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Troy-Bilt Small Frame Tillers

3.5.

Remove the lower cable tie securing the forward
clutch cable to the lower handlebar using side
cutters. See Figure 3.5.

3.6.

Remove the hex flange screw and large flat
washer securing the belt cover to the lower
cable mounting bracket using a 3/8” socket. See
Figure 3.6.

3.7.

Slide the belt cover down the forward clutch
cable until it is out of the work area.

NOTE:

The upper portion of the forward clutch

cable will not fit through the belt cover.

3.8.

Loosen the hex jam nut securing the forward
clutch cable to the lower cable mounting bracket
using a 3/8” wrench and a 7/16” wrench. See
Figure 3.8.

3.9.

Slide the forward clutch cable out of the lower
cable mounting bracket.

3.10. Pivot the forward clutch cable’s Z fitting rear-

ward, and remove it from the forward idler lever.
See Figure 3.10.

3.11. Remove the lower portion of the forward clutch

cable from the belt cover.

3.12. Install the new forward clutch cable in the

reverse order above.

3.13. Perform the Forward Clutch Cable Adjustment

section.

Figure 3.5

Cable Tie

Clutch

Cable

Figure 3.6

Hex Flange Screw

Large

Flat Washer

Belt Cover

Figure 3.8

Hex Jam Nut

Forward Clutch

Cable

Z Fitting

Idler

Lever

Forward

Figure 3.10

Z Fitting

Forward

Idler Lever

Содержание 21A-630B063

Страница 1: ...Service Manual MTD Products LLC Product Training and Education Department FORM NUMBER 769 01529 11 2004 Small Frame Troy Bilt Tillers...

Страница 2: ......

Страница 3: ...Forward return spring replacement 6 Transmission removal 7 Transmission disassembly 12 Transmission assembly 21 Forward Idler lever Pivot 32 Reverse clutch cable replacement 33 Reverse clutch cable ad...

Страница 4: ......

Страница 5: ...wering the tiller and refer to the Engine Owner s Manual for more information 2 FORWARD CLUTCH CABLE ADJUSTMENT 2 1 Remove the spark plug boot from the spark plug and ground it to the engine See Figur...

Страница 6: ...he tension is too loose Continue through this section 2 10 If the second measurement spring coils extended of the forward clutch is too long more than 3 16 the tension is too tight Continue through th...

Страница 7: ...FORWARD CLUTCH CABLE ASSEMBLY REPLACEMENT 3 1 Remove the spark plug boot from the spark plug and ground it to the engine See Figure 3 1 Figure 3 1 Spark Plug Boot Grounded Spark Plug 3 2 Loosen the he...

Страница 8: ...he forward clutch cable to the lower cable mounting bracket using a 3 8 wrench and a 7 16 wrench See Figure 3 8 3 9 Slide the forward clutch cable out of the lower cable mounting bracket 3 10 Pivot th...

Страница 9: ...work area Figure 4 1 Spark Plug Boot Grounded Spark Plug Figure 4 2 Hex Flange Screw Large Flat Washer Belt Cover Clutch Cable 4 4 Remove the belt from the engine drive pulley and forward idler pulley...

Страница 10: ...the return spring from the right engine bracket using needle nose pli ers See Figure 5 4 5 5 Remove the lower hook of the return spring from the forward idler lever using needle nosed pliers See Figur...

Страница 11: ...t cover 6 5 Set the belt cover aside 6 6 Remove both self tapping hex flange screws securing the tine hood to the right and left hood brackets using a 3 8 socket See Figure 6 6 Remove Drive Belt Remov...

Страница 12: ...sting on the tines and not on the trailing shield 6 14 Raise the front of the tiller up until the wheel assemblies are off the ground See Figure 6 14 6 15 Remove both hair pins and clevis pins securin...

Страница 13: ...Handlebar Secured 6 20 Remove both sets of hex screws securing the left and right engine brackets to the transmission using a 1 2 socket See Figure 6 20 6 21 Remove both self tapping hex screws securi...

Страница 14: ...ch 6 28 Remove the forward return spring from the for ward idler lever See Figure 6 28 NOTE There are two holes at the bottom of the forward idler lever The right lower hole in the operators position...

Страница 15: ...Pulley Key Front Support Washer Belleville Hex Screw Figure 6 31 Hex Screw Lock Washer Shoulder Washer Forward Lever Idler Pulley 6 33 Raise the rear of the transmission up and set it on a 2 x 4 block...

Страница 16: ...a 1 2 socket See Figure 7 2 7 3 Remove the front transmission cover and clean it 7 4 Position a suitable oil drain pan directly in front of the bench See Figure 7 4 7 5 Rotate the transmission 180 to...

Страница 17: ...ssembly using a 1 2 socket See Figure 7 9 Figure 7 8 Cover Gasket Wheel Worm Figure 7 9 Rear Transmission Cover Hex Screws 7 10 Remove the rear transmission cover gasket from the transmission using a...

Страница 18: ...re the overall thickness of the rear bear ing shims using a dial caliper See Figure 7 18 7 19 Record the measurement _____ NOTE This is for future reference 7 20 Thoroughly clean the exposed portion f...

Страница 19: ...r Bearing Race Drive Shaft Assembly Figure 7 25 Front Oil Seal Internal Snap Ring Race 7 27 Remove the front tapered roller bearing race by lightly tapping on the perimeter with a small punch and a ru...

Страница 20: ...ssion oil seal bores are not damaged during removal 7 33 Remove the left and right retaining rings secur ing the wheel shaft in position using medium retaining ring pliers See Figure 7 33 7 34 Remove...

Страница 21: ...ze wheel shaft bushing out of the transmis sion housing using a block of wood and a large hammer See Figure 7 38 NOTE The inner spacer will be damaged by the Hi Pro key 7 39 Remove the bronze bushing...

Страница 22: ...y 7 44 Grasp the wheel shaft worm gear with one hand and remove the wheel shaft with the other NOTE Make certain the wheel shaft worm gear does not drop to the bottom of the transmission housing 7 45...

Страница 23: ...re 7 48 Retaining Ring Tine Shaft 7 49 Remove the external shims from the right and left hand sides of the tine shaft using a small hook tool and a stick magnet See Figure 7 49 NOTE Two paper clips wi...

Страница 24: ...aft to the right forcing the bronze tiller shaft bushing out of the transmis sion housing using a block of wood and a ham mer 7 57 Remove the bronze bushing and spacer from the tiller shaft NOTE The l...

Страница 25: ...mission Housing Figure 8 2 Transmission Housing Protective Material Vice 8 3 Make certain all the drive shaft components are accounted for See Figure 8 3 8 4 Locate both hex flange screws that were se...

Страница 26: ...is installed from inside the transmission housing 8 8 Carefully begin sliding the drive shaft assembly into the transmission housing until it reaches the drive shaft area See Figure 8 8 8 9 Slide the...

Страница 27: ...et 8 14 Torque all of the hex screws to 100 In Lbs using a torque wrench and a 1 2 socket Figure 8 11 Rear Tapered Roller Bearing Race Figure 8 12 Rear Bearing Cap Hex Flange Screws Short Hex Flange S...

Страница 28: ...above 8 23 Remove all three hex flange screws and wash ers securing the rear bearing cap in position using a 1 2 socket See Figure 8 23 8 24 Remove the rear bearing cap 8 25 Install the new rear bear...

Страница 29: ...All Drive Shaft Assembly Components Removed Rear Bearing Cap Short Hex Screw Rear Bearing Cap Shims Rear Tapered Roller Bearing Race Drive Shaft Assembly Hex Flange Screws Support Washer Front Tapered...

Страница 30: ...ng certain the lubrica tion cut a ways are facing in 8 41 Drive the second wheel shaft bronze bushing into the transmission housing until it is flush with the outside of the housing using a bushing dr...

Страница 31: ...t 005 to 030 from the second recorded wheel shaft end play NOTE Shims of multiple thicknesses are used as required to obtain 005 to 030 allowable end play for the drive shaft 8 52 Record the new wheel...

Страница 32: ...llation tool NOTE A 1 I D PVC pipe by 7 long works well as a wheel seal installation tool 8 65 Repeat the above wheel shaft oil seal installation procedures for the opposite side 8 66 Drive one of the...

Страница 33: ...using using a bushing driver and hammer See Figure 8 73 NOTE A 1 I D PVC pipe by 7 long works well as a bushing installation tool Figure 8 69 Tine Shaft Bronze Bushing Worm Gear Spacer Spacer Figure 8...

Страница 34: ...econd drive shaft end play 040 minus 005 to 030 equals remaining wheel shaft end play divided by two 8 87 Install the outer retaining rings onto the tine shaft using medium retaining ring pliers 8 88...

Страница 35: ...n be used to keep them together 8 105 Apply a light coat of sealant to the inside mating face of the rear bearing cap Figure 8 96 Tine Shaft Seal Transmission Housing 8 106 Set the rear bearing cap ga...

Страница 36: ...nsmission covers in position NOTE The front transmission cover s oil fill plug faces rearward 8 120 Secure the transmission covers to the transmis sion with the hex flange screws removed earlier using...

Страница 37: ...formation refer to the Tuffy Tiller section UNIT FEATURES 6 5 Hp 4 cycle engine See the Image Below Protective bumper Power forward and reverse 16 tilling width 10 tine diameter Adjustable tilling dep...

Страница 38: ...ing the reverse clutch cable to the belt cover bracket using two 1 2 wrenches See Figure 1 7 1 8 Remove the reverse clutch cable s Z fitting from the reverse idler arm NOTE The reverse return spring w...

Страница 39: ...ully Engaged Threaded Clutch Cable End Hex Jam Nuts 2 5 Adjust both hex jam nuts until the exposed por tion of the reverse clutch cable is between 1 8 and 1 4 when it is engaged See Figure 2 5 2 6 Sec...

Страница 40: ...n using a 1 2 socket and wrench See Figure 3 4 3 5 Remove the reverse drive belt from the reverse idler pulley 3 6 Remove all four self tapping screws securing the pulley belt guard to the left and ri...

Страница 41: ...w Belleville Washer Transmission Pulley Figure 3 9 Transmission Pulley Inside Out Reverse Drive Belt Forward Drive Belt 4 REVERSE IDLER PULLEY ASSEMBLY 4 1 The following picture shows the reverse idle...

Страница 42: ...Troy Bilt Small Frame Tillers 38 6 TRANSMISSION OIL FILL PLUG 6 1 The following picture shows the location of the oil fill plug for the transmission See Figure 6 1 Figure 6 1 Transmission Oil Fill...

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