Life Fitness Lifecycle 3500 Series, Service Manual

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Lifecycle 3500, 4500, 5500 Series Exercise Bikes
How To...REMOVE AND REPLACE THE FREEWHEEL ASSEMBLY
Tools Required: E-Ring tool, light hammer, needle-nose pliers, two standard screwdrivers,
1/2" wrench, two 3/4" wrenches
Step 1
Remove the HOUSING (See “How To...”).
Step 2
Remove the CHAIN (See “How To...”).
Step 3
Locate the TWO INNER NOTCHES in the inner face of the worn FREE-WHEEL GEAR. Place the blade of a
standard screwdriver into one of the NOTCHES. Loosen the FREE-WHEEL GEAR by lightly tapping the
screwdriver with a light hammer to rotate the FREE-WHEEL GEAR in a
counter-clockwise direction.
WARNING: BE EXTREMELY CAREFUL NOT TO OVER-FORCE AND DAMAGE THE
ALUMINUM THREADS OF THE FREE-WHEEL GEAR DURING THIS PROCEDURE.
Step 4
Remove the E-Ring on the FREEWHEEL SHAFT and carefully push the SHAFT and the FREEWHEEL through the
Brass Bearings and out the user-left side of the Bike.
Step 5
Replace with a new FREE-WHEEL GEAR. When you position the new FREE-WHEEL GEAR on the SHAFT, make
certain that you tighten it firmly. Grasping the GEAR TEETH with an old rag is useful when tightening the FREE-
WHEEL GEAR on the PULLEY SHAFT.
Step 6
Reverse steps 1 and 2 to return all parts back into place.
Tighten parts to the following specifications:
Free-wheel Gear 35-40 in. lbs.