Lemond RevMaster Pro User Manual

SERVICE MANUALFor Lemond Exercise Bikes, Models:15100, 15200, 15300, and15400,

Pg. 8 RevMaster Service Manual Figure 7.Right Pedal Crank BoltCrank Pulley AssyDrive BeltBottom Bracket Assembly, 2 pieceIdler Bearing AssemblyIdler

Pg. 9 Figure 8.Plastic Water Bottle HolderBottle Holder Front MountScrew, Socket Head, M5 x 15 (x2)Bottle HolderBack MountAdjustment HandleHandlebar S

Pg. 10 RevMaster Service Manual TOOL LISTASSEMBLY TOOLS INCLUDED WITH BIKE:Tool Where Used3-mm Hex key Used for: H2O bottle mounting screw (mounts th

Pg. 11INSTALLATION CHECK LISTSTABILIZER BARSCheck that the mounting screws, four M8 x 20 screws attach the front stabilizer bar to the frame, and four

Pg. 12 RevMaster Service Manual MAINTENANCE SCHEDULE)PART RECOMMENDED ACTION FREQUENCY CLEANER LUBRICANT1 Pedals Ensure that the pedals are tight in

Pg. 13TROUBLE SHOOTINGSYMPTOM: Seat or handlebar post move after locked into position.Locate smaller 3mm hex bolt at pivot point of cam handle and lo

Pg. 14 RevMaster Service Manual SYMPTOM: Inconsistent resistance or noisy brake pad.Remove fender assembly and make sure brake pad is clean.1. Apply

Pg. 15ASSEMBLY/DISASSEMBLY/ADJUSTMENTHANDLEBARWhen the handlebar is rst installed on the bike there is a slider plunger (or “pill”) at the end of the

Pg. 16 RevMaster Service Manual PEDALS Use a 15mm open end wrench or pedal wrench to install and remove pedals.InstallationOne pedal will be labeled

Pg. 17CRANK ARMSUse a 8mm hex wrench to install/remove crank bolts & use a Park CCP-2 or similar crank arm puller to remove crank arms.REMOVALLeft

Pg. 18 RevMaster Service Manual BELT COVERUse a 3mm hex wrench & 5mm hex wrench to install/remove belt cover.RemovalRemove the three 3mm screws f

Pg. 19DRIVE BELT/DRIVE BELT TENSIONUse a 5mm hex wrench (long T-handle works best) & 8mm hex wrench to remove/install or adjust drive belt. Pleas

Pg. 20 RevMaster Service Manual To tension the belt, tighten the tension screw (with 5mm hex wrench) so the idler bearings begin to put downward pres

Pg. 21BOTTOM BRACKET BEARING ASSEMBLYUse a Park BBT-22 or similar bottom bracket tool & blue medium 242 strength Loctite.RemovalRemove the belt co

Pg. 22 RevMaster Service Manual FLYWHEELUse a 5mm hex wrench to remove ywheel assembly & 4mm hex wrench to remove ywheel hub as-sembly

Pg. 23REMOVING AND REPLACING HUB ASSEMBLY IN FLYWHEELIf the ywheel bearings or pulley are damaged a new ywheel hub assembly will need to be installe

Pg. 24 RevMaster Service Manual BRAKE ASSEMBLYUse an adjustable crescent wrench to remove/install brake assembly.RemovalTurn the brake rod counterclo

Pg. 25FENDER ASSEMBLYA 5mm hex wrench & 4mm hex wrench will be used simultaneously. Also use medium 242 strength Loctite.RemovalRaise the handleb

Pg. 26 RevMaster Service Manual BRAKE PAD REMOVAL/INSTALLUse 3mm hex wrench & brake pad oil (or 3-In-One Multi-purpose oil).With the fender assem

Pg. 27ADJUSTMENT HANDLES HANDLEBAR/SEAT POST HEIGHT ADJUSTMENT HANDLESUse 6mm hex wrench & 3mm hex wrench to adjust the handles.AdjustmentHandle

Pg. 1Table of Contents Exploded Diagrams... 2 Tool List ...

15540 Woodinville-Redmond Road NESuite A100Woodinville, WA 98072 USAwww.LeMondtness.comTelephone (+1) 425.482.6773 x 107 or 109Fax: (+1) 425.482.672

Pg. 2 RevMaster Service Manual EXPLODED DIAGRAMSFigure 1.Seat Post AssemblyDipped HandlePost Handle LimiterPost Plunger FusePost Plunger, EDPost Plun

Pg. 3HB Post AssyPost Plug AssemblyPost Handle IndicatorPost Handle PinHB Post BearingSleeve RetainerScrew, Dome, M4 x 10 (x2)Handlebar Post WeldmentH

Pg. 4 RevMaster Service Manual Figure 3.Screw, Flat Head, M5 x 10Left X-CapX-Cap Gasket, #1X-Cap Gasket, #3X-Cap Gasket, #2Screw, Dome, M8 x 15 (x6)

Pg. 5Figure 4.Socket Head Screw, M6 x 15 (x4)Front Stabilizer/Belt Cover Exploded ViewSocket Head Screw, M6 x 13 (x2)Right X-Cover Pad, PrintedOutside

Pg. 6 RevMaster Service Manual Figure 5.Pillowblock Nut(NO FLANGE)Pillowblock Nut(WITH FLANGE)Pillowblock Nut, No Flange (x2)Pillowblock Nut, Flange

Pg. 7 Figure 6.Brake AssemblyFender AssemblyMale Shoulder BoltFemale Shoulder BoltFender CoverFender WeldmentBrake Pad AdhesiveScrew, Dome, M5 x 10 (x