Troy-Bilt 663B- -Pony User manual

Operator’s Manual
Rear-tine Tiller Model
663B—Pony®
663E—Pony®
665B—ProLine®
E663E—Pony® ES
Warning: This unit is equipped with an internal combustion engine and should not 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 arrester meeting applicable local or state laws (if any).
If a spark arrester is used, it should be maintained in effective working order by the 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. A spark arrester
for the muffler is available by contacting the service department at Troy-Bilt LLC, P.O. Box 361131 Cleveland, Ohio 44136-0019.
IMPORTANT:READ SAFETY RULES AND INSTRUCTIONS CAREFULLY
TROY-BILT LLC, P.O. BOX 361131, CLEVELAND, OH 44136-0019
PRINTED IN USA FROM NO. 770-10597E
10/20/2006
Engine styles vary by model

28 Parts List
Models 663B, 663E, 665B & E663E
HANDLEBAR ASSEMBLY and CONTROL LEVERS
10

Parts List 29
Models 663B, 663E, 665B & E663E
REF. PART
No. No. DESCRIPTION QTY.
REF. PART
No. No. DESCRIPTION QTY.
1 1918801 Handlebars.......................................... 1
2 = Grip 2
3 777I22624 Decal, Control Panel ........................... 1
3A 777D09943 Decal, Model Name/Logo (A) .............. 1
777D09940 Decal, Model Name/Logo (C) .............. 1
4 1916784 Reverse Clutch Control Cable.............. 1
5 1186347 Height Adjustment Screw ................... 1
5A GW-9955 Washer, Keyed .................................... 1
6 1900475001 Bracket, Handlebar Height Adjustment 1
7 710-0514 Hex Hd. Screw, 3/8-16 x 1* ................ 2
8 736-3050 Washer, Plain (flat) 3/8, S.A.E. ............ 2
9 712-3000 Hex Locknut, 3/8-16............................ 2
10 746-04027 Cable, Forward Clutch Control ............ 1
13 GW-9442 Wheel Gear Control and Cable Assy .... 1
14 GW-9057 Knob, Wheel Gear Control Lever ......... 1
15 1186211 Hex Nut, 5/16-24................................. 2
16 GW-90064 Hex Hd. Screw, 3/8-16 x 5/8* ............. 2
17 736-0169 Lockwasher, 3/8.................................. 2
19 725-0157 Cable Ties, Plastic ............................... 2
21 1114748 Round Hd. Screw, #10-32 x 1/2.......... 6
22 1100240 Lockwasher, #10 ................................. 2
23 1186208 Hex Nut, #10-32.................................. 2
24 GW-9390 Grip ..................................................... 2
25 1918840 Bail w/ Grips, Forward Clutch Control . 1
35 GW-9853 Sems Nut ............................................ 4
36 GW-20806 Bracket, Bail Support .......................... 2
42 710-0599 Hex Flange Screw, self-tapping,
1/4-20 x 1/2* .................................. 2
HANDLEBAR ASSEMBLY and CONTROL LEVERS
* Specify GRADE 5 if ordering part locally.
(A) For Model 663E
(B) For Model E663E
(C) For Model 665B

30 Parts List
Models 663B, 663E, 665B & E663E
ENGINE, SUPPORT BRACKETS, PULLEYS, BELTS, BELT COVER
Reverse
Clutch Cable
2
6
5
7
7
3
4
13
14
15
16
17 16
52
21
25
24
23
8
39 46
20
45
43
53
54
41
44
51
43
44 37
31
38
47
35
45
20,45
49
50
40
42
48
12
26
27
3
28
29
30
11
22
18
1
11,32
10
9
8,43
35
36
(Screw, Ref. 47, secures
Forward Clutch Cable
– page 28, Ref. 10)

Parts List 31
Models 663B, 663E, 665B & E663E
ENGINE, SUPPORT BRACKETS, PULLEYS, BELTS, BELT COVER
1 710-0539 Screw, 3/8-24 x 1.75 (A) .................... 1
710-04458 Screw, 5/16-24 x 1.125 (B)................. 1
2 786-04070 Bracket, Clutch Cable .......................... 1
3 736-0119 Lockwasher–5/16................................ 6
4 710-0107 Hex Hd. Screw, 5/16-24 x 1/2 ............. 2
5 777S30651 Decal, Hot Surfaces/Belt Warning ....... 1
6 731-05290 Cover................................................... 1
7 712-3004A Flange Lock Nut, 5/16-18.................... 2
8 714-04042 Key, 3/16 x 1-1/2 (B)........................... 1
9 736-04187 Shim ................................................... 1
10 619-04015 Pulley, Engine Drive (A)....................... 1
619-04310 Pulley, Engine Drive (B)....................... 1
11 736-04193 Belleville Washer (B) ........................... 2
12 710-04458 Hex Hd. Screw, 5/16–24 x 1-1/8 ......... 1
13 710-3103 Hex Hd. Screw, 5/16–18 x 2................ 1
14 786-04276 Reverse Idler Arm ............................... 1
15 756-04169 Pulley, Reverse Idler............................ 1
16 736-0159 Flat Washer, 5/16 ................................ 2
17 732-04081 Belt Guide, Wire Formed .................... 1
18 710-0117 Hex Head Screw, 5/16-24 x 1.............. 1
19 748-04087 Washer, Shoulder................................ 1
20 736-3078 Washer, Flat, 1-1/8 ............................. 3
21 732-04077 Spring, Reverse Return....................... 1
22 619-04123 Transmission Pulley ............................ 1
23 736-04079 Support Washer.................................. 1
24 754-04095 Reverse Clutch Belt............................. 1
25 754-04094 Forward Clutch Belt............................. 1
26 710-04459 Self-tapping Screw, #10-32 x 1/2,....... 4
27 786-04080 Guard, Belts/Pulleys............................ 1
28 712-04063 Hex Flange Nut, 5/16–18..................... 4
29 710-04043 Hex Flange Screw, 5/16-18 x 3/4* ...... 4
30 786-04066 Engine Support Bracket, left side ........ 1
31 786-04067 Engine Support Bracket, right side...... 1
32 736-0452 Bell Washer (A) ................................... 1
35 710-0395 Hex Hd. Screw, 5/16–18 x 2-1/4 ......... 5
36 777I20358 Decal, Stabilization.............................. 1
37 786-04277 Mounting Bar ...................................... 2
38 710-1260 Hex Flange Screw, 5/16-18 x .75......... 4
39 710-0805 Hex Hd. Screw, 5/16-18 x 1-1/2*........ 1
40 736-0275 Flat Washer, 5/16' ............................... 1
41 732-04082 Belt Guide, Pony.................................. 2
42 750-04160 Pivot Bushing...................................... 2
43 714-04029 Key, .188 x 1.75 (A) ............................ 1
44 712-3010 Hex Nut, 5/16-18................................. 2
45 748-04087 Washer, Shoulder................................ 2
46 786-04275 Idler Arm, Forward Tiller Direction...... 1
47 710-04460 Screw, self tapping, #10-24 ................ 1
48 732-04078 Spring ................................................. 1
49 712-3000 Hex Locknut, 5/16-18.......................... 1
50 756-04170 Idler Pulley, Forward .......................... 1
51 710-0347 Screw, 3/8-16 x 1-3/4 ......................... 1
52 712-0158 Hex Lock Nut, 5/16-18 ........................ 1
53 710-04461 Screw, 1/4-20 x 3/4............................. 1
54 736-0463 Flat Washer–1/4 .................................. 1
REF. PART
No. No. DESCRIPTION QTY.
REF. PART
No. No. DESCRIPTION QTY.
* Specify GRADE 5 if ordering part locally.
** See your local authorized engine service dealer for engine parts or
service. Refer to engine nameplate for engine type and code
information.
(A) For Models 663E & E663E
(B) For Model 665B

32 Parts List
Models 663B, 663E, 665B & E663E
TRANSMISSION HOUSING, COVERS, SEALS, GASKETS, PLUGS
1 721-04031 Oil Seal (Double Lip), Wheel Shaft ...... 2
2 1105620 Pipe Plug, 1/4, .................................... 2
3 721-04001 Seal, Transmission Bore...................... 1
4 710-04043 Hex Flange Screw, 5/16-18 x 3/4* ...... 6
5 721-04044 Oil Seal, Input Pinion Shaft ................. 1
6 GW-20910 Transmission Cover ............................ 1
7 GW-20694 Gasket, Transmission Top Cover ......... 1
8 619-04010 Transmission Case Assy...................... 1
9 GW-9467 Plug..................................................... 1
10 1917101001 Mounting Plate, Wheel Clutch Cable ... 1
11 721-04035 Oil Seal, Tiller Shaft............................. 2
12 710-04049 Screw, Hex Flange, 5/16-18 x 5/8”..... 2
13 GW-20873 Cover, Tiller Housing........................... 1
15 1915069 Self-Sealing Screw, 1/4-20 x 7/8” ...... 3
16 GW-1115 Rear Bearing Cap ................................ 1
17 GW-1124-2 Gasket, Rear Bearing Cap, .010" A/R
18 710-1260A Hex Flange Screw, 5/16-18 x 3/4* ...... 4
19 1915068 Self-Sealing Screw, 1/4-20 x 5/8” ....... 5
21 736-0169 Lockwasher, 3/8.................................. 2
22 GW-90064 Hex Hd. Screw, 3/8-16 x 5/8* ............. 2
REF. PART
No. No. DESCRIPTION QTY.
REF. PART
No. No. DESCRIPTION QTY.
* Specify GRADE 5 if ordering part locally.
A/R – As Required
NOTE 1: These screws are a special sealing screw
that cannot be reused without risking the loss of
transmission oil. If these screws are loosened or
removed, they must be replaced with new screws.

Parts List 33
Models 663B, 663E, 665B & E663E
MAIN DRIVE SHAFT
1 GW-1714 Bearing, Tapered Roller with Race .... 1
2 GW-20718 Spur Gear.......................................... 1
3 GW-9301 Key, 3/16 sq. x 1 ............................... 1
4 GW-20912 Main Drive Shaft (Drive shaft is one-
piece with integral, single-lead,
work-hardened front worm, and
integral, six-lead, work-hardened
rear worm. Also includes pressed-
on GW-1714 and GW-9301).......... 1
5 GW-1224-1 Shim, Rear Bearing Cap, .010" thick
(see Note below) ........................... A/R
5 GW-1224-2 Shim, same as above, but .030" thick
(see Note) ..................................... A/R
5 GW-1224-3 Shim, same as above, but .005" thick
(see Note) ..................................... A/R
... GW-1325C Shim Set (Incl. two GW-1224-1; two
1224-2 and one GW-1224-3) ........ A/R
INPUT PINION SHAFT & GEAR ASSEMBLY
6 710-04458 Hex Hd. Screw, 5/16-24 x 1-1/8*...... 1
7 736-04193 Washer, Disc Spring (concave
surface faces pulley) ..................... 1
8 714-04042 Key, 3/16 sq. x 1-1/2......................... 1
9 1916522 Transmission Drive Pulley................. 1
10 736-04079 Support Washer................................ 1
11 721-04044 Oil Seal, Input Pinion Shaft ............... 1
12 1113527 Retaining Ring (external) ................. 1
13 GW-9953 Thrust Washer .................................. 2
14 GW-9428 Bushing............................................. 1
15 GW-9677 Set Screw, 5/16-18 x 3/8*................. 1
16 GW-20791 Input Pinion (steel shaft)................... 1
17 GW-20792 Input Pinion Gear .............................. 1
18 GW-9093 Retaining Ring (external) l ................ 1
19 GW-20799 Pinion Assy. (Incl. one each Refs. 16,
17 and 18...................................... A/R
20 GW-9517 Retaining Ring (internal) .................. 1
REF. PART
No. No. DESCRIPTION QTY.
REF. PART
No. No. DESCRIPTION QTY.
NOTE: Shim between drive shaft rear bearing and rear bearing cap to achieve 5-to-10 thousandths of an inch (.005-.010) end play on drive shaft.
A/R - As Required
* Specify GRADE 5 if ordering part locally.
DRIVE SHAFT, INPUT PINION SHAFT and GEAR ASSEMBLIES

34 Parts List
Models 663B, 663E, 665B & E663E
WHEEL SHAFT, ECCENTRIC SHAFT and TILLER SHAFT ASSEMBLIES
REF. PART
No. No. DESCRIPTION QTY.
REF. PART
No. No. DESCRIPTION QTY.
1 721-04031 Oil Seal.............................................. 2
2 1909950 Retaining Ring (heavy-duty, external) 2
3 GW-1166-1 Shim, 1-1/64 I.D., .062" thick............ A/R
--- GW-1166-2 Shim, as above, but .030" thick......... A/R
--- GW-1166-3 Shim, as above, but .015" thick......... A/R
--- GW-1166-4 Shim, as above, but .010" thick......... A/R
4 GW-1086 Bushing............................................. 2
5 711-04482 Wheel Shaft....................................... 1
6 GW-9373 Hi-Pro Key, 1/4 x 1-5/16.................... 1
7 GW-20914 Wheel Drive Worm Gear (cast-iron).. 1
8 GW-9935 Shim (between key and gear),
1.016 I.D. x 1.468 O.D. x .062
Thick ............................................. 1
9 GW-20712 Wheel Drive Clutch (cast-iron).......... 1
10 611-04002 Eccentric Shaft.................................. 1
11 GW-1442 Pin, Eccentric Shaft........................... 1
12 GW-9055 Spring ............................................... 1
13 721-04034 Oil Seal.............................................. 1
14 786-04001 Eccentric Shaft Lever ........................ 1
15 710-3013 Hex Hd. Screw, 1/4-20 x 1/2* ........... 1
16 741-3037 Ball Bearing....................................... 2
17 711-04080 Tiller Shaft......................................... 1
18 GW-1104 Woodruff Key, 1/4 x 1-1/4................. 1
19 GW-20913 Tiller Drive Worm Gear (bronze) ....... 1
* Specify GRADE 5 if ordering part locally.
A/R - As Required

1 710-0514 Hex Hd. Screw, 3/8-16 x 1* ................ 16
2 742-04119 Bolo Tine-single. Left hand tine ......... 8
3 712-3000 Hex Locknut, 3/8-16............................ 18
4 710-0606 Hex Hd. Screw, 1/4-20 x 1.5 ............... 2
5 710-3096 Hex Hd. Screw, 3/8-16 x 2, Grade 8.... 2
6 712-04064 Hex Locknut, Flange, 1/4-20 ............... 2
7 742-04118 Bolo Tine-single. Right hand tine ....... 8
8 686-04067 Tine Holder. For left and right sides..... 2
-- 1901118 Bolo Tine Replacement Set (Incl. eight
ea. right hand and left hand tines,
and sixteen ea. Refs. 1 and 3) ......... 1
-- GW-2475-1 Custom Tilling Bolo Tine, Left hand
tine (see Note 1 above) ................... 8
-- GW-2475-2 Custom Tilling Bolo Tine, Right hand
tine (see Note 1 above) ................... 8
-- GW-10802 Custom Tilling Bolo Tine Replacement
Set (Incl. eight ea. right hand and
left hand custom tines, and sixteen
each of Refs. 1 and 3) ..................... 1
9 634-04232 Wheel Assembly, 13 x 5 x 6 ............... 2
REF. PART
No. No. DESCRIPTION QTY.
REF. PART
No. No. DESCRIPTION QTY.
Parts List 35
Models 663B, 663E, 665B & E663E
* Specify GRADE 5 if ordering part locally.
BOLO TINES, WHEELS
Hold With Blunt End Facing You
Left-Hand Tine Right -Hand Tine
9
9
4
3
3
3
3
1
1
2
7
7
2
5
8
8
5
6
IMPORTANT: Left and right sides
of tiller are determined by standing
in the operator position and facing
direction of forward travel.
NOTE 1: Custom Tilling Tines are available
for your tiller. These are special hard-faced
tines that are thicker than standard tines.

36 Parts List
Models 663B, 663E, 665B & E663E
BUMPER ATTACHMENT




REF PART
No. No. DESCRIPTION QTY.
1 749-04193 Bumper ............................................ 1
2 712-04063 Lock Nut–Hex, Nylon, 5/16-18* ....... 4
3 710-0395 Screw–hex hd., 5/16-18 x 2-1/4........ 4
4 736-0119 Lockwasher–5/16.............................. 4
5 712-04063 Lock Nut–Hex, Nylon, 5/16-18* ....... 4

Parts List 37
Models 663B, 663E, 665B & E663E
HOOD, BRACKET and DEPTH REGULATOR
1 686-04078 Tine Hood............................................ 1
2 710-0169 Lockwasher, 3/8.................................. 2
3 GW-1925 Bracket–hood & depth regulator ......... 1
4 710-04049 Hex Flange Screw, 5/16-18 x 5/8* ...... 2
5 712-04064 Hex Locknut, 1/4-20............................ 1
6 710-0597 Hex Hd. Screw, 1/4-20 x 1* ................ 1
7 732-04320 Spring ................................................. 1
8 750-04556 Spacer................................................. 1
9 715-04034 Roll Pin (spiral), 1/4 x 1 ..................... 1
10 GW-1117A Depth Adjustment Bar Assembly
(Incl. Refs. 11 and 12) .................... 1
11 GW-9120 Retaining Ring (tolerance ring) ........... 1
12 GW-9119 Knob, Depth Regulator (Incl. Ref. 11) . 1
13 710-3005 Hex Hd. Screw, 3/8-16 x 1-1/4*.......... 2
14 GW-1113-1 Bushing, Drag Bar............................... 2
15 712-04065 Hex Nut, 3/8-16................................... 2
16 GW-20775 Drag Bar ............................................. 1
17 777S30649 Decal, operating instructions .............. 1
18 710-0759 Hex Hd. Screw, self-tapping,
5/16-18 x 5/8* ................................ 2
19 710-0599 Hex Flange Screw, self-tapping,
1/4-20 x 1/2* .................................. 2
REF. PART
No. No. DESCRIPTION QTY.
REF. PART
No. No. DESCRIPTION QTY.
* Specify GRADE 5 if ordering part locally.
Transmission
618-04359

38 Parts List
Model E663E

Parts List 39
Model E663E
ELECTRIC START ASSEMBLY
1 1186073 Carriage Screw, 1/4-20 x 1.25........... 2
2 1186211 Hex Nut, 5/16-24............................... 2
3 1186309 Flange Screw, 1/4-20 x .625.............. 2
4 1186389 Hex Locknut, 1/4-20.......................... 2
5 1901202 Cable (ground wire to starter
motor bracket) .............................. 2
7 725-04346 Wire Harness Assy. (available as
complete assembly only). Incl.
wire assy. w/connector to large
solenoid stud (red wire); wire
assy. w/connector to small
solenoid stud (red wire); wire
assy. w/connector to solenoid
grounding screw (red wire); wire
assy w/connector to engine ground
shut-off (green wire); plastic
protector tube; wire terminal......... 1
8 1917262 Ground Wire Assy. (shut off) ............ 1
9 686-04024 Battery Bracket Assembly, Pony........ 1
10 710-0599 Self-tapping Screw, 1/4-20 x .5......... 3
11 712-3006 Hex Nut, 1/4-20................................. 2
12 725-0157 Cable Tie ........................................... 1
13 725-0267B Ignition Switch .................................. 1
14 725-1706A Battery, 270 CCA ............................... 1
15 736-0119 Lock Washer 5/16 ............................. 2
16 736-0147 Lock Washer, #10 ............................. 1
17 736-0607 External Lock Washer, 5/16............... 2
18 GW-2614 Keyswitch Clamp............................... 1
19 GW-96510 Cable (solenoid to starter motor) ...... 1
20 GW-96514 Solenoid (Incl. nuts and washers
for cables and wires)..................... 1
21 GW-97020 Boot, Insulating................................. 2
22 GW-9853 Hex Locknut, #10-32......................... 1
— 777S30648 Label, Ignition Switch........................ 1
REF. PART
No. No. DESCRIPTION QTY.
REF. PART
No. No. DESCRIPTION QTY.