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Service Bulletin
IC5/IC7 REWORK
Z:\Quality\Rework Instructions\IC7\Service Bulletin Rework IC5 and IC7
Effective Date:
Draft 5 Oct 27
Models Affected:
Prepared by: Stefan Seise,
Tomahawk/Matrix IC7 powered by ICG
Michael Donhauser, Christian
Tomahawk/Matrix IC5 powered by ICG
Bulletin Number
NB-001
Schramm, John Guld, Craig
Melter, Bill Baier, Scott Weber
Serial Number Range Affected:
-
LARB 0000001-14B ~ 0000717-14H Matrix IC7 powered by ICG
-
LAQB 0000003-14F ~ 0000160-14F Matrix IC5 powered by ICG
-
TARB 0000041-14D ~ 00002342-14H Tomahawk IC7 powered by ICG
-
TAQB 0000001-14D ~ 00000531-14H Tomahawk IC5 powered by ICG
NOTE: ALL PRODUCTS FABRICATED AS OF SEPTEMBER 1st. 2014 (….-14 I) ARE NOT
EFFECTED AS CORRECTIVE MEASURES HAVE BEEN IMPLEMENTED INTO PRODUCTION
SYMPTOM / ACTION REQUIRED / RECOMMENDED

Squeaking noise from secondary belt drive may occur after a few hours in operation

Flip lever for horizontal seat post adjustment is breaking and moving in fore/aft direction

Primary drive belt breaking

Replace primary Idler pulley

Loose mounting bolts (emergency brake bracket, generator, gear module bracket)

Cracking console brackets caused by interference with handle bars

Downward load of user being applied to aluminum drum/screw
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2
1. Gas drum hole alignment checks

Tools needed

2.5mm Allen key
Remove screw from gas drum collar using the
2.5mm Allen key.
Place seat and handlebar posts in the down position.
Holes should line up without operator aid. If
not contact John Guld. Reinstall screws using 2.5mm Allen key.
2. Replace horizontal seat slider for short user.
Will also include new HORIZONTAL FLIP LEVER

Tools needed

Small flat head screw driver

3mm Allen key

Size 25 Torx key

13mm socket & drive

Blue Loctite Gel (Vibra-Tite 12535 Thread Loc)
Determine if the short (approx. 1”) seat slider or tall
(approx. 2”). If tall, follow the entire below
instruction. If short only follow the light blue
instructions.
Remove plastic end cap from back of bottom slide
using 3mm allen key.
Remove seat by loosening seat nut using a 13mm
socket.
2
3
Remove horizontal slide assembly, wrap in foam and set gently in the TO BE RETURNED BOX.
Install new SHORT horizontal slider assembly
Reinstall LOWER SLIDER PLASTIC END CAP
using 3mm allen key
Remove plastic cap from flip lever by using a small
screwdriver
Disassemble the original flip lever by removing the
adjustment bolt by using a size 25 Torx key.
Then remove the brass center drum from the flip
lever.
Clean off grease and apply blue thread sealant in a
straight line down the thread (Vibra-tite 12535).
Position the reinforced flip lever into its intended
place and tighten the bolt.
Adjust and test the clamping to make sure the
upper saddle slider stays in its intended position
when the flip lever is locked.
Open and close the lever several times and adjust
the clamping force by tightening/loosening the flip
lever mounting bolt accordingly.
3
4
Apply grease to back slider rails.
Check that front slider slides freely. If not, apply
grease
It is recommended to test the proper clamping on 3
different spots (front -8, middle 0, rear +8) of the
slider and open/close the lever for several times on
each spot. Readjust if it is necessary.
A sharp blow with rubber mallet to the slider end
should not move the seat.
Assemble plastic cap to the flip lever.
Check seat setting
Reinstall seat – make sure it is level and even
side-to-side. Stand back behind unit 3’+ to check
for leveling and evenness
Torque to 25 N-m (both sides) – tighten both sides
slowly & evenly because it is 1 screw
3. Remove the shroud
To learn how to remove the shroud correctly, please watch our service video at:
http://www.icg-internal.com/ic7-bike/service-videos/
Username: icginternal
Password: cytech1995

Tools needed

Bin for screws

2mm Allen key

3mm Allen key

(2) Rubber bands
4
5
Remove E-stop cover and screw, lift knob off
Starting with right side, remove FOUR screws
near handlebar (HB) post top cover (left & right
side)
using 2mm Allen key.
Remove TOP
HB POST COVER and secure to HB using
rubber band
Remove two screws that are located from the
cover you just removed using 3mm Allen key
Hint:
Note:
2nd
screw
Raise seat to the top.
Be careful not to cross thread the brass
insert.
Remove three screws from the SEAT POST 3rd one on right
COVER using 2mm and 3mm Allen keys.
side
Remove COVER and secure seat slider with
rubber band.
Remove CENTER TOP SHROUD
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6
Remove 14 screws holding on the RIGHT
SHROUD using a 3mm Allen key.
RIGHT
SHROUD can be removed.
See picture at
right (cranks will still be on the bike)
Remove 2 screws from right side near HB post
using a 3mm Allen key.
Remove 3 screws from bottom of LEFT SIDE
SHROUD
Hint:
Do not remove this screw all the way.
LOOSEN 1 HIDDEN screw from right side near
seat post. Only loosen until left shroud is free
but do not remove screw ANY further.
Remove the left side shroud.
washer.
Remove
Now screw can be fully removed.
4. Check tension of the secondary drive belt (left side)
set between 150 and 160 Hz

Tools needed

Belt tension meter

5mm Allen Key

8mm Allen key

Torque wrench capable of 12/15 N-m
It is recommended to measure belt tension on
3 different spots of the belt, using a sonic
meter. Each reaching should be between
150-160Hz. If not, then proceed with the
following steps:
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Slightly loosen secondary idler pulley
mounting bolts with size 5 Allen key.
Pre-tension belt with size 8 Allen key and
tight idler pulley mounting bolts (hand tight).
Make sure the pulley mounting arm is not
tipping while the bolts are not fully tightened
Turn crank a few times (using your hand) to
make sure the poly V ribs are settled into its
desired position.
Check belt tension preferably on 3 different
spots of the belt by using a sonic meter or
recommended smartphone app.
Make sure that the highest reading of belt
tension is within the range of 150~160Hz.
The belt usually loses some of its initial set
tension owed to a normal settling.
If you find the belt tension have dropped
below 150Hz, slightly open the 2 pulley
mounting bolts and adjust the belt tension w/o
fully releasing
As soon as belt tension is within specs (150 –
160Hz), tighten the idler pulley mounting bolts
with 12/15NM, ideally using a torque wrench.
5. Belt and Idler Pulley Replacement
If the belt has a BLUE IDENTIFICATION it does not have to be changed.

Tools needed
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8

5mm Allen key

8mm Allen key

Torque Wrench capable of 12/15 N-m

Trash to dispose of old items
Loosen primary idler pulley mounting bolts with
size 5 Allen key.
Remove the timing belt from the primary drive train.
Remove the primary idler pulley assembly inclusive
of the 2 washers and bolts. Note: Make sure both
washers come off of unit. Dispose all parts
immediately to prevent from using these parts
accidentally when mounting the new improved idler
pulley version.
Attach the new primary idler pulley assembly to the
frame fixture. Note that the new idler pulley bracket
is mounted to the fixture w/o washers.
Replace BELT with a new one.
The new one may
or maynot have OPTIBELT printed in blue.
Note: The washer that is included in the
hardware bag is for the slotted idler pulley hole
(circled in light blue)
Pre-tension belt with size 8 allen key and tight idler
pulley mounting bolts (hand tight). Make sure the
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idler pulley assembly is not tipping sideways.
Turn crank a few times forward and backward by
hand to allow the timing belt to settle
The tension of the primary timing belt shall be set between 290-310 Hz.
Check using sonic Gate’s tension gage. Check at
1:00, 5:00, and 9:00. The highest reading must
be between 290-310 Hz and the difference (range)
of the 3 readings should be less than 50Hz.
If you have to provide higher or less tension again,
please make sure to pedal some seconds (using
your hand) before measuring the tension on 3
different spots of the belt again.
As soon as belt tension is within specs, tighten the
idler pulley mounting bolts with 12/15NM by using
a torque wrench.
Turn the crank a few times and double check the
tension of the primary drive.
If not within
specification, loosen the idler mounting bolts and
repeat the previous three steps.
6. Check emergency brake functionality

Tools needed

Allen key
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10

Emergency brake alignment jig
Check if the bolts holding the emergency brake bracket in
place are sufficiently tightened. Manufacturer recommends
2.5~3.0NM. If needed, tighten the bolts.
Check alignment of the emergency brake pad in relation to
the Flywheel using the emergency brake alignment jig
(part no. 200-04-00005-01), adjust position if required.
Reassemble the brake knob to the bike.
Check emergency brake functionality.
The flywheel / cranks must come to complete stop within 1
revolutions of the cranks when E-brake is engaged at
100~110 RPM-
7. Check magnetic brake functionality

Tools needed

3mm Allen key
Spin pedals getting up to approximately 100rpms while turning the brake knob to the right and left and
check if the mechanical function of the magnetic brake is given. Remove the brake knob before the
assembly of the main shroud is performed.
8. Check several connections and fixations

Tools needed

3mm Allen key
-
Check mounting bolts for cable clips (IC5 & IC7)
-
Check mounting bolts generator bracket (IC7)
-
Check mounting bolts gear module bracket (IC7)
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9. Check for gap between HB and Console Bracket and if
needed, create gap

Tools needed

Special bend tool

Computer

3mm Allen key
Place computer onto bracket. If there is interference with handlebars (HB), follow the below steps.
Adjust HB all the way down and center fore/aft adjustment
Removing two screws using 3mm Allen key
Remove the single screw that attaches the
computer to handlebars.
Remove computer bracket. It will hang below
HB horizontal slider.
Hint: It might be difficult to pull the wire through
the handlebar
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Insert SPECIAL BEND TOOL.
Bend until
computer slides without interference.
If larger than 2mm gap between computer and
bracket, flip SPECIAL BEND TOOL over to
minimize gap.
Replace computer bracket and screws.
Recheck that computer does not interfere and smallest gap is not greater than approximately 2mm.
Note: The tool can be rotated 180 degrees to reduce the HB gap.
10.
Test Computer
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13
“” to make
selections
“Arrow” down to “Firmware” (photo 1). Arrow
to “System Check” & press “”. Wait for
green screen to display (photo 2). If display
turns red, pedal 2-3 times and exit out.
1)
2)
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Check that light on top of computer is
working. Press “person”. “Arrow” down to
“standard” and press “”. It selects male or
female and press “”. It displays set age,
press “”. It displays weight, press “”. A
medical disclaimer will display (photo 1),
press “”. The white light will display (photo
1)
2)
2). Pedal the bike while changing the tension
knob and you should be able to see the light
change colors from white to blue to green to
yellow to red. Stop pedaling and light should
return back to white.
11.
Reinstall the shroud
Repeat in reverse order of STEP 2.
Take care to tighten all screws loosely at first and go back and hand tighten all.
12.
Package Computer
Place computer mounting screw in bag (photo
1) with sticker on front of bag. Wrap computer &
bag together in foam. Place wrapped package
into armrest. Stretchwrap package to armrest.
1)
2)
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3)
13.
4)
Lubricate and Wipe Down
Superlube front (photo) and back bars with
lubricant on cloth.
Wipe down entire unit using cloth and windex to
remove all prints.
The REWORK shall be executed on all Bikes in the field and warehouse
prior to production month (September 2014)
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