Billy Goat BC2403 Series Owner's Manual

BILLY GOAT

®

BC2403 Series Brush Cutter

Owner’s Manual

Patent Number D386768

Part No 500360 1 Form No F052609A

BC2403 Series Brush Cutter Owner’s Manual

ABOUT THIS MANUAL

THANK YOU for purchasing a BILLY GOAT

®

Brush Cutter. Your new machine has been carefully designed and manufactured to provide years of reliable and productive service. This manual provides complete operating and maintenance instructions that will help to maintain your Brush Cutter in top running order. Read this manual carefully before assembling, operating or servicing your equipment.

CONTENTS

Serial Plate Data ............................................................................................................................................... 3

BC2403 Series Specifications ........................................................................................................................... 3

Common Replacement Parts ............................................................................................................................ 3

General Safety Instructions and Symbols ......................................................................................................... 4

Sound Data ....................................................................................................................................................... 6

Vibration Data .................................................................................................................................................... 6

Intended Use ..................................................................................................................................................... 6

Instruction Labels .............................................................................................................................................. 7

Engine Labels .................................................................................................................................................... 7

Assembly Instructions ....................................................................................................................................... 9

Operation ........................................................................................................................................................... 10

Starting ........................................................................................................................................................ 11

Cutting ......................................................................................................................................................... 13

Handling and Transporting ................................................................................................................................ 15

Storage .............................................................................................................................................................. 15

Maintenance ...................................................................................................................................................... 16

Cleaning ...................................................................................................................................................... 16

Blade Drive Belt Tension Adjustment ......................................................................................................... 18

Blade Drive Belt Removal and Replacement ............................................................................................. 20

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

Engine Maintenance and Repair ....................................................................................................................... 26

Warranty Claim Procedure ................................................................................................................................ 26

Maintenance Record ......................................................................................................................................... 27

Illustrated Parts List ........................................................................................................................................... 28

Illustrations

Figure 1 Brush Cutter Assembly Drawing .................................................................................................... 8

Figure 2 Belt Routing Diagram ..................................................................................................................... 21

Figure 3 Starter Switch Wiring ..................................................................................................................... 24

Figure 4 Starter Circuit Schematic Diagram ................................................................................................ 24

Figure 5 ON/OFF Switch Circuit Schematic Diagram .................................................................................. 24

Figure 6 Engine and Engine Base Assembly .............................................................................................. 28

Figure 7 Handlebar Assembly ...................................................................................................................... 30

Figure 8 Transaxle and Blade Deck Assembly ............................................................................................ 32

Figure 9 Blade Drive Spindle Assembly Detail Drawing .............................................................................. 34

Part No 500360 2 F052609A


SERIAL PLATE DATA

Record the model number, serial number, date of purchase, and where purchased.

Purchase Date:

Purchased From:

BC 2403 SERIES SPECIFICATIONS

Engine Type

Model Number

Horsepower

Fuel Capacity

Oil Capacity

Engine Weight

Unit Weight

In accordance with

2000/14/EEC standards

Sound at Operator’s ear

Shipping Weight

Overall Length

Briggs and

Stratton INTEK

OHV

Briggs and Stratton

INTEK OHV

21A902-0149-E1 21A902-0149-E1

13.0 (9.7 kW) 13.0 (9.7 kW)

3.0 qt (2.80 L)

1.5 qt (1.4L)

3.0 qt (2.80 L)

1.5 qt (1.4L)

58.0 lb (26.3 kg) 58.0 lb (26.3 kg)

266 lb (120.7 kg) 284 lb (128.8 kg)

106 dB(a) 106 dB(a)

93 dB(a) 93 dB(a)

315 lb (143.2 kg) 333 lb (151 kg)

Honda GXV

GXV390UTIDABG GXV390UTIDABG GXV390K1DE33

13.0 (9.7 kW) 13.0 (9.7 kW) 13.0 (9.7 kW)

2.3 qt (2.18L)

1.2 qt (1.13L)

2.3 qt (2.18L)

1.2 qt (1.13L)

2.3 qt (2.18L)

1.2 qt (1.13L)

70.5 lb (32.0 kg)

294 lb (133.4 kg)

106 dB(a)

70.5 lb (32.0 kg)

278 lb (126.4 kg)

106 dB(a)

72.5 lb (32.9 kg)

291 lb (132.3 kg)

106 dB(a)

93 dB(a)

348 lb (157.9 kg)

82.5 in (2.09 m)

Honda GXV

93 dB(a)

330 lb (150.0 kg)

Honda GXV

93 dB(a)

340 lb (154.7 kg)

Overall Width 32.0 in (0.81 m)

Overall Height 43 in (1.09 m)

Maximum Operating

Slope

15 o

15 o

20 o

20 o

20 o

COMMON REPLACEMENT PARTS

- Blade. P/N 500210. Original equipment replacement blade.

- High Lift Blade. P/N 500102. Optional replacement blade.

- Traction Drive Belt. P/N 500119. Original equipment replacement drive belt.

- Blade Drive Belt. P/N 500237. Original equipment replacement drive belt.

- Skid. P/N 500355. Side deck skid.

- Throttle Control Assembly. P/N 500213. Throttle control assembly, including cable.

Part No 500360 3 F052609A


GENERAL SAFETY INSTRUCTIONS and SYMBOLS

The safety symbols shown below are used throughout this manual. You should be thoroughly familiar with them before assembling, operating or servicing this equipment.

This symbol indicates important information that will prevent injury to yourself or others

.

This symbol indicates ear protection is recommended when operating this equipment.

This symbol indicates eye protection is recommended when operating this equipment.

This symbol indicates gloves should be worn when servicing this equipment.

This symbol indicates that this manual and the engine manufacturer’s manual should be read carefully before assembling, operation or servicing this equipment.

This symbol indicates important information that will prevent damage to your BILLY GOAT

®

Brush Cutter.

This symbol indicates the engine oil level should be checked before operating this equipment.

Read and make sure you thoroughly understand the following safety precautions before assembling, operating or servicing this equipment:

READ this manual and the engine manufacturer’s manual carefully before assembling, operating or servicing this equipment.

EAR PROTECTION is recommended when operating this equipment.

EYE PROTECTION is recommended when operating this equipment

.

EXHAUST from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

DO NOT operate this equipment on any unimproved forested, brushy, or grass covered land unless a spark arrester is installed on the muffler as required by Section 4442 of the

California Public Resources Code. The arrester must be maintained in good working order.

Other states may have similar laws. Federal laws apply on federal lands.

DO NOT run engine in an enclosed area. Exhaust gases contain carbon monoxide, an odorless and possibly fatal poison.

Part No 500360 4 F052609A

Part No 500360


DO NOT run this equipment indoors or in any poorly ventilated area. Refueling outdoors is recommended.

DO NOT refuel this equipment while the engine is running. Allow engine to cool for at least two minutes before refueling.

DO NOT store gasoline near an open flame.

DO NOT remove gas cap while engine is running.

DO NOT start or operate engine if strong odor of gasoline is present.

DO NOT start or operate engine if gasoline is spilled. Move equipment away from spill until gasoline has completely evaporated.

DO NOT smoke while filling the fuel tank.

DO NOT check for spark with spark plug or spark plug wire removed. Use an approved spark tester.

DO NOT operate engine without a muffler. Inspect muffler periodically and replace if necessary. If equipped with muffler deflector, inspect deflector periodically and replace if necessary.

DO NOT operate engine with grass, leaves or other combustible material near the muffler.

DO NOT touch muffler, cylinder or cooling fins when hot. Contact with hot surfaces may cause severe burns.

DO NOT leave equipment unattended while in operation.

DO NOT park equipment on a steep grade or slope.

DO NOT operate equipment with bystanders in or near the work area.

DO NOT start equipment with drive or blade clutch engaged.

DO NOT operate equipment with guards removed.

DO NOT operate equipment in areas containing rock, glass, string-like material, wire, rags, cans, metal or other non-organic material.

DO NOT operate equipment on slopes greater than specified in Specifications section of this manual.

DO NOT operate equipment near hot or burning debris or any toxic or explosive materials.

DO NOT allow children to operate this equipment.

ALWAYS remove spark plug wire when servicing equipment to prevent accidental starting.

ALWAYS check fuel lines and fittings frequently for cracks or leaks. Replace if necessary.

ALWAYS keep hands and feet away from moving or rotating parts.

ALWAYS store fuel in approved safety containers.

5 F052609A


SOUND DATA

SOUND LEVEL 93 Dba at Operator’s position

Sound tests were conducted in accordance with 2000/14/EEC and were performed on 2/21/2002 under the conditions listed below.

Sound power level listed is the highest value for any model covered in this manual. Please refer to serial plate on the unit for the sound power level for your model.

General Conditions:

Temperature:

Sunny

80 o

F (25 o

C)

Wind Speed:

Wind Direction:

Humidity:

Barometric Pressure:

2.0 mph (3.2 kph)

South

63.5%

29.98” Hg (761mm Hg)

VIBRATION DATA

VIBRATION LEVEL .5g (4.87 m/s

2

)

Vibration levels at the operator’s handles were measured in the vertical, lateral and longitudinal directions using calibrated vibration test equipment. Tests were performed on 5/19/1995 under the conditions listed below.

General Conditions: Sunny

Temperature: 89 o

F (31.7

o

C)

Wind Speed:

Wind Direction:

6.1 mph (9.9 kph)

West

Humidity: 49.7%

Barometric Pressure: 29.88” Hg (101.19 kPa)

INTENDED USE

Your BILLY GOAT ® BC Self-Propelled Brush Cutter is designed for cutting overgrown weeds, brush and other growth down to 3½” (8.9 cm) in height. It is not a lawn mower and does not provide the quality cut of a finish cut mower. It is designed for use in rural areas and should not be operated in tight or confined areas.

Part No 500360 6 F052609A


INSTRUCTION LABELS

The labels shown below were installed on your BILLY GOAT

®

Brush Cutter. If any labels are damaged or missing, replace them before operating this equipment. Item numbers from the Illustrated Parts List and part numbers are provided for convenience in ordering replacement labels. The correct position for each label may be determined by referring to the Figure and Item numbers shown.

PN 400268

(See Figure 6 Item 169)

PN 890254


PN 500349


Item No 180 - PN 400424


Item No 184 - PN 810736


Item No 191 - PN 500176


ENGINE LABELS

Honda

Item No 187 - PN 890301


Item No 189 - PN 500168


PN 900327


PN 500279


Briggs and Stratton

Item No 192 - PN 500177


PN 100252

Part No 500360 7 F052609A

Part No 500360


Brush Cutter Assembly Drawing

Figure 1

8 F052609A


ASSEMBLY INSTRUCTIONS

Your BILLY GOAT

®

BC Self-Propelled Brush Cutter was shipped in one carton, completely assembled except for the upper handle assembly and the front guard bar. Mounting hardware for the handle and guard bar is temporarily installed on the lower handle and the front of the deck assembly.

READ all safety instructions before assembling unit.

Electric start units are shipped with a battery. A CB18, C50, SC50 or MCB50 series dry or wet battery with a 17.2 Ah rating is required when replacing the battery.

Numbers in parenthesis ( ) refer to item numbers on Figure 1 on the facing page.

1. Remove unit from carton. Make sure the following items that have been packed with unit:

Upper Handle Assembly, P/N 500256

Guard Bar, P/N 500356

Bar Skids, P/N 500355

Owner’s Manual, P/N 500264

Honda or Briggs and Stratton Engine Manual

Warranty Card, P/N 400972

Ty-Wraps (4 ea)

DISCONNECT spark plug wire before assembling unit.

2. Remove mounting hardware (144, 143, 115, 117, 141) from lower handles (51 and 52).

3. Loosen (but do not remove) four screws (115) securing the lower handles (51 and 52).

4. Attach upper handle (40) to lower handles (51 and 52) with hardware removed in step 2. Tighten finger tight only.

5. Make sure engine pull starter is properly installed in guide (145) and then tighten upper handle fasteners (Honda engine only).

6. Tighten mounting hardware on handle braces (5 and 6).

7. Remove mounting hardware (33, 117, 119, and 141) from bar brace (31) and skids (155).

8. Place a wood block under the deck and attach the skids using hardware removed from them. Use the bottom two holes on the longer end to attach to the front of the deck.

Warning: When attaching the Skids be careful of the blade. Wear thick gloves and check the position of the blade before putting your hands into the deck to install the bolts though the Skids.

9. Attach guard bar (31) to Skid bar by installing the side bolts into the top two holes on the skids.

10. For electric start models secure the battery (not included) in the battery plate (164), hook one side of the strap into the hole then stretch the strap across the top of the battery and hook the opposite side into the opposing hole on the plate.

Make sure the battery will not move then connect terminals.

Items 117, 119 and 141 secure both front skid attachment and sides of front guard bar. Make sure both are securely attached.

11.

Reconnect spark plug wire.

Part No 500360 9 F052609A

OPERATION


DO NOT run engine in an enclosed area. Exhaust gases contain carbon monoxide, an odorless and possibly fatal poison.

DO NOT start or operate engine if strong odor of gasoline is present.

DO NOT start or operate engine if gasoline is spilled. Move equipment away from spill until gasoline has completely evaporated.

DO NOT operate engine without a muffler. Inspect muffler periodically and replace if necessary. If equipped with muffler deflector, inspect deflector periodically and replace if necessary.

DO NOT operate engine with grass, leaves or other combustible material near the muffler.

DO NOT touch muffler, cylinder or cooling fins while engine is running. Contact with hot surfaces may cause severe burns.

DO NOT operate equipment with bystanders in or near the work area.

DO NOT operate equipment with guards removed.

DO NOT operate equipment in areas containing rock, glass, string-like material, wire, rags, cans, metal or other non-organic material.

DO NOT operate equipment on slopes greater than specified in Specifications section of this manual.

DO NOT operate equipment near hot or burning debris or any toxic or explosive materials.

DO NOT allow children to operate this equipment.


ALWAYS check before use, transportation, or storage to make sure the battery is secured and straps holding battery are in good condition. If the strap breaks it will allow the battery to shift and could cause a short damaging the equipment. (Electric start)

ALWAYS connect battery terminals to proper connection cables. (Electric Start)

EAR PROTECTION is recommended when operating this equipment.

EYE PROTECTION is recommended when operating this equipment.

Part No 500360 10 F052609A


O

PERATOR

C

ONTROLS

The operator’s station is at the rear of the machine between the handlebars. The operator should STAND in a position to allow both handlebars to be grasped firmly and which allows sufficient leverage to steer the machine.

Operator’s controls are shown below.

1

2

4

5

6

3

7

Operator Control Locations

2 Gear Shift Lever 6 Drive Clutch Lever

3 Choke

S

TARTING

CHECK engine oil level before operating machine.

1. Place equipment on a level, firm surface that is free of rocks or other debris.

2. Place throttle in START position.

Throttle

11 F052609A Part No 500360


3. Pull choke out (Honda engine only).

Choke

4. Units equipped with electric starters: Press and hold ON/OFF button until engine starts.

ON/OFF (I/O) Switch I-ON O-Off

(Manual start shown)

DO NOT START equipment with drive or blade clutch engaged.

5. Units equipped with manual starters: Pull starter rope to start engine.

Part No 500360 12 F052609A


PULL STARTER CORD slowly until resistance is felt. Then pull cord rapidly to avoid kickback.

6. Push choke in (Honda engine only).

7. Pull throttle control back to and allow engine to reach correct operating speed.

C

UTTING

The best performance is achieved when cutting in dry conditions. The quality of the cut is directly related to ground speed during cutting. Under most conditions cutting should be done in first or second gear. Third gear should be reserved for conditions where weeds and brush are thinned out or not very tall. If the quality of the cut is not satisfactory, shift into a lower gear.

1. Move shift lever to correct position (1, 2, 3 or Reverse) for desired gear.

Gear Shift Lever

2. Press blade clutch handle down to engage blade. Allow blade to spin up to normal operating speed.

Blade Clutch Lever

3. Pull drive clutch handle up to engage transaxle.

Part No 500360 13 F052609A


Drive Clutch Lever

S

HUT

D

OWN

1. Release drive clutch handle to disengage transaxle.

2. Release blade clutch handle to disengage blade.

3. Pull throttle control all the way back to the STOP position.

4. Place the ON/OFF (I/O) switch in the OFF (O) position.

C

LEARING A

C

LOGGED

C

UTTING

D

ECK

DISCONNECT spark plug wire before servicing unit.

1. Shut engine off and wait for blade to stop completely.

2. Disconnect spark plug wire.

3. Remove clog from cutting deck.

WEAR durable gloves. Clog may contain sharp materials.

4. Reconnect spark plug wire.

Part No 500360 14 F052609A


HANDLING and TRANSPORTING

Using four people to lift unit is recommended. Lift holding the handles and front deck guard. Make sure equipment is properly secured before transporting.

NEVER lift the machine while the engine is running.

STORAGE

DO NOT store engine in an enclosed or poorly ventilated area where fuel fumes may reach an open flame or spark from a furnace, water heater, clothes dryer or similar devices.

DO NOT drain fuel in an enclosed or poorly ventilated area.

DO NOT smoke when draining fuel.

DO NOT remove gas cap while engine is running.

DO NOT park equipment on a steep grade or slope.

ALWAYS remove spark plug wire when servicing equipment to prevent accidental starting.


ALWAYS store fuel in approved safety containers.

If the equipment will not be used for 30 days or more, prepare as follows:

1. Make sure engine is cool.

2. Drain gasoline from carburetor and fuel tank to prevent gum deposits from forming.

3. Run engine until tank is empty and engine runs out of gas.

Fuel stabilizer (such as Sta-Bil) is an acceptable alternative for minimizing the formation of gum deposits during storage. Add stabilizer to gasoline in storage container or fuel tank. Follow stabilizer manufacturer’s instructions to determine proper mix ratio. Run engine at least 10 minutes after adding stabilizer to allow it to reach carburetor.

Part No 500360 15 F052609A


MAINTENANCE

P

ERIODIC

M

AINTENANCE

Periodic maintenance should be performed at the following intervals:

Maintenance Operation Every Use Daily or Every 5

Hours

Every 25 Hours Every 50

Hours

Every 100-150

Hours

Inspect for worn or damaged parts. z z

Check for excessive vibration

Inspect for loose parts. z z

Sharpen blade.

Inspect belts for wear. z z

Lubricate throttle control cable and linkage.

Check blade clutch cable tension. z z

Inspect battery for corrosion, damage or leaks

(electric start units only).

Apply anti-seize compound to rear axles. z z

Check battery strap for excessive wear or rips

Replace blade drive and transaxle drive belts. z

C

LEANING

Your BILLY GOAT

®

Brush Cutter should be cleaned periodically to ensure optimum performance and service life. Clogs and debris should be removed from the blade area and debris should be removed from the engine cooling fins. A garden hose or pressure washer may be used for cleaning.

DO NOT SPRAY WATER DIRECTLY ON THE BLADE CLUTCH WHEN USING A

POWER WASHER. SEE FIGURE BELOW.

Part No 500360 16 F052609A


B

LADE

R

EMOVAL AND

S

HARPENING

READ all safety instructions before servicing unit.

Numbers in parenthesis ( N-N ) refer to figure and item numbers in Illustrated Parts List.

Tools required:

- 5/8” socket, 1/2” drive

- torque wrench, 1/2” drive

- jack stands or similar device adequate to support weight of machine.



2. Lift and support front of unit to allow access to underside.

UNIT IS HEAVY. Make sure support is adequate to support weight of machine.

3. Block blade to prevent it from rotating during removal.

4. Remove blade bolt (8-139), lock washer (8-140) and friction washer (8-54).

Blade bolt (8-139) is a standard right-hand thread bolt.

5. Remove blade (8-50) and install replacement blade.

When replacing the blade use BILLY GOAT Industries PN 500210 only.

When sharpening blade make sure to sharpen all cutting edges.

6. Attach new blade with bolt (8-139), lock washer (8-140) and friction washer (8-54 removed earlier.

Inspect fasteners for wear and replace if necessary.

7. Torque blade bolt to 55-60 ft-lbs.


Part No 500360 17 F052609A


B

LADE

D

RIVE

B

ELT

T

ENSION

A

DJUSTMENT





2. Remove two screws holding engine base door (6-7) and remove door.

3. Examine condition of belt and not position of idler assembly and amount of tension on belt.

5. Reset belt tension by reaching in through top of engine base with pry bar or long screwdriver and pushing idler pulley against belt to increase tension (see below).

Adjusting Blade Drive Belt Tension

6. While holding belt under tension tighten two nuts (6-116) holding idler pulley in place.

7. Replace engine base door (6-7) and secure with screws removed earlier.


9. Check belt tension by operating unit under conditions that caused belt slippage. If belt continues to slip it may require replacement before operation may continue.

Part No 500360 18 F052609A


B

LADE

C

LUTCH

A

DJUSTMENT




2. As the clutch/brake wears or begins slipping or squealing, adjustment may be required to maintain proper cable tension and clutch engagement. A properly adjusted blade clutch should require 10 lbs of force to depress the end of the clutch lever. The blade clutch cable spring should stretch 1/4” to 3/8” (6.4-9.5 mm).

3. Adjust cable tension by tightening or loosening cable adjustment nut on rear of engine base (see below). Be sure to leave enough slack in cable to allow blade brake to engage.

Blade Cable Adjustment

If clutch continues to slip or squeal, do not operate equipment until adequate adjustment or repair has been performed. Improper adjustment can cause clutch to overheat and slip, greatly reducing performance and clutch life.


Part No 500360 19 F052609A


B

LADE

D

RIVE

B

ELT

R

EMOVAL AND

R

EPLACEMENT


Numbers in parenthesis (N-N ) refer to figure and item numbers in Illustrated Parts List.

Tools required:


- ratchet, 3/8”

- drive extension, 3/8” drive

- universal joint, 3/8” drive

- pry bar or long screwdriver




2. Lift and support rear of unit to allow access to underside.


3. Remove two screws (6-103) and washers (6-141) holding engine base door (6-7) and remove door. drive belt (8-29).

It may be necessary to pry idler pulley (8-9) away from its original position to release belt.

5. Using drive extension and universal joint, loosen, but do not remove, four screws (6-107) holding belt guides (6-149, 6-150) in place next to crankshaft drive pulley (8-9) at rear of machine.

If extension and universal joint are not available, remove stop bolt (6-110) and nuts (6-116, 6-

117) to allow idler arm to swing back and allow access to screws (6-107).

6. Pull transaxle drive belt (8-10) from groove on pulley (8-9).

7. Pull blade drive belt (8-29) from groove on pulley (8-9) and down past pulley.

8. Pull belt back through hole in top of engine base and remove it from machine.

It will take some force to walk the belt past the front portion of the pulley.

9. Install new blade drive belt (8-29) on groove in pulley (8-9). Push remaining length of belt back through engine base toward clutch/brake drive pulley.

10. Install transaxle drive belt (8-10) on groove in pulley (8-9).

11. Reach through from rear of machine and pull new belt through and install it in the groove on the clutch/brake drive pulley.

Part No 500360 20 F052609A


Make sure blade drive belt is properly seated in clutch/brake drive pulley (6-23) and is not resting in gap between clutch/brake drive pulley (6-23) and transaxle drive pulley

(6-46)

12. Tighten four screws (6-103) to secure belt guides (6-149, 6-150).

Make sure belt is correctly routed. (See Figure 2).

13. Adjust blade drive belt tension by reaching in through top of engine base with pry bar or long screwdriver and pushing idler pulley against belt to increase tension (see below).

Adjusting Blade Drive Belt Tension

14. While holding belt under tension tighten two nuts (6-116) securing idler plate.

15. Check belt tension by applying force on side of belt opposite idler pulley. Belt should deflect 3/16”-1/4” (4.8-

6.4 mm) with force applied perpendicular to belt.

16. Replace engine base door (6-7) and secure with screws (6-103) and washers (6-141).


FRONT

LOOKING THROUGH TOP

Blade Drive Belt (with

Transaxle Belt not Shown)

Belt Routing Diagram

(Top View of Machine)

Figure 2

Blade Drive Belt

(Between Transaxle Drive

Belt and Deck)

Transaxle Drive Belt

Part No 500360 21 F052609A


T

RANSAXLE

D

RIVE

C

LUTCH

A

DJUSTMENT




2. As the belt wears or begins slipping or squealing, adjustment may be required to maintain proper cable tension and clutch engagement. A properly adjusted transaxle drive clutch should require 3 lbs of force to depress the end of the clutch lever.

3. Adjust cable tension by tightening or loosening cable adjustment barrel on rear of engine base (see below).

Moving the cable adjustment barrel IN decreases clutch tension. Moving the barrel OUT increases tension.


DECREASE

INCREASE

Transaxle Cable Adjustment

Part No 500360 22 F052609A


T

RANSAXLE

D

RIVE

B

ELT

R

EMOVAL AND

R

EPLACEMENT



Tools required: ½” socket and ratchet, ½” universal extension bar, pry bar or long screwdriver, adequate support for machine.


- ratchet, 3/8”

- drive extension, 3/8” drive

- universal joint, 3/8” drive

- pry bar or long screwdriver




2. Lift and support rear of unit to allow access to underside.


3. Using drive extension and universal joint, loosen, but do not remove, four screws (6-107) holding belt guides (6-149, 6-150) in place next to crankshaft drive pulley (8-9) at rear of machine.

If extension and universal joint are not available, remove stop bolt (6-10) and nuts (6-116, 6-

117) to allow idler arm to swing back and allow access to screws (6-107).

4. Pull belt (8-10) from groove on pulley (8-9) and down past pulley.

5. Slip belt (8-10) up and over pulley (8-9) and remove belt from machine.

6. Install new belt in grooves on pulley (6-46) and transaxle drive pulley (8-9).

7. Tighten four screws (6-107) to secure belt guides (6-149, 6-150).

8. Engage clutch levers and make sure belt guides do not touch belts.


Part No 500360 23 F052609A


W

IRING

D

IAGRAMS

Starter Switch Wiring

Figure 3

RED

SWITCH

B

RED

A1

WHITE

M

BLACK

FUSE

20A

STARTER

SOLENOID

RED

+

BATTERY

STARTER

MOTOR

-

BLACK

ENGINE

GROUND

Starter Circuit Schematic Diagram

Figure 4

MAGNETO

ON/OFF

SWITCH

ENGINE

GROUND

ON/OFF Switch Circuit Schematic Diagram

Figure 5

SPARK

PLUG

Part No 500360 24 F052609A


TROUBLESHOOTING

Engine will not start.

Starter does not turn.

(Electric start only)

Will not cut or cutting performance is poor.

Abnormal vibrations.

ON/OFF switch is in OFF position.

Out of gasoline.

Old or contaminated gasoline.

Spark plug wire disconnected.

Dirty air cleaner.

Battery low or dead.

Battery cable disconnected or corroded.

Defective starter switch or wiring harness.

Defective starter.

Blade drive belt tension incorrect.

Dull blade.

Clogged deck.

Excessive debris built up on or blocking blade.

Engine RPM set too low.

Blade loose or out of balance.

Belt slips or smokes.

Clutch slips or squeals.

Blade brake will not engage.

Transaxle will not engage.

Engine loose.

Blade drive belt worn.

Belt tension too low.

Belt worn or stretched.

Pulleys worn or damaged.

Clutch cable tension too low.

Clutch worn or damaged.

Inadequate slack in clutch cable.

Clutch worn or damaged.

Clutch lever not engaging clutch.

Corrective Action

Move switch to START position.

Fill gas tank.

Drain gas tank and fill with fresh gasoline.

Connect spark plug wire.

Clean or replace air cleaner.

Charge or replace battery.

Clean and secure battery terminals.

Replace starter switch or wiring harness.

Replace starter.

Adjust blade drive belt tension.

Sharpen or replace blade.

Unclog deck.

Clear debris from blade area.

Check engine RPM.

Check blade for tightness. Rebalance if necessary.

Check engine mounting bolts.

Replace blade drive belt.

Adjust belt tension.

Replace belt.

Replace pulleys.

Adjust clutch tension.

Replace worn or defective clutch assembly parts.

Adjust clutch cable.

Replace clutch/brake assembly.


Transaxle will not disengage.

Engine will not turn over.

Belt worn or broken.

Clutch cable out of adjustment.

Defective blade clutch.

Engine problem.

Replace belt.


Replace clutch.

Contact an authorized servicing dealer for your engine.

Part No 500360 25 F052609A


ENGINE MAINTENANCE AND REPAIR

Refer to the engine manufacturer’s manual for maintenance and service information. Warranty coverage on the engine is the responsibility of the engine manufacturer. If your engine requires warranty repair contact your local servicing engine dealer. Have your engine model number and serial number ready when you contact the dealer.

If you cannot locate a servicing dealer in your area, you may contact the manufacturer’s national service organization at the following numbers:

WARRANTY CLAIM PROCEDURE

Should a BILLY GOAT

®

machine fail due to a defect in material and/or workmanship, the owner should make a warranty claim as follows:

- The machine must be taken to the dealer from whom it was purchased or to an authorized Servicing

BILLYGOAT Dealer.

-

The owner must present the remaining half of the Warranty Registration Card, or, if this is not available, the invoice or receipt.

- The Warranty Claim will be completed by the authorized BILLY GOAT Dealer and submitted to their respective BILLY GOAT Distributor for their territory Attention: Service Manager. Any parts replaced under warranty must be tagged and retained for 90 days. The model number and serial number of the unit must be stated in the Warranty Claim.

- The distributor service manager will sign off on the claim and submit it to BILLY GOAT for consideration.

- The Technical Service Department at BILLY GOAT will study the claim and may request parts to be returned for examination. BILLY GOAT will notify their conclusions to the distributor service manager from whom the claim was received.

- The decision by the Service Department at BILLY GOAT to approve or reject a Warranty Claim is final and binding.

Part No 500360 26 F052609A

Part No 500360


MAINTENANCE RECORD

27 F052609A


ILLUSTRATED PARTS LIST

Engine and Engine Base Assembly

Figure 6

Part No 500360 28 F052609A


ITEM

NO

DESCRIPTION

4 Base Assembly with labels

7 Door Engine

22 Tube Shift With Grip

24

26

27

32

45

45

45

46

47

100

103

104

Grip 3/4 ID - Black

Plate Mount Idler WA

Pulley Idler 4.5" OD X 3/8”

Bushing Shifter

13 HP Honda GXV390 Electric Start

13 HP Honda GXV390

13 HP OHV B & S

Pulley Drive Traction BC

Spacer Engine WA 2401

Roll Pin 1/4- x 1 1/4

Screw cap ¼-20 x 1 1/4

Screw Cap 5/16-18 x 1-1/4”

Washer Split Lock 5/16”

106

109

110

113

Screw Cap 7/16-20 X 3"

Bolt Carriage 5/16-18 x 3/4 “

Washer Flat 1/2"

Nut Lock 3/8-16

117

118

120

121

Nut Lock 5/16-18

Bolt Carriage 5/16-18 x 1”

Washer 3/8 FC

Terminal Piggyback 3/16

140

141

143

149

150

151

162

163

164

165

166

169

Washer Lock 7/16”

Washer 5/16” FC

Screw Cap 5/16-18 x 1-3/4”

Guide Belt LH

Guide Belt RH

Screw Cap 5/16-24 x 1”

Cable Battery Red W/Charge

Cable Battery Black 10"

Bracket Battery Rear

Strap Hold Down

Washer 1/4” SAE

Label Hot Engine

186

Battery 12v w/ Label and hardware

(Hardware can be found at local hardware store)

188 Label Ear Eye Breathe

190

193

194

195

196

198

199

200

202

Label Patent No

Plate Choke Mount BC

Screw Machine 10-32 x 3/4"

Control Cable Choke BC

Ring Retaining External 3/4”

Label Outback BC

Label Product Decal

Screwcap 5/16 –18 x 2

Nut lock ¼-20 2 way

BC2403HEB BC2403H BC2403IC

Part No

500240

QTY

1

Part No

500240

QTY

1

Part No

500240

QTY

1

500233 1 500233 1 500233

500171 1 500171 1 500171

500338 1 500338 1 500338

610102

500228

1

1

610102

500228

1

1

610102

500228

1

1

1

1

1

500270

500130

500333

-

-

500238

500262

1

1

1

-

-

1

1

500270

500130

-

500334

-

500238

500262

1

1

-

1

-

1

1

500270

500130

-

-

520046

500238

500262

1

1

-

-

1

1

1

-

8041007

-

1

8041007

-

1

-

8041007

-

1

-

*8041029 2 *8041029 2 *8041029 2

*8177011 2 *8177011

850443 1 850443

500269

8024039

1

4

500269

8024039

2

1

1

6

*8177011

850443

500269

8024039

2

1

1

6

900230

*8160003

2

2

900230

*8160003

2

2

900230

*8160003

2

2

*8142002 2 *8142002 2 *8142002 2

*8160002

*8024040

8

4

*8160002

*8024040

8

2

*8160002

*8024040

10

2

*8171004 1 *8171004 1 *8171004 1

890010 1 890010 1 - -

830113 1 830113

850132 1 850132

1

1

830113

850132

1

1

*8171003 6 *8171003 6 *8171003 8

*8041031 1 *8041031 2 *8041031 4

500230 1 500230 1 500230 1

500231

*400164

1

2

500231

*400164

1

2

500231

-

1

-

500304

790133

500347

1

1

1

-

-

-

-

-

-

-

-

-

-

-

790303

8172007

1

2

-

8172007

400268 1 400268

900327 2 900327

-

2

1

2

-

8172007

400268

900327

-

2

1

2

890301 1 890301

890254 1 890254

500168 1 500168

500279

500325

1

1

500279

500325

430248

500326

520176

500293

890456

8041032

8142004

1

1

1

2

1

1

1

430248

500326

520176

500293

890456

-

-

2

1

-

-

1

1

1

1

1

1

1

1

890301

890254

500168

500279

-

-

-

520176

500293

890456

-

-

-

-

2

1

-

-

1

1

1

1

1

-

Part No 500360 29 F052609A


Part No 500360

Handlebar Assembly

Figure 7

30 F052609A

ITEM

NO

51

52

55

56

42

43

44

48

5

6

17

18

39

40

41

102

108

115

117

119

124

DESCRIPTION

Handle Brace Left

Handle Brace Right

Cable Clutch Blade BC2402

Cable Clutch Drive BC2402

Lever Control Blade

Handle Upper BC2402

Grip Handle 1” ID x 7.5”

Lever Control Clutch

Bushing Lever Control

Fitting Mount Cable

Throttle Control, Including Cable

Handle Lower RH BC2402

Handle Lower LH BC2402

Guard Hand BC2402

Screw Cap 8-3/8 HWH Type B

Nut Lock 1/4-20

Screw Cap 5/16-18 x 2-3/4”

Nut Lock 5/16-18

Washer 1/4” FC

141

142

143

144

145

Washer 5/16” FC

Bracket Clutch Cable Guard

Guide Rope (Honda only)

147

153

154

157

Label Start/Stop Toggle



Switch Box Assy BC (includes throttle cable)

160 Bushing Strain Relief

170

186

191

192

Bolt Shoulder 5/16-18 x 1-1/2”

Label Shift BC2402

Label Clutch Drive

Label Clutch Blade



Part No QTY Part No QTY Part No

QT

Y

500196 1 500196 1 500196 1

500200

500259

500327

500312

500243-S

500267

500142

500152

500187

500213

500140

500141

500339

100121

*8160001

*8041035

2

2

7

1

2

1

1

1

1

2

1

4

1

1

1

1

500200

500259

500327

500312

500243-S

500267

500142

500152

500187

500213

500140

500141

500339

100121

*8160001

*8041035

2

2

7

1

2

1

1

1

1

2

1

4

1

1

1

1

500200

500259

500327

500312

500243-S

500267

500142

500152

500187

500213

500140

500141

500339

100121

*8160001

*8041035

2

2

6

1

2

1

1

1

1

2

1

4

1

1

1

1

*8160002 10 *8160002 10 *8160002 10

*8171002 2 *8171002 2 *8171002 2

900407 4 900407 4 900407 4

*8171003 5 *8171003 5 *8171003 7

500321 1 500321 1 500321 1

830533 2 830533 2

500181 2 500181 2 500181 2

500329

*8041014

*8041010

1

1

2

*8041014

*8041010

1

2

*8041014

*8041010

1

2

500307 1 500281 1 500281 1

500306 1 890442 1 890442 1

500282 1 500282 1 500282 1

810656 1 810656 1 810656 1

500340

500349

500176

500177

2

1

1

1

500340

500349

500176

500177

2

1

1

1

500340

500349

500176

500177

2

1

1

1

Part No 500360 31 F052609A

Part No 500360


Transaxle and Blade Deck Assembly

Figure 8

32 F052609A


ITEM

NO

DESCRIPTION


103

104

107

108

109

111

112

19

20

21

29

14

15

1

10

11

Deck Assembly with Labels

3 Deflector

8

BC2402

Transaxle 3 SPD BC2402

Belt Traction Drive

Plate Pivot Idler/Shifter

Shifter WA

500358 1 500358 1 500358 1

500125 1 500125 1 500125 1

500342 1 500342 1 500342 1

830180 1 830180 1 830180 1

500119

500122

1

1

500119

500122

1

1

500119

500122

1

1

Wheel & Tire 16" SP LH

500169 1 500169 1 500169 1

800260 1 800260 1 800260 1

500343 1 500343 1 500343 1

Wheel & Tire 16” SP LH Xtrac No flat BC2403HF and ICF only - - 500352 1 500352 1

Wheel & Tire 16" SP RH 500344 1 500344 1 500344 1

Wheel & Tire 16” SP RH Xtrac No flat BC2403HF and ICF only - - 500353 1 500353 1

500170 1 500170 1 500170 1

33

Bar Shift T-axle

Angle Support T-axle

Rod Link Shifter

Belt Blade Drive

Screw Cap 5/16-18 x 1 ¾”

500121

500127

500144

1

1

1

500121

500127

500144

1

1

1

500121

500127

500144

1

1

1

500237 1 500237 1 500237 1

500232 1 500232 1 500232 1

500356 1 500356 1 500356 1

8041031 4 8041031 4 8041031 4

500174 1 500174 1 500174 1

35

36

Bearing 7/8" ID Sealed Press

Shaft Drive Blade

38

49 Nut

54

101

Pulley 7" OD x 7/8" Bore

Thin

Washer Friction Blade

Bolt Carriage 1/4-20 x 3/4”

Screw Cap 5/16-18 x 1-1/4”

Washer Split Lock 5/16”

Screw Cap 5/16-18 x 1"

500101

500107

2

1

500101

500107

2

1

500101

500107

2

1

500115 1 500115 1 500115 1

500253 1 500253 1 500253 1

8161042 1 8161042 1 8161042 1

500210 1 500210 1 500210 1

500191 1 500191 1 500191 1

500108 1 500108 1 500108 1

8024021 4 8024021 4 8024021 4

*8160001 5 *8160001 5 *8160001 5

*8041029 12 *8041029 12 *8041029 12

*8177011 5 *8177011 5 *8177011 5

117

119

122

124

125

Bolt Carriage 5/16-18 x 3/4 “

Pin Cotter 3/32 x 3/4"

Bolt Shoulder 1/2 x 1”

Nut 5/16-18

Nut Lock 5/16-18

Screw Cap 5/16-18 x 1-1/2”

Screw Cap 1/4-28 x 1/2” GR5

Washer 5/16”

Washer 1/4” FC

Screw Self Tap 5/16”

*8041028 7 *8041028 7 *8041028 7

*8041035 4 *8041035 4 *8041035 4

8024039 4 8024039 4 8024039 4

*8197016

500114

1

1

*8197016

500114

1

1

*8197016

500114

1

1

*8160003 1 *816003 1 *8160003 1

800888 1 800888 1 800888 1

*8142002 1 *8142002 1 *8142002 1

*8160002 10 *8160002 10 *8160002 10

*8041030 6 *8041030 6 *8041030 6

850408 1 850408 1 850408 1

128

130

135

138

139

141

152

156

197

Pin Cotter 3/32 x 3/4”

Washer SAE

Washer 0.765 x 1.250 x 0.060”

Ring 0.750”

Key 2-1/8”

Screw Cap 7/16-20 x 1-1/4” GR8

Key Sq 3/16 x 5/8”

Screw Cap 7/16-20 x 2” GR8

Washer 7/16”

Washer 5/16 FC

Screw Cap 1/4-20 x 1-1/4”

Washer lock 7/16 S/T Med

Washer Lock 5/16 twisted tooth

8181008 1 8181008 1 8181008 1

*8171002 1 *8171002 1 *8171002 1

*8123128 1 *8123128 1 *8123128 1

900471 2 900471 2 900471 2

8197016 1 8197016 1 8197016 1

*8172015 2 *8172015 2 *8172015 2

850238 2 850238 2 850238 2

850230 2 850230 2 850230 2

9201087 2 9201087 2 9201087 2

800554 1 800554 1 800554 1

350153 1 350153 1 350153 1

9201072 2 9201072 2 9201072 2

500188 1 500188 1 500188 1

850132 1 850132 1 850132 1

*8171003 20 *8171003 20 *8171003 20

*8041007 2 *8041007 2 *8041007 2

500355 2 500355 2 500355 2

8177013 1 8177013 1 8177013 1

400424 2 400424 2 400424 2

810736 1 810736 1 810736 1

800177 2 800177 2 800177 2

200 Washer Lock 5/16 twisted tooth heavy 430298 4 430298 4 430298 4

850233 1 850233 1 850233 1

Part No 500360 33 F052609A

Part No 500360


Blade Drive Spindle Assembly Detail Drawing

Figure 9

34 F052609A

ITEM

NO

DESCRIPTION

35

36

37

38

Bearing 7/8" ID Sealed Press

Shaft Drive Blade

Spacer Spindle Bearing

Pulley 7" OD x 7/8" Bore

54

135

136

138

139

140

156

Washer Friction Blade

Screw Cap 7/16-20 x 1-1/4” GR8

Washer 7/8 SAE

Key Sq 3/16 x 5/8”

Screw Cap 7/16-20 x 2” GR8

Washer Lock 7/16”

Washer lock 7/16 S/T Med

Part No 500360



Part No QTY Part No QTY Part No QTY

500242 1 500242 1 500242 1

500232 1 500232 1 500232 1

500174 1 500174 1 500174 1

500101

500107

500115

2

1

1

500101

500107

500115

2

1

1

500101

500107

500115

2

1

1

500253 1 500253 1 500253 1

500191 1 500191 1 500191 1

500108

800554

1

1

500108

800554

1

1

500108

800554

1

1

350153

9201072

500188

850132

8177013

1

2

1

1

1

350153

9201072

500188

850132

8177013

1

2

1

1

1

350153

9201072

500188

850132

8177013

1

2

1

1

1

35 F052609A


HIGH WHEEL MOWER FORCE BLOWER

If you liked this product please feel free to view our full line of quality lawn care, renovation, and debris removal products at

www.billygoat.com

DL VACUUM MULTI VACUUM

AERATOR

POWER RAKE

Part No 500360 36 F052609A

Billy Goat BC2403 Series Owner's Manual

BILLY GOAT

®

BC2403 Series Brush Cutter

Owner’s Manual

Patent Number D386768

ABOUT THIS MANUAL

CONTENTS

SERIAL PLATE DATA

BC 2403 SERIES SPECIFICATIONS

COMMON REPLACEMENT PARTS

GENERAL SAFETY INSTRUCTIONS and SYMBOLS

SOUND DATA

VIBRATION DATA

INTENDED USE

INSTRUCTION LABELS

ASSEMBLY INSTRUCTIONS

Warning: When attaching the Skids be careful of the blade. Wear thick gloves and check the position of the blade before putting your hands into the deck to install the bolts though the Skids.

OPERATION

O

C

3

S

C

S

D

C

C

C

D

HANDLING and TRANSPORTING

STORAGE

MAINTENANCE

P

M

C

B

R

S

B

D

B

T

A

B

C

A

B

D

B

R

R

T

D

C

A

T

D

B

R

R

W

D

TROUBLESHOOTING

ENGINE MAINTENANCE AND REPAIR

WARRANTY CLAIM PROCEDURE

MAINTENANCE RECORD

ILLUSTRATED PARTS LIST

If you liked this product please feel free to view our full line of quality lawn care, renovation, and debris removal products at

www.billygoat.com

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