PRO1030 Bi-Directional Assembly Replacement 1. Remove both side covers using the Crank and Cover Removal procedure. Fig. 1 2. Disconnect both brake cables (not shown) from the brake (S3611). (Fig. 1) 3. Check the tension on the belt (P2484). Later when tightening the new belt you will want to try to tension it the same tension. (Fig. 1) 4. Using a ½ socket or wrench, loosen the two (2) brake mounting bracket bolts. (Fig. 1) 5. Using a ½ socket or wrench, remove the nuts and washers on the brake mounting bracket studs. (Fig. 1) 6. With one hand on front of brake mounting bracket (A2990), lift up to loosen the belt. Remove belt from brake pulley. (Fig. 1) 7. Remove the two (2) bracket bolts while supporting the front of the brake with one hand. Let down slowly. Make sure the brake mounting bracket does not damage any cables. (Fig. 1) 1
Fig. 2 8. Remove brake mounting bracket with the brake from inside the monocoque and cover support (B2986 shown in Fig. 1). (Fig. 2) Fig. 3 9. Using a ½ wrench or socket, loosen the idler mounting bolts from the idler mounting slots. (Fig. 3) 2
10. Using a ½ socket, remove the bolts and washers from the bearing housings (A1660) mounting the bi-directional assembly (A3589)). (Fig. 3) 11. Carefully remove the bi-directional assembly with the bearing housings from the monocoque by unhooking the chains and sliding the assembly out the opposite direction of the black pulley (P1097). (Fig. 3) 12. Install the new bi-directional assembly in place. Thread it through the chains. (Fig. 3) Fig. 4 13. Mount the bearing housings on the bi-directional assembly but do not tighten the bolts. (Fig. 4) 14. Pull the bearing housings away the monocoque as far as they can go. The bolts should be resting up against the slots closest to the fat side. (Fig. 4) 15. Tighten bolts. 16. Insert the 5/16 x 18 bolts through the lock washers and flat washers. Thread each bolt with washers into the ends of the bi-directional shaft (A3544) and tighten. (Fig. 3) 17. Verify chain routing. (Fig. 3) 18. Tension long chain and tighten the idler mounting bolts. (Fig. 3) 19. Rotate the cranks so the long chain sets in place. 3
Fig. 5 20. Make sure the long chain tension (A3455) is correct. To check the long chain tension, grab the long chain halfway between the bi-directional assembly (A3589) and the idler assembly (A3447). The long chain should have a total travel distance of ½. If tension is incorrect, loosen idler mounting bolts and reset idler assembly until the long chain tension is correct. (Fig. 5) 21. Install the brake and brake mounting bracket in place inside the monocoque and cover support. Make sure the two (2) brake mounting brake studs are in the brake mounting bracket slots on the monocoque. (Fig. 1) 22. Secure the brake mounting bracket in place by putting the two (2) brake mounting bracket bolts, but do not tighten. (Fig. 1). 23. Start belt on the jackshaft pulley (P1097) and the brake pulley. Rotate brake until the belt is completely on the brake pulley. (Fig. 1) Fig. 6 24. Using a 10" adjustable wrench on the left side of the brake mounting bracket, pull down on the left side of the brake mounting bracket to the tension the belt. (Fig. 6) 4
25. Tighten the brake mounting bracket bolt and the nut on the brake mounting bracket stud. (Fig. 1) 26. Place the adjustable wrench on right side on the brake mounting bracket and pull down on the right side of the brake mounting bracket to the tension the belt. (Fig. 6) 27. Tighten the brake mounting bracket bolt and the nut on the brake mounting bracket stud. (Fig. 1) 28. Rotate the brake a few revolutions to let the belt seat. 29. Check the belt tension. Try to adjust to the same tension as the belt was at the beginning of this procedure. Do not over tighten. If the belt is too tight, loosen the bolts and nuts and repeat steps 24 through 29. 30. Connect both brake cables. 31. Rotate crank or pedal to make sure everything is aligned and there is smooth operation before proceeding. 32. Rotate crank or pedal to where the display will come on. Press START on the keypad, increase resistance by pressing the UP arrow so the unit will have high resistance. 33. Replace side covers and do a complete operations test. Testing it in the ISO STRENGTH mode or at the highest resistance is recommended. 5