NEW Express 100 assembly guidev1.0.qxd 3/12/2003 4:05 PM Page 1
U N P A C K I N G
Unpack your Exercise Bike where you will be using it. Place your bike on a level flat surface. It is recommended that you place a protective cov- ering on your floor. You will only need to attach
STEP 1
STEP 4 STEP 5
the following items. Verify that the following parts and tools are included:
Parts | Tools (included) | |||
• | 1 | Rear Foot Tube | • | 5mm Allen Wrench/ |
• | 1 | Handlebar Set | Phillips Screw Driver | |
• | 1 | Seat Post | • | Flat Wrench |
•1 Seat
•1 Console Mast
•1 Console Mast Boot
•2 Mobile Wheels
•1 Console
•2 AA Batteries
•2 Pedals
•2 Wheel Sleeves
•1 Tension Knob
•1 Hardware Pack (contents listed below)
H a r d w a r e (Actual Size)
A)45mm Bolt Quantity: 2
B)90mm Bolt Quantity: 2
Attach the Front Foot Wheels
a. Insert the wheel sleeves on each side of the front wheel tube.
b. Align the holes in the wheel sleeves with the holes in the wheel tube. Insert two 12mm screws (D) and secure with the screwdriver.
c.Attach the mobile wheels to the wheel sleeves. Insert two 14mm washers (F) and two 20mm bolts
(G) and secure with a screwdriver.
STEP 2
Attach the Rear Foot Tube and Pads
a. Align the holes of the rear foot tube with the holes in the base frame.
b. Insert two 90mm bolts (B), two 20mm arc washers (J) and acorn nut (H) secure with a 5mm allen wrench.
c. Slide the rear foot pads to each end of the rear foot tube.
STEP 3
Attaching the Console Mast
A S S E M B L Y G U I D E
Express
100
CONSOLE
SEAT
GRIP PULSE
CONSOLE DATA CABLE |
TENSION KNOB |
HANDLEBARS |
Connecting the Tension Knob
a. Remove the 20mm long bolt (H) on the back of the tension knob.
b. Turn the tension knob to level 15. Connect the tension knob to the bottom of the tension knob cable (Figure A, Step 2).
c. Grasp the tension knob and firmly pull the tension knob assembly away from the machine in order to attach to the top of the tension knob cable (Figure B, Step 3). Make sure that the copper cable end is seated properly into the "key hole".
d. Insert the tension knob into the rec- tangular opening on the console mast (Figure C, Step 5).
e. Secure the tension knob with the 20mm bolt (H) by using a screw driver (Figure D, Step 6).
I
M
1
2
Figure A
Attaching the Handlebars
a. Align the holes in the handlebars with the holes in the console mast.
b. Insert two 45mm bolts (A) and two washers (E) and secure with a 5mm allen wrench.
STEP 6
Attaching the Console
a. Open the battery cover on the back of the console, insert two AA batteries into the console and replace the battery cover.
b. Connect the cables from the con sole to the console cables running through the console mast, mak- ing sure that both ends snap togeth- er tight.
c. Attach the console to the console mast plate with the 15mm screws
(I). Secure using a screwdriver. Note: Screws (I) are located on the back side of the console.
STEP 7
a. Unfold the console cable and the
K | TENSION KNOB E |
3
4
Attach the Seat
tension knob cable, which is folded into the console mast base. b. Slide the console mast boot onto
L | CABLE |
| |
| A |
Figure B
a. Remove the three nuts (J) and washers (K) from the bottom of the seat.
C)15mm Bolt Quantity: 4
D) 12mm screw
G) 20mm Bolt
Quantity: 2
the bottom of the console mast. c. Slide the tension knob cable and
the console cable through the con- sole mast. (Note: The tension knob cable will only pull as far as the rec-
SOLE
ST
SEAT POST
5
Figure C
b. Attach the seat to the seat post with the three nuts (J) and washers (K), securing with the flat wrench.
c. Loosen the pop pin by turning it one or two revolutions, then pull the pop pin mechanism to the outward
Quantity: 2
tangular opening in the console mast. The console cable will need to be pulled through the end of the console mast.) To assist in pulling the console cable and tension knob
POP PIN
FRONT TUBE
6
position.
d. With the pop pin in the outward position, slide the seat post into the base.
| H) Acorn Nut |
E) 18mm Arc Washer | Quantity: 2 |
cable through the console mast, there should be a guide wire
MOBILE WHEEL
SLEEVE
Figure D
e. Release the pop pin and tighten to the proper position.
Quantity: 2 |
F) 14mm Washer |
|
Quantity: 2 | J) 20mm Arc Washer |
| |
| Quantity: 4 |
NOTE: It is recommended that you apply
grease to the threads of each bolt as you assem- ble your Exercise Bike, to prevent loosening and noise. Also, during each assembly step, ensure that ALL nuts and bolts are in place and partially threaded in before completely tightening any ONE bolt.
attached to the top of the console mast.
d. Insert the console mast into the base, secure both sides of the mast with four 15mm bolts (C) using the 5mm allen wrench. Slide the console mast boot into place.
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| STEP 8 |
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| Attach the Pedals | |
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| MOBILE WHEEL | F |
| a. Thread the right pedal into the right |
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| G | side pedal crank arm. Note: The | ||
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| PEDAL |
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REAR FOOT TUBE |
| B |
| pedals are labeled on the end of the | ||
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| threaded shaft for reference. |
| J |
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| b. Tighten the pedal with the flat |
| H | REAR FOOT PAD |
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| wrench. | |
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| c. Repeat this process on the left side. | |||
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