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SECTION2: ASSEMBLY
WARNING: To prevent
personalinjury or property
damage,do notstartthe engine
until all assemblysteps are
completeandyou haveread
and understandthe safety and
operatinginstructions in this
manual.
INTRODUCTION
Carefullyfollow these assemblysteps to
correctly prepareyour tiller for use. It _s
recommendedthat you readthis Section
in itsentirety beforebeginning assembly.
NOTE: Various tiller models are
presented in this Manual. Use only the
ASSEMBLYSTEPS
STEP 1: UNPACKINGINSTRUCTIONS
NOTE:While unpackin0, do not severely
bendany control cables.
1.Thetiller weighs approximately133 lbs.
Donot attempt to remove it from the ship-
ping platform until instructed to do so in
these Assembly steps.
2. Removeanypackaging materialfrom
the carton. Removeany staplesfrom the
bottom ofthe carton and removethe car-
ton from the shipping platform.
3. Removeallunassembledpartsand the
separatehardwarebagfrom the carton.
Checkthat you havethe items listed in the
information appropriate for your tiller LoosePartsList(contactyourlocaldealer
model, orthe factory itemsare missing or dam-
aged).
INSPECTUNIT
Inspectthe unitand carton for damagetm-
mediatelyafter delivery. Contactthe carri-
er (trucking company) if you find or
suspectdamage. Inform themof thedam-
ageand request instructions for filing a
claim. Toprotect your rights, put your
claim inwriting and maila copyto the car-
rier within 15 days after the unit hasbeen
delivered.Contact Troy-Bilt LLCit you
needassistancein this matter.
NOTE: Use the screw length template
(Fig.2-1) toidentify screws
LoosePartsList
TOOLSMATERIALSNEEDED
(11 3_8"open-endwrench-
(2) 7/16"open-end wrench-
(.2_ 1/2" open-end wrench*
(.2_ 946"open-end wrench-
(1) Largead Jstablewrench
_Models634F/634Bonly)
(.11 Scissors totrim plasticties
(1) Ruler (for belttension check_
Ill Block of wood (to support tiller when
removing wheels)
(1) Tire pressure gauge_formodelswith
pneumatictires_
111 Cleanoil funnel
Ill Motor oil Refertothe EngineOwner's
Manualfor oil specificationsand
quantityrequired.
* Adlustable wrenchesmay Deused.
m
Figure2-1:Toidentifylengthofscrews,place
screwontemplateasshownandmeasuredis-
tancebetweenbottomofscrewheadandtipof
screw,
STEP 2: ATTACHHANDLEBAR
Qty. Description
1 HandlebarSupport (seeA, Fig. 2-2_
1 HandlebarAssembly(seeK,Fig.2-2)
Hardwarebag contents:
1 Slotted hd. screw #10-24 x 2'
1 Hex bd.screw 1/4-20 x 1-1/4
6 Hex hd.screw 5/16-18x 1-1 2"
2 Hex hd.screw. 3/8-16 x 3/4
2 FlatWasher.3/8°
6 Split Iockwashe_5/16_
1 Hex Iocknut. 1/4"-20
8 Hex nut. 5/16"-18
1 Hex nut #10-24
2 Hex Iocknut.3_8"-16
1 Spring, cable(seeW, Fig.2-5'_
1 Bracket.forward clutch cable
(seeP,Fig.2-4_
2 Lockwasher 3/8
2 *Self-tapping screw. 1/4-20 x 1/2
1 *Bracket reverseclutch cable
Model 634F& 634B only
IMPORTANT:Motor oil must beaddedto
the enginecrankcasebeforetheengine is
started. Followthe instructions inthis
Sectionand in theseparateEngine
Owner'sManual.
1. Looselyattachthe legsofthe handlebar
support (A, Fig.2-2) to the inner sides of
thetiller frame usingtwo 3/8"-16x 3/4"hex
hd. screws (B), 3/8"flat washers(C), 3/8"
lock washers (GG',and 3/8"-16 hexlock-
nuts (D',
2. Therearethree heightadjustment holes
in the two handlebarsupport brackets (.E
and E Fig. 2-2). Usea setting that will po-
sition the handlebarsat approximately
waist levelwhenthetines are3"-4" intothe
soil. Looselyattachthe support brackets
to the handlebarsupport (.A_using two
5/16"-18x 1-1/2" screws (G),5/16" split
Iockwashers(.H)and5/16"-18 hexnuts[I).
NOTE: If a support bracketwill not move
loosenattaching screw (J) and nut.
3. Attach the handlebarassembty(.K_to
the handlebarsupporl (A) usingfour 5.
16"-18 x 1-1/2" screws (.G_,5/16"split
Iockwashers(H)and5/16"-18 hexnuts (I).
Tightenthe four screws securely
4. Tighten all handlebarmounting hard-
waresecurely.
STEP3: MOVE TILLER OFF
Toroll thetiller off the shipping platform.
put the wheels in freewhee asfollows:
1. Placea sturdy block underthetransmis-
NOTE:LEFTandRIGHTsidesofthetiller sion to raise one wheelabout 1" off the
are as viewedfrom the operator's position ground.
behind thehandlebars.