Keys Fitness Home Gym 52 Hybrid User Manual

5.2 HYBRID  
OWNER’S MANUAL  
QUESTIONS?  
Call Our Toll Free  
Keys Fitness Helpline  
1-888-340-0482  
315-00028  
06/05 Rev B  
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 unit! 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 illustrations.  
Important Safety Information  
WARNING!  
1) Before using this exercise bicycle or starting any exercise 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 property  
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 impor-  
tant to review this manual and the following precautions before operation.  
It is the owner's responsibility to ensure that all users of this exercise bike have read the Owner's  
Manual and are familiar with warnings and safety precautions.  
• This exercise bike has a maximum user capacity of 250 pounds.  
• The Discovery exercise unit 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 recommends an equipment  
mat be placed under the unit 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 exercise unit.  
• 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 unit 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  
5.2 Hybrid  
REMOVE ALL SECURITY TAPE AND WRAPPING BEFORE BEGINNING.  
Handlebar  
Handlebar  
Computer  
Resistance Knob  
Handlebar Post  
Seat  
Seat Post  
Front Stabilizer  
Mainframe  
Pedal  
Rear Stabilizer  
3
 
M8X70mm Carriage Bolt(12)-4  
M8 Cap nut(14)-4  
8X19 Arc Washer(15)-12  
3/8" Nylock nut(39)-4  
10X26 Washer(37)-4  
3/8"x45 Hex Head Screw(53)-4  
M6 Cap nut (65)-4  
M6X40mm Carriage Bolt(63)-4  
6X13 Washer(64)-4  
M8x15mm Screw (11)-8  
M5 Allen Wrench  
10X13X14 Screw Driver  
17X13X14 Screw Driver  
4
 
1
1. Attach the front stabilizer (3) to the main  
frame (1) with carriage bolt, washers and  
cap nuts (12,15,14).  
12  
3
14  
15  
Attach the rear stabilizer (4) to the main  
frame (1) with carriage bolt, washers and  
cap nuts (12,15,14)  
1
15  
14  
14  
15  
4
15  
14  
12  
2
2
2. Connect sensor cable (50) to the exten-  
sion wire (62).  
62  
11  
59B  
15  
Secure the handlebar post (2) with screws  
and washers (11,15).  
11  
15  
50  
11  
2-1  
59A  
60  
2
A
B
2-1. Guide the cable from the resistance  
knob (59A) through the eyelet (see picture  
A). Then pull the resistance knob (59A)  
over the gap of the resistance cable (59B)  
(see picture B).  
59B  
59B  
59A  
59A  
5
 
3
3. Attach the sleeve (6L, 6R) to the  
handlebar post (2) with washers, nylon  
lock nut and platic cap (44, 22L, 68).  
68  
22L  
44  
Attach the pedal tube arm (7) to the  
crank with nylon lock nut (22L, 22R).  
6R  
2
44  
22L  
68  
7
68  
22R  
6L  
1
68  
7
22L  
53  
4
4. Connect the pedals (8L,8R) onto  
the pedal tube (7) with the nylon lock  
nut (39), washers (37) and screws  
(53).  
8R  
Each pedal is marked “L” for left and  
“R” for right.  
37  
39  
53  
8L  
37  
39  
6
 
5
5. Assemble the seat (55) to the seat post  
tube (54) and fasten the nylon lock nuts  
and attachment bar (78,58).  
55  
78  
79  
79  
54  
78  
Release the seat knob (51) and then insert  
the seat post (70) into the mainframe.  
Secure the desired height by tightening the  
knob.  
79  
58  
70  
51  
6
6. Attach the small handlebars (56) to the  
handlebar post (2) with screws and washers  
(11,15).  
11  
15  
2
7
 
7
61  
7. Connect the extension wire (62) that  
protrudes from the upright tube into the jack  
of the computer (61).  
62  
57  
Attach the computer to the upright tube with  
nuts (49).  
49  
Connect pulse wires (57) to computer (61).  
61  
57  
62  
8
8. Attach two handlebars (5) onto the  
axles of the handlebar post (2) with the  
carriage bolts (63), washers (64) and cap  
nuts (65).  
66  
5
5
64  
65  
64  
63  
2
8
 
DCV 5.2H PARTS LIST  
DCV5.2H Parts List Rev C  
REF #  
ITEM  
DESCRIPTION  
QTY REF #  
ITEM  
DESCRIPTION  
QTY  
1
1
1
4
1
1
1
2
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
4
4
4
2
2
4
2
1
4
5
1
1
1
2
2
3
4
2
2
1
1
1
2
3
4
5
323-00217 MAIN FRAME # 1  
1
1
1
1
2
1
1
2
1
1
2
2
8
4
3
4
12  
1
1
1
1
1
1
1
3
3
2
6
1
1
1
3
1
1
1
1
1
1
2
1
6
1
1
1
41 319-00092 IDLER WHEEL #41  
42 319-00093 NYLOCK NUT M10 #42  
43 302-00637 IDLER WHEEL SPRING#43  
44 302-00638 WASHER#44  
323-00127 CONSOLE TUBE DCV5.2H/EL  
323-00218 FRONT STABILIZER # 3  
323-00219 REAR STABILIZER # 4  
323-00308 FRAME, REVISED FOR NEW TRANS WHEEL  
45 302-00639 SCREW 4X8#45  
6L 323-00310 SLEEVE DCV5.2H  
46 319-00094 ARC MAGNET PLATE R110X2.0 # 46  
47 302-00640 ARC MAGNETIC SPRING #47  
48 302-00641 HEX HEAD SCREW M8X60 #48  
49 302-00642 NYLOCK NUT M8 #49  
50 313-00133 REED SWITCH TRI-6.0R  
51 302-00643 SPRING KNOB#51  
6R 323-00220 SLEEVE (RIGHT) # 6R  
7
323-00309 DCV5.2H/EL #7  
8L 306-00434 PEDAL L, DCV5.2H  
8R 306-00435 PEDAL R, DCV5.2H  
9
306-00430 FRONT WHEEL CAP #9, DCV5.2H  
10 306-00432 END CAP, TRI-5.3E, 8.3E  
11 302-00620 SCREW M8X15 # 11  
12 302-00621 CARRIAGE SCREW M8X70 # 12  
13 302-00622 WASHER # 13  
52 302-00644 BUSHING#52  
53 302-00645 HEX HEAD SCREW 3/8"X45#53  
54 319-00095 SEAT POST #54  
55 306-00436 SEAT, DCV5.2H  
14 302-00623 NYLOCK NUT M8 # 14  
15 302-00624 ARC WASHER # 15  
16 331-00069 BALLBEARING (L) #16  
17 331-00025 BEARING RIGHT  
56 319-00096 HANDLEBAR TUBE #56  
57 313-00134 HAND PULSE TRI-6.0R  
58 302-00646 NUT COVER M8#58  
59A 310-00169 UPPER TENSION KNOB WIRE, DCV5.2H  
59B 313-00136 SENSOR DCV6.0R  
60 302-00647 TENSION KNOB #60  
61 307-00004 COMPUTER U/R/H/EL DCV5.2  
62 313-00137 EXTENSION WIRE DCV6.0R  
63 302-00648 CARRIAGE SCREW M6X350#63  
64 302-00649 WASHER#64  
18 319-00088 MAGNET #18  
19 319-00089 PULLEY #19  
20 304-00022 BELT, POLY V BELT DCV5.2H  
21L 330-00028 LEFT CRANK DCV5.2H  
21R 330-00029 RIGHT CRANK DCV5.2H  
22L 302-00625 NYLOCK NUT 1/2"X20T #22L  
22R 302-00626 NYLOCK NUT 1/2"X21T#22R  
23 306-00433 PLASTIC SPACER, DCV5.2H  
24 306-00567 ROLL DCV5.2H #24  
25 330-00026 RIGHT AXLE DCV5.2H  
26 330-00027 LEFT AXLE DCV5.2H  
27 311-00054 FLYWHEEL #27  
65 302-00650 NYLOCK NUT M6#65  
66 328-00035 FOAM GRIP # 66  
67 306-00437 TUBE CAP, DCV5.2H  
68 306-00438 CAP COVER, DCV5.2H  
69 306-00568 ROLL DCV5.2H #69  
70 319-00097 UPPER SEAT TUBE M8 # 70  
71 302-00651 SCREW 4X15#71  
28 331-00024 BEARING, DCV5.2H  
29 302-00627 ARC WASHER # 19  
30 302-00628 BC NUT #6  
72 302-00652 SCREW 3/16"X2"#72  
73 305-00025 LEFT HOUSING DCV5.2H  
74 305-00026 RIGHT HOUSING DCV5.2H  
75 306-00441 OVALCOVER, DCV5.2H  
76 319-00098 PULSE PLATE # 76  
77 302-00653 SCREW M6X10#77  
78 302-00654 NYLOCK NUT M8#78  
79 302-00655 SPRING WASHER#79  
80 302-00656 BOLT#80  
31 302-00629 BC NUT 3/8" #24  
32 302-00630 SCREW 3/8"#32  
33 302-00631 GREASED WHEEL#33  
34 319-00090 AXLE OF FLY WHEEL #34  
35 302-00632 NYLOCK NUT M8 #35  
36 302-00633 HEX HEAD SCREW 3/8"X26 #36  
37 302-00634 WASHER #37  
38 319-00091 IDLER WHEEL PLATE #38  
39 302-00635 NYLOCK NUT 3/8" #39  
40 302-00636 SPACER OF IDLER WHEEL #40  
81 306-00442 CAP, DCV5.2H  
#
#
315-00028 OWNER'S MANUAL DCV5.2H  
302-01150 BOLT PACK DCV5.3H  
9
 
DCV 5.2H EXPLODED VIEW  
71  
67  
74  
73  
72  
71  
72  
75  
71  
72  
11  
75  
15  
5
67  
61  
42  
28  
41  
40  
38  
65  
64  
69  
62  
68  
66  
22L  
1
44  
24  
39  
37  
49  
59A  
63  
60  
43  
5
37  
55  
78  
36  
68  
22L  
53  
44  
79  
79  
54  
6R  
24  
65  
24  
78  
64  
2
77  
24  
7
8R  
69  
37  
39  
22L  
79  
58  
63  
25  
77  
60  
11  
15  
44  
24  
59B  
70  
52  
9
24  
23  
68  
12  
15  
11  
45  
6L  
81  
80  
9
50  
11  
14  
15  
3
21  
17  
19  
51  
22R  
60  
53  
24  
15 1  
18  
14  
20  
13  
49  
48  
24  
14  
15  
44  
22L  
8L  
24  
22L  
68  
10  
23  
7
16  
4
35  
37  
39  
15  
14  
10  
12  
21  
34  
33  
24  
80  
28  
26  
35  
81  
48  
27  
28  
47  
29  
46  
30  
31  
32  
10  
 
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 tar-  
get heart rate zone is 60%-75% of 180 or 108-135 bpm. See Fitness Safety below.  
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 recommends 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 maximum heart rate may be too stren-  
uous unless you are in top physical condition. Exercising below 60% of your maximum will  
result in minimal cardiovascular conditioning.  
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 average rate zones for different ages. A variety of differ-  
ent 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 profes-  
sional can help you determine the exercise intensity that is appropriate for your age and  
condition.  
11  
 
(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 for additional calculations.  
TARGET HEART RATE ZONE  
200  
195  
100%  
190  
185  
180  
175  
Serious  
170  
165  
athletic  
training range  
160  
155  
85%  
170  
166  
162  
157  
153  
Cardiovascular  
149  
conditioning  
range  
145  
140  
136  
132  
150  
75%  
146  
143  
139  
135  
131  
128  
Fat burning  
range  
124  
120  
116  
60%  
120  
117  
114  
111  
108  
105  
102  
99  
96  
93  
20  
25 30  
35  
40 45  
50  
55 60 65  
AGE  
12  
 
KEYS FITNESS PRODUCTS, LP -  
LIMITED WARRANTY  
PRODUCT:  
DISCOVERY 5.2 HYBRID  
HOME USE WARRANTY: 1 Year Parts  
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  
13  
 
Keys Fitness Products, L.P.  
4009 Distribution Dr.  
Suite 250  
Garland, Texas 75041  
 

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