LeMond Fitness RevMaster, Service Manual

Page 1: ...itness com Service Guide For the LeMond RevMaster Bid Specifications Warranty Exploded Diagrams Parts List Instructions o Installation Check List o Maintance Schedule o Tech Notes o Bottom Bracket Adj...

Page 2: ...New LEMOND RevMasterTM Group cycling will never be the same www LeMondfitness com 1 425 482 6773 Only one group exercise cycle bears his name 2002 LeMond Fitness RevMaster and LeMond are registered tr...

Page 3: ...for every user 4 Features a maintenance free 47 pound precision machined chrome flywheel for smooth pedaling 5 Features uniquely shaped handlebars that are more comfortable due to the multiple hand p...

Page 4: ...r warranty on the cranks bottom bracket flywheel handlebars seat post handlebar post a one year warranty on bottom bracket bearings pillow bearings tension knob assembly and a 90 day warranty on the w...

Page 5: ...f flywheel for long term durability Leg Levelers Extra large diameter adjustable levelers Pedals Standard toe cage style with optional dual sided SPD toe cage Handlebars Biomechanically correct with a...

Page 6: ...f warranty replacement parts are shipped to you you may be required to return the inoperable part To facilitate this process the following policy has been established Please call 425 482 6773 ext 107...

Page 7: ...x 1030 Assy Handlebar 1 x 13906 includes grip Crank Bolt 2 x 885 Pedals Standard Pair 1 x VP 518 AT or SPD Dual Sided Pair 1 x WPD96B Left Crank 1 x 0875 1 Lock Ring Left Bearing Cup Spindle 1 x 0881...

Page 8: ...Spacer Flywheel 1 x 049A Washer 1 x 049C Assembly Pillow Block with Bearing 2 x H050 Flywheel Assembly 12 10 2004 Pulley Flywheel front drive NOTE This is press fit onto the flywheel shaft 1 x 015 Scr...

Page 9: ...AL FRAME LIFE FITNESS 1 50 250 DECAL WARNING 2 00 058A ENDCAP SQUARE CROSSARM 1 50 201 30N ENDCAP SQUARE HANDLEBAR SEAT POST 0 50 103 FLYWHEEL ASSY PRE ASSEMBLED WITH SPLINE SHAFT PILLOW BLOCKS W BEAR...

Page 10: ...NEW LOOP HANDLEBAR 9 50 CB 1427 WATERBOTTLE CAGE PLASTIC INCLUDES 2 SCREWS WASHERS NO CLAMP 9 95 14068 WATERBOTTLE CLAMP W GROMMET OLD HANDLEBAR 7 00 13948 WATERBOTTLE CLAMP W GROMMET NEW LOOP HANDLEB...

Page 11: ...ost groove Install 1 washer onto 1 handle and loosely thread the handle into the first hole of the stainless steel seat slider Note Use the second hole in the seat slider to position yourself closer t...

Page 12: ...he base bolts and use the 5 mm hex key and the wrench tool to secure the nut Once all 4 base bolts are installed test the bike to make sure that the frame is stable Note the base bolt sits into a coun...

Page 13: ...st into the seat post tube Loosely thread a handle without a washer into the main frame Raise the seat post to the desired height and tighten the handle to secure the seat post 6 The handles are sprin...

Page 14: ...with seat slider over the seat post Loosely thread a handle with a washer through the seat post into the seat slider Slide the seat to the desired position and tighten the handle 10 Position the handl...

Page 15: ...to 30 Ft lbs Brake Pad Inspect for excessive wear or a dry leather brake pad Weekly N A 3 IN One Oil or 10W oil Do not use silicone based lubricants Belt Inspect for correct tension replace cracked f...

Page 16: ...ex key Used for cross arm mounting bolts Other tools lubricant recommended 5 8 Pedal wrench easier to set up multiple bikes quickly with lower risk of cross threading the cranks Grease for use on the...

Page 17: ...ces rear Slot in top Keeps seat and seat slider from twisting Adjustment handle and grease 7 Saddle install and check level Adjustment handle washer and grease 8 Pedals install Note the dual sided upg...

Page 18: ...nal Medium strength blue Rubber Mallet Dead blow hammer used to check for spindle radial end play Torque wrench for crank bolts right bearing cup lock ring Flywheel Assembly 4 mm hex key flywheel pull...

Page 19: ...er 4 Scrap any remaining foam tape off of the brake pad holder 5 Remove the protective backing from the foam tape on the new brake pad and align the two holes in the brake pad with the holes in the br...

Page 20: ...om bracket lock ring 5 Use a 4 mm hex key to loosen the belt tension adjustment screw 6 Use an adjustable wrench to loosen the belt tensioner idler pulley bolt Slide the belt tensioner bearings up 7 R...

Page 21: ...pindle with a rubber mallet or dead blow hammer to test for lateral end play If you need to adjust the bearing cup remove it first from the frame apply Locktite 242 243 on 2 3 threads 2 3rds around th...

Page 22: ...u cross thread the crank you will need to use a tap to clean up the threads If you can not clean up the threads you will need to replace the crank A cross threaded crank is not a manufacturing defect...

Page 23: ...n case it is dropped on the frame during removal 5 Remove the flywheel assembly from the frame and place the flywheel on a padded surface Caution the flywheel weighs 47 pounds 6 Use a 4 mm hex key to...

Page 24: ...ler nut located on the inside right frame fork does not get lost 4 Remove the two idler bearings the bearing spacer and the slotted washer from the idler bolt 5 Install the new bearings on the idler b...

Page 25: ...brake pad needs lubrication is excessive drag on the flywheel TOOLS NEEDED Lubricant 3 IN ONE oil Clean dry rag PROCEDURE 1 Rotate the tension knob clockwise until the brake pad lightly contacts the f...

Page 26: ...it from the frame 2 Remove the belt from the bike Loosen the idler pulley nut with an adjustable wrench approx 1 turn and use a 4 mm allen key to loosen the tension adjustment screw located on top of...

Page 27: ...he flywheel up and remove the flywheel from the frame Place the flywheel on a padded surface next to the new bike Note Lay the flywheel down on a padded surface Any surface damage to the flywheel nick...

Page 28: ...om the edge in back Use the 4 mm allen wrench to align the screw into the mounting hole on the brake pad housing and partially thread the screw into the brake pad housing Peel the back off the adhesiv...

Page 29: ...ler pulley and around the rear pulley of the bike Tension the belt by tightening the idler tension screw on top of the idler pulley Tighten the idler pulley nut WARNING WATCH YOUR FINGERS AS YOU INSTA...

Page 30: ...ight side front belt cover Lift the right side belt cover over the right crank arm and remove it from the frame This is easiest when the right side crank arm rests at 9 o clock 2 Remove the belt from...

Page 31: ...ywheel Spline Shaft from the flywheel 5 Install a new flywheel shaft assembly into the flywheel Insert a new flywheel spline shaft into the center of the flywheel line up the holes Apply 1 2 drops of...

Page 32: ...y nut WARNING WATCH YOUR FINGERS AS YOU INSTALL THE BELT ON THE PULLEYS SO THAT YOU DO NOT PINCH THEM BETWEEN THE PULLEY AND THE BELT 8 Test the belt tension Stand on the pedals with the pedals horizo...

Page 33: ...een removed When properly prepared for paint the surface of the frame should be light yellow or black in color and completely dust free 3 Once the affected area is properly prepared shake the 2oz bott...