Troy-Bilt 645A-Bronco Install Forward Clutch Cable, Install Reverse Clutch Cable, R P A, Assembly

Section 2: Assembly

STEP 4: Install Forward Clutch Cable

1. Place the forward clutch cable bracket

(P, Fig. 2-4) on the handlebar support (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 locknut (S). Tighten securely.

2. Carefully unwrap the forward clutch

cable (the cable without a knob attached to

R

P A

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.

S

U

T

3.	Insert the #10-24 x 2" slotted hd. screw
(V, Fig. 2-5) down into the cable spring
(W). The threaded end of the screw will
extend from the bottom of the spring.
4.	Thread the #10-24 hex nut (Z) on the
slotted head screw (V). Thread it halfway up.
5.	Thread screw (V) into cable adjuster (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. See Fig. 2-7.
8.	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

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

Y

W

Fig. 2-5: Assemble
spring and adjuster.	W

V

Z

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).

STEP 5: Install Reverse Clutch Cable

1. Remove the two pre-installed self-tapping

screws (AA, Fig. 2-8) from the handlebars.

2. Position the reverse cable mounting

bracket (BB, Fig. 2-8) as shown and

reinstall the two self-tapping screws.

3. Unwrap the reverse clutch cable (the

X

X

Fig. 2-6: Install forward clutch cable.

5

4

3

2

1

Z

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.

Hold bail against handlebar while measuring spring

Fig. 2-7: Measure cable spring.

8