Section 2: Assembly
9
HANDLEBAR INSTALLATION
NOTE: Handlebar wiring from the oper-
ator presence controls (OPC) is connected
to a switch under the unit. DO NOT dis-
connect this wiring!
1. Before beginning assembly, disconnect
the spark plug wire from the spark plug.
2. Place the handlebars on the ground
behind the unit.
3. With the ends of the bridge (C,
Fig. 2-2) positioned as shown, insert the
bridge in between the handlebars into the
upper set of handlebar holes.
4. Align the holes in the plastic sleeves
(on the bottom ends of the handlebars)
with the corresponding handlebar holes in
the deck. For easier installation, apply a
small amount of oil to the sleeve ends.
5. Insert the bottom ends of the handle-
bars into their mounting brackets in the
deck (Fig. 2-3). Do not pinch or damage
the attached wiring. Align the screw holes
(it may be helpful to align the holes with a
punch or drift pin prior to installing the
screws in the next step).
NOTE: Position the handlebars with
thumb latches (F, Fig. 2-5) on the inner
sides of handlebars.
6. Secure each handlebar with a 5/16-18
x 2-1/4 hex head capscrew (A, Fig. 2-3)
and 5/16"-18 toplock nut (B).
NOTE: When correctly installed, the han-
dlebars feel loose. The looseness or “play”
is intentionally designed to reduce vibra-
tion which occurs during operation. The
rubber sleeves on the handlebar ends act
as “shock absorbers” and also help reduce
vibration.
WHEEL DRIVE CONTROL ROD
INSTALLATION
1. Place the control rods (D, Fig. 2-4)
BETWEEN the handlebars and UNDER the
bridge, with the threaded ends down. For
easier installation, apply oil or grease to
the threads. Thread the rods into the
pivots (E) twelve turns each. If necessary,
use a screwdriver or a punch to move the
pivots into position. Be sure that the wire
harness on each handlebar is located to
the outside of each control rod.
2. Insert the upper end of each control
rod (G, Fig. 2-5) into the plastic thumb
latch (F) slots, then outward through the
holes in the wheel drive levers (H).
3. Insert hair pin clips (J, Fig. 2-5)
through the hole in each control rod. Posi-
tion hair pin clips with loops up, as
shown.
CONTROL ROD ADJUSTMENT
1. With the controls positioned as shown
(Fig. 2-6), measure the gap between the
top of the slot in the thumb latch bracket
and the control rod. Do not put any pres-
sure on the handlebars when measuring.
The gap must measure 1-1/4" (32mm).
If adjustment is required, remove the hair
pin clip (J, Fig. 2-5) from the control rod.
Remove the control rod from the wheel
drive lever (H) and thumb latch (F). Turn
the control rod as needed to achieve the
1-1/4" (32mm) gap.
NOTE: Adjust the wheel drive control rods
properly. Improper adjustment will result
in broken thumb latches.
C
A
B
D
D
C
B
Install hair pins (D) OUTSIDE levers (C)
(l ft id
h
)
D
A
J on outside with loop up
Fig. 2-2
Fig. 2-3
Fig. 2-4
Fig. 2-5
Outer view of left handlebar
F
J
G
H
J
E
