Star Trac eSPINNER User manual

620-7924 Rev A
STAR TRAC
14410 Myford Road
Irvine, CA 926060 USA
COVER PAGE FOR DOCUMENT CONTROL PURPOSES ONLY, NOT TO BE PRINTED
Document:
Document Title: WI, eSPINNER, INSTALLATION
Document Number: 620-7924 Rev: A
Page Number: 1 of 29
Material:
n/a
Notes:
n/a
Approvals:
Originator Print: Steve Kabbani Sign: Date: 07-29-09
Approved By:
Sign: Date:
Document Revision History:
REV EFFECTIVE DATE BY DESCRIPTION ECO NO.
A 07-29-09 HSK DOCUMENT RELEASE 12241
THE INFORMATION CONTAINED HEREIN IS PROPRIETARY AND CONFIDENTIAL TO UNISEN INC/STAR TRAC.
AND SHALL NOT BE USED OR DISCLOSED, IN WHOLE OR IN PART, WITHOUT FIRST OBTAINING THE WRIT-
TEN PERMISSION OF UNISEN, INC.
Print:

2 620-7924 Rev A
STAR TRAC
14410 Myford Road
Irvine, CA 926060 USA
WORK INSTRUCTIONS,
eSPINNER INSTALLATION

3 620-7924 Rev A
GENERAL
Before using this product, it is essential to read ALL installation Instructions and this ENTIRE
operations manual; the manual describes equipment setup and instructs members on how to
use it correctly and safely.
1. Open-End Wrench (Included)
2. Multi-purpose Wrench (Included)
3. 4MM Hex Wrenches (Included)
4. 5MM Hex Wrenches (Included)
5. 6MM Hex Wrenches (Included)
6. Torque Wrench (Not Included)
TOOLS REQUIRED
If you are a Factory Certified Installer you must:
• Adhere to all torque and assembly specifications.
• Use a CALIBRATED TORQUE WRENCH with the necessary hex key sockets
• NOT USE a powered drill, powered driver or powered impact tool for any part of the assembly.
• Complete the assembly checklist is completed on each Star Trac product.
• Complete the final programming, functional and cosmetic checklists for each Star Trac product.
FACTORY CERTIFIED INSTALLER
Copyright 2008. Star Trac by Unisen, Inc. Star Trac Fitness, Star Trac®, and the Star Trac Logo are registered trademarks of Unisen Inc. All rights
reserved, including those to reproduce this book or parts thereof in any form without first obtaining written permission from Star Trac.
Spin
®
, Spinner
®
, Spinning
®
and the Spinning logo are registered trademarks of Mad Dogg Athletics, Inc.
Smart Release™ is a registered trademark of Nautilus, Inc.
SPD is a registered trademark of Shimano American Corporation.
Every effort has been made to keep this information current; however, periodically, changes are made to the information herein, and these changes
will be incorporated into new editions of this publication. All product names and logos are trademarks of their respective owners. Printed in the USA.

4 620-7924 Rev A
Step 3.
Fold back all flaps at the top and at the bottom of
the box.
Step 4.
Slide-up the outer carton.
Step 2.
Open the carton first at the top and bottom. Use
scissors or a knife to cut the tape.
Caution: Be careful not to injure yourself; always
cut away from your body.
Step 1.
Arrange the assembly area so that the area is free
from objects that could potentially damage the
parts.
When positioning the box erify that the HEAVY
END logo is at the bottom as indicated by the
black o al in the picture.
UNPACKING INSTRUCTIONS

5 620-7924 Rev A
Step 8.
Remo e box 2 containing assembly parts.
Step 6.
Remo e box 1 containing assembly parts.
Step 5.
Arrange the unpacking area so that the area is
free from objects that could potentially damage
unpacked components.
Step 7.
Remo e foam insert 1.
1
1
2

6 620-7924 Rev A
Step 9.
Remo e foam insert 2.
Step 10.
Remo e foam insert 3.
Step 11.
Remo e foam insert 4.
Step 12.
Remo e foam insert 5.
4
5
2
3

7 620-7924 Rev A
Step 13.
Remo e plastic protector.
Step 14.
Position the main frame assembly upright and
erify that the assembly area is free from objects
that could potentially damage the bike.
Step 15.
Locate the Carton containing the console.
Place the carton in an area that is free from ob-
jects that could potentially damage the parts .
Step 16.
Use scissors or a knife to cut the tape.
Caution: Be careful not to injure yourself; al-
ways cut away from your body.

8 620-7924 Rev A
Step 17.
Remo e components from inside the carton and
remo e the foam.
Step 18.
Verify that Carton 2 Console contains:
1. Main Console
2. Manual
3. 5/16X18X.75” Philips Pan Head Screw X 4
4. Power Cord X 1
5. Hex Wrench “3/16”
Step 19.
Verify that shipment inside the main Carton contains:
1. Handlebar Post X 1
2. Handlebar w/Grip X 1
3. Seat Post X 1
4. Seat Slider Assembly w/ Saddle X 1
5. Pedals (set of two) X 1
6. Leg Assembly X 2
7. Water Bottle Holder X 1
8. Console Post Plastic Slee e X 1
9. Console Post X 1
10. Transport Wheels X 2
11. Rear Pop Pin X 1
2
4
1
3
5
6
7
8
9
10
2
5
9
6
3
10
4
1
Step 20.
Verify that shipment inside the main Carton contains the hardware
listed below:
1. Open End Wrench X 1
2. Multi Wrench X 1
3. Hex Wrench (5mm, 4mm, and 3mm) X 3
4. M10X1.5,45 Button Head Screw X 2
5. M10X1.5, 60mm Button Head Screw X 4
6. M10X1.5, 65mm Button Head Screw X 4
7. M8X1.25, 20mm Flat Head Screw X 2
8. M8X1.25, 16mm Flat Head Screw X 2
9. Spacer 30mm X 2
10. 20mm Washer Flat X 16
11. M10X1.5 Nyloc Hex Nut X 4
12. M8X1.25, 16mm Socket Set Screw X 1
13. M6X1.0X15mm Hex Bolt X 1
14. M4X1.0X10mm Phillips Pan Head Screw X 2
11
7
8
11
12
14
13
1
4
3 2
5

9 620-7924 Rev A
Step 21.
Verify that the Spare Kit contains:
1. Pedal strap
2. Spare Brake Pad
1
2

10 620-7924 Rev A
Step 22.
Locate the Rear Leg Assembly in the mating posi-
tion under the frame.
Step 23.
Locate (2) M10X60mm Button Head Screws. Pre-
install a 10mm Flat Washer onto each Button
Head Screw.
Step 24.
Secure the Rear Leg Assembly to the frame using
(2) M10X55mm Button Head Screws with 10mm
Flat Washers.
Step 25.
Hand-install (1) Flat Washer and then (1)
M10X1.5 Nyloc Hex Nut onto each Button Head
Screw.
ASSEMBLY INSTRUCTIONS

11 620-7924 Rev A
Step 26.
Utilizing a 5mm Hex Wrench and a Multi Wrench
tighten the nuts onto the screws.
Note: Utilize a torque wrench to tighten all hard-
ware to 85 lbs-in.
Step 27.
Repeat steps 23 through 26 using (2)
M10X1.5X65mm Button Head Screws, for the two
forward mounting locations.
Note: Utilize a torque wrench to tighten all hard-
ware to 85 lbs-in.
Step 28.
Let one assembler lift up the front of the bike or
suspend the front of the bike by wedging a block.
Step 29.
Locate the Front Leg Assembly in mating position
under the frame. Verify that the front and rear leg
assemblies are parallel.

12 620-7924 Rev A
Step 30.
Hand-install (2) M10X1.5X60mm Button Head
Screws each through (1) 20mm Flat Washer in
the rear mounting holes to secure the Front Leg
Assembly to the Frame.
Hand-install (2) M10X1.5X65mm Button Head
Screws each through (1) 20mm Flat Washer in
the forward mounting holes to secure the Front
Leg Assembly to the Frame.
Step 31.
Utilizing a 5mm Hex Wrench tighten all Button
Head Screws.
Note: Utilize a torque wrench to tighten all
screws to 85 lbs-in.
Step 32.
Locate (1) 30mm Spacer and install it into the
mating hole on the Transport Wheel.
Step 33.
With (1) 20mm Flat Washer positioned on oppo-
site sides of the Transport Wheel insert (1)
M10X1.5X45mm Button Head Screw into the
Transport Wheel.

13 620-7924 Rev A
Step 34.
Hand-install the M10X1.5X45mm Button Head
Screw into the mating hole on the Frame.
Note: Utilize a torque wrench to tighten screws to
85 lbs-in.
Step 35.
Utilizing a 5mm Hex Wrench secure the
M10X1.5X45mm Button Head Screw onto the
Frame. Repeat steps 32 through 35 to install the
second Transport Wheel to the right side of the
Frame.
Step 37.
Utilizing an Open End Wrench secure the Pop Pin
to the Frame.
Note: Verify that the op pin is tightened to 50
lbs-in torque value.
Step 36.
Grab the rear Pop Pin.

14 620-7924 Rev A
Step 38.
Grab the Handlebar Post and install it onto Handlebar.
Step 39.
Locate the parts listed below:
1. 5mm Hex Wrench X 1
2. 4mm Hex Wrench X 1
3. M8X1.25, 16mm Flat Head Screw X 2
4. M8X1.25, 16mm Socket Set Screw X 1
4
3
2
1
Step 40.
Align the mating holes and hand-thread (2)
M8X1.25, 16mm Flat Head Screws then, utilizing
a 5mm Hex Wrench tighten the screws.
Note: Tighten both screws to 60 lbs-in.
Step 41.
Utilizing the 4mm Hex Wrench tighten the
M8X1.25, 16mm Socket Set Screw.
Note: Tighten the set screw to 60 lbs-in.

15 620-7924 Rev A
Step 42.
1. Loosen the Pop Pin and pull Pop Pin away from
Handlebar Post Frame.
2. Insert Handlebar Post into Frame Handlebar
Post.
Step 43.
Grab the set of pedals. The right pedal shaft is
marked by letter R and the left pedal shaft is
marked by the letter L.
Note: Take care when installing the pedals to
avoid threading pedal spindles to the wrong
side of the bike and cause damage to the
pedals and the cranks.
Step 45.
Hand-install the Right Pedal and then utilize a
Multi Wrench to install the right pedal to the right-
side crank arm by turning the pedal spindle in the
clockwi e direction.
Step 44.
Hand-thread the Left Pedal and then Utilize a
Multi Wrench to install the left pedal to the left-
side crank arm by turning the pedal spindle in the
counter clockwi e direction.
1
2

16 620-7924 Rev A
Step 46.
1. Loosen the Pop Pin and then pull it away from
the frame Seat Post.
2. Install Seat Post into Frame Seat Post.
Step 47.
1. Lower Seat Post to the lowest le el.
2. Let Pop Pin engage the mating hole on the
Seat Post.
3. Tighten the Pop Pin.
Step 48.
Locate the Seat. Make sure the locking pin mo es
freely by pulling it up and then releasing it.
(The locking pin is spring loaded)
Step 49.
Align the Slider Clamp with the Guide Rail by
turning the Seat Slider Knob.

17 620-7924 Rev A
Step 50.
Pull the locking pin up while mo ing Seat Slider
into position.
Step 51.
When indicator (highlighted by the left side arrow)
points to a alue within the 0 and 9 range release
the pin as highlighted by the right side arrow.
Step 52.
Locate the tool and parts listed below:
1. 5mm Hex Wrench X 1
2. M10X1.5, 25 Flat Head Screw X 2
1
2
Step 53.
Locate the Water Bottle Holder. Utilizing a 5mm Hex
Wrench and (1) M10X1.5, 25 Flat Head Screw install
Water Bottle Holder under the support cross bar onto
the frame. Next, Secure Water Bottle Holder onto frame
using the second screw. Use the Hex Wrench to erify
that both screws are tightened.
Note: Verify that both screws all tightened to 85
lbs-in.

18 620-7924 Rev A
Step 54.
Locate the Console Support Tube.
Step 55.
Install Console Support Slee e onto Console Sup-
port Tube.
Step 56.
Grab the console and locate the 3 cords from the
back of the console.
Step 57.
Note: It is necessary to utilize two installers
in order to successfully perform the follow-
ing assembly steps.
While one installer is securing the console the
second installer routes the three cords from the
back of the console inside the Console Support
Tube.

19 620-7924 Rev A
Step 58.
Locate the tool and parts listed below:
1. 3/16 Allen Wrench X 1
2. 5/16 X 18 Pan Head Screws X 4
1
2
Step 59.
While taking adequate care so that the cords will
not be trapped or pinched between the Console
Tube Plate and the Console, align the Console
Plate to the Console. Next, secure Console Tube
Plate to the Console using the 3/16 Allen Wrench
and (4) 5/16 X 18 Pan Head Screws.
Note: Verify that all screws are tightened to 25
lbs-in.
Step 60.
Utilizing a 5mm Hex Wrench install (1) M6 X 1.0 X
15mm Hex Bolt into the mating hole at the bot-
tom of Console Support Tube.
Note: Verify that the bolt is tightened to 25 lbs-
in.
Step 61.
Gently lift up mating wires from inside the Frame
Console Tube.

20 620-7924 Rev A
Step 62.
Grab the coax cable coming from the Frame end
and the coax cable coming from the Console Sup-
port Tube end. Hand-install the male and female
connectors finger tight.
Step 63.
Utilize a 7/16” Open Wrench to hold the connector
on the Console Support Tube side while using the
second 7/16” Open Wrench to turn the other con-
nector a quarter turn.
Step 64.
Plug the connector pair from the Console end to
the mating connectors from the frame end. Verify
that all connectors are adequately locked.
Step 65.
Connect the ground wire from the Console end to
the ground wire from the Frame end.