Craftsman 987.293330 User manual

Operator's Manual
II:RRFI"SMRN I
8 HORSEPOWER
REAR TINE TILLER
Model No: 987.293330
CAUTION:
Before using this tiller, read
this manual and follow all its
Safety Rules and Operating
Instructions,
•Safety Rules
•Assembly
•Operation
•Maintenance
•Parts
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
Visit the Craftsmanweb page:www.sears.com/craftsman

SAFETY RULES
_CAUTION: ALWAYS DISCONNECT SPARK PLUG WIRE AND PLACE WIRE WHERE IT
CANNOT CONTACT SPARK PLUG TO PREVENT ACCIDENTAL STARTING WHEN SET-
TING UP, TRANSPORTING, ADJUSTING OR MAKING REPAIRS. u
TRAINING
1. Carefully readthis Owner's Manual
andanyother literature you may receive
before operatingthis equipment. Be
thoroughly familiar with the controls and
the proper useof the tiller and its.engine.
Knowhow to stop the unit and disengage
the controls quickly.
2. Neverallowchildrento operatethe
tiller. Neverallowadults to operatethe
tiller without proper instruction.
3. Keepthe areaof operationclearof all
persons, particularly children and pets.
Keepbystanders at least25 feetfrom
areaof operation.
4. Keepin mind that the operator or user
is responsiblefor accidents or hazards
occurring to other people,their property,
and themselves.
5. Familiarizeyourself with allof the
safetyandoperatingdecals on this"
equipifiedt andon any of its attachments
or accessories.
6. Donot run enginein an enclosedarea.
Engineexhaustcontainscarbon monox-
ide gas, a deadlypoison that is odorless,
colorless, and tasteless. Do not operate
this equipmentnear buildings, windows,
or airconditioners.
7. Do not allow handsor anyother part
of the body or clothing nearthe rotating
tines or nearany other moving part. The
tines beginto rotate backward oncethe
engine starts, and eitherthe Forward
Clutchor the
ReverseClutch
Leveris engaged
(theWheelGear
Levermustalways
be moved to EN-
GAGEbeforethe
engine is started).
8. Beforeinspectingor servicing any
partof the equipment, shut off the
engine,wait for all moving parts to come
to a complete stop, disconnect the spark
plug wire from the spark plug, and move
the wire awayfrom the spark plug.
g. Donot operatethis equipment if you
are under the influence of alcohol, medi-
cation,or whentired or ill.
PREPARATION
1. Thoroughly inspect the areawhere
the tiller is to be usedand remove all for-
eign objects.
2. Besure all control levers are released
andthe Wheel GearLever isin ENGAGE
beforestarting the engine.
3. Donot operatethetiller without wear-
ing adequateouter garments. Avoid
loose garmentsor jewelry that could get
caught in moving parts of tiller or engine.
4. Donot operatethetiller whenbarefoot
orwearingsandals,sneakers,or light
footwear. Wearprotectivefootwearthat
will improve footing on slippery surfaces.
5. Do nottill nearundergroundelectricca-
bles,telephonelines,pipesor hoses. If in
doubt, contactyourtelephoneor utility
company.
6. Warning:Handlefuel with care;it is
highlyflammableand itsvaporsareexplo-
sive. Takethefollowing precautions:
a. Store fuel in containersspecifically
designedfor this purpose.
b. Thegas capshall neverbe re-
moved or fuel addedwhile the en-
gine is running. Allow the engine
to coo[ for several minutes before
adding fuel.
c. Keepmatches,cigarettes,cigars,
pipes, open flames, and sparks
awayfrom thefuel tank andfuel
container.
d. Fillfuel tank outdoors with extreme
care. Neverfill fuel tank indoors.
Use afunnel or spout to prevent
spillage.
e. Replaceall fuel tank and container
capssecurely.
f. If fuel is spilled, do not attempt to
start the engine,but move the
machineawayfrom the areaof
spillage andavoid creating any
source of ignition until fuel vapors
havedissipated.
7. Nevermakeadjustmentswhenengine
is running (unless recommendedby
manufacturer).
OPERATION
1. Donot put handsor feet nearor un-
der rotating parts.
2. Exerciseextreme cautionwhen on or
crossing gravel drives,walks, or roads.
Stay alertfor hidden hazardsor traffic.
Do not carry passengers.
3. After striking aforeign object, stop the
engine,disconnect the spark plug wire
and prevent it from touching the spark
plug, carefully inspect thetiller for any
damage,and repairthe damagebefore
restarting and operatLngthe tiller.
4. Exercisecaution to avoidslipping or
falling.
5. If theunit shouldstartto vibrateabnor-
mally,stop theengine. Disconnectthe
spark plug wireand preventit from touch-
ingthe sparkplug, andcheckimmediately
for the cause.Vibration is generallya
warning of trouble.
6. Stop the engine,disconnect the spark
plug wire and prevent it from touching
the spark plug wheneveryou leavethe
operating position, before unclogging the
tines, or when making any repairs, ad-
justments or inspections.
7. Takeall possible precautionswhen
leavingthe machineunattended.Stopthe
engine.Disconnect spark plug wire and
move itawayfrom the spark plug. Move
WheelGearLeverto ENGAGE.
8. Beforecleaning, repairing, or inspect-
ing,stop the engine,and makecertain all
moving parts havestopped. Disconnect
the spark plug wire and preventit from
touching the spark plug to preventacci-
dentalstarting.
9. Always keepthe tiller tine hood flap
down.
LOOK FOR THIS SYMBOL TO POINT OUT IMPORTANT SAFETY PRECAUTIONS.
IT MEANS-ATTENTIONH[ BECOME ALERTIH YOUR SAFETY IS INVOLVED.
© Sears, Roebuck and Co. 2

SAFETY RULES
10. Neverusethe tiller unlessproper
guards,plates,or othersafetyprotective
devicesareinplace.
11. Do not run engine in an enclosed
area.Engineexhaustcontains carbon
monoxide gas, a deadlypoisonthat is
odorless, colorless, and tasteless.
1;'. Keepchildrenand petsaway.
13. Neveroperatethe tiller under engine
power if the WheelGearLeveris in
DISENGAGE(FREEWHEEL).In this posi-
tion, the wheelswill not hold the tiller
back andthe revolving tines could propel
the tiller rapidly backward, possibly caus-
ing loss of control. Always move the
WheelGearLeverto ENGAGEbefore
• starting the engine or engaging the
tines/wheels with the Forward Clutch or
the ReverseClutch.
14. Beawarethattheti_lermay unex-
pectedlybounce upwardor jump back-
ward if thetines should strike extremely
hard packedsoil, frozen ground, or
buried obstacleslike large stones, roots,
Qrstumps. If in doubt about the tilling
conditions, always usethefollowing op-
erating precautionsto assist you in main-
taining control of the tiller:
a. Walk behind and to one side ofthe
.,, tilier,,using one hand on the han-
dlebars. Relaxyour arm, but usea
secure hand grip.
b. Useslower engine speeds.
c. Clearthe tilling area of all large
stones, roots and other debris.
d. Avoid using downward pressure on
handlebars. If needbe, useslight
upward pressure to keepthe tines
..... from digging too deeply.
•e. In an emergency,stoptines and
wheels byreleasingwhichever
ClutchLeveris engaged.Do not
attemptto restrainthetiller.
15. Do not overloadthe tiller's capacity
by attemptingto till too deeplyattoo fast
a rate.
16. Never operatethetillerat high trans-
portspeeds on hard or slippery surfaces,
Lookbehindand usecarewhenbacking
up.
17. Donot operatethetilleron a slope
thatistoo steepfor safety.Whenon
slopes,slowdownand makesureyou
havegoodfooting. Neverpermitthetiller
to freewheeldownslopes.
18. Neverallowbystandersnearthe
unit.
19. Only useattachmentsandacces-
soriesthat areapprovedby thetiller
manufacturer.
20. Usetiller attachmentsand acces-
sories when recommended.
21. Neveroperatethetiller without good
visibilityor light.
22. Neveroperatethetiller ifyou aretired,
or underthe influenceof alcohol,drugsor
medication.
23. Operatorsshallnottamperwiththe
engine-governorsettingsonthemachine;
thegovernorcontrolsthe maximumsafe
operatingspeedto protecttheengineand
all moving partsfrom damagecausedby
overspeed.Authorizedserviceshallbe
sought ifa problemexists.
24. Donottouch enginepartswhich may
behotfrom operation.Letpartscooldown
sufficiently.
25. Pleaseremember:Youcanalways
stopthetines andwheelsbyreleasingthe
ForwardClutchLeveror theReverseClutch
Lever(whicheverleveryou haveengaged)
or bymovingtheThrottleControlLeverto
STOP.
26. Toloador unloadthetiller, seethein-
structionsinthisManual.
27. Useextremecautionwhenreversing
or pullingthemachinetowardsyou.
28. Startthe enginecarefullyaccordingto
instructionsandwith feetwellawayfrom
thetines.
29. Neverpick upor carrya machinewhile
theengineisrunning.
MAINTENANCE/STORAGE
1. Keepthe tiller,attachments andacces-
sories in safe workingcondition.
2. Checkall nuts, bolts, andscrews at
frequent intervalsfor propertightness to
besure the equipment is in safeworking
condition.
3. Neverstorethetillerwith fuel inthe fuel
tank insidea buildingwhereignition
sourcesare present(suchashot waterand
spaceheaters,furnaces,clothesdryers,
stoves,electricmotors, etc.). Allowengine
to coolbeforestoring in anyenclosure.
4. Toreducethechancesof afire hazard,
keeptheenginefreeof grass,leaves,or
excessivegrease.
5. Storegasolineina cool,well-ventilat-
edarea,safelyawayfrom anyspark-or
flame-producing equipment.Storegaso-
lineinanapprovedcontainer,safelyaway
from the reachofchildren.
6. Referto the ServiceandAdjustments
Section ofthis Manualif thetiller is to be
stored for an extendedperiod.
7. Neverperform maintenancewhile the
engine is running or thespark plugwire is
connected,exceptwhen specificallyin-
structed to do so.
8. If the fuel tank hasto be drained,do
this outdoors.
TOAVOIDINJURY:
•READOWNER'SMANUAL.
•KNOW LOCATION AND
FUNCTION OF ALL CON-
TROLS.
•KEEPALL SAFETYDEVICES
AND SHIELDS IN PLACE
ANDWORKING,
•NEVERALLOW CHILDREN
ORUNINSTRUCTEDADULTS
TOOPERATETILLER.
•SHUT OFF ENGINE AND
DISCONNECTSPARKPLUG
WIRE BEFORE UNCLOG-
GING TINES OR MAKING
REPAIRS.
•KEEPBYSTANDERSAWAY
FROMMACHINE,
•KEEPAWAYFROM ROTAT-
INGPARTS.
•USE EXTREME CAUTION
WHEN REVERSING OR
PULLINGTHE MACHINETO-
WARDSYOU.
WARNING:
The engine exhaust from this
product contains chemica!s
knownto the State ofCaliformai
to cause cancer, birth defects,i
orotherreproductiveharm.

CONGRATULATIONS on your purchase of a Sears
Craftsman tiller. It has been designed, engineered and
manufactured to give you the best possible dependability
and performance.
Should you experience any problems you cannot easily
remedy,please contact your nearest Sears Service Cen-
ter/Department. We have competent, well-trained tech-
nicians and the proper tools to service or repair this
machine.
Please read and retain this manual. The instructions will
help you assemble and maintain your machine properly.
Always observe the "SAFETY RULES."
MODEL NUMBER: 987.293330
SERIAL
NUMBER:
DATE OF
PURCHASE:
THE MODELAND SERIAL NUMBERS WILL BE
FOUND ON A DECAL LOCATED ON THE TRANS-
MISSION OF YOUR MACHINE.
YOU SHOULD RECORD BOTH THE SERIAL NUM-
BER AND DATE OF PURCHASE AND KEEP IN A
SAFE PLACE FOR FUTURE REFERENCE.
MAINTENANCEAGREEMENT
A Sears maintenance agreement is available on this
product. Contact your nearest Sears store for details.
CUSTOMERRESPONSIBILITIES
O Read and observe the safety rules.
O Follow a regular schedule in maintaining, caring for
and using this product.
[] Follow the instructions under "CUSTOMER
RESPONSIBILITIES" and "STORAGE" sections of
this manual.
PRODUCTSPECIFICATIONS
HORSEPOWER: 8 HP
DISPLACEMENT: 19.43 CU. iN.
FUEL CAPACITY: 2 Quarts
SPARK PLUG (GAP 0.030-in.): Champion RJ-17LM*
or equivalent
IGNITION: Electronic
NET ENGINE WEIGHT: 50 LBS.
NET TILLER WEIGHT: 204 LBS.
•InCanada, replacespark plugwitharesistorplug.
WARNING
This machine is equipped with an internal combus-
tion engine and shouldnot be used on or near any
unimproved forest-covered, brush-covered or
grass-covered land unless the engine's exhaust
system is equipped with a spark arresfer meeting
applicable local or state laws (if any). If a spark
arrester is used, it should be maintained in
effective workingorder bythe operator.
In the state of California the above is required by
law (Section 4442 of the California Public
Resources Code). Other states may have similar
laws. Federal laws apply on federal lands. This
engine is not equippedwith a spark arrestor for the
muffler. Asparkarrester for the muffler is
available through your nearest Sears authorized
service center. See the REPAIR PARTSsection of
this manual. *,
LIMITEDTWO-YEARWARRANTYONCRAFTSMAN®TILLER
Fortwo years from the dateof purchase,when this Craftsman®Tiller ismaintained,lubricated, and tuned up according to the
operating maintenanceinstructions in the owner's manual, Searswill repair,free of charge, anydefect in material or
workmanship.
Ifthis Craftsman®Tilleris usedfor commercialor rental purposes,thiswarrantyappliesfor only90 daysfrom the dateof
purchase.
THISWARRANTYDOESNOTCOVER:
• Expendableitems whichbecomewornduringnormaluse,suchastJQ.P,.(._,belts,soarkglue, andair cleaner.
• Repairsnecessarybecauseofoperatorabuseor negligenceincludingbentcrankshaftsandthefailureto maintain the
equipmentaccordingtotheinstructionscontainedintheowner'smanual.
WARRANTYSERVICEISAVAILABLEBYRETURNINGTHECRAFTSMAN@TILLERTOTHENEARESTSEARSSERVICECENTERIN
THEUNITEDSTATES.THISWARRANTYAPPLIESONLYWHILETHISPRODUCTISIN USEINTHEUNITEDSTATES.
Thiswarrantygivesyou specificlegalrights,andyou mayalso haveotherrightswhichvary from stateto state.
Sears, Roebuck and Co., D/817WA, Hoffman Estates, IL 60179
4

TABLE OF CONTENTS
SAFETY RULES ................................................... 2
PRODUCT SPECIFICATIONS .............................. 4
WARRANTY .......................................................... 4
ACCESSORIES .................................................... 6
CONTENTS OF HARDWARE PACKAGE ............ 7
ASSEMBLY ........................................................... 8
OPEI_ATION ....................................................... 12
CUSTOMER RESPONSIBILITIES ..................... 22
ii
SERVICE AND ADJUSTMENTS ........................ 26
STORAGE ........................................................... 32
TROUBLESHOOTING ........................................ 33
DECALS .............................................................. 34
REPAIR PARTS -TILLER .................................. 35
REPAIR PARTS -ENGINE: .................... ............ 50
PARTS ORDERING/SERVICE ........... Back Cover
A
Accessories .................. 6
Air Cleaner Maintenance ....... 25
Assembly .................... 8
B
Break-In Operation ........... 16
Belt Tension Adjustment ....... 28
Belt Removal and Replacement ,30
C
Carburetor .................. 25
Changing Engine Oil .......... 24
Changing Transmission Oil ..... 24
Checking/Adding Engine Oil .... 24
Checking/Adding Transmission Oil 24
Checking/Adjusting Belt Tension. 28
Checking for Oil Leaks ......... 23
Check List, Pre-Starting ........ 15
Cleaning .................... 25
Cooling System Maintenance... 25
Controls .................... 12
D
Decals ..................... 34
Depth Regulator Lever ........ 14
E
Engine
Air Filter .................. 25
Carburetor ................ 25
Choke Lever ............... 15
Cooling System ............ 25
Fuel Tank ................. 16
Oil, Checking/Adding ........ 24
O_5_rat'ion.... _............ 16
Parts ..................... 50
Recoil Start Rope ........... 15
Spark Plug ................ 25
Speed .................... 15
Starting Engine ............. 16
Stopping Engine ............ 16
Storage ................... 32
Throttle Lever ........... 10,15
INDEX
F
Features/Controls ............ 12
Forward Clutch ............. 9,13
Forward Travel ............... 17
Fuel Tank ................... 16
G
Guiding the Tiller ............. 17
il
Handlebar Height Adjustment . .8,14
Hardware .................... 7
Leaks, Oil ................... 23
Loading and Unloading Tiller .... 21
Location of Controls ........... 12
Lubrication .................. 23
M
Maintenance Schedule ........ 22
Maintenance Agreement ........ 4
Model/Serial Number ........... 4
Motor Oil, Adding .......... 15, 24
Motor Oil, Changing ........... 24
0
Oil ...................... 15
Off-Season Storage ........... 32
Operation ................... 17
P
Parts List ................... 35
Pre-Start Checklist ............ 15
Product Specifications .......... 4
R
Reverse Clutch .............. 13
Reverse Travel .............. 18
Recoil Starter Rope ........... 15
Repair Parts ................. 35
5
S
Safety Rules ................. 2
Safety Decals ............... 34
Seedbed Preparation .......... 19
Service Recommendation
Checklist ................. 22
Slopes ..................... 20
Spark Plug .................. 25
Starter Rope ................ 15
Storage .................... 32
T
Tiller Parts .................. 35
Tilling ...................... 17
Tilling Depths ................ 19
Tine Cleaning ................ 20
Tine Removal ................ 26
Transmission Gear Oil ......... 24
Troubleshooting .............. 33
Turning Around .............. 18
II
Unpacking ................... 8
Untangling Tines ............. 20
W
Warranty .................... 4
Wheel Gear Lever ............ 12
Wheel Gear Cable Adjustment . .26
RIGHT
SIDE
OPERATOR'S
POSITION
LEFT
FORWARD SIDE
OPERATOR'S POSITION
All references to LEFT and
RIGHT sides of the tiller are
given from the operator's posi-
tion behind the handlebars (un-
less specified otherwise).

ACCESSORIES
These accessories were available when the tiller was purchased. They are available at most Sears retail
outlets, catalog and service centers. Most Sears stores can order repair parts for you when you provide the
model number of your tiller.
ACCESSORIES
Spark Plug GasCan
"'Figure 1-1
Motor Oil
COMPONENTS REQUIRING ASSEMBLY
ENGINE
LEVER
REVERSE
CLUTCHROD
WHEEL
FORWARD
CLUTCHROD
HANDLEBARS
Figure1-2
6

10
©©
©©
Figure1.3
CONTENTS OF HARDWARE PACK
Hardware packed in carton
2
11,
Ref. No,
1
2
3
4
5
6
7
8
9
10
11
12
13
Hardware Description Qty.
Height Adjustment Handle (for handlebar) ........... 1
Keyed Washer (for height adjustment handle) ..... 1
Plastic Tie Strap ................................................... 4
Hairpin Cotter ....................................................... 3
3/8"-16 1" Hex Hd. Screw .................................... 2
3/8" Flat Washer .................................................. 2
3/8"-16 Nylok Lock Nuts ...................................... 2
Throttle Lever Knob ............................................. 1
#10-32 x 1/2" Round Hd. Screw .......................... 4
#10 Lockwasher ................................................... 4
#10-32 Nut ........................................................... 4
Wheel Gear Lever Knob ...................................... 1
5/16" Flat Washer .................................................. 1
T00LS/MATERIALS
NEEDEDFOR ASSEMBLY
(1) *3/8" open end wrench
(2) * 9/16" open end wrenches
(1) Scissors (to trim plasticties)
(1) Ruler
(1) Small Board (to tap plastic
knobs on control levers)
(1) Automotive-type air pressure
gauge
(1) Clean Oil Funnel
(1) Clean high-quality engine oil.
Refer to the assembly instruc-
tions in this manual for engine
oil specifications and quantity
required. Do not overfill.
• Adjustable wrenchesmay be used.
IMPORTANT: Motor oil must be
added to the engine crankcase be-
fore the engine is started. Follow the
instructionsin the "Operation" section.
7

ASSEMBLY
Read these instructions completely
before you attempt to assemble or
operate your new equipment. Your
tiller has been assembled at the fac-
tory with the exception of those parts
left'unassembled for shipping pur-
poses. Steps in this section show
you how to assemble them. To en-
sure safe and proper operation of
your machine, all parts and hard-
ware you install or adjust must be
tightened securely. Use the correct
tools as necessary to ensure proper
tightness.
UNPACKINGINSTRUCTIONS
•Inspect your machine immediately.
Be sure neither the carton nor con-
tents have been damaged. If you
'.find or have reason to suspect
damage, contact the nearest
Sears Service Center for
assistance.
• Once the cardboard shipping car-
ton is open, remove any packing
material from around the machine.
Remove any staples securing bot-
tom of carton to wood pallet. Lift
.,off carton. Before disposing of the
carton or any of the packing mate-
rials, be sure to check them thor-
oughly for any small parts.
Leave unit on base of pallet dur-
ing assembly steps (to safely re-
move unit from pallet, wait until
you have installed the handlebar
assembly and the Wheel Gear
Lever is placed in DISENGAGE).
The procedure for removing the
tiller isexplained in Step 1, item 6
of these assembly steps.
• Also remove any packaging around
the handlebar.
• Perform the assembly on a clean,
level surface. If you need to move
the machine, be careful not to
severely bend any of the control
cables on the equipment.
•Remove the handlebar assembly
from the carton. Do not remove
the two control levers from the
'handlebars.
•A plastic bag inside the literature
envelope contains loose hardware.
Open the bag and check the con-
tents against the hardware list on
Page 7 and the hardware shown in
Figure 1-3.
ASSEMBLYSTEPS
STEP 1: Attach the Handlebars
1. Remove the Reverse Clutch
Lever (B, Figure 2-1) from the han-
dlebars (A). Remove any rubber
bands from the handlebars.
2. Position the handlebar cross-
brace (C, Figure 2-2) in front of the
curved height adjustment bracket (D)
and place the handlebar ends to the
outside of the two mounting tabs on
top of the transmission.
3, Attach the handlebars to the
mounting tabs with two 3/8-16 x 1"
screws (heads of screws go to inside
of tabs), 3/8" flat washers and 3/8"-
16 Nylok lock nuts (see Figure 2-2).
Do not fully tighten the screws at this
time.
4. Move the handlebar to align the
hole in the cross-brace with one of
the four slots in the curved height
adjustment bracket. Place the keyed
washer (E, Figure 2-3) on the height
adjustment handle (F) with the
raised keys (edges) on the keyed
washer facing down.
5. Screw the height adjustment han-
dle (F) into the threaded hole in the
handlebar cross-brace, making sure
that the raised keys on the washer fit
into the selected slot on the curved
bracket. Tighten the height adjust-
ment handle securely. Next, secure-
ly tighten the two screws that attach
the handlebar ends to the mounting
tabs (Figure 2-2).
6. To remove the tiller from its ship-
ping platform, free the wheels by
moving the Wheel Gear Lever (G,
Figure 2-4) to the DISENGAGE posi-
tion (this allows the wheels to ro-
tate). Carefully unwrap the wheel
gear cable from around the unit be-
fore moving the lever. Use this DIS-
ENGAGE mode only when the en-
gine is not running. Before starting
the engine, the Wheel Gear Lever
must be placed in the ENGAGE po-
sition (see the "Operation" section
for details).
Figure2.1:RemoveReverseClutchLever.
D
Figure2-2: Attachhandlebars.,
E F
Figure2-3:Installheightadjustmenthandle.
Figure2-4:PutWheelGearLeverIn
DISENGAGEposition.

ASSEMBLY
STEP2: AttachReverseClutch
Lever
1. Slide the Reverse Clutch Lever
(removed in Step 1) down through
the hole in the left side of the handle-
bar control panel and pass it above
the cross-brace at the lower end of
the handlebar.
2. Insert the end of the lever (I, Fig-
ure 2-5) through the hole in the pivot
(J). Note that there are two small
holes in the lower end of the lever.
3. Install a5/16" flat washer (K) and
secure it with a hairpin cotter (L)
throughthe bottomholein the lever.
Figure2-5:InstaNReverseClutchLever.
IMPORTANT: If the handlebar is ad-
justed to the highest position, then
the bottq_mof the Reverse Clutch
Lever must be secured with the hair-
pin cotter (L) through the top hole in
the lever. Simply remove the hairpin
cotter, slide the washer (K) up the
lever, and replace the hairpin cotter.
STEP3: AttachForwardClutchRod
1. The upper end of the Forward
Clutch rod is attached to the bottom
of the handlebar control panel. Turn
the rod (M, Figure 2-6) so the small
bend at its lower end points inward.
2. Insert a hairpin cotter down
through the hole located closest to
the bend (see Figure 2-6).
3. There are four numbered holes in
the i_ldtchswivel plate (see Figure 2-
7) and four numbered slots in the
curved height adjustment bracket.
For correct operation of the Forward
Clutch rod, the numbered hole used
for the Forward Clutch rod must
match with the numbered slot in the
height adjustment bracket. For ex-
ample, if the handlebar is set in slot
#1, then the Forward Clutch rod
must be installed in hole #1 of the
clutch swivel plate.
IMPORTANT: Whenever the handle-
bar heightischanged, the hole posi-
tion of the Forward Clutch rod must
be changed accordingly. Changing
the handlebar height changes the
tension on the Forward Clutch rod-
this tension must be adjusted by
relocating the rod in the appropriate
hole in the clutch swivel plate.
4. Select the proper hole in the
clutch swivel plate and insert the
Forward Clutch rod so that the tip
faces inward (see Figure 2-7). Se-
cure the rod by inserting a second
hairpin cotter through the hole near
the tip of the rod.
5. Check for correct tension on the
Forward Clutch rod as follows:
(a) There are two interconnected
Forward Clutch paddles that
hang beneath the control panel.
Lift and hold the right-side paddle
against the handlebar grip.
(b) While squeezing the paddle,
measure the gap between the E-
ring and the lower end of the
clutch rod bracket (see Figure 2-
8). The gap should be 3/16"-to-
5/16". NOTE: A stack of 5 pen-
nies is approximately 5/16" thick.
(c) If the gap is incorrect:
(1) First check that the Forward
Clutch rod is in the correct
hole in the clutch swivel plate.
If not, reposition the rod and
repeat Step 5b.
(2) If the Forward Clutch rod is in
the correct hole and the gap is
incorrect, you will need to ad-
just the length of the Forward
Clutch rod. To do this, first re-
lease the Forward Clutch pad-
dle and then disconnect the
rod from the clutch swivel
plate (remove hairpin cotter at
end of rod and pull rod out of
hole in clutch swivel plate).
If the gap is more than 5/16",
rotate the rod counterclock-
wise (as viewed from the front
of tiller) to decrease the gap.
Reinstall the rod in the correct
clutch swivel plate hole, se-
cure it with the hairpin cotter,
and repeat Steps 5a and 5b.
If the gap is less than 3/16",
rotate the rod clockwise (as
viewed from the front of tiller)
to increase the gap. Reinstall
the rod in the correct clutch
swivel plate hole, secure it
with the hairpin cotter, and re-
peat Steps 5a and 5b.
Figure2-6: Install ForwardClutchrod.
Figure2-7:Numberedsettingsforhandle-
barheightslotsandclutchswivelplate
holes.
Gapshouldbej
3/16"-to-5/'16"
Figure2-8. WhilesqueezingForward
Clutchpaddle,measuregapbetweenend
ofbracketandE.ring.
9

ASSEMBLY
STEP4: CheckGearOilLevelin
TranS'm[ssion
The transmission was filled with gear
oil at the factory. However, be sure
to check the oil level at this time.
1. Move the tiller to a level area.
2. Pull the Depth Regulator Lever
(N, Figure 2-9) straight back and
then slide it to the second notch from
the top. If the lever does not move
freely, lift the tine hood flap and look
for a plastic tie securing the lever in
place. Cut and remove the tie.
3. Remove the oil level check plug
(O, Figure 2-10) on the left-side of
the transmission. (Due to dried paint
on the plug threads, it may require
some force to remove the plug the
first time.) The gear oil level is cor-
rect if oil starts to flow out of the hole
as the plug is removed. If so, se-
curely reinstall the plug.
4. If oil does not flow from the check
hole, add SAE 140, SAE 85W-140 or
SAE 80W-90 weight gear oil (prefer-
ably use API rated GL-4 gear oil,
however GL-5 can be used for small
top-offs) as follows:
NOTE: Do not use automatic trans-
mission fluid or engine oil in the
transmission.
(a) Clean area around oil fill hole (P,
,,.Figure,2-11)and unscrew oil fill
plug.
(b) Using a clean funnel, slowly add
gear oil until itflows from the oil
level check hole (O, Figure 2-10).
Securely reinstall the oil level
check plug (O).
(c) Reinstall and tighten the oilfill
plug.
Figure2.9:PutleverInsecondnotch.
Figure2.10: Gearoillevelcheckplug.
Figure2-11: Addinggearoilin o/Ifill hole.
STEP5: AttachThrottle Lever
For shipping purposes, the engine
throttle cable assembly is wrapped
around the engine. Carefully unwrap
the cable and attach it as follows:
1. Route the throttle cable up the
right-side handlebar. Insert its lever
(R, Figure 2-12) up through the slot
in the control panel labeled "ENGINE
THROTTLE."
2. Insert two #10-32 x 1/2" round
head screws down through the "+"
marks on the control panel decal and
through the holes in the base of the
engine throttle lever.
3. Hold the engine throttle lever
base against the bottom of the con-
trol panel and secure it with two #10
Iockwashers and #10-32 nuts.
4. Place the "T" shaped engine
throttle lever knob on the end of the
lever. Use a board to tap knob until it
seats firmly on lever (Figure 2-12).
5. Move the lever forward and back-
ward - it should move freely through
the full range of travel. (Note that
there is a detent at the SLOW setting
Figure2.12:Attachenginethrottlelever.
which catches the lever. This detent
prevents the lever from unintention-
ally moving to the STOP setting
when you are just trying to slow the
engine down.) If the lever is difficult
to move away from the STOP set-
ting, loosen both screws and move
the lever assembly slightly to the left.
Retighten screws and recheck move-
ment. Adjust the lever as needed.
6. Secure the throttle cable to the
right-side handlebar with two plastic
ties (S, Figure 2-13) located about
two feet apart. The serrated side of
the tie must be on the inside of the
loop. Trim tie length with scissors.
STEP6: AttachWheelGearLever
For shipping purposes, the wheel
gear cable is wrapped around the
transmission. Carefully unwrap the
cable and attach it as follows:
1. Route the wheel gear cable up
the left-side handlebar and insert the
lever (T, Figure 2-14) up through the
slot in the control panel that is la-
beled "WHEEL GEAR."
2. Insert two #10-32 x 1/2" round
head screws down through the "+"
marks on the control panel decal and
through the holes in the base of the
wheel gear lever. '....
3. Hold the wheel gear lever base
against the bottom of the control
panel and secure it with two #10
Iockwashers and #10-32 nuts.
4. Place the wheel gear lever knob
on the end of the lever and use a
board to tap the knob down until it
seats firmly on the lever (see Figure
2-14).
5. Secure the cable to the left-side
handlebar with two plastic ties (U,
Figure 2-13) located about two feet
apart. Snip off any excess tie length
with scissors.
10