Troy-Bilt 664DM User Manual

Operator’s Manua

Rear-tine Tiller Model

664D—Pony®

E666M—Pony®

IMPORTANT:READ SAFETY RULES AND INSTRUCTIONS CAREFULLY

Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-covered, brush-

covered or grass-covered land unless the engine’s exhaust system is equipped with a spark arrester meeting applicable local or state laws (if any). If a spark arrester is used, it should be maintained in effective working order by the operator. In the State of California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands. A spark arrester for the muffler is available by contacting the service department at Troy-Bilt LLC, P.O. Box 361131 Cleveland, Ohio 44136-0019.

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

PRINTED IN USA FROM NO. 770-10597A

(11/2002)

TOBLE OF COMTEMTS

Content Page

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

Safety.....................................................................................................................................................3

Assembly...............................................................................................................................................6

Features and Controls......................................................................................................................... 11

Operation...............................................................................................................................................14

Maintenance..........................................................................................................................................20

Tiller Attachments................................................................................................................................ 28

Troubleshooting................................................................................................................................... 29

Parts List...............................................................................................................................................30

Warrany Information.............................................................................................................................Back Cover

FIMPmC MODEL HUMBER

This Operator’s Manual is an important part of your new Rear-tine Tiller. It will help you assemble, prepare and main tain 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 infor

mation from it in the space provided below. This information is very important if you need help from our Customer Support Department or an authorized dealer.

• You can locate the model number by looking at the rear surface of the tine shield. A sample model plate is explained below. For future reference, please copy the model number and the serial number of the equipment in the space below

Copy Model Number Here

TROY-BILT LLC

P. 0. BOX 361131

www.trovbilt.com Cleveland, oh 44136

330-558-7220

Copy Serial Number Here

866-840-6483

EMBIME mFORMfiTIOM

The engine manufacturer is responsible for all engine-related issues with regards to performance, power-rating, speci fications, warranty and service. Please refer to the engine manufacturer’s Owner’s/Operator’s Manual packed sepa

rately with your unit for more information.

CALLIMB CUSTOMER SUPPORT

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.

Call 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 previous section to locate this information. You will be asked to enter the serial number in order to process your call.

For more details about your unit, visit our website at www.troybilt.com

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.

TRAINtNG

1. Carefully read this Owner’s Manual, the sepa rate Engine Owner’s Manual, and any other literature you may receive. Be thoroughly familiar with the controls and the proper use of the tiller and its engine. Know how to stop the unit and disengage the controls quickly.

Never allow children to operate the tiller. Never allow adults to operate the tiller without proper instruction.

Keep the area of operation clear of all persons, particularly children and pets.

Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people, their property and themselves.

PREPARATtON

1. Thoroughly inspect the area where the tiller is to be used and remove all foreign objects.

Be sure all controls are released and the Wheel Gear Lever is in ENGAGE before starting the engine.

Do not operate the tiller without wearing adequate outer garments. Avoid loose garments or jewelry that could get caught in moving parts.

Do not operate the tiller when barefoot or wearing sandals, sneakers, or light footwear. Wear protective footwear that will improve footing on slippery surfaces.

Section

T1 Safety

This machine meets voluntary safety standard B71.8

- 1996, 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.

Do not till near underground electric cables, telephone lines, pipes or hoses. If in doubt, contact your telephone or utility company.

. Warning: Handle fuel with care; it is

highly flammable and its vapors are explo sive. Take the following precautions:

Store fuel in containers specifically

designed for this purpose.

The gas cap shall never be removed

or fuel added while the engine is

running. Allow the engine to cool for several minutes before adding fuel.

Keep matches, cigarettes, cigars,

pipes, open flames, and sparks away from the fuel tank and fuel container.

Fill fuel tank outdoors with extreme

care. Never fill fuel tank indoors.

Use a funnel or spout to prevent spillage.

Replace all fuel tank and container

caps securely.

If fuel is spilled, do not attempt to

start the engine, but move the

machine away from the area of spillage and avoid creating any source of ignition until fuel vapors

have dissipated.

Never make adjustments when engine is running (unless recommended by manufacturer).

A WARNING

OPERATtON

1. Do not put hands or feet near or under rotating parts.

Exercise extreme caution when on or crossing gravel drives, walks, or roads. Stay alert for hidden hazards or traffic. Do not carry passengers.

After striking a foreign object, stop the engine (and remove the ignition key on electric start models), disconnect the spark plug wire and prevent it from touching the spark plug, carefully inspect the tiller for any damage, and repair the damage before restarting and operating the tiller.

Exercise caution to avoid slipping or falling.

If the unit should start to vibrate abnor mally, stop the engine (and remove the ignition key on electric start models). Dis connect the spark plug wire and prevent it from touching the spark plug, and check immediately for the cause. Vibration is generally a warning of trouble.

. Stop the engine (and remove the igni

tion key on electric start models), discon nect the spark plug wire and prevent it from touching the spark plug whenever you leave the operating position, before unclogging the tines, or when making any repairs, adjustments or inspections.

Take all possible precautions when

leaving the machine unattended. Stop the engine. Remove ignition key on electric start models. Disconnect spark plug wire and move it away from the spark plug.

Move Wheel Gear Lever to ENGAGE.

. Before cleaning, repairing, or inspect

ing, stop the engine, remove the ignition

key on electric start models, and make certain all moving parts have stopped.

Disconnect the spark plug wire and

prevent it from touching the spark plug to

prevent accidental starting. On electric start models, always remove the cable from the negative side (-) of the battery.

Always keep the tiller tine hood flap

down, unless using the hiller/furrower attachment.

10. Never use the tiller unless proper

guards, plates, or other safety protective

devices are in place.

11.

Do not run engine in an enclosed

area. Engine exhaust contains carbon

monoxide gas, a deadly poison that is

odorless, colorless, and tasteless.

12.

Keep children and pets away.

13. Never operate the tiller under

engine power if the Wheel Gear Lever is

in DISENGAGE (FREEWHEEL). In this

position, the wheels will not hold the tiller back and the revolving tines could

propel the tiller rapidly, possibly

causing loss of control.

Wheel Gear Lever to ENGAGE before starting the engine or engaging the tines/wheels with the Forward Clutch

Control or the Reverse Clutch Control.

Always move the

14. Be aware that the tiller may unex

pectedly bounce upward or jump forward if the tines should strike

extremely hard packed soil, frozen

ground, or buried obstacles like large stones, roots, or stumps. If in doubt about the tilling conditions, always use the following operating precautions to assist you in maintaining control of the tiller:

a. Walk behind and to one side of the

tiller, using one hand on the han dlebars. Relax your arm, but use a secure hand grip.

b. Use shallower depth regulator set

tings, working gradually deeper with each pass.

c. Use slower engine speeds. d. Clear the tilling area of all large

stones, roots and other debris.

e. Avoid using downward pressure

on handlebars. If need be, use slight upward pressure to keep the tines from digging too deeply.

f. Before contacting hard packed soil

at the end of a row, reduce engine speed and lift handlebars to raise tines out of the soli.

g. In an emergency, stop tines and

wheels by releasing whichever Clutch Lever is engaged. Do not attempt to restrain the tiller.

15.

Do not overload the tiller’s capacity by attempting to till too deeply at too fast a rate.

16.

Never operate the tiller at high trans port speeds on hard or slippery surfaces. Look behind and use care when backing up.

17.

Do not operate the tiller on a slope that is too steep for safety. When on slopes, slow down and make sure you have good footing. Never permit the tiller to freewheel down slopes.

18.

Never allow bystanders near the unit.

19.

Only use attachments and acces sories that are approved by the tiller manufacturer.

20.

Use tiller attachments and acces sories when recommended.

21.

Never operate the tiller without good visibility or light.

22.

Never operate the tiller if you are tired, or under the influence of alcohol, drugs or medication.

23.

Operators shall not tamper with the engine-governor settings on the machine; the governor controls the maximum safe operating speed to protect the engine and all moving parts from damage caused by overspeed. Authorized service shall be sought if a problem exists.

24.

Do not touch engine parts which may be hot from operation. Let parts cool down sufficiently.

25.

The battery on electric start model tillers contains sulfuric acid. Avoid contact with skin, eyes, or clothing. Keep out of the reach of children.

Antidote-External diately with lots of water.

Antidote-Internal: Drink large quantities of water or milk. Follow with milk of

magnesia, beaten eggs or vegetable oil.

Call a doctor Antidote-Eye

for 15 minutes.

Contacf:

Flush imme

immediately. Contact:

Flush with water

Get prompt medical

attention.

26.

Batteries produce explosive gases. Keep sparks, flame, and smoking materials away. Ventilate when charging batteries or when using a battery in an enclosed space. ALWAYS wear safety goggles when working near batteries.

27.

Please remember: You can always stop the tines and wheels by releasing the Forward Clutch Control Lever or the Reverse Clutch Control knob (whichever control you have engaged), or by moving the Engine Throttle Control Lever (located on engine) to STOP on recoil start models or by turning the ignition key to OFF on electric start models.

28.

To load or unload the tiller, see the instructions in Section 4 of this Manual.

29.

Use extreme caution when reversing or pulling the machine towards you.

30.

Start the engine carefully according to instructions and with feet well away from the tines.

. Never pick up or carry a machine while

the engine is running.

MAINTENANCE AND STORACE

1. Keep the tiller, attachments and acces sories in safe working condition.

Check all nuts, bolts, and screws at frequent intervals for proper tightness to be sure the equipment is in safe working condition.

Never store the tiller with fuel in the fuel tank inside a building where ignition sources are present such as hot water and space heaters, furnaces, clothes dryers, stoves, electric motors, etc. Allow engine to cool before storing in any enclosure.

To reduce the chances of a fire hazard, keep the engine free of grass, ieaves, or excessive grease.

Store gasoiine in a cooi, weii-ventiiated area, safeiy away from any sparkorfiame-producing equipment. Store gasoline in an approved container, safely away from the reach of children.

. Refer to the Maintenance section of

this Manual and in the separate Engine Owner’s Manual for instructions if the tiller is to be stored for an extended period.

Never perform maintenance while the engine is running or the spark plug wire is connected, except when specifi cally instructed to do so.

. If the fuel tank has to be drained, do

this outdoors.

Operating Symbols

Various symbols (shown here, with word descriptions) may be used on the tiller and engine.

^TOy

FAST

SLOW

STOP

DECALS

For your safety and the safety of others, various safety message decals are on your unit (see Figure below). Keep the decals clean and legible at all times. Contact your local service dealer or the factory for

Control Descriptions,

Tine Warning (on right

side of hood flap)

Starting Stabilization (on top of engine or fuel tank)

Figure 1: Location of Safety and Operating Decais

replacements if any decals are damaged or missing.

Refer to the Parts List pages for decal locations and part numbers.

Operating Instructions and

Warning Messages

Surfaces/Moving Belts

(on top of belt cover)

STOP

START

l+ l ^

CHOKE ROTATING

OFF TINES

LEVER DIRECTION

TILLER DIRECTION

-[2i

ENGAGED DISENGAGED

CHOKE

REVERSE

A WARNING

TO AVOID SERIOUS INJURY:

• READ THE OWNER’S MANUAL.

• KNOW LOCATIONS AND FUNCTIONS OF ALL CONTROLS.

• KEEP ALL SAFETY DEVICES AND SHIELDS IN PLACE AND WORKING.

• NEVER ALLOW CHILDREN OR UNINSTRUCTED ADULTS TO OPERATE TILLER.

• SHUT OFF ENGINE AND DISCONNECT SPARK PLUG WIRE BEFORE MANUALLY UNCLOG GING TINES OR MAKING REPAIRS.

• KEEP BYSTANDERS AWAY FROM MACHINE.

• KEEP AWAY FROM ROTATING PARTS.

• USE EXTREME CAUTION WHEN REVERSING OR PULLING THE MACHINE TOWARDS YOU.

Section

2 Assembly

A WARNING

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.

INTRODUCTION

Carefully follow these assembly steps to correctly prepare your tiller for use. It Is

recommended that you read this Section In Its entirety before beginning assembly.

INSPECT UNIT

Inspect the unit and carton 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 mall a copy to the carrier within 15 days after the unit has

been delivered. Contact us at the factory If you need assistance In this matter.

UNPACKING AND ASSEMBLY INSTRUCTIONS

STEP 1: UNPACKING iNSTRUCTiONS

1. Remove any cardboard Inserts and

packaging material from the carton.

Remove any staples from the bottom of the carton and remove the carton.

Cut the large, plastic tie strap that

secures the transmission tube to the ship

ping pallet. Leave the handlebars on top of the tiller to avoid damaging any cables.

A bag with loose hardware Is Inside the literature envelope. Check the con tents against the following list and Figure 2-1. Contact your local dealer or the factory If any Items are missing or damaged.

NOTE: For electric start units, a second hardware bag Is located near the battery.

The tiller Is heavy. You should not attempt to remove It from the shipping

platform until Instructed to do so In these

“Assembly” steps.

HARDWARE BAG PARTS LIST

Fig.

Ref.

Qty.

2 3/8-16 X1“ Hex Hd. Screw

1 1 Wheel Gear Lever Knob

3 4

1 Height Adjustment Flange

2 3/8“ Flat Washer

2 #10 Lockwasher

6 7

2 3/8"-16Nylock Lock Nut 2 #10-32x1/2" Round Hd.

2 #10-32 Nut

1 Cotter Pin (not used)

10 11

Tools/Materials Needed for Assembly

(1) 3/8" open-end wrench* (1) 7/16“ open-end wrench* (electric

start unit only) (2) 9/16“ open-end wrench* (1) 7/8" open-end wrench or 8" long

adjustable wrench (1) Scissors (to trim plastic ties) (1) Ruler (1) Small board (to tap plastic knob on

lever) (1) Tire pressure gauge (1) Clean oil funnel (1) Clean, high-quality motor oil. Refer

to the separate Engine Owner’s

Manual for motor oil specifications

and quantity required.

* Adjustable wrenches may be used.

iMPORTANT:

the engine crankcase before the engine is started. Follow the instructions in this “Assembly” Section and in the separate

Engine Owner’s Manual. NOTE: LEFT and RIGHT sides of the tiller

are as viewed from the operator’s posi tion behind the handlebars.

STEP 2: AHACH HANDLEBARS

1. On electric start units, remove one screw and lockwasher from the curved

Description

Keyed Washer

Screw (See Figure 2-1 A)

Screw

Plastic Tie Strap (2 not used)

Motor oil must be added to

Figure 2-1: Loose hardware (shown in reduced size).

Flange

Figure 2- 1A Handlehar height adjustment uses the flange head screw.

Figure 2-2: On electric start units, move height adjustment bracket aside.

height adjustment bracket (A, Figure 2-2), loosen the second screw, and swing the bracket to one side.

Cut the large, plastic cable ties that

secure the handlebar ends to the handle

bar mounting tabs on the transmission

top cover.

Gently lift handlebar (do not over

stretch attached cable) and place handle

bar cross-brace (B, Figure 2-3) in front of

curved height adjustment bracket (C).

Figure 2-3: Forward clutch control cable not

shown for clarity.

4. With the forward clutch cable (N,

Figure 2-4) on the inside of handlebar,

position the handiebar ends on the outside of the two mounting tabs (M, Figure 2-3) on the transmission top

cover.

NOTE: The curved handiebar height

adjustment bracket appears as shown in

C, Figure 2-3 for non-eiectric start units. For eiectric start units, the bracket is loos

ened and moved to one side.

Looseiy attach the handiebars to the

mounting tabs with two 3/8-16 x 1" screws (heads of screws go to inside of tabs), 3/8" fiat washers and 3/8"-16 iock

nuts (0, Figure 2-4).

Figure 2-5: Carefully unwrap Wheel Gear Lever and move lever to DISENGAGE.

bars to roii the tiiier off the piatform. NOTE: The Wheei Gear Lever wili be instaiied later in this procedure.

IMPORTANT:

tion only when the engine is not running.

Before starting the engine, the Wheel Gear Lever must be placed in the ENGAGE position (see Section 3 for details).

Use the DISENGAGE posi

STEP 3: AHACH REVERSE CLUTCH CONTROL CABLE

1. Carefully unwrap the reverse clutch control cable (FI, Figure 2-6) from its

shipping position and route it up along the inside edge of the left side handiebar. A knob and iarge hex nut (I) is instaiied

on the cable.

STEP 4: AHACH FORWARD CLUTCH CONTROL CABLE

1. Remove any fasteners (rubber bands, tape, etc.) that may secure the Forward Clutch Control levers (J, Figure 2-7) to the handiebar.

Figure 2-7: Forward Clutch Control levers (J). Forward clutch control linkage (K).

2. The forward clutch control cable (with attached spring) is hanging iooseiy near the right-side wheel. Being carefui not to kink or stretch the cabie, insert the z-connector (L, Figure 2-8 - end of the spring) into the hole at the end of the forward clutch control linkage (K, Figure 2-7).

. On eiectric start units, reattach the

height adjustment bracket (A, Figure 2-2). Tighten both screws secureiy. Make sure the handiebar cross-brace (B, Figure 2-3)

is under the bracket.

Move the handiebars up or down to aiign the threaded hoie in the cross-brace with one of the four siots in the curved

height adjustment bracket. Place the

keyed washer (E, Figure 2-3) on the flange head height adjustment screw (F) with the raised keys (edges) of the washer facing down.

. Thread the height adjustment screw

(F, Figure 2-3) into the hoie in the handle

bar cross-brace, making sure that the

raised keys on the washer fit into the slot

on the height adjustment bracket. Tighten the height adjustment screw secureiy. Next, secureiy tighten the two screws and nuts in the ends of the han

diebar (M, Figure 2-3).

To remove the tiiler from its shipping

piatform, first carefuliy unwrap the wheel gear cable (with attached iever - see

Figure 2-5) from around the chassis.

Move the Wheei Gear Lever (G) to the

DISENGAGE position-this allows the wheels to rotate freely. Use the handle

Figure 2-6: Attach reverse clutch control assembly to slotted hole In handlebar panel.

Insert the cabie into the siot in the control panel and fit the threaded assembiy into the hole in the siot (see Figure 2

6). Be sure that the flat side of the

threaded assembiy is aiigned with the flat

side of the hoie. Siide the hex nut (I) up

the cabie and tighten it secureiy.

Test the function of the reverse clutch control cable by pulling the knob out and reieasing it. The knob shouid return to its neutral position against the tapered bushing. If it doesn’t, contact your local dealer or the factory for technical assistance.

Attach the cabie adjuster (A, Figure 2-9) to the bracket on the right-side han diebar. Use two 1/2" wrenches to ioosen the two jam nuts (B) just enough to slide the cabie adjuster onto the bracket. Then hand tighten the jam nuts.

A CAUTION

Incorrect cable adjustment could cause

the wheels and tines to rotate unexpect edly. Follow adjustment procedures carefully. Failure to do so could result

in personal injury or property damage.

4. Check for correct spring/cable tension

as instructed in Section 5, Checking and

Adjusting Forward dutch Beit Tension.

5. When tension is correct, tighten the

two jam nuts (B) securely.

STEP 5: CHECK TRANSMISSION GEAR OIL LEVEL

The transmission was filled with gear oil at the factory. However, be sure to check the oil level at this time to make certain it

is correct.

IMPORTANT:

the gear oil level is low. Doing so will

result in severe damage to the transmis

sion components.

1. With the tiller on level ground, pull the Depth Regulator Lever (R, Figure 2-13) back and then slide it to the second notch

from the top. NOTE: If the lever does not

move, lift the tine hood flap and look for a plastic tie securing the lever in place. Cut

and remove the tie.

2. Remove the oil level check plug (M,

Figure 2-10) on the left-side of the trans mission. (Due to dried paint on the plug

threads, it may require some force to

remove the plug the first time.) The gear oil level is correct if oil starts to flow out of the hole as the plug is removed. If so, securely reinstall the plug.

Figure 2-10: Gear oil level check plug.

3. If oil does not flow from the check

hole, add oil as follows: NOTE: Do not use automatic transmission

fluid or motor oil in the transmission.

(a)

Cl ean area around the fill hole (N, Figure 2-11) and unscrew gear oil fill plug.

Do not operate the tiller if

(b)

If adding only a few ounces of gear oil, use API rated GL-4 or GL-5 gear oil having a viscosity of SAE 140, SAE 85W140 or SAE 80W-90. If refilling an empty transmission, use only GL-4 gear oil having a viscosity of SAE 85W-140 or SAE 140.

(c)

Using a clean funnel, slowly add gear oil until it flows from the gear oil level check hole (N, Figure 2-11).

(d)

Reinstall and tighten securely the gear oil fill plug (M, Figure 2-10).

STEP 6: AnACH WHEEL GEAR LEVER

1. Insert the Wheel Gear Lever (P, Figure 2-12) up through the slot in the control panel that is labeled “WHEEL GEAR.”

2. Insert two #10-32x1/2" round head

screws down through the “+” marks on the control panel decal and securely attach the wheel gear mounting bracket using two #10 lockwashers and #10-32 nuts.

3. Use a small board to tap the Wheel

Gear Lever knob securely onto the lever.

4. Secure the wheel gear cable and the

reverse clutch control cable to the left side handlebar with two plastic ties (S, Figure 2-13) located about two feet apart. Snip off any excess tie length with scissors.

STEP 7 AHACHING THE BAnERY CABLES (MODEL E666M)

The positive battery terminal is marked Pos. (+). The negative battery terminal is

marked Neg. (-).

1. Remove the hex bolt and hex nut from

the positive cable (heavy red wire).

2. Remove the plastic cover from the

positive battery terminal and attach the positive cable to the positive battery ter minal (+) with the bolt and hex nut. Make certain that the rubber boot covers the

Figure 2-12: Attach Wheel Gear Lever.

Figure 2-13: Attach wheel gear cable and reverse clutch cable with cable ties (S).

positive terminal to help protect it from corrosion.

3. Remove the hex bolt and hex nut from

the negative cable (heavy black wire).

4. Remove the black plastic cover from

the negative battery terminal and attach the negative cable to the negative battery terminal (-) with the bolt and hex nut.

IMPORTANT:

• If the battery is put into service after the date shown on top of battery, charge the battery as instructed in the Maintenence section of this manual prior to operating the tiller.

STEPS: CHECK AIR PRESSURE IN TIRES

Use a tire pressure gauge to check the air pressure in both tires. Deflate or inflate both tires equally to between 15 PSI and 20 PSI). Be sure that both tires are inflated equally or the unit will pull to one side.

STEP 9: CHECK HARDWARE FDR TIGHTNESS

Inspect the hardware on the unit and

tighten any loose screws, bolts and nuts.

? Features and Controls

A WARNING

Before operating your machine, carefuiiy read and understand aii safety, controis and operating instructions in this Manuai, the separate Engine Owner’s Manuai, and on the decais on the machine.

Faiiure to foiiow these instructions can resuit in serious personai injury.

INTRODUCTION

This Section describes the iocation and function of the controis on your tiiier.

Refer to the foiiowing section “Operation”

for detaiied operating instructions.

Practice using these controis, with the engine shut off, untii you understand the operation of the controis and feei confi dent with them.

iMPORTANT:

manufacturer’s Engine Owner’s Manuai for information about the controis on the engine.

WHEEL GEAR LEVER

This iever (A, Figure 3-1) has two posi tions: ENGAGE and DISENGAGE.

In the ENGAGE position, the wheels will start turning when either the Forward Clutch Control or the Reverse Clutch Control is engaged (the tines will also start turning when either clutch is engaged).

Refer to the separate engine

The DISENGAGE position places the

wheels in the freewheeling mode to allow

the unit to be moved without the engine

running. Use the DISENGAGE position only when the engine is not running. See “DANGER” statement that follows.

To shift to ENGAGE, gently (do not force)

move the lever forward while also rolling

the tiller a few inches forward or back

ward. Moving the tiller helps to align the shift mechanism with the transmission wheel drive gears.

To shift to DISENGAGE (freewheel),

move the lever rearward, without rolling

the tiller. The wheels will roll freely

when the lever is properly set in the DISENGAGE position.

A DANGER

Never place the Wheel Gear Lever In DISENGAGE (Freewheel) when the engine is running.

Having the Wheel Gear Lever in DISENGAGE and then engaging the

tines/wheels with either the Forward

Clutch Control or the Reverse Clutch Control could allow the tines to propel

the tiller rapidly forward or backward.

Failure to follow this instruction could result in personal injury or property damage.

FORWARD CLUTCH CONTROL

The two interconnected levers (B, Figure 3-1) control the engagement of forward drive to the wheels and tines.

To Operate the Forward Clutch Control:

1. Before engaging the Forward Clutch Control, put the Wheel Gear Lever in the ENGAGE position (see “WARNING” below).

Pull up and hold one or both of the levers against the handlebar grips to engage the wheels and tines.

Release BOTH levers to disengage (stop) the wheels and tines. All forward motion will stop (the engine will continue to run).

A WARNING

Never engage the wheels and tines with the Forward Clutch Control or the Reverse Clutch Control unless the Wheel Gear Lever is in ENGAGE.

Engaging the Forward Clutch Control or the Reverse Clutch Control when the wheels are not engaged could allow the tines to rapidly propel the tiller forward or backward.

Failure to follow this warning could result in personal injury or property damage.

REVERSE CLUTCH CONTROL

The Reverse Clutch Control (C, Figure 3-1) controls the engagement of reverse drive to the wheels and tines.

The revers

ing feature is used for maneuvering the tiiier oniy - never engage the tines in the ground whiie going in the reverse direction.

A WARNING

• Use extreme caution when reversing or puiiing the machine towards you. Look behind to avoid obstacies.

• Never attempt to tiii in reverse.

Faiiure to foiiow this warning couid resuit in personai injury or property damage.

Figure 3-2: Depth Regulator Lever.

The highest notch (lever all the way down) raises the tines approximately 1-1/2 Inches off the ground. This “travel” position allows the tiller to be moved without the tines digging Into the ground.

Moving the lever up Increases the tilling depth. The lowest notch allows a tilling depth of approximately six to eight Inches, depending on soil conditions.

For best resuits, aiways begin tiiiing at

To Operate the Reverse Ciutch Controi:

1. Put the Wheel Gear Lever In the

ENGAGE position (see the “WARNING” statement on previous page).

Stop all tiller motion by releasing the

Forward Clutch Control levers.

Lift up the handlebars until the tines

clear the ground, look behind you to avoid any obstacles, and then pull the Reverse Clutch Control knob out. The tines and wheels will rotate In a reverse direction.

Release the Reverse Clutch Control

knob to disengage (stop) the wheels and tines. All reverse motion will stop (the engine will continue to run).

a very shaiiow depth setting and graduaiiy increase the tiiiing depth.

details on using the Depth Regulator are found In the “Operation” Section of this manual.

HANDLEBAR HEIGHT ADJUSTMENT

The handlebar height Is adjustable to four different settings. Set the handlebar height to a comfortable setting, but keep In mind that the handlebars will be lower when the tines are engaged In the soil.

To Adjust the Handlebar Height:

A WARNING

Complete

setting and Insert the raised keys on the

keyed washer Into the slot. Tighten the height adjustment screw securely.

RetIghten the two screws at the ends

of the handlebar.

ENGtNE CONTROLS

Refer to the engine manufacturer’s Engine Owner’s Manual (Included In the tiller lit erature package) to Identify the controls on your engine. The following two con trols are used when stopping or starting the engine.

iWIPORTANT:

the recoil start engine Is located on the engine.

The control for stopping

ENGINE THROHLE CONTROL LEVER

The Engine Throttle Control Lever (located on engIne-see Figure 4-1) Is used to reg

ulate the engine speed. On the recoil start

model only. It Is also used to stop the engine (on the electric start model, the electric start keyswitch Is used to stop the engine). The throttle settings are shown

below.

iWIPORTANT:

the Engine” In the “Operation” Section for detailed engine starting and stopping

instructions.

See “Starting and Stopping

FAST

- Use for most tilling and

cultivating projects.

.SLOW

- Use when idling engine or when slower tilling and cultivating speeds are needed.

• Do not attempt to tiii too deeply too quickly. Gradually work down to deeper tilling depths.

• Place the Depth Regulator Lever in the “travel” position before starting the engine. This position prevents the tines from touching the ground until you are ready to begin tilling.

Failure to follow this warning could result in personal injury or property damage.

DEPTH REGULATOR

The Depth Regulator lever (D, Figure 3-2) controls the tilling depth of the tines. Pull the lever straight back and slide It up or down to engage the notched height set tings.

Figure 3-3: Handlebar height adjustment.

1. Stop the engine, wait for all parts to stop moving and then disconnect the spark plug wire. Remove the Ignition key on electric start models.

Loosen the two screws at the lower

ends of the handlebar.

Loosen the height adjustment screw (E, Figure 3-3) and pull the keyed washer (F) free of the slots In the curved height adjustment bracket.

Move the handlebars to the new slot

STOP

- Stops the engine (on

recoil start models only).

ELECTRIC START KEYSWITCH

(MODEL E666M)

The ignition keyswitch on the electric start

model is used to start and stop the engine. The keyswitch settings are described below.

IMPORTANT:

the Engine” in the “Operation” Section for detailed instructions.

OFF

- Stops engine.

RUN

- After starting, key returns to run

position.

START

engine starts (avoid cranking engine for

longer than 15 seconds for each attempt)

See “Starting and Stopping

- Starts engine. Release key when

A WARNING

Before operating your machine, care fully read and understand all safety (Section 1), controls (Section 3) and operating instructions (Section 4) in this Manual, in the separate Engine Owner’s Manual, and on the decals on the machine.

Failure to follow these instructions can result in serious personal injury.

Section

41 Operation

Forward Clutch Control Lever

Handlebar Height

Adjustment Screw

Engine Throttle Control Lever

Reverse Clutch ControL

-Wheel Gear Lever

^ Forward Clutch

Control Lever

Depth Regulator Lever

INTRODUCTION

Read this Section of the manuai thoroughiy before you start the engine. Then, take the time to famiiiarize yourseif with the basic operation of the tiller before

using it in the garden.

Find an open, ievei area and practice

using the tiiier controis without the tines engaging the soil (put tines in “travei” setting). Only after you’ve become com

pletely familiar with the tiiier should you

begin using it in the garden.

BREAK-IN OPERATION

Perform the foiiowing maintenance after the first two hours of new operation (see “Maintenance” in this manual and the

Engine Owner’s Manual).

Change engine oil.

Check for loose or missing hardware

on unit. Tighten or replace as needed.

Check transmission gear oii ievei.

Check tension on forward clutch belt.

Figure 4-1: Location of main tiller controls.

STARTING AND STOPPING THE ENGINE

A CAUTION

To help prevent serious personal injury or damage to equipment:

• Before starting engine, put Wheel

Gear Lever in ENGAGE position.

• Before starting engine, put Forward Clutch Control levers and Reverse Clutch Control in neutral (disengaged) positions by releasing controls.

• Never run engine indoors or in enclosed, poorly ventilated areas. Engine exhaust contains carbon monoxide, an odorless and deadly gas.

• Avoid engine muffler and nearby areas. Temperatures in these areas may exceed 150°F.

PRE-START CHECKLIST:

Make the following checks and perform the foiiowing services before starting the engine.

_______________

1. Read Sections 1 and 3 in this Manual. Read the separate Engine Owner’s Manuai.

Check unit for ioose or missing hard

ware. Service as required.

Check engine oil ievei. See Engine

Owner’s Manual.

Check that all safety guards and

covers are in piace.

Check air cleaner and engine cooiing

system. See Engine Owner’s Manuai.

. Attach spark piug wire to spark piug.

A DANGER

GASOLINE IS HIGHLY FLAMMABLE AND ITS VAPORS ARE EXPLOSIVE. Follow gasoline safety rules in this manual (see Section 1) and in the sepa rate Engine Owner’s Manual.

Failure to follow gasoline safety instruc

tions can result in serious personal

injury and property damage.

Fiii the fuel tank with gasoline accord ing to the directions in the separate Engine Owner’s Manual. Follow all Instructions and safety rules carefully.

__________

STARTING THE ENGINE

The following steps describe how to start and stop the engine.

Do not attempt to

engage the tines or wheels until you have read all of the operating instruc tions in this Section. Also review the safety rules in Section 1: “Safety” and the tiller and engine controls

information in Section 3: “Features and

Controls.” 1

. Complete the “Pre-Start Checklist” on

the previous page.

Put the Wheel Gear Lever (Figure 4-1

in the ENGAGE position.

Put the Depth Regulator Lever in the “travel” position (lever all the way down) so that the tines are clear of the ground.

Release all controls on the tiller.

Put the Engine Throttle Control Lever

(Figure 4-1) in the “FAST” setting.

. On engines equipped with a fuel valve,

turn valve to open position as instructed

in the separate engine manual.

Choke or prime engine as instructed in the separate Engine Owner’s Manual.

. For recoil (non-electric) starting

models:

(a) Place one hand on fuel tank to stabi

lize unit when you pull the starter handle.

(b) Use the recoil starter rope to start

the engine as instructed in the sepa

rate Engine Owner’s Manual. When the engine starts, gradually move the choke lever (on engines so equipped) to the “NO CFIOKE”, “CHOKE OFF” or “RUN” position.

Lever in the “FAST” setting.

For electric starting models (E666M):

(a) Turn the engine ignition key to the

“START” setting and allow the starter motor to crank the engine for several seconds. Avoid cranking the engine longer than 15 seconds at a

time as doing so could damage the starter motor. NOTE: Refer to the

Engine Owner’s Manual for detailed

starting instructions.

)

(b) When the engine starts, release the

key and it will return to the “RUN”

setting.

engines so equipped) to “NO CHOKE”, “CHOKE OFF” or “RUN”

position.

(d) Leave the Engine Throttle Control

Lever in the “FAST” setting.

To Start the Electric Start Engine With the Recoil Starter Rope

If necessary, the electric start engine can be started with the recoil starter rope by

following the steps below:

1. If the battery is not “dead” or damaged, leave it connected to the tiller so it will be recharged during engine operation. Make sure the battery cells are filled to the UPPER LEVEL line with elec trolyte.

If the battery is “dead” or damaged, remove it (refer to “Battery Removal and Installation” in Section 5) and have it

tested. Before starting engine, cover the terminal on the loose end of the positive

(+) cable with the insulated boot and

secure it in place with electrical tape to

prevent electrical sparks.

Put the ignition key in the “RUN” position and then follow Steps 1-8 of

“Starting the Engine.”

STOPPING THE ENGINE

1. To stop the wheels and tines, release the Forward Clutch Control levers or the

Reverse Clutch Control knob (whichever

control is engaged).

To stop the engine on the recoil start model, move the Engine Throttle Control Lever to the “STOP” position.

To stop the engine on an electric start model, move the ignition key to “OFF”.

IMPORTANT:

start engine, remove the ignition key from the switch to reduce the possibility of

unauthorized starting of the engine.

After stopping an electric

OPERMING THE TILLER

The following pages provide guidelines to using your tiller effectively and safely in various gardening applications. Be sure to read “Tilling Tips & Techniques” in this Section before you actually put the tines into the soil.

This is a traditional “standard rotating tine” tiller with forward rotating tines. It operates completely differently from CRT (Counter Rotating Tines) tillers or from low-cost front tine tillers.

1. Follow the “Pre-Start Checklist” on the previous page. Be sure that the Wheel Gear Lever is in the ENGAGE position.

Put the Depth Regulator Lever in the “travel” position (lever all the way down) so that the tines are clear of the ground. Use this position when practicing with your tiller or when moving to or from the garden. When you are ready to begin tilling, you must move the Depth Regula tor Lever to the desired depth setting (see “Tilling Tips & Techniques”).

Start the engine and allow it to warm up. When warm, put Engine Throttle Control Lever in “FAST” speed setting.

A WARNING

Keep away from rotating tines. Rotating

tines wiii cause injury.

For forward motion of the wheels and

tines:

(a) Pull one or both of the Forward

Clutch Control Levers up and hold them against the handlebars. To stop forward motion of the wheels and tines, release the levers.

A WARNING

Before tilling, contact your telephone or utilities company and inquire if underground equipment or lines are used in your area. Their representative will be glad to answer your questions and tell you if any of their equipment or lines are buried underground on your property.

when moving forward.

(b) As the tiller moves forward, relax

and let the wheels pull the unit along while the tines dig. Walk behind and a little to one side of the tiiler. Use a

light but secure grip with one hand

on the handiebars, but keep your arm ioose. See Figure 4-2. Let the tiiler move ahead at its own pace and do not push down on the han

diebars to try and force the tiiier to

dig deeper - this takes weight off the wheels, reduces traction, and causes the tines to try and propei the tiiier.

A WARNING

Do not push down on the handlebars to try to make the tiller till more deeply. This prevents the wheels from holding the tiller back and can allow the tines to rapidly propel the tiller forward, which could result in loss of control, property damage, or personal injury.

For reverse motion of the wheeis and

tines:

(a) Look behind and exercise caution

when operating in reverse.

till while in reverse.

(b) Stop aii forward motion before

reversing. Lift the handlebars with

one hand untii the tines are off the ground and then puii the Reverse

Ciutch Controi knob out to engage

reverse motion (see Figure 4-3). To stop reverse motion, let go of the

Reverse Clutch Control knob.

Do not

Figure 4-3: Raise tines off ground and iook behind when moving in reverse.

. To Turn the Tiller Around:

(a) Practice turning the tiiier in a ievel,

open area. Be very carefui to keep your feet and legs away from the tines.

(b) To make a turn, reduce the engine

speed and then lift the handiebars untii the engine and tines are baianced over the wheels (Figure 4-4).

ways on the handlebar to move the tiller in the direction of the turn

(Figure 4-5). After completing the turn, siowiy iower the tines into the soii and increase the engine speed.

Stopping the Tiller and Engine

1. To stop the wheels and tines, release

the Forward Clutch Control levers or the

Reverse Clutch Control knob (whichever is engaged).

To stop the recoii start engine, move

the Engine Throttie Control Lever to

“STOP”. On electric start models, turn the Ignition keyswitch to “OFF” to stop the

engine.

Turning the Tiller Around

speed and iift handiebars untii engine and tines are haianced over wheeis.

Figure 4-5: With tiiier haianced over wheeis (and tines out of the ground),

push handiebars sideways to turn tiiier.

Tilling Tips & Techniques

Let the tiller do the work

• While tilling, relax and let the wheels pull the tiller along while the tines do

the digging. Walk on the side that is

not yet finished (to avoid making foot prints in the freshly tilled soil) and lightly, but securely grip the handlebar

with Just one hand.

•Avoid pushing down on the handlebars in an attempt to force the tiller to dig

deeper. Doing so takes the weight off the powered wheels, causing them to

lose traction. Without the wheels helping to hold the tiller back, the tines

will attempt to propel the tiller - often causing the tiller to skip rapidly across the ground. (Sometimes, slight down ward pressure on the handlebars will

help get through a particularly tough

section of sod or unbroken ground, but

in most cases this won’t be necessary

at all.)

Tilling depths

• Avoid trying to dig too deeply too

quickly, especially when busting sod or when tilling soil that hasn’t been tilled for some time. Use shallow depth reg

ulator settings (only an inch or two

deep) for the first passes through the garden area. With each succeeding

pass, adjust the depth regulator to dig

another inch or two deeper. (Watering the garden area a few days prior to tilling will make tilling easier, as will

letting the newly worked soil set for a

day or two before making a final, deep tilling pass.)

• When cultivating (breaking up the

surface soil around plants to help destroy weeds), use very shallow depth settings to prevent injury to plants whose

roots often grow close to the surface. If needed, lift up on the handlebars slightly

to prevent the tines from digging too deeply. (Cultivating on a regular basis

not only eliminates weeds, it also loosens

and aerates the soil for better moisture absorption and faster plant growth.)

Avoid tilling soggy, wet soil

Tilling wet soil often results in large,

hard clumps of soil that can interfere with planting. If time permits, wait a day or two after heavy rains to allow the soil

to dry before tilling. Test soil by squeez

ing it into a ball. If it compresses too easily, it is too wet to till.

Avoid making footprints

When possible, walk on the untilled side of the unit to avoid making footprints in

the freshly tilled soil. Footprints cause

soil compaction that can hamper root penetration and contribute to soil erosion. They can also “plant” unwanted weed seeds back into the freshly tilled ground.

Choosing correct wheel and tine speeds

With experience, you will find the “just right” tilling depth and tilling speed com bination that is best for your garden.

Set the Engine Throttle Control Lever to a speed to give the engine adequate power and yet allow it to operate at the slowest possible speed...at least until

you have achieved the maximum tilling

depth you desire. Faster engine speeds may be desirable when making final passes through the seedbed or when cultivating. Selection of the correct engine speed, in relation to the tilling depth, will ensure a sufficient power level to do the job without causing the engine to labor.

Suggested tilling patterns

• When preparing a seedbed, go over the same path twice in the first row, then overlap one-half the tiller width on the rest of the passes (see Figure 4-6). When finished in one direction, make a second pass at a right angle as shown in Figure 4-7. Overlap each pass for best results (In very hard ground it may

take three or four passes to thoroughly

pulverize the soil).

• If the garden size will not permit lengthwise and then crosswise tilling,

then overlap the first passes by one-

half a tiller width, followed by succes

sive passes at one-quarter width (see

Figure 4-8).

• With planning, you can allow enough room between rows to cultivate (see Figure 4-9). Leave room for the hood

width, plus enough extra room for future plant growth.

Figure 4-6

Figure 4-8

If fte

Figure 4-9

Tilling Tips & Techniques

Clearing the tines

The tines have a self-clearing action

which eliminates most tangling of debris in the tines. However, occasionally dry grass, stringy stalks or tough vines may become tangled. Follow these proce dures to help avoid tangling and to clean

the tines, if necessary.

• To reduce tangling, set the depth regu lator deep enough to get maximum “chopping” action as the tines chop the material against the ground. Also, try

to till under crop residues or cover crops while they are green, moist and tender.

• While power composting, try swaying

the handlebars from side to side (about 6" to 12"). This “fishtailing” action often clears the tines of debris.

• If tangling occurs, lift the tines out of

the soil and run the tiller in reverse for a few feet. This reversing action should unwind a good deal of debris.

• If reversing the tiller doesn’t clear the

debris, it may be necessary to remove the debris by hand (a pocket knife will

help you to cut away the material).

A WARNING

Before clearing the tines by hand, stop the engine, allow all moving parts to stop and disconnect the spark plug wire. Remove the ignition key on elec tric start models.

Failure to follow this warning could

result in personal injury.

Tilling on slopes

If you must garden on a moderate slope, please follow two very important guidelines:

1. Tiii oniy on moderate siopes, never on steep ground where footing is difficult (review safety rules in the “Safety” Section of this Manuai).

2. We recommend tiiiing up and down slopes rather than terracing. Tilling verticaiiy on a siope aliows maximum pianting area and aiso ieaves room for cuitivating.

IMPORTANT:

sure the correct oil level is maintained in the engine (check every one-haif hour of

operation). The inciine of the siope will

cause the oil to slant away from its

normal level and this can starve engine

parts of required lubrication. Keep the engine oil level at the full point at all times!

A. Tilling up and down slopes:

• To keep soil erosion to a minimum, be

sure to add enough organic matter to the soii so that it has good moisture

holding texture and try to avoid leaving

footprints or wheei marks.

• When tiiiing verticaiiy, try to make the

first pass uphill as the tiller digs more deeply going uphili than it does down-

hili. In soft soil or weeds, you may

have to lift the handiebars siightiy whiie going uphiii. When going downhiil, overiap the first pass by about one-half the width of the tiiier.

B. Terrace Gardening:

• When a siope is too steep or too short for verticai tiiiing, it may be necessary to tiii across the slope and create ter

raced rows. Terraces are rows that are

cut into the side of a slope, creating a

narrow, but fiat area on which to piant.

• On a iong siope, you can make several terraces, one below the other.

When tiiiing on siopes, be

’ Terraces should be only 2-to-3 feet

wide. Digging too far into the side of the slope will expose poor subsoil that is unproductive for piants.

’ To create a terrace, start at the top of

the slope and work down. Go back and forth across the first row as shown in Figure 4-10.

’ Each succeeding iower terrace is

started by waiking beiow the terrace you’re preparing. For added stability of the tiiier, aiways keep the uphiii wheel In the soft, newly tilled soil. Do not till the last 12" or more of the downhill outside edge of each terrace. This untiiled strip heips prevents the ter races from breaking apart and washing downhill. It also provides a walking path between rows.

12 ' UNTiLLED

REPEAT

Figure 4-10

C. Tilling across slopes without using terraces:

• If vertical or terracing gardening aren’t practical for you, then you can till later ally across a slope. We don’t really recommend this method as it can create unsure footing and invites soii erosion.

• As in terrace gardening, start at the top of the slope and overlap the first pass by half the width of the tiiier. For added stabiiity of the tiiier, aiways keep the uphill wheel in the soft, newly tilled soil.

POWER COMPOSTING

Power composting simply means tilling under and burying in the soil all manner of organic matter such as crop residues, leaves, grass clippings and cover crops.

This material will decompose during the

non-growing season and add important natural nutrients to the soil.

A WARNING

When power composting, do not keep the Depth Regulator Lever at a deep setting if the tiller jumps or bucks.

If jumping or bucking occurs, move the Depth Regulator Lever down to one of the shallower settings and then slowly increase the tilling depth on later passes.

Failure to follow this warning could result in personal injury.

The first place to begin is with crop

residues such as leftover vines, stalks, stems and roots. Power compost these crop residues as soon as they finish bearing. The sooner this is done, the

better, as tender green matter is easier to till under. Use the deepest depth regula tor setting possible without causing the engine to labor or the tiller to jump ahead.

Standing cornstalks of reasonable height can be power composted. Pushing over

(but not uprooting) cornstalks will often

make it easier for your tiller to chop up the stalks. Keep the tines clear of exces sive tangling by “fishtailing” or frequently

using reverse. Make several passes, then

return a few days later to finish off any

remaining stubble.

After tilling under crop residues, add

more organic matter such as leaves, grass clippings and even kitchen scraps. When tilled into the soil, this organic

matter will decompose and add even

more important nutrients to the soil. After power composting, you may want to

plant a “green manure” cover crop to

protect the soil during the off-season. You simply grow a crop of clover, alfalfa,

buckwheat, peas, beans, rye grass, grain,

or kale and then till it into the soil prior to the planting season.

LOADING AND UNLOADING THE TILLER

A WARNING

Loading and unloading the tiller into a vehicle is potentially hazardous and we

don’t recommend doing so unless abso

lutely necessary, as this could result in

personal injury or property damage.

However, if you must load or unload the tiller, follow the guidelines given next.

• Before loading or unloading, stop the

engine, wait for all parts to stop moving,

disconnect the spark plug wire and let the engine and muffler cool. Remove the ignition key on electric start models.

• The tiller is too heavy (over 170 lbs., depending on model) and bulky to lift safely by one person. Two or more people should share the load.

• Use sturdy ramps and manually (engine shut off) roll the tiller into and out of the

vehicle. Two or more people are needed to do this.

* •

• Ramps must be strong enough to support the combined weight of the tiller and any handlers. The ramps should provide good traction to prevent slip ping; they should have side rails to guide the tiller along the ramps; and they should have a locking device to secure them to the vehicle.

• The handlers should wear sturdy footwear that will help to prevent slipping.

• Position the loading vehicle so that the ramp angle is as flat as possible (the less incline to the ramp, the better). Turn the vehicle’s engine off and apply its parking brake.

• When going up ramps, stand in the normal operating position and push the tiller ahead of you. Have a person at each side to turn the wheels.

• When going down ramps, walk back ward with the tiller following you. Keep alert for any obstacles behind you. Position a person at each wheel to control the speed of the tiller. Never go down ramps tiller-first, as the tiller could tip forward.

• Use wooden blocks to place on the downhill side of the wheels if you need to stop the tiller from rolling down the ramp. Also, use the blocks to temporar ily keep the tiller in place on the ramps (if necessary), and to chock the wheels in place after the tiller is in the vehicle.

• When the tiller is in the vehicle, prevent it from rolling by engaging the wheels in the wheel drive position (put Wheel Gear Lever in ENGAGE). Chock the wheels with blocks and securely tie the tiller down.

Section

UUÌUI ■ ■ ■ ■

5 Maintenance

A WARNING

Before inspecting, cieaning or servicing the machine, shut off engine, wait for aii moving parts to come to a compiete stop, disconnect spark piug wire and move wire away from spark piug. Remove ignition key on eiectric start modeis.

Faiiure to foiiow these instructions can resuit in serious personai injury or prop erty damage.

MAINTENANCE SCHEDULE

PRO CE D UR E

Check motor oil level Clean engine Check drive belt tension Check nuts and bolts 1,4 Change motor oil 1,4, 6 Lubricate tiller Service foam pre-cleaner air filter

(if so equipped) Service paper air filter (if so equipped) Check gear oil level in transmission Check tines for wear Check air pressure in tires 5 Service spark plug

1 - After first 2 hours of break-in operation.

2 - Before each use.

3 - Every 5 operating hours. 4 - Every 10 operating hours. 5 - Every 30 operating hours. 6 - More frequentiy in dusty or dirty conditions.

7 - See Engine Owner's Manuai for service

8 - Whichever time intervai occurs first

_________________________

recommendations.

NOTES

...

NO TE S

...

2,3

1,4

7 7

1,5

TILLER LUBRICATION

Proper lubrication of the tiller is an essen tial part of your maintenance program. After every 10 operating hours, oil or grease the lubrication points shown in

Figure 5-1 as described below.

Use a good quality lubricating oil (#30 weight engine oil is suitable) and a good quality general purpose grease (grease that has a metal lubricant is preferred, if available).

• Remove wheels, clean wheel shaft (A,

Figure 5-1) and apply thin coating of

grease to shaft.

• Grease back, front and sides of depth

regulator lever (B, Figure 5-1).

• Remove tines, clean tine shafts (C,

Figure 5-1) and inspect for rust, rough

spots or burrs (especially around

holes). File or sand smooth and coat

ends of shaft with grease.

• Oil the threads on the handlebar height

adjustment screw (D, Figure 5-1).

• Oil the threads on the handlebar attach

ing screws (E, Figure 5-1).

CHECK HARDWARE

At least every 10 operating hours, check the unit for loose or missing hardware (screws, bolts, nuts, hairpin cotters, etc.). Loose or missing hardware can lead to equipment failure, poor performance or oil leaks.

Be sure to check the three end cap mounting screws located at the rear of the transmission (Figure 5-2). Lift the tine flap to service those screws.

CHECK TIRE PRESSURE

Check the air pressure in both tires. Deflate or inflate both tires evenly to 15to-20 PSI (pounds per square inch). Be sure that both tires have the same air pressure or the unit will tend to pull to one side.

A WARNING

Before inspecting, cieaning or servicing the machine, shut off engine, wait for aii moving parts to come to a compiete stop, disconnect spark piug wire and move wire away from spark piug.

^y#y^l

Remove the key from the keyswitch on units so equipped. Faiiure to toiiow these instructions can resuit in serious personai injury or property damage.

CHECK FOR OIL LEAKS

Before each use, check your tiller for signs of an oil leak - usually a dirty, oily accumulation either on the unit or on the floor where it has been parked.

A little seepage around a cover or oil seal

is usually not a cause for alarm. However,

if the oil drips overnight then immediate attention is needed as ignoring a leak can

result in severe transmission damage.

If a cover is leaking, try tightening any

loose screws or bolts. If the fasteners are tight, a new gasket or oil seal may be

required. If the leak is from around a shaft and oil seal, the oil seal probably

needs to be replaced. See your autho

rized dealer or contact the factory for service or advice.

IMPORTANT:

the transmission is low on oil. Check the oil level after every 30 hours of operation and whenever there is any oil leakage.

Never operate the tiller if

TRANSMISSION GEAR OIL SERVICE

Check the transmission gear oil level after every 30 hours of operation or whenever you notice any oil leak. Operating the tiller when the transmission is low on oil can result in severe damage.

A. To Check Transmission Gear Oil Level:

1. Check the gear oil level when the trans mission is cool. Gear oil will expand in warm operating temperatures and this expansion will provide an incorrect oil level reading.

2. To check the gear oil level (and to add

oil, if necessary), refer to “STEP 5: Check Gear Oil Level in Transmission” in Section 2 of this manual.

B. To Drain and Refill the Transmission:

The transmission gear oil does not need to be changed unless it has been contami nated with dirt, sand or metal particles.

1. Prop up the left side of the unit so that it will be securely supported when the left side wheel is removed. Remove the left side wheel by removing the wheel mount ing hardware.

2. Unscrew the plastic gear oil fill plug

from the top of the transmission.

3. Place a clean pan below the transmis

sion drain plug (see Figure 5-3) and remove the drain plug. The oil will start

flowing out of the drain hole (it may flow

slowly, especially in cold temperatures).

4. Remove the transmission gear oil level

check plug that is located a few inches above the left side wheel shaft.

5. When the oil stops flowing, tilt the

transmission forward to drain oil from the

rear of the transmission.

of the drain plug, apply a non-hardening removable gasket sealant to the threads, and securely reinstall the drain plug.

7. Using a clean funnel, slowly add SAE

140 or SAE 85W-140 weight gear oil (with an API rating of GL-4 only) to the

transmission. The transmission holds

approximately 3-1/4 pints (52-54 ounces). Tilt the tiller slightly backwards

to make sure the gear oil reaches the rear

(tine) end of the transmission. Stop

adding gear oil when it begins to flow from the oil level check hole on the side of the transmission.

plug.

9. Securely reinstall the gear oil fill plug

on top of the transmission.

10. Reinstall the wheel and remove the

prop.

. After draining the oil, clean the threads

. Securely reinstall the oil level check

A WARNING

Before inspecting, cieaning or servicing the machine, shut oft engine, wait for aii moving parts to come to a compiete stop, disconnect spark piug wire and move wire away from spark piug.

* r?

Figure 5-3: Remove drain piug to drain transmission gear oii (aiso remove oii fiii piug and oii ievei check piug).

Remove the key from the keyswitch on units so equipped. Faiiure to foiiow these instructions can resuit in serious personai injury or property damage.

ENGINE OIL SERVICE

Check the engine oil level before starting the engine each day and check it after each 5 hours of continuous operation.

Running the engine when it is low on oil

will quickly ruin the engine.

It is recommended that you change the

motor oil after every 10 hours of opera tion and even sooner when operating in extremely dirty or dusty conditions. Refer to the separate Engine Owner’s Manual for detailed service instructions.

A. To Check the Engine Oil Level:

1. Move the tiller to a level area and shut off the engine.

Level the engine by moving the Depth

Regulator Lever up or down as needed.

Clean the area around the oil dipstick

or oil fill tube to prevent dirt from falling

into the crankcase.

On engines with an oil fill tube, remove

the filler cap, add oil (if required) until it

reaches the top of the tube and reinstall the filler cap.

On engines with a dipstick, remove it,

wipe it clean, and reinstall it finger-tight.

Remove the dipstick and check the reading. Add oil (if required) to bring the level to the FULL mark. Do not overfill.

B. To Change the Engine Oil:

Change the engine oil as instructed in the separate Engine Owner’s Manual.

AIR CLEANER SERVICE

The engine air cleaner filters dirt and dust out of the air before it enters the carbure tor. Operating the engine with a dirty, clogged air filter can cause poor perfor

mance and damage to the engine. Never

operate the engine without the air cleaner

installed. Inspect and service the air cleaner more often if operating in very dusty or dirty conditions.

Service the air cleaner as instructed in the separate Engine Owner’s Manual.

SPARK PLUG SERVICE

Inspect and clean or replace the spark

plug after every 100 operating hours or annually. Clean the plug and set the gap as described in the separate Engine Owner’s Manual.

In some areas, local law requires using

resistor spark plugs to suppress ignition signals. If the engine was originally equipped with a resistor spark plug, use the same type for replacement.

SPARK ARRESTER SCREEN SERVICE

If the engine muffler is equipped with a spark arrester screen, remove and clean it according to the time intervals and

instructions In the separate Engine Owner’s Manual.

ENGINE CLEANING

The engine must be kept clean to assure smooth operation and to prevent damage from overheating. Refer to the separate Engine Owner’s Manual for specific repair and cleaning instructions. All inspections and services must be done with the engine shut off and cool to the touch.

CARBURETOR/GOVERNOR CONTROL AOJUSTMENTS

A WARNING

Operators shall not tamper with the engine governor settings on the machine; the governor controis the maximum safe operating speed to protect the engine and aii moving parts from damage caused by overspeed. Authorized service shaii be sought if a probiem exists.

The carburetor was adjusted at the factory for best operating speed. Refer to the separate Engine Owner’s Manual for any adjustment information or see your authorized engine service dealer.

The governor controls the maximum safe operating speed and protects the engine and all moving parts from damage caused by overspeeding. Do not tamper with the engine governor settings. Seek autho rized service if a problem exists.

THROTTLE CONTROL AOJUSTMENT

If the engine does not respond to various throttle lever settings, refer to the sepa rate Engine Owner’s Manual for service information or contact your local autho rized engine service dealer.

A WARNING

Before inspecting, cieaning or servicing the machine, shut off engine, wait for aii moving parts to come to a compiete stop, disconnect spark piug wire and move wire away from spark piug.

^y#y^l

Remove the key from the keyswitch on units so equipped. Faiiure to toiiow these instructions can resuit in serious personai injury or property damage.

WHEEL GEAR CABLE ADJUSTMENT OFF SEASON STORAGE

When the Wheel Gear Lever is in DISEN

GAGE, the wheels will roll freely (free wheel). The wheels should not roll freely when the lever Is In ENGAGE. If the wheels roll freely when the Wheel Gear Lever Is In ENGAGE, the wheel gear cable needs to be adjusted as described below.

1. With the engine shut off and the spark plug wire disconnected, put the Wheel Gear Lever in ENGAGE.

Loosen the top adjustment nut (A, Figure 5-4) on the wheel gear cable bracket that is located on the left side rear of the transmission.

Push the wheel gear cable (B) down and roll the tiller slightly forward or back ward until the eccentric lever (C) engages (locks) the wheels. Hold the cable in that position and tighten the top (A) and bottom (D) adjustment nuts.

Move the Wheel Gear Lever to ENGAGE and DISENGAGE several times

to check the adjustment. The wheels

should not roll when the lever is in ENGAGE, but they should roll when the lever is in DISENGAGE. Readjust the cable as required.

When the tiller won’t be used for extended periods, prepare it for storage as follows:

Clean the tiller and engine.

Do routine tiller lubrication and check

for loose parts and hardware.

Protect the engine and perform recom

mended engine maintenance by following the engine storage instructions found in the separate Engine Owner’s Manual.

NOTE: Be sure to protect the fuel lines,

carburetor and fuel tank from gum

deposits by removing fuel or by treating fuel with a fuel stabilizer (follow engine

manufacturer’s recommendations).

On electric start units, follow “Battery

Storage” instructions in this Section.

Store unit In a clean, dry area.

. Never store the tiller with fuel in the

fuel tank in an enclosed area where gas fumes could reach an open flame or

spark, or where ignition sources are

present (space heaters, hot water heaters, furnaces, etc.).

BOLD TINES

The tines will wear with use and should

be inspected at the beginning of each tilling season and after every 30 operating

hours. Tines can be replaced individually

or as a complete set. Never inspect or

service the tines unless the engine is

stopped, the spark plug wire is discon

nected, and the ignition key is removed

on electric start models.

A. Tine Inspection:

With use, the tines will become shorter,

Figure 5-4: Wheel gear cable assembly.

narrower and pointed (Figure 5-5). Badly worn tines will result In a loss of tilling

depth and reduced effectiveness when

chopping up and turning under organic

matter. Use Figure 5-5 as a guide to

when the tines should be replaced.

Figure 5-5: Checking tines for wear.

B. Removing a Single Tine:

1. Remove the two screws and nuts that attach a single tine to the tine holder (Figure 5-6). If needed, use penetrating oil to help free the nuts.

When installing a single tine, be sure

to position it so that its cutting edge will

enter the soil first as the tiller moves forward.

C. Removing a Tine Assembly:

1. If removing both tine assemblies, mark them “left” and “right” before removal. Doing so will help ensure that the assem blies are reinstalled on the correct sides of the tiller.

Remove the screw and locknut that secure the tine assembly to the tine shaft (Photo 5-7). Pull the tine assembly off the shaft (if necessary, use a rubber mallet to tap the tine assembly outward).

Before reinstalling the tine assembly, inspect the tine shaft for rust, rough spots or burrs and file or sand as needed. Apply a thin coat of grease to the shaft.

Install each tine assembly so that the cutting edge of the tines will enter the soil first when the tiller moves forward.

Secure the tine assembly to the tine shaft using the screw and locknut previously removed. Tighten securely.

A WARNING

* r?

Before inspecting, cieaning or servicing the machine, shut oft engine, wait for aii moving parts to come to a compiete stop, disconnect spark piug wire and move wire away from spark piug. Remove the key from the keyswitch on units so equipped.

Faiiure to foiiow these instructions can resuit in serious personai injury or property damage.

Figure 5-8: Forward dutch beit. (C, Left side view, no beit cover.)

Figure 5-10: Location of forward dutch cabte spring (E) and forward cabie adjuster (F).

Cutting Edge

of Tine

Figure 5-7: Removing a tine assembiy.

A WARNING

Follow the belt adjustment instructions carefully. An incorrect adjustment could result In the clutch control mechanism engaging too soon. This could cause

loss of tiller control and result in per sonal injury or property damage.

CHECKING AND ADJUSTING TENSION ON CLUTCH BELTS

Maintaining correct beit tension is impor tant to good tiiiing performance and iong

beit iife. A ioose belt will slip on the engine and transmission pulleys and cause the tines and wheels to slow down

- or stop - even though the engine is

running at full speed. A loose belt will also result in premature belt wear.

While checking belt tension, also check for cracks, cuts or frayed edges. A belt in

poor condition should be replaced. Tension on a new forward clutch belt (C,

Figure 5-8) should be checked after the

Figure 5-9: Reverse dutch beit (D). (Right-side view, no beit cover.)

first two (2) hours of operation and after

every ten (10) hours of operation.

The reverse clutch belt (D, Figure 5-9),

because it is used more sparingly, may not require tension adjustment until a sig nificant number of operating hours has passed. A tension adjustment is required only if there is little or no reverse move ment when the Reverse Clutch Control knob is pulled out.

Checking and Adjusting Forward Ciutch Beit Tension

It is important to maintain correct tension on the forward clutch belt. A loose belt will cause the tines and wheels to slow down - or stop completely - even though

the engine is running at full speed.

2-1/2"

extended

spring iength

Figure 5-11: Correct spring iength when Forward Ciutch Levers are engaged is 2-1/2".

A loose belt will also result in premature belt wear.

• Check belt tension after the first two hours of break-in operation and after every 10 operating hours.

• At the end of each tilling season, check the belt for cracks, cuts or frayed edges. A belt in poor condition should be replaced.

igth

* •

A WARNING

Before inspecting, cieaning or servicing the machine, shut off engine, wait for aii moving parts to come to a compiete stop, disconnect spark piug wire and move wire away from spark piug.

^y#y^l

Remove the key from the keyswitch on units so equipped. Faiiure to toiiow these instructions can resuit in serious personai injury or property damage.

A CAUTION

Incorrect cable adjustment could cause

the wheels and tines to rotate unexpect edly. Follow adjustment procedures carefully. Failure to do so could result

in personal injury or property damage.

Checking Forward Belt Tension

1. Before checking, shut off engine, allow the engine and muffier to cooi down, dis connect the spark piug wire, remove the

ignition key on electric start modeis.

The coiied part of the forward ciutch

spring (E, Figure 5-10) measures 2" in

iength when the Forward Ciutch Controi ievers are not puiied up. Puil either

Forward Ciutch Controi Lever up against the handlebar and measure the length of the coil on the forward clutch spring. Tension is correct if the length of the extended coll is 2-1/2" (see Figure 5-11). The forward ciutch controi cable needs adjustment if the extended iength of the coii is not 2-1/2". See Adjusting the

Forward Clutch Beltior a procedure. Adjusting the Forward Clutch Cable

Do this procedure if the forward clutch spring measurement Is not correct (see

Checking Forward Belt Tension).

1. Before adjusting the belt, shut off engine, allow the engine and muffler to cool down, disconnect the spark plug wire, and remove the ignition key on elec tric start models.

forward clutch cable adjuster (F, Figure 5

10). Use two 1/2", open-end wrenches to loosen the two jam nuts (A, Figure 5-12) a few turns.

Move cable adjuster (B, Figure 5-12) downward for more belt tension (see Figure 5-12).

Hand tighten the jam nuts and pull the Forward Clutch Control levers up against the handiebar. Measure the spring coii (Figure 5-11). The extended iength of the coil should be 2-1/2". Repeat this proce dure until the extended spring iength is correct.

Tighten both jam nuts secureiy.

Checking and Adjusting Reverse Ciutch Beit Tension

Checking Reverse Clutch Belt Tension

The reverse ciutch beit (D, Figure 5-9) needs adjustment if the beit siips in reverse or if there is no reverse. See

Adjusting Reverse Clutch Belt beiow. Adjusting Reverse Clutch Belt

1. Before adjusting the belt, shut off engine, aiiow the engine and muffier to cooi down, disconnect the spark piug wire, and remove the ignition key on eiectric start modeis.

Figure 5-14: Reverse clutch cable adjuster. Left-side view with belt cover removed.

Move the cable adjuster (D, Figure 5-14) away from the pulleys to increase beit tension.

Tighten both jam nuts securely.

. Reinstall the belt cover.

Move the unit to an open area and test

the reverse operation. Repeat this proce

dure if the unit does not respond when

the reverse clutch is engaged.

FORWARD CLUTCH BELT REMOVAL

AND REPLACEMENT

The forward ciutch beit (K, Figure 5-15)

engages the engine puliey (I) and the

transmission puliey (J) when either

Forward Clutch Control Lever is puiied up against the handiebar. This tightens the

forward ciutch cable (G) which causes the forward clutch idler pulley (H) to apply

pressure to the forward clutch belt. This causes the pulleys to turn for Forward movement.

adjuster down for more belt tension.

2. Belt adjustments are done with the

Figure 5-13: Belt cover.

2. Remove the two nuts (C, Figure 5-13) and remove the belt cover.

Reverse belt tension adjustments are done with the reverse ciutch cable adjuster located on the left side of the machine near the engine (D, Figure 5-14). Use two 1/2" open-end wrenches to loosen the two adjuster jam nuts (E) a few turns.

Figure 5-15: Forward clutch control

assembly.

A WARNING

* r?

Before inspecting, cieaning or servicing the machine, shut oft engine, wait for aii moving parts to come to a compiete stop, disconnect spark piug wire and move wire away from spark piug. Remove the key from the keyswitch on units so equipped.

Faiiure to foiiow these instructions can resuit in serious personai injury or property damage.

Forward Clutch

Idler Arm

Forward Clutch

Cable

Connection

■

Figure 5-17

Removing Forward Clutch Belt

1. Stop engine, allow it to cool and dis connect spark plug wire before working near belts. Also remove ignition key on electric start models.

2. Remove the two nuts (C, Figure 5-13) and remove the belt cover.

3. Move the reverse clutch belt (B, Figure 5-16) out of the way. You do not need to completely remove the belt. Press the reverse idler pulley inward for slack and then slip the bottom half of the belt com pletely off the transmission pulley (A, Figure 5-16). Pull the bottom half of the belt out of the housing and let it hang off the outside of the unit (B).

Disconnect the forward clutch cable

from the forward clutch idler arm bracket

(Figure 5-17). Note the hole from which you disconnect the cable. It is important that you reconnect the cable to the same

hole.

5. Slide the belt off the engine pulley (C,

Figure 5-18), away from engine, out from

under the belt guide (D), and completely

off the pulley.

. Slip the belt off the front of the trans

mission pulley (F, Figure 5-19).

Work the belt out from between the pulley and the frame, around the trans mission cover spring, then up and out of

the machine.

Installing Forward Clutch Belt

1. Stop engine, allow it to cool and dis

connect spark plug wire before working

near belts. Also remove ignition key on

electric start models.

2. Remove the old forward clutch belt as described in Removing Forward Clutch

Belt

Figure 5-20: Arrow (K) shows insertion point for instaiiing new forward dutch heft.

3. From the front of tiller, insert the forward clutch belt in between the bottom

of the engine drive pulley (I) and the top of transmission pulley (K, Figure 5-20).

Insert the bottom half of belt into the

smaller, rear-most groove of the trans

mission pulley (F, Figure 5-19). Now slip

the top half of belt under the belt guide

(D, Figure 5-18) and onto the large groove of engine drive pulley (L, Figure 5-19).

5. Reconnect the forward clutch cable to the correct hole in the idler arm bracket, as shown in Figure 5-17.

NOTE: Be sure to run the reverse clutch cable on the pulley side of the cover support brackets (G, Figure 5-21).

Figure 5-21: Correct forward dutch cable positioning.

IMPORTANT:

the inside of the belt guide (FI, Figure 5-21).

. Reinstall the reverse clutch belt. Insert

the bottom of the belt into the frame, then

Belt must be installed on

A WARNING

Before inspecting, cieaning or servicing the machine, shut off engine, wait for aii moving parts to come to a compiete stop, disconnect spark piug wire and move wire away from spark piug.

^y#y^l

Remove the key from the keyswitch on units so equipped. Faiiure to toiiow these instructions can resuit in serious personai injury or property damage.

pull down on the belt and roll It onto the large, forward-most groove of the trans mission pulley (P, Figure 5-20).

Reinstall the belt cover.

. Test for correct tension on the forward

clutch belt (see Checking Forward Belt

Tension).

REVERSE CLUTCH BELT REMOVAL

AND REPLACEMENT

Figure 5-22: Right-side view.

The reverse clutch belt (J, Figure 5-22) is driven by the engine drive pulley (I, Figure 5-20). When the Reverse Clutch Control

knob is pulled out, it pulls the reverse

idler arm and pulley (N) which tightens the belt against the engine drive pulley. This drives the transmission drive pulley

(L), resulting in reverse motion.

Removing Reverse Clutch Belt

1. Stop engine, allow it to cool and dis connect spark plug wire before working

near belts. Also remove ignition key on electric start models.

Remove belt cover (Figure 5-13) by

removing two flange locknuts.

Pull the reverse clutch belt downward

and slip it off the transmission pulley

(L, Figure 5-22).

Use two 1/2" wrenches to loosen and

remove wire belt guide (R, Figure 5-22)

from the reverse idler arm pulley. Do not

remove locknut and screw.

Remove the reverse belt and pull it out

through front of transmission housing.

Installing Reverse Clutch Belt

1. Stop engine, allow It to cool and dis connect spark plug wire before working

near belts. Also remove ignition key on

electric start models.

IMPORTANT:

must be installed before the reverse

clutch belt.

2. Install the forward clutch belt (see

Installing Forward Clutch Belt In this

section) before installing reverse belt.

IMPORTANT:

shape. When installing the belt, make sure that the widest (flat) side of the belt

rides against the reverse idler pulley (N, Figure 5-22) and transmission pulley (L).

If needed, the belt can be twisted “inside out” so that the “V” shaped side is on the outside and the widest side is on the

inside.

Insert the belt down into the front of

the transmission housing. Slip the top

half of the belt onto the reverse idler arm

pulley (N).

Pull the belt downward and loop the

bottom half of belt around the front groove of transmission pulley (L, Figure 5-22).

Mount the belt guide between the two flat washers and tighten snugly. The guide needs adjusting before fully tightening.

The forward clutch belt

The reverse belt has a ‘V”

Figure 5-23: Reverse belt guide positioning.

. (You will need an assistant to help

with this step.) Pull the reverse idler

pulley (N) up to its highest point and position the belt guide (R) horizontally

level as shown in Figure 5-23. Securely tighten the screw and lock nut (M, Figure 5-22).

Pull back on the Reverse Clutch

Control knob and make sure that the

reverse clutch belt fully contacts the groove in the engine pulley. Release knob and make sure that the belt doesn’t engage the reverse engine pulley. This

may cause the unit to move in reverse when the Wheel Gear Lever is engaged. Adjust the cable for less tension if this condition occurs. See Checking and

Adjusting Reverse Belt Tension for more

information.

. Reinstall the belt cover and secure it

with two flange locknuts.

Test the unit In an open location.

A WARNING

* ri

Before inspecting, cieaning or servicing the machine, shut oft engine, wait for aii moving parts to come to a compiete stop, disconnect spark piug wire and move wire away from spark piug. Remove the key from the keyswitch on units so equipped.

Faiiure to foiiow these instructions can resuit in serious personai injury or property damage.

BATTERY MAINTENANCE

A DANGER

Use extreme caution when working on or near batteries. To help prevent per

sonal injury or property damage:.

• Batteries generate explosive gases. Keep sparks and flames away from the battery at all times. Ventilate the area

when charging or using the battery in an enclosed area.

Battery Care in Service

The battery is sealed and is maintenancefree. Acid levels cannot be checked.

• Always keep the battery cables and ter

minals clean and free of corrosive build-up.

• After cleaning the battery and terminals,

apply a light coat of petroleum jelly or grease to both terminals

• Always keep the rubber boot positioned

over the positive terminal to prevent shorting.

Charging

If the tractor has not been put into use for

an extended period of time, charge the

battery with an automotive-type 12-volt

charger for a minimum of

amps.

* •

one hour at six

Jump Starting

IMPORTANT:

dead battery with the battery of a running

vehicle.

1. Connect end of one jumper cable to the

positive terminal of the good battery, then the other end to the positive terminal of the dead battery.

Connect the other jumper cable to the

negative terminal of the good battery, then to the frame of the unit with the dead

battery.

Failure to use this procedure could cause

sparking, and the gas in either battery

could explode.

Never jump your tiller’s

Cleaning

Clean the battery by removing it from the tractor and washing with a baking soda

and water solution. If necessary, scrape the battery terminals with a wire brush to

remove deposits. Coat terminals and

exposed wiring with grease or petroleum jelly to prevent corrosion.

Battery Failures

Some common causes for battery failure

are:

• incorrect initial activation

• undercharging

• overcharging

• corroded connections

• freezing

IMPORTANT:

covered by your tractor’s warranty.

These failures are

NOT

Battery Removal and Installation

When removing and installing the battery, disconnect and connect the cables in this order to avoid sparking:

To remove the battery, first disconnect the negative (-) cable from the grounding screw on the back of the battery bracket post. Bend the cable away from any metal parts.

Disconnect the negative (-) cable from the negative (-) battery post.

Disconnect the positive (+) cable from the positive (+) battery post and bend it away from any metal parts. Cover the cable terminal with its rubber boot.

Remove the battery clamp.

To install the battery, reverse the above steps. Be sure that the battery posts face to the rear of the tiller and that the posi tive (+) post is on the left side as you face forward from the handlebars.

Battery Storage

Charge battery fully. The battery loses some of its charge each day when the unit is not used.

IMPORTANT:

without a full charge. Recharge battery before returning to service or every two months, whichever occurs first. When storing unit for extended periods, disconnect battery cables. Removing battery from unit is recommended.

NEVER store battery

A WARNING

Before inspecting, cieaning or servicing the machine, shut off engine, wait for aii moving parts to come to a compiete stop, disconnect spark piug wire and move wire away from spark piug.

^y#y^l

Remove the key from the keyswitch on units so equipped. Faiiure to toiiow these instructions can resuit in serious personai injury or property damage.

TROUBLESHOOTtNG

PROBLEM POSSIBLE CAUSE CORRECTION

Engine dees not start.

Engine runs poorly. 1. Defective or incorrectly gapped spark plug.

1. Spark plug wire disconnected.

2. Engine Throttle Control Lever incorrectly set.

3. Fuel tank empty.

4. Choke control (if so equipped) in incorrect position.

5. Stale gasoline.

6. Dirty air filter(s).

7. Defective or incorrectly gapped spark plug.

8. Carburetor out of adjustment.

9. Misadjusted throttle control.

10. Dirt or water in fuel tank.

2. Dirty air filter(s).

3. Carburetor out of adjustment.

4. Stale gasoline.

5. Dirt or water in fuel tank.

6. Engine cooling system clogged.

1. Reconnect wire.

2. Put lever in FAST position.

3. Add fuel.

4. See Engine Owner’s Manual.

5. Drain fuel and add fresh fuel.

6. Clean or replace filter(s).

7. Inspect spark plug.

8. See Engine Service Dealer.

9. See Engine Service Dealer.

10. See Engine Service Dealer.

1. Inspect spark plug (see Engine Owner’s Manual).

2. Clean or replace (see Engine Owner’s Manual).

3. See Engine Service Dealer.

4. Replace with fresh gasoline.

5. See Engine Service Dealer.

6. Clean air cooling system (see Engine Owner’s Manual).

Engine overheats. 1. Engine cooling system clogged.

2. Carburetor out of adjustment.

3. Oil level is low.

Engine does not

1. Misadjusted throttle control cable (recoil start model). 1. See Engine Owner’s Manual or Engine Service Dealer.

shut otf. Wheels and Tines

will not turn.

Tines turn, but wheels don’t.

Wheels Turn, but

Tines Don’t.

Poor tilling performance.

1. Improper use of controls.

2. Forward Clutch: Misadjusted forward clutch control cable.

3. Reverse Clutch: Misadjusted clutch control cable.

4. Worn or broken clutch belt(s).

5. Internal transmission wear or damage.

6. Bolt and key loose in transmission pulley.

1. Wheel mounting hardware missing.

2. Bolt and key loose in transmission pulley.

3. Internal transmission wear or damage.

4. Misadjusted wheel gear cable.

5. Wheel Gear Lever not fully engaged.

1. Tine holder mounting hardware missing.

2. Internal transmission wear or damage.

1. Worn tines.

2. Improper Depth Regulator setting.

3. Incorrect throttle setting.

4. Belt(s) slipping.

1. Clean air cooling area (see Engine Owner’s Manual).

2. See Engine Service Dealer.

3. Check oil level (see Engine Owner’s Manual).

1. Review Sections 3 and 4.

2. Adjust cable tension (Section 5).

3. Adjust cable tension (Section 5).

4. Check belts. Replace parts as needed (Section 5).

5. Contact local dealer or the factory.

6. Tighten bolt; check that key is in place.

1. Replace hardware.

2. Tighten bolt; check that key is in place.

3. Contact local Dealer or the Factory.

4. See “Wheel Gear Cable Adjustment,” Section 5.

5. Engage lever (see Section 3).

1. Replace hardware.

2. Contact local Dealer or the Factory.

1. See “Bolo Tines” (Section 5).

2. See “Tilling Tips & Techniques,” Section 4.

3. See Section 4.

4. See “Checking Clutch Belt Tension,” Section 5.

A WARNING

* ri

Before inspecting, cieaning or servicing the machine, shut oft engine, wait for aii moving parts to come to a compiete stop, disconnect spark piug wire and move wire away from spark piug. Remove the key from the keyswitch on units so equipped.

Faiiure to foiiow these instructions can resuit in serious personai injury or property damage.

MAINTENANCE SCHEDULE

PRO CE D UR E

Check motor oil level Clean engine Check drive belt tension 1,4 Check nuts and bolts 1,4 Change motor oil 1,4,6 Lubricate tiller Service foam pre-cleaner air filter

(if so equipped) Service paper air filter (if so equipped) Check gear oil level in transmission Check tines for wear Check air pressure in tires 5 Service spark plug

NOTES

1 - After first 2 hours of break-in operation. 2 - Before each use. 3 - Every 5 operating hours. 4 - Every 10 operating hours. 5 - Every 30 operating hours. 6 - More frequentiy in dusty or dirty conditions.

NO TE S

2,3 2,7

7 7

1,5

7 - See Engine Owner's Manuai for service

recommendations.

8 - Whichever time intervai occurs first

TILLER ATTACHMENTS

The attachments listed below are available for your tille Contact your authorized dealer or the factory for current information.

BUMPER — MODEL OEM-290-254

The tubular steel bumper helps to protect the engine from damage.

HtLLER/FURROWER — MODEL OEM-290-251

The furrower blade attaches to the back of the depth regulator assembly and is used to create rows, trenches and ditches up to 8" deep, depending on soil conditions. The two hlller wings attach to the sides of the furrower blade and are used to make hilled rows and raised bed gardens.

ROW MARKER— MODEL OEM-290-257

The row marker attaches to the hiller/furrower attachment and is used to scratch lines in the seedbed for laying out furrows, trenches, raised beds, etc. (eliminates the need for stakes, string and measuring tape). The row marker is adjustable in length from 28" to 49-3/4", allowing you to vary the width of the marked rows as required.

HANDLEBAR ASSEMBLY and CONTROL LEVERS

Models 664D & E666M

HANDLEBAR ASSEMBLY and CONTROL LEVERS

REF. No.

1 2

3 777122088 Decal, Control Panel

4 1916784 5

6 1900475 7 710-0514 Hex Hd. Screw, 3/8-16x1* 8 736-3050

9 712-3000 10 1918791 Cable, Forward Clutch Control 13

14 GW-9057

Specify GRADE 5 if ordering part locally.

PART

No.

1918811 Handlebars (Incl. Refs. 2,3 & 3A) GW-9126

777D05553 Decal, Model Name/Logo

1186347 Height Adjustment Screw GW-9955

GW-9442

DESCRIPTION QTY.

Grip

......................................................

..........................

....................

Reverse Clutch Control Cable

....................

Washer, Keyed Bracket, Handlebar Height Adjustment 1 24

Washer, Plain (flat) 3/8, S.A.E Hex Locknut, 3/8-16

Wheel Gear Control and Cable Assy.

(IncI.Refs. 14,15,19, 21,22 & 23)

Knob, Wheel Gear Control Lever

....................................

...................

............................

........

.............

............

........

REF. No.

16 710-0216 1 17 1

19 1 21 1 22 1

23 1186208

25 1918840 Bail, Forward Clutch Control (Incl. 2 2

35 GW-9853 Sems Nut 1

36 GW-20806

42 1 1/4-20x1/2* 1

PART

No.

1186211 Hex Nut, 5/16-24

736-0169

725-0157 1114748 1100240

GW-9390

710-0599

DESCRIPTION QTY.

Hex Hd. Screw, 3/8-16x3/4* Lockwasher, 3/8

Cable Ties, Plastic

Round Hd. Screw, #10-32 x 1/2 Lockwasher, #10 Hex Nut, #10-32

Grip

..................................................

two Ref. 24)..................................

.........................................

Bracket, Bail Support....................... ... 2

Hex Flange Screw, self-tapping.

..................................

.............................

............

..............................

...........................

......

.............................

..............................

... 2 ... 2 ... 2 ... 2 ... 6 ... 2 ... 2 ... 2

... 1 ... 4

... 2

Models 664D & E666M

ENGINE, SUPPORT BRACKETS, PULLEYS, BELTS, BELT COVER

Models 664D & E666M

ENGINE, SUPPORT BRACKETS, PULLEYS, BELTS, BELT COVER

REF. No.

2 3 736-0119 Lockwasher-5/16 4 710-0107 Hex Hd. Screw, 5/16-24x1/2 5 777S30651

6 1917139 Cover (Incl. Ref. 5)..........................

7 712-3004A Flange Lock Nut, 5/16-18 8

9 GW-1138-1 10 619-04015 Pulley, Engine Drive 11 GW-9944 12 GW-9572 13 710-3103 14

15 1916535 Pulley, Reverse Idler.......................

16 17 18 19 1917746

20 GW-9929

22 1916522 Transmission Pulley

23 GW-1440 24 1918812 Reverse Clutch Belt 25 26 1900396

PART

No.

* * * *

1917326

1108841 Key, 3/16x1-1/2................................... 1

1918731

1107382 Flat Washer, 5/16................................ 2

1916725 Belt Guide, Wire Formed 710-0117 Hex Head Screw, 5/16-24 x 1

1916728

1909404 Forward Clutch Belt

DESCRIPTION QTY.

Engine - standard recoil start Engine - electric start Bracket, Clutch Cable

............................

Decal, Hot Surfaces/Belt Warning....... 1

Shim................................................ .... 1

Belleville Washer Hex Hd. Screw, 5/16-24x1-1/8 Hex Hd. Screw, 5/16-18x2 Reverse Idler Arm

Washer, Shoulder

Washer, Flat, 1-1/8.............................. 3

Spring, Reverse Return

Support Washer

Self-tapping Screw, #10-32 x 1/2,.. .... 4

............................

...........................

........................

..............................

........................

..........

.....................

...........

...............

.......................

.......

..............

...............

.........

..................

REF. No.

.... 1 27

.... 1

.... 6

.... 2

.... 1

.... 2 37 1918774 Mounting Bar....................................... 2

.... 1

28 29 1186329 30 31 1916796 35 710-0805 36

38 GW-90063 39 40 736-0275 Flat Washer, 5/16'

.... 2 41

.... 1 42

.... 1

.... 1 44 712-0267

.... 1

.... 1 47 1767754 Screw, self tapping, #10-24

.... 1

.... 1 52

.... 1

.... 1 54

.... 1

43 736-0119

45 1917746 46

48 49 712-3000 50 GW-9090 Idler Pulley, Forward 51

53 1754128

55 714-04029 Key, .188x1.75 56 710-0539

PART

No.

GW-20339 Guard, Belts/Pulleys 712-0267

1916797 Engine Support Bracket, left side

777120942 Decal, Stabilization

710-3037 Hex Hd. Screw, 5/16-18x2-1/4*

1918846 GW-55088

1918744 Idler Arm, Forward Tiller Direction.... .. 1

1916727 Spring................................................ .. 1

710-0347 Screw, 3/8-16 X1-3/4 712-0158 Hex Lock Nut, 5/16-18

736-0463

DESCRIPTION QTY

.....

........

.. 1 .. 4

.. 1

.. 5 .. 1

.. 4 .. 1 .. 1 .. 2 .. 2

.. 2 .. 2

.. 1

.. 1 .. 1 .. 1 .. 1 .. 1 .. 1 .. 1

.........................

Hex Nut, 5/16-18...............................

Hex Flange Screw, 5/16-18 x 3/4*.... .. 4

Engine Support Bracket, right side...... 1

Hex Hd. Screw, 5/16-18x1-1/2..........

...........................

Hex Flange Screw, 5/16-18 x 1

.............................

Belt Guide, Pony Pivot Bushing

Lockwasher, 5/16.............................. .. 2

Hex Nut, 5/16-18...............................

Washer, Shoulder

Hex Locknut, 5/16-18.......................... 1

Screw, 1/4-20x3/4 Flat Washer-1/4

Screw, 3/8-24 x 1.75

...............................

....................................

.............................

..............

.........................

........................

......................

.............................

................................

..................................

.........................

Specify GRADE 5 if ordering part locally.

See your local authorized engine service dealer for engine parts or service. Refer to engine nameplate for engine type and code information.

TRANSMISSION HOUSING, COVERS, SEALS, GASKETS, PLUGS

Models 664D & E666M

REF. No.

1 GW-9621 2 3 721-04001 4 5 6 GW-11513

7 GW-20694 Gasket, Transmission Top Cover 8 619-04010

9 10 GW-20889 Mounting Plate, Wheel Clutch Cable... 11 12

* Specify GRADE 5 if ordering part locally.

A/R-As Required

PART

No.

1105620 Pipe Plug, 1/4......................................

1186329 1983632 Oil Seal, Input Pinion Shaft

GW-9467

721-04035 1186328 Hex Flange Screw, 5/16-18 x 5/8*

DESCRIPTION QTY.

Oil Seal (Double Lip), Wheel Shaft

Seal, Transmission Bore Hex Flange Screw, 5/16-18 x 3/4*

Transmission Cover (Incl. four Ref. 18

and two ea. Refs. 21 & 22)

Transmission Case Assy..................... 1

Plug.....................................................

Oil Seal, Tiller Shaft

.....................

.................

.............

.......

............................

REF. No.

.....

......

13 GW-20873 2 14 1

6 15 1915089 Screw Kit: Incl. three 1/4-20 x 7/8 1 Self-Sealing Screws

16 GW-1115

1 17 GW-1124-2 Gasket, Rear Bearing Cap, .010" 1 Thick

18 GW-90063

1 Self-Sealing Screws 2 21 2 22

PART

No.

GW-1129-1

1915087

736-0169 710-0216

DESCRIPTION QTY

Tiller Housing Cover, left side

Gasket, Tiller Housing Cover, .010"

(fits all covers)

Rear Bearing Cap

.............................................

Hex Flange Screw, 5/16-18 x 1 * Screw Kit: Incl. five 1/4-20 x 5/8

Lockwasher, 3/8 Hex Hd. Screw, 3/8-16x3/4*

..........

..............................

.....................

............................

.....

.....................

...............................

............

.. 1

.. A/R

.. A/R .. 1

.. A/R .. 4

.. A/R .. 2 .. 2

Models 664D & E666M

REF. No.

3 GW-9301 4 GW-20912

5 GW-1224-3 Shim, same as above, but .005“ thick 18 GW-9093

NOTE: Shim between drive shaft rear bearing and rear bearing cap to achieve 5-to-10 thousandths of an inch (.005-.010) end play on drive shaft. A/R - As Required

* Specify GRADE 5 if ordering part locally.

PART

No.

1 GW-1714 Bearing, Tapered Roller with Race .... 1

GW-20718

GW-1224-1 Shim, Rear Bearing Cap, .010" thick 14

GW-1224-2

GW-1325C Shim Set (Inch two GW-1224-1 ¡two 17 and 18.......................................

DESCRIPTION QTY.

MAIN DRIVE SHAFT INPUT PINION SHAFT & GEAR ASSEMBLY

Spur Gear.......................................... 1 7 GW-9944 Washer, Disc Spring (concave

Key, 3/16sq.x1 Main Drive Shaft (Drive shaft is one- 8

piece with integral, single-lead. 9 work-hardened front worm, and 10 GW-1440 integral, six-lead, work-hardened rear worm. Also includes pressedon GW-1714 and GW-9301)

(see Note below)

Shim, same as above, but .030" thick 16 GW-20791

(see Note)......................................

1224-2 and one GW-1224-3)

..................................

.........

...........................

........

A/R

A/R 17 GW-20792 Input Pinion Gear

A/R

REF. No.

11 721-04044 Oil Seal, Input Pinion Shaft 12 1113527 Retaining Ring (external)

13 GW-9953

19 GW-20799 Pinion Assy. (Inch one each Refs. 16,

PART

No.

GW-9572

1108841 Key,3/16sq.x1-1/2 1916522

GW-9428 GW-9677

GW-9517 Retaining Ring (internal)

DESCRIPTION QTY

Hex Hd. Screw, 5/16-24x1-1/8*.........

surface faces pulley)......................

.............................

Transmission Drive Pulley Support Washer

Thrust Washer

Bushing.............................................. 1

Setscrew, 5/16-18x3/8*

Input Pinion (steel shaft)

Retaining Ring (external) 1

................................

...................................

..............................

.................

...............

..................

.....................

...................

...............

...................

1 1 1 1 1 1

1 1 1 1

A/R

WHEEL SHAFT, ECCENTRIC SHAFT and TILLER SHAFT ASSEMBLIES

Models 664D & E666M

REF. No.

1 2 3 GW-1166-1

4 5 711-04091 Wheel Shaft (Incl. Ref. 6)

6 GW-9373 Hi-Pro Key, 1/4x1-5/16......................

7 GW-20914 Wheel Drive Worm Gear (cast-iron).. 1 8 GW-9935

* Specify GRADE 5 if ordering part locally.

A/R - As Required

PART

No.

721-04031 Oil Seal..............................................

1909950

GW-1166-2 GW-1166-3

GW-1166-4 Shim, as above, but .010" thick......... A/R 14

GW-1086

DESCRIPTION QTY.

Retaining Ring (heavy-duty, external) 2 Shim, 1-1/64 I.D., .062" thick

Shim, as above, but .030" thick.........

Shim, as above, but .015" thick......... A/R

Bushing

.............................................

Shim (between key and gear).

1.016I.D.X1.468 0.D.X.062

Thick

..............................................

............

..................

REF. No.

A/R 11 GW-1442 Pin, Eccentric Shaft A/R 12

2 1 1 17

15 710-3013 16

18 19 GW-20913

PART

No.

GW-20712 Wheel Drive Clutch (cast-iron) 611-04002

GW-9055 721-04034 GW-20700

741-3037 Ball Bearing

711-04080 Tiller Shaft (Incl. Ref. 18)..................

GW-1104 Woodruff Key, 1/4x1-1/4................... 1

DESCRIPTION QTY.

Eccentric Shaft

Spring

...............................................

Oil Seal.............................................

Eccentric Shaft Lever Hex Hd. Screw, 1/4-20x1/2*

Tiller Drive Worm Gear (bronze)

.................................

......................................

.........

..........................

.......................

.............

......

1 1 1 1 1 1 1

Models 664D & E666M

BOLO TINES, WHEELS

REF. No.

3 712-0375 5 710-3096 7 GW-1270-1A

8 1902154010

PART

No.

710-3105

2 GW-1270-2A

1901118

NOTE 1: Custom Tilling Tines are available for your tiller. These are special hard-faced tines that are thicker than standard tines.

IMPORTANT: Left and right sides of

tiller are determined by standing in operator position and facing direc tion of forward travel.

REF.

DESCRIPTION QTY.

Hex Hd. Screw, 3/8-16x1-1/4* Bolo Tine-single. Right hand tine tine (see Note 1 above)

used on left side of tiller. (Incl.

two ea. Refs. 1 and 3)

Hex Locknut, 3/8-16............................ 2

Hex Hd. Screw, 3/8-16x2, Grade 8.... 2

Bolo Tine-single. Left hand tine

used on right side of tiller. (Incl.

two ea. Refs. 1,9 and 10)

Tine Holder. For left and right sides.... 2

Bolo Tine Replacement Set (Incl. eight 11

ea. right hand and left hand tines.

and sixteen ea. Refs. 1 and 3)

............

.....................

................

........

No.

8 tine (see Note 1 above)

8 9

10 736-0169

PART

No.

GW-2475-1

GW-2475-2 Custom Tilling Bolo Tine, Right hand

GW-10802 Custom Tilling Bolo Tine Replacement

712-3017 Hex Nut, 3/8-16...................................

GW-9380 GW-9338 1917487

DESCRIPTION QTY.

Custom Tilling Bolo Tine, Left hand

Set (Incl. eight ea. right hand and

left hand custom tines, and sixteen each of Refs. 1 and 3)

Lock Washer, 3/8 Clevis Pin, .312x1-3/4

Hitch Pin.............................................. 2

Wheel and Tire Assembly

................................

.........................

...................

.....................

...................

1 16 16

Specify GRADE 5 if ordering part locally.

ROW MARKER AHACHMENT

Models 664D & E666M

BUMPER AHACHMENT

Models 664D & E666M

ROW MARKER AHACHMENT & BUMPER AHACHMENT

REF No.

PART

No.

DESCRIPTION QTY.

Row Marker Attachment (option) - OEM-290-254

1 1904522001 Main Support & Yoke Assy-

complete. (Incl. Ref. No.'s

10,11,12,13,14,15,16,17 & 18) 2 GW-1594 Marker Blade-blade only 3 1904524001 Marker Arm-main arm 4 1904523001 Marker Arm-extension arm with

stop pin............................................... 1

5 GW-9347 Hitch Pin-(incl. in Hardware Pkg

GW-1837)

6 GW-9786 Thumbscrew-1/4-20x1/2,not

avail, sep. (see hardware pkg. GW-1837)

7 GW-1596 Nut Bar-(incl. in hardware pkg

GW-1837)

8 GW-9828 Nut-hex, 10-24 w/attached start

washers, not avail, sep. (see hardware pkg #1837)

9 1100135 Screw-round hd.,10-24 X1, not

avail, sep. (see hardware pkg GW-1837)

— GW-1837 Hardware Package-includes: one

GW-9347 hitch pin (Ref. 5), two GW-9786 thumbscrews (Ref. 6), one GW-1596 nut bar (Ref. 7), two GW-9828 hex nuts (Ref. 8), two 1100135 screws (Ref. 9)

..........................................

...........................................

..........................................

...........................................

................

.........................

.............................

.........................

.............

REF

No.

PART

No.

DESCRIPTION QTY.

Row Marker Main Support & Yoke Assembiy - Part #1904522001

10 1186349 Screw-hex flanged locking,

1 1 1

11 GW-1593 Stop Bar................................................... 1

12 GW-1592 Yoke

13 GW-1591 Tube Key-square..................................... 1

14 GW-1590 Washer-friction......................................... 2

15 GW-1588 Main Support 16 GW-1589 Washer-square hole

17 GW-9925 Washer-disc spring.................................. 1

18 1186231 Nut-hex 3/8-16......................................... 1

3/8-16x1-1/2*...................................... 1

........................................................

...........................................

................................

1 1

Bumper-OEM-290-254

19 1918749001 Bumper (includes Ref. 20)

20 777S30653 Decal - Caution........................................ 1

21 710-3073 Screw-hex hd., 5/16-18x2-1/4*,

not avail, separately (order #1918781 hardware kit) .. 4

22 736-0119 Lockwasher-5/16*, notavail.

separately (order #1918781

hardware kit) ...................................... 4

23 712-0267 Nut-hex, 5/16-18*, notavail.

separately (order #1918781

hardware kit) ...................................... 4

— 1918781 Hardware Kit: Incl. four each of

Refs. 21,22 and 23

.....................

............................

Note: Common hardware listed above as “not available separately” can be found at most hardware stores.

Specify GRADE 5 if ordering part locally.

HOOD, BRACKET and DEPTH REGULATOR

Models 664D & E666M

REF. No.

2 3

4 5 712-0291 6

7 GW-9384 Spring............................................... ... 1 5/16-18x1/2*

8 9 1185469

Specify GRADE 5 if ordering part locally.

PART

No.

1917605 Tine Hood (Incl. hood flap and

710-0169 GW-2527

1186328

710-0597 Hex Hd. Screw, 1/4-20x 1*

GW-9534 Spacer................................................. 1

GW-1117A Depth Adjustment Bar Assembly

DESCRIPTION QTY.

Ref.17)

.........................................

Lockwasher, 3/8............................... ... 2

Bracket-hood & depth regulator

(Incl. Ref. No. 9)

Hex Flange Screw, 5/16-18 x 5/8*... ... 2

Hex Locknut, 1/4-20............................ 1 17

Roll Pin (spiral), 1/4x1 ........................ 1 1/4-20x1/2*...................................... 2

(Incl. Refs. 11 and 12)..................

..........................

..............

... 1 12

... 1

REF. No.

13 710-3005 14

15 712-0798 Hex Nut, 3/8-16...................................

16 GW-20775 Drag Bar .............................................

18 GW-9553

19 710-0599

PART

No.

GW-9120

GW-9119 Knob, Depth Regulator (Incl. Ref. 11).

GW-1113-1

777S30649 Decal, operating instructions

DESCRIPTION QTY.

Retaining Ring (tolerance ring)

Hex Hd. Screw, 3/8-16x1-1/4*

Bushing, Drag Bar............................... 2

Hex Hd. Screw, self-tapping.

Hex Flange Screw, self-tapping.

...........

............

..............

....................................

1 1

2 1 1

Models 664D & E666M

HILLER/FURROWER AHACHMENT

REF. No.

2 3 1177548 4 GW-9902 Plain Washer, 5/16 S.A.E 5 6 1900773001 7 8 1900772001

PART

No.

1900771001 1186098

GW-9824 Wing Nut, 5/16-18

1900774001

DESCRIPTION QTY.

Furrower Blade................................. 1

Carriage Bolt, 5/16-18 x 3/4

Star Washer, External Tooth, 5/16.... 4 11

Hiller Wing, left

Hiller Wing, right............................... 1

Blade Mounting Bracket

.................................

............................

.............

................

...................

REF. No.

9 GW-9725 Carriage Bolt, 3/8-16 x 1-1/2

10 1100243 Lockwasher, 3/8, plated

4 12 4 1

PART

No.

1186231 Hex Nut, 3/8-16, plated GW-9318

DESCRIPTION QTY.

Clinch Pin

........

...............

................

.....................................

.... 2

.... 1

Model E666M

ELECTRIC START ASSEMBLY

REF. No.

1 2 1186211 Hex Nut, 5/16-24 3 1186390 Flange Screw, 1/4-20 x .625 4 5

6 7

PART

No.

1186073 Carriage Screw, 1/4-20 x 1.25

1186389 1901202

1901894 1908118 Wire Harness Assy, (available as 15 736-0119 Lock Washer 5/16

DESCRIPTION QTY.

..........

...............................

.............

Hex Locknut, 1/4-20 Cable (ground wire to starter

motor bracket)

Recharge Wire Assembly..................

complete assembly only). Incl. 16 wire assy, w/connector to large solenoid stud (red wire); wire 18 assy, w/connector to small 19 96510 Cable (solenoid to starter motor).. solenoid stud (red wire); wire 20 assy, w/connector to solenoid for cables and wires) grounding screw (red wire); wire assy w/connector to engine ground shut-off (green wire); plastic 777S30648 protector tube; wire terminal

..........................

...............................

..........

REF. No.

2 2 2

10 710-0599

2 11

12 725-0157

1 14

17 736-0607

PART

No.

1917262

686-04024 Battery Bracket Assembly, Pony........ 1

712-3006 Hex Nut, 1/4-20

725-0267 Ignition Switch 725-1706

736-0147

GW-2614 Keyswitch Clamp........................... .... 1

96514

97020 9853

Ground Wire Assy, (shut off)

Self-tapping Screw, 1/4-20 x .5

Cable Tie

Battery, 270 CCA

Lock Washer, #10 External Lock Washer, 5/16

Solenoid (Incl. nuts and washers

Boot, Insulating............................... ... 2

Hex Locknut, #10-32 Label, Ignition Switch

DESCRIPTION QTY.

.... 1

.........

.....

.... 3

..........

.... 2

.... 1

.... 2

.... 1

.... 2

.... 1

.............................

.......................................

...............................

..........................

.........................

.................

.....................

....................

TROY-BILT TILLER LIFETIME LIMITED WARRANTY

WHAT PRODUCT IS COVERED

WHAT IS COVERED BY THIS WARRANTY

WHAT IS NOT This warranty does not apply to parts that have been damaged by accident, alteration, COVERED BY THIS misuse, abuse, neglect, improper maintenance, vandalism, theft, fire, water, or damage WARRANTY because of peril or other natural disaster.

All Troy-Bilt branded rear tine walk-behind tillers with gear drive transmissions. This warranty begins on the date of purchase and is warranted by Troy-Bilt EEC for the life of the tiller, to the original purchaser only.

Troy-Bilt EEC will, at its option, repair or replace any part found to be defective in material or workmanship without charge for parts and labor.

This limited lifetime warranty also applies to non-powered attachments and accessories. Powered attachments and accessories are warranted separately by their manufacturers. Refer to the applicable manufacturer’s warranty on these items for terms and conditions.

The following items are not covered after the first year of this residential use limited warranty: belts, batteries, bushings, seals, tines, tires, wheels, paint, appearance items, and similar items that are nor mally replaced through periodic maintenance.

Charges for pick-up, delivery, and service calls are not covered by this warranty.

Service completed by someone other than an authorized service dealer is not covered by this warranty.

Parts that are not genuine Troy-Bilt EEC service parts are not covered by this warranty.

The engine is warranted separately by the engine manufacturer. Refer to the engine manufacturer’s warranty for terms and conditions.

EIMITED COMMERCIAE USE WARRANTY

HOW TO OBTAIN SERVICE

The provisions set forth in this warranty provide the sole and exclusive remedy arising from the sale. Troy-Bilt LLC shall

not be liable for any incidental or consequential damage or expense of any kind, including but not limited to cost of equipment rental, loss of profits, or costs of hiring services to perform tasks normally performed by the equipment.

Any implied warranties, including any implied warranty of merchantability or fitness for a particular purpose, shall be limited in

duration to the period of ownership by the original purchaser (and a maximum of 90 days from the date of sale if the tiller is

Some states do not allow the exclusion or limitation of incidental or consequential damages, or limitations on how long an

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

If used for commercial, institutional, industrial, rental, or demonstrator purposes, the warranty on the tiller is limited in duration to 90 days from the date of purchase.

This warranty does not apply to parts that have been damaged by accident, alteration, misuse, abuse, neglect, improper maintenance, vandalism, theft, fire, water, or damage because of peril or other natural disaster.

Warranty service is available, with proof of purchase, through your local authorized service dealer. To locate a dealer in your area, consult your Yellow Pages, or contact Troy-Bilt EEC at P.O. Box 361131, Cleveland, Ohio 44136-0019,1-866-840-6483, or log on to our Web site at www.troybilt.com.

purchased for commercial or other non-residential use).

implied warranty lasts, so the above exclusions or limitations may not apply to you.

For customer assistance, contact your nearest authorized dealer, or contact us at:

Troy-Bilt 664DM User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Operator’s Manua

TOBLE OF COMTEMTS

FIMPmC MODEL HUMBER

EMBIME mFORMfiTIOM

CALLIMB CUSTOMER SUPPORT

For more details about your unit, visit our website at www.troybilt.com

Safety Alert Symbol

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

Operating Symbols

2 Assembly

A WARNING

STEP 1: UNPACKING iNSTRUCTiONS

STEP 2: AHACH HANDLEBARS

STEP 3: AHACH REVERSE CLUTCH CONTROL CABLE

STEP 4: AHACH FORWARD CLUTCH CONTROL CABLE

A CAUTION

IMPORTANT:

A WARNING

WHEEL GEAR LEVER

A DANGER

FORWARD CLUTCH CONTROL

To Operate the Forward Clutch Control:

A WARNING

REVERSE CLUTCH CONTROL

A WARNING

To Operate the Reverse Ciutch Controi:

HANDLEBAR HEIGHT ADJUSTMENT

To Adjust the Handlebar Height:

A WARNING

ENGINE THROHLE CONTROL LEVER

DEPTH REGULATOR

A WARNING

41 Operation

STARTING AND STOPPING THE ENGINE

A CAUTION

A DANGER

STARTING THE ENGINE

To Start the Electric Start Engine With the Recoil Starter Rope

STOPPING THE ENGINE

A WARNING

A WARNING

A WARNING

Tilling Tips & Techniques

Let the tiller do the work

Tilling depths

Avoid tilling soggy, wet soil

Avoid making footprints

Choosing correct wheel and tine speeds

Suggested tilling patterns

Tilling Tips & Techniques

Clearing the tines

A WARNING

Tilling on slopes

C. Tilling across slopes without using terraces:

A WARNING

A WARNING

5 Maintenance

A WARNING

TILLER LUBRICATION

CHECK HARDWARE

CHECK TIRE PRESSURE

CHECK FOR OIL LEAKS

TRANSMISSION GEAR OIL SERVICE

A. To Check Transmission Gear Oil Level:

B. To Drain and Refill the Transmission:

A WARNING

ENGINE OIL SERVICE

A. To Check the Engine Oil Level:

B. To Change the Engine Oil:

AIR CLEANER SERVICE

SPARK PLUG SERVICE

SPARK ARRESTER SCREEN SERVICE

ENGINE CLEANING

CARBURETOR/GOVERNOR CONTROL AOJUSTMENTS

THROTTLE CONTROL AOJUSTMENT

WHEEL GEAR CABLE ADJUSTMENT OFF SEASON STORAGE