Manual

SECTION2: ASSEMBLY
WARNING: Toprevent
personal injury or property
damage,do notstart the engine
until all assemblysteps are
complete andyou have read
and understandthe safety and
operating instructions in this
manual.
INTRODUCTION
Carefully follow these assemblysteps to
correctly prepareyour tiller for use. It is
recommendedthatyou readthis Sectionin
its entirety beforebeginning assembly.
NOTE: Various tiller models are
presented in this Manual. Use only the
information appropriate for your tiller
model. Engine styles vary by model, Your
engine may appear differently than those
illustrated in this manual.
INSPECTUNIT
Inspect the unit and carton for damageim-
mediatelyafter delivery.Contactthe carrier
(trucking company) if you find or suspect
damage.Inform them of the damageand
request instructions for filing a claim. To
protect your rights, put your claim in writ-
ing and mail a copyto the carrierwithin 15
days after the unit has beendelivered.
ContactTroy-Bilt LLCif you needassis-
tance in this matter.
TOOLS/ MATERIALSNEEDED
(2) 1/2" open-end wrench*
(2) 9/16" open-endwrench*
(1) 3/8" open-endwrench*
(1) Largeadjustable wrench
(Models 643B & 645A only)
(1) Scissors (to trim plastic ties)
(1) Ruler (for belttension check)
(1) Block of wood (to support tiller when
removing wheels)
(1) Tire pressure gauge (for models with
pneumatic tires)
(1) Cleanoil funnel
(1) Motor oil. Refertothe EngineOwner's
Manualfor oil specificationsand
quantity required.
* Adjustable wrenches may be used.
ASSEMBLYSTEPS
STEP 1: UNPACKING INSTRUCTIONS
NOTE:While unpacking, do not severely
bend any control cables.
1. The tiller weighs approximately 133 Ibs.
Do not attempt to remove it from the ship-
ping platform until instructed to do so in
these Assembly steps.
2. Removeany packagingmaterial from
the carton. Removeany staples from the
bottom of the carton and removethe car-
ton from the shipping platform.
3. Removeall unassembled parts andthe
separatehardware bag from the carton.
Checkthat you havethe items listed in the
Loose Parts List (contactyour localdealer
or the factory items are missing or dam-
aged).
NOTE: Use the screw length template
(Fig,2-1) to identify screws,
LoosePartsList
Qty. Description
1 HandlebarSupport (seeA, Fig. 2-2)
1 HandlebarAssembly(seeK, Fig.2-2)
Hardwarebag contents:
4 Hexhd. screw, 5/16-18 x 1-1/2"
2 Hexhd. screw, 3/8-16 x 3/4"
2 FlatWasher,3/8"
4 Split lock washer,5/16"
4 Hex nut, 5/16"-18
2 HexIocknut,3_8"-16
*Models 643B & 645A only
IMPORTANT:Motor oil must beaddedto
the enginecrankcasebefore the engine is
started. Followthe instructions inthis
Sectionand in the separateEngine
Owner's Manual.
NOTE: LEFTand RIGHTsides of the tiller
are as viewedfrom the operator's position
behind the handlebars.
STEP 2: ATTACHHANDLEBAR
1. Looselyattachthe legs of the handlebar
support (A, Fig. 2-2) to the inner sides of
the tiller frame usingtwo 3/8"-16 x 3/4" hex
hd. screws (B), 3/8" flat washers, and3/8"-
16 hex Iocknuts.
_iiii
Figure2-1: Toidentifylengthofscrews,place
screwontemplateasshownandmeasuredis-
tancebetweenbottomofscrewheadandtipof
screw.
2. Usingtwo 5/16"-18x 1-1/2"screws (C),
5/16"split lock washers (D) and 5/16"-18
hex nuts (G), loosely attach the handlebar
support (A) using the upperholes.Tighten
the two screws securely.
3. Therearethree height adjustment holes
in the two handlebar support brackets (E
and F,Fig. 2-2). Usea setting that will po-
sition the handlebarsat approximately
waist levelwhen the tines are3"-4" into the
soil. Looselyattachthe support bracketsto
theoutsideofthe handlebarassembly (I)
using two 5/16"-18x 1-1/2" screws (G), 5/
16"split lockwashers (D) and5/16"-18 hex
nuts (G). NOTE:If asupport bracket will
not move, loosen attaching screw (H) and
nut.
IMPORTANT:The support bracketsmust
beassembled to theoutside of the
handlebarassembly.
4. Tightenall handlebarmounting hard-
ware securely.
STEP 3: MOVE TILLER OFF CRATE
To roll the tiller off the shipping platform,
put the wheels in freewheel, as follows:
1. Placeasturdy block underthe transmis-
sion to raise one wheel about 1" off the
ground.
2. Removethe Klik Pin (J, Fig. 2-3) from
the wheel hub (K) and wheel shaft (L).
3. Slidethe wheelfully inwardonthe wheel
shaft (N,Fig. 2-3). Reinstallthe Klik pin (J)