Troy-Bilt 42052, 42051 User Manual
Models
42051 - 9.5HP / 26" Auger
42052 - 11HP / 30" Auger
OWNER’S MANUAL
Snow Thrower
• Safety
• Assembly
• Features and Controls
• Operation
• Maintenance
• Parts List
®
GARDEN WAY INCORPORATED
(11HP Model shown)
SAFETY FIRST!
Before operating this equipment, read this
Owner’s Manual and the separate manual
supplied by the engine manufacturer.
Table of Contents
SECTION 1: SAFETY ........................................... 3
Safety Decals ......................................................................... 5
SECTION 2: ASSEMBLY ....................................... 6
Inspect Unit............................................................................. 6
Unpack Unit ............................................................................ 6
Hardware Bag Contents........................................................... 6
Remove (optional) Drift Slicers............................................... 6
Install Handlebars ................................................................... 7
Install Discharge Chute........................................................... 7
Attach Chute Control Rod........................................................ 8
Attach Auger Drive Control Rod.............................................. 8
Attach Wheel Control Rod....................................................... 8
Attach Gear Shift Control Rod................................................. 8
Connect Wiring for Handlebar Warmers and Light.................. 10
Add Motor Oil to Crankcase .................................................... 10
Check Auger Gear Case Oil Level............................................. 10
Check Tire Pressure................................................................10
Install Drift Slicers................................................................... 10
SECTION 3: FEATURES AND CONTROLS...................... 11
SECTION 4: OPERATION ....................................... 12
Pre-Operation Checklist........................................................... 12
Starting the Engine.................................................................. 13
Stopping ................................................................................. 13
Auger Drive Engagement......................................................... 14
Wheel Drive Engagement........................................................14
Auger Drive/Wheel Drive Interlock Feature.............................. 14
Shifting Gears ......................................................................... 14
Transporting the Unit..............................................................14
Snow Throwing Tips...............................................................14
Snow Throwing Patterns......................................................... 15
SECTION 5: MAINTENANCE ................................... 16
Engine Maintenance................................................................ 16
Lubrication.............................................................................. 16
Wheel Drive Disc Adjustment.................................................. 16
Auger Drive Belt and Wheel Drive Belt Replacement
............. 18
Shear Bolts.............................................................................. 18
Auger Drive Belt(s) Adjustment............................................... 18
Gear Shift Rod Adjustment
................................................ 19
Drive Disc Clearance Adjustment............................................ 19
Brake Arm Adjustment............................................................19
Skid Shoes/Scraper Blade....................................................... 20
Slip Differential Adjustment..................................................... 20
Off-Season Storage................................................................. 20
Troubleshooting Chart ............................................................ 21
Required Maintenance Schedule............................................. 23
SPECIFICATIONS/KITS & ACCESSORIES ..................... 24
PARTS LIST ...................................................... 25
CUSTOMER SERVICE INFORMATION .............. BACK COVER
2
Dear Owner:
Thank you for purchasing this product. The unit was care-
fully designed and manufactured to provide excellent
performance if properly operated and maintained.
Review this manual frequently to familiarize yourself with
the unit, its features and its safe operation. Be sure that
you and any other operators carefully follow the recommended safety practices at all times. Failure to do so
could result in personal injury or property damage. This
Manual is considered a permanent part of the unit and it
must stay with the unit if the unit is resold.
The warranty statement is included in the literature package. Read it carefully. Also, please complete and return
the postpaid owner registration card included with this
Manual. The purpose of the card is to register each unit
and owner at the factory to provide product updates.
If you have any problems or questions concerning the unit,
contact your local authorized dealer or the Factory (see
back page of this Manual).
We want to ensure your complete satisfaction at all times.
See Back Cover for
Customer Service Information
Safety Alert Symbol
This is a safety alert symbol. It is used in this manual
and on the unit to alert you to potential hazards. When
you see this symbol, read and obey the message that
follows it. Failure to obey safety messages could
result in personal injury or property damage.
This machine meets voluntary safety standard B71.3 – 1995,
which is sponsored by the Outdoor Power Equipment
Institute, Inc., and is published by the American National
Standards Institute.
The engine exhaust from this product contains chemicals known to the State of California to cause cancer,
birth defects or other reproductive harm.
WARNING
SPARK ARRESTER WARNING TO RESIDENTS
OF CALIFORNIA AND SEVERAL OTHER STATES
Under California law, and under the laws of several other states,
you are not permitted to operate an internal combustion engine
using hydrocarbon fuels on any forest, brush, hay, grain, or
grass covered land; or land covered by any flammable agricultural crop without an engine spark arrester in continuous effective working order.
The engine on the unit is an internal combustion engine which
burns gasoline, a hydrocarbon fuel, and must be equipped with a
spark arrester muffler in continuous effective working order. The
spark arrester must be attached to the engine exhaust system in
such a manner that flames or heat from the system will not ignite
flammable material. Failure of the owner/operator of the unit to
comply with this regulation is a misdemeanor under California
law (and other states) and may also be a violation of other state
and/or federal regulations, laws, ordinances or codes. Contact
your local fire marshal or forest service for specific information
about which regulations apply in your area.
Safety
1
Section
Training
1. Read this Owner’s
Manual and the separate Engine Owner’s
Manual carefully before operating the
unit. Be completely familiar with the
controls and the proper use of the
unit. Know how to stop the unit and
disengage the controls quickly. A replacement manual is available by contacting the factory.
2. Never allow children to operate the
unit. Never allow adults to operate
the unit without proper instruction.
3. Keep the area of operation clear of
all persons, particularly small children
and pets. Keep bystanders at least 25
feet away from the area of operation.
4. Exercise caution to avoid slipping or
falling, especially when operating in
reverse.
5. Familiarize yourself with all of the
safety and operating decals on the
unit and on any attachments or
accessories.
6. Do not run the engine in an enclosed
area. Engine exhaust contains carbon
monoxide gas, a deadly poison that is
odorless, colorless, and tasteless. Do
not operate the unit near buildings,
windows, or air conditioners.
7. Keep hands or any other part of the
body or clothing away from the inside
of the collector (auger/impeller) housing, the discharge chute opening, or
moving parts.
8. Do not operate the unit if you are
under the influence of alcohol, medication, or when tired or ill.
Preparation
1. Wear approved safety glasses or eye
shields during operation or while performing an adjustment or repair to
protect eyes from foreign objects that
may be thrown from the unit.
2. Do not wear loose-fitting clothing,
such as scarves, which could be
caught by moving parts. Tie up or restrain long hair.
3. Before starting the engine, check the
tightness of all screws, nuts, bolts,
and other fasteners. Replace or clean
any damaged or unreadable safety
and operating labels.
4. Wear adequate winter outer garments
when operating the unit. Wear
footwear that will improve footing on
slippery surfaces.
5. Use extra care when handling gasoline
or other fuels. Gasoline and its vapors
are highly flammable and explosive.
To help prevent a fire or explosion:
a. Store gasoline only in an approved
gasoline storage container, safely
out of the reach of children.
b. Never remove the fuel fill cap on
the fuel tank, or add fuel while the
engine is running or hot.
c. Keep matches, smoking materials,
open flames, and sparks away from
the fuel tank and gasoline storage
container.
d. Fill the fuel tank outdoors and with
extreme care. Never fill the fuel
tank indoors.
e. Replace the fuel fill cap on the fuel
tank, the cap on the gasoline storage container, and clean up fuel
spills before starting the engine.
f. Leave 1-1/2 inch (3.81 cm) of air
space at the top of the fuel tank to
allow for fuel expansion.
g. Do not store unit or gasoline stor-
age container where there is a danger of an open flame or spark, or
where ignition sources are present
such as hot water and space
heaters, furnaces, clothes dryers,
stoves, electric motors, etc.
6. For units equipped with electric-start:
a. Only use a 3-pronged, UL rated and
approved, outdoor use power cord.
Do not use any adapters on the
cord.
3
Discharge Chute
Chute Deflector Cap
Auger Drive Control Lever
Chute Directional Control
Wheel Drive
Control Lever
Auger Assembly
Skid Shoe
Collector
(auger/impeller)
Housing
Gear Shift Lever
Section 1: Safety
4
b.The 120V A.C. starter is equipped
with a three-wire power cord and
plug and is designed to operate on
120V A.C. household current. The
starter must be properly grounded
at all times to avoid the possibility
of injury or death from electrical
shock. Determine that your house
wiring is a Ground Fault Interrupted
(G.F.I.) three-wire grounded system, or ask a licensed electrician if
you are not sure. If your house
wiring system is not a G.F.I. threewire grounded system, DO NOT use
the electric starter under any condition. If your house wiring system is
grounded but a G.F.I. three-prong
wall receptacle is not available at
the location your starter will be
used, one should be installed by a
licensed electrician.
c. Inspect the power cord for damage
before use. If it is damaged, do not
use it.
d.Stand on dry ground when handling
the power cord. Do not handle the
power cord with wet hands or wet
gloves. Do not use the electric
starter if it is raining.
e. Connect the cord to the electric
starter first, and then plug the cord
into a properly grounded outlet
(this lessens the chances of sparks
from occurring near the engine).
f. Do not abuse the power cord. Do
not pull the unit by the cord. Do not
pull the cord to disconnect it from
the outlet. Keep the cord away
from sharp edges, oil, and excessive heat.
g.Store the power cord in a secure
place, safely out of the reach of
children.
7. Adjust the skid shoes and scraper
blade so the collector (auger/impeller)
housing clears gravel or crushed rock
surfaces.
8. Never attempt to make any adjustments while the engine is running
(except when specifically recommended by the the manufacturer).
Operation
1. The operator of the unit is responsible
for the safety of all persons in the operating zone of the unit.
2. Before starting the unit, disconnect
the spark plug wire and check the collector (auger/impeller) housing and
discharge chute to make sure they are
free of ice.
3. Disengage all clutches before starting
the engine.
4. Let the unit adjust to outdoor temperature before use.
5. Check the operation of the controls
before using the unit. Do not operate
the unit unless all controls are operating properly.
6. Never carry passengers on the unit.
They could fall off and be seriously injured, or they could interfere with safe
operation.
7. Keep hands, other body parts, and
clothing away from any moving or rotating parts. Keep clear of the intake
and discharge openings at all times.
8. Before starting the engine, inspect the
area where the unit is to be used and
remove all sleds, boards, doormats,
wire, bottles, cans, or other debris.
9. Keep children out of the area of operation and under the watchful eye of an
adult not operating the unit. Never assume that children will remain where
you last saw them.
10. If the unit makes an unusual noise or
vibration, immediately shut the engine
off, wait for all moving parts to stop,
disconnect the spark plug wire from
the spark plug and perform the following steps:
a. Inspect for damage.
b. Replace or repair any damaged
parts.
c. Check for and tighten any loose
parts.
11. Stop the engine and disconnect the
spark plug wire whenever you leave
the operating position, before unclogging the collector (auger/impeller)
housing or discharge chute, and when
making any repairs, adjustments, or
inspections. Use only a wooden stick
(at least 3 feet long) to clear away any
blockage.
12. When cleaning, repairing, or inspecting, make certain the auger, impeller
and all moving parts have stopped.
Disconnect the spark plug wire from
the spark plug and secure the wire
away from the spark plug.
13. Keep all guards, covers, shields and
safety devices in place and in good
working condition. Do not attempt to
defeat the purpose of any safety
device.
14. Exercise extreme caution on slopes.
15. Do not attempt to clear steep slopes.
16. Do not clear snow across the face of
slopes. Exercise extreme caution
when changing direction on slopes.
17. Always observe the terrain. Watch for
and avoid obstacles. Stay away from
holes, ditches, soft or steep embankments and other potentially dangerous terrain. Deep snow can hide obstacles and drop-offs.
18. Do not use the unit near drop-offs,
ditches, or embankments. If a wheel
goes over an edge, or if an edge
caves in, the unit could overturn.
19. Never operate the unit at high transport speeds on slippery surfaces.
Wet surfaces reduce traction and
stability.
20. Look behind and use care when operating the unit in reverse. If you have
to pull the unit backward, disengage
the auger and wheel drives. Always
check behind for hazards.
21. Be extremely careful when using the
unit near blind corners, shrubs, trees,
and other objects that may obscure
vision.
5
Section 1: Safety
22. Be extremely careful when operating
on or crossing gravel drives, walks or
roads. Stay alert for hidden hazards
or traffic. Remove any hearing
protection.
23. Do not overload the machine capacity
by attempting to clear snow at too
fast a rate.
24. After striking a foreign object, stop
the engine, remove the wire from the
spark plug, thoroughly inspect the
unit for any damage, and repair the
damage before restarting and operating the unit.
25. Use only attachments and accessories
that are approved for use with the unit
(such as wheel weights, counterweights, cabs, and the like). Contact
an authorized dealer or the factory if
you are not sure about the use of any
attachment or accessory.
26. Operate the unit only in daylight or in
good artificial light. Always be sure of
your footing, and keep a firm hold on
the handlebars. Walk; never run.
27. Do not tamper with the engine governor settings. The governor controls
the maximum safe engine operating
speed and protects the engine and
moving parts from damage. Contact
your local engine dealer for service if
a problem exists.
28. Disengage the auger drive when the
unit is being transported or is not in
use. Disconnect the spark plug wire
from the spark plug to prevent accidental starting.
29. Do not touch the muffler or other engine parts which may be hot from operation. Wait for parts to cool completely before inspecting, cleaning or
repairing the unit.
30. Never operate the unit near buildings,
glass enclosures, automobiles, window wells, drop-offs, etc., without
first properly adjusting the discharge
angle and direction. Keep children and
pets away.
31. Never direct discharge at persons, animals, vehicles or buildings. Never
allow anyone in front of the unit when
the engine is running.
32. Disengage the auger and wheel drives
if you are approached by any child,
inattentive person or pet.
33. Run the unit for a few minutes after
use to prevent freeze-up. Remove any
snow from the unit (snow can melt,
re-freeze and jam the unit).
Maintenance and Storage
1. When the unit is stopped for servicing,
inspection, storage, or to change an
attachment or an accessory,
disconnect the spark plug wire from
the spark plug and secure the wire
away from the plug. Allow the engine
to cool before making inspections, adjustments or performing any
maintenance.
2. Maintain the unit and all attachments
and accessories in safe working
condition.
3. Never perform any maintenance while
the engine is running, or when the
spark plug wire is connected to the
spark plug.
4. Do not store the unit or fuel container
inside an enclosure where there is an
open flame or spark, or where ignition
sources are present, such as: hot
water and space heaters, furnaces,
clothes dryers, stoves, electric motors,
etc.
5. Allow the engine to cool before storing
in any enclosure.
6. Store gasoline in a cool, well-venti-
lated area, safely away from any sparkor flame-producing equipment.
7. Store gasoline only in an approved
gasoline storage container, safely out
of the reach of children.
8. Use only original equipment replace-
ment parts. Parts manufactured by
others could present a safety hazard
even though they may fit on the unit.
9. Store the unit where children will not
have access to it. Always disconnect
the spark plug wire from the spark
plug to prevent accidental starting. On
units equipped with the electric starting, store the power cord in a secure
place, safely out of the reach of
children.
10. Check the tightness of the auger shear
bolts and other fasteners at frequent
intervals to be sure the unit is in safe
working condition. Torque shear bolts
to 11 ft. lbs. (15 Nm).
11. Maintain or replace safety and instruction decals as needed if they are damaged or illegible.
12. Refer to the separate Engine Owner’s
Manual for complete engine operating
and maintenance information.
13. Refer to the “storage” instructions in
this Manual and in the Engine Owner’s
Manual if the unit is to be stored for an
extended period.
Safety Decals
For your personal safety and the safety of
others, a number of safety message decals
have been affixed to your unit. Keep them
clean and legible at all times. Contact your
local service dealer or the factory for replacements if any decals are damaged or
missing.
Refer to the parts listing for decal
locations, part numbers, and ordering
instructions.
NOTE: Left and right sides of the unit are
determined from the operator position,
facing the direction of forward travel.
A. Inspect Unit
Inspect the unit and shipping crate for
damage immediately after delivery. Contact
the carrier (trucking company) if you find
or suspect damage. Inform them of the
damage and request instructions for filing
a claim. To protect your rights, put your
claim in writing and mail a copy to the carrier within 15 days after the unit has been
delivered. Contact the Factory if you need
assistance.
Tools/Materials Required for Assembly
(1) Scissors or knife (to cut plastic ties)
(1) *5/16" wrench
(1) *3/8" wrench
(2) *7/16" wrenches
(2) *1/2" wrenches
(1) *9/16" wrench
(1) Phillips head screwdriver (medium)
(1) Needle-nosed pliers (medium)
(1) Automotive-type tire pressure gauge
(1) Funnel
(1) Clean, high-quality motor oil. Refer to
the separate Engine Owner’s Manual
for the exact oil specifications and
amount needed for your engine.
* Adjustable wrenches may be used.
IMPORTANT: Motor oil must be added to
the engine crankcase before the engine is
started. Follow the instructions in this
Section.
B. Unpack Unit
Follow these steps to unpack your unit.
1. After removing cardboard carton, remove discharge chute (O, Figure 2-4)
assembly (with attached hardware
bag) from inside cardboard sleeve.
2. Cut plastic ties securing handlebar
ends to chassis and remove handlebars. Remove any protective wrapping
on handlebars.
3. Cut the four plastic ties (two on auger
shaft and two on wheel axle) that secure the unit to the shipping pallet.
4. Move unit onto a clean, level surface.
The unit is heavy. To move the unit
off the shipping pallet, use caution
and obtain the help of at least one
assistant.
5. The hardware bag should contain the
following items:
* These are replacement parts (Figure 2-1)
that should be kept with this manual (if the
auger jams, the shear bolts are designed
to break to prevent damage to the auger
drive). See Section 5 for replacement
information.
C. Remove Drift Slicers
(if equipped)
1. Remove the four screws (B, Figure
2-2) and locknuts (two on each side)
that secure the drift slicers (A) and remove them from both sides of the collector (auger/impeller) housing.
NOTE: For shipping purposes, the drift
slicers are mounted backwards.
2. Place the drift slicers and hardware
aside. The drift slicers can be attached
after the unit is assembled (see last
step of these assembly instructions).
Description Qty.
Engine Stop Switch Key .................... 1
Plastic Cable Tie ................................ 3
Hex Hd. Flange Screw, 3/8-16 x 3/4 .. 4
Hex Hd. Screw, 1/4-20 x 3/4.............. 2
Locknut, 1/4-20 ................................ 2
Phillips Hd. Screw, #10-24 x 3/8 ...... 2
Locknut, #10-24................................ 2
Cotter Pin .......................................... 1
Electric Start Power Cord .................. 1
*Shear Bolt, 5/16-18 x 1-3/4 ............ 2
*Locknut, 5/16-18 ............................ 2
To prevent personal injury or property
damage, do not start the engine until all
assembly steps are complete and you
have read and understand the safety and
operating instructions in this
manual.
WARNING
6
Assembly
2
Section
Figure 2-1
Figure 2-2
B
A
Drift Slicers
(Optional)
Discharge Chute
Chute
Deflector Cap
Auger Drive Control Lever
Light
Chute Directional Control
Wheel Drive
Control Lever
Auger Assembly
Skid Shoe
Collector
(auger/impeller)
Housing
Gear Shift Lever
FULLY ASSEMBLED UNIT
Section 2: Assembly
D. Install Handlebars
1. Use the four 3/8-16 x 3/4" hex flange
screws to attach the handlebars to the
sides of the chassis.
a. Install a screw in the upper mount-
ing hole (C, Figure 2-3) on each
side. Leave screws loose enough to
allow handlebar to pivot.
b. Install a screw (D) in the lower
mounting hole on each side.
c. Using light pressure, press down on
the left side handlebar and tighten
the two screws. Repeat on the right
side.
2. There are four pre-installed screws
(E, Figure 2-3) on the inside of the
handlebars that secure the control
panel. Tighten each screw securely.
E. Install Discharge Chute
1. Remove the cardboard shield from the
discharge chute mount opening.
2. Loosen (do not remove) the left and
right-side sets of plastic shims (G,
Figure 2-4) and plastic hold-down clips
(H) on the toothed flange (J) of the discharge chute assembly. Remove and
save the remaining (front) hold-down
clip, shim and mounting hardware.
3. From either side of the unit, slide the
discharge chute onto the chute mounting flange (K, Figure 2-4), making sure
that the plastic shims (G) are above
the flange and the plastic hold-down
clips (H) are below the flange. Tighten
the clip mounting hardware securely
(if necessary, rotate the discharge
chute to the right to tighten the leftside clip).
4. Hook the front hold-down clip (H,
Figure 2-4) under the mounting flange
(K) and place the front plastic shim (G)
on top of the hold-down clip, between
the top of the flange and the toothed
chute flange. Secure with the mounting hardware previously removed.
5. Remove the plastic tie that secures the
worm gear assembly (L, Figure 2-4) to
the mounting bracket.
C
D
E
E
Figure 2-3
Figure 2-4
N
P
O
H
K
L
M
(Front shim) G
(Front holddown clip) H
J
K
J
G
7
8
Section 2: Assembly
6. Remove the washer and locknut from
the screw (M, Figure 2-4) in the worm
gear assembly (L). Position the worm
gear assembly on the mounting
bracket as follows:
a. Engage the worm gear threads 1/2-
way with the teeth on the flange of
the discharge chute base (rotate
chute as needed).
b. The length of the worm gear should
be centered with the teeth on the
flange of the discharge chute base.
c. Reinstall the washer and locknut on
the screw (M) and tighten securely.
7. Insert the flexible fins on the plastic
snow deflector (N, Figure 2-4) inside
the chute deflector cap (O). Close the
deflector cap by pulling the lever (P)
outward and moving the deflector cap
down. Release the lever to secure the
deflector cap in one of the discharge
angle selector holes.
F. Attach Chute Control Rod
1. Remove the plastic tie that secures the
auger drive control rod (AA, Figure 2-
5) to the right handlebar. Next, remove the plastic tie that secures the
chute crank rod (short rod with plastic
swivel blocks) to the auger drive control rod.
2. Pull the chute crank rod (Z, Figure 2-5)
up through the top of the control
panel.
3. Attach the chute control rod sections
(S and U, Figure 2-5) as follows:
a. Insert the angled end of the chute
control rod, (U, Figure 2-5 inset)
into the hole in the swivel block (V)
that is attached to the end of the
chute crank rod (S).
b. Insert a cotter pin (W) through the
hole in the chute control rod (U) and
spread the ends of the cotter pin.
4. Position the chute control rod support
bracket (Y, Figure 2-6) against the underside of the handlebar console as
shown. Secure the bracket with the
two #10–24 x 3/8" Phillips pan head
screws and #10–24 locknuts supplied.
5. Rotate the chute control crank (Z,
Figure 2-5). The discharge chute
should turn freely, but with enough resistance to prevent free rotation of the
discharge chute during snow removal
operation. Adjust the worm gear assembly bracket (L, Figure 2-4) as necessary to prevent binding.
G. Attach Auger Drive Control Rod
1. Remove the plastic tie that secures the
auger drive control arm (AD, Figure
2-7) to the transmission shift arm
(AB).
2. The auger drive control rod (AA, Figure
2-7) has been pre-adjusted at the factory. To avoid misadjustment, do not
rotate the jam nut (AT, Figure 2-7)
while completing the following steps.
3. Hold jam nut (AT) in place with a 7/16"
wrench and use another 7/16" wrench
to thread the adjusting thimble (AS)
downward a total of 12 turns.
4. Raise Auger Drive Control Lever (X,
Figure 2-5) all the way up. Then hook
the spring (AC, Figure 2-7) at the lower
end of the auger drive control rod (AA)
into the hole in the auger drive control
arm (AD).
5. Thread the adjusting thimble (AS,
Figure 2-7) upward until it contacts the
jam nut (AT). Using two wrenches,
tighten the jam nut against the adjusting thimble.
6. Check that the spring (AC) is under the
correct amount of tension by performing Steps 2 through 5 of Auger Drive
Belt(s) Adjustment in Section 5 of this
manual.
H. Attach Wheel Drive Control Rod
1. Remove the plastic tie that secures the
wheel drive control rod (AE, Figure 2-
7) and the gear shift control rod (AF)
to the left handlebar.
2. Hook the spring (AG, Figure 2-7) at the
lower end of the wheel drive control
rod (AE) into the hole in the wheel
drive control arm (AH). If necessary,
raise the wheel drive control arm (AH)
while attaching the spring.
3. Check that the spring (AG) is under the
correct amount of tension by performing Steps 1 through 4 of Wheel Drive
Disc Adjustment in Section 5.
4. The wheel drive control rod has been
pre-adjusted at the factory. When the
engine is started, as described in the
Operation section, you will be given a
functional check to make sure the
wheel drive control rod is properly
adjusted.
I. Attach Gear Shift Control Rod
1. Place the Gear Shift Select Lever
(T, Figure 2-5) in the No. 5 position.
2. Gently push the transmission shift arm
(AB, Figure 2-8) fully downward.
3. Align the holes in the transmission
shift arm (AB) and the lower end of the
gear shift control rod (AF). If the holes
do not align, follow the Gear Shift Rod
Adjustment procedure in Section 5.
4. Use two 1/4-20 x 3/4 hex head screws
and 1/4-20 locknuts (Figure 2-8) to
attach gear shift control rod (AF) to
transmission shift arm (AB).
9
Section 2: Assembly
Figure 2-6
Y
Figure 2-7
AH
AC
AD
AB
AA
AT
AS
AG
R
AF
AE
Figure 2-5
Z
T
U
S
V
W
U
S
AA
X
Figure 2-8
AF
AB
Section 2: Assembly
J. Connect Wiring for Handlebar
Warmers and Light
1. Gently unwind the electrical wiring harness (A, Figure 2-9) from its shipping
position and route it back toward the
right-side handlebar.
2. Without over-stretching the wiring harness, loop it up and around the handlebar as shown in Figure 2-9.
3. Connect the double-stranded black and
red wires leading from each handlebar
to the matching wires leading from the
wiring harness. The plastic connectors
can only be plugged in one way.
4. Connect the single black wire leading
from the light to the single black wire
leading from the wiring harness.
5. Remove excess slack from the wiring
harness and insert the wires into the
two wire clips shown in Figure 2-9. On
the right-side of the engine, tuck the
wire harness in between the starter box
and the side of the engine (see inset,
Figure 2-9).
6. Using the plastic wire ties (B, Figure
2-9) provided, loosely secure the
wiring harness to the handlebar.
K. Add Motor Oil to Crankcase
1. Be sure that the engine is level before
checking or adding oil.
2. Unscrew dipstick. Fill oil at the dipstick opening with fresh oil. See the
Engine Owner’s Manual for correct oil
specifications and quantity required.
Do not use SAE 10W40.
3. Wait a few minutes after filling, allow-
ing oil to settle. Insert dipstick and
tighten securely. Remove dipstick and
check oil level. Oil level on dipstick
should always be at the “FULL” mark.
Adjust oil level as necessary. Reinsert
and tighten dipstick.
L. Check Auger Gear Case Oil Level
The auger gear case was filled at the factory with the correct amount of SAE 90
gear oil. This level should be checked before using the unit. Refer to Lubrication
in the Maintenance section of this manual
for complete information.
M. Check Tire Pressure
Check the air pressure in both tires using
an automotive-type tire pressure gauge.
Inflate tires evenly to 8-12 psi
(55-82 kPa).
N. Install Drift Slicers (if equipped)
The drift slicers (C, Figure 2-10) are designed for use in deep snow. Their use is
optional for normal snow conditions.
NOTE: For shipping purposes, the drift
slicers are installed backward.
To install the drift slicers:
1. Position the drift slicers as shown, (C,
Figure 2-10) to the outside of the collector (auger/impeller) housing.
2. Attach the drift slicers with the four
5/16–18 x 3/4 screws and locknuts (D)
provided with the drift slicers.
Connect Double
Stranded (Black
and Red) Wires
Connect
Single (Black)
Wires
Wire Clips
A
B
CAUTION
Do not start engine until engine
crankcase has been filled with motor oil.
Failure to follow this instruction will result in serious engine damage.
C
D
D
Figure 2-10
Figure 2-9
B
B
10
Tuck Wire Harness
between Starter Box
and Engine
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