Page 108
3.
As you tighten the crank arm puller on the shaft, the crank arm will pull off the crank arm
shaft. Remove the crank arm from the frame.
III.
Inspect the Bottom Bracket Assembly for Looseness.
1.
Loosen the lock ring on the left side of the bike using a
lock ring removal tool.
2.
Ensure that the right bearing cup is tight. If necessary,
tighten with the bottom bracket tool. Note: the right
bearing cup is reverse threaded!
3.
Check the left bearing cup. If the bearing cup is loose,
tighten with your fingers. Use the bottom bracket tool to
tighten the bearing cup – rotate the bottom bracket tool an
additional 10 degrees clockwise.
4.
Verify that the bottom bracket spindle is not loose by
tugging on the spindle shaft.
5.
Use the lock ring removal tool to tighten the lock ring.
Note: Prevent the left bearing cup from spinning by
stabilizing it with the bottom bracket removal tool.
IV.
Reassemble the bike.
1.
Apply a thin coat of grease on the left bottom bracket shaft and install the left crank arm on
the bottom bracket shaft. Note: use a rubber mallet to tap the arm onto the bottom bracket
spindle.
2.
Apply 1-2 drops of Locktite® 242 on the left crank arm bolt threads. Install the crank arm
bolt and tighten to secure the crank arm. Rotate the pedals a few revolutions and then tighten
the crank arm bolt again to ensure that the crank arm is tightened to 29.5 foot/lbs.
3.
Apply a thin coat of grease on the right bottom bracket shaft and install the right crank arm
on the bottom bracket shaft. Align the right crank arm 180° from the left crank arm and push
the crank arm on to the crank arm shaft.
4.
Apply 1-2 drops of Locktite 242 on the right crank arm bolt threads. Install the crank arm bolt
and tighten to secure the crank arm. Rotate the pedals a few revolutions and then tighten the
crank arm bolt again to ensure that the crank arm is tightened to 29.5 foot/lbs.
5.
Install the belt. Test the belt tension by standing on the pedals with the pedals horizontal to
the floor. Pedal quickly and see if the belt slips. A minimum of slipping is okay, it is impor-
tant not to overtighten the belt.
Note: If you have difficulty keeping the idler pulley aligned remove the tension adjustment screw
and idler pulley from the frame. Slide the idler pulley mounting screw all the way up in the frame.
Install the belt and reinstall the idler pulley nut. Tighten the tension adjustment screw. Tighten
the idler pulley nut. The idler pulley should be aligned with the belt.
6.
Reinstall the right side cover.
Note: Inspect the pedal crank arm bolts again after 30 hours (approx. one week).
If loose, remove the bolts; apply Loctite 242 and reinstall. Tighten the bolts to 29.5 foot/lbs.
Summary of Contents for FreeClimber
Page 12: ...Page 13 BISON TRANSMISSION DETAIL...
Page 15: ...Page 16 Figure 1 Final Assembly Left 4600 PT...
Page 16: ...Page 17 Figure 2 Final Assembly Right 4600 PT...
Page 17: ...Page 18 Figure 3 Final Assembly Left 4600 CL...
Page 18: ...Page 19 Figure 4 Final Assembly Right 4600 CL...
Page 19: ...Page 20 Figure 5 Covers 4600 PT CL...
Page 20: ...Page 21 Figure 6 Pedal Arm Assembly First Reduction Shaft Assembly 4600 4400 PT CL 4200 PT...
Page 21: ...Page 22 Figure 7 Drive Shaft Assembly Eccentric Hub Assembly 4600 4400 PT CL 4200 PT...
Page 22: ...Page 23 Figure 8 Final Assembly Left 4400 4200 PT...
Page 23: ...Page 24 Figure 9 Final Assembly Right 4400 4200 PT...
Page 24: ...Page 25 Figure10 Final Assembly Left 4400 CL...
Page 25: ...Page 26 Figure 11 Final Assembly Right 4400 CL...
Page 26: ...Page 27 Figure 12 Covers 4400 PT CL 4200 PT...
Page 27: ...Page 28...
Page 35: ...Page 36...
Page 38: ...Page 39...
Page 40: ...Page 41 Figure 13 Parts Needing Periodic Lubrication...
Page 41: ...Page 42 Figure 14 Side Cover and Handrail Assemblies...
Page 42: ...Page 43 Figure 15 Poly V Belt Tension...
Page 43: ...Page 44 Figure 16 Drive Chain Assembly...
Page 44: ...Page 45 Figure 17 Step Assembly...
Page 45: ...Page 46 Figure 18 Step Chain and Sprocket Assemblies...
Page 46: ...Page 47 Figure 19 Transmission and Alternator Assemblies...
Page 47: ...Page 48 Figure 20 Wiring Diagram 1...
Page 48: ...Page 49 Figure 21 Wiring Diagram 2...
Page 49: ...Page 50 Figure 22 Wiring Diagram 3...
Page 56: ...Page 57 ELECTRICAL DETAIL...
Page 57: ...Page 58 SAFETY VALVE...
Page 62: ...Page 63 Figure 23 Right Side View 1650 LE...
Page 63: ...Page 64 Figure 24 Left Side View 1650 LE...
Page 64: ...Page 65 Figure 25 Pedal Arm Assembly...
Page 65: ...Page 66 Figure 26 Right Side View 2650 UE...
Page 66: ...Page 67 Figure 27 Top View 2650 UE...
Page 67: ...Page 68 Figure 28 Weight Stack Assembly...
Page 73: ...Page 74 Figure 29 3300 CE Right Side View...
Page 74: ...Page 75 Figure 30 3300 CE Left Side View...
Page 75: ...Page 76 Figure 31 3900 RC Right Side View...
Page 76: ...Page 77 Figure 32 3900 RC Left Side View...
Page 77: ...Page 78 Figure 33 3300 CE Seat Adjustment Pin...
Page 78: ...Page 79 Figure 34 3900 RC Seat Assembly...
Page 79: ...Page 80 Figure 35 Drive Chain Assembly...
Page 80: ...Page 81 Figure 36 Intermediate Shaft Assembly...
Page 81: ...Page 82 Figure 37 J Bolt Assembly...
Page 82: ...Page 83 Figure 38 Crank Assembly...
Page 83: ...Page 84 Figure 39 Alternator Assembly...
Page 89: ...Page 90 Figure 40 Final Assembly Right Side View 3400 CE...
Page 90: ...Page 91 Figure 41 Final Assembly Left Side View 3800 RC...
Page 91: ...Page 92 Figure 42 Seat Post Assembly 3400 CE...
Page 92: ...Page 93 Figure 43 Seat Assembly 3800 RC...
Page 93: ...Page 94 Figure 44 Seat Track Assembly 3800 RC...
Page 94: ...Page 95 Figure 45 Intermediate Poly V Assembly...
Page 96: ...Page 97 Figure 47 Alternator Flywheel Assembly...
Page 97: ...Page 98 Figure 48 Wire Connections...
Page 98: ...Page 99 Figure 49 Power Control Board Plug Ins...
Page 101: ...Page 102...
Page 102: ...Page 103...
Page 103: ...Page 104...
Page 104: ...Page 105...
Page 105: ...Page 106...