Troy-Bilt 680 Series Setup guide

TROY-BILT LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019
Printed In USA
Il l u s t r a t e d Pa r t s Ma n u a l
Large Frame Tiller — 680 Series
Form No. 769-03846
(January 28, 2008)

2
680 Series Drive Lever & Yoke Assembly
12
1
3
14
10
15
9
11 2
7
4
5
6
13
15
10
13
12
11
15
12
14
11
12
13
15
8
4
16
Ref. Part Number Description
1. GW-2595 Forward/Reverse Lever
2. 1908156 Clutch Pawl Spring
3. 710-0805 Hex Bolt, ⁄-18 x 1-⁄”
4. GW-2447 Bushing, ⁄”
5. 117754 8 External Tooth Lockwasher, ⁄”
6. 712-3010 Hex Nut, ⁄”-18
7. 686-04006 Roller Assembly
8. GW-2165-1 Yoke (Left)
9. GW-2165-2 Yoke (Right)
10. GW-2164 Yoke Pivot Link, 6-⁄”
11. 710-0514 Hex Bolt, ⁄-16 x 1”
12. 736-0169 Spring Lockwasher, ⁄”
13. 736-3050 Flat Washer, ⁄”
14. 712-3017 Hex Nut, ⁄”-16
15. GW-1113 -1 Bushing Spacer, ⁄”
16. GW-2595 Knob
2

3
680 Series Handle
3
2
4
1
9
8
7
6
5
29
10
18
17
23
22
25
24
12
21
14
15
13
11
16
19
20
28
18
26
27
Handlebar Engine Base
Ref. Part Number Description
1. GW-9548 Hex Bolt, ⁄-13 x 3-⁄”
2. GW-9119 Handlebar Height Adjustment Knob
3. GW-9120 Retaining Ring
4. GW-2657 Handlebar Height Adjustment Stud
5. 118 6233 Hex Nut, ⁄”-13
6. GW-1021-1 Handlebar Hgt, Adj. Clamp (LT)
7. GW-2542-1 Handlebar Hgt. Adj. Ratchet (LT)
8. GW-2542-2 Handlebar Hgt. Adj. Ratchet (RT)
9. 1901784 Handlebar Hgt. Adj. Clamp (RT)
10. GW-2534A Handlebar Mounting Base
11. 649-04020 Handlebars
12. 720-04083 Handlebars Grip
13. 1918111 Curved Head Bolt, ⁄-20 x 2”
14. 118638 9 Hex Nut, ⁄”-20
15. 1909286 Throttle Control & Cable, 66”
Ref. Part Number Description
16. 725- 0157 Plastic Tie
17. GW-9219 Wire Harness Retainer Plug
18. 725-04367 Handlebar Wire Harness Assembly
19. GW-2563 Switch Assembly
20. 710-0779A Pan Head Screw, #10-16 x ⁄”
21. GW-9733 Phillips Head Screw, 10-32 x ⁄”
22. 786-04003 Operator Presence Control Lever
23. GW-9199 Pivot Pin
24. GW-9514 Retaining Ring
25. GW-9387 Return Spring
26. 712-3010 Hex Nut, ⁄-18
27. 736 - 0119 Washer, ⁄
28. 710-0805 Cap Screw, ⁄-18 x 1.5
29. 1901835 Plug Cap
3

4
680 Series Depth Regulator & Tine Shield
56
7
9
11
10
12
13
14 17
15
16
18
3
4
1
2
8
1
2
10
11
4
12
5
Ref. Part Number Description
1. 710-3005 Hex Bolt, ⁄-16 x 1-⁄”
2. GW-1113-1 Bushing, ⁄”
3. 710-04049 Hex Flange Bolt, ⁄-18 x ⁄”
4. 712- 04065 Hex Nut, ⁄”-16
5. GW-20795 Depth Regulator
6. GW-9120 Retaining Ring
7. GW-9119 Depth Regulator Knob
8. GW-2121 Depth Regulator Bar Drag
9. 710-0599 Thread-forming Screw, ⁄-20 x ⁄”
Ref. Part Number Description
10. 710-04043 Hex Flange Bolt, ⁄-18 x ⁄”
11. GW-9929 Flat Washer, ⁄”
12. 1904563 Hood
13. GW-2525 Bracket
14. 715- 04034 Roll Pin (Spirol), ⁄” x 1”
15. 750-04556 Split Spacer
16. 732-04320 Spring
17. 710-0597 Hex Bolt, ⁄-20 x 1”
18. 712-04064 Locknut, ⁄”-20
4

5
660 Series Drive System
3
1
2
3
1
2
5
6
4
5
35
44
5
4
4
5
5
4
3
5
4
6
5
4
Ref. Part Number Description
1. 686-04068 Tine Holder
2. 710-3096 Hex Bolt, ⁄-16 x 2"
3. 712-3000 Hex Locknut, ⁄"-16
4. 742- 04118 Bolo Tine Left
5. 742- 04119 Bolo Tine Right
6. 710-3005 Hex Bolt, ⁄-16 x 1"
5

6
680 Series Drive System
29
28
25
19
6
16
1
2
3
4
9
11
10
9
18
17
14
13
12
20
13
33
21
22
2324
31 30
27
14
14
13
12
15
26
14
12
14
15
13
35
36
34
7
6

7
680 Series Drive System
Ref. Part Number Description
1. GW-9362 Spring Pin, ⁄"
2. 736-0326 Flat Washer, .510 x 1.0 x .125
3. GW-9934 Shoulder Washer, ⁄"
4. GW-9932 Disc Spring Washer
5. GW-2178 Wheel Speed Shift Lever
6. 1902240 Knob
7. GW-9317 Cotter Pin, ⁄" x 1"
8. GW-1033 Swivel
9. 736-0275 Flat Washer, ⁄"
10. 714-04048 Hair Pin Cotter
11. 712-0158 Hex Locknut, ⁄"-18
12. 710-0514 Hex Bolt, ⁄-16 x 1"
13. 736-0169 Spring Lockwasher, ⁄"
14. 736-3050 Flat Washer, ⁄"
15. GW-1113 -1 Spacer Bushing, ⁄"
16. GW-9120 Retaining Ring
17. GW-2102 Belt Adjustment, 3-⁄"
18. GW-2100 Belt Adjustment Rod
19. 712-3012 Hex Nut, ⁄-20
20. 710-0539 Hex Bolt, ⁄-24 x 1.75
Ref. Part Number Description
21. 756-0 4171 Reverse Disc
22. GW-9245 Forward Drive Belt
23. 619- 04124 Engine Power Take-o Pulley
24. 736 -04192 Flat Washer, .766 x 1.0 x .031*
—736-04187 Flat Washer, .766 x 1.0 x .062*
25. GW-9303 Engine Pulley Key, ⁄"x 2-⁄"
26. 710-0376 Hex Bolt, ⁄-18 x 1"
27. 712-3010 Hex Nut, ⁄-18
28. GW-1034 Engine Mounting Bar
29. GW-9147 Thread Protector Plug
30. 710-04458 Hex Bolt, ⁄-24 x 1-⁄"
31. 73 6 - 0119 Spring Lockwasher, ⁄"
32. 719-04222 Motor Mount
33. 736-3052 Flat Washer, .406 x 1.0 x .105
34. 710-0606 Hex Screw, ⁄-20 x 1-⁄"
35. 634-04231 Wheel Assembly, 16 x 4.6 x 8"
—634-04230 Rim Assembly
—734-0808 Tire, 16.2 x 4.6
36. 712-04064 Hex Flange Nut, ⁄-20
7

8
680 Series Power Transmission Assembly
4
1
21
2
20
19
18
17
16 4
15
14
77 6
5
11
8
9
10
12
13
53
52
61
51
50
30
49
63
62
60
35 36
37
38 39 41
67
68 69
40 39
78
31
32
33 30 34
43
48
76
47
46
45
44
57
56
55
54
75
1
2
21
22
24 23
24
25
26 27
66
64
65
42 41
29 28
72
73
30
71
74
48
46
47
45
46
44 58
59
8

9
Ref. Part Number Description
1. .118 629 9 Hex Bolt, #10-32 x ⁄"
2. GW-9463 Knob
3. GW-2124 Plate
4. 118 6349 Hex Flange Bolt, ⁄-16 x 1-⁄"
5. 118 6329 Hex Flange Bolt, ⁄-18 x ⁄"
6. 736-0275 Flat Washer, ⁄"
7. GW-9362 Spring Pin, ⁄"
8. 712-3012 Hex Nut, ⁄-20
—736-0326 Flat Washer, .510 x 1.0 x .125
9. GW-9934 Shoulder Washer, ⁄"
10. GW-9932 Disc Spring Washer
11. GW-2178 Wheel Speed Shift Lever
12. GW-2523 Power Unit Transmission Cover
13. GW-1123 Transmission Cover Gasket
14. 710-0376 Hex Bolt, ⁄-18 x 1"
15. 712-3010 Hex Nut, ⁄"-18
16. 1901439 Plunger Spring
17. GW-1035-1 Plunger
18. 1901440 Clip Ring
19. 712- 04065 Flange Lock Nut
20. 1902004 Hex Bolt, ⁄-16x1-⁄"
21. 786-04002 Tines/PTO Clutch Lever
22. 710-3013 Hex Bolt, ⁄-20 x ⁄"
23. 741-04008 Tines/PTO Clutch Bushing
24. GW-9516 External Retaining Ring
25. GW-2461 Tines/PTO Clutch Shaft
26. GW-9911 Hi-Collar Lockwasher, ⁄"
27. GW-9672 Socket Head Screw, ⁄-20 x ⁄"
28. 716-0101 External Retaining Ring
29. 1909139 Dog Clutch
30. GW-9301 Key, ⁄ x 1"
31. 1100004 Hex Bolt, ⁄-24 x ⁄"
32. GW-9944 Spring Washer, .827 x .331 x .098
33. GW-2107 Transmission Drive Pulley
34. GW-50027 Flat Washer, 1-⁄"
35. 710-04466 Flange Nut, ⁄-20 x .75
36. 718-04007 Front Bearing Cap
37. 721-04044 Oil Seal
38. 736-04305 Flat Washer, 1.175 x 1.5 x .062
—736-04306 Flat Washer, 1.175 x 1.5 x .005
—736-04307 Flat Washer, 1.175 x 1.5 x .03
—736-04308 Flat Washer, 1.175 x 1.5 x .01
39. 741-04299 Cup Bearing
40. GW-2655 Main Drive Shaft
Ref. Part Number Description
41. 721-04030 Oil Seal
42. 716- 04102 Retaining Ring
43. 715-0121 Roll Pin (Spirol), ⁄ x 2
44. 718-04006 Pinion Bearing
45. GW-9604 O-Ring
46. 736-04310 Flat Washer, 1.234 x 1.015 x .062
—GW-1132-1 Flat Washer, 1.234 x 1.015 x .033
—GW-1132-3 Flat Washer, 1.234 x 1.015 x .01
47. GW-9404 Pinion Shaft
48. GW-1126 Washer
49. GW-1222 Pinion Stem
50. GW-9502 External Retaining Ring
51. GW-2656 Worm Gear
52. GW-9300 Key, ⁄" x ⁄"
53. GW-1233 Fast Speed Pinion Gear
54. 721-04031 Oil Seal
55. 716-04104 External Retaining Ring
56. 736-04257 Flat Washer, 1.375 x 1.015 x .005
—736-04258 Flat Washer, 1.375 x 1.015 x .01
—736-04259 Flat Washer, 1.375 x 1.015 x .015
—736-04260 Flat Washer, 1.375 x 1.015 x .03
—736-04309 Flat Washer, 1.375 x 1.015 x .062
57. 741- 04300 Bushing, 1.25 x 1.005 x 1.5
58. 711- 0425 8 Wheel Shaft
59. 714-04014 Hi-Pro Key, .250 x 1.8125
60. GW-1223 Slow Speed Gear
61. GW-1232 Faste Gear Speed
62. GW-1237 Dog Clutch
63. GW -1112 Clutch Guide Pin, ⁄"
64. 1911372 Roll Pin, ⁄" x 1-⁄"
65. 619-04000 Wheel Speed Shifting Lever
66. 721-04034 Oil Seal
67. GW-1442 Wheel Speed Shifting Pin
68. 611- 04 0 03 Wheel Speed Shifting Shaft
69. GW-1441 Spring
70. GW-2109 Transmission Housing
71. GW-9359 Alignment Pin
72. 1100067 Hex Bolt, ⁄-13 x 2"
73. GW-9928 Disc Spring Washer
74. GW-2126 Post
75. 1105620 Pipe Plug, ⁄"
76. GW-9122 Plug–Red Plastic
77. GW-2149 Clutch Bracket
78. 741- 04298 Cone Bearing
680 Series Power Transmission Assembly
9

10
680 Series Power Transmission Assembly
Ref. Part Number Description
1. 1915068 Self-Sealing Screw, ⁄"-20 x ⁄"*
2. GW-20873 Tiller Housing Cover
3. 711- 0 4 082 Tine Shaft
4. 741-3037 Ball Bearing
5. 1901976 Worm Gear
6. GW-1104 Woodru Key
7. 721-04035 Oil Seal
8. 716-0101 External Retaining Ring
9. 1909138 Dog Clutch
10. GW-9301 Key, ⁄" x 1"
11. GW-2127 Spring
12. 1915069 Self-Sealing Screw, ⁄"-20 x ⁄"
Ref. Part Number Description
13. G W-1115 Cap
14. 736-04305 Flat Washer, 1.75 x 1.5 x .062**
—736-04306 Flat Washer, 1.75 x 1.5 x .005**
—736-04307 Flat Washer, 1.75 x 1.5 x .03**
—736-04308 Flat Washer, 1.75 x 1.5 x .01**
15. 741-04299 Cup Bearing
16. GW-2653 Shaft
17. 721-04030 Oil Seal
18. 716-04102 Retaining Ring
19. 1901971 Attachment Housing
20. 1909157 Oil Dipstick
21. 741-04298 Cone Bearing
* — These screws have a special sealing design and cannot be
re-used. If removed, replace with new hardware.
15 16
15 21 14
13
12
8
9
10
11
14
8
17
18
21
220
19
7
4
5
6
3
4
2
1
7
** — Washers of multiple thickness are used as required to
obtain a thickness of .005" to .015" of allowable end-play in the
drive shaft.
10

11
680 Series Electric Start System
6
7
5
22
Starter
Motor
20
16
22
3
18
824
23
Ground Cable to
Engine Base
16
To Starter Motor
Starter Cable
11
1
3
Starter
Selenoid
Active
Wire (Red)
14
1512
13 2
Ground
Wire
19
21
6
Ground
Terminal
Negative
Battery
Cable
2
9
4
10
2
9
17
Starter Switch
Wire (Red)
Ref. Part Number Description
1. GW-96515 Battery Cable
2. GW-97020 Terminal Insulating Boot
3. 710-0599 TT-Screw, ⁄-2 x ⁄"
4. 118 630 9 Hex Bolt, ⁄-20 x ⁄"
5. GW-2614 Battery Hold-down Clamp
w/ Att. Key Switch Plate
6. 725-0267B Key Switch (Incl. 2 Keys, Ref. 7)
7. 725-0201 Ignition Key
8. 1186073 Carriage Bolt, ⁄-20 x 1-⁄"
9. 712-3006 Hex Nut, ⁄"-20
10. 725-1706A 12-Volt Battery
11. GW-96514 Starter Solenoid
12. 736 - 0119 Lockwasher, ⁄"
Ref. Part Number Description
13. 1186211 Hex Nut, ⁄ "-24
14. 736-0147 External Tooth Lockwasher
15. GW-9853 Hex Nut, #10-32
16. GW-96510 Solenoid Cable
17. GW-2557 Battery Bracket
18. 710-3022 HH Cap Screw, ⁄-16 x 2.75"
19. GW-9265 Plastic Tie
20. 725-0157 Plastic Tie
21. 725-04346 Wire Harness
& Connecting Terminal Assembly
22. 118 6389 Hex Locknut, ⁄"-20
23. 1901202 Ground Cable
24. 750- 0748 Spacer
11

12
3
1
2
Ref. Part Number Description
1. 725-04368 Forward Engine Wire Harness Ass.
2. 736-0508 Internal L-Washer, ⁄"
3. 725-0157 Plastic Tie
680 Series Forward Interlock System
12

13
Ref. Part Number Description
1. 1909748 Spacer, 1.0 x .546 x .5
2. 1910730 Bottom Bumper Brace
3. 1910731 Bumper Guard
4. 710-0514 Hex Screw, ⁄-16 x 1.00
5. 710-0805 Hex Screw, ⁄-18 x 1.50
6. 710-3181 Hex Screw, ⁄-13 x 1.50
7. 712-3010 Hex Nut, ⁄-18
8. 736 - 0119 Lock Washer, ⁄
9. 736-0169 Lock Washer, ⁄
10. 736-0921 Lock Washer, ⁄
52
6
10
1
7
8
9
4
3
680 Series Bumper
13

Notes
14

15no t e s

TROY-BILT LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019
To order replacement parts or locate your nearest service dealer call Customer Support at [phone].
or visit www.troybilt.com to find the nearest authorized dealer in your area.