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Triumph Repair-Part Manual (v13)

1. 12 12 IN 14 lt 1 17 www permagreen com 62 6 192 Jann am 869 _ frase Shimer Power enn 10 654900 6 X 1 2 Screws fam _ 5 9 ree 1 800 346 2001 HOPPER SCHEMATIC GROUP www permagreen com frr Description fm 8 1395 rompe Pie Povo 19997 Hopper Pe o ps feanen Fee 8 ros ear _ 10 24 x 3 4 screw Vom freser _ s _ DREES roars rem Cv Sher Pave 800 346 2001 CABLE AND LEVER SCHEMATIC GROUP 2 O 7654040 5 Brake Complete T654055 Transmission Brake Complete T654060 SS Brake Complete h Te m tz ae aA EE Ze Da JO oe Ze 25 e re TT bt te HAS d 2 4 _
2. 7654220 3 4 Hole Cable 6 449203 Honda Air Cleaner Element 1449415 Damper Assembly 11 1449420 Damper Complete Kit 9 101715 Bolt Lock 10 7651970 Safety Link Axle 2011 7651975 Safety Link 3 4 Axle 2010 64 www permagreen com 1 800 346 2001 CABLE AND LEVER SCHEMATIC GROUP 9 7651967 85 5 38 Block Assembly T422310 Spinner Shaft 7 T422100 Spinner Platter a MN 101045 Pump Gearbox Brkt Welded waw j y 4 DR rang everr rms N fr 9 8812 vi 1606 Jesse ___ eT Ay EE Rear 1 Hub Drum Assy 6 R651450 3 16 x 3 4 Washer has fatet an seater 1 1A 1I see chart 9 9A 65 www permagreen com 1 800 346 2001 CABLE AND LEVER SCHEMATIC GROUP 14 ge s SZ r 11 10 66 www permagreen com z en 9 e roon fiere E saber sot 4 x 1 3 4 Bolt 4 x 2 Bolt oro ee 3 8 x 3 4 Bolt fremme me p pae DR Fee 1 8 fee fro tower 6196 1 800 346 2001
3. NOW BW 8 9 Use a 7 16 wrench to remove the 2 bolts on the engine shroud Push forward on idler arm with right hand and push belt forward over clutch pulley with left hand Remove the air filter and disconnect the throttle cable Use 2 screwdriver to remove conduit clip Use a 7 16 wrench and 1 8 Allen wrench or a 3 Philips screwdriver to remove shaft block Use a 3 8 socket to remove the two screws on the hood Remove hood Disconnect the jumper wire and ground wire from the front of the engine Remove the 2 torque bolts with a 7 16 socket on a 10 inch extension and ratchet and a 7 16 wrench NOTE Some torque bolts may require wrenches Remove the 5 nuts for the dampers using 10 inch extension bar and inch swivel head socket Pull out the engine and set it on level ground or a work table 10 Use a wrench to remove bolts connected to dampers NOTE even if one damper has failed we recommend replacing all 5 dampers Section 2 Installation 1 2 UW 9 10 11 12 13 Install new dampers with bolts and lock washers Torque Bolts The engine vibration Dampers kit includes 2 5 16 18 torque bolts If your machine is already equipped with the 5 16 18 torque bolts no action is necessary Use existing torque bolts If your machine is equipped with 72 20 torque bolts you will need to use 5 16 ream drill bit to make the torque bolt holes on the engine plate
4. R650124 1 4 20 x 2 1 4 bolt R652460 M Grease Zerk R652470 F Grease Zerk 800 346 2001 SULKY SCHEMATIC GROUP www permagreen com 7 9 5 les Che Josee rase Sulky 1 Axle Includes fre fee BEE mm far Ce s oor saywan 800 346 2001 72 www permagreen com 1 800 346 2001
5. ELECTRICAL SCHEMATIC GROUP Description 300307 Starting Module 300297 Kill Switch Wire T300309 Wire Harness Lead Only R344336 Switch 15 2 Jia A 67 www permagreen com 1 800 346 2001 0 1 www permagreen com 1 4 a at SPRAYER SCHEMATIC GROUP 16 68 Soy Sia Compe fres Z hee feae M 16 T205030 High Gear Trim 800 346 2001 SPRAYER SCHEMATIC GROUP PLUMBING SCHEMATIC 2 i B 11 B 2 T454240 Spray Selector Valve Low A A 3 T500270 Spray Control Valve T204983 Left 6 gallon Tank T204987 Right 6 gallonTank R480020 Fill Valve and Drain UT G 454210 Check Valve 3 2 R466440 20 psi Pressure Unloader Valve R466435 30 psi Pressure Unloader Valve R454023 L Fitting 1 4 3 8 hb R454022 L Fitting 1 4 1 4 hb 6 C 17454265 Tank fitting 3 8 hb 7454265 fitting 3 8 hb 454200 1 4 mpt x 1 4 hb x 1 4 hb tee Y 3 8 Fitting 22 28 8 s L L L ER 69 www permagreen com 1 800 346 2001 www permagreen com SULKY SCHEMATIC GROUP ARTICULATING SCHEMATIC 70 8 5 69 em
6. Section2 S Section2 Step7 Section2 Step9 Section2 Step9 39 www permagreen com 1 800 346 2001 Spray Brake Lever Replacement T654140 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual NOTE Before removing any lever become familiar with the factory set position so new levers are mounted properly Parts Included Tools Needed 654140 Spray Brake Lever 5 32 Allen Wrench Section 1 Removing and Replacement of Spray Brake Lever 1 For the front brake sulky brake and spray levers use a 5 32 Allen wrench and remove the 2 bolts on the lever link 2 Pull back on the cable to expose the metal wire and push cable forward to detach Reattach cable and tighten in original place NOTE When replacing spray lever it is not necessary to adjust spray cable when replacing the front brake lever it is recommended that you check brakes for proper cable replacement and front brake cable replacement on adjusting brakes Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 40 www permagreen com 1 800 346 2001 Bar fan j i Section1 Step1 Section1 Step2 4 www permagreen com 800 346 2001 Spray Cable Replacement T654265 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this ma
7. Safety Equipment Needed Wear Protective Eyewear and Gloves Parts Included Tools Needed 1 T422957 Shutoff plate 3 8 Wrench Socket 7 16 Wrench Socket 1 8 Allen Wrench 3 Philips Screwdriver 2 Philips Screwdriver short Dykes Section 1 Remove Shut Off Plate 1 BW Remove shaft block and spinner assembly using a 7 16 wrench and 1 8 Allen wrench or a 3 Philips screwdriver depending on style of shaft block Remove agitator and agitator arm by removing cotter pin using dykes Remove hopper cable from shut off plate using a 3 8 wrench socket Remove three tension screws using a 2 Philips screwdriver short and a 3 8 wrench socket Remove center bolt using a 2 Philips screwdriver short and a 7 16 wrench socket The shut off plate will drop down but it will still be connected to the third hole remote cable Remove bushing from plate 6 Remove two nuts and cable clamp using a 3 8 wrench socket Section 2 Install Shut Off Plate 1 UT Hook third hole remote cable to the slide plate of the shut off plate Install cable clamp on shut off plate positioning it over the same spot on the cable from where it was before removing it Test third hole remote to make sure it operates smoothly and opens and closes properly Insert bushing on the shut off plate Insert bolt through bushing and then up through hopper Make sure bronze bushing is still seated in hopper and then tighten
8. 5 Reattach engine shroud Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 www permagreen com 1 800 346 2001 Section1 Step4 Section1 Step4 Section2 Step1 CO Section2 Step2 Section2 Step4 www permagreen com 800 346 2001 Drive Belt Replacement T653800 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual Safety Equipment Needed Wear Protective Eyewear and Gloves Parts Included Tools Needed 1 T653800 Drive Belt 3 8 Wrench Socket 7 16 Wrench Socket 1 8 Allen Wrench 3 Philips Screwdriver Section 1 Removing Drive Belt 1 Remove shaft block and spinner assembly using a 7 16 wrench and 1 8 Allen wrench or a 3 Philips screwdriver depending on style of shaft block Remove hood screws and hood using a 3 8 wrench socket Place handlebar in upright position Use a 7 16 wrench socket to remove two bolts holding engine shroud in place Push forward on idler arm to remove tension on drive belt While holding idler arm forward with your right hand begin pushing drive belt away from you up and over clutch pulley with your left hand Once belt is off the clutch pulley there is no more tension and can be easily removed Section 2 Installing Drive Belt 1 Start by placing be
9. Section 1 Removing Shift Cable 1 2 8 9 Lower handlebars and remove two screws at top of handlebar cover using 3 8 wrench socket Remove two bolts at pivot point of handlebar cover using 3 8 wrench socket and 2 Philips screwdriver Set handlebar cover in hopper and raise handlebars to upright position Remove shaft block and spinner assembly using a 7 16 wrench socket and 1 8 Allen wrench or 3 Philips screwdriver Remove hood by taking out 2 screws using a 3 8 wrench socket Remove white lock nut with 7 16 wrench socket Remove two orange urethane washers Leave the two nylon washers on pivot stud Remove shift lever using 2 7 16 wrenches sockets Remove rod end from end of cable and slide lower boot up the cable shaft Loosen two nuts using two 15 16 wrenches Twist top nut and washer off by hand and slide over boot and off cable completely Pull cable down through hole Clip cable tie holding shift cable and service cable together Remove clamp using a 3 8 wrench socket and a 2 Philips screwdriver 10 Remove cable rod end from shift arm using two 7 16 wrench sockets 11 Pull cable towards the front to remove completely from machine Section 2 Installing Shift Cable 1 Pull shift arm all the way forward so transaxle is in high gear Before attaching cable to shift arm make sure the rod end is turned all the way on cable This rod end is located on the end of the
10. See Pictures as an example 3 Line up slots of cable guide nut feed cable through and connect barrel fitting of cable to lever 4 Place machine in neutral and start Adjust top rom using cable guide nut tighten nut when 3500rpm is achieved NOTE Check idle rpm Adjustment can be made using a 2 Philips screwdriver in small increments Turn out to decrease and in to increase Rom should be between 1600 1650 Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 48 www permagreen com 1 800 346 2001 Section1 Step5 Section2 Step1 Section2 Step4 49 www permagreen com 800 346 2001 Wire Harness Replacement T300307 T300305 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual NOTE Wear Protective Eyewear and Gloves Parts Included Tools Needed Additional Parts may need to be ordered 1 T300307 Starting Module 3 8 Wrench Socket 1 346276 2 1 2 Seal Patch 1 300309 Wire Harness Lead Only 5 16 Wrench Socket 1 R347042 Wire Tie Stud 3 Philips Screwdriver 3 R347041 8 Wire Tie 2 Philips Screwdriver 7 16 Wrench Socket 1 8 Allen Wrench Dykes Section 1 Removal and Replacement 1 O 00 Remove spinner assembly using 7 16 wrench socket and 1 8 Allen wrench or 3 Philips screwdriver depending on the style of shaft
11. Disconnect wire on front of kill switch Turn control knob to the side so the set screw is facing forward and use a 3 32 Allen wrench to loosen set screw and remove knob Use a 7 8 wrench socket to remove brass nut on valve Pull valve down and out of the dashboard The valve will remain in the same position as they would be if connected to the dashboard NOTE Low selector valve is in back High selector valve is in front Remove hose clamps with pliers If replacing both valves it is recommended you replace one at a time so hoses do not get connected to the wrong valve Hint before disconnecting mark T trim and W wide on the hoses for easy identification when installing new valve Apply heat to the hoses around the three elbow fittings with a heat gun or small torch Do not hold heat source too close to hoses or they will burn If you do not have a heat source you can use needle nose pliers and pry hoses from elbow fittings This method is more difficult but is an alternative option Hoses should remain in position Section 2 Installation 1 BW Assemble new valve according to one removed Low selector valve Trim 1 4 elbow fitting Wide 3 8 elbow fitting High selector valve Trim and wide 1 4 elbow fitting Push hoses on the correct elbow fittings If hoses are difficult to push on you can dip elbow fittings in soapy water Install hose clamps Install valve on da
12. Remove two bolts holding cable bracket on front of gearbox Leave bracket hanging in place Remove four lock nuts on gearbox using a 7 16 socket Pull gearbox out from brackets Note gearbox pump bracket only re moved from machine to show location of lock nuts Remove the bushing and internal star washer from old gearbox to be used on new gearbox Section 2 Installation NOTE New gearbox is shipped with locknuts hand tightened on studs and pulley snug on shaft Remove these parts prior to Installation set screw requires a 5 32 Allen wrench 1 2 Install gearbox on bracket and tighten four lock nuts Install cable bracket on front of gearbox with two bolts Turn gearbox shaft so flat side is facing up Put a couple drops of blue loctite on gearbox shaft and on set screws of pulley Slide pulley on shaft Line up pulley with pump pulley and transaxle pulley Make sure one set screw is lined up over flat side of shaft Tighten both set screws with a 5 32 Allen wrench Slide pump forward but not out of bracket Position belt around all three pulleys Once belt is around pump pulley carefully slide pump pulley back creating tension on belt CAUTION do not push back too far Too much tension may cause pump shaft to bend and could potentially break under high rom Tighten nut on top of bracket and test belt tension To test belt tension place a straight edge from pump pulley to gearbox pulley Push down on belt with your
13. available at www permagreen com or 800 346 2001 42 www permagreen com 1 800 346 2001 Section1 Step3 Section2 Step2 Section2 Step4 Section2 Step4 43 www permagreen com 800 346 2001 Sulky Brake Cable Replacement T654040 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual Safety Equipment Needed Wear Protective Eyewear and Gloves during the removal and installation of sulky brake cable Parts Included Tools Needed Additional Parts may be ordered 1 T654040 Sulky Brake Cable 1 8 Allen Wrench 1 R347041 Wire Tie 8 Nylon 3 8 Wrench Socket 2 R347042 Wire Tie Stud 5 16 Wrench Socket 2 R651206 Locknut 10 24 7 16 Wrench Socket 2 R651450 Fender Washer 3 16 x 3 4 Needle Nose Pliers 2 654525 Band Tension Spring Dykes Side Cutters 3 Philips Screwdriver Section 1 Removing Sulky Brake Cable 1 Raise sulky high enough so that tires are not touching the ground You may use a lift jack or simply have large enough blocks to place under 2 3 sulky deck Remove cotter pin from axle on each side using a pair of dykes or other set of pliers Carefully remove each tire Do not lose spacing washers located on outside of rim NOTE There may be a different quantity for each side make sure you reinstall same amount of spacing washers as removed 4 ef 7 8 9 Remove hairpin from each brake band holder tab Use needle nose pliers and 3 8 wrench socket to rem
14. block the machine is equipped with Remove hood by taking out two screws with a 3 8 wrench socket Lower handlebars Remove two screws on top of handlebar cover using 3 8 wrench socket Remove two bolts at handlebar cover pivot point using 3 8 wrench socket and 2 Philips screwdriver Set handlebar cover inside hopper Use dykes to clip all wire ties that hold the group of plumbing hoses and cables together Clip and remove stud wire tie located on the lower stringer Lift heat shield on gearbox pump bracket and locate where wire harness connects to neutral switch on transaxle Remove seal patch and slide wire harness off neutral switch Disconnect ground wire and jumper wire located in front of engine Unhook front wire from kill switch and unplug black wire from connector that leads to hour meter Remove bolt holding delta located behind spray valve using a 5 16 wrench socket and 3 8 wrench socket The wire harness is now completely disconnected and can be removed When removing existing wire harness make note on how it is routed throughout the machine The plug that connects to neutral switch on transaxle is routed behind the gearbox pump bracket Then passes through cable loop behind plumbing to the back of the spray valve bracket Once everything is connected use supplied cable ties to fasten the plumbing hoses and cables together DO NOT tie down deflector cable Install seal patch 10 Install han
15. either wheel turns slightly as if brake band is not engaging each brake has its own in line adjuster First release lever from lock position Individually adjust each in line adjuster as needed Then repeat beginning of this step Continue this process until you can t turn either wheel by hand NOTE Grease wheel hubs Final Brake Inspection Mark line on the ground Operate machine in high gear Pass over line marked on the ground When sulky wheels reach the line engage the brakes by squeezing the lever Only the sulky brakes Machine should stop within 5 to 8 of starting line Potential Situation Machine does not stop within specified range Solution 1 turn inline adjusters slightly out and test again Solution 2 tighten lock nut on each cable stud in small increments until desired braking results 10 Once brakes are adjusted properly reinstall hood and spinner assembly and handlebar cover Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 44 www permagreen com 1 800 346 2001 Section1 Step4 Section2 Step7 Section2 Step9 Section2 Step9 45 www permagreen com 1 800 346 2001 Throttle Cable Replacement T654270 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual Parts Included Tools Needed 1 T654270 Th
16. holding the back of the engine plate and then install assembly on machine Once all five dampers are seated on Frame make sure there is even spacing between engine plate and frame and then tighten five lock nuts on dampers using gt swivel head socket a 6 or 8 extension Refer to Section2 Step 1 pictures for spacing 2 Insert two torque bolts and turn lock nuts on so that a couple threads show through NOTE these torque bolts must remain loose Do Not Tighten 3 Reconnect jumper wire and ground wire located at the front of the engine 4 Install drive belt Start by placing belt around outer pulley located on the transaxle Feed the belt through so that it follows the diagram shown Once you are in position to route the drive belt over the clutch pulley push forward on idler arm with right hand and feed belt over clutch pulley with your left hand 5 Reconnect throttle cable to throttle linkage Refer to Pictures Section1 Step3 Snug down conduit clip so that ferrule is exposed about halfway This is an initial setting for the throttle cable that should set RPM s close to 3450 DO NOT install air filter and cover at this time Start machine and squeeze throttle lever If RPM s are near 3450 tighten conduit clip completely If not close to 3450 loosen clip pull cable slightly tighter and snug clip and pull lever again Continue this process until results are achieved To adjust RPM in smaller increments loosen cable guide nut To
17. increase RPM turn cable guide screw out To decrease RPM turn cable guide screw in Tighten cable guide nut when finished NOTE Adjusting max RPM may change idle RPM To change idle RPM use a 2 Philips screwdriver and turn idle adjustment screw Turn out to decrease idle and in to increase RPM Idle RPM should be between 1600 1650 Once 5 are set turn machine off and install air filter and cover 6 Install engine shroud 7 Install hood and spinner assembly Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 CON 12 www permagreen com 1 800 346 2001 Section1 Step4 Section1 Step4 Section1 Step5 Section1 Step10 Section2 Step1 Section2 Step2 Section2 Step4 Section2 Step5 Section2 Step5 www permagreen com 1 800 346 2001 Engine Vibration Dampers Replacement T449420 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual Safety Equipment Needed Wear Protective Eyewear and Gloves PARTS Included TOOLS Needed 7449420 Damper Complete Kit 3 Philips Screwdriver or 7 16 Wrench and 1 8 Allen Wrench depending on style of set block Ratchet 3 8 Socket 7 16 Wrench amp Socket 10 inch Extension Bar 2 Wrench Sockets 2 Philips Screwdriver 7 Swivel Head Socket Section 1 Removal
18. larger to allow the 5 16 18 bolts to fit This change has become a standard of the assembly and needs to be converted Put engine back on machine and check for even spacing between engine plate and frame Reattach the 5 nuts for dampers and 2 torque bolts NOTE 2 torque bolts should be left loose enough to spin freely by hand Reconnect ground and jumper wires Reinstall drive belt Start by placing belt around outer pulley located on the transaxle Feed the belt through so that it follows the diagram shown Once you are in position to route the drive belt over the clutch pulley Push forward on idler arm with right hand and feed belt over clutch pulley with your left hand Reconnect throttle cable Snug down conduit clip when ferrule is just past the clip This initial adjustment should set RPM s close to 3450 Start machine and squeeze throttle lever If RPM s are near 3450 tighten conduit clip completely If not close to 3450 loosen clip and pull cable slightly tighter and snug clip and pull lever again Continue this process until results are achieved To adjust RPM in smaller increments loosen cable guide nut To increase RPM turn cable guide screw out To decrease RPM turn cable guide screw in Tighten cable guide nut when finished NOTE Adjusting max RPM may change idle RPM To change idle RPM use a 2 Philips screwdriver and turn idle adjustment screw Turn out to decrease idle and in to increase RPM Final RPM
19. lock nut Install three tension screws Each tension screw consists of 1 screw 1 orange urethane washer 1 counter sunk nylon washer and 1 nylon flat washer The nylon flat washer must go between shut off plate and hopper and then screw orange urethane washer and counter sunk nylon washer go over shut off plate Snug down all three tension screws but do not over tighten Slide plate back and forth by hand to make sure it functions smoothly If it seems tight you may have to loosen one or all tension screws it seems too loose you may have to tighten one or more tension screws a couple turns Install hopper cable on shut off plate Make sure fender washer goes on stud first then the cable rod end Install agitator arm and agitator Insert cotter and bend one end out with dykes to secure it in place Install shaft block and spinner assembly Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 60 www permagreen com 1 800 346 2001 ty i Section1 Step1 Section2 Step2 Section2 Step3 Section2 Step4 6 www permagreen com 1 800 346 2001 10 15 POWER TRANSMISSION SCHEMATIC GROUP
20. of cable above the plumbing that connects the spray tanks underneath the frame and then up and around engine plate Route cable along the right handle column up and behind steering cable Pass through cable loop and then insert into lever Carefully route cable through brake band assembly It is important that you insert cable correctly so that the ferrule seats in the correct brake pin Refer to Section1 Step5 Once cable is through install lock nut so that 11 16 of the threads are shown Then install brake band bracket assembly on sulky and reinstall hairpin to hold in place Repeat this step for both sides Install two stud wire ties on sulky and loop around each cable Do not pull completely tight Leave some room for cable to move freely Install conduit clips on sulky fender as shown Route the cable on top side of screw When tightening conduit clip be sure to leave enough slack as shown so that cable runs straight with brake band bracket Install both tires making sure you put spacing washers in place and then install cotter pin and bend one end with dykes Pull sulky brake lever once and then release You want to make sure there is no gap when lever springs back into position To remove slack turn the upper in line adjuster until lever is drawn against bracket then tighten the white locking nut in position Initial brake testing Place sulky brake lever in lock position See if either wheel turns when lever is locked If
21. shift cable rod end on shift bracket using two 7 16 wrenchs sockets 8 Remove hairpin from front brake bracket and slide assembly off hub Use needle nose pliers to squeeze snap fitting and then pull cable through bracket Disconnect hook from eyelet and remove front brake assembly from machine completely Squeeze snap fitting on service brake cable and remove from bracket 9 Use caution disconnecting elbow fittings from the pump You will have some spillage that may get on your hands or in your eyes Be sure to have protective eyewear and gloves Slide blue locking tabs out and then pull elbow fitting from pump 10 Using a 3 8 wrench loosen nut on bottom of pump bracket at the pivot point Pull pump forward until top bolt and washer are out of bracket Then pull pump up and out 11 Remove four bolts holding pump gearbox bracket on transaxle using socket with extension wrench There are two nylon spacers located under the front bolts of the pump gearbox bracket Do not lose the spacers You will need them when installing new transaxle The torque strap is located under rear bolts Remove entire bracket with gearbox still attached You will have to move hoses aside to get bracket out Nylon spacers may either be on the transaxle or stuck to the bottom of the bracket 12 Peel off seal patch and unplug wire harness from neutral safety switch 13 Lower handlebars and remove two screws using 3 8 wrench socket to open cover Using needl
22. should be between 1600 1650 Reinstall air filter Reinstall engine shroud Reinstall hood shaft block and spinner assembly Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 www permagreen com 800 346 200 Section1 Step4 Section1 Step5 Section1 Step7 Section1 Step7 gt KR Section1 Step10 Section2 Step1 Section2 Step3 Section2 Step7 Section2 Step8 Section2 Step10 www permagreen com 800 346 200 Gearbox Replacement T422350 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual Parts Included Tools Needed 1 T422350 Gearbox 7 16 Wrench Socket 1 653710 Gearbox pulley 3 8 Wrench Socket 4 R651216 20 lock nut 3 Philips Screwdriver 2 P651660 20 5 8 bolts 1 8 Allen Wrench 2 P651480 1 4 Lock washers 5 32 Allen Wrench Section1 Removal 1 Remove shaft block and spinner assembly using a 7 16 wrench and 1 8 Allen wrench or a 3 Philips screw 2 4 5 driver depending on style of shaft block Remove hood screws and hood using a 3 8 wrench socket Use a 3 8 wrench to loosen top nut on the pump Pull pump slightly forward to remove tension on belt Remove belt and slide pump back as far as it goes
23. the shift lever must be properly positioned Push up on the shift lever to extend the cable completely The shift lever should come close to the top of the handle column frame approximately 1 8 to of space between the lever and frame Adjust the two 15 16 nuts either up or down until you achieve the spacing specified Once the shift lever position is set tighten the 15 16 nuts completely Check position of the shift stop Shift into neutral Shift stop should be just below shift lever Adjust nut using 4 socket and 11 32 socket Once set move shift lever through all gears to make sure it is working properly NOTE When pulling lever up to high gear make sure lever does not hit top of column If lever hits the top it may not shift completely into high gear Refer back to section 2 Step 6 to adjust if necessary Install hood spinner assembly and handlebar Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 36 www permagreen com 1 800 346 2001 Section1 Step2 Section2 Step5 Section2 Step6 Section2 Step7 97 www permagreen com 1 800 346 2001 Steering Cable Replacement T654060 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual Safety Equipment Needed Wear Protective Eyewear and
24. tighten log nuts Lower jack and repeat for other side 7 Plug wire harness on neutral switch of transaxle Install seal patch over plug 8 Place round nylon spacers over center mounting holes of transaxle Carefully set the gearbox pump bracket on transaxle lining up holes with the torque strap and nylon spacers Insert four bolts and tighten completely Route hoses over and around bracket as shown in the picture 9 Install pump by inserting bottom stud at pivot of bracket and then insert top nut and washer into slot of bracket making sure washer is on the outside Snug bottom nut with a 3 8 wrench but leave enough room to allow pump to pivot Leave top nut loose until further instruction 10 Install elbow fittings into pump as shown Be sure to push in blue lock tabs on pump to secure fittings 11 Install front brake assembly Insert hairpin to hold in place Make sure cable is routed under the shift bracket and to the bracket located on gearbox Slide cable through slot and snap cable in place Connect eyelet from service cable to front brake cable and then feed into slot and snap into place 12 Mount shift cable to shift bracket using two 7 16 wrench socket 13 Install spinner belt Push pump back to create tension on belt To achieve proper tension place a straight edge on top of pump pulley to top of gearbox pulley Use you finger to push down on belt Belt should be pushed down approximately 1 2 14 Place handlebars in upright p
25. 1 Step18 Section1 Step19 www permagreen com 1 800 346 2001 Section 2 Transaxle Replacement T210303 Continuing from previous page WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual Section 2 Transaxle Installation NOTE Outer pulley on transaxle left loose by manufacturer to be adjusted after installation of transaxle is complete 1 Make sure floor jack is completely lowered Place transaxle so it is centered on floor jack Transaxle should be parallel to the ground if placed on jack properly 2 Carefully guide the jack and transaxle under machine by holding axle with one hand and pushing jack with the other Position transaxle so that it is centered under frame Start raising jack and guide transaxle to line up mounting holes with frame and line up back of transaxle with torque strap Only apply light pressure on jack to allow slight movement for lining up mounting holes Insert four bolts and hand tighten nuts 3 Center transaxle with frame by carefully moving it back and forth until there is an equal amount of reveal on each end cap Tighten all four bolts completely Lower jack and move aside 4 Install brake band assembly on brake tab Insert hairpin to hold in place Install hubs Refer to diagram included with new transaxle kit for proper installation Place jack on either side under lower stringer next to a tire Raise machine enough to slide tire out Install tire on hub and
26. 7 Me 8 9 Gelee ea ao DEE 10 11 Engine Vibration Damper Replat EE 12 13 TN 14 15 Pr NNN 16 17 FANN 18 19 Jan EN 9 EEE usun 20 25 CABLE AND LEVER GROUP Fert Assembly ReplaCE EE 26 27 Font Broke EE 28 29 Front Brake NN 30 31 Hopper CDER u u ua a E E EE NE E 32 33 MENN 34 35 FTV 36 37 Spray Brike Lever Repi EE E T Ve RE 38 39 l O u NE EE ER nha EE 40 41 S lky Brake Cable Ee 42 43 0 Cable Replacemieir ___ __ _______ yan 44 45 Irt bo 46 47 ELECTRICAL GROUP T NNN 48 49 SULKY GROUP MN NNN 50 51 SPRAYER GROUP FET NNN 52 53 54 55 Tr 56 57 SPREADER GROUP si e 5 2 EE EE 58 59 SCHEMATIC SECTION POWER TRANSMISSION SCHEMATIC GROUP NNN 60 HOPPER SCHEMATIC GROUP Hopper Schemat E 61 CABLE AND LEVER SCHEMATIC GROUP Cable and Lever Sche mati EE 62 64 ELECTRICAL SCHEMATIC GROUP Elec mj ea 65 SPRAYER SCHEMATIC GROUP NN 66 Ms NNN 67 SULKY SCHEMATIC GROUP 38 L ME 68 MN 69 3 www permagreen com 1 800 346 2001 Page left intentionally blank www permagreen com 1 800 346 2001 Avoid serious injury Lack of training human error or carelessne
27. Cable 1 2 4 Hook eyelet to front brake cable and pull cable through slotted bracket and snap fitting into place Refer to picture Section1 Step6 Route other end of cable behind stringer and up through cable loop Follow same route as the throttle cable 3 Open lever place end of cable in lever housing and close Refer to picture Section1 Step7 To adjust tension turn in line adjuster until slack in cable is gone and spring on front brake cable opens About 1 8 Before installing hood and spinner assembly carefully follow testing instructions Make sure you are in an open safe area Mark a line on the ground to use to test stopping distance Operate machine in high gear towards designated mark When front of sulky tires reach the line squeeze service brake lever Machine should stop approximately 5 from line If machine stops too suddenly or past 5 you will need to adjust front brake cable See front brake cable instructions and follow steps 3 5 of removing front brake cable Once removed use needle nose pliers to hold stud and tighten nut if machine stops beyond 5 If machine stops too suddenly loosen nut Test braking and continue this procedure until results are achieved Once adjusted to correct stopping distance use supplied cable tie to tie shift cable and service brake cable as shown 5 Reinstall hood and spinner assembly and handlebar cover Referring to page 18 and 19 of Operator s Manual successfu
28. Gloves Note Clean off any debris from hood amp spinner platter and around axle end of front tires Using a jack or lift raise front of machine so that the tire you are working on is off the ground Parts Included Tools Needed 7654060 Smart Steer Cable 3 Philips Screwdriver 3 8 Wrench Socket 7 16 Wrench Socket 1 8 Allen Wrench Section 1 Removing Smart Steer Cable 1 Open handlebar cover by removing two screws using 3 8 wrench Remove shaft block and spinner assembly using a 7 16 wrench and 1 8 Allen wrench or 3 Philips screw driver Remove hood screws and hood using a 3 8 wrench Use a flathead screwdriver to pry e clip from the axle Use caution e clips are under tension and may pop off suddenly Remove tire and make BW N N O Place handlebars in down position sure you do not lose the flat washers and keyways See exploded diagram Remove hairpin that holds brake band bracket in place and remove bracket from tab Use needle nose pliers and 3 8 wrench socket to remove lock nut and then carefully pull cable through brake pins Hint use a marker to mark which brake pin the cable needs to pass through when installed BRAKE PINS When removing cable from brake band assembly it is important to identify which brake pin the cable needs to pass through first when installing There is a universal brake pin and a brake pin that has been counter sunk to allow the ferrule to be seat
29. PERMAGREEN SUPREME INC Triumph Repair Parts Manual For Models BIB serial numbers 12657 and above Avoid serious injury Lack of training human error or carelessness may cause serious in jury or death to the operator mechanic or others e All users mechanics and owners SHALL read and understand the Operator s Manual before inspecting operating or repairing the Triumph If you not entirely familiar with the Operator s Manu al and the Safety Messages it contains read it now before proceed ing with any repairs or maintenance Periodically check permagreen com for available Triumph updates For Technical Support Perma Green Supreme Inc October 31 2012 Contact your local dealer or PermaGreen at 800 346 2001 Triumph Repair Parts Manual v13 or via e mail at tech permagreen com North American Version Copyright 2010 Perma Green Supreme Inc All rights reserved No part of this book covered by the copyright hereon may be reproduced or copied in any form or by any means except as permitted by the proprietary data statement for use with Perma Green Supreme equipment without the written permission of Perma Green Supreme Inc Triumph is protected by US Patent 6 336 600 and 7 954 573 www permagreen com 800 346 200 Page left intentionally blank www permagreen com 1 800 346 2001 Table of Contents REPAIR SECTION POWER TRANSMISSION GROUP ETNE 4 5 UT NNN 6
30. cable without the 15 16 nuts and washers Attach cable to shift arm with one bolt and one lock nut Refer to Picture Section 1 Step 10 Install cable clamp Notice there is a groove in the cable where the clamp should seat itself This will position cable properly on the frame Route end of cable with the 15 16 nuts under the lower stringer then up and over engine shroud Remove rod end and ONLY the top nut and washer from the end of the cable Slide lower boot up the cable to allow nut to pass over Route cable up through hole on handle column frame and then place washer and nut on cable Turn the top nut down until the first thread passes through the top of the nut Push cable back down through hole until the top nut and washer touch the frame Then turn bottom nut up until it is snug on the bottom of the handle column frame Slide boot back in place Install rod end and turn all the way down until it is right Position shift lever as shown in picture and slide between handle column and frame Connect shift lever to rod end and first by inserting bolt through the back of the lever and then through the rod end Tighten nut completely Place end of lever on the pivot stud Install two orange urethane washers and white nylon lock nut Snug down white nut but do not over tighten Orange washers will begin to squeeze out if white nut is too tight Refer to picture Section 1 Step 5 Before tightening the two 15 16 nuts completely
31. d Remove the air filter and disconnect the throttle cable Use 2 screwdriver to remove conduit clip Use a 7 16 wrench and 1 8 Allen wrench or a 3 Philips screwdriver to remove shaft block and spinner assembly Use a 3 8 socket to remove the two screws on the hood Remove hood Disconnect the jumper wire and ground wire from the front of the engine Use gt wrench socket with a 6 or 8 extension bar to remove the 4 bolts that connect the engine to the engine plate Lift engine off of machine We recommend checking vibration dampers after removing engine Remove the 2 torque bolts with a 7 16 socket a 6 or 8 extension and ratchet and a 7 16 wrench NOTE Some torque bolts may require wrenches Remove five bolts that are holding dampers to the engine plate with 72 wrench socket Lift engine plate off dampers and set aside Lift up on each damper to make sure it is secure If any fail it will look like the picture shown If one damper has failed it is recommended to change all five at this time Follow step 9b for damper removal If all five dampers are secure skip to Section 2 Step 1a Remove five nuts holding dampers to frame using a gt swivel head socket a 6 or 8 extension bar while holding the dampers with your hand or pliers Skip to Section2 Step 1b Section 2 Engine Installation NOTE Torque Bolts The engine vibration Dampers kit includes 2 5 16 18 torque bolts If your
32. derneath front of sulky See picture step 1 O CON Raise machine and make sure sulky is supported and will not move when loosened Use a 1 1 8 wrench and remove both top bolts on sulky and remove rod end assembly Make sure the same bolts go back into the same positions When removing rod end assembly do not turn assembly This will change length of assembly Measure or count threads on old rod end assembly and copy to new assembly Start by tightening bolt mounted on the frame Then line up bolt mounted on sulky You may have to move sulky up or down in order to line up sulky properly Make sure bolt is not cross threaded and tighten If only replacing top rod end assembly Stop Here Use 2 7 16 wrenches to remove safety bolt lock Crack bolt loose on bottom rod end but do not remove Raise machine and make sure sulky is supported and will not move when loosened Use 1 1 8 wrench to remove sulky bolt Turn rod end out to remove If rod end is stuck put an adjustable wrench on flat part of rod end and another adjustable wrench 22 16 nut Try to remove end without moving threaded stud 10 Twist new rod on threaded stud until there are of threads showing 11 Line bolt up with frame You may have to raise or lower the sulky to do this Make sure bolt is not cross threaded before tightening Also make sure seal is between frame and top of rod end 12 Reattach safety bo
33. dlebar cover hood and spinner assembly Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 50 www permagreen com 1 800 346 2001 Section1 Step4 W Section1 Step8 Section1 Step9 Section1 Step9 5 www permagreen com 1 800 346 2001 Sulky Rod End Replacement T652510 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual Safety Equipment Needed Wear Protective Eyewear and Gloves Parts Included Tools Needed 3 R652478 Rod End Seal 11 8 Wrench 1 R652462 Rod End Female 34 2 7 16 Wrenches 1 T652662 TOP Female Rod End Adjustable Wrench 1 R652472 Rod End Male Important READ FIRST Lock the front brake and sulky brake by engaging the locks on the levers If replacing top rod end only crack two top bolts loose and follow steps 1 4 If replacing bottom rod end only skip steps 1 4 and begin with step 5 If replacing both rod ends you must remove safety bolt lock first and then crack three bolts loose before raising machine before removing bolts completely Make sure machine and sulky are supported equally Use extreme caution machine is very heavy and could cause serious injury if support fails RECOMMENDATIONS FOR SUPPORT Use two jack stands or bottle jacks underneath back of frame and a floor jack or sturdy block un
34. e Operate machine in high gear towards designated mark When front of sulky tires reach the line squeeze service brake lever Machine should stop approximately 5 from line to the front of sulky tires If machine stops too suddenly or past 5 you will need to adjust front brake cable See front brake cable instructions and follow steps 3 5 of removing front brake cable Once removed use needle nose pliers to hold stud and tighten nut if machine stops beyond 5 If machine stops too suddenly loosen nut Test braking and continue this procedure until results are achieved Once adjusted to correct stopping distance use supplied cable tie to tie shift cable and service brake cable as shown Reinstall hood and Spinner assembly Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 32 www permagreen com 1 800 346 2001 aa Section1 Step3 Section1 Step6 Section2 Step1 Section2 Step2 33 www permagreen com 800 346 2001 Hopper Cable Replacement T654020 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual Parts Included Tools Needed 1 T654020 Hopper Cable 3 8 Wrench Socket 2 Philips Screwdriver 2 11 16 Wrench Section1 Removing Hopper Cable 1 2 3 4 5 Place handlebar in down position Open handlebar cov
35. e nose pliers and 3 8 wrench socket loosen nut on steering cables to remove tension on brake bands WN PR N O Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 22 www permagreen com 1 800 346 2001 Section1 Step1 Section1 Step1 Section1 Step2 Step10 ER Section1 Step13 Section1 Step13 Section1 Step14 23 www permagreen com 800 346 200 Triumph Transaxle Replacement T210303 Continuing from previous page WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual Safety Equipment Needed Wear Protective Eyewear and Gloves PARTS included Tools needed 1 T210303 Triumph Transaxle Replacement 2 7 16 Wrench Socket 1 P645240 20x1 Bolt Philips Screwdriver 1 R651216 20 Lock Nut Needle Nose Pliers 4 T650805 5 16 18x1 Zinc Bolt 2 Socket Wrench 4 R651482 5 16 Lock Washer Flathead Screwdriver 1 346276 Seal Patch 2 1 2 Floor Jack 1 P210110 28x1 2 Hardened Bolt 13 16 Socket 1 8 Allen Wrench Section 1 Removing Transaxle 14 Place sulky brake lever in lock position and place blocks in front and back of sulky tires Crack loose all lug nuts on both front tires Slide floor jack under front of machine to the lower stringer Lower stringer runs directly under spray tanks Rais
36. e one side so tire is at least 3 off ground Remove lug nuts on raised tire only Remove tire and lay flat with valve stem facing down Slide tire under lower stringer according to picture Lower jack and repeat procedure for other tire 15a Remove e clips using a flathead screwdriver or needle nose pliers on both hubs Remove both hubs from the transaxle NOTE If either hub is locked on transaxle and will not come off refer to step 15b for removing brake assembly If both hubs come off easily skip to step 16 Remove hairpin and slide brake assembly off tab Hold cable stud with needle nose pliers and remove nut with a 3 8 wrench socket Slide cable out of brake assembly Remove front brake pin to allow bracket to open up and slide off hub Once brake assembly is off it can be assembled again Brake Pin Instructions When removing cable from brake band assembly it is important to identify which brake pin the cable needs to pass through first when installing There is a universal brake pin and a brake pin that has been counter sunk to allow the ferrule to be seated in the brake pin See pictures If ferrule is not seated in the counter sunk brake pin the brake band will not engage properly which will result in poor brake function Initial setting for left side is to turn lock nut down where 3 8 threads are shown Right side is 1 8 After brake is assembled flip upside down and insert on tab This will keep cable out of the way while remov
37. ed in the brake pin See Pictures If ferrule is not seated in the counter sunk brake pin the brake band will not engage properly which will result in poor brake function Use needle nose pliers and 3 8 wrench socket to remove lock nut on v bracket Use needle nose pliers to squeeze tabs on cable housing and gently pull on cable from underneath and then feed cable out of bracket Then pull from top to remove 10 Repeat steps 1 9 for other side NOTE left side cable is tied to other cables and hoses Clip tie and replace with supplied cable tie Section2 Installing Smart Steer Cable 1 nm OQ 7 Install new cables each brake band assembly Remember route through brake correctly threaded stud is through brake install nut on end of stud Initial settings for nut on left side is approximately 3 8 The right side is approximately 1 8 Using needle nose pliers to hold stud and 3 8 wrench socket to adjust Place each brake band assembly on the brake tab bracket Install hairpin on each side Route left side cable through frame slot Then behind lower stringer up through cable loop Feed cable through slotted bracket tab and snap into place Slide boot over cable Push stud end of cable through v bracket and place nut on stud and hand tighten only Tie all cables and hoses together except for the deflector cable Route right side cable through frame slot Then behind lower stri
38. ep1 Section1 Step2 2 www permagreen com 1 800 346 2001 Triumph Replacement T210303 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual PARTS Included Tools Needed 1 T210303 Triumph Transaxle 2 7 16 wrench socket 1 P645240 20x1 bolt 3 Philips screwdriver 1 8651216 20 lock nut Needle nose pliers 4 T650805 5 16 18x1 zinc bolt 2 7 socket wrench 4 R651482 5 16 lock washer Flathead screwdriver 1 346276 seal patch 2 1 2 Floor jack 1 P210110 28x1 2 hardened bolt 2 2ton jack stands 13 16 socket 1 8 Allen wrench Section 1 Removing Transaxle Remove spinner assembly Style 1 Use a 7 16 wrench socket and 1 8 Allen wrench to loosen shaft block Style 2 Use a 3 Philips screwdriver to loosen shaft block Remove assembly Remove hood by taking out two screws with a 3 8 wrench socket Remove engine guard by using a 7 16 wrench socket and take out two bolts Using your right hand push idler arm forward to relieve tension on belt Use your left hand to push belt forward over clutch pulley Once belt is off pulley remove belt from machine completely Remove spinner belt using a 3 8 wrench to loosen nut on top of pump bracket Pull pump toward you to relieve tension on belt Remove belt from machine completely Peel back heat shield to expose both the front brake bracket and the rod end that connects shift cable to shift bracket Remove bolt holding
39. er by removing two screws using a 3 8 wrench socket Using 2 Philips and 3 8 wrench remove screw holding rod end on hopper control arm Use two 11 16 wrenches to loosen nuts holding cable on slotted tab located inside handlebar cover Use two 11 16 wrenches to loosen nuts on hopper bracket Use a 3 8 wrench socket to remove nut holding rod end to hopper plate Cable can now be removed from the machine Section2 Installing Hopper Cable 1 00 Route end of cable without boot over top stringer of frame and up to slotted bracket Unscrew nuts to open up enough so you can slide the cable on the bracket with one washer and one nut on top and the other washer and nut on bottom Hand tighten only at this point Unscrew nuts on cable and slide onto hopper bracket keeping one nut and washer all the way towards the back of threads Slide onto bracket and tighten nuts using two 11 16 wrenches Refer to Picture Section1 Step4 Place flat washer on stud of hopper plate Hold in place and slide rod end over stud and then tighten lock nut with 3 8 wrench socket Refer to picture Section1 Step5 adjust hopper control plate first open hopper plate completely by hand Push hopper control lever forward all the way in open position Hold rod end up to hopper control lever You want to see if hole on rod end lines up with hopper control lever NOTE This rod end should be tightened down completely so if hole needs to move down
40. est ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 46 www permagreen com 1 800 346 2001 Section1 Step1 Section1 Step5 Section1 Step6 Section2 Step1 Section2 Step3 Section2 Step3 47 www permagreen com 800 346 2001 Throttle Lever Replacement P654136 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual Parts Included Tools Needed 1 P654136 Throttle Lever Pliers 5mm Allen Wrench 5 64 Allen Wrench Section 1 Removing Throttle Lever 1 Use pliers to loosen cable guide nut and line up with slot on bottom of throttle lever 2 Push forward on cable then back on throttle lever 3 Unhook cable barrel on throttle lever 4 Use compressed air or soapy water to remove hand grip 5 Use 5mm Allen wrench to loosen lever and slide out Section 2 Installing Throttle Lever 1 Use a 5 64 Allen wrench to turn adjustment nut until it is flush 2 Slide throttle lever on handle but do not tighten Install grip NOTE if you used soapy water to help remove grip wipe handle clean and dry before installing new grip If you have trouble pushing grip all the way on us a rubber mallet to tap on Seat throttle lever up against brake lever while holding throttle lever Place your index finger between throttle lever and service brake lever This will give you approximate spacing Tighten completely
41. f to the side Use needle nose pliers to remove the hose clamps on each end of spray valve Remove hoses from spray valve use needle nose pliers to pry hoses from spray valve fittings NOW BW FR Lower handlebars and remove two screws at top of handlebar cover using 3 8 wrench socket Section 2 Spray Valve Installation 1 2 3 4 6 7 Hold spray valve with valve closed and handle pointing up Connect hoses to spray valve If you have difficulty pushing hoses over barbed fitting dip barbed fittings in soapy water Install hose clamps on each side of spray valve with the locking side facing towards the back bracket Hold spray valve so it is laying flat against rear bracket Slide front bracket over spray valve and line up bolt holes Insert two bolts and tighten lock nuts evenly Hook cable z bend to the bottom hole of spray valve handle and then close valve by hand so the handle is upright Hook spring to top hole of spray valve handle and then hook other end to bracket Check handle position on valve The bottom should not be making contact with valve Turn in line adjuster until there is a small gap between valve and handle Install handlebar cover Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 56 www permagreen com 1 800 346 2001 Secti
42. finger Belt should be approximately gt from straight edge Samples of straight edges piece of flat stock steel ruler etc Repeat step 4 until proper tension is achieved Place bushing and internal star washer on the upper shaft of gearbox Install hood and spinner assembly Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 www permagreen com 1 800 346 2001 Section1 Step1 mr 2 S __ Section2 Step3 Section2 Step4 Section2 Step5 Section2 Step5 www permagreen com 1 800 346 2001 Spinner Belt Replacement T653805 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual Safety Equipment Needed Wear Protective Eyewear and Gloves Parts Included Tools Needed 1 T653805 Spinner Belt 3 8 Wrench Straight Edge at least 10 long Flat Stock Steel Ruler etc 7 16 Wrench Socket 1 8 Allen Wrench 3 Philips Screwdriver Section 1 Removing Drive and Spinner Belt 1 Remove shaft block and spinner assembly using a 7 16 wrench and 1 8 Allen wrench or a 3 Philips screwdriver depending on style of shaft block Remove hood screws and hood using a 3 8 wrench Place handlebar in upright position Use a 7 16 wrench socket to remove two bolts holding engine shroud in place Push for
43. h pulley with your left hand Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 www permagreen com 1 800 346 2001 Section1 Step 6 Section3 Step1 Section3 Step2 Section3 Step2 www permagreen com 1 800 346 2001 Recoil Starter Replacement T449500 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual Safety Equipment Needed Wear Protective Eyewear and Gloves Parts Included Tools Needed 1 T449500 Recoil Starter 10 mm Socket Section1 Removing Recoil Starter 1 Using a 10 mm socket remove the bolt on the bottom of the recoil starter and the bolt by the pull handle completely 2 Loosen front bolt only a couple of threads The recoil starter is slotted around the front bolt for easier removal and installation Pull recoil starter toward tank and then out Section2 Installing Recoil Starter 1 Insert recoil starter at a slight angle and line up slot with bolt Then push recoil starter closed and insert bottom bolt and the bolt near pull handle Tighten all three bolts Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 20 www permagreen com 1 800 346 2001 Section1 St
44. ing transaxle 15b 16 Remove hairpin from brake tab and remove brake assembly Flip upside down and place back on brake tab and insert hairpin Repeat for other side See picture Section1 Step15b 17 Insert jack from right side of machine and place jack under transaxle lining it up in the center of the mounting holes Raise jack until you make slight contact with transaxle DO NOT apply any more pressure The floor jack is only there to support transaxle when the bolts are removed so it does not fall when bolts are removed 18 Remove four bolts holding transaxle to frame using two wrench socket When removing last bolt use caution because transaxle is loose With one hand hold axle and then slowly lower jack with other hand Lower jack completely Guide transaxle and jack out from under machine Wear gloves when grabbing axle keyway is extremely sharp 19 Remove shift bracket from old transaxle using 3 8 wrench socket Install shift bracket on new transaxle with the new bolt included Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 24 www permagreen com 800 346 2001 s ak k Section1 Step14 Section1 Step15b Section1 Step15b SR Section1 Step17 Section1 Step18 Section1 Step18 Section
45. lly test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 30 www permagreen com 1 800 346 2001 Section1 Step3 s 4 cb EX 1 Section1 Step6 Section2 Step2 Section2 Step2 Section2 Step5 3 www permagreen com 1 800 346 2001 Front Service Brake Cable 2 T654055 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual Safety Equipment Needed Wear Protective Eyewear and Gloves Clean off any debris from hood amp spinner platter Parts Included Tools Needed Additional Parts may need to be Ordered 654055 Front Service Brake Cable 2 3 Philips Screwdriver 1 R347041 Wire Tie 8 Nylon 3 8 Wrench Socket 2 R651206 Lock Nut 10 24 7 16 Wrench Socket 2 R651450 Fender Washer 3 16 x 3 4 1 8 Allen Wrench 2 T654525 Brake Tension Spring Needle Nose Pliers 1 R347042 Wire Tie Stud Side Cutters Dykes 1 R651570 Hair Pin Section 1 Removing Front Brake Cable 1 Remove shaft block and spinner assembly using a 7 16 wrench and 1 8 Allen wrench or 3 Philips screw driver Remove hood screws and hood using a 3 8 wrench or socket Use needle nose pliers to squeeze tabs on the snap fitting and push cable out of slotted bracket Unhook from eyelet of service brake cable Lift heat shield to expose the hairpin and brake band assembly Remove hai
46. lt around outer pulley located on the transaxle 2 Feed the belt through so that it follows the diagram shown Once you are in position to route the drive belt over the clutch pulley Make sure idler spring is attached correctly then push forward on idler arm with right hand and feed belt over clutch pulley with your left hand 3 Reinstall engine shroud hood and spinner assembly Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 www permagreen com 1 800 346 2001 Section1 Step1 Section1 Step5 Section2 Step2 Section2 Step2 Section2 Step2 Section2 Step2 www permagreen com 800 346 2001 Engine Removal and Installation T449403 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual Safety Equipment Needed Wear Protective Eyewear and Gloves Parts Included Tools Needed T449420 Engine Damper Kit 3 Philips Screwdriver T449403 Engine Kit 5 16 Ream Drill bit 1 8 Allen Wrench 7 16 Wrench Socket Drive Ratchet 3 8 Wrench Socket 6 or 8 Extension Bar Socket or Swivel Head 2 Wrench s or Sockets 2 Philips Screwdriver Section 1 Engine Removal Use a 7 16 wrench to remove the 2 bolts on the engine shroud Push forward on idler arm with right hand and push belt forward over clutch pulley with left han
47. lt lock Leave bolt lock loose enough that you can easily move it with your hand Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 52 www permagreen com 1 800 346 2001 53 www permagreen com 1 800 346 2001 Selector Valve Replacement T000530 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual Safety Equipment Needed Wear Protective Eyewear and Gloves Parts Included Tools Needed 1 T454240 701 Valve 3 8 Wrench Socket 1 1454242 701 Locknut 2 Philips Screwdriver 1 1454241 701 Handle w Set Screw 3 32 Allen Wrench 2 R481246 Spare Hose Clamps 26 7 8 Wrench Socket 2 R481243 Spare Hose Clamps 38 Needle Nose Pliers 2 R454022 L Fitting mpt x hose 5 8 Wrench 2 R454023 L Fitting mpt x 3 8 hose Section 1 Removal NOTE It is recommended to remove both valves from dashboard even when one valve is being replaced for easier accessibility Also if replacing both valves it is recommended to replace one at a time not to confuse configuration of plumbing Lower handlebars and remove two screws at top of handlebar cover using 3 8 wrench socket Remove two bolts at pivot point of handlebar cover using a 3 8 wrench socket and 2 Philips screwdriver Set handlebar cover in hopper
48. machine is already equipped with the 5 16 18 torque bolts no action is necessary Use existing torque bolts If your machine is equipped with 20 torque bolts you will need to use 5 16 ream drill bit to make the torque bolt holes on the engine plate larger to allow the 5 16 18 bolts to fit This change has become a standard of the assembly and needs to be converted Remove air filter cover and air filter on new engine prior to installation 1a Set engine plate on dampers and insert five bolts with lock washers Make sure there is even spacing between engine plate and frame and then tighten completely Set new engine on machine and line up the four mounting holes Lift the back of the engine enough to slide two engine spacers in place Insert two bolts Repeat for the two front engine spacers Start lock nuts on bolts by hand and then tighten nuts using a gt wrench and gt socket a 6 8 extension 1b Install five new dampers on engine plate with five bolts and lock washers Tighten completely using wrench socket Set new engine on plate Lift the back of the engine enough to slide two engine spacers in place Insert two bolts Repeat for the two front engine spacers Start lock nuts on bolts by hand and then tighten nuts using two gt wrenches wrench and gt socket Once engine is secure to the engine plate lift assembly with one hand holding the front of the gas tank and the other hand
49. nce contact PermaGreen Tech Support at tech permagreen www permagreen com 1 800 346 2001 Carburetor Replacement P449215 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual Safety Equipment Needed Wear Protective Eyewear and Gloves Parts Included Tools Needed 1 P449215 Carburetor Needle Nose Pliers 10 mm Socket Section 1 Removal 1 BW 00 Remove the air filter Pull the choke and fuel supply towards you Remove the 2 nuts and 1 bolt holding the carburetor cover on with a 10 mm socket Pull the breather tube out of the valve cover and pull the carburetor cover off Pull the spacer for the carburetor off Pull the carburetor forward enough to be able to remove the governor rod and throttle return spring Pull up to unhook governor rod and use needle nose pliers to remove spring Be careful not to bend spring Use needle nose pliers to move clamp on gas line back Pull gas line off gas intake Section 2 Installation 1 Pull old carburetor off and take the gray choke lever and press onto new carburetor 2 Slide new carburetor on and reconnect fuel line Make sure clamp is on the gas intake 3 4 5 Reconnect governor and throttle return spring Put carburetor spacer back on Make sure the notch lines up with the hole in the carburetor Put carburetor cover back on and plug breather tube in 6 Tighten the 2 nuts to cover abo
50. nger and directly up to slotted bracket Make sure cable is routed between spray valve plumbing and the sulky brake and spray cable Feed cable through slotted bracket tab and snap into place Slide boot cover cable Push stud end of cable through v bracket and place nut on Hand tighten only Reinstall tires make sure keyways are in place Install washers and e clips Grease each hub Refer to diagram Initial setting for both cables is slightly different but done in the same manor Using needle nose pliers grab the square bottom of the stud and lift up You will notice a gap between the lock nut and the v bracket This gap should be approximately 1 8 on both the left and right cable You will notice that one side seems tighter than the other That s OK It all depends on the positioning of the handlebars 10 Before closing handlebar cover and reinstalling hood and spinner assembly ride machine in a safe area and engage the left and right steering to ensure proper adjustment If you need either side tighter adjust individual side separately until smart steering is adjusted correctly 11 Once steering is adjusted reinstall hood and spinner assembly and close handlebar cover Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 38 www permagreen com 1 800 346 2001 3
51. ning read Safety Message on page 3 of this manual Safety Equipment Needed Wear Protective Eyewear and Gloves Parts Included Tools Needed 1 T101010 Fert Control Assembly 2 Philips Screwdriver 7 8 Socket 3 8 Wrench 3 32 Allen Wrench 11 32 Socket Socket 7 16 Wrench 7 16 Swivel Head with 10 Extension 3 Philips Screwdriver 1 8 Allen Wrench Section1 Removal 1 Place handlebar in down position 2 Use a 3 8 wrench socket to remove the 2 screws on the handlebar cover 3 Use a 2 Philips screwdriver and a 3 8 wrench socket to remove the 2 bolts on left and right columns and place handlebar cover inside hopper It is not necessary to remove the third hole cable Use a 3 8 wrench and a 2 Philips screwdriver to detach hopper cable Use a 3 32 Allen wrench and 7 8 socket to remove high gear manifold Unplug the 2 wires on the on off switch Remove the 4 bolts for the handlebar assembly and let the handlebar assembly hang down Use a 7 16 wrench and 7 16 swivel head socket with a 10 extension bar to remove bolts Use the 7 16 wrench and 7 16 extension to remove the 2 bolts for the fert control assembly 9 Use 11 32 socket and socket to remove fert control assembly from deflector cable NOUA 00 Section2 Installation 1 Installation is the reverse of removal NOTE When tightening the fert control assembly use 2 bolts in the 2 extra holes to make sure the assembly lines up properly Referring to
52. nual PARTS Included TOOLS Needed 1 T654265 Spray Cable Needle Nose Pliers Dykes Side Cutters 3 8 Wrench Socket 2 Philips Screwdriver Section 1 Removing Spray Valve Cable 1 2 3 4 5 6 Lower handlebar to down position Use a 3 8 wrench socket to remove the 2 screws on the handlebar cover and open Use a 2 Philips screwdriver and 3 8 wrench socket to remove the 2 bolts on left and right columns and place handlebar cover inside hopper It isn t necessary to remove the third hole cable Cut cable ties located on right side of handle column with dykes side cutters Use needle nose pliers and squeeze snap fitting Pull top of cable to free cable from spray valve bracket mount Remove cable from spray valve handle and spray lever Section 2 Installing Spray Valve Cable 1 2 3 4 Route barrel end through cable loop and connect to spray lever Insert z bend of cable into bottom hole of spray valve handle Insert snap fitting into spray valve bracket mount Check handle position on valve The bottom should not be making contact with valve Turn in line adjuster until there is a small gap between valve and handle 5 Use supplied cable ties to fasten cable to right side handle column Refer to picture Section1 Step4 Install handlebar cover Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is
53. on2 Step2 Section2 Step5 Section2 Step6 Section2 Step6 57 www permagreen com 1 800 346 2001 Tank Replacement T204983 Left T204987 Right WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual Safety Equipment Needed Wear Protective Eyewear and Gloves NOTE Drain tanks completely before removing Parts Included Tools Needed 1 T204983 Left Tank 7 16 Wrench Socket and or 1 8 Allen Wrench 1 T204987 Right Tank 3 Philips Screwdriver Needle Nose Pliers 1 Wrench 7 gt Swivel Head Socket 8 or 10 Extension Allen Wrench 3 8 Wrench Socket Heat Gun or Torch Section 1 Remove Tank s 1 Remove shaft block and spinner assembly using a 7 16 wrench socket and 1 8 Allen wrench or a 3 Philips screwdriver 2 Remove hood using a 3 8 wrench socket and take out two screws 3 NOTE Follow step 3 if replacing left tank If replacing right tank skip step 3 Remove engine guard using a 7 16 wrench socket to remove two bolts 4 Each tank has two hoses connected at the bottom of the tank and one hose connected on the top of the tank Remove the two clamps at the connection points of the tank that is being replaced Use a torch or heat gun to soften the hoses around the fittings to make it easier to remove hoses CAUTION Do not hold heat source too close to hoses or for an extended amount of time or hoses will burn 5 Each tank has four bolts holding it on the f
54. osition Leave handlebar cover loose Route drive belt on machine as shown in diagram When ready to place belt over clutch pulley push forward on idler arm with your right hand and feed belt over clutch pulley with your left hand towards you 15 Install engine guard using a 7 16 wrench socket 16 Install hood Tighten down two screws with a 3 8 wrench socket 17 Install spinner assembly Before tightening shaft block make sure cam is positioned in agitator arm as shown in picture Tighten shaft block 18 Lower handlebars and open cover Adjust each steering cable with needle nose pliers and 3 8 wrench socket Lift cable stud and hold Tighten nut down until about 1 to 2 threads are shown This is only the initial setting Once you operate machine and test steering you may have to adjust cable 19 Install handlebar cover 20 Ride machine and test steering See steering cable instructions Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 OY 26 www permagreen com 1 800 346 2001 Section2 Step4 Section2 Section2 Step13 Section2 Step14 Section2 Step12 L Section2 Step17 Section2 Step18 27 www permagreen com 800 346 2001 Fert Control Assembly Replacement T101010 WARNING AVOID INJURY Before begin
55. ove lock nut and then carefully pull cable through brake pins BRAKE PINS When removing cable from brake band assembly it is important to identify which brake pin the cable needs to pass through first when installing There is a universal brake pin and a brake pin that has been counter sunk to allow the ferrule to be seated in the brake pin See pictures If ferrule is not seated in the counter sunk brake pin the brake band will not engage properly which will result in poor brake function Use a 5 16 wrench 3 8 wrench to remove conduit clips on each fender of the sulky Use dykes or other cutters to remove the stud ties at the front of sulky Open handlebar cover using 3 8 wrench and remove two screws Remove shaft block and spinner assembly using a 7 16 wrench socket and 1 8 Allen wrench or 3 Philips screwdriver Remove hood by using 3 8 wrench and take out two screws Steps 8 amp 9 will allow you to see how to route replacement cable 10 Disconnect sulky brake cable from lever NOTE upper lever on left handle bar Cut cable tie on right handle column Push cable through back of frame and then out under frame and feed rest of cable out Section 2 Installing Sulky Brake Cable 1 O Route the threaded stud ends of the cable from under frame through the back center of frame Routing one cable end on each side of center column and over plumbing assembly Feed through until cable no longer pulls through Route single end
56. page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 28 www permagreen com 1 800 346 2001 Section1 Step8 Section1 Step9 Section2 Step1 29 www permagreen com 1 800 346 2001 Front Service Brake 1 T654250 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual Safety Equipment Needed Wear Protective Eyewear and Gloves Parts Included Tools Needed 1 T654250 B Front Brake Cable 1 3 8 Wrench Socket 7 16 Wrench Socket 1 8 Allen Wrench Needle Nose Pliers Side Cutters Dykes 3 Philips Screwdriver Section 1 Removing Service Brake Cable 1 2 3 UT Place Handlebars in down position Open handlebar cover by removing two screws using a 3 8 wrench socket Remove shaft block and spinner assembly using a 7 16 wrench socket and 1 8 Allen wrench or Philips screwdriver Remove hood screws and hood using a 3 8 wrench Cut cable tie and close in line adjuster completely to create slack in cable Unhook eyelet from front brake cable Use needle nose pliers to squeeze snap fitting and pull out of gearbox bracket Open lever to create slack to allow you to remove cable from lever housing Grab end of cable near in line adjuster and pull cable until completely removed from the machine Section 2 Installing Service Brake
57. rame 3 hex bolts 1 socket bolt Use a gt wrench socket to remove two rear hex bolts Use 12 swivel head socket on 8 or 10 extension to remove front hex bolt Use Allen wrench to remove the socket bolt located on the frame under the hopper Section 2 Install Tank s 1 Connect hoses on the appropriate fittings on the bottom of tank 3 8 hose to 3 8 barb fitting to etc Use soapy water if you have trouble pushing hoses on the fittings Install hose clamps around fittings 2 Hold tank in position First get the socket bolt located at front of tank under hopper started by hand Line up other holes and start all three hex bolts by hand Tighten all four bolts 3 Push hose on fitting located at top of tank 4 NOTE Follow step 4 if left tank was replaced If right tank was replaced skip to step 5 Install engine guard on left tank with two bolts using a 7 16 wrench socket 5 Install hood and spinner assembly Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 58 www permagreen com 1 800 346 2001 gt Section1 Step4 Section1 Step5 Section1 Step5 Section1 Step5 59 www permagreen com 1 800 346 2001 Shut off Plate Replacement T422957 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual
58. rottle Cable Pliers 5mm Allen Wrench 5 64 Allen Wrench Section 1 Removing Throttle Lever 1 Use pliers to loosen cable guide nut and line up with slot on bottom of throttle lever 2 Push forward on cable then back on throttle lever 3 Unhook cable barrel on throttle lever 4 Use compressed air or soapy water between the grip and handlebar to remove hand grip 5 Use a 5mm Allen wrench to loosen lever and slide out Section 2 Installing Throttle Lever 1 Use a 5 64 Allen wrench to turn adjustment nut until it is flush 2 Slide throttle lever on handle but do not tighten Install grip NOTE if you used soapy water to help remove grip wipe handle clean and dry before installing new grip If you have trouble pushing grip all the way on us a rubber mallet to tap on Seat throttle lever up against brake lever while holding throttle lever Place your index finger between throttle lever and service brake lever This will give you approximate spacing Tighten completely See Pictures as an example 3 Line up slots of cable guide nut feed cable through and connect barrel fitting of cable to lever 4 Place machine in neutral and start Adjust top rom using cable guide nut tighten nut when 3500rpm is achieved NOTE Check idle rpm Adjustment can be made using a 2 Philips screwdriver in small increments Turn out to decrease and in to increase Rom should be between 1600 1650 Referring to page 18 and 19 of Operator s Manual successfully t
59. rpin Remove brake assembly from tab and pull out Using needle nose pliers hold onto stud and use 3 8 wrench socket to remove lock nut Carefully remove so you do not lose brake band tension spring or washer When pulling stud through brake pins be careful so pins do not fall out BRAKE PINS When removing cable from brake band assembly it is important to identify which brake pin the cable needs to pass through first when installing There is a universal brake pin and a brake pin that has been counter sunk to allow the ferrule to be seated in the brake pin See pictures If ferrule is not seated in the counter sunk brake pin the brake band will not engage properly which will result in poor brake function Section 2 Installing Front Brake Cable 1 Push stud through brake pins in the correct order which was identified in the previous step Use needle nose pliers to hold stud in place Reinstall washer brake band tension spring and locknut Tighten lock nut down until 3 8 of thread is revealed 2 Install brake band assembly on tab Insert hairpin Cable should be routed underneath shift bracket then to gearbox bracket Route cable through slot and push snap fitting through slotted bracket Re attach hook to eyelet of service brake cable Before Installing hood and spinner assembly carefully follow testing instructions Make sure you are in an open safe area Mark a line on the ground to use to test stopping distanc
60. shboard The valve must be turned in the on position to either side in order to fit through dashboard Install brass nut on valve CAUTION DO NOT over tighten These nuts have fine threads and can easily strip or cross thread Install knob on valve and tighten set screw Reconnect wire to kill switch Install handlebar cover Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 54 www permagreen com 1 800 346 2001 BE Section1 Step6 Section1 Step7 Section1 Step8 Section2 Step4 55 www permagreen com 800 346 2001 Spray Valve Replacement T500255 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual Safety Equipment Needed Wear Protective Eyewear and Gloves Parts Included Tools Needed 1 T500270 Spray Valve 2 Philips Screwdriver 1 R347042 Wire Tie Stud Needle Nose Pliers 2 R347041 8 Wire Ties 3 8 Wrench 2 R481243 Hose Clamp 38 Section 1 Spray Valve Removal 1 Remove two bolts at pivot point of handlebar cover using a 3 8 wrench socket and 2 Philips screwdriver Set handlebar cover in hopper Unhook spring from spray valve and bracket Unhook cable from spray valve Remove two bolts holding front bracket to rear bracket using a 3 8 wrench and 2 Philips screwdriver Let bracket hang of
61. ss may cause serious injury or death to the operator mechanic or others e All users mechanics and owners SHALL read and understand the Operator s Manual before inspecting operat ing or repairing the Triumph The Operator 5 Manual is available at www permagreen com or 800 346 2001 e lf you are not entirely familiar with the Operators Manual and the Safety Messages it contains read now before proceeding with any repairs or maintenance e Of particular importance to repair personnel are Operator s Manual Sections 2 New Machine Pre operation Inspection pages 2 3 3 Safety Manual Warnings pages 5 13 particularly important to repair personnel are 1 Owner s Responsibility page 8 2 Supervised Driver s Training page 8 4 Operator Clothing and PPE page 8 5 Safety Devices page 8 6 Operation page 9 8 Fuel Safety page 9 9 Inspect Machine Before Each Use page 10 10 Engine Starting Safety page 10 14 Parking page 10 17 Check Wheel Fasteners page 12 18 Tire Safety page 13 19 Maintenance and Service page 13 20 Pesticide Safety page 13 21 Handling and Disposal of Hazardous Waste Products page 13 22 Replacement Parts page 13 e 4 Driver s Training and Operation pages 14 19 particularly e a Component and Safety Device Identification 14 e g Testing Safety Devices page 18 e 7 Troubleshooting Manual pages 29 31 8 Service Manual pages 33 37 e For additional assista
62. the adjustment is done at the 11 16 nuts If rod end hole needs to move up slightly the adjustment is done by loosening the rod end Depending on which situation described above pertains to the machine you are working on before you attach rod end to hopper control lever the 2 11 16 nuts need to be tightened first Install screw to attach rod end using 2 Philips screwdriver and 3 8 wrench Loosen white lock nut on hopper control lever Operate hopper control to make sure it opens and closes completely and freely with no restrictions NOTE if hopper does not close completely remove rod end screw and tighten rod end a couple of turns hook back up and test again until hopper opens and closes completely Reinstall handlebar cover Re calibrate spreader application rate Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 34 www permagreen com 1 800 346 2001 Section2 Step5 Section2 Step5 35 www permagreen com 800 346 2001 Shift Cable Replacement T654030 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual NOTE Wear Protective Eyewear and Gloves PARTS Included TOOLS Needed 1 T654030 Shift Cable Assembly 3 8 Wrench Socket 2 7 16 Wrench Socket 2 15 16 Wrench 11 32 Socket Socket 2 Philips Screwdriver Side Cutters
63. ut 1 4 turn moving one side to the other until it is tight 7 Tighten bolt on carburetor cover and replace air filter Referring to page 18 and 19 of Operator s Manual successfully test ALL Safety Devices prior to placing the Triumph into service The Operator s Manual is available at www permagreen com or 800 346 2001 www permagreen com 1 800 346 2001 Section1 Step7 Section2 Step1 Section2 Step4 www permagreen com 800 346 2001 Clutch Spring Replacement T654535 WARNING AVOID INJURY Before beginning read Safety Message on page 3 of this manual Safety Equipment Needed Wear Protective Eyewear and Gloves Parts Included Tools Needed 1 T654535 Clutch Spring 7 16 Wrench Needle Nose Pliers Section 1 Removal 1 Remove the 2 bolts on the engine shroud with a 7 16 wrench 2 Push up on the idler arm and at the same time move the drive belt off the engine pulley 3 Use needle nose pliers to unhook spring from the top 4 Pull the spring forward and lift up to remove Use needle nose pliers if spring is difficult to remove Section 2 Installation 1 The top of the spring should be bent in Slightly bend the bottom open 2 Put spring back on engine plate Push back with needle nose pliers and bend to original shape 3 Hook the spring back to idler arm 4 Make sure the belt did not move off any of the pulleys Push up on the idler arm hook the drive belt on the top of the pulley and push down to reinstall
64. ward on idler arm to remove tension on drive belt While holding idler arm forward with your right hand begin pushing drive belt away from you up and over clutch pulley with your left hand Once belt is off of clutch pulley there is no more tension and can be easily removed Use a 3 8 wrench to loosen nut on top of the pump bracket Pull pump forward to relieve tension on belt 8 Remove belt OQ N O Section 2 Installing Spinner Belt 1 Route belt as shown 2 If bolt and washer come out of the slot make sure washer is on the outside when inserting back into slot 3 Once belt is around pump pulley carefully slide pump pulley back creating tension on belt CAUTION do not push back too far Too much tension may cause pump shaft to bend and could potentially break under high rom Tighten nut on top of bracket and test belt tension 4 To test belt tension place a straight edge from pump pulley to gearbox pulley Push down on belt with your finger Belt should be approximately gt from straight edge Samples of straight edges piece of flat stock steel ruler etc Repeat step 3 until proper tension is achieved Section 3 Installing Drive Belt 1 Start by placing belt around outer pulley located on the transaxle 2 Feed the belt through so that it follows the diagram shown Once you are in position to route the drive belt over the clutch pulley Push forward on idler arm with right hand and feed belt over clutc

Triumph Repair-Part Manual (v13)

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