Troy-Bilt PONY 664DM User manual

'0 TRO BI£T°----
Operator's Manual
Rear-tine Tiller Model
664DmPony_
E666MmPony _
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 attester meeting applicable local or state laws (if any).
If a spark attester 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.
TROY-BILT LLC, p.o. BOX 361131, CLEVELAND, OH 44136-0019
PRINTED IN USA FROM NO. 770-10597A
(11/2002)

TABLEOFCONTENTS
Content Page
Calling Customer Support .................................................... 2
Safety ................................................................... 3
Assembly ................................................................. 6
Features and Controls ....................................................... 11
Operation ................................................................ 14
Maintenance .............................................................. 20
Tiller Attachments .......................................................... 28
Troubleshooting ........................................................... 29
Parts List ................................................................. 30
Warrany 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 main-
tain the unit for best performance. Please read and understand what it says.
Before you start assembling your new equipment, please locate the model plate on the equipment and copy the infor-
mation from it in the space provided below. This information is very important if you need help from our Customer
Support Department or an authorized dealer.
You can locate the model number by looking at the rear surface of the tine shield. A sample model plate is
explained below. For future reference, please copy the model number and the serial number of the equipment
in the space below
O]_II__IpD,m...]_. TROY-BILT LLC
P. O. BOX 361131
www.troybilt.com CLEVELAND, OH 44136
330-558-7220
866-840-6483
Copy Model Number Here
Copy Serial Number Here
ENGINEINFORMATION
The engine manufacturer is responsible for all engine-related issues with regards to performance, power-rating, speci-
fications, warranty and service. Please refer to the engine manufacturer's Owner's/Operator's Manual packed sepa-
rately with your unit for more information.
CALLINGCUSTOMERSUPPORT
If you have difficulty assembling this product or have any questions regarding the controls, operation or maintenance
of this unit, please call the Customer Support Department.
Call 1- [phone] or 1- [phone] to reach a Customer Support representative. Please have
your unit's model number and serial number ready when you call. See previous section to locate this
information. You will be asked to enter the serial number in order to process your call.

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.
SafetyAlert Symbol
_ his isa safety alert symbol. It is usedin this
manualandon the unit to alertyou to potential
hazards. Whenyou seethis symbol, readand
obeythe messagethat follows it. Failureto
obeysafety messagescould result in personal
injury or property damage.
WARNING
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects or other reproductive harm.
TRAINING
1. Carefullyreadthis
Owner's Manual,the sepa-
rateEngineOwner's
Manual,and anyother literatureyou may
receive.Bethoroughly familiar with the
controls andthe proper useofthe tiller
and its engine. Knowhow 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 operation clear ofall
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. Besure all 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.Wearprotectivefootwearthat will
improvefooting on slipperysurfaces.
e.
f.
5. Donottill nearundergroundelectric
cables,telephonelines, pipesor hoses.If in
doubt, contactyourtelephoneor utility
company.
6. Warning: Handlefuel with care; it is
highlyflammableand itsvaporsareexplo-
sive. Takethefollowing precautions:
a. Storefuel in containersspecifically
designedfor this purpose.
b. Thegascap shall neverbe removed
or fuel added while the engine is
running. Allow the engineto cool
for several minutes beforeadding
fuel.
c. Keepmatches,cigarettes,cigars,
pipes, open flames, 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.
Replaceall fuel tank and container
caps securely.
If fuel is spilled, do not attempt to
start the engine,but move the
machine awayfrom the area of
spillageand avoid creating any
source of ignition until fuel vapors
havedissipated.
OPERATION
1. Donot 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 aforeign object, stop the
engine (and removethe ignition 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
damagebeforerestarting and operating
the tiller.
4. Exercisecaution to avoid slipping or
falling.
5. Ifthe unitshould startto vibrateabnor-
mally,stop the engine(andremovethe
ignition keyon electricstartmodels).Dis-
connectthespark plugwire andpreventit
from touchingthe spark plug,and check
immediatelyfor thecause.Vibration is
generallya warning of trouble.
6. Stopthe engine (and removethe igni-
tion key on electric start models), discon-
nectthe spark plug wire and prevent it
from touching thespark plug whenever
you leavethe operating position, before
7. Nevermakeadjustments when engine unclogging thetines, or when makingany
is running (unless recommendedby repairs, adjustments or inspections.
manufacturer).

7. Takeall possible precautionswhen
leavingthe machineunattended.Stopthe
engine. Removeignition key on electric
start models. Disconnectspark plug wire
and move it awayfrom the spark plug.
MoveWheelGear Leverto 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
preventit from touching the spark plug to
preventaccidentalstarting. Onelectric
start models,always removethe cable
from the negativeside (-) of the battery.
9. Always keepthetiller tine hood flap
down, unless using the hiller/furrower
attachment.
10. Never usethe tiller unless proper
guards, plates,or othersafetyprotective
devicesarein place.
11. Do not run engine in an enclosed
area.Engineexhaustcontains carbon
monoxide gas,a deadly poisonthat is
odorless, colorless, and tasteless.
12. Keepchildren and pets away.
13. Never operatethetiller under
engine powerif theWheel GearLeveris
in DISENGAGE(FREEWHEEL).In this
position,the wheelswill notholdthe
tiller backand therevolvingtines could
propelthe tiller rapidly, possibly
causinglossofcontrol.Always movethe
WheelGearLeverto ENGAGEbefore
starting the engine or engagingthe
tines/wheelswith the ForwardClutch
Control or the ReverseClutch Control.
14. Beawarethatthe tiller may unex-
pectedlybounceupwardorjump
forwardif thetinesshouldstrike
extremelyhardpackedsoil, frozen
ground,or buriedobstacleslike large
stones,roots,or stumps.If in doubt
aboutthetilling conditions,alwaysuse
thefollowingoperatingprecautionsto
assistyou in maintainingcontrolofthe
tiller:
a. Walk behindandto oneside ofthe
tiller, usingone handonthe han-
dlebars. Relaxyourarm, butusea
securehandgrip.
b. Useshallowerdepthregulatorset-
tings, workinggraduallydeeper
with eachpass.
c. Useslowerenginespeeds.
d. Clearthe tilling area ofall large
stones,rootsand otherdebris.
e. Avoidusingdownwardpressure
on handlebars.If needbe, use
slightupwardpressureto keepthe
tines from diggingtoo deeply.
f. Beforecontactinghardpackedsoil
at the endofa row, reduceengine
speedand lift handlebarsto raise
tines out ofthesoil.
g. In an emergency,stoptinesand
wheels byreleasingwhichever
ClutchLever isengaged.Donot
attemptto restrainthetiller.
15. Do not overloadthetiller's capacity
by attempting to till too deeplyattoo fast
a rate.
16. Neveroperatethetiller at high trans-
port speeds on hard or slippery surfaces.
Look behind and usecare when 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 freewheel down 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 undertheinfluenceof alcohol,drugsor
medication.
23. Operatorsshallnottamperwith the
engine-governorsettingsonthe machine;
the governorcontrolsthemaximumsafe
operatingspeedto protecttheengineand
all movingpartsfrom damagecausedby
overspeed.Authorizedserviceshallbe
soughtif a problemexists.
24. Donottouch enginepartswhich may
be hotfrom operation.Letpartscool down
sufficiently.
25. Thebatteryon electricstartmodeltillers
containssulfuricacid.Avoidcontactwith
skin,eyes,or clothing.Keepoutof the
reachofchildren.
Antidote-External Contact:Flushimme-
diatelywith lotsof 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
usinga batteryinanenclosedspace.
ALWAYSwearsafetygoggleswhen
working nearbatteries.
27. Pleaseremember:Youcanalwaysstop
thetines andwheelsby releasingthe
ForwardClutchControlLeverorthe
ReverseClutchControlknob(whichever
control you haveengaged),or by moving
the EngineThrottleControlLever(located
onengine)to STOPon recoilstartmodels
or byturningthe ignitionkeyto OFFon
electricstartmodels.
28. To loador unloadthetiller, seethe
instructionsinSection4 ofthis Manual.
29. Useextremecautionwhenreversingor
pullingthemachinetowardsyou.
30. Starttheenginecarefullyaccordingto
instructionsandwith feetwellawayfrom
thetines.
31. Neverpick up or carrya machinewhile
theengineis running.
MAINTENANCEANDSTORAGE
1. Keepthe tiller, attachments and acces-
sories in safe working condition.
2. Checkall nuts, bolts, and screws at
frequent intervalsfor proper tightness to
besure the equipment is in safeworking
condition.
3. Neverstorethetillerwith fuel inthefuel
tank insidea buildingwhereignition
sourcesare presentsuchashotwaterand
spaceheaters,furnaces,clothesdryers,
stoves,electricmotors,etc. Allowengineto
cool beforestoring in anyenclosure.

4. To reducethe chancesof a fire
hazard,keeptheenginefree ofgrass,
leaves,or excessivegrease.
5. Storegasolinein acool, well-venti-
latedarea,safelyawayfrom anyspark-
or flame-producingequipment. Store
gasolinein an approvedcontainer,
safelyawayfrom the reachof children.
6. Referto the Maintenancesectionof
this Manualand in the separateEngine
Owner's Manualfor instructions ifthe
tiller isto bestored for an extended
period.
7. Neverperform maintenancewhile
the engineis running or the spark plug
wire is connected,exceptwhenspecifi-
cally instructed to do so.
8. If thefuel tank hasto bedrained,do
this outdoors.
DECALS
Foryour safetyand the safety of others, replacementsif any decalsare damagedor
various safety messagedecalsare on your missing.
unit (seeFigurebelow). Keepthe decals Referto the Parts List pagesfor decal
cleanand legibleat all times. Contactyour locations and partnumbers.
localservicedealer or the factory for
ControlDescri
TineWarning (on right
side ofhoodflap)
StartingStabilization (on
top of engineor fuel tank)
OperatingInstructionsand
WarningMessages
OperatingSymbols
Various symbols (shown here, with
word descriptions)maybe usedon the
tillerandengine.
FAST SLOW STOP
6 I-'-I
CHOKE
STOP START ON
I÷1
CHOKE ROTATING
OFF TINES
R
REVERSE
o--.>
LEVERDIRECTION
<--
TILLERDIRECTION
ENGAGED DISENGAGED
/MovingBelts
(ontopofbeltcover)
Figure 1:Locationof SafetyandOperatingDecals
TO AVOID SERIOUS INJURY:
• READTHEOWNER'SMANUAL.
•KNOWLOCATIONSAND FUNCTIONSOFALLCONTROLS.
•KEEPALLSAFETYDEVICESANDSHIELDSIN PLACEAND WORKING.
•NEVERALLOWCHILDRENORUNINSTRUCTEDADULTSTO OPERATETILLER.
•SHUTOFFENGINEAND DISCONNECTSPARKPLUGWIREBEFOREMANUALLYUNCLOG-
GINGTINESOR MAKINGREPAIRS.
•KEEPBYSTANDERSAWAYFROMMACHINE.
•KEEPAWAYFROMROTATINGPARTS.
•USEEXTREMECAUTIONWHEN REVERSINGORPULLINGTHEMACHINETOWARDSYOU.

2Assembly
To prevent personal injury or property
damage,do notstartthe engine until 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 readthis Section
in its entirety before beginningassembly.
INSPECTUNIT
Inspectthe unit andcarton for damage
immediatelyafter delivery. Contactthe
carrier (trucking company) ifyou find or
suspect damage. Inform them ofthe
damageand request instructions for filing
a claim. To protectyour rights, putyour
claim in writing and mail a copy to the
carrier within 15 days after the unit has
beendelivered.Contact usat the factory if
you needassistancein this matter.
UNPACKINGANDASSEMBLY
INSTRUCTIONS
STEP 1: UNPACKING INSTRUCTIONS
1. Removeanycardboard insertsand
packagingmaterialfrom the carton.
Removeanystaplesfrom the bottom of
the carton and removethe carton.
2. Cutthe large,plastictie strap that
securesthe transmission tubeto the ship-
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 are missing or
damaged.
NOTE:Forelectric start units, a second
hardwarebag is located nearthe battery.
4. Thetiller is heavy. You should not
attempt to remove it from theshipping
platform until instructed to do so inthese
"Assembly" steps.
HARDWARE BAG PARTSLIST
Fig.
Ref. Qty. Description
12 3/8-16 x 1" HexHd. Screw
21 KeyedWasher
3 1 WheelGearLeverKnob
4 1 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-endwrench*
(1) 7/16" open-endwrench* (electric
start unit only)
(2) 9/16" open-endwrench*
(1) 7/8" open-endwrench or 8" long
adjustable wrench
(1) Scissors (to trim plasticties)
(1) Ruler
(1) Small board (to tap plastic knob 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.
* Adjustablewrenches may be used.
IMPORTANT:Motor oil must beaddedto
the enginecrankcasebeforethe engine is
started. Followthe instructions in this
"Assembly" Sectionand in the separate
EngineOwner's Manual.
NOTE:LEFTand RIGHTsides of thetiller
are asviewedfrom the operator's posi-
tion behindthe handlebars.
STEP 2: ATTACHHANDLEBARS
1. On electric start units, removeone
screw and Iockwasherfrom thecurved
5@_, 60 o
8_ @©9
7_ 10_
11
Figure2-1:Loosehardware(shownin
reducedsize).
Figure2-1A Handlebarheightadjustment
usestheflangeheadscrew.
Figure2-2: Onelectric start units, move
heightadjustmentbracket aside.
heightadjustment bracket (A, Figure2-2),
loosenthe secondscrew, and swing the
bracketto one side.
2. Cutthe large,plastic cableties that
securethe handlebarendsto the handle-
bar mounting tabs on the transmission
top cover.
3. Gently lift handlebar (do not over-
stretch attachedcable)and placehandle-
bar cross-brace (B, Figure2-3) in front of
curved heightadjustment bracket (C).
Figure2-3: Forwardclutchcontrolcablenot
shownforclarity.

4. Withtheforwardclutchcable (N,
Figure2-4) onthe inside ofhandlebar,
position the handlebarendson the
outside of thetwo mounting tabs (IVI,
Figure2-3) on the transmission top
cover.
NOTE:Thecurved handlebarheight
adjustment bracketappearsasshown in
C,Figure2-3 for non-electricstart units.
Forelectricstart units, the bracket is loos-
ened and 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 (0, Figure2-4).
Figure 2-4: Attachhandlebars.
6. Onelectric start 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 threaded holein 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) ofthe
washer facing down.
8. Threadthe heightadjustment screw
(F, Figure2-3) intothe hole in the handle-
bar cross-brace, making surethat the
raisedkeyson the washer fit into theslot
on the height adjustment bracket.
Tighten the heightadjustment screw
securely. Next,securelytighten the two
screws and nuts in the endsof the han-
dlebar (M, Figure2-3).
9. To removethe tiller from its shipping
platform, first carefully unwrapthe wheel
gear cable (with attachedlever- see
Figure2-5) from around the chassis.
Movethe WheelGearLever (G)to the
DISENGAGEposition--this allows the
wheels to rotatefreely. Usethe handle-
STEP 4: ATTACHFORWARD
CLUTCH CONTROL CABLE
1. Removeanyfasteners (rubber bands,
tape, etc.) that may securethe Forward
Clutch Control levers(J, Figure2-7) to the
handlebar.
Figure2-5: CarefullyunwrapWheelGear
LeverandmovelevertoDISENGAGE.
barsto roll thetiller off the platform.
NOTE:TheWheelGearLeverwill be
installed later in this procedure.
IMPORTANT: Usethe DISENGAGEposi-
tion only whenthe engine is not running.
Beforestarting the engine,the Wheel Gear
Levermust be placed inthe ENGAGE
position (seeSection 3 for details).
STEP3: ATTACH REVERSE
CLUTCH CONTROL CABLE
1. Carefullyunwrapthe 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.
ILeftSide ReverseClutch]
Handlebar ControlKnob I
Figure2-7: ForwardClutchControllevers
(J). Forwardclutchcontrollinkage(K).
2. Theforward clutch control cable(with
attachedspring) is hanging loosely near
the right-side wheel. Being careful not to
kink or stretch the cable, insert thez-con-
nector (L, Figure2-8 - end of the spring)
into the hole at the endofthe forward
clutch control linkage(K, Figure2-7).
Figure2-6: Attachreverseclutchcontrol
assemblytoslottedhole in handlebarpanel.
2. Insertthe cableinto the slot in the
control paneland fit the threadedassem-
bly into the hole in theslot (seeFigure2-
6). Besurethat theflat side of the
threadedassembly is aligned with the flat
side of the hole. Slide the hex nut (I) up
the cableand tighten it securely.
3. Testthefunction of the reverseclutch
control cableby pulling the knob out and
releasingit. Theknob should return to its
neutral position against the tapered
bushing. If it doesn't, contact your local
dealeror the factory for technical
assistance.
Figure2-8
3. Attachthe cableadjuster (A, Figure
2-9) to the bracket on the right-side han-
dlebar. Usetwo 1/2"wrenchesto loosen
the two jam nuts (B) just enoughto slide
the cableadjuster onto the bracket. Then
hand tighten the jam nuts.
Figure2-9

Incorrectcable adjustment could cause
the wheels andtines 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 Section5, Checkingand
Adjusting ForwardClutch Belt Tension.
5. Whentension is correct, tighten the
two jam nuts (B) securely.
STEP5: CHECKTRANSMISSION
GEAROIL LEVEL
Thetransmission was filled with gear oil
at the factory. However,be sureto check
the oil levelat this time to makecertain it
iscorrect.
IMPORTANT:Do not operatethe tiller if
the gear oil level is low. Doingso will
result in severedamageto the transmis-
sion components.
1. With the tiller on levelground, pull the
Depth Regulator Lever(R, Figure2-13)
backand then slide it to the second notch
from the top. NOTE:If the leverdoes not
move,lift the tine hoodflap 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 painton the plug
threads, it may require some force to
removethe plug thefirst time.) The gear
oil levelis correct if oil starts to flow out
ofthe hole as the plug is removed. If so,
securely reinstall the plug.
Figure2-10: Gearoil level checkplug.
3. If oil does notflow from the check
hole,add oil asfollows:
NOTE:Donot useautomatic transmission
fluid or motor oil in the transmission.
(a) Cleanareaaround the fill hole (N,
Figure2-11) and unscrewgear oil fill
plug.
Figure2-11: Addinggearoil.
(b) If adding only afew ouncesof 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 gear oil level
check hole (N, Figure2-11).
(d) Reinstalland tighten securelythe gear
oil fill plug (M, Figure2-10).
STEP 6: ATTACHWHEEL GEAR
LEVER
1. Insert the WheelGearLever(P, Figure
2-12) up through theslot in the control
panelthat is labeled"WHEELGEAR."
2. Insert two #10-32 x 1/2" round head
screws down through the "+" marks on
the control paneldecaland securely
attach thewheel gear mounting bracket
usingtwo #10 Iockwashersand #10-32
nuts.
3. Usea small board to tap the Wheel
GearLeverknobsecurely onto the lever.
4. Securethe wheelgear cableand the
reverseclutch control cableto the left-
side handlebarwith two plasticties (S,
Figure2-13) locatedabout two feet apart.
Snip off anyexcesstie lengthwith
scissors.
STEP7 ATTACHINGTHE BATTERY
CABLES(MODEL E666M)
The positive batteryterminal is marked
Pos. (+). Thenegative batteryterminal is
marked Neg.(-).
1. Removethe hex bolt and hex nut from
the positive cable(heavy red wire).
2. Removethe plasticcover from the
positive batteryterminal and attachthe
positive cableto the positive batteryter-
minal (+) with the bolt and hex nut. Make
certain that the rubber boot coversthe
Figure2-12: AttachWheel GearLever.
Figure 2-13: Attachwheel gear cable and
reverseclutchcable with cableties(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 negativebattery
terminal (-) with the bolt and hex nut.
IMPORTANT:
•If the battery is put into serviceafter the
dateshown on top of battery, chargethe
batteryas instructed in the Maintenence
sectionof this manualprior to operating
the tiller.
STEP 8: CHECKAIR
PRESSURE IN TIRES
Usea tire pressuregaugeto checkthe air
pressure in bothtires. Deflateor inflate
both tires equallyto between15 PSIand
20 PSI). Besure that both tires are
inflated equally or the unit will pull to one
side.
STEP 9: CHECK HARDWARE
FOR TIGHTNESS
Inspect the hardwareon the unit and
tighten anyloosescrews, bolts and nuts.

3 Featuresand Controls
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
resultin seriouspersonalinjury.
INTRODUCTION
This Sectiondescribesthe location and
function of the controls on your tiller.
Referto thefollowing section "Operation"
for detailedoperating instructions.
Practiceusingthese controls, with the
engine shut off, until you understandthe
operation of the controls and feel confi-
dent with them.
IMPORTANT:Referto the separateengine
manufacturer'sEngineOwner's Manual
for information aboutthe controls on the
engine.
WHEEL GEAR LEVER
This lever(A, Figure3-1) hastwo posi-
tions: ENGAGEand DISENGAGE.
Inthe ENGAGEposition, the wheels will
start turning when eitherthe Forward
Clutch Control or the ReverseClutch
Control is engaged(thetines will also
start turning when eitherclutch is
engaged).
Figure3-1: Controlslocatedonhandlebar.
The DISENGAGEposition placesthe
wheels in thefreewheeling modeto allow
the unitto be moved without the engine
running. Usethe DISENGAGEposition
only whenthe engine is not running. See
"DANGER"statementthat follows.
To shift to ENGAGE,gently (do not force)
movethe 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),
movethe leverrearward, without rolling
the tiller. Thewheels will roll freely
when the lever is properly set inthe
DISENGAGEposition.
FORWARD CLUTCH CONTROL
The two interconnected levers (B, Figure
3-1) control the engagementof forward
drive to the wheelsand tines.
To Operatethe ForwardClutchControl:
1. Beforeengagingthe ForwardClutch
Control, put the WheelGearLeverin the
ENGAGEposition (see"WARNING"
below).
2. Pull up and hold one or both of the
levers againstthe handlebar grips to
engagethe wheels 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 isrunning.
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
thetiller rapidlyforwardor backward.
Failure to follow this instruction could
result in personal injury or property
damage.
Never engagethe wheels andtines 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 rapidlypropelthe tiller forward
or backward.
Failure to follow this warning could
result in personal injury or property
damage.

REVERSE CLUTCH CONTROL
The ReverseClutchControl (C, Figure
3-1) controls the engagementof reverse
driveto thewheels and tines. The revers-
ingfeature isusedfor maneuveringthe
tiller only- neverengagethe tines in
the groundwhile goingin the reverse
direction.
• Use extreme caution when reversing
or pulling the machine towards you.
Lookbehindtoavoidobstacles.
• Neverattempttotill in reverse.
Failure to follow this warning could
result in personal injury or property
damage.
To Operatethe ReverseClutchControl:
1. Putthe WheelGearLeverin the
ENGAGEposition (seethe "WARNING"
statementon previous page).
2. Stopall tiller motion by releasingthe
ForwardClutch Control levers.
3. Lift upthe handlebarsuntil thetines
clearthe ground, look behindyou to avoid
anyobstacles,and then pull the Reverse
ClutchControl knob out. Thetines and
wheelswill rotate in a reverse direction.
4. Releasethe ReverseClutch Control
knobto 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 inthe
"travel" position before starting the
engine. This position prevents the
tines from touching the ground until
youare readytobegintilling.
Failure to follow this warning could
result in personal injury or property
damage.
DEPTH REGULATOR
The Depth Regulator lever(D, Figure3-2)
controls the tilling depth of the tines. Pull
the leverstraight backand slide it up or
downto engagethe notched height set-
tings.
Figure3-2: DepthRegulatorLever.
The highest notch (leverall the way
down) raisesthe tines approximately
1-1/2 inches off the ground. This "travel"
position allows thetiller to be moved
without the tines digging into theground.
Moving the lever upincreasesthe tilling
depth. Thelowest notch allows a tilling
depth of approximately six to eight
inches,depending on soil conditions.
Forbestresults,always begintilling at
a very shallowdepthsettingand 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. Setthe handlebar
heightto a comfortable setting, but keep
in mindthat the handlebarswill be lower
when thetines are engagedinthe soil.
ToAdjusttheHandlebarHeight:
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. Loosenthetwo screws atthe lower
ends of the handlebar.
3. Loosenthe height adjustment screw
(E,Figure3-3) and pull the keyedwasher
(F)free ofthe slots in the curved height
adjustment bracket.
4. Movethe handlebarsto the newslot
setting and insert the raisedkeyson the
keyedwasher into the slot. Tighten the
height adjustment screw securely.
5. Retightenthe two screws at the ends
of the handlebar.
ENGINECONTROLS
Referto theengine manufacturer'sEngine
Owner's Manual(included in thetiller lit-
erature package)to identify the controls
on your engine. Thefollowing two con-
trols are usedwhen stopping or starting
the engine.
IMPORTANT:The control for stopping
the recoil start engine is located on the
engine.
ENGINE THROTTLE CONTROLLEVER
TheEngineThrottleControlLever(located
on engine--seeFigure4-1) is usedto reg-
ulatethe engine speed. Onthe recoil start
model only, it is also 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
detailedenginestarting and stopping
instructions.
FAST- Usefor mosttilling and
cultivating projects.
-l_ SLOW- Usewhen idling engine or
when slower tilling and cultivating
speeds are needed.
_) TOP- Stops the engine (on
recoil start models only).
ELECTRIC START KEYSWITCH
(MODEL E666M)
Theignition keyswitch on the electric start
model is usedto start and stop the
engine. The keyswitch settings are
described below.
IMPORTANT:See"Starting and Stopping
the Engine"in the "Operation" Sectionfor
detailedinstructions.
OFF- Stops engine.
RUN- After starting, keyreturns to run
position.
START- Startsengine. Releasekeywhen
engine starts (avoidcranking engine for
longer than 15 secondsfor eachattempt)