Smooth Fitness EVO REV 400 User manual

USER’S MANUAL
EVO REV 400 ELLIPTICAL TRAINER
MODEL NUMBER: REV 400
USER WEIGHT LIMITATION: 300 lbs.
TOLL FREE CUSTOMER SERVICE NUMBER: 1.888.800.1167
SERIAL NUMBER (found on frame):
V-02-20060119

EVO REV 400 ELLIPTICAL TRAINER
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2
PREASSEMBLY
For future service or related questions:
Please staple your receipt and/or write in the name and phone number of the retail store where you purchased your EVO
Fitness Elliptical Trainer.
Name: ______________________________ Phone Number: ___________________ Receipt: ______________________
Open the boxes:
You are now ready to open the boxes of your new equipment. Make sure to inventory all of the parts that are included in the
boxes. Check the Parts List for a full count of the number of parts included for this product to be assembled properly. If you
are missing any parts or have any assembly questions call your local EVO dealer or contact us directly at 888-800-1167.
Gather your tools:
Before starting the assembly of your unit, make sure that you have gathered all the necessary tools you may require to
assemble the unit properly. Having all of the necessary equipment at hand will save time and make the assembly quick and
hassle-free.
Clear your work area:
Make sure that you have cleared away a large enough space to properly assemble the unit. Make sure the space is free
from anything that may cause injury during assembly. After the unit is fully assembled, make sure there is a comfortable
amount of free area around the unit for unobstructed operation.
Invite a friend:
Some of the assembly steps may require heavy lifting. It is recommended that you obtain the assistance of another person
when assembling this product.
User Weight Limitation:
Please note that there is a weight limitation for this product. If you weigh more than 300lbs. it is not recommended that
you use this product. Serious injury may occur if the user’s weight exceeds the limit shown here. This product is not
intended to support users whose weight exceeds this limit.

EVO REV 400 ELLIPTICAL TRAINER
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HARDWARE COMPARISON CHART
Hardware chart:
For your convenience, we have identified the hardware used in the assembly of this product. This chart is provided to help
you identify those items that may be unfamiliar to you.
NO. DESCRIPTION QTY.
30 20 x 91 x M14mm Bolt 2
77 M8 x 60mm Bolt 2
78 M10 x 90mm Bolt 2
79 M8 x 80mm Bolt 2
80 M8 x 15mm Bolt 2
88 M14 Nut 2
91 ID 8mm Curve Washer 4
97 M4 x 12mm Screw 8
98 M10 Nut 2
100 M4 x 50mm Screw 1
101 ID 10mm Curve Washer 2
102 M4 x 15mm Screw 8
105 M6 x 20mm Bolt 4
A M14 Bushing Tool 1
B 5mm Allen Key 1
C 8mm Wrench 1
D Wrench for M10 Nut 1
E Wrench 1
30 80
102
97
100
101
78
79
77
BC
88
98
D
91
A
E
105
MILLIMETERS

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HARDWARE COMPARISON CHART
Hardware chart:
For your convenience, we have identified the hardware used in the assembly of this product. This chart is provided to help
you identify those items that may be unfamiliar to you.
NO. DESCRIPTION QTY.
1 Computer 1
2 Front Upright Frame 1
5 Left Upright 1
6 Right Upright 1
7 Hand Rail Frame – Left 1
8 Hand Rail Frame – Right 1
9 Water Bottle Holder 2
13 Handlebar Cover 2
14 Handlebar Inside Cover 4
16 Handlebar – Left 1
17 Handlebar – Right 1
59 Front Frame Cover – Upper 1
60 Front Frame Cover –
Lower 1
99 Frame 1
107 Water Bottle 1
256
59
60
13
14
9
78
1
99
16 17
107

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PARTS LIST
No. Description Qty. Order No. No. Description Qty. Order No.
1 Computer 1 REV400-01 30 20 x 91 x M14mm Bolt 2 REV400-30
2 Front Upright Frame 1 REV400-02 31 Bearing 6804zz 4 REV400-31
3 Console Small Cover - Left 1 REV400-03 32 Level Adjusters 2 REV400-32
4 Console Small Cover - Right 1 REV400-04 33 Pedal Arm - Left 1 REV400-33
5 Left Upright 1 REV400-05 34 Pedal Arm - Right 1 REV400-34
6 Right Upright 1 REV400-06 35 C Clips 2 REV400-35
7 Hand Rail Frame - Left 1 REV400-07 36 Bearing 2202zz 2 REV400-36
8 Hand Rail Frame - Right 1 REV400-08 37 Pedal Arm Adjusters
Bushin
g
2 REV400-37
9 Water Bottle Holder 2 REV400-09 38 Bearing 2 REV400-38
10 Hand Rail Cap 4 REV400-10 39 Pedal Arm Rear Shaft 2 REV400-39
11 Handlebar Pivot Outside
B
us
hin
g
2 REV400-11 40
Pedal Arm Rear Shaft
B
us
hin
g
2 REV400-40
12 Handlebar Pivot Inside Bushing 2 REV400-12 41 Adjuster Motor 1 REV400-41
13 Handlebar Cover 2 REV400-13 42 Spiral Shaft 1 REV400-42
14 Handlebar Inside Cover 4 REV400-14 43 Motor Bracket 1 REV400-43
15 Bearing 6004zz 4 REV400-15 44 Volute Shaft 1 REV400-44
16 Handlebar - Left 1 REV400-16 45 Motor Control Board 1 REV400-45
17 Handlebar - Right 1 REV400-17 46 Magnet Bracket Shaft 1 REV400-46
18 Pedal Arm Front Pivot Cover -
L
e
f
t
4 REV400-18 47 Spring 1 REV400-47
19 Hand Rail Frame Foam Grips 2 REV400-19 48 Magnet Bracket Shaft 1 REV400-48
20 Handlebar Foam Grips 2 REV400-20 49 Crank Disk Support Cover 2 REV400-49
21 Hand Pulse Sensor 2 REV400-21 50 Crank 2 REV400-50
22 Pedal Soft Cushion 2 REV400-22 51 Crank Disk 2 REV400-51
23 Pedal 2 REV400-23 52 Belt 1 REV400-52
24 Pedal Support Base 2 REV400-24 53 M8 x 20mm CAP Bolt 1 REV400-53
25 Pedal Buffer Sets 2 REV400-25 54 Flywheel Assembly 1 REV400-54
26 Bearing 608zz 8 REV400-26 55 Bearing 6000zz 3 REV400-55
27 Bushing 8 x 12mm 4 REV400-27 56 Flywheel Axle 1 REV400-56
28 Pedal Fixing Base 2 REV400-28 57 Flywheel Shaft Fixing 1 REV400-57
29 Pedal Cover 2 REV400-29 58 Volute Bracket 1 REV400-58

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PARTS LIST
No. Description Qty. Order No. No. Description Qty. Order No.
59 Front Frame Cover - Upper 1 REV400-59 89 M10 Nylon Nut 2 REV400-89
60 Front Frame Cover - Lower 1 REV400-60 90 M12 Nut 1 REV400-90
61 Crank Disk Axle 1 REV400-61 91 ID 8mm Curve Washer 4 REV400-91
62 Crank Disk Support Bushing 2 REV400-62 92 10 x 22 x 2mm Washer 2 REV400-92
63 Bearing 6005zz 2 REV400-63 93 10 x 15 x 1.5mm 2 REV400-93
64 Bearing 6400zz 4 REV400-64 94 M4 x 40mm CAP Screw 1 REV400-94
65 Strengthen Wheel Adjusters Set 1 REV400-65 95 M4 x 19mm Hard Screw 32 REV400-95
66 Rear Stabilizer Cap 2 REV400-66 96 M4 x 19mm Screw 5 REV400-96
67 Rear Stabilizer Cushion 2 REV400-67 97 M4 x 12mm Screw 8 REV400-97
68 Caster 2 REV400-68 98 M10 Head Nut 2 REV400-98
69 Front Cover 1 REV400-69 99 Frame 1 REV400-99
70 Frame Outside Cover - Left 1 REV400-70 100 M4 x 50mm Bolt 1 REV400-100
71 Frame Inside Cover - Left 1 REV400-71 101 ID 10mm Curve Washer 2 REV400-101
72 Frame Inside Cover - Right 1 REV400-72 102 M4 x 15mm Hard Screw 8 REV400-102
73 Frame Outside Cover - Right 1 REV400-73 103 Upper Computer Wire 1 REV400-103
74 M8 x 15mm Allen Head Bolt 26 REV400-74 104 Lower Computer Wire 1 REV400-104
75 M8 x 20mm CAP Screws 2 REV400-75 105 M6 x 20mm Bolt 4 REV400-105
76 M8 x 90mm Allen Head Bolt 4 REV400-76 106 Lower Hand Pulse Wire 1 REV400-106
77 M8 x 60mm Allen Head Bolt 2 REV400-77 107 Water Bottle 1 REV400-107
78 M10 x 90mm Bolt 2 REV400-78
79 M8 x 80mm Allen Head Bolt 2 REV400-79
80 M8 x 15mm Bolt 6 REV400-80
81 M10 x 45mm Allen Head Bolt 2 REV400-81
82 M10 x 45mm Screw 2 REV400-82
83 M6 x 20mm Allen Head Bolt 8 REV400-83
84 M6 x 15mm Screw 4 REV400-84
85 Fixing Inserts 12 REV400-85
86 M6 Nylon Nut 8 REV400-86
87 M8 Nylon Nut 5 REV400-87
88 M14 Nut 2 REV400-88

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PARTS DIAGRAM
A MAJORITY OF THE PARTS SHOWN HERE HAVE BEEN PREASSEMBLED AT THE FACTORY.
88 18
77
74 86 24
78
26
29
74
34
39 38 37
40
84
36 35
29
37
33 38
84 36
35
95
24
25
18 30 31
74 29
40
39
85 95
29 85
95
28
98
101
28 18
31 30
32
26
26
87 76
27 90
91 2687
32
101
77 27
74
95
76
86
25
916
75
91 79
78
83
23 18 88
5
22 15 12
13 6
13 75
15 11
14
80 97
79 91 15
11 14 97 14
15
12 80
97
17
4
2
3
9
1
10 21
21
95
10 19 20
7
21
10
20 8
19
95 21
10
23
83
22
97 102
102
105

EVO REV 400 ELLIPTICAL TRAINER
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PARTS DIAGRAM
A MAJORITY OF THE PARTS SHOWN HERE HAVE BEEN PREASSEMBLED AT THE FACTORY.
69
51
95 95
72
85 96
95
95
96 71
85
95 70 74
74
84
5049
52
50 49 74
64
80 56 57
95
95
85
67
95
96
95
85 73
95
61
89
68
67
68 95
81 66
81
66 63
80
62
54
74
53
74 84
43
60
82
62 63
55
65 93
94 99
90
48
55 51
44
47
85
100
59
46
92
87 41
42
45
58
95
95
95
95
95

EVO REV 400 ELLIPTICAL TRAINER
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ASSEMBLY
STEP 1:
NOTE: First make sure to connect the Upper Computer Wire (103) and Lower Computer Wire (104) as shown below.
Attach the Front Upright Frame (2) to the Frame (99) and secure using the M10 x 90mm Bolts (78), ID 10mm Curve Washers
(101) and M10 Head Nuts (98).

EVO REV 400 ELLIPTICAL TRAINER
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ASSEMBLY
STEP 2:
NOTE: First make sure to connect the Upper Computer Wires (103) and Lower Hand Pulse Wires (106).
Attach the Computer (1) to the Front Upright Frame (2) using four M6 x 20mm Bolts (105).

EVO REV 400 ELLIPTICAL TRAINER
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ASSEMBLY
STEP 3:
NOTE: First make sure to connect the Hand Pulse Sensor Wires (21).
Slide the Handlebar – Left (16) and Handlebar – Right (17) onto the Front Upright Frame (2).

EVO REV 400 ELLIPTICAL TRAINER
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ASSEMBLY
STEP 4:
Slide the Left Upright (5) on the Front Upright Frame (2) and secure it with an ID 8mm Curved Washer (91) and M8 x 80mm
Allen Head Bolt (79). Repeat the procedure on the Right Upright (6).
79 91
5 2 6 7991

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ASSEMBLY
STEP 5:
Attach the Left Upright (5) and Right Upright (6) to the Frame (99) and secure using M8 x 60mm Allen Head Bolts (77) and ID
8mm Curve Washers (91).
77
65
77
91
91
99
77 77
91
99
65
91

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ASSEMBLY
STEP 6:
Slide the20 x 91 x M14mm Bolt (30) through the Pedal Arm – Left (33) and Handlebar – Left (16) and secure with M14 Nut
(88) using the 8mm Wrench (C), M14 Bushing Tool (A) and 5mm Allen Key (B) as shown.
88
A
B
C
16
33
30
A
B
88
16
33
30
C

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ASSEMBLY
STEP 7:
Slide the 20 x 91 x M14mm Bolt (30) through the Pedal Arm – Right (34) and Handlebar – Right (17) and secure with M14
Nut (88) using the 8mm Allen Key (C), M14 Nut Bushing Tool (A) and 5mm Allen Key (B) as shown.
B
A88
30 C
17
34
88
A
B
17
30
C
34

EVO REV 400 ELLIPTICAL TRAINER
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ASSEMBLY
STEP 8:
Attach the Pedal Arm Front Pivot Cover (18) to the ends of the Handlebar – Right (17) and Pedal Arm – Right (34). Repeat
the procedure on the Pedal Arm – Left (33) and Handlebar – Left (16).
34
18
17
18
16
33
17
18
34
16
33

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ASSEMBLY
STEP 9:
Attach the Front Frame Cover – Upper (59) and Front Frame Cover – Lower (60) to the Left Upright (5), Right Upright (6) and
Frame (99). Secure with Fixing Inserts (85) and M4 x 50mm Screw (100).

EVO REV 400 ELLIPTICAL TRAINER
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ASSEMBLY
STEP 10:
Attach the Handlebar Cover (13) to the front side of the front side of the Handlebar – Right (17) and secure with M4 x 15mm
Hard Screws (102). Then attach the Handlebar Inside Cover (14) to the backside of the Handlebar – Right (17) and secure it
to the Handlebar Cover (13) using M4 x 12mm Screws (97). Repeat the procedure on the Handlebar – Left (16).
14
13
13
102 102
97
97
13
14
14
17
16
17
17

EVO REV 400 ELLIPTICAL TRAINER
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ASSEMBLY
STEP 11:
Slide the Water Bottle Holders (9) onto the Right Upright (6) and Left Upright (5).
9
9
65

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ASSEMBLY
STEP 12:
Slide the Hand Rail Frame – Left (7) through the Water Bottle Holder (9) on the Left Upright (5) and secure with M8 x 15mm
Bolt (80) as shown in FIG1. Repeat the procedure on the Right Upright (6).