Bolens 600 Series User manual

Service Manual
IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY
PRINTED IN USA FORM NO. 769-00947
This Service Manual is not a substitute for the Operator’s Manual. You must read, understand
and follow all of the directions in this manual as well as the Operator’s Manual before working
on this power equipment.
(10/2003)
600 Series Box Frame
TROY-BILT LLC, P.O. BOX 361131, CLEVELAND, OH 44136-0019
Steering Shaft and Segment Gear Servicing
(These procedures are appropriate for box frame tractors produced after November 2002)

Steering Shaft and Segment Gear Servicing
1
600 SERIES BOX FRAME LAWN TRACTORS
BOLENS RIDER SHOWN
If for any reason the steering shaft or segment gear
become damaged, inspect the steering componants
paying particular attention to the steering shaft gear
and hex flange bearing where it mounts to the frame.
Also inspect the sector gear for wear or damage. A
new hex flange bearing is available to replace the old
bearing. Part Number 741-656A
1. STEERING SHAFT REMOVAL
NOTE: For ease of repair refer to DECK
REMOVAL SECTION
1.1. Using a screwdriver, pry the steering wheel cap
from the center of the steering wheel. See Fig-
ure 1.
1.2. Using a ½” socket and extension remove the
hex cap screw securing the steering wheel to the
steering shaft. Remove the steering wheel. See
Figure 2.
1.3. Raise the rider to gain access to the underside
of the unit.
Figure 1
Figure 2
Steering Shaft and Segment Gear Servicing
600 Series Box Frame Lawn Tractors

Steering Shaft and Segment Gear Servicing
2
1.4. Using an impact gun with a large Phillips head
socket, remove the machine screw and cap
securing the steering shaft to the frame. See
Figure 3.
NOTE: During reassembly use Locktite 262 to
secure the screw to the shaft.
1.5. Disconnect the headlight wiring connector inside
the lower right side of the grill. See Figure 4.
1.6. Using a ½” socket and extension, remove the
two hex screws and flat washers securing the
grille to the rider frame. See Figure 4.
1.7. Using a 3/8” socket remove the four (two on
each side) self-tapping screws securing the rear
of each side panel to the dash panel and frame.
See Figure 5.
1.8. Remove the entire hood assembly from the rider.
See Figure 6.
Figure 3
Steering shaft through frame
Figure 4
Wiring Connector
Hex Screws and washers (Both sides of Grille)
Figure 5
Self Tapping Screws (2 on each side)
Figure 6

Steering Shaft and Segment Gear Servicing
3
1.9. Remove the wiring connector attached to the
ignition switch. See Figure 7.
1.10. Using a 3/8” socket, remove the six bolts, two on
each side and two on the back, securing the
dash panel to the frame. See Figure 8.
Figure 7
Figure 8
Dash Mounting Bolts (6)
Mountng Bolts
1.11. Lift and pivot the dash panel to the left while
removing the steering shaft from the hole in the
frame by the steering segment gear. See Figure
9.
1.12. Slide the steering shaft from the hole in the dash
panel. See Figure 9.
Figure 9

Steering Shaft and Segment Gear Servicing
4
1.13. Inspect the steering shaft, pressed-on gear,
washer, hex flange bearing, cap and machine
screw for wear or damage. See Figure 10.
NOTE: Install the steering shaft in the reverse
order of disassembly.
NOTE: A new hex flange bearing is available
that replaces the old bearing. Part Number 741-
656A
NOTE: Figure 11 shows the mounting of the
steering shaft and sector gear through the
frame. See Figure 11.
2. STEERING SEGMENT GEAR REMOVAL
NOTE: For ease of repair refer to DECK
REMOVAL SECTION.
NOTE: Remove the steering shaft. SEE STEER-
ING SHAFT REMOVAL SECTION.
2.1. Set the parking brake by fully depressing the
clutch-brake pedal. Move the speed control lever
all the way to the rear and release it into the
parking brake position. This will allow access to
placement of a wrench or socket on the bolt and
flange lock nuts holding the steering segment
from beneath the rider. See Figure 12.
2.2. Using 9/16” box end wrench on the upper side of
the hex cap screw and an air gun with a 9/16”
socket on the flange lock nut, remove the flange
lock nut. See Figure 13.
Figure 10
Steering shaft and pressed gear
Flat Washer
Hex Flange Bearing
Cap
Machine Screw
(Locktite during assembly)
Figure 11
Figure 12
Parking Brake Engaged
Figure 13
Hex Cap Screw
Flange Lock Nut

Steering Shaft and Segment Gear Servicing
5
2.3. Using a 5/8” box end wrench on the upper side
of the shoulder screw and an air gun with a ½”
socket on the flange lock nut, remove the flange
lock nut. See Figure 14.
2.4. Using a ½” opened end wrench on the top and a
9/16” opened end wrench on the bottom, remove
the ball joint from the steering arm. See Figure
15.
Figure 14
Shoulder Screw
Flange Lock Nut
Figure 15
Ball Joint
Steering Arm
2.5. Remove the segment gear, steering drag link,
and ball joint as one assembly from the rider and
inspect for any wear or damage. Pay particular
attention to the segment gear teeth. See Figure
16.
IMPORTANT: There is a spacer in the center of
the segment gear that also acts as a bushing.
NOTE: Removing the Segment gear in the man-
ner maintains the correct toe-in for the tractor.
NOTE: Install the steering segment gear in
reverse order of disassembly.
Figure 16
Steering Segment Gear
Steering Drag Link
Ball Joint