LeMond RevMaster Classic User Manual

Owner's Manual

LeMond Fitness Inc.

17820 Woodinville-Redmond Rd.

Building B, Suite 888

Tel.: [phone]
Fax: [phone]

Visit our website at

www.LeMondfitness.com

P/N 300202

© 2002 LeMond Fitness Inc. LeMond and RevMaster

are registered trademarks.

Page iii

WARRANTY

®

This is to certify that the LeMond
LeMond Fitness Inc. to be free of all defects in materials and workmanship. This
warranty does not apply to any defect caused by negligence, misuse, accident,
alteration, improper maintenance, or an “act of God.”

The LeMond RevMaster carries a five-year frame warranty, a one-year
warranty on bottom bracket bearings, pillow block bearings, tension knob
assembly, a three-year warranty on cranks, bottom bracket spindle, flywheel,
handlebar, seat post, handlebar post, and a 90 day warranty on wearables such
as seat, grip, handles, and brake pad. Contact our Customer Service Department
to report any problems. When calling, please be prepared to provide the
customer service representative with the following information:

• Your name, customer number, shipping address, and telephone
number

• The serial number of the inoperable bike

• The date(s) of purchase for the inoperable bike(s)

• Your billing address

This information will ensure that you are the only one ordering parts
under your warranty protection. If warranty replacement parts are shipped to
you, you may be required to return the inoperable part. To facilitate this process,
the following policy has been established:

• Please call our Customer Service Department to receive a return
goods authorization prior to shipment.

• LeMond Fitness will incur all ground freight charges for warranty
parts ordered for a machine that is less than 45 days old.

• You are responsible for freight charges on warranty parts for
machines that are more than 45 days old. You will not be
responsible for the return shipment of the inoperable parts.

• Some inoperable warranty parts must be promptly returned to our
Customer Service Department. We will pay the shipping cost for the
inoperable warranty parts. Detailed instructions are included with
each warranty replacement part.

RevMaster

™

exercise bike is warranted by

LeMond Fitness Inc. neither makes, assumes nor authorizes any
representative or other person to make or assume for us, any other warranty
whatsoever, whether expressed or implied, in connection with the sale, service, or
shipment of our products. We reserve the right to make changes and improve­ments in our products without incurring any obligation to similarly alter products
previously purchased. In order to maintain your product warranty and to ensure
the safe and efficient operation of your machine, only authorized replacement
parts can be used. This warranty is void if parts other than those provided by
LeMond Fitness are used.

Page iv

PREFACE

The LeMond® RevMaster™ bike is a safe, functional, and effective
exercise modality for developing aerobic fitness and increasing the
strength of the major muscle groups of the lower body. It is designed for
use by individuals of all ages and fitness levels. Your purchase of this bike
is a positive affirmation of your commitment to use the best available
methods for enhancing your functional fitness capabilities. In order to
derive optimal benefits from your equipment, you should read this manual
thoroughly and adhere closely to the instructions.

WHAT IS IN THIS MANUAL?

Following the information on safety guidelines and an explanation of
installation procedures, this manual will provide general exercise guide­lines and explain how the LeMond RevMaster exercise bike works.
Detailed instructions of parts removal and replacement are then followed
by exploded diagrams of the bike components.

WHAT IS THE LEMOND REVMASTER BIKE?

The LeMond RevMaster is a revolutionary new group exercise stationary
cycle from LeMond Fitness Inc. that delivers an extraordinary workout.
It has been designed to be stronger, more stable, feel more comfortable,
be easier to adjust, and have a more durable crank system then conven­tional group exercise bikes.

The LeMond RevMaster bike was designed by Paul Swift under the
direction of Greg LeMond. LeMond is the first American to win the Tour
de France. A cyclist who has won the world's most challenging races,
Greg LeMond has also revolutionized the sport by introducing cutting
edge technology that is commonplace today. Paul Swift is a 15-year
member of the USA cycling team, eight-time national champion and 1998
Goodwill Games Gold Medalist.

Page v

CONTENTS

SAFETY GUIDELINES .......................................................... 1

INSTALLATION INSTRUCTIONS..................................... 3

Delivery ........................................................................... 3

GUIDELINES FOR SAFE OPERATION ........................... 7

BASIC OPERATING INSTRUCTIONS ............................. 8

Your first workout on the LeMond® RevMaster

Exercise Bike ................................................................. 8

Seat Adjustment ............................................................. 8

Handlebar Adjustment ................................................... 8

Pedal Strap Adjustment ................................................. 9

GENERAL EXERCISE GUIDELINES ................................ 10

Setting a goal ................................................................. 10

Flexibility Training .......................................................... 10

Exercise Principles ........................................................ 11

MAINTENANCE INSTRUCTIONS .................................... 12

Helpful Hints .................................................................. 12

Tool List ......................................................................... 12

Preventive Maintenance ................................................ 12

Daily ........................................................................ 13

Weekly .................................................................... 13

Monthly ................................................................... 13

TROUBLESHOOTING ......................................................... 1 4

Symptom: Adjustment Handles do not engage .............. 14

Symptom: Handlebar/Seat post will not slide up or down

................................................................................ 14

Symptom: Pedals are slipping ........................................ 14

Symptom: Pedals do not rotate ...................................... 14

®

PARTS REMOVAL AND REPLACEMENT ...................... 1 5

Adjustment Handles....................................................... 15

Belt ................................................................................ 16

Bottom Bracket Bearings .............................................. 16

Brake Pad Assembly ..................................................... 18

Page vi

CONTENTS

Covers ............................................................................ 19

Flywheel/Pillow Block Bearings .................................... 19

Handlebar ...................................................................... 20

Handlebar Post .............................................................. 20

Pedals ............................................................................ 21

Pedal Crank Arms ......................................................... 21

Seat ................................................................................ 22

Seat Slider ...................................................................... 22

Seat Post ........................................................................ 23

Tension Knob Assembly ................................................ 23

FIGURES ................................................................................ 2 4

Figure 1: Final Assembly ................................................ 24

Figure 2: Crank Assembly.............................................. 25

Figure 3: Flywheel Assembly ......................................... 26

Figure 4: Belt Tension .................................................... 27

Figure 5: Front Base Assembly...................................... 28

Figure 6: Rear base Assembly ....................................... 29

Figure 7: Brake Tension Knob Assembly ...................... 30

Figure 8: Brake Pad Assembly ...................................... 31

Figure 9: V-Plunger & Plug ........................................... 32

SPECIFICATIONS ................................................................. 33

LIST OF TABLES

Table 1. Dimensions and Specifications for the

LeMond® RevMaster® Exercise Bike............................ 3

Page vii

SAFETY GUIDELINES

IMPORTANT SAFETY INSTRUCTIONS

This symbol appearing throughout this manual means

!

Attention! Be Alert! Your safety is involved.

The following definition applies to the word “WARNING” found
throughout this manual:

WARNING - Used to call attention to POTENTIAL hazards that

could result in personal injury or loss of life.

READ ALL INSTRUCTIONS BEFORE USING THIS EXERCISE EQUIPMENT.

1. Close supervision is necessary whenever the equipment is used by, or
near children, invalids, or disabled persons. A serious injury could result
from a child's fascination with the moving components of the exercise
system.

2. Keep your hands away from all moving parts and keep your feet on the
pedals while exercising. Do not remove your feet from the RevMaster® bike
pedals while they are in motion.

3. Use this equipment only for its intended use as described in this Manual. Do
not attempt to ride this bike at high pedal speeds or in a standing position
until you practiced and are comfortable riding at slower pedal speeds.

4. Rotate the tension knob clockwise to apply resistance to the flywheel prior
to standing on the pedals.

5. Do not dismount the RevMaster bike until both of the pedals and the
flywheel are at a complete stop.

6. Never turn the pedal crank arms by hand. Do not expose your hands or your
arms to the drive mechanism as possible injury could occur.

Page 1

SAFETY GUIDELINES

7. Do not perform push-up type movements on the handlebars.

8. After exercising, turn the tension knob clockwise or push down on the
tension knob to slow the flywheel down so that the pedals do not rotate
freely and possibly hurt somebody.

9. Never drop or insert any object into any opening on the exercise equipment.

The safety level given by the design of this equipment can only be maintained
when the equipment is regularly examined for damage and wear. Inoperable
components should be replaced immediately or the equipment should be put out
of use until it is repaired.

Failure to follow all guidelines may compromise the effectiveness of the

exercise experience, expose yourself (and possibly others) to injury, and reduce
the longevity of the equipment.

SAVE THESE INSTRUCTIONS

Your comments and suggestions are welcome. Congratulations, and thank
you for buying the RevMaster!

Your serial
number(s):___________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
____________________________________________________________
___________________________________________________________

Your LeMond Fitness
Dealer:______________________________________
Phone:______________________________________________________

Page 2

INSTALLATION INSTRUCTIONS

Before leaving the manufacturing facility, your LeMond® RevMaster
exercise bike was thoroughly inspected and tested for proper operation.
To minimize shipping damage, careful attention was given to making your
bike ready for shipment. The dimensions of the machine are listed in
Table 1.

Table 1. Dimensions for the LeMond® RevMaster™ Bike

Physical Dimensions:

Length 41.50 inches (105 cm)
Width 22.25 inches (57 cm)
Height 38.00 inches (97 cm)
Weight 116 pounds (53 kg)

DELIVERY

Your LeMond RevMaster will arrive packed in 1 carton. Upon arrival
fully inspect the carton for damage. Point out any damage to the delivery
person and have the delivery person record the damage on the delivery
paperwork. Contact the Customer Service Department at [phone]
to report any damage.

®

Please follow these detailed instructions and you will find that your

bike can be unpacked and assembled with ease.

A. Remove the bike and components from the shipping carton

1. Move the box to the desired location. Ensure that the carton is

standing upright and remove the strapping material.

2. Pull the cardboard edge out along the bottom of the box to

remove the staples. Lift the top of the box up and set aside.

3. Remove the two smaller boxes from the main frame of the bike.

4. Open both boxes and verify that you have all of the hardware

and parts necessary to assemble your bike. You should have an
owner's manual and the following parts:

Page 3

INSTALLATION INSTRUCTIONS

Seat

Pedals

Water Bottle Cage

4x Handles

Rear Base

Seat Post

Handlebar Assembly

Front Base

Handlebar Post

4x Mounting Bolts

3x Hex Keys

Wrench Tool

B. Assemble the Bike

5. With the help of an assistant, lift the bike up and off the pallet.

6. The base that has wheels is the

front base and connects to the
main frame below the flywheel.
Ensure that the wheels are
facing out, and align the 2 holes
in the front base with the 2
holes in the frame. Insert a
mounting bolt into the top of the
hole and push the bolt through the base and the main
frame. Use the 8-mm hex key and wrench tool to secure the
mounting bolt nut. Repeat this procedure for the rear base.

Note: If you are having difficulty threading the nut on the
bolt, prop up the main frame using the inclosed wooden
blocks to allow accessibility to the nut.

Page 4

INSTALLATION INSTRUCTIONS

7. The handlebar post is the post that has a smooth finish, and no

groove on top. Insert the handlebar post into the handlebar tube.
Loosely thread a handle without a washer into the main frame.
Raise the handlebar post to the desired height and tighten the
handle to secure the handlebar post.

Handlebar Post

Seat Post

Note: The black handles are spring loaded. Once tightened,
ensure that the handle does not stick out to the side from the
main frame. Pull down on the handle and rotate it such that it
does not stick out. Release the handle and lock it into place.

8. Position the handlebar over the handlebar post. Loosely thread a

handle with a washer through the handlebar post into the handle­bar. Slide the handlebar to the desired
position and tighten the handle.

9. The 4-mm screw that mounts the

water bottle cage is located in the
water bottle clamp on the handlebar
assembly. Remove the screw from
the clamp and position the water
bottle cage over the clamp. Reinstall the screw and tighten the
water bottle cage to the clamp.

10. The seat post is the post that has a rough finish, and a groove on

top. Insert the seat post into the seat post tube. Loosely thread a
handle without a washer into the main frame. Raise the seat post
to the desired height and tighten the handle to secure the seat
post.

Page 5

INSTALLATION INSTRUCTIONS

11. Position the seat with seat slider over

the seat post. Loosely thread a
handle with a washer through the seat
post into the seat slider. Slide the seat
to the desired position and tighten the
handle.

12. The pedals are marked as if you are seated on the bike, "R" for

right, and "L" for left. Carefully thread the right pedal into the
crank arm with your fingers - do not cross thread the pedal in the
crank arm! Use the wrench tool to tighten the pedal. Repeat this
step for the left pedal.

Note: The left pedal is reverse-threaded.

Seat Adjustment
Handle

Seat Post
Adjustment
Handle

Back Cross Arm

Seat

Seat Post

Handlebar

Handlebar Post
Adjustment Handle

Front Cross Arm

Page 6