Keys Fitness Bicycle Discovery 60R User Manual

6.0R  
OWNER’S MANUAL  
QUESTIONS?  
Call Our Toll Free  
Keys Fitness Helpline  
1-888-340-0482  
CAUTION!  
Please read the precautions and instructions in this manual before  
using this equipment. Please save this manual for future reference.  
 
Before You Start  
Thank you for purchasing a Discovery exercise bicycle!  
This quality product you have chosen was designed to  
meet your needs for cardiovascular exercise.  
Prior to assembly, remove components from the box and  
verify that all the listed parts were supplied. Assembly  
instructions are described in the following steps and illustra-  
tions.  
Important Safety Information  
WARNING!  
1) Before using this exercise bicycle or starting any exer-  
cise program, consult your physician. This is especially  
important for persons over the age of 35 and/or persons  
with pre-existing health problems. Keys Fitness Products  
LP assumes no responsibility for personal injury or prop-  
erty damage sustained by or through the use of this  
product.  
2) To reduce the risk of electrical shock, burns, fire or other  
possible injuries to the user, it is important to review  
this manual and the following precautions before opera-  
tion.  
1
 
Safety Precautions and Tips  
It is the owner's responsibility to ensure that all users of this  
exercise bike have read the Owner's Manual and are famil-  
iar with warnings and safety precautions.  
• This exercise bike has a maximum user capacity of 300  
pounds.  
• The HealthTrainer Exercise Bike should only be used on a  
level surface and is intended for indoor use only. It should  
not be placed in a garage, patio or near water. Keys rec-  
ommends an equipment mat be placed under the bicycle  
to the protect the floor or carpet and for easier cleaning.  
• Wear comfortable, good-quality walking or running shoes  
and appropriate clothing. Do not use this exercise bike  
with bare feet, sandals, socks or stockings!  
• Always examine your exercise bike before using to ensure  
all parts are in working order.  
• Do not leave children unsupervised near or on the exer-  
cise bicycle.  
• Never operate the exercise bicycle where oxygen is being  
administered or where aerosol products are being used.  
• Never insert any object or body parts into any opening.  
• Service to your Discovery Exercise Bike should only be  
performed by an authorized service representative, unless  
authorized and/or instructed by a Keys technician. Failure  
to follow these instructions will void the warranty.  
2
 
Assembly of Discovery  
6.0 Recumbent Bike  
REMOVE ALL SECURITY TAPE AND  
WRAPPING BEFORE BEGINNING  
1. Attach front foot tube (27) to frame (1) using:  
Qty 2 - (37) Carriage Bolt  
Qty 2 - (39) Flat Washer  
Qty 2 - (54) Cap Nut  
3
 
2. Connect back pad to seat support bracket using:  
Qty 4 - Allen Head Screw  
Connect seat pad to seat support bracket using:  
Qty 4 - Allen Head Screw  
4
 
3. Attach handlebar to seat support bracket using:  
Qty 2 - (53) Button Head Screw  
Qty 2 - (39) Flat Washer  
Qty 2 - (41) Locknut  
5
 
4. Attach rear foot tube to the main frame as pictured  
above.  
6
 
5. Attach pedals (35, 36). Axles of pedals are branded “L”  
and “R.” The pedal marked “R” goes on the right hand  
side of the bike and the one marked “L” on the left hand  
side. Tighten the left pedal by turning counter-clockwise  
and the right pedal by turning clockwise.  
7
 
6. Slide seat carriage onto seat carriage tube and secure  
with cam lock as pictured above.  
Connect seat carriage tube to main frame using:  
Qty 3 - (33) Button Head Screw  
Qty 3 - (39) Flat Washer  
8
 
7. Attach wires in main frame to those in the console tube  
then secure console tube to main frame.  
Secure front handlebar to console tube and pull hand  
pulse wires up through the top of the tube.  
Attach wires to back of console then secure to top of  
console tube with screws.  
9
 
8. Insert 4 “D” size batteries into the back of the console.  
10  
 
DCV6.0R EXPLODED VIEW  
11  
 
DCV6.0R PARTS LIST  
#
1
2
3
4
5
6
7
8
9
PART  
Frame  
QTY  
1
1
1
1
8
1
1
2
2
2
1
1
4
1
2
2
2
2
1
1
1
1
1
1
1
1
1
6
1
1
2
2
1
2
1
7
1
1
1
4
6
#
PART  
QTY  
15  
1
2
2
2
1
18  
1
1
1
1
1
1
1
1
1
1
2
2
1
4
1
1
1
1
4
1
1
3
2
2
1
1
39 M8x18.8mm Flat Washer  
39a Spacer  
40 1” Ball Plug  
40a Hand Pulse  
Seat Cushion  
Back Cushion  
Monitor  
M6x1x12 Long Allen Head Screw  
Mag Brake  
Crank Washer  
Sleeve  
Bearing Cup  
41 M8 Locknut  
42 Idler Pulley Bearing  
43 M4x16mm Sheet Metal Screw  
44 Seat Handlebar  
44a Handlebar  
45 M6x1 Locknut  
46 Cam Lock  
47 Magnet  
48 Sensor Wire  
49 Console Tube  
10 Bearing  
11 Crank  
12 Pulley  
13 M6x1x10mm Machine Screw  
14 “V” Belt  
15 M10x1 Cap Nut  
16 10mm IDx22mm OD Washer  
17 Eyebolt  
18 Adjustment Channel  
19 Belt Tension Bracket  
20 Spring  
50 Notched Bearing Nut  
50-1 Slotted Bearing Nut  
51 Crank Washer  
52 M5x8 Hex Nut  
53 M8x45mm Button Head Screw  
53a M8x38mm Button Head Screw  
54 M8x1.25 Cap Nut  
55 Crank Nut  
56 Owner’s Manual  
57 2” Square Cap  
21 Idler Pulley  
22 Bottom Front Right Cover  
22a Bottom Rear Right Cover  
23 Bottom Front Left Cover  
23a Bottom Rear Left Cover  
24 Top Right Cover  
25 Top Left Cover  
26 M4x12mm Sheet Metal Screw  
27 Front Foot Tube  
27a Rear Foot Tube  
28 Wheel  
58 Gear Box  
59 M5x20 Button Head Screw  
60 Rear Support Tube  
61 Gear Box Plate  
62 M3.5x15mm Sheet Metal Screw  
63 Hand Pulse Wire  
64 Sleeve  
65 Connecting Right Cover  
66 Connecting Left Cover  
67 Eyebolt  
68 Adjustment Channel  
69 6mm Hex Nut  
70 M5x50mm Sheet Metal Screw  
71 Extension Wire  
29 Foot Cap  
30 Seat Carriage  
31 M5x8x70 Screw  
32 M6x1x20 Screw  
33 M8x15 Button Head Screw  
34 Seat Support Bracket  
35 Left Pedal  
36 Right Pedal  
37 M8x1.25x60mm Carriage Bolt  
38 M6x1 Nut  
2
2
2
2
1
1
1
72 Extension Sensor Wire  
73 Gear Box Wire  
12  
 
Monitoring Your Heart Rate  
To obtain the greatest cardiovascular benefits from your  
exercise workout, it is important to work within your target  
heart rate zone. The American Heart Association (AHA)  
defines this target as 60%-75% percent of your maximum  
heart rate.  
Your maximum heart rate may be roughly calculated by  
subtracting your age from 220. Your maximum heart rate  
and aerobic capacity naturally decreases as you age. This  
may vary from one person to another, but use this number  
to find your approximate effective target zone. For example,  
the maximum heart rate for an average 40 year-old is 180  
bpm. The target heart rate zone is 60%-75% of 180 or 108-  
135 bpm. See Fitness Safety on page 14.  
Before beginning your workout, check your normal resting  
heart rate. Place your fingers lightly against your neck, or  
against your wrist over the main artery. After finding your  
pulse, count the number of beats in 10 seconds. Multiply  
the number of beats by six to determine your pulse rate per  
minute. We recommend taking your heart rate at these  
times; at rest, after warming up, during your workout and  
two minutes into your cool down, to accurately track your  
progress as it relates to better fitness.  
During your first several months of exercising, the AHA rec-  
ommends aiming for the lower part of the target heart rate  
zone-60%, then gradually progressing up to 75%.  
According to the AHA, exercising above 75% of your maxi-  
mum heart rate may be too strenuous unless you are in top  
physical condition. Exercising below 60% of your maximum  
will result in minimal cardiovascular conditioning.  
13  
 
Check your pulse recovery rate – If your pulse is over 100  
bpm five minutes after you stop exercising, or if it’s higher  
than normal the morning after exercising, your exertion may  
have been too strenuous for your current fitness level. Rest  
and reduce the intensity next time.  
Fitness Safety The target heart rate chart indicates aver-  
age rate zones for different ages. A variety of different factors (including  
medication, emotional state, temperature and other conditions) can  
affect the target heart rate zone that is best for you. Your physician or  
health care professional can help you determine the exercise intensity  
that is appropriate for your age and condition.  
(MHR) = Maximum Heart Rate  
(THR) = Target Heart Rate  
220 - age = maximum heart rate (MHR).  
MHR x .60 = 60% of your maximum heart rate.  
MHR x .75 = 75% of your maximum heart rate.  
For example, if you are 30 years old, your  
calculations will be as follows:  
220 - 30 = 190  
190 x .60 = 114 (low end or 60% of MHR)  
190 x .75 = 142 (high end or 75% of MHR)  
30 year-old (THR) Target Heart Rate would be 114-142  
See Table on page 16 for additional calculations.  
14  
 
TARGET HEART RATE ZONE  
200  
195  
190  
100%  
185  
180  
175  
170  
165  
160  
Serious  
athletic  
training range  
155  
132  
85%  
170  
166  
162  
157  
153  
149  
145  
140  
136  
Cardiovascular  
conditioning  
range  
150  
146  
75%  
143  
139  
135  
131  
128  
124  
120  
Fat burning  
range  
116  
93  
60%  
120  
117  
114  
111  
108  
105  
102  
99  
96  
20  
25 30  
35 40 45  
50 55 60 65  
AGE  
15  
 
CONSOLE INSTRUCTIONS  
OPERATING CONSOLE: (After the computer is powered  
on with batteries installed)  
Step One  
You may use UP or DOWN to select training  
mode in MANUAL or PROGRAM (12 different  
profiles) or USER or TARGET HEART RATE  
control (4 different options for training). If you  
select training with Target Heart Rate control  
mode, you need to input AGE data, and  
switch to next procedure.  
Step Two  
You may use UP or DOWN to adjust the  
training LOAD/DIFFICULTY level from 1 to 16  
under MANUAL, PROGRAM and USER  
mode. (Excludes TARGET HEART RATE  
CONTROL mode)  
Step Three You may use UP or DOWN to preset training  
function data. Once each function data has  
been set, press MODE/ENTER.  
Available preset training functions:  
TIME:  
Preset number is from 00:00 to 99:00,  
each increment is 1:00 (minute).  
DISTANCE: Preset number is from 0.00 to 99.90,  
each increment is 0.10 km or ml.  
CALORIE: Preset number is from 0 to 990, each  
increment is 10 calories.  
PULSE:  
Preset number is from 30 to 240, each  
increment is 1 BPM. (Excluded in  
TARGET H.R control mode)  
Step Four  
Press START/STOP button to start training.  
16  
 
TRAINING MODE INSTRUCTION: To start your training  
As soon as you press START/STOP button, the computer  
starts working:  
Training with PRESET TIME:  
If you have a preset TIME, each unit of the workout  
profile switches forward to another unit per preset  
TIME divided by 16.  
Training without preset time:  
If you do not preset TIME, each unit of the workout  
profile switches forward to another unit per 0.1 km or  
ml in counting up (no preset DISTANCE) or counting  
down (has preset DISTANCE).  
Tension difficulty adjustment:  
Training in MANUAL - You may adjust the tension load from  
1 to 16 during training.  
Training with 12 profiles - You can adjust the tension  
difficulty during training any time.  
Training in TARGET H.R. control - The tension difficulty will  
be auto-adjusted according to the current heart rate  
figure. If your heart rate figure is under the target  
pulse, the tension difficulty will be up-adjusted one  
level per 30 seconds, up to the maximum level. As  
soon as your heart rate figure is achieved at the  
target pulse, tension difficulty will be down-adjusted  
one level immediately, and keep down-adjusting one  
level per 15 seconds until level 1. If your current  
heart rate is still over (or equal to) the target  
pulse for 30 seconds when tension is level 1, the  
computer system will STOP and ALARM for 6 beeps  
to alert you for training protection.  
17  
 
To stop your training:  
Training with PRESET function datas:  
As soon as the preset function data counts down to  
zero,(pulse figures excluded) the computer has 8  
beep sounds to alert you. At this moment, the  
computer will stop working. You may press  
START/STOP button to start the computer working  
and counting up from the previous data.  
Interupt training:  
You may press START/STOP button to stop the  
computer during training at any time.  
To reset program:  
You may press RESET button to reset the  
PROGRAM and select the training mode and  
tension load or difficulties under STOP mode. If you  
hold on pressing the RESET button for 2 seconds, all  
data (including personal data) will be reset.  
BUTTON FUNCTIONS:  
START/STOP  
MODE  
To start or stop training.  
To select each function of Time,  
Distance and Pulse.  
UP  
DOWN  
RESET  
To increase data or tension.  
To decrease data or tension.  
1. To reset each function of Time,  
Distance and Pulse figures.  
2. To reset program setting and back to  
initial selection mode with Manual,  
Program, User or Target Heart Rate  
(all blinking display).  
RECOVERY  
Press the button to activate heart rate  
recovery function.  
18  
 
FUNCTIONS:  
TIME  
Count Up - The computer starts counting up  
from 00:00 up to 99:59 during training.  
Count Down - The computer will count down  
from the preset Time to 00:00.  
SPEED  
Displays the current SPEED from 0.0 to  
maximum 99.9 km or ml.  
DISTANCE Count Up - The computer accumulates total  
workout distance from 0.00 to max 99.90 km  
or ml during training.  
Count Down - The computer will count down  
from the preset Distance to 0.00.  
CALORIES Count Up- The computer accumulates the  
calorie comsuption from 0 to max 990 cal  
during training.  
Count Down - The computer will count down  
from the preset Calories to 0.  
This data is a rough guide for comparison of  
different exercise sessions and can not  
be used for medical treatment.  
PULSE  
The heart rate figure displays with the symbol  
flashing on the bottom field after you hold on  
the grips with both hands. The heart rate  
figure displays a range from 0 to 240 BPM.  
You may preset target pulse to assist in your  
training. The options you have are as follows:  
Alarm - If you preset the target pulse while  
training with Manual or 4 profiles, then the  
computer will alarm to remind as soon as your  
current heart rate is achieved at the preset  
figure.  
19  
 
Load tension adjustment - If you are training  
with one of the four target pulse percentages,  
then the load tension difficulty will be  
controlled by your current heart rate figure  
compared with the preset target.  
RECOVERY After exercising for a period of time, keep  
holding on grips and press "RECOVERY"  
button, all function displays will stop except  
"Time". Time starts counting down from 00:60  
- 00:59 - 00:58 - to 00:00. As soon as 00:00  
is reached, the bottom area of the LCD will  
show your heart rate recovery status with the  
grade F1, F2,… F6. F1 is the best, and F6 is  
the worst. You may keep exercising to improve  
the heart rate recovery status day by day from  
F6 up to F1.  
** Press the RECOVERY button again to  
return to the main display.  
NOTE:  
1. When no signal has been transferred into the computer  
for 4 minutes, the LCD display will shut off automatically  
and all previous training data will be stored. You may press  
any button to have the computer restart working.  
2. You may change monitor calculation to KM or ML scale  
by pushing the switch fixed on the back of the console.  
3. If the LCD display is improper, please remove the  
batteries and reinstall again.  
4. The monitor can be powered on with 4 D size batteries.  
20  
 
KEYS FITNESS PRODUCTS, LP -  
LIMITED WARRANTY  
PRODUCT:  
HOME USE WARRANTY:  
DISCOVERY 6.0 RECUMBENT BIKE  
Frame: 2 Years, Parts: 1 Year, Labor: None  
This Limited Warranty applies in the United States and Canada to products manufactured or distributed by Keys  
Fitness Products, LP (“Keys”) under the KEYS brand name. The warranty period to the original purchaser is listed above  
in the table.  
Keys warrants that the Product you have purchased for use from Keys or from an authorized Keys reseller is free  
from defects in materials or workmanship under normal use during the warranty period. Your sales receipt, showing the  
date of purchase of the Product, is your proof of purchase. This warranty only extends to you, the original purchaser. It is  
not transferable to anyone who subsequently purchases the Product from you. It excludes expendable parts (wear items).  
Wear items pertain to components that might need to be replaced due to normal wear and tear. These items vary per  
product but will include computer overlays, pedal straps, rope cords, seats, grips, chains, bottom bracket assemblies,  
pads, upholstery, pulleys, bearings, etc. Please contact a Keys Fitness customer service representative for specifics on  
wear items. This Limited Warranty becomes VALID ONLY if the product is purchased through a Keys Fitness authorized  
dealer unless otherwise authorized by Keys Fitness in writing.  
During the warranty period Keys will repair or replace (at Keys' option) the product if it becomes defective, malfunc-  
tions, or otherwise fails to conform with this Limited Warranty under normal use. In repairing the Product, Keys may  
replace defective parts, or at the option of Keys, serviceable used parts that are equivalent to new parts in performance.  
All exchanged parts and Products replaced under this warranty will become the property of Keys. Keys reserves the  
right to change manufacturers of any part to cover any existing warranty.  
This warranty DOES NOT COVER shipping charges, export taxes, custom duties and taxes, or any other charges  
associated with transportation of the parts or Product.  
To obtain warranty service, you must contact a Keys authorized retailer, service technician or Keys Fitness at our  
phone numbers located in this manual. Any parts determined to be defective must be returned to Keys to obtain warran-  
ty service. You must prepay any shipping charges, export taxes, custom duties and taxes, or any other charges associat-  
ed with transportation of the parts or Product. In addition, you are responsible for insuring any parts or Product shipped  
or returned. You assume the risk of loss during shipment. You must present Keys with proof-of-purchase documents  
(including the date of purchase). Any evidence of alteration, erasing or forgery of proof-of-purchase documents will be  
cause to void this Limited Warranty.  
This warranty does not extend to any product not purchased from Keys or from an authorized Keys reseller. This  
Limited Warranty does not extend to any Product that has been damaged or rendered defective; (a) as a result of acci-  
dent, misuse, or abuse; (b) by the use of parts not manufactured or sold by Keys; (c) by modification of the Product or  
normal wear and tear; (d) operation on incorrect power supplies; or (e) as a result of service by anyone other than Keys,  
or an authorized Keys warranty service provider. Product on which the serial number has been defaced or removed is  
not eligible for warranty service. Should any Product submitted for warranty service be found ineligible, an estimate of  
repair cost will be furnished and the repair will be made if requested by you upon Keys' receipt of payment or acceptable  
arrangements for payment.  
EXCEPT AS EXPRESSLY SET FORTH IN THIS WARRANTY, KEYS MAKES NO OTHER WARRANTIES, EXPRESSED  
OR IMPLIED, INCLUDING ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR  
PURPOSE. KEYS EXPRESSLY DISCLAIMS ALL WARRANTIES NOT STATED IN THIS LIMITED WARRANTY. ANY  
IMPLIED WARRANTIES THAT MAY BE IMPOSED BY LAW ARE LIMITED TO THE TERMS OF THIS LIMITED WAR-  
RANTY. NEITHER KEYS NOR ANY OF ITS AFFILIATES SHALL BE RESPONSIBLE FOR INCIDENTAL OR CONSE-  
QUENTIAL DAMAGES. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY  
LASTS OR THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE  
LIMITATIONS OR EXCLUSION MAY NOT APPLY TO YOU. This Limited Warranty gives you specific legal rights and  
you may also have other rights that may vary from state to state. This is the only express warranty applicable to Keys-  
branded products. Keys neither assumes nor authorizes anyone to assume for it any other express warranty.  
PLEASE SEND IN THE ATTACHED WARRANTY CARD WITHIN TEN (10) DAYS OF PURCHASE TO REGISTER  
YOUR UNIT WITH KEYS FITNESS PRODUCTS, LP.  
MAIL WARRANTY CARD TO:  
KEYS FITNESS PRODUCTS, PO BOX 551239, DALLAS, TX 75355  
 
Keys Fitness Products, L.P.  
4009 Distribution Dr.  
Suite 250  
Garland, Texas 75041  
 

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