Troy-Bilt Pony Operator's Manual page 5

Contents of Carton
• Tiller
• Handlebar Support
• Handlebar Assembly
• Hardware Pack
• Operator's Manual
• Engine Operator's Manual
NOTE: This Operator's Manual covers several garden tiller models. The tiller depicted may
differ from yours.
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.
Recommended Tools for Assembly
• Two 1⁄2" open-end wrenches
• Block of wood (to support tiller when removing wheels)
• Tire pressure gauge
• Clean oil funnel
• Motor oil. Refer to the Engine Operator's Manual for oil specifications and
quantity required
Assembly
Unpacking Instructions
NOTE: While unpacking, do not severely bend any of the control cables.
1. The tiller is heavy. You should not attempt to remove it from the shipping
platform until instructed to do so.
2. Remove any cardboard inserts and packaging material from the carton.
Remove any staples from the bottom of the carton and remove the carton.
3. Cut the large, plastic tie strap that secures the transmission tube to the
shipping pallet. Leave the handlebars on top of the tiller to avoid damaging
any cables.
4. The hardware bag is inside the literature envelope. Check the contents with
the list above.
Handle
NOTE: All references to the right or left side of
the tiller are from the operator's position.
1. Remove the knob from the center
of the lower end of the handle by
rotating it counter-clockwise. See
Figure 1.
2. Cut the large, plastic cable ties that
secure the handlebar ends to the
handlebar mounting tabs on the
transmission top cover.
3. Gently lift the handlebar (do not
overstretch the attached cables)
and place the handlebar cross-brace
in front of the curved height
adjustment bracket. See Figure 2.
4. With the forward clutch cable on
the inside of the handlebar, position
the handlebar ends on the outside
of the two mounting tabs atop the
transmission cover. See inset in
Figure 2.
ASSEMBLY & SET-UP
WARNING
Figure 1
Figure 2
5. Loosely attach the handlebars
to the mounting tabs with two
shoulder screws (.437 x .268:
5/16-18), inserted through two
Belleville washers (.450 x 1.0 x
.062), then through the lower
ends of the handle and the front
holes on the bracket. Add flat
washers (.349 x .879 x .063) on
the ends of each and secure
them by threading a hex lock
nut (5/16-18) on each end. See
Figure 3.
6. Make sure the handlebar
cross-brace is under the bracket.
Move the handlebars up or down
to align the threaded hole in
the cross-brace with one of the
three slots in the curved height
adjustment bracket.
7. Thread the height adjustment
knob through the washer (.760 x
1.250 x .041) then into the hole
in the handlebar cross-brace. See
Figure 4.
8. Securely tighten the height
adjustment screw.
9. Securely tighten the shoulder
screws and hex lock nuts from Step 5 on the ends of the handlebar.
10. To remove the tiller from its shipping platform, first carefully unwrap the
wheel gear cable with the attached lever from around the chassis. Move the
neutral ENGAGE/DISENGAGE lever to the DISENGAGE position. This allows the
wheels to rotate freely.
NOTE: See Controls & Operation section for location and operation instructions.
11. Use the handlebars to roll the tiller off the platform.
NOTE: Use the DISENGAGE position
to move tiller only when the engine
is not running. Before starting
the engine, the neutral ENGAGE/
DISENGAGE lever must be placed
in the ENGAGE position (see the
Controls & Operation section
for details).
Reverse Clutch Control
1. Carefully unwrap the reverse
clutch control cable (red) from
its shipping position and route
it up the right side handle.
Position the cable so that it
rests above the small groove on
the handle assembly in front of
the reverse drive handle. See
Figure 5.
2. Insert the cable Z-connector
into the slot in the control panel
from the inside of the handle
outward. See inset in Figure 5.
3. Snap the cable tab into place in
the upper hole on the handle
cable bracket. See Figure 6.
5
Figure 3
Figure 4
Red
Figure 5
Figure 6