Troy Bilt 645A Bronco Users Manual 769 00585 (21A 644H/645A063

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Operator’s Manual

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 arrester meeting applicable local or state laws (if any).

If a spark arrester 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.

IMPORTANT:READ SAFETY RULES AND INSTRUCTIONS CAREFULLY

TROY-BILT LLC, P.O. BOX 361131, CLEVELAND, OH 44136-0019

PRINTED IN USA FROM NO. 769-00585A

(01/2003)

Rear-tine Tiller Models

644H—BroncoTM

645A—BroncoTM

Model 644H Shown (bumper syles vary)

2

For more details about your unit, visit our website at www.troybilt.com

TABLE OF CONTENTS

Content Page

Calling Customer Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Features and Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Off-Season Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Warrany Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover

FINDING MODEL NUMBER

This Operator’s Manual is an important part of your new Rear-tineTiller. It will help you assemble, prepare and

maintain 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

ENGINE INFORMATION

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.

CALLING CUSTOMER SUPPORT

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- (330) 558-7220 or 1- (866) 840-6483 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 ..

Copy Model Number Here

Copy Serial Number Here

www.troybilt.com

TROY-BILT LLC

P. O. BOX

361131

CLEVELAND, OH 44136

866-840-6483

330-558-7220

3

Training

1. Carefully read this

Owner’s Manual, the

separate Engine Owner’s

Manual, and any other literature you may

receive. Be thoroughly familiar with the

controls and the proper use of the tiller

and its engine. Know how to stop the unit

and disengage the controls quickly.

2. Never allow children to operate the

tiller. Never allow adults to operate the

tiller without proper instruction.

3. Keep the area of operation clear of all

persons, particularly children and pets.

4. Keep in mind that the operator or user

is responsible for accidents or hazards

occurring to other people, their property,

and themselves.

Preparation

1. Thoroughly inspect the area where the

tiller is to be used and remove all foreign

objects.

2. Be sure all tiller controls are released

and both wheels are in the Wheel Drive

position before starting the engine.

3. Do not operate the tiller without

wearing adequate outer garments. Avoid

loose garments or jewelry that could get

caught in moving parts.

4. Do not operate the tiller when barefoot

or wearing sandals, sneakers, or light

footwear. Wear protective footwear that

will improve footing on slippery surfaces.

5. Do not till near underground electric

cables, telephone lines, pipes or hoses. If

in doubt, contact your telephone or utility

company.

6. Warning: Handle fuel with care; it is

highly flammable and its vapors are

explosive. Be sure to take the following

precautions:

a. Store fuel in containers specifically

designed for this purpose.

b. The gas cap shall never be removed

or fuel added while the engine is

running. Allow the engine to cool

for several minutes before adding

fuel.

c. Keep matches, cigarettes, cigars,

pipes, open flames, and sparks

away from the fuel tank and fuel

container.

d. Fill fuel tank outdoors with extreme

care. Never fill fuel tank indoors.

Use a funnel or spout to prevent

spillage.

e. Replace all fuel tank and container

caps securely.

f. If fuel is spilled, do not attempt to

start the engine, but move the

machine away from the area of

spillage and avoid creating any

source of ignition until fuel vapors

have dissipated.

7. Never make adjustments when engine

is running (unless recommended by

manufacturer).

Operation

1. Do not put hands or feet near or under

rotating parts. The tines begin to rotate

once the engine starts and the Forward

Clutch Bail (or Reverse Clutch Control) is

engaged.

2. Exercise extreme caution when on or

crossing gravel drives, walks, or roads.

Stay alert for hidden hazards or traffic. Do

not carry passengers.

3. After striking a foreign object, stop the

engine, remove the wire from the spark

plug and prevent it from touching the

spark plug, thoroughly inspect the

machine for any damage, and repair the

damage before restarting and operating

the machine.

4. Exercise caution to avoid slipping or

falling.

5. If the unit should start to vibrate abnor-

mally, stop the engine, disconnect the

spark plug wire and prevent it from

touching the spark plug, and check

immediately for the cause. Vibration is

generally a warning of trouble.

6. Stop the engine, disconnect the spark

plug wire and prevent it from touching

the spark plug whenever you leave the

operating position, before unclogging the

tines, or when making any repairs, adjust-

ments or inspections.

Section

1

Safety

SPARK ARRESTER WARNING TO RESIDENTS OF CALIFORNIA AND SEVERAL OTHER STATES

Under California law, and under the laws of several other states, you are not permitted to operate an

internal combustion engine using hydrocarbon fuels on any forest, brush, hay, grain, or grass

covered land; or land covered by any flammable agricultural crop without an engine spark arrester in

continuous effective working order.

The engine on the unit is an internal combustion engine which burns gasoline, a hydrocarbon fuel, and must be equipped with a

spark arrester muffler in continuous effective working order. The spark arrester must be attached to the engine exhaust system in

such a manner that flames or heat from the system will not ignite flammable material. Failure of the owner/operator of the unit to

comply with this regulation is a misdemeanor under California law (and other states) and may also be a violation of other state

and/or federal regulations, laws, ordinances or codes. Contact your local fire marshal or forest service for specific information

about which regulations apply in your area.

7. Take all possible precautions when

leaving the machine unattended. Stop the

engine. Disconnect spark plug wire and

move it away from the spark plug. Be

sure both wheels are in the Wheel Drive

position.

8. Before cleaning, repairing, or inspect-

ing, stop the engine and make certain all

moving parts have stopped. Disconnect

the spark plug wire and prevent it from

touching the spark plug to prevent acci-

dental starting.

9. The flap on the tine hood must be

down when operating the tiller.

10. Never use the tiller unless proper

guards, plates, or other safety protective

devices are in place.

11. Do not run engine in an enclosed

area. Engine exhaust contains carbon

monoxide gas, a deadly poison that is

odorless, colorless, and tasteless.

12. Keep children and pets away.

13. Never operate the tiller under

engine power if the wheels are in the

Freewheel position. In the Freewheel

position, the wheels will not hold the

tiller back and the revolving tines could

propel the tiller rapidly, possibly

causing loss of control. Always engage

the wheels with the wheel drive pins in

the Wheel Drive position before starting

the engine or engaging the tines/wheels

with the Forward Clutch Bail or the

Reverse Clutch Control .

14. Be aware that the tiller may unexpect-

edly bounce upward or jump backward

and be propelled toward you if the tines

should strike extremely hard packed soil,

frozen ground, or buried obstacles like

large stones, roots, or stumps. If in doubt

about the tilling conditions, always use

the following operating precautions to

assist you in maintaining control of the

tiller:

a. Walk behind and to one side of the

tiller, using one hand on the han-

dlebars. Relax your arm, but use a

secure hand grip.

b. Use a deep depth regulator

setting.

c. Use slower engine speeds.

d. Clear the tilling area of all large

stones, roots and other debris.

e. Avoid using downward pressure

on handlebars. If need be, use

slight upward pressure to keep the

tines from digging too deeply.

f. Before contacting hard packed soil

at the end of a row, reduce engine

speed and lift handlebars to raise

tines out of the soil.

g. In an emergency, stop tines and

wheels by releasing whichever

clutch control is engaged. Do not

attempt to restrain the tiller.

15. Do not overload the tiller’s capacity

by attempting to till too deeply at too fast

a rate.

16. Never operate the tiller at high

transport speeds on slippery surfaces.

Look behind and use great care when

backing up.

17. Do not operate the tiller on a slope

that is too steep for safety. When on

slopes, slow down and make sure you

have good footing. Never permit the tiller

to freewheel down slopes.

18. Never allow bystanders near the unit.

19. Only use attachments and acces-

sories that are approved by the manufac-

turer of the tiller.

20. Use tiller attachments and acces-

sories when recommended.

21. Never operate the tiller without good

visibility or light.

22. Never operate the tiller if you are

tired, or under the influence of alcohol,

drugs or medication.

23. Operators shall not tamper with the

engine-governor settings on the machine;

the governor controls the maximum safe

operating speed to protect the engine and

all moving parts from damage caused by

overspeed. Authorized service shall be

sought if a problem exists.

24. Do not touch engine parts which may

be hot from operation. Let parts cool

down sufficiently.

25. Please remember: You can always

stop the tines and wheels by releasing the

Forward Clutch control or the Reverse

Clutch control (whichever control you

have engaged), or by moving the throttle

control lever on the engine to “OFF” or

“STOP”.

26. To load or unload the tiller, see the

instructions in Section 4 of this Manual.

27. Use extreme caution when reversing

or pulling the machine towards you.

28. Start the engine carefully according to

instructions and with feet well away from

the tines.

29. Never pick up or carry a machine

while the engine is running.

Maintenance and Storage

1. Keep the tiller, attachments and acces-

sories in safe working condition.

2. Check all nuts, bolts, and screws at

frequent intervals for proper tightness to

be sure the equipment is in safe working

condition.

3. Never store the tiller with fuel in the

fuel tank inside a building where ignition

sources are present such as hot water

and space heaters, furnaces, clothes

dryers, stoves, electric motors, etc.).

Allow engine to cool before storing in any

enclosure.

4. To reduce the chances of a fire hazard,

keep the engine free of grass, leaves, or

excessive grease.

5. Store gasoline in a cool, well-ventilated

area, safely away from any spark- or

flame-producing equipment. Store

gasoline in an approved container, safely

away from the reach of children.

6. Refer to the Maintenance sections of

this Manual and the separate Engine

Owner’s Manual for instructions if the

tiller is to be stored for an extended

period.

7. Never perform maintenance while the

engine is running or the spark plug wire

is connected, except when specifically

instructed to do so.

8. If the fuel tank has to be drained, do

this outdoors.

4

Section 1: Safety

Section 1: Safety

5

Decals

For your safety and the safety of others,

various safety and operational decals are

located on your unit (see Figure 1 below).

Keep the decals clean and legible at all

times. Contact your local service dealer

or the factory for replacements if any

decals are damaged or missing.

Refer to the separate parts catalog for

decal locations, part numbers and

ordering instructions.

Forward Clutch Control

Operating Instruction

Reverse Clutch Control

Operating Instruction

Warning Messages

on tine hood

Hot Surfaces

Warning on belt cover

Starting Stabilization

Message on engine

Figure 1: Location of Safety and Operating Decals (Model 644H shown).

TO AVOID SERIOUS INJURY:

• READ THE OWNER’S MANUAL.

• KNOW LOCATIONS AND FUNCTIONS OF ALL CONTROLS.

• KEEP ALL SAFETY DEVICES AND SHIELDS IN PLACE AND WORKING.

• NEVER ALLOW CHILDREN OR UNINSTRUCTED ADULTS TO OPERATE TILLER.

• SHUT OFF ENGINE AND DISCONNECT SPARK PLUG WIRE BEFORE MANUALLY UNCLOG-

GING TINES OR MAKING REPAIRS.

• KEEP BYSTANDERS AWAY FROM MACHINE.

• KEEP AWAY FROM ROTATING PARTS.

• USE EXTREME CAUTION WHEN REVERSING OR PULLING THE MACHINE TOWARDS YOU.

WARNING

Operating Symbols

Various symbols (shown here, with word

descriptions) are used on the tiller and engine

(your unit may not have all of the symbols).

FAST SLOW

CHOKE

ON

CHOKE

OFF

STOP

STOP

REVERSE

R

ROTATING

TINES

BAIL

ENGAGED

BAIL

DISENGAGED

TILLER DIRECTION LEVER DIRECTION

6

WARNING

To prevent personal injury or

property damage, do not start

the engine until all assembly

steps are complete 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.

Loose Parts List

Qty. Description

1Handlebar Support (see A, Fig. 2-2,

page 7)

1Handlebar Assembly

(see K, Fig. 2-2)

The following items are in the

hardware bag:

1Slotted hd. screw, #10-24 x 2"

1Hex hd. screw, 1/4-20 x 1-1/4"

6Curved hd. screw, 5/16-18 x 1-1/2"

2Hex hd. screw, 3/8-16 x 3/4"

2Flat washer, 3/8"

6Split lockwasher, 5/16"

1Hex locknut, 1/4"-20

6Hex nut, 5/16"-18

2Hex locknut, 3/8"-16

1Hex nut, #10-24

1Spring, cable (see W, Fig. 2-5,

page 8)

1Bracket, forward clutch cable (see

P, Fig. 2-5, page 8)

1Bracket, 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.

Section

2

Assembly

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.

1

2

3

1

2

3

7

Section 2: Assembly

STEP 2: Attach Handlebar

1. Attach the two legs of the handlebar

support (A, Fig. 2-2) loosely to the inner

sides of the tiller frame using two 3/8"-16

x 3/4" hex hd. screws (B), 3/8" flat

washers (C) and 3/8"-16 hex locknuts (D).

2. Using the middle holes in the handlebar

support brackets (E and F, Fig. 2-2),

loosely attach the support brackets to the

handlebar support (A) using two 5/16"-18

x 1-1/2" curved hd. screws (G), 5/16" split

lockwashers (H) and 5/16"-18 hex nuts (I).

NOTE: If a support bracket will not move,

loosen attaching screw (J) and nut.

3. Attach the handlebar assembly (K) to

the handlebar support (A) using four

5/16"-18 x 1-1/2" curved hd. screws (G),

5/16" split lockwashers (H) and 5/16"-18

hex nuts (I). Tighten the four screws

securely.

4. Tighten all handlebar mounting

hardware securely.

STEP 3: Move Tiller Off Shipping

Platform

To move the tiller without the engine

running, put the wheels in their

FREEWHEEL position, as described below.

1. Use a sturdy block to raise one wheel

off the ground.

2. Remove the hairpin cotter (L, Fig. 2-3)

and wheel drive pin (M). Slide the wheel

inward on the wheel shaft (N). Reinstall

the wheel drive pin and hairpin cotter

through the wheel shaft only (not through

the wheel hub). Repeat with the other

wheel.

3. Using the handlebar as a lever, roll the

tiller to a flat area.

IMPORTANT: Before starting the engine,

the wheels must be placed in their WHEEL

DRIVE position (pins through wheel hubs

and wheel shaft). This procedure is

described in “Wheel Drive Pins” in

Section 3.

Fig. 2-2: Attach handlebar.

G

G

H

A

IH

F

E

I

HI

B

C

G

K

J

D

Fig. 2-3: Wheel in FREEWHEELING

position (wheel drive pin through wheel

shaft only).

M

N

L

8

Section 2: Assembly

STEP 4: Install Forward Clutch Cable

1. Place the forward clutch cable bracket

(P, Fig. 2-4) on the handlebar support (A).

Attach the cable bracket using a 1/4"-20 x

1-1/4" hex hd. screw (R, Fig. 2-4) and

1/4"-20 hex locknut (S). Tighten securely.

2. Carefully unwrap the forward clutch

cable (the cable without a knob attached to

it) from its shipping position and slide the

thin cable wire (T, Fig. 2-4) into the slot in

the cable bracket. Push the cable connector

(U, Fig. 2-4) up through the hole in the

bracket until the groove in the connector

snaps into place on the bracket.

3. Insert the #10-24 x 2" slotted hd. screw

(V, Fig. 2-5) down into the cable spring

(W). The threaded end of the screw will

extend from the bottom of the spring.

4. Thread the #10-24 hex nut (Z) on the

slotted head screw (V). Thread it halfway up.

5. Thread screw (V) into cable adjuster (X).

6. Hook cable spring (W, Fig. 2-6) into “V”-

shaped bend in the forward clutch bail (Y).

7. Lift and hold the Forward Clutch bail

against the handlebar. See Fig. 2-7.

8. Measure the length of the cable spring

between the ends of the coils (Fig. 2-7).

The length should be approximately 1-7/8".

If the length is correct, turn the #10-24 hex

nut (Z) down tightly against the cable

adjuster (X) while holding the adjuster in

place. See Figure 2-7. If the length is

incorrect, you must make an adjustment to

the cable tension as described in

“Checking and Adjusting Forward Drive

Belt Tension” in Section 5. When the

spring length is correct, tighten the hex nut

(Z) against the cable adjuster (X).

STEP 5: Install Reverse Clutch

Cable

1. Remove the two pre-installed self-tapping

screws (AA, Fig. 2-8) from the handlebars.

2. Position the reverse cable mounting

bracket (BB, Fig. 2-8) as shown and

reinstall the two self-tapping screws.

3. Unwrap the reverse clutch cable (the

cable with a knob and a large hex nut

attached to it) from around its shipping

position and route the cable (CC, Fig. 2-8

and Fig. 2-9) up to the cable bracket (BB,

Fig. 2-8). Be sure that the cable goes

beneath the Forward Clutch Bail as it is

routed up to the cable bracket.

Fig. 2-5: Assemble

spring and adjuster.

VZ

X

W

Fig. 2-6: Install forward clutch cable.

Fig. 2-4: Installing forward clutch cable bracket and cable.

Fig. 2-7: Measure cable spring.

1234

5

P

R

ST

Y

W

U

A

Hold bail against handlebar

while measuring spring

Z

X

9

Section 2: Assembly

Fig. 2-8: Install reverse cable mounting

bracket and the reverse clutch cable.

4. Insert the cable up through the slot in

the cable bracket and position the

threaded assembly as shown in Fig. 2-8.

Make sure that the flat side of the

threaded assembly is aligned with the flat

side of the mounting hole. Slide the large

hex nut (DD) up the cable and tighten it

securely.

5. Use a cable tie (EE, Fig. 2-9) to fasten

the reverse clutch cable to the left side

handlebar.

6. Test the function of the reverse clutch

cable by pulling the knob out and

releasing it. The knob should return to its

neutral position (resting against bracket)

when it is released. If it doesn’t, contact

your local dealer or the factory for

technical assistance.

STEP 6: Check Level of

Transmission Gear Oil

The transmission was filled with gear oil

at the factory. However, you should check

the gear oil level to make certain it is

correct.

IMPORTANT: Do not operate the tiller if

the gear oil level is low. Doing so will

result in severe damage to the transmis-

sion components.

1. Put the tiller on level ground. Pull the

Depth Regulator Lever (FF, Fig. 2-10)

back and then adjust it up or down to the

notch that makes the tiller level.

2. Remove the oil fill plug (GG, Fig. 2-11)

from the transmission housing and look

into the oil fill hole. You will see the main

drive shaft on one side of the hole.

3. The gear oil level is correct if the gear

oil is approximately halfway up the side of

the drive shaft.

4. If the gear oil level is low, add gear oil

by referring to “A. To Check the Transmis-

sion Gear Oil Level” in Section 5.

STEP 7: Add Motor Oil to Engine

The tiller is shipped without oil in the

engine.

IMPORTANT: Do not start the engine

without first adding motor oil. Severe

engine damage will result if the engine is

run without oil.

1. Refer to the Engine Owner’s Manual

(supplied with tiller) for engine oil specifi-

cations and capacities.

2. With the tiller on level ground, pull the

Depth Regulator Lever (FF, Fig. 2-10)

back and then slide it up or down as

necessary until the engine is level.

3. Add motor oil as described in the

Engine Owner’s Manual.

4. Move the Depth Regulator Lever all the

way down until the highest notch is

engaged. This places the tines in the

“travel” position.

STEP 8: Check Hardware for

Tightness

Check all nuts and screws for tightness.

CC

AA

AA

BB

Flat Side

DD

Fig. 2-9: Route reverse clutch cable (CC) as

shown. Attach to handlebar with cable tie

(EE).

CC

EE

Fig. 2-11: Remove gear oil fill plug.

Fig. 2-10: Adjust Depth Regulator Lever.

FF

GG

STEP 9: Check Air Pressure in

Tires)

Use a tire pressure gauge to check the air

pressure in both tires. Deflate or inflate

both tires equally to 15-to-20 PSI

(pounds per square inch). Be sure that

both tires are inflated equally or the unit

will pull to one side.

IMPORTANT: This completes the

assembly steps. Before operating your

tiller, make sure you read the following

Sections in this Manual, as well as the

separate Engine Owner’s Manual:

• Section 1: “Safety”

• Section 3: “Features and Controls”

• Section 4: “Operation”

Wheel Drive Pins

Each wheel is equipped with a Wheel

Drive Pin (A, Figures 3-2 and 3-3) that

secures the wheel to the wheel shaft (B).

The wheels can be positioned in either a

WHEEL DRIVE or a FREEWHEEL mode.

Before starting the engine, put both

wheels in the WHEEL DRIVE position by

inserting the Wheel Drive Pins through

the wheel hubs and the wheel shaft. This

“locks” the wheels to the wheel shaft,

causing the wheels to turn when either

the Forward Clutch Bail or the Reverse

Clutch Control is engaged.

Use the FREEWHEEL mode only when the

engine is not running. In FREEWHEEL,

the Wheel Drive Pins are placed only

through the holes in the wheel shaft (not

the wheel hubs), thus allowing the wheels

to turn freely when the tiller is pushed or

pulled by hand.

To Place the Wheels in WHEEL DRIVE or

FREEWHEEL:

1. Stop the engine, disconnect the spark

plug wire from the spark plug and allow

the engine to cool.

2. Raise one wheel off the ground and

place a sturdy support under the

transmission.

3. Remove the wheel drive pin (A,

Figures 3-2 and 3-3) by removing the

hairpin cotter (C).

WARNING

Never allow either of the

wheels to be in the

FREEWHEEL position when

the engine is running. Always

put both wheels in the WHEEL

DRIVE position before starting

the engine.

Failure to comply could cause

loss of tiller control, property

damage, or personal injury.

WARNING

Do not place the tiller on its

side when changing the wheel

drive positions as doing so

could result in gasoline

leaking from the fuel tank.

Failure to follow this instruc-

tion could result in personal

injury or property damage.

WARNING

Before operating your

machine, carefully 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

instructions can result in

serious personal injury.

Section

3

Features and Controls

Figure 3-1: Features and controls.

Wheel Drive Pin

(on each wheel)

Forward

Clutch Bail

Reverse Clutch

Control

Depth Regulator

Anti-Reverse Stake

Handlebar Height

Adjustment

10

Introduction

This section describes the locations and

functions of the controls on your tiller.

Refer to the next section (“Operation”)

for detailed operating instructions.

Practice using these controls, with the

engine shut off, until you understand the

operation of the controls and feel

confident with each of them.

IMPORTANT: Refer to the separate

engine manufacturer’s Engine Owner’s

Manual for information about the

controls on the engine.

11

Section 3: Features and Controls

4. FOR WHEEL DRIVE mode (Figure 3-2):

Slide the wheel outward and align the

holes in the wheel hub (D, Figure 3-2))

and the wheel shaft (B). Insert the wheel

drive pin (A) through the wheel hub and

the wheel shaft. Secure the wheel drive

pin with the hairpin cotter (C) by pushing

the hairpin cotter in as far as it will go.

Repeat for the other wheel and then

remove the support from beneath the

transmission.

5. FOR FREEWHEEL mode (Figure 3-3):

Slide the wheel inward and insert the

wheel drive pin (A, Figure 3-3) only

through the hole in the wheel shaft (B).

Secure the wheel drive pin with the

hairpin cotter (C) by pushing the hairpin

cotter in as far as it will go. Repeat for the

other wheel and then remove the support

from beneath the transmission.

Forward Clutch Bail

The Forward Clutch Bail (E, Figure 3-4)

controls the engagement of forward drive

to the wheels and power to the tines.

NOTE: The wheels will rotate in a forward

direction; the tines will rotate counter-

clockwise (backward toward the operator).

To Operate the Forward Clutch Bail:

1. Put the wheels in the WHEEL DRIVE

position (see the following “WARNING”

statement).

2. Lift and hold the bail against the

handlebar. The wheels and tines will

rotate– and the tiller will move in a

forward direction.

3. Release the bail to disengage (stop)

the wheels and tines. Forward tiller motion

will stop (the engine will continue to run).

Reverse Clutch Control

The Reverse Clutch Control (F, Figure 3-4)

controls the engagement of reverse drive

to the wheels and tines. This powered

reversing feature is used for maneuvering

the tiller only – never engage the tines in

the ground while going in the reverse

direction.

To Operate the Reverse Clutch Control:

1. Operate only when the wheels are in

the WHEEL DRIVE position (see the

“WARNING” statement at the left).

2. Stop all tiller motion by releasing the

Forward Clutch Bail.

3. Lift up the handlebar until the tines

clear the ground, look behind you to avoid

any obstacles, and then pull the reverse

clutch control knob toward you. The

wheels will rotate in a reverse direction.

4. Release the reverse clutch control

knob to disengage (stop) the wheels and

tines. All reverse motion will stop (the

engine will continue to run).

Figure 3-2: WHEEL DRIVE position.

A

B

D

C

Figure 3-3: FREEWHEEL position.

Figure 3-4: Forward Clutch Bail (E) and Reverse

Clutch Control (F).

A

EF

B

D

C

WARNING

Before starting the engine, be

sure that both wheels are in

the WHEEL DRIVE position.

See “Wheel Drive Pins” for

instructions.

Engaging the Forward Clutch

Bail or the Reverse Clutch

Control when the wheels are

not in the WHEEL DRIVE

position could allow the tines

to rapidly propel the tiller

forward or backward.

Failure to comply could cause

loss of tiller control, property

damage, or personal injury.

WARNING

• Use extreme caution when

reversing or pulling the

machine towards you. Look

behind to avoid obstacles.

• Never attempt to till in

reverse.

Failure to follow this warning

could result in personal injury

or property damage.

12

Section 3: Features and Controls

Depth Regulator Lever

This lever (G, Figure 3-5) controls the

tilling depth of the tines. Pull the lever

straight back and slide it up or down to

engage the notched height settings.

The highest notch (lever all the way

down) raises the tines approximately 1-

1/2" off the ground. This “travel” setting

allows the tiller to be moved without the

tines digging into the ground. Also use

this setting when starting the engine.

Move the lever upward to increase the

tilling depth. The lowest notch allows a

tilling depth of approximately 6"-8",

depending on soil conditions.

For best results, begin tilling at the

deepest depth possible without causing

the tiller to bog down. Increase the tilling

depth from one pass over the soil to the

next.

Handlebar Height Adjustment

The handlebar height is adjustable to

three different settings (see Figure 3-6).

As a general rule, adjust the handlebars

so they are at waist level when the tines

are 3"-4" into the soil.

To Adjust the Handlebars:

1. Stop the engine, disconnect the spark

plug wire from the spark plug and allow

the engine to cool.

2. Remove the screws, lockwashers and

nuts, reposition the handlebars, and

reinstall the hardware.

Anti-Reverse Stake

This stake is located at the rear of the

transmission, under the tine hood (see H,

Figure 3-7). Its purpose is to automati-

cally help prevent the counter-rotating

tines from letting the tiller back up in the

direction of the operator if the tiller

wheels had been inadvertently left in the

FREEWHEEL position. In this situation,

the Anti-Reverse Stake will be forced

down into the ground, lifting the tines

upward out of the soil and helping

prevent backward motion of the tiller.

The Anti-Reverse Stake requires no adjust-

ment, but should be inspected before

each tiller use to verify that it swivels

freely. Remove any clogged materials

(dirt, roots, rocks, etc.) that prevent the

Anti-Reverse Stake from swinging freely.

ENGINE CONTROLS

Refer to the engine manufacturer’s Engine

Owner’s Manual (included in the tiller lit-

erature package) to identify the controls

on your engine.

IMPORTANT: The control for stopping the

engine is located on the engine.

Figure 3-5: Depth regulator lever.

Travel

Position

Shallow

Settings Deep

Settings

G

Figure 3-6: Handlebar height adjustment.

Figure 3-7: Anti-Reverse Stake.

WARNING

• Place the Depth Regulator

Lever in the “travel”

position before starting the

engine. This position

prevents the tines from

touching the ground until you

are ready to begin tilling.

Failure to follow this warning

could result in personal injury

or property damage.

High

Low

Medium

H

13

Figure 4-1

Section

4

Operation

WARNING

Before operating your

machine, carefully read and

understand all safety (Section

1), controls (Section 3) and

operating instructions (Section

4) in this Manual, in the

separate Engine Owner’s

Manual, and on the decals on

the machine.

Failure to follow these instruc-

tions can result in serious

personal injury.

INTRODUCTION

Read this Section of the manual thor-

oughly before you start the engine. Then,

take the time to familiarize yourself with

the basic operation of the tiller before

using it in the garden. Find an open, level

area and practice using the tiller controls

without the tines engaging the soil (put

tines in “travel” setting). Only after

you’ve become completely familiar with

the tiller should you begin using it in the

garden.

INITIAL OPERATION

Perform the following maintenance during

the first hours of new operation (see

“Maintenance” section in this manual and

in the Engine Owner’s Manual).

1. Change engine oil after first 2 hours of

new engine operation.

2. Check for loose or missing hardware

on unit. Tighten or replace as needed.

3. Check tension on forward drive belt

after first 2 hours of operation.

4. Check transmission gear oil level after

first 2 hours of operation.

STARTING AND STOPPING THE

ENGINE

Pre-Start Checklist

Make the following checks and perform

the following services before starting the

engine.

1. Read the “Safety” and “Controls”

sections in this manual. Read the

separate Engine Owner’s Manual

provided by the engine manufacturer.

2. Check that the wheels are in the

WHEEL DRIVE position (wheel pins must

be through the wheel hubs and the wheel

shaft holes).

3. Check unit for loose or missing

hardware. Service as required.

4. Check engine oil level. See Engine

Owner’s Manual.

5. Check that all safety guards and

covers are in place.

6. Check air cleaner and engine cooling

system. See Engine Owner’s Manual.

7. Attach spark plug wire to spark plug.

8. Fill the fuel tank with gasoline

according to the directions in the

separate Engine Owner’s Manual. Follow

all instructions and safety rules carefully.

Forward Clutch Bail

Depth Regulator Lever

Anti-Reverse Stake

Recoil Starter Wheel Drive Pin

(on each wheel)

Reverse Clutch Control

(knob on back of bracket)

DANGER

GASOLINE IS HIGHLY

FLAMMABLE AND ITS

VAPORS ARE EXPLOSIVE.

Follow gasoline safety rules in

this manual (see Section 1)

and in the separate Engine

Owner’s Manual.

Failure to follow gasoline

safety instructions can result

in serious personal injury

and property damage.

Starting the Engine

The following steps describe how to start

and stop the engine. Do not attempt to

engage tines or wheels until you have

read all the operating instructions in this

Section. Also review the safety rules in

Section 1: “Safety” and the tiller and

engine controls information in Section

3: “Features and Controls.”

1. Complete the “Pre-Start Checklist” on

the previous page.

2. Put the wheels in the WHEEL DRIVE

position (see “Wheel Drive Pins” in

Section 3).

3. Put the Depth Regulator Lever in the

“travel” position (lever all the way down)

so that the tines are clear of the ground.

4. Release all controls on the tiller.

5. If engine is equipped with a fuel valve,

turn valve to open position as instructed

in the separate Engine Owner’s Manual.

6. Put ignition switch and/or throttle

control lever on engine in “ON,” “RUN,”

“FAST” or “START” position as instructed

in the separate Engine Owner’s Manual.

7. Choke or prime engine as instructed in

the separate Engine Owner’s Manual.

8. Place one hand on the fuel tank to

stabilize the unit when you pull the starter

handle. Use the recoil starter rope to start

the engine as instructed in the separate

Engine Owner’s Manual. When engine

starts, gradually move choke lever (on

engines so equipped) to “NO CHOKE,”

“CHOKE OFF” or “RUN” position.

9. Use the “FAST” throttle speed setting

when tilling.

Stopping the Engine and Tiller

1. To stop the wheels and tines, release

the Forward Clutch Bail or the Reverse

Clutch Control — whichever control is in

use.

2. To stop the engine, put the throttle

control lever on engine in “OFF” or

“STOP” position.

OPERATING THE TILLER

The following pages provide guidelines to

using your tiller effectively and safely in

various gardening applications. Be sure

to read “Tilling Tips & Techniques” in this

Section before you actually put the tines

into the soil.

This is a CRT (counter-rotating tine) tiller.

As the wheels pull forward, the tines

rotate backward.

CAUTION

To help prevent serious

personal injury or damage to

equipment:

• Before starting engine, put

both wheels in the WHEEL

DRIVE position. Never have

the wheels in the

FREEWHEEL position when

the engine is running. When

the wheels are in

FREEWHEEL, they do not

hold back the tiller and the

tines could propel the tiller

rapidly backward.

• Before starting engine, put

Forward Clutch Bail (all

Models) and Reverse Clutch

Control in neutral (disen-

gaged) positions by releasing

levers.

• Never run engine indoors or

in enclosed, poorly venti-

lated areas. Engine exhaust

contains carbon monoxide,

an odorless and deadly gas.

• Avoid engine muffler and

nearby areas. Temperatures

in these areas may exceed

150oF.

This creates an “uppercut” tine action

which digs deeply, uprooting soil and

weeds. Don’t overload the engine, but dig

as deeply as possible on each pass. On

later passes, the wheels may tend to spin

in the soft dirt. Help them along by lifting

up slightly on the handlebar (palm facing

up).

1. Follow the “Pre-Start Checklist” on the

previous page. Be sure that the wheels

are in the WHEEL DRIVE position.

2. Put the Depth Regulator Lever in the

“travel” position (lever all the way down)

so that the tines are clear of the ground.

Use this position when practicing with

your tiller or when moving to or from the

garden. When you are ready to begin

tilling, you must move the Depth

Regulator Lever to the desired depth

setting (see “Tilling Tips & Techniques”).

Check that the Anti-Reverse Stake swivels

freely back and forth. Remove any clogged

material on or around the stake.

3. Start the engine and allow it to warm

up. When warm, put throttle control in

fast speed setting.

4. For forward motion of wheels and

power to the tines:

(a) Pull the Forward Clutch Bail up and

hold it against the handlebar. Release

the bail to stop forward motion of

the wheels and power to the tines.

(b) As the tiller moves forward, relax and

let the wheels pull the unit along while

the tines dig. Walk behind and a

little to one side of the tiller. Use a

light but secure grip with one hand

on the handlebars, keeping your arm

loose. See Figure 4-2.

Section 4: Operation

WARNING

Keep away from rotating

tines. Rotating tines will

cause injury.

WARNING

WARNING

Hot surfaces can cause severe

burns. Do not touch muffler or

adjacent areas.

Figure 4-2: Use one hand to guide tiller

when moving forward.

14

Section 4: Operation

Let the tiller move at its own pace and do

not push down on the handlebars to try to

dig deeper– this takes weight off the

wheels, cuts traction, and causes the tines

to try and propel the tiller.

5. For reverse motion of the wheels and

tines:

(a) Look behind and exercise caution

when operating in reverse. Do not

till while in reverse.

(b) Stop all forward motion before

reversing. Lift the handlebars with

one hand until the tines are off the

ground and then pull the Reverse

Clutch Control knob out to engage

reverse motion (see Figure 4-3). To

stop reverse motion, let go of the

Reverse Clutch Control knob.

6. To Turn the Tiller Around:

(a) Practice turning the tiller in a level,

open area. Be very careful to keep

your feet and legs away from the

tines.

(b) To make a turn, lift the handlebars

until the engine and tines are

balanced over the wheels (Figure

4-4). The tines must be out of the

ground while turning the tiller.

(c) With the tiller balanced, push

sideways on the handlebar to move

the tiller in the direction of the turn

(Figure 4-5). After completing the

turn, slowly lower the tines into the

soil to resume tilling.

Turning the Tiller Around

Figure 4-3: Raise tines off ground and look

behind when moving in reverse.

Figure 4-4: To begin turn, lift handlebars

until engine and tines are balanced over

wheels. Be sure tines are out of ground.

Figure 4-5: With tiller balanced over

wheels (and tines out of the ground), push

handlebars sideways to turn tiller.

WARNING

Do not push down on the

handlebars to try to make the

tiller till more deeply. This

prevents the wheels from

holding the tiller back and can

allow the tines to rapidly

propel the tiller backward

toward the operator, which

could result in loss of control,

property damage, or personal

injury.

Stopping the Tiller and Engine

1. To stop the wheels and tines, release

the Forward Clutch Bail or the Reverse

Clutch Control –whichever is engaged.

2. To stop the engine, move the throttle

control lever on engine to “OFF” or

“STOP” position.

15

WARNING

Before tilling, contact your

telephone or utilities company

and inquire if underground

equipment or lines are used in

your area. Their representa-

tive will be glad to answer

your questions and tell you if

any of their equipment or lines

are buried underground on

your property.

16

Section 4: Operation

Tilling Tips &Techniques

Let the tiller do the work

• While tilling, relax and let the wheels

pull the tiller along while the tines do

the digging. Walk on the side that is

not yet finished (to avoid making foot-

prints in the freshly tilled soil) and

lightly, but securely grip the handlebar

with just one hand. See Figure 4-2.

• Avoid the temptation to push down on

the handlebars in an attempt to force

the tiller to dig deeper. Doing so takes

the weight off the powered wheels,

causing them to lose traction. Without

the wheels helping to hold the tiller

back, the tines will attempt to propel

the tiller backward toward the

operator– often causing the tiller to

skip rapidly across the ground.

Tilling depths

• When preparing the soil, till a fresh

path on each pass rather than overlap-

ping passes. This gives the wheels

maximum traction on undisturbed soil.

See Figure 4-6. Dig as deeply as

possible on each pass without over-

loading the engine. Later passes can

be overlapped. (Watering the garden

area a few days prior to tilling will

make tilling easier, as will letting the

newly worked soil set for a day or two

before making a final, deep tilling

pass.)

• When cultivating (breaking up the

surface soil around plants to help

destroy weeds), adjust the tines to dig

only 1-1/2" to 2" deep. Using shallow

tilling depths helps prevent injury to

plants whose roots often grow close to

the surface. If needed, lift up on the

handlebars slightly to prevent the tines

from digging too deeply. Cultivating on

a regular basis not only eliminates

weeds, it also loosens and aerates the

soil for better moisture absorption and

faster plant growth.

Avoid tilling soggy, wet soil

Tilling wet soil often results in large,

hard clumps of soil that can interfere

with planting. If time permits, wait a day

or two after heavy rains to allow the soil

to dry before tilling. Test soil by

squeezing it into a ball. If it compresses

too easily, it is too wet to till.

Avoid making footprints

Whenever possible, walk on the untilled

side of the unit to avoid making foot-

prints in your freshly tilled or cultivated

soil. Footprints cause soil compaction

that can hamper root penetration and

contribute to soil erosion. They can also

“plant” unwanted weed seeds back into

the freshly tilled ground.

Choosing correct wheel

and tine speeds

With experience, you will find the “just

right” tilling depth and tilling speed

combination that is best for your

garden.

Set the engine throttle lever at a high

enough speed to give the engine

adequate power and yet allow it to

operate without overloading it. Fastest

engine speeds may be desirable when

making final passes through the

seedbed or when cultivating. Selection

of the correct engine speed, in relation

to the tilling depth, will ensure a suffi-

cient power level to do the job without

causing the engine to labor.

Suggested tilling patterns

• When preparing a seedbed, go over

the same path twice in the first row,

then make individual passes right next

to each other (see Figure 4-6). When

finished in one direction, make second

passes at a right angle as shown in

Figure 4-7.

In very hard ground it may take three

or four overlapping passes to thor-

oughly pulverize the soil. (See Figure

4-8.)

• If the garden size will not permit

lengthwise and then crosswise tilling,

then overlap the first passes by one-

half a tiller width, followed by succes-

sive passes at one-quarter width (see

Figure 4-8).

• With planning, you can allow enough

room between rows to cultivate (see

Figure 4-9). Leave room for the hood

width, plus enough extra room for

future plant growth.

1

2

3

Figure 4-6

Figure 4-7

Figure 4-8

Figure 4-9

17

Section 4: Operation

Tilling Tips &Techniques

Clearing the tines

Dry grass, stringy stalks or tough vines

may become tangled in the tines. Follow

these procedures to help avoid tangling

and to clean the tines, if necessary.

• To reduce tangling, set the depth

regulator to maximum depth.

• While tilling, try swaying the handle-

bars from side to side (about 6" to 12").

This “fishtailing” action often clears the

tines of debris.

• If tangling occurs, lift the tines out of

the soil and run the tiller in reverse for

a few feet. This may unwind a good

deal of debris.

• It may be necessary to remove the

debris by hand (a pocket knife will help

you to cut away the material).

Tilling on slopes

If you must garden on a moderate slope,

please follow two very important guide-

lines:

1. Till only on moderate slopes, never on

steep ground where footing is difficult

(review safety rules in the “Safety”

section of this manual).

2. We recommend tilling up and down

slopes rather than terracing. Tilling

vertically on a slope allows maximum

planting area and also leaves room for

cultivating.

IMPORTANT: When tilling on slopes, be

sure the correct oil level is maintained in

the engine (check every one-half hour of

operation). The incline of the slope will

cause the oil to slant away from its

normal level and this can starve engine

parts of required lubrication. Keep the

engine oil level at the full point at all

times!

A. Tilling up and down slopes:

• To keep soil erosion to a minimum, be

sure to add enough organic matter to

the soil so that it has good moisture-

holding texture and try to avoid leaving

footprints or wheel marks.

• When tilling vertically, try to make the

first pass uphill as the tiller digs more

deeply going uphill than it does

downhill. In soft soil or weeds, you

may have to lift handlebars slightly

while going uphill.

B. Tilling across slopes without

using terraces:

If previously described tilling methods

aren’t practical for you, then you can till

laterally across a slope. However, we

don’t really recommend this method as

it can create unsure footing and invites

soil erosion.

WARNING

Before clearing the tines by

hand, stop the engine, allow

all moving parts to stop and

disconnect the spark plug

wire.

Failure to follow this warning

could result in personal

injury.

18

Section 4: Operation

LOADING AND UNLOADING THE

TILLER

• Before loading or unloading, stop the

engine, wait for all parts to stop

moving, disconnect the spark plug wire

and let the engine and muffler cool.

• The tiller is too heavy and bulky to lift

safely by one person. Two or more

people should share the load.

• Use sturdy ramps and manually (engine

shut off) roll the tiller into and out of the

vehicle. Two or more people are needed

to do this.

• Ramps must be strong enough to

support the combined weight of the tiller

and any handlers. The ramps should

provide good traction to prevent

slipping; they should have side rails to

guide the tiller along the ramps; and

they should have a locking device to

secure them to the vehicle.

• The handlers should wear sturdy

footwear that will help to prevent

slipping.

• Position the loading vehicle so that the

ramp angle is as flat as possible (the

less incline to the ramp, the better).

Turn the vehicle’s engine off and apply

its parking brake.

• When going up ramps, stand in the

normal operating position and push the

tiller ahead of you. Have a person at

each side to turn the wheels.

WARNING

Loading and unloading the

tiller into or from a vehicle is

potentially hazardous. We

don’t recommend doing so

unless absolutely necessary,

as this could result in person-

al injury or property damage.

However, if you must load or

unload the tiller, follow the

guidelines given next.

• When going down ramps, walk

backward with the tiller following you.

Keep alert for any obstacles behind you.

Position a person at each wheel to

control the speed of the tiller. Never go

down ramps tiller-first, as the tiller could

tip forward.

• Use wooden blocks to place on the

downhill side of the wheels if you need

to stop the tiller from rolling down the

ramp. Also, use the blocks to temporar-

ily keep the tiller in place on the ramps

(if necessary), and to chock the wheels

in place after the tiller is in the vehicle.

• When the tiller is in the vehicle, prevent

it from rolling by chocking the wheels

with blocks and securely tie the tiller

down.

19

Section

5

Maintenance

REQUIRED MAINTENANCE SCHEDULE

Before Every Every As

PROCEDURE Each 10 30 Noted

Use Hours Hours

Check engine oil level •And every 5

operating hours

Clean engine •▲

Check drive belt tension •✝

Check nuts and bolts •✝

Change engine oil •*

Lubricate tiller •

Service engine air cleaner system ▲

Check gear oil level in •✝

transmission

Check tines for wear •

Check air pressure in tires

(if pneumatic) •

Service spark plug ▲

Check Anti-Reverse Stake •

* Change more frequently in dusty or dirty conditions. Change after first 2 hours of

break-in operation.

✝ Check after first 2 hours of break-in operation.

▲See Engine Owner’s Manual for service intervals and instructions.

WARNING

Before inspecting,

cleaning or servicing the

machine, shut off engine,

wait for all moving parts to

come to a complete stop,

disconnect spark plug wire

and move wire away from

spark plug.

Failure to follow these

instructions can result in

serious personal injury or

property damage.

20

Section 5: Maintenance

TILLER LUBRICATION

Proper lubrication of the tiller is an

essential part of maintenance. After

every 10 operating hours, oil or grease

the lubrication points shown in Figures

5-1 and 5-1A and described below.

Use a good quality lubricating oil (#30

weight engine oil is suitable) and a quality

general purpose grease (with a metal

lubricant, if available).

• Remove wheels, clean wheel shaft (A,

Fig. 5-1) and apply thin coating of

grease to the shaft.

• Grease back, front and sides of depth

regulator lever (B, Fig. 5-1).

• Remove tines, clean tine shafts (C, Fig.

5-1). Inspect for rust, rough spots or

burrs (look around holes). File or sand

smooth, coat ends of shaft with grease.

• Oil the threads on the handlebar height

adjustment screws and the handlebar

attaching screws (D, Fig. 5-1).

• Shifting Mechanism. Lightly oil pivot

points for smooth operation (E, Fig. 5-1A).

TRANSMISSION GEAR OIL SERVICE

Check the transmission gear oil level after

every 30 hours of operation or whenever

you notice any oil leak. Operating the

tiller when the transmission is low on oil

can result in severe damage.

A. To Check the Transmission

Gear Oil Level:

1. Check the gear oil level when the trans-

mission is cool. Gear oil will expand in

warm operating temperatures and this

expansion will provide an incorrect oil

level reading.

2. With the tiller on level ground, adjust

the Depth Regulator Lever up or down to

the notch that makes the tiller level..

3. Remove the oil fill plug (A, Fig. 5-2)

from the transmission housing and look

into the oil fill hole. You will see the main

drive shaft on one side of the hole.

4. The gear oil level is correct if the gear

oil is approximately half way up the side

of the drive shaft.

5. If the gear oil level is low, add gear oil

as described next. If the gear oil level is

okay, securely replace the oil fill plug.

IMPORTANT: Do not operate the tiller if

the gear oil level is low. Doing so will

result in severe damage to the transmis-

sion components.

6. If adding only a few ounces of gear

oil, use API rated GL-4 or GL-5 transmis-

sion gear oil having a viscosity of SAE

140, SAE 85W-140 or SAE 80W-90. If

refilling an empty transmission, use only

GL-4 transmission gear oil having a

viscosity of SAE 85W-140 or SAE 140.

NOTE: Do not use automatic transmission

fluid or engine oil in the transmission.

7. While checking frequently to avoid

overfilling, slowly add gear oil into the oil

fill hole until it reaches the halfway point

on the drive shaft.

8. Securely replace the oil fill plug.

CHECK FOR OIL LEAKS

Before each use, check your tiller for

signs of an oil leak – usually a dirty, oily

accumulation either on the unit or on the

floor where it has been parked.

A little seepage around a cover or oil seal

is usually not a cause for alarm. However,

if the oil drips overnight then immediate

attention is needed as ignoring a leak can

result in severe transmission damage.

If a cover is leaking, try tightening any

loose screws. If the screws are tight, a

new gasket or oil seal may be required. If

the leak is from around a shaft and oil

seal, the oil seal probably needs to be

replaced. See your authorized dealer or

contact the factory for service or advice.

IMPORTANT: Never operate the tiller if

the transmission is low on oil. Check the

oil level after every 30 hours of operation

and whenever there is any oil leakage.

CHECK HARDWARE

Check for loose or missing hardware after

every 10 operating hours. Tighten or

replace hardware before using the tiller.

Be sure to check the screws underneath

the tiller hood (lift the hood flap) that

secure the transmission cover and the

depth regulator lever to the transmission.

CHECK TIRE PRESSURE (on

machines equipped with

pneumatic tires)

Check the air pressure in both tires.

Deflate or inflate both tires evenly from

15-to-20 PSI (pounds per square inch).

Be sure that both tires have the same air

pressure or the unit will tend to pull to

one side.

NOTE: Your tiller may not be equipped

with pneumatic tires, eliminating the need

for air pressure checks.

Figure 5-1

A

B

C

D

D

WARNING Before inspecting, cleaning or servicing the unit, shut off engine, wait for all

parts to come to a complete stop, disconnect spark plug wire and move wire away from spark

plug. Failure to follow these instructions can result in serious personal injury or

property damage.

E

Figure 5-1A

Section 5: Maintenance

B. To Drain the Transmission Gear Oil:

The transmission gear oil does not need

to be changed unless it has been contam-

inated with dirt, sand or metal particles.

1. Drain gasoline from the fuel tank or

run the engine until the fuel tank is empty.

See “DANGER” statement above.

2. Drain the oil from the engine.

3. Remove the four screws (B, Figure 5-2)

and washers from the transmission cover

and remove the cover and gasket.

4. Remove the left-side wheel.

5. Tilt the left-side wheel shaft into a

drain pan and allow the gear oil to drain

through the top of the transmission.

6. After draining oil, reinstall the wheel,

install a new gasket (do not reuse old

gasket) and screw on transmission cover.

7. Refill transmission using GL-4 gear oil

(SAE 85W-140 or SAE 140).

8. Refill the engine with motor oil and

replenish the fuel tank with gasoline.

TINES

The tines wear with use and they should

be inspected at the beginning of each

tilling season and after every 30 operating

hours. The tines can be replaced individ-

ually or as a complete set. Refer to the

Parts List Section of this manual for tine

identification information.

NOTE: You must first remove the tiller

hood before removing either a single tine

holder or individual tines. Remove the

two screws at the front of the hood and

the two screws at the rear of the hood

and lift off the hood. Be sure to replace

the hood securely after changing a tine or

tine holders.

A. Tine Inspection:

With use, the tines will become shorter,

narrower and pointed. Badly worn tines

will result in a loss of tilling depth and

reduced effectiveness in general, and

specifically when chopping up and

turning under organic matter.

B. Removing and Installing

Tine Assemblies

1. Use a 9/16" socket, 6" extension, a

ratchet, and a 9/16" box end wrench to

loosen the nut (A, Figure 5-3) and screw

(B) that secure the tine holder to the tine

shaft.

2. Use a rubber mallet to tap the tine

holder loose. Slide tine assembly off.

3. Repeat Steps 1 and 2 above to remove

the other tine assembly.

4. Installing the tine assembly is simply

the reverse of its removal. First be sure

to remove any rust, uneven spots or burrs

from the tine shaft using fine sandpaper.

Then grease the tine shaft before rein-

stalling the tine assemblies. Be sure all

the cutting edges face so they will enter

the soil first when the tiller is moving

forward– this means the cutting edge on

the top of each tine faces toward the

operator position. Tighten hardware.

C. Removing and Installing

Individual Tines

1. Use two 9/16" box end wrenches to

remove the two screws (C, Figure 5-3)

and nuts (D) that secure the tine to its

tine holder.

NOTE: If the nuts are rusted, apply pene-

trating oil, then loosen the hardware.

2. When installing individual tines, do so

in the reverse order from which they were

removed. The two sets of inboard tines

are installed so one set faces toward the

transmission and the other faces away

from it. The single outboard tine set

faces toward the transmission housing.

Also be sure the cutting edge at the top

of each tine faces toward the operator

position. (See Figure 5-3.)

Figure 5-2: Remove oil fill plug (A) to check

gear oil level and to add gear oil. Remove

four cover screws (B) to drain gear oil.

WARNING Before inspecting, cleaning or servicing the unit, shut off engine, wait for all

parts to come to a complete stop, disconnect spark plug wire and move wire away from spark

plug. Failure to follow these instructions can result in serious personal injury or

property damage.

A

B

B

DANGER

Gasoline is highly flammable

and its vapors explosive. Fol-

low these safety practices to

prevent injury or property

damage from fire or explosion.

• Allow the engine and

muffler to cool before

draining the tiller’s gasoline

tank.

• Do not allow open flames,

sparks, matches or smoking

in the area.

• Wipe away spills and push

tiller away from spilled fuel.

• Use only an approved fuel

container and store it safely

out of the reach of children.

• Do not store gasoline where

its vapors could reach an

open flame or spark, or

where ignition sources are

present (such as hot water

and space heaters, furnaces,

clothes dryers, stoves,

electric motors, etc.) WARNING

This is a CRT (counter-rotating

tine) tiller and its tines must

be mounted in the direction

shown in Figure 5-3. If

mounted with curves in the

opposite direction, tiller will

dig poorly and be more likely

to run backward.

Failure to comply could result

in personal injury or property

damage.

21

22

Clutch Bail all the way up to the bottom of

the upper handlebars, you will need to

loosen the belt tension.

Also check the belt for cracks, cuts or

frayed edges and replace it as soon as

possible.

• Check belt tension after the first two

hours of initial operation (new belt).

• Check belt tension after every 10

operating hours.

To Check Forward Belt Tension:

1. Be sure that the engine is stopped and

the spark plug wire is disconnected and

moved away from the spark plug.

2. Loosen nut “C” (Figure 5-4) several

turns so it is about halfway up the

threaded adjustment screw.

3. Lift the Forward Clutch Bail up and

hold it to the bottom of the handlebars.

Measure the length of the clutch bail

spring (A, Figure 5-4) with a ruler. If the

belt tension is correct, the length of the

coiled portion of the spring should be

approximately 1-7/8". Nut “C” should

then be snugged down against the top of

the adjuster (B).

4. If the spring is too short, the belt

tension will be too loose. If the spring is

too long, the belt tension will be too tight.

5. To adjust the length of the spring,

release the Forward Clutch Bail. Thread

the hex nut (C, Fig. 5-4) halfway up the

adjustment screw. Turn the screw inside

the spring (A, Figure 5-4) counterclock-

wise (as viewed from the operator’s

position) while holding the adjuster (B)

steady to increase the length of the

spring, or turn clockwise (as viewed from

the operator’s position) to decrease the

length of the spring.

NOTE: If you have difficulty holding the

adjuster steady by hand, use a pliers or

wrench on the adjuster. While you turn

the screw, keep the Forward Clutch Cable

Figure 5-3: Tines, tine holders and installation hardware.

Section 5: Maintenance

WARNING Before inspecting, cleaning or servicing the unit, shut off engine, wait for all

parts to come to a complete stop, disconnect spark plug wire and move wire away from spark

plug. Failure to follow these instructions can result in serious personal injury or

property damage.

ENGINE

TINE

SHAFT

DENOTES CUTTING EDGE

OF TINE

A

D

C

C

Figure 5-4: Lift bail and check length of Clutch Bail Spring to check for correct belt tension

(1-7/8").

12345

A

C

B

B

OPERATOR

POSITION

CHECKING AND ADJUSTING

FORWARD DRIVE BELT TENSION

Maintaining correct tension on the

forward drive belt is important to good

tilling performance and long belt life. A

loose belt will slip on the engine and

transmission pulleys and cause the tines

and wheels to slow down – or stop com-

pletely – even though the engine is

running at full speed. A loose belt can

also result in premature belt wear.

If you find you can not bring the Forward

Section 5: Maintenance

WARNING Before inspecting, cleaning or servicing the unit, shut off engine, wait for all

parts to come to a complete stop, disconnect spark plug wire and move wire away from spark

plug. Failure to follow these instructions can result in serious personal injury or

property damage.

from turning by gripping the upper end of

the threaded adjuster (B) with pliers.

6. Repeat Step 3 to measure the length

of the clutch bail spring. Once the length

is correct, retighten the hex nut against

the top of the adjuster.

Forward Belt Replacement Information

If the drive belt needs to be replaced, see

your local authorized dealer or phone the

factory as instructed on Page 2. Refer to

the Parts List in the back of this manual

for correct components Use only OEM

(Original Equipment Manufacturer) fre-

placement belts. A substitute belt may

not perform satisfactorily. The procedure

requires average mechanical ability and

commonly available tools.

FORWARD CLUTCH

BAIL ADJUSTMENT

If the Forward Clutch Bail does not

function properly, first check that the

forward drive belt is adjusted properly

(see “Checking and Adjusting Forward

Drive Belt Tension”). If this fails to

correct the problem, contact the factory

technical service department or your

authorized dealer for service advice.

CHECKING AND ADJUSTING

REVERSE DRIVE BELT TENSION

Maintaining correct tension on the

reverse drive belt is important to good

performance and long belt life. A loose

belt will slip on the engine and transmis-

sion pulleys and cause the tines and

wheels to slow down – or stop com-

pletely – even though the engine is

running at full speed. A loose belt can

also result in premature belt wear.

If there is no reverse action when the

Reverse Clutch Control knob is pulled

out, then the belt tension is too loose.

When checking belt tension, also check

the belt for cracks, cuts or frayed edges

and replace it as soon as possible.

• Check belt tension after the first two

hours of break-in operation (new belt).

• Check belt tension after every 10

operating hours.

To Check Reverse Belt Tension:

1. Be sure that the engine is stopped and

the spark plug wire is disconnected and

moved away from the spark plug.

2. Remove the screw in the plastic belt

cover and slide the cover (which is

attached to the forward clutch cable) out

of the way.

3. Have an assistant pull the Reverse

Clutch Control knob all the way out and

hold it in that position. Measure the

length of the cable wire between the end

of the threaded cable adjuster (A, Figure

5-5) and the end of the Z-fitting (B) to

which the cable wire is attached.

4. The belt tension is ideal if the cable

wire length measures between 1/8" to

1/4". If the length is less than 1/8" (and if

there is no reverse action when the tiller

is running), then make the following

adjustments. NOTE: If the length is more

than 1/4", no adjustment is needed, as

long as the reverse action functions

properly.

5. Release the Reverse Clutch Control

knob. Unthread the inner jam nut (C,

Figure 5-6) one to two turns and pull the

threaded cable adjuster (A, Figure 5-6) to

the left until the inner jam nut rests

against the bracket.

6. Prevent the inner jam nut (C) from

turning and tighten the outer jam nut (D)

against the bracket. Prevent the outer

jam nut (D) from turning and tighten the

inner jam nut (C) against the bracket.

7. Measure the gap by repeating Step 3.

Readjust as needed by repeating Steps 5

and 6.

8. Reinstall the belt cover.

Reverse Belt Replacement Information

If the drive belt needs to be replaced, see

your local authorized dealer or phone the

factory as instructed on Page 2. Refer to

the Parts List in the back of this manual

for correct components Use only OEM

(Original Equipment Manufacturer) fre-

placement belts. A substitute belt may

not perform satisfactorily. The procedure

requires average mechanical ability and

commonly available tools.

Figure 5-5: Measure cable wire length to

check for correct reverse belt tension.

A B

Figure 5-6: Move threaded

adjuster (A) to left to

increase belt tension.

DCA

23

24

Section 5: Maintenance

WARNING Before inspecting, cleaning or servicing the unit, shut off engine, wait for all

parts to come to a complete stop, disconnect spark plug wire and move wire away from spark

plug. Failure to follow these instructions can result in serious personal injury or

property damage.

ENGINE OIL SERVICE

Check the engine oil level before starting

the engine each day and check it after each

5 hours of continuous operation. Running

the engine when it is low on oil will quickly

ruin the engine.

It is recommended that you change the

motor oil after every 10 hours of operation

and even sooner when operating in

extremely dirty or dusty conditions. Refer

to the separate Engine Owner’s Manual for

detailed service instructions.

A. To Check the Engine Oil Level:

1. Move the tiller to a level area and shut

off the engine.

2. Level the engine by adjusting the Depth

Regulator Lever. The tines must be in

contact with the ground. Move the Anti-

Reverse Stake back if necessary.

3. Clean the area around the oil dipstick or

oil fill tube to prevent dirt from falling into

the crankcase.

4. On engines with an oil fill tube, remove

the filler cap, add oil (if required) until it

reaches the top of the tube and reinstall the

filler cap.

5. On engines with a dipstick, remove it,

wipe it clean, and reinstall it finger-tight.

Remove the dipstick and check the reading.

Add oil (if required) to bring the level to the

FULL mark. Do not overfill.

B. To Change the Engine Oil:

Change the engine oil as instructed in the

separate Engine Owner’s Manual.

ENGINE CLEANING

Keep the engine clean to assure smooth

operation and to prevent damage from

overheating. Refer to the separate Engine

Owner’s Manual for specific repair and

cleaning instructions. All inspections and

services must be done with the engine shut

off and cool to the touch.

AIR CLEANER SERVICE

The engine air cleaner filters dirt and dust

out of the air before it enters the carbure-

tor. Operating the engine with a dirty,

clogged air filter can cause poor perfor-

mance and damage to the engine. Never

operate the engine without the air cleaner

installed. Inspect and service the air

cleaner more often if operating in very

dusty or dirty conditions.

Service the air cleaner as instructed in the

separate Engine Owner’s Manual.

SPARK PLUG SERVICE

Inspect and clean or replace the spark plug

after every 100 operating hours or

annually. Clean the plug and set the gap as

described in the separate Engine Owner’s

Manual.

In some areas, local law requires using

resistor spark plugs to suppress ignition

signals. If the engine was originally

equipped with a resistor spark plug, use

the same type for replacement.

SPARK ARRESTER SCREEN SERVICE

If the engine muffler is equipped with a

spark arrester screen, remove and clean it

according to the time intervals and instruc-

tions in the separate Engine Owner’s

Manual.

THROTTLE LEVER ADJUSTMENT

If the engine does not respond to various

throttle lever settings, refer to the separate

Engine Owner’s Manual for service infor-

mation or contact your local authorized

engine service dealer.

CARBURETOR/GOVERNOR CONTROL

ADJUSTMENTS

The carburetor was adjusted at the factory

for best operating speed. Refer to the

separate Engine Owner’s Manual for any

adjustment information or see your autho-

rized engine service dealer.

The governor controls the maximum

safe operating speed and protects the

engine and all moving parts from

damage caused by overspeeding. Do

not tamper with the engine governor

settings.

OFF SEASON STORAGE

When the tiller won’t be used for

extended periods, prepare it for storage

as follows:

1. Clean the tiller and engine.

2. Do routine tiller lubrication and check

for loose parts and hardware.

3. Protect the engine and perform rec-

ommended engine maintenance by

following the engine storage instruc-

tions found in the separate Engine

Owner’s Manual. NOTE: Be sure to

protect the fuel lines, carburetor and

fuel tank from gum deposits by

removing fuel or by treating fuel with a

fuel stabilizer (follow engine manufac-

turer’s recommendations).

4. Store unit in a clean, dry area.

5. Never store the tiller with fuel in the

fuel tank in an enclosed area where gas

fumes could reach an open flame or

spark, or where ignition sources are

present (space heaters, hot water

heaters, furnaces, etc.).

WARNING

Operators shall not tamper

with the engine governor

settings on the machine;

the governor controls the

maximum safe operating

speed to protect the

engine and all moving

parts from damage caused

by overspeed. Authorized

service shall be sought if a

problem exists.

25

Section 5: Maintenance

TROUBLESHOOTING

Before performing any corrections, refer to the appropriate information in this Manual, or in the Engine Owner’s Manual, for the

correct safety precautions and operating or maintenance procedures. Contact your local authorized Engine Service Dealer for

engine service. Contact your local authorized equipment dealer or the factory for all other service problems.

PROBLEM POSSIBLE CAUSE CORRECTION

Engine does 1. Spark plug wire disconnected. 1. Reconnect wire.

not start. 2. Engine Throttle Control Lever incorrectly set. 2. Put lever in START position.

3. Fuel tank empty. 3. Add fuel.

4. Choke control (if so equipped) in incorrect position. 4. See Engine Owner’s Manual.

5. Stale gasoline. 5. Drain fuel and add fresh fuel.

6. Dirty air filter(s). 6. Clean or replace filter(s).

7. Defective or incorrectly gapped spark plug. 7. Inspect spark plug.

8. Carburetor out of adjustment. 8. See Engine Service Dealer.

9. Misadjusted throttle control cable. 9. See Engine Service Dealer

10.Dirt or water in fuel tank. 10. See Engine Service Dealer.

Engine runs poorly. 1. Defective or incorrectly gapped spark plug. 1. Inspect spark plug (see Engine Owner’s Manual).

2. Dirty air filter(s). 2. Clean or replace (see Engine Owner’s Manual).

3. Carburetor out of adjustment. 3. See Engine Service Dealer.

4. Stale gasoline. 4. Replace with fresh gasoline.

5. Dirt or water in fuel tank. 5. See Engine Service Dealer.

6. Engine cooling system clogged. 6. Clean air cooling system (see Engine Owner’s Manual).

Engine overheats. 1. Engine cooling system clogged. 1. Clean air cooling area (see Engine Owner’s Manual).

2. Carburetor out of adjustment. 2. See Engine Service Dealer.

3. Oil level is low. 3. Check oil level (see Engine Owner’s Manual).

Engine does not

shut off. 1. Misadjusted throttle control or ignition switch. 1. See Engine Owner’s Manual or Engine Service Dealer.

Wheels and Tines 1. Improper use of controls. 1. Review Sections 3 and 4.

will not turn. 2. Worn, broken, or misadjusted drive belt(s). 2. See “Checking Drive Belt Tension,” Section 5.

3. Internal transmission wear or damage. 3 Contact local dealer or the factory.

4. Bolt loose in transmission pulley. 4. Tighten bolt.

Tines turn, but 1. Wheel Drive Pins not in WHEEL DRIVE. 1. See “Wheel Drive Pins” in Section 3.

wheels don’t. 2. Internal transmission wear or damage. 2. Contact local Dealer or the Factory.

Wheels Turn, but 1. Tine holder mounting hardware missing. 1. Replace hardware.

Tines Don’t. 2. Internal transmission wear or damage. 2. Contact local Dealer or the Factory.

Poor tilling 1. Worn tines. 1. See “Tines” (Section 5).

performance. 2. Improper Depth Regulator setting. 2. See “Tilling Tips & Techniques,” Section 4.

3. Incorrect throttle setting. 3. See Section 4.

4. Forward Drive Belt slipping. 4. See “Checking Forward Drive Belt Tension,” Section 5.

26

Section

6

Parts List

5

1

3

14

2

11 18

17

16

10

9

84

15

12

6

4

15

1

7

9

819

20

13

721

22

24

23

25

7

26

27

27

MODELS 644H & 645A

REF

NO. PART NO. DESCRIPTION

1 1185469 Spirol Pin

2 710-0597 Hex Hd. Screw, 1/4-20 x 1

3 710-0599 Screw, Self-Tapping,1/4-20 x 1/2

4 710-0874 Hex Hd. Screw, 5/16-18 x 1-1/4

5 1186331 Hex Hd. Screw, 5/16-18 x 1.0

6 712-0291 Hex Lock Nut, 1/4-20

7 712-3004A Hex Flange Lock Nut, 5/16-18

8 712-3009 Hex Nut, 5/16-18

9 736-0119 Lock Washer, 5/16

10 GW-55013-1 Hood Bracket, Left Hand

11 GW-55013-2 Hood Bracket, Right Hand

12 GW-55015 Drag Bar

13 GW-55018 Depth Regulator Lever

14 686-04029 Tine Hood Assembly

15 GW-55088 Bushing

16 GW-9384 Spring, Depth Regulator

17 GW-9534 Spacer

18 710-04048 Hex Hd. Flange Screw, 5/16-18 x 1

19 618-04046 Transmission Assembly (CRT)

20 1916569 Flap Stop Bracket

21 1916570 Reverse Stop Arm

22 710-3073 Hex Screw, 5/16-18 x 2.25

23 1916771 Spacer, .462 x .328 x 1.63

24 1107382 Flat Washer, 5/16

25 710-3025 Hex Screw, 5/16-18 x .625

26 1916708 Hood Support Bracket

27 1916707 Channel Support Bracket

28

MODELS 644H & 645A

5

10

2

5

15

1

12

16

21

3

13

20

4

17

11

25

7

22

7

25

20

6

8

20

6

23

14

18

18

7

9

29

MODELS 644H & 645A

REF

NO. PART NO. DESCRIPTION

1 1916719 Cable Assembly, Reverse Clutch

2 1916755 Upper Handlebar

3 1917479 Bail, Forward Clutch

4 1918745 Cable Assembly, Forward Clutch

5 710-0599 Screw, Self-Tapping,1/4-20 x 1/2

6 710-3008 Screw, Hex, 5/16-18 x 3/4

7 712-3009 Hex Lock Nut, 5/16-18

8 GW-55042 Handlebar Support

9 GW-55043 Lower Handlebar

10 GW-55102 Panel

11 GW-55044 Tab, Conduit Mount

12 GW-9855 Screw, #10-24 x 2

13 725-0157 Cable Tie

14 736-3050 Flat Washer, 3/8

15 1916674 Bracket, Reverse Clutch Cable

16 1916712 Spring, Forward Clutch

17 710-0106 Hex Hd. Screw, 1/4-20 x 1-1/4

18 710-0216 Screw, Hex, 3/8-16 x 3/4

20 710-0805 Screw, Hex, 5/16-18 x 1-1/2

21 712-0121 Hex Nut, #10-24

22 712-0291 Hex Lock Nut, 1/4-20

23 712-3000 Hex Nut, 3/8-16

25 736-0119 Lock Washer, 5/16

REF

NO. PART NO. DESCRIPTION

1 1918749 Bumper

2 710-0395 Hex Screw, 5/16-18 x 2-1/4, Gr5

3 712-0267 Nut, Hex, 5/16-18

4 736-0119 Lock Washer, 5/16

14

3

2

30

MODELS 644H & 645A

* Use as required to obtain between .005” and .015” allowable end-play.

REF

NO. PART NO. DESCRIPTION

1 GW-9517 Snap Ring

2 GW-1714 Bearing, Tapered Roller (with race)

3 GW-50043 Support Washer, Rear

4 711-04110 Drive Shaft (CRT)

5 GW-1224-1* Shim, Rear Bearing Cap, .010" thick

GW-1224-2* Shim, same as above, except .030" thick

GW-1224-3* Shim, same as above, except .005" thick

GW-1224-4* Shim, same as above, except .062" thick

— GW-1325C Shim Set (Incl. the following shims:

two #1224-1, two 1224-2 & one #1224-4)

3

4

5

2

2

1

31

MODELS 644H & 645A

* Use as required to obtain between .005” and .030” allowable end-play.

REF

NO. PART NO. DESCRIPTION

1 GW-9512 Retainer, Snap Ring, “E” Type

2 1909950 Retainer, Snap Ring

3 GW-1166-1* Shim, 0.062" thick

GW-1166-2* Shim, 0.030" thick

GW-1166-3* Shim, 0.015" thick

GW-1166-4* Shim, 0.010" thick

GW-1166-5* Shim, 0.005" thick

4 GW-1086 Bronze Bushing

5 711-04092 Wheel Shaft (CRT)

6 GW-9305 Key, Hi-Pro, 1/4 x 1

7 GW-1132-2 Spacer

8 1904278 Worm Gear, Wheel Shaft

9 711-04078 Tiller Shaft

10 GW-1104 Woodruff Key

11 1904279 Worm Gear, Tiller Shaft

1

2

3

4

7

7

4

3

2

FRONT

9

5

6

10

11

8

32

MODELS 644H & 645A

REF

NO. PART NO. DESCRIPTION

1 GW-9727 Plug, Transmission Oil Fill

2 710-04049 Hex Hd. Flange Screw, 5/16-18 x 5/8,Gr. 5

3 736-0119 Lock Washer, 5/16

4 1918377 Rear Cover, Transmission

5 1916641 Front Cover, Transmission

6 GW-50032 Gasket, Housing Cover

7 721-04030 Oil Seal, Drive Shaft

8 721-04031 Oil Seal, Wheel Shaft

9 619-04013 Transmission Housing Assembly

10 721-04036 Oil Seal, Tine Shaft

11 736-3008* Washer, Flat, .344 x .750 x .120

12 718-04008 Rear Bearing Cap

13 710-04048 Hex Hd. Flange Screw, 5/16-18 x 1

14 710-3008 Hex Hd. Flange Screw, 5/16-18 x 3/4

REF

NO. PART NO. DESCRIPTION

2

2

1

5

4

6

6

8

8

9

10

10

12

3

14

13

11*

7

* Included with transmission when purchased as an assembly only.

Remove and discard when installing the transmission on tiller.

33

ENGINE

TINE SHAFT

DENOTES CUTTING EDGE

OF TINE

MODELS 644H & 645A

REF

NO. PART NO. DESCRIPTION

1 710-3008 Hex Hd. Screw, 5/16-18 x 3/4, Grade 5

2 1817060 Single Tine - Right Hand

3 712-3009 Hex Lock Nut, 5/16-18

4 710-3096 Hex Hd. Screw, 3/8-16 x 2

5 1817059 Single Tine - Left Hand

6 1916702 LH Tine Holder

7 1916703 RH Tine Holder

8 1917487 Wheel & Tire Ass’y — Left/Right Side

9 GW-9380 Clevis Pin, .312" x 1-3/4"

10 GW-9338 Hair Pin Cotter

11 712-3000 Hex Lock Nut, 3/8-16

— 1817059 Replacement Tines Set (Incl. three LH tines,

three RH tines and required hardware)

REF

NO. PART NO. DESCRIPTION

LEFT-HAND TINERIGHT-HAND TINE

Hold Tines With Cutting Edge at the TOP

of each tine facing TOWARD You

9

WHEEL SHAFT

9

10

11

6

5

2

3

5

4

2

5

210

8

3

4

1

1

11

3

8

1

1

6

34

MODELS 644H & 645A

9

24

28

20

30

25

27

1

1

11

5

17

19

28

1

12

10

14

16

38

32

31

3

2

7

8

37

19

39

33

4

38

34

FORWARD

CLUTCH CABLE

35

42

28

24 22

22

24

6

13

21 28

16

29

18

36

23

40

REVERSE

CLUTCH CABLE

15

28

26

35

MODELS 644H & 645A

REF

NO. PART NO. DESCRIPTION

1 1107382 Flat Washer, 5/16

2 1108841 Key, 3/16" x 1-1/2"

3 619-04016 Pulley, Engine Drive

4 1916532 Transmission Pulley

5 1916535 Pulley, Reverse Idler

6 1916652 Guard, Belts/Pulleys

7 1916657 Forward Drive Belt

8 1916658 Reverse Drive Belt

9 1916660 Belt Cover

10 1916724 Reverse Return Spring

11 1916725 Belt Guide

12 1916726 Forward Belt Guide

13 1916794 Engine Bracket, Left

14 1916795 Engine Bracket, Right

15 1917326 Bracket, Belt Cover

16 1917746 Shoulder Washer

17 1918731 Reverse Idler Arm

18 1918744 Forward Idler Lever

19 710-0117 Hex Hd. Screw, 5/16-24 x 1

20 710-0237 Hex Hd. Screw, 5/16-24 x 5⁄8

21 710-0376 Hex Hd. Screw, 5/16-18 x 1

22 710-04049 Hex Hd. Screw, 5/16-18 x 5/8

23 710-0520 Hex Hd. Screw, 3/8-16 x 1-1/2

24 710-0599 Screw, Self-Tapping, 1/4-20 x 1/2

25 710-3103 Hex Hd. Screw, 5/16-18 x 2

26 712-3000 Lock Nut, 3/8-16

27 712-3009 Lock Nut, 5/16-18

28 736-0119 Lock Washer, 5/16

29 736-3050 Flat Washer, 3/8

30 736-3090 Flat Washer

31 736-0452 Bell Washer

32 710-0459A Hex Hd. Screw, 3/8-24 x 1.5, GR5

33 GW-50027 Support Washer

34 GW-55034 Forward Return Spring

35 GW-55049 Bracket, Cable Mounting

36 GW-9090 Forward Idler Pulley

37 GW-9301 Key, 3/16" x 1"

38 GW-9929 Flat Washer

39 GW-9944 Belleville Washer

40 710-0395 Hex Screw, 5/16-18 x 2.25 Gr5

TROY-BILT TILLER LIFETIME LIMITED WARRANTY

WHAT PRODUCT All Troy-Bilt branded rear tine walk-behind tillers with gear drive transmissions.

IS COVERED This warranty begins on the date of purchase and is warranted by Troy-Bilt LLC for the life of the

tiller, to the original purchaser only.

WHAT IS COVERED Troy-Bilt LLC will, at its option, repair or replace any part found to be defective in material or

BY THIS WARRANTY workmanship without charge for parts and labor

This limited lifetime warranty also applies to non-powered attachments and accessories.

Powered attachments and accessories are warranted separately by their manufacturers. Refer

to the applicable manufacturer’s warranty on these items for terms and conditions.

WHAT IS NOT This warranty does not apply to parts that have been damaged by accident, alteration, misuse,

COVERED BY THIS abuse, neglect, improper maintenance, vandalism, theft, fire, water, or damage because of peril

WARRANTY or other natural disaster.

The following items are not covered after the first year of this residential use limited warranty:

belts, batteries, bushings, seals, tines, tires, wheels, paint, appearance items, and similar items

that are normally replaced through periodic maintenance.

Charges for pick-up, delivery, and service calls are not covered by this warranty.

Service completed by someone other than an authorized service dealer is not covered by this

warranty.

Parts that are not genuine Troy-Bilt LLC service parts are not covered by this warranty.

The engine is warranted separately by the engine manufacturer. Refer to the engine

manufacturer’s warranty for terms and conditions.

LIMITED If used for commercial, institutional, industrial, rental, or demonstrator purposes, the warranty

COMMERCIAL on the tiller is limited in duration to 90 days from the date of purchase.

USE WARRANTY

This warranty does not apply to parts that have been damaged by accident, alteration, misuse,

abuse, neglect, improper maintenance, vandalism, theft, fire, water, or damage because of

peril or other natural disaster.

HOW TO OBTAIN Warranty service is available, with proof of purchase, through your local authorized service

SERVICE dealer. To locate a dealer in your area, consult your Yellow Pages, or contact Troy-Bilt LLC at

P.O. Box 361131, Cleveland, Ohio 44136-0019, 1-866-840-6483, or log on to our Web site at

www.troybilt.com.

The provisions set forth in this warranty provide the sole and exclusive remedy arising from the sale. Troy-Bilt LLC shall

not be liable for any incidental or consequential damage or expense of any kind, including but not limited to cost of

equipment rental, loss of profits, or costs of hiring services to perform tasks normally performed by the equipment.

Any implied warranties, including any implied warranty of merchantability or fitness for a particular purpose, shall be limited

in duration to the period of ownership by the original purchaser (and a maximum of 90 days from the date of sale if the tiller is

purchased for commercial or other non-residential use).

Some states do not allow the exclusion or limitation of incidental or consequential damages, or limitations on how long an

implied warranty lasts, so the above exclusions or limitations may not apply to you.

This limited warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

For customer assistance, contact your nearest authorized dealer, or contact us at:

TROY-BILT LLC, P.O. Box 361131, Cleveland, Ohio 44136-0019, 1-866-840-6483