Life Fitness Lifecycle 9500RHR Series Service Manual Download Page 43 | Manualshive

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Lifecycle 9500RHR Series Exercise Bikes

2

How To...REMOVE AND REPLACE THE ALTERNATOR

Tools Required:

3/4, 5/16, 1/2, and 1/4 inch wrenches.

STEP 1

Remove the HOUSING. Refer to “How To...” in this section.

STEP 2

Remove the two POSITIVE RED WIRES from
their POSTS on the ALTERNATOR. Using a 1/4
inch wrench, remove the two nuts securing the
BLACK FIELD WIRE and the YELLOW WIRE.
Then with a 5/16 inch wrench, remove the
REGULATOR TERMINAL NUT and the GROUND
TERMINAL NUT.

STEP 3

With a 1/2 inch wrench, loosen and remove the
ALTERNATOR ADJUSTMENT BOLT and two
WASHERS.

STEP 4

With two 3/4 inch wrenches, loosen the
ALTERNATOR PIVOT BOLT and LOCKNUT. DO
NOT remove the ALTERNATOR until STEP 7.

STEP 5

Push the ALTERNATOR forward to relieve the belt tension, then loop the BELT around the small FLYWHEEL
SHAFT. Once the BELT is free, temporarily set it on top of the PULLEY to keep it out of the way.

STEP 6

Remove the PIVOT BOLT and its three WASHERS from the ALTERNATOR.

STEP 7

Remove the ALTERNATOR and install the new ALTERNATOR in place.

STEP 8

Reverse this procedure for reassembly using specified torques, however note the following:

NOTE: THE ALTERNATOR BELT MUST BE PROPERLY POSITIONED ON THE LARGE PULLEY AND

ALTERNATOR FLYWHEEL. MISALIGNMENT WILL RUIN THE BELT AND PULLEY.

NOTE: USING A BELT TENSION GAUGE, MEASURE THE BELT TENSION. IF THE BELT TENSION

MEASURES LESS THAN 60-70 LBS., MAKE ADJUSTMENTS USING

THE ALTERNATOR ADJUSTMENT BOLT.

How To...REMOVE AND REPLACE THE

Alternator
Adjustment
Bolt

Washer

Alternator
Pivot Bolt

Belt

Locknut

Washer

Large Pulley

Detail

Belt

Alternator Fly Wheel

Alternator

Black / White
Field Return
Wire

Black
Ground Wire

Yellow Wire

Positive
Red Wires (2)

Orange

Torque Nuts
20-25 IN

LBS

Torque
30-35 ft-lbs

Torque
18-20 ft-lbs

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Summary of Contents for Lifecycle 9500RHR Series

Page 1: ... 9500RHR heart rate function chain and belt drive recumbent exercise bikes Information is appropriate to all models unless otherwise noted Note Information represents typical configuration and may differ slightly from actual equipment Customer Support Services SERVICE MANUAL ...

Page 2: ...w To guides for recommended repair procedures How To sub sections are organized by replaceable part or assembly name For convenience sub section lists recommended Tools Required to complete specific function Refer to PARTS IDENTIFICATION to identify proper name and number of part to order for repair of equipment A reproducible FAX order claim form is given in COMMUNICATING BY TELEFACSIMILE for con...

Page 3: ...omic handlebars you ll be much more likely to stick with your exercise plan and accomplish your goals The ability to select a program to match your particular needs is what distinguishes Lifecycle bikes as the world s most popular physical conditioning device Its user flexibility means that you will never outgrow the innumerable challenges the Lifecycle exercise bike has to offer The beginner star...

Page 4: ...S STATE 1 ALL LEDS and KEYPAD TEST 4 ALL LED TEST KEYPAD TEST SPEAKER TEST DIAGNOSTICS STATE 2 INDIVIDUAL LED TEST 4 INDIVIDUAL LED TEST DIAGNOSTICS STATE 3 VERSION RPM HR and LOAD TESTS 4 PROGRAM VERSION NUMBER PEDAL RPM HEART RATE LOAD DUTY CYCLE CONTROL DIAGNOSTICS STATE 4 LIFEPULSE and NETWORK STATUS TESTS 5 LIFEPULSE HC05 and DSP PROGRAM VERSION REVISION s LIFE LINK CONNECTION STATUS DIAGNOST...

Page 5: ...HAIN 5 CRANK ARM AND BEARINGS 6 7 EXTRUSION SEAT ASSEMBLY 8 FREE WHEEL GEAR 9 MAIN WIRE HARNESS 10 SEAT ROLLER BEARINGS 11 BATTERY 12 DISPLAY CONSOLE 13 ALTERNATOR CONTROL BOARD 14 FOOT STRAP 15 FRONT WHEELS 16 HANDLEBAR ASSEMBLY 17 DIGITAL HEART RATE SENSORS 18 19 HEART RATE PC BOARD 20 SEAT LIFEPULSE GRIP ASSEMBLY 21 HOUSING 22 PEDALS 23 SEAT BACK PAD 24 STABILIZER BAR 25 SECTION IV WIRING BLOCK...

Page 6: ...Lifecycle 9500RHR Series Exercise Bikes SECTION I TROUBLESHOOTING GUIDES ...

Page 7: ...ry Loose wire connections Disconnect then reconnect connections Worn or damaged wire harnesses Inspect wire harnesses Replace worn or damaged harness Malfunctioning Display Console Test with substitute Display Console Replace malfunctioning Display Console Malfunctioning Alternator Control Board ACB Test with substitute ACB Replace malfunctioning ACB Malfunctioning Alternator Test Alternator outpu...

Page 8: ...maged harness Malfunctioning Display Console Test with substitute Display Console Replace malfunctioning Display Console Malfunctioning Alternator Control Board Test with substitute Alternator Control Board Replace malfunctioning board Malfunctioning Alternator Test Alternator output or test with substitute Alternator Replace malfunctioning Alternator Refer to Alternator Voltage Test For Assistanc...

Page 9: ...onnect connections Worn or damaged wire harnesses Inspect wire harnesses Replace worn or damaged harnesses Malfunctioning Display Console Test with substitute Display Console Replace malfunctioning Display Console Malfunctioning Alternator Control Board Test with substitute Alternator Control Board Replace malfunctioning board Malfunctioning Alternator Test Alternator output or test with substitut...

Page 10: ...onnect then reconnect the connections Worn or damaged harnesses Inspect wire harnesses Replace worn or damaged harnesses Malfunctioning Alternator Control Board Test with substitute Alternator Control Board Replace defective board Malfunctioning Display Console Inspect for damage or depression at START key Test with substitute Display Console Replace malfunctioning Display Console For Assistance C...

Page 11: ...than 45 RPM Attempting to enter improper duration of time Refer to Operation Manual for time duration requirements Malfunctioning Display Console Test with substitute Display Console Replace malfunctioning Display Console Malfunctioning Alternator Control Board ACB Test with substitute Alternator Control Board Replace Malfunctioning board For Assistance Contact Life Fitness Customer Support Servic...

Page 12: ...unctioning Display Console Test with substitute Display Console Replace malfunctioning Display Console Malfunctioning Alternator Control Board Test with substitute ACB Replace defective Alternator Control Board Malfunctioning Alternator Test Alternator output or test with substitute Alternator Replace malfunctioning Alternator Refer to Alternator Voltage Test For Assistance Contact Life Fitness Cu...

Page 13: ...ram not available Refer to Operation Manual for program availability Keypad is cold Massage keypad with fingertips Display Console connection loose Test with substitute Display Console Replace malfunctioning Display Console Malfunctioning Display Console Test with substitute Display Console Replace malfunctioning Display Console For Assistance Contact Life Fitness Customer Support Services Teleph ...

Page 14: ...oose wire connections Disconnect then reconnect connections Worn or damaged wire harnesses Inspect wire harnesses Replace worn or damaged harness Malfunctioning Display Console Test with substitute Display Console Replace malfunctioning Display Console Malfunctioning Alternator Control Board Test with substitute Alternator Control Board Replace malfunctioning board Malfunctioning Alternator Test A...

Page 15: ...Inspect wire harnesses Replace worn or damaged harness Malfunctioning Display Console Test with substitute Display Console Replace malfunctioning Display Console Malfunctioning Alternator Control Board ACB Test with substitute ACB Replace malfunctioning ACB Malfunctioning Alternator Test Alternator output or test with substitute Alternator Replace malfunctioning Alternator Refer to Alternator Volt...

Page 16: ...reconnect connections Worn or damaged harnesses Inspect wire harnesses Replace worn or damaged harness Malfunctioning Display Console Test with substitute Display Console Replace malfunctioning Display Console Malfunctioning Alternator Control Board Test with substitute Alternator Control Board Replace defective board Malfunctioning Alternator Test Alternator output or test with substitute Alterna...

Page 17: ... Disconnect then reconnect connections Worn or damaged harnesses Inspect wire harnesses Replace worn or damaged harness Malfunctioning Display Console Test with substitute Display Console Replace malfunctioning Display Console Malfunctioning Alternator Control Board Test with substitute Alternator Control Board Replace defective board Malfunctioning Alternator Test Alternator output or test with s...

Page 18: ...rward rotation Replace malfunctioning Gear Alternator Belt excessively tight Inspect belt deflection Adjust as necessary Alternator Belt Deflection 1 4 inch 6mm Stiff chain Link s Inspect Links Replace chain Left side Crank Nut excessively tight Loosen nut 1 16 one sixteenth of a turn Crank Bearings worn or corroded Replace Crank Bearings Seat incorrectly adjusted Adjust Seat Refer to Operation Ma...

Page 19: ...Inspect wire harnesses Replace worn or damaged harness Malfunctioning Display Console Test with substitute Display Console Replace malfunctioning Display Console Malfunctioning Alternator Control Board Test with substitute Alternator Control Board Replace defective board Malfunctioning Alternator Test Alternator output or test with substitute Alternator Replace malfunctioning Alternator Refer to A...

Page 20: ...ve lead Worn Battery Wires Inspect Wires Replace Wires or harness Battery leads grounding upon frame Inspect leads Replace battery Malfunctioning Display Console Test with substitute Display Console Replace malfunctioning Display Console Malfunctioning Alternator Control Board Test with substitute Alternator Control Board Replace defective board For Assistance Contact Life Fitness Customer Support...

Page 21: ...rectly Adjust Foot Pads Floor surface not level Position Aerobic Trainer upon level surface Stabilizer Bar not attached firmly to frame Tightened attaching hardware Wheel s damaged Replace damaged wheel s Frame damaged Contact Life Fitness Customer Support Services For Assistance Contact Life Fitness Customer Support Services Teleph 847 451 0036 or 800 351 3737 Telefacs 847 288 3702 or 800 216 889...

Page 22: ...ngs not adjusted properly or worn Inspect Bearings Adjust or replace as necessary Alternator Belt excessively loose Inspect belt deflection Adjust as necessary Alternator Belt Deflection 1 4 inch 6mm Alternator Belt worn Replace Belt Malfunctioning Alternator Operate Aerobic Trainer as in normal use with light and heavy load levels Listen for excessive noise from Alternator Replace Alternator as n...

Page 23: ...rective Action Seat wobbles or has excessive side to side movement Seat rollers out of adjustment or excessively worn Inspect seat rollers Adjust or replace worn rollers as necessary For Assistance Contact Life Fitness Customer Support Services Teleph 847 451 0036 or 800 351 3737 Telefacs 847 288 3702 or 800 216 ...

Page 24: ...ltage 1 Attach DC voltmeter to Alternator Voltmeter positive probe to Alternator red lead Voltmeter negative lead to Alternator black lead 2 Maintain pedal speed greater than 45 RPM 3 Press START key Alternator Voltage Specification 9 11 VDC when pedal speed greater than 45 RPM For Assistance Contact Life Fitness Customer Support Services Teleph 847 451 0036 or 800 351 3737 Telefacs 847 288 3702 o...

Page 25: ...ulse Assembly Life Pulse handlebar Verify that the handlebar is functioning See diagrams Using an ohmmeter verify continuity between Lifepulse sensor and cable connection See wiring diagram for pin location Handlebar Lifepulse Grip Assembly Dry wipe sensors Loose or malfunctioning heart rate lead connection at Display Console Secure connection Replace malfunctioning Handlebar Lifepulse Grip Assemb...

Page 26: ... Handlebar grips loosening Excessive wear or damage to grip Replace the handlebar assembly Lifepulse sensor molding loose Cleaning solution that contains an acid or ammonia base Replace the Lifepulse Sensor Kit For Assistance Contact Life Fitness Customer Support Services Teleph 847 451 0036 or 800 351 3737 Telefacs 847 288 3702 or 800 216 8893 ...

Page 27: ...Lifecycle 9500RHR Series Exercise Bikes NOTES 2 ...

Page 28: ...Lifecycle 9500RHR Exercise Bike SECTION II DIAGNOSTIC MODES ...

Page 29: ... DIAGNOSTIC MODE 2 Diagnostics can be entered while holding the the 5 key and pressing the Start key while pedaling the bike over 45 RPM s The Enter key will prompt you forward while the Clear Pause key you prompt you backward in diagnostic modes ...

Page 30: ...E 6 MAXIMUM PROGRAM DURATION MAXIMUM PROGRAM TIME DIAGNOSTICS STATE 7 TELEMETRY ENABLE DISABLE TELEMETRY ENABLE DISABLE DIAGNOSTICS STATE 8 ENGLISH METRIC UNITS ENGLISH UNITS METRIC UNITS CONFIGURATION DIAGNOSTICS STATE 9 UPRIGHT RECUMBENT SELECTION LC9500 or LC9500R CONFIGURATION DIAGNOSTICS STATE 10 WATTS WATTS ENABLE DISABLE DIAGNOSTICS STATE 11 METS METS ENABLE DISABLE DIAGNOSTICS STATE 12 POW...

Page 31: ...ts and profile LED s will all animate independently Pressing the CLEAR PAUSE key will return to DIAGNOSTICS STATE 1 Pressing the START ENTER key will advance to DIAGNOSTICS STATE 3 DIAGNOSTICS STATE 3 VERSION RPM HR and LOAD TESTS The PROGRAM VERSION NUMBER ex P2 41 will be displayed in the ELAPSED TIME window The present RPM will be displayed in the RPM window The HEART RATE if present will be di...

Page 32: ...tly RS232 OFF will be displayed Pressing the CLEAR PAUSE key will return to DIAGNOSTICS STATE 4 Pressing the START ENTER key will advance to DIAGNOSTICS STATE 6 DIAGNOSTICS STATE 6 MAXIMUM PROGRAM DURATION Within this state the MAXIMUM PROGRAM DURATION is displayed and can be adjusted Valid range is from 10 99 minutes The DOWN ARROW will decrease the value by 1 minute Key will Auto Repeat if held ...

Page 33: ...t can be selected The DOWN ARROW will configure as a Recumbent The UP ARROW will configure as a Upright The ENTER key led will indicate when the value is the default This value is stored in EEROM and is kept when the unit is not in use Pressing the CLEAR PAUSE key will return to DIAGNOSTICS STATE 8 Pressing the START ENTER key will advance to DIAGNOSTICS STATE 10 DIAGNOSTICS STATE 10 WATTS Within ...

Page 34: ...d Pressing the CLEAR PAUSE key will return to DIAGNOSTICS STATE 12 Pressing the START ENTER key will advance to DIAGNOSTICS STATE 14 DIAGNOSTICS STATE 14 NUMERIC KEYS CONFIGURATION Within this state the unit can be configured as to the presence of numeric keys The DOWN ARROW will display NUMERICS OFF The UP ARROW will display NUMERICS ON This value is stored in EEROM and is kept when the unit is n...

Page 35: ...se Bike DIAGNOSTIC TESTS 8 In ALL DIAGNOSTICS STATES the user must keep pedaling the bike If the pedal RPM drops too low the bike will shut down requiring at least 45 RPM or greater and a START switch closure to operate again ...

Page 36: ... to Diagnostics State 2 DIAGNOSTICS STATE 2 This test indicates that all LED s on the Display are working properly Upon entry the system will beep and begin walking a column of the 8 X 8 matrix from left to right When the rightmost column has been lit a row of the 8 X 8 matrix will walk from bottom to top Next a single segment in all of the 7 segment displays will animate through the digits Next a...

Page 37: ...1 The selected jumper options are displayed in the ELAPSED TIME WINDOW as shown Left most digit 1234 q NON RECHARGABLE is indicated by an A q RECHARGEABLE is indicated by a C Left center digit 1234 q ENGLISH units of measurement are indicated by an E q METRIC units of measurement are indicated by a G Right center digit 1234 q RECUMBENT is indicated by an r q UPRIGHT is indicated by a U Right most ...

Page 38: ... maximum program default times Upon entry the system will beep and display the MAXIMUM PROGRAM DURATION permitted on the unit in the ELAPSED TIME WINDOW A t will be displayed in the leftmost digit of the MULTI FUNCTION DISPLAY WINDOW to indicate that this represents the maximum time This value is stored in EEROM and is kept when the bike is not in use Valid values for MAXIMUM PROGRAM DURATION can ...

Page 39: ...RN and CARDIO will not allow selection Any attempt to choose either program will result in an invalid PROGRAM SELECTION When the TELEMETRY HEART RATE system is available a user will observe NOTHING in the DATA ENTRY window during normal PROGRAM SELECTION and the programs will be allowed to be chosen Diagnostics State 8 can be entered now by pressing the START ENTER key or Diagnostics State 6 can b...

Page 40: ...returned to by pressing the CLEAR PAUSE key DIAGNOSTICS STATE 10 This test indicates if the Lifepulse feature is enabled disabled When the default is set for the Lifepulse system to be enabled it will read HRT in the DATA ENTRY WINDOW When the default is set for the Lifepulse system to be enabled it will read NHR in the DATA ENTRY WINDOW The user can change the default setting of the system by pre...

Page 41: ...Lifecycle 9500RHR Exercise Bike NOTES 14 ...

Page 42: ...SECTION III How To SERVICE AND REPAIR GUIDES ...

Page 43: ... small FLYWHEEL SHAFT Once the BELT is free temporarily set it on top of the PULLEY to keep it out of the way STEP 6 Remove the PIVOT BOLT and its three WASHERS from the ALTERNATOR STEP 7 Remove the ALTERNATOR and install the new ALTERNATOR in place STEP 8 Reverse this procedure for reassembly using specified torques however note the following NOTE THE ALTERNATOR BELT MUST BE PROPERLY POSITIONED O...

Page 44: ... 7 Remove the three FLAT INNER E RINGS and the BENT OUTER E RING Use either two screwdrivers long nose pliers or an E Ring tool CAUTION THE E RINGS ARE UNDER LOAD PLEASE REMOVE THEM SLOWLY AND CAREFULLY STEP 8 From the BELT side use a center punch and a small hammer to tap out the SHAFT from the PULLEY BRACKET STEP 9 Pull the PULLEY forward and out of the bike frame Remove the WORN BELT and replac...

Page 45: ...ove the three FLAT INNER E RINGS and the BENT OUTER E RING Use either two screwdrivers long nose pliers or an E Ring tool CAUTION THE E RINGS ARE UNDER LOAD PLEASE REMOVE THEM SLOWLY AND CAREFULLY STEP 4 From the BELT side use a center punch and a small hammer to tap out the SHAFT from the PULLEY BRACKET STEP 5 Pull the PULLEY forward and out of the bike frame and remove the BELT STEP 6 Remove the...

Page 46: ...iers remove the MASTER LINK RETAINING CLIP the MASTER LINK and the MASTER LINK PLATE from the worn CHAIN Step 3 Install the new CHAIN on the SPROCKET and FREEWHEEL GEAR Step 4 Insert the new MASTER LINK through the ends of the new CHAIN and snap the new MASTER LINK PLATE over the new MASTER LINK Then with a needle nose pliers install the new RETAINER CLIP onto the new MASTER LINK with the ends of ...

Page 47: ...ike frame Discard the two bearing clamp bolts two split washers and four bearing clamps DO NOT reuse STEP 5 Bend the outward tab of the TAB LOCK WASHER to allow rotation of the REVERSE THREADED LOCK NUT Using the 32mm crank arm wrench loosen and remove the REVERSE THREAD LOCK NUT Remember that this nut is reverse threaded NOTE NUTS ON THE LEFT SIDE ARE REVERSE THREADED CLOCKWISE TO LOOSEN COUNTER ...

Page 48: ...the CRANK ARM with the bent tab facing toward the bike FRAME Slide the key of the TAB LOCK WASHER through the notch and into position against the CRANK BEARING NUT ASSEMBLY Align the flat of the bent TAB against the flat of the NUT STEP 15 Slide the REVERSE THREADED LOCK NUT over the CRANK ARM thread it into position and with the 32mm crank arm wrench tighten the REVERSE THREADED LOCK NUT to 4 FT ...

Page 49: ...ove the SEAT STOP and set it aside NOTE DO NOT LET MORE THAN ONE OF THE THREE SETS OF ROLLERS SIT OFF THE EDGE OF THE EXTRUSION TO AVOID BREAKING THE FLAT FLEX CABLE STEP 7 Remove the two TORX SCREWS holding the retainer bracket for the flat FLEX CABLE STEP 8 Disconnect the 4 PIN CONNECTOR and FLAT FLEX CABLE located beneath the SEAT GUIDE Unhook the cable from the stress relief clamp Remove the G...

Page 50: ... nose pliers or and E Ring tool STEP 8 From the BELT side use a center punch and a light hammer to tap the PULLEY SHAFT from the PULLEY BRACKET STEP 9 Pull the PULLEY forward and out of the bike Lay the PULLEY flat Using a screwdriver loosen the FREEWHEEL from the threads on the PULLEY Note that there are two notches in the inner face STEP 10 Place the blade of the screwdriver into one of the NOTC...

Page 51: ...TEP 6 Disconnect the 11 PIN CONNECTOR at P1 5 PIN CONNECTOR at P3 and 12 PIN CONNECTOR at P2 on the ALTERNATOR CONTROL BOARD STEP 7 Remove the WIRE HARNESS through the FRAME STEP 8 Position the new WIRE HARNESS and replace any cable ties that were cut during removal STEP 9 Reconnect the five TERMINAL CONNECTIONS to their proper locations on the ALTERNATOR the BATTERY TERMINALS to their respective ...

Page 52: ...he EXTRUSION Repeat this step on the other ROLLER BEARINGS WARNING DO NOT LIFT THE SEAT PLUNGER AT THIS TIME THE SEAT WILL FREE FALL AND MAY CAUSE DAMAGE STEP 4 Do not hold onto the seat while using the 7 8 inch wrench to turn the ROLLER BEARING in a clockwise direction closing the gap between the top of the ROLLER BEARING and underside of the EXTRUSION Repeat this step on the other ROLLER BEARING...

Page 53: ...ost on the BATTERY followed by the RED pos wire from the post STEP 4 Use a straight blade screwdriver remove the two SCREWS securing the BATTERY to the bracket Remove the old BATTERY and discard STEP 5 Position the new BATTERY in place of the old one and secure with the two SCREWS STEP 6 Reconnect the BLACK neg wire to the post on the BATTERY and the RED pos wire to the post Gently tuck the BATTER...

Page 54: ...ORS from the back of the DISPLAY CONSOLE taking note of their positions Remove the DISPLAY CONSOLE F STEP 3 Set the back of the DISPLAY CONSOLE on the HANDLEBAR DISPLAY PAD Using a Phillips screwdriver attach the new DISPLAY CONSOLE using the four DISPLAY SCREWS NOTE DO NOT OVER TIGHTEN THE SCREWS THE RUBBER PAD SHOULD COMPRESS ONLY SLIGHTLY THE DISPLAY CONSOLE ASSEMBLY SHOULD NOT APPEAR MOUNTED U...

Page 55: ...TEP 2 Note the WIRE HARNESS position then disconnect the WIRE HARNESS from locations P1 and P2 from the ALTERNATOR CONTROL BOARD STEP 3 Using a straight blade screwdriver remove the four SCREWS from the ALTERNATOR CONTROL BOARD STEP 4 Remove the ALTERNATOR CONTROL BOARD from the ALTERNATOR CONTROL BRACKET and replace with a new ALTERNATOR CONTROL BOARD STEP 5 Reverse this procedure for reassembly ...

Page 56: ...the worn STRAP and pull AWAY and DOWN from the knob on the PEDAL STEP 2 Grasp the inside of the worn STRAP and pull AWAY and DOWN from the knob on the PEDAL STEP 3 Insert the outside of the new STRAP with the slit on the outside knob of the PEDAL Pull the STRAP UP until it locks in place STEP 4 Insert the inside of the new STRAP with the slit on the inside knob of the PEDAL Pull the STRAP UP until...

Page 57: ...HE FRONT WHEEL Tools Required Phillips screwdriver STEP 1 Using a Phillips screwdriver remove the two screws and washers from the wheel STEP 2 Guide the new wheel onto the axle and secure with the two Phillips screws and washers Axle Wheel Washer Screw Torque 20 25 IN LBS ...

Page 58: ...ESS D up through the tube as shown with your free hand Continue feeding the DISPLAY WIRE HARNESS until the CONNECTOR extends through the rectangular hole at the top end of the HANDLEBAR ASSEMBLY STEP 6 Slide the HANDLEBAR ASSEMBLY into the FRAME POST E Be careful not to pinch the DISPLAY WIRE HARNESS NOTE BOTH THE HANDLEBAR ASSEMBLY AND THE HANDLEBAR POST ARE KEYED TO EASE THE ALIGNMENT AND POSITI...

Page 59: ...ou as if you were the user gripping the Lifepulse heart rate monitoring sensors if screw access holes are already provided in the sensor you wish to replace simply remove the two screws and continue to Step 2 This will be the sensor on which your fingertips rest during use This sensor will be referred to as the ground sensor black or green wire hereafter in these instructions The sensor closest to...

Page 60: ...ew pre assembled ground sensor assembly this will be the assembly with the screw access holes in the sensor and locate it into position This is the sensor on which the fingertips rest during use Step 6 Install the two screws through the access holes in the ground sensor and torque to 5 7 In Lb Step 7 Repeat Steps 1 through 6 to remove and replace the second set of sensors included in the kit Kit N...

Page 61: ...ound yourself to the machine by attaching one end of a DISPOSABLE ANTI STATIC GROUNDING STRAP to your wrist and the other to a suitable grounding point on the exercise bike e g the metal part of the pedal crank shaft STEP 5 Use the pliers to squeeze the tips of the five SPACERS one at a time to allow removal of the HEART RATE PC BOARD Before lifting the HEART RATE PC BOARD from position be aware t...

Page 62: ...F THE EXTRUSION TO AVOID BREAKING FLAT FLEX CABLE Step 5 Remove the two TORX SCREWS holding the retainer bracket for the flat FLEX CABLE Step 6 Disconnect the 4 PIN FLAT FLEX CABLE CONNECTOR located beneath the SEAT GUIDE EXTRUSION Unhook the cable from the stress relief clamp Remove the GROMMET from the underside of the SEAT GUIDE EXTRUSION at the FLAT FLEX CABLE Carefully pull the cable from the...

Page 63: ...e place a 5 8 inch open end wrench on the PEDAL BOLT and turn the wrench counterclockwise STEP 3 With a phillips screwdriver remove the five A SCREWS near the SEAT EXTRUSION With a straight blade screwdriver remove the sixteen B SCREWS from around the HOUSING STEP 4 Swing the SPROCKET side right CRANK ARM up to the 2 o clock position and guide the HOUSING up and over the CRANK ARM STEP 5 Swing the...

Page 64: ... BOLT and turn the wrench clockwise STEP 2 To remove the RIGHT PEDAL place a 5 8 inch open end wrench on the PEDAL BOLT and turn the wrench counterclockwise STEP 3 Install the new PEDALS onto the CRANK ARMS To tighten the PEDALS place a 5 8 inch open end wrench on the PEDAL BOLT Move the wrench counterclockwise for the LEFT PEDAL and clockwise for the RIGHT PEDAL Left Pedal Pedal Bolt Right Pedal ...

Page 65: ... wrench STEP 1 With a 5 32 inch hex key wrench remove four SCREWS from the SEAT PAD and remove the PAD STEP 2 Hold the new SEAT PAD against the SEAT FRAME and secure and tighten with the four SCREWS using a 5 32 inch hex key wrench NOTE MAKE SURE THE SEAT IS PROPERLY SECURE BEFORE RIDING Screw Washer Seat Frame Seat Pad ...

Page 66: ...ith the 1 2 wrench remove the two STABILIZER BOLTS from the bottom of the STABILIZER BAR Remove the STABILIZER BAR from the bike frame STEP 3 Install the new STABILIZER BAR and tighten the bolts to a torque of 10 to 15 INCH LBS The stabilizer bar must be flush against the rear frame of the bike STEP 4 After placing the bike in the intended location for use check the stability of the Lifecycle If t...

Page 67: ...Life Cycle 9500RHR Series Exercise Bikes SECTION IV WIRING BLOCK DIAGRAMS AND PARTS IDENTIFICATION ...

Page 68: ...T W O R K V S Y S S C K M O S I M I S O N E T S E L N E T O F F w h i t e 1 0 4 7 5 2 b l u e b r o w n o r a n g e g r e e n G N D 8 3 r e d b l a c k M O L E X M I N I F I T J r F i e l d E x c i t a t i o n A L T E R N A T O R F i e l d R e t u r n A C T a p P M A N D O K O R E A E X C L2 S O u t p u t G n d E B N O T T O S C A L E A L T R E G L O A L T R E G L O H R E N A B L E L E F T R I G H...

Page 69: ... T F L D C M D L O A D C M D C O N S O L E 1 5 1 3 1 1 7 1 0 b l u e 3 9 2 1 w h t b l a c k w h t b l u e w h t g r e e n w h t r e d 1 0 P O S N E T W O R K V S Y S V S Y S I R Q S C K M O S I M I S O N E T S E L N E T O F F w h t r e d 1 0 9 4 7 5 2 w h t y e l l o w w h t o r a n g e w h t g r e e n w h t b l u e w h t b l a c k 6 G N D G N D 8 3 1 r e d b l a c k b l a c k r e d W B O S C H A...

Page 70: ...Life Cycle 9500RHR Series Exercise Bikes SECTION IV WIRING BLOCK DIAGRAMS AND PARTS IDENTIFICATION ...

Page 71: ...T W O R K V S Y S S C K M O S I M I S O N E T S E L N E T O F F w h i t e 1 0 4 7 5 2 b l u e b r o w n o r a n g e g r e e n G N D 8 3 r e d b l a c k M O L E X M I N I F I T J r F i e l d E x c i t a t i o n A L T E R N A T O R F i e l d R e t u r n A C T a p P M A N D O K O R E A E X C L2 S O u t p u t G n d E B N O T T O S C A L E A L T R E G L O A L T R E G L O H R E N A B L E L E F T R I G H...

Page 72: ... T F L D C M D L O A D C M D C O N S O L E 1 5 1 3 1 1 7 1 0 b l u e 3 9 2 1 w h t b l a c k w h t b l u e w h t g r e e n w h t r e d 1 0 P O S N E T W O R K V S Y S V S Y S I R Q S C K M O S I M I S O N E T S E L N E T O F F w h t r e d 1 0 9 4 7 5 2 w h t y e l l o w w h t o r a n g e w h t g r e e n w h t b l u e w h t b l a c k 6 G N D G N D 8 3 1 r e d b l a c k b l a c k r e d W B O S C H A...

Page 73: ...19 00039 0004 R Spn Met SK19 00039 0005 R Swe Met SK19 00039 0008 R Itl Met SK19 00039 0009 R Dut Met Overlay Bezel AK19 00060 0001 Eng Eng AK19 00060 0002 Eng Met AK19 00060 0003 Ger Met AK19 00060 0006 Jap Met AK19 00060 0004 Spn Met AK19 00060 0005 Swe Met AK19 00060 0008 Itl Met AK19 00060 0009 Dut Met Console Logo Decal OK18 01178 0005 Console Case OK18 01243 0003 Console Post w Decal SK19 00...

Page 74: ...4 0000 Freewheel Pulley Assembly SK17 00036 0000 Poly V Belt 0017 00009 0749 Alternator Control Assy SK19 00063 0000 R Alternator Pulley Assy SK19 00070 0000 Extruded Tube Assembly SK19 00088 0002 Freewheel Gear 0017 0009 0785 Master Link Assembly GK18 00004 0002 6 Volt Battery 0017 00003 0685 Bearing Nut RT AK18 00116 0000 Bearing Nut LT AK18 00116 0000 Crankarm Bearing Set GK18 00004 0024 Clamps...

Page 75: ...ud w Decal LT AK19 00033 0002 End Cap OK19 01136 0000 Shroud w Decal RT AK19 00033 0001 Crankarm Dust Cover OK19 01134 0000 Alternator Mando 0017 00009 0841 Leg Cover Screws 2 0017 00101 0017 Leg Covers 2 OK18 01006 0001 Wheel Inserts 2 OK18 01057 0000 Wheels Bearings 2 SK18 00016 0000 Wheel Insert Washers 2 OK17 01029 0000 Wheel Insert Screws 2 OK17 00101 0932 Leg Cover Washers 2 OK18 01023 0100 ...

Page 76: ...9 00084 0007 R Frn Met SK19 00084 0004 R Spn Met SK19 00084 0008 R Itl Met SK19 00084 0009 R Dut Met Overlay Bezel AK18 00166 0001 Eng Eng AK18 00166 0002 Eng Met AK18 00166 0003 Ger Met AK18 00166 0006 Jap Met AK18 00166 0007 Frn Met AK18 00166 0004 Spn Met AK18 00166 0008 Itl Met AK18 00166 0009 Dut Met Console Logo Decal OK18 01178 0005 Console Case OK18 01243 0003 Console Post w Decal SK19 001...

Page 77: ...y Assembly SK17 00036 0000 Poly V Belt 0017 00009 0749 Alternator Control Assy SK19 00087 0000 R Alternator Pulley Assy SK19 00070 0000 Extruded Tube Assembly SK19 00088 0002 Freewheel Gear 0017 0009 0785 Master Link Assembly GK18 00004 0002 6 Volt Battery 0017 00003 0685 Bearing Nut RT AK18 00116 0000 Bearing Nut LT AK18 00116 0000 Crankarm Bearing Set GK18 00004 0024 Clamps 2 OK18 01104 0002 Cla...

Page 78: ...d w Decal LT AK19 00086 0002 End Cap OK19 01136 0000 Shroud w Decal RT AK19 00086 0001 Crankarm Dust Cover OK19 01134 0000 Alternator Mando 0017 00009 0841 Leg Cover Screws 2 0017 00101 0017 Leg Covers 2 OK18 01006 0001 Wheel Inserts 2 OK18 01057 0000 Wheels Bearings 2 SK18 00016 0000 Wheel Insert Washers 2 OK17 01029 0000 Wheel Insert Screws 2 OK17 00101 0932 Leg Cover Washers 2 OK18 01023 0100 ...

Page 79: ... Met SK19 00094 0007 R Frn Met SK19 00094 0004 R Spn Met SK19 00094 0008 R Itl Met SK19 00094 0009 R Dut Met Overlay Bezel AK18 00172 0001 Eng Eng AK18 00172 0002 Eng Met AK18 00172 0003 Ger Met AK18 00172 0007 Frn Met AK18 00172 0004 Spn Met AK18 00172 0008 Itl Met AK18 00172 0009 Dut Met Console Logo Decal OK18 01178 0005 Console Case OK18 01243 0003 Console Post w Decal SK19 00108 0000 Console ...

Page 80: ...17 01024 0000 Freewheel Pulley Assembly SK17 00036 0000 Poly V Belt 0017 00009 0749 Alternator Control Assy AK19 00134 0000 R Alternator Pulley Assy SK19 00070 0000 Extruded Tube Assembly SK19 00088 0002 Freewheel Gear 0017 0009 0785 Master Link Assembly GK18 00004 0002 6 Volt Battery 0017 00003 0685 Bearing Nut RT AK18 00116 0000 Bearing Nut LT AK18 00116 0000 Crankarm Bearing Set GK18 00004 0024...

Page 81: ...015 Shroud w Decal LT AK19 00033 0002 End Cap OK19 01136 0000 Shroud w Decal RT AK19 00033 0001 Crankarm Dust Cover OK19 01134 0000 Alternator Mando 0017 00009 0841 Leg Cover Screws 2 0017 00101 0017 Leg Covers 2 OK18 01006 0001 Wheel Inserts 2 OK18 01057 0000 Wheels Bearings 2 SK18 00016 0000 Wheel Insert Washers 2 OK17 01029 0000 Wheel Insert Screws 2 OK17 00101 0932 Leg Cover Washers 2 OK18 010...

Page 82: ...07 R Frn Met AK19 00106 0004 R Spn Met AK19 00106 0008 R Itl Met AK19 00106 0009 R Dut Met Overlay Bezel AK18 00192 0001 Eng Eng AK18 00192 0002 Eng Met AK18 00192 0003 Ger Met AK18 00192 0007 Frn Met AK18 00192 0004 Spn Met AK18 00192 0008 Itl Met AK18 00192 0009 Dut Met Console Logo Decal OK18 01178 0005 Console Case OK18 01243 0003 Console Post w Decal SK19 00108 0000 Console Post Cap OK19 0112...

Page 83: ...wheel Pulley Assembly SK17 00036 0000 Poly V Belt 0017 00009 0749 Alternator Control Assy AK19 00134 0000 R Alternator Pulley Assy SK19 00070 0000 Extruded Tube Assembly SK19 00088 0002 Freewheel Gear 0017 0009 0785 Master Link Assembly GK18 00004 0002 6 Volt Battery 0017 00003 0685 Bearing Nut RT AK18 00116 0000 Bearing Nut LT AK18 00116 0000 Crankarm Bearing Set GK18 00004 0024 Clamps 2 OK18 011...

Page 84: ... LT AK19 00033 0002 End Cap OK19 01136 0000 Shroud w Decal RT AK19 00033 0001 Crankarm Dust Cover OK19 01134 0000 Alternator Mando 0017 00009 0841 Leg Cover Screws 2 0017 00101 0017 Leg Covers 2 OK18 01006 0001 Wheel Inserts 2 OK18 01057 0000 Wheels Bearings 2 SK18 00016 0000 Wheel Insert Washers 2 OK17 01029 0000 Wheel Insert Screws 2 OK17 00101 0932 Leg Cover Washers 2 OK18 01023 0100 ...

Page 85: ...0007 R Frn Met AK19 00105 0004 R Spn Met AK19 00105 0008 R Itl Met AK19 00105 0009 R Dut Met Overlay Bezel AK18 00191 0001 Eng Eng AK18 00191 0002 Eng Met AK18 00191 0003 Ger Met AK18 00191 0006 Jap Met AK18 00191 0007 Frn Met AK18 00191 0004 Spn Met AK18 00191 0008 Itl Met AK18 00191 0009 Dut Met Console Logo Decal OK18 01178 0005 Console Case OK18 01243 0003 Console Post w Decal SK19 00108 0000 ...

Page 86: ...ly SK17 00036 0000 Poly V Belt 0017 00009 0749 Alternator Control Assy SK19 00087 0000 R Alternator Pulley Assy SK19 00070 0000 Extruded Tube Assembly SK19 00088 0002 Freewheel Gear 0017 0009 0785 Master Link Assembly GK18 00004 0002 6 Volt Battery 0017 00003 0685 Bearing Nut RT AK18 00116 0000 Bearing Nut LT AK18 00116 0000 Crankarm Bearing Set GK18 00004 0024 Clamps 2 OK18 01104 0002 Clamps 2 OK...

Page 87: ...l LT AK19 00086 0002 End Cap OK19 01136 0000 Shroud w Decal RT AK19 00086 0001 Crankarm Dust Cover OK19 01134 0000 Alternator Mando 0017 00009 0841 Leg Cover Screws 2 0017 00101 0017 Leg Covers 2 OK18 01006 0001 Wheel Inserts 2 OK18 01057 0000 Wheels Bearings 2 SK18 00016 0000 Wheel Insert Washers 2 OK17 01029 0000 Wheel Insert Screws 2 OK17 00101 0932 Leg Cover Washers 2 OK18 01023 0100 ...

Page 88: ...07 R Frn Met AK19 00105 0004 R Spn Met AK19 00105 0008 R Itl Met AK19 00105 0009 R Dut Met Overlay Bezel AK18 00191 0001 Eng Eng AK18 00191 0002 Eng Met AK18 00191 0003 Ger Met AK18 00191 0006 Jap Met AK18 00191 0007 Frn Met AK18 00191 0004 Spn Met AK18 00191 0008 Itl Met AK18 00191 0009 Dut Met Console Logo Decal OK18 01178 0005 Console Case OK18 01243 0003 Console Post w Decal SK19 00108 0000 Co...

Page 89: ... SK17 00036 0000 Poly V Belt 0017 00009 0749 Alternator Control Assy SK19 00087 0000 R Alternator Pulley Assy SK19 00070 0000 Extruded Tube Assembly SK19 00088 0002 Freewheel Gear 0017 0009 0785 Master Link Assembly GK18 00004 0002 6 Volt Battery 0017 00003 0685 Bearing Nut RT AK18 00116 0000 Bearing Nut LT AK18 00116 0000 Crankarm Bearing Set GK18 00004 0024 Clamps 2 OK18 01104 0002 Clamps 2 OK18...

Page 90: ...LT AK19 00112 0002 End Cap OK19 01136 0000 Shroud w Decal RT AK19 00112 0001 Crankarm Dust Cover OK19 01134 0000 Alternator Mando 0017 00009 0841 Leg Cover Screws 2 0017 00101 0017 Leg Covers 2 OK18 01006 0001 Wheel Inserts 2 OK18 01057 0000 Wheels Bearings 2 SK18 00016 0000 Wheel Insert Washers 2 OK17 01029 0000 Wheel Insert Screws 2 OK17 00101 0932 Leg Cover Washers 2 OK18 01023 0100 ...

Page 91: ...5 0003 Ger Met AK19 00115 0007 Frn Met AK19 00115 0004 Spn Met AK19 00115 0008 Itl Met AK19 00115 0007 Dut Met AK19 00115 0016 Jap Met Console Assembly AK19 00116 0001 R Eng Met AK19 00116 0003 R Ger Met AK19 00116 0007 R Frn Met AK19 00116 0004 R Spn Met AK19 00116 0008 R Itl Met AK19 00116 0007 R Dut Met AK19 00116 0016 R Jap Met Handlebar Assembly AK19 00138 0000 Console Post Cap OK19 01125 000...

Page 92: ...01 Freewheel Pulley Assy AK46 00016 0000 Idler Pulley OK46 01008 0002 Power Grip Belt OK46 01009 0000 Crank Arm Pulley Assembly AK46 00015 0001 Crank Arm OK18 01281 0000 Console Cable Assembly AK19 00081 0001 Idler Arm Bracket OK46 01056 0001 Seat Assy w o Back SK19 00075 0000 Extruded Tube Assembly SK19 00083 0002 Alternator Control Assy AK19 00129 0000 R Alternator Pulley Assy SK17 00106 0000 Ro...

Page 93: ...17 01029 0000 Wheel Insert Screws 2 OK17 00101 0932 Leg Cover Washers 2 OK18 01023 0100 Clamps 2 OK18 01104 0002 Clamps 2 OK18 01104 0001 Tabbed Lockwasher OK18 01280 0000 Crankarm Locknut OK18 01059 0002 Pedal w Strap RT AK17 00026 0014 Pedal w Strap LT AK17 00026 0015 Shroud w Decal LT AK19 00113 0002 Shroud Decal LT OK19 01297 0001 End Cap OK19 01136 0000 Shroud w Decal RT AK19 00113 0001 Shrou...

Page 94: ...07 R Frn Met AK19 00106 0004 R Spn Met AK19 00106 0008 R Itl Met AK19 00106 0009 R Dut Met Overlay Bezel AK18 00192 0001 Eng Eng AK18 00192 0002 Eng Met AK18 00192 0003 Ger Met AK18 00192 0007 Frn Met AK18 00192 0004 Spn Met AK18 00192 0008 Itl Met AK18 00192 0009 Dut Met Console Logo Decal OK18 01178 0005 Console Case OK18 01243 0003 Console Post w Decal SK19 00108 0000 Console Post Cap OK19 0112...

Page 95: ...wheel Pulley Assembly SK17 00036 0000 Poly V Belt 0017 00009 0749 Alternator Control Assy AK19 00134 0000 R Alternator Pulley Assy SK19 00070 0000 Extruded Tube Assembly SK19 00088 0002 Freewheel Gear 0017 0009 0785 Master Link Assembly GK18 00004 0002 6 Volt Battery 0017 00003 0685 Bearing Nut RT AK18 00116 0000 Bearing Nut LT AK18 00116 0000 Crankarm Bearing Set GK18 00004 0024 Clamps 2 OK18 011...

Page 96: ... LT AK19 00033 0002 End Cap OK19 01136 0000 Shroud w Decal RT AK19 00033 0001 Crankarm Dust Cover OK19 01134 0000 Alternator Mando 0017 00009 0841 Leg Cover Screws 2 0017 00101 0017 Leg Covers 2 OK18 01006 0001 Wheel Inserts 2 OK18 01057 0000 Wheels Bearings 2 SK18 00016 0000 Wheel Insert Washers 2 OK17 01029 0000 Wheel Insert Screws 2 OK17 00101 0932 Leg Cover Washers 2 OK18 01023 0100 ...

Page 97: ...04 Spn Met AK19 00115 0006 Jap Met AK19 00115 0007 Frnl Met AK19 00115 0008 Itl Met AK19 00115 0009 Dut Met Console Assembly AK19 00141 0001 R Eng Met AK19 00141 0003 R Ger Eur AK19 00141 0004 R Jap Eur AK19 00141 0005 R Frn Eur AK19 00141 0006 R Spn Eur AK19 00141 0007 R Spn Met AK19 00141 0008 R Itl Eur AK19 00141 0009 R Dut Eur AK19 00141 0010 R Frn Met Handlebar Assembly AK19 00138 0000 Consol...

Page 98: ... Freewheel Pulley Assy AK46 00016 0000 Idler Pulley OK46 01008 0002 Power Grip Belt OK46 01009 0000 Crank Arm Pulley Assembly AK46 00015 0001 Crank Arm OK18 01281 0000 Console Cable Assembly AK19 00081 0001 Idler Arm Bracket OK46 01056 0001 Seat Assy w o Back SK19 00075 0000 Extruded Tube Assembly SK19 00083 0002 Alternator Control Assy AK19 00129 0000 R Alternator Pulley Assy SK17 00106 0000 Roll...

Page 99: ... 01029 0000 Wheel Insert Screws 2 OK17 00101 0932 Leg Cover Washers 2 OK18 01023 0100 Clamps 2 OK18 01104 0002 Clamps 2 OK18 01104 0001 Tabbed Lockwasher OK18 01280 0000 Crankarm Locknut OK18 01059 0002 Pedal w Strap RT AK17 00026 0014 Pedal w Strap LT AK17 00026 0015 Shroud w Decal LT AK19 00113 0002 Shroud Decal LT OK19 01297 0001 End Cap OK19 01136 0000 Shroud w Decal RT AK19 00113 0001 Shroud ...

Page 100: ...Lifecycle 9500RHR Series Exercise Bikes 1 Lifecycle 9500RHR Series Exercise Bikes SECTION V MISCELLANEOUS INFORMATION ...

Page 101: ...Lifecycle 9500RHR Series Exercise Bikes 2 MODEL IDENTIFICATION and SERIAL NUMBER LOCATION Serial Number ...

Page 102: ...g Inside C Outside C Alternator Control C Heatsink C Connectors I I Board I Chain Master Link C L Drive Belt I Crank Bearings I Pedals C L Freewheel Gear C L Freewheel Pulley C I Alternator Flywheel C Plunger Assembly I Seat Rollers C I Seat Pads C Alternator Belt Tension I Wear I Lifepulse sensors C Key C Clean I Inspect R Replace L Lubricate ...

Page 103: ...roblem we have included for your convenience a FAX form on the following page Simply make a copy or copies of the FAX sheet and fill in the necessary information You may FAX us at any time 24 hours a day to either of the numbers shown A Life Fitness service representative will process your order or respond to your problem as quickly as possible ...

Page 104: ...DAY GROUND PARTS ORDER FORM ITEM NO PART NUMBER DESCRIPTION QUANTITY 1 2 3 4 5 6 PRODUCT TROUBLESHOOTING PRODUCT NAME SERIAL NO DETAILED DESCRIPTION OF PROBLEM PRODUCT NAME SERIAL NO DETAILED DESCRIPTION OF PROBLEM TIME RECEIVED TIME COMPLETED TECHNICIAN NAME CUSTOMER SUPPORT SERVICES 10601 W Belmont Ave Franklin Park IL 60131 PHONE 800 351 3737 Toll Free or 708 451 0036 FAX 800 216 8893 Toll Free...

Page 105: ...Lifecycle 9500RHR Series Exercise Bikes 6 MISCELLANEOUS NOTES ...

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