Loss of Resistance – Spirit Recumbent Stepper

Loss of Resistance – Spirit Recumbent Stepper

Bulletin Number: SB-RS-001

Applies To Models: Spirit CS800S, MS300, MS350

Issue: Loss of resistance / inconsistent resistance control

Release Date: 04/01/2026

SUMMARY

This service bulletin outlines four (4) common resistance-related issues found in Spirit Recumbent Steppers and provides diagnostic procedures and corrective actions.

ISSUE 1: Resistance Level Changes on Console but No Actual Adjustment

Symptoms

• Resistance level changes on display

• Pedal tension present

• No increase or decrease in resistance

Possible Causes

• Broken resistance cable (Part #26)

• Faulty flywheel (Part #36)

Inspection Procedure

1. Remove outer casing.

2. Inspect resistance cable connection between motor and flywheel.

3. Adjust resistance from console while observing:

   • If motor pulls cable ? cable is functional

   • If cable moves but resistance does not change ? flywheel failure

Corrective Action

• Replace resistance cable (if damaged)

• Replace flywheel (if cable is functioning properly)

ISSUE 2: No Resistance Adjustment + E2 Error Code

Symptoms

• No change in resistance

• Console displays E2 motor error

Cause

• Failed resistance motor (Part #115)

Corrective Action

• Replace resistance motor assembly

ISSUE 3: No Resistance on One or Both Pedals (Free Movement)

Symptoms

• Pedal moves freely with little to no resistance

• Typically occurs on one side

Possible Causes

• Drive cable off track

• Broken drive cable (Part #23 – less common)

Inspection Procedure

1. Remove casing and inspect cable routing

2. Compare with opposite side (reference side)

Corrective Action

• Reinstall or replace drive cable

Cable Routing Guidelines

• Both sides are routed identically (ignore left/right orientation)

• Loosen tensioner (Bolt #150) fully before adjustment

• Wrap cable 3 times around Cable Drive Pulley (Part #40L / #40R)

  • Start: bottom left

  • Finish: top right

• Ensure proper seating in pulley grooves

Verification

• Operate unit for minimum 3 minutes

• Confirm cable remains properly seated

• Adjust tension if cable slips

ISSUE 4: Resistance in One Direction Only (Partial Engagement)

Symptoms

• Resistance present in one direction only

• Pedal does not free-spin

• Typically isolated to one side

Cause

• Failed one-way bearing in Cable Drive Pulley (Part #40L / #40R)

Corrective Action

• Replace Cable Drive Pulley

Important Installation Notes

• Bearings are directional – must match original orientation

• Note pulley direction before removal

• Bearings protrude on one side—use as reference

Right Side Pulley Warning

• Includes speed sensor decal

• Incorrect installation or damaged decal will result in:

  • No speed reading

  • No distance tracking

SERVICE PROCEDURE NOTES

• Always document cable routing before disassembly:

  • Take photos

  • Record short video of operation

• Use opposite side as routing reference

• Expect 1–2 open grooves on pulley after proper installation

• Always reset tension using Bolt #150 after reassembly

FINAL TESTING

After any repair:

• Operate unit under load for minimum 3 minutes

• Verify:

  • Smooth resistance changes

  • No cable slippage

  • Proper console feedback (speed, distance, resistance levels)

FIELD RELIABILITY NOTE

This platform has demonstrated high reliability with minimal failure rates across large service volumes. Most resistance issues are isolated to cable routing or wear components.

Complete Spirit Stepper Parts Listing