Expresso Bikes S2 Service Guide 1a

Expresso Fitness Corporation
S2 Service Guide 1
S2 Service Guide

845 Stewart Drive, Suite D
Sunnyvale, CA 94085 USA
Phone: +1 (408) 746-9122
E-mail: support@expressofitness.com
October 2006
S2 Service Guide
Table of Contents
May 15, 2007
Safety instructions
Loss of heart rate
Steering Issues
Shifter Issues
Console Issues
RPM Issues
10
Speed Issues
11
Resistance Issues
12
Audio Issues
13
Video Issues
14
TV Issues
15
Power Issues
16
Checking Heart Rate
17
Steering Configuration
17
Steering & shifter connection check
18
Interconnect connection check
18
Console connection checks
18
RPM Optical Sensor connection check
19
MRD Speed connection check
19
28V MRD check
19
Page 2
S2 Service Guide
Table of Contents Continued

Console Audio jack check
20
Music Menu Bar check
20
TV Enable check
21
TV Channel configuration check
21
Monitor VGA connection check
22
System connection checks
22
Console Replacement
23
Steering Assembly Replacement
24
Shifter Replacement
27
MRD Replacement
29
1st Stage Drive Belt Replacement (Cogged belt)
33
2nd Stage Drive Belt Replacement (V belt)
36
Monitor Replacement
38
CAUTION: Any changes or modifications to this equipment by other than authorized

personnel will void the product warranty.
While every attempt was made to verify the information in this document at the time of writing, the
information in this document is provided as is without warranty of any kind and is subject to change
without notice.
Copyright 2005 by Expresso Fitness Corporation. All rights reserved. No part of the contents of this
document may be reproduced or transmitted in any form or by any means without written consent of the
publisher.
Expresso Fitness and the Expresso Fitness logo are trademarks of Expresso Fitness Corporation.
All other designated trademarks, registered trademarks, copyrights and brands are the property of their
respective owners.
Part identifier 2500.0012.01
May 15, 2007
Page 3
S2 Service Guide
Safety instructions
Installation/movement
DANGER: Never open the S2 computer pedestal.
This may expose you to risk of shock, fires or
injury.
DANGER: To reduce risk of burns or shocks only
use grounded (three prong) power cords.
Yes
No!
DANGER: To reduce the risk of electrical shock,

always unplug the S2 before attempting any
maintenance activity.
CAUTION: Keep the power cord away from
heated surfaces. Do not pull the equipment by the
power cord or use the cord as a handle.
CAUTION: If the electrical cord is damaged, it
must be replaced by the manufacturer, an
authorized service agent or a similarly qualified
person to avoid a hazard.
CAUTION: Never operate a S2 with the air vents
blocked. Keep air openings free of lint, hair or any
obstructing materials.
CAUTION: Do not use this product in areas where
aerosol spray products are being used or where
oxygen is administered. Such substances create the
danger of combustion and explosion.
CAUTION: Do not install the S2 outdoors, near
swimming pools or in areas of high humidity.
CAUTION: Any changes or modifications to this
equipment by other than authorized personnel
could void the product warranty.
If you are not used to regular physical activity, it

may be dangerous to suddenly engage in
strenuous activity. Increase your exercise level
gradually.
If you feel sick or sense that something is wrong
with your body during exercise, stop
immediately.
Health-related injuries may result from incorrect
or excessive use of exercise equipment. Expresso
also recommends consulting a fitness professional
on the correct use of this product.
Use the S2 only as described in this guide.

Children or developmentally-challenged individuals
must be monitored while using S2.
Never place containers filled with liquids directly on
the unit, except in the water bottle holders.
Containers should be covered with lids.
Carefully mount the S2 when starting to exercise,
and dismount carefully when youre finished,
especially if you are tired.
Wear shoes with rubber or high-traction soles. Do
not use shoes with heels, leather soles, cleats, or
spikes. Do not use the S2 with bare feet.
Keep all loose clothing, shoelaces, and towels away
from moving parts.
Do not reach into, or underneath, the S2; and do not
tip the S2 on its side during operation.
Keep the area around the S2 clear of any
obstructions, including walls and furniture. Provide
at least three feet of clearance behind the unit.
Use caution when stepping on or off of the S2 bike.
Never face backward while using the S2 bike.
This equipment has been certified to comply

with the limits for a Class B computing
device, pursuant to Subpart J of Part 15 of
FCC Rules.
Usage
Before using the S2, Expresso Fitness strongly
recommends seeing a medical specialist, particularly
if you are suffering from any of the following: heart
disease (angina pectoris, myocardial infarction),
hypertension, diabetes, respiratory disease (asthma,
chronic bronchitis, pulmonary emphysema, etc.),
articular metamorphosis, rheumatism, gout, or other
diseases and physical complaints. Pregnant women
should also consult their doctor before beginning a
training program.
May 15, 2007
Page 4
S2 Service Guide
Lose of heart rate

Start
Heart Rate grip

not working or
lost heart rate
message
displayed?
Yes
No
Wirele ss HR
working?
No
Replace console.
See page 23
Yes
Replace steering
assembly.
See page 24
Problem
fixed?
Problem
fixed?
No
No
Yes
Yes
Finish
Contact Expresso
Support
May 15, 2007
Page 5
S2 Service Guide
Steering Issues
Start
Yes
Does steering
respond in
route?
Continue on page 7
No
Calibrate steering
See page 17
Checking steering
connector& wires.
See page 18
Problem
fixed?
Yes
Problem
fixed?
No
Replace Steering
Unit.
See page 24
Yes
Finish
May 15, 2007
Page 6
S2 Service Guide
Steering Issues continued
Start
Doe s ste e ring

drift or doe sn't
stay ce nte re d in
route ?
No
Finished
Yes
Calibrate steering
See page 17
Replace steering
assembly.
See page 24
Problem
fixed?
No
Yes
Problem
fixed?
No
Contact Expresso
Support
Yes
Finish
May 15, 2007
Page 7
S2 Service Guide
Shifter Issues
Start
Is gear shifte r
working?
No
Verify Shifter
connections.
See page 18
Yes
Yes
Problem
fixed?
No
Verify Connection
to console.
See page 18
No
Yes
Replace shifter.
See page 27
Problem
fixed?
Yes
Problem
fixed?
No
Finish
May 15, 2007
Contact Expresso
Support
Page 8
S2 Service Guide
Console Issues
Start
Is console
responding?
No
Power bi ke off,
wai t 20 seconds &
power on.
See page 22
Yes
Yes
Problem
fixed?
No
Verify Connection at
i nterconnect &
console.
See page 18
No
Yes
Replace consol e.
See page 18
Problem
fixed?
Yes
Problem
fixed?
No
Fini sh
May 15, 2007
Contact Expresso
Support
Page 9
S2 Service Guide
RPM Issues
Start
Is there
RPM?
No
Verify Connection
at interconnect &
console.
See page 18
Yes
Yes
Problem
fixed?
No
Replace console.
See page 23
No
Yes
Problem
fixed?
Yes
Ve rify RPM optical

sensor connecte d &
che ck pins.
Se e page 19
Problem
fixed?
No
Finish
May 15, 2007
Contact Expresso
Support
Page 10
S2 Service Guide
Speed Issues
Start
Is there
Speed?
No
Verify Connection
at interconnect &
console.
See page 18
Yes
Yes
Problem
fixed?
No
Replace console.
See page 23
No
Yes
Problem
fixed?
Verify speed
connection on
MRD.
Se e page 19
Yes
Problem
fixed?
No
Fini sh
May 15, 2007
Contact Expresso
Support
Page 11
S2 Service Guide
Resistance Issues
Start
Verify Connection
at interconnect .
See page 18
No
Is there full
resistance?
Yes
Yes
Problem
fixed?
No
Verify 28 v DC
from CPU.
See page 18
Yes
Problem
fixed?
Verify 28v to MRD

and Verify
thermocouple 1/3
ohms (orange/white) .
No
Se e page 19
Yes
Yes
Finish
May 15, 2007
No
Problem
fixed?
Problem
fixed?
Check Console
connections (ribbon
& Large bottom)
See page 18
No
Contact Expresso
support.
Page 12
S2 Service Guide
Audio Issues
Start
Does Music
menu load?
No
Check to make sure

that all music
groups display
artist and titles.
See page 20
Yes
Do all groups
display songs?
No
Yes
Check console jack

for wear and tear.
See page 20
Does console
jack show any
wear or te ar?
Contact Expresso
Support
No
Checking System
audio connection.
Yes
Replace console.
See page 23
Problem
fixed?
No
Yes
Finish
May 15, 2007
Page 13
S2 Service Guide
Video Issue
Start
Is there a
Video Issue?
Yes
Check power to
monitor.
Yes
Yes
Doe s console
Bee p?
No
see page 22
No
Problem
fixed?
Check to see if bike

is powered on
Problem
fixed?
Yes
No
Check VGA
connection on monitor
and syste m.
see page 22
Problem
fixed?
Contact Expresso
Support.
No
Yes
Finish
May 15, 2007
Page 14
S2 Service Guide
TV Issues
Start
Is there TV?
No
Check to see if
TV is enabled.
See page 21
No
Was TV
enabled?
Yes
Yes
Check to se e if
channels are
configured correctly.
see page 21
Is TV clear?
No
Checking TV cable is
connected (75 ohm
cable).
Enable TV.
Were channels
configured
correctly?
Yes
See page 22
No
Problem
fixed?
Problem
fixed?
No
Configure the
correct channels.
Problem
fixed?
No
Yes
Finish
May 15, 2007
Contact Expresso
Support.
Page 15
S2 Service Guide
Power Issues
Start
Is there a
Powe r Iss ue ?
Yes
Check to see i f bike
is powered on
See page 22
Is Bike
powe re d on?
No
Power bi ke on.
Yes
Yes
Verify 120v from

source.
Probl em
fi xed?
No
Probl em
fi xed?
Yes
No
Veri fy 120v thru
power cord.
see page 22
Probl em
fi xed?
Fi ni sh
No
Veri fy fuse
i nstal led or good.
see page 22
Probl em
fi xed?
No
Yes
Fini sh
May 15, 2007
Contact Expresso
Support.
Page 16
S2 Service Guide
Checking Heart rate

1. Put hands on the handlebar sensors and check BPM function.
2. Check the BPM function using the Polar pulse simulator.
Steering Calibration
Log into Configuration Mode (7913)
Press <enter> to select Calibrate steering
If steering bar is not centered then
press <enter> and follow instructions
to calibrate steering.
If steering bar is centered go to next step.
Properly calibrated steering
makes the virtual bike go down
the road straight when the
steering is centered.
May 15, 2007
Page 17
S2 Service Guide
Checking Steering and Shifter Connectors
Shifter Connector
Heart Rate Connector

(4-wire connector)
Steering Connector
(3-wire connector)
Interconnect connectors
Connector A (MRD)
(Large red cables 28v)
Connector B
(Console/Shifter/Steering)
Console Connectors
MRD Connector
Game Controller
(Shifter/Steering/Heart
Rate)
All Other Connector
May 15, 2007
Page 18
S2 Service Guide
RPM Optical Sensor Connector and Check
RPM Optics Board

Connector
MRD Speed control connector
MRD Speed control

connector
28v check on MRD
28v for MRD
May 15, 2007
Page 19
S2 Service Guide
Audio Console Jack check
Audio Jack (Headset jack)
Music menu Bar check
Music Menu
May 15, 2007
Page 20
S2 Service Guide
TV Enable/Disable screen
TV Channel Configuration screen
May 15, 2007
Page 21
S2 Service Guide
Monitor VGA connection check
System connection checks
System Fuse
AC Power plug
RJ-45 Ethernet
USB Port
Coax connector (TV)

Power switch
May 15, 2007
Page 22
S2 Service Guide
Console Replacement
Tools Needed
#2 Phillips screw driver
3. Remove screws from back of

console.
2. Remove cables from back of

console.
4. Re-install cables on back of

console.
1. Re-install screws on back of

console.
May 15, 2007
Page 23
S2 Service Guide
Steering assembly replacement

Tools Needed
#2 metric Allen
#5 metric Allen
3/32 Allen
Torque wrench
Loctite Red
1. Remove water bottle holder.
2. Remove shifter cover.
3. Remove shifter.
Note: Do not let shifter hang by
wire.
May 15, 2007
Page 24
S2 Service Guide
Steering assembly replacement continued
4. Unplug shifter wire.
5. Unplug steering wires.
6. Remove steering assembly

screws. Use Metric #5 first if
it does not fit then it may be a
3/16 Allen.
7. Remove steering assembly.

8. Re-install new steering
assembly.
Note: Make sure steering
assembly handles face up and
wires are not pinched.
May 15, 2007
Page 25
S2 Service Guide
Steering assembly replacement continued
9. Re-install steering assembly

screws using torque wrench
set to 55 inch-lbs.
Note: Make sure to use Loctite
red on screws.
10. Re-connect shifter

11. Re-connect steering assembly
wires.*
12. Re-install shifter.
*Note: make sure 4-wire plug is
installed on 4-wire plug & 3wire plug onto 3 wire plug.
13. Re-install shifter covers.
14. Re-install water bottle holder.
May 15, 2007
Page 26
S2 Service Guide
Shifter Replacement
Tools Needed
3/32 Allen
1. Remove water bottle

holder.
2. Remove shifter cover
3. Remove shifter.
Note: Do not let shift
hang by wires.
4. Unplug shifter wire.
May 15, 2007
Page 27
S2 Service Guide
Shifter Replacement Continued
5. Connect wire to new

shifter.
Note: Do not let shift
hang by wires.
6. Install new shifter.
7. Re-install shifter
cover.
8. Re-install water bottle

holder.
May 15, 2007
Page 28
S2 Service Guide
MRD Replacement
Tools Needed
#3 metric Allen
#8 metric Allen
Crank puller
1. Remove kick plate.
2. Remove right side cover.
3. Remove left side crank arm.
May 15, 2007
Page 29
S2 Service Guide
MRD Replacement continued
4. Remove left side cover.

Note: When removing left cover
use caution, there is a fan on
cover that needs to be unplugged.
5. Remove tie wraps on wire to

MRD.
Note: Use caution not to cut
wires when cutting tie wraps.
6. Disconnect wires and move

wires out of the way of MRD.
7. Loosen tension arm on left

side by using socket
extension.
May 15, 2007
Page 30
S2 Service Guide
8. Remove 2nd stage Vee belt.
9. Remove four (4) bolts

holding MRD.
10. Re-install new MRD.

Note: It is important that the
proper alignment of the MRD is
used. To align MRD looking
from the front of bike the left
side of MRD plate should line up
with the bike frame plate as it
looks in photo to the right.
11. Re-install belt and tighten the

tension arm screws.
Note: the belt tension is created
by the spring.
May 15, 2007
Page 31
S2 Service Guide
12. Re-install all wires and tie

wraps the wires.
13. Re-install left side cover and

connect the fan.
14. Re-install left side crank arm.
15. Re-install right side cover.
16. Re-install kick plate.
May 15, 2007
Page 32
S2 Service Guide
1st Stage drive belt Replacement (Right side cogged belt)

Tools Needed
#3 metric Allen
#5 metric Allen
#6 metric Allen
#8 metric box wrench
#12 metric box wrench
2. Remove right side cover.
3. Loosen 1st stage tension

arm aliens.
May 15, 2007
Page 33
S2 Service Guide
1st Stage drive belt replacement (Right side cogged belt) continued
4. Loosen lock nut and

remove tension are idle
arm.
5. Remove drive belt.
6. Install new drive belt.
7. Tighten tension arm bolt

until the correct tension is
on drive belt, tighten lock
nut.
May 15, 2007
Page 34
S2 Service Guide
1st stage Drive Belt replacement (Right side cogged belt) continued
8. Tighten Allen bolts on

tension arm.
9. Re-install right side

cover.
May 15, 2007
Page 35
S2 Service Guide
2nd Stage Drive Belt Replacement (left side V belt)

Tools Needed
#3 metric Allen
#8 metric Allen
Socket extension
Socket wrench
Crank puller
3. Remove left side cover.

Note: When removing left
cover use caution, there is a
fan on cover that needs to be
unplugged.
May 15, 2007
Page 36
S2 Service Guide
2nd Stage Drive Belt Replacement (left side V belt) continued
4. Loosen tension arm using

a socket extension and
remove V belt.
5. Loosen tension arm using

a socket extension and
install new V belt.
6. Re-install left side cover

making sure that cove fan
in reconnected.
May 15, 2007
Page 37
S2 Service Guide
Monitor Replacement
Tools Needed
Straight edge screw driver
#2 metric Allen
1. Remove Allen screws from

rear monitor cover.
2. Disconnect power and VGA

cable from monitor.
3. Remove monitor mount

screws.
May 15, 2007
Page 38
S2 Service Guide
Monitor Replacement continued
4. Install new monitor.
5. Install power and VGA cable.
6. Re-install rear cover.
May 15, 2007
Page 39
S2 Service Guide
May 15, 2007
Page 40

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May 15, 2007

Loss of heart rate

Checking Heart Rate

Steering & shifter connection check

Interconnect connection check

Console connection checks

RPM Optical Sensor connection check

MRD Speed connection check

28V MRD check

Expresso Fitness Corporation

Table of Contents Continued

Music Menu Bar check

TV Channel configuration check

Monitor VGA connection check

System connection checks

Steering Assembly Replacement

1st Stage Drive Belt Replacement (Cogged belt)

2nd Stage Drive Belt Replacement (V belt)

CAUTION: Any changes or modifications to this equipment by other than authorized

May 15, 2007

Expresso Fitness Corporation

DANGER: To reduce the risk of electrical shock,

If you are not used to regular physical activity, it

Use the S2 only as described in this guide.

This equipment has been certified to comply

May 15, 2007

Expresso Fitness Corporation

Lose of heart rate

Heart Rate grip

May 15, 2007

Expresso Fitness Corporation

May 15, 2007

Expresso Fitness Corporation

Steering Issues continued

Doe s ste e ring

May 15, 2007

Expresso Fitness Corporation

May 15, 2007

Expresso Fitness Corporation

May 15, 2007

Expresso Fitness Corporation

Ve rify RPM optical

May 15, 2007

Expresso Fitness Corporation

May 15, 2007

Expresso Fitness Corporation

Verify 28v to MRD

May 15, 2007

Expresso Fitness Corporation

Check to make sure

Check console jack

May 15, 2007

Expresso Fitness Corporation

Check to see if bike

May 15, 2007

Expresso Fitness Corporation

May 15, 2007

Expresso Fitness Corporation

Verify 120v from

May 15, 2007

Expresso Fitness Corporation