R7 Service Manual

Lifecycle LC9500R, LC9100R, LC8500R,
R9, R7 Series Bikes
Customer Support Services

SERVICE MANUAL
•
•
Lifecycle LC95R, LC91R, LC85R, R9, and R7 Recumbent Exercise Bikes
•
INTRODUCTION
This service manual is applicable to Recumbent Exercise Bikes LC9500R, LC9100R, LC8500R, R9, and R7.
Information represents typical configuration and may differ slightly from actual equipment. The service manual
provides recommendations for safe and efficient approaches to problem situations. This Service Manual is
separated Five Sections. They are:
SPECIAL SERVICE TOOL REQUIREMENTS

COMPONENTS IDENTIFICATION
TABLE OF CONTENTS
Section I
o TROUBLESHOOTING
Section II
o DIAGNOSTICS
Section III
o "How To..."
Section IV
o ELECTRONICS
o WIRING DIAGRAMS
Section V
o MISCELLANEOUS
If an operating problem should arise, tum to the TROUBLESHOOTING GUIDES and attempt to isolate what is
•
causing the malfunction. The GUIDES are listed by symptoms and follow with suggestions as to the most probable
cause of the problem.
Once you have pinpointed the source of the problem, tum to the appropriate "How To ..... section and review the
proper procedures for removing, replacing or adjusting a part. The "How To ..... sections are organized by
replaceable part (or assembly) name and each page lists the "Special Tools Required" to complete the specific
task.
Refer to COMPONENT IDENTIFICATION in the front part of this section to locate and identify in order service
repair parts for your machine.
If you do not have a part in stock, a form to order by FAX has been included in Section V for your convenience or
you can call Life Fitness Customer Support Services any Monday through Friday from 8:00 AM to 6:00 PM (
C.ST ). When you place a call, in order to speed our response to your particular situation, please have the
following information available for the customer service phone technician who will be prepared to assist you:
1. The Lifecycle equipment model number

2. The serial number
3. The symptom of the problem
4. The part name and number to order
When you receive your order, review the appropriate "How To..... section and follow the step by step procedures
designed to help you install the part quickly and correctly.
If you have any questions or comments please phone, mail, or fax us at:
• LIFE FITNESS COMPANY - CUSTOMER SUPPORT SERVICES

10601 Belmont Avenue, Franklin Park,IL 60131; U.S.A.
Telephone: 847-451-0036, Toll Free: 800-351-3737, FAX: 847-288-3702
Lifecycle LC95R, LC91 R, LC85R, R9, and R7 Recumbent Exercise Bikes
SPECIAL SERVICE TOOL REQUIREMENTS
Unless otherwise specified, only basic hand tools are required to perform service procedures
outlined in this section. Some of these standard tools should consist of Philips and Straight-
Blade Screw Drivers, Torx Set, Pliers, Rubber Mallet, Pry Bar, Snap Ring Pliers (internal and
•
external), Standard and Metric size Socket Set (318 or 1/2 drive), and Standard and Metric size
Combination, open-end, or Box Wrenches.
Specialized tools will be listed after the sub-heading Special Service Tools:, which appears
below the Service Procedure Heading at the top of the page. If no specialized tools are
required, then the title would read: Special Service Tools: NONE, which means that standard
hand tools should be employed to provide service to the product.
Specialized tools must be used to safely and effectively complete the service procedures.
Improvisation or attempts to use any other tool could result in unnecessary damage to the
equipment or personal injury.
•
ii
COMPONENT IDENTIFICATION
• - - - - - - - - - - -
Console ----L...-
Console
Support
Assembly
Seat Back Left Pedal
Seat Pad
Handlebar \
Right
Crank Arm
•
Left Side
Shroud Wheel
Accessory
Tray
Right Side
Shroud
Rear Stabilizer
Leveler
•
iii
Heart
Rate Main Cable
Cable
~seat
Assembly
Shroud
/Gasket
Extrusion
Left
Crank Arm
Hub
I
I
Inter~ediate
Pulley
I
•
Alternator
Belt
•
iv
Lifecyc/e LC95R, LC91R, LC85R, R9, and R7 Recumbent Exercise Bikes
Rack
• Crank Arm
Pulley
Right
Crank Arm
/
/ Hub
A1temator /
Cable Alternator
•
v
TABLE OF CONTENTS
SECTION I TROUBLESHOOTING GUIDES

Display Console LEOs Not Illuminating
Display Console Initializes Then Fails
No Prompt
LEOs Not Constant
LEOs Do Not Extinguish
Page
2
2
3
3
3
•
Prompt Flashes 3
Display Console Keys Do Not Function 4
Excessive Resistance 4
Resistance Varies 5
Resistance Constant 5
Pedaling Is Difficult 5
Pedaling Is To Easy 6
Battery Over-Heating 6
Bike Not Stable 6
Loud Noise 7
No Heart Rate 8
Handlebar Grips Loose 8
Notes 9
SECTION II DIAGNOSTICS
LC9500 2
LC9100 Console 3
LC8500 Console 4
R9 Console 5
R7 Console 6
MAP 7
ENTRY LEVEL 8
Test/Service - All LEOs And Keypad Test.. 9
Test/Service - Walking LED Test 10
Test/Service - Miscellaneous 1 Test 11
Test/Service - Miscellaneous 2 Test 12
TesUService - Port I/O Test 13
TesUService - Life Pulse Test 14
Test/Service - CSAFE Network Test 15
Test/Service - EEPROM Test 16
TesUService - Telemetry Enable/Disable 17
TesUService - Language 18
Optional Settings - MAX Workout Duration 19
Optional Settings - EnglishlMetric Units 20
Optional Settings - WATI Display Enable/Disable 21
Optional Settings - METS Display EnablelDisable 22
Optional Settings - CAUHR Display Enable/Disable 23
Optional Settings - WATIS Program Enable/Disable 24
Optional Settings - METS Program EnablelDisable 25
Optional Settings - Statistics 26
Optional Settings - Photo Shoot 27
Notes 28
•
vi
TABLE OF CONTENTS (continued)
SECTION III HOW TO REPLACE THE .

Side Shrouds 2
Drive Belt 3
Alternator Belt. 4
Crank Shaft Hub Assembly 5
Crank Shaft Bearings 6
Clutch Assembly 9
Intermediate Pulley Shaft and Bearings 10
Idler Roller 15
Altemator 16
Seat Locking Mechanism 18
Seat Assembly and Extrusion 19
Adjust Seat Rollers 20
Seat Pad and Handlebar Assembly 21
Locking Rack 22
Accessory Tray 23
Main Cable 24
Heart Rate Cable 25
Polar Receiver. 26
Altemator Cable 27
Reed Switch and Cable 28
9-Volt Console Battery (LC8500R and R7) 29
6-Volt Battery (LC95R, LC91 Rand R9) 30
•
Display Console and Console Support 31
Power Control Board 32
Pedals 33
Front Wheel Assembly 34
Levelers 35
Resistor Assembly 36
Console Circuit Board 37
Notes 38
SECTION IV ELECTRONICS OVERVIEW

Display Console Board - Model LC95R 2
Display Console Board - Model LC91 R 5
Display Console Board - Model LC85R and R7 7
Display Console Board - Model R9 9
Altemator Control Board - Model R7 and LC85R. 11
Altemator Control Board - Model R9, LC91 R, and LC95R 12
Alternator 14
Wiring Block Diagram LC85R and R7 15
Wiring Block Diagram R9 16
Wiring Block Diagram LC91 R 17
Wiring Block Diagram LC95R 18
SECTION V MISCELLANEOUS
Model Identification and Serial Number Location 2
Preventative Maintenance Schedule 3
• Important Safety Instructions

Parts Description
Assembly Instructions
4
5
7
vii
NOTES:
•
viii
SECTIO I
TROUBLESHOOTI G
GUIDES
•
TROUBLESHOOTING GUIDE
Malfunction
O'splay Console LEDs not
illuminating
Probable Cause
Auto start not respondinQ.
Keypad not responding.

Corrective Action
Check auto start not responding.
Test keypad in diagnostics.

•
Insufficient battery voltage. Check battery voltage. The LC9S00, LC91 DO,
and C9i have a 6VDC battery (non-alkaline)
which should test out between 5.8 to 6.3 VDC.
The LC8S0D, and C7 has a 9VDC alkaline
battery and it should test out between (8.8 -
9.2VDC).
Loose wire connections. Disconnect then reconnect connections.
Worn or damaged wire Inspect wire harnesses. Replace worn or

harnesses. aarnaged harness.
Malfunctioning display Test with substitute display console. Replace

console. malfunctioning display console.
Malfunctioning alternator Test with substitute ACB. Replace

control board (ACB). malfunctioning ACB.
Display console initializes Loose wire connections. Disconnect then secure connections.
then fails
No RPM.
Malfunctioning alternator.
1
,
I
Enter Diagnostic and check for RPM.
Test alternator output or test with substitute

alternator. Replace malfunctioning alternator.
Refer to Alternator Voltage Test.
•
Malfunctioning alternator Test with substitute alternator control board.
control board. Replace malfunctioning board.
Malfunctioning display Test with substitute display console. Replace

console. malfunctioning display console.

harnesses. damaged harness.
•
2
Malfunction Probable Cause Corrective Action

..
No prompt upon release of Malfunctioning display Test with substitute display console. Replace
START key. Entry of console. malfunctionina display console.
additional information not
allowed. Batterv drained. Replace Batterv with new one.
I
I Display Console LeOs are I Pedaling to slowly
I
I Pedal faster than 30 RPM.
I not constant I
I
Insufficient battery voltage Check battery voltage. The LC9500, LC91 DO,
and C9i have a 6VDC battery (non-alkaline)
which should test out between 5.8 to 6.3 VDC.
The LC8S00, and C7 has a 9VDC alkaline
battery and it should test out between (8.8 -
9.2VDC).
Loose wire connections Disconnect then reconnect connections.
I Worn or damaged wire Inspect wire harnesses. Replace wom or

harnesses I damaqed harnesses.
• Malfunctioning Display
Console
Malfunctioning Alternator
Control Board
Test with substitute Display Console. Replace
malfunctionino Display Console.
Test with substitute Alternator Control Board.

Replace malfunctioning board.
Malfunctioning Alternator Test Alternator output or test with substitute

Alternator. Replace malfunctioning Alternator.
Refer to Alternator Voltaae Test.
. . . ....
, Display Console LEOs do Software !
I not extinguish in timely
manner at the end of a Malfunctioning Alternator Test with substitute Alternator Control Board.
workout, when the CLEAR Control Board Replace defective board.
key is pressed, or when the
pedaling stops. Malfunctioning Display Inspect for damage or depression at START
Console key. Test with substitute Display Console.
Replace malfunctionina DisplaY Console.
Prompt persistently Attempting to enter improper Refer to Operation Manual for time duration
flashes and entry of duration of time requirements.
I additional infonnation is
not allowed. Malfunctioning Display I Test with suostitute Display Console. Replace
Consoie I malfunctionina Disolay Console.
•
3
Malfunction
Display Console keys
(except START key) do not
function and Exercise Bike
Probable Cause
Attempting to enter program
not available.
Corrective Action
Refer to Operation Manual for program
availability.
•
j does no~ re$pond. iv1alfunctioning Keypad I I est Keypad in Diagnostics.
I
I Malfunctioning Display I I est with substitute Display Console. Replace
Console malfunctioning Display Console.
Upon start of program, Insufficient battery voltage Check battery voltage. The LC9S00, LC91 00,
excessive resistance load and C9i have a 6VDC battery (non-alkaline)
is immediate; no normal, which should test out between 5.8 to 6.3 VDC.
incremental increase from The LC8S00, and C7 has a 9VDC alkaline
"no load." battery and it should test out between (8.8 -
9.2VDC).
,
i Loose wire connections Disconnect then, reconnect connections.
I
! Worn or damaged wire Inspect wire harnesses. Replace worn or
harnesses damaged harness.
Malfunctioning Display Test with substitute Display Console. Replace

Console malfunctioninQ Display Console.
I
,
I
I
I
Control Board
Test with substitute Alternator Control Board .
Replace malfunctioninQ board.
Test Alternator output or, test with substitute

?<efer to Alternator Voltage Test.
•
During program, excessive Loose wire connections I Disconnect then. reconnect connections.
resistance loading occurs. I
harnesses damaged harness.

Malfunctioning Alternator Test with substitute ACB. Replace

Control Board (ACB) malfunctioning ACB.
I
Malfunctioning Alternator . Test Alternctor output or, test with substitute

I
I I
Refer to Alternator VoltaQe Test.
•
4
.----------- Malfunction
I During MANUAL program,
I resistance variation
Probable Cause
Pedaling too slowly
Corrective Action
I Pedal faster than 45 RPM.
occurs. Loose wire connections Disconnect then, reconnect connections.
Worn or damaged hamesses I Inspect wire harnesses. Replace worn or

damaged harness.

Malfunctioning Alternator Test with substitute Alternator Control Board.

I
I
I
Control Board Replace defective board.
i
i Malfunctioning Alternator Test Alternator output or, test with substitute

I Alternator. Replace rnalfunctioning Alternator.
I Refer to Alternator Voltage Test.
During RANDOM or HILL Loose wire connections Disconnect then, reconnect connections.
programs, resistance is
constant without variation Worn or damaged harnesses Inspect wire harnesses. Replace worn or
for interval training nor hill damaged harness.
incline/decline.
• I
I
Console
Control Board
I
malfunctioning Display Console.
Test with substitute Alternator Control Board.

Replace defective board.
Test Alternator output or, test with substitute

I Refer to Alternator Voltage Test.
Pedaling is difficult, feels Malfunctioning Pulley Clutch Inspect Clutch for free backward and forward
restricted or, is not Assembly rotation. Replace malfunctioning Pulley Clutch
possible when Exercise or Freewheel.
Bike has not been started
I
STAR key not pressed). Alternator Belt excessively Inspect belt deflection. Adjust as necessary.
I
! tight !
! Alternator 8elt Deflection: 1/4 inch (6mm)
Alternator Belt Alignment is Realign alternator belt to far users left groove
OFF of the alternator pulley, not in the center.
Crank bearings worn or Replace Crank Bearings.

corroded
•
5
Malfunction Probable Cause Corrective Action

During exercise program, Pedaling too slowly I Pedal faster than 30 RPM.
pedaling is insufficiently
easy, not providing Program level doesn't Select higher level.
adequate resistance. challenae user abilitv
Loose wire connections Disconnect then, reconnect connections.

I
;
i
Worn or damaged harnesses : !ns;:>ect wire harnesses. Replace worn or
, damaged harness.
I

Console malfunctionina Display Console.
Malfunctioning Alternator Test with substitute Alternator Control Board.

Control Board Replace defective board.
Malfunctioning Alternator I Test Alternator output or, test with subst~ute

Refer to Alternator Voltaae Test.
I Alternator Belt excessively

loose
Inspect belt deflection. Adjust as necessary.
Alternator Belt Deflection: 1/4 inch (6mm)
Battery over-heating
during exercise program.
Drive Belt excessively loose
Battery Wires incorrectly

connected
Wom Battery Wires

Inspect Belt. Replace Belt.
Inspect connections: red wire to positive (+)

lead: black wire to neaative (-) lead.
Inspect Wires. Replace Wires or harness.

•
Battery leads grounding upon Inspect leads. Replace battery.
,
I
I
I frame

Console malfunctioning Displav Console.
Exercise Bike not stable Stabilizer Foot Pads not Adjust Foot Pads.
upon floor. adiusted correctly
Floor surface not level Position Exercise Bike upon level surface.
Wheel(s) damaged Replace damaged wheel(s).

I
Frame aamaged I Contact Customer Support Services.
•
6
.-----------
During exercise program,
loud noise issuing from
Non-carpeted, hard surface
floor
Place Exercise Bike upon softer surfaced floor.
! Exerc'se 9ike.
Improper riding STyle I ~:-ange style. Do not lean excessively to either
I sloe.
Crank Bearin sworn
Alternator Belt excessively Inspect belt deflection. Adjust as necessary.

loose
Alternator Belt Deflection: 1/4 inch (6mm)
Alternator Belt worn Re lace Belt.
Malfunctioning Alternator ODerate Exercise Bike as in normal use with

i fignt and heavy load levels. liSTen for
I excessive noise from Alternator. Replace
Alternator as necessa .
Drive Belt excessively loose Inspect Belt. Re lace Belt.
Free-wheel Pulley Assembly
•
7
Malfunction
No heart rate or, display
reads (No HR).
Probable Cause
No heart rate reading
Corrective Action
Executive Diagnostic Mode to verify
performance of heart rate function.
•
Faulty cable connection Verify heart-rate cable is properly connected.
Using an ohmmeter, verify continu:ty at the

main console cable. See wiring diagram for pin
location.
! Malfunctioning Rep'ace Hanaleoar/Lifepulse Assembly.

; , ~andleDar/Lifepu!-e Gn I
I
I Assemoly (inclUde. Worn or
i
I
damaged heart rate lead) I
Life Pulse handlebar Verify that the handlebar is functioning. See
diagrams.
Using an ohmmeter, verify continuity between

Lifepulse sensor and cable connection. See
wiring diagram for pin location.
Handlebar/Lifepulse Grip Dry wipe sensors.
•
Assembly
f
i
I Loose or malfunctioning heart Secure connection. Replace malfunctioning
rate lead connection at Display Handlebar/Lifepulse Grip Assembly
Console
,
Malfunctioning Display I Test with substitute Display Console. Replace
Excessive wear or damage to Replace the handlebar assembly.

grip
•
8
SECTION II
DIAGNOSTICS
•
DISPLAv CONSOLE LC95R
•
Heart Rate Distana! RPM calories
[
For Quick Start:
Begin pedaling.
J
Press Quick Start below.
LC95R
•
2
DISPLAY CONSOLE LC91 R
• Level • <:aories
• Heart Rate Dis<:ance RPt-: • Time
.\-A
~
~ For Quick Start: -,

r ~
~ Begin pedaling. .J~
~ Press Quid< Start.
• :::"':"::';::::::::;:';;H:::::;~:q
Manual
WORKOUT PROFILES Fitlinxx.
:/::tt::::#P::N??:1 I:NW:('::ii:}t?:':::1
Random Hill
?:o::;N:~::ii~i;~n ;",,:~::::~'±:;II
Heart Rate . Heart Rate
Interval Hill
Lc91 R
•
3
DISPLAY CONSOLE LC85R
• Level • calories
•
• Heart Rate Distance RPM • Time
I
.r : .
;: ~ ....... ~:,; ~:' .
• ~
....... /;..•... ;.. ..:; .
_
(
For Quick Start:
Begin pedaling.
Press Start.
J
Press Quick Start.
FrtIirrxx ht:1lK'r Pa:I.tf

•
/<:,::':":}})::),{):}:,! ::::"{:::'~;~·'l IW~~
Manual Fat Burn Cardio
,',,41,;:::;tW;::,:i':1 /?':::;;t:'?:':::::')?::":T~1
Random Hill
Lc85R
•
4
Life=ycle LC95R, LC91R, LC85R, R9, and R7 Recumbent Exercise Bikes
DISPLAY CONSOLE R9
• Calories
• .a-'I' .,<+\
Workout,
f"""""---~df
Profiles I
--_.. - ---.
.-....... '~
FarBum :::::::::::::
r""1
\~i------------~Cae-~rd~roJ
s _..-....._._.- )~
i ••:::::::::::.
>.~80:l!: St.. ~ HR ,..;;
_ _._-1~"'~-
\ ':' 0(; ::
:: :::: ~
Hean Rate Int rv~t.::::::::::::....J
U! MaxH.
~
-------
}::. ::.
::::. ::::. I~
EJc~ Hurt Race· ••••••••••••••
85%_HR
R9
•
5
DISPLAY CONSOLE R7
• level C.loroes
•
• Heart Rate • Time
{
PO
Quick Start:
'Beij;np'e<iai1iig"
?ress Stan
P",ss OUlci< Start
~"
--,...
'£~\
,,~
~,._ _ ......"x .,,",, ....
FilBum! ::::::::::::::
:
fNM"
•••••••••
~~.~......,J
~l
•
I
•
Workout
Profiles
r\
Y':::1..
" , '~ ••••••••••••••
..::::::::.
G
c.r~O: l
_i9is;:;;i;~·· §
\ ~ '$
\'\ f :: ::::
H...u1 Rille InteTVIl l .::::::::::::.
i!
\ t,l{!% M... HR __ J
\~_''h_'_[ ..:::55 l
~ Heart Rate Hllll ••:::::::::::. ~
" l!.'!~ M... HR _J
" ._...... 'lI' l'O'lO-'I7"" .......".......
'? 5
~~.-_~ :::. :::. 1
Ext,..,.",. Heart Riltel ••:::::.:::::. l
\".15% 1IlI.... :.,R , ..J
R7
•
6
Lifecycle LC95R, Le91R, LC85R, R9, and R7 Recumbent Exercise Bikes
MAP
e-----------
e
7
ENTRY LEVEL
calories
•
Co de V er 13 0 )
c: For Quic* Sbrt: ]

Begin pedaling.
Pnss Quick Start below.
•
Hold down the number 5 key or the UP ARROW key, then the press the CLEAR key twice. Press the up ARROW
key. The display menu will show after each press:
CODE VERSION ex: CODE VER - X.XX

CSAFE VERSION ex: Csafe ver-- X.XX.XX
PART NUMBER ex: xxxx-- xxxxx--oooo
BOOT LOADER VERSION ex: BOOT VER -- X
Press ENTER for entry into the OPTIONAL SETTINGS.

To enter the TEST/SERVICE MENU press and hold the COOL DOWN key. and then press the ENTER key.
•
8
TEST/SERVICE ALL LEOS AND KEYPAD TEST
For Quiet Start: ]

[ Begin peaaIing.
Press Quid: start below.
On entry to this state, all of the LEDs will tum ON. Pressing the keys will result in a beep sound for all but the
S ART, ENTER and CLEAR keys, a character repeated across the message center will be displayed.
KEYS DISPLA YED CHARACTER KEYS DISPLA YED CHARACTER

0 0 Display Lock L
•
1 1 Workouts Plus K
2 2 Change Workout W
'3 3 Up arrow U
.,.
~
14 Down Arrow ID
-
6
5
6
Bike Mode
Constant Cal. I Hr.
B
A
17 7 Quick Start Q
18 8 Start S
9 9 Pause P
TIME UP U COOl down -
TIME DOWN D
LEVEL UP ...
LEVEL DOWN T
BIKE MODE B
I
CONSTANT CaI.iHR. IA
i ...
rAT BURN Ir I
CARDIO Ic I
RANDOM R
MANUAL M
QUICK START Q
: ZONE TRAINING Z
PERSONAL TRAINER T
HILL PLUS H
COOL DOWN -
Press, e:: '-::R Key 10 advance to the next diagnostic sta e. Press tl,e CLEAR key 0 the previous diagnostic
sta-e, - repe2 eo pre~slOg to exit diagnostics.
•
9
TEST/SERVICE - WALKING LED TEST
Message Center •
[
For Quidc Stare]
Begin pedaling.
Press QuIdc Start below.
Profile Window
On emry to this state, the LED segments in the MESSAGE CENTER and the PROFILE WINDOW will give the •
animated effect of moving, henceforth, 'Walking LED."
Press the eNTER key to advance to the next diagnostic state. Press the CLEAR key to the previous diagnostic
state, or repea-ed pressing to exit diagnostics.
•
10
TEST/SERVICE - MISCELLANEOUS 1 TESTS
.----------- /49~"
Distan.:le RPM calories
9&)00 (]
••• •••••••••••
................
................
••••••••••••••••
................
••••••••••••••••
••••••••••••••
For Quiet Start: ]
[ Begin peciaWlg.
Press Qua Start below.
FIE 0 D TV CYCLE: In the Heart Rate Window, the Field Duty Cycle being applied to the alternator will be
splaye I ~g5R and R91 only). This value ranges from 0-255.
• ALTERNATOR OUTPUT: In the Distance Window, the alternator output voltage is displayed for LC9SR, LC91 R,
and R9.
RPM: In the RPM window, the present altemator RPM will be displayed.
CALORIES: In the Calories window, the present Load Duty Cycle being applied to the altemator will be displayed.
Load duty cycle ranges from 0-320 for LC9SR model, 0-280 for LC91R and R9 models, and 0-415 for LC8SR and
R7 models. This value can be adjusted using the Time Up and Time Down arrow keys on the LC9SR console, and
the P and 0 \IV arrow keys on all other models.
9. :: MODe .':=Y: Press 'he Bike Mode key to togg e -he s;:>ea:er 0 an OFr.
'0' KEY: Press the '0' key to toggle the RPM display between the alternator RPM and Reed Switch RPM. The
Enter LED will be ON when alternator RPM is displayed. RPM from the reed switch will not display when the
alternator is running.
'5' KEY: Press me '5' key (9SR only) to toggle the alternator 0 and OFF.
ENTER KEY: Press the ENTER key to advance to the next diagnostic state.
CLEAR KEY: Press the CLEAR key to go back to a previous diagnostic state, or repeated pressing to exit
diagnostics.
•
11
TEST/SERVICE - MISCELLANEOUS 2 TESTS
5~B 0 8:) OJ
................
•••••••••••••••
•••••••••••••••
•••••••••••••••
................
•••••••••••••••
................
REED SWITCH RPM: In the Distance Window, the Reed Switch RPM is displayed. Note: The Reed Switch RPM
will not display when the alternator is running.
RPM: In the RPM window, the alternator RPM will be displayed.
SYSTEM VOLTAGE (Vsys): In the Heart Rate Window, the present system voltage 01sys) supplied to the console
is displayed.
•
'5' KEY or DOWN ARROW KEY: Pressing the '5' key or the DOWN Arrow key will display the value of Vsys at
startup, before the alternator is turned ON. This is useful because you can get an indication of the battery voltage
of the 6V battery. Note: This voltage will be slightly lower than if you read the voltage of the 6V battery directly
from its terminals.
ENTER KEY: Press the ENTER key to advance to the next diagnostic state.
CLEAR KEY: Press the CLEAR key to go back to a previous diagnostic state, or repeated pressing to exit
diagnostics.
•
12
Lifecyc/e LC9SR, LC91R, LCBSR, R9, and R7 Recumbent Exercise Bikes
TEST/SERVICE - PORT I/O TEST
For Quick Start: ]

[ Begin pedating.
Press Quidc Start Delow.
• Press the ENTER key to advance to the next diagnostic state. Press the CLEAR key to the previous diagnostic
state, or epeated pressing to exit diagnostics.
•
13
TEST/SERVICE - LIFE PULSE TEST (LC95R and R9 ONLY)
-- - - -LlP~
•
C- 0 G 99
.-..
\\
.-
• •••• • •••
•
••
-- - 1
c:-te-J
_~t-. j
/
Upon initial entry to this test, a heart-shaped image will be displayed in the profile window along with two
messages in the message center when the user has both hands on the lifepulse sensors. The first message
indicates the lifepulse software version number. The second is the configuration of the Iifepulse communication
•
system, which is either ON or OFF. This setting enables external communications for Iifepulse development only
and should be left OFF. Following these messages, the display will change to a mode to display diagnostic
information as described below, and the lifepulse system will be ready to be manually tested.
When both hands are detected on the sensors, the letters 'L' and 'R' will be displayed in the profile window along
with the heart-shaped image.
Two timers will begin counting from the time both the left and right hands on condition occurs. The first timer,
located on the upper console message center display, will stop counting when lifepulse computes and displays an
initial peak detected heart rate reading. The second timer, located on the lower console display window, will
continue counting until lifepulse can reliably display the users heart rate. These timer readings are used for
reference only.
The gain value of the heart rate signal is shown following the 'G' in the message display window. The value ranges
from 0 to 99. A gain value of 99 is considered to be high and undesirable. A gain value of 0 is considered to be low
and also undesirable. Gain values of between 15 and 40 are considered normal depending upon whether the user
is exercising or standing still during this test.
Press the ENTER key to advance to the next diagnostic state. Press the CLEAR key to the previous diagnostic
state, or repeated pressing to exit diagnostics.
•
14
TEST/SERVICE - CSAFE NElWORK TEST
.-----------
r
I
( )
itnin :n:s stale ~he CS.A.FE neTWork can De tested.
Tms is now you can check to see if you're receiving any communications from the network system.
1. Remain in the CSAFE Test Mode above (by not exiting out of if).
2. Make sure the network cable is plugged in.
3. Press the COOLDOWN key. This will reset the console and send out the standard power up message to the
network. The console should display "RESETTING NETWORK". The power up message sent to the network
is the same one the console sends every time it is turned on (or anytime it is used by a user on self-powered
products).
• 4. If the network has received the CSAFE communication packet from the console and the network sends
configuration communication packet to the console the console will display "RECEIVING ... "
5. If the console has been properly configured by the network and is allowed to accept user ID's then the console
woula snow -GETID MODE XX". The "GETID" message means were in the get 10 mode. This is the mode the
networ ;m.:st put the console in, before it will ask the user to enter in their ID's. If the console is not put in this
:node :nen tne console will not ask for ID's.
o. If tne network does not respond to the console then the console will display a "NOT CONNECTED" message.
This indicates there is a problem with the network cable or network itself. This means the console has not
received any valid CSAFE communications from the network.
•
15
TEST/SERVICE - EEPROM TEST
Heart Rate calories

•
lo-.-- ----J)
For Quldt st.t: ]

Begin pedaling.
.0•..~
.
[
r>ress Quick Start below.
This diagnostic state tests the Display Console EEPROM by reading, writing, and replacing all used locations in
the Display Console EEPROM. The EEPROM location oeing tested will appear in the display message center.
?ressi, , r:c 0 "N r.RROW will initiate the EEPROM test. f the 'est completes successfully, the message •
==?ROM GOOD will appear. If the test fails, the message EEPROM B.t'.D AT XX will dispiay with the bad
EEPROM location.
state, or iepeated pressing to exit diagnostics.
•
16
TEST/SERVICE - TELEMETRY ENABLE/DISABLE
TELEMETRY OFF
For Quick start: ]

[ Begin pedaling.
Press Quidc Start below.
W'tmn In S S ate, me TELEMETRY can be tumea ON or OFF. If a telemetry heart rate is detected, it will be
displayea wnen telemetry is set to ON .
By default, the litecycles will have TELEMETRY ON except for C91 has telemetry OFF.
• The DOWN ARROW will tum OFF the telemetry.
The UP ARROW will tum ON tne telemetry and display a heart shape in the program profile window.
The ENTER key LED indicates when the value is at the default setting of TELEMETRY ON. This value is stored in
EEPROM and is kept when the unit is not in use.
Press :~e =:,"i=R key to advance to the next d:agnosti~ state. Press the CL:=AR key to the previous diagnostic
state. c; re. eatec pressing to exit diagnostics.
•
17
TEST/SERVICE - LANGUAGE
caiories
•
l
LANG ENGLISH )
For Quiet Stan:: ]

[ Begin pedaling.
Press Quick s:art below.
Within this state, one of seven languages can be selected to include: English, German, French, Italian, Dutch,
Spanish or Portuguese.
The UP ARROW, when pressed, displays the next language in the list.
T .e DOW; A?.ROW, when pressed, displays ~he previous language ir: the list.
-:-~E: E T::R Ke; LED indicates when the language is set to the aefault of ENGLISH.
•
Trlis value is stored EEPROM and is kept when the unit is not in use.
Press the CLEAR key to the previous diagnostic state, or repeated pressing to exit diagnostics.
•
18
OPTIONAL SETTINGS - MAX PROGRAM DURATION
.-----------
MAX DURATION
r-----/'2'1Hh7PJ1~tij&-r
~ ... '
For QuIcIt SQrt: ]

[ Begin pedaling
Press Quidt Start below.
Within this slate, me MAXIMUM PROGRAM DURATiON is displayed and can be adjusted from a range of 1-99
minutes on the LC9100, LC8S00, C9i, and C7i. LC9S00 can be adjusted from 10-99 minutes.
• The DOWN ARROW will decrease the value by 1 minute. Key wi!: Auto-Repeat if held.
The UP ARROW will increase the value by 1 minute. Key will Auto-Repeat if held.
The ENTER key LED indicates when the value is at the defaun of 60 minutes. This value is stored in EEPROM and
is kept when the unit is not in use.
Press the :=! iT:=R key to advance to the next diagnostic state. Press he CLEAR key to the previous diagnostic
sta:6 or re:--eateo pressing to exit diagnostics.
•
19
.,ecycie C95R, LC91R, LC85R, R9, and R7 Recumbent Exercise Bikes
OPTIONAL SETTINGS - ENGLISH/METRIC UNITS
Heart Rate
•
.! ~_E_N_G_LI_S_H_U_N_I_T_S----J}
II ,----/'7fJI1!~~-cr
For Quidt SQrt: ]

[ Begin pedaling.
Within this state, ENGLISH or METRIC units can be selected.
The DOWN ARROW will select METRIC units.
The UP ARROW will select ENGLISH units.
The EN,ER key LED indicates when the value is at the default setting of ENGLISH UNITS.
. •5 vaiu5 's Sl~rea in =E?ROM and is kept wnen the unit is not in use.
•
Press the :=NTER key to advance to the next diagnostic state. Press the CLEAR key to the previous diagnostic
•
20
OPTIONAL SETTINGS - WATTS DISPLAY ENABLE/DISABLE
.-----------
\"I\TT DISPLAY
For Quick StiIrt: ]

[ Begin pedaling.
If his option is enabled, the MESSAGE CENTER displays the Watts equivalent of the workload. This message will
only be displayed after a level change.
The DOWN ARROW will tum OFF the WATIS PROGRAM.
• Tne UP ARROW will t~m 0, the WATIS PROGRAM.
I,e =. -r=R Key ~D i dicates when the value is at the default setting of WADS PROGRAM ON.
Tne value IS stored in EEPROM and is kept when the bike is not in use.
Slate, or repeated pressing to exit diagnostics.
•
21
OPTIONAL SETTINGS - METS DISPLAY ENABLE/DISABLE
•
OFF)
For Quldt Start: ]

[ Begin pedaling.
Press Quid Start below.
If this option is enabled, the MESSAGE CENTER displays the METs equivalent of the workload. This message will
only be displayea after a level change.
Tne DOW ' ARROW will tum OFF the METS PROGRAM.
The UP ARROW will turn ON the METS PROGRAM.
The ENT~R Key LED indicates when the value is at the default setting of METS PROGRAM ON.
The value is stored in EEPROM and is kept when the bike is not in use.
•
•
22
-lee C G _C9SR; LC91R, LCBSR, R9, and R7 Recumbent Exercise Bikes
OPT.C. AL SETTINGS - CAUHR DISPLAY ENABLE/DISABLE
.-----------
CALI H 01 SP OFF
,,----
I
[ 1
for QuIck Start: ]
[ Begin pedmg.
Press QuIdc Slilrt below.
tnis opti n's enabled, he MESSAGE CENTER displays the Calories/Hour equivalent of the workload. This
message will only be displayed after a level change.
The DOWN ARROW will tum OFF the CAUH program.
• The UP ARROW will turn ON the CAUH program.
The ENTER key LED indicates wnen the value is at the defauit setting of CAUH PROGRAM ON.
The value is stored in EEPROM and is kept when the bike is not in use.
?ress ;-e =: ;-cR ey to aavance to the next diagnostic state. Press the CLEAR key to the previous diagnostic
S Gte, r repeated pressing to exit diagnostics.
•
23
Lifecycle LC95R, LC9tR, LC85R, R9, and R7 Recumbent Exercise Bikes
OPTIONAL SETTINGS - WATTS PROGRAM ENABLE/DISABLE
•
~TT DISPLAY
[Press~~=J
Quid Start
below.
If this option is enabled, the MESSAGE CENTER displays the Watts equivalent of the workload. This message will
only be dispiayed after a level change.
The DOWN ARROW will tum OFF the WAITS PROGRAM.
The UP ARROW will tum ON the WAITS PROGRAM.
T e
The
ENT=~
"ILIIS is
key -=D indicates when the value is
st()~ed
a~ tne defau.. sening of NATIS PROGRAM ON.
ir. =E?ROM and is kept wnen the bike is not in 'se.

•
state, or repeatea pressing to exit diagnostics.
•
24
OPTIONAL SETTINGS - METS PROGRAM ENABLE/DISABLE
.-----------
(METS PROGRAM OFF)
Within this state, METS PROGRAM can be turned ON or OFF.
By default, the LifeCycle will have the METS PROGRAM OFF.
• he DOW ARROW will tum OFF the METS PROGRAM.
Tne P ARROW will tum ON the METS PROGRAM.
The ENT:R key LED indicates when the value is at the default of METS PROGRAM ON.
This value is stored in EEPROM and is kept when the bike is not in use.
state or repeated pressing to exit diagnostics.
•
25
Lffecycle LC95R, LC91R, LC85R, R9, and R7 Recumbent Exercise Bikes
OPTIONAL SETTINGS - TOTAL HOURS AND STATISTICS
ClIIorfes
•
HOURS= o )
[
ForQulck~:
BegIn pedali
Press Quick
J
Start't.ow.
pun e:n : In S st2te, TOTAL HOURS are displayed.
S ATISTICS can De displayed using the UP and DOWN arrow keys. The UP ARROW allows scrolling through the
available programs and shows the number of times each program has been selected. The DOWN ARROW backs •
up through the list of available programs and back to the total hours displayed.
The Programs are:
HOUR = Total hours on the console

DIST = Total distance in miles on the console
HILL
RANDOM
MA: uA:"
~A-:
CARDI
AcR031CS
X-REV
WATTS
METS
QUICK
HEART HILL
HEART INT
HEART EXT
PRESeT
C 'S"7"OM
?res :ne:: TER ey tV aavance to tne next diagnostic state. Press the C EAR key to the previous diagnostic
state, or epeated pressing to exit diagnostics.
•
26
Lifecycie LC95R, LC91R, LC85R, R9, and R7 Recumbent Exercise Bikes
OPTIONAL SETTINGS - ENTERTAINMENT CONTROLS
• ON/OFF (LC9500 ONLY)
\
fr-"'~~-~-"'"
Istc..- R \\
:1: 1\ I I C "lOr I 1\ I LrllLr rC
\LI~ I LI\ 111~
\
1
:
~ ' ,
••••••••••••••••
••••••••••••••••
••••••••••••••••
•••••••••••••••• 1 \
1• • • • • • • • • • • • • • • • 1 I
~···············f
_
....-
...- -~.-...--~-----
.
. . • ..,
- . c ....,.
~IIQIIIClW
__ --
-.Mllltaa:rtca
CIIIa".8U'U •
..
-.
.". ,.-. I
1..._
• Channel or Volume Control
The ENTERTAINMENT CONTROL SETTING
Using the arrow keys will tum ON or OFF the entertainment (cardio theater/broadcast vision) controls for the
CSAFE PORT outpL.:t for volume and channel change. Off is the default setting.
Note: The Channel or Volume Control is supplied by Cardio Theater or Broadcast Theater. These controls can be
found as indicated by the dashed-box.
•
27
Lifecycle LC95R, LC91 R, LC85R, R9, and R7 Recumbent Exercise Bikes
OPTIONAL SETTINGS - PHOTO SHOOT
•
13 5 2. 18 8 2 17. 4 4
[
For QuIck Start:
Begin pedaling.
J
Press Quid: Start below.
uCl a Q SPi2, eo or. tr.e rressage cer.ter is non-f ncrional and imenae on y to sOm' late values for photographic
Press the C EAR key to the previous diagnostic state, or repeated pressing to exit diagnostics. •
•
28
•
SECTION III
How To...
SERVICE AND REPAIR GUIDES
•
How To... Replace the Side Shrouds and Crank Arms
Special Service Tools: NONE
Shroud Left Shroud

End Cap
Screws(7) Screws(2)
"
Crank Arm j
Screws(3) 1/
'/
End Cap
Shroud
./screWS(4)
Left Shroud
~Left Crank Arm

~~ w/Pedal
."
~CrankArm •
Screws(3)
Note: To remove the side shrouds, it
will be necessary to remove both
pedals and crank arms, and the end
cap. Use the illustrations on this page
to aid in this procedure.
1. Remove three screws from the left

and right crank hubs, and then
remove the crank arms with pedals
attached.
2. Remove two screws from the end

cap at the end of the frame which
allows access to the left and right
side shroud screws.
3. Remove the left and right side End Cap

shroud screws, and then remove w/Screws
the side shrouds. Discard shrouds.
4. Install new side shrouds in reverse

order. Torque the shroud screws
12-15 in Ibs.
5. Torque crank arm screws 15-20 ft

Ibs.
•
2
Lifecycle LC95R, LC~1 R, LC85R, R9, and R7 Recumbent Exercise Bikes
How To... Remove the Drive Belt
• Special Service Tools: NONE
Note: An access hole in the crank pulley

allows removal or loosening of the idler
bracket bolt with a socket. Access
Hole
1. Remove the right side shroud. See Drive
"How To ... " in this section. Belt
2. Rotate the crank pulley until the idler
bracket mounting bolt is visible
through the access hole in the crank
pulley, then loosen the bolt.
3. Loosen the belt tension by loosening

the adjusting bolt on the idler
bracket.
4. Remove old belt and discard.
5. Install new belt in reverse order.
6. Adjust belt tension 100-11 0 Ibs by

moving the idler bracket down. Insert
a straight blade screwdriver in the
•
slotted lip of the bracket to obtain specified tension. When belt tension is achieved, then tighten the mounting
bolt and adjustable bracket bolt. Remove the right shroud. See "How To ... " in this section.
•
3
Lifecycle LC95R, LC91R, LCB5R, R9, and R7 Recumbent Exercise Bikes
How To... Replace. the Alternator Belt
1.
2.
Remove the side shrouds. See "How
To ... • in this section.
Index the location of the tensioning /

Tensioning
Bolt
/
•
bolt to the alternator mounting bracket,
and then loosen the tensioning bolt.
3. Loosen the pivot bolt, and then rotate

the alternator until the belt can be
removed from the alternator pulley
and the intermediate pulley.
\
Pivot Bolt
4. Install new alternator belt in reverse order. Position the

alternator belt on the far left groove of the alternator
flywheel pulley (towards user side) and in the center of
the alternator pulley (large pulley). Then tighten the belt
back to the index mark or 70-80 Ibs.
•
Altemator
Alternator Belt Belt
D
I· !
I Ii ,. .1
m __ J__i_
Alternator Pulley Flywheel Pulley
L---·-L _
•
4
How To... Replace the Crank Shaft Hub Assembly
• Special Service Tools: Bearing Service Tool Kit - Part Number: BearingToolKit
Note: The left shroud does not require Hub

removal to service the left crank shaft Arrow
hub. Marl<
1. Remove the right crank arm and

shroud. See "How To ...• in this
section. FIatWosher
2. Remove the drive belt. See "How Hub

To ... • in this section.
I /Lrt Mounting
o
3. Remove the bolt and washer in the
.....-::;;;;;;.-o~
center of the hub.
NOTE: There is an arrow mark on each

hub which is located 180 degrees apart,
and is used for proper crank arm
position.
4. Install the disc puller plate as

illustrated on the left hub.
5. Tum the puller forcing bolt clockwise
•
until the let hub is removed. Discard
the hub. Forcing Bolt Mounting Bo1t(3)
(1/2-13) (1/4-20)
NOTE: The right hub is removed with the
crank shaft pulley attached. Use the puller
as described in left hub removal. Once off, \\
remove the three screws at the back of the
pulley to separate it from the hub.
I
I Disc Puller Plate

NOTE: Make sure the arrow mark on the GK63-00002-0009
hub is pointing 180 degrees from the other
hub.
6. Position the new hub on the crank

shaft with the washer. Install the
mounting bolts and tighten evenly until
the hub is fully seated on the shaft.
Hub
Torque: 220-240 in Ibs.
NOTE: If the right hub was replaced, then Crankshaft

install the hub back on the pulley first and
secure using the three mounting screws.
7. Reinstall the side shrouds, crank arms,

and pedals.
• REMOVING THE HUB
---------
How To... Replace the Crank Shaft Bearings
Special Service Tools: Bearing Service Tool Kit - Part Number: BearingToolKit
1. Remove the side shrouds.

See "How To ... • in this
section.
Snap Ring
(Iarge)\ Snap Ring
Bowed (small) Frame
•
/
2. Remove the main drive Thrust / ~earingS(2)

belt. See "How To ... " in Washer. 1\
(large) ~. t?t
this section. Crank
Thrust
~© I Spaft Washer
Thrust~/
3. Remove the crank shaft
hubs. See "How To ... • in
this section.
IL(small)Thrust
Bearing
4. Remove the large snap
Thrust o • ,~Bearing
rings, the bowed snap Washer /
rings, the large and small (small)
thrust washers, and the
..... Snap Ring
Frame
thrust bearings from both / O.~(large)
5.
6.
sides of the crank shaft.
Push the crank shaft out

from the frame bearings.
Inspect, and if necessary,

I I wThrushl
as er
(I arge )
s1 Ri"d
Bowed (small)
7.
replace any crank shaft
component parts before reassembling onto the
new crank shaft.
Install the bearing puller on the crank frame

bearings as illustrated. Hex Nut_
,/eadedRod
I /rustWasher
•
~::=::;;;~
m
Bike ~Spacer
~
Frame
I
Lj
Iu
Hub
~
INSTALLING CRANK BEARING KIT
•
6
---------------------- ----
How To... Replace the Crank Shaft Bearings· Continued
• Special Service Tools: ~aring Service Tool Kit - Part Number: BearingToolKit
8. Press out the frame bearings by rotating

the hex nut clockwise until the bearings Threaded Rod
drop into the puller hub. Once the bearings
are out of the frame, disassemble the puller
assembly, and discard the bearings. HexNutil rust Washer
9. Clean the housing before installing new r';::=====~'irlQc=t;;r r-..·-· · .-· .

frame bearings.
SJ:lCIcer
Frame
lL:!--- Beartngs
Hub
•
PUSHING OUT FRAME
BEARINGS INTO THE HUB
10. Position the new frame bearings with markings (on Threaded Rod
the face of the bearings), positioned facing out. \
r+--
Make sure bearings are aligned straight and square.
Spacer
Thrust Washer
Frame
Bearings
Bike
/
• Frame
INSTALLING NEW FRAME BEARINGS

Hub
7
How To... Replace the Crank Shaft Bearings - Continued
11. Start tightening the hex nut. You may have to

hold the spacer to stop it from turning.
12. Continue pressing in the new frame bearings

Hex Nut
~~t;;---Threaded Rod •
Spacer
until the thrust washer and hub stop against the
frame housing shoulder. Make sure that the
bearing races seat flush against the inner hub
Thrust Washer
face.
Inner Hub Frame

Face.....:;;;...---I'+-.. Bearings
Bike
Frame
PRESSING IN NEW BEARINGS
13. Reinstall crank shaft and components. Use the exploded view below to aid in reassembly.
14. Reinstall the hubs.
15. Reinstall the main drive

belt.
16. Reinstall the side shrouds, Thrust

Snap Ring
(large)
\
\
Snap Ring
Bowed (small)
~
Crank Shaft
Btearing
•
crank arms and pedals. Washer __ /
(large) ~ - f?'i' Crank Thrust
y© S9
aft
Washer
Thrust~/ / (small)
Bearing
Thrust
Washer
(small)
/1 :
_....
/ Thrust
g:VBearing
Snap Ring
Frame
- \ -~ (largeJ
I
I
I II Thrust Snap Ring
Washer
Bowed (small)
(large)
•
8
Lifecyc/e LC95R, LC91R, LCB5R, R9, and R7 Recumbent Exercise Bikes
How To... Replace the Clutch Assembly
1. Remove the right shroud. See

"How To ... • in this section.
Main
2. Remove the main drive belt. Drive
See "How To ... • in this section. Belt
3. Remove the snap ring from the

intermediate shaft.
4. Remove the washers and clutch

assembly. Discard the clutch
assembly.
5. Install the new clutch and its

parts in reverse order. Make
sure to install the step side
going into the frame.
6. Install main drive belt.

Washer Snap
Ring
7. Install shrouds and then pedals.
•
9
How To... Replace the Intermediate Pulley Shaft and Bearings
1. Remove the side shrouds. See "How To ... • in this section.

•
Snap
Ring OUtch
~rrbIy
I
Alternator
Belt
Main
Drive
Belt
In errrediote
Bearing
•
Interrrediate
Puliey
2. Remove the alternator and main

drive belt. See "How To ... • in this Intermediate
section. Pulley/Shaft
Assembly
3. Remove the clutch assembly. See \
4. Assemble 2-jaw puller to the bike

frame at the intermediate pulley Bearings Spacer
shaft as shown.
Note: Some bearing spacer mayor may

not have shoulder on spacer.
Use Standard
: - - - - 2-Jaw Puller
Spacer w/o Shouldel Spacer w!Shoulder
SETIING UP 2-JAW PULLER
•
10
Lifecycle LC9SR, LC91R, LCBSR, R9, and R7 Recumbent Exercise Bikes
How To... Replace the Intermediate Pulley Shaft and Bearings - Continued
5. Tum the forcing screw clockwise to

press out the pulley shaft assembly
from the bearings and spacer. t
6. Once the pulley shaft is free of the
bearings, proceed to remove the
bearings. Intermediate ' - - - - - - - + _
Pulley/Shaft
Note: Do Not replace the pulley without Assembly
Spacer
replacing the bearings.
Bearings
Use Standard
2-Jaw Puller
Forcing
SCrew
I!
PUSHING OUT THE PULLEY SHAFT
• 7. Install the bearing puller to the frame as illustrated. Threaded

Rod--_ _..J
Spacer _ _
Bearing
Bearings
Spacer
SETIING UP INTERMEDIATE
• BEARING PULLER
11
8. Tum the hex nut clockwise to push the 1st bearing out into the hub. Loosen puller assembly and remove the 1sl
bearing. At this time, remove the free floating
spacer.
.1.----Hex Nut
•
9. Retighten puller assembly and continue tightening
nd
until 2 bearing is pressed out of its housing into
the hub. Thrust
Washer
10. Remove the puller and discard the bearings.
11. Clean the housing.
2nd Bearing Bearing

Spacer
1st Bearing Hub
•
PUSHING OUT 1st BEARING
Thread Rod
12. Install the bearing spacer back in the housing,
and then position the bearings in the housing.
13. Install the puller assembly as shown. Make sure

that the hub is reversed. Make sure all parts are
aligned straight and square.
Note: The bearings MUST be pressed firmly against Thrust

the bearing spacer. Wasner
Bearing
Bearings N::'C;&..----
Spacer
~--"":lhrust
Washer
Hub
SETIING UP THE PULLER FOR
PRESSING IN BEARINGS
•
12
14. Start tightening the hex nut to press in the bearings. Continue pressing in the bearings until the thrust
washers(2) stop against the housing shoulder as shown. Thread Rod
15. Remove the puller assembly and check to see that the
Hex Nut
bearing spacer is securely held in position between the
bearings. If so, proceed to press in the intermediate
shaft. If the bearing spacer is loose, proceed to the next Spacer
step.
16. If the bearing spacer is loose, then reinstall the puller Thrust
assembly without the thrust washer on the side of the Washer
intermediate pulley (see illustration below). Continue
pressing in the bearing. When the bearing (next to the
pulley) is proper1y seated against the bearing spacer, it
Bearings 1-.1':':':'._--- Bearing
will be slightly below flush and the puller hub will be free Spacer
to spin. Proceed to press in the intermediate
pulley/shaft.
Thrust
r i r - , h - - - - - Hex Nut Washer
Spacer
Puller Hub
PRESSING IN THE BEARINGS
• Bearings N::';;:,....---- Bearing

Spacer
C-elomp
Thrust
Washer
Puller Hub
PRESSING IN THE BEARING ON THE SWivel
PULLEY SIDE W/O THRUST WASHER Spacer
17. Position the intermediate pulley/shaft in the housing. Position the

swivel spacer on top of the pulley and the stop block against the f------t1:rr-reJ--I-:!-.-Dearing
bottom bearing, then secure the C-clamp as illustrated. Make Spacer
sure the shaft is aligned straight and square. Also make sure the
plastic bearing spacer between the bearings is centered.
Note: Once the pulley/shaft gets started in the bearing, remove the
C-Clamp to ensure the bearing spacer is in alignment to receive the
• shaft, then continue to press in the pulley/shaft.

SETTING UP C-elAMP,
SWIVEL SPACER,
AND STOP BLOCK
13
18. Press in the pulley/shaft until the shaft bottoms against the 2
19. Remove the C-clamp and stop block.

nd
bearing.
•
20. Install the clutch assembly.
21. Reinstall altemator belts. C-Clamp

22. Install side shrouds and then the pedals.
Pulley/Shaft
•
2nd Bearing
Stop Block
Pressing in Pulley Shaft
•
14
How To... Replace the Idler Roller
Note: An access hole in the crank pulley

exist to allow a socket to access the idler
bracket mounting bolt to loosen.
1. Remove the right side shroud. See

"How To ... " in this section. era Puley
2. Rotate the crank pulley until the idler

bracket mounting bolt is visible
through the access hole in the crank
pulley, then loosen this bolt.
3. Loosen the belt tension by loosening

the adjusting bolt on the idler
bracket.
4. Remove the idler nut and pull off the

idler roller. Discard idler roller.
Adjusling
5. Install new idler roller in reverse Idler
Bolt
order. Roller
6. Adjust belt tension 100-110 Ibs by
•
moving the idler bracket down. Insert
a straight blade screwdriver in the
slotted lip of the bracket to obtain
specified tension. When belt tension
is achieved, then tighten the
mounting bolt and adjustable bracket
bolt.
•
15
How To... Replace the Alternator
1. Remove the side shrouds. See "How

To .... in this section.
A1temator
Mo . g
Brocke
Tensioning
Bo,
Mai Wiring
Cable Connector
! /
•
2. Remove the altemator belt. See "How
To .... in this section.
3. Disconnect the main wiring cable

connector from the back of the power
control board.
4. Tag and identify all wiring at the back of

the altemator, and then remove them
from their mounting posts.
,
Pivo
Yellow Wire Bo Black Wires
5. Index the tensioning bolt to the

altemator mounting bracket, and
then remove the tensioning bolt
and pivot bolt.
•
6. Remove the altemator and install
new altemator in reverse order.
Tensioning
Bolt. Lock and
Flat Washers
Pivot Bolt Nut ----~~~\1~~~l~~~::::

and Lock Washer ~
•
16
How To... Replace the Alternator - Continued
7. Make sure to position the altemator belt on

the far left groove of the alternator flywheel Alternator Belt
pulley (towards user side) and in the center
of the alternator pulley (large pulley).
Tighten the belt back to the index mark or
70-801bs.
•
17
How To... Replace the Seat Locking Mechanism
Note: Illustration shown without

components or shrouds for clarity
purpose.
•
1. Disengage the locking mechanism
and slide the seat to its forward most
position.
2. Remove the two 5/32 inch mounting

screws from the locking mechanism. Mounting
SCrew(2)
3. Remove the locking mechanism.
4. Install new locking mechanism in

reverse order. /
seat Locking
Mechanism
•
18
--~-------
How To... Replace the Seat Assembly and Extrusion
1. See "How To ... • replace shrouds in

this section.
2. Remove the seat stop by removing two

screws from the top seat assembly.
3. From under the extrusion, disconnect

the flat flex connector from the main
cable, then unhook the flat flex cable
from the clips.
4. Disengage the locking mechanism

and carefully back the seat
assembly off the extrusion while
•
guiding the flat flex cable out the
seat extrusion.
5. If necessary to replace the

extrusion, remove four mounting
bolts under the extrusion, and lift
off the extrusion.
Clips
6. Install extrusion in reverse order.
7. Install new seat assembly in

reverse order of removal.
8. Adjust seat rollers. See "How

To .. ." in this section.
Flo Wire
Clip Connector
•
19
How To... Replace and Adjust Seat Rollers
Note:The seat rollers are adjusted to a

specified resistance load. If the seat moves too
freely with excessive side-to-side movement,
then the seat rollers must be adjusted as
•
follows.
1. Using a Y:z inch wrench, loosen all four(4) seat

roller clamp nuts, then retighten by hand.
NOTE: In this step, you must make initial

adjustments to the seat rollers on the right side of
the unit first. This is done to insure that the two
Right Side
right guide rollers are properly seated in the V-
channel of the seat extrusion. Once the seat rollers
on the right side are adjusted, then proceed to
adjust the seat rollers on the left side of the unit.
Seat Roller
The following requires use of two, inch pound Clamp Nut
torque wrenches. One to maintain a resistance
Take-Up Take-Up
load against the take-up roller and the other to
torque the roller clamp nut. Roller Nut Roller Nut
2. Starting with the right side seat rollers, adjust the

first take-up roller nut to 60-65 in. Ibs. in a
•
seat ocl<ing
clockwise direction. Observe that the roller clamp Mechanism
nut will move up. This indicates that the seat roller
is being forced up against the extrusion. Continue /
to maintain the 60-65 in. Ibs. resistance load on
the take-up roller, and secure the seat roller
position by tightening the roller clamp nut from
100-120 in. Ibs. Repeat this procedure for other
remaining right roller. Once the right side is
adjusted, repeat this procedure for the left side.
Always set the right side seat rollers first. Failure
to do so, will result in side-ta-side seat movement. V-eha el
(righ SIde
of seat extrusan)
3. With all seat rollers adjusted, test operation of the
seat assembly for a 15-25 Ibs. pulling force and to
insure that no side-to-side movement exists. e Side 'gn Side
Repeat this procedure as required.
•
20
How To... Replace the Seat Pad and Handlebar Assembly
(Seat Pad)
1. Remove four Allen screws and Seat Pad
washers from the frame under
the seat pad, and lift off the seat
pad from the seat assembly
frame. Handlebar
Assembly
(Handlebar Assembly)
2. If equipped, disconnect the
heart rate sensor connector.
3. Remove four TORX screws and

washers securing the handlebar Torx Screws
assembly to the seat assembly 160-180 in Ibs ---_~
frame, and lift off the handlebar.
(Installation) Washers
Install handlebar in reverse order of
removal. Tighten TORX screws
160-180 in. Ibs.
Heart Rate
Install seat pad in reverse order of Cable
removal. Tighten Allen screws 55-
•
60 in Ibs. Seat
Assembly
I
~----washer(4)
-------Allen Screws(4)
55-60 IN. LBS.
•
21
Lifecycle LC9SR, LC91R, LCBSR, R9, and R7 Recumbent Exercise Bikes
How To... Replace the Locking Rack
Note: The locking racking is

located on the right side of the
extrusion. The rack allows the
locking mechanism to engage the Extrusion
locking rack to secure the seat
assembly at a desired location
along the rack. To replace the
rack, proceed as follows:
1. Disengage the locking
,,,
mechanism and slide seat
assembly to the rear of the
extrusion and lock in place.
2. Remove the Allen screw at the o

front of the locking rack. Allen -~~'4J' -'
Screw
3. Disengage locking mechanism
Locking o
and slide the seat assembly
forward to the front end of the Rack Allen
extrusion. Screw
4. Remove the Allen screw from the rear of the locking rack.
5.
6.
Slide the locking rack out of the extrusion.
Replace the locking rack in the reverse order of removal. Torque the Allen screws 50-55 in Ibs. •
•
22
How To... Replace the Accessory Tray
1. Remove four Allen screws and Accessory

washers securing the seat back. I~~ Tray
"
2. Remove the seat back and set it Seat Back

aside.
,
3. Remove the accessory tray ,
clamp bracket from around the Seat Back ~/
seat handlebar.
Post
4. Install new accessory tray in
reverse order of removal.
Washer(4) ~'
Mounting
Screw(4)
~.y.,-----Llamp
.---'=-- Clamp
•
BolttWaSher(2)
•
23
How To... Replace the Main Cable
1. Remove the side shrouds. See "How To ... " in

this section.
Console
2. Remove the display console. See "How To ... " in Assembly
this section.
3. Remove the console support assembly. See

"How To ... " in this section.
4. Disconnect the main cable (10-pin connector)

from the power control board (PCB).
Console
5. Disconnect two wires from the 6V Battery. Support
Disconnect the BLACK (neg) wire from the (-) Assem~1y
terminal and the RED (pas) wire from the (+)
terminal.
Console
6. Cut the cable ties along the frame. __ --.~t
. /~unting
7. Disconnect the main cable 10-pin connector
from the power control board (PCB). ='~\ IV Screw(4)
8. Pull the main cable out

from the console post. Heart Rate Cable
•
Main Cable 4-Pin Connector
9. Install new main cable 1O-Pin Connector /
through the console post in
reverse order.
Cable
Ties
6V Battery •
24
How To... Replace the Heart Rate Cable
1. Remove the side shrouds. See "How To ... n in

this section. ~~==;;;;;;:.:-"" ---.JL_- Console
.x·..
Assembly
2. Remove the display console from the console
support assembly and then, disconnect the main
cable and the heart rate cable. See "How To .. ." i1'L-_~"'/ . Hear Rate Cable
in this section. 4-Pin Connector
3. Disconnect the heart rate cable (4-pin

connector) from flex cable under the bottom
Console
Support
\, :d----- Main Cable
. , ~. 1G-Pin
frame. .... . /.-
Assembly
4. Remove the heart rate cable from the clip along
the bottom of the frame.
5. Pull the heart rate cable out from the console _ _ _ _--1' " • Console
post.
I . . , '.~ '\. \/Mounting
6. Install new heart rate cable through the console

post in reverse order.
Frame
Post -+-, . Screw(4)
Flat Wire
\Heart Rate Cable

• to Flat Wire
25
How To... Replace the Polar Receiver
1. Remove the side shrouds. See "How To ... inft
this section. Console

Assembly
2. Remove the display console from the console
3.
support assembly and then, disconnect the main
cable and the heart rate cable. See "How To ...•
in this section.
Disconnect the heart rate cable (4-pin

.y . Hear Rate Cable
4-~n Connector
Console \~ ~\ Main Cable

connector) from flex cable under the bottom
Support \\ ~ lG-Pin
frame.
Assembly '4~"
4. Remove the heart rate cable from the clip along
the bottom of the frame.
5. Pull the heart rate cable out from the console Console
post. \ , / tv10unting
Screw(4)
6. Split the two halves of the console by removing .~
the screws holding the case halves together.
7. Remove the polar rec~iver and replace

with new one. See illustration. ,r- Polar HR Coble
Assembly
•
Lower Display
Console Cable
Console
Cose. Bec
Console Screw(l7)
Torque 6-8 n Ibs
Battery
Door
~---r-.------,,------"'::;:'JIJ L..Jo--- Position the po receiver

PC as shown. Apply pressure
to center 0 boord.
/ \\
Pos' 'on he tape edge 0
the boss g sse and flush
PoI~ Double-sided
•
to he rib.
Coil adhesive tape
Clean the surface of the
eonsole . oleo 01 before
assembling the tape.
26
How To... Replace the Alternator Cable
Alternator Cable
Connector at
Back of Alternator Power Control Board
Alternator
Cable /
\
Orange Wire \
Load Resistor
• I
Alternator Cable
I
Yellow Wire
Red Wires
to Load Resistor Black Wires
1. Remove the side shrouds. See "How To ... " in this section.
2. Disconnect the alternator cable connector from the power control board (PCB), and then remove the other end
of the cable from the load resistor.
3. Before disconnecting any wires from the alternator terminals, mark and tag each terminal post to its
appropriate wire.
4. With the alternator wires marked and tagged to their corresponding terminals, remove the alternator wires
from the back of the alternator.
5. Cut any cable ties, and remove the alternator cable.
6. Install new alternator cable in reverse order.
•
27
How To... Replace the Reed Switch and Cable
Reed Switch
Connector
•
1. Remove the side shrouds. See "How To .... in this section.
2. Disconnect the reed switch connector from the power control board (PCB).
3. To replace just the reed switch cable assembly, remove two screws securing the reed switch it to the bracket.
4. To replace both the reed switch cable assembly and bracket, remove the screw securing the bracket to the
frame.
5. Cut any cable ties, and remove the reed switch cable assembly.
6. Install new reed switch cable asembly in reverse order.
•
28
How To... Replace. the 9-Volt Console Battery (LC8500R and R7)
NOTE: Console removed for clarity.

Sock of the
NOTE: The 9V battery is located in back of the Console Acisembly
console. To access:
1. Remove the cover at the back of the console to

reveal the battery.
2. Unplug the connector, and remove the battery

from the console.
3. Install new battery in reverse order.
Battery
Cover
•
29
How To... Replace. the 6-Volt Battery (LC95R, LC91 Rand R9)
Note: It is not necessary to remove the

shrouds for this procedure unless, the
battery bracket requires replacement.
•
1. Tilt the bike on its side.
2. Remove the two mounting screw securing

the battery to the bracket. Remove the
battery just enough to access and disconnect
the BLACK (neg) wire from the (-) terminal
and the RED (pos) wire from the (+) terminal.
Note: If the battery bracket requires replacement,

then remove the left or right side shroud and
then, remove two mounting screws securing the
bracket to the frame.
3. Reconnect the BLACK (neg) wire to the (-)

terminal on the battery, and the RED (pos)
wire to the (+) terminal, and then secure the
battery to the mounting bracket with the two
mounting screws.
4. Lift the bike to its upright position.
•
Bracket
Mounting
-- Screw(2)
•
30
How To... Replace the Display Console and Console Support
1. Remove four mounting screws from the back of

the console at the console support.
Console
2. Lift the console up just enough to disconnect the
1O-pin main wiring connector, and if equipped,
the 4-pin heart rate cable.
3. Remove the console from the console support. 4-Pln

\ Heart Rate Cable
\ \
4. Remove four frame post bolts securing the \
\
\
\
console support. 9V Battery . \
\
\
\
\(
--V
A.I'7"\\ "\
5. Lift out the console support from the frame post
be careful of the wiring.
Battery
CcNef "\
\
\£.0_-_
\
\
6. Install console and console support in reverse
order of removal.
\
\
\
I \
I
I
\
I
--n
I
I
I
-r-,
cL
MolXlting
•
I ,
SCrews
I I
I I
Frame Post
•
31
How To... Replace the Power Control Board
1. Remove the left side

Reed Switch Cable
shroud. See UHow TO ... in
Connector
this section. Power Control
Board
2. Disconnect the alternator
cable connector, reed
Alternator Cable
switch cable connect, and
Connector
battery cable connector
from the power control
board.
3. Remove four screws

securing the PCB to the
•
bracket.
4. If necessary to replace
Bracket
the mounting bracket,
(
remove two screws Bracket
secured to the frame.
/ Screw(2)
5. Install new PCB board in
reverse order. Philip Screw(4)
Power
Control
'.
Board
•
32
How To... Replace the Pedal
Right Pedal
(Facing End of Pedal,
tum Clockwise to tighten)
• Left Pedal
(Facing End of Pedal,
tum Counterclockwise
to tighten)
1. Remove the right pedal by turning it counterclocKwise.
2. Install the right pedal by turning it clockwise.
3. Remove the left pedal turning it clockwise.
4. Install the left pedal turning it counterclocKwise.
•
33
How To... Replace the Front Wheel Assembly
1. Remove two TORX screws from

each side of the stabilizer bar.
•
2. Pull the wheel assembly out from
the ends of the stabilizer bar.
3. Install new front wheel assemblies

in the reverse order.
Stabilizer
Bar
Torx/
Screw(4)
Wheel
•
Assembly(2)
•
34
How To... Replace and Adjust Levelers
Note: The levelers are located under the ends Rear

of the rear stabilizer bar. It is very important Stabilizer
that the unit be properly leveled before using. Bar
1. Remove the leveler assembly by first
loosening the jam nut.
2. Tum the leveler assembly

counterclockwise to remove it from the
rear stabilizer bar.
3. Install the new leveler, with jam nut, in the JamNut--{Q

reverse order.
Leve",r~
4. Adjust the levelers by loosening the jam
nut, then tum each leveler clockwise, to
move it into the stabilizer, or
counterclockwise, to move it out of the
stabilizer. Do this for both levelers until
the unit is stable and level.
•
35
How To... Replace the Resistor Assembly
1.
2.
Remove the side shrouds. See
Remove two cable mounting

•
screws, and then lift off the
cables from the resister.
3. Remove mounting screws

securing the resistor assembly
to the frame, and then lift out
the resistor assembly from the
frame. Cable
Mounting
4. Install new resistor in reverse
Screw
order.
Mounting
Screw(2)
Cable
Mounting
Screw
•
36
How To... Replace the Console Circuit Board
1. Remove the battery cover and

Console PCB
I
battery.
Console / Console
2.
3.
Remove the four screws from
under the console support.
Lift the console up just enough to

Cover (Front)
lover (Bock)
disconnect the main cable and / Screws(8]

heart rate cable (if equipped).
4. Remove eight screws from the

...
back of the console and split the
halves.
.
5. Remove the screws securing the
console circuit board to the front
..
half of the console, and then
remove the console circuir board.
..
6. Install new circuit board in reverse
order of removal. ..
..
• Battery Cover
•
37
NOTES:
•
38
.-----------
SECTION IV
ELECTRONICS
AND
WIRING DIAGRAMS
•
1
Lifecyc/e LC95R, LC~1 R, LC85R, R9, and R7 Recumbent Exercise Bikes
DISPLAY CONSOLE BOARD - Model LC95R
I' - " - ...

o 0
o
0'
•
c=:::J
o
I:, , 0 •..
p-
/?_£ ~
o 000
,. 00 0
.----------- .
P12
iP2
o
o
I I
1'11 .JvV3 .NIIB TPl
Functional Description •
The Display Console Board is designed to work in conjunction with the Alternator Control Board. It reads the
keypad input for changes or updates by the user, and refreshes the status LEOs, data display, and profile display
matrix.
Connector and Pin Descriptions

Connector Location Pin Functional Description
P1 and P12 is a 17 pin ribbon 1 Ground
connector that connects to the 2 Strobe
switch membrane. 3 Return
.;.;-:.:.:-;-;-:.;.;.;.:.:;:-:.;.;-;.;.;.:. 4 Strobe
5 Strobe
6 Return
-:';';';':';';';';';':':';':':";'.'.':"
7 Strobe
.;-:-:.:.;:;:;::.;.;.;::.:-:::-::;.;:;::-;. 8 Return
;.:-;-;-;.;.;.;.;.:.;:;.;.;-;.;-:.;.:.:-;:
9 Strobe
10 Return
11 Ground
12 Strobe
13 Strobe
:.:.;.:;:::::;:.:.;.:.:.;.;.;.:.:.:.;.:;:;
14 Return
15 Strobe
16 Return
17 Ground
•
2
DISPLAY CONSOLE BOARD· Model LC95R
.-----------
c onnector an d p.In 0 escnptlons
P2 is a 16 pin connector that 1 N.C.
connects to the alternator 2 GND (NOT USED)
control board. ....-0 .... 3 VSYS (NOT USED)
4 VBAT (NOT USED)
....
:l) N
5 RPM REED (NOT USED)
....
~ CO') 6 RPM ALT
7 ASTART (NOT USED)
J~ ~
8 VALT. (NOT USED)
I
.... 9 RELAY (NOT USED)
.- 10 GND
.... ..0
11 GND
I~ 12 VBAT
13 FIELD-KICK
10- e:> 14 FIELD
15 LOAD-CMD
16 VSYS
P4 is 4 pin connector that LEFT +

connects to the heart rate
sensor.
.., . LEFT -
•
~ N RIGHT -
RIGHT +
r.;;
;
P7 is a 3 pin connector that 2 1 +VCC (5VDC)
connects to the polar signal. 3 2 POLAR SIGNAL
3 GROUND
P9 and P10 are 8 pin 1 N/U - not used

1 8
connectors that connect to the
lt~~~ ~~
2 N/U - not used
CSAFE and Cardio Theater or 3 Receive Data
broadcast vision interface. 4
-----' Transmit Data
5 +8 Vdc
6 CTS
7 Ground
8 N/U - not used
P11 is a 10 pin connector that 1 IDS

connects to the background (iJl ·6) 2 IBERR
debug mode signals. 3 Ground
2) 7 4 IBKPT IDSCLK
3) 8 5
6
Ground
FREEZE/QUaT
~Ol '9) 7 IRESET
1<"5) @ 8 IPIPE1/DS1
+5 Vdc
9
•
10 IPIPEO/DSO
3
c onnec t or an d p.In Descnp

Connector
. lf lons
P5 is a 24 pin connector that

connects to the lower console
Location Pin
1
Functional Description
•
l'<::t ..- 2
display board. N 3
,~ 4
5
~ 6
I
7
N '<::t
8
~ LO 9
10
Ie: 11
-OJ 12
..-
13
... 14
15
..- 0-
16
... 0
..-
17
... ...
"'2' r-
18
19
I~ ... N 20
•
21
22
23
24
•
4
DISPLAY CONSOLE BOARD· Model LC91 R
.----------- o
SP 1
o
o
,~j 0000
~_~P8
= = =
~ [J o ...,n",nnn~ f'
-'-~_.:J 0
.-
.f-P1
I:
::=
u-
-c:;-
ITK )]CJ
o e=
B
I·
0
o 0
• Functional Description
keypad input for changes or updates by the user. and refreshes the status LEOs. data display. and profile display
matrix.

P12 is a 17 pin ribbon 1 Ground
switch membrane. 3 Return
4 Strobe
5 Strobe
6 Return
7 Strobe
8 Return
9 Strobe
10 Return
11 Ground
12 Strobe
13 Strobe
14 Return
15 Strobe
16 Return
17 Ground
•
5
Connector
P2 is a 16 pin connect that
Location Pin
1
N.C.
•
connects to the alternator 2 GND (NOT USED)
control board. -0 .- 3 VSYS (NOT USED)
.-
4 VBAT (NOT USED)
I L..')
.... N 5 RPM REED (NOT USED)
~ (0)
6 RPM ALT
.- 7 ASTART (NOT USED)
I~ ~I 8 VALT. (NOT USED)
IN 9 RELAY (NOT USED)
tl)
.- 10 GND
....
~
.0 11
12
GND
VBAT
....
0
13 FIELD-KICK
0- CO 14 FIELD
15 LOAD-CMD
16 VSYS
P7 is a 3 pin connector that 1 1 +VCC (5VDC)

connects to the polar signal. 2 2 POLAR SIGNAL
•
3 3 GROUND
P8 is an 7 pin connector that 1 GND

1
connects to the CSAFE card. 2 LEU
2..
31 3 TOO
4i 4 RDI
EJ:- 5 CTS
6
---; 6 VCC
L 7 VCARDIO
•
6
Lifecycle LC9SR, LC~1 R, LCBSR, R9, and R7 Recumbent Exercise Bikes
DISPLAY CONSOLE BOARD - Model LC85R and R7
.----------- o
o
SPK1
0
0
0
, -,
o0
~01:1
= = = 0
1:1 o .E=J ;- 0000
-
o
[
-e:::J-
J (J i 1:1
o
o o
SNAP HQl..DER
matrix.

P12 is a 17 pin ribbon Ground
switch membrane_ 3 Return
4 Strobe
5 Strobe
6 Return
7 Strobe
;.:.:.:.:.:-:.:.:.:.:.;.:.;.;.;.:.;.:....... 8 Return
.....;..;.;.;.;.;-:...;.:.;..;.;.;.;....;.:.:.; 9 Strobe
10 Return
.-:.:.:.::.:.:.:.:.:-:.;.:.:.;.:-:.:-:.:.
11 Ground
12 Strobe
13 Strobe
• 14
15
16
17
Return
Strobe
Return
Ground
7
DISPLAY CONSOLE BOARD - Model LC85R and R7
connect or an d p.In Descnp110ns

Connector
. f

Location Pin
1
N.C.
GND (NOT USED)
•
2
connects to the alternator
control board.
1.- .-
3 VSYS (NOT USED)
Lt:i N 4 VBAT (NOT USED)
.-
~ ('t)
.- 6 RPM ALT
7 ASTART (NOT USED)
I~ 8 VAlT (NOT USED)
I !.t)
.- 9 RELAY (NOT USED)
I::: .f:)
I
10
11
GND
GND
0
.-
" 12
13
VBAT
FIELD-KICK
0- CO
14 FIELD
15 LOAD-CMD
16 VSYS
.- . _·-:':"::b':~l;: - _.
P7 is a 3 pin connector that· 1 1 +VCC (5VDC)
connects the polar connector. 2 2 POLAR SIGNAL
3 3 GROUND
•
8
.-----------
DISPLAY CONSOLE BOARD - Model R9
11111111111:1
p I
o
, . ,
o
DO 0
c=J
= = = = o o
1:1 o
ill==:::J C c::J !EJ ElEUillJ EJEl GJf.B mElEHillJ ;:?<' .~;~~ ~:>"
=
o 1:1 P12
TP2
P2
matrix.
Connectors and Pin Descriptions

P12 is a 17 pin ribbon Ground
overlay board. ;.;.;"'.;.;::.;.:.;.:.:.:.:.:.:.:.;.;..:.: 3 Return
4 Strobe
5 Strobe
6 Return
7 Strobe
8 Return
9 Strobe
10 Return
:...:..
~.;.:::.:.:._.,; ...:"......:...:.
11 Ground
12 Strobe
•
.... :.:._.:.:.~ :.:._.~.. 13 Strobe
·:···:·:·:·;.:·:·N·..·:·:·~·:·:··.-:·. 14 Return
;:.:...:.:;:-:;;..: .....:.:.:.:.:...:.;.:
15 Strobe
16 Return
17 Ground
9
DISPLAY CONSOLE BOARD - Model R9

Connector
connects to the altemator
Location Pin
1
N.C.
•
2 GND (NOT USED)
control board. 3 VSYS (NOT USED)
It) •
4 VBAT (NOT USED)
6 RPM ALT
7 ASTART (NOT USED)
8 I VALT. (NOT USED)
9 RELAY (NOT USED)
10 GND
11 GND
12 VBAT
13 FIELD-KICK
14 FIELD
15 LOAD-CMD
16 VSYS
':':' ~{_. .,. .·':::::{·,:··::::···:;,:'i: ·f}t~:~ ..
P4 is a 4 pin connector that 1 Left +

connects to the heart rate 1(2)1@~ 2 Left -
sensor. i(j)@j 3 Right -
•
4 Right +
P11 is a 10 pin connector that 1 IDS

connects to the background IBERR
debug mode signals.
1) ~6) 2
3 Ground
(2)1( 7)1 4 IBKPT IDSCLK
(3) (8)1 5 Ground
(4) 9)1 6 FREEZE/QUaT
7 IRESET
~Q9)1 8 IPIPE1/DS1
9 +5 Vdc
10 IPIPEO/DSO
P7 is a 3 pin connector that i1 1 +VCC (5VDC)

connects to the polar signal. II 2 POLAR SIGNAL
~ 3 GROUND
•
10
ALTERNATOR CONTROL BOARD - Model R7 and LC85R
The Alternator Control Board is
designed to regulate the alternator
UFE ATNESS
voltage by modulating the field

current. It regulates the pass current
(RPM signal) from the Alternator to
the Console, and the pass current
form the alternator to the load ,---- --e=:-
resistor while providing supply I I~I
voltage for the console while I
charging the system battery.
-1=-
c=
/
I
I , o
P2
Connector and Pin Connections

•
P1 is a Molex 9 pin connector 1 RPM (D-7.5 VDC)
/>1)
that connects to the console.
~ 2 VBAT (9VDC)
3 NOT USED (BLANK)
>t
~ 4 LOAD
~
5 START
~I
>e<
6
7
GROUND
GROUND
~ 8
9
ALTREGLO (9-11 VDC)
VSYS (7-8 VDC)
....' .
P2 is a 14 pin connector that 1 FLO RTN
~2
connects to the alternator and 2 FIELD (1-4 VDC)
power resistor. 3 VALT (10 VDC)
4 LOAD
'1· I I 5
6
LOAD
GROUND
1 11 14 ,
7
8
GROUND
RPM (D-7.5VDC)
112 9 VALT
10 LOAD
13 11 LOAD
12 GROUND
13 GROUND
14 GROUND
•
11
ALTERNATOR CONTROL BOARD - Model R9, LC91 R, and LC95R
The Alternator Control Board
is designed to regulate the
alternator voltage by
P3 1ftRH$
AOllG-92218-XXXX
0 2001 -
o •
modulating the field current.
It regulates the pass current
(RPM signal) from the
Alternator to the Console, r
and the pass current form
the alternator to the load P4
resistor while providing
supply voltage for the
console while charging the
system battery.
., o
Connector and Pin Pl
Connections
P1 is a Molex 11 pin connector
that connects to the console. rrv
>.l<
l<
>t
>g
~7
1
2
3
4
5
6
7
GROUND - BLACK
GROUND - BATIERY
NOT USED (BLANK)
VSYS (7-8VDC)
AlTREGLO(~11VDC)
LOADCMD
RPM (0-7.5VDC)
•
>a) 8 START (7-8VDC)
~
~ 9 VBAT - (6VDC)
: 10 GROUND - BATIERY
~ 11 GROUND
.
P2 is a 12 pin connector that 1 GROUND - ALTERNATOR
connects to the alternator and CJ 2 GROUND - ALTERNATOR
power resistor ) 3 1~Il i 3 GROUND - ALTERNATOR
11(6
,
@1'4"' i
11<9 8 71
. 4
5
RPM (5VDC)
GROUND -ALTERNATOR
6 FIELD (1-4 VDC)
JI@ 11 iaJl: 7 LOAD
LJ
8 LOAD
9 LOAD
10 VALT (10VDC)
11 VALT (10VDC)
12 LOAD
•
12
ALTERNATOR CONTROL BOARD - Model R9, LC91 R, and LC95R
.-----------
Connector
P2 Connector is a
12 pin Molex
Location Pin
1
GND
2 GND
connector that
connects to the
12 10000 3
3 GND
Alternator.
[ 00 0 4 RPM-ALT
10 G I 5 GND
6 FIELD
7 VALTR
8 VALTR
9 VALTR
10 VALT
11 Valt OPEN
12 VALTR

P3 is a 3 pin 1 GND
1
connector that
connect to the reed g~ 2 Vbat
•
Switch P3 3 RPM-REED

P4 is a 2 Pin 1
~DDr
connector that
provides external 2
power (LC95 only).
•
13
ALTERNATOR
The 12 volt, 35 amp Alternator is designed to provide electrical power to the product, supply load
resistance while providing electrical power, and provide the RPM signal from the AC TAP to the
Alternator Control Board.
•
C TAP TERMINA
OUTPUT TERMINA~
GROUND TERMINAL
•
•
14
----------~ - - -
.-----------
WIRING BLOCK DIAGRAM LC85R and R7
CONTROL
UPPER CO !SOlE ~W'tRr.R.
•
I
I
PoIa Receiver and Coble

optional crl lc8500 ad
standad on C7. Also corres
with Telemetry strap.
P12
19POS.LF
lJ'l'ER KE'/I'lI\l)
•
15
WIRING BLOCK DIAGRAM R9
C01 TROl
•
15 OHMs
ResstOf
I
P1 13!'OS. 10<-156
LEFT
RED
•
TOO
RDI
GND
Vsyrc
llJ'OS. os
BACKGIROU'm-:-u BERR
DEWG GND
Hal. BKPT
GNO
FREEZE
RESET
011
Vee
Dso
•
16
.-----------
WIRING BLOCK DIAGRAM LC91R
CONTROL
--_._ .._,
, I
: :
• 4POS.
t.tCROFIT
TESlER
COM
P61
2
•
•
i
m~ 100
: ROl
; Gt()
I v.,tc
UPPER CONSOLE
I
I
I
I
1
i
I
I
I
1
P8
•
17
WIRING BLOCK DIAGRAM LC95R
CONTROL
I~m
---
-~~-
......- ;-;" PI
HR Hardie BOl' 24'05.~
Coble
•
~==:::~~'1O
for. n,
fot.•_r-----"---{~J_i m
.u
fot.0-----'--{.!.J-lJ_i ..
.
III
,
..
•
we;
we; K>l"r---...IUL----{~>i 0:
LoL."J---...llIU<"'--{~>i'"
no r - - - - " - - - - - l....H>I ..
lI'I'm CONSOlE ~----"--~J-oj",
--
co
'"
0-..
.. ·~I...
we;
we;
no
co
"
•
....
...:.....
• Kr'
-
~
• -r,...
'g
·.. ..
co '" 0
Pll ~:
· .
·kJ ..
lCJlOS.
BI'OCGROl/ID
-
-
'"
.. .
51
•
•
n
...!!...;-V- 6
~~
.... .
g'
0E!lJG • --<}- . .
--.~..
HDR. "1
···· ..-
w ..
I--"~"""
'" w
_ n
... Pl "
17POS.1J'
lClWBllCFlll'D ~-
19f'OSJE
lI'PBl iCPIf'AO
•
18
- - - - -- ------ -------------------
.-----------
SECTION V
MISCELLANEOUS
•
1
MODEL IDENTIFICATION and SERIAL NUMBER LOCATION
Model/Serial Number
•
2
.-----------
PREVENTIVE MAINTENANCE TIPS
Preventive Maintenance Schedule
I DAILY MONTHLY BI-ANNUALLY

HOUSING
Inside Clean
Outside Clea"
ALTERNATOR CONTRCL
Heatsink Clean
Connectors Inspect
Board Inspect
Crank Bearings I I Inspect
Pedals Clean/Inspect
Freewheel Pulley Clean/Inspect
Alternator Flywheel Clean/Inspect
SEAT ASSEMBLY
I Top Surface I
I
Clean i
I Release Lever I I Inspect
ALTERNATOR BELT
• Tension
Wear
Lifepulse sensors I Clean I
Inspect
Inspect
•
3
IMPORTANT SAFETY INSTRUCTIONSI
~ DO NOT iocate the Recumbent Exercise Bike outdoors, near swimming pools, or in areas of high
humidity.
•
~ DO NOT operate your Recumbent Exercise Bike if it has been dropped, damaged, or even partially
immersed in water. Contact Ute Fitness Customer Support Services at the number in the Operation
Manual.
~ DO NOT locate the Recumbent Exercise Bike any closer than 30 inches (76 cm) to a television set.
~ DO NOT ocate additional Recumbent Exercise Bike any closer than a minimum of 42 inches (107
em) from center to center to avoid interference (cross talk) between Heart Rate monitors.
~ DO keep the area around your Recumbent Exercise Bike clear of any obstructions, including walls
and furniture.
=> DO verify the contents of the delivery carton against the accompanying Parts Listing prior to setting
the cartons and shipping material aside. If any parts are missing, contact Life Fitness Customer
Support Services at the number listed in the Operation Manual. Save the shipping cartons in case of
return.
= DO read the entire Operation Manual prior to attempting to operate this machine as this is essential
for proper use. •
•
4
TOOLS REQUIRED FOR ASSEMBLY... Phillips screwdriver, 3/16" hex key wrench, T-40 Torx wrench
PARTS DESCRIPTION
1 Seat Back Screw Qty:4 2 Seat Back Washer Qty:4

0017-00101-1131 0017-00104-0253
3 Console Support Assembly Bolt Qty:4 4 Console Screw Qty:4
I 017-00101-1737 0017-00101-1253
5 I Seat Sack Qty: 1 6 Console Support Assembly
AK39-00003-0000
Qty: 1
7 Display Console ..
Qty0 " 8 Accessory Tray Assembly (If so equipped) Qty: 1
9 Left Pedal Strap Qty: 1 10 Right Pedal Strap Qty: 1
11 9V Battery (Model 8500 Only) Qty: 1

0017..QOOO3..Q757
• CD
@
•
5
•
8
---"~
•
6
,-----;-------_._. -
51: 'e m::; ACCESSORY -:-~A,. Y (;:;8) (if so equipped) over the
~g
user sea!
SEA ~ HAJ'\lDLEBAR
0 c:· POSl and down to make contact v.ith the '8'
• 1. Position the underside clamp bracket (A) around the

SEAT HANDLEBAR and tighten the two clamp
SCREWS and WASHERS (8).
NOTE: BE CAREFUL NOT TO OVER-TIGHTEN
THE SCREWS.
2. Align the four holes in the SEAT BACK (#5) with
those in the SEAT BACK POSTS. Insert the four
SCREWS (#1) and WASHERS (#2) through the
:J3C. sice of tne SEAT BACK POSTS and into the
SEAT BACK. Tighten the four SCREWS with a hex
Key wrench.
NOTE: BE CAREFUL NOT TO OVER-TIGHTEN
THE SCREWS.
3. Unfola the CONSOLE WIRE HARNESSES (C) from
the POST extending from the FRAME.
4. Feed the WIRE HARNESSES at the top of the
FRAME POST through the bottom of the CONSOLE
SUPPORT ASSEMBLY COLUMN. Continue pushing the
WIRE :-iARNESSES until the CONNECTORS at the end
of ·r;e WIRE HARNESSES exit through tne opening at tne
'up ot :r.~ COLUMN. Gently pull the WIRE HARNESSES
:0 iemove tne slack.
5. Position the CONSOLE SUPPORT ASSEMBLY (#6) so
•
that the HANDLEBAR is facing the user and slide the
CONSOLE SUPPORT ASSEMBLY into the FRAME
POST (D), being careful not to pinch the WIRES in the
process. Align the holes in the top of the CONSOLE
SUPPORT ASSEMBLY with those in the FRAME POST.
Install the four CONSOLE SUPPORT ASSEMBLY BOLTS
(#3) to secure it into position. Tighten the four CONSOLE
SUPPORT ASSEMBLY BOLTS to 15-20 ft. Ibs.
NOTE: BE VERY CAREFUL NOT TO DAMAGE THE
WIRES WHEN PASSING THE BOLTS THROUGH THE
I
HOLES. TIGHTEN THE BOLTS SECUREL Y. I
I
I
6. Align tne LOCKING TABS of the 1O-PIN CONNECTOR I
I I
and the 4-PIN CONNECTOR (Models 9500HR) and plug - - f,
them together until they SNAP into place. ,,
-1- - I
7. Model 8500 Only

Remove the BATTERY DOOR (E) located on the back of
the DISPLAY CONSOLE (#7). Carefully pull the
~---'
0=>-
BATTERY WIRE HARNESS (F) out of the BATTERY
COMPARTMENT. Plug the BATTERY (#11) into the
BATT:::R':" WiRE HARNESS CONNECTOR. Carefully
;> ace me SATTERY and BATTERY WIRE HARNESS into
:, E: i3 -:!:::RY COMPARTMENT. Replace the BATTERY DOOR.
•
7
8. Caref Iy feed the wires back into the top of
the CONSOLE SUPPORT ASSEMBLY (#6)
and attach the DISPLAY CONSOLE (#7) to
the CONSOLE SUPPORT ASSEMBLY
using the four CONSOLE SCREWS (#4)
and a Phillips screwdriver. Tighten the four
SCREWS in a criss-cross pattern.
0-£: BE CAREFUL NOT TO OVER-
TIGHTEN
THE SCREWS.
s. After placing the exercise bike in the
intended location for use, check the stability
of me bike. If the exercise bike is not level,
turn a LEVELER (G) in the rear
STABiliZER BAR (H) in either direction
until me rocking motion is eliminated. Tighten
the JAM NUT (J) when the exercise bike is level.
NOTE: ONL Y ONE LEVELER NEEDS TO BE
TURNED.
1 _Jcate me RIGHT PEDAL STRAP (#10) marked
it. an "R". Attach the RIGHT PEDAL STRAP to
the RIGHT PEDAL (K) with the double slot on
the inward pedal strap tab looping upward and
anaching to the outward pedal strap tab. Repeat
for the L!::FT PEDAL STRAP (#9) marked with
an -L'
•
8
I
•
•
•
©2000 Brunswick Corporation. All rights reserved. Ufe Fitness and Ufecycle are registered trademarks of Brunswick Corporation.
•
·fepulse, Zone Trainer and Heart Rate Zone Training are trademarks of Brunswick Corporation. Any use of these trademarks, without the express
written consent of Brunswick Corporation, is forbidden.
M051-00K39-A012
September 2002

R7 Service Manual

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R7 Service Manual

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Lifecycle LC9500R, LC9100R, LC8500R,

R9, R7 Series Bikes

Customer Support Services

SPECIAL SERVICE TOOL REQUIREMENTS

1. The Lifecycle equipment model number

• LIFE FITNESS COMPANY - CUSTOMER SUPPORT SERVICES

SPECIAL SERVICE TOOL REQUIREMENTS

Seat Back Left Pedal

SECTION I TROUBLESHOOTING GUIDES

SECTION III HOW TO REPLACE THE .

SECTION IV ELECTRONICS OVERVIEW

• Important Safety Instructions

Keypad not responding.

Test keypad in diagnostics.

Loose wire connections. Disconnect then reconnect connections.

Worn or damaged wire Inspect wire harnesses. Replace worn or

Malfunctioning display Test with substitute display console. Replace

Malfunctioning alternator Test with substitute ACB. Replace

Test alternator output or test with substitute

Malfunctioning display Test with substitute display console. Replace

Worn or damaged wire Inspect wire harnesses. Replace worn or

Malfunction Probable Cause Corrective Action

Loose wire connections Disconnect then reconnect connections.

I Worn or damaged wire Inspect wire harnesses. Replace wom or

Test with substitute Alternator Control Board.

Malfunctioning Alternator Test Alternator output or test with substitute

Malfunctioning Display Test with substitute Display Console. Replace

Test Alternator output or, test with substitute

Malfunctioning Display Test with substitute Display Console. Replace

Malfunctioning Alternator Test with substitute ACB. Replace

Malfunctioning Alternator . Test Alternctor output or, test with substitute

Worn or damaged hamesses I Inspect wire harnesses. Replace worn or

Malfunctioning Display Test with substitute Display Console. Replace

Malfunctioning Alternator Test with substitute Alternator Control Board.

i Malfunctioning Alternator Test Alternator output or, test with substitute

Test with substitute Alternator Control Board.

Test Alternator output or, test with substitute

Crank bearings worn or Replace Crank Bearings.

Malfunction Probable Cause Corrective Action

Loose wire connections Disconnect then, reconnect connections.

Malfunctioning Display Test with substitute Display Console. Replace

Malfunctioning Alternator Test with substitute Alternator Control Board.

Malfunctioning Alternator I Test Alternator output or, test with subst~ute

I Alternator Belt excessively

Alternator Belt Deflection: 1/4 inch (6mm)

Battery Wires incorrectly

Wom Battery Wires

Inspect connections: red wire to positive (+)

Inspect Wires. Replace Wires or harness.

Malfunctioning Display Test with substitute Display Console. Replace

Wheel(s) damaged Replace damaged wheel(s).

Crank Bearin sworn

Alternator Belt excessively Inspect belt deflection. Adjust as necessary.

Alternator Belt worn Re lace Belt.

Malfunctioning Alternator ODerate Exercise Bike as in normal use with

Drive Belt excessively loose Inspect Belt. Re lace Belt.

Free-wheel Pulley Assembly

Using an ohmmeter, verify continu:ty at the

! Malfunctioning Rep'ace Hanaleoar/Lifepulse Assembly.

Using an ohmmeter, verify continuity between

Handlebar/Lifepulse Grip Dry wipe sensors.

Excessive wear or damage to Replace the handlebar assembly.

~ For Quick Start: -,