Troy-Bilt 204 Operator's Manual page 12

• Remove the plastic belt cover on the front of the
engine by removing two self-tapping screws. Refer
to Figure 14.
• Tip the unit backward so that it rests on the
handles.
• Remove the lower belt guard by removing the two
self-tapping screws. See Figure 15.
Self-Tapping
Screw
Lower
Belt Guard
Self-Tapping
Screws
Figure 15
• Remove the safety switch from the front of the outer
housing by removing the two self-tapping screws.
See Figure 15.
• Remove the two hex bolts and hex lock nuts which
extend through the housing. Lift the flail screen out
of the housing. Refer to Figure 13.
• Remove the outer housing and housing blades by
removing the fourteen self-tapping screws.
• Remove the hex bolt, lock washer, and flat washer
that secures the impeller assembly to the
crankshaft. See Figure 16.
Hex Bolt
Lock Washer
Flat Washer
Figure 16
• Thread the special impeller tool into the crankshaft.
Stop when the impeller assembly can move on the
crankshaft.
• If the old belt is still on the unit, cut belt to remove
from unit.
• Remove the impeller assembly from the crankshaft
and unthread the special impeller tool from the
impeller assembly.
• Remove the inner housing and mounting adapter
by removing the five hex bolts and two hex nuts.
See Figure 17.
Hex Bolts
Safety
Switch
• Insert the new belt between the frame and
transmission pulley. It may be necessary to use a
screwdriver to pry the frame away from the pulley in
order to insert the belt. Being careful not to damage
the pulley, apply a slight upward pressure and
place belt around transmission pulley.
See Figure 18.
Belt Guard
Spring
Idler
Impeller
Assembly
Frame
• Press down on the belt guard spring by the idler
pulley and release spring from the slot on the idler
bracket. Place the belt on the idler pulley and place
belt guard spring back into the slot on the idler
bracket. See Figure 18.
• Place the mounting adapter against the engine and
make sure the hole in the mounting adapter is
facing up.
• Place the inner housing against mounting adapter
and frame. Secure with the five hex bolts and two
hex nuts previously removed. Refer to Figure 17.
12
Hex Bolts
Figure 17
Mounting
Adapter
Idler
Bracket
Transmission Pulley
Figure 18