Troy-Bilt 644A, 640C manual 5 Cable, springand, adjuster, clutchcable spring to, forwardclutch bail

4.Checkfor correct tension onthe 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. Squeezethe ForwardClutch Bailagainst the handlebar(see Fig. 2-7) and re-mea- sure the spring length. The belt tension is correct if this second measurementis 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 preventingthe cable adjuster from turning.

c. If the spring length is incorrect, you must adjustthe cabletension as described in Checkingand Adjusting Forward Drive

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Fig. 2-7: Tocheckforwardbelt tension, take two measurementsof the length of the coils in the spring--first with the bail open, then with the bail held against the handlebar.

Belt Tensionin 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 (cabletension too tight).

Wm

W

Fig.2-5: Cable	Fig. 2-6: Attach forward
springand	clutchcable spring to
adjuster.	forwardclutch bail.

STEP 5: INSTALL REVERSE CLUTCH

CABLE (MODEL 644A ONLY)

1.Unwrapthe reverseclutch 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 beneaththe Forward Clutch Bail.

2.Insertthe cable(CC,Fig. 2-8)through the slot inthe cablebracketandpositionthe flat side of the threadedassemblynextto the flat side of the hole. Slidethe hex nut (DD) up the cable andtighten it securely.

3.Fastenthe reverseclutch cable to the

left side handlebarwith acabletie (EE,Fig. 2-9).

4.Testthe function ofthe reverseclutch by pulling out and releasingthe cable knob. The knob should return to its neutral posi- tion (resting against bracket). If it doesn't,

contact your local dealeror Troy-Bilt LLC for technical assistance.

Flat Side

Fig. 2-8:/nsta//reverse cable bracketand reverse clutchcable.

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