Overview

Step by step guide to replacing the flywheel belt tensioner on the SB20 StagesBike.

Time required: 20 minutes

Tools required

3 mm hex key
6 mm hex key
7 mm wrench or socket
14 mm open end wrench

Replacement parts required

000-3512 - ASSY, BELT ADJUSTER

Replacement instructions

Unplug bike - Remove the power connector from the bike behind the rear leg before starting the repair.

Remove the front plastic caps from the flywheel of the bike

Note: For the purposes of this article the side’s of the bike will be referred to as the Drive Side (side with belt) and Non-Drive Side to avoid confusion between rider’s right/left (sitting on the bike) and technician right/left (facing the bike).

Removal of the Drive Side belt guard cap is required, as is removal of the front and rear flywheel caps on the Non-Drive Side.

Use the 3 mm hex key to loosen 2 screws and remove the front drive side belt guard cap; set aside for reassembly later.

Slide the cap forward and rotate the cap away from the bike to remove it from 2 shoulder bolts holding the cap in place. You may need to push on the cap to get the upper shoulder bolt to clear the cap.

Repeat this procedure to remove the two flywheel caps on the non-drive side of the bike.

Using a 6 mm hex key, loosen the cap head set screw above the bracket on the non-drive side of the flywheel, about 1 turn.

Remove the Flywheel Tensioners from the axle

With a 14 mm box end wrench, remove the non-drive side and drive side axle nuts:

With a 7 mm socket or wrench - loosen the nut on the end of the belt tensioner adequately to allow the end of the tensioner to clear the nose of the dropouts. Remove the tensioner from the axle and set aside. Repeat for both sides.

Install the new Tensioner(s) and adjust belt tension

Install the new tensioner(s) on to the axle followed by the axle nut(s). Leave the axle nut(s) loose against the tensioner to hold it in place until final adjustment is made. Tighten the 7 mm nuts evenly until the tensioner makes contact with the end of the drop out. Repeat for both sides.
Once installed, adjust the 7 mm nuts on the drive side belt tensioner until there is about ¼” of play in the belt. You can check the tension with your finger by pushing on the belt just behind the pulley.

Adjust the 7 mm nut on the non-drive side tensioner so that the flywheel sits square in the dropouts. If you gently rotate the flywheel counter clock wise, you can view how the belt tracks.
Tighten the 14 mm axle bolts until snug.

Torque axle bolts to to 22 ft·lbs or 30 N·m.

Use a 6 mm hex key to tighten the cap head set screw above the bracket on the left side of the flywheel. The bolt should not be too tight, but ensure there is no gap.