Troy-Bilt 644H manual Install ReverseClutch Cable, Install Forward Clutch Cable, Assembly

Section 2: Assembly

STEP4: Install Forward Clutch Cable

1.Placethe forward clutch cable bracket (P, Fig. 2-4) on the handlebarsupport (A). Attach the cable bracket using a 1/4"-20 x 1-1/4" hex hd. screw (R, Fig. 2-4) and 1/4"-20 hex Iocknut (S). Tighten securely.

2.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. Pushthe cableconnector (U, Fig. 2-4) up through the hole in the bracket until the groove in the connector snaps into place on the bracket.

8.Insert the #10-24 x 2" slotted hd. screw

(V, Fig. 2-5) down into the cable spring

(W). Thethreaded end of the screw will extend from the bottom of the spring.

4.Threadthe #10-24 hex nut (Z) on the slotted headscrew (V). Threadit halfway up.

5.Threadscrew (V) into cableadjuster (X).

6.Hook cable spring (W, Fig. 2-6) into "V'- shaped bend in the forward clutch bail (Y).

7.Lift and hold the Forward Clutch bail against the handlebar. SeeFig. 2-7.

8.Measurethe length of the cable spring betweenthe 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 againstthe cable adjuster (X) while holding the adjuster in place. See Figure2-7. If the length is incorrect, you must makean adjustment to the cabletension as described in

"Checking andAdjusting ForwardDrive Belt Tension" in Section 5. When the

spring length is correct, tighten the hex nut

(Z) against the cable adjuster (X).

R

Fig, 2-4: Installing forwardclutchcable bracketand cable.

W--Fig,2-5: Assemble

springandadjuster,

V----Z

X--

Fig, 2-6: Installforwardclutchcable,

STEP5: Install ReverseClutch

Cable

1.Removethe two pre-installedself-tapping screws (AA, Fig. 2-8) from the handlebars.

2.Positionthe reversecable mounting bracket (BB, Fig. 2-8) as shown and reinstall the two self-tapping screws.

8.Unwrapthe reverseclutch 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
beneaththe Forward Clutch Bailas it is	Fig.2-7: Measurecablespring.
routed upto the cable bracket.

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