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XE860 Service Manual
Plastic Parts
Front Mast Cover Console Rear Handlebar Cover (R)
Rear Mast Cover Console Mast Cover Round Disk Cover, Crank
Rear Handlebar cover (L) Chain Cover (R)
Round Disk Cover
front Stabilizer Cover Rear Stabilizer Cover Right Pedal
Connecting Arm CoverA(L, R) Left Pedal Left Rail Cover(Metal)
Pedal Arm Cover Right Rail Cover(Metal)
Connecting Arm Cover B(L, R) Chain Cover (L) Rail Suppoert Assembly(Metal)
Slide Wheel Cover (Inside metal Rail Cover)
Skeleton
Bushing Housing Left Handlebar
Left Pedal Console mast
Left Pedal Arm Right handlebar
Rail Assembly Inductive Flywheel
Right Pedal Arm Cross Bar
Right Connecting arm Idler Wheel Assembly Main Frame
Drive Pulley
CONTENTS：
I. Disassembling and assembling pf parts
1. Console
2. Connecting Arm Assembly
3. Pedal Arm Assembly
4. Left and right Chain Covers
5. Cross Bar Assembly
6. The Belt
7. Idler Wheel assembly
8. Inductive Flywheel
9. Drive Pulley
10. Bushing Housing
11. Slide Wheel
II. Troubleshooting
1. Console
2. Left/Right Chain covers and Round Disk Cover,
Crank
3. Inductive Flywheel
4. The Belt
5. Left and right Handlebars
6. Bushing Housing
7. Pedal Arms, Connecting Arms and Slide Wheels
III. Q＆A
1. Noises
2. Slippage
3. Wobble
4. Smoothness
5. Other Problems
Model XE860 Work Assembling/Disassembling
Part 1 Console Rev
Procedures
1. Use Phillips head screwdriver to
release
3pcs of M5x12mm screws,
2pcs of self tapping screws and
4pcs of M5 x 10 mm screws.
Disconnect computer cables and
handpulse cables and take apart
the Console, as shown in figure 1
and 2.
2. To resume, Connect the cables
back on and tighten 4pcs of M5 x
10 mm to secure the Console.
Return and secure Fron Mast
Covers.
1
2
Model XE860 Work Assembling/Disassembling
Part 2 Connecting Arms Rev
Procedures
1. Use Phillips head screwdriver to
unscrew Connecting arm Covers
A and B, as shown in figure 1.
2. Use 12 mm and 13 mm wrenches
to release hex head bolt, which
secures the Fish-eye bearing,
together with 5/16" x 18 x 1.5T
flat washer and 5/16" x 7T
nut, as
shown in figure 2.
3. Use 12 mm wrench to
release5/16" x 15m/m hex head
bolt and 5/16" x 23 x 1.5T flat
washer, which secure the
Connecting Arm. Then release
the carriage bolt and take apart
the Connecting Arm, as shown in
figures 3 and 4.
1
2
3
4
Model XE860 Work Assembling/Disassembling
Part 2 Connecting Arms Rev
Procedures
4. Use Phillips head screwdriver to
release 4pcs ofM5x10mm and
take apart the plastic Pedal, as
shown in figure 5.
5. To resume, return and tighten the
Pedal back on the Connecting
Arm and joint it with Pedal Arm
by inserting the carriage bolt and
tighten with 5/16" x 15m/m hex
head bolt and 5/16" x 23 x 1.5T
flat washer, as shown in figure 6.
6. Secure Fish-eye bearing with
5/16" x1-1/4" hex head bolt,
5/16"x 18 x 1.5T flat washer and
5/16" x 7T nut.
7. Return Connecting Arm Covers
A and B.
5
6
Model XE860 Work Assembling/Disassembling
Part 3 Pedal Arms Rev
Procedures
1. Follow procedure 2 to take apart
Connecting Arm.
2. Use Phillips head screwdriver to
release Pedal Arm Cover, then
release 6pcs of M5x12m/m
screws to and take left and right
Front Covers, as shown in figures
1 and 2.
3. Use M6 and 13 mm wrenches to
release M8 x 50 socket head cap
screw, which secures Pedal Arm
and Bushing Housing, together
with 2pcs of 5/16"×20×1.5T flat
washer and M8 x 7T nut. Pull
Pedal arm backward to take it
apart, as shown in figures 3 and
4.
4. To resume, join Pedal Arm with
Bushing Housi
ng and secure with
M8 x 50socket head cap screw,
2pcs of 5/16"×20×1.5T flat
washer and M8 x7T nut and
return Pedal Arm Cover and
Front Covers.
5. Follow procedure 2-5 to return
Connecting Arm.
1
2
3
4
Model XE860 Work Assembling/Disassembling
Part 4 Chain Covers Rev
Procedures
1. Follow procedures 2 and 3 to
take apart Connecting Arm and
Pedal Arm.
2. Press Console Mast Cover
slightly to release it from left and
right Chain Covers, as shown in
figure 1.
3. Use Phillips head screwdriver to
release 7 4x19 self tapping
screws and 3pcs of 5x16 tapping
screws and take apart right Chain
Cover, as shown in figures 2 and
3.
4. To release left Chain cover,
release 4x15 self tapping screw
and 1/4"x19 flat washer, which
are on the main frame, as well as
3pcs of 5x16 tapping screws.
Disconnect red and black power
cables with grounding cable to
release left Chain cover, as
shown in figures 4, 5 and 6.
1
2
3
4
Model XE860 Work Assembling/Disassembling
Part 4 Chain Covers Rev
Procedures
5. To resume, Connect AC cables
together with grounding wire.
6. Return left Chain cover onto the
main frame (be sure to place a
5/16" x 23 x 1.5T flat washer
between Chain Cover and
mainframe) and use Phillips head
screwdriver to return 4x15 self
tapping screw and 1/4"x19 flat
washer on the main frame (not
too tight for now), then tighten
with 3pcs of 5x16 self tapping
screws (with Chain Cover and
Crank Round Disk Cover match
well). Tighten 4x15 self tapping
screw, as shown in figures 7 and
8.
7. Match right Chain Cover with
left and secure with 7pcs of
4x19self tapping screws and 3pcs
of tappinf screws.
8. Follow procedures 3-4 and 2-5 to
resume Pedal Arm and
Connecting Arm.
5
6
7
8
Model XE860 Work Assembling/Disassembling
Part 5 Cross Bar Rev
Procedures
1. Follow procedures 2, 3and 4 to
take apart Connecting Arm, Pedal
Arm and both Chain covers.
2. Use a sharp tip stick to take off
Round Disk Cover, as shown in
figure 1.
3. Use 12 mm wrench to release
5/16" x 15m/m hex head bolt
with 5/16" x 35 x 1.5T flat
washer. Then use M6 wrench to
release M8x30 socket head cap
screw and take apart Cross Bar
with Round Disk, Crank, as
shown in figures 2 and 3.
4. Use Phillips head screwdriver to
release 8pcs of 5x16 tapping
screws with 1/4"x19 flat washers
and take apart Round Disk
Cover, Crank from Cross Bar, as
shown in figure 4.
1
2
3
4
Model XE860 Work Assembling/Disassembling
Part 5 Cross Bar Rev
Procedures
5. To resume, return Crank Round
Disk on the Cross Bar and put
them back on the Crank Axle,
match with the square hole for
7x7x25L Woodruff Key to return
it in the hole. Return M8x30
socket head cap screw and
tighten until it reads 600 Kgf-cm.
Then tighten with 5/16" x 15m/m
hex head bolt and 5/16" x 35 x
1.5T flat washer, as shown in
figures 5 and 6.
6. Follow procedures 4, 3 and 2 to
return Connecting Arm, Pedal
Arm, Chain covers and Round
Disk Cover.
5
6
Model XE860 Work Assembling/Disassembling
Part 6 The Belt Rev
Procedures
1. Follow procedures 2, 3, 4 and 5
to take Connecting Arm, Pedal
Arm, both Chain Covers and
Cross Bar.
2. Use 13 mm wrench to loosen
M8 x 7T nut on M8x170mm
J-bolt Then use Phillips head
screwdriver to loosen 3pcs of
M6x15 screws on the Idler
Wheel Assembly and take off the
Belt, as shown in figures 1, 2 and
3.
3. To resume, return the Belt onto
the Drive Pulley and Induction
Flywheel then adjust M8 x 7T
nut so tight the acoustic tension
gauge reads 170 Hz +/- 10 Hz, as
shown in figure 4.
4. Follow procedures 5, 4, 3, and 2
to resume other parts.
1
2
3
4
Model XE860 Work Assembling/Disassembling
Part 7 Idler Wheel Assembly Rev
Procedures
1. Follow procedures 2, 3, 4, 5 and
6 to take apart Connecting Arm,
Pedal Arm, both Chain Covers,
Cross Bar and the Belt.
2. Use 13 mm wrench to loosen M8
x 7T nut and 5/16" x 23 x 1.5T
flat washer on M8x170mm J-bolt
to release it. Then use Phillips
head screwdriver to release 3pcs
of M6x15 screws with 1/4"
spring washers and 1/4"x13x1T
flat washers and take apart the
Idler Wheel Assembly, as shown
in figures 1 and 2.
3. To resume, use 3pcs of M6x15
screws with 1/4" spring washers
and 1/4"x13x1T flat washers to
return Idler Wheel Assembly (not
too tight until the Belt has been
returned). Then return the J-bolt
and follow procedures 6, 5, 4, 3
and 2 to return other parts.
1
2
Model XE860 Work Assembling/Disassembling
Part 8 Inductive Flywheel Rev
Procedures
1. Follow procedures 2, 3, 4, 5, 6
and 7 to take off Connecting
Arm, Pedal Arm, both Chain
Covers, Cross Bar, the Belt and
Idler Wheel Assembly.
2. Disconnect all electric cables for
Inductive Flywheel and cut the
tie for the Cables, as shown in
figures 1, 2 and 3.
3. Use 11 mm wrench to release
4pcs of 1/4" x 3/4" hex head bolt
with 1/4" spring washers and
1/4"x13x1T
flat washers and take
the Inductive Flywheel apart, as
shown in figure 4.
4. To resume, Return the Inductive
Flywheel back on the Main
Frame and secure with 4pcs of
1/4" x 3/4" hex head screws with
3pcs of 1/4" spring washer and
3pcs of flat washers then connect
all electric cables back on.
5. Follow procedures 7, 6, 5, 4, 3
and 2 to resume all other parts.
1
2
3
4
Model XE860 Work Assembling/Disassembling
Part 9 Drive Pulley Rev
Procedures：
1. Follow procedures 2, 3, 4, 5 and
6 to take apart Connecting Arm,
Pedal Arm, both Chain Covers,
Cross Bar and the Belt.
2. Use C-ring pliers to release 2pcs
of ψ25 C-rings on Crank Axle
to release Crank Axle together
with Drive Pulley, as shown in
figures 1 and 2. Use a hammer if
necessary.
3. To separate Drive Pulley from
the Crank Axle, use C-ring pliers
to release ψ25 C-ring and use
two 11 mm wrenches to release
4pcs of 1/4" x 3/4" hex head bolt
and 1/4" nuts, as shown in figure
3.
4. To resume Drive Pulley, return
one C-ring back on the Crank
Axle and put it back on the Main
Frame then secure with
remaining C-rings.
5. Follow procedures 6, 5, 4, 3 and
2 to return other parts.
1
2
3
Model XE860 Work Assembling/Disassembling
Part 10 Bushing Housing Rev
Procedures：
1. Follow procedures 2 and 3 to
release Connecting Arm and
Pedal Arm.
2. Use 12 mm wrench to release
5/16" x 15m/m hex head bolt
with 5/16" x 35 x 1.5T flat
washer and take Bushing
Housing apart, as shown in figure
1.
3. To resume, return ψ25 wave
washer on the shaft and place
Bushing Housing back on the
shaft, which is applied with
lubricant. Secure Bushing
Housing with 5/16" x15m/mhex
head bolt and 5/16" x 35 x 1.5T
flat washer, as shown in figures 2
and 3.
4. Follow procedures 3-4 and 2-5 to
resume Pedal Arm and
Connecting Arm
1
2
3
Model XE860 Work Assembling/Disassembling
Part 11 Slide Wheels Rev
Procedures：
1. Follow procedures 2 and 3 to
release Connecting arm and
Pedal Arm.
2. Use Phillips head screwdriver to
unscrew Slide Wheel Cover, as
shown in figure 1.
3. Use C-ring pliers to release ψ17
C-ring and take apart the Slide
Wheel, as shown in figure 2.
4. To resume, return ψ17 wave
washer, Slide Wheel, ψ17 wave
washer in sequence onto the
wheel shaft and secure with
C-ring, as shown in figure 3.
Return the Slide Wheel Cover
5. Follow procedures 3-4 and 2-5 to
return Pedal Arm and Connecting
Arm.
1
2
3
Model XE860 Work Troubleshooting
Part 1 Console Rev
Procedures
1. Display: Follow the procedures
below if the display is blank.
2. Make sure that power is plug in
properly and AC breaker is not
activated, as shown in figure 1.
3. Make sure that all connectors,
including computer cables vs.
Console, are connected properly.
Disassemble the Console to check
computer cables inside the Console
if necessary.
4. If cables are all connected properly,
then check for cable damage or
Console/lower Controller failure, as
shown in figure 2.
1
2
Model XE860 Work Troubleshooting
Part 2 Chain covers and Round Disk, CrankRev
Procedures
1. Major problem is noises cause by
rubbing between two parts. Identify
if the noise is caused by shifting or
swing of the Round Disk, Crank, as
shown in figures 1 and 2.
2. If it is the shifting of the Round
Disk, Crank which is causing the
noise, release both left and right
Chain Covers and re-assemble them
again. (Follow procedure 4)
3. If it the swing of the Round Disk,
Crank which is causing the noise,
then release both Chain Covers and
Round Disk, Crank then use Phillips
head screwdriver to release 16pcs of
5x16m/m tapping screws with
1/4"x19m/m flat washers on Round
Disk, Crank. Put Cross Bar with
Round Disk, Crank on a level
surface and check for any sign of
warp. Correct the warp with force to
within 3 mm tolerance.
1
2
Model XE860 Work Troubleshooting
Part 3 Inductive Flywheel Rev
Procedures
1. The problem with Inductive
Flywheel is rare. If there is no
resistance, take off both Chain
Covers and check for disconnection
or breakage for electric cables, as
shown in figure 1.
2. If there is no power generated, check
AC power switch for fuse blown.
Replace with a new AC switch if
necessary. (follow procedure 8) as
shown in figure 2 and 3.
1
2
3
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