LeMond Revolution Service Manual
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LeMond Revolution Service Manual

Bike trainer
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  • Page 1 S E R V I C E M A N U A L...
  • Page 3 Visit our web site at www.LeMondRevolution.com LeMond Revolution LLC Minneapolis, MN USA Telephone (+1) 612.486.5750 Fax: (+1) 612.293.7894 © 2013 LeMond Revolution LLC LeMond and Revolution are registered trademarks. Document #300154 Rev. A...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SAFETY INSTRUCTIONS ..............5 ASSEMBLY INSTRUCTIONS .

  • Page 5: Safety Instructions

    ATING, SERVICING OR MAINTENANCE INSTRUCTIONS READ ALL INSTRUCTIONS BEFORE WORKING ON THIS EQUIPMENT This service manual should be used in conjunction with the Revolution Owner’s Manual (Docu- ment #250128). All warnings and instructions contained in the Revolution Owner’s Manual should be read and understood prior to working on this equipment.

  • Page 6: Assembly Instructions

    Your LeMond should arrive packed in 1 carton. Upon arrival fully inspect the carton for EVOLUTION damage. If damage is found please contact the delivery company and the LeMond Customer Service Department at (612) 486-5750 to report any damage. UNPACKING Remove all components and parts from the packaging and check them against the list below and Figure 1.1.
  • Page 7 ASSEMBLY INSTRUCTIONS ASSEMBLY WARNING: THE BODY ASSEMBLY WEIGHS 28LBS 12.7 KG . USE CAUTION WHEN HANDLING THE BODY ASSEMBLY AND BE SURE TO SUPPORT THE ASSEMBLY PROPERLY WHILE INSTALLING THE BASE ASSEMBLY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PROPERTY DAMAGE OR INJURY.
  • Page 8 ASSEMBLY INSTRUCTIONS ASSEMBLY INSTRUCTIONS Install the base assembly to the body assembly using the included 60mm screw and two 15mm screws removed from the shipping base. (Figure 1.2) Begin by starting the longer (60mm) screw through the center arm of the base assembly into the body assembly.

  • Page 9: Bicycle Mounting Instructions

    BICYCLE MOUNTING INSTRUCTIONS MOUNTING YOUR BICYCLE TO THE LEMOND REVOLUTION Note: The LeMond is shipped from the factory equipped with a Shimano®/SRAM® compatible EVOLUTION 10-speed cassette. If your bike is equipped with a 9-speed Shimano®/SRAM® derailleur or Campagno- lo® derailleur please follow the instructions on page 12 to change cassettes and/or cassette adapters.
  • Page 10 BICYCLE MOUNTING INSTRUCTIONS With the chain resting on the smallest sprocket and the chain stays resting on the axle, EVOLUTION press down gently on the bicycle seat and roll the bicycle forward. As the bicycle rolls forward it will drop about an inch as the dropouts seat onto the axle. (Figure 2.3) FIGURE 2.3 seated squarely in the dropouts.
  • Page 11 BICYCLE MOUNTING INSTRUCTIONS Tighten the acorn nut on the quick release skewer while holding the lever on the opposite side and lock the skewer with the lever. (Figure 2.4) Lock Skewer Tighten Skewer Acorn Nut FIGURE 2.4 Note: The quick-release lever should be fully closed with enough e ort to leave an impression in the palm of your hand.
  • Page 12 Torque Wrench REQUIRED PARTS Shimano®, SRAM® or Campagnolo® Cassette of Choice (9 or 10-speed) Campagnolo® Cassette Adaptor (if changing to Campagnolo®) [LeMond P/N: 250094] INSTRUCTIONS Remove the axle skewer from the using caution to retain the spacer on the fan side.
  • Page 13 CASSETTE ADAPTOR ASSEMBLY With the cassette removed, use the 16mm socket to remove the hub nut from the shaft at the center of the cassette adaptor. (Figure 3.2) Hub Nut FIGURE 3.2 Remove the cassette adaptor assembly. (Figure 3.1) Before proceeding make sure that the adaptor spacer is still present on the shaft in the hub recess. The adaptor spacer slides freely on the shaft and may have slid out during removal of the cassette adaptor.
  • Page 14 CASSETTE ADAPTOR ASSEMBLY Install the replacement Campagnolo® adaptor onto the shaft and reinstall the 16mm hub nut. Tighten the nut to 2.5 N m (22 in-lb). (Figure 3.1) Note: In some cases the bearing inside the adaptor will come loose during installation. If the bearing moves, be sure that the spacer between the bearings is still in place and push the bearing back into place by pressing around the outside edge of the bearing.
  • Page 15 BELT REMOVAL BELT REMOVAL/INSTALLATION REQUIRED TOOLS 4mm Hex Key or Hex Socket 3mm Hex Key or Hex Socket REQUIRED PARTS Replacement Belt If Needed (P/N: 250122) REMOVAL INSTRUCTIONS Remove the body side cover by removing the three screws. (Figure 4.1) FIGURE 4.1 Loosen the lower belt tensioner screw (A), and then the upper belt tensioner screw (B).
  • Page 16 BELT TENSIONING BELT TENSIONING INSTRUCTIONS REQUIRED TOOLS 4mm Hex Key or Hex Socket 3mm Hex Key or Hex Socket INSTRUCTIONS Remove the body side cover. (Figure 5.1) FIGURE 5.1 Loosen the belt tensioner lock screw 1/4 to 1/2 turn. (A in Figure 5.2) Loosen the adjustment screw (B in Figure 5.2).

  • Page 17: Cassette And Cassette Adaptor

    PULLEY REMOVAL AND INSTALLATION PULLEY REMOVAL/INSTALLATION REQUIRED TOOLS Chain Whip Shimano®/SRAM® or Campagnolo® Lockring Tool 16mm Socket and Socket Wrench Torque Wrench 4mm Hex Key or Hex Socket REQUIRED PARTS REMOVAL INSTRUCTIONS Remove the belt. (p. 15) Remove the Cassette and Cassette Adaptor (p. 12) Slide the Pulley assembly o the shaft.
  • Page 18 PULLEY HUB REPLACEMENT PULLEY HUB ASSEMBLY REPLACEMENT REQUIRED TOOLS Chain Whip Shimano®/SRAM® or Campagnolo® Lockring Tool 16mm Socket and Socket Wrench Torque Wrench 4mm Hex Key or Hex Socket REQUIRED PARTS Pulley Hub Assembly (P/N: 250068) REMOVAL INSTRUCTIONS Remove the belt. (p.15) Remove the cassette and cassette adaptor.
  • Page 19 PULLEY FLANGE REPLACEMENT OUTER PULLEY FLANGE REPLACEMENT REQUIRED TOOLS 2.5mm Hex Key or Hex Socket or Phillips Head Screwdriver REQUIRED PARTS Drive Pulley Flange (P/N: 250071) Note: The Outer (Cassette side) Flange can be replaced without removing the pulley from the unit. REMOVAL INSTRUCTIONS Remove the 8-4mm screws from the perimeter on the ange using a 2.5mm hex key.
  • Page 20 PULLEY FLANGE REPLACEMENT INNER PULLEY FLANGE REPLACEMENT REQUIRED TOOLS Chain Whip Shimano®/SRAM® or Campagnolo® Lockring Tool 16mm Socket and Socket Wrench Torque Wrench 4mm Hex Key or Hex Socket 2.5mm Hex Key or Hex Socket or Phillips Head Screwdriver REQUIRED PARTS Inner Pulley Flange (P/N: 250145) INSTRUCTIONS Remove the belt.

  • Page 21: Flywheel Removal

    FLYWHEEL REMOVAL AND INSTALLATION FLYWHEEL REMOVAL REQUIRED TOOLS 3mm Hex Key or Hex Socket Flathead Screwdriver or Pliers 17mm Socket and Socket Wrench Gear/Sheave Puller or Flywheel Puller Tool (P/N 250143) INSTRUCTIONS Remove the six socket head screws with a 3mm hex key from the outer fan shroud and remove the fan shroud.
  • Page 22 FLYWHEEL REMOVAL AND INSTALLATION the washer from the shaft. (Figure 9.3) FIGURE 9.3 Using the Flywheel Puller (P Note: FLYWHEEL PULLER INSTRUCTIONS REQUIRED TOOLS Flywheel Puller Tool (P/N 250143) 6mm Hex Key or Hex Socket 10mm Hex Key or Hex Socket INSTRUCTIONS Pass the 6mm socket head screws through the service puller plate and...
  • Page 23 FLYWHEEL REMOVAL AND INSTALLATION FLYWHEEL INSTALLATION INSTRUCTIONS Slide the ywheel onto the shaft and rmly press it in place. Place the at washer onto the shaft and start the nylock nut onto the shaft threads. (Figure 9.5) FIGURE 9.5 Firmly hold the pulley and begin tightening the nylock nut. After the ywheel has started to press onto the shaft hold the ywheel and nish tightening the nylock nut onto the shaft.
  • Page 24 Note: In some cases the largest sprocket on the rear cassette is not accessible due to variations in derail- leur style and setup. We DO NOT recommend modifying your bicycle for use with the Revolution as please follow the steps below.
  • Page 25 Rear derailleur skips shifts while riding Note: We designed the Revolution to be compatible with a large variety of bicycles, however, there are some cases where the derailleur may not be fully compatible with the cassette. If skipped and missed shifts Check that the bicycle is mounted properly according to the instructions in this manual.

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