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Part No 500264 

29 

F091506B 

BC2402 Series Brush Cutter Owner’s Manual

 

BC2402HE BC2402H BC2402ICE BC2402IC 

ITEM  

NO 

 DESCRIPTION 

Part 

No QTY Part 

No  QTY  Part No 

QTY 

Part No 

QTY 

Base Assembly with labels  

500240 

500240 

500240 

500240 

Door 

Base 

Engine 

500233 1 500233  1  500233 1 500233  1 

22 

Tube Shift With Grip  

500171 

500171 

500171 

500171 

23 

Clutch 

Brake 

500338 1 500338  1  500338 1 500338  1 

24 

Grip 3/4 ID - Black  

610102 

610102 

610102 

610102 

26 

Plate 

Mount 

Idler 

WA 

 

500228 1 500228  1  500228 1 500228  1 

27 

Pulley Idler 4.5" OD X 3/8”  

500270 

500270 

500270 

500270 

32 

Bushing 

Shifter 

 

500130 1 500130  1  500130 1 500130  1 

45 

13 HP Honda GXV390 Electric Start 

500333 

45 

13 HP Honda GXV390  

500334 

45 

13 HP OHV B & S  

520046 

45 

13 HP OHV Briggs Electric Start 

520039 

46 

Pulley Drive Traction BC 

500238 

500238 

500238 

500238 

47 

Spacer 

Engine 

WA 

2401 

500262 1 500262  1  500262 1 500262  1 

100 

Roll Pin 1/4 x 1 1/4 

500351 

500351 

500351 

500351 

103 

Screw Cap 5/16-18 x 1-1/4” 

*8041029 2 *8041029  2  *8041029 2 *8041029  2 

104 

Washer Split Lock 5/16”  

 *8177011 

 *8177011 

 *8177011 

 *8177011 

105 

Plate 

Impeller 

Washer 

850443 1 850443  1  850443 1 850443  1 

106 

Screw Cap 7/16-20  X  3" 

500269 

500269 

500269 

500269 

109 

Bolt Carriage 5/16-18 x 3/4 “ 

8024039 

8024039 

8024039 

8024039 

110 

Washer Flat 1/2"  

900230 

900230 

900230 

900230 

113 

Nut Lock 3/8-16 

*8160003 

2 *8160003 2 *8160003 2 *8160003  2 

116 

Nut 

Jam 

5/16-18 

*8142002 2 *8142002  2  *8142002 2 *8142002  2 

117 

Nut Lock 5/16-18 

*8160002 8 *8160002  8  *8160002 10 *8160002  10 

118 

Bolt Carriage 5/16-18 x 1” 

*8024040 

*8024040 

*8024040 

*8024040 

120 

Washer 3/8 FC 

*8171004 

1 *8171004 1 *8171004 1 *8171004  1 

121 

Terminal Piggyback 3/16 

890010 

890010 

131 

Spacer 

Engine 

830113 1 830113  1  830113 1 830113  1 

140 

Washer 

Lock 

7/16” 

850132 1 850132  1  850132 1 850132  1 

141 

Washer 5/16” FC 

*8171003 6 *8171003  6  *8171003 8 *8171003  8 

143 

Screw Cap 5/16-18 x 1-3/4” 

*8041031 1 *8041031  2  *8041031 1 *8041031  4 

149 

Guide 

Belt 

LH 

500230 1 500230  1  500230 1 500230  1 

150 

Guide Belt RH  

500231 

500231 

500231 

500231 

151 

Screw Cap 5/16-24 x 1” 

*400164 

*400164 

 

 

 

 

162 

Cable Battery Red W/Charge 

500304 

520111 

163 

Cable Battery Black 10" 

790133 

  

790133 

164 

Bracket Battery Rear 

500347 

500347 

165 

Strap Hold Down 

790303 

790303 

166 

Washer 

1/4” 

SAE 

8172007 2 8172007  2  8172007 2 8172007  2 

167 

Screw Cap 1/4-20 x 3/4” 

8041004 

8041004 

8041004 

8041004 

168 

Cable Battery Positive 8" 

520123 

169 

Label 

Hot 

Engine 

400268 1 400268  1  400268 1 400268  1 

185 

Label 

Guards 

900327 2 900327  2  900327 2 900327  2 

186 

Label 

Shift 

BC2402 

500349 1 500349  1  500349 1 500349  1 

187 

Label 

Read 

890301 1 890301  1  890301 1 890301  1 

188 

Label Ear Eye Breathe 

890254 

890254 

890254 

890254 

189 

Label 

Chock 

Wheels 

500168 1 500168  1  500168 1 500168  1 

190 

Label 

Patent 

No 

500279 1 500279  1  500279 1 500279  1 

193 

Plate Choke Mount BC 

500325 

500325 

194 

Screw Machine 10-32 x 3/4" 

430248 

430248 

195 

Control Cable Choke BC 

500326 

500326 

196 

Ring 

Retaining 

External 

3/4” 

520176 1 520176  1  520176 1 520176  1 

198 

Label 

Outback 

BC 

500293 2 500293  2  500293 2 500293  2 

199 

Label 

Product 

Decal 

890456 1 890456  1  890456 1 890456  1 

200 

Screwcap 5/16 –18 x 2 

8041032 

 

 

8041032 

 

 

Summary of Contents for BC2402 Series

Page 1: ...Part No 500264 1 Form No F091506B BILLY GOAT BC2402 Series Brush Cutter Owner s Manual Patent Number D386768...

Page 2: ...Cutting 13 Shut Down 14 Cutting Height Adjustment 14 Clearing a Clogged Cutting Deck 14 Handling and Transporting 15 Storage 15 Maintenance 16 Periodic Maintenance 16 Cleaning 16 Blade Removal and Sha...

Page 3: ...27 3 kg Unit Weight 266 lb 120 7 kg 278 lb 126 4 kg 291 lb 132 3 kg 273 lb 124 1 kg In accordance with 2000 14 EEC standards 106 dB a 106 dB a 106 dB a 106 dB a Sound at Operator s ear 93 dB a 93 dB a...

Page 4: ...utter 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 opera...

Page 5: ...perate 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 equi...

Page 6: ...761mm Hg VIBRATION DATA VIBRATION LEVEL 5g 4 87 m s2 Vibration levels at the operator s handles were measured in the vertical lateral and longitudinal directions using calibrated vibration test equip...

Page 7: ...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 See Figure 6 Item 188 PN 500349 See Figure 6 Item 186 Ite...

Page 8: ...Part No 500264 8 F091506B BC2402 Series Brush Cutter Owner s Manual Brush Cutter Assembly Drawing Figure 1...

Page 9: ...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 Att...

Page 10: ...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...

Page 11: ...ped firmly and which allows sufficient leverage to steer the machine Operator s controls are shown below Operator Control Locations 1 Blade Clutch Lever 5 ON OFF Switch 2 Gear Shift Lever 6 Drive Clut...

Page 12: ...nda 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 blad...

Page 13: ...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 a...

Page 14: ...ecommended that you operate the brush cutter at the standard top cutting height 1 Shut engine off and wait for blade to stop completely 2 Disconnect spark plug wire 3 Remove bolts nuts and washers ite...

Page 15: ...rk equipment on a steep grade or slope ALWAYS remove spark plug wire when servicing equipment to prevent accidental starting ALWAYS keep hands and feet away from moving or rotating parts ALWAYS store...

Page 16: ...e and linkage z Check blade clutch cable tension z Inspect battery for corrosion damage or leaks electric start units only z Apply anti seize compound to rear axles z Check battery strap for excessive...

Page 17: ...it 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...

Page 18: ...y and amount of tension on belt 4 Loosen but do not remove two nuts 6 116 on top on engine base 5 Reset belt tension by reaching in through top of engine base with pry bar or long screwdriver and push...

Page 19: ...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...

Page 20: ...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...

Page 21: ...ewdriver 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...

Page 22: ...ing 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...

Page 23: ...d support rear of unit to allow access to underside UNIT IS HEAVY Make sure support is adequate to support weight of machine 3 Using drive extension and universal joint loosen but do not remove four s...

Page 24: ...RAMS Starter Switch Wiring Figure 3 Starter Circuit Schematic Diagram Figure 4 ON OFF Switch Circuit Schematic Diagram Figure 5 SWITCH WHITE RED STARTER SOLENOID BATTERY BLACK 20A FUSE RED STARTER MOT...

Page 25: ...de area Will not cut or cutting performance is poor Engine RPM set too low Check engine RPM Blade loose or out of balance Check blade for tightness Rebalance if necessary Engine loose Check engine mou...

Page 26: ...e 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...

Page 27: ...Part No 500264 27 F091506B BC2402 Series Brush Cutter Owner s Manual MAINTENANCE RECORD Date Service Performed...

Page 28: ...Part No 500264 28 F091506B BC2402 Series Brush Cutter Owner s Manual ILLUSTRATED PARTS LIST Engine and Engine Base Assembly Figure 6...

Page 29: ...60002 8 8160002 8 8160002 10 8160002 10 118 Bolt Carriage 5 16 18 x 1 8024040 2 8024040 2 8024040 2 8024040 2 120 Washer 3 8 FC 8171004 1 8171004 1 8171004 1 8171004 1 121 Terminal Piggyback 3 16 8900...

Page 30: ...Part No 500264 30 F091506B BC2402 Series Brush Cutter Owner s Manual Handlebar Assembly Figure 7...

Page 31: ...41035 1 8041035 1 8041035 1 115 Screw Cap 5 16 18 x 2 8041032 4 8041032 2 8041032 4 8041032 2 117 Nut Lock 5 16 18 8160002 10 8160002 10 8160002 10 8160002 10 119 Screw Cap 5 16 18 x 1 1 2 8041030 4 8...

Page 32: ...Part No 500264 32 F091506B BC2402 Series Brush Cutter Owner s Manual Transaxle and Blade Deck Assembly Figure 8...

Page 33: ...9 11 8041029 11 104 Washer Split Lock 5 16 8177011 5 8177011 5 8177011 5 8177011 5 107 Screw Cap 5 16 18 x 1 8041028 8 8041028 8 8041028 8 8041028 8 108 Screw Cap 5 16 18 x 2 3 4 8041035 4 8041035 4 8...

Page 34: ...Part No 500264 34 F091506B BC2402 Series Brush Cutter Owner s Manual Blade Drive Spindle Assembly Detail Drawing Figure 9...

Page 35: ...2 36 Shaft Drive Blade 500107 1 500107 1 500107 1 500107 1 37 Spacer Spindle Bearing 500115 1 500115 1 500115 1 500115 1 38 Pulley 7 OD x 7 8 Bore 500253 1 500253 1 500253 1 500253 1 53 Adapter Blade...

Page 36: ...ush Cutter Owner s Manual 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 AERATOR POWER RAKE QL VACUUM...

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