Service Handbook - Horizon Fitness
Contents
1. from the left pedal arm with a Phillips screwdriver 9 Locate the magnetic brake S02 10 The correct position for the magnetic brake is 2 3mm from the flywheel at the highest resistance level 11 Locate the 13mm nut S11 attached to the magnetic brake spring S10 Adjust the nut clockwise to reduce the brake resistance and counterclockwise to increase the brake resistance By adjusting this nut the lower half of the brake will either move closer or further from the flywheel 12 It may be necessary to also adjust the top half of the magnetic brake To do this loosen the two 5mm bolts S08 that attach the magnetic brake to the frame Adjust the position of the magnetic brake closer or further from the flywheel 13 Attach the left side cover and secure with screws 14 Attach the accent piece placing the bottom tab into position first then placing the top tab into position 52 53 15 Attach the crank disk and crank arm to the crank axle Place black cap onto the center of the crank disk 16 Replace pedal arm cap 17 Attach the pedal 18 Test ride the exercise bike to make sure it is working correctly Adjusting the Exercise Bike Magnetic Brake 3 1R 3 1B Tools Phillips screwdriver Smm Allen wrench 15mm wrench 14mm socket 13mm wrench crank puller Note Diagram on following page 1 Turn the tension knob to the highest resistance level Remove the tension knob from the tension cable by pulling up on the tension2. knob 2 Remove the screw that attaches the tension knob to the console mast using a Phillips screwdriver 3 Remove the left pedal with a 15mm wrench 4 Remove the black cap from the center of the crank disk 5 Remove the crank arm nut with a 14mm socket 6 Using a crank puller thread the puller onto the crank arm Extract the crank arm and crank disk from the axle and remove 7 Remove the accent piece by gently lifting up at the bottom of the accent piece and tilting towards the front of the machine 8 Remove the screws that attach the left side cover in place Remove the crank arm cover from the left pedal arm with a Phillips screwdriver 9 Locate the magnetic brake S02 10 The correct position for the magnetic brake is 2 3mm from the flywheel at the highest resistance level 11 Locate the 8mm short and long nut A and B respectively covering the tension wire that is attached to the magnetic brake flywheel assembly Loosen the short nut A and adjust the long nut B clockwise to reduce the brake resistance and counterclockwise to increase the brake resistance 12 Attach the left side cover and secure with screws 13 Attach the accent piece placing the bottom tab into position first then placing the top tab into position 14 Attach the crank disk and crank arm to the crank axle Place black cap onto the center of the crank disk 15 Replace pedal arm cap 16 Attach the pedal 17 Test ride the exercise bike to make su
3. set Metric Open end wrenches of assorted sizes Metric 44 drive ratchet and sockets of assorted sizes Bearing loctite Cable ties Needle nose pliers Damp cloth Rubber mallet Drop cloth to protect floor surfaces Ruler Snap ring pliers Wire cutters Crank Puller Bearing Extractor Available through Horizon Fitness at cost Preventative Maintenance Procedures Cleanliness of your Horizon Fitness exercise equipment and its operating environment will keep maintenance problems and service calls to a minimum For this reason Horizon Fitness recommends that the following preventive maintenance schedule be followed After Each Use e Wipe down the console handlebars and side covers with a damp cloth Never use solvents as they can cause damage to the exercise equipment Every Week Clean underneath the exercise equipment following these steps e Move the exercise equipment to a remote location e Wipe or vacuum any dust particles or other objects that may have accumulated underneath the exercise equipment e Return the exercise equipment to its previous position Every Month e Inspect all assembly bolts of the machine for proper tightness CONSOLE TROUBLESHOOTING CONTENTS No display on console Partial LCD display on console No RPM speed or watts readout Console resets intermittently Erratic or no heart rate readout Switching from mph to km 13 14 15 16 17 18 No Display on
4. 13 Attach the left side cover and secure with screws 14 Attach the accent piece placing the bottom tab into position first and then placing the top tab into position 15 Attach the crank disk and crank arm to the crank axle Place black cap onto the center of the crank disk 16 Attach the pedal 17 Test ride the exercise bike to make sure it is working correctly AS QI Nee Replacing the Exercise Bike RPM Sensor R52hr B52hr 3 IR 3 1B R6055 Tools Phillips screwdriver 14mm socket 15mm wrench crank puller 41 HKH QI Nee 8 9 Remove the left pedal with a 15mm wrench Remove the black cap from the center of the crank disk Remove the crank arm nut with a 14mm socket Using a crank puller thread the puller onto the crank arm Extract the crank arm and crank disk from the axle and remove Remove the accent piece by gently lifting up at the bottom of the accent piece and tilting towards the front of the machine Remove the screws that attach the left side cover in place Locate the sensor wire bracket Remove the screw from the sensor wire bracket and remove the old sensor wire from the bracket Detach the sensor wire from the console cable Attach the new sensor wire to the sensor wire bracket and plug into connector into console cable 10 Attach the sensor wire bracket to the frame 11 Turn crank by hand to make sure that there is a RPM reading on the console If no RPM reading check t
5. C P4 BROWN 5 VOLTS DC P9 BLUE 0 VOLTS DC P5 GREEN 46 VOLTS DC P10 RED 5 5 VOLTS DC To check for voltages coming from a specific part i e sensor wire power supply DC motor place the negative lead of the multimeter in pin P9 ground and the positive lead in the desired pin Follow the pin voltages listed above to diagnosis a specific part The power supply must be plugged into the power jack and the console should be plugged into the console cable to receive accurate readings 34 Power Supply Voltage Check R52hr B52hr 3 IR 3 1B R6055 With the power supply plugged in to the wall place the positive lead of your multimeter into the power supply jack and the negative lead on the outside of the power supply jack The voltage of the power supply should be between 7 5 11 5 volts DC for models 2 1R 3 1R 2 1B 3 1B and between 14 5 16 5 volts DC for models R52hr B52hr and R6055 IC Board Voltage Check R52hr B52hr 3 1B 3 IR R6055 To check for voltage going to the photo sensor board place the positive lead of your multimeter on the top soldered pin on the backside of the photo sensor board and the negative lead on the second soldered pin on the backside of the photo sensor board The voltage reading should be between 5 to 6 volts DC 35 36 RPM Sensor Continuity Check To check for continuity on the sensor wire turn your mult
6. Console Possible causes 1 Weak batteries R51 B51 2 Loose connection between power supply and power jack R52hr B52hr 2 1R 2 1B 3 1R 3 1B R6055 3 Loose connection between console cable and console R52hr B52hr 2 1R 2 1B 3 1R 3 1B R6055 4 Defective power supply R52hr B52hr 2 1R 2 1B 3 1R 3 1B R6055 5 Defective photo sensor board R52hr B52hr 3 1R 3 1B R6055 6 Pinched or cut console cable R52hr B52hr 2 1R 2 1B 3 1R 3 1B R6055 7 Defective console All Models Fix 1 Check voltage on batteries or replace with known good batteries R51 B51 2 Check connection between power supply and power jack R52hr B52hr 2 1R 2 1B 3 1R 3 1B R6055 3 Remove the console by removing the four attachment screws and verify that the console cable is properly attached to the console R52hr B52hr 2 1R 2 1B 3 1R 3 1B R6055 4 Verify that the proper amount of voltage is coming from the power supply Reference the power supply voltage checkpoint in the table of contents R52hr BS2hr 2 1R 2 1B 3 1R 3 1B R6055 5 Verify voltage going to photo sensor board see photo sensor board voltage checkpoint in table of contents Replace if necessary R52hr B52hr 3 1R 3 1B R6055 6 Perform a physical check on the console cable to verify that it is not pinched or cut Verify that proper voltage is present at the end of the console cable which plugs into the console see console cabl
7. Horizon Fitness 2004 2005 Exercise Bike Service Manual R51 R52hr B51 B52hr 2 1R 2 1B 3 1R 3 1B R6055 If you have any questions please call the Horizon Fitness Service Hotline at 1 800 244 4192 TABLE OF CONTENTS NET EE EN acale asec tbewcaomatant 3 Safety Instructions nnspeniesneesinieeenieessieessssisesvessssesvesssssrsseesss 6 Basic Troubleshooting TipS een 7 Required Tool cl esta 8 Preventive Maintenance ssscoeeereeee eee 9 Console TrOubleshooting ssssseeeeeeee eee erre 10 Resistance Troubleshooting nnuepevvnmeeveeevevsssssssereeeeeene 20 Drive Train Troubleshooting eeovveessmeevevvsessssereeerveveveeessssereeereen 25 Voltage Checkpoints saa i i 32 Exercise Bike Part Replacement n jvnnmeeenneeessiseies 37 Bike Home Warranty Models R51 R52hr B51 BS2hr R6055 LIMITED HOME USE WARRANTY Horizon Fitness extends the following exclusive limited warranty which shall apply to the use of the device in the home for residential non commercial purposes only Any other use shall void this warranty Horizon Fitness hereby extends the following limited warranties for the following components of the device for the time period indicated FRAME LIFETIME Horizon Fitness warrants the frame against defects in workmanship and materials for the life of the product so long as it remains in the possession o
8. able is defective R51 B51 2 1B 2 1R only 4 Photo sensor board is defective R52hr B52hr 3 1B 3 1R R6055 only 5 Servomotor is defective R52hr B52hr 3 1B 3 IR R6055 only 6 Console cable is defective R52hr B52hr 3 1B 3 1R R6055 only 7 Console is defective R52hr B52hr 3 1B 3 1R R6055 only Fix 1 Remove tension knob from the console mast Verify that the copper cable from the tension knob is seated properly in the keyhole located on the tension cable 2 Remove the side covers and verify that the tension cable is connected to the brake 3 If problem persists replace the tension cable 4 Check voltages of console cable see console cable voltage chart in table of contents to verify proper function of photo sensor board servomotor and console cable Replace parts if defective 5 If problem persists replace the console 21 Erratic or Continuous Resistance Change Possible causes 1 Tension cable is not connected properly to the tension knob R51 B51 2 1B 2 1R only 2 Tension cable is not connected properly to the brake all models 3 Tension cable is binding or is crimped R51 B51 2 1B 2 1R only 4 Tension cable is defective R51 B51 2 1B 2 1R only 5 Zero switch is not positioned properly R52hr B52hr 3 1B 3 1R R6055 only 6 Defective photo sensor board R52hr B52hr 3 1B 3 1R R6055 only 7 Defective console cable R52hr B52hr 3 1B 3 1R R6055 o
9. about 0 25 deflection when pressing down firmly on the drive belt 18 Once the belt tension is set properly tighten the 17mm nuts on both sides of the flywheel 19 Attach the right and left side covers and secure with screws 20 Replace wood grain accent piece 21 Attach crank arms and crank disks and secure with 14mm nut Place black crank disk cap over 14mm nut 22 Slide console mast boot back into place 23 Attach the pedals 24 Ride the exercise bike to make sure it is working properly RIS R14 RI 51 Adjusting the Exercise Bike Magnetic Brake 3 1R 3 1B Tools Phillips screwdriver Smm Allen wrench 15mm wrench 14mm socket 13mm wrench crank puller Note Diagram on following page 1 Turn the tension knob to the highest resistance level Remove the tension knob from the tension cable by pulling up on the tension knob 2 Remove the screw that attaches the tension knob to the console mast using a Phillips screwdriver 3 Remove the left pedal with a 15mm wrench 4 Remove the black cap from the center of the crank disk 5 Remove the crank arm nut with a 14mm socket 6 Using a crank puller thread the puller onto the crank arm Extract the crank arm and crank disk from the axle and remove 7 Remove the accent piece by gently lifting up at the bottom of the accent piece and tilting towards the front of the machine 8 Remove the screws that attach the left side cover in place Remove the crank arm cover
10. arts if defective If problems persist replace the console R52hr B52hr 3 1B 3 1R R6055 Resistance is Too Hard or Too Weak Possible causes 1 Tension cable is not connected properly to the tension knob R51 B51 2 1B 2 1R only 2 Tension cable is not connected properly to the brake 3 Tension cable is binding or is crimped R51 B51 2 1B 2 1R only 4 Verify that brake is within 2 3 mm from the brake at the highest resistance level Fix 1 Remove tension knob from the console mast Verify that the copper cable from the tension knob is seated properly in the keyhole located on the tension cable 2 Remove the side covers and verify that the tension cable is connected securely to the brake 3 Remove side covers and inspect for any binding or crimping in the tension cable Keep in mind that the tension cable has an outer plastic sleeve with a small wire running internally If the small internal wire is binding or is crimped slightly it will not move smoothly Remove any binding or crimping by repositioning the tension wire 4 If magnetic brake is not within 2 3mm of flywheel at the highest resistance level follow the directions for adjusting the magnetic brake see adjusting the magnetic brake in the table of contents 24 DRIVETRAIN PROBLEM TROUBLESHOOTING CONTENTS Noise internally while pedaling nnn neesessnneeeeeeee 26 Internal noise while pedaling at high resistance levels on
11. ary When replacing either the crank or flywheel bearings be sure to remove any excess loctite after removing defective bearings and reinstalling new bearings Make sure that both the inner and outer diameters of the bearings have fresh loctite applied before reinstalling new bearings Crank Arms Loosen During Use Possible causes 1 Crank axle nut is defective Fix 1 Replace crank axle nut with updated nut Contact Horizon Fitness for update kit 31 VOLTAGE READINGS CONTENTS Console cable voltage chart r unnnseeemnvseeressseseeeeeeeen 33 Power supply voltage check nnnnreeererereeeeeerereeeeeeeeereeeeeeeeeeeeeeeeeeeeeeee 34 IC Board voltage check asssssssssssssssssssseseeeesetssssssssseeeeeeestiasssset 35 RPM sensor continuity check nnnnessennmnsseseeeereeeeerern 36 32 Console Cable Voltage Chart R52hr B52hr 3 1B 3 1R R6055 ON OFF Hhooogoooodg 5 Imput from RPM Sensor Motor Ground da Power to Photo Optic Reset ES Power to Photo Optic Count ES Power to Magnet Motor P5 Power to Magnet Motor P6 0 Input from RPM Sensor P7 0 Power to Console P8 Ground Wire P9 Power to Console P10 CORRECT VOLTAGE FOR WIRE HARNESS P1 PURPLE 0 VOLTS DC P6 WHITE 46 VOLTS DC P2 BLACK 0 VOLTS DC P7 YELLOW 5 VOLTS DC P3 ORANGE 5 VOLTS DC P8 GREY 9 5 VOLTS D
12. e look for a 0 or I in the upper right hand corner of display 0 represents Miles and 1 represents KM R52hr B52hr R6055 Remove console and flip switch on back of console control board to appropriate speed setting Note To verify speed setting upon powering up console look for MILE or KM to flash briefly on top of display 2 1B 2 1R Remove console and flip switch on back of console control board to appropriate speed setting Note To verify speed setting press and hold the time buttons simultaneously and check for a 0 or I in right hand display window 0 represents Miles and 1 represents KM 3 1B 3 1R Press Resistance buttons simultaneously for a few seconds to get into Engineering Mode Press Select to change Engineering Mode to ENG4 Press Start to enter ENG4 Once in this mode press select to toggle between Miles and KM Once correct speed setting is selected press and hold Stop to exit ENG4 Note To verify speed setting upon powering up console look for MI or KM to flash briefly on display RESISTANCE TROUBLESHOOTING CONTENTS No resistance change n nmsssesvsssssnreressssreevessssssssssireesveesessssssssenes 21 Erratic Continuous resistance change 22 Resistance is too hard or too weak 24 20 No Resistance Change Possible causes 1 Tension cable is not connected to tension knob R51 B51 2 1B 2 1R only 2 Tension cable is not connected to the brake all models 3 Tension c
13. e Readout Possible causes Fix Improper hand placement Verify console display is on pulse screen R51 B51 Verify wiring of pulse grips 2 1R 2 1B 3 1R 3 1B R6055 Defective remote sensor in seat back 2 1R 3 1R Defective chest strap 3 1R 3 1B Defective console Make sure that both hands are holding the grip pulse handlebars It is important to use a loose cupping hold when using the grip pulse Press the select button until a P is displayed on the console screen RS1hr BS1hr 2 1R 2 1B 3 1R 3 1B R6055 Replace pulse grips 2 1R 2 1B 3 1R 3 1B R6055 Check batteries and connections for remote sensor located in seat back 2 1R 3 1R If the problem persists replace the console Switching the Console from MPH to KM R51 B51 Once you insert the batteries into the back of the console the console will be set to mph To switch from mph to km press and hold the select button for three seconds While holding the select button down the time on the console will begin to increase Once the select button is held for three seconds the time will reset to zero Continue to hold the select button for two additional seconds Again the time will begin to increase but will reset to zero once the select button is held for two seconds The console is now set for km To switch back to mph simply remove the batteries and replace Note To verify speed setting upon powering up consol
14. e crank arm Extract the crank arm and crank disk from the axle and remove Remove the accent piece by gently lifting up at the bottom of the accent piece and tilting towards the front of the machine Remove the screws that attach the left side cover in place Repeat steps for right side Adjust the tension knob to the lowest setting Loosen the 11mm nut R15 holding horizontal tensioning bolt R13 into position on both sides of the flywheel It is a good idea to note the position of this nut in order to set the drive belt for the correct belt tension 10 Remove the 17mm nut R16 and the belt tensioning bolt which hold the flywheel to frame on both sides 11 Remove flywheel R03 12 Remove belt R10 from crank pulley R02 13 Slide new flywheel into position making sure to reattach the drive belt 14 Turn belt onto crank pulley Caution Use care to avoid pinching fingers 15 Attach the 17mm nut and the belt tensioning bolt which hold the flywheel to frame on both sides 16 Tighten the horizontal bolts with metal guards on both sides with the 11mm lock nuts It is important to tighten both sides evenly 17 Check belt tightness Adjust tightness by loosening or tightening lock nut on horizontal bolt To measure the belt tension a timing belt tension gauge is required The correct belt tension tolerance is 120 140 lbs If a belt tension gauge is not available the drive belt should Nn SUNT 0 90 ID 50 have
15. e crank arm nut with a 14mm socket Using a crank puller thread the puller onto the crank arm Extract the crank arm and crank disk from the axle and remove 5 Remove the accent piece by gently lifting up at the bottom of the accent piece and tilting towards the front of the machine 6 Remove the screws that attach the left side cover in place 7 Repeat steps for right side 8 Locate the idler spring U05 and bracket U06 on the right hand side of the machine Remove the attachment screw U07 9 Remove the three screws R12 that hold the right bearing housing R09 onto the main frame 10 Remove the three screws that hold the left bearing housing and idler wheel onto the main frame 11 Adjust the tension knob to the lowest setting 12 Carefully slide the flywheel R01 forward being careful to avoid pinching your fingers 13 Remove the drive belt R03 from the flywheel 14 Remove the flywheel from the main frame The brake assembly may need to be adjusted back or removed to easily remove the flywheel 15 Attach the new flywheel making sure to attach the drive belt around the flywheel clutch first 16 Align the holes in the main frame and bearing housing and insert the three screws on the right side Do not completely tighten any one screw until all three have been threaded in partially 17 Align the holes between the mainframe idler wheel and bearing housing on the left side and insert the three screws Do not complet
16. e voltage chart in table of contents Replaced if necessary R52hr B52hr 2 1R 2 1B 3 1R 3 1B R6055 7 If problem persists replace console All Models Partial LCD Display on Console Possible causes 1 Weak batteries R51 B51 2 Console subjected to cold temperatures All Models 3 Defective console All Models Fix 1 Check voltage on batteries or replace with known good batteries R51 B51 2 Allow console to warm to room temperature It may be necessary to gently massage the LCD crystal with your hand to allow for full display Pressing against the LCD crystal with excessive force may damage the crystal 3 If problem persists replace console Only Time Works On Console No workload distance etc Possible causes l di 3 4 Fix Poor connection between sensor wire and console All Models Missing rpm magnet on crank assembly All Models Defective sensor wire All Models Defective console All Models Verify proper connection between sensor wire and console by removing console and snapping console wire and sensor wires together firmly R51 B51 For R52hr B52hr 2 1R 2 1B 3 IR 3 1B and R6055 models remove the side cover and verify that the sensor wire 1s properly connected to the console cable connection Verify that magnet is installed in crank assembly Inspect sensor wire for damage Check continuity of rpm sensor wire see sensor wire continuity checkpoint
17. ed from the frame make sure to remove all dirt or grease from the frame bearing housing 12 Insert new crank assembly and bearings Make sure that bearing loct tite is applied to both the inner and outer diameter for both the left and right bearings Note It is helpful to insert the right side bearing and crank pulley first Once the right bearing and the crank pulley are in place carefully tap the left bearing into position It is best to let the loctite set for 24 hours before using the bike 13 Attach the c clip in place on the crank assembly 14 Attach the right side cover crank arm crank disk and black cap in that order 15 Attach the left side cover crank arm crank disk and black cap 16 Attach the accent piece placing the bottom tab into position first then placing the top tab into position 17 Attach the crank disk and crank arm to the crank axle Place black cap onto the center of the crank disk 18 Attach the pedals BR WN Re 47 19 Ride the exercise bike to make sure it is working properly Once the test is complete it is best to let the Loctite set for 24 hours before using the bike Replacing the Exercise Bike Flywheel Drive Belt 2 IR 3 IR 2 1B 3 1B Tools Phillips screwdriver 11mm wrench 14mm socket 15mm wrench crank puller vice grips Note Diagram on following page 48 Remove the left pedal with a 15mm wrench Remove the black cap from the center of the crank disk Remove th
18. ely tighten any one screw until all three have been threaded in partially 18 Attach the idler spring bracket U06 to the frame SUNT 19 Attach the idler spring U05 to the idler wheel U01 first and then using a vice grips carefully lift the idler spring up and hook it onto the main frame 20 Turn crank by hand to make sure that the drive belt and idler wheel are properly aligned 21 If the brake was adjusted or removed while removing the flywheel reposition the brake to the correct position Turn the resistance knob to verify that the brake is positioned properly 22 Attach the right side cover crank arm crank disk and black cap in that order 23 Attach the left side cover crank arm crank disk and black cap 24 Attach the accent piece placing the bottom tab into position first then placing the top tab into position 25 Attach the crank disk and crank arm to the crank axle Place black cap onto the center of the crank disk 26 Attach the pedals 27 Ride the exercise bike to make sure it is working properly gy ROT Replacing the Bike Flywheel Drive Belt R51 R52hr B51 B52hr R6055 Tools Phillips screwdriver 11mm wrench 14mm socket 15mm wrench crank puller vice grips Note Diagram on following page Remove the left pedal with a 15mm wrench Remove the black cap from the center of the crank disk Remove the crank arm nut with a 14mm socket Using a crank puller thread the puller onto th
19. ere may be excessive noise created Reposition the drive belt by carefully 2T walking the drive belt towards the appropriate direction with one hand while spinning the flywheel with the other Take caution to avoid pinched fingers 5 Remove the side covers and manually spin the flywheel Confirm that there is approximately a 3mm gap between the crank pulley wheel and the side of the brake assembly Ifthe crank pulley wheel is rubbing against the brake assembly manually push the brake assembly in the appropriate direction Verify that the proper gap has been achieved 6 If problem persists verify whether or not the noise is coming from the crank pulley wheel bearings or the flywheel bearings To verify whether the crank or flywheel bearings are defective remove the side covers and accent piece Carefully turn the crank arms Take caution to avoid pinching fingers Once the flywheel is spinning at a fairly fast rpm listen carefully to both sets of bearings crank and flywheel bearings If it is still not apparent which set of bearings are defective place your hand on the bearing housing cup that bearing is positioned in on the flywheel and feel for any excessive vibration or clicking on both the right and left bearings housing If there is not any vibration in the flywheel bearings 1f is more likely that the crank bearings are defective Replace as necessary When replacing either the crank or flywheel bearings be sure to remove a
20. f the original owner BRAKE RSI B51 5 YEARS R52hr B52hr R6055 10 YEARS Horizon Fitness warrants the brake against defects in workmanship and materials for the above warranty periods so long as it remains in the possession of the original owner ELECTRONICS amp PARTS ONE YEAR Horizon Fitness warrants the electronic components and all original parts against defects in workmanship and materials for a period of one year from the date of purchase so long as the device remains in the possession of the original owner LABOR R51 B51 90 DAYS R52hr B52hr R6055 ONE YEAR Horizon Fitness shall cover the labor cost for the repair of the device for the above warranty periods so long as the device remains in the possession of the original owner Models 2 1B 2 1R 3 1B 3 1R FRAME LIFETIME Horizon Fitness warrants the frame against defects in workmanship and materials for the life of the product so long as it remains in the possession of the original owner BRAKE LIFETIME Horizon Fitness warrants the frame against defects in workmanship and materials for the life of the brake so long as it remains in the possession of the original owner ELECTRONICS amp PARTS TWO YEARS Horizon Fitness warrants the electronic components and all original parts against defects in workmanship and materials for a period of two years from the date of purchase so long as the device remains in the possession of the orig
21. imeter setting to Ohms Place the positive lead of your multimeter into the tip of the sensor wire console cable connection and the negative lead into the other tip of the sensor wire console cable connection There must be an rpm present in order to get continuity through the sensor wire all models EXERCISE BIKE PART REPLACEMENT CONTENTS Removing the side case Replacing the sensor wire Proper sensor wire position Replacing the console cable Replacing the tension cable Replacing the crank assembly Replacing the flywheel drive belt Adjusting the magnetic brake Replacing the servomotor 37 40 42 43 44 46 48 52 56 Removing the Exercise Bike Side Case Tools Phillips screwdriver 14mm socket 15mm wrench crank puller Note Diagram on following page Remove the pedal T07 with a 15mm wrench Remove the black cap Q11 from the center of the crank disk Remove the crank arm nut T09 with a 14mm socket Using a crank puller thread the puller onto the crank arm ATI Extract the crank arm and crank disk from the axle and remove 5 Remove the accent piece by gently lifting up at the bottom of the accent piece and tilting towards the front of the machine 6 Remove the screws that attach the side cover Q02 in place 7 Attach new side cover 8 Attach the accent piece placing the bottom tab into position first then placing the top tab into position 9 Attach the crank dis
22. in table of contents Replace if defective If problem persists replace console RPM Sensor Continuity Check To check for continuity on the sensor wire turn your multimeter setting to Ohms Place the positive lead of your multimeter on the tip of the sensor wire jack and the negative lead on the outside of the sensor wire jack There must be an rpm present in order to get continuity through the sensor wire Console Resets Intermittently Possible causes Fix Poor connection between sensor wire and console R51 B51 Weak batteries in console R51 B51 Loose connection between the power jack and power supply R52hr B52hr 2 1R 2 1B 3 IR 3 1B R6055 Sensor wire is pinched or cut R52hr B52hr 2 1R 2 1B 3 IR 3 1B R6055 Defective console All Models Verify proper connection between sensor wire and console by removing console and snapping console wire and sensor wires together firmly R51 B51 Verify battery voltage or replace with know good batteries R51 B51 Verify that the power supply is securely inserted into the power jack Replace power supply and or power jack if there is a loose connection R52hr B52hr 2 1R 2 1B 3 1R 3 1B R6055 Inspect sensor wire for damage Check continuity of rpm sensor wire Replace if defective R52hr B52hr 2 1R 2 1B 3 1R 3 1B R6055 If problem persists replace console All Models Erratic or No Heart Rat
23. inal owner LABOR ONE YEAR Horizon Fitness shall cover the labor cost for the repair of the device for a period of one year from the date of original purchase so long as the device remains in the possession of the original owner EXCLUSIONS AND LIMITATIONS This warranty applies only to the original owner and is not transferable This warranty is expressly limited to the repair or replacement of a defective frame electronic component or defective part and is the sole remedy of the warranty The warranty does not cover normal wear and tear improper assembly or maintenance or installation of parts or accessories not originally intended or compatible with the exercise equipment as sold The warranty does not apply to damage or failure due to accident abuse corrosion discoloration of paint or plastic or neglect Horizon Fitness shall not be responsible for incidental or consequential damages All returns must be pre authorized by Horizon Fitness Horizon Fitness obligation under this warranty is limited to replacing or repairing at Horizon Fitness option the product at one of its authorized service centers A Horizon Fitness authorized service center must receive all products for which a warranty claim is made These products must be received with all freight and other transportation charges prepaid accompanied by sufficient proof of purchase Parts and electronic components reconditioned to As New Condition by Horizon Fitness o
24. k and crank arm to the crank axle Place black cap onto the center of the crank disk 10 Replace pedal arm cap 11 Attach the pedal 12 Test ride the exercise bike to make sure it is working correctly B WN Re 38 39 Replacing the Exercise Bike RPM Sensor R51 B51 2 IR 2 1B Tools Phillips screwdriver 14mm socket 15mm wrench crank puller 40 Remove the left pedal with a 15mm wrench Remove the black cap from the center of the crank disk Remove the crank arm nut with a 14mm socket Using a crank puller thread the puller onto the crank arm Extract the crank arm and crank disk from the axle and remove 5 Remove the accent piece by gently lifting up at the bottom of the accent piece and tilting towards the front of the machine 6 Remove the screws that attach the left side cover in place 7 Locate the sensor wire bracket Remove the screw from the sensor wire bracket 8 Remove the old sensor wire from the sensor wire bracket 9 Remove the console from the console mast Attach the new sensor wire to the old sensor wire in order to fish the sensor through the console mast 10 Once the new sensor wire is fished through the console mast attach the new sensor wire to the sensor wire bracket 11 Attach the sensor wire bracket onto the frame 12 Turn crank by hand to make sure that there is a RPM reading on the console If no RPM reading check to make sure the sensor is in the correct position
25. le cable from the console and attach the new console cable to the old console cable in order to fish the cable through the console mast You may need to unscrew the water bottle bracket screws in order to fish the console cable easily 11 Once the new console cable is fished through the console mast plug the proper connections to the sensor wire and IC Board 12 Screw the power jack into position 13 Attach the console and plug in the machine 14 Turn crank by hand to make sure that there is a RPM reading on the console and all other functions are working properly If no RPM reading check to make sure the sensor is in the correct position 17 Attach the left side cover and secure with screws 18 Attach the accent piece placing the bottom tab into position first and then placing the top tab into position 19 Attach the crank disk and crank arm to the crank axle Place black cap onto the center of the crank disk 20 Attach the pedal 21 Test ride the exercise bike to make sure it is working correctly nN aA QD eR 023 43 Replacing the Exercise Bike Tension Cable Tools Phillips screwdriver 14mm socket 15mm wrench crank puller 1 Turn the tension knob to the highest resistance level Remove the tension knob from the tension cable by pulling up on the tension knob 2 Remove the screw that attaches the tension knob to the console mast using a Phillips screwdriver 3 Remove the left pedal with a 15mm wrench 4 Rem
26. ly 28 Rough feel while pedaling uurrrrie eee 29 Crank arms loosen during Use nnn nmmeevsvsssneresssvssssreeveesessssssis 31 25 Fix 26 Noise Internally While Pedaling Possible causes l 2 3 Crank disks rubbing against side cover Loose crank arms Pedals are loose or defective Improper alignment of the drive belt Crank pulley wheel is rubbing against the side of the brake assembly Defective flywheel or crank pulley wheel bearings Inspect the crank disks as the machine is being used If the crank disk has some wobble to it as it is rotating the crank disk may be rubbing against the side cover To resolve verify which part of the crank disk is hitting the side cover and remove the crank arm and crank disk from the bike Remove the crank disk from the crank arm by removing the attachment screws Insert additional washers between the crank arm and crank disk in the area where the disk was rubbing against the side cover If problem persists replace crank arm Remove the side covers and verify that the crank arms are tight There should not be any side to side play in the crank arms if tightened properly Tighten if necessary Tighten the pedals with a 15mm wrench Remove and grease the pedal threads if necessary Replace pedals if necessary Remove the side covers and inspect the drive belt alignment If the drive belt is not centered on the one way pulley th
27. nly 8 Defective console R52hr B52hr 3 1B 3 1R R6055 only Fix 1 Remove tension knob from the console mast Verify that the copper cable from the tension knob is seated properly in the keyhole located on the tension cable 2 Remove the side covers and verify that the tension cable is connected securely to the brake 3 Remove side covers and inspect for any binding or crimping in the tension cable Keep in mind that the tension cable has an outer plastic sleeve with a small wire running internally If the small internal wire 22 23 is binding or is crimped slightly it will not move smoothly Remove any binding or crimping by repositioning the tension wire If problem persists replace the tension cable Remove the side covers Locate the servomotor and photo sensor board Below the servomotor there should be a black sensor wire zero switch which also connects to the photo sensor board On the zero switch there is an orange switch that should come in contact with the servomotor shaft when at resistance level 0 If the zero switch does not come into connect with the servomotor the resistance will continuously cycle back and forth To resolve adjust the position of the zero switch by loosening the two attach screws and reposition Check voltages of console cable see console cable voltage chart in table of contents to verify proper function of photo sensor board servomotor and console cable Replace p
28. not rock the unit Do not stand or climb on the handrails electronic console or side covers e Ifyou experience chest pains nausea dizziness or shortness of breath stop exercising immediately and consult your physician before continuing CHILDREN e Keep children off of your exercise equipment at all times e When the exercise equipment is in use young children and pets should be kept at least 10 feet away Basic Troubleshooting Tips When using this service guide for troubleshooting problems on a Horizon Fitness bike or elliptical follow the step by step procedures listed in the troubleshooting section The step by step procedures start with the most basic checkpoints to more extensive checkpoints However it is still extremely important to follow the step by step procedures from start to finish to ensure that the proper steps are taken to resolve all issues It is also helpful to have a known good component to verify the defective part to eliminate troubleshooting errors When calling for service assistance or technical support be sure to gather as much information as possible such as the model name serial number and a very detailed description of the defect i e when does problem occur how often etc Required Tools and Equipment The following list is a summary of the tools and equipment required by the procedures in this manual Phillips screwdrivers Flat head screwdrivers Digital multi meter Allen wrench
29. ny excess loctite after removing defective bearings and reinstalling new bearings Make sure that both the inner and outer diameters of the bearings have fresh loctite applied before reinstalling new bearings Noise Internally While Pedaling at Higher Resistance Levels Only Possible causes 1 Crank pulley wheel is rubbing against the side of the brake assembly 2 Brake assembly is rubbing against the flywheel Fix 1 Remove the side covers and manually spin the flywheel Confirm that there is approximately a 3mm gap between the crank pulley wheel and the side of the brake assembly If the crank pulley wheel is rubbing against the brake assembly manually push the brake assembly in the appropriate direction Verify that the proper gap has been achieved 2 Remove the side covers and verify that there is approximately a 3mm gap between the entire magnet surface of the brake assembly and the flywheel If the brake assembly is rubbing against the flywheel adjust the position of the brake assembly Reference replacing adjusting the brake assembly in the table of contents 28 Rough Feel While Pedaling Possible causes l di 3 4 Fix 29 Loose crank arms Loose or defective pedals Drive belt mis aligned Defective flywheel or crank pulley wheel bearings Remove the side covers and verify that the crank arms are tight There should not be any side to side play in the crank arms if tightened properly Tigh
30. o make sure the sensor is in the correct position 12 Attach the left side cover and secure with screws 13 Attach the accent piece placing the bottom tab into position first and then placing the top tab into position 14 Attach the crank disk and crank arm to the crank axle Place black cap onto the center of the crank disk 15 Attach the pedal 16 Test ride the exercise bike to make sure it is working correctly 42 Proper sensor wire alignment guide Crank pulley Sensor bracket Magnet should pass evenly over the edge of the sensor wire The sensor wire should not cover the whole magnet Replacing the Exercise Bike Console Cable R52hr B52hr 3 1R 3 1B R6055 Tools Phillips screwdriver 14mm socket 15mm wrench Smm Allen wrench crank puller Unplug power supply from the exercise bike Remove the left pedal with a 15mm wrench Remove the black cap from the center of the crank disk Remove the crank arm nut with a 14mm socket Using a crank puller thread the puller onto the crank arm Extract the crank arm and crank disk from the axle and remove Remove the accent piece by gently lifting up at the bottom of the accent piece and tilting towards the front of the machine Remove the screws that attach the left side cover in place Unscrew the power jack from the frame Unplug the console cable from the sensor wire and IC Board 0 Unscrew the console from the console mast Unplug the conso
31. ove the black cap from the center of the crank disk 5 Remove the crank arm nut with a 14mm socket 6 Using a crank puller thread the puller onto the crank arm Extract the crank arm and crank disk from the axle and remove 7 Remove the accent piece by gently lifting up at the bottom of the accent piece and tilting towards the front of the machine 8 Remove the screws that attach the left side cover in place Remove the crank arm cover from the left pedal arm with a Phillips screwdriver 9 Locate the position where the tension cable attaches to the magnetic brake Disconnect the tension cable from the flywheel brake assembly 10 Using a 10mm wrench disconnect the nut that attaches the tension cable to the main frame 11 Fish the current tension knob through the console mast and replace with new cable 12 Adjust the tension knob to the highest resistance level Attach the tension knob to the tension cable and secure to the console mast with Screw 13 Connect the tension knob cable to the flywheel brake assembly 14 Slide the tension cable through the bracket on the main frame Secure by tightening the two 10mm nuts 15 The proper resistance setting is set when the magnetic brake 1s 2 3 mm from the flywheel at the highest resistance setting 16 Adjust the tension knob from the lowest to highest resistance settings to ensure proper movement and position of the flywheel brake assembly 17 Attach the left side cover and secure
32. placing the bottom tab into position first then placing the top tab into position 18 Attach the crank disk and crank arm to the crank axle Place black cap onto the center of the crank disk 18 Replace pedal arm cap 19 Attach the pedal 20 Test ride the exercise bike to make sure it is working correctly ate ae nd 56 57 58 Notes
33. r its vendors may sometimes be supplied as warranty replacement parts and constitute fulfillment of warranty terms This warranty gives you specific legal rights and your rights may vary from state to state WARRANTY REGISTRATION Your warranty card must be completed and sent to Horizon Fitness or register on line at www horizonfitness com before a warranty claim can be processed Important Safety Instructions Warning statements indicate a particularly dangerous activity Please read the following warnings before using repairing or maintaining your exercise equipment e Never drop or insert any object into any opening e Do not remove the exercise equipment s side covers Service should be performed only by an authorized Horizon Fitness service provider e Never operate the exercise equipment if it is not working properly if it has been damaged or immersed in water e Visually check the machine before beginning service or maintenance operations If it is not completely assembled or is damaged in any way exercise extreme caution while operating and checking the exercise equipment e Do not use outdoors e Do not wear clothing that might catch on any part of the exercise equipment e Use this exercise product for its intended use as described in the Owner s guide Do not use attachments not recommended by the manufacture e Use care when getting on of off the exercise equipment Use the handrails whenever possible e Do
34. re it is working correctly 54 55 Replacing the Bike Servomotor IC Board R52hr 3 1B 3 IR R6055 Tools Phillips screwdriver 14mm socket 15mm wrench 2 5mm wrench 5mm Allen wrench crank puller Note Refer to diagram on following page Unplug power supply from exercise bike Remove the left pedal with a 15mm wrench Remove the black cap from the center of the crank disk Remove the crank arm nut with a 14mm socket Using a crank puller thread the puller onto the crank arm Extract the crank arm and crank disk from the axle and remove 6 Remove the accent piece by gently lifting up at the bottom of the accent piece and tilting towards the front of the machine 7 Remove the screws that attach the left side cover in place 8 Unplug the console cable from the IC Board 9 Remove the brake cable from the servomotor S25 with a 2 5mm Allen wrench 10 Remove the entire servomotor assembly bracket S14 from the frame 11 Replace with new servomotor assembly 12 Attach the brake cable to the servomotor 13 Plug in the console cable to the IC Board 14 Plug in the machine 15 Turn crank by hand to make sure that there is a RPM reading on the console and all other functions are working properly If no RPM reading check to make sure the sensor is in the correct position Make sure the resistance is working properly 16 Attach the left side cover and secure with screws 17 Attach the accent piece
35. ten if necessary If problems persist replace the crank axle nut with updated nut Contact Horizon Fitness for update kit Remove the pedals and apply white lithium grease to the pedal threads Reattach the pedals using a large 15mm wrench If problem persists it may be necessary to replace the pedals Remove the side covers and inspect the drive belt alignment If the drive belt is not centered on the one way pulley there may be excessive noise created Reposition the drive belt by carefully walking the drive belt towards the appropriate direction with one hand while spinning the flywheel with the other Take caution to avoid pinched fingers 30 4 If problem persists verify whether or not the noise is coming from the crank pulley wheel bearings or the flywheel bearings To verify whether the crank or flywheel bearings are defective remove the side covers and accent piece Carefully turn the crank arms Take caution to avoid pinching fingers Once the flywheel is spinning at a fairly fast rpm listen carefully to both sets of bearings crank and flywheel bearings If it is still not apparent which set of bearings are defective place your hand on the bearing housing cup that bearing is positioned in on the flywheel and feel for any excessive vibration or clicking on both the right and left bearings housing If there is not any vibration in the flywheel bearings if is more likely that the crank bearings are defective Replace as necess
36. with screws 18 Attach the accent piece placing the bottom tab into position first then placing the top tab into position 44 19 Attach the crank disk and crank arm to the crank axle Place black cap onto the center of the crank disk 20 Replace pedal arm cap 21 Attach the pedal 22 Test ride the exercise bike to make sure it is working correctly 45 Replacing the Exercise Bike Crank Assembly Tools Phillips screwdriver 14mm socket 15mm wrench crank puller snap ring pliers rubber mallet bearing Loctite Note Diagram on next page 46 Remove the left pedal with a 15mm wrench Remove the black cap from the center of the crank disk Remove the crank arm nut with a 14mm socket Using a crank puller thread the puller onto the crank arm Extract the crank arm and crank disk from the axle and remove 5 Remove the accent piece by gently lifting up at the bottom of the accent piece and tilting towards the front of the machine 6 Remove the screws that attach the left side cover in place 7 Repeat steps for right side 8 Locate the idler spring U05 and bracket U06 on the right hand side of the machine Remove the attachment screw U07 9 Locate the c clip on the left hand side of the crank assembly axle and remove the c clip with a snap ring pliers 10 Tap the crank assembly T05 from the frame pounding on the left hand side towards the right 11 Once the crank assembly and the bearings are remov
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