Schwinn Airdyne, AD6 Airdyne 6, Replacing the Connector Arm

This article guides you on how to replace the connector arm on a Schwinn Airdyne 6 exercise bike.

The connector arm does just as it is named. It connects the handlebar with the pedal crank. It allows the handlebar to move with the rotation of the pedal crank.

The steps to replace the connector arm are the same for both sides of the bike. The steps you take on the left side of the bike are the same steps you will take on the right side.

Tools Required:

• Phillips Screwdriver, #2
• Socket Wrench
• 14mm Socket
• 10mm Open-Face Wrench
• 4mm Hex Wrench
• 6mm Hex Wrench
• Spindle Service Kit, OEM parts 8001474 or 1000511185

Procedure:

1. You will begin by removing the crank arm and pedal assembly on the side being serviced. The 14mm socket and wrench will work to remove the largest crank screw. This screw goes through the crank arm. The 4mm hex wrench removes the two smaller screws in the crank plate. Support the crank arm during removal of the hardware to prevent the arm from falling.
   Note: The crank cover will be loose inside the shroud until you complete the next step.
2. Remove the shroud and crank cover. You will need the screwdriver to remove six screws. There are two screws at the front top of the shroud near the fan. There are four, self-tapping screws. There are two at the top of the shroud. One is midway and the other is toward the rear, above the crank arm. The other two are at the bottom of the shroud. One is midway and the other is toward the rear, below the crank arm.
3. The shroud and crank cover can now be removed to expose the connector arm. Set the covers and their hardware aside for reassembly. Note the 4 self-tapping screws.
4. Remove the foot peg with the 6mm hex wrench. Remove the screws connecting the foot peg to the handlebar. Support the foot peg while removing the hardware to prevent it from falling.
5. Remove the handlebar from the arm pivot assembly and set it aside for reassembly.
6. Place a piece of material such as cardboard or a cloth rag, below the connector arm, to protect the flooring.
7. Remove the bolt that connects the arm pivot assembly to the connector arm. You will need the 14mm socket and wrench.
8. Remove the connector arm from the arm pivot assembly.
9. Lock the Fan. Push and turn the locking knob of the fan until the fan is locked and the knob is fully engaged.
10. Using the spindle service kit, attach the plate in the kit to the connector arm with the two screws included in the kit. Tighten only until the hardware is snug.
11. You will need the 10mm wrench. Gradually tighten the hardware making equal turns between the two screws. Continue tightening with equal turns to each screw until the connector arm pops off.
    Note: Keep the area below the connector arm clear aside from the material placed to protect the floor. The connector arm will fall. Do not try to catch the arm. Let it fall.
12. You will need the 10mm wrench to remove the hardware holding the removal plate onto the old connector arm.
13. Reattach the old connector arm or install the new connector arm. You will need the 14mm socket with the wrench, the spacer included in the spindle service kit, and the large crank arm bolt you removed in the beginning. Insert the large screw with the spacer into the connector arm.
14. Tighten the screw with the spacer until it is completely tight.
15. After the screw with the spacer is fully tight, remove the screw and spacer from the connector arm.
16. Unlock the fan. Push and turn the locking knob until the fan is released and the knob is no longer engaged.
17. Reattach the connector arm to the arm pivot assembly.
18. Reinstall the bolt that connects the arm pivot assembly to the connector arm. Tighten with the 14mm socket and wrench.
19. Reinstall the handlebar onto the arm pivot assembly.
20. Apply the foot peg in its place between the handlebar and the arm pivot assembly and install the two screws with the 6mm hex wrench. Tighten the hardware.
21. Reinstall the crank cover and shroud. You will need the six screws and screwdriver to install the shroud. There are two screws at the front top of the shroud near the fan. There are four self-tapping screws. There is one midway along the top and another toward the rear of the bike above the crank arm. The last two are on the bottom of the shroud. One is midway and the other is located toward the rear below the crank arm.
22. Reinstall the crank arm and pedal assembly. Before installing any hardware, check to ensure that the crank arm, crank cover, and connector arm are all properly aligned. If you are confident of part alignment, install the large screw with the 14mm socket and wrench. Install the two smaller screws with the 4mm hex wrench. Tighten hardware.
23. Check bike performance and operation.

This completes the steps on how to replace the connector arm on a Schwinn Airdyne 6, AD6 exercise bike.