BODY BIKE Indoor Cycle User manual

Instructions
BODY BIKE Indoor Cycle
B O D Y
B I K E ®
INDOORCYCLE
BODY BIKE Magic
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TABLE OF CONTENTS
Intro Equipment required 2
Introduction 3
Specifications 4
Warranty 4
Safety 5
General information 5
Assembly Unpacking 7
Bottom frame 8
Handlebar and saddle 8
Bottle holder 8
Pedals 9
Use Optimising the use 11
Adjusting the cycle 12
The light guide 13
10 easy steps 14
Maintenance Cleaning 17
Sidewards play in posts 18
Cleaning the posts 18
Adjustment handles 18
Adjusting the coil house 19
Replacing the brake block 20
Poly-V belt 21
Removal of side cover 22
Removal of top cover 22
Removal of saddle 22
Trouble-shooter 23
Index 23
EQUIPMENT REQUIRED
Unpacking
Screwdriver with torx 30
Bottom Frame
13mm wrench
Handlebar and Saddle
14mm wrench
Pedals
15mm pedal wrench
Grease
Cleaning
Tissue paper or cloth
Spray bottle with water
Antistatic washing-up liquid
Vaseline oil
Sidewards play in posts
A coin
3mm Allen wrench
32mm wrench
Adjustment Handle
Brush
Grease
Post Cleaning
Cloth
Vaseline oil
Adjustment of coil house
5mm Allen wrench
Small screwdriver
Brake block
A coin
8 mm wrench
Poly-V Belt
A coin
10 and 19mm wrench
Measuring device
Side cover
A coin
3, 4 and 8mm Allen wrenches
13mm wrench
Top cover
17mm wrench
Combination pliers
1mm distance piece

B O D Y
B I K E ®
INDOORCYCLE
INTRODUCTION
This manual provides information on the assembly and
maintenance of the BODY BIKE indoor cycle.The manual
is intended for the owners, instructors 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 of all BODY BIKE’s spare parts
on our web site 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
web site www.body-bike.com.
We wish you the best of luck with your
BODY BIKE indoor cycle
3

SPECIFICATIONS
Manufacturer:
BODY BIKE International A/S
Pier 6 Nord
DK-9900 Frederikshavn
Denmark
Tlf: [phone]
Fax: [phone]
Email: [email protected]
www.body-bike.com
Product description:
Indoor cycle for young people
Length,Width, Height:
Assembled size:
105cm, 55cm, 100cm
Packed size (5 cycles):
120cm, 80cm, 114cm
Weight:
Assembled: 60 kilogram
Packed weight (5 cycles): 325 kg
Patents held for:
BODY BIKE crank system
Recommended user
specifications:
Maximum user weight
100kg/220pounds
(Please note that the max. pedal
load may be lower)
Minimum height 135cm/55inches
Minimum age 8 years
Materials:
Cast iron.
Stainless steel.
Steel.
Plastic (ABS) side and top covers.
Plastic (PETG) service hatches.
Plastic (PA6 with glass fibre
reinforcement) bottle holder.
Plastic (PA6) ergonomical
adjustment handles.
High quality bearings.
Frame: Robot-welded and powder
coated.
WARRANTY
Warranty for the Danish
manufactured BODY BIKE
Indoor Cycle:
A two-year warranty against
manufacturing defects,
excluding normal wear and
tear. A three-year warranty is
given on the crank and the
pedalarms, and a five year
warranty is given against
frame breakage.
Consumable items (such as
the poly V-belt, brake pad,
handlebar rubber, saddle and
pedals, etc.) which are subject
to continuous wear and tear,
are not covered by a warranty.

B O D Y
B I K E ®
INDOORCYCLE
GENERAL INFORMATION
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 the pedals every 14 days to avoid
them getting loose or breaking off.
Pedals 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
5
SAFETY
When dealing with young people safety is especially
important. Magic is a not a toy, but a piece of
sporting equipment. It has a flywheel with no free
wheeling, meaning that the pedals keep turning a
while after you stop pedalling. It is highly important
to have strict rules around the cycles.Therefore:
NEVER use the cycles without professional adult
guidance
ALWAYS double check that all adjustment
handles are firmly tightened before getting on
the cycle
ALWAYS inform the young people about the red
emergency brake and let them try it
ALWAYS inform the young people about the
flywheel with no free wheeling
NEVER cycle in upright position without holding
on to the handlebar
ONLY use the cycle as intended
Please also see“10 steps to a safe cycling experience”

Unpacking 7
Bottom frame 8
Handlebar and saddle 8
Bottle holder 8
Pedals 9
ASSEMBLY

B O D Y
B I K E ®
INDOORCYCLE
Unpacking 7
Bottom frame 8
Handlebar and saddle 8
Bottle holder 8
Pedals 9
UNPACKING THE PALLET
1: Begin by opening 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.
5: Lift the cycle off the pallet and place it
on the flattened box to spare your floor
from getting marks.
7

BOTTOM FRAME
1: Arrange the bottom frames
parallel on the floor next to the
cycle with the correct mounting
distance between them, see figure 1.
2:Take hold of the front post and
seat post and lift the cycle onto the
bottom frames, see figure 1. Ensure
that the holes in the frame match
the holes in the bottom frames.
3: Put on the spring lock washer
with the rough side facing upwards,
Figure 3Figure 1
LIFT
FRONT BOTTOM
FRAME WITH WHEELS Figure 2
SPRING LOCK
WASHER
CAP NUT
A
HANDLEBAR AND SADDLE
1: Screw the handle into the side of
the handlebar’s fitting.
2: Slide the handlebar onto the
posts as shown on figure 3.
To fasten the saddle to the adaptor
and adjust the tilt of the saddle,
use a 14mm wrench on the bolt
marked with an A on figure 1.
BOTTLE HOLDER
1: Mount the bottle holder at the
top of the handlebar, see figure 3.
and the cap nut and tighten by
using a 13mm wrench, see figure 2.
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.
Please note
Do not tighten the nuts for
the bottom frame too much.

ASSEMBLY
B O D Y
B I K E ®
INDOORCYCLE
Figure 5Figure 4
PEDALS
1: Place the right pedalarm with
the socket pointing upwards, see
figure 4.
2: Put maximum resistance on
the brake, so the pedalarm is
unable to rotate, see figure 4.
3: Grease the hole of both the
pedalarms.
4:Take the pedal marked with
R for right and screw it by hand
into the pedalarm on the right
9
Please note
The pedals should
always be screwed on
in the direction of the
handlebar, see figure 5.
Start mounting the
pedal by hand as tools
will tighten the pedal
at a wrong angle.
side of the cycle. It should
be turned in the direction
of the handlebar, see figure
5. Afterwards tighten with a
15mm pedal wrench (45Nm).
5:Take the pedal marked with
L for left and screw it by hand
into the pedalarm on the left
side of the cycle. It should
be turned in the direction
of the handlebar, see figure
5. Afterwards tighten with a
15mm pedal wrench (45Nm).

Optimising the use 11
Adjusting the cycle 12
The light guide 13
10 easy steps 14
USE

B O D Y
B I K E ®
INDOORCYCLE
Optimising the use 11
Adjusting the cycle 12
The light guide 13
10 easy steps 14
OPTIMISING THE USE
When cycling in upright position always have
shoulders behind elbows.
Adjust the tension to the user’s individual need.
Relax the shoulders and wrists, tighten the
abdominal muscles and let the legs do the work.
Use different grips on the handlebar.
Never cycle in upright position without holding on
to the handlebar.
Create an interesting cycling experience by
varying between the different levels and choose
popular music to spark the motivation.
11

ADJUSTING THE CYCLE
It is individual how the adjustment of the cycle is
preferred.Therefore the following are only guidelines.
1: Stand next to the cycle and adjust the height of the
saddle to the top of the hip, see figure 6.
2: Adjust the height of the handlebar so the lowest part
is the same height as the saddle, see figure 7.
3:To adjust the saddle horizontally, place the pedal
pointing forward.Adjust the saddle in order for the knee
to be straight over the palm of the foot, see figure 8.
4: Adjust the handlebar so the distance between the
saddle and the handlebar equals the length of the user’s
forearm, see figure 9.
Figure 6 Figure 7
Figure 8 Figure 9
Please note:
Do not slide the
handlebar past
the red line as
the handle then
cannot get a
firm grip of the
post.

USE
B O D Y
B I K E ®
INDOORCYCLE
THE LIGHT GUIDE
The light guide in the top cover
is a tool to optimise the training.
It can be difficult to follow the
beat in the music, but it is easy
and fun to achieve the colour
the instructor requests. Each
user adjusts the tension on
the cycle to fit their own
physical fitness, and in
that way everyone can
cycle in all levels just
with different amounts
of tension on.
13
350
250
200
150
100
LEVEL 350 RED:
This level is for maximum speed.It is perfect
for interval training where maximum speed
is required for a shorter period of time.
LEVEL 250 ORANGE:
Orange is for cycling to up-beat songs.
Cycling for a longer period at this level can
build up the pulse.
LEVEL 200 GREEN:
Green is the medium level.This level is good
for practicing how to sit and stand correctly
on the cycle. Also additional assignments
can be given at this level e.g. placing hands
in a certain position on the handlebar.
LEVEL 150 BLUE:
Blue level is for slow cycling. It can be used
to get the pulse down or for tough cycling
with maximum tension on.
LEVEL 100 WHITE:
To get the best exercise always keep the
legs moving.The white level is for cooling
down. It motivates the user to keep the
display lit and thereby keep the legs
moving.
Please note
When starting out, the cycle takes a few moments
to generate enough power to light up the display.
Cycling too slow will not generate enough power
to light up the display.
Please note
Never cycle without tension.You should always
be able to feel the resistance, especially when
cycling fast. If you cannot feel the resistance, it
can harm your knees.

S
T
O
P
S
T
O
P
TEN EASY STEPS TO A SAFE
CYCLING EXPERIENCE
Before cycling
1: Always secure all four
adjustment handles
before cycling. Make
sure that the handlebar
is not slided beyond its
outermost position.
2:The feet should be
firmly fixed to the
pedals. Pull upwards in
the strap to tighten and
then tuck it in to keep it
in place.
3: Make the young people
aware that the flywheel
momentum will keep the
pedals turning even after
they stop pedalling.
4: Show the young people
the emergency brake and
let them try it out.
5:Teach the young people
about good behaviour on
the cycles. E.g. always keep
hands on handlebar when
cycling in upright position.
x 4
1
2

B O D Y
B I K E ®
INDOORCYCLE
After cycling
6: Avoid a sudden stop by
slowing down the pace over a
period of time. Use the lights
when slowing down by first
cycling in the green level,
then blue and last in white
level until the young people
are cycling slow enough to
stop completely.
7: Loosen both pedal straps
before getting off the cycle.First
untuck the strap and then press
downwards on the small black
plastic piece.
8: Get off
the cycle
slowly as the
floor can be
slippery from
sweat.
9: Always
release
tension and
loosen all
handles.
10: Clean
the cycles
with water
and tissue
paper.
1
2
USE
15

Cleaning (After every use) 17
Sidewards play in posts (When necessary) 18
Adjustment handles (Every 3 months) 18
Cleaning the posts (Every other week) 18
Adjusting the coil house (When necessary) 19
Replacing the brake block (When necessary) 20
Poly-V belt (When necessary) 21
Removal of side cover (When necessary) 22
Removal of top cover (When necessary) 22
Removal of saddle (When necessary) 22
MAINTENANCE

B O D Y
B I K E ®
INDOORCYCLE
CLEANING
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 tis-
sue with some antistatic washing-up liquid.
Remember handlebar and saddle.
NEVER use alcohol or chemicals.
To make the cycle look its best, use a cloth
with a little vaseline oil on all parts except
the handlebar and saddle.
The inside of the cycle is well protected by
the side covers. If water should enter the
frame by the handlebar, it can exit through
a little hole at the bottom of the frame. If the
hole plugs up, the right side cover can be
removed and the hole can be cleaned.
SMALL HOLE
17
Figure 10

SIDEWARDS PLAY IN POSTS
Front post
1: Remove the right service hatch by
loosening the locks with the coin,
see figure 16, page 20.
2: Adjust the screw marked S1 by
using a 3mm Allen wrench, see
figure 11.
Seat post
1: Remove the seat post, the handle,
the 32mm nut and the brass piston
with a 32mm wrench.
See figure 12.
2: Carefully lift up the top cover as
shown on figure 12.
3: Remount the seat post and adjust
the right-hand side screw marked
S2 with a 3mm Allen wrench.
4: Push the top cover back in place.
5: Remove the seat post and
remount the brass piston, 32mm
nut and the handle. Remount the
seat post.
S1
CLEANING THE POSTS
Every other week the posts need
cleaning to protect them from
sweat etc.
1: Pull out the seat post and the
front post and wipe them clean
with an oily cloth, see figure 13.
Figure 11
S2
BRASS PISTON
32 MM NUT
HANDLE
Figure 12
Please note:
The adjustment has to be
very subtle in order for the
posts to retain a smooth
motion up and down.
ADJUSTMENT HANDLE
Every 3 months the handles need
cleaning and grease to protect them
from sweat, dust, dirt and water.
1: Remove the adjustment handle
and clean the thread thoroughly
with a brush.
2: Add grease to the thread before
mounting it on the cycle.
Please note
Do not use a tool when
tightening the adjustment
handle on the cycle.

MAINTENANCE
B O D Y
B I K E ®
INDOORCYCLE
Figure 15 19
Figure 14
ADJUSTING THE COIL HOUSE
It is important that the coil house is placed
1mm from the magnets. It should be placed
exactly in front of the magnets so the whole
magnet is passing the entire coil house.
1: Loosen the bolt holding the fitting to the
side member. It is marked with B on figure 14.
2: Align the fitting in order for the whole
magnet to pass the entire coil house and the
fitting to be parallel to the side member, see
figure 14.Tighten the bolt marked with B.
3: Adjust the two adjustment screws so
there is 1mm between the magnet and the
coil house. The screws are marked with C
on figure 15.This is easily done by placing a
piece of 1mm thin cardboard between the
two parts and then tightening the screws.
Figure 13
FITTING IS
PARALLEL WITH
SIDE MEMBER
TOP VIEW
SIDE VIEW
MAGNET
COIL HOUSE
C
1MM
MAGNET PASSING
THE ENTIRE COIL
HOUSE
B
Please note:
The power is generated by
magnets and no batteries
are used.

Figure 19
REMOVE
Figure 18
The Synthetic BODY BIKE Kevlar
Brake Pad 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. It is only
possible to
purchase
the
complete
brake
block.
Figure 17
SERVICE HATCH REPLACING THE BRAKE BLOCK
1: Remove both service hatches by
loosening the locks with a coin, see figure
16.
2: Release tension completely on the brake.
3: Remove the two screws holding the
brake block to the frame by using an 8mm
wrench, see figure 17.
4: Take the new brake block and fasten it to
the frame by tightening the screw closest
to the brake block., see figure 18
5. 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.
6:Turn the block back in place.
7: Fasten the remaining screw furthest
away from the block, and then make sure
that both screws are tightened properly,
see figure 19.
8: Remount both service hatches.
Figure 16