True Fitness 500R Service Manual Download

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Removal & Replacement

600R

Remove Left Side Tensioner Assembly

Step 1.

Remove snap ring.

Step 2.

Slide tensioner assembly off pivot
shaft.

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
bolts are loose.

Summary of Contents for 500R

Page 1: ...anual We reserve the right 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 of such revisions or changes 2004 True Fitness Inc All rights reserved Printed in the United States of America 865 Hoff Road O Fallon MO 63366 1 800 426 6570 Fax 636 272 3026 www truefitness com Revision 9 2004 ...

Page 2: ...ls Screwdrivers 1 Phillips 2 Phillips large flat blade small flat blade short handled flat blade Metric hex key Allen wrench set Metric socket set and ratchet with 6mm to 19mm sizes and 21mm and 34mm sizes Metric combination wrenches with 4mm to 21mm sizes and a 27mm El crank Snap ring pliers both internal and external Rubber mallet Channel lock pliers or standard pliers with a jaw opening of 2 9 ...

Page 3: ...True Fitness Bicycle Service Manual START Symptom guide Wiring Diagrams Parts Manual Removal and Replacement Procedures Page 1 ...

Page 4: ...ction test Press Enter key again all LED s should be on Press Enter key RPM s displayed in the far right window Press Enter key A beep should sound when each key is pressed Press Enter key Hold both handle pick ups Heart symbol will flash and readout will display Press Enter key Press to increase resistance and to decrease resistance To quit diagnostics press Enter key or stop pedaling and the uni...

Page 5: ...r Heart Rate Page 7 600U 600R Irregular or No Display Page 8 No RPM Reading Page 9 No Contact Heart Rate Page 10 Handle Bar Buttons Do Not Function Page 11 750U 750R No Resistance Page 12 Heavy Resistance Page 13 Irregular or No Display Page 14 No Contact Heart Rate Page 15 No Polar Heart Rate Page 16 Page 3 ...

Page 6: ...ard If ECB does not fix connect 6PA and 6PB Check DC volts between pins 2 and 3 Rotate blades of the motor shaft voltage should shift from 0 VDC and 5VDC If voltage does not shift replace EC B Board Check for 6 VDC or more between pins 5 6 on 6 pin PBA ECB board connection If 6 VDC exists but motor doesn t rotate replace motor Check continuity between pins 2 and 4 of 6PB Press lower limit switch I...

Page 7: ...amaged Test for 9VDC output If not 9 VDC then replace adaptor Connect DC plug to Bike Does it seat into the socket properly If not replace adapter or jack Check DC voltage between pins 2 and 4 for 9 VDC on 5PB Page 18 If 9 VDC is found replace the Control Panel Perform continuity checks on all upper and lower cables Replace defective cables If cables OK replace DC Jack Multi meter Support Services...

Page 8: ...between 2 and 5 of 5PB Does continuity change from off to on If yes cables and sensor are good Replace Control Panel If no Go to Defective RPM Set When the sensor is over the pickup continuity will exist When sensor is not over pickup cicuit will be open Perform continuity checks on all upper and lower cables Replace defective cables If cables OK Replace RPM sensor set Multi meter Support Services...

Page 9: ...ontrol Panel If heart rate registers with use of HR simulator but not chest strap replace chest strap If erroneous readings continue check for and eliminate external interference Locate RF sources and use process of elimination Common sources of RF interference are Invisible fences for pets wireless networks cordless phones Cell phones radios home security sensors etc Heart Rate Simulator Support ...

Page 10: ... 5 VDC Replace Control Board Perform continuity checks on all upper and lower cables Replace defective cables Check for AC Voltage between pins 1 and 2 of 3PB and pins 2 and 3 of 3PB Is there AC voltage output in both places If yes replace Control Board Check for AC Voltage between pins 1 and 2 of 3PD and pins 2 and 3 of 3PD Is there AC voltage output in both places If no replace Generator Perform...

Page 11: ...y If Yes Replace Control Panel If No continue to next step Check continuity of RPM Sensor when magnet is in alignment with the sensor there should be continuity when not aligned no continuity If it does not respond properly replace the sensor Check gap on RPM Sensor Perform a continuity check on all upper and lower cables No continuity Replace defective cable Continuity Replace RPM Sensor Set Mult...

Page 12: ...P6B HRLR and pin 2 of 7P6B HRLL and pin 1 of 7P6B Is there continuity If yes replace computer If No continue to the next step Perform a contact and continuity check on cable 600 12P 600 12P coils upper cables and the handle cables Are cables OK If No Replace defective cables If Yes continue on to the next step Remove and carefully check all connections to the contact plates Reconnect loose connect...

Page 13: ...lace handlebar assembly Check for continuity between pin 7 and pin 2 at 10P7B Press Start button See A above Check for continuity between pin 7 and pin 3 at 10P7B Press Shift button See A above Check for continuity between pin 7 and pin 4 at 10P7B Press _ button See A above Check for continuity between pin 7 and pin 5 at 10P7B Press Select button See A above Check for continuity between pin 7 and ...

Page 14: ... continue on DO NOT PEDAL Set meter for resistance Disconnect 3 pin connector at the lower control board Measure resistance between 1 pin and 3 pin Resistance should be 10 ohms 1 ohm If less than 10 Ohms replace power resistance If resistance checks OK continue on DO NOT PEDAL Remove main body cover set meter for continuity Disconnect brake cable from brake and lower board Check continuity of all ...

Page 15: ...et Remove pedal and if 3 piece crank remove crank arm Remove right side cover assembly Disconnect 7 pin connector from the lower control board Pedal If resistance is normal replace cable for console Disconnect 3 pin connector from the brake Resistance still heavy Replace brake Resistance normal Check brake cables for cross continuity Replace lower control board Multi meter Support Services 800 883...

Page 16: ... RPM If No replace Brake If yes continue on Remove pedal and if 3 piece crank remove crank arm Remove right side cover Disconnect 3 wire cable from brake and lower control board Set meter for continuity Check all 3 wires in cable for continuity No continuity Replace cable Set meter for DC volts Reconnect cable to brake and lower control board Pedal Measure for 5 5 7 5 VDC between 1 and 4 wires on ...

Page 17: ...nue on Check wire connections handlebar console mast joint Check connections of wires to hand pulse sensor by removing hand pulse sensor plates To remove hand pulse sensor plates carefully pry under one end to free them from the plastic handgrips Bad connections Reconnect Replace bad wires Recheck continuity Note You must pedal at least 30 RPM when performing any voltage test You may require the a...

Page 18: ...nsole display heart rate with chest strap Does console display heart rate with HR simulator If unit responds with simulator and not chest strap then replace chest strap If unit does not respond with strap or simulator then replace Console set Note You must pedal at least 30 RPM when performing any voltage test You may require the assistance of another person when performing voltage checks Polar He...

Page 19: ...WIRING DIAGRAMS TR TU 500 Page 18 600 U Page 19 600 R Page 20 TR TU 750 Page 21 Page 17 ...

Page 20: ...Page 18 TR TU 500 WIRING DIAGRAM ...

Page 21: ...Page 19 TU 600 WIRING DIAGRAM ...

Page 22: ...TR 600 WIRING DIAGRAM Page 20 ...

Page 23: ...Page 21 TR TU 750 WIRING DIAGRAM ...

Page 24: ...Page 22 ...

Page 25: ...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 26: ...Page 24 ...

Page 27: ...AL 1 SET 12 6 7T001306 HEX NUT SIDE COVER 3 PCS 12 7 7T011200 DECAL WHITE RIGHT 1 PC 12 8 7T001311 SHROUD DECAL B WHITE 1 PC 12 9 7T001312 SHROUD DECAL D WHITE 1 PC 12 10 7T011300 DECAL WHITE LEFT 1 PC 12 11 7T001308 SHROUD DECAL A WHITE 1 PC 12 12 7T001309 SHROUD DECAL C WHITE 1 PC 13 7T001400 PEDALSET WITH STRAPS 1 SET 14 7T004000 HANDLE BAR 6 PIN WITH BOLTS 1 SET 14 1 1 7T004001 CABLE ASSY 6 PI...

Page 28: ...NSE 1 PC 31 7T004800 CABLE ASSY 6 PIN LOWER SECTION 1 PC 7T013000 MODEL DECAL SILVER 1 SET 7T012901 DECAL A SILVER 1 PC 7T012902 DECAL B SILVER 1 PC 7T012903 DECAL C SILVER 1 PC 7T012904 DECAL D SILVER 1 PC 7TU50100 ASSY HDW KIT 1 SET 7TU50200 COMPUTER SCREW KIT 1 SET 7TU60200 FRONT STABILIZER HDW KIT 1 SET 7TU60500 HANDLE BAR HDW KIT 1 SET 7TU60600 CD HOLDER HDW KIT 1 SET 7TU60700 TOOL KIT 1 SET ...

Page 29: ...Page 27 TR 500 Exercise Bike ...

Page 30: ...ud Left Complete w Model Decal and Shroud Decals 1 SET 14 2 7T001302 Screw Side Cover 1 PC 14 3 7T001303 Screw 3 PCS 14 5 7T001305 500R Shroud Right Complete w Model Decal and Shroud Decals 1 PC 14 6 7T001306 Hex Nut Side Cover 3 PCS 14 7 7T001307 Model Decal for 500R Left Wht 1 PC 14 8 7T001308 Shroud Decal A Wht 1 PC 14 9 7T001309 Shroud Decal C Wht 1 PC 14 10 7T001310 Model Decal for 500R Right...

Page 31: ...ever w Bolts 1 SET 34 7T003300 Seatback w Bolts 1 SET 35 7T003400 Seat Shuttle 1 SET 36 7T003500 Bottle Holder w Screws 1 SET 37 7T003600 Rear Handlebar w Bolts 1 SET 38 7T003700 Roller Set C LH Ft RR 2 SET 39 7T003800 DC Jack 1 PC 40 7T003900 Adapter 9vdc1 2a 1 PC 7T013000 Model Decal 7T012901 Decal A 7T012902 Decal B 7T012903 Decal C 7T012904 Decal D 7T012800 Pneumatic Cylinder Seat Back 7TR5010...

Page 32: ...Page 30 ...

Page 33: ...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 ...

Page 34: ...TU 600 PARTS DIAGRAM Page 32 ...

Page 35: ...SET W BEARINGS 1 10 7T005600 J8 POLY V BELT PRIMARY 1 11 7T005200 ALUMINUM IDLER AND IDLER ARM 1 12 7T012400 C RING IDLER ARM 1 13 7T012500 SPRING IDLER ARM 1 14 7T011500 BRAKE KIT 1 14 9 7T007200 BRAKE CABLE 1 15 7T005700 GENERATOR BRACKET SET 16 7T006000 CONTROL BOARD W SCREWS 1 17 7T005900 RESISTOR W SCREWS 1 18 7T005800 RPM SENSOR W WIRE AND NUT 1 19 7T000900 SHROUD TRIM CAP 1 20 7T004300 SEAT...

Page 36: ...EFT 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 STABILIZER SCREW KIT 1 Page 34 ...

Page 37: ...TR 600 PARTS DIAGRAM Page 35 ...

Page 38: ...KIT 1 32 7T002600 REAR STABILIZER W BOLTS 1 33 7T002700 LEVELS W LOCKS 1 34 7T002800 REAR STABILIZER END CAP 2 35 7T002900 ROLLER SET A RT LT FRT 2 36 7T003000 ROLLER SET B RT LT CTR 2 37 7T003100 SEAT BOTTOM W SCREWS 1 38 7T003300 SEATBACK W SCREWS 1 39 7T003200 SEAT ADJ LEVER W BOLTS 1 2 7T000100 FRT STABILIZER W BOLTS 3 7T000200 TRANSPORTS WHEEL KIT 1 4 7T000300 FRT STABILIZER END CAP 2 5 7T011...

Page 39: ...DLR W SCREWS 1 42 7T006600 REAR HNDLBR W SWITCHES BOLTS 1 43 7T003400 SEAT SHUTTLE 1 44 7T006700 THUMB SWITCH ASSY LT 1 45 7T006800 THUMB SWITCH ASSY RT 1 7T011800 MODEL DECAL LT WHITE 7T011900 MODEL DECAL RT WHITE 24 08 7T012901 DECAL A SILVER 24 11 7T012902 DECAL B SILVER 24 9 7T012903 DECAL C SILVER 24 12 7T012904 DECAL D SILVER 7T013000 MODEL DECAL 43 1 7T012800 PNEUMATIC CYLINDER SEAT BK 2 1 ...

Page 40: ...Page 38 ...

Page 41: ...g 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 42: ...Page 40 TU 750 PARTS DIAGRAM 3 PIECE CRANK ...

Page 43: ...9 NYLON NUT SEAT CUSHION 3 D05 7TME0501007 SPRING WASHER SEAT CUSHION 3 J05 7TMB0103001 MOVING WHEEL 2 J07 7TSZCB24RST REAR GROUNDING BAR ASSEMBLY 1 J08 7TMB0304006 REAR FEET PAD 4 J09 7TME0112024 BOLT MOVING WHEEL FT GROUNDING BAR 4 J10 7TME0112044 BOLT REAR GROUNDING BAR ASSEMBLY 2 J11 7TME0502108 WASHER MOVING WHEEL 2 J12 7TMB0705001 MOVING WHEEL COVER 2 P01 7TMC0501027 CONSOLE DATA CABLE 1 P08...

Page 44: ...1012 NUT BRAKE AXLE 2 S05 7TME0502127 WASHER BRAKE TENSION BOLT 2 S06 7TME0502115 WASHER BRAKE AXLE 2 T01 7TSZRB40DAX BOTTOM BRACKET WHEEL ASSY 3 PC CRANK 1 T02 7TMD0405001 LEFT CRANK 1 T03 7TMD0406001 RIGHT CRANK 1 T04 7TMD0402002 PEDALS WITH STRAP 2 SET T05 7TMD0403002 PEDAL STRAP SET OF 2 1 T06 7TMD0602013 POLY V BELT 400 J08 1 T08 7TMB0622001 CRANK COVER CAP 2 T09 7TME01132012 SCREW CRANK ARM ...

Page 45: ...Page 43 TU 750 PARTS DIAGRAM 1 PIECE CRANK ...

Page 46: ...RIM CAP 1 C16 7TMJ1291001 END CAP OF HDLBR 2 D03 7TMB1001018 SEAT CUSHION 1 D04 7TME0204019 NYLON NUT SC 3 D05 7TME0501007 SPRING WASHER ST 3 CUSHION J05 7TMB0103001 MOVING WHEEL 2 J07 7TSZCB24RST REAR GROUNDING BAR 1 ASSEMBLY J08 7TMB0304006 REAR FEET PAD 4 J09 7TME0112024 BOLT MOVING WHEEL 2 FT GROUND BAR J10 7TME0112044 BOLT REAR GROUND 2 BAR ASSEMBLY J11 7TME0502108 WASHER MVG WHEEL 2 J12 7TMB...

Page 47: ...2 WASHER FLYWHEEL 6 ATTACH S01 7TMJ3247002 EYE BOLT BRAKE BLT 2 TENSION S02 7TMJ1245003 HOOK CVR BRAKE 2 BELT TENSION S03 7TME0204010 NYLON NUT BRAKE 2 BELT TENSION S04 7TME0201012 NUT BRAKE AXLE 2 S05 7TME0502127 WASHER BRAKE 2 TENSION BOLT S06 7TME0502115 WASHER BRK AXLE 2 T01 7TSZRB40PAX 1 BTTM BRKT WHEEL 1 T02 7TMD0405001 LEFT CRANK 1 T03 7TMD0406001 RIGHT CRANK 1 T04 7TSM0915027A 1 2 PEDALS W...

Page 48: ...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 ...

Page 49: ... 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 3 Piece Crank TR 750 Exploded Diagram Pg 52 After Serial 02 RE0283C 1 Piece Crank TR 750 Parts List Pg 53 After Serial 02 RE0283C 1 Piece Crank Page 47 ...

Page 50: ...Page 48 ...

Page 51: ...RB40ESR ECCENTRIC SEAT ROLLER ASSY W HARDWARE 1 SET 7TMB0104065 SCREW SEAT LOCK PLATE BRACKET 4 PCS 7TME0104004 SCREW SEAT LEVER FIXTURE PIN 1 PC 7TME0112023 SCREW BULB CONNECTOR SEAT LEVER 1 PC 7TME0204004 NUT CLEVIS 1 PC D28 7TME0112013 SCREW SEAT BOTTOM 4 PCS 7TME0112039 SCREW DIP BAR MOUNT 4 PCS D33 7TME0501006 SPRING WASHER SEAT BACK BOTTOM 8 PCS D34 7TME0112014 SCREW SEAT BACK 4 PCS G06 7TMB...

Page 52: ...P FOR FRONT GROUNDING BAR LH 1 PC Q07 7TMB0609035 END CAP OF REAR GROUNDING BAR R OR L 2 PCS Q08 7TME0104055 SCREW CONTROL PANEL 4 PCS Q11 7TSZRB40SCV L SIDE COVER LEFT WITH DECALS 1 SET Q12 7TSZRB40SCV R SIDE COVER RIGHT WITH DECALS 1 SET R3 7TSZRB40PAX FLYWHEEL SHAFT ASSY WITH TENSIONER 1 SET R06 7TMD0602018 POLY V BELT SECONDARY 1 PC 7TME0104014 SCREW FLYWHEEL 6 PCS 7TME0502092 WASHER FLYWHEEL ...

Page 53: ...TR 750 PARTS DIAGRAM After 08 05 01 and Prior to Serial 02 RE0283C Page 51 ...

Page 54: ...HAND PULSE 4 PCS 053 G12 7TME0201028 NUT HAND PULSE 4 PCS 090 H01 7TSZRB40RAL 1 SEAT RAIL ASSY 1 PC 028 H33 7TMB0103001 TRANSPORT WHEEL 2 PCS 091 H37 7TMZE0112042 BOLT SEAT RAIL 8 PCS 093 H38 7TMZE 0107015 SCREW RAIL AND CAP 2 PCS 094 H39 7TMB0211008 END CAP OF REAR SLIDE TUBE 1 PC 092 H41 7TMB0632007A RAIL CAP END 1 PC 097 J07 7TSZRB40RST REAR STABILIZER 1 PC 024 J08 7TMB0304006 LEVELER 4 PCS 098...

Page 55: ...L COVER 032 7TMZE0112119 BOLT FOOT PAD FRONT 033 7TMB0304020A FOOT PAD FRONT 038 7TMJ1208001 FIXTURE SIDE COVER BOTTOM 1 PC 046 7TME0103022 FLATHEAD SCREW 047 7TME0514002 WASHER 059 FRONT GROUNDING BAR ASSY 1 SET 061 7TME0107043 SCREWS CONTROL BOARD 062 7TME0104014 SCREW FLYWHEEL 6 PCS 063 7TME0502092 WASHER FLYWHEEL 6 PCS 065 7TMJ1245003 HOOK COVER BELT ADJ 2 PCS 066 7TME0204010 NYLON NUT BELT AD...

Page 56: ...Page 54 TR 750 PARTS DIAGRAM After Serial 02 RE0283C 1 Piece Crank ...

Page 57: ...PCS G06 7TMB0401021 HANDLE BAR FOAM GRIP 2 PCS G08 7TMJ1278001 HANDPULSE SENSOR 2 SETS G09 7TMB06A7001 HANDPULSE BRACKET 2 SETS G10 7TMB0609031 HAND PULSE END CAP 4 PCS G11 7TME0102069 SCREW HAND PULSE 4 PCS G12 7TME0201028 NUT HAND PULSE 4 PCS H01 7TSZRB40RAL 1 SEAT RAIL ASSY 1 PC H37 7TMZE0112042 BOLT SEAT RAIL 8 PCS H41 7TMB0632007A RAIL CAP END 1 PC H40 7TMZE0107015 SCREW RAIL AND CAP 2 PCS H3...

Page 58: ... 1 PC R17 7TME0104014 SCREW FLYWHEEL 6 PCS R20 7TME0502092 WASHER FLYWHEEL 6 PCS S01 7TMJ3247001 EYE BOLT BELT ADJUSTER 2 PCS S02 7TMJ1245003 HOOK COVER BELT ADJ 2 PCS S03 7TME0204010 NYLON NUT BELT ADJ 2 PCS S04 7TME0201012 NUT BRAKE AXEL 2 PCS 7TSZRB40PAX 1 BOTTOM BRACKET WHEEL ASSY 1 SET 7TSZRB40KIT BEARING KIT BOTTOM BRACKET WHEEL ASSY 1 SET T04 7TSM0915027A PEDAL SET 1 2 02 XXXXXL 1 SET T05 7...

Page 59: ...True Fitness Removal Replacement 500R 500U 600U 600R Page 57 ...

Page 60: ...sembly Page 69 Remove Crank Hub Assembly Page 72 600U Remove Right Belt Poly V Pulley Page 75 Remove Right Side Tensioner Assembly Page 77 Remove Belt Tensioner Assembly Page 78 Remove Left Side Belt from Assembly Page 81 Remove Left Side Poly V Wheel Page 83 Remove Crank Hub Assembly Page 84 600R Remove Left Belt Poly V Pulley Page 87 Remove Left Side Tensioner Assembly Page 89 Remove Belt Tensio...

Page 61: ...ve 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 counter clockwise Step 1 Remove Pedals Step 2 Remove Cover Screws ...

Page 62: ...t 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 only Step 1 Remove Electrical Connection 500 series only Step 2 Remove Cover ...

Page 63: ...e 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 Set Screw Tools Required 4 mm Hex Wrench Flat blade Screwdriver Hammer Handle ...

Page 64: ... 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 5 Remove Belt ...

Page 65: ... 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 Snap Ring Pliers Step 1 Remove Small Poly V Pulley Step 2 Remove Keyway ...

Page 66: ...500R Remove Belt Tensioner 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 ...

Page 67: ...escent 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 Step 2 Remove Keyed Washer Note The crank nut has left handed threads Turn clockwise to loosen Note The hex nut bearing has left handed threads Turn clockwise to loosen Step 3 Remove Hex Nut Bearing ...

Page 68: ...escent 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 pulley to clear frame ...

Page 69: ...ammer 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 Frame Step 7 Drive spanner nut off to remove bearing Note Right hand thread Note Pulley and crank are a welded assembly cannot be separated Step 8 Remove Bearing Washer ...

Page 70: ...se 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 Set Screw Tools Required 4 mm Hex Wrench Flat blade Screwdriver Hammer Handle Caution Take care not damage outer surface of flywheel on brake assembly ...

Page 71: ... 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 ...

Page 72: ...sembly 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 ...

Page 73: ...tinued 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 ...

Page 74: ...Use rubber mallet to knock out the shaft pulley assembly Copyright 2001 True Fitness Technology Inc Page 72 Step 1 Remove Crank Nut Step 3 Remove Hex Nut Bearing Step 2 Remove Keyed Washer Tools Required Large Crescent Wrench Rubber Mallet Flat Blade Screwdriver Note The crank nut has left handed threads Turn clockwise to loosen Note The Hex nut bearing has left handed threads Turn clockwise to lo...

Page 75: ...rge pulley until bearing clears Frame Step 6 Twist assembly thru frame hub Pull assembly until clear of frame Copyright 2001 True Fitness Technology Inc Page 73 Step 4 Pull Hex Nut Bearing Free Note A flat blade screwdriver may be used to pry hub from frame Step 4 Pull Hex Nut Bearing Free Step 5 Twist Unit Thru Hub Frame ...

Page 76: ...g 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 has right handed threads Turn counter clockwise to loosen Note Pulley and crank are a welded assembly cannot be separated ...

Page 77: ...y 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 ...

Page 78: ... 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 snap ring and washers Step 5 Remove the small poly V pulley ...

Page 79: ...ve 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 bolts are loose ...

Page 80: ... 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 Hammer Handle Step 1 Remove Locking Screw Step 2 Loosen Bracket Bolts Note Frame is slotted to allow brake bracket to slide when bolts are loose ...

Page 81: ...d 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 Belt ...

Page 82: ... 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 Step 6 Remove Loosened Screws ...

Page 83: ... 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 External Snap Ring Pliers Flat Blade Screwdriver ...

Page 84: ... continued Step 4 Use 4 mm Hex Wrench to remove Screws and washers holding Brake to bracket Step 5 Remove brake bracket until belt Can be removed Copyright 2001 True Fitness Technology Inc Page 82 Step 4 Remove Screws Washers Step 5 Remove Bracket to Check Belt ...

Page 85: ...e 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 Through Frame Note Crank not welded to pulley so 1 extra step showing separating these for 600U set ...

Page 86: ...Use rubber mallet to knock out the shaft pulley assembly Copyright 2001 True Fitness Technology Inc Page 84 Step 1 Remove Crank Nut Step 3 Remove Hex Nut Bearing Step 2 Remove Keyed Washer Tools Required Large Crescent Wrench Rubber Mallet Flat Blade Screwdriver Note The crank nut has left handed threads Turn clockwise to loosen Note The Hex nut bearing has left handed threads Turn clockwise to lo...

Page 87: ...ge pulley until bearing clears Frame Step 6 Twist assembly thru frame hub Pull assembly until clear of frame Copyright 2001 True Fitness Technology Inc Page 85 Step 4 Pull Hex Nut Bearing Free Note A flat blade screwdriver may be used to pry hub from frame Step 5 Remove Large Pulley Assembly Step 6 Twist Unit Thru Hub Frame ...

Page 88: ...ng 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 Bearing Washer Note The spanner nut has right handed threads Turn counter clockwise to loosen Note Pulley and crank are a welded assembly cannot be separated Step 9 Pull Crank Thru Pulley to Remove ...

Page 89: ...ulley 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 ...

Page 90: ...ley 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 ...

Page 91: ...ve 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 bolts are loose ...

Page 92: ... 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 Handle Step 1 Remove Locking Screw Step 2 Loosen Bracket Bolts Note Frame is slotted to allow brake bracket to slide when bolts are loose ...

Page 93: ...d 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 Belt ...

Page 94: ... 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 Step 6 Remove Loosened Screws ...

Page 95: ... 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 External Snap Ring Pliers Flat Blade Screwdriver ...

Page 96: ...y continued Step 4 Use 4 mm Hex Wrench to remove Screws and washers holding Brake to bracket Step 5 Remove brake bracket until belt Can be removed Copyright 2001 True Fitness Technology Inc Page 94 Step 4 Remove Screws Washers Step 5 Remove Bracket to Check Belt ...

Page 97: ...haft 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 Shaft Through Frame Note Crank not welded to pulley so 1 extra step showing separating these for 600U set ...

Page 98: ...Use rubber mallet to knock out the shaft pulley assembly Copyright 2001 True Fitness Technology Inc Page 96 Step 1 Remove Crank Nut Step 3 Remove Hex Nut Bearing Step 2 Remove Keyed Washer Tools Required Large Crescent Wrench Rubber Mallet Flat Blade Screwdriver Note The crank nut has left handed threads Turn clockwise to loosen Note The Hex nut bearing has left handed threads Turn clockwise to lo...

Page 99: ...ge pulley until bearing clears Frame Step 6 Twist assembly thru frame hub Pull assembly until clear of frame Copyright 2001 True Fitness Technology Inc Page 97 Step 4 Pull Hex Nut Bearing Free Note A flat blade screwdriver may be used to pry hub from frame Step 5 Remove Large Pulley Assembly Step 6 Twist Unit Thru Hub Frame ...

Page 100: ...ng 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 Bearing Washer Note The spanner nut has right handed threads Turn counter clockwise to loosen Note Pulley and crank are a welded assembly cannot be separated Step 9 Pull Crank Thru Pulley to Remove ...

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True Fitness 500R, Service Manual

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Summary of Contents for 500R

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