Assembly - Troy-Bilt Horse E686N Operator's Manual

Section
2

Assembly

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: Three different Horse model tillers
are covered in this Manual. Use only the
information applicable to your model.
Tiller engines vary by model. Your engine
may appear differently than those found
in illustrations of this manual.
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: Do not severely bend any of the
control cables on the unit.
1. The tiller is heavy. Do not attempt to
remove it from the shipping platform until
instructed to do so in these Assembly
steps.
2. Remove all unassembled parts from
the carton. The hardware bag is included
in your literature packaging.
3. Check that you have the items listed
below (contact your local dealer or the
6
Factory if any items are missing or
damaged).
NOTE: Use the screw length template
(Figure 2-1) to identify screws.
Loose Parts List
Qty. Description
1 Handlebar Assembly
1 Wheels/Tines PTO Drive Lever
The following items
are in the hardware bag:
1 26 oz. Bottle SAE 30W Oil
1 Clutch Pawl Spring
1 Belt Adjusting Tool
2 Plastic Cable Ties
1 Curved Head Screw, 1/4-20 x 2
1 Flanged Lock Nut, 1/4-20
1 Pan Head Screw, #10-32 x 1/2
The following parts (electric start models
only), packaged separately.
2 Nuts, 1/4-20
(for battery terminals)
2 Screws, 1/4-20 x 5/8
(for battery terminals)
2 Keys
(in ignition switch)
NOTE: LEFT and RIGHT sides of the
tiller are as viewed from the
operator's position behind the han-
dlebars (unless otherwise noted).
Tools/Materials Needed
for Assembly
(1) 3/8" open-end wrench*
(2) 7/16" open-end wrench*
(2) 1/2" open-end wrench*
(1) 9/16" open-end wrench*
(1) 3/4" open-end wrench*
(1) Flat blade screwdriver
(1) Scissors (to trim plastic ties)
(1) Tire pressure gauge
(1) 4-1/2" high wood block to prop unit
* Adjustable wrenches may be used.
1
1
2
2
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.
STEP 2: Attach Handlebar
IMPORTANT: When disassembling
handlebar assembly, keep left-side clamp
and ratchet separated from the right-side
clamp and ratchet.
1. Disassemble the handlebar assembly.
To do this, remove the height adjustment
lever by turning the lever in a counter-
clockwise direction (Figure 2-2).
2. Place the handlebar ends on either side
of the base, with the wire harness toward
the rear of the base (Figure 2-2).
3. Install the height adjustment lever
through the right-side clamp, handlebar
end, ratchet, and base; then out through
the left-side ratchet, handlebar end, and
clamp (Figure 2-2). Secure with nut, but
don't fully tighten.
IMPORTANT: Do not force the height
adjustment lever through the handlebars.
The interlock wires may be blocking the