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Replacing the Lower Wire – Frame Style A

Our products can vary in model style. While the model used in this video may not look exactly like you machine, the procedure demonstrated here is virtually identical. Do not be concerned if your elliptical’s console is different from the one in this video, but if the body style you see here is radically different, go back and select the video that more closely matches the body style of your elliptical

 

 

Introduction

Always unplug your machine from the outlet when working around moving or electrical components. If you need to use power while diagnosing an issue, please use caution. Do not use power tools during this procedure. Sure, they make the job move along more quickly, but they can just as quickly damage your treadmill’s components. If you have any questions while watching this video, see the replacement instructions that shipped with the incline sensor.

 

Removing the top shield cover.

Carefully remove the top shield cover.
It snaps off.
Separating the left and right-hand, upper body legs from the front of the left and right-hand pedal arm.
Using an Allen wrench, separate the right-hand, upper body leg from the front of the right-hand pedal arm.

Do the same to the left-hand, upper body leg and the left-hand pedal arm.
Make sure you put the loose pieces aside in a bowl so they don’t get lost.

 

Removing the rear right-hand pedal arm from the right-hand pedal disc.

Using the same Allen wrench, remove the rear right-hand pedal arm from the right-hand pedal disc.
Do the same to the left-hand pedal arm and the left-hand pedal disc.
Removing the right-hand disc cover Using a standard screw driver with a thin tip, remove the right-hand disc cover.
Do this gently.
It should just pop off.
Do the same to the left-hand disc cover.
Removing the right-hand pedal disc

Remove the screws from the both the left and right-hand pedal disc and pull off both.
Some of the screws can only be accessed from one side or the other.
Again, be sure to place these screws aside in a bowl.
Removing the left and right-hand rear shields

In order to remove the right and left-hand rear shields, you must remove several screws.
Removing the left and right-hand front shields.

Once you have the right and lefthand rear shields off, you must remove the right and left-hand front shields at the bottom of the machine’s upright.
Slide the front shield cover up the upright.
Now remove the screws holding the left and right-hand front shields to the upright and then remove both front shields.
This exposes the lower wire harness.
Freeing the lower wire

Clip off nay zip ties securing the wire harness to the upright.
Disconnecting the lower wire harness from the upper wire harness

Disconnect the lower wire harness from the upper wire harness.
Lift up on the small plastic catch, and they should pull easily apart.
Freeing the wires for the reed switch and the resistance motor to the frame.

Free up the wires to the resistance motor and the reed switch from the frame.
You do this by removing the screw that pins them to the frame as well as the ground screw that connects the ground wire to the frame.
Clip any zip ties that are holding the two connectors together.
Disconnecting the reed switch and the resistance motor from the lower wire harness

Disconnect the reed switch and the resistance motor from the lower wire harness.
You have four connectors here and two connections.
Each connection has a small plastic catch that when lifted allows the connectors to pull apart easily.
Tying off the new wire harness to the old.

The new wire harness must be pulled through the frame by tying it off on the end of the old wire harness.
You can clip off the connector on the old wire, wrap it around the new wire, and tape both securely together.
Then they are ready to be pulled through the frame, pulling the old wire out while pulling the new wire in.
Do not just pull the old wire out by itself.
You would find it very difficult to get the new wire through the frame on its own.
In this video we are using a wire tie to pull the old wire out and then using the wire tie we’ve pulled inside the frame to pull the new wire harness through the frame to the upright.
The process is essentially the same, but tying off with a wire tie takes two steps.
Tying off with the new wire, takes only one step.
Make sure you are pulling the front end of the wire harness through the frame to the upright.
The front end has only one connector on it.
The end with two connectors is the back end and should stick out the frame.
Gently pull the old wire through the frame and out the upright.
Do not pull so hard that the two wires get pulled apart.
Securing the new wire harness to the frame

Once the new wire harness is pulled through the frame, you can connect the back end of it to the reed switch and the resistance motor.
These connectors snap easily together.
If they don’t, you might have one of them up-side-down.
Flip one of them over and try again.
Bundle the connected wires together with a short wire tie and re-secure them to the frame.
Make sure you also reconnect the ground wire to the frame.
Connecting the front end of the lower wire harness to the upper wire harness.

Now connect the front end of the lower wire harness to the bottom end of the upper wire harness sticking out of the upright.
Zip tie the lower wire harness snugly to the upright and replace the left and right front shields to the upright.
Replacing the components over the flywheel assembly.

Now replace the components you removed back over the pulley assembly, but in reverse order:
The left and right-hand rear shields;
The left and right-hand pedal discs;
The left and right-hand disc covers;
The left and right hand peddle arms;
and, The top shield cover.
Reconnecting the peddle arms to the upper body legs

With that done, now you can reconnect the left and right-hand peddle arms to the left and righthand upper body legs, and the job is done.

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