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LeMond Fitness RevMaster Service Manual

Indoor cycling bike
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For the LeMond
• Bid Specifications
• Warranty
• Exploded Diagrams
• Parts List
• Instructions
o Installation Check List
o Maintance Schedule
o Tech Notes
o Bottom Bracket Adjustment
o Brake pad Lubrication
o Brake pad & Spring steel Replacement
o Flywheel Assembly
o Touch Up paint Kit
Service Guide
RevMaster
®
15540 Woodinville-Redmond Rd NE
Woodinville, WA 98072
(425) 482-6724 Fax
www.LeMondFitness.com
®
Bldg A, Ste 100
(425) 482-6773

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Summary of Contents for LeMond Fitness RevMaster

  • Page 1 Service Guide For the LeMond RevMaster ® ® • Bid Specifications • Warranty • Exploded Diagrams • Parts List • Instructions o Installation Check List o Maintance Schedule o Tech Notes o Bottom Bracket Adjustment o Brake pad Lubrication o Brake pad & Spring steel Replacement...
  • Page 2 Tour de France 3 times. Only one group exercise cycle bears his name. The New L RevMaster ® Group cycling will never be the same. 1-425-482-6773 www.LeMondfitness.com © 2002 LeMond Fitness RevMaster and LeMond are registered trademarks of Greg LeMond...
  • Page 3 Equipped with an exceptionally strong, Cr-Moly machined BMX bottom bracket (23.0 mm x 124.5 mm) and cast stainless steel cranks (170 mm) with chrome plating, the LeMond RevMaster is designed to better withstand the high force loads (as compared to conventional group cycles) that occur during “out of saddle”...
  • Page 4 RevMaster Bid Specifications Continued Page 2 Designed with extra large in-line skate wheels, the LeMond RevMaster bikes are easier to move than other bikes that have casters. Note: Wheel brackets are welded to the frame. Created by Joan Wenson – national and world SportAerobic Gold Medalist, racing cyclist, renowned choreographer and certified personal trainer –...
  • Page 5 Fitness Inc. 15540 Woodinville-Redmond Rd. Building A, Suite 100 (425) 482-6773 Fax: (425) 482-6724 www.LeMondfitness.com ® ™ LeMond RevMaster Indoor Cycling Bike Bid Specifications (Summary) Machine Height 38" (97 cm) Machine Length 41.5" (105 cm) Machine Width 22.25" (48 cm) Weight 116 lbs.
  • Page 6 • Please call 425-482-6773 ext. 107 to receive a return goods authorization prior to shipment. • LeMond Fitness, Inc. will incur all ground freight charges for warranty parts ordered for a bike that is less than 45 days old. •...
  • Page 7 SPD Dual Sided Pair 2 x 885 Left Crank *Lock Ring Left Bearing Cup w/ Bearings 1 x WPD96B 1 x 0875-1 Lock Ring LeMond® RevMaster® Rear Base Assy. Base Levelers (with levelers) 4 x 0850 Final Assembly 1 x 108AA 01-05-2005...
  • Page 8 *Tension Knob/Rod *Assy, Tension Knob 1 x PN 0270 Screw, Hex Head Includes: 2 x 14099 Tension Knob/Rod Bolt, Belt Tensioner 1 x PN 0276 1 x M640 Cover Nut, Belt Tensioner 1 x PN 0271 Square Spring 1 x 41208 *Cover 2 x PN 0273 Spacer, Belt...
  • Page 9 LeMond Fitness Inc. - 15540 WOODINVILLE-REDMOND RD NE SUITE A-100 WOODINVILLE, WA 98072 PARTS & SERVICE (425)482-6773 WWW.LEMONDFITNESS.COM FAX (425)482-6724 REVMASTER - DEALER PARTS LIST Item Number Item Description List Price 1030 ADJUSTMENT HANDLE, STANDARD $3.00 6004ZZ BEARING, BELT TENSIONER/FLYWHEEL $8.00...
  • Page 10 HEARTRATE CHEST STRAP, CARDIOSPORT, ANALOG $34.95 250018 LEMOND BANNER, 18" X 60" $79.95 250019 LEMOND POSTER $7.95 250043 SEAT COVER, GEL $21.95 11203 SEAT POST, EXTRA TALL $69.00 250058 SERVICE GUIDE, REVMASTER $5.00 250208 VIDEO, 3 PK REVMASTER VIDEO KIT (VHS) $60.00...
  • Page 11 • Use the 15-mm pedal wrench to tighten the pedal onto the crank arm. Note: After the first 5 hours of use, inspect the pedals and Handle Right Pedal retighten if necessary. © 2004. LeMond Fitness Inc. All rights reserved.
  • Page 12 Tighten the pedal with a pedal wrench. Page 1 of 4 ® ©2003 LeMond Fitness Inc. LeMond, RevMaster, and LeMond Fitness Inc. are registered trademarks.

  • Page 13: Left Pedal

    8. Secure the water bottle cage to the water bottle cage mount with the 3-mm screw. Page 2 of 4 ® ©2003 LeMond Fitness Inc. LeMond, RevMaster, and LeMond Fitness Inc. are registered trademarks.
  • Page 14 10. Position the handlebar over the handlebar post. Loosely thread a handle with a washer through the handlebar post into the handlebar. Slide the seat to the desired position and tighten the handle. BRASS WASHER Page 3 of 4 ® ©2003 LeMond Fitness Inc. LeMond, RevMaster, and LeMond Fitness Inc. are registered trademarks.
  • Page 15 ® ® LeMond RevMaster Recommended Maintenance Schedule PART RECOMMENDED ACTION FREQUENCY CLEANER LUBRICANT Ensure that the pedals are tight Before each use Pedals in crank arms; that all screws on pedals are tight; and that the pedal straps are not frayed...
  • Page 16 ® LeMond Fitness Inc. 17820 Woodinville-Redmond Rd. Building B, Suite 888 Woodinville, WA (425) 482-6773 ext. 103 Fax: (425) 482-6724 Tech Service Notes General Assembly Installation - Assembly tools included with bike: Multi-tool wrench Used for: pedals and the cross arm mounting nuts 3-mm Hex key Used for: H O bottle mounting screw (mounts the cage to the handlebar...
  • Page 17 3. Handlebar post – insert V-Plunger may need to be pushed back in pocket (show and explain) Smooth finish on top face - faces forward - no slot in top Seat Post Handlebar Post Adjustment handle and grease 4. Handle bars – install 1 washer and adjustment handle and grease 5.
  • Page 18 Bottom Bracket Removal/Adjustment: 8-mm hex key – crank bolts Crank Puller Lock Ring Wrench –lock ring on left bearing cup ® Bottom Bracket Socket (Shimano -compatible cartridge style) + ½” drive ® ® Locktite 242 (United States) or Locktite 243 (International) – Medium strength (blue) Rubber Mallet/ Dead-blow hammer –...

  • Page 19: Cover Removal

    Necessary only if the pillow block housing pulls off the bearing during removal and leaves the bearing stuck on the spline shaft Block of wood/metal – use to tap the pillow block bearings onto the spline shaft. Brake Pad Assembly 4-mm hex key –...
  • Page 20 Bottom Bracket Removal Remove the right cover and belt. Use an 8-mm hex key to remove the left crank bolt. Remove the left crank with a crank puller. Use a lock ring tool to loosen and then remove the bottom bracket lock ring.
  • Page 21 Pull the spindle out of the frame from the left side. Use a bottom bracket removal tool to remove the right bearing cup. Note: The right bearing cup is reverse threaded. Bottom bracket adjustment Note: If not adjusted properly the bike will feel as though the crank bearings, crank arms and/or spindle are damaged/ worn and you may hear a knocking noise.
  • Page 22 Tension knob assembly Note: An additional spring was added to the tension knob assembly (09/01 starting sn 010850374), the new assembly is backward compatible. Use the 4-mm hex key to remove the two tension knob cover mounting screws. Unscrew the plastic acorn nut from the tension knob rod. Pull the tension knob assembly up and out of the frame.
  • Page 23 Use a 5-mm hex key to remove the five pulley mounting screws from the crank. Separate the right crank from the rear pulley. Attach the new rear pulley to the right crank. Use the rubber mallet to reinstall the right crank assembly onto the spindle.
  • Page 24 Install the new pillow block bearings on the spline shaft. Note: Do not tap directly on the bearings. Use a block of wood/metal on top of the pillow block bearings and tap the bearings onto the spline shaft. Reinstall the flywheel spacer, pulley, washer, and screw. Remember to use the block when tapping the pulley back on the spline shaft.

  • Page 25: Tools Needed

    The leather on your RevMaster brake pad is pre-soaked in oil, but will require occasional lubrication. Inspect your brake pad daily until the pad settles into normal use. After the pad has settled into normal use, periodically inspect the brake pad for proper lubrication.
  • Page 26 Keep the hardware to use during reinstallation. • Twist the tension knob counterclockwise until the acorn nut meets the frame. 2/27/2007 Page 1 of 4 P/N 300104 ©2002 LeMond Fitness Inc., RevMaster, and LeMond are registered trademarks...
  • Page 27 5. Remove the old brake spring steel from the brake pad assembly • Use the 4-mm Allen wrench to remove the 4-mm screw on the front of the brake pad assembly. 2/27/2007 Page 2 of 4 P/N 300104 ©2002 LeMond Fitness Inc., RevMaster, and LeMond are registered trademarks...
  • Page 28 10-mm mounting nut on the post. • Insert the 4-mm mounting screw into the forward hole on the brake pad assembly and secure. 2/27/2007 Page 3 of 4 P/N 300104 ©2002 LeMond Fitness Inc., RevMaster, and LeMond are registered trademarks...
  • Page 29 • Ride the new bike to test and make sure that no abnormal noise is heard and that the bike functions properly. While the flywheel is in motion, push down on the brake and verify that the flywheel stops correctly. 2/27/2007 Page 4 of 4 P/N 300104 ©2002 LeMond Fitness Inc., RevMaster, and LeMond are registered trademarks...

  • Page 30: Replacement Instructions

    Building A, Suite 100 (425) 482-6773 Fax: (425) 482-6724 www.LeMondfitness.com ® ® REPLACEMENT PROCEDURES FOR THE LEMOND REVMASTER FLYWHEEL ASSEMBLY Tools Required: • 4-mm Allen Key • 5-mm Allen Key • Phillips Screwdriver • Adjustable wrench (medium) • Hand towel •...
  • Page 31 Remove the flywheel from the bike. • Use a 5-mm Allen key to remove the two pillow block screws that secure each of the pillow block bearing on either side of the flywheel to the frame. Keep the hardware to use during installation.
  • Page 32 While the flywheel is in motion, push down on the brake and verify that the flywheel stops correctly. For telephone assistance, please contact your local distributor or the Customer Service Department of LeMond Fitness Inc.. at 1-425-482-6773 x109 from 0800AM – 1700PM PST Monday through Friday.
  • Page 33 Remove tape and inspect previously chipped/scratched area for complete paint coverage. P/N 300108 Page 1 of 1 © 2003 LeMond Fitness Inc. LeMond, RevMaster, and LeMond Fitness Inc. are registered trademarks.