Troy-Bilt 664D-Pony manual Maintenance, Ki J G H, Forward Clutch Belt Removal And Replacement

22Section 5: Maintenance

WARNING

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to come to a complete stop, disconnect spark plug wire and move wire away from spark plug. Remove the key from the keyswitch on units so equipped.

Failure to follow these instructions can result in serious personal injury or property damage.

CAUTION

Incorrect cable adjustment could cause the wheels and tines to rotate unexpect- edly. Follow adjustment procedures carefully. Failure to do so could result in personal injury or property damage.

Checking Forward Belt Tension

1.Before checking, shut off engine, allow the engine and muffler to cool down, dis- connect the spark plug wire, remove the ignition key on electric start models.

2.The coiled part of the forward clutch spring (E, Figure 5-10) measures 2" in length when the Forward Clutch Control levers are not pulled up. Pull either Forward Clutch Control Lever up against the handlebar and measure the length of the coil on the forward clutch spring. Tension is correct if the length of the extended coil is 2-1/2" (see Figure 5-11). The forward clutch control cable needs adjustment if the extended length of the coil is not 2-1/2". See Adjusting the Forward Clutch Belt for a procedure.

Adjusting the Forward Clutch Cable

Do this procedure if the forward clutch spring measurement is not correct (see Checking Forward Belt Tension).

1.Before adjusting the belt, shut off

engine, allow the engine and muffler to cool down, disconnect the spark plug wire, and remove the ignition key on elec- tric start models.

B

AMore Belt Tension.

Figure 5-12: Move forward clutch cable adjuster down for more belt tension.

2.Belt adjustments are done with the

forward clutch cable adjuster (F, Figure 5- 10). Use two 1/2", open-end wrenches to loosen the two jam nuts (A, Figure 5-12) a few turns.

3.Move cable adjuster (B, Figure 5-12) downward for more belt tension (see Figure 5-12).

4.Hand tighten the jam nuts and pull the Forward Clutch Control levers up against the handlebar. Measure the spring coil (Figure 5-11). The extended length of the coil should be 2-1/2". Repeat this proce- dure until the extended spring length is correct.

5.Tighten both jam nuts securely.

Checking and Adjusting Reverse Clutch Belt Tension

Checking Reverse Clutch Belt Tension

The reverse clutch belt (D, Figure 5-9) needs adjustment if the belt slips in reverse or if there is no reverse. See Adjusting Reverse Clutch Belt below.

Adjusting Reverse Clutch Belt

1.Before adjusting the belt, shut off

engine, allow the engine and muffler to cool down, disconnect the spark plug wire, and remove the ignition key on elec- tric start models.

C

Figure 5-13: Belt cover.

2.Remove the two nuts (C, Figure 5-13) and remove the belt cover.

3.Reverse belt tension adjustments are done with the reverse clutch cable adjuster located on the left side of the machine near the engine (D, Figure 5-14). Use two 1/2" open-end wrenches to loosen the two adjuster jam nuts (E) a few turns.

	E
D	F
	Move cable
	adjuster away
	from pulleys to
	increase reverse
	belt tension.

Figure 5-14: Reverse clutch cable adjuster. Left-side view with belt cover removed.

4.Move the cable adjuster (D, Figure

5-14) away from the pulleys to increase belt tension.

5.Tighten both jam nuts securely.

6.Reinstall the belt cover.

7.Move the unit to an open area and test the reverse operation. Repeat this proce- dure if the unit does not respond when the reverse clutch is engaged.

FORWARD CLUTCH BELT REMOVAL AND REPLACEMENT

The forward clutch belt (K, Figure 5-15) engages the engine pulley (I) and the transmission pulley (J) when either Forward Clutch Control Lever is pulled up against the handlebar. This tightens the forward clutch cable (G) which causes the forward clutch idler pulley (H) to apply pressure to the forward clutch belt. This causes the pulleys to turn for Forward movement.

KI

J

G

H

Figure 5-15: Forward clutch control assembly.