Nautilus Schwinn 450 User manual

1
Important Safety Instructions - Before servicing or using this equipment, obey the following warnings:
This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and understand all Warnings on this machine.
004-4738-121511.A
Service manual
• Read and understand the Service Manual before working on the machine. Failure to obey the instructions and safety warnings could cause injury to the service technician or by-
standers. • Keep bystanders and children away from the product being serviced at all times. • Make sure that the repair is done in an appropriate work space away from foot trafc
and exposure to bystanders. • ! Disconnect all power and allow to sit for 5 minutes before you service this machine. • Some components of the equipment can be
heavy or awkward. Enlist the service of a second person when you do maintenance steps involving these components. Do not try to do heavy or awkward steps on your own. • Use
only replacement parts and hardware that are supplied or approved by Nautilus. Failure to use Nautilus-approved replacement parts can adversely affect the safety and functionality
of the equipment creating a risk to users. • Be sure that all warning stickers and instructional placards applied to the product stay present and in good condition when doing main-
tenance or replacing components. If necessary request replacement warning stickers or placards from Nautilus® customer service. • Do not try to change the design or functionality
of the machine being serviced as this can adversely effect user safety. • Do not use the machine until all shrouds, instructions, warning labels and correct functionality have been
verified and tested for correct performance.
Nautilus, Inc., (800) NAUTILUS / [phone], www.NautilusInc.com - Customer Service: North America [phone], [e-mail] | outside U.S. +01-360-859-5180, [email protected] | © 2011 Nautilus, Inc.,
All rights reserved. ™ and ® indicate a trademark or registered trademark. Nautilus, Inc. (www.NautilusInc.com) trademarks include NAUTILUS®, BOWFLEX®, SCHWINN® and UNIVERSAL® and respective logos. Other trademarks are
the property of their respective owners.
Serial Number
AAAAAAA Nautilus® part number (SKU)
BBB Vendor Code
PPPPPP Purchase Order Number
LL Purchase Order Line Number
CCCCCC Unique Identier
Schwinn® 450 Elliptical Fitness Machine
Important Safety Instructions 1
Specifications 1
Maintenance 2
Maintenance Parts 3
Troubleshooting 4
Console Setup Mode 5
Replacing the Console Assembly 6
Replacing the Static Handlebar Assembly 7
Removing the Upper and Lower Handlebar Arms 8
Replacing the Pedals and Legs 9
•
•
•
•
•
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300lbs. (136kg).
Keep children away.
Prior to use, read and understand the
Owners Manual.
Injury or death is possible if Caution is not
used while using this machine.
The maximum user weight for this
machine is 300 lbs (136 Kg).
Replace any “Caution” “Warning” or
“Danger” label that is illegible, damaged,
or removed.
This machine is for home use only.
•
•
•
•
•
•
Maximum User Weight: 300 lbs. (136 kg)
Power Requirements:
Operational Voltage: Operational Voltage 9VDC
Operating Current: 1500 mA
Regulatory Approvals:
AC Power Adapter: UL listed, CSA certied (or equivalent),
Rated 120V 60Hz Input, 9VDC, 1500mA
Output. Class 2 or LPS.
AAAAAAABBBPPPPPPLLCCCCCC
Replacing the Front Stabilizer 10
Replacing the Rail Assembly 11
Removing the Shrouds 13
Replacing the Tensioner Assembly 14
Replacing the Flywheel, Drive Belt and Drive Pulley 15
Replacing the Servo Motor 16
Adjusting the Servo Motor 18
Replacing the Brake Assembly 19
Replacing the Speed Sensor Assembly 21
Replacing the Power Inlet Assembly 22
This product, its packaging, and components contain chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. This Notice is provided in
accordance with California’s Proposition 65. If you would like additional information, please refer to our Web site at www.nautilus.com/prop65.

2
Serial Number
AAAAAAA Nautilus® part number (SKU)
BBB Vendor Code
PPPPPP Purchase Order Number
LL Purchase Order Line Number
CCCCCC Unique Identier
Maintenance
! To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the machine and wait 5
minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
Read all maintenance instructions fully before you start any repair work. In some conditions, an assistant is necessary to do the necessary tasks.
Equipment must be regularly examined for damage and repairs. The owner is responsible to make sure that regular maintenance is done. Worn or damaged components
must be replaced immediately or the equipment removed from service until the repair is made. Only manufacturer supplied components can be used to maintain and repair
the equipment.
Daily: Before each use, examine the exercise machine for loose, broken, damaged, or worn parts. Do not use if found in this condition. Repair or replace
all parts at the rst sign of wear or damage. After each workout, use a damp cloth to wipe your machine and Console free of sweat.
Note: Avoid excessive moisture on the Console.
Weekly: Check for smooth roller operation. Wipe the machine to remove dust, dirt, or grime. Clean the rails and surface of the rollers with a damp cloth.
Note: Do not use petroleum based products.
Monthly
or after 20 hours:
Make sure all bolts and screws are tight. Tighten as necessary.
NOTICE: Do not clean with a petroleum based solvent or an automotive cleaner. Be sure to keep the Console free of moisture.

3
A Console N Roller AA Transport Roller
B Handlebar,Static O Transport Handle BB Handlebar Arm, Lower Left
C Arm Pivot Rod P Leveler CC Handlebar Arm, Upper Left
DConsole Mast QRail Assembly DD Console Cable, Lower
E Shroud, Right R Incline Assembly EE Console Cable, Upper
F Crank Assembly, Right S Leg, Left FF Speed Sensor Magnet
GHandlebar Arm, Upper Right T Pedal, Left GG Speed Sensor
H Handlebar Arm Adjustment
Knob
U Pedal Arm, Left HH Pulley
I Pedal, Right V Crank Assembly, Left II Drive Belt
JPedal Arm, Right W AC Power Connector JJ Fly Wheel
KHandlebar Arm, Lower Right X Shroud, Left KK Brake Assembly
L Pedal Plate YStorage Bin LL Servo Motor
M Leg, Right ZFront Stabilizer
FF
A
CD
B
F
E
Q
Y
X
K
N
M
L
JI
H
G
H
CC
BB
Z
R
AA
P
PO
W
L
N
S
T
U
GG HH
II
JJ
KK
LL
V
DD EE
Maintenance Parts

4
Troubleshooting
Condition/Problem Things to Check Solution
No display/partial display/unit will
not turn on
Check electrical (wall) outlet Make sure unit is plugged into a functioning wall outlet.
Check connection at front of unit Connection should be secure and undamaged. Replace adapter or connection at unit if
either are damaged.
Check data cable integrity All wires in cable should be intact. If any are visibly crimped or cut, replace cable.
Check data cable
connections/orientation
Be sure cable is connected securely and oriented properly. Small latch on connector
should line up and snap into place.
Check console display for damage Check for visual sign that console display is cracked or otherwise damaged. Replace
Console if damaged.
Console Display If Console only has partial display and all connections are ne, replace the Console.
If the above steps do not resolve the problem, contact Customer Care for further
assistance.
Unit operates but Contact HR not
displayed
HR cable connection at Console Be sure cable is connected securely to
Console.
HR cable box connection Be sure cables from handlebars and cable to Console are secure and undamaged.
Sensor grip Be sure hands are centered on HR sensors. Hands must be kept still with relatively
equal pressure applied to each side.
Dry or calloused hands Sensors may have difculty with dried out or calloused hands. A conductive electrode
cream such as “Signa Crème” or “Buh-Bump” can help make better conduct. These
are available on the web or at medical or some larger tness stores.
Static Handlebar If tests reveal no other issues, Static Handlebar should be replaced.
Unit operates but Telemetric HR not
displayed
Chest Strap (optional) Strap should be “POLAR®” compatible and uncoded. Make sure strap is directly
against skin and contact area is wet.
Interference Try moving unit away from sources of interference (TV, Microwave, etc).
Replace Chest Strap If interference is eliminated and HR does not function, replace strap.
Replace Console If HR still does not function, replace Console.
Console displays “E2” error code Check data cable integrity All wires in cable should be intact. If any are cut or crimped, replace cable.
Check data cable
connections/orientation
Be sure cable is connected securely and oriented properly. Small latch on connector
should line up and snap into place.
Reset Console Unplug and plug in the machine for 10 seconds ten times
Console Electronics If tests reveal no other issues, Console
should be replaced.
No speed/RPM reading, Console
displays “Please Stride” error code
Check data cable integrity All wires in cable should be intact. If any
are cut or crimped, replace cable.
Check data cable
connections/orientation
Be sure cable is connected securely and oriented properly. Small latch on connector
should line up and snap into place.
Check magnet position (requires
shroud removal)
Magnet should be in place on pulley.
Check Speed Sensor (requires
shroud removal)
Speed sensor should be aligned with magnet and connected to data cable. Realign
sensor if necessary. Replace if there is any damage to the sensor or the connecting
wire.
Console shuts off (enters sleep
mode) while in use
Check electrical (wall) outlet Make sure unit is plugged into a functioning wall outlet.
Check connection at front of unit Connection should be secure and undamaged. Replace adapter or connection at unit if
either are damaged.
Check data cable integrity All wires in the cable should be intact. If any are cut or crimped, replace cable.
Check data cable
connections/orientation
Be sure cable is connected securely and oriented properly. Small latch on connector
should line up and snap into place.
Reset machine Unplug unit from electrical outlet for 3 minutes. Reconnect to outlet.
Check magnet position (requires
shroud removal)
Magnet should be in place on pulley.
Check Speed Sensor Contact Customer Care for further assistance.
A Console N Roller AA Transport Roller
B Handlebar,Static O Transport Handle BB Handlebar Arm, Lower Left
C Arm Pivot Rod P Leveler CC Handlebar Arm, Upper Left
DConsole Mast QRail Assembly DD Console Cable, Lower
E Shroud, Right R Incline Assembly EE Console Cable, Upper
F Crank Assembly, Right S Leg, Left FF Speed Sensor Magnet
GHandlebar Arm, Upper Right T Pedal, Left GG Speed Sensor
H Handlebar Arm Adjustment
Knob
U Pedal Arm, Left HH Pulley
I Pedal, Right V Crank Assembly, Left II Drive Belt
JPedal Arm, Right W AC Power Connector JJ Fly Wheel
KHandlebar Arm, Lower Right X Shroud, Left KK Brake Assembly
L Pedal Plate YStorage Bin LL Servo Motor
M Leg, Right ZFront Stabilizer

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Condition/Problem Things to Check Solution
Fan will not turn on or will not turn
off
Check data cable integrity All wires in cable should be intact. If any are cut or crimped, replace cable.
Check data cable
connections/orientation
Be sure cable is connected securely and oriented properly. Small latch on connector
should line up and snap into place.
Reset machine Unplug unit from electrical outlet for 3 minutes. Reconnect to outlet.
Fan will not turn on, but Console
operates
Check for blockage of fan Unplug unit from electrical outlet for 5 minutes. Remove material from fan. If neces-
sary, detach the Console to help with removal. Replace the Console if unable to
remove blockage.
Unit rocks/does not sit level Check leveler adjustment Adjust levelers until machine is level.
Check surface under unit Adjustment may not be able to compensate for extremely uneven surfaces. Move
machine to level area.
Foot pedals loose/unit difcult to
operate
Hardware Tightly secure all hardware on the Pedal Arms and Handlebar Arms.
Clicking sound when operating Check pedal arm to crank arm con-
nection
Remove pedal arms and reattach.
Motor Unplug machine and operate. If the clicking sound is gone, replace the Servo Motor.
Console Setup Mode
The Console Setup Mode lets you set the units of measurement to either English or Metric, change the machine type, or see maintenance statistics (Error Log and
Run Hours – for service technician use only).
1. Hold down the Increase button and Decrease button together for 3 seconds while in the Power-Up Mode to go into the Console Setup Mode.
Note: Push STOP to go back to the previous screen or the Power-Up Mode screen.
2. The Console display shows the Units prompt. Push START/ENTER to start Units option. Push the Increase/Decrease buttons to change between “Miles-Lb”
(Imperial English units) and “Km-Kg” (metric units).
Note: If the units change when there is data in User Statistics, the statistics convert to the new units.
3. Push START/ENTER to set. For the next option, push the Increase button.
4. The Console display shows the Machine Type prompt. Push START/ENTER to start Machine Type option. Push the Increase/Decrease buttons to change
between ELLIPTICAL and BIKE.
5. Push START/ENTER to set. For the next option, push the Increase button.
6. The Console display shows the Brightness prompt. Push START/ENTER to start the brightness option. Push the Increase/Decrease buttons to change the
backlight levels from 1 (lowest) to 5 (highest).
7. Push START/ENTER to set. For the next option, push the Increase button.
8. The Console display shows the Error Log prompt. Push START/ENTER to start Error Log option. The Error Log stores the last 10 errors (error type and system
time of error), listed newest to oldest. Push the Increase/Decrease buttons to move through the Error Log. If there are no errors, the Console display shows
“Index=0”.
9. Push STOP to exit. For the next option, push the Increase button.
10. The Console shows the RUN HOURS prompt. Push START/ENTER to see total hours and minutes for the machine.
11. Push STOP to exit. For the next option, push the Increase button.
12. The Console display shows the Units prompt again. Push STOP to go back to the Power-Up Mode screen.

6
Part Replacement
Replacing the Console Assembly
! To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the
machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
Tools Required: #2 Phillips Screwdriver
1. Using a #2 Phillips screwdriver, remove the 4 indicated
screws from the Console Assembly.
2. Gently lift the Console Assembly and disconnect the
Console Cable and the Heart Rate Cable.
Note: Do not crimp the cables. Do not allow the cables to
fall down the Console Mast. Use a rubber band or wire tie.
3. Installation is the reverse procedure.
4. Dispose of the old parts.
5. Inspect your machine to ensure that all hardware is tight and components are properly assembled.
Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner’s Manual.
6. Initial Setup of the Console
During the rst power-up, the Console must be setup for your preferred measurement units, the machine type, and brightness of the screen.
a. Units of Measurement: Push the Increase/Decrease buttons to change between “Miles-Lb” (Imperial English) or “Km-Kg” (metric).
b. Push START/ENTER to set.
c. Machine Type: Push the Increase/Decrease buttons to change between “BIKE” and “ELLIPTICAL”.
d. Push START/ENTER to set.
e. Backlight: Push the Increase/Decrease buttons to change the screen contrast, with “1” the lowest and “5” the highest.
f. Push START/ENTER to set. The Console goes back to the Power-Up / Idle Mode screen.
Note: To change these choices, consult the “Console Set-Up Mode” section.
#2
*
X4

7
Replacing the Static Handlebar Assembly
! To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the
machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
Tools Required: #2 Phillips Screwdriver, 4 mm hex wrench,
10 mm wrench
1. Using a #2 Phillips screwdriver, remove the 4 indicated
screws from the Console Assembly.
2. Gently lift the Console Assembly and disconnect the Con-
sole Cable and the Heart Rate Cable.
Note: Do not crimp the cables. Do not allow the cables to
fall down the Console Mast. Use a rubber band or wire tie.
3. Using a 4 mm hex wrench and a 10 mm
wrench, remove the 4 indicated bolts and
remove the Static Handlebar.
Note: Do not crimp the Console Cable when
removing the Static Handlebar.
Do not allow the Console Cable to fall into the
Console Mast.
4. Installation is the reverse procedure.
5. Dispose of the old parts.
6. Inspect your machine to ensure that all
hardware is tight and components are properly
assembled.
Do not use until the machine has been
fully assembled and inspected for
correct performance in accordance
with the Owner’s Manual.
#2
*
X4
X4
10 mm
X4
4mm

8
Replacing the Upper and Lower Handlebar Arms
! To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the
machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
Tools Required: 6 mm hex wrench, small Standard Screwdriver, 13 mm wrench
1. Using a 6 mm hex wrench, remove the 8 indicated bolts from the Upper Handle-
bar Arms.
2. Remove the Upper Handlebar Arms.
3. Using a 6 mm hex wrench and a 13 mm wrench, remove the 2 indicated bolts
from the Lower Handlebar Arms and Pedals.
4. Using a small Standard Screwdriver, pry up the Caps from the Lower Handlebar
Arms.
5. Using a 13 mm wrench, remove the hardware from the Lower Handlebar Arms
and the Pivot Arm and remove them.
6. Installation is the reverse procedure.
6mm
X8
6mm
X2
X2 13 mm
13 mm

9
Replacing the Pedals and Legs
! To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the
machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
Tools Required: 6 mm hex wrench, 13 mm wrench
1. Using a 6 mm hex wrench, remove the 3 indicated bolts from below the Pedal.
2. Using a 6 mm hex wrench, remove the indicated bolts from the Pedal and Lower
Handlebar Arm.
Be aware that the Handlebar Arms will be loose and may pivot when the
hardware is removed.
3. Remove the Pedal.
4. Using a small Standard Screwdriver, pry up the Cap from the Crank Arm.
5. Using a #13 mm wrench, remove the indicated bolt from the Pedal and remove
it.
6. Repeat steps on opposite side.
7. Installation is the reverse procedure.
8. Discard the old parts.
9. Inspect your machine to ensure that all hardware is tight and components are
properly assembled.
Do not use until the machine has been fully assembled and inspected for
correct performance in accordance with the Owner’s Manual.
6mm
X1
13 mm
X3
6mm
X2
13 mm

10
Replacing the Front Stabilizer
! To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the
machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
Tools Required: 6 mm hex wrench, static object (like a book or box)
1. Place a static object (like a book or box) under the front of the machine but not under the Front Stabilizer. The static object should not be compressible.
2. Using a 6 mm hex wrench, remove the four bolts that attach the Front Stabilizer.
3. Installation is the reverse procedure.
4. Dispose of the old parts.
5. Inspect your machine to ensure that all hardware is tight and
components are properly assembled.
Do not use until the machine has been fully assembled and
inspected for correct performance in accordance with the
Owner’s Manual.
6mm

11
Replacing the Rail Assembly
! To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the
machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
Tools Required: 6 mm hex wrench, static object (like a book or box)
1. Be sure the Incline Assembly on the Rail Assembly is fully lowered.
If the Incline Assembly is raised:
a. Grasp the Incline Handle and be prepared to support the weight of the raised parts of the machine.
When released, the Incline Assembly may fully disengage. Make sure that you are able to support the weight
of the raised parts of the machine safely.
b. With your foot, step and hold down one of the Incline Release Pedals. This releases the Incline Assembly.
Note: The Incline Handle may need to be slightly lifted to disengage the Incline Assembly.
c. Fully lower the Incline Assembly.
In order to avoid possible serious injury when lowering the Rails, be careful to avoid ngers or hands being caught or pinched.
d. Step off the Incline Release Pedal.
2. Perform the removal steps of “Replacing the Pedals and Legs” Procedure.
3. Perform the removal steps of “Replacing the Upper and Lower Handlebars” Procedure.
4. Tilt the Machine and remove the two indicated bolts using a 6 mm hex wrench.
The machine may be moved by one or more persons depending on their physical abilities and capacities. Make sure that you and others are all physically fit
and able to move the machine safely.
NOTICE: This step requires at least
two people.
5. Stand the machine upright.
The machine may be moved by one or more
persons depending on their physical
abilities and capacities. Make sure that you
and others are all physically fit and able to move the machine safely.
NOTICE: This step requires at least two people.
X2
6mm

12
6. Using a 6 mm hex wrench, remove the four bolts that attach the Rail As-
sembly.
Be aware that the Frame Assembly may be unstable and slightly top
heav y.
7. Remove the Rail Assembly.
8. Installation is the reverse procedure.
9. Dispose of the old parts.
10. Inspect your machine to ensure that all hardware is tight and components
are properly assembled.
Do not use until the machine has been fully assembled and inspected
for correct performance in accordance with the Owner’s Manual.
6mm

13
Removing the Shrouds
! To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the
machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
Tools Required: #2 Phillips screwdriver, Crank Puller, small Standard Screwdriver, 9/16” socket and ratchet
1. Perform the removal steps of “Replacing the Pedals and Legs” Procedure.
2. Perform the removal steps of “Replacing the Upper and Lower Handlebars”
Procedure.
3. Using a #2 Phillips screwdriver, remove the two screws from the Storage Bin
Insert.
4. Using a small Standard Screwdriver, remove the Cap (Item A) from the Crank Arm.
5. Using a 9/16” socket and ratchet, remove the Lock Nut from the Crank Arm with
Plastics.
6. Using a Crank Puller, thread it into the Crank Arm with Plastics.
Note: Be sure the end of the Bolt of the Crank Puller is ush with the Nut (as shown)
before use.
7. Using a wrench, turn the inner portion (the Bolt) of the Crank Puller clockwise. The
Crank Arm with Plastics will slide off as it is tightened.
8. Using a #2 Phillips screwdriver, remove the 10 indicated screws from the Shrouds and
remove them.
Note: Disconnect the AC Inlet cables from the Shroud to the wiring harness. Be sure not to
crimp any cables.
9. Installation is the reverse procedure.
10. Dispose of the old parts.
11. Inspect your machine to ensure that all hardware is tight and components are properly
assembled.
Do not use until the machine has been fully assembled and inspected for correct
performance in accordance with the Owner’s Manual.
A
#2
X2

14
Replacing the Tensioner Assembly
! To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the
machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
Tools Required: 10 mm hex wrench, 13 mm wrench, large #2 Standard Screwdriver
1. Perform the removal steps of “Replacing the Pedals and Legs” Procedure.
2. Perform the removal steps of “Replacing the Upper and Lower Handle-
bars” Procedure.
3. Perform the removal steps of “Removing the Shrouds” Procedure.
4. Measure, or mark a piece of scrap paper, the lengths of the Tensioner
Spring and Bolt.
5. Using a 10 mm hex wrench, loosen the Spring Insert (Item C) until the
Tension Spring (Item D) can be released.
6. Using a 13 mm wrench, remove the Tensioner Assembly Hardware (Item
A).
7. Remove the Tensioner Assembly (Item B) from the Frame Assembly and
the Drive Belt.
8. Installation is the reverse procedure.
Note: Be sure to adjust the Tensioner Bolt and Spring to the previous
lengths.
9. Dispose of the old parts.
10. Inspect your machine to ensure that all hardware is tight and compo-
nents are properly assembled.
Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner’s Manual.
A
B
D
C

15
Replacing the Flywheel, Drive Belt and Drive Pulley
! To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the
machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
Tools Required: 13 mm wrench, 17 mm wrench, large #2 Standard Screwdriver, eye protection, rubber mallet (or wooden block and hammer), needle nose pliers
1. Perform the removal steps of “Replacing the Pedals and Legs” Procedure.
2. Perform the removal steps of “Replacing the Upper and Lower Handlebars” Procedure.
3. Perform the removal steps of “Removing the Shrouds” Procedure.
4. Place a piece of cardboard the entire length of the Brake Magnet As-
sembly (Item F) and the Flywheel (Item E).
5. Using a large #2 Standard Screwdriver, loosen the Spring Insert (Item A)
until the Tension Spring can be released.
6. Turn the Drive Pulley (Item D) clockwise while forcing the Drive Belt to
the outside. Belt will come off of the Drive Pulley.
Keep ngers out of any pinch opportunities when turning the
Pulleys.
7. Using a 17 mm wrench, remove the hardware (Item B) securing the
Flywheel from both sides.
8. Using a 13 mm wrench, remove the hardware (Item C) from the Crank
Spindle Weldment that contains the Drive Pulley Assembly.
Note: The Speed Sensor Magnet is on the Drive Pulley Assembly.
9. Using eye protection and needle nose pliers, remove the Snap Ring
(Item H) from the Crank Spindle Weldment (Item G)
10. Using eye protection and a rubber hammer (or wooden block and ham-
mer), gently strike the Crank Spindle Weldment until it works out of the Frame releasing the Drive Pulley Assembly.
11. Installation is the reverse procedure.
12. Dispose of the old parts.
13. Inspect your machine to ensure that all hardware is tight and components are properly assembled.
Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner’s Manual.
B
A
D
C
E
F
G
H

16
B
A
D
C
E
F
G
H
Replacing the Servo Motor
! To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the
machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
Tools Required: 10 mm wrench
1. Perform the removal steps of “Replacing the Pedals and Legs” Procedure.
2. Perform the removal steps of “Replacing the Upper and Lower Handlebars” Procedure.
3. Perform the removal steps of “Removing the Shrouds” Procedure.
4. Using a long 6 mm hex wrench, remove
the hardware from the Console Mast.
5. Remove the Console Mast and discon-
nect the Console Cables.
Note: Do not crimp the cables.
6. Insert a piece of cardboard between the Brake Magnet
(Item C) and the Fly Wheel (Item B).
Note: Be sure the cardboard covers all of the Brake Magnet.
7. Disconnect the Speed Sensor Cables (Item A).
8. Pull the lower Console Cable (Item D) from the Mast Base.
A
B
C
D
X6
6mm (long)

17
9. Pull downward and release the Magnet Arm (Item F) enough to disengage it
from the Motor Pulley Shaft (Item E).
10. Remove the two hex head bolts (Item G) from the Servo Motor (Item H) and
the Spring Tension Arm (Item K).
Note: To assist with reassembly, be sure to observe how the Spring Tension Arm (Item K) is oriented.
11. Remove the Servo Motor from the Brake Plate (Item J).
12. Installation is the reverse procedure.
Notice: Do not touch the Potentiometer (Item I). Do not crimp any cables when routing through the Brake Plate and the Frame Assembly.
Note: Before fully attaching the Shrouds, remove the cardboard from between the Brake Magnet and the Fly Wheel. Power up the machine to verify that the Magnet
Arm can move freely, and that the Brake Magnet and Fly Wheel are not
touching.
13. Dispose of the old parts.
14. Inspect your machine to ensure that all hardware is tight and compo-
nents are properly assembled.
Do not use until the machine has been fully assembled and
inspected for correct performance in accordance with the Owner’s
Manual.
After replacing the Servo Motor, the resistance levels of the machine may
be different. The user should adjust their workout levels accordingly.
EF
G
G
I
H
KJ

18
Adjusting the Servo Motor
! To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the
machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
Tools Required: hex wrench, 10 mm wrench
If resistance has shifted out of the factory specication, the Servo Motor may need to be adjusted.
1. Perform the removal steps of “Replacing the Pedals and Legs” Procedure.
2. Perform the removal steps of “Replacing the Upper and Lower Handlebars” Procedure.
3. Perform the removal steps of “Removing the Shrouds” Procedure.
4. Insert a piece of cardboard between the Brake Magnet
(Item E) and the Flywheel (Item D).
5. Inspect the Servo Motor Assembly (Item A) and decide which way to
adjust it.
6. Using a 10 mm wrench, loosen the Snap Nut (Item B) that will allow
the Servo Motor to adjust in the correct direction. Count the number of
exposed threads to assist with resetting the Servo Motor to the factory
specications.
7. Using a hex wrench, loosen the hardware (Item C) securing the Servo
Motor.
8. Using the Snap Nuts, adjust the position of the Servo Motor.
9. Secure hardware when the Servo Motor is in the correct position.
After adjusting the Servo Motor, the resistance levels of the machine may
be different. The user should adjust their workout levels accordingly.
ABC
E
D

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Replacing the Brake Assembly
! To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the
machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
Tools Required: 6 mm hex wrench , 10 mm wrench, (2) 13 mm (1/2”) wrench, 17 mm wrench
1. Perform the removal steps of “Replacing the Pedals and Legs” Procedure.
2. Perform the removal steps of “Replacing the Upper and Lower Handlebars” Procedure.
3. Perform the removal steps of “Removing the Shrouds” Procedure.
4. Insert a piece of cardboard between the Brake Magnet
(Item B) and the Flywheel (Item F).
Note: Be sure the cardboard covers all of the Brake Magnet.
5. Disconnect the Speed Sensor Cables (Item A).
Note: Do not crimp the cables.
6. Pull the lower Console Cable (Item D) from the Frame Assembly.
Note: Do not crimp the cables.
7. Count the number of exposed threads above the Upper Snap Nut
(Item E). This will assist with resetting the Servo Motor to the factory
specications.
8. Remove the bolt (Item F) and upper Snap Nut from the Servo Motor/
Brake Assembly.
9. Remove the bolt (Item H) from below the Flywheel.
A
H
D
C
F
B
G
E

20
10. Remove the bolt (Item I) from below the Flywheel.
11. Remove the Servo Motor/ Brake Assembly (Item J).
Note: Do not crimp the cables.
12. Pull downward and release the Magnet Arm (Item L) enough to disengage
it from the Motor Pulley Shaft (Item K).
13. Remove the two hex head bolts (Item N) from the Servo Motor (Item O) and the Spring
Tension Arm (Item M).
14. Remove the Servo Motor from the Brake Plate (Item Q).
Note: Do not touch the Potentiometer (Item P).
15. Installation is the reverse procedure. Be sure the cardboard will completely cover the new
Brake Magnet before installation. Do not crimp any cables when routing through the Brake
Plate.
Note: Before fully attaching the Shrouds, remove the cardboard from between the Brake
Magnet and the Fly Wheel. Power up the machine to verify that the Magnet Arm can move
freely, and that the Brake Magnet and Fly Wheel are not touching.
After replacing the Brake Assembly, the resistance levels of the machine may be different. The user should adjust their workout levels accordingly.
IJKL
NP
N
Q
M
O