Troy-Bilt 7 Hp Horse Manual

							31
3. Using the 3⁄8” wrench, remove the drain plug. The gear 
oil will drain quite slowly since it is thick. After about two 
quarts have drained, tilt the tiller forward so any oil at the 
rear of  the transmission will drain out.
4. Clean the drain plug threads, put non-hardening gasket 
sealant on the threads, and reinstall the plug.
5. Refill the transmission with the correct amount of gear oil 
before operating the tiller again. When oil seeps from the 
oil level check hole, the right amount of gear oil has been 
added. Replace all plugs.
Adding Gear Oil to the Tine Attachment Transmission
1. Select the right Depth Regulator Lever setting:
a. If filling an empty transmission, raise the Depth 
Regulator Lever so tines are on the ground.
b.  If topping off the gear oil, move Depth Regulator 
Lever down to engage its top notch.
2. Remove the dipstick from the tine attachment. See Fig. 6-6.
3. Slowly add gear oil in the dipstick hole. Add 1⁄2-ounce at a 
time to avoid overfilling. It takes about 12-1⁄2 ounces.
4. Take dipstick readings frequently. Stop when oil reaches 
“Cold” range marking on dipstick. Replace dipstick securely.
Draining and Filling the Tine Attachment Transmission
1. The tine attachment transmission is not equipped with 
an oil drain plug. To drain just a small amount of gear oil, 
remove the dipstick and tilt the attachment forward, first 
uncoupling it from the Power Unit.
2. For complete drainage, remove the left-side tine assembly 
(See Tine Replacement in the Service section.), then 
remove just one of the lower screws from the tiller housing 
cover. See Fig. 6-9. To speed drainage, remove the tine 
attachment dipstick to vent transmission.
NOTE: If you find a plastic washer on the cover screw you 
removed, discard the washer. There is no need to install a 
replacement washer.
3.  Once all the gear oil has drained, reinstall the housing cover 
screw securely (first coat its threads with non-hardening 
gasket sealant).
4. Be certain to refill the transmission with the correct amount 
of gear oil before operating the tiller again.
Forward Interlock System
The wiring circuit for the Forward Interlock Safety System is 
designed to ground out the engine’s ignition system.
There are three switches in the circuit which, when open, let the 
engine run. One switch is on the neutral plunger tab of the cast 
iron motor mount. This switch is open whenever the Wheels/
Tines/PTO Drive Lever is in NEUTRAL or REVERSE positions. The 
other two switches are located inside the handlebars, directly 
above the two Forward Interlock Levers. The switches are wired 
so when squeezed (open) the engine will run. There is a fourth 
switch located in the wiring harness connector on the top, right 
side of the transmission cover. It warns you if the connection is 
not mated by not letting the engine run while the Wheels/Tines/
PTO Drive Lever is in FORWARD.
1. A broken or disconnected wire could let the engine run 
without you having to press one of the Forward Interlock 
Levers.
2. A bare wire touching the tiller or engine metal could 
ground out the engine’s ignition.
3.  A switch that has failed allows the engine to run. Or it may 
prevent the engine from running.
Lubrication
Proper lubrication of the tiller’s mechanical parts is an essential 
part of good maintenance. Lubrication should be done after 
every ten (10) hours of operation.
Use ordinary motor oil (#30 weight or lighter) where oil is 
specified. Use a quality grease with a metal lubricant where 
grease is recommended (regular grease is acceptable). Do not 
over lubricate. If there is a build-up of dirt, remove the build-up 
and re-apply oil or grease.
NOTE: Do not allow oil or grease to contact the pulleys, drive 
belt or reverse disc. This can cause the belt or disc to slip on the 
pulleys.
Figure 6-9
SECTION 6 
						

							32
Lubricate the tiller as follows:
1. Oil the wheel shaft between the wheel hubs and the 
transmission housing. See Fig. 6-10.
2. Oil all pivoting and connecting points on the Wheels/
Tines/PTO Drive Lever and the Wheel Speed Lever. See Fig. 
6 -10 .
3.  Grease the face of the belt adjustment block. See Fig. 6-10.
4. Oil the Depth Regulator Lever, including the spring in the 
mounting bracket. See Fig. 6-10.
5. Oil the full length of the throttle cable casing. Oil threads 
on Handlebar Height Adjustment Lever. See Fig. 6-10.
6. Grease the left- and right-side engine mounting bars at the 
top, middle and bottom. See Fig. 6-10.
7. Grease the zerk grease fitting located on the pivot point 
at the end of the Wheel Speed Lever. See Fig. 6-10. If 
the Wheel Speed Lever has a grease fitting on the pivot 
assembly, apply 2-to-3 strokes of multipurpose grease at 
beginning and end of tilling season.
Wheel Shaft
Wheel Speed Lever
Wheels/Tines/PTO 
Drive Lever
Throttle
Cable
Casing
Engine 
Mounting
Bars
Grease FittingDepth 
Regulator 
Lever
Belt Adjustment Block
Handlebar Height
Adjustment Lever
Figure 6-10
8. Keep the PTO access area well-greased. See Fig. 6-11. If 
the Tines/PTO Clutch Lever becomes hard to move, squirt 
some oil into its access hole, and work it back and forth to 
disperse the oil.
Adjustments
Drive Belt
On a new tiller (or if a new belt is installed), the belt tension 
will probably need to be adjusted after the first two (2) hours 
of operation. Thereafter, check the belt tension every ten (10) 
operating hours.
Maintaining the right tension is important to good tiller  
performance and long belt life. If too loose, the belt will slip on 
the pulleys, and be unable to deliver full power to the wheels 
and tines. A loose belt will also wear prematurely. 
While checking the belt tension, also inspect the belt for cuts, 
cracks, deterioration, etc. Don’t continue using a belt that isn’t in 
good shape. You’re sacrificing tiller performance by doing so. 
Tips on keeping the drive belt in top condition include:
• Always put the Wheels/Tines/PTO Drive Lever in NEUTRAL 
when the tiller is not in use.
• Keep the tension adjusted correctly.
• Don’t “speed shift” when moving the Wheels/Tines/PTO 
Drive Lever between FORWARD and REVERSE.
PTO Access Area
Figure 6-11
SECTION 6
						

							33
How to Measure the Belt Tension
1. Before taking a measurement, be sure the linkages and 
pivot points on the Wheels/Tines/PTO Drive Lever are clean 
and lubricated. If there is any binding, you won’t get true 
measurements. Also, you’ll need the belt adjustment tool 
you received with your new tiller. See Fig. 6-12.
2. Move the Wheels/Tines/PTO Drive Lever fully down to the 
FORWARD position. The clutch roller at the bottom of the 
lever should be positioned underneath the belt adjustment 
block. See Fig. 6-13. Don’t let the clutch roller move during 
the next few steps. If it moves, you’ll get a false belt tension 
reading.
3.  The belt tension is correct if the front of the clutch roller 
is 1⁄4”-to -5⁄16” away from the face of the upright bracket 
that holds the adjustment block in place. See Fig. 6-13. To 
measure this distance:
a. Without moving the clutch roller, try inserting the 
1⁄4”-thick, slotted end of the belt adjustment tool in 
between the roller and the upright bracket. The flat 
edge of the tool must be facing the roller. See Fig. 
6 -14 .
b.  If only the slotted portion of the tool will fit, the belt 
tension is correct.
c. If the slotted part of the tool will not fit in, the belt is 
too loose.
d. If the full thickness (5⁄16”) of the tool easily fits in, the 
belt is too tight.
4. If the belt tension is correct, move the Wheels/Tines/PTO 
Drive Lever back to NEUTRAL.
How to Adjust the Belt Tension
1. As described in the following steps, the drive belt tension 
is adjusted by moving the adjustment block up or down. 
Moving it down will tighten the belt; moving it up loosens 
the belt.
NOTE: The distance the block moves approximately equals 
the distance the roller moves. In most cases, the clutch 
roller will not have been very far out of position, so the 
adjustment block will only need to be moved slightly (up 
or down).
2. Move the Wheels/Tines/PTO Drive Lever to NEUTRAL 
position. The clutch roller will come to rest anywhere on 
the face of the belt adjustment block, depending upon 
drive belt length and current belt tension adjustment.
Slotted End
Figure 6-14
7. 9 4  m m
5⁄16”
1⁄4”
6.35 mm
Belt Adjustment Tool
Figure 6-12
1⁄4” - 5⁄16”
Figure 6-13
SECTION 6 
						

							34
3. Insert the belt adjustment tool through the hole in the 
side of the adjustment block, spacing the ends of the tool 
equally on both sides. See Fig. 6-15. Rotate the tool so the 
slotted end faces down.
4. Place the Wheels/Tines/PTO Drive Lever in FORWARD 
position. The arms of the clutch control yoke will be resting 
on the belt adjustment tool and the clutch roller should be 
engaged slightly beneath the adjustment block. See Fig. 
6 -16 .
Adjustment Block
Belt Adjustment Tool
Figure 6-15
Clutch Roller
Adjustment Block
Figure 6-16
5. Use one hand to hold the drive lever in FORWARD while 
using a 9⁄16” wrench to loosen — don’t remove — the bolt 
at the back of the belt adjustment block. See Fig. 6-17. 
The adjustment block should be free to move either up or 
down.
6. Push the drive lever down if the belt needs tightening. Pull 
the lever up if the belt needs to be loosened. Hold the drive 
lever in place and tighten the bolt in the adjustment block 
f irmly.
7. Let go of the drive lever and remove the belt adjustment 
tool from the hole in the adjustment block.
8. Check the tension on the belt by following the previous 
instructions “How to Measure Belt Tension.”
NOTE: If the adjustment block is all the way down and the 
measurement between the clutch roller and the bracket is 
less than 1⁄4”, then a new drive belt is needed.
Reverse Drive System
These instructions explain how to inspect and adjust the various 
reverse drive components.
But first, here’s how the reverse drive system works. When you 
raise the Wheels/Tines/PTO Drive Lever up in REVERSE position, 
this lowers the rubberized reverse disc — it’s attached to the 
engine drive pulley — until this rotating disc contacts the 
transmission drive pulley. The friction between the rotating 
reverse disc and the transmission pulley causes the transmission 
drive shaft to be powered in a counterclockwise direction  — as 
viewed from the operator’s position behind handlebars. The 
drive shaft then turns the wheels and tine shafts in a reverse 
direction.
The reverse disc is made of steel with a special, long-lasting 
rubber compound bonded to the disc rim. Since this is a wearing 
part, it should be inspected after every 30 operating hours. 
Bolt
Drive Lever
Figure 6-17 
SECTION 6
						

							35
1. Measure the width of the outside edge of the disc as shown 
in Fig. 6-18. Replace the disc before the rubber edge wears 
to a thickness of 1⁄8” or less. Failure to do so could cause the 
steel underneath the rubber to damage the transmission 
pulley.
2. Look for big cracks or missing chunks of rubber from 
the disc. If so damaged, the disc should be replaced 
immediately. See the Service section of this manual for 
instructions on replacing the disc.
NOTE: Extend the life of the reverse disc by always pausing 
in NEUTRAL before shifting between FORWARD and 
REVERSE. Also, the reverse disc is not suited for continuous 
or sustained reverse operation. Use reverse sparingly.
Checking and Adjusting the Reverse Drive System
When the Wheels/Tines/PTO Drive Lever is moved up into 
REVERSE, the engine and engine mount move down to press on 
the reverse adjustment bolt. See Fig. 6-19. 
This action compresses the reverse spring and plunger assembly, 
requiring you to hold the lever up in REVERSE. When you release 
the lever, the spring automatically pushes the lever back into 
NEUTRAL position.
The spring and plunger assembly is designed to prevent the 
reverse disc from making contact with the transmission pulley 
until you shift into REVERSE. When the lever is in NEUTRAL, the 
switch body on the bottom of the engine mount tab should be 
resting squarely on top of the reverse adjustment bolt. See Fig. 
6-19. The reverse adjustment bolt can be adjusted up or down 
to correct a number of reverse drive operating problems, as 
explained next.
Checking and Adjusting the Reverse Disc
1. Verify that the linkages for Wheels/Tines/PTO Drive 
Lever are lubricated with oil and engine mount bars and 
belt adjustment block are lubricated with grease. See 
Lubrication earlier in this section.
2. Place Wheels/Tines/PTO Drive Lever in NEUTRAL. Briefly 
pull out the engine recoil starter handle while watching the 
reverse disc. The disc should turn, but lower pulley should 
not. See Fig. 6-20. If the reverse disc turns the lower pulley, 
or if it is located closer than 3⁄16” to the pulley, reverse 
adjustment bolt should be adjusted upward. Moving the 
adjustment bolt upward will also solve the problem of a 
tiller that goes into REVERSE on its own.
Switch Body
Adjustment Bolt
Spring and Plunger
Figure 6-19
Recoil Starter Handle
Reverse
Disc
Figure 6-20
Disc Edge
Figure 6-18
SECTION 6 
						

							36
3. Use your left hand to hold the Wheels/Tines/PTO Drive 
Lever up in REVERSE, while briefly pulling out the engine 
recoil starter. The reverse disc should turn the lower pulley. 
See Fig. 6-21. If not, or it requires a lot of pressure to hold 
the lever up in REVERSE, then the reverse adjustment bolt 
must be adjusted downward. When correctly adjusted, the 
Wheels/Tines/PTO Drive Lever should pop out of reverse 
when the lever is released, but not require exceptional 
effort to hold it up in the reverse position.
4. Shift the Wheels/Tines/PTO Drive Lever to REVERSE and 
then let it go. The lever should return to NEUTRAL. If 
not, the reverse adjustment bolt will have to be adjusted 
upward.
Adjusting the Reverse Drive:
1. Place the Wheels/Tines/PTO Drive Lever in FORWARD 
position.
2. On the left side of the tiller, put a 1⁄2” wrench on the plunger 
retaining bolt and another 1⁄2” wrench on the jam nut next 
to it. See Fig. 6-22.
3.  While holding the bolt steady, loosen the jam nut 
(counterclockwise) until it touches the bolt head.
4. Turn the bolt in until it tightens against the plunger inside 
the spring. The bolt must be tight to prevent the plunger 
from turning — be careful not to overtighten and break the 
bolt.
5. Place a 7⁄8” wrench on the head of the reverse adjustment 
bolt and a 9⁄16” wrench on the jam nut below it. See Fig 6-23. 
Hold the bolt steady while loosening the jam nut three or 
four turns.
Retaining Bolt
Jam Nut
Figure 6-22
Adjustment Bolt
Jam Nut
Figure 6-23
Recoil Starter Handle
Reverse
Disc
Wheels/Tines/PTO
Drive Lever
Figure 6-21
SECTION 6
						

							37
6. Move the Wheels/Tines/PTO Drive Lever to NEUTRAL. 
The switch body on the bottom of the engine mount 
tab should be resting squarely on top of the reverse 
adjustment bolt, and the reverse disc should be at least 
3⁄16” away from the transmission drive pulley. See Fig. 6-19. 
If the reverse disc is any closer than this, raise the reverse 
adjustment bolt (turn it counterclockwise).
7. Check that the reverse disc is at least 3⁄16” away from 
the transmission drive pulley. Then hold the reverse 
adjustment bolt steady with one wrench while tightening 
the jam nut with a second wrench. See Fig. 6-23.
8. Place a chalk or pencil mark on the top edge of the plunger 
retaining bolt. Now, while watching the mark, loosen the 
bolt 3⁄4-turn. See Fig. 6-24. Do not exceed a 3⁄4 turn. This 
would disengage the bolt from the locking groove in the 
side of the plunger.
9.  Hold the plunger retaining bolt steady with a wrench while 
tightening the jam nut against the side of the plunger 
housing. See Fig. 6-22.
10. Check the action of the reverse disc as explained 
previously.
NOTE: If the above adjustments have not corrected an 
improperly working reverse drive, contact an authorized 
dealer or the TROYBILT Technical Service Department for 
assistance.
Throttle Cable
The throttle lever settings are factory adjusted, so unnecessary 
adjustments should not be made. However, if the engine does 
not start or stop, or respond immediately to various throttle lever 
settings, then adjustments may be necessary. Please refer to the 
Engine Operator’s Manual supplied with your tiller for specific 
adjustment instructions.
Ignition System
Your engine is equipped with an electronic ignition. It does not 
have a condenser or points, so there is no need to perform any 
regular tune-up maintenance on this system other than adjusting 
or replacing the spark plug.
Spark Plug
1. The spark plug must be in good condition for proper 
engine operation. Remove and inspect the plug every 50 
operating hours or annually, whichever occurs first. The 
correct electrode gap is .030”. Check the gap with a feeler 
gauge. Do not use a spark plug if the porcelain is cracked, 
the electrodes are pitted or burned, or if other visible 
damage is present.
NOTE: Do not wire brush or sandblast the spark plug to 
clean it  — loose particles can enter the engine, causing 
damage. To replace the plug, first tighten it securely by 
hand, then use a spark plug wrench to tighten the plug an 
extra 1⁄4 turn.
Off-Season Storage
When your tiller will not be used during the off-season, prepare it 
for storage with the following steps:
1. Clean the tiller and the engine.
2. Do routine tiller lubrication and check for loose hardware.
3.  Protect the engine from deterioration or damage by 
referring to the engine storage instructions in your engine 
manual literature.
4. When engine is still warm, drain oil from engine crankcase. 
Refill with fresh motor oil.
5. Protect the internal cylinder against rust by removing the 
spark plug and pouring one ounce of clean engine oil into 
spark plug hole. Then slowly pull out the recoil start rope 
2 or 3 times to distribute the oil internally. Replace spark 
plug, but do not reconnect the plug wire. Pull the rope 
until resistance is felt — let rope rewind.
6. Charge the battery (electric start option). Store the battery 
in cool, dry location.
7. Move the Wheels/Tines/PTO Drive Lever to NEUTRAL 
position. Keep the tiller in a clean, dry area.
8. 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.).
Plunger Retaining Bolt
Figure 6-24
SECTION 6 
						

							38
Belt Replacement
Drive Belt
1. Move the Wheels/Tines/PTO Drive Lever to NEUTRAL 
position.
2. While kneeling on the right side of the tiller, create slack in 
the belt by reaching over to the left side of the pulleys and 
pushing in on the center of the belt with your finger.
3.  Use your right hand to move the belt down and away from 
the lower pulley, in the direction of the engine. See Fig. 7-1.
4. Push the belt upward to create slack in the belt. See Fig. 7-2.
5. Lift the top half of the belt up and over the upper pulley 
and the rubber reverse disc, moving it in front of the 
reverse disc. See Fig. 7-3.
6. Push the Wheels/Tines/PTO Drive Lever down into the 
FORWARD position. This increases the distance between 
the upper and lower pulleys. Next, lift and pull the entire 
belt out from between the pulleys. See Fig. 7-4.
7. Place the Wheels/Tines/PTO Drive Lever in FORWARD 
position.
8. Squeeze the belt in the middle and insert one end in 
between the pulleys. See Fig. 7-4.
Drive Belt
Lower Pulley
Figure 7-1
Push Belt Up
Figure 7-2
Drive Belt
Reverse Disc
Figure 7-3
Pulley
Drive Belt
Figure 7-4
Service7  
						

							9. Push the belt forward then down until it is looped over the 
lower pulley. See Fig. 7-2. Do not yet seat it in either of the 
lower pulley’s grooves.
NOTE: A blunt object, like a ruler, can help you push the 
belt downward if needed.
10. Move the top half of the belt up and over the rubber 
reverse disc, but do not seat it in either of the grooves in 
the top pulley.
11 .  Place the Wheels/Tines/PTO Drive Lever in NEUTRAL.
12 .  Move the top half of the belt into the HIGH Range groove, 
the groove closest to the engine, on the top pulley. See Fig. 
7-5.
13 . Move the bottom half of the belt into the HIGH Range 
groove of the lower pulley. If extra slack is needed, hold 
up Wheels/Tines/PTO Drive Lever while moving the belt. 
Verify the belt is seated properly on the pulleys.
14 .  To move the belt to the Low Range position. See Changing 
Belt Speed in the Operation Section.
15 . After installing the belt, check and adjust for correct belt 
tension as explained previously.
Reverse Disc
Follow these steps to replace the reverse disc. If your tiller has a 
Bumper Attachment mounted, it must be removed first.
1. Move Wheels/Tines/PTO Drive Lever in NEUTRAL position.
2. Wedge a 5⁄16”-thick board between the top of the engine 
pulley and the cast iron housing next to it. This immobilizes 
the pulley. Avoid contacting the reverse disc.
3.  Use a 9⁄16” wrench to loosen the mounting bolt shown in 
Fig. 7-6. Remember to immobilize the pulley with the wood 
wedge while loosening the bolt. If necessary, pry the disc 
from the pulley with the tip of a screwdriver. Back the bolt 
out as far as possible. Then angle the disc a little to remove 
it. Bring the bolt and lockwasher along with the disc. 
Installing a new Reverse Disc.
4. Do steps 1-through-3,in the opposite order to install the 
new reverse disc.
5. Tighten the mounting bolt securely, and check for correct 
operation — see the Maintenance & Adjustments section.
Tines
Inspect the tines for wear or damage after every 30 operating 
hours. The rate of wear depends upon the hours of use and soil 
conditions. With use, the tines get shorter, narrower and more 
pointed. See Fig. 7-7.
Drive
Belt
Figure 7-5
O
IL
Mounting Bolt 
Reverse Disc
Wood Wedge
Figure 7-6
WornNew
Figure 7-7
39SECTION 7 
						

							40
If badly worn, they lose the ability to till deeply. Worn tines leave 
an ever-increasing gap in the middle of a tilled row. The normal 
gap is 3” between the tine tips — replace the tines when the gap 
widens to 5”. See Fig. 7-8. The tines can be replaced individually 
or as a complete set. 
Replacing a Single Tine
WARNING! The tines or tine hooded edges may be 
sharp . Wear thick gloves to protect your hands from 
cuts or scrapes.
WARNING! Wear safety goggles to protect your 
eyes . When loosening hardware, do not hit a 
wrench with a metal tool. This could shatter the tool 
or wrench sending metal particles into your eyes.
1. Move the Wheels/Tines/PTO Drive Lever to NEUTRAL, the 
Wheel Speed Lever to either FAST or SLOW position, and 
the Tines/PTO Clutch Lever to ENGAGE.
2. Gently tilt the tiller forward until the engine rests on the 
ground.
3.  Raise the hood flap at the back of the tiller and tie it up 
with string. 
4. Before removing a tine, note in which direction the bent 
tip points. The new tine must be installed in the same 
direction.
5. Use two 9⁄16” wrenches to remove the two bolts and nuts 
securing the tine to the tine holder plate. See Fig. 7-9. Use 
penetrating oil on the hardware if it is rusted or hard to 
remove.
6. Mount the new tine exactly the way the old tine was 
positioned. (The sharp edge of the tine, which enters the 
soil first, must face forward when above the tine shaft.) 
Replace the bolts and nuts and tighten them securely.
Replacing A Tine Holder Assembly
The 16 Bolo Tines are mounted eight per side on left-side and 
right-side tine holders. Here’s how to replace the tines and 
holders as assemblies. 
1. Follow steps 1-3 in Single Tine Replacement above.
2. Identify the tine holders as left-side and right-side holders 
— they must be replaced on the same side from which 
they were removed. Use a piece of chalk or a grease pencil 
to mark them L and R.
3.  Remove the two bolts and nuts securing each holder. See 
Fig. 7-9.
4. Use a soft mallet to drive the holder off the tine shaft. 
Use a heavy hammer and block of wood to knock off the 
immobilized tine holder.
5. When the holder is off, clean all dirt and debris from the 
shaft and the holder. Apply fresh grease to the tine shaft. 
Replacing Tines Holder Assembly
1. Replace the holder so the sharp tine edges face forward 
(toward the front of the tiller). Tap tine holder back on the 
tine shaft.
2. Grease the threads on the mounting bolt(s). Install and 
tighten the bolt(s) securely.
1 2 34
5 6
7 8
Tines
Figure 7-8
Tine Shaft
Left-Side
Tine Holder
Right-Side
Tine Holder
Nut
Bolt
Figure 7-9 
SECTION 7