Troy-Bilt PONY 664DM - Manual (Page 22)

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A WARNING
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Before inspecting, cieaning or servicing the machine, shut off engine, wait for aii moving parts to
come to a compiete stop, disconnect spark piug wire and move wire away from spark piug.
Remove the key from the keyswitch on units so equipped.
Faiiure to toiiow these instructions can resuit in serious personai injury or property damage.
A 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 muffier to cooi down, dis­
connect the spark piug wire, remove the
ignition key on electric start modeis.
2. The coiied part of the forward ciutch
spring (E, Figure 5-10) measures 2" in
iength when the Forward Ciutch Controi
ievers are not puiied up. Puil either
Forward Ciutch Controi 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 coll is 2-1/2" (see Figure 5-11).
The forward ciutch controi cable needs
adjustment if the extended iength of the
coii is not 2-1/2". See Adjusting the
Forward Clutch Beltior 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.
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 handiebar. Measure the spring coii
(Figure 5-11). The extended iength of the
coil should be 2-1/2". Repeat this proce­
dure until the extended spring iength is
correct.
5. Tighten both jam nuts secureiy.
Checking and Adjusting Reverse
Ciutch Beit Tension
Checking Reverse Clutch Belt Tension
The reverse ciutch beit (D, Figure 5-9)
needs adjustment if the beit siips in
reverse or if there is no reverse. See
Adjusting Reverse Clutch Belt beiow.
Adjusting Reverse Clutch Belt
1. Before adjusting the belt, shut off
engine, aiiow the engine and muffier to
cooi down, disconnect the spark piug
wire, and remove the ignition key on eiec-
tric start modeis.
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
beit 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 ciutch beit (K, Figure 5-15)
engages the engine puliey (I) and the
transmission puliey (J) when either
Forward Clutch Control Lever is puiied up
against the handiebar. This tightens the
forward ciutch 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.
adjuster down for more belt tension.
2. Belt adjustments are done with the
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 ciutch 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.
Figure 5-15: Forward clutch control
assembly.