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BLACKSPIRE DESIGNS LIMITED

PEDALS D U BU S H I N G R E P L AC E M E N T (SUB3 / SUB 4 / BIG SLIM MKII / EL GORDO) CREATED BY: KELVIN WONG

REVISION

DAT E

A P P ROV E D B Y:

IR

1/19/13

KW

A

2/14/13

KW

# 5 - 7 3 0 E A T O N WAY A N N A C I S I S L A N D, D E L T A , B C C A N A DA V 3 M 6 J 9 1 


REVISION

CHANGES

IR

-INITIAL PRELIMINARY RELEASE.

A

-RELEASED FOR ONLINE PUBLICATION.

B

-ADDED STEP TO REMOVE 686 BEARING.

   

   

 

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TOOLS REQUIRED FOR REPLACING PEDAL DU BUSHINGS 

1/4" Drive Torque Wrench

6 mm Hex Bit 1/4" Drive Socket

6 mm Hex Key Wrench

1/4" Drive Ratcheting Socket Wrench

9 mm 6-point 1/4" Drive Socket

1/2" Drive Ratcheting Socket Wrench

5/16" 6-point 1/2" Drive Socket

2 x 3/8" UNC or UNF x 4.5" Long Hex Socket Cap Screw

3/8" UNC or UNF Nut

2 x 3/8" Flat Washer

Packing Tape

1/2"-20 Tap and Tap Handle

6 mm or 8 mm Tool Punch

Alloy Steel Hammer

Needle Nose Pliers

Heavy Duty Grease of Your Choice

Rag

   

   

 

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MATERIALS REQUIRED FOR REPLACING PEDAL DU BUSHINGS 

2 x 14 mm OD, 12 mm ID, 12 mm Long, Split DU Bushing

2 x 686Z Bearing (Optional)

   

   

 

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DU BUSHING REPLACEMENT PROCESS 1. Loosen and remove the endcap from the pedal body using the 6 mm hex key wrench.

Figure 1: Holding the pedal body with a hand and removing the endcap with the 6 mm hex key wrench.

2. Remove the pedal axle nut by holding the pedal axle stationary with the 6 mm hex key

wrench on the larger threaded end of the pedal axle and using the 9 mm 6-point socket on the ratcheting socket wrench. Wipe down the pedal axle of grease with a clean rag.

Figure 2: Holding the pedal axle stationary with the 6 mm hex key wrench and loosening the pedal axle nut with the 9 mm 6-point socket.

   

   

 

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3. Remove the 686 bearing by gently tapping it out using the 6 mm or 8 mm tool punch.

Figure 3: Insert the 6 mm or 8 mm tool punch through the bushing side and gently tap it to push out the 686 bearing.

4. Gently tap the split DU bushing using the 1/2"-20 tap and tap handle until the tap bottoms

out.

Figure 4: Tapping the split DU bushing until the 1/2"-20 tap bottoms out.

   

   

 

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5. Rest the pedal body between two blocks of wood with the tap pointing down. Insert the 6

mm or 8 mm tool punch through the opposing hole of the pedal body. Gently hit the tool punch with a hammer to push out the tap with the split DU bushing attached.

Figure 5: Hammering the 6 mm or 8 mm tool punch against the tap to push out the split DU bushing.

6. Remove the split DU bushing attached to the tap by using the needle nose pliers and peeling

the bushing apart at the split.

Figure 6: Peeling the split DU bushing away from the 1/2"-20 tap using needle nose pliers at the split.

   

   

 

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7. Press a new split DU bushing into the pedal by doing the following steps:

a. Slide a 3/8" flat washer over the 3/8" UNC or UNF x 4.5" long hex socket cap screw and apply packing tape to the shank of the cap screw until the thickness of the tape matches roughly to the thickness of the split DU bushing's ID.

Figure 7: A 3/8" flat washer is put against the head of the 3/8" UNC or UNF bolt before packing tape is wrapped onto the shank.

b. Slide a new split DU bushing over the 3/8" UNC or UNF bolt with packing tape and flat washer and insert the assembly into axle bore of the pedal body.

Figure 8: A new split DU bushing is slid over the 3/8" UNC or UNF bolt against the 3/8" flat washer.

   

   

 

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c. Hand tighten the 3/8" UNC or UNF nut over the respective 3/8" UNC or UNF socket cap screw with a 3/8" flat washer between the nut and the pedal body.

Figure 9: Hand tighten the 3/8" UNC or UNF nut over the respective 3/8" UNC or UNF socket cap screw.

d. Hold the 3/8" UNC or UNF socket cap screw stationary by inserting the 5/16" hex key onto the head of the bolt. Tighten the 3/8" UNC or UNF nut down using the 5/16" 6-point socket on the ratcheting socket wrench until the 3/8" flat washer bottoms out against the pedal body.

Figure 10: The split DU bushing is pressed into the pedal body until the flat washer bottoms out against the pedal body.

   

   

 

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e. Remove the 3/8" UNC or UNF nut and flat washer and insert the 3/8" UNC or UNF socket cap screw with only the packing tape on the shank of the cap screw through the pedal axle bore. Hand tighten the 3/8" UNC or UNF nut over the respective 3/8" UNC or UNF socket cap screw with a 3/8" flat washer between the nut and the pedal body.

Figure 11: Hand tighten the 3/8" UNC or UNF bolt with 3/8" UNC or UNF nut and 3/8" flat washer.

f. Hold the 3/8" UNC or UNF socket cap screw stationary by inserting the 5/16" hex key onto the head of the bolt. Carefully tighten the 3/8" UNC or UNF nut down using the 5/16" 6-point socket on the ratcheting socket wrench until the bushing is properly seated inside the pedal body.

Figure 12: The split DU bushing is pressed into the pedal body until it bottoms out against the internal bushing seat of the pedal body.

g. Remove the 3/8" UNC or UNF socket cap screw, 3/8" UNC or UNF nut, and the 3/8" flat washer.    

   

 

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8. Insert the original or new 686 bearing into the threaded end of the pedal body by using the

pedal axle as a guide.

Figure 13: The 686 bearing is placed onto the pedal axle (left) and inserted into the pedal body (right).

9. Insert the pedal axle into the left pedal body while holding the 686 bearing in place and spin

the pedal to ensure smooth rotation.

Figure 14: The pedal axle is being checked for fit against the 686 bearing and the split DU bushing.

NOTE: If the pedal axle does not fit through the pedal body easily or if the pedal axle does not spin freely, do the following steps: a. Follow Steps 3 - 6 to remove the split DU bushing. b. Follow Step 7 to press in a new split DU bushing. c. Repeat steps 9a and 9b until the pedal axle fits inside the pedal body easily and the pedal axle spins freely.    

   

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10. Reinsert the rubber seal against the end of the pedal axle if it was removed while doing

Step 2. Re-apply an even coat of heavy duty grease of your choice onto the largest diameter step of the pedal axle, extending down to the middle step of the pedal axle.

Figure 15: Applying grease onto the split DU bushing seat on the pedal axle. Notice the final location of the rubber seal.

11. Insert the greased pedal axle back into the pedal body and spin the pedal axle to displace the

grease evenly throughout the bushing, inside the pedal body.

Figure 16: Inserting the greased pedal axle into the pedal body.

   

   

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12. Insert the pedal axle nut onto the smaller threaded end of the pedal axle. Hold down the

pedal axle nut against the smaller threaded end of the pedal axle with a finger and spin the pedal axle to allow the threads to engage and hand tighten.

Figure 17: Applying (left) and tightening (right) the pedal axle nut by turning the pedal axle until it is hand tight.

13. Place the larger threaded end of the pedal axle onto the 6 mm hex bit of the torque wrench.

Hold the torque wrench stationary and tighten the left pedal axle nut onto the pedal axle using the 9 mm 6-point socket on the ratcheting socket wrench. Tighten the pedal axle nut to the torque specification of 4 Nm.

Figure 18: Tightening the pedal axle nut onto the pedal axle to the torque specification of 4 Nm.

   

   

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14. Insert an end cap into the threaded end of the pedal body. Tighten the end cap to the torque

specification of 4 Nm.

Figure 19: Tightening the end cap onto the pedal body to the torque specification of 4 Nm.

15. Repeat Steps 1 - 14 with the other pedal to finish replacing the split DU bushings for both

pedals.

   

   

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Pedals dubushing b