MINOURA FG540 Instruction Manual

Indoor Bike Trainer

[Applicable Wheel Size]

650c – 700c, 26 – 29 inch

[Applicable Wheebase Size]

950 – 1,200mm

(ver.1.2 2016/12)

(Shown with 700c road bike)

Caution

Contact

• This trainer is designed for use only on stable or indoor surfaces. The trainer is not
designed to be used in muddy or off road conditions. Getting dirt in the resistance unit
could may cause damage. Using muddy or dirty tires will cause premature wear on the
rollers.

• Using wheels smaller than 24" will put too much stress on the unit.

• When setting up the FG540 pedal slowly at rst to make sure the rear wheel stays on
the roller and is positioned properly.

If you need help, please contact the shop first where you originally purchased this product or call the distributors
in your country. The distributors list can be found on our web site.

MINOURA North American Tech Center MINOURA Japan Headquraters

(for U.S. residents ONLY)

Hayward, California, U.S.A. 1197-1 Godo, Anpachi, Gifu 503-2305 Japan
Phone: [phone] (8 am - 5 pm, Mon - Fri, PST) Phone: [phone]
Fax: [phone] Fax: [phone]
Email: [e-mail] Email: [e-mail]
Web: www.minoura.jp

(for ALL customers)

MADE IN JAPAN

Important Notes

• For use with a standard 2-wheel bike with the wheel size between 650c and 700c or 26 and 29 inch
and the wheelbase size between 950 and 1,200mm.
Any longer wheelbase bike such as a tandem or long-tail or other types of bike such as recumbent
or folding bike won't t FG540.

• The front hub is 100mm width and equipped with 9mm standard or 15mm thru-axle type. Any other
hub size cannot be used.
Boost hub and 12mm Thru Axle can be used by using the optional adapter (sold separately).

• The rear triangle of your bike rides freely on the roller. Be careful not to fall down while getting on or
off the bike. Use the handlebar to steady yourself put do not pull on the bars as this may cause the
bike to tip.

The best way to mount the trainer is to stand close to the side of the saddle. Center yourself low

and to the center of the bike, clip into one pedal then slowly swing your other leg over the bike and
clip into the second pedal.

• The quick release skewer in the front fork support is oating mounted with a plastic bushing to avoid
the damage caused by side-to-side shaking during riding. For this reason, the bolts which hold the
bushing are not fully tightened intentionally and there is some space above the bolt.

• Minoura recommends the use of a completely slick (no tread) tire to reduce noise and increase the

longevity of the tire and rollers.

Please Read Carefully Before Use

• The FG540 comes equipped with a standard quick release skewer (Q/R) for the front fork mount.

Tighten the Q/R as you would your wheel to your bike, close it rmly and tightly.

If you are unsure, consult your local bike shop for help.

• Your rear tire must contact both rollers evenly. Adjust the center arm/frame exactly.

Incorrect adjustment will result in unbalanced resistance and poor bike stability.

• For your safety, place the FG540 on a at, even oor or surface. Make sure all legs are fully opened.

Make sure to check the trainer stability, especially when raising the front fork mount.

• DO NOT USE YOUR BRAKE TO REDUCE SPEED!

Doing so will decrease stability, cause your tire to burst or throw you off the bike. Simply reduce your

cadence and let the bike come to a natural stop.

• Keep the children and pets away from the spinning wheel or moving parts.

• It's impossible to change to non-remote type. Removing the remote shifter will automatically set the

resistance level at the maximum position.

• Minoura recommends to use a mat underneath the trainer to protect the oor from sweat or stain

from the rubber feet.

• If you hear a strange noise or smell something unusual, immediately stop using the the trainer and

contact your Minoura dealer. Do not try to disassemble the product without consulting your dealer
or Minoura rst.

• Any warranty will be void if you use FG540 for other purpose than instructed.

Minorua offers 1-year limited warranty on this product from the date of your purchase for any
problem caused by manufacturer's defect. Natural wear will not be covered.
Any damage or problem caused by transporting process is not covered under warranty. Any damage
from shipping or moving must be made to the shipping company.
Read the enclosed "Minoura Limited Warranty Policy" card for more detail.
For the latest information, refer Minoura web site (http://www.minoura.jp).

- 2 -

Part Names

Front Fork Support
(9mm Q/R, 15mm Thru Axle compatible)

Adapter Sleeve for 15mm Thru Axle
(Red, inside)

Stopper Pin

Knob Lever (backside)

Flywheel

Remote Shifter

Front Roller
(free spinning side)

V-belt

Front Frame
Tripod Left Side Leg

Center Frame Locking Knob

/

Remote Cable

Center Frame

Front Frame /
Tripod Center Leg

Front Frame /
Tripod Right Side Leg

Center Frame Connecting Q/R

Remote Cable Guide
(backside, Right side only)

Rubber Cap

Rear Roller
(driven side)

How To Setup FG540

1

Fully open all tripod
legs, and place on the
floor.

!

Conrm all legs
are fully opened.

!

Magnetic Resistance Unit

Rear Frame

No Tool Required

Do not pinch
your nger when
closing the legs.

- 3 -

Flip out the retracted center frame, and place

2

on the floor.

Loosen the center frame locking knob to
prepare for sliding.

3

Connect the center frame to the tripod
center leg. Tighten the Q/R firmly.

Assembling FG540 is now finished.

!

Firmly tighten
the Q/R.

- 4 -

How To Adjust The Front Fork Support Height

Turn the knob lever counter-clockwise to loosen,

1

and pull up the front fork support.
The lever becomes free by pulling the lever. You can
set the lever at your favorite angle.

The stopper pin can be removed only while the fork

2

mount is lifted up.

Slide down the fork mount until the stopper pin

4

reaches the front frame.

Turn the knob lever clockwise and tighten

5

firmly.

Insert the pin into the hole that corresponds best to

3

the incline you want.

Simulating Uphill Angle

Each hole corresponds to an angle that simulates
climbing. (based on a 700c wheel)

0％

3％

6％

8％

10％

- 5 -

How To Use The 15mm Thru Axle

Required Tool : 3mm Hex Wrench

(not included)

The front fork support is compatible with both the standard 9mm quick release
skewer and the 15mm thru type axle.

To use 15mm thru axle, remove the headless bolts under the sleeve guide end
in the fork mount (do not remove the normal bolts) and pull out both the red
adapter sleeve and the Q/R.

Align the front fork and the fork support hole, insert the 15mm axle to set the
front fork.

Make sure the bolt type you are going to remove.

!

Do not remove the standard bolt with head.

Adapter Sleeve (red)

How To Mount Your Bike

(The bottom side of the fork mount)

Headless
Bolt

Remove the front wheel from your bicycle and set the front fork into the mount firmly.

1

Place the rear wheel on both rear rollers.

2

Slide and adjust the center frame position so that your rear tire contacts both rollers evenly.

3

Finally, tighten the center frame locking knob firmly.

3

!

Do NOT grasp brake lever after
removing the wheel if your bike is
equipped with hydraulic disc brake.

- 6 -

The rear tire sits in the center of the

!

roller and doesn't touch any other parts.

Adjust the center frame position properly that the rear tire contacts both rollers.

!

If the tire touches the rear roller only and a clearance exists between the tire and the front
roller, the center frame repeats jumping while riding. Set the rear frame backward.
If the tire touches the front roller only, slippage occurs and it will bring premature tire wear.
Set the rear frame forward.

It's normal for the rear tire to sway or move back and forth slightly
when in use. As long as the tire doesn't touch the sides of the rollers
this is ok.

If you find the tire is not centered properly, check if the front fork is
mounted on the quick release skewer properly, or if the handlebar
has been twisted a little.
If the bike has been slanted, loosen the quick release skewer and
push down the front fork until end.
If the handlebar has been twisted, loosen the Knob Lever, adjust the
steering angle, and tighten the lever firmly.

There is a guide bracket on the right side
tripod leg to hold the remote cable.

- 7 -

How To Operate Remote Shifter

FG540 comes with a convenient remote shifter device.
By installing it on your handlebar or stem, you can adjust the resistance
level in 13 levels without getting off the bike.
The plastic band is soft enough to fit aero-shaped carbon handlebar or
round shaped stem as well as the standard round dimension handlebars.

Required Tool : 4mm Hex Wrench

How to install the remote shifter

2) Hook the tip to the edge on the plastic shifter base

3) Flip up the lever to lock

1) Loop the plastic band around the handlebar

①

②

How to increase the resistance level

Twist the shifter dial toward "H" symbol

How to reduce the resistance level

Twist the shifter dial toward "L" symbol

(not included)

2

1

Lock
Lever

!

The remote shifter is pre-adjusted to fit the standard handlebar size;
22mm (7/8") diameter.
If it becomes loose or too tight, or you need to install the shifter onto an
oversized handlebar or stem, adjust the band length by turning the plastic
screw with an M4 hex wrench.

!

"L" does not mean no resistance. Due to the tire contact
to the roller, there will still be some small resistance.

Do not overtighten the plastic screw. It will break
the plastic band. Release the hook before adjusting.

How To Adjust Cable Tension

Required Tool : 8mm Spanner

If you cannot shift at L or H position, it's time to adjust the cable tension.

(not included)

x 2

Decrease

Indicator
(red dot)

Increase

4mm Hex
Wrench

1) Set the remote shifter lever at "H" position and straighten the cable.

2) Pull off the black plastic cap on foot of the cable, then the adjusting
screw with two lock nuts will appear.

3) While pushing the outer cable toward the shifter, push the adjusting
screw to the outer cable.

4) Turn the left side lock nut until it touches the Mag unit. You should

not overtighten the nut, otherwise you won't be able to set the shifter
at "L" position.

5) Turn the right side lock nut until it touhes the left side nut, then twist

the nuts each other to be locked as the method of "Double Nut".

6) Put the plastic cap over the screw again.

- 8 -

You must release the
hook for adjusting screw.

Adjust Screw

Lock Nut x 2

Turn the nut and tighten

Cap

FG540 How To Adjust The Belt Tension

With normal use you may find that the roller belt has become loose. A loose belt could be a serious issue if
unattended. If you find the belt has become loose, it is important to tighten the tension on the belt correctly.

To do so, use an M4 hex wrench to loosen the previously mentioned bolts while sliding the mag unit
forward to increase the tension on the belt until the correct tension has been achieved.

MINOURA JAPAN

1197-1 Godo, Anpachi, Gifu 503-2305 Japan / Web: www.minoura.jp / Mail: [e-mail]