True Fitness 500U manual

True Fitness Service Manual Exercise Bicycles 500R, 500U 600R, 600U 750R, 750U True fitness technology, Inc. makes no representations or warranties regarding the contents of this manual. We reserve the righ t to revise this document at any time or to make changes to the product described within it without notice or obligation to notify any person o[...]

Recommended Tool List Technicians will need at minimum the tools lis ted below to work on the True Fitness equipment covered by these procedures. Electrical Tools A multi meter capab le of testing voltage, am perage, resistance and continuity. Outlet tester with a grounding indicator. Wire stripper, cutter and crimper. Flashlight Mechanical Tools S[...]

True Fitness Bicycle Service Manual START  Symptom guide  Wiring Diagrams  Parts Manual  Removal and Replacement Procedures Page 1[...]

Test Mode *750 ONLY Procedure D I A G N O S T I C S To Enter Diagnostic Mode Console / Disp lay Output RPM Console Key Input Contact Heart Rate DA (Resistance) Exit Diagnostics • Press and hold the “Start” key as you begin pedali ng . • Continue pe daling t hroughout the test. ------- • Press “Enter” key – initiates the second LED f[...]

SYMPTOM GUIDE 500U, 500R  ECB Malfunction . . . . . . . . . . . . . . . . . . . . . . . Page 4  Irregular or No Display . . . . . . . . . . . . . . . . . . Page 5  No RPM Reading . . . . . . . . . . . . . . . . . . . . . . . . Page 6  No Polar Heart Rate . . . . . . . . . . . . . . . . . . . . . . Page 7 600U, 600R  Irregular or No D[...]

Note: If motor has been bound and then freed the moto r may h ave be en weak ened. If component s no w m ove freel y but t he m otor is laborin g – re p lace the motor. Symptom Probable Cause Corrective Action ECB MALFUNCTION 500R, 500U Control Panel Defective Cables Defective ECB Control Board Optical Sensor DC Motor ECB Limit Switch Loud Contin[...]

Symptom Probable Cause Correc tive Action Recommended Tools IRREGULAR OR NO DISPLAY 500R, 500U DC Adaptor Adapter Plug or Jack Control Panel Cables • Connect DC Adapter to 110 VAC power supply. • Look for p rinted out put on a dapters label. If greater than 9 VDC com puter board m ay be damaged. • Test for 9VDC o utput. If not 9 VDC then repl[...]

Symptom Probable Cause Correc tive Action Recommended Tools NO RPM READING 500R, 500U Control Panel/ RP M Sensor Defective Cables Defective RPM Sensor Set • Disconnect 5PA from 5PB. Set meter to check continui ty between 2 and 5 of 5PB. (See Page 18 ) • Turn pedals sl owly, c heck cont inuity between 2 and 5 of 5PB. • Does contin uity change [...]

Symptom Probable Cause Correc tive Action Recommended Tools NO POLAR HEART RATE 500R, 500U Control Panel Heart Rate Chest Strap External Interference • Attach a known g ood heart rate transmitter around chest or use polar simulator. • If control panel doe s not di splay a hea rt rate – replace Control Panel. -------- • If heart rate registe[...]

Symptom Probable Cause Correc tive Action Recommended Tools IRREGULAR OR NO DISPLAY 600R, 600U Control Panel Control Board Cables AC Voltage Outpu t Generator Output Cable • Probe leads bet ween pin 1 and 2 of 5PB. ( Page 19-20 ) • Pedal unit up to at least 30 RPM. • Is voltage 5 VDC ? • If not 5 VDC – replace Control Panel. -------- • [...]

Symptom Probable Cause Correc tive Action Recommended Tools NO RPM READING 600R, 600U Control Panel Defective Cables Defective RPM Sensor Set • Disconnect 5PA from 5PB. ( Page 19- 20 ). • Set meter to check continuity between pins 2 and 5 of 5PB • Turn crank and align the magn e t with the sensor • Is there continuity? If Yes – Replace Co[...]

Symptom Probable Cause Correc tive Action Recommended Tools NO CONTACT HEART RATE 600R, 600U Control Panel Defective Cables Defective Handles • Disconnect 7P 6A and 7P6B from control panel . 60 0U ( Page 19 ) 600R ( Page 20 ). Check con tinuity between 7P6B and ha ndle m ounted hea rt rate sensor plates of the fol l owi ng: HRRR and pin 6 of 7P6B[...]

Symptom Probable Cause Correc tive Action Recommended Tools HANDLEBAR BUTTONS DO NOT FUNCTION 600R “Cruise Control” “Start” Button “Shift” Button “_“ Button “Select” Button “+” Button • Remove cons ole-m ounting screws . Locate 10P7B ( Page 20 ). • Check for continuity between pin 7 and pin 1 at 10P 7B. Press Cr uise con[...]

Symptom Probable Cause Correc tive Action Recommended Tools NO RESISTANCE 750U, 750R Console Set Defective Cables Power Resistance Brake Harness/ Lower Board • Remove console bolts t o access 7-pin connector. Do not disconnect cons ole set. • Enter DA (resistance) test mode. (Page 2). • Press + key to force .7 VDC out of panel. • Set meter [...]

Symptom Probable Cause Correc tive Action Recommended Tools HEAVY RESISTANCE 750U, 750R Console Set Defective Cables Lower control Board/Brake • Remove the co nsole set. • Disconnect the 7 pin connector from the back of the console set. • Pedal. • Resistance normal? Replace console set. -------- • Remove pedal and if 3 piece crank remove [...]

Symptom Probable Cause Correc tive Action Recommended Tools No Display 750U, 750R Console Set Brake Defective Cable Console Cable/ Lower Control Board • Remove console set bolts. Verify goo d connection at the back of the console set. Set meter for DC volts • Pedal. • Measure betwee n #1 and #4 w i res (P age 21) for 5.5 – 7. 5 VDC . • Is[...]

Symptom Probable Cause Correc tive Action Recommended Tools NO CONTACT HEART RATE 750U, 750R Dirty Sensors Console Set/ Wiring Wire Connections • Verify hand pulse sensors are clean. -------- • Set meter for continuity. • Remove Cons ole set. • Check for cont inuity i n both s ets of hand pulse sens ors between t he console set and hand pul[...]

Symptom Probable Cause Correc tive Action Recommended Tools NO POLAR HEART RATE 750U, 750R Control Panel Defective Cables Defective ECB Control Board • Attach known g ood heart rate transmitter around chest or use Polar simulator. • Do not touc h the hand pulse sens ors. • Start pedalin g • Check display for heart rate. -------- • Does co[...]

WIRING DIAGRAMS  TR / TU 500 Page 18  600 U Page 19  600 R Page 20  TR/TU 750 Page 21 Page 17[...]

Page 18 TR/ TU 500 WIRING DIAGRAM[...]

Page 19 TU 600 WIRING DIAGRAM[...]

TR 600 WIRING DIAGRAM Page 20[...]

Page 21 TR/ TU 750 WIRING DIAGRAM[...]

Page 22[...]

True Upright Bike 500 True Recumbent Bike 500  TU 500 Exploded Diagram Pg 22  TU 500 Parts List Pg 23  TR 500 Exploded Diagram Pg 25  TR 500 Parts List Pg 26 Page 23[...]

Page 24[...]

TU 500 EXERCISE BIKE REF. # PART # DESCRIPTION QTY 2 7T010800 FRONT STABILIZER WITH BOLTS 1 SET 3 7T000200 TRANSPORTATION WHEEL HIT 1 SET 4 7T000300 FTONT STABILIZER END CAP 2 PCS 5 7T000400 CRANK PULLEY WITH CAPS AND BEARINGS 1 SET 6 7T000600 BOLT BELT TENSION 1 PC 7 7T010900 BRAKE ASSY 1 SET 8 7T001700 ALUMINUM IDLER ASSY 1 SET 9 7T001800 ECB DC [...]

25 7T002600 REAR STABILIZER WITH BOLTS 1 SET 26 7T002700 ADJUSTING STAND KIT 1 SET 27 7T002800 REAR STABILIZER END CAP 2 PCS 28 7T012700 POLY V BELT 1 PC 29 7T005800 RPM SENSOR WITH WIRE AND NUT 1 SET 30 7T004700 CABLE ASSY 5 PIN LOWER SPEED SENSE 1 PC 31 7T004800 CABLE ASSY 6 PIN LOWER SECTION 1 PC 7T013000 MODEL DECAL SILVER 1 SET 7T012901 DECAL [...]

Page 27 TR 500 Exercise Bike[...]

TR 500 REF # PART# DESCRIPTION QTY. 02 7T000100 Front Stabilizer w/Bolts 1 SET 03 7T000200 Transportation Wheel Kit 1 SET 04 7T000300 Front Stabilizer End Cap 2 PCS 05 7T000400 Crank Pulley w/E Caps & Bearings 1 SET 06 7T005800 RPM Sensor w/Wire & Nut 1 SET 07 7T000600 Bolt - Belt Tension 1 PC 08 7T000700 Cable Assembly - 6 Pin Lower 1 PC 0[...]

26 7T002500 Transportation Handle Set w/Screws 1 SET 27 7T002600 Rear Stabilizer w/Bolts 1 SET 28 7T002700 Adjusting Stand Kit 1 SET 29 7T002800 Rear Stabilizer End Cap 2 PCS 30 7T002900 Roller Set (A) Rt Ft & RR 2 SET 31 7T003000 Roller Set (B) Center 2 SET 32 7T003100 Seat Bottom w/Bolts 1 SET 33 7T003200 Fore and Aft Adjusting Lever w/Bolts [...]

Page 30[...]

True Upright Bike 600 True Recumbent Bike 600  TU 600 Exploded Diagram Pg- 29  TU 600 Parts List Pg- 30  TR 600 Exploded Diagram Pg- 32  TR 600 Parts List Pg- 33 Page 31[...]

TU 600 PARTS DIAGRAM Page 32[...]

TU 600 BIKE REF # PART NUMBER DESCRIPTION QTY. 02 7T010800 FRONT STABILIZER WITH BOLTS 1 03 7T000200 TRANSPORTATION WHEEL KIT 1 04 7T000300 FRONT STABILIZER END CAP 2 05 7T011400 DRIVE BELT KIT 1 7T004900 DO NOT ORDER 06 7T005000 POLY V PULLEY SET KIT SECONDARY 1 7-1 7T012000 LEFT COMPLETE W/ MODEL SHROUD DECALS 1 7-2 7T001302 SIDE COVER SCREW 1 7-[...]

7T011800 MODEL DECAL LEFT WHITE 1 7T011900 MODEL DECAL RIGHT WHITE 1 7T012901 DECAL A 1 7T012902 DECAL B 1 7T012903 DECAL C 1 7T012904 DECAL D 1 7TU60100 PARTS KIT 7TU60200 FRONT STABILIZER SCREW KIT 1 7TU60300 REAR ST ABILIZER SCREW KIT 1 Page 34[...]

TR 600 PARTS DIAGRAM Page 35[...]

TR600 BIKE REF. # PART # DESCRIPTION QTY USED 24-1 7T011600 600R L SHROUD & DECALS 1 24-2 7T001202 SIDE CVR SCREW 6 24-3 7T001303 SIDE CVR SCREW 3 24-4 7T001302 SIDE CVR SCREW 1 24-5 7T011700 600R R SHROUD & DECALS 1 24-6 7T001306 HEX NUT SIDE CVR SCREW 3 24-7 7T011800 MODEL DECAL 66R L WHITE 1 24-8 7T001308 SHROUD DECAL A BLUE 1 24-9 7T001[...]

20 7T006200 CONSOLE MAST W/BOLTS 1 20-1-1 7T006201 CABLE ASSY 12 PIN UPPER 1 20-1-2 7T006202 CABLE ASSY 52 PIN UPPER 1 21 7T006300 COMPUTER SET 660RIU LT FRT 1 22 7T003700 ROLLER SET SEAT LT RR 2 23 7T006400 IDLER ARM SHAFT KIT 1 40-1 7T001201 REAR SHROUD RT 1 24-2 7T001202 ROUND CROSS SCREW 4 40-3 7T001204 TAPPING SCREW 1 40-4 7T001203 REAR SHROUD[...]

Page 38[...]

True Upright Bike 750  TU 750 Exploded Diagram Pg- 37 (Prior to serial # 02- UP0161C (3) Piece Crank)  TU 750 Parts List Pg- 38 (Prior to serial # 02- UP0161C (3) Piece Crank)  TU 750 Exploded Diagram Pg- 40 (After serial # 02-UP0161C (1) Piece Crank)  TU 750 Parts List Pg- 41 (After serial # 02-UP0161C (1) Piece Crank) Page 39[...]

Page 40 TU 750 PARTS DIAGRAM ( 3 PIECE CRANK )[...]

TU 750 3 PIECE CRANK TU750: 02- UP0161C REF # PART# DESCRIPTION QTY. AB1 7TSP0101006 FRAME AC1 7TSZCB2 4CSM UPRIGHT HANDLE BAR 1 AD1 7TSW0150005 SEAT POST 1 AJ1 7TSZCB24FST FRONT GR OUNDING BAR ASSEMBLY 1 AN1 7TSM0209004 CONSOLE SET 1 AS1 7TMD0208006 BRAKE ASSEMBLY 1 B22 7TME0701001 C CLAMP SIDE COVE R 14 B24 7TME0107014 SCRE W SIDE COVER 16 B31 7T[...]

Q06R 7TMB0609028 END CAP FOR FRONT GROUNDING BAR RT. 1 Q06L 7TMB0609026 END CAP FOR FRONT GROUNDING BAR LT. 1 Q07 7TMB0609035 END CAP FO R REAR GROUNDI NG B AR 2 Q11 7TSZCB24SCV-L SIDE COVER ASSY. LEFT 3 PC. CRANK 1 Q12 7TSZCB24SCV-R SIDE COVER ASSY. RIGHT 3 PC. CRANK 1 R03 7TSZRB40PAX FLYWHEEL SHAFT ASSEMBLY 1 R06 7TMD0602018 POLY V BELT 520-J8 1 [...]

Page 43 TU 750 PARTS DIAGRAM (1 PIECE CRANK)[...]

TU 750 1PC CRANK REF.# PART# DESCRIPTION QTY. AB1 7TSP001006 FRAME AC1 7TSZCB24CSM HANDLE BAR W/HR 1 AD1 7TSW0150005 SEAT POST 1 AJ1 7TSZCB24FST FRON T GROUND BAR ASSEMBLY 1 AN1 7TSM0209004 CONSOLE ASSEMBLY 1 AS1 7TMD0208006 BRAKE ASSEMBLY 1 B22 7TME0701001 C CLAMP SIDE CVR 14 B24 7TME0107014 SCREW SIDE CVR 16 B31 7TMJ1208001 SIDE CVR BRACKET 1 C07[...]

FRAME Q01 7TMN1101006 SEAT ADJ KNOB 1 BLUE J14 7TMB030402A FOOT PAD FRONT 2 J15 7TMZE0112119 BOLT FRONT FT PAD 2 Q02 7TMB0604018 SEAT POST SLEEVE 1 Q06R 7TMB0609028 END CAP FOR FRONT 1 GRNDG BAR FOR RIGHT Q06L 7TMB0609026 END CAP FOR FRONT 1 GRNDG BAR FOR LEFT Q07 7TMB0609035 END CAP FOR REAR 2 GROUNDING BAR Q11 7TSZCB24SCV-L SIDE CVR ASSY LEFT 1 1[...]

V03 7TMG0102036 MODEL DECAL WHITE 2 7TMG0214009C SIDE CVR DECAL SILVR 7TMG0214016C SIDE CVR DECAL SILVR 7TMH0205023 OWNERS MANUAL 1 7TME0601017 ASSEMBLY KIT 1 Q08 7TMB0237002 UPPER FRAME CVR 1 Page 46[...]

True Recumbent Bike 750  TR 750 Exploded Diagram Pg- 46 (Prior to 08/05/2001 (3) Piece Crank)  TR 750 Parts List Pg- 47 (Prior to 08/05/2001 (3) Piece Crank)  TR 750 Exploded Diagram Pg- 49 (After 08/05/2001 & Prior to Serial # 02-RE0283C (3) Piece Crank)  TR 750 Parts List Pg- 50 (After 08/05/2001 & Prior to Serial # 02-RE0283C[...]

Page 48[...]

TR750 PRIOR 8-5-01 (3 PIECE CRANK) REF. # PART # DESCRIPTION QTY. AD1 7TSP0203003 SEAT SLIDE WELDMENT 1 SET AD2 7TSZRB40SLP SEAT SLIDE PLATE LOCK 1 SET AG1 7TSP0206006 SEAT HANDLE BAR WELDMENT 1 SET AG2 7TSP0212003 CONCOLE HANDLE BAR WELDMENT 1 SET AJ1 7TSZRB40FST FRONT GROUNDING BAR ASSY. 1 SET AN1 7TSM0209004 CONSOLE ASSEMBLY 1 SET AS1 7TMD020800[...]

J07 7TSW222100 5 REAR GROUNDI NG BAR 1 PC. J08 7TMB0304006 FOOT PAD REAR ADJUSTABLE 4 PCS. J09 7TME0112109 BOLT GROUNDING BAR 4 PCS. J10 7TME0112024 BOLT TRANSPORT WHEEL 2 PCS. J11 7TME0502108 WASHER TRANSPORT WHEEL 2 PCS. J12 7TME0902007 EXTERNAL C RING-TRANSPORT WHEEL 2 PCS. 7TMC0501027 CABLE DISPLAY CONTROL BOARD 1 PC. 7TMC0520002 CABLE SEAT RAI[...]

TR 750 PARTS DIAGRAM After 08/05/01 and Prior to Serial # 02-RE0283C Page 51[...]

TR 750 AFTER 8/5/01 PRIOR TO 02-RE0283C NEW SEAT ASSY - 3 PIECE CRANK REF. # PART # DESCRIPTION QTY 114 AD5 7TSZRB40SAS SEAT SLIDE SET 1 SET 117 AG2 7TSP0212003 CONSOLE HANDLE BAR 1 SET 001 AN1 7TSM0209004 CONSOLE ASSY. 1 SET 003 AS1 7TMD0208006 BRAKE ASSY. 1 SET 039 B26 7TME0701001 C CLAMP - SIDE COVER 16 PCS. 043 B27 7TME0107014 SCREW SIDE COVER [...]

023 Q07 7TMB0609035 END CAP REAR GROUNDING BAR 2 PCS 105 Q08 7TME0104055 SCREW DISPLAY 4 PCS. 081 Q11 7TSZRB40SCV-L SIDE COVER LEFT 1 SET 082 Q12 7TSZRB40SCV-R SIDE COVER RIGHT 1 SET 005 R03 7TSZRB40PAX FLYWHEEL SHAFT ASSY 1 SET 018 R06 7TMD0602018 SECONDARY POLY V BELT 1 PC 010 T02 7TMD0405001 LEFT CRANK 1 PC 011 T03 7TMD0406001 RIGHT CRANK 1 PC 0[...]

Page 54 TR 750 PARTS DIAGRAM After Serial # 02-RE0283C ( 1 Piece Crank )[...]

TR 750 AFTER SERIAL # 02-RE0283C NEW SEAT ASSEMBLY - 1 PIECE CRANK REF. # PART # DESCRIPTION QTY AD5 7TSZRB40SAS SEAT SLIDE SET 1 SET 7TSZRB40SER-1 SEAT ROLLER ASSY. 4 PCS. AG1 7TSP0206006 SEAT HANDLE BAR 1 SET AG2 7TSP0212003 CONSOLE HANDLE BAR 1 SET FRONT GROUNDIN G BAR ASSY. 1 SET AN1 7TSM0209004 CONSOLE ASSY. 1 SET AS1 7TMD0208006 BRAKE ASSY. 1[...]

P17 7TMJ1393002 RESISTOR COVER 1 PC 7TME0102027 SCREW RESISTOR 4 PCS. 7TME0204003 NYLON NUT RESISTOR 4 PCS. 7TME0502082 WASHER RESISTOR 4 PCS. 7TMB0601005 WATER BOTTLE CAGE 1 PC Q06R 7TMB0609028 END CAP FRONT GROUNDING BAR RIGHT 1 PC Q06L 7TMB0609026 END CAP FRONT GROUNDING BAR LE FT 1 PC Q07 7TMB0609035 END CAP REAR GROUNDING BAR 2 PCS Q08 7TME010[...]

True Fitness Removal & Replacement  500R  500U  600U  600R Page 57[...]

TABLE OF CONTENTS Support Services 800-883- 878 3 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 Removal and Replacement Remove Access Covers – A ll Bikes Page 59 500R Remove Small Poly V Pulley Page 61 Remove Belt & Tensioner A s s e m b l y P a g e 6 3 Remove Crank Hub Assembly Page 65 500U Remove Small Poly V Pulley Page 68 Remo[...]

Removal & Replacement Remove Access Covers ~ 50 0R, 500U, 600R & 600U Step 1. Use pedal wrench to remove both pedals from pedal cranks. Step 2. Remove front cover screws and nuts. Copyright 2001 True Fitness Technology, Inc. Page 59 Tools Required: Pedal Wrench Phillips Screwdriver Note: Left pedal loosens clockwise. Right pedal loosens cou[...]

Removal & Replacement Remove Access Covers ~ 500R , 500U, 600R & 600U ( continued) Step 3. Disconnect electrical power adapter. Step 4. Rotate crank handle forward to 2 o’clock Position to allow removal of cover. Copyright 2001 True Fitness Technology, Inc. Page 60 Note: Electrical connections are on 500 series bikes onl y . Step 1. Remov[...]

Removal & Replacement 500R Remove Small Poly-V Pulley Step 1. Use hammer handle to prevent Rotation of large wheel when Removing pulley. Step 2. Use 4 mm wrench to loosen set screw in pulley. Copyright 2001 True Fitness Technology, Inc. Page 61 Note: Leave belt in place to help lock pulley Step 1. Prevent Rotation of Fly Wheel Step 2. Loosen Se[...]

Removal & Replacement 500R Remove Small Poly-V Pulley (continued) Step 3. Use 17 mm box wrench to loosen Nut from belt tension screw. Step 4. Loosen rear hub bracket screws. Step 5. Remove belt from belt tensioner Assembly and wheels. Copyright 2001 True Fitness Technology, Inc. Page 62 Step 3. Loosen Nut Step 4. Loosen Hub Bracket Screws Step [...]

Removal & Replacement 500R Remove Belt & Te nsioner Assembly Step 1. Remove small poly-V pulley. Step 2. Remove keyway using flat blade Screwdriver as required. Copyright 2001 True Fitness Technology, Inc. Page 63 Tools Required: 17 mm Box Wrench 5mm Hex Wrench Sna p Rin g Pliers Step 1. Remove Small Poly-V Pulley Step 2. Remove Keyway[...]

Removal & Replacement 500R Remove Belt & Te nsioner Assembly (continued) Step 3. Remove snap ring from belt Tensioner. Step 4. Remove belt tensioner. Copyright 2001 True Fitness Technology, Inc. Page 64 Step 2. Remove Snap Ring Step 3. Remove Belt Tensioner[...]

Removal & Replacement 500R Remove Front Hub Assembly Step 1. Use crescent wrench to remove Large nut on crank. Step 2. Remove keyed washer from under nut. Step 3. Use crescent wrench to remove hex nut bearing. Copyright 2001 True Fitness Technology, Inc. Page 65 Tools Required: Large Crescent Wrench Hammer & Punch Step 1. Remove Crank Nut S[...]

Removal & Replacement 500R Remove Front Hub Assembly (continued) Step 4. Use crescent wrench to remove Large nut on crank. Step 5. Use crescent wrench to remove hex nut bearing. Copyright 2001 True Fitness Technology, Inc. Page 66 Step 4. Pull Hex Nut Bearing Free Step 5. Remove Large Pulley Assembly Note: Slide brake towards seat to allow pull[...]

Removal & Replacement 500R Remove Front Hub Assembly (continued) Step 6. Twist assembly thru frame hub. Pull assembly until clear of f rame. Step 7. Use hammer & punch to loosen spanner nut on bearing. Step 8. Remove bearing and washer by Slipping off crank. Copyright 2001 True Fitness Technology, Inc. Page 67 Step 6. Twist Unit Thru Hub Fr[...]

Removal & Replacement 500U Remove Small Poly-V Pulley Step 1. Use hammer handle to prevent Rotation of large wheel when Removing pulley. Step 2. Use 4 mm wrench to loosen set screw in pulley. Copyright 2001 True Fitness Technology, Inc. Page 68 Note: Leave belt in place to help lock pulley Step 1. Prevent Rotation of Fly Wheel Step 2. Loosen Se[...]

Removal & Replacement 500U Remove Belt & Te nsioner Assembly Step 1. Remove small poly-v pulley. Step 2. Remove keyway, using flat blade Screwdriver as required. Copyright 2001 True Fitness Technology, Inc Page 69 Step 1. Remove Small Poly-v Wheel Tools Required: 17 mm Box Wrench 5 mm-Hex Wrench Snap Ring Pliers Step 2. Remove keyway[...]

Removal & Replacement 500U Remove Belt & Te nsioner Assembly (continued) Step 3. Use 17 mm box wrench to loosen Nut from belt tensioning screw. Step 4. Use 5 mm hex wrench to loosen Rear hub bracket screws. Copyright 2001 True Fitness Technology, Inc Page 70 Step 3. Prevent Wheel Rotation Step 4. Loosen setscrew[...]

Removal & Replacement 500U Remove Belt & Te nsioner Assembly (continued) Step 5. Remove belt from belt tensioner Assembly and wheels. Step 6. Remove snap ring from belt tensioner. Step 7. Remove belt tensioner. Copyright 2001 True Fitness Technology, Inc Page 71 Step 5. Remove Belt Step 6. Remove Snap Ring. Step 7. Remove belt tensioner[...]

Removal & Replacement 500U Remove Crank Hub Assembly Step 1. Use crescent wrench to remove Large nut on crank. Step 2. Remove keyed washer from under nut. Step 3. Use crescent wrench to remove hex nut bearing. Use rubber mallet to knock out the shaft pulley assembly. Copyright 2001 True Fitness Technology, Inc. Page 72 Step 1. Remove Crank Nut.[...]

Removal & Replacement 500U Remove Crank Hub Assembly (continued) Step 4. Pull hex nut bearing clear of frame Hub. Step 5. Pull large pulley until b earing clears Frame. Step 6. Twist assembly thru frame hub. Pull assembly until clear of f rame. Copyright 2001 True Fitness Technology, Inc. Page 73 Step 4. Pull Hex Nut Bearing Free. Note: A flat [...]

Removal & Replacement 500U Remove Crank Hub Assembly (continued) Step 7. Use hammer and punch to loosen spanner nut on bearing. Step 8. Remove bearing & washer by slipping off crank. Copyright 2001 True Fitness Technology, Inc Page 74 Step 7. Drive Spanner Nut Off to Remove Bearing Step 8. Remove Bearing & Washer Note: The spanner nut h[...]

Removal & Replacement 600U Remove Right Belt Poly-V Wheel Step 1. Use pliers or needle nose pliers to remove the belt tensioning spring Step 2. Remove the belt. Copyright 2001 True Fitness Technology, Inc. Page 75 Tools Required: Pliers Snap Ring Pliers Step 1. Belt Tensioning Spring Step 2. Remove Belt[...]

Removal & Replacement 600U Remove Right Belt Poly-V Wheel (continued). Step 3. Use snap ring pliers to pry snap ring from center of small poly-V pulley. Step 4. Remove the snap ring and washers. Step 5. Remove the small poly-V pulley. Copyright 2001 True Fitness Technology, Inc. Page 76 Step 3. Prying with snap ring pliers Step 4. Remove the sn[...]

Removal & Replacement 600U Remove Right Side Tensioner Assembly Step 1. Remove snap ring. Step 2. Slide tensioner assembly off pivot shaft. Copyright 2001 True Fitness Technology, Inc. Page 77 Tools Required: Snap Ring Pliers Step 1. Remove Snap Ring Step 2. Slide Tensioner Assembly Note: Frame is slotted to allow brake bracket to slide when b [...]

Removal & Replacement 600U Remove Belt & Te nsioner Assembly Step 1. Use 6 mm hex wrench to remove brake bracket locking screw. Step 2. Use 13 mm open-end wrench to loosen the 4 bolts holding the brake bracket to the frame. Copyright 2001 True Fitness Technology, Inc. Page 78 Tools Required: 6 mm Hex Wrench 13 mm Open-End Wrench Hamme r Han[...]

Removal & Replacement 600U Remove Belt & Te nsioner Assembly (continued) Step 3. Use hammer handle to pry the brake and bracket assembly toward the back of the bike to loosen the belt. Step 4. Remove brake belt from larger poly-V wheel. Copyright 2001 True Fitness Technology, Inc. Page 79 Step 3. Pry on Brake to Loosen Belt. Step 4. Remove [...]

Removal & Replacement 600U & 600R Remove Belt & Te nsioner Assembly (continued) Step 5. Disconnect wiring harness from brake. Step 6. Remove the loosened bottom screws. Step 7. Remove brake and belt assembly. Copyright 2001 True Fitness Technology, Inc. Page 80 Step 5. Disconnect Wiring Harness. Step 7. Remove Brake & Belt Assembly [...]

Removal & Replacement 600U Remove Left Side Belt From Assembly Step 1. Remove snap ring. Step 2. Carefully pry bearing out of housing. Step 3. Remove inner snap ring. Copyright 2001 True Fitness Technology, Inc. Page 81 Step 1. Remove Snap Ring. Step 7. Remove Inner Snap Ring Step 2. Pry Bearing Out of Housing Tools Required: Internal & Ext[...]

Removal & Replacement 600U Remove Left Side Be lt From Assembly (continued) Step 4. Use 4 mm Hex Wrench to rem ove Screws and washers holding Brake to bracket. Step 5. Remove brake bracket until b elt Can be removed. Copyright 2001 True Fitness Technology, Inc. Page 82 Step 4. Remove Screws & Washers. Step 5. Remove Bracket to Check Belt[...]

Removal & Replacement 600U Remove Left Side Poly-V Wheel Step 1. Remove snap ring from shaft on Right side. Step 2. Slide shaft through bearing in Frame to remove pulley and shaft assembly. Copyright 2001 True Fitness Technology, Inc. Page 83 Tools Required: External Snap Ring Pliers Step 1. Remove Snap Ring on Right Side Step 2. Slide Shaft Th[...]

Removal & Replacement 600U Remove Crank Hub Assembly Step 1. Use crescent wrench to remove Large nut on crank. Step 2. Remove keyed washer from under nut. Step 3. Use crescent wrench to remove hex nut bearing. Use rubber mallet to knock out the shaft pulley assembly. Copyright 2001 True Fitness Technology, Inc. Page 84 Step 1. Remove Crank Nut.[...]

Removal & Replacement 600U Remove Crank Hub Assembly (continued) Step 4. Pull hex nut bearing clear of frame Hub. Step 5. Pull large pulley until b earing clears Frame. Step 6. Twist assembly thru frame hub. Pull assembly until clear of f rame. Copyright 2001 True Fitness Technology, Inc. Page 85 Step 4. Pull Hex Nut Bearing Free. Note: A flat [...]

Removal & Replacement 600U Remove Crank Hub Assembly (continued) Step 7. Use hammer and punch to loosen spanner nut on bearing. Step 8. Remove bearing & washer by slipping off crank. Step 9. Pull crank thru pulley to remove. Copyright 2001 True Fitness Technology, Inc Page 86 Step 7. Drive Spanner Nut Off to Remove Bearing Step 8. Remove Be[...]

Removal & Replacement 600R Remove Left Belt Poly-V Pulley Step 1. Use pliers, or needle nose pliers, to remove the belt tensioning spring. Step 2. Remove the belt. Copyright 2001 True Fitness Technology, Inc. Page 87 Tools Required: Pliers Snap Ring Pliers Step 1. Remove Belt Tensioning Spring Step 2. Remove Belt[...]

Removal & Replacement 600 Remove Poly-V Wheel Pulley (continued) Step 3. Use snap ring pliers to snap Ring from center of small poly-V pulley. Step 4. Remove the small poly-V pulley. Copyright 2001 True Fitness Technology, Inc. Page 88 Step 1. Prying with Snap Ring Pliers. Step 2. Remove Small Poly-V Pulley[...]

Removal & Replacement 600R Remove Left Side Tensioner Assembly Step 1. Remove snap ring. Step 2. Slide tensioner assembly off pivot shaft. Copyright 2001 True Fitness Technology, Inc. Page 89 Tools Required: Snap Ring Pliers Step 1. Remove Snap Ring Step 2. Slide Tensioner Assembly Note: Frame is slotted to allow brake bracket to slide when b o[...]

Removal & Replacement 600R Remove Belt & Te nsioner Assembly Step 1. Use 6 mm hex wrench to remove brake bracket locking screw. Step 2. Use 13 mm open-end wrench to loosen the 4 bolts holding the brake bracket to the frame. Copyright 2001 True Fitness Technology, Inc. Page 90 Tools Required: 6 mm-Hex Wrench 13 mm Open-End Wrench Hammer Hand[...]

Removal & Replacement 600R Remove Belt & Te nsioner Assembly (continued) Step 3. Use hammer handle to pry the brake and bracket assembly toward the back of the bike to loosen the belt. Step 4. Remove brake belt from larger poly-V wheel. Copyright 2001 True Fitness Technology, Inc. Page 91 Step 3. Pry on Brake to Loosen Belt. Step 4. Remove [...]

Removal & Replacement 600U & 600R Remove Belt & Te nsioner Assembly (continued) Step 5. Disconnect wiring harness from brake. Step 6. Remove the loosened bottom screws. Step 7. Remove brake and belt assembly. Copyright 2001 True Fitness Technology, Inc. Page 92 Step 5. Disconnect Wiring Harness. Step 7. Remove Brake & Belt Assembly [...]

Removal & Replacement 600R Remove Right Side Belt From Assembly Step 1. Remove snap ring. Step 2. Carefully pry bearing out of housing. Step 3. Remove inner snap ring. Copyright 2001 True Fitness Technology, Inc. Page 93 Step 1. Remove Snap Ring. Step 7. Remove Inner Snap Ring Step 2. Pry Bearing Out of Housing Tools Required: Internal & Ex[...]

Removal & Replacement 600R Remove Right Side Belt From Assembly (contin ued) Step 4. Use 4 mm Hex Wrench to rem ove Screws and washers holding Brake to bracket. Step 5. Remove brake bracket until b elt Can be removed. Copyright 2001 True Fitness Technology, Inc. Page 94 Step 4. Remove Screws & Washers. Step 5. Remove Bracket to Check Belt[...]

Removal & Replacement 600R Remove Right Side Poly-V Wheel Step 1. Remove snap ring from shaft on Right side. Step 2. Slide shaft through bearing in Frame to remove pulley and shaft assembly. Copyright 2001 True Fitness Technology, Inc. Page 95 Tools Required: External Snap Ring Pliers Step 1. Remove Shaft Snap Ring on Right Side Step 2. Slide S[...]

Removal & Replacement 600R Remove Crank Hub Assembly Step 1. Use crescent wrench to remove Large nut on crank. Step 2. Remove keyed washer from under nut. Step 3. Use crescent wrench to remove hex nut bearing. Use rubber mallet to knock out the shaft pulley assembly. Copyright 2001 True Fitness Technology, Inc. Page 96 Step 1. Remove Crank Nut.[...]

Removal & Replacement 600R Remove Crank Hub Assembly (continued) Step 4. Pull hex nut bearing clear of frame Hub. Step 5. Pull large pulley until b earing clears Frame. Step 6. Twist assembly thru frame hub. Pull assembly until clear of f rame. Copyright 2001 True Fitness Technology, Inc. Page 97 Step 4. Pull Hex Nut Bearing Free. Note: A flat [...]

Removal & Replacement 600R Remove Crank Hub Assembly (continued) Step 7. Use hammer and punch to loosen spanner nut on bearing. Step 8. Remove bearing & washer by slipping off crank. Step 9. Pull crank thru pulley to remove.. Copyright 2001 True Fitness Technology, Inc Page 98 Step 7. Drive Spanner Nut Off to Remove Bearing Step 8. Remove B[...]