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:

SECTION 1: GENERAL INFORMATION

TRAIL BLAZER MOWER

TECHNICAL MANUAL

Page 7

3/90

Taking the Mower Out

0-'

Storage

The following instructions explain what you must doinorder to ready a TRAIL BLAZER®

Mower for use after it has been stored according to the storage instructions

in

the Owner/Operator

Manual.

1. Charge the battery. See Section
5 of the Owner/Operator Manual for
instructions.

2. Thoroughly inspect the mower for
any loose, broken, or missing com­ponents. Repair them as necessary.

3. Check all bolts to ensure that they
are tight.

4.

Add fuel to the fuel tank.

5. Check the oil level, adding oil
inecessary.

6.

Remove the spark plug.

7.

Inspect the spark plug to see if any
oilispresentonthe plug's electrode.
the plugisfouled, cleanitor replace
Then reinstall the plug.
8 Make sure the spark plug wire
securely connected to the spark plug.
9 Check the tire pressure. The tires

is

should have a pressure of 10 to 20 PSI.
Equally inflate or deflate the tires as
necessary Don't over-inflate the

..

tires

If

NOTE: After you start the engine,

it.

you may see white smoke. This
the oil in the cylinder burning off.
This white smoke will soon disap-

pear.

is

TRAIL BLAZER MOWER

TECHNICAL MANUAL

Page 8 3/90

WARNING: When servicing the mower, prevent unintentional starting of the engine by dis-

connecting the spark plug wire and keeping the wire away from the spark plug. Place the

A

engine throttle lever
released.

SECTION

in

its OFF position and make sure that the two handlebar levers are

2:

PRE-SERVICE INSPECTION

Engine

leaks
tube/cap.

use
Then
to

bletostrip
the

tube

drain

Engine Oil Drain

this
tions.

Wheel

ward.

If

make

not
Owner/Operator Manual
tions.
wheels

Spark Arrester

damagedorrusted.

Cable

the
pinching

Oil

Drain

Tube

Fill

the

engine

from

a pairofplierstotighten

tighten

over-tighten

engine.

If

oil

still leaks after

and

cap,

the

oil.

manual

Assembly

Push

the

The

the

wheelsdonot

sure

adjusted

Also

are

Make

sure

Guard

Make

sure

engine

the

with

the

engine

If

oil

leaks

the

cap.

the

oil

the

aluminum threads

remove

See

Servicing

Tube

for reinstallation instruc-

mower forward

mower

the

not

deck)isnot

should

move

wheel drive

too

tight.

make

sure

obstructed.

the spark arresterisnot

the

cable

blade drive

from

tube;itis

and

Cap

oiltoseeifoil
oil

drain

this

area,

the

tube.

Be

you

the

and

(See

that

guard

bent

cable.

careful

cap

roll
easily,

for

tighten

and

the

Cap

and

easily.

cable

the

instruc-

the

(below

and

not

possi-

in

in

back-

is

Decals

Make

sure

allofthe
decals
Replace
or

• A

the

the

• A control
tions/warning
panel

• A
the

• A stabilization
left

• A danger
deflector.

• A danger

• A
ward

•
left-hand
plate.

• A
belt

•
tion
electric start

• A battery instruction/warning
on
els

• A TRAIL BLAZER® Mower
decalonthe

are

present

any

unreadable.

blade

drive lever

right

hand

panel

between

wheel

drive lever

left

hand

hand

grip.

single

danger

portionofeach

An

oil

drain

sideofthe

warning

cover.

An

engine

decal

near

the

rear

hood

only).

decals that

grip.

decalonthe

the

grip.

decalonthe

decalonthe

location

decalonthe

ignition

the

models

hood.

following

and

readable.

are

missing

decalinfront

operating instruc-

control

handlebars.

decalinfront of

decalinfrontofthe

weed

hood.

decalonthe

side

decalonthe

engine deck

switch

keyswitch

only).

(electric start

for-

plate.

wheel

identifica-

(for

decal

mod-

logo

drive

Tires

Make

sure that

ly

inflatedto10-20

that

both

tires

Also

make

ter

and

the

both

of

wheel

Cables

Make

sure

cable

and
crimped.
move
adjusted
throttle
engine

Cutter

•
bar
attached.

•

Make

place.

•

Make
See
tightening instructions.

•

Make
cutter bar mounts

•

Make
height adjuster
ledger bar

Make

•
fastenedtothe

Grease

Make
on
on
place

Make

freely

properly.
cableisconnectedtothe
and

Bar

Make

sure

areinplace

sure

sure

the

Owner/Operator

sure

sure

sure

Fittings

sure

the

cutter bar support

the

drive

andingood condition.

the

PSI.

areingood

sure

that

the

clevis

pin

areinplace

hubs.

that

the

wheel drive

sure

both

and

that

the

Make

thatitoperates

all

rivetsonthe

and

securely

all

the

blades

the

blades

the

bolts that

are

the

nuts

to

the

backofthe

are

tight.

the

drive

cutter

bar.

the

two

arm

assembly

tires

are

equal-

Make

sure

condition.

hair

pin

cot-

in

blade

drive

cable

are

not

levers

cables

tightly secured.

that secure the

pinissecurely

grease fittings

sure

that the

properly.

cutter

are

are

tight.

Manual

hold

and

the one

are

are

in

for

the

in

SECTION 3: SERVICING THE MOWER

TRAIL BLAZER MOWER

TECHNICAL MANUAL

Page 9 3/90

This section, SERVICING THE MOWER,discusses repair procedures that are not included

the TRAIL BLAZER® Mower Owner/Operator Manual.

A WARNING: When servicing the mower, prevent unintentional starting of the engine by discon-

~

Servicing the Drive Arm

These instructions describe how to service the drive arm assembly.

these instructions.

See Section 5 of the

Owner/Operator Manual, Cutter Bar

Drive Belt Removal

Steps 1 through 5 under removal for
instructions on removal of the drive

arm assembly.

Disassembling the Drive

You
arm to replace the drive arm pivot
bearings and drive arm spacer.
find out if the bearings and spacer
need to be replaced, grab the drive

arm near the pivot point and rock the
drive arm side to side and check for

play. See Figure 2 for

You

arm before proceeding with these

instructions.

1. Remove the lower (internal) snap

(1)

ring
pivot bearings.

2.

Remove the upper (internal) snap

ring

(2)

pivot bearings.

3.

Remove the two drive arm pivot
bearings (3) and the drive arm spacer
(4).

You

these bearings by hand or you may

have to carefully press them out.

Inspecting the Drive

These instructions describe how to
inspect vital parts on the drive arm
assembly.
the parts you have removed, you

necting the spark plug wire and keeping the wire away from the spark plug. Place the engine

in

throttle lever

and

would disassemble the drive

an

must first remove the drive

that retains the drive arm

that retains the drive arm

may be able to remove

In

addition to inspecting

its OFF position and make sure that the two handlebar levers are released.

See Figure 1 as a reference for part locations

Installation,

Arm

To

illustration.

Arm

should also inspect any replacement
parts you will use.

NOTE: Thoroughly degrease and

clean all parts (except the bearings)

before inspection.

Channel Bolt Holes

The four channel bolt holes should
be just large enough to fit the bolt.
Replace the drive arm if the bolt holes
have elongated.

Also, there should be no cracks

the drive arm leading out from the
channel bolt holes. Replace the drive
arm if there are any fatigue cracks.

Channel

Check the entire channel for

cracks.
cracks, replace

If

the channel has any

it.

Grease Fitting

Make sure the grease fitting on the

front of the drive arm is
Grease the fitting to make sure it
works correctly.
grease coming out of the tube on the
front of the
of the grease gun.

driv.e

in

place.

You

should see

arm after two pumps

Welds

Inspect the welds that hold the

drive socket holder and the bearing

retainer to the drive

the welds are sound - that there are

in

no cracks

them.

arm.

Make sure

Drive Socket Holder

Make sure the hole in the drive
socket holder has not expanded.
Insert a new drive socket
socket holder and move the socket

If

back and forth.
.020" play, replace the drive arm.

you find more than

Assembling the Drive Arm.

1. Install the lower drive arm pivot

You

bearing (3).
the bearing

in

need to press it
sealed bearing, it does not need to be
lubricated.

2.

Install the drive arm spacer (4)

3.

Install the upper drive arm pivot
bearing (3).
the bearing
need to press it
sealed bearing, it does not need to be
lubricated.

4. Install the upper (internal) snap
ring (2) that retains the drive arm
pivot bearings.

5.

Install the lower (internal) snap
ring (1) that retains the drive arm
pivot bearings.

may be able to push

in

by hand or you may

in.

Since thisisa

You

may be able to push

in

by hand or you may

in.

Since thisisa

Installing the Drive Arm

See Section 5 of the

Owner/Operator Manual, Cutter

Drive Belt Removal and Installation,

Steps 6 through 9 for drive arm
assembly installation instructions.

in

the drive

in

in

bar

TRAIL BLAZER MOWER

TECHNICAL MANUAL

Page 10 3/90

SECTION

3:

SERVICING THE MOWER

Figure 1: Drive Arm Assembly.

Figure 2: Testing the Drive Arm Pivot Bearing.

SECTION

3:

SERVICING THE MOWER

Servicing the Wheel Shaft.

TRAIL BLAZER MOWER

TECHNICAL MANUAL

Page

11

3/90

These

these

Removing the Wheel Shaft See Figure

See

Owner/Operator Manual,

Wheel

under removal, for instructionsonhow slackwhile you are pressing the and down. If the wheel shaft moves
to

remove

Inspecting the Wheel Shaft

These

inspection of vital parts

shaft assembly.

ing

the
should
parts

NOTE:

clean

inspection.

Drive Belt

The belt should not be frayed,
stretched, or excessively worn. Look
at the belt near the idler pulley. If the
two sides of the belt are touching or
are nearly touching, replace the belt.

instructions describe servicing

instructions. The numbersinparenthesis

Section 5 of the Engage the Wheel Drive Lever. If sary to obtain this tolerance.

Removing

Drive

Belt,

Steps 1through

the wheel shaft. Wheel Drive Lever, readjust the at all,

instructions describe the

on

the wheel

In

additiontoinspect-

parts

you

have removed,

also inspect any replacement

you

will

use.

Thoroughly degrease and

all

parts (except the belt) before

the

10

you

the

wheel

the beltisproperly adjusted, the belt • Grab the wheel shaft and try

shouldbeunder tension. If the belt

wheel drive system. If there

ther adjustment

replace the belt. (See the wheel shaft section that rests

Owner/Operator Manual.) bushing; it may be worn. If the wheel

Wheel Shaft Sprocket

Check for signs of sprocket wear

If the sprocket

should also be replaced.

Checking the Wheel Shaft for

Play

After you install the wheel shaft,

check it for

• Check the wheel shaft for end
There shouldbeno
end

play.

shaft.

refertoitem

4.

in

is

worn, the chain

play.

The wheel shaft should

See

Figure3asareference

numbersinthe

isnofur- bushing (1). If playispresent after

both adjusters, replacing the bushing, inspect the

more than .030"

play.

for

part

figure.

spin freely. Add shims

is

moveitforward and backward and

you

should replace the axle

shaft

is

worninthis area, replace the

wheel shaft.

Installing the Wheel Shaft

See Section 5 of the

Owner/Operator Manual,

Drive Belt Removal and Installation,

Steps 5 through11under installation
for instructions
bly installation.

on

drive arm assem-

locations

(1)

as neces-

Cutter Bar

to

in

the

in

up

Figure 3: Wheel Shaft and Jackshaft.

TRAIL BLAZER MOWER

TECHNICAL MANUAL

Page 12

3/90

SECTION

Servicing the Jackshaft

These instructions describe how to service the jackshaft.

instructions.

Removing the Jackshaft

See Section 5 of the

Owner/Operator Manual, Removing

and

Installing the Wheel Drive Belt,

Steps 1 through 10 under removal
for instructions on jackshaft removal.

Inspecting the Jackshaft

These instructions describe

inspecting vital parts of the jackshaft

In

assembly.
the parts you have removed, you
should also inspect any replacement
parts you will use.
NOTE: Thoroughly degrease and
clean all parts before inspection.

addition to inspecting

Jackshaft Sprocket

Check for signs of sprocket wear.
If the sprocket must be replaced,
also replace the chain.

Checking the Jackshaft for
Play

• After you install the jackshaft,
check it for play.

• Check the jackshaft for end play.
There should be no more than .030"
end play. Also, the jackshaft should
spin freely. Add shims (2) as neces­sary to obtain this tolerance.

Grasp the jackshaft and try to
move it forward and backward and
up and down. If the jackshaft moves
more than .030" you should replace
the bushing (3). If play is present

3:

SERVICING THE MOWER

See Figure 3 as a reference for part locationsinthese

after replacing the bushing, inspect
the jackshaft section that rests
bushing; it may be worn. If the sec­tion of the jackshaft that rests
bushing is worn, replace the jack­shaft.

in

Installing the Jackshaft

See Section 5 of the

Owner/Operator Manual, Removing

and

Installing the Wheel Drive Belt,

Steps 4 through 12 for jackshaft
installation instructions.

in

the

the

PTO Pulley

Figure4:Checking

Jackshaft Pulley

Wheel Drive Belt Wear.

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SECTION

3:

SERVICING THE MOWER

TECHNICAL MANUAL

Page 13

3/90

Servicing the Flywheel

These instructions describe how to service the flywheel.
engaging the Blade Drive Lever, you hear a knocking noise, which indicates that the bearings are bad. See Figure 6
as a reference for part locations

in

these instructions. The numbersinparenthesis refer to item numbersinthe figure.

You

would check the bearing on the flywheel if, when

Removing the Flywheel remove the bearing by hand. Then while you put another wrench

on

Bearings remove the flywheel pin shim (10). flywheel bolt (4). Then remove the

nut and bolt.

6.

There are two kinds of bearings

the flywheel:

Flywheel Bearing

The flywheel has to be removed to
remove this bearing.
remove this bearing by hand. Then
remove the flywheel shim (7).

You

can

Eccentric Bearing

You

can remove the bearing while
the flywheel is still
remove this bearing you must first
take off the snap ring (9). Then

in

the mower.

Removing the Flywheel

on

Assembly

1. Remove the drive arm. See

Section 5 of the Owner/Operator

Manual,

Removal

through 5 under removal.

2.
the cutter bar drive belt
the mower. Then remove the cutter
bar drive belt cover.

3.

To

4. Lift the cutter bar drive belt over

the flywheel. If the tension

wheel belt

the belt over the flywheel, relax the

tension

upper or lower cutter bar drive cable
adjusters. See Section 5 of the
Owner/Operator Manual,

Drive Initial Setting, Steps 1 and

5.

retaining nut

Cutter

Bar

Drive Belt

and

Installation, Steps 1

Remove the bolts

Remove the left side belt guide pin.

is

such that you cannot lift

on

the belt by loosening the

Put a wrench on the flywheel

(3)

(1)

and hold the nut

that secure

cover

(2)

on

the fly-

Cutter

to

Bar

3.

Discard the flat washer (5).

7. Lift the flywheel off.

8.

Remove the flywheel bearing

and discard the flywheel shim (7).

9.

Remove the (external) snap ring

(8)

that retains the eccentric bearing.

10. Remove the eccentric bearing
and discard the flywheel pin shim
(10).

Inspecting the Flywheel

These instructions describe how to

inspect vital parts

assembly.
the parts you have removed, you
should also inspect any replacement
parts you will use.
NOTE: Thoroughly degrease and

clean all parts (except the bearings)

before inspection.

on

the flywheel

In

addition to inspecting

the

(6)

(9)

Figure5:The Flywheel Installation.

'--,0

TRAIL BLAZER MOWER

TECHNICAL MANUAL

Page 14

3/90

SECTION

3:

SERVICING THE MOWER

Bearings

If a bearing has a bluish color

indicates a lack of lubrication; replace
the bearing. Both bearings are a
press fit - it
on

the flywheel before pressing them
out. Check the eccentric bearing by
turning its outside race with your fin­gers. Check the flywheel bearings by
rotating the flywheel by hand.
However, if you have already
removed the bearings check them as
follows: Pinch the bearing's inner
race and spin it. If you hear a growl­ing noise, if the bearing doesn't spin,
if the bearing feels tight or if the
bearing wobbles as it spins, replace
the bearing.

is

easier to check them

it

Cutter Bar Drive Belt

This inspection must be performed
before you remove the flywheel.
Engage the Blade Drive Lever and
observe the belt. If the belt
under tension and the blade drive
cable

is

properly adjusted, then the
belt has stretched and you must
replace it. See Section

Belt Drive Removal

in

the Owner/Operator Manual for

instructions.

Also check the belt for cracks and

wear.

and

is

not

5,

Cutter Bar

Installation,

Flywheel Pin

Make sure the pinonwhich the
eccentric bearing sits has no rough
edges or burrs.

Check the pin and the casting

around the pin for cracks.

Use a piece of 200 grit emery

cloth, if necessary, to smooth the pin.
Then apply a small amount of grease
to the pin to hellp prevent rust.

Flywheel Bolt

Make sure there arenoflat spots

on

the bolt

If

there are any flat spots, replace the
bolt. Also, make sure the threads
the bolt are not stripped.

Thoroughly check the flywheel bolt
for any cracks or signs of deteriora­tion. Replace a damaged bolt.

(4)

that holds the flywheel.

on

Installing the Flywheel
Assembly

1. Install a new flywheel pin shim
(10).

2.

Press fit the eccentric bearing (9).

3.

Install the (external) snap ring

that retains the eccentric bearing.

4.

Install the flywheel shim

5.

Install the flywheel bearing
first pressing the bearing onto the bolt
and then pressing the bolt/bearing
into the flywheel.

6.

Position the flywheelinplace on

the mower's chassis.

7.

Install a new flat washer
thread the flywheel retaining nut
on

the flywheel bolt (4).

8.

Tighten the flywheel bolt
to 200 ft.-Ibs.

9.

Move the cutter bar drive belt back
onto the flywheel. Make sure the cut­ter bar drive belt's tension
See Section 5 of the Owner/Operator
Manual,

Setting.

10. Install the left belt guide pin.

11. Install the cutter bar drive belt
cover
secure the cutter bar drive belt cover
to the mower.

Cutter BarDrive Initial

(2)

and tighten the bolts

is

(7).

(6)

(5)

and

(4)

to 180

correct.

(1)

(8)

by

-

(3)

that

SECTION

3:

SERVICING THE MOWER

TRAIL BLAZER MOWER

TECHNICAL MANUAL

Page 15 3/90

•

Removing

These instructions describe

The numbers in parenthesis refer to item numbers in the figure.

Removing the Engine

1. Disconnect the throttle cable from

the engine.

2.

Remove

that secure the wheel drive belt

(2) to the mower. Then remove the

belt cover.

3. Remove the hex head bolts (3)

that secure the cutter
cover (4) to the mower. Then remove

the belt cover.

4. Remove the cutter
(4A).

5. Loosen and remove the

that secures the crankshaft pulley to
the engine. Also remove

washer
nal) snap ring (8) .

6. Remove the crankshaft pulley (9)

and cutter

7. Using a pair

cotter key (13) from

(14).

8. Remove the
PTO belt guide (15).

9 Loosen and remove the three bolts

(11) that secure the engine to the
mower.

10. Lift the engine off the mower's

engine deck.

the

(6), flat

bar

and

hex head screws (1)

bar

bar

washer

drive pulley key (10).

of

pliers, remove the

the

PTO

pulley and the

Installing the Engine

how

cover

drive belt

belt

guide

screw

the

disc

(7), and (inter-

PTO

pulley

to remove and install the engine. Use Figure 7 as a reference for part locations.

Installing the Engine

1. Place the engine back onto the

mower deck.

2. Place the engine mount spacers

(12) and washers between the engine

and the engine deck. Install the three
bolts (11) and the three belleville
washers that secure the engine to the
mower. Tighten these bolts to 25

~.

3. Make sure the belt washer is on

the PTO shaft. Install the PTO belt
guide (15) and the PTO pulley (14).

4. Install the cotter key (13) into the

(5)

PTO pulley 14.

5. Install the cutter

key (10) and the crankshaft pulley (9).
Then install the (internal) snap ring
(8), the flat washer (7), the disc wash­er

(6), and the screw (5) that secures
the crankshaft pulley to the engine.
Reinstall the cutter bar belt guide
(4A).

6. Install the cutter
cover (4a) with the bolts (3).

7. Install the wheel drive belt cover
(2) and the hex head screws (1) that
secure it to the mower.

8. Attach the throttle cable to the
engine.

To

make sure the belts are proper-

9.
ly connected, remove the
hood and inspect the belts.

10. Add oil to the engine (if needed),
start the engine, and

of

ation
drive levers. Adjust the blade drive
system and the wheel drive system if
necessary. (See Section 5,
Maintenance,
Manual.)

the wheel drive and cutter

bar

bar

of

the Owner/Operator

drive pulley

drive belt

mower

check

the oper-

ft..-

bar

SerVicing the Engine Oil Drain
Tube and Cap

If you see oil leaking from the oil

drain tube/oil drain cap, you will have

cap

to make sure the tube and
properly tightened. Tips for tightening
the tube/cap are:

the

• Use loctite on
the tube. Install and tighten the tube
first. Then wrap teflon tape around
the lower threads on the tube. Install
and tighten the cap. Don't try to tight­en the tube by tightening the
is attached to it. If you do, the next
time you remove the
oil you will also remove the tube and
oil will spill on the belt.

• Do not over tighten
possible to strip the aluminum
threads in the engine.

• When removing the oil drain cap,
use a pair
drain tube to
move.

of

pliers to hold the oil
make

upper

cap

the

sure it doesn't

are

threads of

cap

that

to drain the

tube. It is

TRAIL BLAZER MOWER

TECHNICAL MANUAL

Page 16 3/90

12)----~

SECTION

3:

SERVICING THE MOWER

----~@

----~

*

11

*

*-----<.:=:::;...

Figure6:Engine Removal/Installation.

INDEX

TRAIL BLAZER MOWER

TECHNICAL MANUAL

Page 17 3/90

A

Air Pressure Tires 8
Arrester, Spark 8

B

Bearing, Drive Arm 13
Bearing, Eccentric 13
Bearing, Flywheel 13, 14
Belt, Cutter Bar 14
Belt, Wheel Drive

11

C

Cable Guard, Inspection ' 8
Cables, Inspection 8
Channel, Drive Arm 9
Cutter Bar Inspection 8

D

Decals 8
Drive Arm Assembly

Assembling 9
Disassembling 9
Inspection 9

Drive Socket Holder 9

J

Jackshaft

Inspection 12
Removal 12

M

Maintenance 9 - 16

o

Off-Season Storage 7

p

Parts 3
Pre-Service Inspection 8

Q

Quick Reference Guide 6

S

Safety Instructions .4
Spark Arrester 8
Sprocket, Jackshaft
Storage, removal of mower from 7

11

E

Engine

Installation 15
Remova 15

Engine Oil Drain Tube

& Cap 8

F

Flywheel

Inspection 13
Installation 13

Removal. 13
Flywheel Bolt 14
Flywheel Pin 14

G

Grease Fittings 8
Inspecting

Drive arm assembly 9
Flywheel. 13, 14

Jackshaft 12

Wheel Shaft

11

T

Tires, Air Pressure 8

w

Wheel Shaft

Inpection
Installation
Removal

11

11
11

•

.'

MN1390590

:

Printed

in

the USA ©1990 Garden Way Inc.

..