LeMond Revolution User manual

SERVICE MANUAL

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LeMond Revolution LLC
Minneapolis, MN USA
Telephone [phone]
Fax: [phone]
Visit our web site at
© 2013 LeMond Revolution LLC
LeMond and Revolution are registered trademarks.
Document #300154 Rev. A
www.LeMondRevolution.com

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SAFETY INSTRUCTIONS .................................................................... 5
ASSEMBLY INSTRUCTIONS ................................................................. 6
BICYCLE MOUNTING INSTRUCTIONS ....................................................... 9
CASSETTE AND CASSETTE ADAPTOR ...................................................... 12
BELT REMOVAL AND TENSIONING ......................................................... 15
PULLEY REMOVAL AND FLANGE REPLACEMENT............................................ 17
FLYWHEEL REMOVAL....................................................................... 21
TABLE OF CONTENTS

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!
THIS SYMBOL AND/OR THE WORD “WARNING” IN BOLD INDICATE A POTENTIAL
FOR PROPERTY DAMAGE OR PERSONAL INJURY. TAKE NOTE OF IMPORTANT OPER
ATING, SERVICING OR MAINTENANCE INSTRUCTIONS
READ ALL INSTRUCTIONS BEFORE WORKING ON THIS EQUIPMENT
This service manual should be used in conjunction with the Revolution Owner’s Manual (Docu-t
ment #250128).
All warnings and instructions contained in the Revolution Owner’s Manual should be read andt
understood prior to working on this equipment.
If you are unsure about your ability to perform any procedures in this manual please contact thet
LeMond Service Department (612.486.5750) for more information.
The safety level of this equipment can only be maintained if all instructions in this manual are fol-t
lowed precisely.
IMPORTANT SAFETY INSTRUCTIONS

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Before leaving the manufacturing facility, your LeMond REVOLUTIONbike trainer was thoroughlyinspected.
Your LeMond REVOLUTION should arrive packed in 1 carton. Upon arrival fully inspect the carton for
damage. If damage is found please contact the delivery company and the LeMond Customer Service
Department at [phone] to report any damage.
UNPACKING
Remove all components and parts from the packaging andcheck them against the listbelow and Figure 1.1.
The following items are included with your LeMond REVOLUTION bike trainer:
FIGURE 1.1
Trainer Body Assembly
M8 x 60
5mm Hex Key
Trainer Base Assembly
Skewer Assembly
Trainer Body Assemblyt
Trainer Base Assemblyt
One (1) long button head M8 by 60mm screwt
Skewer Assemblyt
5mm Allen key for assemblyt
Quick-Start Guidet
Owner’s Manualt
ASSEMBLY INSTRUCTIONS

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ASSEMBLY INSTRUCTIONS
ASSEMBLY
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WARNING: THE BODY ASSEMBLY WEIGHS 28LBS (12.7 KG). USE CAUTION WHEN HANDLING
THE BODY ASSEMBLY AND BE SURE TO SUPPORT THE ASSEMBLY PROPERLY WHILE INSTALLING
THE BASE ASSEMBLY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PROPERTY
DAMAGE OR INJURY.
Note: Ensure that you have all the parts listed and illustrated above prior to beginning assembly.
Place the body assembly fan-side down on the edge of a table with the belt wheel away from you1.
and the black shipping base overhanging the edge of the table. (Figure 1.2)
Note: The fan shroud should hang 1-2 inches over the table edge to allow full installation of the base.
Remove the shipping base and set two of the screws aside for use in the next step. Discard the2.
shipping base and the remaining screw. (Figure 1.2)
60mm
15 mm
FIGURE 1.2

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ASSEMBLY INSTRUCTIONS
Install the base assembly to the body assembly using the included 60mm screw and two 15mm3. screws removed from the shipping base. (Figure 1.2)
Begin by starting the longer (60mm) screw through the center arm of the base assembly into thet
body assembly. Do not fully tighten to allow the other two screws to thread in easily.
Next, install the two shorter (15mm) screws into the recessed holes near the center foot.t
Tighten all three screws.t
Insert the skewer into the body assembly from the fan side and thread the acorn nut onto the4. skewer on the cassette side. (Figure 1.3) Do not fully thread the acorn nut in place to allow for bike
mounting.
Note: Ensure the spacer is installed on the fan side of the unit and that both springs are present on the skewer
as shown in Figure 1.3.
P
5. stability. (Figure 1.4)
Note: Handle the unit by lifting from the base assembly, NOT the fan cover or the belt wheel.
!
WARNING: IF THE LEVELING FEET ARE NOT SET PROPERLY IT CAN RESULT IN AN UNSTABLE
BASE FOR THE UNIT AND LEAD TO PROPERTY DAMAGE OR RIDER INJURY.
ASSEMBLY INSTRUCTIONS
FIGURE 1.3
FIGURE 1.4

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BICYCLE MOUNTING INSTRUCTIONS
MOUNTING YOUR BICYCLE TO THE LEMOND REVOLUTION
Note: The LeMond REVOLUTION is shipped from the factory equipped with a Shimano®/SRAM® compatible
10-speed cassette. If your bike is equipped with a 9-speed Shimano®/SRAM® derailleur or Campagno-
lo® derailleur please follow the instructions on page 12 to change cassettes and/or cassette adapters.
If you are unsure about the type of derailleur installed on your bike please consult the documentation
for your bicycle or visit your local bike specialist to ensure proper compatibility with the REVOLUTION.
Shift the chain on your bicycle to the smallest sprocket on the rear cassette.1.
Open the rear brake calipers on your bicycle and remove the rear wheel.2.
!
WARNING: CONSULT THE MANUFACTURER’S DOCUMENTATION FOR YOUR BICYCLE ORYOUR
LOCAL BIKE SPECIALIST IF YOU ARE UNSURE ABOUT THE CORRECT PROCEDURE FOR REMOV-
ING THE REAR WHEEL OFYOUR BICYCLE.
Loosen the quick-release axle on the3. REVOLUTION and locate the axle spacer on the fan side of the
axle. Be sure to position the spacer properly based on the type of bicycle you are using. (See Figure 2.1)
With the rear wheel removed guide the rear of your bicycle over top of the4. REVOLUTION and ensure
that the chain rests on the smallest sprocket of the cassette on the REVOLUTION and the bicycle chain
stays rest on the axle of the REVOLUTION. (Figure 2.2)
Road Bike/ Time Trial Bike Mountain Bike
Spacer Outside
Frame
Spacer Inside
Frame
Note: If you are using a time trial
bike with the REVOLUTION
you will need to remove the
skewer completely to install
your bike.
FIGURE 2.1
Chain on Smallest
Sprocket
Chainstays Resting
on Axle
FIGURE 2.2

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With the chain resting on the smallest sprocket and the chain stays resting on the5. REVOLUTION axle,
press down gently on the bicycle seat and roll the bicycle forward. As the bicycle rolls forward it will
drop about an inch as the dropouts seat onto the axle. (Figure 2.3)
C
6. seated squarely in the dropouts. Both the left and right dropouts should be in contact with the axle
of the REVOLUTION.
Note: Before securing the quick release axle ensure that the bicycle is squarely seated onto the REVOLUTION
by lightly pushing the seat from side to side. If the dropouts do not shift on the axle then the bicycle is
secure and the axle can be tightened. If the bicycle seems unstable return to step 4 above and repeat
the process.
Roll Bike Forward
FIGURE 2.3
BICYCLE MOUNTING INSTRUCTIONS