Troybilt TB90BC, 41BDT90C063, 41ADT90C063 Owner’s Manual

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Operator's Manual

2 -Cycle Gasoline

Brushcutter

Model TB90BC

IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY

P/N 769-00662 (3/03)

PRINTED IN USA

Page 2

Content Page

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

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

Z,now Your Unit ........................................................... 7

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

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

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

Operating Instructions ...................................................... 13

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

Cleaning and Storage ....................................................... 21

Accessories and Replacement Parts ........................................... 21

Troubleshooting Chart ...................................................... 22

Specifications ........................................................... 23

Warranty Information ....................................................... 26

Parts Dst .................................................... Inside Back Cover

NOTE: For users on U.S. Forest Land and in the states of California, Maine, Oregon and Washington. All U.S. Forest Land and the state of California (Public Resources Codes 4442 and 4443), Oregon and Washington require_ by law that certain internal combustion engines operated

on forest brush and/or grass-covered areas be equipped with a spark arrestor, maintained in effective working order, or the engine be constructed, equipped and maintained for the prevention of fire. Check with your state or local authorities for regulations pertaining to these

requirements. Failure to follow these requirements could subject you to liability or a fine, This unit is factory equipped with a spark arrestor, !f it requires replacement, Accessory Part #182747 Spark Arrestor Screen is available by contacting the service department.

This operator's manual is an important part of your new trimmer. It will help you assemble, prepare and maintain the unit for best performance. Please read and understand what it says.

Before you start assembling your new equipment, please locate the model plate on the equipment and copy the information from it in the space provided below. This information is very important if you need help from our Customer Support Department or an authorized dealer.

Serial Numb Model Number

ParentPertNumber

Copy the model and parent

part number here:

S/N: ITEM:

lilllllllllllBIllllHBIIIIIIIllllllll€opy,h0s0,,0,n0mborher0:

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 1-800-520-5520 to reach a Customer Support representative. Please have your unit's model number

f/_ and serial number ready when you call. See the previous section to locate this information. You will be asked

to enter the serial number in order to process your call.

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The purpose of safety symbols is to attract your attention to possible dangers. The safety symbols, and their explanations, deserve your careful attention and understanding. The safety warnings do not by

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

accident prevention measures.

SYMBOL MEANING

_ I L SAFETY ALERT SYMBOL: Indicates

NOTE: Advises you of information or instructions vital

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

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

to the operation or maintenance of the equepment.

SYMBOL MEANING

_;L DANGER: Failure to 0bey a safetywaming

_L WARNING: Failureto obey a safety

4Bli

_ ' L CAUTION: Failure to 0bey a safety warning

will result in serious injury to yourself or to others. Always follow the safety

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

warning Can result in injury to yourself and others. Always follow the safety

precautions to reduce the risk of fire,

electric shock and personal injury.

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

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

California Proposition 65 Warning:

THE ENGINE EXHAUST FROM THIS

PRODUCT CONTAINS CHEMICALS

KNOWN TO THE STATE OF CALIFORNIA

TO CAUSE CANCER, BIRTH DEFECTS

OR OTHER REPRODUCTIVE HARM.

READ ALL INSTRUCTIONS

BEFORE OPERATING

A WARNING:When usingthe unit, you must I A_I, follow the safety rules.For your own safety

and that of bystanders, please read these I

I instructions before operating the unit. I

P ease keep the nstruct ons for ater use. J

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

• Do not operate this unit when tired, ill or under the

influence of alcohol, drugs or medication.

• Children under the age of 15 must not use the unit; teens may operate the unit with adult guidance.

• Inspect the unit before use. Replace damaged parts.

Check for fuel leaks. Make sure all fasteners are in place and secure. Replace cutting attachment parts

that are cracked, chipped or damaged in any way.

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

attachment shield is properly attached, and positioned as recommended. Failure to do so can result in

personal injury to the operator and bystanders, as well as damage to the unit.

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

• Use only 0.105 inch (2.667 mm) diameter original equipment manufacturer's replacement line. Never use metal-reinforced line, wire, chain or rope. These can

break off and become dangerous projectiles.

• Clear the area to be cut before each use. Remove rocks, broken glass, nails, wire, string and other objects which

may be thrown or become entangled in the cutting attachment. Clear the area of children, bystanders and

pets; keep them outside a 50-foot (15 m.) radius, at a minimum. Even then, they are still at risk from thrown

objects. Encourage bystanders to wear eye protection. If you are approached, stop the unit immediately.

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

or repairs before using the unit.

SAFETY WARNINGS FOR GAS TRIMMERS

i_I WARNING: Gasoline is highly flammable, and ]

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

• Always stop the engine and allow it to cool before filling the fuel tank. Never remove the cap of the fuel tank, or add fuel, when the engine is hot. Never operate the unit without the fuel cap securely in place. Loosen the fuel tank cap slowly to relieve any pressure in the tank.

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

cap only after stopping engine. Do not smoke while fueling or mixing fuel. Wipe up any spilled fuel from the

unit immediately.

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

• Move the unit at least 30 feet (9.1 m) from the fueling source and site before starting the engine. Do not smoke. Keep sparks and open flames away from the

area while adding fuel or operating the unit.

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

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WHILE OPERATING

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

Operate this unit only in a well-ventilated outdoor area.

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

protection when operating this unit. Wear a face or

dust mask if the operation is dusty.

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

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

• The cutting attachment shield must always be in place

while operating the unit as a trimmer. Do not operate

unit without both trimming lines extended, and the proper line installed. Do not extend the trimming line beyond the length of the shield.

• This unit has a clutch. The cutting attachment remains stationary when the engine is idling. If it does not, have

the unit adjusted by an authorized service technician.

• Adjust the J-handle to your size in order to provide the best grip.

• Be sure the cutting attachment is not in contact with anything before starting the unit.

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

• Avoid accidental starting. Be in the starting position

whenever pulling the starter rope. The operator and

unit must be in a stable position while starting. Refer

to Starting/Stopping Instructions.

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

• Do not overreach. Always keep proper footing and balance.

• Always hold the unit with both hands when operating. Keep a firm grip on both handles or grips.

• Keep hands, face, and feet at a distance from all moving parts. Do not touch or try to stop the cutting

attachment when it rotates.

• Do not touch the engine, gear housing or muffler.

These parts get extremely hot from operation, even

after the unit is turned off.

• Do not operate the engine faster than the speed needed to cut, trim or edge. Do not run the engine at

high speed when not cutting.

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

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

damage. Do not operate before repairing damage. Do not operate the unit with loose or damaged parts.

• Stop the unit, switch the engine to off, and disconnect the spark plug for maintenance or repair.

• Use only original equipment manufacturer replacement parts and accessories for this unit. These are available

from your authorized service dealer. Use of any unauthorized parts or accessories could lead to

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

• Keep unit clean of vegetation and other materials. They may become lodged between the cutting

attachment and shield.

• To reduce fire hazard, replace a faulty muffler and spark arrestor. Keep the engine and muffler free from

grass, leaves, excessive grease or carbon build up.

WHILE OPERATING WITH CUTTING BLADE

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

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

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

• NEVER cut when the cutting blade is 30 inches (76 cm) or more above the ground level.

• Blade thrust may occur when the spinning blade contacts an object that it does not immediately cut.

Blade thrust can be violent enough to propel the unit and/or operator in any direction, possibly causing a

loss of control. Blade thrust can occur without warning if the blade snags, stalls or binds. This is more likely to

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

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

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

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

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

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

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

damage. Have any damage repaired before attempting further operations. Do not operate unit with a bent, cracked or dull blade. Discard blades that are bent,

warped, cracked or broken.

• Do not sharpen the cutting blade. Sharpening the blade can cause the blade tip to break off while in use. This can result in severe personal injury. Replace the blade.

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

severe personal injury to yourself or others may incur. Use the cutting blade only for the purpose described

in this manual.

• Stop the engine IMMEDIATELY if you feel excessive vibration. Vibration is a sign of trouble. Inspect thoroughly for loose nuts, bolts or damage before

continuing. Repair or replace affected parts as

necessary.

After Use

• Clean cutting blades with a household cleaner to

remove any gum buildup. Oil the blade with machine

oil to prevent rust.

• Lock up and store the cutting blade _nan appropriate area to protect the blade from unauthonzed use or

damage.

OTHER SAFETY WARNINGS

• Never store a fueled unit inside a building where fumes

may reach an open flame or spark.

• Allow the engine to cool before storing or transporting.

Be sure to secure the unit while transporhng.

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

prevent unauthorized use or damage, out of the reach

of children.

Never douse or squirt the unit with water or any other

iquid. Keep handles dry, clean and free from debris

Clean after each use see Cleaning and Storage

nstructlons

• Keep these instruct_ons. Refer to them often and use them to instruct other users. If you loan someone this

Jnit also loan them these instructions.

SAVE THESE INSTRUCTIONS

Page 6

SAFETY AND INTERNATIONAL SYMBOLS

This operator's manual describes safety and international symbols and pictographs that may appear On this product.

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

SYMBOL MEANING SYMBOL MEANING

• ON/OFF STOP CONTROL

Indicates danger, warning or caution.

• SAFETY ALERT SYMBOL O

May be used in conjunction with other

symbols or pictographs.

• WARNING - READ - Y,ilk_

OFF or STOP

• THROWN OBJECTS AND ROTATING CUTTER CAN

CAUSE SEVERE INJURY

O OPERATOR'S MANUAL / _-

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

all warnings and safety instructions.

Failureto do so can result in serious injury

to the operator and/or bystanders.

• WEAR EYE AND HEARING

WARNING: Thrown objects and loud

noise can cause severe eye injury and

PROTECTION

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

Use a full face shield when needed.

• KEEP BYSTANDERS AWAY

WARNING: Keep all bystanders,

especially children and pets, at least

50 feet (15 m) from the operating area.

• UNLEADED FUEL

Always use clean, fresh unleaded fuel.

• OIL Refer to operator's manual for the

proper type of oil.

• ON/OFF STOP CONTROL

ON /START / RUN

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

attachment.

• HOT SURFACE WARNING

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

unit is turned off.

• SHARP BLADE

WARNING: Sharp blade on cutting attachment shield. To prevent serious

injury, do not touch line cutting blade.

• BRUSHCUTTERS • REPLACE DULL BLADE

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

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

oTRIMMER/BRUSHCUTTER

SAFETY

WARNING: Thrown objects and rotating cutter can cause severe injury. Keep bystanders, especially children

and pets, at least 50 feet (15 m) away from the cutting area. The cutting

attachment shield must be used when using the trimmer cutting attachment.

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APPLICATIONS

As a trimmer:

• Cutting grass and light weeds

• Edging

• Decorative trimming around trees, fences, etc.

As a brushcutter:

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

diameter

Other optional accessories may be used with the TB90BC. Refer to Operating the EZ-Link System for a

list of add-ons.

Shoulder Strap Clip

Fuel Cap

\\\\

Starter Rope Grip

Shaft Grip -_

Throttle

Lock-Out

Throttle

Control

EZ.Start TM

Lever

Brush Blade

Gear Housing ._

Blade Shield /

Shield Mount

EZ.Link TM

Shaft

Housing

Cutting Attachment

Shield

J-Handle

Spark Plug

Engine Stand

Air Filter/Muffler

\ Muffler

Primer Bulb

Cover

Cutting Attachment

Line Cutting Blade

Page 8

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

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

INSTALL AND ADJUST THE J-HANDLE

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

(4)

Top Clamp J-Handle

Middle Clamp

INSTALL THE HARNESS

WARNING: Always use the shoulder I

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

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

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

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

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

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

Bottom Clamp Nuts_,_,

Fig. 1

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

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

only when assembled correctly.

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

4. Hold each hex nut in the bottom clamp recess with a finger. Start screws with a large Phillips screwdriver.

Do not tighten until you make the handle adjustment.

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

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

Fig. 2

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

the best grip.

)

Fig. 4

_ Support Fitting

Fig. 6

REMOVE AND INSTALL THE CUTTING ATTACHMENT SHIELD

Fig. 3

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

Remove the cuttingattachment shield when using the unit as abrushcutter

A WARNING: The cutting attachment shield _,lh, should NOT be installed when operating I

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

installing the blade. I

Remove the cutting attachment shield from the shield mount by removing the three (3)screws with a screwdriver (Fig. 7). Store parts for future use.

Page 9

Cutting

Attachment

Shield

Fig. 7

Screws

Gear Housing

Install the cutting attachment shield when using

the unit as a grass trimmer

WARNING: To avoid serious personal 1

injury, the cutting attachment shield MUST be in place at all times while operating the I

unit as a grass trimmer. J

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

Tighten securely with a screwdriver (Fig. 7).

REMOVE THE CUTTING ATTACHMENT AND INSTALL THE CUTTING BLADE

NOTE: To make cutting blade removal and installation easier,

place the unit onthe ground or on a work bench.

Remove the Cutting Attachment Shield

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

WARNING: The gear housing gets hot with 1

use. It can result in injury to the operator. I

The housing remains hot for a short time even after the unit is turned off. Do not I

touch thegear hous!ng until !thas coo!ed: J

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

3. While holding the locking rod, remove the cutting

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

NOTE: The blade retainer under the cutting attachment

will be used when installing the cutting blade.

Fig. 9

Cutting Attachment

Locking Rod

Slot

Locking Rod

Fig. 10

Install the Cutting Blade

WARNING: TOavoid serious personal

injury, always wear gloves while handling or installing the blade. I

4. Place the cutting blade on the output shaft bushing

(Fig. 11).

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

Output Shaft

Shaft Bushing Hole

LOC , RodS,ot

Output Shaft

Locking Rod

Fig. 8

Blade Retainer _ Nut

Cutting

Blade

Shield Mount

Pilot Hole

Output Shaft

Bushing

Locking Rod

Fig. 11

Page 10

5. Make sure that the cutting blade is centered on the pilot step and sitting f!at against the output shaft

bushing (Fig. 12),

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

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

may fly off, causing possible serious

I personal injury. I

Pilot Step

REMOVE THE CUTTING BLADE AND INSTALL THE CUTTING ATTACHMENT

WARNING: TOavoid serious personal

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

Remove the Cutting Blade

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

Hold the locking rod in place by grasping it next to

the boom of the unit (Fig. 14).

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

end or socket wrench (Fig. 14).

Fig. 12

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

(Fig. 8).

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

8. Tighten nut counterclockwise against the blade while holding the locking rod:

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

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

socket wrench, turning the nut until the blade retainer is snug against the shaft bushing. Make sure that the

blade is installed correctly, then rotate the nut an additional 1/4 to 1/2 turn counterclockwise (Fig. 13).

1/4-1/2 turn

Counterclockwise

Clockwise

Fig. 14

4. Remove the nut, blade retainer and blade. Store the nut and blade together for future use in a secure

place. Store out of children's reach.

Install the Cutting Attachment

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

Place the blade retainer on the output shaft with the fiat surface against the output shaft bushing (Fig. 15). Screw

the cutting attachment counterclockwise onto the output

shaft. Tighten securely.

NOTE: The blade retainer must be installed on the output

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

Cutting Attachment _

Blade Retainer.

Fig. 13

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

A I WARNING: TO avoid serious personal I

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

operate this unit with the locking rod in the

I locking rod slot.

WARNING: Do not sharpen the Cutting blade. 1

Sharpening the blade can cause the blade tip I

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

severe personal injury, Replace the blade, l

Output Shaft

Bushing

Locking Rod

Fig. 15

Remove the locking rod.

Install the cutting attachment shield. Refer to Remove

and Install the Cutting Attachment Shield.

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

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

Page 11

OIL AND FUEL MIXING INSTRUCTIONS

Old and/or improperly mixed fuel are the main reasons for the unit not running properly. Be sure to use fresh, clean unleaded fuel. Follow the instructions carefully for the proper fuel/oil mixture.

Definition of Blended Fuels

Today's fuels are often a blend of gasoline and oxygenates such as ethanol, methanol, or MTBE (ether).

Alcohol-blended fuel absorbs water. As little as 1% water in the fuel can make fuel and oil separate. It forms

acids when stored. When using alcohol-blended fuel, use fresh fuel (less than 60 days old).

Using Blended Fuels

If you choose to use a blended fuel, or its use is unavoidable, follow recommended precautions:

• Always use the fresh fuel mix explained in your operator's manual

• Always agitate the fuel mix before fueling the unit

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

Thoroughly mix the proper ratio of 2-cycle engine oil with unleaded gasoline in a separate fuel can. Use a 40:1

fuel/oil ratio. Do not mix them directly in the engine fuel tank. See the table below for specific gas and oil mixing

ratios.

NOTE: One gallon (3.8 liters) of unleaded gasoline mixed

with one 3.2 oz. (95 ml.) bottle of 2-cycle oil makes a 40:1 fuel/oil ratio.

UNLEADED GAS I 2 CYCLE OIL

1 GALLON US 3.2 FL OZ.

(3.8 LITERS) (95 ml)

1 LITER I 25 ml

Using Fuel Additives

The bottle of 2-cycle oil that came with your unit contains a fuel additive which will help inhibit corrosion and minimize the formation of gum deposits. It is recommended that you use our 2-cycle oil with this unit.

If unavailable, use a good 2-cycle oil designed for air-cooled engines along with a fuel additive, such as STA-BIL ®Gas Stabilizer or an equivalent. Add 0.8 oz. (23 ml.) of fuel additive per gallon of fuel according to the

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

A CAUTION: For proper engine operation and I

,_, I maximum reliability, pay strict attention to I

the oil and fuel mixing instructions on the 2-cycle oil container. Using improperly

m xed rue can severe y damage the eng ne.

MIXING RATIO - 40:1

WARNING: Gasoline is extremely

flammable. Ignited Vapors may explode.

,_, Always stop the engine and allow it to cool

before filling the fuel tank. Do not smoke

while filling the tank. Keep sparks and open flames at a distance from the area.

A WARNING: Remove fuel cap slowly to avoid I

,_" I injury from fuel spray. Never operate the unit

_wthoutthe rue cap securey n pace. J

WARNING: Add fuel in a clean, well ] ventilated area outdoors. Wipe up any |

spilled fuel immediately. Avoid creating a | source of ignition for spilt fuel. Do not start |

the engine until fuel vapors dissipate. |

NOTE: Dispose of the old fuel/oil mix in accordance to

Federal, State and Local regulations.

Page 12

I _ ] WARNING_ Operate this unit only in a well_

fumes can be lethal in a confined area.

WARNING: Avoid accidental starting. Make sure you are in the starting position when pulling the

starter rope (Fig. 18). To avoid serious injury, the operator and unit must be in a stable position while

To avoid serious personal injury, ensure any Add-On being used is installed correctly and secure before starting the unit.

ventilated outdoor area. Carbon monoxide exhaust

Start/On (I)

Throttle

Control

Fig. 16

STARTING INSTRUCTIONS

1. Mix gas with oil. Fill fuel tank with fuel/oil mixture. See Oil and Fuel Mixing Instructions.

NOTE: There is no need to turn the unit on. The On/Off

Stop Control is in the ON (I) position at all times.

_ ii_ ¸¸ 2.

Fully press and release the primer bulb 10 times, slowly. Some amount of fuel should be visible in the primer bulb and fuel lines (Fig. 17). If you can't

see fuel in the bulb, press and release the bulb as many times as it takes before you can see fuel in it.

Push the EZ-Start TM Lever to the left until it clicks and locks into place (Fig. 17).

Crouch in the starting position and do not squeeze the throttle control (Fig. 18). Pull the starter rope

up to 10 times briskly, (making sure the EZ-Start rM lever is pushed to the left).

i; i

When the engine starts, squeeze the throttle lock-out and then squeeze the throttle control for 15 to 30

seconds. This will warm up the unit. The EZ-Start TM Lever will click off automatically when you

il i!

squeeze the throttle control.

;......IF...The engine does not start, go back to step 2.

Primer

EZ-Start TM

Lever

Fig. 17

Starting

Position

................IF... The engine stops while you are squeezing the

throttle, go back to step 3.

IF... The engine stops before you squeeze the throttle

control, hold the throttle control and pull the starter rope until the trimmer starts.

WARM... If the outside temperature or engine

temperature exceeds 90° F and/or the engine repeatedly fails to start, fully squeeze the throttle control and pull the starter rope 3 to 8 more times.

The engine should start within these pulls.

STOPPING INSTRUCTIONS

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

2. Put the On/Off Stop Control in the OFF (O) position (Fig. 16).

Starter Rope

Throttle Control /

(Do NOT squeeze during

a standard start)

Fig. 18

Page 13

OPERATING THE EZ-LINK TM SYSTEM

The EZ-Link TM system enables the use of these optional Add-Ons:

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

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

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

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

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

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

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

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

_IWARNING: Read and understand the I

operator s manual rOt each add:0n prior to operation.

Removing the Cutting Attachment or Add-Ons

1. Turn the knob counterclockwise to loosen (Fig. 19).

2. Press and hold the release button (Fig. 19).

3. While firmly holding the upper shaft housing, pull the cutting attachment or add-on straight out of the

EZ-Link TM coupler (Fig. 20).

_IWARNING: T° avoid serious pers°nal injury I

and damage to the unit, shut offthe unit before remov ng or nsta ng add-ons.

2. While firmly holding the add-on, push it straight into the EZ-Link TM coupler (Fig. 20).

NOTE: Aligning the release button with the guide recess

will help installation (Fig. 19).

Release Button

EZ-LinkTMCoupler Hole

Upper Shaft Hous ng Lower Shaft Housing

Fig. 20

3. Turn the knob clockwise to tighten (Fig. 21).

CAUTION: Lock the release button in the primary hole and securely tighten the knob

before operat ng th sun t

90" Edging Hole _-

(Trimmer Only)

Installing the Cutting Attachment or Add-On NOTE: Place the unit on the ground or on a work bench

to make add-on installation or removal easier.

1. Turn knob counterclockwise to loosen (Fig. 20).

EZ'LinkTMC°upler Release Button

GuideRecess

Fig. 19

180"EdgingHole

(Trimmer Only)

Fig. 21

CAUTION: The cutting attachment and add-

ons with the EZ-LinkTM system are to be used i_ [he primary hole unless stated otherwise in the specific add-ons operator's manual. Using the

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

For edging (when using the line head cutting attachment

wtth EZ-Link TM models_ ock the release button of the cuttmg attachment into the 90° edging hole or the 180°

edging hole (Fig. 21).

Page 14

HOLDING THE TRIMMER

_[WARNING: Always wear eye, hearing, foot

Before operating the unit, stand in the operating position

(Fig. 22). Check for the following:

• The operator is wearing eye protection and proper clothing

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

is holding the shaft grip

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

• The unit is at waist level

and body protection to reduce the tisk of

njury when operat ng this un t.

Each time the head is bumped, about 1 inch (25.4 mm) of trimming line is released. A blade in the cutting attachment shield will cut the line to the proper length if

excess line is released. For best results, tap the Bump HeadTM on bare ground or

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

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

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

while the unit is running.

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

will make the clutch overheat. This may lead to

Jserous persona njury or damage to the un t. i

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

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

Fig. 22

ADJUSTING TRIMMING LINE LENGTH

The Bump HeadTM cutting attachment allows you to release trimming line without stopping the engine. To

release more line, lightly tap the cutting attachment on the ground (Fig. 23) while operating the trimmer at high speed.

NOTE: Always keep the trimming line fully extended.

Line release becomes more difficult as the cutting

line becomes shorter.

Some line breakage will occur from:

• Entanglement with foreign matter

• Normal line fatigue

• Attempting to cut thick, stalky weeds

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

TIPS FOR BEST TRIMMING RESULTS

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

• Keep the cutting attachment parallel to the ground.

• Do not force the cutting attachment. Allow the tip of the line to do the cutting, especially along walls.

Cutting with more than the tip will reduce cutting efficiency and may overload the engine.

• Cut grass over 8 inches (200 mm) by working from top to bottom in small increments to avoid premature line

wear or engine drag.

• Cut from left to right whenever possible. Cutting to the right improves the unit's cutting efficiency. Clippings

are thrown away from the operator.

• Slowly move the trimmer into and out of the cutting area at the desired height. Move either in a forward-

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

• Trim only when grass and weeds are dry.

• The life of your cutting line is dependent upon:

• Proper adherence of trimming techniques (explained above}

• What vegetation is cut

• Where vegetation is cut

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

Fig. 23

Page 15

DECORATIVE TRIMMING

Decorative trimming is accomplished by removing all

vegetation around trees, posts, fences and more.

Rotate the whole unit so that the cutting attachment is at

a 30° angle to the ground (Fig. 24).

_ ARNING: The blade Continues to Spin after

the engine is turned off. The coasting blade can seriously cut you if accidentally touched. I

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

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

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

upside down, and reinstalling it.

WARNING: Do not sharpen the cutting ] blade. Sharpening the blade can cause the |

blade tip to break off while in use. This can | result in severe personal injury to yourself |

or others. Replace the blade. ]

Fig. 24

USING THE CUTTING BLADE

body protection and the shoulder strap to

_[WARNING: Always wear eye, hearing, foot, '

_ ARNING: Do not Use the cutting blade

reduce the rsk of njury when operat ng this unt.

for edging or as an edger. Severe personal

njury to yourse f or others can resu t.

Before operating the unit with the cutting blade, stand in

the operating position (Fig. 25). Refer to Holding the

Trimmer.

Cutting Blade Operating Tips

To establish a rhythmic cutting procedure:

• Plant feet firmly, comfortably apart.

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

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

personal injury to the operator or others).

the spinning blade contacts an object that

WARNING: Blade thrust may Occur when it does not _mmediately cut. Blade thrust

can be violent enough to cause the unit and/or operator to be propelled in any

direction, and possibly lose control ofthe unit. Blade thrust can occur without

warning if the blade snags, stalls or binds. This is _nore likely to occur in areas where it

is difficult to see the material being cut.

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

• Cut at full throttle

• Swing the unit into material to be cut from your left to your right (Fig. 26)

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

[WARNING: Do not clear away any Cut ]

|material with the engine running or blade | |turning. To avoid serious personal injury, |

Iturn offthe engine. Allow the blade to stop |

|before removing materials wrapped around | |the blade shaft, l

Fig. 25

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

• Always release the throttle trigger and allow the engine

to return to idle speed when not cutting.

• When you are finished, always unsnap the unit from

the harness before taking off the harness.

Fig. 26

Page 16

MAINTENANCE SCHEDULE

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

NOTE: Some maintenance procedures may require

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

authorized service dealer.

NOTE: Maintenance, replacement, or repair of the

emission control devices and system may be performed by any non-road engine repair

establishment, individual or authorized service dealer.

In order to assure peak performance of your engine, inspection of the engine exhaust port may be necessary after 50 hours of operation. Ifyou notice lost RPM, poor performance or general lack of acceleration, this service may be required. If you feel your engine is in need of this

-WARNING: TO prevent serious injury, never 1 perform maintenance or repairs with unit I running. Always service and repair a cool unit.

Disconnect the spark plug wire to ensure that

the unit cannot start.

inspection, refer service to any non-road engine repair establishment, individual or authorized service dealer for

repair. DO NOT attempt to perform this process yourself as engine damage may result from contaminants involved in the cleaning process for the port.

FREQUENCY MAINTENANCE REQUIRED REFER TO

Before starting engine Fill fuel tank with fresh fuel Page 11 Every 10 hours Clean and re-oil air filter Page 18

Every 25 h0urs Check and clean spark arrestor Page 19

Check spark plug condition and gap Page 20

Every 50 hours Inspect exhaust port and spark arrestor screen for clogging or Page 19

LINE INSTALLATION

This section covers both SplitLine TM and standard single

line installation.

Always use original equipment manufacturer 0.105 in. (2.67 ram) replacement line. Other types of line may

make the engine overheat or fail.

obstruction to assure maximum performance levels

2. Remove the inner reel from the outer spool (Fig. 27).

3. Remove spring from the inner reel (Fig. 27).

4. Use a clean cloth to clean the the inner reel, spring, shaft and inner surface of the outer spool (Fig. 28).

5. Check the indexing teeth on the inner reel and outer spool for wear (Fig. 29). If necessary, remove burrs or replace the reel and spool.

line, wire, chain or rope. These can break I

I_[WARNING: Never use metal-reinforced I

off and become dangerous projectiles. I

There are two methods to replace the trimming line:

• Wind the inner reel with new line

• Install a prewound inner reel

Winding the Existing Inner Reel

1. Hold the outer spool with one hand and unscrew the Bump Knob clockwise (Fig. 27). Inspect the bolt inside

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

Spring

Inner Reel _ _ Bolt

Bump Knob _

Fig. 27

Fig. 29

Page 17

For Use with Single

Line ONLY

_ Slotted

Holes

For Use with SplitLineTM

or Single Line

Fig. 30

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

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

NOTE: Always use the correct line length when installing

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

Loop

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

small as possible (Fig. 33).

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

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

NOTE: Failure to wind the line inthe direction indicated will

cause the cutting attachment to operate incorrectly.

Fig. 33

12.

Insert the ends of the line into the two holding slots (Fig. 34).

13.

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

outer spool (Fig. 35). Push the inner reel and outer spool together. While holding the inner reel and outer

spool, grasp the ends and pull firmly to release the line from the holding slots in the reel.

Fig.31

Single Line Installation _.

Go To Step 8 for SplitLine TM Installation

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

the line through one of the two holes in the inner reel (Fig. 31). Pull the line through the inner reel so that the loop is as small as possible.

7. Wind the lines in tight even layers, onto the reel (Fig. 32). Wind the line in the direction indicated on

the inner reel. Place your index finger between the two lines to stop the lines from overlapping. Do not overlap the ends of the line. Proceed to step 11.

NOTE: The spring must be assembled on the inner reel

before reassembling the cutting attachment.

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

Fig. 32

SplitLine TM Installation

8. Take approximately 20 feet (6.1 m) of new trimming line. Insert one end of the line through one of the two holes in the inner reel (Fig. 33). Pull the line through

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

Slots

Fig. 34

Fig. 35

Page 18

INSTALLING A PREWOUND REEL

1. Hold the outer spool with one hand and unscrew the bump knob clockwise (Fig. 27). Inspect the bolt inside the bump knob to make sure it moves freely. Replace the bump knob if damaged.

2. Remove the old inner reel from the outer spool (Fig. 27).

3. Remove the spring from the old inner reel (Fig. 27).

4. Place the spring in the new inner reel. NOTE: The spring must be assembled on the inner reel

before reassembling the cutting attachment.

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

outer spool (Fig. 35).

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

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

7. Hold the inner reel in place and install the bump knob

by turning counterclockwise. Tighten securely.

Replacement Parts

See Accessories / Replacement Parts.

AIR FILTER MAINTENANCE

Cleaning the Air Filter Clean and re-oil the air filter every 10 hours of operation.

It is an important item to maintain. Failure to maintain the air filter will VOID the warranty.

1. Remove air filter/muffler cover. Refer to Removing

the Air Filter/Muffler Cover.

2. Turn cover over and look inside to locate the air filter. Remove the air filter from inside the air filter/muffler

cover (Fig. 37).

3. Wash the filter in detergent and water (Fig. 38). Rinse

the filter thoroughly. Squeeze out excess water. Allow

it to dry completely.

4. Apply enough clean SAE 30 oil to lightly coat the filter (Fig. 39).

5. Squeeze the filter to spread and remove excess oil (Fig. 40).

Removing the Air Filter/Muffler Cover

"" I always turn your trimmer off and allow i[ to

I A I WARNING: TO avoid serious personal injury, I

I cool before you clean or service it.

1. Remove the four (4) screws securing the air filter/muffler cover (Fig. 36). Use a flat blade or

T20 Torx bit screwdriver.

2 Pull the cover from the engine. Do not force.

EZ-StartT_

Lever

Screws

_ rm

L I I I

I I I /

Screws

Fig. 36

Air Filter

V II II II II

/ Inside Muffler

Cover

Fig. 37

Fig. 39 Fig. 40

Fig. 38

6. Replace the air filter inside the air filter/muffler cover (Fig. 37).

NOTE: Operating the unit without the air filter and air

filter/muffler cover assembly will VOID the warranty.

Page 19

Reinstalling the Air Filter/Muffler Cover

1. Place the air filter/muffler cover over the back of the carburetor and muffler. Align the screw holes.

2. Insert the four (4) screws into the holes in the air filter/muffler cover (Fig. 36) and tighten.

Do not over tighten.

SPARK ARRESTOR MAINTENANCE

1. Remove air filter/muffler cover. Refer to Removing

the Air Filter/Muffler Cover.

2. Locate muffler front and the two (2) bolts securing it to the engine (Fig. 41). Remove the two (2) bolts using a fiatblade screwdriver or 5/16-inch socket or nut driver. Pull muffler off of the engine.

3. Turn muffler over to the back side and locate the exhaust gasket. Remove the muffler gasket from the

muffler (Fig. 41).

NOTE: If the exhaust gasket is torn or damaged, replace

it with a new gasket before reassembling muffler.

4. Using a small flatblade screwdriver, carefully pry up the spark arrestor from the recessed hole (Fig. 42).

Remove the spark arrestor from the muffler.

5. Clean the spark arrestor with a wire brush. Replace it if it is damaged or if it is impossible to clean thoroughly (Fig. 42).

6. Reinstall the spark arrestor by pressing it into the recessed hole on the muffler's back side. Make sure

it fits tightly against the muffler and is not raised up.

7. Place the exhaust gasket against muffler's back side. Align the gasket bolt holes with the bolt holes in the

muffler. While holding exhaust gasket in place, insert the bolts into the muffler's front side (Fig. 41).

8. Place the muffler (with the exhaust gasket in place and bolts inserted), against the engine, aligning the

bolt holes. Tighten the bolts to secure the muffler to the engine.

If using a torque wrench, torque to:

80-90 in.,Ib. (9-10.2 N,m)

Muffler - Front Side

Spark

Arrestor

Muffler - Back Side

Fig. 41

Fig. 42

Spark Exhaust

Arrestor Gasket

Muffler - Back Side

Flatblade

Screwdriver

Spark Arrestor

I_[WARNING: Ifthe muffler is n0t tightened I

the unit and possible serious personal _njury J

9. Reinstall the air filter/muffler cover.

securely, it could fall off causing damage to

Page 20

CARBURETOR ADJUSTMENT

The idle speed of the engine is adjustable through the air filter/muffler cover (Fig. 43).

NOTE: Careless adjustments can seriously damage your

unit. An authorized service dealer should make carburetor adjustments.

Check Fuel Mixture

Old and/or improperly mixed fuel is usually the reason for improper unit performance. Drain and refill the tank

with flesh properly-mixed fuel pnor to making any adJustments. Refer to Oil and Fuel Information.

Clean Air Filter The condition of the air filter is important to the operation

of the unit. A dirty air filter will restrict air flow and change the air/fuel mixture. This is often mistaken for an

out of adjustment carburetor. Check the condition of the air filter before adJusting the idle speed screw. Refer to

Air Filter Maintenance.

Adjust Idle Speed Screw

If. after checking the fuel mixture and cleaning the air

filter, the engine still will not idle, adjust the idle speed screw as follows:

1. Start the engine and let it run at a high idle for a m_nute to warm up. Refer to Starting/Stopping

Instructions.

A WARNING: The cutting attachment may be AL_, spinning during idle speed adjustments.

Wear protective clothing and observe all I

safety instructions to prevent serious persona njury.

2. Release the throttle trigger and let the engine idle. If the engine stops, insert a small phillips or flat blade screwdriver into the hole in the air filter/muffler cover (Fig. 43). Turn the idle speed screw in, clockwise,

1/8 of a turn ate time (as needed) until the engine

idles smoothly.

NOTE: The cutting attachment should not rotate when

the engine idles.

3. If the cutting attachment rotates when the engine idles, turn the idle speed screw counterclockwise

1/8 of a turn at a time (as needed), to reduce idle speed.

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

problems. If not and:

• the engine will not idle

• the engine hesitates or stalls on acceleration

• there is a loss of engine power

Have the carburetor adjusted by an authorized service dealer.

[ jl_ [WARNING: TO prevent serious personal ]

.. | injury, make sure the cutting attachment |

| has stopped rotating before you turn it off |

and set it down. ]

REPLACING THE SPARK PLUG

Use a Champion RDJ7Y spark plug, or equivalent. The correct airgap is 0.020 inch (0.5 ram}. Remove the plug

after every 25 hours of operation and check its condition.

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

Clean around the spark plug. Remove the spark plug

from the cylinder head by turning a 5/8-inch socket

counterclockwise.

Replace a cracked, fouled or dirty spark plug. Set

the air gap at 0.020 in. (0.5 ram) using a feeler gauge

(Fig. 44).

clean electrodes. Grit in the engine could

CAUTION: Do not sand blast, scrape or damage the cy nder.

Fig. 43

Idle Speed Screw

4. Install a correctly-gapped spark plug in the cylinder head. Tighten by turning the 5/8-inch socket

clockwise until snug.

If using a torque wrench torque to:

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

Fig. 44

Page 21

CLEANING

_1_ WARNING: TOavoid serious personal injury, I "_, Ialways turn your trimmer off and allow it tO I

[_[COO before you c ean or serv ce t. [ i i 1

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

contain aromatic oils such as pine and lemon, and solvents such as kerosene, can damage plastic housing

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

STORAGE

• Never store a fueled unit where fumes may reach an open flame or spark.

• Allow the engine to cool before storing.

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

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

• Store the unit out of the reach of children.

LONG TERM STORAGE

If you plan on storing the unit for an extended time, use

the following storage procedure:

1. Drain all fuel from the fuel tank into a container with

the same 2-cycle fuel mixture. Do not use fuel that has been stored for more than 60 days. Dispose of

the old fuel/oil mix in accordance to Federal, State and Local regulations.

2. Start the engine and allow it to run until it stalls. This

ensures that all fuel has been drained from the carburetor.

3. Allow the engine to cool. Remove the spark plug and

put 1 oz. (30 ml) of any high quality motor oil or 2-cycle oil into the cylinder. Pull the starter rope slowly to distribute the oil. Reinstall the spark plug.

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

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

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

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

TRANSPORTING

• Allow the engine to cool before transporting.

• Drain fuel from unit.

• Tighten fuel cap before transporting.

• Secure the unit while transporting.

ACCESSORIES/REPLACEMENT PARTS

2-Cycle Oil ............................. 147543

Spark Plug .............................. 610311

Spark Arrestor ........................... 182747

Replacement Line ..................... 753-04216

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

Inner Reel Spring ........................ 610636

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

Inner Reel .............................. 147495

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

Fuel Cap ............................... 180000

Shoulder Strap .......................... 682075

For specific replacement parts, refer to the parts list located on the inside back cover of this manual.

Page 22

CAUSE Empty fuel tank Primer bulb wasn't pressed enough

Engine is flooded

Old or improperly mixed fuel

Fouled spark plug Plugged spark arrestor EZ-Start lever wasn't flipped/set

! |

CAUSE

Air filter is plugged Old or improperly mixed fuel

Improper carburetor adjustment

ACTION Fill fuel tank with properly mixed fuel Press primer bulb fully and slowly 10 times

Squeeze the trigger and pull the starter rope Drain gas tank and add fresh fuel mixture Replace or clean the spark plug

Clean or replace spark arrestor

Move lever to the starting position

ACTION

Replace or clean the air filter Drain gas tank and add fresh fuel mixture

Adjust according to the Carburetor Adjustments section

CAUSE

Old or improperly mixed fuel

Improper carburetor adjustment

Cutting attachment bound with grass

Dirty air filter Plugged spark arrestor

CAUSE

Old or improperly mixed fuel

Improper carburetor adjustment Fouled spark plug Plugged spark arrestor

CAUSE Cutting attachment bound with grass Cutting attachment out of line

Inner reel bound up

Cutting head dirty

Line welded Line twisted when refilled

Not enough line is exposed

ACTION

Drain gas tank and add fresh fuel mixture

Take to an authorized service dealer for an adjustment

Stop the engine and clean the cutting attachment

Clean or replace the air filter Clean or replace spark arrestor

ACTION

Drain gas tank and add flesh fuel mixture

Take to an authorized service dealer for an adjustment

Replace or clean the spark plug

Clean or replace spark arrestor

ACTION

Stop the engine and clean cutting attachment Refill with new line

Replace the inner reel

Clean inner reel and outer spool

Disassemble, remove the welded section and rewind Disassemble and rewind the line

Push the bump knob and pull out line until 4 inches

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

CAUSE ACTION Oil, cleaner or lubricant in cutting head Clean and thoroughly dry the cutting head

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

Page 23

Engine Type ........................................................................................................................................... Air-Cooled, 2-Cycle

Stroke ..................................................................................................................................................... 1.25 in. (31.75 mm)

Displacement .............................................................................................................................................. 1.9 cu in. (31 cc)

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

Idle Speed RPM ....................................................................................................................................... 2,800 - 4,000 rpm

Operating RPM .................................................................................................................................................. 7,200+ rpm

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

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

Spark Plug Gap ........................................................................................................................................ 0.020 in. (0.5 mm)

Lubrication ................................................................................................................................................... Fuel/Oil Mixture

Fuel/Oil Ratio .................................................................................................................................................................. 40:1

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

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

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

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

Fuel Tank Capacity ........................................................................................................................................ 13 oz. (385 ml)

Drive Shaft Housing .......................................................................................................................... Steel Tube, EZ-Link TM

Throttle Control ................................................................................................................. Finger-Tip Trigger with Lock-Out

Approximate Unit Weight (No fuel, with J-handle, cutting attachment and shield) ................................. 14.75 Ibs. (6.5 kg)

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

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

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

Trimming Line Diameter ...................................................................................................................... 0.105 inch (2.67 mm)

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

Cutting Path Diameter, Cutting Blade ..................................................................................................... 8 inches (204 mm)

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

*All specifications are based on the latest product information available at the time of printing. We reserve the right to

make changes at any time without notice,

Page 24

Page 25

EPA Emission Control Warranty Statement

Your Warranty Rights and Obligations

The Environmental Protection Agency and Troy-Bilt LLC (Troy-Bilt) are pleased to explain the emission control system

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

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

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

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

Where a warrantable condition exists, Troy-Bilt will repair your small off-road engine at no cost to you including

diagnosis, parts and labor.

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

defective, the part will be repaired or replaced by Troy-Bilt.

Owners Warranty Responsibilities

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

operator's manual. Troy-Bilt recommends that you retain all receipts covering maintenance on your small off-road engine, but Troy-Bilt cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of

all scheduled maintenance.

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

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

modifications.

• You are responsible for presenting your small off-road engine to a Troy-Bilt Authorized Service Center as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

If you have any questions regarding your warranty rights and responsibilities, you should call 1-800-520-5520.

Manufacturer's Warranty Coverage

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

• The manufacturer warrants to the initial owner and each subsequent purchaser, that the engine is free from defects in material and workmanship which cause the failure of a warranted part for a period of two years.

• Repair or replacement of warranted part will be performed at no charge to the owner at an Authorized Troy-Bilt Service

Center. For the nearest location please contact Troy-Bilt at: 1-800-520-5520.

• Any warranted part which is not scheduled for replacement, as required maintenance or which is scheduled for only

for regular inspection to the effect of "Repair or Replace as Necessary" is warranted for the warranty period. Any warranted part which is scheduled for replacement as required maintenance will be warranted for the period of time up

to the first scheduled replacement point for that part.

• The owner will not be charged for diagnostic labor which leads to the determination that a warranted part is defective, if the diagnostic work is performed at an Authorized Troy-Bilt Service Center.

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

under warranty.

• Failures caused by abuse, neglect or improper maintenance are not covered under warranty.

• The use of add-on or modified parts can be grounds for disallowing a warranty claim. The manufacturer is not liable to

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

• In order to file a claim, go to your nearest Authorized Troy-Bilt Service Center. Warranty services or repairs will be provided at all Authorized Troy-Bilt Service Centers.

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

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

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

obligations of the manufacturer

• The following components are included in the emission related warranty of the engine, air filter, carburetor, primer, fuel lines, fuel pick up/fuel filter, ignition module, spark plug and muffler.

Page 26

ENGINE PARTS - MODEL TB90bc

2-CYCLE GAS TRIMMER/BRUSHCUTTER

Item

2 3 4

5 6 7 8 9

10 11

12 13

14 15

16 17 18

19 20 21

22 23 24 25 26

27 28 29

Part No.

753-1192

791-180350B 79%180351

753-1193 753-1194

753-04338 791-610675 791-181860 79%683974B

753-1196 791-684451 753-1208

753-04369

791-612134 753-04307

791-182612 791-181168 753-04233

791-145308 791-182064 791-182736 791-181065

753-1199 753-04286 753-1200 791-181247

791-181079 791-613103 753_1201

753-1202

Description

Air Cleaner/Muffler Cover Assembly (includes 2 & 37) Air Cleaner Filter

Carburetor Mounting Screw Assembly Choke Extension

Choke Plate Carburetor Assembly (includes 7 & 18)

Carburetor Gasket Carb Mount Screw

Primer and Hose Assembly Carb Mount Assembly (includes 8 & 11)

Reed Assembly Carburetor Mount Gasket

Crank Case Service Assembly (includes 8)

Rear Mounting Pad Fuel Tank Assembly (includes 16-18) Fuel Cap Assembly

Fuel Return Line Fuel Line Assembly

Front Mounting Pad Shroud Extension & Stand (includes 37)

Flywheel Assembly Spacer Recoil Pulley Recoil Spring

Rope Guide Pulley Retainer

Pull Handle Rope

Pressure Plate Assembly (includes 30) Plate Screw

Item Part NO. Description

31 753q203 Starter Housing Assembly

(includes 23_30, 32 & 37)

32 79%181862 Housing Screw 33 79%182368 Clutch Washer

34 791q 82369 Clutch Rotor Assembly 35 791-153592 Clutch Drum Assembly

36 753q 204 Clutch Cover Assembly

(includes 37-40)

37 79%181345 Cover Screw 38 791_182519 Anti-Rotation Screw

39 753_04003 Clamping Screw 40 79%180217 Clamping Nut

41 791_182798 Wire Leads and Sleeve 42 791_611063 Ground Tab

43 753_04337 Module Assembly 44 79%610311B Spark Plug

45 791_182066 Muffler Assembly (includes 46-48) 46 791_182747 Spark Arrestor Screen

47 753_04159 Exhaust Gasket 48 791_147575 Muffler Mounting Bolt Assembly

49 753_04323 Cylinder Assembly (includes 51 & 52) 50 753_1207 Piston and Rod Assembly 51 753_1197 Cylinder Gasket

52 79%182723 Cylinder Bolt

79%180090 O.E.M, Carburetor Repair Kit 791_180091 Gasket Diaphragm Repair Kit

753-1209 Piston Ring Set 753_04334 Short Block Assembly

(includes& 12, 13, 44, 47_52)

791q81599 Clutch Springs (Qty. 2)

Items Not Shown

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Page 27

Item Part NO. Descri#tion

1 753*04118 Throttle Housing & Trigger

Assembly (includes 2*5)

2 791-00041 Throttle Trigger Lock*Out 3 753*04119 ThrotBe Trigger 4 791-182690 Throttle Trigger Spring 5 791-182405 Switch Assembly

6 753*04136 ThrotBe Cable 7 791-610327 Harness Clip

8 753*04236 Upper Drive Shaft Housing Assembly 9 791-181099 J-Handle Assembly (includes 10 & 11)

10 791-612831 Grip 11 791-612021 Tube Closure

12 791-683295 Handle Bracket Assembly (includes 13-18) 13 791-181811 Screw

14 791-181812 Upper Handle Clamp 15 791-181813 Middle Handle Clamp 16 791-181814 Lower Handle Clamp

17 791-181815 Nut 18 791-145569 AntFRotation Screw

19 791-181980 Split-Boom Coupler (includes 20*23) 20 791-182057 Screw

21 791-181617 Bolt 22 791-181981 Adjustment Knob

23 791-181886 Knob Retaining Nut 24 791-180804 Lower Drive Shaft Housing Assembly 25 791-613300 Lower Flexible Drive Shaft

26 791 *182200 Shield Mount Screw Assembly 27 791-182193 2 piece Gearbox Assembly (includes 28-30)

28 791-182195 Gearbox Mounting Hardware 29 791-145569 AntFRotation Screw

30 791-182196 Blade Driver 31 791-147492 Blade Shield/Shield Mount

32 791 *683304 Shield Mounting Screw 33 791 *683299 Shield and Blade Assembly (includes 34)

34 791 *682061 Blade Assembly 35 791-147490 Retaining Washer 36 791-612483 Spool Shaft 37 791 *683301 Outer Spool and Eyelet Assembly

38 791-612026 Retainer 39 791-610636 Spring

40 791-147495 Inner Reel 41 791-180814 Bump Head Knob Assembly

42 791-145873 4-Tooth Blade 43 791-181699 Nut

791-180014 Blade Retaining Kit (includes 35 & 43) 791-613226 Locking Rod Tool 791 *682075 Shoulder Harness

2 Piece Gearbox Assembl_ Parts - Item 27

44 791-182191 Left Housing 45 791-182192 Right Housing

46 791-182194 Pinion Gear Assembly 47 791-182199 Output Shaft Bushing 48 791-182198 Output Shaft Gear

49 791-182197 Output Shaft Assembly (includes 46 & 47) 50 753*04348 Palnut

791-180120 Replacement Line,

791-147345B Reel and Line Assembly 791q47498B Bump Head Assembly

Optional Accessories __

791q47543 Ryobi 2*Cycle Oil

Items Not Shown

0.095 Diameter

(includes 36_41)

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Page 28

TROKBILT

n n mII m n

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

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

Troy-Bilt LLC warrants this product against defects in

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

commencing on the date of original purchase and will, at its option, repair or replace, free of charge, any part found to

be defective in material or workmanship. This limited warranty shall only apply if this product has been operated and maintained in accordance with the Operator's Manual furnished with the product, and has not been subject to

misuse, abuse, commercial use, neglect, accident,

improper maintenance, alteration, vandalism, theft, fire, water or damage because of other peril or natural disaster.

Damage resulting from the installation or use of any accessory or attachment not approved by Troy-Bilt LLC for

use with the product(s) covered by this manual will void your warranty as to any resulting damage. This warranty is

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

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

purpose.

HOW TO OBTAIN SERVICE: Warranty service is available, WITH PROOF OF PURCHASE THROUGH YOUR LOCAL AUTHORIZED SERVICE DEALER. To locate

the dealer in your area, visit our website at www.troybilt.com, check for a listing in the Yellow Pages, call 1-800-520-

5520 or write to P.O. Box 361131, Cleveland, OH 44136-

0019.

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

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

Filters

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

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

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

products sold or exported outside of the United States of America, its possessions and territories, except those sold through Troy-Bilt's authorized channels of export distribution.

Troy-Bilt LLC reserves the right to change or improve the

design of any Troy-Bilt Product without assuming any

obligation to modify any product previously manufactured.

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

applies after the applicable period of express written warranty above as to the parts as identified. No other

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

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

the Warranty, the exclusive remedy is repair or replacement of the product as set forth above. (Some

states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to

you.)

The provisions as set forth in this Warranty provide the

sole and exclusive remedy arising from the sales. Troy- Bilt LLC shall not be liable for incidental or

consequential loss or damages including, without limitation, expenses incurred for substitute or

replacement lawn care services, for transportation or for related expenses, or for rental expenses to

temporarily replace a warranted product. (Some states

do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.)

In no event shall recovery of any kind be greater than the amount of the purchase price of the product sold.

Alteration of the safety features of the product shall void this Warranty. You assume the risk and liability for loss,

damage, or injury to you and your property and/or to others and their property arising out of the use or misuse

or inability to use the product. This limited warranty shall not extend to anyone other than

the original purchaser, original lessee or the person for whom it was purchased as a gift.

How State Law Relates to this Warranty: This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

To locate your nearest service dealer dial 1-800-520-5520.

Troy-Bilt LLC

RO. Box 361131

Cleveland, OH 44136-0019