Bolens 643C, 643B, 645A warranty Install Forward Clutch Cable, Thread the #10-24 hex nut Z, Fig

STEP 4: INSTALL FORWARD CLUTCH CABLE

1.Carefully unwrap the forward clutch cable (cable without an attached knob) from its shipping position and slide the thin cable wire (M, Fig. 2-4) into the slot in the cable bracket. Push the cable connector (N, Fig. 2-4) up through the hole in the bracket until the groove in the connector snaps into place.

2.Thread the #10-24 hex nut (Z, Fig.

2-5) halfway onto the screw (V) which runs through the spring (W, Fig. 2-5).

3.Thread the screw (V) into the cable adjuster (X).

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Fig. 2-4: Installing forward clutch cable bracket and cable.

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Assembly

NOTE: Incorrect

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.

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

b.Squeeze the Forward Clutch Bail against the handlebar (see Fig. 2-7) and re-measure the spring length. The belt tension is correct if this second measurement is between 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 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 Neutral (cable tension too tight).

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

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 position 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 position (resting against bracket). If it doesn’t, contact your local dealer.

cable tension can result in belt slippage (cable tension too loose), or unintentional tine movement when the clutch bail is in Neutral (cable tension too tight).

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