Troy-Bilt 645A, 643D, 643B manual While preventing the cable adjuster from turning

4.Check for correct tension on the forward drive belt by taking two measurements of the cable spring, as follows:

a. With the Forward Clutch Bail (Y, Fig. 2-

6)in an open (released) position, measure the length of the cable spring (W) from the outermost coil to the outermost coil.

b. Squeeze the Forward Clutch Bail against the handlebar (see Fig. 2-7) and re-mea- sure the spring length. The belt tension is correct if this second measurement is be- tween 1/16" to 3/16" longer than the first measurement. If so, turn the hex nut (Z, Fig. 2-7) tightly against the cable adjuster

(X)while preventing the cable adjuster from turning.

c. If the spring length is incorrect, you must adjust the cable tension as described in Checking and Adjusting Forward Drive

6

5

4

3

2

Z	1
X

Hold bail against handlebar while taking second measurement of spring

Fig. 2-7: To check forward belt tension, take two measurements of the length of the coils in the spring — first with the bail open, then with the bail held against the handlebar.

Belt Tension in Section 5. Incorrect cable tension can result in belt slippage (cable tension too loose), or unintentional tine movement when the clutch bail is in Neu- tral (cable tension too tight).

Y

W

V	W
Z
X

Fig. 2-5: Cable	Fig. 2-6: Attach forward
spring and	clutch cable spring to
adjuster.	forward clutch bail.

STEP 5: INSTALL REVERSE CLUTCH CABLE (MODELS 643B AND 645A ONLY)

1.Unwrap the reverse clutch cable (CC, Fig. 2-8 and Fig. 2-9) from its shipping po- sition and route it up to the handlebar. Be sure that the cable is routed beneath the Forward Clutch Bail.

2.Insert the cable (CC, Fig. 2-8) through the slot in the cable bracket and position the flat side of the threaded assembly next to the flat side of the hole. Slide the hex nut (DD) up the cable and tighten it securely.

3.Fasten the reverse clutch cable to the left side handlebar with a cable tie (EE, Fig. 2-9).

4.Test the function of the reverse clutch by pulling out and releasing the cable knob. The knob should return to its neutral posi- tion (resting against bracket). If it doesn’t, contact your local dealer or Troy-Bilt LLC for technical assistance.

BB

DD

CC

Flat Side

Fig. 2-8: Install reverse cable bracket and reverse clutch cable.

CC

BRONCO

EE

Fig. 2-9: Route reverse clutch cable (CC) as shown. Attach with cable tie (EE).

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