Troy-Bilt 645A - Manual (Page 6)

Section
2 Assembly
WARNING
To prevent personal Injury or
property damage, do not start
the engine until all assembly
steps are eomplete and you
have read and understand the
safety and operating Instruc­
tions in this manual.
Introduction
Carefully follow these assembly steps to
correctly prepare your tiller for use. It is
recommended that you read this Section
in its entirety before beginning assembly.
NOTE: Engine syles vary by model. The
engine on your tiller may appear differ­
ently than those shown in illustrations
and Figures throughout this manual.
Inspect unit
Inspect the unit and carton for damage
immediately after delivery. Contact the
carrier (trucking company) if you find or
suspect damage. Inform them of the
damage and request instructions for filing
a claim. To protect your rights, put your
claim in writing and mail a copy to the
carrier within 15 days after the unit has
been delivered.
STEP 1: Unpacking Instructions
1. Remove any cardboard inserts and
packaging material from the carton.
Remove any staples from the bottom of
the carton and then lift the carton up and
off the unit.
2. The tiller is heavy and you should not
attempt to remove it from the shipping
platform until the handlebars are
installed. The procedure for removing the
tiller is explained in Step 3 of these
assembly steps.
NOTE: Be careful not to severely bend any
of the control cables on the unit.
3. Remove all unassembled parts and
the separate hardware bag from the
carton. Check that you have the items
listed below (contact your local dealer or
the factory if any items are missing or
damaged). NOTE: Use the screw length
template (Fig. 2-1) to identify screws.
Qfy.
Loose Parts List
Description
1 Handlebar Support (see A, Fig. 2-2,
page 7)
1 Handlebar Assembly
(see K, Fig. 2-2)
The following items are in the
hardware bag:
1 Slotted hd. screw, #10-24 x 2"
1 Hex hd. screw, 1/4-20 x 1-1/4"
6 Curved hd. screw, 5/16-18 X1-1/2"
2 Hex hd. screw, 3/8-16 x 3/4"
2 Flat washer, 3/8’
6 Split lockwasher, 5/16"
1 Hex locknut, 1/4"-20
6 Hexnut, 5/16"-18
2 Hex locknut, 3/8“-16
1 Hex nut, #10-24
1 Spring, cable (see W, Fig. 2-5,
page 8)
1 Bracket, forward clutch cable (see
P, Fig. 2-5, page 8)
1 Bracket, reverse clutch cable (see
BB, Fig. 2-8, page 9).
IMPORTANT: Motor oil must be added to
the engine crankcase before the engine
is started. Follow the instructions in this
“Assembly” section.
NOTE; LEFT and RIGHT sides of the tiller
are as viewed from the operator’s
position behind the handlebars.
Tools/Materials Needed for
Assembly
(1) 3/8” open-end wrench*
(2) 7/16" open-end wrench*
(1) 1/2" open-end wrench*
(2) 9/16" open-end wrench*
(1) Large adjustable wrench
(1) Scissors (to trim plastic ties)
(1) Ruler (for belt tension check)
(1) Block of wood (to support tiller
when removing wheels)
(1) Automotive-type air pressure gauge
(1) Clean oil funnel
(1) Clean, high-quality engine oil. Refer
to the Engine Owner Manual for
engine oil specifications and quantity
required. Do not overfill.
* Adjustable wrenches may be used.
Figure 2-1: To identify length of screw,
place screw on template as shown and
measure distance between bottom of screw
head and tip of screw.