Helio Electric Cycle Owner's Manual page 34

Replacing the drive belt
The drive belt (secondary belt) on your Helio Cycle is extremely long wearing and is
designed to last for many years. However, if one is damaged, it may need to be
replaced. Replacement of the belt is relatively simple, however, if you are unsure of
your ability to correctly follow the procedure or you simply do not want to do it
yourself, your local eGO Vehicles service center or bicycle shop can help. Contact us
for the authorized service center nearest you.
To replace the drive belt yourself, here's what you'll need: a new drive belt, a 15 mm
spanner, 10mm spanner, and a block of wood (or other support) to support your Helio
Cycle while the rear wheel is off the ground.
To replace the drive belt:
1. Place block of wood under the rear of the chassis so that the rear wheel is
slightly off the ground.
2. Loosen the rear quick-release brakes in three steps:
• Grip the brake calipers with your hands, squeeze the brake pads against
the rim, and hold them there. This will slacken the brake cable.
• Pull the L-shaped cable tube (the thing that looks like an aluminum noodle)
out of its slot in the retaining bracket.
• Release the calipers. They should spring away from the rim leaving at least
a ½ inch (1cm) gap between the rim and the pads.
3. Loosen the two rear axle retaining nuts.
4. Turn the belt-tension adjuster nuts counterclockwise until the rear wheel can
be pushed forward about ¼ inch (0.5cm).
5. Push the rear wheel forward as far as it will go. This will loosen the old belt
enough to slide it off the rear wheel pulley.
6. Slip the belt off the rear-wheel pulley.
7. Slide the rear wheel out of the chassis.
8. Fit the new belt around the small drive pulley (just forward of the rear fender
inside the chassis).
9. Reinstall the rear wheel and fit the belt loosely around the rear wheel pulley.
(Washer placement: On the right side of the axle, the washer is between the
wheel pulley and chassis. On the left side of the axle, the washer is between
the tension adjuster and the axle nut.
10. Reinstall the belt tension adjusters. Make sure they are properly oriented and
aligned with the chassis dropouts.
11. Tension the belt by turning the belt-tension adjuster nuts clockwise with the 10
mm spanner. Refer to the section on adjusting belt tension on page 48 for the
proper procedure. The belt is properly tensioned if you can push the belt
inward about ¼ inches with your thumb.
12. Make sure the wheel is properly aligned with the chassis by rotating it
manually a few turns. If the belt rides in the center of the rear wheel pulley, it is
correctly aligned.
13. Retighten the rear-wheel axle retaining nuts.
14. Re-engage the quick-release brakes.
Page 34
Owners manual