Schwinn® & Schwinn® A.C.™ Classic, Sport & Performance Schwinn® AC™ Performance Smart Release™ Enhancement If you need assistance, please call Nautilus® Customer Service at 1-800-628-8458. This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and understand all the warnings on this machine.

Tools

• Extra long 1/2" drive ratchet • 17mm socket • Protective gloves • 4 prong BMX freewheel removal tool • Large steel hammer • Eye protection • Adjustable Wrench • Loctite Quickstix 7088 and Loctite Quickstix 268

• Medium Philips Screwdriver • 2.5 mm Allen wrench • 3mm Allen wrench • 6mm Allen wrench • 7mm Allen wrench • 8mm Allen wrench • 14mm socket and driver • 1" socket, 1/2" drive

NOTE: Only the quickstix formula should be used as it is a semisolid. Using liquid thread sealing materials will not yield desirable results.

Preparation • Remove all Philips screws that hold on the outer chain guard • Remove chain guard, this is easiest with the crank pointing straight down • Remove the 14mm axle nuts • Remove the 3mm chain tension screws from the front of the bike • Remove the 6 Philips screws that hold both sweat protectors • Remove the 2 black tension blocks • Remove the pivot hardware using the 8mm Allen (hex) wrench and the 17mm socket. After removing the 17mm nut and small silver bushing behind the nut, tap the 8mm hex bolt a couple of times to loosen it.

Remove the bolt from the non-drive side of the frame.

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Schwinn® & Schwinn® A.C.™ Classic, Sport & Performance Schwinn® AC™ Performance Smart Release™ Enhancement Place a thick rag or other protective material over the frame tube directly below the flywheel to protect the frame from the flywheel during the removal process.

Remove the chain from the crank; pull it forward and out of the way of the axle. Let it hang on the frame tab, OFF of the flywheel sprocket and out of the way of the axle.

Pull the fly wheel back as far as possible towards the very rear of the axle tab by sliding the flywheel rearward until it reaches the hooked end of the dropout.

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Schwinn® & Schwinn® A.C.™ Classic, Sport & Performance Schwinn® AC™ Performance Smart Release™ Enhancement Standing over the bike, grab hold of the flywheel with both hands (griping the cast iron center portion of the flywheel). Lift up and back against the pivot spring pressure that is applied to the E-brake pad and then the flywheel. There is enough movement in the free brake mechanism to allow the flywheel to clear the drop-out tab.

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Schwinn® & Schwinn® A.C.™ Classic, Sport & Performance Schwinn® AC™ Performance Smart Release™ Enhancement This will cause the aluminum ring on the flywheel to make contact with the back end of the Emergency Stop brake pad within the magnetic brake assembly. Lifting pressure on the brake assembly can flex against the spring allowing the flywheel to clear the drop-out tabs and it can be lowered to a resting position on the frame tube below the flywheel.

Carefully rotate the flywheels so that the Smart Release Mechanism clears the inner chain guard. Once clear of the chain guard pull the flywheel back and toward the non-drive side where it can rest on the ground. Be careful as the flywheel is heavy and should not be dropped.

The above procedure should be executed in reverse after the flywheel is serviced.

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Schwinn® & Schwinn® A.C.™ Classic, Sport & Performance Schwinn® AC™ Performance Smart Release™ Enhancement Clutch Disassembly First, release all pressure from the SR locking ring by turning it clockwise until it bottoms out on the flywheel threads. This will reduce the torque required to move the SR mechanism. Remove flywheel from bike. Place BMX freewheel tool on the Smart Release™ system. Keep the freewheel tool in place with one of the axle nuts. Do not overtighten the axle nut against the 4-prong bmx freewheel removal tool. Only finger tighten.

Place an axle nut on the end of the axle that contacts the ground to protect the threads if setting the flywheel on the ground.

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Schwinn® & Schwinn® A.C.™ Classic, Sport & Performance Schwinn® AC™ Performance Smart Release™ Enhancement Place the ratchet at 9 o’clock, use one hand to stabilize the ratchet and strike in a downward direction with a medium rubber mallet. If the system cannot be “broken” loose with the rubber mallet, a large metal hammer may be needed. Note: The Smart Release™ assembly has never been adjusted or removed so it can be quite difficult to loosen. This job will be easier with the aid of another person.

Use a 6-7mm Allen wrench to keep the adjustment ring flat against the face of the flywheel and separate from the SR mechanism. If the adjustment ring is allowed to turn with the clutch, it will bind together tightening the SR system.

Remove the Clutch from the flywheel, leaving the adjustment ring and conical washer on the flywheel.

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Schwinn® & Schwinn® A.C.™ Classic, Sport & Performance Schwinn® AC™ Performance Smart Release™ Enhancement Replace the black plastic rings with white nylon rings. During reassembly, ensure that the grooves of the interface plates are facing the white nylon rings. Figure A shows black rings orientation to assembly. Figure B shows the white rings installed.

Never leave the bike unattended while it is disassembled.

Figure A

Figure B

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Schwinn® & Schwinn® A.C.™ Classic, Sport & Performance Schwinn® AC™ Performance Smart Release™ Enhancement Remove the SR conical washer and SR locking ring from flywheel Obtain Loctite Quickstix 7088 and Loctite Quickstix 268 from a local retailer. NOTE: Only the quickstix formula should be used as it is a semisolid. Using liquid thread sealing materials will not yield desirable results.

Each material is applied to 1/2 the thread circumference in roughly equal amounts. After application, the locking ring should be threaded down to bottom out, and then rotated a few turns in both directions to "mix" the compounds. From this point the curing will start to take place and initial set is as soon as 20 min with full cure in 24 hours. Service providers need to continue the rework and get the tension on the SR set within 20 or so minutes for best results. The bike should not be ridden for 24 hours for best results. When applying the materials we only want to apply it to the locking ring threads, any over application to the outer threads where the SR mechanism sits should be wiped off.

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Schwinn® & Schwinn® A.C.™ Classic, Sport & Performance Schwinn® AC™ Performance Smart Release™ Enhancement Smart Release™ Re-Assembly Place the conical spring washer onto the flywheel with the flat portion of the spring washer facing the clutch assembly. Ensure that the point of the conical washer is facing the flywheel. There is a clutch assembly binder that is screwed inside the cylinder of the outer plate. When the clutch is disassembled, this mechanism sometimes turns into the cylinder. If this binder (dark metal with two slots) isn’t flush with the face of the outside interface ring and you attempt to re-install the clutch, it will hang up on axle nuts before it is completely screwed into place. NOTE: The flywheel sprocket is unidirectional. This means that there is only one correct way to put the flywheel sprocket and clutch plates together.

The best way to check that the clutch parts are in the right order is to hold the hub sprocket in one hand and place the flanged hub lock ring through the outside of the hub sprocket. Picture it as if it were on the flywheel, the outer interface plate should spin clockwise. Tighten by hand as far as possible, then use the freewheel tool and a 1" socket and large ratchet 1/2" driver to tighten the system down.

Ensure the internal lock ring on the outside clutch plate is screwed out almost flush with the outer interface ring. If the internal lock ring is screwed into the outer interface plate it will prevent the clutch from being installed correctly and will cause the clutch to drag on the frame drop-out tabs. Remember to use the axle nut to hold the freewheel tool to the system to avoid slippage. Use the mallet to strike the ratchet. The system must be very tight and locked down to avoid the possibility of loosening during use. The recommended torque foot pound (TFP) level for the clutch on the flywheel is 65-75 ft./lbs. Once the Smart Release™ is locked down completely, you are ready for reassembly of the bike.

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Schwinn® & Schwinn® A.C.™ Classic, Sport & Performance Schwinn® AC™ Performance Smart Release™ Enhancement Flywheel Installation Replace the chain around the axle and place the flywheel back onto the frame. During reinstallation of the flywheel assembly, reverse the process used to remove the flywheel, being very careful to assure the Aluminum disc on the flywheel is inserted between the magnets before applying the upward pressure to the assembly (SR Alignment Figure)

This, in turn, compresses the brake mechanism against the pivot spring. Lift the flywheel up and forward until it clears the rear tabs on the drop-out and can be fully supported by the drop-outs

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Schwinn® & Schwinn® A.C.™ Classic, Sport & Performance Schwinn® AC™ Performance Smart Release™ Enhancement

Replace each tension bracket to the axles. It is advisable to lubricate the 3mm chain tension fasteners before screwing them into the tension blocks. Re-thread the chain tension bolts until the chain is tight. Align the flywheel with the bottom of the frame, adjust the chain to the correct tension and lock down the 14mm axle nuts. Test the tension on the clutch. NOTE: If the clutch slips forward without turning the flywheel while attempting to engage the drive train, the flywheel sprocket has been installed backwards.

Refer to the Smart Release™adjustment specifications either supplied with your Schwinn AC series bikes or call Schwinn® at 1-800-NAUTILUS and request that the material be emailed or sent to you. Adjusting the load on the “New” Smart Release™ requires a special tool from Schwinn® Part #71709.

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Schwinn® & Schwinn® A.C.™ Classic, Sport & Performance Schwinn® AC™ Performance Smart Release™ Enhancement Flywheel Alignment / Chain Tensioning Alignment of the flywheel is best defined by the looking through the brake mechanism from the front to assure the flywheel disc is parallel to the magnets. The image below shows proper alignment.

Use the distance between the magnets as an alignment guide to check flywheel alignment. Loosen the axle nuts before you adjust the chain using a 3/8" driver with a 15mm socket. Failure to do so will damage threads on tension adjusters and alignment plates. Always tighten axle nuts when finished. Chain adjustment is easiest while on the bike. Put the pedals in a horizontal position, stand on the pedals and rock back and forth about a quarter to a half inch. Next, roll the crank around 180 degrees and do the same test. You are testing chain tension at two places. Chain wheels are rarely perfectly round and, quite often, not straight. When you stand on the pedals and rock back and forth, it will not be unusual at one of the two test points to feel a very slight amount of play. If you feel play at both points, then you need to adjust. A near perfect adjustment usually means there’s a little play at only one of the two test points! While on the bike lean forward and examine the flywheel alignment first. Then check chain tension at the two rotation points. Remember to loosen the axle nuts before you attempt to do chain adjustments and Always tighten axle nuts when finished. You can now test ride the bike. If you over tighten the chain, you will get a rough or grinding feeling. Never put hands into or near the drivetrain while it is in motion.

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