Spirit Johnny G User manual

JOHNNY G SPIRIT BIKE
SERVICE MANUAL

Johnny G by Spirit

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4 1. PARTS REPLACEMENT
23 2. ELECTRONIC PARTS
24 2.1 UPPER CONTROLLERS
25 2.2 LOWER CONTROLLER AND DRIVER
26 3. ELECTRICAL CONFIGURATIONS
28 4. BASIC CONNECTIONS AND WIRING
29 4.1 LED DISPLAY PCB BOARD
30 4.2 MPU PCB BOARD
31 4.3 MCU BOARD WIRE CONNECTIONS & FUNCTION
33 4.4 LOWER CONTROL BOARD WIRE CONNECTIONS
35 4.5 BRAKE ASSEMBLY
36 4.6 LIMIT SENSOR BOARD
37 4.7 DC MOTOR ENCODER BOARD
38 5. ERROR MESSAGES AND TROUBLESHOOTING
39 5.1 ERROR MESSAGES
40 5.2 CIRCUIT DIAGRAM
41 5.3 MAINTENANCE MODE
51 5.4 TROUBLESHOOTING
52 6 CONSOLE UPDATE
53 6.1 CONSOLE SOFTARE UPDATE
54 6.2 GFIT MODEL UPDATE

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Johnny G by Spirit
SECTION 1
PARTS REPLACEMENT

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JOHNNY G SPIRIT BIKE PARTS
1. Plastic Cover
2. Front stabilizer assembly
3. Crank arm
4. Aluminum ywheel
5. Generator
6. Generator mounting bracket
7. Generator drive belt
8. Secondary pulley
9. Primary pulley
10. Drum brake assembly
11. RPM sensor
12. Timing belt
13. Idler wheel assembly
14. Lower control board
15. Brake assembly

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Johnny G by Spirit
PARTS REPLACEMENT GENERATOR
1. Use Phillips head screw
driver to remove four 12mm
Phillips head screws #134
and two 16mm Sheet Metal
Screws #131 from both
Plastic Covers (R and L).
2. Move the crank arm to
the horizontal position to
facilitate disassembly of the
Plastic Cover.
3. Remove both Plastic Covers
(R and L).
4. Remove the Drive Belt #43.
5. Use Phillips head screw driver

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PARTS REPLACEMENT GENERATOR
to remove four 12mm
Phillips head screws #134
from the Mounting Bracket
#42.
6. Unplug the Generator
Power Cable (96) from the
Generator (57).
7. Use Phillips head screw
driver to remove four Flat
Washers #118 and four
8mm Phillips Head Screw
#130 from the mounting
Bracket #42.
8. Use diagonal pliers to cut
the cable tie.

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Johnny G by Spirit
PARTS REPLACEMENT GENERATOR
9. Remove the Generator
Bracket #42.
10.Replace with new
Generator #57.
Reverse above steps to
install new parts.

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PARTS REPLACEMENT GENERATOR DRIVE BELT
1. Use Phillips head screw driver
to remove four 12mm Phillips
head screws #134 and two
16mm Sheet Metal Screws
#131 from both Plastic Covers
(R and L).
2. Move the crank arm to
the horizontal position to
facilitate disassembly of the
Plastic Cover.
3. Remove both Plastic Covers
(R and L).
4. Use M8 L Allen wrench to
remove the M12 Axle Bolt
#105 on the Crank Arm (L)
#46.
5. Use Crank wrench to remove

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Johnny G by Spirit
PARTS REPLACEMENT GENERATOR DRIVE BELT
the Crank Arm (L) #46.
6. The two drive Belts #43
then replace new Belts.
Reverse above steps to
reinstall parts.

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PARTS REPLACEMENT LOWER CONTROL BOARD
1. Use Phillips head screw driver
to remove four 12mm Phillips
head screws #134 and two
16mm Sheet Metal Screws
#131 from both Plastic Covers
(R and L).
2. Move the crank arm to
the horizontal position to
facilitate disassembly of the
Plastic Cover.
3. Remove both Plastic Covers
(R and L).
4. Use 7mm open end wrench
to remove four Nylon Nuts
#163.

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Johnny G by Spirit
5. Use diagonal pliers to cut
the cable tie. 6. Unplug the Generator
Power Cable from the
Lower Control Board #87.
7. Remove the Lower Control
Board #87 then replace
with new Lower Control
Board.
Reverse above steps to
reinstall parts.

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PARTS REPLACEMENT BELT REPLACEMENT
1. Use Phillips head screw driver
to remove four 12mm Phillips
head screws #134 and two
16mm Sheet Metal Screws
#131 from both Plastic Covers
(R and L).
2. Move the crank arm to
the horizontal position to
facilitate disassembly of the
Plastic Covers.
3. Remove both Plastic Covers
(R and L).
4. Use 10mm open end
wrench to remove the M6
Nyloc Nut.

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Johnny G by Spirit
5. Use 13mm open end
wrench to remove the M8
Hex Head Bolt #139 and
M6 Eye Bolt #129.
6. Use 10mm open end
wrench to remove the M6
Nyloc Nut #171.
7. Use M4 Allen wrench to
remove two M5 Bolts #145
and Flat Washers #120.
8. Use Phillips head screw
driver to loosen the M5
Phillips Head Screw #134
to remove the RPM Sensor
#86.

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9. Support front of main
frame off ground to allow
access to Front Stabilizer
bolts and removal of
ywheel. For safety, two
people should lift and
support the frame when
elevating off the ground.
10.There are 4 M10 hex head
bolts in front Stabilizer
Assembly. Remove the 2 in
the front side and loosen the
2 in the rear.
11. Rotate the front Stabilizer
Assembly #5 down about
45 degrees.
12. Use 19mm open end wrench
to remove 2 M12 Nylon
Nuts #169 and the M6 Eye
Bolt #129 then remove the
Flywheel Assembly. Replace
the belt. (Place a towel under
the ywheel to avoid ywheel
scratches). Replace the belt.
Reverse above steps to
reinstall parts and adjust the
belt tension between
100-110 pounds.

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Johnny G by Spirit
PARTS REPLACEMENT BRAKE ASSEMBLY
1. Use Phillips head screw driver
to remove four 12mm Phillips
head screws #134 and two
16mm Sheet Metal Screws
#131 from both Plastic Covers
(R and L).
2. Move the crank arm to
the horizontal position to
facilitate disassembly of the
Plastic Cover.
3. Remove both Plastic Covers
(R and L).
4. Use 10mm open end
wrench to remove the M6
Nyloc Nut.

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5. Use 13mm open end
wrench to remove the M8
Hex Head Bolt #139 and
M6 Eye Bolt #129.
6. Use 10mm open end
wrench to remove the M6
Nyloc Nut #171.
7. Use M4 Allen wrench to
remove two M5 Bolts #145
and Flat Washers #120.
8. Use Phillips head screw
driver to loosen the M5
Phillips Head Screw #134
to remove the RPM Sensor
#86.

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Johnny G by Spirit
2. Support front of main
frame off ground to allow
access to Front Stabilizer
bolts and removal of
ywheel. For safety, two
people should lift and
support the frame when
elevating off the ground.
3. There are 4 M10 hex head
bolts in front stabilizer
Assembly, remove the 2 in
the front and loosen the 2 in
the rear.
4. Rotate the front Stabilizer
Assembly #5 down about
45 degrees.
5. Use 19mm open end wrench
to remove 2 M12 Nylon
Nuts #169 and the M6 Eye
Bolt #129 then remove the
Flywheel Assembly. Replace
the belt. (Place a towel under
the ywheel to avoid ywheel
scratches). Replace the belt.
Reverse above steps to
reinstall parts and adjust the
belt tension between
100-110 pounds.

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13. Use 14mm open end
wrench to remove 2 M8
Hex Head Bolts #139 and
the Lock Washers #122 as
shown above.
14. With assistance, raise front
of bike frame to allow
for clearance of Brake
Assembly from ywheel
during removal and when
reinstalling.
15. Using diagonal pliers cut
the cable tie then unplug
the Brake Power Cable.
Reverse above steps to
reinstall parts.

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Johnny G by Spirit
PARTS REPLACEMENT DRUM BRAKE ASSEMBLY
1. Use Phillips head screw driver
to remove four 12mm Phillips
head screws #134 and two
16mm Sheet Metal Screws
#131 from both Plastic Covers
(R and L).
2. Move the crank arm to
the horizontal position to
facilitate disassembly of the
Plastic Cover.
3. Remove both Plastic Covers
(R and L).
5. Use M4 Allen wrench to
remove two M5 Bolts #145
and Flat Washers #120.