Page 1
Service Manual
SPINNER
SPINNER
INDOOR CYCLES
SBK800-16
®
CHRONO™ POWER
&
®
CLIMB™
Page 2
Contents
1Introduction 1
About This Document 1
2General Information 3
Orientation Convention 3
Tools 3
Specification Summary 4
Parts 4
Lubrication 5
Cleaning 5
Safety Guidelines 6
Safety guideline you need to know and follow: 6
3Operation Verification 7
About 7
Operation Verification Checklist 7
4Adjustment Procedures 10
About 10
Available Adjustment Procedures 10
AutoCal 10
Procedure 11
Brake Pad Adjustment 12
Procedure 12
Drive Belt Tension and Tracking Adjustment 16
About 16
Procedure 16
Generator Belt Tension Adjustment 24
About 24
Specifications 24
Page ii
Page 3
Procedure 24
Bike Leveling Adjustment 27
5Replacement Procedures 28
Replacement Procedures 28
Battery Replacement 30
About 30
Specifications 30
Determining the battery condition 30
Battery Fuse 31
Procedure 31
Belt Guard Cover Replacement 34
About 34
Procedure 34
Brake Pad Replacement 39
About 39
Specialized Tools 40
Procedure 40
Caliper Assembly Replacement 44
About 44
Strain gauge cable routing 44
Specialized Tools 45
Replacement Procedures 45
Replacement Procedure - (Spinner® Chrono™ Power models only) 45
Replacement Procedure - (Spinner® Climb™ models only) 52
Data COMM Cable Replacement 55
About 55
Specialized Tools 56
Procedure 56
Drive Belt, Generator Belt, and Flywheel Replacement 66
Page iii
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About 66
Specifications 66
Procedure 67
Generator Assembly Replacement 78
About 78
Procedure 78
Handlebar Assembly Replacement 81
About 81
Procedure 81
Handlebar Adjustment Knob Replacement 84
About 84
Procedure 84
Handlebar Post Removal 86
About 86
Procedure - (Spinner® Chrono™ Power models only) 86
Procedure - (Spinner® Climb™ models only) 89
LPCA board Replacement 92
About 92
LPCA Interface Cable Connections 92
LPCA Status LEDs 93
Procedure 94
Pedal Replacement 100
About 100
Specifications 100
Specialized Tools 100
Procedure 100
Crank Arm Replacement 105
About 105
Specialized Tools 105
Page iv
Page 5
Procedure 105
Resistance Knob Replacement 108
About 108
Procedure 108
Seat Assembly Replacement 112
About 112
Procedure 112
Stabilizer Replacement 114
About 114
Front Stabilizer Replacement 115
Rear Stabilizer Replacement 118
6Troubleshooting 121
About 121
Introduction To Troubleshooting 121
Basic Steps 121
Service and Diagnostic Menus 124
About 124
Service/Setup Mode Access 124
Menu Navigation 125
Service and Settings Menus 126
Error Log 129
Active Status Light (ASL) 130
About 130
ASL Overview 130
ASL States 131
ASL Setup and Test 132
Resetting the ASL state and Maintenance Counter 132
Clearing a Pulsing Yellow and/or Steady Yellow ASLstate 132
Error Log 134
Page v
Page 6
About 134
Accessing the Error Log 134
Clearing the Error Log 134
Exporting the Error Log 134
System Troubleshooting Procedures 136
About 136
Available procedures 136
Belt Drive Issues 137
Resistance Issues 138
Eratic Power (WATTS) Measurements 139
7Preventive Maintenance 141
About 141
Maintenance Schedule 141
Precor Preventative Maintenance Plan 141
8Parts 142
About 142
Exploded View Diagram 143
Parts List 144
9Consoles 146
About 146
Spinner® Chrono™ Console 147
About 147
Powering ON the Console 148
Installation and Removal 149
Service/Setup Menu Access 150
Menu Navigation 150
Menus and Settings 151
Error Log Information 153
Spinning® Studio Console 155
Page vi
Page 7
About 155
Cadence (RPM) sensor installation 156
Heart Rate Belt Bluetooth Pairing 156
Service and Maintenance 156
Appendix A : Edition Information i
Edition i
Additional Documentation i
Copyright i
Appendix B : Notices and Safety ii
Trademarks ii
Intellectual Property ii
Warranty ii
Safety Instruction ii
Safety Notices ii
Page vii
Page 8
1Introduction
About This Document
If you are not a Precor certified servicer, you must not attempt to service any Precor Product.
Call your dealer for service information.
WARNING: This service documentation is for use by Precor certified servicer pro-
viders only. Personal injury can result from electrical shock and/or mechanical moving
parts.
This service manual applies to the SBK800 series model Spinner®Chrono™ Power and Spinner®Climb™ indoor cycles. This document contains information required to service, repair,
troubleshoot, and maintain the machines.
Indoor Cycle Model Feature Summary
Spinner® Chrono™ Power SBK869 Magnetic braking,
Self-powered, Direct
PowerMeasurements
(Watts), ASL1, & Spinner® Chrono™ console
Spinner® Climb™ SBK867 Magnetic braking &
1
Active Status Light: Service and maintenance status light.
1
Page 9
1 Introduction
About This Document
Indoor Cycle Model Feature Summary
Spinning® Studio™
console
Additional Documentation
There is also an online web version if you have internet access at: Online Service Manuall
See Also
"General Information" on page3
"Safety Guidelines" on page6
"Operation Verification" on page7
"Adjustment Procedures" on page10
"Replacement Procedures" on page28
"Troubleshooting" on page121
"Parts" on page142
2
Page 10
2General Information
The following information provides general equipment and service information that will help
you to use this manual to properly repair and maintain the bike.
Orientation Convention
The equipment orientation (front, right, left, back) used in manual is referenced to a user sitting
on the equipment facing the handlebars.
Tools
Required service and repair tools:
l Metric Hex Key set (2.5 - 6mm)
l Torque wrench 40 ft-lbs (54 N•m l MagneticGap Fixture kit
l Metric Wrench set (10 - 21mm)
l Screw driver set l Belt Tension Gauge (recommended Kent-Moore
Notes:
[1] Required for pedal removal.
[2] The bike tool kit contains all the specialized tools to repair the bike. (Does not include the
magnetic gap fixture tool.)
[3] Required for magnetic brake pad adjustment.
[4] (Included in the Spinner Bike Tool Kit (PPPFT0000007308000)
[4]
[4]
l Spinner Bike Tool Kit (PPPFT0000007308000)
[2]
(PPP000000058248101)
l Crank Extractor (X-Tools Crank Extractor)
[3][4]
[1][4]
BT-33-73-F)
3
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Specification Summary
This table provides a summary of system component specifications.
System Component Specification
Pedal Torque 33 ft-lb (45 N•m)
Drive Belt Tension 60 +/- 5 lbs (27 */- 2 kgs)
Generator Belt Tension 1/2 in (1.3 cm) up/dwn travel
Stabilizer fastener Torque 15.6 ft-lbs (21 N•m)
Axle Nut Torque 29.5 ft-lbs (40 Nm)
.
Parts
IMPORTANT: Always purchase OEM replacement parts and hardware from Precor.
If you use parts not approved by Precor, you could void the Precor Limited Warranty.
Use of parts not approved by Precor may cause injury.
2 General Information
Specification Summary
Major Assembly and Parts Location
Exploded View Diagram and Parts List
There is a copy of the parts
the "Parts" on page142 chapter that you can use as a quick reference. It is recommended that
Exploded View Diagram
and
Parts Identification List
included in
4
Page 12
you go to the servicer partners Precor Connect website to view the most current parts
information including the
l
Precor Connect Partner Website
Exploded View Diagram
and
Parts Identification List
.
Lubrication
Common metal parts Use only synthetic lubricants such as Mobile 1 Synthetic grease or
Super Lube with Teflon. Use of unapproved lubricants, cleaners, or solvents may void the bike
warranty.
Cleaning
1. Wipe down equipment with recommended cleaning solution.
l General: 1 oz. mild soap to 30 oz. water.
l Consoles: a diluted solution of one part 91% Isopropyl alcohol to one part water.
CAUTION: Do not use acidic cleaners and do not spray directly onto the equipment
surfaces.
2. Rinse using a clean lint-free cloth and dampened with water only. Dry completely with
another clean lint-free cloth.
5
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2 General Information
Safety Guidelines
Safety Guidelines
Safety guideline you need to know and follow:
l Read and follow all Warning notices to protect yourself from personal injury.
l Read and follow all Caution notices to prevent damage to the equipment.
l Read the owner’s manual and follow all operating instructions.
l Operate the equipment on a solid, level surface.
l Visually check the equipment before beginning service or maintenance operations. If it
is not completely assembled or is damaged in anyway, do not attempt to operate the
equipment.
l Never place liquids on any part of the equipment while performing service.
l To prevent electrical shock, keep all electrical components away from water and other
liquids.
l Do not use accessory attachments that are not recommended by the manufacturer-
such attachments can cause injury.
l Do not stand or climb on the handlebars, display enclosure or cover.
When servicing the equipment:
l During service operations you will be very close to moving machinery and voltage bear-
ing components:
o
Remove jewelry (especially from ears and neck),
o
Tie up long hair,
o
Remove neck ties, and
o
Do not wear loose clothing
See Also
"Safety Instruction" on pageii
"Safety Notices" on pageii
6
Page 14
3Operation Verification
About
Use the Operation Verification Checklist to verify the [[[Undefined variable ProductInfo.EqptType]]] operation. Verify the [[[Undefined variable ProductInfo.EqptType]]] operation at the completion of any maintenance procedure and when it is necessary to ensure that
the [[[Undefined variable ProductInfo.EqptType]]] is operating properly.
Operation Verification Checklist
Do an overall visual inspection of the bike looking for any loose hardware and/or missing
parts. .Repair and replace as needed.
Verify that the bike sets level and is stable on the floor, see "Bike Leveling Adjustment"
on page27.
Verify that the seat position is level and does not rotate or tilt. Tighten and adjust as
needed.
Verify that the seat height and forward/back adjustment work correctly.
l Make sure that the seat post up/down movement is smooth and that the pop-pins
lock at different positions. .
l Make sure the forward/back slider movement is smooth and the adjustment knob
locks the seat in position.
Verify that the handlebar height and forward/back adjustment work correctly.
l Make sure the handlebar post up/down movement is smooth and that the pop-
pins lock at different positions.
l Make sure the forward/back slider movement is smooth and the adjustment knob
locks the handlebar in position.
Set the resistance to minimum and pedal the bike at a moderate pace (55 rpm or
greater), increase the resistance to maximum and return to zero resistance.
l Verify that the resistance knob functions normally from min to max resistance.
l Verify that there were no unusual noises from the brake pads or flywheel during
operation.
l Verify that at maximum resistance, the bike was very hard to pedal.
Pedal the bike at a moderate pace (55 rpm or greater), stop pedaling and press down on
the resistance knob. Verify that the flywheel immediately begins to slow and quickly
stops.
Power (Watts) measurement auto-cal verification:
(Spinner®Chrono™ Power only).
l Set the resistance to minimum and pedal the bike at 55 rpm or greater.
IMPORTANT: The resistance must be set to minimum to correctly perform
auto-cal.
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3 Operation Verification
Operation Verification Checklist
l Stop pedaling and wait for the pedals to completely stop. Wait 10 seconds to allow
the bike to complete the power measurement auto-cal function.
l While continuously pedaling the bike at 60 RPM, verify that the measured
workout WATTS at minimum and maximum resistance levels is within spe-
cification.
Power (WATTS) specification
ResistanceLevel Power (WATTS)
minimum ≤40 Watts @ 60 rpm
maximum ≥415 Watts @ 60 rpm
IMPORTANT: The bike must be auto-cal'd before making the WATTS measurement. Also, the bike must be continuously pedaled between the min and max
resistance WATTS measurements. If the pedals stop, a new auto-cal may occur
invalidating the measurements.
Generator verification:
(Spinner®Chrono™ Power only).
l Pedal the bike at 60 RPM.
l Verify that the measured generator voltage (service menu GEN VOLT) and cur-
rent output (service menu GEN AMP) is within specification.
Generator specification
Generator Spec Power (WATTS)
Generator voltage (GEN VOLT) approx: 9 Vac @ 60 rpm
Generator current (GEN AMP) approx: 0.4 amps @ 60 rpm
Error Log & ASL1verification:
(Spinner®Chrono™ Power only).
l Verify that there are no current active error codes, view the service menu
ERROR LOG. If there are logged error codes, resolve them and clear the error
log (service menu CLEAR ERROR
l Verify the ASL blue state (Some facilities may choose to switch the ASL function
OFF, see ASL SETUP): Ride the bike and stop. Make sure that the console ASL
state is steady blue. If not, resolve any issues and reset the ASL to blue state.
Return to service
(Spinner® Chrono™ Power models only)
l Auto-cal the bike, set the resistance level to minimum, start pedaling greater than
55 rpm and then stop pedaling. Wait for the pedals to stop and dismount the bike.
l If verification tests were successfully completed, return to service.
1
Active Status Light: Service and maintenance status light.
8
Page 16
.
9
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4 Adjustment Procedures
About
4Adjustment Procedures
About
Adjustment procedures provide you with the step-by-step adjustment instructions to bring systems and components into specification. Perform the adjustment procedures whenever a
trouble symptom points to a particular component and after a major component is removed/replaced.
Available Adjustment Procedures
"Brake Pad Adjustment" on page12
"Drive Belt Tension and Tracking Adjustment" on page16
"Generator Belt Tension Adjustment" on page24
"Bike Leveling Adjustment" on page27
AutoCal
(Spinner®Chrono™ Power bikes only)
AutoCal is an automatic power (WATTS) measurement calibration feature offered on
Spinner®Chrono™ Power model bikes. To insure accurate power (WATTS) results, an
AutoCal should be performed before starting a workout.
AutoCal removes strain gauge sensor and brake pad magnetic field errors from the Power
measurement (WATTS) results. Items you should know to perform a good AutoCal:
l AutoCal is performed every time the pedals stop moving for more than 3-5 seconds.
l The resistance must be completely removed (resistance knob turned fully coun-
terclockwise) while AutoCal is being performed.
l The brake pads must be correctly gaped to achieve a good AutoCal, see "Brake Pad
Adjustment" on page12.
Two use cases that can cause a bad AutoCal
There are two common use cases that can inadvertently cause an inaccurate AutoCal:
l Exerciser momentarily stops and starts pedaling during a workout.
Momentarily stopping and starting the pedals during a workout for more than 3-5
seconds will start a new AutoCal. If the resistance was not set to minimum, the Autocal
will be bad resulting in inaccurate power WATTS measurements.
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l An exerciser quits a workout and dismounts the bike without setting the resistance level
to minimum.
In this case the bike will perform an inaccurate AutoCal because the resistance was not
set to minimum. The new exerciser will read inaccurate power WATTS results unless a
new AutoCal is performed with the resistance set to minimum.
Procedure
Review entire procedure before starting.
3. Set the resistance level to minimum (resistance knob turned fully counterclockwise):
4. Start pedaling the bike at 55 rpm or greater, then slow down and allow the pedals to
stop. When the pedals and flywheel stop, the bike will perform the power measurement
AutoCall. Wait a minimum of 10 seconds for the auto-cal to complete
IMPORTANT: The resistance knob must be set to the minimum resistance level to
correctly perform the auto-cal function. The WATTS parameter will be incorrectly computed if the resistance knob is not set to minimum resistance level during auto-cal.
5. Verify the measured WATTS at minimum and maximum resistance levels:
a. Set the resistance to minimum.
b. Start pedaling and maintain the speed at 60 rpm as reported on the console RPM
indicator. While continuously pedaling, verify the measured WATTS at minimum
and maximum resistance levels. Continuously pedal between measurements.
Power (WATTS) specification
Resistance
Level Power (WATTS)
minimum ≤40 Watts @ 60 rpm
maximum ≥415 Watts @ 60 rpm
IMPORTANT: The bike must be AutoCal'd before making the WATTS measurement. Also, the bike must be continuously pedaled between the min and max resistance WATTS measurements. If the pedals stop, a new AutoCal may occur
invalidating the measurements.
9. Verify the bike operation per and return to service.
See Also
11
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4 Adjustment Procedures
Brake Pad Adjustment
Brake Pad Adjustment
This procedure provides instruction to adjust the Magnetic Brake Pads.
The brake pad-flywheel gap must be correctly set to insure proper resistance level, auto-cal,
and power measurement (watts).
Perform the brake pad adjustment any time the brake pads are replaced or any condition were
the resistance is not performing correctly or the power measurement is not being correctly
computed.
Strong magnetic force
The brake pads have a very strong magnetic force and attraction to the flywheel or any ferromagnetic metal object. . The brake pads can easily be ripped from your grasp and snap
against the metal object damaging the pad. Be very careful to hold the brake pads tightly when
in close proximity to the flywheel during the brake pad removal and installation procedures.
CAUTION:The magnetic force of the brake pad is very strong and when in close
proximity to the flywheel (or any metal object) will quickly snap the pad against the flywheel (or other metal) object causing damage to the brake pad magnets. Firmly hold
the magnetic brake pads during removal/installation procedures to avoid damaging
the brake pads.
Specialized Tools
Tool Part Number Qty
Magnetic Gap Fixture
kit*
Note: *Each Magnetic Gap Fixture kit contains two (2x) Magnetic Gap Fixture tools.
Only one kit is required to complete the brake pad adjustment.
PPP000000058248101 1*
Procedure
Review entire procedure before starting.
1. Loosen the resistance knob enough to allow the installation of the magnetic gap fixture
tool.
2. Mount a magnetic gap fixture (2x) onto both the left and right brake pads. Slip the back
of the magnetic gap fixture into the gap between the brake magnetic pad and the fly-
12
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wheel surface. Continue sliding the fixture over the brake pad and press into position.
Note:It is recommended that a magnetic gap fixture (2x) be mounted on both the left
and right brake pads before starting and while performing the brake pad gap adjustment procedure.
3. loosen, but do not remove, the left and right brake pad 3 mm hex key mounting bolts (2x
per pad).
13
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4 Adjustment Procedures
Brake Pad Adjustment
4. Apply maximum resistance, fully turn the resistance knob in the clockwise (+) direction.
5. Adjust the left and right brake pads so that the magnetic gap fixture tool touches the flywheel surface. Then fully tighten the 3 mm hex key fasteners (2x per pad).
6. Loosen the resistance and remove the magnetic gap fixture tools from the left and right
brake pads.
7. Verify resistance operation:
a. Turn the resistance knob to minimum resistance.
b. Start pedaling the bike at 60 rpm or greater while increasing the resistance level
to maximum and returning to minimum resistance. Stop pedaling and allow the flywheel to stop:
l Verify that changing the resistance level from minimum to maximum and
back to minimum was smooth and that there were no issues with the resistance knob or caliper assembly.
l Verify that at maximum resistance, the pedal resistance was very strong (If
possible, compare with a similar bike in known good operating condition).
l Verify that there were no unusual noises from the brake pads during this
operation.
8. Verify the power (watts) measurement:
(Spinner®Chrono™ Power model only)
a. Auto-cal the bike:
l Set the resistance to minimum.
l Start pedaling the bike at 55 rpm or greater, then slow down and allow the
pedals to stop. When the flywheel stops, the bike will perform the power
measurement auto-cal. Wait a minimum of 10 seconds for the auto-cal to
complete.
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IMPORTANT: The resistance knob must be set to the minimum resistance level to
correctly perform the auto-cal function. The WATTS parameter will be incorrectly computed if the resistance knob is not set to minimum resistance level during auto-cal.
b. Verify the measured WATTS at minimum and maximum resistance levels:
l Set the resistance to minimum.
l Start pedaling and maintain the speed at 60 rpm as reported on the con-
sole RPM. While continuously pedaling, verify the measured WATTS is
within spec at the minimum and maximum resistance levels. Continuously
pedal between measurements.
Power (WATTS) specification
Resistance
Level Power (WATTS)
minimum ≤40 Watts @ 60 rpm
maximum ≥415 Watts @ 60 rpm
IMPORTANT: The bike must be auto-cal'd before making the WATTS measurement.
Also, the bike must be continuously pedaled between the min and max resistance
WATTS measurements. If the pedals stop, a new auto-cal may occur invalidating the
measurements.
9. While riding the bike at 60 rpm, stop pedaling and firmly press down the resistance
knob. Verify that the flywheel immediately slows down and stops rotating.
10. Verify the bike operation per "Operation Verification Checklist" on page7 and return to
service.
See Also
"Adjustment Procedures" on page10
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4 Adjustment Procedures
Drive Belt Tension and Tracking Adjustment
Drive Belt Tension and Tracking Adjustment
About
This procedure provides instruction to verify and make adjustments to the drive belt tension
and tracking. The belt tension and tracking should be verified anytime the flywheel is removed,
the belt is replaced, at regularly scheduled preventative maintenance, or when there are any
unusual belt related issues (noises, pedal skip, fraying, etc.) while operating the bike.
CAUTION: Improper belt tension and tracking adjustment will cause premature
wear and may void the Precor Limited Warranty.
Specifications
System Component Specification
Belt Drive Tension 60 +/- 5 lbs (27 */- 2 kgs)
Axle Nut torque 29.5 ft-lbs (40 Nm)
Specialized Tools
Tool Part Number
Belt Tensiongauge Belt Tension Gauge (recommended Kent-Moore BT-33-73-F
Procedure
Review entire procedure before starting.
Belt Tension adjustment
1. Remove the front and rear drive belt covers, see "Belt Guard Cover Replacement" on
page34.
2. Remove all brake resistance by turning the resistance knob counter clockwise (-).
3. Loosen the left and right 17 mm axle nuts enough to allow flywheel axle movement. Do
not fully remove the axle nuts.
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4. Place the belt tension gauge on the drive belt midway between the front and rear
sprockets. Position the tension gauge so that the center tension tab rests on the belt
tooth ridge and not in the gap between the teeth. Read and record the measured belt
tension.
a. If the measured tension is within the specification limits 60 +/- 5 lbs (27 */- 2 kgs),
remove the tension gauge and verify the belt tracking, go to "Belt tracking adjust-
ment" on page21.
b. If the measured tension is not within spec, remove the tension gauge and con-
tinue the belt tension adjustment.
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4 Adjustment Procedures
Drive Belt Tension and Tracking Adjustment
5. If the belt is under tension, remove the belt tension by alternately loosening the right and
left 10 mm hex key belt tension adjustment nuts. Keep a small amount of belt tension so
that the belt remains seated on the front and rear sprockets.
6. If the drive belt is not centered on the flywheel pulley, slowly turn the pedals while
nudging the belt to the center of the sprocket.
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7. Place the belt tension gauge on the drive belt midway between the front and rear sprockets Position the tension gauge so that the center tension tab rests on the belt tooth ridge
and not in the gap between the teeth.
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4 Adjustment Procedures
Drive Belt Tension and Tracking Adjustment
8. Incrementally and alternately tighten the left and right tension adjustment nuts so that
the flywheel remains centered between the left and right fork weldments. Continue the
adjustment process until the belt tension gauge reads, 60 +/- 5 lbs (27 */- 2 kgs).
20
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9. Remove the tension gauge. Then hand turn the crank to break-in the belt. Stop the belt,
place the tension gauge onto the belt and remeasure the belt tension. Make sure the
belt tension remains in spec 60 +/- 5 lbs (27 */- 2 kgs). Readjust the tension if out-ofspec.
10. Verify the belt tracking, go to "Belt tracking adjustment" below.
.
Belt tracking adjustment
The drive belt tracking does not need to remain perfectly centered on the pulley. The belt is correctly tracking when the belt edges do not rub against either the left or right flywheel pulley
rims during use.
Note:Always use the LEFT belt tension adjustment bolt to make belt tracking adjust-
ments.
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4 Adjustment Procedures
Drive Belt Tension and Tracking Adjustment
1. Hand rotate the pedals and verify that the drive belt does not track either the left or right
so that it rubs against the flywheel pulley left (inner) or right (outer) rims. If the drive belt
rubs against the pulley inner or outer rims, adjust the tracking alignment to correct the
issue:
a. If the belt is tracking to the left causing the belt to rub against the inner rim of the
pulley, adjust the belt to track to the right and remain centered on the pulley.
While rotating the pedals, loosen the LEFT adjustment nut in 1/8 counter-clockwise increments until the belt moves towards the center and no longer rubs
against the pulley inner rim.
If the belt moves past the pulley center, slightly tighten (turn clockwise) the LEFT
adjustment nut to recenter the belt.
Continue this process until the belt no longer rubs against either the inner or outer
pulley rims.
b. If the belt is tracking to the right causing the belt to rub against the outer rim of the
pulley, adjust the belt to track to the left and remain centered on the pulley. While
rotating the pedals, tighten the LEFT adjustment nut in 1/8 clockwise increments
until the belt moves towards the center and no longer rubs against the sprocket
outer rim.
If the belt moves past the sprocket center, slightly loosen (turn counter-clockwise)
the LEFT adjustment nut to recenter the belt.
Continue this process until the belt no longer rubs against either the inner or outer
sprocket rim.
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CAUTION:Damage to the belt edges and unusual noises will occur if the belt is not
properly aligned and is rubbing against the sprocket inner or outer rims.
2. Tighten the left and right axle nuts, torque to 29.5 ft-lbs (40 Nm).
3. Ride and pedal the bike at high speed for several minutes Verify that there were no
tracking issues while riding the bike.
4. Stop the pedals, dismount the bike and verify that the belt tension and tracking remain
within specification:
a. Remeasure the belt tension and verify that it remains within spec 60 +/- 5 lbs (27
*/- 2 kgs). Readjust if out-of-spec.
b. Inspect the drive belt tracking and make sure the belt is not rubbing against the
inner or outer sprocket rims. Readjust if out-of-spec.
5. Reinstall the front and rear drive belt covers, see "Belt Guard Cover Replacement" on
page34.
6. Verify the bike operation per "Operation Verification Checklist" on page7 and return to
service.
See Also
"Adjustment Procedures" on page10
23
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4 Adjustment Procedures
Generator Belt Tension Adjust ment
Generator Belt Tension Adjustment
Applies To: (Spinner® Chrono™ Power models only)
About
This procedure provides instruction to verify and make adjustments to the Generator belt tension. The belt tension should be verified anytime the flywheel is removed, the belt is replaced,
at regularly scheduled preventative maintenance, or when there are any unusual belt related
issues (noises, low charging voltages, etc.) while operating the bike.
CAUTION: Improper belt tension adjustment will cause premature wear and may
void the Precor Limited Warranty.
Specifications
System Component Specification
Generator Drive Tension 1/2 in (1.3 cm) up/dwn travel
Procedure
Review entire procedure before starting.
1. Remove the front and rear drive belt covers, see "Belt Guard Cover Replacement" on
page34.
2. Remove all brake resistance by turning the resistance knob counter clockwise (-).
Belt tension check
3. Measure the belt tension up/down travel.by positioning a ruler next the belt edge while
firmly pressing down and releasing the belt. The belt up/down travel should be within
1/2 in (1.3 cm) up/dwn travel
a. . If the belt tension is within spec, tension adjustment is not required. If
b. the belt is not within spec, continue belt tension adjustment.
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Belt tension adjustment
4. Loosen the generator 4 mm hex key mounting bolt enough so that the generator can be
moved forward and rearward. Do not remove the mounting bolt.
5. Slowly hand rotate the pedals and make sure the belt is correctly seated on the generator and flywheel generator pulleys.
6. Adjust the belt tension by sliding the generator forward or rearward as needed so that
there is 1/2 in (1.3 cm) up/dwn travel. Measure the belt travel.by positioning a ruler next
the belt edge and measuring the belt down travel distance while firmly pressing down on
the belt (The belt should be tensioned to half the full up/down travel spec distance).
CAUTION:Do not over tension the belt which will lead to premature belt wear and
possible damage to the generator pulley.
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4 Adjustment Procedures
Generator Belt Tension Adjust ment
7. Fully tighten the 4 mm generator mounting bracket bolt.
8. Ride and pedal the bike at high speed for several minutes and verify there are no issues
with the belt (unusual noised etc.).
9. Slow down and stop the pedals and flywheel. Verify that the belt tension travel remains
at 1/2 in (1.3 cm) up/dwn travel.
10. Reinstall the front and rear drive belt covers, see "Belt Guard Cover Replacement" on
page34.
11. Verify the bike operation per "Operation Verification Checklist" on page7 and return to
service.
See Also
"Adjustment Procedures" on page10
26
Page 34
Bike Leveling Adjustment
Use this procedure to level the bike. Make sure the bike is level and sits firmly on the floor
before allowing anyone to use the bike.
IMPORTANT: Place the unit on a flat surface. Rotating the adjustable feet does not
compensate for extremely uneven surfaces.
Leveling the bike
1. Tighten all four leveling feet to fully lower the bike.
2. Push on the bike and try to rock the bike. If there is any movement make foot adjustments as needed to stabilize the bike. Turn the leveling feet clockwise (+) to lower the
bike or counterclockwise (-) to raise the bike.
3. Test ride the bike at slow and high speed verifying that the bike remained stable while
pedaling.
4. Dismount the bike and recheck for stability, readjust the feet as necessary to stabilize
the bike.
See Also
"Adjustment Procedures" on page10
27
Page 35
5 Replacement Procedures
5Replacement Procedures
Replacement procedures provide you with the step-by-step instructions to remove and
replace system components.
Replacement Procedures
"Battery Replacement" on page30
"Belt Guard Cover Replacement" on page34
"Brake Pad Replacement" on page39
"Caliper Assembly Replacement" on page44
"Drive Belt, Generator Belt, and Flywheel Replacement" on page66
"Drive Belt, Generator Belt, and Flywheel Replacement" on page66
"Drive Belt, Generator Belt, and Flywheel Replacement" on page66
"Drive Belt, Generator Belt, and Flywheel Replacement" on page66
"Generator Assembly Replacement" on page78
"Handlebar Assembly Replacement" on page81
"Handlebar Adjustment Knob Replacement" on page84
"LPCA board Replacement" on page92
"Pedal Replacement" on page100
"Crank Arm Replacement" on page105
28
Page 36
"Resistance Knob Replacement" on page108
"Seat Assembly Replacement" on page112
"Stabilizer Replacement" on page114
See Also
"Brake Pad Adjustment" on page12
"Drive Belt Tension and Tracking Adjustment" on page16
"Generator Belt Tension Adjustment" on page24
"Bike Leveling Adjustment" on page27
29
Page 37
5 Replacement Procedures
Battery Replacement
Battery Replacement
(Spinner® Chrono™ Power models only)
About
This procedure provides instruction to determine the condition of the battery and replacement
procedure.
Specifications
Battery Voltage Specification
Battery Specification 6 VDC, 1.2 AH
GOOD battery state* 5.8 - 6.6 VDC*
LOW battery state* 5.5 - 5.7 VDC*
Console OFF state* < 5.4 VDC*
Charging voltage
(while pedaling)
Note:*static voltage measurements: no pedal movement and no
power adapter connected.
7.5 VDC max
Determining the battery condition
If the measured voltage is below 5.5 vdc, charge the battery by pedaling greater than 55 rpm
(or using an optional battery adapter) until the battery static (non-pedaling) voltage level
reaches 5.8 to 6 vdc.
If the static battery voltage will not charge to and remain at 5.8 - 6 vdc:
30
Page 38
1. While pedaling the bike, make sure the battery charging voltage is greater than 6 vdc
(7.5 vdc max). Access the console service test menu, select the BAT VOLT parameter
to read the battery charging voltage, see "Spinner® Chrono™ Console" on page147.
2. Stop pedaling the bike and verify that the battery voltage remains ≥ 5.8 vdc. If not,
replace the battery. If the battery does not remain ≥ 5.5 vdc after a few hours with no
pedaling, replace the battery
Battery Fuse
The inline battery fuse is part of the battery assembly cable red wire connected to the battery
positive terminal. To remove the fuse, open the fuse holder by twisting the fuse holder top cap
and removing the fuse.
Fuse specification: Inline fuse, 5 amp/250 vdc
Procedure
Review entire procedure before starting.
Removal procedure
1. Remove the front and rear belt guard covers, see "Belt Guard Cover Replacement" on
page34.
2. Determine the battery condition, see "Determining the battery condition" on the pre-
vious page .
3. Carefully disconnect the battery cable Black wire from the Negative (-) battery terminal
and then the Red wire from the Positive (+) battery terminal. Disconnect the battery
Negative (-) terminal wire first:
31
Page 39
5 Replacement Procedures
Battery Replacement
4. Cut the cable tie that is securing the battery to the cross member and remove the battery.
Installation procedure.
1. Place the battery on the cross member and secure with an 8" cable tie.
2. Carefully reconnect the battery cable Red wire to the Positive (+) battery terminal and
then the Black wire to the Negative (-) battery terminal. Reconnect the Negative terminal cable last.
3. Slowly pedal the bike enough to power ON the console, access the console service test
menu BAT VOLT parameter (see "Spinner® Chrono™ Console" on page147).
Continue pedaling and verify that the battery voltage is between 6.0 - 7.5 vdc, then stop
32
Page 40
pedaling and verify that the voltage remains ≥ 5.8 vdc. If the battery voltage is low, start
pedaling faster than 55 rpm to charge the battery until the non-pedaling voltage remains
at ≥ 6 vdc (a new battery may need to be charged.).
4. Replace the front and then rear belt guard covers, see "Belt Guard Cover Replace-
ment" on the next page.
5. Verify the bike operation per "Operation Verification Checklist" on page7 and return to
service.
.See Also
"Replacement Procedures" on page28
33
Page 41
5 Replacement Procedures
Belt Guard Cover Replacement
Belt Guard Cover Replacement
About
This procedure provides instruction to remove and install the front and rear Belt Guard
Covers.
The front belt guard cover includes an access panel used to access the right tensioner nut and
axle nut. It is easiest to remove the rear guard cover first and then the front guard cover, install
in reverse order. All rear guard fasteners must be removed before the front guard can be
removed.
Available Movies
(Internet Only)
belt Guard Cover Replacement
Procedure
Review entire procedure before starting.
Removal instructions
1.
Remove the rear (left side) belt guard cover by removing the three outer 5 mm hex
key fasteners (3x) and then the center 4 mm fastener (1x). Remove center 4 mm
34
Page 42
hex key fastener last. Retain fastener hardware for installation.
2.
Remove the front belt guard access panel by removing the one fastener using a 5
mm hex key. Retain fastener hardware for installation.
3.
Remove the front belt guard cover by removing the 5 mm hex key (4x) fasteners.
The 4 mm hex key center back cover bolt needs to also be removed to remove the front
cover. Retain fastener hardware for installation.
35
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5 Replacement Procedures
Belt Guard Cover Replacement
4. Position the crank arm to the 9 o'clock position and then carefully slide the front cover
over the crank arm and pedal to remove. Retain fastener hardware for installation.
Installation Instructions
1. Position the crank arm to the 9 o'clock position and then carefully slide the front cover
over the pedal and crank arm. Retain fastener hardware for installation.
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2. Position the cover over the frame cover mounting bolts and secure using the 5 mm hex
key fasteners (4x).
3.
Install the front cover access panel onto the front belt cover, insert the left side tabs
first and close. Secure using the removed 5 mm hex key bolt (1x).
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5 Replacement Procedures
Belt Guard Cover Replacement
4.
Then install the rear (left side) belt guard cover , installing the center 4 mm hex
key fastener (1x) first and then the three outer 5 mm hex key fasteners (3x).
See Also
"Replacement Procedures" on page28
38
Page 46
Brake Pad Replacement
About
This procedure provides instruction to remove and install the magnetic Brake Pads.
The brake pads use opposed magnetic force to vary the flywheel resistance level and integrated caliper strain gauge to calculate the measured power in watts. The brake pads are mounted on the bottom of the left and right caliper.
Brake pad replacement
The brake pad magnets are north-south polarized and must be replaced as a set to ensure
proper polarization.
39
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5 Replacement Procedures
Brake Pad Replacement
Strong magnetic force
The brake pads have a very strong magnetic force and attraction to the flywheel or any ferromagnetic metal object. . The brake pads can easily be ripped from your grasp and snapped
against the metal object damaging the pad. Be very careful to hold the brake pads tightly when
in close proximity to the flywheel during the brake pad removal and installation procedures.
CAUTION:The magnetic force of the brake pad is very strong and when in close
proximity to the flywheel (or any metal object) will quickly snap the pad against the flywheel (or other metal) object causing damage to the brake pad magnets. Firmly hold
the magnetic brake pads during removal/installation procedures to avoid damaging
the brake pads.
Incorrect Power measurements
The brake pad-flywheel gap must be calibrated for each installation or whenever it is detected
that the power measurement is incorrectly computed. If the brake pad gap is not correctly set,
the power measurement auto-cal correction will not be correctly determined causing the resultant Power (watts) measurement to be incorrect. You must use the OEM magnetic gap fixture tool to properly set the gap at installation. The pads have slotted mounting holes to allow
brake pad-flywheel gap adjustment.
I
nconstant Power measures
If multiple bikes are not showing similar power (watts) results at common torque and rpm settings, the bikes most probably have been incorrectly auto-calibrated, see "Verify the power
(watts) measurement: " on page14.
Specialized Tools
Tool Part Number Qty
Magnetic Gap Fixture
kit*
Note: *Each Magnetic Gap Fixture kit contains two (2x) Magnetic Gap Fixture tools.
Only one kit is required to complete the brake pad adjustment.
PPP000000058248101 1*
Procedure
Review entire procedure before starting.
40
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Removal
1. Remove all brake pad resistance by turning the resistance knob fully counterclockwise
(-).
2. Mount a magnetic gap fixture onto both the left and right brake pads.
Note:It is recommended that a magnetic gap fixture (2x) be mounted on both the left
and right brake pads before starting the brake pad installation procedure.The fixture
will help to prevent accidental damage to the brake pad and/or scratching the flywheel
surface.
3. Firmly hold the left brake pad while removing the two 3 mm hex key bolts and washers.
When removing the brake pad past the flywheel the pads strong magnetic attraction can
quickly pull the pad from your hand snapping it against the flywheel damaging the brake
pad. Retain the pads and fastener hardware for installation.
CAUTION:The magnetic force of the brake pad is very strong and when in close
proximity to the flywheel (or any metal object) will quickly snap the pad against the flywheel (or other metal) object causing damage to the brake pad magnets. Firmly hold
the magnetic brake pads during removal/installation procedures to avoid damaging
the brake pads.
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4. Repeat the procedure to remove the right brake pad.
Installation
1. Mount a magnetic gap fixture onto the left and right brake pads.
5 Replacement Procedures
Brake Pad Replacement
Note:It is recommended that a magnetic gap fixture (2x) be mounted on both the left
and right brake pads before starting the brake pad removal procedure.The fixture will
help to prevent accidental damage to the brake pad and/or scratching the flywheel surface.
1. Reinstall the left and right brake pads onto the respective calipers and secure using the
two 3 mm hex key bolts (2x) and washers (2x). Loosely hand tighten the fasteners allowing brake pad movement.
TIP: Increasing the resistance will move the calipers closer to the flywheel which
provides more room between the caliper and frame weldment to install the mounting
bolts and washers.
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2. Adjust the brake pad gap and verify the resistance knob operation, see "Brake Pad
Adjustment" on page12.
3. Verify the bike operation per "Operation Verification Checklist" on page7 and return to
service.
See Also
"Replacement Procedures" on page28
43
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5 Replacement Procedures
Caliper Assembly Replacement
Caliper Assembly Replacement
About
This procedure provides instruction to remove and install the Caliper assembly. There are separate replacement procedures, one for the Spinner® Chrono™ Power and one for the Spinner® Climb™ models.
Caliper replacement requires removal of the flywheel, drive belt, and generator belt.
Strain gauge cable routing
(Spinner® Chrono™ Power models only)
Beginning from the strain gauge left side caliper, the cable crosses to the right side and enters
the right fork weldment cable upper cable access hole. From there the cable travels down the
right fork weldment exiting at the lower cable access hole. Travels across the cross member
connecting to the LPCA1board.
1
Lower PCA board
44
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Specialized Tools
Tool Part Number Qty
Magnetic Gap Fixture
PPP000000058248101 1*
kit*
Cable Puller (fish tape) PPP000000058248101 1
Note: *Each Magnetic Gap Fixture kit contains two (2x) Magnetic Gap Fixture tools.
Only one kit is required to complete the brake pad adjustment.
Replacement Procedures
l Spinner
l Spinner® Climb™ models only models
®
Chrono™ Power models
Replacement Procedure - (Spinner®Chrono™ Power models only)
Review entire procedure before starting.
45
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5 Replacement Procedures
Caliper Assembly Replacement
Removal
1. Remove front and rear belt guard covers, see "Belt Guard Cover Replacement" on
page34.
2. Cut the four cross member cable-ties (4x) that secure the strain gauge cable to the
cross member. Discard the cable ties.
3. Remove the flywheel, see "Drive Belt, Generator Belt, and Flywheel Replacement" on
page66.
4. Carefully cut and remove the upper and lower push mount cable ties (2x) that secure
the strain gauge cable to the inside right fork frame weldment. Discard the push mount
cable ties.
46
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5. Remove the strain gauge cable from the cable clip located on the upper left fork frame
weldment (next to the left caliper).
47
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5 Replacement Procedures
Caliper Assembly Replacement
6. Attach a cable puller (or fish tape) to the LPCA connector end of the cable.
7. Remove the cable from the inside of the right fork frame weldment. Pull from the top
access hole feeding both the cable and cable puller upward out of the frame. Disconnect the cable puller from the cable.
IMPORTANT: Attach a cable puller (or fish tape) to the LPCA connector end of the
strain gauge cable before removing from the inside of the fork frame weldment. The
cable puller will be used to reinstall the cable through the frame.
1. Remove the two 4 mm hex key bolts (2x) and washers (2x) that secure the caliper
assemble to the frame and remove the caliper. Hold the caliper assembly while removing to prevent it from falling to the floor causing damage. Retain fastener hardware for
installation.
48
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Installation
1. Install the caliper assembly :
a. :Position the caliper assembly onto the frame weldment mounting bolts and
secure using the two previously removed 4 mm hex key bolts (2x) and washers
(2x). For Spinner® Chrono™ Power models, install the caliper assembly so that
the strain gauge is located on the left side of the frame.
b. Make sure that the resistance rod end bushing is seated over the caliper
49
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assembly plate screw and fully tighten the fasteners.
5 Replacement Procedures
Caliper Assembly Replacement
Note:Make sure that the resistance knob rod end bushing is seated over the caliper
plate screw.
2. Reinstall the strain gauge cable through the right fork frame weldment (Spinner® Chrono™ Power models only).
a. Attach the connector end of the strain gauge cable to the cable puller (or fish
tape) at the upper fork frame weldment access hole.
b. Use the cable puller to carefully pull the strain gauge cable downward through the
fork frame weldment entering at the top access hole and exiting though the lower
access hole. When completed remove the cable puller from the cable.
c. Insert the cable into the left frame cable clip next to the left caliper magnetic
sensor.
d. Then route the cable across the frame to the right side fork frame weldment. Use
a new push mount cable tie to secure the cable next to the upper access hole.
Leave a small amount of slack in the cable, do not pull the cable to tight.
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e. Lightly pull the strain gauge and data COMM cables exiting from the lower frame
cable access hole until snug. Then use a new push mount cable-tie to secure
both cables to the frame weldment.
51
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5 Replacement Procedures
Caliper Assembly Replacement
3. Reinstall the flywheel, see "Drive Belt, Generator Belt, and Flywheel Replacement" on
page66.
4. Replace the front and rear belt guard covers, see "Belt Guard Cover Replacement" on
page34
5. Verify the bike operation per "Operation Verification Checklist" on page7 and return to
service.
Replacement Procedure - (Spinner® Climb™ models only)
Review entire procedure before starting.
Removal
1. Remove front and rear belt guard covers, see "Belt Guard Cover Replacement" on
page34.
2. Remove the flywheel, see "Drive Belt, Generator Belt, and Flywheel Replacement" on
page66.
1. Remove the two 4 mm hex key bolts (2x) and washers (2x) that secure the caliper
assemble to the frame and remove the caliper. Hold the caliper assembly while removing to prevent it from falling to the floor causing damage. Retain fastener hardware for
installation.
52
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Installation
1. Install the caliper assembly :
a. :Position the caliper assembly onto the frame weldment mounting bolts and
secure using the two previously removed 4 mm hex key bolts (2x) and washers
(2x). For Spinner® Chrono™ Power models, install the caliper assembly so that
the strain gauge is located on the left side of the frame.
b. Make sure that the resistance rod end bushing is seated over the caliper
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assembly plate screw and fully tighten the fasteners.
5 Replacement Procedures
Caliper Assembly Replacement
Note:Make sure that the resistance knob rod end bushing is seated over the caliper
plate screw.
2. Reinstall the flywheel, see "Drive Belt, Generator Belt, and Flywheel Replacement" on
page66.
3. Replace the front and rear belt guard covers, see "Belt Guard Cover Replacement" on
page34
4. Verify the bike operation per "Operation Verification Checklist" on page7 and return to
service.
See Also
"Replacement Procedures" on page28
54
Page 62
Data COMM Cable Replacement
Applies To: (Spinner® Chrono™ Power models only)
About
This procedure provides instruction to remove and install the Data COMMcable.
DataCOMM cable routing
Starting from the console connection, the data COMM cable enters and travels down the
handle bar post continuing down the inside of the right fork weldment exiting the lower cable
access hole located next to the upper edge of the cross member. The cable continues rearward on the right side of the cross member crossing over to the left side connecting to the
LPCA1data COMM cable port.
1
Lower PCA board
55
Page 63
Specialized Tools
Tool Part Number Qty
5 Replacement Procedures
Data COMM Cable Replacement
Magnetic Gap
PPP000000058248101 1*
Fixture kit*
Cable Puller
General purpose 1
(fish tape)
Note: *Each Magnetic Gap Fixture kit contains two (2x) Magnetic Gap Fixture
tools.
Only one kit is required to complete the brake pad adjustment.
Procedure
Review entire procedure before starting.
Removal
1. Remove front and rear belt guard covers, see "Belt Guard Cover Replacement" on
page34.
2. Cut the four cross member cable-ties (4x) that secure the data COMM, strain gauge,
generator and battery cables to the cross member. Discard the cable ties.
56
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3. Remove the flywheel which also requires removing the LPCA board, the cross member, drive belt, and generator belt, see "Drive Belt, Generator Belt, and Flywheel
Replacement" on page66.
4. Carefully cut and remove the data COMM and strain gauge cables from the lower right
fork weldment push-mount-cable-tie (1x). Remove and discard the
push-mount-cable-tie (the lower push-mount-cable-tie is located on the inside of the
right fork weldment adjacent to the top of the cross member mounting bracket.
5. Remove the four 4 mm (4x) hex key bolts and remove the console backplate cover. Disconnect the data COMM cable from the console and set the console aside, see the
"SPINNER®CHRONO™ CONSOLE" Operator's Guide.
57
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5 Replacement Procedures
Data COMM Cable Replacement
6. Remove the data COMM cable from the handlebar assembly:
a. Remove the two 2.5 mm hex key bolts (2x) and remove the handlebar post cable
cover.
b. Attach a cable puller to the console connector end of the data COMM cable.
c. Pull the handlebar height adjust pop pin and carefully lift the handlebar post from
the top of the frame weldment. While holding the handlebar assembly, gently pull
the data COMM cable and attached cable puller from the inside of the handlebar
post.
d. Disconnect the data COMM cable from the cable puller and set the handlebar
post aside. The cable puller will be used to reinstall the cable through the inside of
58
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the handlebar assembly.
7. Remove the data COMMcable from the inside of the right fork weldment:
a. Attach a cable puller to the LPCA connector end of the data COMM cable.
b. Gently pull the cable and attached cable puller upward through the inside of the
right fork weldment and out of the top of the handlebar post weldment. Disconnect the cable puller from the data COMM cable leaving the cable puller inside
the right fork weldment.
IMPORTANT: Attach a cable puller (or fish tape) to the LPCA connector end of the
data COMM cable before removing from the inside of the fork frame weldment. The
cable puller will be used to reinstall the cable through the frame.
59
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5 Replacement Procedures
Data COMM Cable Replacement
Installation
1. Reinstall the data COMM cable through the inside of the right fork weldment.
a. Attach the LPCA connector end of the data COMM cable to the previously
installed cable puller at the top of the handlebar post weldment.
b. Gently pull the cable puller with attached data COMM cable downward through
the inside of the right fork weldment exiting though the lower right fork weldment
cable access hole.
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c. Disconnect the cable puller from the cable.
2. Secure the data COMM and strain gauge cables to the inside of the lower right fork weldment:
a. Insert a new push-mount-cable-tie into the lower right fork cable tie mounting
hole located next to the lower right fork weldment cable access hole.
b. Adjust the data COMM cable length from the lower push mount cable tie to the
LPCA cable connector to 25.5 inches (65 cm).
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5 Replacement Procedures
Data COMM Cable Replacement
c. Secure both the data COMM and strain gauge cables to inside of the lower right
fork weldment using the lower push-mount-cable-tie.
3. Reinstall the flywheel which also reinstalls the LPCA board, the cross member, drive
belt, and generator belt, see "Drive Belt, Generator Belt, and Flywheel Replacement"
on page66.
4. Use a new cable tie to secure the data COMM and strain gauge cables to the top of the
flywheel axle bracket near the right fork weldment. If any one of the other three cable
ties are missing, replace them.
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5. Reinstall the data COMM cable in the handlebar assembly weldment:
a. Connect the data COMM cable console connector to the cable puller exiting from
the bottom of the handlebar post.
b. Lift the handlebar post next to the top of the frame neck weldment.
c. Install the handlebar post into the frame neck weldment while gently pulling the
cable puller and data COMM cable upward through the handlebar post. Make
sure to not pinch or damage the data COMMcable during installation.
d. Pull the handlebar height adjust pop pin to secure the post and adjust the handle-
bar height.
e. Reinstall the handlebar post cable cover using the two 2.5 mm hex key bolts (2x).
63
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5 Replacement Procedures
Data COMM Cable Replacement
Do not fully tighten the fasteners until after the console has been installed.
6. Position the console on the handlebars and connect the data COMM cable. Adjust the
cable slack and reinstall the console backplate, secure using the four hex key bolts (4x)
(see the "SPINNER®CHRONO™ CONSOLE" Operator's Guide).
7. Make final adjustments to the data COMM cable slack and fully tighten the fasteners
handlebar post cable cover.
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8. Ride the bike and verify that the console powers on and is operating normally.
l Make sure the WATTS, RPM, TIME, DISTANCE, and INTERVAL metrics are
reporting correct information.
l Access the service mode and review the ERROR LOG. Make sure there are no
current logged error code 30s "Communication issue with the LPCA".
9. Replace the front and rear belt guard covers, see "Belt Guard Cover Replacement" on
page34
10. Verify the bike operation per "Operation Verification Checklist" on page7 and return to
service.
See Also
"Replacement Procedures" on page28
65
Page 73
5 Replacement Procedures
Drive Belt, Generat or Belt, and Flywheel Replacement
Drive Belt, Generator Belt, and Flywheel Replacement
Applies To: (Spinner® Chrono™ Power models only)
About
This procedure provides instruction to remove and install the Drive Belt, Generator Belt, and
Flywheel.
Drive belt and generator belt replacement requires removal of the flywheel so this one procedure provides removal and installation procedures for the flywheel, drive belt and generator
belt.
WARNING:Personal injury is possible while removing/installing the flywheel. The
flywheel weighs approximately 26 lbs (12 kgs) and can pinch or fall onto fingers or
other extremities causing personal injury.
Specifications
System Component Specification
Drive Belt Tension 60 +/- 5 lbs (27 */- 2 kgs)
Generator Belt Tension 1/2 in (1.3 cm) up/dwn travel
Axle Nut Torque 29.5 ft-lbs (40 Nm)
Flywheel Weight 26 lbs (12 kgs)
66
Page 74
Procedure
Review entire procedure before starting.
Removal procedure
1. Remove the front and rear belt guard covers, see "Belt Guard Cover Replacement" on
page34.
2. Remove all brake pad resistance by turning the resistance knob fully counterclockwise
(-).
3. Remove the left and right brake pads, see "Brake Pad Replacement" on page39.
4. Disconnect the battery cable Black wire from the Negative (-) battery terminal and then
the Red wire from the Positive (+) battery terminal, see "Battery Replacement" on
page30 . Disconnect the battery Negative (-) terminal wire first:
5.
Disconnect the battery cable from the LPCA1battery connector (J4) , see the fol-
lowing diagram. (If there is a LPCA moisture barrier cable tie installed, cut,
remove, and discard.)
1
Lower PCA board
67
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5 Replacement Procedures
Drive Belt, Generat or Belt, and Flywheel Replacement
6.
Lift the Mylar moisture barrier and disconnect the Generator (J5) cable connector,
then the Data COMM (J3) cable connector and last the Strain Gauge (J1) cable
connector.
7. Remove the two 4 mm hex key LPCA bracket mounting bolts (2x) and washers (2x) and
remove the LPCA bracket. Retain fastener hardware for installation.
8. Loosen, but do not remove, the left and right 17 mm axle nuts enough to allow flywheel
axle movement.
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9. Remove drive belt tension by alternately loosening the left and right tension adjustment
nuts using a 10 mm wrench. Then fully remove the nuts and retain for installation.
10. Cut the back three cable-ties that secure the generator, data COMM, strain gauge (Spinner® Chrono™ Power models only), and battery cables to the cross member.
TIP: It is not absolutely necessary to remove the back three cable ties from the cross
member during flywheel removal and installation. However, care must be taken to not
damage the cables when setting the cross member to the side.
11. Remove the frame cross member four 6 mm hex key bolts (4x) and washers (4x) and
remove the cross member. Remove the generator belt from the generator pulley and
then carefully set the cross member to the side taking care to not damage the cables
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5 Replacement Procedures
Drive Belt, Generat or Belt, and Flywheel Replacement
12. Remove the flywheel (weight: 26 lbs (12 kgs)) by carefully sliding it rearward off the
frame axle brackets.
WARNING:Personal injury is possible while removing/installing the flywheel. The
flywheel weighs approximately 26 lbs (12 kgs) and can pinch or fall onto fingers or
other extremities causing personal injury.
Drive belt removal
13. Remove the drive belt by carefully removing the belt off the flywheel pulley and then sliding the belt over the crank sprocket and pedal.
Generator belt removal
14. Remove the generator belt from the flywheel generator pulley.
Installation procedure.
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1. Place the drive belt over the pedals and rest it on the crank.
2. Position the flywheel in front of the flywheel axle bracket. Then put the generator belt
onto the flywheel generator pulley and the drive belt onto the flywheel drive pulley.
IMPORTANT: The generator and drive belts must be placed onto the flywheel generator and drive belt pulleys before installing the flywheel onto the axle mounting
bracket.
3. Reinstall the flywheel by carefully sliding the flywheel axle into the frame axle brackets.
The belt tension adjustment bolts need to be aligned so that they slide thru the bolt holes
71
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in the tension adjustment bracket.
5 Replacement Procedures
Drive Belt, Generat or Belt, and Flywheel Replacement
TIP: You may find it is easier to stand the bike frame on its front (resting on the front
stabilizer and handlebar) and then installing the flywheel into the axle mounting slots.
The weight of the flywheel will help to slide the flywheel into the mounting slots. Carefully hold the flywheel and return bike to the upright position.
4. Place the drive belt onto the crank sprocket and flywheel pulley.
5. Continue to slide the flywheel forward until the drive belt tension is snug and the belt
teeth seat properly into the crank sprocket and flywheel pulley. Install the left and right
tension adjustment bolts until snug. Adjust the left tension bolt so that the flywheel rim is
centered between the left and right front forks (do not fully tension the belt at this step).
CAUTION: Thread the belt tension nuts onto the tension adjustment bolts to prevent
the flywheel from accidentally falling off the flywheel axle bracket.
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6. Reinstall the frame cross member using a 6 mm hex key to secure the four bolts (4x)
and washers (4x). Fully tighten the four fasteners.
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5 Replacement Procedures
Drive Belt, Generat or Belt, and Flywheel Replacement
7. Place the LPCA bracket into position on the frame cross member bracket and secure
using the two 4 mm hex key bolts (2x) and washers (2x). Fully tighten the fasteners.
8.
Reconnect the Strain Gauge (J1) cable connector, then the Data COMM (J3)
cable connector and last the Generator (J5) ,cable connector.
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9. Fold the Mylar moisture barrier over the front of the LPCA and route the battery cable
over the moisture barrier and reconnect to the LPCA battery cable connector (J4) .
Note:The zip tie that removed and used to hold the Mylar moisture barrier over the
LPCA board is not required to be replaced.
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5 Replacement Procedures
Drive Belt, Generat or Belt, and Flywheel Replacement
10. (Spinner® Chrono™ Power models only)
If the cross member cable ties were removed, replace them with new cable ties to
secure the generator, data COMM, strain gauge , and battery interface cables to the
cross member (4x locations).
11. Place the generator belt onto the generator and flywheel generator pulleys. Place the
belt onto the smaller generator pulley and walk the belt onto the larger flywheel generator pulley
12. Adjust the drive belt tension and tracking to specification, go to "Drive Belt Tension and
Tracking Adjustment" on page16
13. If the axle nuts were not previously tightened to specification, tighten the left and right
axle nuts torque to 29.5 ft-lbs (40 Nm).
14. Adjust the generator belt tension to 1/2 in (1.3 cm) up/dwn travel, see "Generator Belt
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Tension Adjustment" on page24 .
15. Install the left and right brake pads and adjust the brake pad gap to specification, see
"Brake Pad Replacement" on page39.
16. Replace front and rear belt guard covers in reverse order, see "Belt Guard Cover
Replacement" on page34.
17. Verify the bike operation per "Operation Verification Checklist" on page7 and return to
service.
.See Also
"Replacement Procedures" on page28
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5 Replacement Procedures
Generator Assembly Replacement
Generator Assembly Replacement
Applies To: (Spinner® Chrono™ Power models only)
About
This procedure provides instruction to remove and install the Generator Assembly.
Specifications
System Component Specification
Generator Belt Tension 1/2 in (1.3 cm) up/dwn travel
Generator Output Voltage: approx. 9 Vac @ 60 rpm
Current: approx. 0.4 amps @ 60 rpm
Procedure
Review entire procedure before starting.
Removal procedure
1. Remove the front and rear drive belt covers, see "Belt Guard Cover Replacement" on
page34.
2. Remove all brake resistance by turning the resistance knob counter clockwise (-).
3. Disconnect the generator interface cable from the LPCA1- 5 connector. Cut the two
cable ties that hold the cable to the cross member and remove.
1
Lower PCA board
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4. Loosen the generator 4 mm hex key mounting bolt enough so that the generator can be
moved forward. Move the generator forward to loosen tension and remove the belt off
the generator pulley.
5. Remove the 4 mm hex key bolt and washer mounting fasteners and remove the generator.
Installation procedure
1. Install the generator onto the cross member and secure using the 4 mm hex key bolt
and washer fasteners. Loosely tighten the fasteners allowing forward and rearward
movement.
2. Install the generator belt onto the generator and flywheel generator pulleys.
3. Route the generator interface cable across the cross member and connect to the LPCA
- J5 connector. Reinstall the previously removed two cable ties that hold the generator
and other electrical component interface cables to the cross member.
4. Adjust the generator belt tension see "Generator Belt Tension Adjustment" on page24.
CAUTION:Do not over tension the belt which will lead to premature belt wear and
possible damage to the generator pulley.
5. Access the console service test menu and select RPM. Pedal the bike and verify that
the RPMs value is showing and varies with pedal speed.
Note:RPM is computed from pin 3 of the generator cable connector. If this generator
output phase has quite working, the console may not operate and will not display
RPM.
6. Ride and pedal the bike at 60 rpms and verify that the generator is providing the specified charging voltage and current. Access the console service test menu and verify the
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5 Replacement Procedures
Generator Assembly Replacement
generator voltage and current outputs:
l GEN VOLT:approx. 9 Vac @ 60 rpm (voltage will increase as rpms increase)
l GEN AMP:approx. 0.4 amps @ 60 rpm (current will increase as rpms increase)
7. Reinstall the front and rear drive belt covers, see "Belt Guard Cover Replacement" on
page34.
8. Verify the bike operation per "Operation Verification Checklist" on page7 and return to
service.
.See Also
"Replacement Procedures" on page28
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Handlebar Assembly Replacement
About
This procedure provides instruction to remove and install the Handlebar Assembly.
Procedure
Review entire procedure before starting.
Removal Instructions
1. (Spinner® Chrono™ Power models only)
Remove the four 4 mm (4x) hex key bolts and remove the console backplate cover. Disconnect the data COMM cable from the console and set the console aside, see the
"SPINNER®CHRONO™ CONSOLE" Operator's Guide.
2. Remove the rear handlebar post slider end cap by removing the two 2.5 mm hex key
bolts. Retain for installation.
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5 Replacement Procedures
Handlebar Assembly Replacement
3. Slide the handlebar forward enough to allow access to handlebar assembly travel limit
set screw located at the back end of the handlebar post slider. Remove the rear slider
travel limit set screw using a 2.5 mm hex key. Retain fastener hardware for installation.
4. Remove the handlebar assembly by loosening and lifting up on the fwd/back adjustment
knob while sliding the assembly towards the back of the bike.
Installation instructions
1. Loosen the fwd/back adjustment knob and then reinstall the handlebar assembly by sliding the assembly rearwards onto the handlebar post.
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2. Slide the handlebar forward enough to allow access to handlebar assembly travel limit
set screw located at the back end of the handlebar post slider. Reinstall the rear slider
travel limit set screw using a 2.5 mm hex key.
3. Reinstall the rear handlebar post slider end cap and secure using the two mounting 2.5
mm hex key bolts.
4. (Spinner® Chrono™ Power models only)
Position the console on the handlebars and connect the data COMM cable. Adjust the
cable slack and reinstall the console backplate, secure using the four hex key bolts (4x)
(see the "SPINNER®CHRONO™ CONSOLE" Operator's Guide).
5. Verify the handlebar forward/back travel is smooth and that the handlebar slider is
stopped from sliding off the post slider by the travel limit screw. For Spinner® Chrono™
Power models, verify the data COMM cable has enough slack for handlebar minimum
to maximum travel adjustment.
6. Verify the handlebar adjustment knob operation and that it holds the handlebar in position.
See Also
"Handlebar Adjustment Knob Replacement" on the next page
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5 Replacement Procedures
Handlebar Adjustment Knob Replacement
Handlebar Adjustment Knob Replacement
About
This procedure provides instruction to remove and install the Handlebar Adjustment Knob.
Procedure
Review entire procedure before starting.
Removal Instructions
1. Remove the handlebar assemble, see "Handlebar Assembly Replacement" on
page81.
2. Fully tightening the handlebar adjustment knob. This will push the locking nut slightly
above the bottom edge of the adjustment knob bracket mounting hole enough to place a
thin wall deep socket onto the 5/16" locking nut.
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3. Then use a thin wall deep 5/16' socket to hold the locking nut from turning while loosening the adjustment knob to remove. Keep light pressure on the adjustment knob while
loosening.
Installation instructions
1. Reinstall the handlebar adjustment knob in reverse order.
2. Reinstall the handlebar assembly and verify the handlebar adjustment knob operation,
see "Handlebar Assembly Replacement" on page81.
See Also
"Replacement Procedures" on page28
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5 Replacement Procedures
Handlebar Post Removal
Handlebar Post Removal
About
This procedure provides instruction to remove and install the handlebar Post.
For Spinner® Chrono™ Power models, the data COMM cable must be removed from the
inside the handle bar post weldment to remove the handlebar post.
Select procedure:
l Spinner® Chrono™ Power
l Spinner® Climb™
Procedure - (Spinner® Chrono™ Power models only)
Review entire procedure before starting.
Removal
1. Remove the four 4 mm (4x) hex key bolts and remove the console backplate cover. Disconnect the data COMM cable from the console and set the console aside, see the
"SPINNER®CHRONO™ CONSOLE" Operator's Guide.
2. Remove the data COMM cable from the handlebar assembly:
a. Remove the two 2.5 mm hex key bolts (2x) and remove the handlebar post cable
cover.
b. Attach a cable puller to the console connector end of the data COMM cable.
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c. Pull the handlebar height adjust pop pin and carefully lift the handlebar post from
the top of the frame weldment. While holding the handlebar assembly, gently pull
the data COMM cable and attached cable puller from the inside of the handlebar
post.
d. Disconnect the data COMM cable from the cable puller and set the handlebar
post aside. The cable puller will be used to reinstall the cable through the inside of
the handlebar assembly.
Installation
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5 Replacement Procedures
Handlebar Post Removal
1. Reinstall the data COMM cable in the handlebar assembly weldment:
b. Connect the data COMM cable console connector to the cable puller exiting from
the bottom of the handlebar post.
c. Lift the handlebar post near to the top of the frame neck weldment.
d. Install the handlebar post into the frame neck weldment while gently pulling the
cable puller and data COMM cable upward through the handlebar post. Make
sure to not pinch or damage the data COMMcable during installation.
e. Pull the handlebar height adjust pop pin to secure the post and to adjust the
handlebar height.
f. Reinstall the handlebar post cable cover using the two 2.5 mm hex key bolts (2x).
Do not fully tighten the fasteners until after the console has been installed.
2. Position the console on the handlebars and connect the data COMM cable. Adjust the
cable slack and reinstall the console backplate, secure using the four hex key bolts (4x)
(see the "SPINNER®CHRONO™ CONSOLE" Operator's Guide).
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3. Make final adjustments to the data COMM cable slack and fully tighten the fasteners
handlebar post cable cover.
4. Ride the bike and verify that the console powers on and is operating normally.
l Make sure the WATTS, RPM, TIME, DISTANCE, and INTERVAL metrics are
reporting correct information.
5. Verify the bike operation per "Operation Verification Checklist" on page7 and return to
service.
Procedure - (Spinner® Climb™ models only)
Review entire procedure before starting.
Removal
1. Pull the handlebar height adjust pop pin and carefully lift the handlebar post from the top
of the frame weldment, see the Operator's Guide for more information.
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5 Replacement Procedures
Handlebar Post Removal
Installation
1. Reinstall the handlebar post into the frame neck weldment
2. Pull the handlebar height adjust pop pin to secure the post and to adjust the handlebar
height, see the Operator's Guide for more information.
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3. Verify the bike operation per "Operation Verification Checklist" on page7 and return to
service.
See Also
"Replacement Procedures" on page28
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5 Replacement Procedures
LPCA board Replacement
LPCA board Replacement
Applies To: (Spinner® Chrono™ Power models only)
About
This procedure provides instruction to remove and install the LPCA1(Lower PCA) board.
LPCA Interface Cable Connections
1
Lower PCA board
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ID Interface Cables
Generator (J5)
Strain Gauge(J1)
Data COMM(J3)
Battery (J4)
Optional AC/DC Power Adapter(J1)
LPCA Status LEDs
ID LED Description
Logic microprocessor ON (flashes green)
3.3 vdc supply (red)
5 vdc supply (red)
9 vdc supply (red)
(while pedaling or AC/DC adapter plugging in)
Battery Charging (red)
l ON ≥ 55 rpm (charging battery)
l OFF ≥ 55 rpm and battery fully charged
l OFF < 55 rpm
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