Troybilt 41BDT49C063 Owner’s Manual

n n m mum

Operator's Manual

4-Cycle Gasoline

Trimmer/

Brushcutter

Model TB490BC

IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY

P/N 769-00386 (10/02)

PRINTED IN USA

Content

Page

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

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

<now Your Unit ........................................................... 6

Assembly Instructions ................................................. 7

Oil and Fuel Information ..................................................... 10

Starting/Stopping Instructions ................................................ 12

Operating Instruct=ons ...................................................... 13

Maintenance and Repair Instructions ...................................... 16

Cleaning and Storage ....................................................... 24

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

Troubleshooting Chart ...................................................... 25

Specifications ........................................................... 26

Warranty Information ....................................................... 28

Parts L=st.................................................... Inside Back Cover

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 law 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, !f
it requires replacement, Accessory Part #180890 Spark Arrestor Screen is available by contacting the service department.

This operator's manual is an important part of your new trimmer. 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.

ri I- " Modei/ParefitPartHunlber

_e 8 NUmDOr

Copy the model / parent part

MDUPPN:

Set.No:

Copy the serial number here:

If you have difficulty assembling this product or have any questions regarding the controls, operation or maintenance of

this unit, please call the Customer Support Department.

Ca11,1-(330)-558-7220 or 1-(866)-840-6483 to reach a Customer Support representative. Please have

your

(/_ unit s model number and serial number ready when you call. See the previous section to locate this

information. You will be asked to enter the serial number in order to process your call.

2

The purpose of safety symbols is to attract your
attention to possible dangers. The safety 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

_1_ 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.

SYMBOL MEANING

4_ ' i ' SAFETY ALERT SYMBOL: Indicates

NOTE: Advises you of information or instructions vital to

Idanger, warning or caution. Attention is

! irequired in order to avoid serious personal

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

the operation or maintenance of the equipment.

California Proposition 65 Warning:

THE ENGINE EXHAUST FROM THIS

PRODUCT CONTAINS CHEMICALS

KNOWN TO THE STATE OF CALIFORNIA

TO CAUSE CANCER, BIRTH DEFECTS

OR OTHER REPRODUCTIVE HARM.

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 fuel 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 do so can result in personal

injury to the operator and bystanders, as well as

damage to the unit.

• Use only 0.105 inch (2.66 mm) diameter Genuine
Factory Parts rM replacement line. Never use metal-
reinforced line, wire or rope. These can break off and

become dangerous projectiles.

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

• Squeeze the throttle control and check that it returns
automatically to the idle position. Make all adjustments

or repairs before using unit.

I_il WARNING: Failureto obey a safety

_1_ CAUTION: Failure to obey a safety warning

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

string. They 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-foot (15 m.) radius;

there still 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.

warning Can result in injury to yourse!f and
others. Always follow the safety

precautions to reduce the risk of fire,

electric shock and personal injury.

may result in property damage or personal
injury to yourself or to others. Always follow

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

SAFETY WARNINGS FOR GAS TRIMMERS

_ ARNING: Gasoline is highly flammable, and

• 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 fuel 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 fuel in a clean, well-ventilated outdoor area where
there are no sparks or flames. Slowly remove the fuel

cap only after stopping engine. Do not smoke while
fueling or mixing fuel. 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 away from the
area while adding fuel or operating the unit.

its Vapors Can explode if ignited. Take the
following precautions:

WHILE OPERATING

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

this unit only in a well ventilated outdoor area.

• Wear safety glasses or goggles that are marked as
meeting ANSI Z87.1-1989 standards. Also wear
ear/hearing protection when operating this unit. Wear
a face or dust mask if the operation is dusty.

3

• Wear heavy, long pants, boots and gloves. 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]ines 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
gnp.

• 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 or muffler. These parts get
extremely hot from operation. They remain hot for a

short time after you turn off the untt.

• Do not operate the engine faster than the speed

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

• Always stop the engine when cutting is delayed or
when walking from one cutting location to another.

• If you strike or become entanqled with a foreign
object, stop the engine immecqiately 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 Factory Parts TM replacement parts
and accessories for this unit. These are available from

your authorized service dealer. Use of any

unauthorized parts or accessories could lead to
serious injury to the user, or damage to the unit, and

void your warranty.

• Keep unit clean of veqetation 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 spinninq blade
contacts an object that it does not tmmediately 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. Blaae 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_he engine is stopped or the throttle trigger

is released. Maintain proper control until the blaae has
completely stopped rotating.

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

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

damage. Have any Llamage repaired before attempting
further operations. Do 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 wNe 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 yoursdlf or others can
occur. Use the cutting blade only for the purpose as

described in this manual.

• Stop the engine IMMEDIATELY ifyou 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 upand 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 otthe

reach of children.

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

Clean after each use. bee the 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

4

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 SYMBOL MEANING

• ON/OFF STOP CONTROL

Indicates danger, warning or caution.

• SAFETY ALERT SYMBOL O

May be used in conjunction with other

symbols or pictographs.

• WARNING - READ - Y,,Ik_

OFF or STOP

• THROWN OBJECTS AND
ROTATING CUTTER CAN

CAUSE SEVERE INJURY

O OPERATOR'S MANUAL / _-

Read the operator's manual(s) and follow _/

all warnings and safety instructions.

Failureto do so can result in serious injury

to the operator and/or bystanders.

• WEAR EYE AND HEARING

WARNING: Thrown objects and loud

noise can cause severe eye injury and

PROTECTION

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

Use a full face shield when needed.

•KEEP BYSTANDERS AWAY

WARNING: Keep all bystanders,
especially children and pets, at least

50 feet (15 m) from the operating area.

• UNLEADED FUEL

Always use clean, fresh unleaded fuel.

• OIL
Refer to operator's manual for the

proper type of oil.

WARNING: Do not operate without
the cutting attachment shield in place.
Keep away from the rotating cutting

attachment.

• HOT SURFACE WARNING

Do not touch a hot muffler, gear housing
or cylinder. You may get burned. These
parts get extremely hot from operation.
They remain hot for a short time after the

unit is turned off.

• SHARP BLADE

WARNING: Sharp blade on cutting

attachment shield. To prevent serious
injury, do not touch line cutting blade.

• 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.

oTRIMMER/BRUSHCUTTER

SAFETY

I

• ON/OFF STOP CONTROL

ON / START / RUN

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.

5

APPLICATIONS

As a trimmer:

Cutting grass and light weeds

Edging
Decorative trimming around trees, fences, etc.

As a brushcutter:

Cutting weeds and light bush of up to 112 inch in

diameter

Other optional accessories may be used with the
TB490BC. Refer to Operating the EZ-Link System for a

list of add-ons.

On/Off Sto_

Shoulder Strap

Spark Arrestor

.,G_ Spark Plug

Fuel Cap

Starter Rope Grip

Shaft Grip

Throttle

Lock-C

Throttle

Control

Brush
Blade

Gear

Housing

EZ.Link TM

Blade Shield /

Shield Mount \\

Shaft

Housing

\

\

\

\

\

Cutting Attachment

\

Shield

Air Filter Cover

Engine Feet

J-Handle

Spark Plug

Primer Bulb

f-

Oil Fill Plug / Dipstick

Cutting Attachment

Line Cutting Blade

6

On some units, the J-handle may be pre-installed. In this
case you must loosen screws and adjust the handle to fit

the operator. Go to step 5 if the J-handle is pre-installed.

INSTALL AND ADJUST THE J-HANDLE

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

(4)

Top Clamp

-_ Middle Clamp

2. While holding the three pieces together, installthe four
(4) screws through the top clamp and into middle clamp.

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

only when assembled correctly.

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

4. Hold each hex nut in 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).You must

first loosen the screws if the handle is pre-installed.

Decal

INSTALL THE HARNESS

WARNING: Always use the shoulder I

harness when using the cutting blade to
avo d serous persona njury. J

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).

3. Put the harness on over head and onto shoulder.

Snap it on to the support fitting (Fig. 5).

4,

Adjust length to fit the operator's size. Pull tab to
lengthen, pull strap to shorten (Fig 6).

)

Fig. 4

J Support Fitting

Fig. 5

Fig. 2

6. While holding the unit in the operating position (Fig. 3),
position the J-handle to the location that provides you

the best grip.

Fig. 3

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

Fig. 6

REMOVE AND INSTALL THE CUTTING
ATTACHMENT SHIELD

Remove the cuttingattachment shield when
using the unit as abrushcutter

A WARNING: The cutting attachment shield

,_1= should NOT be installed when operating I

the unit with a blade. Remove the cutting
attachment shield before removing or

installing the blade. I

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.

7

Cutting

Attachment

Screws

Shield

Gear Housing

Shield Mount

Fig. 7

Install the cutting attachment shield when using
the unit as a grass trimmer

_1_ fWARNING: To avoid serious personal

_, | njury, the cutting attachment shield MUST

_|be in place at all times while operating the I

|unit as a grass trimmer. I

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 cutting blade removal and installation easier,

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

Remove the Cutting Attachment Shield
See Remove and Install the Cutting Attachment Shield.

Remove the Cutting Attachment

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

will be used when installing the cutting blade.

Fig. 9

Cutting Attachment

LockingRod

Slot

Locking Rod

Fig. 10

Install the Cutting Blade

use. It can result in injury to the operator. I
The housing remains hot for a short time I

_[WARNING: The gear housing gets hot with,

even after the unit is turned off. Do not
touch the gear hous ng unt t has coo ed.

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

Output Shaft

Shaft Bushing Hole__\ _ j

._ _ Output Shaft

_ Bushing

Locking Rod - _ _

Fig. 8

8

injury, always wear gloves while handling or

WARNING: To avoid Serious personal
installing the blade. I

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

Blade Retainer

Nut

Cutting

Blade

Shield

Mount

/

Pilot Hole

Output Shaft

Bushing

Locking Rod

Fig. 11

5. Makesurethatthecuttingbladeiscenteredonthe
pilotstepandsittingf!atagainsttheoutputshaft

bushing(Fig.12),

Allk I center, the unit will vibrate and the blade I

I _III_ WARNING: If the Cutting blade is off- I

may fly off, causing possible serious

I personal injury. I

Pilot Step

REMOVE THE CUTTING BLADE AND
INSTALL THE CUTTING ATTACHMENT

WARNING: TOavoid serious personal

I Allk l injury, always wear gloves while handling or
l_ l installing the blade. 1

Remove the Cutting Blade

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

2.

Hold the locking rod in place by grasping it next to

the boom of the unit (Fig. 14).

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).

Fig. 12

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

(Fig. 8).

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:

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

• Without a torque wrench, use a 5/8 inch closed-end or

socket wrench, turning the nut until the blade retainer
is snug 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).

1/4-1/2 turn

Counterclockwise

Clockwise

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 children's reach.

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).

Place the blade retainer on the output shaft with the fiat
surface against the output shaft bushing (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.

Cutting Attachment _

Blade Retainer.

Fig. 13

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

A I WARNING: TO avoid serious personal I

Allk I injury or damage to the unit, do not start or I

operate this unit with the locking rod in the

I locking rod slot.

WARNING: Do not sharpen the Cutting blade. 1

Sharpening the blade can cause the blade tip I

to break off while in use. This can result in I

severe personal injury, Replace the blade, l

Output Shaft

Bushing

Locking Rod

Fig. 15

,

Remove the locking rod.

7.

Install the cutting attachment shield. Refer to Remove

and Install the Cutting Attachment Shield.

WARNING: To avoid serious personal injuryl I
the cutting head guard MUST be in place at

a t mes wh e operat ng the unt as a tr miner.

9

DANGER: OVERFILLING OIL CRANKCASE
MAY CAUSE SERIOUS PERSONAL

INJURY. Checking and maintaining the
proper oil level in the crank case (_annot is

important and 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 oil. In 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 the top.
Next, 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).

O-Ring _i

Oil FillPlug/Dipstick- _.._ /

Oil Fill Hole /

Fig. 17

4. Pour the entire bottle of oil into the oil fill hole
(Fig. 18).

Funnel Spout_

10

Fig. 16

Fig. 18

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

5. Wipe up any oil that may have spilled and reinstall

the oil fill plug / dipstick.

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

Check oil before each use and change as needed. Refer
to Changing the Oil.

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 little as 1%
water in the fuel can make fuel and oil separate or form

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 fuel 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.

FUELING THE UNIT

WARNING: Gasoline is extremely flammable
and its vapors can explode if ignited. To avoid

serious personal injury, always stop the engine

and allow it to cool before filling the fuel tank.

Do not smoke while filling the tank. Keep
sparks and open flames away from the area.

1. Removefuel cap (Fig. 19).

I_ WARNING: Remove fuel Cap Slowly to

ldHLlavo d njury from gaso ne spray.

Fig. 19

2. Place spout of gas container into the fill hole on the

fuel tank (Fig. 19) and fill tank.

l_ WARNING:Add gasoline in a clean, well- I

NOTE: Do not overfill tank.

3. Wipe up any gasoline that may have spilled

4. Reinstall the fuel cap.

I_ [WARNING: Never operate the unit without

5. Move the unit at least 30 ft. (9.1 m) from the fueling

NOTE: Dispose of the old gasoline in accordance to

ventilated outdoor area. Avoid creating a

l source of gn t on for Sp t fue. J

lthe rue! cap securely in place.

source and site before starting the engine.

Federal, State and Local regulations.

11

STARTING INSTRUCTIONS

ventilated area outdoors. Carbon monoxide

_1 wARNING: Operate this unit °nly in a well- J

exhaust fumes can be ethan a Confined area. I

WARNING: Avoid accidental starting. Remain
in the starting position when pulling the
starter rope (Fig. 22). The operator and unit
must be in a stable position while starting to

avoid Serious personal injury.
Make Sure that any Add-On item is installed

correctly and secure before starting the unit.

1. Check the oil level in the crankcase. Refer to

Checking the Oil Level.

2. Fill the fuel tank with fresh, clean unleaded gasoline.
Refer to Fueling the Unit.

3. Make sure the On/OFFStop Control is in the ON (I)

position (Fig. 20).

NOTE: For cold weather conditions (when the

temperature is below 40°F), flip the Cold Weather
Start Lever (Fig. 23) to the choked position and
continue to step 4. The choked position is down

and closed. DO NOT flip this lever down if the
temperature is above 40°F.

4. Fully press and release the primer bulb 10 times,
slowly, until FUEL IS VISIBLE IN THE PRIMER

BULB (Fig. 21). If you can't see fuel in the bulb, press
and release the bulb as many times as it takes before

you can see fuel in it.

5. With the unit in the starting position (Fig. 22), DO
NOT SQUEEZE THE THROTTLE CONTROL. Pull

the starter rope briskly 5 times. If the engine starts to
run before the fifth pull, proceed to step 6. If the
engine does not start, go back to step 4.

NOTE: For cold weather conditions (when the

temperature is below 40°C), flip the Cold Weather
Start Lever back to the open/up position.

6. Squeeze the throttle control to warm up the engine
for 5 to 10 seconds. In cold weather, let the engine

warm up for 30 to 60 seconds.

NOTE: If the engine stalls while squeezing the trigger, go

back to step 5.

STOPPING INSTRUCTIONS

1. Release your hand from the throttle control (Fig. 22).
Allow the engine to cool down by idling.

2. Put the On/Off Stop Control in the OFF (O} position
(Fig. 20).

Stop/Off (O)

Throttle Control

Cold Weather

Start Lever

Starter Rope

\x\\\\\

Throttle Control "

On/Off Stop Control

Fig. 20

Fig. 21

Fig. 22

(I)

Throttle Lock-Out

Primer

Bulb

Open

Start Lever

Cold _

Closed

12

Fig. 23

OPERATING THE EZ-LINK TM SYSTEM

The EZ-LinkTM system enables the use of these optional
Add-Ons.

Blower/Vacuum ........................... TBBV

Cultivator ................................ TBGC

Edger ................................... TBLE

Hedge Trimmer ........................... TBHS

Snow Thrower ............................ TBST

Straight Shaft Trimmer ...................... TBSS

Tree Pruner .............................. TBTP

Turbo Blower ............................. TBTB

2. While firmly holding the add-on, push it straight into
the EZ-Link TM coupler (Fig. 25).

NOTE: Aligning the release button with the guide recess

will help installation (Fig. 24).

Release Button

EZ-LinkTM Coupler

Hole

_[WARNING: Read and understand the

Removing the Cutting Attachment or Add-Ons

1. Turn the knob counterclockwise to loosen (Fig. 24).

2. Press and hold the release button (Fig. 24).

3. While firmly holding the upper shaft housing, pull

I_IWARNING: To avoid serious personal injury J

Installing the Cutting Attachment or Add-Ons
NOTE: To make installing or removing the add-on

1. Turn knob counterclockwise to loosen (Fig. 24).

operator s manual for each add-on prior to
operation.

the cutting attachment or add-on straight out of the

EZ-Link TM coupler (Fig. 25).

and damage to the unit, shut unit off be[o[e
remov ng or nsta ng add-ons.

easier, place the unit on the ground or on a work

bench.

EZTLinETMcoupler Release Button

Upper Shaft Housing /

Fig. 25

3. Turn the knob clockwise to tighten (Fig. 26).

,_ CAUTION: Lock the release button in the

primary hole and securely tighten the knob
before operat ng th sun t.

90_EdgingHole

Lower Shaft Housing

180_Edging Hole

L

Fig. 26

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

manual. Using the wrong hole could lead to
personal inJury, or damage to the unit

Knob

Fig. 24

\

Guide Recess

For edging when using the line head cutting attachment

wtth EZ-Link TM models, lock the release button of the
cutting attachment into the 90 ° edging hole or the 180°

edging hole (Fig 26L

13

HOLDING THE TRIMMER

_[WARNING: Always wear eye, hearing, foot

Before operating the unit, stand in the operating position

(Fig. 27). Check for the following:

• The operator is wearing eye protection and proper
clothing

• With a slightly-bent right arm, the operator's right hand

is holding the shaft grip

• The operator's left arm is straight, the left hand holding
the J-handle

• The unit is at waist level

and body protection to reduce the tisk of

njury when operat ng this un t.

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 rMon 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 to

Jser ous persona njury or damage to the un t. i

• The cutting attachment is parallel to the ground and
easily contacts the grass without the need to bend over

Once you are in the operating position, hook the
shoulder strap to the unit.

Fig. 27

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. 28) while operating the trimmer at high speed.

NOTE: Always keep the trimming line fully extended.

Line release becomes more difficult as the cutting

line becomes shorter.

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

• For best trimming results, operate unit at full throttle.

• 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:

• Proper adherence of trimming techniques (explained
above}

• What vegetation is cut

• Where vegetation is cut

For example, the line will wear faster when trimming against
a foundation wall as opposed to trimming around a tree.

14

Fig. 28

DECORATIVE TRIMMING

Decorative trimming is accomplished by removing all

vegetation around trees, posts, fences and more.

Rotate the whole unit so that the cutting attachment is at

a 30° angle to the ground (Fig. 29).

• Swing the unit in the opposite direction that the blade
spins which increases the cutting action.

• After the return swing move forward to the next area
to be cut plant your feet again.

• Ihe cutting blade is designed with a second cutting
edge. You can use it by removing the blade turning it

upside down, and reinstalling it.

Fig; 29

USING THE CUTTING BLADE

Before operating the unit with the cutting blade, stand in

the operating position {Fig. 30). Refer to Holding the

Trimmer.

Cutting Blade Operating Tips
I o establish a rhythmic cutting procedure:

• Plant feet firmly, comfortably apart.

• Bring the engine to full throttle before entering the
material to be cut. At full throttle the blade has

maximum cutting power and is less likely to bind, stall
or cause blade thrust (which can result in serious

personal injury to the operator or others).

Io 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. 31)

• Avoid the material just cut as you make the return swing

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

• Always release the throttle trigger and allow the engine

to return to idle speed when not cutting.

• When you are finished, always unsnap the unit from

the harness before taking off the harness.

!+

MAINTENANCE SCHEDULE

Perform these required maintenance procedures at the
frequency stated in the table. I hose procedures should
also be a part of any seasonal tune-up.

NOTE: Maintenance, replacement, or repair of the emission

control devices and system may be performed by
any non-road engine repair establishment, individual

or authorized service dealer.

NOTE: Some maintenance procedures may require

special tools or skills. If you are unsure about
these procedures take your unit to any non-road

engine repair establishment, individual or
authorized service dealer.

FREQUENCY MAINTENANCE REQUIRED _ REFERTO

: [

LINE INSTALLATION

I his section covers both SplitLine TM and standard single

line installation.

Always use Genuine Factory I_artsTM 0.105 in. I2.66 ram)
replacement line. Line other than the specified may make

the engine overheat or fail.

I here are two methods to replace the trimming line:

• Wind the inner reel with new line
* Install a prewound inner reel

Winding the Existing Inner Reel

1. Holdthe outar spool with one hand and unscrew the

Bump Knob clockwise {Fig.32). Inspect the bolt inside
the bump knob to make sure i_moves freely. Replace
the bump knob if damaged.

2,

I_emove the inner reel from the outer spool (Fig. 32).

3.

I_emove spring from the inner reel (Fig. 32).

4.

Use a clean cloth to clean the the inner reel, spring
shaft and inner surface of the outer spool (Fig. 33).

Check the indexing teeth on the inner reel and outer
spool for wear [Fig. 34). If necessary, remove burrs or
replace the reel and spool.

\\

.................................... i i i_i_i_"

Hg+ 3

Indexing

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/

/

/

/

Slotted

Holes

/

F0_US_ _itl_ Sp!itLi_!_

9. Insert the end of the line into the open hole in the
inner reel and pull the line tight to make the loop as

small as possible (Fig. 38).

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

11. Wind the line in tight even layers in the direction

i

indicated on the inner reel.

NOTE: I-ailure to wind the line in the direction indicated will

cause the cutting attachment to operate incorrectly.

8x6 } _ SS//

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

.6},

with the slotted holes. Single line can be used on
either type of inner reel. Use Figure 35 to identify
the inner reel you have.

NOTE: Always use the correct line length when installing

trimming line on the unit I he line may not release
properly if the line is too long.

12. Insert the ends of the line into the two holding slots
(Fig. 39).

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. 40). 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.

Figi36

Single Line Installation

Go To Step 8 for "Sp/itLineTM installation

6. lake approximately 40 feet (12.2 m) of new trimnlfng
line, loop it into two equal lengths. Insert each end of

the line through one of the two holes in the inner reel
(Fig. 36). Pull the line through the inner reel so that
the loop is as small as possible.

7. Wind the lines in tight even layers, onto the reel
(Fig. 37). Wind the line in the direction indicated on

the inner reel. Place your index finger between the

NOTE: I he spring must be assembled on the inner reel

two lines to stop the lines from overlapping. Do not
overlap the ends of the line. Proceed to step 11.

14. Hold the inner reel in place and install the bump knob
by turning counterclockwise. Iighten securely.

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Fig;39

before reassembling the cutting attachment.

37

SplitLine TM Installation

8. lake approximately 20 feet (6.1 m) of new trimming
line. Insert one end of the line through one of the two
holes in the inner reel {Fig. 38). Pull the line through

the inner reel until only about 4 inches is left out.

Spring

INSTALLING A PREWOUND REEL

1. Hold the OLiterspool with one hand and unscrew the
blimp knob clockwise {Fig. 32). Inspect the bolt inside
the bump knob to make sure it moves freely. FZeplace
the bump knob if damaged.

2. I_emove the old inner reel from the outer spool
[Fig. 32).

3. I_emove the spring from the old inner reel
[Fig. 32).

4. Place the spring in the new inner reel.

NOTE= Ihe 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. 40).

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

7. Hold the inner reel in place and install the bump knob
by turning counterclockwise, lighten securely.

Replacement Parts

See Acce&_ories / Replacement Parts.

CHECKING THE OIL LEVEL

Oil Fill Plug/Dipstick ....

O-Ring

Full -

Add 1.4-1,5 Oz.

(41-44 ml)

Top of Dipstick

6. If the level is low, add a sltlall amoLint of oil to the oil
fill hole and recheck (Fig. 42). Repeat until the oil

level reaches the top of the dipstick.

NOTE: Do not overfill the Linit.

Ihe 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 oil to drain into the crankcase.

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

3. Keep dirt, grass clippings, etc., out of the engine.
Clean the area around the oil fill plug/dipstick before

removing it.

4. I_emove the oil fill plug/dipstick and wipe off' oil.

Reinsert it all the way back in.

5. Remove the oil fill plug/dipstick and check oil level.
Oil should be up to the top of the dipstick (Fig. 41).

o!! .....

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

plug/dipstick when checking and changing the
oil [Fig. 42).

!18!!!!!!!!

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. I he
oil will flow freely and carry away more impurities.

1. Unplug spark plug boot to prevent accidental starting.

2. Remove the oil fill plug/dipstick.

3. I_our the oil out of the oil fill hole and into a container
by tipping the unit to a vertical position (Fig. 43).

Allow ample time for complete drainage.

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

according to Federal, State and local regulations.

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

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

measure the correct amount. 3.4 ounce (100 ml)
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. Do not overfill (Fig. 44).

y • •

Figi 43

6. I,leplace the oil fill plug/dipstick.

7. I,Zeconnect spark plug boot.

AIR FILTER MAINTENANCE

Cleaning the Air Filter

Clean and re-oil the air filter every 10 hours of operation.
It is an important item to maintain. Failure to maintain 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).

Air Filter

,\

Air Filter Cover

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

6. I,Zeplace the filter.

NOTE: If the unit is operated without the air filter, you

will VOID the warranty.

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_ig49

7. I_einstall the air filter cover. _osition the hooks on
the left side of the air filter cover intothe slots at the
left side of the back plate (Fig. 4,9).

Fig; 45

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

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

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

reinstall the air filter cover.

filter cover snaps into place in the slot on the back
plate (Fig. 49).

9. I,Zeplace the fuel cap if it was removed.

CARBURETOR ADJUSTMENT
Ihe 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

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Fig; 46

4. Apply enough clean SAE 30 motor oil to lightly coat
the filter (Fig. 47).

Old fuel is usually the reason for improper unit
performance. Drain and refill the tank with fresh fuel prior

to making any adjustments. I,Zeferto Oiland Fuel

information.

_!_a _ Air Fi!ter

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ROCKER ARM CLEARANCE

I his 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.

* I he engine must be cold when checking or adjusting

the valve clearance.
I his task should be performed inside, in a clean,

dust free area.

1.

I_emove the muffler cover by pressing down on it,
separating it from the engine cover. Using a flat

blade screwdriver, disengage the middle and front
tabs and slots first. I he cover will hinge off' from the

rear tab [Fig. 51).

Eng

Checking the fuel, cleaning the air filter, and adjusting
the idle speed should solve most engine problems, If not
and all of the following are true:

* 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 ser,o4Cedealer.

,Idle Adjustment Screw

/

2. I,Zemove the two (2)screws on top of the engine cover
with a Flat-head or 1-20 I orx screwdriver (Fig. 52).

Top View Of The Engine

Engine Cover ....

3. Removethescrewbehindtheenginecover(Fig.53). Adjusting Huts

Screw

Figi 53

4. Disconnect the spark plug wire.

5. Clean dirt from around the spark plug. I,Zemovethe
spark plug from the cylinder head by turning a 5/8 in.

socket counterclockwise.

,

Remove the engine cover (Fig. 52).

7.

Clean dirt from around the rocker arm cover.

Remove the screw holding the rocker arm cover with
a large flat blade screwdriver or Iorx 1-25 bit
(Fig. 54). Remove the rocker arm cover and gasket.

Rocker Arms

Feeler Gauge

Exhaust

Clearance:

.013-,016in.

"- INTAKE

Rocker Arm Cover

Spark Plug Hole

8. Pull the starter rope slowly to bring the pis!on to the top
of its travel, (known as tol_ dead center). Check that:

* Ihe 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 these statements are not true, 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).
Measure both the intake and exhaust valves.

I he recommended clearance for the intake is .003 - .006

in. (.076 -0.152 mm). I he recommended clearance for

the exhaust is .013 - .016 in. (.330 - 0.406 mm).

Use a standard automotive .005 in. (0.127 mm) feeler gauge.

I he feeler gauge should slide between the rocker arm and
valve stem with a slight amount of resistance, without

binding. Figure 55 shows how to measure the intake

clearance, while Figure 56 shows the exhaust clearance.

Intake Valve Feeler Gauge

Stem

Intake Clearance:

T003--T006 inT

(.076-0.152 mm) Exhaust

Valve Stem

F!g! 8

10. Ifthe clearance is not within specification:

a. lurn the adjusting nut using a 5116 inch (8 mm)

wrench or nut driver (Fig. 56).

* I o increase clearance, turn the adjusting nut

counterclockwise.

* Io decrease clearance turn the adjusting nut

clockwise.

b. Recheck both clearances, and adjust as necessary.

11. I,Zeinstallthe rocker arm cover using a new gasket.
Iorque the screw to 20-30 in,lb (2.2-3.4 N,m).

12. I,Zeinstallthe engine cover. Check alignment of the

cover before tightening the screws. Iighten screws.

13. I,Zeinstallthe muffler cover. Slip the rear tab on the

muffler cover into the engine cover rear slot. I hen
slide the remaining slots into the taps until they snap

into place (Fig. 51).

141

Check the spark plug and reinstall. See Replacinq

the 5park Plug.

151

I,Zeplace the spark plug wire.

REPLACING THE SPARK PLUG

Use only Champion I,ZI_)Z19Hspark plug or equivalent. I he

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 cool. Grasp the plug
wire firmly and pull the cap f'rom the spark plug.

2. Clean dirt f'rom around the spark plug. Remove the
spark plug from the cylinder head by turning a 5/8 in.

socket counterclockwise.

3. Replace cracked fouled or dirty spark plug. Set the air
gap at 0.025 in. (0.655 ram.) using a reeler'gauge (Fig. 57).

s7

4. Install a correctly-gapped spark plug in the cylinder
head. lurn the 5/8 in. socket clockwise until snug.

If using a torque wrench torque to:

110-120 in,.Ib, (12.3-13.5 N.m)
Do not over tighten.

SPARK ARRESTOR MAINTENANCE

1. I;_emovethe mL_ff]ercover. See RockerArm Cfearance.

2. With a flat blade screwdriver or Iorx 1-20 bit,
remove the screw attaching the spark arrestor cover

to the muffler (Fig. 58).

,

I_ull the tab on the spark arrestor cover out of the
muffler. Remove the spark arrestor cover.

4.

Remove the spark arrestor screen f'rom the spark
arrestor cover.

6.

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

6.

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

CLEANING

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
solvents such as kerosene, can damage plastic housing

or handle. Wipe off any moisture with a soft cloth.

STORAGE

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

• Allow the engine to cool before storing.

• Lock up the unit to prevent unauthorized use or damage.

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

• Store the unit out of the reach of children.

LONG TERM STORAGE

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 to

Federal, State, and Local regulations.

2. Start the engine and allow it to run until it stalls. Ihis
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. I,Zeinstallthe spark plug.

NOTE: I,Zemovethe spark plug and drain all of the oil

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

4. Change the oil referring to Chanqtng the Oil.
Dispose of the old oil in accordance to Federal, State

and Local regulations.

,

Ihoroughly clean the unit and inspect for any loose

or damaged parts. Repair or replace damaged parts
and tighten loose screws, nuts or bolts. I he unit is

ready for storage.

TRANSPORTING

Allow the engine to cool before transporting.
Secure the unit while transporting.

Drain the gas tank before transporting.
lighten gas cap before transporting.

ACCESSORIES/REPLACEMENT PARTS

4-Cycle Oil .............................. 181786

Spark Plug .............................. 180852

Spark Arrestor Screen ..................... 180890

I,Zeplacement Line ...................... 753-04216

I,Zeplacement Line Cartridge .............. 753-1160

Inner I,ZeelSpring ........................ 610636

Outer Spool ............................. 683301

Inner I,Zeel .............................. 147495

Bump Knob ............................. 180814

Fuel Cap .............................. 753-1229

Shoulder Harness ........................ 682075

!24!!!!!!!!

CAUSE

Empty f'ueltank
Primer bulb wasn't pressed enough

Old f'uel

Fouled spark plug
Plugged spark arrestor

When it is above 40°F outside, the Cold Start Lever is in the
CLOSED/DOWN position

When it is below 40°1- outside, the Cold Start Lever is in the
OPEN/UP position

ACTION

Fill fuel tank with new fuel
Press primer bulb fully and slowly 10 times

Drain gas tank and add fresh f'uel
Replace or clean the spark plug

Clean or replace spark arrestor

Flip the Cold Start Lever to OPEN/UP
Flip the (;old Start Lever to CLOSED/DOWN and follow

the 5tarring instructions

CAUSE

Air filter is plugged
Old f'uel

Improper carburetor adjustment

CAUSE

Old f'uel

Improper carburetor adjustment

Cutting attachment bound with grass

Dirty air filter
Plugged spark arrestor

CAUSE

Old f'uel

Improper carburetor adjustment
Fouled spark plug

Plugged spark arrestor

ACTION

Replace or clean the air filter
Drain gas tank and add fresh f'uel

Adjust carburetor

ACTION

Drain gas tank and add fresh f'uel

Iake to an authorized service dealer for adjustment
Stop the engine and clean the cutting attachment

Clean or replace the air filter
Clean or replace spark arrestor

ACTION

Drain gas tank and add fresh f'uel

Iake to an authorized service dealer for adjustment

Replace or clean the spark plug

Clean or replace spark arrestor

CAUSE

Cutting attachment bound with grass
Cutting attachment out of line

Inner reel bound up

Cutting head dirty

Line welded
Line twisted when refilled
Not enough line is exposed

CAUSE

Oil, cleaner or lubricant in cutting head

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
Disassemble and rewind the line

Push the bump knob and pull out line until 4 inches

(102 ram) of line is outside of the cutting attachment

Clean and thoroughly dry the cutting head

ACTION

ACTION

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

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

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

Clutch lype ......................................................................................................................................................... Centrif'ugal

Operating RPM ....................................................................................................................................... 6,800 - 9,300 rpm

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

Ignition lype .......................................................................................................................................................... Electronic

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

Valve clearance [intake) ......................................................................................................... 003-.006 in. [.076-.152 mm)

Valve clearance [exhaust) ...................................................................................................... 013-.016 in. [.330-.406 mm)

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

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

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

I-uel ....................................................................................................................................................................... Unleaded

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

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

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

I hrottle ............................................................................................................................................... Manual Spring I_eturn

I-uel Iank Capacity ........................................................................................................................................ 12 oz (355 ml)

Drive Shaft Housing .................................................................................................................. Aluminum I ube (EZ-Link ]_A)

I hrottle Control ........................................................................................................................................ I-inger-I ip I rigger

Unit Weight (No Fuel, with J-handle, Cutting attachment shield and Cutting attachment) ........................ 13.15 Ibs (6 kg)

Cutting Mechanism ................................................................................. 4-1 ooth Cutting Blade, Dual String Cutting Head

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

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

I rimming Line L)iameter ..................................................................................................................... 0.105 inch (2.68 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

_AII _e_ifiRati_ns a_e base_n [he latest p_d[ict infori_a_i0i_ available at tBe_ii#e ofprinti_ig We reseWet #etig[itto

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EPA Emission Control Warranty Statement

Your Warranty Rights and Obligations

Ihe Environmental Protection Agency and MID SOUl HWESI INC (MID) are pleased to explain the emission control

system warranty on your 2002 and later small off-road engine. New small off-road engines must be designed, built and
equipped to meet stringent anti-smog standards. MII_) must warrant the emission control system on your small off-road

engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your
small off-road engine.

Your emission control system may include parts such as the carburetor or fuel-injected system, the ignition system, and

catalytic converter. Also included may be hoses, belts, connectors and other emission-related assemblies.

Where a warrantable condition exists MID will repair yoLIrsmall off-road engine at no cost to you including diagnosis,

parts and labor.

Ihe 2002 and later small off-road engines are warranted for two years. If any emission-related part on your engine is

defective, the part will be repaired or replaced my MID.

Owners Warranty Responsibilities

• As the small off-road engine owner, you are responsible for the performance of the required maintenance listed in yoLir

operator's manual. MID recommends that you retain all receipts covering maintenance on your small off-road engine,

but MID cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all
scheduled maintenance.

• As the small off-road engine owner, you however should be aware that M113 may deny you warranty coverage if your

small off-road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

* You are responsible for presenting your small off-road engine to a MID Authorized Service Center as soon as a

problem exists. I he warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

Ifyou have any questions regarding your warranty rights and responsibilities, you should call 1-800-345-8746.

Manufacturer's Warranty Coverage

• Ihe warranty period begins on the date the engine or equipment is delivered to the retail purchaser.

• Ihe manufacturer warrants to the initial owner and each subsequent purchaser, that the engine is free from defects in

material and workmanship which cause the failure of a warranted part for a period of two years.

* I,Zepairor replacement of warranted part will be performed at no charge to the owner at an Authorized MID Service
Center. For the nearest location please contact MID at: 1-800-345-8746.

* Any warranted part which is not scheduled for replacement, as required maintenance or which is scheduled for only
for regular inspection to the eff'ect of "Repair or Replace as Necessary" is warranted for the warranty period. Any

warranted part which is scheduled for replacement as required maintenance will be warranted for the period of time up
to the first scheduled replacement point for that part.

* Ihe owner will not be charged for diagnostic labor which leads to the determination that a warranted part is defective,

if the diagnostic work is performed at an Authorized MID Service Center.

• Ihe manufacturer is liable for damages to other engine components caused by the failure of a warranted part still

under warranty.

* Failures caLised by abuse, neglect or improper maintenance are not covered under warranty.

• Ihe LISeof add-on or modified parts can be grounds for disallowing a warranty claim. I he manufacturer is not liable to

cover failures of warranted parts caused by the use of add-on or modified parts.

• In order to file a claim, go to your nearest Authorized MID Service Center. Warranty services or repairs will be

provided at all Authorized M113Service Centers.

• Any manufacturer approved replacement part may be used in the performance of any warranty maintenance or repair

of emission related parts and will be provided without charge to the owner. Any replacement part that is equivalent in

performance or durability may be used in non-warranty maintenance or repair and will not reduce the warranty
obligations of the manufacturer

• Ihe following components are included in the emission related warranty of the engine, air filter, carburetor, primer, fuel

lines, fuel pick up/fuel filter, ignition module spark plug and muffler.

ENGINE PARTS - MODELS TB490BC

4-CYCLE GAS TRIMMER

PPN - 41BDT49C063

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ENGINE PARTS - MODEL TB49OBC
4-CYCLE GAS TRIMMER

PPN - 41BDT49C063

Item Part No, Descr!ption !tern Pa_ NQ, Descr!ption

1 753-04083 Engine Cover 46 781-181247 Palrrut
2 791-182339 Engine Cover Screws 47 753-1 lgg Recoil Pulley

3 791-181025 Valve Cover Screw 48 753-04286 Recoil Sprfng
4 791-182098 Valve Cover 48 781-182368 Nut Clip

5 791-182099 Valve Cover Gasket 50 791-181079 Pull Handle
6 791-182340 Rc<:kef Adjustri'ierrt Nut 51 781-611061 Rope Guide

7 791-182101 Rc<:kef Arm Pivot 52 791-613103 Rope
8 791-182100 Rc<:kef Arm 53 791-181020 Starter Housing Scr e_-e

8 791-182341 Rc<:kef Arm Stud 54 753-1237 Starter Housing Assembly (irrcludes 48-52)
10 791-182103 Valve Spring Re4airrer 55 791-182368 Clutcrr Washer
11 791-181038 Valve Spring 56 753-1238 Clutcrr with Spacer

12 791-182102 Pusrr Rod Guide 57 791-153592 Clutcrr Brum
13 791-181033 Pusrr Rod 58 753-1239 Clutcrr Cover

14 791-182745 Cylinder Head (includes 9 & 12) 58 781-145569 Anti-Rotagon Scfe'_
15 791-182344 Cylinder Screw 60 753-1240 Screw

18 791-182345 Irrtake Baffle 61 753-1241 Nut
17 791-182749 Carbur_[or Mount Gaske4 62 781-181345 Clutter Cover Screws

18 791-181034 Nut 63 753-04298 Ignition Module with ScrP_s
19 791-182347 Carbur_[or Mount {includes18) 64 791-181065 Spacer

20 791-182348 Carbur_[or Mount Screw 65 753-04299 Fl_o¢,,heel
21 791-182732 Carbur_[or Gaske4 66 781-182743 Shroud Assembly wirer Screv_3
22 753-04298 Carbur_[or with Primer 67 781-182378 Crarrkcase Assembly (includes 68 & 68)
23 791-181751 O-Rirrg, Carbure[or 68 791-182375 80 ° Elbow

24 753-04305 Air FilteHChoke Cover h_ernbly 68 781-182379 Breather Hose

25 791-182097 Breather Tube 71 753-1242 Cam Follower Set
28 791-181750 Air Filter Moungrrg Screw 72 791-181013 Cam Bracket

27 791-181757 Air Filter 73 791-181012 Cam Bracket Screw
28 753-04318 Air Filter Cover 74 791-181040 Valves, Intake and Ex_raust

29 753-1229 Fuel Cap 75 791-182374 Cylinder Gaske4
30 791-182352 Fuel r_e[urn Lirre 76 791-181018 Oil Parr Gasket

31 791-182353 Fuel Pick-Up Line with Fiiter 77 781-182377 Oil Parr (includes 76 _ 78)
32 791-181080 Screw 78 791-181020 Oil Parr Screw

33 791-182354 Washer 78 753-04041 Dipstick Assembly (includes 84)
34 753-1230 Fuel Tarrk Assembly (includes 28-31} 80 781-182280 O-Ring
35 791-182356 Fuel Tarrk Shield 81 78%181009 Corlrrecgrrg Rod

38 753-04287 T_rrottle Cable 82 781-181008 Wrist Pin Buttorr
37 791-182358 Muffler BalTle 83 753-1243 Pistorr

38 791-181048 Muffler Gasket 84 791-181008 WristPin
39 791-182359 Muffler (includes 38, 40-42) 85 781-182285 Pistorr r_ing Se_

40 791-180890 SparkArtes_orScr_rr 86 79%182409 Washer
41 791-181045 Screen Cover 87 791-181861 Screw

42 791-181046 Screw 88 791-612468 Cornpressiorr Spring
42 791-182361 Muffler Mourrdng Screw 88 781-182537 Gfomme[

44 753-04092 Muffler Cover 781-180852B Spark Plug
45 791-182804 S'_i[ch Wife Assembly 753-1245 Sho_t Block Assembly iirrcludes 3-15, 68-85)

iirrcludes 27) 70 791-181015 Cam Gear

791-180142 Starter Pawl Repair Kit
791-182158 Carburetor Repair Kit

753-1248 Gaske4 E)iapfrragrn r_epair Kit

Parts not showrl

BOOM AND TRIMMER PARTS - MODEL TB49OBC

4-CYCLE GAS TRIMMER

PPN - 41BDT49C063

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!tem Pa_ No, De_cdption

1 791-00840
2 791-00841

3 791-00842
4 791-182688
5 791=182405

6 791=618327
7 753-1247

8 791=181099
8 791-683295

10 791-181811
11 791-181812

12 791-181813
13 791-181814

14 791-181815
15 791-145569
16 753-1190
17 791-182057

18 791-181617
18 791=181881

20 791=181886
21 791-182541

22 791-613300
23 791-182200
24 791-182183

25 791-182195
26 791-145569
27 791-147492

28 791-182196
28 791-683304

30 753-1191
31 791-682061

32 791-147498
33 791-612483
34 791-683301
35 791-612026

36 791-618636B
37 791-147495
38 791-188814B

38 791-145873B

40 791=181699

791-188014B
791-613226

791=682075B

_hrottle Housing and rrfgger Assembly (irlcludes 2-4)
_hrottle Trigger Lock=OL$
_hrottle Trigger
_hrottle Trigger Spring

Swit_:fl _&_lrirlbly

Harness Clip
Upper Drive Shaft Housing Assembly
J-Handle hz_ern bly

Har_dle Bracket h_ernbly (includes 10-15)
Screw

Upper Handle Clamp
Middle Handle Clamp

Lower Handle Clamp

Nu[

Anti-Rotadorl Scr e_-_
EZ-Lir_k Coupler (includes 17-20)

Screw
Bolt

Adjustment Knob

Knob Re[aining Nut

Lower Drive Shaft Housing Assembly
Lower Flexible Drive Shaft

Shield Mount Screw Assembly
2 piece Gearbox Assembly iirlcludes 25-28)

Gearbox Scr _
Anti-Rotadorl Scr e_-_

Blade Shield/Shield Mount " " ......

Blade r)river 2 Piece Gea[box Assemb!y Pa_ - !tern 24 _" _-_
Shield Mounting Screw 41 791-182191 Left Housing '\,_, _

Shield arid Blade Assembly {includes 31 ) 42 781-182192 Righ[ Housirlg ........................

Blade Assembly 43 781-182194 Pinion Gear Assembly \
Relair_ing Washer 44 781-182198 Output Shalt Bushing

Spool Shalt 45 781-182198 Ou[put Shalt Gear
Outer Spool arid Eyele4 Assembly 48 781-182197 Ou[put Shalt h_ernbly
Re/airier iirlcludes 44 _ 45)

Sprirtg 47 753-1159 O-Rirt9
Inr_er Reel

Bump Head Krlob Assembly Ogtiona! Accessories
4-_ooth Blade 753-1160 Reel and Line Assembly
Nut 753-1161 Bump Head Assembly

Blade Re[aining Kit (includes 32 & 40) iir_cludes 33-38)
Lc<:kirlg Rod Tool

Shoulder Hame_ I_ems Not Sho'_n

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/

MA NUFACTURER:S ElM D WARRANT FOR!

Ihe limited warranty set forth below is given by I roy-Bilt

LLC with respect to new merchandis_ purchasedand

used in the United States, its possessions and territories.
Iroy-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, r_pair or replace, free of charge, any part found
to be defective in material or workmanship. I his 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 sabject 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 an_

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

your warranty as to any resulting damage. I his warranty is
limited to nir_ety (90) clays fronl the date of original retail

purchase for any lroy-Silt product that is used for rental or
commercial purposes, or any other income-producing

purpose.
HOW TO OBTAIN SERVICE: Warranty service is

available, WIIH PI,_OOF OF PUFZCHASE I HROUGH
YOUR LOCAL AUIHOI,_IZED SEI,_VlCE DEALEI,L I o

locate the dealer in your area, visit our website at
_A_A_,.troybilt.com,check for a listing in the Yellow Pages,
call 1 (81_6)840-6483 or 1 (330) 558-'7220 or write to li:oy-

8lit LLC, PO Box 361131, Cleveland, OH 44136-0019.

This limited warranty does not provide coverage in
the following cases:

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

Filters

8. Wear items - Bump Knobs, Outer Spools, Cutting
Line, Inner Reels, Starter Pulley, Starter Ropes, [)rive

Belts

C. Iroy-Silt 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 I roy-Slit's authorized
channels of export distribution.

Iroy-Silt LLC reserves the right to change or improve the
design of any I roy-Silt 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 idenbtied, No other

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

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 _om the sales.

Troy-Bilt LLC shall not be hable 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 limitations on 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 pri_e 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.

Ihis limited warranty shall not extend to anyone other
than the original purchaser, original lessee or the person

fur whom it was purchased as a gift.
How State Law Relates to this Warranty: I his warranty

gives you specific legal rights, and you may also have
other rights which vary from state to state.

I o locate your nearest service dealer dial 1 [phone].

Troy-Bilt LLC

PO Box 361131

Cleveland, OH 44136-0019