Repairing the Lifecycle 5000

One of the stranger things of modern life is that the more stuff we get, the more stuff breaks. Yet the TV repairman is nearly out of business. Many things can only be repaired in distant specialty shops. And some of it is hard to transport -- getting an exercise bike out of the basement, into an SUV/pickup, dropped off, picked up, etc. is a lot of work. If I were looking for a small business for a mechanically/electrically inclined high school student, exercise equipment repair would be ideal.

So here's my Lifecycle 5000 story. The first computerized bike with variable resistance (though only one resistance program). Built for gyms, lasts forever. Doesn't require electrical power -- everything is powered by the alternator you're driving by pedal. Bought it used in 1997. Stopped working in 2001 (dead battery). From 2000 on, had problems where after 5 minutes or so, "surges" would occur requiring intense peddling far beyond normal to keep going.

1) Get to know National Gym Supply. They are your friend. The manufacturer could care less about individuals. NGS is tuned to small gyms, but they'll work with you. They provide phone technical support for troubleshooting -- not always the best help, but beats banging your head against a wall. They also offer exchange service, so you can have both your old and new parts on hand and really determine if the old part is broken. And a good catalog. Other sources have fewer parts at pretty much the same price.

2) Replace the battery ($25). That's their first advice. It may be wrong. I'd already replaced it in 2001. If you don't have a high enough battery voltage, the field won't flash on the alternator, thus power won't be produced at the right voltage. Being off a volt or two can cause a range of tricky problems and behavior. But if you can get "correct" behavior (select time, select level, pedal a couple of minutes) its not a battery problem. If the battery is below field flash voltage, you can't recharge it. Unless you flash the field with an external battery (one for power tools worked well for me)

3) Replace the alternator control board ($55). The "difficulty" of pedaling is controlled by adding artificial load to the alternator. The more power you're producing, the tougher it is to pedal. The ACB "bleeds" power through the huge honking resistor attached and has a circuitry to control the amount of power. Seems like the culprit, but its not. If this had failed you would likely see no change in perceived resistance, or a consistent increase.

4) Replace the alternator ($85). Interesting job -- get out your muscle wrenches. Ultimately, this fixed the problem. The alternator produces power based on the load applied. Once the power got beyond a certain level, the damaged brushes couldn't carry enough power, thus resistance increased exponentially trying to "force" the extra power demanded. Requires removal of the crank which requires a bearing puller (available at any auto parts store). There's a funny looking thing that looks like a setscrew on the crank -- ignore it -- just pull it off. If you could figure out another application of the same alternator, you could probably get it cheaper somewhere else.

5) Replace the alternator brush ($10.50). Probably an easier solution. I'd already bought the alternator so was committed. But on further reflection, probably would have solved the problem. No evidence of a general alternator problem, just a problem handling high power. And brushes are the wearable part.

Comments

[Dave Warde]

Do you know how to access the diagnostic/configuration mode on the LifeCycle 5000? I love this bike and have recently done a partial overhaul. But there is a program limit on the ride - 12 minutes max which has always frustrated me.

Found instructions on Nat Gym Supply for the 9500 which were close enough to get me into diagnostics, but I could not figure out how to change the Program Duration.

Thanks

[Mike Bianculli]

I have the same problem with my 5000, only my workout duration can't get past 6 min. Are you sure there is programming involved and not a keypad problem?

[Chris]

Anybody know where one can purchase replacement brushes (for a LifeCycle 5500)?
Thanks everyone.
Chris

[George Yates]

Hi - loved your LifeCycle story. I have the same one - Model 5000. Your story inspired me to fix mine. I purchased a battery online for $27. And now it works fine! Any idea where I could get my hands on a owners manual? I've had no luck finding a PDF manual anywhere online!

Thanks,

George

[Brett Everett]

When I pedal on Lifecycle 5000 and push start, resistance gets very strong and buzzer stays on. Tried replacing battery with no success. Any suggestions?

[Mary Kay]

Any response to George Yates' question about an owners manual? I just got a Lifecycle 5000 without ANY information and I have absolutely no idea how to even begin to program it or use it. Any help or assistance would be immensely appreciated!! Thanks!

[Ray Laska]

I have a LifeCycle 5500. The bearings are shot.
How do I take that apart and where can I get parts.
Thanks. Ray Laska

[Larry]

I have a LifeCycle 5500 that I bought in 1997. Bike has been great for 11 years, but just recently started "slipping" when the resistance is heavy and I am peddling hard. If I back the resistance down it doesn't happen as much. It is progressively getting worse. It is almost as if the chain or crank slips. Anybody know how to fix this?

[Tammy Quattlebaum]

My pedal straps broke. Does anyone know where to get them for a LifeCycle 5500?

[Paul]

Does anyone have an Owners manual for the Life Cycle 5500? I lost mine and cannot find anything online.

[Jim Lockbaum]

Looking for Lifecycle5500 owners or users manual. Anyone???? Please send responsed to [email protected]. Love this bike, just need to learn how to program some settings. Thanks. I will pay for any kind of copies, someone has to have a manual. Please help

[Patty Dolan]

My Lifecycle 5500 was purchased in 1996 but until 7 months ago, it was not used more than 3 months. For the last 7 months, I have been riding it 99 minutes almost every day. Three days ago, the pedals began slipping about every couple minutes when I am on manual setting level 4 but not nearly as often when on level 3. I love this bike and would love to try to troubleshoot myself. Does anyone have any suggestions?
Patty

[Joyce Musselman]

I have a Lifecycle 5000 that was given to me. It does not work. I was told that the battery just needed to be charged but I can not find a charger adapter anywhere!! The battery required is 8 volt, 2.5 amp. I called Lifecycle and they require a serial number before they can help me. The strip that looks like it would contain the serial number is worn away. Any pointers on where else I might find the serial number?

Thanks.

[Bob]

I need a control panel for my Lifecycle 5500. Does anyone know where i can get one?