RSX1500 Step-by-Step Assembly Instructions
1. Console Mast and Stabilizers
Hardware Needed for This Step:
a. Use the Allen wrench (#131) to tighten both front and rear stabilizers (#12, #13) with four socket head cap bolts (#100), four split washers (#98) and four flat washers (#99).
b. Connect the computer cable (#21) and hand pulse wire (#26) in the console mast (#2) with the wires from the main frame before you slide the console mast onto the main frame. Be careful not to pinch any of the wires during this step.
c. Insert the console mast (#2) onto the main frame (#1) and use the Allen wrench (#131) to tighten with four socket head cap bolts (#100), four flat washers (#99), five split washers (#98) and one curved washer (#101).
d. Connect the console (#19) with the computer cable (#21) and hand pulse wire (#26) to the console mast (#2) and use the combination M5 Allen wrench & Phillips head screw driver (#130) to secure with four Phillips head screws (#81).
2. Right Swing Arm
Hardware Needed for This Step:
a. Insert the handgrip axle (#76) to slide through the lower handlebar (R, #6) and use the Allen wrench and Phillips head screw driver (#130) to secure with button head socket bolt (#112), split washer (#98) and flat washer (#99).
3. Upper Swing Arms
Hardware Needed for This Step:
a. Slide lower handlebar (L, #5) through the handgrip axle (#76, refer to assembly Step Two) and use the Allen wrench & Phillips head screw driver (#130) to tighten one button head socket bolt (#112) and one split washer (#98) and one flat washer (#99) and tighten each other.
b. Install the front handlebar cover (#38) and rear handlebar cover (#39) on the right and left lower handlebar (#6, #5) with eight sheet metal screws (#96) by using the Allen wrench & Phillips head screw driver (#130).
4. Lower Crank Arms and Pedals
Hardware Needed for This Step:
a. Make sure that the powder metallurgy bushings (#42) are to be mounted on the crank arm (#15) before assembly.
b. Join the pedal bar assembly (#10) with the crank axle and use the Allen wrench & Phillips head screw driver (#130) to secure with four button head socket bolts (#112), four flat washers (#99) and four split washers (#98).
c. Use the wrench (#129) to tighten the pedal (#62) on the lower handlebar.
5. Sliding Seat, Handlebar, and Seatback
Hardware Needed for This Step:
a. Install the seat (#65) on sliding seat assembly and use the Allen wrench & Phillips head screw driver (#130) to secure with four Phillips head screws (#106).
b. Install the handlebar (#7) on the sliding seat assembly by using the Allen wrench (#131) to tighten four button head socket bolts (#92), going through the handlebar (#7) and four flat washers (#93), then use the wrench (#129) to tighten four Nyloc nuts (#94).
c. Install the seat back fixing plate (#16) on the handlebar (#7) by using the Allen wrench (#131) to tighten two button head socket bolts (#95), going through the handlebar (#7) and two flat washers (#93), then use the wrench (#129) to tighten two Nyloc nuts (#94).
d. Install the seat back (#64) on the seat back fixing plate (#16) and use the Allen wrench & Phillips head screw driver (#130) to tighten with four Phillips head screws (#97) and four flat washers (#89) to secure the seat back fixing plate (#16) then with seat back cover (#56).
e. Connect the lower and upper hand pulse wires (#27, 26).
6. Seat Adjustment Lever
a. Use the Allen wrench (#130) to loosen the flat head socket screws (#105) from the seat assembly (#18).
b. Detach the lever (#78) from the plastic tie that secures the handle for shipping. Move out the lever (#78) from seat assembly (#18). DO NOT CUT OR DETACH THE METAL WIRE ON THE END OF THE LEVER.
c. Turn the lever (#78) and lever anchor (#44) to 90 degrees (as seen in diagram) so the anchor can slide into the seat assembly (#18) with the holes aligned.
d. Use the Allen wrench (#130) to secure the flat head socket screws (#105), on the seat assembly (#18).