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XR895 Service Manual

Release

Lever console

Front Stabilizer Cover

Round Disk Cover

Rear Stabilizer Cover Bottom Cover Console Mast Cover

Rear Chain Cover (L) Cup Holder (R) Front Chain Cover (R)

Cup Holder (L) Rear Chain Cover (R) Front Chain Cover (L)

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Summary of Contents for XR895

Page 1: ...l Release Lever console Front Stabilizer Cover Round Disk Cover Rear Stabilizer Cover Bottom Cover Console Mast Cover Rear Chain Cover L Cup Holder R Front Chain Cover R Cup Holder L Rear Chain Cover R Front Chain Cover L ...

Page 2: ...Structure Seat Back Frame Seat Carriage Handle Console Mast Seat Handle Bar Rear Stabilizer Controller Mainframe Flywheel Drive Pulley Cylinder Aluminum Rail Crank Idle Arm ...

Page 3: ...lt and Idle Arm 6 Drive Pulley Axle and Drive Pulley 7 Generator Flywheel 8 Cylinder 9 Seat Back 10 Rear Chain Cover 11 Sliding Seat 2 Problem Solving 1 Console 2 Chain Covers and Round Disk Cover 3 Belt and Idle Arm 4 Generator Flywheel 5 Cylinder 6 Sliding Seat 3 Q A 1 Noise 2 Slippage 3 Smoothness 4 Other Problems ...

Page 4: ...16 x15 Hex Head Screws 68 2pcs of ψ8x1 5T Split Washers and 2pcs of 5 16 x19x1 5T Flat Washers 76 and the Handlebar Assembly 3 can be released 2 Reverse the above step to resume the Handlebar Assembly 3 3 Release the Console Mast Cover by flapping or pressing it with hand as shown in the figure below Use 12 m m wrench to unscrew 6pcs of 5 16 x15 Hex Head Screws 68 together with 4pcs of 5 16 x19x1 ...

Page 5: ... x 19 x 1 5T Flat Washers 76 and 2pcs of 5 16 x20x 1 5Tcurved Washers 83 3 Disassembling Assembling of Cranks 51L 51R and Pedals 116 117 1 Use 13 15m m wrench to turn the Left Pedal 116 clockwise and Right Pedal 117 counterclockwise to disassemble these two pedals 2 To resume the pedals turn the pedals with reversal orientations 3 Take off the Crank Arm End Cap 28 and release the M10x1 0 Nut 108 b...

Page 6: ... 4 Disassembling Assembling Front Chain Covers 1 To release Left Front Chain Cover 29 use Phillips Head Screw Driver to release 7pcs of ψ 3 5x12 Self Tapping Screws 103 and 2pcs of 5x16 Tapping Screws 102 2 To release Right Front Chain Cover 30 on the mainframe unscrew 2pcs of ψ3 5x20 Self Tapping Screws 107 with 2pcs of ψ5 x16x1 5Tflat Washers 78 then on the Right Front Chain Cover unscrew 2pcs o...

Page 7: ...in Cover 30 and secure both covers with 7pcs ofψ3 5x12 Self Tapping Screws 103 and then 2pcs of 5x16 Tapping Screws 102 5 Disassembling Assembling Belt 54 and Idle Arm 10 Note Must be done after Front Chain Covers L and R 29 and 30 have been released 1 Use 13 m m wrench to release M8x7T Nut 88 and take off the J Bolt 87 2 Use Phillips Head Screw Driver to unscrew 3pcs of M6x7T Phillips Head Screws...

Page 8: ...xle 8 and Drive Pulley 20 Note Must be done after Front Chain Covers L and R 29 and 30 have been released 1 Use C ring pliers to take offψ20 C ring 86 axle and the Drive Pulley Axle 8 can be released 2 To release the Drive Pulley use 2pcs of wrench to unscrew 4pcs of 1 4 x3 4 Hex Head Screws 66 with 8pcs of 1 4 x13x1T Flat Washers 72 and 4pcs of 1 4 x5T Nut 90 3 Reverse the above steps to resume D...

Page 9: ...ke off Cup Holders 38 39 2 Use M5 Allen Wrench Phillips Head Screw Driver Combination 115 to take off the Release Lever 40 3 Use wrench to release adjusting nut on the Seat Recline Release Cable 58 to take off the cable 4 Use 12 m m and 13 m m wrenches to unscrew the 5 16 x1 3 4 Grade 8 Hex Head Screw 70 with 5 16 x 19 x 1 5T Flat Washer 76 and 5 16 x 6T Nut 91 which are under the Set Back Frame 5...

Page 10: ...Release Cable 58 to the Cylinder 57 Use 5 16 x1 3 4 Grade 8 Hex Head Screw 70 5 16 x 19 x 1 5T Flat Washer 76 and 5 16 x 6T Nut 91 to secure the other end of Cable 58 onto the Seat Back Frame 5 Secure the Plastic Seat Carriage Cover with M5x12 Phillips Head Screws 99 9 Disassembling Assembling Seat Back Frame 5 1 Use 2pcs of 14 m m wrenches to unscrew 2pcs of 3 8 x4 Hex Head Screws 67 with 3 8 x7T...

Page 11: ...e Right Rear Chain Cover 36 can be released 3 To resume the Right Rear Chain Cover 36 secure the Cover onto the mainframe withψ3 5x20 Self Tapping Screws 107 withψ5 x16x1 5T Flat Washers 78 and 2pcs of 5x16 102 Tapping Screws To resume Left rear Chain Cover 35 plug in the Handpulse Wires 26 then match Left and Right Chain Covers and secure with 7pcs ofψ3 5x12Self tapping Screws 103 and 2pcs of 5x1...

Page 12: ...to release Left Release Lever 40 5 Use 2pcs of 14 m m wrench to unscrew 4pcs of 3 8 1 3 4 Hex Head Screws 71 4pcs of 3 8 x 19 x 1 5T Flat Washers 77 and 4pcs of 3 8 x 7T Nuts 89 to release Seat Handle Bar 6 6 Use M5 Allen Wrench Phillips Head Screw Driver Combination 115 and 8 m m wrench to unscrew M6 x40mm Socket Head Cap Screw 93 with M6 Nut 129 and the Seat Positioning Latch 12 Seat Recline Rel...

Page 13: ...19 x 1 5T Flat Washers 77 and 4pcs of 3 8 x 7T Nuts 89 then use M5 Allen Wrench Phillips Head Screw Driver Combination 115 to secure Release Lever 40 on Seat Handle Bar 6 2 Problem Solving 1 Console When the display is blank check the following 1 Make sure the computer cable is insert onto the console properly 2 The connecting cables between the generator flywheel and the controller are plug in pr...

Page 14: ...part which is misaligned is required The Idle Arm 10 must be replaced if it is misaligned Slippage Tightening M8x7T Nut 88 on M8 x 170J Bolt 87 will fix the problem 5 Cylinder 1 8 If the cylinder cannot function properly replace it following Step 8 6 Seat Carriage 1 If the seat wobbles follow step 11 8 to secure the seat carriage 2 It the Seat Carriage cannot move smoothly refer to step 11 8 to di...

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