Schwinn Z Operating instructions

Page 1
637-8808 Rev. J
Technical Procedure
Schwinn X/Z Troubleshooting & Replacement
Applies to: Schwinn X (9-7470 + 9-7480), Schwinn Z (9-7510 + 9-7520)
Enhanced Images: Pictures can be zoomed in to any level for
detail. Use the standard zoom tools for your platform to zoom in.
This document covers procedures for the Schwinn Z and X bikes. The Schwinn Z is pictured, procedures are
applicable for the Schwinn X cycle except where specified. Click on procedure below to jump to section:
Fore-Aft Adjustment Lever Replacement ...................................................... 2
Tighten Loose Handlebars or Seat................................................................. 7
Handlebars 7
Seat 8
Cycle Belt and Flywheel Replacement......................................................... 10
Z Bike Gear-Angle Sensor Replacement ..................................................... 16
Z Bike LED Board Replacement ................................................................. 19
Z Bike Battery Replacement ................................................................. 22
Bike Battery Replacement 22
4iiii Crank Arm Battery Replacement 23
Crank Removal............................................................................................. 24
Pedal Removal............................ ................................................................. 25
Flywheel Position Adjustment ................................................................. 26

Page 2
637-8808 Rev. J
Technical Procedure
Fore-Aft Adjustment Lever Replacement
Required Tools:
• 4mm Allen Key
• 5mm Allen Key
• Ratchet Wrench
• 11mm Deep Socket
• Torque Wrench
• #2 Phillips Screwdriver
Required Parts*:
• For seat: 727-0177-XX “ASSY, CAM LEVER, SEAT, ACPU”
• For seat: 300-0245 “BLOCK, GAUGE, TORQUE, SEAT, UGC”*
• For handlebars: 727-0176-XX “ASSY, CAM LEVER, HBAR”
*Please note that 300-0245 300-0245 “BLOCK, GAUGE, TORQUE, SEAT, UGC” is only required for
bikes PRIOR to serial number(s): GC7470L22091069 (Schwinn XA), GC7520L21491157 (Schwinn ZA),
GC7510L2213127 (Schwinn ZS), GC7480L22141001 (Schwinn XS).
Seat Slider
1. Loosen the fore/aft adjustment lever then use
a 5mm allen key to remove the locking screw
from under the seat post.
Notice: When reinstalling the this screw, be sure
to torque to 2 Nm (9 Ft-Lbs).
Fig. 1

Page 3
637-8808 Rev. J
Technical Procedure
2. Slide the seat slider off of the seat post.
Fig. 2
3. Use a ratchet wrench with a 11mm deep
socket to remove the 1/4” nylock nut and
M6 flat washer, then remove the adjustment
lever.
4. Install the new lever using the same hardware
from Step 3.
Notice: If a torque wrench is not available,
please skip to Step 7.
Fig. 3
5. Install 300-0245 “BLOCK, GAUGE, TORQUE,
SEAT, UGC” onto the seat slider so the lever
adjustment nut can be accessed through the
hole int he top of the torque block.
Notice: Step 5 is ONLY valid for bikes PRIOR
to serial number GC7470L22091069 (Schwinn XA),
GC7520L21491157 (Schwinn ZA), GC7510L2213127
(Schwinn ZS), GC7480L22141001 (Schwinn XS).
Fig. 4

Page 4
637-8808 Rev. J
Technical Procedure
6. Ensure that the fore/aft adjustment lever
is closed, then use a torque wrench with a
11mm deep socket to tighten the fore/aft
lever adjustment nut to 4 Nm (2.95 Ft-Lbs).
7. Reinstall the seat slider and locking screw
from Steps 1+2. This will conclude the
procedure - DO NOT CONTINUE TO STEP 7.
8. With the fore/aft adjustment lever open,
tighten the adjustment lever nut 1/4 of a turn,
then close the adjustment lever and check
the function by reinstalling the seat slider
removed in Step 2 and pushing backwards
on the seat slider - it SHOULD NOT move.
9. Repeat Step 7 as needed until the seat slider
is tight. This will conclude the procedure. Fig. 5

Page 5
637-8808 Rev. J
Technical Procedure
Handlebar Slider
1. Flip the fore/aft adjustment lever up.
Fig. 6
2. Move the handlebars forward until the fore/
aft adjustment lever nut is visible through the
hole on the underside of the handlebar post.
Fig. 7
3. Use a ratchet wrench with a 11mm deep
socket to remove the 1/4” nylock nut and
M6 flat washer, then remove the adjustment
lever.
Fig. 8

Page 6
637-8808 Rev. J
Technical Procedure
NOTE: If a torque wrench is not available, please
skip to Step 4.
4. Close the fore/aft adjustment lever, then use
a torque wrench with a 11mm deep socket
to tighten the fore/aft lever adjustment nut
to 3 Nm (2.21 Ft-Lbs). This will conclude the
procedure.
5. With the fore/aft adjustment lever up, tighten
the adjustment lever nut 1/4 of a turn, then
close the adjustment lever and check the
function by pushing backwards on the
handlebars - they SHOULD NOT move.
6. Repeat Step 4 as needed until the handlebars
are tight. This will conclude the procedure. Fig. 9

Page 7
637-8808 Rev. J
Technical Procedure
Tighten Loose Seat or Handlebars or Seat
Required Tools:
• #2 Phillips Screwdriver
• Torque Wrench
• 10mm Deep Socket
• 3mm Allen Key
NOTE: While the images below show a Schwinn Z cycle, this procedure is also applicable for the Schwinn X
cycle.
Handlebars
1. Flip the fore/aft adjustment lever up.
Fig. 10
2. Move the handlebars forward until the fore/
aft adjustment lever nut is visible through the
hole on the underside of the handlebar post.
Notice: If a torque wrench is not available,
please skip to Step 4.
3. Close the fore/aft adjustment lever, then use
a torque wrench with a 11mm deep socket
to tighten the fore/aft lever adjustment nut
to 3 Nm (2.21 Ft-Lbs). This will conclude the
procedure.
4. With the fore/aft adjustment lever up, tighten
the adjustment lever nut 1/4 of a turn, then
close the adjustment lever and check the
function by pushing backwards on the
handlebars - they SHOULD NOT move.
5. Repeat Step 4 as needed until the handlebars
are tight. This will conclude the procedure.
Fig. 11

Page 8
637-8808 Rev. J
Technical Procedure
Seat
1. Use a 3mm allen key to remove the socket
head cap screw from the underside of the
seatpost.
Notice: When reinstalling the this screw, be sure
to torque to 2 Nm (9 Ft-Lbs).
Fig. 12
2. Remove the seat slider assembly from the
seat post.
Notice: If a torque wrench is not available,
please skip to Step 5.
Fig. 13
3. Install 300-0245 “BLOCK, GAUGE, TORQUE,
SEAT, UGC” onto the seat slider so the lever
adjustment nut can be accessed through the
hole int he top of the torque block.
Notice: Step 3 is ONLY valid for bikes PRIOR
to serial number GC7470L22091069 (Schwinn XA),
GC7520L21491157 (Schwinn ZA), GC7510L2213127
(Schwinn ZS), GC7480L22141001 (Schwinn XS).
Fig. 14

Page 9
637-8808 Rev. J
Technical Procedure
4. Ensure that the fore/aft adjustment lever
is closed, then use a torque wrench with a
10mm deep socket to tighten the fore/aft
lever adjustment nut to 4 Nm (2.95 Ft-Lbs).
5. Reinstall the seat slider and locking screw
from Steps 1+2. This will conclude the
procedure - DO NOT CONTINUE TO STEP 7.
6. With the fore/aft adjustment lever open,
tighten the adjustment lever nut 1/4 of a turn,
then close the adjustment lever and check
the function by reinstalling the seat slider
removed in Step 2 and pushing backwards
on the seat slider - it SHOULD NOT move.
7. Repeat Step 7 as needed until the seat slider
is tight. This will conclude the procedure. Fig. 15

Page 10
637-8808 Rev. J
Technical Procedure
Cycle Belt and Flywheel Replacement
Required Tools:
• 3mm Allen Key
• 4mm Allen Key
• 6mm Allen Key
• #2 Phillips Head Screwdriver
• 18mm Open-Ended Wrench
• 19mm Open-Ended Wrench x2
• Permanent Marker or Pencil
WARNING: Procedure below involves removal of the flywheel. The flywheel is heavy and two people are
recommended to complete this task. Keep flywheel on blanket or similar to prevent damage.
1. Use a 4mm allen key to remove he two (2)
socket head cap screws securing the left side
belt guard cap.
Fig. 16
2. Use a 4mm allen key to remove the four (4)
socket head cap screws securing the left side
belt guard to the bike, then remove the belt
guard.
Fig. 17

Page 11
637-8808 Rev. J
Technical Procedure
3. Use a 4mm allen key to remove the two (2)
socket head cap screws securing the rear
of the right side belt guard to the bike, use a
3mm allen key to remove the two (2) button
head cap screws from the front of the right
side seld belt guard, then remove the belt
guard.
Fig. 18
4. Use a 4mm allen key to remove the socket
head cap screw securing the nose cover to
the front of the bike frame, then remove the
nose cover.
Fig. 19
5. Use a 3mm allen key to remove the four (4)
button head cap screws from the right side
outer fork guard, then remove the fork guard.
6. Carefully disconnect the LED board cable
from the LED board.
Fig. 20

Page 12
637-8808 Rev. J
Technical Procedure
7. Use a #2 phillips screwdriver to remove the
four (4) button head screws securing the inner
right fork guard assembly to the bike, then
remove the inner fork guard.
Fig. 21
8. Use a 3mm allen key to remove the five (5)
button head cap screws from the left side
outer fork guard, then remove the fork guard.
9. Carefully disconnect the LED board cable
from the LED board.
Fig. 22
10. Use a #2 phillips screw driver to remove the
four (4) button head screws securing the
inner left fork cover to the frame, then use a
3mm allen key to remove the single button
head cap screw, finally, remove the inner fork
cover.
Fig. 23

Page 13
637-8808 Rev. J
Technical Procedure
11. Use a 3mm allen key to remove the button
head cap screw from the top of the outer
generator belt guard, use a #2 phillips
screwdriver to remove the pan head machine
screw from the bottom of the belt guard, then
remove the belt guard.
Fig. 24
12. Use a 3mm allen key to remove the button
head cap screw securing the inner generator
belt guard to the frame, then remove the belt
guard.
Fig. 25
13. Mark the location of the belt tension lock nut
(this will be used to help when re-tensioning
the belt) using a permanent marker or pencil.
14. Use a 18mm open-ended wrench to loosen
the lock nut.
Fig. 26

Page 14
637-8808 Rev. J
Technical Procedure
15. Use a 6mm allen key to loosen the belt
tension screw to loosen the belt.
NOTE: Be sure to mark the location of the
belt pulley tension block before loosening, so
during reinstall, the belt tension can be returned
to factory settings.
Fig. 27
16. After loosening the drive belt, walk the belt off
of the crank pulley.
Fig. 28

Page 15
637-8808 Rev. J
Technical Procedure
17. Remove the generator band/belt from the
generator pulley.
18. Use two 19mm open-ended wrenches to
loosen the flywheel axle nut.
19. Support the flywheel, then remove the
flywheel axle from the left side of the bike.
WARNING: With the axle removed, the
flywheel is only supported by two tabs on
the frame. If the flywheel moves forward
unexpectedly, it could drop out of the frame.
20. After removing the axle, bring the flywheel
forward and down out of the frame.
CAUTION: The flywheel is heavy and two
people are recommended to complete this task.
Fig. 29
21. After removing the flywheel from the forks,
the flywheel, drive belt, and/or generator belt
can all be replaced.
Note For Z Bike: If replacing the flywheel,
remember to remove the generator belt from the
left side of the flywheel and install it onto the new
flywheel.
22. Re-tension the drive belt and tighten the lock
nut - refer to Step 13.
Fig. 30

Page 16
637-8808 Rev. J
Technical Procedure
Z Bike Gear-Angle Sensor Replacement1
Required Tools:
• 4mm Allen Key
• #2 Phillips Screwdriver
•
Required Parts:
• 718-6131 “ASSY, SENSOR, ENCODER, ACPU”
1. Use a 4mm allen key to remove the socket
head cap screw securing the nose cover to
the bike, then remove the cover.
Fig. 31
2. Disconnect the gear sensor from the junction
board.
Fig. 32
1 Applies to: Schwinn Z Bike (9-7510 + 9-7520)

Page 17
637-8808 Rev. J
Technical Procedure
3. Use a #2 phillips screwdriver to remove the
pan head screw securing the sensor to the
brake assembly.
Fig. 33
4. Remove the sensor from the brake assembly.
5. Follow steps 1-4 in reverse to install the new
sensor.
Fig. 34

Page 18
637-8808 Rev. J
Technical Procedure
6. Tap the and buttons simultaneously
then tap the button to enter Maintenance
Mode.
7. Press the button until GEAR is shown in
the message center then press the button.
8. If the value in the message center reads OFF
Press the button to switch to ON then
press the button to save the change.
9. Return to the Maintenance Mode main menu.
10. Press the button until GEAR CAL is
shown in the message center then press the
button.
11. Slide the red calibration tool onto the flywheel
between the first magnets.
12. Tighten the brake knob by turning
clockwise until there is contact with the tool
as shown.
13. Press the button to complete the
calibration. CAL COMPLETE will show in the
message center.
14. The GEAR option can now be turned back to
ON in Maintenance Mode.
Fig. 35

Page 19
637-8808 Rev. J
Technical Procedure
Z Bike LED Board Replacement2
Required Tools:
• 3mm Allen Key
• 4mm Allen Key
• #2 Phillips Screwdriver
Required Parts:
• 740-9602 “MODULE, LED, MULTI-COLOR, GROUP CYCLE”
1. Use a 4mm allen key to remove the socket
head cap screw from the nose cap, then
remove the nose cap.
Please continue to Step 2 ONLY if
replacing the left side LED board, otherwise
skip to Step 3.
Fig. 36
2. Use a 3mm allen key to remove the five (5)
button head cap screws securing the left side
outer fork cover to the frame, remove the
cover, then disconnect the LED cable from
the LED board. Skip to Step 6.
Notice: While the instructions below show the
right side LED board replacement, they are still valid
for the left side LED board replacement.
Fig. 37
2 Applies to: Schwinn Z Bike (9-7510 + 9-7520)

Page 20
637-8808 Rev. J
Technical Procedure
3. Use a 4mm allen key to remove the two (2)
socket head cap screws from the front of the
left side belt guard.
Fig. 38
4. Use a 3mm allen key to remove the two (2)
button head cap screws from the front of the
right side belt guard, then remove the four (4)
button head cap screws securing the right
side, outer fork guard from the frame.
Fig. 39
5. Carefully lift the front of the right side belt
guard away from the frame, then remove the
right side fork guard.
Fig. 40