StarTrac Elliptical Edge, Service Manual

Page: 53 / 74

Transmission Bearings Replacement
NOTE: Support the
free end of the crank
belt to keep it from faI-
ling inside the frame.
NOTE: If needed,
back off the transmis-
sion idler tension nut to
allow proper adjust-
ment of the transmis-
sion idler pulley.
5.26
4. Using 3/32-in. Allen wrench, loosen the Allen screws in the transmission shaft pillow
blocks and gently slide the pillow blocks of the transmission shaft.
5. Using 3/32-in. Allen wrench, loosen the Allen screw or the transmission idler pUlley and
gently slide the transmission idler pulley of the transmission shaft. BE CAREFUL not to
lose the transmission idler pulley key.
Install the transmission assembly:
1. Install the transmission idler pulley key on the transmission shaft, then GENTLY slide the
transmission idler pulley onto the transmission shaft.
2. Using 3/32-in. Allen wrench, tighten the Allen screw on the transmission idler pulley firmly.
DO NOT OVERTIGHTEN THE ALLEN SCREW.
3. Install the two pillow blocks on the transmission shaft with the Allen screws facing out-
ward (toward the ends of the transmission shaft). MAKE SURE the Allen screws in the
pillow blocks align with the flats on the transmission shaft.
4. Using 3/32-in. Allen wrench, tighten the pillow block Allen screws firmly. DO NOT
OVERTIGHTEN THE ALLEN SCREWS.
5. Insert the transmission assembly through the crank belt and position the transmission
assembly in place on the frame. MAKE SURE the crank belt is properly positioned on the
transmission idler pulley.
6. Using 9/16-in. hex head socket wrench and 9/16-in. open-end wrench, secure the trans-
mission assembly to the frame with the four bolts and nuts. TIGHTEN THE NUTS
SECURELY.
7. GENTLY slide the alternator pUlley and key onto the transmission shaft.
8. Using 3/32-in. Allen wrench, tighten the two Allen screws on the alternator pulley. Pull the
alternator belt into place on the alternator pulley.
Re-tension the transmission pulley:
1. Using 9/16-in. open-end wrench, tighten the transmission idler tension bolt to increase
crank belt tension.
2. Using belt tensioner gauge to check crank belt tension, continue to tighten the transmis-
sion idler tension bolt to achieve 80 pounds tension.
• If a belt tensioner gauge is not available, check the crank belt tension by pressing
down hard on top of the belt, midway between the transmission idler pulley and the
crank pulley. The belt should deflect between 3/8-in.-1/2-in. (9.5-12.5 mm).
3. Once the correct crank belt tension is obtained, tighten the transmission idler tension nut
SECURELY using 1/2-in. open-end wrench.
Install the front shroud:
1. Install the front shroud in position on the unit.
2. Using Phillips head screwdriver, secure the front shroud to the unit with the eight Phillips
head screws.
Elliptical Edge Service Manual