Main Wire Harness - Life Fitness Lifecycle 9100 Service Manual

Lifecycle 9100 and 9500HR Series Exercise Bikes
How To...REMOVE AND REPLACE THE MAIN WIRE HARNESS
Tools Required: 1/4,5/16, and 3/8 inch wrenches, side cutters, standard screwdriver
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1. Remove the HOUSING. Refer to See How To... .in this section.
2. With side cutters, cut off the CABLE TIES holding the WIRE
HARNESS to the bike frame.
3. Remove the two POSITIVE RED WIRES from their POSTS on
the ALTERNATOR. Using a 1/4 inch wrench, remove the two
NUTS securing the BLACK FIELD WIRE and the YELLOW
WIRE. Then with a 5/16 inch wrench, remove the
REGULATOR TERMINAL NUT and the GROUND TERMINAL
NUT.
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Gnd
Output
o
ACTa
Field Excitati
4. Disconnect the BLACK (neg) wire from the (-) post on the BATTERY then, the RED (pos) wire from the (+)
post.
5. Disconnect the 11-PIN CONNECTOR at P1, 5-PIN CONNECTOR at P3 and 12-PIN CONNECTOR at P2 on
the ALTERNATOR CONTROL BOARD.
6. Remove the WIRE HARNESS from the FRAME.
7. Position the new WIRE HARNESS and replace any cable ties that were cut during removal.
8. Reconnect the five TERMINAL CONNECTIONS to their proper locations on the ALTERNATOR, the BATTERY
TERMINALS to their respective POSTS on the BATTERY, and the three WIRE CONNECTORS to P1, P2 and
P3 on the ALTERNATOR CONTROL BOARD (Torque alternator hardware 20-25 in. Ibs).
9. Guide the new WIRE HARNESS up the front of the bike frame. It will be routed on the side of the
HANDLEBAR ASSEMBLY.
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8