Troy-Bilt PONY 664D User manual

0TROY RILTr"
Operator's Manual
Rear-tine Tiller Model
664D--Pony _
E666M--Pony _
IMPORTANT:READ SAFETY RULES AND INSTRUCTIONS CAREFULLY
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 attester
for the muffler is available by contacting the service department at Troy-Bilt LLC, P.O. Box 361131 Cleveland, Ohio 44136-0019.
TROY-BILT LLC, P.O. BOX 361131, CLEVELAND, OH 44136-0019
PRINTED IN USA FROM NO. 770-10597B
(9/2003)

TABLEOF CONTENTS
Content Page Content Page
Customer Support 2 Maintenance 20
Safety 3 Tiller Attachments 28
Assembly 6 Troubleshooting 29
Features and Controls 11 Parts List 30
Operation 14 Warranty Information Back Cover
FINDINGMODELNUMBER
This Operator's Manual is an important part of your new rear-tine tiller. It will help you assemble, prepare and maintain
the unit for best performance. Please read and understand what it says.
Oefore you start assembling your new equipment, please locate the model plate on the equipment and
copy the informationfrom itin the space provided below. A sample model plate is also given below. You can
locate the model plate by standing behind the unit and looking down at rear surface of the tine shield. This
information will be necessary to use the manufacturer's web site and/or help from the Customer Support
Department or an authorized service dealer.
copythemode,numberhere:
Copy the serial number here:
O_P_J_BX_..T" TROY-BILT LLC
..... P.O. BOX 361131
www.troybilt.com CLEVELAHD,OH44136
330-558-7220
,1-800-520-5520)
CUSTOMERSUPPORT
PleasedoNOTreturntheunittotheretailer from whereit waspurchased,withoutfirstcontactingCustomerSupport.
If you have difficulty assembling this product or have any questions regarding the controls, operation or maintenance of
this unit, you can seek help from the experts. Choose from the options below:
Visit troy-bilt.com for many useful suggestions. Click on Customer Support button and you
will get the four options reproduced here. Click on the appropriate button and help is
immediately available.
............. _e a_swer you are
_oo_ g'-"n for could oej s_"u- _"'" " _"°'_"..........'_'""'""'+"...... looking for could u_j _":u"_"
p_ofil÷.
a mouse crick away! a mouse crick away!
: _ Manuml_ On_ine
_ If you prefer to reach a Customer Support Representative, please call 1(800) 520-5520.
The engine manufacturer is responsible for all engine-related issues with regards to
:_erformance, power-rating, specifications, warranty and service. Please refer to the engine
manufacturer's Owner's/Operator's Manual, packed separately with your unit, for more
information.

Safety
This machine meets voluntary safety standard B71.8
- 1996, which is sponsored by the Outdoor Power
Equipment Institute, Inc., and is published by the
American National Standards Institute.
Safety AlertSymbol
This isa safety alert symbol. It is usedin this
manualandon the unitto alertyou to potential
hazards. When you seethis symbol, readand
obeythe messagethat follows it. Failureto
obeysafety messagescould result in personal
injuryor property damage.
WARNING
The engine exhaust from this product contains
chemicalsknowntothe Stateof Californiato cause
cancer,birthdefectsorotherreproductiveharm.
TRAINING
1. Carefullyread this
Owner's Manual, the sepa-
rateEngineOwner's
Manual,andany other literature you may
receive.Bethoroughly familiar with the
controls and the proper useof thetiller
and itsengine.Know how to stop the unit
and disengagethe controls quickly.
2. Neverallow children to operatethe
tiller. Neverallow adults to operatethe
tiller without proper instruction.
3. Keepthe areaof operationclearof all
persons,particularly children and pets.
4. Keepin mind that the operator or user
is responsiblefor accidents or hazards
occurring to other people,their property
and themselves.
PREPARATION
1. Thoroughly inspectthe areawherethe
tiller is to be usedand removeall foreign
objects.
2. Be sureall controls are releasedand
the WheelGearLeveris in ENGAGE
beforestarting the engine.
3. Do not operatethetiller without
wearing adequateouter garments. Avoid
loosegarments or jewelry that could get
caught in moving parts.
4. Donotoperatethetiller whenbarefoot
or wearingsandals,sneakers,or light
footwear.Wearprotectivefootwearthatwill
improvefooting on slipperysurfaces.
5. Donottill nearundergroundelectric
cables,telephonelines,pipesor hoses.If in
doubt, contactyourtelephoneor utility
company.
6. Warning: Handlefuelwith care;it is
highlyflammableand its vaporsareexplo-
sive. Takethefollowing precautions:
a. Storefuel in containersspecifically
designedfor this purpose.
b. Thegas capshall neverbe removed
or fuel addedwhile the engine is
running. Allow the engineto cool
for severalminutes beforeadding
fuel.
c. Keepmatches,cigarettes,cigars,
pipes, openflames, and sparks
awayfrom the fuel tank and fuel
container.
d. Fillfuel tank outdoors with extreme
care. Neverfill fuel tank indoors.
Usea funnel or spout to prevent
spillage.
e. Replaceall fuel tank and container
caps securely.
f. If fuel is spilled, do notattempt to
start the engine, but movethe
machine awayfrom the area of
spillageand avoid creating any
source of ignition until fuel vapors
havedissipated.
7. Never makeadjustmentswhen engine
is running (unless recommendedby
manufacturer).
OPERATION
1. Do not put handsor feet near or under
rotating parts.
2. Exerciseextremecaution when on or
crossing graveldrives, walks, or roads.
Stayalert for hidden hazardsor traffic. Do
not carry passengers.
3. After striking a foreign object, stop the
engine(and removethe ignition key on
electricstart models), disconnect the
spark plug wire and prevent it from
touching the spark plug, carefully inspect
the tiller for anydamage,and repair the
damagebefore restarting and operating
the tiller.
4. Exercisecaution to avoid slipping or
falling.
5. If theunit shouldstartto vibrateabnor-
mally,stop theengine(andremovethe
ignition key onelectricstartmodels).Dis-
connectthespark plugwire andpreventit
from touching thespark plug,and check
immediatelyfor thecause.Vibration is
generallya warning of trouble.
6. Stopthe engine (and remove the igni-
tion keyon electric start models), discon-
nect thespark plug wire and prevent it
from touching the spark plug whenever
you leavethe operating position, before
unclogging thetines, or when makingany
repairs, adjustments or inspections.

7. Takeall possible precautionswhen
leavingthe machine unattended.Stop the
engine. Removeignition key on electric
start models. Disconnectspark plug wire
and move it awayfrom thespark plug.
MoveWheel GearLeverto ENGAGE.
8. Beforecleaning, repairing, or inspect-
ing,stop the engine,remove the ignition
keyon electric start models,and make
certain all moving parts havestopped.
Disconnectthe spark plug wire and
prevent itfrom touching the spark plug to
preventaccidentalstarting. On electric
start models,always removethe cable
from the negativeside (-) ofthe battery.
9. Always keepthe tiller tine hood flap
down, unlessusing the hiller/furrower
attachment.
lB. Never usethe tiller unless proper
guards, plates,or othersafetyprotective
devicesare in place.
11. Do not run engine in an enclosed
area.Engineexhaustcontains carbon
monoxide gas,a deadlypoisonthat is
odorless,colorless, and tasteless.
12. Keepchildren and pets away.
13. Never operatethetiller under
enginepoweriftheWheel GearLever is
in DISENGAGE(FREEWHEEL).In this
position,thewheels will not holdthe
tiller backandthe revolvingtines could
propelthetiger rapidly, possibly
causinglossofcontrol.Always movethe
WheelGearLeverto ENGAGEbefore
starting theengine or engagingthe
tines/wheelswith the ForwardClutch
Control or the ReverseClutchControl.
14. Beawarethatthe tiller may unex-
pectedlybounceupwardor jump
forwardif thetines shouldstrike
extremelyhardpackedsoil, frozen
ground,or buriedobstacleslike large
stones,roots,or stumps.If in doubt
aboutthe tilling conditions,alwaysuse
thefollowingoperatingprecautionsto
assistyou in maintainingcontrolofthe
tiger:
a. Walk behindand toone sideofthe
tiller, usingone handon thehan-
dlebars. Relaxyourarm, butusea
securehandgrip.
b. Useshallowerdepthregulatorset-
tings, workinggraduallydeeper
with eachpass.
c. Useslowerenginespeeds.
d. Clearthetilling area ofall large
stones,rootsandotherdebris.
e. Avoidusingdownwardpressure
on handlebars.If needbe, use
slightupwardpressuretokeepthe
tinesfrom diggingtoodeeply.
f. Beforecontactinghardpackedsoil
at the endofa row, reduceengine
speedand lift handlebarstoraise
tinesout ofthesoil.
g. In an emergency,stoptines and
wheelsbyreleasingwhichever
ClutchLever isengaged.Do not
attemptto restrainthetiller.
15. Do not overloadthetiller's capacity
by attempting to till too deeplyat too fast
a rate.
16. Neveroperatethe tiller at high trans-
port speedson hard or slippery surfaces.
Look behind and usecarewhen backing
up.
17. Do not operatethe tiller on a slope
that istoo steepfor safety.When on
slopes, slow down and makesureyou
havegood footing. Never permit the tiller
to freewheeldown slopes.
18. Neverallow bystanders nearthe unit.
19. Onlyuseattachments and acces-
sories that areapproved bythe tiller
manufacturer.
20. Usetiller attachments and acces-
sories when recommended.
21. Neveroperatethetiller without good
visibility or light.
22. Neveroperatethetiller ifyouaretired,
or underthe influenceof alcohol,drugsor
medication.
23. Operatorsshallnottamperwith the
engine-governorsettingson themachine;
thegovernorcontrolsthe maximumsafe
operatingspeedto protectthe engineand
all movingpartsfrom damagecausedby
overspeed.Authorizedserviceshallbe
soughtif a problemexists.
24. Donottouch enginepartswhich may
be hotfrom operation.Letpartscooldown
sufficiently.
25. Thebatteryon electricstartmodeltillers
containssulfuricacid.Avoidcontactwith
skin,eyes,or clothing.Keepout ofthe
reachofchildren.
Antidote-External Contact:Flushimme-
diatelywith lots of water.
Antidote-Internal: Drinklargequantities
ofwateror milk.Followwith milk of
magnesia,beateneggs or vegetableoil.
Calla doctor immediately.
Antidote-EyeContact:Flushwith water
for 15 minutes.Getpromptmedical
attention.
26. Batteriesproduceexplosivegases.Keep
sparks,flame,andsmoking materialsaway.
Ventilatewhenchargingbatteriesor when
usingabatteryin an enclosedspace.
ALWAYSwearsafetygoggleswhen
working nearbatteries.
27. Pleaseremember:You canalwaysstop
thetinesand wheelsby releasingthe
ForwardClutchControlLeveror the
ReverseClutchControlknob(whichever
controlyou haveengaged),or by moving
theEngineThrottleControlLever(located
onengine)to STOPon recoilstartmodels
or byturningthe ignitionkeyto OFFon
electricstartmodels.
28. Toloador unloadthetiller, seethe
instructionsinSection4 ofthis Manual.
29. Useextremecautionwhen reversingor
pullingthemachinetowardsyou.
30. Starttheenginecarefullyaccordingto
instructionsandwith feetwellawayfrom
thetines.
31. Neverpick up or carrya machinewhile
theengineis running.
MAINTENANCEANDSTORAGE
1. Keepthe tiller, attachments and acces-
sories in safeworking condition.
2. Checkall nuts, bolts, and screws at
frequent intervalsfor proper tightness to
besure the equipment is in safeworking
condition.
3. Neverstorethetillerwith fuel in thefuel
tankinsidea buildingwhereignition
sourcesarepresentsuchashotwaterand
spaceheaters,furnaces,clothesdryers,
stoves,electricmotors,etc. Allowengineto
coolbeforestoring in anyenclosure.

4.Toreducethechancesofafire
hazard,keeptheenginefreeofgrass,
leaves,orexcessivegrease.
5.Storegasolineinacool,well-venti-
latedarea,safelyawayfromanyspark-
orflame-producingequipment.Store
gasolineinanapprovedcontainer,
safelyawayfromthereachofchildren.
6.RefertotheMaintenancesectionof
thisManualandintheseparateEngine
Owner'sManualforinstructionsifthe
tilleristobestoredforanextended
period.
7.Neverperformmaintenancewhile
theengineisrunningorthesparkplug
wireisconnected,exceptwhenspecifi-
callyinstructedtodoso.
8.Ifthefueltankhastobedrained,do
thisoutdoors.
DECALS
Foryour safetyand the safety of others,
various safety messagedecalsare on your
unit (seeFigurebelow). Keepthe decals
cleanand legibleat all times. Contactyour
localservicedealer or the factory for
TineWarning(on right
side ofhoodflap)
StartingStabilization(on
topofengineorfueltank)
replacementsif any decalsare damagedor
missing.
Referto the Parts List pagesfor decal
locationsand part numbers.
instructionsand
WarningMessages
OperatingSymbols
Various symbols (shown here, with
worddescriptions)maybe usedon the
tillerandengine.
FAST SLOW STOP
8 I-'-I
CHOKE
STOP START ON
I÷1 R
REVERSE
CHOKE ROTATING
OFF TINES
<--o-->
LEVERDIRECTION
<--qNE
TILLERDIRECTION
£r
ENGAGED DISENGAGED
hgBelts
(on topof belt cover)
Figure1: LocationofSafetyand OperatingDecals
TOAVOIDSERIOUSINJURY:
• READTHEOWNER'SMANUAL.
•KNOWLOCATIONSANDFUNCTIONSOFALLCONTROLS.
•KEEPALLSAFETYDEVICESANDSHIELDSIN PLACEANDWORKING.
• NEVERALLOWCHILDRENORUNINSTRUCTEDADULTSTOOPERATETILLER.
•SHUTOFFENGINEANDDISCONNECTSPARKPLUGWIREBEFOREMANUALLYUNCLOG-
GINGTINESORMAKINGREPAIRS.
•KEEPBYSTANDERSAWAYFROMMACHINE.
•KEEPAWAYFROMROTATINGPARTS.
•USEEXTREMECAUTIONWHENREVERSINGORPULLINGTHEMACHINETOWARDSYOU.

Assembly
To prevent personal injury or property
damage,do not startthe engineuntil all
assembly steps are complete and you
havereadand understandthesafetyand
operatinginstructionsin this Manual.
INTRODUCTION
Carefullyfollow these assembly stepsto
correctly prepareyour tiller for use. It is
recommendedthat you read this Section
in its entirety before beginning assembly.
INSPECTUNIT
Inspectthe unit and carton for damage
immediately after delivery. Contactthe
carrier (trucking company) if you find or
suspect damage. Inform them of the
damageand request instructions for filing
a claim. To protectyour rights, put your
claim in writing and maila copy to the
carrier within 15 days after the unit has
been delivered.Contact usat the factory if
you needassistance in this matter.
UNPACKINGANDASSEMBLY
INSTRUCTIONS
STEP 1: UNPACKING INSTRUCTIONS
1. Removeanycardboard insertsand
packaging materialfrom the carton.
Removeany staplesfrom the bottom of
the carton and removethe carton.
2. Cutthe large,plastictie strap that
securesthetransmission tube to theship-
ping pallet. Leavethe handlebarson top
of the tiller to avoid damaginganycables.
3. A bag with loose hardwareis inside
the literature envelope. Checkthe con-
tents against thefollowing list and Figure
2-1. Contactyour local dealeror the
factory if any items aremissing or
damaged.
NOTE: Forelectric start units, a second
hardware bag is located nearthe battery.
4. Thetiller is heavy. You should not
attempt to remove it from the shipping
platform until instructed to do so in these
"Assembly" steps.
HARDWARE BAG PARTSLIST
Fig.
Ref. Qty. Description
12 3/8-16 x 1" HexHd. Screw
2 1 KeyedWasher
31 WheelGearLeverKnob
41 Height Adjustment Flange
Screw (SeeFigure2-1A)
5 2 3/8" FlatWasher
6 2 #10 Lockwasher
7 2 3/8"-16 Nylock Lock Nut
8 2 #10-32 x 1/2" RoundHd.
Screw
92 #10-32 Nut
10 1 Cotter Pin (not used)
11 4 PlasticTie Strap (2 not used)
Tools/Materials Needed
for Assembly
(1) 3/8"open-end wrench*
(1) 7/16" open-endwrench* (electric
start unit only)
(2) 9/16" open-endwrench*
(1) 7/8" open-endwrench or 8" long
adjustablewrench
(1) Scissors (to trim plasticties)
(1) Ruler
(1) Small board (to tap plasticknob on
lever)
(1) Tire pressuregauge
(1) Cleanoilfunnel
(1) Clean,high-quality motor oil. Refer
to the separateEngineOwner's
Manualfor motor oil specifications
and quantity required.
* Adjustable wrenches may be used.
IMPORTANT:Motor oil must beadded to
the enginecrankcasebeforethe engine is
started. Follow the instructions in this
"Assembly" Sectionand in the separate
EngineOwner's Manual.
NOTE:LEFTand RIGHTsides of the tiller
areas viewedfrom the operator's posi-
tion behindthe handlebars.
STEP 2: ATTACHHANDLEBARS
1. On electric start units, remove one
screw and Iockwasherfrom the curved
'T 600
7_ 8_' _ _9
10 _.
11
Figure2-1:Loosehardware(shownin
reducedsize).
Figure2.1A Hand/ebarheightadjustment
usestheflangeheadscrew.
Figure2-2: Onelectricstartunits,move
heightadjustmentbracketaside.
heightadjustment bracket (A, Figure2-2),
loosenthe second screw, and swing the
bracketto oneside.
2. Cut the large,plastic cableties that
securethe handlebarendsto the handle-
bar mounting tabs on thetransmission
top cover.
3. Gently lift handlebar(do not over-
stretch attachedcable)and placehandle-
bar cross-brace (B, Figure2-3) in front of
curved height adjustment bracket (C).
Figure2-3: Forwardclutchcontrolcablenot
shownforclarity.

4. Withtheforwardclutchcable (N,
Figure2-4) on the insideofhandlebar,
position the handlebarendson the
outside of the two mounting tabs (M,
Figure2-3) on the transmission top
cover.
NOTE:Thecurved handlebarheight
adjustment bracketappearsasshown in
C,Figure2-3 for non-electric start units.
Forelectric start units, the bracket is loos-
enedand moved to one side.
5. Loosely attachthe handlebarsto the
mounting tabs with two 3/8-16 x 1"
screws (headsof screws go to insideof
tabs), 3/8" flat washersand 3/8"-16 lock
nuts (O,Figure2-4).
Figure24: Attachhandlebars.
6. On electricstart units, reattachthe
heightadjustment bracket (A,Figure2-2).
Tighten both screws securely. Makesure
the handlebarcross-brace (B, Figure2-3)
is under the bracket.
7. Move the handlebarsup or down to
align the threadedhole in the cross-brace
with one of thefour slots in the curved
heightadjustment bracket. Placethe
keyedwasher (E,Figure2-3) on the
flange head heightadjustment screw (F)
with the raisedkeys (edges)of the
washer facing down.
8. Threadthe heightadjustment screw
(F, Figure2-3) into the hole in the handle-
bar cross-brace, making surethat the
raisedkeyson thewasher fit into the slot
on the height adjustment bracket.
Tighten the heightadjustment screw
securely. Next, securelytighten the two
screwsand nuts in the ends ofthe han-
dlebar (M, Figure2-3).
9. To removethe tiller from its shipping
platform, first carefully unwrapthe wheel
gearcable (with attachedlever- see
Figure2-5) from around the chassis.
Move theWheelGear Lever(G) to the
DISENGAGEposition--this allows the
wheels to rotatefreely. Usethe handle-
g
#
Figure25: CarefullyunwrapWheelGear
LeverandmovelevertoDISENGAGE.
barsto roll the tiller off the platform.
NOTE:TheWheelGearLeverwill be
installed later in this procedure.
IMPORTANT: Usethe DISENGAGEposi-
tion only when the engineis not running.
Beforestarting the engine,theWheel Gear
Levermust beplaced in the ENGAGE
position (seeSection 3 for details).
STEP3: ATTACHREVERSE
CLUTCH CONTROL CABLE
1. Carefullyunwrap the reverseclutch
control cable(H, Figure2-6) from its
shipping position and route it up along
the insideedge ofthe left side handlebar.
A knoband large hexnut (I) is installed
on the cable.
LeftSide ReverseClutch
Handlebar ControlKnob
Figure2-6."Attachreverseclutchcontrol
assemblytoslottedholeinhandlebarpanel.
2. Insert the cableinto the slot in the
control paneland fit the threadedassem-
bly into the hole in theslot (seeFigure2-
6). Besurethat the flat sideof the
threaded assemblyis aligned with the flat
side ofthe hole. Slidethe hex nut (I) up
the cableand tighten it securely.
3. Testthe function of the reverseclutch
control cableby pulling the knob out and
releasingit. Theknob should returnto its
neutral position against the tapered
bushing. If it doesn't, contact your local
dealer or thefactory for technical
assistance.
STEP 4: ATTACHFORWARD
CLUTCH CONTROLCABLE
1. Removeanyfasteners (rubber bands,
tape, etc.)that may secure the Forward
Clutch Control levers (J, Figure2-7) to the
handlebar. I
Figure2-7: ForwardClutchControllevers
(J). Forwardclutchcontrollinkage(K).
2. Theforward clutch control cable(with
attachedspring) is hanging loosely near
the right-side wheel. Beingcareful not to
kink or stretch the cable, insert the z-con-
nector (L, Figure2-8 - end of the spring)
into the hole at the end of theforward
clutch control linkage(K, Figure2-7).
Figure2-8
3. Attach thecableadjuster (A, Figure
2-9) to the bracket onthe right-side han-
dlebar. Usetwo 1/2"wrenchesto loosen
thetwo jam nuts (B)just enough to slide
the cableadjuster onto the bracket. Then
hand tighten the jam nuts.
Figure2-9

Incorrect cable adjustment could cause
the wheels and tines to rotate unexpect-
edly. Follow adjustment procedures
carefully. Failure to do so could result
in personalinjuryorpropertydamage.
4. Checkfor correct spring/cable tension
as instructed in Section 5, Checkingand
Adjusting Forward ClutchBelt Tension.
5. Whentension is correct, tighten the
two jam nuts (B) securely.
STEP 5: CHECKTRANSMISSION
GEAROIL LEVEL
Thetransmission was filled with gearoil
at the factory. However,be sure to check
the oil levelat this time to makecertain it
is correct.
IMPORTANT:Do not operatethe tiller if
the gear oil level is low.Doing so will
result in severedamageto thetransmis-
sion components.
1. With thetiller on levelground, pull the
Depth Regulator Lever(R, Figure2-13)
backand then slide it to the second notch
from thetop. NOTE:If the leverdoes not
move, lift thetine hood flap and look for a
plastictie securing the leverin place. Cut
and removethe tie.
2. Removethe oil levelcheck plug (M,
Figure2-10) on the left-side of the trans-
mission. (Dueto dried paint onthe plug
threads, it may require some force to
removethe plug thefirst time.) The gear
oil levelis correct if oil starts to flow out
of the hole asthe plug is removed. If so,
securelyreinstall the plug.
Figure2-1O:Gearoilleve/checkplug.
3. If oil doesnot flow from the check
hole,add oil as follows:
NOTE:Donot useautomatic transmission
fluid or motor oil in thetransmission.
{a) Cleanareaaround thefill hole (N,
Figure2-11) and unscrewgear oil fill
plug.
Figure2-11: Addinggear oil,
(b) If addingonly a few ounces of gear
oil, useAPI ratedGL-4 or GL-5 gear oil
havinga viscosity of SAE140, SAE85W-
140 or SAE80W-90. If refilling an empty
transmission, useonly GL-4 gear oil
havinga viscosity of SAE85W-140 or
SAE140.
(c) Usinga cleanfunnel, slowly add gear
oil until itflows from the gearoil level
checkhole (N, Figure2-11).
(d) Reinstalland tighten securelythe gear
oil fill plug (M, Figure2-10).
STEP 6: ATTACHWHEEL GEAR
LEVER
1. Insertthe WheelGearLever(P, Figure
2-12) upthrough the slot in the control
panelthat is labeled"WHEELGEAR."
2. Inserttwo #10-32 x 1/2" round head
screws down through the "+" marks on
thecontrol paneldecaland securely
attachthe wheelgear mounting bracket
using two #10 Iockwashersand #10-32
nuts.
3. Useasmall boardto tap the Wheel
GearLeverknob securelyonto the lever.
4. Securethe wheel gearcableand the
reverseclutch control cableto the left-
side handlebarwith two plasticties (S,
Figure2-13) locatedabout two feet apart.
Snip off anyexcesstie lengthwith
scissors.
STEP 7 ATTACHINGTHE BATTERY
CABLES(MODELE666M)
Thepositive batteryterminal is marked
Pos. (+). The negativebatteryterminal is
marked Neg. (-).
1. Removethe hex bolt and hexnut from
the positive cable (heavyredwire).
2. Removethe plasticcover from the
positive batteryterminal and attachthe
positive cableto the positive batteryter-
minal (+) with the bolt and hexnut. Make
certainthat the rubber boot coversthe
Figure2-12: AttachWheel GearLever,
Figure2-13: Attachwheelgearcableand
reverseclutchcablewithcableties(S).
positive terminal to help protect itfrom
corrosion.
3. Removethe hexbolt and hexnut from
the negativecable(heavy blackwire).
4. Removethe black plastic cover from
the negativebatteryterminal and attach
the negativecableto the negative battery
terminal (-) with the bolt and hexnut.
IMPORTANT:
•If the batteryis put into serviceafter the
dateshown on top of battery, chargethe
batteryas instructed in the Maintenence
section of this manual prior to operating
thetiller.
STEP 8: CHECKAIR
PRESSURE IN TIRES
Usea tire pressuregauge to checkthe air
pressure in both tires. Deflateor inflate
both tires equallyto between15 PSIand
20 PSI). Besurethat both tires are
inflated equally or the unit will pull to one
side.
STEP 9: CHECK HARDWARE
FOR TIGHTNESS
Inspectthe hardwareon the unit and
tighten any loose screws, bolts and nuts.

FeaturesandControls
Before operating your machine, care-
fully read and understand all safety,
controls and operating instructions in
this Manual, the separate Engine
Owner's Manual, and on the decals on
the machine.
Failure to follow these instructionscan
result inseriouspersonalinjury.
INTRODUCTION
This Sectiondescribesthe location and
function of the controls on your tiller.
Referto thefollowing section "Operation"
for detailedoperating instructions.
Practiceusing thesecontrols, with the
engine shut off, until you understandthe
operationof the controls and feelconfi-
dent with them.
IMPORTANT:Referto the separateengine
manufacturer's EngineOwner'sManual
for information aboutthe controls on the
engine.
WHEEL GEAR LEVER
This lever(A, Figure3-1) hastwo posi-
tions: ENGAGEand DISENGAGE.
Inthe ENGAGEposition, the wheelswill
startturning when either the Forward
ClutchControl or the ReverseClutch
Control is engaged(the tines will also
startturning when either clutch is
engaged).
Figure3-1: Controlslocatedon handlebar.
The DISENGAGEposition placesthe
wheels in thefreewheeling modeto allow
the unitto be movedwithout the engine
running. Usethe DISENGAGEposition
only whenthe engine is not running. See
"DANGER"statementthat follows.
To shift to ENGAGE,gently (do notforce)
move the leverforward while also rolling
the tiller afew inchesforward or back-
ward. Moving the tiller helpsto align the
shift mechanismwith the transmission
wheel drive gears.
To shift to DISENGAGE(freewheel),
move the leverrearward, without rolling
the tiller. Thewheelswill roll freely
when the lever is properly set in the
DISENGAGEposition.
FORWARD CLUTCH CONTROL
Thetwo interconnected levers (B, Figure
3-1) control the engagementof forward
drive to the wheelsand tines.
To Operatethe ForwardClutchControl:
1. Beforeengaging the Forward Clutch
Control, put the WheelGearLeverin the
ENGAGEposition (see"WARNING"
below).
2. Pull up and hold one or both of the
levers against the handlebargrips to
engagethewheels and tines.
3. ReleaseBOTHleversto disengage
(stop) the wheels andtines. All forward
motion will stop (the enginewill continue
to run).
Never place the Wheel Gear Lever in
DISENGAGE (Freewheel) when the
engine is running.
Having the Wheel Gear Lever in
DISENGAGE and then engaging the
tines/wheels with either the Forward
Clutch Control or the Reverse Clutch
Control could allow the tines to propel
the tiller rapidlyforwardor backward.
Failure to follow this instruction could
result in personal injury or property
damage.
Never engagethe wheels and tines with
the Forward Clutch Control or the
Reverse Clutch Control unless the
Wheel GearLeveris in ENGAGE.
Engagingthe ForwardClutch Controlor
the Reverse Clutch Control when the
wheels are not engagedcouldallow the
tines to rapidly propelthe tiller forward
or backward.
Failure to follow this warning could
result in personal injury or property
damage.

REVERSECLUTCHCONTROL
TheReverseClutch Control (C, Figure
3-1) controls the engagementof reverse
drive to thewheels and tines. The revers-
ingfeature isusedfor maneuveringthe
tiller only- neverengagethetines in
thegroundwhile goingin the reverse
direction.
• Use extreme caution when reversing
or pulling the machine towards you.
Lookbehindto avoidobstacles.
• Neverattempttotill in reverse.
Failure to follow this warning could
result in personal injury or property
damage.
ToOperatetheReverseClutchControl:
1. Putthe WheelGearLeverin the
ENGAGEposition (seethe "WARNING"
statementon previous page).
2. Stopall tiller motion by releasingthe
Forward ClutchControl levers.
3. Lift up the handlebarsuntil the tines
clearthe ground, look behindyou to avoid
anyobstacles,and then pull the Reverse
ClutchControl knob out. Thetines and
wheelswill rotate in a reversedirection.
4. Releasethe ReverseClutch Control
knob to disengage(stop) the wheels and
tines. All reversemotion will stop (the
enginewill continue to run).
• Do not attempt to till too deeply too
quickly. Gradually work down to
deepertilling depths.
• Placethe DepthRegulatorLever in the
"travel" position before starting the
engine. This position prevents the
tines from touching the ground until
youare readyto begintilling.
Failure to follow this warning could
result in personal injury or property
damage.
DEPTHREGULATOR
TheDepth Regulator lever(D, Figure3-2)
controls the tilling depth ofthetines. Pull
the leverstraight backand slide it up or
down to engagethe notchedheight set-
tings.
Figure3-2: DepthRegulatorLever,
The highest notch (leverall the way
down) raises thetines approximately
1-1/2 inches off the ground. This "travel"
position allows the tiller to be moved
without the tines digging into the ground.
Moving the lever up increasesthe tilling
depth. Thelowest notch allows a tilling
depthof approximately six to eight
inches,depending on soil conditions.
Forbestresults, alwaysbegintilling at
a veryshallowdepthsettingand gradu-
ally increasethetilling depth. Complete
details on using the Depth Regulatorare
found in the "Operation" Section of this
manual.
HANDLEBAR HEIGHT ADJUSTMENT
The handlebarheight is adjustableto four
different settings. Set the handlebar
heightto a comfortable setting, but keep
in mind that the handlebarswill be lower
when the tines are engagedinthe soil.
To AdjusttheHandlebarHeight:
F
Figure3-3: Handlebarheightadjustment.
1. Stopthe engine,wait for all parts to
stop moving and then disconnect the
spark plug wire. Removethe ignition key
on electric start models.
2. Loosenthe two screws at the lower
endsof the handlebar.
3. Loosenthe height adjustment screw
(E,Figure3-3) and pull the keyedwasher
(F)free of theslots in the curved height
adjustment bracket.
4. Move the handlebarsto the newslot
setting and insert the raisedkeyson the
keyedwasher into theslot. Tighten the
heightadjustment screw securely.
5. Retightenthe two screws at the ends
of the handlebar.
ENGINECONTROLS
Referto the engine manufacturer'sEngine
Owner's Manual(included in the tiller lit-
erature package)to identify the controls
on your engine. Thefollowing two con-
trols are usedwhen stopping or starting
the engine.
IMPORTANT:Thecontrol for stopping
the recoil start engine is located on the
engine.
ENGINETHROTTLE CONTROLLEVER
TheEngineThrottleControlLever(located
on engine--seeFigure4-1) is usedto reg-
ulatethe engine speed. Onthe recoil start
modelonly, it isalso usedto stop the
engine (on the electric start model,the
electric start keyswitch is usedto stop the
engine). Thethrottle settings are shown
below.
IMPORTANT:See"Starting and Stopping
the Engine" in the "Operation" Sectionfor
detailedengine starting and stopping
instructions.
,_ FAST- Usefor most tilling and
cultivating projects.
,_b_ SLOW- Usewhen idling engine or
when slower tilling and cultivating
speedsare needed.
_STOP - Stops theengine (on
recoil start models only).
ELECTRICSTART KEYSWITCH
(MODEL E666M)
Theignition keyswitch on the electricstart
model is usedto start and stop the
engine. Thekeyswitch settings are
described below.
IMPORTANT:See"Starting and Stopping
the Engine" in the "Operation" Sectionfor
detailed instructions.
OFF -Stops engine.
RUN- After starting, key returns to run
position.
START- Startsengine. Releasekeywhen
engine starts (avoidcranking enginefor
longer than 15 secondsfor eachattempt)