Star Trac Schwinn X Troubleshooting And Replacement

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Technical Procedure

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Schwinn X/Z Troubleshooting & Replacement

Applies to: Schwinn X (9-7470 + 9-7480), Schwinn Z (9-7510 + 9-7520)

Fore-Aft Adjustment Cam Replacement or Slider Loose .................................

Seat

Handlebars

Belt and Flywheel Replacement.. ......................................................................

Schwinn X

Schwinn Z

Flywheel Adjustment................... ................................................................. 25

Gear-Angle Sensor Replacement................................................................. 30

Crank Arm Battery Replacement. ................................................................ 32

Pedal Removal............................ ................................................................. 33

Left Crank Arm Removal............................ .................................................. 34

Right Crank Arm Removal............................ ................................................ 38

Page 1

637-8808 Rev. K

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Summary of Contents for Star Trac Schwinn X

Page 1 Technical Procedure Schwinn X/Z Troubleshooting & Replacement Applies to: Schwinn X (9-7470 + 9-7480), Schwinn Z (9-7510 + 9-7520) Enhanced Images: Pictures can be zoomed in to any level for detail. Use the standard zoom tools for your platform to zoom in.
Page 2 Technical Procedure Seat Fore-Aft Adjustment Cam Replacement or Loose Seat Slider Required Tools: • Ratchet Wrench • 7/16” Deep Socket • Torque Wrench Required Parts: • 727-0285 ” ASSY, SEAT, CAM LEVER, UGC” For a loose seat slider, skip to the final step in this procedure and follow the torque instructions. The seat post assembly with the adjustment cam located on the underside of the post has been discontinued.
Page 3 Technical Procedure 1. Flip the fore/aft adjustment cam upward to loosen the seat slider. Fig. 2 2. Move the seat slider until the cam nut can be seen through the access hole in the underside of the seat post. Fig. 3 Page 3 637-8808 Rev.
Page 4 Technical Procedure 3. Use a ratchet wrench with a 7/16” deep socket to remove the cam nut from the lever, then remove the cam. Fig. 4 4. To install the new cam assembly (727-0285), insert the assembly into the seat slider in the closed position, then use a torque wrench with a 7/16”...
Page 5 Technical Procedure Handlebar Fore-Aft Adjustment Cam Replacement or Loose Handlebar Slider Required Tools: • Ratchet Wrench • 1/2” Deep Socket • Torque Wrench Required Parts: • 727-0238 ” ASSY, CAM LEVER V2, HBAR V2” For a loose handlebar slider, skip to the final step in this procedure and follow the torque instructions. The handlebar post assembly with the longer, curved cam base has been discontinued.
Page 6 Technical Procedure 1. Flip the fore/aft adjustment cam upward to loosen the handlebar slider. Fig. 8 2. Move the handlebar slider until the cam nut can be seen through the access hole in the underside of the handlebar post. Fig. 9 Page 6 637-8808 Rev.
Page 7 Technical Procedure 3. Use a ratchet wrench with an 1/2” deep socket to remove the cam nut from the lever, then remove the cam. Fig. 10 4. To install the new cam assembly (727-0238), insert the assembly into the handlebar slider in the closed position, then use a torque wrench with an 1/2”...
Page 8 Technical Procedure Schwinn Xa/s Belt and/or Flywheel Replacement Required Tools: • 3mm Allen Key • 4mm Allen Key • 6mm Allen Key • #2 Phillips Head Screwdriver • 10mm Open-Ended Wrench • 18mm Open-Ended Wrench • 19mm Open-Ended Wrench x2 •...
Page 9 Technical Procedure 2. Use a 4mm allen key to remove the four (4) socket head cap screws securing the left side belt guard to the bike, then remove the belt guard. Fig. 13 3. Use a 3mm allen key to remove the two (2) flat head machine screws from the left and right sides of the nose cap.
Page 10 Technical Procedure 5. Use a 4mm allen key to remove the two (2) socket head cap screws securing the rear of the right side belt guard to the bike, use a 3mm allen key to remove the two (2) button head cap screws from the front of the right side belt guard, then remove the belt guard.
Page 11 Technical Procedure 7. Use a #2 phillips screwdriver to remove the four (4) button head screws securing the inner right fork guard assembly to the bike, then remove the inner fork guard. Fig. 17 8. Use a 3mm allen key to remove the four (4) button head cap screws from the left side outer fork guard, use a #2 phillips screwdriver to remove the single screw at the bottom of the guard, then...
Page 12 Technical Procedure 9. Use a #2 phillips screw driver to remove the four (4) button head screws securing the inner left fork guard to the frame, then use a 3mm allen key to remove the single button head cap screw at the bottom of the shroud, as well as the two (2) screws securing the front shroud cover.
Page 13 Technical Procedure 11. Mark the location of the belt tension lock nut (this will be used to help when re-tensioning the belt) using a permanent marker or pencil. 12. Use a 18mm open-ended wrench to loosen the lock nut. Fig. 21 13.
Page 14 Technical Procedure 15. With the belt loosened, walk the belt off of the right crank arm pulley. Fig. 23 16. Use a 5mm allen key to loosen the flywheel adjustment screws on the left and right side of the flywheel. Remember to adjust these evenly when reinstalling the flywheel so that the flywheel sits evenly between the brake magnets - See Flywheel Adjustment - Page 25...
Page 15 Technical Procedure 17. Use an 18mm and a 19mm open-ended wrenches to remove the flywheel axle nut from the axle. 18. Support the flywheel, then remove the flywheel axle from the left side of the bike. WARNING: With the axle removed, the flywheel is only supported by two tabs on the frame.
Page 16 Technical Procedure Schwinn Za/s Belts and/or Flywheel Replacement Required Tools: • 3mm Allen Key • 4mm Allen Key • 6mm Allen Key • #2 Phillips Head Screwdriver • 10mm Open-Ended Wrench • 18mm Open-Ended Wrench • 19mm Open-Ended Wrench x2 •...
Page 17 Technical Procedure 2. Use a 4mm allen key to remove the four (4) socket head cap screws securing the left side belt guard to the bike, then remove the belt guard. Fig. 28 3. Use a 3mm allen key to remove the two (2) flat head machine screws from the left and right sides of the nose cap.
Page 18 Technical Procedure Use a 4mm allen key to remove the two (2) socket head cap screws securing the rear of the right side belt guard to the bike, use a 3mm allen key to remove the two (2) button head cap screws from the front of the right side belt guard, then remove the belt guard.
Page 19 Technical Procedure Use a #2 phillips screwdriver to remove the four (4) button head screws securing the inner right fork guard assembly to the bike, then remove the inner fork guard. Fig. 32 Use a 3mm allen key to remove the five (5) button head cap screws from the left side outer fork guard, then remove the fork guard.
Page 20 Technical Procedure Use a 3mm allen key to remove the button head cap screw from the top of the outer generator belt guard, use a #2 phillips screwdriver to remove the pan head machine screw from the bottom of the belt guard, then remove the belt guard.
Page 21 Technical Procedure Walk the generator belt off of the generator pulley. Fig. 36 Mark the location of the belt tension lock nut (this will be used to help when re-tensioning the belt) using a permanent marker or pencil. Use a 18mm open-ended wrench to loosen the lock nut.
Page 22 Technical Procedure Use a 6mm allen key to loosen the belt tension screw to loosen the belt. NOTE: Be sure to mark the location of the belt pulley tension block before loosening, so during install of new parts, the belt tension can be returned to factory settings.
Page 23 Technical Procedure 18. Use a 5mm allen key to loosen the flywheel adjustment screws on the left and right side of the flywheel. Remember to adjust these evenly when reinstalling the flywheel so that the flywheel sits evenly between the brake magnets - See Flywheel Adjustment - Page 25 Fig.
Page 24 Technical Procedure After removing the flywheel from the forks, the flywheel, drive belt, and generator belt can all be replaced. Remember to properly adjust flywheel so that it sits between the brake magnets - See Flywheel Adjustment - Page 28, Step 8. Note: If replacing the flywheel, remember to move the generator and drive belts over to the new flywheel.
Page 25 • #2 Phillips Head Screwdriver • 19mm Open-Ended Wrench x2 Note that while the images below show the Schwinn X bike, the procedure is valid for the Schwinn Z bike. Use a 4mm allen key to remove he two (2) socket head cap screws securing the left side belt guard cap.
Page 26 Technical Procedure Use a 4mm allen key to remove the four (4) socket head cap screws securing the left side belt guard to the bike, then remove the belt guard. Fig. 44 Use a 3mm allen key to remove the two (2) flat head machine screws from the left and right sides of the nose cap.
Page 27 Technical Procedure Use a 4mm allen key to remove the two (2) socket head cap screws securing the rear of the right side belt guard to the bike, use a 3mm allen key to remove the two (2) button head cap screws from the front of the right side belt guard, then remove the belt guard.
Page 28 Technical Procedure Use a 3mm allen key to remove the four (4) button head cap screws from the left side outer fork guard, use a #2 phillips screwdriver to remove the single screw at the bottom of the guard, then remove the fork guard. Fig.
Page 29 Technical Procedure Adjust the flywheel position using a 5mm allen key to turn the left and right flywheel jack screws in 1/4 turn increments until the flywheel is centered between the brake magnets. Fig. 50 Fig. 51 Brake Magnets 10. Once the flywheel is centered between the brake magnets, re-tighten the flywheel axle nut.
Page 30 Technical Procedure Gear-Angle Sensor Replacement Required Tools: • #2 Phillips Screwdriver Required Parts: • 718-6131 “ASSY, SENSOR, ENCODER, ACPU” 1. Use a 3mm allen key to remove the two (2) flat head machine screws from the left and right sides of the nose cap.
Page 31 Technical Procedure 4. Use a #2 phillips screwdriver to remove the screw securing the angle sensor to the brake. Fig. 55 5. Push in on the angle sensor body clip from the left side of the bike then pull the angle sensor assembly off of the brake.
Page 32 Technical Procedure 4iiii Crank Arm Battery Replacement Required Tools: • #2 Phillips Screwdriver Use a small phillips screwdriver to remove the screw securing the battery cover to the crank arm, remove the battery cover, remove the old batteries, then install the new AA batteries.
Page 33 Technical Procedure Pedal Replacement Required Tools: • 8mm Allen Key • Crank Puller Tool with 22mm X 1mm Threading (CWP-7) Spin the crank arms until the pedal is toward the rear of the bike. Use an 8mm allen key to remove the pedal bolt securing the pedal to the crank arm.
Page 34 Technical Procedure Left Crank Arm Removal Required Tools: • 8mm Allen Key • Crank Puller Tool with 22mm X 1mm Threading (CWP-7) • Torque Wrench • 8mm Allen Socket Required Parts: 740-9524 “CRANK, WITH 4iiii, LEFT,NEXT GEN AC BIKE” Use an 8mm allen key to remove the crank bolt securing the crank arm to the bottom bracket.
Page 35 Technical Procedure Tap the buttons simultaneously then tap the button to enter Maintenance Mode. Press the button until 4iiii SCAN is shown in the message center then press the button to begin the pairing process. Check the side of the power sensor for a 4 or 5-digit ANT+ ID code then spin the crank to activate it for pairing.
Page 36 Technical Procedure 3. Select your bike and Connect 4. Enter Settings Fig. 65 Fig. 66 6. Go Back. 5. Update Features and Software 7. Calibrate via 4iiii app if power appears (black if available) low or high Fig. 67 Fig. 68 Page 36 637-8808 Rev.
Page 37 Technical Procedure 9. Follow the directions (point left crank straight 8. Select Calibrate in the app down to 6 o’clock) and tap crank image Fig. 69 Fig. 70 Page 37 637-8808 Rev. K...
Page 38 Technical Procedure Right Crank Arm Removal Required Tools: • 8mm Allen Key • Crank Puller Tool with 22mm X 1mm Threading (CWP-7) • Torque Wrench • 8mm Allen Socket Required Parts: • 740-9523 “ASSY, CRANK, DRIVE SIDE, POLY V, NEXT GEN AC BIKES” Use a 4mm allen key to remove he two (2) socket head cap screws securing the left side belt guard cap.
Page 39 Technical Procedure Use a 4mm allen key to remove the two (2) socket head cap screws securing the rear of the right side belt guard to the bike, use a 3mm allen key to remove the two (2) button head cap screws from the front of the right side belt guard, then remove the belt guard.
Page 40 Technical Procedure Use a 6mm allen key to loosen the belt tension screw to loosen the belt. NOTE: Be sure to mark the location of the belt pulley tension block before loosening, so during reinstall, the belt tension can be returned to factory settings.
Page 41 Technical Procedure Use an 8mm allen key to remove the crank bolt securing the crank arm to the bottom bracket. NOTE: When installing new crank arm, the crank bolt needs to be torqued to 50 Nm (37 Ft- Lbs). Fig. 77 Use a crank puller tool with the large tip to remove the crank arm.

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