Schwinn Z Betriebsanleitung

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637-8808 Rev. J

Technical Procedure

Schwinn X/Z Troubleshooting & Replacement

Applies to: Schwinn X (9-7470 + 9-7480), Schwinn Z (9-7510 + 9-7520)

Enhanced Images: Pictures can be zoomed in to any level for

detail. Use the standard zoom tools for your platform to zoom in.

This document covers procedures for the Schwinn Z and X bikes. The Schwinn Z is pictured, procedures are

applicable for the Schwinn X cycle except where speciﬁed. Click on procedure below to jump to section:

Fore-Aft Adjustment Lever Replacement ...................................................... 2

Tighten Loose Handlebars or Seat................................................................. 7

Handlebars 7

Seat 8

Cycle Belt and Flywheel Replacement......................................................... 10

Z Bike Gear-Angle Sensor Replacement ..................................................... 16

Z Bike LED Board Replacement ................................................................. 19

Z Bike Battery Replacement ................................................................. 22

Bike Battery Replacement 22

4iiii Crank Arm Battery Replacement 23

Crank Removal............................................................................................. 24

Pedal Removal............................ ................................................................. 25

Flywheel Position Adjustment ................................................................. 26

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637-8808 Rev. J

Technical Procedure

Fore-Aft Adjustment Lever Replacement

Required Tools:

• 4mm Allen Key

• 5mm Allen Key

• Ratchet Wrench

• 11mm Deep Socket

• Torque Wrench

• #2 Phillips Screwdriver

Required Parts*:

• For seat: 727-0177-XX “ASSY, CAM LEVER, SEAT, ACPU”

• For seat: 300-0245 “BLOCK, GAUGE, TORQUE, SEAT, UGC”*

• For handlebars: 727-0176-XX “ASSY, CAM LEVER, HBAR”

*Please note that 300-0245 300-0245 “BLOCK, GAUGE, TORQUE, SEAT, UGC” is only required for

bikes PRIOR to serial number(s): GC7470L22091069 (Schwinn XA), GC7520L21491157 (Schwinn ZA),

GC7510L2213127 (Schwinn ZS), GC7480L22141001 (Schwinn XS).

Seat Slider

1. Loosen the fore/aft adjustment lever then use

a 5mm allen key to remove the locking screw

from under the seat post.

Notice: When reinstalling the this screw, be sure

to torque to 2 Nm (9 Ft-Lbs).

Fig. 1

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637-8808 Rev. J

Technical Procedure

2. Slide the seat slider off of the seat post.

Fig. 2

3. Use a ratchet wrench with a 11mm deep

socket to remove the 1/4” nylock nut and

M6 ﬂat washer, then remove the adjustment

lever.

4. Install the new lever using the same hardware

from Step 3.

Notice: If a torque wrench is not available,

please skip to Step 7.

Fig. 3

5. Install 300-0245 “BLOCK, GAUGE, TORQUE,

SEAT, UGC” onto the seat slider so the lever

adjustment nut can be accessed through the

hole int he top of the torque block.

Notice: Step 5 is ONLY valid for bikes PRIOR

to serial number GC7470L22091069 (Schwinn XA),

GC7520L21491157 (Schwinn ZA), GC7510L2213127

(Schwinn ZS), GC7480L22141001 (Schwinn XS).

Fig. 4

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637-8808 Rev. J

Technical Procedure

6. Ensure that the fore/aft adjustment lever

is closed, then use a torque wrench with a

11mm deep socket to tighten the fore/aft

lever adjustment nut to 4 Nm (2.95 Ft-Lbs).

7. Reinstall the seat slider and locking screw

from Steps 1+2. This will conclude the

procedure - DO NOT CONTINUE TO STEP 7.

8. With the fore/aft adjustment lever open,

tighten the adjustment lever nut 1/4 of a turn,

then close the adjustment lever and check

the function by reinstalling the seat slider

removed in Step 2 and pushing backwards

on the seat slider - it SHOULD NOT move.

9. Repeat Step 7 as needed until the seat slider

is tight. This will conclude the procedure. Fig. 5

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637-8808 Rev. J

Technical Procedure

Handlebar Slider

1. Flip the fore/aft adjustment lever up.

Fig. 6

2. Move the handlebars forward until the fore/

aft adjustment lever nut is visible through the

hole on the underside of the handlebar post.

Fig. 7

3. Use a ratchet wrench with a 11mm deep

socket to remove the 1/4” nylock nut and

M6 ﬂat washer, then remove the adjustment

lever.

Fig. 8

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637-8808 Rev. J

Technical Procedure

NOTE: If a torque wrench is not available, please

skip to Step 4.

4. Close the fore/aft adjustment lever, then use

a torque wrench with a 11mm deep socket

to tighten the fore/aft lever adjustment nut

to 3 Nm (2.21 Ft-Lbs). This will conclude the

procedure.

5. With the fore/aft adjustment lever up, tighten

the adjustment lever nut 1/4 of a turn, then

close the adjustment lever and check the

function by pushing backwards on the

handlebars - they SHOULD NOT move.

6. Repeat Step 4 as needed until the handlebars

are tight. This will conclude the procedure. Fig. 9

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637-8808 Rev. J

Technical Procedure

Tighten Loose Seat or Handlebars or Seat

Required Tools:

• #2 Phillips Screwdriver

• Torque Wrench

• 10mm Deep Socket

• 3mm Allen Key

NOTE: While the images below show a Schwinn Z cycle, this procedure is also applicable for the Schwinn X

cycle.

Handlebars

1. Flip the fore/aft adjustment lever up.

Fig. 10

2. Move the handlebars forward until the fore/

aft adjustment lever nut is visible through the

hole on the underside of the handlebar post.

Notice: If a torque wrench is not available,

please skip to Step 4.

3. Close the fore/aft adjustment lever, then use

a torque wrench with a 11mm deep socket

to tighten the fore/aft lever adjustment nut

to 3 Nm (2.21 Ft-Lbs). This will conclude the

procedure.

4. With the fore/aft adjustment lever up, tighten

the adjustment lever nut 1/4 of a turn, then

close the adjustment lever and check the

function by pushing backwards on the

handlebars - they SHOULD NOT move.

5. Repeat Step 4 as needed until the handlebars

are tight. This will conclude the procedure.

Fig. 11

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637-8808 Rev. J

Technical Procedure

Seat

1. Use a 3mm allen key to remove the socket

head cap screw from the underside of the

seatpost.

Notice: When reinstalling the this screw, be sure

to torque to 2 Nm (9 Ft-Lbs).

Fig. 12

2. Remove the seat slider assembly from the

seat post.

Notice: If a torque wrench is not available,

please skip to Step 5.

Fig. 13

3. Install 300-0245 “BLOCK, GAUGE, TORQUE,

SEAT, UGC” onto the seat slider so the lever

adjustment nut can be accessed through the

hole int he top of the torque block.

Notice: Step 3 is ONLY valid for bikes PRIOR

to serial number GC7470L22091069 (Schwinn XA),

GC7520L21491157 (Schwinn ZA), GC7510L2213127

(Schwinn ZS), GC7480L22141001 (Schwinn XS).

Fig. 14

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637-8808 Rev. J

Technical Procedure

4. Ensure that the fore/aft adjustment lever

is closed, then use a torque wrench with a

10mm deep socket to tighten the fore/aft

lever adjustment nut to 4 Nm (2.95 Ft-Lbs).

5. Reinstall the seat slider and locking screw

from Steps 1+2. This will conclude the

procedure - DO NOT CONTINUE TO STEP 7.

6. With the fore/aft adjustment lever open,

tighten the adjustment lever nut 1/4 of a turn,

then close the adjustment lever and check

the function by reinstalling the seat slider

removed in Step 2 and pushing backwards

on the seat slider - it SHOULD NOT move.

7. Repeat Step 7 as needed until the seat slider

is tight. This will conclude the procedure. Fig. 15

Page 10

637-8808 Rev. J

Technical Procedure

Cycle Belt and Flywheel Replacement

Required Tools:

• 3mm Allen Key

• 4mm Allen Key

• 6mm Allen Key

• #2 Phillips Head Screwdriver

• 18mm Open-Ended Wrench

• 19mm Open-Ended Wrench x2

• Permanent Marker or Pencil

WARNING: Procedure below involves removal of the ﬂywheel. The ﬂywheel is heavy and two people are

recommended to complete this task. Keep ﬂywheel on blanket or similar to prevent damage.

1. Use a 4mm allen key to remove he two (2)

socket head cap screws securing the left side

belt guard cap.

Fig. 16

2. Use a 4mm allen key to remove the four (4)

socket head cap screws securing the left side

belt guard to the bike, then remove the belt

guard.

Fig. 17

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