Troy-Bilt 630B-Tuffy, 634F-Bronco, 634B-Super Bronco manual Assembly

8Section 2: Assembly

4.Thread the #10-24 hex nut (Z, Fig. 2-5) halfway onto the screw (V).

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

6.Hook the cable spring (W, Fig. 2-6) into the V-shaped bend in the Forward Clutch Bail (Y).

7.Check for correct tension on the for- ward drive belt by taking two measure- ments of the cable spring, as follows:

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

6) in an open (released) position, mea-

sure the length of the cable spring (W)

from the outermost coil to the outer-

most coil.

b. Squeeze the Forward Clutch Bail against

the handlebar (see Fig. 2-7) and re-

measure the spring length. The belt

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.

tension is correct if this second mea-

surement 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 pre-

venting 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).

Y

W W

STEP 5: INSTALL REVERSE CLUTCH CABLE (MODELS 634F AND 634B 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. Using the two self-tapping screws (AA,

Fig. 2-8) secure the reverse cable

mounting bracket (BB)to the handlebars,

as shown.

3. 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.

4. Fasten the reverse clutch cable to the

left side handlebar with a cable tie (EE,

Fig. 2-9).

5. Test the function of the reverse clutch

by pulling out and releasing the cable

knob. The knob should return to its neu-

tral position (resting against bracket). If it

AA
BB	AA
DD
CC
	Flat Side

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

CC

BRONCO

Z

X

V

doesn’t, contact your local dealer or the

factory for technical assistance.

EE

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

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