Spirit Johnny G Service Manual
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Spirit Johnny G Service Manual

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JOHNNY G SPIRIT BIKE
SERVICE MANUAL

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  • Page 1 JOHNNY G SPIRIT BIKE SERVICE MANUAL...
  • Page 2 Johnny G by Spirit...
  • Page 3 PARTS REPLACEMENT 2. ELECTRONIC PARTS 2.1 UPPER CONTROLLERS 2.2 LOWER CONTROLLER AND DRIVER 3. ELECTRICAL CONFIGURATIONS 4. BASIC CONNECTIONS AND WIRING 4.1 LED DISPLAY PCB BOARD 4.2 MPU PCB BOARD 4.3 MCU BOARD WIRE CONNECTIONS & FUNCTION 4.4 LOWER CONTROL BOARD WIRE CONNECTIONS 4.5 BRAKE ASSEMBLY 4.6 LIMIT SENSOR BOARD 4.7 DC MOTOR ENCODER BOARD...
  • Page 4 SECTION PARTS REPLACEMENT Johnny G by Spirit...
  • Page 5 JOHNNY G SPIRIT BIKE PARTS 1. Plastic Cover 5. Generator 12. Timing belt 2. Front stabilizer assembly 6. Generator mounting bracket 13. Idler wheel assembly 3. Crank arm 7. Generator drive belt 14. Lower control board 4. Aluminum flywheel 8. Secondary pulley 15.

  • Page 6: Parts Replacement

    (R and L). 5. Use Phillips head screw driver facilitate disassembly of the Phillips head screws #134 Plastic Cover. and two 16mm Sheet Metal Screws #131 from both Plastic Covers (R and L). Johnny G by Spirit...
  • Page 7 PARTS REPLACEMENT GENERATOR to remove four 12mm 6. Unplug the Generator 7. Use Phillips head screw 8. Use diagonal pliers to cut Phillips head screws #134 Power Cable (96) from the driver to remove four Flat the cable tie. from the Mounting Bracket Generator (57).
  • Page 8 PARTS REPLACEMENT GENERATOR 9. Remove the Generator 10. Replace with new Bracket #42. Generator #57. Reverse above steps to install new parts. Johnny G by Spirit...

  • Page 9: Generator Drive Belt

    PARTS REPLACEMENT GENERATOR DRIVE BELT 1. Use Phillips head screw driver 2. Move the crank arm to 3. Remove both Plastic Covers 4. Use M8 L Allen wrench to to remove four 12mm Phillips the horizontal position to (R and L). remove the M12 Axle Bolt head screws #134 and two facilitate disassembly of the...
  • Page 10 PARTS REPLACEMENT GENERATOR DRIVE BELT the Crank Arm (L) #46. Reverse above steps to 6. The two drive Belts #43 reinstall parts. then replace new Belts. Johnny G by Spirit...

  • Page 11: Lower Control Board

    PARTS REPLACEMENT LOWER CONTROL BOARD 1. Use Phillips head screw driver 2. Move the crank arm to 3. Remove both Plastic Covers 4. Use 7mm open end wrench to remove four 12mm Phillips the horizontal position to (R and L). to remove four Nylon Nuts head screws #134 and two facilitate disassembly of the...
  • Page 12 5. Use diagonal pliers to cut 6. Unplug the Generator 7. Remove the Lower Control the cable tie. Power Cable from the Board #87 then replace Lower Control Board #87. with new Lower Control Board. Reverse above steps to reinstall parts. Johnny G by Spirit...

  • Page 13: Belt Replacement

    PARTS REPLACEMENT BELT REPLACEMENT 1. Use Phillips head screw driver 2. Move the crank arm to 3. Remove both Plastic Covers 4. Use 10mm open end to remove four 12mm Phillips the horizontal position to (R and L). wrench to remove the M6 head screws #134 and two facilitate disassembly of the Nyloc Nut.
  • Page 14 M5 Bolts #145 driver to loosen the M5 Hex Head Bolt #139 and Nyloc Nut #171. and Flat Washers #120. Phillips Head Screw #134 M6 Eye Bolt #129. to remove the RPM Sensor #86. Johnny G by Spirit...
  • Page 15 9. Support front of main 10. There are 4 M10 hex head 11. Rotate the front Stabilizer 12. Use 19mm open end wrench frame off ground to allow bolts in front Stabilizer Assembly #5 down about to remove 2 M12 Nylon access to Front Stabilizer Assembly.

  • Page 16: Brake Assembly

    (R and L). wrench to remove the M6 head screws #134 and two facilitate disassembly of the Nyloc Nut. 16mm Sheet Metal Screws Plastic Cover. #131 from both Plastic Covers (R and L). Johnny G by Spirit...
  • Page 17 5. Use 13mm open end 6. Use 10mm open end 7. Use M4 Allen wrench to 8. Use Phillips head screw wrench to remove the M8 wrench to remove the M6 remove two M5 Bolts #145 driver to loosen the M5 Hex Head Bolt #139 and Nyloc Nut #171.
  • Page 18 (Place a towel under support the frame when the flywheel to avoid flywheel elevating off the ground. scratches). Replace the belt. Reverse above steps to reinstall parts and adjust the belt tension between 100-110 pounds. Johnny G by Spirit...
  • Page 19 13. Use 14mm open end 14. With assistance, raise front 15. Using diagonal pliers cut wrench to remove 2 M8 of bike frame to allow the cable tie then unplug Hex Head Bolts #139 and for clearance of Brake the Brake Power Cable. the Lock Washers #122 as Assembly from flywheel shown above.

  • Page 20: Drum Brake Assembly

    (R and L). remove two M5 Bolts #145 head screws #134 and two facilitate disassembly of the and Flat Washers #120. 16mm Sheet Metal Screws Plastic Cover. #131 from both Plastic Covers (R and L). Johnny G by Spirit...
  • Page 21 6. Use M5 Allen wrench to 7. Use diagonal pliers cut the 8. Use pliers to remove the 9. Use 8mm open end remove the Socket Head cable tie. front end rope clip off the wrench to remove the Cap Bolt on the Drum steel cable.
  • Page 22 10. Replace with a new Drum Brake Assembly. Reverse above steps to reinstall parts as shown above. Install a new cable tie to keep parts clear from flywheel. Johnny G by Spirit...

  • Page 23: Electronic Parts

    SECTION ELECTRONIC PARTS www.johnnygspiritbike.com...

  • Page 24: Upper Controllers

    UPPER CONTROLLERS Forward control panel Console Handlebar shifters Dynamic braking handle Johnny G by Spirit...
  • Page 25 LOWER CONTROLLERS & DRIVER RPM Sensor Brake assembly Generator Lower controller www.johnnygspiritbike.com...

  • Page 26: Electrical Configurations

    SECTION ELECTRICAL CONFIGURATIONS Johnny G by Spirit...
  • Page 27 The console contains the LED display, computer IC (MCU), memory, control circuitry and communications module for BLE (2 channels) and ANT+. This is the interface that controls all functions of the Johnny G Spirit Bike. LOWER CONTROLLER The controller consists of the generator interface and switching power supply for the console and brake motor control circuitry.
  • Page 28 SECTION BASIC CONNECTIONS AND WIRING Johnny G by Spirit...
  • Page 29 LED DISPLAY PCB BOARD LED Display PCB Board www.johnnygspiritbike.com...
  • Page 30 MPU PCB BOARD LED Display PCB Board Johnny G by Spirit...
  • Page 31 MCU BOARD WIRE CONNECTIONS & FUNCTION System cable to LED display Intrinity logo USB software Keyboard lower board backlight update www.johnnygspiritbike.com...
  • Page 32 VLED BL_CTRL J4: USB SOFTWARE UPDATE PIN 1 PIN 2 PIN 3 PIN 4 USB_VBUS USB_D- USB_D+ J5: KEYBOARD CABLE PIN 1 PIN 2 PIN 3 KB_DATA1 PIN 4 KB_DATA4 PIN 5 KB_DATA5 PIN 6 KB_DATA6 Johnny G by Spirit...
  • Page 33 LOWER CONTROL BOARD WIRE CONNECTIONS Speed RPM sensor Generator power in External power 9 V DC System cable (9 PIN) to console Brake cable (Motor, encoder, position sensors) www.johnnygspiritbike.com...
  • Page 34 J4: LEVEL CONTROL BRAKE CABLE PIN 1 MTR UP PIN 2 MTR DN PIN 3 HOME PIN 4 PIN 5 PIN 6 OPT1 VCC_5V PIN 7 VCC_6V PIN 8 MCT_IN J5: POWER 9 VIN PIN 1 PIN 2 VCC_9V Johnny G by Spirit...
  • Page 35 BRAKE ASSEMBLY DC motor Limit sensor board DC motor encoder board www.johnnygspiritbike.com...
  • Page 36 LIMIT SENSOR BOARD DC motor power cable Brake cable DC motor encoder board cable Upper limit sensor Home position sensor Brake position flag Johnny G by Spirit...
  • Page 37 DC MOTOR ENCODER BOARD DC motor encoder board Encoder optical sensor Encoder wheel Encoder sensor www.johnnygspiritbike.com...

  • Page 38: Error Messages And Troubleshooting

    SECTION ERROR MESSAGES & TROUBLESHOOTING Johnny G by Spirit...

  • Page 39: Error Messages

    ERROR MESSAGES ERROR MESSAGE EXPLANATION TROUBLESHOOTING 1. Press Play and + Keys to reset 1. Generator power up sequence is not complete causing an error when console reading the EEPROM 2. Replace the upper control board USING DEFAULT SETUP 2. If USING DEFAULT SETUP still (MCU Board) appears after resetting the Console, MCU board must be replaced...

  • Page 40: Circuit Diagram

    CIRCUIT DIAGRAM Johnny G by Spirit...

  • Page 41: Maintenance Mode

    It is necessary for the console to be powered on in order to access maintenance mode. Pedaling above 30 RPM is all that is needed to illuminate console. Or use optional 9v power adapter to power console without pedaling. (Adapter available as a service part through your Spirit distributor). Maintenance mode offers following menu: •...
  • Page 42 Play Key and + Key simultaneously for 3 seconds. CONSOLE RESET displays on console. NOTE: If console displays CONSOLE RESET, instead of MAINTENANCE MODE, then ALL 3 keys on Forward Control Pad were possibly not pressed and held simultaneously or for enough time; attempt action again. Johnny G by Spirit...

  • Page 43: Display Test

    KEY TEST The purpose of this setting is to ensure that each of the buttons are signaling properly. • Press Play Key to enter setting. • Press Play Key and follow console direction PRESS ALL KEYS. • There are 5 buttons that control the bike: •...
  • Page 44 • Press Play Key to change setting. • Default setting is ENGLISH. • SPD AVG and SPD PEAK in workout results will only display MPH. • Press + Key for next screen or reset console to exit Maintenance Mode. Johnny G by Spirit...
  • Page 45 BRAKE TEST Brake test controls are a sensitive setting for your bike's functionality. Proper training is required for this setting. The purpose of this setting is to test the magnetic resistance system. • Press Play Key to enter Brake Test. MOTOR TEST AUTO is displayed. •...

  • Page 46: Limit Sensor

    • When REED switch is open, displays OFF. • RPM displays PEDAL RPM. • Press Play Key to exit to setting screen. • Press + Key for next screen or reset console to exit Maintenance Mode. Johnny G by Spirit...

  • Page 47: Update Software

    If successful, displays UPDATE DONE (flashing) • If unsuccessful, displays UPDATE FAIL, check USB for proper insertion and re-attempt. • Co nsole will reset with JOHNNY G METHOD flashing. • Re move the USB stick LED BRIGHTNESS The purpose of this setting is to change the brightness of the display.
  • Page 48 • Default HR pairing setting is OFF. • Press + or – Key switch OFF and ON. • Press Play Key to accept and exit to setting screen. • Press + Key for next screen or reset console to exit Maintenance Mode. Johnny G by Spirit...

  • Page 49: Demo Mode

    • Purpose of this setting is allowing the console to display. • Press Play Key to enter Demo Mode and display in a loop: JOHNNY G. METHOD, THE RIDE OF TRUTH, ENJOY THE RIDE. • Press Play Key to exit to setting screen. between ON and OFF.

  • Page 50: Software Update

    Sofware displays the current version of the Garmin G-Fit module and the current software version. • Press Play Key to view software version. • Press Play Key to exit software version • Press + Key to exit Maintenance Mode. Johnny G by Spirit...

  • Page 51: Troubleshooting

    TROUBLESHOOTING CONDITION REASON SOLUTION 1. LED brightness set to low. 1. Check LED brightness setting in 2. LED board malfunction. maintenance mode. 3. Generator Power to console too low. 2. Check connection between LED board and MCU board. 3. Check connection between generator LED not bright enough and controller 4.
  • Page 52 SECTION CONSOLE UPDATE Johnny G by Spirit...
  • Page 53 CONSOLE SOFTWARE UPDATE 4. Press + or – Key to change 1. Download the .zip file and 3. Turn on the console 6. Once the update finish, extract the two software and enter Maintenance Bootloader to ON and the console shows update files.
  • Page 54 (ZIP)" and click put the .zip file into phone. "OK". 3. Turn on the console of the Johnny G Spirit Bike and open the nRF Connect App (need to turn on the Bluetooth and location on your Smartphone). Find GFIT and connect.
  • Page 55 8. Open the device 9. Update the console and information and check reset. The Myzone+number the firmware version. The should show on the console update was success if the after scanning the HR version is 4.3. device. NOTE: GFIT module cannot update to the previous version, please update the GFIT module before updating the...
  • Page 56 Dyaco Commercial & 866.463.2662 Medical North America www.johnnygspiritbike.com 18303 Bothell Everett Hwy. Suite 210 Bothell, WA 98012 Johnny G Spirit Bike Service Manual © 2020 All Rights Reserved Revision: 02.05.2020...

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