Billy Goat BC2600 User manual

P a r t N o 501505 1 F 100515 D
BC 2600 Hy d ro -Drive Series Brush Cutter
B e g i nn i ng Se rial # : 100515001
Ori g i n al I n s t r u t i on s
I M P O RT A NT- R EA D C A R E FU LLY BE F O R E U SE A ND KEEP F O R FUTUR E R E F E R E NC E

Pa r t N o 501505 2 F 100515 D
SPE C I F I C A T I O N S A ND SO UND /VIB R A T IO N 3
I N S TRUCT IO N LABELS
ASSE M BLY I N S TRUCT IO N S 5 - 6
OPE R A T IO N 7 - 8
M AI NT E N A NC E A ND BA TT E R Y M AI NT E N A NC E 10 - 13
TR O U BLES H OO T I N G 1
ILL U S TR A T E D PA RT S LIS T 15 - 22
D E C LA R A T IO N O F C O NF O RM I T Y 23 - 25
G o to http:// www .b illy goat. c o m fo r Fr en c h -C anad i an t r an sl at i on s of the p r odu c t m anua ls .
V isi te z http:// www .b illy goat. c o m pou r l a v e rsi on c anad i enne - f r an ç a is e de s m anue ls de p r odu i t s

Pa r t N o 501505 3 F 100515 D
BC 2600 HHFT BC 2600 HH BC 2600 H E BH
Eng i ne Ty pe H onda GXV390 H onda GXV390 H onda GXV390
M ode l N u m be r GX390 UT 2 D ABG GX390 UT 2 D ABG V390 UTD E33
Dis p l a c e m ent 390 cc 390 cc 390 cc
F ue l C apa ci t y 3.0 qt ( 2.80 L ) 3.0 qt ( 2.80 L ) 2.3 qt ( 2.18L )
O il C apa ci t y 1.2 qt ( 1.1L ) 1.2 qt ( 1.1L ) 1.2 qt ( 1.1L )
U n i t W e i ght 367 l b ( 167 k g ) 325 l b ( 1 7. k g ) 335 l b ( 152 k g )
O v e r a ll Length 72 i n ( 1.83 m)
O v e r a ll Wi dth 31 i n ( 0.78 m)
O v e r a ll H e i ght 8 i n ( 1.21 m)
M a xim u m Ope r at i ng
S l ope
20
o
20
o
20
o
S O UND LEVEL 91.6
Sound te s t s w e r e c ondu c ted i n a cc o r dan c e wi th 2000/1 /EE C and w e r e pe r fo rm ed on 11/30/11 unde r the c ond i t i on s lis ted
be l o w .
N O T E: Sound po w e r l e v e l lis ted is the h i ghe s t v a l ue fo r an y m ode l c o v e r ed i n th is m anua l . P l ea s e r efe r to s e ri a l p l ate on the
un i t fo r the s ound po w e r l e v e l fo r y ou r m ode l .
Gene r a l C ond i t i on s : Sunn y
T e m pe r atu r e: 7
o
F ( 8.3
o
C)
Wi nd Speed: 9 m ph ( 1 .5 k ph )
Wi nd Dir e c t i on: South
H u mi d i t y : 25 %
Ba r o m et ric P r e ss u r e: 30.
VIB R A T IO N LEVEL .3g ( 3.13 m / s
2
)
d
vi b r at i on te s t equ i p m ent. T e s t s w e r e pe r fo rm ed on 11/30/11 unde r the c ond i t i on s lis ted be l o w .
Gene r a l C ond i t i on s : Sunn y
T e m pe r atu r e: 7
o
F ( 8.3
o
C)
Wi nd Speed: 9 m ph ( 1 .5 k ph )
Wi nd Dir e c t i on: South
H u mi d i t y : 25%
Ba r o m et ric P r e ss u r e: 30.07 83 k Pa )
112 dB

Pa r t N o 501505 F 100515 D
T he l abe ls s ho w n be l o w w e r e i n s ta ll ed on y ou r BILLY GOA T
®
Hy d r o -Driv e B r u s h C utte r . If an y l abe ls a r e da m aged o r missi ng,
r ep l a c e the m befo r e ope r at i ng th is equ i p m ent. Ite m nu m be rs f r o m the I ll u s t r ated Pa r t s L is t and pa r t nu m be rs a r e p r o vi ded fo r
c on v en i en c e i n o r de ri ng r ep l a c e m ent l abe ls . T he c o rr e c t po si t i on fo r ea c h l abe l m a y be dete rmi ned b y r efe rri ng to the Fi gu r e
and Ite m nu m be rs s ho w n.
P N 100261
( Ite m 61 )
P N 1003 6
( Ite m 13 )
P N 810736
( Ite m 136 )
P N 100256
( Ite m 62 )
P N 900327
( Ite m 20 )
P N 500177
( Ite m 135 )
P N 501502
( Ite m 85 )
P N 00 2
( Ite m 5 )
P N 50150
( Ite m 139 )
P N 500168
( Ite m 1 0 )
H onda B ri gg s and St r atton

Pa r t N o 501505 5 F 100515 D
B r u s h C utte r A ss e m b ly Dr a wi ng

Pa r t N o 501505 6 F 100515 D
You r BILLY GOA T
®
B C Se l f - P r ope ll ed Hy d r o -Driv e B r u s h C utte r w a s s h i pped i n one c a r ton, c o m p l ete ly a ss e m b l ed e xc ept fo r
the uppe r hand l e a ss e m b ly and the f r ont gua r d ba r . M ount i ng ha r d w a r e fo r the hand l e and gua r d ba r is te m po r a rily i n s ta ll ed on
the l o w e r hand l e and the f r ont of the de ck a ss e m b ly . T he th r ott l e c ab l e ha r d w a r e is l o c ated on the b r a ck et on the ri ght si de of
the hand l e N O T E : B C 2600 HHFT m ode ls a r e s h i pped c o m p l ete ly a ss e m b l ed and will need to ha v e the b l ade c ab l e atta c hed
befo r e ga s and o il is added to the m a c h i ne. A C B18, C 50, S C 50 o r MC B50 s e ri e s d ry o r w et batte ry wi th a 17.2 Ah r at i ng is
r equ ir ed w hen r ep l a ci ng the batte ry .
R
E
A
D
a ll s afet y i n s t r u c t i on s befo r e a ss e m b li ng un i t.
P ART S BA G & L I T E RATUR E A SSY
W a rr ant y c a r d P/ N- - 501505, Gene r a l Safet y and W a rr ant y M anua l P/ N- 100296, D e cl a r at i on of
c onfo rmi t y P/ N 501506
N O T E : Ite ms i n ( ) c an be r efe r en c ed i n the Pa r t s I ll u s t r at i on s and Pa r t s L is t s on page s 15 - 22.
1. R E M OVE un i t f r o m c a r ton and c he ck the c ontent s of the pa r t s bag wi th the lis t abo v e.
2. R E M OVE m ount i ng ha r d w a r e f r o m the ha r d w a r e bag.
3. ATTACH the hand l e to the eng i ne ba s e wi th i te ms 72, 73, and 8.
4. T IG HT E N m ount i ng ha r d w a r e on hand l e b r a c e s (i te ms 5 and 6 ) .
5. ATTACH gua r d ba r (i te m 16 ) to S ki d ba r b y i n s ta lli ng the si de bo l t s i nto the top t w o ho l e s on the ski d s wi th i te ms 12, 9
and 8.
6. ATTACH the th r ott l e (i te m 82 ) to the ri ght hand b r a ck et (i te m 70 ) u si ng the ha r d w a r e i te ms 83 and 8 . Ti ghten s e c u r e ly
F O R ELE CTR I C S T A RT M O D ELS, Atta c h the th r ott l e to the b r a ck et then r e m o v e
the s ta r te r swi t c h (i te m 1 ) f r o m the pa r t s bag. F eed the wir e ha r ne ss (i te m 153 ) fo r the s ta r t swi t c h i nto the bo x (i te m
1 3 ) th r ough the botto m and atta c h the s ta r te r swi t c h to i t. T hen p r e ss the swi t c h i nto ho l e on the top of the bo x , m a ki ng
s u r e i t is s eated p r ope rly . ( See pa r t s ill u s t r at i on pg. 23 fo r a ss e m b ly)
7. ATTACH the B l ade d riv e c ab l e to the l e v e r and s eat the p l a s t ic i n s e r t i nto the b r a ck et on the l eft si de of the hand l e.
8. SE CUR E the d riv e and b l ade c ab l e s wi th the t y-wr ap s p r o vi ded.
9. ( E L E CTR I C S TART O NL Y ) F o r e l e c t ric s ta r t m ode ls s e c u r e the batte ry i n the batte ry p l ate (i te m 1 1 ) , hoo k one si de of
the s t r ap (i te m 1 7 ) i nto the ho l e then s t r et c h the s t r ap a cr o ss the top of the batte ry and hoo k the oppo si te si de i nto the
oppo si ng ho l e on the p l ate. M a k e s u r e the batte ry will not m o v e then c onne c t te rmi na ls . R ep l a c e m ent ha r d w a r e to
atta c h the c ab l e s to the batte ry c an be found at a l o c a l ha r d w a r e s to r e.
10. R E C O NN E CT s pa rk p l ug wir e.
D IS C O NN E CT s pa rk p l ug wir e befo r e a ss e m b li ng un i t.
B
o
x
i
n
g
P
a
r
t
s
Ch ecklis t
Upp er H a nd le A sse m b ly, P/ N 501010, Ele t ri m od el P/ N 501009
G u ar d B ar, P/ N 501403
T y -W ra p s P/ N 900402 (qt y 4 )
f la t P/ N 8171004 (qt y 4 )
- 16 P/ N 8160003 (qt y 4 )
Nut l o k #10 - 24 h ex P/ N 8164005 (qt y 2 )
S rew ma h i n e f la t HD P h il P/ N 830514 (qt y 2 )
-
Nut L - 18 h ex Z P P/ N 8160002 (qt y 4 )
S t ar t er swi t h P/ N 501286 ( Ele t ri s t ar t on ly )
E ng i n e M a nu al Per Mod el
Hond a
B ri gg s

Pa r t N o 501505 7 F 100515 D
OPE RAT O R C O NTR O L S
l eba rs . T he ope r ato r s hou l d S T A ND i n a po si t i on to a ll o w
be l o w .
Ope r ato r C ont r o l Lo c at i on s
1 B l ade Cl ut c h Le v e r 5 Sta r t S wi t c h ( E l e c t ric on ly)
2 F o rw a r d Le v e r 6 Pu ll Sta r te r
3 R e v e rs e Le v e r 7 C ho k e
T h r ott l e
S TART I N G E N GI N E
CH E CK eng i ne o il l e v e l befo r e ope r at i ng m a c h i ne.
D O N O T S TART equ i p m ent wi th d riv e o r b l ade cl ut c h engaged.
Fi g. 1
1. P l a c e equ i p m ent on a l e v e l , f irm s u r fa c e that is f r ee of r o cks o r othe r deb ris .
2. P l a c e th r ott l e i n a s t po si t i on. ( See Fi g. 1 )
3. Pu ll c ho k e out ( See Fi g. 3 , H onda eng i ne on ly) .
4. U n i t s equ i pped wi th e l e c t ric s ta r te rs : T u r n the swi t c h ri ght unt il eng i ne s ta r t s , on ly
cr an ki ng o v e r the eng i ne fo r 10 s e c ond s at a t im e i f i t doe s not imm ed i ate ly s ta r t. ( See
Fi g. 2 )
5. U n i t s equ i pped wi th m anua l s ta r te rs : Pu ll s ta r te r r ope to s ta r t eng i ne. ( See Fi g. 4 )
N O T E : P ULL S TART E R C O RD sl o wly unt il r e sis tan c e is fe l t. T hen pu ll c o r d r ap i d ly to
a v o i d kick ba ck .
6. Pu s h c ho k e i n (H onda eng i ne on ly) .
7. Pu ll th r ott l e c ont r o l ba ck to and a ll o w eng i ne to r ea c h c o rr e c t ope r at i ng s peed. Fi
g. 2
Fi g. 3
F
i
g
.
4
3
1
2
5
6
7

Pa r t N o 501505 8 F 100515 D
CUTT I N G OPE RAT IO N
1. P r e ss b l ade cl ut c h hand l e do w n ( See Fi g. 5 ) to engage b l ade. A ll o w
b l ade to s p i n up to no rm a l ope r at i ng s peed.
2. Pu ll F o rw a r d ( See Fi g. 6 ) o r R e v e rs e Driv e l e v e r ( See Fi g. 7 ) up to
engage t r an s a xl e i n de sir ed d ir e c t i on.
CL E AR I N G A CL OGGE D D E CK
D IS C O NN E CT s pa rk p l ug wir e befo r e s e rvici ng un i t.
1. Shut eng i ne off and w a i t fo r b l ade to s top c o m p l ete ly .
2. Disc onne c t s pa rk p l ug wir e.
3. R e m o v e cl og f r o m c utt i ng de ck .
W E AR du r ab l e g l o v e s . Cl og m a y c onta i n s ha r p m ate ri a ls .
4. R e c onne c t s pa rk p l ug wir e.
S HUT D O WN
1. R e l ea s e d riv e l e v e r (Fi g. 6/7 ) to d is engage t r an s a xl e.
2. R e l ea s e b l ade cl ut c h hand l e (Fi g. 5 ) to d is engage b l ade.
3. (N on - E l e c t ric) M o v e the th r ott l e to the sl o w e s t po ssi b l e po si t i on on the
th r ott l e c ont r o l .
4. ( E l e c t ric s ta r t m ode ls) T u r n the k e y to the O FF po si t i on .
***** T I PS*****
T he be s t pe r fo rm an c e is a c h i e v ed w hen c utt i ng i n d ry c ond i t i on s . T he qua li t y of the c ut is d ir e c t ly r e l ated to g r ound s peed du ri ng
c utt i ng. U nde r m o s t c ond i t i on s c utt i ng s hou l d be done at a sl o w e r g r ound s peed. F a s t s peed s s hou l d be r e s e rv ed fo r c ond i t i on s
w he r e w eed s and b r u s h a r e th i nned out o r not v e ry ta ll . If the qua li t y of the c ut is not s at is fa c to ry , atte m pt at sl o w e r s peed s .
Fi g. 5 Left H and l e
Fi g. 6 Ri ght H and l e
Fi g. 7 Left H and l e

Pa r t N o 501505 9 F 100515 D
PE R IO D I C MA I NT E NANC E
Pe ri od ic m a i ntenan c e s hou l d be pe r fo rm ed at the fo ll o wi ng i nte rv a ls :
M a i ntenan c e Ope r at i on E v e ry
Us e
D a ily o r E v e ry
5 H ou rs
E v e ry 25
H ou rs
E v e ry 50
H ou rs
E v e ry 100 - 150
H ou rs
In s pe c t fo r w o r n o r da m aged pa r t s
C he ck fo r e xc e ssiv e vi b r at i on
In s pe c t fo r l oo s e pa r t s
Sha r pen b l ade. N ote: nut will need to be
r ep l a c ed w hen b l ade is r e m o v ed
In s pe c t be l t s fo r w ea r
Lub ric ate th r ott l e c ont r o l c ab l e and li n k age
C he ck b l ade cl ut c h c ab l e ten si on
In s pe c t batte ry fo r c o rr o si on, da m age o r
l ea ks ( e l e c t ric s ta r t un i t s on ly)
App ly ant i-s e iz e c o m pound to r ea r a xl e s
C he ck batte ry s t r ap fo r e xc e ssiv e w ea r o r ri p s
R ep l a c e b l ade d riv e and t r an s a xl e d riv e be l t s
B l ade. P/ N 50122 . O ri g i na l equ i p m ent r ep l a c e m ent b l ade.
Tr an s a xl e Driv e Be l t. P/ N 501268. O ri g i na l equ i p m ent r ep l a c e m ent d riv e be l t.
B l ade Driv e Be l t. P/ N 501220. O ri g i na l equ i p m ent r ep l a c e m ent d riv e be l t.
S ki d. P/ N 501 07. S i de de ck ski d.
T h r ott l e C ont r o l A ss e m b ly . T h r ott l e c ont r o l i n cl ud i ng c ab l e.
CL E AN I N G
You r BILLY GOA T
®
B r u s h C utte r s hou l d be cl eaned pe ri od ic a lly to en s u r e opt im u m pe r fo rm an c e and s e rvic e li fe. Cl og s and
deb ris s hou l d be r e m o v ed f r o m the b l ade a r ea and deb ris s hou l d be r e m o v ed f r o m the eng i ne c oo li ng f i n s . A ga r den ho s e o r
p r e ss u r e w a s he r m a y be u s ed fo r cl ean i ng.
D
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B
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8
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Fi g. 8

Pa r t N o 501505 10 F 100515 D
N O T E : Ite ms i n ( ) c an be r efe r en c ed i n the Pa r t s I ll u s t r at i on s and Pa r t s L is t s on page s 15 - 22.
BLAD E S HAR PE N I N G AND R E M OV AL ( See page s 15 and 16 fo r Pa r t s I ll u s t r at i on and Pa r t s L is t )
R E AD a ll s afet y i n s t r u c t i on s befo r e s e rvici ng un i t.
1. Disc onne c t s pa rk p l ug wir e.
2. L i ft and s uppo r t f r ont of un i t to a ll o w a cc e ss to unde rsi de.
UN I T IS H E A VY. M a k e s u r e s uppo r t is adequate to s uppo r t w e i ght of m a c h i ne.
3. B l o ck b l ade to p r e v ent i t f r o m r otat i ng du ri ng r e m o v a l .
4. R e m o v e b l ade bo l t (i te m 23 ) , and f ric t i on w a s he r (i te m 39 ) .
5. R e m o v e b l ade (i te m 2 ) and i n s ta ll r ep l a c e m ent b l ade. W hen r ep l a ci ng the b l ade u s e BILLY GOA T Indu s t ri e s P N
50122 on ly . N O T E : W hen s ha r pen i ng b l ade m a k e s u r e to s ha r pen a ll c utt i ng edge s . If the l o ck nut is r e m o v ed and
r ep l a c ed m o r e than on c e, i t s hou l d be r ep l a c ed wi th a ne w l o ck nut ( P/ N 8160009 ) .
6. Atta c h ne w b l ade wi th ne w b l ade bo l t (i te m 23 ) , and ne w f ric t i on w a s he r (i te m 39 ) r e m o v ed ea rli e r i n cl uded wi th y ou r
ne w b l ade. N O T E : In s pe c t fa s tene rs fo r w ea r and r ep l a c e i f ne c e ss a ry .
7. T o r que b l ade l o ck nut to 0 ft -l b s .
8. R e c onne c t s pa rk p l ug wir e.
BLAD E DR IVE AND T E N SIO N ( See page s 15 and 16 fo r Pa r t s I ll u s t r at i on and Pa r t s L is t )
N O T E : T he B l ade Driv e be l t is unde r c on s tant ten si on b y the i d l e r a rm on the de ck
D IS C O NN E CT s pa rk p l ug wir e befo r e s e rvici ng un i t.
1. Disc onne c t s pa rk p l ug wir e.
2. Loo s en fou r scr e ws (i te m 27 ) ho l d i ng be l t de ck c o v e r (i te m 29 ) and r e m o v e the c o v e r .
3. E x a mi ne c ond i t i on of be l t and a m ount of ten si on on be l t.
4. If the i d l e r is not p r o vi d i ng enough ten si on i n s pe c t the s p ri ng (i te m 50 ) atta c h i ng i t to the s p i nd l e ba s e. If not enough
ten si on is be i ng put on the a rm , r ep l a c e the s p ri ng.
5. R ep l a c e eng i ne ba s e doo r (i te m 29 ) and s e c u r e wi th scr e ws r e m o v ed ea rli e r .
6. R e c onne c t s pa rk p l ug wir e.
7. C he ck be l t ten si on b y ope r at i ng un i t unde r c ond i t i on s that c au s ed be l t sli ppage. If be l t c ont i nue s to sli p i t m a y r equ ir e
r ep l a c e m ent befo r e ope r at i on c an be c ont i nued.
BLAD E CLUTCH AD J U S TM E NT ( See page s 17 and 18 fo r Pa r t s I ll u s t r at i on and Pa r t s L is t )
D IS C O NN E CT s pa rk p l ug wir e befo r e s e rvici ng un i t.
If cl ut c h c ont i nue s to sli p o r s quea l , do not ope r ate equ i p m ent unt il adequate ad j u s t m ent o r r epa ir ha s been
pe r fo rm ed. I m p r ope r ad j u s t m ent c an c au s e cl ut c h to o v e r heat and sli p, g r eat ly r edu ci ng pe r fo rm an c e and cl ut c h li fe.
D IS C O NN E CT s pa rk p l ug wir e befo r e s e rvici ng un i t.
1
.
Disc onne c t s pa rk p l ug wir e.
2. A s the cl ut c h/b r a k e w ea rs o r beg i n s sli pp i ng o r s quea li ng, ad j u s t m ent m a y be
r equ ir ed to m a i nta i n p r ope r c ab l e ten si on and cl ut c h engage m ent. A p r ope rly
ad j u s ted b l ade cl ut c h s hou l d r equ ir e 10 l b s . of fo rc e to dep r e ss the end of the
- 9.5
mm) .
3. Ad j u s t c ab l e ten si on b y t i ghten i ng o r l oo s en i ng c ab l e ad j u s t m ent nut on r ea r of
eng i ne ba s e ( See Fi g. 9 ) . Be s u r e to l ea v e enough sl a ck i n c ab l e to a ll o w
b l ade b r a k e to engage.
4
.
R
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c
o
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n
e
c
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p
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Fi g. 9

Pa r t N o 501505 11 F 100515 D
N O T E : See Fi g 12 fo r p r ope r be l t r out i ng.
TRAN S A X L E DR IVE B E LT R E M OV AL AND R EP LAC E M E NT ( See page s 21 and 22 fo r Pa r t s I ll u s t r at i on and Pa r t s
L is t )
BLAD E DR IVE B E LT R E M OV AL AND R EP LAC E M E NT ( See page 15 and 16 fo r Pa r t s I ll u s t r at i on and Pa r t s lis t )
Be l t R out i ng Di ag r a m
(T op V i e w of M a c h i ne )
D IS C O NN E CT s pa rk p l ug wir e befo r e s e rvici ng un i t.
D IS C O NN E CT s pa rk p l ug wir e befo r e s e rvici ng un i t.
B l ade Driv e Be l t (wi th Tr an s a xl e
Be l t not Sho w n )
LOOKI N G THR O U G H T OP
Tr an s a xl e Driv e Be l t
( Seated be l o w d riv e be l t on
cl ut c h )
1
.
Disc onne c t s pa rk p l ug wir e.
2. L i ft and s uppo r t the r ea r of the un i t to a ll o w a cc e ss to the unde rsi de
3. U natta c h the s p ri ng (i te m 50 ) f r o m the b r a ck et (i te m 98 ) that is k eep i ng
ten si on on the d riv e be l t. ( See Fi g. 10 )
4. W a lk the be l t (i te m 121 ) off of the cl ut c h (i te m 5 ) b y sl o wly pu lli ng the
eng i ne o v e r . WARN I N G: u s e c aut i on not to p i n c h f i nge rs bet w een the
be l t and cl ut c h.
5. S li p the be l t off of the t r an s a xl e pu ll e y .
6. R ep l a c e the be l t i n r e v e rs e o r de r . N O T E : m a k e s u r e the be l t is s eated
p r ope rly i n the cl ut c h and t r an s a xl e and m a k e s u r e that i t doe s not bend
o v e r the fan b l ade s on the t r an s a xl e.
Fi g. 10
1
.
Disc onne c t s pa rk p l ug wir e.
2. L i ft and s uppo r t r ea r of un i t to a ll o w a cc e ss to unde rsi de.
UN I T IS H E A VY. M a k e s u r e s uppo r t is adequate to s uppo r t w e i ght of
m a c h i ne.
3. Loo s en the fou r scr e ws (i te m 27 ) ho l d i ng de ck be l t c o v e r (i te m 29 ) and r e m o v e
c o v e r .
4. F o ll o w the s tep s 3 and i n the Tr an s a xl e d riv e be l t r e m o v a l s e c t i on to r e m o v e
the Tr an s a xl e d riv e be l t. N O T E: It m a y be ne c e ss a ry to p ry i d l e r pu ll e y (i te m
35 ) a w a y f r o m i t s o ri g i na l po si t i on to r e l ea s e be l t, u si ng a r at c het wi th an
e x ten si on i n the s qua r e ho l e on the i d l e r a rm s hou l d a ll o w the p r ope r l e v e r age
to pu ll i t off the be l t. ( See Fi g. 11 )
5. R e li e v e the ten si on on the b l ade be l t b y pu lli ng the de ck i d l e r a rm off of the be l t.
T hen w a lk the be l t off of the de ck pu ll e y .
6. F eed the be l t ba ck to the eng i ne ba s e then sli p the be l t off of the cl ut c h.
7. In s ta ll the ne w be l t i n r e v e rs e o r de r m a ki ng s u r e the be l t is s eated p r ope rly i n
the cl ut c h.
8. R e c onne c t s pa rk p l ug wir e
Fi g. 11
Fi g. 12

Pa r t N o 501505 12 F 100515 D
TRAN S A X L E DR IVE AD J U S TM E NT
W I R I N G D I A G RAM S
Sta r te r S wi t c h Wiri ng
Sta r te r Circ u i t S c he m at ic Di ag r a m
D IS C O NN E CT s pa rk p l ug wir e befo r e s e rvici ng un i t.
D E CR E A SE
I NCR E A SE
S TARTER
M OTOR
R ED
RED
GREEN /
YELLOW
BLACK
BLACK
BATTERY
ENGINE
GROUND
STARTER
SOLENOID
ENGINE
GROUND
FUSE
20 A
M
G
L
S
WHITE
RED
SWITCH
1
.
Disc onne c t s pa rk p l ug wir e.
2. Ad j u s t m ent s to c ab l e ten si on a r e m ade at the ba rr e l ente ri ng the Driv e
C ont r o l Le v e rs . ( See Fi g. 13 )
3. Ad j u s t c ab l e ten si on b y t i ghten i ng o r l oo s en i ng c ab l e ad j u s t m ent ba rr e l
on r ea r of eng i ne ba s e (s ee be l o w) .
N O T E : M o vi ng the c ab l e ad j u s t m ent ba rr e l O UT i n cr ea s e s ten si on. M o vi ng
the ba rr e l I N de cr ea s e s ten si on. In cr ea si ng the ten si on too m u c h will c au s e
the d riv e to s ta y engaged w he r ea s not enough will c au s e i t not to engage
w hen the l e v e r is pu ll ed.
4. R e c onne c t s pa rk p l ug wir e.
Fi g. 13

Pa r t N o 501505 13 F 100515 D
B a tt ery C are (Fo r Ele t ri - S t ar t i ng Mod els )
P r ope r c a r e c
l ong li fe:
D o not a ll o w the batte ry c ha r ge to get too l o w . If the m a c h i ne is not u s ed, c ha r ge the batte ry e v e ry 6 w ee ks . Ope r ate
the eng i ne fo r at l ea s t 5 mi nute s to m a i nta i n p r ope r batte ry c ha r ge.
Sto r e an unu s ed batte ry i n a d ry a r ea that doe s not f r ee z e.
D o not c ha r ge an a lr ead y c ha r ged batte ry . In theo ry , y ou c annot o v e rc ha r ge ou r batte ry wi th a t rickl e c ha r ge r ; ho w e v e r ,
w hen a batte ry is fu lly c ha r ged and the c ha r ge r is s t ill on, i t gene r ate s heat that c ou l d be ha rm fu l to the batte ry . A fu lly
c ha r ged batte ry will r ead 12V - 13.2V wi th a v o l t m ete r .
D o not c ont i nue to cr an k y ou r eng i ne w hen the batte ry c ha r ge is l o w .
Ch ar g i ng th e B a tt ery
Ope r ate the eng i ne fo r at l ea s t 5 mi nute s to m a i nta i n p r ope r batte ry c ha r ge. If the batte ry l o s e s i t s c ha r ge, y ou will need to
u s e a t rickl e c ha r ge r to r e c ha r ge i t. C a ut i on : T he c ha r ge r s hou l d ha v e an output of 12 v o l t s at no m o r e than 2 a m p s . Usi ng a
c ha r ge r wi th h i ghe r a m p s will c au s e si gn i f ic ant da m age to the batte ry .
At 1 a m p, the batte ry m a y need c ha r g i ng fo r a s l ong a s 8 hou rs .
At 2 a m p s , the batte ry m a y need c ha r g i ng fo r a s l ong a s 2 hou rs .
N O T E : Usi ng the R e c o il Sta r te r and then r unn i ng the eng i ne will not r e c ha r ge a dead o r si gn i f ic ant ly d isc ha r ged batte ry .
N O T E: WH E N YO U A R E F I N IS H E D CH A R GI N G TH E BA TT E R Y, d isc onne c t the c ha r ge r f r o m the out l et f irs t, then
d isc onne c t the batte ry c ha r ge r wir e s f r o m the batte ry . If y ou l ea v e the batte ry c ha r ge r wir e s c onne c ted to the batte ry , the
batte ry will d isc ha r ge i t s e l f ba ck i nto the c ha r ge r .

Pa r t N o 501505 1 F 100515 D
Pr ob lem P o ssi b le C a u se Co rre t ive A t i on
Eng i ne will not s ta r t T h r ott l e is s et to S l o w /Stop po si t i on. M o v e th r ott l e to fa s t po si t i on.
Out of ga s o li ne. Fill ga s tan k .
O l d o r c onta mi nated ga s o li ne. Dr a i n ga s tan k and f ill wi th f r e s h
ga s o li ne.
Spa rk p l ug wir e d isc onne c ted. C onne c t s pa rk p l ug wir e.
Dir t y a ir cl eane r . Cl ean o r r ep l a c e a ir cl eane r .
Sta r te r doe s not tu r n
( E l e c t ric s ta r t on ly)
Batte ry l o w o r dead. C ha r ge o r r ep l a c e batte ry .
Batte ry c ab l e d isc onne c ted o r
c o rr oded.
Cl ean and s e c u r e batte ry te rmi na ls .
D efe c t iv e s ta r te r swi t c h o r wiri ng
ha r ne ss .
R ep l a c e s ta r te r swi t c h o r wiri ng
ha r ne ss .
D efe c t iv e s ta r te r . R ep l a c e s ta r te r .
B l ade d riv e c ab l e ten si on i n c o rr e c t. Ad j u s t b l ade d riv e c ab l e ten si on.
Will not c ut o r c utt i ng pe r fo rm an c e is
poo r
D u ll b l ade. Sha
r pen o r r ep l a c e b l ade. N O T E : a
ne w bo l t will need to be i n s ta ll ed i f
b l ade is r e m o v ed.
Cl ogged de ck . U n cl og de ck .
E xc e ssiv e deb ris bu il t up on o r b l o cki ng
b l ade.
Cl ea r deb ris f r o m b l ade a r ea.
Eng i ne R P M s et too l o w . C he ck eng i ne R P M .
Abno rm a l vi b r at i on s B l ade l oo s e o r out of ba l an c e. C he ck b l ade fo r t i ghtne ss . R eba l an c e i f
ne c e ss a ry .
Eng i ne l oo s e. C he ck eng i ne m ount i ng bo l t s .
B l ade d riv e be l t w o r n. R ep l a c e b l ade d riv e be l t.
Be l t sli p s o r sm o k e s Be l t ten si on too l o w . Ad j u s t be l t ten si on.
Be l t w o r n o r s t r et c hed. R ep l a c e be l t.
Pu ll e ys w o r n o r da m aged. R ep l a c e pu ll e ys .
Cl ut c h sli p s o r s quea ls Cl ut c h c ab l e ten si on too l o w . R ep l a c e s p ri ng on i d l e r a rm .
Cl ut c h w o r n o r da m aged. R ep l a c e w o r n o r defe c t iv e cl ut c h
a ss e m b ly pa r t s .
B l ade b r a k e will not engage Inadequate sl a ck i n cl ut c h c ab l e. Ad j u s t cl ut c h c ab l e.
Cl ut c h w o r n o r da m aged. R ep l a c e cl ut c h/b r a k e a ss e m b ly .
Tr an s a xl e will not engage Cl ut c h l e v e r not engag i ng cl ut c h. Ad j u s t cl ut c h c ab l e.
Cl ut c h c ab l e defe c t iv e. R ep l a c e c ab l e.
Be l t w o r n o r b r o k en. R ep l a c e be l t.
Tr an s a xl e will not d is engage Cl ut c h c ab l e out of ad j u s t m ent. Ad j u s t cl ut c h c ab l e.
Eng i ne will not tu r n o v e r D efe c t iv e b l ade cl ut c h. R ep l a c e cl ut c h.
Eng i ne p r ob l e m . C onta c t an autho riz ed s e rvici ng dea l e r
fo r y ou r eng i ne.