Troy Bilt Trail Blazer Technical Manual
o
T-."D~BILT
Technical
Manual
Trail
Sicklebar
Blazer®
Mower
GARDEN WAY INC.
TRAIL BLAZER MOWER
TECHNICAL MANUAL
Page 2 3/90
TABLE OF CONTENTS
Page
No.
SECTION 1: General Information 2
Safety
Quick
Taking
First
Reference Guide....... 6
the
Mower
Out
of
Storage 7
4
SECTION
SECTION
Servicing the Drive Arm 9
Servicing the Wheel Shaft
Servicing the Jackshaft 12
Servicing the Flywheel 13
Removing and Installing the Engine 14
Servicing the Engine Oil Drain Tube and Cap 15
2:
Pre-Service Inspection 8
3:
Servicing the Mower 9
Disassembling
Inspecting
Assembling
Installing
Removing
Inspecting
Drive
Belt
Checking
Installing
Removing
Inspecting
Jackshaft
Checking
Installing
Removing
Removing
Inspecting
Bearings
Cutter
Flywheel
Flywheel
Installing
Removing
Installing
Bar
the
Drive
Arm
the
Drive
Arm
the
Drive
Arm.................................. 9
the
Drive
Arm................................................................................................................. 9
the
Wheel
the
Wheel
the
Wheel
the
Wheel
the
Jackshaft
the
Jackshaft
Sprocket
the
Jackshaft
the
Jackshaft
the
Flywheel
the
Flywheel
the
Flywheel 13
Drive
Pin
Bolt
the
Flywheel
the
Engine
the
Engine
Belt
Shaft
Shaft
Shaft
Shaft.
for
Bearings
Assembly
Assembly
for
Play
Play
; 9
9
11
11
11
11
11
11
12
12
12
12
12
13
13
14
14
14
14
14
14
15
INDEX 17
SECTION 1: GENERAL INFORMATION
TRAIL BLAZER MOWER
TECHNICAL MANUAL
Page 3
3/90
• This Manual provides service
information for the TRAIL SLAZER®
Sickle Sar Mower built by TROY-
SILT Manufacturing Company, Troy,
New York. Use this Manual for mowers with serial number Y00001 00
and up.
• All information, illustrations, and
specifications contained in this
Manual are based on the latest information available at the time of publication. The right
changes at any time without notice.
If you have any questions concerning the information contained
Manual, please contact:
Technical Service Department
TROY-SILT Manufacturing Company
102nd St.
Troy, New York 12180
Call Toll-Free: 1-800-833-6990
is
reserved to make
& 9th Ave.
.
in
this
This symbol is used to
A alert you to important safety
..
Owner/Operator Manual, and on
decals affixed to the mower. When
you see this symbol, carefully read
and follow its safety message.
Failure to do so could result
sonal injury or property damage.
• This Manual is divided into three
sections as shown
Contents. For best results, read
each section
performing the procedure.
• This Technical Manual
to be used
Owner/Operator Manual. The
Owner/Operator Manual contains
additional service and maintenance
information that is not covered in this
messagesinthis Technical
in
Manual,
in
the
in
per-
in
the Table of
in
its entirety before
is
designed
combination with the
Technical Manual. Refer to the
"Quick Reference Guide"on Page 6
for a listing of the service and maintenance topics that are covered
the Owner/Operator Manual.
• Service and maintenance
information regarding engines is not
covered
mation can be obtained by consulting
the Service Repair Manuals available
from the engine manufacturer.
should, however, call our Technical
Service Department with questions
concerning engine replacement.
• Throughout this Manual, you will
see references to the left and right
side of the mower. This refers to the
left and right sides of the mower as
you would see them when you are
standing
in
this Manual. Such infor-
in
the operator's position.
in
You
TRAIL BLAZER MOWER
TECHNICAL MANUAL
Page 4
3/90
SECTION
1:
GENERAL INFORMATION
Safety First!
When working on the mower or its engine, closely follow operating instructions and safety practices at all times.
Failure to do so could result
keep in mind at all times when doing repair work:
in
personal injury or property damage. Here are some basic safety precautions you should
KNOW THE MOWER AND ENGINE!
Read the Owner/Operator Manual
carefully. Be sure you know what
each mower and engine control does
before you attempt to operate
Read and follow all safety rules.
Never allow inexperienced persons or
children to operate the mower or its
engine.
WEAR PROPER APPAREL!
Don't wear loose clothing orjewelry
that could get caught
of the mower or its engine.
AVOID MOVING PARTS!
Keep hands, feet, hair, clothing,
and tools safely away from moving
parts when the engine is running.
AVOID ACCIDENTAL STARTING!
Prevent unintentional starting by
disconnecting the spark plug wire and
keeping the wire away from the spark
plug. Place engine controls
OFF
position and make sure that both
handlebar levers are not engaged
(make sure they are released).
WEAR EYE PROTECTION!
Safety goggles or a face shield
should be worn whenever there is the
possibility of danger to the eyes from
flying parts or particles.
PREVENT FIRES AND EXPLOSIONS!
Gasoline is highly flammable and
explosive.
stored with extreme caution. Keep
gasoline away from open flames and
sparks. Do not smoke near gasoline
cans or fuel tanks. Do not add gasoline to a fuel tank when the engine is
running or still hot (wait until the
engine has cooled before adding
fuel). Fill the fuel tank outdoors
It
should be used and
in
it.
moving parts
in
the
in
a
well-ventilated area. Store gasoline
a cool, well-ventilated place, safely
away from any spark or flame producing equipment.
Store only
tainer. Make sure this container
safely out of reach of children. Wipe
off any spilled gasoline and move the
engine away from gasoline fumes
before starting the engine.
Use cleaning solvents only according to recognized safety practices
(never use gasoline as a cleaning sol-
vent). Oily rags and waste should be
packed
metal safety container to prevent fire
from spontaneous combustion.
HANDLE BATTERIES WITH CARE!
Do not charge the battery while the
engine is running or hot.
Before charging the battery, disconnect the spark plug wire and make
sure it cannot accidentally touch the
spark plug during charging. Also
remove the engine ignition key from
the keyswitch (electric start models
only).
Use only the battery charger pro-
vided with the mower.
Do not allow the battery wires to
touch each other.
metal object that
battery wire to touch another metal
object that is
battery wire.
Do not place the battery
tight container when charging the battery.
Remove all rings and metal jewelry
when working on the battery or electrical system.
AVOID ENGINE EXHAUST FUMES!
Do not run the engine
enclosed area. Exhaust gases con-
tain carbon monoxide, an odorless
in
a U.L. approved con-
in
a U.L. approved covered
Do
not allow a
isincontact with a
in
contact with the other
in
in
an
is
an air-
in
and deadly poison. Provide adequate
ventilation at all times. After running
the engine, don't touch the muffler or
other hot engine parts until they have
cooled down.
HANDLE PARTS CAREFULLY!
With continued use, the teeth on
sprockets or other moving parts may
wear to sharp, knife-like edges.
Therefore, when handling these parts,
always use care to avoid cutting your-
self.
USE GENUINE TROY-BILT
REPLACEMENT PARTS!
Replacement parts manufactured
by others could present safety hazards even though they may fit on this
mower.
KEEP UNAUTHORIZED PERSONNELAWAY!
Keep the area of operation clear of
all persons (particularly small children)
and pets. Stop both the cutter bar
blade and the wheel drive when you
are approached by any child, inatten-
tive person, or pet.
LEAVE GUARDS AND SAFETY
DEVICES IN PLACE!
Never attempt to disconnect or
remove guards or other safety
devices, or to defeat the purpose of
them.
CHECK OPERATION OF HAND
LEVERS BEFORE EACH USE!
Before each use, check the operation of the handlebar levers. See
Section
Owner/Operator Manual for specific
instructions. Do not use the
either handlebar lever is not functioning properly.
4,
Mower Operation,inthe
mower
if
SECTION 1: GENERAL INFORMATION
TRAIL BLAZER MOWER
TECHNICAL MANUAL
Page 5 3/90
KEEP CHILDREN AWAY WHEN
OPERATING THE MOWER!
Keep children out of the mowing
area. Keep them under the watchful
eye of an adult other than the person operating the mower. Never
assume that children will remain
where you last saw them.
LOOK BEHIND WHEN BACKING
THE MOWER UP!
Before you back the mower up,
and while you're backing it up, be
sure to look behind you for small
children.
KEEP HANDS AND FEET
FROM MOVING PARTS!
Do not put hands or feet near or
under any moving parts. Keep clear
of the cutter bar at all times when the
engine is running.
AWAY
SHUT MOWER OFF WHEN PERFORMING ANY MAINTENANCE!
Before inspecting, cleaning,
adjusting, or repairing the mower or
cutter bar: 1) stop the engine,
connect the spark plug wire and prevent it from touching the spark plug,
3) wait for all moving parts to stop,
and
4) reinstall the plastic blade pro-
tector on the blade. On electric start
models, also remove the Engine
Ignition key from the keyswitch.
2) dis-
TRAIL BLAZER MOWER
TECHNICAL MANUAL
Page 6 3/90
Quick Reference Repair Index
SECTION 1: GENERAL INFORMATION
Informationonthe
Air Filter
Air Pressure, Tires
Battery Removal
Belts
Cutter Bar
Wheel Drive
(See this Technical Manual for additional
information.)
Blade Drive Lever
Blade Guide Adjustment
Carburetor
Cutter Bar
Adjustment
Assembly
Removing
Drive Arm
Removal
Installation
(See this Technical Manual for additional
information.)
Engine
Ignition Switch
(See this Technical Manual for additional
information. )
Throttle Lever
Fuel
Grease Points
Handlebar Height Adjustment
Lubrication Points
Motor Oil
Oil
Adjustment1
1
following
topics
canbefoundinthe
Operation
Ordering Parts
PreStart Checklist
Recoil Starter
Spark Plug
Specifications
Starting
Storage for Off-Season
Throttle Lever, Engine
Tire Pressure
Troubleshooting
Wheel Drive Lever
Wheel Shaft
Removal (In Section 5 of the Owner/Operator
Manual, "Removing and Installing the Wheel
Drive Belt", removal Steps 1 through 10)
Installation (In Section 5 of the Owner/Operator
Manual," Removing and Installing the Wheel
Drive Belt", installation Steps 4 through 12)
Jackshaft
Removal (In Section 5 of the Owner/Operator
Manual, "Removing and Installing the Wheel
Drive Belt" removal steps 1 through 10)
Installation (In Section 5 of the Owner/Operator
Manual, "Removing and Installing the Wheel
Drive
TRAIL
(See this Technical Service Manual for addition
al information.)
(See this Technical Manual for additional
mation)
BLAZER®
1
1
Belt",
installation Steps 4 through 12)
Owner/Operator
Manual:
in
for
Information
Cutter Bar
Drive Belt Guide
Rubber Bushing and Drive Pin
(See the Owner/Operator Manual for more
information.)
Drive Arm Assembly
Disassembly
Inspecting
(See the Owner/Operator Manual for more
information.)
Engine
Removal
Drain Tube and Cap Replacement
(See the Owner/Operator Manual for more information.)
on
the
following topics
canbefoundinthis
1 Also see Engine Owner's Manual.
TRAIL BLAZER®
Flywheel
Jackshaft
Checking For Play
Inspecting
Shimming
Pre-Service Inspection
Weed Deflector and Support
Wheel Shaft
Checking For Play
Inspecting
Shimming
(See the Owner/Operator Manual for more
information.)
Technical
Manual:
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