Life Fitness 95ci

Lifecycle Upright Bikes
LC9500, LC9100, LC8500, C9, C7,

95Ce, 95Ci, 93Ci, and 90C
Customer Support Services

SERVICE MANUAL
Lifecycle Upright Bikes LC95, LC91, LC85, C9, C7, 95Ce, 95Ci, 93Ci, and 90C
GENERAL CONTENTS
INTRODUCTION ...............................................................................................................ii
SPECIAL SERVICE TOOLS .............................................................................................iii
GLOSSARY (Pending) .....................................................................................................iv
COMPONENT IDENTIFICATION......................................................................................v
SECTIONAL CONTENTS
TROUBLESHOOTING 1
DIAGNOSTICS LED 2A
DIAGNOSTICS LCD 2B
HOW TO…SERVICE 3
ELECTRONICS 4
MISCELLANEOUS 5
i
INTRODUCTION
This service manual is applicable to Upright Exercise Bikes LC9500, 9100, 8500, C9, C7, 95Ci, 93Ci, 90C, and
95Ce LCD. Information represents typical configuration and may differ slightly from actual equipment. The service
manual provides recommendations for safe and efficient approaches to problem situations.
If an operating problem should arise, turn to the TROUBLESHOOTING GUIDES and attempt to isolate what is
causing the malfunction. The GUIDES are listed by symptoms and follow with suggestions as to the most probable
cause of the problem.
Once you have pinpointed the source of the problem, turn to the appropriate "How To..." section and review the
proper procedures for removing, replacing or adjusting a part. The "How To..." sections are organized by
replaceable part (or assembly) name and each page lists the “Special Tools Required“ to complete the specific
task.
Refer to COMPONENT IDENTIFICATION in the front part of this section to locate and identify in order service
repair parts for your machine.
If you do not have a part in stock, a form to order by FAX has been included in Section V for your convenience or
you can call Life Fitness Customer Support Services any Monday through Friday from 8:00 AM to 6:00 PM ( C.S.T.
). When you place a call, in order to speed our response to your particular situation, please have the following
information available for the customer service phone technician who will be prepared to assist you:
1. The Lifecycle equipment model number

2. The serial number
3. The symptom of the problem
4. The part name and number to order
When you receive your order, review the appropriate "How To..." section and follow the step by step procedures
designed to help you install the part quickly and correctly.
If you have any questions or comments please phone, mail, or fax us at:
LIFE FITNESS COMPANY - CUSTOMER SUPPORT SERVICES

10601 Belmont Avenue, Franklin Park, IL 60131; U.S.A.
Telephone: 847-451-0036, Toll Free: 800-351-3737, FAX: 847-288-3702
ii
INTRODUCTION
SPECIAL SERVICE TOOL REQUIREMENTS
Unless otherwise specified, only basic hand tools are required to perform service procedures
outlined in this section. Some of these standard tools should consist of: Philips and Straight-
Blade Screw Drivers, Torx Set, Pliers, Rubber Mallet, Pry Bar, Snap Ring Pliers (internal and
external), Standard and Metric size Socket Set (3/8 or 1/2 drive), and Standard and Metric size
Combination, open-end, or Box Wrenches.
Specialized tools will be listed after the sub-heading Special Service Tools:, which appears
below the Service Procedure Heading at the top of the page. If no specialized tools are
required, then the title would read: Special Service Tools: NONE, which means that standard
hand tools should be employed to provide service to the product.
Specialized tools must be used to safely and effectively complete the service procedures.
Improvisation or attempts to use any other tool could result in unnecessary damage to the
equipment or personal injury.
iii
GLOSSARY
PENDING
iv
COMPONENT IDENTIFICATION – C9 and C7 Consumer Bikes
Handlebar
Console
Standard Seat
Accessory Tray
Seat Pull-Pin
Console Post
Seat Post
Side Shroud
Front Wheels
Pedal
Crankarm
C9 Assembly Components
Note: C7 will not have accessory tray

and handlebars are without electrodes.
v
Shroud
Gasket
Main
Cable
Resistor
Assembly
PCB
Alternator
Crankshaft
Intermediate Hub
Pulley
Alternator
Belt
C7 Left Side Components
Note: C9 has a 6 volt battery
mounted on a bracket above
the PCB.
vi
Idler
Assembly
Crank
Pulley
PCB
Bracket
Crank Shaft
Hub
Main Drive
Belt Clutch
Assembly
C7 Right Side Components
vii
COMPONENT IDENTIFICATION - LC9500, LC9100, LC8500 Commercial Bikes
Handlebar
Console
Deluxe Seat
Accessory Tray
Seat Post
Console Post
Cover
Seat Latch
Side Shroud
Front Wheels
Pedal
Crankarm
Lc9500 Assembly Components
viii
Shroud
Gasket
Main
Cable Resistor
Assembly
PCB
Alternator
Crankshaft
Intermediate Hub
Pulley
Alternator
Belt
Lc8500 Left Side Components
Note: The Lc9500 and 9100 has a
6 volt battery mounted on a bracket
above the PCB.
ix
Idler
Crank
Assembly
Pulley
PCB
Bracket
Crank Shaft
Hub
Main Drive Clutch

Belt Assembly
Lc8500 Right Side Components
x
SECTION I
TROUBLESHOOTING
GUIDES
Page
Display Console LEDS Not Illuminating .............................................................................. 3
Display Console Initializes Then Fails................................................................................. 3
No Prompt ........................................................................................................................... 3
LEDS Not Constant ............................................................................................................. 4
LEDS Do Not Extinguish ..................................................................................................... 4
Prompt Flashes ................................................................................................................... 4
Display Console Keys Does Not Function........................................................................... 4
Excessive Resistance Is Immediate.................................................................................... 5
Excessive Resistance Loading Occurs ............................................................................... 5
Resistance Varies During Manual Mode ............................................................................. 5
Random And Hill Resistance Is Constant, No Variation...................................................... 6
Pedaling Is Difficult.............................................................................................................. 6
Pedaling Is To Easy ............................................................................................................6
Inadequate Resistance While Pedaling .............................................................................. 7
Battery Over-Heating...........................................................................................................7
Bike Not Stable ................................................................................................................... 7
Loud Noise .......................................................................................................................... 7
No Heart Rate ..................................................................................................................... 8
Channels Do Not Change ................................................................................................... 8
Sound Does Not Change .................................................................................................... 8
Faulty PCB .......................................................................................................................... 8
No Sound ............................................................................................................................ 8
Unable To Receive Channels.............................................................................................. 9
Snow and Noise .................................................................................................................. 9
Screen Is Blank ................................................................................................................... 9
Screen Does Not Respond To Touch ................................................................................. 9
Wrong Buttons Activated when Touching Screen ............................................................... 9
No Buttons Activated When Touching Screen .................................................................... 9
Screen Does Not Turn On And No Audio............................................................................ 9
Testing The Inverter Board.................................................................................................. 10
Testing The Power Supply Cable........................................................................................ 11
Notes ................................................................................................................................... 12
1
TROUBLESHOOTING GUIDE
Notes
2
SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

Display Console LEDs not illuminating Auto start not responding. Check auto start not responding.
Keypad not responding. Test keypad in diagnostics.
Insufficient battery voltage. Check battery voltage. The LC9500,
LC9100, and C9i have a 6VDC
battery (non-alkaline) which should
test at a minimum of 6.0 VDC. The
LC8500, and C7 has a 9VDC alkaline
battery and it should test at a
minimum of 9.0 VDC. Replace battery
if it fails to meet minimum
requirements.
Loose wire connections. Disconnect then reconnect
connections.
Worn or damaged wire Inspect wire harnesses. Replace
harnesses. worn or damaged harness.
Malfunctioning display Test with substitute display console.
console. Replace malfunctioning display
console.
Malfunctioning alternator Test with substitute ACB. Replace
control board (ACB). malfunctioning ACB.
Display console initializes then fails Loose wire connections. Disconnect then secure connections.
No RPM. Enter Diagnostic and check for RPM.
Malfunctioning alternator. Test alternator output or test with
substitute alternator. Replace
malfunctioning alternator. Refer to
Alternator Voltage Test.
Malfunctioning alternator Test with substitute alternator control
control board. board. Replace malfunctioning board.
Malfunctioning display Test with substitute display console.
console. Replace malfunctioning display
console.
harnesses. worn or damaged harness.
No prompt upon release of START Malfunctioning display Test with substitute display console.
key. Entry of additional information not console. Replace malfunctioning display
allowed. console.
Battery drained. Replace Battery with new one.
3

Display Console LEDs are not Pedaling to slowly Pedal faster than 35 RPM.
constant
Insufficient battery voltage Check battery voltage. The LC9500,
LC9100, and C9i have a 6VDC
battery (non-alkaline) which should
test at a minimum of 6.0 VDC. The
requirements.
Loose wire connections Disconnect then reconnect
connections.
harnesses worn or damaged harnesses.
Malfunctioning Display Test with substitute Display Console.
Console Replace malfunctioning Display
Console.
Malfunctioning Alternator Test with substitute Alternator Control
Control Board Board. Replace malfunctioning board.
Malfunctioning Alternator Test Alternator output or test with
substitute Alternator. Replace
malfunctioning Alternator. Refer to
Display Console LEDs do not Malfunctioning Alternator Test with substitute Alternator Control
extinguish in timely manner at the end Control Board Board. Replace defective board.
of a workout, when the CLEAR key is
Malfunctioning Display Inspect for damage or depression at
pressed, or when the pedaling stops.
Console START key. Test with substitute
Display Console. Replace
malfunctioning Display Console.
Prompt persistently flashes and entry Attempting to enter improper Refer to Operation Manual for time
of additional information is not allowed. duration of time duration requirements.
Console.
Display Console keys (except START Attempting to enter program Refer to Operation Manual for
key) do not function and Exercise Bike not available. program availability.
does not respond.
Malfunctioning Keypad Test Keypad in Diagnostics.
Console.
4

Upon start of program, excessive Insufficient battery voltage Check battery voltage. The LC9500,
resistance load is immediate; no LC9100, and C9i have a 6VDC
normal, incremental increase from “no battery (non-alkaline) which should
load.” test at a minimum of 6.0 VDC. The
requirements.
Loose wire connections Disconnect then, reconnect
connections.
harnesses worn or damaged harness.
Console.
Control Board Board. Replace malfunctioning board.
Malfunctioning Alternator Test Alternator output or, test with
During program, excessive resistance Loose wire connections Disconnect then, reconnect
loading occurs. connections.
harnesses worn or damaged harness.
Console Replace Display Console.
Malfunctioning Alternator Test with substitute ACB. Replace
Control Board (ACB) malfunctioning ACB.
During MANUAL program, resistance Pedaling too slowly Pedal faster than 35 RPM.
variation occurs.
connections.
Worn or damaged harnesses Inspect wire harnesses. Replace
worn or damaged harness.
Console Replace Display Console.
5

During MANUAL program, resistance Malfunctioning Alternator Test with substitute Alternator Control
variation occurs. Control Board Board. Replace defective board.
During RANDOM or HILL programs, Loose wire connections Disconnect then, reconnect
resistance is constant without variation connections.
for interval training nor hill
incline/decline.
Console Replace malfunctioning Console.
Control Board Board. Replace defective board.
Pedaling is difficult, feels restricted or, Malfunctioning Pulley Clutch Inspect Clutch for free backward and
is not possible when Exercise Bike has Assembly forward rotation. Replace
not been started (START key not malfunctioning Pulley Clutch or
pressed). Freewheel.
Alternator Belt excessively Inspect belt deflection. Adjust as
tight necessary. Alternator Belt Deflection:
1/4 inch (6mm)
Alternator Belt Alignment OFF Realign alternator belt to far users left
groove of the alternator pulley, not in
the center.
Crank bearings worn Replace Crank Bearings.
During exercise program, pedaling is Pedaling too slowly Pedal faster than 30 RPM.
insufficiently easy, not providing
Program level doesn’t Select higher level.
adequate resistance.
challenge user ability
connections.
Console.
Control Board Board. Replace defective board.
6

During exercise program, pedaling is Malfunctioning Alternator Test Alternator output or, test with
insufficiently easy, not providing substitute Alternator. Replace
adequate resistance. malfunctioning Alternator. Refer to
loose necessary. Alternator Belt Deflection:
1/4 inch (6mm)
Drive Belt excessively loose Inspect Belt. Replace Belt.
Battery over-heating during exercise Battery Wires incorrectly Inspect connections: red wire to
program. connected positive (+) lead; black wire to
negative (-) lead.
Worn Battery Wires Inspect Wires. Replace Wires or
harness.
Battery leads grounding upon Inspect leads. Replace battery.
frame
Console Replace malfunctioning Console.
Exercise Bike not stable upon floor. Stabilizer Foot Pads not Adjust Foot Pads.
adjusted correctly
Floor surface not level Position Exercise Bike upon level
surface.
Wheel(s) damaged Replace damaged wheel(s).
Frame damaged Contact Customer Support Services.
During exercise program, loud noise Non-carpeted, hard surface Place Exercise Bike upon softer
issuing from Exercise Bike. floor surfaced floor.
Improper riding style Change style. Do not lean excessively
to either side.
Crank Bearings worn Inspect Bearings. Replace as
necessary.
loose necessary.
Alternator Belt Deflection: 1/4 inch
(6mm)
Alternator Belt worn Replace Belt.
Malfunctioning Alternator Operate Exercise Bike as in normal
use with light and heavy load levels.
Listen for excessive noise. Replace
Alternator as necessary.
Drive Belt excessively loose Inspect Belt. Replace Belt.
Free-wheel Pulley Assembly Inspect clutch for free rotation.
Replace defective Freewheel Pulley.
7

No heart rate or, display reads (No No heart rate reading Executive Diagnostic Mode to verify
Heart Rate). performance of heart rate function.
Faulty cable connection Verify heart-rate cable is properly
connected.
Using an ohmmeter, verify continuity
at the main console cable. See wiring
diagram for pin location.
Malfunctioning Replace Handlebar/Lifepulse
Handlebar/Lifepulse Grip Assembly.
Assembly (include. Worn or
damaged heart rate lead)
Life Pulse handlebar Verify that the handlebar is
functioning. See diagrams.
Using an ohmmeter, verify continuity
between Lifepulse sensor and cable
connection. See wiring diagram for
pin location.
Handlebar/Lifepulse Grip Dry wipe sensors.
Assembly
Loose or malfunctioning heart Secure connection. Replace
rate lead connection at Display malfunctioning Handlebar/Lifepulse
Console Grip Assembly
Console.
Wear or damage to grip Replace the handlebar assembly.
Channels do not change. Key pad malfunction. Run Key pad test in diagnostics.
Replace if defective.
Interface PC board defective. Replace Interface PC board.
Sound does not change. Key pad malfunction. Run Key pad test in diagnostics.
Replace if defective.
Interface PC board defective. Replace Interface PC board.
Faulty PCB Only one channel programmed Follow the setup procedures in the
operator manual.
No sound. Faulty headphones. Replace headphones.
Faulty headphone jack Replace headphone jack assembly.
Faulty cable to Headphone Replace Headphone jack cable.
jack assembly
Air/cable setting may not be Follow the set up procedures in the
correct operators’ manual.
Power applied prior to video Power down, install video, and follow
hookup channel instruction.
8

Unable to receive any channels when Air/cable setting may not be Follow the setup procedures in the
using cable. correct. operator manual.
Coax Cable may be bad. Replace Coax Cable.
Coax Cable may be unplugged Reconnect Cable.
Cable system may not be Notify installer.
producing clear signal
Snow and noise appear on the screen. Air/cable setting may not be Follow the setup procedures in the
correct. operator manual.
Coax cable may be bad. Replace Coax cable.
Screen is blank with audio beeps or LCD Back Light burned up. Replace LCD/Touch Screen.
dark.
Back Light power inverter bad Replace backlight inverter
LCD Screen failure Replace LCD/Touch Screen.
Problem on the single board Replace Single Board Computer.
computer
Screen Does not respond to touch. Touch screen failure. Replace LCD/Touch Screen.
Problem with Single Board Replace Single Board Computer.
Computer.
The wrong buttons activate when the Touch Screen not calibrated Calibrate Touch Screen. Refer to
touch screen is touched. correctly Diagnostics.
Touch Screen Damaged. Replace LCD/Touch Screen.
No buttons activate when the touch Touch Screen Damaged. Replace LCD/Touch Screen.
screen is touched.
Failure On the single board Replace the single board Computer.
computer.
Screen does not turn ON and no No power. Check Main Cable for 5 & 12VDC.
audio. Check wiring diagram pin locations.
Faulty wire harness to console. Replace Wire Harness
LCD defective. Replace LCD\TOUCH screen
9
TROUBLESHOOTING GUIDE – TESTING THE INVERTER BOARD
Special Service Tools Required: Multi-meter
CAUTION! HIGH VOLTAGE ON CONNECTORS J2 AND J3

Test Points
1.
6
5
4
3 J1
J3 J2
2
1
Remove the Integrated System Console from the Unit.
2. Remove Rear Cover from the Console Assembly.
3. Plug in Power Supply and Remote Control to the Console
4. Press the Power On Key on the Remote Control.
5. TEST NO. 1: Place the Red Lead from the multi-meter onto Test Point 1 and the Black Lead onto Test
Point 3. Voltage should be 12 Vdc (+/- .5V).
6. TEST NO. 2: Place the Red Lead from the multi-meter onto Test Point 5 and the Black Lead to Test Point
3. Voltage should be 12 Vdc (+/- .5V)
PROBLEM SOLUTION
No Voltage on TP1 Replace Cable, Remote, or Main PC Board.
Voltage present on TP1 Replace the Inverter Board
Voltage on TP1 and TP2 but NO Voltage on TP5 Replace Cable between Inverter Board and Main PC Board
TEST POINT VOLTAGE DESCRIPTION PIN NUMBER

TP 1 & 2 12 Vdc VIN 1&2
TP 3 &4 0 Vdc Ground 3&4
5 12 Vdc Enable 5
5 0 Vdc Disable 5
6 Not Used Not Used 6/7/8
10
TROUBLESHOOTING GUIDE – TESTING THE POWER SUPPLY CABLE
Special Service Tools Required: Multi-meter
1. Unscrew the Retaining Nut securing the Power

Cable Plug. Remove the Cable. Positive
2. Using a Multi-meter, touch the Red Lead to the
POSITIVE area on the Cable, which is the center
of the cable. Next touch the Black Lead to the Negative
NEGATIVE area, which is the side of the inner
Cable. The voltage should read 12 Vdc.
Retaining nut
11
Notes
12
SECTION IIA
DIAGNOSTIC MODES
FOR LED UNITS
Page
LC9500................................................................................................................................ 3
LC9100 Console ................................................................................................................. 4
LC8500 Console ................................................................................................................. 5
C9 Console ......................................................................................................................... 6
C7 Console ......................................................................................................................... 7
Map ..................................................................................................................................... 8
Entry Level .......................................................................................................................... 9
Test/Service - All Leds And Keypad Test........................................................................... 10
Test/Service - Walking Led Test ........................................................................................ 11
Test/Service - Miscellaneous 1 Test .................................................................................. 12
Test/Service - Miscellaneous 2 Test .................................................................................. 13
Test/Service - Port I/O Test................................................................................................ 14
Test/Service - Life Pulse Test ............................................................................................ 15
Test/Service - Csafe Network Test..................................................................................... 16
Test/Service - Eeprom Test................................................................................................ 17
Test/Service - Telemetry Enable/Disable ........................................................................... 18
Test/Service - Language .................................................................................................... 19
Optional Settings - Max Workout Duration ......................................................................... 20
Optional Settings - English/Metric Units ............................................................................. 21
Optional Settings - Watt Display Enable/Disable ............................................................... 22
Optional Settings - Mets Display Enable/Disable ............................................................... 23
Optional Settings - Cal/Hr Display Enable/Disable............................................................. 24
Optional Settings – Watts Program Enable/Disable........................................................... 25
Optional Settings - Mets Program Enable/Disable ............................................................. 26
Optional Settings - Statistics .............................................................................................. 27
Optional Settings – Entertainment Controls ....................................................................... 28
Optional Settings - Photo Shoot ......................................................................................... 29
Notes .................................................................................................................................. 30
1
DISPLAY CONSOLE LC9500
NOTES
2
Lc9500
3
Lc9100
4
Lc8500
5
DISPLAY CONSOLE C9
C9
6
DISPLAY CONSOLE C7
C7
7
MAP
Test/service
Display Test All Led’s On
Walking Led Keypad Test Units
Alt. Voltage
Port I/o Test Relay
Fld Kick Alt Rpm
Entertainment
Language
8
ENTRY LEVEL
Co d e v e r - 13 0
Hold down the number 5 key (9500) or the UP ARROW key on (non-9500 units), then the press the CLEAR key
twice. Press the up ARROW key. The display menu will show after each press:
CODE VERSION ……………….ex: CODE VER - X.XX

CSAFE VERSION ……………...ex: Csafe ver-- X.XX.XX
PART NUMBER ………………..ex: XXXX-- XXXXX--0000
BOOT LOADER VERSION……ex: BOOT VER -- X
Press ENTER for entry into the OPTIONAL SETTINGS.

Press and hold COOL DOWN, and then press ENTER for entry into the TEST/SERVICE MENU.
9
TEST/SERVICE ALL LEDS AND KEYPAD TEST
On entry to this state, all of the LEDs will turn ON. Pressing the keys will result in a beep sound for all but the
START, ENTER and CLEAR keys, a character repeated across the message center will be displayed.
KEYS DISPLAYED CHARACTER KEYS DISPLAYED CHARACTER

0 0 Display Lock L
1 1 Workouts Plus K
2 2 Change Workout W
3 3 Up arrow U
4 4 Down Arrow D
5 5 Bike Mode B
6 6 Constant Cal. / Hr. A
7 7 Quick Start Q
8 8 Start S
9 9 Pause P
TIME UP U Cool down --
TIME DOWN D
LEVEL UP ▲
LEVEL DOWN ▼
BIKE MODE B
CONSTANT Cal./HR. A
FAT BURN F
CARDIO C
RANDOM R
MANUAL M
QUICK START Q
ZONE TRAINING Z
PERSONAL TRAINER T
HILL PLUS H
COOL DOWN --
Press the ENTER key to advance to the next diagnostic state. Press the CLEAR key to the previous diagnostic
state, or repeated pressing to exit diagnostics.
10
TEST/SERVICE - WALKING LED TEST
Message Center
Profile Window
On entry to this state, the LED segments in the MESSAGE CENTER and the PROFILE WINDOW will give the
animated effect of moving, henceforth, 'Walking LED."
11
TEST/SERVICE - MISCELLANEOUS 1 TESTS
0 950 80 0
FIELD DUTY CYCLE: In the Heart Rate Window, the Field Duty Cycle being applied to the alternator will be
displayed (LC9500 and C9I only). This value ranges from 0-255.
ALTERNATOR OUTPUT: In the Distance Window, the alternator output voltage is displayed for LC9500, LC9100,
and C9i.
RPM: In the RPM window, the present alternator RPM will be displayed.
CALORIES: In the Calories window, the present Load Duty Cycle being applied to the alternator will be displayed.
Load duty cycle ranges from 0-320 for LC9500 model, 0-280 for LC9100 and C9I models, and 0-415 for LC8500
and C7i models. This value can be adjusted using the Time Up and Time Down arrow keys on the LC9500
console, and the UP and DOWN arrow keys on all other models.
BIKE MODE KEY: Press the Bike Mode key to toggle the speaker ON and OFF.
‘0’ KEY: Press the ‘0’ key to toggle the RPM display between the alternator RPM and Reed Switch RPM. The
Enter LED will be ON when alternator RPM is displayed. RPM from the reed switch will not display when the
alternator is running.
‘5’ KEY: Press the ‘5’ key (9500 only) to toggle the alternator ON and OFF.
ENTER KEY: Press the ENTER key to advance to the next diagnostic state.
CLEAR KEY: Press the CLEAR key to go back to a previous diagnostic state, or repeated pressing to exit
diagnostics.
12
TEST/SERVICE - MISCELLANEOUS 2 TESTS
REED SWITCH RPM: In the Distance Window, the Reed Switch RPM is displayed. Note: The Reed Switch RPM
will not display when the alternator is running.
RPM: In the RPM window, the alternator RPM will be displayed.
SYSTEM VOLTAGE (Vsys): In the Heart Rate Window, the present system voltage (Vsys) supplied to the console
is displayed.
‘5’ KEY or DOWN ARROW KEY: Pressing the ‘5’ key (9500) or the DOWN Arrow key (91/85/C9i/C7I) will display
the value of Vsys at startup, before the alternator is turned ON. This is useful because you can get an indication of
the battery voltage of the 6V battery. Note: This voltage will be slightly lower than if you read the voltage of the 6V
battery directly from its terminals.
ENTER KEY: Press the ENTER key to advance to the next diagnostic state.
CLEAR KEY: Press the CLEAR key to go back to a previous diagnostic state, or repeated pressing to exit
diagnostics.
13
TEST/SERVICE - PORT I/O TEST
14
TEST/SERVICE - LIFE PULSE TEST
C- O G99
Upon initial entry to this test, a heart-shaped image will be displayed in the profile window along with two messages
in the message center when the user has both hands on the LifePulse sensors. The first message indicates the
LifePulse software version number. The second is the configuration of the LifePulse communication system, which
is either ON or OFF. This setting enables external communications for LifePulse development only and should be
left OFF. Following these messages, the display will change to a mode to display diagnostic information as
described below, and the LifePulse system will be ready to be manually tested.
When both hands are detected on the sensors, the letters ‘L’ and ‘R’ will be displayed in the profile window along
with the heart-shaped image.
Two timers will begin counting from the time both the left and right hands on condition occurs. The first timer,
located on the upper console message center display, will stop counting when LifePulse computes and displays an
initial peak detected heart rate reading. The second timer, located on the lower console display window, will
continue counting until LifePulse can reliably display the users heart rate. These timer readings are used for
reference only.
The gain value of the heart rate signal is shown following the ‘G’ in the message display window. The value ranges
from 0 to 99. A gain value of 99 is considered to be high and undesirable. A gain value of 0 is considered to be low
and also undesirable. Gain values of between 15 and 40 are considered normal depending upon whether the user
is exercising or standing still during this test.
15
TEST/SERVICE - CSAFE NETWORK TEST
Within this state, the CSAFE network can be tested.
This is how you can check to see if you’re receiving any communications from the network system.
1. Remain in the CSAFE Test Mode above (by not exiting out of if).
2. Make sure the network cable is plugged in.
3. Press the COOLDOWN key. This will reset the console and send out the standard power up message to the
network. The console should display “RESETTING NETWORK”. The power up message sent to the network is
the same one the console sends every time it is turned on (or anytime it is used by a user on self-powered
products).
4. If the network has received the CSAFE communication packet from the console and the network sends
configuration communication packet to the console the console will display “RECEIVING…"
5. If the console has been properly configured by the network and is allowed to accept user ID’s then the console
would show “GETID MODE XX”. The “GETID” message means were in the get ID mode. This is the mode the
network must put the console in, before it will ask the user to enter in their ID’s. If the console is not put in this
mode then the console will not ask for ID’s.
6. If the network does not respond to the console then the console will display a “NOT CONNECTED” message.
This indicates there is a problem with the network cable or network itself. This means the console has not
received any valid CSAFE communications from the network.
16
TEST/SERVICE - EEPROM TEST
This diagnostic state tests the Display Console EEPROM by reading, writing, and replacing all used locations in the
Display Console EEPROM. The EEPROM location being tested will appear in the display message center.
Pressing the DOWN ARROW will initiate the EEPROM test. If the test completes successfully, the message
EEPROM GOOD will appear. If the test fails, the message EEPROM BAD AT XX will display with the bad
EEPROM location.
17
TEST/SERVICE - TELEMETRY ENABLE/DISABLE
T E L E ME T R Y OF F
Within this state, the TELEMETRY can be turned ON or OFF. If a telemetry heart rate is detected, it will be
displayed when telemetry is set to ON.
By default, the lifecycles will have TELEMETRY ON except for C9I has telemetry OFF.
The DOWN ARROW will turn OFF the telemetry.
The UP ARROW will turn ON the telemetry and display a heart shape in the program profile window.
The ENTER key LED indicates when the value is at the default setting of TELEMETRY ON. This value is stored in
EEPROM and is kept when the unit is not in use.
18
TEST/SERVICE - LANGUAGE
L A NG E N GL I S H
Within this state, one of seven languages can be selected to include: English, German, French, Italian, Dutch,
Spanish or Portuguese.
The UP ARROW, when pressed, displays the next language in the list.
The DOWN ARROW, when pressed, displays the previous language in the list.
The ENTER key LED indicates when the language is set to the default of ENGLISH.
This value is stored EEPROM and is kept when the unit is not in use.
Press the CLEAR key to the previous diagnostic state, or repeated pressing to exit diagnostics.
19
OPTIONAL SETTINGS - MAX PROGRAM DURATION
MA X D U R A T I ON
Within this state, the MAXIMUM PROGRAM DURATION is displayed and can be adjusted from a range of 1-99
minutes on the LC9100, LC8500, C9i, and C7i. LC9500 can be adjusted from 10-99 minutes.
The DOWN ARROW will decrease the value by 1 minute. Key will Auto-Repeat if held.
The UP ARROW will increase the value by 1 minute. Key will Auto-Repeat if held.
The ENTER key LED indicates when the value is at the default of 60 minutes. This value is stored in EEPROM and
is kept when the unit is not in use.
20
OPTIONAL SETTINGS - ENGLISH/METRIC UNITS
E N GL I S H U N I T S
Within this state, ENGLISH or METRIC units can be selected.
The DOWN ARROW will select METRIC units.
The UP ARROW will select ENGLISH units.
The ENTER key LED indicates when the value is at the default setting of ENGLISH UNITS.
This value is stored in EEPROM and is kept when the unit is not in use.
21
OPTIONAL SETTINGS - WATTS DISPLAY ENABLE/DISABLE
WA T T D I S P L A Y OF F
If this option is enabled, the MESSAGE CENTER displays the Watts equivalent of the workload. This message will
only be displayed after a level change.
The DOWN ARROW will turn OFF the WATTS PROGRAM.
The UP ARROW will turn ON the WATTS PROGRAM.
The ENTER key LED indicates when the value is at the default setting of WATTS PROGRAM ON.
The value is stored in EEPROM and is kept when the bike is not in use.
22
OPTIONAL SETTINGS - METS DISPLAY ENABLE/DISABLE
ME T S D I S P L A Y OF F
If this option is enabled, the MESSAGE CENTER displays the METs equivalent of the workload. This message will
The DOWN ARROW will turn OFF the METS PROGRAM.
The UP ARROW will turn ON the METS PROGRAM.
The ENTER key LED indicates when the value is at the default setting of METS PROGRAM ON.
23
OPTIONAL SETTINGS - CAL/HR DISPLAY ENABLE/DISABLE
C A L / H D I S P OF F
If this option is enabled, the MESSAGE CENTER displays the Calories/Hour equivalent of the workload. This
message will only be displayed after a level change.
The DOWN ARROW will turn OFF the CAL/H program.
The UP ARROW will turn ON the CAL/H program.
The ENTER key LED indicates when the value is at the default setting of CAL/H PROGRAM ON.
24
OPTIONAL SETTINGS - WATTS PROGRAM ENABLE/DISABLE
WA T T D I S P L A Y OF F
If this option is enabled, the MESSAGE CENTER displays the Watts equivalent of the workload. This message will
The DOWN ARROW will turn OFF the WATTS PROGRAM.
The UP ARROW will turn ON the WATTS PROGRAM.
The ENTER key LED indicates when the value is at the default setting of WATTS PROGRAM ON.
25
OPTIONAL SETTINGS - METS PROGRAM ENABLE/DISABLE
ME T S P R OGR A M OF F
Within this state, METS PROGRAM can be turned ON or OFF.
By default, the LifeCycle will have the METS PROGRAM OFF.
The DOWN ARROW will turn OFF the METS PROGRAM.
The UP ARROW will turn ON the METS PROGRAM.
The ENTER key LED indicates when the value is at the default of METS PROGRAM ON.
This value is stored in EEPROM and is kept when the bike is not in use.
26
OPTIONAL SETTINGS - TOTAL HOURS AND STATISTICS
H OU R S = 0
Upon entry to this state, TOTAL HOURS are displayed.
STATISTICS can be displayed using the UP and DOWN arrow keys. The UP ARROW allows scrolling through the
available programs and shows the number of times each program has been selected. The DOWN ARROW backs
up through the list of available programs and back to the total hours displayed.
The Programs are:
HOUR = Total hours on the console

DIST = Total distance in miles on the console
HILL
RANDOM
MANUAL
FAT
CARDIO
AEROBICS
X-REV
WATTS
METS
QUICK
HEART HILL
HEART INT
HEART EXT
PRE SET
CUSTOM
27
OPTIONAL SETTINGS - ENTERTAINMENT CONTROLS
ON/OFF (LC9500 ONLY)
Channel or Volume Control
The ENTERTAINMENT CONTROL SETTING
Using the arrow keys will turn ON or OFF the entertainment (cardio theater/broadcast vision) controls for the
CSAFE PORT output for volume and channel change. Off is the default setting.
Note: The Channel or Volume Control is supplied by Cardio Theater or Broadcast Theater. These controls can be
found as indicated by the dashed-box.
28
OPTIONAL SETTINGS - PHOTO SHOOT
13 5 2 . 18 8 2 17 . 4 4
Data displayed in the message center is non-functional and intended only to simulate values for photographic
sessions.
Press the CLEAR key to the previous diagnostic state, or repeated pressing to exit diagnostics.
29
NOTES
30
SECTION IIB
DIAGNOSTIC MODES
FOR
95Ce LCD UNIT ONLY
Page
Welcome Screen ............................................................................................................... 3
Workout Screen ................................................................................................................. 4
Main Menu ......................................................................................................................... 5
System Test Menu ............................................................................................................. 6
System Diagnostics............................................................................................................ 7
Test Engineering ................................................................................................................ 8
Telemetry Test ................................................................................................................... 9
LifePulse Test ................................................................................................................... 10
CSAFE Network Test ........................................................................................................ 11
EEPROM Test................................................................................................................... 12
Information Menu .............................................................................................................. 13
Information Statistics......................................................................................................... 14
Software Versions ............................................................................................................. 15
System Errors ................................................................................................................... 16
Usage Log Report ............................................................................................................. 17
Configuration Menu........................................................................................................... 18
Managers Configuration.................................................................................................... 19
Custom Message Setup.................................................................................................... 20
Manufacturers Configuration............................................................................................. 21
TV Set Up .................................................................................................................... 22
Max Volume Setup............................................................................................................ 23
Touch Screen Configuration ............................................................................................. 24
1
DISPLAY CONSOLE 95Ce LCD ONLY
NOTES
2
DISPLAY CONSOLE 95Ce LCD ONLY
WELCOME SCREEN
LCD Console Welcome Screen

The Welcome Screen initially appears after Power-Up or when the bike is not in use. Touching the Screen will
change the screen to the WORKOUT SELECTION screen.
3
DISPLAY CONSOLE 95Ce LCD
WORKOUT SELECTION SCREEN
Double-Tap
Press and
Hold Down
From the Workout Selection Screen you will be able to enter the Systems Option Menu. To
enter, go to the Workout Selection Screen then press and hold the COOLDOWN key, and then
double-touch the Life Fitness icon.
After entering the System Options the Main Menu will appear. For further information about the
programs on this screen, refer to the Operators Manual.
4
SYSTEM OPTIONS – MAIN MENU
The System Options - Main Menu selections, when pressed, allows access to the System Test Menu, Information
Menu, and Configuration Menu.
Pressing the screen Exit key will return you back to the Workout Selection Screen.
5
SYSTEM TEST MENU
The System Test Menu allows the user to access the above by pressing the appropriate key.
Pressing the screen Back key will return you to the System Options – Main Menu screen.
6
SYSTEM DIAGNOSTICS
In the SYSTEM DIAGNOSTICS screen the feedback from various sources can be read.
SYSTEM VOLTAGE Displays the voltage present at the console.

ALTERNATOR VOLTAGE Displays the voltage out of the Alternator.
RPM Displays the Crank Arm RPM from the Alternator
REED RPM Displays the Crank Arm RPM from the Reed Switch
FIELD DUTY CYCLE Will display the percentage that the Alternator is being activated to produce a
load. The Higher the number the harder it is to Pedal.
KEY PAD VALUE Displays an acknowledgment when a key is pressed on the Console
REED When lit, the circles in the Reed Box indicate that the Reed Switch is Enabled or
Disabled. The setting can be toggled by pressing corresponding circle.
TEST ENGINEERING This test is for engineering purposes and is not applicable to servicing.
Pressing the screen Back button will return you to previous screen. Pressing the screen MAIN MENU key will
return you back to the MAIN MENU.
7
TEST ENGINEERING
All status windows on this screen should display OFF and should not be changed unless instructed to do so by Life
Fitness Customer Support.
Pressing the screen Back key will return you to the System Diagnostics screen.
8
TELEMETRY TEST
The circles in the Telemetry Box indicate whether Telemetry is Enabled or Disabled. Touching the appropriate
circle can enable or disable Telemetry. The Heart rate value window will display the users Heart Rate when
Telemetry is enabled.
Pressing the screen Back key will return you to the previous screen. Pressing screen MAIN MENU key will return
you back to the MAIN MENU.
9
LIFE PULSE TEST
The LifePulse™ System can be tested manually. The system will display a “Hands-On” reading when the user has
placed their hands on the LifePulse™ Sensors.
A timer will commence (and will show in the Acquisition Time window ) from the time both Hands-On condition
occurs to when the LifePulse system can generate a heart rate reading. The timer will stop when a numeric heart
rate reading appears in the Heart Rate Value window.
The Gain value and Confidence Level will also be displayed in their appropriate windows. Gain indicates the
strength of the heart rate signal being received. A low number indicates a strong signal where as a high number
indicates a weak signal. The value ranges for confidence go from 0 to 9, with 0 having the lowest confidence value.
Pressing the screen Back key will return you to the previous screen. Pressing the screen Main Menu key will return
you to Main Menu.
10
CSAFE TEST
CSafe Test - Not Available at This Time.
11
EEPROM TEST
Pressing the screen EEPROM Internal Test key allows testing of the EEPROM on the Single Board Computer.
Pressing the screen EEPROM External Test key allows testing of the EEPROM on the Interface Board.
In either instance, a PASS message will appear if the EEPROM is good
Pressing the screen Back button will return you to previous screen. Pressing the screen MAIN MENU key will return
you back to the MAIN MENU.
12
INFORMATION MENU
STATISTICS Displays various historical data regarding individual workout program usage and
critical system power levels.
SOFTWARE VERSIONS Displays current software version information.
SYSTEM ERRORS Displays historical information regarding system errors encountered during
operation.
USAGE LOG Displays historical information regarding pedal speeds and user weights.
Pressing the screen Back key will return you to System Options – Main Menu screen. Pressing the screen MAIN
MENU key will return you back to the MAIN MENU.
13
INFORMATION STATISTICS
N/A
Entry to this screen allows to user to view statistics such as: total hours of use on the unit and hours of use per
program used along with other information.
14
SOFTWARE VERSION
Note: Values shown are for reference only.
This screen allows the user to view the current software programs loaded into the unit along with its corresponding
Life Fitness part number if applicable.
15
SYSTEM ERRORS
This screen allows the user to view system errors that have been logged into the unit’s memory.
16
USAGE LOG REPORT
This screen allows the user to view detailed information in relation to RPMs used at different levels.
17
CONFIGURATION MENU
MANAGER Supervisory workout parameter setup.

MANUFACTURER Critical system parameter setup.
TV Television configuration.
TOUCH SCREEN CONFIGURATION Proximity calibration of touched screen.
18
MANAGER’S CONFIGURATION
Maximum Workout Duration: Allows the manager to set a maximum workout limit between 1 and 99 minutes. The
time can be modified using the up or down arrow keys. The unit default is 60 minutes.
Standby Configuration: Sets the desired amount of time of inactivity before the system automatically turns the
LCD screen backlight off. The LCD screen will illuminate the next time activity is detected. Inactivity Timer can be
set from 0 to 24 hours.
Program Timeout: Sets the amount of time the user can go without touching the Touchscreen while setting up
their workout, before the console resets back to the Welcome Screen. Program Timeout can be set from 20 to 255
seconds. The unit default is 60 seconds.
Pause Time: Set the amount of time the unit can be inactive before it reverts back to the Welcome Screen. Pause
Time can be set from 1 to 99 minutes. The unit default is 1 minute.
Units: Choose between English and Metric.
Language: The language of the message area display. Choices include English, Portuguese, Spanish, Dutch,
Japanese, Italian, French, and German.
Custom Message Setup: Allows for a custom message to be displayed across the Welcome Screen.
19
CUSTOM MESSAGE SETUP
This configuration allows for a custom message to be displayed across the Welcome Screen. Creating/changing a
Custom Message—after entering the Manager’s Configuration, check to make sure that Custom Message is
enabled, and then select Custom Message Setup. Upon entering the setup screen, a message can be entered
using the on-screen keyboard. Use the Shift button to input special characters and capital letters. The message
will scroll across the top of the screen as the message is being inputted, giving real time feedback. Accepting a
Custom Message—To accept the Custom Message, simply select the Main Menu button.
Erasing a Custom Message—to erase a Custom Message, enter the Custom Message Setup screen. Then select
Clear Message and then Main Menu.
20
MANUFACTURERS CONFIGURATION MENU
Access to this screen will only be available to Life Fitness certified technicians.
21
TV CONTROLS
This screen brings up the TV screen and allows adjustment of brightness, contrast, saturation and hue. Also allows
the choice of TV format, antenna setup and channel setup. To Set up channels: Select Auto in Channel Setup and
then press Start.
To delete an unwanted channel: Select Manual in Channel Setup window, then press Manual, then use the channel
controls on the Control Panel to choose the channel to be deleted, press Delete and then press Auto to return
Channel Setup to Auto.
To restore a channel: Press the Manual key in Channel Setup, use the channel controls to choose the channel to
be restored, press the Add key and the press Auto to return Channel Setup to Auto.
To Adjust Picture Setup: Brightness, Contrast, Saturation and Hue can be adjusted by using the corresponding
arrow buttons. To return to the unit default settings, press Default key. The default settings are: Brightness-180,
Contrast-71, Saturation-64 and Hue-0.
Press the Max Volume Setup key to adjust volume.
22
MAX VOLUME SETUP
Entry to this screen allows the user to adjust Volume by using the Arrow keys.
Note: Headphones must be used for this function.
The upper set of arrows adjusts the volume capacity higher or lower, allowing clubs to compensate for average
noise levels within the club. The maximum volume returns to this default after each workout.
The Volume Down, Volume Up arrows control the volume of the unit for the current usage. After each session
ends, the unit resets to mid-range volume corresponding to the maximum volume setup.
23
TOUCH SCREEN CONFIGURATION
Entry into this screen will allow to user to

reconfigure the Touch Screen. The
display will show a blank screen with a +
sign in the middle. Follow the directions at
the top of the screen to properly
reconfigure the Touch Screen. This
procedure may have to be repeated more
than once. Once the screen has been
successfully calibrated the screen will exit
Calibration State automatically.
24
SECTION III
How To...
SERVICE AND REPAIR
Page
Pedals, Crank Arms, and Side Shrouds.............................................................................. 3

Crank Shaft Hub Assembly ................................................................................................ 5
Crank Shaft and Bearings ................................................................................................... 7
Clutch Assembly.................................................................................................................. 10
Intermediate Pulley Shaft and Bearings .............................................................................. 11
Idler Roller ........................................................................................................................... 16
Main Drive Belt .................................................................................................................... 17
Alternator............................................................................................................................. 18
Alternator Belt ..................................................................................................................... 19
Seat Post Assembly (Latch LC8500, 9100, 9500) .............................................................. 20
Seat Post Assembly (Pull-Pin C7 and C9) .......................................................................... 21
Main Wire Harness..............................................................................................................22
9 Volt Console Battery (LC8500 and C7) ............................................................................ 23
6 Volt Battery on Frame (LC9500, 9100, and C9)............................................................... 24
Display Console and Accessory Tray.................................................................................. 25
Console Post Assembly, Main Cable, and Coax Cable for LCD ......................................... 26
Power Control Board (LC8500 and C7) .............................................................................. 27
Power Control Board (LC9500, 9100, and C9) ................................................................... 28
Pedal ................................................................................................................................... 29
Front Wheels ....................................................................................................................... 30
Handlebar Assembly ........................................................................................................... 31
Heart Rate Sensor (LC9500 and C9) .................................................................................. 32
Telemetry Receiver LC9500, 9100, 8500, and C7)............................................................. 33
Resistor Assembly............................................................................................................... 34
Auto Start Switch................................................................................................................. 35
Console PCB....................................................................................................................... 36
LCD Integrated Console Service Overview......................................................................... 37
Headphone Jack .................................................................................................................38
Inverter Board...................................................................................................................... 39
Single Board Computer ....................................................................................................... 40
Interface Board.................................................................................................................... 41
Touch Screen Assembly ..................................................................................................... 42
1
Notes:
2
How To... Remove Pedals, Crank Arms, and Shrouds
Special Service Tools: NONE
NOTE: Each shroud can be removed independently Seat Post Covers

of each other. This procedure covers removal of the
right shroud first and then the left shroud. However,
the order is not critical, but what is important, is to
know that three screws secure the shrouds to the
frame while the remaining five screws secures the
shroud halves to each other. See illustration below.
Seat Post
1. Remove the mounting screw on the right side Cover
seat cover and then remove the seat post Screw
covers.
Shroud to
Frame Screw (3)
2. Remove three screws from the right (12-15 in lbs)
crank arm, and then remove the right
crank arm from the crank hub with
pedal attached.
3. To remove the right shroud, remove

eight screws as follows:
• Four screws at the bottom of the

shroud Crank Hub
• One at the top rear of the shroud which Screws(3)
are secured into the left shroud (15-20 ft lbs)
• Three screws, as shown, which secure
the right shroud to the frame.
4. After removing these screws, remove

the right shroud from the unit. The left Shroud-to-Shroud
shroud will remain attached to the left Screws (5)
side of the frame. (12-15 in lbs)
3
How To... Remove Pedals, Crank Arms, and Shrouds - Continued
4. Remove three screws from the

left crank hub, and then remove
the left crank arm from the crank
shaft with pedal attached.
5. Remove the remaining three

frame screws from the upper
half of the left shroud, and then Left Shroud
remove the left shroud.
Note: If only the left shroud needs Shroud Screw (3)

removal, then remove the four lower to Frame
screws and one screw in the top (12-15 in lbs)
rear of the shroud from the right
shroud which secures the two
shroud halves together, and then Crank Hub
remove the remaining three frame Screws(3)
screws on the upper-side of the left (15-20 ft lbs)
shroud. See illustration on previous
page.
6. Install shrouds in reverse order.
7. Torque the shroud screws 12-15 Plug

in lbs.
8. Torque crank hub screws 15-20 ft lbs. These screws can be reused up to 5 times before needing replacement.
Torque the pedals 10-15 ft lbs if removed.
4
How To... Replace the Crank Shaft Hub Assembly
Special Service Tools: Bearing Service Tool Kit – Part Number: BearingToolKit
Right Pedal/
1. Remove the crank arm with pedal from the Crank Arm
defective crank shaft hub.
Right Shroud
2. Remove the side shrouds. Refer to How
To…Remove Pedals, Pedal Levers, and Side
Shrouds.
3. Remove the main drive belt. Refer to, How

To…Remove Main Drive Belt.
Pedal
Screws(3)
4. Remove the bolt and washer in the center of each hub.
NOTE: The arrow mark on the hub. The other hub

also has same mark 180 degrees apart for proper
crank arm location. Hub
Arrow
Mark
Hub
Mounting Flat
Bolt Washer
5
How To... Replace the Crank Shaft Hub Assembly - Continued
5. Install the disc puller plate as illustrated on the Forcing Bolt Mounting Bolt(3)
left hub. (1/2-13) (1/4-20)
6. Turn the puller forcing bolt clockwise until the
let hub is removed. Discard the hub.
NOTE: The right hub is removed with the crank

shaft pulley attached. Use the puller as described
in left hub removal. Once off, remove the three
screws at the back of the pulley to separate it from
the hub.
NOTE: Make sure the arrow mark on the hub is

pointing 180 degrees from the other hub. Hub
7. Position the new hub on the crank shaft with
the washer. Install the mounting bolts and
tighten evenly until the hub is fully seated on Crankshaft
the shaft. Torque: 220-240 in lbs. This bolt can
be reused up to 5 times before needing
replacing.
NOTE: If the right hub was replaced, then install

the hub back on the pulley first and secure using
the three mounting screws.
8. Reinstall the side shrouds, crank arms, and

pedals.
REMOVING THE HUB
6
How To... Replace the Crank Shaft Bearings
Thrust
Thrust Washer
Washer (Large) Snap Ring
Thrust (Small) (Large)
Thrust Washer
Washer (Small) Crank Shaft
(Large)
Snap Ring
Bowed (Small)
Thrust
Bearing
Snap Ring Thrust
Bowed (Small) Bearing
1. Remove the pedals, crank arms, and side Threaded Rod

shrouds. Refer to, How To… Remove
Pedals, Pedal Levers, and Side Shrouds.
Hex Nut Thrust Washer
2. Remove the main drive belt. Refer to, How
To…Remove Main Drive Belt.
Bike Spacer
3. Remove the crank shaft hubs. Refer to,
How To…Remove Crank Shaft Hubs. Frame
4. Remove the snap rings, large thrust

washer, thrust bearing, and small thrust
washer from both sides the crank shaft.
Needle
5. Push the crank shaft out from the frame Bearings
bearings.
6. Inspect, and if necessary, replace any

crank shaft component parts as necessary
before reassembling onto the new crank Hub
shaft.
7. Install the bearing puller on the crank

INSTALLING CRANK BEARING KIT
needle bearings as illustrated
7
How To... Replace the Crank Shaft Bearings - Continued
8. Press out the needle bearings by rotating

the hex nut clockwise until the bearings Threaded Rod
drop into the puller hub. Once the bearings
are out of the frame, disassemble the puller
assembly, and discard the bearings. Hex Nut Thrust Washer
9. Clean the housing before installing new

needle bearings.
Spacer
Needle
Bike Bearings
Frame
Hub
PUSHING OUT THE NEEDLE

BEARINGS INTO THE HUB
10. Position the new needle bearing with markings, on Threaded Rod
the face of the bearings, are positioned facing out.
Make sure bearings are aligned straight and square.
Hex Nut
Spacer
Thrust Washer
Needle
Bearings
Bike
Frame Hub
INSTALLING NEW NEEDLE BEARINGS
8
How To... Replace the Crank Shaft Bearings - Continued
11. Start tightening the hex nut. You may have to Threaded Rod
hold the spacer to stop it from turning.
12. Continue pressing in the new needle bearings

Hex Nut
until the thrust washer and hub stop against the Spacer
frame housing shoulder. Make sure that the
bearing races seat flush against the inner hub
face. Thrust Washer
Inner Hub Needle

Face Bearings
Bike Hub
Frame
PRESSING IN NEW BEARINGS
13. Reassemble shaft and components. Use the exploded view below to aid in reassembly.
14. Reinstall the hubs. Refer to, How To…Remove Crank Shaft Hubs.
15. Reinstall the main drive belt. Refer to, How To…Remove Main Drive Belt.
16. Reinstall the side shrouds, crank arms, and pedals. Refer to, How To…in this section.
Thrust
Thrust Washer
Washer (Large) Snap Ring
Thrust (Small) (Large)
Thrust Washer
Washer (Small) Crank Shaft
(Large)
Snap Ring
Bowed (Small)
Thrust
Bearing
Snap Ring Thrust
Bowed (Small) Bearing
9
How To... Replace the Clutch Assembly
1. Remove the right side shrouds. Refer to,

How To…Remove Pedals, Pedal Levers,
and Side Covers.
2. Remove the main drive belt. Refer to,

How To…Remove Main Drive Belt.
Main Drive Snap Washer
3. Remove the snap ring from the Belt Ring
intermediate shaft.
4. Remove the washer, clutch assembly and

washer from the shaft. Discard the clutch Intermediate
assembly. Shaft
Clutch
5. Install the new clutch and its parts in Assembly
reverse order. Make sure to install the
step side into the frame.
6. Install main drive belt. Refer to, How To… Step Side
Install Main Drive Belt. must face
into frame
7. Install shrouds and then pedals.
10
How To... Replace the Intermediate Pulley Shaft and Bearings
1. Remove the side covers. Refer to, How To…Remove Pedals, Pedal Levers, and Side Shrouds.
Main Drive Intermediate

Bearing Intermediate
Belt Pulley
Clutch Alternator
Assembly Belt
Snap Washer
Ring
Washer
Spacer
Intermediate
Bearing
Intermediate
2. Remove the main drive belt. Refer to, Pulley/Shaft
How To…Remove Main Drive Belt. Assembly
3. Remove the clutch assembly. Refer

to, How To…Remove the Clutch
Assembly.
Bearings Spacer
4. Remove the alternator belt. Refer to,
How To…Remove the Alternator
Belt.
5. Assemble 2-Jaw Puller, OTC Model

1025 to the bike frame at the Use Standard
intermediate pulley shaft as shown. 2-Jaw Puller
OTC Model 1025
SETTING UP 2-JAW PULLER

OTC MODEL 1025
11
How To... Replace the Intermediate Pulley Shaft and Bearings - Continued
6. Turn the forcing screw clockwise to press out the pulley shaft assembly from the bearings and spacer.
7. Once the pulley shaft is free of the

bearings, proceed to remove the
bearings.
Note: Do Not replace the pulley without

replacing the bearings.
Intermediate
Pulley/Shaft
Assembly
Spacer
Bearings
Use Standard
2-Jaw Puller
OTC Model 1025
Forcing
Screw
PUSHING OUT THE PULLEY SHAFT
8. Install the bearing puller to the frame as illustrated.
Threaded
Rod
Hex Nut
Thrust
Spacer Washer
Bearing
Bearings
Spacer
Hub
SETTING UP INTERMEDIATE
BEARING PULLER
12
9. Turn the hex nut clockwise to push the 1st bearing out into the hub. Loosen puller assembly and remove the 1st
bearing. At this time, remove the free floating
spacer. Threaded
Rod Hex Nut
10. Retighten puller assembly and continue tightening
until 2nd bearing is pressed out of its housing into
the hub. Thrust
Washer
11. Remove the puller and discard the bearings.
12. Clean the housing.
2nd Bearing Bearing

Spacer
1st Bearing Hub
PUSHING OUT 1st BEARING
Thread Rod
13. Install the bearing spacer back in the housing,
and then position the bearings in the housing. Hex Nut
14. Install the puller assembly as shown. Make sure
that the hub is reversed. Make sure all parts are Spacer
aligned straight and square.
Note: When pressing in new bearings, it is important Thrust

to understand that proper installation is critical to the Washer
life of the pulley shaft bearings, and that these
bearings MUST be pressed firmly against the
bearing spacer, which means that the bearing
spacer MUST be held tightly in place (not loose). Bearing
Step 16, on the next page describes a normal Bearings Spacer
installation. However, should that not render the
specified results, then proceed to Step 17. The
difference being that Step 16 uses both thrust
washers, whereas in Step 17 only one thrust washer
is used. Thrust
Washer
Hub
SETTING UP THE PULLER FOR

PRESSING IN BEARINGS
13
15. Start tightening the hex nut to press in the bearings. Continue pressing in the bearings until the thrust
washers(2) stop against the housing shoulder as shown. Thread Rod
16. Remove the puller assembly and check to see that the
Hex Nut
bearing spacer is securely held in position between the
bearings. If the bearing spacer is secured between these
bearings, then proceed to pressing in the intermediate Spacer
shaft. If the bearing spacer is loose, then proceed to the
next step.
Thrust
17. If the bearing spacer is loose, then reinstall the puller Washer
assembly without the thrust washer on the side of the
intermediate pulley (see illustration below). Continue
pressing in the bearing, without holding or clamping the
Bearing
puller hub. When the bearing (next to the pulley) is Bearings
Spacer
properly seated against the bearing spacer, it will be
slightly below flush and the puller hub will be free to spin.
Proceed to press in the intermediate pulley/shaft. Thrust
Washer
Hex Nut
Thread Rod
Spacer
Puller Hub
PRESSING IN THE BEARINGS
NO Thrust
Washer
Bearing
Bearings
Spacer
C-Clamp
Thrust
Washer
Puller Hub Swivel

PRESSING IN THE BEARING ON THE Spacer
PULLEY SIDE W/O THRUST WASHER
7.700”
Pulley/Shaft
Bearing
18. Position the intermediate pulley/shaft in the housing. Position the Spacer
swivel spacer on top of the pulley and the stop block against the
bottom bearing, then secure the C-clamp as illustrated. Make Stop Block
sure the shaft is aligned straight and square. Also make sure the
plastic bearing spacer between the bearings is centered.
Note: Once the pulley/shaft gets started in the bearing, remove the
C-Clamp to ensure the bearing spacer is in alignment to receive the SETTING UP C-CLAMP,
shaft, then continue to press in the pulley/shaft. SWIVEL SPACER,
AND STOP BLOCK
14
19. Press in the pulley/shaft until the shaft bottoms against the 2nd bearing.
20. Remove the C-clamp and stop block.
21. Install the clutch assembly. Refer to, How

To…Remove the Clutch Assembly.
C-Clamp
22. Reinstall alternator belts. Refer to, How To in
this section.
23. Install side shrouds and then the pedals.
Pulley/Shaft
2nd Bearing
Stop Block
Pressing in Pulley Shaft
15
How To... Replace the Idler Roller
Note: The crank pulley and

idler bracket are shown
removed for clarity purposes
Idler Bracket
only. Neither have to be
removed to remove the idler
roller.
1. Remove the right pedal, Rear

crank arm, and side Mounting
shrouds. See "How Bolt
To…" in this section.
2. Rotate the crank pulley Idler

Tension Roller
until the rear mounting Lock Nut
Crank Pulley Adjusting Flat
bolt on the idler bracket Bolt Washer
Access Hole
is visible.
3. Loosen the rear mounting bolt through the access hole in the crank pulley
4. Loosen the tension adjusting bolt and washer on the bracket.
5. Remove the belt.
6. Remove the lock nut and remove the idler roller.
7. Install new idler roller in reverse order.
8. Adjust belt tension 100-110 lbs by moving the idler bracket down. Insert a straight blade screwdriver in the
slotted lip of the bracket to obtain specified tension. When belt tension is achieved, then tighten the rear bolt
and then the tensioning bolt in the bracket.
16
How To... Remove the Main Drive Belt
1. Remove the right pedal, right crank arm,

and right shroud. See "How To…" in this
section.
2. Rotate the crank shaft pulley until the

access hole until the rear mounting bolt,
on the idler bracket, is visible.
3. Loosen the rear mounting bolt on the idler

bracket through the access hole in the
crank arm pulley
4. Loosen the tension adjusting bolt at the

front of the bracket.
5. Move the idler bracket assembly up to

reduce belt tension.
Rear Bolt
showing
6. Remove the main drive belt from the Tensioning
through
crank shaft pulley and the clutch
Access Hole Bolt
assembly. Discard the main drive belt.
7. Snug the mounting bolts on the idler Main Drive Belt

bracket to allow for belt tensioning.
8. Install a new main drive belt on the crank shaft pulley and the clutch assembly.
9. Move the idler bracket down to increase belt tension. Adjust the belt tension 100-110 lbs. When belt tension is
achieved, then tighten the bracket bolts.
17
How To... Remove the Alternator
Special Service Tools: Belt Tensioning Gauge
Alternator
Tensioning Bolt,
Alternator Lock Washer,
Wiring Flat Washer
Alternator
Alternator
Belt
Alternator
Mounting
Bolt/Washer Alternator
Washer/
Lock Nut
1. Remove the pedals, crank arms, and side shrouds. See "How To…" in this section.
2. Remove alternator wiring from alternator. Note the location of each wire.
3. Remove the alternator tensioning bolt.
4. Loosen the alternator mounting bolt, and then pivot the alternator enough to slacken the alternator belt, then
remove the alternator belt.
5. Remove the alternator mounting bolt, washers, and lock nut, and lift the alternator off the frame.
6. Install new alternator in reverse order.
7. Position new alternator belt on the far left groove of the alternator pulley (user’s side) and not in the center of
the pulley. Tighten the alternator belt 70-80 lbs.
18
How To... Remove the Alternator Belt
Special Service Tools: Belt Tensioning Gauge
1. Remove the pedals, crank arms, and side shrouds. See

"How To…" in this section.
2. Loosen the alternator tensioning bolt.
3. Loosen the alternator mounting bolt, and then pivot the

alternator enough to slacken the alternator belt.
Alternator
Tensioning
Bolt
Alternator
Mounting
Bolt
4. Remove the alternator belt.
5. Position new alternator belt on the far left groove of the

alternator pulley (user’s side) and not in the center of the
pulley. Tighten the alternator belt 70-80 lbs.
Alternator
Belt
19
How To... Remove the Seat Post Assembly (Latch LC8500, 9100, 9500)
1. Remove the side shrouds. Refer to, How To…in

this section.
2. Remove two screws on the seat post collar.
3. Remove four mounting screws securing the latch

assembly to the frame. If disassembly is
Seat Post
required, refer to the procedure below.
Collar
4. Lift out the seat post assembly with seat
attached.
Seat Post
5. Remove four mounting screws securing the seat Collar Seat Latch
to the seat post. Screws(2) Mounting
Screws(4)
6. Service the seat post assembly as required.
7. Reinstall the seat and seat post in reverse order.
8. Reassemble the latch assembly and secure to

frame with four mounting screws.
Release Latch Disassembly Handle

w/Shaft
1. Remove the two set screws from the latch rack.
2. Slide the handle-shaft out from the latch bracket, latch Latch
rack, and spring. Catch the latch rack and spring as Rack
shaft is removed.
NYLINER
3. Remove the two NYLINER from the sides of the latch Latch
bracket. Bracket
E-Ring STOP
4. If necessary, the E-Ring can be removed from the shaft for latch
for replacement. rack
NYLINER
Latch
5. When reinstalling parts, make sure that the latch rack Spring
is seated up against the shaft STOP, and then tighten Set Screws
the latch rack set screws.
6. Reinstall latch assembly back on the seat post.
20
How To... Remove the Seat Post Assembly (Pull-Pin C7 and C9)
1. Remove the side shrouds. Refer to, Seat

How To…in this section.
2. Remove the seat post collar

screws(2). Seat Post
Collar
3. Compress the internal snap ring in
front of the pull-pin knob and pull Seat Post
out the pull-pin assembly.
Seat Post
4. Lift out the seat post assembly with Collar
seat, from the frame. Screw(2)
5. Remove four screws securing the
seat to the seat post.
6. Service the seat post as required. Bike Frame
7. Reinstall seat post in reverse order Seat Post

and reattach seat. Pull-Pin
Internal
Snap Ring Seat
Pull-Pin
Knob
21
How To... Remove the Main Wiring Harness
1. Remove the side shrouds. Refer to, How To… in

this section.
2. Remove the handlebar. Refer to, How To… in this

section.
3. Disconnect the main wiring harness at the power

control board.
Power
4. Disconnect the main wiring harness from the Control Resistor
cable ties along the frame. Board
5. Route the cable out of the console post assembly.

Main
6. Install new main wiring harness in reverse order. Left Side Wiring
Harness
Power
Control
Board
Resistor
Main
Right Side Wiring
Harness
22
How To... Remove the 9-Volt Console Battery (LC8500 and C7)
NOTE: The 9 Volt console battery is located

back of the console. Back of the
Console Assembly
1. Remove the cover at the back of the console
assembly to reveal the battery.
NOTE: Console removed for clarity.
2. Remove the battery and replace with new one.
3. Reinstall the battery cover.
Battery
Cover
23
How To... Remove the 6-Volt Battery (LC9500, 9100 and C9)
1. Remove the side shrouds. Refer to,

How To…in this section.
6 Volt
2. Disconnect the wires from the
Battery
battery terminals.
3. Remove the battery mounting

screws(2) and battery harness clip. Battery
Mounting
4. Remove the battery and discard.
Screws(2)
5. Install new battery in reverse order. Battery
Harness
Clip
24
How To... Remove the Display Console and Accessory Tray
1. Remove four mounting screws from the

back of the console at the console Accessary
support. Tray Screws
2. Lift the console up just enough to
disconnect the main wiring, and then
remove the console and the accessory
tray.
3. Remove four mounting screws from Console

under the accessory tray which mounts Assembly Accessary
to the underside of the console.
Tray
Console
Support
Console
Screws
25
How To... Remove the Console Post Assembly, Main cable and Coax (on
LCD only)
End Cap
Console
Post
Console
Post
Console
Cable
Console
Support Elbow
and Screws
Console
Post Screws
Cover and
Frame Mounting
Assembly Screws
1. Remove the handle bars. Refer to, How To… in this section.
2. Remove the console and if equipped, the accessory tray. Refer to, How To…in this section.
3. Remove the left side shroud. See How To…Remove Shrouds.
4. Unplug the main console cable from the power control board (large connector).
5. Remove four mounting screws securing the console support elbow to the frame, and lift the console post and
elbow out of the frame.
6. Remove the side covers from the support elbow and discard the console post.
7. Replace the console post in the reverse order of removal.
26
How To... Remove the Power Control Board (LC8500 and C7)
Main
Cable
PCB
Bracket
PCB
Board
Mounting
Screws
1. Remove the left pedal and crankarm, and then remove the left side shroud.
2. Disconnect the two cables to the PCB.
3. Remove four screws securing the PCB to the bracket.
4. Install new PCB board in reverse order.
27
How To... Remove the Power Control Board (LC9500, 9100 and C9)
Battery
PCB
PCB
Mounting
Screws(4)
1.
Remove the left pedal and crankarm, and then remove the left side shroud.
2. Disconnect the two cables to the PCB.
3. Remove four screws securing the PCB to the bracket.
4. Install new PCB board in reverse order.
28
How To... Remove the Pedal
1. Remove the right pedal using an

open end wrench and loosening
the pedal shaft by rotating it
counterclockwise.
Pedal
2. Remove the left pedal using an
open end wrench and loosening
the pedal shaft by rotating it
clockwise.
3. Install the right pedal using an

open end wrench and tighten the
pedal shaft into the crankarm by
rotating it clockwise.
4. Install the left pedal using an open

end wrench and tighten the pedal Crankarm
shaft into the crankarm by rotating
it counterclockwise.
29
How To... Remove the Front Wheels
1. Remove the two wheel insert

screws from each side of the
front stabilizer.
2. Pull out the wheel bearing and

wheel insert together. The
wheel and insert are held
together by a screw and
washer.
3. Install new front wheel assembly

in the reverse order.
Wheel
Screw
Wheel
Flat Insert
Washer Screw(2)
Wheel
Insert
Wheel/Bearing
Assembly
30
How To... Remove the Handlebar Assembly
Sensor
1. Remove four screws securing the top Cover
half of the sensor cover.
2. Remove four mounting screws securing

the handle bar to the post.
3. Lift out the handlebar just enough to Hear Rate Handlebar

disconnect heart rate sensor wiring.
Wiring
Note: C7, LC8500, and LC9100 have no Handlebar
heart rate sensors. Mounting
Screws
4. Remove the handlebar.
5. Install the handle bar in reverse order.
C9 and Lc9500
Handlebar Assembly
C7, Lc8500,
and Lc9500
Handlebar
31
How To... Remove the Heart Rate Sensor (LC9500 and C9)
Electrode
Molder Grip
Molded Insert
Cable
Assembly
Cable
Assembly
Handlebar
End Cap
Insulated Plug
Phillips Screw
Torque 6-8 in lbs
1. Remove the Phillips screw securing the molded insert to the handlebar.
2. Lift the molded insert enough to disconnect the cable.
3. Before pulling out the cable, attach a 3 ft piece of string at one end of the old cable, and then pull the other end
of the cable out until the string appears. Detach the string and discard the cable
4. Attach new cable to string. Pull the string to fish out the cable through the handle bar.
5. Reinstall new electrode molded insert in reverse order.
32
How To... Remove the Telemetry Receiver and Telemetry Receiver Cable
(LC9500, 9100, 8500, and C7)
Telemetry Receiver
1. Remove four screws securing the top sensor cover.
2. Unplug the telemetry sensor from its connector.
3. Install new telemetry sensor in reverse order.
Telemetry Receiver Cable
Note: The telemetry cable is connected to a connector mounted in a Sensor

bracket. This bracket is mounted to the inside of the console post, Cover
(Top)
under the sensor cover. The other end of the cable is connected into
the back of the console display board. Proceed with the following
steps to properly replace this cable. Telemetry
Sensor
1. Remove the telemetry sensor as indicated above.

Sensor
Cover
2. Remove the console display. See How To…Remove Display (Bottom)
Console and Accessory Tray.
3. Raise the console display just enough to access the telemetry

cable connector and disconnect it from the back of the console
board. Now tie a 3 ft piece of string around the end of this
connector. This will act as a fish line for pulling in the new cable.
4. Lower the bottom sensor cover on the console post to access the
bracket screws. Remove two screws in the back of console post, which secures the bracket which is located
inside the console post where the telemetry connector mounts and telemetry sensor plugs-in.
5. Pull out the bracket with attached telemetry connector and Screws(2)
cable from the console post just enough to disconnect the Bracket
telemetry cable leads from the connector on the bracket
6. Now gently pull out the telemetry cable until the string appears. Telemetry
Remove the string from the old cable and attach it around the Connector Screw
new telemetry cable. Inserts(2)
7. Before fishing the new cable through the console post,

reconnect the telemetry cable leads back into the connector on
the bracket. Now start pulling on the string until the new Telemetry
Connector
telemetry cable appears through the console post. Reconnect Cable
to Display
the connector at the other end of the cable to the back of the Board
console board.
8. Reattach the console display back on the console post.
9. Now go back and secure the bracket inside the console post with the two screws.
10. Plug-in the telemetry sensor back into its connector.
11. Secure the top cover to the bottom cover.
33
How To... Remove the Resistor Assembly
CAUTION! BEFORE REPLACING Mounting

CIRCUIT BOARD(S), GROUND Screws
YOURSELF TO EARTH GROUND
USING AN ANTI-STATIC GROUND
Resistor
STRAP.
Assembly
1. Remove the side shrouds. Refer to, How
To… in this section.
2. Remove two cable mounting screws and

nuts securing the cable to the terminals.
3. Remove mounting screws securing the

resistor to the frame, and then lift out the
resistor assembly.
4. Install new resistor in reverse order.
Cable
Mounting
Screws
34
How To... Remove the Auto Start Switch and Bracket
CAUTION! BEFORE REPLACING

CIRCUIT BOARD(S), GROUND
YOURSELF TO EARTH GROUND Auto Start
USING AN ANTI-STATIC GROUND PCB Switch Cable
STRAP.
1. Remove the side shrouds. Refer to

How To in this section.
2. Disconnect the auto start switch cable

from the left side of the unit at the
PCB.
Auto Start
Switch Mounting
Bracket
3. Remove the screw

securing the auto start Auto Start
switch to the right side Switch and
of the upper frame. Screws(2)
4. Remove the cable and
switch, and if necessary
the mounting bracket by
removing the one
mounting screw.
5. Install new cable and

switch in reverse order.
35
How To... Remove the Console PCB
CAUTION! BEFORE REPLACING Console PCB

CIRCUIT BOARD(S), GROUND Console Console
YOURSELF TO EARTH GROUND Cover (Front) Cover (Back)
USING AN ANTI-STATIC GROUND
STRAP.
Screws(8)
1. Remove the battery cover and battery.
2. Remove the four screws under the

console, securing the console to the
console support.
3. Lift the console up just enough to

disconnect the main cable.
4. Remove eight screws from the back of

the console and split the halves.
5. Remove the screws securing the PCB to

the front half of the console, and remove
the PCB.
6. Discard the PCB, and install new PCB in

the console in the reverse order.
Battery Cover
7. Reconnect console and secure onto the
console support with the mounting screws.
36
LCD Integrated Console Service Overview
Special Service Tools Required: NONE
CAUTION! BEFORE REPLACING CIRCUIT BOARD(S), GROUND YOURSELF TO EARTH GROUND

USING AN ANTI-STATIC GROUND STRAP.
NOTE: The following pages provide service procedures for servicing the LCD Integrated Console.
While the Console Housings may differ between the various products, the internal components,
which make up the Console, are identical. Use the exploded view below to help identify parts and
component location during service.
LCD Touch
Screen/Screws(4)
Interactive
Console Board/
Screws(8)
Inverter Board/ Interface
Screws (2) Board/
Screws(3)
Cable
37
How To... Replace the Headphone Jack
CAUTION! BEFORE REPLACING CIRCUIT BOARD(S),

GROUND YOURSELF TO EARTH GROUND USING AN
ANTI-STATIC GROUND STRAP.
Note: For clarity purposes the Console is shown off the unit.
Headphone Jack replacement does not require removal of the
Console from the unit.
1. At the bottom of the Console, remove the Phillip Screw

securing the Headphone Jack.
2. Remove the Headphone Jack from the Console. Console

3. Install new Headphone Jack in reverse order. Assembly
Headphone
Jack Assembly
Screw
38
How To... Replace the Inverter Board
CAUTION! BEFORE REPLACING CIRCUIT

BOARD(S), GROUND YOURSELF TO EARTH
GROUND USING AN ANTI-STATIC GROUND
STRAP.
Back Cover
1. Remove console from unit refer to Display Console
and Accessory Tray Removal.
2. Remove seven screws from the Back Cover and lift

the Back Cover off.
Back Cover
Screws (7)
LCD Touch
Inverter Screen
Pink/White Board
3. Disconnect the Pink/White Power Wire
Connectors (2) from the top of the Inverter Power Wire
Board, and the 4-Yellow Wires Connector, Connectors(2)
which receives Power from the PC to the
Inverter, at the bottom of the Inverter
Board.
4. Remove two Phillips screws securing the

Inverter Board to the back of the LCD
Touch Screen and lift it out.
Screws
5. Install new Inverter Board in reverse order.
Yellow Wires(4)
Connector
(Power from PC
to Inverter Board)
39
How To... Replace the Single Board Computer
Single Board
Single Board Computer
Computer
Mounting
Screws (7) 24-Pin Connector 5-Pin Touch Screen
Receptacle
Communication
Connector
Connector
Pin Pin Ribbon Cable
41-Pin LCD
Communication
Ribbon Cable
24-Pin
Polar Cable Connector
CAUTION! BEFORE REPLACING CIRCUIT BOARD(S), GROUND YOURSELF TO EARTH GROUND

USING AN ANTI-STATIC GROUND STRAP.
1. Remove console from unit refer to Display Console and Accessory Tray Removal.
2. Remove seven screws from the Back Cover.
3. Disconnect all of the cables from the Single Board Computer.
4. Remove seven screws securing the Single Board Computer to the back of the LCD Touch Screen. The
Single Board Computer remains engaged into a 24-Pin Connector Receptacle, which is located between
two Connector Pins on the Interface Board. Carefully wiggle the Single Board Computer up and out of the
Interface Board Connector Receptacle and Connector Pins.
5. Install Board in reverse order. Been careful on connecting the single board computer to the machine
interface board.
40
How To... Replace the Interface Board
CAUTION! BEFORE REPLACING

CIRCUIT BOARD(S), GROUND
YOURSELF TO EARTH GROUND USING Mounting
AN ANTI-STATIC GROUND STRAP. bracket
1. Remove console from unit refer to
Display Console and Accessory Tray
Removal.
2. Remove seven screws from the Back

Cover.
3. Remove Single Board Computer

Interface
4. Disconnect all Cables from the interface Board
board.
5. Remove 5 screws securing the

Interface Board to the mounting Polar
bracket.
Cable
CAUTION! HIGH VOLTAGE ON INTERFACE
BOARD CONNECTORS J2 AND J3.
Single Board
6. Remove the Interface Board. Computer
7. Install board in reverse order. Been careful on connecting the single board computer to the machine
interface board.
41
How To... Replace the Touch Screen Assembly
CAUTION! BEFORE REPLACING CIRCUIT

Touch Screen
BOARD(S), GROUND YOURSELF TO EARTH
Assembly
GROUND USING AN ANTI-STATIC GROUND
STRAP.
1. Remove console from unit refer to Display Touch

Console and Accessory Tray Removal. Screen Touch
Screws Screen
2. Remove seven screws from the Back Cover.
Screws
3. Remove the Single Board Computer. See “How

To Replace the Single Board Computer” in this
section.
4. Remove the Interface Board. See “How To

Replace the Interface Board” in this section.
5. Remove the Inverter Board. See “How To Replace the Mounting

Inverter Board” in this section.
bracket
6. Remove four screws securing the Touch Screen Bracket
Assembly to the bezel Assembly. Remove the Touch
Screen Assembly from the Console.
7. Remove the four nuts securing the LCD/touch screen to

the bracket then separate the bracket from the assembly.
Interface
8. Install new Touch Screen in reverse order. Board
Polar
Cable
Front
Cover Single Board
Computer
Touch
Screen
42
SECTION IV
ELECTRONICS
AND
WIRING DIAGRAMS
Page
Display Console Board - Model LC9500 ............................................................................. 3
Display Console Board - Model C7 ..................................................................................... 10
Display Console Board - Model C9 ..................................................................................... 12
Alternator Control Board - Model C7 and LC8500 .............................................................. 14
Alternator Control Board - Model C9, LC9100, and LC9500............................................... 15
Alternator............................................................................................................................. 17
Wiring Block Diagram LC8500 and C7................................................................................ 18
Wiring Block Diagram C9 .................................................................................................... 19
Wiring Block Diagram LC9100 ............................................................................................ 20
Wiring Block Diagram LC9500 ............................................................................................ 21
Wiring Block Diagram 95CE Single Power Control Board .................................................. 22
Wiring Block Diagram 95CE Power Control Board ............................................................. 23
Wiring Block Diagram 95CE Machine Interface Board........................................................ 24
Wiring Block Diagram 95CE Single Board Computer ......................................................... 25
Notes ................................................................................................................................... 26
1
Notes
2
DISPLAY CONSOLE BOARD - Model LC9500
Functional Description
The Display Console Board is designed to work in conjunction with the Alternator Control Board. It reads the
keypad input for changes or updates by the user, and refreshes the status LEDs, data display, and profile display
matrix.
Connector and Pin Descriptions

Connector Location Pin Functional Description
P1 and P12 is a 17 pin ribbon 1 Ground
connector that connects to the 2 Strobe
switch membrane. 3 Return
4 Strobe
5 Strobe
6 Return
7 Strobe
8 Return
9 Strobe
10 Return
11 Ground
12 Strobe
13 Strobe
14 Return
15 Strobe
16 Return
17 Ground
3

P2 is a 16 pin connector that 1 N.C.
connects to the alternator 2 GND (NOT USED)
control board. 3 VSYS (NOT USED)
4 VBAT (NOT USED)
5 RPM REED (NOT USED)
6 RPM ALT
7 ASTART (NOT USED)
8 VALT. (NOT USED)
9 RELAY (NOT USED)
10 GND
11 GND
12 VBAT
13 FIELD-KICK
14 FIELD
15 LOAD-CMD
16 VSYS
P4 is 4 pin connector that LEFT +

connects to the heart rate LEFT -
sensor.
RIGHT -
RIGHT +
P7 is a 3 pin connector that 1 +VCC (5VDC)

connects to the polar signal. 2 POLAR SIGNAL
3 GROUND
P9 and P10 are 8 pin 1 N/U - not used

connectors that connect to the 2 N/U - not used
CSAFE and Cardio Theater or 3 Receive Data
broadcast vision interface.
4 Transmit Data
5 +8 Vdc
6 CTS
7 Ground
8 N/U - not used
P11 is a 10 pin connector that 1 /DS

connects to the background 2 /BERR
debug mode signals. 3 Ground
4 /BKPT /DSCLK
5 Ground
6 FREEZE/QUOT
7 /RESET
8 IPIPE1/DS1
9 +5 Vdc
10 IPIPE0/DS0
4

P5 is a 24 pin connector that 1
connects to the lower console 2
display board. 3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
5
matrix.

P12 is a 17 pin ribbon 1 Ground
4 Strobe
5 Strobe
6 Return
7 Strobe
8 Return
9 Strobe
10 Return
11 Ground
12 Strobe
13 Strobe
14 Return
15 Strobe
16 Return
17 Ground
6

P2 is a 16 pin connect that 1 N.C.
4 VBAT (NOT USED)
6 RPM ALT
7 ASTART (NOT USED)
8 VALT. (NOT USED)
9 RELAY (NOT USED)
10 GND
11 GND
12 VBAT
13 FIELD-KICK
14 FIELD
15 LOAD-CMD
16 VSYS

connects to the polar signal. 2 POLAR SIGNAL
3 GROUND
P8 is an 7 pin connector that 1 GND

connects to the CSAFE card. 2 LEU
3 TDO
4 RDI
5 CTS
6 VCC
7 V CARDIO
7
matrix.

4 Strobe
5 Strobe
6 Return
7 Strobe
8 Return
9 Strobe
10 Return
11 Ground
12 Strobe
13 Strobe
14 Return
15 Strobe
16 Return
17 Ground
8

1 N.C.
P2 is a 16 pin connector that 2 GND (NOT USED)
connects to the alternator 3 VSYS (NOT USED)
control board. 4 VBAT (NOT USED)
6 RPM ALT
7 ASTART (NOT USED)
8 VALT (NOT USED)
9 RELAY (NOT USED)
10 GND
11 GND
12 VBAT
13 FIELD-KICK
14 FIELD
15 LOAD-CMD
16 VSYS

connects the polar connector. 2 POLAR SIGNAL
3 GROUND
9
DISPLAY CONSOLE BOARD - Model C7
matrix.

1 Ground
P12 is a 17 pin ribbon 2 Strobe
connector that connects to the 3 Return
overlay board. 4 Strobe
5 Strobe
6 Return
7 Strobe
8 Return
9 Strobe
10 Return
11 Ground
12 Strobe
13 Strobe
14 Return
15 Strobe
16 Return
17 Ground
10

4 VBAT (NOT USED)
6 RPM ALT
7 ASTART (NOT USED)
8 VALT. (NOT USED)
9 RELAY (NOT USED)
10 GND
11 GND
12 VBAT
13 FIELD-KICK
14 FIELD
15 LOAD-CMD
16 VSYS
P7 is a 3 pin connector that to 1 +VCC (5VDC)

the polar connector. 2 POLAR SIGNAL
3 GROUND
11
matrix.
Connectors and Pin Descriptions

overlay board. 3 Return
4 Strobe
5 Strobe
6 Return
7 Strobe
8 Return
9 Strobe
10 Return
11 Ground
12 Strobe
13 Strobe
14 Return
15 Strobe
16 Return
17 Ground
12

4 VBAT (NOT USED)
6 RPM ALT
7 ASTART (NOT USED)
8 VALT. (NOT USED)
9 RELAY (NOT USED)
10 GND
11 GND
12 VBAT
13 FIELD-KICK
14 FIELD
15 LOAD-CMD
16 VSYS
P4 is a 4 pin connector that 1 Left +

connects to the heart rate 2 Left -
sensor. 3 Right -
4 Right +
P11 is a 10 pin connector that 1 /DS

connects to the background 2 /BERR
debug mode signals. 3 Ground
4 /BKPT /DSCLK
5 Ground
6 FREEZE/QUOT
7 /RESET
8 IPIPE1/DS1
9 +5 Vdc
10 IPIPE0/DS0
13
ALTERNATOR CONTROL BOARD - Model C7 and LC8500
The Alternator Control Board is
designed to regulate the alternator
voltage by modulating the field
current. It regulates the pass current
(RPM signal) from the Alternator to
the Console, and the pass current
form the alternator to the load
resistor while providing supply
voltage for the console while
charging the system battery.
P1 P2
Connector and Pin Connections

P1 is a Molex 9 pin connector 1 RPM (0-7.5 VDC)
that connects to the console. 2 VBAT (9VDC)
3 NOT USED (BLANK)
4 LOAD
5 START
6 GROUND
7 GROUND
8 ALTREGLO (9-11 VDC)
9 VSYS (7-8 VDC)
P2 is a 14 pin connector that 1 FLD RTN

connects to the alternator and 2 FIELD (1-4 VDC)
power resistor. 3 VALT (10 VDC)
4 LOAD
5 LOAD
6 GROUND
7 GROUND
8 RPM (0-7.5VDC)
9 VALT
10 LOAD
11 LOAD
12 GROUND
13 GROUND
14 GROUND
14
ALTERNATOR CONTROL BOARD - Model C9, LC9100, and LC9500
The Alternator Control Board
is designed to regulate the P3
alternator voltage by
modulating the field current.
It regulates the pass current
(RPM signal) from the
Alternator to the Console,
and the pass current form
the alternator to the load P4
resistor while providing
supply voltage for the
console while charging the
system battery.
Connector and Pin P2 P1

Connections
P1 is a Molex 11 pin connector 1 GROUND - BLACK
that connects to the console. 2 GROUND – BATTERY
3 NOT USED (BLANK)
4 VSYS (7-8VDC)
5 ALTREGLO (9-11 VDC)
6 LOADCMD
7 RPM (0-7.5VDC)
8 START (7-8VDC)
9 VBAT – (6VDC)
10 GROUND – BATTERY
11 GROUND
P2 is a 12 pin connector that 1 GROUND – ALTERNATOR

connects to the alternator and 2 GROUND – ALTERNATOR
power resistor 3 GROUND – ALTERNATOR
4 RPM (5VDC)
5 GROUND – ALTERNATOR
6 FIELD (1-4 VDC)
7 LOAD
8 LOAD
9 LOAD
10 VALT (10VDC)
11 VALT (10VDC)
12 LOAD
15
ALTERNATOR CONTROL BOARD - Model C9, LC9100, and LC9500

P2 Connector is a 1 GND
12 pin Molex
2 GND
connector that
connects to the 3 GND
Alternator.
4 RPM-ALT
5 GND
6 FIELD
7 VALTR
8 VALTR
9 VALTR
10 VALT
11 Valt OPEN
12 VALTR

P3 is a 3 pin 1 GND
connector that
connect to the reed 2 Vbat
Switch
3 RPM-REED

P4 is a 2 Pin 1
connector that
provides external 2
power (LC95 only).
16
ALTERNATOR
The 12 volt, 35 amp Alternator is designed to provide electrical power to the product, supply load
resistance while providing electrical power, and provide the RPM signal from the AC TAP to the
Alternator Control Board.
AC TAP TERMINAL
OUTPUT TERMINAL
N
ITATIO
EXC
FIELD TERMINALS RETURN
GROUND TERMINAL
17
WIRING BLOCK DIAGRAM LC8500 and C7
Vbat
GND
TDO
RDI
GND
Vsysc Vcc
Signal
GND
Polar Receiver and Cable

optional on Lc8500 and
standard on C7. Also comes
with Telemetry Strap.
18
WIRING BLOCK DIAGRAM C9
Valt
Valt
RPM
GND
GND
GND
GND
ValtR
ValtR
ValtR
ValtR
FIELD
19
Vbat
Vbat PINK
Vbat
RPM_REED BLUE RPM_REED
RPM_ALT YELLOW RPM_ALT
GREEN A_START
A_START Valt
WHITE
Valt GND
BLK
GND FIELD_KICK
BROWN FIELD
FIELD_KICK ORANGE Vsys
FIELD PURPLE KEY
Vsys N.C. LOAD_CMD
Vsysc GREY RELAY_C
GND
LOAD_CMD N.C. RELAY_C
GND N.C. GND
GND TAN
RELAY_C N.C.
Resistor
15 OHMs
RPM_REED
Vbat
GND
WIRING BLOCK DIAGRAM LC9100
15 OHMs
Resistor
20
WIRING BLOCK DIAGRAM LC9500
15 OHMs
Resistor
21
WIRING BLOCK DIAGRAM 95Ce
22
1-GROUND
2-GROUND
3-GROUND
4-ALTRPM
5-GROUND
6-FIELD
7-N.C.
8-ValtR
9-ValtR
10-Valt
11-N.C.
12-ValtR
1
1-NORMALY OPEN
2-NORMALY CLOSED
1-GREEN - +5.5 Vdc 3-COMMON
2-BLACK - GROUND
3-WHITE - VSLEEP
4-BROWN - GROUND
5-RED - +12 Vdc
23
RED 1--VSC
BLUE 2--GROUND
GREEN 3--VALT
WHITE 4--ALT_RPM
BLACK 5--FIELD
ORANGE 6--REED_DISABLE
RED/BLACK 7--LOAD_CMD
GRN/BLACK 8--N/C
WHT/BLACK 9--RPM_REED
ORN/BLACK 10-V/C
BLUE/WHT 11-KICK/
BLACK/WHT 12-N/C
RED/WHT 13-N/C
GREEN/WHT 14-VSYS
Machine Interface Board
1--VSC
2--GROUND 1-RED
3--VALT 2-BLUE
4--ALT_RPM 3-GREEN
5--FIELD 4-WHITE
6--REED_DISABLE 5-BLACK
7--LOAD_CMD 6-ORANGE
8--N/C 7-RED/BLACK
9--RPM_REED 8-GRN/BLACK
10-V/C 9-WHT/BLACK
11-KICK/ 10-ORN/BLACK
12-N/C 11-BLUE/WHT
13-N/C 12-BLACK/WHT
14-VSYS 13-RED/WHT
14GREEN/WHT
1-RIGHT SIGNAL
2-N.C. 1-RS232_HC12_TxD
3-N.C. 2-RS232_HC12_RxD
4-LEFT SIGNAL 3-RS232_Csafe_CTS
4-RS232_Csafe_RxD
5-RS232_Csafe_TxD
1-VCC -------- RED 6-PON_SLEEP
2-SIGNAL --- WHITE 7-PON_AND
3-GROUND - BLACK 8-HC12_Wakeup_PULSE
4-TEST MODE 9-GND
10-GND
1- N.C. 11-PX_Wakeup_PULSE
2-N.C. 12-X_RESET
3-RxD 13-GPI00
4-TxD 14-GPI01
5-VCARDIO 15-GPI02
6-CTS 16-GPI03
7-GROUND 17-GND
8-VSC 18-GND
19-GND
20-Tuner_SDA
1-BACKGROUND 21-Tuner_SCL
2-GROUND 22-Tuner_GND
3-N.C. 23-Tuner_5V
4-RESET 24-Tuner_GND
5-N.C.
6-+5 Vdc
1-GROUND
2-PAO
3-PA1
4-PA2
5-PA3
6-PA4
7-START+
8-PA5
24
Single Board Computer
1-G REEN - +5.5 Vdc

2-BLACK - G ROUND
3-WHITE - VSLEEP
4-BROWN - GRO UND
5-RED - +12 Vdc
1-G REEN - +5.5 Vdc

2-BLACK - GROUND
RS232_HC1 2_T xD 3-WHITE - VSLEEP
RS232_HC1 2_RxD 4-BROWN - GRO UND
RS232_Csafe_CTS 5-RED - +12 Vdc
RS232_Csafe_RxD
RS232_Csafe_TxD
PON_SLEEP
PON_AN D
HC 12_Wakeup_PULSE
GND
GND
PX_Wakeup_PULSE
X_RESET
GPI00
GPI01
GPI02
GPI03
GND
GND
GND
Tu ner_SDA
Tu ner_SCL
Tu ner_GN D
Tu ner_5V
Tu ner_GN D
25
Notes
26
SECTION V
MISCELLANEOUS
Page
Model Identification & Serial Number Location ................................................................... 2
Preventative Maintenance Tips ........................................................................................... 3
Safety Instruction ................................................................................................................ 4
1
MODEL IDENTIFICATION and SERIAL NUMBER LOCATION
Serial Number
Label
Patent Label
Bottom Front
2
PREVENTIVE MAINTENANCE TIPS
Preventive Maintenance Schedule
DAILY MONTHLY BI-ANNUALLY

HOUSING
Inside Clean
Outside Clean
ALTERNATOR CONTROL
Heatsink Clean
Connectors Inspect
Board Inspect
Crank Bearings Inspect
Pedals Clean/Inspect
Freewheel Pulley Clean/Inspect
Alternator Flywheel Clean/Inspect
SEAT ASSEMBLY
Top Surface Clean
Release Lever Inspect
ALTERNATOR BELT
Tension Inspect
Wear Inspect
Lifepulse sensors Clean
3
IMPORTANT SAFETY INSTRUCTIONS!
⇒ DO NOT locate the Exercise Bike outdoors, near swimming pools, or in areas of high
humidity.
⇒ DO NOT operate your Exercise Bike if it has been dropped, damaged, or even partially
immersed in water. Contact Life Fitness Customer Support Services at the number in the
Operation Manual.
⇒ DO NOT locate the Exercise Bike any closer than 30 inches ( 76 cm ) to a television set.
⇒ DO NOT locate additional Exercise Bike any closer than a minimum of 42 inches (107 cm)
from center to center to avoid interference (cross talk) between Heart Rate monitors.
⇒ DO keep the area around your Exercise Bike clear of any obstructions, including walls and
furniture.
⇒ DO verify the contents of the delivery carton against the accompanying Parts Listing prior to
setting the cartons and shipping material aside. If any parts are missing, contact Life Fitness
Customer Support Services at the number listed in the Operation Manual. Save the shipping
cartons in case of return.
⇒ DO read the entire Operation Manual prior to attempting to operate this machine as this is
essential for proper use.
4
©2000 Brunswick Corporation. All rights reserved. Life Fitness and Lifecycle are registered trademarks of Brunswick Corporation.
Lifepulse, Zone Trainer and Heart Rate Zone Training are trademarks of Brunswick Corporation. Any use of these trademarks, without the
express written consent of Brunswick Corporation, is forbidden.
M051-00K63-B012
March 2004

Life Fitness 95ci

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Life Fitness 95ci

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Lifecycle Upright Bikes

LC9500, LC9100, LC8500, C9, C7,

Customer Support Services

1. The Lifecycle equipment model number

LIFE FITNESS COMPANY - CUSTOMER SUPPORT SERVICES

SPECIAL SERVICE TOOL REQUIREMENTS

COMPONENT IDENTIFICATION – C9 and C7 Consumer Bikes

Note: C7 will not have accessory tray

COMPONENT IDENTIFICATION – C9 and C7 Consumer Bikes

COMPONENT IDENTIFICATION – C9 and C7 Consumer Bikes

COMPONENT IDENTIFICATION - LC9500, LC9100, LC8500 Commercial Bikes

Lc9500 Assembly Components

COMPONENT IDENTIFICATION - LC9500, LC9100, LC8500 Commercial Bikes

COMPONENT IDENTIFICATION - LC9500, LC9100, LC8500 Commercial Bikes

Main Drive Clutch

Lc8500 Right Side Components

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

CAUTION! HIGH VOLTAGE ON CONNECTORS J2 AND J3

Remove the Integrated System Console from the Unit.

2. Remove Rear Cover from the Console Assembly.

3. Plug in Power Supply and Remote Control to the Console

4. Press the Power On Key on the Remote Control.

Voltage present on TP1 Replace the Inverter Board

TEST POINT VOLTAGE DESCRIPTION PIN NUMBER

1. Unscrew the Retaining Nut securing the Power

Display Test All Led’s On

Walking Led Keypad Test Units

Port I/o Test Relay

Fld Kick Alt Rpm

CODE VERSION ……………….ex: CODE VER - X.XX

Press ENTER for entry into the OPTIONAL SETTINGS.

KEYS DISPLAYED CHARACTER KEYS DISPLAYED CHARACTER

RPM: In the RPM window, the alternator RPM will be displayed.

Within this state, the CSAFE network can be tested.

The DOWN ARROW will turn OFF the telemetry.

Within this state, ENGLISH or METRIC units can be selected.

The DOWN ARROW will select METRIC units.

The UP ARROW will select ENGLISH units.

The DOWN ARROW will turn OFF the WATTS PROGRAM.

The UP ARROW will turn ON the WATTS PROGRAM.

The DOWN ARROW will turn OFF the METS PROGRAM.

The UP ARROW will turn ON the METS PROGRAM.

The DOWN ARROW will turn OFF the CAL/H program.

The UP ARROW will turn ON the CAL/H program.

The DOWN ARROW will turn OFF the WATTS PROGRAM.

The UP ARROW will turn ON the WATTS PROGRAM.

Within this state, METS PROGRAM can be turned ON or OFF.

By default, the LifeCycle will have the METS PROGRAM OFF.

The DOWN ARROW will turn OFF the METS PROGRAM.

The UP ARROW will turn ON the METS PROGRAM.

Upon entry to this state, TOTAL HOURS are displayed.

The Programs are:

HOUR = Total hours on the console

Channel or Volume Control

The ENTERTAINMENT CONTROL SETTING

LCD Console Welcome Screen