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If the lever does not move freely, lift the tine hood flap and look for a plastic tie securing the lever in place. Cut and remove the tie. 3. Remove the oil level check plug (N, Figure 2-13) on the left-side of the transmission. (Due to dried paint on the plug threads, it may require some force to remove the plug the first time.) The gear oil level is correct if oil starts to flow out of the hole as the plug is removed. If so, securely reinstall the plug. 4. If oil does not flow from the check hole, add SAE 140, SAE 85W-140 or SAE 80W-90 weight gear oil (preferably use API rated GL-4 gear oil, however GL-5 is okay for small top-offs) as follows: NOTE: Do not use automatic transmission fluid or engine oil in the transmission. (a) Clean area around oil fill hole (0, Figure 2-14) and unscrew oil fill plug. (b) Using a clean funnel, slowly add gear Figure 2-12: Put lever in second notch. Figure 2-13: Gear oil level check plug. Figure 2-14: Adding gear oil. STEP 6: Add Motor Oil to Engine 1. With the unit on level ground, pull the Depth Regulator Lever (M, Figure 2-12) back and then move it to the second notch from the top. This places the engine in a level position. 2. Add motor oil according to the instructions provided in the engine manufacturer’s Engine Owner’s Manual that was included in the unit’s literature package. WARNING Do not start the engine until motor oil has been added to engine crankcase. Failure to follow this instruction will result in serious engine damage. 9 Section 2: Assembly STEP 7: Attach Engine Throttle Lever For shipping purposes, the engine throttle cable assembly is wrapped around the engine. Carefully unwrap the cable and attach it as follows: 1. Route the throttle cable up the right-side handlebar and insert the lever (P, Figure 2-15) up through the slot in the control panel that is labeled “ENGINE THROTTLE.” 2. Insert two #10-32x1/2” round head screws down through the “+” marks on the control panel decal and through the holes in the base of the engine throttle lever. 3. Hold the engine throttle lever base against the bottom of the control panel and secure it with two #10 lockwashers and #10-32 nuts. 4. Place the “T” shaped engine throttle lever knob on the end of the lever and use a board to tap the knob down until it seats firmly on the lever (see Figure 2-15). 5. Move the lever forward and backward - it should move freely through the full range of travel. (Note that there is a detent at the SLOW setting which catches the lever. This detent prevents the lever from unintentionally moving to the STOP setting when you are just trying to slow the engine down.) If the lever is difficult to move away from the STOP setting, loosen both screws and move the lever assembly slightly to the left. Retighten both screws and recheck the movement. Adjust the lever as needed. 6. Secure the throttle cable to the right-side handlebar with two plastic ties (R, Figure 2-16) located about two feet apart. The serrated side of the tie should be on the inside of the loop. Snip off any excess tie length with scissors. STEP 8: Attach Wheel Gear Lever For shipping purposes, the wheel gear cable is wrapped around the transmission. Carefully unwrap the cable and attach it as follows: 1. Route the wheel gear cable up the leftside handlebar and insert the lever (S, Figure 2-17) up through the slot in the control panel that is labeled “WHEEL GEAR.” 2. Insert two #10-32 x 1/2" round head screws down through the “+” marks on the control panel decal and through the holes in the base of the wheel gear lever. 3. Hold the wheel gear lever base against the bottom of the control panel and secure it with two #10 lockwashers and #10-32 nuts. 4. Place the wheel gear lever knob on the end of the lever and use a board to tap the knob down until it seats firmly on the lever (see Figure 2-17). 5. Secure the cable to the left-side handlebar with two plastic ties (T, Figure 2-16) located about two feet apart. Snip off any excess tie length with scissors. STEP 9: Check Air Pressure in Tires Use an automotive-type tire pressure gauge to 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 pull to one side. STEP 10: Check Hardware for Tightness Inspect the hardware on the unit and tighten any loose screws, bolts and nuts. Figure 2-15: Attach engine throttle lever. plastic ties (R). Attach wheel gear cable with plastic ties (T). s Figure 2-17: Attach wheel gear lever. This completes the assembly steps for the standard (recoil) start tiller. Be sure to read the rest of this Manual before you operate your tiller. If you have an electric start PONY model, continue with the following electric start assembly steps. 10 Section 2: Assembly Assembling the PONY Model Electric Start System DANGER Battery electrolyte is a sulfuric acid solution that is poisonous and ...

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