Section 2: Assembly

STEP 4: Install Forward Clutch Cable

1. Carefully unwrap the forward clutch

cable (the cable without a knob attached to

it) from its shipping position and slide the

thin cable wire (T, Fig. 2-4) into the slot in

the cable bracket. Push the cable connector

(U, Fig. 2-4) up through the hole in the

bracket until the groove in the connector

snaps into place on the bracket.

2. Thread the #10-24 hex nut (Z) halfway

onto the screw (V) which runs through the

spring (W, Fig. 2-5).

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

4. Lift and hold the Forward Clutch bail

against the handlebar. See Fig. 2-7.

5. Measure the length of the cable spring

between the ends of the coils (Fig. 2-7).

The length should be approximately 1-7/8".

If the length is correct, turn the #10-24 hex

nut (Z) down tightly against the cable

adjuster (X) while holding the adjuster in

place. See Figure 2-7. If the length is

incorrect, you must make an adjustment to

the cable tension as described in

“Checking and Adjusting Forward Drive

Belt Tension” in Section 5. When the

spring length is correct, tighten the hex nut

(Z) against the cable adjuster (X).

T

U

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

Y

W

Fig. 2-5: Assemble

 

spring and adjuster.

W

 

V

Z

STEP 5: Install Reverse Clutch Cable

1. Unwrap the reverse clutch cable (the

cable with a knob and a large hex nut

attached to it) from around its shipping

position and route the cable (CC, Fig. 2-8

and Fig. 2-9) up to the cable bracket (BB,

Fig. 2-8). Be sure that the cable goes

beneath the Forward Clutch Bail as it is

routed up to the cable bracket.

2. Insert the cable up through the slot in

the cable bracket and position the threaded

assembly as shown in Fig. 2-8. Make sure

that the flat side of the threaded assembly

is aligned with the flat side of the mounting

X

X

Fig. 2-6: Install forward clutch cable.

5

4

3

2

1

Z

hole. Slide the large hex nut (DD) up the

cable and tighten it securely.

Hold bail against handlebar while measuring spring

Fig. 2-7: Measure cable spring.

8

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Troy-Bilt 644H-Bronco, 645A-Bronco manual Install Reverse Clutch Cable, Install Forward Clutch Cable