Troy-Bilt BRONCO 5 HP User Manual
Page 8
8
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
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.
3. Insert the #10-24 x 2" slotted hd. screw
(V, Fig. 2-5) down into the cable spring
(W). The screw threads will extend down
through the spring.
4. Thread the #10-24 hex nut (Z, Fig. 2-5)
on the screw (V). Thread the hex nut
about halfway up the screw.
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. 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 hex nut (Z,
Fig. 2-7) tightly against the cable adjuster
(X) while holding the adjuster in place. 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.
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.
Fig. 2-5: Assemble
spring and adjuster.
Z
V
X
W
Fig. 2-6: Install forward clutch cable.
Fig. 2-4: Installing forward clutch cable bracket and cable.
Fig. 2-7: Measure cable spring.
1
2
3
4
5
P
R
S
T
T
Y
W
X
Z
U
A
Hold bail against handlebar
while measuring spring