XBR95 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

XBR25 Step-by-Step Assembly

1. Stabilizers and Seat Back

a. Gather all hardware needed for this step.
b. Attach the rear stabilizer (7) to the main frame (1) with the two bolts (#65) and two flat washers (#84) and two cap nuts (#191). Tighten completely with the wrench (112).
c. Attach the seat back (5) to the seat carriage (4) of the main frame. Slide one bolt (#67) through each side, then attach a Nyloc nut (#89) to each bolt. Tighten the bolts just enough so there is no side to side play, but freedom of movement front to back. Use the wrenches provided (112, 130). 
d. Insert an end cap (32) into each opening of the front stabilizer tube. You may need to tap them in with a rubber mallet if they are tight.

2. Computer Cables and Console Mast

a. Gather all hardware needed for this step.
b. Slide the computer cable (44), handlebar resistance control cable (148), and hand pulse cable (45) through the bottom of the console mast cover (31) and then the bottom of the console mast (2). Make sure the console mast cover is correctly oriented (see illustration).
c. Install the console mast (2) into the receiving tube [make sure not to pinch the cable (44); damage to the electronics could occur] of the main frame (1). Insert two bolts (#68) and two flat washers (#76) on each side. Insert two bolts (#68) and two curved washers (#83) on the front. Tighten all six bolts firmly with the wrench (112).
d. Remove the white Styrofoam pad (factory installed to prevent bolts from being accidentally dropped into the console mast tube).
e. Attach the handlebar (3) onto the console mast (2) bracket with the two bolts (#68), two split washers (#82), and two flat washers (#76). Completely tighten with the wrench (112). Insert the computer cable (44), handlebar resistance control cable (148), and hand pulse cable (45) into their respective connectors in the back of the console (19). Attach the console onto the mounting plate with four Phillips head screws (#99). Tighten with the Phillips head screwdriver (114).

3. Seat and Handlebars

a. Gather all hardware needed for this step.
b. Install the seat (61) on the seat carriage (4) with four Phillips head screws (#98). Tighten with the Phillips head screwdriver (114).
c. Attach the seat handlebar (6) to the seat carriage (4) with the four bolts (#71), four flat washers (#77), and four Nyloc nuts (#89). Tighten with the wrenches provided (112, 132).
d. Plug the hand pulse sensor cables (27) into the rear two holes on the left side of the rear plastic cover. Plug the handlebar resistance cables (150) into the remaining front hole.

4. Pedals

a. Gather all hardware needed for this step.
b. Install the gas cylinder (57) on the seat back frame (5) with one bolt (#70), one flat washer (#76) and one Nyloc nut (#91) by using the wrenches provided (112, 113). 
c. Attach the pedals (L-116, R-117) to the crank arms (L-51, R-51). Tighten with the wrench (113). Remember that the left pedal has a reverse thread and will be threaded onto the crank arm in a counterclockwise motion. There is an “L” stamped in the end of the threaded post of the left pedal and an “R” in the right. Make sure to tighten the pedals as firmly as you can. It may be necessary to re-tighten the pedals if you feel a thumping while pedaling the bike. A thumping or clicking noise is usually caused by loose pedals.
d. Attach the cup holders (39-L, 38-R) to the sides of the seat handlebar (6) with four sheet metal screws (#105). Tighten with the Phillips head screwdriver (114).