Chain tension adjustment
Remember to check/adjust the tension as needed particularly when the chain is new. You will know that the chain needs to be adjusted by any of three different ways:
1) Shake the drive unit back & forth; if you hear the chain hitting the sides it is too loose
2) Hold the prop still while gently turning the pedals; should not have more than about an inch of play
3) Chain slips or derails unexpectedly
New drive units or chains should have the chain tensioned:
1. After 1 hour of use, again at 2-3 hours & checked after 6 hours of use
2. Chain should be checked at least 1 time per month after that for home use and a minimum of weekly in resort/commercial use.
3. This is also a good time to check drive shaft for tangled debris to avoid damage to O-Ring seal that keeps it water tight. Marine grade silicone sealant can be applied to keep water out as needed.
Chain tightening & stop bracket adjustment procedure:
Chain tension is accomplished by moving the **main crank shaft spindle up or down.
Step 1: Loosen BOTH sides of the ***spindle hub washers on **main crank shaft, using the large wrench that came with your parts to loosen them one complete turn. If you loosen it more than that you will begin to disassemble parts.
Step 2: Once both spindle hub washers are loosened the main crank shaft assembly will, with slight pressure, move up & down in slots in the sides of the *drive unit housing. To pull the main crank assembly up: tighten the two Phillips head screws in the top of *drive unit housing cap until tight being careful to not over tighten.
Step 3: Re-tighten both the spindle hub washers with the large wrench firmly.
Step 4: Check the vertical stop bracket & adjust the set screws as needed to keep the unit balanced vertically. To adjust this bracket, loosen the 4 bolts two or three turns; slide the bracket up or down as needed & re-tighten.
Loosen the ***spindle hub washers, loosen/remove the Phillips head screws on drive unit housing cover to disengage the chain tensioner & then remove the drive unit cover. You will be breaking the silicone seal to remove it while being careful to not damage the rubber gasket. Open the master link on the chain; both on the old chain & on the new chain to install it. To correctly install the chain, start with the drive unit (with prop facing towards yourself) just like it is on the boat. Drop the chain down to the lower gear & with the help of another person, slowly turn the propeller until the chain turns onto the gear. IMPORTANT: The chain on the right side of the gear should be closest to you for correct installation to propel forward. Your drive unit will propel in reverse if this is done incorrectly.
Once the chain is around the gear, turn drive unit upside down to allow chain to drop out of top as you slowly turn the propeller to advance it. Re-attach the master link & feed the chain to the upper sprocket by turning the pedals. Replace the drive unit cover/rubber gasket & apply marine grade silicone to seal the cover. Proceed to adjust the chain tension by slowly tightening the screws on the top of the drive unit cover. Then re-tighten the spindle hub washers. (see chain tension adjustment instructions above)
*DRIVE UNIT HOUSING: Exterior component that holds the drive unit components
**MAIN CRANK SHAFT: Spindle that pierces the drive unit housing to which the pedals attach.
***SPINDLE HUB WASHER: Black round discs about 2" in diameter with a flat side; mounted to each side of the drive housing through which the Main Crank Shaft protrudes. The drive bushings slip into the U shaped cutouts in the main yoke that hold the drive unit in place.
****VERTICAL STOP BRACKET: On the back side of the upper end of the drive unit housing
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