7
-
.
-
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).
Fig. 2-4: Installing forward clutch cable bracket and cable.
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.
7
6
:
8
9
7
Fig. 2-5: Cable
spring and
adjuster.
Fig. 2-6: Attach forward
clutch cable spring to
forward clutch bail.
NOTE: 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).
2
Assembly
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 sl ot 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.
(OLDBAILAGAINSTHANDLEBARWHILE
TAKINGSECONDMEASUREMENTOFSPRING
:
8
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.
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 ad just
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).