Troy-Bilt 12087 Owner's manual

$7.50
Owner/Operator
Manual
PTO HORSE® Tiller
• Safety
• Assembly
• Features and Controls
• Operation
• Maintenance
)

Be sure to fill
out and return
your Owner
Registration
Card, which is
located in
your
literature pack- .~~~ ••
age. The infor-
mation con-
tained on this card will register
your machine with us and entitle
you
to full coverage under our
Full No-Time-Limit Warranty.
NOTE: AWarranty Transfer Card
is included
in this Manual. This
card should be filled out and re-
turned to us ONLY if you transfer
ownership of your machine
to
someone else.
Be Sure To Return Your Owner
Registration Card
This is asafety alert
symbol.
It is used in
this Owner/Operator
Manual to alert you
to potential hazards.
Whenever you see
this symbol, read and obey the
safety message that follows it.
Failure to obey the safety message
could result in petsonal injury or
property damage.
Dear Owner,
You now own one of the finest rear-
tine rototillers available. Your new PTO
Horse Model tiller allows you to till and
cultivate your garden with ease, and ac-
complish dozens
of other property man-
agement projects as well. Its PTO capa-
bility allows it to power avariety
of at-
tachments, including achipper/shredder
and agenerator. Your tiller is famous for
its ruggedness, performance and high-
quality engineering.
We know you'll
enjoy using it.
Please carefully read this ManuaL It
tells you how
to safely and easily assem-
ble, operate and maintain your machine.
Be sure that you and any other operators
carefullyfollow the recommended safety
practices
at all times. Failure to do so
could result in personal injury
or prop-
erty damage.
Of course, if you should ever have any
problems or questions, or for afree re-
placement copy
of this Manual, please
contact your local authorized service
dealer or call us Toll-Free. Our tele-
phone numbers and mailing addresses
are listed on Page 4and on the back
cover
of this ManuaL
We want to be sure that you are com-
pletely satisfied at all times.
This machine meets voluntary safety stan-
dard B71.8 -1986, which
is sponsored by
the Outdoor Power Equipment Institute, Inc.,
and
is published by the American National
Standards Institute.
A WARNING:
The engine exhaust from
this product contains
chemicals known to the
State of California to
cause cancer, birth de-
fects, or other reproduc-
tive harm.
2

Owner's Record
Please write the Model and Serial
numbers
of your machine in
the spaces provided. You
can find the location of
these numbers by refer-
ring to the illustration
below.
Model Number:
Serial Number:
Model and Serial Number location
Table of Contents
SERVICE INFORMATION 4
SECTION 1: SAFETY 5
Training 5
Preparation 6
Operation 6
Maintenance and Storage 8
Decals 8
SECTION 2: ASSEMBLY 9
SECTION 3: FEATURES AND CONTROLS 20
Tiller Features and Controls Identification 20
Engine Features and Controls Identification 23
SECTION 4: OPERATION 24
Break-In Operation 25
Test Forward Interlock Safety System 26
Starting and Stopping the Engine 27
Cold Weather Operation 28
To Operate Tiller 29
Turning Around 30
Transporting Your Tiller 31
To Change Belt Speeds 32
Tilling in the Garden 34
The PTO Power Unit .40
SECTION 5: MAINTENANCE & REPAIRS 44
Required Maintenance Schedule .44
Tighten Bolts and Nuts .45
Tiller Lubrication .46
Transmission Gear Oil Maintenance .46
Drive Belt Maintenance .49
Reverse Drive Maintenance 52
Bolo Tine Maintenance 54
Tine Shaft Maintenance 56
Tire and Wheel Maintenance 56
Engine Oil Maintenance 56
Air Cleaner, Throttle Cable, Ignition System, Spark Plug 57
Battery Care 58
Storing the Tiller 60
Inspect Forward Interlock Wiring System 60
Troubleshooting Forward Interlock Safety System 60
TROUBLESHOOTING PROCEDURES 61
ATTACHMENTS & ACCESSORIES 64
TILLER SPECiFiCATIONS 65
INDEX 66
NO-TIME-L1MIT WARRANTY Back Cover
3

Address
HOW TO
REACH
US
~
t=:J
If you have any
Questions or
Problems...
...Please contact your local TROY-BILT® Tiller
authorizeddealer or call or write the Factory. When calling
or writing, please be sure to provide the Model
and Serial
Numbers
of your machine (refer to Page 3).
Our trained parts special-
ists will gladly assist you
if
you have any difficulty in
identifying the part that you need.
number, description, and quantity
of the part you need. Then,
call or write our Parts
Department, being sure to
provide the Model and
Serial Numbers
of your
machine.
"Engines-Gasoline" (call us if you
need assistance in obtaining en-
gine service or parts).
Please remember that your engine
is covered by the engine manufac-
turer's Limited Warranty. Any
unauthorized work performed on
the engine during the warranty pe-
riod may void the warranty. For
full details on the engine manufac-
turer's Limited Warranty, refer to
the separate Engine Owner's
Manual.
If your engine should ever require
service or re-
pair, contact
your nearest
authorized
engine service
dealer.
To find the name and address of
your nearest authorized engine
service dealer, look
in the Yellow
Pages
of the telephone book under
If You Need Engine
Service:
Factory specified replacement
parts for your machine are
available from either your
TROY-BILT® Tiller autho-
rized dealer or directly
from the Factory.
To order apart from
the Factory, refer to
your separate Parts
Catalog to find the part
If You Need Parts:
Canada
(Toll Free)
For Technical
Service and Parts
Service:
1-800-225-3585
Canada
Mon.-Fri.,
8 A.M. to 4:30 P.M.
Canada
Garden Way
Incorporated,
320 Van Sickle Rd.,
Unit 12,
St. Catherines, Ont.
L2R 6P7
U.S.A.
(Toll Free)
U.S.A.
Garden Way
Incorporated,
102nd St. &
9th Ave.,
Troy, N.Y.
12180
For Technical
Service:
1-800-520-5520
For Parts
Service:
1-800-648-6776
Overseas callers
may use:
518-391-7000
U.S.A.
Mon.-Fri.,
8 A.M.ta 7 P.M.
Saturday
9 A.M. to 4 PM.
4

Sclio Safety
A WARNING
4. Familiarize yourself with all of
the safety and operating decals on
this equipment and on any
of its
attachments or accessories.
S. Do not run engine in an en-
closed area. Engine exhaust con-
tains carbon monoxide gas, a
deadly poison that
is odorless, col-
orless, and tasteless.
6. Do not allow hands or any
other part
of the body or clothing
near the rotating tines or near any
other moving part. The tines
begin to rotate
forward once
the engine
starts, the
Tines/PTO
Clutch Lever is
in the ENGAGE R~\EfT~N~AT~::SO:I~~~~~::I~jNuE~y.
position, the
Forward Interlock Levers are
squeezed closed and the
Wheels/Tines/PTO Drive Lever is
shifted to FORWARD. The tines
rotate in Reverse whether the
Interlock Levers are squeezed
closed or left open.
WARNING TO ALL CALIFORNIA
AND OTHER POWER EQUIPMENT OPERATORS
A
TRAINING
3. Keep the area of operation clear
of all persons, particularly small
children and pets. Keep by-
standers at least
25 feet away from
the area
of operation.
1. Read this Owner/Operator
Manual and the separate Engine
Owner's Manual carefully before
operating this equipment. Be com-
pletely familiar with the controls
and the proper use
of this equip-
ment. Know how to stop the unit
and disengage the controls quickly.
2. Never allow children or un-
trained adults to operate this equip-
ment.
Under California law, and under the laws of several other states,
you are not permitted to operate
an internal combustion engine
using hydrocarbon fuels
on any forest-covered, brush-cov-
,---=. ered, or grass-covered land, or on land covered with grain,
:;;;~==~~~~ hay, or other flammable agricultural crop, without an en-
gine spark arrester
in continuous effective working order.
The engine on your power equipment, like most outdoor power equipment, is an
internal combustion engine that burns gasoline, ahydrocarbon fuel. Therefore,
your power equipment must be equipped with aspark arrester muffler in continu-
ous effective working order. The spark arrester must
be attached to the engine
exhaust system
in such amanner that flames or heat from the system will not ig-
nite flammable material. Failure of the owner/operator of the equipment to com-
ply with this regulation
is amisdemeanor under California law, and may also be a
violation of other state and/or federal regulations, laws, ordinances, or codes.
Contact your local fire marshal or forest service for specific information about
what regulations apply
in your area. Contact your authorized engine dealer for in-
formation about obtaining aspark arrester.
This is a safety alert
symbol. It is used
in this Owner/ Oper-
ator Manual and on
your equipment to
alert you to poten-
tial hazards.
Whenever you see
this symbol, read
and obey the safety
message that fol-
lows it. Failure to
obey those safety
messages could re-
sult in serious per-
sonal injury or cause
property damage.
Please read and follow all of the
safety rules in this Safety Section.
Failure to comply could result in
serious personal injury or prop-
erty damage.
If you should lend this equipment
to another person, make sure that
he or she reads, understands, and
always follows these safety in-
structions.
If you are not completely sure
about any of the information
found here or elsewhere in the
Manual, please contact either
your local authorized dealer or the
factory for assistance.
5

Safety
7. Before inspecting or servicing
any part
of the equipment, shut off
the engine, wait for all moving
parts to come to acomplete stop,
disconnect spark plug wire from
PREPARATION
o
o
1. Thoroughly inspect the area
where the tiller will be used. Re-
move foreign objects before tilling.
2. Put the WheelsfTines/pTO
Drive Lever
in NEUTRAL before
starting the engine.
3. Do not operate the tiller without
wearing suitable clothing. Avoid
loose garments orjewelry that
could get caught in moving parts
of the tiller or its engine.
OPERATION
1. Do not put hands or feet near or
under rotating parts.
2. Use extreme caution when on or
crossing driveways, walks or roads.
Be alert for hidden hazards or traf-
fic. Do not carry passengers.
3.
If you hit aforeign object, stop
the engine (remove key on electric
start models), let all moving parts
come to acomplete stop, discon-
nect spark plug wire and move
wire away from the spark plug,
and inspect for damage. Repair
damage before restarting.
spark plug and move wire away
from the spark plug.
8. Do not operate this equipment
if you are under the influence of
4. Do not operate the tiller when
you are barefoot, in
san_~-~~~n
daIs, sneakers or ,4
other light footwear.
Wear shoes that grip
well on slippery surfaces.
5. Do not till near underground
electric cables, telephone lines,
pipes, or hoses. Contact your tele-
phone or utility to verify locations
of underground cables or lines.
6. Handle gasoline with care; it is
flammable, the vapors explosive.
a. Use an approved gas container.
b. Gas cap shall never be re-
moved or fuel added with en-
gine running. Engine shall be
4. Exercise caution to avoid slip-
ping or falling.
5.
If abnormal tiller vibration oc-
curs, stop engine immediately, dis-
connect the spark plug wire and
move wire away from spark plug.
Check for the cause. Carefully in-
spect for any damage. Fix the prob-
lem before using the tiller again.
6. Stop the engine, remove the key
on electric start models, and dis-
connect the spark plug wire and
move wire away from spark plug
before leaving the operating posi-
tion, unclogging tines, or making
repairs, adjustments or inspections.
7. Before leaving tiller unattended,
shift to NEUTRAL, stop engine
(remove key on electric start mod-
els), and disconnect spark plug
wire and move wire away from
plug to prevent accidental starting.
8. Before cleaning, repairing or in-
specting, stop the engine (remove
6
alcohol, medication, or when you
are tired or ill.
allowed to cool before refuel-
ing. Operators shall not smoke.
c. Keep matches, cigarettes,
cigars, pipes, open flames, or
sparks away from the fuel
tank and fuel container.
d. Fill fuel tank outdoors using
extreme caution. Never add
fuel indoors. Use afunnel or
spout to prevent spillage.
e. Replace fuel cap securely and
clean up fuel spills before
starting the engine.
7. Never attempt to make any ad-
justments while the engine is run-
ning or the spark plug wire
is con-
nected, except when so instructed.
key on electric start models), let all
moving parts stop, and disconnect
spark plug wire and move wire
away from spark
plug to prevent
accidental
~~~~
starting. Foe.::..-- ....".i!i'"~"'"
electrical
safety on electric start models, al-
ways disconnect the negative (-)
cable from the battery post.
9. Flap on tine hood must be down
when running tiller, unless using
the hiller/furrower attachment.
10. Never operate the tiller unless
safety guards or other protective
devices are in place.
11. Do not run the engine in an en-
closed area. Engine exhaust con-
tains carbon monoxide gas, a
deadly poison that is odorless, col-
orless, and tasteless.
12. Keep children and pets away.

13. Never operate the tiller under
engine power
if the Wheel Speed
Lever is in the FREE WHEEL po-
sition. In
FREE WHEEL, the
wheels will not hold the tiller back
and the revolving tines could pro-
pel the tiller rapidly, possibly caus-
ing loss
of control. Always engage
the Wheel Speed
Lever in either
FAST
or SLOW position before
starting the engine or engaging the
tines with the
Wheelsffines/PTO
Drive Lever.
14. The tiller could unexpectedly
bounce upward or
jump forward
and be propelled away from you if
the tines strike
or catch very hard-
packed soil, sod, frozen ground,
or
any buried obstacle such as large
stones or roots.
If in doubt about
tilling conditions, use the follow-
ing precautions to assist you in
maintaining tiller control:
a. Walk behind and on either
side
of the tiller, using one
hand on the handlebars.
Relax your arm, but use ase-
cure hand grip.
b. Use shallow depth regulator
settings, gradually working
deeper with each tilling pass.
c. Use slower wheel, tine and en-
gine throttle speeds.
d. Clear the tilling area
of big
stones, roots and other debris.
e. Avoid putting downward pres-
sure on the handlebars.
If
necessary, apply slight upward
pressure to prevent the tines
from digging too deeply.
f. Avoid contacting hard-packed
soil
or sod at the end of arow
by reducing engine speed and
lifting handlebars up to raise
tines out
of the soil.
g. In an emergency, stop the
tines and wheels by shifting
the Wheelsffines/PTO Drive
Lever to NEUTRAL. If you
can not reach the lever
or have
lost control
of the tiller, let go
of the handlebars and all con-
trols.
Do not try to restrain it.
15. Do not overload the machine
capacity by trying to till too deeply
at too fast arate.
16. Never use the tiller at high
ground speeds on slippery surfaces.
17. Do not operate tiller on aslope
too steep for safety. On slopes,
slow down and be sure you have
good footing.
Don't let the tiller
"free-wheel" down slopes.
18. Clear the area of bystanders be-
fore tilling.
19. Use only attachments and ac-
cessories approved by Troy-Bilt
Manufacturing Company.
20. Use tiller attachments and ac-
cessories when recommended.
21. Never operate the tiller without
good visibility or light.
22. Never operate the tiller
if you
are fatigued, or under the influence
of alcohol, drugs or medication.
23. Operators shall not tamper with
the engine-governor settings on the
machine; the governor controls the
maximum safe operating speed and
protects the engine and all moving
parts from damage caused by over-
speed. Authorized service shall be
sought if aproblem exists.
24.
Do not touch engine parts that
may be hot from operation (muffler,
fins, etc.). Make certain all parts
have cooled down before inspect-
ing, cleaning or repairing.
25.
POISONIDANGER-
CAUSES SEVERE BURNS. The
battery on electric start models con-
tains sulfuric acid. Avoid contact
with skin, eyes or clothing.
Antidotes:
External- Flush imme-
diately with lots
of water.
Internal- Drink large quantities of
water or milk. Follow with milk of
magnesia, beaten eggs or vegetable
oil. Call adoctor immediately.
Eyes- Flush with water for 15 min-
utes. Get prompt medical attention.
Keep out
of reach of children.
7
Safety
26. DANGER- BATTERIES
PRODUCE EXPLOSIVE
GASES. Keep sparks, flame or
smoking materials away. Ventilate
when charging battery or using in
an enclosed space. Always shield
eyes when working near battery.
27.
Remember-To stop tines and
wheels, either put Wheels/
Tines/PTO Drive Lever in NEU-
TRAL, or move Throttle Lever to
STOP position.
If you lose control
of the tiller and can not reach the
levers, let go
of the handlebars and
controls and do not try to restrain
the tiller. The Forward Interlock
Safety System will stop the engine.
28. Look behind and exercise cau-
tion when backing up.
For added
safety, put Wheel Speed Lever in
SLOW position before reversing.
29. When loading or unloading the
tiller, always disengage the tines
and use slower wheel and engine
throttle speeds. Use sturdy ramps
wide and strong enough to easily
support the tiller (280-to-325 Ibs.,
depending on model) and operator.
Never go down ramps
in FOR-
WARD
drive-the tiller could tip
forward, exposing you to the tines
(which should be disengaged).
Always use REVERSE drive and
back down ramps. To go up ramps,
use FORWARD drive and walk up
following the tiller.
30.
The Forward Interlock Safety
System should be tested for correct
functioning every time the tiller
or
PTO power unit is used. See
Section 4in this Manual for the test
procedure to take.
31.
If using the optional Dozer
Blade, either remove the tine at-
tachment, or disengage the tines
with the Tines/PTO Clutch Lever.
Revolving tines are dangerous.

Safety
MAINTENANCE AND
STORAGE
1. Never perform maintenance
when engine is running or spark
plug wire is connected except
when specifically directed to do so.
2. Keep tiller, attachments and ac-
cessories
in safe working condition.
3. Check all nuts, bolts, and screws
frequently for proper tightness.
Always verify your equipment is in
safe working condition.
4. Never store the machine with
fuel in the fuel tank inside abuild-
ing where fumes may reach
an
open flame or spark, or where igni-
tion sources are present (such
as
hot water and space heaters, fur-
naces, clothes dryers, etc.).
5. Let the engine cool down before
storing it in an enclosure.
6.
To reduce fire hazard possibili-
ties, keep the engine free
of grass,
leaves or grease.
7. Store gasoline
in acool, well-
ventilated area, safely away from
any spark- or flame-producing
equipment. Store gasoline in an
approved container, safely out
of
the reach of children.
8. Refer to the Maintenance sec-
tion
in this Manual for storage in-
formation if your tiller is to be
stored for an extended period.
SAFETY DECALS
Make certain that all safety decals on this equipment
are kept clean and in good condition. The safety
decal locations are shown (at areduced size) below.
There are other decals located on your equipment for
operation and controls identification. They are also
shown below and
in your Parts Catalog. If you need a
replacement decal, please refer to the Parts Catalog
that accompanied this Manual.
A) WARNING: Hot Surfaces decal. On
8HP Kohler engines (shown), located
on top of the engine. On Briggs &
Stratton engines (not shown), located
on top of the muffler guard.
F) Engine Stabilization
decal. On 8HP Kohler en-
gines (shown), located on
top of the engine. On Briggs
& Stratton engines (not
shown), located on the top,
front of the engine cover.
Decal Locations
C) WARNING: Operating Instructions
decal. Five groups of safety state-
ments are provided along with tiller
operating instructions.
B) WARNING: Engine Ignition. Provides
safety and operational information for
using the Keyswitch Ignition. On electric
start models only.
8
E) Forward Interlock
Lever decals (2).
D) Power Unit Operating
Instructions decal.

eelio
Assembly
Please carefully follow the steps in
this Section to properly assemble
your new machine. These steps
will not take very long and they
will assure you of having assem-
bled your machine correctly.
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.
Subjects covered in this Section:
•Inspection After Delivery
: ~:~:~k:::: ~::d~:::::ng Contents ~
•Remove Tiller from Shipping Platform I}
•Connect Forward Intl!tlock Wire Harness
•Attach WheelslTineslPTO Drive Leve
•Check
Gear Oi Levels in Power Unitt and
Tine Attachment Tral1smissionst rL
•Add Motor Oil to ·Iler Engin .J'!~,'. "-.
~/v j
•Attach Engine Throttle Leverto Handlebar
•Adjust the Air Pressur ·n the Tires "
•Assembling the Electric Start System
Tools Needed:
One 3/8" Open End or
Adjustable Wrench
One 9/16" Open End or
Adjustable Wrench
One 3/4" Open End or
Adjustable Wrench
Two 7/16" Open End or
Adjustable Wrenches
Two 1/2" Open End or
Adjustable Wrenches
One Flat Blade Screwdriver
Scissors (to trim plastic ties)
Quality Motor Oil (refer to the
Engine Owner Manual
provided with your unit
for motor oil specifica-
tions and capacities).
Tire Pressure Gauge
A strong 41 12" high prop (a
wood box, a brick, or
boards)
I
Inspection After Delivery
Inspect your machine immediately
after it has been delivered. Make
sure that neither the carton nor the
contents have been damaged.
If you find or suspect any damage,
contact the carrier (trucking com-
pany) right away. Inform them
of
the specific damage and that you
wish to file aclaim.
To protect
your rights, be sure
to put this in
writing to the carrier within 15
days after your machine arrives.
The carrier will let you know how
to proceed with your claim.
Please let us know
if you need any
assistance with this matter.
IMPORTANT: Motor oil must
be added to the engine before it
is
started. The procedure for
adding oil is explained
later on
in these assembly instructions.
9
STEP 1: Unpacking Contents
If you haven't done so, unpack
and check the loose parts as listed
in the table on page 10. Contact
us
if any parts are missing.
A. Remove the handlebars and
the WheelslTineslPTO Drive
Lever (Items 1and 2in Photo
2-1).
You may need to cut aplas-
tic tie to free the handlebars from
its shipping location. Set them on
aclean surface. Do not get dirt on
the wire harness plug located at
the bottom
of the handlebars!
B. Remove the loose parts from
the plastic envelope that contained
these instructions (Items 3through
8in Photo 2-2).
C.
If you ordered an Electric Start
Tiller, take out the items from a
sealed plastic hardware package
under the battery clamp (Items 9
through
11 in Photo 2-3). Your ig-
nition keys are in the keyswitch.

Use This Ruler
to Check the
Hardware
Lengths:
Assembly
1- Handlebars
2- Wheels/Tines/
PTO Drive Lever
Photo 2-1. Put Handlebars (/tern #1) and Wheelsflines/PTO Lever (/tern #2)
aside.
Table 1- Carton Contents Parts List
KEY
OTY
DESCRIPTION
FOR MODEL:
7HP 7HP 8HP
8HP
Std.
Elec. Std. Elec.
Photo 2-1:
11
Handlebars ............................................... • • • •
21 Wheels/Tines/PTO Drive Lever ................. • • • •
Photo 2-2:
31
Clutch Pawl Spring ................................... • • • •
41 Belt Adjusting Tool .................................... • • • •
52
Plastic Cable Ties ...................................... • • • •
61
Curved Head Bolt, 1/4"-20 x 2" (Grade 5) ..
• • • •
71
Flanged Lock Nut, 1/4"-20 ........................
• • • •
81
Panhead Screw, #20 -24 x 1/2" ................
• • • •
Photo 2-3:
92
Nuts, 1/4"-20, for battery terminals ..........
• •
10 2 Bolts, 1/4"-20 x 5/8", for battery terminals • •
11 1
Battery Vent Tube ..................................... • •
2
Keys for Electric Start Models ..................
• •
(located in ignition keyswitch)
10
~_;-:)3
4
•
-5
•-
678
1lIlIl;;;;"
~
...
Photo 2-2. Parts inside the litera-
ture envelope.
10
9
11
Photo 2-3. Parts for Electric Start
Tiller models. (Ignition keys are not
shown.)

STEP 2: Attach the Handlebars
Do not move tiller off shipping
platform unless handlebars are at-
tached. This makes moving the
tiller easier and more controllable.
All the parts shown in Figure 2-4
(except the handlebars) are shipped
assembled.
You must disassemble
these parts in order to attach the
handlebars.
A. Unwind the Handlebar Height
Adjustment Lever (Figure 2-4)
counterclockwise. Be prepared to
catch the nut, left clamp and left
ratchet as you remove the lever.
Completely withdraw the lever,
taking with it the right clamp and
right ratchet. Keep mating clamps
and ratchets grouped together.
B. Place the handlebar ends on ei-
ther side
of the handlebar base and
the wire harness at the bottom
of
the handlebars at the rear of the
base (Fig. 2-4).
C. Hold the right-side ratchet and
right-side clamp in position next
to
right handlebar arm. Insert adjust-
ment lever through the clamp, han-
dlebar, ratchet and the base. Let
the adjustment lever protrude from
the other side
of the base.
Note: The lever should pass freely
through the holes
in the handlebar
ends.
If it won't- do not force it.
The wires to the Forward Interlock
Safety System may be blocking the
lever. Push apencil through the
holes to gently move the wires
aside.
D. Position the left-side ratchet
and left-side clamp next to the left
handlebar arm (see Fig. 2-4). Move
the adjustment lever all the way
through these parts. Hold the nut
in place and screw the lever into it.
Don't fully tighten the lever yet.
E. Raise the handlebars Uiggling
them on the ratchets helps) to one
of two pre-set height settings.
Then tighten the lever (Photo 2-5).
Assembly
Handlebars
~
Handlebar Height
Adjustment Lever
FRONT
OF TILLER
Figure 2-4. Unwind the Handlebar Height Adjustment Lever to separate the
handlebar
assembly parts. Keep the mating left-side ratchet and clamp
grouped together, and the right-side ratchet and clamp grouped. Place the
handlebars
so the ends are on either side of the handlebarbase. Reas-
semble
all parts securely.
Left Side
Clamp With
Nut
Photo 2-5. When handlebars are in position, reassemble all the compo-
nents. Insert the Handlebar Adjustment Lever from right to left through all
the parts. As shown above, securely tighten the lever.
11

Assembly
STEP 3: Remove Tiller from
Shipping Platform
A. The Depth Regulator Lever
(Photo 2-6) may be secured to its
own mounting bracket with aplas-
tic tie strap. Removing the tie
strap lets you move the Depth
Regulator Lever up or down. To
check, lift the hinged flap at the
end
of the hood and look for atie
strap around the lever. Use ascis-
sors to cut it loose.
B. Move the Wheel Speed Lever
(Photo 2-6) to FREEWHEEL posi-
tion which lets the wheels
tum
freely. FREEWHEEL
position is midway be-
tween SLOW and
FAST positions. Then
lift the handlebars up
to clear the tines from
the platform. Pull the
handlebars firmly back
to roll the wheels out
of the platform wheel
wells.
C. Roll the tiller to a
level area where you
can complete the as-
sembly steps.
Photo 2-6. Move tiller off shipping platform. Move
Wheel Speed Leverup
or down to take wheels out
of gear.
STEP 4: Connect Forward
Interlock Wire Harness
A. Connect the plug on the wire
harness that leads from the lower
ends
of the handlebars into the
wire harness receptacle on the top,
right side
of the transmission
(Photo 2-7). This connection com-
pletes the wiring circuit for the
Forward Interlock Safety System.
It must be connected or the engine
will not start.
B. Before connecting the plug, be
sure that it and the receptacle it's
going into are clean.
WARNING
To avoid personal injury, test
the Forward Interlock Safety
System prior to each use of
the tiller to be sure it is func-
tioning properly. See Section
4 in this Manual for the test-
ing procedure to use.
Photo 2-7. Connect forward inter-
lock wire harness plug to receptacle.
STEP 5: Attach the Wheels/Tines/PTO Drive Lever
This control lever is shown in Photo 2-1. To attach
it, you'll need the clutch pawl spring (see Photo 2-2). Tools required: one 3/4" and two 1/2" wrenches.
A. Loosen the large bolt at the top
of the handlebar base (Photo 2-8)
with a3/4" wrench.
Don't remove
it. Swing the handlebars out
of the
way to the right side
of the tiller.
Photo 2-8. Loosen the large bolt
securing the handlebar base.
Swing handlebars to right side.
B. With two 1/2" wrenches, re-
move and save the nut, star washer,
bushing and bolt from the hole at
the rear
of the clutch yoke assem-
bly plates (see Fig. 2-9, items
A,
B,C,D).
C. Using two 1/2" wrenches, re-
move (and save) the nut, star
washer and bolt (items E,
F, and G,
Figure 2-9) attaching the short ver-
tical link to the center
of the yoke.
Keep the short link (with abushing
inside it) upright after the bolt
comes out.
If it swings down,
reposition it upright again.
12
D. Slide the plates located at the
end
of the PTa drive lever over the
yoke and align the upper hole in
the plates with the hole at the rear
of the yoke (refer to Photo 2-10).
Insert the bushing (C, Figure 2-9)
inside the yoke and install the bolt
through the lever's plates, bushing
and yoke. (Tap the bolt
if neces-
sary.) Add the star washer and nut
and tighten the nut finger-tight.

Figure 2-9. First remove hardware from rear of yoke plates (hardware items
A,
B, C, and D); then remove hardware securing short, upright steel link to
yoke plates (hardware items E, F, and G).
Assembly
Photo 2-10. Insert bushing, then in-
stall bolt through upper hole in
lever and yoke plates. Loosely add
the star washer and the hex nut.
E. Look at both ends on the clutch
pawl spring. One hook end has a
wider opening. Insert the end with
the wider opening fully into the
small hole in the lever (hook point-
ing down). See A, Figure 2-11.
F. Tilt the lever fully up and insert
the other end
of the spring in the
hole in the top
of the long steel
link (B, Figure 2-11). Apliers
may help. Do not overstretch the
spring. (Note: push handlebars to
the right for extra clearance.)
G. Pull the lever back down. See
Photo 2-12. Insert bolt removed
earlier (per paragraph C) back in the
remaining holes in the lever, yoke
and short vertical link. Add star
washer and nut.
H. Securely tighten both bolts.
I. Swing handlebars to the
straight-ahead position and tighten
the bolt
in the handlebar base.
J. Test the operation of the lever.
Push it down until it's engaged in
the FORWARD position. See
Photo 2-13 (the roller at the end
of
the shift linkage must be engaged
beneath the belt adjustment block).
Next, move the lever up to the
NEUTRAL
position- lift or tap it
up and let it go. The roller should
be resting on the face
of the belt
Figure 2-11. Install clutch pawl
spring.
Photo 2-13. Push
lever down into
FORWARD position. The roller must
go under the adjustment block.
adjustment block (Photo 2-14).
Last, lift and hold the lever all the
way up
in REVERSE position-
then let it go.
It should automati-
cally return to the NEUTRAL po-
13
Photo 2-12. Pull lever back down.
Reinstall
last bolt, star washer and
nut as shown above.
Photo 2-14. When
lever is in NEU-
TRAL,
roller rests against the face
of the adjustment block.
sition. If not, do not use the tiller.
See your local authorized Dealer
or call our Technical Service
Department for instructions.

Assembly
STEP 6: Check Gear Oil Levels in Power Unit Transmission and Tine Attachment Transmission
Your tiller has two separate
transmissions: one for the Power
Unit; the other for the Tine Attach-
ment. Both were filled with
SAE
#85W-140 weight gear oil (with
an A.P.I rating
of GL-4) at the
Factory. Please check level in both
transmissions to verify that levels
are still correct.
To Check Power Unit
Transmission:
A. Put the tiller on level ground.
B. Pull Depth Regulator Lever
back and then up so tines are rest-
ing on the ground (Photo 2-15).
C. Use a3/8" wrench to remove
oil level check plug on left side
of
the transmission Gust above the
wheel shaft). See Photo 2-16. You
may need to break the grip
of any
dried paint on the check plug.
D. Oil should seep out hole if
level is correct (in cold weather, it
will seep out slowly). Reinstall
plug securely
if gear oil level is
correct.
E. If no oil seeped out, see if tilt-
ing tiller slightly toward check
hole (roll right wheel on aI" thick
board) causes oil to seep out.
If oil
starts to seep, only asmall amount
should be added.
But - if there is
still no oil seeping out, the oil level
may be seriously low. In either
case, add the correct amount
of
gear oil before using the tiller -
Photo 2-15: Pull Depth Regulator
Lever
back and then up to lower the
tines
to the ground.
see" Adding or Changing Gear
Oil" in Section 5
of this Manual.
To Check Tine Attachment
Transmission:
Two different gear oil level
checking procedures for the tine
attachment transmission follow.
Use the procedure described first
for Tine Attachment dipsticks
with a'Check Cold' marking.
Use the second procedure ifdip-
stick has both 'cold'
and 'hot'
markings at end. First remove
dipstick from tine transmission
(Photo 2-17) to see which type
dipstick you have. Then replace
dipstick.
For Diosticks With 'Check Cold' Marking:
A. Put the tiller on level ground.
B. Pull Depth Regulator Lever
back, then push it down all the way
to engage its top notch. This raises
tines
off ground and lets tiller rest
on drag bar.
C. Place asupport under engine to
prevent tiller from tilting too far.
Now slide three pieces
of 2" x4"
lumber under drag bar -raising
drag bar about 4-1/2" above
ground. This elevation is needed
to take an accurate "cold" gear oil
reading ("cold" means tiller was
never operated,
or 2hours have
passed since it was used last).
Photo 2-16: Gear oil should seep
out from oil level check hole in
power unit transmission.
14
D. Wait two hours with tiller ele-
vated (allow more time
if tempera-
ture is below 40°F).
E. Loosen and remove transmis-
sion dipstick. (Photo 2-17). Wipe
with aclean rag.
F. Holding dipstick so markings
face rear
of tiller, lower it straight
down into sump hole until it
touches driveshaft inside (Photo 2-
17).
Don't force or try to thread it
back in -
or reading won't be cor-
rect.
G. Remove dipstick and check oil
level.
It should be within cross-
hatched area
or even slightly above
the
'Max' marking. If correct, re-
place dipstick and remove boards.
H. If no oil showed on dipstick,
correct amount
of oil must be
added to tine transmission.
For
complete instructions, see "Adding
or Changing Gear Oil" in Section 5
of this Manual.
For Dipsticks With Hot/Cold Markings:
A. Follow Steps Aand Bgiven
for other type
of dipstick.
B. Put one 2"x4" board under drag
bar- raising tiller and drag bar
about 3-1/2" above ground. This
elevation is for a
'cold' gear oil
reading (tiller never used
or 2
hours since used last).
C. Follow Steps D, E, and Fgiven
for other dipstick type.
Photo 2-17: Remove dipstick to
check gear oil in tine attachment
transmission. Insert dipstick so
markings face rear of tiller.

D. Remove dipstick and check
that gear oil level is within or
above 'Cold' range marking (use
of 'Hot' marking is explained in
Section 5). If correct, replace dip-
stick and remove the board.
STEP 7: Add Motor
Oil to Engine
Add high-quality API-rated
"SF"
or "SG" motor oil to engine
before starting. Refer to the Engine
Owner Manual provided with your
unitfor motor oil specifications and
capacities.
To Add Oil:
A. Park the tiller on level ground.
Place asturdy block under the drag
bar at the rear
of the tiller to level
the base
of the engine.
B. An oil fill tube is located on
each side
of the engine. Either can
be used. See Photo 2-18.
C. Clean around the oil fill tube and
remove the oil
fill plug. Use aclean
funnel and slowly pour motor oil
into the tube until the oil reaches the
top
of the fill hole.
D. Reinstall the oil fill plug and
re-
move the block under the drag bar.
STEP 8: Attach Engine Throttle
Lever to Right Handlebar
The throttle cable (with throttle
lever) is wound around the engine
for shipping purposes. Carefully
unwind the cable.
If the throttle
control decal
is covered with apro-
tective coating, peel it off. Attach
the lever as follows.
A. You will need the curved head
bolt, flange locknut, panhead
screw and two plastic ties which
are shown in Photo 2-2, Page
10.
B. Run the throttle cable up the in-
side edge
of the right handlebar
and position the lever
as shown in
Photo 2-19.
E. If the level is incorrect, see
"Adding or Changing Gear Oil" in
Section 5
of this Manual.
IMPORTANT:
•Always maintain oil level
at the
overflow point in the oil fill tube.
•Check engine oil level every 5
hours ofoperation
or daily.
•Change engine oil after first 5
hours ofnew operation.
C. From the outside of the handle-
bar, insert the curved head bolt
through the handlebar and the cen-
ter hole in the throttle lever mount-
ing bracket.
D. Loosely install the locknut.
E. Move the throttle lever to the
STOP position.
F. From the lever side of the
bracket, thread the panhead screw
into the small hole in the throttle
lever bracket and into the handle-
bar. See Photo 2-19. Tighten the
screw securely.
G. Use a7/16" wrench to securely
tighten the locknut and the curved
head bolt.
15
Assembly
IMPORTANT
Recheck gear oil level in both trans-
missions after the first two hours
of
new tiller operation, then every 30
operating hours thereafter. See
Section 5for instructions.
Photo 2-18: Add
oil until it reaches
top of oil fill tube.
F. Using two plastic ties, secure
the throttle cable to the right han-
dlebar in two places,
as shown in
Photo 2-20. Loop each tie around
the handlebar and cable (serrated
side faces in) and pull the ties
tight. Trim the ends.
Photo 2-19: Attach engine throttle
lever to handlebar.

Assembly
Photo 2-20: Use plastic ties in two
places to hold cable to handlebars.
WARNING
On electric start tillers, to
avoid electric shock from a
short circuit, never allow
throttle cable
to touch the
battery. Route cable below
the battery, on the outside of
the battery holder.
STEP 9: Adjust the Air Pressure
in the Tires
A. For shipping purposes only, the
tires are overinflated.
B. Before using the tiller, check
the air pressure and adjust it
to be-
tween 10-to-20 psi (pounds per
square inch). Each tire should be
inflated to the same pressure.
IMPORTANT
If you have arecoil start tiller,
it is now completely assem-
bled.
If you have an electric
start tiller, please continue
with the few
remaining steps.
ASSEMBLING THE ELECTRIC START SYSTEM
The following steps explain battery activation, battery charging and installation. For your safety, follow
all steps and observe all accompanying safety messages. Section 5has further general battery maintenance and
recharging instructions you will find helpful.
STEP 1: Activating and
Charging the Battery
IMPORTANT
The battery was shipped
"dry." It needs battery elec-
trolyte fluid
(battery-grade
sulfuric acid) added to it. It
must then be fully charged
with a battery charger before
being used.
Adding electrolyte fluid to the
battery and battery charging can be
dangerous work. The electrolyte
contains acid that can burn or blind
you. Battery charging also pro-
duces explosive gases.
To ensure that the battery is
properly activated and charged,
you should review these instruc-
tions with your battery technician.
It is strongly recommended
that you have the battery acti-
vated
and charged by a trained
professional (Troy-Bilt Dealer,
service station,
farm equipment
dealer, etc.) if you are not experi-
enced with these procedures.
DANGER
Battery produces explosive
gases.
• Keep sparks, flames, and
cigarettes away.
• Ventilate area when charg-
ing or using battery in an en-
closed space.
• Make sure venting path of
battery is always open once
battery is filled with acid.
16
DANGER
Battery electrolyte fluid is
poisonous and burns severely.
Electrolyte is asulfuric acid
solution. Avoid spills or con-
tact with skin, eyes, clothing.
• To prevent accidents, wear
protective clothes, rubber
gloves and shield eyes with
safety goggles when working
on or near the battery.
• Neutralize acid spills with a
baking soda and water solu-
tion. Neutralize electrolyte
container with same solution.
Then rinse with clear water.
Antidote: External- Flush with
water; Eyes- Flush with water
for 15 minutes and get imme-
diate medical attention.
Antidote: Internal- Drink large
quantity of water or milk.
Follow with milk of magnesia,
beaten eggs, or vegetable oil.
Call a doctor immediately.

To Activate the Battery:
WARNING
Remove metal jewelry before
working near the battery or
near the electrical system.
Failure to comply may cause
ashort circuit, resulting in
electrical burns, a shock, or
explosion of battery gases.
For shipping purposes only, the
unserviced battery and its hold-
down clamp were installed back-
wards at the factory. When rein-
stalling the battery and hold-down
clamp, be sure to turn them around
so they face
in the opposite direc-
tion from which they were shipped.
A. Use a7/16" wrench to remove
the two
I-liz" long bolts and the two
1/4" whiz nuts securing the front
and rear hold-down clamp legs
to
the battery bracket (Photo 2-23).
Lift off the clamp. Remove battery.
.Save the hardware.
B.
If there is ashort piece of
sealed plastic tubing covering the
vent fitting on the negative side
of
the battery (see Photo 2-23), re-
move and discard
it.
C. Put the battery on alevel work
surface, far away from heat- or
flame-producing sources like
stoves, water heaters, dryers, fur-
naces, etc.
D. Take off the six filler caps on
top
of the battery. Put them aside.
Refer
to Photo 2-24.
To Charge the Battery:
A. Follow one of the three charg-
ing methods described next for
maximum starting capacity and
longest battery life.
E. Be sure you are wearing pro-
tective clothes, rubbergloves
and
eye protection. Fill each cell to the
"Upper Level" line printed on the
battery case using battery-grade
electrolyte solution. (This is 1.265
specific gravity sulfuric acid.)
Temperature
of battery and elec-
trolyte is ideal when between
600F-to-80°F. Do not add water or
any other liquid to the battery dur-
ing this initial activation.
F. Let battery stand for 30 min-
utes. Check electrolyte level
in
each cell. Add more electrolyte
solution if needed. Don't overfill
battery-this could lead to flooding
from the cells during charging.
Note: The electrolyte solution
within the cells
is gassing freely
when the surface
of the electrolyte
is covered with small bubbles.
When checking for bubbles, al-
ways wear safety goggles to pro-
tect eyes. Aflashlight makes the
inspection easier. Inspect all cells.
17
Assembly
Photo 2-23:
Remove
hold-down
clamp (A).
Remove
the piece of
clear plas-
tic tubing
(B) if so
supplied.
Photo 2-24: Remove all six filler
caps (A). Fill each cell up to the
"Upper" level line (B).
Our Recommended Method:
Charge the battery at arate of I-to-
2amperes until all cells gas freely.
Do not exceed 24 hours charging.
FirstAlternative Charging Method:
Charge the battery at arate of 4-to-
6amperes until all cells gas freely.
Do not exceed 8hours charging.

Assembly
Second Alternative ChargingMethod:
Charge the battery at arate from
6-to-12 amperes until all cells gas
freely. Do not exceed 4hours
charging time.
B. Turn
off the charging equip-
ment and disconnect the charger
cables from the battery terminals.
C. Recheck electrolyte level
in
each cell. Top off any low cells
with electrolyte solution up to the
"Upper" level line.
D. Securely replace all six filler
caps. Use abaking soda and water
mixture to rinse off electrolyte that
may have spilled on the battery.
DANGER
Never jump start the battery
with a vehicle battery or charg-
ing system. This may produce
abattery explosion, causing
acid or electrical burns.
STEP 2: Connect the Wire
Harness Receptacle
A. The keyswitch (A, Figure 2-25)
is part
of the hold-down clamp as-
sembly (D). The prongs at the
DANGER
To Avoid Personal Injury or
Property Damage:
• Batteries produce explosive
gases -always keep sparks
and flame away from battery.
• Ventilate area when charg-
ing or using the battery.
•During charging, don't
leave battery unattended.
Charging time
need not be
continuous.
• Follow safety rules and in-
structions supplied by battery
and charger manufacturers.
• Do not charge battery at a
rate higher than 12 amperes
to avoid generating excessive
heat and gassing which could
damage the battery.
back of the keyswitch must be se-
curely inserted into the plastic wire
harness receptacle (B).
B. Remove the pair
of ignition
keys from the keyswitch. Store
DANGER
To Avoid Personal Injury or
Property Damage:
• Do not touch positive bat-
tery terminal and any sur-
rounding metal objects with
tools, jewelry
or other metal
items. Failure to comply
could
cause ashort circuit
leading to electrical burns or
explosion of battery gases.
• Never bring a gas can near
the positive (+) battery termi-
nal. Ashort
circuit could
occur leading to an explosion
of the gasoline or the battery
gases. Always fill the engine
fuel tank from the front or
side of the engine.
them safely away. Do not put a
key
in the keyswitch until you
have read the sections in this
Owner/Operator Manual covering
features, controls and operation.
Figure 2-25: First connect Keyswitch (A) to wire harness (8). Then, the acti-
vated battery must be secured to mounting platform (C) using the hold-
down clamp (D) with its mounting hardware (H, I). Last, install plastic vent
tube (E) over the vent fitting (F), and down into vent tube shield (G).
18

STEP 3: Installing the Battery
A. Carefully place the activated
battery back on the battery mount-
ing platform as seen in Fig. 2-25.
The side of the battery with the
terminals (the posts)
and the fill
lines on it
must face the rear of
the tiller. [Another way to verify
the correct placement
of the bat-
tery is when the positive (+) bat-
tery post is on the left side
of the
tiller as you face forward when
standing behind the handlebars.]
CAUTION
Incorrect installation of the
battery can result in electri-
cal system damage.
Follow these installation in-
structions carefully to avoid
damage to your tiller.
STEP 4: Installing the
Battery Cables
A. Locate the two (2) 5/8" long
bolts and 1/4"-20 hex nuts
shown
in Photo 2-3 on page 10. Use them
to connect the loose ends
of the
two battery cables to the two bat-
tery terminals (posts).
B.
On the left side of the tiller (as
viewed from behind the handle-
bars), connect the loose
end of the
positive (+) battery cable (A,
Figure 2-26 -this is the red cable
already attached at the other end to
the solenoid) to the positive (+)
battery post (B). Hold the cable
terminal against the side
of the
post facing the keyswitch. Install
and tighten abolt (E) and nut (F)
with two wrenches.
Assembly
e. Slide the pre-installed black
rubber boot (G) completely
over
the battery post and hardware.
D. Repeat this procedure on the
right side
of the battery. Position
the
end of the negative cable (C)
against the negative battery post
(D) as shown, and secure it with
the remaining bolt (E) and nut (F).
Again, slide the black rubber boot
completely
over the battery post.
E. Check the lower end of the
vent tube shield into which you in-
serted the clear plastic vent tube.
The lower end of the black shield
must be located in front
of the
wheel shaft axle.
Move it there if
necessary. Your electric start tiller
is now fully assembled.
B. Place the battery hold-down
clamp (D, Figure 2-25) over the
battery, and secure the two legs
of
the clamp to the platform (C) using
the two bolts and whiz nuts (H, I)
removed previously. Insert the
bolts up from the bottom. Tighten
the hardware to make the battery
secure, but
don't overtighten the
nuts
or the clamp tabs will bend.
e. The clear plastic vent tubing
must be installed next. If coiled
up, straighten it out. Slide one end
of the tube (E, Figure 2-25) over
the vent fitting (F) at the top
of the
battery. Slide the other end down
into the black vent tube shield (G).
WARNING
Improper battery venting can
cause abattery to explode,
resulting in severe personal
injury.
Be sure the vent tube is not
crimped, pinched or folded.
E
Figure 2·26: Connect positive (+) cable (A) to positive battery post (B).
Connect negative (-) cable (C) to negative
battery post (D). Be sure to posi-
tion bolts (E) and nuts (F) as shown. After the connections are secure, slide
black rubber boots (G) completely over battery posts.
19

eclio
Features and Controls
TILLER FEATURES AND CONTROLS IDENTIFICATION
The major tiller controls and features are identified and illustrated on the
next few pages. The use and operation
of each control and feature is cov-
ered
in detail in Section 4"Operating Instructions."
Figure 3-1: A- Wheelsflines/PTO Drive Lever; B- Forward Interlock Levers;
C- Wheel Speed Lever; D- Tines/PTO Clutch Lever; E- Depth Regulator
Lever;
F- Handlebar Height Adjustment Lever.
Learn the locations of the features
and controls on your machine
before starting the engine. Taking
the time now to understand the lo-
cation, function and operation of
these controls will greatly add to
the productive use, safe operation,
and enjoyment of your machine.
For detailed step-by-step operating
instructions, please refer to
"Section 4: Operation."
WARNING
TO AVOID PERSONAL INJURY OR
DAMAGE TO EQUIPMENT:
Before using your tiller or PTO
Power Unit for the first time, be-
come thoroughly familiar with the
operation of the controls by mov-
ing them to their various posi-
tions while the engine is not run-
ning. The proper operation of
each control is discussed in detail
in Section 4.
NOTE: All references to left, right,
front and rear of the machine are
determined by standing behind the
handlebars and facing the direction
of forward travel.
WheelS/Tines/PTO Drive Lever
This lever (A, Figure 3-1)
engages and disengages power
from the engine
to the transmis-
sion.
It has three operating posi-
tions: FORWARD, NEUTRAL and
REVERSE.
FORWARD -Lever moved down
until it engages in drive position
(clutch roller at end
oflever is en-
gaged below adjustment block, as
shown in Photo 3-1A). Use this
setting for forward motion
of the
wheels and tines, or to apply
power
to any optional PTO (Power
Take Off) attachment.
20
To stop the wheels, tines or any
PTO attachment, move the lever
to
NEUTRAL by lifting or tapping
the lever upwards and letting it go
(in NEUTRAL the clutch roller
will be located on the face
of the
adjustment block, as shown in
Photo
3-lB).
REVERSE -Lever moved all the
way up and held in that position
(clutch roller will be located higher
on the face
of the adjustment
block,
as shown in Photo 3-1C).
Use this setting for moving the
machine in reverse. To stop mov-
ing in reverse, let go
of the lever
and it will automatically return to
the NEUTRAL position.