Belt and Flywheel Replacement
About
This procedure provides instruction to remove and install the Belt and flywheel.
The Poly V drive belt is the latest generation of drive systems for spinner bikes. The flywheel axle and front pulley are mounted in a fixed position providing front-rear belt pulley alignment. Also, after the belt tension is set, the belt tensioner mechanism is designed to not require adjustment and will not allow belt slip.
Belt replacement requires removal of the flywheel so this procedure provides instructions to remove/install both the belt and flywheel.
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WARNING: Personal injury is possible while removing/installing the flywheel. The flywheel weighs approximately 43 lbs (19.5 kgs) and can pinch or fall onto fingers or other extremities causing personal injury. |
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Specifications
| System Component | Specification |
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| Belt Drive Tension | 140 - 150 lbs |
| Axle Nut TorqueTorque is a measure of the force that can cause an object to rotate about an axis. Bolt/nut example: 5 nM torque is equivalent to 5 newtons of force applied one meter from the center of the bolt, 6 ft-lb is equivalent to 6 lb of force applied 1 foot away from the center of the bolt. | 29.5 ft-lbs (40 Nm) |
Available Movies
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Belt Drive Replacement |
Procedure
Review entire procedure before starting.
Removal instructions
- Remove front and rear belt guard covers, see Belt/Chain Guard Cover Replacement.
- Remove all brake pad resistance by turning resistance knob counterclockwise (-).
- Release belt tension by loosening the belt tension adjustment nut
using a 13 mm wrench. Release as much tension as possible without removing the nut off the tension bolt. - Remove the rear belt pulley finger guard
by removing the fasteners (2x) using a 5 mm hex key. Retain part(s) and/or fastener(s) for installation.
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CAUTION: It is important to release belt tension prior to removing the frame cross member. |
- Remove the frame cross member
by removing fasteners (4x) using 6 mm hex key. Firmly grasp the cross member while removing. The belt tensioner is mounted onto the cross member and may have a small amount of belt tension applied.
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NOTE: Make sure to note how the belt is installed onto the tension mechanism pulleys for installation. |
- Loosen, but do not remove, the left and right axle nuts
using a 19 mm wrench.
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NOTE: Make sure there is no brake pad resistance against the flywheel. |
- Remove the left and right axle mounting plate fasteners
(2x each) using a 6 mm hex key. Retain part(s) and/or fastener(s) for installation. - Carefully slide the flywheel off the frame and remove the belt.
- Install the belt over the front flywheel pulley and rear pulley.
- Use two service techs to carefully install the flywheel by inserting the axle mounting plates into the frame axle mounting slots.
Installation Instructions.
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TIP: You may find it easier to stand the bike frame on its front (resting on the front stabilizer and handlebar) and then installing the flywheel into the axle mounting slots. The weight of the flywheel will help to slide the flywheel into the mounting slots. Secure axle plate with mounting plate bolts and carefully return bike to the upright position. |
- Position the flywheel to align the left and right axle mounting plate holes to the frame mounting threads. Secure axle mounting plate with fasteners (2x each) using a 6 mm hex key.
- Tighten the left and right axle bolts , torque to 29.5 ft-lbs (40 Nm).
- Reinstall the frame cross member onto frame, make sure the drive belt is correctly installed onto the tension mechanism pulleys. Secure with fasteners (4x) using 6 mm hex key.
- Reinstall the rear belt pulley finger guard , secure with the fasteners (2x) using a 5 mm hex key.
- Tension belt to specification, go to Belt Drive Tension Adjustment.
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NOTE: Make sure the frame cross member is installed before tensioning belt. |
- Verify that the brake pad is centered on the flywheel and operating correctly.
- Replace front and rear belt guard covers, see Belt/Chain Guard Cover Replacement
- Verify the bike operation per Operation Verification Checklist and return to service.
See Also