Spirit 16116605 CU800 User manual

Retain For Future Reference
Owner’s Manual
Model No.
161168800
CR800
16116605
CU800
- Assembly
- Operation
- Adjustments
- Parts
- Warranty
CAUTION:
Read and
understand this
manual before
operating unit

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Product Registration…………………………………………………………………….……. 2
Important Safety Instructions………………………………………………………………… 3
Important Electrical Information……………………………………………………………… 4
Important Operation Instructions…………………………………………………………….. 4
CR800 161168800 Instructions……………………………………………………………… 5
CU800 16116605 Instructions……………………………………………………………… 12
Features……………………………………………………………………………………..... 18
Operation of Your New Bike………………………………………………………………… 19
Maintenance………………………………………………………………..………………… 33
161168800 CR800 Part list and diagram ……………………………………………….… 34
16116605 CU800 Part list and diagram ………………………………………..…………. 39
Manufacturer’s Limited Warranty…………………………………………………….…….. 43
Serial number sticker is located:
CR800 CU800
Under Mast Cover Under Mast Cover
Table of Contents

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Thank you for your purchase of this quality stationary bike trainer from Dyaco Canada
Inc. Your new bike was manufactured by one of the leading fitness manufacturers in the
world and is backed by one of the most comprehensive warranties available. Through
your dealer, Dyaco Canada Inc. will do all we can to make your ownership experience
as pleasant as possible for many years to come. The local dealership where you
purchased this bike is your administrator for all Dyaco Canada Inc. warranty and service
needs. Their responsibility is to provide you with the technical knowledge and service
personnel to make your experience more informed and any difficulties easier to remedy.
Please take a moment at this time to record the name of the dealer, their telephone
number, and the date of purchase below to make any future, needed contact easy. We
appreciate your support and we will always remember that you are the reason that we
are in business. Please complete and mail your registration card today and enjoy your
new bike.
Yours in Health,
Dyaco Canada Inc.
Name of Dealer______________________________________
Telephone Number of Dealer___________________________
Purchase Date_______________________________________
RECORD YOUR SERIAL NUMBER
Please record the Serial Number of this fitness product in the space provided below.
Serial Number_______________________________________
REGISTER YOUR PURCHASE
The self-addressed product registration card must be completed in full and returned to
Dyaco Canada Inc.
CONGRATULATIONS ON YOUR
NEW BIKE AND WELCOME
TO THE SPIRIT FAMILY!
Product Registration

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WARNING - Read all instructions before using this appliance.
Do not operate the bike on deeply padded, plush or shag carpet. Damage to both the carpet
and bike may result.
Keep children away from the bike. There are obvious pinch points and other areas of caution
that can cause harm.
Keep hands away from all moving parts.
Never operate the bike if it has a damaged cord or plug. If the bike is not working properly, call
your dealer.
Keep the cord away from heated surfaces.
Never drop or insert any object into any openings.
Do not use outdoors.
To disconnect, turn all controls to the off position, then remove the plug from the outlet.
Do not attempt to use your bike for any purpose other than for the purpose it is intended.
The hand pulse sensors are not medical devices. Various factors, including the user’s
movement, may affect the accuracy of heart rate readings. The pulse sensors are intended only
as exercise aids in determining heart rate trends in general.
Wear proper shoes. High heels, dress shoes, sandals or bare feet are not suitable for use on
your bike . Quality athletic shoes are recommended to avoid leg fatigue.
SAVE THESE INSTRUCTIONS - THINK SAFETY!
Important Safety Instructions

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WARNING!
This product is self powered by a built in generator but does have the option of being plugged into
an A.C. outlet (Optional 24 VAC transformer available through your local Dyaco Canada Inc.
fitness dealer). The following are warnings to be observed when using the A.C. plug in option.
NEVER remove any cover without first disconnecting AC power supply.
If A.C. voltage varies by ten percent (10%) or more, the performance of your bike may be affected.
Such conditions are not covered under your warranty. If you suspect the voltage is low, contact
your local power company or a licensed electrician for proper testing.
When operated in the generator mode, be aware that the generator is producing A.C. power while
the bike is being used. Do not service the bike while the generator is spinning. Serious electric
shock could occur.
NEVER: expose the bike to rain or moisture. This product is NOT designed for Use outdoors, near
a pool or spa, or in any other high humidity environment.
NEVER operate the bike without reading and completely understanding the results of any
operational change you request from the computer.
NEVER use your bike in the A.C. power mode during an electrical storm. Surges may occur in your
household power supply that could damage the bike’s electrical components.
Do not use excessive pressure on console control keys. They are precision set to properly function
with little finger pressure. Pushing harder is not going to make the unit go faster or slower. If you
feel the buttons are not functioning properly with normal pressure, contact your Dyaco Canada Inc.
dealer.
Important Electrical Information
Important Operation Instructions

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Assembly Pack Check List For 161168800 CR800
Step 1
#
77
-
3/8" X 3/4” Flat
Washer (6 pcs)
#
84
-
3/8" X 1” Flat
Washer (4 pcs)
#
71
-
3/8” x 2”
Hex Head Bolt (4 pcs)
#
89
-
3/8"
Nylon Nut (6 pcs)
Step 2
#
136
-
M5 x 15mm
Phillips Head Screw (4 pcs)
#
77
-
3/8" x 3/4”
Flat Washer (6 pcs)
#
176
-
3/8” x 3/4”
Hex Head Bolt (6 pcs)
#
175
-
3/8” x 2-3/4”
Hex Head Bolt (2 pcs)
#
65
-
3/8” x 2-1/4”
Hex Head Bolt (4 pcs)

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Step 3
#
68
-
5/16” x 5/8”
Hex Head Bolt (8 pcs)
#
83
-
5/16" X 3/4“
Curved Washer (2 pcs)
#
76
-
5/16" X 11/16“
Flat Washer (6 pcs)
#
82
-
5/16”
Split Washer (2pcs)
Step 4
#
105
–
4mm x 16mm
Self Tapping Screw (4 pcs)
#
98
-
M6 x 15mm
Phillips Head Screw (4 pcs)
#
99
-
M5 x 12mm
Phillips Head Screw (8 pcs)

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Tools
#114 - Phillips Screw Driver (1 pc)
#
112
-
12/14mm Wrench (1 pc)
#
132
-
14/15mm Wrench (1 pc)

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STEP 1: REAR STABILIZER & SEAT HANDLEBAR ASSEMBLY
1. Install the Rear Stabilizer (7) onto the Main Frame with four 3/8” x 2-1/4” Hex Head bolts (65)
and four 3/8” x 1” Flat Washers (84).
2. Install the handlebar assembly (6) onto the seat carriage (4) with four 3/8” X 2” bolts (71)
installed through the top holes and secured with four 3/8” flat washers (77) and 3/8” nylon nuts
(89). Install two 3/8” X 2-3/4” bolts (175) through the side holes and secure with two 3/8” flat
washers (77) and 3/8” nylon nuts (89).
3. Plug the Left hand pulse wire (27) into the corresponding left socket (42) located in the left
plastic side case under the seat carriage, and the Right hand pulse wire (21) into the right
socket (26).
Assembly Instructions For 161168800 CR800

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STEP 2: SEAT BACK
4. Install Seat Back Frame (5) onto the Seat Carriage (4) with six 3/8” x 3/4” Hex Head bolts (176)
and 3/8”x 3/4” flat washers (77).
5. Install the Seat Back Cover (128) onto the Seat Back with four M5 × 15m/m Phillips Head
Screws (136).

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STEP 3: CONSOLE MAST ASSEMBLY
1. Install the console mast cover (31) onto the console mast (2), making sure it is facing the correct
direction as in the picture below. Run the two wire harnesses through the bottom of the console
mast tube and out the top opening.
2. Slide the console mast into the receiving tube (1) being careful to not pinch the wires. Fasten the
console mast with six 5/16” x 5/8” bolts (68) and four 5/16” flat washers (76) on the side bolts and
two 5/16” curved washers (83) on the front bolts. Snap the console mast cover in place.
3. Install the front handlebars (3) onto the console mast with two 5/16” x 5/8” bolts (68), 5/16” split
washers (82) and 5/16” flat washers (76).

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STEP 4: CONSOLE, SEAT, COVERS, PEDALS
1. Install the front and rear stabilizer covers (32 & 37) and secure to the frame with four M5 x 12mm
screws (99).
2. Install the left and right cup holders (39 & 38) to the rear handlebars with four self tapping screws
(105).
3. Install the bottom seat cushion (61) to the seat carriage (4) with four M6 x 15mm screws (98).
4. Install the Pedals (116 L, 117 R) into the Crank arms (51L, 51R). Remember that the left pedal has
a reverse thread and will be screwed into the crank in the opposite rotation from normal threads.
There is an “L” stamped into the end of the threaded post of the left pedal and an “R” in the right.
Make sure to tighten the pedals as much as you possibly can. It may be necessary to re-tighten
the pedals if you feel a thumping during pedaling the bike. A clicking noise, or thumping, sound
during pedaling is usually caused by the pedals being too loose.
5. Connect the two wire harnesses (44 & 45) to the corresponding connectors on the back of the
console. Install the console onto the console mast and secure with four M5 x 12mm screws (99)
being careful to not pinch the wires.

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Assembly Pack Check List For 16116605 CU800
Step 1
#
71
-
3/8" X 25
Flat Washer (4pcs)
#
50
-
3/8” x 2-1/4”
Hex Head Bolt (4pcs)
Step 2
#
51
-
5/16” x 5/8”
Hex Head Bolt (7pcs)
#
99
-
5/16" X 19
Curved Washer (1pcs)
#
72
-
5/16" X 18
Flat Washer (6pcs)
Step 3
#
51
-
5/16” x 5/8”
Hex Head Bolt (2pcs)
#
72
-
5/16" X 18
Flat Washer (2pcs)
#
103
-
5/16”
Split Washer (2pcs)
Step 4
#
58
-
M5 x 12mm
Phillips Head Screw (10pcs)

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Tools
#93 - Phillips Screw Driver (1pc)
#
100
-
12/14mm Wrench (1pc)
#
117.
13/15mm Wrench (1pc)

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STEP 1: REAR STABILIZER ASSEMBLY
1. Install the Rear Stabilizer (5) onto the Main Frame (1) with the four 3/8” x 2-1/4” Hex Head
Bolts (50) and four 3/8” Flat Washers (71).

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STEP 2: FRONT CONSOLE MAST ASSEMBLY
1. Unravel the Computer Cable (29) and snake it through the Console Mast Cover (38) and the
Console Mast (2) until the cable connector comes out the top opening of the console mast.
Slide the plastic cover (38) onto the console mast, ensuring the correct orientation of the cover.
2. Install the Console Mast (2) onto the Main Frame (1) with seven 5/16” x 5/8” Hex Head bolts
(51), six 5/16” Flat Washers (72) on the side screws and one 5/16” Curved Washer (99) on the
front screw.

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STEP 3: HANDLE BAR ASSEMBLY
1. Run the two hand pulse wires (26) into the hole in the handle bar mounting plate and out
through the hole in the console plate. Install the Handle Bar (3) onto the Console Mast (2) with
two 5/16” x 5/8” Hex Head bolts (51), two 5/16” Flat Washers (72) and two 5/16” Split Washers
(103) being careful not to pinch the hand pulse wires.

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STEP 4: CONSOLE, SEAT, PEDALS AND BEAUTY COVERS ASSEMBLY
1. Insert the Computer Cable (29) and two Hand pulse cables (26, 28) into the connectors in the
back of the Console (34). Install the Console (34) onto the Console Mast (2). Install the two
M5x12mm bottom screws first (58). Install the cover plate (12) with the two top mounting
screws (58).
2. Install the Front Stabilizer Cover (40) and the Rear Stabilizer Cover (41) onto the Main Frame (1)
with four M5x12mm Phillips Head Screws (58).
3. Install the Pedals (45 L, 46R) onto the Crank arms (16L, 16R). Remember that the left pedal
has a reverse thread and will be screwed into the crank in the opposite rotation from normal
threads. There is an “L” stamped into the end of the threaded post of the left pedal and an “R”
in the right. Make sure to tighten the pedals as much as you possibly can. It may be necessary
to re-tighten the pedals if you feel a thumping during pedaling the bike. A noise or feeling such
as a thumping or clicking is usually caused by the pedals being too loose.
4. Install the Seat mount slide (7) onto the track on top of the seat tube with the seat post facing
forward. Install the seat (19) onto the seat post.
5. Install the Drink Bottle Holder (116) onto the Console Mast (2) with two M5x12mm Phillips Head
Screws (58).

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Foot pedals
Through research performed with a leading sports scientist and physical rehabilitation expert,
Spirit engineering has developed a breakthrough in pedal design. Typical stationary exercise
bikes are wider than a normal road bike. The reason is to allow for the braking mechanism,
pulleys, drive components and beauty covers. Since the bike is wider so is the distance between
the pedals; this width between the pedals is called the Q factor.
Spirit has designed our pedal system so the Q factor is the smallest in the industry, but we did not
stop there. We have also custom designed and tooled a new pedal that provides a two degree
inward tilt to compensate for the Q factor not being perfect. Having a small Q factor in addition to
the two degree inward tilt of the pedals puts the user into a biomechanical neutral alignment. This
means that your feet, ankles, knees and hips are lined up properly ensuring a comfortable
workout.
Transportation
The bike is equipped with two transport wheels, which are engaged when rear of the bike is lifted.
Features

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■ 161168800 CR800 & 16116605 CU800 Console
Power on
Spirit commercial bikes have a built-in generator for power and do not need to be plugged into an
AC outlet. To power up the Bike simply start to pedal, the console will turn on automatically.
When initially powered on the console will perform an internal self-test. During this time all the
lights will turn on for a short time. When the lights go off the dot matrix display will show a software
version (i.e. VER 1.0) and the message window will display an odometer reading. The odometer
reading displays how many hours the bike has been used and how many virtual miles the bike has
gone. The display shows: ODO 123 MI 123 HRS.
The odometer will remain displayed for only a few seconds then the console will go to the start up
display. The dot matrix display will be scrolling through the different profiles, showing the programs,
and the message window will be scrolling the start up message. You may now begin to use the
console.
Operation of Your Stationary Bike