Troy-Bilt 12214 - 5.5HP User manual

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$4.50

GARDEN

WAY

”

Owner’s

Manual

REAR-TINE

TILLERS

•

Safety

•

Assembly

•

Controls

•

Operation

•

Maintenance

•

Parts

List

Models

12214-5.5HP

12193-6.5

HP

GARDEN

WAY

INCORPORATED

Table

of

Contents

Dear

Owner:

You

now

own

one

of

the

finest

counter-rotating-tine

(CRT)

tillers

available.

Your

tiller

provides

excellent

sod

busting

and

seedbed

preparation,

making

it

ideal

for

starting

new

gardens

and

for

a

variety

of

landscaping

jobs.

Your

tiller

is

well-known

for

its

ruggedness,

performance

and

high-

quality

engineering.

We

know

you’ll

enjoy

using

it.

Please

carefully

read

this

Manual.

It

tells

you

how

to

safely

and

easily

assemble,

operate

and

maintain

your

machine.

Be

sure

that

you

and

any

other

operators

carefully

follow

the

recommended

safety

practices

at

all

times.

Failure

to

do

so

could

result

in

personal

injury

or

property

damage.

Of

course,

if

you

should

ever

have

any

problems

or

questions,

please

contact

your

local

authorized

dealer

or

call

the

Factory

(see

back

cover

of

this

manual).

We

want

to

be

sure

that

you

are

completely

satisfied

at

all

times.

NOTE:

Be

sure

to

fill

out

and

return

the

Warranty

Registra¬

tion

Card

that

was

supplied

with

this

Manual.

See

Back

Cover

for

Customer

Service

Information

Safety

Alert

Symbol

This

is

a

safety

alert

symbol.

It

is

used

in

this

manual

and

on

the

unit

to

alert

you

to

potential

hazards.

When

you

see

this

symbol,

read

and

obey

the

message

that

follows

it.

Failure

to

obey

safety

messages

could

result

in

personal

injury

or

property

damage.

This

machine

meets

voluntary

safety

standard

B71.8

-

1996,

which

Is

sponsored

by

the

Outdoor

Power

Equipment

Institute,

Inc.,

and

is

published

by

the

American

National

Standards

Institute.

A

WARNING

The

engine

exhaust

from

this

product

contains

chemicals

known

to

the

State

of

California

to

cause

cancer,

birth

defects

or

other

reproductive

harm.

SECTION

1:

SAFETY.

3

Safety

Decals.

5

SECTION

2:

ASSEMBLY....

6

Attach

Handlebar.

7

Move

Tiller

Off

Shipping

Platform.

7

Install

Fonward

Clutch

Cable.

8

Install

Reverse

Clutch

Cable.

9

Check

Level

of

Transmission

Gear

Oil.

9

Add

Motor

Oil

to

Engine.

9

Check

Hardware

for

Tightness.

9

Check

Air

Pressure

in

Tires.

9

SECTIONS:

FEATURES

&

CONTROLS.

10

Wheel

Drive

Pins.

10

Forward

Clutch

Bail.

11

Reverse

Clutch

Control...

11

Depth

Regulator

Lever.

12

Handlebar

Height

Adjustment.

12

Anti-Reverse

Stake.

12

Engine

Controls.

12

SECTION

4:

OPERATION.

13

Break-In

Operation.

13

Starting

and

Stopping

the

Engine.

13

Operating

the

Tiller.

14

Loading

and

Unloading

the

Tiller.

15

Tilling

Tips

&

Techniques.

16

SECTION

5:

MAINTENANCE

.

18

Required

Maintenance

Schedule.

18

Tiller

Lubrication.

19

Check

for

Oil

Leaks.

19

Check

Hardware.

19

Check

Tire

Pressure.

19

Transmission

Gear

Oil

Service.

19

Tines.

20

Checking

and

Adjusting

Forward

Drive

Belt

Tension.

20

Forward

Clutch

Bail

Adjustment.

21

Checking

and

Adjusting

Reverse

Drive

Beit

Tension.

22

Engine

Cleaning.

22

Air

Cleaner

Service.

22

Engine

Oil

Service.

23

Spark

Plug

Service.

23

Spark

Arrester

Screen

Service.

23

Carburetor/Governor

Control

Adjustments.

23

Throttle

Lever

Adjustment.

23

Off

Season

Storage.

23

Troubleshooting.

24

PARTS

LIST...

25

CUSTOMER

SERVICE

INFORMATION.Back

Cover

2

SPARK

ARRESTER

WARNING

TO

RESIDENTS

OF

CALIFORNIA

AND

SEVERAL

OTHER

STATES

Under

California

law,

and

under

the

laws

of

several

other

states,

you

are

not

permitted

to

operate

an

internal

combustion

engine

using

hydrocarbon

fuels

on

any

forest,

brush,

hay,

grain,

or

grass

covered

land;

or

land

covered

by

any

flammable

agricultural

crop

without

an

engine

spark

arrester

in

continuous

effective

working

order.

The

engine

on

the

unit

is

an

Internal

combustion

engine

which

burns

gasoline,

a

hydrocarbon

fuel,

and

must

be

equipped

with

a

spark

arrester

muffler

in

continuous

effective

working

order.

The

spark

arrester

must

be

attached

to

the

engine

exhaust

system

in

such

a

manner

that

flames

or

heat

from

the

system

will

not

ignite

flammable

material.

Failure

of

the

owner/operator

of

the

unit

to

comply

with

this

regulation

is

a

misdemeanor

under

California

law

(and

other

states)

and

may

also

be

a

violation

of

other

state

and/or

federal

regulations,

laws,

ordinances

or

codes.

Contact

your

local

fire

marshal

or

forest

service

for

specific

information

about

which

regulations

apply

in

your

area.

Training

1.

Carefully

read

this

Owner’s

Manual,

the

separate

Engine

Owner’s

Manual,

and

any

other

literature

you

may

receive.

Be

thoroughly

familiar

with

the

controls

and

the

proper

use

of

the

tiller

and

Its

engine.

Know

how

to

stop

the

unit

and

disengage

the

controls

quickly.

2.

Never

allow

children

to

operate

the

tiller.

Never

allow

adults

to

operate

the

tiller

without

proper

instruction.

3.

Keep

the

area

of

operation

clear

of

all

persons,

particularly

children

and

pets.

4.

Keep

in

mind

that

the

operator

or

user

is

responsible

for

accidents

or

hazards

occurring

to

other

people,

their

property,

and

themselves.

Preparation

1.

Thoroughly

Inspect

the

area

where

the

tiller

is

to

be

used

and

remove

all

foreign

objects.

2.

Be

sure

all

tiller

controls

are

released

and

both

wheels

are

in

the

Wheel

Drive

position

before

starting

the

engine.

3.

Do

not

operate

the

tiller

without

wearing

adequate

outer

garments.

Avoid

loose

garments

or

jewelry

that

could

get

caught

In

moving

parts.

4.

Do

not

operate

the

tiller

when

barefoot

or

wearing

sandals,

sneakers,

or

light

footwear.

Wear

protective

footwear

that

will

Improve

footing

on

slippery

surfaces.

5.

Do

not

till

near

underground

electric

cables,

telephone

lines,

pipes

or

hoses.

If

in

doubt,

contact

your

telephone

or

utility

company.

6.

Warning:

Handle

fuel

with

care;

it

is

highly

flammable

and

its

vapors

are

explosive.

Be

sure

to

take

the

following

precautions:

a.

Store

fuel

in

containers

specifically

designed

for

this

purpose.

fa.

The

gas

cap

shall

never

be

removed

or

fuel

added

while

the

engine

Is

running.

Allow

the

engine

to

cool

for

several

minutes

before

adding

fuel.

c.

Keep

matches,

cigarettes,

cigars,

pipes,

open

flames,

and

sparks

away

from

the

fuel

tank

and

fuel

container.

d.

Fill

fuel

tank

outdoors

with

extreme

care.

Never

fill

fuel

tank

indoors.

Use

a

funnel

or

spout

to

prevent

spillage.

e.

Replace

all

fuel

tank

and

container

caps

securely.

f.

If

fuel

is

spilled,

do

not

attempt

to

start

the

engine,

but

move

the

machine

away

from

the

area

of

spillage

and

avoid

creating

any

source

of

ignition

until

fuel

vapors

have

dissipated.

7.

Never

make

adjustments

when

engine

Is

running

(unless

recommended

by

manufacturer).

Operation

1.

Do

not

put

hands

or

feet

near

or

under

rotating

parts.

The

tines

begin

to

rotate

backward

once

the

engine

starts

and

the

Forward

Clutch

Bail

or

the

Reverse

Clutch

Control

Is

engaged.

2.

Exercise

extreme

caution

when

on

or

crossing

gravel

drives,

walks,

or

roads.

Stay

alert

for

hidden

hazards

or

traffic.

Do

not

carry

passengers.

3.

After

striking

a

foreign

object,

stop

the

engine,

remove

the

wire

from

the

spark

plug

and

prevent

it

from

touching

the

spark

plug,

thoroughly

inspect

the

machine

for

any

damage,

and

repair

the

damage

before

restarting

and

operating

the

machine.

4.

Exercise

caution

to

avoid

slipping

or

falling.

5.

If

the

unit

should

start

to

vibrate

abnor¬

mally,

stop

the

engine,

disconnect

the

spark

plug

wire

and

prevent

it

from

touching

the

spark

plug,

and

check

immediately

for

the

cause.

Vibration

is

generally

a

warning

of

trouble.

6.

Stop

the

engine,

disconnect

the

spark

plug

wire

and

prevent

it

from

touching

the

spark

plug

whenever

you

leave

the

operating

position,

before

unclogging

the

tines,

or

when

making

any

repairs,

adjust¬

ments

or

inspections.

3

Section

1:

Safety

7.

Take

all

possible

precautions

when

leaving

the

machine

unattended.

Stop

the

engine.

Disconnect

spark

plug

wire

and

move

it

away

from

the

spark

plug.

Be

sure

both

wheels

are

in

the

Wheel

Drive

position.

8.

Before

cleaning,

repairing,

or

Inspect¬

ing,

stop

the

engine

and

make

certain

all

moving

parts

have

stopped.

Disconnect

the

spark

plug

wire

and

prevent

it

from

touching

the

spark

plug

to

prevent

acci¬

dental

starting.

8.

The

flap

on

the

tine

hood

must

be

down

when

operating

the

tiller.

10.

Never

use

the

tiller

unless

proper

guards,

plates,

or

other

safety

protective

devices

are

in

place.

11.

Do

not

run

engine

in

an

enclosed

area.

Engine

exhaust

contains

carbon

monoxide

gas,

a

deadly

poison

that

is

odorless,

colorless,

and

tasteless.

12.

Keep

children

and

pets

away.

13.

Never

operate

the

tiller

under

engine

power

if

the

wheels

are

in

the

Freewheel

position.

In

the

Freewheel

position,

the

wheels

will

not

hold

the

tiller

back

and

the

revolving

tines

could

propel

the

tiller

rapidly,

possibly

causing

loss

of

control.

Always

engage

the

wheels

with

the

wheel

drive

pins

in

the

Wheel

Drive

position

before

starting

the

engine

or

engaging

the

tines/wheels

with

the

Forward

Clutch

Bail

or

the

Reverse

Clutch

Control.

14.

Be

aware

that

the

tiller

may

unex¬

pectedly

bounce

upward

or

jump

backward

and

be

propelled

toward

you

if

the

tines

should

strike

extremely

hard

packed

soil,

frozen

ground,

or

buried

obstacles

like

large

stones,

roots,

or

stumps.

If

in

doubt

about

the

tilling

con¬

ditions,

always

use

the

following

operating

precautions

to

assist

you

In

maintaining

control

of

the

tiller:

a.

Walk

behind

and

to

one

side

of

the

tiller,

using

one

band

on

the

han¬

dlebars.

Relax

your

arm,

but

use

a

secure

hand

grip.

b.

Use

a

deep

depth

regulator

setting.

c.

Use

slower

engine

speeds.

d.

Clear

the

tilling

area

of

all

large

stones,

roots

and

other

debris.

e.

Avoid

using

downward

pressure

on

handlebars.

If

need

be,

use

slight

upward

pressure

to

keep

the

tines

from

digging

too

deeply.

f.

Before

contacting

hard

packed

soil

at

the

end

of

a

row,

reduce

engine

speed

and

lift

handlebars

to

raise

tines

out

of

the

soil.

g.

In

an

emergency,

stop

tines

and

wheels

by

releasing

whichever

clutch

control

is

engaged.

Do

not

attempt

to

restrain

the

tiller.

15.

Do

not

overload

the

tiller’s

capacity

by

attempting

to

till

too

deeply

at

too

fast

a

rate.

16.

Never

operate

the

tiller

at

high

transport

speeds

on

slippery

surfaces.

Look

behind

and

use

great

care

when

backing

up.

17.

Do

not

operate

the

tiller

on

a

slope

that

is

too

steep

for

safety.

When

on

slopes,

slow

down

and

make

sure

you

have

good

footing.

Never

permit

the

tiller

to

freewheel

down

slopes.

18.

Never

allow

bystanders

near

the

unit.

19.

Only

use

attachments

and

acces¬

sories

that

are

approved

by

the

manufac¬

turer

of

the

tiller.

20.

Use

tiller

attachments

and

acces¬

sories

when

recommended.

21.

Never

operate

the

tiller

without

good

visibility

or

light.

22.

Never

operate

the

tiller

if

you

are

tired,

or

under

the

Influence

of

alcohol,

drugs

or

medication.

23.

Operators

shall

not

tamper

with

the

engine-governor

settings

on

the

machine;

the

governor

controls

the

maximum

safe

operating

speed

to

protect

the

engine

and

all

moving

parts

from

damage

caused

by

overspeed.

Authorized

service

shall

be

sought

if

a

problem

exists.

24.

Do

not

touch

engine

parts

which

may

be

hot

from

operation.

Let

parts

cool

down

sufficiently.

25.

Please

remember:

You

can

always

stop

the

tines

and

wheels

by

releasing

the

Forward

Clutch

Bail

or

the

Reverse

Clutch

Control

{whichever

control

is

engaged),

or

by

moving

the

ignition

switch

and/or

throttle

control

lever

on

the

engine

to

“OFF”

or

“STOP”.

26.

To

load

or

unload

the

tiller,

see

the

instructions

in

Section

4

of

this

Manual.

27.

Use

extreme

caution

when

reversing

or

pulling

the

machine

towards

you.

28.

Start

the

engine

carefully

according

to

instructions

and

with

feet

well

away

from

the

tines.

29.

Never

pick

up

or

carry

a

machine

while

the

engine

is

running.

Maintenance

and

Storage

1.

Keep

the

tiller,

attachments

and

acces¬

sories

in

safe

working

condition.

2.

Check

all

nuts,

bolts,

and

screws

at

frequent

Intervals

for

proper

tightness

to

be

sure

the

equipment

is

in

safe

working

condition.

3.

Never

store

the

tiller

with

fuel

In

the

fuel

tank

inside

a

building

where

ignition

sources

are

present

such

as

hot

water

and

space

heaters,

furnaces,

clothes

dryers,

stoves,

electric

motors,

etc.).

Allow

engine

to

cool

before

storing

in

any

enclosure.

4.

To

reduce

the

chances

of

a

fire

hazard,

keep

the

engine

free

of

grass,

leaves,

or

excessive

grease.

5.

Store

gasoline

In

a

cool,

well-ventilated

area,

safely

away

from

any

spark-

or

flame-producing

equipment.

Store

gasoline

in

an

approved

container,

safely

away

from

the

reach

of

children.

6.

Refer

to

the

Maintenance

sections

of

this

Manual

and

the

separate

Engine

Owner’s

Manual

for

instructions

if

the

tiller

Is

to

be

stored

for

an

extended

period.

7.

Never

perform

maintenance

while

the

engine

is

running

or

the

spark

plug

wire

is

connected,

except

when

specifically

instructed

to

do

so.

8.

If

the

fuel

tank

has

to

be

drained,

do

this

outdoors.

4

Section

1:

Safety

Decals

For

your

safety

and

the

safety

of

others,

Keep

the

decals

clean

and

legible

at

all

various

safety

and

operational

decals

are

times.

Contact

your

local

service

dealer

located

on

your

unit

(see

Figure

1

below),

or

the

factory

for

replacements

if

any

decals

are

damaged

or

missing.

Refer

to

the

Parts

List

at

the

back

of

this

Manual

for

decal

locations,

descriptions

and

part

numbers.

Forward

Clutch

Bail

Operating

instruction

Reverse

Clutch

Control

Operating

Instruction

Starting

Stabilization

Message

(on

engine)

Warning

Messages

Hot

Surfaces/Moving

Belts

Warning

(on

belt

cover)

Figure

1:

Location

of

Safety

and

Operating

Decats.

Operating

Symbols

Various

symbols

(shown

here,

with

word

descriptions)

are

used

on

the

tiHer

and

engine

(your

unit

may

not

have

all

of

the

symbols).

^

•At

^

FAST

SLOW

CTHD

CHOKE

ON

CHOKE

OFF

TILLER

DIRECTION

R

REVERSE

ROTATING

TINES

n

N

BAIL

ENGAGED

BAIL

DISENGAGED

LEVER

DIRECTION

WARNING

TO

AVOID

SERIOUS

INJURY:

•

READ

THE

OWNER’S

MANUAL.

•

KNOW

LOCATIONS

AND

FUNCTIONS

OF

ALL

CONTROLS.

•

KEEP

ALL

SAFETY

DEVICES

AND

SHIELDS

IN

PLACE

AND

WORKING.

•

NEVER

ALLOW

CHILDREN

OR

UNINSTRUCTED

ADULTS

TO

OPERATE

TILLER.

•

SHUT

OFF

ENGINE

AND

DISCONNECT

SPARK

PLUG

WIRE

BEFORE

MANUALLY

UNCLOG¬

GING

TINES

OR

MAKING

REPAIRS.

•

KEEP

BYSTANDERS

AWAY

FROM

MACHINE.

•

KEEP

AWAY

FROM

ROTATING

PARTS.

•

USE

EXTREME

CAUTION

WHEN

REVERSING

OR

PULLING

THE

MACHINE

TOWARDS

YOU.

n

Assembly

A

WARNING

To

prevent

personal

injury

or

property

damage,

do

not

start

the

engine

until

all

assembly

steps

are

complete

and

you

have

read

and

understand

the

safety

and

operating

instructions

in

this

manual.

Introduction

Carefully

follow

these

assembly

steps

to

correctly

prepare

your

tiller

for

use.

It

is

recommended

that

you

read

this

Section

in

its

entirety

before

beginning

assembly.

NOTE:

If

an

assembly

step

applies

only

to

certain

models,

those

models

are

noted

at

the

beginning

of

that

step.

Otherwise,

a

step

applies

to

all

models.

Inspect

unit

Inspect

the

unit

and

carton

for

damage

immediately

after

delivery.

Contact

the

carrier

(trucking

company)

if

you

find

or

suspect

damage.

Inform

them

of

the

damage

and

request

instructions

for

filing

a

claim.

To

protect

your

rights,

put

your

claim

in

writing

and

mail

a

copy

to

the

carrier

within

15

days

after

the

unit

has

been

delivered.

Contact

us

at

the

factory

if

you

need

assistance

in

this

matter.

STEP

1:

Unpacking

Instructions

NOTE:

Be

careful

not

to

severely

bend

any

of

the

control

cables

on

the

unit.

1.

Remove

any

cardboard

Inserts

and

packaging

material

from

the

carton.

Remove

any

staples

from

the

bottom

of

the

carton

and

remove

the

carton.

2.

The

tiller

is

heavy

(approximately

133

lbs.).

Do

not

attempt

to

remove

it

from

the

shipping

platform

until

instructed

to

do

so

in

these

“Assembly”

steps.

3.

R

emove

all

unassembled

parts

and

the

separate

hardware

bag

from

the

carton.

Check

that

you

have

the

items

listed

below

(contact

your

local

dealer

or

the

factory

if

any

items

are

missing

or

damaged).

MOTE:

Use

the

screw

length

template

(Fig.

2-1)

to

identify

screws.

Loose

Parts

List

Qty.

Description

1

Handlebar

Support

(see

A,

Fig.

2-2,

page?)

1

Handlebar

Assembly

(see

K,

Fig.

2-2)

The

following

items

are

in

the

hardware

bag:

1

Slotted

hd.

screw,

#10-24

x

2"

1

Hex

hd.

screw,

1/4-20

x

1

-1/4“

6

Hex

hd.

screw,

5/16-18x1-1/2"

2

Hex

hd.

screw,

3/8-16

x

3/4"

2

Flat

washer,

3/8“

6

Split

lockwasher,

5/16"

1

Hex

locknut,

1/4“-20

6

Hexnut,5/16“-18

2

Hex

locknut,

3/8"-16

1

Hex

nut,

#10-24

1

Spring,

cable

(see

W,

Fig.

2-5,

page

8)

1

Bracket,

forward

clutch

cable

(see

P,

Fig.

2-4,

page

8)

1

Bracket,

reverse

clutch

cable

(see

BB,

Fig.

2-8,

page

9).

IMPORTANT:

Motor

oil

must

be

added

to

the

engine

crankcase

before

the

engine

is

started.

Follow

the

instructions

In

this

"Assembly”

section.

MOTE:

LEFT

and

RIGHT

sides

of

the

tiller

are

as

viewed

from

the

operator’s

position

behind

the

handlebars.

Tools/Materials

Needed

for

Assembly

(1)

3/8”

open-end

wrench*

(2)

7/16"

open-end

wrench*

(1)

1/2*

open-end

wrench*

(2)

9/16"

open-end

wrench*

(1)

Large

adjustable

wrench

(1)

Scissors

(to

trim

plastic

ties)

(1)

Ruler

(for

belt

tension

check)

(1)

Block

of

wood

(to

support

tiller

when

removing

wheels)

(1)

Automotive-type

air

pressure

gauge

(for

models

with

pneumatic

tires)

(1)

Clean

oil

funnel

(1)

Clean,

high-quality

motor

oil.

Refer

to

the

Engine

Owner’s

Manual

for

motor

oil

specifications

and

quantity

required.

*

Adjustable

wrenches

may

be

used.

Figure

2~1:

To

identify

length

of

screw,

place

screw

on

template

as

shown

and

measure

distance

between

bottom

of

screw

head

and

tip

of

screw.

6

Section

2:

Assembly

STEP

2:

Attach

Handlebar

1.

Attach

the

two

legs

of

the

handlebar

support

{A,

Fig.

2-2)

loosely

to

the

inner

sides

of

the

tiller

frame

using

two

3/8"-16

X

3/4"

hex

hd.

screws

(B),

3/8"

flat

washers

(C)

and

3/8"-16

hex

locknuts

(D).

2.

There

are

three

height

adjustment

holes

in

the

two

handlebar

support

brackets

(E

and

F,

Fig.

2-2).

Choose

a

setting

that

will

position

the

handlebars

at

approximately

waist

level

when

the

tines

are

3"-4"

Into

the

soil.

Loosely

attach

the

support

brackets

to

the

handlebar

support

(A)

using

two

5/16"-18

x

1-1/2"

screws

(G),

5/16"

split

lockwashers

(H)

and

5/16"-18

hex

nuts

(I).

NOTE:

If

a

support

bracket

will

not

move,

loosen

attaching

screw

(J)

and

nut.

3.

Attach

the

handlebar

assembly

(K)

to

the

handlebar

support

(A)

using

four

5/16"-18

X1-1/2"

screws

(G),

5/16"

split

lockwashers

(H)

and

5/16M8

hex

nuts

(1).

Tighten

the

four

screws

securely.

4.

Tighten

ail

handlebar

mounting

hardware

securely.

STEP

3:

Move

Tiller

Off

Shipping

Platform

To

move

the

tiller

without

the

engine

running,

put

the

wheels

in

their

FREEWHEEL

position,

as

described

below.

1.

Use

a

sturdy

block

to

raise

one

wheel

off

the

ground.

2.

Remove

the

hairpin

cotter

(L,

Fig.

2-3)

and

wheel

drive

pin

(M).

Slide

the

wheel

inward

on

the

wheel

shaft

(N).

Reinstall

the

wheel

drive

pin

through

the

wheel

shaft

only

(not

through

the

wheel

hub)

and

secure

it

with

the

hairpin

cotter

(push

hairpin

cotter

In

as

far

as

It

will

go).

Repeat

with

the

other

wheel.

3.

Using

the

handlebar

as

a

lever,

roll

the

tiller

to

a

flat

area.

IMPORTANT:

Before

starting

the

engine,

the

wheels

must

be

placed

in

their

WHEEL

DRIVE

position

(pins

through

wheel

hubs

and

wheel

shaft).

This

procedure

is

described

in

“Wheel

Drive

Pins”

In

Section

3.

Fig.

2-2:

Attach

handlebar.

Fig.

2-3:

Wheel

in

FBEEWHEELING

position

(wheel

drive

pin

Uirough

wheel

shaft

only).

7

Section

2:

Assembly

STEP

4;

install

Forward

Clutch

Cable

1.

Attach

the

forward

clutch

cable

bracket

(P,

Fig.

2-4)

to

the

handlebar

support

(A)

with

a

1/4"-20

X1-1/4"

hex

hd.

screw

{R,

Fig.

2-4)

and

1/4"-20

hex

locknut

(S).

Tighten

securely.

2.

Carefully

unwrap

the

forward

clutch

cable

(cable

without

a

knob)

from

its

shipping

position

and

slide

the

thin

cable

wire

(T,

Fig.

2-4)

into

the

slot

in

the

cable

bracket.

Push

the

cable

connector

(U,

Fig.

2-4)

up

through

the

hole

In

the

bracket

until

the

groove

in

the

connector

snaps

into

place.

3.

Insert

the

#10-24

x

2"

slotted

hd.

screw

(V,

Fig.

2-5)

into

the

cable

spring

(W)

until

the

screw

threads

extend

through

the

spring.

4.

Thread

the

#10-24

hex

nut

(2,

Fig.

2-5)

halfway

onto

the

screw

(V).

5.

Thread

the

screw

into

the

cable

adjuster

(X).

6.

Hook

the

cable

spring

(W,

Fig.

2-6)

Into

the

“V^-shaped

bend

in

the

Forward

Clutch

Bail

(Y).

7.

Check

for

correct

tension

on

the

forward

drive

belt

by

taking

two

measurements

of

the

cable

spring,

as

follows:

a.

With

the

Forward

Clutch

Bail

(Y,

Fig.

2-6)

in

an

open

(released)

position,

measure

the

length

of

the

cable

spring

(W)

from

the

outermost

coil

to

the

outermost

coil.

b.

Lift

and

hold

the

Forward

Clutch

Bail

against

the

handlebar

(see

Fig.

2-7)

and

re¬

measure

the

length

of

the

coils

while

the

spring

is

under

tension.

The

belt

tension

is

correct

if

this

second

measurement

is

between

1/16"

-to-

3/16"

longer

than

the

first

measurement.

If

so,

turn

the

hex

nut

(Z,

Fig.

2-7)

tightly

against

the

cable

adjuster

(X)

while

preventing

the

adjuster

from

turning.

c.

If

the

spring

length

is

incorrect,

you

must

adjust

the

cable

tension

as

described

in

“Checking

and

Adjusting

Forward

Drive

Belt

Tension”

in

Section

5,

Incorrect

tension

on

the

forward

drive

belt

can

result

In

belt

slippage

(tension

too

loose)

or

unintentional

tine

movement

when

the

clutch

bail

is

in

Neutral

(tension

too

tight).

Fig.

2’4:

Installing

forward

clutch

cable

bracket

and

cable.

Fig.

2-5:

Assemble

spring

and

adjuster.

8

Fig.

2-T.

To

check

forward

belt

tension,

take

two

measurements

of

the

overall

length

of

the

coils

in

the

spring

-

first

widt

the

clutch

bail

open,

then

witit

the

clutch

bail

closed

against

the

handlebar.

STEPS:

Install

Reverse

Clutch

Gable

1.

Remove

the

two

pre-installed

self-

tapping

screws

(AA,

Fig.

2-8)

from

the

handlebars.

2.

Position

the

reverse

cable

mounting

bracket

(BB,

Fig.

2-8)

as

shown

and

reinstall

the

two

self-tapping

screws.

3.

Unwrap

the

reverse

clutch

cable

(cable

with

a

knob

and

a

large

nut

attached

to

it)

from

around

its

shipping

position

and

route

the

cable

(CC,

Fig.

2-8

and

Fig.

2-9)

up

to

the

cable

bracket

(BB,

Fig.

2-8).

Be

sure

that

the

cable

is

routed

beneath

the

Forward

Clutch

Bail.

4.

Insert

the

cable

through

the

slot

in

the

cable

bracket

and

position

the

threaded

assembly

as

shown

in

Fig.

2-8.

Make

sure

that

the

flat

side

of

the

threaded

assembly

is

aligned

with

the

flat

side

of

the

mounting

hole.

Slide

the

large

hex

nut

(DD)

up

the

cable

and

tighten

it

securely.

Fig.

2’B:

InstaU

reverse

cable

mounting

bracket

and

the

reverse

clutch

cable.

Fig.

2-9:

Route

reveme

dutch

cable

(CC)

as

shown.

Attach

to

handlebar

with

cable

tie

(BE).

Section

2:

Assembly

5.

Use

a

cable

tie

(EE,

Fig.

2-9)

to

fasten

the

reverse

clutch

cable

to

the

left

side

handlebar.

6.

Test

the

function

of

the

reverse

clutch

cable

by

pulling

the

knob

out

and

releasing

it.

The

knob

should

return

to

its

neutral

position

(resting

against

bracket)

when

it

is

released,

if

It

doesn’t,

contact

your

local

dealer

or

the

factory

for

technical

assistance.

STEP

6:

Check

Level

of

Transmission

Gear

Oil

The

transmission

was

filled

with

gear

oil

at

the

factory.

However,

you

should

check

the

gear

oil

level

to

make

certain

it

is

correct.

IMPORTANT:

Do

not

operate

the

tiller

if

the

gear

oil

level

is

low.

Doing

so

will

result

in

severe

damage

to

the

transmis¬

sion

components.

1.

With

the

tiller

on

level

ground,

pull

the

Depth

Regulator

Lever

(FF,

Fig.

2-10)

back

and

then

move

it

up

or

down

until

the

tiller

Is

level.

2.

Remove

the

oil

fill

plug

(GG,

Fig.

2-11)

from

the

transmission

housing

and

look

into

the

oil

fill

hole.

You

will

see

the

main

drive

shaft

on

one

side

of

the

hole.

3.

The

gear

oil

level

is

correct

If

the

gear

oil

is

approximately

halfway

up

the

side

of

the

drive

shaft.

4.

If

the

gear

oil

level

is

low,

add

gear

oil

by

referring

to

“A.

To

Check

the

Transmis¬

sion

Gear

Oil

Level”

in

Section

5.

STEP

7:

Add

Motor

OR

to

Engine

The

tiller

is

shipped

without

o\\

in

the

engine.

IMPORTANT:

Do

not

start

the

engine

without

first

adding

motor

oil.

Severe

engine

damage

will

result

if

the

engine

is

run

without

oil.

1.

Refer

to

the

Engine

Owner’s

Manual

for

engine

oil

specifications

and

capacities.

2.

With

the

tiller

on

level

ground,

move

the

Depth

Regulator

Lever

(FF,

Fig.

2-10)

up

or

down

until

the

engine

is

level.

3.

Add

motor

oil

as

described

In

the

Engine

Owner’s

Manual.

Fig.

2-10:

Adjust

Depth

Regulator

Lever.

Fig.

2-11:

Remove

gear

oil

fill

plug.

4.

M

ove

the

Depth

Regulator

Lever

all

the

way

down

until

the

highest

notch

is

engaged.

This

places

the

tines

in

the

“travel”

position.

STEP

8:

Check

Hardware

for

Tightness

Check

all

nuts

and

screws

for

tightness.

STEP

9:

Check

Air

Pressure

In

Tires

(units

with

pneumatic

tires)

If

the

tires

are

equipped

with

air

valves,

check

the

air

pressure

with

a

tire

gauge.

Deflate

or

inflate

the

tires

equally

to

15-

to-20

PSl

(pounds

per

square

inch).

Be

sure

that

both

tires

are

inflated

equally

or

the

unit

will

pull

to

one

side.

IMPORTANT:

This

completes

the

assembly

steps.

Before

operating

your

tiller,

make

sure

you

read

the

following

Sections

in

this

Manual,

as

well

as

the

separate

Engine

Owner’s

Manual:

•

Section

1:

“Safety”

•

Section

3:

“Features

and

Controls”

•

Section

4:

“Operation”

9

n

Features

and

Controls

A

WARNING

Before

operating

your

machine,

carefully

read

and

understand

all

safety,

controls

and

operating

instruc¬

tions

in

this

Manual,

the

separate

Engine

Owner’s

Manual,

and

on

the

decals

on

the

machine.

Failure

to

follow

these

instructions

can

result

in

serious

personal

injury.

Introduction

This

section

describes

the

locations

and

functions

of

the

controls

on

your

tiller.

Refer

to

the

next

section

“Operation”

for

detailed

operating

instructions.

Practice

using

these

controls,

with

the

engine

shut

off,

until

you

understand

the

operation

of

the

controls

and

feel

confident

with

each

of

them.

Figure

3-1:

Features

and

controls.

IMPORTANT:

Refer

to

the

separate

engine

manufacturer’s

Engine

Owner’s

Manual

for

Information

about

the

controls

on

the

engine.

Wheel

Drive

Pins

A

WARNING

Never

allow

either

of

the

wheels

to

be

in

the

FREEWHEEL

position

when

the

engine

is

running.

Always

put

both

wheels

in

the

WHEEL

DRIVE

position

before

starting

the

engine.

Failure

to

comply

could

cause

loss

of

tiller

control,

property

damage,

or

personal

injury.

Each

wheel

is

equipped

with

a

Wheel

Drive

Pin

(A,

Figures

3-2

and

3-3)

that

secures

the

wheel

to

the

wheel

shaft

(B).

The

wheels

can

be

positioned

in

either

a

WHEEL

DRIVE

or

a

FREEWHEEL

mode.

Before

starting

the

engine,

put

both

wheels

in

the

WHEEL

DRIVE

position

by

inserting

the

Wheel

Drive

Pins

through

the

wheel

hubs

and

the

wheel

shaft.

This

“locks”

the

wheels

to

the

wheel

shaft,

causing

the

wheels

to

turn

when

either

the

Forward

Clutch

Ball

or

the

Reverse

Clutch

Control

is

engaged.

Use

the

FREEWHEEL

mode

only

when

the

engine

Is

not

running,

in

FREEWHEEL,

the

Wheel

Drive

Pins

are

placed

only

through

the

holes

in

the

wheel

shaft

(not

the

wheel

hubs),

thus

allowing

the

wheels

to

turn

freely

when

the

tiller

Is

pushed

or

pulled

by

hand.

To

Place

the

Wheels

in

WHEEL

DRIVE

or

FREEWHEEL:

A

WARNING

Do

not

place

the

tiller

on

its

side

when

changing

the

wheel

drive

positions

as

doing

so

could

result

in

gasoline

leaking

from

the

fuel

tank.

Failure

to

follow

this

instruction

could

result

in

personal

injury

or

property

damage.

1.

Stop

the

engine,

disconnect

the

spark

plug

wire

from

the

spark

plug

and

allow

the

engine

to

cool.

2.

Raise

one

wheel

off

the

ground

and

place

a

sturdy

support

under

the

unit.

3.

Remove

the

hairpin

cotter

(C,

Figures

3-2

and

3-3)

and

the

wheel

drive

pin

(A).

10