Precor C842i Service Manual page 45

Procedure 7.13 - Replacing the Secondary Pulley,
1. Remove the left, right and top covers.
2. If only the secondary pulley is being replaced (the secondary pulley assembly contains the
clutch bearing), skip this step and continue with step 16. Loosen the idler pulley locknut and
release tension from the primary belt.
3. Loosen the secondary belt adjustment bolt and remove tension from the secondary belt.
4. Remove the retaining ring from the left side of the secondary pulley shaft.
5. Slide the large thrust washer off of the secondary pulley shaft. Slide the secondary pulley off
of the secondary pulley shaft. If only the secondary pulley is being replaced, skip to step 13.
6. Slide the remaining thrust washer off of the secondary pulley shaft and remove the second
retaining ring from the secondary pulley shaft.
7. Insert an allen wrench into the left end of the secondary pulley shaft and remove the
secondary axle with a 20030-119 secondary sheave tool and a 1/2 inch drive socket
wrench. See Diagram 7.9.
8. Remove the large retaining from the right hand side bearing pocket and slide the secondary
shaft out of the frame. There is now a loose wave washer still inside the frame bearing
pocket. Remove and retain the wave washer.
9. The left side bearing, secondary axle or secondary shaft assembly may now be replaced as
required.
10. Slide the wave washer, from step 8 onto the longer end of the secondary shaft. Slide the
longer end of the secondary shaft into the left side bearing. Replace the large retaining ring,
removed in step 21, into the right hand side bearing pocket.
11. Insert an allen wrench into the left end of the secondary pulley shaft, thread the secondary
axle onto the secondary axle and tighten with a 20030-119 secondary sheave tool and a
1/2 inch drive socket wrench.
12. Replace the inside retaining ring, removed in step 6, onto the secondary pulley shaft. Slide
one of the thrust washers onto the secondary pulley shaft.
13. Slide the replacement secondary pulley onto the secondary pulley shaft.
14. Slide the remaining thrust washer onto the secondary pulley shaft. Replace the outside
retaining ring, removed in step 14
Intermediate Pulley or Secondary Bearings
C842i, C846i Upright and Recumbent Cycle
Page 45