Troy-Bilt E666M-Pony Reverse Clutch Belt Removal and Replacement, Removing Reverse Clutch Belt

24Section 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.

pull down on the belt and roll it onto the large, forward-most groove of the trans- mission pulley (P, Figure 5-20).

7.Reinstall the belt cover.

8.Test for correct tension on the forward clutch belt (see Checking Forward Belt Tension).

REVERSE CLUTCH BELT REMOVAL AND REPLACEMENT

MN

R

J

L

Figure 5-22: Right-side view.

The reverse clutch belt (J, Figure 5-22) is driven by the engine drive pulley (I, Figure 5-20). When the Reverse Clutch Control knob is pulled out, it pulls the reverse idler arm and pulley (N) which tightens the belt against the engine drive pulley. This drives the transmission drive pulley (L), resulting in reverse motion.

Removing Reverse Clutch Belt

1.Stop engine, allow it to cool and dis- connect spark plug wire before working near belts. Also remove ignition key on electric start models.

2.Remove belt cover (Figure 5-13) by removing two flange locknuts.

3.Pull the reverse clutch belt downward and slip it off the transmission pulley (L, Figure 5-22).

4.Use two 1/2" wrenches to loosen and remove wire belt guide (R, Figure 5-22) from the reverse idler arm pulley. Do not remove locknut and screw.

5.Remove the reverse belt and pull it out through front of transmission housing.

Installing Reverse Clutch Belt

1.Stop engine, allow it to cool and dis- connect spark plug wire before working near belts. Also remove ignition key on electric start models.

IMPORTANT: The forward clutch belt must be installed before the reverse clutch belt.

2.Install the forward clutch belt (see Installing Forward Clutch Belt in this section) before installing reverse belt.

IMPORTANT: The reverse belt has a ‘V” shape. When installing the belt, make sure that the widest (flat) side of the belt rides against the reverse idler pulley (N, Figure 5-22) and transmission pulley (L). If needed, the belt can be twisted “inside out” so that the “V” shaped side is on the outside and the widest side is on the inside.

3.Insert the belt down into the front of the transmission housing. Slip the top half of the belt onto the reverse idler arm pulley (N).

4.Pull the belt downward and loop the bottom half of belt around the front groove of transmission pulley (L, Figure 5-22).

5.Mount the belt guide between the two flat washers and tighten snugly. The guide needs adjusting before fully tightening.

Figure 5-23: Reverse belt guide positioning.

6.(You will need an assistant to help with this step.) Pull the reverse idler pulley (N) up to its highest point and position the belt guide (R) horizontally level as shown in Figure 5-23. Securely tighten the screw and lock nut (M, Figure 5-22).

7.Pull back on the Reverse Clutch Control knob and make sure that the reverse clutch belt fully contacts the groove in the engine pulley. Release knob and make sure that the belt doesn’t engage the reverse engine pulley. This may cause the unit to move in reverse when the Wheel Gear Lever is engaged. Adjust the cable for less tension if this condition occurs. See Checking and Adjusting Reverse Belt Tension for more information.

8.Reinstall the belt cover and secure it with two flange locknuts.

9.Test the unit in an open location.