True Fitness Service Manual Exercise Bicycles 500R, 500U 600R, 600U 750R, 750U True fitness technology, Inc. makes no representations or warranties regarding the contents of this manual. We reserve the right to revise this document at any time or to make changes to the product described within it without notice or obligation to notify any person of such revisions or changes. © 2004, True Fitness, Inc. All rights reserved. Printed in the United States of America. 865 Hoff Road. O’Fallon, MO 63366.
Recommended Tool List Technicians will need at minimum the tools listed below to work on the True Fitness equipment covered by these procedures. Electrical Tools A multi meter capable of testing voltage, amperage, resistance and continuity. Outlet tester with a grounding indicator. Wire stripper, cutter and crimper. Flashlight Mechanical Tools Screwdrivers: #1 Phillips, #2 Phillips, large flat blade, small flat blade, short handled flat blade. Metric hex-key (Allen wrench) set.
True Fitness Bicycle Service Manual START Symptom guide Wiring Diagrams Parts Manual Removal and Replacement Procedures Page 1
Test Mode *750 ONLY To Enter Diagnostic Mode Procedure • • D I A G N O S T I C S ------Console / Display Output • • Press “Enter” key – initiates the second LED function test. Press “Enter” key again –all LED’s should be on. -------- RPM • Press “Enter” key – RPM’s displayed in the far right window. -------- Console Key Input • Press “Enter” key –A beep should sound when each key is pressed. -------- Contact Heart Rate • Press “Enter” key. Hold both handle pick-ups.
SYMPTOM GUIDE 500U, 500R ECB Malfunction . . . . . . . . . . . . . . . . . . . . . . . Page 4 Irregular or No Display . . . . . . . . . . . . . . . . . . Page 5 No RPM Reading . . . . . . . . . . . . . . . . . . . . . . . . Page 6 No Polar Heart Rate . . . . . . . . . . . . . . . . . . . . . . Page 7 600U, 600R Irregular or No Display . . . . . . . . . . . . . . . . . . . Page 8 No RPM Reading . . . . . . . . . . . . . . . . . . . . . . . . No Contact Heart Rate . . . . . . . .
Symptom Probable Cause ECB MALFUNCTION 500R, 500U Control Panel Corrective Action • • • • Defective Cables • • Power on unit. Check for 5VDC between pins 1 and 2. (Page 18) No 5VDC? Replace control panel. Check for 6VDC or more between pins 5 and 6 of 6PA while issuing a resistance command. No 6VDC or more? Replace control panel. -------Perform continuity check on upper section and lower section cables. Replace broken cables.
Symptom IRREGULAR OR NO DISPLAY 500R, 500U Probable Cause DC Adaptor Corrective Action • • • Recommended Tools Connect DC Adapter to 110 VAC power supply. Look for printed output on adapters label. If greater than 9 VDC computer board may be damaged. Test for 9VDC output. If not 9 VDC then replace adaptor. Multi-meter -------- Adapter Plug or Jack • Connect DC plug to Bike. Does it seat into the socket properly? If not- replace adapter or jack.
Symptom NO RPM READING 500R, 500U Probable Cause Control Panel/ RPM Sensor Corrective Action • • • • • Disconnect 5PA from 5PB. Set meter to check continuity between 2 and 5 of 5PB. (See Page 18) Turn pedals slowly, check continuity between 2 and 5 of 5PB. Does continuity change from off to on? If yes – cables and sensor are good – Replace Control Panel. If no – Go to Defective RPM Set. Recommended Tools Multi-meter When the sensor is over the pickup, continuity will exist.
Symptom NO POLAR HEART RATE 500R, 500U Probable Cause Control Panel Corrective Action • • Recommended Tools Attach a known good heart rate transmitter around chest or use polar simulator. If control panel does not display a heart rate – replace Control Panel. Heart Rate Simulator -------- Heart Rate Chest Strap • If heart rate registers with use of HR simulator but not chest strap – replace chest strap.
Symptom Probable Cause IRREGULAR OR NO DISPLAY 600R, 600U Control Panel Corrective Action • • • • Probe leads between pin 1 and 2 of 5PB. (Page 19-20) Pedal unit up to at least 30 RPM. Is voltage 5 VDC? If not 5 VDC – replace Control Panel. Recommended Tools Multi-meter -------- Control Board • • • • Disconnect 6PG from 6PH. Pedal. Check DC voltage between pins 2 and 3 for 5 VDC. No 5 VDC? – Replace Control Board. ------- Cables • • Perform continuity checks on all upper and lower cables.
Symptom NO RPM READING 600R, 600U Probable Cause Control Panel Corrective Action • • • • Recommended Tools Disconnect 5PA from 5PB. (Page 1920). Set meter to check continuity between pins 2 and 5 of 5PB Turn crank and align the magnet with the sensor Is there continuity? If Yes – Replace Control Panel. If No- continue to next step.
Symptom NO CONTACT HEART RATE 600R, 600U Probable Cause Control Panel Corrective Action • Recommended Tools Multi-meter Disconnect 7P6A and 7P6B from control panel. 600U (Page 19) 600R (Page 20). Check continuity between 7P6B and handle mounted heart rate sensor plates of the following: HRRR and pin 6 of 7P6B HRRL and pin 5 of 7P6B HRLR and pin 2 of 7P6B HRLL and pin 1 of 7P6B • • • Is there continuity? If yes – replace computer.
Symptom HANDLEBAR BUTTONS DO NOT FUNCTION 600R Probable Cause “Cruise Control” Corrective Action • • Recommended Tools Remove console-mounting screws. Locate 10P7B (Page 20). Check for continuity between pin 7 and pin 1 at 10P7B. Press Cruise control button. Multi-meter (A) • No continuity? Perform a continuity check on the appropriate cable. • Replace cable or if cable good – replace handlebar assembly. -------“Start” Button • Check for continuity between pin 7 and pin 2 at 10P7B.
Symptom Probable Cause Console Set Corrective Action • NO RESISTANCE 750U, 750R • • • • Defective Cables • • • Power Resistance • • • • Brake Harness/ Lower Board • • • • • • • Page 12 Support Services 800-883-8783 Remove console bolts to access 7-pin connector. Do not disconnect console set. Enter DA (resistance) test mode. (Page 2). Press + key to force .7 VDC out of panel. Set meter for DC Volts. Measure between #2 pin and #4 pin at 7- pin connector. Is .
Symptom HEAVY RESISTANCE 750U, 750R Probable Cause Console Set Corrective Action • • • • Defective Cables • • • • • Recommended Tools Multi-meter Remove the console set. Disconnect the 7 pin connector from the back of the console set. Pedal. Resistance normal? Replace console set. -------Remove pedal and if 3 piece crank remove crank arm. Remove right side cover assembly. Disconnect 7- pin connector from the lower control board. Pedal. If resistance is normal- replace cable for console.
Symptom No Display 750U, 750R Probable Cause Console Set Corrective Action • • • • • Brake • • • • • • • • Recommended Tools Note: Remove console set bolts. Verify good connection at the back of the console set. Set meter for DC volts Pedal. Measure between #1 and #4 wires (Page 21) for 5.5 – 7.5 VDC. Is required voltage present? If yes- replace console set. If not, continue on. -------Remove pedal and if 3 piece crank remove crank arm. Remove right side cover. Disconnect 3- wire connector at brake.
Symptom NO CONTACT HEART RATE 750U, 750R Probable Cause Dirty Sensors Corrective Action • Recommended Tools Note: Verify hand pulse sensors are clean. -------- Console Set/ Wiring • • • • Set meter for continuity. Remove Console set. Check for continuity in both sets of hand pulse sensors between the console set and hand pulse sensor plates. If continuity is OK – Replace Console set. If no- continue on. You must pedal at least 30 RPM when performing any voltage test.
Symptom Probable Cause NO POLAR HEART RATE 750U, 750R Control Panel Corrective Action • • • • Recommended Tools Note: Attach known good heart rate transmitter around chest or use Polar simulator. Do not touch the hand pulse sensors. Start pedaling Check display for heart rate. You must pedal at least 30 RPM when performing any voltage test. You may require the assistance of another person when performing voltage checks.
WIRING DIAGRAMS TR / TU 500 Page 18 600 U Page 19 600 R Page 20 TR/TU 750 Page 21 Page 17
TR/ TU 500 WIRING DIAGRAM Page 18
TU 600 WIRING DIAGRAM Page 19
TR 600 WIRING DIAGRAM Page 20
TR/ TU 750 WIRING DIAGRAM Page 21
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True Upright Bike 500 True Recumbent Bike 500 TU 500 Exploded Diagram Pg 22 TU 500 Parts List Pg 23 TR 500 Exploded Diagram Pg 25 TR 500 Parts List Pg 26 Page 23
Page 24
TU 500 EXERCISE BIKE REF.
25 26 27 28 29 30 31 Page 26 7T002600 7T002700 7T002800 7T012700 7T005800 7T004700 7T004800 7T013000 7T012901 7T012902 7T012903 7T012904 7TU50100 7TU50200 7TU60200 7TU60500 7TU60600 7TU60700 7TU60300 REAR STABILIZER WITH BOLTS ADJUSTING STAND KIT REAR STABILIZER END CAP POLY V BELT RPM SENSOR WITH WIRE AND NUT CABLE ASSY 5 PIN LOWER SPEED SENSE CABLE ASSY 6 PIN LOWER SECTION MODEL DECAL SILVER DECAL A SILVER DECAL B SILVER DECAL C SILVER DECAL D SILVER ASSY HDW.
TR 500 Exercise Bike Page 27
TR 500 Page 28 REF # 02 03 04 05 06 07 08 09 10 11 11-1-1 11-1-2 12 13-1 13-2 13-3 13-4 14-1 14-2 14-3 PART# 7T000100 7T000200 7T000300 7T000400 7T005800 7T000600 7T000700 7T000800 7T000900 7T001000 7T001001 7T004700 7T001100 7T001201 7T001202 7T001203 7T001204 7T001301 7T001302 7T001303 DESCRIPTION Front Stabilizer w/Bolts Transportation Wheel Kit Front Stabilizer End Cap Crank Pulley w/E Caps & Bearings RPM Sensor w/Wire & Nut Bolt - Belt Tension Cable Assembly - 6 Pin Lower Cable Assembly - 5 Pin Low
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 7T002500 7T002600 7T002700 7T002800 7T002900 7T003000 7T003100 7T003200 7T003300 7T003400 7T003500 7T003600 7T003700 7T003800 7T003900 7T013000 7T012901 7T012902 7T012903 7T012904 7T012800 7TR50100 7TR50200 7TR50300 7TR50400 7TU60700 Transportation Handle Set w/Screws Rear Stabilizer w/Bolts Adjusting Stand Kit Rear Stabilizer End Cap Roller Set (A) Rt Ft & RR Roller Set (B) Center Seat Bottom w/Bolts Fore and Aft Adjusting Lever w/Bolts Seatback w/Bolts Seat S
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True Upright Bike 600 True Recumbent Bike 600 TU 600 Exploded Diagram Pg- 29 TU 600 Parts List Pg- 30 TR 600 Exploded Diagram Pg- 32 TR 600 Parts List Pg- 33 Page 31
TU 600 PARTS DIAGRAM Page 32
TU 600 BIKE REF # PART NUMBER DESCRIPTION 02 03 04 05 7T010800 7T000200 7T000300 7T011400 7T004900 7T005000 7T012000 7T001302 7T001202 7T001303 7T012100 7T001306 7T012200 7T001311 7T001312 7T012300 7T001308 77T001309 7T001400 7T005500 7T005600 7T005200 7T012400 7T012500 7T011500 7T007200 7T005700 7T006000 7T005900 7T005800 7T000900 7T004300 7T004400 7T004500 7T004600 7T006900 7T006202 7T004100 7T006300 7T004200 7T007000 7T012600 7T002600 7T002700 7T002800 7T005100 7T013100 FRONT STABILIZER WITH BOLTS T
7T011800 7T011900 7T012901 7T012902 7T012903 7T012904 7TU60100 7TU60200 7TU60300 Page 34 MODEL DECAL LEFT WHITE MODEL DECAL RIGHT WHITE DECAL A DECAL B DECAL C DECAL D PARTS KIT FRONT STABILIZER SCREW KIT REAR STABILIZER SCREW KIT 1 1 1 1 1 1 1 1
TR 600 PARTS DIAGRAM Page 35
TR600 BIKE Page 36 REF.
20 20-1-1 20-1-2 21 22 23 40-1 24-2 40-3 40-4 41 42 43 44 45 24-08 24-11 24-9 24-12 43-1 ^2-1 20-1 41-1 21-1 7T006200 7T006201 7T006202 7T006300 7T003700 7T006400 7T001201 7T001202 7T001204 7T001203 7T003500 7T006600 7T003400 7T006700 7T006800 7T011800 7T011900 7T012901 7T012902 7T012903 7T012904 7T013000 7T012800 7TR50200 7TR50300 7TR50400 7TR60100 7TU50200 7TU60700 CONSOLE MAST W/BOLTS CABLE ASSY 12 PIN UPPER CABLE ASSY 52 PIN UPPER COMPUTER SET 660RIU LT FRT ROLLER SET SEAT LT RR IDLER ARM SHAFT KIT R
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True Upright Bike 750 TU 750 Exploded Diagram Pg- 37 (Prior to serial # 02-UP0161C (3) Piece Crank) TU 750 Parts List Pg- 38 (Prior to serial # 02-UP0161C (3) Piece Crank) TU 750 Exploded Diagram Pg- 40 (After serial # 02-UP0161C (1) Piece Crank) TU 750 Parts List Pg- 41 (After serial # 02-UP0161C (1) Piece Crank) Page 39
TU 750 PARTS DIAGRAM (3 PIECE CRANK) Page 40
TU 750 3 PIECE CRANK TU750: 02UP0161C REF # PART# DESCRIPTION QTY.
Q06R Q06L Q07 Q11 Q12 R03 R06 R09 R14 R17 R20 S01 S02 S03 S04 S05 S06 T01 T02 T03 T04 T05 T06 T08 T09 U06 U07 U09 U10 U12 U13 V01 V03 Q08 Page 42 7TMB0609028 7TMB0609026 7TMB0609035 7TSZCB24SCV-L 7TSZCB24SCV-R 7TSZRB40PAX 7TMD0602018 7TME0103022 7TME0514002 7TME0104014 7TME0502092 7TMJ3247002 7TMJ1245003 7TME0204010 7TME0201012 7TME0502127 7TME0502115 7TSZRB40DAX 7TMD0405001 7TMD0406001 7TMD0402002 7TMD0403002 7TMD0602013 7TMB0622001 7TME01132012 7TME0112088 7TMJ1914002 7TME1104002 7TME0502084 7TME010401
TU 750 PARTS DIAGRAM (1 PIECE CRANK) Page 43
TU 750 1PC CRANK Page 44 REF.
Q01 7TMN1101006 J14 J15 Q02 Q06R 7TMB030402A 7TMZE0112119 7TMB0604018 7TMB0609028 Q06L 7TMB0609026 Q07 7TMB0609035 Q11 7TSZCB24SCV-L Q12 7TSZCB24SCV-R R03 7TSZRB40PAX R06 R09 7TMD0602018 7TME0103022 R14 7TME0514002 R17 7TME0104014 R20 7TME0502092 S01 7TMJ3247002 S02 7TMJ1245003 S03 7TME0204010 S04 S05 7TME0201012 7TME0502127 S06 T01 T02 T03 T04 T05 T06 T08 T09 U06 U07 U09 U10 U12 U13 V01 7TME0502115 7TSZRB40PAX-1 7TMD0405001 7TMD0406001 7TSM0915027A 7TMD0403002 7TMD0602013 7TM
V03 Q08 Page 46 7TMG0102036 7TMG0214009C 7TMG0214016C 7TMH0205023 7TME0601017 7TMB0237002 MODEL DECAL WHITE SIDE CVR DECAL SILVR SIDE CVR DECAL SILVR OWNERS MANUAL ASSEMBLY KIT UPPER FRAME CVR 2 1 1 1
True Recumbent Bike 750 TR 750 Exploded Diagram Pg- 46 (Prior to 08/05/2001 (3) Piece Crank) TR 750 Parts List Pg- 47 (Prior to 08/05/2001 (3) Piece Crank) TR 750 Exploded Diagram Pg- 49 (After 08/05/2001 & Prior to Serial # 02-RE0283C (3) Piece Crank) TR 750 Parts List Pg- 50 (After 08/05/2001 & Prior to Serial # 02-RE0283C (3) Piece Crank) TR 750 Exploded Diagram Pg- 52 (After Serial # 02-RE0283C (1) Piece Crank) TR 750 Parts List Pg- 53 (After Serial # 02-RE0283C (1) Piece Crank)
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TR750 PRIOR 8-5-01 (3 PIECE CRANK) REF.
J07 J08 J09 J10 J11 J12 P11 P12 P13 P15 P17 P22 P23 P24 Q06R Q06L Q07 Q08 Q11 Q12 R3 R06 T02 T03 T04 T05 T06 T07 T08 V01 V02 Page 50 7TSW2221005 REAR GROUNDING BAR 7TMB0304006 FOOT PAD REAR ADJUSTABLE 7TME0112109 BOLT GROUNDING BAR 7TME0112024 BOLT TRANSPORT WHEEL 7TME0502108 WASHER TRANSPORT WHEEL 7TME0902007 EXTERNAL C RING-TRANSPORT WHEEL 7TMC0501027 CABLE DISPLAY CONTROL BOARD 7TMC0520002 CABLE SEAT RAIL 7TMC0550001 WIRE HEART RATE SEAT RAIL CONSOLE 7TMC0203004 CONTROL BOARD 7TMC0736002 POWER RESIST
TR 750 PARTS DIAGRAM After 08/05/01 and Prior to Serial # 02-RE0283C Page 51
TR 750 AFTER 8/5/01 PRIOR TO 02-RE0283C NEW SEAT ASSY - 3 PIECE CRANK Page 52 114 117 001 003 039 043 118 083 084 085 086 087 031 045 088 116 050 051 089 052 053 090 028 091 093 094 092 097 024 098 031 030 099 035 102 100 002 054 060 055 056 057 058 026 027 REF.
023 105 081 082 005 018 010 011 006 107 019 049 048 109 110 112 004 029 032 033 038 046 047 059 061 062 063 065 066 067 095 095 101 103 104 106 108 111 113 115 120 143 Q07 Q08 Q11 Q12 R03 R06 T02 T03 T04 T05 T06 T08 T09 V02 V03 V08 7TMB0609035 7TME0104055 7TSZRB40SCV-L 7TSZRB40SCV-R 7TSZRB40PAX 7TMD0602018 7TMD0405001 7TMD0406001 7TMD0402002 7TMD0403002 7TMD0602013 7TMB0622001 7TME0113012 7TMG0214008 7TMG0214014 7TMG0222006 7TSZRB40DAX 7TMB0705001 7TMZE0112119 7TMB0304020A 7TMJ1208001 7TME0103022 7TME0514
TR 750 PARTS DIAGRAM After Serial # 02-RE0283C (1 Piece Crank) Page 54
TR 750 AFTER SERIAL # 02-RE0283C NEW SEAT ASSEMBLY-1 PIECE CRANK REF.
P17 7TMJ1393002 RESISTOR COVER 7TME0102027 SCREW RESISTOR 7TME0204003 NYLON NUT RESISTOR 7TME0502082 WASHER RESISTOR 7TMB0601005 WATER BOTTLE CAGE Q06R 7TMB0609028 END CAP FRONT GROUNDING BAR RIGHT Q06L 7TMB0609026 END CAP FRONT GROUNDING BAR LEFT Q07 7TMB0609035 END CAP REAR GROUNDING BAR Q08 7TME0104055 SCREW DISPLAY Q11 7TSZRB40SCV-L1 SIDE COVER LEFT Q12 7TSZRB40SCV-R1 SIDE COVER RIGHT R03 7TSZRB40PAX FLYWHEEL SHAFT ASSY R06 7TMD0602018 SECONDARY POLY V BELT R17 7TME0104014 SCREW FLYWHEEL R20 7TME0502092
True Fitness Removal & Replacement 500R 500U 600U 600R Page 57
TABLE OF CONTENTS Removal and Replacement Remove Access Covers – All Bikes Page 59 500R Remove Small Poly V Pulley Remove Belt & Tensioner Assembly Remove Crank Hub Assembly Page 61 Page 63 Page 65 500U Remove Small Poly V Pulley Remove Belt & Tensioner Assembly Remove Crank Hub Assembly Page 68 Page 69 Page 72 600U Remove Right Belt Poly-V Pulley Remove Right Side Tensioner Assembly Remove Belt & Tensioner Assembly Remove Left Side Belt from Assembly Remove Left Side Poly-V Wheel Remove Crank Hub Ass
Removal & Replacement Remove Access Covers ~ 500R, 500U, 600R & 600U Tools Required: Pedal Wrench Phillips Screwdriver Step 1. Use pedal wrench to remove both pedals from pedal cranks. Step 1. Remove Pedals Note: Left pedal loosens clockwise. Right pedal loosens counter- clockwise. Step 2. Remove front cover screws and nuts. Step 2. Remove Cover Screws Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement Remove Access Covers ~ 500R, 500U, 600R & 600U (continued) Note: Electrical connections are on 500 series bikes only. Step 3. Disconnect electrical power adapter. Step 1. Remove Electrical Connection (500 series only). Step 4. Rotate crank handle forward to 2 o’clock Position to allow removal of cover. Step 2. Remove Cover Page 60 Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 500R Remove Small Poly-V Pulley Tools Required: 4 mm-Hex Wrench Flat blade Screwdriver Hammer Handle Note: Leave belt in place to help lock pulley Step 1. Use hammer handle to prevent Rotation of large wheel when Removing pulley. Step 1. Prevent Rotation of Fly Wheel Step 2. Use 4 mm wrench to loosen set screw in pulley. Step 2. Loosen Set Screw Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 500R Remove Small Poly-V Pulley (continued) Step 3. Use 17 mm box wrench to loosen Nut from belt tension screw. Step 3. Loosen Nut Step 4. Loosen rear hub bracket screws. Step 4. Loosen Hub Bracket Screws Step 5. Remove belt from belt tensioner Assembly and wheels. Step 5. Remove Belt Page 62 Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 500R Remove Belt & Tensioner Assembly Tools Required: 17 mm Box Wrench 5mm Hex Wrench Snap Ring Pliers Step 1. Remove small poly-V pulley. Step 1. Remove Small Poly-V Pulley Step 2. Remove keyway using flat blade Screwdriver as required. Step 2. Remove Keyway Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 500R Remove Belt & Tensioner Assembly (continued) Step 3. Remove snap ring from belt Tensioner. Step 2. Remove Snap Ring Step 4. Remove belt tensioner. Step 3. Remove Belt Tensioner Page 64 Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 500R Remove Front Hub Assembly Tools Required: Large Crescent Wrench Hammer & Punch Step 1. Use crescent wrench to remove Large nut on crank. Note: The crank nut has left-handed threads. Turn clockwise to loosen. Step 1. Remove Crank Nut Step 2. Remove keyed washer from under nut. Step 3. Step 2. Remove Keyed Washer Use crescent wrench to remove hex nut bearing. Note: The hex nut bearing has lefthanded threads. Turn clockwise to loosen. Step 3.
Removal & Replacement 500R Remove Front Hub Assembly (continued) Step 4. Use crescent wrench to remove Large nut on crank. Note: Slide brake towards seat to allow pulley to clear frame. Step 4. Pull Hex Nut Bearing Free Step 5. Use crescent wrench to remove hex nut bearing. Step 5. Remove Large Pulley Assembly Page 66 Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 500R Remove Front Hub Assembly (continued) Step 6. Twist assembly thru frame hub. Pull assembly until clear of frame. Note: Right hand thread. Step 6. Twist Unit Thru Hub Frame Step 7. Use hammer & punch to loosen spanner nut on bearing. Step 7. Drive spanner nut off to remove bearing Step 8. Remove bearing and washer by Slipping off crank. Note: Pulley and crank are a welded assembly (cannot be separated). Step 8.
Removal & Replacement 500U Remove Small Poly-V Pulley Tools Required: 4 mm-Hex Wrench Flat blade Screwdriver Hammer Handle Note: Leave belt in place to help lock pulley Step 1. Use hammer handle to prevent Rotation of large wheel when Removing pulley. Caution! Take care not damage outer surface of flywheel on brake assembly. Step 1. Prevent Rotation of Fly Wheel Step 2. Use 4 mm wrench to loosen set screw in pulley. Step 2. Loosen Set Screw Page 68 Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 500U Remove Belt & Tensioner Assembly Tools Required: 17 mm Box Wrench 5 mm-Hex Wrench Snap Ring Pliers Step 1. Remove small poly-v pulley. Step 1. Remove Small Poly-v Wheel Step 2. Remove keyway, using flat blade Screwdriver as required. Step 2.
Removal & Replacement 500U Remove Belt & Tensioner Assembly (continued) Step 3. Use 17 mm box wrench to loosen Nut from belt tensioning screw. Step 3. Prevent Wheel Rotation Step 4. Use 5 mm hex wrench to loosen Rear hub bracket screws. Step 4.
Removal & Replacement 500U Remove Belt & Tensioner Assembly (continued) Step 5. Remove belt from belt tensioner Assembly and wheels. Step 5. Remove Belt Step 6. Remove snap ring from belt tensioner. Step 6. Remove Snap Ring. Step 7. Remove belt tensioner. Step 7.
Removal & Replacement 500U Remove Crank Hub Assembly Tools Required: Large Crescent Wrench Rubber Mallet Flat Blade Screwdriver Step 1. Use crescent wrench to remove Large nut on crank. Step 1. Remove Crank Nut. Note: The crank nut has left-handed threads. Turn clockwise to loosen. Step 2. Remove keyed washer from under nut. Step 2. Remove Keyed Washer Step 3. Use crescent wrench to remove hex nut bearing. Use rubber mallet to knock out the shaft pulley assembly.
Removal & Replacement 500U Remove Crank Hub Assembly (continued) Note: A flat blade screwdriver may be used to pry hub from frame. Step 4. Pull hex nut bearing clear of frame Hub. Step 4. Pull Hex Nut Bearing Free. Step 5. Pull large pulley until bearing clears Frame. Step 4. Pull Hex Nut Bearing Free. Step 6. Twist assembly thru frame hub. Pull assembly until clear of frame. Step 5. Twist Unit Thru Hub Frame. Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 500U Remove Crank Hub Assembly (continued) Step 7. Use hammer and punch to loosen spanner nut on bearing. Note: The spanner nut has righthanded threads. Turn counter-clockwise to loosen. Step 7. Drive Spanner Nut Off to Remove Bearing Step 8. Remove bearing & washer by slipping off crank. Note: Pulley and crank are a welded assembly (cannot be separated). Step 8.
Removal & Replacement 600U Remove Right Belt Poly-V Wheel Tools Required: Pliers Snap Ring Pliers Step 1. Use pliers or needle nose pliers to remove the belt tensioning spring Step 1. Belt Tensioning Spring Step 2. Remove the belt. Step 2. Remove Belt Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 600U Remove Right Belt Poly-V Wheel (continued). Step 3. Use snap ring pliers to pry snap ring from center of small poly-V pulley. Step 3. Prying with snap ring pliers Step 4. Remove the snap ring and washers. Step 4. Remove the snap ring and washers Step 5. Remove the small poly-V pulley. Step 5. Remove the small poly-V pulley Page 76 Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 600U Remove Right Side Tensioner Assembly Tools Required: Snap Ring Pliers Step 1. Remove snap ring. Step 1. Remove Snap Ring Step 2. Slide tensioner assembly off pivot shaft. Note: Frame is slotted to allow brake bracket to slide when bolts are loose. Step 2. Slide Tensioner Assembly Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 600U Remove Belt & Tensioner Assembly Tools Required: 6 mm Hex Wrench 13 mm Open-End Wrench Hammer Handle Step 1. Use 6 mm hex wrench to remove brake bracket locking screw. Step 1. Remove Locking Screw Step 2. Use 13 mm open-end wrench to loosen the 4 bolts holding the brake bracket to the frame. Note: Frame is slotted to allow brake bracket to slide when bolts are loose. Step 2. Loosen Bracket Bolts Page 78 Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 600U Remove Belt & Tensioner Assembly (continued) Step 3. Use hammer handle to pry the brake and bracket assembly toward the back of the bike to loosen the belt. Step 3. Pry on Brake to Loosen Belt. Step 4. Remove brake belt from larger poly-V wheel. Step 4. Remove Belt Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 600U & 600R Remove Belt & Tensioner Assembly (continued) Step 5. Disconnect wiring harness from brake. Step 5. Disconnect Wiring Harness. Step 6. Remove the loosened bottom screws. Step 6. Remove Loosened Screws Step 7. Remove brake and belt assembly. Step 7. Remove Brake & Belt Assembly Page 80 Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 600U Remove Left Side Belt From Assembly Tools Required: Internal & External Snap Ring Pliers Flat Blade Screwdriver Step 1. Remove snap ring. Step 1. Remove Snap Ring. Step 2. Carefully pry bearing out of housing. Step 2. Pry Bearing Out of Housing Step 3. Remove inner snap ring. Step 7. Remove Inner Snap Ring Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 600U Remove Left Side Belt From Assembly (continued) Step 4. Use 4 mm Hex Wrench to remove Screws and washers holding Brake to bracket. Step 4. Remove Screws & Washers. Step 5. Remove brake bracket until belt Can be removed. Step 5. Remove Bracket to Check Belt Page 82 Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 600U Remove Left Side Poly-V Wheel Tools Required: External Snap Ring Pliers Step 1. Remove snap ring from shaft on Right side. Step 1. Remove Snap Ring on Right Side Step 2. Slide shaft through bearing in Frame to remove pulley and shaft assembly. Note: Crank not welded to pulley so (1) extra step showing separating these for 600U set. Step 2. Slide Shaft Through Frame Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 600U Remove Crank Hub Assembly Tools Required: Large Crescent Wrench Rubber Mallet Flat Blade Screwdriver Step 1. Use crescent wrench to remove Large nut on crank. Step 1. Remove Crank Nut. Note: The crank nut has left-handed threads. Turn clockwise to loosen. Step 2. Remove keyed washer from under nut. Step 2. Remove Keyed Washer Step 3. Use crescent wrench to remove hex nut bearing. Use rubber mallet to knock out the shaft pulley assembly.
Removal & Replacement 600U Remove Crank Hub Assembly (continued) Note: A flat blade screwdriver may be used to pry hub from frame. Step 4. Pull hex nut bearing clear of frame Hub. Step 4. Pull Hex Nut Bearing Free. Step 5. Pull large pulley until bearing clears Frame. Step 5. Remove Large Pulley Assembly. Step 6. Twist assembly thru frame hub. Pull assembly until clear of frame. Step 6. Twist Unit Thru Hub Frame. Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 600U Remove Crank Hub Assembly (continued) Step 7. Use hammer and punch to loosen spanner nut on bearing. Note: The spanner nut has righthanded threads. Turn counter-clockwise to loosen. Step 7. Drive Spanner Nut Off to Remove Bearing Step 8. Remove bearing & washer by slipping off crank. Note: Pulley and crank are a welded assembly (cannot be separated). Step 8. Remove Bearing & Washer Step 9. Pull crank thru pulley to remove. Step 9.
Removal & Replacement 600R Remove Left Belt Poly-V Pulley Tools Required: Pliers Snap Ring Pliers Step 1. Use pliers, or needle nose pliers, to remove the belt tensioning spring. Step 1. Remove Belt Tensioning Spring Step 2. Remove the belt. Step 2. Remove Belt Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 600 Remove Poly-V Wheel Pulley (continued) Step 3. Use snap ring pliers to snap Ring from center of small poly-V pulley. Step 1. Prying with Snap Ring Pliers. Step 4. Remove the small poly-V pulley. Step 2. Remove Small Poly-V Pulley Page 88 Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 600R Remove Left Side Tensioner Assembly Tools Required: Snap Ring Pliers Step 1. Remove snap ring. Step 1. Remove Snap Ring Step 2. Slide tensioner assembly off pivot shaft. Note: Frame is slotted to allow brake bracket to slide when bolts are loose. Step 2. Slide Tensioner Assembly Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 600R Remove Belt & Tensioner Assembly Tools Required: 6 mm-Hex Wrench 13 mm Open-End Wrench Hammer Handle Step 1. Use 6 mm hex wrench to remove brake bracket locking screw. Step 1. Remove Locking Screw Step 2. Use 13 mm open-end wrench to loosen the 4 bolts holding the brake bracket to the frame. Note: Frame is slotted to allow brake bracket to slide when bolts are loose. Step 2. Loosen Bracket Bolts Page 90 Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 600R Remove Belt & Tensioner Assembly (continued) Step 3. Use hammer handle to pry the brake and bracket assembly toward the back of the bike to loosen the belt. Step 3. Pry on Brake to Loosen Belt. Step 4. Remove brake belt from larger poly-V wheel. Step 4. Remove Belt Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 600U & 600R Remove Belt & Tensioner Assembly (continued) Step 5. Disconnect wiring harness from brake. Step 5. Disconnect Wiring Harness. Step 6. Remove the loosened bottom screws. Step 6. Remove Loosened Screws Step 7. Remove brake and belt assembly. Step 7. Remove Brake & Belt Assembly Page 92 Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 600R Remove Right Side Belt From Assembly Tools Required: Internal & External Snap Ring Pliers Flat Blade Screwdriver Step 1. Remove snap ring. Step 1. Remove Snap Ring. Step 2. Carefully pry bearing out of housing. Step 2. Pry Bearing Out of Housing Step 3. Remove inner snap ring. Step 7. Remove Inner Snap Ring Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 600R Remove Right Side Belt From Assembly (continued) Step 4. Use 4 mm Hex Wrench to remove Screws and washers holding Brake to bracket. Step 4. Remove Screws & Washers. Step 5. Remove brake bracket until belt Can be removed. Step 5. Remove Bracket to Check Belt Page 94 Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 600R Remove Right Side Poly-V Wheel Tools Required: External Snap Ring Pliers Step 1. Remove snap ring from shaft on Right side. Step 1. Remove Shaft Snap Ring on Right Side Step 2. Slide shaft through bearing in Frame to remove pulley and shaft assembly. Step 2. Slide Shaft Through Frame Note: Crank not welded to pulley so (1) extra step showing separating these for 600U set. Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 600R Remove Crank Hub Assembly Tools Required: Large Crescent Wrench Rubber Mallet Flat Blade Screwdriver Step 1. Use crescent wrench to remove Large nut on crank. Step 1. Remove Crank Nut. Note: The crank nut has left-handed threads. Turn clockwise to loosen. Step 2. Remove keyed washer from under nut. Step 2. Remove Keyed Washer Step 3. Use crescent wrench to remove hex nut bearing. Use rubber mallet to knock out the shaft pulley assembly.
Removal & Replacement 600R Remove Crank Hub Assembly (continued) Note: A flat blade screwdriver may be used to pry hub from frame. Step 4. Pull hex nut bearing clear of frame Hub. Step 4. Pull Hex Nut Bearing Free. Step 5. Pull large pulley until bearing clears Frame. Step 5. Remove Large Pulley Assembly. Step 6. Twist assembly thru frame hub. Pull assembly until clear of frame. Step 6. Twist Unit Thru Hub Frame. Copyright 2001 True Fitness Technology, Inc.
Removal & Replacement 600R Remove Crank Hub Assembly (continued) Step 7. Use hammer and punch to loosen spanner nut on bearing. Note: The spanner nut has righthanded threads. Turn counter-clockwise to loosen. Step 7. Drive Spanner Nut Off to Remove Bearing Step 8. Remove bearing & washer by slipping off crank. Note: Pulley and crank are a welded assembly (cannot be separated). Step 8. Remove Bearing & Washer Step 9. Pull crank thru pulley to remove.. Step 9.