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4. Check for correct tension on the forward
drive belt by taking two measurements of
the cable spring, as follows:
a. With the Forward Clutch Bail (Y, Fig. 2-
6) in an open (released) position, measure
the length of the cable spring (W) from the
outermost coil to the outermost coil.
b. Squeeze the Forward Clutch Bail against
the handlebar (see Fig. 2-7) and re-mea-
sure the spring length. The belt tension is
correct if this second measurement is be-
tween 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 preventing 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 Neu-
tral (cable tension too tight).
STEP 5: INSTALL REVERSE CLUTCH
CABLE (MODEL 644A ONLY)
1. Unwrap the reverse clutch cable (CC,
Fig. 2-8 and Fig. 2-9) from its shipping po-
sition and route it up to the handlebar. Be
sure that the cable is routed beneath the
Forward Clutch Bail.
2. 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.
3. Fasten the reverse clutch cable to the
left side handlebar with a cable tie (EE, Fig.
2-9).
4. Test the function of the reverse clutch by
pulling out and releasing the cable knob.
The knob should return to its neutral posi-
tion (resting against bracket). If it doesn’t,
contact your local dealer or Troy-Bilt LLC
for technical assistance.
W
V
Z
X
Fig. 2-6: Attach forward
clutch cable spring to
forward clutch bail.
Fig. 2-5: Cable
spring and
adjuster.
1
2
3
4
5
6
Hold bail against handlebar while
taking second measurement of spring
Z
X
Fig. 2-8: Install reverse cable bracket and
reverse clutch cable.
Fig. 2-9: Route reverse clutch cable (CC) as
shown. Attach with cable tie (EE).
BRONCO
CC
EE
Y
W
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.
BB
DD
CC
Flat Side