HIITMill (X) Brake Lever Drift Applies to: HIITMill (9-4590) + HIITMIll X (9-4640) On some HIITMill and HIITMill X units, the brake lever can drift when the user is Rev. A applying load to the belt. This is due to the force between the flywheel and the magnets pulling the magnets toward the flywheel. To correct this, some hardware inside the brake lever assembly will need to be replaced. Tools Required: 3mm Allen Key 4mm Allen Key 8mm Combination Wrench (x2) 10mm Combination Wrench (x2) 8mm Socket Torque Wrench Needle Nose Pliers 715-4073-KT HIITMill Brake Lever Rebuild Kit 1. Using a 3mm allen key, remove the two (2) screws securing the lever covers to the frame then remove the lever covers. 2. Carefully pull the brake lever assembly out of the frame. Page 1
3. Use the 10mm wrenches to loosen the two hex nuts on the brake cable. 4. Disconnect the brake cable from the lever assembly by first rotating the level assembly forward until it is perpendicular to the brake cable. 5. After rotating the level assembly, slide the lever assembly back so that the brake cable pin comes loose from the lever assembly. Page 2
6. With the level assembly free, use the 8mm wrenches to remove ONE of the 5mm hex head screws then slide the other screw and attached lever axle out from the other side. Discard the loose hex head screw and washer. If both screws begin to come free from the lever axle, remove and discard both screws. NOTE: DO NOT discard the lever axle as this will be reused at a later step. 7. Remove the lever from the lever housing. 8. Remove the two (2) polymer IGUS bushings and replace with the IGUS bushings contained in 715-4073-KT. Page 3
9. Remove the two (2) metal thrust washers and replace them with the Delrin washers contained in 715-4073-KT. 10. Reinsert the lever into the lever housing then insert the screw and lever axle so that is passes through the IGUS bushings replaced in Step 8 and the Delrin washers replaced in Step 9. Finally, apply a drop of Loctite #243 to the new hex head screw from 715-4073-KT and secure the screw into the other side of the lever axle using a torque wrench, torque to 45 in-lb (5.1 NM). NOTE: If both screws came loose from the lever axle in Step 6, they will both need to have Loctite applied and torque values applied as described above. 11. Once the lever assembly has been reassembled, follow Steps 1-5 in reverse to reinstall the lever assembly into the frame. Ensure that the lever assembly cutouts face the front of the machine and that the red stop portion of the lever shroud decals is facing the rear of the machine. Page 4
12. Remove the three (3) screws securing the brake shrouds to the frame then remove the brake shrouds. 13. Pull the resistance lever towards the rear of unit so that maximum resistance is applied then check to ensure that the rubber brake pad is contacting the edge of the flywheel. If the rubber pad is resting on the edge of the flywheel, replace the shrouds that were removed in Step 12, this will conclude the instructions, otherwise proceed to the next Step 14. 14. Use a 4mm allen key to loosen the brake wire tension screw then use a pair of needle nose pliers to pull the brake wire so that it is under tension. Finally tighten the wire tension screw while continuing to provide tension on the brake wire. NOTE: The belt has been removed to show clarity. Page 5