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3.
Remove the flywheel from the bike.
•
Use a 5-mm Allen key to remove the two pillow block screws that secure each of the pillow
block bearing on either side of the flywheel to the frame. Keep the hardware to use during
installation.
•
Place a towel on the frame in between the forks and under the flywheel to prevent damage when
removing the flywheel from the frame. Have an assistant help you lift the flywheel up and
remove it from the frame.
•
Place the flywheel on a padded surface next to the bike.
Note: Lay the flywheel down on a padded
surface. Any surface damage to the flywheel (i.e. nicks, dings, etc.) will affect its future performance.
*Note: if you are installing a new Flywheel Assembly, please proceed to step #6.
4.
Remove the Flywheel Shaft Assembly.
•
Pull the left pillow block and bearing off of the
flywheel shaft using the Flywheel Pulley Puller.
•
Flip the flywheel over and use a 4-mm Allen key to
remove the front pulley mounting screw and
washer.
•
Remove the front pulley from the flywheel using
the Flywheel Pulley Puller.
•
Remove the right pillow block w/bearing and the
flywheel spacer from the Flywheel Spline Shaft.
•
Use a 4-mm Allen key to remove the three flywheel
shaft mounting screws.
•
Remove the Flywheel Spline Shaft from the
flywheel.
5.
Install a new flywheel shaft assembly into the
flywheel.
•
Insert a new flywheel spline shaft into the center of
the flywheel & line up the holes.
•
Apply 1-2 drops of Loc-Tite
®
242 on the flywheel
spline shaft screw threads. Install the screws and
tighten to secure the spline shaft. Use a torque
wrench to tighten the spline shaft screws to 13-14.5
Newton-meters (about 120-130 in-lbs). Failure to
tighten properly may allow the screws to become
loose. Let the Loc-Tite
®
set for about 20 minutes.
•
Re-install the right pillow block with a new bearing.
NOTE: in order to assure that your pillow block
bearings are not damaged during re-installation, use a ¾ inch ratchet wrench socket placed on the center
ring of the bearing to apply force during installation (see picture).
•
Re-install the flywheel spacer so that it rests in between the flywheel pillow block and the
flywheel pulley.
•
Re-install the flywheel pulley onto the right side of the flywheel spline shaft. Make sure to
position the Flywheel Spacer in between the right side pillow block and flywheel pulley.
•
Re-install the front pulley mounting screw and washer.
•
Re-install the left pillow block with a new bearing.
NOTE: in order to assure that your pillow block
bearings are not damaged during re-installation, use a ¾” ratchet wrench socket placed on the center
ring of the bearing to apply force during installation (see picture).