BODY BIKE Classic User manual

01
INSTRUCTIONS
BODY BIKE®INDOOR CYCLE
BODY BIKE®CLASSIC
ENGLISH

Equipment required 2
Introduction 3
Specifications 4
General information 4
Warranty 5-6
Assembly
Unpacking 8
Handlebar 10
Bottom frame 10
Saddle 11
Pedals 11-12
Maintenance
Adjustment handles 14
Cleaning the posts 15
Cleaning 16
Removal of side covers 17-18
Service hatch 19
Replacing the brake block 19-20
Poly-V belt 21
Support
Online information 22
Index 23
TABLE OF CONTENTS
Unpacking
Drill bit
Drill
Bottom frame
6 mm allen wrench
13 mm wrench
Saddle
14 mm wrench
Pedals
15mm pedal wrench
Grease
Cleaning
Tissue paper or cloth
Spray bottle with water
Soap (only washing-up liquid)
Vaseline oil
Post cleaning
Cloth
Vaseline oil
Adjustment handle
5mm Allen Wrench
Screwdriver
Steel brush
Grease
Brush
Brake block
8 mm wrench
Poly-V belt
10 mm Allen wrench
19 mm wrench
Measuring device
Screwdriver
Side covers
4 mm Allen wrench
PZ2 drill bit
Drill
EQUIPMENT REQUIRED
02

This manual provides information on the assembly and
maintenance of the BODY BIKE® indoor cycle. The manual
is intended for the owners and service people responsible
for cleaning and maintenance.
Before assembling the cycle, please read the manual and
prepare the correct tools, see equipment required page
2. When assembling the cycle, we recommend that you
follow the manual step by step.
Maintaining the cycle is very important. In the manual you
will find clear instructions on how to maintain the cycle.
Over time it will be necessary to replace worn-out parts.
You will find a detailed description and exploded drawings
of BODY BIKE®’s spare parts on our website www.body-
bike.com. When ordering spare parts from the local BODY
BIKE® distributor, please refer to the item number (P/N
no.) in order to make sure you will receive the correct
spare part.
We recommend that you order original parts, accessories
and materials necessary for the maintenance of the cycle
at your local BODY BIKE® distributor.
For further information on accessories, please check our
website www.body-bike.com
INTRODUCTION
03

Manufacturer:
BODY BIKE® International A/S
Niels Bohrs Vej 2
DK-9900 Frederikshavn
Denmark
Phone: [phone]
Weight:
Assembled: 65 kilogram
Packed weight(5 cycles): 350kg
Length, Width, Height:
Assembled size:
105cm, 60cm, 100cm
Packed size (5 cycles):
120cm, 80cm, 114cm
Maximum user weight
150 kg (Please note that the
max. pedal load may be lower)
SPECIFICATIONS
Patent held for:
Crank system
Materials
Cast iron
Stainless steel
Plastic (ABS) covers
High quality bearings
Frame: Robot-welded, fully
galvanized, powder coated and
hardened
Wipe off the cycle after EVERY use.
ALWAYS loosen all handles
and release tension after use.
The rubber feet should always be adjusted to
ensure that the cycle is in level.
Every other year the rubber feet should be
replaced as the rubber hardens and becomes
unable to absorb the impact.
Tighten up the pedals every 14 days or every month to avoid
them getting loose or breaking off.
Pedals and adjustment handles should be changed once a year.
DO NOT perform stretch exercises on the cycle, pedals or up
against the cycle, except against the stretch area at the rear end
of the cycle.
DO NOT switch the front or seat post from one cycle to another.
DO NOT lift the cycle by the saddle.
GENERAL INFORMATION
04

®
®
®
® SMART
®
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®
WARRANTY
Figure 1
As information to our customers we hereby outline the warranty obligations applicable to BODY BIKE®Indoor Cycles.
The warranty comes into force the moment the unit leaves BODY BIKE International A/S.
To get an overview see figure 1.
05

WARRANTY
Warranty for the Danish manufactured BODY
BIKE® Indoor Cycle:
A two-year warranty against manufacturing
defects, excluding normal wear and tear, is given
for the flywheel and pulley. A three-year warranty is
given on the crank and the pedal arms, and a five
year warranty is given against frame breakage.
Consumable items (such as the poly V-belt, brake
pad, handlebar rubber, adjustment handles, saddle
and pedals, etc.) which are subject to continuous
wear and tear, are not covered by a warranty.
There is currently no warranty applying to the pedals.
The warranty only applies to cycles equipped with
original BODY BIKE®spare parts. All warranties are
cancelled if the cycle has been modified or in any way
not used as intended.
PLEASE NOTE
ALWAYS RELEASE TENSION AFTER USE
!
In order for the warranty to be sustained, all instructions in
the respective manuals have to be followed.
This particularly relates to:
• Replacement of rubber feet on the bottom frames
once a year
• Replacement of pedals once a year and tightening of
these
• General cleaning of the bikes after use with correct
materials
• Lubrication of the adjustment handles every 3 months
• Original spare parts must be used on the bike
Warranty repairs are to be carried out by BODY BIKE In-
ternational A/S in Denmark.
At the expense of BODY BIKE International A/S.
Related freight costs are held by the customer.
Warranty spare parts are shipped ex. works.
06

Unpacking 8
Bottom frame 8-9
Handlebar 10
Saddle 10
Pedals 11-12
ASSEMBLY
ASSEMBLY
07

1) Open the top of the box.
2) Remove all the unmounted parts.
3) Flatten the box on the floor next to the pallet.
4) Loosen the two screws mounting the first cycle to
the pallet. See figure 2
5) Lift the cycle off the pallet and place it on the flat-
tened box to spare your floor from getting marks.
UNPACKING
Figure 2
A fixing tool can be bought at BODY BIKE®
International A/S to ease the mounting of the bottom
frame. Go to page 22.
1. Arrange the bottom frames parallel on the floor
next to the cycle with the correct mounting distance
between them, see figure 3. On the front bottom
frame, the transport wheels should point forward.
2. Take hold of the front post and seat post and lift
the cycle onto the bottom frames, see figure 3. Ensure
that the holes in the frame match the holes in the
bottom frames.
3: Put on the spring lock washer and the cap nut and
tighten by using a 13 mm wrench, see figure 4.
4: Unscrew the rubber feet a little. Place the cycle in
the correct position. Turn them up and down until the
cycle stands properly and it is in level.
BOTTOM FRAME
PLEASE NOTE
Do not overtighten the nuts. Max 12 Nm.
!
08

ASSEMBLY
BOTTOM FRAME
Figure 3
Figure 4
Front bottom
frame with wheels
pointing forward
Back bottom frame
LIFTING SPOTS. Be sure that the saddle
and handlebar are locked before lifting
CAP NUT
WASHER
Tighten with no
more than 12 Nm
09

1) Place the handlebar on top of the front
post.
2) Screw an adjustment handle (size 32mm)
clockwise into the socket from underneath
the post, see figure 5. Fix the handlebar
completely to the front post by tightening
the adjustment screw on the side of the
handlebar.
HANDLEBAR
WASHER
SADDLE
ONLY RELAVENT IF THE SADDLE IS NOT ALREADY
INSTALLED.
1) Place the saddle in the track on the seat post.
2) Secure the saddle with the remaining adjustment handle,
see figure 6.
To fasten the saddle to the adaptor and adjust the tilt of the
saddle, use a 14 mm wrench on the bolt marked with an A
on figure 6.
WASHER
Figure 5
Figure 6
A
010

ASSEMBLY
PEDALS
1) Place the right pedal arm with the socket
pointing upwards, see figure 8.
2) Put maximum resistance on the brake, so
the pedalarm is unable to rotate, see figure 7.
Please note
The pedals are marked with R for Right and
L for Left side.
The pedals should always be screwed on in
the direction of the handlebar, see figure 9
and 10.
Make sure that the hole in the pedal arm is
greased when mounting the pedal.
Start mounting the pedal by hand as tools
will tighten the pedal at a wrong angle.
3) After tightening by hand, use a 15mm ped-
al wrench to tighten the pedal completely
(45N/4,5kg).
!
Figure 7
Clockwise will increase
the resistance
Counterclockwise will
loosen the resistance
011

Figure 8
Figure 9
Figure 10
Tighten in the direction
of the handlebar
Point upwards
012

ASSEMBLY
MAINTENANCE
Adjustment handles 14
Cleaning the posts 15
Cleaning 16
Removal of side covers 17-18
Service hatch 19
Replacing the brake block 19-20
Poly-V belt 21
013

Every 3 months the handles need
cleaning and grease to protect the
parts from sweat, dust, dirt and
water.
1) Remove the adjustment handle
and disassemble the handle
completely into a screw, a spring,
a handlegrip, a main screw and a
brass washer, see figure 9. Do this
with both the horizontal and vertical
adjusment handle. You don’t need
to remove the 32mm nut.
2) Clean all the parts thoroughly
one by one using a steel brush. If
the residue is extreme, a sharp
object can be used, for example a
screwdriver.
3) Lubricate the internal parts with
grease before reassembling the
handle. Remember to lubricate
inside the handle as well.
4) Reassemble the handle by
inserting the main screw in the
handle grip.
5) The spring is inserted into the
top of the handle and fixed in
place with the remaining screw.
6) Tighten with a 5mm Allen
wrench.
7) Add grease to the main screw
before mounting it on the cycle.
ADJUSTMENT HANDLE
Figure 11
Vertical
adjustment
Heizontal
adjustment Washer
Screw Main
screw
Spring
Hand grip
32mm nut
PLEASE NOTE
Never use a tool when tightening
the adjustment handle on the cycle.
By pulling the handle it can be turned
freely.
!
014

MAINTENANCE
Every other week the posts need clean-
ing to protect them from sweat etc.
Pull out the seat post and the front post
and wipe them clean with an oily cloth,
see figure 12.
If there is a slight sideways play in the
front post you can adjust it on both sides
of the cycle with the screws marked with
an S on figure 12. This adjustment has to
be very subtle in order for the post still
to be able to move up and down.
CLEANING THE POSTS
PLEASE NOTE
The posts should be cleaned
every other week to keep them in
good condition
!
CreatedbyOlenaPanasovska
fromtheNounProject
1x oily cloth
Release
Figure 12
Vertical
adjustment
Herizontal
adjustment
S
S
S
015

After each workout, wipe the cycle down with
tissue paper.
If the cycle is covered in sweat or dirt, use water
in a spray bottle and if necessary a tissue with
some washing-up liquid.
Remember handlebar and saddle.
To make the cycle look its best, use a cloth with a
little vaseline oil on all parts except the handlebar
and saddle.
Vacuum clean the bike inside when necessary to
prevent dust from gathering on the flywheel. If
dirt has already gathered on the flywheel edge,
use a piece of rough felt to sand it down.
Always make sure that the small hole by the front
bottom frame is not blocked and allows water
and sweat to exit the frame, see figure 13.
CLEANING
PLEASE NOTE
NEVER use alcohol or chemicals
!
In the backside
of the front
frame, you will
find the small
drainage hole.
Figure 13
016

MAINTENANCE
REMOVAL OF SIDE COVERS
The side covers can be removed e.g. if the
belt needs to be changed.
1) Dismount the right pedal arm with an 8mm
Allen wrench. See figure 14.
2) Loosen the two bolts on the bottle holder
with a 4 mm Allen wrench. See figure 15.
2) Loosen all the screws holding the side cov-
er with a PZ2 drill bit. See figure 15.
3) Keep all the bolts together in order not to
lose them.
5) Slide the side cover free from the top cov-
er. Do always this in the direction of the steer.
See figure 16.
Figure 14
PLEASE NOTE
You dont need to remove the top
cover in order to remove the side
covers.
!
017

Figure 15
Remove the 7 bolts and
slide the side cover off in
the dirrection of the steer.
Figure 16
018

MAINTENANCE
The Kevlar® pad on the BODY BIKE Synthetic Brake
has an expected durability of a minimum of 1500
hours, so eventually the brake pad will be worn. To
ensure that the brake pad is correctly mounted,
it has been pre-fitted to the block, and it is only
possible to purchase the complete brake block. Go
to page 22.
Inspect the Kevlar®brake pad after the first month
and hereafter every 3rd month. The Kevlar®brake
pad should be replaced before it is worn through
and reveal the black rubber.
To get to the brake block, it is necessary to remove
the right side cover from the cycle. See figure 14-16
1) Loosen all the screws in the side cover and
remove them as well as the bottle holder.
2) Remove the side cover by sliding the side cover in
the direction of the steer. See figure 16
3) Release tension completely on the brake. Coun-
terclockwise will loosen the resistance. See figure 7.
4) Remove the two screws holding the brake block
to the frame by using an 8 mm wrench, see figure
19.
REPLACING THE BRAKE BLOCK
SERVICE HATCH
Figure 17
Figure 18
In order to remove the service hatch, use a PZ2 drill bit
and a drill. Remove the 2 screws and then the hatch.
See figure 17.
Quick acces to adjust the poly-v belt. See figure 18
019

Remove
screws
Install and
twist
Reinstall the
last screw
Figure 21
Figure 20
Figure 19
5) Take the new brake block and fasten
it to the frame by tightening the screw
closest to the brake block. Then place
the block in the correct position under
the brake, see figure 20.
6) Fasten the remaining screw furthest
away from the block, and then make
sure that both screws are tightened
properly, see figure 21.
7) Grease should be applied to the
cavity on top of the brake block or to
the top nut on the brake to ensure a
smooth interaction between the two.
8) Finally, remount the side cover by
screwing in the corner screws first.
Hereafter the remaining screws.
PLEASE NOTE
Clean the flywheels outer
diameter to an even smoother
ride.
!
020