RevMaster Pro Service Manual
Contents
1. 11 Maintenance Schedule 12 Troubleshooting 13 Disassembly Adjustment Assembly 15 Handlebar 15 Pedals 16 Crank Arms 17 Belt Cover 18 Drive Belt2. 19 Drive Belt Tension 20 Bottom Bracket 21 Flywheel 22 Pillow Block 23 Brake Assembly 24 Fender 25 Brake Pad 26 Adjustment Handle
3. Monthly N A N A Bottom Bracket Inspect for side to side play in spindle and a grinding feeling in crank area when pedaling If necessary replace bottom bracket Monthly N A N A 1 We do not recommend you attempt to service the internal parts of the pedals If they are found to be worn internally we recommend replacing the pedal 2 Use of lubricants or cleaning solutions other than those so specified will result in diminished perfor mance and a shorter life span for that part Pg 13 TRoUbLE ShooTINg SYMPToM Seat or handlebar post move after locked into position Locate smaller 3mm hex bolt at pivot point of cam handle and loosen 1 turn 1 Disengage 6mm hex bolt on other side from indicator plate and rotate one notch towards sign 2 Tighten smaller 3mm hex bolt 3 Test post and repeat process if needed until post no longer moves 4 SYMPToM Clicking noise with each pedal revolution Check shoelaces to make sure the aglet is not tapping the bike as the pedals turn 1 Assure pedal straps are tight and that no excess strap on inner part of pedal is catching on the crank 2 arm as it turns Assure that pedals are tight on crank arms 3 SYMPToM Clicking noise when flywheel rotates Check edge of flywheel that brake pad rubs against for small burrs 1 If burr is present gently remove while being careful not to damage flywheel surface 2 If symptom persists
4. check for noisy flywheel bearings 3 If flywheel bearings are noisy or rough have authorized service technician replace flywheel hub as 4 sembly SYMPToM Drive belt is slipping Remove belt cover 1 Note Use caution around belt when cover is removed Loosen idler with 8mm hex and tighten tensioner bolt 2 3 turns with 5mm hex wrench 2 Tighten idler and test belt 3 If belt still slips repeat process until belt no longer slips 4 Reinstall belt cover 5 SYMPToM knocking noise or play felt in pedals cranks Make sure pedals are tight on crank arms 1 Note Left pedal is reverse threaded Make sure crank bolts are tight If loose apply blue Loctite 242 to threads and tighten crank bolts 2 with 8mm hex wrench If problem persists check the bottom bracket bearing cups for looseness Tighten if necessary with 3 a bottom bracket tool and use blue Loctite 242 on threads If knocking noise still persists contact authorized service technician for replacement of bottom 4 bracket bearings Pg 14 RevMaster Service Manual SYMPToM Inconsistent resistance or noisy brake pad Remove fender assembly and make sure brake pad is clean 1 Apply brake pad oil or 3 In One oil to surface of brake pad 2 Let oil soak into pad and reapply if needed until brake pad is thoroughly saturated 3 Reinstall fender assembly 4 SYMPToM Rocking or movement from Rev
5. instAll Use 3mm hex wrench amp brake pad oil or 3 In One Multi purpose oil With the fender assembly off the bike use a 3mm hex wrench to remove the two screws that hold the brake pad to the fender Remove the pad and scrape away any of the foam padding still stuck to the fender Peel off the backing of the foam on the new brake pad to expose the sticky surface of the foam Screw the new brake pad onto the fender with the foam side facing the fender and press across the length of the pad so the foam sticks to the fender Coat the surface of the brake pad with brake pad oil and allow it to soak into the pad Repeat the process 4 5 times or until the pad is saturated with oil but not dripping The fender assembly is now ready to be installed on bike Installation Apply Loctite to the male portion of the bolt that holds the fender to the frame Lift up on the brake rod and slide the fender assembly over the top of the flywheel and line the holes in the back of the fender with the hole in the frame Insert the female section of the bolt from either side through the hole in the fender and into the hole in the frame Then insert the male portion of the bolt from the other side and thread the two parts of the bolt into each other Gently snug the bolt down with hex wrenches but be careful not to over tighten or the bolt will break Ride and test bike with resistance l Use Loctite 242 Pg 27 AdJustment hAndles hAndlebAr seAt
6. still sitting on the shoulder bolt with the bearings and has not fallen off Reinstall the belt cover Pg 21 bottom brAcket beArinG Assembly Use a Park BBT 22 or similar bottom bracket tool amp blue medium 242 strength Loctite Removal Remove the belt cover drive belt and crank arms Then remove the left bearing cup using the bottom bracket tool by turning the cup counterclockwise Loosen the right cup reverse threaded by turning the cup clockwise until you are able to remove the right cup with the remainder of the cartridge assem bly from the frame Remove Leftside Remove Rightside Installation Clean the bottom bracket threads in the frame Set the left cup of the bearing assembly aside for now Apply a few drops of medium strength Loctite to the right bearing cup and insert the cartridge assem bly into the bottom bracket from the right side drive side Carefully screw the right cup into the frame with your hand by turning the cup counterclockwise right cup is reverse threaded while being cautious not to cross the threads Firmly tighten the right cup with the bottom bracket tool Apply a few drops of Loctite to the left bearing cup Carefully screw the left cup into the frame with your hand by turning clockwise while again being cautious not to cross the threads and torque to 175 inch lbs If you do not have a torque wrench tighten the cup but stop and twist the spindle with your hand periodically as you go t
7. 3mm hex wrench amp 5mm hex wrench to install remove belt cover Removal Remove the three 3mm screws from left side non drive side of the bike Rotate the right crank arm to the 10 o clock position Remove the four 5mm screws from the right side drive side and remove belt cover Please note Always use caution around drive belt when cover is removed Installation Rotate the right crank arm to the 10 o clock position Pass the right crank arm through hole of belt cover and line up screw holes of belt cover with threaded holes in frame of bike Insert and gently snug down each of the 5mm screws from the right side and each of the 3mm screws from the left side Pg 19 drive belt drive belt tension Use a 5mm hex wrench long T handle works best amp 8mm hex wrench to remove install or adjust drive belt Please use caution around drive belt when installing removing or adjusting belt Removal Remove belt cover Loosen the shoulder bolt of idler bearing assembly turn with a 8mm hex wrench Loosen the tension screw M6 x 60 with a 5mm hex wrench until the idler bearings can be pushed to the top of the slot in frame and bearings are loose enough to allow you to remove the drive belt from the pulleys IInstallation Wrap the drive belt around the front flywheel pulley Pass the top of the belt under the tensioner bear ings tensioner bearing assembly should be loose and able to move freely in slot and over the
8. Bearing Pg 8 RevMaster Service Manual Figure 7 Right Pedal Crank Bolt Crank Pulley Assy Drive Belt Bottom Bracket Assembly 2 piece Idler Bearing Assembly Idler Spacer Screw Socket M6 x 60 Idler Traveller Post Oval Idler Washer Screw Dome M4 x 15 Magnet Holder Assembly Drive System Pg 9 Figure 8 Plastic Water Bottle Holder Bottle Holder Front Mount Screw Socket Head M5 x 15 x2 Bottle Holder Back Mount Adjustment Handle Handlebar Slider Bearing x2 Handlebar Slider Plug Handlebar Overmolded Handlebar Slider Plunger Screw Socket Head M4 x 10 x4 Handlebar Assembly Screw Countersunk M5 x 10 Pg 10 RevMaster Service Manual TooL LIST Assembly tools included with bike tool where used 3 mm Hex key Used for H2O bottle mounting screw mounts the cage to the handlebar clamp and handlebar track cap 6 mm Hwx Key Used for front and rear stabilizer mounting bolts 15 mm Open End Wrench Left and Right Pedals AdditionAl tools required For service tool where used Crank Puller Pull crank arm off spindle after removing the crank arm bolts Bottom Bracket Socket Shimano Bottom Bracket Socket Torque Wrench Bottom Bracket Socket 8 mm Hex key Crank Bolts Locktite 242 243 blue To secure Bottom Bracket Belt Tension Gauge Measure drive belt tension Metric Hex Key Set 4mm 5mm Pg 11 INSTALLATI
9. Left Pedal Magnet Access Cover Screw Flat Head M4 x 8 Rear Stabilizer Adjustable Foot x2 Stabilizer End Cap x2 Frame Bolt Washer M8 x2 Brake Cover Right Pillowblock Left Side Rear Stabilizer Pg 5 Figure 4 Socket Head Screw M6 x 15 x4 Front Stabilizer Belt Cover Exploded View Socket Head Screw M6 x 13 x2 Right X Cover Pad Printed Outside Belt Cover Label RevMaster Ellipse Frame Bolt Washer M8 x2 Dome Head Screw M8 x 15 x4 Star Washer M8 x2 Stabilizer End Cap x2 Adjustable Foot x2 Socket Head Screw M6 x 40 x2 Assembly Transport Wheel x2 Flange Nut M6 x2 Front Stabilizer Inside Belt Cover Pg 6 RevMaster Service Manual Figure 5 Pillowblock Nut NO FLANGE Pillowblock Nut WITH FLANGE Pillowblock Nut No Flange x2 Pillowblock Nut Flanged x2 Left Pillowblock Flywheel Hub Assy Flywheel Flat Head Screw M6 x 16 x3 Screw Socket M6 x 35 x4 Flywheel Assembly Pg 7 Figure 6 Brake Assembly Fender Assembly Male Shoulder Bolt Female Shoulder Bolt Fender Cover Fender Weldment Brake Pad Adhesive Screw Dome M5 x 10 x2 Formed Brake Pad Screw Dome M4 x 5 x2 Fender Spring Brake Rod Assembly Brake Frame Nut Upper Brake Spacer Brake Distance Tube Brake Rod Nut Brake Contact Bearing Lower Brake Spring Upper Brake Spring Fender Spring
10. Master while in use Using a 6mm hex wrench check the attachment bolts on the front and rear stabilizers and make 1 sure they are tight 4 bolts on each stabilizer Note You will have to remove the stretch pad to check the rear stabilizer mounting bolts Assure the bike is level by checking the leveling feet on the bottom of the front and rear stabilizers 2 Pg 15 ASSEMbLY DISASSEMbLY ADjUSTMENT hAndlebAr When the handlebar is first installed on the bike there is a slider plunger or pill at the end of the ad justment handle that is held in place by shipping material The material is pushed out of the way when the handlebar assembly is slid onto the track of the handlebar post The adjustment handle pushes the slider plunger against the track to secure the handlebar assembly in place Installation Loosen the adjustment handle on the handlebar assembly Slide the assembly onto the track of the handlebar post and tighten the adjustment handle Then install the handlebar track cap onto the end of the track with two 2 M4 X 10mm screws Removal To remove the handlebar assembly first remove the track end cap Loosen the adjustment handle and slide the handlebar off the end of the track Take care not to dislodge the slider plunger at the end of the adjustment handle Pg 16 RevMaster Service Manual PedAls Use a 15mm open end wrench or pedal wrench to install and remove pedals Installation On
11. Post heiGht AdJustment hAndles Use 6mm hex wrench amp 3mm hex wrench to adjust the handles Adjustment Handles need to be unlocked to adjust the tightness of the handle against the post Lift up on the handle to unlock and lower the post until it bottoms out If adjusting the seat post first remove the seat with the seat slider from post so the fore aft adjustment handle is out of the way Loosen the screw on right side of bike one turn with 3mm hex wrench Push in on this screw so the 6mm screw Post Handle Pin on the other side disengages from the teeth in the indicator plate To increase the handle pressure on the post rotate the 6mm screw towards the sign by 1 tooth while lifting up on the handle Then push the screw in so it locks into the teeth on the indicator plate and let go of the handle Tighten the 3mm screw on the right side of the bike and raise the post up and test Repeat the process if more pressure is needed To decrease the handle pressure on the post rotate the 6mm screw towards the sign by 1 tooth while lifting up on the handle Then push the screw in so it locks into the teeth on the indicator plate and let go of the handle Tighten the 3mm screw on the right side of the bike and raise the post up and test Repeat the process if the handle is hard to lock down and less pressure is needed 15540 Woodinville Redmond Road NE Suite A100 Woodinville WA 98072 USA www LeMondfitness com Tele
12. SERVICE MANUAL For Lemond Exercise Bikes Models 15100 15200 15300 and15400 Pg 1 Table of Contents Exploded Diagrams 2 Tool List 10 Installation Check List 11 Stabilizer Bars 11 Pedals 11 Handlebar 11 Seat Slider 11 Water Bottle Holder
13. e pedal will be labeled L for left and the other pedal R for right Also note the left pedal is reverse threaded Carefully thread the left pedal into the left crank arm by turning counterclockwise and tighten by hand being careful not to cross the threads With the same mindfulness tighten the right pedal into the right crank arm Then firmly tighten down both pedals with the wrench Removal Unscrew the left pedal by turning it clockwise with a wrench Unscrew the right pedal by turning it counterclockwise Pg 17 crAnk Arms Use a 8mm hex wrench to install remove crank bolts amp use a Park CCP 2 or similar crank arm puller to remove crank arms removAl Left crank Unscrew the crank bolt with 8mm hex wrench Thread crank puller into the threads of crank arm being careful not to cross the threads and tighten by hand Turn the handle of crank puller clock wise until crank arm is removed Right crank Remove the belt cover and drive belt Unscrew the crank bolt with 8mm hex wrench and follow same directions as Left crank Installation Lubricate the taper of the spindle with a small amount of multi purpose grease Slide the crank arms onto the spindle assuring they are rotated 180 degrees from each other Screw in crank bolts new bolts are factory coated with Loctite or if needed use medium 242 strength Loctite and firmly tighten Recheck periodically Pg 18 RevMaster Service Manual belt cover Use a
14. ged a new flywheel hub assembly will need to be installed Pull the left pillow block off the bearings after flywheel is removed from bike Remove the three screws M6 x 16 from the left side of the flywheel with a 4mm hex wrench These screws hold the hub assem bly to the flywheel Once hub assembly is removed apply medium strength Loctite to the three M6 x 16 screws Insert the new hub assembly in the flywheel and install the three M6 x 16 screws with Loctite Firmly tighten screws and place left pillow block back on bearings Flywheel assembly is now ready to be installed on the bike Installation Place the pillow block nuts back in the frame The flanged nuts need to be inserted on the left side and the nuts with no flange need to be inserted on the right side Note These cannot be reversed since a flanged nut on the right side will rub on the drive belt Rotate the pillow blocks so the tops of both are facing up and are parallel with each other if one or both of the pillow blocks rotates during the install and is inserted into the cutaway upside down the flywheel will sit cockeyed and or up too high Care fully lift the flywheel assembly back into the frame and lower the pillow blocks into the cutaways in the frame Once the flywheel sits securely in the frame apply Loctite to the pillow block screws Insert the screws through the pillow blocks start tightening by hand and then firmly tighten with a 5mm hex wrench Reinstall t
15. he fender assembly drive belt and belt cover Ride the bike to test Pg 24 RevMaster Service Manual brAke Assembly Use an adjustable crescent wrench to remove install brake assembly Removal Turn the brake rod counterclockwise to loosen the tension Loosen the brake frame nut with a crescent wrench Make sure the two flat edges of the plastic nut on the very bottom of the rod are facing the front and rear of the bike The flat surface of the plastic nut will then line up with the flat surface inside the tube Pull up on the brake assembly and remove from the frame Installation Check that the brake rod nut located between the two springs is threaded on the lower portion of the top set of threads Line up the flat surface of the brake rod nut with the flat surface of the plastic nut on the bottom of the brake rod Insert the brake rod assembly into the frame with the flat surfaces of both nuts facing the back of the bike so they meet the flat surface inside the tube Tighten down the brake frame nut Pg 25 Fender Assembly A 5mm hex wrench amp 4mm hex wrench will be used simultaneously Also use medium 242 strength Loctite Removal Raise the handlebar post to a higher position to get it out of the way Locate the bolt at the rear of the fender and remove with 5mm and 4mm hex wrenches Hold the brake rod up and pull the fender as sembly from the bike Pg 26 RevMaster Service Manual brAke PAd removAl
16. lling the handlebar seAt slider Ensure that the large brass washer is installed on the adjutment handle attaching the seat slider to the seat post See Figure 1 Apply a small amount of grease to the threads to allow adjustments wAter bottle holder The water bottle holder is attached with an M5 countersunk screw to the bottle holder front mount If the bottle holder is not already attached remove one of the one of the M5 countersunk screws from the front mount with a 3mm hex wrench and use it to attach the bottle holder to the bracket Pg 12 RevMaster Service Manual MAINTENANCE SChEDULE PArt recommended Action Frequency cleAner lubricAnt 1 Pedals Ensure that the pedals are tight in crank arms that all screws on pedals are tight and that the pedal straps are not frayed Before each use N A N A Frame Wipe down Daily Soap amp water or di luted non abrasive cleaning solution N A Flywheel Wipe down Weekly WD 40 spray Spray on rag amp apply light coat to sides of flywheel N A Crank Bolts Inspect for looseness Weekly N A If loose remove bolt apply Loctite 242 on bolt threads and reinstall Tighten to 48 ft lbs or 575 in lbs Brake Pad Inspect for excessive wear or a dry leather brake pad Weekly N A 2 Use 3 IN One oil or 10W oil Do not use silicone based lubri cants Belt Inspect for correct tension replace cracked frayed or oth erwise non uniform belt
17. o assure that the cup is fully threaded into the frame but loose enough to allow the spindle to rotate freely If the rotation of the spindle feels rough or clunky loosen the cup and test again Reinstall the crank arms drive belt and belt cover Allow loctite to dry for 24 Hours before using the unit Use Loctite 242 Pg 22 RevMaster Service Manual Flywheel Use a 5mm hex wrench to remove flywheel assembly amp 4mm hex wrench to remove flywheel hub as sembly from flywheel Also use medium 242 strength Loctite Removal Remove belt cover drive belt and fender assembly and raise handlebar post to a higher position It is also helpful to raise the brake rod up and wrap a piece of electrical tape around the brake shaft just above the brake nut to prevent the bottom of the rod from getting in the way Using a 5mm hex wrench remove the two pillow block screws M6 x 35 from right pillow block and the two pillow block screws M6 x 35 from the left pillow block Before removing the flywheel assembly please note it is heavy and weights 48lbs Carefully lift the flywheel so the pillow blocks unseat themselves from the frame and slowly move the flywheel forward out of the frame Be careful not to scratch or dent the surface of the flywheel If needed a rag can be put under the flywheel when removing to provide a softer surface Pg 23 removinG And rePlAcinG hub Assembly in Flywheel If the flywheel bearings or pulley are dama
18. oN ChECk LIST stAbilizer bArs Check that the mounting screws four M8 x 20 screws attach the front stabilizer bar to the frame and four more attach the rear stabilizer are properly aligned not cross threaded and use the correct washers Check that the top mounting screws use an M8 star washer and that the bottom mounting screws use a curved washer with the concave surface facing the stabilizer Check that the screws are securely tightened PedAls Left Crank Left Pedal Insert Counter Clockwise Check that the pedals are not cross threaded into the crank arms The right pedal has a normal thread pattern clockwise to tighten counter clockwise to loosen and left pedal has a reverse thread pattern counter clockwise to tighten etc When installing the pedals use your fingers to start the pedal so you can feel if you are cross threading them into the crank arms Use a 15mm box end wrench to tighten the pedals after you have installed them finger tight hAndlebAr When the handlebar is installed the slider plunger see figure below may become dislodged If this happened during assembly the adjustment lever alone will not provide a sufficient grip to secure the handlebar to the mounting track if threaded up against the mounting track it could damaging the track Slider Plunger If the slider plunger is missing see Handlebar Adjustment and Assembly below for instructions on replacing the slider plunger and insta
19. phone 1 425 482 6773 x 107 or 109 Fax 1 425 482 6724 Email service lemondfitness com Document 300137 Rev
20. s 27 Pg 2 RevMaster Service Manual ExPLoDED DIAgRAMS Figure 1 Seat Post Assembly Dipped Handle Post Handle Limiter Post Plunger Fuse Post Plunger ED Post Plunger Bearing Screw Dome M5 x 10 Lock Washer M5 Adjustment Handle Black Brass Washer Seat Slider Seat with Clamp Seat Post Weldment Casting Cap Sleeve Retainer Seat Post Bearing Post Handle Indicator Post Handle Pin Screw Dome M4 x 10 x2 Post Plug Assembly Screw Socket M6 x 65 amp M6 Flat Washer Pg 3 HB Post Assy Post Plug Assembly Post Handle Indicator Post Handle Pin HB Post Bearing Sleeve Retainer Screw Dome M4 x 10 x2 Handlebar Post Weldment Handlebar Post Bumpstop M5 x 10 Screw Dome x2 Track End Cap x2 Screw Socket M4 x 10 x4 M6 Lock Washer M5 x 10 Screw Dome Post Plunger Bearing Post Plunger Post Plunger Fuse Post Handle Limiter Dipped Handle Casting Cap Screw Socket M6 x 65 amp M6 Flat Washer Figure 2 Pg 4 RevMaster Service Manual Figure 3 Screw Flat Head M5 x 10 Left X Cap X Cap Gasket 1 X Cap Gasket 3 X Cap Gasket 2 Screw Dome M8 x 15 x6 Stretch Pad Cover Star Washer M8 x2 Screw Dome M4 x 15 x3 Crank Bolt Left Crank
21. top of the rear crank pulley Continue feeding the belt onto the crank pulley while working your way counterclock wise If the belt is too tight near the bottom to slide over the pulley keep tension on the belt and slowly rotate the right crank arm counterclockwise to walk the rest of the drive belt onto the pulley Check to make sure the belt is centered on both pulleys and the upper portion of the belt is under the tensioner bearings Also check that the idler spacer located directly behind the idler bearings is still sitting on the shoulder bolt with the bearings Pg 20 RevMaster Service Manual To tension the belt tighten the tension screw with 5mm hex wrench so the idler bearings begin to put downward pressure on the belt Test the belt tension intermittently while tightening the tension screw by getting on the bike and standing up on the pedals With the cranks parallel to the floor slowly rock back and then give a quick downward thrust with your forward foot If the belt slips continue to tighten and repeat the process of testing and tightening until no slippage is detected Also note that a heavier person or one who uses very heavy resistance may need more tension on the belt When the proper belt tension is reached firmly tighten the shoulder bolt If the tensioner bearings sit at an angle and are not perpendicular to the frame after tightening check to make sure the idler spacer that sits directly behind the idler bearings is
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