Hi, I have a problem with my Kettler Ergo Racer. I replaced the drive belt and had to remove a number of components to fit the belt. On re-assembly the bike does not increase resistance when I increase the power rating on the display. Any thoughts on what I may have done wrong in re-assembly would be appreciated. All looks OK, no wires hanging off or anything like that. Thanks in advance Barry

Tim, I am not familiar with this piece of equipment. Try the link for your manual it may have some info. Good luck. You can also try google search for your make and model # assembly manual.
Kettler Canada Online shopping for Bikes Fitness Patio Table Tennis Toys
Kettler MONDEO 07852 690 Assembly Manual Page 12
http://fitness.manualsonline.com/manuals/mfg/kettler/kettler_elliptical_trainer_product_list.html

Water pump is Timing belt driven. It is below the Camshaft sprocket, in the timing case. If you want to repair/replace it here are the instructions.
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COMPONENTS

REMOVAL

1. Using the drain plug, drain the coolant.
2. Remove the drive belt and the engine coolant pump pulley.
3. Remove the timing belt cover, the auto tensioner and idler pulley.
4. Remove the water outlet fitting, the thermostat case and the water pump fitting.
5. Remove the engine coolant pump mounting bolts.

1. Remove the engine coolant pump assembly from the cylinder block.

INSPECTION

1. Check the engine coolant Water pump for cracks, damage or wear, and replace the pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation and replace the pump assembly if necessary.
3. Check the seal it for leaks and replace the pump assembly if necessary.

INSTALLATION
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1. Clean the gasket surfaces of the engine coolant pump body and the cylinder block.

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1. Install the new engine coolant pump gasket and pump assembly. Tighten the bolts to the specified torque. Tightening torque

Engine coolant pump bolt:
Head mark "7": 17 - 22 Nm(170 - 220 kg.cm, 12 - 16 ft. lbs.)

1. Install the water pump fitting, the thermostat case and the water outlet fitting.
2. Install the auto tensioner and timing belt. Adjust the timing belt tension, then install the timing belt cover.
3. Install the drive belt, coolant pump pulley and then adjust the auto tensioner.
4. Refill the coolant.
5. Run the engine and check for leaks.

Courtesy All Data LLC
© 2015 ALLDATA LLC. All rights reserved. Terms and Condit

Google for the manual online and you should be able to find it. Although they say they don't need lubrication.

Try emailing the parts department at Kettler USA: Kettler USA online shopping for tricycles pedal tractors ellipticals...

I used to have to contact them when I repaired Kettlers at the bike shop.

I just ordered a replacement belt (67005127) from Kettler USA parts.
Requests can be submitted by phone to 866.804.0440, fax to 757.563.9273 or e-mail to [email protected]. Model number of your product, your name, phone number or e-mail address

To ensure you have the correct part number, download the assembly & spare part manual from the corporate website in Germany.

1) To find the part number go to: Service-Center menu, select Assembly and Spare Parts
http://intl.sport.kettler.net/service-center/assembly-and-spare-parts.html

2) Select the category ("Crosstrainer" in my case) and enter the model number "XTR 1"
note: the space is important since it won't find "XTR1"

3) Select the appropriate document by selecting the language, and the download will commence.

4) These documents have an exploded assembly diagram and the list of all parts.

Most questions like tghis find answers on search engines...

"Kettler Ergo Racer user manual pdf" ;eads to...

http://kurser.iha.dk/eit/eit-lab/Bike_autopilot_website/Ergoracer_Car_Simulator_User_Guide_And_Tehcnical_Documentation.pdf

https://www.manualslib.com/manual/646856/Kettler-Condor.html
http://fitness.manualsonline.com/manuals/mfg/kettler/kettler_elliptical_trainer_product_list.html

from
http://access.kettlerusa.com/retail/manuals/fitness/crosstrainers/7653-309.A.pdf
you'll find that -------------- The computer calculates and assesses the difference between load pulse and recovery pulse and your resulting "fitness value" on the basis of the following formula:
Note ( F ) = 6 - (10 x ( P1 - P2 )/P1)^2
P1 = load pulse P2 = recovery pulse Value 1 = very good Value 6 = unsatisfactory The comparison of load and recovery pulse is a simple and fast method to control your physical fitness. The fitness value is a value of orientation with regard to your ability to recover after physical load. Before you press the recovery pulse button and have the computer calculate your fitness value you should train in your load range for a longer time, this means for at least 10 minutes. With regular cardiovascular training you will notice that your "fitness value" will improve --------------

Locate where the noise is coming from, chances are the bearings have gone bad go to Kettler fitness.com they have contact info on their web site.

check the barrings if you can and lube it