Brake Pad Replacement - RevMaster Classic
- 4-mm Allen key
- 5-mm Allen key
- 10-mm Wrench
- Phillips screwdriver
- Pocket knife
1. Remove the right side cover from the bike frame.
* Use a philips screwdriver to remove the two philips screws on the left side cover.
* Use a 4-mm allen key to remove the four mounting screws on the right side cover.
* Lift the right side cover over the right crank arm and remove it from the frame.
2. Remove the belt from the bike.
* Loosen the idler pulley nut with an adjustable wrench (approx. 1 turn) and use a 4-mm allen key to loosen the tension adjustment screw located on top of the idler pulley.
* Slide the idler pulley up in the frame and relieve tension on the belt.
* Remove the belt by rotating the pedals forward and pulling the belt towards you and off the crank pulley. Remove the belt from the flywheel pulley.
WARNING: WATCH YOUR FINGERS AS YOU REMOVE THE BELT FROM THE PULLEY SO THAT YOU DO NOT PINCH THEM BETWEEN THE PULLEY AND THE BELT.
3. Remove the flywheel from the bike so that you can replace the brake spring.
* Use a 5-mm allen key to remove the two mounting bolts that secure each of the pillow block bearings on either side of the flywheel to the frame. Keep the hardware to use during reinstallation.
* Twist the tension knob counterclockwise until the acorn nut meets the frame.
* Move the brake pad off to one side to allow room to lift the flywheel up off the frame.
* 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 the flywheel from the frame.
* Place the flywheel on a padded surface next to the new bike. Note: Lay the flywheel down on a padded surface. Any surface damage to the flywheel (nicks, dings, etc.) will effect performance.
4. Remove the brake spring steel and brake pad assembly from the frame
* Use a 5-mm allen key loosen and remove the 2 brake assembly mounting screws from the bike frame.
5. Remove the old brake spring steel from the brake pad assembly
* Use the 4-mm Allen wrench to remove the 4-mm screw on the front of the brake pad assembly.
* Reinstall the brake assembly with new brake spring on the bike frame using two new mounting screws from the accessory kit.
6. Replace the brake pad
* Place the brake pad assembly on a flat surface with the brake pad facing up.
* Note the location of the two different 4-mm mounting screws that hold the brake pad in place. The 4-mm socket cap screw goes in front and the longer, chamfered screw goes in back. Note also that the mounting hole in the brake pad material is closer to the edge in front, and further from the edge in back.
* Remove both mounting screws from the brake pad using the 4-mm allen wrench.
* Pull the old brake material (felt) off the brake pad housing. Next, pull the rubber padding material out from the brake pad housing. Use the pocketknife to clean out any large pieces of debris.
* Locate the new leather brake pad and orient it so that the adhesive backing aligns with the underside of the brake pad housing. Insert the 4-mm socket cap screw through the correct mounting hole in the new leather brake pad (the mounting hole in the brake pad material is closer to the edge in front, and further from the edge in back).
* Use the 4-mm allen wrench to align the screw into the mounting hole on the brake pad housing and partially thread the screw into the brake pad housing.
* Peel the back off the adhesive padding on the leather brake pad. Starting from the side that has the partially threaded screw, run your thumb over the leather pad and seat the brake pad in the brake pad housing. Ensure that there are no air pockets in the adhesive padding.
* Insert the other mounting screw through the leather pad and into the brake pad housing. Tighten both screws. The back screw is longer and will go through the brake pad housing so that the brake spring steel can attach to it.
7. Attach the new brake spring steel to the brake pad assembly
* Turn the brake pad assembly over.
* The new brake spring steel has two mounting holes on one end, and one mounting hole and a mounting slot next to an adhesive pad on the other end. The end that has the mounting slot mounts to the frame and the other end mounts to the brake pad assembly.
* Position brake spring steel with the adhesive pad facing up. Orient the end with the two mounting holes over the brake pad assembly. Align the hole that is furthest in over the threaded post of the mounting screw that attaches the leather brake pad to the brake pad housing. Thread the 10-mm mounting nut on the post.
* Insert the 4-mm mounting screw into the forward hole on the brake pad assembly and secure.
8. Attach the brake spring steel and brake pad assembly to the frame
* Secure the brake spring steel to the frame using two 5-mm mounting screws. Ensure that the adhesive pad is between the frame and the brake spring steel.
9. Position the flywheel back in place on the bike frame.
* Lift the flywheel up and position it on the frame with the shiny side of the pillow blocks facing up. Secure the flywheel to the bike using four pillow block mounting bolts. Tighten the bolts in a cross-pattern sequence.
10. Reinstall the belt.
* Reinstall the belt around the front pulley, under the idler pulley, and around the rear pulley of the bike. Tension the belt by tightening the idler tension screw on top of the idler pulley. Tighten the idler pulley nut.
WARNING: WATCH YOUR FINGERS AS YOU INSTALL THE BELT ON THE PULLEYS SO THAT YOU DO NOT PINCH THEM BETWEEN THE PULLEY AND THE BELT.
11. Test the belt tension.
* Stand on the pedals with the pedals horizontal to the floor. Pedal quickly and see if the belt slips. A minimum of slipping is okay, it is important not to over-tighten the belt.
12. Reinstall the right side cover on the bike with the new screws.
* Install 4 cover screws on the right side cover.
* Install 2 cover screws on the left side cover.
13. Test the bike.
* Ride the new bike to test and make sure that no abnormal noise is heard and that the bike functions properly. While the flywheel is in motion, push down on the brake and verify that the flywheel stops correctly.