Namco Downhill Biker Operators Manual

							Page 63 8-5 Replacing the Pedals
1. Remove the pedals by using an allen key fitted to the inner end of the
pedal shaft, and turning the allen key, when pointing up, to the rear of the
bike. (i.e. the left hand pedal has a left hand thread.) When replacing the
pedals, ensure that the correct pedal is used. The pedals have L or R
stamped on them.
8-6 Replacing the Crank Arms
A two part tool is supplied to enable the fitting and removal of the crank arms.
Ensure that this tool is kept with the machine at all times.
1. Remove the push fit plastic end cap.
2. Screw end A of the special tool fully out.
3. Place end B of the special tool over the crank nut and using a spanner,
turn end B to remove the crank nut. 
						

							Page 64
4. Screw end A into the crank shaft  and using a spanner, screw end B
clockwise to remove the crank arm.
5. To refit the crank arm, place the crank arm onto the pedal shaft, enuring
that the correct crank arm is being fitted.
6. Fit the crank nut, and fully tighten using end B of the special tool.
7. Refit the plastic end cap. 
						

							Page 65
8-7 Adjusting the Belt
1. Remove both left and right crank arms complete with pedals. (See sectio\
n 8-6 page 35)
2. Remove 10off security screw (M5x16) and 4off security screw (M5x20), and remove both side vac-forms.
8-8 Adjusting the Chain 1. Remove the pedals and crank arms.  (see section 8-6 page 63)
2. Remove the side vac-forms. (see section 8-7 above) 
3. Loosen 4off flanged socket head screws (M6x14) and 2off nuts (M8) of the work load unit. ( Do not remove the screws or nuts).
4. Adjust the position of the work load unit so that the upper right edge o\
f the tensioner matches the marking on the work load unit. 
						

							Page 66
8-9 Replacing the Chain
1. Remove the pedals and crank arms.  (see section 8-6 page 63)
2 . Remove the side vac-forms.  (see section 8-7 page 65)
3. Disengage the chain by turning the chain wheel in the direction of arrow\
 2 while pulling the chain toward you (in the direction of arrow 1).
4. Engage the chain with the chain wheel of the work load unit and between the pedal chain wheel and sensor sprocket. Turn the pedal chain wheel 
clockwise until the chain is fully engaged.
5 . Adjust the tension of the chain.  (see Section 8-7 page 65)
6. Redit the side vac-forms and pedals.
5. Retighten the flanged socket head screws and nuts. 
6. Refit the side vac-forms and pedals. 
						

							Page 67
8-10 Replacing the Sensor PCB
1. Remove the pedals and crank arms.  (see section 8-6 page 63)
2 . Remove the side vac-forms.  (see section 8-7 page 65)
3. Remove 2off pozi head screw (M4x8) and remove the sensor PCB cover, and disconnect the connector.
4. Remove 2off pozi head screw (M4x8) and remove the sensor PCB.
8-11 Replacing the Sensor Assembly 1. Remove the pedals and crank arms.  (see section 8-6 page 63)
2 . Remove the side vac-forms.  (see section 8-7 page 65)
3. Disconnect the connector from the sensor PCB. 
4. Remove the 2off flanged socket head bolts (M6x16) and remove the Sensor Assembly. 
						

							Page 68 Refitting the Sensor Assy
1. Refit the sensor assembly and fit loosely with two 2off flanged socket
head bolts (M6x14).
2. Adjust the position of the sensor assembly so that the 10T sprocket of the
sensor assembly is in line with the chain and not moving the chain to one
side..
3. Tighten fully the 2off flanged socket head bolts (M6x14).
4. Refit the side vac-forms and pedals. 
						

							Page 69
8-12 Replacing the Saddle
1. Remove the pedals and crank arms.  (see section 8-6 page 63)
2 . Remove the side vac-forms.  (see section 8-7 page 65)
3. Remove the socket cap screw (M8x25) and remove the saddle and stem. 
4. Remove 2off socket cap screws (M8x35) and remove the saddle from the stem.
5. Replace the saddle and reassemble in reverse order. 
						

							Page 70
8-13 Replacing the Brake Switch
1. Remove 2off security screw (M5x16) and remove the handle cover vac-
form.
2. Remove 2off pozi head screws (M2x10) and remove the microswitch
sufficiently to remove the wires from the switch terminals.
3. Replace the microswitch.
4.  Reassemble in reverse order. 
						

							Page 71
10.PARTS
m e t Ino i t p i r c s e DoN t r a P
1mr o F - c a V r o t i n o M2 8 7 0 0 0 6 4
2la c e D e r t n e C r e p p U m r o F - c a V r o t i n o M1 2 1 0 0 0 0 4
3la c e D n o i t c u r t s n i y a l P9 2 1 0 0 0 0 4
4)S H R ( m r o F - c a V e d i S t e n i b a C r o t i n o M4 8 7 0 0 0 6 4
5le n a P h s e M r e k a e p S t e n i b a C r o t i n o M9 8 7 0 0 0 6 4
6la c e D e r t n e C r e w o L m r o F - c a V r o t i n o M4 2 1 0 0 0 0 4
7)t e S ( l a c e D r e b m u N t e n i b a C r o t i n o M5 2 1 0 0 0 0 4
8mm 5 7 r o t s a C l e v i w S9 7 0 0 0 3 8 8
959 x 6 1 M t o o F e l b a t s u j d A5 0 0 0 0 0 9 5
0 1st r o p p u S e d i S t e n i b a C r o t i n o M6 8 7 0 0 0 6 4
1 1t t a w 0 2  ½ 4 r e k a e p S d u o L6 0 0 0 0 0 2 6
n a C d l e i h S r e k a e p S d u o L4 0 0 0 0 0 2 6
2 1et o m e R o / w  o l o P   8 2 r o t i n o M x e r a t n a H6 2 0 0 0 0 4 8
3 1)S H L ( m r o F - c a V e d i S t e n i b a C r o t i n o M3 8 7 0 0 0 6 4
4 1)S H L ( l a c e D e d i S t e n i b a C r o t i n o M4 1 1 0 0 0 0 4
5 1)S H R ( l a c e D e d i S t e n i b a C r o t i n o M5 1 1 0 0 0 0 4
6 1)S H L ( l a c e D r e t s a M H D7 2 1 0 0 0 0 4
7 1)S H R ( l a c e D r e t s a M H D6 2 1 0 0 0 0 4 
						

							Page 72
m e t Ino i t p i r c s e DoN t r a P
1)S H L ( m r o F - c a V r e d a e H2 0 8 0 0 0 6 4
2)S H L ( t e S l a c e D m r o F - c a V r e d a e H1 4 1 0 0 0 0 4
3ci l y r c A r e d a e H0 0 0 0 0 0 0 3
4te k c a r B g n i r u c e S p o T c i l y r c A r e d a e H4 0 8 0 0 0 6 4
5et e l p m o c - g n i t t i F t n e c s e r o u l F  45 4 0 0 0 0 4 6
6eb u T t n e c s e r o u l F  49 3 0 0 0 5 4 6
7)S H R ( m r o F - c a V r e d a e H1 0 8 0 0 0 6 4
8)S H R ( t e S l a c e D m r o F - c a V r e d a e H0 4 1 0 0 0 0 4