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6

1. Attach the Rear Stabilizer (33) to the Frame (1) with

two M10 x 75mm Carriage Bolts (47) and two M10
Nylon Locknuts (29).

2. Hold the Console Bracket (45) near the Upright (3)

and insert the Resistance Cable (26) down through
the Upright. Feed the Extension Wire (62) up through
the Console Bracket. 

Attach the Console Bracket (45) to the Upright (3)
with two M6 x 16mm Button Screws (54) and two M6
Split Washers (38). Make sure not to pinch the
Resistance Cable (26) or the Extension Wire (62).

ASSEMBLY

Assembly requires two people. Place all parts of the elliptical in a cleared area and remove the packing mate-
rials. Do not dispose of the packing materials until assembly is completed.  

Assembly requires a phillips screwdriver                      , two adjustable wrenches                     , and a rubber
mallet                        . 

2

1

47

33

1

29

29

3

45

62

38

54

54

26

38

3. Making sure that the Reed Switch Wire (25) and the

Resistance Cable (58) are in the indicated slot in the
Frame (1), slide the Front Stabilizer (34) into the Frame.
Do not allow the Wire or the Cable to get pinched.

While a second person holds the Upright (3) near the
Frame (1), connect the Reed Switch Wire (25) to the
Extension Wire (62). Next, connect the Resistance
Cable (26) to the Lower Cable (58) in the following way:

• Refer to drawing A. Pull up on the metal bracket,

and insert the tip of the Resistance Cable (26) into
the wire clip on the Lower Cable (58) as shown. 

• Refer to drawing B. Firmly pull the Resistance

Cable (26) and slide it into the metal bracket on the
Lower Cable (58) as shown. 

• Refer to drawing C. Using pliers, squeeze the prongs

on the upper end of the metal bracket together.

Pull any slack Resistance Cable (26) out of the top of
the Upright (3). Attach the Upright to the Front
Stabilizer (34) with two M10 Nylon Locknuts (29).
Attach the Upright to the Frame (1) with two M10 x
68mm Carriage Bolts (60) and two M10 Nylon
Locknuts (29).

29

3

62

25

26

58

29

1

3

34

Slot

60

A

B

C

58

26

26

Metal

Bracket

Metal

Bracket

58

Summary of Contents for 545 S

Page 1: ...damaged parts we will guarantee com plete satisfaction through direct assistance from our factory TO AVOID DELAYS PLEASE CALL DIRECT TO OUR TOLL FREE CUSTOMER HOT LINE The trained technicians on our c...

Page 2: ...IONS 3 BEFORE YOU BEGIN 4 PART IDENTIFICATION CHART 5 ASSEMBLY 6 HOW TO USE THE ELLIPTICAL 9 MAINTENANCE 11 CONDITIONING GUIDELINES 12 PART LIST 14 EXPLODED DRAWING 15 HOW TO ORDER REPLACEMENT PARTS B...

Page 3: ...clothing when using the elliptical Always wear athletic shoes for foot protection 9 When mounting and dismounting the ellipti cal always hold the handlebars or the T handle and step onto and off the p...

Page 4: ...before you use the elliptical If you have questions after reading the manual call our Customer Service Department toll free at 1 800 999 3756 Monday through Friday 6 a m until 6 p m Mountain Time excl...

Page 5: ...tity needed for assembly Note Some small parts may have been pre attached for shipping If a part is not in the parts bag check to see if it has been pre attached Pedal Arm Spacer 41 2 M4 x 19mm Flange...

Page 6: ...istance Cable 58 are in the indicated slot in the Frame 1 slide the Front Stabilizer 34 into the Frame Do not allow the Wire or the Cable to get pinched While a second person holds the Upright 3 near...

Page 7: ...6 Slide the other Handlebar 8 onto the Pivot Axle 2 Secure the Handlebars to the Upright 3 by tapping a 5 8 Axle Cap 57 onto the end of the Pivot Axle 4 While a second person holds the Console 6 near...

Page 8: ...t 3 with two M6 x 16mm Button Screws 54 and two M6 Nylon Locknuts 55 8 Make sure that there are four Pedal Arm Bushings 11 in each Pedal Arm 12 Identify the Left Pedal 31 which has an L molded into it...

Page 9: ...y to your exercise you may choose to turn the pedal disks in the opposite direction To dismount the elliptical allow the pedals to come to a complete stop CAUTION The elliptical does not have a freewh...

Page 10: ...ss the on reset button or simply begin exercising When the power is turned on one LED indicator will light in the LED track and the entire display will appear for two seconds The console will then be...

Page 11: ...vent damage to the console keep liquids away from the console Use only a sealable water bottle in the console CONSOLE TROUBLE SHOOTING If the console does not function properly the batteries should be...

Page 12: ...heart rate is near the smallest number in your training zone as you exercise For maximum fat burning adjust the intensity of your exercise until your heart rate is near the middle num ber in your trai...

Page 13: ...etching of the achilles tendons bend your back leg as well Stretches Calves achilles tendons and ankles 4 Quadriceps Stretch With one hand against a wall for balance reach back and grasp one foot with...

Page 14: ...Cable 27 2 Rear Stabilizer Endcap 28 1 Tension Spring 29 6 M10 Nylon Locknut 30 1 Belt 31 1 Left Pedal 32 1 Pulley w Shaft 33 1 Rear Stabilizer 34 1 Front Stabilizer 35 2 5 16 Zinc Bolt Key No Qty Des...

Page 15: ...5 59 40 37 13 12 41 11 43 5 16 4 16 16 13 49 13 42 11 43 9 39 22 23 24 17 18 19 20 22 53 21 17 18 19 20 53 28 52 48 1 54 55 63 63 10 56 57 56 8 8 57 56 56 3 29 16 16 7 50 51 51 26 6 47 29 29 33 45 2 3...

Page 16: ...This warranty does not extend to any product or damage to a product caused by or attributable to freight damage abuse misuse improper or abnormal usage or repairs not provided by an ICON authorized s...

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