True Fitness 500R Users Manual Bike Service

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.

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 Procedure

D

I

A

G

N

O

S

T

I

C

S

To Enter Diagnostic

Mode

Console / Display

Output

RPM

Console Key Input

Contact Heart Rate

DA (Resistance)

Exit Diagnostics

•

Press and hold the “Start” key as you

begin pedaling.

• Continue pedaling throughout the test.

-------

• Press “Enter” key – initiates the second

LED function 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 unit will reset.

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148

Page 2

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 . . . . . . . . . . . . . . . . . . . . . . . . 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

Note: If motor has been bound and then

freed the motor may have been weakened. If

components now move freely but the motor

is laborin

g

–

re

p

lace the motor.

Symptom Probable Cause Corrective Action

ECB

MALFUNCTION

500R, 500U

Control Panel

Defective Cables

Defective ECB

Control Board

Optical Sensor

DC Motor

ECB Limit Switch

Loud Continuous

Tone from lower

board (ECB board)

•

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.

--------

• 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.

--------

• 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.

Check the front pivot point for the magnet bar and loosen the

bolt to allow for the motor to freely move the magnet bar.

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148

Page 4

Symptom Probable Cause Corrective Action Recommended Tools

IRREGULAR OR

NO DISPLAY

500R, 500U

DC Adaptor

Adapter Plug or

Jack

Control Panel

Cables

• 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.

--------

• 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 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 Page 5

Symptom Probable Cause Corrective Action Recommended Tools

NO RPM

READING

500R, 500U

Control Panel/ RPM

Sensor

Defective Cables

Defective RPM

Sensor Set

• 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.

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 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148

Page 6

Symptom Probable Cause Corrective Action Recommended Tools

NO POLAR

HEART RATE

500R, 500U

Control Panel

Heart Rate Chest

Strap

External

Interference

• 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.

--------

• 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 Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 Page 7

Symptom Probable Cause Corrective Action Recommended Tools

IRREGULAR OR

NO DISPLAY

600R, 600U

Control Panel

Control Board

Cables

AC Voltage Output

Generator Output

Cable

• 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.

--------

• Disconnect 6PG from 6PH.

• Pedal.

• Check DC voltage between pins 2 and 3

for 5 VDC.

• No 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 a continuity check on the

generator output cable.

• If no continuity – replace cable

Multi-meter

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148

Page 8

Symptom Probable Cause Corrective Action Recommended Tools

NO RPM

READING

600R, 600U

Control Panel

Defective Cables

Defective RPM

Sensor Set

• Disconnect 5PA from 5PB. (Page 19-

20).

• 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.

--------

• 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.

Multi-meter

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 Page 9

Symptom Probable Cause Corrective Action Recommended Tools

NO CONTACT

HEART RATE

600R, 600U

Control Panel

Defective Cables

Defective Handles

• 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

--------

• 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 connections.

• If connections OK – Replace handles.

Multi-meter

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148

Page 10

Symptom Probable Cause Corrective Action Recommended Tools

HANDLEBAR

BUTTONS DO

NOT FUNCTION

600R

“Cruise Control”

“Start” Button

“Shift” Button

“_“ Button

“Select” Button

“+” Button

• Remove console-mounting screws.

Locate 10P7B (Page 20).

• Check for continuity between pin 7 and

pin 1 at 10P7B. Press Cruise control

button.

(A)

• No continuity? Perform a continuity

check on the appropriate cable.

• Replace cable or if cable good – replace

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

pin 6 at 10P7B. Press + button. See (A)

above.

--------

• If all have continuity and problem

persists – replace Console

Multi-meter

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 Page 11

Symptom Probable Cause Corrective Action Recommended Tools

NO RESISTANCE

750U, 750R Console Set

Defective Cables

Power Resistance

Brake Harness/

Lower Board

•

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.

--------

• 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 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 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.

Note:

You must pedal at least

30 RPM when

p

erforming any voltage

test. You may require the

assistance of another

p

erson when performing

volta

g

e checks.

Multi-meter

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148

Page 12

Symptom Probable Cause Corrective Action Recommended Tools

HEAVY

RESISTANCE

750U, 750R

Console Set

Defective Cables

Lower control

Board/Brake

• 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.

--------

• 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 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 Page 13

Symptom Probable Cause Corrective Action Recommended Tools

No Display

750U, 750R Console Set

Brake

Defective Cable

Console Cable/

Lower Control

Board

• 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.

--------

• 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.

Note:

You must pedal at least

30 RPM when

p

erforming any voltage

test. You may require the

assistance of another

p

erson when performing

volta

g

e checks.

Multi-meter

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148

Page 14

Symptom Probable Cause Corrective Action Recommended Tools

NO CONTACT

HEART RATE

750U, 750R

Dirty Sensors

Console Set/

Wiring

Wire Connections

• Verify hand pulse sensors are clean.

--------

• 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.

--------

• 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

p

erforming any voltage

test. You may require the

assistance of another

p

erson when performing

volta

g

e checks.

Multi-meter

Double sided tape

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 Page 15

Symptom Probable Cause Corrective Action Recommended Tools

NO POLAR

HEART RATE

750U, 750R

Control Panel

Defective Cables

Defective ECB

Control Board

• 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.

--------

• 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.

Note:

You must pedal at least

30 RPM when

p

erforming any voltage

test. You may require the

assistance of another

p

erson when performing

volta

g

e checks.

Polar Heart Rate

Simulator

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148

Page 16

WIRING DIAGRAMS

 TR / TU 500 Page 18

 600 U Page 19

 600 R Page 20

 TR/TU 750 Page 21

Page 17

Page 18

TR/ TU 500 WIRING DIAGRAM

Page 19

TU 600 WIRING DIAGRAM

TR 600 WIRING DIAGRAM

Page 20

Page 21

TR/ TU 750 WIRING DIAGRAM

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.

# PART # DESCRIPTION QTY

2 7T010800 FRONT STABILIZER WITH BOLTS 1 SET

3 7T000200 TRANSPORTATION WHEEL HIT 1 SET

4 7T000300 FTONT STABILIZER END CAP 2 PCS

5 7T000400 CRANK PULLEY WITH CAPS AND BEARINGS 1 SET

6 7T000600 BOLT BELT TENSION 1 PC

7 7T010900 BRAKE ASSY 1 SET

8 7T001700 ALUMINUM IDLER ASSY 1 SET

9 7T001800 ECB DC MOTOR WITN SCREWS 1 SET

10 7T002000 ECB CONTROL BOARD WITH SCREWS 1 SET

11 7T001900 ECB LIMIT SWITCH WTH SCREWS 1 SET

^12-

1 7T011000 LEFT SHROUD WITH DECALS 1 SET

^12-

2 7T001302 SCREW 1 PC

^12-

3 7T001202 SCREW 6 PCS.

^12-

4 7T001303 SCREW 3 PCS.

^12-

5 7T011100 RIGHT SHROUD WITH DECAL 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 PIN UPPER 1 PC.

14-

1-2 7T004002 CABEL ASSY 5 PIN UPPPER 1 PC.

15 7T004100 BOTTLE CAGE WITH SCREWS 1 SET

16 7T001100 COMPUTER WITH SCREWS 1 SET

17 7T003800 DC JACK 1 PC

18 7T003900 ADAPTER 9VDC 1.2A 1 PC

19 7T004200 CD PLAYER HOLDER WITH SCREWS 1 SET

20 7T004300 SEAT ADJUSTING KNOB 1 PC

21 7T000900 SHROUD TRIM CAP 1 PC

22 7T004400 SEAT POST SLEAVE 1 PC

23 7T004500 SEAT POST 1 PC

24 7T004600 SADDDLE WITH CLAMP 1 PC Page 25

25 7T002600 REAR STABILIZER WITH BOLTS 1 SET

26 7T002700 ADJUSTING STAND KIT 1 SET

27 7T002800 REAR STABILIZER END CAP 2 PCS

28 7T012700 POLY V BELT 1 PC

29 7T005800 RPM SENSOR WITH WIRE AND NUT 1 SET

30 7T004700 CABLE ASSY 5 PIN LOWER SPEED SENSE 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

7TU60300 REAR STABILIZER HDW KIT 1 SET

Page 26

Page 27

TR 500 Exercise Bike

TR 500

REF # PART# DESCRIPTION QTY.

02 7T000100 Front Stabilizer w/Bolts 1 SET

03 7T000200 Transportation Wheel Kit 1 SET

04 7T000300 Front Stabilizer End Cap 2 PCS

05 7T000400 Crank Pulley w/E Caps & Bearings 1 SET

06 7T005800 RPM Sensor w/Wire & Nut 1 SET

07 7T000600 Bolt - Belt Tension 1 PC

08 7T000700 Cable Assembly - 6 Pin Lower 1 PC

09 7T000800 Cable Assembly - 5 Pin Lower 1 PC

10 7T000900 Shroud Trim Cap 1 PC

11 7T001000 Console Mast Set 1 SET

11-1-1 7T001001 Cable Assy, 6 Pin Upper 1 PC

11-1-2 7T004700 Cable Assy, 5 Pin Upper 1 PC

12 7T001100 Computer Set 1 SET

13-1 7T001201 Rear Shroud - Right 1 PC

13-2 7T001202 Screw, Sidecover 10 PCS

13-3 7T001203 Rear Shroud - Left 1 PC

13-4 7T001204 Screw, Rear Cover 1 PC

14-1 7T001301 500R Shroud - 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 (Wht) 1 PC

14-11 7T001311 Shroud Decal - B (Wht) 1 PC

14-12 7T001312 Shroud Decal - D (Wht) 1 PC

15 7T001400 Pedal Set w/Straps 1 SET

16 7T001500 Poly-v Belt 1 PC

17 7T010700 TR500 Brake Assy 1 SET

18 7T001700 Aluminum Idler Assembly 1 SET

19 7T001800 ECB DC Motor w/Screws 1 SET

20 7T001900 ECB Limit Switch w/Screws 1 SET

21 7T002000 ECB Control Board w/Screws 1 SET

22 7T002100 Aluminum Rail Trim Cap 1 PC

23 7T002200 Aluminum Rail w/Bolts 1 SET

24 7T002300 Stopper Kit 1 SET

25 7T002400 Fore and Aft Adjusting Rack w/Bolts 1 SET

Page 28

26 7T002500 Transportation Handle Set w/Screws 1 SET

27 7T002600 Rear Stabilizer w/Bolts 1 SET

28 7T002700 Adjusting Stand Kit 1 SET

29 7T002800 Rear Stabilizer End Cap 2 PCS

30 7T002900 Roller Set (A) Rt Ft & RR 2 SET

31 7T003000 Roller Set (B) Center 2 SET

32 7T003100 Seat Bottom w/Bolts 1 SET

33 7T003200 Fore and Aft Adjusting Lever 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

7TR50100 Assy Hdw Kit

7TR50200 Ft/RR Stabilizer Hdw Kit

7TR50300 H/Bar Hdw Kit

7TR50400 Bottle Holder Hdw Kit

7TU60700 Tool Kit

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 QTY.

02 7T010800 FRONT STABILIZER WITH BOLTS 1

03 7T000200 TRANSPORTATION WHEEL KIT 1

04 7T000300 FRONT STABILIZER END CAP 2

05 7T011400 DRIVE BELT KIT 1

7T004900 DO NOT ORDER

06 7T005000 POLY V PULLEY SET KIT SECONDARY 1

7-1 7T012000 LEFT COMPLETE W/ MODEL SHROUD DECALS 1

7-2 7T001302 SIDE COVER SCREW 1

7-3 7T001202 SIDE COVER SCREW 6

7-4 7T001303 SIDE COVER SCREW 3

7-5 7T012100 RIGHT SHROUD W/ MODEL DECALS 1

7-6 7T001306 HEX NUT 3

7-7 7T012200 MODEL DECAL LEFT WHITE 1

7-8 7T001311 SHROUD DECAL BLUE 1

7-9 7T001312 SHROUD DECAL BLUE 1

7-10 7T012300 MODEL DECAL RIGHT WHITE 1

7-11 7T001308 SHROUD DECAL BLUE 1

7-12 77T001309 SHROUD DECAL BLUE 1

08 7T001400 PEDAL SET W/ STRAPS LFT. & RT. 1

09 7T005500 CRANK AND CUPS PULLEY 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 ADJUSTING KNOB 1

21 7T004400 SEAT POST SLEAVE 1

22 7T004500 SEAT POST SET 1

23 7T004600 SADDLE W/ CLAMP 1

24 7T006900 HANDLEBAR W/ CONTACT HR AND BOLTS 1

24-1-1 7T006202 CABLE ASSY. 1

25 7T004100 BOTTLE CAGE W/ SCREWS 1

26 7T006300 COMPUTER W/ SCREWS 1

27 7T004200 CD PLAYER HOLDER W/ SCREWS 1

28 7T007000 CABLE ASSEMBLY 5 PIN LOWER 1

29 7T012600 IDLER ARM AXLE KIT 1

30 7T002600 REAR STABILIZER W/ SCREWS 1

31 7T002700 LEVELERS x2 WITH LOCKS 1

32 7T002800 REAR STABILIZER END CAP 2

33 7T005100 POLY V PULLEY SET KIT CLUTCH 1

24-2 7T013100 HANDLEBAR END CAPS 2 Page 33

7T011800 MODEL DECAL LEFT 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

TR 600 PARTS DIAGRAM

Page 35

TR600 BIKE

REF. # PART # DESCRIPTION QTY USED

24-1 7T011600 600R L SHROUD & DECALS 1

24-2 7T001202 SIDE CVR SCREW 6

24-3 7T001303 SIDE CVR SCREW 3

24-4 7T001302 SIDE CVR SCREW 1

24-5 7T011700 600R R SHROUD & DECALS 1

24-6 7T001306 HEX NUT SIDE CVR SCREW 3

24-7 7T011800 MODEL DECAL 66R L WHITE 1

24-8 7T001308 SHROUD DECAL A BLUE 1

24-9 7T001309 SHROUD DECAL C BLUE 1

24-10 7T012300 MODEL DECAL 600R RT WHITE 1

24-11 7T001311 SHROUD DECAL B BLUE 1

24-12 7T001312 SHROUD DECAL D BLUE 1

25 7T001400 PEDAL W/STRAPS LT&RT 1

26 7T002100 ALUM RAIL TRIM CAP 1

27 7T002200 ALUM RAIL W/HDRW 1

28 7T002300 SEAT STOP KIT LT& RT 1

29 7T006500 CABLE ASSY 12 PIN LWR SEAT RAIL 1

30 7T002400 SEAT ADJ RACK 1

31 7T002500 TRANSPORT HNDL 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 7T011400 TR/TU600 DR BELT REPLACE KIT 1

6 7T005000 POLY-V SEONDARY KIT CLUTCH 1

7 7T005100 POLY-V CLUTCH PULLEY KIT 1

8 7T005200 ALUM IDLER & IDLER ARM 1

9 7T005300 C RING IDLER ARM 1

10 7T005400 SPRING IDLER ARM 1

11 7T005500 CRANK & PULLEY W/BEARINGS 1

12 7T005600 J-8 POLY-V BELT PRIM 1

13 7T011500 TU/TR600 BRAKE KIT 1

13-9 7T007300 CABLE BRAKE 1

15 7T005800 RPM SENSOR & KNOT CBL 1

16 7T005900 RESISTOR W/SCREWS 1

17 7T006000 CNTRL BOARD W/SCREWS 1

18 7T006100 CABLE ASSY SPIN LWR 1

19 7T000900 MAST TRIM CAP 1

Page 36

20 7T006200 CONSOLE MAST W/BOLTS 1

20-1-1 7T006201 CABLE ASSY 12 PIN UPPER 1

20-1-2 7T006202 CABLE ASSY 52 PIN UPPER 1

21 7T006300 COMPUTER SET 660RIU LT FRT 1

22 7T003700 ROLLER SET SEAT LT RR 2

23 7T006400 IDLER ARM SHAFT KIT 1

40-1 7T001201 REAR SHROUD RT 1

24-2 7T001202 ROUND CROSS SCREW 4

40-3 7T001204 TAPPING SCREW 1

40-4 7T001203 REAR SHROUD LT 1

41 7T003500 BTTL HDLR 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 7TR50200 FH RR STABILIZER HDW KIT

20-1 7TR50300 HNDLBR HDW KIT

41-1 7TR50400 BTTL HLDR HDW KIT

7TR60100 ASSY HDW KIT

21-1 7TU50200 CPANEL HDW KIT

7TU60700 ASSY TOOL KIT

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

Page 40

TU 750 PARTS DIAGRAM

(

3 PIECE CRANK

)

TU 750 3 PIECE CRANK

TU750:

02-

UP0161C

REF # PART# DESCRIPTION QTY.

AB1 7TSP0101006 FRAME

AC1 7TSZCB24CSM UPRIGHT HANDLE BAR 1

AD1 7TSW0150005 SEAT POST 1

AJ1 7TSZCB24FST FRONT GROUNDING BAR ASSEMBLY 1

AN1 7TSM0209004 CONSOLE SET 1

AS1 7TMD0208006 BRAKE ASSEMBLY 1

B22 7TME0701001 C CLAMP SIDE COVER 14

B24 7TME0107014 SCREW SIDE COVER 16

B31 7TMJ1208001 SIDE COVER BRACKET 1

C07 7TMJ1278001 HAND PULSE SENSOR 1

C08 7TMB06A7001 SENSOR BRACKET PULSE 1

C10 7TME0102069 SCREW PULSE BRACKET 4

C11 7TMB0201028 NUT PULSE BRACKET 4

C12 7TMB0601005 WATER BOTTLE CAGE 1

C13 7TME0102043 SCREW BOTTLE CAGE 2

C14 7TME0111014 SCREW HANDLEBAR MAST 6

C15 7TMB0605006 TRIM CAP 1

C16 7TMJ1291001 END CAP OF HANDLEBAR 2

D03 7TMB1001018 SEAT CUSHION 1

D04 7TME0204019 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 7TMC0549002 CONTACT HEART RATE CABLE 2

P11 7TMC0203004 CONTROL BOARD 1

NEXT FIVE PIECES ASSEMBLY BUT NO ASSY. NUMBER

P12 7TMC0736002 POWER RESISTANCE 1

P17 7TMJ1393002 COVER POWER RESISTENCE 1

P22 7TME0102027 SCREW 4

P23 7TME0204003 NUT 4

P24 7TME0502082 WASHER 4

P15 7TMB06B8001 CONTROL BOARD BRACKET 1

P19 7TME0107043 SCREW CONTROL BOARD 8

P20 7TME0107043 SCREW RESISTOR TO FRAME 8

Q01 7TMN1101006 SEAT ADJUSTMENT KNOB BLUE 1

J14 7TMB0304020A FOOT PAD FRONT 2

J15 7TMZE0112119 BOLT FRONT FOOT PAD 2

Q02 7TMB0604018 SEAT POST SLEEVE 1

Page 41

Q06R 7TMB0609028 END CAP FOR FRONT GROUNDING BAR RT. 1

Q06L 7TMB0609026 END CAP FOR FRONT GROUNDING BAR LT. 1

Q07 7TMB0609035 END CAP FOR REAR GROUNDING BAR 2

Q11 7TSZCB24SCV-L SIDE COVER ASSY. LEFT 3 PC. CRANK 1

Q12 7TSZCB24SCV-R SIDE COVER ASSY. RIGHT 3 PC. CRANK 1

R03 7TSZRB40PAX FLYWHEEL SHAFT ASSEMBLY 1

R06 7TMD0602018 POLY V BELT 520-J8 1

R09 7TME0103022 FLAT HEAD SCREW 2

R14 7TME0514002 WASHER 2

R17 7TME0104014 SCREW FLYWHEEL ATTACH 6

R20 7TME0502092 WASHER FLYWHEEL ATTACH 6

S01 7TMJ3247002 EYE BOLT BRAKE BELT TENSION 2

S02 7TMJ1245003 HOOK COVER BRAKE BELT TENSION 2

S03 7TME0204010 NYLON NUT BRAKE BELT TENSION 2

S04 7TME0201012 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 ATTACH 2

U06 7TME0112088 SCREW BELT TENSIONER 1

U07 7TMJ1914002 STRETCH ADJUSTER BELT TESIONER 1

U09 7TME1104002 STRETCH SPRING BELT TENSIONER 1

U10 7TME0502084 WASHER BELT TENSIONER 1

U12 7TME0104014 SCREW BELT TENSIONER 1

U13 7TME0201003 NUT BELT TENSIONER 1

V01 7TMG0214009 SIDE COVER DECAL BLUE 1

V03 7TMG0102036 MODEL DECAL WHITE 2

7TMH0205023 OWNERS MANUAL 1

7TME0601017 ASSEMBLY KIT 1

Q08 7TMB0237002 UPPER FRAME COVER 1

Page 42

Page 43

TU 750 PARTS DIAGRAM

(1 PIECE CRANK)

TU 750 1PC CRANK

REF.# PART# DESCRIPTION QTY.

AB1 7TSP001006 FRAME

AC1 7TSZCB24CSM HANDLE BAR W/HR 1

AD1 7TSW0150005 SEAT POST 1

AJ1 7TSZCB24FST FRONT GROUND BAR ASSEMBLY 1

AN1 7TSM0209004 CONSOLE ASSEMBLY 1

AS1 7TMD0208006 BRAKE ASSEMBLY 1

B22 7TME0701001 C CLAMP SIDE CVR 14

B24 7TME0107014 SCREW SIDE CVR 16

B31 7TMJ1208001 SIDE CVR BRACKET 1

C07 7TMJ1278001 HAND PULSE SENSOR 2

C08 7TMB06A7001 SENSOR BRACKET PULSE 2

C10 7TME0102069 SCREW PULSE BRKT 4

C11 7TMB0201028 NUT PULSE BRKT 4

C12 7TMB0601006 WATER BTL CAGE 1

C13 7TME0102043 SCREW BTL CAGE 2

C14 7TME0111014 SCREW HANDLEBAR 6

MAST

C15 7TMB0605006 TRIM 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 7TMB0705001 MOVING WHEEL CVR 2

DO NOT ORDER

P01 7TMC0501027 CONSOLE DATA CBL 1

P08 7TMC0549002 CONTACT HEART RATE 2

CABLE

P11 7TMC0203004 CONTROL BOARD 1

P12 7TMC0736002 POWER RESISTANCE 1

P17 7TMJ1393002 COVER POWER 1

RESISTANCE

P22 7TME0102027 SCREW 4

P23 7TME0204003 NUT 4

P24 7TME0502082 WASHER 4

P15 7TMB06B8001 CONTROL BRD BRKT 1

P19 7TME0107043 SCREW CNTRL BRD 8

P20 7TME0107043 SCREW RESISTER TO 8

Page 44

FRAME

Q01 7TMN1101006 SEAT ADJ KNOB 1

BLUE

J14 7TMB030402A FOOT PAD FRONT 2

J15 7TMZE0112119 BOLT FRONT FT PAD 2

Q02 7TMB0604018 SEAT POST SLEEVE 1

Q06R 7TMB0609028 END CAP FOR FRONT 1

GRNDG BAR FOR RIGHT

Q06L 7TMB0609026 END CAP FOR FRONT 1

GRNDG BAR FOR LEFT

Q07 7TMB0609035 END CAP FOR REAR 2

GROUNDING BAR

Q11 7TSZCB24SCV-L SIDE CVR ASSY LEFT 1

1 PIECE CRANK

Q12 7TSZCB24SCV-R SIDE CVR ASSY RT 1

1 PIECE CRANK

R03 7TSZRB40PAX FLYWHEEL SHAFT 1

ASSEMBLY

R06 7TMD0602018 POLY V BELT 520-J8 1

R09 7TME0103022 FLAT HEAD SCREW 2

DO NOT ENTER

R14 7TME0514002 WASHER 2

DO NOT ENTER

R17 7TME0104014 SCREW FLYWHEEL 6

ATTACH

R20 7TME0502092 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/STRAP 1

T05 7TMD0403002 PEDAL STRAP SET 2 1

T06 7TMD0602013 POLY V BELT 400-J08 1

T08 7TMB0622001 CRANK CVR CAP 2

T09 7TME0113012 SCREW CRANK ARM 2

U06 7TME0112088 SCREW BELT TENSIONER 1

U07 7TMJ1914002 STRETCH ADJUSTER 1

U09 7TME1104002 STRETCH SPRING 1

U10 7TME0502084 WASHER 1

U12 7TME0104014 SCREW BELT TENSIONER 1

U13 7TME0201003 NUT BELT TENSIONER 1

V01 7TMG0214009 SIDE CVR DECAL BLUE 1

7TMG0102053D MODEL DECAL SILVER

Page 45

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

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. # PART # DESCRIPTION QTY.

AD1 7TSP0203003 SEAT SLIDE WELDMENT 1 SET

AD2 7TSZRB40SLP SEAT SLIDE PLATE LOCK 1 SET

AG1 7TSP0206006 SEAT HANDLE BAR WELDMENT 1 SET

AG2 7TSP0212003 CONCOLE HANDLE BAR WELDMENT 1 SET

AJ1 7TSZRB40FST FRONT GROUNDING BAR ASSY. 1 SET

AN1 7TSM0209004 CONSOLE ASSEMBLY 1 SET

AS1 7TMD0208006 BRAKE ASSY 1 SET

B37 7TME0701001 C CLAMP-SIDECOVER 1 SET

B27 7TME0107014 SCREW- SIDE COVER 16 PCS.

7TMJ3251001 FIXTURE SHAFT SIDE COVER 1 PC.

7TME0102047 SCREW FOR SIDE COVER SHAFT 2 PCS.

7TMJ1208001 SIDE COVER BOTTOM FIXTURE 1 PC.

D01 7TMB1001005 SEAT BOTTOM PAD 1 PC.

D02 7TMB1002002 SEAT BACK PAD 1 PC.

7TMJ3228002 ADJUSTMENT BAR FIXTURE PIN 1 PC.

7TMJ3243001 BULB CONNECTOR 1 PC.

7TMJ3244001 CLEVIS 1 PC.

7TMJ3220006 SPACER 1 PC.

7TME1111002 OPPOSITE SPRING 1 PC.

D16 7TMJ3245001 ADJUSTMENT BAR WITH GRIP 1 PC.

7TSZRB40SER RECUMBANT SEAT ROLLER W/ HARDWARE 1 SET

7TSZRB40ESR 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 7TMB0401021 HANDLE FOAM GRIP 2 PCS.

G07 7TMJ1278001 HANDPULSE SENSOR 1 SET

G09 7TMB06A7001 HANDPULSE BRACKET 1 SET

G10 7TMB0609031 END CAP HANDLE BAR 4 PCS.

G11 7TME0102069 SCREW PULSE BRACKET 4 PCS.

G12 7TME0201028 NUT PULSE BRACKET 4 PCS.

H01 7TSZRB40RAL RECUMBANT SEAT ASSY. TUBE 1 PC.

H02 7TMJ3230001 FIXTURE PIN BRACKET 1 PC.

H03 7TMJ1228019 PLATE FIXTURE BRACKET SHIM 1 PC.

H09 7TME0112042 SCREW REAR TUBE MOUNT 8 PCS.

H13 7TME0502018 WASHER REAR TUBE MOUNT 8 PCS.

H16 7TMB0632001 END CAP OF FRONT SLIDE TUBE 1 PC.

H15 7TME0107015 SCREW SEAT TUBE END CAP 2 PCS.

H14 7TMB0211008 END CAP OF REAR SLIDE TUBE 1 PC.

7TMB0634002 WIRE CLAMP 1 PC.

7TME0102027 WIRE CLAMP 1 PC.

J05 7TMB0103001 TRANSPORT WHEEL 2 PCS. Page 49

J07 7TSW2221005 REAR GROUNDING BAR 1 PC.

J08 7TMB0304006 FOOT PAD REAR ADJUSTABLE 4 PCS.

J09 7TME0112109 BOLT GROUNDING BAR 4 PCS.

J10 7TME0112024 BOLT TRANSPORT WHEEL 2 PCS.

J11 7TME0502108 WASHER TRANSPORT WHEEL 2 PCS.

J12 7TME0902007 EXTERNAL C RING-TRANSPORT WHEEL 2 PCS.

7TMC0501027 CABLE DISPLAY CONTROL BOARD 1 PC.

7TMC0520002 CABLE SEAT RAIL 1 PC.

7TMC0550001 WIRE HEART RATE SEAT RAIL CONSOLE 1 PC.

P11 7TMC0203004 CONTROL BOARD 1 PC.

P12 7TMC0736002 POWER RESISTANCE 1 PC.

P13 7TMC0535006 CABLE GENERATOR 1 PC.

P15 7TMB06B8001 CONTROL BOARD BRACKET 1 PC.

P17 7TMJ1393002 POWER RESISTANCE COVER 1 PC.

P22 7TME0102027 SCREW RESISTOR 4 PCS.

P23 7TME0204003 NYLON NUT RESISTOR 4 PCS.

P24 7TME0502082 WASHER RESISTOR 4 PCS.

7TMB0601005 WATER BOTTLE HOLDER 1 PC.

Q06R 7TMB0609028 END CAP FOR FRONT GROUNDING BAR-RH 1 PC.

Q06L 7TMB0609026 END CAP 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 6 PCS.

7TMJ3247001 BELT ADJUSTOR-BRAKE 2 PCS.

7TMJ1245003 HOOK COVERBELT ADJUSTOR-BRAKE 2 PCS.

7TME0204010 NYLON NUT BELT ADJUSTOR - BRAKE 2 PCS.

7TME0201012 NUT - BRAKE AXEL 2 PCS.

7TSZRB40DAX BOTTOM BRACKET WHEEL ASSY. 1 SET

T02 7TMD0405001 LEFT CRANK 1 PC.

T03 7TMD0406001 RIGHT CRANK 1 PC.

T04 7TMD0402002 PEDALS - 9/16" WITH STRAPS 1 SET

T05 7TMD0403002 PEDAL STRAP-PR 1 SET

T06 7TMD0602013 POLY V BELT PRIMARY 1 PC.

T07 7TMB0622001 CRANK CAVER ARM BOLT 2 PCS.

T08 7TME0113012 CRANK ARM BOLT 2 PCS.

7TME1103002 SPRING BELT TENSIONER 1 PC.

V01 7TMG0214008 SIDE COVER DECAL LEFT- BLUE 1 SET

V02 7TMG0214014 SIDE COVER DECAL RIGHT- BLUE 1 SET

Page 50

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

REF. # PART # DESCRIPTION QTY

114 AD5 7TSZRB40SAS SEAT SLIDE SET 1 SET

117 AG2 7TSP0212003 CONSOLE HANDLE BAR 1 SET

001 AN1 7TSM0209004 CONSOLE ASSY. 1 SET

003 AS1 7TMD0208006 BRAKE ASSY. 1 SET

039 B26 7TME0701001 C CLAMP - SIDE COVER 16 PCS.

043 B27 7TME0107014 SCREW SIDE COVER 16 PCS.

118 B35 7TMJ3251001 FIXTURE SHAFT SIDE COVER 1 PC

083 D76 7TMB1001005 SEAT BOTTOM 1 PC

084 D77 7TMB1002002 SEAT BACK 1 PC

085 D78 7TME0112013 SCREW SEAT BOTTOM 4 PCS.

086 D79 7TME0112014 SCREW SEAT BACK 4 PCS.

087 D80 7TME0501006 WASHER SEAT BACK AND BOTTOM 8 PCS.

031 D81 7TME0112024 SCREW SEAT HANDLE BAR 4 PCS.

045 D82 7TME0501007 WASHER SEAT HANDLE BAR 4 PCS.

088 G06 7TMB0401021 HANDLE BAR FOAM GRIP 2 PCS.

116 G06 7TSP0206006 SEAT HANDLE BAR 1 SET

050 G08 7TMJ1278001 HANDPULSE SENSOR 2 SETS

051 G09 7TMB06A7001 HANDPULSE BRACKET 2 SETS

089 G10 7TMB0609031 HAND PULSE END CAP 4 PCS.

052 G11 7TME0102069 SCREW 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 J09 7TME0112109 BOLT REAR STAILIZER 4 PCS.

031 J10 7TME0112024 BOLT TRANSPORT WHEEL 2 PCS.

030 J11 7TME0502108 WASHER TRANSPORT WHEEL 2 PCS.

099 J12 7TME0902007 EXTERNAL C RING TRANSPORT WHEEL 2 PCS.

035 P01 7TMC0501027 CABLE DISPLAY/CONTROL BOARD 1 PC

102 P04 7TMC0550001 WIRE HRC RAIL TO CONSOLE 1 PC

100 P05 7TMC0549005 HR SENSOR WIRE 2 PCS.

002 P11 7TMC0203004 CONTROL BOARD 1 PC

054 P12 7TMC0736002 RESISTOR 1 PC

060 P15 7TMB06B8001 BRACKET CONTROL BOARD 1 PC

055 P17 7TMJ1393002 RESISTOR COVER 1 PC

056 P22 7TME0102027 SCREW RESISTOR 4 PCS.

057 P23 7TME0204003 NYLON NUT RESISTOR 4 PCS.

058 P24 7TME0502082 WASHER RESISTOR 4 PCS.

026 Q06L 7TMB0609026 END CAP FRONT GROUNDING BAR LEFT 1 PC

027 Q06R 7TMB0609028 END CAP FRONT GROUNDING BAR RIGHT 1 PC

Page 52

023 Q07 7TMB0609035 END CAP REAR GROUNDING BAR 2 PCS

105 Q08 7TME0104055 SCREW DISPLAY 4 PCS.

081 Q11 7TSZRB40SCV-L SIDE COVER LEFT 1 SET

082 Q12 7TSZRB40SCV-R SIDE COVER RIGHT 1 SET

005 R03 7TSZRB40PAX FLYWHEEL SHAFT ASSY 1 SET

018 R06 7TMD0602018 SECONDARY POLY V BELT 1 PC

010 T02 7TMD0405001 LEFT CRANK 1 PC

011 T03 7TMD0406001 RIGHT CRANK 1 PC

006 T04 7TMD0402002 PEDAL SET 9/16" 1 SET

107 T05 7TMD0403002 PEDAL STRAP SET RT & LT 1 SET

019 T06 7TMD0602013 POLY V BELT PRIMARY 1 PC

049 T08 7TMB0622001 CRANK BOLT CAP 2 PCS.

048 T09 7TME0113012 CRANK BOLT 2 PCS.

109 V02 7TMG0214008 SIDE COVER DECAL LEFT BLUE 1 SET

110 V03 7TMG0214014 SIDE COVER DECAL RIGHT BLUE 1 SET

112 V08 7TMG0222006 SEAT RAIL DECAL 1 PC

004 7TSZRB40DAX BOTTOM BRACKET WHEEL ASSY 1 SET

029 7TMB0705001 MOVING WHEEL 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 ADJ 2 PCS.

067 7TME0201012 NUT BRAKE AXEL 2 PCS.

095 7TMJ1215008C SEAT LOCK 1 PC

095 7tszrb40sld seat install kit

101 7TMC0520002 HR WIRE SENSOR PLATE 1 PC

103 7TMC0535006 WIRE BREAK 1 PC

104 7TMB0601005 WATER BOTTLE CAGE 1 PC

106 7TMJ3247001 EYE BOLT BELT ADJUSTER 2 PCS.

108 7TME1103002 SPRING BELT TENSIONER 1 SET

111 7TMG0102054 MODEL DECAL WHITE 2 PCS.

113 7TME0602016 ASSY. HARDWARE KIT 1 SET

115 7TSZRB40SER-1 SEAT ROLLER ASSY. 4 PCS.

120 7TME0107015 SCREWS RAIL CAP END

143 7TME0502018 WASHER REAR TUBE MOUNT

7TME0102047 SCREW SIDE COVER 2 PCS.

7TMZE0103007 SCREW SEAT LOCK 3 PCS.

Page 53

Page 54

TR 750 PARTS DIAGRAM

After Serial # 02-RE0283C

(

1 Piece Crank

)

TR 750 AFTER SERIAL # 02-RE0283C

NEW SEAT ASSEMBLY-1 PIECE CRANK

REF. # PART # DESCRIPTION QTY

AD5 7TSZRB40SAS SEAT SLIDE SET 1 SET

7TSZRB40SER-1 SEAT ROLLER ASSY. 4 PCS.

AG1 7TSP0206006 SEAT HANDLE BAR 1 SET

AG2 7TSP0212003 CONSOLE HANDLE BAR 1 SET

FRONT GROUNDING BAR ASSY. 1 SET

AN1 7TSM0209004 CONSOLE ASSY. 1 SET

AS1 7TMD0208006 BRAKE ASSY. 1 SET

AS1 7TSM0206008D BRAKE ASSY-AFTER SERIAL # 02-RE1237K 1 SET

B26 7TME0701001 C CLAMP - SIDE COVER 16 PCS.

B27 7TME0107014 SCREW SIDE COVER 16 PCS.

7TMJ3251001 FIXTURE SHAFT SIDE COVER 1 PC

7TME0102047 SCREW SIDE COVER 2 PCS.

7TMJ1208001 FIXTURE SIDE COVER BOTTOM 1 PC

D76 7TMB1001005 SEAT BOTTOM 1 PC

D77 7TMB1002002 SEAT BACK 1 PC

D78 7TME0112013 SCREW SEAT BOTTOM 4 PCS.

D79 7TME0112014 SCREW SEAT BACK 4 PCS.

D80 7TME0501006 WASHER SEAT BACK AND BOTTOM 8 PCS.

D81 7TME0112024 SCREW SEAT HANDLE BAR 4 PCS.

D82 7TME0501007 WASHER SEAT HANDLE BAR 4 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.

H39 7TMB0211008 END CAP OF REAR SLIDE TUBE 1 PC

7TMJ1215008C SEAT LOCK 1 PC

7TMZE0103007 SCREW SEAT LOCK 3 PCS.

7TMB0103001 TRANSPORT WHEEL 2 PCS.

7TSZRB40RST REAR STABILIZER 1 PC

7TMB0304006 LEVELER 4 PCS.

7TME0112109 BOLT REAR STAILIZER 4 PCS.

7TME0112024 BOLT TRANSPORT WHEEL 2 PCS.

7TME0502108 WASHER TRANSPORT WHEEL 2 PCS.

7TME0902007 EXTERNAL C RING TRANSPORT WHEEL 2 PCS.

P01 7TMC0501027 CABLE DISPLAY/CONTROL BOARD 1 PC

P05 7TMC0549005 HR WIRE SENSOR 2 PCS.

7TMC0520002 HR WIRE SENSOR PLATE 1 PC

P04 7TMC0550001 WIRE HRC RAIL TO CONSOLE 1 PC

7TMC0203004 CONTROL BOARD 1 PC

P12 7TMC0736002 RESISTOR 1 PC

7TMC0535006 WIRE BREAK 1 PC

P15 7TMB06B8001 BRACKET CONTROL BOARD 1 PC

Page 55

P17 7TMJ1393002 RESISTOR COVER 1 PC

7TME0102027 SCREW RESISTOR 4 PCS.

7TME0204003 NYLON NUT RESISTOR 4 PCS.

7TME0502082 WASHER RESISTOR 4 PCS.

7TMB0601005 WATER BOTTLE CAGE 1 PC

Q06R 7TMB0609028 END CAP FRONT GROUNDING BAR RIGHT 1 PC

Q06L 7TMB0609026 END CAP FRONT GROUNDING BAR LEFT 1 PC

Q07 7TMB0609035 END CAP REAR GROUNDING BAR 2 PCS

Q08 7TME0104055 SCREW DISPLAY 4 PCS.

Q11 7TSZRB40SCV-L1 SIDE COVER LEFT 1 SET

Q12 7TSZRB40SCV-R1 SIDE COVER RIGHT 1 SET

R03 7TSZRB40PAX FLYWHEEL SHAFT ASSY 1 SET

R06 7TMD0602018 SECONDARY POLY V BELT 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 7TMD0403002 PEDAL STRAP SET RT & LT 1 SET

T06 7TMD0602013 POLY V BELT PRIMARY 1 PC

7TME1103002 SPRING BELT TENSIONER 1 SET

V02 7TMG0214008 SIDE COVER DECAL LEFT BLUE 1 SET

V03 7TMG0214014 SIDE COVER DECAL RIGHT BLUE 1 SET

7TMG0102054 MODEL DECAL WHITE 2 PCS.

V08 7TMG0222006 SEAT RAIL DECAL 1 PC

7TME0602016 ASSY. HARDWARE KIT 1 SET

Page 56

True Fitness

Removal &

Replacement

 500R

 500U

 600U

 600R

Page 57

TABLE OF CONTENTS

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148

Removal and Replacement

Remove Access Covers – All Bikes Page 59

500R

Remove Small Poly V Pulley Page 61

Remove Belt & Tensioner Assembly Page 63

Remove Crank Hub Assembly Page 65

500U

Remove Small Poly V Pulley Page 68

Remove Belt & Tensioner Assembly 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 & Tensioner Assembly Page 90

Remove Right Side Belt from Assembly Page 93

Remove Right Side Poly-V Wheel Page 95

Remove Crank Hub Assembly Page 96

Page 58

Removal & Replacement

Remove Access Covers ~ 500R, 500U, 600R & 600U

Step 1.

Use pedal wrench to remove

both pedals from pedal cranks.

Step 2.

Remove front cover screws and nuts.

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

Removal & Replacement

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

Step 3.

Disconnect electrical power adapter.

Step 4.

Rotate crank handle forward to 2 o’clock

Position to allow removal of cover.

Page 60

Note:

Electrical connections

are on 500 series bikes

onl

y

.

Step 1. Remove Electrical Connection

(500 series only).

Step 2. Remove Cover

Removal & Replacement 500R

Remove Small Poly-V Pulley

Step 1.

Use hammer handle to prevent

Rotation of large wheel when

Removing pulley.

Step 2.

Use 4 mm wrench to loosen

set screw in pulley.

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

Removal & Replacement 500R

Remove Small Poly-V Pulley (continued)

Step 3.

Use 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.

Page 62

Step 3. Loosen Nut

Step 4. Loosen Hub Bracket Screws

Step 5. Remove Belt

Removal & Replacement 500R

Remove Belt & Tensioner Assembly

Step 1.

Remove small poly-V pulley.

Step 2.

Remove keyway using flat blade

Screwdriver as required.

Tools Required:

17 mm Box Wrench

5mm Hex Wrench

Sna

p

Rin

g

Pliers

Step 1. Remove Small Poly-V Pulley

Step 2. Remove Keyway

Removal & Replacement 500R

Remove Belt & Tensioner Assembly (continued)

Step 3.

Remove snap ring from belt

Tensioner.

Step 4.

Remove belt tensioner.

Page 64

Step 2. Remove Snap Ring

Step 3. Remove Belt Tensioner

Removal & Replacement 500R

Remove Front Hub Assembly

Step 1.

Use crescent wrench to remove

Large nut on crank.

Step 2.

Remove keyed washer from

under nut.

Step 3.

Use crescent wrench to remove

hex nut bearing.

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

Removal & Replacement 500R

Remove Front Hub Assembly (continued)

Step 4.

Use crescent wrench to remove

Large nut on crank.

Step 5.

Use crescent wrench to remove

hex nut bearing.

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.

Removal & Replacement 500R

Remove Front Hub Assembly (continued)

Step 6.

Twist assembly thru frame hub.

Pull assembly until clear of frame.

Step 7.

Use hammer & punch to loosen

spanner nut on bearing.

Step 8.

Remove bearing and washer by

Slipping off crank.

Step 6. Twist Unit Thru Hub Frame

Step 7. Drive spanner nut off to remove bearing

Note:

Ri

g

ht hand thread.

Note:

Pulley and crank are a welded

assembly (cannot be separated).

Step 8. Remove Bearing & Washer

Removal & Replacement 500U

Remove Small Poly-V Pulley

Step 1.

Use hammer handle to prevent

Rotation of large wheel when

Removing pulley.

Step 2.

Use 4 mm wrench to loosen

set screw in pulley.

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

assembl

y

.

Removal & Replacement 500U

Remove Belt & Tensioner Assembly

Step 1.

Remove small poly-v pulley.

Step 2.

Remove keyway, using flat blade

Screwdriver as required.

Step 1. Remove Small Poly-v Wheel

Tools Required:

17 mm Box Wrench

5 mm-Hex Wrench

Snap Ring Pliers

Step 2. Remove keyway

Removal & Replacement 500U

Remove Belt & Tensioner Assembly (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.

Step 3. Prevent Wheel Rotation

Step 4. Loosen setscrew

Removal & Replacement 500U

Remove Belt & Tensioner Assembly (continued)

Step 5.

Remove belt from belt tensioner

Assembly and wheels.

Step 6.

Remove snap ring from belt

tensioner.

Step 7.

Remove belt tensioner.

Step 5. Remove Belt

Step 6. Remove Snap Ring.

Step 7. Remove belt tensioner

Removal & Replacement 500U

Remove Crank Hub Assembly

Step 1.

Use crescent wrench to remove

Large nut on crank.

Step 2.

Remove keyed washer from

under nut.

Step 3.

Use crescent wrench to remove

hex nut bearing. Use rubber mallet

to knock out the shaft pulley assembly.

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

loosen.

Removal & Replacement 500U

Remove Crank Hub Assembly (continued)

Step 4.

Pull hex nut bearing clear of frame

Hub.

Step 5.

Pull large pulley until bearing clears

Frame.

Step 6.

Twist assembly thru frame hub.

Pull assembly until clear of frame.

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.

Removal & Replacement 500U

Remove Crank Hub Assembly (continued)

Step 7.

Use hammer and punch to loosen

spanner nut on bearing.

Step 8.

Remove bearing & washer by

slipping off crank.

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).

Removal & Replacement 600U

Remove Right Belt Poly-V Wheel

Step 1.

Use pliers or needle nose pliers to

remove the belt tensioning spring

Step 2.

Remove the belt.

Tools Required:

Pliers

Snap Ring Pliers

Step 1. Belt Tensioning Spring

Step 2. Remove Belt

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 4.

Remove the snap ring and washers.

Step 5.

Remove the small poly-V pulley.

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

Removal & Replacement 600U

Remove Right Side Tensioner Assembly

Step 1.

Remove snap ring.

Step 2.

Slide tensioner assembly off pivot

shaft.

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

b

olts are loose.

Removal & Replacement 600U

Remove Belt & Tensioner Assembly

Step 1.

Use 6 mm hex wrench to remove

brake bracket locking screw.

Step 2.

Use 13 mm open-end wrench to

loosen the 4 bolts holding the

brake bracket to the frame.

Page 78

Tools Required:

6 mm Hex Wrench

13 mm Open-End Wrench

Hamme

r

Handle

Step 1. Remove Locking Screw

Step 2. Loosen Bracket Bolts

Note:

Frame is slotted to allow

brake bracket to slide when

b

olts are loose.

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 4.

Remove brake belt from larger

poly-V wheel.

Step 3. Pry on Brake to Loosen Belt.

Step 4. Remove Belt

Removal & Replacement 600U & 600R

Remove Belt & Tensioner Assembly (continued)

Step 5.

Disconnect wiring harness from

brake.

Step 6.

Remove the loosened bottom

screws.

Step 7.

Remove brake and belt assembly.

Page 80

Step 5. Disconnect Wiring Harness.

Step 7. Remove Brake & Belt Assembly

Step 6. Remove Loosened Screws

Removal & Replacement 600U

Remove Left Side Belt From Assembly

Step 1.

Remove snap ring.

Step 2.

Carefully pry bearing out of housing.

Step 3.

Remove inner snap ring.

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

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 5.

Remove brake bracket until belt

Can be removed.

Page 82

Step 4. Remove Screws & Washers.

Step 5. Remove Bracket to Check Belt

Removal & Replacement 600U

Remove Left Side Poly-V Wheel

Step 1.

Remove snap ring from shaft on

Right side.

Step 2.

Slide shaft through bearing in

Frame to remove pulley and shaft

assembly.

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.

Removal & Replacement 600U

Remove Crank Hub Assembly

Step 1.

Use crescent wrench to remove

Large nut on crank.

Step 2.

Remove keyed washer from

under nut.

Step 3.

Use crescent wrench to remove

hex nut bearing. Use rubber mallet

to knock out the shaft pulley assembly.

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

loosen.

Removal & Replacement 600U

Remove Crank Hub Assembly (continued)

Step 4.

Pull hex nut bearing clear of frame

Hub.

Step 5.

Pull large pulley until bearing clears

Frame.

Step 6.

Twist assembly thru frame hub.

Pull assembly until clear of frame.

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.

Removal & Replacement 600U

Remove Crank Hub Assembly (continued)

Step 7.

Use hammer and punch to loosen

spanner nut on bearing.

Step 8.

Remove bearing & washer by

slipping off crank.

Step 9.

Pull crank thru pulley to remove.

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

Removal & Replacement 600R

Remove Left Belt Poly-V Pulley

Step 1.

Use pliers, or needle nose pliers,

to remove the belt tensioning

spring.

Step 2.

Remove the belt.

Tools Required:

Pliers

Snap Ring Pliers

Step 1. Remove Belt Tensioning Spring

Step 2. Remove Belt

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 4.

Remove the small poly-V pulley.

Page 88

Step 1. Prying with Snap Ring Pliers.

Step 2. Remove Small Poly-V Pulley

Removal & Replacement 600R

Remove Left Side Tensioner Assembly

Step 1.

Remove snap ring.

Step 2.

Slide tensioner assembly off pivot

shaft.

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

b

olts are loose.

Removal & Replacement 600R

Remove Belt & Tensioner Assembly

Step 1.

Use 6 mm hex wrench to remove

brake bracket locking screw.

Step 2.

Use 13 mm open-end wrench to

loosen the 4 bolts holding the

brake bracket to the frame.

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

b

olts are loose.

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 4.

Remove brake belt from larger

poly-V wheel.

Step 3. Pry on Brake to Loosen Belt.

Step 4. Remove Belt

Removal & Replacement 600U & 600R

Remove Belt & Tensioner Assembly (continued)

Step 5.

Disconnect wiring harness from

brake.

Step 6.

Remove the loosened bottom

screws.

Step 7.

Remove brake and belt assembly.

Page 92

Step 5. Disconnect Wiring Harness.

Step 7. Remove Brake & Belt Assembly

Step 6. Remove Loosened Screws

Removal & Replacement 600R

Remove Right Side Belt From Assembly

Step 1.

Remove snap ring.

Step 2.

Carefully pry bearing out of housing.

Step 3.

Remove inner snap ring.

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

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 5.

Remove brake bracket until belt

Can be removed.

Page 94

Step 4. Remove Screws & Washers.

Step 5. Remove Bracket to Check Belt

Removal & Replacement 600R

Remove Right Side Poly-V Wheel

Step 1.

Remove snap ring from shaft on

Right side.

Step 2.

Slide shaft through bearing in

Frame to remove pulley and shaft

assembly.

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.

Removal & Replacement 600R

Remove Crank Hub Assembly

Step 1.

Use crescent wrench to remove

Large nut on crank.

Step 2.

Remove keyed washer from

under nut.

Step 3.

Use crescent wrench to remove

hex nut bearing. Use rubber mallet

to knock out the shaft pulley assembly.

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

loosen.

Removal & Replacement 600R

Remove Crank Hub Assembly (continued)

Step 4.

Pull hex nut bearing clear of frame

Hub.

Step 5.

Pull large pulley until bearing clears

Frame.

Step 6.

Twist assembly thru frame hub.

Pull assembly until clear of frame.

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.

Removal & Replacement 600R

Remove Crank Hub Assembly (continued)

Step 7.

Use hammer and punch to loosen

spanner nut on bearing.

Step 8.

Remove bearing & washer by

slipping off crank.

Step 9.

Pull crank thru pulley to remove..

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

True Fitness 500R Users Manual Bike Service

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

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