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.