Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com |

registered or otherwise protected by common law in the United States and other nations. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY

8030508.071523.A

Schwinn

Page Number

Audio (Input)

Heart Rate Monitor

490 / 590e Ellipticals

™

Service Manual

8030507.071523.A

Table of Contents

Summary of Contents for Schwinn 490e

Page 1: Table Of Contents
Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2023 Nautilus, Inc. | Schwinn and the Schwinn logo are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations.
Page 2: Important Safety Instructions
Nautilus, Inc., www.nautilus.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2023 Nautilus, Inc. | Schwinn and the Schwinn logo are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations.
Page 3: Safety Warning Labels And Serial Number
The heart rate displayed is an approximation and should be used for reference only. This exercise unit does not have a freewheel and pedal speed must be reduced in a controlled manner. For Consumer Use Only. Consult a physician prior to using any exercise equipment. (Label on Schwinn™ 490 machine is available in English and French Canadian only.)
Page 4: Specifications
SPECIFICATIONS Power Requirements: 120V 220V Operational Voltage: 110-127V AC, 60Hz 220V - 240V AC, 50Hz Operating Current: Maximum User Weight: 150 kg (330 lb) Total Surface Area (footprint) of equipment: 12,723 cm 172.6 cm Maximum Pedal Height - with full incline: 28.3 in ( 72 cm) ( 68 in ) Machine Weight:...
Page 5: Grounding Instructions
Grounding Instructions This product must be grounded. If it should malfunction or break down, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. This product is equipped with a cord having an equipment-grounding Safety Warning Labels and Serial Number conductor and a grounding plug.
Page 6: Moving And Storing The Machine
Moving the Machine Use the Transport Handle / Rear Step and Transport Wheels to move the machine. The Transport Handle / Rear Step is located in the middle of the Rail Assembly at the rear of the machine. Tilt the machine forward by lifting upward with the Transport Handle / Rear Step until the weight is on the Transport Wheels.
Page 7: Using The Jrny™ App With Your Machine
CONNECTIVITY Using the “JRNY™” App with Your machine This fitness machine is equipped with Bluetooth connectivity and can be wirelessly connected for workouts using the ® “JRNY™” app. The app can be accessed with your JRNY™ membership. Note: Do not connect this machine through your Bluetooth settings on your device.
Page 8 Connected icon. Note: Any previously connected Heart Rate devices will be disconnected. However, if they are within range, the Console may find them again if unable to locate your Monitor. 3. When connected, the Bluetooth Heart Rate Monitor Connected icon will flash with your pulse and your current heart ® rate value will be displayed on the Console. You are now ready to workout. Note: Once a Bluetooth Low Energy (BLE) Heart Rate device is connected, that device is engaged to that machine.
Page 9: Maintenance
Console in direct sunlight or at high temperatures Be sure to keep the Console free of moisture. The Schwinn™ 490 machine is for home use only. When the Schwinn™ 590e machine is used in a Studio/Institutional environment, we recommend that the Pedals be replaced every year to maintain maximum user safety and performance. Only use replacement Pedals available from Nautilus.
Page 10: Maintenance Parts
Maintenance Parts Console Assembly Upper Handlebar, Left Console Pivot Cover Upper Handlebar, Right Console Mast Handlebar Handlebar Cover, Interior Cover, Interior Handlebar Handlebar Cover, Cover, Exterior Exterior Pedal, Left Power Cord Main Assembly Leg, Left Leg, Right Pedal, Right Rail Assembly...
Page 11 Maintenance Parts - Main Assembly Front Upper Shroud Pivot Cover Inner Pivot Outer Cap Shroud Front Lower Inner Pivot Crank Shroud Shroud Lower Handle- bar, Left Pivot Rod Pivot Cover Outer Cap Crank Shroud Crank Left Main Shroud Shroud Lower Handle- bar, Right Rear Shroud Main Assembly Frame...
Page 12: Troubleshooting
TROUBLESHOOTING Condition/Problem Things to Check Solution No display/partial display/ Check electrical (wall) Make sure unit is plugged into a functioning wall outlet. unit will not turn on outlet Check connection at front Connection should be secure and undamaged. Replace cord of unit or power inlet if either are damaged.
Page 13 Condition/Problem Things to Check Solution No speed/RPM reading Check data cable integrity All wires in cable should be intact. If any are cut or pinched, replace cable. Check data cable Be sure each cable is connected securely and oriented proper- connections/orientation ly.
Page 14 Roller squeaking on rail Apply silicone lubricant to a dry cloth and wipe the rails to eliminate roller noise. Console continuously Console is in demonstra- Press and hold the Schwinn logo button for 3 seconds. The ™ cycles through program tion mode...
Page 15: Console Setup Mode
CONSOLE SETUP MODE The Console Setup Mode allows you to set units of measurement to either Imperial or metric, adjust screen brightness, view maintenance statistics (such as Run Time hours and software version – for service technician use only), or reset the Console. 1. Push the Programs button and hold for 3 seconds while in the Power-Up Mode to go into the Console Setup Mode (System Menu).
Page 16 26. The Console display shows the Reset Console prompt. The default option is NO. Push the Pause/Stop button to exit without starting Reset. Note: The YES option will reset the System Units, Screen Brightness and Demo Mode to default settings. It does not reset the Run Time Hours. Push the Resistance Increase/Decrease buttons to change between options (YES/NO). Push the Start button to set the selection and exit the System Menu.
Page 17: Electrical Wiring
ELECTRICAL WIRING CONSOLE WIRE ASSY, CONSOLE TO MAST HANDLEBAR RIGHT HANDLEBAR, LEFT ASSY, CABLE/PCBA, REMOTE BUTTON ASSY, CABLE/PCBA, - RESISTANCE REMOTE BUTTON - INCLINE WIRE, CABLE ASSY, CONSOLE MAST WIRE ASSY - RESISTANCE WIRE ASSY - INCLINE CONSOLE MAST DOWN HANDLE BAR BUTTONS CABLE ASSEMBLY, HUB to MAST HARNESS...
Page 18: Replacement Procedure Skill Level
REPLACEMENT PROCEDURE SKILL LEVEL Level I : Low - very little mechanical knowledge or exposure. Level II : Intermediate - some experience with mechanical procedures Level III : Advanced - knowledgeable about mechanical procedures To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and wait 5 minutes before cleaning, maintaining or repairing this machine.
Page 19: Calibrating The Resistance
Nautilus, Inc., www.nautilus.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2023 Nautilus, Inc. | Schwinn and the Schwinn logo are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations.
Page 20 Do not use the Console Resistance Quick Keys to set resistance until the calibration process is complete and calibration saved. Note: During the calibration process no one should be pedaling the machine. Standing on the pedals is okay during the calibration process.
Page 21 6. The Console display shows the AUTO CAL_RESIS- TANCE (Automated Calibrate Resistance) option. Push the Start button. Note: If the Pause/Stop button is pushed part way through the calibration (exit), the new calibration is not saved. 7. The console will display changing text and numbers for approximately 30 seconds as the servo motor moves. The console display will change to “CNFRM C4095 AGC xx”.
Page 22: Replace The Cables
Nautilus, Inc., www.nautilus.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2023 Nautilus, Inc. | Schwinn and the Schwinn logo are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations.
Page 23 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and wait 5 minutes before cleaning, main- taining or repairing this machine. Place the power cord in a secure location. Note: Your machine may not match the images provided exactly.
Page 24 To replace the: ASSY, CAB Offline Power Supply to Sensor Hub (DC Power) and/or Lift Motor Control Cable Section 1 page 4 REMOTE B BLE/PCBA, - RESISTAN E BUTTON Split Cable (Servo, Speed and Resistance) Assembly Section 2 page 6 - INCLINE Sensor Hub to Upper Handlebar Buttons (Resistance and Incline) Cable Section 3...
Page 25 Section 1 - Replacing the Offline Power Supply to Sensor Hub (DC Power) and/or Lift Motor Control Cables Make sure that power to the machine is discon- nected before beginning this step. Offline Power Supply Cover 1. Using a 4 mm hex wrench, remove the 4 screws (indicated by circles) that secure the Offline Power Supply Cover, and remove it.
Page 26 2. Remove the cable that is being replaced (Offline Power Supply to Sensor Hub (DC Power) Cable, or Lift Motor Control Cable) from the Sensor Hub and the Offline Power Supply. Sensor Hub Note: Be sure to note where all cables attach for re-assembly. Do not let the cables fall into the machine. If the Cable Connectors are secured by a small amount of glue, use a pair of small nose pliers to grab and remove the glue.
Page 27 Section 2 - Replacing the Split Cable (Servo, Speed and Resistance) Assembly Note: The Split Cable Assembly has a single connector on one end that connects to the Sensor Hub, with the other end having three cable connectors. The three Sensor Hub connectors go to the Servo Motor, Speed Sensor, and Resistance Sensor.
Page 28 5. Disconnect the Speed Sensor Cable Connector. Split Cable Assembly (Servo, Speed and Resistance) 6. Route the appropriate cable of the new Split Cable Speed Sensor Cable Connector Assembly to the Speed Sensor Cable Connector, and connect it. NOTICE: Do not pinch or cut the cables. Speed Sensor Cable Speed Sensor...
Page 29 Section 3 - Replacing the Sensor Hub to Upper Handlebar Buttons (Resistance and Incline) Cable Note: The Sensor Hub to Upper Handlebar Buttons Cable is a ‘T’ Cable, connecting the lower solo end to the Sensor Hub and the other two ends going to each of the Upper Handlebars.
Page 30 3. Using a 6mm hex wrench, remove the four screws that attach the Upper Handlebar to the Lower Handlebar. 4. Slightly pull the Upper Handlebar out of the Lower Handlebar, and disconnect the cables. Set the old Upper Handlebar and hardware safely aside. NOTICE: Do not cut or pinch the cables. Do not let the cable fall down into the Lower Handlebar.
Page 31 5. Gently compress the sides of the Pivot Cap to release it from the Inner Pivot Shroud. Sensor Hub to Upper Handle- bar Buttons 6. Using a #2 Phillips screwdriver, remove the 2 screws Cable (indicated by ovals) from the Inner Pivot Shroud. Pivot Cap 7.
Page 32 9. Using a 6mm hex wrench, remove the hardware (indicated by oval) that secures the Lower Handlebar. Sensor Hub to Upper Handle- bar Buttons Cable Inner Pivot Shroud 10. Slide the Lower Handlebar outward only about 1 inch (2.5 cm) from the machine. Inner Pivot Shroud 11. Push the Inner Pivot Shroud toward the machine, off of the Lower Handlebar.
Page 33 13. Remove the wire or string from the old cable, and secure it to the appropriate end of the new cable. 14. Route the new cable through the Lower Handlebar by gently pulling the wire or string from the Lower Handlebar. NOTICE: Do not pinch or cut the cables.
Page 34 Section 4 - Re-assembly and Final Inspection 1. Re-install all remaining parts that were removed in reverse order. 2. Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembled. Do not use until the machine has been fully assembled and inspected for correct perfor- mance in accordance with the Owner’s Manual.
Page 35: Replace The Console
Nautilus, Inc., www.nautilus.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2023 Nautilus, Inc. | Schwinn and the Schwinn logo are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations.
Page 36 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and wait 5 minutes before cleaning, main- taining or repairing this machine. Place the power cord in a secure location. Note: Your machine may not match the images provided exactly. Upper Handlebars removed for clarity.
Page 37 5. Tilt the new Console to install the wide tab at the top of the Console Mount Bracket. Route the Console cable through the bracket. 6. Attach the Console to the Console Mount Bracket before connecting the cables. Start lower screws first, then tighten all screws. Connect the Console cable to the Console Mast cable.
Page 38 7. Replace the Console Rear Cover on the back of the Console. 8. Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembled. Do not use until the machine has been fully assem- bled and inspected for correct performance in accor- dance with the Owner’s Manual.
Page 39: Replace The Console Mast
Nautilus, Inc., www.nautilus.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2023 Nautilus, Inc. | Schwinn and the Schwinn logo are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations.
Page 40 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and wait 5 minutes before cleaning, main- taining or repairing this machine. Place the power cord in a secure location. Note: Your machine may not match the images provided exactly. Upper Handlebars removed for clarity.
Page 41 5. Using a 6mm hex wrench, remove the hardware that attaches the Console Mast to the Frame Assembly. 6. Slightly pull the Console Mast upward, and disconnect the cables. Set the old Console Mast and hardware safely aside. NOTICE: Do not cut or pinch the cables. This step may require two people.
Page 42 7. With the new Console Mast, connect the cable to the cable from the Frame Assembly. Align the clips on the cable connectors and make sure the connectors lock. NOTICE: Do not cut or pinch the cables. This step may require two people.
Page 43 9. Tilt the Console to install the wide tab at the top of the Console Mount Bracket. Route the Console cable through the bracket. 10. Attach the Console to the Console Mount Bracket before connecting the cables. Start lower screws first, then tighten all screws. Connect the Console cable to the Console Mast cable.
Page 44 11. Replace the Console Rear Cover on the back of the Console. 12. Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembled. Do not use until the machine has been fully assem- bled and inspected for correct performance in accor- dance with the Owner’s Manual.
Page 45: Replace The Resistance Sensor
Nautilus, Inc., www.nautilus.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2023 Nautilus, Inc. | Schwinn and the Schwinn logo are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations.
Page 46 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and wait 5 minutes before cleaning, main- taining or repairing this machine. Place the power cord in a secure location. Note: Your machine may not match the images provided exactly.
Page 47 3. Using a #2 Phillips screwdriver, remove the screw that secures the Right and Left Main Shrouds just above the exposed Flywheel. Left Main Shroud Right Main Shroud 4. Using a #2 Phillips screwdriver, remove the screw (indicated by oval) that secures the Left Main Shroud to the Frame.
Page 48 Note: The Resistance Sensor can be accessed by gently flexing the Right Main Shroud outward slightly. The Shrouds have been removed from the images to provide additional details. 5. Disconnect the Resistance Sensor Cable Connector from the Resistance Sensor. Split Cable As- sembly (Servo, Speed and Resistance) Resistance Sensor Resistance Sensor...
Page 49 HANDLE BAR BUTTONS CABLE ASSEMBLY, HUB ELECTRICAL WIRING ROUTE DETAIL to MAST HARNESS - Resistance Sensor CABLE, SPEED SENSOR WIRE ASSY, SPLIT CBL RESISTANCE SENS, SPEED SENSOR, & SERVO Speed Sensor SENSOR HUB Resistance Sensor SENSOR HUB SERVO LIFT MOTOR CONTROL 9.
Page 50: Replace The Sensor Hub
Nautilus, Inc., www.nautilus.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2023 Nautilus, Inc. | Schwinn and the Schwinn logo are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations.
Page 51 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and wait 5 minutes before cleaning, main- taining or repairing this machine. Place the power cord in a secure location. Note: Your machine may not match the images provided exactly.
Page 52 Note: The Shrouds have been removed from some of the images to provide additional details. Sensor Hub Cover 3. Flex the sides of the Sensor Hub Cover to disengage the 2 side tabs. 4. Remove the connectors from the Sensor Hub after noting their locations. Note: Be sure to note where all cables attach for re-assembly.
Page 53 WIRE, CABLE ASSY, CONSOLE MAST ELECTRICAL WIRING ROUTE DETAIL WIRE ASSY - Sensor Board Y - INCLINE CONSOLE MAST To Console Mast DOWN To Handlebar Resis- To Handlebar tance Buttons Incline Buttons HANDLE BAR BUTTONS CABLE ASSEMBLY, HUB to MAST HARNESS CABLE, SPEED SENSOR SUB ASSY, WIRE ASSY, SPLIT CBL...
Page 54 5. Using a 6mm hex wrench, remove the 2 screws (indicated by ovals) that attach the Sensor Hub to the Frame. 6. Remove the old Sensor Hub, and install the new Sensor Hub. Connect all the cables to the Sensor Hub in their proper locations. Be sure not to crimp any cables. 7.
Page 55 10. The Console display shows the System Units prompt with the current setting. Tap the Programs button 4 times to advance through the System Menu. 11. The Console display shows the Hardware Variant & Console Firmware Version. The sample screen shows the format (values may be different).
Page 56 15. The console display will change to “CNFRM C4095 AGC xx”. 16. Push the Start button to confirm and save the resistance calibration values. The display will momentarily change to “SAVING CAL”, then display “AUTO CAL_RESISTANCE”. Calibration is complete. Note: Pushing the Pause/Stop button will abort the calibration process, with the new calibration values not being saved, and the last saved calibration values being restored.
Page 57: Replace The Servo Motor
Nautilus, Inc., www.nautilus.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2023 Nautilus, Inc. | Schwinn and the Schwinn logo are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations.
Page 58 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and wait 5 minutes before cleaning, main- taining or repairing this machine. Place the power cord in a secure location. Note: Your machine may not match the images provided exactly.
Page 59 5. Using a 3mm hex wrench, remove the hardware (indicated by ovals) from the old Servo Motor. WIRE ASSY, CONSOLE TO M 6. Using a 3mm hex wrench, attach the new Servo Motor to the Frame. HANDLEBAR, LEFT Be sure that the Servo Motor Arm is in the range shown below before securing the Linkage Arm. Servo Motor Arm ASSY, CABLE/PCBA, REMOTE BUTTON...
Page 60 9. Re-assemble the machine in the reverse order of when the parts were removed. 10. Plug the power cord into the machine and wall outlet. 11. Power on the machine. After the Power-Up/Welcome screen appears, use the Resistance Level Quick keys 25 and 1 to confirm that the magnet caliper moves properly between resistance level 1 and 25.
Page 61: Replace The Shrouds
Nautilus, Inc., www.nautilus.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2023 Nautilus, Inc. | Schwinn and the Schwinn logo are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations.
Page 62 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and wait 5 minutes before cleaning, main- taining or repairing this machine. Place the power cord in a secure location. Note: Your machine may not match the images provided exactly.
Page 63 Section 2 - Replacing the Front Upper Shroud 1. If replacing the Upper Front Shroud, remove the hardware (indicated with oval) that attaches the Console Mast with a 6mm hex wrench. 2. Slightly lift the Console Mast from the Frame Assembly and disconnect the Cables. Fully remove the Console Mast with Cables.
Page 64 3. Flex the edges of the Front Upper Shroud to disengage the 4 inside tabs (2 on each side) from the Main Shrouds. 4. Place the new Front Upper Shroud onto the Frame Assembly. Upper Front Shroud 5. With the Console Mast, connect the cable to the cable from the Frame Assembly. Align the clips on the cable connectors and make sure the connectors lock.
Page 65 Section 3 - Replacing the Rear Shroud 1. If replacing the Rear Shroud, the Incline Arm will need to be released. Using 6mm hex wrench and a 13mm open faced wrench, remove the indicated hardware that attaches the Incline Arm. 2. Slide the Incline (Lift) Motor Arm from the Rail Assembly. In order to avoid possible serious injury, when the Rail Assembly has been released from the Main Assembly, be careful to avoid fingers or hands...
Page 66 Section 4 - Replacing the Main Shrouds (continued after previous sections) Note: To replace the Main Shrouds, the Front Lower and Rear Shrouds must be removed, and the Front Upper Shroud needs to be resting unsnapped on the Main Shrouds. 1. Gently compress the Exterior Handlebar Cover to release it from the Interior Handlebar Cover. There are five tabs that snap to secure each Cover.
Page 67 3. Using a 6mm hex wrench, remove the four screws that attach the Upper Handlebar to the Lower Handlebar. 4. Slightly pull the Upper Handlebar out of the Lower Handlebar, and disconnect the cables. Set the old Upper Handlebar and hardware safely aside. NOTICE: Do not cut or pinch the cables. Do not let the cable fall down into the Lower Handlebar.
Page 68 5. Using a 6mm hex wrench, remove the hardware (indicated by ovals) that attaches the Pedals and remove them. Pedal Note: To assist with re-assembly, notice that the Pivot Pin is flush with the outside of the Lower Handlebar. Pivot Pin Pedal There is also a Wave Washer on the post from the Pedal.
Page 69 7. Using a #2 Phillips screwdriver, remove the indicated screw from the Crank Cap Shroud from the Crank Arm. Crank Arm Crank Cap Shroud 8. Using a 14mm wrench and socket, remove the Hex Nut from the Crank Arm. Crank Arm...
Page 70 Note: Your machine may not match the following images exactly. 9. Thread the Crank Puller into the Crank Arm (B). When the Crank Puller is in the correct position, only 1-2 threads on the outer portion (CP2) of the Crank Puller should show. Note: Be sure the end of the Bolt (CP1) of the Crank Puller is flush with the Nut (CP2) as shown, before use.
Page 71 11. Gently compress the sides of the Pivot Cap to release it from the Inner Pivot Shroud. Handlebar Cable 12. Using a #2 Phillips screwdriver, remove the 2 screws from the Inner Pivot Shroud. Pivot Cap 13. Tie a 60 cm (24 inch) long piece of wire or string to the end of the Cable.
Page 72 15. Slide the Lower Handlebar outward only about 1 inch (2.5 cm) from the machine. Inner Pivot Shroud 16. Push the Inner Pivot Shroud toward the machine, off of the Lower Handlebar. This will release the Cable from the clips on the Inner Pivot Shroud. 17. With the wire or string still attached to the end of the Cable, pull the Cable toward the machine out of the Lower Handlebar.
Page 73 20. Using a #2 Phillips screwdriver, remove the 8 screws from the Right Main Shroud. Note: The Upper Front Shroud may need to be lifted to access the upper screw for the Right Main Shroud. Upper Front Shroud Right Main Shroud Note: Crank Arm and Lower Handlebar have been removed, but are shown here.
Page 74 21. Using a #2 Phillips screwdriver, remove the 3 screws from the Left Main Shroud. Left Main Shroud Note: Crank Arm and Lower Handlebar have been removed, but are shown here.
Page 75 Section 5 - Re-assembly and Final Inspection 1. Re-install all remaining parts that were removed in reverse order. 2. Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembled. Do not use until the machine has been fully assembled and inspected for correct perfor- mance in accordance with the Owner’s Manual.
Page 76: Replace The Speed Sensor
Nautilus, Inc., www.nautilus.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2023 Nautilus, Inc. | Schwinn and the Schwinn logo are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations.
Page 77 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and wait 5 minutes before cleaning, main- taining or repairing this machine. Place the power cord in a secure location. Note: Your machine may not match the images provided exactly.
Page 78 3. Using a #2 Phillips screwdriver, remove the screw that secures the Right and Left Main Shrouds just above the exposed Flywheel. Left Main Shroud Right Main Shroud 4. Using a #2 Phillips screwdriver, remove the screw (indicated by oval) that secures the Left Main Shroud to the Frame.
Page 79 Note: The Speed Sensor can be accessed by gently flexing the Left Main Shroud outward slightly. Speed Sensor Left Main Shroud Note: The Shrouds have been removed from the images to provide additional details. Speed Sensor Cable Speed Sensor Flywheel Note: Main Shrouds removed for clarity.
Page 80 5. After noting how the Zip-Tie secures the Speed Sensor Cable and other cables to the Frame, cut the Zip-Tie that secures the cables. Be sure not to damage or cut any cables. Speed Sensor Cable Connector 6. Disconnect the Speed Sensor Cable Connector. 7.
Page 81 DOWN ELECTRICAL WIRING ROUTE DETAIL - Speed Sensor HANDLE BAR BUTTONS CABLE ASSEMBLY, HUB to MAST HARNESS CABLE, SPEED SENSOR WIRE ASSY, SPLIT CBL RESISTANCE SENS, SPEED SENSOR, & SERVO Speed Sensor SENSOR HUB Resistance Sensor SENSOR HUB SERVO LIFT MOTOR CONTROL LIFT CONTRO DC POWER OFFLINE POWER SUPPLY...
Page 82: Replace The Upper Handlebars
Nautilus, Inc., www.nautilus.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2023 Nautilus, Inc. | Schwinn and the Schwinn logo are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations.
Page 83 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and wait 5 minutes before cleaning, main- taining or repairing this machine. Place the power cord in a secure location. Note: Your machine may not match the images provided exactly. Though the procedure shows the removal of both Upper Handlebars, only remove one if you are not replacing both Upper Handlebars.
Page 84 4. Using a 6mm hex wrench, remove the four screws that attach the Upper Handlebar to the Lower Handlebar. 5. Slightly pull the Upper Handlebar out of the Lower Handlebar, and disconnect the cables. Set the old Upper Handlebar and hardware safely aside. NOTICE: Do not cut or pinch the cables. Do not let the cable fall down into the Lower Handlebar.
Page 85 6. Connect the cable from the new Upper Handlebar to the cable from the Lower Handlebar. Align the clips on the cable connectors and make sure the connectors lock. Then safely insert the Upper Handlebar being careful to avoid fingers or hands being caught or pinched.
Page 86 8. Adjust the angle of the Console and tighten the tilting hardware. Then replace the Console Rear Cover on the back of the Console. 9. Re-install all remaining parts that were removed in reverse order. 10. Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembled.

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