Star Trac CrossTrainer User manual

CrossTrainer Service Manual
27 CrossTrainer Service Manual Rev A 620-7575
Part Installation Procedure – Upper Crank Arm
Parts Needed:
•Crank Arm (721-0109) Note: They are ordered individually and you may need two.
Tools Needed:
•3/16 (Allen) Hex Key •5/16 (Allen) Hex Key
•Torque Wrench (foot pounds)
w/5/16 (Allen) Hex Driver •¾ inch Cold Chisel
•Large Flat-Head Screwdriver •Short Punch
•1/8 (Allen) Hex Key
Procedure
Remove the Upper Crank Arm
1. Using a 1/8 (Allen) hex key, loosen both of the sets screws on the pedal shaft, under the pedal
pad.
2. Using the short punch (or socket), gently tap the shaft into the pedal base until it is clear of the
collar on the outside.
3. Remove the plastic cap from the end of the leg beam bearing housing.

CrossTrainer Service Manual
28 CrossTrainer Service Manual Rev A 620-7575
Part Installation Procedure – Upper Crank Arm (cont.)
4. With one hand cupped over the e-clip, use a flat-head screwdriver to pop the e-clip off the
upper crank pin. Be careful not to lose the e-clip.
5. Carefully slide the leg beam off of the upper crank pin. You may want to use your foot to
support the lower end of the leg beam as you pull. Remove the shims and wavy washers from
the crank pin and set them aside for re-use.
6. Remove the plastic cap and retaining ring from the center of the upper crank arm. Completely
remove both of the pinch bolts using a 5/16 (Allen) hex key.
7. Insert a ¾ inch cold chisel or a large flat-head screwdriver in the slot in the end of the upper
crank arm and tap with a hammer to slightly spread open the end of the crank arm. The crank
arm should easily slide off the main shaft assembly.

CrossTrainer Service Manual
29 CrossTrainer Service Manual Rev A 620-7575
Part Installation Procedure – Upper Crank Arm (cont.)
Install the New Upper Crank Arm
1. Insert a ¾ inch cold chisel or a large flat-head screwdriver in the slot in the end of the new
upper crank arm and tap with a hammer to slightly spread open the end of the crank arm. The
crank arm should easily slide on the main shaft assembly.
2. Insert and tighten the two pinch bolts to 60 ft-lbs with torque wrench and 5/16 hex driver.
3. Replace the retaining ring and plastic cap.
4. Slide the shim and wavy washer onto the upper crank pin. Then slide the leg beam bearing
housing on the upper crank pin.
5. Replace the e-clip and plastic cap.
6. Tap the pedal pin back into position in the pedal base. Be sure to align the flat on the shaft to
the set screws.
7. Tighten the set screws.
8. Test for functionality.