Schwinn IC2 Indoor Cycling Bike User manual

Schwinn®IC2 Bike
Service Manual 004-4774.070118.C
Service Manual
Section Code Section Page Number
1 Important Safety Instructions 2
1 Safety Warning Labels and Serial Number 3
1 Reading the Serial Number 3
1 Specifications 4
1 Maintenance 4
1 Moving the Machine 6
1 Leveling the Machine 6
1 Troubleshooting 7
1 Console Service Mode 8
1 Maintenance Parts Exploded View 9
1 Replacement Procedure Skill Level 10
Mechanical Procedures 11
2 Brake Lubrication 11
3 Brake Adjustment 14
4 Chain Tension Adjustment 16
Part Replacement 20
5 Pedals 20
6 Console 22
7 Handlebars and Handlebar Post 24
8 Brake Cover 27
9 Brake Assembly and Resistance Knob Assembly 29
10 Left Crank Arm 32
11 Speed Sensor 35
12 Chain Guard Covers 39
13 Retainer Clips 41
14 Drive Chain 45
15 Flywheel Assembly 52
16 Right Crank Arm and Sprocket Drive 60
Table of Contents
Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: NorthAmerica [phone], [email protected] | outside U.S.
www.nautilusinternational.com | © 2013 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by
common law. Schwinn and the Schwinn logo are trademarks owned by or licensed to Nautilus, Inc. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY
8019183.070118.A

2
Important Safety Instructions and General Troubleshooting
Information for the Schwinn®IC2 Bike 8003616.070118.B
Service Procedures
Important Safety Instructions
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.
Before servicing or using this equipment, obey the following warnings:
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 bystanders.
• 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 traffic and exposure to bystanders.
• 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.
• If replacement parts are necessary, use only genuine Nautilus replacement parts and hardware. Failure to use genuine replacement
parts can cause a risk to users, keep the machine from operating correctly and void the warranty.
• Be sure that all warning stickers and instructional placards applied to the product stay present and in good condition when doing
maintenance 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 affect user safety.
• Do not put the machine back in service until all shrouds, instructions, warning labels and correct functionality have been verified
and tested for correct performance.
Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: NorthAmerica [phone], [email protected] | outside U.S. www.nautilusin-
ternational.com | © 2013 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Schwinn and
the Schwinn logo are trademarks owned by or licensed to Nautilus, Inc. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY
NOTICE: This document provides important safety instructions, adjustments, and general troubleshooting information for the maintenance of the
Schwinn®IC2 Bike.
If you need assistance, please call Schwinn Customer Service at 1-800-605-3369.
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.

3
Safety Warning Labels and Serial Numbers
Reading the Serial Number
The instructions below show how to decode the information contained on the serial number.
SERIAL NO. FORMAT
AAAAAA - Product SKU
VVV - Supplier code
YY - Manufactured year
WW - Manufactured week
9999 - Sequential number
SERIAL NO. FORMAT (old)
AAAAAA - Product SKU
BBB - Supplier code
PPPPPP - Purchase order number
LL - Purchase order line number
CCCCCC - Unique identifier
s
s
s
s
s
s
250lbs. (113kg).
s
s
s
s
s
s
250lbs. (113kg).
Serial number
AAAAAAVVVYYWW9999
AAAAAABBBPPPPPPLLCCCCCC
Serial Number

4
Maintenance
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 first 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 Clean the machine to remove any dust, dirt, or grime from the surfaces. If needed, sparingly
apply a thin coating of silicone lube to ease operation.
Note: Do not use petroleum based products.
Monthly Check pedals and crank arms, and tighten as necessary. Make sure all bolts and screws are
tight. Tighten as necessary. Lubricate chain with lithium grease.
NOTICE: Do not clean with a petroleum based solvent or an automotive cleaner. Be sure to keep the Console free of
moisture.
Specifications
Maximum User Weight 250 lbs. (113 kg)
Power Requirements 2 AA batteries (LR6)
Operational Voltage 1.0 - 3.3VDC
.
48.4”
(123cm)
22.2” (56.4cm)
44.5” (113cm)

5
Chain Lubrication
Do not apply lubricant when the chain is moving.
Be sure to keep fingers clear of all pinch hazards.
Remove the chain guard door and apply a small amount of lithium grease to the chain (C).
Note: Use caution to avoid staining clothes or carpet.
Replacing the Console Batteries
The Console display will show “Batt” during power up if the battery level is low.
When replacing the batteries, make sure the batteries point in the +/– direction
shown in the battery bay.
Note: The console uses AA size batteries (LR6).
Do not mix old and new batteries.
Do not mix alkaline, standard (carbon-zinc), or rechargeable (Ni-Cd,
Ni-MH, etc) batteries.
Be sure to remove the batteries to prevent corrosion damage if you are not going to
use the machine for an extended period of time.
+
-
X2
C

6
Leveling the Bike
Levelers are found on each side of the stabilizers. Turn the knob to
adjust the stabilizer foot. Make sure the bike is level and stable before
you exercise.
Moving the Bike
To move the bike, carefully pull the Handlebars toward you while pushing the front
of the bike downward. Push the bike to the desired location.
NOTICE: Be careful when you move the machine. Abrupt motions can affect the
computer operation.

7
Troubleshooting
Condition/Problem Things to Check Solution
Console will not power up/turn
on/start
Batteries Make sure batteries are installed correctly. If batteries are
correctly installed, replace with a set of new batteries.
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
Make 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.
If the above steps do not resolve the problem, contact
Customer Care for further assistance.
Speed displayed is not accurate Display set to wrong unit of
measure. (English/Metric)
Change display units.
Speed displayed is always “0”/
stuck in Pause mode
Data cable Make sure the data cable is connected to the back of the
Console and the main frame assembly.
No speed/RPM reading 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 RPM Sensor (requires
shroud removal)
RPM 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 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.
Check magnet position (requires
shroud removal)
Magnet should be in place on pulley.
Check RPM Sensor Contact Customer Care for further assistance.
Unit rocks/does not sit level Check leveler adjustment Leveling feet may be turned in or out to level bike.
Check surface under unit Adjustment may not be able to compensate for extremely
uneven surfaces. Move bike to level area.
Pedals loose/unit difficult to
pedal
Check pedal to crank connection Pedal should be tightened securely to crank. Be sure con-
nection is not cross-threaded.
Check crank to axle connection Crank should be tightened securely to axle.
Clicking sound when pedaling Check pedal to crank connection Remove pedals and reattach fully.
Rattling or grinding sound when
pedaling/unit difficult to pedal
Check chain tension (requires
chain guard door removal)
Open chain guard door to see the chain. Tension should not
be too loose (nor too tight). Contact Customer Care for as-
sistance.
Seat post movement Check locking pin Be sure adjustment pin is locked into one of the seat post
adjustment holes.
Check adjustment knob Be sure knob is securely tightened.

8
Console Service Mode
Service Mode lets you set the units of measure to either English or Metric, see machine statistics and firmware version (for technician
use only).
1. When the Console is in Workout Mode or Pause Mode, push and hold down the button for 5 seconds to go into Service Mode.
Note: Tap the button to move through the Service Mode Menu options. When the Console display shows “dOnE”, push and hold
the button for 3 seconds to reset the workout data and go back to Workout Mode.
2. The Console display shows the Units prompt. Push and hold the button to start Units option. Push the button to change between
“LbS” (English units) and “SI” (metric units).
3. Push and hold the button for 3 seconds to set the units. The Console display shows the Units prompt.
4. Push the button to go to the Stats prompt. Push and hold the button to start the machine Stats option. The Console display shows
Total Distance. Push the button to change between Total Distance and Total Time.
Note: The Total Distance value is a whole number of miles/km (no decimal point).
5. Push and hold the button for 3 seconds to go back to the Stats prompt.
6. Push the button to go to the Firmware Version prompt. Push and hold the button to see the firmware version of the Console.
7. Push and hold the button for 3 seconds to go back to the Firmware Version prompt.
8. Push the button to go to the exit option. The Console display shows “dOnE”.
To go back to Workout Mode, push and hold the button for 3 seconds. The workout data is reset.
To go through the Service Mode Menu again, tap the button. The Console display will show the Units prompt.
In Service Mode if the Console does not receive any input in approximately 5 minutes, it goes into Sleep Mode.

9
Maintenance Parts Exploded View
Your machine may differ. Use only as a guide.
A Console I Crank Arms Q Chain
B Water Bottle Holder J Pedals R Speed Sensor Magnet
C Handlebars K Seat S RPM Sensor
D Brake/Resistance Knob L Seat Post T Sprocket Drive
E Brake Assembly M Adjustment Knobs U Data Cable
F Chain Guard N Chain Guard Door V Flywheel
G Chain Guard Center Plate O Levelers W Flywheel Retainer Clip
H Chain Guard Inside P Transport Wheels X Brake Cover
I
H
Q
R
S
TU
A
B
C
U
M
D
E
V
H
W
P
O
MF
G
J
O
Q
I
J
MM
L
K
N
X

10
REPLACEMENT PROCEDURE SKILL LEVEL
Level I : Low - very little mechanical knowledge or exposure.
Level II : Intermediate - some experience with mechanical procedures
Level III : Advanced - knowledgeable about mechanical procedures
For instructions to replace the following parts, please refer to the Assembly Manual for your bike:
• Seat
• Seat Post
• Front Stabilizer
• Rear Stabilizer
• Water Bottle Holder

11
Lubricate the Brake
on the Schwinn®IC2 Bike Skill Level: I
8003618.070118.B
Replacement Procedure
Nautilus, Inc., (800) NAUTILUS / [phone], www.NautilusInc.com - Customer Service: North America [phone], [email protected] | outside U.S. [email protected] | © 2013 Nautilus, Inc.
NOTICE: This document provides instructions for the lubrication of the Brake Pad on the Schwinn®IC2 Bike.
If you need assistance, please call Schwinn Customer Service at 1-800-605-3369.
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.
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.
• Read and understand the Part Replacement Procedure before working on the machine. Failure to obey the instructions and
safety warnings could cause injury to the service technician or bystanders.
• 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 traffic and exposure to bystanders.
• 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.
• If replacement parts are necessary, use only genuine Nautilus replacement parts and hardware. Failure to use genuine re-
placement parts can cause a risk to users, keep the machine from operating correctly and void the warranty.
• Be sure that all warning stickers and instructional placards applied to the product stay present and in good condition when
doing maintenance 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 affect user safety.
• Do not use the machine until all shrouds, instructions, warning labels and correct functionality have been verified and tested
for correct performance.
Tools Required (not included)
#2 Phillips screwdriver Silicone lubricant
4mm Hex key
8 mm Wrench

12
Note: Your machine may not match the image. For reference only.
1. Using a #2 Phillips screwdriver, loosen and remove the hardware
that attaches the Brake Cover to the Main Frame. Set the Brake
cover and hardware safely aside for reassembly.
NOTICE: Hold the Brake Cover so that it does not fall.
2. Loosen the Resistance Knob (A) to the minimum resistance
setting.
3. Loosen and remove the hardware that attaches the Brake Pad
(B) to the Brake Assembly (C).
4. Slide the Brake Pad (B) out of the Brake Assembly (C).
Disconnect the data cable from the console before you service this machine.
A
B
C

13
D
B
5. Saturate the Brake Pad felt (D) with silicone lubricant. Wipe off
the excess lubricant to prevent drips and stains.
6. Reinstall the Brake Pad (B).
NOTICE: Do not crimp the cable.
7. Reinstall the Brake Cover.
NOTICE: Do not crimp the cable.
8. Adjust the Resistance Knob (A) as necessary.
9. Final Inspection
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.

14
Adjust the Brake Assembly
on the Schwinn®IC2 Bike Skill Level: I
8003617.070118.B
Replacement Procedure
Nautilus, Inc., (800) NAUTILUS / [phone], www.NautilusInc.com - Customer Service: North America [phone], [email protected] | outside U.S. [email protected] | © 2013 Nautilus, Inc.
NOTICE: This document provides instructions for the adjustment of the Brake Assembly on the Schwinn®IC2 Bike.
If you need assistance, please call Schwinn Customer Service at 1-800-605-3369.
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.
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.
• Read and understand the Part Replacement Procedure before working on the machine. Failure to obey the instructions and
safety warnings could cause injury to the service technician or bystanders.
• 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 traffic and exposure to bystanders.
• 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.
• If replacement parts are necessary, use only genuine Nautilus replacement parts and hardware. Failure to use genuine re-
placement parts can cause a risk to users, keep the machine from operating correctly and void the warranty.
• Be sure that all warning stickers and instructional placards applied to the product stay present and in good condition when
doing maintenance 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 affect user safety.
• Do not use the machine until all shrouds, instructions, warning labels and correct functionality have been verified and tested
for correct performance.
Tools Required (not included)
#2 Phillips screwdriver
3 mm Hex key
Small flathead screwdriver

15
Note: Your machine may not match the image. For reference only.
1. Using a #2 Phillips screwdriver, loosen and remove the
hardware that attaches the Brake Cover to the Main Frame. Set the
Brake cover and hardware safely aside for reassembly.
NOTICE: Hold the Brake Cover so that it does not fall.
2. Loosen the Resistance Knob (A) to the minimum resistance
setting.
3. Using a 3mm hex key, loosen the hardware (B1) that attaches
the Brake Assembly (B) to the Frame Mount (C). The screw holes in
the Brake Assembly arm are slots to let you adjust the position of
the arm on the Frame Mount.
Note: The nuts may turn along with the screws when you try to
loosen the hardware (B1). To hold the nut stable, wedge
a small flathead screwdriver diagonally between the nut
and the inside of the Frame Mount bracket (C).
4. Move the Brake Assembly (B) on the Frame Mount (C) as
necessary. Hold it in position and tighten the hardware.
5. Tighten the Resistance Knob (A) and inspect the Brake
Assembly movement. Adjust the Brake as necessary.
6. Reinstall the Brake Cover.
NOTICE: Do not crimp the cable.
7. Final Inspection
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.
Disconnect the data cable from the console before you service this machine.
A
B
B1
C

16
Adjust the Chain Tension
on the Schwinn®IC2 Bike Skill Level: II
8003619.070118.B
Replacement Procedure
Nautilus, Inc., (800) NAUTILUS / [phone], www.NautilusInc.com - Customer Service: North America [phone], [email protected] | outside U.S. [email protected] | © 2013 Nautilus, Inc.
NOTICE: This document provides instructions for the adjustment of the Drive Chain Tension on the Schwinn®IC2 Bike.
If you need assistance, please call Schwinn Customer Service at 1-800-605-3369.
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.
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.
• Read and understand the Part Replacement Procedure before working on the machine. Failure to obey the instructions and
safety warnings could cause injury to the service technician or bystanders.
• 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 traffic and exposure to bystanders.
• 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.
• If replacement parts are necessary, use only genuine Nautilus replacement parts and hardware. Failure to use genuine re-
placement parts can cause a risk to users, keep the machine from operating correctly and void the warranty.
• Be sure that all warning stickers and instructional placards applied to the product stay present and in good condition when
doing maintenance 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 affect user safety.
• Do not use the machine until all shrouds, instructions, warning labels and correct functionality have been verified and tested
for correct performance.
Tools Required (not included)
Pedal wrench 15 mm Wrench
10 mm Wrench
#2 Phillips screwdriver 15 mm Socket and
Wrench
Flathead screwdriver

17
Note: Your machine may not match the image. For reference only.
1. Loosen and remove the right Pedal. Set it safely aside for
reassembly.
Disconnect the data cable from the console before you service this machine.

18
2. Carefully remove the Chain Guard Center from the Chain Guard
Cover, and set it safely aside for reassembly.
3. Remove the hardware that attaches the Chain Guard Cover
to the Chain Guard Inside, and set it safely aside for reassembly.
Carefully remove the Chain Guard Cover and set it safely aside for
reassembly.
X4
X2

19
D
B
C
B
E
A
4. Use a 15 mm crescent wrench to hold the Axle Nut (B) on one
side steady and loosen the Axle Nut on the opposite side with a 15
mm socket and wrench.
Be sure to keep fingers clear of all pinch hazards.
5. Check the tension:
Find the point where the Drive Chain (A) is tightest during one
revolution of the Crank (C). You should be able to move the chain up
and down about 3/8” (in either direction).
If the Drive Chain is too loose—use a 10mm wrench to turn each
Flywheel Retainer bolt (D) 1/4 turn to the right.
If the Drive Chain is too tight—use a 10mm wrench to adjust the
Flywheel Retainer bolts (D).
6. Reinstall the right Pedal. Carefully align the threads and hand
tighten to prevent crossthreading. Then tighten fully with pedal
wrench.
7. Get on the bike and check the movement of the Drive Chain (A)
by rocking back and forth on the pedals. The Pedals and Flywheel
(E) should move as one.
Adjust the Drive Chain tension again if necessary.
8. Tighten the Axle Nuts (B) when the Drive Chain tension is
correct.
NOTICE: Make sure the Flywheel (E) is aligned with the Frame.
Be sure the Flywheel axle does not touch the Chain
Guard Inside.
9. Remove the right Pedal. Reinstall the Chain Guard Cover, Chain
Guard Center and Pedal.
10. Final Inspection
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.

20
Replace the Pedals
on the Schwinn®IC2 Bike Skill Level: I
8003620.070118.B
Replacement Procedure
Nautilus, Inc., (800) NAUTILUS / [phone], www.NautilusInc.com - Customer Service: North America [phone], [email protected] | outside U.S. [email protected] | © 2013 Nautilus, Inc.
NOTICE: This document provides instructions for the replacement of the Pedals on the Schwinn®IC2 Bike.
If you need assistance, please call Schwinn Customer Service at 1-800-605-3369.
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.
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.
• Read and understand the Part Replacement Procedure before working on the machine. Failure to obey the instructions and
safety warnings could cause injury to the service technician or bystanders.
• 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 traffic and exposure to bystanders.
• 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.
• If replacement parts are necessary, use only genuine Nautilus replacement parts and hardware. Failure to use genuine re-
placement parts can cause a risk to users, keep the machine from operating correctly and void the warranty.
• Be sure that all warning stickers and instructional placards applied to the product stay present and in good condition when
doing maintenance 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 affect user safety.
• Do not use the machine until all shrouds, instructions, warning labels and correct functionality have been verified and tested
for correct performance.
Tools Required (not included)
Pedal wrench