The Bowflex Revolution®, Revolution®XP, and
Contents
1. BOWFLEX REVOLUTION The Bowflex Revolution Revolution XP and Revolution FT Home Gym way POWERED BY NSPIRAFLEX P N 000 6911 Rev A 04 2007 Table of Contents Specifications Approvals eese 3 Revolution Modlels 4 Preventative Maintenance 5 Untangle Derailed Rope 6 Adjust Rope Tension 15 Replace Cam Assembly 15 Replace ROPE aan 22 Product Weight Shipping Weight Product Dimensions Workout Area Number of Exercises SpiralFlex Resistance SpiralFlex Upgradability User Weight Limit Specifications EE Product Specifications Revolution Revolution FT Revolution XP XP with Lat Tower Revolution Revolution FT Revolution XP XP with Lat Tower Revolution Revolution FT Revolution XP XP with Lat Tower Revolution Revolution FT Revolution XP XP with Lat Tower Revolution Revolution FT Revolution XP XP with Lat Tower Revolution Revolution FT Revolution XP XP with Lat Tower Revolution Revolution FT Revolution XP XP with Lat Tower Revolution Revolution FT Revolution XP XP with Lat Tower 336 2 Ibs 152 5 kg 234 3 Ibs 106 1kg 291 2 Ibs 131 4kg 319 9 Ibs 144 4kg 0 414 46 Ibs 188 1kg 253 9 Ibs2. Bowflex Revolution Service Manual 22 Maintenance Procedures jr Replace Rope 1 Follow Steps 1 5 of Replace Cam Assembly to Remove Shroud 2 Remove Lower Spool 2 1 Use a 7 32 allen wrench to remove the bolt securing the Lower Spool 2 2 Remove the Spool Figure A unwrap the Strap Figure B and hook the Spool behind the frame Figure C to keep it out of your way Figure A Figure B Figure C 3 Remove Large Pulley 3 1 Slide the Large Pulley off of the axle Large Pulley Maintenance Procedures Replace Rope continued 4 Remove Rope From Pulley 9 1 Remove Cam from Cam Axle 5 1 Raise the Arm to fully upright position 5 2 Tie a piece of string about 6 feet long to the end of the old Rope Figure A 5 3 Gently pull the old Rope through the Arm and and over the Upper Pulley leaving the string theaded through the arm Figure B Note Do not pull the string through the arm Leave enough string exiting at the Lower Pulley to pull the new Rope back through YN Bowflex Revolution Service Manual 23 24 Maintenance Procedures Replace Rope continued Lower Pulley 6 Route New Rope 6 1 Untie the old Rope from the string at the Upper Pulley and tie the string to the new Rope 6 2 Thread the new Rope through the Arm by gently pulling the string from the Lower Pulley Rope 7 Clamp Rope In Large Pulley 7 1 Feed the Rope through the hole
3. Allen Wrench e 6 Phillips Screwdriver e 7 32 Allen Wrench Note All instructions in this bulletin are given with the orientation of standing facing the engine with the bench behind you Instructions Before beginning this procedure remove all resistance packs except for the attached pre stretch pack Step 1 Remove Top Cover 1 1 Use a 1 8 allen wrench to remove the four Top Cover allen bolts that secure theTop Cover See g Figure 1 Set bolts aside for Step 14 f 1 n i Pre stretch 1 2 Remove Top Cover and set aside Pack Figure 1 Step 2 Remove Shroud Clip 2 1 If there is a Clip securing the shrouds under top inside remove the Clip The clip may already have been removed after shipping See Figure 2 Set Clip aside for Step 11 If Clip is not present go to Step 3 Figure 2 Maintenance Procedures Untangle Derailed Rope continued Step 3 Remove Tension Adjust Knob Cap 3 1 Use a phillips head screwdriver to remove the screw securing Tension Adjust Knob Cap Figure 3a and set aside for Step 13 3 2 Once the Screw is removed use the screwdiver to gently pry the cap out of the knob Figure 3b Tension Adust Knob ension Adust Kno Tension Adust Knob Cap Figure 3a Figure 3b Step 4 Remove Tension Adjust Knob 4 1 Use a phillips head screwdriver to remove the four screws securing the Tension Adust Knob See Figure 4 Set screws aside for Step 12 4 2 Remove t
4. 115 1kg 316 6 Ibs 143 5kg 350 8 Ibs 159kg 112 L x 63 W x 73 H 284cm x 160cm x 185cm 64 5 Lx378 Wx 73 H 163 8cm x 98cm x 185 4cm 64 5 Lx 378 W x 73 H 163 8cm x 98cm x 185 4cm 64 5 Lx 378 W x 83 2 H 163 8cm x 98cm x 211 3cm 112 x 63 284cm x 160cm 84 x 64 213 4cm x 162 6cm 84 x 64 213 4cm x 162 6cm 84 x 64 213 4cm x 162 6cm 90 80 90 90 220 Ibs 99 8 kg 200 Ibs 90 7 kg 200 Ibs 90 7 kg 200 Ibs 90 7 kg 300 Ibs 136 kg 280 Ibs 127 kg 280 Ibs 127 kg 280 Ibs 127 kg 300 Ibs 136 kg 300 Ibs 136 kg 300 Ibs 136 kg 300 Ibs 136 kg Bowflex Revolution Service Manual Revolution Models Revolution Revolution FT Revolution XP Preventative Maintenance Daily Wipe down with a damp cloth Pay special attention to areas where perspiration could settle Monthly Inspect the unit for loose parts nuts bolts etc Inspect ropes and straps for fraying or excessive wear Yearly Remove the Top Cover and inspect the condition of the internal components look for fraying or excessive wear on straps ropes and moving parts and replace as necessary Note Before adding or removing resistance packs spray a light coating of silicone lube on the shaft This will allow the packs to slide easily on and off the shaft Bowflex Revolution Service Manual Maintenance Procedures a cre Untangle Derailed Rope Tools needed e 1 8
5. in the Large Pulley and clamp in place Note To be sure Rope is securely clamped leave about 1 4 showing on the inside of the clamp 1 4 of Rope showing v 8 Reverse Steps 3 2 and 1 to reassemble E BOWFLEX REVOLUTION 2005 Nautilus Inc All rights reserved 16400 S E Nautilus Drive Vancouver Washington USA 98683 Bowflex Bowflex Revolution Spiraflex and the Bowflex and Nautilus logos are either registered trademarks or trademarks of Nautilus Inc Bowflex Revolution Service Manual 25
6. sure it stays in the channel while performing the next step Large Pulley Figure 8a Figure 8b Maintenance Procedures Untangle Derailed Rope continued Step 9 Replace Lower Spool 9 1 While still holding the Large Pulley in place coil the Strap around the Spool in a counter clockwise dirction See Figure 9a 9 2 Slide the Spool back onto the axle Figure 9b and secure the Lower Spool with allen bolt Figure 9c Strap Figure 9a Figure 9b Figure 9c Bowflex Revolution Service Manual Maintenance Procedures Untangle Derailed Rope continued Step 10 Replace Shroud 10 1 Make sure that the right Rope Figure 10a passes above the flat guide to the upper right side of the Pulley 10 2 Replace the Shroud Figure 10b making sure the left Rope passes between the guides on the inside of the Shroud Figure 10c and beneath the fender on the left side of the Pulley see Figure 10a 10 3 Secure the Shroud with five phillips head screws one longer screw and four shorter screws from Step 5 Note the location for the long screw in Figure 10d Right Rope Figure 10a Right rope and rope guide Figure 10b pulley not shown Left Rope Figure 10c Left rope and rope guides Figure 10d Location of long screw to secure shroud 12 Maintenance Procedures Untangle Derailed Rope continued Step 11 Replace Shroud Clip 11 1 Replace the Clip securing the shrouds under top i
7. he Tension Adjust Knob and set aside gt Tension Adust Knob e Figure 4 Bowflex Revolution Service Manual Maintenance Procedures EE Untangle Derailed Rope continued Step 5 Remove Shroud 5 1 Use a phillips head screwdriver to remove the five screws securing the shroud one longer screw and four shorter screws Set screws safely aside for Step 10 5 2 Remove the Shroud and set aside See Figure 5 Figure 5 Step 6 Remove Lower Spool 6 1 Use a 7 32 allen wrench to remove the bolt securing the Lower Spool See Figure 6a Set bolt aside for Step 9 6 2 Remove the Spool Figure 6a unwrap the Strap Figure 6b and hook the Spool behind the frame Figure 6c to keep it out of your way Figure 6a Figure 6b Figure 6c Maintenance Procedures Untangle Derailed Rope continued Step 7 Remove Large Pulley 7 1 Slide the Large Pulley Figure 7a and tangled Rope Figure 7b off of the axle Large Pulley Tangled Rope Figure 7b Figure 7a Bowflex Revolution Service Manual 10 Maintenance Procedures g Untangle Derailed Rope continued Step 8 Re wrap Rope 8 1 Begin to re wrap the rope in the outer most channel on the Large Pulley Figure 8a 8 2 Slide the Large Pulley back onto the axle and finish wrapping the Rope by turning the Large Pulley in a clockwise direction NOTE Do not let go of the Large Pulley See Figure 8b Keep tension on the Rope to make
8. k Figure B FigureA 8 Remove Lock Collar From Cam 8 1 Use a flat head screwdriver to pry up the bottom tab on the Lock Collar Figure A Detail A 8 2 Remove the Lock Collar from Cam Figure B Lock Collar Figure Figure B 18 Maintenance Procedures Replace Cam Assembly continued 9 Remove Cam 9 1 Remove Cam from Cam Axle 10 Remove Lower Spool 10 1 Use a 7 32 allen wrench to remove the bolt securing the Lower Spool 10 2 Remove the Lower Spool Bowflex Revolution Service Manual Maintenance Procedures Replace Cam Assembly continued 11 Install New Cam Assembly Reverse the disassembly procedure to install the new Cam Assembly with the following notes 1 When replacing the Lower Spool make sure to wind the strap counter clockwise Figure A 2 When sliding theTension Shaft back into position slowly slide the shaft through until it clicks into place If you do not feel or hear a distinct click make sure the shaft is centered by measuring the amount of exposed shaft on each side of the main unit 20 Maintenance Procedures Replace Cam Assembly continued 2 When tightening the Tension Shaft Holder tighten the screws in numerical order shown on the tensioner Tighten the two screws marked 1 then the two marked 2 and so on Tension Screws Tighten screws in order 1 amp 1 2 amp 2 3 amp 3 then 4 amp 4 Tension Shaft Holder 21
9. nside See Figure 11 If there is no Clip go to Step 12 Step 12 Replace Tension Adjust Knob 12 1 Use a phillips head screwdriver and four screws to secure the Tension Adjust Knob See Figure 12 Step 13 Replace Tension Adjust Knob Cap 13 1 Use a phillips head screwdriver and one screw to secure the Tension Adjust Knob Cap See Figure 13 Figure 13 Bowflex Revolution Service Manual 13 14 Maintenance Procedures Untangle Derailed Rope continued Step 14 Replace Top Cover 14 1 Use a 1 8 allen wrench and four allen bolts rom step 1 to secure the Top Cover See Figure 14 Figure 14 Large Pulley Step 15 Adjust Rope Tension 15 1 Pull out Tension Adjust Knob and rotate Large Pulley in a clockwise direction until It stops then release the Tension Adjust Knob to lock See Figure 15 Figure 15 Step 16 Final Check Please inspect your machine to ensure that all fasteners are tight and everything is properly assembled Tension Adjust Knob Maintenance Procedures Adjust Rope Tension Large Pulley Tension Adjust Knob Pull out Tension Adjust Knob and rotate Large Pulley in a clockwise direction until it stops then release the Tension Adjust Knob to lock Replace Cam Assembly 1 Remove Top Cover 1 1 Use a 1 8 allen wrench to remove the four allen bolts that secure theTop Cover 1 2 Remove Top Cover and set aside 2 Remove Shroud Clip 2 1 Remo
10. ve the Clip securing the shrounds under top inside Bowflex Revolution Service Manual 15 Maintenance Procedures Replace Cam Assembly continued 3 Remove Tension Adjust Knob Cap 3 1 Use a phillips head screwdriver to remove the screw securing Tension Adjust Knob Cap Figure A 3 2 Once the Screw is removed use the screwdiver to gently pry the cap out of the knob Figure B Tension Adust Figure A 4 Remove Tension Adjust Knob 4 1 Use a phillips head screwdriver to remove the four screws securing the Tension Adust Knob 4 2 Remove the Tension Adjust Knob and set aside Tension Adust Knob 16 Maintenance Procedures Replace Cam Assembly continued 5 Remove Shroud 5 1 Use a phillips head screwdriver to remove the five screws securing the shroud 5 2 Remove the Shroud and set aside 6 Remove Tension Shaft From Cam Assembly Tension Shaft Holder 6 1 Use a 7 32 allen wrench to loosen the eight bolts on theTension Shaft Holder Figure A 6 2 Pull theTension Shaft through Figure B until it clears the Cam Assembly Figure C being replaced Tension Shaft Cam Assembly Figure C Bowflex Revolution Service Manual 17 Maintenance Procedures Replace Cam Assembly continued 7 Remove Pre Tension Pack 7 1 Use a 3 32 allen wrench to remove the six allen bolts from the Pre Tension Pack Figure A 7 2 Remove the Pre Tension Pac
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