Troy-Bilt PONY 664DM - Manual (Page 7)

4. With the forward clutch cable (N,
Figure 2-4) on the inside of handlebar,
position the handiebar ends on the
outside of the two mounting tabs (M,
Figure 2-3) on the transmission top
cover.
NOTE: The curved handiebar height
adjustment bracket appears as shown in
C, Figure 2-3 for non-eiectric start units.
For eiectric start units, the bracket is loos­
ened and moved to one side.
5. Looseiy attach the handiebars to the
mounting tabs with two 3/8-16 x 1"
screws (heads of screws go to inside of
tabs), 3/8" fiat washers and 3/8"-16 iock
nuts (0, Figure 2-4).
6
. On eiectric start units, reattach the
height adjustment bracket (A, Figure 2-2).
Tighten both screws secureiy. Make sure
the handiebar cross-brace (B, Figure 2-3)
is under the bracket.
7. Move the handiebars up or down to
aiign the threaded hoie in the cross-brace
with one of the four siots in the curved
height adjustment bracket. Place the
keyed washer (E, Figure 2-3) on the
flange head height adjustment screw (F)
with the raised keys (edges) of the
washer facing down.
8
. Thread the height adjustment screw
(F, Figure 2-3) into the hoie in the handle­
bar cross-brace, making sure that the
raised keys on the washer fit into the slot
on the height adjustment bracket.
Tighten the height adjustment screw
secureiy. Next, secureiy tighten the two
screws and nuts in the ends of the han­
diebar (M, Figure 2-3).
9. To remove the tiiler from its shipping
piatform, first carefuliy unwrap the wheel
gear cable (with attached iever - see
Figure 2-5) from around the chassis.
Move the Wheei Gear Lever (G) to the
DISENGAGE position-this allows the
wheels to rotate freely. Use the handle­
STEP 4: AHACH FORWARD
CLUTCH CONTROL CABLE
1. Remove any fasteners (rubber bands,
tape, etc.) that may secure the Forward
Clutch Control levers (J, Figure 2-7) to the
handiebar.
Figure 2-5: Carefully unwrap Wheel Gear
Lever and move lever to DISENGAGE.
bars to roii the tiiier off the piatform.
NOTE: The Wheei Gear Lever wili be
instaiied later in this procedure.
IMPORTANT: Use the DISENGAGE posi­
tion only when the engine is not running.
Before starting the engine, the Wheel Gear
Lever must be placed in the ENGAGE
position (see Section 3 for details).
STEP 3: AHACH REVERSE
CLUTCH CONTROL CABLE
1. Carefully unwrap the reverse clutch
control cable (FI, Figure 2-6) from its
shipping position and route it up along
the inside edge of the left side handiebar.
A knob and iarge hex nut (I) is instaiied
on the cable.
Figure 2-7: Forward Clutch Control levers
(J). Forward clutch control linkage (K).
2 . The forward clutch control cable (with
attached spring) is hanging iooseiy near
the right-side wheel. Being carefui not to
kink or stretch the cabie, insert the z-con-
nector (L, Figure 2-8 - end of the spring)
into the hole at the end of the forward
clutch control linkage (K, Figure 2-7).
Figure 2-6: Attach reverse clutch control
assembly to slotted hole In handlebar panel.
2. Insert the cabie into the siot in the
control panel and fit the threaded assem-
biy into the hole in the siot (see Figure 2­
6). Be sure that the flat side of the
threaded assembiy is aiigned with the flat
side of the hoie. Siide the hex nut (I) up
the cabie and tighten it secureiy.
3. Test the function of the reverse clutch
control cable by pulling the knob out and
reieasing it. The knob shouid return to its
neutral position against the tapered
bushing. If it doesn’t, contact your local
dealer or the factory for technical
assistance.
3. Attach the cabie adjuster (A, Figure
2-9) to the bracket on the right-side han­
diebar. Use two 1/2" wrenches to ioosen
the two jam nuts (B) just enough to slide
the cabie adjuster onto the bracket. Then
hand tighten the jam nuts.