Troy-Bilt PONY 664D Operator's Manual page 6

Assembly
To prevent personal injury or property
damage, do not startthe engine until all
assembly steps are complete and you
have read and understandthe safety and
operatinginstructionsin 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.
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.
UNPACKING AND ASSEMBLY
INSTRUCTIONS
STEP 1: UNPACKING INSTRUCTIONS
1. Removeany cardboard inserts and
packaging material from the carton.
Removeany staplesfrom the bottom of
the carton and remove the carton.
2. Cut the large, plastic tie strap that
secures the transmission tube to the ship-
ping pallet. Leavethe handlebarson top
of the tiller to avoid damaging any cables.
3. A bag with loose hardware is inside
the literature envelope. Checkthe con-
tents against the following list and Figure
2-1. Contact your local dealer or the
factory if any items are missing or
damaged.
NOTE: For electric start units, a second
hardware bag is located near the battery.
4. The tiller is heavy. You should not
attempt to remove it from the shipping
platform until instructed to do so in these
"Assembly" steps.
HARDWARE BAG PARTS LIST
Fig.
Ref. Qty. Description
1 2 3/8-16 x 1" Hex Hd. Screw
2 1 KeyedWasher
3 1 Wheel Gear Lever Knob
4 1 Height Adjustment Flange
Screw (See Figure 2-1A)
5 2 3/8" Flat Washer
6 2 #10 Lockwasher
7 2 3/8"-16 Nylock Lock Nut
8 2 #10-32 x 1/2" Round Hd.
Screw
9 2 #10-32 Nut
10 1 Cotter Pin (not used)
11 4 PlasticTie Strap (2 not used)
Tools/Materials Needed
for Assembly
(1) 3/8"open-end wrench*
(1) 7/16" open-end wrench* (electric
start unit only)
(2) 9/16" open-end wrench*
(1) 7/8" open-end wrench or 8" long
adjustable wrench
(1) Scissors (to trim plastic ties)
(1) Ruler
(1) Small board (to tap plastic knob on
lever)
(1) Tire pressure gauge
(1) Cleanoilfunnel
(1) Clean, high-quality motor oil. Refer
to the separate Engine Owner's
Manual for motor oil specifications
and quantity required.
* Adjustable wrenches may be used.
IMPORTANT: Motor oil must be added to
the engine crankcase beforethe engine is
started. Follow the instructions in this
"Assembly" Section and in the separate
Engine Owner's Manual.
NOTE:LEFTand RIGHTsides of the tiller
are as viewed from the operator's posi-
tion behind the handlebars.
STEP 2: ATTACH HANDLEBARS
1. On electric start units, remove one
screw and Iockwasherfrom the curved
'T
600
7_ 8_' _ _9
10 _.
11
Figure2-1: Loose hardware (shown in
reduced size).
Figure2.1A Hand/ebar h eight adjustment
usestheflangeheadscrew.
Figure2-2: Onelectricstartunits,move
height adjustment bracket a side.
height adjustment bracket (A, Figure2-2),
loosenthe second screw, and swing the
bracket to one side.
2. Cut the large, plastic cable ties that
secure the handlebar ends to the handle-
bar mounting tabs on the transmission
top cover.
3. Gently lift handlebar (do not over-
stretch attached cable) and place handle-
bar cross-brace (B, Figure 2-3) in front of
curved height adjustment bracket (C).
Figure 2-3: Forward clutch control c ablenot
shown forclarity.