Troy-Bilt 644HMBRONCO, 645AMBRONCO manual Install ReverseClutch Cable, Install Forward Clutch Cable

Section2: Assembly

STEP4: 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. 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.

2.Threadthe #10-24hex 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 ForwardClutch bail against the handlebar. SeeFig. 2-7.

5.Measurethe length of the cable spring betweenthe ends of the coils (Fig. 2-7). The length should beapproximately 1-7/8". If the length is correct, turn the #10-24hex nut (Z) down tightly againstthe cable adjuster (X) while holding the adjuster in place. SeeFigure 2-7. If the length is

incorrect, you must makean adjustment to the cable tension as described in

"Checking andAdjusting ForwardDrive BeltTension" in Section 5. When the

spring length is correct, tighten the hex nut

(Z) against the cable adjuster (X).

STEP5: Install ReverseClutch Cable

1.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). Besure that the cable goes beneaththe ForwardClutch Bail as it is

routed upto 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. Makesure that the flat side of the threaded assembly is aligned with the flat side of the mounting hole. Slide the large hex nut (DD) up the cable and tighten it securely.

Fig. 2-4: Installing forwardclutchcable bracket and cable.

Fig. 2-5: Assemble springand adjuster.

Fig. 2-6: Install forwardclutch cable.

Fig. 2-7: Measure cable spring.