only when assembled correctly.

3. Place the clamps and J-handle the over the shaft
housing and onto the bottom clamp.

4. Hold each hex nutin the bottom clamp recess with a

finger. Start screws with a large Phillips screwdriver.

Do not tighten until you make the handle adjustment.

5. Slide the J-handle in or out until the arrow/white line
on the decal touches the clamp assembly (Fig. 2).

IA WARNING: Always use the shoulder harness

personalwhenus nginjury.thecutt ng bade to avo d ser cue

1. Push the strap through the center of the buckle.

2. Pull the strap over the cross bar and down through
the slot in the buckle (Fig. 4).

\

\

Fig,4 ................................

3. Put the harness on over head and onto shoulder.
Snap it on to the support fitting (Fig. 5).

Support Fitting

\

S

Fig. 3

Fig, 5

4. Adjust length to fit the operator's size. Pull tab to

lengthen, pull strap to shorten (Fig 6).

#

\

Fig. 6

REMOVING AND INSTALLING CUTTING

ATTACHMENT SHIELD

Remove the cutting attachment shield when using

the unit as a brushcutter.

WARNING: The cutting attachment shield I

should NOT be installed when operating the

unit with a blade. Remove the cutting

attachment shield before removing or

installing the blade.

Remove the cutting attachment shield from the shield
mount by removing the three (3) screws with a flat blade

screwdriver (Fig. 7). Store parts for future use.

OutputShaft

I

j OutputSh

• _ | Bushing

Locking Rod i _ _dl_m_mmm.__

Cutting

Attachment

Shield

Shield Mount

............ Fig. 7

Install the cutting attachment shield when using the

unit as a grass trimmer.

WARNING: To avoid serious personal injury,
the cutting attachment shield SHALL be in

place at all times while operating the unit as
a grass trimmer.

Install the cutting attachment shield on the shield mount
by inserting the three (3) screws into the shield mount.

Tighten securely with a flat blade screwdriver (Fig. 7).

REMOVE THE CUTTING ATTACHMENT AND
INSTALL THE CUTTING BLADE

NOTE: To make removing or installing the cutting blade

or cutting attachment easier, place the unit on

the ground or on a work bench.

Remove the Cutting Attachment Shield

See Removing and Installing Cutting Attachment Shield,.

Remove the Cutting Attachment

WARNING: The gear housing gets hot with

use and can result in injury to the operator.

When the unit is turned off it remains hot for
a short time. Do not touch the gear housing

until it has cooled.

1. Align the shaft bushing hole with the locking rod slot
and insert the locking rod into the shaft bushing hole
(Fig. 8).

Screws

Gear Housing

........ Fig, 8

2. Hold the locking rod in place by grasping it next to
the boom of the unit (Fig. 9).

3, While holding the locking rod, remove the cutting

attachment by turning it clockwise off of the output
shaft (Fig. 10). Store the cutting attachment for future

use.

NOTE: The blade retainer under the cutting attachment

wil! be used when installing the cutting blade.

Fig. g .......

Cutting Attachment

Locking Rod

Slot

r

Locking Rod

....... Fig. 10

9

Install the Cutting Blade

WARNING: To avoid serious personal injury,
always wear gloves while handling or

installing the blade.

4. Place the cutting blade on the output shaft bushing
(Fig. 11).

5. Make sure that the cutting blade is centered on the

pilot step and sitting flat against the output shaft
bushing (Fig. 12).

WARNING: If the cutting blade is oft-center,
the unit will vibrate, and the blade may fly
off, which can cause serious personal injury.

Blade Retainer

Pilot Hole

Nut

Cutting

Blade

Shield
Mount

I

6. Align the shaft bushing hole with the locking rod
slot and insert the locking rod into the bushing hole

(Fig. 8, Pg. 9).

7. Put the blade retainer and nut on the output shaft.
Make sure that the blade is installed correctly.

8. Tighten nut counterclockwise against the blade while
holding the locking rod. (Fig. 13)

• If using a torque wrench and an 5/8 inch socket tighten
to: 325 - 335 inolb, 27 - 28 ft.-Ib, 37 - 38 Nora.

• Without a torque wrench, use a 5/8 inch closed-end or
socket wrench, turning the nut until the blade retainer

issnug against the shaft bushing. Make sure that the
blade is installed correctly, then rotate the nut an

additional 1/4 to 1/2 turn counterclockwise (Fig. 13).

9, Remove the locking rod from the locking rod slot.

WARNING: To avoid serious personal injury I

or damage to the unit, do not start or
operate this unit with the locking rod in the

locking rod slot.

I

Output Shaft

Bushing

Locking Rod __--

Fig. 11 .............

Pilot Step

Fig. 12 ..............

Sharpening the blade can cause the blade tip I

l,_ WARNING: Do not sharpen the cutting blade. I

REMOVE THE CUTTING BLADE AND INSTALL

THE CUTTING ATTACHMENT

Remove the Cutting Blade

[,_ ARNING: To avoid serious personal injury,

1, Align the shaft bushing hole with the locking rod

2. Hold the locking rod in place by grasping it next to

to break off while in use. This can result in
severe personal injury. Rep ace the bade.

always wear gloves while handling or

installing the blade.

slot and insert the locking rod into the bushing hole
(Fig, 8, Pg. 9).

the boom of the unit (Fig. 14).

1/4-1/2 turn

Counterclockwise

10

Clockwise

Fig. 13 ...... Fig. !4

3. While holding the locking rod, loosen the nut on
the blade by turning it clockwise with a 5/8 inch

closed-end or socket wrench (Fig. 14).

4. Remove the nut, blade retainer, and blade. Store the

nut and blade together for future use in a secure
place. Store out of reach of children.

Install the Cutting Attachment

5. Align the shaft bushing hole with the locking rod slot
and insert the locking rod into the shaft bushing hole.
(Fig. 8, Pg. 9). Place the blade retainer on the output
shaft with the flat surface against the output shaft
bushing as shown in Fig. 15. Screw the cutting

attachment counterclockwise onto the output shaft.
Tighten securely.

NOTE: The blade retainer must be installed on the

output shaft in the position shown for the cutting
attachment to work correctly.

6. Remove the locking rod,

7. Install the cutting attachment shield. See Removing
and Installing Cutting Attachment Shield, Pg. 9.

Cutting Attachment

\

Blade Retainer

Output Shaft

Bushing

Locking Rod

......... Fig. 15 .....

WARNING: To avoid serious personal injury,

the cutting attachment shield SHALL be in

place at all times while operating the unit as

a grass trimmer.

DANGER: OVERFILLING OIL CRANKCASE
MAY CAUSE SERIOUS PERSONAL INJURY!

The importance of checking and maintaining

the proper oil level in the crank case cannot

be overemphasized. Check oil before each
use and change as needed. See Changing

the Oil.

RECOMMENDED OIL TYPE

_ Using the proper type and weight of oil in the

crankcase is extremely important. Check the
oil before each use and change the oil
regularly. Failure to use the correct oil, or

using dirty oil, can cause premature engine wear and

failure.

Use a high-quality SAE 30 weight oil of API (American
Petroleum Institute) service class SF, SG, SH.

ADDING OIL TO CRANKCASE - INITIAL USE
NOTE: This unit is shipped without being filled with oil tn

order to avoid damage to the unit, put oil in the
crankcase before attempting to start unit.

Your unit is supplied with one 3.4 fluid oz. (100 ml.)
bottle of SAE 30 SF, SG, SH oil (Fig. 16).

NOTE: Save the bottle to measure the correct amount

for future oil changes. See Changing the Oil.

1. Unscrew the top of the bottle of oil and remove the
paper seal covering the opening. Replace top. Cut

the tip off the funnel spout (Fig. 16).

2. Place the unit on a flat level surface.

3. Remove the oil plug / dipstick from the crankcase
(Fig. 17).

........ Fig. 16 ........

O-Ring

Oil Fill

Oil Fill Hole

..... Fig, 17 ........

11

4. Pour the entire bottle of oil into the oil fill hole

(Fig, 18),

FUELING UNIT

and its vapors can explode if ignited. To
avoid serious personal injury, always stop the

engine and allow it to cool before filling the

I4_ ARNING: Gasoline is extremely flammable

fuel tank. Do not smoke while filling the tank.

Keep sparks and open flames away from the

area.

1. Remove fuel cap (Fig. 19).

J

Oil F

LJ

...... Fig.18 ..........

NOTE: Never add oil to the fuel or fuel tank.

5. Wipe up any oil that may have spilled and reinstall
the oiI fill plug / dipstick.

RECOMMENDED FUEL TYPE

Old fuel is the primary reason for the unit not running

properly. Be sure to use fresh, clean, unleaded Gasoline.

NOTE: This is a four cycle engine. In order to

avoid damage to the unit, do not mix oil with

Gasoline.

Definition of Blended Fuels

Today's fuels are often a blend of gasoline and

oxygenates such as ethanol, methanol or MTBE (ether).
Alcohol-blended fuel absorbs water. As littleas t %

water in the fuel can make fuel and oil separate orform
acids when stored. Use fresh fuel (less than 60 days

old), when using alcohol-blended fuel.
Using Blended Fuels

If you choose to use a blended fuel, or its use is

unavoidable, follow recommended precautions.

• Always use fresh unleaded gasoline

• Use the fuel additive STA-BIL ® or an equivalent.

• Drain tank and run the engine dry before storing unit.

Using Fuel Additives

The use of fuel additives, such as STA-BIL ® Gas

Stabilizer or an equivalent, will inhibit corrosion and
minimize the formation of gum deposits. Using a fuel

additive can keep fueI from forming harmful deposits in
the carburetor for up to six (6) months. Add 0.8 oz.
(23 mL) of fuel additive per gallon of fuel according to the

instructions on the container. NEVER add fuel additives
directly to the unit's gas tank.

_ WARNING: Remove fuel cap slowly to avoid

njury from gaso ne spray.

Gas Can S _r_

FuelCap _ Fuel Tank

Fig. 19 ....

2. Place spout of gas container into the fill hole on the
fuel tank (Fig. 19) and fill tank,

ventilated area outdoors. Avoid creating a

[_lb WARNING: Add gasoline in a clean, well

source of ignition for spilt fuel.

NOTE: Do not overfill tank.

3. Wipe up any gasoline that may have spilled

4. Reinstallthe fuel cap.

WARNING: Never operate the unit without
the fuel cap securely in place.

5. Move the unit at least 30 ft. (9.1 m) from the fueling
source and site before starting the engine.

NOTE: Dispose of the old gasoline in accordance to

Federal, State, and Local regulations.

12

STARTING INSTRUCTIONS
Cold Start - First Start of the Day or Engine Ran Out

of Fuel

WARNING: Operate this unit only in a well

ventilated area outdoors. Carbon monoxide
exhaust fumes can be lethal in a confined

area.

1. Check oil level in crankcase. See Checking the Oil
LevelPg. 19.

2. Fill the fuel tank with fresh, clean, unleaded gasoline
(see page 12).

3. Put the Start/Stop Engine Control in the START [I]
position (Fig. 20).

9. PulI the starter rope 1 to 3 pulis until the engine
starts. Run for 15-30 seconds, if the unit fails to start

return to step 7.

10. Move the choke lever to the RUN (C) I{ I position and
run at full throttle for 30 seconds.

WARNING: Avoid accidental starting. Be in I
the starting position whenever pulling the

starting rope. To avoid serious personal
injury, the operator and unit must be in a
stable position while starting.

J

Stop Control

START {1)

....... Fig. 20

4. Place the choke lever in the FULL choke (A) H
position (Fig. 21)•

NOTE: Slide the choke lever directly above the

appropriate symbol on air filter cover decal
(Fig. 2!).

5,

Fully press and release the primer bulb slowly 7

times. Gasoline should be felt and visible in the bulb
(Fig. 21). If gasoline has not entered the bulb, press

three more times, or until it does.

Choke Lever

Primer Bulb

Fig. 21 .......

6. While pressing the throttle lock-out, squeeze the
throttle control to the wide open (full throttle)

position (Fig. 20).

7. With the unit in the starting position (Fig. 21) pull the
starter rope briskly 5 times in the FULL choke (A)H

position. If the engine attempts to run before the
fifth pull, proceed to step 8.

8. Move the choke lever to the PARTIAL (B) I'*'l position
(Fig. 21).

NOTE: The engine will not run in the FULL choke (A)_-I

position.

Starter Rope

Throttle Control

............... Fig,22 .......

11. Release the throttle control to the idle position and
begin operation.

NOTE: If the engine does not start using these

procedures, repeat steps 5 through 11 using

TWO (2) pulls in the FULL choke (A) H position.

Engine Re-Start - Warm Engine With Fuel

1. Put the Start/Stop Engine Control in the START [I]
position (Fig. 20).

2, Move the choke lever to the PARTIAL (B) I*'-Iposition

(Fig. 21).

3, Fully press and release the primer bulb slowly 7

times, Gasoline should be felt and visible in the bulb

(Fig. 21). If gasoline has not entered the bulb, press
three more times, or until it does.

4. While pressing the throttIe lock-out, squeeze the
throttle control to the wide open (full throttle)

position (Fig. 20).

5. With the unit in the starting position (Fig. 22), pull the
starter rope briskly until the engine starts.

6. When the engine starts, move the choke lever to the
RUN (C) I {I position, and run at full throttle for 30

seconds.

NOTE: if the engine does not start using the Engine

Re-start procedures, revert to the Cold Start

procedures.

NOTE: 4-stroke engines, like cars, are able to start in

the idle position. As an alternate method, you
may want to start your unit in the idle position

when the unit is warm. With the Start/Stop
control in the START position, puii the starter
rope briskly. When the engine starts, run at full

throttle for 30 seconds, if the unit fails to start or
dies, revert to the Engine Re-Start procedure.

13

STOPPINGINSTRUCTIONS

1. Release your hand from the throttle control (Fig. 22).
Allow the engine to idle.

2. To stop the engine, put the Start!Stop Engine
Control in the STOP [O] position (Fig. 20).

OPERATING THE EZ-LINK TM SYSTEM
The EZ-LInk TM system enables the use of these

optional add-ons.

Blower/Vacuum .......................... BV720r

Cultivator ............................... GC720r

Edger .................................. LE720r

Hedge Trimmer .......................... HS720r

Snow Thrower ........................... ST720r

Straight Shaft Trimmer ..................... SS725r

Sweeper/Blower .......................... SB720r

Tree Pruner .............................. TP720r

Turbo Blower ............................ TB720r

WARNING: Read and understand operator's I

manual for add-on prior to operation.

Removing the Cutting Attachment or Add-Ons:

1. Turn the knob counterclockwise to loosen (Fig. 23).

2. Press and hoId the release button (Fig. 23).
3, While firmly holding the upper shaft housing, pull

the cutting attachment or add-on straight out of the

EZ-LInk TM coupler (Fig, 24).

Installing the Cutting Attachment or Add-Ons:

l_hL ARNING: TO avoid serious personal injury

NOTE: To make installing or removing the add-on easier,

1. Turn knob countercIockwise to loosen (Fig. 23).

and damage to the unit, shut unit off before
removing or installing add-ons.

place the unit on the ground or on a work bench.

EZ-Link TM Coupler

Release Button

I

2. While firmly holding the add-on, push it straight into
the EZ-Link TM coupler (Fig. 24).

NOTE: Aligning the release button with the guide recess

will help instalIation (Fig. 23).

EZ-LinkTM Coupler

"_'_s_ Primary Hole

Release Button

\-

UpperShaft Housing Lower Shaft Housing

........ Fig. 24

3. Turn the knob clockwise to tighten (Fig. 25).

,_ CAUTION: Lock the release button in the I

90°EdgingHole _'-J_

(Trimmer only)'_ \

.... Fig. 25 ........

primary hole and securely tighten the knob
before operating this unit.

Hole

(Trimmer only)

!

L<___Knob

J

CAUTION: The cutting attachment and
add-ons with the EZ-LInk TM system are to be

used in the primary hole unless stated

otherwise in the specific add-ons operator's

manuaI, Using the wrong hole could lead to
personal injury, or damage to the unit.

I

I

14

Guide Recess

.... Fig. 23 .........

Foredging when using the line head cutting attachment

with EZ-Link TM modeIs, lock the release button of the

cutting attachment into the 90° edging hole or the 180 °
edging hole (Fig. 25).

_ll ARNING: Do not use the cutting blade for I

edging or as an edger, severe personal injury
to yourse f or ethers can occur.

I

I

HOLDING THE TRIMMER

WARNING: Always wear eye, hearing, foot, I

body protection and strap to reduce the risk
of injury when operating this unit.

Before operating the unit, stand in the operating position

(Fig. 26), Check for the following:

• The operator is wearing eye protection and proper
clothing.

• The right arm is slightly bent, and the hand is holding
the shaft grip.

• The left arm is straight, and the hand is holding the
J-handle,

• The unit is at waist level.

• The cutting attachment is parallel to the ground and
easily contacts the vegetation to be cut without the

operator having to bend over.

........... Fig. 26

ADJUSTING TRIMMING LINE LENGTH

The Bump HeadTM cutting attachment allows you to

release trimming line without stopping the engine. To

release more line, lightly tap the cutting attachment on
the ground (Fig. 27) while operating the trimmer at high
speed.

NOTE: Always keep the trimming line fully extended.

Line release becomes more difficult as cutting

line becomes shorter

\

I

Each time the head is bumped, about 1 inch (25.4 mm,)

of trimming line is released. A blade in the cutting
attachment shield will cut the line to the proper length if

excess line is released.
For best results, tap the Bump Head TM on bare ground

or hard soil. If line release is attempted in tall grass, the
engine may stall. Always keep the trimming line fully

extended. Line release becomes more difficult as the
cutting line becomes shorter.

NOTE: Do not rest the Bump Head TM on the ground

while the unit is running.

CAUTION: Do not remove or alter the line
cutting blade assembly. Excessive line length I

will make the clutch overheat. This may lead I
to serious personal in ury or damage to the

unt.

Some line breakage will occur from:

• Entanglement with foreign matter

• Normal line fatigue

- Attempting to cut thick, stalky weeds

• Forcing the line into objects such as walls or fence
posts

TIPS FOR BEST TRIMMING RESULTS

• Keep the cutting attachment parallel to the ground.

• Do not force the cutting attachment. Allow the tip of
the line to do the cutting, especially along walls.
Cutting with more than the tip will reduce cutting

efficiency and may overload the engine.

• Cut grass over 8 inches (200 mm) by working from

top to bottom in small increments to avoid

premature line wear or engine drag.

• Cut from left to right whenever possible. Cutting to

the right improves the unit's cutting efficiency.
Clippings are thrown away from the operator.

• Slowly move the trimmer into and out of the cutting

area at the desired height. Move either in a forward-

backward or side-to-side motion. Cutting shorter
lengths produces the best results.

• Trim only when grass and weeds are dry.

• The life of your cutting line is dependent upon;

• Following the previous trimming techniques

• What vegetation is being cut

• Where it's being cut

For example, the line will wear faster when trimming

against a foundation wall as opposed to trimming
around a tree.

............. Fig. 27 ...........

15

DECORATIVE TRIMMING

Decorative trimming is accomplished by removing all
vegetation around trees, posts, fences, etc.

Rotate the whole unit so that the cutting attachment is at
a 30° angle to the ground (Fig. 28).

........ Fig. 28 ......

USING THE CUTTING BLADE

WARNING: Always wear eye, hearing, foot, I

body protection and the strap to reduce the

WARNING: Do not use the cutting blade for
edging or as an edger, severe personal injury

to yourself or others can occur. I

Before operating the unit with the cutting blade stand in
the operating position (Fig. 29).

Cutting Blade Operating Tips:

To establish a rhythmic cutting procedure:

• Plant feet firmly, comfortably apart.

• Bring the engine to full throttle before entering the
material to be cut. The blade has maximum cutting

power at full throttle and is less likely to bind, stall, or
cause blade thrust, which can result in serious

personal injury to the operator or others.

WARNING: The blade continues to spin after!
the engine is turned off. The coasting blade

can seriously cut you if accidentally touched.

• Swing the unit inthe same direction as the blade
spins, which increases the cutting action.

• Move forward to the next area to be cut after the

return swing and plant feet again.

•' The cutting blade is designed with a second cutting
edge, which can be used by removing the blade,
turning it upside down, and reinstalling it.

WARNING: Do not sharpen the cutting

blade. Sharpening the blade can cause the
blade tip to break off while in use. This can
result in severe personal injury to yourself or

others. Replace the blade.

To reduce the chance of material wrapping around the
blade, follow these steps:

• Cut at full throttle.

• Swing the unit into material to be cut from your right to

your left (Fig. 30).

• Avoid the material just cut as you make the return

Irisk of injury when operating this unit.

swing.

WARNING: De not clear away cut material
with the engine running or blade turning. To
avoid serious personal injury, turn off engine.

Allow the blade to stop before removing
materials wrapped around the blade shaft.

i

WARNING: Blade thrust may occur when the

spinning blade contacts an object that it

does not immediately cut. Blade thrust can
be violent enough to cause the unit and/or

operator to be propelled in any direction, and
possibly lose control of the unit. Blade thrust
can occur without warning if the blade snags,
stalls or binds. This is more likely to occur in

areas where it is difficult to see the material
being cut.

• Cut while swinging the upper part of your body from
right to left.

• Always release the throttle trigger and allow the engine
to return to idle speed when not cutting.

', When done always unsnap unit from harness before

taking harness off.

16

........ Fig. 29

NOTE: Some maintenance procedures may require

special tools or skills. If you are unsure about
these procedures take your unit to an authorized

service dealer.

MAINTENANCE SCHEDULE

These required maintenance procedures should be
performed at the frequency stated in the table. They
should also be included as part of any seasonal tune-up.

FREQUENCY MAINTENANCE REQUIRED REFER TO:

Before Starting Engine Fill fuel tank with fresh fuel Page 12

Check oil Page 19
Every 10 Hours Clean and re-oil air filter. Page 21
1st Change at 10 Hours Change oil Page 19

Every 25 Hours there after Change oil Page 19
Every 25 Hours Clean Spark Arrestor Page 24

10 hours on new engine Check rocker arm to valve clearance and adjust as required Page 23
Every 25 Hours Check rocker arm to valve clearance and adjust as required Page 23

Every 25 Hours Check spark plug condition and gap Page 24

LINE INSTALLATION 4. Use a clean cloth to clean the the inner reel, spring,
This section covers both SpIitLine TM and standard single

line installation.
Always use geniune Troy-Bilt TM 0.105 in. (2.667 mm)

replacement line. Line other than specified may make the
engine overheat or fail.

WARNING: Never use metal-reinforced line, I
wire, chain, or rope, etc. These can break off

and become dangerous projectiles.

I

r

5. Check the indexing teeth on the inner reel and outer

WARNING: To prevent serious injury, never
do maintenance or repairs with unit running.

Always do maintenance and repairs on a
cool unit. Disconnect spark plug wire to

ensure the unit will not start.

shaft, and inner surface of the outer spool (Fig. 32).

spool for wear (Fig. 33). If necessary, remove burrs or
replace the reel and spool.

There are two methods to replace the trimming line.

• Wind the inner reel with new line

• Install a prewourtd inner reel

Winding the Existing Inner Reel

1. Hold the outer spool with one hand and unscrew the
Bump Knob clockwise (Fig. 31). Inspect the bolt

inside the bump knob to make sure it moves freely.
Replace the bump knob if damaged.

2. Remove the inner reel from the outer spool (Fig. 31).

3. Remove spring from the inner reel (Fig. 31).

Spring

Inner Reel _-

Bump Knob _

Fig. 31 ..............

Bolt

Fig. 32

Indexing Teeth

- Fig. 33

NOTE: SplitLine TM can only be used with the inner reel

with the slotted holes. Single line can be used on
either type of inner ree!. Use Figure 30 to identify

the inner reel you have.

NOTE: Always use the correct line length when installing

trimming line on the unit. The line may not

release properly if the line istoo long.

17

ForUsewithSingle

LineONLY

Slotted _

Holes

Fig. 34

ForUsewithSplitLineTM

or Single Line

Single Line Installation
Go To Step 8 for SplitLine TM Installation

6. Take approximately 30 feet (9.14 m/ of new trimming

line, loop it into two equal lengths, Insert each end of
the line through one of the two holes in the inner reel
(Fig. 35). Pull the line through the inner reel so that
the loop is as small as possible.

/

Fig. 35 .........

7. Wind the lines intight even layers, onto the reel
(Fig. 36). Wind the line in the direction indicated on
the inner reel. Place your index finger between the
two lines to stop the lines from overlapping. Do not
overlap the ends of the line. Proceed to step 11.

Loop

Fig. 37

10. Before winding, split the line back about 6 inches.

11. Wind the line in tight even layers in the direction
indicated on the inner reel.

NOTE: Failure to wind the line in the direction indicated

wilt cause the cutting attachment to operate

incorrectly.

12. Insert the ends of the line into the two holding slots
(Fig. 38).

13. Insert the ends of the line through the eyelets in the
outer spool and place inner reel with spring inside the

outer spool (Fig. 39), Push the inner reel and outer
spool together. While holding the inner reel and outer
spool, grasp the ends and pull firmly to release the
line from the holding slots in the reel.

NOTE: The spring must be assembled on the inner reel

before reassembling the cutting attachment.

14. Hold the inner reel in place and installthe bump knob
by turning counterclockwise, Tighten securely.

Fig. 36 ......

SplitLine TM Installation

8. Take approximately 15 feet (4,57 m) of new trimming
line. Insert one end of the line through one of the two

holes in the inner reel (Fig. 37). Pull the line through
the inner reel until only about 4 inches is left out.

9. Insert the end of the line into the open hole in the

inner reel and pull the linetight to make the loop as

small as possible (Fig. 37).

18

Holding Slots

...... Fig. 38 ......

Fig. 39 .................

INSTALLING A PREWOUND REEL

1. Hold the outer spool with one hand and unscrew the
bump knob clockwise (Fig. 15, Pg. 11). Inspect the
bolt inside the bump knob to make sure it moves

freely. Replace the bump knob if damaged.

2. Remove the old inner reel from the outer spool
(Fig. 31),

3. Remove the spring from the old inner reel

(Fig. 31),
4, Place the spring in the new inner reel.
NOTE: The spring must be assembled on the inner reel

before reassembling the cutting attachment.

5. Insert the ends of the line through the eyelets in the

outer spool (Fig. 39, Pg. 18),

6. Place the new inner reel inside the outer spool. Push

the inner reel and outer spool together. While holding

the inner reeI and outer spool, grasp the ends and

pull firmly to release the line from the holding slots in

the spool.

7. Hold the inner reel in place and installthe bump knob
by turning counterclockwise. Tighten securely, Fig, 41

Replacement Parts: plug/dipstick when checking and changing the

See Accessories / Replacement Parts. oil (Fig. 42).

5, Remove the oil fill plug/dipstick and check oil level,

Oil should be up to the top of the dipstick (Fig. 40).

6. If the level is low, add a small amount of oil to the oil
fill hole and recheck (Fig, 41), Repeat until the oil level

reaches the top of the dipstick.

NOTE: Do not overfill the unit.

Oil Fill Hole

NOTE: Make sure the O-ring is in place on the oil fill

CHECKING THE OIL LEVEL I _I_ DANGER: OVERFILLING OIL CRANKCASE

and damage to the unit, always maintain the the proper oil level in the crank case cannot

I_k CAUTION: To prevent extensive engine wear { The importance of checking and maintaining

The importance of checking and maintaining the proper
oil level in the crankcase cannot be overemphasized.

Check oil before each use:

1. Stop engine and allow oit to drain into the crankcase,

2. Place the unit on a flat, level surface to get a proper

3. Keep dirt, grass clippings, etc., cut of the engine.

4. Remove the oil fill plug/dipstick and wipe off oil.

proper oil level in the crankcase, Never be overemphasized, Check oil before each

bottom°perateofthetheUnitdipstick.Withthe 0 eve be ow the theUseOil.andchange as needed. See Changing

oil level reading,

Clean the area around the oil fill plug/dipstick before
removing it.

Reinsert it all the way back in.

I_k MAY CAUSE SERIOUS PERSONAL INJURY!

L

Fig. 42

Full _

Add 1.4-1.5 Oz.

141-44 ml)

Top of Dipstick

Fig. 40

19

CHANGING THE OIL

For a new engine, change the oil after the first 10 hours
of operation. Change the oil while the engine is still
warm. The oil will flow freely and carry away more

impurities.

4. Wipe up any oil residue on the unit and clean up any
oil that may have spilled. Dispose of the oil

according to Federal, State and local regulations.

5. Refill the crankcase with 3.4 fluid ounce (100 ml) of
SAE 30 SF, SG, SH oil.

_k AUTION: Wear gloves to prevent injury

1. Unplug spark plug boot to eliminate starting

2. Remove the oil fill plug/dipstick.

3. Pour the oil out of the oil fill hole and into a container

when handling the unit.

by tipping the unit to a vertical position (Fig. 43).
Allow ample time for complete drainage.

I

NOTE: Use the bottle and spout saved from initial use to

measure the correct amount. 3.4 ounce (100 mt)
is approximately to the top of the label on the

bottle (Fig. 44) Check the level with the dipstick.
If the level is low, add a small amount of oil and

recheck (Fig. 40). Do net overfill.

-<-- Fill Level

OW

4-Cycle Motor Oil

i

............. Fig.44

6. Replace the oil fill plug/dipstick.

7. Reconnect spark plug boot.

2O

AIR FILTER MAINTENANCE

Cleaning the Air Filter

WARNING: To avoid serious personal injury, t

always turn your trimmer off and allow it to I
cool before you clean or do any maintenance

on it,

Clean and re-oil the air filter every 10 hours of operation,
It is an important item to maintain, Not maintaining the

air filter will VOID the warranty,

1. Open the air filter cover. Push the tab on the right
side of the cover in, pull the air filter cover out and to

the left (Fig. 45),

NOTE: It may be necessary to remove the fuel cap to

completely remove the air filter cover

2. Remove the air filter (Fig, 45).

Choke Lever

Air Filter

Air Filter Cover

Fig,47

5. Squeeze the filter to spread and remove excess oil
(Fig. 48).

Tab

Fig, 45

3. Wash the filter in detergent and water (Fig, 46). Rinse
the filter thoroughly and allow it to dry,

<

Fig. 46 ...............

4, Apply enough clean SAE 30 motor oil to lightly coat

the filter (Fig. 47),

Fig. 48

6. Replace the filter (Fig, 49),
NOTE: If the unit is operated without the air filter, you

will VOID the warranty.

Back Plate

Back Plate Slot

Slots

Fig,49

7. Reinstall the air filter cover. Position the hooks on
the left side of the air filter cover into the slots at the
left side of the back plate (Fig. 49),

NOTE: It may be necessary to remove the fuel cap to

reinstall the air filter cover

8, Swing the cover to the right until the tab on the air

filter cover snaps into place in the slot on the back

plate (Fig. 49).

9. Replace the fuel cap, if removed,

21

CARBURETOR ADJUSTMENT

The idle speed of the engine is adjustable. An idle
adjustment screw is reached though a hole in the top of

the engine cover (Fig 50).

NOTE: Careless adjustments can seriously damage your

unit. An authorized service dealer should make
carburetor adjustments.

Check Fuel

Old fuel is usually the main reason for the unit not

running properly. Drain and refill the tank with clean,

fresh unleaded fuel prior to doing any adjustments. Refer

to Oil and Fuel Information.

Clean Air Filter

The condition of the air filter is important to the

operation of the unit. A dirty air filter will restrict air flow
and change the airifueI mixture. This is often mistaken
for an out of adjustment carburetor. Check the condition

of the air filter before adjusting the idle speed screw.
Refer to Air Filter Maintenance.

Adjust Idle Speed Screw

WARNING: The cutting attachment may be

spinning during idle speed adjustment. Wear

protective clothing and observe all safety
instructions to prevent serious personal

injury.

If after checking the fuel and cleaning the air
filter the engine still will not idle, adjust the idle speed
screw as follows.

1. Start the engine and let it run at a high idlefor a
minute to warm up.

2. Release the throttle trigger and let the engine idle. If
the engine stops, insert a small phillips or flat blade

screwdriver into the hole in the engine cover

(Fig. 50). Turn the idle speed screw in, clockwise,
1/8 of a turn at a time (as needed) until the engine

idles smoothly.

NOTE: The cutting attachment should not rotate when

the engine idles.

3. If the cutting attachment rotates when the engine
idles, turn the idle speed screw counterclockwise 1/8
of e turn at a time (as needed), to reduce idle speed.

Checking the fuel, cleaning the air filter, and adjusting
the idle speed screw should solve most engine

problems.
If not and:

• The engine will not idle,

• The engine hesitates or stalls on acceleration,

• There is a loss of engine power,
have the carburetor adjusted by an authorized service

dealer.

WARNING: When the unit is turned off make I
sure the cutting attachment has stopped [

before the unit is set down to prevent serious
persona njury.

ROCKER ARM CLEARANCE

This requires disassembly of the engine. If you feel

unsure or unqualified to perform this, take the unit to an

authorized service center.

NOTE: Inspect the valve to rocker arm clearance with a

feeler gauge after the first 10 hours of operation

and then every 25 hours of operation thereafter.

• The engine must be cold when checking or adjusting
the valve clearance.

• This task shouId be performed inside, in a clean, dust
free area.

1. Remove the muffler cover by pressing down on the

comer with a flat blade screwdriver (Fig. 51). Slide
the notches on the sides of the muffler cover over

the tabs on the engine cover and remove

/

..... Fig.51

2, Remove the two (2) screws on top of the engine cover

with a flathead or T-20 Torx screwdriver (Fig. 52).

22

idle Adjustment Screw

Engine Cover

Top View Of

The Engine

Muffler

Fig. 52

3. Remove the screw on back of the engine cover
(Fig. 53).

Rocker Arms

Nuts

Fig. 53

4. Clean dirt from around the spark plug. Remove the
spark plug from the cylinder head by turning a 5/8 in.
socket counterclockwise.

5. Disconnect the spark plug wire.

6. Remove the engine cover.

7. Clean dirt from around the rocker arm cover.
Remove the screw holding the rocker arm cover with
a large flat blade screwdriver or Torx T25 bit

(Fig. 54). Remove the rocker arm cover and gasket.

Rocker Arm Cover

Spark Plug Hole

Fig. 54

8. Pullthe starter rope slowly to bring the piston to the
top of its travel, (known as top dead center). Check

that:

', The piston is at the top of its travel while looking in

the spark plug hole (Fig, 54),

• Both rocker arms move freely, and both valves are
closed.

If not, repeat this step,

9. Slide the feeler gauge between the rocker arm and
the valve return spring. Measure the clearance
between the valve stem and rocker arm (Fig 55),

Do both intake and exhaust valves.

The recommended clearance for both intake and

exhaust is .003- .006 in. (,076- 0.152 mm). Use a
standard automotive .005 in. (0,127 mm) feeler gauge,

The fee_ergauge should sl{de between the rocker arm

and valve stem with a slight amount of resistance,
without binding (Fig. 56),

Feeler Gauge

Gasket

Fig, 55 .............

Adjustinl

Rooker Arm

.003-,006 in.

(,076-0.152 ram)

J

Valve Stem

Fig. 56

10. If the clearance is not within specification:
a. Turn the adjusting nut using a 5/16 inch (8 mm)

wrench or nut driver (Fig. 55).
To increase clearance, turn the adjusting nut

counterclockwise,

• To decrease clearance, turn the adjusting nut

clockwise.

b. Recheck both clearances, and adjust as necessary.

11. Reinstall the rocker arm cover using a new gasket.

Torque the screw to 20-30 in.lb (2.2-3.4 N.m).

NOTE: A rocker arm cover gasket, Part # 182099 can be

purchased from your local authorized dealer.

12. Reinstall the engine cover, Check alignment of the
cover before tightening the screws. Tighten screws.

13. Replace the muffler cover. Slip the long tabs on the
muffler cover into the engine cover. Stide the

notches on the side of the muffler cover over the
tabs on the engine cover and snap into place
(Fig. 51).

14. Check the spark plug and reinstall See Replacing

the Spark Plug,

15. Replace the spark plug wire.

23

REPLACING THE SPARK PLUG

Use only Champion RDZ19H spark plug or equivelent. The
correct air gap is 0.025 in. (0.655 mm). Remove the plug

after every 25 hours of operation and check its condition.

1. Stop the engine and allow it to coo]. Grasp the plug
wire firmly and pull the cap from the spark plug.

2. Clean dirt from around the spark plug. Remove
the spark plug from the cylinder head by turning

counterclockwise using a 5/8 inch deep socket.

3. Replace cracked, fouled or dirty spark plug. Set the
air gap at 0.025 in. (0.655 mm) using a feeler gauge

(Fig, 57).

SPARK ARRESTOR MAINTENANCE

1. Remove the muffler cover. See Rocker Arm

Clearance, Pg. 22.

2. With a flat blade screwdriver or Torx T20 bit, remove

the screw attaching the spark arrestor cover to the

muffler (Fig, 56).

Muffler

Spark Arrestor Screen

Tab Screw

Spark Arrestor Cover

Slot

0.025 in.

(0.655 mm.)

Fig.57 ...........

CAUTION: Do notsand blast, scrape, or clean

electrodes. Gdt inthe engine could damage the
cylinder,

4. install a correctly gaped spark plug in the cylinder
head. Tighten by turning the 5/8 inch deep socket

clockwise until snug.

If using a torque wrench torque to;
110-120 in.olb. (12.3-13.5 N*m).

Do not over tighten.

........... Fig.58 .................................

3. Pull the tab on the spark arrestor cover out of the
muffler. Remove the spark arrestor cover.

4. Remove the spark arrestor screen from the spark
arrestor cover.

5. Clean the spark arrestor screen with a wire brush, or
replace.

6. Reinstall the spark arrestor screen, spark arrestor
cover, and screw.

ACCESSORIES/REPLACEMENT PARTS

4-Cycle Oil ......................... 753-1249

Oil Fill Plug / Dipstick ................. 791-182378

Spark Plug ......................... 791-180852B

Spark Arrestor Screen ................ 791-180890

Replacement Line ............... 0.105in (2,667mm)

Replacement Line Cartridge ........... 753-1160

Inner Reel Spring .................... 791-610636B

Outer Spool ........................ 791-683301

Inner Reel .......................... 791-147495

Bump Knob TM ...................... 791-!80814B

Fuel Cap .......................... 791-181083

Shoulder Harness ................... 791-682075B

24

These replacement parts can be purchased from your
local authorized dealer or by calling 1-330-558-7220 or

1-866-840-6483.

CLEANING

WARNING: To avoid serious personal injury,
always turn your trimmer off and allow it to
cool before you clean or do any maintenance

on it.

Use a small brush to clean off the outside of the unit. Do
not use strong detergents. Household cleaners that

contain aromatic oils such as pine and lemon, and such
as kerosene, can damage plastic housing or handle.

Wipe off any moisture with a soft cloth.
STORAGE

• Never store the unit with gasoline in the tank where
fumes may reach an open flame or spark.

• Allow the engine to cool before storing.

• Store the unit locked up to prevent unauthorized use
or damage.

• Store the unit in a dry, well ventilated area.

• Store the unit out of the reach of children.

Store the unit in one of three (3) positions:

1. The unit hanging by the cutting attachment end.

2, The unit hanging by the engine.

3. The unit setting upright on the cutting attachment
shield and engine feet.

LONG TERM STORAGE

If the unit wilBbe stored for an extended time,

1. Drain all gasoline from the gas tank into a container.
Do not use gas that has been stored for more than

60 days. Dispose of the old gasoline in accordance
with Federal, State, and Local regulations.

2. Start the engine and allow it to run until it stalls. This
ensures that all gasoline has been drained from the

carburetor.

3.

Allow the engine to cool. Remove the spark plug and
put 1 oz. (30 ml) of high quality motor oil into the

cylinder. Pull the starter rope slowly to distribute the
oil. Reinstall the spark plug.

NOTE: Remove the spark plug and drain all of the oil

from the cylinder before attempting to start the
trimmer after storage.

4. Change the oil. See Changing the Oi!. Dispose of

the old oil in accordance with Federal, State, and
Local regulations.

5. Thoroughly clean the unit and inspect for any loose
or damaged parts. Repair or replace damaged parts

and tighten loose screws, nuts or bolts. The unit is
ready for storage.

TRANSPORTING

• Allow the engine to cool before transporting.

• Secure the unit while transporting.

• Drain the gas tank before transporting.

• Tighten gas cap before transporting.

25

CAUSE

IgnitionswitchisOFF

Empty fuel tank
Primer bulb wasn't pressed enough
Engine flooded

Old Gasoline

Fouled spark plug

ACTION

Turn switch to ON

FillfueI tank
Press primer bulb fully and slowly 5-7 times

Use starting procedure with choke lever in the
RUN position, Pg+13

Drain fuel tank/Add fresh Gasoline
Replace or clean the spark plug

CAUSE

Air Filter is Plugged
Old Gasoline

improper carburetor adjustment

CAUSE

Old Gasoline
improper carburetor adjustment

Cutting head bound with grass
Dirty air filter
Clogged Spark Arrestor Screen

CAUSE

Old Gasoline

improper carburetor adjustment

Clogged Spark Arrestor Screen

ACTION

Replace or clean the air filter

Drain fuel tank / Add fresh Gasoline

Adjust per instruction Pg. 22

ACTION

Drain gas tank / Add fresh Gasoline

Take to an authorized service dealer for

carburetor adjustment
Stop the engine and clean the cutting attachment

Clean or replace the air filter
Clean or Replace. See Pg. 24

ACTION

Drain fuel tank / Add fresh Gasoline

Take to an authorized service dealer for

carburetor adjustment
Clean or Replace. See Pg. 24

CAUSE

Cutting head bound with grass
Cutting head out of line

Inner reel bound up
Cutting head dirty

Line welded

Line twisted when refilled
Not enough line is exposed

if further assistance is required, contact your authorized service dealer.

26

ACTION

Stop the engine and clean cutting attachment
Refill with new line

Replace the inner reel
Clean inner reel and outer spool

Disassemble, remove the welded section

and rewind the line

Disassemble and rewind the line
Push the Bump Knob and pull out line until

4 inches (102 mm) of line is outside of the
cutting attachment

Engine Type ................................................................. Air-Cooled, 4-Cycle

Displacement ................................................................. 1.6 cu. in. (26.2 cc)

Clutch Type ......................................................................... Centrifugal

Operating RPM (Trimmer) ......................................................... 7,200-8,300 rpm

Operating RPM (Brushcutter) ...................................................... 7,200-9,800 rpm

Idle Speed RPM ................................................................. 3,000-3,600 rpm

Ignition Type ......................................................................... Electronic

Ignition Switch .................................................................... Rocker Switch

Valve clearance (intake and exhaust) ...................................... 003-.006 in. (.076-.0152 mm)

Spark Plug Gap ............................................................ 0.025 inch (0.655 mm)

Lubrication .......................................................................... SAE 30 Oil

Crankcase Oil Capacity ............................................................ 3.4 oz (100 ml)

Fuel ................................................................................ Unleaded

Carburetor ................................................................ Diaphragm, All-Position

Starter ............................................................................ Auto Rewind

Muffler ....................................................................... Baffled with Guard

Throttle .................................................................... Manual Spring Return

Fuel Tank Capacity ................................................................. 20 oz (591 ml)

Fuel Tank ....................................................................... HD Polyethylene

Drive Shaft Housing ...................................................... Aluminum Tube (EZ-Link TM)

Throttle Control ................................................................. Finger-Tip Trigger

Unit Weight (No Fuel, with J-handle, Cutting attachment shield and Cutting attachment) ....... 13.5 Ibs (6.13 kg)

Cutting Mechanism ..................................... 4-Tooth Cutting Blade, Dual String Cutting Head

Line Spool ................................................................... Bump Line Releaser

Line Spool Diameter .......................................................... 4 inches (101.6 mm)

Trimming Line Diameter ....................................................... 0.105 inch (2.66 ram)

Cutting Path Diameter, Cutting Attachment ......................................... 18 inches (45.7 cm)

Cutting Path Diameter, Cutting Blade ............................................... 8 Inches (204 ram)

Shoulder Harness .............................................................. Single Quick-Snap

27

ENGINE PARTS - MODEL TB490BC
4-CYCLE GAS TRIMMER

(ppn - 41ADT49C063) (Serial Number 011 ...... and greater)

Part Numbers On Following Page

22B

%

/

@

28 Reissued12/01

ENGINE PARTS - MODEL TB490BC

4-CYCLE GAS TRIMMER

(ppn - 41ADT49C063) (Serial Number 011 ...... and greater)

!_m Part_Lo_

1 79!-182338
2 791-182339

3 791-!8!925
4 791-!82098

5 791-182099
8 791-182340

7 791-182101
8 791-182100

9 791-!82341
10 791-182103
11 791-181038

12 791-182102
13 791-181033

14 791-182700
15 791-182344

16 791-182345
17 791-182749
18 791-181034

19 791-182347
20 791-182348

21 791-182732

22A 791-182654
22B 753-1225

23 791-181751
24 753-1227

25 791-182097
26 791-181750

27 791-181757

28 753-1228
29 753-1229
30 791-182352

31 791-182353
32 791-181080

33 791-182354
34 753-1230

35 791-182356

36A 753-1234
36B 753-1231

37 791-182358
38 791-181045

39 791-182359
40 791-180890

41 791-181845
42 791-181046

43 791-182360
44 791-182361

45 791-182362
46 791-182804

Engine Cover
Engine Cover Screws

Valve Cover Screw
Valve Cover
Valve Cover Gasket
Rocker Adjustment Nut

Rocker Arm Pivot
Rocker Arm
Rocker Arm Stud
Valve Spring Retainer

Valve Spring

Push Rod Guide
Push Rod

Cylinder Head (includes 9 & 12)
Cylinder Screw
intake Baffle

Carburetor Mount Gasket

Nut

Carburetor Mount (includes t8)
Carburetor Mount Screw
Carburetor Gasket

Carburetor with Primer
Carburetor with Primer

O-Ring, Carburetor
Air Filter/Choke Cover Assembly

(includes 27 & 28)
Breather Tube

Air Filter Mounting Screw
Air Filter

Air Filter Cover

FueI Cap
Fuel Return Line

FueI Pick-Up Line with Filter

Screw
Washer

Fuel Tank Assembly (includes 29-31)
Fuel Tank Shield

Throttle Cable
Throttle Cable

Muffler Baffle

Muffler Gasket
Muffler (includes 40, 42-44)

Spark Arrestor Screen
Screen Cover
Screw
Muffler Shield

Muffler Mounting Screw
Muffler Cover

Switch Wire Assembly

IJ,_m _:t _L_.

47 791-18t247 Painut
48 753-1199 Recoil Pulley
49 791-613102 Recoil Spring

50 791-182366 Nut Clip
51 791-181079 Pull Handle

52 791-611061 Rope Guide
53 791-613103 Rope

54 791-181020 Starter Housing Screw
55 753-1237 Starter Housing Assembly

(includes 49-56)

55 791-182368 Clutch Washer
57 753-1238 C_utch with Spacer

58 791-153592 Clutch Drum
59 753-1239 Clutch Cover

60 791-145569 Anti-Rotation Screw
61 753-1240 Screw

82 753-1241 Nut
63 791-181345 Clutch Cover Screw
64 79!-182725 Ignition Module with Screws
65 791-181065 Spacer

66 791-181867 Flywheel
67 791-182743 Shroud Assembly with Screws
68 753-1244 Crankcase Assembly

(includes 69-73)

69 791-610309 Oil Seal
70 791-!82372 Bearing

71 791-182380 Crankshaff
72 791-182375 90 ° EIbow

73 791-182379 Breather Hose
74 791-181015 Cam Gear
75 753-1242 Cam Fo!_ower Set

76 791-181013 Cam Bracket
77 791-181012 Cam Bracket Screw
78 791-181040 Valves, Intake and Exhaust
79 791-182374 Cylinder Gasket

80 791-181018 Oi_Pan Gasket
81 791-182377 Oil Pan (incIudes 80 & 82)

82 791-181020 Oil Pan Screw
83 791-182378 Dipstick Assembly (includes 84)

84 791-182290 O-Ring
85 791-181009 Connecting Rod
86 791-181008 Wdst Pin Bu_on
87 753-1243 Piston

88 791-181006 Wnst Pin
89 791-182295 Piston Ring Set

90 791-182409 Washer
91 791-181851 Screw

92 791-612468 Compression Spnng

93 791 -I 82537 Grommet

791-180852B Spark P_ug
753-1245 Short Block Assembly

(includes 3-7, 68-89)

791-182745 Cylinder Assembly

(includes 9, 12, 14 & 79)

791-180142 Starter Pawl Repair Kit
791-182156 Carburetor Repair Kit

753-1248 Gasket Diaphragm Repair Kit

Parts not shown

Reissued 12/01 29

BOOM AND TRIMMER PARTS - MODEL
TB490BC

4-CYCLE GAS TRIMMER

®(

1 791-00040

2 791-00041
3 791-00042

4 791-182690
5 791-182673

6 791-6!0327
7 753-1247

8 79!-!81099
9 791-612831

10 79t-612021
11 791-683296

12 791-181811
13 791-181812

14 791-181813
15 791-181814
16 791-181815

17 791-145569
18 753_1190
19 791-182057

20 791-181617
21 791-181981

22 791-181886
23 791-182541

24 791-613300
25 791-182200
26 791-182193

27 791-182195
28 791-145569
29 791-147492

30 791-182196
31 791-683304

32 753-1191
33 791-68206I

34 791-147490
35 791-612483

36 791-683301

37 791-612026
38 791-610636B

39 791-147495
40 791-180814B

41 791-145873B
42 791-181699

791-180014B

791-613226
791-682075B

Descrij_tion

Throttle Housing and Tdgger
Assembly (includes 2-4) (_'

Throttle Trigger Lock-Out _Throttle Trigger

Throttle Trigger Spring
Switch Assembly

Harness Clip
Upper Drive Shaft Housing Assembly

J-Handle Assembly (includes 9 & 1(3)
Grip

Tube Closure
Handle Bracket Assembly (includes 12-!7)

Screw
Upper Handle Clamp

Middle Handle Clamp
Lower Handle Clamp

Nut
Anti-Rotation Screw

Click-Link Coupler (includes 18-22)
Screw

Bott

Adjustment Knob

Knob Retaining Nut
Lower Drive Shaft Housing Assembly
Lower Flexible Drive Shaft

Shield Mount Screw Assembly
2 piece Gearbox Assembly

(includes 25, 97 & 28)
Gearbox Screw

Anti-Rotation Screw

Blade Shield/Shield Mount
Blade Driver
Shield Mounting Screw
Shield and Blade Assembly (includes 33)

Blade Assembly
Retaining Washer

Spool Shaft
Outer Spool and

Eyelet Assembly
Retainer

Spring
Inner Reel

Bump Head Knob Assembly
4-Tooth Blade

Nut
Blade Retaining Kit

(includes 34 & 42)

Locking Rod Tool

_Shoulder Harness

2 Pjec_e Gearbox Assembly Parts - IJLe_ _ __

43 791-182191 Left Housing _ _ )_
44 791-182192 Right Housing __

45 791-182194 Pinion Gear Assembty _ _
46 791-182199 Output Shaft Bushing

47 791-182198 Output Shaft Gear
46 791-182197 Output Shaft Assembly

49 753-1159 O-Ring

_ptional Accessories

753-1160 Reel and Line Assembly
753-1161 Bump Head Assembly

753_1249 4-Cycle Oil

@

[J

(includes 46 & 47)

(includes 35-40)

Items Not Shown

30 Reissued 12/01

31

MANUFACTURER'S LIMITED WARRANTY FOR:

O _ +glIIIIIIL _ ,llmllllV _mmm

The limited warranty set forth below is given by Troy-Bilt

LLC with respect to new merchandise purchased and
used in the United States, its possessions and territories.

Troy-Bilt LLC warrants this product against defects in

material and workmanship for a period of two (2) years

commencing on the date of original purchase and will, at

its option, repair or replace, free of charge, any part found
to be defective in material or workmanship. This limited
warranty shall only apply if this product has been operated
and maintained in accordance with the Operator's Manual
furnished with the product, and has not been subject to

misuse, abuse, commercial use, neglect, accident,

improper maintenance, alteration, vandalism, theft, fire,

water or damage because of other peril or natural disaster.

Damage resulting from the installation or use of any

accessory or attachment not approved by Troy-Bilt LLC
for use with the product(s) covered by this manual will void

your warranty as to any resulting damage. This warranty is

limited to ninety (90) days from the date of original retail

purchase for any Troy-BUt product that is used for rental or

commercial purposes, or any other income-producing

purpose.

HOW TO OBTAIN SERVICE." Warranty service is

available, WITH PROOF OF PURCHASE THROUGH

YOUR LOCAL AUTHORIZED SERVICE DEALER. To

locate the dealer in your area, visit our website at

www.troybiit.com, check for a listing in the Yellow Pages,

call 1 [phone] or 1 [phone] or write to P.O.

Box 361131, Cleveland, OH 44136-0019.

This limited warranty does not provide coverage in

the following cases:

A. Tune-ups - Spark Plugs, Carburetor Adjustments,

Filters

TRO RILT °

entity, including a dealer or retailer, with respect to
any product shall bind Troy-Bilt LLC During the period
of the Warranty, the exclusive remedy is repair or

replacement of the product as set forth above. (Some
states do not allow limitations on how long an implied
warranty lasts, so the above limitation may not apply to

you.)

The provisions as set forth in this Warranty provide

the sole and exclusive remedy arising from the sales.

Troy-Bilt LLC shall not be liable for incidental or
consequential loss or damages including, without

limitation, expenses incurred for substitute or
replacement lawn care services, for transportation or
for related expenses, or for rental expenses to
temporarily replace a warranted product. (Some states

do not allow limitationson how long an implied warranty

lasts, so the above limitation may not apply to you.)
In no event shall recovery of any kind be greater than the

amount of the purchase price of the product sold.
Alteration of the safety features of the product shall void

this Warranty. You assume the risk and liability for loss,
damage, or injury to you and your property and/or to
others and their property arising out of the use or misuse
or inability to use the product.

This limited warranty shall not extend to anyone other
than the original purchaser, original lessee or the person
for whom it was purchased as a gift.

How State Law Relates to this Warranty: This warranty

gives you specific legal rights, and you may also have

other rightswhich vary from state to state.

To locate your nearest service deaier dial

1 [phone]

B. Wear items - Bump Knobs, Outer Spools, Cutting

Line, Inner Reels, Starter Pulley,Starter Ropes, Drive
Belts

C. Troy-Bilt LLC does not extend any warranty for

products sold or exported outside of the United
States of America, its possessions and territories,

except those sold through Troy-Bilt's authorized
channels of export distribution.

Trey-Bilt LLC reserves the right to change or improve the
design of any Troy-Bilt Product without assuming any
obligation to modify any product previously

manufactured.

No implied warranty, including any implied warranty
of merchantability or fitness for a particular purpose,

applies after the applicable period of express written

warranty above as to the parts as identified. No other

express warranty or guaranty, whether written or oral,
except as mentioned above, given by any person or

32

Troy-Bilt LLC

P.O. Box 361131

Cleveland, OH 44136-0019