Troy-Bilt ECONO-HORSE Owner's manual

$7.50
Owner/Operator
Manual
ECONO·HORSETM
PONY ®& JUNIOR ®
Model Tillers
- Safety
- Assembly
- Controls
- Operation
-
Maintenance

TABLE OF CONTENTS
SECTION 1: SAFETY INSTRUCTIONS .4
Safety Alert Symbol .4
Training .4
Preparation .4
Operation .4
Maintenance and Storage 6
Decals 6
SECTION 2: EASY ASSEMBLY 7
SECTION 3: TILLER AND
ENGINE
CONTROLS 18
Tiller Controls 18
Wheel Gear Lever (Econo-Horse &Pony) 18
Wheel Drive Pins (Junior only) 19
Forw ard Clutch 20
Maneuvering Clutch 20
Depth Regulator 21
Handlebar Height Adjustment 21
Engine Controls 22
Starting Your Engine 22
Starting the Electric Start Engine
With the Recoil Starter Rope 23
Stopping the Engine 23
SECTION 4: OPERATION OF TILLER 24
Be
for e Starting 25
To Begin Tilling 25
Turning Around 25
Stopping the Tiller and Engine 25
Changing Speeds (Econo-Horss only) 26
To
Change from LOW Speed to HIGH 26
To Change from HIGH Speed to LOW 27
Tilling in the Garden 27
Guiding Your Tiller. 27
Tilling Depths 27
Tilling Patterns 28
Choosing Wheel and Tine Speeds 29
Avoid Making Footprints 29
Clearing Debris from the Tine Area 29
Power
Comp osting 30
Use Reverse to Turn in Tight Areas 30
Tilling Near Obstacles 30
Tilling Up and Down Slopes 31
Tilling Across Slopes Using Terraces 31
Tilling Across Slopes Without Terraces 32
Loading and Unloading the Tiller 32
SECTION 5: TILLER AND
ENGINE MAINTENANCE. 33
Lubrication , 33
Check for Oil Leaks 34
Tightening Nuts and Bolts , 34
Checking, Adding or Changing
Transmission
Gear Oil 34
To Check the Transmission
Gear Oil Level 34
To Add Gear Oil to the
Transmission 35
To Drain and Refill the
Transmission 35
Checking Engine Oil Level 35
Changing Engine Oil 36
Air Cleaner Service 36
Spark Plug Maintenance 37
Ignition System Maintenance 37
Air Cooling System Maintenance 37
Bolo Tines 37
Removing Bolo Tine Assemblies 38
Removing Individual Bolo Tines 38
Checking Tension on the Drive Belts 38
Forward Drive Belt Tension 39
Reverse Drive Belt Tension 39
Adjusting Forward Drive Belt Tension 39
Removing Forward Drive Bel
t.. .41
Installing Forward Drive Belt.. .41
Removing Reverse Drive Belt.. .42
Installing Reverse Drive
BelL .42
Adjusting Reverse Drive Belt Tension .43
Wheel Gear Cable Adjustment .43
Engine Throttle Cable Adjustment .44
Off-Season Storage .44
Troubleshoot Electric Start System .45
Starter Motor Won't Turn Over .45
Ignition Switch Doesn't Stop Engine 46
Battery Care and Maintenance .47
Care in Service .47
Battery Storage .47
Carburetor Adjustment .47
Specifications .48
Recommended Maintenance Intervals .49
INDEX REFERENCE 52

TO THE OWNER:
Congratulations on the purchase of your new tiller! The ECONO-HORSE'" Model, the PONY®
Model and the JUNIOR®Model, along with the rest of the TROY-BILT® models, make up the finest
family of tillers available anywhere.
The ECONO-HORSE'" , PONY® and JUNIOR®Tillers are covered in this manual. They have many
features in common, but there are substantial differences too, and where differences occur, they are so
noted. Your new tiller is basically a simple machine to operate. However, as with all new equipment,
you should thoroughly read and understand this Owner/Operator Manual and any other product litera-
ture you received before you operate your tiller. Then, you should practice operating the tiller controls
and maneuvering the tiller in a safe area until you feel very comfortable using the tiller.
Your tiller was designed with the tines in the rear and the engine up front. This design, first perfected
in the larger Horse Model tiller, gives a superb balance combination which allows you to easily chop up,
shred, and bury all sorts of vegetation and organic matter directly into your garden's soil.
This is a rugged, dependable machine that will give you many years of use if properly maintained.
You can ensure long-lasting performance from your tiller by following the operating and maintenance
procedures in this manual and in the other literature sent to you.
Thank you,
afJ UK '/ edJ. , ~
Dean Leith, Jr., Sales Manager

My Engine Make Is: _
oRecoil Start 0Electric Key Start
To help you as quickly as possible when you
write or call for parts or service assistance, we'll
need to know your tiller's serial number. This
number tells us when your tiller was made and
what features it has.
The arrow in the graphic to the right points to
the top of the transmission where the serial num-
ber is located. For your convenience and ready
reference, please enter the serial number below
and check the model you've purchased.
My Tiller Model Is:
oEcono-Horse 0Pony
The Tiller Serial Number Is:
00000000
oJunior
Date of Tiller D
eli ver y:, _ACAUTION
TO AVOID INJURY:
• READ THE OWNER / DPERATOR MANUAL.
• KNOW LOCATION AND FUNCT ION OF ALL
CONTROLS.
• KEEP AL L SAFETY DEVICES ANO SHIELDS
IN PLACE.
• NEVER A LLOW CH ILOREN OR UN IN-
STRUCTED ADULTS TO OPERATE TILLER.
• SHUT OFF ENGINE AND DISCONNECT
SPARK PLUG WIRE BEFORE UNCLOGGING
TINE S OR MAKING REPAIRS.
• KEEP BYSTANDERS AWAY FROM MA·
CHINE .
•
KEEP AWAY FROM ROTATING PART S.
AWARNING TO ALL CALIFORNIA AND OTHER POWER EQUIPMENT OPERATORS
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 covered, 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 orde
r.
The engine on your power equipment, like most outdoor power equipment, is an internal combustion
engine that burns gasoline, a hydrocarbon fuel. Therefore, your power equipment must be equipped
with a spark arrester muffler in continuous effective working order. The spark arrester must be at-
tached to the engine exhaust system in such a manner that flames or heat from the system will not
ignite flammable material. Failure of the owner / operator of the equipment to comply with this regula-
tion is a misdemeanor under California law, and may also be a violation of other state and/or fe
der al
regulations, laws, ordinances, or codes. Contact your local fire marshal or forest service for specific
information about what regulations apply in your area.
2

ENGINE SERVICE
If your tiller engine ever needs service or re-
pair, contact your nearest Briggs &Stratton or
Tecumseh Service Dealer.
To find the nearest Service Dealer, look in the
Yell ow
Page s of your phone book under
"Engines- Gasoline", or "Gasoline Engines."
If you have problems getting engine service or
parts locally, let us know so we can provide you
with the name of the nearest Service Dealer.
QUESTIONS OR PROBLEMS?
1. Check this OwnerlOperator Manual:
The answer to your question or problem may be
in this Manual. Refer to the index at the back of
this Manual to find the listing that concerns your
problem. Turn to that page and read the informa-
tion provided.
2. Call or write to us:
If you can't find the answer to your question or
problem in this Manual, please call us or write to
us. One of our helpful, friendly tiller experts will
gladly help you. Be sure to include your tiller
model name and the serial number of your tiller.
3. If you need a part:
Call or write to our Parts Department (see the
Toll-Free telephone number below). Please have
your tiller model name and serialnumber at
hand. Use the Parts Catalog to find the part
number and quantity of the part you need.
Remember that you can purchase many of the
common hardware items at your local hardware
store as well as ordering them from us.
For Fa
st est Service, Use The Toll-Free Numbers Below
In the U.S.A.:
Technical Service 1-800-833-6990
Parts Orders 1-800-648-6776
Customer Service 1·800-437-8686
In Canada:
Local only (416 Area Code) 624-8423
From Ontario and Quebec 1-800-387-3351
From Western Canada &the Maritimes 1-800-387-3316
Our H
our s are (Eastern Standard Time):
In the U.S.A. In Canada
Mon - Fri.- 8 A.M. to 7 P.M. Mon - Fr
i- 8 A.M. to 5 P.M.
Saturday- 9 A.M. to 4 P.M.
If you w
ould rather writ e to us, our mailing addresses are:
In the U.S.A. In Canada
TROY-BILTMfg. Co. Garden Way Canada, Inc.
102nd S
1. &9th Ave. 1 51 5 Matheson Blvd.• Unit B11
Troy, New York 12180 Mississauga. Ontario L4W 2P5
IMPOR TANT!
IF YOU NOTICE any freight damage or missing parts, either at the time of delivery or later during
assembly, make sure that you put it in writing, within 15 days, and send your letter to the shipper
to confirm that you intend to file a claim.Tell the driver, or inform the truck terminal, that you intend
to file a written claim. They will advise you as to how to proceed. HOWEVER, if you have any
problems with this procedure, please call us so that we can help you get satisfaction.
3

Section 1: Safety Instructions
Your TROY-BILT Model Tiller has been designed w ith many safety features. However, as w ith
a ny other piece of powered equipment, the operator must fo llow safe operating practices at all
times. Failure to do so could resu lt in pe
rso nal injury or damage to the equipment or property.
Before assembling,operating or
servicing the tiller or its engine, care fully read and fo llow all
of
the safety instructions found in this Owner /Operator Manual, in the separate Engine
O
wner's Manual, and in any ot her literature you may receive. If you ever have any questions,
please call us'at one of the numbers listed on page 3 of this manual.
If you ever lend yo
ur tiller to someone, make sure that he or she reads, understands, and tol -
lows the Safety Instructions. Always use
your tiller carefully and keep safety in mind.
ASAFETY ALERT SYMBOL. This symbol is used to alert you to
.. important safety messages in this Manual and on decals which
are on your tiller regarding potential hazards. When you see this
symbol, carefully read and follow its safety message. Failure to do so can
result in personal injury or property damage.
TRAINING
1. Carefully read this Owner/Operator Manual,
the separate Engine Owner's Manual, and any
other literature you may receive. Be thoroughly
familiar with the controls and the proper use of
the tiller and its engine. Know how to stop the
unit and disengage the controls quickly.
2. Never allow children to operate the tiller. Let
adults operate the tiller only if instructed properly.
3. Keep the area of operation clear of all persons
(particularly children) and pets.
PREPARATION
1. Thoroughly inspect the area where the tiller is
to be used and remove all foreign objects.
2. Be sure all control levers are released and the
ECONO-HORSE or PONY Model Wheel Gear
Lever is in "ENGAGE" before starting the engine.
On the JUNIOR Model, which does not have a
Wheel Gear Lever, be sure the Wheel Drive Pins
engage the wheels.
3. Do not operate the tiller without wearing ade-
quate outer garments. Avoid loose garments or
jewelry that could get caught in moving parts of
the tiller or its engine.
4. Do not operate the tiller when barefoot or wear-
ing sandals, sneakers, or light footwear. Wear
footwearwhich gripswell on slipperysurfaces.
5. Do not till near underground electric cables,
telephone lines, pipesor hoses. If in doubt, contact
yourtelephoneor utility company.
6. Handlefuel with care; it is highly flammable and
its vapors are explosive.
a. Use an approved fuel container.
b. Never add fuel to a running or hot engine.
4
c. Keep matches, cigarettes, cigars, pipes ,
open flames, and sparks away from the fuel
tank and fuel container.
d. Fill fuel tank outdoors with extreme care.
Never fill fuel tank indoors. Use a funnel or
spout to prevent spillage.
e. Replace the fuel tank cap securely and
clean up any fuel before starting engine.
7. Never make adjustments when engine is run-
ning (unless recommended by manufacturer).
OPERATION
1. Do not put hands or feet near rotating parts.
2. Exercise extreme caution when on or crossing
gravel drives, walks, or roads. Stay alert for hid-
den hazards or traffic. Do not carry passengers.
3. After striking a foreign object, stop the engine
(and remove the Ignition Switch Key on electric
start models), disconnect the spark plug wire and
prevent it from touching the spark plug, carefully
inspect the tiller for any damage, and repair the
damage before restarting and operating the tille
r.
4. Exercise caution to avoid slipping or falling.
5. If the machine should start to vibrate abnor-
mally, stop the engine (and remove the Ignition
Switch Key on electric start models). Disconnect
the spark plug wire and prevent it from touching
the spark plug, and check immediately for the
cause.Vibration is generally a warning of trouble.
6. Stop the engi ne (and remove the Ignition
Switch Key on electric start models), disconnect
the spark plug wire and prevent it from touching
the spark plug whenever you leave the operating
position, before unclogging the tines, or when
making any repairs, adjustments or inspections.

7. Before leaving the tiller unattended, stop the
engine. Remove the Ignition Key on electric start
models. Disconnect the spark plug wire and pre-
vent it from touching the spark plug. Move the
Wheel Gear
Lever to "ENGAGE" on Econo-
Horse and Pony models. On Junior models, the
Wheel Drive Pins must engage the wheels.
8. Before cleaning, repairing, or inspecting, stop
the engine, remove the Ignition Switch Key on
electric start models, and make certain all moving
parts have stopped. Disconnect the spark plug
wire and prevent it from touching the spark plug
to prevent accidental starting. On electric start
models, always remove the cable from the nega-
tive side (
-) of the battery.
9. Always keep the flap on the tine hood down
when operating the tiller, except when using the
hiller/furrower attachment.
10.
Nev er operate the till er with out proper
guards, plates, or other protective safety devices
in place.
11. Do not run
the engine indoors; exhaust
fumes are dangerous.
12. Keep children and pets away.
13. Never operate the tiller under engine power if
the Econo-Horse or Pony Wheel Gear Lever is in
"DISENGAGE" (FREEWHEEL), or if the Junior
Wheel Drive Pins do not engage the wheels. In
this position, the wheels will not hold the tiller
back and the revolving tines could propel the
tiller rapidly, possibly causing loss of control.
Always move the Wheel Gear Lever to "EN-
GAGE" (or, on the Junior, ENGAGE the wheels
with the Wheel Drive Pins) before starting the
engine or engaging the tines / wheels with the
Forward Clutch or the Maneuvering Clutch.
14. Be aware that the tiller may unexpectedly
bounce
upward or jump forward if the t ines
should strike extremely hardpacked soil, frozen
g
round , or bur ied obstac les such as large
stones, roots, or stumps. If you are in doubt
about the tilling conditions, always use the fol-
lowing operating precautions to assist you in
maintaining control of the tiller:
a. Walk behind and to one side of the tiller,
using one hand on the handlebars. Relax
your arm, but use a secure hand grip.
b. Use shallower depth regulator settings,
working gradually deeper with each pass.
c. Place the forward drive belt in its LOW
Range position (Econo-Horse only). Use
slower engine speeds.
d. Clear the tilling area of all large stones,
roots and other debris.
e. Avoid using downward pressure on handle-
bars. If need be, use slight upward pressure
to keep the tines from digging too deeply.
f. Before contacting hardpacked soil at the end
of a row, reduce engine speed and lift han-
dlebars to raise tines out of the soil.
g. In
an eme rge ncy , stop the t ines and
wheels by releasing whicheve r Clutch
Lever you have engaged. Do not attempt
to restrain the
tiller .
15. Do not overload the tiller's capacity by at-
tempting to till too deeply at too fast a rate.
16. Never operate the tiller at high transport
speeds on slippery surfaces. Look behind and
use care when backing up.
17. Do not operate the tiller on a slope that is too
steep for safety. When on slopes, slow down and
make sure you have good footing. Never permit
the tiller to freewheel down slopes.
18. Never allow bystanders near the unit.
19. Only use attachments and accessories that
are approved by Troy-Bilt Manufacturing Co.
20. Use tiller attachments and accessories when
recommended.
21. Never operate the tiller without good visibility
or light.
22. Never operatethe tiller if you are tired, or under
the influenceof a
lcohol ,drugsor medication.
23. Do not change the engine governor settings or
overspeed the engine.
24. Do not touch engine parts which may be hot
from operation. Allow parts to cool before inspect-
ing, cleaningor repairing.
25. The battery on electric start model tillers con-
tains sulfuric acid. Avoid contact with skin, eyes, or
clothing. Keepout of the reach of children.
Antidote-External Contact: Flush immediately
with lots ofwater.
Antidote-Internal: Drink large quantitiesof water
or milk. Follow with milk of magnesia, beaten
egg or vegetable oil. CALL A PHYSICIAN IM-
MEDIATELY.
Antidote-Eye Contact: Flush with water for 15
minutes. GET PROMPT MEDICAL ATTEN-
TION.
26. Batteries produce explosive gases. Keep
spar ks, flame, and smoking materials away.
Ventilate when charging batteries or when using a
batteryin an enclosed space.
ALWA YS wearsafety
goggles when working near batte
ries.
27. Please remember: You can always stop the
tines and wheels by releasing the Forward Clutch
Lever or the Maneuvering Clutch Lever (whichever
lever you have e
ngaged ) or by moving the T hrottle
Control Leverto STOP.
28. To load or unload the tiller, see the instructions
in Section4 of this Manual.
5

MAINTENANCE AND STORAGE
1. Keep the tiller, attachments and accessories
in safe working condition.
2. Check all nuts, bolts, and screws at frequent
intervals for proper tightness to be sure the
equipment is in safe working condition.
3. Never store the tiller with fuel in the fuel tank in-
side a building where fumes may reach an open
flame or spark (hot water and space heaters, fur-
naces, clothes dryers, stoves, electric motors, etc.).
4. Allow the engine to cool before storing it.
5. To reduce the chances of a fire hazard, keep the
engine free of grass, leaves, or excessive grease.
6. Store gasoline in a cool, well-ventilated area,
safely away from any spark or flame-producing
equipment. Store gasoline in an approved con-
tainer, safely away from the reach of children.
7. Refer to the Tiller and Engine Maintenance
section of this Manual for instructions if the tiller is
to be stored for an extended period.
8. Never perform maintenance while the engine
is running or the spark plug wire is connected, ex-
cept when specifically instructed to do so.
DECALS
If any of the decals below become illegible, damaged, or missing, contact us immediately for a re-
placement. Use the appropriate part number noted below for your particular model tiller.
6
Control Panel
(located on
upper handlebars)
#1900357Econo-Horse & Pony Models
#1900356 Junior Model
Warning-Ignition Keyswitch
(on Electric Start Keysw
itch -
not shown)
#97127 ..... Econo-H or se &
Pony Models
Starting Stabilizat
ion
(on top 01 engine or on air cleaner)
#97125 Econo-Horse & Jun ior Models
#97126 Pony Model
,j
Warning - Hot Surfaces &
Belts (on belt cover)
#20818 . .. . .AII Models
Warning - Belt Positions
(on belt cover)
#2730 . . . . .Eco no- Horse
Model Only
Operat
ing Instructions
(located on the
hood)
#2718 Econo-Horse Model
#20925 Pony Model
#50277 Junio r Model
1-1: ECONO-HORSE MODEL SHOWN

Section 2: Ea sy Assembly
Please follow the steps in this Section to assemble your ECONO·HORSE" , PONY" or JUNIOR®
Model tiller and prepare it for use. Due to assembly similarities, we show one model in the as-
sembly photos to represent the three tiller models. Steps unique to any single model(s) are
noted. These steps will
not take long and will assure correct assembly of your new tiller.
We recommend you read this Section all the way through
firs t. Then begin the assembly steps.
STEP 1: UNPACKING AND LOOSE PARTS
Your tiller was shipped fully assembled except for the parts shown in Photos 2-1 and 2-2. The small
hardware items are inside a plastic bag within the literature package.
If you ordered an electric start ECONO-HORSE'" or PONY®Model Tiller, you also get a second plas-
tic bag with electric start parts and hardware- it is near the battery. The battery will be in place on its
stand or in its own carton. These parts are called out later in this section.
ENGINE
THROTTLE
CABLE
(Econo-Horse Model Shown)
FORWARD
CLUTCH ROD
HANDLEBARS
MANEUVERING
CLUTCH \
LEVER I
WHEEL
GEAR CABLE
(Except Junior)
-,
Photo 2-2 :Contents of Hardware Package.
Photo 2-1: Contents of the shipping carton.
The items in the following list are found in your
hardware bag. They are keyed to Photo 2-2.
1. One Handlebar Height Adjustment Handle.
2. One keyed washer.
3. Four plastic tie straps (Junior requires two).
4. Three hairpin cotters.
5. Two 3/8" - 16 x 1" hex head bolts.
6. Two 3/8" flat washers.
7. Two 3/8" - 16 nylon insert lock nuts.
8. One Engine Throttle Lever Knob.
9. Four #10 - 32 x 1/2" slotted head screws
(Junior requires two).
10. Four
#1 0 lockwashers (Junior requires two).
11.
Four#10 - 32 nuts (Junior requires two).
12. One Wheel Gear Lever knob (Econo-Horsa
and Pony).
2
I
•
-0 - 4
'\-a
• -a
"- ° 0'"
/ fI'"" ~ , 7 8 9 10 11
5 "'6
1' t .
....
- 0"
"" 0 •
(See detailed hardware list)
11 10 9
• • I
b 0-
.. .- 12
t
•
7

the control levers.
7. Automotive-type tire pressure gauge.
8. Ruler.
9. Sturdy wood box or block 2-1/2"
-3 -1/2" high
(Junior Model only).
• You may subs t itu te adj ustab le wrenche s.
Compare the parts that you received to Photos 2-1 and 2-2. If you are missing any items, please call
us at one of the telephone numbers listed on page 3 of this Manual.
If you notice any freight damage, either at the time of delivery or later during assembly, contact the
freight terminal and tell them you will be filing a written claim (do so within 15 days). The terminal will
advise you as to how to proceed.However, if you meet any problems with this procedure, please call
us so we can provide assistance.
Before you attempt to move the tiller off the shipping carton, please install the handlebars (Step 2).
With the handlebars installed, you'll have better leverage and be more easily able to move the tiller to a
level area so you can continue the assembly.
You'll need the following tools to assemble your tiller:
1. Two 9/16" wrenches. *
2. One medium-size flat blade screwdriver.
3. One open end 3/8" wrench.*
4. Scissors (to trim the plastic ties).
5. One 7/16" wrench (electric models only).*
6. A piece of wood to tap the knobs securely on
NOTE
Before moving the tiller off its shipping plat-
form, you must move the Wheel Gear Lever (on
Econo-Horse and Pony models) to the "DISEN-
G
AGE " position . For shipping purposes, the
Wheel Gear Cable is wrapped around the trans-
mission tube, between the engine and the tine
hood. Unwrap the Wheel Gear cable and move
the Wheel Gear Lever to its "DISENGAGE" posi-
tion as shown in Photo 2-3. On the Junior Model,
aWheel Drive Pin must be removed from the
hub of each wheel, the wheels moved inward as
far as possible, and the Wheel Pins replaced
through the wheel shaft holes and secured with
their cotter pins. Each wheel is then free to turn
on the wheel shaft. See Inset Photo at right. Photo 2-3: Move the Wheel
Gear Lever back to
"Disengage" posit ion on Econo-Horse and Pony
models. Inset Photo shows Wheel Pins that need to
be moved on the Junior Model.
STEP 2: ATTACHING THE HANDLEBARS
1. On electric start models only, remove one of
the bolts and lockwashers that secures the lower
end of the curved height adjustment bracket to
the back of the transmission. Loosen the second
bolt so you can swing the curved height adjust-
ment bracket out of the way. See Photo 2-4.
~
Photo 2-4: SWing the Height Ad justm ent Bracket
down to one side (Electric start models only).
8
2. Remove the Maneuvering Clutch Lever from
the handlebars. See Photo 2-5.
Photo 2-5: Removing the Maneuvering Clutch Lever
from the handlebars.

3. Place the lower end of the handlebars on the
outside of the two mounting tabs on the top of
the transmission. Make sure that the handlebar
crossbrace (on the lower end of the handlebars)
goes underneath the curved height adjustment
bracket.
4. Secure the lower ends of the handlebar to the
two mounting tabs with a 3/8"-16 x 1" bolt, a 3/8"
flat washer, and a 3/8"-16 nylon insert lock nut.
Use 9/16" wrenches. The bolt head should be to
the inner side of the mounting tab.
The flat
washer and lock nut must face out.
5. On electric start models, move the curved
heig ht adjustment brac ket back in place.
Reinstall the bolt and lockwasher you previously
removed. Tighten both bolts very securely.
Photo 2-6: Attaching the handlebars.
6. Note the four handlebar height settings (the
four slots) in the curved height ad justment
bracket. Align the hole in the handlebar cross
brace with one of these slots. Place the keyed
washer on the Height Adjustment Handle. Screw
the handle into the hole in the handlebar cross
brace. Make sure that both raised keys on the
bottom of the keyed washer fit into one of the
four slots on the bracket. Tighten the Handlebar
Height Adjustment Handle.
Phot o 2-7 :Insta ll ing the Ha ndleba r Height
Adjustment Handle.
7. With the handlebars installed, you can now
easily move the tiller off its shipping platform.
STEP 3: ATTACHING THE
MANEUVERING CLUTCH LEVER
1. Slide the Maneuvering Clutch Lever down
through the hole in the left-hand side of the han-
dlebar control panel . Make sure that the
Maneuvering Clutch Lever passes above the
cross brace on the lower end of the handlebar.
2. Turn the Maneuvering Clutch Lever so the
small bend on the lower side points inward.
3. I
nsert the lower end of the Maneuvering
Clutch Lever into the hole in the pivot as shown
in Photo 2-8. Secure the Maneuvering Clutch
Lever in place by inserting a hairpin cotter down
through the hole in the end of the Maneuvering
Clutch Lever.
Photo 2-8: Installing Maneuvering Clutch Lever.
STEP 4: INSTALLING THE
FORWARD CLUTCH ROD
1. Turn the Forward Clutch Rod so the small
bend at the lower end points inward.
2. Insert a hairpin cotter down into the inner hole
in the small bend of the Forward Clutch Rod.
Photo 2-9: Installing the Forward Clutch Rod.
9

3. Note the four holes in the swivel plate on the
shifting mechanism. The hole that you'd insert
the lower end of the Forward Clutch Rod into de-
pends upon which handlebar height setting (on
the curved handlebar height adjustment bracket)
you have the handlebars set at. Refer to Photo
2-10 to determine which hole in the swivel plate
to use. For example: if you set the handlebar in
slot number 1, then the Forward Clutch Rod
must be installed in hole number 1 of the swivel
plate.
Photo 2-10: Handlebar Height setting and Forward
Clutch Rod positioning.
4. Insert the lower end of the Forward Clutch
Rod into the proper hole in the swivel plate.
Secure it to the swivel plate by inserting a hairpin
cotter through the outer hole in the small bend of
the Forward Clutch Rod.
IMPORTANT
Whenever the handlebar height is changed,
the position of the Forward Clutch Rod must
be changed accordingly. Changing the han-
dlebar height changes the tension on the
Forward Clutch Rod. This tension must be
adjusted by relocating the rod in the appro-
priate hole in the clutch swivel plate.
5. To make sure the tension on the Forward
Clutch Rod is correct:
a. Stand on the right-hand side of the tiller
and pull the Forward Clutch Lever up and
hold it in place. See Photo 2
-11.
b. Check the gap between the "E-ring" and
the lower end of the bracket at the upper
end of the Forward Clutch Rod. The gap
should be 3/16"-to-5/16". If you do not
have a ruler handy, the thickness of five
pennies is approximately 5/16" thick. Refer
to Photo 2-11.
10
c. If the gap is incorrect, check to make sure
that you have the Forward Clutch Rod lo-
cated in the correct hole in the swivel
plate. If it isn't, move the lower end of the
Forward Clutch Rod into the correct hole
and check the measurement again.
d. If the Forward Clutch Rod is in the correct
hole in
the swivel plate (and the gap
remains incorrect) you must make a sim-
ple adjustment to the Forward Clutch Rod.
Please refer to handlebar height adjust-
ment in Chapter 3 for fine tuning this im-
portant adjustment.
3/16" -10-5/16"
GAP REQUIRED
Photo 2-11: Carefully measure the gap between the
Forward Clutch Bracket and the "E-Ring."
STEP 5: CHECKING THE
TRANSMISSION GEAR OIL LEVEL
Once the handlebars are securely installed on
the tiller, move the tiller to a level area.
We have installed gear oil in the tiller trans-
mission here at the
Factory . Howev er , yo u
shou ld make t his very important che ck to be
sure that the oil level is still correct.
1. Make sure that your tiller is on a level area.
2. Lower the depth regulator to the second notch
to make sure that the transmission is as level as
possible. (See Photo 2-12.)
NOTE
For shipping purposes only,the depth regulator
lever may be secured with a plastic tie. If so,
before moving the depth reguiator lever, liftthe
hoodflapattherearofthetillerandcutthetie.

Photo 2-12: Move Depth Regulator Lever to second
notch.
3. Use a 3/8" open end wrench to remove the
transmission oil level check plug (on the left-
hand side of the transmission). Due to dried
paint on the plug threads, it may require some
force to remove the plug the first time. If the
transmission oil level is correct, oil should start to
flow out of the hole. If oil flows from the hole,
your check is finished; reinstall the plug and
tighten it securely with a 3/8" open end wrench.
Photo 2- 13: Removing the transmission Oil Level
Check Plug. When the level is correct, gear oil will
flow from this check hole.
4. If no oil flowed from the transmission oil level
check hole, add SAE 140 or 90 we
igh tgear oil
(never use multi-v
iscosity oil) to bring the gear
oil up to the correct level. Use this procedure:
a. Unscrew filler plug from top left-hand side
of transmission. Clean around plug first.
b. Insert a clean funnel into the oil fill hole
and slowly add 140 weight gear oil until it
flows from the transmission oil check hole.
Photo 2-14: Add ing gearoil to transmission.
c. Reinstall the transmission oil check plug.
Tighten securely with the 3/8" wrench.
d. Reinstall the transmission oil fill plug .
Tighten it securely by hand.
STEP 6: CHECKING THE
ENGINE OIL LEVEL
Your till er' s engine was filled with a quality
SAE 30 weight classified engine oil here at the
factory.However, check the engine oil level
again to be certain it is correct.
Tocheck the engine oil level:
1. Make sure that the tiller is on level ground.
Lower the depth regulator lever to the second
notch (placing the tiller in a level position).
2. Wipe the area around the dipstick or oil fill
tube clean so no debris will fall into the engine.
3. On the Econo-Horse's 6HP Tecumseh engine,
unscrew the engine oil dipstick from the fill hole.
II is at the top left rear of the engine. See Photo
2-15A. Wipe it clean, screw it back in, take it out
and check the level. Add oil to "Full" mark.
11

4. On the Pony's 5HP Briggs engine and the
Junior's 4HP Tecumseh engine, remove the filler
cap from the oil fill tube at the side of the engine.
See Photo 2-15B. Add oil unti l overflowing.
Replace the filler cap securely.
Photo 2-15A: On 6HP Tecumseh engine, check oil
level with the dipstick. Photo 2-15B: On 5HP Briggs
and 4HP Tecumseh engines, oil must overflow from
the oil fill tube to be correct.
5. If oil needs to be added, use quality SAE 30
weight oil with an API rating of
SF. Add a little oil
at a time, and check the oil level. Keep adding oil
until the oil level is correct. Be careful not to
overfill the engine as this can cause engine dam-
age-drain out any excess oil.
STEP 7: ATTACHING THE
ENGINE THRO
TT LE LEVER
TO THE CONTROL PANEL
The engine throttle cable (with lever) is
wrapped around the engine for shipping pur-
poses. Unwrap it from the engine and install it as
follows:
1.
Locate two #10-32 x 1 /2" slotted head
screws, two #10-32 nuts, and two #10 lock-
washers in your hardware bag. Keep this hard-
ware at hand so you can attach the Engine
Throttle Lever to the control panel.
2. Run the engine throttle cable alongside the
right-hand handlebar.
3. Position the Engine Throttle Lever beneath
the control panel. Insert the lever up through the
slot in the control panel that is marked "ENGINE
THROTTLE."
4. Insert each of the screws through a "+" mark
on the control panel decal. Align the holes in the
Engine Throttle Lever base with the screws and
be sure the screws go through the base.
12
5. Snug the base of the throttle lever up against
the bottom of the control panel. Install a lock-
washer and a nut on each of the threaded ends
of the screws. Use a 3/8" wrench and a flat tip
screwdriver to tighten both screws.
Photo 2-16: Installing Engine Throttle Lever.
6. Place the "T-shaped" Engine Throttle Lever
knob on the end of the Engine Throttle Lever.
Use the piece of wood to tap the knob until it
seats firmly on the Engine Throttle Lever.
Photo 2 -17 :Installing the Engine Throttle Lever
Knob.
7. Move the Engine Throttle Lever forward and
backward to check its movement. It should move
smoothly through the full range of its travel.
P
lease note there is a detent (a catch) at
"SLOW." This prevents you from unintentionally
shutting off the engine when you are just trying
to slow the engine down. If it is difficult to move
the Engine Throttle Lever away from "STOP",
loosen both screws and move the lever assem-
bly slightly to the left. Tighten both screws and
re-check the Engine Throttle Lever's movement.
Spend a couple of minutes adjusting this assem-
bly until the lever moves smoothly.

8. Take two of the red plastic ties from the hard-
ware bag. Locate them as shown in Photo 2-18.
Space them about two feet apart.
The serrated side of each plastic tie should be
on the inside of the loop when you wrap the tie
around the handlebar and Engine Throttle Lever
cable. Tighten each tie by pulling on the free
end. Snip off any excess with a scissor.
Ph ot o 2- 18: Se cure Engine Throttle Cable to
Handlebars with two plastic ties.
STEP 8: ATTACHING THE
WHEELGEAR LE V ER TO T HE
CONTROL PANEL (Econo-Horse
and Pony Models only)
The Wheel Gear cabie is wrapped around the
transmission for shipping purposes. Unwrap the
cable and install it as follows:
1. Locate the last two #10-32 x1/2" slotted head
screws, #10
-32 nuts, and #10 lockwashers.
2. Position the Wheel Gear cable along the side
and up the left handlebar.
3. Position the Wheei Gear Lever beneath the
control panel. Insert the lever up through the slot
in the panel marked "WHEEL GEAR."
4. Insert both of the screws through a "+" mark
on the control panel decal. Align the holes in the
Wheel Gear Lever base with the screws and
place the base over the screws.
5. Double check to make sure that the screws go
through the holes in the lever's base. Install a
lockwasher and nut on each of the screws. Use
a3/8" wrench and a flat tip screwdriver.
Photo 2-19:Installing the Wheel Gear Lever. (Econo-
Horse and Pony Models
only)
6. Place the Wheel Gear Lever knob on the end
of the Wheel Gear Lever. Use the piece of wood
to tap the knob until it seats on the lever.
Photo 2 -20: Installing Wheel Gear Lever Knob .
(Econo-Horse and Pony Models only.)
7. Use the two remaining plastic ties in the hard-
ware bag to secure the Wheel Gear cable to the
left-hand handlebar. Position the ties as shown
in Photo 2-21. Remember that the serrated side
of the tie should be on the inside when you loop
the tie around the handlebar and Wheel Gear
cable. After you've tightened the ties by pulling
on the loose ends, snip off any excess.
Photo 2-21: Secure Wheel Gear Cable to Handlebar.
IEcono-Horse
and Pony Models.)
STEP 9: ADJUSTING THE AIR
PRESSURE IN THE TIRES
To be sure of a good seal between the tires
and wheels, we've inflated you r till er's tires
above the recommended operating pressure.
Before using your tiller, be sure to evenly de-
flate both tires until their pressure is 15 to 20 psi
(pounds per square inch). You can check the air
pressure with an automotive-type tire pressure
gauge.
Be sure that both tires have the same air pres-
sure or the tiller wilt pull to one side when you
are using it.
13

If you have a standard start ECONO-HORSE'", PONY'"
or JUNIOR"'Tiller, it is now completely assembled and
ready to be used.
Please read the rest of this Owner/Operator Manual
before you begin to operate your tiller.
You should become very familiar with, and follow all
the safety rules, the tiller operating instructions, and
the engine operating instructions at all times.
If yo u have an E
lectr ic Start ECON O-HORSE'" or
PONY
'" Tiller, you will have to perform the following
steps to assemble the electric starting system on your
tiller.
ASSEMBLINGTHE ECONO-HORSE
OR PONY ELECTRIC START SYSTEM
Compare the parts in your tiller's electric start
hardware package with the parts shown in Photo
2-22. The parts listed below are keyed to the
hardware items in the photo.
1. Battery (for shipping purposes, it is either se-
cured to the battery support bracket or
in a pro-
tective carton).
2. Vent tube.
3. Screws and nuts (used to attach battery ca-
bles to battery).
STEP 10: BATTERY ACTIVATION
AND CHARGING
NOTE
Your battery was shipped to you DRY. You must
have battery electrolyte solution (battery grade
sulfuric acid) added to the battery.
You then must
have the battery fully charged before using it on
your tiller. A
DANGER
• Electrolyte is a sulfuric acid solution.
2
t3
n•
• Avoid spillage and contact with skin, eyes,
and clothing.
• To prevent accidents, wear protective cloth-
ing, rubber gloves, and shield eyes with
safety goggles when working near battery.
• Neutralize acid spills with baking soda and
water solution. Neutralize empty container
with baking soda and rinse with water.
Photo 2-22: The Electric Start parts.
14
ANTIDOTE: External contact: Flush with water.
Eye
s- Flush with water for 15 minutes and get
prompt medical attention.
ANTIDOTE: Internal: Drink large quantities of
wate r or milk.Follow with milk of magnesia,
beaten eggs, or vegetable oil. Call physician im-
mediately.

A DANGER
BATTERIES PRODUCE
EXPLOSIVE
GAS ES!
• Keep sparks, flame, and cigarettes away.
• Ventilate area when charging or using bat-
tery in an enclosed space.
• Make sure venting path of battery is al-
ways open once battery is filled with acid.
Adding electrolyte to the battery and charging
the battery can be dangerous. The sulfuric acid
in the electrolyte can severely burn you or blind
you. Also, a battery that is charging gives off
gases that could explode if a spark or flame
should contact the gases.
We strongly recommend that you take your
battery to a TROY-BILT tiller dealer, a reliable
service station, battery store, or farm equipment
store where atrained battery technician can
complete the job safely.
PL EASE DO N OT ATT E MPT TO ACTI -
VATE THE BATTERY U
NLESS YOU ARE
FULLY EXPERIENCED IN BATTERY S ET -
UP
AND CHARGING PROCEDURES.
To ensure proper activation of your battery, we
suggest you review the following activating and
charging instructions with your battery technician
and make sure that he follows the instructions.
To Activate the Battery:
1. Placethe battery on a level area away from any
spark- or flame-producing sources such as a gas
stove, heater, electrical switch, pilot light, (etc.).
2. Remove and discard the short sealing tube (if
installed) on the battery side vent.
3. Remove the six filler caps that are on top of
the battery. Leave the caps off while activating
and charging the battery.
4. Carefully fill each of the six cells in the battery
with electrolyte (battery grade sulfuric acid that
has a specific gravity of 1.265) until the level
reaches the "UPPER LEVEL" line on the battery.
NOTE
• The battery and electrolyte should be between
600and 800F for best results.
• Do not add water or any other liquid to activate
the battery.
5. Allow the battery to stand for thirty minutes.
Then check the electrolyte level in each cell. If
needed, add more electrolyte to bring the elec-
trolyte level up to the "UPPER LEVEL" line on
the battery. Do not overfill the battery as this
could lead to flooding from the cells when the
battery is being charged.
6. Charge the battery by following the next set of
instructions.
To Charge the Battery
To obtain maximum battery life, charge the
battery by the following method until all cells are
gassing freely. A battery is gassing freely when
the surface of the electrolyte is covered with tiny
bubbles. A
DANGER
When checking the battery for gassing, AL-
WAYSwear safety goggles and use a flash-
light to look down into the cells.
Failure to do so could result in serious per-
sonalinjury.
Be sure to follow all instructions given by the
manufacturer of the battery charging equipment
that is being used to charge the battery.
1. Hook up the battery charger and charge the
battery approximately three to five hours at one
to two amperes. Turn the battery charger
OFF.
2. Ifthe electrolyte level has fallen after charging,
refill the battery with distilled water until the elec-
trolyte level reaches the "UPPER LEVEL" line on
the battery.
3. After charging, reinstall the six filler caps on
the battery.
4. Unplug the battery charger from the electrical
outlet (or turn the battery charger OFF). Then
disconnect the cables from the battery posts.
5. Wash any acid spillage off the battery with
water. Then dry the battery.
15

STEP 12: INSTALLING
THE BATTERY CABLES
1. The Positive battery cable is already con-
nected at one end to the so
leno id which is
mounted a few inches below the battery on a
post. You are to connect the loose end of the
positive cable to the positive (+) post on the bat-
tery. Use a bolt and nut from the hardware bag.
Use a screwdriver and a 3/8" wrench to tighten
the bolt. See Photo 2-25.
Photo 2-25: Attach Positive Cable to Battery.
3. Use the two 1/4" -20 x 1 1/4" carriage bolts,
1/4" lockwashers, and 1/4"-20 nuts to secure the
hold-down bracket to the b
attery mo unt ing
bracket. Insert the bolts from beneath the battery
mounting bracket, up through the battery hold-
down bracket, and secure them with the lock-
washers and nuts. Use a 7/16-inch wrench to
evenly tighten both nuts. Do not tighten the nuts
so that the tabs on the battery hold-down bracket
become bent.
Photo 2-26: Attach the Negative
Battery Cable to
the battery.
2. Slide the black rubber boot up the positive
cable and slip it over the positive battery post.
3. The Negative cable is already connected at
one end to one of the mounting bolts securing
the solenoid to the post. This is the grounding
point for the negative
cable-connect the loose
end of the nega-
tive (-) cable to
the negative bat-
tery
pos t. Use
the last nut and
last bolt to se-
curely attach the
negative battery
cable to the neg-
ative (-) battery
post.
STEP 11 : INSTALLING THE
BATTERY ON THE TILLER
• Be sure that the battery is positioned on
the tiller as explained in Step 1. Hooking the
battery cables to the wrong posts could re-
sult in damage to the battery and other
electrical parts.
AWARNING
• Do not touch the positive (+) battery post
and any surrounding metal with tools, jew-
elry, or other metal objects. Doing so could
cause a short circuit that could result in
electrical burns or an explosion of battery
gases.
Photo 2- 23 :Installing the Battery.
1. Use both hands to carefully place the battery
on the battery mounting bracket. The battery
posts should face to the rear of the tiller. The
positive (+) post should be on the left-hand side
of the tiller and the negative (-) post should be
on the right-hand side of the tiller.
2. Place the battery hold-down bracket over the
battery. Center the bolt holes in the lower part of
the hold-down bracket with the bolt holes in the
battery mounting bracket. Make sure that the
Engine Ignition Switch is on the forward side of
the battery.
Photo 2-24: Securing the Battery in Place.
16

4. Use a 3/8" wrench to check the tightness of
the upper mounting bolt on the starter solenoid.
This bolt
secures the Negative Cable to its
ground location. Scrape away any paint between
the cable and the bolt as this would prevent a
proper electrical ground.See Photo 2-27.
-1
Photo 2-27 :The Negative Battery Cable must be se-
curely grounded to the Upper Mounting Bolt on the
Solenoid.
STEP 13: INSTALLING THE
BATTERY VENT TUBE
1. Push the battery vent tube down into the vent
tube sheath. Attach the upper end of the vent
tube to the side vent on right side of battery.
AWARNING
Be sure that the vent tube does not become
kinked, folded, or pinchedwhen you install it.
Improper venting could cause the battery to
explode, resulting in personal injury or prop-
erty damage.
l!o...
Photo 2-28:Installing the Battery Vent Tube.
STEP 14: CONNECT WIRING HAR-
NESS TO IGNITION KEYSWITCH
Slide the wiring harness connector over the
prongs on the back of the Ignition Keyswitch .
You r keyswitch has either a 3-prong or 5-prong
design. See Sketch 2-29 or 2-29A.
•
Sketch 2-29: Connect the Wiring Harness to the
Ignition Keyswitch. The 5-prong design is shown.
Inset Sketch 2-29A -sh ows the 3-prong type which
you may have instead 01the 5-prong type.
You 're now finished assembling your ECONO-
HORSE'" or PONY
®Til ler.
Before you add gasoline to the gas tank and
begin to operate the tiller, please read the rest of
this Owner/Operator Manual so that you become
familiar with the location of, and the operation of,
the various tiller and engine controls.
Without starting your tiller's engine, operate
the tiller controls so that you understand what
each one does. After you've done this, move the
tiller to a safe, level area to practice starting the
engine and maneuvering the tiller without actu-
ally tilling. Make sure that the depth regulator
lever is in the "travel" position (one of the higher
notches) while you're becoming familiar with
your new tiller.
Take this Manual along for ready reference
while you're practicing in case you have any
questions about operating your tiller.
AWARNING
To avoid serious personal injury or damage
to equipment, do not attempt to operate the
tiller or its engine until after you've read and
understood all of the Safety, Controls, and
Operating Instructions in this Manual, in the
Engine Owner's Manual, and in other litera-
ture you may receive.
17

Section 3:
T ill er And Eng ... in ... e ...... C .... o .... n....,t_r ... o....,ls ...... _
Before attempting to operate you r new tiller, become thoroug hly familiar with the location of
and
function of all the operational c ontr ols.
Practice
using the se contr ol s-with the engine shut off-until you unders tand the operation
of the controls and feel conf ident with each one of them.
TILLER CONTROLS
There are four tiller controls you will be using when you operate your tiller. These controls are: the
Wheel Gear Lever (ECONO-HORSE and PONY Models only). the Forward Clutch, the Maneuvering
Clutch, and Depth Regulator Lever. Refer to Photos below for the location of these controls.
ECON O -HOR SE and PONY M ODEL COf'l \lol s
MANEUVERING WHEELGEAR
CLUTCH , / LE VER
.~ ,!: ~~~ ENGINETHROn l E
- ~ LEVER
H AN DLEBAR
HEIGHT
ADJU STMENT
/
DEPTH
RE GULATOR
LEVER
RECOIL
STARTER
DEPTH
REGULATOR
LEVER-
HANDLEBAR
HEIGHT
"D i TMENT
Photo 3-t : Location of controls on ECONO-HORSE
and PONYModels.
Wh eel Gear L ev er
(Ec ono -H or se and P ony Models only)
This lever is located on the left-hand side of
the handlebar control panel. It has two positions:
ENGAGE and DISENGAGE (FREE WHEEL).
The ENGAGE position allows power from the
engine to turn the wheels and tines whenever:
a. The Forward Clutch is engaged. OR
b. The Maneuvering Clutch is engaged in either
forward or reverse.
The DISENGAGE (FREE WHEEL) position
should only be used when the engine is not run-
ning. Use the DISENGAGE (FREE WHEEL) po-
sition ONLY when you are rolling the tiller to an-
other location.
18
AIR ClEANER
Photo 3-t A: Location of controls on the JUN IOR
Model tiller.
.A DANGER
NEVER place the Wheel Gear Lever in DIS-
ENGAGE (FREE WHEEL) when the engine
is running.
Having the Wheel Gear Lever in DISEN-
GAGE (FREE WHEEL) and then engaging
the tines/wheels with either the Forward
Clutch or the Maneuvering Clutch could
allow the tines to propel the tiller rapidly for-
ward or backward.
Failure to follow this instruction could result
in personal injury or property damage.