How To - Life Fitness Lifecycle 3500 Series Service Manual

Lifecycle 3500, 4500, 5500 Series Exercise Bikes
How To...REMOVE AND REPLACE THE ALTERNATOR
Tools Required: Grease pencil, 5/16" wrench, 1/4" wrench, 1/2" wrench, 3/4" wrenches (2)
Step 1
Remove the HOUSING (See "How To...").
Step 2
Remove the two POSITIVE RED WIRES from their POSTS on the ALTERNATOR. With a 1/4" wrench, remove the
two NUTS securing the BLACK FIELD WIRE and the WHITE WIRE. With a 5/16" wrench, remove the
REGULATOR TERMINAL NUT and the GROUND TERMINAL NUT.
HELPFUL HINT: Use a grease pencil to mark the direction of the alternator belt in case it slips
Step 3
With a 1/2" wrench, loosen and remove the ALTERNATOR ADJUSTMENT BOLT.
Step 4
With two 3/4" wrenches, loosen the PIVOT BOLT
and LOCKNUT located on the ALTERNATOR.
DO NOT REMOVE THE PIVOT BOLT AND
LOCKNUT UNTIL STEP 7.
Step 5
Cup your hand under the worn ALTERNATOR
and lift upward. This will relieve the tension from
the ALTERNATOR BELT.
Step 6
With your other hand, slide the ALTERNATOR BELT
off the large FREE-WHEEL PULLEY. Loop the
ALTERNATOR BELT around
located at the end of the ALTERNATOR SHAFT to
remove.
Step 7
Remove the PIVOT BOLT securing the worn
ALTERNATOR to the bike FRAME. Locate a new
ALTERNATOR into position and loosely re-install the
PIVOT BOLT to hold it in place .
Step 8
Reverse Steps 1 through 6 to return all parts to
their proper position.
Tighten parts to the following specifications:
Alternator Adjustment Bolt
Alternator Pivot Bolt
Alternator Belt
off the pulley and needs to be reinstalled.
the FLYWHEEL
18-20 ft. lbs.
30-35 ft. lbs.
60-70 lbs.
1