Troy-Bilt PONY 664DM - Manual (Page 6)

Section
2 Assembly
A 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.
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 mall 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. Remove any cardboard Inserts and
packaging material from the carton.
Remove any staples from 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. Leave the handlebars on top
of the tiller to avoid damaging any cables.
3. A bag with loose hardware Is Inside
the literature envelope. Check the 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 X1“ Hex Hd. Screw
2 1 Keyed Washer
3 1 Wheel Gear Lever Knob
4 1 Height Adjustment Flange
Screw (See Figure 2-1 A)
5 2 3/8“ Flat Washer
6 2 #10 Lockwasher
7 2 3/8"-16Nylock Lock Nut
8 2 #10-32x1/2" Round Hd.
Screw
9 2 #10-32 Nut
10 1 Cotter Pin (not used)
11 4 Plastic Tie 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) Clean oil funnel
(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 before the engine is
started. Follow the instructions in this
“Assembly” Section and in the separate
Engine Owner’s Manual.
NOTE: LEFT and RIGHT sides of the tiller
are as viewed from the operator’s posi­
tion behind the handlebars.
STEP 2: AHACH HANDLEBARS
1. On electric start units, remove one
screw and lockwasher from the curved
Figure 2-1: Loose hardware (shown in
reduced size). H
Flange
mi
Figure 2- 1A Handlehar height adjustment
uses the flange head screw.
Figure 2-2: On electric start units, move
height adjustment bracket aside.
height adjustment bracket (A, Figure 2-2),
loosen the 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 cable not
shown for clarity.