Indoor Cycle Assembly Service Manual
Comp 200E and Club Pro 300PT
CHAPTERS:
1. UNPACKING THE CYCLEOPS INDOOR CYCLE.......1
2. BIKE ASSEMBLY.............................................................1
Attach Stabilizer Feet
Attach Handlebars
Seat Assembly
Attach Pedals
Attach Console Bracket and Console
Leveling the Bike
3. COMMON ADJUSTMENTS........................................5
Flywheel Adjustment
Replacing Hub Batteries
Brake Adjustment
Replacing Brake Pads
Replacing Resistance Knob
4. LUBRICATION................................................................9
5. RF INTERFERENCE......................................................11
6.WARRANTY..................................................................11
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Step 2: Attach Handlebars
A. Insert the handlebar post into the head tube and
tighten the 6mm pinch bolt or L-Handle.
B
B. Carefully slide the handlebar onto the handlebar
post, ensuring that the cables are not twisted. Once
the handlebar is in place, secure it with the quick-re-
lease lever. The lever must be in the“Closed”position
in order to safely use the IC.
C
C. Once the handlebar is properly installed, attach the
plastic end cap with two of the included Phillips-head
screws.
A
Step 3: Seat Assembly
A. Open the quick-release lever and slide the seat clamp assembly
onto the seat tube. The clamp should be pointing towards the
front of the CycleOps IC. Slide the clamp assembly all the way
forward to allow access to the clamp. The seat clamp assembly is
secured to the seat post tube via a quick-release lever. Secure the
mechanism by rotating the lever into the“Closed”position prior to
using the IC.
C
B
A
B.To attach the saddle to the seat post clamp, use a 6mm Allen
wrench. Make sure both rails of the saddle are properly seated in
the clamp and tighten the 6mm Allen bolt. If desired, you can at-
tach any standard bicycle saddle to the CycleOps Indoor Cycle. Be
sure to tighten the saddle so that it is level and parallel to the floor
for optimum comfort. Note: Seat may need to be retightened after
first few uses. Retighten screw for the seat assembly as well as for
the angle of the seat.
C. Once the Saddle is level and properly tightened in the clamp,
attach the plastic end cap with two of the included screws.
D. In some instances, a shorter seat post is required for individu-
als under five feet tall. You can replace the standard seat clamp
mechanism with part # 16616. Contact Saris Cycling Group to
order this part. Follow the instructions provided with that part for
installation.
B
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Step 4: Attach Pedals
In order to mimic the fit and feel of your own bike, CycleOps IC do not
come with pedals. Attach your own pedals per the manufacturers’specifications.
Note that pedals are designed to be installed specifically on the right or left-hand
side of the IC. Improper installation can result in damage to the crank. Damage
caused by improper crank installation is not covered under warranty.
Attach your pedals onto the bike with a pedal wrench. Typically, each
pedal is marked with an“R”or an“L”on the very end of the spindle past the threads.
This mark indicates which side of the bike the pedal is intended to mount on.
This is important since the thread directions are different for each pedal.
A
B
A. Locate the pedal that has the“R”on the spindle. This pedal is for the right side crank
arm of the bike (chain guard side) and is right hand threaded
(turn clockwise to tighten).
B. Locate the pedal that has the“L”on the spindle.Turn the spindle left (counter-clock-
wise) to tighten as the“L”spindle is reverse threaded.
Step 5: Attach Console Bracket and Console
Bracket
When first setting up the CycleOps IC you must attach the console bracket to the bike.To
do this, follow the instructions below:
Place bracket onto the handlebars as
shown.
Insert screws through console bracket,
handlebar bracket, and tighten together. onto the bracket.To ensure a solid con-
nection between the console and the
Slide the console down completely down
bracket make sure the contact points
between the console and bracket remain
clean and free from moisture or debris.
Batteries: The console ships with batteries. In the event the batteries need to be replaced over time, follow these simple steps:
Remove the back cover with a small Phillips-head screwdriver.
Remove batteries.
Replace with fresh AAA batteries, paying attention to properly line up the +/- poles.
Replace battery door and secure with small Phillips-head screwdriver.
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Leveling the bike
Once the above assembly instructions have been followed, move the bike to where it will be used and level it properly.To level the
bike, adjust the leveling feet underneath the stabilizers until there is no rocking or movement of the bike.
Leveler Lock
You can secure the feet by tightening the
leveler locks.
IMPORTANT! How To Zero Torque
The torque must be zeroed to ensure that the console displays the most accurate power information. If the
instantaneous power is positive or negative, the torque needs to be zeroed.These operations must be done
with NO tension on the chain or with NO force being placed on the pedals. Also, the transmission icon must
be illuminated.
To zero torque, first ensure the transmission icon is showing.Then press [DOWN ARROW] to move the cursor
to [WATTS]. Press [SELECT] to change to [INCH-LBS].Then hold down [SELECT] again until“0”is shown (about
10 seconds). Press [SELECT] to return to [WATTS].The torque value will now read zero.
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CHAPTER 3: COMMON ADJUSTMENTS
Flywheel Adjustment
Chain tension/Flywheel Alignment
Over time, the chain on your CycleOps IC will stretch due to the load applied to it. The following instructions will aid you in prop-
erly tensioning the chain and aligning the flywheel in the frame of the CycleOps IC. CAUTION: Improper chain adjustment will
cause premature wear and may void the warranty. ** CAUTION: NEVER put hands into or near the drive train while it is motion! **
1/2”
Acorn
Nut
Axle Lock
Nut
1/2”
Using a 3mm Allen wrench, remove the
chain guard bolts (3).
Move the crank arms back and forth. If
there is more than 1/2”movement in the
chain before the flywheel rotates, the
chain needs to be re-adjusted.
Use a 17mm cone wrench to hold the
axle locking nuts into place. Do not turn
the wrench, it is only to be used as a sta-
bilizer.With your other hand, use a 15mm
box wrench to loosen the acorn nuts on
the axle. Repeat this process on each side
of the flywheel.
10 mm chain
tension
Once the acorn nuts are loose, you can ad-
just the alignment of the flywheel as well
as the chain tension. Using a 10 mm box
wrench, adjust the tensioning hardware
until the desired chain tension is achieved
evenly on both sides.
Check the alignment of the flywheel
against the seat post of the CycleOps
IC. Once the proper tension had been
achieved and the flywheel is properly
aligned, tighten the Acorn nuts to 75
in-lbs.
NOTES:
Be sure to make small adjustments to the drive train. Adjust both sides of the tensioning hardware. Only adjusting one side will
lead to improper flywheel alignment and unwanted drive train wear and/or noise. Adjusting the tension/alignment is a difficult
task and improper adjustment can lead to premature chain/cog wear.This is not covered under warranty.The chain tension has
been adjusted properly when there is little or no play felt when the pedals are rocked back and forth.
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Replacing Hub Batteries Pro 300PT (AA type)
Over time, the batteries that power the electronics in the hub will need to be changed. The split battery cap on the Club Pro 300PT
flywheel was designed to make this task as easy as possible. When it is necessary to change the hub batteries, follow these steps:
Rotate the flywheel to a position where you can access the Allen bolt on the handle
side of the battery cap.
Using a 2.5 mm Allen wrench, remove the screw on the battery cap.
Pull the plastic battery cap out via the molded handle.
Replace the batteries, paying close attention to properly line up the +/- poles.
Replace the battery cap and tighten the set screw.
NOTE: If you have a wired console, the hub requires 2 E90 batteries. Using a 2.5 mm
Allen wrench, remove the side of the plastic battery cap with the“teeth.”Replace the
batteries, paying close attention to properly line up the +/- poles. Replace the battery
cap and tighten the set screw.
Replacing Sensor Batteries Comp 200E
Over time, the 3 volt lithium battery in the speed/cadence sensor in the COMP 200E indoor cycle will need to be changed.
Follow these steps to change speed/cadence sensor battery:
1. Using a 3mm Allen wrench, remove
the three chain guard bolts.
3. Using a 5 mm Allen wrench, remove the bolt for the
bracket arm that holds the speed/cadence sensor.
2. Remove the chain guard.
Fig. 2 – Remove Bolt
Fig. 3 – Slide Sensor Out of Frame
Fig. 1 – Remove chain guard
4. Using a quarter, remove the battery cover on the back of the sensor by turning counterclockwise approximately one half turn.
5. Replace the battery.
Fig. 4 – Remove Battery Cover
Fig. 5 – Battery
6. Reattach the bracket arm and the speed/cadence sensor inside indoor cycle frame.
NOTE: After replacing the battery, the indoor cycle console must relearn the coded ID for the speed/cadence sensor.
Refer to the Indoor Cycle Console Manual for instructions (available at www.cycleops.com).
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Brake Adjustment
Aligning Brake Pads
When aligning the brake pads after replacement or after adjusting the flywheel, use the following guidelines for accurate
alignment:
Ensure the pads sit parallel to the smooth
part of the flywheel.
Ensure the top of the pad does not
contact the flywheel above the
smooth part of the flywheel.
Ensure the pad mimics the curvature of
the flywheel. NOTE: Brake pads should
always be touching the flywheel.
Cable adjustment (under bottle cage)
Proper adjustment of the cables on the sliding splitter should look like this (Fig 1) In the event you need to adjust the cables, use
the following steps:
Fig 1
Release all cable tension in the handlebar
resistance knob.
Using a vice-grips or other clamping
mechanism, secure the bottom lip of
the cable carrier to the bottom of the
carrier assembly.
Using a set of pliers, grasp the end of the
cable that needs adjustment. Loosen the
brass set screw and slide it towards the
top of the cable carrier.
Once the brass set screw is touching the
top of the cable carrier, tighten it securely
onto the cable.
Repeat on other side if necessary.
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Replacing Brake Pads
The brake pads on the IC are made of a consumable felt material. Over time, the pads will wear out and need to be replaced.
Follow these steps to replace your brake pads:
With a 5mm Allen wrench, loosen the
cable holding wire on the right hand side
brake arm.
Loosen the pinch bolt that holds the
washers onto the post of the brake
pad.
Remove old pads and hardware from the
brake arms. Pay attention to the orienta-
tion of the washers and spacers as you
remove them.
Insert new brake pads and hardware
exactly as they were positioned prior to
removal.
Align brake pads (see page 7)and
tighten pinch bolts.
Replacing Resistance Knob
Using a Phillips-head screwdriver, loosen
the setscrew on the underside of the
handlebar near the resistance knob. Note:
ICs shipped prior to 2007 use an Allen
bolt for the set screw.
Remove water bottle holder by removing
the four screws that hold it on.
Loosen the right hand brass cable stop
until you can remove the cable from
the stop.
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Pull the old resistance knob out of the
handlebar.
Insert new resistance knob, paying
attention to fishing the cable and
housing through the handlebar.
Tighten the setscrew underneath to
secure the knob in the handlebar.
Insert cable through the hole in the slider
and through brass cable stop.
See CABLE ADJUSTMENT for instructions
on properly adjusting the resistance cable.
CHAPTER 4: LUBRICATION
Chain
Over time, the chain on your indoor cycle will require additional lubrication. It is
recommended that you lube the chain every six months to maximize chain life.
To lubricate the chain on your indoor cycle, use the lubrication port that is at the
back of the chain guard Liberally spray a Teflon-based lubricant onto the chain.
Be sure each link gets lube. Be careful not to over-lubricate the chain as excess lube
will drip out of the chain guard and can stain floors/carpet.
Nuts & Bolts
It is recommended that you put a light coating of lithium grease on the threads of the
following hardware to ensure proper tightening and to prevent the parts from seizing
over time:
•Stabilizer bolt threads
•Rubber feet threads
•Pull-pin threads
Lube Port
•Pedal spindle threads
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Preventative Maintenance
Performing necessary preventative maintenance is key to keeping your CycleOps IC in proper working condition.
Following these recommended maintenance procedures will help extend the life of your CycleOps IC.
DAILY
Wipe Down/Cleaning:
After your ride, be sure to release all tension from the resistance mechanism.Wipe down the entire unit using an absorbent cloth.
A standard bicycle polish can be used on the painted parts of the IC. Focus on areas where sweat can settle. Give particular atten-
tion to the following:
• Handlebar
• Seat/Seat tube
• Flywheel
• Frame
• Chain Guard
• Resistance Knob
• Handlebar Tube
• Stabilizers
**Never use abrasive cleaning liquids or petroleum-based solvents when wiping down the bicycle.
Inspection/Adjustment:
Inspect the CycleOps IC for any loose parts, nuts, bolts, etc. Pay special attention to the
following:
• Pedals
• Seat Assembly bracket
• Handlebar assembly bracket
• Crank arms – tighten to 75 in-lbs.
WEEKLY
Perform all daily maintenance recommendations. In addition:
• Inspect screws on console bracket.Tighten if necessary.
• Inspect and properly tighten brake pads.
• Properly tighten pedals and all hardware attaching toe clips/straps (if applicable)
• Inspect handlebar clamp assembly.
• Inspect seat clamp assembly.Tighten clamp bolt if necessary
• Inspect stabilizer feet.Tighten if necessary.
• Inspect flywheel. Check for proper alignment.Tighten acorn locking nuts to 75 in-lbs.
• Inspect crank/bottom bracket interface.Tighten to 75 in-lbs
MONTHLY
• Perform all Daily and Weekly maintenance recommendations. In addition:
• Perform thorough cleaning of the CycleOps IC. This includes:
• Remove handlebar tube and seat tube and clean both the stainless steel tube as well as inside the plastic sleeve. Inspect sleeves
for scoring. Replace if no longer properly securing vertical adjustment.
• Clean the underside of the stabilizer feet.
• Remove console bracket and clean the handlebar assembly
• Clean the flywheel with mild detergent or a damp cloth
• Check the chain tension to ensure that the chain is properly adjusted. See“Adjusting the Chain Tension”for instructions
• Inspect plastic sleeves for damage. Replace if necessary.
• Inspect brake pads for wear. Replace pads if there is less than 2mm of felt pad exposed.
• Lube the drive train. See“Lubrication”for instructions.
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CHAPTER 5: RF INTERFERENCE:
If during use you are experiencing wireless drop out this is due to frequency interference. Wireless Internet access points,
microwaves, cordless phones, or other wireless devices may cause frequency interference. To mitigate the chance of
interference set wireless access points to the lowest channel possible, and keep bikes away for interfering devices. To
change the channel on your access point, please consult your manufacturers documentation or your technology staff.
CHAPTER 6:WARRANTY
Frame - Lifetime
Parts - 3 years (excludes wear items)
Electronics - 1 year
NOT FOR COMMERCIAL USE - NO COMMERCIAL WARRANTY
Saris Cycling Group, Inc. warrants its PowerTap products against defects in manufacturing and workmanship for a period of one year, beginning at the date of purchase, or from the date
of manufacture in the absence of a proof of purchase. In the event of a warranty issue, Saris Cycling Group, Inc. will repair or replace the item at its discretion. Saris Cycling Group, Inc. is
not responsible for any indirect or consequential costs or damages associated with the warranty of the product. Our products are not covered under warranty in cases exhibiting signs of
abuse, improper maintenance or installation, crash, using the product with non-compatible components, or using the product for purposes for which it was not designed.This warranty is
also void if the product has been modified from its original form, including changes in aesthetics, serial numbers or logos. Saris Cycling Group Inc., is not responsible for basic hub main-
tenance, such as re-packing bearings and bearing adjustments.Warranty Procedures If it appears that a PowerTap component is not working properly, please take the time to inspect and
troubleshoot the system as best as possible. In many instances, solutions may be as simple as replacing a bearing or adjusting a sensor. Often small parts can repaired at the shop, instead
of the longer and more expensive option of sending the unit back for repair. If you feel the need to warranty your PowerTap, please return your product through the channel that you
purchased it from or contact Saris Cycling Group, Inc. at 1-800-783-7257.
Copyright
Copyright 2007. All rights reserved. No part of this publication may be copied, photographed, reproduced, translated, transmitted electronically or placed on digital media without the prior written consent of Saris
Cycling Group, Inc.
Trademarks
Saris Cycling Group, Inc , PowerTap and the PowerTap logo, are all registered trademarks of Saris Cycling Group, Inc. All other product, brand, or trade names used in this manual may be trademarks or registered trade-
marks of their respective owners.
Modifications
Saris Cycling Group, Inc reserves the right to make improvements and/or updates to the products described herein at any time without notice.
FCC Statement of Compliance:
Statement of Compliance for FCC and Industry Canada:
“This device complies with Industry Canada and Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any
interference received, including interference that may cause undesired operation.”
The term“IC:”before the radio certification number only signifies that Industry Canada technical specifications were met.
Changes or modifications to this device not expressly approved by the party responsible for compliance with FCC regulations (the manufacturer) could void the user’s authority to operate the equipment.
This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules.These limits are designed to provide reasonable protection against harmful
interference in a normal installation.This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio
communications. However, there is no guarantee that interference will not occur in a particular installation
16417G 0907
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