CS800 (800640) Assembly

Pre-Assembly

Unpacking

1. Cut the straps, then lift the box over the unit and unpack.

2. Carefully remove all parts from the carton and inspect for any damage or missing parts. If parts are damaged or missing, contact your dealer immediately.

3. Locate the hardware package. 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

CS800 Step-by-Step Assembly

Before beginning assembly, use the M8 L-Allen wrench (119) to remove two 3/8” x 3/4” socket head cap bolts that hold the protective side back (17) onto the mounting plate on the main frame. Discard the bolts and set the side back (17) aside.

1. Rear Stabilizer and Console Mast

a. Attach the rear stabilizer with handle (11) to mounting plate on the main frame and secure with two hex head bolts (#78), two spring washers (#108) and curved washers (#106) by using the wrench (116).
b. Pull the tie on the console mast (2) to have computer cable (31) and handpulse cables (35) go through the mast from bottom and out of the mast on top. Secure the console mast (2) on the mounting plate on the main frame with four socket head cap bolts (#81), four spring washers (#108) and four flat washers (#100) by using the L-Allen wrench (119). 

2. Handlebars

a. Place the upper left handlebar (15) (with orientation of 90-degree bend at front) onto the connecting plate welded to the console mast (2) and secure it with a hex head bolt (#75) and a curved washer (#106) to the connecting plate (do not tighten completely). Then, insert one of handlebar connecting tube (10) to connect with the upper left handlebar (15) at the 107 degree-bending end and temporarily with two button head socket bolts (#75) with the M6 L-Allen wrench (120). Then, attach the bottom end of handlebar connecting tube (10) to the U-shape mounting at left side of rear stabilizer with the handle (11). Use two hex head bolts (#77) together with two flat washers (#100), two curved washers (#106) and two Nyloc nuts (#93). Tighten by using the wrench (116) and wrench (117). Tighten and secure all other bolts.
b. Repeat this process for the upper right handlebar (16) and the other handlebar connecting tube (10).
c. Attach the handlebar connecting plate (13) to the upper handlebars (15, 16). Secure with two button head socket bolts (#76) and two curved washers (#106) by using the wrench (#116). Tighten all hardware listed in this step.

3. Handgrip Stabilizers

a. Match the left console mast cover (57) with the right console mast cover (58) on top of the left and right chain covers and around the console mast (2) and secure with three sheet metal screws (#85) by using the Phillips head screwdriver (118).
b. Match the left and right handlebar caps (68, 69) together on the U-shape mounting at the left side of the rear stabilizer with the handle (11) and use the Phillips head screwdriver (118) to tighten two Phillips head screws (#83) and secure. Match the left and right handlebar caps (68, 69) together on U-shape mounting at the right side of the rear stabilizer with the handle (11) and repeat the process above.
c. Take off the tie from the computer cable (31) and plug it into the console assembly (30) together with the two handpulse assembly cables (35). Place the console (30) on the mounting plat of the console mast (2). Secure with four Phillips head screws (#83) by using the Phillips head screwdriver (118).
d. Secure the water bottle holder (113) on the console mast (2) with two Phillips head screws (#83) by using the Phillips head screwdriver (#118).