Horizon Fitness GR3 User manual

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GR3 SERVICE MANUAL

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TABLE OF CONTENTS
CHAPTER 1: Serial Number Location…………………………………………3
CHAPTER 2: Indoor Cycle Operation………………………………………4
2.1 How to Move the Indoor Cycle…………………………………………4
2.2 How to Adjust the Indoor Cycle…………………………………………4
CHAPTER 3: Basic Maintenance………………………………………………7
3.1 Common Product Questions……………………………………………7
3.2 Basic Maintenance………………………………………………………7
CHAPTER 4: Troubleshooting……………………………………………………9
4.1 Bottom Bracket Noise or Damage………………………………………9
4.2 Brake Pad Noise…………………………………………………………11
4.3 Chain Lubrication………………………………………………………11
4.4 Flywheel Hub Axle Replacement………………………………………12
4.5 Flywheel Hub Bearing Replacement…………………………………14

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CHAPTER 1: Serial Number Location
The serial number is located on the front stabilizer.

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CHAPTER 2: Indoor Cycle Operation
2.1 HOW TO MOVE THE INDOOR CYCLE
Due to the weight of the indoor cycle, it is recommended that two people move it. While one
person lifts the back of the indoor cycle, the second person firmly holds the handlebar and tips
the indoor cycle forward until it rolls on the wheels. Carefully move the indoor cycle to the
desired location and then lower it.
If the indoor cycle rocks on the floor after being set down, turn the leveling feet underneath the
front or rear stabilizer until the rocking motion is eliminated.
Location of the Indoor Cycle
Place the indoor cycle on a level surface. There should be 2 feet (60cm) of each side surround
the indoor cycle. Do not place the cycle in any area that will block any vent or air openings.
The indoor cycle should not be located in a garage, covered patio, near water nor outdoors.
Warning
To reduce the risk of injury, use extreme caution while moving the indoor cycle. Do not attempt
to move it over uneven surfaces and make sure there’s a safety space of 20 inch (minimum) to
the nearest equipment is recommended.
2.2 HOW TO ADJUST THE INDOOR CYCLE
The indoor cycle can be adjusted for maximum comfort and exercise effectiveness. The
instructions below describe one approach to adjust the indoor cycle to ensure optimal user
comfort and ideal body position. You may choose to adjust the indoor cycle differently.
Saddle adjustment
Proper saddle height helps ensure maximum exercise efficiency and comfort, while reducing
the risk of injury. Adjust the saddle height to make sure it’s in proper position, one that keeps a
slightly bent in your knee while your legs are in the extended position.

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Handlebar adjustment
Proper position for the handlebar is based primarily on comfort. Typically, the handlebar should
be positioned slightly higher than the saddle for beginning cyclists. Advanced cyclists could try
different heights to get the arrangement most suitable for you.
To adjust the saddle height:
Rotate the adjustment lever counter clockwise and adjust the saddle to a comfortable pedaling
position. Rotate the lever clockwise to lock the saddle position.
To adjust the saddle horizontal position:
Rotate the adjustment lever counter clockwise to slide the saddle forward or backward as
desired. Rotate the lever clockwise to lock saddle position. Test the saddle slide for proper
operation.
To adjust the handlebar height
Rotate the adjustment lever counter clockwise to adjust the handlebar height. Raise or lower
the handlebar to the desired height. Rotate the lever clockwise to lock the handlebar position.
To adjust the pedal straps
Place each foot ankle on the pedal and in the toe clip strap that the foot ankle is centered over
the pedal spindle (center of the pedal). Rotate one foot the arms reach and pull up on the tow
clip strap. Repeat for the other foot. Keep your knees over your feet as you pedal. To remove
your foot from the toe clip, loosen the strap and pull out.

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Tension control and Emergency lever
The preferred level of difficulty in pedaling (resistance) can be regulated in fine increments by
use of the tension control knob. To increase to resistance, turn the tension control knob
clockwise. To decrease the resistance, turn the knob counter clockwise.
Important:
To stop the flywheel while pedaling, push down on the red emergency brake lever.
The flywheel should quickly come to a complete stop.
Make sure your shoes are fixed into the toe clip.
Apply full resistance load when the bike is not in sue to prevent injuries due to moving
drive gear components.
Warning:
The indoor cycle does not have a free moving flywheel; the pedals will continue to move
together with the flywheel until the flywheel stops. Reducing speed in a controlled manner is
required. To stop the flywheel immediately, push down the red emergency brake lever. Always
pedal in a controlled manner and adjust your desired cadence according to your own ability.
Push the red lever down=emergency stop.
The indoor cycle uses a fixed flywheel that builds momentum and will keep the pedals turning
even after the user stops pedaling or the user’s feet slip off. Do not attempt to remove your feet
from the pedals or dismount the machine until both pedals and flywheel completely stop.
Failure to follow these instructions may lead to loss of control and the potential for serious
injuries.

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Chapter 3: Basic Maintenance
3.1 COMMON PRODUCT QUESTIONS
Are the sounds my indoor cycle makes normal?
Our indoor cycles are some of the quietest available because they use belt drives (GR5/6)
and chain drives (GR3) and cantilever brake resistance. We use the highest grade
bearings and chains/belts to minimize noise. However, since the resistance system itself
is so quiet, you will occasionally hear other slight mechanical noises. Unlike older, louder
technologies, there are no fans, friction belts, or alternator noises to mask these sounds
on our indoor cycle. These mechanical noises, which may or may not be intermittent, are
normal and are caused by the transfer of significant amounts of energy to a rapidly
spinning flywheel. All bearings, chains/belts and other rotating parts will generate some
noises which will transmit through the casing and frame. It is also normal for these
sounds to change slightly during a workout and over time because of thermal expansion
of the pars.
Why is the indoor cycle I had delivered louder noise than the one at the store?
All fitness products seem quieter in a large store showroom because there is generally
more background noise than in your home. Also, there will be less reverberation on a
carpeted concrete floor than on a wood overlay floor. Sometimes a heavy rubber mat will
help reduce reverberation through the floor. If a fitness product is placed close to wall,
there will be more reflected noise.
How long will the belt last?
The computer modeling we have done indicated virtually thousands of maintenance free
hours. You should not have to replace the belt as long as you have the indoor cycle.
Can I move the indoor cycle easily once it is assembled?
Your indoor cycle has a pair of transport wheels built into the front stabilizer tube. Please
follow the moving the indoor cycle section to transport your indoor cycle. It is important
that you place your indoor cycle in a comfortable and inviting room. Your indoor cycle is
designed to use minimum floor space. Many people will place their indoor cycle facing TV
or a picture window. If at all possible, avoid putting your indoor cycle in an unfinished
basement. To make exercise a desirable daily activity for you, the indoor cycle should be
in a comfortable setting.
3.2 BASIC MAINTENANCE
The safety level given by the design of the indoor cycle can only be maintained when the
equipment is regularly examined for damage and wear. Inoperable components should be
replaced or the equipment should be put out of use until it is repaired.

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DAILY
Wipe down the indoor cycle after each use to remove sweat and moisture. Use soap and
water, or a diluted non-abrasive domestic cleaner solution. Rinse to remove detergent
residue and then dry off.
Before each session, inspect for loose components such as pedals or cranks prior to
commencing the next use. Tighten up any loose parts.
WEEKLY
Check for proper flywheel alignment. Torque flywheel nuts as necessary.
Remove chain guard and check for loose chain. Adjust and lubricate the chain as
necessary.
Check to make sure the crank arms are tight to the bottom bracket.
Inspect all parts, nuts, bolts, or screws for adjustments, replacements or maintenance.
MONTHLY
Inspect the frame and main assembly components for rust or corrosion. Tilt the cycle or
place in an upside down position to locate areas where rust and corrosion may develop.
Use a small, wire brush to remove rust build-up in small crevasses, such as leveling feet,
quick release levers and other bolt assemblies.
Inspect all wear items for adjustments or possible part replacement. Give particular
attention to the following:
a. Inspect brake pad for wear. Excessive wear or dryness indicates replacement is
required.
b. Inspect seat pad for wear. Rips, tears or excessive movement indicates
replacement is required.
c. Inspect pedals for play. Excessive movement of pedals indicates replacement is
required.
Inspect the chain for tensioning by rotating the crank to drive the flywheel forward. Do
this motion in 1/4 turns to assess if there is free play between the crank and the flywheel.
Dryness or prolonged use may cause the height and reach adjustments for the seat and
handlebar to become tight. If this is the case, the sliding assembly should be removed
from the frame and have a smear of light duty grease applied along the sliding surface
before assembly. Similarly, apply some light grease to the clamping assembly to ensure it
does not seize up. Clean off excessive grease before reassembly.
Please lubricate the seat post, brake pad and handlebar adjustment regularly with
lubricant in your parts package.

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Chapter 4: Part Replacement
4.1 BOTTOM BRACKET NOISE OR DAMAGE
Symptom: Clicking noise or damage
Tools required: Combination Wrench; 15mm Socket Wrench; 6mm Allen Wrench; Slotted
Screwdriver; 14mm Socket Wrench.
Solution:
a. Counter clockwise disassemble the pedals (L&R) using a combination wrench, and
remove all bolts fastened outer chain guard, then take the outer chain guard
(Figures 1,2)
Figure 1 Figure 2
b. Remove two Flange nuts at both sides of the flywheel using a 15mm Socket wrench
(Figure 3)
Figure 3
c. Loosen the flywheel’s adjusting screw using an 6mm Allen Wrench, then pull out
the chain wheel. (Figure 4, 5)
Figure 4 Figure 5

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d. Take apart two crank caps using a Slotted Screwdriver, then remove the chain.
(Figure 6, 7)
Figure 6 Figure 7
e. Remove the crank bolt using a 14mm Socket Wrench, then remove the crank with a
crank remover. (Figure 6, 7)
Figure 6 Figure 7
f. Loosen the BB with a Socket Wrench and then take it out of the bike. (Figure 8,9)
Figure 8 Figure 9
g. Install a new BB and fasten it by a Socket Wrench. (Figure 10, 11)
Figure 10 Figure 11
h. Reverse the instruction to reassemble

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4.2 BRAKE PAD NOISE
Symptom: Squeaking noise from the brake pads
Tools required: Philips screwdriver and 8mm Combination Wrench.
Solution: Check to see if the brake is worn which may cause the noise. If so, replace a
pair of brake pads as follows.
a. Using a Philip Screwdriver and a Combination Wrench of 8mm to remove Allen Nus
and screws of the brake pads. (Figure 12,13)
Figure 12 Figure 13
b. Holding the tension control knob and take out the brake pad assembly
simultaneously. (Figure 14,15)
Figure 14 Figure 15
c. Replace a new brake pad assembly and put on all removed parts in a reverse way/
4.3 CHAIN LUBRICATION
Symptom: Chain squeaking noise
Tools required: Combination Wrench
Solution:
a. Remove the right pedal using a Combination Wrench, and remove all bolts fastened
at outer chain guard, then take out the outer chain guard. (Figure 16,17,18)
Figure 16 Figure 17 Figure 18

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b. Manually and slowly rotating the flywheel and apply lubricant on chain. (Figure 18)
Figure 18
c. Make sure the chain was lubricant evenly, then put on all removed parts in a
reverse way.
4.4 FLYWHEEL HUB AXLE REPLACEMENT
Symptom: Flywheel hub axle damaged or noise
Tools required: Combination Wrench; 15mm Socket Wrench; Philip Screwdriver
Solution:
a. Counter clockwise disassemble the right pedal using a Combination Wrench, and
remove all bolts fastened at the outer chain guard, then take out the chain guard.
( Figure 19,20,21)
Figure 19 Figure 20 Figure 21
b. Remove two flange nuts at both sides of the flywheel with a 15mm Socket Wrench.
(Figure 22)
Figure 22

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c. Loosen the flywheel’s adjusting screw using an 6mm Allen Wrench, then pull the
chain out of the chain wheel. (Figure 23,24)
Figure 23 Figure 24
d. Remove all screws fastened on the inner chain guard using a Philip Screwdriver,
and adjust it uprightly as the following picture. (Figure 25, 26)
Figure 25 Figure 26
e. Carefully move the flywheel out of the frame, and remove two nuts and two spacers
using a Combination Wrench. (Figure 27, 28, 29)
Figure 27 Figure 28 Figure 29
f. Use a hammer to slightly kick the hub axle out of the flywheel from the side without
the sprocket and take apart the axle. (Figure 30, 31)
Figure 30 Figure 31

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g. Install a new hub axle and put the bearing on. (Figure 32, 33)
Figure 32 Figure 33
h. Install spacer and Allen nuts. (Figure 34, 35) Please be aware that the spacer at the
side of sprocket is shorter than another one.
Figure 34 Figure 35
i. Put on all removed parts in a reverse way.
4.5 FLYWHEEL HUB BEARING REPLACEMENT
Symptom: Flywheel hub bearing damaged or noise
Tools required: Combination Wrench; 15mm Socket Wrench; Philip Screwdriver
Solution:
a. Repeat the steps mentioned in 3.4 a to f.
b. Kick another hub bearing out of the flywheel at another side with a hammer. (Figure
36)
Figure 36
c. Install a new bearing and slightly kick into the flywheel. (Figure 37, 38) Please use a
thick paper or bushing when using the hammer to prevent hurting the flywheel itself.

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Figure 37 Figure 38
d. Install the hub axle at another side of the flywheel with sprocket and put the bearing
on. (Figure 39, 40)
Figure 39 Figure 40
e. Install spacer and Allen nuts. (Figure 41, 42) Please be aware that the spacer at the
side of sprocket is shorter than another one.
Figure 41 Figure 42
f. Put on all removed parts in a reverse way.