StarTrac Elliptical Edge, Service Manual

Page: 57 / 74

Crank Bearings Replacement
NOTE:
the crank belt is prop-
erly positioned before
tightening the crank
pulley screws.
NOTE: Install ONL Y
skate rail at
a
time.
5.29
5. Using 5/64-in. Allen wrench, tighten the pillow block Allen screws just until snug against
the crank shaft. DO NOT OVERTIGHTEN THE SCREWS.
Install the crank assembly:
1. Insert the crank assembly through the crank belt and position the crank assembly in place
on the frame.
2. Using 9/16-in. hex head socket wrench and 9/16-in. open-end wrench, secure the crank
assembly to the frame with the four bolts, washers and nuts. TIGHTEN THE NUTS
SECURELY.
3. GENTLY slide the two crank arms onto the crank shaft, aligning the key slots in the crank
arm with the key slots in the crank shaft. Insert the two crank arm keys into the crank
shaft key slots.
4. Using a straight edge ruler, line up the crank belt with the transmission idler pulley by ad-
justing the position of the crank pulley on the crank shaft as needed.
5. Using 7/64-in. Allen wrench, tighten the two crank pulley Allen screws to 80 in.-Ibs.
6. Using 5/64-in. Allen wrench, tighten the two pillow block Allen screws to 34 in.-Ibs.
7. Using 3/16-in. Allen wrench, tighten the two crank arm Allen screws (securing the crank
arms to the crank shaft) to 80 in.-Ibs.
Re-tention 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 9/16-in. open-end wrench.
Install the skate rails on the crank arms:
1. Install one nylon washer on the crank arm shaft. CAREFULLY insert the crank arm shaft
through the skate rail, then install the remaining nylon washer on the crank arm shaft.
2. Insert the crank arm shaft through the crank arm.
3. Rotate the crank arm shaft, as needed, until the flats on the shaft are aligned with the
holes in the crank arm.
4. Using 5/32-in. Allen wrench, install the two Allen screws in the crank arm. TIGHTEN THE
SCREWS SECURELY.
Elliptical Edge Service Manual