Motus M660BU, M660BUL, M660BR, M660BRL Service Manual

M660BU, M660BUL, M660BR, M660BRL

Exercise Bike

SERVICE MANUAL

This service manual is for use by Motus trained service providers only. If you are not a Motus Trained Servicer, you must not attempt to service any Motus product.

Ver 0.1, Oct., 2007

Unauthorized Reproduction and Distribution Prohibited By Law

Motus Exercise Bikes M660BU, M660BUL, M660BR and M660BRL

Table of Contents

SECTION I TROUBLESHOOTING GUIDE

SECTION II HOW TO REPLACE & REPAIR GUIDE

General

SECTION III HOW TO REPLACE & REPAIR GUIDE,

Electronic PCB

SECTION IV ELECTRONIC PCB, CONNECTOR AND CABLE OVERVIEW

APPENDIX EXPLODED VIEW

Motus Exercise Bikes M660BU, M660BUL, M660BR and M660BRL

SECTION I

TROUBLESHOOTING GUIDE

1.1 System Block Diagram

1.2 Troubleshooting Guide

1.3 Troubleshooting Guide for LCD

1.1 System Block Diagram

Note: Dotted line is applied to M660BUL/M660BRL

Membrane Overlay Key

Contact HR/ Wireless HR

PCB

MPU PCB

(Main

Processing

Unit)

Operation PCB

(Intensity Up/

Intensity Down/

Start/Enter)

Contact HR

PCB

A/D

PCB

LCD Screen

LCD Lamp Inverter PCB

OSD Button PCB for Channel/Volume/Power-on

Video & Audio Input

(Coaxial, RCA)

Back-Light

Audio Interface

Headphone Jack

SMPS-5V

LCD Power

Adapter

AC 100V/220V

Power ON/OFF

Switch

Switching Mode Power Supply &

Brake Control

3-Phase

Rectifier with

DC Filter

Gener-

ator

Battery

1.2 Troubleshooting Guide

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

Line voltage is not present at equipment.

Check the main circuit breaker and wall outlet voltage at the Facility. If wall outlet voltage is present, then replace line cord.

No power to

Console

(On M660BUL/BRL)

Power-on Switch is damaged.

Replace Power-on Switch if the output voltage of Power Switch is not present.

Defective SMPS-5V (MPU Power Supply)

If no voltage, replace Defective SMPS-5V (MPU Power Supply).

Defective Wire Harness

If no voltage, verify that CBB3 interconnected with CBB4 cable is plugged into both MPU Board and SMPS-5V. Replace if necessary.

LCD TV is normal,

but Dot-LED and

Numeric LED do not

light up

(On M660BUL/BRL)

Defective MPU Board

Measure the voltage between pin 1 and pin 4 on CN2.

If no voltage, replace MPU PCB.

Dot-LED and

Numeric LED are

normal, but LCD TV

does not light up or

is blank

Refer to 1.3 Troubleshooting Guide for LCD. Refer to 1.3 Troubleshooting Guide for LCD.

Using a Multi-meter, verify more than 6VDC at pin-7 and pin-8 on CN1. If voltage is present, replace MPU board. If not, replace Drive board.

Faulty MPU board or Drive board

Test with substitute MPU board or Drive board. Replace if necessary.

Cable connection or loose wire connection

Verify that main cable CN1 is securely plugged into both MPU board and Drive board. Replace if necessary.

Console LEDs are

not illuminating

(On M660BU/BR)

Worn or damaged wire harness Inspect wire harness. Replace worn or damaged harness.

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

Faulty Battery, Note: Battery is used only for M660BU/BR, self-powered model.

Verify that Battery voltage is greater than 6 volts DC. Replace Battery if the voltage is lower than 6 volts DC. Test with substitute MPU board. Replace if necessary.

Faulty MPU board or Drive board

Test with substitute Drive board. Replace if necessary.

Cable connection or loose wire connection

Verify that main cable CN1 is plugged into both MPU board and Drive board. Replace if necessary.

Dot-LED or Numeric

LED lights up and

then fails.

(On M660BU/BR)

Worn or damaged wire harness Inspect wire harness. Replace worn or damaged harness. Faulty Battery

Verify that Battery voltage is greater than 6 volts DC. Replace Battery if the voltage is lower than 6 volts DC.

Cable connection

Verify that the cable connection at MPU board and Drive board or the connection between cables at midpoint is plugged in properly. Using a Multi-meter, verify continuity on all cables. Replace any defective cables.

Unit does not Auto

Start

(On M660BU/BR)

Faulty Drive board If cable connection is verified as good, replace the Drive board.

Unit does not display

SPEED on Console

Cable connection

Verify that the cable connection at MPU board and Drive board or the connection between cables at midpoint is plugged in properly. Using a

Multi-meter, verify continuity on all cables. Replace any defective cables. Pedaling is too slow. Pedal faster. Program intensity doesn’t challenge user ability. Select higher workout intensity. Drive Belt is excessively loose Inspect Belt tension. Adjust if necessary.

Cable connection or loose wire connection

Verify that the cable connection at MPU board and Drive board or the

connection between cables at midpoint is securely plugged in properly.

Using a Multi-meter, verify continuity on all cables. Replace any

defective cables. Worn or damaged wire harness Inspect wire harness. Replace worn or damaged harness.

Faulty Button Switch or Operation Button board

Verify that workout intensity on Console is increased or decreased by

pressing UP/DOWN button switch. Replace Button Switch or Operation

Button board if there is no change on intensity profile.

During exercise

program, pedaling is

insufficiently easy

without providing

adequate resistance.

Defective MPU board or Defective Drive board Test with substitute MPU board or Drive board. Replace if necessary.

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

Malfunction Overlay, Button Switch or Operation Button board

Replace Overlay, Button Switch or Operation Button board. Display Console

Keys do not function

and Bike does not

respond.

Defective MPU board Test with substitute MPU board. Replace if necessary.

Defective MPU board Test with substitute MPU board. Replace if necessary. Defective Drive board Test with substitute Drive board. Replace if necessary.

During MANUAL

program, excessive

resistance loading

occurs.

Worn or damaged wire harness Inspect wire harness. Replace worn or damaged harness.

During MANUAL

program, resistance

variance occurs

Pedaling is too slow Pedal faster.

Pedaling is difficult

with restricted

feeling or is not

possible when Bike

has not been started

(no STARY key)

Drive Belt is jammed. Inspect by opening the body covers. Replace if necessary.

Loose hardware

Verify that all hardware has been tightened. Apply Loctite where

necessary. Drive Belt is worn Replace Belt. Drive Belt is too loose Inspect Belt. Replace Belt if necessary.

During exercise

program, loud noise

issuing from Bike

Drive Belt is off track, touching other parts Inspect Belt. Relocate if necessary.

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

Electromagnetic interference from television sets, cell phones, refrigerator, or motor driven exercise equipment.

Keep the treadmill away from the probable cause until the heart rate readings are accurate.

RF energy source from another chest straps.

Keep another chest strap away more than 1 meter until the heart rate readings are accurate.

Heart rate reading is abnormally high or is displayed even when

Chest Strap or

Contact Heart Rate

sensors are not in

use.

Contact Heart Rate cables are pinched at handle bars. Replace damaged cables. Chest strap electrodes are not wet enough to sense accurate

heart rate.

Dampen the Chest strap electrodes with tap waters. The distance between cardio equipments are too close. Maintain the distance more than 30 cm. Chest strap electrodes are out of monitoring range.

Make sure the chest strap is within 60cm from Wireless

HR PCB. Chest strap battery is discharged. Replace chest strap or the battery. Chest strap electrodes are not laid flat or horizontally across your skin.

Make sure the chest strap electrodes lies flat and

horizontally across your skin. Faulty chest strap. Replace chest strap. Faulty Wireless HR PCB. Replace Wireless HR PCB.

Heart rate reading using wireless chest strap is erratic or not

displayed

Defective cable or bad connection between Wireless HR PCB and MPU PCB.

Check the cable and connection is no problem.

Faulty CHR PCB. Replace CHR PCB Dirty handlebar sensors. Wipe stainless steel sensors with a clean soft cloth.

Defective cable or bad connection between CHR PCB and MPU PCB.

Check the cable and connection is no problem

Contact Heart Rate reading is erratic or

not displayed.

User may have an unusual heart rate condition. Let different user grasp sensors to detect any variances.

1.3 Troubleshooting Guide for LCD

Symptom/Condition PROBABLE CAUSE CORRECTIVE ACTION

Air/cable setting is not correct

Follow the set up procedures in LCD manual.

TV signal source is not supplied.

- Check if the TV signal source is correctly supplied to A/D PCB from external source.

- Make sure the cable is properly secure.

- If external TV signal is correct, try to connect the coaxial cable directly to the internal connector in AD PCB of Console to check whether the internal cables are wrong or not.

75 ohm coaxial cable is bad. Replace 75 ohm coaxial cable.

Snow and noise are scattering on LCD screen. Any picture is not found even though channel-up button or channel-down button is pressed.

A/D Board is damaged. Replace A/D Board with new one.

LCD screen is uniformly white

Internal cable connection is loose or disconnected.

Check if the connection between LCD screen and A/D Board is tight. In other word, LVDS cable shown

in picture. Vertical large white-stripe or Vertical stripe block on LCD screen

Problem with LCD screen Replace LCD screen

When LCD power is turned on by pressing TV on/off, “VIDEO”, “S-VIDEO” or “ANALOG” appears temporarily and then disappears on the left upper corner of LCD screen.

TV mode is not set-up.

1) Whenever you press Volume down button, words

are displayed in following order on the left upper

corner of LCD screen.

“ANALOG”=>”VIDEO”=>”S-VIDEO”=>”TV”

2) Press the button until “TV” is displayed.

3) As soon as “TV” is displayed, snow and noise will

be scattering on LCD screen or any picture will be

captured.

LCD screen is dark or black.

When LCD power is turned on by pressing TV on/off, “VIDEO”, “S-VIDEO” or “ANALOG” is NOT displayed on the

LCD Power Supply has a problem. Power Supply is used for supplying 12 VDC

Check if LCD Power supply is normally operated or

LED lamp on Power supply body is turned on.

If LED is off,

to LCD Overlay Bezel Assembly.

z replace Power Adapter.

If LED is on,

z tighten midpoint (LCD Power Supply side)

& endpoint (A/D Board side) connection.

z or make sure the voltage of end point is

DC 12 volt. The cable related to LCD Lamp Inverter is loose in either side.

Check if the connection is secure.

TV on/off button is wrong or stuck.

Replace OSD Button Board.

A/D Board is damaged. Replace A/D Board. LCD Lamp inverter is damaged.

Replace LCD Lamp inverter.

LCD Back Light is damaged. Replace LCD screen.

left upper corner of LCD screen.

The connector or cable is bad.

Replace the connector or cable

Channels or Volume does not change

Button to change channels or volume does not work.

Replace the button, OSD Button Board or harness

related to it. Air/cable setting is not correct

Follow the set up procedures in LCD manual. Faulty headphones Replace headphones

No sound

Faulty headphone jack assembly or Audio Interface Board.

Replace Audio Interface Board or headphone jack.

Motus Exercise Bikes M660BU, M660BUL, M660BR and M660BRL

SECTION II

HOW TO REPLACE & REPAIR GUIDE

General

2.1 How to Adjust the Drive Belt (or POLY V-BELT) Tension

2.2 How to Replace the Drive Belt (or POLY V-BELT)

2.3. How to Replace the PEDAL SHAFT

2.4. How to Replace the GENERATOR

2.5. How to Replace the SEAT

2.6. How to Replace the GAS CYLINDER

2.7. How to Replace the PEDAL

2.8. How to Replace the IDLER ASSEMBLY

2.1 How to Adjust the Drive Belt (or POLY V-BELT) Tension

The tension of the Drive Belt can be slackened by a long time use and it can cause a slip between the Drive Belt and Pulleys. The tension is corrected by rotating the TENSION BOLT connected to the TENSION SPRING.

2.1.1 M660BU/BUL

Do the steps below while referring to the following Exploded Views in Appendix. C.1 M660BU/BUL_MAIN BODY

1) Turn off the unit power at the switch and then unplug the line cord at wall outlet.

2) Remove the CENTER FOOT_UP (61) by removing two bolts (52) securing the CENTER FOOT_UP (61) to the Main Body Frame.

3) Remove two bolts (55) securing MAIN BODY CAP (54) to the Main Body Frame.

4) Lift the MAIN BODY CAP (54) and SEAT POST CAP (56) and then fix these to the Gas Cylinder temporarily by a tape to make it easy to remove the MAIN BODY_R (50).

5) Remove five bolts (51, 52) securing the MAIN BODY_R (50) to the Main Body Frame and remove the MAIN BODY_R (50).

6) To increase the belt tension, turn the HEX NUT (17) clockwise in two or three turns. It makes the TENSION SPRING (15) tauter.

7) Rotate Pedal in two or three turns and then measure the tension of the Drive Belt using Tension Gauge in the position marked in “2”.

8) Repeat 6) thru 8) until the tension reaches 160 Hz.

9) Re-install all of parts in reverse order.

2.1.2 M660BR/BRL

Do the steps below while referring to the following Exploded Views in Appendix. I.1 M660BR/BRL_MAIN BODY

1) Turn off the unit power at the switch and unplug the line cord at wall outlet.

2) Remove two bolts (52) securing the CENTER FOOT_RE (59) to the Main Body Frame and Remove the CENTER FOOT_RE (59).

3) Remove two bolts (50) securing the FRONT BODY CAP_FRONT/REAR(58,57) to the Main

Body Frame and remove the FRONT BODY CAP_FRONT/REAR (58,57).

4) Remove six bolts (46, 56) fastening the FRONT BODY_R (54) to the Body Frame and remove the FRONT BODY_R (54) from the Body Frame.

5) To increase the belt tension, turn the HEX NUT (14) clockwise in two or three turns. It makes the TENSION SPRING (12) tauter

Turning the HEX NUT (14) counter clockwise decreases the belt tension.

6) Rotate Pedal in two or three turns and then measure the tension of the Drive Belt using Tension Gauge in the position marked in “2.”

7) Repeat 5) thru 7) until the tension reaches 160 Hz.

8) Re-install all of parts in reverse order.

2.2 How to Replace the Drive Belt (or POLY V-BELT)

The drive belts indicating cracks, fraying or excessive wear should be replaced.

2.2.1 M660BU/BUL

Do the steps below while referring to the following Exploded Views in Appendix. C.1 M660BU/BUL_MAIN BODY

1) For M660BUL, turn off the unit power at the switch and then unplug the line cord at wall outlet.

2) Remove the CENTER FOOT_UP (61) by removing two bolts (52) securing the CENTER FOOT_UP (61) to the Main Body Frame.

3) Remove two bolts (55) securing MAIN BODY CAP (54) to the Main Body Frame.

4) Lift the MAIN BODY CAP (54) and SEAT POST CAP (56) and then fix these to the Gas Cylinder temporarily by a tape to make it easy to remove the MAIN BODY_R (50).

5) Remove five bolts (51, 52) securing the MAIN BODY_R (50) to the Main Body Frame and remove the MAIN BODY_R (50).

6) To decrease the belt tension, turn the HEX NUT (17) counterclockwise until the HEX NUT (17) reaches the end side of the TENSION BOLT (16) as shown.

7) Remove the Drive Belt from the PEDAL PULLEY (28) by pushing the upper surface of the Drive Belt outward while rotating the Pedal little by little. Keep in mind that removing the Belt under high tension may make damages to the Belt and Bearings.

8) Install new Drive Belt in reverse order by installing the Belt around the GENERATOR (5) PULEY first and then walking it onto the IDLER PULLEY (8) and PEDAL PULLEY (28). You had better install the Belt while rotating the Pedal little by little.

9) Adjust the tension of the Drive Belt. See 2.1 How to Adjust the Drive Belt (or POLY V-BELT) Tension.

10) Re-install all of parts in reverse order.

Caution: To avoid risk of injury, it is recommended that one person replaces the Belt rather than two persons.

2.2.2 M660BR/BRL

Do the steps below while referring to the following Exploded Views in Appendix. I.1 M660BR/BRL_MAIN BODY

1) Turn off the unit power at the switch and unplug the line cord at wall outlet.

2) Remove two bolts (52) securing the CENTER FOOT_RE (59) to the Main Body Frame and Remove the CENTER FOOT_RE (59).

3) Remove two bolts (50) securing the FRONT BODY CAP_FRONT/REAR (58, 57) to the Main Body Frame and remove the FRONT BODY CAP_FRONT/REAR (58, 57).

4) Remove six bolts (46, 56) fastening the FRONT BODY_R (54) to the Body Frame and remove the FRONT BODY_R (54) from the Body Frame.

5) To decrease the belt tension, turn the HEX NUT (14) counterclockwise until the HEX NUT (14) reaches the end side of the TENSION BOLT (13) as shown.

6) Remove the Drive Belt from the PEDAL PULLEY (27) by pushing the upper surface of the Drive Belt outward while rotating the Pedal little by little. Keep in mind that removing the Belt under high tension may make damages to the Belt and Bearings.

7) Install new Drive Belt in reverse order by installing the Belt around the GENERATOR (2) PULEY first and then walking it onto the IDLER PULLEY (5) and PEDAL PULLEY (27). You had better install the Belt while rotating the Pedal little by little.

8) Adjust the tension of the Drive Belt. See 2.1 How to Adjust the Drive Belt (or POLY V-BELT) Tension.

9) Re-install all of parts in reverse order.

Caution: To avoid risk of injury, it is recommended that one person replaces the Belt rather than two persons.

2.3. How to Replace the PEDAL SHAFT

2.3.1 M660BU/BUL

Do the steps below while referring to the following Exploded Views in Appendix. C.1 M660BU/BUL_MAIN BODY

1) Turn off the unit power at the switch and then unplug the line cord at wall outlet.

2) Remove the CENTER FOOT_UP (61) by removing two bolts (52) securing the CENTER FOOT_UP (61) to the Main Body Frame.

3) Remove two bolts (55) securing MAIN BODY CAP (54) to the Main Body Frame.

4) Lift the MAIN BODY CAP (54) and SEAT POST CAP (56) and then fix these to the Gas Cylinder temporarily by a tape to make it easy to remove the MAIN BODY_R (50).

5) Remove five bolts (51, 52) securing the MAIN BODY_R (50) to the Main Body Frame and remove the MAIN BODY_R (50).

6) Remove the CRANK CAP (45) from the CRANK ARM_R (43) by using a tool with tip.

7) Remove the Bolt (44) securing the CRAMK ARM_R (43) to the PEDAL SHAFT (27) by using 6 mm wrench.

8) The PEDAL TOOL for pulling the Crank Arm out is shown. Maintain the PEDAL TOOL as shown in A by placing the rear section of the PEDAL TOOL as backward as possible.

9) Install the PEDAL TOOL into the hole of the CRANK ARM_R (43) where the CRANK CAP (45) was extracted.

10) Insert the PEDAL TOOL into the hole of the CRANK ARM_R (43) by turning the front hex-section of the PEDAL TOOL clockwise with Adjustable Spanner as shown.

11) Turn the rear hex-section of the PEDAL TOOL clockwise as shown until the CRANK ARM_R (43) is extracted from the PEDAL SHAFT.

12) Remove three Bolts (32) and remove the PEDAL IN COVER (31).

13) Remove the Drive Belt (46). See 2.2 How to Replace the Drive Belt

14) Remove the PEDAL PULLEY (28) from the unit by removing four Bolts (29).

15) Remove the MAIN BODY_L (49), CRANK CAP (45), CRANK ARM_L (41) and PEDAL IN COVER (31) in opposite side while using same procedures as 5) thru

12).

16) Remove the SNAP RING (30) by using Snap Ring Plier.

17) Pull the PEDAL SHAFT (27) out of the unit.

18) Install new PEDAL SHAFT (27) in reverse order.

19) Adjust the Drive Belt Tension before re-assembling the MAIN BODY_R (50). See “How to Adjust the Drive Belt Tension”

20) Re-install all of parts in reverse order.

2.3.2 M660BR/BRL

Do the steps below while referring to the following Exploded Views in Appendix. I.1 M660BR/BRL_MAIN BODY

1) Turn off the unit power at the switch and then unplug the line cord at wall outlet.

2) Remove the CENTER FOOT_RE (59) by removing two bolts (56) securing the CENTER FOOT_RE (59) to the Main Body Frame.

3) Remove two bolts (50) securing the FRONT BODY CAP_FRONT/REAR (58, 57) to the Main Body Frame and remove the FRONT BODY CAP_FRONT/REAR (58, 57).

4) Remove six bolts (46, 56) fastening the FRONT BODY_R (54) to the Body Frame and remove the FRONT BODY_R (54) from the Body Frame.

5) Replace the Pedal Shaft while referring to 6) thru 19) in section 2.3.1 M660BU/BUL.

6) Re-install all of parts in reverse order.

2.4. How to Replace the GENERATOR

2.4.1 M660BU/BUL

Do the steps below while referring to the following Exploded Views in Appendix. C.1 M660BU/BUL_MAIN BODY

1) Turn off the unit power at the switch and then unplug the line cord at wall outlet.

2) Remove the CENTER FOOT_UP (61) by removing two bolts (52) securing the CENTER FOOT_UP (61) to the Main Body Frame.

3) Remove two bolts (55) securing MAIN BODY CAP (54) to the Main Body Frame.

4) Lift the MAIN BODY CAP (54) and SEAT POST CAP (56) and then fix these to the Gas Cylinder temporarily by a tape to make it easy to remove the MAIN BODY_R (50).

5) Remove five bolts (51, 52) securing the MAIN BODY_R (50) to the Main Body Frame and remove the MAIN BODY_R (50).

JACK

CABLE HOLDER

6) Remove the CABLE HOLDER and disconnect two JACKs (or connector).

7) Remove the Drive Belt while referring to section 2.2 How to Replace the Drive Belt.

8) Remove the TENSION BOLT (16) and TENSION SPRING (15) by unscrewing the HEX BOLT (17).

9) Remove four ALLEN BOLTs (6) by using 5mm hex wrench.

10) Lift off the GENERATOR (5) from the MAIN FRAME (1).

11) Remove the IDLER BRACKET (7) and IDLER BRACKET BUSH (13) from the GENERATOR (5) by unscrewing three bolts (14) securing the IDLER BRACKET (7) to the GENERATOR.

12) Remove and discard three bolts on the pulley side of new GENERATOR to be replaced as shown.

13) Install the IDLER BRACKET (7) and IDLER BRACKET BUSH (13) onto the new GENERATOR by screwing three bolts (14). Note: Make sure the IDLER BRACKET (7) moves (or rotates) a little on the pulley as shown.

14) Install new GENERATOR in reverse order.

15) re-assemble the TENSION SPRING(15), TENSION BOLT(16) and HEX NUT(17).

16) Install the Drive Belt (46) while referring to section

2.2 How to Replace the Drive Belt.

17) Adjust the tension of the Drive Belt while referring to section 2.1 How to

Adjust the Drive Belt (or POLY VBELT) Tension.

18) The re-assembled new GENERATOR is shown.

19) Re-assemble all of parts in reverse order.

2.4.2 M660BR/BRL

Do the steps below while referring to the following Exploded Views in Appendix. I.1 M660BR/BRL_MAIN BODY

1) Turn off the unit power at the switch and then unplug the line cord at wall outlet.

2) Remove the CENTER FOOT_RE (59) by removing two bolts (56) securing the CENTER FOOT_RE (59) to the Main Body Frame.

3) Remove two bolts (50) securing the FRONT BODY CAP_FRONT/REAR (58, 57) to the Main Body Frame and remove the FRONT BODY CAP_FRONT/REAR (58, 57).

4) Remove six bolts (46, 56) fastening the FRONT BODY_R (54) to the Body Frame and remove the FRONT BODY_R (54) from the Body Frame.

5) Replace the GENERATOR while referring to 6) thru 18) in section 2.4.1 M660BU/BUL.

6) Re-assemble all of parts in reverse order.

2.5. How to Replace the SEAT

2.5.1. M660BU/BUL

Do the steps below while referring to the following Exploded Views in Appendix. F.1 M660BU/BUL_SEAT

1) Remove the SEAT (6) by unscrewing three HEX NUTs (8) and three SPRING WASHERs (7) securing the SEAT to the SEAT FRAME (1) by the use of 13 mm Spanner or Adjustable Spanner.

2) Discard the SEAT and install new SEAT in reverse order.

2.5.2. M660BR/BRL Do the steps below while referring to the following Exploded Views in Appendix. K.1 M660BR/BRL_SEAT

2.5.2.1. SEAT

1) Remove the SEAT (21) by unscrewing four ALLEN BOLTs (22) and four SPRING WASHERs (23) securing the SEAT to the SEAT FRAME (1)

2) Discard the SEAT (21) and install new SEAT in reverse order.

2.5.2.2. SEAT BACK

1) Remove the SEAT BACK COVER (25) by unscrewing eight TRUSS SCREWs (26) securing the SEAT BACK COVER to SEAT BACK (24).

2) Remove four ALLEN BOLTs (22) and four SPRING WASHERs (23) securing the SEAT BACK (24) to the SEAT FRAME (1).

3) Discard the SEAT BACK (24) and then install new SEAT BACK in reverse order.

2.6. How to Replace the GAS CYLINDER

Do the steps below while referring to the following Exploded Views in Appendix. A.1 M660BU C.1 M660BU/BUL_MAIN BODY

1) Remove the SEAT ASSEMBLY (15) from the GAS CYLINDER (38) by unscrewing four setscrews (16).

2) Remove the SEAT POST CAP (56).

3) Remove the MAIN BODY CAP (54) from the MAIN BODY by unscrewing two screws (55).

4) Remove four setscrews (39) securing the GAS CYLINDER (38) to the MAIN FRAME (39).

5) Install new GAS CYLINDER in reverse order.

2.7. How to Replace the PEDAL

2.7.1. Left PEDAL

The picture shown is the left Pedal as viewed from the rear side of the bike.

1) Turn the connecting section in between the PEDAL_L and CRANK ARM_L clockwise as shown in picture by using Adjustable Spanner or Spanner while holding the CRANK ARM_L.

2) Turn the PEDAL_L until it is distracted.

3) Discard the PEDAL_L and install new PEDAL_L in reverse order.

2.7.2 Right Pedal

The picture shown is the Right Pedal as viewed from the rear side of the bike.

1) Turn the connecting section in between the PEDAL_R and CRANK ARM_R counterclockwise as shown in picture by using Adjustable Spanner or Spanner while holding the CRANK ARM_R.

2) Turn the PEDAL_R until it is distracted.

3) Discard the PEDAL_R and install new PEDAL_R in reverse order.

2.8. How to Replace the IDLER ASSEMBLY

2.8.1 M660BU/BUL

Do the steps below while referring to the following Exploded Views in Appendix. C.1 M660BU/BUL_MAIN BODY

1) For M660BUL, turn off the unit power at the switch and then unplug the line cord at wall outlet.

2) Remove the CENTER FOOT_UP (61) by removing two bolts (52) securing the CENTER FOOT_UP (61) to the Main Body Frame.

3) Remove two bolts (55) securing MAIN BODY CAP (54) to the Main Body Frame.

4) Lift the MAIN BODY CAP (54) and SEAT POST CAP (56) and then fix these to the Gas Cylinder temporarily by a tape to make it easy to remove the MAIN BODY_R (50).

5) Remove five bolts (51, 52) securing the MAIN BODY_R (50) to the Main Body Frame and remove the MAIN BODY_R (50).

6) Mark the position of HEX LOCK NUT (17) on HANGER BOLT (16) for restoring BELT tension when reassembling it.

7) Loosen HEX LOCK NUT (17) by using 13 mm spanner until it reaches the end of HANGER BOLT (16) to slacken POLY V-BELT (46).

8) Remove POLY V-BELT (46) from PEDAL PULLEY (28), IDLER PULLEY (8) and GENERATOR PULLEY. Be careful not to get your hands be caught between the BELT and PULLEYS.

9) Remove IDLER BRACKET (7), IDLER BRACKET SPACER (12) and IDLER BRACKET BUSH (13) by removing three bolts (14) securing these to the GENERATOR. Note If you find IDLER BRACKET SPACER (12)

, discard both IDLER BRACKET SPACER (12) and IDLER BRACKET BUSH (13) and new IDLER BRACKET BUSH (13) should be used for reassembling. If no IDLER BRACKET SPACER (12),

the removed IDLER BRACKET BUSH (13) should be used for reassembling.

10) Install new IDLER ASEMBLY on the GENERATOR by using three bolts (14) and IDLER BRACKET BUSH (13). Do not tighten three bolts (14) too strongly

because it can spoil the threads of GENERATOR plate. IDLER BRACKET SPACER (12) should not be installed.

11) Make sure IDLER BRACKET (7) is partially rotated smoothly on the axis of the GENERATOR. If the rotation is not smooth, make sure it by replace IDLER BRACKET BUSH (13) with another one.

12) Install POLY V-BELT (46) in reverse order and then adjust the position of POLY V-BELT (46) to be located in the center of IDLER PULLEY (8) by rotating the pedal. The POLY V-BELT (46) can be aligned by using the Groove of PEDAL PULLEY (28).

13) Adjust the tension of the POLY V-BELT (46) by moving HEX LOCK NUT (17) into the position marked in 4).

14) Make sure POLY V-BELT (46) is located in the center of IDLER PULLEY (8) when you are pedaling. If the POLY V-BELT (46) drifts off the center of IDLER PULLEY (8), realign the BELT by using the Groove of PEDAL PULLEY (28).

15) Install all of other parts in reverse order.

Motus Exercise Bikes M660BU, M660BUL, M660BR and M660BRL

SECTION III

HOW TO REPLACE & REPAIR GUIDE

Electronic PCB

3.1 How to Replace the LCD Screen in Model M660BUL or M660BRL

3.2 How to Replace the A/D Board in Model M660BUL or M660BRL

3.3 How to Replace the MPU Board in Model M660BUL or M660BRL

3.4 How to Replace the MPU Board in Model M660BU or M660BR

3.5 How to Replace the OPERATION BUTTON Board

3.6 How to Replace the LAMP INVERTER Board in Model M660BUL or M660BRL

3.7 How to Replace the Program BUTTON Board, OSD BUTTON Board & AUDIO INTERFACE & DOWNLOAD Board in Model M660BUL and M660BRL

3.8 How to Replace the DRIVE Board.

3.9 How to Replace the SMPS-5V (or MPU POWER SUPPLY)

3.10 How to Replace the LCD POWER ADAPTER.

3.1 How to Replace the LCD Screen in Model M660BUL or M660BRL

Do the steps below while referring to the following Exploded Views in Appendix and Section 4

ELECTRONIC PCB, CONNECTOR AND CABLE OVERVIEW.

D.1 M660BU/BUL_CONSOLE POST G.1 CONSOLE, M660BUL/BRL_CONSOLE J.1 M660BR/BRL_CONSOLE POST

Note: The steps below are performed based on Upright Bike while referring to D. 1 M660BU/BUL_CONSOLE POST and .G.1 CONSOLE, M660BUL/BRL_CONSOLE.

1) Turn off the unit power at the switch and then unplug the line cord at wall outlet.

2) Remove the DISPLAY REAR COVER (13, D.1) from the DISPLAY PANEL BOTTM (10, D.1) by unscrewing four screws (8, D.1).

3) Remove the DISPLAY PANEL TOP (12, D.1) from the DISPLAY PANEL BOTTOM (10, D.1) by unscrewing four screws (11, D.1) securing the DISPLAY PANEL TOP (12, D.1).

4) Disconnect all the cables from the DISPLAY PANEL TOP (12, D.1) and then place the DISPLAY PANEL TOP (12, D.1) on the flat and clean surface so that the LCD screen faces downward.

5) Disconnect one end of the OSD BUTTON CABLE (CB21) from the side of A/D BOARD (8, G.1). The OSD BUTTON CABLE (CB21) is connected in between the A/D BOARD (8, G.1) and OSD BOARD (11, G.1).

6) Remove the LCD PANEL BRACKET (3, G.1) from the DISPLAY PANEL TOP (1, G.1) by unscrewing six screws (7, G.1).

7) Disconnect one end of the LVDS CABLE (CB31) from the side of the LCD PANEL (2, G.1). The other end of the LVDS CABLE (CB31) doesn’t need to be disconnected from the A/D BOARD (8, G.1).

8) Disconnect the LAMP INVERTER CABLE (CB32) from the LAMP INVERTER (6, G1).

9) Place the LCD BRACKET (3, G.1) upside down so that the LCD PANEL (2, G.1) faces upward.

10) Remove the LCD PANEL (2, G.1) by unscrewing four screws (4, G.1) securing the LCD PANEL (2, G.1) to the LCD BRACKET.

11) Install new LCD PANEL (2, G.1) in reverse order.

3.2 How to Replace the A/D Board in Model M660BUL or M660BRL

Do the steps below while referring to the following Exploded Views in Appendix and Section 4

ELECTRONIC PCB, CONNECTOR AND CABLE OVERVIEW.

D.1 M660BU/BUL_CONSOLE POST G.1 CONSOLE, M660BUL/BRL_CONSOLE

1) Turn off the unit power at the switch and then unplug the line cord at wall outlet.

2) Remove the DISPLAY REAR COVER (13, D.1) from the DISPLAY PANEL BOTTM (10, D.1) by unscrewing four screws (8, D.1).

3) Remove four screws (11, D.1) securing the DISPLAY PANEL TOP (12, D.1) to the DISPLAY PANEL BOTTOM (10, D.1).

4) Lift off the DISPLAY PANEL TOP (12, D.1) while disconnecting all the cables from the DISPLAY PANEL TOP (12, D.1) and then place the DISPLAY PANEL TOP (12, D.1) on the flat and clean surface so that the LCD screen faces downward.

5) Disconnect all the cables from the A/D BOARD (8, G.1).

6) Remove the A/D BOARD (8, G.1) from the LCD PANEL BRACKET (3, G.1) by unscrewing four screws (7, G.1).

7) Install new A/D BOARD (8, G.1) in reverse order.

3.3 How to Replace the MPU Board in Model M660BUL or M660BRL

Do the steps below while referring to the following Exploded Views in Appendix and Section 4

ELECTRONIC PCB, CONNECTOR AND CABLE OVERVIEW.

D.1 M660BU/BUL_CONSOLE POST G.1 CONSOLE, M660BUL/BRL_CONSOLE

1) Turn off the unit power at the switch and then unplug the line cord at wall outlet.

2) Remove the DISPLAY REAR COVER (13, D.1) from the DISPLAY PANEL BOTTM (10, D.1) by unscrewing four screws(8, D.1).

3) Remove four screws (11, D.1) securing the DISPLAY PANEL TOP (12, D.1) to the DISPLAY PANEL BOTTOM (10, D.1).

5) Disconnect all the cables from the MPU BOARD_FRONT (13, G1).

6) Remove three screws (7, G.1) securing the MPU BOARD_BACK (15, G.1) to the MPU BOARD_FRONT (13, G.1).

7) Carefully lift the MPU BOARD_BACK (15, G.1) off the MPU BOARD_FRONT (13, G.1) so that the pins on the both edges of the MPU BOARD_FRONT are not damaged or bended.

8) Remove four screws (12, G.1) and three HEXGON SPACER (14, G.1) securing the MPU BOARD_FRONT (13, G.1) to the DISPLAY PANEL_TOP (1, G.1).

9) Lift off the MPU BOARD_FRONT (13, G.1)

10) Install new MPU BOARD_FRONT or MPU BOARD_BACK in reverse order.

3.4 How to Replace the MPU Board in Model M660BU or M660BR

Do the steps below while referring to the following Exploded Views in Appendix and Section 4

ELECTRONIC PCB, CONNECTOR AND CABLE OVERVIEW.

D.1 M660BU/BUL_CONSOLE POST G.1 CONSOLE, M660BU/BR_CONSOLE

1) Remove the DISPLAY REAR COVER (13, D.1) from the DISPLAY PANEL BOTTM (10, D.1) by unscrewing four screws (8, D.1).

2) Remove four screws (11, D.1) securing the DISPLAY PANEL TOP (12, D.1) to the DISPLAY PANEL BOTTOM (10, D.1).

3) Lift off the DISPLAY PANEL TOP (12, D.1) while disconnecting all the cables from the DISPLAY PANEL TOP (12, D.1) and then place the DISPLAY PANEL TOP (12, D.1) on the flat and clean surface so that it faces downward.

4) Disconnect all the cables including Ribbon cable from the MPU BOARD (27, G1).

5) Remove eight screws (12, G.1) securing the MPU BOARD (27, G1) to the DI SPLAY PANEL TOP (1, G.1).

6) Lift off the MPU BOARD (27, G1) out of the DISPLAY PANEL TOP (1, G.1).

7) Install new MPU BOARD (27, G1) in reverse order.

3.5 How to Replace the OPERATION BUTTON Board

Do the steps below while referring to the following Exploded Views in Appendix and Section

ELECTRONIC PCB, CONNECTOR AND CABLE OVERVIEW.

D.1 M660BU/BUL_CONSOLE POST G.1 CONSOLE

1) If the machine is M660BUL or M660BRL with LCD monitor, turn off the unit power at the switch and then unplug the line cord at wall outlet.

2) Remove the DISPLAY REAR COVER (13, D.1) from the DISPLAY PANEL BOTTM (10, D.1) by unscrewing four screws (8, D.1).

2) Remove four screws (11, D.1) securing the DISPLAY PANEL TOP (12, D.1) to the DISPLAY PANEL BOTTOM (10, D.1).

4) Disconnect all of cables from the OPERATION BUTTON BOARD (21, G.1).

5) Remove the OPERATION BUTTON BOARD from the DISPLAY BUTTON CONTROL (20, G.1) by unscrewing five screws (12, G.1).

6) Install new OPERATION BUTTON BOARD (21, G.1) in reverse order.

+ 67 hidden pages

Motus M660BU, M660BUL, M660BR, M660BRL Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual