How to Remove and Replace a Bottom Bracket and Spindle on a LeMond RevMaster - Part 1

This Part 1 video will demonstrate how to inspect, adjust or remove the bottom bracket and spindle on your Lemond Revmaster indoor cycle.

Tools Required

• 8mm Allen Wrench or Socket
• Cotterless Crank Puller Tool
• Lock Ring Removal Tool
• Bottom Bracket Tool
• Phillips Screwdriver
• 4mm Allen Wrench
• Bungee (optional)
• Rubber Mallet
• 7/8" Wrench

Procedure:

1. To begin remove the belt cover; there are four screws.
   1. You will need a 4MM Allen wrench.
2. Now remove the two screws on the back from the opposite side of the bike.
   1. You will need a Phillips screwdriver.
3. Now position the crank arm as seen in the video and remove the belt cover from the bike.
4. Before removing the drive belt, tighten the brake assembly so that the flywheel is locked in place and loosen the torque on both bolts using an 8mm Allen wrench or socket.
   1. Do not remove them at this time only loosen them by half a turn or so.
5. Using a 7/8" wrench loosen the belt idler.
6. Now use a 4mm Allen wrench to loosen the tension adjustment bolt completely, but do not remove it from the frame.
7. Now remove the drive belt.
   1. To aid in this process you can use a bungee to slide in behind the belt at the top, as shown in the video.
   2. Then pull away from the bike while spinning the crank arms.
8. Now remove both crank bolts with an 8MM Allen wrench or socket.
   1. Removal of the crank bolt on the left side of the bike is the same as removal from the right side.
9. Now remove the crank arms with a crank arm puller, threading the outer portion into the crank arm as shown in the video.
   1. Be sure to thread the outer portion in as far as possible to prevent damage to the crank arm threads or the threads of the tool.
   2. Use a 7/8" wrench to make sure the outer portion is threaded in completely.
   3. Now spin the handle clockwise to press the crank arm off of the bike.
   4. Be careful when the crank arm comes off as if you are not holding it, it can fall to the floor.
   5. Also, use the wrench to loosen the tool before removing the crank arm from the unit.
   6. Now you can unthread the tool from the crank arm by hand after removing the crank arm from the bike.
10. Next, inspect the bottom bracket cups for looseness; to do this use the bottom bracket tool by hand to see if you can turn either of the bearing cups.
    1. To further verify the adjustment of your bottom bracket use a rubber mallet to tap lightly on each side of the spindle to check for movement from side to side, if you have movement, or one or both of the bearing cups is loose, you need to re-adjust the bottom bracket.
    2. If you are only inspecting the bottom bracket and did not find any need for the adjustment you would re-assemble the bike at this point.
11. Once the crank arms are removed look closely at the spindle.
    1. It should have defined edges and be smooth.
    2. As you can see by the video our spindle needs to be replaced.
12. Next, you will need to remove the lock ring. The lock ring is around the bottom bracket cup on the left side of the bike. 
    
    1. The video shows an example of a lock ring.
       1. This one needs to be turned counter-clockwise to loosen.
    2. To use the lock ring tool you slip it over the lock ring using the three notches and torque the lock ring in the proper direction.
    3. Then remove the lock ring by spinning it off the bearing cup.
13. Next, you will need to use the bottom bracket tool to remove the bottom bracket cups.
    1. Begin with the left side.
       1. Slip the tool into the splines of the cup and loosen.
          1. For a stubborn bottom bracket use a 5/16"-24 x 2" bolt and some washers with a 1-1/4" wrench.
          2. Slip the tool into the splines and thread the bolt with the washers into the spindle.
          3. Get it snug but not completely tight.
       2. Now use the wrench to turn the cup counter-clockwise for the left side and remove it completely.
    2. Now, remove the cup from the right side.
       1. Slip the bottom bracket tool into the splines of the cup and turn it clockwise to loosen.
          1. For a stubborn bottom bracket use a 5/16"-24 x 2" bolt and some washers with a 1-1/4" wrench.
          2. Slip the tool into the splines and thread the bolt with the washers into the spindle. Begin with the left side.
       2. If you cannot get the cups loose with this method try turning the bike on its side to get better leverage as shown in the video.
14. This concludes the dis-assembly and inspection procedure of the LeMond RevMaster bottom bracket & spindle.
15. Click here to see Part 2, re-assembly and installation to complete the replacement procedure.