XR895 Service Manual
Release Lever console
Front Stabilizer Cover
Round Disk Cover
Rear Stabilizer Cover Bottom Cover Console Mast Cover
Rear Chain Cover (L) Cup Holder (R) Front Chain Cover (R)
Cup Holder (L) Rear Chain Cover (R) Front Chain Cover (L)
Structure
Seat Back Frame Seat Carriage Handle Console Mast
Seat Handle Bar Rear Stabilizer Controller Mainframe Flywheel Drive Pulley
Cylinder
Aluminum Rail Crank Idle Arm
Content
1. Dismantle and Replacement
1. Console
2. Handle and Console Mast
3. Cranks and Pedals
4. Front Chain Cover
5. Belt and Idle Arm
6. Drive Pulley Axle and Drive Pulley
7. Generator Flywheel
8. Cylinder
9. Seat Back
10. Rear Chain Cover
11. Sliding Seat
2. Problem Solving
1. Console
2. Chain Covers and Round Disk Cover
3. Belt and Idle Arm
4. Generator Flywheel
5. Cylinder
6. Sliding Seat
3. Q & A
1. Noise
2. Slippage
3. Smoothness
4. Other Problems
1. Dismantle and Replacement
1. Console (19) dismantle and assembling
Unscrew 4pcs of M5x12m/m Phillips Head Screws (99) with Phillips Head Screw Drier (114) and
the Console can be released.
2 Handle (3) and Console Mast
1. Take off the Handle Bar Cover (141) then use 12/14 m/m wrench (112) to release 2pcs of
5/16”x15 Hex Head Screws (68), 2pcs of ψ8x1.5T Split Washers and 2pcs of 5/16”x19x1.5T
Flat Washers (76) and the Handlebar Assembly (3) can be released.
2. Reverse the above step to resume the Handlebar Assembly (3).
3. Release the Console Mast Cover by flapping or pressing it with hand as shown in the figure below.
Use 12 m/m wrench to unscrew 6pcs of 5/16”x15 Hex Head Screws (68) together with 4pcs of
5/16”x19x1.5T Flat Washers (76) and 2pcs of 5/16”x20x1.5T Curved Washers (83) and the
Console Mast can be released.
4. To resume the Console Mast (2), guide the computer cable through the Console Mast (2) and out
of the console plate first and the use 12 m/m wrench to tighten 6pcs of 5/16”x15 Hex Head
Screws (68) together with 4pcs of 5/16" x 19 x 1.5T Flat Washers (76) and 2pcs of 5/16" x20x
1.5Tcurved Washers (83).
3.Disassembling/Assembling of Cranks (51L, 51R) and Pedals (116, 117)
1.Use 13/15m/m wrench to turn the Left Pedal (116) clockwise and Right Pedal (117)
counterclockwise to disassemble these two pedals.
2.
To resume the pedals, turn the pedals with reversal orientations.
3. Take off the Crank Arm End Cap (28) and release the M10x1.0 Nut (108) by using the wrench.
4. Use the plug matching with the Cranks (51L, 51R) and turn with hex wrench to release the
Cranks (51L, 51R).
5.To resume the Cranks (51L, 51R), use the hammer to hit the Cranks tightly match with the Drive
Pulley Axle (8) and turn the nut tightly onto the Axle. Plug in the Crank Arm End Cap.
4. Disassembling/Assembling Front Chain Covers
1.To release Left Front Chain Cover (29), use Phillips Head Screw Driver to release 7pcs of ψ
3.5x12 Self Tapping Screws (103) and 2pcs of 5x16 Tapping Screws (102).
2. To release Right Front Chain Cover (30), on the mainframe, unscrew 2pcs of ψ3.5x20 Self
Tapping Screws (107) with 2pcs of ψ5 x16x1.5Tflat Washers (78) then, on the Right Front
Chain Cover, unscrew 2pcs of 5x16 Tapping Screws and unplug the electric wires connected to
AC power switch.
3. To resume the Right Front Chain Cover, put it on the mainframe and plug in the electric wires
back to the AC power switch. Locate 2pcs ofψ3.5x20 Self Tapping Screws (107) with 2pcs ofψ5
x16x1.5T Flat Washers (78) on the mainframe loosely then tighten 2pcs of 5x16 Tapping Screws
(102) on the mainframe and tighten up all loose screws.
4. Match Left Front Chain Cover (29) with Right Front Chain Cover (30) and secure both covers
with 7pcs ofψ3.5x12 Self Tapping Screws (103) and then 2pcs of 5x16 Tapping Screws (102).
5.Disassembling/Assembling Belt (54) and Idle Arm (10) Note: Must be done
after Front Chain Covers (L) and (R), (29 and 30) have been released.
1.Use 13 m/m wrench to release M8x7T Nut (88) and take off the J-Bolt (87).
2. Use Phillips Head Screw Driver to unscrew 3pcs of M6x7T Phillips Head Screws on Idle Arm (10)
and the Belt (54) can be taken off.
3. To release the Idle Arm (10), Unscrew 3pcs of M6x15 Phillips Head Screws (98) with 3pcs ofψ
1/4" Split Washers (80) and 3pcs of 1/4”x13x1T (72).
4. To resume the Belt (54) and Idle Arm (10), use Phillips Head Screw Driver to secure the
Generator Flywheel (55) with 3pcs of M6x15 Phillips Head Screws together with 3pcs ofψ1/4"
Split Washers (80) and 3pcs of 1/4”x13x1T Flat Washers (72). Turn the Drive Pulley (20) to let
the Belt on the Pulley, hook the J-Bolt on the mainframe and use 13 m/m wrench to tighten
M8x7T Nut (88) on the J-Bolt until the Belt (54) is with acceptable tension. Use audio tension
gauge to make sure the frequency within the range of 170 +/- 10 Hz.
6.Disassembling/Assembling of Drive Pulley Axle (8) and Drive Pulley (20)
Note: Must be done after Front Chain Covers (L) and (R), (29) and (30),
have been released.
1.Use C-ring pliers to take offψ20 C-ring (86) axle and the Drive Pulley Axle (8) can be released.
2.To release the Drive Pulley, use 2pcs of wrench to unscrew 4pcs of 1/4”x3/4” Hex Head Screws
(66) with 8pcs of 1/4”x13x1T Flat Washers (72) and 4pcs of 1/4”x5T Nut (90).
3. Reverse the above steps to resume Drive Pulley Axle (8) and the Drive Pulley (20).
7. Disassembling/Assembling Generator Flywheel (55)
Note: Must be done after Front Chain Covers (L) and (R), (29) and (30), have
been released.
1.Unplug electric wires connected to the Generator Flywheel (55) then use 11 m/m wrench to
unscrew 4pcs of 1/4”x3/4” Hex Head Screws (66) with 4pcs of 1/4"x13x1T Flat Washers (72) and
4pcs ofψ1/4"Split Washers (80) and you can release Generator Flywheel (55).
2. Reverse the above step to resume the Generator Flywheel (55).
8. Disassembling/Assembling Cylinder (57)
1. On Left and Right Cup Holder (38, 39) use Phillips Head Screw Driver to unscrew 4pcs ofψ4x16
Self Tapping Screws (105) to take off Cup Holders (38,39)
2. Use M5 Allen Wrench/Phillips Head Screw Driver Combination (115) to take off the Release Lever
(40).
3. Use wrench to release adjusting nut on the Seat Recline Release Cable (58) to take off the cable.
4. Use 12 m/m and 13 m/m wrenches to unscrew the 5/16" x1- 3/4"(Grade 8) Hex Head Screw (70)
with 5/16" x 19 x 1.5T Flat Washer (76) and 5/16" x 6T Nut (91), which are under the Set Back Frame
(5).
5. Use Phillips Head Screw Driver to unscrew M5x12 (99) on Plastic Seat Carriage Cover (125) then
unscrew 5/16" x2- 1/2"(Grade 8) Hex Head Screw (69) with 5/16"x19 x 1.5T Flat Washer (76) and
5/16"x 6T Nut (91) on the Seat Carriage (4) and you can release the Cylinder (57).
6. Use 5/16" x2- 1/2"(Grade 8) Hex Head Screw (69) with 5/16"x19 x 1.5T Flat Washer (76) and
5/16"x 6T Nut (91) to secure the Cylinder (57) on the Seat Carriage (4) and connect the Seat Recline
Release Cable (58) to the Cylinder (57). Use 5/16" x1-3/4"(Grade 8)Hex Head Screw (70), 5/16" x 19 x
1.5T Flat Washer (76) and 5/16" x 6T Nut (91) to secure the other end of Cable (58) onto the Seat Back
Frame (5). Secure the Plastic Seat Carriage Cover with M5x12 Phillips Head Screws (99).
9. Disassembling/Assembling Seat Back Frame (5)
1. Use 2pcs of 14 m/m wrenches to unscrew 2pcs of 3/8”x4”Hex Head Screws (67) with 3/8”x7T Nut
(89) and the Seat Back Frame can be released.
2. To resume the Seat Back Frame (5), Put the Frame onto the Seat Carriage and secure with 2pcs of
3/8”x4”Hex Head Screws (67) with 2pcs of 3/8"x7T Nut (89) by using 2pcs of 14 m/m wrench.
10. Disassembling/Assembling Rear Chain Covers (L) and (R) (35, 36)
1. Use Phillips Head Screw Driver to unscrew 7pcs ofψ3.5x12 Self Tapping Screws (103) and 2pcs of
5x16 Tapping Screws (102), which are on Left Rear Chain Cover (35). Unplugging Handpulse wire (26)
and Left Rear Chain Cover can be released.
2. On the Right Rear Chain Cover (36), unscrewψ3.5x20 Self Tapping Screws (107) withψ5
x16x1.5T Flat Washers (78) and 2pcs of 5x16 Tapping Screws (102) and the Right Rear Chain Cover
(36) can be released.
3. To resume the Right Rear Chain Cover (36), secure the Cover onto the mainframe withψ3.5x20 Self
Tapping Screws (107) withψ5 x16x1.5T Flat Washers (78) and 2pcs of 5x16 (102) Tapping Screws.
To resume Left rear Chain Cover (35), plug in the Handpulse Wires (26) then match Left and Right
Chain Covers and secure with 7pcs ofψ3.5x12Self tapping Screws (103) and 2pcs of 5x16 Tapping
Screws (102).
11. Disassembling/Assembling of Seat Carriage (4)
Note: Must be done after Rear Chain Covers (L) and (R) (35, 36) have been
released.
1. Use Phillips Head Screw Driver to unscrew and releaseψ13x19 x26.5L Seat Stop (16), M6x15
Phillips Head Screw (98) with 1/4"x19x1.5T Flat Washer (73) and Seat Stop Axle. Press the Release
Lever (40) and slide out the Seat Carriage.
3. Use Phillips Head Screw Driver to unscrew 4pcs of M6x15 Phillips Head Screws (98) on the Seat
Carriage (4) and the Seat Bottom Cushion can be released.
4. Use M5 Allen Wrench/Phillips Head Screw Driver Combination (115) to release Left Release Lever
(40).
5. Use 2pcs of 14 m/m wrench to unscrew 4pcs of 3/8"×1-3/4" Hex Head Screws (71), 4pcs of 3/8" x
19 x 1.5T Flat Washers (77) and 4pcs of 3/8"x 7T Nuts (89) to release Seat Handle Bar (6).
6. Use M5 Allen Wrench/Phillips Head Screw Driver Combination (115) and 8 m/m wrench to unscrew
M6 x40mm Socket Head Cap Screw (93) with M6 Nut (129) and the Seat Positioning Latch (12), Seat
Recline Release Cable (58) and Seat Release Spring (104) can be released.
7. Use 13 m/m wrench to release M8 x 7T Black Nyloc But (88) andψ8x18x3T Lock Washer (79),
which are on the Seat Carriage, and the Seat Wheel Adjustment Plate (9) can be removed.
8. To resume Seat Carriage (4), locate the Seat Wheel Adjustment Plate (9) with screws loosely and
secure the Seat Positioning Latch (12), Seat Recline Release Cable (59) and Seat Release Spring (104)
with M6 x40mm Socket Head Cap Screw (93) and M6 Nut (129). Resume Seat Carriage onto the
aluminum rail and secure with 11 m/m and 13 m/m wrenches. Use 2pcs of 14 m/m wrenches to secure
Seat Handle Bar (6) on the Seat Carriage with 4pcs of 3/8"×1-3/4" Hex Head Screws (71), 4pcs of 3/8"
x 19 x 1.5T Flat Washers (77) and 4pcs of 3/8"x 7T Nuts (89), then use M5 Allen Wrench/Phillips Head
Screw Driver Combination (115) to secure Release Lever (40) on Seat Handle Bar (6).
2. Problem Solving:
1 Console
When the display is blank, check the following..
1. Make sure the computer cable is insert onto the console properly.
2. The connecting cables between the generator flywheel and the controller are plug in properly
2 Chain Covers and Round disk Cover
1. Almost all problems are rubbing noises. In most cases noises are caused by the alignment of the
Round Disk Cover or the rubbing between Crank and Chain Covers. Since every product goes through
acoustic room for performance test prior to packing, such a problem is rather rare.
2.If there is noise caused by rubbing between crank and chain covers, follow steps 1-4, 3-3 and 3-4 for
disassembling.
3 .Belt and Idle Arm
1.When the Belt (54) falls off, refer to step 4 in item 1 to disassemble Chain Covers and Idle Arm (10),
referring to step 5 in item 1. Then refer to steps in item 1 to resume the Belt and check the running of
the belt at low speed to investigate the swing of the Drive Pulley (20) and the Belt (54) and the
alignment of the Belt (54), Drive Pulley (20) and Generator Flywheel. Make sure they are in line. Then
test the running of the belt at speed as high as100 – 120 RPM and investigate with a sudden stop, as the
way in the assembly line. If everything is normal, resume and secure the Chain Covers. The
falling-off of the belt is normally caused by misalignment among the Belt (54), Drive Pulley (20) and
Generator Flywheel. When there is misalignment, the belt shifts from one side of the Drive Pulley to
the other when it changes orientation of the running and the determination of the part, which is
misaligned, is required. The Idle Arm (10) must be replaced if it is misaligned.
Slippage: Tightening M8x7T Nut (88) on M8 x 170J-Bolt (87) will fix the problem.
5 Cylinder
1 , 8
If the cylinder cannot function properly, replace it following Step 8.
6 Seat Carriage
1. If the seat wobbles, follow step 11-8 to secure the seat carriage.
2.It the Seat Carriage cannot move smoothly, refer to step 11-8 to disassemble Seat Position Latch (12)
and adjust the width of the notch of Index Plate (15). Replace it if it cannot be adjusted.
3. Q & A
1 Q Noise
A: Besides the noise caused by the rubbing between Drive Pulley and Chain Covers, The major cause
of the noise is the foreign material falling into chain covers and interact with Flywheel. Removing the
foreign material fixes the problem.
2 Q Slippage
A: Tightening M8x7T Nut on the J-Blot will fix the problem of belt slippage.
3 Q Smoothness
A: If you feel pedal clicks, Tighten the M10x1.0 Nut to secure the Crank will fix the problem.
4 Q Others
A: The problem varies and cannot be described completely. You can always contact DYACO for
technical support.
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