SCHWINN AIR SYSTEMS

AIRDYNE EVOLUTION COMP

16

18 79 17 56 71

40

74 9

35 21

37 48

62 72

68 48

58 55 57

73

36

67 12

42

49 10

55

14

58 57 52 51 11

77 76 75 74

63

13 TECHNICAL SERVICE

(800) 864-1270

FAX (877) 686-6466

SCHWINN AIR SYSTEMS

AIRDYNE EVOLUTION COMP

80

14 TECHNICAL SERVICE

(800) 864-1270

FAX (877) 686-6466

SCHWINN AIR SYSTEMS

PART# REF# GRAPHITE

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AIRDYNE EVOLUTION COMP 1 2 3 4 5 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 42 43 44 45 46 48 49 51 52 53 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80

2002 DARK GRAY DESCRIPTION (CHARCOAL)

95501 ○ ○ 91322 ○ ○ 95502 ○ ○ 90830 ○ ○ 97990 ○ ○ 95503 ○ ○ 91312 ○ ○ 95544 95545 90485 ○ ○ 90489 ○ ○ 90484 ○ ○ 90804 ○ ○ 93079 ○ ○ 91313 ○ ○ 98063 ○ ○ 95507 ○ ○ 95509 ○ ○ 98069 ○ ○ 95510 ○ ○ 95547 ○ ○ 95536 ○ ○ 95537 ○ ○ 95533 ○ ○ 91700 ○ ○ 95539 ○ ○ 91311 ○ ○ 91750 ○ ○ 91055 ○ ○ 95540 ○ ○ 95513 ○ ○ 95514 ○ ○ 98057 ○ ○ 98058 ○ ○ 84994 ○ ○ 95546 ○ ○ 50428 ○ ○ 95542 ○ ○ 90481 ○ ○ 95543 ○ ○ 95531 ○ ○ 95529 ○ ○ 90873 ○ ○ 91626 ○ ○ 98350 ○ ○ 90482 ○ ○ 98198 ○ ○ 98100 ○ ○ 91652 ○ ○ ○ ○ INCL W/18 84995 ○ ○ 98190 ○ ○ 50372 ○ ○ 95530 ○ ○ 98191 ○ ○ 95517 ○ ○ 90483 ○ ○ 95520 ○ ○ 95521 ○ ○ 95518 ○ ○ 98053 98054 33157 ○ ○ 90837 ○ ○ 98052 001-7948 98067 ○ ○ 95496 ○ ○ 95497 ○ ○ 95498 ○ ○ 95499 ○ ○ 98078 ○ ○ 95535 ○ ○ 97990 ○ ○ 97997 ○ ○ 98077 ○ ○ 92707 ○ ○ 74025 ○ ○

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98715 98711

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98712 98714 ○

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98713 98710 ○

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FAN HUB ASSEMBLY BELT PROTECTOR FAN PROTECTOR W/ MAGNET EARLIER MODELS ○ BELT TENSIONER EYEBOLT SET OF THE EVOLUTION ○ CHAIN TENSIONER ASSEMBLY USED THE SAME ○ 80T PULLEY BOTTOM BRACKET AND ○ 22T PULLEY CRANK ARMS AS THE LEFT LEVER ARM, GRAPHITE AIRDYNE 4 . THIS MODEL RIGHT LEVER ARM, GRAPHITE ○ USES A SQUARE BOTTOM FOOT REST GRIP PAIR BRACKET AXLE INSTEAD ○ LEVER ARM GRIPS & PLUGS SET ○ OF A WEDGE PIN. LEVER ARM PIVOT BOLT ○ BE SURE TO CHECK PEDALS, PAIR ○ WHICH MODEL YOU HAVE SEAT ○ BEFORE ORDERING. SEAT POST ○ COMPUTER (NEW LARGE WINDOW CNSL- 002-5179) ○ SENSOR MOUNTING BRACKET ○ FAN PROTECTOR MOUNTING BRACKET ○ SEAT POST STOP ○ 13T INTERMEDIATE SPROCKET OLD ○ BEARING, 10/19 X 5.5/7T ○ CONNECTING ARM ○ RIGHT CRANK ARM ○ BOTTOM BRACKET, UN52 68 X 122.5 ○ INTERMEDIATE BOTTOM BRACKET 68 X 113 ○ LEFT CRANK ARM ○ PULLEY LOCKNUT LEFT HAND THREAD ○ FLANGE BOLT ○ ROLLER BEARING W/ SNAP RING NEW ○ RIGHT ECCENTRIC CRANK W/ 46 TOOTH SPROCKET ○ DRIVE BELT ○ CHAIN ○ LEFT SHROUD ○ RIGHT SHROUD ○ T-HANDLE POP PIN ○ CRANK BOLT WITH DUST CAP ○ TINNERMAN NUT, BAG OF 10 ○ SEAT POST BUSHING SET ○ LEVER ARM OILITE BUSHING ○ LEFT ECCENTRIC CRANK ○ FLANGE FOR 80 TOOTH PULLEY ○ TRANSPORT WHEEL ASSEMBLY ○ AIRDYNE TRANSPORT BRACKET HOOK BOLT ○ STABILIZER END CAP ○ SHROUD MOUNTING HARDWARE SET ○ LEVER ARM LOCKNUT WASHER ○ LEVER ARM NYLON WASHER ○ NYLON WASHER SPACER BLACK ○ LEVELER LOCKNUT ○ COMPUTER MOUNTING HARDWARE ○ LEVELER ○ FRAME SUPPORT BOLT SET ○ FAN CAGE SCREWS, BAG OF TEN ○ FAN ○ 80 TOOTH PULLEY HARDWARE ○ LOCK KNOB W/ SPRING ○ LEVER ARM LOCKNUT ○ LEFT FAN CAGE ○ RIGHT FAN CAGE ○ FAN MOUNTING HARDWARE SET FRONT STABILIZER REAR STABILIZER ○ FAN AXLE NUT SET ○ SENSOR COMPUTER MAST FRAME ○ CAM WASHER ○ ALLEN BOLT ○ WASHER ○ SPACER ○ LOCK NUT ○ CONSOLE MAST HARDWARE ○ COMPUTER WIRE ○ TENSIONER SPRING ○ HARDWARE PACK ○ DECAL SET ○ OWNERS MANUAL ○ CRANK REMOVAL TOOL

TECHNICAL SERVICE

(800) 864-1270

FAX (877) 868-6466

15

SCHWINN AIR SYSTEMS

AIRDYNE EVOLUTION COMP ELECTRONIC TROUBLESHOOTING 1. PROBLEM:

The LCD shows no display

SOLUTION: a. Make sure the batteries are seated properly, installed correctly (+/-), and the correct voltage. b. Check the battery contacts for oxidation or corrosion. c. Check all connections. d. Inspect the cable for breaks or bad connections. e. If all of the above are ok, replace the computer.

NOTE:

2. PROBLEM:

We have seen a number of PC boards damaged by use of mounting screws other than those supplied with the unit. This is not a manufacturer's defect and does not qualify for warranty replacement.

The computer will not start

SOLUTION: a. Replace the batteries. b. Make sure the gap between the sensor and the fan wheel magnet is between 2 and 4mm. If the gap is correct, see step c. c. If no signal is received by the computer, use a multimeter to check the continuity of the sensor and then the sensor wire. If both the sensor and wire are functioning, replace the computer

16 TECHNICAL SERVICE

(800) 864-1270

FAX (877) 868-6466

SCHWINN AIR SYSTEMS

AIRDYNE EVOLUTION COMP ELECTRONIC TROUBLESHOOTING (continued) 3. PROBLEM:

No RPM reading

SOLUTION: a. Check all connections. b. Without removing the wire, remove the sensor from the mounting bracket and pass a hand held magnet over the surface of the sensor. If a signal is received by the com puter, remount the sensor and make sure the gap between the flywheel magnet and the sensor is between 2 and 4mm. c. If no signal is received by the computer, use a multimeter to check the continuity of the sensor and then the sensor wire. If both the sensor and wire are functioning, replace the computer

4. PROBLEM:

Computer does not read properly

SOLUTION: a. Check all connections. b. Make sure local sea level elevation is entered. Press and hold the upper select button for fifteen seconds then use up button to increase the elevation to the proper level. Press select to exit.

MECHANICAL TROUBLESHOOTING 1. PROBLEM:

If you have vibration

SOLUTION: a. Reduce belt tension by first loosening the axle nuts (A) and then loosening the tensioner nuts (B). b. Check the hub for loose races or a rough bearing.

17 TECHNICAL SERVICE

(800) 864-1270

FAX (877) 868-6466

SCHWINN AIR SYSTEMS

AIRDYNE EVOLUTION COMP MECHANICAL TROUBLESHOOTING (continued) 2. PROBLEM:

If you have squeaking, tapping or rubbing noises

SOLUTION: a. See if the fan is rubbing the cage. b. Check chain tension device. c. Lube chain. d. Lube pivot points. e. Align the belt using the fan tensioner. f. Check all bearings for binding or play.

3. PROBLEM:

Pedals feel loose

SOLUTION: a. Make sure the pedals are tightly screwed into the crank arms. b. Make sure the crank bolts on both crank arms and eccentrics are tight. c. Make sure the square tapered extensions are tightly bolted to the eccentrics. d. Make sure the square openings in both the crank arms and eccentrics have not been rounded out. This problem is caused when the bike has been ridden with loose arms. e. Make sure the the bottom bracket is tight in the frame and bearings operate smoothly.

4. PROBLEM:

Lever arm feels loose

SOLUTION: a. Check Oilite bushing for excessive wear. b. Tighten the pivot bolt to eliminate play. c. Check threads on pivot bolt. d. Look for cracks on frame at pivot area.

18 TECHNICAL SERVICE

(800) 864-1270

FAX (877) 868-6466

SCHWINN AIR SYSTEMS

AIRDYNE EVOLUTION COMP MECHANICAL TROUBLESHOOTING (continued) 5. PROBLEM:

Connecting arm feels sloppy or loose

SOLUTION: a. Check the bearings for excessive play. b. Add another spacer to the connection at the eccentric.

6. PROBLEM:

Belt squeaking or out of alignment

SOLUTION: a. Adjust tension and alignment at fan hub.

NOTES

FOR MORE DETAILED INFORMATION CONTACT TECHNICAL SUPPORT AT 1-800-864-1270 19 TECHNICAL SERVICE

(800) 864-1270

FAX (877) 868-6466

SCHWINN AIR SYSTEMS

AIRDYNE EVOLUTION COMP MAINTENANCE

AirDyne Evolution Comp YST Bottom Bracket Replacement Assembly Instructions Tools Required: 2 - Sealed Cartridge Bottom Bracket Tools Torque Wrench 8 mm Allen Wrench 6 mm Allen Wrench 1/2" Wrench Phillips Head Screw Driver Crank Puller

Step 1:

A

Using an 8mm Allen Wrench, remove the bolts (A) from the left and right side cranks. Using a Crank Puller, remove both the left and right side cranks (B). B

A

B

Step 2:

E

G

Using a ½" Wrench and a 6 mm Allen Wrench, remove nylock nut (A) from the shoulder bolt (B) on the left and right side pivot arms. Carefully remove the shoulder bolt (B), 2-thick washers (spacers) (C) and 1-additional washer (D) from the pivot arms (E). Remove the connecting arms (F) from the eccentrics (G) and the pivot arms (E). Rest the two pivot arms (E) in a forward position. F

A

F

A

B

B

E C

D

D

Page 1

20 TECHNICAL SERVICE

(800) 864-1270

FAX (877) 868-6466

C

SCHWINN AIR SYSTEMS

AIRDYNE EVOLUTION COMP MAINTENANCE (continued) E

Step 3:

Using a Phillips Head Screw Driver, remove the 3-screws (A) and washers (C) holding the left side of the shroud (D), and the 4-screws (A) and washers (C) holding the right side of the shroud (B) in place. Carefully remove the shrouds (B+D) from the bike, ensuring to retain the nut (E) that holds the 4th screw (F) in place.

A

C

D

F

B

C

A

A

Step 4:

A

B

Using an 8mm Allen Wrench, remove the bolts (A) from the left (B) and right side Eccentrics/Chain Ring (C). Using a Crank Puller, remove the left side Eccentric (B), and loosen the right side Eccentric/Chain Ring (C). Carefully remove the chain (D) from the Eccentric/ Chain Ring (C), and let the chain (D) rest on the intermediate drive pulley (E).

D

E

A

C

Step 5:

Using a Cartridge Bottom Bracket Tool, remove the BB from the damaged Airdyne Evolution Comp. Turn the Left side (A) of the damaged Bottom Bracket counter-clockwise to remove it, and then the right side (B) of the bottom bracket clockwise to remove it..

B

Step 6:

Unthread the left (non-drive) side collar from the YST Bottom Bracket. Insert the YST bottom bracket in the right (drive) side of the Airdyne. Hand thread the left (non-drive) side of the YST BB in the left side of the Airdyne. Using 2-Cartridge Bottom Bracket Tools and a torque wrench, thread the YST BB into itself, to a torque of 40 ft-lb.

Step 7:

Follow Step 4 through Step 1, in reverse order, to re-assemble AirDyne

Page 2 TECHNICAL SERVICE

(800) 864-1270

21 FAX (877) 868-6466