FG540 HYBRID ROLLER instructions manual | MINOURA JAPAN

FG540 HYBRID ROLLER instructions manual | MINOURA JAPAN
Indoor Bike Trainer
(ver.1.1 2016/6)
[Applicable Wheel Size]
650c – 700c, 26 – 29 inch
[Applicable Wheebase Size]
950 – 1,200mm
(Shown with 700c road bike)
• This trainer is designed for use only on stable or indoor surfaces. The trainer is not
designed to be used in muddy or off road conditions. Getting dirt in the resistance unit
could may cause damage. Using muddy or dirty tires will cause premature wear on the
• Using wheels smaller than 24" will put too much stress on the unit.
• When setting up the FG540 pedal slowly at first to make sure the rear wheel stays on
the roller and is positioned properly.
If you need help, please contact the shop first where you originally purchased this product or call the distributors
in your country. The distributors list can be found on our web site.
MINOURA North American Tech Center
MINOURA Japan Headquraters
(for U.S. residents ONLY) (for ALL customers)
Hayward, California, U.S.A.
1197-1 Godo, Anpachi, Gifu 503-2305 Japan
Phone:1-510-538-8599 (8 am - 5 pm, Mon - Fri, PST)
Fax: 1-510-538-5899
Fax: +81-584-27-7505
Email: support@minourausa.com
Email: minoura@minoura.jp
Web: www.minoura.jp
Important Notes
Please Read Carefully Before Use
• For use with a standard 2-wheel bike with the wheel size between 650c and 700c or 26 and 29 inch
and the wheelbase size between 950 and 1,200mm.
Any longer wheelbase bike such as a tandem or long-tail or other types of bike such as recumbent
or folding bike won't fit FG540.
• The front hub is 100mm width and equipped with 9mm standard or 15mm thru-axle type. Any other
hub size cannot be used.
• The rear triangle of your bike rides freely on the roller. Be careful not to fall down while getting on or
off the bike. Use the handlebar to steady yourself put do not pull on the bars as this may cause the
bike to tip.
The best way to mount the trainer is to stand close to the side of the saddle. Center yourself low
and to the center of the bike, clip into one pedal then slowly swing your other leg over the bike and
clip into the second pedal.
• Minoura recommends the use of a completely slick (no tread) tire to reduce noise and increase the
longevity of the tire and rollers.
• The FG540 comes equipped with a standard quick release skewer (Q/R) for the front fork mount.
Tighten the Q/R as you would your wheel to your bike, close it firmly and tightly.
If you are unsure, consult your local bike shop for help.
• Your rear tire must contact both rollers evenly. Adjust the center arm/frame exactly.
Incorrect adjustment will result in unbalanced resistance and poor bike stability.
• For your safety, place the FG540 on a flat, even floor or surface. Make sure all legs are fully opened.
Make sure to check the trainer stability, especially when raising the front fork mount.
Doing so will decrease stability, cause your tire to burst or throw you off the bike. Simply reduce your
cadence and let the bike come to a natural stop.
• Keep the children and pets away from the spinning wheel or moving parts.
• It's impossible to change to non-remote type. Removing the remote shifter will automatically set the
resistance level at the maximum position.
• Minoura recommends to use a mat underneath the trainer to protect the floor from sweat or stain
from the rubber feet.
• If you hear a strange noise or smell something unusual, immediately stop using the the trainer and
contact your Minoura dealer. Do not try to disassemble the product without consulting your dealer
or Minoura first.
• Any warranty will be void if you use FG540 for other purpose than instructed.
Minorua offers 1-year limited warranty on this product from the date of your purchase for any
problem caused by manufacturer's defect. Natural wear will not be covered.
Any damage or problem caused by transporting process is not covered under warranty. Any damage
from shipping or moving must be made to the shipping company.
Read the enclosed "Minoura Limited Warranty Policy" card for more detail.
For the latest information, refer Minoura web site (http://www.minoura.jp).
Part Names
Front Fork Support
(9mm Q/R, 15mm Thru Axle compatible)
Adapter Sleeve for 15mm Thru Axle
(Red, inside)
Stopper Pin
Knob Lever (backside)
Front Frame /
Tripod Left Side Leg
Remote Cable Guide
(backside, Right side only)
Remote Shifter
Front Frame /
Tripod Center Leg
Front Roller
(free spinning side)
Front Frame /
Tripod Right Side Leg
Center Frame Locking Knob
Center Frame Connecting Q/R
Center Frame
Remote Cable
Magnetic Resistance Unit
Rear Roller
(driven side)
Rear Frame
How To Setup FG540
No Tool Required
Fully open all tripod
legs, and place on the
Confirm all legs
are fully opened.
Do not pinch
your finger when
closing the legs.
Rubber Cap
Flip out the retracted center frame, and place
on the floor.
Loosen the center frame locking knob to
prepare for sliding.
Connect the center frame to the tripod
center leg. Tighten the Q/R firmly.
Assembling FG540 is now finished.
Firmly tighten
the Q/R.
How To Adjust The Front Fork Support Height
Turn the knob lever counter-clockwise to loosen,
and pull up the front fork support.
The lever becomes free by pulling the lever. You can
set the lever at your favorite angle.
Slide down the fork mount until the stopper pin
reaches the front frame.
The stopper pin can be removed only while the fork
mount is lifted up.
Turn the knob lever clockwise and tighten
Insert the pin into the hole that corresponds best to
the incline you want.
Simulating Uphill Angle
Each hole corresponds to an angle that simulates
climbing. (based on a 700c wheel)
How To Use The 15mm Thru Axle
Required Tool : 3mm Hex Wrench (not included)
The front fork support is compatible with both the standard 9mm quick release
skewer and the 15mm thru type axle.
(The bottom side of the fork mount)
To use 15mm thru axle, remove the headless bolts under the sleeve guide end
in the fork mount (do not remove the normal bolts) and pull out both the red
adapter sleeve and the Q/R.
Align the front fork and the fork support hole, insert the 15mm axle to set the
front fork.
Make sure the bolt type you are going to remove.
Do not remove the standard bolt with head.
Adapter Sleeve (red)
How To Mount Your Bike
Remove the front wheel from your bicycle and set the front fork into the mount firmly.
Place the rear wheel on both rear rollers.
Slide and adjust the center frame position so that your rear tire contacts both rollers evenly.
Finally, tighten the center frame locking knob firmly.
The rear tire sits in the center of the
roller and doesn't touch any other parts.
Adjust the center frame position properly that the rear tire contacts both rollers.
If the tire touches the rear roller only and a clearance exists between the tire and the front
roller, the center frame repeats jumping while riding. Set the rear frame backward.
If the tire touches the front roller only, slippage occurs and it will bring premature tire wear.
Set the rear frame forward.
It's normal for the rear tire to sway or move back and forth slightly
when in use. As long as the tire doesn't touch the sides of the rollers
this is ok.
If you find the tire is not centered properly, loosen the center frame
locking knob and move the rear of the trainer to center the tire, then
tighten the knob again securely.
There is a guide bracket on the right side
tripod leg to hold the remote cable.
How To Operate Remote Shifter
Required Tool : 4mm Hex Wrench (not included)
FG540 comes with a convenient remote shifter device.
By installing it on your handlebar or stem, you can adjust the resistance
level in 13 levels without getting off the bike.
The plastic band is soft enough to fit aero-shaped carbon handlebar or
round shaped stem as well as the standard round dimension handlebars.
How to install the remote shifter
1) Loop the plastic band around the handlebar
2) Hook the tip to the edge on the plastic shifter base ①
3) Flip up the lever to lock ②
How to increase the resistance level
Twist the shifter dial toward "H" symbol
How to reduce the resistance level
Twist the shifter dial toward "L" symbol
"L" does not mean no resistance. Due to the tire contact
to the roller, there will still be some small resistance.
The remote shifter is pre-adjusted to fit the standard handlebar size;
22mm (7/8") diameter.
If it becomes loose or too tight, or you need to install the shifter onto an
oversized handlebar or stem, adjust the band length by turning the plastic
screw with an M4 hex wrench.
Do not overtighten the plastic screw. It will break
the plastic band. Release the hook before adjusting.
(red dot)
How To Adjust Cable Tension
Required Tool : 8mm Spanner (not included) x 2
4mm Hex
If you cannot shift at L or H position, it's time to adjust the cable tension.
1) Set the remote shifter lever at "H" position and straighten the cable.
2) Pull off the black plastic cap on foot of the cable, then the adjusting
screw with two lock nuts will appear.
3) While pushing the outer cable toward the shifter, push the adjusting
screw to the outer cable.
4) Turn the left side lock nut until it touches the Mag unit. You should
not overtighten the nut, otherwise you won't be able to set the shifter
at "L" position.
You must release the
hook for adjusting screw.
Adjust Screw
Lock Nut x 2
5) Turn the right side lock nut until it touhes the left side nut, then twist
the nuts each other to be locked as the method of "Double Nut".
6) Put the plastic cap over the screw again.
Turn the nut and tighten
FG540 ベルトテンション調整について
ベルトが弛んできたと思った時は矢印の 2 ヶ所のボルトを 4mm 六角レンチで緩め、負荷装置を前方に押し出
株式会社 箕浦
〒 503-2305 岐阜県安八郡神戸町神戸 1197-1 TEL (0584) 27-3131 / infodesk@minoura.jp
FG540 How To Adjust The Belt Tension
With normal use you may find that the roller belt has become loose. A loose belt could be a serious issue if
unattended. If you find the belt has become loose, it is important to tighten the tension on the belt correctly.
To do so, use an M4 hex wrench to loosen the previously mentioned bolts while sliding the mag unit
forward to increase the tension on the belt until the correct tension has been achieved.
1197-1 Godo, Anpachi, Gifu 503-2305 Japan / Web: www.minoura.jp / Mail: minoura@minoura.jp
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