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8 Section 2: Assembly
4. Thread the #10-24 hex nut (Z, Fig. 2-5)
halfway onto the screw (V).
5. Thread the screw (V) into the cable
adjuster (X).
6. Hook the cable spring (W, Fig. 2-6) into
the V-shaped bend in the Forward Clutch
Bail (Y).
7. Check for correct tension on the for-
ward drive belt by taking two measure-
ments of the cable spring, as follows:
a. With the Forward Clutch Bail (Y, Fig. 2-
6) in an open (released) position, mea-
sure the length of the cable spring (W)
from the outermost coil to the outer-
most coil.
b. Squeeze the Forward Clutch Bail against
the handlebar (see Fig. 2-7) and re-
measure the spring length. The belt
tension is correct if this second mea-
surement is between 1/16" to 3/16"
longer than the first measurement. If
so, turn the hex nut (Z, Fig. 2-7) tightly
against the cable adjuster (X) while pre-
venting the cable adjuster from turning.
c. If the spring length is incorrect, you
must adjust the cable tension as
described in Checking and Adjusting
Forward Drive Belt Tension in Section 5.
Incorrect cable tension can result in belt
slippage (cable tension too loose), or
unintentional tine movement when the
clutch bail is in Neutral (cable tension
too tight).
STEP 5: INSTALL REVERSE CLUTCH
CABLE (MODELS 634F AND 634B
ONLY)
1. Unwrap the reverse clutch cable (CC,
Fig. 2-8 and Fig. 2-9) from its shipping
position and route it up to the handlebar.
Be sure that the cable is routed beneath
the Forward Clutch Bail.
2. Using the two self-tapping screws (AA,
Fig. 2-8) secure the reverse cable
mounting bracket (BB)to the handlebars,
as shown.
3. Insert the cable (CC, Fig. 2-8) through
the slot in the cable bracket and position
the flat side of the threaded assembly next
to the flat side of the hole. Slide the hex
nut (DD) up the cable and tighten it
securely.
4. Fasten the reverse clutch cable to the
left side handlebar with a cable tie (EE,
Fig. 2-9).
5. Test the function of the reverse clutch
by pulling out and releasing the cable
knob. The knob should return to its neu-
tral position (resting against bracket). If it
doesn’t, contact your local dealer or the
factory for technical assistance.
W
Z
X
V
Fig. 2-6: Attach forward
clutch cable spring to
forward clutch bail.
Y
W
Fig. 2-5: Cable
spring and
adjuster.
Fig. 2-7: To check forward belt tension, take two measurements of the length of the coils in
the spring – first with the bail open, then with the bail held against the handlebar.
1
2
3
4
5
X
Z
Hold bail against handlebar while
taking second measurement of
spring
Fig. 2-8: Install reverse cable bracket and
reverse clutch cable.
CC
AA
AA
BB
Flat Side
DD
Fig. 2-9: Route reverse clutch cable (CC) as
shown. Attach with cable tie (EE).
BRONCO
CC
EE