Viking MB 655 Repair Instructions

EN

Repair instructions

2008 - 05

www.viking-garden.com

MB 650, MB 655

- Notes on the repair instructions -

Notes on the repair instructions

2. End of modified operations

3. Continuation of further, unmodified

operations

from serial number 9 xx xxx xxx

Marks the further operations which

are required for the completion of this

section.

 x.x.x (A)

x.x.x (A)

1. Beginning of one or of several

modified operation(s)

The black bar with the serial number

marks the beginning of one or several

modified operations.

Marks the end of one or of several

modified operation(s).

No further operations must be

performed for the completion of this

section.

Marks the end of one or of several

modified operation(s).

Further unmodified operations are

required for the completion of this

section

(see pt. 3)

General:

For easier use and better

understanding of these repair

instructions, graphic symbols with the

following meanings are used in the

text and illustrations:

In the text:

• = operation to be performed, which

corresponds to the illustration

(above the text field).

- = operation to be performed, but

which is not shown in the

illustration (above the text field).

The item numbers contained in the

text refer exclusively to the illustration

above the relevant text field.

Modifications:

The appliances described in these

repair instructions are subject to

technical improvements and

modifications, which also affect the

individual operations.

Modified operations are documented

as follows:

The beginning and end of one

operation, or of several sequential

operations, are marked by two black

bars.

2 RA_6360_6375_01 - EN

- Contents -
Preface 7
Handlebar 8
01 Replacing cable guide 8
01.01 Removing right / left cable guide 8
01.02 Installing right / left cable guide 8
02 Replacing reinforcement strut 8
02.01 Removing reinforcement strut 8
02.02 Installing reinforcement strut 8
03 Opening housing halves 8
03.01 Removing inside right housing half 8
03.02 Removing outside right housing half 9
03.03 Removing inside left housing half 9
03.04 Removing outside left housing half 10
04 Closing housing halves 11
04.01 Attaching outside right housing half 11
04.02 Attaching inside right housing half 11
04.03 Attaching outside left housing half 11
04.04 Attaching inside left housing half 12
05 Replacing housing halves 12
05.01 Removing / dismantling inside 
right housing half 12
05.02 Attaching / assembling inside 
right housing half 12
05.03 Removing / dismantling inside 
left housing half 13
05.04 Assembling inside left housing half 13
05.05 Dismantling outside left housing half 13
05.06 Assembling outside left housing half 13
05.07 Dismantling outside right housing half 13
05.08 Attaching outside right housing half 13
06 Replacing upper handlebar 14
06.01 Removing upper handlebar 14
06.02 Attaching upper handlebar 14
07 Replacing cable anti-kink protection 14
07.01 Removing cable anti-kink protection 14
07.02 Installing cable anti-kink protection 15
08 Replacing starter cable guide 15
08.01 Removing starter cable guide 15
08.02 Installing starter cable guide 15
09 Replacing centre handlebar section 16
09.01 Removing left centre handlebar section 16
09.02 Installing left centre handlebar section 16
09.03 Removing right centre handlebar section 17
09.04 Installing right centre handlebar section 17
10 Replacing lower handlebar 18
10.01 Removing left lower handlebar 18
10.02 Installing left lower handlebar 18
10.03 Removing right lower handlebar 19
10.04 Installing right lower handlebar 20
11 Replacing handlebar  height adjustment 21
11.01 Removing handlebar  height adjustment 21
11.02 Installing handlebar  height adjustment 21
12 Replacing charging socket 22
12.01 Removing charging socket 22
12.02 Installing charging socket 22
13 Replacing ignition lock 23
13.01 Removing ignition lock 23
13.02 Installing ignition lock 23
Control bars and levers 24
01 Replacing wheel drive control bar 24
01.01 Removing wheel drive control bar 24
01.02 Installing wheel drive control bar 24
02 Replacing motorstop control bar 24
02.01 Removing motorstop control bar 24
02.02 Installing motorstop control bar 25
03 Replacing blade stop / 
Quick-Start control bar 25
03.01 Removing blade stop / 
Quick-Start control bar 25
03.02 Installing blade stop / 
Quick-Start control bar 26
04 Replacing blade clutch / 
Quick-Start lever 27
04.01 Removing blade clutch / 
Quick-Start lever 27
04.02 Dismantling blade  clutch / 
Quick-Start lever 27
04.03 Assembling blade  clutch / 
Quick-Start lever 28
04.04 Installing blade  clutch /  Quick-Start lever 28
05 Replacing detent lever 29
05.01 Removing detent lever 29
05.02 Installing detent lever 29
06 Replacing locking lever 29
06.01 Removing locking lever 29
06.02 Installing locking lever 30
07 Replacing Vario /three-speed lever 30
07.01 Removing Vario /three-speed lever 30
07.02 Installing Vario /three-speed lever 31
08 Replacing bracket 32
08.01 Removing bracket 32
08.02 Installing bracket 33
09 Replacing throttle lever 33
09.01 Removing throttle lever 33
09.02 Installing throttle lever 34
Chassis 35
01 Replacing front axle 35
01.01 Removing front axle 35
01.02 Dismantling front axle 36
01.03 Assembling front axle 36
01.04 Installing front axle 36
02 Replacing rear axle 37
02.01 Removing rear axle (with gearbox) 37
02.02 Dismantling rear axle 39
02.03 Assembling rear axle 40
02.04 Installing rear axle (with gearbox) 43
03 Replacing wheel cap 45
03.01 Removing front wheel cap 45
03.02 Removing rear wheel cap 45
03.03 Installing front wheel cap 46
03.04 Installing rear wheel cap 46
04 Replacing wheel 46
04.01 Removing front wheel 46
04.02 Removing rear wheel 47
04.03 Installing front wheel 48
04.04 Installing rear wheel 48
Contents
RA_6360_6375_01 - EN

- Contents -
Contents
05 Replacing wheel bearing 49
05.01 Removing wheel bearing 49
05.02 Installing wheel bearing 50
06 Replacing rear wheel cover 50
06.01 Removing rear wheel cover 50
06.02 Installing rear wheel cover 51
07 Replacing drive pinion 51
07.01 Removing right drive pinion 51
07.02 Removing left drive pinion 51
07.03 Installing right drive pinion 52
07.04 Installing left drive pinion 52
08 Replacing freewheel wedge 52
08.01 Removing right freewheel wedge 52
08.02 Removing left freewheel wedge 53
08.03 Installing right freewheel wedge 53
08.04 Installing left freewheel wedge 54
09 Replacing drive shaft bearing 54
09.01 Removing drive shaft bearing 54
09.02 Installing drive shaft bearing 54
10 Replacing carrying handle 54
10.01 Removing carrying handle 54
10.02 Installing carrying handle 54
Housing 55
01 Replacing housing 55
01.01 Removing housing 55
01.02 Installing housing 55
02 Replacing housing cover assembly 55
02.01 Removing housing cover assembly 55
02.02 Dismantling housing cover assembly 56
02.03 Assembling housing cover assembly 56
02.04 Attaching housing cover assembly 56
03 Replacing height adjustment handle  57
03.01 Removing height adjustment handle 57
03.02 Installing height adjustment handle 58
04 Replacing spring 58
04.01 Removing spring 58
04.02 Installing spring 58
05 Replacing flap 59
05.01 Removing flap 59
05.02 Dismantling flap 59
05.03 Assembling flap 59
05.04 Installing flap 59
06 Replacing handle shell 60
06.01 Removing handle shell 60
06.02 Installing handle shell 60
07 Replacing  translatory  lever cover 60
07.01 Removing  translatory  lever cover 60
07.02 Dismantling translatory  lever cover 61
07.03 Assembling translatory lever cover 61
07.04 Installing translatory lever cover 61
08 Replacing sight glass 61
08.01 Removing sight glass 61
08.02 Installing sight glass 62
09 Replacing V-belt cover 62
09.01 Removing V-belt cover 62
09.02 Installing V-belt cover 62
10 Replacing left/right protection bumpers 63
10.01 Removing left/right protection bumpers 63
10.02 Installing left/right protection bumpers 63
11 Replacing guiding plate 63
11.01 Removing guiding plate 63
11.02 Installing guiding plate 64
12 Replacing lower cover 64
12.01 Removing lower cover 64
12.02 Attaching lower cover 64
Gearbox 65
01 Replacing gearbox 65
01.01 Removing gearbox 65
01.02 Installing gearbox 65
02 Replacing V-belt pulley 65
02.01 Removing single-speed V-belt pulley 65
02.02 Installing single-speed V-belt pulley 66
02.03 Removing Vario V-belt pulley and  adjusting
element 66
02.04 Installing Vario V-belt pulley and  adjusting
element 67
02.05 Removing three-speed V-belt pulley 68
02.06 Installing three-speed V-belt pulley 68
03 Replacing Vario V-belt  pulley ball bearing 69
03.01 Removing Vario V-belt  pulley ball bearing 69
03.02 Installing Vario V-belt  pulley ball bearing 69
04 Replacing gearbox support 70
04.01 Removing single-speed / Vario gearbox
support 70
04.02 Installing single-speed / Vario gearbox
support 70
04.03 Removing three-speed gearbox support 70
04.04 Installing three-speed gearbox support 70
05 Replacing wheel drive lever return spring 71
05.01 Removing Vario gearbox return spring 71
05.02 Installing Vario gearbox return spring 71
05.03 Removing three-speed gearbox 
return spring 71
05.04 Installing three-speed gearbox 
return spring 71
06 Replacing cable support 72
06.01 Removing cable support 72
06.02 Installing cable support 72
Height adjustment 73
01 Replacing height  adjustment spring 73
01.01 Removing height  adjustment spring 73
01.02 Installing height  adjustment spring 73
02 Replacing detent segment tension spring 74
02.01 Removing detent segment tension spring 74
02.02 Installing detent segment tension spring 74
RA_6360_6375_01 - EN 

- Contents -
5
Contents
03 Replacing translatory lever 74
03.01 Removing translatory lever 74
03.02 Installing translatory lever 75
04 Replacing detent segment 77
04.01 Removing detent segment 77
04.02 Dismantling detent segment 77
04.03 Assembling detent segment 77
04.04  Installing detent segment 78
05 Replacing height adjustment indicator 78
05.01 Removing height  adjustment indicator 78
05.02 Installing height adjustment indicator 78
Console 79
01 Replacing strut 79
01.01 Removing strut 79
01.02 Installing strut 79
02 Replacing left / right cover 79
02.01 Removing left / right cover 79
02.02 Installing left / right cover 80
03 Replacing console 80
03.01 Removing left console 80
03.02 Installing left console 80
03.03 Removing right console 81
03.04 Installing right console 81
Mowing blade 82
01 Replacing mowing blade 82
01.01 Removing mowing blade 82
01.02 Installing mowing blade 83
Blade bushing 84
01 Replacing blade bushing 84
01.01 Removing blade bushing 84
01.02 Installing blade bushing 84
Blade clutch 86
01 Replacing blade mounting 86
01.01 Removing blade mounting 86
01.02 Dismantling blade mounting 86
01.03 Assembling blade mounting 86
01.04 Installing blade mounting 86
02 Replacing clutch linings 87
02.01 Removing clutch linings 87
02.02 Installing clutch linings 87
03 Replacing stop plate 87
03.01 Removing stop plate 87
03.02 Installing stop plate 88
04 Replacing thrust springs 88
04.01 Removing thrust springs 88
04.02 Installing thrust springs 88
05 Replacing clutch shoes 89
05.01 Removing clutch shoes 89
05.02 Installing clutch shoes 89
06 Replacing blade mounting  ball bearing 89
06.01 Removing blade mounting  ball bearing 89
06.02 Installing blade mounting  ball bearing 90
07 Replacing clutch drum 90
07.01 Removing clutch drum 90
07.02 Installing clutch drum 91
08 Replacing brake band lever 92
08.01 Removing brake band lever 92
08.02 Installing brake band lever 93
09 Replacing brake band 94
09.01 Removing brake band 94
09.02 Installing brake band 94
10 Replacing clutch flange 94
10.01 Removing clutch flange 94
10.02 Dismantling clutch flange 95
10.03 Assembling clutch  flange 95
10.04 Installing clutch flange 96
Engine 98
01 Deactivating Quick-Start 98
02 Replacing engine cover 98
02.01 Removing engine cover 98
02.02 Attaching engine cover 99
03 Replacing V-belt pulley 99
03.01 Removing V-belt pulley 99
03.02 Installing V-belt pulley 99
04 Replacing V-belt 100
04.01 Removing V-belt 100
04.02 Installing V-belt 101
05 Replacing engine 102
05.01 Removing engine 102
05.02 Installing engine 104
06 Replacing vibration damper 107
06.01 Removing vibration damper 107
06.02 Installing vibration damper 107
Starter battery 108
01 Removing starter battery 108
01.01 Disconnecting starter battery 108
01.02 Removing starter battery 108
02 Installing starter battery 108
02.01 Mounting starter battery 108
02.02 Connecting starter battery 109
Cables, wiring harness 110
01 Replacing motorstop cable 110
01.01 Detaching motorstop cable 110
01.02 Attaching motorstop cable 110
02 Replacing blade clutch / 
Quick-Start cable 110
02.01 Detaching blade clutch / 
Quick-Start cable 110
02.02 Attaching blade clutch / 
Quick-Start cable 110
03 Replacing wheel drive cable 110
03.01 Detaching wheel drive cable 110
03.02 Attaching wheel drive cable 110
03.03 Adjusting wheel drive cable 111
RA_6360_6375_01 - EN

RA_6360_6375_01 - EN 6
04 Replacing Vario / three-speed  drive speed
control cable 111
04.01 Detaching Vario / three-speed  drive speed
control cable 111
04.02 Attaching Vario / three-speed  drive speed
control cable 111
05 Replacing throttle cable 111
05.01 Detaching throttle cable 111
05.02 Attaching throttle cable 111
06 Replacing wiring harness 112
06.01 Disconnecting wiring harness 112
06.02 Connecting wiring harness 112
07 Cable, wiring harness guide 112
07.01 MB 650.0 T 113
07.02 MB 650.0 V/VM, MB 655.0 V/VM 113
07.03 MB 650.0 VS 114
07.04 MB 650.0 VE 114
07.05 MB 655.0 G/GM 115
07.06 MB 655.0 GS 115
07.07 MB 650.0 VQ 116
07.08 MB 655.0 GQ 116
07.09 MB 650.0 TK 117
07.10 MB 650.0 KS 117
07.11 MB 655.0 KS 118
07.12 MB 655.0 GK 118
07.13 MB 650.0 OS, MB 655.0 OS, 
MB 655.1 VS 119
07.14 MB 655.1 V/ VM 119
07.15 MB 655.1 G 120
07.16 MB 655.1 GS 120
General 121
01 Troubleshooting 121
02 Maintenance table 123
03 Torque values 124
- Contents -
Contents

RA_6360_6375_01 - EN7

- Preface -

These repair instructions contain a

comprehensive description of all the

typical repair operations for this lawn

mower series.

The design of the

MB 650.0 T/ TK/ V/ VM/ VQ/ VS/ KS,

MB 655.0 V/ VM/ G/ GK/ GM/ GQ/

GS/ KS, MB 655.1 V/ VM/ G/ GS/ VS

lawn mowers is largely identical,

however, they represent different

equipment versions. For the

illustrations, a model version with

Vario drive and blade clutch has been

selected. The descriptions of the

repair operations generally relate to all

the mowers.

Model-specific parts and repair

operations are identified as such and

are treated separately.

Please also use the illustrated spare

parts lists when performing repair

work. These show the installation

position and assembly sequence of

the various assemblies.

To determine the part numbers of the

spare parts required, please use the

latest edition of the relevant spare

parts list (DVD-ROM).

A fault to the appliance may have

several causes. The faults known to us

with regard to this lawn mower series

are outlined in the section

“Troubleshooting” in these repair

instructions.

Refer to the “Technical Information”

(DVD-ROM), this provides information

on technical modifications which have

been implemented since these repair

instructions were written. The

Technical Information is valid until the

new edition as a supplement to the

spare parts list.

The Repair Instructions and Technical

Information should be available at the

place where the repair work is being

carried out. Distribution to third parties

is prohibited.

Only use high-quality tools,

accessories and spare parts.

Otherwise, there may be a risk of

accidents resulting in personal injury

or damage to the appliance.

VIKING recommends the use of

original VIKING tools, accessories

and spare parts. Their properties are

optimally adapted to the appliance

and the user’s requirements.

When replacing the cutting tool,

ensure that the correct type of cutting

tool is installed.

Safety instructions:

Always detach the spark plug socket

before performing any work on the

appliance;

also remove the ignition key from the

appliance (for MB 650.0 VE);

additionally deactivate the Quick-

Start, turn the safety key to the locked

position and remove

(for MB 650.0 VQ, MB 655.0 GQ).

Following all repair or maintenance

operations on the machine and prior

to return of the customer appliance by

the specialist dealer, it is imperative

that safety checks be performed.

If the lawn mower is operated during

repair or maintenance, the relevant

national legislation and the safety

instructions in the instruction manual

must be observed.

Petrol is highly inflammable and is

explosive under certain conditions.

Improper handling may result in burns

or other severe injuries.

Warning! Always keep heat sources

sparks and naked flames away.

All work with fuel must only be

performed out-of-doors.

Wipe up spilt fuel immediately.

Always wash hands thoroughly

following contact with used oil.

Do not allow used oil to enter into the

sewage system or penetrate into the

ground.

Collect used oil and dispose of it in an

environmentally friendly manner.

01. Preface

RA_6360_6375_01 - EN 8

- Handlebar -

02.01 Replacing cable guide

02.01.01 Removing right / left

cable guide

02.01.02 Installing right / left

cable guide

02.02.02 Installing

reinforcement strut

02.02 Replacing

reinforcement strut

02.03 Opening housing

halves

02.02.01 Removing

reinforcement strut

• Lever off cable guide(s) 1 from

handlebar using a screwdriver 2.

• Push cable guide(s) 1 into housing 2

and clip onto handlebar.

02. Handlebar

1

2

1

2

1

• Remove cap nuts 1 and remove

washers 2.

• Pull out bolts 3 from handlebar and

remove strut 4.

1

2

3

4

3

2

1

•Fit strut 1 and insert bolts 2 through

handlebar.

• Install cap nuts 4 with washers 3

and tighten (8-10 Nm).

4

3

2

1

2

3

4

02.03.01 Removing inside right

housing half

- Remove right / left cable guide

(see section 02.01.01)

• Push wheel drive control bar 1 to the

left and detach from inside right

housing half 2.

• Pull wheel drive control bar 1

upwards and rest on right housing

halves.

1

2

1

RA_6360_6375_01 - EN9

- Handlebar -

02.03.02 Removing outside right

housing half

- Remove inside right housing half

(see section 02.03.01).

Models with blade clutch / with

Quick-Start

• Detach blade clutch cable 1 from

guide.

• Remove screw 1.

• Remove outside right housing

half 2.

1

2

02.03.03 Removing inside left

housing half

- Remove right / left cable guide

(see section 02.01.01)

- Remove reinforcement strut

(see section 02.02.01)

• Push wheel drive control bar 1 to the

left and detach from inside right

housing half 2.

• Pull wheel drive control bar 1

upwards and rest on right housing

halves.

1

2

1

• Remove screws 1, 2.

1

2

1

• Lift inside left housing half 1 slightly

and push wheel drive lever 2

forwards.

1

2

1

• Remove screws 1, 2 and remove

inside right housing half 3.

1

3

1

2

RA_6360_6375_01 - EN 10

- Handlebar -

• Detach wheel drive cable 1.

1

• Remove inside left housing half 1

together with wheel drive control

bar 2.

1

2

• Remove screw 1.

1

Models without blade clutch /

without Quick-Start

• Remove cable support 1.

1

• Remove outside left housing half 1.

1

02.03.04 Removing outside left

housing half

- Remove inside left housing half

(see section 02.03.03)

RA_6360_6375_01 - EN11

- Handlebar -

02.04 Closing housing

halves

02.04.02 Attaching inside right

housing half

- Install reinforcement strut

(see section 02.02.02)

- Install right/left cable guide

(see section 02.01.02)

- Attach inside left housing half

(see section 02.04.02)

• Fit inside right housing half 1 onto

handlebar.

• Tighten screws 2, 3 (1-2 Nm).

1

3

2

02.04.01 Attaching outside right

housing half

• Fit housing half 1 and tighten

screw 2 (1-2 Nm).

1

2

02.04.03 Attaching outside left

housing half

• Fit outside left housing half 1

onto handlebar and tighten

screw 2 (1-2 Nm).

1

2

Models without blade clutch /

without Quick-Start

• Insert cable support and attach

motorstop cable.

2

1

Models with blade clutch /

with Quick-Start

• Attach blade clutch cable 1.

• Push wheel drive control bar 1 to the

left and then attach in bore A.

A

1

- Attach inside left housing half

(see section 02.04.03)

1

RA_6360_6375_01 - EN 12

- Handlebar -

02.05 Replacing housing

halves

02.05.01 Removing /

dismantling inside

right housing half

02.04.04 Attaching inside left

housing half

• Attach control bar together with left

housing half 1 in bore A on

handlebar.

Note:

Ensure that control lever is

positioned on both housing halves

on the right side.

1

A

• Attach wheel drive cable 1 in wheel

drive control bar.

1

• Tighten screws 1, 2 (1-2 Nm).

2

1

• Press wheel drive control bar 1

together to the left and insert in

bore A on the right.

22

A

1

- Install right/left cable guide

(see section 02.01.02)

Models without blade clutch /

without Quick-Start

- Remove bracket

(see section 03.08.01)

Models with blade clutch

- Remove throttle lever

(see section 03.09.01)

MB 650.0 TK, MB 655.0 GK

- Remove throttle lever

(see section 03.09.01)

MB 650.0 T

- Remove inside right housing half

(see section 02.03.01)

MB 650.0 T

- Attach inside right housing half

(see section 02.04.02)

02.05.02 Attaching / assembling

inside right housing

half

Models without blade clutch /

without Quick-Start

- Install bracket

(see section 03.08.02)

Models with blade clutch

- Install throttle lever

(see section 03.09.02)

MB 650.0 TK, MB 655.0 GK

- Install throttle lever

(see section 03.09.02)

RA_6360_6375_01 - EN13

- Handlebar -

02.05.03 Removing /

dismantling inside left

housing half

MB 650.0 VE

- Remove charging socket

(see section 02.12.01)

MB 650.0 VE

- Remove ignition lock

(see section 02.13.01)

- Remove inside left housing half

(see section 02.03.03)

02.05.05 Dismantling outside

left housing half

• Remove screw 1.

• Remove wheel drive cable adjusting

element 2 from outside left housing

half.

- Remove outside left housing half

(see section 02.03.04)

- Attach outside left housing half

(see section 02.04.04)

02.05.06 Assembling outside

left housing half

• Insert wheel drive cable adjusting

element 1.

• Tighten screw 2 (1-2 Nm).

02.05.04 Assembling inside left

housing half

- Attach inside left housing half

(see section 02.04.03)

MB 650.0 VE

- Install ignition lock

(see section 02.13.02)

MB 650.0 VE

- Install charging socket

(see section 02.12.02)

1

2

1

02.05.07 Dismantling outside

right housing half

- Remove outside right housing half

(see section 02.03.02)

02.05.08 Attaching outside right

housing half

- Attach outside right housing half

(see section 02.04.01)

RA_6360_6375_01 - EN 14

- Handlebar -

1

2

3

2

02.06 Replacing upper

handlebar

02.06.01 Removing upper

handlebar

- Remove outside left housing half

(see section 02.03.04)

• Remove nuts 1 and pull out bolts 2.

• Remove handlebar 3.

- Remove outside right housing half

(see section 02.03.02)

2

1

2

3

02.07 Replacing cable

anti-kink protection

02.07.01 Removing cable

anti-kink protection

• Detach cables 1.

1

• Remove rotary handles 1.

• Remove cable anti kink protection 2/

bolt 3 from centre handlebar

section.

Note:

Only one cable anti-kink protection

2 is required on the MB 650.0 T.

A bolt 3 is installed in place of the

second cable guide.

1

2

3

02.06.02 Attaching upper

handlebar

- Attach outside right housing half

(see section 02.04.01)

• Attach handlebar 1.

• Insert bolts 2 through handlebar

tube and tighten nuts 3 (8-10 Nm).

- Attach outside left housing half

(see section 02.04.04)

RA_6360_6375_01 - EN15

- Handlebar -

02.07.02 Installing cable anti-kink protection

2

1

3

1

O.K.

1

O.K.

• Insert cable anti-kink protection 1/ bolt 3 in centre handlebar section

(ensure correct installation position of cable anti kink protection, see Fig.).

• Tighten rotary handles 2.

• Attach cables 1

(ensure correct installation position of cables, see Fig.).

02.08 Replacing starter cable

guide

02.08.01 Removing starter cable

guide

- Detach starter cable.

• Remove screw 1.

• Remove starter cable guide 2.

1

2

02.08.02 Installing starter cable

guide

• Attach starter cable guide 1 to

handlebar.

• Tighten screw 2 (5-7 Nm).

- Insert starter cable.

2

1

RA_6360_6375_01 - EN 16

- Handlebar -

02.09 Replacing centre

handlebar section

02.09.01 Removing left centre

handlebar section

02.09.02 Installing left centre

handlebar section

• Detach motorstop control bar 1 /

blade stop control bar 1 on left of

centre handlebar section.

1

• Remove left centre handlebar

section 1.

1

• Tighten nut 1 (8-10 Nm).

1

• Attach motorstop control bar 1 /

blade stop control bar 1 on left in

bore A on centre handlebar section.

1

A

1

• Remove nut 1.

• Attach left centre handlebar

section 1.

- Remove outside left housing half

(see section 02.03.04)

- Remove cable anti-kink protection

(see section 02.07.01)

- Install cable anti-kink protection

(see section 02.07.02)

- Attach outside left housing half

(see section 02.04.04)

RA_6360_6375_01 - EN17

- Handlebar -

02.09.03 Removing right centre

handlebar section

• Detach motorstop control bar 1 /

blade stop control bar 1 on right of

centre handlebar section.

Models with blade clutch / with

Quick-Start

- Remove blade clutch / Quick-Start

lever

(see section 03.04.01)

1

• Remove nut 1.

1

• Remove right centre handlebar

section 1.

1

- Remove outside right housing half

(see section 02.03.02)

- Remove starter cable guide

(see section 02.08.01)

- Remove cable anti-kink protection

(see section 02.07.01)

- Install cable anti-kink protection

(see section 02.07.02)

02.09.04 Installing right centre

handlebar section

• Attach right centre handlebar

section 1.

1

• Tighten nut 1 (8-10 Nm).

RA_6360_6375_01 - EN 18

- Handlebar -

• Attach motorstop control bar 1 /

blade stop control bar 1 on right in

bore (A) on centre handlebar

section.

Models with blade clutch /

with Quick-Start

- Install blade clutch lever /

without Quick-Start

(see section 03.04.04)

1

A

- Install starter cable guide

(see section 02.08.02)

- Attach outside right housing half

(see section 02.04.01)

02.10 Replacing lower

handlebar

02.10.01 Removing left lower

handlebar

• Remove handlebar 1.

1

2

3

• Remove nut 1.

• Remove collared washer 2 and

spring washer 3.

2

1

• Pull out bolt 1 and remove left lower

handlebar 2.

- Remove cable anti-kink protection

(see section 02.07.01)

- Remove housing cover assembly

(see section 05.02.01)

02.10.02 Installing left lower

handlebar

• Insert lower handlebar 1 in guide

and insert bolt 2.

1

2

RA_6360_6375_01 - EN19

- Handlebar -

- Attach housing cover assembly

(see section 05.02.04)

• Attach handlebar 1.

1

- Install cable anti-kink protection

(see section 02.07.02)

02.10.03 Removing right lower

handlebar

• Remove handlebar 1.

1

- Remove cable anti-kink protection

(see section 02.07.01)

- Remove housing cover assembly

(see section 05.02.01)

2

1

• Remove cap nut 1 and remove

washer 2.

1

2

3

• Remove nut 1.

• Remove collared washer 2 and

spring washer 3.

• Fit spring washer and collared

washer onto bolt.

Note:

Ensure correct installation position

of spring washer 1 (see Fig.).

1

2

1

2

• Tighten nut 1 (12-18 Nm).

1

RA_6360_6375_01 - EN 20

- Handlebar -

• Tighten nut 1 (12-18 Nm).

1

• Fit washer 1 onto rod 2 and tighten

cap nut 3 (12-18 Nm).

3

1

2

• Attach handlebar 1.

1

- Install cable anti-kink protection

(see section 02.07.02)

2

1

• Pull out bolt 1 and remove right

lower handlebar 2.

02.10.04 Installing right lower

handlebar

• Fit left lower handlebar 1 and insert

bolt 2.

2

1

• Fit spring washer and collared

washer onto bolt.

Note:

Ensure correct installation position

of spring washer 1 (see Fig.).

2

1

2

- Attach housing cover assembly

(see section 05.02.04)

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