True Fitness 500R Users Manual Bike Service

600r to the manual e3ef28d4-0abc-45f6-8276-fb1f4c33e9f4

2015-02-03

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True Fitness Service
Manual
Exercise Bicycles
500R, 500U
600R, 600U
750R, 750U

True fitness technology, Inc. makes no representations or warranties regarding the
contents of this manual. 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

Recommended Tool List
Technicians will need at minimum the tools listed below to work on the True Fitness
equipment covered by these procedures.

Electrical Tools
A multi meter capable of testing voltage, amperage, resistance and continuity.
Outlet tester with a grounding indicator.
Wire stripper, cutter and crimper.
Flashlight

Mechanical Tools
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 9/16” for use in removing
and tightening sleeve nuts.
Needle nose pliers.
Crescent wrench

Special Tool
Bicycle crank puller
Park Tool USA CCP-2

True Fitness Bicycle
Service Manual

START
Symptom guide
Wiring Diagrams
Parts Manual
Removal and Replacement Procedures

Page 1

Test Mode *750 ONLY
To Enter Diagnostic
Mode

Procedure
•
•

D
I
A
G
N
O
S
T
I
C
S

------Console / Display
Output

•
•

Press “Enter” key – initiates the second
LED function test.
Press “Enter” key again –all LED’s
should be on.
--------

RPM

•

Press “Enter” key – RPM’s displayed in
the far right window.
--------

Console Key Input

•

Press “Enter” key –A beep should sound
when each key is pressed.
--------

Contact Heart Rate

•

Press “Enter” key. Hold both handle
pick-ups. Heart symbol will flash and
readout will display.
-------

DA (Resistance)

•

Press “Enter” key – Press + to increase
resistance and – to decrease resistance.

Exit Diagnostics

•

To quit diagnostics press “Enter” key or
stop pedaling and the unit will reset.

Support Services 800-883-8783

Page 2

Press and hold the “Start” key as you
begin pedaling.
Continue pedaling throughout the test.

Mon-Fri 8:30am-5:00pm Central Time Zone

Fax: 636-272-7148

SYMPTOM GUIDE
500U, 500R

ECB Malfunction . . . . . . . . . . . . . . . . . . . . . . .

Page 4

Irregular or No Display . . . . . . . . . . . . . . . . . .

Page 5

No RPM Reading . . . . . . . . . . . . . . . . . . . . . . . .

Page 6

No Polar Heart Rate . . . . . . . . . . . . . . . . . . . . . . Page 7

600U, 600R

Irregular or No Display . . . . . . . . . . . . . . . . . . . Page 8

No RPM Reading . . . . . . . . . . . . . . . . . . . . . . . .

No Contact Heart Rate . . . . . . . . . . . . . . . . . . . . Page 10

Handle Bar Buttons
Do Not Function . . . . . . . . . . . . . . . . . . . . . . . . . Page 11

Page 9

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

Symptom

Probable Cause

ECB
MALFUNCTION
500R, 500U

Control Panel

Corrective Action
•
•
•
•

Defective Cables

•
•

Power on unit. Check for 5VDC between pins 1 and 2. (Page 18)
No 5VDC? Replace control panel.
Check for 6VDC or more between pins 5 and 6 of 6PA while issuing
a resistance command.
No 6VDC or more? Replace control panel.
-------Perform continuity check on upper section and lower section cables.
Replace broken cables.
--------

Defective ECB
Control Board

•
•

Optical Sensor

•

DC Motor

•

If cables test OK and voltage is correct on 5 &6 pins – replace ECB
board
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.
--------

ECB Limit Switch

•
•

Loud Continuous
Tone from lower
board (ECB board)

•

Check continuity between pins 2 and 4 of 6PB. Press lower limit
switch.
If no continuity shift- replace ECB limit switch assembly.
--------The loud continuous tone is a safety feature designed to protect the
ECB motor. If the motor binds and cannot move the ECB board will
divert the power from the motor to a speaker that emits this tone. If
you have the continuous tone check to see if the motor is bound.
for the magnet bar and loosen the
Check the front pivot point
bolt to allow for the motor to freely move the magnet bar.

Note: If motor has been bound and then
freed the motor may have been weakened. If
components now move freely but the motor
is laboring – replace the motor.

Page 4

Support Services 800-883-8783

Mon-Fri 8:30am-5:00pm Central Time Zone

Fax: 636-272-7148

Symptom
IRREGULAR OR
NO DISPLAY
500R, 500U

Probable Cause

DC Adaptor

Corrective Action

•
•
•

Recommended Tools

Connect DC Adapter to 110 VAC power
supply.
Look for printed output on adapters
label. If greater than 9 VDC computer
board may be damaged.
Test for 9VDC output. If not 9 VDC
then replace adaptor.

Multi-meter

--------

Adapter Plug or
Jack

•

Connect DC plug to Bike. Does it seat
into the socket properly? If not- replace
adapter or jack.

-------Control Panel

•
•

Check DC voltage between pins 2 and 4
for 9 VDC on 5PB. (Page 18)
If 9 VDC is found replace the Control
Panel.

--------

Cables

•
•
•

Support Services 800-883-8783

Perform continuity checks on all upper
and lower cables.
Replace defective cables.
If cables OK- replace DC Jack.

Mon-Fri 8:30am-5:00pm Central Time Zone

Fax: 636-272-7148

Page 5

Symptom
NO RPM
READING
500R, 500U

Probable Cause

Control Panel/ RPM
Sensor

Corrective Action

•
•
•
•
•

Disconnect 5PA from 5PB. Set meter to
check continuity between 2 and 5 of
5PB. (See Page 18)
Turn pedals slowly, check continuity
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.

Recommended Tools

Multi-meter

When the sensor is over the
pickup, continuity will exist.
When sensor is not over pickup,
cicuit will be open.

--------

Defective Cables

•
•

Perform continuity checks on all upper
and lower cables.
Replace defective cables.

--------

Defective RPM
Sensor Set

Page 6

Support Services 800-883-8783

•

If cables OK- Replace RPM sensor set.

Mon-Fri 8:30am-5:00pm Central Time Zone

Fax: 636-272-7148

Symptom
NO POLAR
HEART RATE
500R, 500U

Probable Cause

Control Panel

Corrective Action

•
•

Recommended Tools

Attach a known good heart rate
transmitter around chest or use polar
simulator.
If control panel does not display a heart
rate – replace Control Panel.

Heart Rate Simulator

--------

Heart Rate Chest
Strap

•

If heart rate registers with use of HR
simulator but not chest strap – replace
chest strap.
--------

External
Interference

•
•

Support Services 800-883-8783

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.

Mon-Fri 8:30am-5:00pm Central Time Zone

Fax: 636-272-7148

Page 7

Symptom

Probable Cause

IRREGULAR OR
NO DISPLAY
600R, 600U

Control Panel

Corrective Action

•
•
•
•

Probe leads between pin 1 and 2 of 5PB.
(Page 19-20)
Pedal unit up to at least 30 RPM.
Is voltage 5 VDC?
If not 5 VDC – replace Control Panel.

Recommended Tools

Multi-meter

--------

Control Board

•
•
•
•

Disconnect 6PG from 6PH.
Pedal.
Check DC voltage between pins 2 and 3
for 5 VDC.
No 5 VDC? – Replace Control Board.
-------

Cables

•
•

Perform continuity checks on all upper
and lower cables.
Replace defective cables

-------AC Voltage Output

•
•
•
•
•
•

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.

-----Generator Output
Cable

•
•

Page 8

Support Services 800-883-8783

Perform a continuity check on the
generator output cable.
If no continuity – replace cable

Mon-Fri 8:30am-5:00pm Central Time Zone

Fax: 636-272-7148

Symptom

NO RPM
READING
600R, 600U

Probable Cause

Control Panel

Corrective Action

•
•
•
•

Recommended Tools

Disconnect 5PA from 5PB. (Page 1920).
Set meter to check continuity between
pins 2 and 5 of 5PB
Turn crank and align the magnet with
the sensor
Is there continuity? If Yes – Replace
Control Panel. If No- continue to next
step.

Multi-meter

--------

Defective Cables
Defective RPM
Sensor Set

•

•
•
•
•

Support Services 800-883-8783

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.

Mon-Fri 8:30am-5:00pm Central Time Zone

Fax: 636-272-7148

Page 9

Symptom
NO CONTACT
HEART RATE
600R, 600U

Probable Cause

Control Panel

Corrective Action

•

Recommended Tools

Multi-meter
Disconnect 7P6A and 7P6B from
control panel. 600U (Page 19) 600R
(Page 20). Check continuity between
7P6B and handle mounted heart rate
sensor plates of the following:
HRRR and pin 6 of 7P6B
HRRL and pin 5 of 7P6B
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

--------

Defective Cables

•
•

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.

-------Defective Handles

•
•
•

Page 10

Support Services 800-883-8783

Remove and carefully check all
connections to the contact plates.
Reconnect loose connections.
If connections OK – Replace handles.

Mon-Fri 8:30am-5:00pm Central Time Zone

Fax: 636-272-7148

Symptom
HANDLEBAR
BUTTONS DO
NOT FUNCTION
600R

Probable Cause
“Cruise Control”

Corrective Action

•
•

Recommended Tools

Remove console-mounting screws.
Locate 10P7B (Page 20).
Check for continuity between pin 7 and
pin 1 at 10P7B. Press Cruise control
button.

Multi-meter

(A)
• No continuity? Perform a continuity
check on the appropriate cable.
• Replace cable or if cable good – replace
handlebar assembly.
-------“Start” Button

•

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.
--------

“Shift” Button
•
“_“ Button
“Select” Button

Check for continuity between pin 7 and
pin 5 at 10P7B. Press Select button. See
(A) above.
--------

•
“+” Button

Check for continuity between pin 7 and
pin 6 at 10P7B. Press + button. See (A)
above.
--------

•

Support Services 800-883-8783

If all have continuity and problem
persists – replace Console

Mon-Fri 8:30am-5:00pm Central Time Zone

Fax: 636-272-7148

Page 11

Symptom

Probable Cause
Console Set

Corrective Action
•

NO RESISTANCE
750U, 750R
•
•
•
•

Defective Cables

•
•
•

Power Resistance

•
•

Brake Harness/
Lower Board

•
•
•
•
•
•
•

Page 12

Support Services 800-883-8783

Remove console bolts to access 7-pin
connector. Do not disconnect console
set.
Enter DA (resistance) test mode.
(Page 2).
Press + key to force .7 VDC out of
panel.
Set meter for DC Volts. Measure
between #2 pin and #4 pin at 7- pin
connector.
Is .7 VDC present? No- replace console
set. If present, continue on.

Recommended Tools

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.

Multi-meter

-------Remove right mast cover and handlebar.
Measure between the #2and #4 wires at
the 7 –pin connector on the lower board.
Is .7 VDC present? No- replace cable
for console. If present, continue on.
-------DO NOT PEDAL.
Set meter for resistance. Disconnect 3pin 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 wires in cable.
Check for cross continuity- this would
indicate multiple shorts in the cable.
No continuity? Replace Brake cable.
Yes continuity? Replace lower board.

Mon-Fri 8:30am-5:00pm Central Time Zone

Fax: 636-272-7148

Symptom
HEAVY
RESISTANCE
750U, 750R

Probable Cause

Console Set

Corrective Action

•
•
•
•

Defective Cables

•
•
•
•
•

Recommended Tools

Multi-meter
Remove the console set.
Disconnect the 7 pin connector from the
back of the console set.
Pedal.
Resistance normal? Replace console set.
-------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.
--------

Lower control
Board/Brake

•
•
•
•
•

Support Services 800-883-8783

Disconnect 3- pin connector from the
brake.
Resistance still heavy- Replace brake.
Resistance normal
Check brake cables for cross continuity.
Replace lower control board.

Mon-Fri 8:30am-5:00pm Central Time Zone

Fax: 636-272-7148

Page 13

Symptom
No Display
750U, 750R

Probable Cause

Console Set

Corrective Action

•
•
•
•
•

Brake

•
•
•
•
•
•
•
•

Recommended Tools

Note:
Remove console set bolts. Verify good
connection at the back of the console
set. Set meter for DC volts
Pedal.
Measure between #1 and #4 wires (Page
21) for 5.5 – 7.5 VDC.
Is required voltage present?
If yes- replace console set. If not,
continue on.
-------Remove pedal and if 3 piece crank
remove crank arm.
Remove right side cover.
Disconnect 3- wire connector at brake.
Set meter for AC volts.
Pedal.
The voltage should increase as pedaling
increases.
Is minimum voltage 9 VAC @ 30
RPM?
If No- replace Brake. If yes, continue
on.

You must pedal at least
30 RPM when
performing any voltage
test. You may require the
assistance of another
person when performing
voltage checks.

Multi-meter

-------Defective Cable

•
•
•
•
•
•

Console Cable/
Lower Control
Board

---------•
•
•
•
•

Page 14

Support Services 800-883-8783

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 7- pin cable for the
console at the lower control board.
Voltage is present? Replace cable for
console.
Voltage not present? Replace lower
control board.

Mon-Fri 8:30am-5:00pm Central Time Zone

Fax: 636-272-7148

Symptom
NO CONTACT
HEART RATE
750U, 750R

Probable Cause

Dirty Sensors

Corrective Action

•

Recommended Tools

Note:
Verify hand pulse sensors are clean.
--------

Console Set/
Wiring

•
•
•
•

Set meter for continuity.
Remove Console set.
Check for continuity in both sets of
hand pulse sensors between the console
set and hand pulse sensor plates.
If continuity is OK – Replace Console
set. If no- continue on.

You must pedal at least
30 RPM when
performing any voltage
test. You may require the
assistance of another
person when performing
voltage checks.

Multi-meter
Double sided tape

--------

Wire Connections

•
•
•
•
•

Support Services 800-883-8783

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.

Mon-Fri 8:30am-5:00pm Central Time Zone

Fax: 636-272-7148

Page 15

Symptom

Probable Cause

NO POLAR
HEART RATE
750U, 750R

Control Panel

Corrective Action

•
•
•
•

Recommended Tools

Note:
Attach known good heart rate
transmitter around chest or use Polar
simulator.
Do not touch the hand pulse sensors.
Start pedaling
Check display for heart rate.

You must pedal at least
30 RPM when
performing any voltage
test. You may require the
assistance of another
person when performing
voltage checks.

--------

Defective Cables

•
•
•

Defective ECB
Control Board

Page 16

Support Services 800-883-8783

•

Does console 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.

Mon-Fri 8:30am-5:00pm Central Time Zone

Polar Heart Rate
Simulator

Fax: 636-272-7148

WIRING DIAGRAMS

TR / TU 500

Page 18

600 U

Page 19

600 R

Page 20

TR/TU 750

Page 21

Page 17

TR/ TU 500 WIRING DIAGRAM

Page 18

TU 600 WIRING DIAGRAM

Page 19

TR 600 WIRING DIAGRAM

Page 20

TR/ TU 750 WIRING DIAGRAM

Page 21

Page 22

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 24

TU 500 EXERCISE BIKE
REF.
#
2
3
4
5
6
7
8
9
10
11
^121
^122
^123
^124
^125
^126
^127
^128
^129
^1210
^1211
^1212
13
14
141-1
141-2
15
16
17
18
19
20
21
22
23
24

PART #
7T010800
7T000200
7T000300
7T000400
7T000600
7T010900
7T001700
7T001800
7T002000
7T001900

DESCRIPTION
FRONT STABILIZER WITH BOLTS
TRANSPORTATION WHEEL HIT
FTONT STABILIZER END CAP
CRANK PULLEY WITH CAPS AND BEARINGS
BOLT BELT TENSION
BRAKE ASSY
ALUMINUM IDLER ASSY
ECB DC MOTOR WITN SCREWS
ECB CONTROL BOARD WITH SCREWS
ECB LIMIT SWITCH WTH SCREWS

QTY
1 SET
1 SET
2 PCS
1 SET
1 PC
1 SET
1 SET
1 SET
1 SET
1 SET

7T011000

LEFT SHROUD WITH DECALS

1 SET

7T001302

SCREW

1 PC

7T001202

SCREW

6 PCS.

7T001303

SCREW

3 PCS.

7T011100

RIGHT SHROUD WITH DECAL

1 SET

7T001306

HEX NUT SIDE COVER

3 PCS.

7T011200

DECAL---WHITE----RIGHT

1 PC

7T001311

SHROUD DECAL B WHITE

1 PC

7T001312

SHROUD DECAL D WHITE

1 PC

7T011300

DECAL---WHITE----LEFT

1 PC

7T001308

SHROUD DECAL-A WHITE

1 PC

7T001309
7T001400
7T004000

SHROUD DECAL C WHITE
PEDALSET WITH STRAPS
HANDLE BAR 6 PIN WITH BOLTS

1 PC
1 SET
1 SET

7T004001

CABLE ASSY 6 PIN UPPER

1 PC.

7T004002
7T004100
7T001100
7T003800
7T003900
7T004200
7T004300
7T000900
7T004400
7T004500
7T004600

CABEL ASSY 5 PIN UPPPER
BOTTLE CAGE WITH SCREWS
COMPUTER WITH SCREWS
DC JACK
ADAPTER 9VDC 1.2A
CD PLAYER HOLDER WITH SCREWS
SEAT ADJUSTING KNOB
SHROUD TRIM CAP
SEAT POST SLEAVE
SEAT POST
SADDDLE WITH CLAMP

1 PC.
1 SET
1 SET
1 PC
1 PC
1 SET
1 PC
1 PC
1 PC
1 PC
1 PC

Page 25

25
26
27
28
29
30
31

Page 26

7T002600
7T002700
7T002800
7T012700
7T005800
7T004700
7T004800
7T013000
7T012901
7T012902
7T012903
7T012904
7TU50100
7TU50200
7TU60200
7TU60500
7TU60600
7TU60700
7TU60300

REAR STABILIZER WITH BOLTS
ADJUSTING STAND KIT
REAR STABILIZER END CAP
POLY V BELT
RPM SENSOR WITH WIRE AND NUT
CABLE ASSY 5 PIN LOWER SPEED SENSE
CABLE ASSY 6 PIN LOWER SECTION
MODEL DECAL SILVER
DECAL A SILVER
DECAL B SILVER
DECAL C SILVER
DECAL D SILVER
ASSY HDW. KIT
COMPUTER SCREW KIT
FRONT STABILIZER HDW. KIT
HANDLE BAR HDW. KIT
CD HOLDER HDW. KIT
TOOL KIT
REAR STABILIZER HDW KIT

1 SET
1 SET
2 PCS
1 PC
1 SET
1 PC
1 PC
1 SET
1 PC
1 PC
1 PC
1 PC
1 SET
1 SET
1 SET
1 SET
1 SET
1 SET
1 SET

TR 500 Exercise Bike

Page 27

TR 500

Page 28

REF #
02
03
04
05
06
07
08
09
10
11
11-1-1
11-1-2
12
13-1
13-2
13-3
13-4
14-1
14-2
14-3

PART#
7T000100
7T000200
7T000300
7T000400
7T005800
7T000600
7T000700
7T000800
7T000900
7T001000
7T001001
7T004700
7T001100
7T001201
7T001202
7T001203
7T001204
7T001301
7T001302
7T001303

DESCRIPTION
Front Stabilizer w/Bolts
Transportation Wheel Kit
Front Stabilizer End Cap
Crank Pulley w/E Caps & Bearings
RPM Sensor w/Wire & Nut
Bolt - Belt Tension
Cable Assembly - 6 Pin Lower
Cable Assembly - 5 Pin Lower
Shroud Trim Cap
Console Mast Set
Cable Assy, 6 Pin Upper
Cable Assy, 5 Pin Upper
Computer Set
Rear Shroud - Right
Screw, Sidecover
Rear Shroud - Left
Screw, Rear Cover
500R Shroud - Left Complete w/ Model Decal and Shroud Decals
Screw - Side Cover
Screw

QTY.
1 SET
1 SET
2 PCS
1 SET
1 SET
1 PC
1 PC
1 PC
1 PC
1 SET
1 PC
1 PC
1 SET
1 PC
10 PCS
1 PC
1 PC
1 SET
1 PC
3 PCS

14-5
14-6
14-7
14-8
14-9
14-10
14-11
14-12
15
16
17
18
19
20
21
22
23
24
25

7T001305
7T001306
7T001307
7T001308
7T001309
7T001310
7T001311
7T001312
7T001400
7T001500
7T010700
7T001700
7T001800
7T001900
7T002000
7T002100
7T002200
7T002300
7T002400

500R Shroud - Right Complete w/ Model Decal and Shroud Decals
Hex Nut - Side Cover
Model Decal for 500R - Left (Wht)
Shroud Decal - A (Wht)
Shroud Decal - C (Wht)
Model Decal for 500R - Right (Wht)
Shroud Decal - B (Wht)
Shroud Decal - D (Wht)
Pedal Set w/Straps
Poly-v Belt
TR500 Brake Assy
Aluminum Idler Assembly
ECB DC Motor w/Screws
ECB Limit Switch w/Screws
ECB Control Board w/Screws
Aluminum Rail Trim Cap
Aluminum Rail w/Bolts
Stopper Kit
Fore and Aft Adjusting Rack w/Bolts

1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

PC
PCS
PC
PC
PC
PC
PC
PC
SET
PC
SET
SET
SET
SET
SET
PC
SET
SET
SET

26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

7T002500
7T002600
7T002700
7T002800
7T002900
7T003000
7T003100
7T003200
7T003300
7T003400
7T003500
7T003600
7T003700
7T003800
7T003900
7T013000
7T012901
7T012902
7T012903
7T012904
7T012800
7TR50100
7TR50200
7TR50300
7TR50400
7TU60700

Transportation Handle Set w/Screws
Rear Stabilizer w/Bolts
Adjusting Stand Kit
Rear Stabilizer End Cap
Roller Set (A) Rt Ft & RR
Roller Set (B) Center
Seat Bottom w/Bolts
Fore and Aft Adjusting Lever w/Bolts
Seatback w/Bolts
Seat Shuttle
Bottle Holder w/Screws
Rear Handlebar w/Bolts
Roller Set (C) LH, Ft & RR
DC Jack
Adapter 9vdc1.2a
Model Decal
Decal A
Decal B
Decal C
Decal D
Pneumatic Cylinder/Seat Back
Assy Hdw Kit
Ft/RR Stabilizer Hdw Kit
H/Bar Hdw Kit
Bottle Holder Hdw Kit
Tool Kit

1
1
1
2
2
2
1
1
1
1
1
1
2
1
1

SET
SET
SET
PCS
SET
SET
SET
SET
SET
SET
SET
SET
SET
PC
PC

Page 29

Page 30

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

TU 600 PARTS DIAGRAM

Page 32

TU 600 BIKE
REF #

PART NUMBER

DESCRIPTION

02
03
04
05

7T010800
7T000200
7T000300
7T011400
7T004900
7T005000
7T012000
7T001302
7T001202
7T001303
7T012100
7T001306
7T012200
7T001311
7T001312
7T012300
7T001308
77T001309
7T001400
7T005500
7T005600
7T005200
7T012400
7T012500
7T011500
7T007200
7T005700
7T006000
7T005900
7T005800
7T000900
7T004300
7T004400
7T004500
7T004600
7T006900
7T006202
7T004100
7T006300
7T004200
7T007000
7T012600
7T002600
7T002700
7T002800
7T005100
7T013100

FRONT STABILIZER WITH BOLTS
TRANSPORTATION WHEEL KIT
FRONT STABILIZER END CAP
DRIVE BELT KIT
DO NOT ORDER
POLY V PULLEY SET KIT SECONDARY
LEFT COMPLETE W/ MODEL SHROUD DECALS
SIDE COVER SCREW
SIDE COVER SCREW
SIDE COVER SCREW
RIGHT SHROUD W/ MODEL DECALS
HEX NUT
MODEL DECAL LEFT WHITE
SHROUD DECAL BLUE
SHROUD DECAL BLUE
MODEL DECAL RIGHT WHITE
SHROUD DECAL BLUE
SHROUD DECAL BLUE
PEDAL SET W/ STRAPS LFT. & RT.
CRANK AND CUPS PULLEY SET W/BEARINGS
J8 POLY V BELT PRIMARY
ALUMINUM IDLER AND IDLER ARM
C RING IDLER ARM
SPRING IDLER ARM
BRAKE KIT
BRAKE CABLE
GENERATOR BRACKET SET
CONTROL BOARD W/ SCREWS
RESISTOR W/ SCREWS
RPM SENSOR W/ WIRE AND NUT
SHROUD TRIM CAP
SEAT ADJUSTING KNOB
SEAT POST SLEAVE
SEAT POST SET
SADDLE W/ CLAMP
HANDLEBAR W/ CONTACT HR AND BOLTS
CABLE ASSY.
BOTTLE CAGE W/ SCREWS
COMPUTER W/ SCREWS
CD PLAYER HOLDER W/ SCREWS
CABLE ASSEMBLY 5 PIN LOWER
IDLER ARM AXLE KIT
REAR STABILIZER W/ SCREWS
LEVELERS x2 WITH LOCKS
REAR STABILIZER END CAP
POLY V PULLEY SET KIT CLUTCH
HANDLEBAR END CAPS

06
7-1
7-2
7-3
7-4
7-5
7-6
7-7
7-8
7-9
7-10
7-11
7-12
08
09
10
11
12
13
14
14-9
15
16
17
18
19
20
21
22
23
24
24-1-1
25
26
27
28
29
30
31
32
33
24-2

QTY.
1
1
2
1
1
1
1
6
3
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2

Page 33

7T011800
7T011900
7T012901
7T012902
7T012903
7T012904
7TU60100
7TU60200
7TU60300

Page 34

MODEL DECAL LEFT WHITE
MODEL DECAL RIGHT WHITE
DECAL A
DECAL B
DECAL C
DECAL D
PARTS KIT
FRONT STABILIZER SCREW KIT
REAR STABILIZER SCREW KIT

1
1
1
1
1
1
1
1

TR 600 PARTS DIAGRAM

Page 35

TR600 BIKE

Page 36

REF. #

PART #

DESCRIPTION

QTY USED

24-1
24-2
24-3
24-4
24-5
24-6
24-7
24-8
24-9
24-10
24-11
24-12
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
2
3
4
5
6
7
8
9
10
11
12
13
13-9
15
16
17
18
19

7T011600
7T001202
7T001303
7T001302
7T011700
7T001306
7T011800
7T001308
7T001309
7T012300
7T001311
7T001312
7T001400
7T002100
7T002200
7T002300
7T006500
7T002400
7T002500
7T002600
7T002700
7T002800
7T002900
7T003000
7T003100
7T003300
7T003200
7T000100
7T000200
7T000300
7T011400
7T005000
7T005100
7T005200
7T005300
7T005400
7T005500
7T005600
7T011500
7T007300
7T005800
7T005900
7T006000
7T006100
7T000900

600R L SHROUD & DECALS
SIDE CVR SCREW
SIDE CVR SCREW
SIDE CVR SCREW
600R R SHROUD & DECALS
HEX NUT SIDE CVR SCREW
MODEL DECAL 66R L WHITE
SHROUD DECAL A BLUE
SHROUD DECAL C BLUE
MODEL DECAL 600R RT WHITE
SHROUD DECAL B BLUE
SHROUD DECAL D BLUE
PEDAL W/STRAPS LT&RT
ALUM RAIL TRIM CAP
ALUM RAIL W/HDRW
SEAT STOP KIT LT& RT
CABLE ASSY 12 PIN LWR SEAT RAIL
SEAT ADJ RACK
TRANSPORT HNDL KIT
REAR STABILIZER W/BOLTS
LEVELS W/LOCKS
REAR STABILIZER END CAP
ROLLER SET (A) RT& LT FRT
ROLLER SET (B) RT & LT CTR
SEAT BOTTOM W/SCREWS
SEATBACK W/SCREWS
SEAT ADJ LEVER W/BOLTS
FRT STABILIZER W/BOLTS
TRANSPORTS WHEEL KIT
FRT STABILIZER END CAP
TR/TU600 DR BELT REPLACE KIT
POLY-V SEONDARY KIT CLUTCH
POLY-V CLUTCH PULLEY KIT
ALUM IDLER & IDLER ARM
C RING IDLER ARM
SPRING IDLER ARM
CRANK & PULLEY W/BEARINGS
J-8 POLY-V BELT PRIM
TU/TR600 BRAKE KIT
CABLE BRAKE
RPM SENSOR & KNOT CBL
RESISTOR W/SCREWS
CNTRL BOARD W/SCREWS
CABLE ASSY SPIN LWR
MAST TRIM CAP

1
6
3
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

20
20-1-1
20-1-2
21
22
23
40-1
24-2
40-3
40-4
41
42
43
44
45

24-08
24-11
24-9
24-12
43-1
^2-1
20-1
41-1
21-1

7T006200
7T006201
7T006202
7T006300
7T003700
7T006400
7T001201
7T001202
7T001204
7T001203
7T003500
7T006600
7T003400
7T006700
7T006800
7T011800
7T011900
7T012901
7T012902
7T012903
7T012904
7T013000
7T012800
7TR50200
7TR50300
7TR50400
7TR60100
7TU50200
7TU60700

CONSOLE MAST W/BOLTS
CABLE ASSY 12 PIN UPPER
CABLE ASSY 52 PIN UPPER
COMPUTER SET 660RIU LT FRT
ROLLER SET SEAT LT RR
IDLER ARM SHAFT KIT
REAR SHROUD RT
ROUND CROSS SCREW
TAPPING SCREW
REAR SHROUD LT
BTTL HDLR W/SCREWS
REAR HNDLBR W/SWITCHES BOLTS
SEAT SHUTTLE
THUMB SWITCH ASSY LT
THUMB SWITCH ASSY RT
MODEL DECAL LT WHITE
MODEL DECAL RT WHITE
DECAL A SILVER
DECAL B SILVER
DECAL C SILVER
DECAL D SILVER
MODEL DECAL
PNEUMATIC CYLINDER SEAT BK
FH RR STABILIZER HDW KIT
HNDLBR HDW KIT
BTTL HLDR HDW KIT
ASSY HDW KIT
CPANEL HDW KIT
ASSY TOOL KIT

1
1
1
1
2
1
1
4
1
1
1
1
1
1
1

Page 37

Page 38

True Upright Bike
750

TU 750 Exploded Diagram

Pg- 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

TU 750 PARTS DIAGRAM
(3 PIECE CRANK)

Page 40

TU 750 3 PIECE CRANK

TU750:
02UP0161C

REF # PART#

DESCRIPTION

QTY.

AB1
AC1
AD1
AJ1
AN1
AS1
B22
B24
B31
C07
C08
C10
C11
C12
C13
C14
C15
C16
D03
D04
D05
J05
J07
J08
J09
J10
J11
J12
P01
P08
P11

FRAME
UPRIGHT HANDLE BAR
SEAT POST
FRONT GROUNDING BAR ASSEMBLY
CONSOLE SET
BRAKE ASSEMBLY
C CLAMP SIDE COVER
SCREW SIDE COVER
SIDE COVER BRACKET
HAND PULSE SENSOR
SENSOR BRACKET PULSE
SCREW PULSE BRACKET
NUT PULSE BRACKET
WATER BOTTLE CAGE
SCREW BOTTLE CAGE
SCREW HANDLEBAR MAST
TRIM CAP
END CAP OF HANDLEBAR
SEAT CUSHION
NYLON NUT SEAT CUSHION
SPRING WASHER SEAT CUSHION
MOVING WHEEL
REAR GROUNDING BAR ASSEMBLY
REAR FEET PAD
BOLT MOVING WHEEL FT. GROUNDING BAR
BOLT REAR GROUNDING BAR ASSEMBLY
WASHER MOVING WHEEL
MOVING WHEEL COVER
CONSOLE DATA CABLE
CONTACT HEART RATE CABLE
CONTROL BOARD

7TSP0101006
7TSZCB24CSM
7TSW0150005
7TSZCB24FST
7TSM0209004
7TMD0208006
7TME0701001
7TME0107014
7TMJ1208001
7TMJ1278001
7TMB06A7001
7TME0102069
7TMB0201028
7TMB0601005
7TME0102043
7TME0111014
7TMB0605006
7TMJ1291001
7TMB1001018
7TME0204019
7TME0501007
7TMB0103001
7TSZCB24RST
7TMB0304006
7TME0112024
7TME0112044
7TME0502108
7TMB0705001
7TMC0501027
7TMC0549002
7TMC0203004

1
1
1
1
1
14
16
1
1
1
4
4
1
2
6
1
2
1
3
3
2
1
4
4
2
2
2
1
2
1

NEXT FIVE PIECES ASSEMBLY BUT NO ASSY. NUMBER
P12
P17
P22
P23
P24
P15
P19
P20
Q01
J14
J15
Q02

7TMC0736002
7TMJ1393002
7TME0102027
7TME0204003
7TME0502082
7TMB06B8001
7TME0107043
7TME0107043
7TMN1101006
7TMB0304020A
7TMZE0112119
7TMB0604018

POWER RESISTANCE
COVER POWER RESISTENCE
SCREW
NUT
WASHER
CONTROL BOARD BRACKET
SCREW CONTROL BOARD
SCREW RESISTOR TO FRAME
SEAT ADJUSTMENT KNOB BLUE
FOOT PAD FRONT
BOLT FRONT FOOT PAD
SEAT POST SLEEVE

1
1
4
4
4
1
8
8
1
2
2
1

Page 41

Q06R
Q06L
Q07
Q11
Q12
R03
R06
R09
R14
R17
R20
S01
S02
S03
S04
S05
S06
T01
T02
T03
T04
T05
T06
T08
T09
U06
U07
U09
U10
U12
U13
V01
V03

Q08

Page 42

7TMB0609028
7TMB0609026
7TMB0609035
7TSZCB24SCV-L
7TSZCB24SCV-R
7TSZRB40PAX
7TMD0602018
7TME0103022
7TME0514002
7TME0104014
7TME0502092
7TMJ3247002
7TMJ1245003
7TME0204010
7TME0201012
7TME0502127
7TME0502115
7TSZRB40DAX
7TMD0405001
7TMD0406001
7TMD0402002
7TMD0403002
7TMD0602013
7TMB0622001
7TME01132012
7TME0112088
7TMJ1914002
7TME1104002
7TME0502084
7TME0104014
7TME0201003
7TMG0214009
7TMG0102036
7TMH0205023
7TME0601017
7TMB0237002

END CAP FOR FRONT GROUNDING BAR RT.
END CAP FOR FRONT GROUNDING BAR LT.
END CAP FOR REAR GROUNDING BAR
SIDE COVER ASSY. LEFT 3 PC. CRANK
SIDE COVER ASSY. RIGHT 3 PC. CRANK
FLYWHEEL SHAFT ASSEMBLY
POLY V BELT 520-J8
FLAT HEAD SCREW
WASHER
SCREW FLYWHEEL ATTACH
WASHER FLYWHEEL ATTACH
EYE BOLT BRAKE BELT TENSION
HOOK COVER BRAKE BELT TENSION
NYLON NUT BRAKE BELT TENSION
NUT BRAKE AXLE
WASHER BRAKE TENSION BOLT
WASHER BRAKE AXLE
BOTTOM BRACKET WHEEL ASSY. 3 PC. CRANK
LEFT CRANK
RIGHT CRANK
PEDALS WITH STRAP
2(SET)
PEDAL STRAP SET OF 2
POLY V BELT 400-J08
CRANK COVER CAP
SCREW CRANK ARM ATTACH
SCREW BELT TENSIONER
STRETCH ADJUSTER BELT TESIONER
STRETCH SPRING BELT TENSIONER
WASHER BELT TENSIONER
SCREW BELT TENSIONER
NUT BELT TENSIONER
SIDE COVER DECAL BLUE
MODEL DECAL WHITE
OWNERS MANUAL
ASSEMBLY KIT
UPPER FRAME COVER

1
1
2
1
1
1
1
2
2
6
6
2
2
2
2
2
2
1
1
1
1
1
2
2
1
1
1
1
1
1
1
2
1
1
1

TU 750 PARTS DIAGRAM
(1 PIECE CRANK)

Page 43

TU 750 1PC CRANK

Page 44

REF.#
AB1
AC1
AD1
AJ1
AN1
AS1
B22
B24
B31
C07
C08
C10
C11
C12
C13
C14

PART#
7TSP001006
7TSZCB24CSM
7TSW0150005
7TSZCB24FST
7TSM0209004
7TMD0208006
7TME0701001
7TME0107014
7TMJ1208001
7TMJ1278001
7TMB06A7001
7TME0102069
7TMB0201028
7TMB0601006
7TME0102043
7TME0111014

C15
C16
D03
D04
D05

7TMB0605006
7TMJ1291001
7TMB1001018
7TME0204019
7TME0501007

J05
J07

7TMB0103001
7TSZCB24RST

J08
J09

7TMB0304006
7TME0112024

J10

7TME0112044

J11
J12

7TME0502108
7TMB0705001

P01
P08

7TMC0501027
7TMC0549002

P11

7TMC0203004

P12
P17

7TMC0736002
7TMJ1393002

P22
P23
P24
P15
P19
P20

DESCRIPTION
FRAME
HANDLE BAR W/HR
SEAT POST
FRONT GROUND BAR ASSEMBLY
CONSOLE ASSEMBLY
BRAKE ASSEMBLY
C CLAMP SIDE CVR
SCREW SIDE CVR
SIDE CVR BRACKET
HAND PULSE SENSOR
SENSOR BRACKET PULSE
SCREW PULSE BRKT
NUT PULSE BRKT
WATER BTL CAGE
SCREW BTL CAGE
SCREW HANDLEBAR
MAST
TRIM CAP
END CAP OF HDLBR
SEAT CUSHION
NYLON NUT SC
SPRING WASHER ST
CUSHION
MOVING WHEEL
REAR GROUNDING BAR
ASSEMBLY
REAR FEET PAD
BOLT MOVING WHEEL
FT. GROUND BAR
BOLT REAR GROUND
BAR ASSEMBLY
WASHER MVG WHEEL
MOVING WHEEL CVR
DO NOT ORDER
CONSOLE DATA CBL
CONTACT HEART RATE
CABLE
CONTROL BOARD

QTY.
1
1
1
1
1
14
16
1
2
2
4
4
1
2
6
1
2
1
3
3
2
1
4
2
2
2
2
1
2
1

7TME0102027
7TME0204003
7TME0502082

POWER RESISTANCE
COVER POWER
RESISTANCE
SCREW
NUT
WASHER

1
1
4
4
4

7TMB06B8001
7TME0107043
7TME0107043

CONTROL BRD BRKT
SCREW CNTRL BRD
SCREW RESISTER TO

1
8
8

Q01

7TMN1101006

J14
J15
Q02
Q06R

7TMB030402A
7TMZE0112119
7TMB0604018
7TMB0609028

Q06L

7TMB0609026

Q07

7TMB0609035

Q11

7TSZCB24SCV-L

Q12

7TSZCB24SCV-R

R03

7TSZRB40PAX

R06
R09

7TMD0602018
7TME0103022

R14

7TME0514002

R17

7TME0104014

R20

7TME0502092

S01

7TMJ3247002

S02

7TMJ1245003

S03

7TME0204010

S04
S05

7TME0201012
7TME0502127

S06
T01
T02
T03
T04
T05
T06
T08
T09
U06
U07
U09
U10
U12
U13
V01

7TME0502115
7TSZRB40PAX-1
7TMD0405001
7TMD0406001
7TSM0915027A
7TMD0403002
7TMD0602013
7TMB0622001
7TME0113012
7TME0112088
7TMJ1914002
7TME1104002
7TME0502084
7TME0104014
7TME0201003
7TMG0214009
7TMG0102053D

FRAME
SEAT ADJ KNOB
BLUE
FOOT PAD FRONT
BOLT FRONT FT PAD
SEAT POST SLEEVE
END CAP FOR FRONT
GRNDG BAR FOR RIGHT
END CAP FOR FRONT
GRNDG BAR FOR LEFT
END CAP FOR REAR
GROUNDING BAR
SIDE CVR ASSY LEFT
1 PIECE CRANK
SIDE CVR ASSY RT
1 PIECE CRANK
FLYWHEEL SHAFT
ASSEMBLY
POLY V BELT 520-J8
FLAT HEAD SCREW
DO NOT ENTER
WASHER
DO NOT ENTER
SCREW FLYWHEEL
ATTACH
WASHER FLYWHEEL
ATTACH
EYE BOLT BRAKE BLT
TENSION
HOOK CVR BRAKE
BELT TENSION
NYLON NUT BRAKE
BELT TENSION
NUT BRAKE AXLE
WASHER BRAKE
TENSION BOLT
WASHER BRK AXLE
BTTM BRKT WHEEL
LEFT CRANK
RIGHT CRANK
1/2 PEDALS W/STRAP
PEDAL STRAP SET 2
POLY V BELT 400-J08
CRANK CVR CAP
SCREW CRANK ARM
SCREW BELT TENSIONER
STRETCH ADJUSTER
STRETCH SPRING
WASHER
SCREW BELT TENSIONER
NUT BELT TENSIONER
SIDE CVR DECAL BLUE
MODEL DECAL SILVER

1
2
2
1
1
1
2
1
1
1
1
2
2
6
6
2
2
2
2
2
2
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1

Page 45

V03

Q08

Page 46

7TMG0102036
7TMG0214009C
7TMG0214016C
7TMH0205023
7TME0601017
7TMB0237002

MODEL DECAL WHITE
SIDE CVR DECAL SILVR
SIDE CVR DECAL SILVR
OWNERS MANUAL
ASSEMBLY KIT
UPPER FRAME CVR

1
1
1

True Recumbent
Bike 750
TR 750 Exploded Diagram

Pg- 46

(Prior to 08/05/2001 (3) Piece Crank)

TR 750 Parts List

Pg- 47

(Prior to 08/05/2001 (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 48

TR750 PRIOR 8-5-01 (3 PIECE
CRANK)
REF. #
AD1
AD2
AG1
AG2
AJ1
AN1
AS1
B37
B27

D01
D02

D16

D28
D33
D34
G06
G07
G09
G10
G11
G12
H01
H02
H03
H09
H13
H16
H15
H14

J05

PART #
7TSP0203003
7TSZRB40SLP
7TSP0206006
7TSP0212003
7TSZRB40FST
7TSM0209004
7TMD0208006
7TME0701001
7TME0107014
7TMJ3251001
7TME0102047
7TMJ1208001
7TMB1001005
7TMB1002002
7TMJ3228002
7TMJ3243001
7TMJ3244001
7TMJ3220006
7TME1111002
7TMJ3245001
7TSZRB40SER
7TSZRB40ESR
7TMB0104065
7TME0104004
7TME0112023
7TME0204004
7TME0112013
7TME0112039
7TME0501006
7TME0112014
7TMB0401021
7TMJ1278001
7TMB06A7001
7TMB0609031
7TME0102069
7TME0201028
7TSZRB40RAL
7TMJ3230001
7TMJ1228019
7TME0112042
7TME0502018
7TMB0632001
7TME0107015
7TMB0211008
7TMB0634002
7TME0102027
7TMB0103001

DESCRIPTION
SEAT SLIDE WELDMENT
SEAT SLIDE PLATE LOCK
SEAT HANDLE BAR WELDMENT
CONCOLE HANDLE BAR WELDMENT
FRONT GROUNDING BAR ASSY.
CONSOLE ASSEMBLY
BRAKE ASSY
C CLAMP-SIDECOVER
SCREW- SIDE COVER
FIXTURE SHAFT SIDE COVER
SCREW FOR SIDE COVER SHAFT
SIDE COVER BOTTOM FIXTURE
SEAT BOTTOM PAD
SEAT BACK PAD
ADJUSTMENT BAR FIXTURE PIN
BULB CONNECTOR
CLEVIS
SPACER
OPPOSITE SPRING
ADJUSTMENT BAR WITH GRIP
RECUMBANT SEAT ROLLER W/ HARDWARE
ECCENTRIC SEAT ROLLER ASSY. W/ HARDWARE
SCREW-SEAT LOCK PLATE BRACKET
SCREW-SEAT LEVER FIXTURE PIN
SCREW-BULB CONNECTOR SEAT LEVER
NUT CLEVIS
SCREW SEAT BOTTOM
SCREW-DIP BAR MOUNT
SPRING WASHER SEAT BACK/BOTTOM
SCREW SEAT BACK
HANDLE FOAM GRIP
HANDPULSE SENSOR
HANDPULSE BRACKET
END CAP HANDLE BAR
SCREW PULSE BRACKET
NUT PULSE BRACKET
RECUMBANT SEAT ASSY. TUBE
FIXTURE PIN BRACKET
PLATE FIXTURE BRACKET SHIM
SCREW REAR TUBE MOUNT
WASHER REAR TUBE MOUNT
END CAP OF FRONT SLIDE TUBE
SCREW SEAT TUBE END CAP
END CAP OF REAR SLIDE TUBE
WIRE CLAMP
WIRE CLAMP
TRANSPORT WHEEL

QTY.
1 SET
1 SET
1 SET
1 SET
1 SET
1 SET
1 SET
1 SET
16 PCS.
1 PC.
2 PCS.
1 PC.
1 PC.
1 PC.
1 PC.
1 PC.
1 PC.
1 PC.
1 PC.
1 PC.
1 SET
1 SET
4 PCS.
1 PC.
1 PC.
1 PC.
4 PCS.
4 PCS.
8 PCS.
4 PCS.
2 PCS.
1 SET
1 SET
4 PCS.
4 PCS.
4 PCS.
1 PC.
1 PC.
1 PC.
8 PCS.
8 PCS.
1 PC.
2 PCS.
1 PC.
1 PC.
1 PC.
2 PCS.

Page 49

J07
J08
J09
J10
J11
J12

P11
P12
P13
P15
P17
P22
P23
P24
Q06R
Q06L
Q07
Q08
Q11
Q12
R3
R06

T02
T03
T04
T05
T06
T07
T08
V01
V02

Page 50

7TSW2221005
REAR GROUNDING BAR
7TMB0304006
FOOT PAD REAR ADJUSTABLE
7TME0112109
BOLT GROUNDING BAR
7TME0112024
BOLT TRANSPORT WHEEL
7TME0502108
WASHER TRANSPORT WHEEL
7TME0902007
EXTERNAL C RING-TRANSPORT WHEEL
7TMC0501027
CABLE DISPLAY CONTROL BOARD
7TMC0520002
CABLE SEAT RAIL
7TMC0550001
WIRE HEART RATE SEAT RAIL CONSOLE
7TMC0203004
CONTROL BOARD
7TMC0736002
POWER RESISTANCE
7TMC0535006
CABLE GENERATOR
7TMB06B8001
CONTROL BOARD BRACKET
7TMJ1393002
POWER RESISTANCE COVER
7TME0102027
SCREW RESISTOR
7TME0204003
NYLON NUT RESISTOR
7TME0502082
WASHER RESISTOR
7TMB0601005
WATER BOTTLE HOLDER
7TMB0609028
END CAP FOR FRONT GROUNDING BAR-RH
7TMB0609026
END CAP FOR FRONT GROUNDING BAR-LH
7TMB0609035
END CAP OF REAR GROUNDING BAR- R OR L
7TME0104055
SCREW CONTROL PANEL
7TSZRB40SCV-L SIDE COVER LEFT WITH DECALS
7TSZRB40SCV-R SIDE COVER RIGHT WITH DECALS
7TSZRB40PAX FLYWHEEL SHAFT ASSY. WITH TENSIONER
7TMD0602018
POLY V BELT SECONDARY
7TME0104014
SCREW FLYWHEEL
7TME0502092
WASHER FLYWHEEL
7TMJ3247001
BELT ADJUSTOR-BRAKE
7TMJ1245003
HOOK COVERBELT ADJUSTOR-BRAKE
7TME0204010
NYLON NUT BELT ADJUSTOR - BRAKE
7TME0201012
NUT - BRAKE AXEL
7TSZRB40DAX BOTTOM BRACKET WHEEL ASSY.
7TMD0405001
LEFT CRANK
7TMD0406001
RIGHT CRANK
7TMD0402002
PEDALS - 9/16" WITH STRAPS
7TMD0403002
PEDAL STRAP-PR
7TMD0602013
POLY V BELT PRIMARY
7TMB0622001
CRANK CAVER ARM BOLT
7TME0113012
CRANK ARM BOLT
7TME1103002
SPRING BELT TENSIONER
7TMG0214008
SIDE COVER DECAL LEFT- BLUE
7TMG0214014
SIDE COVER DECAL RIGHT- BLUE

1 PC.
4 PCS.
4 PCS.
2 PCS.
2 PCS.
2 PCS.
1 PC.
1 PC.
1 PC.
1 PC.
1 PC.
1 PC.
1 PC.
1 PC.
4 PCS.
4 PCS.
4 PCS.
1 PC.
1 PC.
1 PC.
2 PCS.
4 PCS.
1 SET
1 SET
1 SET
1 PC.
6 PCS.
6 PCS.
2 PCS.
2 PCS.
2 PCS.
2 PCS.
1 SET
1 PC.
1 PC.
1 SET
1 SET
1 PC.
2 PCS.
2 PCS.
1 PC.
1 SET
1 SET

TR 750 PARTS DIAGRAM
After 08/05/01 and Prior to
Serial # 02-RE0283C

Page 51

TR 750 AFTER 8/5/01 PRIOR TO
02-RE0283C
NEW SEAT ASSY - 3 PIECE CRANK

Page 52

114
117
001
003
039
043
118
083
084
085
086
087
031
045
088
116
050
051
089
052
053
090
028
091
093
094
092
097
024
098
031
030
099
035
102
100
002
054
060
055
056
057
058
026
027

REF. # PART #
AD5 7TSZRB40SAS
AG2 7TSP0212003
AN1 7TSM0209004
AS1 7TMD0208006
B26 7TME0701001
B27 7TME0107014
B35 7TMJ3251001
D76 7TMB1001005
D77 7TMB1002002
D78 7TME0112013
D79 7TME0112014
D80 7TME0501006
D81 7TME0112024
D82 7TME0501007
G06 7TMB0401021
G06 7TSP0206006
G08 7TMJ1278001
G09 7TMB06A7001
G10 7TMB0609031
G11 7TME0102069
G12 7TME0201028
H01 7TSZRB40RAL-1
H33 7TMB0103001
H37 7TMZE0112042
H38 7TMZE 0107015
H39 7TMB0211008
H41 7TMB0632007A
J07 7TSZRB40RST
J08 7TMB0304006
J09 7TME0112109
J10 7TME0112024
J11 7TME0502108
J12 7TME0902007
P01 7TMC0501027
P04 7TMC0550001
P05 7TMC0549005
P11 7TMC0203004
P12 7TMC0736002
P15 7TMB06B8001
P17 7TMJ1393002
P22 7TME0102027
P23 7TME0204003
P24 7TME0502082
Q06L 7TMB0609026
Q06R 7TMB0609028

DESCRIPTION
SEAT SLIDE SET
CONSOLE HANDLE BAR
CONSOLE ASSY.
BRAKE ASSY.
C CLAMP - SIDE COVER
SCREW SIDE COVER
FIXTURE SHAFT SIDE COVER
SEAT BOTTOM
SEAT BACK
SCREW SEAT BOTTOM
SCREW SEAT BACK
WASHER SEAT BACK AND BOTTOM
SCREW SEAT HANDLE BAR
WASHER SEAT HANDLE BAR
HANDLE BAR FOAM GRIP
SEAT HANDLE BAR
HANDPULSE SENSOR
HANDPULSE BRACKET
HAND PULSE END CAP
SCREW HAND PULSE
NUT HAND PULSE
SEAT RAIL ASSY.
TRANSPORT WHEEL
BOLT SEAT RAIL
SCREW RAIL AND CAP
END CAP OF REAR SLIDE TUBE
RAIL CAP END
REAR STABILIZER
LEVELER
BOLT REAR STAILIZER
BOLT TRANSPORT WHEEL
WASHER TRANSPORT WHEEL
EXTERNAL C RING TRANSPORT WHEEL
CABLE DISPLAY/CONTROL BOARD
WIRE HRC RAIL TO CONSOLE
HR SENSOR WIRE
CONTROL BOARD
RESISTOR
BRACKET CONTROL BOARD
RESISTOR COVER
SCREW RESISTOR
NYLON NUT RESISTOR
WASHER RESISTOR
END CAP FRONT GROUNDING BAR LEFT
END CAP FRONT GROUNDING BAR RIGHT

QTY
1 SET
1 SET
1 SET
1 SET
16 PCS.
16 PCS.
1 PC
1 PC
1 PC
4 PCS.
4 PCS.
8 PCS.
4 PCS.
4 PCS.
2 PCS.
1 SET
2 SETS
2 SETS
4 PCS.
4 PCS.
4 PCS.
1 PC
2 PCS.
8 PCS.
2 PCS.
1 PC
1 PC
1 PC
4 PCS.
4 PCS.
2 PCS.
2 PCS.
2 PCS.
1 PC
1 PC
2 PCS.
1 PC
1 PC
1 PC
1 PC
4 PCS.
4 PCS.
4 PCS.
1 PC
1 PC

023
105
081
082
005
018
010
011
006
107
019
049
048
109
110
112
004
029
032
033
038
046
047
059
061
062
063
065
066
067
095
095
101
103
104
106
108
111
113
115
120
143

Q07
Q08
Q11
Q12
R03
R06
T02
T03
T04
T05
T06
T08
T09
V02
V03
V08

7TMB0609035
7TME0104055
7TSZRB40SCV-L
7TSZRB40SCV-R
7TSZRB40PAX
7TMD0602018
7TMD0405001
7TMD0406001
7TMD0402002
7TMD0403002
7TMD0602013
7TMB0622001
7TME0113012
7TMG0214008
7TMG0214014
7TMG0222006
7TSZRB40DAX
7TMB0705001
7TMZE0112119
7TMB0304020A
7TMJ1208001
7TME0103022
7TME0514002

END CAP REAR GROUNDING BAR
SCREW DISPLAY
SIDE COVER LEFT
SIDE COVER RIGHT
FLYWHEEL SHAFT ASSY
SECONDARY POLY V BELT
LEFT CRANK
RIGHT CRANK
PEDAL SET 9/16"
PEDAL STRAP SET RT & LT
POLY V BELT PRIMARY
CRANK BOLT CAP
CRANK BOLT
SIDE COVER DECAL LEFT BLUE
SIDE COVER DECAL RIGHT BLUE
SEAT RAIL DECAL
BOTTOM BRACKET WHEEL ASSY
MOVING WHEEL COVER
BOLT FOOT PAD FRONT
FOOT PAD FRONT
FIXTURE SIDE COVER BOTTOM
FLATHEAD SCREW
WASHER
FRONT GROUNDING BAR ASSY.
7TME0107043
SCREWS CONTROL BOARD
7TME0104014
SCREW FLYWHEEL
7TME0502092
WASHER FLYWHEEL
7TMJ1245003
HOOK COVER BELT ADJ.
7TME0204010
NYLON NUT BELT ADJ
7TME0201012
NUT BRAKE AXEL
7TMJ1215008C SEAT LOCK
7tszrb40sld
seat install kit
7TMC0520002
HR WIRE SENSOR PLATE
7TMC0535006
WIRE BREAK
7TMB0601005
WATER BOTTLE CAGE
7TMJ3247001
EYE BOLT BELT ADJUSTER
7TME1103002
SPRING BELT TENSIONER
7TMG0102054
MODEL DECAL WHITE
7TME0602016
ASSY. HARDWARE KIT
7TSZRB40SER-1 SEAT ROLLER ASSY.
7TME0107015
SCREWS RAIL CAP END
7TME0502018
WASHER REAR TUBE MOUNT
7TME0102047
SCREW SIDE COVER
7TMZE0103007 SCREW SEAT LOCK

2 PCS
4 PCS.
1 SET
1 SET
1 SET
1 PC
1 PC
1 PC
1 SET
1 SET
1 PC
2 PCS.
2 PCS.
1 SET
1 SET
1 PC
1 SET

1 PC

1 SET
6 PCS.
6 PCS.
2 PCS.
2 PCS.
2 PCS.
1 PC
1 PC
1 PC
1 PC
2 PCS.
1 SET
2 PCS.
1 SET
4 PCS.

2 PCS.
3 PCS.

Page 53

TR 750 PARTS DIAGRAM
After Serial # 02-RE0283C
(1 Piece Crank)

Page 54

TR 750 AFTER SERIAL # 02-RE0283C
NEW SEAT ASSEMBLY-1 PIECE CRANK
REF. # PART #
AD5 7TSZRB40SAS
7TSZRB40SER-1
AG1 7TSP0206006
AG2 7TSP0212003
AN1
AS1
AS1
B26
B27

D76
D77
D78
D79
D80
D81
D82
G06
G08
G09
G10
G11
G12
H01
H37
H41
H40
H39

P01
P05
P04
P12
P15

7TSM0209004
7TMD0208006
7TSM0206008D
7TME0701001
7TME0107014
7TMJ3251001
7TME0102047
7TMJ1208001
7TMB1001005
7TMB1002002
7TME0112013
7TME0112014
7TME0501006
7TME0112024
7TME0501007
7TMB0401021
7TMJ1278001
7TMB06A7001
7TMB0609031
7TME0102069
7TME0201028
7TSZRB40RAL-1
7TMZE0112042
7TMB0632007A
7TMZE0107015
7TMB0211008
7TMJ1215008C
7TMZE0103007
7TMB0103001
7TSZRB40RST
7TMB0304006
7TME0112109
7TME0112024
7TME0502108
7TME0902007
7TMC0501027
7TMC0549005
7TMC0520002
7TMC0550001
7TMC0203004
7TMC0736002
7TMC0535006
7TMB06B8001

DESCRIPTION
SEAT SLIDE SET
SEAT ROLLER ASSY.
SEAT HANDLE BAR
CONSOLE HANDLE BAR
FRONT GROUNDING BAR ASSY.
CONSOLE ASSY.
BRAKE ASSY.
BRAKE ASSY-AFTER SERIAL # 02-RE1237K
C CLAMP - SIDE COVER
SCREW SIDE COVER
FIXTURE SHAFT SIDE COVER
SCREW SIDE COVER
FIXTURE SIDE COVER BOTTOM
SEAT BOTTOM
SEAT BACK
SCREW SEAT BOTTOM
SCREW SEAT BACK
WASHER SEAT BACK AND BOTTOM
SCREW SEAT HANDLE BAR
WASHER SEAT HANDLE BAR
HANDLE BAR FOAM GRIP
HANDPULSE SENSOR
HANDPULSE BRACKET
HAND PULSE END CAP
SCREW HAND PULSE
NUT HAND PULSE
SEAT RAIL ASSY.
BOLT SEAT RAIL
RAIL CAP END
SCREW RAIL AND CAP
END CAP OF REAR SLIDE TUBE
SEAT LOCK
SCREW SEAT LOCK
TRANSPORT WHEEL
REAR STABILIZER
LEVELER
BOLT REAR STAILIZER
BOLT TRANSPORT WHEEL
WASHER TRANSPORT WHEEL
EXTERNAL C RING TRANSPORT WHEEL
CABLE DISPLAY/CONTROL BOARD
HR WIRE SENSOR
HR WIRE SENSOR PLATE
WIRE HRC RAIL TO CONSOLE
CONTROL BOARD
RESISTOR
WIRE BREAK
BRACKET CONTROL BOARD

QTY
1 SET
4 PCS.
1 SET
1 SET
1 SET
1 SET
1 SET
1 SET
16 PCS.
16 PCS.
1 PC
2 PCS.
1 PC
1 PC
1 PC
4 PCS.
4 PCS.
8 PCS.
4 PCS.
4 PCS.
2 PCS.
2 SETS
2 SETS
4 PCS.
4 PCS.
4 PCS.
1 PC
8 PCS.
1 PC
2 PCS.
1 PC
1 PC
3 PCS.
2 PCS.
1 PC
4 PCS.
4 PCS.
2 PCS.
2 PCS.
2 PCS.
1 PC
2 PCS.
1 PC
1 PC
1 PC
1 PC
1 PC
1 PC

Page 55

P17 7TMJ1393002
RESISTOR COVER
7TME0102027
SCREW RESISTOR
7TME0204003
NYLON NUT RESISTOR
7TME0502082
WASHER RESISTOR
7TMB0601005
WATER BOTTLE CAGE
Q06R 7TMB0609028
END CAP FRONT GROUNDING BAR RIGHT
Q06L 7TMB0609026
END CAP FRONT GROUNDING BAR LEFT
Q07 7TMB0609035
END CAP REAR GROUNDING BAR
Q08 7TME0104055
SCREW DISPLAY
Q11 7TSZRB40SCV-L1 SIDE COVER LEFT
Q12 7TSZRB40SCV-R1 SIDE COVER RIGHT
R03 7TSZRB40PAX
FLYWHEEL SHAFT ASSY
R06 7TMD0602018
SECONDARY POLY V BELT
R17 7TME0104014
SCREW FLYWHEEL
R20 7TME0502092
WASHER FLYWHEEL
S01 7TMJ3247001
EYE BOLT BELT ADJUSTER
S02 7TMJ1245003
HOOK COVER BELT ADJ.
S03 7TME0204010
NYLON NUT BELT ADJ
S04 7TME0201012
NUT BRAKE AXEL
7TSZRB40PAX-1 BOTTOM BRACKET WHEEL ASSY
7TSZRB40KIT
BEARING KIT-BOTTOM BRACKET WHEEL ASSY
T04 7TSM0915027A
PEDAL SET 1/2'' (02-XXXXXL)
T05 7TMD0403002
PEDAL STRAP SET RT & LT
T06 7TMD0602013
POLY V BELT PRIMARY
7TME1103002
SPRING BELT TENSIONER
V02 7TMG0214008
SIDE COVER DECAL LEFT BLUE
V03 7TMG0214014
SIDE COVER DECAL RIGHT BLUE
7TMG0102054
MODEL DECAL WHITE
V08 7TMG0222006
SEAT RAIL DECAL
7TME0602016
ASSY. HARDWARE KIT

Page 56

1 PC
4 PCS.
4 PCS.
4 PCS.
1 PC
1 PC
1 PC
2 PCS
4 PCS.
1 SET
1 SET
1 SET
1 PC
6 PCS.
6 PCS.
2 PCS.
2 PCS.
2 PCS.
2 PCS.
1 SET
1 SET
1 SET
1 SET
1 PC
1 SET
1 SET
1 SET
2 PCS.
1 PC
1 SET

True Fitness
Removal &
Replacement
500R
500U
600U
600R
Page 57

TABLE OF CONTENTS
Removal and Replacement
Remove Access Covers – All Bikes

Page 59

500R
Remove Small Poly V Pulley
Remove Belt & Tensioner Assembly
Remove Crank Hub Assembly

Page 61
Page 63
Page 65

500U
Remove Small Poly V Pulley
Remove Belt & Tensioner Assembly
Remove Crank Hub Assembly

Page 68
Page 69
Page 72

600U
Remove Right Belt Poly-V Pulley
Remove Right Side Tensioner Assembly
Remove Belt & Tensioner Assembly
Remove Left Side Belt from Assembly
Remove Left Side Poly-V Wheel
Remove Crank Hub Assembly

Page 75
Page 77
Page 78
Page 81
Page 83
Page 84

600R
Remove Left Belt Poly-V Pulley
Remove Left Side Tensioner Assembly
Remove Belt & Tensioner Assembly
Remove Right Side Belt from Assembly
Remove Right Side Poly-V Wheel
Remove Crank Hub Assembly

Page 58

Support Services 800-883-8783

Mon-Fri 8:30am-5:00pm Central Time Zone

Page 87
Page 89
Page 90
Page 93
Page 95
Page 96

Fax: 636-272-7148

Removal & Replacement

Remove Access Covers ~ 500R, 500U, 600R & 600U
Tools Required:
Pedal Wrench
Phillips Screwdriver

Step 1.
Use pedal wrench to remove
both pedals from pedal cranks.

Step 1. Remove Pedals

Note:
Left pedal loosens clockwise. Right
pedal loosens counter- clockwise.

Step 2.
Remove front cover screws and nuts.

Step 2. Remove Cover Screws

Page 59

Removal & Replacement

Remove Access Covers ~ 500R, 500U, 600R & 600U (continued)

Note:
Electrical connections
are on 500 series bikes
only.

Step 3.
Disconnect electrical power adapter.

Step 1. Remove Electrical Connection
(500 series only).

Step 4.
Rotate crank handle forward to 2 o’clock
Position to allow removal of cover.

Step 2. Remove Cover

Page 60

Removal & Replacement

500R

Remove Small Poly-V Pulley

Tools Required:
4 mm-Hex Wrench
Flat blade Screwdriver
Hammer Handle

Note:
Leave belt in place to
help lock pulley

Step 1.
Use hammer handle to prevent
Rotation of large wheel when
Removing pulley.

Step 1. Prevent Rotation of Fly Wheel

Step 2.
Use 4 mm wrench to loosen
set screw in pulley.

Step 2. Loosen Set Screw

Page 61

Removal & Replacement

500R

Remove Small Poly-V Pulley (continued)

Step 3.
Use 17 mm box wrench to loosen
Nut from belt tension screw.

Step 3. Loosen Nut

Step 4.
Loosen rear hub bracket screws.

Step 4. Loosen Hub Bracket Screws

Step 5.
Remove belt from belt tensioner
Assembly and wheels.

Step 5. Remove Belt

Page 62

Removal & Replacement

500R

Remove Belt & Tensioner Assembly
Tools Required:
17 mm Box Wrench
5mm Hex Wrench
Snap Ring Pliers

Step 1.
Remove small poly-V pulley.

Step 1. Remove Small Poly-V Pulley

Step 2.
Remove keyway using flat blade
Screwdriver as required.

Step 2. Remove Keyway

Page 63

Removal & Replacement

500R

Remove Belt & Tensioner Assembly (continued)

Step 3.
Remove snap ring from belt
Tensioner.

Step 2. Remove Snap Ring

Step 4.
Remove belt tensioner.

Step 3. Remove Belt Tensioner

Page 64

Removal & Replacement

500R

Remove Front Hub Assembly
Tools Required:
Large Crescent Wrench
Hammer & Punch

Step 1.
Use crescent wrench to remove
Large nut on crank.

Note:
The crank nut has left-handed
threads. Turn clockwise to
loosen.

Step 1. Remove Crank Nut

Step 2.
Remove keyed washer from
under nut.

Step 3.

Step 2. Remove Keyed Washer

Use crescent wrench to remove
hex nut bearing.

Note:
The hex nut bearing has lefthanded threads. Turn
clockwise to loosen.

Step 3. Remove Hex Nut Bearing

Page 65

Removal & Replacement

500R

Remove Front Hub Assembly (continued)

Step 4.
Use crescent wrench to remove
Large nut on crank.

Note:
Slide brake towards seat to
allow pulley to clear frame.

Step 4. Pull Hex Nut Bearing Free

Step 5.
Use crescent wrench to remove
hex nut bearing.

Step 5. Remove Large Pulley Assembly

Page 66

Removal & Replacement

500R

Remove Front Hub Assembly (continued)

Step 6.
Twist assembly thru frame hub.
Pull assembly until clear of frame.

Note:
Right hand thread.

Step 6. Twist Unit Thru Hub Frame

Step 7.
Use hammer & punch to loosen
spanner nut on bearing.

Step 7. Drive spanner nut off to remove bearing

Step 8.
Remove bearing and washer by
Slipping off crank.

Note:
Pulley and crank are a welded
assembly (cannot be separated).
Step 8. Remove Bearing & Washer

Page 67

Removal & Replacement

500U

Remove Small Poly-V Pulley

Tools Required:
4 mm-Hex Wrench
Flat blade Screwdriver
Hammer Handle

Note:
Leave belt in place to
help lock pulley

Step 1.
Use hammer handle to prevent
Rotation of large wheel when
Removing pulley.

Caution!
Take care not damage outer
surface of flywheel on brake
assembly.

Step 1. Prevent Rotation of Fly Wheel

Step 2.
Use 4 mm wrench to loosen
set screw in pulley.

Step 2. Loosen Set Screw

Page 68

Removal & Replacement

500U

Remove Belt & Tensioner Assembly
Tools Required:
17 mm Box Wrench
5 mm-Hex Wrench
Snap Ring Pliers

Step 1.
Remove small poly-v pulley.

Step 1. Remove Small Poly-v Wheel

Step 2.
Remove keyway, using flat blade
Screwdriver as required.

Step 2. Remove keyway

Page 69

Removal & Replacement

500U

Remove Belt & Tensioner Assembly (continued)

Step 3.
Use 17 mm box wrench to loosen
Nut from belt tensioning screw.

Step 3. Prevent Wheel Rotation

Step 4.
Use 5 mm hex wrench to loosen
Rear hub bracket screws.

Step 4. Loosen setscrew
Page 70

Removal & Replacement

500U

Remove Belt & Tensioner Assembly (continued)

Step 5.
Remove belt from belt tensioner
Assembly and wheels.

Step 5. Remove Belt

Step 6.
Remove snap ring from belt
tensioner.

Step 6. Remove Snap Ring.

Step 7.
Remove belt tensioner.

Step 7. Remove belt tensioner

Page 71

Removal & Replacement

500U

Remove Crank Hub Assembly
Tools Required:
Large Crescent Wrench
Rubber Mallet
Flat Blade Screwdriver

Step 1.
Use crescent wrench to remove
Large nut on crank.
Step 1. Remove Crank Nut.
Note:
The crank nut has left-handed
threads. Turn clockwise to loosen.

Step 2.
Remove keyed washer from
under nut.

Step 2. Remove Keyed Washer

Step 3.
Use crescent wrench to remove
hex nut bearing. Use rubber mallet
to knock out the shaft pulley assembly.
Note:
The Hex nut bearing has lefthanded threads. Turn clockwise to
loosen.

Step 3. Remove Hex Nut Bearing

Page 72

Removal & Replacement

500U

Remove Crank Hub Assembly (continued)
Note:
A flat blade screwdriver may be
used to pry hub from frame.

Step 4.
Pull hex nut bearing clear of frame
Hub.
Step 4. Pull Hex Nut Bearing Free.

Step 5.
Pull large pulley until bearing clears
Frame.

Step 4. Pull Hex Nut Bearing Free.

Step 6.
Twist assembly thru frame hub.
Pull assembly until clear of frame.

Page 73

Removal & Replacement

500U

Remove Crank Hub Assembly (continued)

Step 7.
Use hammer and punch to loosen
spanner nut on bearing.

Note:
The spanner nut has righthanded threads. Turn
counter-clockwise to loosen.

Step 7. Drive Spanner Nut Off to Remove Bearing

Step 8.
Remove bearing & washer by
slipping off crank.

Note:
Pulley and crank are a welded
assembly (cannot be separated).
Step 8. Remove Bearing & Washer

Page 74

Removal & Replacement

600U

Remove Right Belt Poly-V Wheel
Tools Required:
Pliers
Snap Ring Pliers

Step 1.
Use pliers or needle nose pliers to
remove the belt tensioning spring

Step 1. Belt Tensioning Spring

Step 2.
Remove the belt.

Step 2. Remove Belt

Page 75

Removal & Replacement

600U

Remove Right Belt Poly-V Wheel (continued).

Step 3.
Use snap ring pliers to pry snap
ring from center of small poly-V
pulley.

Step 3. Prying with snap ring pliers

Step 4.
Remove the snap ring and washers.

Step 4. Remove the snap ring and washers

Step 5.
Remove the small poly-V pulley.

Step 5. Remove the small poly-V pulley
Page 76

Removal & Replacement

600U

Remove Right Side Tensioner Assembly
Tools Required:
Snap Ring Pliers

Step 1.
Remove snap ring.

Step 1. Remove Snap Ring

Step 2.
Slide tensioner assembly off pivot
shaft.

Note:
Frame is slotted to allow
brake bracket to slide when
bolts are loose.

Step 2. Slide Tensioner Assembly

Page 77

Removal & Replacement

600U

Remove Belt & Tensioner Assembly
Tools Required:
6 mm Hex Wrench
13 mm Open-End Wrench
Hammer Handle

Step 1.
Use 6 mm hex wrench to remove
brake bracket locking screw.

Step 1. Remove Locking Screw

Step 2.
Use 13 mm open-end wrench to
loosen the 4 bolts holding the
brake bracket to the frame.

Note:
Frame is slotted to allow
brake bracket to slide when
bolts are loose.

Step 2. Loosen Bracket Bolts

Page 78

Removal & Replacement

600U

Remove Belt & Tensioner Assembly (continued)

Step 3.
Use hammer handle to pry the
brake and bracket assembly
toward the back of the bike to
loosen the belt.

Step 3. Pry on Brake to Loosen Belt.

Step 4.
Remove brake belt from larger
poly-V wheel.

Step 4. Remove Belt

Page 79

Removal & Replacement

600U & 600R

Remove Belt & Tensioner Assembly (continued)

Step 5.
Disconnect wiring harness from
brake.

Step 5. Disconnect Wiring Harness.

Step 6.
Remove the loosened bottom
screws.

Step 6. Remove Loosened Screws

Step 7.
Remove brake and belt assembly.

Step 7. Remove Brake & Belt Assembly

Page 80

Removal & Replacement

600U

Remove Left Side Belt From Assembly
Tools Required:
Internal & External Snap
Ring Pliers
Flat Blade Screwdriver

Step 1.
Remove snap ring.
Step 1. Remove Snap Ring.

Step 2.
Carefully pry bearing out of housing.

Step 2. Pry Bearing Out of Housing

Step 3.
Remove inner snap ring.

Page 81

Removal & Replacement

600U

Remove Left Side Belt From Assembly (continued)

Step 4.
Use 4 mm Hex Wrench to remove
Screws and washers holding
Brake to bracket.

Step 4. Remove Screws & Washers.

Step 5.
Remove brake bracket until belt
Can be removed.

Step 5. Remove Bracket to Check Belt

Page 82

Removal & Replacement

600U

Remove Left Side Poly-V Wheel
Tools Required:
External Snap Ring Pliers

Step 1.
Remove snap ring from shaft on
Right side.

Step 1. Remove Snap Ring on Right Side

Step 2.
Slide shaft through bearing in
Frame to remove pulley and shaft
assembly.

Note:
Crank not welded to pulley so
(1) extra step showing
separating these for 600U set.

Step 2. Slide Shaft Through Frame

Page 83

Removal & Replacement

600U

Remove Crank Hub Assembly
Tools Required:
Large Crescent Wrench
Rubber Mallet
Flat Blade Screwdriver

Step 1.
Use crescent wrench to remove
Large nut on crank.
Step 1. Remove Crank Nut.
Note:
The crank nut has left-handed
threads. Turn clockwise to loosen.

Step 2.
Remove keyed washer from
under nut.

Step 2. Remove Keyed Washer

Step 3.
Use crescent wrench to remove
hex nut bearing. Use rubber mallet
to knock out the shaft pulley assembly.
Note:
The Hex nut bearing has lefthanded threads. Turn clockwise to
loosen.

Step 3. Remove Hex Nut Bearing
Page 84

Removal & Replacement

600U

Remove Crank Hub Assembly (continued)
Note:
A flat blade screwdriver may be
used to pry hub from frame.

Step 4.
Pull hex nut bearing clear of frame
Hub.

Step 4. Pull Hex Nut Bearing Free.

Step 5.
Pull large pulley until bearing clears
Frame.

Step 5. Remove Large Pulley Assembly.

Step 6.
Twist assembly thru frame hub.
Pull assembly until clear of frame.

Step 6. Twist Unit Thru Hub Frame.

Page 85

Removal & Replacement

600U

Remove Crank Hub Assembly (continued)

Step 7.
Use hammer and punch to loosen
spanner nut on bearing.
Note:
The spanner nut has righthanded threads. Turn
counter-clockwise to loosen.

Step 7. Drive Spanner Nut Off to Remove Bearing

Step 8.
Remove bearing & washer by
slipping off crank.
Note:
Pulley and crank are a welded
assembly (cannot be separated).

Step 8. Remove Bearing & Washer

Step 9.
Pull crank thru pulley to remove.

Step 9. Pull Crank Thru Pulley to Remove

Page 86

Removal & Replacement

600R

Remove Left Belt Poly-V Pulley
Tools Required:
Pliers
Snap Ring Pliers

Step 1.
Use pliers, or needle nose pliers,
to remove the belt tensioning
spring.

Step 1. Remove Belt Tensioning Spring

Step 2.
Remove the belt.

Step 2. Remove Belt

Page 87

Removal & Replacement

600

Remove Poly-V Wheel Pulley (continued)

Step 3.
Use snap ring pliers to snap
Ring from center of small poly-V
pulley.

Step 1. Prying with Snap Ring Pliers.

Step 4.
Remove the small poly-V pulley.

Step 2. Remove Small Poly-V Pulley

Page 88

Removal & Replacement

600R

Remove Left Side Tensioner Assembly
Tools Required:
Snap Ring Pliers

Step 1.
Remove snap ring.

Step 1. Remove Snap Ring

Step 2.
Slide tensioner assembly off pivot
shaft.

Note:
Frame is slotted to allow
brake bracket to slide when
bolts are loose.
Step 2. Slide Tensioner Assembly

Page 89

Removal & Replacement

600R

Remove Belt & Tensioner Assembly
Tools Required:
6 mm-Hex Wrench
13 mm Open-End Wrench
Hammer Handle

Step 1.
Use 6 mm hex wrench to remove
brake bracket locking screw.

Step 1. Remove Locking Screw

Step 2.
Use 13 mm open-end wrench to
loosen the 4 bolts holding the
brake bracket to the frame.

Note:
Frame is slotted to allow
brake bracket to slide when
bolts are loose.
Step 2. Loosen Bracket Bolts

Page 90

Removal & Replacement

600R

Remove Belt & Tensioner Assembly (continued)

Step 3.
Use hammer handle to pry the
brake and bracket assembly
toward the back of the bike to
loosen the belt.

Step 3. Pry on Brake to Loosen Belt.

Step 4.
Remove brake belt from larger
poly-V wheel.

Step 4. Remove Belt

Page 91

Removal & Replacement

600U & 600R

Remove Belt & Tensioner Assembly (continued)

Step 5.
Disconnect wiring harness from
brake.

Step 5. Disconnect Wiring Harness.

Step 6.
Remove the loosened bottom
screws.

Step 6. Remove Loosened Screws

Step 7.
Remove brake and belt assembly.

Step 7. Remove Brake & Belt Assembly

Page 92

Removal & Replacement

600R

Remove Right Side Belt From Assembly
Tools Required:
Internal & External Snap
Ring Pliers
Flat Blade Screwdriver

Step 1.
Remove snap ring.
Step 1. Remove Snap Ring.

Step 2.
Carefully pry bearing out of housing.

Step 2. Pry Bearing Out of Housing

Step 3.
Remove inner snap ring.

Page 93

Removal & Replacement

600R

Remove Right Side Belt From Assembly (continued)

Step 4.
Use 4 mm Hex Wrench to remove
Screws and washers holding
Brake to bracket.

Step 4. Remove Screws & Washers.

Step 5.
Remove brake bracket until belt
Can be removed.

Step 5. Remove Bracket to Check Belt

Page 94

Removal & Replacement

600R

Remove Right Side Poly-V Wheel
Tools Required:
External Snap Ring Pliers

Step 1.
Remove snap ring from shaft on
Right side.

Step 1. Remove Shaft Snap Ring on Right Side

Step 2.
Slide shaft through bearing in
Frame to remove pulley and shaft
assembly.

Step 2. Slide Shaft Through Frame
Note:
Crank not welded to pulley so
(1) extra step showing
separating these for 600U set.

Page 95

Removal & Replacement

600R

Remove Crank Hub Assembly
Tools Required:
Large Crescent Wrench
Rubber Mallet
Flat Blade Screwdriver

Step 1.
Use crescent wrench to remove
Large nut on crank.
Step 1. Remove Crank Nut.

Note:
The crank nut has left-handed
threads. Turn clockwise to loosen.

Step 2.
Remove keyed washer from
under nut.

Step 2. Remove Keyed Washer

Step 3.
Use crescent wrench to remove
hex nut bearing. Use rubber mallet
to knock out the shaft pulley assembly.
Note:
The Hex nut bearing has lefthanded threads. Turn clockwise to
loosen.

Step 3. Remove Hex Nut Bearing

Page 96

Removal & Replacement

600R

Remove Crank Hub Assembly (continued)
Note:
A flat blade screwdriver may be
used to pry hub from frame.

Step 4.
Pull hex nut bearing clear of frame
Hub.
Step 4. Pull Hex Nut Bearing Free.

Step 5.
Pull large pulley until bearing clears
Frame.

Step 5. Remove Large Pulley Assembly.

Step 6.
Twist assembly thru frame hub.
Pull assembly until clear of frame.
Step 6. Twist Unit Thru Hub Frame.

Page 97

Removal & Replacement

600R

Remove Crank Hub Assembly (continued)

Step 7.
Use hammer and punch to loosen
spanner nut on bearing.
Note:
The spanner nut has righthanded threads. Turn
counter-clockwise to loosen.

Step 7. Drive Spanner Nut Off to Remove Bearing

Step 8.
Remove bearing & washer by
slipping off crank.
Note:
Pulley and crank are a welded
assembly (cannot be separated).

Step 8. Remove Bearing & Washer

Step 9.
Pull crank thru pulley to remove..

Step 9. Pull Crank Thru Pulley to Remove
Page 98

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Create Date                     : 2005:07:18 17:08:38-05:00
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Modify Date                     : 2005:07:18 17:08:38-05:00
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Title                           : Microsoft Word - True Fitness Bike Service Manual.doc
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Author                          : gstracy

EXIF Metadata provided by EXIF.tools

True Fitness 500R Users Manual Bike Service

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