Troy-Bilt PONY 664DM, PONY E666M Operator's Manual

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Operator's Manual

Rear-tine Tiller Model

664DmPony_

E666MmPony _

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 attester meeting applicable local or state laws (if any).

If a spark attester 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)

TABLEOFCONTENTS

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

FINDINGMODELNUMBER

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

O]_II__IpD,m...]_. TROY-BILT LLC

P. O. BOX 361131

www.troybilt.com CLEVELAND, OH 44136

330-558-7220 866-840-6483

Copy Model Number Here

Copy Serial Number Here

ENGINEINFORMATION

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.

CALLINGCUSTOMERSUPPORT

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.

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.

SafetyAlert Symbol

_ his isasafetyalert symbol. It is usedin this

manualand on the unit to alertyou to potential hazards. Whenyou seethis symbol, readand obeythe messagethat follows it. Failureto obeysafety messagescould result in personal injury or property damage.

WARNING

The engine exhaust from this product contains

chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

TRAINING

1. Carefullyreadthis

Owner's Manual,the sepa-

rateEngineOwner's Manual,and anyother literatureyou may

receive.Bethoroughly familiar with the controls andthe proper useofthe tiller and itsengine. Knowhow to stop the unit and disengagethe controls quickly.

2. Neverallow children to operatethe tiller. Neverallow adultsto operatethe tiller without proper instruction.

3. Keepthe areaof operation clear ofall

persons,particularly children and pets.

4. Keepin mind thatthe operator or user

is responsiblefor accidents or hazards occurring to other people,their property

and themselves.

PREPARATION

1. Thoroughly inspectthe areawherethe tiller is to be usedand removeall foreign objects.

2. Besure all controls are releasedand the WheelGearLeveris in ENGAGE

beforestarting the engine.

3. Do not operatethetiller without wearing adequateouter garments. Avoid

loosegarments or jewelry that could get caught inmoving parts.

4. Donotoperatethetiller when barefoot or wearing sandals,sneakers,or light footwear.Wearprotectivefootwearthat will

improvefooting onslipperysurfaces.

5. Donottill nearundergroundelectric cables,telephonelines, pipesor hoses.If in doubt, contactyourtelephoneor utility

company.

6. Warning: Handlefuel with care; it is highlyflammableand itsvaporsareexplo- sive. Takethefollowing precautions:

a. Storefuel in containersspecifically

designedfor this purpose.

b. Thegascap shall neverbe removed

or fuel addedwhile the engine is running. Allow the engineto cool

for several minutes beforeadding fuel.

c. Keepmatches,cigarettes,cigars,

pipes, open flames, and sparks awayfrom the fuel tankand fuel

container.

d. Fillfuel tank outdoors with extreme

care. Neverfill fuel tank indoors. Usea funnel or spout to prevent

spillage.

Replaceall fuel tankand container

caps securely. If fuel is spilled, do not attemptto

start the engine, but move the machine awayfrom the area of spillageand avoid creating any source of ignition until fuel vapors havedissipated.

OPERATION

1. Donot put handsor feet nearor under rotating parts.

2. Exerciseextremecaution when on or crossing graveldrives, walks, or roads.

Stayalert for hidden hazardsor traffic. Do not carry passengers.

3. After striking aforeign object, stop the engine (andremovethe ignition key on electric start models), disconnect the spark plugwire and prevent it from touching the spark plug,carefully inspect the tiller for any damage,and repair the

damagebeforerestarting and operating

the tiller.

4. Exercisecaution to avoid slipping or falling.

5. Ifthe unitshould startto vibrateabnor- mally,stop the engine(andremovethe

ignition keyon electric start models). Dis-

connectthespark plugwire andpreventit from touchingthe spark plug,and check

immediatelyfor thecause.Vibration is

generallya warning of trouble.

6. Stopthe engine(and removethe igni-

tion key on electric start models), discon-

nectthe spark plug wire and prevent it

from touching thespark plugwhenever you leavethe operating position, before

7. Nevermakeadjustments when engine unclogging thetines, or when making any is running (unless recommendedby repairs, adjustments or inspections.

manufacturer).

7. Takeall possible precautionswhen leavingthe machineunattended.Stopthe

engine. Removeignition key on electric start models. Disconnect sparkplug wire and moveit awayfrom the spark plug.

MoveWheelGear Leverto ENGAGE.

8. Beforecleaning, repairing, or inspect- ing,stop the engine,remove the ignition keyon electric start models,and make

certain all moving parts havestopped.

Disconnectthe spark plug wire and preventit from touchingthe spark plug to preventaccidentalstarting. Onelectric

start models,always removethe cable from the negativeside (-) of the battery.

9. Always keepthe tiller tine hood flap

down, unlessusing the hiller/furrower attachment.

10. Never usethe tiller unless proper

guards, plates,or othersafetyprotective devicesarein place.

11. Do not run enginein an enclosed

area.Engineexhaustcontains carbon

monoxide gas,a deadly poisonthat is

odorless, colorless, and tasteless.

12. Keepchildren and pets away.

13. Never operatethe tiller under

engine powerif theWheel GearLeveris

in DISENGAGE(FREEWHEEL).In this

position,the wheelswill notholdthe tiller backand therevolvingtines could

propelthe tiller rapidly, possibly causinglossof control.Always movethe

WheelGearLeverto ENGAGEbefore starting the engine or engagingthe

tines/wheelswith the ForwardClutch Control orthe ReverseClutch Control.

14. Be aware that the tiller mayunex-

pectedlybounceupwardorjump forwardif the tinesshouldstrike

extremelyhard packedsoil, frozen ground,or buried obstacleslike large

stones,roots,or stumps.If in doubt aboutthe tilling conditions,always use

thefollowingoperatingprecautionsto assistyou in maintainingcontrolof the

tiller:

Walk behindandto oneside of the tiller, usingone handonthe han- dlebars. Relaxyour arm, butusea

securehand grip.

b. Use shallowerdepth regulatorset-

tings, working graduallydeeper

with eachpass. c. Useslowerenginespeeds. d. Clearthe tilling area ofall large

stones,rootsandotherdebris.

e. Avoidusingdownwardpressure

on handlebars.If needbe, use slightupwardpressureto keepthe

tines from diggingtoo deeply. f. Beforecontactinghardpackedsoil

at the endof a row, reduceengine

speedand lift handlebarsto raise

tines out of the soil.

g. In an emergency,stoptinesand

wheels by releasing whichever

ClutchLever is engaged. Donot attemptto restrainthetiller.

15. Do not overloadthetiller's capacity

by attempting to till too deeplyattoo fast a rate.

16. Neveroperate thetiller at high trans- port speeds on hardor slippery surfaces. Look behind and use carewhen backing

up.

17. Do not operatethe tiller on a slope

that istoo steepfor safety.When on

slopes,slow down and makesureyou havegood footing. Never permit the tiller

to freewheel down slopes.

18. Neverallow bystanders nearthe unit.

19. Onlyuseattachments and acces- sories that areapproved bythe tiller

manufacturer.

20. Usetiller attachments and acces- sories when recommended.

21. Neveroperatethetiller without good

visibility or light.

22. Neveroperatethetiller ifyouaretired, or undertheinfluenceof alcohol,drugs or

medication.

23. Operatorsshallnottamperwith the engine-governorsettingsonthe machine;

the governorcontrolsthemaximumsafe

operatingspeedto protecttheengineand all movingpartsfrom damagecausedby overspeed.Authorizedserviceshallbe soughtif a problemexists.

24. Donottouch enginepartswhich may be hotfrom operation.Letpartscool down sufficiently.

25. Thebatteryon electricstart modeltillers containssulfuricacid.Avoidcontactwith

skin,eyes,or clothing.Keepoutof the

reachof children.

Antidote-External Contact:Flushimme-

diatelywith lotsof water.

Antidote-Internal: Drinklargequantities

ofwateror milk.Followwith milk of magnesia,beateneggs or vegetableoil.

Calla doctor immediately.

Antidote-EyeContact:Flushwith water for 15 minutes.Getpromptmedical

attention.

26. Batteriesproduceexplosivegases.Keep

sparks,flame,andsmoking materialsaway. Ventilatewhencharging batteriesor when

usinga batteryinanenclosedspace. ALWAYSwearsafetygoggleswhen working nearbatteries.

27. Pleaseremember:Youcanalwaysstop thetines andwheelsby releasingthe

ForwardClutchControlLeverorthe

ReverseClutchControlknob(whichever control you haveengaged),or by moving the EngineThrottleControlLever(located

onengine)to STOPon recoilstart models

or by turning the ignitionkeyto OFFon electricstartmodels.

28. To loador unloadthetiller, seethe

instructionsinSection4 ofthis Manual.

29. Useextremecautionwhen reversingor

pullingthemachinetowardsyou.

30. Starttheenginecarefullyaccordingto

instructionsandwith feetwellawayfrom thetines.

31. Neverpick up or carrya machinewhile theengineis running.

MAINTENANCEANDSTORAGE

1. Keepthe tiller, attachments and acces-

sories insafe working condition.

2. Checkall nuts, bolts, andscrews at frequent intervalsfor proper tightness to

besure the equipment is in safeworking condition.

3. Neverstorethe tillerwith fuel inthefuel tank insidea buildingwhere ignition

sourcesare presentsuchas hotwaterand spaceheaters,furnaces,clothesdryers, stoves,electric motors,etc. Allow engineto cool beforestoring inanyenclosure.

4. To reducethe chancesof a fire hazard,keeptheenginefree of grass,

leaves,orexcessivegrease.

5. Storegasolinein acool, well-venti- latedarea, safelyawayfrom anyspark-

or flame-producingequipment. Store gasolinein an approved container, safelyawayfrom the reach of children.

6. Referto the Maintenancesectionof

this Manualand in the separateEngine Owner's Manualfor instructions if the

tiller isto bestored for an extended

period.

7. Neverperform maintenancewhile

the engineis running orthe spark plug wire is connected,exceptwhenspecifi- cally instructed to do so.

8. If thefuel tankhasto bedrained,do

this outdoors.

DECALS

Foryour safetyand the safety of others, replacementsif any decalsare damagedor

various safety messagedecalsare on your missing.

unit (seeFigurebelow). Keepthe decals Referto the Parts List pagesfor decal

cleanand legibleat all times. Contactyour locations and partnumbers.

localservicedealer or the factoryfor

ControlDescri

TineWarning (onright

side of hoodflap)

StartingStabilization (on

top of engine or fuel tank)

OperatingInstructionsand

WarningMessages

OperatingSymbols

Various symbols (shown here, with word descriptions)maybe usedonthe tillerandengine.

FAST SLOW

STOP

6 I-'-I

CHOKE

STOP START

I÷1

CHOKE ROTATING

OFF TINES

REVERSE

o--.>

LEVERDIRECTION

<--

TILLERDIRECTION

ENGAGED DISENGAGED

/MovingBelts

(ontopofbeltcover)

Figure 1:Locationof SafetyandOperatingDecals

TO AVOID SERIOUS INJURY:

• READTHEOWNER'S MANUAL.

• KNOWLOCATIONSAND FUNCTIONSOFALLCONTROLS.

• KEEPALLSAFETYDEVICESANDSHIELDSIN PLACEANDWORKING.

• NEVERALLOWCHILDRENORUNINSTRUCTEDADULTSTO OPERATETILLER.

• SHUTOFFENGINEANDDISCONNECTSPARKPLUGWIREBEFOREMANUALLYUNCLOG-

GINGTINESOR MAKINGREPAIRS.

• KEEPBYSTANDERSAWAYFROMMACHINE.

• KEEPAWAYFROMROTATINGPARTS.

• USEEXTREMECAUTIONWHEN REVERSINGORPULLINGTHEMACHINETOWARDSYOU.

2 Assembly

To prevent personal injury or property

damage,do notstartthe engine until all

assembly steps are complete and you

havereadand understandthe safetyand operatinginstructionsin this Manual.

INTRODUCTION

Carefullyfollow theseassembly stepsto correctly prepareyour tiller for use. It is

recommendedthat you readthis Section in its entirety before beginningassembly.

INSPECTUNIT

Inspectthe unit andcarton for damage

immediatelyafter delivery. Contactthe carrier (trucking company) ifyou find or suspect damage. Inform them ofthe damageand request instructions for filing a claim. To protectyour rights, put your claim inwriting and mail a copy to the carrier within 15 days after the unit has

beendelivered.Contact us at the factory if you needassistancein this matter.

UNPACKINGANDASSEMBLY INSTRUCTIONS

STEP 1: UNPACKING INSTRUCTIONS

1. Removeanycardboard inserts and

packagingmaterialfrom the carton.

Removeany staples from the bottom of the carton and removethe carton.

2. Cutthe large,plastictie strap that securesthe transmission tubeto the ship-

ping pallet. Leavethe handlebarson top of the tiller to avoid damaginganycables.

3. A bag with loose hardware is inside the literature envelope. Checkthe con- tents against thefollowing list and Figure 2-1. Contactyour local dealeror the factory if any items aremissing or damaged.

NOTE:Forelectric start units, a second

hardwarebag is located nearthe battery.

4. The tiller is heavy. You should not attempt to remove it from theshipping

platform until instructed to do so in these "Assembly" steps.

HARDWARE BAG PARTSLIST

Fig. Ref. Qty. Description

1 2 3/8-16 x 1" HexHd. Screw 2 1 KeyedWasher

3 1 WheelGearLeverKnob 4 1 Height Adjustment Flange

Screw (SeeFigure 2-1A)

5 2 3/8" FlatWasher 6 2 #10 Lockwasher

7 2 3/8"-16 Nylock Lock Nut 8 2 #10-32 x 1/2" Round Hd.

Screw

9 2 #10-32 Nut 10 1 Cotter Pin (not used)

11 4 PlasticTie Strap (2 not used)

Tools/Materials Needed

for Assembly

(1) 3/8" open-endwrench* (1) 7/16" open-endwrench* (electric

start unit only)

(2) 9/16" open-endwrench* (1) 7/8" open-endwrench or 8" long

adjustable wrench (1) Scissors(to trim plasticties) (1) Ruler

(1) Small board (to tap plastic knob on

lever)

(1) Tire pressuregauge (1) Cleanoilfunnel

(1) Clean,high-quality motor oil. Refer

to the separateEngineOwner's

Manualfor motor oil specifications and quantity required.

* Adjustablewrenches may be used.

IMPORTANT:Motor oil must beaddedto

the enginecrankcasebeforethe engine is

started. Followthe instructions in this "Assembly" Sectionand inthe separate

EngineOwner's Manual. NOTE:LEFTandRIGHTsides of thetiller

are as viewedfrom the operator's posi-

tion behindthe handlebars.

STEP 2: ATTACHHANDLEBARS

1. On electric start units, removeone screw and Iockwasherfrom the curved

5@_, 60 o

8_ @©9

7_ 10_

Figure2-1:Loosehardware(shownin reducedsize).

Figure2-1A Handlebarheightadjustment usestheflangeheadscrew.

Figure2-2: Onelectric start units, move heightadjustmentbracket aside.

heightadjustment bracket (A, Figure2-2), loosenthe secondscrew, andswing the

bracketto one side.

2. Cutthe large, plastic cableties that securethe handlebarendsto the handle-

bar mounting tabs on the transmission

top cover.

3. Gently lift handlebar (do not over- stretch attached cable) and placehandle- bar cross-brace (B, Figure2-3) in front of curved height adjustment bracket (C).

Figure2-3: Forwardclutchcontrolcable not shownforclarity.

4. With the forwardclutchcable (N, Figure2-4) onthe inside of handlebar,

position the handlebarendson the outside of thetwo mounting tabs (IVI, Figure2-3) on the transmission top

cover.

NOTE:Thecurved handlebarheight

adjustment bracketappears asshown in

C,Figure2-3 for non-electricstart units. Forelectricstart units, the bracket is loos-

ened and moved to one side.

5. Loosely attachthe handlebars to the mounting tabs with two 3/8-16 x 1"

screws (headsof screws go to insideof tabs), 3/8" flat washersand 3/8"-16 lock

nuts (0, Figure2-4).

Figure 2-4: Attachhandlebars.

6. Onelectric start units, reattach the heightadjustment bracket(A, Figure2-2).

Tighten both screws securely. Makesure the handlebarcross-brace (B, Figure2-3)

is under the bracket.

7. Move the handlebarsup or down to

align the threaded hole in the cross-brace with one of thefour slots in the curved

heightadjustment bracket. Placethe keyedwasher (E,Figure2-3) on the

flange head heightadjustment screw (F) with the raisedkeys(edges) of the

washer facing down.

8. Threadthe height adjustment screw (F, Figure2-3) into the hole in the handle- bar cross-brace, makingsure that the raisedkeyson the washer fit into theslot on the height adjustment bracket.

Tighten the heightadjustment screw securely. Next,securely tighten the two

screws andnuts in the endsof the han-

dlebar (M, Figure2-3).

9. To removethe tiller from its shipping platform, first carefully unwrap the wheel

gear cable (with attachedlever - see

Figure2-5) from around the chassis. Movethe Wheel GearLever (G)to the DISENGAGEposition--this allows the

wheels to rotatefreely. Usethe handle-

STEP 4: ATTACHFORWARD CLUTCH CONTROL CABLE

1. Removeanyfasteners (rubber bands,

tape, etc.) that maysecurethe Forward

Clutch Control levers (J, Figure2-7) to the handlebar.

Figure2-5: CarefullyunwrapWheelGear LeverandmovelevertoDISENGAGE.

barsto roll thetiller off the platform. NOTE:TheWheelGearLever will be

installed later inthis procedure. IMPORTANT: Usethe DISENGAGEposi-

tion only when the engine is not running.

Beforestarting the engine,the Wheel Gear Levermust be placed inthe ENGAGE position (seeSection 3 for details).

STEP3: ATTACH REVERSE CLUTCH CONTROL CABLE

1. Carefullyunwrapthe reverseclutch control cable(H, Figure2-6) from its shipping position and route it up along the insideedge ofthe left side handlebar. A knoband large hexnut (I) is installed

on the cable.

LeftSide ReverseClutch]

Handlebar ControlKnob

Figure2-7: ForwardClutchControllevers (J). Forwardclutchcontrollinkage(K).

2. Theforward clutch control cable(with attachedspring) is hanging loosely near

the right-side wheel. Being careful not to

kink orstretch the cable, insert thez-con- nector (L, Figure2-8 - end of the spring)

into the hole at the end of the forward clutch control linkage(K, Figure2-7).

Figure2-6: Attachreverse clutch control assemblyto slottedhole in handlebarpanel.

2. Insertthe cable into the slot in the control paneland fit the threadedassem-

bly into the holein theslot (see Figure2-

6). Besure that theflat side of the threadedassembly is aligned with the flat side of the hole. Slide the hex nut (I) up the cableand tighten it securely.

3. Testthefunction of the reverseclutch control cableby pulling the knob out and

releasingit. Theknob should return to its neutral position against the tapered bushing. If it doesn't, contact your local dealeror the factory for technical

assistance.

Figure2-8

3. Attachthe cableadjuster (A, Figure 2-9) to the bracket onthe right-side han-

dlebar. Usetwo 1/2"wrenchesto loosen

the two jam nuts (B) just enoughto slide the cableadjuster onto the bracket. Then

hand tighten the jam nuts.

Figure2-9

Incorrectcable adjustment could cause the wheels andtines to rotate unexpect- edly. Follow adjustment procedures carefully. Failure to do so could result

in personalinjury orpropertydamage.

4. Checkfor correct spring/cable tension

as instructed in Section5, Checkingand Adjusting ForwardClutch Belt Tension.

5. Whentension is correct, tighten the two jam nuts (B) securely.

STEP5: CHECKTRANSMISSION

GEAROIL LEVEL

Thetransmission was filled with gear oil at the factory. However,be sureto check

the oil levelat this time to makecertain it

iscorrect.

IMPORTANT:Do not operatethe tiller if the gear oil level is low. Doingso will

result inseveredamageto the transmis- sion components.

1. With the tiller on levelground, pull the

Depth Regulator Lever(R, Figure2-13)

backand then slide it to the second notch from the top. NOTE:If the lever does not

move,lift the tine hoodflap and look for a

plastictie securing the lever in place. Cut and removethe tie.

2. Removethe oil levelcheck plug (M,

Figure2-10) on the left-side of the trans-

mission. (Dueto dried painton the plug threads, it may require some force to

removethe plug the first time.) The gear

oil levelis correct if oil starts to flow out

ofthe hole asthe plug is removed. If so, securely reinstall the plug.

Figure2-10: Gearoil level checkplug.

3. If oil does notflow from the check

hole,add oil as follows:

NOTE:Donot use automatic transmission fluid or motor oil inthe transmission.

(a) Cleanareaaround the fill hole (N,

Figure2-11) and unscrewgear oil fill

plug.

Figure2-11: Addinggearoil.

(b) If adding only a few ouncesof gear oil, useAPI ratedGL-4 or GL-5 gear oil havinga viscosity of SAE140, SAE85W- 140 or SAE80W-90. If refilling anempty

transmission, useonly GL-4 gear oil

havinga viscosity of SAE85W-140 or SAE140.

check hole (N, Figure2-11).

(d) Reinstalland tighten securelythe gear oil fill plug (M, Figure2-10).

STEP 6: ATTACHWHEEL GEAR LEVER

1. Insert the Wheel GearLever(P, Figure

2-12) up through theslot in the control

panelthat is labeled"WHEELGEAR."

2. Insert two #10-32 x 1/2" round head screws down through the "+" marks on

the control paneldecal and securely attach thewheel gear mounting bracket

usingtwo #10 Iockwashersand #10-32 nuts.

3. Usea small board to tap the Wheel GearLeverknobsecurely onto the lever.

4. Securethe wheelgear cableand the reverseclutch control cableto the left-

side handlebarwith two plastic ties (S,

Figure2-13) locatedabout two feet apart. Snip off anyexcesstie lengthwith

scissors.

STEP7 ATTACHINGTHE BATTERY CABLES(MODEL E666M)

The positive battery terminal is marked

Pos. (+). The negativebattery terminal is marked Neg.(-).

1. Removethe hex bolt and hex nut from the positive cable (heavy red wire).

2. Removethe plastic cover from the positive batteryterminal and attachthe positive cableto the positive batteryter- minal (+) with the bolt and hex nut. Make

certain that the rubber boot coversthe

Figure2-12: AttachWheel GearLever.

Figure2-13: Attach wheel gear cable and reverseclutchcable with cable ties (S).

positive terminal to help protect it from corrosion.

3. Removethe hexbolt and hex nut from the negativecable (heavyblackwire).

4. Removethe black plastic cover from the negativebattery terminal andattach the negativecableto the negativebattery terminal (-) with the bolt and hex nut.

IMPORTANT:

• If the battery is put into serviceafter the

dateshown ontop of battery, chargethe batteryas instructed in the Maintenence sectionof this manualprior to operating

the tiller.

STEP 8: CHECKAIR PRESSURE IN TIRES

Usea tire pressuregaugeto check the air pressure in bothtires. Deflateor inflate both tires equallyto between15 PSI and 20 PSI). Besure that both tires are inflated equally orthe unit will pull to one

side.

STEP 9: CHECK HARDWARE FOR TIGHTNESS

Inspect the hardwareon the unit and tighten anyloose screws, bolts and nuts.

3 Featuresand Controls

Before operating your machine, care- fully read and understand all safety,

controls and operating instructions in this Manual, the separate Engine Owner's Manual, and on the decals on

the machine.

Failure to follow these instructionscan

resultin seriouspersonalinjury.

INTRODUCTION

This Sectiondescribesthe location and function of the controls on your tiller.

Referto thefollowing section "Operation"

for detailedoperating instructions.

Practiceusingthese controls, with the engine shut off, until you understandthe operation of the controls and feel confi-

dent with them.

IMPORTANT:Referto the separateengine

manufacturer'sEngineOwner's Manual for information about the controls on the

engine.

WHEEL GEAR LEVER

This lever(A, Figure3-1) has two posi- tions: ENGAGEand DISENGAGE.

Inthe ENGAGEposition, the wheels will start turning when eitherthe Forward

Clutch Control or the ReverseClutch Control is engaged(the tines will also

start turning when eitherclutch is engaged).

Figure3-1: Controlslocatedon handlebar.

The DISENGAGEposition placesthe wheels inthefreewheeling modeto allow the unitto be moved without the engine

running. Usethe DISENGAGEposition only whenthe engineis not running. See

"DANGER"statementthat follows.

To shift to ENGAGE,gently (do not force)

movethe leverforward while also rolling

the tiller afew inchesforward or back- ward. Moving the tiller helpsto align the

shift mechanismwith the transmission wheel drive gears.

To shift to DISENGAGE(freewheel),

movethe lever rearward, without rolling the tiller. Thewheels will roll freely when the lever is properly set in the

DISENGAGEposition.

FORWARD CLUTCH CONTROL

The two interconnected levers (B, Figure

3-1) control the engagementof forward drive to the wheelsand tines.

To Operatethe ForwardClutchControl:

1. Beforeengagingthe ForwardClutch

Control, put the WheelGearLeverin the ENGAGEposition (see"WARNING" below).

2. Pull up and hold one or both of the levers againstthe handlebar grips to engagethe wheels and tines.

3. ReleaseBOTHleversto disengage (stop) the wheels andtines. All forward motion will stop (the enginewill continue

to run).

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 thetiller rapidlyforwardor backward.

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

damage.

Never engagethe wheels andtines with

the Forward Clutch Control or the

Reverse Clutch Control unless the Wheel GearLeveris in ENGAGE.

Engagingthe ForwardClutch Controlor

the Reverse Clutch Control when the wheels are not engagedcouldallow the

tines to rapidlypropelthe tiller forward

or backward. Failure to follow this warning could

result in personal injury or property damage.

REVERSE CLUTCH CONTROL

The ReverseClutchControl (C, Figure

3-1) controls the engagementof reverse driveto thewheels and tines. The revers-

ingfeature is usedfor maneuveringthe

tiller only- neverengagethe tines in the groundwhile goingin the reverse

direction.

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

Lookbehindto avoid obstacles.

• Neverattemptto till in reverse.

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

To Operatethe ReverseClutchControl:

1. Putthe WheelGearLeverin the

ENGAGEposition (seethe "WARNING" statementon previouspage).

2. Stopall tiller motion by releasingthe

ForwardClutch Control levers.

3. Lift upthe handlebarsuntil thetines

clearthe ground, look behindyou to avoid anyobstacles,and then pull the Reverse

ClutchControl knob out. Thetines and wheelswill rotate in a reverse direction.

4. Releasethe ReverseClutch Control

knobto disengage(stop) the wheels and

tines. All reversemotion will stop (the

enginewill continue to run).

• Do not attempt to till too deeply too quickly. Gradually work down to deepertilling depths.

• Placethe DepthRegulatorLever inthe "travel" position before starting the engine. This position prevents the tines from touching the ground until youare readytobegintilling.

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

DEPTH REGULATOR

The Depth Regulator lever(D, Figure3-2)

controls the tilling depth of the tines. Pull

the leverstraight backand slide it upor

downto engagethe notched height set-

tings.

Figure3-2: DepthRegulatorLever.

The highest notch (leverall the way down) raisesthe tines approximately

1-1/2 inches off the ground. This "travel" position allowsthetiller to be moved

without the tines digging into the ground.

Moving the lever up increasesthe tilling depth. Thelowest notch allows a tilling depth of approximately six to eight

inches,depending on soil conditions.

Forbest results,always begintilling at a very shallowdepthsettingand gradu- ally increasethe tilling depth. Complete

details onusing the Depth Regulatorare found in the "Operation" Section of this

manual.

HANDLEBAR HEIGHT ADJUSTMENT The handlebarheight is adjustableto four

different settings. Setthe handlebar

heightto a comfortable setting, but keep

in mindthat the handlebarswill be lower when thetines are engagedin the soil.

ToAdjusttheHandlebarHeight:

Figure3-3: Handlebarheightadjustment.

1. Stopthe engine, wait for all partsto stop moving and then disconnectthe spark plugwire. Removethe ignition key

on electric start models.

2. Loosenthetwo screws atthe lower ends of the handlebar.

3. Loosenthe height adjustment screw

(E,Figure3-3) and pull the keyedwasher

(F)free ofthe slots in the curved height adjustment bracket.

4. Movethe handlebarsto the newslot

setting and insert the raisedkeyson the keyedwasher into the slot. Tighten the height adjustment screw securely.

5. Retightenthe two screws at the ends of the handlebar.

ENGINECONTROLS

Referto the engine manufacturer'sEngine Owner's Manual(included in thetiller lit- erature package)to identify the controls on your engine. The following two con- trols areusedwhen stopping or starting the engine.

IMPORTANT:The control for stopping the recoil start engineis locatedon the engine.

ENGINE THROTTLE CONTROLLEVER TheEngineThrottleControlLever(located

on engine--see Figure 4-1) is usedto reg- ulatethe engine speed. Onthe recoil start model only, it is also usedto stop the engine (on the electric start model,the electric start keyswitch is usedto stop the engine). The throttle settings are shown

below. IMPORTANT:See"Starting and Stopping

the Engine" inthe "Operation" Sectionfor detailedenginestarting andstopping

instructions.

FAST- Usefor most tilling and

cultivating projects.

-l_ SLOW- Usewhen idling engineor when slower tilling and cultivating

speeds are needed.

_) TOP- Stops the engine (on

recoil start models only).

ELECTRIC START KEYSWITCH (MODEL E666M)

Theignition keyswitch on the electric start model is used to start and stop the engine. The keyswitch settings are

described below. IMPORTANT:See"Starting and Stopping

the Engine" inthe "Operation" Sectionfor detailedinstructions.

OFF- Stops engine. RUN- After starting, keyreturns to run

position. START- Startsengine. Releasekeywhen

engine starts (avoidcranking engine for longer than 15 secondsfor eachattempt)

Operation

ReverseClutch

ForwardClutch

ControlLever

Wheel GearLever

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.

Failureto follow these instructionscan

resultin seriouspersonalinjury.

INTRODUCTION

Readthis Section ofthe manual thor-

oughly beforeyou start the engine. Then, takethe time to familiarize yourself with the basic operation of thetiller before

using it in the garden. Findan open,levelareaand practice

usingthe tiller controls without the tines engagingthe soil (put tines in "travel" setting). Only after you've becomecom-

pletelyfamiliar with the tiller should you

begin using it in the garden.

BREAK-IN OPERATION

Perform the following maintenanceafter thefirst two hours of newoperation (see

"Maintenance" in this manualand the

EngineOwner's Manual).

1. Changeengineoil.

2. Checkfor looseor missing hardware on unit. Tighten or replace as needed.

3. Checktransmission gear oil level.

4. Checktension on forward clutch belt.

HandlebarHeight

AdjustmentScrew

,ill!iih,

ForwardClutch ControlLever

DepthRegulatorLever

EngineThrottle ControlLever

Figure4-1: Locationof main tiller controls.

STARTINGANDSTOPPING

THE ENGINE

To help preventserious personal injury

or damageto equipment:

*Before starting engine, put Wheel

GearLever in ENGAGEposition.

* Before starting engine, put Forward

Clutch Control levers and Reverse ClutchControl in neutral (disengaged)

positionsbyreleasingcontrols.

*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 exceed150OF.

PRE-START CHECKLIST:

Makethe following checksand perform

the following services beforestarting the

engine.

1. ReadSections1 and 3 in this Manual. Readthe separateEngineOwner's

Manual.

2. Checkunit for looseor missing hard- ware. Serviceas required.

3. Checkengine oil level. SeeEngine Owner's Manual.

4. Checkthat all safety guards and coversare in place.

5. Checkair cleanerand enginecooling system. SeeEngineOwner's Manual.

8. Attachspark plugwire to spark plug.

GASOLINEIS HIGHLYFLAMMABLEAND ITSVAPORSAREEXPLOSIVE.

Follow gasoline safety rules in this manual(see Section1) andin the sepa- rateEngineOwner'sManual.

Failureto follow gasolinesafety instruc-

tions can result in serious personal

injuryand propertydamage.

7. Fillthe fueltank with gasolineaccord-

ing to the directions in the separate EngineOwner's Manual. Follow all instructions and safety rules carefully.

STARTINGTHE ENGINE

Thefollowing steps describe howto start and stop the engine, go notattempt to

engagethe tines orwheels untilyou haveread all ofthe operatinginstruc-

tionsin this Section. Alsoreview the safetyrules in Section1: "Safety"

and the tiller and enginecontrols

informationin Section3: "Features and Controls."

1. Completethe "Pre-Start Checklist" on

the previous page.

2. Put the WheelGearLever(Figure4-1) in the ENGAGEposition.

3. Putthe DepthRegulator Lever inthe "travel" position (leverall the way down)

so that the tines are clearof the ground.

4. Releaseall controls on the tiller.

5. Putthe EngineThrottle Control Lever (Figure4-1) inthe "FAST"setting.

6. On enginesequippedwith afuel valve,

turn valveto open position as instructed

in the separateengine manual.

7. Chokeor prime engineas instructed in

the separateEngineOwner's Manual.

8. Forrecoil (non-electric) starting models:

(a) Placeone hand onfuel tankto stabi-

lizeunit whenyou pull the starter handle.

(b) Usethe recoil starter ropeto start

the engineas instructed inthe sepa- rate EngineOwner's Manual. When the enginestarts, graduallymove

the choke lever(on enginesso equipped) to the "NO CHOKE",

"CHOKEOFF"or "RUN" position.

Leverinthe "FAST"setting.

9. Forelectric starting models (E666M):

(a) Turn the engine ignition keyto the

"START"setting andallow the starter motor to crank the enginefor several seconds. Avoid cranking the engine longer than 15seconds at a time as doing so could damage the

starter motor. NOTE: Referto the

EngineOwner's Manualfor detailed starting instructions.

(b) When the engine starts, releasethe

keyand it will returnto the "RUN"

setting.

enginesso equipped)to "NO CHOKE","CHOKEOFF"or "RUN" position.

(d) Leavethe EngineThrottle Control

Leverinthe "FAST"setting.

To Start the ElectricStart EngineWith the Recoil StarterRope

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

following the steps below:

1. If the battery is not "dead" or damaged,leaveit connectedto the tiller so it will be rechargedduring engine operation. Makesure the battery cells are

filled to the UPPERLEVELline with elec- trolyte.

2. If the battery is "dead" or damaged, remove it (referto "Battery Removal and

Installation" in Section 5) and have it

tested. Beforestarting engine, coverthe terminal on the looseend of the positive

(+) cable with the insulatedboot and secure it in placewith electricaltape to

prevent electrical sparks.

3. Put the ignition key in the "RUN" position andthenfollow Steps 1-8 of "Starting the Engine."

STOPPING THE ENGINE

1. Tostop the wheels andtines, release

the ForwardClutch Control levers or the

ReverseClutch Controlknob (whichever control is engaged).

2. Tostop the engine on the recoil start model, move the EngineThrottle Control Leverto the "STOP" position.

3. Tostop theengine on an electricstart model, move the ignition keyto "OFF".

IMPORTANT:Afterstopping anelectric start engine, removethe ignition keyfrom

the switch to reduce the possibility of

unauthorizedstarting of the engine.

OPERATINGTHETILLER

Thefollowing pagesprovideguidelines to

usingyour tiller effectively and safely in various gardening applications. Besure to read"Tilling Tips &Techniques" in this Section before you actually put the tines

intothe soil. This isa traditional "standard rotating

tine" tiller with forward rotating tines. It operatescompletely differently from CRT

(CounterRotating Tines)tillers or from

low-cost front tine tillers.

1. Followthe "Pre-Start Checklist" on the

previous page. Besure thatthe Wheel GearLeveris in the ENGAGEposition.

2. Putthe Depth Regulator Leverin the "travel" position (lever all the way down) so that the tines areclear of the ground.

Usethis position when practicingwith your tiller or when movingto orfrom the garden. When you are readyto begin tilling, you must movethe Depth Regula- tor Leverto the desireddepth setting (see "Tilling Tips & Techniques").

3. Start theengine and allow it to warm

up. When warm, put EngineThrottle Control Leverin "FAST"speedsetting.

Keepawayfrom rotatingtines. Rotating

tines will causeinjury.

4. For forward motion of the wheelsand tines:

(a) Pull one or both of the Forward

Clutch Control Levers upand hold them against the handlebars.To stop forward motion of the wheels

and tines, releasethe levers.

Figure4-2: Useone handtoguide tiller

whenmovingforward.

(b) Asthe tiller movesforward, relax

and let the wheels pull the unit along while the tines dig. Walk behind and

a little to oneside of the tiller. Usea light but secure grip with one hand

on the handlebars,but keepyour arm loose. SeeFigure4-2. Letthe tiller move aheadat its own pace and do not push down on the han- dlebarsto try andforce the tiller to dig deeper- this takesweight off the wheels, reducestraction, and causes the tines to try and propel the tiller.

Do not push down on the handlebars to try to make the tiller till more deeply. This preventsthe wheels from holding the tiller back and can allow the tines to rapidly propel the tiller forward,whichcould resultin loss of control,propertydamage, or personal

injury.

5. Forreverse motion of the wheelsand tines:

(a) Look behind andexercisecaution

when operating in reverse. Do not

till while in reverse.

(b) Stop all forward motion before

reversing. Lift the handlebarswith one hand until the tines areoff the

ground andthen pull the Reverse Clutch Control knob out to engage reverse motion (seeFigure 4-3). To stop reversemotion, let go ofthe

ReverseClutch Control knob.

Figure4-3: Raise tinesoffgroundand look behindwhen movingin reverse.

6. To Turn the Tiller Around: (a) Practiceturning the tiller in a level,

open area. Bevery careful to keep your feet and legsawayfrom the

tines.

(b) To makea turn, reducethe engine

speedandthen lift the handlebars until the engine and tines are bal- ancedoverthe wheels (Figure4-4).

ways on the handlebarto move the tiller in the direction ofthe turn

(Figure4-5). After completing the turn, slowly lower the tines into the soil and increasethe enginespeed.

StoppingtheTiller and Engine

1. To stop the wheelsandtines, release

the Forward ClutchControl levers or the

ReverseClutch Control knob whichever isengaged).

2. To stop the recoil start engine, move the EngineThrottle Control Leverto "STOP". Onelectric start models,turn the

ignition keyswitchto "OFF"to stop the

engine.

Beforetilling, contactyour telephoneor 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 oftheir equipmentor

lines are buried underground on your

property.

Turningthe Tiller Around

Figure4-4: Tobegin turn,reduce engine speedand lift handlebars until engine

and tines are balancedover wheels.

Figure4-5: Withtiller balanced over

wheels(and tines outof the ground),

pushhandlebarssidewaysto turn tiller.

TillingTips& Techniques

Letthetiller dothe work

• While tilling, relaxand let the wheels pull the tiller along while thetines do

the digging. Walk on the sidethat is

notyet finished (to avoid making foot- prints inthe freshly tilled soil) and

lightly, butsecurely gripthe handlebar

with just one hand.

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

deeper. Doing so takesthe weight off the poweredwheels,causing them to

losetraction. Without the wheels helpingto 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 pressureon the handlebarswill

helpget through a particularly tough

section of sod or unbrokenground, but

in mostcases this won't be necessary

at all.)

Tilling depths

• Avoid trying to dig too deeplytoo

quickly, especiallywhen busting sod or when tilling soil that hasn't beentilled for some time. Useshallow depth reg-

ulator settings (only an inch or two

deep) for the first passesthrough the garden area. With eachsucceeding

pass,adjust the depth regulatorto dig

another inch or two deeper. (Watering the garden areaa few days prior to tilling will maketilling easier,as will

letting the newlyworked soil set for a

day or two beforemaking a final, deep tilling pass.)

• When cultivating (breaking up the

surfacesoil around plantsto help destroyweeds),usevery shallow depth settingsto preventinjury to plantswhose

rootsoftengrow closetothesurface. If needed,lift uponthe handlebarsslightly

to preventthetinesfrom diggingtoo deeply. (Cultivatingona regularbasis

notonlyeliminatesweeds,it also loosens

andaeratesthesoil for bettermoisture absorptionandfaster plantgrowth.)

Avoidtillingsoggy,wetsoil

Tilling wet soil often results in large,

hardclumps of soil that can interfere with planting. Iftime permits, wait aday or two after heavyrainsto 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 untilledside of the unit to avoid makingfootprints in thefreshly tilled soil. Footprintscause soil compaction that canhamperroot

penetrationandcontribute to soil erosion. They can also"plant" unwanted weedseedsback intothe freshly tilled ground.

Choosing correctwheel

and tine speeds

With experience,you will find the "just

right" tilling depth andtilling speed com-

binationthat is best for your garden. Setthe EngineThrottle Control Lever to

a speed to give the engineadequate

powerand yet allow it to operate at the slowest possiblespeed...atleast until you haveachievedthe maximum tilling depth you desire. Fasterengine speeds

may bedesirablewhen making final

passesthrough the seedbedor when cultivating. Selectionof the correct engine speed, in relationto the tilling depth, will ensurea sufficient power

levelto do the job without causingthe engine to labor.

Suggestedtilling patterns

• When preparinga seedbed,go overthe

same path twice in thefirst row, then overlapone-half thetiller width on the rest ofthe passes(see Figure4-6). Whenfinished in onedirection, make a second pass ata right angle asshown in Figure4-7. Overlapeach passfor best results (in very hardground it may takethree or four passesto thoroughly pulverizethe soil).

• Ifthe gardensizewill not permit lengthwiseand then crosswisetilling,

then overlapthe first passesby one-

halfa tiller width, followed by succes-

sive passesat one-quarter width (see

Figure4-8).

• With planning,you canallow enough room between rows to cultivate (see Figure4-9). Leaveroom for the hood

width, plus enough extra room for future plantgrowth.

Figure4-6

r y V

Figure4-7

Figure4-8

Figure4-9

TillingTips& Techniques

Clearingthetines

Thetines havea self-clearing action which eliminates most tangling of debris

in the tines. However,occasionally dry

grass, stringy stalks or tough vines may

becometangled. Followthese proce- duresto help avoidtangling and to clean

the tines, if necessary.

• To reducetangling, setthe depth regu- lator deepenough to get maximum

"chopping" action asthe tines chop the

materialagainst the ground. Also, try

to till under crop residuesor cover crops while they are green, moist and

tender.

• While power composting, try swaying

the handlebarsfrom sideto side (about 6"to 12"). This "fishtailing" action

often clearsthe tines of debris.

• Iftangling occurs, liftthe tines out of

the soil and run the tiller in reversefor a few feet. This reversing action

should unwind a good deal of debris.

• If reversingthe tiller doesn't clearthe

debris, it may be necessaryto remove the debris by hand(a pocketknife will

helpyou to cut away the material).

Beforeclearingthetines byhand, stop

the engine, allow all moving parts to

stop and disconnect the spark plug

wire. Removethe ignition keyon elec- tric start models.

Failure to follow this warning could resultin personalinjury.

Tillingonslopes

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

1.Till only onmoderate slopes, neveron steep ground where footing isdifficult

(reviewsafety rules in the "Safety"

Section of this Manual).

2. We recommend tilling up and down slopes ratherthan terracing. Tilling vertically ona slope allows maximum

plantingarea andalso leavesroom for

cultivating.

IMPORTANT:Whentilling on slopes, be

sure thecorrect oil levelis maintained in the engine (checkevery one-half hour of

operation). The incline of the slope will causethe oil to slant awayfrom its

normal levelandthis canstarveengine parts of required lubrication. Keepthe

engine oil levelat the full point at all times!

A. Tilling up anddownslopes:

• To keepsoil erosionto a minimum, be

sureto add enough organic matterto the soil so that it hasgood moisture- holding texture andtry to avoid leaving footprints or wheelmarks.

• When tilling vertically, try to makethe

first pass uphill asthe tiller digs more deeplygoing uphillthan it does down- hill. Insoft soil or weeds,you may haveto lift the handlebarsslightly while going uphill. When going downhill, overlapthe first pass by about one-half

the width of the tiller.

B. Terrace Gardening:

• When a slope is too steep or too short

for vertical tilling, it may be necessary to till across theslope and createter-

racedrows. Terracesare rows that are cut into the side of a slope, creating a

narrow, but flat areaon which to plant.

• Ona long slope,you can makeseveral terraces, one below the other.

Terracesshould be only 2-to-3 feet wide. Digging too far intothe side of the slope will expose poor subsoil that

is unproductivefor plants.

To createa terrace, start atthe top of the slope and work down. Goback and

forth acrossthe first row asshown in

Figure4-10.

Eachsucceeding lower terraceis started bywalking belowthe terrace you're preparing. Foraddedstability of the tiller, always keepthe uphill wheel

in the soft, newlytilled soil. Do not till the last 12" or more of the downhill

outside edgeof each terrace. This

untilled strip helps preventsthe ter-

racesfrom breakingapart and washing

downhill. It also provides a walking

path betweenrows.

, ll::e

o3mmr,

O_l_' REPEAT

Figure4-10

C. Tilling acrossslopeswithout usingterraces:

• Ifvertical or terracing gardening aren't practicalfor you, then you cantill later-

ally across a slope. We don't really

recommendthis methodas it can

create unsure footing andinvites soil erosion.

As in terracegardening,start at thetop

ofthe slopeand overlapthefirst pass by halfthe width of the tiller. Foradded

stability of thetiller, always keepthe

uphill wheel inthe soft, newlytilled soil.

POWERCOMPOSTING

Powercomposting simply meanstilling under and burying in the soil all manner of organic matter such ascrop residues, leaves,grass clippings and covercrops.

This materialwill decomposeduring the

non-growing season andadd important naturalnutrients to the soil.

When power composting, do not keep the Depth Regulator Lever at a deep settingifthetiller jumpsor bucks.

If jumping or buckingoccurs, movethe Depth Regulator Lever downto one of the shallower settings and then slowly increase the tilling depth on later

passes. Failure to follow this warning could

resultin personalinjury.

Thefirst placeto begin is with crop

residuessuch as leftover vines, stalks, stems and roots. Powercompost these crop residues assoon as they finish bearing. Thesooner this is done, the

better,astender green matter is easierto till under. Usethe deepestdepth regula- tor setting possiblewithout causing the engine to labor orthe tiller to jump ahead.

Standingcornstalks of reasonableheight can be power composted. Pushing over

(but not uprooting) cornstalks will often

makeit easier for your tiller to chop up the stalks. Keepthe tines clear of exces- sive tangling by "fishtailing" or frequently

using reverse. Makeseveral passes,then

return afew days laterto finish off any

remainingstubble.

After tilling under crop residues,add

more organic matter such as leaves, grass clippings and evenkitchenscraps. Whentilled intothe soil, this organic matter will decompose andadd even more important nutrients to the soil.

After power composting, you may want to

planta "greenmanure" cover crop to protect the soil during the off-season.You •The handlers should wearsturdy simply grow a crop of clover, alfalfa, footwear that will help to prevent buckwheat,peas, beans,ryegrass, grain, slipping. or kaleand then till it into the soil prior to

• Position the loadingvehicle so that the

the plantingseason.

ramp angle isas flat aspossible (the less incline to the ramp, the better).

LOADINGANDUNLOADING Turnthe vehicle's engine off and apply THETILLER its parking brake.

Loading and unloading the tiller into a vehicle is potentially hazardousand we don't recommenddoingso unlessabso- lutely necessary,as this couldresult in personalinjuryor propertydamage.

However, if you must load or unloadthe tiller, followthe guidelinesgivennext.

• Beforeloading or unloading,stop the engine,wait for all partsto stop moving,

disconnectthe 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 Ibs., dependingon model) and bulky to lift

safely by one person.Two or more

peopleshould share the load.

• Usesturdy ramps and manually (engine

shut off) roll the tiller into and out of the vehicle. Two or more people are needed

• Ramps must bestrong enough to support the combined weight of the tiller and any handlers.The ramps should provide good traction to preventslip- ping; they should haveside rails to guidethe tiller along the ramps;and

they should havea locking deviceto

securethem to the vehicle.

• When going up ramps, stand in the normal operating position and push the

tiller aheadof you. Havea personat

eachsideto turn the wheels.

• When going down ramps, walk back- ward with thetiller following you. Keep alertfor any obstaclesbehind you. Position a personat eachwheel to control the speedof the tiller. Nevergo down ramps tiller-first, as thetiller could

tip forward.

• Usewooden blocks to placeon the downhill side of the wheels if you need

to stop the tiller from rolling down the

ramp. Also, usethe blocks to temporar- ily keepthetiller in placeon the ramps (if necessary),and to chock the wheels in placeafter thetiller is in the vehicle.

• When thetiller is inthe vehicle, prevent it from rolling byengagingthe wheels in

the wheel drive position (put Wheel Gear

Leverin ENGAGE).Chockthe wheels with blocks and securelytie thetiller

to do this. down.

5 Maintenance

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to come to a

complete stop, disconnect spark plug wire and move wire away from spark

plug. Remove ignition key on electric start models.

Failure to follow these instructionscan

resultin seriouspersonalinjuryor prop-

ertydamage.

MAINTENANCESCHEDULE

PROCEDURE NOTES

Checkmotor oil level 2, 3 Cleanengine 2, 7 Checkdrive belt tension 1, 4

Checknuts and bolts 1, 4 Change motor oil 1, 4, 6

Lubricate tiller 4 Service foam pre-cleaner airfilter 7

(if so equipped) Service paper air filter (if soequipped) 7

Checkgear oil level in transmission 1, 5 Checktines for wear 5

Checkair pressure in tires 5 Service spark plug 7

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 frequently in dusty or dirty conditions.

7 - SeeEngine Owner's Manual for service

recommendations.

6 - Whichever time interval occurs first.

TILLERLUBRICATION

Figure5-1: Lubricationpoints.

Proper lubrication of thetiller isan essen- tial part of your maintenanceprogram. After every10 operating hours, oil or greasethe lubrication points shown in

Figure5-1 as described below.

Usea good quality lubricating oil (#30 weight engine oil is suitable) anda good quality general purpose grease (grease

that hasa metal lubricant is preferred, if available).

• Removewheels,clean wheel shaft (A,

Figure5-1) andapply thin coating of greaseto shaft.

• Greaseback,front and sides of depth

regulator lever(B, Figure5-1).

• Removetines, cleantine shafts (C,

Figure5-1) and inspectfor rust, rough spots or burrs (especiallyaround holes). File or sand smooth and coat

endsof shaft with grease.

• Oilthe threads on the handlebarheight

adjustment screw (D, Figure5-1).

• Oilthe threads on the handlebarattach-

ing screws (E,Figure 5-1).

CHECKHARDWARE

At least every 10operating hours,check the unit for loose or missing hardware

(screws, bolts, nuts, hairpin cotters, etc.). Looseor missing hardwarecan leadto

equipment failure, poor performanceor oil leaks.

Besureto checkthethree end cap mounting screws locatedat the rear of the

transmission (Figure5-2). Liftthe tine flap to service those screws.

Figure5-2

CHECKTIRE PRESSURE

Checkthe air pressure in bothtires.

Deflateor inflate bothtires evenlyto 15-

to-20 PSI (pounds per square inch). Be sure that bothtires havethe sameair

pressureor the unit will tendto pull to

one side.

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to come to a complete stop, disconnect spark plug wire and move wire away from spark plug.

Remove the keyfrom the keyswitch on unitsso equipped. Failure to follow these instructionscan result in serious personal injury or property damage.

CHECKFOROILLEAKS

Beforeeach use, checkyour tiller for

signs of an oil leak- usually a dirty, oily accumulation either onthe unit or on the

floor where it has beenparked. A littleseepagearound a cover or oil seal

is usually not a causefor alarm. However, ifthe oil drips overnight then immediate

attention is neededas ignoring aleakcan

result in severetransmission damage. If a cover is leaking,try tightening any

loosescrews or bolts. Ifthe fasteners are

tight, a newgasket or oil seal may be

required. If the leak isfrom around a

shaft and oil seal,the oil seal probably

needsto be replaced. Seeyour autho- rizeddealeror contact the factory for

service or advice.

IMPORTANT:Neveroperatethe tiller if

the transmission is low on oil. Checkthe oil levelafter every 30 hours of operation

and wheneverthere is anyoil leakage.

TRANSMISSIONGEAR01LSERVICE 3. Placea clean pan belowthetransmis-

Checkthe transmission gear oil levelafter sion drain plug (see Figure5-3) and every 30 hours of operation or whenever removethe drain plug. The oil will start you notice anyoil leak. Operatingthe flowing out ofthe drain hole (it may flow

tiller whenthe transmission is low onoil slowly, especiallyin cold temperatures). can result in severedamage. 4. Removethe transmission gearoil level

A. To CheckTransmissionGearOil

Level:

1. Checkthe gear oil levelwhen thetrans-

mission iscool. Gearoil will expandin warm operating temperaturesand this expansion will provide an incorrect oil

levelreading.

2. To check the gear oil level(andto add

oil, if necessary), referto "STEP5: Check

GearOil Levelin Transmission" in Section 2 of this manual.

B.To Drainand Refill theTransmission:

Thetransmission gear oil does not need to be changedunless it hasbeencontami-

natedwith dirt, sand or metalparticles.

1. Prop up the left sideof the unit sothat

it will be securely supported when the left side wheel is removed. Removethe left

side wheel by removing the wheelmount-

ng hardware.

2. Unscrewthe plastic gearoil fill plug from thetop of the transmission.

checkplug that is locateda few inches abovethe left side wheelshaft.

5. Whenthe oilstops flowing, tilt the

transmission forward to drain oil from the

rear of thetransmission.

6. After draining the oil, clean the threads of the drain plug,apply a non-hardening removablegasketsealantto thethreads, and securely reinstall the drain plug.

7. Using a cleanfunnel, slowly add SAE 140 orSAE85W-140 weight gear oil (with anAPI rating of GL-4 only) to the

transmission. Thetransmission holds approximately 3-1/4 pints (52-54

ounces). Tilt the tiller slightly backwards to makesure the gear oil reachesthe rear (tine) end ofthe transmission. Step adding gear oil when it beginsto flow

from the oil levelcheck hole on the sideof thetransmission.

8. Securely reinstallthe oil levelcheck plug.

9. Securely reinstallthe gearoil fill plug on top of thetransmission

10. Reinstallthe wheeland remove the prop.

Ir!lv_vl._!:t_ll_[fll

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to

come to a complete stop, disconnect spark plug wire and move wire away from spark plug.

Removethe key from the keyswitchon units so equipped. Failure to follow these instructionscan result in serious personal injury or propertydamage.

5. Onengines with adipstick, remove it,

wipe it clean, and reinstall it finger-tight. Removethe dipstick and checkthe reading. Add oil (if required) to bring the

levelto the FULLmark. Do not overfill.

B. To Changethe EngineOil:

Changethe engineoil as instructed in the separateEngineOwner's Manual.

ENGINECLEANING

Theengine must be kept cleanto assure smooth operationand to prevent damage from overheating. Referto the separate EngineOwner's Manualfor specific repair and cleaning instructions. All inspections

and services must bedone with the engine shut off and cool to the touch.

AIR CLEANERSERVICE

Theengine air cleanerfilters dirt and dust out ofthe air before it entersthe carbure-

tor. Operatingthe engine with a dirty, clogged air filter can causepoor perfor-

Figure5-3: Removedrainplugto drain manceand damageto the engine. Never transmissiongearoil(alsoremoveoilfill operatethe enginewithout the aircleaner

plugandoil levelcheckplug).

installed. Inspect andservicethe air cleanermore often if operating invery dusty or dirty conditions.

CARBURETOR/GOVERNOR CONTROLADJUSTMENTS

Operators shall not tamper with the engine governor settings on the machine; the governor controls the maximum safe operating speed to protectthe engine and all moving parts

from damage caused by overspeed.

ENGINEOILSERVICE Authorized service shall be sought if a

Checkthe engineoil levelbeforestarting the engineeach dayand checkit after

each5 hours of continuous operation. SPARKPLUGSERVICE

Runningthe enginewhen it is low on oil

will quickly ruinthe engine.

It is recommendedthat you changethe motor oilafter every 10 hours of opera-

tion andeven sooner when operating in

Owner's Manual.

extremely dirty or dusty conditions. Refer to the separateEngineOwner's Manual Insome areas, local law requires using for detailedserviceinstructions, resistor spark plugs to suppress ignition

signals. Ifthe enginewas originally

A. To Checkthe EngineOil Level: equipped with a resistor spark plug, use

Servicethe air cleaner as instructed in the problemexists. separateEngineOwner's Manual.

Inspectand cleanor replacethe spark plug afterevery 100 operating hours or annually. Cleanthe plug and set the gap as described in theseparate Engine

Thecarburetor was adjusted at the factory for best operatingspeed. Referto the separateEngineOwner's Manualfor anyadjustment information or seeyour authorizedengine servicedealer.

Thegovernor controls the maximum safe operating speedand protectsthe engine and all moving parts from damagecaused by overspeeding. Do not tamper with the engine governor settings. Seekautho- rizedservice if aproblem exists.

1. Move the tiller to a level areaand shut off the engine.

2. Levelthe engineby moving the Depth RegulatorLever up or downas needed.

3. Cleanthe areaaround the oil dipstick

or oil fill tubeto prevent dirt from falling

intothe crankcase.

4. On engineswith an oil fill tube, remove

thefiller cap, add oil (if required) until it

reachesthe top of the tube and reinstall

thefiller cap.

the sametype for replacement.

THROTTLECONTROLADJUSTMENT SPARKARRESTERSCREEN SERVICE

If the enginemuffler isequipped with a spark arrester screen, removeand clean it according to the time intervalsand instructions inthe separateEngine

If the enginedoes not respondto various throttle leversettings, referto the sepa- rate EngineOwner's Manualfor service information or contact your localautho- rizedengine service dealer.

Owner's Manual.

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to come to a complete stop, disconnect spark plug wire and move wire away from spark plug.

Remove the keyfrom the keyswitch on unitsso equipped. Failure to follow these instructionscan result in serious personal injury or property damage.

WHEELGEARCABLEADJUSTMENT OFF SEASONSTORAGE

When the Wheel GearLeveris in DISEN-

GAGE,the wheels will roll freely (free- wheel). Thewheels should not roll freely

whenthe lever is in ENGAGE.Ifthe wheels roll freely whenthe Wheel Gear

Leveris in ENGAGE,the wheel gearcable needsto be adjustedas described below.

1. With the engineshut off and the spark plug wire disconnected,put the Wheel

GearLeverin ENGAGE.

2. Loosenthetop adjustment nut (A, Figure5-4) on the wheel gear cable

bracketthat is located on the leftside rear of thetransmission.

3. Pushthe wheelgearcable (B) down and roll thetiller slightly forward or back-

ward until the eccentric lever (C)engages (locks) the wheels. Holdthe cable in that position andtighten the top (A) and bottom (D) adjustment nuts.

4. Movethe WheelGear Leverto ENGAGEand DISENGAGEseveraltimes

to checkthe adjustment. Thewheels

should not roll when the leveris in ENGAGE,but they should roll whenthe

leveris in DISENGAGE.Readjustthe cableasrequired.

Figure5-4: Wheelgear cable assembly.

Whenthe tiller won't beused for extended periods, prepare it for storage

asfollows:

1. Cleanthe tiller and engine.

2. Do routine tiller lubrication and check for loose parts and hardware.

3. Protect the engineand perform recom- mendedengine maintenanceby following

the engine storage instructions found in the separateEngineOwner's Manual.

NOTE:Besure to protectthe fuel lines,

carburetor andfuel tank from gum deposits by removing fuel or by treating fuel with a fuel stabilizer (follow engine

manufacturer's recommendations).

4. On electricstart units, follow "Battery

Storage" instructions in this Section.

5. Store unit in a clean, dry area.

6. Neverstore the tiller with fuel in the

fuel tank in an enclosedarea where gas fumes could reach anopenflame or spark, or where ignition sources are

present (spaceheaters,hot water heaters,

furnaces, etc.).

BOLOTINES

Thetines will wear with useand should

be inspected at the beginning of each

tilling season andafter every30 operating

hours. Tines can be replaced individually

or as acomplete set. Neverinspector servicethe tines unlessthe engineis stopped, the spark plug wire is discon-

nected,and the ignition keyis removed

on electric start models.

A. Tine Inspection:

With use,thetines will becomeshorter,

narrowerand pointed (Figure5-5). Badly

worn tines will result in a loss of tilling depth and reducedeffectivenesswhen chopping up and turning under organic

matter. UseFigure 5-5 asa guide to

when thetines should be replaced.

ModerateWear

Replace

Figure5-5: Checkingtinesforwear.

B. Removinga SingleTine:

1. Removethe two screws and nutsthat attacha single tine to the tine holder

(Figure5-6). If needed,use penetrating

oil to helpfree the nuts.

2. When installing a single tine, besure to position it so that its cutting edgewill

enterthe soil first as thetiller moves forward.

C. Removinga Tine Assembly:

1. If removing both tine assemblies,mark them "left" and "right" before removal.

Doingso will help ensure that the assem- bliesare reinstalled on the correct sides

of the tiller.

2. Removethe screw andIocknut that securethe tine assembly to the tine shaft

(Photo5-7). Pull thetine assembly off

the shaft (if necessary,use a rubber

malletto tap the tine assembly outward).

3. Beforereinstalling the tine assembly, inspectthetine shaft for rust, rough

spots or burrs andfile or sand as needed. Apply athin coat of greaseto the shaft.

4. Install each tine assembly sothat the

cutting edge of the tineswill enter the

soil first when thetiller moves forward.

Securethe tine assembly to the tine shaft

usingthe screw andIocknut previously removed. Tighten securely.

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to

come to a complete stop, disconnect spark plug wire and move wire away from spark plug.

Removethe key from the keyswitchon units so equipped. Failure to follow these instructionscan result in serious personal injury or propertydamage.

Figure5-6: Removingsingle tine.

Figure5-7: Removingatineassembly.

Figure5-8: Forwardclutchbelt. (C, Left- side view, nobelt cover.)

Followthe belt adjustment instructions

carefully. An incorrectadjustmentcould result in the clutch controlmechanism

engaging too soon. This could cause

loss of tiller control and result in per-

sonalinjuryor propertydamage.

CHECKINGAND ADJUSTING

TENSION ON CLUTCH BELTS

Maintaining correct belt tension is impor-

tant to good tilling performance and long

belt life. A loosebelt will slip on the

engine andtransmission pulleysand causethe tines andwheels to slow down

- or stop - eventhough theengine is running at full speed. A loose beltwill

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 newforward clutch belt (C,

Figure5-8) should becheckedafter the

Figure5-9: Reverse clutchbelt (D). (Right-side view,nobelt cover.)

Figure5-10: Locationofforwardclutchcable spring(E)andforwardcableadjuster(F).

2-1/2"

first two (2) hours of operation and after every ten (10) hours of operation.

Figure5-11: Correctspringlengthwhen ForwardClutchLeversareengagedis 2-1/2".

The reverseclutch belt (D, Figure5-9), A loose beltwill also result in premature

becauseit is used moresparingly, may belt wear. not require tension adjustment until asig-

nificant number of operating hours has • Checkbelt tension after thefirst two passed. A tension adjustment is required hours of break-in operation and after only if there is little or no reversemove- every10 operating hours. ment when the ReverseClutchControl

knob is pulled out.

CheckingandAdjusting ForwardClutchBeltTension

It is important to maintain correct tension on the forward clutch belt. A loosebelt

will causethe tines andwheels to slow

down- or stop completely - even though

the engine is running atfull speed.

• Atthe endof eachtilling season,check the beltfor cracks, cuts or frayed edges. A belt in poor condition should be

replaced.

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to come to a complete stop, disconnect spark plug wire and move wire away from spark plug.

Remove the keyfrom the keyswitch on unitsso equipped. Failure to follow these instructionscan result in serious personal injury or property damage.

Incorrectcable adjustment could cause the wheels andtines to rotate unexpect- edly. Follow adjustment procedures carefully. Failure to do so could result

in personalinjury orpropertydamage.

CheckingForwardBelt Tension

1. Beforechecking, shut off engine, allow the engine and muffler to cool down, dis- connect the spark plug wire, removethe

ignition keyon electric start models.

2. Thecoiled part of the forward clutch spring (E, Figure5-10) measures2" in

lengthwhen the Forward Clutch Control leversare not pulled up. Pull either

ForwardClutch Control Lever upagainst the handlebar and measurethe length of the coil on the forward clutch spring. Tension is correct if the length of the extended coil is 2-1/2" (seeFigure5-11).

Theforward clutch control cableneeds adjustment if the extendedlength of the

coil is not 2-1/2". SeeAdjusting the

Forward Clutch Beltfor a procedure.

Adjustingthe Forward ClutchCable

Dothis procedure if the forward clutch spring measurement is not correct (see

CheckingForward Belt Tension).

1. Beforeadjusting the belt, shut off engine, allowthe engine and muffler to cool down, disconnect the spark plug wire, andremove the ignition key on elec-

tric start models.

Tension.

Figure5-12: Moveforwardclutchcable

adjusterdownformorebelttension.

2. Belt adjustments aredone with the

forward clutch cableadjuster (F,Figure 5-

10). Usetwo 1/2", open-end wrenchesto loosenthetwo jam nuts (A, Figure5-12)

a few turns.

3. Movecable adjuster (B, Figure5-12) downward for more belt tension (see Figure5-12).

4. Handtighten thejam nuts and pull the ForwardClutch Control leversup against

the handlebar. Measurethe spring coil

(Figure5-11). The extendedlength of the

coil should be2-1/2". Repeatthis proce-

dure until the extendedspring length is

correct.

5. Tighten bothjam nuts securely.

CheckingandAdjustingReverse ClutchBeltTension

CheckingReverseClutchBelt Tension

The reverseclutch belt (D, Figure5-9)

needsadjustment if the belt slips in reverseor if there is no reverse. See

Adjusting ReverseClutch Belt below.

AdjustingReverseClutchBelt

1. Beforeadjusting the belt, shut off

engine,allow the engine and muffler to cool down, disconnectthe spark plug wire, and removethe ignition key on elec-

tric start models.

Figure5-13: Belt cover.

2. Removethetwo nuts (C, Figure5-13)

and removethe belt cover.

3. Reversebelttension adjustmentsare donewith the reverseclutch cable

adjuster locatedon the left side of the

machine nearthe engine (D, Figure5-14). Usetwo 1/2" open-endwrenches to

loosenthetwo adjuster jam nuts (E) afew

turns.

Figure5-14: Reverse clutchcable adjuster. Left-side viewwith belt coverremoved.

4. Move thecableadjuster (D, Figure 5-14) awayfrom the pulleys to increase

belt tension.

5. Tighten both jam nutssecurely.

6. Reinstallthe beltcover.

7. Move the unit to an openareaand test the reverseoperation. Repeatthis proce- dure if the unit does not respondwhen the reverseclutch isengaged.

FORWARD CLUTCH BELTREMOVAL AND REPLACEMENT

Theforward clutch belt (K, Figure5-15) engagesthe enginepulley (I) and the transmission pulley (J) wheneither

Forward Clutch Control Lever is pulled up againstthe handlebar. This tightens the

forward clutch cable (G)which causesthe forward clutch idler pulley (H) to apply

pressureto the forward clutch belt. This causesthe pulleysto turn for Forward

movement.

Figure5-15: Forwardclutchcontrol assembly.

Ir!ly_vl._!:t_ll_[fll

Figure5-16

Figure5-17

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to

come to a complete stop, disconnect spark plug wire and move wire away from spark plug.

Removethe key from the keyswitchon units so equipped. Failure to follow these instructionscan result in serious personal injury or propertydamage.

RemovingForwardClutchBelt

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

connect spark plug wire beforeworking

nearbelts. Also remove ignition key on

electric start models.

2. Removethe two nuts (C, Figure5-13) and removethe belt cover.

3. Move the reverseclutch belt (B, Figure 5-16) out ofthe way. You do not needto completely removethe belt. Pressthe

reverseidler pulley inward for slackand

then slip the bottom half of the belt com-

pletelyoff the transmission pulley (A, Figure5-16). Pullthe bottom halfof the beltout ofthe housingand let it hang off

the outside of the unit (B).

4. Disconnectthe forward clutch cable from the forward clutch idler arm bracket

Figure5-18

Figure5-19: Left-side view.

(Figure5-17). Notethe holefrom which you disconnect the cable. It is important that you reconnectthe cableto the same

hole.

5. Slide the belt offthe engine pulley (C,

Figure5-18), awayfrom engine,out from

underthe belt guide (D),and completely off the pulley.

6. Slip the belt off the front ofthe trans-

mission pulley (F, Figure5-19).

7. Work the belt out from betweenthe

pulleyand the frame, around the trans-

mission cover spring, then up and out of the machine.

InstallingForwardClutchBelt

1. Stop engine, allow it to cool and dis- connect spark plug wire beforeworking

nearbelts. Also remove ignition key on electric start models.

2. Removethe old forward clutch beltas described in RemovingForward Clutch

Belt.

Figure5-20: Arrow(K)showsinsertionpoint forinstallingnewforwardclutchbelt.

3. From thefront of tiller, insert the forward clutch belt in betweenthe bottom

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

4. Insert the bottom half of belt into the smaller, rear-mostgroove of the trans-

mission pulley (F, Figure5-19). Now slip

the top half of belt underthe beltguide

(D, Figure5-18) and onto the large groove of engine drive pulley (L, Figure 5-19).

5. Reconnectthe forward clutch cableto the correct hole in the idler arm bracket, asshown in Figure5-17.

NOTE:Besure to run the reverseclutch cableon the pulleyside of the cover

support brackets(G, Figure5-21).

Figure5-21: Correctforwardclutchcable

positioning.

IMPORTANT:Belt must beinstalledon the insideof the beltguide (H,Figure

5-21).

6. Reinstallthe reverseclutch belt. Insert the bottom of the belt into theframe, then

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to come to a complete stop, disconnect spark plug wire and move wire away from spark plug.

Remove the keyfrom the keyswitch on unitsso equipped. Failure to follow these instructionscan result in serious personal injury or property damage.

pull down on the belt and roll it onto the large,forward-most groove of the trans- mission pulley(P, Figure5-20).

7. Reinstallthe belt cover.

8. Testfor correct tension on the forward clutch belt (see CheckingForward Belt

Tension).

REVERSE CLUTCH BELT REMOVAL

AND REPLACEMENT

Figure5-22: Right-side view.

4. Usetwo 1/2"wrenchesto loosen and remove wire belt guide (R, Figure5-22)

from the reverse idler arm pulley. Do not

remove Iocknut and screw.

5. Removethe reversebelt and pull it out

through front of transmission housing.

InstallingReverseClutchBelt

1. Stopengine,allow it to cool and dis- connectspark plugwire beforeworking near belts. Also remove ignition keyon

electricstart models. IMPORTANT:Theforward clutch belt

must be installed beforethe reverse clutch belt.

The reverseclutch belt (J, Figure5-22) is driven by the enginedrive pulley (I, Figure 5-20). Whenthe ReverseClutchControl

knobis pulled out, it pulls the reverse

idler arm andpulley (N) which tightens the belt againstthe engine drive pulley. This drivesthe transmission drive pulley

(L), resulting in reversemotion.

RemovingReverseClutchBelt

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

connect spark plug wire beforeworking

nearbelts. Also remove ignition key on electric start models.

2. Removebeltcover (Figure5-13) by

removingtwo flange Iocknuts.

3. Pull the reverseclutch belt downward

2. Installthe forward clutch belt (see Installing Forward ClutchBeltin this section) before installing reversebelt.

IMPORTANT:The reversebelt has a 'V" shape. When installing the belt, make

surethat the widest (flat) side of the belt rides againstthe reverseidler pulley (N, Figure5-22) andtransmission pulley (L). If needed,the belt canbe twisted "inside out" sothat the "V" shapedside ison the

outside and the widest side is on the inside.

3. Insertthe belt down into the front of

the transmission housing. Slip the top

half of the belt ontothe reverseidler arm pulley (N).

4. Pull the beltdownward and loop the bottom half of belt around thefront

grooveof transmission pulley(L, Figure 5-22).

5. Mount the belt guide betweenthe two

Figure5-23: Reversebelt guide positioning.

6. (You will needan assistant to help with this step.) Pull the reverseidler pulley (N) up to its highest point and position the belt guide (R) horizontally levelas shown in Figure5-23. Securely tighten the screwand lock nut (M, Figure 5-22).

7. Pull back on the ReverseClutch Control knob and makesure that the

reverseclutch belt fully contactsthe groove in the engine pulley. Releaseknob

and makesurethat the belt doesn't engagethe reverseengine pulley. This

may causethe unit to move inreverse when theWheel GearLeveris engaged. Adjust the cablefor less tension if this condition occurs. SeeCheckingand Adjusting ReverseBelt Tensionfor more

information.

flat washers andtighten snugly. The 8. Reinstallthe belt cover andsecure it

guide needs adjusting beforefully with two flange Iocknuts.

tightening. 9. Testthe unit inan open location.

and slip it off the transmission pulley

(L, Figure5-22),

W!IW._!:t_II_[fll

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to

come to a complete stop, disconnect spark plug wire and move wire away from spark plug.

Removethe key from the keyswitchon units so equipped. Failure to follow these instructionscan result in serious personal injury or propertydamage.

BATTERYMAINTENANCE

Use extreme caution when working on or near batteries. To help preventper-

sonal injuryor propertydamage:.

• Batteries generate explosive gases. Keepsparksand flamesaway fromthe batteryat all times. Ventilate thearea when charging or using the battery in

an enclosedarea.

BatteryCare in Service

The batteryis sealedand is maintenance- free. Acid levelscannot bechecked.

• Always keepthe batterycables and ter

minals clean andfree of corrosive build-up.

• After cleaningthe batteryand terminals,

apply a light coat of petroleum jelly or greaseto both terminals

• Always keepthe rubber boot positioned

over the positive terminal to prevent shorting.

Charging

If the tractor hasnot beenput into usefor

an extendedperiod of time, charge the

batterywith anautomotive-type 12-volt

chargerfor a minimum of onehourat six

amps.

JumpStarting

IMPORTANT:Neverjump your tiller's

deadbattery with the batteryof a running

vehicle.

1. Connectend of one jumper cable to the

positiveterminal of the good battery, then the other end to the positiveterminal of the dead battery.

2. Connectthe otherjumper cableto the

negativeterminal ofthe good battery, then to the frame ofthe unit with the dead

battery.

Failureto use this procedure could cause sparking, and the gas in either battery could explode.

BatteryRemovaland Installation

Whenremoving andinstalling the battery, disconnect and connectthe cablesin this

order to avoidsparking:

1. To remove the battery,first disconnect

the negative(-) cable from the grounding

screw on the back of the battery bracket post. Bendthe cable awayfrom any metal parts.

2. Disconnectthe negative(-) cablefrom

the negative(-) batterypost.

3. Disconnectthe positive (+) cable from

the positive (+) battery post and bendit

awayfrom anymetal parts.Coverthe cableterminal with its rubber boot.

Cleaning

Cleanthe 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.

4. Removethe battery clamp.

5. To install the battery,reversethe above

steps. Besure that the battery postsface to the rear of the tiller andthat the posi- tive (+) post is on the left side asyou face

forward from the handlebars.

BatteryFailures

BatteryStorage

Chargebattery fully. The battery loses

Some common causesfor battery failure some of its charge eachday whenthe unit

is not used.

are:

• incorrect initial activation

• undercharging

• overcharging

• corroded connections

• freezing IMPORTANT:Thesefailures areNOT

covered by your tractor's warranty.

IMPORTANT:NEVERstore battery without afull charge. Rechargebattery before returningto service or every two

months, whicheveroccurs first. Whenstoring unitfor extended periods,

disconnect batterycables. Removing batteryfrom unit is recommended.

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to come to a complete stop, disconnect spark plug wire and move wire away from spark plug.

Remove the keyfrom the keyswitch on unitsso equipped. Failure to follow these instructionscan result in serious personal injury or property damage.

TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE CORRECTION

Enginedoes notstart.

Enginerunspoorly.

Engineoverheats.

Enginedoesnot shutoff.

WheelsandTines will notturn.

Tinesturn,but wheelsdon't.

WheelsTurn,but TinesDon't.

Poortilling performance.

1. Sparkplugwire disconnected.

2. EngineThrottleControlLeverincorrectly set.

3. Fueltankempty.

4. Chokecontrol (if soequipped)in incorrectposition.

5. Stalegasoline.

6. Dirtyair filter(s).

7. Defectiveorincorrectly gappedsparkplug.

8. Carburetorout of adjustment.

1. Reconnectwire.

2. Putleverin FASTposition.

3. Addfuel.

4. SeeEngineOwner'sManual.

5. Drainfuel andaddfresh fuel.

6. Cleanor replacefilter(s).

7. Inspectspark plug.

8. SeeEngineServiceDealer.

9. Misadjustedthrottle control.

10.Dirtor waterin fuel tank.

10.

Defectiveorincorrectlygappedsparkplug. 1. Dirtyair filter(s). 2. Carburetoroutof adjustment. 3.

Stalegasoline. 4. Dirtor waterin fuel tank. 5.

Enginecooling systemclogged. 6.

Enginecooling systemclogged. 1. Carburetoroutof adjustment. 2. Oillevel islow. 3.

Misadjustedthrottle control cable(recoil startmodel).

Improper useof controls. ForwardClutch:Misadjustedforwardclutchcontrol cable. ReverseClutch: Misadjustedclutch controlcable.

Worn or brokenclutch belt(s). 4. Internaltransmissionwearor damage. 5.

Boltand keyloose intransmissionpulley. 6.

1. Wheelmountinghardwaremissing.

2. Boltandkeyloose intransmission pulley.

3. Internaltransmissionwearor damage.

4. Misadjustedwheelgearcable.

5. WheelGearLevernot fully engaged.

1. Tineholdermountinghardwaremissing.

2. Internaltransmissionwearor damage.

1. Worntines.

2. Improper DepthRegulatorsetting.

3. Incorrectthrottle setting.

4. Belt(s)slipping.

SeeEngineServiceDealer. SeeEngineServiceDealer.

Inspectsparkplug(see EngineOwner'sManual). Cleanor replace(see EngineOwner'sManual).

SeeEngineServiceDealer.

Replacewith freshgasoline.

SeeEngineServiceDealer.

Cleanaircooling system (seeEngineOwner'sManual).

Cleanaircooling area(seeEngineOwner'sManual).

SeeEngineServiceDealer.

Checkoil level(see EngineOwner'sManual).

1. SeeEngineOwner'sManualor EngineServiceDealer.

1. ReviewSections3 and4.

2. Adjustcabletension(Section5).

3. Adjust cabletension(Section5). Checkbelts. Replacepartsas needed(Section5).

Contactlocaldealeror the factory.

Tightenbolt;checkthat keyis in place.

1. Replacehardware.

2. Tightenbolt;checkthatkeyis in place.

3. ContactlocalDealeror the Factory.

4. See"WheelGearCableAdjustment,"Section5.

5. Engagelever(seeSection 3).

1. Replacehardware.

2. ContactlocalDealeror the Factory.

1. See"BoloTines"(Section5).

2. See"TillingTips & Techniques,"Section4.

3. SeeSection4.

4. See"CheckingClutchBeltTension,"Section5.

Ir!lv_vl._!:t_ll_[fll

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to

come to a complete stop, disconnect spark plug wire and move wire away from spark plug.

Removethe key from the keyswitchon units so equipped. Failure to follow these instructionscan result in serious personal injury or propertydamage.

MAINTENANCESCHEDULE

PROCEDURE NOTES

Check motor oil level 2, 3 Clean engine 2, 7

Check drive belt tension 1, 4

Checknutsandbolts 1,4

Change motor oil 1,4, 6

Lubricatetiller 4

Service foam pre-cleaner air filter 7

(if so equipped)

Service paper air filter (if so equipped) 7 Check gearoil level in transmission 1, 5 Checktines for wear 5

Check air pressure in tires 5 Service spark plug 7

NOTES

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

2 - Before eachuse.

3 - Every 5 operating hours.

4 - Every 10 operating hours. 5 - Every 30 operating hours.

6 - More frequently in dusty or dirty conditions. 7 - SeeEngine Owner's Manual for service

recommendations.

8 - Whichever time interval occurs first.

TILLERATTACHMENTS

Theattachments listed below are availablefor your tille Contactyour authorized dealeror the factory for current information. BUMPER-- MODEL0EM-290-254

Thetubular steel bumper helpsto protect the enginefrom damage. HILLER/FURROWER-- MODEL0EM-290-251

Thefurrower bladeattachesto the backof the depth regulator assemblyand is usedto create rows, trenches and ditches upto 8" deep,depending on soil conditions. Thetwo hiller wings attachto the sides of the furrower bladeand are used to makehilled rows and raisedbedgardens.

ROWMARKER--MODEL0EM-290-257

The row marker attachesto the hiller/furrower attachmentand is usedto scratch linesin the seedbedfor layingout furrows, trenches, raised beds,etc. (eliminates the needfor stakes,string and measuringtape). The row marker is adjustablein lengthfrom 28"to 49-3/4", allowing you to varythe width ofthe marked rows as required.

I Models 664D & E666M

HANDLEBARASSEMBLY and CONTROL LEVERS

(See page30, //I/I/

Ref. 47, for j attachment

sc,ewl.... J

[

COVER

Models 664D & E666M I

HANDLEBAR ASSEMBLY and CONTROL LEVERS

REF. PART No. No. DESCRIPTION QTY.

1 1918811 2 GW-9126 3 777122088

3A 777D05553

4 1916784 5 1186347

5A GW-9955

6 1900475 7 710-0514

8 736-3050

9 712-3000 10 1918791 13 GW-9442

14 GW-9057

Handlebars(Incl. Refs.2, 3 & 3A) ....... 1

Grip ..................................................... 2

Decal,Control Panel ........................... 1

Decal,Model Name/Logo.................... 1

ReverseClutch Control Cable.............. 1

HeightAdjustment Screw ................... 1

Washer, Keyed..................................... 1

Bracket,HandlebarHeightAdjustment 1

HexHd. Screw, 3/8-16 x 1*. ................ 2

Washer, Plain(flat) 3/8, S.A.E............. 2

HexLocknut, 3/8-16 ............................ 2

Cable,Forward ClutchControl ............. 1

Wheel GearControl and CableAssy.

(Incl. Refs. 14, 15, 19,21,22 & 23) 1

Knob,Wheel GearControl Lever.......... 1

REF. PART No. No. DESCRIPTION QTY.

15 1186211 16 710-0216 17 736-0169 19 725-0157

21 1114748

22 1100240

23 1186208 24 GW-9390

25 1918840

35 GW-9853 36 GW-20806 42 710-0599

Hex Nut, 5/16-24 ................................. 2

Hex Hd. Screw, 3/8-16 x 3/4". ............. 2

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

CableTies, Plastic................................ 2

Round Hd. Screw,#10-32 x 1/2 .......... 6

Lockwasher, #10 ................................. 2

Hex Nut, #10-32 .................................. 2

Grip ..................................................... 2

Bail, Forward Clutch Control (Incl.

two Ref. 24) ..................................... 1

Sems Nut............................................. 4

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

Hex FlangeScrew, self-tapping,

1/4-20 x 1/2". .................................. 2

* Specify GRADE5 if ordering part locally.

I Models 664D & E666M

22 8 i

ENGINE, SUPPORT BRACKETS, PULLEYS, BELTS, BELTCOVER

,__Reverse

ClutchCable

_ 43

44 _ 37 47

(Screw, Ref. 47, secures

ForwardClutchCable-

page28, Ref. 10)

26_

Models 664D & E666M I

ENGINE, SUPPORT BRACKETS, PULLEYS, BELTS, BELT COVER

REF. PART No. No. DESCRIPTION QTY.

1 ** Engine- standard recoil start ............ 1

** Engine- electric start ........................ 1

2 1917326 Bracket,Clutch Cable.......................... 1

3 736-0119 Lockwasher-5/16 ................................ 6

4 710-0107 HexHd. Screw, 5/16-24 x 1/2 ............. 2

5 777S30651 Decal,Hot Surfaces/Belt Warning ....... 1

6 1917139 Cover (Incl. Ref.5).............................. 1

7 712-3004A Flange Lock Nut, 5/16-18 .................... 2

8 1108841 Key,3/16 x 1-1/2 ................................ 1

9 GW-1138-1 Shim ................................................... 1

10 619-04015 Pulley,Engine Drive ............................ 1

11 GW-9944 BellevilleWasher ................................. 2

12 GW-9572 HexHd. Screw,5/16-24 x 1-1/8 ......... 1

13 710-3103 HexHd. Screw,5/16-18 x 2 ............... 1

14 1918731 ReverseIdler Arm ............................... 1

15 1916535 Pulley,ReverseIdler ........................... 1

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

17 1916725 Belt Guide, Wire Formed .................... 1

18 710-0117 HexHeadScrew, 5/16-24 x 1.............. 1

19 1917746 Washer, Shoulder ............................... 1

20 GW-9929 Washer, Flat, 1-1/8.............................. 3

21 1916728 Spring, ReverseReturn....................... 1

22 1916522 Transmission Pulley............................ 1

23 GW-1440 Support Washer.................................. 1

24 1918812 ReverseClutch Belt............................. 1

25 1909404 Forward ClutchBelt............................. 1

26 1900396 Self-tapping Screw, #10-32 x 1/2....... 4

REF. PART No. No. DESCRIPTION QTY.

27 GW-20339

28 712-0267 29 1186329 30 1916797 31 1916796

35 710-0805 36 777120942 37 1918774 38 GW-90063 39 710-3037

40 736-0275 41 1918846 42 GW-55088 43 736-0119 44 712-0267

45 1917746 46 1918744 47 1767754 48 1916727 49 712-3000

50 GW-9090 51 710-0347 52 712-0158 53 1754128 54 736-0463

55 714-04029 56 710-0539

Guard,Belts/Pulleys............................ 1

Hex Nut, 5/16-18 ................................ 4

Hex FlangeScrew, 5/16-18 x 3/4". ..... 4

EngineSupport Bracket,left side ........ 1

EngineSupport Bracket, right side...... 1

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

Decal,Stabilization.............................. 1

Mounting Bar...................................... 2

Hex FlangeScrew, 5/16-18 x 1 ........... 4

Hex Hd. Screw, 5/16-18 x 2-1/4". ....... 1

FlatWasher,5/16'. .............................. 1

Belt Guide,Pony ................................. 2

Pivot Bushing...................................... 2

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

Hex Nut, 5/16-18................................. 2

Washer, Shoulder ............................... 2

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

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

Spring ................................................. 1

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

Idler Pulley,Forward .......................... 1

Screw, 3/8-16 x 1-3/4 ......................... 1

Hex Lock Nut,5/16-18 ........................ 1

Screw, 1/4-20 x 3/4 ............................ 1

FlatWasher-I/4 .................................. 1

Key, .188 x 1.75 .................................. 1

Screw, 3/8-24 x 1.75........................... 1

* Specify GRADE5 if ordering part locally.

** Seeyour local authorized engine service dealer for engine parts or

service. Referto engine nameplatefor engine type and code information.

I Models 664D & E666M

TRANSMISSION HOUSING, COVERS, SEALS, GASKETS, PLUGS

REF. PART No. No. DESCRIPTION QTY.

1 2 3

4 5 6

GW-9621 1105620 721-04001 1186329

1983632 GW-11513

7 GW-20694 8 619-04010

9 GW-9467 10 GW-20889 11 721-04035 12 1186328

Oil Seal(Double Lip), Wheel Shaft ...... 2

Pipe Plug, 1/4.................................... 2

Seal,Transmission Bore..................... 1

Hex FlangeScrew, 5/16-18 x 3/4". ..... 6

Oil Seal, Input Pinion Shaft................. 1

Transmission Cover (Incl. four Ref. 18

andtwo ea. Refs.21 & 22).............. 1

Gasket,Transmission Top Cover ........ 1

Transmission CaseAssy..................... 1

Plug .................................................... 1

Mounting Plate,WheelClutch Cable... 1

Oil Seal,Tiller Shaft............................. 2

Hex FlangeScrew, 5/16-18 x 5/8". ..... 2

REF. PART No. No. DESCRIPTION QTY.

13 GW-20873 14 GW-1129-1

15 1915089

16 GW-1115 17 GW-1124-2

18 GW-90063 19 1915087

21 736-0169 22 710-0216

Tiller Housing Cover,left side ............. 1

Gasket,Tiller Housing Cover, .010"

(fits all covers)................................ A/R

Screw Kit: Incl. three 1/4-20 x 7/8

Self-Sealing Screws ........................ A/R

RearBearingCap................................ 1

Gasket,RearBearingCap, .010"

Thick ............................................... A/R

Hex FlangeScrew, 5/16-18 x 1*. ........ 4

Screw Kit: Incl. five 1/4-20 x 5/8

Self-Sealing Screws ........................ A/R

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

Hex Hd. Screw, 3/8-16 x 3/4". ............ 2

* Specify GRADE5 if ordering part locally.

A/R- As Required

Models 664D & E666M I

DRIVE SHAFT, INPUT PINION SHAFT and GEARASSEMBLIES

MAIN DRIVE SHAFT ASSEMBLY

INPUT PINION SHAFT&

GEAR ASSEMBLY

REF. PART No. No. DESCRIPTION QTY.

MAIN DRIVESHAFT

1 2 3 4

5 5

GW-1714 GW-20718

GW-9301 GW-20912

GW-1224-1

GW-1224-2

GW-1224-3

GW-1325C

Bearing,Tapered Roller with Race.... 1

Spur Gear.......................................... 1

Key,3/16 sq. x 1 ............................... 1

Main Drive Shaft (Drive shaft is one-

piece with integral, single-lead, work-hardened front worm, and

integral, six-lead, work-hardened

rearworm. Also includes pressed-

on GW-1714 and GW-9301).......... 1

Shim, Rear Bearing Cap, .010"thick

(see Notebelow) ........................... A/R

Shim,same as above, but .030"thick

(see Note)...................................... A/R

Shim,same as above, but .005"thick

(see Note)...................................... A/R

Shim Set(Incl. two GW-1224-1;two

1224-2 andone GW-1224-3) ........ A/R

REF. PART No. No. DESCRIPTION QTY.

INPUTPINIONSHAFT& GEARASSEMBLY

6 7

GW-9572 GW-9944

8 1108841 9 1916522

10 GW-1440 11 721-04044

12 1113527 13 GW-9953 14 GW-9428 15 GW-9677

16 GW-20791 17 GW-20792 18 GW-9093 19 GW-20799

20 GW-9517

HexHd. Screw, 5/16-24 x 1-1/8". ..... 1

Washer, Disc Spring (concave

surface faces pulley)...................... 1

Key,3/16 sq. x 1-1/2 ......................... 1

Transmission DrivePulley................. 1

Support Washer................................ 1

Oil Seal, Input Pinion Shaft................ 1

RetainingRing (external) .................. 1

Thrust Washer................................... 2

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

Set Screw, 5/16-18 x 3/8". ................ 1

Input Pinion (steel shaft) ................... 1

Input Pinion Gear.............................. 1

RetainingRing (external) I................. 1

Pinion Assy. (Incl. one each Refs. 16,

17 and18 ...................................... A/R

RetainingRing (internal) .................. 1

NOTE:Shim betweendrive shaft rear bearing and rear bearing cap to achieve5-to-10 thousandths of an inch (.005-.010) end play on drive shaft.

A/R- As Required

* SpecifyGRADE5 if ordering part locally.

I Models 664D & E666M

WHEEL SHAFT, ECCENTRIC SHAFT and TILLER SHAFT ASSEMBLIES

Assembled

Internally

15 / / / "_'_'_/l'_ll _

ECCENTRIC

SHAFT ASSEMBLY

\ 2

[] Wheel Shaft Parts

REF. PART No. No. DESCRIPTION QTY.

1 721-04031

2 1909950 3 GW-1166-1

--- GW-1166-2

--- GW-1166-3

--- GW-1166-4 4 GW-1086

5 711-04091 6 GW-9373 7 GW-20914 8 GW-9935

0il Seal.............................................. 2

Retaining Ring(heavy-duty, external) 2

Shim, 1-1/64 I.D., .062"thick ............ A/R

Shim, as above,but .030"thick ......... A/R

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

Shim, as above,but .010"thick ......... A/R

Bushing............................................. 2

Wheel Shaft (Incl. Ref.6) .................. 1

Hi-Pro Key,1/4 x 1-5/16.................... 1

Wheel DriveWorm Gear (cast-iron).. 1

Shim (between key and gear),

1.016 I.D.x 1.468 0.D. x .062

Thick.............................................. 1

REF. PART No. No. DESCRIPTION QTY.

9 GW-20712

10 611-04002 11 GW-1442

12 GW-9055 13 721-04034 14 GW-20700 15 710-3013

16 741-3037 17 711-04080 18 GW-1104 19 GW-20913

Wheel DriveClutch (cast-iron) .......... 1

Eccentric Shaft.................................. 1

Pin, Eccentric Shaft........................... 1

Spring ............................................... 1

Oil Seal.............................................. 1

Eccentric Shaft Lever......................... 1

Hex Hd. Screw, 1/4-20 x 1/2". .......... 1

Ball Bearing....................................... 2

Tiller Shaft (Incl. Ref. 18).................. 1

Woodruff Key,1/4 x 1-1/4 ................. 1

Tiller Drive Worm Gear(bronze) ....... 1

* SpecifyGRADE5 if ordering part locally.

A/R- As Required

Models 664D & E666M I

BOLOTINES, WHEELS

FRON_

FORWARD

TINE

SHAFT

FRONT/

FORWARD

NOTE1: Custom Tilling Tines are availablefor your tiller. These are special hard-facedtines 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. PART No. No. DESCRIPTION QTY.

1 710-3105 HexHd.Screw, 3/8-16 x 1-1/4". ......... 16

2 GW-1270-2A BoloTine-single. Right hand tine

usedon left side of tiller. (Incl.

two ea. Refs.1and 3) ..................... 8

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

5 Hex Hd. Screw, 3/8-16 x 2, Grade8.... 2

7 Bolo Tine-single. Left hand tine

usedon right side of tiller. (Incl.

two ea. Refs.1,9 and 10) ............... 8

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

-- Bolo Tine ReplacementSet(Incl. eight ea. right handand left handtines,

and sixteen ea. Refs. 1 and 3) ......... 1

712-0375 710-3096

GW-1270-1A

1902154010 1901118

REF. NO.

10 11

12 13

PART

No. DESCRIPTION QTY.

GW-2475-1

GW-2475-2

GW-10802

712-3017 736-0169 GW-9380

GW-9338 1917487

CustomTilling BoloTine, Left hand

tine (seeNote 1 above) ................... 8

CustomTilling BoloTine, Right hand

tine (seeNote 1 above) ................... 8

CustomTilling BoloTine Replacement

Set(Incl. eight ea. right handand left handcustom tines, and sixteen

eachof Refs. 1 and 3) ..................... 1

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

Lock Washer,3/8 ................................ 16

ClevisPin, .312 x 1-3/4 ...................... 2

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

Wheeland Tire Assembly ................... 2

* SpecifyGRADE5 if ordering part locally.

I Models 664D & E666M

ROW MARKER ATTACHMENT

2 m

8 8

) (See Detail A) \\

DETAILA

ROWMARKERATTACHMENT- 0EM-290-257 (Complete- Attaches to FurrowerAttachment)

MAIN SUPPORT/YOKEASSEMBLY

PART# 1904522001

BUMPER ATTACHMENT

BUMPER

0EM-290-254

Models 664D & E666M I

ROW MARKER ATTACHMENT & BUMPER ATTACHMENT

REF PART No. No. DESCRIPTION QTY.

Row Marker Attachment (option) - 0EM-290-254

1 1904522001 Main Support & YokeAssy-

complete. (Incl. Ref. No.'s

10,11,12,13,14,15,16,17 & 18) .......... 1

2 GW-1594 Marker Blade-blade only ................... 1

3 1904524001 Marker Arm-main arm ...................... 1

4 1904523001 Marker Arm-extension arm with

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

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

GW-1837)...................................... 1

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

avail, sep. (see hardware pkg.

GW-1837)...................................... 2

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

GW-1837)...................................... 1

8 GW-9828 Nut-hex, 10-24 w/attachedstart

washers, not avail,sep. (see

hardwarepkg #1837) .................... 2

9 1100135 Screw-round hd.,10-24 x 1, not

avail, sep. (see hardware pkg

GW-1837)...................................... 2

--- 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) ........ 1

REF PART No. No. DESCRIPTION QTY.

RowMarkerMainSupport& YokeAssembly- Part#1904522001

10 1186349 Screw-hexflangedlocking,

11 GW-1593 12 GW-1592 13 GW-1591

14 GW-1590 15 GW-1588 16 GW-1589 17 GW-9925 18 1186231

3/8-16 x 1-1/2". ............................ 1

Stop Bar ............................................ 1

Yoke.................................................. 1

Tube Key-square............................... 1

Washer-friction ................................. 2

Main Support .................................... 1

Washer-square hole.......................... 1

Washer-disc spring .......................... 1

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

19 1918749001

20 777S30653

21 710-3073

22 736-0119

23 712-0267

1918781

Bumper - 0EM-290-254

Bumper (includes Ref. 20) ................ 1

Decal- Caution........................................

Screw-hex hd., 5/16-18 x 2-1/4",

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

Lockwasher-5/16*, not avail.

separately(order #1918781

hardwarekit) ............................... 4

Nut-hex, 5/16-18", not avail.

separately(order #1918781

hardwarekit) ............................... 4

Hardware Kit: Incl. four each of

Refs.21,22 and 23 ....................... 1

Note: Common hardware listed aboveas"not availableseparately" can befound at most hardware stores.

* SpecifyGRADE5 if ordering part locally.

I Models 664D & E666M

HOOD, BRACKETand DEPTH REGULATOR

18 1 17

TRANSMISSION

REF. PART No. No. DESCRIPTION QTY.

1 1917605 Tine Hood (Incl. hoodflap and

Ref.17)............................................ 1

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

3 Bracket-hood & depth regulator

(Incl. Ref. No. 9)............................. 1

4 Hex FlangeScrew, 5/16-18 x 5/8". ..... 2

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

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

7 Spring ................................................. 1

8 Spacer................................................. 1

9 Roll Pin (spiral), 1/4 x 1 ..................... 1

10 Depth Adjustment BarAssembly

(Incl. Refs. 11 and 12) .................... 1

710-0169 GW-2527

1186328 712-0291 710-0597 GW-9384

GW-9534 1185469 GW-1117A

REF. PART No. No. DESCRIPTION QTY.

11 GW-9120 12 GW-9119 13 710-3005 14 GW-1113-1

15 712-0798 16 GW-20775 17 777S30649 18 GW-9553

19 710-0599

Retaining Ring(tolerance ring) ........... 1

Knob, DepthRegulator (Incl. Ref.11). 1

Hex Hd. Screw, 3/8-16 x 1-1/4". ......... 2

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

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

DragBar ............................................. 1

Decal,operating instructions .............. 1

Hex Hd. Screw, self-tapping,

5/16-18 x 1/2". ............................... 2

HexFlangeScrew, self-tapping,

1/4-20 x 1/2". ................................. 2

* SpecifyGRADE5 if ordering part locally.

Models 664D & E666M I

HILLER/FURROWER ATTACHMENT

4 \

12 8

(

10 ,

HILLER/FURROWER- 0EM-290-251

(Viewed from front of tiller)

REF. PART No. No. DESCRIPTION QTY.

1 2 3 4 5

6 7 8

1900771001 1186098 1177548 GW-9902 GW-9824

1900773001 1900774001 1900772001

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

CarriageBolt, 5/16-18 x 3/4 .............. 4

StarWasher, ExternalTooth, 5/16..... 4

PlainWasher, 5/16 S.A.E................... 4

Wing Nut, 5/16-18 ............................. 4

Hiller Wing, left.................................. 1

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

BladeMounting Bracket .................... 1

REF. PART No. No. DESCRIPTION QTY.

9 GW-9725 10 1100243 11 1186231 12 GW-9318

CarriageBolt, 3/8-16 x 1-1/2 ............. 2

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

Hex Nut,3/8-16, plated..................... 2

Clinch Pin .......................................... 1

I ModelE666M

(+l POSITIVE

BATTERY CABLE

GROUND WIRE

STARTER SOLENIOD ACTIVATE WIRE (RED)

STARTER WIRE (RED)

ENGINE WIRE (GREEN)

BATTERY RECHARGE f"_'___ WIRE (RED) _

/-e

(-) NEGATIVE

BATTERY CABLE

STARTER CABLE

GROUND CABLE TO ENGINE

ENGINE

Model E666M I

ELECTRIC STARTASSEMBLY

REF. PART No. No. DESCRIPTION QTY.

1 2 3 4 5

6 7

1186073 1186211

1186390 1186389 1901202

1901894 1908118

CarriageScrew, 1/4-20 x 1.25........... 2

HexNut, 5/16-24 ............................... 2

FlangeScrew, 1/4-20 x .625.............. 2

HexLocknut, 1/4-20 .......................... 2

Cable(ground wire to starter

motor bracket)............................... 2

RechargeWire Assembly .................. 1

Wire HarnessAssy. (availableas

complete assembly only). Incl. wire assy. w/connector to large

solenoid stud (red wire); wire assy.w/connector to small solenoid stud (red wire); wire

assy.w/connector to solenoid grounding screw (red wire); wire assyw/connector to engineground shut-off (greenwire); plastic

protector tube; wire terminal ......... 1

REF. PART No. No. DESCRIPTION QTY.

8 9

10 11 12 13

14 15 16 17 18 19

1917262 686-04024

710-0599 712-3006 725-0157 725-0267 725-1706

736-0119 736-0147 736-0607 GW-2614 96510

96514

97020 9853 777S30648

Ground WireAssy. (shut off) ............ 1

Battery BracketAssembly, Pony........ 1

Self-tapping Screw, 1/4-20 x .5......... 3

Hex Nut, 1/4-20 ................................. 2

CableTie............................................ 1

Ignition Switch .................................. 1

Battery, 270 CCA............................... 1

Lock Washer5/16 ............................. 2

Lock Washer,#10 ............................. 1

ExternalLock Washer,5/16............... 2

Keyswitch Clamp............................... 1

Cable(solenoid to starter motor) ...... 1

Solenoid (Incl. nuts and washers

for cables and wires) ..................... 1

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

Hex Locknut, #10-32 ......................... 1

Label, Ignition Switch........................ 1

TROY-BILT TILLER LIFETIME LIMITED WARRANTY

WHAT PRODUCT IS COVERED

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 LLC for the life of the tiller, to the original purchaser only.

WHAT IS COVERED BY THIS WARRANTY

Troy-Bilt LLC 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.

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

because of peril or other natural disaster.

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.

LIMITED COMMERCIAL USE WARRANTY

Parts that are not genuine Troy-Bilt LLC 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.

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.

HOW TO OBTAIN SERVICE

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 LLC at P.O. Box 361131, Cleveland, Ohio 44136-0019, 1-866-840-6483, or log on to our Web site at

www.troybilt.com.

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

purchased for commercial or other non-residential use).

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

implied warranty lasts, so the above exclusions or limitations may not apply to you.

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

For customer assistance, contact your nearest authorized dealer, or contact us at:

TROY-BILT LLC, P.O. Box 361131, Cleveland, Ohio 44136-0019, 1-866-840-6483

Troy-Bilt PONY 664DM, PONY E666M Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual