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Nautilus Schwinn 800IC, Service Manual

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Nautilus Schwinn 800IC Service Manual Download Page 59

59

Speed Sensor

Speed Sensor 

Magnet

25.

  Re-install all remaining parts that were removed in reverse order.

 NOTICE:

   Do not crimp any cables. Install the Flywheel Tensioners 

at the position that you recorded in step 15. Make sure 

the Flywheel can turn easily. Verify that the Speed 

Sensor and Speed Sensor Magnet on the Flywheel do 

not touch.

Re-install the Fender, making sure the Resistance Cable is routed 

between the Frame and the top of the Fender. 

Installation does not require the use of the Crank Puller. Be sure the 

Crank Arms are connected at 180° from each other. 

26.

  Make sure that the Drive Belt tension is correct. Refer to the “Adjust 

the Belt Tension” procedure.

27.

  Add Loctite

®

 272 (or equivalent) to the inner threads of the Crank 

Nut. Do not to apply the Loctite

®

 272 to the Crank Shaft.

Resistance Cable

Fender

Crank Nut

Summary of Contents for Schwinn 800IC

Page 1: ...aintenance 5 1 Moving Storing the Machine 6 1 Leveling the Machine 6 1 Heart Rate Armband 7 1 Adjustments 8 1 Locking the Flywheel for Storage 9 1 Troubleshooting 10 1 Maintenance Parts Exploded View...

Page 2: ...or replacement labels If purchased outside US Canada contact your local distributor for them Do not try to change the design or functionality of the machine being serviced as this can adversely affect...

Page 3: ...r is encouraged to try to correct the interference by one or more of the following measures Reorient or relocate the receiving antenna Increase the separation between the equipment and receiver Consul...

Page 4: ...product as refuse This product is to be recycled For proper disposal of this product please follow the prescribed methods at an approved waste center 77 9 cm 30 7 in 138 6 cm 54 6 in 131 6 cm 51 8 in...

Page 5: ...eekly Check pedals and tighten as necessary Since this machine operates with a fixed gear do not back or reverse pedal Doing so may loosen the Pedals which could result in damage to the machine and or...

Page 6: ...r safe storage of the machine remove the power supply and place in a secure location Tighten the Brake Resis tance Adjustment Knob as described until the Flywheel is locked Place the machine in a secu...

Page 7: ...worn on the upper portion of your forearm with the Heart Rate Sensor to the inside of your forearm It should be snug enough not to move around on your arm but not so tight that it restricts blood cir...

Page 8: ...Adjustment Foot pedals with straps provide secure footing to the exercise bike 1 Put the ball of each foot in the Foot Restraint on the Pedals 2 Fasten the strap over the shoe 3 Repeat for the other f...

Page 9: ...nd push it back in to reposition it Continue turning as needed Locking the Flywheel for Storage When the machine is not in use be sure to lock the Flywheel with the Emergency Brake Resistance Adjustme...

Page 10: ...Sensor Make sure the RPM Sensor Magnet and the RPM Sensor are in place No Speed RPM reading Check data cable integrity All wires in cable should be intact If any are cut or crimped replace cable Check...

Page 11: ...ensor or the connecting wire Contact Customer Service if inside US Canada or your local distributor if outside US Canada Unit rocks does not sit level Check level adjustment Levelers may be turned to...

Page 12: ...ap E Seat Post Adjustment Knob P Power Inlet AA Pedal w Foot Restraint F Brake Resistance Knob Q Front Stabilizer BB Axle Nut G Console R Transport Wheel CC Flywheel Retainer Nut H Media Tray S Levele...

Page 13: ...edgeable about mechanical procedures Disconnect all power to the machine before you service it When disposing of old parts obey the applicable local and provincial requirements For instructions to rep...

Page 14: ...ponents Do not try to do heavy or awkward steps on your own Use only replacement parts and hardware that are supplied or approved by Nautilus Failure to use Nautilus approved replacement parts can adv...

Page 15: ...Drive Belt slips continue to step 3 3 Using a flathead screwdriver remove the threaded Cap from the right Crank Arm 4 Using a 16mm socket and wrench remove the Flange Nut under the threaded Cap 5 Thr...

Page 16: ...Push the Drive Belt downward at the midpoint M between the pulleys and measure the distance The Drive Belt should have only 0 25 0 64 cm of give Or Hold the edges of the Drive Belt at the midpoint M a...

Page 17: ...the Frame Be sure the Flywheel Axle does not touch the Drive Belt inside 13 Remove the right Pedal and Crank Arm Reinstall the Drive Belt Cover Crank Arm and Pedal 14 Add Loctite 272 or equivalent to...

Page 18: ...away from the product being serviced at all times Disconnect all power to the machine before you service it Make sure that the repair is done in an appropriate work space away from foot traffic and e...

Page 19: ...alibrated and is the one flashing Turn the Resistance Knob counter clockwise until it is unable to turn and then turn it clockwise a quarter of a turn 5 Push the START ENTER button to set this value a...

Page 20: ...ew 100 Configured Value The Console will update the displayed value 10 Unplug the machine from the power adapter for 5 minutes and then plug it back into the machine The Console will activate with the...

Page 21: ...awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own Use only replacement parts and hardware that...

Page 22: ...sconnect the Cables that connect the Console to the Frame Assembly NOTICE Do not crimp any cables 5 Being prepared to support the Handlebars loosen the Handlebar Post Adjustment Handle and remove the...

Page 23: ...g exposed behind the Threaded Cap from the Frame Assembly or safely tilt the machine until the Wedge Bushing falls from the Frame Assembly Note Be sure to notice how the Wedge Bushing engages within t...

Page 24: ...everse order 11 Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembled Do not use until the machine has been fully assembled and inspected for...

Page 25: ...before working on the machine Failure to obey the instructions and safety warnings could cause injury to the service technician or bystanders Keep bystanders and children away from the product being...

Page 26: ...reassembly NOTICE Hold the Brake Cover so that it does not fall 3 Loosen the Resistance Knob to the minimum resistance setting 4 Loosen and remove the hardware indicated by arrows that attaches the E...

Page 27: ...nto the opening of the Emergency Brake Pad to keep it in place and install the hardware from the other side 7 Reinstall the Fender NOTICE Do not crimp the cable 8 Adjust the Resistance Knob as necessa...

Page 28: ...on when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own Use only replacement parts and hardware that are supplied or approved by Nautilus Failur...

Page 29: ...inimum resistance setting 4 Using a small 2 3mm steel pin and hammer push the Roll Pin out of the Collar and Resistance Adjustment Shaft You may need to push down slightly on the Resistance Knob at th...

Page 30: ...ing the bike upside down 7 Using a 2 Phillips screwdriver remove the hardware indicated by ovals that secures the Resistance Sensor Allow the Resistance Sensor to hang from the Cable NOTICE Do not cri...

Page 31: ...side the square mount until the Shaft is threaded through the Square Spacer 11 Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembled Do not u...

Page 32: ...d exposure to bystanders Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy...

Page 33: ...de for reassembly Note The Left Pedal is reverse threaded Orientation is based from a seated position on the bike The Left Pedal has an L the Right Pedal an R 3 Using a flathead screwdriver remove the...

Page 34: ...as shown before use 6 Using a 15mm wrench turn the inner portion CP3 of the Crank Puller clockwise The Crank Arm will slide off as it is tightened Discard the old parts 7 Place the new Crank Arms onto...

Page 35: ...started by several hand turns into the Crank Arm fully tighten it with the Pedal Wrench 13 Confirm that the Pedal is fully tightened with the Pedal Wrench 14 Repeat with the other Pedal Note Be sure...

Page 36: ...only replacement parts and hardware that are supplied or approved by Nautilus Failure to use Nautilus approved replacement parts can adversely affect the safety and functionality of the equipment cre...

Page 37: ...3 Using a 16mm socket and wrench remove the Crank Nut under the threaded Cap 4 Thread the Crank Puller into the Crank Arm A When the Crank Puller is in the correct position only 1 2 threads on the ou...

Page 38: ...that it does not fall 7 Loosen the Resistance Knob to the minimum resistance setting 8 Using a 2 Phillips screwdriver remove the hardware indicated by ovals that secures the Resistance Sensor Allow th...

Page 39: ...s screwdriver remove the indicated hardware from the Drive Belt Cover Carefully remove the Drive Belt Cover and set it safely aside for reassembly Note The oval indicates the two machine screws with w...

Page 40: ...e outer Flywheel Retainer Nut from the Tensioner Eyebolt Remove the Tensioner Eyebolt and inner Retaining Nut from the Flywheel Axle and Tensioner Support Bracket Set the Tensioner hardware aside for...

Page 41: ...fully walk the Drive Belt onto the Drive Pulley Make sure the Drive Belt is aligned on the Flywheel Pulley and Drive Pulley Be sure to keep fingers clear of all pinch hazards as you turn the Drive Pul...

Page 42: ...to the Crank Shaft and fully tighten it 26 Replace the threaded Cap onto the Crank Arm 27 Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembl...

Page 43: ...nvolving these components Do not try to do heavy or awkward steps on your own Use only replacement parts and hardware that are supplied or approved by Nautilus Failure to use Nautilus approved replace...

Page 44: ...Flange Nut under the threaded Cap 5 Thread the Crank Puller into the Crank Arm A When the Crank Puller is in the correct position only 1 2 threads on the outer portion CP2 of the Crank Puller should...

Page 45: ...NOTICE Installation of the Crank Arms does not require the use of the Crank Puller Be sure the Crank Arms are connected at 180 from each other 10 Final Inspection Inspect your machine to ensure that...

Page 46: ...ur own Use only replacement parts and hardware that are supplied or approved by Nautilus Failure to use Nautilus approved replacement parts can adversely affect the safety and functionality of the equ...

Page 47: ...3 Using a 16mm socket and wrench remove the Crank Nut under the threaded Cap 4 Thread the Crank Puller into the Crank Arm A When the Crank Puller is in the correct position only 1 2 threads on the ou...

Page 48: ...se disregard the Right Crank Arm in the above image It was removed during an earlier step 7 Record the number of threads showing on the Tensioner Eyebolt on each side of the Tensioner Support Bracket...

Page 49: ...remove the Snap Ring from the Pulley Shaft Assembly on the left side 12 Using eye protection and a rubber mallet or wooden block and hammer gently strike the Pulley Shaft Assembly from the left side o...

Page 50: ...ler Be sure the Crank Arms are connected at 180 from each other 15 Make sure that the Drive Belt tension is correct Refer to the Adjust the Belt Tension procedure 16 Add Loctite 272 or equivalent to t...

Page 51: ...service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own Use only replacement parts and hardware that are supplied or ap...

Page 52: ...t fall 3 Remove the Fender from the front of the machine after noting how the Resistance Cable routes through it NOTICE Do not crimp the cable 4 Install the new Fender making sure the Resistance Cable...

Page 53: ...eavy or awkward steps on your own Use only replacement parts and hardware that are supplied or approved by Nautilus Failure to use Nautilus approved replacement parts can adversely affect the safety a...

Page 54: ...of the Crank Puller should show Note Be sure the end of the Bolt CP1 in the Crank Puller is flush with the inner surface CP2 as shown before use 6 Using a 15mm wrench turn the inner portion CP3 of the...

Page 55: ...ugh it Place the Fender outside the work area 9 Loosen the Resistance Knob to the minimum resistance setting 10 Using a 2 Phillips screwdriver remove the hardware indicated by ovals that secures the R...

Page 56: ...g a 3 5mm hex wrench remove the hardware indicated by ovals that attaches the Brake Assembly to the Resistance Nut from both sides of the machine Carefully remove the Brake Assembly NOTICE Be prepared...

Page 57: ...bolt Remove the Tensioner Eyebolt and inner Retaining Nut from the Flywheel Axle and Tensioner Support Bracket Set the Tensioner hardware aside for reassembly NOTICE It may be necessary to move the Fl...

Page 58: ...ywheel Drive Pulley Drive Belt Flywheel Pulley Drive Belt Speed Sensor and Spacer Thin Nut 20 Remove the Drive Belt from the Flywheel Pulley to the outside Remove the Thin Nut from the right end of th...

Page 59: ...the Flywheel do not touch Re install the Fender making sure the Resistance Cable is routed between the Frame and the top of the Fender Installation does not require the use of the Crank Puller Be sure...

Page 60: ...lace the threaded Cap onto the Crank Arm 30 Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembled Do not use until the machine has been fully...

Page 61: ...hese components Do not try to do heavy or awkward steps on your own Use only replacement parts and hardware that are supplied or approved by Nautilus Failure to use Nautilus approved replacement parts...

Page 62: ...of the Crank Puller should show Note Be sure the end of the Bolt CP1 in the Crank Puller is flush with the inner surface CP2 as shown before use 6 Using a 15mm wrench turn the inner portion CP3 of the...

Page 63: ...ut Flywheel Bracket Tensioner Eyebolt Tensioner Support Bracket 8 Mark the position of the Flywheel Axle Nut on the Flywheel Bracket Also record the number of threads showing on the Tensioner Eyebolt...

Page 64: ...stall the Flywheel Tensioners at the position that you recorded in Step 9 Make sure the Flywheel can turn easily and is centered on the Brake Assembly Installation does not require the use of the Cran...

Page 65: ...ce steps involving these components Do not try to do heavy or awkward steps on your own Use only replacement parts and hardware that are supplied or approved by Nautilus Failure to use Nautilus approv...

Page 66: ...Bushing skip to Step 15 5 Disconnect the Cables that connect the Console to the Frame Assembly NOTICE Do not crimp any cables 6 Being prepared to support the Handlebars loosen the Handlebar Post Adju...

Page 67: ...turer as regards to the proper and safe use of the Heat Gun Do not grasp any items or surfaces that have been heated without the proper heat resistant materials 9 Use the small standard screwdriver to...

Page 68: ...Post Bushing 11 With the Handlebar Post Bushing released place the end of the screwdriver under the lip of the Bushing Pivot upward until the Handlebar Post Bushing is released Continue pushing upwar...

Page 69: ...Assembly 17 On the left side of the Seat Post there is a small opening indicated by oval where the Seat Post Bushing Tab is secured Place the end of a small standard screwdriver into the opening and...

Page 70: ...nd will set into the small opening 20 Re install all remaining parts that were removed in reverse order 21 Final Inspection Inspect your machine to ensure that all hardware is tight and components are...

Page 71: ...to the machine before you service it Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Some components of the equipment can be heavy or a...

Page 72: ...e Pedal Note The Left Pedal is reverse threaded Orientation is based from a seated position on the bike The Left Pedal has an L the Right Pedal an R 3 Apply Loctite 242 or equivalent to the pedal thre...

Page 73: ...Pedal is fully tightened with the Pedal Wrench 7 Repeat with the other Pedal Note Be sure to check the Pedals weekly to confirm that they are fully tightened Since this machine operates with a fixed...

Page 74: ...Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own Use only replacement parts and hardware that are supp...

Page 75: ...e images provided exactly 1 Unplug the AC Adapter from the wall outlet and machine 2 Fully turn the Resistance Knob clockwise to lock the Flywheel into place 3 Remove the Console Cable Grommet from th...

Page 76: ...Gently push the Console Cable into the Frame Assembly up to where the Resistance Cable joins it which is about 2 5cm 1 5 Using a 14mm Open Faced Wrench remove the securing ring from the Power Inlet R...

Page 77: ...move the old Power Inlet Cable from the Power Input Connection and replace with the new Power Inlet Cable 9 Gently pivot the Power Inlet Cable into place on the Frame Assembly and secure it to the Fra...

Page 78: ...p the Cable 13 Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembled Do not use until the machine has been fully assembled and inspected for...

Page 79: ...e heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own Use only replacement parts and har...

Page 80: ...by ovals that secures the Resistance Sensor Allow the Resistance Sensor to hang from the Resistance Cable NOTICE Do not crimp the cable 5 Remove the old Resistance Sensor from the end of the Resistanc...

Page 81: ...he Console displays four values with one of them flashing Note The Magnetic Resistance Sensor can only be calibrated three times If the Console displays the Calibration Round as 3 then it cannot be ca...

Page 82: ...Flywheel can move by turning it If the Flywheel cannot turn the Resistance Knob has been turned too far Go back to Step 14 17 Push the START ENTER button to set this value as the new 100 Configured Va...

Page 83: ...or awkward steps on your own Use only replacement parts and hardware that are supplied or approved by Nautilus Failure to use Nautilus approved replacement parts can adversely affect the safety and fu...

Page 84: ...f the Crank Puller should show Note Be sure the end of the Bolt CP1 in the Crank Puller is flush with the inner surface CP2 as shown before use 6 Using a 15mm wrench turn the inner portion CP3 of the...

Page 85: ...ugh it Place the Fender outside the work area 9 Loosen the Resistance Knob to the minimum resistance setting 10 Using a 2 Phillips screwdriver remove the hardware indicated by ovals that secures the R...

Page 86: ...s screwdriver remove the indicated hardware from the Drive Belt Cover Carefully remove the Drive Belt Cover and set it safely aside for reassembly Note The oval indicates the two machine screws with w...

Page 87: ...ench Remove the Flywheel Axle Nuts from the Flywheel Axle Set the hardware safely aside for reassembly 17 Using a 10mm wrench loosen and remove the outer Flywheel Retainer Nut from the Tensioner Eyebo...

Page 88: ...refully remove the Speed Sensor and Spacer from the Axle Set the old Speed Sensor safely aside NOTICE This step may require two people 22 Put the new Speed Sensor and Spacer in position on the Axle Re...

Page 89: ...Cable to the harness plug and push the connection into the Left Frame Upright 26 Reinstall the Lower Rubber Grommet in the lower opening in the Left Frame Upright to hold the Speed Sensor Cable in po...

Page 90: ...e 29 Add Loctite 272 or equivalent to the inner threads of the Crank Nut Do not to apply the Loctite 272 to the Crank Shaft 30 Install the Crank Nut onto the Crank Shaft and fully tighten it 31 Replac...

Page 91: ...you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own Use only replacement parts and hardware that are supplied or approved by Nautilus Failure to us...

Page 92: ...llips screwdriver loosen and remove the hardware indicated on one side by ovals that attaches the Fender to the Main Frame Set the hardware safely aside for reassembly NOTICE Hold the Fender so that i...

Page 93: ...aptures the Resistance Cable Note The Resistance Cable Grommet is needed for shipment of the machine only The Grommet does not need to be re installed and can be discarded 10 Remove the Speed Sensor G...

Page 94: ...94 12 Attach a string to the end of the Speed Sensor Connection NOTICE Do not crimp the Cable 13 Using a 14mm Open Faced Wrench remove the securing ring from the Power Inlet Power Inlet Securing Ring...

Page 95: ...er Inlet Grommet that is on the other side of the Frame Assembly from the Power Inlet 15 From the Power Inlet Grommet opening gently pull the Power Inlet Cable from the Frame Assembly 16 Remove the Po...

Page 96: ...release them 19 Holding the new Wiring Harness next to the old one remove the string from the old Speed Sensor Connection and attach it to the new Speed Sensor Connection Be sure that it is the Speed...

Page 97: ...Grommet Be sure not to push it into the Frame Assembly 27 Replace the Speed Sensor Grommet NOTICE Do not crimp the Cable 28 Replace the Console Cable Grommet NOTICE Do not crimp the Cable 29 Connect...

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