LeMond Fitness RevMaster User manual

15540 Woodinville-Redmond Rd NE
Bldg A, Ste 100
Woodinville, WA 98072
[phone]
[phone] Fax
www.LeMondFitness.com
Service Guide
For the LeMond®RevMaster®
•Bid Specifications
•Warranty
•Exploded Diagrams
•Parts List
•Instructions
oInstallation Check List
oMaintance Schedule
oTech Notes
oBottom Bracket Adjustment
oBrake pad Lubrication
oBrake pad & Spring steel Replacement
oFlywheel Assembly
oTouch Up paint Kit

The first
American
to win the
Tour de
France
3 times.
The New LEMOND®RevMasterTM.
Group cycling will never be the same.
www.LeMondfitness.com
1-425-482-6773
Only one
group
exercise
cycle bears
his name.
© 2002 LeMond Fitness RevMaster and LeMond are registered trademarks of Greg LeMond
L1141.qxd 6/24/02 6:23 PM Page 1

LeMond®Fitness Inc.
15540 Woodinville-Redmond Rd.
Building A, Suite 100
[phone]
Fax: [phone]
www.LeMondfitness.com
LeMond®RevMaster™Indoor Cycling Bike
Bid Specifications
1. Built to deliver an amazing workout, the LeMond RevMaster was designed by eight-time national
champion cyclist Paul Swift with input from legendary cyclist Greg LeMond -the first American to
win the Tour de France. A cyclist who has won the world’s most challenging bike races, Greg
LeMond has also revolutionized the sport of cycling by introducing cutting edge technology that is
commonplace today.
2. Equipped with an exceptionally strong, Cr-Moly machined BMX bottom bracket (23.0 mm x 124.5
mm) and cast stainless steel cranks (170 mm) with chrome plating, the LeMond RevMaster is
designed to better withstand the high force loads (as compared to conventional group cycles) that
occur during “out of saddle” cycling, which is common during group cycling classes.
3. Features an ultra-strong, X-frame design that is extremely stable and allows fast and easy access to
all seat, handlebar, and height adjustments. Height and fore-aft adjustments are clearly marked and
easy to adjust. Exclusive to LeMond Fitness Inc., this design creates a comfortable and high
performance custom fit for every user.
4. Features a maintenance-free, 47-pound precision-machined, chrome flywheel for smooth pedaling.
5. Features uniquely shaped handlebars that are more comfortable due to the multiple hand positions
from which to choose.
6. Requires minimal maintenance due to:
•A non-slip belt-drive that is smoother and quieter than a chain, never needs oil, and has a longer
product life. The belt is accessible without removing the flywheel.
•A rotated handlebar and seat tube design that eliminates the need for a sleeve.
•Unique V-clamp pressure points that create complete stability without the need to replace parts.
7. The rock-solid construction of the extra wide, high-quality steel base, along with over-sized
support levelers that allow users to make adjustments for uneven floor surfaces, provides
outstanding stability.
8. Designed for ease of use, the resistance knob adjusts easily. By simply pressing down on the same
knob, the braking system quickly and safely activates. The resistance knob also allows users to
adjust (increase or decrease) the intensity of their workouts at any time during the exercise session.
9. Designed with the resistance pad on top of the flywheel for improved long-term durability.
10. Seat accessories are fast and easy to exchange for accommodating personal preferences. The
comfortable Velo™saddle is also fitted with an innovative fore and aft lever so the seat can be
positioned for maximum workout comfort and effectiveness.

RevMaster Bid Specifications Continued Page 2
11. Designed with extra large in-line skate wheels, the LeMond RevMaster bikes are easier to move
than other bikes that have casters. Note: Wheel brackets are welded to the frame.
12. Created by Joan Wenson –national and world SportAerobic Gold Medalist, racing cyclist,
renowned choreographer and certified personal trainer – and Greg LeMond, the new RevMaster
cycling program is easy to follow and keeps users motivated. With a choice of videotapes or
personal instruction, the RevMaster program combines the outstanding benefits of group cycling
with the fun and excitement of world-class racing.
13. Features a water bottle holder that is mounted to the handlebar, allowing users to take a drink
without disrupting their exercise form.
14. Carries a five-year warranty on the frame; a three-year warranty on the cranks, bottom bracket,
flywheel, handlebars, seat post, handlebar post; a one-year warranty on bottom bracket bearings,
pillow bearings, tension knob assembly, and a 90-day warranty on the wearable items (e.g., seat,
grips, pedals, and brake pad).
15. Features a 17-step manufacturing process on each frame that includes the following:
•Steel X-Frame is robotically welded to precise tolerances
•Steel X-Frame is degreased to remove lubricants left over from the manufacturing process
•Steel X-Frame is placed into an acid bath to remove the rust, scale, and impurities from the
surface of the steel.
•Steel X-Frame is then completely submerged in an ED treatment which applies a rust resistant
coating to the steel. This is an electro-deposited (ED) organic coating used by the automotive
industry to protect non-painted surfaces exposed to harsh environments.
•Finally, the steel X-Frame is finished with powder coating.
16. Specifications: Machine Height 38" (97 cm)
Machine Length 41.5" (105 cm)
Machine Width 22.25" (48 cm)
Weight 116 lbs. (53 kg)

LeMond®Fitness Inc.
15540 Woodinville-Redmond Rd.
Building A, Suite 100
[phone]
Fax: [phone]
www.LeMondfitness.com
LeMond®RevMaster™Indoor Cycling Bike
Bid Specifications (Summary)
Machine Height 38" (97 cm)
Machine Length 41.5" (105 cm)
Machine Width 22.25" (48 cm)
Weight 116 lbs. (53 kg)
Flywheel 47-lb precision-machined, chrome-plated flywheel
Machined stainless steel axle
Crank Set Cast stainless steel and chrome-plated cranks (170 mm)
Exceptionally strong, Cr-Moly machined BMX bottom bracket (23.0 mm
x 124.5 mm)
Bearing cups fit standard road bike frame –2 bearings per bearing cup –
4 total
Braking and Resistance Turn-knob design for tension; push down for braking
Leather resistance pad on top of flywheel for long-term durability
Leg Levelers Extra large diameter adjustable levelers
Pedals Standard toe cage style with optional dual sided (SPD/toe cage)
Handlebars Biomechanically correct with anatomical bend
Stainless steel, micro adjust up/down and fore/aft
Rubber grip
Unique V-clamp and rotated tube design for enhanced stability
Adjustment marks for up/down and fore/aft fit
Stainless steel post and tube
Water Bottle Cage Standard
Seat Post Stainless steel, micro adjust up/down
Dual position seat slider for fore/aft fit
Unique V-clamp and rotated tube design for enhanced stability
Adjustment marks for up/down and fore/aft fit
Stainless steel post and tube
Frame 17 step mfg process –electro deposit/powder coated
Ultra strong X-style design
Stainless steel components
Drive Belt Non-slip, Kevlar re-enforced automotive poly-v belt
Belt is accessible without removing the flywheel

Page 1of 1
LeMond®Fitness Inc.
15540 Woodinville-Redmond Rd
Building A, Suite 100
Woodinville, WA 98270
425-482-6773
Fax. [phone]
This is to certify that the LeMond®RevMaster™is warranted LeMond Fitness Inc., Inc. to be free of
all defects in materials and workmanship. This warranty does not apply to any defect caused by
negligence, misuse, accident, alteration, improper maintenance, or an “act of God.” This warranty is
nontransferable from the original owner.
The LeMond RevMaster carries a five-year frame warranty, a three-year warranty on cranks,
bottom bracket spindle, flywheel, handlebar, seat post, handlebar post, a one-year warranty on bottom
bracket bearings, pillow blocks, pillow block bearings, tension knob assembly, and a 90 day warranty
on wearable items, such as the seat, grip, pedals, handles, and brake pad. Contact our Technical Service
Department to report any problems. When calling, please be prepared to provide the following
information:
•Your name, customer number, shipping address, and telephone number
•The serial number of the inoperable bike
•The date(s) of purchase for the inoperable bike(s)
•Your billing address
This information will ensure that you are the only one ordering parts under your warranty
protection. If warranty replacement parts are shipped to you, you may be required to return the
inoperable part. To facilitate this process, the following policy has been established:
•Please call 425-482-6773 ext. 107 to receive a return goods authorization prior to shipment.
•LeMond Fitness, Inc. will incur all ground freight charges for warranty parts ordered for a bike that is less
than 45 days old.
•You are responsible for freight charges on warranty parts for bikes that are more than 45 days old.
You will not be responsible for the return shipment of the inoperable part
•Some inoperable warranty parts must be promptly returned to our Technical Service Department.
We will pay the shipping cost for the inoperable warranty parts. Detailed instructions are included
with each warranty replacement part.
LeMond Fitness, Inc. neither makes, assumes nor authorizes any representative or other
person to make or assume for us, any other warranty whatsoever, whether expressed or implied,
in connection with the sale, service, or shipment of our products. We reserve the right to make
changes and improvements in our products without incurring any obligation to similarly alter
products previously purchased. In order to maintain your product warranty and to ensure the safe
and efficient operation of your machine, only authorized replacement parts can be used. This
warranty is void if parts other than those provided by LeMond Fitness, Inc. are used.

Assy, Water Bottle Cage
1 x HNUL - 131A
Handlebar Post, STD
1 x 100
Assy, Tension
Knob
1 x 0270
Brass Washer
2 x 1005
Plug
2 x 024
V-Plunger
2 x 025
Assy, Brake Pad Holder
1 x 0220
Flywheel
1 x 040
Spline Shaft
1 x 052
Pillow Block
w/ Bearing
2 x H050
Front Base Assembly
(w/ wheels & levelers)
1 x 107AA
Washer
1 x 049C
Flywheel Pulley
1 x 015
Spacer
1 x 049A
LeMond® RevMaster®
Final Assembly
01-05-2005
Handle
4 x 1030
Assy, Handlebar
1 x 13906
(includes grip)
Crank Bolt
2 x 885
Pedals, Standard Pair
1 x VP-518-AT
 or
SPD Dual Sided Pair
1 x WPD96B Left Crank
1 x 0875-1 *Lock Ring
*Left Bearing Cup
Spindle
1 x 0881
Seat
1 x VL-3017
Seat Slider
1 x 020
Seat Post
1 x 101
Front Cover
1 x 059
Belt
1 x 6PK1160
Right Crank
1 x 0875
Pulley, Crank
(Rear Drive)
1 x 009 *Assy, bottom Bracket
1 x BB396
Includes:
 Right Bearing Cup w/ Bearings
 Left Bearing Cup w/ Bearings
 Lock Ring
(885)
(1030)
(024)
(025)
(Pedals)
Rear Base Assy.
(with levelers)
1 x 108AA
(0850)
Assy, Transport Wheel
(w/ bearings)
2 x H062
*Right Bearing Cup
Base Levelers
4 x 0850

Bearing, Belt Tensioner
2 x 6004ZZ
Spacer, Belt
Tensioner
1 x 2602
Shoulder Bolt
1 x M1245
Nut, Belt Tensioner
Square
1 x 41208
Bolt, Belt Tensioner
1 x M640
Washer, Slotted
1 x 049D
Screw, Hex Head
2 x 14099
*Cover
*Springs
*Detent Nut
*Acorn Nut
*Tension Knob/Rod *Assy, Tension Knob
1 x PN 0270
Includes:
 Tension Knob/Rod
 1 x PN 0276
 Cover
 1 x PN 0271
 Spring
 2 x PN 0273
 Detent Nut
 1 x PN 0275
 Acorn Nut
 1 x PN 0274
Tension Knob Assembly
   11-1-2004
Flywheel
1 x 040
(H050)
Screw, Pillow Block Bearing
4 x M635
Nut, Pillow Block Square
4 x 4600
Screw, Flywheel Shaft
3 x H616
Spacer, Flywheel
1 x 049A
Washer
1 x 049C
Assembly, Pillow Block
with Bearing
2 x H050
Flywheel Assembly
  12-10-2004
Pulley, Flywheel
(front drive)
*NOTE: This is press fit onto the flywheel shaft
1 x 015
Screw, Flywheel Shaft
1 x H616
Flywheel Shaft, Splined
1 x 052
Frame
Pulley, Crank (Rear Drive)
1 x 009
Bolt, Right Crank Pulley Mounting
5 x RCW-125
(885)
Right Crank
1 x 0875
*Right Bearing Cup
(2 bearings are pressed in cup)
Bottom Bracket Spindle
1 x 0881
*Assy, Bottom Bracket
1 x BB-396
Includes:
 Right Bearing Cup
 Left Bearing Cup
 Lock Ring
*Left Bearing Cup
(2 bearings are pressed in cup)
*Lock Ring
Crank Bolt
2 x 885 Left Crank
1 x 0875-1
Crank Assembly
  11-1-2004
Pedal, Pair, SPD Dual-sided
1 x WPD96B
 or
Pedal, Pair, Standard
1 x VP-518-AT
(Pedal)
Belt Tension
 12-10-2004

LeMond Fitness Inc. - 15540 WOODINVILLE-REDMOND RD NE SUITE A-100 WOODINVILLE, WA 98072
PARTS & SERVICE [phone] WWW.LEMONDFITNESS.COM FAX [phone]
REVMASTER - DEALER PARTS LIST
Item Number Item Description List Price
1030 ADJUSTMENT HANDLE, STANDARD $3.00
6004ZZ BEARING, BELT TENSIONER/FLYWHEEL $8.00
6PK1160A BELT, POLY-V $28.00
M855 BOLT, M8X55, CROSSARM, FLT HD SKT, SS $1.50
M640 BOLT, M6X45, BELT TENSIONER, RD HD SKT $0.75
M645 BOLT, M6X45, TRANSPORT WHEEL, SS $0.50
885 BOLT, M8X20, CRANK BOLT $1.50
RCW-125 BOLT, RT CRANK, PULLEY MOUNTING (COMPLETE SET OF 5 BOLTS) $4.50
M1245 BOLT, SHOULDER (FOR BELT TENSIONER BEARING) $5.50
BB396 BOTTOM BRACKET CUPS W/BEARINGS & LOCKRING $39.95
0220 BRAKE PAD HOLDER W/ LEATHER BRAKE PAD $22.00
11252 BRAKE PAD, LEATHER $4.50
0270 BRAKE TENSION KNOB ASSY (ALSO NEEDS 2 SCREWS #14099) $15.00
0276 BRAKE TENSION ROD W/KNOB $8.00
060 COVER, BACK $5.00
0271 COVER, BRAKE TENSION (ALSO NEEDS 2 SCREWS #14099) $5.00
059 COVER, FRONT (BELT COVER) $15.00
H059-1 COVER, FRONT, LIFE FITNESS LOGO $15.00
0875-1 CRANK ARM, LEFT, STD 170MM $49.00
0875 CRANK ARM, RIGHT, STD 170MM $79.00
107AA CROSSARM ASSY, FRONT (INCLUDES WHEELS & LEVELERS) $30.00
108AA CROSSARM ASSY, REAR (INCLUDES LEVELERS) $20.00
3M468A DECAL SET, SM & LG $15.00
059-1 DECAL, BELT COVER, LEMOND $2.00
059-1LF DECAL, BELT COVER, LIFE FITNESS $2.00
3M468C DECAL, FRAME, LIFE FITNESS $1.50
250 DECAL, WARNING $2.00
058A ENDCAP, SQUARE, CROSSARM $1.50
201-30N ENDCAP, SQUARE, HANDLEBAR & SEAT POST $0.50
103 FLYWHEEL ASSY (PRE-ASSEMBLED WITH SPLINE SHAFT, PILLOW BLOCKS W/BEARINGS, PULLEY) $289.00
052 FLYWHEEL SHAFT, SPLINED $24.00
VLG-041 GRIPS, HANDLEBAR, PAIR (OLD HANDLEBAR) $7.95
YL-100 GROMMET, WATER BOTTLE CAGE MOUNT (OLD HANDLEBAR) $0.50
160 HANDLEBAR (W/GRIP) (OLD HANDLEBAR) $80.00
100 HANDLEBAR POST, STANDARD $59.00
13906 HANDLEBAR, NEW LOOP (INCLUDES WATERBOTTLE CAGE/CLAMP) $109.00
0850 LEG LEVELERS $2.50
0274 NUT, BELT TENSION ROD, NYLON $1.50
41208 NUT, BELT TENSIONER, SQUARE $3.00
0275 NUT, DETENT, BRAKE TENSION ROD $1.50
6600 NUT, M6, TRANSPORT WHEEL/BRAKE PAD HOLDER $0.50
6800 NUT, M8, CROSSARM $0.75
4600 NUT, PILLOWBLOCK, SQUARE $0.50
11101 OWNER'S MANUAL, ENGLISH $5.00
11248 PEDAL STRAPS, PAIR $5.00
WPD96B1 PEDALS, LEMOND DUAL-SIDED, PAIR $89.00
VP-518-AT PEDALS, STANDARD, PAIR $19.00
H050 PILLOW BLOCK W/BEARING $24.00
13992 PILOT CADENCE METER $169.00
250215-1 PILOT CADENCE METER UPGRADE KIT (PILOT & LOOP HANDLEBAR) $258.00
13974 PILOT, ASSY, BACK CLAMP $10.00
14113 PILOT, ASSY, FRONT CLAMP $10.00
14115 PILOT, BATTERY COVER, CONSOLE $0.50
14133 PILOT, BATTERY COVER, TRANSMITTER $0.50
14120 PILOT, CLAMP KNOB $0.50
14146 PILOT, INSTRUCTION MANUAL $1.00
14145 PILOT, MAGNET $1.00
SE20208 PILOT, SCREW, M2.5x8L, CONSOLE BATTERY COVER $0.50
14138 PILOT, SCREW, M4x93L, CLAMP $0.50
14093 PILOT, SCREW, M5x12L, CLAMP ASSY $0.50
024 PLUG, FRAME (FOR ADJ. HANDLE) $7.00
009 PULLEY, CRANK ARM $49.00
015 PULLEY, FLYWHEEL $19.00

REVMASTER - PARTS LIST (CONTINUED)
Item Number Item Description List Price
T415 SCREW, BACK COVER $0.50
14099 SCREW, HEX-HEAD, NEW BRAKE COVER $0.50
14081 SCREW, M5X10, HEX SKT DRIVE, WATERBOTTLE CLAMP $0.50
14194 SCREW, M5X15, SKT HD CAP, WATERBOTTLE CLAMP $0.50
14095 SCREW, M6X6, HEX HEAD, SPRING STEEL-FRAME $0.50
H616 SCREW, M6X10, FLT HD SKT, FLYWHEEL SPLINE SHAFT $0.50
M610 SCREW, M6X10, RD HD SKT, BRAKE PAD HOLDER/FRONT COVER $0.50
H620 SCREW, M6X20, BRAKE PAD HOLDER/SPRING STEEL $0.50
M635 SCREW, M6X35, RD HD SKT, PILLOWBLOCK $1.00
14119 SEAT CLAMP $3.00
101 SEAT POST, STANDARD $59.00
020 SEAT SLIDER $14.95
VL-3017 SEAT, STANDARD $25.00
2602 SPACER, BELT TENSION BEARING $0.75
049A SPACER, FLYWHEEL $1.00
0881 SPINDLE, BOTTOM BRACKET $22.00
058 SPRING STEEL (2 USED PER BIKE - ALSO USE 2 SCREWS #14095 PER BIKE) $3.00
0273 SPRING, TENSION ROD $0.75
025 V-PLUNGER, FRAME $3.00
1005 WASHER, ADJUSTMENT HANDLE (BRASS) $1.00
049C WASHER, FRONT DRIVE PULLEY $0.75
049D WASHER, SLOTTED, FOR SHOULDER BOLT $2.50
HUL-131A WATERBOTTLE CAGE ASSY (OLD HANDLEBAR) $9.50
HNUL-131A WATERBOTTLE CAGE ASSY, NEW LOOP HANDLEBAR $9.50
CB-1427 WATERBOTTLE CAGE, PLASTIC (INCLUDES 2 SCREWS & WASHERS-NO CLAMP) $9.95
14068 WATERBOTTLE CLAMP W/ GROMMET (OLD HANDLEBAR) $7.00
13948 WATERBOTTLE CLAMP W/ GROMMET, NEW LOOP HANDLEBAR $7.00
H062 WHEEL, TRANSPORT (INCLUDES BEARINGS) $2.50
TOOLS
Item Number Item Description List Price
11227 KIT, HARDWARE, INSTALLATION (BLISTER PAK) $20.00
250204A KIT, SERVICE TOOLS (UNCLUDES ALL TOOLS BELOW & TOUCH-UP PAINT) $99.00
BBT-2 TOOL, BB CARTRIDGE $13.95
CCP-4 TOOL, CRANK PULLER $13.00
HCW5 TOOL, LOCK RING REMOVAL $16.95
LIFU-33F5 TOOL, PEDAL WRENCH $10.95
11225 TOOL, PULLER FOR FLYWHEEL PULLEY $68.00
250201 TOUCH-UP PAINT $8.50
ACCESSORIES
Item Number Item Description List Price
250062 CLOUD 9, HANDLEBAR AEROPAD $24.95
0875-1-175 CRANK ARM, LEFT, 175MM $55.00
0875-175 CRANK ARM, RIGHT, 175MM $85.00
250064 DVD, ASSEMBLY & MAINTENANCE $7.95
250212 DVD, CYCLING PROGRAMS (START-UP/INTERVAL/ENDURANCE) $60.00
250017 DVD, DEALER MARKETING/SERVICE TOOL KIT $14.95
11204 HANDLEBAR POST, EXTRA TALL $69.00
HRMONTRX HEARTRATE CHEST STRAP, CARDIOSPORT, ANALOG $34.95
250018 LEMOND BANNER, 18" X 60" $79.95
250019 LEMOND POSTER $7.95
250043 SEAT COVER, GEL $21.95
11203 SEAT POST, EXTRA TALL $69.00
250058 SERVICE GUIDE, REVMASTER $5.00
250208 VIDEO, 3 PK REVMASTER VIDEO KIT (VHS) $60.00

LeMond RevMasterAssembly Guide
Please follow these instructions in the steps listed to prevent possible damage to the bike.
It is recommended that you apply multipurpose grease to the pedal shaft threads and the
handle threads when assembling the bike.
Please contact the customer service department at 1-425-482-6773 ext. 107 or email
[email protected] if you have any questions or need help.Additional information
and exploded diagrams are also listed on our website at www.LeMondfitness.com.
REVIT UP!!!
STEP3
• Locate the handlebar post (it is flat on top,
with no groove).
• Insert the handlebar post into the handlebar post
tube. Note: If having difficulty inserting the
handlebar post, push the v-plunger back
into the tube to clear the pathway.
• Thread 1 handle into the stainless steel frame plug.
• Lift the handlebar post up to the desired height and
tightenhandle.
Caution: Do not overtighten handle
• Slide the handlebar on top of the handlebar post.
• Install 1 washer onto 1 handle and loosely thread
the handle through the handlebar post and into the
handlebar assembly.
• Position the handlebar assembly where desired and
tightenhandle.
• Locate the water bottle cage. Use the 3-mm hex key
to remove the screw from the water bottle clamp on
the handle bar assembly.
• Position the water bottle cage in front of the clamp
and insert the screw through the water bottle cage
and into the clamp. Tighten the screw.
STEP4
• Locate the seat post (it has a groove on top).
• Insert the seat post into the seat post tube.
Note: If having difficulty inserting the seat post,
push the v-plunger back into the tube to clear the
pathway.
• Thread 1 handle into the stainless steel frame plug.
• Lift the seat post up to desired height and tighten handle.
Caution: Do not overtighten handle
• Slide the seat with seat slider into the seat post groove.
• Install 1 washer onto 1 handle and loosely thread the handle
into the first hole of the stainless steel seat slider.
Note: Use the second hole in the seat slider to
position yourself closer to the handlebar
• Position the seat where desired and tighten handle.
Washer
Handle
Seatw/SeatSlider
Handle
Seat Post
4
STEP5
• Locate the right pedal (“R” is stamped on the end of the spindle).
• Apply multipurpose grease to the pedal threads.
• Using your fingers, thread the pedal into the right crank arm (the side
with the belt cover) clockwise.
• Use the 15-mm pedal wrench to tighten the pedal onto thecrank arm.
• Locate the left pedal (“L” is stamped on the end of the spindle)
• Apply multipurpose grease to the pedal threads.
• Using your fingers, thread the pedal into the left crank arm (the side
with out the belt) counterclockwise.
Note: The left pedal is reverse threaded - take care not to
cross thread the crank arm!
• Use the 15-mm pedal wrench to tighten the pedal onto thecrank arm.
Note: After the first 5 hours of use, inspect the pedals and
retighten if necessary.
5
LeftPedal
RightPedal
© 2004. LeMond Fitness Inc.All rights reserved.
STEP1
• Locate the rear base assembly (it does not
have any wheels attached).
• Position the rear base assembly under the rear
frame and align the 2 holes.
• Insert 1 bolt (M8) into each hole.
• Thread 1 nut (M8) onto each bolt and use the
5-mm hex key and multi-tool wrench to
tighten the bolts and secure the rear base
assembly to the frame.
M8 Bolts
M8 Nuts
1
STEP2
• Locate the front base assembly (it has 2 wheels
attached).
• Position the front base assembly (with wheels pointing
out and up) under the front forks and align the 2 holes.
• Insert 1 bolt (M8) into each hole.
• Thread 1 nut (M8) onto each bolt and use the 5-mm
hex key and the multi-tool wrench to tighten the bolts
and secure the front base assembly to the frame.
• Pull the plastic bag off the stainless steel brake pad
holder located above the flywheel.
M8 Bolts
M8 Nuts
2
Handlebarpost
Handlebar
Washer
Handle
Water Bottle Cage
Screw
Handle
3

Page 1of 4
©2003LeMond®Fitness Inc. LeMond, RevMaster, and LeMond Fitness Inc. are registered trademarks.
LeMond®Fitness Inc.
15540 Woodinville-Redmond Rd.
Building A, Suite 100
[phone]
Fax: [phone]
www.LeMondfitness.com
Installation Check List
For the LeMond RevMaster
A. Properly align the base bolts through the yellow frame and cross arms
1. Align the 2holes in the cross arm with the 2 holes in the frame. Insert a base bolt
into the top of each hole in the frame and push the bolt through the cross arm(do not
force the bolt through). Finger-thread a nut onto each of the base bolts,and use the
5 mm hex key and the wrench tool to secure the nut. Once all 4 base bolts are
installed,test the bike to make sure that the frame is stable.
Note: the base bolt sits into a counter sink in the yellow frame
B. Do not cross thread the pedal arms –a cross-threaded crank arm is not a
manufacturing defect, since cross threading can only occur during the
installation of the pedals, and the bikes ship without the pedals attached.
2. Right Pedal:
The right pedal has a normal thread pattern (turn
right to tighten, turn left to loosen). Use your
fingers to start the pedal, so that you can feel if
you start to cross thread the crank arm. Tighten
the pedal with a pedal wrench.
Correct Incorrect –note the bent base
bolt. This is caused by improper
installation
TIGHTEN

Page 2of 4
©2003LeMond®Fitness Inc. LeMond, RevMaster, and LeMond Fitness Inc. are registered trademarks.
3. Left Pedal:
The left pedal has a reverse thread pattern (turn
left to tighten, turn right to loosen). Use your fingers
to start the pedal, so that you can feel if you start to
cross thread the crank arm. Tighten the pedal with a
pedal wrench.
B. Do not switch the seat post and handlebar post
4. The handlebar post is the post that has a smooth finish on top. Insert the handlebar
post into the handlebar tube. Loosely thread a handle without a washer into the main
frame. Raise the handlebar post to the desired height and tighten the handle to
secure the handlebar post.
5. The seat post is the post that has a rough finish on top. Insert the seat post into the
seat post tube. Loosely thread a handle without a washer into the main frame.
Raise the seat post to the desired height and tighten the handle to secure the seat
post.
6. The handles are spring loaded. Once tightened, ensure that the handle does not
stick out to the side from the main frame. Pull down on the handle and rotate it such
that it does not stick out. Release the handle and lock it into place.
Note: If the seat/handlebar post does not insert all the way into the frame tube,
use your fingers in the frame tube to push the v-plunger out of the way.
C. Ensure that the water bottle cage is secured to the handlebar
7. Position the handlebar over the handlebar post.
Loosely thread a handle with a washer through the
handlebar post into the handlebar. Slide the
handlebar to the desired position and tighten the
handle.
8. Secure the water bottle cage to the water bottle cage
mount with the 3-mm screw.
Handlebar Post
Seat Post
TIGHTEN

Page 3of 4
©2003LeMond®Fitness Inc. LeMond, RevMaster, and LeMond Fitness Inc. are registered trademarks.
D. Ensure that there is a brass washer on the seat handle and handlebar handle
9. Position the seat with seat slider over the seat post. Loosely thread a handle with a
washer through the seat post into the seat slider. Slide the seat to the desired
position and tighten the handle.
10. Position the handlebar over the handlebar post. Loosely thread a handle with a
washer through the handlebar post into the handlebar. Slide the seat to the desired
position and tighten the handle.
BRASS WASHER
BRASS WASHER

LeMond®RevMaster®Recommended Maintenance Schedule
PAR
T
RECOMMENDED ACTION FREQUENCY CLEANE
R
LUBRICANT
Pedals Ensure that the pedals are tight
in crank arms; that all screws on
pedals are tight; and that the
pedal straps are not frayed
Before each use N/A N/A
Frame Wipe down Daily Soap & water; or,
diluted non-
abrasive cleaning
solution
N/A
Flywheel Wipe down Weekly WD-40® spray.
Spray on rag & apply
light coat to sides of
flywheel.
N/A
Crank
Bolts Inspect for loosness Weekly N/A *If loose, remove bolt,
apply Locktite®242 on
bolt threads and
reinstall. Tighten to 30
Ft/lbs
Brake Pad Inspect for excessive wear or a
dry leather brake pad Weekly N/A 3-IN-One®Oil or 10W
oil *Do not use
silicone-based
lubricants
Belt Inspect for correct tension;
replace cracked, frayed, or
otherwise non-uniform belt
Monthly N/A N/A
Bottom
Bracket Inspect for side-to-side play in
spindle, and a grinding feeling in
crank area when pedaling. If
necessary, replace bottom
bracket bearings (see
instructions on maintenance
dvd).
Monthly N/A N/A
Handles Lubricate threads Monthly N/A Multi-purpose Grease
Belt
Tensioner
Screw
Lubricate around base of screw Monthly N/A Multi-purpose Grease
*Note: Use of lubricants or cleaning solutions other than those so specified will result
in diminished performance and a shorter life span for that part.

LeMond®Fitness Inc.
17820 Woodinville-Redmond Rd.
Building B, Suite 888
Woodinville, WA
[phone] ext. 103
Fax: [phone]
Tech Service Notes
I. General Assembly
A. Installation -
Assembly tools included with bike:
Multi-tool wrench
Used for: pedals and the cross arm mounting nuts
3-mm Hex key
Used for: H2O bottle mounting screw (mounts the cage to the handlebar
clamp)
4-mm Hex key
Used for: right cover screws, tension knob cover screws, brake pad screws
5-mm Hex key
Used for: cross arm mounting bolts
Other tools/lubricant recommended
5/8” Pedal wrench - easier to set up multiple bikes quickly with lower risk
of cross-threading the cranks.
Grease – for use on the belt tension screw and handle threads.
T-handle 3mm – easier to use
Longer 5mm hex key – easier to hold and get more leverage on the cross
arm bolt
2 X 14-mm wrench – for seat tilt adjustment
1. Open the box –
Remove the staples from the bottom of box, lift box up, and remove components
2. Bases – front has wheels that point out when properly oriented.
Show the mounting bolts and nuts, and the tools used to attach the mounting bolts and
nuts
MPatzer Page 1 7/8/2002

3. Handlebar post – insert
V-Plunger may need to be pushed back in pocket (show and explain)
Smooth finish on top face - faces forward - no slot in top
Handlebar Post Seat Post
Adjustment handle and grease
4. Handle bars – install
1 washer and adjustment handle and grease
5. H20 bottle cage – install
Point out 3-mm tool, positioning
6. Seat post – insert
V-Plunger may need to be pushed back in pocket (show and explain)
Textured finish on top face - Faces rear - Slot in top
Keeps seat and seat slider from twisting
Adjustment handle and grease
7. Saddle – install and check level
Adjustment handle, washer and grease
8. Pedals – install
Note the dual sided upgrade option for clip less pedals that may
Labeled left and right
Left side reverse threaded
Toe strap
II. Service
Tools/Lubricant/Glue Required:
Cover Removal:
4-mm hex key – right cover screws (Qty – 4)
Philips Screwdriver – left cover screws (Qty – 2)
Belt Removal:
4-mm hex key – belt tensioner screw
Adjustable Wrench – idler bolt
Belt tension gauge
Torque wrench – for idler bolt
Multi-purpose grease – for belt tensioner screw
MPatzer Page 2 7/8/2002

Bottom Bracket Removal/Adjustment:
8-mm hex key – crank bolts
Crank Puller
Lock Ring Wrench –lock ring on left bearing cup
Bottom Bracket Socket (Shimano®-compatible cartridge style) + ½” drive
Locktite®242 (United States) or Locktite®243 (International) – Medium strength
(blue)
Rubber Mallet/ Dead-blow hammer – used to check for spindle radial end play
Torque wrench – for crank bolts, right bearing cup, & lock ring
Flywheel Assembly:
4-mm hex key – flywheel pulley mounting screw
5-mm hex key - pillow block bearing mounting bolt
*Flywheel pulley puller – flywheel pulley
Custom-made tool – the pulley is pressed onto the spline shaft
*Flat base pry bar/lever – pillow block bearing
MPatzer Page 3 7/8/2002

Necessary only if the pillow block housing pulls off the bearing during
removal and leaves the bearing stuck on the spline shaft
Block of wood/metal – use to tap the pillow block bearings onto the spline
shaft.
Brake Pad Assembly
4-mm hex key – brake pad mounting screws, brake pad holder mounting screw
10-mm box end wrench – brake pad mounting nut
Grips
Carpet knife
Hair spray
Tension knob assembly
Metal round file – older frames may need to be de-burred to allow clearance for
the new tension knob assembly to drop down into the frame.
Instructions:
Brake Pad Replacement
1. Remove the brake pad holder from the spring steel using a 4-mm hex
key and a 10-mm box end wrench.
2. Use a 4-mm hex key to remove each screw at both ends of the brake
pad holder.
3. Pull the old brake pad and foam away from the brake pad holder.
4. Scrap any remaining foam tape off of the brake pad holder.
5. Remove the protective backing from the foam tape on the new brake
pad and align the two holes in the brake pad with the holes in the brake
pad holder (The hole closest to the end of the leather pad faces toward
the front wheels of the bike). Press the foam tape firmly against the
groove in the brake pad holder along the length of the entire brake pad.
6. Insert and evenly tension the two screws that hold the new brake pad
in place. The tapered head screw is mounted closest to the spring steel.
7. Re-attach the brake pad holder to the spring steel.
8. Make sure that the new pad is properly lubricated and broken in.
Cover Removal
1. Use the 4-mm hex keys to remove the four cover screws on the right
cover.
2. Use the Philips screwdriver to remove the two screws on the left side
cover.
3. Rotate the right crank up and slide the cover off the right crank.
4. Rotate the left crank up and slide the left cover off the left crank.
MPatzer Page 4 7/8/2002

Bottom Bracket Removal
1. Remove the right cover and belt.
2. Use an 8-mm hex key to remove the left crank bolt.
3. Remove the left crank with a crank puller.
4. Use a lock ring tool to loosen and then remove the bottom bracket lock
ring.
5. Use a 4-mm hex key to loosen the belt tension adjustment screw.
6. Use an adjustable wrench to loosen the belt tensioner (idler pulley)
bolt. Slide the belt tensioner bearings up.
7. Remove the drive belt.
8. Use an 8-mm hex key to remove the right crank bolt.
9. Remove the right crank with a crank puller.
10. Use a bottom bracket removal tool to remove the left bearing cup.
MPatzer Page 5 7/8/2002