Part Replacement

STAR TRAC FITNESS 1 of 13 637-1498 Rev: A

Generator Flywheel

Spinner® Blade ION

Parts Required:

• Spinner® Blade ION Generator Flywheel Assembly (PN: 740-8343)

Tools Required:

• Metric Hex Key Wrench Set or Specific Keys o 3mm Hex Key o 4mm Hex Key o 5mm Hex Key o 7mm Hex Key

• Metric Open Wrench Set or Specific Wrenches o 18mm Open End Wrench

• Screw Driver Set or Specific Drivers o #2 Phillips Screw Driver o #1 Phillips Screw Driver o Flat Head Screw Driver

• Tape – Masking, Painters, Scotch, or Clear

Instructions:

1. Remove the user right side external chain guard using a 5mm hex key to unscrew the three socket head cap screws located on the right side of the Spinner

® (Fig. 1). Using a #2 phillips head screw driver, remove the two

screws on the user left side of the Spinner® (Fig. 2).

Fig. 1

Fig. 2

Part Replacement

STAR TRAC FITNESS 2 of 13 637-1498 Rev: A

2. Remove the two flat head cap screws securing the plastic block caps onto the spring plate and load sensor blocks

from the user right side using a 3mm hex key (Fig 3) and hover the left hand over the left side cap to catch the unthreading nylock nuts. Once the screws are removed – pop off each cap.

Fig. 3

3. Turn the brake knob counter-clockwise until turning locks and knob moves up and down with ease (Fig. 4).

Fig. 4

Part Replacement

STAR TRAC FITNESS 3 of 13 637-1498 Rev: A

4. Using a flat head screw driver remove retainers on the two master links that join the spring plate blocks (Fig. 5)

and remove spacing plates (Fig. 6).

Fig. 5

Fig. 6

5. Gently slide out the lower spring plate block with the brake pad attached (Fig. 7) and maneuver the assembly at

an angle to pull out and away from Spinner® frame (Fig. 8).

Fig. 7

Fig. 8

Part Replacement

STAR TRAC FITNESS 4 of 13 637-1498 Rev: A

6. Push out the remaining master links and store in a safe location (Fig. 9).

Fig. 9

7. Remove the upper load sensor block by removing the two socket head cap screws with a 5mm hex key (Fig. 10).

Fig. 10

Part Replacement

STAR TRAC FITNESS 5 of 13 637-1498 Rev: A

8. Secure the load sensor block assembly to the Spinner

® frame using tape (Fig. 11).

Fig. 11

9. From the user left side of the flywheel – notice routing of the power & RPM wire harness (Fig. 12).

Fig. 12

Part Replacement

STAR TRAC FITNESS 6 of 13 637-1498 Rev: A

10. Loosen and remove the two button head screws that mount the flywheel adjustment block on the left side of the

flywheel using a 4mm hex key (Fig. 13)

Fig. 13

11. Using the #1 Phillips head screw driver – remove the two Phillips head screws (Fig. 14) that secure the PCB

generator shield to the flywheel.

Fig. 14

Part Replacement

STAR TRAC FITNESS 7 of 13 637-1498 Rev: A

12. Rotate the flywheel clockwise until the flywheel generator wire harness is visible (Fig. 15) and clocked between

the 11 & 12 o’clock position.

Fig. 15

13. Tilt the clear plastic shield (Fig. 16) to expose the four pin connector.

Fig. 16

Part Replacement

STAR TRAC FITNESS 8 of 13 637-1498 Rev: A

14. Using a screw driver for leverage; place it directly over wire harness (Fig. 17) and firmly pull back to separate the

harness connector from the flywheel generator PCB.

Fig. 17

15. From the user right side of the Spinner

®, take off the finger guard (Fig. 18) by removing the two screws with a #2

phillips screw driver.

Fig. 18

Part Replacement

STAR TRAC FITNESS 9 of 13 637-1498 Rev: A

16. Remove the two socket head cap screws that mount the left side of the center frame support strut using a 7mm

hex key (Fig. 19). In the process; a small bracket that supports the crank sprocket chain guard will become loose (Fig 20).

Fig. 19

Fig. 20

17. Loosen the two button head screws that mount the flywheel adjustment blocks on both sides of the flywheel using

a 4mm hex key (Fig. 21).

Fig. 21

Part Replacement

STAR TRAC FITNESS 10 of 13 637-1498 Rev: A

18. Completely unscrew the button head screws by hand and remove the flywheel adjustment blocks (Fig. 22). In the

process of removing the adjustment block on the user right side; the center frame support strut will come loose and will need to be completely removed.

Fig. 22

19. From the user left side of the Spinner

®; locate and remove the rubber nut cap that covers the flywheel axle

securing hex nut (Fig. 23).

Fig. 23

Part Replacement

STAR TRAC FITNESS 11 of 13 637-1498 Rev: A

20. Using an 18mm wrench, loosen the user left & right side flywheel axle securing hex nut (Fig. 24).

Fig. 24

21. Grasp and compress the upper & lower sections of the chain (Fig. 25) by hand to remove the front flywheel

sprocket chain guard.

Fig. 25

Part Replacement

STAR TRAC FITNESS 12 of 13 637-1498 Rev: A

22. Remove the left and right flywheel securing hex nuts (Fig. 26).

Fig. 26

23. With firm grip under flywheel; maneuver and push the flywheel towards the center of the frame until the axle

slides out the frame guide channels (Fig. 27).

Fig. 27

Part Replacement

STAR TRAC FITNESS 13 of 13 637-1498 Rev: A

24. Rest the flywheel on the ground directly under the center of Spinner

® frame and remove the chain from the front

sprocket (Fig. 28).

Fig. 28

25. Roll out flywheel and set off to the side.

26. To reinstall flywheel and assemble unit – Reverse the previous procedure and adjust chain for proper tension and

alignment.