5.2 HYBRID
OWNER’S MANUAL
QUESTIONS?
Call Our Toll Free
Keys Fitness Helpline
1-888-340-0482
315-00028
06/05 Rev B
CAUTION!
Please read the precautions and instructions in this manual before
using this equipment. Please save this manual for future reference.
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Before You Start
Thank you for purchasing a DISCOVERY exercise unit! This quality product you have chosen was
designed to meet your needs for cardiovascular exercise. Prior to assembly, remove components
from the box and verify that all the listed parts were supplied. Assembly instructions are described
in the following steps and illustrations.
Important Safety Information
WARNING!
1) Before using this exercise bicycle or starting any exercise program, consult your physician. This
is especially important for persons over the age of 35 and/or persons with pre-existing health
problems. Keys Fitness Products LP assumes no responsibility for personal injury or property
damage sustained by or through the use of this product.
2) To reduce the risk of electrical shock, burns, fire or other possible injuries to the user, it is impor-
tant to review this manual and the following precautions before operation.
It is the owner's responsibility to ensure that all users of this exercise bike have read the Owner's
Manual and are familiar with warnings and safety precautions.
• This exercise bike has a maximum user capacity of 250 pounds.
• The Discovery exercise unit should only be used on a level surface and is intended for indoor use
only. It should not be placed in a garage, patio or near water. Keys recommends an equipment
mat be placed under the unit to the protect the floor or carpet and for easier cleaning.
• Wear comfortable, good-quality walking or running shoes and appropriate clothing. Do not use this
exercise bike with bare feet, sandals, socks or stockings!
• Always examine your exercise bike before using to ensure all parts are in working order.
• Do not leave children unsupervised near or on the exercise unit.
• Never operate the exercise bicycle where oxygen is being administered or where aerosol products
are being used.
• Never insert any object or body parts into any opening.
• Service to your Discovery unit should only be performed by an authorized service representative,
unless authorized and/or instructed by a Keys technician. Failure to follow these instructions will
void the warranty.
2
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Assembly of DISCOVERY
5.2 Hybrid
REMOVE ALL SECURITY TAPE AND WRAPPING BEFORE BEGINNING.
Handlebar
Handlebar
Computer
Resistance Knob
Handlebar Post
Seat
Seat Post
Front Stabilizer
Mainframe
Pedal
Rear Stabilizer
3
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M8X70mm Carriage Bolt(12)-4
M8 Cap nut(14)-4
8X19 Arc Washer(15)-12
3/8" Nylock nut(39)-4
10X26 Washer(37)-4
3/8"x45 Hex Head Screw(53)-4
M6 Cap nut (65)-4
M6X40mm Carriage Bolt(63)-4
6X13 Washer(64)-4
M8x15mm Screw (11)-8
M5 Allen Wrench
10X13X14 Screw Driver
17X13X14 Screw Driver
4
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1
1. Attach the front stabilizer (3) to the main
frame (1) with carriage bolt, washers and
cap nuts (12,15,14).
12
3
14
15
Attach the rear stabilizer (4) to the main
frame (1) with carriage bolt, washers and
cap nuts (12,15,14)
1
15
14
14
15
4
15
14
12
2
2
2. Connect sensor cable (50) to the exten-
sion wire (62).
62
11
59B
15
Secure the handlebar post (2) with screws
and washers (11,15).
11
15
50
11
2-1
59A
60
2
A
B
2-1. Guide the cable from the resistance
knob (59A) through the eyelet (see picture
A). Then pull the resistance knob (59A)
over the gap of the resistance cable (59B)
(see picture B).
59B
59B
59A
59A
5
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3
3. Attach the sleeve (6L, 6R) to the
handlebar post (2) with washers, nylon
lock nut and platic cap (44, 22L, 68).
68
22L
44
Attach the pedal tube arm (7) to the
crank with nylon lock nut (22L, 22R).
6R
2
44
22L
68
7
68
22R
6L
1
68
7
22L
53
4
4. Connect the pedals (8L,8R) onto
the pedal tube (7) with the nylon lock
nut (39), washers (37) and screws
(53).
8R
Each pedal is marked “L” for left and
“R” for right.
37
39
53
8L
37
39
6
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5
5. Assemble the seat (55) to the seat post
tube (54) and fasten the nylon lock nuts
and attachment bar (78,58).
55
78
79
79
54
78
Release the seat knob (51) and then insert
the seat post (70) into the mainframe.
Secure the desired height by tightening the
knob.
79
58
70
51
6
6. Attach the small handlebars (56) to the
handlebar post (2) with screws and washers
(11,15).
11
15
2
7
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7
61
7. Connect the extension wire (62) that
protrudes from the upright tube into the jack
of the computer (61).
62
57
Attach the computer to the upright tube with
nuts (49).
49
Connect pulse wires (57) to computer (61).
61
57
62
8
8. Attach two handlebars (5) onto the
axles of the handlebar post (2) with the
carriage bolts (63), washers (64) and cap
nuts (65).
66
5
5
64
65
64
63
2
8
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DCV 5.2H PARTS LIST
DCV5.2H Parts List Rev C
REF #
ITEM
DESCRIPTION
QTY REF #
ITEM
DESCRIPTION
QTY
1
1
1
4
1
1
1
2
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
4
4
4
2
2
4
2
1
4
5
1
1
1
2
2
3
4
2
2
1
1
1
2
3
4
5
323-00217 MAIN FRAME # 1
1
1
1
1
2
1
1
2
1
1
2
2
8
4
3
4
12
1
1
1
1
1
1
1
3
3
2
6
1
1
1
3
1
1
1
1
1
1
2
1
6
1
1
1
41 319-00092 IDLER WHEEL #41
42 319-00093 NYLOCK NUT M10 #42
43 302-00637 IDLER WHEEL SPRING#43
44 302-00638 WASHER#44
323-00127 CONSOLE TUBE DCV5.2H/EL
323-00218 FRONT STABILIZER # 3
323-00219 REAR STABILIZER # 4
323-00308 FRAME, REVISED FOR NEW TRANS WHEEL
45 302-00639 SCREW 4X8#45
6L 323-00310 SLEEVE DCV5.2H
46 319-00094 ARC MAGNET PLATE R110X2.0 # 46
47 302-00640 ARC MAGNETIC SPRING #47
48 302-00641 HEX HEAD SCREW M8X60 #48
49 302-00642 NYLOCK NUT M8 #49
50 313-00133 REED SWITCH TRI-6.0R
51 302-00643 SPRING KNOB#51
6R 323-00220 SLEEVE (RIGHT) # 6R
7
323-00309 DCV5.2H/EL #7
8L 306-00434 PEDAL L, DCV5.2H
8R 306-00435 PEDAL R, DCV5.2H
9
306-00430 FRONT WHEEL CAP #9, DCV5.2H
10 306-00432 END CAP, TRI-5.3E, 8.3E
11 302-00620 SCREW M8X15 # 11
12 302-00621 CARRIAGE SCREW M8X70 # 12
13 302-00622 WASHER # 13
52 302-00644 BUSHING#52
53 302-00645 HEX HEAD SCREW 3/8"X45#53
54 319-00095 SEAT POST #54
55 306-00436 SEAT, DCV5.2H
14 302-00623 NYLOCK NUT M8 # 14
15 302-00624 ARC WASHER # 15
16 331-00069 BALLBEARING (L) #16
17 331-00025 BEARING RIGHT
56 319-00096 HANDLEBAR TUBE #56
57 313-00134 HAND PULSE TRI-6.0R
58 302-00646 NUT COVER M8#58
59A 310-00169 UPPER TENSION KNOB WIRE, DCV5.2H
59B 313-00136 SENSOR DCV6.0R
60 302-00647 TENSION KNOB #60
61 307-00004 COMPUTER U/R/H/EL DCV5.2
62 313-00137 EXTENSION WIRE DCV6.0R
63 302-00648 CARRIAGE SCREW M6X350#63
64 302-00649 WASHER#64
18 319-00088 MAGNET #18
19 319-00089 PULLEY #19
20 304-00022 BELT, POLY V BELT DCV5.2H
21L 330-00028 LEFT CRANK DCV5.2H
21R 330-00029 RIGHT CRANK DCV5.2H
22L 302-00625 NYLOCK NUT 1/2"X20T #22L
22R 302-00626 NYLOCK NUT 1/2"X21T#22R
23 306-00433 PLASTIC SPACER, DCV5.2H
24 306-00567 ROLL DCV5.2H #24
25 330-00026 RIGHT AXLE DCV5.2H
26 330-00027 LEFT AXLE DCV5.2H
27 311-00054 FLYWHEEL #27
65 302-00650 NYLOCK NUT M6#65
66 328-00035 FOAM GRIP # 66
67 306-00437 TUBE CAP, DCV5.2H
68 306-00438 CAP COVER, DCV5.2H
69 306-00568 ROLL DCV5.2H #69
70 319-00097 UPPER SEAT TUBE M8 # 70
71 302-00651 SCREW 4X15#71
28 331-00024 BEARING, DCV5.2H
29 302-00627 ARC WASHER # 19
30 302-00628 BC NUT #6
72 302-00652 SCREW 3/16"X2"#72
73 305-00025 LEFT HOUSING DCV5.2H
74 305-00026 RIGHT HOUSING DCV5.2H
75 306-00441 OVALCOVER, DCV5.2H
76 319-00098 PULSE PLATE # 76
77 302-00653 SCREW M6X10#77
78 302-00654 NYLOCK NUT M8#78
79 302-00655 SPRING WASHER#79
80 302-00656 BOLT#80
31 302-00629 BC NUT 3/8" #24
32 302-00630 SCREW 3/8"#32
33 302-00631 GREASED WHEEL#33
34 319-00090 AXLE OF FLY WHEEL #34
35 302-00632 NYLOCK NUT M8 #35
36 302-00633 HEX HEAD SCREW 3/8"X26 #36
37 302-00634 WASHER #37
38 319-00091 IDLER WHEEL PLATE #38
39 302-00635 NYLOCK NUT 3/8" #39
40 302-00636 SPACER OF IDLER WHEEL #40
81 306-00442 CAP, DCV5.2H
#
#
315-00028 OWNER'S MANUAL DCV5.2H
302-01150 BOLT PACK DCV5.3H
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DCV 5.2H EXPLODED VIEW
71
67
74
73
72
71
72
75
71
72
11
75
15
5
67
61
42
28
41
40
38
65
64
69
62
68
66
22L
1
44
24
39
37
49
59A
63
60
43
5
37
55
78
36
68
22L
53
44
79
79
54
6R
24
65
24
78
64
2
77
24
7
8R
69
37
39
22L
79
58
63
25
77
60
11
15
44
24
59B
70
52
9
24
23
68
12
15
11
45
6L
81
80
9
50
11
14
15
3
21
17
19
51
22R
60
53
24
15 1
18
14
20
13
49
48
24
14
15
44
22L
8L
24
22L
68
10
23
7
16
4
35
37
39
15
14
10
12
21
34
33
24
80
28
26
35
81
48
27
28
47
29
46
30
31
32
10
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Monitoring Your Heart Rate
To obtain the greatest cardiovascular benefits from your exercise workout, it is important to
work within your target heart rate zone. The American Heart Association (AHA) defines this
target as 60%-75% percent of your maximum heart rate.
Your maximum heart rate may be roughly calculated by subtracting your age from 220. Your
maximum heart rate and aerobic capacity naturally decreases as you age. This may vary
from one person to another, but use this number to find your approximate effective target
zone. For example, the maximum heart rate for an average 40 year-old is 180 bpm. The tar-
get heart rate zone is 60%-75% of 180 or 108-135 bpm. See Fitness Safety below.
Before beginning your workout, check your normal resting heart rate. Place your fingers
lightly against your neck, or against your wrist over the main artery. After finding your pulse,
count the number of beats in 10 seconds. Multiply the number of beats by six to determine
your pulse rate per minute. We recommend taking your heart rate at these times; at rest,
after warming up, during your workout and two minutes into your cool down, to accurately
track your progress as it relates to better fitness.
During your first several months of exercising, the AHA recommends aiming for the lower
part of the target heart rate zone-60%, then gradually progressing up to 75%.
According to the AHA, exercising above 75% of your maximum heart rate may be too stren-
uous unless you are in top physical condition. Exercising below 60% of your maximum will
result in minimal cardiovascular conditioning.
Check your pulse recovery rate – If your pulse is over 100 bpm five minutes after you stop
exercising, or if it’s higher than normal the morning after exercising, your exertion may have
been too strenuous for your current fitness level. Rest and reduce the intensity next time.
Fitness Safety
The target heart rate chart indicates average rate zones for different ages. A variety of differ-
ent factors (including medication, emotional state, temperature and other conditions) can
affect the target heart rate zone that is best for you. Your physician or health care profes-
sional can help you determine the exercise intensity that is appropriate for your age and
condition.
11
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(MHR) = Maximum Heart Rate
(THR) = Target Heart Rate
220 - age = maximum heart rate (MHR).
MHR x .60 = 60% of your maximum heart rate.
MHR x .75 = 75% of your maximum heart rate.
For example, if you are 30 years old, your calculations will be as follows:
220 - 30 = 190
190 x .60 = 114 (low end or 60% of MHR)
190 x .75 = 142 (high end or 75% of MHR)
30 year-old (THR) Target Heart Rate would be 114-142.
See Table for additional calculations.
TARGET HEART RATE ZONE
200
195
100%
190
185
180
175
Serious
170
165
athletic
training range
160
155
85%
170
166
162
157
153
Cardiovascular
149
conditioning
range
145
140
136
132
150
75%
146
143
139
135
131
128
Fat burning
range
124
120
116
60%
120
117
114
111
108
105
102
99
96
93
20
25 30
35
40 45
50
55 60 65
AGE
12
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KEYS FITNESS PRODUCTS, LP -
LIMITED WARRANTY
PRODUCT:
DISCOVERY 5.2 HYBRID
HOME USE WARRANTY: 1 Year Parts
This Limited Warranty applies in the United States and Canada to products manufactured or distributed by Keys
Fitness Products, LP (“Keys”) under the KEYS brand name. The warranty period to the original purchaser is listed above
in the table.
Keys warrants that the Product you have purchased for use from Keys or from an authorized Keys reseller is free
from defects in materials or workmanship under normal use during the warranty period. Your sales receipt, showing the
date of purchase of the Product, is your proof of purchase. This warranty only extends to you, the original purchaser. It is
not transferable to anyone who subsequently purchases the Product from you. It excludes expendable parts (wear items).
Wear items pertain to components that might need to be replaced due to normal wear and tear. These items vary per
product but will include computer overlays, pedal straps, rope cords, seats, grips, chains, bottom bracket assemblies,
pads, upholstery, pulleys, bearings, etc. Please contact a Keys Fitness customer service representative for specifics on
wear items. This Limited Warranty becomes VALID ONLY if the product is purchased through a Keys Fitness authorized
dealer unless otherwise authorized by Keys Fitness in writing.
During the warranty period Keys will repair or replace (at Keys' option) the product if it becomes defective, malfunc-
tions, or otherwise fails to conform with this Limited Warranty under normal use. In repairing the Product, Keys may
replace defective parts, or at the option of Keys, serviceable used parts that are equivalent to new parts in performance.
All exchanged parts and Products replaced under this warranty will become the property of Keys. Keys reserves the
right to change manufacturers of any part to cover any existing warranty.
This warranty DOES NOT COVER shipping charges, export taxes, custom duties and taxes, or any other charges
associated with transportation of the parts or Product.
To obtain warranty service, you must contact a Keys authorized retailer, service technician or Keys Fitness at our
phone numbers located in this manual. Any parts determined to be defective must be returned to Keys to obtain warran-
ty service. You must prepay any shipping charges, export taxes, custom duties and taxes, or any other charges associat-
ed with transportation of the parts or Product. In addition, you are responsible for insuring any parts or Product shipped
or returned. You assume the risk of loss during shipment. You must present Keys with proof-of-purchase documents
(including the date of purchase). Any evidence of alteration, erasing or forgery of proof-of-purchase documents will be
cause to void this Limited Warranty.
This warranty does not extend to any product not purchased from Keys or from an authorized Keys reseller. This
Limited Warranty does not extend to any Product that has been damaged or rendered defective; (a) as a result of acci-
dent, misuse, or abuse; (b) by the use of parts not manufactured or sold by Keys; (c) by modification of the Product or
normal wear and tear; (d) operation on incorrect power supplies; or (e) as a result of service by anyone other than Keys,
or an authorized Keys warranty service provider. Product on which the serial number has been defaced or removed is
not eligible for warranty service. Should any Product submitted for warranty service be found ineligible, an estimate of
repair cost will be furnished and the repair will be made if requested by you upon Keys' receipt of payment or acceptable
arrangements for payment.
EXCEPT AS EXPRESSLY SET FORTH IN THIS WARRANTY, KEYS MAKES NO OTHER WARRANTIES, EXPRESSED
OR IMPLIED, INCLUDING ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE. KEYS EXPRESSLY DISCLAIMS ALL WARRANTIES NOT STATED IN THIS LIMITED WARRANTY. ANY
IMPLIED WARRANTIES THAT MAY BE IMPOSED BY LAW ARE LIMITED TO THE TERMS OF THIS LIMITED WAR-
RANTY. NEITHER KEYS NOR ANY OF ITS AFFILIATES SHALL BE RESPONSIBLE FOR INCIDENTAL OR CONSE-
QUENTIAL DAMAGES. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY
LASTS OR THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE
LIMITATIONS OR EXCLUSION MAY NOT APPLY TO YOU. This Limited Warranty gives you specific legal rights and
you may also have other rights that may vary from state to state. This is the only express warranty applicable to Keys-
branded products. Keys neither assumes nor authorizes anyone to assume for it any other express warranty.
PLEASE SEND IN THE ATTACHED WARRANTY CARD WITHIN TEN (10) DAYS OF PURCHASE TO REGISTER
YOUR UNIT WITH KEYS FITNESS PRODUCTS, LP.
MAIL WARRANTY CARD TO:
KEYS FITNESS PRODUCTS, PO BOX 551239, DALLAS, TX 75355
13
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Keys Fitness Products, L.P.
4009 Distribution Dr.
Suite 250
Garland, Texas 75041
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