Stairmaster AirFit User manual

Assembly Manual
StairMaster AirFit Assembly & Setup
Use the following procedures to unpack and assemble your AirFit manufactured by StairMaster.
UNPACKING AND PARTS LIST
Position the shipping carton so the “Heavy End” logo is located at the bottom. Open the top of the carton and fold back all four flaps. Carefully
tilt the box forward so that the box may be lifted to expose the bike. Remove all parts from the shipping carton and foam inserts, and verify
that the following parts are included in your shipment:
NOTE: All tools required to assemble the bike are included within the packaging, except for a Rubber Mallet, which is recommended
when assembling the pedals onto the bike.
AirFit Parts List
Description
Qty.
Description
Qty.
Main Frame Assembly
1
M8x15mm Button Head Bolt
14
Console Mast
1
M8x16 O.D. Flat Washer
14
Console
1
M8x20mm Socket Head Cap Screw
2
Left and Right Arms
2
M8x25mm O.D. Flat washer
2
Left and Right Foot Stand
2
M24x1.5 Hex Jam Nut
2
Left and Right Foot Pedals
2
M8x20mm Button Head Bolt
4
Seat Post
1
M8x1.25x12mm Hex Screw
M
4x10mm Socket Head Cap Screw
M
4x10mm Phillips Pan Head Form Screw
2
2
2
Take time now to enter your AirFit serial number in the space below (serial number is located on underside the bottom rear cross member).
If parts are missing, or if you have any operational questions, please call StairMaster’s Service department at [phone].
Have your serial number ready.
Serial No.
NOTE: If you are missing any of the parts listed above, inspect the packing material and the box for items that may have been
overlooked.
If parts are missing, or if you have any product questions, please call StairMaster’s Service Department at [phone], please have
your bike’s serial number ready.
CAUTION: Damage to the bike during assembly is not covered as part of the limited StairMaster warranty. Take care not to drop or lean the
bike on the handle bar pop-pin. Carefully stand the bike up in the normal upright position on a stable surface so it will not tip over during
assembly.

Assembly Manual
ASSEMBLYINSTRUCTIONS
1.
Locate an open area to unbox the packaged machine
(Fig. 1
).
Fig. 1
2.
Cut all straps and remove the top half (Fig. 2) of the
c
ardboard box to expose the base and assembly components of the
m
achine.
Fig. 2
3.
Extract the base (Fig. 3) from the lower box.
Fig. 3

Assembly Manual
4. Hover the console mast (Fig. 5) over the base joints and
mate the wires coming out of each component.
Fig. 4
5. Slide the console mast (Fig. 6) over the neck joints of
the base and align the three securing bolt holes.
WARNING
To prevent any damage, verify the cable harness is
not kinked
and out of the way of the brackets when
mating the console
mast to the base of the
machine.
6. Install three bolts with washers (Fig. 7) thru each neck joint
hole and torque all bolts to their final value. Repeat this for
the opposite side.
Hardware
QTY
M8 x 15mm Button Head Bolt
M
8 x 16mm O.D. FlatWasher
6
6
Final Torque:
18-19 Lb-Ft (24-26 Nm)
Fig. 5
Fig. 6

Assembly Manual
Hardware
QTY
M8 x 20mm Socket Head Cap Screw
M
8 x 25mm O.D. FlatWasher
2
2
7. Hover the console (Fig. 8) over the neck mast and connect
the cable coming out of the mast into the cable protruding
from the console.
Fig. 7
8. Mount the console (Fig. 9) to the frame using the four pre-
installed Phillips head screws thru each of the available
holes on the neck plate.
Fig. 8
9. Mount the left & right grip arms (Fig. 10) onto the
corresponding pivot shafts located on the base of the
machine while mating the end of the grip arms to each of
the crank linkages and keeping the arms together by
loosely inserting a socket head cap screw with washer to
each joint.
Fig. 9

Assembly Manual
Hardware
QTY
M8 x 20mm Button Head Bolt
4
10. Lock the grip arms in place (Fig. 11) by threading the large
jam nut onto each pivot shaft and applying the
corresponding final torque to each nut.
Hardware
QTY
M24 x 1.5 Hex Jam Nut
2
Final Torque
48-50 Lb-Ft (65-67.8 Nm)
Fig. 10
11. Secure the left & right grip arms to the crank linkages by
applying final toque (Fig. 12) to the joining bolt and
plugging the bearing housings with the corresponding
plastic caps.
Final Torque
100-110 Lb-Ft (136-149 Nm)
Fig. 11
12. Mount the left & right foot stand mounting plate (Fig. 13) onto
the arm pivot shafts and secure them in place by bolting the
respective button head cap screws thru the center of each plate
and into the pivot shafts.
Fig. 12

Assembly Manual
Hardware
QTY
M8 x 15mm Button Head Bolt
M
8 x 16mm O.D. FlatWasher
8
8
13. Attach the left & right plastic foot stand covers (Fig. 14) over the
mounting plates and secure the covers from the underside by
bolting four button head cap screws along with washers into the
corresponding four available holes.
Fig. 13
14. Locate the left & right foot pedals.
ASSEMBLY TIP
Each pedal has an “L” or “R” marking (Fig. 15) stamped
into the strap that indicates the user side for installation
purposes.
Fig. 14
15. Insert each pedal (Fig. 16) into the corresponding crank
arm.
F
ig

Assembly Manual
16. Insert the pedal securing bolts into each pedal (Fig. 17)
thru the back of each crank arm and torque each screw
to its final value.
Hardware
QTY
M8x1.25x12mm hex Screw
2
Final Torque
33-37 Lb-Ft (45-50 Nm)
Fig. 16
17. Locate the seat slider and mount the assembly (Fig. 18)
onto the seat post by sliding the post into the seat slider
while pulling on the pull pin under the seat slider.
Fig. 17
18. Install the corresponding stopper bolt (Fig. 19) into the
slider section of the seat post.
Hardware
QTY
M4 x10mm Socket Head Cap Screw
2
Fig. 18

Assembly Manual
Hardware
QTY
M4 x 10mm Phillips Pan Head Thread Form
S
crew
2
19. Insert the assembled seat post (Fig. 20) into the frame by
pulling on the pull pin located on the upright column of
the frame and sliding the post downward along with the
plastic sleeve verifying to lock the post into one of the
available positions.
Fig. 19
20. Mate the edge of the plastic sleeve flush with the edge of
the upright tube (Fig. 21) and install the corresponding
hardware to lock the plastic sleeve in place.
Fig. 20
21. Review all areas of the machine to verify no hardware
was left loose and install the leveling feet. Adjust each
leveling foot (Fig. 21) if needed to compensate for
uneven ground.
Fig. 21

Assembly Manual
Testing Bike
Use this checklist to perform the bike test procedure.
Recheck all the bolts and make sure they are all tightened to the proper torque specification (when indicated) and no parts are
missing.
Test the seat post to make sure they move freely and you are able to lock in at different positions.
Check the seat to make sure it is level and tight and does not rotate around or tilt. Tighten and adjust as needed.
Test the seats horizontal adjustment for movement front to rear and check it by settings it at different settings.
Adjust seat post to your needs. Ride / test the bike for proper operation according to this owner's manual.
CAUTION: The movement arms move whenever the pedals are turning. Do Not dismount the bike until the pedals and
movement arms come to a complete stop.
Pedal the bike at a moderate pace and test for proper and smooth movement of the pedals and arms.
When the testing is complete, even the movement arms, and tip the bike forward using the ams and roll it on a smooth surface to
the final location and adjust the leveling feet so the bike is stable.