XBU55 Assembly

Pre-Assembly

Unpacking

1. To remove the bike safely from its packaging, cut the straps along the dotted line on the bottom of the box, then lift the box over the unit and unpack.

2. Locate the hardware package. The hardware is separated into four steps. Remove the tools first. Remove the hardware for each step as needed to avoid confusion. The numbers in the instructions that are in parenthesis (#) are the item number from the assembly drawing for reference. 

Tools and Parts Included

Assembly

XBU55 Step-by-Step Assembly Instructions

1. Stabilizers

a. Gather all hardware needed for this step.
b. Install the rear stabilizer (5) onto the main frame (1) with the two bolts (#50) and two flat washers (#71) and two nuts (#135). Tighten using the wrench (100).
c. Insert an end cap (41) into each opening of the front stabilizer tube. Note: You may need to tap them in with a rubber mallet if they are tight.

2. Console Mast

a. Gather all hardware needed for this step.
b. Unravel the computer cable (29) and snake it through the console mast cover (38) and the console mast (2) until the cable connector comes out the top opening of the console mast. BE SURE NOT TO PINCH THE CABLE OR DAMAGE TO THE ELECTRONICS MAY OCCUR. Slide the plastic cover (38) onto the console mast, ensuring the correct orientation of the cover.
c. Install the console mast (2) onto the main frame (1) with seven bolts (#51), six flat washers (#72) on the side bolts and one curved washer (#99) on the front bolt. Tighten using the wrench (100).

3. Handlebars

a. Gather all hardware needed for this step.
b. Run the two hand pulse wires (26) into the hole in the handle bar mounting plate and out through the hole in the console plate. Remove the black plastic cover from the handlebars by cutting the plastic tie.
c. Install the handlebar (3) onto the console mast (2) with two bolts (#51), two flat washers (#72), and two split washers (#103), being careful not to pinch the hand pulse wires. Tighten using the wrench (100). Snap the black plastic handlebar cover over the joint.

4. Console, Pedals, Seat

a. Gather all hardware needed for this step.
b. Insert the computer cable (29) and two hand pulse cables (26, 28) into the connectors in the back of the console (34). Install the console (34) onto the console mast (2). Install the four Phillips head screws (#58) with the Phillips head screwdriver (93).
c. Install the pedals (45L, 46R) onto the cranks arms (16L, 16R). Remember that the left pedal has a reverse thread and will be screwed into the crank in the opposite rotation from normal threads. There is an “L” stamped into the end of the threaded post of the left pedal and an “R” in the right. Make sure to tighten the pedals as much as you possibly can. It may be necessary to re-tighten the pedals if you feel a thumping while pedaling the bike. A noise or feeling such as a thumping or clicking is usually caused by the pedals being too loose. Tighten using the wrench (92).
d. Install the seat mount slide (7, top post) onto the track on top of the seat bracket (6) by sliding a flat washer (#71) onto the seat adjustment knob (86), then slide it through the slots of each and attach a flange nut (#8) to the end. Install the seat (19) onto the seat post by securely tightening the nut on each the side, below the seat.
e. Install the bottle holder (116) onto the console mast (2) with two Phillips head screws (#58). Tighten using the Phillips head screwdriver (93).