True Fitness Service
Manual
Exercise Bicycles
500R, 500U
600R, 600U
750R, 750U
True fitness technology, Inc. makes no representations or warranties regarding the
contents of this manual. We reserve the right to revise this document at any time or
to make changes to the product described within it without notice or obligation to
notify any person of such revisions or changes.
© 2004, True Fitness, Inc. All rights reserved. Printed in the United States of
America.
865 Hoff Road. O’Fallon, MO 63366. 1-800-426-6570. Fax 636-272-3026.
www.truefitness.com
Revision 9/2004
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True Fitness Bicycle
Service Manual
START
™Symptom guide
™Wiring Diagrams
™Parts Manual
™Removal and Replacement Procedures
Page 1
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Test Mode *750 ONLY
Procedure
To Enter Diagnostic
Mode
•
•
Press and hold the “Start” key as you
begin pedaling.
Continue pedaling throughout the test.
-------
D
I
Console / Display
Output
•
•
Press “Enter” key – initiates the second
LED function test.
Press “Enter” key again –all LED’s
should be on.
--------
A
G
N
O
S
RPM
•
•
•
Press “Enter” key – RPM’s displayed in
the far right window.
--------
Console Key Input
Press “Enter” key –A beep should sound
when each key is pressed.
--------
Contact Heart Rate
Press “Enter” key. Hold both handle
pick-ups. Heart symbol will flash and
readout will display.
T
I
C
S
-------
•
•
Press “Enter” key – Press + to increase
resistance and – to decrease resistance.
DA (Resistance)
Exit Diagnostics
To quit diagnostics press “Enter” key or
stop pedaling and the unit will reset.
Support Services 800-883-8783
Mon-Fri 8:30am-5:00pm Central Time Zone
Fax: 636-272-7148
Page 2
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SYMPTOM GUIDE
500U, 500R
‰
ECB Malfunction . . . . . . . . . . . . . . . . . . . . . . . Page 4
‰
‰
‰
Irregular or No Display . . . . . . . . . . . . . . . . . . Page 5
No RPM Reading . . . . . . . . . . . . . . . . . . . . . . . . Page 6
No Polar Heart Rate . . . . . . . . . . . . . . . . . . . . . . Page 7
600U, 600R
‰
Irregular or No Display . . . . . . . . . . . . . . . . . . . Page 8
‰
No RPM Reading . . . . . . . . . . . . . . . . . . . . . . . . Page 9
No Contact Heart Rate . . . . . . . . . . . . . . . . . . . . Page 10
‰
‰
Handle Bar Buttons
Do Not Function . . . . . . . . . . . . . . . . . . . . . . . . . Page 11
750U, 750R
‰
No Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 12
‰
Heavy Resistance . . . . . . . . . . . . . . . . . . . . . . . . . Page 13
‰
‰
Irregular or No Display . . . . . . . . . . . . . . . . . . . Page 14
No Contact Heart Rate . . . . . . . . . . . . . . . . . . . . Page 15
‰
No Polar Heart Rate . . . . . . . . . . . . . . . . . . . . . . Page 16
Page 3
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Symptom
Probable Cause
Control Panel
Corrective Action
ECB
MALFUNCTION
500R, 500U
•
•
•
Power on unit. Check for 5VDC between pins 1 and 2. (Page 18)
No 5VDC? Replace control panel.
Check for 6VDC or more between pins 5 and 6 of 6PA while issuing
a resistance command.
•
No 6VDC or more? Replace control panel.
--------
Defective Cables
•
•
Perform continuity check on upper section and lower section cables.
Replace broken cables.
--------
Defective ECB
Control Board
•
•
If cables test OK and voltage is correct on 5 &6 pins – replace ECB
board
If ECB does not fix- connect 6PA and 6PB.
--------
Optical Sensor
DC Motor
•
•
Check DC volts between pins 2 and 3. Rotate blades of the motor
shaft, voltage should shift from 0 VDC and 5VDC. If voltage does
not shift- replace EC B Board
Check for 6 VDC or more between pins 5&6 on 6 pin PBA @ ECB
board connection. If >6 VDC exists but motor doesn’t rotate, replace
motor.
--------
ECB Limit Switch
•
•
Check continuity between pins 2 and 4 of 6PB. Press lower limit
switch.
If no continuity shift- replace ECB limit switch assembly.
---------
Loud Continuous
Tone from lower
board (ECB board)
•
The loud continuous tone is a safety feature designed to protect the
ECB motor. If the motor binds and cannot move the ECB board will
divert the power from the motor to a speaker that emits this tone. If
you have the continuous tone check to see if the motor is bound.
Check the front pivot point
for the magnet bar and loosen the
bolt to allow for the motor to freely move the magnet bar.
Support Services 800-883-8783
Mon-Fri 8:30am-5:00pm Central Time Zone
Fax: 636-272-7148
Page 4
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Symptom
Probable Cause
DC Adaptor
Corrective Action
Recommended Tools
IRREGULAR OR
NO DISPLAY
500R, 500U
•
•
Connect DC Adapter to 110 VAC power
supply.
Look for printed output on adapters
label. If greater than 9 VDC computer
board may be damaged.
Multi-meter
•
Test for 9VDC output. If not 9 VDC
then replace adaptor.
--------
Adapter Plug or
Jack
•
Connect DC plug to Bike. Does it seat
into the socket properly? If not- replace
adapter or jack.
--------
Control Panel
•
•
Check DC voltage between pins 2 and 4
for 9 VDC on 5PB. (Page 18)
If 9 VDC is found replace the Control
Panel.
--------
Cables
•
Perform continuity checks on all upper
and lower cables.
•
•
Replace defective cables.
If cables OK- replace DC Jack.
Support Services 800-883-8783
Mon-Fri 8:30am-5:00pm Central Time Zone
Fax: 636-272-7148
Page 5
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Symptom
Probable Cause
Corrective Action
Recommended Tools
NO RPM
READING
500R, 500U
Control Panel/ RPM
Sensor
Multi-meter
•
•
Disconnect 5PA from 5PB. Set meter to
check continuity between 2 and 5 of
5PB. (See Page 18)
Turn pedals slowly, check continuity
between 2 and 5 of 5PB.
•
•
Does continuity change from off to on?
If yes – cables and sensor are good –
Replace Control Panel.
•
If no – Go to Defective RPM Set.
When the sensor is over the
pickup, continuity will exist.
When sensor is not over pickup,
cicuit will be open.
--------
•
•
Perform continuity checks on all upper
and lower cables.
Replace defective cables.
Defective Cables
--------
•
If cables OK- Replace RPM sensor set.
Defective RPM
Sensor Set
Support Services 800-883-8783
Mon-Fri 8:30am-5:00pm Central Time Zone
Fax: 636-272-7148
Page 6
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Symptom
Probable Cause
Control Panel
Corrective Action
Recommended Tools
NO POLAR
HEART RATE
500R, 500U
Heart Rate Simulator
•
•
Attach a known good heart rate
transmitter around chest or use polar
simulator.
If control panel does not display a heart
rate – replace Control Panel.
--------
Heart Rate Chest
Strap
•
If heart rate registers with use of HR
simulator but not chest strap – replace
chest strap.
--------
External
Interference
•
•
If erroneous readings continue, check
for and eliminate external interference.
Locate RF sources and use process of
elimination. Common sources of RF
interference are: Invisible fences for
pets; wireless networks; cordless
phones, Cell phones, radios, home
security sensors, etc.
Support Services 800-883-8783
Mon-Fri 8:30am-5:00pm Central Time Zone
Fax: 636-272-7148
Page 7
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Symptom
Probable Cause
Control Panel
Corrective Action
Recommended Tools
IRREGULAR OR
NO DISPLAY
600R, 600U
•
Probe leads between pin 1 and 2 of 5PB.
(Page 19-20)
Multi-meter
•
•
•
Pedal unit up to at least 30 RPM.
Is voltage 5 VDC?
If not 5 VDC – replace Control Panel.
--------
Control Board
•
•
•
Disconnect 6PG from 6PH.
Pedal.
Check DC voltage between pins 2 and 3
for 5 VDC.
•
No 5 VDC? – Replace Control Board.
-------
Cables
•
•
Perform continuity checks on all upper
and lower cables.
Replace defective cables
--------
AC Voltage Output
•
•
Check for AC Voltage between pins 1
and 2 of 3PB, and pins 2 and 3 of 3PB.
Is there AC voltage output in both
places?
•
•
If yes – replace Control Board.
Check for AC Voltage between pins 1
and 2 of 3PD, and pins 2 and 3 of 3PD.
Is there AC voltage output in both
places?
•
•
If no – replace Generator.
------
Generator Output
Cable
•
•
Perform a continuity check on the
generator output cable.
If no continuity – replace cable
Support Services 800-883-8783
Mon-Fri 8:30am-5:00pm Central Time Zone
Fax: 636-272-7148
Page 8
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Symptom
Probable Cause
Control Panel
Corrective Action
Recommended Tools
•
•
•
•
Disconnect 5PA from 5PB. (Page 19-
20).
Set meter to check continuity between
pins 2 and 5 of 5PB
Turn crank and align the magnet with
the sensor
Is there continuity? If Yes – Replace
Control Panel. If No- continue to next
step.
NO RPM
READING
600R, 600U
Multi-meter
--------
Defective Cables
Defective RPM
Sensor Set
•
Check continuity of RPM Sensor, when
magnet is in alignment with the sensor
there should be continuity, when not
aligned- no continuity. If it does not
respond properly- replace the sensor.
Check gap on RPM Sensor
•
•
•
•
Perform a continuity check on all upper
and lower cables.
No continuity? – Replace defective
cable.
Continuity? – Replace RPM Sensor Set.
Support Services 800-883-8783
Mon-Fri 8:30am-5:00pm Central Time Zone
Fax: 636-272-7148
Page 9
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Symptom
Probable Cause
Control Panel
Corrective Action
Recommended Tools
NO CONTACT
HEART RATE
600R, 600U
Multi-meter
•
Disconnect 7P6A and 7P6B from
control panel. 600U (Page 19) 600R
(Page 20). Check continuity between
7P6B and handle mounted heart rate
sensor plates of the following:
HRRR and pin 6 of 7P6B
HRRL and pin 5 of 7P6B
HRLR and pin 2 of 7P6B
HRLL and pin 1 of 7P6B
•
•
•
Is there continuity?
If yes – replace computer.
If No- continue to the next step
--------
Defective Cables
•
•
Perform a contact and continuity check
on cable 600 12P, 600 12P coils upper
cables and the handle cables.
Are cables OK? If No- Replace
defective cables. If Yes- continue on to
the next step.
--------
Defective Handles
•
Remove and carefully check all
connections to the contact plates.
Reconnect loose connections.
•
•
If connections OK – Replace handles.
Support Services 800-883-8783
Mon-Fri 8:30am-5:00pm Central Time Zone
Fax: 636-272-7148
Page 10
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Symptom
Probable Cause
“Cruise Control”
Corrective Action
Recommended Tools
HANDLEBAR
BUTTONS DO
NOT FUNCTION
600R
•
•
Remove console-mounting screws.
Locate 10P7B (Page 20).
Check for continuity between pin 7 and
pin 1 at 10P7B. Press Cruise control
button.
Multi-meter
(A)
•
No continuity? Perform a continuity
check on the appropriate cable.
Replace cable or if cable good – replace
handlebar assembly.
•
--------
“Start” Button
•
Check for continuity between pin 7 and
pin 2 at 10P7B. Press Start button. See
(A) above.
--------
•
•
•
•
Check for continuity between pin 7 and
pin 3 at 10P7B. Press Shift button. See
(A) above.
--------
Check for continuity between pin 7 and
pin 4 at 10P7B. Press _ button. See (A)
above.
--------
“Shift” Button
Check for continuity between pin 7 and
pin 5 at 10P7B. Press Select button. See
(A) above.
“_“ Button
“Select” Button
--------
Check for continuity between pin 7 and
pin 6 at 10P7B. Press + button. See (A)
above.
“+” Button
--------
•
If all have continuity and problem
persists – replace Console
Support Services 800-883-8783
Mon-Fri 8:30am-5:00pm Central Time Zone
Fax: 636-272-7148
Page 11
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Symptom
Probable Cause
Console Set
Corrective Action
Recommended Tools
•
Remove console bolts to access 7-pin
connector. Do not disconnect console
set.
Enter DA (resistance) test mode.
(Page 2).
Press + key to force .7 VDC out of
panel.
Set meter for DC Volts. Measure
between #2 pin and #4 pin at 7- pin
connector.
Note:
NO RESISTANCE
750U, 750R
You must pedal at least
30 RPM when
•
•
•
performing any voltage
test. You may require the
assistance of another
person when performing
voltage checks.
•
Is .7 VDC present? No- replace console
set. If present, continue on.
Multi-meter
--------
Defective Cables
Power Resistance
•
•
Remove right mast cover and handlebar.
Measure between the #2and #4 wires at
the 7 –pin connector on the lower board.
Is .7 VDC present? No- replace cable
for console. If present, continue on.
•
--------
DO NOT PEDAL.
Set meter for resistance. Disconnect 3-
pin connector at the lower control board.
Measure resistance between #1 pin and
#3 pin.
•
•
•
•
Resistance should be 10 ohms, +/- 1
ohm.
If less than 10 Ohms- replace power
resistance. If resistance checks OK,
continue on.
--------
DO NOT PEDAL.
Remove main body cover, set meter for
continuity.
Brake Harness/
Lower Board
•
•
•
Disconnect brake cable from brake and
lower board.
•
•
Check continuity of all wires in cable.
Check for cross continuity- this would
indicate multiple shorts in the cable.
No continuity? Replace Brake cable.
Yes continuity? Replace lower board.
•
•
Support Services 800-883-8783
Mon-Fri 8:30am-5:00pm Central Time Zone
Fax: 636-272-7148
Page 12
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Symptom
HEAVY
RESISTANCE
750U, 750R
Probable Cause
Console Set
Corrective Action
Recommended Tools
Multi-meter
•
•
Remove the console set.
Disconnect the 7 pin connector from the
back of the console set.
•
•
Pedal.
Resistance normal? Replace console set.
--------
Defective Cables
•
Remove pedal and if 3 piece crank
remove crank arm.
•
•
Remove right side cover assembly.
Disconnect 7- pin connector from the
lower control board.
•
•
Pedal.
If resistance is normal- replace cable for
console.
--------
Lower control
Board/Brake
•
Disconnect 3- pin connector from the
brake.
•
•
•
•
Resistance still heavy- Replace brake.
Resistance normal
Check brake cables for cross continuity.
Replace lower control board.
Support Services 800-883-8783
Mon-Fri 8:30am-5:00pm Central Time Zone
Fax: 636-272-7148
Page 13
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Symptom
Probable Cause
Console Set
Corrective Action
Recommended Tools
No Display
750U, 750R
Note:
•
Remove console set bolts. Verify good
connection at the back of the console
set. Set meter for DC volts
Pedal.
Measure between #1 and #4 wires (Page
21) for 5.5 – 7.5 VDC.
Is required voltage present?
If yes- replace console set. If not,
continue on.
You must pedal at least
30 RPM when
performing any voltage
test. You may require the
assistance of another
person when performing
voltage checks.
•
•
•
•
--------
Brake
•
Remove pedal and if 3 piece crank
remove crank arm.
•
•
•
•
•
Remove right side cover.
Disconnect 3- wire connector at brake.
Set meter for AC volts.
Pedal.
The voltage should increase as pedaling
increases.
Multi-meter
•
•
Is minimum voltage 9 VAC @ 30
RPM?
If No- replace Brake. If yes, continue
on.
--------
Defective Cable
•
Remove pedal and if 3 piece crank
remove crank arm.
•
•
Remove right side cover.
Disconnect 3- wire cable from brake and
lower control board.
•
•
•
Set meter for continuity.
Check all 3 wires in cable for continuity.
No continuity? Replace cable
----------
Console Cable/
Lower Control
Board
•
Set meter for DC volts. Reconnect
cable to brake and lower control board.
Pedal.
Measure for 5.5 – 7.5 VDC between #1
and #4 wires on 7- pin cable for the
console at the lower control board.
Voltage is present? Replace cable for
console.
•
•
•
•
Voltage not present? Replace lower
control board.
Support Services 800-883-8783
Mon-Fri 8:30am-5:00pm Central Time Zone
Fax: 636-272-7148
Page 14
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Symptom
Probable Cause
Dirty Sensors
Corrective Action
Recommended Tools
NO CONTACT
HEART RATE
750U, 750R
Note:
•
Verify hand pulse sensors are clean.
--------
You must pedal at least
30 RPM when
performing any voltage
test. You may require the
assistance of another
person when performing
voltage checks.
Console Set/
Wiring
•
•
•
Set meter for continuity.
Remove Console set.
Check for continuity in both sets of
hand pulse sensors between the console
set and hand pulse sensor plates.
If continuity is OK – Replace Console
set. If no- continue on.
Multi-meter
•
Double sided tape
--------
•
•
Check wire connections @ handlebar
console mast joint
Check connections of wires to hand
pulse sensor by removing hand pulse
sensor plates.
Wire Connections
•
To remove hand pulse sensor plates
carefully pry under one end to free them
from the plastic handgrips.
Bad connections? - Reconnect/ Replace
bad wires.
•
•
Recheck continuity.
Support Services 800-883-8783
Mon-Fri 8:30am-5:00pm Central Time Zone
Fax: 636-272-7148
Page 15
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Symptom
NO POLAR
HEART RATE
750U, 750R
Probable Cause
Control Panel
Corrective Action
Recommended Tools
Note:
•
Attach known good heart rate
transmitter around chest or use Polar
simulator.
You must pedal at least
30 RPM when
performing any voltage
test. You may require the
assistance of another
person when performing
voltage checks.
•
•
•
Do not touch the hand pulse sensors.
Start pedaling
Check display for heart rate.
--------
Polar Heart Rate
Simulator
•
•
•
•
Does console display heart rate with
chest strap?
Does console display heart rate with HR
simulator?
If unit responds with simulator and not
chest strap then replace chest strap.
If unit does not respond with strap or
simulator then replace Console set.
Defective Cables
Defective ECB
Control Board
Support Services 800-883-8783
Mon-Fri 8:30am-5:00pm Central Time Zone
Fax: 636-272-7148
Page 16
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WIRING DIAGRAMS
™TR / TU 500
™600 U
Page 18
Page 19
Page 20
Page 21
™600 R
™TR/TU 750
Page 17
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TR/ TU 500 WIRING DIAGRAM
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TU 600 WIRING DIAGRAM
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TR 600 WIRING DIAGRAM
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TR/ TU 750 WIRING DIAGRAM
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True Upright Bike
500
True Recumbent
Bike 500
™TU 500 Exploded Diagram
™TU 500 Parts List
Pg 22
Pg 23
Pg 25
Pg 26
™TR 500 Exploded Diagram
™TR 500 Parts List
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Page 24
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TU 500 EXERCISE BIKE
REF.
#
PART #
DESCRIPTION
QTY
2
3
4
5
6
7
8
9
7T010800 FRONT STABILIZER WITH BOLTS
7T000200 TRANSPORTATION WHEEL HIT
7T000300 FTONT STABILIZER END CAP
7T000400 CRANK PULLEY WITH CAPS AND BEARINGS 1 SET
7T000600 BOLT BELT TENSION
7T010900 BRAKE ASSY
1 SET
1 SET
2 PCS
1 PC
1 SET
1 SET
1 SET
1 SET
1 SET
7T001700 ALUMINUM IDLER ASSY
7T001800 ECB DC MOTOR WITN SCREWS
10 7T002000 ECB CONTROL BOARD WITH SCREWS
11 7T001900 ECB LIMIT SWITCH WTH SCREWS
^12-
1
^12-
2
7T011000 LEFT SHROUD WITH DECALS
1 SET
1 PC
7T001302 SCREW
^12-
3
^12-
4
^12-
5
^12-
6
^12-
7
^12-
8
^12-
9
7T001202 SCREW
6 PCS.
3 PCS.
1 SET
3 PCS.
1 PC
7T001303 SCREW
7T011100 RIGHT SHROUD WITH DECAL
7T001306 HEX NUT SIDE COVER
7T011200 DECAL---WHITE----RIGHT
7T001311 SHROUD DECAL B WHITE
7T001312 SHROUD DECAL D WHITE
1 PC
1 PC
^12-
10 7T011300 DECAL---WHITE----LEFT
1 PC
^12-
11 7T001308 SHROUD DECAL-A WHITE
1 PC
^12-
12 7T001309 SHROUD DECAL C WHITE
1 PC
13 7T001400 PEDALSET WITH STRAPS
14 7T004000 HANDLE BAR 6 PIN WITH BOLTS
1 SET
1 SET
14-
1-1 7T004001 CABLE ASSY 6 PIN UPPER
1 PC.
14-
1-2 7T004002 CABEL ASSY 5 PIN UPPPER
1 PC.
1 SET
1 SET
1 PC
1 PC
1 SET
1 PC
1 PC
1 PC
1 PC
15 7T004100 BOTTLE CAGE WITH SCREWS
16 7T001100 COMPUTER WITH SCREWS
17 7T003800 DC JACK
18 7T003900 ADAPTER 9VDC 1.2A
19 7T004200 CD PLAYER HOLDER WITH SCREWS
20 7T004300 SEAT ADJUSTING KNOB
21 7T000900 SHROUD TRIM CAP
22 7T004400 SEAT POST SLEAVE
23 7T004500 SEAT POST
Page 25
24 7T004600 SADDDLE WITH CLAMP
1 PC
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25 7T002600 REAR STABILIZER WITH BOLTS
26 7T002700 ADJUSTING STAND KIT
27 7T002800 REAR STABILIZER END CAP
28 7T012700 POLY V BELT
1 SET
1 SET
2 PCS
1 PC
29 7T005800 RPM SENSOR WITH WIRE AND NUT
30 7T004700 CABLE ASSY 5 PIN LOWER SPEED SENSE
31 7T004800 CABLE ASSY 6 PIN LOWER SECTION
7T013000 MODEL DECAL SILVER
7T012901 DECAL A SILVER
1 SET
1 PC
1 PC
1 SET
1 PC
7T012902 DECAL B SILVER
1 PC
7T012903 DECAL C SILVER
1 PC
7T012904 DECAL D SILVER
1 PC
7TU50100 ASSY HDW. KIT
1 SET
1 SET
1 SET
1 SET
1 SET
1 SET
1 SET
7TU50200 COMPUTER SCREW KIT
7TU60200 FRONT STABILIZER HDW. KIT
7TU60500 HANDLE BAR HDW. KIT
7TU60600 CD HOLDER HDW. KIT
7TU60700 TOOL KIT
7TU60300 REAR STABILIZER HDW KIT
Page 26
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TR 500 Exercise Bike
Page 27
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TR 500
REF # PART#
DESCRIPTION
QTY.
SET
SET
PCS
SET
SET
PC
PC
PC
PC
SET
PC
02
03
04
05
06
07
08
09
10
11
7T000100 Front Stabilizer w/Bolts
7T000200 Transportation Wheel Kit
7T000300 Front Stabilizer End Cap
7T000400 Crank Pulley w/E Caps & Bearings
7T005800 RPM Sensor w/Wire & Nut
7T000600 Bolt - Belt Tension
7T000700 Cable Assembly - 6 Pin Lower
7T000800 Cable Assembly - 5 Pin Lower
7T000900 Shroud Trim Cap
1
1
2
1
1
1
1
1
1
1
1
1
1
1
7T001000 Console Mast Set
11-1-1 7T001001 Cable Assy, 6 Pin Upper
11-1-2 7T004700 Cable Assy, 5 Pin Upper
PC
SET
PC
12
7T001100 Computer Set
13-1 7T001201 Rear Shroud - Right
13-2 7T001202 Screw, Sidecover
10 PCS
13-3 7T001203 Rear Shroud - Left
13-4 7T001204 Screw, Rear Cover
14-1 7T001301 500R Shroud - Left Complete w/ Model Decal and Shroud Decals
14-2 7T001302 Screw - Side Cover
14-3 7T001303 Screw
1
1
1
1
3
PC
PC
SET
PC
PCS
14-5 7T001305 500R Shroud - Right Complete w/ Model Decal and Shroud Decals 1 PC
14-6 7T001306 Hex Nut - Side Cover
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
PCS
PC
PC
PC
PC
PC
PC
SET
PC
SET
SET
SET
SET
SET
PC
SET
SET
SET
14-7 7T001307 Model Decal for 500R - Left (Wht)
14-8 7T001308 Shroud Decal - A (Wht)
14-9 7T001309 Shroud Decal - C (Wht)
14-10 7T001310 Model Decal for 500R - Right (Wht)
14-11 7T001311 Shroud Decal - B (Wht)
14-12 7T001312 Shroud Decal - D (Wht)
15
16
17
18
19
20
21
22
23
24
25
7T001400 Pedal Set w/Straps
7T001500 Poly-v Belt
7T010700 TR500 Brake Assy
7T001700 Aluminum Idler Assembly
7T001800 ECB DC Motor w/Screws
7T001900 ECB Limit Switch w/Screws
7T002000 ECB Control Board w/Screws
7T002100 Aluminum Rail Trim Cap
7T002200 Aluminum Rail w/Bolts
7T002300 Stopper Kit
7T002400 Fore and Aft Adjusting Rack w/Bolts
Page 28
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26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
7T002500 Transportation Handle Set w/Screws
7T002600 Rear Stabilizer w/Bolts
7T002700 Adjusting Stand Kit
7T002800 Rear Stabilizer End Cap
7T002900 Roller Set (A) Rt Ft & RR
7T003000 Roller Set (B) Center
7T003100 Seat Bottom w/Bolts
7T003200 Fore and Aft Adjusting Lever w/Bolts
7T003300 Seatback w/Bolts
7T003400 Seat Shuttle
7T003500 Bottle Holder w/Screws
7T003600 Rear Handlebar w/Bolts
7T003700 Roller Set (C) LH, Ft & RR
7T003800 DC Jack
7T003900 Adapter 9vdc1.2a
7T013000 Model Decal
1
1
1
2
2
2
1
1
1
1
1
1
2
1
1
SET
SET
SET
PCS
SET
SET
SET
SET
SET
SET
SET
SET
SET
PC
PC
7T012901 Decal A
7T012902 Decal B
7T012903 Decal C
7T012904 Decal D
7T012800 Pneumatic Cylinder/Seat Back
7TR50100 Assy Hdw Kit
7TR50200 Ft/RR Stabilizer Hdw Kit
7TR50300 H/Bar Hdw Kit
7TR50400 Bottle Holder Hdw Kit
7TU60700 Tool Kit
Page 29
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True Upright Bike
600
True Recumbent
Bike 600
™TU 600 Exploded Diagram
™TU 600 Parts List
Pg- 29
Pg- 30
Pg- 32
Pg- 33
™TR 600 Exploded Diagram
™TR 600 Parts List
Page 31
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TU 600 PARTS DIAGRAM
Page 32
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TU 600 BIKE
REF #
PART NUMBER
DESCRIPTION
QTY.
02
03
04
05
7T010800
7T000200
7T000300
7T011400
7T004900
7T005000
7T012000
7T001302
7T001202
7T001303
7T012100
7T001306
7T012200
7T001311
7T001312
7T012300
7T001308
77T001309
7T001400
7T005500
7T005600
7T005200
7T012400
7T012500
7T011500
7T007200
7T005700
7T006000
7T005900
7T005800
7T000900
7T004300
7T004400
7T004500
7T004600
7T006900
FRONT STABILIZER WITH BOLTS
TRANSPORTATION WHEEL KIT
FRONT STABILIZER END CAP
DRIVE BELT KIT
1
1
2
1
DO NOT ORDER
06
POLY V PULLEY SET KIT SECONDARY
LEFT COMPLETE W/ MODEL SHROUD DECALS
SIDE COVER SCREW
SIDE COVER SCREW
SIDE COVER SCREW
RIGHT SHROUD W/ MODEL DECALS
HEX NUT
MODEL DECAL LEFT WHITE
SHROUD DECAL BLUE
SHROUD DECAL BLUE
MODEL DECAL RIGHT WHITE
SHROUD DECAL BLUE
1
1
1
6
3
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
7-1
7-2
7-3
7-4
7-5
7-6
7-7
7-8
7-9
7-10
7-11
7-12
08
09
10
11
12
13
14
14-9
15
16
SHROUD DECAL BLUE
PEDAL SET W/ STRAPS LFT. & RT.
CRANK AND CUPS PULLEY SET W/BEARINGS
J8 POLY V BELT PRIMARY
ALUMINUM IDLER AND IDLER ARM
C RING IDLER ARM
SPRING IDLER ARM
BRAKE KIT
BRAKE CABLE
GENERATOR BRACKET SET
CONTROL BOARD W/ SCREWS
RESISTOR W/ SCREWS
RPM SENSOR W/ WIRE AND NUT
SHROUD TRIM CAP
SEAT ADJUSTING KNOB
SEAT POST SLEAVE
SEAT POST SET
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
17
18
19
20
21
22
23
24
SADDLE W/ CLAMP
HANDLEBAR W/ CONTACT HR AND BOLTS
CABLE ASSY.
24-1-1 7T006202
25
26
27
28
29
30
31
32
33
24-2
7T004100
7T006300
7T004200
7T007000
7T012600
7T002600
7T002700
7T002800
7T005100
7T013100
BOTTLE CAGE W/ SCREWS
COMPUTER W/ SCREWS
CD PLAYER HOLDER W/ SCREWS
CABLE ASSEMBLY 5 PIN LOWER
IDLER ARM AXLE KIT
REAR STABILIZER W/ SCREWS
LEVELERS x2 WITH LOCKS
REAR STABILIZER END CAP
POLY V PULLEY SET KIT CLUTCH
HANDLEBAR END CAPS
2
Page 33
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7T011800
7T011900
7T012901
7T012902
7T012903
7T012904
7TU60100
7TU60200
7TU60300
MODEL DECAL LEFT WHITE
MODEL DECAL RIGHT WHITE
DECAL A
DECAL B
DECAL C
DECAL D
PARTS KIT
FRONT STABILIZER SCREW KIT
REAR STABILIZER SCREW KIT
1
1
1
1
1
1
1
1
Page 34
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TR 600 PARTS DIAGRAM
Page 35
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TR600 BIKE
REF. #
PART #
DESCRIPTION
QTY USED
24-1 7T011600 600R L SHROUD & DECALS
24-2 7T001202 SIDE CVR SCREW
24-3 7T001303 SIDE CVR SCREW
1
6
3
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
1
1
1
24-4 7T001302 SIDE CVR SCREW
24-5 7T011700 600R R SHROUD & DECALS
24-6 7T001306 HEX NUT SIDE CVR SCREW
24-7 7T011800 MODEL DECAL 66R L WHITE
24-8 7T001308 SHROUD DECAL A BLUE
24-9 7T001309 SHROUD DECAL C BLUE
24-10 7T012300 MODEL DECAL 600R RT WHITE
24-11 7T001311 SHROUD DECAL B BLUE
24-12 7T001312 SHROUD DECAL D BLUE
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
2
3
4
5
6
7
8
9
7T001400 PEDAL W/STRAPS LT&RT
7T002100 ALUM RAIL TRIM CAP
7T002200 ALUM RAIL W/HDRW
7T002300 SEAT STOP KIT LT& RT
7T006500 CABLE ASSY 12 PIN LWR SEAT RAIL
7T002400 SEAT ADJ RACK
7T002500 TRANSPORT HNDL KIT
7T002600 REAR STABILIZER W/BOLTS
7T002700 LEVELS W/LOCKS
7T002800 REAR STABILIZER END CAP
7T002900 ROLLER SET (A) RT& LT FRT
7T003000 ROLLER SET (B) RT & LT CTR
7T003100 SEAT BOTTOM W/SCREWS
7T003300 SEATBACK W/SCREWS
7T003200 SEAT ADJ LEVER W/BOLTS
7T000100 FRT STABILIZER W/BOLTS
7T000200 TRANSPORTS WHEEL KIT
7T000300 FRT STABILIZER END CAP
7T011400 TR/TU600 DR BELT REPLACE KIT
7T005000 POLY-V SEONDARY KIT CLUTCH
7T005100 POLY-V CLUTCH PULLEY KIT
7T005200 ALUM IDLER & IDLER ARM
7T005300 C RING IDLER ARM
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
10
11
12
13
7T005400 SPRING IDLER ARM
7T005500 CRANK & PULLEY W/BEARINGS
7T005600 J-8 POLY-V BELT PRIM
7T011500 TU/TR600 BRAKE KIT
13-9 7T007300 CABLE BRAKE
15
16
17
18
7T005800 RPM SENSOR & KNOT CBL
7T005900 RESISTOR W/SCREWS
7T006000 CNTRL BOARD W/SCREWS
7T006100 CABLE ASSY SPIN LWR
7T000900 MAST TRIM CAP
Page 36
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20
7T006200 CONSOLE MAST W/BOLTS
1
1
1
1
2
1
1
4
1
1
1
1
1
1
1
20-1-1 7T006201 CABLE ASSY 12 PIN UPPER
20-1-2 7T006202 CABLE ASSY 52 PIN UPPER
21
22
23
40-1 7T001201 REAR SHROUD RT
24-2 7T001202 ROUND CROSS SCREW
40-3 7T001204 TAPPING SCREW
40-4 7T001203 REAR SHROUD LT
41
42
43
44
45
7T006300 COMPUTER SET 660RIU LT FRT
7T003700 ROLLER SET SEAT LT RR
7T006400 IDLER ARM SHAFT KIT
7T003500 BTTL HDLR W/SCREWS
7T006600 REAR HNDLBR W/SWITCHES BOLTS
7T003400 SEAT SHUTTLE
7T006700 THUMB SWITCH ASSY LT
7T006800 THUMB SWITCH ASSY RT
7T011800 MODEL DECAL LT WHITE
7T011900 MODEL DECAL RT WHITE
24-08 7T012901 DECAL A SILVER
24-11 7T012902 DECAL B SILVER
24-9 7T012903 DECAL C SILVER
24-12 7T012904 DECAL D SILVER
7T013000 MODEL DECAL
43-1 7T012800 PNEUMATIC CYLINDER SEAT BK
^2-1
7TR50200 FH RR STABILIZER HDW KIT
20-1 7TR50300 HNDLBR HDW KIT
41-1 7TR50400 BTTL HLDR HDW KIT
7TR60100 ASSY HDW KIT
21-1 7TU50200 CPANEL HDW KIT
7TU60700 ASSY TOOL KIT
Page 37
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True Upright Bike
750
™TU 750 Exploded Diagram
Pg- 37
Pg- 38
Pg- 40
Pg- 41
(Prior to serial # 02-UP0161C (3) Piece Crank)
™TU 750 Parts List
(Prior to serial # 02-UP0161C (3) Piece Crank)
™TU 750 Exploded Diagram
(After serial # 02-UP0161C (1) Piece Crank)
™TU 750 Parts List
(After serial # 02-UP0161C (1) Piece Crank)
Page 39
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TU 750 PARTS DIAGRAM
(3 PIECE CRANK)
Page 40
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TU750:
02-
TU 750 3 PIECE CRANK UP0161C
REF # PART#
DESCRIPTION
QTY.
AB1
AC1
AD1
AJ1
AN1
AS1
B22
B24
B31
C07
C08
C10
C11
C12
C13
C14
C15
C16
D03
D04
D05
J05
J07
J08
J09
J10
J11
J12
P01
P08
P11
7TSP0101006
7TSZCB24CSM UPRIGHT HANDLE BAR
FRAME
1
1
1
1
1
14
16
1
1
1
4
4
1
2
6
1
2
1
3
3
2
1
4
4
2
2
2
1
2
1
7TSW0150005
7TSZCB24FST
7TSM0209004
7TMD0208006
7TME0701001
7TME0107014
7TMJ1208001
7TMJ1278001
7TMB06A7001
7TME0102069
7TMB0201028
7TMB0601005
7TME0102043
7TME0111014
7TMB0605006
7TMJ1291001
7TMB1001018
7TME0204019
7TME0501007
7TMB0103001
SEAT POST
FRONT GROUNDING BAR ASSEMBLY
CONSOLE SET
BRAKE ASSEMBLY
C CLAMP SIDE COVER
SCREW SIDE COVER
SIDE COVER BRACKET
HAND PULSE SENSOR
SENSOR BRACKET PULSE
SCREW PULSE BRACKET
NUT PULSE BRACKET
WATER BOTTLE CAGE
SCREW BOTTLE CAGE
SCREW HANDLEBAR MAST
TRIM CAP
END CAP OF HANDLEBAR
SEAT CUSHION
NYLON NUT SEAT CUSHION
SPRING WASHER SEAT CUSHION
MOVING WHEEL
7TSZCB24RST REAR GROUNDING BAR ASSEMBLY
7TMB0304006
7TME0112024
7TME0112044
7TME0502108
7TMB0705001
7TMC0501027
7TMC0549002
7TMC0203004
REAR FEET PAD
BOLT MOVING WHEEL FT. GROUNDING BAR
BOLT REAR GROUNDING BAR ASSEMBLY
WASHER MOVING WHEEL
MOVING WHEEL COVER
CONSO
CONTACBLE
CONTROL BOARD
NEXT FIVE PIECES ASSEMBLY BUT NO ASSY. NUMBER
P12
P17
P22
P23
P24
P15
P19
P20
Q01
J14
J15
Q02
7TMC0736002
7TMJ1393002
7TME0102027
7TME0204003
7TME0502082
7TMB06B8001
7TME0107043
7TME0107043
7TMN1101006
POWER RESISTANCE
COVER POWER RESISTENCE
SCREW
NUT
WASHER
CONTROL BOARD BRACKET
SCREW CONTROL BOARD
SCREW RESISTOR TO FRAME
SEAT ADJUSTMENT KNOB BLUE
1
1
4
4
4
1
8
8
1
2
2
1
7TMB0304020A FOOT PAD FRONT
7TMZE0112119 BOLT FRONT FOOT PAD
7TMB0604018
Page 41
SEAT POST SLEEVE
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Q06R 7TMB0609028
END CAP FOR FRONT GROUNDING BAR RT.
END CAP FOR FRONT GROUNDING BAR LT.
END CAP FOR REAR GROUNDING BAR
1
1
2
1
1
1
1
2
2
6
6
2
2
2
2
2
2
1
1
1
Q06L
Q07
Q11
Q12
R03
R06
R09
R14
R17
R20
S01
S02
S03
S04
S05
S06
T01
T02
T03
T04
T05
T06
T08
T09
U06
U07
U09
U10
U12
U13
V01
V03
7TMB0609026
7TMB0609035
7TSZCB24SCV-L SIDE COVER ASSY. LEFT 3 PC. CRANK
7TSZCB24SCV-R SIDE COVER ASSY. RIGHT 3 PC. CRANK
7TSZRB40PAX FLYWHEEL SHAFT ASSEMBLY
7TMD0602018
7TME0103022
7TME0514002
7TME0104014
7TME0502092
7TMJ3247002
7TMJ1245003
7TME0204010
7TME0201012
7TME0502127
7TME0502115
POLY V BELT 520-J8
FLAT HEAD SCREW
WASHER
SCREW FLYWHEEL ATTACH
WASHER FLYWHEEL ATTACH
EYE BOLT BRAKE BELT TENSION
HOOK COVER BRAKE BELT TENSION
NYLON NUT BRAKE BELT TENSION
NUT BRAKE AXLE
WASHER BRAKE TENSION BOLT
WASHER BRAKE AXLE
7TSZRB40DAX BOTTOM BRACKET WHEEL ASSY. 3 PC. CRANK
7TMD0405001
7TMD0406001
7TMD0402002
7TMD0403002
7TMD0602013
7TMB0622001
LEFT CRANK
RIGHT CRANK
PEDALS WITH STRAP
PEDAL STRAP SET OF 2
POLY V BELT 400-J08
CRANK COVER CAP
2(SET)
1
1
2
2
1
1
1
1
1
1
1
2
1
1
1
7TME01132012 SCREW CRANK ARM ATTACH
7TME0112088
7TMJ1914002
7TME1104002
7TME0502084
7TME0104014
7TME0201003
7TMG0214009
7TMG0102036
7TMH0205023
7TME0601017
7TMB0237002
SCREW BELT TENSIONER
STRETCH ADJUSTER BELT TESIONER
STRETCH SPRING BELT TENSIONER
WASHER BELT TENSIONER
SCREW BELT TENSIONER
NUT BELT TENSIONER
SIDE COVER DECAL BLUE
MODEL DECAL WHITE
OWNERS MANUAL
ASSEMBLY KIT
UPPER FRAME COVER
Q08
Page 42
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TU 750 PARTS DIAGRAM
(1 PIECE CRANK)
Page 43
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TU 750 1PC CRANK
REF.#
AB1
AC1
AD1
AJ1
AN1
AS1
B22
B24
B31
C07
C08
C10
C11
C12
C13
C14
PART#
DESCRIPTION
FRAME
HANDLE BAR W/HR
SEAT POST
QTY.
7TSP001006
7TSZCB24CSM
7TSW0150005
7TSZCB24FST
7TSM0209004
7TMD0208006
7TME0701001
7TME0107014
7TMJ1208001
7TMJ1278001
7TMB06A7001
7TME0102069
7TMB0201028
7TMB0601006
7TME0102043
7TME0111014
1
1
1
1
1
14
16
1
2
2
FRONT GROUND BAR ASSEMBLY
CONSOLE ASSEMBLY
BRAKE ASSEMBLY
C CLAMP SIDE CVR
SCREW SIDE CVR
SIDE CVR BRACKET
HAND PULSE SENSOR
SENSOR BRACKET PULSE
SCREW PULSE BRKT
NUT PULSE BRKT
WATER BTL CAGE
SCREW BTL CAGE
SCREW HANDLEBAR
MAST
4
4
1
2
6
C15
C16
D03
D04
D05
7TMB0605006
7TMJ1291001
7TMB1001018
7TME0204019
7TME0501007
TRIM CAP
END CAP OF HDLBR
SEAT CUSHION
NYLON NUT SC
SPRING WASHER ST
CUSHION
1
2
1
3
3
J05
J07
7TMB0103001
7TSZCB24RST
MOVING WHEEL
REAR GROUNDING BAR
ASSEMBLY
2
1
J08
J09
7TMB0304006
7TME0112024
REAR FEET PAD
BOLT MOVING WHEEL
FT. GROUND BAR
BOLT REAR GROUND
BAR ASSEMBLY
4
2
J10
7TME0112044
2
J11
J12
7TME0502108
7TMB0705001
WASHER MVG WHEEL
MOVING WH
DO NOT OR
2
2
P01
P08
7TMC0501027
7TMC0549002
CONSOLE DATA CBL
CONTACT HEART RATE
CABLE
1
2
P11
7TMC0203004
CONTROL BOARD
1
P12
P17
7TMC0736002
7TMJ1393002
POWER RESISTANCE
COVER POWER
RESISTANCE
SCREW
NUT
WASHER
1
1
P22
P23
P24
7TME0102027
7TME0204003
7TME0502082
4
4
4
P15
P19
P20
7TMB06B8001
7TME0107043
7TME0107043
CONTROL BRD BRKT
SCREW CNTRL BRD
SCREW RESISTER TO
1
8
8
Page 44
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FRAME
Q01
7TMN1101006
SEAT ADJ KNOB
BLUE
1
J14
J15
Q02
Q06R
7TMB030402A
7TMZE0112119
7TMB0604018
7TMB0609028
FOOT PAD FRONT
BOLT FRONT FT PAD
SEAT POST SLEEVE
END CAP FOR FRONT
GRNDG BAR FOR RIGHT
END CAP FOR FRONT
GRNDG BAR FOR LEFT
END CAP FOR REAR
GROUNDING BAR
SIDE CVR ASSY LEFT
1 PIECE CRANK
2
2
1
1
Q06L
Q07
Q11
Q12
R03
7TMB0609026
7TMB0609035
7TSZCB24SCV-L
7TSZCB24SCV-R
7TSZRB40PAX
1
2
1
1
1
SIDE CVR ASSY RT
1 PIECE CRANK
FLYWHEEL SHAFT
ASSEMBLY
R06
R09
7TMD0602018
7TME0103022
POLY V BELT 520-J8
FLAT HEAD SCREW
DO NOT ENTER
1
2
R14
R17
R20
S01
S02
S03
7TME0514002
7TME0104014
7TME0502092
7TMJ3247002
7TMJ1245003
7TME0204010
WASHER
DO NOT ENTER
SCREW FLYWHEEL
ATTACH
WASHER FLYWHEEL
ATTACH
EYE BOLT BRAKE BLT
TENSION
HOOK CVR BRAKE
BELT TENSION
NYLON NUT BRAKE
BELT TENSION
2
6
6
2
2
2
S04
S05
7TME0201012
7TME0502127
NUT BRAKE AXLE
WASHER BRAKE
TENSION BOLT
2
2
S06
T01
T02
T03
T04
T05
T06
T08
T09
U06
U07
U09
U10
U12
U13
V01
7TME0502115
7TSZRB40PAX-1
7TMD0405001
7TMD0406001
7TSM0915027A
7TMD0403002
7TMD0602013
7TMB0622001
7TME0113012
7TME0112088
7TMJ1914002
7TME1104002
7TME0502084
7TME0104014
7TME0201003
7TMG0214009
7TMG0102053D
WASHER BRK AXLE
BTTM BRKT WHEEL
LEFT CRANK
2
1
1
1
1
1
1
2
2
1
1
1
1
1
1
RIGHT CRANK
1/2 PEDALS W/STRAP
PEDAL STRAP SET 2
POLY V BELT 400-J08
CRANK CVR CAP
SCREW CRANK ARM
SCREW BELT TENSIONER
STRETCH ADJUSTER
STRETCH SPRING
WASHER
SCREW BELT TENSIONER
NUT BELT TENSIONER
SIDE CVR DECAL BLUE
MODEL DECAL SILVER
Page 45
1
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V03
Q08
7TMG0102036
7TMG0214009C
7TMG0214016C
7TMH0205023
7TME0601017
7TMB0237002
MODEL DECAL WHITE
SIDE CVR DECAL SILVR
SIDE CVR DECAL SILVR
OWNERS MANUAL
ASSEMBLY KIT
UPPER FRAME CVR
2
1
1
1
Page 46
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True Recumbent
Bike 750
™TR 750 Exploded Diagram
Pg- 46
(Prior to 08/05/2001 (3) Piece Crank)
™ TR 750 Parts List
Pg- 47
Pg- 49
(Prior to 08/05/2001 (3) Piece Crank)
™TR 750 Exploded Diagram
(After 08/05/2001 & Prior to Serial # 02-RE0283C
(3) Piece Crank)
™TR 750 Parts List
Pg- 50
(After 08/05/2001 & Prior to Serial # 02-RE0283C
(3) Piece Crank)
™TR 750 Exploded Diagram
Pg- 52
Pg- 53
(After Serial # 02-RE0283C (1) Piece Crank)
™TR 750 Parts List
(After Serial # 02-RE0283C (1) Piece Crank)
Page 47
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Page 48
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TR750 PRIOR 8-5-01 (3 PIECE
CRANK)
REF. # PART #
DESCRIPTION
QTY.
AD1
AD2
AG1
AG2
AJ1
AN1
AS1
B37
B27
7TSP0203003
7TSZRB40SLP SEAT SLIDE PLATE LOCK
7TSP0206006
7TSP0212003
7TSZRB40FST FRONT GROUNDING BAR ASSY.
SEAT SLIDE WELDMENT
1 SET
1 SET
1 SET
1 SET
1 SET
1 SET
1 SET
1 SET
16 PCS.
1 PC.
2 PCS.
1 PC.
1 PC.
1 PC.
1 PC.
1 PC.
1 PC.
1 PC.
1 PC.
1 PC.
1 SET
SEAT HANDLE BAR WELDMENT
CONCOLE HANDLE BAR WELDMENT
7TSM0209004
7TMD0208006
7TME0701001
7TME0107014
7TMJ3251001
7TME0102047
7TMJ1208001
7TMB1001005
7TMB1002002
7TMJ3228002
7TMJ3243001
7TMJ3244001
7TMJ3220006
7TME1111002
7TMJ3245001
CONSOLE ASSEMBLY
BRAKE ASSY
C CLAMP-SIDECOVER
SCREW- SIDE COVER
FIXTURE SHAFT SIDE COVER
SCREW FOR SIDE COVER SHAFT
SIDE COVER BOTTOM FIXTURE
SEAT BOTTOM PAD
SEAT BACK PAD
ADJUSTMENT BAR FIXTURE PIN
BULB CONNECTOR
CLEVIS
SPACER
OPPOSITE SPRING
ADJUSTMENT BAR WITH GRIP
D01
D02
D16
7TSZRB40SER RECUMBANT SEAT ROLLER W/ HARDWARE
7TSZRB40ESR ECCENTRIC SEAT ROLLER ASSY. W/ HARDWARE 1 SET
7TMB0104065
7TME0104004
7TME0112023
7TME0204004
7TME0112013
7TME0112039
7TME0501006
7TME0112014
7TMB0401021
7TMJ1278001
7TMB06A7001
7TMB0609031
7TME0102069
7TME0201028
SCREW-SEAT LOCK PLATE BRACKET
SCREW-SEAT LEVER FIXTURE PIN
SCREW-BULB CONNECTOR SEAT LEVER
NUT CLEVIS
4 PCS.
1 PC.
1 PC.
1 PC.
D28
SCREW SEAT BOTTOM
4 PCS.
4 PCS.
8 PCS.
4 PCS.
2 PCS.
1 SET
1 SET
4 PCS.
4 PCS.
4 PCS.
1 PC.
SCREW-DIP BAR MOUNT
SPRING WASHER SEAT BACK/BOTTOM
SCREW SEAT BACK
HANDLE FOAM GRIP
HANDPULSE SENSOR
HANDPULSE BRACKET
END CAP HANDLE BAR
SCREW PULSE BRACKET
NUT PULSE BRACKET
D33
D34
G06
G07
G09
G10
G11
G12
H01
H02
H03
H09
H13
H16
H15
H14
7TSZRB40RAL RECUMBANT SEAT ASSY. TUBE
7TMJ3230001
7TMJ1228019
7TME0112042
7TME0502018
7TMB0632001
7TME0107015
7TMB0211008
7TMB0634002
7TME0102027
7TMB0103001
FIXTURE PIN BRACKET
PLATE FIXTURE BRACKET SHIM
SCREW REAR TUBE MOUNT
WASHER REAR TUBE MOUNT
END CAP OF FRONT SLIDE TUBE
SCREW SEAT TUBE END CAP
END CAP OF REAR SLIDE TUBE
WIRE CLAMP
1 PC.
1 PC.
8 PCS.
8 PCS.
1 PC.
2 PCS.
1 PC.
1 PC.
WIRE CLAMP
TRANSPORT WHEEL
1 PC.
2 PCS.
Page 49
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J07
J08
J09
J10
J11
J12
7TSW2221005
7TMB0304006
7TME0112109
7TME0112024
7TME0502108
7TME0902007
7TMC0501027
7TMC0520002
7TMC0550001
7TMC0203004
7TMC0736002
7TMC0535006
7TMB06B8001
7TMJ1393002
7TME0102027
7TME0204003
7TME0502082
7TMB0601005
REAR GROUNDING BAR
FOOT PAD REAR ADJUSTABLE
BOLT GROUNDING BAR
BOLT TRANSPORT WHEEL
WASHER TRANSPORT WHEEL
EXTERNAL C RING-TRANSPORT WHEEL
CABLE DISPLAY CONTROL BOARD
CABLE SEAT RAIL
1 PC.
4 PCS.
4 PCS.
2 PCS.
2 PCS.
2 PCS.
1 PC.
1 PC.
1 PC.
1 PC.
1 PC.
1 PC.
1 PC.
1 PC.
4 PCS.
4 PCS.
4 PCS.
1 PC.
WIRE HEART RATE SEAT RAIL CONSOLE
CONTROL BOARD
POWER RESISTANCE
P11
P12
P13
P15
P17
P22
P23
P24
CABLE GENERATOR
CONTROL BOARD BRACKET
POWER RESISTANCE COVER
SCREW RESISTOR
NYLON NUT RESISTOR
WASHER RESISTOR
WATER BOTTLE HOLDER
Q06R 7TMB0609028
Q06L 7TMB0609026
END CAP FOR FRONT GROUNDING BAR-RH
END CAP FOR FRONT GROUNDING BAR-LH
END CAP OF REAR GROUNDING BAR- R OR L
SCREW CONTROL PANEL
1 PC.
1 PC.
Q07
Q08
Q11
Q12
R3
7TMB0609035
7TME0104055
2 PCS.
4 PCS.
1 SET
1 SET
1 SET
1 PC.
6 PCS.
6 PCS.
2 PCS.
2 PCS.
2 PCS.
2 PCS.
1 SET
1 PC.
7TSZRB40SCV-L SIDE COVER LEFT WITH DECALS
7TSZRB40SCV-R SIDE COVER RIGHT WITH DECALS
7TSZRB40PAX FLYWHEEL SHAFT ASSY. WITH TENSIONER
R06
7TMD0602018
7TME0104014
7TME0502092
7TMJ3247001
7TMJ1245003
7TME0204010
7TME0201012
POLY V BELT SECONDARY
SCREW FLYWHEEL
WASHER FLYWHEEL
BELT ADJUSTOR-BRAKE
HOOK COVERBELT ADJUSTOR-BRAKE
NYLON NUT BELT ADJUSTOR - BRAKE
NUT - BRAKE AXEL
7TSZRB40DAX BOTTOM BRACKET WHEEL ASSY.
T02
T03
T04
T05
T06
T07
T08
7TMD0405001
7TMD0406001
7TMD0402002
7TMD0403002
7TMD0602013
7TMB0622001
7TME0113012
7TME1103002
7TMG0214008
7TMG0214014
LEFT CRANK
RIGHT CRANK
1 PC.
PEDALS - 9/16" WITH STRAPS
PEDAL STRAP-PR
POLY V BELT PRIMARY
CRANK CAVER ARM BOLT
CRANK ARM BOLT
SPRING BELT TENSIONER
SIDE COVER DECAL LEFT- BLUE
SIDE COVER DECAL RIGHT- BLUE
1 SET
1 SET
1 PC.
2 PCS.
2 PCS.
1 PC.
V01
V02
1 SET
1 SET
Page 50
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TR 750 PARTS DIAGRAM
After 08/05/01 and Prior to
Serial # 02-RE0283C
Page 51
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TR 750 AFTER 8/5/01 PRIOR TO
02-RE0283C
NEW SEAT ASSY - 3 PIECE CRANK
REF. # PART #
DESCRIPTION
QTY
114
117
001
003
039
043
118
083
084
085
086
087
031
045
088
116
050
051
089
052
053
090
028
091
093
094
092
097
024
098
031
030
099
035
102
100
002
054
060
055
056
057
058
026
AD5 7TSZRB40SAS SEAT SLIDE SET
1 SET
1 SET
1 SET
1 SET
16 PCS.
16 PCS.
1 PC
AG2 7TSP0212003
AN1 7TSM0209004
AS1 7TMD0208006
B26 7TME0701001
B27 7TME0107014
B35 7TMJ3251001
D76 7TMB1001005
D77 7TMB1002002
D78 7TME0112013
D79 7TME0112014
D80 7TME0501006
D81 7TME0112024
D82 7TME0501007
G06 7TMB0401021
G06 7TSP0206006
G08 7TMJ1278001
G09 7TMB06A7001
G10 7TMB0609031
G11 7TME0102069
G12 7TME0201028
CONSOLE HANDLE BAR
CONSOLE ASSY.
BRAKE ASSY.
C CLAMP - SIDE COVER
SCREW SIDE COVER
FIXTURE SHAFT SIDE COVER
SEAT BOTTOM
SEAT BACK
SCREW SEAT BOTTOM
SCREW SEAT BACK
WASHER SEAT BACK AND BOTTOM
SCREW SEAT HANDLE BAR
WASHER SEAT HANDLE BAR
HANDLE BAR FOAM GRIP
SEAT HANDLE BAR
HANDPULSE SENSOR
HANDPULSE BRACKET
HAND PULSE END CAP
SCREW HAND PULSE
NUT HAND PULSE
1 PC
1 PC
4 PCS.
4 PCS.
8 PCS.
4 PCS.
4 PCS.
2 PCS.
1 SET
2 SETS
2 SETS
4 PCS.
4 PCS.
4 PCS.
1 PC
2 PCS.
8 PCS.
2 PCS.
1 PC
1 PC
1 PC
4 PCS.
4 PCS.
2 PCS.
2 PCS.
2 PCS.
1 PC
1 PC
2 PCS.
1 PC
H01 7TSZRB40RAL-1 SEAT RAIL ASSY.
H33 7TMB0103001 TRANSPORT WHEEL
H37 7TMZE0112042 BOLT SEAT RAIL
H38 7TMZE 0107015 SCREW RAIL AND CAP
H39 7TMB0211008
END CAP OF REAR SLIDE TUBE
H41 7TMB0632007A RAIL CAP END
J07 7TSZRB40RST REAR STABILIZER
J08 7TMB0304006
J09 7TME0112109
J10 7TME0112024
J11 7TME0502108
J12 7TME0902007
P01 7TMC0501027
P04 7TMC0550001
P05 7TMC0549005
P11 7TMC0203004
P12 7TMC0736002
P15 7TMB06B8001
P17 7TMJ1393002
P22 7TME0102027
P23 7TME0204003
P24 7TME0502082
Q06L 7TMB0609026
Q06R 7TMB0609028
LEVELER
BOLT REAR STAILIZER
BOLT TRANSPORT WHEEL
WASHER TRANSPORT WHEEL
EXTERNAL C RING TRANSPORT WHEEL
CABLE DISPLAY/CONTROL BOARD
WIRE HRC RAIL TO CONSOLE
HR SENSOR WIRE
CONTROL BOARD
RESISTOR
BRACKET CONTROL BOARD
RESISTOR COVER
SCREW RESISTOR
1 PC
1 PC
1 PC
4 PCS.
4 PCS.
4 PCS.
NYLON NUT RESISTOR
WASHER RESISTOR
END CAP FRONT GROUNDING BAR LEFT 1 PC
END CAP FRONT GROUNDING BAR RIGHT 1 PC
Page 52
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023
105
081
082
005
018
010
011
006
107
019
049
048
109
110
112
004
029
032
033
038
046
047
059
061
062
063
065
066
067
095
095
101
103
104
106
108
111
113
115
120
143
Q07 7TMB0609035
Q08 7TME0104055
Q11 7TSZRB40SCV-L SIDE COVER LEFT
Q12 7TSZRB40SCV-R SIDE COVER RIGHT
R03 7TSZRB40PAX FLYWHEEL SHAFT ASSY
R06 7TMD0602018
T02 7TMD0405001
T03 7TMD0406001
T04 7TMD0402002
T05 7TMD0403002
T06 7TMD0602013
T08 7TMB0622001
T09 7TME0113012
V02 7TMG0214008
V03 7TMG0214014
V08 7TMG0222006
END CAP REAR GROUNDING BAR
SCREW DISPLAY
2 PCS
4 PCS.
1 SET
1 SET
1 SET
1 PC
SECONDARY POLY V BELT
LEFT CRANK
RIGHT CRANK
1 PC
1 PC
PEDAL SET 9/16"
1 SET
1 SET
1 PC
2 PCS.
2 PCS.
1 SET
1 SET
1 PC
PEDAL STRAP SET RT & LT
POLY V BELT PRIMARY
CRANK BOLT CAP
CRANK BOLT
SIDE COVER DECAL LEFT BLUE
SIDE COVER DECAL RIGHT BLUE
SEAT RAIL DECAL
7TSZRB40DAX BOTTOM BRACKET WHEEL ASSY
7TMB0705001 MOVING WHEEL COVER
7TMZE0112119 BOLT FOOT PAD FRONT
7TMB0304020A FOOT PAD FRONT
7TMJ1208001
7TME0103022
7TME0514002
1 SET
FIXTURE SIDE COVER BOTTOM
FLATHEAD SCREW
WASHER
FRONT GROUNDING BAR ASSY.
SCREWS CONTROL BOARD
SCREW FLYWHEEL
WASHER FLYWHEEL
HOOK COVER BELT ADJ.
NYLON NUT BELT ADJ
NUT BRAKE AXEL
1 PC
1 SET
7TME0107043
7TME0104014
7TME0502092
7TMJ1245003
7TME0204010
7TME0201012
6 PCS.
6 PCS.
2 PCS.
2 PCS.
2 PCS.
1 PC
7TMJ1215008C SEAT LOCK
7tszrb40sld
seat install kit
HR WIRE SENSOR PLATE
WIRE BREAK
WATER BOTTLE CAGE
EYE BOLT BELT ADJUSTER
SPRING BELT TENSIONER
MODEL DECAL WHITE
ASSY. HARDWARE KIT
7TMC0520002
7TMC0535006
7TMB0601005
7TMJ3247001
7TME1103002
7TMG0102054
7TME0602016
1 PC
1 PC
1 PC
2 PCS.
1 SET
2 PCS.
1 SET
4 PCS.
7TSZRB40SER-1 SEAT ROLLER ASSY.
7TME0107015
7TME0502018
7TME0102047
SCREWS RAIL CAP END
WASHER REAR TUBE MOUNT
SCREW SIDE COVER
2 PCS.
3 PCS.
7TMZE0103007 SCREW SEAT LOCK
Page 53
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TR 750 PARTS DIAGRAM
After Serial # 02-RE0283C
Page 54
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TR 750 AFTER SERIAL # 02-RE0283C
NEW SEAT ASSEMBLY-1 PIECE CRANK
REF. # PART #
DESCRIPTION
QTY
AD5 7TSZRB40SAS
7TSZRB40SER-1 SEAT ROLLER ASSY.
AG1 7TSP0206006
SEAT SLIDE SET
1 SET
4 PCS.
1 SET
1 SET
1 SET
1 SET
1 SET
1 SET
16 PCS.
16 PCS.
1 PC
SEAT HANDLE BAR
AG2 7TSP0212003
CONSOLE HANDLE BAR
FRONT GROUNDING BAR ASSY.
CONSOLE ASSY.
AN1 7TSM0209004
AS1 7TMD0208006
AS1 7TSM0206008D
B26 7TME0701001
B27 7TME0107014
7TMJ3251001
BRAKE ASSY.
BRAKE ASSY-AFTER SERIAL # 02-RE1237K
C CLAMP - SIDE COVER
SCREW SIDE COVER
FIXTURE SHAFT SIDE COVER
SCREW SIDE COVER
FIXTURE SIDE COVER BOTTOM
SEAT BOTTOM
SEAT BACK
7TME0102047
7TMJ1208001
2 PCS.
1 PC
1 PC
D76 7TMB1001005
D77 7TMB1002002
D78 7TME0112013
D79 7TME0112014
D80 7TME0501006
D81 7TME0112024
D82 7TME0501007
G06 7TMB0401021
G08 7TMJ1278001
G09 7TMB06A7001
G10 7TMB0609031
G11 7TME0102069
G12 7TME0201028
1 PC
SCREW SEAT BOTTOM
SCREW SEAT BACK
4 PCS.
4 PCS.
8 PCS.
4 PCS.
4 PCS.
2 PCS.
2 SETS
2 SETS
4 PCS.
4 PCS.
4 PCS.
1 PC
WASHER SEAT BACK AND BOTTOM
SCREW SEAT HANDLE BAR
WASHER SEAT HANDLE BAR
HANDLE BAR FOAM GRIP
HANDPULSE SENSOR
HANDPULSE BRACKET
HAND PULSE END CAP
SCREW HAND PULSE
NUT HAND PULSE
H01 7TSZRB40RAL-1 SEAT RAIL ASSY.
H37 7TMZE0112042
H41 7TMB0632007A
H40 7TMZE0107015
H39 7TMB0211008
7TMJ1215008C
BOLT SEAT RAIL
RAIL CAP END
SCREW RAIL AND CAP
END CAP OF REAR SLIDE TUBE
SEAT LOCK
8 PCS.
1 PC
2 PCS.
1 PC
1 PC
7TMZE0103007
7TMB0103001
7TSZRB40RST
SCREW SEAT LOCK
TRANSPORT WHEEL
REAR STABILIZER
3 PCS.
2 PCS.
1 PC
7TMB0304006
7TME0112109
7TME0112024
7TME0502108
LEVELER
4 PCS.
4 PCS.
2 PCS.
2 PCS.
2 PCS.
1 PC
2 PCS.
1 PC
1 PC
BOLT REAR STAILIZER
BOLT TRANSPORT WHEEL
WASHER TRANSPORT WHEEL
EXTERNAL C RING TRANSPORT WHEEL
CABLE DISPLAY/CONTROL BOARD
HR WIRE SENSOR
HR WIRE SENSOR PLATE
WIRE HRC RAIL TO CONSOLE
CONTROL BOARD
7TME0902007
P01 7TMC0501027
P05 7TMC0549005
7TMC0520002
P04 7TMC0550001
7TMC0203004
1 PC
1 PC
P12 7TMC0736002
7TMC0535006
P15 7TMB06B8001
RESISTOR
WIRE BREAK
BRACKET CONTROL BOARD
Page 55
1 PC
1 PC
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P17 7TMJ1393002
7TME0102027
RESISTOR COVER
SCREW RESISTOR
NYLON NUT RESISTOR
WASHER RESISTOR
1 PC
4 PCS.
4 PCS.
4 PCS.
1 PC
7TME0204003
7TME0502082
7TMB0601005
WATER BOTTLE CAGE
Q06R 7TMB0609028
Q06L 7TMB0609026
Q07 7TMB0609035
Q08 7TME0104055
Q11 7TSZRB40SCV-L1 SIDE COVER LEFT
Q12 7TSZRB40SCV-R1 SIDE COVER RIGHT
R03 7TSZRB40PAX
R06 7TMD0602018
R17 7TME0104014
R20 7TME0502092
S01 7TMJ3247001
S02 7TMJ1245003
S03 7TME0204010
S04 7TME0201012
END CAP FRONT GROUNDING BAR RIGHT
END CAP FRONT GROUNDING BAR LEFT
END CAP REAR GROUNDING BAR
SCREW DISPLAY
1 PC
1 PC
2 PCS
4 PCS.
1 SET
1 SET
1 SET
1 PC
6 PCS.
6 PCS.
2 PCS.
2 PCS.
2 PCS.
2 PCS.
1 SET
FLYWHEEL SHAFT ASSY
SECONDARY POLY V BELT
SCREW FLYWHEEL
WASHER FLYWHEEL
EYE BOLT BELT ADJUSTER
HOOK COVER BELT ADJ.
NYLON NUT BELT ADJ
NUT BRAKE AXEL
7TSZRB40PAX-1 BOTTOM BRACKET WHEEL ASSY
7TSZRB40KIT
T04 7TSM0915027A
T05 7TMD0403002
T06 7TMD0602013
7TME1103002
V02 7TMG0214008
V03 7TMG0214014
7TMG0102054
BEARING KIT-BOTTOM BRACKET WHEEL ASSY 1 SET
PEDAL SET 1/2'' (02-XXXXXL)
PEDAL STRAP SET RT & LT
POLY V BELT PRIMARY
1 SET
1 SET
1 PC
SPRING BELT TENSIONER
SIDE COVER DECAL LEFT BLUE
SIDE COVER DECAL RIGHT BLUE
MODEL DECAL WHITE
1 SET
1 SET
1 SET
2 PCS.
1 PC
V08 7TMG0222006
7TME0602016
SEAT RAIL DECAL
ASSY. HARDWARE KIT
1 SET
Page 56
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True Fitness
Removal &
Replacement
™ 500R
™ 500U
™ 600U
™ 600R
Page 57
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TABLE OF CONTENTS
Removal and Replacement
Remove Access Covers – All Bikes
Page 59
500R
Remove Small Poly V Pulley
Remove Belt & Tensioner Assembly
Remove Crank Hub Assembly
Page 61
Page 63
Page 65
500U
Remove Small Poly V Pulley
Remove Belt & Tensioner Assembly
Remove Crank Hub Assembly
Page 68
Page 69
Page 72
600U
Remove Right Belt Poly-V Pulley
Remove Right Side Tensioner Assembly
Remove Belt & Tensioner Assembly
Remove Left Side Belt from Assembly
Remove Left Side Poly-V Wheel
Remove Crank Hub Assembly
Page 75
Page 77
Page 78
Page 81
Page 83
Page 84
600R
Remove Left Belt Poly-V Pulley
Remove Left Side Tensioner Assembly
Remove Belt & Tensioner Assembly
Remove Right Side Belt from Assembly
Remove Right Side Poly-V Wheel
Remove Crank Hub Assembly
Page 87
Page 89
Page 90
Page 93
Page 95
Page 96
Support Services 800-883-8783
Mon-Fri 8:30am-5:00pm Central Time Zone
Fax: 636-272-7148
Page 58
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Removal & Replacement
Remove Access Covers ~ 500R, 500U, 600R & 600U
Tools Required:
Pedal Wrench
Phillips Screwdriver
Step 1.
Use pedal wrench to remove
both pedals from pedal cranks.
Step 1. Remove Pedals
Note:
Left pedal loosens clockwise. Right
pedal loosens counter- clockwise.
Step 2.
Remove front cover screws and nuts.
Step 2. Remove Cover Screws
Page 59
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Removal & Replacement
Remove Access Covers ~ 500R, 500U, 600R & 600U (continued)
Note:
Electrical connections
are on 500 series bikes
only.
Step 3.
Disconnect electrical power adapter.
Step 1. Remove Electrical Connection
(500 series only).
Step 4.
Rotate crank handle forward to 2 o’clock
Position to allow removal of cover.
Step 2. Remove Cover
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Page 60
Removal & Replacement
500R
Remove Small Poly-V Pulley
Note:
Leave belt in place to
help lock pulley
Tools Required:
4 mm-Hex Wrench
Flat blade Screwdriver
Hammer Handle
Step 1.
Use hammer handle to prevent
Rotation of large wheel when
Removing pulley.
Step 1. Prevent Rotation of Fly Wheel
Step 2.
Use 4 mm wrench to loosen
set screw in pulley.
Step 2. Loosen Set Screw
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Removal & Replacement
500R
Remove Small Poly-V Pulley (continued)
Step 3.
Use 17 mm box wrench to loosen
Nut from belt tension screw.
Step 3. Loosen Nut
Step 4.
Loosen rear hub bracket screws.
Step 4. Loosen Hub Bracket Screws
Step 5.
Remove belt from belt tensioner
Assembly and wheels.
Step 5. Remove Belt
Page 62
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Removal & Replacement
500R
Remove Belt & Tensioner Assembly
Tools Required:
17 mm Box Wrench
5mm Hex Wrench
Snap Ring Pliers
Step 1.
Remove small poly-V pulley.
Step 1. Remove Small Poly-V Pulley
Step 2.
Remove keyway using flat blade
Screwdriver as required.
Step 2. Remove Keyway
Page 63
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Removal & Replacement
500R
Remove Belt & Tensioner Assembly (continued)
Step 3.
Remove snap ring from belt
Tensioner.
Step 2. Remove Snap Ring
Step 4.
Remove belt tensioner.
Step 3. Remove Belt Tensioner
Page 64
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Removal & Replacement
500R
Remove Front Hub Assembly
Tools Required:
Large Crescent Wrench
Hammer & Punch
Step 1.
Use crescent wrench to remove
Large nut on crank.
Note:
The crank nut has left-handed
threads. Turn clockwise to
loosen.
Step 1. Remove Crank Nut
Step 2.
Remove keyed washer from
under nut.
Step 2. Remove Keyed Washer
Step 3.
Use crescent wrench to remove
hex nut bearing.
Note:
The hex nut bearing has left-
handed threads. Turn
clockwise to loosen.
Step 3. Remove Hex Nut Bearing
Page 65
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Removal & Replacement
500R
Remove Front Hub Assembly (continued)
Step 4.
Use crescent wrench to remove
Large nut on crank.
Note:
Slide brake towards seat to
allow pulley to clear frame.
Step 4. Pull Hex Nut Bearing Free
Step 5.
Use crescent wrench to remove
hex nut bearing.
Step 5. Remove Large Pulley Assembly
Copyright 2001 True Fitness Technology, Inc.
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Removal & Replacement
500R
Remove Front Hub Assembly (continued)
Step 6.
Twist assembly thru frame hub.
Pull assembly until clear of frame.
Note:
Right hand thread.
Step 6. Twist Unit Thru Hub Frame
Step 7.
Use hammer & punch to loosen
spanner nut on bearing.
Step 7. Drive spanner nut off to remove bearing
Step 8.
Remove bearing and washer by
Slipping off crank.
Note:
Pulley and crank are a welded
assembly (cannot be separated).
Step 8. Remove Bearing & Washer
Page 67
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Removal & Replacement
500U
Remove Small Poly-V Pulley
Note:
Leave belt in place to
help lock pulley
Tools Required:
4 mm-Hex Wrench
Flat blade Screwdriver
Hammer Handle
Step 1.
Use hammer handle to prevent
Rotation of large wheel when
Removing pulley.
Caution!
Step 1. Prevent Rotation of Fly Wheel
Take care not damage outer
surface of flywheel on brake
assembly.
Step 2.
Use 4 mm wrench to loosen
set screw in pulley.
Step 2. Loosen Set Screw
Page 68
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Removal & Replacement
500U
Remove Belt & Tensioner Assembly
Tools Required:
17 mm Box Wrench
5 mm-Hex Wrench
Snap Ring Pliers
Step 1.
Remove small poly-v pulley.
Step 1. Remove Small Poly-v Wheel
Step 2.
Remove keyway, using flat blade
Screwdriver as required.
Step 2. Remove keyway
Copyright 2001 True Fitness Technology, Inc
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Removal & Replacement
500U
Remove Belt & Tensioner Assembly (continued)
Step 3.
Use 17 mm box wrench to loosen
Nut from belt tensioning screw.
Step 3. Prevent Wheel Rotation
Step 4.
Use 5 mm hex wrench to loosen
Rear hub bracket screws.
Step 4. Loosen setscrew
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Removal & Replacement
500U
Remove Belt & Tensioner Assembly (continued)
Step 5.
Remove belt from belt tensioner
Assembly and wheels.
Step 5. Remove Belt
Step 6.
Remove snap ring from belt
tensioner.
Step 6. Remove Snap Ring.
Step 7.
Remove belt tensioner.
Step 7. Remove belt tensioner
Copyright 2001 True Fitness Technology, Inc
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Removal & Replacement
500U
Remove Crank Hub Assembly
Tools Required:
Large Crescent Wrench
Rubber Mallet
Flat Blade Screwdriver
Step 1.
Use crescent wrench to remove
Large nut on crank.
Step 1. Remove Crank Nut.
Note:
The crank nut has left-handed
threads. Turn clockwise to loosen.
Step 2.
Remove keyed washer from
under nut.
Step 2. Remove Keyed Washer
Step 3.
Use crescent wrench to remove
hex nut bearing. Use rubber mallet
to knock out the shaft pulley assembly.
Note:
The Hex nut bearing has left-
handed threads. Turn clockwise to
loosen.
Step 3. Remove Hex Nut Bearing
Page 72
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Removal & Replacement
500U
Remove Crank Hub Assembly (continued)
Note:
A flat blade screwdriver may be
used to pry hub from frame.
Step 4.
Pull hex nut bearing clear of frame
Hub.
Step 4. Pull Hex Nut Bearing Free.
Step 5.
Pull large pulley until bearing clears
Frame.
Step 4. Pull Hex Nut Bearing Free.
Step 6.
Twist assembly thru frame hub.
Pull assembly until clear of frame.
Step 5. Twist Unit Thru Hub Frame.
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Removal & Replacement
500U
Remove Crank Hub Assembly (continued)
Step 7.
Use hammer and punch to loosen
spanner nut on bearing.
Note:
The spanner nut has right-
handed threads. Turn
counter-clockwise to loosen.
Step 7. Drive Spanner Nut Off to Remove Bearing
Step 8.
Remove bearing & washer by
slipping off crank.
Note:
Pulley and crank are a welded
assembly (cannot be separated).
Step 8. Remove Bearing & Washer
Page 74
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Removal & Replacement
600U
Remove Right Belt Poly-V Wheel
Tools Required:
Pliers
Snap Ring Pliers
Step 1.
Use pliers or needle nose pliers to
remove the belt tensioning spring
Step 1. Belt Tensioning Spring
Step 2.
Remove the belt.
Step 2. Remove Belt
Copyright 2001 True Fitness Technology, Inc.
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Removal & Replacement
600U
Remove Right Belt Poly-V Wheel (continued).
Step 3.
Use snap ring pliers to pry snap
ring from center of small poly-V
pulley.
Step 3. Prying with snap ring pliers
Step 4.
Remove the snap ring and washers.
Step 4. Remove the snap ring and washers
Step 5.
Remove the small poly-V pulley.
Step 5. Remove the small poly-V pulley
Page 76
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Removal & Replacement
600U
Remove Right Side Tensioner Assembly
Tools Required:
Snap Ring Pliers
Step 1.
Remove snap ring.
Step 1. Remove Snap Ring
Step 2.
Slide tensioner assembly off pivot
shaft.
Note:
Frame is slotted to allow
brake bracket to slide when
bolts are loose.
Step 2. Slide Tensioner Assembly
Copyright 2001 True Fitness Technology, Inc.
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Removal & Replacement
600U
Remove Belt & Tensioner Assembly
Tools Required:
6 mm Hex Wrench
13 mm Open-End Wrench
Hammer Handle
Step 1.
Use 6 mm hex wrench to remove
brake bracket locking screw.
Step 1. Remove Locking Screw
Step 2.
Use 13 mm open-end wrench to
loosen the 4 bolts holding the
brake bracket to the frame.
Note:
Frame is slotted to allow
brake bracket to slide when
bolts are loose.
Step 2. Loosen Bracket Bolts
Copyright 2001 True Fitness Technology, Inc.
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Removal & Replacement
600U
Remove Belt & Tensioner Assembly (continued)
Step 3.
Use hammer handle to pry the
brake and bracket assembly
toward the back of the bike to
loosen the belt.
Step 3. Pry on Brake to Loosen Belt.
Step 4.
Remove brake belt from larger
poly-V wheel.
Step 4. Remove Belt
Copyright 2001 True Fitness Technology, Inc.
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Removal & Replacement
600U & 600R
Remove Belt & Tensioner Assembly (continued)
Step 5.
Disconnect wiring harness from
brake.
Step 5. Disconnect Wiring Harness.
Step 6.
Remove the loosened bottom
screws.
Step 6. Remove Loosened Screws
Step 7.
Remove brake and belt assembly.
Step 7. Remove Brake & Belt Assembly
Page 80
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Removal & Replacement
600U
Remove Left Side Belt From Assembly
Tools Required:
Internal & External Snap
Ring Pliers
Flat Blade Screwdriver
Step 1.
Remove snap ring.
Step 1. Remove Snap Ring.
Step 2.
Carefully pry bearing out of housing.
Step 2. Pry Bearing Out of Housing
Step 3.
Remove inner snap ring.
Step 7. Remove Inner Snap Ring
Copyright 2001 True Fitness Technology, Inc.
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Removal & Replacement
600U
Remove Left Side Belt From Assembly (continued)
Step 4.
Use 4 mm Hex Wrench to remove
Screws and washers holding
Brake to bracket.
Step 4. Remove Screws & Washers.
Step 5.
Remove brake bracket until belt
Can be removed.
Step 5. Remove Bracket to Check Belt
Page 82
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Removal & Replacement
600U
Remove Left Side Poly-V Wheel
Tools Required:
External Snap Ring Pliers
Step 1.
Remove snap ring from shaft on
Right side.
Step 1. Remove Snap Ring on Right Side
Step 2.
Slide shaft through bearing in
Frame to remove pulley and shaft
assembly.
Note:
Step 2. Slide Shaft Through Frame
Crank not welded to pulley so
(1) extra step showing
separating these for 600U set.
Page 83
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Removal & Replacement
600U
Remove Crank Hub Assembly
Tools Required:
Large Crescent Wrench
Rubber Mallet
Flat Blade Screwdriver
Step 1.
Use crescent wrench to remove
Large nut on crank.
Step 1. Remove Crank Nut.
Note:
The crank nut has left-handed
threads. Turn clockwise to loosen.
Step 2.
Remove keyed washer from
under nut.
Step 2. Remove Keyed Washer
Step 3.
Use crescent wrench to remove
hex nut bearing. Use rubber mallet
to knock out the shaft pulley assembly.
Note:
The Hex nut bearing has left-
handed threads. Turn clockwise to
loosen.
Step 3. Remove Hex Nut Bearing
Page 84
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Removal & Replacement
600U
Remove Crank Hub Assembly (continued)
Note:
A flat blade screwdriver may be
used to pry hub from frame.
Step 4.
Pull hex nut bearing clear of frame
Hub.
Step 4. Pull Hex Nut Bearing Free.
Step 5.
Pull large pulley until bearing clears
Frame.
Step 5. Remove Large Pulley Assembly.
Step 6.
Twist assembly thru frame hub.
Pull assembly until clear of frame.
Step 6. Twist Unit Thru Hub Frame.
Copyright 2001 True Fitness Technology, Inc.
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Removal & Replacement
600U
Remove Crank Hub Assembly (continued)
Step 7.
Use hammer and punch to loosen
spanner nut on bearing.
Note:
The spanner nut has right-
handed threads. Turn
counter-clockwise to loosen.
Step 7. Drive Spanner Nut Off to Remove Bearing
Step 8.
Remove bearing & washer by
slipping off crank.
Note:
Pulley and crank are a welded
assembly (cannot be separated).
Step 8. Remove Bearing & Washer
Step 9.
Pull crank thru pulley to remove.
Step 9. Pull Crank Thru Pulley to Remove
Copyright 2001 True Fitness Technology, Inc
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Removal & Replacement
600R
Remove Left Belt Poly-V Pulley
Tools Required:
Pliers
Snap Ring Pliers
Step 1.
Use pliers, or needle nose pliers,
to remove the belt tensioning
spring.
Step 1. Remove Belt Tensioning Spring
Step 2.
Remove the belt.
Step 2. Remove Belt
Copyright 2001 True Fitness Technology, Inc.
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Removal & Replacement
600
Remove Poly-V Wheel Pulley (continued)
Step 3.
Use snap ring pliers to snap
Ring from center of small poly-V
pulley.
Step 1. Prying with Snap Ring Pliers.
Step 4.
Remove the small poly-V pulley.
Step 2. Remove Small Poly-V Pulley
Page 88
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Removal & Replacement
600R
Remove Left Side Tensioner Assembly
Tools Required:
Snap Ring Pliers
Step 1.
Remove snap ring.
Step 1. Remove Snap Ring
Step 2.
Slide tensioner assembly off pivot
shaft.
Note:
Frame is slotted to allow
brake bracket to slide when
bolts are loose.
Step 2. Slide Tensioner Assembly
Copyright 2001 True Fitness Technology, Inc.
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Removal & Replacement
600R
Remove Belt & Tensioner Assembly
Tools Required:
6 mm-Hex Wrench
13 mm Open-End Wrench
Hammer Handle
Step 1.
Use 6 mm hex wrench to remove
brake bracket locking screw.
Step 1. Remove Locking Screw
Step 2.
Use 13 mm open-end wrench to
loosen the 4 bolts holding the
brake bracket to the frame.
Note:
Frame is slotted to allow
brake bracket to slide when
bolts are loose.
Step 2. Loosen Bracket Bolts
Page 90
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Removal & Replacement
600R
Remove Belt & Tensioner Assembly (continued)
Step 3.
Use hammer handle to pry the
brake and bracket assembly
toward the back of the bike to
loosen the belt.
Step 3. Pry on Brake to Loosen Belt.
Step 4.
Remove brake belt from larger
poly-V wheel.
Step 4. Remove Belt
Page 91
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Removal & Replacement
600U & 600R
Remove Belt & Tensioner Assembly (continued)
Step 5.
Disconnect wiring harness from
brake.
Step 5. Disconnect Wiring Harness.
Step 6.
Remove the loosened bottom
screws.
Step 6. Remove Loosened Screws
Step 7.
Remove brake and belt assembly.
Step 7. Remove Brake & Belt Assembly
Copyright 2001 True Fitness Technology, Inc.
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Removal & Replacement
600R
Remove Right Side Belt From Assembly
Tools Required:
Internal & External Snap
Ring Pliers
Flat Blade Screwdriver
Step 1.
Remove snap ring.
Step 1. Remove Snap Ring.
Step 2.
Carefully pry bearing out of housing.
Step 2. Pry Bearing Out of Housing
Step 3.
Remove inner snap ring.
Step 7. Remove Inner Snap Ring
Copyright 2001 True Fitness Technology, Inc.
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Removal & Replacement
600R
Remove Right Side Belt From Assembly (continued)
Step 4.
Use 4 mm Hex Wrench to remove
Screws and washers holding
Brake to bracket.
Step 4. Remove Screws & Washers.
Step 5.
Remove brake bracket until belt
Can be removed.
Step 5. Remove Bracket to Check Belt
Page 94
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Removal & Replacement
600R
Remove Right Side Poly-V Wheel
Tools Required:
External Snap Ring Pliers
Step 1.
Remove snap ring from shaft on
Right side.
Step 1. Remove Shaft Snap Ring on Right Side
Step 2.
Slide shaft through bearing in
Frame to remove pulley and shaft
assembly.
Step 2. Slide Shaft Through Frame
Note:
Crank not welded to pulley so
(1) extra step showing
separating these for 600U set.
Page 95
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Removal & Replacement
600R
Remove Crank Hub Assembly
Tools Required:
Large Crescent Wrench
Rubber Mallet
Flat Blade Screwdriver
Step 1.
Use crescent wrench to remove
Large nut on crank.
Step 1. Remove Crank Nut.
Note:
The crank nut has left-handed
threads. Turn clockwise to loosen.
Step 2.
Remove keyed washer from
under nut.
Step 2. Remove Keyed Washer
Step 3.
Use crescent wrench to remove
hex nut bearing. Use rubber mallet
to knock out the shaft pulley assembly.
Note:
The Hex nut bearing has left-
handed threads. Turn clockwise to
loosen.
Step 3. Remove Hex Nut Bearing
Page 96
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Removal & Replacement
600R
Remove Crank Hub Assembly (continued)
Note:
A flat blade screwdriver may be
used to pry hub from frame.
Step 4.
Pull hex nut bearing clear of frame
Hub.
Step 4. Pull Hex Nut Bearing Free.
Step 5.
Pull large pulley until bearing clears
Frame.
Step 5. Remove Large Pulley Assembly.
Step 6.
Twist assembly thru frame hub.
Pull assembly until clear of frame.
Step 6. Twist Unit Thru Hub Frame.
Page 97
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Removal & Replacement
600R
Remove Crank Hub Assembly (continued)
Step 7.
Use hammer and punch to loosen
spanner nut on bearing.
Note:
The spanner nut has right-
handed threads. Turn
counter-clockwise to loosen.
Step 7. Drive Spanner Nut Off to Remove Bearing
Step 8.
Remove bearing & washer by
slipping off crank.
Note:
Pulley and crank are a welded
assembly (cannot be separated).
Step 8. Remove Bearing & Washer
Step 9.
Pull crank thru pulley to remove..
Step 9. Pull Crank Thru Pulley to Remove
Copyright 2001 True Fitness Technology, Inc
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